ject report

List of Annexures

Annex. No. Annex. Description

1 Permission letter from Ministry of Commerce & Industry, New Delhi

2 Site Plan of the land

3 Layout Plan of the project site

4 (1) Flow Chart for manufacture of SSP / GSSP

4(2) Flow Chart for manufacture of Sulphuric Acid

4(3) Flow Chart for Captive Power Plant

5 List of Plant & Machinery

6 Material Balance

7 Water Balance

8 Fluorine Balance

9 MSDS for Hazardous chemicals in use

10 Details of proposed pollution control measures

11 Treatment of domestic waste

12 Reuse of liquid effluent

13 Risk analysis

14 Environment Management Plan

ANNEXURE 1

PERMISSION LETTER FROM MINISTRY OF COMMERCE & INDUSTRY, NEW DELHI

ANNEXURE 2

SITE PLAN OF THE LAND

ANNEXURE 3

LAYOUT PLAN OF THE PROJECT SITE

ANNEXURE 4 (1)

MANUFACTURING PROCESSES FOR SSP, GSSP AND SULPHURIC ACID

FLOW CHART FOR SSP/GSSP PRODUCTION PROCESS

ANNEXURE 4 (2)

FLOW CHART FOR SULPHURIC ACID PRODUCTION PROCESS

Caustic

Scrubber

Stack To

Atmosphere

Soft Water

Mist

Candle

IPAT Economiser

1st

Converter

3rd Bed

HHE (T) Converter

2nd Bed

AP Tank 98.4% Conc.

Sulphuric Acid

CHE (S)

2 nd

CHE (S)

1st

HHE (S) Converter

IV Bed

CHE

(T) 2ND

SSP for Captive

Consumption

FAT Candle

Filter

Sulphuric Acid

Storage Tanks (NF)

Sulphuric Acid

Storage Tanks (F)

SALE

FAT

Sulphur Sulphur

(NF) (F)

Molten Molten

Sulphur Sulphur

(NF) (F)

Saturated Steam

Condensate to

Boiler Feed Water

Sulphur

Burner

Boiler I Super Heater Hot Gas Filter Converter 1st Bed Boiler II

Super Heated Steam Captive Power Plant

Steam Turbine Captive

Power Generation &

Supply to SAP.

Drying

Tower

Air Blower

Economizer

IInd

CHE

(T)

1ST

Oleum

Tower

Oleum

Process Tank

Oleum

Storage

Tank

Sale

NF = Non Fertilizer

F = Fertilizer

ANNEXURE 4 (3)

FLOW CHART FOR CAPTIVE POWER PLANT

The captive power plant is based on the steam generated in Sulphuric Acid as a bye product. The fully condensing Steam Turbo generating set is proposed. No fuel,

raw materials are used and hence there is no emissions / effluent from this captive power plant. The blow down of Cooling Tower is recycled to SSP lagoon for

using in SSP process.

Cool Hot

Water Water

Superheated steam

from Sulphuric

Acid Plant.

Fully Condensing Steam Turbo

Generating set

5MW..

Power

Generation.

Condenser Condensate to

Boiler feed water

Tank.

Cooling Tower Blow down water

to SSP Process.

ANNEXURE 5

List of Plant and Machinery

(A) SSP Fertilizer Plant

S. No. Equipment Quantity

1 EOT Crane 7.5 MT capacity 2 Nos.

2 Rock Feed Hopper 1 No

3 Feed Bell Conveyor 1 No

4 Ball Mill for Rock grinding 1 No

5 Hot air Generator 1 No

6 Grit Seperator / cyclones 1 set

7 D.C. Bags 1 set

8 Ground Rock hopper 1 No

9 Screw conveyer 1 No

10 Ground Rock Bucket Elevater 1 No

11 Mass flow hopper 1 No

12 Belt weigher 1 No

13 Screw conveyer 1 No

14 Mixer 1 No

15 Den 1 No

16 Scrubber 1 No

17 scrubbing fan 1 No

18 scrubbing pumps 6 Nos

19 Sulphuric Acid pump 1No

20 Raw Water Pump 1No

21 Sulphuric Acid Storage Tanks 2Nos

22 Raw Water Storage Tank 1 No

23 Fo Storage Tank 1No

24 Lagoon 1No

25 powder packing RM hopper 1 No

26 Feed Belt 1 No

27 Bucket Elevator 1 No

28 Vibrating Screen 1 No

29 Crusher 1 No

30 Powder hopper 1 No

31 Stiching m/c 1 No

32 Slat Conveyor 1 No

33 Weighing Machinery 1 No

34 Portable Tank Loader 1 No

35 Stack 30 Meter high 1No

(B) Granulated SSP Fertilizer Plant

1 Feed Hopper 1No

2 Feed Belt 1No

3 Recycle Belt 1No

4 Bucket Elevator 1No

5 Granulator Drum 1No

6 Dryer Drum 1No

7 Hot Air Generator 1No

8 Dryer to cooler belt 1No

9 Cooler Drum 1No

10 Raw Material Pump 1No

11 FO Storage Tank 1No

12 Cooler to Bucket Elevator Belt 1No

13 Cyclones Dryer / Cooler 1No

14 Multiclones Dryer / Cooler 1No

15 Stack 30 Meter high 1No

16 Bucket Elevator 1No

17 Vibrating Screens oversize & under size 1 Set

18 Chain Mill 2 Nos

19 Product belt 1No

20 Product Hopper 1No

21 Weighing m/c 1No

22 Slat Conveyor 1No

23 Stitching M/c 1No

( C ) Sulphuric Acid

1 Sulphur Melter Agitator 1No

2 Molten Sulphur Pumps 2Nos

3 Air Blower 1No

4 Air Drying Tower 1No

5 Sulphur Burner 1No

6 Waste Heat Boiler with BFW Pumps 1 Set

7 Hot Gas Filter 1 No

8 Converter 1No

9 Hot Heat Exchanger 1No

10 Cold Heat Exchanger 2 Nos.

11 Economizer 1No

12 Super Heater 1No

13 Inter Pass Absorption Tower 1No

14 Acid Process Tank Pumps 2Nos

15 Acid Coolers DT / IPAT / FAT 1Set Each

16 Final Absorption Tower 1No

17 Mist Eliminators IPAT / FAT 1Set Each

18 DT Mist Pad 1Set

19 Alkali Scrubbing Tower 1No

20 Acid Process Tank 1No

21 Acid Transfer / Dispatch pumps 2 Nos.

22 Acid Storage Tanks 5 Nos.

23 Cooling tower with pumps 1 Set

24 Raw Water Pumps 2 Nos.

25 D/M. Water plant 1 Set

26 Soft Water Plant 1 Set

27 stack 50 m high 1 No

(D) Captive Power Plant

1 Steam Turbine Fully Condensing type 1 Set

2 Condenser 1 No

3 Condensate Pumps 2 Nos.

4 Oil Tank, Oil Pumps, Oil Filters 1 Set

5 Cooling Tower 1 Set

6 Vacuum Pumps 2 Nos.

ANNEXURE - 6

Material Balance – Single Super Phosphate Fertilizer

For 1 MT SSP Fertilizer Powder Rock Phosphate having + 31.5% Total P2O5 0.565 MT

Sulphuric Acid 0.370 MT

(98.4% Concentration Technical Grade)

