FORM – 1

(I) BASIC INFORMATION.

Name of the Project. :

WASTE MANAGEMENT AND RESOURCE

RECOVERY PROJECT using 30 T/Day hazardous

solid waste and 15 T/day aqueous liquid waste

destruction using Plasma thermal Destruction and

recovery (PTDR) technology

Location / site

alternatives under

consideration.

:

M/S. PLASMA ENERGY APPLIED

TECHNOLOGIES ANKLESHWAR PVT.LTD

Plot No. 9206 , Gidc Estate,

Ankleshwar – 393 002

Dist: Bharuch,

Gujarat.

Size of the project * :

30 T/Day hazardous solid waste and 15 Tons /day

aqueous liquid waste destruction using PEAT

proprietary Plasma thermal Destruction and

recovery (PTDR) technology

Expected cost of the

project. : Apprx. Rs. 46.2 Crores

Contact Information. :

DR.C.B.UPASANI, DIRECTOR

M/S. PLASMA ENERGY APPLIED TECHNOLOGIES

ANKLESHWAR PVT.LTD

SHED NO. K1 7705/2,3,4, GIDC,

Phone No.: +91.2646 220293

E. Mail ID : hinaupasani@yahoo.com

Screening category. : 7 (d)

* capacity corresponding to sectorial activity ( such as production capacity for

manufacturing, mining lease area and production capacity for mineral production,

area for mineral exploration, length for linear transport, infrastructure, generation

capacity for power generation etc.,)

(II) ACTIVITY.

1.

Construction, operation or decommissioning of the Project involving actions,

which will cause physical changes in the locality (topography, land use,

changes in water bodies, etc)

Sr.

No.

Information / checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities/ rates, wherever

possible) with source of

information data.

1.1

Permanent or temporary change in

land use, land cover or topography

including increase in intensity of

land use (with respect to local land

use plan.)

Yes

Presently the proposed project site

is barren land. The site is located in

GIDC estate, Ankleshwar, Dist.

Bharuch.

1.2 Clearance of existing land,

vegetation and buildings? No

Plots already marked by GIDC as

service plot.

1.3 Creation of new land uses. Yes

Reserved service plot of GIDC will

be used for waste management and

resource recovery activity.

1.4 Pre-construction investigations e.g.

bore house, soil testing? Yes

Soil testing will be carried out by

unit.

1.5 Construction works? Yes

The present open plot will be

changed in to PTDR (Plasma

Thermal Destruction and Recovery

plant.)

1.6 Demolition works? No Not Required.

1.7

Temporary sites used for

construction works or housing of

construction workers? No

Local workers will be employed for

construction work.

1.8

Above ground buildings, structures

or earthworks including linear

structures, cut and fill or

excavations.

Yes Tentative Plant Layout is attached

as ANNEXURE – I

1.9 Underground works including

mining or tunneling? No

No such underground work is

required.

1.10 Reclamation works? No Not Required.

1.11 Dredging? No Not Required.

1.12 Offshore structures? No Not Required.

1.13 Production and manufacturing

processes? Yes

This is common infrastructure

facility for destruction of hazardous

waste and energy recovery. Detailed

process description is attached as

ANNEXURE-II

1.14 Facilities for storage of goods or

materials? Yes

Proper storage of hazardous waste

will be done. Detailed is attached as

ANNEXURE-II: Refer para 2.3.4

1.15 Facilities for treatment or disposal

of solid waste or liquid effluents? Yes

Only slag as a bio-product will

come out.

Liquid effluent expected discharge:

25KL/day will be disposed off in

CETP of BEAIL /ETL upon

confirmation from them. Till then

the proposed facility will observe

zero effluent discharge.

Please refer EMP attached vide

ANNEXURE-VI

1.16 Facilities for long term housing of

operational workers? No

Skilled operational manpower is

available in Ankleshwar region.

1.17 New road, rail or sea traffic during

construction or operation? No

The notified area has well

developed road facilities.

1.18

New road, rail, air waterborne or

other transport infrastructure

including new or altered routes and

stations, ports, airports etc?

No The notified area has well

developed road facilities.

1.19

Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No The proposed site is located in

GIDC notified area.

1.20 New or diverted transmission lines

or Pipelines? Yes Source: GEB

1.21

Impoundment, damming,

culverting, realignment or other

changes to the hydrology of

watercourses or aquifers?

No The proposed site is located in

GIDC notified area.

1.22 Stream crossing? No Not applicable

1.23 Abstraction or transfers of water

form ground or surface waters? No Source of water supply :GIDC

1.24

Changes in water bodies or the land

surface affecting drainage or run-

off? No

The proposed site is located in

GIDC notified area.

1.25

Transport of personnel or materials

for construction, operation or

decommissioning? Yes

The transportation of construction

material, man power, raw materials

& finished goods will be done by

road trucks.

1.26

Long-term dismantling or

decommissioning or restoration

works? No

No such activities will be involved

in proposed project.

1.27

Ongoing activity during

decommissioning which could

have an impact on the

environment?

No There will be no decommissioning

activities in the proposed project.

1.28 Influx of people to an area in either

Temporarily or permanently? No Local man power will be employed.

1.29 Introduction of alien species? No No such activity is associated with

proposed project.

1.30 Loss of native species or genetic

diversity? No

No such activity will be carried out

which will lead to loss of native

species or genetic diversity.

1.31 Any other actions? No Not required.

2

Use of Natural resources for construction or operation of the project (such as

land, water, materials or energy, especially any resources which are non-

renewable or in short supply):

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

2.1 Land especially undeveloped or

agricultural land (ha) No

Proposed project site is located in

GIDC notified area.

2.2 Water (expected source & competing

users) unit: KLD Yes

Expected water requirement:

250KL/day which shall be sourced

through the water supply network of

GIDC.

Attached as Annexure – III

2.3 Minerals (MT) No No such type of activity is

associated with proposed project.

2.4 Construction material – stone,

aggregates, sand / soil (expected

source – MT) Yes

All construction materials shall be

sourced from local source with legal

authorization for supply.

2.5 Forests and timber (source - MT) No No forest and timber products will

be used.

2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel

(MT),energy (MW) Yes

Connected Load will be 1500 KVA.

This power shall be utilized during

the start up of the plant only from

GEB Grid. During the regular

operation phase power will be

generated as a recovery from

resources in the tune of apprx. 0.2

MW. This surplus power shall be

used within the proposed facility or

rolled over to the GEB Grid.

CNG will be used as an auxiliary

fuel in the steam boiler during the

plant start up and heat up period.

During the regular operations phase

CNG shall be use as pilot flame fuel

only which shall be approximately

30 Kg./ Hr.

For Details please refer Energy

Balance attached vide

Annexure –IV

2.7 Any other natural resources (use

appropriate standard units) No No other natural resources are used.

3 Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about

actual or perceived risks to human health.

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

3.1

Use of substances or materials, which

are hazardous (as per MSIHC rules)

to human health or the environment

(flora, fauna, and water supplies)

Yes

The proposed facility will handle

waste capacity of 30 T/Day

hazardous solid waste and 15

Tons/day aqueous liquid waste

Refer Annexure II para 2.3.2 &

Annexure V

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases) No

No change in occurrence of disease

due to proposed project.

3.3 Affect the welfare of people e.g. by

changing living conditions? No

The area is already well developed

and industrialized.

3.4

Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.,

No

There will be no such effects due to

proposed project. The proposed site

is located in GIDC Estate.

3.5 Any other causes. No No other cause.

4 Production of solid wastes during construction or operation or decommissioning

(MT/month).

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

4.1 Spoil, overburden or mine waste. No No such waste will be generated

from the proposed project.

4.2 Municipal waste (domestic and or

commercial wastes) No

Trash papers & food waste is

expected to be generated by the

proposed project

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules) Yes

Generation of other wastes such as

used oil, contaminated

containers/barrels; waste packing

materials, is envisioned. For details

please refer EMP provided vide

ANNEXURE - VI

4.4 Other industrial process wastes No

Vitrified Slag and Na2S solution

will be generated from the proposed

project activity as recovered

resources. For details please refer

ANNEXURE - VI

4.5 Surplus product Yes

Vitrified Slag and Na2S solution

will be generated from the proposed

project activity as recovered

resources. For details please refer

ANNEXURE - VI

Surplus power in the tune of 0.2

MW will be generated which shall

be either utilized within proposed

facility or rolled over to GEB Grid.

4.6 Sewage sludge or other sludge from

effluent treatment. Yes

Sewage shall be disposed in soak

pit/ septic tank.

4.7 Construction or demolition wastes YES

Solid waste generated from

construction activity shall be

utilized as filling and levelling of

low lying area within the proposed

facility. No demolition work is

needed.

4.8 Redundant machinery or equipment. No No such waste will be generated.

4.9 Contaminated soils or other

materials. No No such waste will be generated.

4.10 Agricultural waste. No No such waste will be generated.

4.11 Other solid wastes. No No extra waste will be generated

from the project.

5 Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr):

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

5.1 Emissions from combustion of fossil

fuels from stationary or mobile

sources Yes

Through DG sets which operate

temporarily during power failure

/emergency.

5.2 Emissions from production

processes. Yes

Compliance with the emission

standards: Guidelines of CPCB-Flue

gas emission standards.

Refer Annexure II Project basis para

1.7 & ANNEXURE –V & EMP

Vide ANNEXURE - VI

5.3 Emissions from materials handling

including storage or transport. Yes

Adequate measures will be taken to

control emissions from the storage

of input hazardous waste. Please

refer EMP Vide ANNEXURE - VI

5.4 Emissions from construction

activities including plant and

equipment YES

Adequate measures will be taken to

control emissions from the proposed

project. Please refer EMP Vide

ANNEXURE - VI

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste.

YES Please refer EMP Vide

ANNEXURE - VI

5.6 Emissions from incineration of

waste. Yes

Compliance with the emission

standards: Guidelines of CPCB-Flue

gas emission standards.

Refer Annexure II Project basis para

1.7 & ANNEXURE –V & EMP

Vide ANNEXURE - VI

5.7 Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No No burning activities will be carried

out in the proposed unit.

5.8 Emission from any other sources. No No other emission from any other

sources.

6 Generation of Noise & Vibration and Emissions of Light & Heat:

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

6.1 From operation of equipment e.g.

engines, Ventilation plant, crushers. YES

Appropriate measure will be taken

to abate Noise pollution at source.

The noise levels will be well within

the prescribe units. Please refer

EMP Vide ANNEXURE - VI

6.2 From industrial or similar processes. No

No significant noise, vibration or

emission of light and heat from the

unit. The noise levels will be well

within the prescribe units.

6.3 From construction or demolition. No

No significant noise, vibration or

emission of light and heat from the

unit. The noise levels will be well

within the prescribe units.

6.4 From blasting or piling. No No such activities are involved.

6.5 From construction or operational

traffic. No

No significant noise, vibration or

emission of light and heat from the

unit. The noise levels will be well

within the prescribe units.

6.6 From lighting or cooling systems. No

No significant noise, vibration or

emission of light and heat from the

unit. The noise levels will be well

within the prescribe units.

6.7 From any other sources. No No emissions from any other

sources.

