environmentalimpact assessment report for...

ENVIRONMENTALIMPACT ASSESSMENT REPORT

For

PROPOSED EXPANSION OF ORGANIC CHEMICALS INDUSTRY

(Synthetic Organic Dyes)

(Cat.5 (f) B1)

OF

M/s. INDO COLCHEM PVT. LTD. at Plot No. 36, Phase – II, GIDCVatva, Ahmedabad

Prepared by

M/S. ULTRA – TECH

(Environmental Consultancy & Laboratory)

GazzetedByMoEF Unit No. 206, 224, 225, Jai Commercial Complex, Eastern Express Highway, Opp. Cadbury

Factory, Khopat, Thane (W) – 400601.

Tel.: 91-22-25342776, 25380198, 25331438.

Fax : 91-22-25429650 Email : [email protected]

Website: www.ultratech.in

December2017

EIA Report –M/s. Indo ColchemPvt. Ltd., Vatva, GIDC, Ahmedabad 1

mailto:[email protected]

INDEX

LIST OF TABLES .................................................................................................................................................. 7

LIST OF FIGURES ................................................................................................................................................. 8

1 CHAPTER– INTRODUCTION ............................................................................................................................ 9

1.1 Introduction: ........................................................................................................................................ 9

1.2 Location of the project ........................................................................................................................ 9

1.3 TOR Compliance ................................................................................................................................ 12

2 CHAPTER 2 - PROJECT DESCRIPTION .................................................................................................... 21

2.1 Products: ............................................................................................................................................ 21

2.2 List of name of products ................................................................................................................... 21

2.3 2.3 Details of Manufacturing Process .............................................................................................. 23

Details & MSDS of Raw Materials Required .............................................................................................. 141

2.4 Project Planning: ............................................................................................................................. 147

2.4.1 Resource Requirement and Other Specifications ................................................................. 147

2.4.2 Air Emission and Fuel ............................................................................................................. 147

2.4.3 Water Balance: ......................................................................................................................... 148

2.5 Manpower and Occupational Health Safety .................................................................................. 149

2.5.1 Existing Proposed Infrastructure ........................................................................................... 149

2.6 Project Layout: ................................................................................................................................. 150

2.7 R&R Plan .......................................................................................................................................... 151

2.8 Project Schedule and Cost Estimates ............................................................................................. 151

3 CHAPTER : BASELINE ENVIRONMENTAL STATUS ............................................................................ 152

3.1 Introduction: .................................................................................................................................... 152

3.2 Air Quality ........................................................................................................................................ 152

3.3 Water Environment ......................................................................................................................... 155


3.3.1 Ground Water and surface water Sampling Locations: ........................................................ 155

3.4 Soil .................................................................................................................................................... 158

3.5 Noise ................................................................................................................................................. 159

3.5.1 Noise Levels ............................................................................................................................. 159

3.6 Land use Studies .............................................................................................................................. 160

3.7 Topography ...................................................................................................................................... 161

3.7.1 Drainage Map: .......................................................................................................................... 162

3.7.2 Hydrogeology ........................................................................................................................... 163

3.7.3 Temperature: ........................................................................................................................... 164

3.7.4 Relative Humidity: ................................................................................................................... 164

3.7.5 Rainfall: .................................................................................................................................... 165

3.7.6 Wind speed and Wind direction ............................................................................................. 166

3.7.7 Windrows ................................................................................................................................. 166

3.8 BIOLOGICAL ENVIRONMENT ......................................................................................................... 167

3.8.1 Field Surveys: ........................................................................................................................... 168

3.8.2 Sampling Strategy: ................................................................................................................... 168

3.9 Socio-economy ................................................................................................................................. 173

3.9.1 Population ................................................................................................................................ 173

3.9.2 Religion Diversity .................................................................................................................... 173

3.9.3 Literacy Rate ............................................................................................................................ 174

3.9.4 Sex Ratio ................................................................................................................................... 174

3.10 Chapter Conclusion: ........................................................................................................................ 174

4 CHAPTER: ANTICIPATED ENVIRONMENTAL IMPACT ASSESSMENT, PREDICTION AND MITIGATION MEASURES ................................................................................................................................ 175

4.1 INTRODUCTION ............................................................................................................................... 175

4.1.1 IDENTIFICATION OF IMPACTS .............................................................................................. 175


4.1.2 IMPACT DURING CONSTRUCTION PHASE ............................................................................ 176

Operation Phase ......................................................................................................................................... 176

4.2 Impacts during Operation Phase and Mitigation Measures ......................................................... 176

4.2.1 Impact on Air Environment .................................................................................................... 176

4.2.1 Emissions from Proposed Project .......................................................................................... 176

4.2.2 Evaluation of Impacts using mathematical model and it’s mitigation ................................ 177

4.2.3 Analysis details ........................................................................................................................ 178

4.2.4 Methodology ............................................................................................................................ 178

4.2.5 Data Collection ......................................................................................................................... 178

4.2.6 Model Inputs ............................................................................................................................ 180

4.2.7 Conclusion ................................................................................................................................ 181

4.2.8 Environmental Management Plan .......................................................................................... 182

4.3 Water Environment:........................................................................................................................ 183

4.3.1 Impact on Water Environment and It’s Mitigation ............................................................... 183

4.3.2 ETP Details: .............................................................................................................................. 183

4.4 Noise Environment:......................................................................................................................... 184

4.4.1 Impacts on Noise Levels and It’s Mitigation .......................................................................... 184

4.5 Solid and Hazardous Waste Generation and Disposal.................................................................. 184

4.6 Land Environment (Green Belt) ..................................................................................................... 186

4.7 Ecological Environment: ................................................................................................................. 186

4.8 Socioeconomic Environment: ......................................................................................................... 186

5 ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE) ...................................................................... 187

5.1 Raw materials and Technology ...................................................................................................... 187

5.2 Site Alternatives: ............................................................................................................................. 187

5.3 ‘NO-PROJECT’ Option: ..................................................................................................................... 187

6 CHAPTER: ENVIRONMENTAL MONITORING PROGRAM .................................................................... 188


6.1 Introduction ..................................................................................................................................... 188

6.2 EMP structure and funds ................................................................................................................ 188

6.3 Environmental Monitoring Schedule: ............................................................................................ 190

6.3.1 Action Schedules:..................................................................................................................... 190

7 CHAPTER - ADDITIONAL STUDIES ....................................................................................................... 192

7.1 Public consultation .......................................................................................................................... 192

7.2 Risk assessment - Expansion of Specialty Chemicals ................................................................... 192

7.2.1 Approach to the Study ............................................................................................................. 193

7.2.2 Methodology: ........................................................................................................................... 193

7.3 Mitigation Measures: ....................................................................................................................... 195

7.4 Noise Exposure ................................................................................................................................ 196

7.5 Hazard Identification: ..................................................................................................................... 196

7.5.1 Quantification of Risk Assessment: ........................................................................................ 197

7.6 Identification of Hazardous Areas.................................................................................................. 199

7.6.1 Identification of Failure Cases for Hazardous Areas ............................................................ 199

7.6.2 Major Hazardous Areas ........................................................................................................... 199

7.7 Consequence Analysis ..................................................................................................................... 202

7.7.1 Damage Criteria ....................................................................................................................... 203

Scenario No. 3: Releases of Ammonia: ...................................................................................................... 210

7.7.2 RISK MITIGATION MEASURES SUGGESTED ......................................................................... 213

7.8 COAL HANDLING: ............................................................................................................................ 214

8 CHAPTER - PROJECT BENEFITS ............................................................................................................ 217

8.1 Improvements in the physical infrastructure ............................................................................... 217

8.2 Improvements in the social infrastructure ................................................................................... 217

8.3 Employment potential – skilled, semi-skilled and unskilled ....................................................... 218

8.4 Other tangible benefits.................................................................................................................... 218


8.5 Corporate Social Responsibility: .................................................................................................... 219

8.7 Environment Policy: ........................................................................................................................ 220

9 CHAPTER - ENVIRONMENT MANAGEMENT PLAN (EMP) ................................................................. 221

9.1 Need: ................................................................................................................................................. 221

9.2 Objectives: ........................................................................................................................................ 221

9.2.1 Environment Components: ..................................................................................................... 221

a) Monitor the work zone temperature levels. ......................................................................................... 222

b) Monitor the work zone humidity. .......................................................................................................... 222

c) Examine the health of workers and keep record. ................................................................................ 222

9.2.2 Environmental Monitoring Schedule: .................................................................................... 223

9.2.3 Schedules: ................................................................................................................................ 223

9.2.4 Consent Compliance ................................................................................................................ 224

9.2.5 Watch-dog Committee: ........................................................................................................... 225

9.3 Conclusion: ....................................................................................................................................... 227

10 CHAPTER -CONSULTANTS ENGAGED .................................................................................................. 228


LIST OF TABLES Table 1: TOR Compliance .................................................................................................................................. 13 Table 2: Existing and Proposed Products ........................................................................................................ 21 Table 3: List of Machineries for Manufacturing .............................................................................................. 22 Table 4: Flue Gas Emission Details ................................................................................................................ 147 Table 5: Water Balance ................................................................................................................................... 148 Table 6: Waste water Generation ................................................................................................................... 148 Table 7: Project Cost ....................................................................................................................................... 151 Table 8: Location of AAQ stations .................................................................................................................. 153 Table 9: Parameters and Frequency of monitoring during Nov.16 – Jan. 17 ............................................. 154 Table 10: Results for Location of AAQ stations ............................................................................................. 154 Table 11: Ground water sampling locations ................................................................................................. 155 Table 12: Surface water sampling locations ................................................................................................. 156 Table 13: Ground water monitoring Analysis Reports ................................................................................ 157 Table 14: Surface water Analysis Reports ..................................................................................................... 157 Table 15: Soil Quality Reports of Study Area ............................................................................................... 158 Table 16: Noise monitoring locations and Results ....................................................................................... 159 Table 17: Land Use details for 10km study area........................................................................................... 161 Table 18: Temperature Data of Study Area ................................................................................................... 164 Table 19: Relative Humidity Data of Study Area .......................................................................................... 165 Table 20: Rainfall Data of Study Area ............................................................................................................ 165 Table 21: Wind Speed Data of Study Area ..................................................................................................... 166 Table 22: List of Dominant Flora Observed in Study Area ........................................................................... 169 Table 23: List of Dominant Fauna Recorded in Study Area ......................................................................... 171 Table24: Existing Storages. ............................................................................................................................ 176 Table 25: Emission from Boiler Stack ............................................................................................................ 177 Table 26: Input and Assumptions .................................................................................................................. 178 Table 27: Stack and flue gas emissions details ............................................................................................. 179 Table 28: Modelled concentrations for present scenario ............................................................................ 181 Table29:Comparative Account of resultant concentration .......................................................................... 181 Table 30: ETP details ....................................................................................................................................... 183 Table 31: Effluent Characteristic .................................................................................................................... 184 Table 32: Management of Hazardous wastes ................................................................................................ 185 Table 33: Summary of Sampling .................................................................................................................... 188 Table 34: Functions of Environment Management Cell ............................................................................... 189 Table 35: Environmental Funds ..................................................................................................................... 190 Table 36: Other Hazards and Controls- Storage and Handling details of Hazardous Chemicals .............. 200 Table 37: Other Hazards and Control ............................................................................................................ 201 Table 38: Transportation, Unloading and Handling Procedure for Hazardous Chemicals ....................... 212 Table 39: Budgetary Provisions for the next five years (Every Year) ......................................................... 219 Table 40: Consent Compliance ....................................................................................................................... 224 Table 41:List of EIA coordinator, functional area experts & associates: .................................................... 231


Table 42: Laboratory Details .......................................................................................................................... 232

LIST OF FIGURES Figure 1: Location Map ..................................................................................................................................... 11 Figure 2 : Location of the Plant ........................................................................................................................ 12 Figure 3: Layout of the existing and proposed expansion ........................................................................... 150 Figure 4: Air monitoring stations ................................................................................................................... 153 Figure 5: Location Ground water and Surface Water stations .................................................................... 156 Figure 6: Land use/land cover map of study area ........................................................................................ 160 Figure 7: LULC for 10 km study area ............................................................................................................. 161 Figure 8: Drainage Map ................................................................................................................................... 163 Figure 9: Contour Map ................................................................................................................................... 163 Figure 10: Wind Rose (Dec. 2016 to Feb. 2017) ........................................................................................... 167 Figure 11:Wind rose Plot for the study period ............................................................................................. 179 Figure 12: Present 24hr average emission dispersion contours for PM10 .................................................. 181 Figure 13 : Present 24hr average emission dispersion contours for SO2 ................................................... 182 Figure 14: Present 24hr average emission dispersion contours for NOx ................................................... 182 Figure 15: Structure of Environment Management Cell .............................................................................. 189 Figure 16: Structure & duty of Envt. Cell ....................................................................................................... 191 Figure 17: QRA Methodology ......................................................................................................................... 197 Figure 18: Flow chart for quantitative Risk Assessment ............................................................................. 198 Figure 20: Toxic Effects ................................................................................................................................... 208

List of Annexures:

1) ToR letter/Corrigendum in TOR and its Acceptance

2) Water permission letter

3) Monitoring Reports

4) Risk & Hazop Report

5) Mathematical modelling Report


1 CHAPTER– INTRODUCTION

1.1 Introduction:

M/s Indo Colchem Pvt. Ltd. (ICPL) is involved in the manufacturing the Dyes & Dyes Intermediates at

Plot No. 36, Phase-II, GIDC, Vatva, Ahmedabad, for which we have obtain consolidated consent &

authorization vide order allot- AWH-51237 which is valid up to 04/10/2017. The renewal of the same is

currently in process at GPCB.ICPL is promoted by Mr. Satish Shah, and he has planned expansion of

Synthetic Organic Dyes & Dyes Intermediates from 300 MT/Month to 1050 MT/Month. ICPL has

adequate experience in the field of Mfg of Dyes & Dyes intermediates. ICPL existing unit is located at

Vatva GIDC and due to market demand, the unit is planning to expand their mfg. activity within the plant

premises. The project falls under category B as per schedule of 5(f) of EIA notification 2006 and its

further amendments, as it is located in GIDC, Vatva. ICPL have got the ToR from the SEIAA, Gujarat dated

01.05.2017 and have prepared the EIA accordingly.. The site is well connected with road and railway of

Ahmedabad city and Sabarmati` river passing at distance of 9.26 km. There is no forest, national park,

wild life sanctuary, eco sensitive areas in surrounding 10 km radius. The project doesn’t fall under CRZ

boundaries.

Today ICPL is among India’s large players in the production of all type of synthetic organic dyes with

many of starting materials being self-manufactured along with the final products to be competitive and

quality consistent. ICPL has reached production capacity of 12600 MT / annum currently. Moreover,

ICPL is recognized with ISO9001:2015 and ISO 14001:2015, GOTS, REACH, and ECOPASSPORT. ICPL has

its own primary treatment plant plus common effluent treatment plant in order to manage

environmental issue in the compliance of law.

The demand for products intended to be manufactured is increasing in the country and by setting up

this unit ICPL will be able to meet the demand of various products at the domestic & international

market. The unit will use good faith efforts to employ local people from the nearby villages depending

upon the availability of skilled & un-skilled man-power surrounding the project site. In operation phase,

the proposed project would require significant workforce of non-technical and technical persons.

1.2 Location of the project

ICPL is located at Vatva, GIDC, Ahmedabad at longitude 72°38’36.11” E and latitude 22°57’42.20”N. The

nearest railway station is Vatva, Ahmedabad on broad gauge section of Ahmedabad Railway Station. The

station is located at about 2.14 km from the project site. Nearest Airport is at Ahmedabad, which is


located at a distance of about 12.4 km from project site. Water for industrial purpose will be available

through GIDC itself.

The salient features of the site are as under:

1. Minimum distances:

a) From City: Ahmedabad 3.26 km North

b) Village: Vinzol, GIDC1.26 km South

c) Historical Site:Kankariya Lake 6.26 km North-West

d) Sanctuaries: None

e) Highway: NH – 8 (1.71 km, North-East)

2. Use of forest land: None

3. Use of prime agricultural land: None

4. Planned submergence: None

5. Displacement of population: None

The location of the Plant is shown in Figure 1 and Figure 2. The plant is accessible by all-weather road.


Figure 1: Location Map


Figure 2 : Location of the Plant

Commitment to safety, health and environment is at the core of corporate philosophy. The Project Proponents are known for their track record of honest and transparent business. The team is law abiding, and goes much beyond mere obedience to the letters. They go to the spirit of law. The track record of merit and honesty is evident from the working of existing unit. The company is well aware about energy crisis and takes various steps for Conservation of energy, such as

- Electrical load management to restrict maximum demand - Power factor improvement - Energy management and monitoring software installation - Variable frequency drive application for motors - Energy conservation awareness training and

1.3 TOR Compliance

The project was presented for ToR at SEAC, Gujarat under Category 5(f) B1 Expansion of Existing Synthetic OrganicUnit.We have received ToR Letter for the same on 01.05.2017. Further request letter for corrigendum in TOR was made on 13.05.2017 for certain changes and the same had been accepted by SEAC/SEIAA on 19.07.2017. Attached as Annexure 1is the approved TOR as well as the request made for changes in the TOR. The same has been incorporated in the EIA report.Additionally, guidelines given in the Manual Published by MoEF in April 2015 for preparation of EIA were also followed.


The compliance for the ToR issued is given in Table No. 1

Table 1: TOR Compliance

S. No. Standard ToR Compliance Executive Summary Covered 1 Introduction

i. Details of EIA consultant Chapter 11 ii. Info about PP Chapter 1

iii. Importance and benefits of project Chapter 1 2 Project description

i. Project cost and time of completion Chapter 2 ii. Product with capacities for proposed project Chapter 2

iii. If expansion project, details of existing product with capacities and whether adequate land is available for expansion, reference of earlier EC if any

NA

iv. List of raw materials required along with their source and mode of transportation

Chapter 2

v. Other chemicals and materials required with quantities and storage capacities

Chapter 2

vi. Details of emission, effluents, hazardous waste generation and their management

Chapter 2

vii. Requirement of water, power with source of supply, status of approval water balance diagram man-power requirement (regular and contract)

Chapter 2

viii. Process description alongwith major equipments and machineries, process flow sheet (quantative)

Chapter 2

ix. Hazard Identification and details of proposed safety systems

Chapter 7

x. Expansion/Modernization proposals: NA A Copy of all the environmental clearance(s)

including Amendments thereto obtained for the project from MoEF/SEIAA shall be attached as Annexure. A certified copy of the latest monitoring report of the Regional office of the Ministry of Environment and Forests as per circular dated 30th May,2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to operate for the ongoing existing operation of the project from SPCB shall be attached with the EIA-EMP report.

NA


S. No. Standard ToR Compliance B In case the existing project has not obtained EC,

reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish /No Objection Certificate and Consent to Operate (in case of operating prior to EIA Notification,2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the spcb SHALL BE SUBMITTED.

NA

4 Site Details i. Location of the project site covering village,

taluka/tehsil, district and state, Justification for selecting the site, whether other sites were considered.

Chapter 2

ii. A toposheet of the study area of radius 10 Km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet ( including all eco-sensitive areas and environmentally sensitive places.

Chapter 3

iii. Details w.r.t option analysis for selection of site. Chapter 5

iv. Co-ordinates (lat-long) of all the four corners of the site.

Chapter 2

v. Google-map earth downloaded of the project site. Chapter 3

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial area indicating location

Chapter 3

vii.

Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular

Chapter 2

viii. Landuse break-up of total land of the project site (identified and acquired), government/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)

Chapter 3

ix. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area

Chapter 1

x. Geological features and Geo-hydrological status of the study area shall be included.

Chapter 3


S. No. Standard ToR Compliance xi. Details of Drainage of the project upto 5km

radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river shall also be provided. (mega green field projects)

Chapter 3

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.

Chapter 2

xiii. R&R details in respect of land in line with state Government policy

NA

5 Forest and wildlife related issues (if applicable):

NA

i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)

NA

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)

NA

iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

NA

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon

NA

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in the study area

NA

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife

NA

6 Environmental Status i. Determination of atmospheric inversion level at Chapter 3


S. No. Standard ToR Compliance the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

Chapter 3

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Chapter 3

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

Chapter 3

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if yes give details.

NA

vi. Ground water monitoring at minimum at 8 locations shall be included.

Chapter 3

vii. Noise levels monitoring at 8 locations within the study area.

Chapter 3

viii. Soil Characteristic as per CPCB guidelines. Chapter 3

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

Chapter 7

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

Chapter3

xi. Socio-economic status of the study area. Chapter 3

7 Impact and Environment Management Plan


S. No. Standard ToR Compliance i. Assessment of ground level concentration of

pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modelling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modelling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.

