Royal Commission for Jubail and Yanbu

FORM PA-G1
PERMIT APPLICATION FOR INDUSTRIAL FACILITIES - GENERAL

1. APPLICANT

Name of Industrial Facility: English: AQUACHEMIE SAUDI INDUSTRIAL CO. LTD.

Name of the Project: English: Light Manufacturing & Warehousing & Storage Facility

Name of Industrial Facility: Arabic: ‫شركة أكواشيمي السعودية الصناعية‬

Name of the Project: Arabic: ‫مرفق لتصنيع المنتجات الكيميائية الخفيفة وتخزينها‬

Owner(s) of the Facility: AQUACHEMIE SAUDI INDUSTRIAL CO. LTD.

(Attach a copy of Commercial Registration and Industrial License)
Please refer to Attachment 1/PA-G1

(Attach a copy of Saudi Energy Efficiency Center (SEEC) Certificate complying with
SEEC’s standards and requirements for new facilities including facilities to be
reconstructed, modified or expanded)
Aquachemie Saudi Industrial Co. Ltd received communication from the SEEC via e-
mail which states that the facility does not require a SEEC certificate. Please see
Attachment 2/PA-G1 for reference.

Operator of the Facility: Aquachemie Saudi Industrial Co. Ltd

Applicant Address: 118, Building 2550, Support Industrial Area-1 , Jubail, KSA, PO-
35717

Project Coordinator: Mr. Sanjeev Gupta

Title: VP-Operation & Projects

Tel: +971-508608262 Fax: NA

E-mail: [email protected]

Technical Contact: Mr. Diptiranjan Agasti

Title: Project Coordinator

Tel: +971-509573696 Fax: NA

E-mail: [email protected]

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Royal Commission for Jubail and Yanbu

Area of the Facility: 20,010 Square Meters.

Facility Status (Tick the option)

[X] New [ ] Existing In Case of renewal of EPO, attach the expiring EPO and its conditions.

[ ] Modification In Case of modification complete the following:

Before Expansion After Expansion

Name Industrial Hazardous Number of Industrial Hazardous
of Number of Production
Production Wastewater Waste Air Wastewater Waste
Plant Air Emission %
Capacity Quantity Quantity Capacity Emission Quantity Quantity
Sources Change
(m3/day) TPY Sources (m3/day) TPY

Item Before Expansion After Expansion

Raw Material
Consumption
Production
Capacity

2. OPERATIONAL ACTIVITIES:

2.1 Operations / Process Description

a. Describe the proposed operations at the facility including the main chemical
reactions and process units involved

List the relevant section/ page numbers in the addendum

Please refer to Attachment 3/PA-G1, 4/PA-G1, 5/PA-G1, 6/PA-G1

b. Provide a block flow diagram outlining the main process units

List the relevant section/ page numbers in the addendum

Please refer to Attachment 3/PA-G1, 4/PA-G1, 5/PA-G1, 6/PA-G1

c. Provide mass / material balance calculations indicating inputs and outputs of process
units including air, water and waste releases.

List the relevant section/ page numbers in the addendum

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 Royal Commission for Jubail and Yanbu

Please refer to Attachment 7/PA-G1

d. Provide detailed process flow diagrams (PFDs) with stream summaries.

Drawings No Please refer to Attachment 8/PA-G1

e. Are there are any loading and unloading operations at the port

[ ] Yes [X] No

List the relevant section/ page numbers in the addendum

NA

2.2 Operating Schedule

a. Operating hours of the facility per day: 24 Hours/day

b. No. of Shifts/day: 3 Shifts
c. Scheduled operating days per calendar year: 312 Days
d. No. of employees:
i. Admin: 40 Persons (Including Operations)
ii. Technical (Production, Tech. Services, Maintenance) & others: ____________
iii. Total: 40 Persons

2.3 Raw Materials and Product Description

Provide detailed description of raw materials used, products and by-products.

a. Raw Materials Used Directly in Production (Insert more rows if needed)

Hourly Annual Maximum

Delivery Consumptio Consumptio Storage Country of
Material Process and Storage n n Capacity Origin
Method
(Unit) (Unit) (Unit)
Road & Sea Since Since Since
Ethylene glycol
Import IBC & blending of blending of blending of KSA/China
monobutyl ether
Drum chemicals is chemicals is chemicals is
Road & Sea batch batch batch
Group 2 base oil Import IBC & process, the process, the process, the KSA
Drum raw material raw material raw material
Distillates(petroleu Import Road & Sea will be will be will be KSA