Moisture 0.110 MT

(-) CO2 Gaseous losses (-) 0.027 MT

(-) Water Vapour Losses (-) 0.018 MT

TOTAL 1.000 MT

• Specific Furnace Oil or Equivalent Wood / Biomass Consumption SSP 2.0 Ltrs / MT SSP or equivalent wood / biomass GSSP 10 Ltrs / MT GSSP or equivalent wood / biomass The additional furnace oil or equivalent wood/biomass requirement will be 14.4 Kl /day

day for the proposed 2x600 MTPD SSP & 3x400 MTPD GSSP Plants.

• Specific Raw Water Consumption

SSP 0.30 MT / MT SSP

GSSP 0.06 MT / MTGSSP

SA 1.75 MT / MT SA

Captive Power Plant 6 Kgs / KWH

Domestic 25 KL / day

The Raw Water requirement will be 2052 Kl / day for the proposed 2x600 MTPD SSP

3x400 MTPD GSSP, 500 MTPD Sulphuric Acid & 5 MW Captive power plants. KCFL

is paying water cess as per the prevailing rates to the CG. Govt. for drawing ground water

from the tube wells.

• Specific Sulphur Consumption

Sulphur 0.335 MT / MT Sulphuric Acid

ANNEXURE - 7

Water Balance

Break Up Of Water Uses and Water Balance for proposed 4.00 Lac MT/Yr SSP Fertilizer,

3.96 Lac MT/Yr Granulated SSP Fertilizers, 500 MTPD Sulphuric Acid, 5 MW Captive Power Plant

Raw water from Bore wells

2052 KL / Day

SSP Fertilizer Plant

1200 MTPD @ 0.30 KL/MT SSP

360 KLD

GSSP Fertilizer Plant

1200 MTPD @ 0.06 KL/MT GSSP

72 KLD

72 KL/Day

Domestic use

25KL/Day

Sewage Septic

Tank

Horticulture

Use within the

Premises

Scrubber Liquor

Microbiological

vermiculture

treatment

Sulphuric Acid Plant

500 MTPD @ 1.75 MT /MT Acid 875 KLD

Captive Power

Plant 5 MW @ 6kgs / KWH

720 KLD

720 KL / Day

Blow Down

Boiler, CT,

DM/Softner

Back wash

Blow down CT

Mixer

ANNEXURE - 8

Fluorine and H2SiF6 Balance

(A) H2SiF6 Liquor

The 100% H2SiF6 Liquor is recycled into the SSP Mixer for acidulation of Rock Phosphate.

(B) Fluorine

Total Fluorine 25 mg / Nm³

„F‟0.0131 0.00003

H2SiF6 0.0166

(CaSiF6 as insoluble)

„F’ 0.01307MT/SSPMT

Sulphuric Acid H2SiF6 Liquor

Rock Phosphate

Ca3(PO4)2.CaF2

Mixer / Den Scrubber Stack

Input Fluorine 0.565 x 0.03

= 0.01695 MT / SSP MT

HF/ SIF4 Curing Shed Silica

‘F’ 0.007 MT / SSP MT

SSP Fertilizer

‘F’ 0.01622 MT / MT SSP

‘F’ 0.00003MT /MT SSP

ANNEXURE 9

MATERIAL SAFETY DATA SHEET FOR HAZARDOUS MATERIALS

1. SULPHURIC ACID

Common

synonyms Sulphuric acid, vitriol, oil of vitriol

Formula H2SO4

CAS /

EINECS No. 7664-93-9

Physical

properties

Form: Colourless oily liquid when concentrated; colourless liquid when diluted

Stability: Stable, but hygroscopic

Melting point: -2 °C

Water solubility: Miscible in all proportions (dissolution is very exothermic)

Specific gravity: 1.84 (concentrated), close to 1 (dilute)

Principal

hazards

Contact with the eyes or skin can cause serious permanent damage

Concentrated solutions of acid are extremely corrosive

Dissolution of sulfuric acid in water is very exothermic; enough heat may be released

to make the water boil

Hazard

Codes

NFPA

Flammability (Red) = 0, Reactivity (Yellow) = 2, Health (Blue) = 3 Sulfuric acid is

water-reactive if concentrated.

Safe Always wear safety glasses. Do not allow the acid or a solution of it to come into

http://ptcl.chem.ox.ac.uk/MSDS/glossary/hygroscopic.html

http://ptcl.chem.ox.ac.uk/MSDS/glossary/miscible.html

http://ptcl.chem.ox.ac.uk/MSDS/glossary/exothermic.html

handling contact with your skin. Concentrated sulfuric acid acid should not be diluted by

inexperienced users. When diluting acid always wear eye protection, and ALWAYS

add acid to water (not the reverse) slowly and with great care. Use constant stiring

(sulfuric acid is much denser than water, and if you do not stir when adding acid to

water, a layer of concentrated acid may form at the bottom of the beaker, creating a

substantial temperature gradient where acid and water meet).

Note that freshly-prepared solutions will be warm or hot, and will as a consequence be

more corrosive than a cool solution.

Emergency

Eye contact: Immediately flush the eye with plenty of water. Continue for at least ten

minutes and call for immediate medical help.

Skin contact: Wash off with plenty of water. Remove any contaminated clothing. If

the skin reddens or appears damaged, call for medical aid.

If swallowed: Drink plenty of water and call for immediate medical help

Disposal

Small amounts of dilute sulfuric acid can be flushed down a sink with a large quantity

of water, unless local rules prohibit this.

Larger amounts should be neutralised before disposal. Concentrated acid should not be

flushed down a sink.