Chapter 4

ii. Water Quality modelling - in case of discharge in water body

NA

iii. Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyorcum- rail transport shall be examined.

Chapter 7

iv. A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E(P) Rules.

Chapter 4

v. Details of stack emission and action plan for control of emissions to meet standards.

Chapter 4

vi. Measures for fugitive emission control Chapter 4

vii. Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Chapter 4


S. No. Standard ToR Compliance viii. Proper utilization of fly ash shall be ensured as

per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Chapter 4

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated.

Chapter 4

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.

Chapter 4

xi. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included

Chapter 6

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Chapter 6

8 Occupational health i. Plan and fund allocation to ensure the

occupational health &safety of all contract and casual workers.

Chapter 7

ii. Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.

Chapter 7

iii. Details of existing Occupational & Safety Hazards. NA


S. No. Standard ToR Compliance What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved.

iv. Annual report of heath status of workers with special reference to occupational Health and Safety.

Chapter 7

9 Corporate Environment Policy i. Does the company have a well laid down

Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.

Chapter 9

ii. Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA.

Chapter 9

iii. What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Chapter 4

iv. Does the company have system of reporting of non compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report.

Chapter 4

10 Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.

Chapter 4

11 Enterprise Social Commitment (ESC) Chapter 8

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Chapter 8


S. No. Standard ToR Compliance 12 Any litigation pending against the project and/or

any direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

No

13 A tabular chart with index for point wise compliance of above TOR.

Chapter 1


2 CHAPTER 2 - PROJECT DESCRIPTION 2.1 Products:

The demand for products intended to be manufacture is increasing in the country by setting up this expansion of synthetic organics dyes at unit M/s. INDO COLCHEM PVT. LTD. will be able to meet the demand of various products domestic & international market. The existing products and additional ones are presented in Table 2

Table 2: Existing and Proposed Products Sr. No.

Name of Products Quantity in MT/Month

Existing Proposed Total after Proposed

1 Sulpho Tobias Acid 50 - 50

2 Synthetic Organic Dyestuff (Crude) (As per last CC&A)

250 - 250

3 Synthetic Organic Dyestuff(Crude) (Proposed Expansion)

- 750 750

Total 300 750

1050

2.2 List of name of products

1. Reactive Black 5/Mix 2. Reactive Blue 203

3. Reactive Red 195 4. Reactive Blue XLE/19

5. Reactive Yellow 145 6. Reactive Blue 250

7. Reactive Orange 122 8. Reactive Blue 21

9. Reactive Orange 13 10. Reactive Black 39

11. Reactive Red 250 12. Reactive Red CD

13. Reactive Red 223 14. Reactive Black 8 15. Reactive Red 111 16. Reactive Orange R (Daba) 17. Reactive Red 198 18. Reactive Red 21

19. Reactive Red 120 20. Reactive Red 222

21. Reactive Blue 160 22. Reactive Blue 222

23. Reactive Blue 221 24. Reactive Red 141

25. Reactive Blue 198 26. Reactive Yellow 160


27. Reactive Blue FNG/FNR 28. Reactive Blue 194

29. Reactive Blue 220 30. Reactive Blue 171

31. Reactive Yellow 44 32. Reactive Black 31

33. Reactive Orange 107 34. Reactive Orange 12

35. Reactive Yellow 84 36. Reactive Violet 5

37. Reactive Yellow 18 38. Reactive Orange 84

39. Reactive Yellow 15 40. Direct Black 22

41. Reactive Yellow XLR 42. Acid Black 210

43. Reactive Yellow HEXL 44. Acid Black 194

45. Reactive Yellow HE4G 46. Acid Black 234

47. Reactive Yellow WNN(Ciba Yellow)

48. Reactive Blue 203

Table 3: List of Machineries for Manufacturing

Sr. No. Name of Machinery/Equipment

Nos. Capacity Status Existing/Proposed

1 Reaction Vessel 20 (P-1) & 20 (P-2)

List attached Existing and proposed both.

2 Finished Product Storage Vessel

NA NA Godown for storage products

3 Raw Materials Storage Vessel

NA NA Godown for raw materials

4 Filter Press 16 Existing 5 RO 5 Existing 6 Centrifuge 7 Existing 7 SFD No Existing 8 Spray Dryer 3 500 Lt/Hr.

700 Lt/Hr. 1000 Lt/Hr.

Existing

9 3 Boilers, Cooling plant, chilling plant, effluent treatment plant & other ancillary machineries

- Existing utilities detail are given in chapter-4

Existing

10 Spray Dryer -4 1 1000 Lt/Hr. Proposed 11 Boiler -4 1 5Tonne/ Hr. Proposed 12 High Temperature Spray

Dryer -1 1 4000 Lt./Hr. Proposed

The above machinery is tabulated in planning stage, it may very at the time of actual commissioning stage and at the time of operation.


Packing & dispatch: The products are packed and dispatched in MS or HMHDPE drums of 210 lits and PP bags of 50 kg. 2.3 2.3 Details of Manufacturing Process

Reactive Black 5

Manufacturing Process:

First Diazotization:

VS charged to a MSRL reaction vessel along with water and ice to maintain temperature between

0oc to 5oc. then hydrochloric acid will be added followed by sodium nitrite powder gradually till

diazotization completed, which can be confirmed by starch iodide paper. Any excess nitrite will

be removed by adding sulfamic acid just before coupling. Keep temperature between 0oc to 5oc

throughout diazotization reaction.

First Coupling:

Charged H Acid to the Diazotized BntsAnd Stir It Keeping the Temperature Between 0oc To 5oc

By Adding Ice.

Second Coupling:

OAVS charged to a MSRL reaction vessel along with water and ice to maintain temperature

between 0oc to 5oc. then hydrochloric acid will be added followed by sodium nitrite powder

gradually till diazotization completed, which can be confirmed by starch iodide paper. Any

excess nitrite will be removed by adding sulfamic acid just before coupling. Keep temperature

between 0oc to 5oc throughout the diazotization reaction.

Spray Drying:

The standardized dye liquid will be transfer to the spray drying holding tank and spray dried.


REACTIVE BLACK 5


Q

REACTIVE BLACK 5


Reactive Black 31


MASS BALANCE

INPUT QTY(KG) OUTPUT QTY(KG)

Water 20000 Water Evaporate 32900 Ice 10000 Dye 10000

6- Nitro 5000 Beta Naphthol 2600 Caustic Flakes 2000 Salisylic Acid 500

B.C.S 2800 Total 42900 42900


REACTIVE RED 141

PROCESS DESCRIPTION:-

H-ACID IS ACETYLATED & COUPLED WITH S.T. ACID DIAZO. THE COUPLED MASS IS HYDROLYZED, ISOLATED & FILTERED. THE WET CAKE SOLUTION IS PREPARED AND THEN CYNURATED AND THEN BRANDING IS DONE WITH PPD TO GET FINAL PRODUCT. THE FINAL PRODUCT IS SPRAY DRIED AND PDR IS OBTAINED. CHEMICAL REACTION:


REACTIVE RED 222


J ACID IS ACETYLATED AND THEN COUPLED WITH PA3SA DIAZO TO GIVE COUPLING MASS, WHICH IS HYDROLYSED, ISOLATED AND FILTERED WET CAKE SOLUTION IS PREPARED AND THEN CYNURATED WITH CYNURIC CHLORIDE AT 0-2°C° AND THEN CONDESATION IS DONE WITH N-ETHYL META BASE ESTER V.S. TO GET FINAL PRODUCT. IT IS THEN SPRAY DRIED AND THEN DRY POWDER IS OBTAINED

CHEMICAL REACTION:


REACTIVE RED 223


Meta base V.S condensed charged in 98 % Sulphuric acid at 20- 25°C stir for 36 hours and isolate in ice cold water.

Vinyl sulfone ester is Cyanurated and then condensed with MPDSA and the resultant product is diazotized and coupled with acetyl h-acid and then spray dried.

CHEMICAL REACTION:

MASS BALANCE


REACTIVE RED RB (C.I. REACTIVE RED 198)


V.S. ESTER IS CONDENSED WITH CYNURIC CHLORIDE CONDENSED MASS IN AGAIN CONDENSED WITH HACID IN ACIDIC MEDIUM. THIS IS CONDENSED MASS-2. V.S. ESTER DIAZOTIZED AND THEN COUPLED WITH CONDENSED MASS-2 TO GET FINAL PRODUCT. THEN FINAL PRODUCT IS SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE RED HE3B (C.I. REACTIVE RED 120)


H ACID IS CYNURATED AND COUPLED WITH ORTHANILIC ACID DIAZO AND THEN CONDESED WITH PPD. CLARIFIED AND SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE RED ME4BL (195)


TAKE INITIAL WATER AND CHARGE VINYL SULFONE ESTER PDR IN IT.

THEN ADJUST pH = 5.5 WITH SODIUM BI CARBONATE.

TAKE WATER INTO ANOTHER VESSEL. ADD ICE + CAL. OIL + CYNAURIC CHLORIDE IN IT.

CONDENSE BOTH THE SOLUTION. THIS IS KNOWN AS COULPLER-1.

THEN COUPLED THIS MASS WITH H ACID SOLUTION. THIS IS KNOWN AS COUPLER-II.

THEN PREPARE DIAZO OF SULFO TOBIAS ACID.

THEN PROCEED FOR FINAL COUPLING WITH S.T.A DIAZO & COUPLER-II.

THEN SEND LIQUID FOR SPRAY DRYING.

FINALLY, POWDER MATERIAL IS STANDARDISED AND PACKED INTO BAGS.

CHEMICAL REACTION:


REACTIVE RED ME6BL (250)


STEP-1 :- COUPLER PREPARATION

TAKE WATER IN REACTION VESSEL 1. NOW CHARGE H ACID PDR IN IT. THEN STIR FOR 30 MINUTES. ADJSUT pH=7.0 BY SODA SOLUTION & STIR FOR 30 MINUTES. NOW COOL TO 10oC BY ADDING ICE. THEN CHARGE ACETIC ANHYDRIDE AND STIR FOR 5 HOURS. TEST ACETYLATION, WHEN O.K. CHARGE C. FLAKES AND TAKE pH = 8.5 & T = 85oC. MAINTAIN FOR 1 HOUR & COOL TO R.T. AND THEN COOL TO 50oC BY ADDING ICE.

STEP-2 :- DIAZO PREPARATION

TAKE WATER IN REACTION VESSEL 2. CHARGED TOBIAS ACID PDR INTO IT. THEN STIR FOR 30 MINUTES. ADJUST pH =7.0 BY SODA SOLUTION STIR FOR 30 MINUTES. ADD ICE TO COOL TO 50oC. CHARGE NaNo2 SOLUTION & COOL TO 0oC BY ADDING ICE IN A REACTION VESSEL 3. TAKE ICE + HCL. STIR FOR ½ HOUR. RECEIVE ABOVE TOBIAS ACID + NaNo2 MIXTURE IN ½ HOUR AT 0-2oC.

STIR FOR DIAZOTISATION FOR 2 HOURS, AT 0-2oC, KEEPING ST+VE, CR+VE.

STEP-3 :- COUPLING

TAKE DIAZO, SLOWLY ADD FIRST COUPLING MASS AND ADJUST pH FROM 6.5 TO 7 BY ADDING SODA ASH. NOW STIR IT FOR 10 HOURS AND MAINTAIN TEMP. 0oC < 10oC. NOW COUPLING IS O.K.

STEP-4 :-

TAKE COUPLING MASS AND HEAT IT UP TO 70oC. NOW STIR IT FOR 3 HOURS. NOW HYDROLYSIS IS O.K.


REACTIVE RED CD


SULFO V.S. ESTER IS DIAZOTISED AND COUPLED WITH J ACID SOLUTION TO GIVE COUPLING MASS-1. PCVS IS DIAZOTISED AND THEN COUPLED WITH J ACID (I.E. COUPLING MASS-1) TO GIVE COUPLING MASS-2. THE COUPLING MASS-2 IS CLARIFIED AND SPRAY DRIED TO GIVE DRY POWDER.

CHEMICAL REACTION:


REACTIVE YELLOW 15 (GR) (C.I. REACTIVE YELLOW 15)


PCVS IS DIAZO IS COUPLED WITH SPMP ANDSPRAY DRIED.

CHEMICAL REACTION:


REACTIVE YELLOW 160

PROCES DESRIPTION:

MONO ETHYL AMINE IS TAKEN AND COOL TO 10°C AND THEN METHYL CYANO ACETATE IS ADDED AT 10-20°C. THEN METHYL ACETO ACETATE IS ADDED AT 20-25°C AND THE LIQUID AMMONIA IS ADDED. HEATED TO 98-100°C AND MAINTAINED FOR 10HRS. THEN THE PRODUCT IS ISOLATED IN DILUTE SULFURIC ACID (40%) AT T=20°C AND FILTERED. THE WET CAKE OBTAINED IS HYDROLYSED BY 98% H₂SO4 AT 75-80°C FOR 6HRS. THEN THE FINAL PRODUCT IS ISOLATED IN ICE WATER AT 20°C. THEN IT FILTERED. THE WET CAKE OBTAINED IS CENTRIFUGED AND DRIED.

MPDSA IS CONDENSED WITH CYANURIC CHLORIDE AND CONDENSED PRODUCT IS DIAZOTISED AND COUPLED WITH 2 PYRIDONE. THE COUPLING MASS OBTAINED IS FURTHER CONDENSED WITH VINYL SULFONE ESTER TO GIVE FINAL PRODUCT, WHICH IS SPRAY DRIED TO GIVE DRY POWDER.

CHEMICAL REACTION:

C₂H₅NH₂ + CH₃COCH₂COOCH₃ + CH₃COOCH₂CN+ Liq NH₃

(MEA) (MAA) MCA (17)

(45) (116) (99)


REACTIVE YELLOW H4G (C.I. REACTIVE YELLOW 18)


MPDSA IS CYNURATED WITH CYNURIC CHLORIDE AND CYNURATED MPDSA IS DIAZOTISED AND COUPLED WITH 1:4 SPCP AND THEN CONDENSED WITH METANILIC ACID AND THEN CLARIFIED AND SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE YELLOW HE4G

(C.I. REACTIVE YELLOW 105)


CYNURATED MPDSA DIAZOTISED AND COUPLED WITH SPCP. PRODUCTS ARE CONDENSED WITH DASDA AND SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE YELLOW HE4R (C.I. REACTIVE YELLOW 84)


K-ACID IS DIAZOTISED AND COUPLED WITH MUA & CYNURATED AND CONDENSED WITH BDSA AND SPRAY DRIED.

CHEMICAL REACTION:

REACTIVE YELLOW SEL (YELLOW HEXL)



C ACID DIAZOTISED COUPLED WITH 3AMA PRODUCT IS CYNURATED AND CONDENSED WITH OPD AND SPRAYS DRIED.

CHEMICAL REACTION:

REACTIVE YELLOW WNN (C.I. REACTIVE CIBA YELLOW)


PROCESS DESCRIPTION:

PARA BASE V.S. ESTER SULPHONATED WITH SULPHURIC ACID AND OLEUM 65% AT 130°C FOR 4 HOUR AND ADDING OF WATER HYDROLYSIED AT 115°C FOR 3 HOURS BLOW IN WATER AND ICE AND ISOLATED WITH SALT.

SULPO PARA V.S. ESTER AND PARA V.S. ESTER DIAZOTIZED AND COUPLED WITH MPDSA AND THE PRODUT OBTAINED IS SPRY DRIED.

CHEMICAL REACTION:

REACTIVE YELLOW DS5R (C.I. REACTIVE YELLOW XLR)



K. ACID IS DIAZOTIZED AND COUPLED WITH MUA AND CYNURATED AND CONDENSED WITH G YELLOW R AND SPRAY DRIED.

CHEMICAL REACTION:


MASS BALANCE INPUT


SR. RAW MATERIALS CIBA YELLOW

1 3-AMINO 4-METHOXY -

2 C-ACIDIC -

3 OPD -

4 MPDSA 1752

5 OIL HS -

6 V.S. ESTER 2640

7 CYCL3 -

8 ANTIFOAM 60

9 SPD OIL 24

10 DDC OIL -

11 DASDA -

12 1:4 SPCP -

13 SULFO PARA B.V.S 3384

14 METANILIC ACID -

15 K-ACID -

16 MUA / HCL -

17 SULFANIC ACID 12

18 SODA BI CARB 3012

19 SODA ASH -

20 CAUSTIC LYE -

21 SODIUM SULFATE -

22 SODIUM NITRITE 1308

23 PCVS -

24 SPMP -

25 BDSA -

26 HCL 2712

Total 14904


MASS BALANCE OUTPUT

SR. TOTAL MASS REMOVED FROM REACTION AND PROCESS CIBA YELLOW 1 TOTAL WATER EVAPORATED 1332 2 CO2 GAS EVOLUATED DURING THE REACTION 1572 3 SALF FORMATION DURING THE REACTION - 4 TOTAL FINISH PRODUCT 12000 TOTAL 14904

REACTIVE GOLDEN YELLOW MERL (REACTIVE YELLOW 145)

Process Description:

AMINO G ACID CHARGED IN 98% SULPHURIC ACID AND 65% OLEUM AT 130°C FOR 16 HOURS BLOW THE BATCH IN WATER AT 90-95° C ISOLATE WITH SALT FILTER AT 50°C ANF CERIFUGE.

TAKE WATER IN A VESSEL. THEN ADD K ACID, SODIUM NITRITE, AND HCL IN IT. THE DIAZO OF K ACID IS COUPLED WITH MUA. THIS IS KNOWN AS COUPLER-I. THIS COUPLER IS CYNURATED BY CYNURIC CHLORIDE. THIS CYNURATED MASS IS COUPLED WITH VS. AFTER CONDENSATION THE LIQUEFIED MATERIAL IS SENDING FOR SPRAY DRYING. FINALLY, THE POWER MATERIAL IS PACKED INTO BAGS.


CHEMICAL REACTION:

NHCONH2

NHCONH2


REACTIVE GOLDEN YELLOW R


(C.I REACTIVE YELLOW 44) PROCESS DESCRIPTION:

VINYL SULPHONE DIAZOTISED COUPLED WITH MPDSA AND SPRAY DRIED.

CHEMICAL REACTION:


MASS BALANCE

SR. NO. RAW MATERIAL TOTAL INPUT

GOLDEN YELLOW RNL

QUANTITY (KG)

GOLDEN YELLOW R

1 ACETYL M.P.D.S.A 1190 -

2 MPDSA - 936

3 VINYL SULFONE 1490 1401

4 ANTI FOAM 20 15

5 SPD OIL 20 15

6 DDC OIL 100 -

7 SULFAMIC ACID 5 3

8 SODIUM BI CARBONATE 1185 420

9 HCL 810 309

10 CAUSTIC LYE - 198

11 SODIUM SULFATE 880 -

12 SODIUM NITRITE 360 210

TOTAL 6060 3507

OUTPUT

SR. NO. TOTAL MASS REMOVED

FROM REACTION PROCESS

TOTAL OUTPUT QUANTITY(KG)

GOLDEN YELLOW RNL GOLDEN YELLOW -R

1 TOTAL WATER EVAPORATED 440 288

2 CO2 EVOLVED DURING REACTION 620 219

3 TOTAL FINISHED PRODUCT 5000 3000

TOTAL 6060 3507


REACTIVE GOLDEN YELLOW RNL (C.I. REACTIVE ORANGE 107)


VINYL SULPHONE ESTER IS DIAZOTISED COUPLED WITH ACETYL MPDSA AND SPRAY DRIED.

CHEMICAL REACTION:


MASS BALANCE

SR. NO. RAW MATERIAL TOTAL INPUT

GOLDEN YELLOW RNL

QUANTITY (KG)

GOLDEN YELLOW R

1 ACETYL M.P.D.S.A 1190 -

2 MPDSA - 936

3 VINYL SULFONE 1490 1401

4 ANTI FOAM 20 15

5 SPD OIL 20 15

6 DDC OIL 100 -

7 SULFAMIC ACID 5 3

8 SODIUM BI CARBONATE 1185 420

9 HCL 810 309

10 CAUSTIC LYE - 198

11 SODIUM SULFATE 880 -

12 SODIUM NITRITE 360 210

TOTAL 6060 3507

OUTPUT

SR. NO. TOTAL MASS REMOVED

FROM REACTION PROCESS

TOTAL OUTPUT QUANTITY(KG)

GOLDEN YELLOW RNL GOLDEN YELLOW -R

1 TOTAL WATER EVAPORATED 440 288

2 CO2 EVOLVED DURING REACTION 620 219

3 TOTAL FINISHED PRODUCT 5000 3000

TOTAL 6060 3507


REACTIVE ORANGE 84


J ACID IS ACETYLATED AND THEN COUPLED WITH SULFO TOBIAS ACID DAIZO. THE COUPLED MASS IS HYDROLYSED, ISOLATED AND FILTERED. THE WET CAKE SOLUTION IS PREPARED AND THEN CYNURATED WITH CYNURIC CHLORIDE. THE CYNURATED MASS IS FURTHER CONDENZED WITH BDSA TO GET FINAL PRODUCT. THE FINAL PRODUCT IS SPRAY DRIED AND DRY POWDER IS OBTAINED.