7 Risks of contamination of land or water from releases of pollutants into the

ground or into sewers, surface waters, groundwater, coastal waters or the sea:

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

7.1 From handling, storage, use or

spillage of hazardous materials. No

Proper storage facilities for the

handling of chemicals and waste

will be provided in the unit.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No

Treated effluent confirming the

CETP inlet norm shall be disposed

in CETP of BEAIL/ETL.

7.3 By deposition of pollutants emitted to

air into the land or into water No

All the air emissions will be well

within the prescribed limits.

7.4 From any other sources. No No other sources will be there.

7.5 Is there a risk of long term build up

of pollutants in the environment from

these sources? No

There will not be any long term

build up of pollutants in the

environment from these sources.

8 Risk of accidents during construction or operation of the Project, which could

affect human health or the environment.

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

8.1 From explosions, spillages, fires etc.

from storage, handling, use or

production of hazardous substances.

Yes

Moderate risk is envisioned. Risk

minimisation through minimum

storage of of waste.

8.2 From any other causes. Yes. Moderate risk is envisioned by hot

equipment/exposure to power.

8.3

Could the project be affected by

natural disasters causing

environmental damage (e.g. floods,

earthquakes, landslides, cloudburst

etc)?

No. Earthquake proof structures will be

made.

9

Factors which should be considered (such as consequential development) which

could lead to environmental effects or the potential for cumulative impacts with

other existing or planned activities in the locality.

Sr.

No.

Information / Checklist

conformation.

Yes /

No.

Details thereof (with approximate

quantities / rates, wherever

possible) with source of

information data.

9.1

Lead to development of supporting

localities, ancillary development or

development stimulated by the

project which could have impact on

the environment e.g.:

• Supporting infrastructure (roads,

power supply, waste or waste water

treatment, etc.)

• housing development

• extractive industries

• supply industries

• other

No

The GIDC notified area is already

well developed and proposed

activity will not have significant

impact on the locality

9.2 Lead to after – use of the site, which

could have an impact on the

environment.

No There will not be any significant

impact on the environment.

9.3 Set a precedent for later

developments. YES

“ THIS PROJECT WILL SET

AN EXAPLE OF

HAZARDOUS WASTE

TREATMENT USING MOST

ENVIROMENTAL

FRIENDLY TECHNOLOGY

AND IT WILL CHART A

WAY FOR ALL FUTURE

PROJECTS PLANNED FOR

THE TREATMENT OF

HAZARDOUS WASTE”

9.4 Have cumulative effects due to

proximity to other existing or

planned projects with similar effects. Yes

THIS PROJECT WILL

SIGNIFICANTLY REDUCE

HAZARDOUS WASTE

STORAGE AT ANY POINT

OF TIME FACILITATING

DISPOSAL OF HAZARDOUS

WASTE & REDUCE

ACCUMULATION OF

HAZARDOUS WASTE IN

ANKLESHWAR AREA.

(III) ENVIRONMENTAL SENSITIVITY.

Sr.

No. Area.

Name /

Identity

Aerial distance (within 15 km.)

Proposed project location boundary.

1

Areas protected under international

conventions, national or local

legislation for their ecological,

landscape, cultural or other related

value.

No.

Not Applicable

2

Areas which are important or

sensitive for ecological reasons -

Wetlands, watercourses or other

water bodies, coastal zone,

biospheres, mountains, forests.

No.

Not Applicable

3

Areas used by protected, important

or sensitive species of flora or fauna

for breeding, nesting, foraging,

resting, over wintering, migration.

No.

Not Applicable

4 Inland, coastal, marine or

underground waters.

5 State, National boundaries. No. Not Applicable

6

Routes or facilities used by the

public for access to recreation or

other tourist, pilgrim areas.

No.

Not Applicable

7 Defense installations. No. Not Applicable

8 Densely populated or built – up area.

Anklesh

war &

Bharuch

city

Approximate distance – 9 kms &

14 kms respectively.

9

Areas occupied by sensitive man-

made land uses (hospitals, schools,

places of worship, community

facilities)

No.

Not Applicable

10

Areas containing important, high

quality or scare resources (ground

water, surface resources, forestry,

agriculture, fisheries, tourism,

minerals)

No.

Not Applicable

11

Areas already subjected to pollution

or environmental damage. (those

where existing legal environmental

standards are exceeded)

Anklesh

war.

The proposed project is located

within the GIDC estate,

Ankleshwar, which has been

declared as critical problem area by

CPCB

12

Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence, landslides,

erosion, flooding or extreme or

adverse climatic conditions)

No. Not Applicable

ANNEXURE-I

PLANT LAYOUT

ANNEXURE-II

WASTE TREATMENT & RESOURCE

RECOVERY PROCESS

(Using PEAT Proprietary PTDR Technology)

1. Project Basis

2. Project Description

3. Process Flow Diagram

4. Material Balance

1. Project Basis

1.1 Waste Disposal Capacity: 45 Tons/Day

1.1.1 PTDR-1000 Plant:

Capacity 30 Tons/Day

Avg Feed Calorific Value of Waste: 4000 kcal/kg

Feed Rate of Waste: 1.5 Tons/hr

(Single Stream, at avg

CV of Waste)

Thermal Capacity: 6.0 Million

kcal/hr

Operating Hours: 7200 hrs/year

1.1.2 Multi Effect Evaporation Plant:

Capacity 15 Tons/Day

Avg Feed Calorific Value of Waste: < 500 kcal/kg

Waste Criteria: Non volatile, Toxic

compound, high TDS,

requires thermal

treatment for disposal.

Target Waste reduction: 75-80%

Residual Mass Treatment: to PTDR-1000 plant

for thermal

destruction

Operating Hours: 7200 hrs/year

1.2 Operation Range

Both plant will be designed to operate between 60% and 100% capacity with

respect to thermal capacity of the feed.

1.3 Waste Characteristics

Table 1.1: Waste Characteristics

Type of Waste Type 1

Packed

Waste(drums)

Type 2

Loose Solid

Waste

Type 3

Liquid Waste

High CV

Type 4

Liquid

Waste Low

CV

Type 5

Slurry and

Sludge

Waste

Distribution,

TPD

6 18 3 15 3

Mode of

Treatment Direct to

PTDR-1000

Direct to

PTDR-1000

Direct to

PTDR-1000

Volume

reduction in

MEE and

residues to

PTDR-1000

Direct to

PTDR-1000

Avg Calorific

Value

(Kcal/kg)

3094 3756 6670 <500 5566

Free Moisture

Content wt% 15 14 3 80 5

Inorganic

Content wt% 12 5 2 5 1

Halogens

Average in % 2

(F+Br+I < 1%)

2

(F+Br+I <

1%)

2

(F+Br+I <

1%)

2

(F+Br+I <

1%)

2

(F+Br+I <

1%)

Sulfur

Average in % 2 2 2 2 2

Consistence Powder, Solid,

Semi-solid,

Liquid

Solid

Powdery

Liquid with

impurities

Liquid with

impurities Viscous

Particle Size

Max size in

mm

500 500 <3 mm < 3 mm < 3 mm

Strips

Max size in

mm

<1000 <1000 - - -

Heavy Metals < 1%

Ultimate Analysis Considered for the process design of PTDR-1000 is tabulated as under

in table 1.2.

Combined

Waste

Packed

Solid

Waste

(Drums)

Loose

solid

Waste

(Bags)

Liquid

waste high

CV

Liquid

Waste

Low

CV

Slurry and

Sludge

Type 1 Type 2 Type 3

Type

4 Type 5

% DISTRIBUTION 100.00 20 55 10 5.00 10

QUANTITY Kg/hr 1500 300 825 150 75.00 150

COMPOSITION % by wt

CARBON C 47.50 42 47 66 7 63

HYDROGEN H 3.05 2 3 6 0 4

OXYGEN O 23.25 24 26 18 3 22

NITROGEN N 1.00 1 1 1 1 1

CHLORIDE Cl 2.00 2 2 2 2 2

SULFUR S 2.00 2 2 2 2 2

MOISTURE H20 15.50 15 14 3 80 5

INORGANIC/INERT 5.70 12 5 2 5 1

TOTAL 100.00 100.00 100.00 100.00 100.00 100.00

GCV KCAL/KG 3932.54 3094.00 3756.45 6670.05 481.38 5566.15

NCV KCAL/KG 3842.64 3007.00 3675.25 6652.65 17.38 5537.15

Table 1.2: Ultimate Analysis of Waste

Notes:

For design of PTDR-1000 design small fraction of Type 4 waste is considered to

directly inject into plasma furnace for accounting some waste categories which can

not be concentrated if those waste consists of volatile solvents and are not fit for

taking into Multi Effect Evaporator plant.

Maximum Limit of Hg+Cd+Th will be < 0.3 ppm by weight in combined waste.

Maximum Drum Size: Drum size of 500 mm diameter and 500 mm height can be

accepted in Plasma Reactor if drum is fed in horizontal position. Client to make sure

that when drum is kept in horizontal position waste does not spill out. Feeding of steel

drum will result in more energy consumption for melting of drum metal. If drum of

HDPE material is used it will save the energy cost to client and also reduce damage of

refractory lining.

1.4 Waste Heat Boiler

Steam Pressure: 40 kg/cm2 g

Steam Temperature: 400 deg C

Steam Flow Rate: 6.5 Tons/hr with Boiler Feed

Water at 100 deg C

1.5 Power Plant

Turbine: Condensing Type

Turbine Rating: 1.3 MW

Steam Rating: 5.2 Kg/Kwh

1.6 Utilities

1.6.1 GIDC water will be available as process water for use in plant. Specification of

GIDC water shall be as under.

pH: 6.5 to 7.5

Total Dissolved Salts: < 300 mg/lit

Total Hardness: < 120 mg/lit

Suspended Particles: < 25 mg/lit

1.6.2 Grid Electric Power from GEB will be available with following rating

Voltage: 11/ 22 / 33 KVA (Subject to confirmation from local GEB

authority), 3 Phase

Frequency: 50 Hz

1.7 Emission Standards

While operating at 100 % rated capacity, emission limit from the discharge of

stack shall be as under:

Parameter Emission Limit (mg/Nm3)

Particulates 50

HCl 50

SO2 200

CO 100

TOC 20

HF 4

NOX (NO and NO2 expressed 400

expressed as NO2)

Note: All values above shall be corrected to 10% oxygen on dry volume basis.

Hydrocarbon: 10 ppm, over an hourly rolling average on dry basis, measured as

propane.

Opacity: While operating properly at 100% rated capacity, the system shall have

visible emission rate of less than on equal to 10%, except for condensed water

vapour, from the discharge of stack (one hour rolling average ).

Dioxin / Furans: While operating at 100% rated capacity, the system shall have an

emission of dioxin and furans less than or equal to 0.1 ng TEQ / Nm3 corrected to

10% Oxygen. Sampling period shall be minimum 6 hours and maximum 8 hours.

Metals: While operating properly at rated capacity, the system shall have an

emission rate from the discharge of stack to atmosphere less than or equal to

Metals: Emission Limit (mg/NM3)

Cd+Th (& it’s compounds) 0.05

Hg (& it’s compounds) 0.05

Sb+As+Pb+Cr+Cu+Mn+Ni+V (& it’s compounds) 0.5

Note: All values above shall be corrected to 10% oxygen on dry volume basis.

