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Prepared by M/s. ENVIROCARE ENGINEERS & CONSULTANT 201, New Opera House, Nr. Gurudev Petrol pump & Harish Dyeing,

Khatodara, Surat –395 002.

E –mail: [email protected]

Tele: (0261) 2630781 Telefax: (0261) 2630782

mailto:[email protected]�

LIST OF CHAPTERS

Sr. No. Title Page No. TOR & Its Compliance

0.0 Copy of TOR obtained from SEAC -- 0.1 Compliance report of TOR --

Abbreviation --

Chapter 1:- Introduction 1.1 Introduction 1-1 1.2 Basic Information 1-1 1.3 Distance of Nearest Key Infrastructure / Features from Project Site 1-2 1.4 Scope of EIA 1-3 1.5 Methodology of EIA 1-3 1.6 Air Environment 1-5 1.7 Noise Environment 1-5 1.8 Water Environment 1-5 1.9 Land Environment 1-5 1.10 Biological Environment 1-6 1.11 Socio- Economic Environment 1-6 1.12 The EIA Process 1-6 1.13 Statutory Requirement of EIA 1-7 1.14 Structure of the EIA Report 1-7

Chapter 2:- Project Description

2.1 Background 2-1 2.2 Land Distribution at Site 2-1 2.3 Main Phases of the Project 2-5 2.4 Manufacturing Process, Chemical Reaction & Mass Balance 2-16 2.5 Water Balance 2-31 2.6 Sources of Energy 2-33

Chapter 3:- Description of the Environment

3.1 Baseline Environmental Status 3-1 3.2 Establishment of Impact Zone 3-2 3.3 Meteorology 3-2 3.4 Micro-Meteorology of the Area 3-2 3.5 Site Specific Meteorological Data 3-5 3.6 Air Environment 3-8 3.7 Water Environment 3-43 3.8 Ambient Noise Monitoring 3-50 3.9 Soil Quality Monitoring 3-54 3.10 Land Use Pattern 3-61

LIST OF CHAPTERS

3.11 Geological Structure 3-63 3.12 Hydrology 3-64 3.13 Physiography 3-64 3.14 Forest Boundaries 3-65 3.15 Flora 3-67 3.16 Fauna 3-68 3.17 Demographic & Socio Economic Profile 3-70 3.18 Public Amenities 3-78

Chapter 4:- Anticipated Environmental Impact & Mitigation Measures

4.1 Introduction 4-1 4.2 Impact Assessment Matrix 4-1 4.3 Overall Impacts 4-11 4.4 Mitigation Measures 4-14

Chapter 5:- Environmental Monitoring Program

5.1 Details of Measures Proposed for the Online Monitoring & Its Monitoring Plan 5-1

5.2 Details of Provisions for the Work Area Air Quality Monitoring 5-1 5.3 Waste Water Management 5-1 5.4 Solid Waste Management 5-2 5.5 Summary of the Environmental Monitoring Program 5-6

Chapter 6:- Additional Studies

6.1 Objectives 6-1 6.2 Emergency Plan: Structure 6-1 6.3 Policy 6-1 6.4 Planning 6-2

6.5 Consequences of Containment Failure & Release of material into Environment 6-4

6.6 Individual Risk Analysis 6-5

6.7 Details of Hazardous Characteristic & Toxicity of Raw Materials & Products 6-8

6.8 Details of Possibilities of Occupational Health Hazards 6-10

Chapter 7:- Project Benefits 7.1 Green Belt Development 7-1 7.2 Expenditure on Green Belt Development 7-2 7.3 Socio-Economic Benefits 7-3

Chapter 8:- Environmental Management Plan

8.1 Environmental Management Plan 8-1 8.2 Environmental Management Cell 8-2

LIST OF CHAPTERS

8.3 Water Conservation 8-3 8.4 Waste Management 8-5 8.5 Expenditure on Environmental Matters 8-5 8.6 Disaster Management Plan 8-6 8.7 Implementation 8-11 8.8 Emergency Structure & Responsibility 8-11 8.9 Awareness, Training & Competence 8-20 8.10 Communication 8-21 8.11 Emergency Documentation & Document Control 8-25 8.12 Checking & Corrective Action 8-30 8.13 Recommendations 8-33 8.14 Unloading of Tank Trucks 8-34 8.15 Hazardous Waste Transport 8-34 8.16 General Safety Practices 8-35 8.17 Personnel Safety 8-39 8.18 Safety of Plant Equipment 8-40 8.19 Reactors 8-42 8.20 Equipment Safety 8-43 8.21 Emergency Management 8-50 8.22 Emergency Response 8-52 8.23 Details of the Separate Isolated Storage Areas 8-54 8.24 Checklist in Form of Do’s & Don’ts 8-54

8.25 Compliance status of the Existing Unit with Respect to Conditions In Consent of G.P.C.B 8-56

8.26 Details of Past Occurred Fatal/Non Fatal Accidents 8-59 8.27 Details of Any Legal Breach of Environmental Laws 8-59

Chapter 9:- Alternatives (Technology & Site)

9.1 Alternatives 9-1

Chapter 10:- Environmental Cost Benefit 10.1 Environmental Cost Benefits 10-1

Chapter 11:- Summary & Conclusion

11.1 Introduction & Project Justification 11-1 11.2 Purpose of Study 11-1 11.3 Extent of Study & Area Covered 11-2 11.4 Method of Study 11-2 11.5 Project Details 11-2 11.6 Environmental Setting 11-4 11.7 Fuel/ Energy Requirement 11-5 11.8 Water Requirement 11-6 11.9 Baseline Environment 11-7

LIST OF CHAPTERS

11.10 Environmental Impact & Mitigation Measures 11-7 11.11 Environmental Monitoring Program 11-7 11.12 Ambient Air 11-8 11.13 Water Resources 11-10 11.14 Noise Levels 11-10 11.15 Soil/Land Quality 11-10 11.16 Environmental Management Plan 11-10 11.17 Solid & Hazardous Waste Management 11-11 11.18 Green Belt Development 11-12 11.19 Monitoring Schedule 11-12 11.20 Expenditure for Environmental Activities 11-12 11.21 Conclusion 11-12

Chapter 12:- Disclosure of Consultant Engaged

12.1 Consultant Engaged 12-1 12.2 Brief Profile of Consultant 12-1 12.3 Scope of Work 12-1

LIST OF TABLES

Table No Title Page No. Chapter 1:- Introduction

1.1 Nearest Key Infrastructure/ Feature from Project Site 1-2

Chapter 2:- Project Description 2.1 Land Distribution at Site 2-2

2.2A List of Equipment & Machinery 2-4 2.2B List of Utilities 2-5 2.3 Physico-Chemical Properties of Raw Material 2-6 2.4 Physico-Chemical Properties of Product 2-7 2.5 Means of Transportation of Raw Material & Product 2-8 2.6 Storage Details of Raw Material & Product 2-10

2.7 A The List of Raw Material Product wise 2-14 2.7 B List of Product 2-15


3.1 Predominant Wind Direction 3-4 3.2 Mean Meteorological Data During Study Period 3-6 3.3 Details of Ambient Air Quality Monitoring Location 3-9

3.4A Ambient Air Quality Status 3-11 3.4B Cumulative Percentile of PM 3-12 10 3.4C Cumulative Percentile of PM 3-12 2.5 3.4D Cumulative Percentile of SO 3-13 2 3.4E Cumulative Percentile of HF 3-13 3.4F Cumulative Percentile of PM 3-14 2.5 3.5 Technique Used for AAQM 3-14

3.6A Proposed Details of Stack, APCS & Its Emission Estimate 3-15 3.6B Proposed Details of Process Vent, APCS & Its Emission Estimate 3-16 3.7A Result for Fugitive Gas 3-23 3.7B Result for HF Gas 3-27 3.7C Result for NOx 3-31 Gas 3.7D Result for SO2 3-35 Gas 3.7E Result for PM 3-39 3.8 Details of Water Monitoring Locations 3-44

3.9A Ground Water Quality 3-46 3.9B Surface Water Quality 3-48 3.9C Limits For Surface Water 3-49 3.10 Details of Noise Monitoring Locations 3-51 3.11 Noise Level Data 3-53 3.12 Details of Soil Monitoring Locations 3-54 3.13 Soil Classification 3-56 3.14 Physico Chemical Characteristic of Soil 3-58

LIST OF TABLES

3.15 Areas Under Different Landuse 3-61 3.16 Area Statistic of Forest Map 3-66 3.17 Flora Found in Savli Area 3-67 3.18 Fauna Found in Savli Area 3-68 3.19 Demographic Data 3-71 3.20 Population Density 3-72 3.21 Literacy Rate 3-74 3.22 Occupational Structure 3-76 3.23 Details of Amenities Available in Study Area 3-80