CHEMICAL REACTION:

SODA ASH

C. FLAKES


REACTIVE ORANGE MERL

(C.I. ORANGE 122) PROCESS DESCRIPTION:-

TOBIAS ACID CHARGED IN 23% OLEUM AT 20-25°C THEN HEATED TO 110°C AND MAINTAIN FOR 12 HRS. SULPHOMASS BLOW IN WATER AND HYDROLYSISED AT 130°C. MAINTAIN FOR 6 HRS. COOL TO 20-22°C FILTER. WET CAKE FUSSED WITH CAUSTIC SODA AND CAUSTIC POTTASH FLAKES AT 200°C AND MAINTAIN FOR 6 HRS. ISOLATE WITH DILUTE SULPHURIC ACID. FILTER WET CAKE DRY.

CHARGE REAL QUANTITY OF J ACID INTO WATER AND TAKE PH 7 BY USE OF 20% SOLUTION OF NAOH. THEN ADD ICE AND TAKE TEMPRATURE 15°C AND THEN CHARGE ACETIC ANHYDRIDE. THEN CHECK UNREACTED J ACID IF IT IS OK THEN TAKES PH BY USE OF 20% SOLUTION OF NAOH FLAKES.

DIAZOTIZATION OF SULPHO TOBIAS ACID:

CHARGE REAL QUANTITY OF S.T.A IN WATER. HEN CHARGE HCI IN THE SOLUTION. THEN SLOWLY CHARGE SODIUM NITRITE SOLUTION TILL SI POSITIVE STABLE AND CR POSITIVE.

COUPLING:

ADD ACETYL J SOLUTION TO S.T.A. DIAZO. AFTER COMPLETION OF ADDING TAKE PH 6.5 BY SODIUM BI CARBONATE. AFTER ADJUSTING PH STIRR IT TILL DIAZO NAGATIVE IN COUPLING TEST.

HYDROLYSIS:

HEAT THE COUPLED MASS TO 40-45°C AND THEN CHARGE NAOH FLAKES. AND THEN HEAT TO 80 0C AND MAINTAIN THE MASS FOR 3-4 HOURS TILL HYDROLYSIS COMPLETION. AFTER COMPLETION OF HYDROLYSIS ADJUST PH 7.0 BY USE OF HCI.

BASE DISSOLVING

TAKE UPPER FILTER INTO WATER AND STIRR THE MATERIAL TILL CLEAR ON SPOT.

CYNURATION OF UPPER CLEAR BASE SOLUTION

TAKE CYNURIC CHLORIDE INTO WATER ICE THEN ADD UPER CLEAR BASE SOLUTION SLOWLY AND STIRR THE MATERIAL. THEN TAKE PH 6.5 BY USE OF SODA SOLUTION AFTER COMPLETION OF CYNURATION REACTION THE TOTAL MASS WILL BE TRANSFERRED FOR CONDENSATION PROCESS VINYL SULPHONE.

THEN AFTER THE MASS IS SEND FOR SPRAY DRYING ACTIVITY FOR OBTAUN FINISHED PRODUCT.


REACTIVE ORANGE R (DABA)

PROCESS DESCRIPTION: -

ORTHANILIC AICD IS DIAZOTISED AND COUPLED WITH 3:5 DABA TO GIVE COUPLING MASS-1. V.S. ESTER IS DIAZOTISED & COUPLED FURTHER WITH COUPLING MASS-1 TO GIVE COUPLING MASS-2. THE COUPLING MASS-2 IS SPRAY DRIED AND DRY POWDER IS OBTAINED.

CHEMICAL REACTION:


REACTIVE ORANGE 12

PROCESS DESCRIPTION: -

K ACID IS DIAZOTISED AND COUPLED WITH META URIEDO ANILINE. THE COUPLED MASS IS CYNURATED WITH CYNAURIC CHLORIDE. THE CYNURATION MASS IS HOT BRANDED WITH LIQUID AMMONIA TO GET FINAL PRODUCT, WHICH IS THEN ISOLATED, FILTERED AND WET CAKE IS OBTAINED. THE WET CAKE SOLUTION IS PREPARED AND THEN SPRAY DRIED TO GET DRY POWDER.

CHEMICAL REACTION:


REACTIVE ORANGE H2R:


J- ACID CONDENSED WITH MONO METHYL AMINE IN THE PRESENT OF SODIUM BI SULPHITE AT AH 6

TEMP 105°C FOR 16 HRS. ISOLATE WITH DIL. SULPHURIC ACID AND PURIFIED THE CRUDE BY HCL.

CHARGE REAL QUANTITY OF NMJ ACID INTO WATER. AND TAKE pH 7 BY USE OF 20% SOLUTION OF

NaOH. THE ADD ICE AND TAKE TEMPERATURE 15oC. AND THEN CAHRGE ACETIC ANHYDRIDE THEN

STIR FOR 06 HOURS.

THEN CHECK UNREACTED NMJ ACID. IF IT IS OK THEN TAKE pH BY USE OF 20% SOLUTION OF NaOH

FLAKES.

DIAZOTIZATION OF SULPHO TOBIAS ACID:-

CHARGE REAL QUANTITY OF S.T.A. IN WATER. CHARGE HCL IN THE SOLUTION. THEN, SLOWLY

CHARGE SODIUM NITRITE SOLUTION STILL SI POSITIVE STABLE AND CR POSITIVE.

COUPLING:-

ADD ACETYL NMJ SOLUTION TO S.T.A. DIAZO. AFTER COMPLETION OF ADDING TAKE pH 6.5 BY

SODIUM BI CARBONATE. AFTER ADUSTING pH IT TILL DIAZO NEGATIVE IN COUPLING TEST.

HYDROLYSIS:-

HEAT THE COUPLED MASS TO 40-45oC AND THEN CHARGE NaOH FLAKES. AND THEN HEAT TO 80oC

AND MAINTAIN THE MASS FOR 3-4 HOURS. TILL HYDROLYSIS COMPLETION.

BASE DISSOLVING:-

TAKE UPPER FILTER WET CAKE INTO WATER AND STIR THE MATERIAL WILL CLEAR ON SPOT.

CYNURATION OF UPPER CLEAR BASE SOLUTION:-

TAKE CYANURIC CHLORIDE INTO WATER WITH ICE. THEN ADD UPPER CLEAR BASE SOLUTION

SLOWLY AND STIR THE MATERIAL.

REACTIVE VIOLET 5:



V.S. ESTER DIAZOTISATION IS DONE AND COUPLED WITH ACETYL H ACID. THE COUPLED PRODUCT IS REACTED WITH COPPER SULFATE AND HYDROGEN PEROXIDE. THEN IT IS ISOLATED, FILTERED AND WET CAKE IS OBTAINED. THE WET CAKE SOLUTION IS PREPARED AND SPRAY DRIED AND DRY POWDER IS OBTAINED.

CHEMICAL REACTION:


REACTIVE NAVY BLUE

1. NAVY BLUE GG (C.I. REACTIVE BLUE 203)


VINYL SULPHONE ESTER & DMAVS ARE DIAZOTIZED & COUPLED WITH H ACID AND SPRAY DRIED.

CHEMICAL REACTION:


2. NAVY BLUE XLE PROCESS DESCRIPTION: MPDSA IS CONDENSED WITH CYANURIC CHLORIDE AND CONDENSED MASS IS DIAZOTISED AND COUPLED WITH H ACID IN ACIDIC MEDIUM & THEN COUPLED WITH ORTHO TOLUIDINE 5 SULFONIC ACID AND THEN SPRAY DRIED. CHEMICAL REACTION:


NAVY BLUE RGB (C.I. REACTIVE BLUE 250)


VINYL SULPHONE ESTER & OAVS ARE DIAZOTIZED & COUPLED WITH H ACID AND SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE BLUE 220


OAVS IS SULPHONATED WITH 23% OLIEM AT 140°C FOR 24 HOURS. BLOW IN ICE AND WATER TO 15°C ISOLATE WITH ADDING SALT.

4 SULPHO ANTHRANILIC ACID DIAZOTISED WITH HCL AND NANO2 AT 0.5°C THEN COUPLED WITH SODIUM BI SULPHATE AT 25°C AND COUPLED MASS CONDESED WITH BENZALDEHYDE IN ACIDIC MEDIA AT 70-75°C FOR 6 HOUR COOL AND FILTER.

4 SLUFO ANTHRANILIC ACID HYDRAZONE IS COUPLED WITH SULFO OAVS ESTER DIAZO AND PRODUCT IS COMPLEXED WITH COPPER SULFATE AND SPRAY DRIED.


MASS BALANCE INPUT

SR.

NO.

RAW MATERIALS TOTAL INPUT

QUANTITY (KGS)

BLUE 220

1 CYNURIC CHLORDIE -

2 CAL.OIL -

3 6-ACETYL OAPSA -

4 4-SULFO HYDROZONE 1820

5 N-ETHYL M.B. ESTER -

6 ANTIFOAM 25

7 SULFONIC ACID 5

8 SULFO O.A.V.S 2265

9 SPD OIL 50

10 DDC OIL -

11 SODA ASH 565

12 SODIUM SULFATE -

13 SODA BI CARB 1435

14 SODIUM NITRITE 395

15 COPPER SULFATE 1655

16 CAUSTIC SODA -

17 HCL -

18 PPDDSA -

TOTAL 8215


MASS BALANCE OUTPUT

REACTIVE BLUE 221


4 SLUFO ANTHRANILIC ACID HYDROZONE IS COUPLED WITH 6A-OAPSA DIAZO PRODUCT OBTAINED IS COMPLEXED WITH COPPER SULPHATE. THE MASS FILTERED WET CAKED HYDROLYSIS AND BASE IS CONDENSED WITH N ETHYL META BASE ESTER AND SPRAY DRIED.

CHEMICAL REACTION:

TOTAL MASS REMOVED TOTAL OUTPUT

QUANTITY (KGS)

BLUE 220

TOTAL WATER EVAPORATED 630

CARBON DIOXIED GAS

EVALUATED DURING

THE REACTION

985

SALT FORMATION DURING

THE REACTION

1600

TOTAL FINISHED PRODUCT 5000

8215


REACTIVE BLUE FNG


ANILINE 2,5 DISULPHONIC ACID IS CYNURATED AND CONDENSED WITH BLUE 198 BASE AND META BASE V.S. ESTER AND THE PRODUCT IS SPRAY DRIED.

CHEMICAL REACTION:


REACTIVE BLUE HERD (C.I REACTIVE BLUE 160)


4 SLUFO ANTHRANILIC ACID HYDRAZONE IS COUPLED WITH 6 ACETYL OAPSA DIAZO AND THE PRODUCT OBTAINED IS COMPLEXED WITH COPPER SULPHATE. THE OBTAINED COUPLED MASS IS HYDROLYSED, ISOLATED, FILTERED TO GET BASE WET CAKE. BASE SOLUTION IS PREPARED AND ANALYSED AND THEN IS CONDENSED WITH CYNURATED METANILIC ACID AND WITH CYNURATED PPDDSA. THE PRODUCT OBTAINED IS CLARIFIED AND SPRAY DRIED.

CHEMICAL REACTION:


MASS BALANCE INPUT

SR.

NO.

RAW MATERIALS TOTAL INPUT

QUANTITY (KGS)

BLUE HERD BLUE 221 BLUE 220

1 CYNURIC CHLORDIE 443.5 436 -

2 CAL.OIL 9 8 -

3 6-ACETYL OAPSA 318 684 -

4 4-SULFO HYDROZONE 399 924 1820

5 N-ETHYL M.B. ESTER - 712 -

6 ANTIFOAM 9 20 25

7 SULFONIC ACID 3 4 5

8 SULFO O.A.V.S - - 2265

9 SPD OIL 9 12 50

10 DDC OIL 30 40 -

11 SODA ASH 285 500 565

12 SODIUM SULFATE 840 1140 -

13 SODA BI CARB 360 848 1435

14 SODIUM NITRITE 90 188 395

15 COPPER SULFATE 337.50 764 1655

16 CAUSTIC SODA 771 1232 -

17 HCL 597 1452 -

18 PPDDSA 207 - -

TOTAL 4698 8964 8215


MASS BALANCE OUTPUT

TOTAL MASS REMOVED TOTAL OUTPUT QUANTITY (KGS) BLUE HERD BLUE 221 BLUE 220

TOTAL WATER EVAPORATED 522 912 630

CARBON DIOXIED GAS EVALUATED DURING THE REACTION

306 652 985

SALT FORMATION DURING THE REACTION

870 3400 1600

TOTAL FINISHED PRODUCT 3000 4000 5000 4698 8964 8215

MANUFACTURING PROCESS OF REACTIVE BLUE HEGN

STEP 1 → MANUFACTURING OF CHLORONIL WITH ZERO DISCHARGE.

STEP 2→ NITRO HEGN

10000 LITER WATER CHARGE

1800 KGS. E.D.A. CHARGE

1800 KGS. PNCBOSA HEAT TO 100ºC FOR 6 HRS.

COOL TO 30ºC TRANSFER IN WATER.

Add

3570 KGS. HCL 30% TO pH 6.5

FILTER CENTRIFUGE

STEP 2 → REDUCTION OF NITRO HEGN

8330 LITER WATER

1430 KGS. IRON POWDER

785 KGS. HCL HEAT TO 90ºC

CHARGE NITRO CAKE HEGN SLOWLY IN 6 HRS.

∆ 95ºC. MAINTAIN FOR 3 HRS.

CHARGE

857 KGS. SODA ASH TO pH 8.5-9 FILTER


THE BATCH. WASH THE CAKE.

VOLUME ABOUT 10,000 LITER ADJUST

pH 6.0 BY CHARGING

500 KGS. 30% HCL.

STEP 3 → CHLORANIL CONDENSATION- BROWN BASE

10000 LITER ABOVE AMINE (STEP 2) ADD

715KGS CHLORANIL SUSPENSION WITH ADDING

715 KGS. SODA BI CARB TO pH 6-6.5 AT

55ºC. MAINTAIMN FOR 12 HRS.

FILLTER IN PRESS

CENTRIFUGE, DRY PULVERISE.

YIELD= WEIGHT – 1150 KGS. BROWN BASE

STEP 4 → BLUE BASE FOR HEGN

TAKE

4286 KGS. SULPHURIC ACID CHARGE

2857 KGS OLEUM 65% CHARGE

1643 KGS. BROWN BASE HEGN AT 20ºC CHARGE

1143 KGS. POTTASIUM PER SULPHATE MAINTAIN 20ºC

FOR 6 HRS. TRANSFER THE BATCH IN

WATER + ICE AT 25-30ºC.

FILLTER, WASH WITH WATER TO CANGO

RED PAPER FAINT.

DUMP THE PRESS. YIELD= 245KGS.

STEP 5 → CYNURATION OF ANILINE 2:4 D.S.A

10070 LITER WATER CHARGE

1429 KGS. ANILINE 2:4 D.S.A ADJUST pH 6.5 BY


350 KGS. SODA ASH SOLN. DUMP

1430 KGS. CYANURIC CHLORIDE ADJUST pH 2.5-3 BY

1354 KGS SODA ASH SOLN TO pH 0-5ºC. CLARIFY

STEP 6 → REACTIVE BLUE BASE OF HEGN

5000 LITER WATER CHARGE BLUE BASE HEGN MOIST 3500 KG WC

CAKE (STEP 4)

RECEIVE CLARIFY CYNURATED ANILINE

2:4 D.S.A. SOLN. ADJUST pH 8.5 BY

500 KGS. SODA ASH SOLN.AT 45-50ºC.


REACTIVE BLUE 171


MPDSA IS CONDENSED WITH CYNURIC CHLORIDE AND THE CONSDESED PRODUCT IS DIAZOTISED AND COUPLED WITH H-ACID ACID IN ACIDIC MEDIUM AND THEN HOT BRANDING IS DONE WITH METANILIC AID TO GIVE FINAL RPDOCUT WHICH IS THEN SPRAY DRIED TO GIVE DRY POWDER

CHEMICAL REACTION:

REACTIVE BLUE 171(M.W. 1288)


REACTIVE BLUE 194


MPDSA IS CONDENSED WITH CYCL3 AND CONDENSED PRODUCT IS AGAIN 2ND CONDENSED WITH SULFANILIC ACID, WHICH IS THEN DIAZOTIZED AND COUPLED WITH H-ACID TO GIVE COUPLING MASS – 1. V.S ESTER DIAZO IS PREPARED & THEN CONDENZED WITH COUPLING MASS-1 TO GIVE COUPLING MASS- 2, WHICH IS THEN SPRAY DRIED AND DRY POWDER IS OBTAINED.

CHEMICAL REACTION:


REACTIVE BLUE 21

Manufacturing Process:

Charge orthonitro toluene (solvent) in glass lined vessel. Charge required quantity of Phthalic Anhydride, Urea in a Glass Vessel and give the

desire temperature. Heating the content to higher temperature and then, addition of catalyst (ammonium

molybdate) and Cuprous Chloride to it. Raise the temperature of the reaction mass at desire temperature and maintain this

temperature for 6/8 hours. Scrub the ammonia and carbon dioxide gas evolved during the process to water

scrubber to get the solution of ammonium carbonate. After reaction is over, draw the sample and check for complete conversion of Phthalic

Anhydride to CPC Blue Crude. Discharge the batch into Horizontal Rotary Vacuum Dryer (HRVD) and remove the

solvent under vacuum. After complete removal of solvent add water to the Horizontal Rotary Vacuum Dryer (HRVD) and transfer the material to treatment tank.

Charge crude CPC in another vessel and add Sodium Hydroxide and dilute by water, raise the temperature of the total mass for the alkali treatment. Filter the material through filter press and wash the wet cake by water.


Charge the wet cake of crude CPC in another vessel and add dilute sulphuric acid from Alpha plant (@ 16 to 18 % Acid), raise the temperature to the total mass for the acid treatment. Filter the material through filter press and wash the wet cake by water.

Dry the material using Spin Flash Dryer (SFD) and collect the dried powder in bags.

Charge ChloroSulphuric acid. Then add cpc. Keep Temp. 500C then raise temperature maintain then cool. Then add pcl3. Raise temp and 2hrs maintain after cool then dumping drying and then washing. In condensation vessel takes VS &stirrable water take pH 5-8. Then add wet cake sulphonated add then maintain temp. add pyridine then spray Drying.

Chemical Reaction:

4C8H4O3+2CO (NH2)2 4C8 NO2H5 + 2CO2 + 2H2O

Phthalamine Eq.-I

4C8NO2H5+8CO (NH2)2 4C8 H7NO2+2CO2+2H2O

Di-Amino Phthalamide Eq.-II

4C8H7N3+CuCI C32H16N8Cu+NH4CI+1/6N2+2/3 NH3

Amm. Molybdate CPC Blue Equ - III


REACTIVE BLUE 222


D.N.C.B IS SULPHONATED IN WATER AND SODIUM BI SULPHITE IN THE PRESENT MGO AT 75-80°C FILTER CENTRIFUGE. NITRO PRODUCT REDUCED BY IRON/ HCL AT 95°C CHARGE SODA AND FILTER ISOLATE BY SALT FILTER CENTRIFUGE. TOBIAS ACID SULPHONATED IN 23% OLEUM AT 25°C MAINTAIN TEMPERATURE FOR 6 HOURS BLOW THE BATCH IN WATER AND ICE AT 20- 22°C AND ISOLATED WITH SALT FILTER AND CENTRIFUGE.

MPDSA IS CONDENSED WITH CYNURIC CHLORIDE AND WHICH IS FURTHER CONDENSED WITH MBVS ESTER AND THEN THE PRODUCT OBTAINED IS DIAZOTISED AND COUPLED WITH H ACID TO GET COUPLING MASS-1. S.T. ACID IS DIAZOLISED AND FURTHER COUPLED WITH COUPLING MASS-1 TO GET COUPLING MASS-2, WHICH IS SPRAY DRIED AND DRY PDR IS OBTAINED.

