consent order for establishment - andhra pradesh the...chloro alkali plant 1 1 x 10 tph + 1 x 15 tph...

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EGD.POST WITH ACK.DUE

CONSENT ORDER FOR ESTABLISHMENT

Order No. APPCB/VSP/KKD/449/HO/2015 Dt.24 .07.2019

Sub: PCB – CFE - M/s. The Andhra Sugars Limited, R.S.No.132,133,134 & 137,

Saggonda (V), Gopalapuram (M), West Godavari District – Consent for

Establishment for Expansion of the Board under Sec.25 of Water (P & C of P)

Act, 1974 and under Sec.21 of Air (P&C of P) Act, 1981 - Issued – Reg.

Ref: 1) CFE CPM order dt. 18.02.2015.

2) Industry’s application received through A.P. Single Desk Portal on

27.06.2019.

3) R.O’s inspection report dt. 04.07.2019.

4) CFE Committee meeting held on 18.07.2019.

5) Industry’s lr. dt. 18.07.2019.

1.

In the reference 2nd cited, an application was submitted to the Board seeking Consent for Establishment (CFE) for Expansion of Chloro Alkali Plant and inclusion of Synthetic organic chemicals manufacturing unit to produce the products with installed capacities as mentioned below, with the additional project cost of Rs.800.00 Crores.

I. Chlor-Alkali Plant Consented

capacity as per

CFE order dt.

18.02.2015 & CFO

order

dt.09.02.2016

Proposed for

Expansion

Total

capacity

after

expansion

1. Caustic Soda Lye 260 TPD 400 TPD 660 TPD

2. Caustic Soda Flakes 140 TPD 140 TPD 280 TPD

3. Caustic Potash -- 100 TPD 100 TPD

4. Liquid Chlorine 160 TPD 4 TPD 164 TPD

5. Hydrogen Gas (bottling) 2.83 TPD 1 TPD 3.83 TPD

6. Liquid Hydrogen 1 TPD 1 TPD 2 TPD

II. Chloromethanes

1. Methyl Chloride -- 10 TPD 10 TPD

2. Methylene Chloride -- 61 TPD 61 TPD

3. Chloroform -- 56 TPD 56 TPD

Website : https://pcb.ap.gov.in/

ANDHRA PRADESH POLLUTION CONTROL BOARD

D.No. 33-26-14 D/2, Near Sunrise Hospital, Pushpa Hotel Centre,

Chalamalavari Street, Kasturibaipet, Vijayawada – 520010.

https://pcb.ap.gov.in/

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III. Synthetic Organic Chemicals

1. Mono Chloro Acetic Acid -- 20 TPD 20 TPD

2. Chlorinated Paraffin Wax

(52%)

-- 20 TPD 20 TPD

IV. Non – EC Products

1. Sulphuric Acid 300 TPD -- 300 TPD

2. Poly Aluminum Chloride 90 TPD -- 90 TPD

By products:

I. Chlor-Alkali Plant Existing Expansion After

expansion

1. Hydrochloric Acid (33%) 600 TPD 400 TPD 1000 TPD

2. Sodium Hypochlorite (100%) 20 TPD 20 TPD 40 TPD

3. Sodium Chlorate -- 60 TPD 60 TPD

II. Chloromethanes

1. Carbon tetrachloride* -- 7.6 TPD 7.6 TPD

2. Hydrochloric Acid -- 65.8 TPD 65.8 TPD

III. Synthetic Organic Chemicals

1. Hydrochloric Acid (33%)

from Chlorinated Paraffin Wax

(52%)

-- 30 TPD 30 TPD

2. Hydrochloric Acid (33%)

from Monochloro Acetic Acid

-- 30 TPD 30 TPD

2. As per the application, the above expansion activity is to be located within the existing

plant premises located at R.S.No.132,133,134 & 137, Saggonda (V), Gopalapuram (M), West Godavari District in the total area of 320 acres.