1.8 Design Standard

ENPRO will follow good engineering practice for gas and liquids which either operates

at ambient conditions or near to ambient conditions and at less than 3.5 kg/cm2 g

operating pressure.

For design of pressure parts and vessels (especially boiler system) ENPRO will follow

ASME standards for design.

2. Project Basis

2.1 Project Objectives

The proposed project will be carried out under a project-specific Joint Venture that would

be established by a team led by PEAT International for the deployment of a proprietary

Plasma Thermal Destruction and Recovery (PTDR) system with a process capacity of 30

metric tons per day of industrial/hazardous solid, semi-solid and organic liquid (non-

aqueous) wastes. The system shall be designed to use the energy-rich syngas generated by

the PTDR system to generate electricity and dewater an expected total of 15,000 litres of

aqueous organic liquid wastes per day. The resulting solids generated by the dewatering

operations (approximately 20% moisture content) would then be processed in the PTDR

along with the other industrial/hazardous wastes.

The PTDR facility would be installed at a site within the Ankleshwar Industrial Estate in

Gujarat, India. The facility will have following objectives

To collect & receive the industrial hazardous wastes required to de destruct

through thermal treatment generated from the various industries situated in and

around Bharuch District.

To ensure safe and proper storage of the wastes receipt at site with respect to their

classification, characterization and compatibility. To ensure minimum storage

inventory at site limited to 30 days storage maximum.

To provide hazardous waste treatment using Plasma Thermal Destruction and

Recovery System (PTDR).

To educate and make the individual industry aware of storing the hazardous waste

in scientific manner and comply with the regulations.

To educate the industry to minimize the generation of hazardous waste at source

and manage the industrial growth in sustainable manner.

The project will provide the following benefits to the Ankleshwar Industries Association

(AIA) and vicinity:

Provide the ability to significantly expand the current treatment capacity for

industrial/hazardous wastes for AIA and other industrial facilities in the vicinity

Present an innovative and cost-effective use of the valuable alternative energy

produced by the syngas generated by the PTDR system that will allow for a

significant increase in the capacity of the plant to process aqueous organic wastes

(currently these wastes are typically incinerated, but due to their high water content

– approximately 92% - their calorific value is very low and thus require very high

consumption of fossil fuels during the incineration process).

In addition to the energy used in the processing of aqueous organic wastes, the

energy-rich syngas would be used in an onsite energy recovery system to produce

electric power that will supply the needs of the PTDR system with excess electric

power available to be supplied to the grid.

The Project is projected to result in a net reduction of CO2 emissions and should

therefore qualify for Clean Development Mechanism benefits.

Offer the above benefits while exhibiting the highest levels of safety and

environmental compliance. PTDR systems produce virtually no secondary wastes;

while generating valuable end-products with commercial value. Emissions from the

PTDR shall be far below regulatory limits (and significantly lower than current

regulatory standards). PTDR systems do not produce any harmful pollutants such

as dioxins and furans.

This project will utilize the proprietary and patented PTDR technology, PEAT's

environmentally benign process converts waste streams into three end-products:

a clean synthesis gas (“syngas”)

an inert glass silicate

a Na2S solution from scrubber as by product and

recovered metal alloys

Simply put, organic constituents of the feedstock is shifted into syngas to generate valuable

alternative energy (such as electric power, thermal energy or it can be used to create liquid

fuels such as ethanol) and inorganic constituents of the feedstock melt and are converted

into a hard, non-leachable glass product that can be used for a variety of commercial

purposes; sulfur content of feed stock is converted into Sodium Sulfide Solution which is

commercially saleble product; metal constituents in the feedstock are also recovered as a

pure metal or metal alloy. Essentially, all of the waste feedstock is converted into usable

end-products thus there is a 100% utilization of the waste, which totally eliminates the need

for a landfill.

The technology uses the ultra-high thermal energy from a plasma generation system (e.g.

torches) in an oxygen starved environment to first, pull apart the molecules that make-up

organic constituents of the waste, then, through the addition of controlled amounts of pure

oxygen and steam the dissociated molecules reform the base elements into the syngas,

consisting mainly of Carbon Monoxide (CO) and Hydrogen (H2) to be used as a fuel.

Inorganic waste, (e.g. batteries, printed circuit boards) is vitrified into an environmentally

safe glass silicate and recovered metal alloys.

The PTDR process provides a unique, cost-effective and virtually emissions-free

technology that is superior to other mainstream methods of waste treatment:

The PTDR process can utilize virtually any type of feedstock containing

combinations of organic, inorganic and heavy-metal constituents.

The PTDR process brings inherent synergies whereby the treatment of inorganic and

organic feedstock streams can be processed together, thus the pre-processing, staging

and management costs are minimized thereby reducing processing costs and

enhancing revenue streams.

Unlike incineration or metal-bearing waste stabilization, the PTDR process does not

create any secondary wastes that will require further treatment or landfilling. For

example, in addition to the excessive air pollution generated by the combusted flue

gases, incinerators produce large quantities of bottom and fly ash which are toxic in

nature, require further treatment (with stabilization agents) and the resulting post-

treated materials (whose disposal volume has been doubled by the addition of

stabilizing agents) will require final disposal, usually in specially designed hazardous

waste landfills.

The syngas end-product generated from processing the organic portions of the

feedstock is a valuable source of Alternative Energy (Approximate heat value: 9 to 11

MJ/Nm3, ~2,150 Kcal/Nm3 to 2,625 Kcal/Nm3). The synthesis gas end-product can

be used to generate thermal energy (that can offset the purchase of fossil fuels or

produce process steam), electricity and/or as a feedstock for the production of liquid

fuels such as ethanol. In addition, the hydrogen-rich composition of the syngas can

provide a valuable and in-expensive source of hydrogen for industrial, energy (e.g.

fuel cells), or transportation uses.

In February, 2008, PEAT successfully commissioned a demonstration PTDR-100

system at the Ankleshwar GIDC, adjacent to the Jayaben Modi Hospital. The

PTDR-100 is a fully self-contained waste processing platform with a design-basis

capacity of 60 kg/hr. During the demonstration phase, the PTDR-100 successfully

processed a wide range of waste streams generated by local Industries within the

Ankleshwar GIDC. The PTDR-100 system was designed and manufactured solely with

indigenous resources within India. PEAT therefore has the distinction of being the first

technology provider in India that can deploy a waste management solution that supports

the goals of sustainable development. The PTDR technology is NOT incineration and,

indeed, is far superior to incineration.

PTDR Incineration

• Mass-less heat created from

plasma torch at very high

temperatures– heat value of waste

is irrelevant to the process

• Molecular Dissociation of organic

wastes in an oxygen-starved

environment and vitrification of

inorganic constituents

• Uniform, reactor temperatures

above 1,500°C (plasma “plume”

temperature > 6,000 deg. C);

Controlled processing atmosphere

• Volume of gases generated by the

process are low, thus reducing the

complexity and size of the system

components

• Depending on waste composition

treated, PTDR generates 2 to 4

times the thermal energy that it

consumes

• No bottom or fly ashes generated

• Production of dioxins or furans is

impossible (due to factors such as,

high temperatures, oxygen starved

environment)

• No bottom or fly ashes generated;

no solid wastes requiring landfill

disposal

• Generates valuable end-products

• Combustion –excess air required

• Heat value of waste required to

maintain combustion reaction or

supplementary fossil fuels

required

• Operating temperatures around

1,000 °C (potential for “cold”

spots in the furnace

• Large volumes of off-gas

generated

• “Cold” spots, excess oxygen in

the furnace, unreacted carbon

due to incomplete combustion

can result in the formation of

unwanted pollutants, including

Dioxins and Furans

• Fly and bottom ash treatment

and landfill disposal needed

2.2 Site

PTDR project is proposed at Plot No 9602 in GIDC estate of Ankleshwar. The plot has

been allotted by GIDC. Plot size is 10000 M2. Key plan and Plot Plan of proposed site is

enclosed.

2.3 Project Component

Proposed PTDR project will have following major activities:

Collection and Transportation of Hazardous Waste to proposed facility

Storage of Hazardous Waste to Max 30 days of plant operation capacity.

Treatment of Hazardous Waste using PTDR System and conversion of waste into

resources.

The entire facility will be divided into the following components

1. Dedicated collection and transportation Vehicle for waste.

2. Weighing of incoming waste to site.

3. Laboratory for testing of incoming waste and for monitoring of plant

performance.

4. PTDR (Plasma Thermal Destruction and Recovery) System with Power Plant

using syn gas generated from the facility.

5. Multi Effect Evaporation (MEE) system for concentration of Aqueous waste.

6. Bleed Recycle Plant

7. Utilities: Cooling Tower, Water Treatment Plant, O2 & N2 Plant, Compresed Air

System, Power Distribution System

8. Administration Office

9. Maintenance Room

10. Emergency Exit Gate

11. Approach Roads

12. Wheel Washing Stations

13. Green Belt

2.3 Process Description

2.3.1 Pre Shipment Waste Analysis

Before a facility receives waste, waste profiling including a detailed chemical & physical

analysis of a representative sample of waste will be carried out. The purpose of the full

characterization before shipment is to satisfy the following requirements.

Determine if the waste is acceptable for receipt at the facility in terms of (a) the

facility’s permit and (b) the capability of the facility to treat or dispose of the waste.

Identify the inherent hazards of the waste so that appropriate precautions can be taken

during its handling and storage at the facility to prevent incidents.

Determine the physical characteristics and chemical constituents of the waste to allow

selection of effective waste processing and disposal methods.

Select the verification parameters to be tested upon arrival at the facility. These

parameters would ensure that each shipment of waste is the same type as the fully

characterized waste.

Select any treatability parameters to be tested that could vary so as to influence how

waste processing would be programmed.

Develop an estimate of the cost of treatment or disposal.

Finger print and bar code will be developed for each type of waste. Waste profile will be

recorded and documented.

2.3.2 Transportation of Hazardous Waste

Transportation is one of the most important areas of concern associated with handling

HW because the packaging and method of transporting HW will determine the

likelihood that an accident or spill with occur. Proper and rapid identification of a

spilled substance will determine how effectively and safely the situation can be

controlled.

Off-side transportation requirements involve proper:

Container: appropriate material, leak proof, mechanical stability...

Labeling of container: Identification, description…

Vehicles: equipment, labeling...

Collector/transporter: technical competence and relevant skills and other

requirements.

License/Manifest : application and documents,

Emergency procedures: spills, accidents...

Fees and fines : license, break of regulation

On site transportation typically involves smaller amounts of materials over shorter

distances. On-site transport does, however, pose significant risks from the frequency

of the activity and the lack of proper regulation. It is ensured that hazardous wastes

are packaged, based on the composition in a manner suitable of handling, storage and

transport. The labeling and packaging is required to be easily visible and be able to

withstand physical conditions and climatic factors.

The facility will meet following transportation requirement for hazardous waste:

Regulatory requirements of packaging, labeling and transportation of hazardous

wastes are given under Rule 7 of Hazardous Wastes (management & Handling )

Rules, 1989, as amended, notified under the Environment (Protection) Act, 1986

Shall possess requisite copies of the certificate (valid authorization obtained from the

concerned SPCB/PCC for transportation of wastes by the waste generator and

operator of a facility) for transportation of hazardous waste.