CHEMICAL REACTION:


REACTIVE NAVY BLUE P2R (C.I. REACTIVE BLACK 39)



ANILINE 2:5 DSA IS DIAZOTISED AND COUPLED WITH H-ACID AND COUPLING -1 MASS IS OBTAINED. MPDSA IS CONDENSED WITH CYNURIC CHLORIDE AND THEN DIAZOTISED AND THEN ADDED TO COUPLING MASS- 1 AND COUPLING -2 IS DONE. THEN HOT BRANDING IS DONE WITH LIQUID AMMONIA AT 45° C TO GET THE FINAL PRODUCT, WHICH IS THEN CLARIFIED AND SPRAY DRIED TO GET DRY POWDER.

CHEMICAL REACTION:


REACTIVE BLACK HN C.I REACTIVE BLACK 8


4 NAP IS DIAZOTIZED AND COUPLED WITH H- ACID SOLUTION IN ALKALINE MEDIUM. COUPLING MASS OBTAINED IS THEN CHROMINATED AND COBALTING IS DONE. THE RESULTANT MASSIS THEN CYNURATED AND HOT BRANDINGIS DONE WITH LIQUID AMMONIA. THE FINAL PRODUCT IS SPRAY DRIED TO GET DRY POWDER CHEMICAL REACTION:


Details & MSDS of Raw Materials Required

Sr.No Name Of Raw Material State Size Of Container

Parameter (Kg/M3)

Parameter ( O C)

1 VINYL SULFONE ESTER Solid 50kg Atm. Pressure

Room Temp

2 H-ACID Solid 50kg Atm. Pressure

Room Temp

3 CYNURIC CHLORIDE Solid 50kg Atm. Pressure

Room Temp

4 SULFO TABIAS ACID Solid 50kg Atm. Pressure

Room Temp

5 K-ACID Solid 50kg Atm. Pressure

Room Temp


Sr.No Name Of Raw Material State Size Of Container

Parameter (Kg/M3)

Parameter (O C)

6 META URIEDO ANILINE 4 Solid 50kg Atm. Pressure

Room Temp

7 N.M.J.ACID Solid 50kg Atm. Pressure

Room Temp

8 AMONIUM CHLORIDE Solid 50kg Atm. Pressure

Room Temp

9 TOBIAS ACID Solid 50kg Atm. Pressure

Room Temp

10 MPDSA Solid 50kg Atm. Pressure

Room Temp

11 M.B.V.S.ESTER Solid 50kg Atm. Pressure

Room Temp


2.4 Project Planning:

The total manufacturing facility having 11137 m2 total plot area. Project layout is shown in Figure 2.5.

Proposed boiler capacity is adequate to cater need of proposed products. Waste water generated from

manufacturing process will be treated, recycled and utilized for process and greenbelt purpose. No

waste water from new products will be released in drains or river. Domestic waste water will be treated

in soak pits as quantity is very minimal. The water requirement and waste water generated in the

factory will be as follows. Water requirement will be met through GIDC Vatva itself.

2.4.1 Resource Requirement and Other Specifications

Requirement of fuel will be met from Fuel (Coal – 35.00 MT/Day) and Diesel (35 Lit/Hr). Power

requirement will be met from Torrent Energy (1150 KW) and 275 three Nos KVA stand by DG set. Air

Emission and Fuel

2.4.2 Air Emission and Fuel

Table 4: Flue Gas Emission Details

Sr. No.

Stack attached To Stack

Height (m)

Air Pollution Control System

Pollutants

SPM mg/NM3

SO2 ppm

NOX ppm

1. Boiler-1 (0.8 TPH)

10 Cyclone separators 2 Nos.

<150 <100 <50

2. Boiler-2 (0.8 TPH)


<150 <100 <50

3 Boiler-3 (0.6 TPH)


<150 <100 <50



<150 <100 <50

5 HAG Boiler

20 2 Cyclones + 1 Twin Cyclone system (Additional)

<150 <100 <50

6. Evaporation Spray (8000 Lit/Hr)

15 2 Cyclones <150 <100 <50

7. D.G. Set (275 KVA)

3 2 Nos. <150 <100 <50

8. Spray Dryer-1 (1000 Lit/Hr)

20 2 Cyclones <150 <100 <50



15 2 Cyclones <150 <100 <50


20 2 Cyclones <150 <100 <50


20 2 Cyclones <150 <100 <50

Sr. No.

Type of Fuel

Fuel Used in Quantity

1. Coal High temperature spray dryer & Hot Air Generator attached with four spray dryers & Boiler-4

35 MT/Day

2. Diesel D.G. Set 35 Lit/Hr

2.4.3 Water Balance:

Water Balance of Proposed Project Total water requirement after expansion is 440 m3/d. Water will be met from GIDC. Water permission is available and attached as Annexure 2

Table 5: Water Balance Water Consumption (m3/day)

Category Existing Proposed Total after expansion Domestic &Gardening 10 - 10 Industrial Process (including Ice) 183 177 360 Washing 9 11 20 Boiler 30 - 30 Cooling 5 5 10 Other 2 8 10 Total 239 201 440

Source of water : GIDC Vatva

Table 6: Waste water Generation Waste Water Generation (m3/day)

Existing Proposed Total after expansion Domestic &Gardening 8 -- 8 Industrial Process Concentrate +Dilute

0+105

40+125

40+230


Washing 9 11 20 Boiler 13 17 30 Cooling 5 5 10 Other 2 8 10 Total Industrial Waste Water to CETP, Vatva (Booked Quantity)

134 166 300

Total Industrial Waste Water to MEE, Novel, Vatva

- 40 40

2.5 Manpower and Occupational Health Safety

The proposed project will generate employment for 12 workers. We will have its own

Occupational Health Center Factory Act for management of medical & accidental casualty.

Occupational Health Center is having established infrastructural and in-house facilities as per

factory Act to ensure services to the company and contract employees in Plant. The aims and

objectives of the department is to provide a preventive, curative and supportive services to all

employees. The area for green belt is approx. 3680 m2.

2.5.1 Existing Proposed Infrastructure

Existing facility have quite enough infrastructure for propose project.

The proposed infrastructure for manufacturing, ancillary operations, transport of raw material

and final products are adequate. Raw material and final products will be transported through

tankers/trucks.


2.6 Project Layout:

Figure 3: Layout of the existing and proposed expansion


2.7 R&R Plan

This existing unit is located in GIDC Vatva. The proposed expansion will carry out within plant premises,

hence R&R plan is not applicable to this project.

2.8 Project Schedule and Cost Estimates

Unit has ability to complete proposed project within 4 – 6 months and likely to be commission

the project for operation purpose. Total estimated cost of project will be 350 lakhs.

Table 7: Project Cost

Particulars Amount in INR

Land & Building 1,15,00,000 Plant & Machineries 1,50,00,000 Manpower 5,00,000 Environ Protection Measures 80,00,000 Total 350,00,000

--00--


3 CHAPTER : BASELINE ENVIRONMENTAL STATUS 3.1 Introduction:

The EIA determines the environmental consequences of the project prior to construction, assess the

impact on environment due to construction, on existing baseline environmental parameters and also

importantly on land use and socio-economic parameters. Baseline study is an integral part of EIA study,

as it helps to identify the environmental concerns already existing in that area. The entire baseline data

has been collected through actual physical surveys and observations, literature surveys, interaction with

locals, government agencies and departments.

This chapter describes the existing environmental settings in the study area. The purposes of describing

the environmental settings of the study area are:

To understand the project need and environmental characteristics of the area

To assess the existing environmental quality, as well as the environmental impacts due

to the proposed development around the study area

To identify environmentally significant factors or geographical areas that could preclude

any future development

The baseline data has been ascertained for the environmental components to be considered in general

to industrial projects: land, groundwater, surface water, marine, air and meteorology, noise, biology,

socio economic and occupational health, solid waste and public utilities.

The establishment of baseline for different environmental components in the designated study area and

at the project site has been conducted by field monitoring/investigation for baseline data generation.

The data generation was carried out covering Ambient Air Quality, Noise Levels, Water Quality, Land

Use, Soil Quality, Ecology, Hydrology and Socio-economic features. Besides, additional data/information

regarding water availability, ecology, demographic pattern and socio-economic conditions were also

collected from secondary sources.

3.2 Air Quality

Eight ambient air quality monitoring stations were established in the study zone of 10 km radius around the project site as shown in Figure 4. The location of stations and its distance from site are presented in Table 8. The main sources of air pollution in the region are small scale industries and traffic.


Figure 4: Air monitoring stations

Table 8: Location of AAQ stations

Sr. No. Name of Village Distance (km) & Direction

AAQ1 Project Site ---

AAQ 2 Jashodanagar 1.8 , S

AAQ 3 Isanpur 3.29 , SW

AAQ 4 Maninagar 3.45 , S

AAQ 5 Narol Residential 7.13 , W

AAQ 6 Narol Char Rasta, Industrial Area

7.53 , W

AAQ 7 Hathijan 4.53 , N

AAQ 8 Dhamatvan 7.3 , ENE


Selection of sampling Locations :

The location of the station was selected on following considerations:

• Predominant wind direction as per IMD data • Sensitivity of the area, if applicable

Monitoring was done for PM2.5, PM10, SO2, NOX. The frequency of monitoring is mentioned in Table 8 and results of monitoring are presented in Table 10

Table 9: Parameters and Frequency of monitoring during Nov.16 – Jan. 17

Parameters Sampling Frequency

PM2.5, PM10 SO2 and NOX 24 hourly, twice a week

(CO) 8 hourly, six sample/station

Table 10: Results for Location of AAQ stations

Parameters Particular Location A1 A2 A3 A4 A5 A6 A7 A8

PM 10 in μg/m3

Max. 74.6 62.4 66.4 64.7 62.9 72.6 52.4 50.2

Min. 60.4 50.4 54.4 52.2 56.6 58.2 44.9 42.6

Mean 67.4 56.4 60.4 58.45 59.75 65.4 48.65 46.4

PM 2.5 in μg/m3

Max. 50.4 42.6 44.4 43.2 42.2 49.2 40.8 39.2

Min. 42.4 36.4 36.6 34.5 32.5 40.6 39.0 38.4

Mean 46.4 39.5 40.5 38.85 37.35 44.9 39.9 38.8

SO2 in μg/m3

Max. 44.1 22.2 22.8 25.2 23.4 36.8 6.9 5.4

Min. 38.2 17.9 16.6 22.4 19.2 28.4 4.2 3.6

Mean 41.15 20.05 19.7 23.8 21.3 32.6 5.55 4.5

NOx in μg/m3

Max. 36.8 25.8 22.6 24.2 25.6 39.5 19.4 20.1

Min. 30.3 19.9 18.4 20.8 20.4 36.4 12.2 18.2

Mean 33.55 22.85 20.5 22.5 23 37.95 15.8 19.15

VOC in μg/m3

Max. 0.3 0.2 0.16 0.2 0.18 0.3 0.1 0. 2

Min. 0.12 0.14 0.1 0.12 0.12 0.11 0.1 0.17

Mean 0.21 0.17 0.13 0.16 0.15 0.205 0.1 0.17 The full sets of monitoring results for winter season are presented in Annexure 3.


(Annexure-I- All Baseline Results- Air, Soil, Noise & Water)

Discussions

It could be noticed from the results, the air quality of the study area is within NAAQS November 2009, in µg/m3

Values of PM10 in the background environment ranged from 42.6 µg/m3 to 74.6 µg/m3. Average values of

PM10 found to be around 67.4 µg/m3 was observed to be within the permissible limit of 100 µg/m3.

The values of PM2.5 range from 32.5 µg/m3 to 50.4 µg/m3. The average value of PM2.5 was 46.4 µg/m3

and found to be within NAAQ standard of 60 µg/m3.

The values of Sulfur dioxide levels were found to vary from 3.6 µg/m3 to 44.1µg/m3.The values of SO2

were found to be well within NAAQ standard of 80µg/m3.

The value of Nitrogen oxide ranged from 12.2 µg/m3 to 39.6 µg/m3. The values of oxides of Nitrogen

were observed to be well within the NAAQ standard of 80µg/m3.

The value of VOC ranged from 0.10µg/m3 to 0.21 µg/m3.

3.3 Water Environment

3.3.1 Ground Water and surface water Sampling Locations:

No water bodies exist at project site. Surface water samples were collected from Sabarmati River and

Kankaria Lake. Locations of surface water and ground water sample collection are shown in Table 11

and 12 Laboratory analysis results are shown in Table 13 and 14 resp.

Table 11: Ground water sampling locations

Sr. No. Name of Village Type of Sample Distance (km) & Direction

GW1 Project Site Ground Water ---

GW2 Jashodanagar Ground Water 1.8 , S

GW3 Isanpur Ground Water 3.29 , SW

GW4 Maninagar Ground Water 3.45 , S

GW5 Narol Residential Ground Water 7.13 , W

GW6 Narol Char Rasta, Industrial Area Ground Water 7.53 , W

GW7 Hathijan Ground Water 4.53 , N

GW8 Dhamatvan Ground Water 7.3 , ENE


Table 12: Surface water sampling locations

Sr. No. Name of Village Type of Sample Distance (km) & Direction

SW1 ChandolaTalav Surface Water 3.6 , ENE

SW2 Sabarmati River Surface Water 1.3, W

SW3 Kankaria Lake Surface Water 2.6, SW

Three surface water sources were selected for collecting water samples within the study area

Figure 5: Location Ground water and Surface Water stations


Table 13: Ground water monitoring Analysis Reports

Parameter Unit GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8

pH - 7.3 7.2 7.5 7.5 7.6 7.2 7.22 7.5

Electric Conductivity µS/cm 659 600 621 638 610 649 646 638

TDS mg/l 816 435 414 423 812 439 426 423

Hardness mg/l 104 102 110 106 100 96 101 106

Total Alkalinity mg/l 106 124 120 116 127 118 135 116

Calcium mg/l 24 23 27.3 26.5 24.8 23 24 26.5

Magnesium mg/l 11 10.7 10.2 9.7 9.2 9 9 9.7

Chloride mg/l 135 124 149 124 124 134 129 124

Sulphate mg/l 146 116 137 136 147 139 126 136

Discussion:

Ground water samples analyzed during the study period indicate that all parameters are found are also within the IS 10500:2012 limits.

Table 14: Surface water Analysis Reports

Parameter Unit SW1 SW2 SW3

pH - 7.54 7.24 7.56

Electric Conductivity µS/cm 650 280 340

TDS mg/l 428 284 596

Hardness mg/l 105 50 110

Total Alkalinity mg/l 102 40 80

Calcium mg/l 27 10 30

Magnesium mg/l 9 9.8 19.5

Chloride mg/l 129 50 110

Sulphate mg/l 135 10 30


Discussion

Surface water samples analysed during the study period indicate that All parameters are found within the prescribed limits

3.4 Soil

The soil in and around the proposed site is formed due to weathering of rocks and can be classified as reddish gray / brown silky type. Rocks underneath are of volcanic origin. The rocks are dark colored of basaltic composition and mainly comprise of plagioclase, pyroxenes iron ores, primary glass and some secondary minerals. The location of the sampling stations is marked in Figure 3. The names and the distance from Project are presented in Table 8. The results of soil analysis are presented in Table 15

Physical Parameters

Particle Size: Particle sizes of the different constituents (clay, silt, sand and gravel) control the porosity

and water holding characteristic of the soil. Clay (size < 0,002mm) amount in the soil samples is 14% to

15% and Sand (size 0.002 to 0.075mm) in the soil sample is 68% to 70%. All the samples in the study

area are free of gravel (size > 4.75mm). Analysis shows it is sandy soil with less water holding capacity.

Table 15: Soil Quality Reports of Study Area

Para Meter Unit Project

Site Jashoda

nagar Isanpur Maninagar

Narol Residen

tial

Narol Industrial

Area

Hathijan Dhamat Van

Moisture Contain

in % % 10 10 12 12 14 10

14

18

pH - 7.2 7.3 7.5 7.3 7.6 7.2

7.4

7.6

Nitrogen mg/ kg 0.06 0.04 0.06 0.06 0.04 0.04

0.06

0.10

Phosphorus

mg/ kg 0.03 0.06 0.05 0.08 0.06 0.03

0.04

0.08

Potassium

mg/ kg 0.06 0.07 0.04 0.02 0.03 0.05

0.04

0.06

Copper mg/ kg Nil Nil Nil Nil Nil Nil

Nil

Nil

Total Organic Carbon

% 5.6 3.6 3.2 4.1 4.0 5.2

3.8

3.2


Flouride mg/ kg ND ND ND ND ND ND

ND

ND

SAR % 4.0 3.0 1.7 1.4 1.6 1.4

1.2

1.0

3.5 Noise

3.5.1 Noise Levels

The noise levels were monitored at seven locations selected for AAQ monitoring on an hourly basis during the study period. A digital noise level meter of Lutron make was used to record the noise levels. Leq day and Leq night noise levels were derived and reported accordingly. Day time was considered as 1000 hrs to 2200 hrs and night time as 2200 hrs to 0600 hrs. The day time and night time equivalent noise levels at selected locations are given in Table 16

Table 16: Noise monitoring locations and Results

Sr. No. Location Noise Level in dB (A)

Day Time Night Time

1 Project Site 68-70 66-68

2 Jashodanagar 66-68 67-60

3 Isanpur 64-66 65-48

4 Maninagar 56-57 47-50

5 Narol Residential 58-62 50-52

6 Narol Char Rasta, Industrial Area 68-70 56-68

7 Hathijan 52-42 50-48

8 Dhamatvan 55-45 46-48

AMBIENT NOISE LEVEL STATNDARDS

Category of Area Limits in dB (A) Leq

Day Time (6.00 am to 10.00 pm)

Night Time (10.00 pm to 6.00 am)

Industrial Area 75 70 Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40


Inference: Noise levels are within prescribed limit.

3.6 Land use Studies

Satellite Data: RESOURCESAT-2 cloud free data has been used for Land use / land cover analysis.

PC based GIS and image processing software’s are used for the purpose of image classification and for delineating drainage and other features in the study area. Number of peripheral devices such as scanner, plotter, printer etc. has also been interfaced with the system.

Figure 6: Land use/land cover map of study area

Land use/Land cover Classification System The present Land use/Land cover maps were prepared based on the classification system of National standards. Break up of land use is given in Table-16

The relevant statistics of this subject is as given below;


Table 17: Land Use details for 10km study area LULC Class Area(Sq.Km) % River Bed 0.3 0 Road 79.2 25 Open Land 74.1 24 Agriculture 32.7 10 Fallow Land 9.4 3 Built Up Land 76.5 24 Waterbody 2.7 1 Total Area 305.80 100.00

Figure 7: LULC for 10 km study area

3.7 Topography

Ahmedabad is located near north side of Gujarat; therefore, most of the land is dry and arid in nature. Moreover, the topography of Gujarat is characterized by the small hilly tracts especially around the Rann of Kutch region. Thus spread over a vast area, the topography of Gujarat is divided into 3 major regions, namely, (1) The Peninsular - the region, which is also known as Saurashtra, is essentially a hilly tract. (2) The Kutch - It is a barren and rocky area containing the great Rann. The Rannis further divided into the Greater Rann and the Lesser Rann. (3)The mainland that extends from the Rann of Kutch and the Aravalli hills to the river Damanganga. The Gujarat has six major drainage systems namely, (1) Narmada River, (2) Sabarmati River, (3) Tapi, (4) Purna, (5) Damanganga, (6) Rukmavati, etc.


As per the Seismic Zone classification by IS 1893 (Part-I): 2002, Ahmedabad falls under Seismic Zone III (Figure 3.2) which falls under Moderate Risk Zone.

Figure : Seismic Zones of India as per IS 1893 (Part-I): 2002

3.7.1 Drainage Map:

Drainage layer, which was generated after scanning the thematic manuscripts, was edited for line the errors. Two different layers were made separately for line drainage. Drainage order was given to all the drain lines in the layer‘s. Strahlermethod of ordering was used for giving order to drainage. Whenever two drains of any order joined the order of next drain was increase by one. The study area has an order of fourth. River name also attached as attribute to drainage layer. All the water bodies and river with sufficient width were put in polygon layer.

The area shows not much of undulating topography thus it shows the Dendritic drainage patterns.


Figure 8: Drainage Map

Thematic manuscript for contour layer was generated from Survey of India toposheet at 1:50,000 scale. After scanning, coverage was generated. Coverage was edited to remove all errors of dangle. Attribute value was given to each contour in the coverage.