Chapter 4:- Anticipated Environmental Impact & Mitigation Measures 4.1 Impact Identification Matrix 4-2 4.2 Environmental Impact Assessment 4-4 4.3 Mitigation Measures 4-15

Chapter 5:- Environmental Monitoring Program

5.1A Total Solid Waste Generation 5-3 5.1B Details of Hazardous Waste Management 5-4 5.2 Environmental Monitoring Plan 5-6

Chapter 6:- Additional Studies

6.1 Event Classification 6-2 6.2 Vulnerability Analysis 6-7 6.3 Details of Hazardous & Toxicity of Raw Materials & Products 6-8 6.4 Details of Occupational Health Hazards 6-10

Chapter 7:- Project Benefits

7.1 Types & Number of Trees to be Planted 7-2

Chapter 8:- Environmental Management Plan 8.1 Environmental Management Cell 8-2 8.2 Detail of Rain Water Harvesting Pits 8-3 8.3 Details of Maximum Strom Water Generated 8-4 8.4 Expenditure on Environmental Matters 8-5 8.5 Applicable EHS regulatory Requirement 8-8 8.6 Type of Fire Accidents & Medium of Extinguisher 8-18 8.7 Composition of Offsite Crisis Group 8-29 8.8 Checklist in Form of Do’s & Don’ts 8-55

8.9 Compliance status of the Existing Unit with Respect to Conditions In Consent of G.P.C.B 8-56

Chapter 11:- Summary & Conclusion

11.1 Proposed Product List 11-3 11.2 Proposed Raw Material List 11-4

LIST OF TABLES

11.3A Total Water Requirement For The Project 11-6 11.3B Total Waste Water Generation For The Project 11-6 11.4 Environmental Monitoring Program 11-7

11.5A Proposed Detail of Stack, APCS & Its Emission Estimate 11-8 11.5B Proposed Emission Rate 11-8 11.5C Proposed Detail of Process Vent, APCS & Its Emission Estimate 11-9 11.5D Proposed Emission Rate for Process Vent 11-9 11.6 Solid & Hazardous Waste Management Requirement 11-11

LIST OF FIGURES

Figure No Title Page No. Chapter 1:- Introduction

1.1 Site Layout Plan 1-4

Chapter 2:- Project Description 2.1 Water Balance Diagram 2-32


3.1 Wind Rose Diagram 3-7 3.2 Location of Ambient Air Quality Monitoring 3-10 3.3 Scrubber Details 3-18

3.4A Guassian Plume Model For Fugitive Gas 3-25 3.4B Air Quality Contour For Fugitive Gas 3-26 3.5A Guassian Plume Model For HF Gas 3-29 3.5B Air Quality Contour For HF Gas 3-30 3.6A Guassian Plume Model For NOx 3-33 Gas 3.6B Air Quality Contour For NOx 3-34 Gas 3.7A Guassian Plume Model For SO2 3-37 Gas 3.7B Air Quality Contour For SO2 3-38 Gas 3.8A Guassian Plume Model For PM 3-41 3.8B Air Quality Contour For PM 3-42 3.9 Location of Water Sampling Station 3-45 3.10 Location of Noise Monitoring Station 3-52 3.11 Location of Soil Sampling Station 3-55 3.12 Land Use Pattern Within Study Area 3-62 3.13 Geology of Gujarat 3-63 3.14 Ground Water Level of Gujarat State 3-64 3.15 Male & Female Within Study Area 3-72 3.16 Population Density & Sex Ratio 3-73 3.17 Literacy Rate 3-75 3.18 Workers Categorization 3-78

Chapter 8:- Environmental Management Plan

8.1 Rain Water Harvesting Pit 8-4

LIST OF ANNEXURES

Annexure No Title

1. Undertaking

2. MoU/Agreement for accepting Fluorosilisilic Acid

3. Compliance of CREP Guidelines

4. Minutes of Public Hearing

\?r""'"

HARDIK SHAHSECRETARY

State Level Exper:t Appraisal CommitteE';

Ref. No.: EIA-1 0-201 0-700-E.b3...2..1}--

To,

~. Agro Fertilizers P Ltd

A-2/3, J.K. Tower, Mazenine Floor,Near Grid, Kabilpore, Navsari - 396 424.Fax: 02637-236494

5TATE LEVELEXPERT APPRAISALCOMMITTEE,GUJARAT.Office: Gujarat Pollution Control Board,

"Paryavaran Bhavan", Sector 1O-A,

Gandhinagar-382010, GUJARATPhone:079 -23232152, 23241514Fax: 079 -23222784.Email: [email protected]: Novemh~ 15,2010.

J ~ NOV 2010

Sub:Environment Clearance under the EIA Notification 2006 for your proposed projectat P.O. Mahapura Tundav Rania Road, Tal. Savli, Dist. Vadodara

Dear Sir,

This refers to your application on the subject mentioned above and the meeting held with the

State Level Expert Appraisal Committee, Gujarat, on 28th Sep, 2010. The relevant information

furnished in Form I, Form IA and presentation made before the SEAC was considered and the

additional information required was communicated to you by the SEAC immediately after the

said presentation. However, a copy of the same is attached herewith for further necessary action

at your end. You may please furnish the desired information / documents to enable us to process

the application further.

With regards,

YO~SinCere~~) "

Secretary, State Level Expert Appraisal Committee

End: As above.

T.J. Aaro Fertilizers P.Ltd., R.S. No. 41/42, P.O. Mahapura, Ta: Savli, Dist: Vadodara.

The project falls under the project activity 5(a) as per the schedule of the EIA notification 2006.Total cost of the proposed expansion is 122.5 lacs. The existing land area of the project is30831 m2 and the proposed expansion will be carried out in the existing premises. Mahi riveris 4.4 km away from the proposed project. Existing water consumption of 8.5 KL/day willincrease upto 32.5 KLD due to the proposed expansion. Process water consumption willincrease due to HzSiF6recovery in water scrubber. No process waste water will be generated.

1.5 KL/day of sewage will be disposed into existing septic tank. Multi Cyclone Separator for 2Nos. of Hot Air Generator and Water Scrubber for process emissions from Den and Mixture,are proposed as APCM. Bio Coal or Industrial Wood (16 MT/day) is proposed to be used asfuel in 2 nos. of Hot Air Generator.

As the proposed project is situated in severely polluted area Vadodara as per CEPI publishedby the MoEF, in view of the MoEF's Office Memorandum no. J-11013/5/2010-IQ.II(I) dated13/01/2010, the Gujarat Pollution Control Board was requested to depute their representativeto provide comments with respect to pollution load in terms of ambient air quality water qualityetc. Shri V. R Ghadge (Env. Engr.) and Shri D. M. Thaker (Dy. Env. Engr.), GPCB attendedthe meeting for this case.

Presentation by the project proponent included general information about the project, plantlayout, google image, plot area break-up, production capacity, list of raw material

consumption, manufacturing process, storage details of raw materials and products, hazardidentification, water consumption, effluent generation, proposed stacks and APCS, hazardouswaste generation and management, EMP, proposed TOR etc.

After detailed deliberation, the project proponent was asked to go through the public

consultation process and following additional ToR were prescribed for the EIA study covering10 Km radius from the project boundary:

1. Project site specific details such as distance of the project site from the nearest (1) Village(2) Water Body: Creek 1Nallah 1Lake 1Pond 1Reservoir 1Canal (3) National Highway (4)State Highway (5) Railway line (6) Heritage site (7) National Park 1Wild Life Sanctuary 1Reserve Forest shall be included in the rapid EIA report to be prepared covering oneseason (other than monsoon) data.

2. Need for the proposed expansion plant shall be justified in detail.

3. Present land use pattern of the study area based on satellite imagery.

4. Demarcation of proposed expansion activities in layout of the existing premises.5. Provision of separate entry, exit and adequate margin all round the periphery for easy

unobstructed movement of fire tender without reversing. Mark the same in the plant layout.6. Detailed manufacturing process along with chemical reactions.

7. Copy of permission obtained from Central Ground Water Authority for withdrawal of groundwater. Detailed study of hydrology of the area. Quality of ground water at site and impactsof ground water withdrawal on hydrology and ground water quality.

8. Detailed mass balance and water balance (including reuse-recycle, if any) alongwithqualitative and quantitative analysis of the each waste stream to be generated from allsources.

9. Specific measures proposed to conserve water and plans for the future in this regard

10. Explore the possibility of reuse / recycle and other cleaner production options to beadopted for reduction of wastes.