Protective

equipment

ALWAYS wear safety glasses when handling sulfuric acid or its solutions.

If you need gloves, use neoprene, butyl rubber, natural rubber, polyethylene or PVC

for handling solutions at concentrations of up to 70%. Use butyl rubber or

polyethylene for concentrated sulfuric acid.

2. FURNACE OIL

Common

synonyms Diesel fuel; Fuel Oil; Gas Oil; or Product use Fuel Heating Oil

CAS No.

Physical

properties

Form Clear, slightly viscous, oily liquid

Specific gravity 0.881 max @ 15°C (59°F)

Colour Clear to golden

Odour Petroleum odour

Vapour pressure Typically 2.1 to 2.6 mm Hg @ 21°C (70°F)

Boiling point Typically 130-400°C (266-752°F)

Hazard Codes

NFPA - Health: 0; Flammability: 2; Reactivity: 0

Combustible Liquid Class B, Division 3; Classification: Very Toxic

Fire & Explosion

Hazards

Conditions May be ignited by heat or flames.

Flash point 43°C (109°F)

Auto ignition temperature 241°C (466°F)

Lower flammable limit 0.6 to 1.3%

Upper flammable limit 6 to 7.5%

Explosion data: Sensitivity to: Mechanical impact Not expected to be sensitive

Static discharge Vapor: Yes

Hazardous

combustion

products

Carbon monoxide (CO). Nitrogen oxides. PAHs and other aromatic hydrocarbons.

Reactivity

Information

Stability: Stable

Conditions to avoid: Sources of ignition. Static discharges. High temperatures.

Incompatible substances: Oxidizers such as peroxides, nitric acid, and per

chlorates.

Extinguishing of

fire

Means of extinction In general, do not extinguish fire unless flow can be stopped.

Use carbon dioxide, dry chemical, or foam. Cool containers with flooding

quantities of water until well after the fire is out.

Special precautions Vapor may spread along the ground and collect in low or

confined areas (sewers, basements). May also travel to a source of ignition and

flash back. Containers may explode when heated.

Principal health

hazards

Route of Entry Inhalation Hazardous Contact Eye, Ingestion Skin, Skin

absorption

Acute exposure: Headache and giddiness following inhalation. Aspiration into

the lungs can cause severe pneumonitis (serious lung irritation), with coughing,

gagging, shortness of breath, chest pain, and/or pulmonary edema (fluid

accumulation in the lungs). Ingestion may produce nausea, vomiting, and

cramping. Kidney effects have been reported.

Chronic exposure Kidney, liver, lung, blood, and skin disorders.

Irritation to Skin and respiratory tract.

Sensitization Skin, in some animal studies.

Protective

equipment

Use of gloves recommended.

Eye Chemical safety goggles or face shield, as a good general safety practice.

Respiratory NIOSH-approved SCBA or air line respirator with escape cylinder for

confined spaces. If an air purifying respirator is appropriate, use a “P series” filter

& organic vapor cartridges. A qualified occupational health and safety

professional should advise on respirator selection.

Personal protective equipment Clothing & footwear.

Coveralls to prevent skin contact with product. If clothing or footwear becomes

contaminated with product, completely decontaminate it before re-use, or discard

it.

Engineering controls.

Enclose processes. Use local exhaust ventilation to remove vapour at its site of

generation. Handle laboratory samples in a fume hood. Use mechanical

ventilation in confined spaces.

First – Aid

Inhalation Move victim to fresh air. Give artificial respiration if breathing has

stopped and if a qualified AR administrator is available. Apply CPR if both pulse

and breathing have stopped. Get medical help immediately.

Ingestion Never give anything by mouth if the person is unconscious, rapidly

losing consciousness, or convulsing. If the person is conscious, have them drink 8

to 10 ounces of water or milk to dilute the material in the stomach. Do not induce

vomiting. If vomiting occurs spontaneously, have the person lean forward to

avoid aspiration. Get medical help immediately.

Eye If irritation occurs, flush eye with lukewarm, gently flowing fresh water for at

least 10 minutes. Get medical help.

Skin Quickly and gently blot away excess product. Gently remove contaminated

clothing and shoes under running water.

Wash gently and thoroughly with water and non-abrasive soap. Get medical help.

Handling

procedure &

equipment

Avoid heating open containers of product so as to minimize vapour production

and accumulation. Use non-sparking equipment, explosion-proof ventilation, and

intrinsically safe electrical equipment. Ground handling equipment. Have clean

eyewash and shower near the work area. Never siphon product by mouth. Leaks

& spills Keep unauthorized persons away. Eliminate all sources of ignition.

Ventilate area. Stop leak if it can be done safely. Prevent entry into sewers,

waterways, or confined spaces. Absorb or cover with dry earth, sand or other non-

combustible material and use clean, non-sparking tools to transfer to container.

Storage May be stored at ambient temperatures. Containers should be vented and

equipped with a flame arrester.

3. SULPHUR

Common

synonyms

Sulphur, brimstone, flowers of sulfur, precipitated sulfur, sublimed sulfur,

bensulfoid, flowers of sulphur, precipitated sulphur

CAS No. 7704-34-9

Physical properties

Appearance: Bright yellow powder

Melting point: ca. 116 °C (depending upon form)

Boiling point: 445 °C

Vapour density: 8.8 (air = 1)

Density (g cm-3

): 2.01

Flash point: 188 °C

Water solubility: negligible

Hazard Code

NFPA Hazard code

Health – 2, Fire -1 , Reactive- 0.

Fire & Explosion

Hazards

Explosive Limits: LEL 35 gm/m3; UEL - 1400 gm/m

3

Dust suspended in air is readily ignited by flame, static electricity or friction

spark. Every reasonable step must be taken to minimize dust formation. Dust

tight casings should be equipped with explosion relief vents. Sparkless electrical

equipment is recommended.

Handling equipment must be grounded or bonded to avoid static electricity. Keep

away from sources of flame or sparks.

Hazardous

combustion

products

Mixtures with chlorates, nitrates or other oxidizing agents may be explosive.

Sulphur will react with alkalis or alkaline earths.

Reactivity

Information

Stability: Stable.

Dust may form a flammable or explosive mixture with air. Incompatible with

strong oxidizing agents, most common metals, hydrogen, chlorine, fluorine.

Extinguishing of

fire

1. A fine water spray or fog is recommended.

2. CO2 or dry chemical.

3. Small fires may be smothered with sand or solid sulphur.

Because burning sulphur evolves sulphur dioxide, breathing apparatus or gas

masks approved for use in acid-gas atmosphere should be used. Fumes from

unprotected sulphur fires shall be avoided, if possible, by approaching for the

upwind side.