Shall have valid “Pollution Under Control Certificate” (PUCC) during the

transportation of HW and shall be properly displayed.

Vehicles shall be painted preferably in blue colour with white strip of 15 to 30 cm

width running centrally all over the body. This is to facilitate easy identification.

Vehicle shall be fitted with mechanical handling equipment as may be required for

safe handling and transportation of the wastes.

The words "HAZARDOUS WASTE" shall be displayed on all sides of the vehicle in

Vernacular Language, Hindi, English.

Hazardous waste shall be packaged in a manner suitable for safe handling, storage

and transportation. Labeling on packaging shall be readily visible & material used for

packaging shall withstand physical and climatic conditions

Information regarding characteristics of wastes particularly in terms of being

Corrosive, Reactive, Ignitable or Toxic will be is provided on the label.

All hazardous waste containers shall be provided with a general label as given in

Form 12 in Hazardous Waste (Management & Handling) Rules, 1989, as amended

Transporter shall not accept hazardous wastes from an occupier (generator) unless

six-copy (with colour codes) of the MANIFEST (Form 13) is provided by the

generator. The transporter shall give a copy of the manifest signed and dated to the

generator and retain the remaining four copies to be used for further necessary action

prescribed in the Hazardous Wastes (Management & Handling) Rules, 1989, as

under:

Copy 1 (White) Forwarded to the Pollution Control Board by the

occupier

Copy 2 (Light

Yellow)

Signed by the transporter and retained by the

occupier

Copy 3 (Pink) Retained by the operator of a facility

Copy 4 (Orange) Returned to the transporter by the operator of

facility after accepting waste

Copy 5 (Green) Forward to Pollution Control Board by the operator

of facility after disposal.

Copy 6 (Blue) Returned to the occupier by the operator of the

facility after disposal.

Generator shall provide the transporter with relevant information in Form 11 i.e.

Transport Emergency (TREM) Card regarding the hazardous nature of the waste and

measures to be taken in case of an emergency.

Name of the facility operator or the transporter, as the case may be, shall be

displayed.

Vehicle shall be fitted with roll-on / roll-off covers if the individual containers do not

possess the same.

Carrying of passengers is strictly prohibited and those associated with the waste

haulers shall be permitted only in the cabin.

Transporter shall carry documents of manifest for the wastes during transportation as

required under Rule 7 of the Hazardous Waste (M & H) Rules, 1989, as amended.

The trucks shall be dedicated for transportation of hazardous wastes and they shall

not be used for any other purpose.

Each vehicle shall carry first-aid kit, spill control equipment and fire extinguisher.

HW transport vehicle shall run only at a speed specified under Motor Vehicles Act in

order to avoid any eventuality during the transportation of HW.

Educational qualification for the driver shall be a minimum of 10thpass (SSC). The

driver of the transport vehicle shall have valid driving license for heavy vehicles from

the State Road Transport Authority and shall have experience in transporting the

chemicals. Driver(s) shall be properly trained for handling the emergency situations

and safety aspects involved in the transportation of hazardous wastes.

The design of the trucks shall be such that there is no spillage during transportation.

Packaging of Containers

The packing containers shall be able to withstand normal handling and retain integrity

for a minimum of six months. In general, packaging for hazardous substances shall

meet the following requirements:

Items shall be of such a strength; construction and type as not break open or become

defective during transportation.

Items shall be constructed and closed in a manner to prevent spillage of hazardous

substances.

Re-packaging materials including fastening shall not be affected by the contents or

form a dangerous combination with them.

Labelling

There are two types of labelling requirements:

Labelling of individual transport containers

Labelling of transport vehicles.

All hazardous wastes containers shall be clearly marked with current contents. The

marking shall be water proof and firmly attached so that they cannot be removed.

Previous content labels, when different, shall be obliterated. Proper marking of

containers is essential.

Containers that contain HW shall include the words "HAZARDOUS WASTE". The

information on the label shall include the code number of the waste, the waste type,

the origin (name, address, telephone number of the generator), hazardous property

(e.g. flammable) and the symbol for the hazardous property (e.g. the red square with

flame symbol).

The label shall withstand the effects of rain and sun. Labelling of containers is

important for tracking the wastes from the point of generation up to the final disposal.

The label shall contain the name and address of the waste management facility where

it is being sent for treatment and final disposal.

Emergency contact phone number shall be prominently displayed. For example

respective Regional Officer of the Station Pollution Control Board, Fire Station,

Police Station.

2.3.3 Waste Receipt at site

After arriving of the shipment at the gate following steps would be followed.

Check the pre shipment analysis has already completed and the shipment scheduled.

Weighing of truck.

Representative sample is collected for testing & verification of parameters.

Laboratory analysis for verification.

Truck is directed to designated storage space for the incoming waste.

After unloading truck is directed to wheel wash area.

The truck is then reweighed before it leaves the facility.

An Analysis Laboratory will have following min facility:

COD, BOD & TOC Apparatus

Spectrophotometer

Muffle Furnace & Laboratory oven

Atomic Absoprtion Spectorphotometer

Stirrer Magnetic & Electric

Water Bath & Hot Plate

pH Meter

Hardness, TDS Meter

2.3.4 Hazardous Waste Storage

For hazardous waste storage following will be implemented:

Storage Area (Storage Shed)

Flammable, ignitable, reactive and non-compatible wastes shall be stored separately

and never shall be stored in the same storage shed. There will be separate and

designated storage area for such waste.

In order to minimize risk of storage of hazardous waste the facility will not stored for

more than 30 days waste at site. In normal operating condition waste storage will be

limited to max 10 days only.

Storage area shall be designed to withstand the load of material stocked and any

damage from the material spillage.

Storage area shall be provided with the flameproof electrical fittings and it shall be

strictly adhered to.

Automatic smoke, heat / temp detection system and auto water sprinkler with alarm

shall be provided in the sheds.

Adequate fire fighting systems shall be provided for the storage area, along with the

areas in the facility.

Loading and unloading of wastes in storage sheds shall only be done under the

supervision of the well trained and experienced staff.

Fire break of at least 04 meter between two blocks of stacked drums shall be provided

in the storage shed. One block of drum shall not exceed 300 MT of waste.

Minimum of 1 meter clear space shall be left between two adjacent rows of drums in

pair for inspection.

The storage and handling shall have at least two routes to escape in the event of any

fire in the area.

Doors and approaches of the storage area shall be of suitable sizes for entry of fork

lift and fire fighting equipment;

The exhaust of the vehicles used for the purpose of handling, lifting and

Transportation within the facility such as forklifts or trucks shall be fitted with the

approved type of spark arrester.

In order to have appropriate measures to prevent percolation of spills, leaks etc. to the

soil and ground water, the storage area shall be provided with concrete floor

depending on the characteristics of waste handled and the floor must be structurally

sound and chemically compatible with wastes.

Measures shall be taken to prevent entry of runoff into the storage area.

The Storage area shall be designed in such a way that the floor level is at least 150

mm above the maximum flood level.

The storage area floor shall be provided with secondary containment such as proper

slopes as well as collection pit so as to collect wash water and the leakages/spills etc.

All the storage yards shall be provided with proper peripheral drainage system

connected with the sump so as to collect any accidental spills in roads or within the

storage yards as well as accidental flow due to fire fighting.

Storage Drums/Containers

The container shall be made or lined with the suitable material, which will not react

with, or in other words compatible with the hazardous wastes proposed to be stored.

The stacking of drums in the storage area shall be restricted to three high on pallets

(wooden frames). Necessary precautionary measures shall be taken so as to avoid

stack collapse. However, for waste having flash pointless than 65.5 O C, the drums

shall not be stacked more than one height

No drums shall be opened in the storage sheds for sampling etc. and such activity

shall be done in designated places out side the storage areas;

Drums containing wastes stored in the storage area shall be labelled properly

indicating mainly type, quantity, characteristics, source and date of storing etc.

Container shall be of mild steel with suitable corrosion and roll-on roll-off cover

which may either be handled by articulated crane or by a hook lift system works

comfortably for a large variety of wastes.

Other modes of packaging like collection in 200-L MS and plastic drums, card board

cartons, PP and HDPE/LDP containers also works for variety of waters. However, all

such containers shall be amenable to mechanical handling. It shall be leak proof.

In general, containers for liquid HW shall be completely closed (in fact: sealed).

There shall be no gas generation due to chemical reaction and therefore, no need for

air vents; expansion due to temperature increase/decrease normally does not need air

vents.

Container shall be covered with a solid lid or a canvas to avoid emissions, spillage,

and dust and to minimize odour generation both at the point of loading as well as

during transportation.

Container shall be easy to handle during transportation and emptying. As far as

possible manual handling of containers shall be minimized. Appropriate material

handling equipment is to be used to lad, transport and unload containers. This

equipment includes drum, dollies, forklifts, drum handling equipment, lift gates and

pallets. Drums shall not be rolled on or off vehicles.

Where 2-tier or 3-tier storage is envisaged the frames will have adequate strength to

hold the container.

The multi-use containers shall be re-usable. One-way containers (especially 160 I -

drums) are also allowed.

Loads are to be properly placed on vehicles. HW containers are not to overhang,

perch, lean or be placed in other unstable positions. Load shall be secured with straps,

clamps, braces or other measures to prevent movement and loss. Design of the

container shall be such that it can be safely accommodated on the transport vehicle.

Dissimilar wastes shall not be collected in the same container. Wastes shall be

segregated and packed separately. This is necessary to ensure that each waste finds its

way to the right disposal pathway.

Occupier/hazardous waste generator shall not resort to the dilution of wastes

(predominantly organic wastes).

Spillage/leakage control measures

The storage areas shall be inspected daily for detecting any signs of leaks or

deterioration if any. Leaking or deteriorated containers shall be removed and ensured

that such contents are transferred to a sound container.

Incase of spills / leaks dry adsorbents/cotton shall be used for cleaning instead of

water.

Proper slope with collection pits be provided in the storage area so as to collect the

spills/leakages.

Storage areas shall be provided with adequate number of spill kits at suitable

locations. The spill kits shall be provided with compatible sorbent material in

adequate quantity.

Record Keeping and Maintenance

Proper records with regard to the industry –wise type of waste received,

characteristics as well as the location of the wastes that have been stored in the

facility shall be maintained.

Miscellaneous

Smoking shall be prohibited in and around the storage areas.

Good house keeping shall be maintained around the storage areas

Signboards showing precautionary measures to be taken, in case of normal and

emergency situations shall be displayed at appropriate locations.

To the extent possible, manual operations with in storage area are to be avoided.

Incase of manual operation, proper precautions need to be taken, particularly during

loading / unloading of liquid hazardous waste in drums.

A system for inspection of storage area to check the conditions of the containers,

spillages, leakages etc. shall be established and proper records shall be maintained.

The wastes containing volatile solvents or other low vapor pressure chemicals shall

be adequately protected from direct exposure to sunlight and adequate ventilation

shall be provided.

Tanks for storage of liquids waste shall be properly dyked and shall be provided with

adequate transfer systems.

Storage sites shall have adequate & prompt emergency response equipment systems

for the hazardous waste stored on-site. This shall include fire fighting arrangement

based on the risk assessment, spill management, evacuation and first aid.