11. One season site-specific meteorological data including temperature, relative humidity,hourly wind speed and direction and rainfall shall be provided

12. One complete season AAQ data (except monsoon) to be given along with the dates ofmonitoring. The parametersto be coveredshall includePM1O,PM2.5,S02, NOx,and HF.The location of the monitoring stations should be so decided so as to take intoconsideration the pre-dominantdownwind direction, population zone and sensitive

receptors including reserved forests. There should be at least one monitoring station inthe upwind direction. There should be at least one monitoring station in the pre dominantdownwind direction at a location where maximum ground level concentration is likely tooccur.

13. Impact of the project on the AAQ of the area. Details of the model used and the input theparameters used for modeling should be provided. The air quality contours may be plottedon a location map showing the location of project site, habitation, sensitive receptors, ifany. The wind roses should also be shown on this map.

14. Type, quantity and source of fuel to be used. Undertaking stating that they shall not usewood as a fuel in the Hot Air Generator.

15. Specific details of (i) Process emission from each unit process with its quantification, (ii) Airpollution control measures proposed (iii) Adequacy of the air pollution control measures toachieve the GPCB Norms (iv) Details of the utilities required (v) Flue gas emission rateemission from the utilities along with stack height. (v) Air Pollution Control Measuresproposed to the utilities along with its adequacy (vi) Sources of fugitive emission from theunit along with its quantification and proposed measures to control it.

16. Details of measures proposed for the online monitoring of the pollutants from the processstack and its monitoring plan.

17. Impact of the project on local infrastructure of the area such as on road network due totransportation of fuel, ash etc. Whether any additional infrastructure would need to beconstructed and the agency responsible for the same with time frame.

-

18. Details of flora and fauna duly authenticated should be provided. In case of any scheduled

fauna, conservation plan should be provided.19. Details of management of the hazardous wastes to be generated from the project stating

detail of storage area for each type of waste, its handling, its utilization and disposal etc.How the manual handling of the hazardous wastes will be minimized.

20. Name and address of end consumers to which Fluorosilisilic Acid will be sold. Copies of

agreement I MoU / acceptance letter obtained from them showing their willingness foraccepting Fluorosilisilic Acid.

21. Methodology of de-contamination and disposal of discarded containers and its record

keeping. .

22. Details of measures proposed for the noise pollution abatement and its monitoring.

23. Detailed five year greenbelt development program including annual budget, types &number of trees to be planted, area under green belt development [with map], budgetary

outlay; along with commitment of the management to carry out the tree plantation activitiesoutside the premises at appropriate places in the nearby areas and elsewhere.

24. A detailed EMP including the protection and mitigation measures for impact on humanhealth and environment as well as detailed monitoring plan and environmental

management cell proposed for implementation and monitoring of EMP. The EMP shouldalso include the concept of waste-minimisation, recycle/reuse/recover techniques, energy

conservation, and natural resource conservation. Total capital cost and recurringcosUannum earmarked for environment pollution control measures.

25. An action plan showing list of socio-economic upliftment activities based on socio-economic profile of the surrounding villages and need base field assessment along withthe fund allocation for the five years, shall be incorporated in the EMP.

26. Details of hazardous characteristics and toxicity of raw materials and products to behandled and the control measures proposed to ensure safety and avoid the human healthimpacts. This shall include the details of Antidotes also.

27. Details of quantity of each hazardous chemical to be stored, Material of Construction ofmajor hazardous chemical storage tanks, threshold storage quantity as per schedules ofthe Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardouschemicals. Revised details of capacity and numbers of hazardous chemicals storagetanks, so that storage of hazardous chemicals should be in multiple small capacity tanks /

containers instead of one single large capacity tank for safety purpose. How manualhandling of the hazardous chemicals will be minimized?

28. Occupational health impacts on the workers and mitigation measures proposed to avoidthe human health hazards along with the personal protective equipment to be provided tothe workers. Plan for periodic medical check up of the workers exposed.

29. Measures proposed to be taken for the work zone ambient air quality monitoring as per

Gujarat Factories Rules. Details of equipments / instruments to be deployed to measure,record and analyze workplace exposure.

30. Risk assessment including prediction of the worst-case scenario and maximum credibleaccident scenario related to fire and explosion issues due to storage and use of fuelshould be carried out. The worst-case scenario should take into account the maximum

inventory of storage at site at any point in time. The risk contours should be plotted on theplant layout map clearly showing which of the activities would be affected in case of anaccident taking place. Based on the same, proposed safeguard measures including'emergency management plan should be provided.

31. Submit checklist in the form of Do's & Don'ts of preventive maintenance, strengthening of

HSE, manufacturing utility staff for safety related measures.32. A tabular chart for the issues raised and addressed during public hearing/consultation and

commitment of the project proponent on the same should be provided. An action plan toaddress the issues raised during public hearing and the necessary allocation of funds forthe same should be provided.

33. Details of scheme for surface as well as roof top rain water harvesting and ground water

recharge revealing that quantity of ground water extraction would be compensated byequivalent or more quantity of rain water recharged, with proper scientific calculationsconsidering rainfall in the region, catchment area, land / soil characteristics, ground waterrecharge rate, duration of rain water harvesting etc. Details of provisions of pre-treatmentof the rainwater in the case of surface run off is to be harvested. Location of recharge

percolation wells on tne layout plan.34. Plan for compliance of the CREP guidelines for the proposed plant.35. Compliance status of the existing unit with respect to various conditions given in the CC&A

of Gujarat Pollution Control Board (GPCB).36. Records of any legal breach of Environmental laws Le. details of showcause notices,

closure notices, closure orders etc. served by the GPCB to the existing unit in last three

years and actions taken then after for prevention of pollution.37. Details of fatal/non-fatal accidents, loss of life or man hours, if any, occurred in the

existing unit in last three years and measures proposed to be taken for avoidingreoccurrence of such accidents in future.

38. Any litigation pending against the project and / or any direction / order passed by any Courtof Law against the company, if so, details thereof

These additional TORs should be considered for the preparation of the draft EIA report inaddition to all the relevant information as per the generic structure of EIA given in Appendix IIIin the EIA Notification, 2006. The draft EIA report shall be submitted to the Gujarat Pollution

Control Board for conducting the public consultation process as per the provisions of the EIANotification, 2006. The project shall be appraised on receipt of the final EIA report.

Compliance of the Term of Reference (TOR)

SR.

NO.

COMPLIANCE COMPLIANCE STATUS REFERENCE/EXPLANATION

1 Project site specific details such as distance of the

project site from the nearest (1) village (2) Water

Body: Creek / Nallah / Lake / Pond / Reservoir /

Canal (3) National Highway (4) State Highway

(5) Railway line (6) Heritage site (7) National

Park / Wild Life Sanctuary / Reserve Forest shall

be included in the rapid EIA report to be prepared

covering one season (other than monsoon) data.

Complied Included in EIA report Please Refer Chapter No 1, Table

1.1, Page No: 1-2.

2 Need for the proposed expansion plant shall be

justified in detail.

Complied Included in EIA report Please Refer Chapter No 11, Para-2,

and Line 3 Page No: 11-1.

3 Present land use pattern of the study area based on

satellite imagery.

Complied Included in EIA report Please Refer Chapter No: 3, Point

3.10, Page No: 3-61.

4 Demarcation of proposed expansion activities in

lay out of the existing premises.

Complied Included in EIA report Please Refer Chapter No: 1, Figure

1.1, Page No: 1-4.

5 Provision of separate entry, exit and adequate

margin all round the periphery for easy

unobstructed movement of fire tender without

reversing. Mark the same in the plant layout.

Complied Included in EIA report For plant layout Please Refer

Chapter No: 1, Figure 1.1. Page No:

1-4

For Assembly point Please Refer

Chapter No: 8 Point 8.8.7 line 2.

Page No: 8-15

For internal road width Please Refer

Chapter No: 8 Point 8.8.10 line 2.

Page No: 8-17

6 Detailed manufacturing process along with

chemical reactions.

Complied Included in EIA report Please Refer Chapter No: 2 Point

2.4 Page No: 2-16

As production of NPK is a

formulation based process in which

no chemical reaction take place only

proportionate mixing will be done.


7 Copy of permission obtained from Central

Ground Water Authority for withdrawal of

ground water. Detailed study of hydrology

of the area. Quality of ground water at site

and impacts of ground water withdrawal on

hydrology and ground water quality.

Not Applicable

As per central Ground Water Board

(CWGB) website our project location

doesn’t fall under their critical or dark

zone area. Thus we don’t require

permission for the same.

The quality of ground water is

summarized in Chapter No. 3, Table

No. 3.9(A) Page No: 3-46 to 3-47.