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IBC &
m)
Drum
Road & Sea
hydrotreated light Import IBC & KSA
Drum
Road & Sea
Acetic acid Import IBC & China
Drum
Road & Sea
Polyether amine Import IBC & China
Drum
Road & Sea
Polypropylene
Import IBC & China
glycol
Drum
Road & Sea
UAE/KSA/
Caustic soda lye Import IBC &
Oman
Drum
Road & Sea
Formic acid Import IBC & China
Drum
Road & Sea
Glycerol Import IBC & India
consumed consumed consumed
Drum
based on based on based on
Road & Sea
requirement requirement requirement
Ethylene glycol Import IBC & KSA
Drum
Road & Sea
Cinnamaldehyde Import IBC & China
Drum
Road & Sea
Sodium chloride Import KSA
Bag
Road & Sea Germany/
Potassium chloride Import
Bag China/Jordan
Methyl Road & Sea
Import KSA/China
diethanolamine ISO tank
Road & Sea Germany/
Perchloroethylene Import
ISO tank China
Road & Sea
Diethanolamine Import KSA/China
ISO tank
Road & Sea
Dimethyl disulfide Import France/China
ISO tank
Solvent naphtha 150 Import Road & Sea UAE/India

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ISO tank
Road & Sea
Solvent naphtha 200 Import UAE/India
ISO tank
Road & Sea
Sodium Chlorite Import IBC & China/Spain
Drum
Sodium Road & Sea
Import China/KSA
Metabisulfide Bag
Road & Sea
Magnisium Oxide Import India
Bag
Road & Sea
Methanol Import IBC & KSA
Drum
Road & Sea
Calcium Carbonate Import KSA
Bag
Road & Sea
Propionaldehyde Import China
ISO tank
Road & Sea
Perchloro Ethylene Import Germany
ISO tank
Road & Sea
Calcium Stearate Import Singapore
ISO tank

b. Other Materials Used (Insert more rows if needed) NA

Maximum
Delivery Hourly Annual
Storage Country of
Material Process and Storage Consumption Consumption
Capacity Origin
Method (Unit) (Unit)
(Unit)

c. Raw Materials available from the Industrial City. NA

Maximum
Delivery Hourly Annual
Storage City of
Material Process and Storage Consumption Consumption
Capacity Origin
Method (Unit) (Unit)
(Unit)

d. Final Products (Insert more rows if needed)

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Storage/ Maximum
Hourly Annual End Users
Delivery to Storage
Process Product Production Production Name &
end users Capacity
(Unit) (Unit) Location
Method (Unit)
Maaden
Anticaking
Blending Phosphate,
agent
KSA
Maaden
Coloring
Blending Phosphate,
agent
KSA
Granulating Maaden
Blending aid Phosphate,
Defoamer KSA
Antifoamin
Maaden
g agent for
Blending Phosphate,
Phosphoric
KSA
acid
Curing aid Maaden
Blending for Rock Phosphate,
Phosphate KSA
Since it is Maaden
Flotation batch
Blending Phosphate,
agent process, it is Drums/ KSA
Urea difficult to IBCs/ISO Maaden
1,400 to
Blending anticaking mention the 60 KTA Tanks/Big Phosphate,
1,600 MT
agent hourly Bags/Small KSA
production Bags Maaden
Urea Melt rate of these
Blending Phosphate,
additive chemicals KSA
Dust Maaden
Blending suppression Phosphate,
agent KSA
Corrosion Aramco,
Blending
inhibitor SABIC
Cement Aramco (Up
Blending expanding Stream),
additive KSA
Aramco (Up
Drilling
Blending Stream),
Emulsifier
SLB, KSA
Shale
Blending SBL
inhibitor
Polyacrylam Aramco ((Up
Blending
ide friction Stream),

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reducer KSA
Sodium
Blending Maaden
Bisulfite
Caustic
Blending Soda S-Chem
Dilution
DEA
Blending Satorp
Dilution
MSP 40%
Blending Satorp
Soln

Blending Morpholene Farabi

Big Maaden
Drossary
Blending 0.57 TPH 5 KTA Bags/Small Aluminum,
furnace salt
Bags KSA

e. By-Products (Insert more rows if needed) NA

Maximum End
Hourly Annual Storage/
Storage Users
Process Product Production Production Delivery to end
Capacity Name &
(Unit) (Unit) users Method
(Unit) Location

2.4 Process Technology Suppliers for Major Process Units e.g. Catalytic Cracking,
Catalytic Reforming, Polymerization, Thermal Cracking, etc.