Principal health

hazards

Inhalation: Sulphur dust may irritate the mucous membranes of the respiratory

passages.

Ingestion: Solid sulphur is virtually non-toxic. It can be taken internally in fairly

large doses without injury.

Skin: In some individuals, sulphur dust has an irritant action, which may be

aggravated by perspiration or moisture.

Eyes: Sulphur dust is capable of irritating the inner surfaces of the eyelids.

Protective

equipment

Respiratory Protection: Dust-type respirators shall be provided for dusty

conditions. Breathing apparatus must be available for emergency use in case of

fire.

Eyes and Face: Dust-tight goggles with plastic or rubber frames may be helpful

in dusty conditions.

Hands, Arms and Body: Workers whose skin may be sensitive to sulphur dust

should button collars, roll sleeves down, and gather trousers at the ankle. Gloves

may be helpful.

Other Clothing and Equipment: Hard hat and safety shoes. Fire-retardant fabric is

recommended. Sulphur impregnated clothing should not be worn.

First – Aid

Skin: Wash with mild soap and water.

Eyes: Irrigate thoroughly with copious quantities of plain water. Inadequate

irrigation may increase the irritation. Do not use Boric Acid.

Handling

procedure &

equipment

Ventilation: Local exhaust if dusty conditions prevail.

Normal Handling: Avoid breathing dust and keep clothing as free from dust as

possible.

Storage: Solid becomes corrosive to metals when stored wet. Sulphur/bentonite

fertilizer will physically break down when exposed to moisture or water.

Spill or Leak: Shovel into disposal containers or cover with tarp. For landfill

disposal, mix with limestone 3 times the weight of sulphur.

ANNEXURE - 10

Details of facility for controlling air pollution from manufacturing process and process

plant

A. Air

S.No.

Name of Equipment Attached to Efficiency %

Reduction

Final Concentration of

pollutant being emitted

A. SSP Plant

1. DC bags

Ball Mill for Rock

Grinding

PM – 150 PPM

2. Venturi Scrubber I Den and Mixer for

SSP Manufacturing

3. Separator Scrubber I Venturi Scrubber I

4. Venturi Scrubber II Seperator Scrubber I

4. Separator Scrubber II Ventury Scrubber II

5. Scrubber Fan Separator Scrubber II

6. MSRL Stack 40 meters high Scrubber Fan PM - 150 PPM

Total Fluoride 25 mg / Nm³

B. GSSP Plant

1. Multi-clones Dryer and Cooler

Drums

2. Cyclones Multi Clones

3. Fans Cyclones

4. Stack 30 meters high Fans PM - 150 PPM

C. Sulphuric Acid Plant

1. MIST Eliminator for DT

2. MIST Eliminator for IPAT

3. MIST Eliminators FAT

4. Tail End Gas Scrubber

5. 50 m high stack SO2 4 kgs / MT SA, Acid MIST

50 mg / N m³

6. DCDA Technology

Two stacks of 40 meters height for each SSP plant & one stack of 30 meters height for each GSSP plant are proposed. From

each stack air flow rate shall be 36000 m3/hr. One stack of 50 m high for SAP with air flow of 50000 m³ / hr. is proposed.

These stacks are for:

a. Rock Phosphate Grinding and Drying

b. Scrubber for Acidulation

c. Granulated SSP

d. Sulphuric Acid Plant

FO / Agro waste shall be used as fuel.

B. Water

INDUSTRIAL :

PLANT POLLUTANTS POLLUTION CONTROL MEASURES

SULPHURIC ACID PLANTS DM/SOFTNER/RO PLANT EQUALISED WITH RAW WATER AND USED FOR

REGENERATED WATER

AND THE BACK WASH OF

WATER TREATMENT PLANT

UNITS.

SCRUBBING THE OFF GASES OF SSP PLANTS.

SINGLE SUPER PHOSPHATE PLANTS SCRUBBER LIQUOR i.e.

FLUOROSILICIC ACID

1) USED ALONG WITH CONCENTRATED

SULPHURIC ACID FOR ACIDULATION OF

ROCK PHOSPHATE TO MANUFACTURE

SINGLE SUPER PHOSPHATE FERTILIZER, THIS

ALSO REDUCES SULPHURIC ACID SPECIFIC

CONSUMPTION BY 4.3 KGS PER MT SSP.

2) RCC FRP LINED LAGOON FOR

SCRUBBER LIQUOR.

C. DOMESTIC (25 M³ / DAY):

UTILITIES POLLUTANTS POLLUTION CONTROL MEASURES

ADMINISTRATIVE OFFICE & COLONY DOMESTIC SEWAGE

WATER

1) SEWAGE TREATMENT PLANT TO TREAT

25 M³ / DAY WASTE WATER IS PROPOSED

ON VERMI-CULTURE TECHNOLOGY

INSTALLED AFTER SEPTIC TANK. THE

TREATED WATER IS FREE FROM ODOUR

AND IS BEING USED FOR HORTICULTURE.

D. HAZARDOUS WASTES:

PLANTS WASTES MANAGEMENT OF DISPOSAL

SULPHURIC ACID PLANTS 1) VANADIUM

PENTOXIDE CATALYST

WASTE (CAT 17.20) 3.5

MT/ANNUM

SENT FOR SAFE AND SECURE DISPOSAL TO UTTER

PRADESH WASTE MANAGEMENT PROJECT AT

KANPUR (U.P.). WHICH IS AN AUTHORISED AGENCY

BY UPPCB LUCKNOW.

2) SULPHUR SLUDGE

(CAT 17.10) 230

MT/ANNUM

REUSED WITH ROCK PHOSPHATE FOR ENRICHMENT

OF ELEMENTAL SULPHUR IN SSP FERTILIZER,

WHICH IS RECOGNISED AS FOURTH ESSENTIAL

NUTRIENT FOR AGRICULTURE CROPS IN FCO 1985

REVISION JUNE-03.

SINGLE SUPER PHOSPHATE PLANTS 1. FLUOROSILICIC ACID

(CAT 36.10) 2700

MT/ANNUM (100%)

2. USED LUBRICATING

OIL

3. SPENT RESIN FROM

DM PLANT

USED FOR ACIDULATION OF ROCK PHOSPHATE

WITH SULPHURIC ACID TO MANUFACTURE SSP

FERTILIZER.