Immediately on receipt of the hazardous waste, it shall be analyzed and depending

upon its characteristics its storage shall be finalized.

Only persons authorized to enter and trained in hazardous waste handling procedures

shall have access to the storage site.

Mock drill for onsite emergency shall be conducted regularly and records maintained.

2.3.5 PTDR Process Description

Plasma Thermal Destruction and Recovery (PTDR) plant consists of following major

components

Waste Feed System: Solid and Liquid Waste Feed System, fork lift for drum amd

waste conveying, drum crusher, drum unloading and pumping system.

Plasma Reactor

Molten slag quenching and granulation system

Spray Dryer

Gas Conditioning and Cleaning System

Bag House

HCl Scrubbing System

Alkali Scrubbing System and Na2S recovery system

Solution preparation tanks.

ID Fan

PSA Plant for Nitrogen and Oxygen generation

Plasma Torch and Plasma Power Supply System

Syn Gas Utilization System: Syn Gas High Pressure Boiler, Auxiliary fuel supply and

burner, Condensing type Steam Turbine, Alternator and Power Panel

Exhaust Stack

PCC/MCC Panel, Substation, synchronizing panel, emergency DG Set.

Instrumentation and Control System

Raw water storage tank, elevated water storage tank, Water Treatment Plant, water

storage tank.

Cooling tower and cooling water circulation system

Air Compressor and compressed air network

Plant bleed water collection and recycling system

Fire water storage tank, fire water pumps and fire hydrant network and system. Fire

detection, alarm, auto sprinkler system, fire extinguisher.

Description of major sub system of PTDR plant and process is

described as under

2.3.5.1: Feed system

Solid Waste Feeding System:

1. Solid and semi-solid waste will be collected and received in various containers.

The maximum size of any waste material which can not be twisted / bent will not

be more than 400 mm. It means that any part will not have length more than 400

mm. The feed door to the system will have clear opening of 600 mm on both

sides:

2. Member Industries will be guided for packing of waste in drums and bags and

will be provided required dimensions of packing material so that waste which is

received at site will not be required to rehandle and repacked. However, till

member industries are not completely trained and till there is resistance in

adapting the packing material dimensions PEAT will follow following

methodology for handling of waste

3. Waste which is received in drums of 200 litres and if drum consists of material

which can be removed and repacked safely the contents repacked in smaller sized

containers and/or HDPE bags of acceptable size for charging into the reactor.

4. Drums whose contents cannot be removed for repacking would require pre-

treatment. While it is possible to charge the reactor with entire drums, the

contents of the drums must be such that the total quantity of organic material

contained in the drum is deemed to be within the ability of the reactor system to

accept the material without causing an overpressure condition in the furnace once

the material in the drum is exposed to the high temperature, reducing environment

of the plasma reactor. Given that the nature of wastes generated in the

Ankleshwar region is such that in all likelihood drummed wastes will have a high

calorific value, thus charging entire drums into the reactor would likely cause an

overpressure condition and the resulting “spike” in gas generation would

overwhelm the capacity of the Gas Conditioning and cleaning system.. Therefore,

for such types of wastes, the drums would be collected, sampled/evaluated and

prior to charging into the reactor, they would be processed in an on-site drum

crushing/shredding system. The drum crusher/shredding system would be

operated in an inert Nitrogen environment (Nitrogen to be supplied by an on-site

PSA system). The crushed/shredded contents would then be repacked into smaller

sized containers for charging into the plasma reactor.

5. Solid, Semi-solid/tarry wastes which are collected in HDPE bags or

drums/containers of acceptable size would be charged directly into the reactor at

the appropriate feeding interval, consistent with the design basis capacity of the

PTDR system, 1,500 kg/hr (25 kg/minute).

6. The solid Waste feed system will consist of two components: a solid waste feeder

outfitted with a hydraulically operated ram and gravity feed system, capable of

charging appropriately sized or shredded solid wastes into the reactor. The ram

feeding and gravity feeding systems will have double door systems. When waste

is charged to charging hopper(s), the hopper door will be kept open with plasma

reactor door in closed condition. After charging cycle is over hopper door will be

closed and plasma reactor door will be opened. For the case of the ram feeder,

after opening plasma reactor door Ram Pusher will push the waste inside the

plasma reactor at pre decided speed.

7. The hydraulic doors and ram operating mechanism sequences are interlocked

ensuring process safety and the continuity of feed. The section of the feeder

closest to the plasma reactor is refractory-lined to ensure the feeding chamber

remains within a prescribed temperature limit, also ensuring that any plastic bags

containing waste do not thermally degrade in the ram feeding chamber. A load

cell monitors the quantity of feedstock being introduced into the feeding

subsystem.

8. The total Capacity of the Solids Feeding System will be 1,500 kg/hr.

9. Liquid Waste Feeding System:

Liquid wastes are assumed to be “pumpable” and will be pumped from one or

more “Day Storage tank(s)” or directly from individual drums by an appropriately

sized pumping system, whose configuration and materials will be consistent and

compatible with the nature of the liquid wastes to be processed. The liquid wastes

will be pumped into the plasma reactor through one or more water-cooled spray

nozzles.

The capacity of the Liquids Feeding System will be in the range of 750 to

1,000 kg/hr

2.3.5.2 Plasma Reactor

The waste then enters the plasma reactor (with a design volume of approx 9.0 m3) made

of mild steel and lined with refractory and insulation, where the high temperature created

by the plasma torches will dissociate the molecules that make up the waste into their

elemental constituents. The dissociated constituents of the waste are then “re-formed”

(through the addition of stoichiometric amounts of oxidant: oxygen and/or steam) into a

synthesis gas, comprised mainly of Carbon Monoxide and Hydrogen gas. The plasma

reactor allows for a residence time of 2.0 seconds based on design basis gas flow. The

refractory and insulating materials are selected and designed to minimize heat losses,

ensure high levels of reliability in operations (including resistance to erosion and thermal

shock) and optimize the time required for pre-heating the system and natural cool down

and such that entire replacement should not be required for an average interval of two

years.

Due to nature of assumed design basis waste feedstock, it is required to inject oxidant to

meet the stoichiometric requirement of Oxygen to convert Carbon to Carbon Monoxide.

Oxygen of 90 to 93% purity shall be used as oxidant for the process. Oxygen shall be

generated from air using stand alone Pressure Swing Adsorption (PSA) plant. The use of

Oxygen instead of air will not only reduce the physical size of many system components

but also reduces the energy required to maintain Plasma Reactor Temperature up to

1200°C. In addition, and also due to the nature and variety of the potential waste streams,

it may also be necessary to inject steam or atomized water into the reactor. The steam or

water will also function as an oxidant and will provide additional temperature control as

well as reduce the amount of un-reacted carbon carried over into the syngas. The

addition of steam or water will also tend to enrich the calorific value of the syngas

through an increase in the amount of hydrogen gas produced.

Inorganic constituents in the waste will be vitrified (i.e. melted) in the plasma reactor and

then recovered, through a tapping process, as a product with valuable commercial

applications (such as a construction material). During non-tapping operations, the tapping

port is closed using tap plugs. When tapping is to be initiated, the tap plug is pulled out

of the plasma reactor allowing the molten vitrified matrix mixture to flow out of the

plasma reactor into the quench tanks. Quench tanks are continuously circulated with

water for maintaining quench water temp to less than 70 deg C. The heat of slag

solidification is removed by evaporation of water. Such water quenching will create small

granules of slag.

2.3.5.3 PSA Plant

Oxygen shall be used as oxidant for meeting the requirement of Oxygen to convert

Carbon to Carbon Monoxide. Oxygen was selected as the principal oxidant to be injected

(instead of Air) from the point of view of energy conservation, optimizing the energy

value of the synthesis gas and to minimize the plant foot print area. A PSA plant with a

nominal capacity of 250 Nm3/hr will be provided and shall consist of a screw air

compressor, molecular sieve columns, storage tanks and a local control panel.

Nitrogen will be used for a variety of purposes in the plant, including the pulsing of the

bag house filters. The nitrogen gas will be provided by an on-site PSA plant with a

nominal capacity of 150 Nm3/hr will be provided

2.3.5.3 Spray Dryer

The syngas leaving the Plasma Reactor at approximately 1,000 to 1,200°C will enter a

Spray Dryer where it will come into contact with a stream of scrubber bleed liquor which

will be an aqueous inorganic liquid waste. The waste water will cool the gas to a

temperature of approximately 220oC. Heavy solids will be collected at the bottom of the

Spray Dryer and will be taken out with double gate rotary air lock valve. Solids will be

collected in manual cart and will be fed to plasma reactor to convert it to vitrified slag.

2.3.5.4 Gas Conditioning and Cleaning System

The cooled syngas will be conveyed to the activated carbon injection and mixing system.

This system consists of storage hopper and a feeder for activated carbon. Accessories,

instrumentation, local control panel and terminal panels are provided for system

operation. A predetermined amount of material will be metered via a variable speed

screw conveyor into the ductwork before the bag-house. Activated carbon is injected into

the system to eliminate the potential for the reformation of any undesired compounds.

The cooled gas stream enters the Bag House (i.e. fabric filter) through the inlet damper

into the hopper. The syngas containing particulate and acid gas constituent’s strikes

baffle plates, which distribute the syngas uniformly through the housing and drop out

heavy particulate into the hopper. The hotter syngas flows upward into the bag module.

Particulate filtration is accomplished as the syngas flows from the outside (dirty side) of

the filter bag, across the filter bag media, to the inside (clean side) of the filter bag. The

clean gas exits the bag at the tube-sheet, flows through the clean gas plenum, and into the

outlet duct.

As the collector operates, the collected dust begins to form a dust cake, which increases

the resistance to flow (porosity of the filter). This is measured by a pressure sensor and is

defined as the system pressure drop or differential pressure. To maintain a moderate

pressure drop, the bags are cleaned using a pulsing nitrogen gas type system. The pulse

gas system delivers a momentary burst (or pulse) of high-pressure nitrogen gas down

through the inner bag surface. It expands the bag and dislodges the dust cake. The dust

cake falls directly into the hopper where it is removed by the dust conveying system.

The fabric filter cleaning is performed on-line whereby the cleaning procedure occurs on

a row-by-row basis. Therefore, only a fraction of the total filter gas is interrupted for

cleaning, allowing continuous filtration with no modules being taken off line. The

frequency and the duration of the nitrogen gas pulses and the time between pulses are

operator preset but can be adjusted.

Pulse gas for bag-house cleaning will be Nitrogen. The Nitrogen gas needed for the

operation of the following equipment will be provided by the on site nitrogen PSA plant:

The PSA plant will also provide process gas for the atomization of the liquid feed stream

at spray dryer and miscellaneous purges. The entire Gas Cleaning and Conditioning

System will be purged with nitrogen prior to start-up of the system. The bag house

“catch” will be collected at the bottom of the bag house and will be periodically recycled

back to the plasma reactor where they will be converted into vitrified slag.

The syngas, cleaned of particulate matter, is then conveyed to an HCl scrubbing system.