Process Name Technology Country of Origin

Supplier
Blending Tejas Technical Services Majiwade, India

2.5 Energy Requirements

Average
Type Units Annual Consumption
Consumption
Electricity kVA 597 771
Oil tones/day NA NA

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Gas scm NA NA
Other (specify)

2.6 Water Consumption

Type of water used / required Average Maximum

Desalinated water for process (m3/day) NA NA
Drinking water for Process (m3/day) 149.52 154.08
Reclaimed water (IWTP Effluent) for
NA NA
process (m3/day)
Reclaimed water (SWTP Effluent) for
NA NA
process (m3/day)
Non-Contact Cooling Seawater (m3/hr)
NA NA
Other water (m3/day)
Drinking water (m3/day) 1.68 1.92
Irrigation water (m3/day) NA NA

2.7 Wastewater Generation

Average Maximum
Type of wastewater
Process wastewater (m3/day) 3.6 4.08
Sanitary wastewater (m3/day) 1.2 1.2
Other wastewater (Cooling 0.12 0.12
tower blow down) (m3/day)

3. SITE PLANS:

Provide site plans indicating the following:

a. Buildings
Drawing No. Please refer to Attachment 9/PA-G1

b. Plant facility boundaries

Drawing No. Please refer to Attachment 10/PA-G1

c. Specific process areas

Drawing No. Please refer to Attachment 11/PA-G1

d. All sanitary and industrial effluent discharge sources to the wastewater collection
system.

Drawing No. Will be provided in detailed engineering stage

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e. All non-contact cooling water discharge sources

Drawing No. Please refer to Attachment 12/PA-G1

f. All wastewater and storm water lagoons and surface impoundments

Drawing No. NA

g. Storm water drainage plan

Drawing No. Will be provided in detailed engineering stage

h. All effluent treatment facilities

Drawing No. NA

i. All atmospheric emission point sources emitting greater than 10 tons/year of any
hazardous air pollutant (see RCER-2015, Volume I, Table 2C) and all point sources
emitting greater than 100 tons/year of any ambient air standards pollutant (see RCER-
2015, Volume I, Table 2A).

Drawing No. NA

j. All air pollution control equipment locations

Drawing No. Please refer to Attachment 13/PA-G1

k. Areas of hazardous waste storage, treatment or disposal

Drawing No. Please refer to Attachment 14/PA-G1

4. LAND USE PLANNING (for new or modified facilities within the boundaries of an
existing site)

Indicate on the Site Plan the following:

a) Areas subject for development

NA SQ. M.

b) Areas potentially contaminated with previous activities or storage of materials.

NA SQ. M.
The Project site is greenfield in nature. Therefore, there are no known possible
sources of contamination or previous storage of materials.

c) Areas with known or potential groundwater contamination.

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Drawing No. NA

The Project site is greenfield in nature. Therefore, there are no known possible
sources of contamination or previous storage of materials.

5. CONSTRUCTION ACTIVITIES

a. Estimated length of the construction period 3 months

b. Anticipated volume of dredged material, if any, during construction? cu. m. NA
c. Describe below, any site dewatering which will be required during construction of the
facility, including anticipated dewatering and disposal rates? m3/day. 10
d. Describe the type, quantities and disposal methods of municipal wastes during
construction of the facility.
Annual Waste Generated
Category/Waste Type
< 1 ton < 10 tones < 100 tones > 100 tones
Non-hazardous Combustible Solid Waste
Kitchen Waste X
Paper and Cardboard X
Wood X
Hazardous or Potentially Hazardous Solid Waste

Empty Drums (metal

X
and plastic)
Batteries (lead-acid) X
Oily Rags X
Clinical Waste X
Filters X
Hazardous Liquid Waste
Greases X
Hydraulic Fluid X
Oil X
Tires X

e. Describe the type, quantities, and disposal methods of industrial wastes during
construction of the facility.

Please see table above for types of wastes generated. Disposal shall be undertaken
by approved licensed third parties.
f. Provide the details of any temporary construction activities.