For Impact on ground water: Please

Refer Chapter No: 4, Point 4.3.3, Page

No: 4-12.

8 Detailed mass balance and water balance

(including reuse-recycle, if any) alongwith

qualitative and quantitative analysis of the

each waste stream to be generated from all

sources.

Complied Included in EIA report Please Refer Chapter No: 2 Point 2.5

& Figure 2.1.Page No: 2-31. The

industry will not produce any

industrial waste water thus quality

analysis of the wastewater will not be

available.

9 Specific measures proposed to conserve

water and plants for the future in this regard.

Complied Included in EIA report Measures for Water Conservation

Please Refer Chapter No: 8 , Point 8.3,

Page No: 8-3

For Conservation of plants

Development of Green Belt is

proposed for details Please Refer

Chapter No: 7, Point 7.1, Page No: 7-1

to 7-2.

10 Explore the possibility of reuse / recycle and

other cleaner production options to be

adopted for reduction of wastes.

Complied Included in EIA report Please Refer Chapter No: 5 Point 5.4

Table 5.1B. Page No: 5-2 to 5-4.

11 One season site-specific meteorological data

including temperature, relative humidity,

hourly wind speed and direction and rainfall

shall be provided.

Complied Included in EIA report Please Refer Chapter No: 3. Point 3.5

Page No: 3-5 to 3-7.

For rainfall data Please Refer Chapter

No: 3. Point No 3.4.3 Page No: 3-4


12 One complete season AAQ data (except

monsoon) to be given along with the dates

of monitoring. The parameters to be covered

shall including PM10, PM2.5, SO2, NOx, and

HF. The location of the monitoring stations

should be so decided so as to take into

consideration the pre-dominant downwind

direction, population zone and sensitive

receptors including reserved forests. There

should be at least one monitoring station in

the upwind direction. There should be at

least one monitoring station in the pre

dominant downwind direction at a location

where maximum ground level concentration

is likely to occur.

Complied included in EIA report Please Refer Chapter No: 3 Point

3.6 to 3.9 Page No: 3-8 to 3-60.

13 Impact of the project on the AAQ of the

area. Details of the model used and the input

the parameters used for modeling should be

provided. The air quality contours may be

plotted on a location map showing the

location of project site, habitation, and

sensitive receptors, if any. The wind roses

should also be shown on this map.

Complied included in EIA report Please Refer Chapter No:3 Point

3.6, Page No: 3-8 to 3-42

14 Type, quantity and source of fuel to be used.

Undertaking stating that they shall not use

wood as a fuel in the Hot Air Generator.

Complied included in EIA report Please Refer Chapter No: 3 Table

3.6A Page No: 3-15

Undertaking Attached as per

Annexure: 1


15 Specific details of (i) Process emission from

each unit process with its quantification, (ii)

Air pollution control measures proposed (iii)

Adequacy of the air pollution control

measures to achieve the GPCB Norms (iv)

Details of the utilities required (v) Flue gas

emission rate emission from the utilities

along with stack height. (vi) Air Pollution

Control Measures proposed to the utilities

along with its adequacy (vii) Sources of

fugitive emission from the unit along with

its quantification and proposed measures to

control it.

Complied included in EIA report For details of

1. Process emission, propose

APCM and its adequacy, flue gas

emission rate &its Source ( i , ii,

iii, v, vi & vii): Please Refer

Chapter No: 3, Table No. 3.6 A

&B Page No: 3-15 to 3-16

2. List of utility Please Refer

Chapter No: 2, Table No. 2.2B

Page No: 2-5.

16 Details of measures proposed for the online

monitoring of the pollutants from the

process stack and its monitoring plan.


5.1, Page No: 5-1

17 Impact of the project on local infrastructure

of the area such as on road network due to

transportation of fuel, ash etc. Whether any

additional infrastructure would need to be

constructed and the agency responsible for

the same with time frame.

Complied The existing unit has enough

facilities for the proposed

expansion. No additional

construction required. No

construction or alternation required

to be done on local infrastructure.

18 Details of flora and fauna duly authenticated

should be provided. In case of any scheduled

fauna, conservation plan should be provided.

Complied included in EIA report Please Refer Chapter No: 3 Table

3.17 & 3.18 Page No: 3-68 to 3-70


19 Details of management of the hazardous

waste to be generated from the project

stating detail of storage area for each type of

waste, its handling, its utilization and

disposal etc. How the manual handling of

the hazardous wastes will be minimized.


No. 5.4 Page No: 5-3

20 Name and address of end consumers to

which Fluorosilisilic Acid will be sold.

Copies of agreement / MoU / acceptance

letter obtained from them showing their

willingness for accepting Fluorosilisilic

Acid.

Complied For copy of agreement please refer

Annexure 2

21 Methodology of de-contamination and

disposal of discarded containers and its

record keeping.


No. 5.4.2 Page No: 5-5

22 Details of measures proposed for the noise

pollution abatement and its monitoring.



23 Detailed five year greenbelt development

program including annual budget, types &

number of trees to be planted, area under

green belt development [with map],

budgetary outlay; along with commitment of

the management to carry out the tree

plantation activities outside the premises at

appropriate place in the nearby areas and

elsewhere.

Complied included in EIA report For five years green belt plan :

Please Refer Chapter No: 7 Point

No. 7.1.3, Page No: 7-1


24 A detailed EMP including the protection and

mitigation measures for impact on human

health and environment as well as detailed

monitoring plan and environmental

management cell proposed for

implementation and monitoring of EMP.

The EMP should also include the concept of

waste-minimisation, recycle/reuse/recover

techniques, energy conservation, and natural

resource conservation. Total capital cost and

recurring cost/annum earmarked for

environment pollution control measures.


No 5.5 Table No. 5.2 Page No: 5-6

(Environmental Monitoring

Schedule)

Please Refer Chapter No: 8 Page

No:8-2 to 8-6.

25 An action plan showing list of socio-

economic upliftment activities based on

socio-economic profile of the surrounding

villages and need base field assessment

along with the fund allocation for the five

years, shall be incorporated in the EMP.


No. 7.3, Page No: 7-3

26 Details of hazardous characteristics and

toxicity of raw materials and products to be

handled and the control measures proposed

to ensure safety and avoid the human health

impacts. This shall include the details of

Antidotes also.



Only two raw materials (H2SO4 &

H2SiF6) will have hazardous

characteristic.

For MSDS Please Refer Chapter

No: 6 Point No. 6.10 Page No: 6-13


27 Details of quantity of each hazardous

chemical to be stored, Material of

Construction of major hazardous chemical

storage tanks, threshold storage quantity as

per schedules of the manufacture, Storage &

Import of Hazardous Chemicals Rules of

major hazardous chemicals. Revised details

of capacity and numbers of hazardous

chemicals storage tanks, so that storage of

hazardous chemicals should be in multiple

small capacity tanks / containers instead of

one single large capacity tank for safety

purpose. How manual handling of the

hazardous chemicals will be minimized?

Complied included in EIA report Please Refer Chapter No:2, Table

No. 2.6 Page No: 2-10 to 2-13

28 Occupational health impact on the workers

and mitigation measures proposed to avoid

the human health hazards along with the

personal protective equipment to be

provided to the workers. Plan for periodic

medical check up of the workers exposed.

Complied included in EIA report For occupational health checkup &

its periodic plan: Please Refer

Chapter No: 6 Point No. 6.9 Page

No: 6-13

29 Measures proposed to be taken for the work

zone ambient air quality monitoring as per

Gujarat Factories Rules. Details of

equipments / instruments to be deployed to

measure record and analyze workplace

exposure.

Complied included in EIA report Please Refer Chapter No:5, Point

No 5.1 Page No: 5-1

Yearly Monitoring contract given to

the environmental consultant for the

monitoring of all the parameters as

per the time framed mention in

Environmental Monitoring Program

Schedule.


30 Risk assessment including prediction of the

worst-case scenario and maximum credible

accident scenario related to fire and

explosion issues due to storage and use of

fuel should be carried out. The worst-case

scenario should take into account the

maximum inventory of storage at site at any

point in time. The risk contours should be

plotted on the plant layout map clearly

showing which of the activities would be

affected in case of an accident taking place.

Based on the same, proposed safeguard

measures including emergency management

plan should be provided.

Complied included in EIA report Please Refer Chapter No: 6 Page

No: 6-1

31 Submit checklist in the form of Do’s &

Don’ts of preventive maintenance,

strengthening of HSE, manufacturing utility

staff for safety related measures.


No: 8.24 Table No: 8.8 Page No: 8-

54.

For strengthening of HSE Please

Refer Chapter No: 8 Point No: 8.2

& For Utility staff refer Table No:

8.1.Page No: 8-2.