Figure 9: Contour Map 3.7.2 Hydrogeology

The geology of the area is underlain by recently placed alluvium, brown sand and millolite sand. As per the Geo-Environmental Regions of Gujarat, the study area falls in the Northern Alluvial Plains. The average elevation of the study area is about 70 m above mean sea level. There are no hills or hillocks in the study area. The entire area of the


district is underlain by the basaltic lava flows of upper Cretaceous to lower Eocene age. The shallow alluvial formation of Recent age also occurs as narrow stretch along the major rivers flowing in the area. Central Ground Water Board monitors water levels in 43 Ground Water Monitoring wells (GWMW) in the district.

3.7.3 Temperature:

Minimum, Maximum and Average Temperatures for Ahmedabad Station of the year 2016 and up to January 2017are given in Table 18. (Source: Online Ahmedabad Airport Station)

Table 18: Temperature Data of Study Area

Month (2016)

Minimum Temperature

(0C)

Maximum Temperature

(0C)

Average Temperature

(0C) January 12.25 29.70 21

February 23.17 31.48 15.10

March 29.00 36.87 21.06

April 32.33 38.83 25.17

May 35.90 48.39 28.29

June 34.37 40.50 28.57

July 29.90 33.68 26.26

August 28.29 31.35 28.29

September 29.20 33.73 24.50

October 27.77 33.45 21.71

November 23.73 33.27 14.57

December 22.06 31.03 13.38

3.7.4 Relative Humidity:

Minimum, Maximum and Average Monthly Relative Humidity for Ahmedabad Station of the year 2016are given in Table 19. (Source: Online Ahmedabad Airport Station)


Table 19: Relative Humidity Data of Study Area Month(2016) Minimum R.H.% Maximum R.H.% Average R.H.%

January 53.22 81.19 20.35

February 39.31 64.51 15.93

March 33.32 59.12 11.77

April 36.67 62.43 12.20

May 41.23 63.22 15.61

June 51.37 69.57 26.97

July 74.096 87.77 54.32

August 81.70 92.38 65.35

September 70.67 87.36 51.07

October 66.29 86.71 40.38

November 52.13 81.13 17.7

December 51.77 81.22 18.23

The mean monthly average of Relative Humidity values for Ahmedabad station was recorded& Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period.

3.7.5 Rainfall:

Rainfall data for Ahmedabad Station of the year 2016is presented in Table 20.Total rainfall, during the monsoon period, has been recorded as 201 mm

Table 20: Rainfall Data of Study Area Month(2016) Monthly Total(mm) Numbers of Rainy Days

January 00 0

February 00 0

March 00 0

April 00 0

May 100 5

June 280 15

July 300 15


3.7.6 Wind speed and Wind direction

Wind speed for Ahmedabad Station of the year March 2017 to May 2017is given in Table21

Table 21: Wind Speed Data of Study Area

(Source: Online Ahmedabad Airport Station)

3.7.7 Windrows

The wind direction is predominantly from NE to SW. Diurnal shift in wind direction was not observed during study period. The wind rose diagram prepared from data collected at site is shown in Figure

August 350 10

September 200 10

October 180 5

November 00 0

December 00 0

Meteorological Parameter

Wind Speed in Km/Hr March’17 April’17 May’17

Min. 0 0 0

Max. 6.69 34.46 8.75

Avg. 1.80 2.86 3.45


Figure 10: Wind Rose (Dec. 2016 to Feb. 2017)

3.8 BIOLOGICAL ENVIRONMENT

Introduction

Study of biological environment is one of the most important aspects for Environmental Impact Assessment, in view of the need for conservation of environmental quality and biodiversity. Ecological systems show complex inter-relationships between biotic and abiotic components including dependence, competition and mutualism. Biotic components comprises of both plant and animal communities which interact not only within and between themselves but also with the abiotic components viz. Physical and chemical components of the environment.

Generally, biological communities are the good indicators of climatic and edaphic factors. Studies on biological aspects of ecosystems are important in Environmental Impact Assessment for safety of natural flora and fauna. Information on the impact of environmental stress on the community structure serves as an inexpensive and efficient early warning system to check the damage to a particular ecosystem. The biological environment includes mainly terrestrial ecosystem and aquatic ecosystem.

A change in the composition of biotic communities is reflected by a change in the distribution pattern, density, diversity, frequency, dominance and abundance of natural species of flora and fauna existing in the ecosystem. These changes over a span of time can be quantified and related to the existing environmental factors. The specific parameters in the study of biological environment are biological characteristics through quadrate method. The sensitivity of animal and plant species to the changes occurring in their existing ecosystem can therefore, be used for monitoring Environmental Impact Assessment studies of any project.


3.8.1 Field Surveys:

Sampling locations were identified for study on biological environment based on topography, vegetation structure, pattern and distribution.The observations were taken from different villages along agricultural field, marshy, land, waste land, riverside vegetation and built up and according to the objectives delineated for environmental impact Assessment studies.The field surveys were conducted for 10km area to assess baseline status of flora and fauna between periods of December 2016 to February 2017.

3.8.2 Sampling Strategy:

For assessment of flora and fauna, study team randomly sampled in 10.0 km radius of the project site. We collected the data on flora and fauna in each sample plot of 10X10 mtr quadrate. Total 30 quadrates were laid in the study area in order to rapidly study the fauna and flora of the region. No national Park / Wildlife Sanctuary / Reserve Forest cover was found in 10 Km radius of the project area. A detailed survey report with the methodology and study is as given in the following section.

a)Flora

Dominant families of plants recorded in the study area are CaesalpiniaceaeMimosaceae, Euphorbiaceae, Cucurbitaceae,Papilionaceae.The area showed overall 71 plant species from 60 genera and 32 families the list of dominant flora observed in study area given in below Table


Table 22: List of Dominant Flora Observed in Study Area

SN Scientific Name Local Name Family Trees

1 Acacia nilotica Babul Ceasalpiniaceae 2 Albizilebbeck Siras Mimosaceae 3 Azadirachtaindica Neem Balanitaceae 4 Bombaxceiba Shimdo Bombacaceae 5 Bauhinia racemosa

- Papilionaceae

6 Buteamonosperma Chola Papilionaceae 7 Cassia fistula Garmalo Ceasalpiniaceae 8 Carica papaya Papaya Caricaeae 9 Cassia siamea Kashid Caesalpiniaceae 10 Casuarinaequisetifolia Sharu Casuarinaceae 11 Coldeniaprocumbens - Ehretiaceae 12 Derris indica - Papilionaceae 13 Eucalyptus species Nilgiri Myrtaceae 14 Ficusbengalensis Vad Moraceae 15 Ficusreligiosa Pipdo Moraceae 16 Madhucaindica Mahudo Asteraceae 17 Mangiferaindica Amba Sapindaceae 18 Manilkarahexandra - Sapotaceae 19 Maytenusemarginata vikdo Meliaceae 20 Prosopis cineraria Khijdo,Samdo Mimosaceae 21 Samaneasaman RatoSarasdo Mimosaceae 22 Syzygiumcumunii Jambudo Myrtaceae 23 Tamarindusindica Amli Ceasalpiniaceae

Shrubs 1 Abelmoschusesculentus Bhindi Malvaceae 2 Abubutilonindicum* Khapat Malvaceae 3 Baliospermummentanum Jamalgota (

Danti) Euphorbiaceae

4 Balntiesaegyptiaca Ingorie Balanitaceae 5 Calotropisgigantea Akdo Asclepiadaceae 6 Calotropisprocera Akdo Salvadoraceae 7 Cassia italica Garmalo Ceasalpiniaceae 8 Cordiagharaf - Gentianaceae 9 Cressacretica - Convulvulaceae 10 Crotolariaburhia - Papilionaceae 11 Indigoferalinnaei - Papilionaceae 12 Indigoferaoblongifolia - Papilionaceae 13 Launaeaprocumbens - Asteraceae 14 ProsopisChilensis Khijdo, Mimosaceae 15 Riveahypocrateriformis - Convulvulaceae 16 Vernoniacinerarea sadori Asteraceae 17 Zizyphusnummularia Chanibor Celastraceae

Herbs 1. Alysicarpus sp. - Papilionaceae


b) Fauna:

Methodology

Field observations of fauna were carried out. The commonly available mammals, amphibians, reptiles, butterflies, dragonflies and damselflies within 10 km surroundings were enumerated. List of Dominant Fauna Recorded in Study area are Given in below Table 23

2. Capparis decidua Bare Caper Capparaceae 3. Capparissepiaria - Capparaceae 4. Cardiospermumhalicacabum - Rhamnaceae 5. Cassia auriculata Aval Ceasalpiniaceae 6. Cassia tora Kunvandio Ceasalpiniaceae 7. Cleome viscosa Pilitalvani Capparaceae 8. Corchorusaestuans - Malvaceae 9. Corchorusfascicularis - Tiliaceae 10. Corchorusolitorius - Tiliaceae 11. Corchorus sp. - Tiliaceae 12. Datura metal Dhanturo Convulvulaceae 13. Ecliptaprostrata - Asteraceae 14. Enicostemahyssopifolium - Asclepiadaceae 15. Evolvulusalsinoides - Convulvulaceae 16. Gilnuslotoides Lotus Sweetjuice, Cucurbitaceae 17. Grangeamaderaspatana - Asteraceae 18. Melilotus alba - Papilionaceae 19. Melilotusindica - Papilionaceae 20. Neptuniaoleracea - Mimosaceae 21. Rhynchosia minima - Papilionaceae 22. Sphaeranthusindicus - Asteraceae 23. Tephrosiapurpurea Sharpunkha Papilionaceae 24. Tribulusterrestris Ghokhru Tiliaceae 25. Tridexprocumbens PardesiBhangaro, Asteraceae 26. Trigonellaocculta - Papilionaceae

Climbers Xanthium strumarium Godrian Asteraceae

1 Cocciniagrandis Tindora Mimosaceae 2 Cocculushirsutus PatalaGarudi Menispermaceae 3 Mukiamaderaspatana - Cucurbitaceae 4 Convolvulus microphyllus - Boraginaceae 5 Trichosanthescucumerina - Cucurbitaceae


Table 23: List of Dominant Fauna Recorded in Study Area

No. Common Name Scientific Name Scheduled Mammals

1. Common dog Canis lupus familiaris Not enlisted 2. Common cat Felissilvestriscatus Not enlisted 3. Squirrel Funambuluspalmarum Sch-IV 4. Domestic buffalo Bubalusbubalis Not enlisted 5. Cow Bostaurus Not enlisted 6. Goat Capra hircusaegagrus Not enlisted 7. Rat Rattusrattus Sch-V 8. Indian grey mongoose Herpestesedwardsii Sch – II

Reptiles 1. Common garden lizard Calotesversicolor Not enlisted 2. Rock lizard Psmmophilusblanfordanus Not enlisted

Avifauna 1. Black kite Milvusmigrans Not enlisted 2. Blue rock pigeon Columba livia Sch – IV 3. Cattle egret Bubulcus ibis Sch – IV 4. Common swallow Hirundsrustica Sch – IV 5. Crow pheasant Centropussinensis Sch – IV 6. House crow Corvussplendens Sch – V 7. House sparrow Passer domesticus Sch – IV 8. House swift Apusaffinus Sch – IV 9. Indian black drongo Dicrurusadsimilis Sch – IV 10. Indian myna Acridotherestristis Sch – IV 11. Koel Eudynamysscolopacea Sch – IV 12. Little swift Apusaffinis Sch – IV 13. Magpie robin Copsychussaularis Sch – IV 14. Purple sunbird Nactariniaasiatica Sch – IV 15. Red wattled lapwing Vanellusindicus Sch – IV 16. Roseringed parakeet Paittaculakrameri Sch – IV 17. Redvented bulbul Pycronotuscafer Sch – IV 18. Small blue kingfisher Alcedoatthis Sch – IV 19. Small green bee eater Meropsorientalis Sch – IV 20. Jungle babbler Turdoidesstriata Sch – IV 21. Common babbler Turdoidescaudatus Sch – IV 22. Indian roller Coraciasbenghalensis Sch – IV

Butterflies 1. Blue mormon Papiliopolymnestor Not enlisted 2. Blue pansy Junoniaorithya Not enlisted 3. Common sailor Neptishylas Not enlisted 4. Common evening brown Melanitisleda Not enlisted 5. Common grass yellow Euremahecabe Not enlisted 6. Common Indian crow Euploea core Sch – IV


There are no protected areas in the vicinity of the project area. There are also no monuments of historical and archaeological importance within the study area. c) Aquatic Preamble Plankton is an important component of ecosystem, which responds to ecosystem alterations rather rapidly. It is due to the fact that planktonic organisms, which react to different types of water pollution, play a key role in turnover of organic matter and energy through the ecosystem. This reaction is very rapid because of relatively short lifetime and high reproduction rates of the organisms. Water sample within 10km periphery were collected fromSabermati river. To enumerate phytoplankton, unfiltered surface waters were colleced from the water bodies. Phytoplankton samples were immediately fixed after collection in Lugols Iodine solution so as to prevent adverse effects of light and temperature which might cause rapid decay of organisms. Further microscopic analysis was undertaken in laboratory. For zooplankton, desired volumes of water were filtered through plankton net having mesh size of 75µ to represent all the available groups.Drop count method for the analysis were followed, as prescribed in APHA (1995). Phytoplankton Amongst 5 groups, Chlorophyceae dominated over Cyanophyceae and Bacillariophyceae. Euglenophyceae and Pyrophyceae were rarely present.Genera like, Anabaena sp., Phormidium, &Oscillatoria from cyanophyceae and Spirogyra, Chlorella,Ankistrodesmus, Pediastrum, Scenedesmus, Microspora ,Cosmarium , Oedogonium , Sorastrum and Ulothrix from Chlorophyceaewere dominant. Source: Ecological evaluation of water of Sabarmati, AhmedabadKiranPrajapati Zooplankton Protozoa was dominant followed by Rotifera and Cladocera. Copepoda and Ostracoda were rarely present. Genera likeDaphnia,Moina, Keratella ,Philudinaetc,besides Nauplius larva were dominant.

7. Common leopard Phalantaphalantha Not enlisted 8. Common mormon Papiliopolytes Not enlisted 9. Gray pansy Junoniaatlites Not enlisted 10. Lime butterfly Papiliodemoleus Not enlisted 11. Plain tiger Danauschrysippus Not enlisted 12. Common wanderer Pareroniavaleria Not enlisted 13. Common emigrant Catopsiliapomona Not enlisted

Dragonflies 1. Red marsh trotter Trameabasilaris Not enlisted 2. Common clubtail Ictinogomphusrapax Not enlisted


3.9 Socio-economy

Socio-economic profile is an important part of the Environment Impact Assessment of any developmental project. This section studies the socio-economic profile of the 10 km radius area for the Indo Colchem Pvt. Ltd. and analyses the baseline status as well as assess the social impacts of the projects in the influence area and try to suggest mitigation measures to the adverse impacts of the project. The socio-economic aspects in general, divided into economy, demography, education, health & infrastructure in the study area.

3.9.1 Population

According to the 2011 national census, the population of Ahmedabad was declared to be 7,214,225. This figure was only limited to the municipality region. The total population of the Ahmedabad Urban Agglomeration (which also includes the region governed by AUDA) came to 7.2 million people. There were 886 females to every 1000 males in 2001. Now there are 904 women to 1000 men in 2011. Ahmedabad had a literacy rate of 79.89% in 2001 which rose to 89.62 percent in 2011. Out of this, male and female literacy are 93.96 and 84.81 percent as of 2011 census. According to the census for the ninth plan, there are 30737 rural families living in Ahmedabad. Out of those, 5.41% (1663 families) live below the poverty line. There are 439,843 people who live in slums in the city. The majority of residents of Ahmedabad are native Gujaratis and speak Gujarati. There is also a sizable population of Punjabis, Marathis, Tamils, Sindhis,Malayalis and Marwaris who bring in their native language and culture to the city. The government institutions and military base near the city also bring peoples from across India. The city's population has increased in a major way following increasing economic expansion and modernization.

3.9.2 Religion Diversity

Ahmedabad also enjoys great religious diversity. According to the 2011 census, 83% of the population in Ahmedabad is Hindu, 2.5% Jain, 13.8% Muslim and 0.72% Christian. The community of Muslims is large and culturally significant in Ahmedabad, dating from the times of the sultanate. The city is also home to a major population of Parsis in India. There is also a small population of 300 Bene Israel Jews living in Ahmedabad. Owing to the religious and cultural influence of Jains and many Hindus, there is widespread vegetarianism across the city's hotels and restaurants.

The initial provisional data released by census India 2011, shows that density of Ahmedabad district for 2011 is 890 people per sq. km. In 2001, Ahmedabad district density was at 719 people per sq. km. Ahmedabad district administers 8,107 square kilometers of areas.


https://en.wikipedia.org/wiki/Ahmedabad

https://en.wikipedia.org/wiki/Literacy

https://en.wikipedia.org/wiki/Five-Year_Plans_of_India

https://en.wikipedia.org/wiki/Poverty_threshold

https://en.wikipedia.org/wiki/Slum

https://en.wikipedia.org/wiki/Gujarati_people

https://en.wikipedia.org/wiki/Punjabi_people

https://en.wikipedia.org/wiki/Marathi_people

https://en.wikipedia.org/wiki/Tamil_people

https://en.wikipedia.org/wiki/Sindhi_people

https://en.wikipedia.org/wiki/Malayali

https://en.wikipedia.org/wiki/Marwaris

https://en.wikipedia.org/wiki/Parsi_people

https://en.wikipedia.org/wiki/Bene_Israel

https://en.wikipedia.org/wiki/Vegetarianism

3.9.3 Literacy Rate

Average literacy rate of Ahmedabad in 2011 were 85.31 compared to 79.50 of 2001. If things are looked out at gender wise, male and female literacy were 90.74 and 79.35 respectively. For 2001 census, same figures stood at 87.31 and 70.83 in Ahmedabad District. Total literate in Ahmedabad District were 5,435,760 of which male and female were 3,025,463 and 2,410,297 respectively. In 2001, Ahmedabad District had 4,012,140 in its district.

3.9.4 Sex Ratio

With regards to Sex Ratio in Ahmedabad, it stood at 904 per 1000 male compared to 2001 census figure of 892. The average national sex ratio in India is 940 as per latest reports of Census 2011 Directorate. In 2011 census, child sex ratio is 857 girls per 1000 boys compared to figure of 836 girls per 1000 boys of 2001 census data.

3.10 Chapter Conclusion:

In the last Chapter, the new activity and its environment friendly nature is examined. The present environmental setting is discussed in this Chapter. The new activity alters the land use planning for better, fits in present Government Policy and other related matters are shown. The existing environment (both natural and man-made) is discussed by collective information from many sources. Statistics is provided for various media such as air, noise, water, solids, soils and biology. Present social and economic status is discussed and to what extent, if any, it is sensitive is found out. This Project is already socially accepted organization and is committed to the ecological restoration and maximizes social benefits. The community development and rehabilitation efforts as may be reasonably expected will be undertaken.


4 CHAPTER: ANTICIPATED ENVIRONMENTAL IMPACT ASSESSMENT, PREDICTION AND

MITIGATION MEASURES 4.1 INTRODUCTION

Environmental Impact Assessment (EIA) is an activity or an attempt to identify, predict, evaluate and communicate the likely environmental impacts of the proposed project on the surrounding environment. Although, in general, a number of impacts have been identified while describing the baseline environmental status, it is necessary at this stage to identify the critical impacts that are likely due to proposed manufacturing of Dyes & DYES INTERMEDIATESs on the environment i.e. such predictions are superimposed over the baseline status of environmental quality to derive the ultimate scenario of environmental conditions. The quantitative prediction of impacts leads to delineate suitable environmental plan needed for implementation during operational phase in order to mitigate the adverse impact on environmental quality.

The activities at the project site and their impact on various environmental components like air, water, noise, land, biological and socio-economic have been assessed and evaluated in this chapter.

Environmental impact assessment study includes

• Identification of all the probable impacts (be it positive or negative) of the various activities involved in the completion of the project.

• Classification of the probable impacts i.e. positive or negative, reversible or irreversible, short term or long term

• Evaluation of the probable impacts i.e. qualitative and quantitative assessment of the likely impacts

• This chapter presents the identification, prediction and evaluation of impacts with mitigation measures of the proposed project.

4.1.1 IDENTIFICATION OF IMPACTS

Identification of significant environmental impact is essential in the preparation of EIA report, an attempt has been made here through the use of matrix.

The proposed expansion project divided in to two phases;

1. Construction phase 2. Operation phase

Various activities belonging to each phase have been grouped separately and arranged in Columns. The environmental Factor or parameter, which is anticipated to be impacted, has been arranged in rows. A preliminary scrutiny has been done and the cells, which fall at the


junction of the ‘Activity’ or ‘Factor’, that have possible interaction with each other, have been ‘marked’. The matrix thus establishes the possible cause-effect’ relationship and identifies the environmental factors likely to be impacted and activities responsible for the same. The impact identified may be positive and negative, short term and long term, reversible and irreversible, minor and major. The determination will be done at prediction stage.