TURBINE OIL IS CENTRIFUSED AND REUSED. DG SET

(400 KVA) AND OTHEREQUIPMENTS USING

LUBRICATING OIL IS OPEN DRIVE CHAINS ON DEN,

BUCKET ELEVETORS MIXTURE DRUM ETC.

WITHOUT AFFECTING SOIL CONDITIONS. USED OIL

SHALL BE DISPOSED OFF TO AUTHORISED

RECYCLERES / VENDORS AS APPROVED BY UPPCB,

LUCKNOW.

SHALL BE DISPOSED OFF TO UTTAR PRADESH

WASTE MANAGEMENT PROJECT, KANPUR (U.P.) AS

AND WHEN REPLACEMENT OF RESIN IS DONE.

ACHIEVED ZERO LIQUID DISCHARGE FROM JHANSI WORKS

LIQUID EFFLUENTS ARE TOTALLY RECYCLED BACK INTO PROCESS WITHOUT AFFECTING GROUND WATER QUALITY.

RECYCLE OF SOLID HARZADOUS WASTES IS DONE WITHOUT AFFECTING SOIL CONDITION.

E. SOLID WASTES:

SULPHURIC ACID PLANTS AND SINGLE

SUPER PHOSPHATE PLANTS

1) MS SCRAP

2) POLYETHYLENE/ PLASTIC

3) USED BATTERIES

1) SALE FOR RECYCLE AND

REUSE.

2) SALE FOR RECYCLE AND REUSE

AFTER WASHING IN THE ETP

LAGOON.

3) SELL TO AUTHORISED VENDOR

ONLY.

SOLID HARZADOUS WASTES DISPOSED TO AUTHORISED VENDOR ONLY WITHOUT AFFECTING SOIL CONDITION.-

ANNEXURE 11

DOMESTIC EFFLUENT TREATMENT FACILITY

Filter Feed

Pump

Sump

Horticulture Solid collected

during cleaning

P

S

F

A

C

F

Vermiculture Technology

based treatment plant

Stage I Stage II

Pump Sump Septic tank Domestic waste

ANNEXURE 12

REUSE OF LIQUID EFFLUENT

Drained off liquor

100% Recycling

H2SiF6 liquor

Ov

erflow

SiO2 Solids to SSP Godown

Scrubber

Unit

Lagoon FRP Lined

RCC Pit

Mixer SSP

Process Feed Tank to

Mixer

Raw Water

H2SiF6 liquor Gases from Den/

mixer

ANNEXURE 13

HAZARD AND RISK ANALYSIS OF ACTIVITIES RELATED TO MANUFACTURING PROCESS, STORAGE, HANDLING AND

USE OF CHEMICALS AND RAW MATERIALS FOR SSP, GSSP, SULPHURIC ACID PRODUCTION

Sl.

No.

Activity Hazards Cause Risk Receptor Consequences Frequency Recommendations

1. Operation of

conveyor belts

Accidental

startup of

conveyor

belt

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers/

persons

Low Low Engineering

a. SOP

b. Regular inspection for electrical

connections

Administrative

a. Proper training

b. PPE will be provided and their use will

be made mandatory

c. First-aid box will be available

Spillage of

green SSP or

rock

phosphate

a. Improper

loading

b. Procedure

violation

c. Operator error

a. Exposure to

material

hence skin

irritation

Immediate

workers/

persons

Low Low Engineering

a. SOP

b. Shower to be provided

Administrative

a. Proper training


be made mandatory Contact with

moving parts

a. Safety guard

not provided

b. Not using PPE

a. Contact

with

moving

parts

Immediate

workers/

persons

Low Low Engineering

a. SOP

b. Guard will be provided

Administrative

a. Proper training


be made mandatory

2. Operation of

pumps

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

a. Body injury

Immediate

workers/

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Sl.

No.


Spillage of

sulphuric

acid

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

e. Equipment

failure

a. Body Burn Immediate

workers/

persons

Low Low Engineering

a. SOP


connections

c. Proper inspection for pump, pipe lines,

flanges, union and valves

d. Shower

Administrative

a. Proper training


be made mandatory


d. MSDS will be available at the site

which shall be explained to all

Spillage of

Hydrofluoro

silic acid,

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

e. Equipment

failure

a. Skin

irritation

Immediate

workers/

persons

Low Low Engineering

a. SOP


connections



d. Shower

Administrative

a. Proper training


be made mandatory


d. MSDS will be available at the site

which shall be explained to all

Spillage of

Water

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective

tightness or

incomplete

closing of

valves and

connections

a. Slip and fall

b. Exposure to

contaminate

d water

c. Skin

contact

with

contaminate

d water

Immediate

workers/

persons

Low Low Engineering

a. Proper slope

b. Proper drainage lines to Lagoon



Administrative

a. Proper training

b. Shower

c. SOP

d. PPE will be provided and their use will

be made mandatory

Sl.

No.


e. Not following

SOP

f. Equipment

failure

3. Operation of air

compressor

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

a. Body injury

Immediate

workers/

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Body

contact with

hot parts

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body burn

Immediate

workers/

persons

Low Low Engineering

a. SOP

Administrative

a. Proper training


be made mandatory


d. Signage indicating hot parts

Noise

generation

a. Incorrect

procedure

a. Hearing

loss

Immediate

workers

Low Low Engineering

a. Acoustic enclosure provided

b. Regular inspection

Administrative

a. Proper training

b. Ear muff will be provided and their use

will be made mandatory

c. Signage indicating high noise area will

be displayed

Spillage of

Water

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective

tightness or

incomplete

closing of

a. Slip and fall

b. Exposure to

contaminate

d water

c. Skin

contact

with

contaminate

d water

Immediate

workers/

persons

Low Low Engineering

a. Proper slope

b. Proper drainage lines to Lagoon



Administrative

a. Proper training

b. Shower

c. SOP

Sl.

No.


valves and

connections

e. Not following

SOP

f. Equipment

failure

d. PPE will be provided and their use will

be made mandatory

4. Operation and

maintenance of

dust collection

bag filters

Dust

emission

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lun

g

dise

ase

Immediate

workers/

persons

Normal Low Engineering

a. Regular inspection and maintenance

Administrative

a. Proper training

b. Mask and other PPE will be provided

their use will be made mandatory

5. Operation of

ball mill

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Spillage of

Rock

Phosphate

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lung

disease

Immediate

workers /

persons



Administrative

a. Proper training



6. Operation of

crane

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

a. Body injury

Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

Sl.