32 A tabular chart for the issue raised and

address during public hearing/consultation

and commitment of the project proponent on

the same should be provided. An action plan

to address the issues rose during public

hearing and the necessary allocation of

funds for the same should be provided.

Complied included in EIA report Please refer Annexure 4 attached


33 Details of scheme for surface as well as roof

top rain water harvesting and ground water

recharge revealing that quantity of ground

water extraction would be compensated by

equivalent of more quantity of rain water

recharged, with proper scientific calculations

considering rainfall in the region, catchment

area, land / soil characteristics, ground water

recharged rate, duration of rain water

harvesting etc. Details of provisions of pre-

treatment of the rainwater in the case of

surface run off are to be harvested. Location

of recharged percolation well on the layout

plan.


No. 8.3.1 Page No: 8-4

34 Plan for compliance of the CREP guidelines

for the proposed plant.

Complied All applicable points included in the

EIA report. Compliance report of

the CREP guidelines attached as per

Annexure 3

35 Compliance status of the existing unit with

respect to various conditions given in the

CC&A of Gujarat Pollution Control Board

(GPCB).

Complied included in EIA report Please Refer Chapter No:8 Page No:

8-56


36 Records of any legal breach of

Environmental laws i.e. details of show-

cause notices, closure notices, closure order

etc. served by the GPCB to the existing unit

in last three years and actions taken then

after for prevention of pollution.

Complied Please Refer Chapter No:8 Page No:

8-59

No legal breach of environmental

laws till date observed.

37 Details of fatal / Non-fatal accidents, loss of

life or man hours, if any, occurred in the

existing unit in last three years and measures

proposed to be taken for avoiding

reoccurrence of such accidents in future.

Complied included in EIA report Please Refer Chapter No:8 Page No:

8-59. Since factory has not started

its production yet no accidents are

recorded for which measures can be

proposed for avoiding its

reoccurrence.

38 Any litigation pending against the project

and / or any direction / order passed by any

Court of Law against the company, if so,

details thereof

Complied As per the knowledge of the

authorized persons there are no

pending litigations against the

project /company.

M/s. T.J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011

ABBREVIATION

SR. NO ABBREVIATION FULL FORM

1. AAQM Ambient Air Quality Monitoring 2. Ac Adult Literacy Class 3. BS Bus Station 4. C College 5. C Canal 6. CHW Community Health Worker/Health Worker 7. CONC Concentration 8. CPCB Central Pollution Control Board 9. CWC Child Welfare Centre 10. D Dispensary 11. DA Ayurvedic Dispensary 12. DAP Di-Ammonium Phosphate 13. EA Electricity for all purposes 14. EAG Electricity for Agriculture 15. ED Electricity for domestic 16. ENGG Engineering 17. EO Electricity for other purpose like Industrial, Commercial etc 18. F.G Finished Good 19. FP Foot Path 20. FPC Family Planning Centre 21. FWC Family Welfare Centre 22. GNVFCL Gujarat Narmada Valley Fertilizer Corp. LTD. 23. GPCB Gujarat Pollution Control Board 24. GR. FL Ground Floor 25. GSSP Granulated Single Super Phosphate 26. H Matriculation or Secondary 27. H Hospital 28. H.V High Velocity 29. HDPE High Density Poly Ethylene 30. HP Hand Pump 31. I Industrial School 32. I.D Induced Draft 33. IPL Indian Potash Ltd. 34. KR Kuchcha Road 35. LAB Laboratory 36. LCM Light Calcined Magnesite 37. M Middle School 38. MAINT. Maintenance 39. MCW Maternity & Child Welfare 40. MH Maternity Home

M/s. T.J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011

ABBREVIATION

41. MOP Magnesium Oxide Phosphate 42. MR Mud Road 43. MS Mild Steel 44. N Nallah 45. N.P.K Nitrogen, Phosphorus and Potassium 46. NA Not Applicable 47. NAAQS Nation Ambient Air Quality Standards 48. NH Nursing Home 49. NW Navigable Waterway 50. O Other Educational Institution 51. O Others 52. P Primary School 53. PH Telephone Connection 54. PHC Primary Health Centre 55. PHC Public Health Centre 56. PHS Primary Health Sub-Centre 57. PM Particulate Matter 58. PO Post Office 59. PR Pucca Road 60. PSSP Powder Single Super Phosphate 61. PTO Post & Telegraph Office 62. PUC Senior Secondary School 63. QCD Quality Control Department 64. R River Water 65. R.M Raw Material 66. RCC Reinforce Concrete Cement 67. RCF Rashtriya Chemical Fertilizer 68. RSMML Rajasthan State Mines & Minerals Ltd. 69. RMP Registered Private Practitioner 70. RO Regional Officer 71. RS Railway Station 72. S Higher Secondary School 73. S Spring 74. SSP Single Super Phosphate 75. T Tap Water 76. TB T.B Clinic 77. TK Tank Water 78. TO Telegraph Office 79. Tr Training School 80. TVA Tennenanse Valley Authority 81. TW Tube well Water 82. W Well Water 83. WP Water Proof

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011____

CHAPTER 1 INTRODUCTION

[1-1]

1.1 Introduction:

Unit is located in R.S. NO: 41/42, P.O. Mahapura, Tundav Rania Road, Taluka Savli,

District Vadodara of Gujarat State.

Unit is producing Magnesium Sulphate (MgSO4

1. Name of the Unit : M/s. T.J. Agro Fertilizers Pvt. Ltd.

) & Filler (by product) at above location.

To expand our business strength in middle of Gujarat, we intend to produce new products

namely NPK granulated mixed fertilizers, single super phosphate powder, single super

phosphate granulated & Fluorosilisilic Acid (by product) in addition of old products.

We have a valid CC& A for the existing above products & will apply to get NOC from

GPCB for new production facility.

1.2 Basic Information

2. Location of the project : R.S. No. 41/42, At: Mahapura, Tundav Rania Road,Ta: Savli, Dist: Vadodara, Pin: 391 770, Gujarat.

3. Nearest Airport : Baroda Domestic Airport, Approximate Dist: 18.3 Km 4. Nearest Railway Station : Vasad Railway Station, Approximate Dist. 10.8 Km 5. Area of the Project : 30,831 Meter Square.

6. Expected Cost of the Project : 106.50 lacs Existing

122.50 lacs for proposed expansion

M/s. T.J. Agro Fertilizers Pvt. Ltd is about 24 – 25 km from Vadodara, which is the 3rd

district in terms of population in the state.

The economy of the district basically depends on agriculture as 53 % workers are engaged

in primary sector. Apart from agriculture activity production of Basic chemicals and

Chemical products, Machinery & Equipments other than transport equipments, Rubber,

Plastic, Petroleum and Coal products processing, Metal and their parts manufacturing are

the most important non- agriculture economic activities of the district.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011________ CHAPTER 1 INTRODUCTION

[1-2]

1.3 Distance of Nearest Key Infrastructure Features from Project Site

The distance of nearest infrastructure features are presented in Table 1.1 below

TABLE – 1.1 NEAREST KEY INFRASTRUCTURE FEATURE FROM PROJECT SITE

Sr. No. Nearest Infrastructure Feature Distance from Project Site

1. Vasad Village 10.3 km

2. Vasad Railway Station 10.8 km

3. Mahi Sagar River 7.4 km

4. Sardar Patel Institute 8.6 km

5. Haridham Temple 8.6 km

6. National Highway No. 8 8.18 km

7. State Highway No. 11 19.74 km

8. Velavadar National Park 123.10 km

9. Jambughoda Wildlife Sanctuary 60.50 km


[1-3]

1.4 Scope Of EIA

The scope of the study includes detailed characterization of the status of environment in

an area of 10 km radius around M/s. T.J. Agro Fertilizers Pvt. Ltd for identifying

environmental components, viz. air, noise, water, land, biological and socio-economic.

Under the scope of EIA, it is envisaged

• To assess the present status of air, noise, water, land, biological and socio-economic

components of environment

• To identify and quantify significant impacts of various operations on environmental

components

• To evaluate existing and proposed pollution control measures

• To prepare Environmental Management Plan (EMP) outlining additional control

technologies to be adopted for mitigation of adverse impacts

• To evaluate existing Environmental Quality Monitoring Programme and suggest

strengthening of existing monitoring Programme keeping in view pollution potential

of the proposed project.

1.5 Methodology of EIA

Keeping in view the nature of activities envisaged, size of the existing industries in the

region and various environmental guidelines available, it was decided to cover an area of

10 km radius (As per guidelines of EIA) from the center of the M/s. T.J. Agro Fertilizers

Pvt. Ltd for the purpose of environmental impact assessment studies.