HCl scrubbing system is provided to cool down the gas and to capture HCl gas in

continuous circulating stream of HCl solution of 2-5% concentration. HCl scrubbing

system is provided with Acid Resistance Tile Lined low pressure drop ventury scrubber

followed by FRP (v) packed bed scrubber. Here gas is cooled down to it saturation temp

of approx 78 deg C. HCl is captured in circulating low concentration HCl stream. Due to

gas cooling and absorption of HCl gas heat will be generated. Heat generated in the

system will be removed in graphite tube heat exchanger using cooling water on other

side. Equivalent to HCl gas scrubbed a continuous bleed stream will be removed from the

system and will be collected in neutralization tank. There will be additional particulate

matter collection in the system which will be continuously removed in side stream filter

press. Filter cake generated from this filter press will be fed to plasma reactor. Cleaned

syngas from HCl scrubbing system is fed to Alkali scrubber for recovery of NA2S as by

product. HCl scrubber bleed will be neutralized with caustic solution to form NaCl

solution which will be fed to spray dryer as mentioned above.

Alkali scrubbing system will be two stages packed bed scrubber. Bottom part of scrubber

will be circulating 18-20% NA2S solution with 1-2% free caustic which will capture most

of H2S gas from the syn gas. Caustic will react with H2S gas under highly alkaline

condition to form NA2S

H2S + NaOH = NA2S + H2O

Upper part of alkali scrubber will have packed bed. Here gas is contacted with lean

solution of NA2S with more concentration of free NaOH (5-6%) to achieve almost

complete absorption of H2S here.

Depending on incoming H2S gas quantity; NA2S by product bleed stream will be

removed from the system from the bottom circulating stream of alkali scrubber. This

stream will be provided polishing filtration treatment to make it suitable for commercial

sale. Equivalent overflow will be received from the upper portion of alkali scrubber.

Make up caustic solution will be added to upper circulating stream of alkali scrubber.

Alkali scrubber is provided with Chevron type of mist eliminator at the top of scrubber to

entrap any entrained liquid droplets from the system. Heat of reaction and cooling of

gases will be removed from the system using indirect heat exchanger provided in the

scrubber liquor circulating circuit using cooling water.

Thus cleaned and conditioned syn gas from alkali scrubbing system is taken down stream

for syn gas utilization system.

2.3.5.5 ID Fan

An induced draft fan, constructed of SS304 impeller and casing in MSRL / MSFRP lined

to resist corrosion due to the presence of wet gases, is integrated within the system

downstream of the gas cleaning and conditioning system to create negative pressure

within the plasma reactor and the rest of the process train (-0.1 inches Water Column

(“W.C.”) to about -1/2 inches W.C.). The ID fan ensures a fast response by the Variable

Frequency Drive during pressure excursions that may occur in the Plasma Reactor during

operations.

2.3.5.6 Synthesis Gas Storage/Accumulation and Utilization Systems

A tank of approximate dimensions of 5.5 m3 will accumulate the syngas at a pressure of

+100 mmwcg. This system is designed to provide a uniform supply of syngas to the

syngas utilization and energy production systems. The synthesis gas will then be

conveyed to an on-site co-generation system consisting of a steam generator and a steam

turbine system that will produce approximately 1,100 KWe of electric power.

Co generation system will consists of steam boiler which will generate superheated steam

at 40 kg/cm2 G and 400 deg C. Steam boiler will consist of Syn gas combustion furnace,

syn gas burner, auxiliary fuel burner for start up and piloting, combustion air fan, steam

economizer, evaporator and super heater, steam drum, and boiler blow down system.

High pressure superheated steam is then fed to condensing type steam turbine which will

provide steam rating in the range of 5.0 to 5.2 kg/kwh. Steam turbine will drive alternator

which will generate power to the tune of 1000-1300 KWe depending on the syn gas

calorific value. Power generated from the power panel is fed to synchronizing electrical

panel which will synchronize power from o generation plant and power from grid and

will supply power to the PTDR facility.

From steam turbine extraction steam at 8 kg/cm2 g pressure will be obtained for

operation of multi effect evaporation system and to meet misc plant steam requirement.

Steam turbine is attached with steam condenser; vacuum system and condensate return

system. From condensing type turbine steam is taken to steam condenser from where

condensate obtained is recycled back to boiler feed water tank. Cooling water required

for steam condenser is obtained from cooling tower.

2.3.5.7 Multieffect Evaporation System for Aqueous Organic Liquid Waste

Dewatering System

The facility has proposed to install multi effect evaporation system for dewatering

aqueous in organic liquid waste having non volatile organic compounds. Such waste is

having water content as high as 90% and inorganic salts as high as 5 to 7% and organic

content as low as 1-2%. Still this type of waste is required to provide thermal treatment

due to toxic nature of organic and due to in ability of treating this waste conventionally.

For such specific waste facility will install multi effect evaporation system having alloy

tube (Cupro-Nickel / Zirconia) construction material. Such waste will be concentrated in

multiple effect evaporation system to achieve almost 80% volume reduction. For

concentrated mass it is proposed to use screw dryer to achieve min water content in the

bottom sludge. Evaporated and condensed water after polishing treatment (carbon

adsorption system) will be recycled back to water treatment make up water system.

Bottom sludge from the evaporation system will be repacked and fed to plasma reactor

for further treatment. Energy required evaporation will be met through extraction steam

available from the steam turbine as described above. Spent carbon from carbon polishing

treatment will be sent to plasma reactor for further destruction.

2.3.5.8 : 1,050 kWe Plasma graphite electrode Torch System with an Insulated Gate

Bipolar Transistor power supply

The plasma generation system utilized within the PTDR system is comprised of three

individual systems, each with a capacity of 350 KWe. The arc is transferred between the

bottom-mounted anodes and the vertically mounted cylindrical cathode electrodes for

each of the three torch assemblies.

The three torches, mounted at the top of the plasma reactor vessel, move up and down

within the plasma reactor. Due to this movement, the torches are housed within a sealing

and insulating assembly. This assembly insulates the torch body and ensures that its

structural elements are maintained within a prescribed temperature range. This avoids the

need for additional cooling, which would remove excess thermal energy from the torch

and thereby reduce the electrical-to-thermal efficiency. The process control system uses

an “inching” motor and guide column to position the electrodes into place.

The three bottom anodes are positioned at the bottom of the plasma reactor and are

elevated compared to the rest of the plasma reactor bottom which is lined with either 25

mm thick graphite plates (tiles) or, depending on the nature and composition of the

wastes being processed, a material with equal thermal properties that will enhance the

conduction of heat transferred from the plasma torch and prevent corrosion/erosion and

chemical attack from the inorganic constituents of the waste. These lining pates are

designed to quickly conduct the heat transferred by the arc throughout the entire plasma

reactor bottom. Plates are also provided on the sides of the plasma reactor bottom to an

elevation of approximately 250 to 300 mm above the plasma reactor bottom. These plates

also ensure the even and effective conduction of heat. The only portion of the graphite

that requires replacement are the anodes, which are cylindrical with an approximate

diameter of 225 mm and are inserted from the bottom of the reactor into an electrode

holding assembly that is elevated above the slag pool. Depending on the final

configuration chosen during the final design, the anodes will be manufactured in

replaceable sections of approximately 450 mm in length that are outfitted with threaded

connections at each end. The replacement sections are attached to each other by means

of these threaded connections. As the anodes are consumed, replacement sections of the

anode “rods” are inserted into the plasma reactor and a new replacement section is

attached to the end piece from the outside of the plasma reactor.

The configuration of the lining plates at the bottom of the plasma reactor is such that a

slope is created relative to the central portion of the plasma reactor. This slope is

designed to allow any solid residues to fall away from the centrally located plate, thus

preventing or limiting the ability of the arc to be formed.

The three cylindrical graphite electrode “cathodes” (mounted at the top of the plasma

reactor with an approximate diameter of 225 mm) are lowered to within 10 mm of the

corresponding bottom-mounted anode electrodes where the arcs are struck. Once the arc

is struck, the transferred-arc electrode assembly is raised to a height of approximately 25

mm to 75 mm above the bottom of the plasma reactor. Temperature in the plasma reactor

is measured from a minimum of two locations: one location in the upper section of the

plasma reactor; the other location measures the temperature of the lower sections of the

plasma reactor. The electrodes are operated without feeding commencing until the plasma

reactor bulk temperature reaches a minimum of 1,000°C to ensure proper

dissociation/pyrolysis/gasification of the organic constituents of the wastes. Once feeding

operations commence, the bulk temperature quickly increases to the desired operating

temperature range of 1,000 to 1,200°C (1,500oC when melting operations are conducted)

and above.

Any inorganic constituents in the waste are melted (vitrified) into an environmentally

safe, leach-resistant, vitrified matrix. The removal of the vitrified matrix presents no

hazards of any kind to personnel, requires no special tools and does not disrupt the

operating process. The vitrified matrix can be used in a variety of applications including

roadbed/fill construction, blast media and concrete aggregate. Depending on the nature of

the wastes to be processed, a continuous or intermittent tapping system would be

provided.

The replacement electrode sections for the plasma generation system can be continuously

attached to the back of the existing electrode from the outside of the reactor. There is no

need to remove system components during electrode replacement activities, thus there is

little down-time. Platforms and access ladders are provided to provide access to the top of

the plasma reactor and in between the two skids to allow for greater access to these areas,

particularly when adding electrodes.

The entire plasma generating system has an electrical-to-thermal efficiency greater than

75% and requires no pressurized external supply of carrier gas. The system supplies its

own gas flow - approximately 5 litres per minute of air per torch assembly. This small

flow of air enhances the thermal energy distribution within the reactor.

The torches are powered by an advanced Insulated Gate Bipolar Transistor (IGBT) power

supply that provides the following advantages over other plasma torch power supplies:

• Requires an input current that is approximately 30% less than silicon controlled rectifier

(SCR) systems

• Power factors around 0.97

• Low harmonic distortion (approximately 10 times less than SCR systems)

• High arc stability compared to SCR systems

• Control panel size is approximately 66% smaller than a comparable SCR system

2.3.5.9 Power Panel and Process Control System

The power/electrical panel houses the motor control center and the Process Logic

Controller (PLC) system and provides complete access to operate and monitor the

process. It is designed for continuous operation. The electrical panel houses the PLC

system which interfaces with the plant control system containing graphic interfaces (e.g.

flow diagrams and process indications of temperature, pressure, for example) of each

subsystem and major components critical for the safe operation and efficient monitoring

of the system.

Power generated in the PTDR plant at 11 KV shall be fed to a 11 KV swichgear which

feeds the in plant captive power demand. Accordingly two unit auxiliary transformers are

proposed. The various MCCs are the fed by the 415 V switchgear. The voltage levels in

the proposed plant will be 11 KV, 50 Hz generation, auxiliary utility voltage at 415 V, 50

Hz for 3 phase and 240 V for single phase and 110 V ac for control supply requirement.

There will be separate centralized MCC room from where power will be fed to all drives

of the plant. The MCC shall be fixed type cubicle, vermin proof with standard fuses,

relays and indication lamps. Weatherproof start – stop push button stations shall be

provided near each motor for local start stop control Necessary power and control cables

running from MCC to motors and back shall be provided. The cables shall confirm to

relevant Indian standards. All motors shall be of TEFC construction, and Class F

insulation. All drives above 50 HP shall be provided with VFDs as power saving option

and for better plant control.