No.


violation

Administrative

a. Proper training


be made mandatory


Falling of

object from

height

a. Failure of crane

b. Operator error

c. More load on

crane

d. Procedure

violation

a. Body injury Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

c. Crane with siren

Administrative

a. Proper training


be made mandatory


7. Operation of

bucket elevator

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Falling of

object from

height

a. Failure of crane

b. Operator error

c. More load on

crane

d. Procedure

violation


workers /

persons

Low Low Engineering

a. SOP


connections

c. Crane with siren

Administrative

a. Proper training


be made mandatory


Contact with

moving parts

a. Safety guard

not provided

b. Not using PPE

a. Contact

with moving

parts

Immediate

workers /

persons

Low Low Engineering

a. SOP

b. Guard will be provided

c. Regular inspection

Administrative

Sl.

No.


a. Proper training


be made mandatory

8. Operation of mil

fan

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Falling of

object from

height

a. Failure of fan

b. Operator error

c. Procedure

violation


workers /

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Dust

emission

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lung

disease

Immediate

workers /

persons



Administrative

a. Proper training



9.

Operation of

mixing unit:

Transfer of

sulphuric acid,

spent acid,

hydrofluorosilic

acid, silica

liquor to pits,

Spillage of

acid /

material

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Equipment

failure

e. Handling is

a. Inhalation

of chemicals

b. Skin

contact with

chemicals

hence burn

injury

Immediate

workers /

persons

Moderate Low Engineering

a. Exhaust will be provided

b. Proper equipment designs

c. Regular maintenance and inspection of

transfer pumps, pipelines, valves and

other fittings

Administrative

a. MSDS will be available at the point of

Sl.

No.


solid silica

sludge as

diluents,

operation of

venturi fluorine

gas scrubber

done without

reference to

contents and

MSDS

f. Not using PPE

use and explained to the operator

b. Shower

c. SOP

d. Mask and other PPE will be provided


10. Operation and

maintenance of

furnace unit

Falling from

height

a. Operator error

b. Not using PPE


workers /

persons


a. Hand rail and support structure will be

provided

Administrative

a. PPE will be provided their use will be

made mandatory

Spillage of

FO

a. Operator error

b. Cleaning and

mopping not done

c. Procedure

violation

d. Leakages in

transfer lines

a. Slip and

fall

Immediate

workers /

persons


a. Immediate cleaning and mopping

b. Regular inspection and maintenance of

transfer pump and lines

Body

contact with

hot parts

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body burn

Immediate

workers /

persons

Low Low Engineering

a. SOP

Administrative

a. Proper training


be made mandatory


d. Signage indicating hot parts will be

displayed

Sl.

No.


Fire a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body burn

Immediate

workers /

persons

High Low Engineering

a. SOP

Administrative

a. Proper training


be made mandatory


Emission of

fumes

a. Fans not

working

b. Improper

maintenance

c. Operator error

d. Procedure

violation

a. Inhalation

of fumes

Immediate

workers /

persons

Low Low Engineering

a. SOP

b. ID and FD fans will be provided

c. Stack will be provided

d. Exhaust will be provided

e. Regular maintenance and inspection

Administrative

a. Proper training


be made mandatory

11. Operation of

scrubber fan

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers /

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Spillage of

silica liquor

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Equipment

a. Inhalation

of chemicals

b. Skin

contact with

chemicals

hence

Immediate

workers/

persons

Low Low Engineering





other fittings

Sl.

No.


failure

irritation

c. Slip and

fall

Administrative

a. Shower

b. SOP

c. Mask and safety shoes will be provided


12. Cleaning of

scrubber tower

and tanks

Falling from

height

a. Operator error

b. Not using PPE


workers/

persons


a. Hand rail and support structure will be

provided

Administrative

a. PPE will be provided their use will be

made mandatory

Spillage of

silica liquor

a. Personnel‟s

error

b. Incorrect

procedure

c. Procedure

violation

d. Not using PPE

a. Inhalation

of chemicals

b. Skin

contact with

chemicals

hence

irritation

c. Slip and

fall

Immediate

workers/

persons

Low Low Engineering





other fittings

Administrative

a. Shower

b. SOP

c. PPE and safety shoes will be provided


13. Operation of

screw conveyors

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Body injury

Immediate

workers/

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Spillage of

dust

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

a. Lung

disease

Immediate

workers/

persons



Administrative

a. Proper training



Sl.

No.


f. Equipment

failure

Slippage

during

handling

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

a. Slip and

fall hence

body injury

Immediate

workers/

persons



Administrative

a. Proper training

b. PPE and safety shoes will be provided


14. Operation of

rotary valves

Spillage of

ground rocks

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lung

disease

Immediate

workers/

persons



Administrative

a. Proper training



15. Operation of den Spillage of

SSP slurry

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Breathing

problem

Immediate

workers/

persons



Administrative

a. Proper training



Generation

of fumes

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

e. Defective tools

f. Defective

equipments

g. Equipment

failure

a. Lung

disease

Immediate

workers/

persons



Administrative

a. Proper training



17. Operation of Accidental a. Operator error a. Body injury Immediate Low Low Engineering

Sl.

No.


vibrating screen startup

b. Incorrect

procedure

c. Procedure

d. violation

workers/

persons

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Spillage of

material

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lung

disease

b. Body injury

due to slip

and fall

Immediate

workers/

persons



Administrative

a. Proper training

b. Mask and safety shoes will be

provided their use will be made

mandatory

18. Operation of

crushers

Accidental

startup

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

a. Body injury

Immediate

workers/

persons

Low Low Engineering

a. SOP


connections

Administrative

a. Proper training


be made mandatory


Spillage of

material

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Defective tools

e. Defective

equipments

f. Equipment

failure

a. Lung

disease

b. Body injury

due to slip

and fall

Immediate

workers/

persons



Administrative

a. Proper training

b. Mask and safety shoes will be

provided their use will be made

mandatory

19. Operation and

use of electrical

Exposure to

live wire

a. Missing earth

b. Operator error

c. Electrical

shock may

Immediate

Worker / person

High Low Engineering


Sl.

No.


control panel

and appliances

c. Not using PPE

be fatal b. Earthing will be checked regularly for

continuity

Administrative

a. Proper training

b. Use of gloves will be made mandatory

20. Use and

handling of

chemicals

Spillage,

leakage and /

or exposure

to material

/ potent

chemicals

a. Operator error

b. Incorrect

procedure

c. Procedure

violation

d. Equipment

failure

a. Cuts

b. Inhalation

or skin

contact of

chemicals

c. Burn injury

Immediate

workers/

persons

Moderate Low

Engineering

a. Proper design of equipments and tools

b. Regular inspection of chemical transfer

pumps, lines, valves, etc.