NA

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Attachment 1/PA-G1

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Attachment 2/PA-G1

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Attachment 3/PA-G1
(Liquid blending of chemicals Process)
Process Control

The raw material is received in the

facility through bulk (road tanker/
iso tanks) or smaller packing
(IBCs, drums, bags)
The warehouse supervisor verifies
documentation part and initiate for
QC check with preparation of GRN

Post approval the material will be

taken as stock IN and the iso tanks
will be offloaded at the iso tank The QC chemist checks the
storage area. The drums/ IBCs/ material as per company’s
bags will be stored in the standard operating procedures
warehouse based on the designated with verification of COA and third-
classification party report

The Production Supervisor checks

the MSDS of the raw materials and
finish products and ensure that all
Materials are charged into the the control measure required are in
blender as per the formulation on place. A toolbox talk is held prior
the batch sheet and mixed for the to blending in the presence of the
pre-defined time as per the batch EHS supervisor and make all
instruction of the product. Heating/ involved aware of the Hazards and
Cooling is provided as per the required control measures
blending instruction if required including PPEs
using Boiler/ Cooling tower.

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Then according to the respective

BOM (bill of material) and SOP
(standard operation procedure) the
other components are added and
mixed. Depending on the batch size
this step will need desired hour to
produce the finished goods (FG)

final QC check is performed for

final approval

FG filling process initiated in IBC/

drum/ iso tank as per desired
customer need & will be stored in
the central warehouse in IBC/
drum or iso tank storage area. and
until dispatch.

Ventilation system for warehouse

and process area will be designed
with smoke & fire detectors and
dust extraction system as per local
norms.
All the products used in the
production process are stored in a
well-maintained dust free
warehouse. And even segregated in
such a way that no mixing is
possible. Since the production
process involves handling of liquid,
so there is no emission of any dust/
any sort of other pollutant.

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Attachment 4/PA-G1
(Solid blending Process)

Salts like Sodium chloride, Potassium Chloride (in

powder form) stored in bags are brought from the
warehouse to the process area through forklifts.

These bags are fed into the hopper located in the

start of the belt conveyor.

With the control movement of the belt conveyor, the

material is lifted to the mixer inlet for mixing. These
bags are unloaded in series for complete mixing.

Once the mixing is completed, the finished goods are

collected in the storage hopper and with the control
movement of the belt conveyor, the material is lifted
to the storage vessel. Material from storage vessel is
unloaded in the bags and it will be packed and
moved in the warehouse and delivered to customer
as per order.

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Attachment 5/PA-G1
(Chemical drumming Process)
Chemical drumming
The material is received in the facility through bulk (road tanker/ iso tanks).
The warehouse supervisor verifies documentation part and initiate for QC check with preparation of
GRN.
The QC chemist checks the material as per company’s standard operating procedures with
verification of COA and third-party report.
Post approval the material will be taken as stock IN and the iso tanks will be offloaded at the iso
tank storage area. In case of rejection, QC chemist inform logistics supervisor to proceed for the
return as per standard operating procedures.
With due diligence of EHS and safety measures and post plant manager clearance, drumming
process
initiated.
Storage tank will feed RM to the drumming line of various drum machines which will be then
ready for filling the drums. Typical drum filling system has been shown below:

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Attachment 6/PA-G1
(Repacking Process)
Repacking of salts from big bags to small bags
Jumbo bags from warehouse are brough to the repackaging area via forklift and it is loaded in the
feeder.
Small bags will be placed on the load cell platform which will be ready to receive material.
Then the material is transferred to the small bags through series of conveyors (screw conveyor,
coarse screw conveyor and fine screw conveyor).
Once the small bag is loaded completely, the bag will be automatically moved to stitching stand via
belt conveyor and the bags will be loaded on to pallets and will be shrink wrapped & moved to the
warehouse and delivered to customer as per order.
The process area has dust extraction and collection system where there will be designated ducts at
the
top and at strategic locations which collects the dust coming out while solid handling process and
sent to venturi scrubber through blower as shown in the annexure.
The venturi scrubber outlet emission values to the atmosphere are in the not detectable range.

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Attachment 7/PA-G1
(Mass / Material Balance Calculations Indicating
Inputs and Outputs of Process Units Including Air,
Water and Waste Releases)

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Attachment 8/PA-G1
(Detailed Process Flow Diagrams (Pfds) With Stream
Summaries)

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Attachment 9/PA-G1
(Plant Buildings)

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Attachment 10/PA-G1
(Plant facility boundaries)

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Attachment 11/PA-G1
(Specific Process Areas)

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Attachment 12/PA-G1
(All non-contact cooling water discharge sources)

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Attachment 13/PA-G1
(All Air Pollution Control Equipment Locations)

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Attachment 14/PA-G1
(Areas Of Hazardous Waste Storage, Treatment or
Disposal)

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End of the Document

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