The PTDR process is driven by proprietary, state-of-the-art instrumentation and a

computerized control system. A Supervisory Control And Data Acquisition (SCADA)

system which is a distributed measurement and control system that includes hardware and

software components is provided as the process control system providing a graphics-

based visualization of the control and monitoring system. The SCADA system

communicates with the PLC system. The control system obtains inputs from all of the

PTDR process subsystems to achieve total overall control of the system. Safety,

interlocking features and emergency shut-down aspects specific to each subsystem are

incorporated to assure safety features are not compromised.

Each subsystem has customized interface screens. The SCADA system monitors all input

and output parameters and prompts the operator to make appropriate adjustments (or

makes automatic adjustments for critical safety-related conditions) to the waste feed rate,

plasma reactor temperature, oxidant input (if required), and the gas cleaning and

conditioning system to ensure that the system operates to meet prescribed environmental

requirements. The SCADA system also records and logs all events onto a hard disk,

which can be printed for further assessment.

2.3.5.10: SAFETY MEASURES

Following overall safety measures is proposed for the facility -

Automated, PLC based control system for plant operation.

Safety interlocks for the plant normal start up and shut down (normal /

emergency) operation.

Standby emergency power supply for the system. Will include DG set as well as

battery back up for critical components such as waste feed system, emergency

venting system, nitrogen purging system.

Provision of Emergency Safety valve venting in case of power failure and

pressure built up in furnace.

Installation of smoke detectors, fire alarm, ambient/personal CO monitors fire

hydrant fighting system and fire extinguisher system.

Preparation of on- site emergency plan and risk assessment study.

Preventive maintenance.

Use of PPE’s

DO’s and DON’TS boards for workers at prominent place

Mock drills and training.

2.3.5.11 FIRE FIGHTING SYSTEM

The fire protection system shall comprise of

Hydrant system - For Haz waste storage, PTDR Plant, power plant block and

administration building area

Fixed Medium velocity water deluge spray system for cable spreader rooms.

Mobile foam system for liquid waste storage tanks

Fixed High velocity water spray system - For transformers and turbine lubrication

oil tank(s)

Wet pipe Sprinkler system for hazardous waste storage area operating based on

temperature indications and UV sensors feed back.

Fire detection and alarm system for haz waste storage area, PTDR plant, power

plant block and administration building area.

Fire Fighting system shall comprises of following major equipment and systems

Diesel driven main fire pumps for hydrant network serving of hydrants, water

spray, sprinkler and foam system.

Electric motor driven standby fire pumps for hydrant network serving hydrants

water spray, sprinkler and foam system.

Electric motor driven jockey pumps for hydrant network serving of hydrants,

water spray sprinkler and foam system.

All necessary pump controls complete with all accessories for the above-

mentioned pumps.

All buried piping and over-ground pipes, fitting ,valves, automatic actuators,

supports etc for fire water distribution networks

All necessary sign-posting for the water-hydrant ring system including brackets,

complete with accessories.

All necessary water spray rings, risers, pipes, valves, fittings, spray nozzles ,

sprinkler nozzles etc.

Complete Addressable analogue fire detection system with heat and smoke

detectors for various plant area including storages with necessary cabling,

interface panels, controllers, sounders, manual call points, sirens, response

indicators, and all necessary hardware and accessories.

All necessary electrical equipment like LV switch-gear, LV motors, LV power

and control cables, control panels with alarm, PBB and interlocks, necessary DC

systems, push button stations, cable trays and accessories, cabling, glands lugs,

earthing and lightning protection conforming to relevant electrical specifications.

PROCESS FLOW DIAGRAM (Block diagram)

ANNEXURE-III

WATER BALANCE

ANNEXURE-IV

ENERGY BALANCE

ANNEXURE-V

MASS BALANCE

ANNEXURE-VI

ENVIRONMENTAL MANAGEMENT PLAN

ENVIRONMENTAL MANAGEMENT PLAN

Environmental management plan is prepared for construction and operational stage to

mitigate negative impacts. This document describes the Environmental Management Plan

consisting of mitigation measures and monitoring plan.

Construction Stage

The construction activities of the project site will mainly comprise of civil foundation

work, site preparation, shed and building construction, excavation, and earthmoving,

water treatment plant and water storage tanks, roads and drainage and erection of other

infrastructural facilities. These activities will involve movement of a substantial quality

of soil and debris. During dry season, it is necessary to control the dust nuisance created

by excavation and transportation activities. Using proper dust suppression measure on the

site like spraying of water at regular intervals shall be adopted.

Sanitation: During construction stage, suitable sanitation and other essential

facilities shall be provided for workers. These facilities shall be well designed and

maintained to minimize environmental impacts. Adequate drinking water supply

should be provided for on-site workers.

Noise: To keep the ambient noise levels within the permissible limits, the following

measures shall be taken:

i. Innovative approaches of using improvised machinery designs, with in-built

mechanism to reduce sound emissions like improved silencers, mufflers and closed

noise generating parts.

ii. Procurement of drill, loaders and dumpers and other equipment with noise proof

system in operator's cabin.

iii. Regular and proper maintenance of noise generating machinery including the

transport vehicles to maintain the low noise levels.

Provision shall be made for noise absorbing pads at foundations of vibrating

equipment to reduce noise emissions. It shall be ensured that no worker is exposed

to a noise generating construction equipment for more than 8 hours a day.

Construction Equipment and Waste: It shall be ensured that all the construction

vehicles specially trucks, bulldozers etc are properly maintained to minimize smoke

in exhaust emissions. The waste generated should be collected in garbage bins. The

temporary garbage bins be provided in the area. The waste generated and collected

shall be disposed off at an approved dumpsite.

Site Security: The site shall be secured by fencing and entry point shall be manned.

Operation Stage

Various Sources of Pollutants generated from PTDR-1000 facility with their abatement

method is described as under

Air Environment

Flue Gas Emission from PTDR system after Syn gas combustion: Following table

shows the details of mitigation measures proposed to meet emission norms:

Sr

No

Name of

Equipment

Location Brief Specification

1 Bag Filter After

Spray

Dryer

Type: Reverse Pulse Jet Type bag filter

system

Duty: To remove particulate matter from syn

gas.

Inlet Gas Flow: 3500 kg/hr

Inlet Gas Temperature: 220 deg C Max

Inlet Gas Particulate Matter: 4200 mg/NM3.

Max

Outlet Particulate Matter: < 80 mg/NM3 (All

submicron particles and mostly un burnt

carbon)

Bag Filter removal efficiency: Min 95%

Ash Removal System: Sequentially controlled

reverse jet pulsing of Nitrogen gas. Bottom

collected ash is removed through rotary air

lock valve.

Material of Construction: Casing: SS Lined

MS / SS, Bags: Teflon lined / Teflon and

antistatic type.

2 HCl Scrubber After Bag Type: Ventury Scrubber followed by Packed

Filter bed scrubber.

Duty: To capture HCl from Syn gas in

scrubbing liquor

Inlet Gas Flow: 3552.03 kg/hr

HCL Removal Efficiency: 98% Min

Scrubbing Media: Dilute HCl solution.

Other details:

Side stream filter provided to maintain min

suspended solids in scrubbing liquor.

External Heat Exchanger provided to remove

heat of condensation of water and heat of

formation of dilute HCl solution.

Material of Construction:

Ventury Scrubber: SS with Rubberlined and

Tile lined.

Packed Bed Scrubber: FRP (Vinyl Ester

resin) / MSRL with PP Packing

Pump: PVDF

Piping: HDPE / PP / MSRL

Side Stream Filter: PP / MSRL

Heat Exchanger: Graphite Tubes & Tubesheet

3 Alkali

Scrubber

After HCl

Scrubber

Type: 2 Stage packed bed scrubber.

Duty: To scrubb H2S and traces of HCl from

syn gas in caustic solution and to produce

Na2S solution as by product

Inlet Gas Flow: 2530.56 kg/hr

H2S removal efficiency: Min 99%

Scrubbing Media: Lower Section: 9 pH Na2S

solution; Upper section: 10 pH NaOH

solution.

Other Details:

External heat exchanger provided to remove

heat of reaction.

Polishing treatment provided for Na2S bleed

solution.

Mist Eliminator provided at the top of

scrubber

Material of Construction:

Packed Bed Scrubber: FRP (Vinyl Ester

resin) / MSRL with PP Packing

Pump: PVDF / SS

Piping: HDPE / PP / MSRL

Side Stream Filter: PP / MSRL

Heat Exchanger: SS Tubes & Tubesheet

4 Syn Gas

Utilization

System (Steam

Boiler)

After

Alkali

Scrubber

Cleaned syn gas from alkali scrubber is

combusted in steam boiler to use chemical

heat available in syn gas. Syn gas from alkali

scrubber is completely cleaned with respect to

acidic gases. Any carried over carbon

particulate matter with syn gas will complete

burn in steam boiler. Flue gas generated in

syn gas boiler at 180 deg C will be exhausted

from the stack of steam boiler at 30 M high.

Emission Standard for PTDR-1000 project

Parameter Emission Limit (mg/Nm3)

Particulates 50

HCl 50

SO2 200

CO 100

TOC 20

HF 4

NOX (NO and NO2 expressed 400

expressed as NO2)

Note: All values above shall be corrected to 10% oxygen on dry volume basis.

Hydrocarbon: 10 ppm, over an hourly rolling average on dry basis, measured as

propane.

Opacity: While operating properly at 100% rated capacity, the system shall have

visible emission rate of less than on equal to 10%, except for condensed water

vapour, from the discharge of stack (one hour rolling average ).

Dioxin / Furans: While operating at 100% rated capacity, the system shall have an

emission of dioxin and furans less than or equal to 0.1 ng TEQ / Nm3 corrected to

10% Oxygen. Sampling period shall be minimum 6 hours and maximum 8 hours.

Metals: While operating properly at rated capacity, the system shall have an

emission rate from the discharge of stack to atmosphere less than or equal to

Metals: Emission Limit (mg/NM3)

Cd+Th (& it’s compounds) 0.05

Hg (& it’s compounds) 0.05

Sb+As+Pb+Cr+Cu+Mn+Ni+V (& it’s compounds) 0.5

Note: All values above shall be corrected to 10% oxygen on dry volume basis.

In order to continuously monitor emissions from the flue gas stack and also to optimize

plant performance on line gas analysers shall be provided as under

DG Set exhaust:

DG Set will be installed at emergency power supply for safe shut down of plant in

case of power failure. DG set capacity will be 450 KVA and will be based on LDO as

fuel.

Emission monitoring plan

Sr No Location of on line gas

analyser

Parameter to

be monitored

Frequency of

Monitoring

1 Stack gas HCl, SO2, CO,

O2

On line continuous, 24

hrs

NOx, VOC,

Particulate

Matter

Every week by self

analytical facility

Every Month by

monitoring agency

approved by the GPCB

HF, Heavy

Metals

Every Month by

monitoring agency

approved by GPCB

2 Syn Gas at the outlet of

Plasma Reactor

CO, O2, H2 On line continuous, 24

hrs

3 DG set exhaust PM, Sox, Nox

Fugitive emissions expected from PTDR-1000 system: Source and mitigation of

these fugitive emissions are tabulated as under

Fugitive emissions and abatement method

Name and source of

fugitive emissions

Abatement Method

VOC from liquid

storage tank

All vents from the liquid storage tank will be connected to

exhaust header. Exhaust header will be connected to

exhaust blower. Exhaust blower discharge will be

connected to inlet of Steam Boiler furnace where syn gas

will be combusted.