3. The above site was inspected by the Environmental Engineer, A.P Pollution Control Board on 02.07.2019 and found that the site is surrounded by

North : Agricultural lands

South : Hillock

East : Agricultural lands

West : Agricultural lands

4. The Board, after careful scrutiny of the application, verification report of Regional Officer

and recommendations of the CFE committee, hereby issues CONSENT FOR ESTABLISHMENT for expansion under Section 25 of Water (Prevention & Control of Pollution) Act 1974 and Section 21 of Air (Prevention & Control of Pollution) Act, 1981 and the rules made there under. This order is issued to manufacture the products as mentioned at para (1) only.

5. This Consent Order now issued is subject to the conditions mentioned in Annexure.

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6. This order is issued from pollution control point of view only. Zoning and other regulations

are not considered.

7. This order is valid for a period of 7 years from the date of issue. Encl: Annexure

MEMBER SECRETARY To M/s. The Andhra Sugars Limited, R.S.No.132,133,134 & 137, Saggonda (V), Gopalapuram (M), West Godavari District [email protected] Copy to: 1. The JCEE, Z.O: Visakhapatnam for information and necessary action. 2. The E.E., R.O: Eluru for information and necessary action.

mailto:[email protected]

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Annexure 1. The proponent shall obtain Consent for Operation (CFO) from APPCB, as required Under

Sec.25/26 of the Water (P&C of P) Act, 1974 and under sec. 21/22 of the Air (P&C of P) Act, 1981, before commencement of the trail runs.

2. The applicant shall provide separate energy meters for Effluent Treatment Plant (ETP) and Air pollution Control equipments to record energy consumed. An alternative electric power source sufficient to operate all pollution control systems shall be provided.

3. The industry shall construct separate storm water drains. No effluents shall be discharged in to the storm water drains.

Water:

4. The source of water is Godavari River and the maximum permitted water consumption is as following:

S. No

Purpose

Quantity as per CFO order dt.

09-02-2016

Quantity for expansion

Total after expansion

1. Process and washings

1590 KLD 1235 KLD 2825 KLD

2. Boiler Feed 355 KLD 155 KLD 510 KLD

3. Cooling Tower 1175 KLD 3326 KLD 4501 KLD

4. RO / DM Plant regeneration

175 KLD 75 KLD 250 KLD

5. Domestic 15 KLD 75 KLD 90 KLD

6. Gardening and irrigation


TOTAL 3360 KLD 4948 KLD 8308 KLD

5. The maximum waste water generation shall not exceed the following:

S. No

Source Quantity as per CFO order dt.

09-02-2016

Quantity for expansion

Total after expansion

1. Process and washings


2. Boiler Blow down 30 KLD 35 KLD 65 KLD

3. Cooling Tower blow down


4. RO / DM Plant regeneration


5. Washings from MCA Plant

-- 9.5 KLD 9.5 KLD

6. Domestic 12 KLD 70 KLD 82 KLD

TOTAL 287 KLD 1069.5 KLD 1356.5 KLD

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ETP Details & Mode of Disposal: Existing and after expansion

Source of effluent Treatment Mode of final dispsoal

Process & Washings, Boiler Blow Down & Others (DM & RO Plant regeneration)

ETP of capacity 400 KLD consists of Equalization and Neutralization tank, Clarifier, , Pressure sand filter, Sludge drying beds, Ultra Filtration, RO plant (800 KLD). New ETP of 1200 KLD capacity and RO Plant of capacity 800 KLD to treat the waste water of expansion products. MCA plant washings shall be treated in de-chlorination plant followed by air stripping, forced evaporation and rotary vaccum dryer.

RO permeate shall be recycled for cooling tower make up. The RO rejects shall be used in the brine plant of caustic plant for mixing with the Brine / Solution.

Domestic effluents Sewage Treatment Plant of capacity 120 KLD

On land for irrigation after treatment

6. The Effluent Treatment Plant (ETP) shall be operated regularly. All the units of the ETP

shall be impervious to prevent ground water pollution.

