Site Selection Considerations

• The process has been selected as Solvay process which uses concentrated brine and limestone to produce soda ash. Therefore the availability of these raw materials is important in the site selection. Brine is present all around the country. Since saturated brine is required the ideal option is to place the plant close to a saltern. Presently salterns are present at Puttalam, Muturagawela and Hambantota. Makeup ammonia for the plant will have to be imported. CO2 can be generated onsite by burning limestone. Limestone is available in Sri Lanka in 4 forms. Miocene limestone is present in the land strip stretching from Puttalam to the Jaffna peninsula. Dolomite reserves are present to the middle of the country. Areas well known in this aspect is present in the Matale district. Also Calcium Carbonate can be found in the form of coral reefs in various parts of the costal belt in Sri Lanka though this is not an environmental friendly and feasible option. Also sea shells that is present in the coastal areas is a good form of Calcium Carbonate but this is not a viable and secure raw material source for a soda ash production facility of the proposed scale. The distribution of the limestone resources in Sri Lanka can be seen in Figure 6.1. Therefore according to the availability of raw materials placing the plant at Puttalam or Mutragawela is suitable. But Mutragawela is not an option because of the present security threat.

• When we consider the market availability in the Puttalam area no huge demand exists for soda ash. But there is considerable potential that many industries will be built in the near future in this area because of land availability and climate.

• The population density of the area is very low. This has its advantages as well as disadvantages. There amount of people affected by the plant would be less because of less population while there would be difficulties in finding manpower for the construction phase and the maintenance of the plant. But this problem can be dealt with by recruiting workforce from other areas and developing a residential workforce.

• The dry and sunny condition that is present throughout the year in this area is extremely suitable for a process plant because loss of heat by cooling of process due to rain is avoided. This also saves energy and makes it possible to obtain consistent product quality.

• The geology and topology of the area has been assessed as being suitable for process plants because of the solid soil condition. From the feasibility study done to assess the feasibility of Norchcholai coal power plant it has shown that the area around Puttalam is one of the ideal areas to construct huge plants and factories.

• The possibility of a natural disaster like an earthquake, flood, etc occurring in this area is very low. This is great advantage because the consequences of such an event will be very disastrous for the plant.

• When we consider the site at Puttalam a secure security situation has been prevailing for several years. Also a tight security parameter presently has been set in the area because of the presence of the Palavi air force base, and the security would be further strengthened once the Norochcholai coal power plant has been commissioned. Therefore it can be said that the security threat or risk is minimum.

• There is a considerable amount of infrastructure development in the area. The port that is been developed to assist the Norchcholai power plant will be of assistance in the process of constructing the soda ash plant at the proposed site.

• There is a sound network of roads in the area. These roads have withstood the constant movement of container loads of cement and raw materials to and from the Holcim Cement plant, salt laden trucks and food containers moving to the North.

• The Puttalam lagoon has been naturally sited to assist a network of salt water canals. Most of these canals lead to the salterns in the area. The white salt piles can be seen in close proximity to the proposed land in figure 6.2. Also a canal network has been highlighted in light blue in the diagram. The tanks with the mother liquor is just south of the proposed area.

• Other infrastructure requirements like municipal water for general activities are available in the area. Once the Norochcholai coal power plant is complete high tension lines from the plant will

pass near these areas and connect to the National grid. Hence the capital cost that has to be incurred in the event of power line erection in the construction phase will be less.

• The plant will require a constant supply of limestone from a quarry at the North. The most viable option would be to transport limestone via rail. Limestone for the Holcim cement factory is brought through by rail carriages through a network of railroads from its quarry at Aruwakkaru. Since the cement factory is present farther to the south of the proposed land as seen the figure 6.2, the rail line from the quarry can be used to transport limestone to the soda ash plant from a quarry at the north.

• As mentioned in the technical feasibility the plant will require a source of process water. There are several water streams flowing through the area which can be utilized. But the proposed site has the option of using on-site water from the water pond that has been highlighted in figure 6.2 by a red circle.

• Another great advantage of the selected site at Karadipuval is the availability of land for expansion. There are several pieces of bare land across the main road to the west and adjacent to the North and eastern boundaries of the proposed land. Also the availability of land can be used to aid in the establishment of an effective waste disposal system.

• Because the area is gradually transforming into an industrial area rather than an attractive residential area the cost of land is low. Therefore the initial investment and cost for land in the event of an expansion is low.

• The proposed land has a main road on the western perimeter while it has remote roads on the northern and the eastern boundaries. This is of great advantage because the access to the plant will not be restricted.

• A positive aspect of the proposed site is that it is not situated close to vegetation or agricultural land. This is important because the impact on environment in the event of an unforeseen incident is low.

Figure 6.1- Mineral Map of Sri Lanka

Figure 6.2- Geographical map of proposed land

CaCO3 Unload

CaCO3 Crusher

CaCO3Miller

Crushed CaCO3 storage area

Kiln

Slaker of CaO Dryer

Na2CO3 Storage Product packing Product Storage

Carbonator Unit

NH4 Absorption Unit

Gas Cooler

NH4 Recovery Unit

Brine storage area Gas washing

with brine

Filter

Brine purifying unit

Control Room Boiler Room Cooling Tower NH4 Storage Security Post Office Area a a a a Security Post Water Source Security Post 6.3 Plant layout                  

CHAPTER 07

ENVIRONMENTAL IMPACT