Administrative

a. Proper Training

b. Shower

c. SOP

Cleaning the

spills and

leakages

Land and

water

pollution

Premises High Low Engineering

a. Drainage line to ETP

b. Operational ETP

21. Cleaning of

tanks, pipeline,

storage vessels,

Slippage

during

handling

a. Operator error

b. Incorrect

procedure

c. Procedure

d. violation

a. Slip and

fall hence

body injury

Immediate

workers/

persons



Administrative

a. Proper training

b. PPE and safety shoes will be provided


Draining

contaminate

d water

Environmenta

l

Land and

water

pollution

Premises High High a. Drainage line to ETP

b. Operational ETP

ANNEXURE - 14

ENVIRONMENTAL MANAGEMENT PLAN

Environmental Management Plan (EMP) of the organization will ensure that the residual environmental impacts are minimized by adopting best possible economically viable techniques. The EMP has also to ascertain compliance with all statutory conditions.

A comprehensive plan has been worked out keeping in view these requirements.

The environmental management plan shall be directed to the following:

a. Insuring the operations of various process units as per specified operating guidelines/operating manuals.

b. Strict adherence to maintain schedule for various machinery/equipments/road repair and maintenance.

c. Good house keeping practices.

d. Periodic and planned environmental monitoring.

1. Overview of the Project Site

The project site is in the village Farhad Somni, Distt. & Teh.: Rajnandgaon (CG.) Attached maps shows land use within a 1 and 10 km radius of the site under consideration. Nearest airport is Raipur and the nearest railway station is Rajnandgaon (CG.). The estate does not have any environmentally sensitive areas. It has adequate infrastructure, such as roads, water supply, and electricity supply. The Project will require no new infrastructure.

Climate

This region of C.G. has four distinct seasons: winter (December–March), summer (April–June), rainy season (July–September), and monsoon season (October–November). Air temperatures range from an average daily maximum around 45 C, normally recorded in April and May, to an average daily minimum around 13 C in the winter. Relative humidity is quite high, exceeding 70% during rainy season. The sky is mostly cloudy during the rainy season and less cloudy in the post–monsoon months, with clear sky during the other months of the year. Wind speeds are generally low, though they accelerate during the latter part of summer and early southwest monsoons. Wind speeds range from calm to more than 24 km per hour.

(a) Impact on Land Use and Soil

The project is coming up in the existing premises of KCFL. The area has been marked for the industrial activities. Thus the land use will not change due to the proposed industrial activity. The area will not undergo any topographical changes.

During Construction Phase To avoid erosion of the top soil the development is planned in the shortest possible time and land-clearing activity shall be kept to the absolute minimum by working at the specific sites one by one where construction is to take place so as to increase detention and infiltration. The activities that result in soil being laid bare shall be scheduled in such a way that some type of vegetative cover appropriate to the site shall be established. Natural waterways/drainage pattern shall be maintained by providing culverts where needed.

The solid waste generated from the construction activities shall be effectively recycled within the project. The requirements of sand and aggregates for the construction works will be met from in and around area, where, these are taken out from seasonal rivulets that get replenished annually.

For the development works the use of wood shall not be allowed (Timber Free Construction) and shall be replaced by Mild Steel, Aluminium, Glass and Plastic.

During Operational Phase

Management has planned to develop thick green belt in the area and hence there is low level of weathering and soil erosion. M/s Khaitan Chemical & Fertilizers Limited will take appropriate action for plantation inside and outside the

premises. Due to the proposed programme and project, the topographic features shall remain unaffected and unaltered. The more and thick plantation in the area shall create a positive impact to the landscape and shall help in the reduction of barren land. This will not only reduce soil erosion but shall also act as air purifier and control the air pollution further.

The various solid wastes will be collected at the point of origin and will be disposed off through the registered vendor. Thus there is little or no chance for land pollution due to solid wastes. For on-site storage of solid waste, management has already planned a proper arrangement. The manufacturing of Single Super Phosphate & Granulated Single Super Phosphate do not generate any solid or hazardous waste. Entire dust, slurry, etc from pollution control equipments will be reused in the process. Solid waste generated from domestic waste water treatment facility shall be used as bio-manure in the factory premises.

(b) Impact on Surface Water

The impact can be discussed under following three sub-heads:

(i) Physical characteristics,

(ii) Chemical Nature and

(iii) Biological Nature.

During Construction Phase

The run-off during development shall be controlled by removing construction related solid waste as malba, loose soil etc. quickly. Further land clearing activity shall be kept to the absolute minimum by working at the specific sites one by one where construction is to take place.


No surface water course exist in the area therefore there will be no effect of mining on the water regime. The ground water structures fall under tube well. Soil permeability studies shall be made prior to discharge of scrubber liquid containing 10 – 12% hydroflorosilicic acid into the holding tanks or lagoons and steps will be taken to prevent percolation and ground water contamination. Organisation has planned RCC structure with FRP lining for lagoon. A septic tank shall be provided with Toilet facilities. Entire domestic waste will be treated through the septic tank. Overflow of septic tank shall be taken into the sewage treatment plant based on vermiculture bio-technology followed by tertiary treatment to meet the requirement of CPCB and CGPCB. Entire treated domestic effluent will be used for gardening and plantation purpose within the factory premises.

There is no generation of liquid effluent from the process. Scrubber liquid and slurry from air pollution control equipments

will be reused in the manufacturing process through a closed loop system. Thus the organization will work on zero

discharge concept.

Both roof top rainwater harvesting and storm water run off shall be tapped for recharging the aquifers and storage.

The analysis of water samples for physical, chemical and biological parameters of the ground water shall be done on half-

yearly basis.

c. Impact on Air Environment


Provision shall be made for sprinkling of water on loose soil to avoid dust generation. The debris and unutilized

construction material and earth from the construction site shall be removed immediately to recycle within the project so

that no nuisance dust is generated due to wind.

The vehicles used during construction activity shall be checked for vehicular emissions.

The steps shall be taken to reduce the impact of noise by taking to plantations from the very beginning. Construction

Activities shall not be allowed at Night.

The mitigation measures shall include regular maintenance of machinery and provision of personnel protective

equipments to workers where needed.