[1-4]

The general plot plan for the plant area is shown in Figure 1.1.

FIGURE: 1.1 SITE LAYOUT PLAN


[1-5]

1.6 Air Environment

Ambient air quality status with respect to parameters like Suspended Particulate Matter

(PM10), Particulate Matter (PM2.5), Sulphur dioxide (SO2), Hydrogen Fluoride (HF) and

Oxides of Nitrogen (NOx) has been established. SO2, NOx, PM10, PM2.5 and HF were

monitored on 24 hourly average bases. Gaussian dispersion model was developed and used

to predict likely changes in ambient air quality due to proposed units. The data on

meteorological and microclimatic parameters collected at project site during winter season

was used for mathematical modeling. The prediction exercise was carried out for NOx,

PM10, PM2.5, HF and SO2

1.7 Noise Environment

Noise levels were measured in the premises of M/s. T.J. Agro Fertilizers Pvt. Ltd and

several locations in the human settlements around the plant at different times of the day

using precision noise level meter. Noise levels are predicted using empirical mathematical

equations to estimate probable increase in noise levels due to proposed project.

. Based on the results of the prediction exercise mitigation

measures are suggested.

1.8 Water Environment

Information on water resources (Ground/Surface) was collected. Parameters of prime

importance were selected under physical, chemical inorganic, chemical organic, nutrient

and heavy metal categories to describe baseline environmental status. Samples were

collected at selected locations in and around the plant to determine the surface and ground

water quality. Water requirement for various units was also estimated.

1.9 Land Environment

Surface soil samples from the plough layer depth (15-20 cms) were collected for

determination of the physico-chemical properties of the soils. The baseline data was used in

assessing the impacts of the project on land environment.


[1-6]

1.10 Biological Environment

Study of vegetation was carried out within 10 km radius around M/s. T.J. Agro Fertilizers

Pvt. Ltd. site. Observations were made at different sampling points and qualitative as well

as quantitative analysis of the vegetation was carried out. Presence of various types of

animal species was recorded. Field observations were used for calculating indices. Survey

of Avifauna was carried out with the help of binocular and field identification guide.

Information related to social forestry, tree plantation programmes, indigenous fauna,

endangered animals was also collected. For assessing the biological and bacteriological

quality, observations were made with the help of bacteriological, phytoplankton,

zooplankton counts and different indices were calculated. Species of fishes available in the

study area were also recorded.

1.11 Socio-Economic Environment

Existing baseline status of the socio-economic profile of the study area with reference to

demographic structure, provision of basic amenities, health status incorporating morbidity

pattern, economy, social welfare programmes in the nearby rural areas as well as

infrastructural facilities to the employees being implemented by the M/s. T.J. Agro

Fertilizers Pvt. Ltd. management was studied. A socio-economic survey in villages located

within 10 km radius study area was also undertaken to study the people's perceptions about

the proposed plant operations as well as their opinion and aspirations about the proposed

project activity.

1.12 The EIA Process

The EIA process comprises of the following phases:

• Screening • Scoping and consideration of alternatives • Baseline data collection • Impact prediction • Assessment of alternatives, delineation of mitigation measures and environmental

impact statement • Public hearing • Environment Management Plan • Decision making • Monitoring the clearance conditions


[1-7]

1.13 Statutory Requirement of EIA

Every anthropogenic activity has some impact on the environment. More often it is harmful

to the environment than benign. However, mankind as it is developed today cannot live

without taking up these activities for his food, security and other needs. Consequently,

there is a need to harmonize developmental activities with the environmental concerns.

Environmental impact assessment (EIA) is one of the tools available with the planners to

achieve the above-mentioned goal.

The objective of EIA is to foresee the potential environmental problems that would arise

out of a proposed development and address them in the project's planning and design stage.

The EIA process should then allow for the communication of this information to:

• The project proponent;

• The regulatory agencies; and,

• All stakeholders and interested groups.

EIA integrates the environmental concerns in the developmental activities right at the time

of initiating for preparing the feasibility report. In doing so, it can facilitate the integration

of environmental concerns and mitigation measures in project development. EIA can often

prevent future liabilities or expensive alterations in project design.

1.14 Structure of the EIA Report

Chapter 1: Introduction

Chapter 2: Project Description

Chapter 3: Description of the Environment

Chapter 4: Anticipated Environmental Impact & Mitigation Measures. Chapter 5: Environmental Monitoring Program

Chapter 6: Additional Studies

Chapter 7: Project Benefits

Chapter 8: Environmental Management Plan

Chapter 9: Analysis of Alternatives (Technology & Site)

Chapter 10: Environmental Cost Benefit Analysis

Chapter 11: Summary & Conclusion

Chapter 12: Disclosure of Consultants engaged

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat January-2011

CHAPTER 2 PROJECT DESCRIPTION

[2-1]

PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES 2.1 BACKGROUND At present the unit is producing Magnesium Sulphate (MgSO4

2.2 LAND DISTRIBUTION AT SITE

) & Filler (by product) at

above location. To expand our business strength in middle of Gujarat, we intend to

produce new products namely NPK granulated mixed fertilizers, Single Super

Phosphate powder, Single Super Phosphate granulated & Fluorosilisilic Acid in

addition of old products. We have a valid CC& A for the existing above products &

will apply to get NOC from GPCB for new production facility.

Land:

The unit is located at R.S. NO: 41/42, P.O. Mahapura, Tundav Rania Road, Taluka

Savli, District Vadodara of Gujarat State. No additional land will be required for

proposed production. Addition of proposed products will be done in existing premises

only. Area breakup provided in Table No. 2.1.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat January-2011 CHAPTER 2 PROJECT DESCRIPTION

[2-2]

TABLE 2.1 LAND DISTRIBUTIONS AT SITE

ROOM NO. NAME OF SECTION AREA

(M2SEC AREA

(M) 2)

(A) RAW MATERIAL SECTION

R.M. Store (Under test) 2200 70 X 25 (PSSP/ GSSP)

30 X 15 (N.P.K)

R.M. Rejected --

(B) PACKING MATERIAL SECTION

P.M. Store 480 40 X 12

(C ) FINISHED GOOD SECTION

Quarantine 1250 50 X 25 (PSSP curing)

50 X 15 (PSSP/ GSSP)

50 X 15 (N.P.K)

10 X 10

F.G.Store 1500

F.G.Recall 100

(D) MANUFACTURING AREA

Packing Room (WP) NA

60 X 20 (PSSP PLANT) 30 X 16 (GSSP) 30 X 16 (N.P.K)

Centrifuge Area NA

Pulvariser Room (WP) NA

Drier Room (WP) NA

Mfg Area – A (GR FL) 2160

Mfg Area – B (GR FL) --


[2-3]

(E) C.H. ROOM, ENGG ROOM E.T.C.

Male Room 15.55 4.26 X 3.65

Entrance Lobby Cum Lounge 36.0 6 X 6

Extra Room 27.81 4.26 X 6.53

Electrical Panel Room 80.0 10.0 X 8.0

(Main dist. Panel)

Extra Room 55.3 7.9 X 7.4

Engg & Maint. Room 75.0 15.0 X 5.0

Scrap Yard 120.0 20.6 X 5.0

Clerical Office 84.0 6.0 X 7.0

(Ground & First Floor)

Director office Cum Board Room 32.0 4.0 X 8.0

Pantry 6.0 2.0 X 3.0

(F) QUALITY CONTROL SECTION

Chemical Lab. 40.0 10.0 X 4.0


[2-4]

TABLE 2.2A LIST OF EQUIPMENT & MACHINERY

SR. NO.

NAME OF EQUIPMENT

MAKE

MOC CAPACITY MOTOR HP

1. MIXER MEGHVEE M.S./BL/LL 18 MT/ HR 30

2. DEN MEGHVEE M.S 20 MTS. 25

3. CUTTER -- M.S -- 15

4. CONVEYERS -- -- -- 90

5. GRINDING MILL

USHA M.S 15 MT/HR 400

6. H.V. JET EJECTOR

-- PP/FRP -- 15

7. VENTURY SCRUBBER

-- PP/FRP -- 15

8. CYCLONE -- PP/FRP -- --

9. CHIMNEY -- PP/FRP -- --

10. GRANULATOR (Rotary Drum)

-- M.S. 5 MT/HR 20

11. ELEVATOR -- M.S. -- 15

12. SCREENS -- M.S. -- 15

13. CHAIN MILL -- M.S. -- 40

14. CONVEYERS -- M.S. -- 20

15. CHIMNEY -- M.S. -- --

16. STORAGE HOPPER

-- M.S. -- --

17. BAG FILTER ENVIROCARE M.S 32 BAGS 1

Note: There will be two sets of same machinery set up for serial no. 11 to 17 (Their

motor HP and section area are mentioned likewise), for granulation of N.P.K. & S.S.P.