4.1.2 IMPACT DURING CONSTRUCTION PHASE

There will be only structural fabrication work, no major civil construction activity. Table24: Existing Storages.

Operation Phase

Present activities involved in the operation are listed below: • Raw Material Handling and Storage • Product Manufacturing • Utility Consumption • Effluent Generation • Gaseous Emissions • Hazardous Waste Generation • Employment • Green Belt maintenance and Development

4.2 Impacts during Operation Phase and Mitigation Measures

4.2.1 Impact on Air Environment

The impacts on air environment from proposed manufacturing facility depend on various factors like production capacity, types of processes involved, type of raw material used, control technology in use and operation & maintenance. Apart from the above, there will be other activities associated with any industrial project, viz. transportation of raw materials and finished products, storage facilities and material handling within the plant premises which may contribute significantly to air pollution. The impacts on air environment from any industrial project are also governed by terrain conditions and the prevailing micro-meteorological conditions in the project region.

4.2.1 Emissions from Proposed Project

Emission from Proposed boiler stack is given in below.


Table 25: Emission from Boiler Stack

4.2.2 Evaluation of Impacts using mathematical model and it’s mitigation

Indo Coal Chem are proposing proposed 4 boilers of capacity 0.8TPHx2, 0.6TPx1, 5.0TPHx1, HAG boiler in the premises of plant to be located near Ahmedabad city in Gujarat state. Air quality impact is envisaged due to operation of this proposed boiler. Boiler will be operated on Coal.Dispersion modeling has been carried out using point source emissions with meteorology data to predict ground level pollutant concentration.

S. No.

Stack attached to

Stack height (m)

Stack Dia (m)

Stack exit gas velocity m/s

Stack gas temperature at exit OC

Fuel type

Quantity of fuel T/day

Sulfur content %

Ash content %

Air pollution control system

Pollutants

SPM SO2 NOx 1 Boiler No.

1 (0.8 TPH)

10 0.2 7.2 120 Coal 6 2.8 3.0 Cyclone Separator

2 nos.

<150

<100

<50



2 nos.

<150

<100

<50



2 nos.

<150

<100

<50


32 20 Cyclone separators

2 Nos.

5 HAG boiler

20 0.2 9.5 110 Coal 10 2.8 3.0 2 cyclones <150

<100

<50

6 Evaporatio spray 4000 Lit/hr

15 2 Nos. <150

<100

<50

7 DG set 275 KVA

3 2 cyclones <150

<100

<50

8 Spray dryer-1 1000 lit/hr

20 2 cyclones <150

<100

<50


15 2 cyclones <150

<100

<50


20 2 cyclones <150

<100

<50



4.2.3 Analysis details

4.2.3.1 Tools and methods

Sourcedispersion analysis is assumed based on AERMODViewTM model. Coal contributes to particulate matter and gases in exit gas. Here the model enables analysis with respect to PM10, SO2 and NOx gives results in simple to understand graphical format.

The following steps are involved in the analysis:

I. Inputs are entered into the software as per the general modeling parameters.

II. Information on the stack i.e. height, diameter, exit gas velocity, temperature and receptor is

added to the software.

III. The analysis process is done by the model.

Input(s) needed and assumption Table 26: Input and Assumptions

Sr. No Inputs Required Availability for this project

1. Stack emission parameter

Stack height Yes

Stack diameter Yes

Flue gas velocity Yes

Exit gas temperature Yes

2. Meteorological Parameters

Wind Speed, Wind Direction, Cloud Cover, Temperature,

Humidity, Station Pressure, etc. Onsite monitoring

3. Emission Parameters Expressed in grams/second emitted US-EPA, AP42

4. Receptor Location Uniform grid Uniform grid

4.2.4 Methodology

For the stackproposed on site detailsprocured from Emission Regulations – Part IV, CPCB’86 was utilized for emissions estimation. Widespread method based on the data available was to use emissions in terms of pollutant mass per second emitted.

4.2.5 Data Collection

Proposed boiler will be connected to stack attached to boilers (capacity 0.8TPHx2, 0.6TPx1, 5.0TPHx1, HAG boiler). The stack details and flue gas characteristics are provided in Table below


Table 27: Stack and flue gas emissions details

Parameters Unit Boiler-1 (0.8 TPH)

Boiler-2 (0.8 TPH)

Boiler-3 (0.6 TPH)

Boiler-4 (5.0 TPH)

HAG Boiler

Stack height m 10 10 10 20 20 Stack diameter m 0.2 0.2 0.2 0.2 0.2 Exitgas velocity m/s 7.2 7.2 6.4 10.4 9.5 Stack gas temp OC 120 118 105 110 110 Fuel type -- Coal Coal Coal Coal Coal Fuel requirement T/day 6 6 3 10 10 Sulfur Content % 2.8 2.8 2.8 2.8 2.8 Ash Content % 3.0 3.0 3.0 3.0 3.0 PM Emission g/sec 0.0231 0.0232 0.0213 0.0342 0.0313 SO2 Emission g/sec 0.0154 0.0155 0.0142 0.0228 0.0208 NOx Emission g/sec 0.0077 0.0077 0.0071 0.0114 0.0104 Air pollution control equipment

Cyclone Separator (2 nos.)

Cyclone Separator

& Twin cyclone

Site specific wind-rose for this season is shown in Figure11. For the site-specific mixing heights CPCB document PROBES/88/2002-2003 is followed. Average hourly data for 24 hrs used for modeling is represented in Table 27.

Figure 11:Wind rose Plot for the study period


4.2.6 Model Inputs

AERMODViewTMhas been used for evaluating the emission scenarios for proposed project. The inputs to the model are defined in 5 functional pathways as represented in the following sections. Each of these functional parameters include several options that may be user defined or set as default, the details of some of these essential elements of AERMOD ViewTMruns have been explained in the discussions.

A. Control pathway inputs Default option Emission concentration Averaging period of 24 hr as per NAAQS pollutant type

B. Source pathway inputs Includes definition of source, its locations Stack source parameter include emissions (g/s)

C. Receptors pathway inputs Cartesian grid starting at the SE corner of the ward with 2000m increment over X & Y

coordinates, thus forming a receptor output grid radius of 10km. Uniform grid is selected with 10x10 cell size.

D. Meteorology pathways inputs One hourly data for period that is from November to November’13 and February’14 was

used as an input in the meteorology processor to generate model ready one hourly input surface & profile meteorology files.

Roughness length of 1m of measurement height, displacement height of 0.2m, Albedo of 0.2 & measurement height at which measurements of meteorology have been done.

The minimum wind speed (0.5 m/s lower than 1m/s considered as calm by IMD), minimum mixed layer height (50m), and minimum heat flux 20 W/M2/s).

The Bowen ratio=Sensible Heat flux/Latent Heat Flux as a function of month to allow smaller Bowen Ratios during the Indian monsoon season when the ground is wet and latent heat fluxes become significant (from 2 in non-monsoon to 0.5 in monsoon).

The potential temperature gradient above the mixed layer (0.008 degrees/m) The weather data for project site station have been used for the present project. The

data was compiled in AERMET module of AERMOD ViewTM and the results of this final analysis were used as input meteorological data.

Output Pathway The model has been run for 24hr average as per the pollutant type and the NAAQS standards criteria. The contour for 1st highest reading is shown for each pollutant based on BAU scenario. Model outputs were obtained for emissions of each of the pollutants in each of the 2km x 2km receptor grid spread across gridded impact zone. Contour maps are plotted for each of the study pollutants and the impact by the point source. This map is superimposed on the road tile map of the proposed location.


4.2.7 Conclusion

The point source was represented in the contour plots for concentration to understand the impact of on the study domain. Modeled pollutant concentrations for operations phase is given in Table 26 and dispersion trend is shown as isopleths in Figure ----.

Table 28: Modelled concentrations for present scenario

Parameters IncrementalLevel(µg/m3) Distance from Site PM10(24hr average) 4.31

On Site SO2(24hr average) 2.87 NOx(24hr average) 1.43

The maximum incremental concentration of PM10, SO2 and NOX are superimposed on the baseline concentrations recorded during the study period to arrive at the likely resultant concentrations after implementation of the proposed boiler. Comparative account of each pollutant concentration with respective National Ambient Air Quality Standards (NAAQS) is represented in below Table

Table29:Comparative Account of resultant concentration

Parameters Concentrations

NAAQS* (µg/m3) Baseline

(µg/m3) Incremental

(µg/m3) Resultant

(µg/m3) PM10(24hr average) 67.40 4.31 71.71 100 SO2(24hr average) 41.15 2.87 44.02 80 NOx(24hr average) 33.55 1.43 34.98 80

*NAAQS – National Ambient Air Quality Standards, 2009 Figure 12: Present 24hr average emission dispersion contours for PM10


Figure 13 : Present 24hr average emission dispersion contours for SO2

Figure 14: Present 24hr average emission dispersion contours for NOx

4.2.8 Environmental Management Plan

The predicted average concentrations with baseline BAU from the project will be below the standards. Hence, it can be concluded that there is minimal impact because of the said project. Whereas negligible impacts have to be maintainedso as to control shock load and intern to keep the air quality pollutant free.

Tow Cyclone Separatoreach for Boiler 1-4 and Cyclone Separatoralong with twin cycloneare provided as air pollution control measures and stack of adequate height is also provided to disperse theflue gas.


4.3 Water Environment:

4.3.1 Impact on Water Environment and It’s Mitigation

Total water requirement for the after proposed project will be 440 KLD. The total wastewater generation from industrial process will be 300 + 10 KLD. M/s. INDO COLCHEM PVT. LTD. is having a ETP of capacity 350 KLD consisting of primary and tertiary treatment facility (flow chart of ETP is shown in below diagram) and domestic effluents shall be disposed through soak pit. Characteristic of effluent is depicted below: The total wastewater generation from Industrial will be 300 KLD. 10 KLD Domestic effluents shall be disposed through septic tank& soak pit. 300 KLD treated effluent will be treated in ETP and shall dispose to the CETP, Vatva and 10 KLD of concentrated effluent will be sent to the MEE. The nature of effluent is as follows: Details on strategy for the implementation of cleaner production activities: We have already study the cleaner production activities and segregate the effluent stream, Diluted stream to CEPT after treatment in ETP We will take participate in cleaner production program We will dispose 300 MT spent acid to novel Vatva. 4 KLD high temperature spray dryer to evaporate high COD effluent. We will also in planning to carry out detail cleaner production report at the time of commissioning stage as well as in operation stage to assess best result of cleaner production.

4.3.2 ETP Details: Table 30: ETP details

Sr. No. Name Capacity (m3)

1 Collection Tank – 1 No. 400

2 Storage Tank 400

3 Neutralization Tank 400

4 O & G Tank 50

5 R.O. System-I -

6 R.O. System-II -

7 Filter Press-I 48’ x 48’

8 Filter Press-II 48’ x 48’

9 Primary Clarifier 100

10 Secondary Clarifier 100

11 Final Holding Tank 400


Table 31: Effluent Characteristic

Sr. No. Parameter Unit Before Treatment

After Treatment

1 pH - 6.5 7.5

2 COD

mg/L

4564 910

3 BOD 442 300

4 TDS 9654 9962

5 TSS 210 52

6 Oil & Grease 10 4

7 Ammonical Nitrogen 18 12

4.4 Noise Environment:

4.4.1 Impacts on Noise Levels and It’s Mitigation

During construction phase only prefabricated structures will be installed hence, noise levels during construction phase are envisaged to be very low. Noise will be generated due to vehicular movement during transport of raw material and finished products. Noise level around the plant site was measured. Adequate noise control measures such as mufflers, silencers at the air inlet/outlet, anti vibration pad for equipment with high vibration, earmuff and earplugs to the operators, etc. are provided. Acoustic enclosure) will be provided for all noise generating machines. The effect due such sources will be minimized by locating them to the area where less human intervention occur. 4.5 Solid and Hazardous Waste Generation and Disposal

Minimization at all levels needs to be attempted for discarded products, empty containers, packing surpluses, incoming raw material unloading spillages and fugitives. The hazardous waste generated from the process activities shall contain sludge/residue of ETP. This will be disposed at TSDF. The details of solid waste are as follows.

Sr.No. Type of Hazardous

Waste Cat. No.

Existing Quantity

Proposed Quantity

Total Quantity

1. ETP Sludge

35.3 90

MT/Month 160

MT/Month 250

MT/Month

2. Iron Sludge

26.1 -- 10

MT/Month 10

MT/Month

3. Discarded Bags/Containers/Drums

33.1 2 MT/Month -- 2 MT/Month

12 Overhead Storage Tank to CETP 10


4. Used Oil 5.1 5 Lit/Year 45 Lit/Year 50 Lit/Year

5

Spent Acid

26.3 --

300 MT/Month To be sent to Novel.

300 MT/Month

To be sent to Novel.

Table 32: Management of Hazardous wastes

Sr. No.

Type of Waste and Category

Source of Generation Collection Treatment Storage Disposal

1 ETP Sludge

Effluent treatment plant

H.D.P.E Bags

--- Solid waste storage area with proper bag packing

Collection, Storage, Transportation, Disposal to TSDF site

2 Iron Sludge Manufacturing Process

--- Collection, Storage, Transportation, Disposal to TSDF or Sell to Cement Industry.

3 Spent Acid Manufacturing Process

Tank ---- Reused in manufacturing processes in own premises/Sell to NOVEL in case when there is no production of those products in which spent acid is used.

4 Discarded Bags/ Containers/ Drums

Raw material section

--- --- Solid waste storage area

Used for packing of ETP waste.

5 Used Oil Lubrication of plant machineries

H.D.P.E carboys

--- Solid waste storage area

Storage into carboys and ultimately sell to registered re refiners


The hazardous waste generated will be stored and handled as per the Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008. Hence, there will not be any impact on land and soil environment due to effluent disposal, chemical handling and storage & handling of hazardous wastes from the proposed project.

4.6 Land Environment (Green Belt)

The unit has developed green belt in the area admeasuring 100m2 within the premises,The green belt area will not only improve the landscape and environment but also enhance soil conditioning, prevent soil erosion give slight beneficial impact on the land usage. In consequence of development of green belt, it will create a beneficial impact on land and soil environment. 4.7 Ecological Environment:

No direct impact would be envisaged due to the upcoming project on nearby ecological environment. Further greenbelt development will help to improve ecology. Necessary environmental protective measure has been planned under EMP for air, water and hazardous waste management systems and regular environmental surveillance will be carried out so as to prevent any short-term or cumulative effect on the crops and natural vegetation of the area. Adequate stack height will be provided as per CPCB guidelines for the proper dispersion of pollutants, so that it will not hamper the plants. There will be no disposal of effluent from the unit. 4.8 Socioeconomic Environment:

The issue such as land acquisition, compensation & rehabilitation are not involved. Due to this upcoming project will create direct or indirect positive impact on the society. The operation of the project, provide value addition to the existing infrastructure facility such as public transport, water supply, telecommunications, etc. The operation of project and other allied facilities, will improve the employment opportunities. Local People will be getting direct or indirect employment due to the proposed project. The employment will have positive impact on the local economy thereby increasing the quality of life.


5 ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

It is necessary that project proponent should look for alternatives and select the one which is environmentally best.

5.1 Raw materials and Technology

We are already into the manufacturing of these products and have already gained expertise over a long period of time.

Competing technologies were evaluated and based on the techno-economic viabilities; we have finalized the processing schemes which are identical to our present operations.

5.2 Site Alternatives:

The proposed expansion is within the existing premises. This will also help proponents to optimize the use of existing facilities.

It may also be noted that other industrial units are located on all sides of this plot and no habitation exists nearby. There are no sensitive receptors in the vicinity.

5.3 ‘NO-PROJECT’ Option:

The district statistical Census report and Gazetteer of the District states that the socio-economic conditions in this district are very poor. To improve the status, industrialization will be a big boost. In this background, ICPL has proposed this Project to produce quality chemicals to meet the market demand.


6 CHAPTER: ENVIRONMENTAL MONITORING PROGRAM 6.1 Introduction

The proposed project, though, has minimal environmental impact, nonetheless, to control and limit the pollution level to desired level; an effective EMP is a must.

In view of above, it is proposed to establish a monitoring protocol for air, water, noise and solid waste soil. The stations will be the same as where the samples are taken while preparing this EIA. It is proposed to outsource the EMP to an accredited Consultant.

Table 33: Summary of Sampling

Aspects Parameters to be monitored

Frequency of Monitoring Locations Compliance

Air Quality PM10, PM2.5, SO2, NO2, CO, NH3

Twice in a week for one season Project Site + 7 NAAQ Standards,

2009 Noise Levels

Day and night noise Levels

Quarterly Project Site + 7 CPCB Standards

Water Quality

pH, Temp, Salinity, TDS, TSS, DO, BOD, Hardness, Alkalinity, Chlorides, Turbidity, Conductivity, Oil and Grease, Heavy Metals

Quarterly

Kankaria Lake, Sabarmati River

IS10500: 2012

ETP Inlet

pH, SS, TDS, BOD, COD, Chlorides, Sulphates, Total Ammonical Nitrogen

Monthly Collection Tank GPCB Standards

ETP Outlet

pH, SS, TDS, BOD, COD, Chlorides, Sulphates, Total Ammonical Nitrogen

Monthly Final ETP Sump GPCB Standards

Stack PM10, SO2 Monthly Boiler Stack GPCB Standards

6.2 EMP structure and funds

ICPL will have an environmental cell responsible for pollution control and for coordinating with monitoring laboratory. The cell shall be reporting to the MD of ICPL, pl see Figure 11


Figure 15: Structure of Environment Management Cell

Table 34: Functions of Environment Management Cell

Sr. no.

Aspect Areas of work

1 Construction Phase

Waste minimization, General sanitation, Airborne dust control, Noise and accident prevention.

Post-construction site remediation 2 Air AP control system monitoring, Car/truck PUC, Noise

mitigation, dust control. Water Water budget, O & M of ETP Solid waste Collection, segregation and proper disposal Greening Green belt development, landscaping Monitoring Coordinate with third party laboratory, interpretation

& reporting to Promoter 3 Occupational

Health Routine surveillance, prevention, accident relief

Regulatory Coordination with MPCB, filing analysis reports/ statements

Managing Director

Executive Director

VicePresident (Operations &

Projects)

Sr. EHS Manager

EHS Officer (Unit I & II)

ETP Operators (Unit I)

ETP Operators (Unit II)


For the purpose of Pollution Control, Resource Conservation and Environmental Protection, the Project Proponents will set aside suitable amount as capital expenditure and provision for recurring expenditure per year. The funds earmarked on pollution control system as detailed below:

Table 35: Environmental Funds

S. No.

Recurring Cost per annum Rs in Lakhs

Capital Cost Rs in Lakhs

1 Air Pollution Control 5.0 55.00 2 Water Pollution Control 5.0 4.0 3 Noise Pollution Control 1.0 1.0 4 Environment Monitoring and

Management 2.0 5.0

5 Hazardous Waste Management 2.0 5.0 6 Occupational Health 2.0 5.0 7 Green Belt 1.0 3.0 8 Others ( Pl. Specify) Rain Water

Harvesting, Safety, Security etc 1.0 3.0

Total 20.0 80.0 6.3 Environmental Monitoring Schedule:

The monitoring schedule is decided as under (may be modified, if required)

6.3.1 Action Schedules:

There will be three facets to design and follow the schedules viz.: (A) for compliance of responsibilities, (B) for day-to-day operation and management of ETP and control equipment and (C) for routine environmental monitoring, to assess the impact and take timely warning. The schedule, for third aspect is:

Daily Compliance:

1. Take the meter readings - initial and final, for checking the water consumption. 2. Maintain the electricity consumption record for pollution control. 3. Monitor ambient air periodically as per Consent.

Monthly Compliance:

1. Monitor the emission sources through the competent authority and submit the analysis reports to the board.

2. Monitor ambient/work zone noise levels & ensure conformance to standards.


Quarterly Compliance:

1. Monitor the ambient air quality at upwind and downwind locations of the factory. 2. Review the Water Reuse performance. 3.

Yearly Compliance:

1. Carryout “Environmental Audit Statement” of various environmental aspects, review the environmental policies with the help of experts and make the up gradation /changes accordingly.

2. Submit the “Environmental Statement” to the State Pollution Control Board in Form V under Rule 14 of the Environment (Protection) Second Amendment Rules 1992 of the Environment (Protection) Act, 1986.