The proposed unit shall have a number of stacks as point source for discharge. These stacks shall be associated with various equipments. These plants and therefore stacks emit fluorides fumes and dust particles. Efficient pollution control equipments having wet scrubbers, cyclones, dust collection bag filters will be installed to arrest fine dust particles and for converting fluorides fumes into hydroflorosilicic acid. Thus the industry will maintain the clean air emission. The emission levels of pollutants from the various stacks would be well within the permissible limits as per CPCB or CGPCB norms.

The 10 – 12% hydroflorosilicic acid generated from wet scrubber will be recycled back to mixer along with concentrated Sulphuric acid by incorporating a Distributed Control System (DCS) / PLC for computerized control of the total process.. In-plant control measures should be taken to contain the fugitive emissions. A Sewage Treatment Plant with tertiary level of treatment is being provided to avoid any odor pollution from the sewage generated. Extensive plantation is planned to mitigate the impact of noise and to improve the ambient air in general. Infrastructural facilities will be provided for monitoring the stack emissions and measuring the ambient air quality. Monitoring of ambient air and stack emission shall be done on monthly basis for various parameters.

d. Noise Environment


Entire construction shall be restricted during day time only.

During Operation Phase

Adequate measures will be taken for control of noise and vibrations in the industry. Equipments and machinery shall be inspected regularly. Regular and routine maintenance will be done. Wherever feasible, acoustic enclosure will be provided to machines creating high noise. Signage will be displayed indicating high noise area. Ear muff and plug will be provided to users. Road side plantations shall be a part of the regular activity to control the noise level.

f. Socio-Economic Environment

With the establishment of industries in this area, the local inhabitants have adopted a western culture. They have now modern electrical and electronic gadgets. The villagers now enjoy good food and they have better choice. The villagers and local inhabitants have better choice for employment. They have all modern communication and transportation facility. These observations and the study indicate positive impact of industries on the socio-economic aspect of the area.

g. Green belt development h.

The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas. The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving the aesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away of topsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and to restore water balance. While making choice of plant species for cultivation in green belts, weight age has to be given priority to the natural factor of bio-climate. It is also presumed that the selected plants will be grown as per normal horticultural (or forestry) practice and authorities responsible for plantation will also make sure that adequate provision for watering and protection of the saplings exists at site. For effective removal of pollutants, it is necessary that:

Plants grow under conditions of adequate nutritional supply (for health and vigor of growth),

Absence of water stress (to maintain openness of stomata apertures and form of epidermal structures),

Plants are well exposed to atmospheric conditions of light and breeze (i.e. away form engineering structures hindering free flow of air) to maintain free interaction with gases.

Selection of plants will also take into consideration:

For absorption of gases:

For removal of suspended particulate matter

The landscaping and green belt will be designed and trees will be planted in open areas, around factory boundary along footpaths and dividers. Treated domestic effluent will be used for watering of plants and trees.

h. Transport Systems

Proper parking places will be provided for the trucks and other vehicles by the industries to avoid any congestion or blocking of roads. Spillage of chemicals/substances or furnace oil on roads inside the plant will be cleaned immediately. Proper road safety signs both inside and outside the plant will be displayed for avoiding road accidents. Vehicles having PUC certificate will be allowed to move inside the factory premises.

i. Disaster Management Planning

Proper disaster planning will be done to meet any emergency situation arising due to fire or explosion, or sudden leakage of gas etc. Fire fighting equipment and other safety appliances will be provided as per the requirement. Regular mock drilling will be done. To avoid any hazards and accidents due to chemical process and storage of chemicals industry has taken following administrative and design controls. (i) Administrative Control

1. Work Instruction 2. Operational Control Procedures i.e., Standard Operating Procedure (SOP) 3. Training to all employees on safety and storage of chemicals 4. Emphasis on segregation of different chemicals and fuels based on flammability, toxicity, hazard nature, oxidization

property etc. 5. On-site Emergency Management Plan will be established 6. Calibration and testing of vessels, gauges, etc shall be done regularly 7. Monitoring of tank during filling and transfer of chemicals and fuels shall be done 8. Acceptable working conditions for operators 9. Emergency services will be provided 10. Emergency escape routes to on-site emergency personnel 11. Control access of unauthorised personnel at the Main Gate 12. Proper warehousing management system 13. Proper labelling of chemical / fuel storage containers

14. Proper recording of inventories of on-site chemcials 15. Marking of emergency escape routes to on-site emergency personnel 16. Chemical inventory system are sufficient to address and categorise hazardous materials into compatible groups 17. Classification and segregation of compatible, hazardous materials to avoid overlap of these areas. 18. Instructions are given that oxidising agents and flammable substances areas will not overlap, strong acids

compound areas will not overlap, peroxides will not be stored near any metallic compounds that could cause decomposition and the liberation of oxygen.

19. Prior approval will be required from Technical Director / Manager – Production / Manager Ware Housing / Manager - QC before carrying out any process.

(ii) Design Control

1. Personnel Protective Equipments will be provided

2. Emergency shower will be provided at all critical points 3. Dyke and confinement for bulk storage of flammable and hazardous chemicals and fuels 4. Proper drain to lagoon and STP 5. Concrete structure with sufficient slope for storage of chemicals and fuels 6. No nearby heat source

7. Fire fighting systems with alarm 8. Wet scrubbers, cyclones, dust collection bag filters to control emissions from various manufacturing operations 9. Lighting protection 10. Earthing pits 11. Operations to start if scrubber is working

The areas containing flammable and toxic chemicals will be sufficiently ventilated

j. Environment Management Cell

To implement the Environment Management Programme, a structured Environment Management Cell (EMC) interwoven with the management system will be created.

EMC will undertake regular monitoring of the environment and conduct yearly audit of the environmental performance during the operational phase. It will also check that the stipulated measures are being satisfactorily implemented and operated. It shall also co-ordinate with local authorities to see that all environmental measures are well coordinated. k. Monitoring Frequency

A comprehensive environmental monitoring program that has been prepared for the purpose of implementation in the proposed project by the EMC is described below:

The frequency of monitoring for air, effluent, water and hazardous waste is as follow:

Ambient air quality shall be monitored on monthly basis for SPM, RSPM, SO2, NOx, and CO.

Ambient noise level shall be monitored on monthly basis at different locations.

Quality of under ground water shall be monitored on half-yearly basis as per IS-10500 standard.

Stack monitoring will be done on monthly basis.

ject report

Education