[2-5]

TABLE 2.2B LIST OF UTILITIES:

SR. NO.

NAME OF EQUIPMENT

MAKE

MOC CAPACITY MOTOR HP

1. SUCTION BLOWER

KARYASID DHI

M.S./RL 15000 M3 50 /HR

2. DRYER (Rotary Drum)

-- M.S. 5 MT/HR 20

3. COOLER (Rotary Drum)

-- M.S. 5 MT/HR 20

4. HOT AIR GENERATOR

-- M.S./BL -- 15

5. SUCTION BLOWER

-- M.S. 12500 M3 60 /HR

6. SUCTION BLOWER

-- M.S. 12500 M3 60 /HR

7. D.G SET POWERTECH -- 125 KVA --

2.3 MAIN PHASES OF THE PROJECT 2.3.1 Pre Construction Activities: As proposed production of the Agro Fertilizers is within the existing premises, there is

no need to construct any approach road or site access. Roof type Shed (cement) required

for additional products including process machinery. For raw materials & finished

product storage area, we already have extra spare storage capacity. Only ground floor

structure will be constructed for Roof type shed.

2.3.2 Construction Activities: Existing building/premises & plant-machinery will be utilized and extra slab

construction required to meet additional project including process machinery. Area to be

utilized is 1733.74 m2

Manufacturing activities proposed in the project include various processes as a part of

manufacturing Agro Fertilizers. The activities shall also include operation of various

utilities. The manufacturing process is described in details in following sections.

of undeveloped additional land within premises.

2.3.3 Manufacturing Activities:

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat January-2011

CHAPTER 2 PROJECT DESCRIPTION

[2-6]

TABLE 2.3 PHYSICO - CHEMICAL PROPERTIES OF RAW MATERIAL

Sr. No.

Name Formula Molecular

Weight

CAS No. State Color Odor Melting Point

°C

Boiling Point

°C

Packing

1. Diluted Sulphuric Acid (70 %) H2SO 98 4 - Liquid --- -- -- -- Tanker Load

2. Light Calcined Magnasite MgO 41 - Solid Off

white odourless NA NA 50 kg HDPE bags

3. Urea CH4N2 60.06 O 57-13-6 Solid White odourless 132.7 NA 50 kg HDPE bags

4. DAP (NH4)2HPO 132.07 4 7783-28-0 Solid White odourless 155.0 NA 50 kg HDPE bags

5. SSP Ca (H2PO4). H2 252 O 7758-23-8 Solid Grey odourless 109.0 203 50 kg HDPE bags

6. MOP (Potash) KCL 74.55 7447-40-7 Solid White odourless 770.0 1420 50 kg HDPE bags

7. Filler CaMg (CO3) - 2 - Solid White odourless NA NA Loose Truck Load

8. Rock Phosphate Ca3 (PO4) 310 2 7758-87-4 Solid White/brown odourless 1391.0 NA Loose Truck

Load

9. Conc. Sulphuric Acid (98 %) H2SO 98 4 7664-93-9 Liquid Colour

less Acidic NA 290 Tanker Load

10. Fluoro Silisilic Acid (by product) H2SiF6. H2 96 O 16961-83-4 Liquid Colour

less NA NA NA In house


[2-7]

TABLE 2.4 PHYSICO - CHEMICAL PROPERTIES OF PRODUCT

Sr. No. Name Formula Molecular

Weight CAS No. State Color Odor

Melting Point

°C

Boiling Point

°C Packing

1. Magnesium Sulphate MgSO4. 7H2 247 O 7487-88-9 Solid White Odourless 150 -- 25 kg / 50 kg

HDPE Bag

2. Filler (by product) - - - Solid Brown Odourless NA NA 50 kg HDPE Bag

3. NPK Granulated mixed Fertilizers - - - Solid Brown NA NA NA 50 kg HDPE Bag

4. Single Super Phosphate Powder Ca (H2PO4). H2 252 O - Solid white NA NA NA 50 kg

HDPE Bag

5. Single Super Phosphate Granulated Ca (H2PO4). H2 252 O - Solid Grey NA NA NA 50 kg

HDPE Bag

6. Fluoro Silisilic Acid (by product) H2SiF6. H2 96 O 16961-

83-4 Liquid Colour less NA NA NA Tanker Load


[2-8]

TABLE 2.5 MEANS OF TRANSPORTATION OF RAW MATERIAL & PRODUCT

Sr. No. Raw Material

Physical & Chemical Composition Sources of Supply

Means of Transportation

Distance of Supplier from Project Km. Chemical Formula State

RAW MATERIAL

1. Diluted Sulphuric Acid (70 %) H2SO Liquid 4

GNVFCL IND.

SOLVENT By Truck 120

2. Light Calcined Magnasite MgO Solid - By Truck 1380

3. Urea CH4N2 Solid O RCF, IPL By Truck 710

4. DAP (NH4)2HPO Solid 4 RCF, IPL By Truck 710

5. SSP Ca (H2PO4). H2 Solid O CAPTIVE By Truck CAPTIVE

6. MOP (Potash) KCL Solid RCF, IPL By Truck 710

7. Filler CaMg (CO3) Solid 2 CAPTIVE By Truck 430

8. Rock Phosphate Ca3 (PO4) Solid 2 RCCML By Truck 790

9. Conc. Sulphuric Acid (98 %) H2SO Liquid 4

HINDUSTAN ZINC By Truck 570

10. Fluoro Silisilic Acid (by product) H2SiF6. H2 Liquid O INHOUSE BY PUMP &

PIPES WITHIN

PREMISES


[2-9]

FINISHED PRODUCT

Sr. No. Trade Name Chemical Formula Chemical Name State Means of

Transportation

1. INDOMAG MgSO Magnesium Sulphate 4 Solid By Truck

2. - - Filler (by product) Solid By Truck

3. AGROPHOS - NPK Granulated mixed Fertilizers Solid By Truck

4. BAIL (OX) BRAND Ca (H2PO4). H2 Single Super Phosphate Powder O Solid By Truck

5. BAIL (OX) BRAND Ca (H2PO4). H2 Single Super Phosphate Granulated O Solid By Truck

6. - H2SiF6. H2 Fluoro Silisilic Acid (by product) O Liquid By Truck


[2-10]

TABLE 2.6 STORAGE DETAILS OF RAW MATERIAL & PRODUCT

Sr. No. Chemicals State

Consumption /Production (MT/Month)

Hazard Involved

Means of Storage

Capacity of Vessel / Bag/Box

No. of Vessels / bag/Box

Storage Capacity

Max. Qty. of Storage

RAW MATERIAL (EXISTING)

1.

Diluted Sulphuric

acid (70%)

Liquid 375 Yes M.S. Storage Tanks rubber inner lined

Tanker Load

Tanks 5 Nos.

50 MT.

60 MT

2.

Light Calcined

Magnasite

Solid 150 No

Godown RCC structure

A/C sheets roofing

Loose Form in Close

Body Truck

20 Nos. 250 MT.

300 MT.

RAW MATERIAL (PROPOSED)

1. Urea solid 2760 No


A/C sheets roofing

50 KG. HDPE Bags

20 Nos. 1000 MT.

1100 MT.

2. DAP solid 360 No


A/C sheets roofing

50 KG. HDPE Bags

10 Nos. 700 MT.

800 MT.


[2-11]



Hazard Involved

Means of Storage



Storage Capacity


3. SSP

(Single Super Phosphate)

solid 480 No


A/C sheets roofing

50 KG. HDPE Bags

10 Nos. 10000 MT.

11000 MT.

4. MOP (Potash) solid 1626 No


A/C sheets roofing

50 KG. HDPE Bags

10 Nos. 700 MT.

800 MT.

5. Filler solid 1800 No


A/C sheets roofing

50 KG. HDPE Bags

20 Nos. 100 MT.

250 MT.

6. Rock

phosphate

Solid 6000 No


A/C sheets roofing

Loose Form

- 4000 MT.

5000 MT.

7. Diluted

sulphuric acid (70%)

Liquid 3000 Yes HDPE Storage

Tanks Tanker Load

Tanks 5 Nos.

50 MT.

60 MT.

8.

Concentrated sulphuric acid

(98%)

Liquid 1562.50 Yes M.S. storage

Tanks Tanker Load

Tanks 2 Nos.

20 MT.

30 MT


[2-12]



Hazard Involved

Means of Storage



Storage Capacity


9. SSP

Solid 6000 No


A/C sheets roofing

Loose Form

- 6000 MT.