3. Renew the Consent to Operate under the Water and Air Acts. 4. File the Cess returns to the State PCB under the Water (Prevention and Control of

Pollution) Cess Act, 1977. 5. Renew the Hazardous Waste Authorization under Hazardous Wastes

(Management, Handling and Transboundary Movement) Rules, 2008.

Figure 16: Structure & duty of Envt. Cell

The ultimate aim is that the Proponents isSustainable Production.

Top Management

SPCB

Public

Environment Management Plan

In-plant Control

Treatment

Disposal

Attenuation

Monitoring

Prevention, Abatement

Waste minimization

Operation

Documentation

Operation

Awareness

Feedback

Internal Lab.

III- Party Lab.

Training


7 CHAPTER - ADDITIONAL STUDIES 7.1 Public consultation

This is a proposal for expanding an established specialty chemicals industrial unit for producing synthetic organic dyes, which is in a notified Government GIDC industrial area. The Proponents are M/s. Indo Colchem Pvt Ltd presently located at shed no. 36 Phase II, GIDC, Vatva, Ahmadabad and having operating unit. However, in order to ascertain the concern of the local persons, who have plausible stake in the environmental impact of this project, the Proponents thought it fit to interview some people as sample survey basis. These interviews were oral and informal. This was not to meet any statutory requirement or a mechanical formality. Proponent really wanted to know as to whether this project is a welcome addition in the minds of surrounding people. They never wanted to force their presence.

The interviews generally brought out the following points –

• The workings of existing unit are working well to give benefit to the local people. • The payment of materials and wages here will be satisfactory, as also the weighment • There is a constant rapport, open corridors for discussion and transparency in

transactions. • No odour or noise nuisance is felt. • Sons of soil are employed and benefited. • It is however, necessary to see that no water pollution and odour nuisance is created

by the unit, for which the proposed arrangement appears to be satisfactory. • Sons of the soil should get preference in employment.

The GIDC neighbouring industrial units, local people and Proponents are generally comfortable with each other.

7.2 Risk assessment - Expansion of Specialty Chemicals

Hazard analysis involves the identification and quantification of the various hazards (unsafe conditions). On the other hand, risk assessment deals with recognition and computation of risks, the equipment in the plant and personnel are prone to, due to accidents resulting from the hazards present in the plant.

Risk assessment follows an extensive hazard analysis. It involves the identification and assessment of risks the neighboring populations are exposed to as a result of hazards present. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate. Consequently, the risk assessment is often confined to maximum credible


accident studies. It provides basis for what should be type and capacity of its on-site and off-site emergency plan also what types of safety measures shall be required.

7.2.1 Approach to the Study

Risk involves the occurrence or potential occurrence of some accidents consisting of an event or sequence of events. The risk assessment study covers the following:

Identification of potential hazard area;

Identification of representative failure cases;

Visualization of the resulting scenarios in terms of fire and explosion;

Assess the overall damage potential of the identified hazardous events and the impact zones form the accidental scenarios;

Furnish the recommendations on the minimization of the worst accident possibilities

Preparation of Disaster Management Plan;

Emergency Plan, which includes Occupational and Health Safety Plan

7.2.2 Methodology:

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the risks from hazardous activities, and forming a rational evaluation of their significance, in order to provide input to a decision- assessment is widely used, but strictly this refers to the purely numerical assessment of risks without any evaluation of their significance. The study has been conducted based on the premises of a traditional Quantitative Risk Assessment.

QRA is a mathematical approach of engineers to predict the risks of accidents and give guidance on appropriate means of minimizing them. Nevertheless, while it uses scientific methods and verifiable data, QRA is a rather immature and highly judgmental technique, and its results have a large degree of uncertainty. Despite this, many branches of engineering have found that QRA can give useful guidance. However, QRA should not be the only input to decision-making about safety, as other techniques based on experience and judgment may be appropriate as well. Risk assessment does not have to be quantitative, and adequate guidance on minor hazards can often be obtained using a qualitative approach.

The Key Components of QRA


It is a very flexible structure, and has been used to guide the application of risk assessment to many different hazardous activities. With minor changes to the wording, the structure can be used for qualitative risk assessment as well as for QRA.

The first stage is system definition, defining the installation or the activity whose risks are to be analysed. The scope of work for the QRA should define the boundaries for the study, identifying which activities are included and which are excluded, and which phases of the installation's are to be addressed. Then hazard identification consists of a qualitative review of possible accidents that may occur, based on previous accident experience or judgment where necessary. There are several formal techniques for this, which are useful in their own right to give a qualitative appreciation of the range and magnitude of hazards and indicate appropriate mitigation measures. This qualitative evaluation is described in this guide as 'hazard assessment'. In a QRA, hazard identification uses similar techniques, but has a more precise purpose - selecting a list of possible failure cases that are suitable for quantitative modeling.

Once the hazards have been identified, frequency analysis estimates how likely it is for the accidents to occur. The frequencies are usually obtained from analysis of previous accident experience, or by some form of theoretical modeling.

In parallel with the frequency analysis, consequence modeling evaluates the resulting effects if the accidents occur, and their impact on personnel, equipment and structures, the environment or business. Estimation of the consequences of each possible event often requires some form of computer modeling, but may be based on accident experience or judgments if appropriate. When the frequencies and consequences of each modeled event have been estimated, they can be combined to form measures of overall risk. Various forms of risk presentation may be used. Risk to life is often expressed in two complementary forms:

1. Individual risk - the risk experienced by an individual person.

2. Group (or societal) risk - the risk experienced by the whole group of people exposed to the hazard.

Up to this point, the process has been purely technical, and is known as risk analysis. The next stage is to introduce criteria, which are yardsticks to indicate whether the risks are acceptable, or to make some other judgment about their significance. This step begins to introduce non-technical issues of risk acceptability and decision-making, and the process is then known as risk assessment.

In order to make the risks acceptable, risk reduction measures may be necessary. The benefits from these measures can be evaluated by repeating the QRA with them in place, thus introducing an iterative loop into the process. The economic costs of the measures


can be compared with their risk benefits using cost-benefit analysis. The results of QRA are some form of input to the design or ongoing safety management of the installation, depending on the objectives of the study.

Qualitative Method

Preliminary risk analysis

Hazard and operability studies(HAZOP)

Failure mode and effects analysis(FMEA/FMECA)

Discussion and conclusion:

In this section, we will deal with the qualitative methods used in risk analysis namely preliminary hazard analysis(PHA), hazard and operability study(HAZOP), and failure mode and effects analysis (FMEA/FMECA).

Preliminary Risk Analysis:

Preliminary Risk Analysis Preliminary risk analysis or hazard analysis a qualitative technique which involves a disciplined analysis of the event sequences which could transform a potential hazard into an accident. In this technique, the possible undesirable events are identified first and then analysed separately. For each undesirable events or hazards, possible improvements, or preventive measures are then formulated.

The result from this methodology provides a basis for determining which categories of hazard should be looked into more closely and which analysis methods are most suitable. Such an analysis also proved valuable in the working environment to which activities lacking safety measures can be readily identified. With the aid of a frequency/ consequence diagram, the identified hazards can then be ranked according to risk, allowing measures to be prioritized to prevent accidents.

7.3 Mitigation Measures:

The purpose of mitigation is to identify measures that safeguard the environment and the community affected by the proposal. Mitigation is both a creative and practical phase of the EIA process. It seeks to find the best ways and means of avoiding, minimizing and remedying impacts. Mitigation measures must be translated into action in the correct way and at the right time, if they are to be successful. This process is referred to as impact management and takes place during project implementation. A written plan should be prepared for this purpose, and includes a schedule of agreed actions. Opportunities for impact mitigation will occur throughout the project cycle.


7.4 Noise Exposure

High sound levels may be generated from the equipments used in the manufacturing and utilities (e.g.-compressed air, vacuum sources, unit operations system, etc.). Irrespective of the enclosed design and anti-vibration control measures in the work place modules, the workers are located close to the machines during manufacturing and exposed to noise. Mitigation measures Good engineering practices. The rotation of employees in shift should be followed so as to reduce their exposure to noise sources for longer period.

Good engineering practices.

The rotation of employees in shift should be followed so as to reduce their exposure to noise sources for longer period.

Hearing protective devices in the form of ear muff and plug should be used to reduce employee’s exposure to high noise levels.

Comprehensive hearing conservation programs should be carried out to identify noise sources for its prevention/control.

Noise monitoring and medical surveillance should be carried out at regular intervals so as to assess the workers exposures to noise and corrective measures.

7.5 Hazard Identification:

Identification of hazards in the proposed project activity is of primary significance of the analysis, and quantification. Hazard states the characteristics of system/plant/process that presents potential for an accident. All the components of a system/plant/process need to be thoroughly examined to assess their potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an accident. A core challenge faced by emergency managers is how to prevent, prepare, mitigate, respond and recover from a myriad of hazards. Several questions arise when faced with this challenge: What hazards exist in my area? How frequently do they occur? How severe can their impact be on the community, infrastructure, property, and the environment? Which hazards pose the greatest threat to the community? A Hazard Identification and Risk Assessment (HIRA) assist emergency managers in answering these questions. It is a systematic risk assessment tool that can be used to assess the risks of various hazards.


There are three reasons why a HIRA is useful to the emergency management profession: It helps emergency management professionals prepare for the worst and/or most likely risks. Allows for the creation of exercises, training programs, and plans based on the most likely scenarios. Saves time and resources by isolating hazards that cannot occur in the designated area.

7.5.1 Quantification of Risk Assessment:

Detailed Risk & Hazop Report is attached as Annexure 4

Figure 17: QRA Methodology


Figure 18: Flow chart for quantitative Risk Assessment


7.6 Identification of Hazardous Areas

The procedure for QRA starts with identification of major risk areas in the installation. Operation carried out in specialty chemical manufacturing unit usually come under certain board, general categories. At M/s. INDO COLCHEM, major risk areas are as follows:

Bulk storage area for Raw Materials at ambient temperature and atmospheric pressure.

Process Plant involving pumping, transportation, reactors, distillation, heating, cooling, etc.

Bulk loading and unloading from storage tanks to road takers and vice versa.

7.6.1 Identification of Failure Cases for Hazardous Areas

• Release due to catastrophic failure of storage tanks or process vessels. • Rupture of connected pipe with storage tank or process vessels. • Continuous release at significant rates for long durations transfer pipelines caused by

sudden, major break of the pipeline. • Continuous release at low rate through small holes or cracks in piping and vessels,

flange leaks, and leakage from pump glands and similar seals. It is to be noted that for Quantitative Risk Assessment, worst case scenarios has been considered, though their frequency of occurrence is much lower than the cases of small leaks.

7.6.2 Major Hazardous Areas

The major Hazardous chemicals to be stored, transported, handled and utilized within the plot area are summarized. Other hazards and control measures are summarized in Table-6.1. Facilities / System for process safety, transportation, firefighting system and emergency capabilities to be adopted are stated below.

• Always use the road tankers having authorization/registration for transporting the said liquids.

• Vendor will be asked to provide TREM CARD to Tanker Driver. • Tankers will have clearly marked identification of material being contained with

mentioning Safety Card. • Provide Flame Arrester on exhaust while entering tanker within premises. • Ensure Earthing Boss connection before starting any transferring. • SOP to cover routine checking of Tank farm area to be carried out for checking any

spillage / leakage. • Tanks will be inspected physically daily for visual abnormality. • Readings of Temperature & Pressure will be noted, recorded & reported immediately in

case of abnormality. • Safety instruments like rupture disc, safety valves will be checked at defined duration

for intactness. • Scheduled testing of tanks to be done for thickness testing.


• Tanks to be painted on regular interval defined as per laws to protect them from atmospheric corrosion.

• Barrels to be checked for proper fixing of bungs before sending it outside the premises.

• Barrels to be monitored physically daily for developing any pressure or vacuum within it on long storage.

Table 36: Other Hazards and Controls- Storage and Handling details of Hazardous

Chemicals

Sr. No. Raw Materials Storage CapacityMT

Type of Storage & MOC

No. of Vessel

Vessel CapacityMT

Type of Hazards

1 Sulphuric Acid 98% 25 MS Tank 1 25 Corrosive

2 Hydrochloric Acid 20 HDPETank 2 10 Corrosive

3 Oleum 25 MS Tank 2 (1 empty and 1 filled)

25 Corrosive

4 Liquor Ammonia 2 Plastic Carboys

10 0.2 Corrosive

5 ChloroSulphonic Acid

25 MS Tank 1 25 Corrosive


Table 37: Other Hazards and Control

Sr. No.

Name Of The Possible

Hazard Or Emergency

Its Sources &Reasons

Effects On Persons,

Property & Environment

Place Of Its Effect

Control Measures Provided

1 Boiler

(1) Burning

(2) Physical injury

(3) Explosion

Over pressure in the boiler if safety valve not working. Water

level indicator not working. Low water level indicator fail. Hightemp. System fails.

Minor/Major Injury Loss of human life

Loss of property

(Loss of Main/Machine

Material)

Boiler House

And surrounding

places

Lower & Upper Level Indication System provision. Safety valves for pressure control fixed temp.& pressure indicator provided. Blow down & blowing system provided for cleaning tube and shell. Soft water used. Interlocking provided on pumps, FD fan, ID fan. Periodical checking &inspection maintenance done. Yearly inspection done by Boiler Inspector

2 Electricity

(1) Burning

(2) Fire

(3) Shock

Loose Contacts, Weak

earthling Short Circuit

Improper Insulation

Burning, Shock, Death

Surrounding the

accident area

Proper Earthling, Periodical

Checking of joints, proper

Insulations of Equipments, etc.

Flame proof fitting in solvent

storage area, bounding and

Jumpers to all solvent barriers.

3 House Keeping Bad House keeping

Physical /Chemical

In all Proper Handling, regular


7.7 Consequence Analysis In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits.

(1) Physical

(2) Burning

(3) Fire

(4) Chemical Exposure

Thermal Burn Injury

(Major /Minor)

surrounding

areas i.e.

Storage, Plants

cleaning, Proper placement of material (RIGHT THING AT THERIGHT PLACE)

4 Pipe line

Leakages

Spillages etc.

(1) Corrosion

(2) Toxic gas release

Leaking of pipe line due to corrosion, Loose

contact etc.

Physical /

Chemical Thermal

Burn Injury(Major /

Minor)

Plant area Proper maintenance, Proper

Selection of Material for pipe

lines, Immediate attention,

Earthling provided, flame proof fitting, NO SMOKING Boards displayed.

5 Structural

Failure

Inside the factory

(Corrosion)

Injury/Death to persons,

damage to property

Within the

factory

Automatic operation Periodic

Testing of safety valves Regular Inspection

6 Toxic Release Outside the factory

Injury/Death Within &

outside the unit

Alarm, Evacuation rescue &

shelter/ Welfare

7 Natural

Calamity

Nature Injury /Death to

persons, damage to

property

Within &

outside the unit

Alarm, Evacuation rescue &

shelter/ Welfare


Operating Parameters Potential vapour release for the same material depends significantly on the operating conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential. If we take up an example of ammonia, if it is stored at ambient temperature, say 30oC, and then the vapour release potential of the inventory is much higher as compared to the case if it is stored at 0oC. Inventory Inventory Analysis is commonly used in understanding the relative hazards and short listing of release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a vessel or a system, larger the quantity of potential release. The potential vapour release (source strength) depends upon the quantity of liquid release, the properties of the materials and the operating conditions (pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source strength estimated for each release case, a ranking should become a credible exercise. Loss of Containment Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all significant release cases and then to short list release scenarios for a detailed examination. Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden appearance of such a major crack that practically all of the contents above the crack shall be released in a very short time. The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is depending on the size of the hole as well as on the pressure, which was present, in front of the hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The vaporisation of released liquid depends on the vapour pressure and weather conditions. Such consideration and others have been kept in mind both during the initial listing as well as during the short listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the largest potential hazard inventories have been considered for consequence estimation.

7.7.1 Damage Criteria In consequence analysis, use is made of a number of calculation models to estimate the physical effects of an accident (spill of hazardous material) and to predict the damage (lethality, injury, material destruction) of the effects. The calculations can roughly be divided in three major groups: a) Determination of the source strength parameters; b) Determination of the consequential effects; c) Determination of the damage or damage distances. The basic physical effect models consist of the following.


Figure 19: Toxic Effects


Scenario No. 3: Releases of Ammonia:


Table 38: Transportation, Unloading and Handling Procedure for Hazardous Chemicals

S. No. Activity Possible Hazard Mitigation Measures 1 Transportation

of Solvents by road tanker

Leakage& Spillage • Check the source of leakage point. • Do not touch damaged containers or spilled

material unless wearing appropriate protective clothing.

• Stop leak if you can do it without risk. Fire,& explosion • Use water spray to reduce vapours; do not put

water directly on leak, spill area or inside container.

• Keep combustibles (wood, paper, oil, etc.) away from spilled material.

Toxic release • Isolate the area • Isolate the container • Training will be provided to driver and

cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling.

• TREM card will kept with TL. • Fire extinguishers will be kept with TL. • Flame arrestor will be provided to TL exhaust. • Instructions will be given not to stop road

tanker in populated area. • Clear Hazard Identification symbol and

emergency telephone number will be displayed as per HAZCHEM CODE.


• Appropriate PPEs will be kept with TL.

7.7.2 RISK MITIGATION MEASURES SUGGESTED

LIKELIHOOD REDUCTION MEASURES

1. Safe Operating Procedure (SOP) for handling of ketene 2. Use rotary equipment with high integrity seals 3. Use process interlocks/shutdown systems in case of control failure

CONSEQUENCE REDUCTION MEASURES

• Consider relocation of OHC to safe zone. • Provision of fire water storage 850 m3. • Regular Testing of Fire hydrant system. • Provide Smoke detector at ware house, Leak detector at scrubber, Safety shower & eye

wash fountains at corrosive chemicals handling area, Fire call points, portable Fire extinguishers and Personnel Protective Equipment (PPE).

• Provide emergency gate at north east side of the plot. • A separate document “DMP” based on MCLS Analysis for the site is developed and

enclosed separately.


7.8 COAL HANDLING:

Coal handling aspect for prevention of fire in storage and conveying system.

Coal is used as fuel for steam and power generation in boiler and in coal gasification plant for

generation of producer gas to be used as fuel in furnaces.

Following aspects of coal handling are considered for prevention of fire in coal storage and

handling area.

Identification of hazards involved in coal handling:

A. Spontaneous fire

B. Emission of trapped gases

C. Dust/particulate matter emission

D. Dust explosions

Following aspects will be considered in designing of coal storage and conveying to mitigate

hazards.

A) Spontaneous fire:

1. In order to eliminate the possibility of spontaneous fires, "first in, first out" rule of using

stock will be implemented which will reduce the chance for hot spots by helping

preclude heat build-up for portions of stock which remain undisturbed for a long time.

2. Short coal handling procedures which will not allow long-time retention of coal, which

increases the possibility of overheating.

3. Avoiding new coal added on top of old coal created segregation of particle sizes, which is

a major cause of overheating.

4. Air circulating within a coal pile will be restricted as it contributes to heating,

compacting helps seal air out.

5. Coal having high moisture content will be segregated and used as quickly as possible

and efforts will be made to keep stored coal from being exposed to moisture.

6. Dry coal shall be kept dry and shall be not exposed to any rain during storage period.

This concerns what is known as the heat-of-wetting.


7. The shape and composition of open stockpiles can help prevent fires. Dumping coal into

a big pile with a trestle or grab bucket can lead to problems, hence will be avoided.

8. Coal will be packed in horizontal layers, which are then levelled by scraping and

compacted by rolling. This method helps distribute the coal evenly and thus avoids

breakage and segregation of fine coal. Segregation of coal particles by size will be

avoided, as it may allow more air to enter the pile and subsequent heating of finer sizes.

9. The height of the coal pile is also important. To limit un-layered, un-compacted high

grade coal to a height of 5m; maximum height is 8m for layered and packed coal.

10. Properly inspect, test and maintain installed fire protection equipment.

B) Emission of trapped gases

1. The trapped hydrocarbon gases can escape to atmosphere during coal handling.

The concentration of such gases will be avoided by providing roof extractors in the

ware house.

2. Proper cross ventilation will be provided in the ware house by proving openings in

the warehouse.

C) Dust/particulate matter emission:

1. Dust emission during unloading of coal in the hopper will be controlled by provided

dust handling systems.

2. Fogging system will be provided to suppress dust during charging of coal.

D) Dust explosions:

1. Coal dust can form explosive mixture. The hazard will be mitigated by providing

explosion proof fixtures.

2. Proper earthing will be provided for equipment for equipment

3. Freefall will be provided during designing of material handling.

Mitigation measures:

The coal storage area will be provided with following arrangements.