7. The effluents shall be treated to the on land for irrigation standards, as stipulated under Schedule-VI of Environment (Protection) Rules, 1986, notified by Ministry of Environment and Forests, Government of India vide G.S.R.422 (E), dt.19.05.1993 and its amendments thereof.

8. During transfer of materials, spillages shall be avoided and garland drains shall be constructed to avoid mixing of accidental spillages with domestic waste and storm drains.

9. The industry shall install magnetic flow meters with totalizers at the inlet and outlet of ETP for the purpose of measuring the quantity of treated effluents recycled.

10. Floor washing shall be admitted into the effluent collection system only and shall not be allowed to find their way in storm drains or open areas. All pipe valves, sewers, drains shall be leak proof.

11. The industry shall install and connect online effluent quality monitoring system at the outlet of ETP as per CPCB directions.

12. Separate meters with necessary pipe-line shall be provided for assessing the quantity of water used for each of the purposes mentioned below.

a) Industrial cooling, boiler feed.

b) Domestic purposes.

c) Processing, whereby water gets polluted and pollutants are easily bio- degradable.

d) Processing, whereby water gets polluted and the pollutants are not easily bio-degradable.

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Air:

9. The Air Pollution Control equipment shall be installed along with the commissioning of the activity and shall comply with the following for controlling air pollution after expansion.

S.

No.

Source of Pollution

Control equipment

provided

Stack ht. in m -

above GL

Existing plant

Chloro Alkali Plant

1 1 x 10 TPH + 1 x 15 TPH Wet Scrubber 45 m

2 1 x 5 TPH Oil fired Boiler --- 18 m

3 15 TPH Waste Heat Recovery Boiler --- --

4

Waste Chlorine absorption tower Three Stage Alkali

scrubbing

(Dilute NaOH)

60 m

5 HCl Plant Two stage water

scrubber system

20 m each

6 H2SO4 Plant Alkali Scrubber 50 m

7 Flare stack for Liquid Hydrogen purge

gasses

Flare Stack 20 m

8 4750 KVA DG Set Silencer & Muffler 8 m

9 1250 KVA DG Set Silencer & Muffler 8 m

10 3 x 1000 KVA DG Set Silencer & Muffler 8 m

Poly Aluminum Chloride Plant

11 Reactor of Liquid PAC Process Water Scrubber 25 m

Proposed expansion:

1 1 x 25 TPH ESP 40 m

2 1 x 383 Kg/hr Incinerator (for burning of

Carbon Tetra Chloride generated from

Chloro Methanes )

-- 30 m

10. The evaporation losses in solvents shall be controlled by taking the following measures:

i) Chilled brine circulation shall be carried out to effectively reduce the solvent losses into the atmosphere.

ii) Transfer of solvents shall be done by using pumps instead of manual handling. iii) Closed centrifuges shall be used to reduce solvent losses. iv) The reactor vents shall be connected with primary & secondary condensers to catch

the solvent vapours. v) All the solvent storage tanks shall be connected with vent condensers to prevent

solvent vapours.

11. Use of halogenated solvents shall be avoided and shall be phase out from process.

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12. The industry shall properly maintain online continuous stack emission monitoring system (CSEMS) and CAAQM stations along with web camera facilities as per the directions of CPCB. The industry shall ensure that they should be connected to APPCB / CPCB websites as per CPCB directions.

13. The proponent shall ensure compliance of the National Ambient Air quality standards notified by MoEF, GoI vide notification No. GSR. 826 (E), dated. 16.11.2009 during construction and regular operational phase of the project at the periphery.