VOC/Odorous air from

haz. Waste storage area

Combustion air fan for syn gas boiler will draw air from the

hazardous waste storage area. Suction of combustion air fan

will be taken from hazardous waste storage area.

Emergency Vent from

Plasma Reactor

Emergency vent will open in abnormal plant condition

only. Exhaust of emergency vent will be connected at the

inlet of syn gas boiler.

Scrubber Circulation

Tank vents

Scrubber circulation vent will be connected to down stream

gas ducting of syn gas which will be always under negative

pressure.

Mitigation of other air pollutants

o Air borne particulate may results during handling and transportation of waste due

to wind. The status of ambient air quality shall be closely monitored.

o Ambient air quality at the facility and at the vicinity shall be monitored to meet

the prescribed standards prescribed by CPCB.

o Watering of road as well as constructing of metalled roads shall be carried out.

o Approx 3000 M2 Green belt development shall be carried out.

o Traffic Operation Plan for better traffic management shall be worked out.

o Ambient air monitoring will be carried out as per following plan

Ambient Air quality Monitoring Plan

Sr No Environmental Monitoring Frequency

1 Ambient Air Quality ( SPM, NOx, CO2, SO2,

CO,HC and CH4)

Once in two months at

two locations

2 Noise level monitoring Once in two months and

two locations

Water Environment

WATER CONSUMPTION

Average daily water consumption of unit is about 261.936 m3. Water consumption is

primarily for scrubber, washing, boiler, cooling and domestic purpose. The entire water

requirement is meeting through GIDC water supply system. GIDC Ankleshwar has its

own water reservoir and distribution network throughout the industrial estate. The detail

of water consumption is shown in Table 7.1.

Table 7.1

DETAILS OF WATER CONSUMPTION

Sr. No. Water Consumption Consumption

(litres/Day)

1. Domestic 12,000

2. Industrial

Process and Washing 26,580

Boiler and Cooling 2,23,356

Total 2,61,936

Bleed stream generated from plant and its mitigation measures are tabulated as under

WASTE WATER GENERATION AND MANAGEMENT

The average total wastewater generation will be 105.691 m3/day. The details of waste

water generation and treatment disposal mechanism are given in table 7.2 .

Table 7.2

DETAILS OF WASTE WATER GENERATION AND ITS DISPOSAL

Waste Water Generation Quantity

(Liters / day)

Remark

(1) Domestic 10,000 Sewage will be disposed

through septic tank and

soak pit system.

(2) Industrial

Stream 1: MEE condensed

water generated from the

12000 Stream will be reused to

cooling tower.

MEE

Stream 2: Scrubber Bleed

Stream 3: Boiler BD

Stream 5: MB Plant bleed

Stream 7: Softener BD

36771 Stream will be reused in

gas quencher and slag

quench tank.

Stream 6: RO plant reject

Stream 8: Filter back wash

20220 Stream will be discharged

into CETP line as per

CETP norms for further

treatment and disposal.

For zero discharge:

stream will be reused for

wheel wash make up,

dedusting road and green

belt development etc.

Stream 4: Cooling tower

BD

26700 Stream will be discharged

into CETP line as per

CETP norms for further

treatment and disposal.

For zero discharge:

Stream will be fed as RO

feed water after

pretreatment

section of RO

plant.

TOTAL 1,05,691

Water Pollutants and Abatement Plan

Name and source of

bleed stream

Quantity

(liters/day)

Quality Abatement Method

Stream 1: MEE

condensed water

generated from the MEE

during concentration of

liq aq waste stream

12000 pH; Neutral

TDS: < 100 ppm

COD: < 100

mg/lit

BOD: < 30 mg/lit

MEE condensed water

is provided polishing

treatment using

activated carbon to get

rid of any expected

VOCs in worst

conditions. This stream

is reused as make up

water to cooling tower.

Stream 2: Scrubber

Bleed

Stream 3: Boiler BD

Stream 5: MB Plant

bleed

Stream 7: Softener BD

36771

pH; Neutral

TDS: 2-3 by wt

(almost all due to

inorganic salts,

mostly NaCl)

SS: < 50 mg/lit

All taken is taken to

High TDS bleed water

storage tank. From this

tank mixed high TDS

water is used in spray

dryer and slag quench

tank.

Stream 6: RO plant

reject

Stream 8: Filter back

wash

20220 pH; Neutral

TDS: < 1600

mg/lit

SS: < 100

mg/lit

COD: < 100

mg/lit

BOD: < 30 mg/lit

For zero discharge

condition this stream

will be reused for

wheel wash make up,

dedusting of road,

green belt

development, toilet

flushing and cleaning,

fire water tank make

up, plant floor

washing.

For discharge

condition this stream

will be discharged into

CETP line as per

CETP norms for

further treatment and

disposal.

Stream 4: Cooling tower

BD

26700 pH; Neutral (after

neutralization)

TDS: < 1000

mg/lit

SS: < 50 mg/lit

COD: < 100

mg/lit

BOD: < 30 mg/lit

For zero discharge

condition this stream

will be fed as RO feed

water after pre-

treatment section of

RO plant.

For discharge

condition this stream

will be discharged into

CETP line as per

CETP norms for

further treatment and

disposal.

Sewage 10000 Sewage will be

disposed through

septic tank and soak pit

system through

separate drain.

Spillage collection from

haz waste storage area

- - Spillages and wash

water from haz waste

storage area will be

collected in separate

pit located in haz waste

storage area and will

be pumped back to

liquid waste storage

tanks for disposal

through MEE or

through PTDR plant

depending on nature

and type of spillage.

Bleed water collection, treatment and distribution system will consist of following units:

Low TDS Water Collection and neutralization Tank

High TDS water collection and neutralization Tank

Neutralization system

Pressure Sand Filter and Activated Carbon Filter

From bleed water collection and neutralization tank bleed water will be reused in plant /

disposed into CETP discharge line as per details provided in above table.

Other Mitigation Measures

In order to minimize any potential negative impact on surface and ground water, the

mitigation plan shall include the following:

Hazardous waste storage area and plant area will be completely covered from top and

side. Strom water run off will be managed through separate storm water drains.

Before discharging storm water into GIDC drain, it will be passed through small RCC

pit where online pH sensor and recorder will be provided to keep check on pH of

outgoing storm water.

Prompt cleanup of any spillage of Haz Waste using dry method.

Regular monitoring of ground water quality through four monitoring wells one

upstream, one at site and two at downstream of the disposal site.

The water samples shall be analyzed for the 36 physical, chemical and bacteriological

parameters as per MOEF guidelines.

Following table describes water monitoring plan

Water Quality monitoring Plan

Sl. No. Description Frequency

1 High and Low TDS bleed quality Daily

2 Ground water quality – within the site Once in 3 months

3 Ground water quality – outside the site Once in 6 months

Resource Recovery

Resource recovery and its use is tabulated as under

Name and Source

Quantity Quality Use of resource

Vitrified Slag 5.6

Tons/day

Vitrified solid slag

in granules or in

solid lump form

Construction filler

material.

Sodium Sulphide

Solution (20%)

8 Tons/day

pH: Alkaline

Na2S: 20%

NaOH: 1-2%

NaCl: 1% Max

Balance: Water

Na2S Solution as raw

material for chemical

and dye manufacturer

Power 1.2 MW 415 V, 50 Hz In plant consumption

and balance approx 0.2

MW export to grid

Hazardous Waste Management

Type of hazardous waste generated and its abatement method is described in

following table for construction and operation phase of plant.

CATEGORY

NO.

TYPE OF WASTE QUANTITY DISPOSAL METHOD

CONSTRUCTION PHASE

- Brick-bats, debris etc.

As per

generation

Used in pavements, roads, etc. / through

existing solid waste disposal facility

- Steel scrap Sold to steel scrap dealers

- Packing wood scrap Sold to wooden scrap dealers

OPERATON PHASE

Category of

waste

Type of solid waste Total Qty Disposal Method

34.3 Inorganic Salts from

Gas Quencher and filter

cake from scrubbing

system

1.24 Tons/Day

Recycled back to PTDR plant

for vitrification into slag

5.1 Used/ Spent Oil 0.50 KL/Year Disposed off through PTDR

plant

33.3 Discarded drums/

Carboys/ Liners/ bags

As Per generation

Bags will be used for repacking

of waste and will be fed to

PTDR plant.

Drums/carboys will be crushed

in drum crusher and will be fed

to PTDR plant. Metallic drum

will get vitrified and plastic

drum will be disposed off in

plasma reactor

28.2 spent carbon and bag

house bottom solids

450 kg/day Disposed off through PTDR

plant

Soil Environment

Waste spillage may lead to soil pollution. Therefore, regular monitoring of soil is

required. Soil monitoring plan is given in following table

Sr No Environmental Monitoring Frequency

1 Soil Monitoring Once in a two season at

2 locations

Noise Environment

Plant and equipment will be designed to ensure that noise generated is limited to CPCB

norms. Equipment will be provided with noise control measures such as acoustic

insulation etc, to ensure noise abatement. Rotating equipment will be properly balanced.

Where high noise levels are produced, employees will be provided with ear protection

devices.

Green Belt Development

Approx 3000 m2 Green belt is proposed primarily for effective control of pollution. The

tolerant plants, having tremendous sink capacity, can help contain and attenuate pollutant

concentration in air and thereby restore and revitalize the stressed and impaired

environment on long term basis. The basic need for developing pollution sink or shelter

belt plantation is to use properly selected plants having pre requisites to tolerance and

detoxify pollutants and long life span endowed with large and dense canopy and

extensive foliage. The proposed green belt around the proposed site may be designed

taking into consideration the availability of space as the efficiency of green belt in

mitigating environmental impact mainly depends on the width of green belt, distance

from source and tree height. Locally useful species shall be selected in consultation with

forest departments.

The following criterion is to be considered while selecting the species for plantation:

The plant species should be fast growing.

They should have thick canopy cover.

They should be perennial and evergreen.

They should have high sink potential.

They should be effective in absorbing pollutants without significantly

affecting their growth.

Based on above following plant species are recommended for plantation:

Acacia nilotica (Babul)

Deldergia sissoo (Shishum)

Acacia auriculiformis (Australian Babul)

Azadirachta indica (Neem)

Lagerstroemia speciosa (Jamun)

Pongamia pinnata (Karanji)

Minimum two rows of plants are required for plantation on roadside to minimize the

pollution effects. While planting care should be taken to ensure that plants in second row

fall in between the two plants of the first row.

Management and Training

The site operator, waste transporters and the person responsible for monitoring and

management of the shall be provided regular training through structured training program

covering all aspects of waste storage, handling and transportation and plant operation and

maintenance besides the effective enforcement of regulations by CPCB/MPCB. This will

ensure safety of workers, general public and the environment.

The unit will become member of Disaster Prevention and Management Centre, GIDC,

Ankleshwar and get the benefit of trainings, surveys and expert third party inspections.