1. Covered shed for coal storage.

2. Adequate cross ventilation in the ware house.

3. Retaining wall on all sides up to 2 met height.


4. Dust handling systems for coal hoppers

5. Fogging system for dust suppression.

6. Approach road from all sides for access for fire tender and fire fighting

7. Fire hydrants and fire monitors in loop at appropriate locations

8. Fire hose boxes and fire reels.

9. Fire drills

10. Standard operating procedures for coal stacking.

1. Silos will be provided with dust suppression system to avoid any release of dust from the

top.

2. Pneumatic bulk conveying system will be installed.


8 CHAPTER - PROJECT BENEFITS

It is seen that the Project is aimed to fulfil the objective of Sustainable Development. It will improve economic status of the nearby area in the district.

8.1 Improvements in the physical infrastructure

This Project will improve the physical infrastructure of this area:

• As roof rain harvesting and recharging is proposed, there will not be any incremental run-off causing floods downstream. It will improve the water table in the long run. The nearby nalla is trained by good civil engineering practice and hence physical infrastructure will improve.

• The industry is dependent on raw materials and helping chemicals, which arrives by road. The finished goods will be dispatched by road. All the labour force will come by road. The proponents will assist the administration to maintain the roads in good conditions. This improved physical infrastructure will be an added facility to the community for surface transport.

• Greening drive in the premises will give a pleasant look to the land. It will absorb some portion of the CO2 produced by fuel burning (utilities) as well as created by induction furnace (process). It is proposed to use treated domestic wastewater for green area development. Canopy of trees will arrest dust fugitive SPM as well as the noise.

8.2 Improvements in the social infrastructure

The Project will aid in the improvement of the social infrastructure of this area:

• In the District, similar industries are already running their units over the years. These are not only running with efficiency but are running with no disturbance to the local people. Local people have even encouraged the expansion of such mills for production. The same is the case for diversification.

• PP will employ sons of the soil without discrimination, wherever feasible. The Proponent’s management keeps the transparent account.

• Education level goes along with flow of funds and avenue of livelihood. Dependence on Government subsidy also goes along with political stability of the area. The level of education and literacy (especially rural and women) is very poor, needing improvement. This activity by this Proponent will certainly play a catalytic role in this.

• Likewise, the health level goes along with flow of funds and avenue of livelihood. Dependence on Government institutes like PHC (Primary Health Centre) also goes


along with political stability of the area. The level of health and medication (especially children and women) is very poor, needing improvement. This activity by this Proponent will certainly play a catalytic role in this.

• Health awareness and economic independence may also help in Family Planning decision-making.

• Living in harmony is an important aspect of the society. This can happen only if all the components are comfortably placed. Persons engaged in their respective vocation and accruing job satisfaction leads to this. This will become possible by this venture.

8.3 Employment potential – skilled, semi-skilled and unskilled

The industry and its supporting activity need many types of people right from manual to managerial strength, in a pyramid. The raw material growing may need unskilled workers with people on tractors and tractor repairers as skilled ones. So in manufacturing activity all three types i. e. skilled, semi-skilled and unskilled people are required. The overall potential including the garages, loading-unloading actions, eateries, small repair shops, etc is essential. The local people can get a good share out of this. If the second generation local people acquire that skill, they too will be able to fill the gap and accrue benefit of higher jobs.

8.4 Other tangible benefits

Both tangible and non-tangible benefits will result from this activity and many of those are described above. Apart from direct employment, many other benefits will accrue like

• Flood control by rain-water arresting and harvesting • Groundwater level enhancing by recharging • Time saving by quicker transport • Aesthetics improvement by general greening with emphasis on biodiversity • Strengthened democratic set-up will bring weightage to secure better school-subsidy

and health-institutes • Improved safety-security in surrounding with better Law and Order.


8.5 Corporate Social Responsibility:

There will be more employment generated due to the proposed project both during the construction phase and operation phase. On the basis of technical knowledge acquired by the local village youths, they will be providing with suitable employment Opportunity in the company. The labour force required during construction and operation phase shall be sourced from nearby village. Free medical checkup for villagers. Tree Plantation in rural areas. Provision of sanitation (toilets) facility. Funds will be provided to arrange extracurricular activities for nearby school and

colleges. Special Health awareness camp and medical camps for primary check upwill be arranged

at least once in a year in nearby villages for health check-ups.

Table 39: Budgetary Provisions for the next five years (Every Year)

Sr. No.

Activities Budgetary Provision (INR in Lakhs)

1 Educational 7.0 2 Preservation the Environment

and Sustainable Development 2.0

3 Health & Family Welfare 3.0 4 Drinking water & Sanitation facility 2.0 5 Miscellaneous as per the demand

by study areas 2.0

Total 16.0


8.7 Environment Policy:

ICPL is existing industry and it has already well developed Environment Policy as follows.

--00--


9 CHAPTER - ENVIRONMENT MANAGEMENT PLAN (EMP) 9.1 Need:

Indian and worldwide demand for green solvents and specialty chemicals is increasing steadily. Thus there is a gap in demand and supply. Our efforts of generating products and recycling are indeed required.

9.2 Objectives:

a) To define the components of environmental management. b) To prepare an environmental hierarchy. c) To prepare a checklist for statutory compliance. d) To prepare environmental organization. e) To prepare a schedule for monitoring and compliance.

9.2.1 Environment Components:

ICPL is aware that environmental management is not a job, which can be handled without a careful planning. The success lies if three components are simultaneously present viz. (1) management support, (2) efficiency of the environment management cell and (3) acceptability of resulting environmental quality, both by SPCB and by public. A structure of this plan and hierarchy of process flow for environmental management is prepared and enclosed as logics, which is self-explanatory. ICPL will adopt this structure and hierarchy, which is akin to principles and practice.

Air Environment:

a) Monitor the consented parameters at ambient stations. b) Monitor the work zone at various stations to satisfy the corporate requirements

for health and environment. c) Maintain a record of running of DG (diesel generating) sets d) Monitor the stacks.

Water Environment:

a) Keep record of input water every day for quantity and periodically of quality. b) Measures are taken to segregate the sub-streams of effluent as per their

characterization. c) Water conservation is accorded high priority in every section of the factory. d) Keep record of wastewater returned back to process, to utilities and to

gardening, both the quantity and quality details.


Aesthetic (Noise &Odour) Environment:

a) Monitor the ambient noise level and work zone noise level to conform the stipulated norms.

b) Creation of awareness for noise attenuation and mitigation program. c) Monitor the ambient Odour level and work zone Odour level by sensing. d) Creation of awareness for Odour attenuation and mitigation program

Biological Environment:

a) Special attention is planned to maintain green belt in and around the factory premises.

b) Adequate provisions are made to facilitate daily watering of all plants and lawns. Special attention provided during summer to ensure that the green belt does not suffer from water shortage.

c) Development & maintenance of green belt to be considered as a priority issue. d) No outside soil is brought for any building/ greenery developments.

Work-zone Comfort Environment:

a) MONITOR THE WORK ZONE TEMPERATURE LEVELS. b) MONITOR THE WORK ZONE HUMIDITY. c) EXAMINE THE HEALTH OF WORKERS AND KEEP RECORD.

Socio- Economic Environment:

a) The operators and workers are trained in various aspects of ESH (Environment, Safety and Health).

b) The managers and officers involved in Environment Management Cell shall undergo refresher workshop and up gradation of information on various environmental issues.

c) The industry shall help in promoting the activities related to environmental awareness in nearby villages/ neighbours.

d) The industry shall help in promoting local people for livelihood commensurate with their will, skill and abilities.


9.2.2 Environmental Monitoring Schedule:

A judgment can become truncated if it is not scientifically supported. This work is done by an appropriate monitoring which is a technique of drawing a sample and deriving inferences from the same for knowledge and improvements.

A scheme for this is already prepared and presented in chapter six above. Watch-dog committee will also help in examining this physically for organoleptic tests.

A judgment can become truncated if it is not scientifically supported. This work is done by an appropriate monitoring which is a technique of drawing a sample and understanding from it the universe. The sampling station, the parameters and frequency is of extreme importance as also the careful analysis, reporting and interpretation. The schedule decided for a small activity like that of LOILis as given in chapter six:

9.2.3 Schedules:

There will be three facets to design and follow the schedules viz.: (A) for compliance of responsibilities, (B) for day-to-day operation and management of ETP and ECE, and (C) for routine environmental monitoring, to assess the impact and take timely warning. The schedule:

Daily Compliance:

1. Take the meter readings - initial and final, for checking the water consumption. 2. Maintain the electricity consumption record for pollution control.

Monthly Compliance:

1. Monitor the effluent quality. 2. Monitor ambient/work zone noise levels & ensure conformance to standards.

Quarterly Compliance:

1. Monitor the ambient air quality at upwind and downwind locations of the factory. 2. Review the Water Reuse performance.

Yearly Compliance:

1. Carryout “Environmental Audit Statement” of various environmental aspects, review the environmental policies with the help of experts and make the up-gradation /changes accordingly.


2. Submit the “Environmental Statement” to the State Pollution Control Board in Form V under Rule 14 of the Environment (Protection) Second Amendment Rules 1992 of the Environment (Protection) Act, 1986.

3. Renew the Consent to Operate under the Water and Air Acts. 4. File the Cess returns to the State PCB under the Water (Prevention and Control of

Pollution) Cess Act, 1977. 5. Renew the Hazardous Waste Authorization under sub-rule 3 of the Hazardous

Waste (Management and Handling) Rules, 1989. 6. Monitor ambient air periodically as per Consent.

9.2.4 Consent Compliance

ICPL undertakes to comply the conditions prescribed by the Consent. In this direction, the following discipline will be followed:

Table 40: Consent Compliance

#

Condition Regarding

Mode of Compliance

1 Validity Period Keeping a watch, Application for renewal will be submitted in advance

2 Production Quantity Not to exceed the permitted quantity. Feed will be adjusted to recovery

3 Quantity of Effluent To be measured daily and in-plant control. Not to exceed any time

4 Quantity of Sewage To be measured periodically. Not to exceed

5 Total water input To be measured daily. Repair meters. Not to exceed. Make break-up as per usages. Fill monthly Cess returns. Pay as per assessment

6 Quality of Effluents By running treatment units in correct fashion. Monitor. Report

7 Disposal of treated effluent

Not over application. No percolation, no spillages. Monitor.

8 Fuel Quantity Not to exceed permitted quantity


9 Emission System Regular running, monitoring & maintenance

10 Ambient Keep monitoring.

11 Noise levels Check foundation for vibrations, Tree plantation

12 Solid Waste Quantity to be measured & record kept.

13 Environ. Audit To be complied every year before 30th Sept.

14 Inspections Inspection Book to be opened. Instructions given by SPCB visiting officer to be complied and reported.

For above compliance Action will be taken by the Cell under the Managing Director himself.

9.2.5 Watch-dog Committee:

A high power watch dog committee will be set up which will have a power of sudden spot inspections, checking of documents and listening to complaints if any. This committee will supervise over the monitoring and environmental management cell as may be necessary, generally over the following facets of works:

1. Permit management 2. Construction management 3. Treatment and emission management 4. Transport management 5. Disposal management 6. Monitoring 7. Documentation 8. Law enforcement

Construction Phase Management:

Site Preparation:

There is no need of site preparation, it is expansion project in existing premises. No major leveling operations are envisaged. During dry weather conditions it is necessary to control dust nuisance created by excavation and transportation activities in minor amount. However, because the proposed built-up area is of considerable low requirement, this problem should not be insurmountable, or else some water sprinkling will be resorted to.

Sanitation:


The construction site shall be provided with sufficient and suitable toilet facilities for construction workers to allow proper standards of personal hygiene. These facilities shall be connected to a STP and maintained to ensure minimum or no environmental impact.

Noise:

Though the noise effect on the nearest inhabitants due to construction activity will be negligible (being away) it is advisable that on site workers using high noise equipment adopt noise protection devices like earmuffs.

Construction Equipment and Waste:

It shall be ensured that both gasoline and diesel powered construction vehicles are properly maintained to minimize smoke in the exhaust emissions. The vehicle maintenance area shall be located in such a manner to avoid sources by accidental spillage of oil. Unauthorized dumping of waste oil should be prohibited. Wastes shall be disposed off at an approved site.

Storage of Hazardous Material:

The following hazardous materials if used for site preparation and construction activity, shall be stored as per international standards.

1. Explosives for rock blasting (This will not be permitted) 2. Petrol and diesel 3. LPG 4. Painting materials 5. Asbestos products

Site Security:

Construction site is a potential hazardous environment. To ensure that the local inhabitants and stray cattle are not exposed to these hazards, the site shall be secured by fencing and manned entry points. It will be fully illuminated.

Land Environment:

This is an expansion project, so there is no need of major construction work. There is only fabrications work. An inventory shall be prepared of standing trees and bushes of significance. To prevent unauthorized felling of trees by construction workers for their fuel needs it will be ensured that the contractor provides fuel to them.


9.3 Conclusion:

Commencing from Introductory, this EIA study has reported the details on Proponents, Project, natural and manmade facets of background environment, how and how much residual pollution will be added after prevention, abatement, control and mitigation. Whether the overall impact will be adverse, beneficial or marginal is found out by two accredited systems. This, however, is required to be manned properly. Unless an EMP is prepared in advance, as like production campaign the environmental protection will not automatically happen. Such EMP, and its implementation with commitment from the higher management is stated. This Study when scrupulously followed, will meet the objectives of fulfilling the legal requirements and not causing any hardships to people.

Environment Management Cost Estimation:

Sr. No. Description Recurring Cost

Rs Lakh/Year

Capital Cost

Rs Lakh/Year

1 Air Pollution Control 5.0 55.0

2 Water Pollution Control 5.0 4.0

3 Noise Pollution Control 1.0 1.0

4 Environment Monitoring &

Management

2.0 5.0

5 Occupational Health 2.0 4.0

6 Green Belt Development Plan 1.0 3.0

7 Hazardous Waste Management 2.0 5.0

8 Rain Water Harvesting 1.0 3.0

Total 20.0 80.0


10 CHAPTER -CONSULTANTS ENGAGED

This EIA report is prepared on behalf of the proponents, taking inputs from proponent’s office staff, Architects, Project Management Professionals etc. by Environmental Consultants M/s Ultra-Tech Environmental Consultancy & Laboratory, Thane - Pune, who have been accredited by QCI-NABET vide No. NABET/EIA/1417/RA010 ULTRA-TECH Environmental Consultancy and Laboratory [recognised by Ministry of Environment & Forests, Govt. of India] is an established Environmental Services provider since 1986. Ultra-Tech, a confluence of environmental analysts and experts, engineers, geologists, sociologists, ecologists and monitoring and management professionals offers services for

• Environmental Impact Assessment (EIA) studies and Environmental Clearance • Environmental Due Diligence and Audits, • Environmental Status Reports for ULBs. • Environmental Advisor for ULBs • Water and Wastewater Project consultancy and turnkey execution, • Post EC Compliances, • Environmental laboratory services and • O&M for ETP/STP

Ultra-Tech has well developed infrastructure at Thane, Pune, Kolkatta, Bangalore, Kochi and Singapore to cater to needs of the clients for all environmental services.

CREDENTIALS

• NABET, Quality Council of India, Accreditation for EIA is in process. • ISO 9001:2008, OSHAS 18001:2008 certified State of the art Environmental Laboratory

and Trained Manpower, recognised by Ministry of Environment & Forests. • Environmental Advisor for Municipal Corporations. • Affiliated to Indian Green Building Council (IGBC), Hyderabad. • Affiliated to United States Green Building Council (USGBC), US. • Environmental Consultants for Federation of All India Textile Manufacturing Association • Environmental Consultants for All India Lead Manufacturing Association.

HONORS

We are honoured by the following reputed firms for quality environmental consultancy and monitoring services.

• TECHNICAL CONSULTANT TO CRISIL, MUMBAI: CETP issues in Gujarat, India • TECHNICAL CONSULTANT TO FAITMA, MUMBAI • TECHNICAL CONSULTANCY SERVICE, PUNE: Environmental Quality Monitoring for

Panvel-Karjat Railway Project • RASTRIYA CHEMICALS & FERTILIZERS , MUMBAI: Ambient Air Monitoring


INFRASTRUCTURE

Well-equipped and networked office/laboratory at Thane for conducting

• Air/Stack Quality monitoring • Water and Wastewater monitoring • Treatability and Feasibility studies • Soil Analysis • Microbial Analysis

Apart from Thane Head Office, we have branches in Thane, Pune, Kolkatta, Bangalore and Kochi with qualified and experienced professionals. We are planning to extend our services to Middle East and SEA countries in the near future.

ISO 9001:2008 Certification

We are ISO 9001:2008 certified with effect from 26th March, 2011

FUNCTIONAL AREAS

We have well defined six functional areas as mentioned earlier.

ENVIRONMENTAL IMPACT ASSESSMENT AND CLEARANCE SERVICES

Ultra-Tech assists Project proponent to obtain Environmental Clearance from Ministry of Environment and Forests [MoEF] or State level Environment Impact Assessment Authority as well as High Rise Committees [HRC, MCGM] for Projects by preparing EIA Reports based on Primary and Secondary data for following NABET accredited sectors:

Sr. No.

Sector As per MoEFCC Notification

Category (A/B)

1 Mining of minerals including opencast / underground mining

1(a) (i) A

2 Offshore and Onshore Oil & Gas exploration, development & production

1(b) A

3 River Valley, Hydel, Drainage and Irrigation projects

1(c) A

4 Thermal Power Plants ( 1(d) A


Sr. No.

Sector As per MoEFCC Notification

Category (A/B)

5 Mineral beneficiation including pelletisation

2 (b) A

6 Metallurgical industries (ferrous & nonferrous)

3 (a) A

7 Cement plants 3 (b) A

8 Synthetic organic chemicals industry 5(f) B

9 Distilleries 5(g) A

10 Sugar Industry 5(j) B

11 Oil & Gas transportation pipeline (crude and refinery/ petrochemical products) passing through national parks/ sanctuaries/coral reefs/ecologically sensitive areas including LNG terminal)

6 (a) A

12 Isolated storage & handling of Hazardous chemicals (as per threshold planning quantity indicated in column 3 of schedule2 & 3 of MSIHC rules 1989 amended in 2000

6(b) B

13 Ports, harbours, jetties, marine terminals, break waters and dredging

7(e) A

14 Highways railways, Transport Terminals, Mass Rapid transport System.

7(f) A

15 Building & Large construction projects 8(a) B

16 Townships and Area development projects

8(b) B

In addition to above, we provide service for clearance of CRZ related Projects.


Our key services include assistance for environmental clearances, consent to establish/ operate/renewal from respective authorities apart from development of environmental management plan, environmental status reports, disaster management plan, environmental and water audits, etc.

Ownership of organization

Though, Ultra-Tech is a proprietorship firm, actually it is a confluence of environmental engineers, ecologists, geologists, hydrologists, socio-economic and management experts apart from environmental laboratory sampling and monitoring teams. The company is established in 1986 and celebrated 2011 as its silver jubilee year.

Table 41:List of EIA coordinator, functional area experts & associates:

S. No

.

Name of Sector

Name of Project

Name of Client

EIA Coordinat

or

Functional Area Experts involved

Name/s FA Name/s Sign 1. 5 (f), &

1(d) B1 Synthetic Organic Industry

M/s. Indo ColchemPvt. Ltd.

M/s. Indo ColchemPvt. Ltd. at Shed No. 36, Phase II, GIDC, Vatva, Ahmedabad

Mr. Timir Shah

LU Mr. YogeshRaskar

AQ Mrs. Anjali

Singam Mr. UtkarshMukkannawar

AP Mr. ShekharTamhane

WP Mr. Timir Shah

EB Mrs. Padmini Shinde

SE Mr. Yogesh

Raskar

RH Mr. S. L. Bonde

SHW

Mrs. Deepa Tamhane-Karnik


S. No

.

Name of Sector

Name of Project

Name of Client

EIA Coordinat

or

Functional Area Experts involved

Name/s FA Name/s Sign

Table 42: Laboratory Details NAME OF LABORATORY SCOPE OF SERVICES ACCREDITATION

STATUS

ENVIRO-TECH SERVICES

G-232, M.G. ROAD, HAPUR- GAZIABAD(UP)

Recognized by Ministry of Environment and Forest (MoEF), Govt. of India

ISO 9001: 2008 and OHSAS ISO 18001: 2007 Certified Company

Monitoring and Analysis of:

1. Ambient Air Quality Monitoring 2. Ground and Surface Water

Quality Monitoring 3. Noise Level Monitoring and 4. Soil Quality Monitoring 5. Metrological data collection

Gazetted by MoEF- Govt. of India


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