Solid Waste:

14. The industry shall comply with the following after expansion:

S.No. Type of waste Quantity Disposal option

1. Brine sludge (dry basis) 22 TPD To secured landfill within the premises.

2. Saturated mud (dry basis)

1.3 TPD To secured landfill within the premises.

3. Sulphur sludge 100 TPA As filler material for recycling in the process at Kovvur plant.

4. Spent V2O5 1.0 TPA To TSDF, Parawada, Visakhapatnam District

5. KCl Brine sludge (dry basis)


6. Gypsum 1.5 TPD To cement industries / Sent to secured landfill within the premises.

7. Alumina sludge 1.35 TPD To secured landfill within the premises.

8. Salts from Forced evaporation


9. Organic residue from Chloromethanes

30 TPD To cement industries

10. Spent Sulphuric acid 11.8 KLD Sold as product/sent to SSP production for sister unit located at Kovvur.

11. Ash from boilers 18.5 TPD To Cement and brick manufacturers.

12. ETP Sludge 4 TPA To secured land fill within the premises.

13. Used Batteries 64 Nos/annum

To Authorized Recyclers

Hazardous Solid Waste details:

S. No.

Type of Waste Quantity Disposal Option

Existing

1. Waste oil 2400 LPA Authorised Reprocessors / Recyclers / used as lubricant within the premises.

After Expansion

2. Waste oil 8300 LPA Authorised Reprocessors / Recyclers / used as lubricant within the premises.

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15. The proponent shall place the chemical drums and / any drums in the concrete platform

only. The Platform shall be provided with sufficient dyke wall and effluent collection system.

16. Container & Container liners shall be detoxified at the specified covered platform with dyke walls and the wash wastewater shall be routed to effluent collection tank.

17. The following rules and regulations notified by the MoE&F, GoI shall be implemented.

a) Regulation of Persistent Organic Pollutants Rules, 2018.

b) Hazardous waste and other wastes (Management and Transboundary Movement)

Rules, 2016.

c) Plastic Waste Management Rules, 2016.

d) Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989

e) Fly Ash Notification, 2016.

f) Batteries (Management & Handling) Rules, 2010.

g) E-Waste (Management) Rules, 2016.

h) Construction and Demolition waste Management Rules, 2016.

i) Solid Waste Management Rules, 2016.

j) The Public Liability Insurance Act, 1991 and its amendments thereof. Other Conditions:

18. The industry shall start construction activity only after obtaining Environmental Clearance from MoEF&CC, GoI, New Delhi.

19. Monthly production details of all the products should be submitted to the RO, Eluru.

20. Existing Green belt shall not be disturbed in the proposed expansion activity.

21. The proponent shall ensure that there shall not be any change in the process technology and scope of working without prior approval from the Board.

22. The proponent shall comply with all the directions issued by the Board from time to time.

23. Concealing the factual data or submission of false information / fabricated data and failure to comply with any of the conditions mentioned in this order attracts action under the provisions of relevant pollution control Acts.

24. Notwithstanding anything contained in this conditional letter or consent, the Board hereby reserves its right and power Under Sec. 27(2) of Water (Prevention and Control of Pollution) Act, 1974 and Under Sec.21(4) of Air (Prevention and Control of Pollution) Act, 1981 to revoke the order, to review any or all the conditions imposed herein and to make such modifications as deemed fit and stipulate any additional conditions.

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25. Any person aggrieved by an order made by the State Board under Section 25, Section

26, Section 27 of Water Act, 1974 or Section 21 of Air Act, 1981 may within thirty days from the date on which the order is communicated to him, prefer an appeal as per Andhra Pradesh Water Rules, 1976 and Air Rules,1982, to such authority (hereinafter referred to as the Appellate Authority) constituted under Section 28 of Water (Prevention and Control of Pollution)Act,1974 and Section 31 of the Air (Prevention and Control of Pollution) Act, 1981.

MEMBER SECRETARY To M/s. The Andhra Sugars Limited, R.S.No.132,133,134 & 137, Saggonda (V), Gopalapuram (M), West Godavari District [email protected]

mailto:[email protected]

consent order for establishment - andhra pradesh the...chloro alkali plant 1 1 x 10 tph + 1 x 15 tph...

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