8000 MT.

10. Fluorosilisilic Acid (by product)

Liquid 220 Yes HDPE storage

Tanks -

Tanks 3 Nos.

30 MT

40 MT

PRODUCT (EXISTING)

1. Magnesium Sulphate (MgSO4

Solid )

600 No


A/C sheets roofing

Loose Form

- 600 MT.

700 MT.

2. Filler (by product) Solid 60 No


A/C sheets roofing

Loose Form

- 60

MT. 70

MT.


[2-13]

PRODUCT (PROPOSED)

1.

NPK Granulated Mixed Fertilizers

Solid 6000 No

RCC structure

with slab

50 Kg HDPE Bags

20000 600 MT.

1000 MT.

2.

Single Super Phosphate Powder

Solid 10,000 No

RCC structure with A/C sheets

roofing & impervious

flooring

5O Kg HDPE Bags & Loose

Form for Curing

20000 2000 MT.

3000 MT.

3.

Single Super Phosphate Granulated

Solid 6000 No RCC structure

with A/C sheets roofing

50 Kg HDPE Bags

20000 800 MT.

1000 MT.

4.

Diluted Fluorosilisilic acid (70%)

Liquid 120 Yes HDPE storage

Tanks Tanker Load

TANKS 3 NOS.

30 MT

40 MT


[2-14]

PRODUCT PROFILE

TABLE 2.7[A] THE LIST OF RAW MATERIAL PRODUCTWISE

Sr. No. Name of Raw Material

Existing Quantity

(MT/Month)

Proposed Quantity

(MT/Month)

Total Quantity

(MT/Month) (A) NPK Granulated Mixed Fertilizers

1. Urea Nil 2760 2760

2. DAP Nil 360 360

3. SSP (Single Super Phosphate) Nil 480 480

4. MOP (Potash) Nil 1626 1626

5. Filler Nil 1800 1800

(B) Single Super Phosphate Powder

6. Fluorosilisilic Acid Nil 220 220

7. Rock phosphate Nil 6000 6000

8. Diluted sulphuric acid (70%) Nil 3000 3000

9. Concentrated sulphuric acid (98%) Nil 1562.5 1562.5

(C) Single Super Phosphate Granulated

10. Single Super Phosphate Powder Nil 6000 6000

(D) Magnesium Sulphate (MgSO4)

11. Diluted Sulphuric acid (70%) 375 Nil 375

12. Light Calcined Magnasite

150 Nil 150


[2-15]

TABLE 2.7[B] THE LIST OF PRODUCT

Sr. No. Name of Products

Existing Quantity

(MT / Month)

Proposed Quantity

(MT / Month)

Total Quantity

(MT / Month)

1. NPK Granulated Mixed Fertilizers Nil 6,000 6,000

2. Single Super Phosphate Powder Nil 10,000 10,000

3. Single Super Phosphate Granulated Nil 6,000 6,000

4. Fluro Silisilic Acid (by product) Nil

Total Produce: 340

120 Total Reuse: 220

Total Sell: 120

5. Magnesium Sulphate (MgSO4

600 ) Nil 600

6. Filler (by product) 60 Nil 60


[2-16]

2.4 MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE A.

The following are the equipments/machineries required for the manufacture of Magnesium Sulphate. 1. Acid Storage tank with pump

2. Reactor

3. Settling tanks

4. Weak liquor storage tanks

5. Crystallizers

6. Centrifuge

7. Mother liquor storage tanks

8. Drying yard for Magnesium Sulphate

9. Sludge storing yard

10. Sludge drying yard

11. Filter press

Apart from above, small items like pumps, weighing machine and Bag closer are also

needed.

Equipments/ Machineries

Manufacturing Process Recycled mother liquor & weak Magnesium Sulphate solution from the washing and

fresh water are taken in the reactor up to 2.5.m in height. Approximately 2.5 MT of

L.C.M. is added into the reactor with constant stirring. Sulphuric Acid is added into

the reactor till all the L.C.M. is neutralized. Settling agent is added and the solution is

drained into the settling tanks. After allowing it to settle for above 30 minutes the

solution is filtered through a filter press.

The hot solution from the filter press is drained into the crystallizers where it is cooled

to room temperature with constant stirring.


[2-17]

It is then fed into the centrifuge, where the crystals of Magnesium Sulphate are

separated from the mother liquor. The mother liquor is taken back to the reactor for the

next batch. Water is pumped to the settling tank and the impurities left in the settling

tank are leached 4 or 5 times with water till it is free from Magnesium Sulphate. Then

it is filtered through a filter press and stored in weak solution tanks. The filter cake

obtained in the filter press is dried in the drying yard along with the un-reacted ore

removed from the settling tank periodically, pulverized, packed, stored and sold. The

Magnesium Sulphate crystals obtained from centrifuge is packed and dispatched, or it

is dried in the MgSO4 drying yard and packed depending upon the requirement of the

buyer.

Reactor

The main reaction for the manufacture of Magnesium Sulphate takes place here. The

reactor is a circular M.S. tank with a dia. of 3M and a height of 4M placed at a height

of 2M above the ground level Reactor is fitted with an agitator, gear box & electric

motor. Fresh water, mother liquor and weak Magnesium Sulphate solution obtained

from the mud washers are taken to the reactor. Required quantity of LCM (MgO) is

added-Spent Sulphuric acid from the measuring tank is slowly added into the reactor

till all the added LCM is neutralized. The neutral solution is drained into settling tank

below.

Acid Storage Tank

These are horizontal cylindrical tanks made up of mild steel, and are used to store

spent Sulphuric Acid. Spent Sulphuric acid which is transported in lorry tankers are

pumped into these tanks and stored.

They are housed over a platform made up of granite slabs and the platform is provided

with dyke wall for safe keeping.


[2-18]

Settling Tank & Weak Liquor Storage Tank

Settling tank is a M.S. tank of 12.5 KL capacity with a size of 2 M x 5 M x 1.25 M.

This tank is used to store the impure MgSO4 coming from the reactor.

The weak liquor storing tanks are made up of M.S with diameter of 2.4 M and a height

of 2.5 M. These tanks are used to store the weak MgSO4 solutions.

Crystallizers

These are again made up of Mild steel and are half cylindrical at the bottom and

rectangular at the top. It is provided with stirrers for constant stirring.

Hot concentrated solution of Magnesium Sulphate from the filter press is drained into

these and is allowed to cool slowly to room temperature with constant stirring, when

crystals of MgSO4 are formed. When the solution reaches the room temperature which

it normally does in 24 hrs it is drained into the centrifuge.

Centrifuge

This is used to separate the crystals of MgSO4 present in the solution drained from

crystallizer. The crystal magma is drained into the inner drum at the top, which has

perforations. When switched on, the inner drum containing the crystals rotates thereby

edging the solution out. The solution coming out is collected in a storage tank known

as mother liquor storage tank. The crystals are removed through a false cone provided

at the bottom

Light Calcined Magnesite

This is an industrial product obtained by the calcinations of Magnesite lumps in a

calcinator and is the other raw material for MgSO4. After calcination, the lumps are

powdered and sold. Its chemical formula is MgO.


[2-19]

Mass Balance

The chemical reaction taking place in the manufacture of Magnesium Sulphate can be

written as follows.

MgO + H2S04 +6 H2O → MgSO4 7 H2O

(40) (98) (108) (246)

Apart from the above said main reaction, following side reactions also take place

because of the presence of impurities like

A12O3 and Fe2O3

A12O3 + 3 H2SO4 → Al2(SO4) 3+ 3 H2O

(102) (294) (342) (54)

Fe2O3+ 3 H2SO4 → Fe2 (S04)3 +3 H2

O

(160) (294) (400) (54)

The molecular weights of raw materials and the products are as follows.

Magnesium Oxide: 41gm

Sulphuric Acid: 98 gm

Water: 18 gm

Magnesium Sulphate: 247 gm


[2-20]

FLOW CHART FOR MANUFACTURINGOF MAGNESIUM SULPHATE (MgSO4)

BASE: MT/ MONTH

REACTOR

SETTLING TANK

FILTER PRESS

CRYSTALUSER

CENTRIFUGE

MUD WASHER

DILUTE SULPHURIC ACID (70%) LIGHT CALCINED MAGNASITE (MgO)

FRESH WATER

IMPURE MgSO4 SOLUTION

IMPURE MgSO4 SOLUTION

CLEAR PURE MgSO4 SOLUTION

MgSO4 CRYSTALS + MOTHER LIQUOR

MgSO4 CRYSTAL SECTION (100)

FILTER CAKE

WEAK MgSO4 LIQUOR

MOTHER LIQUOR


[2-21]

(1) MFG. PROCESS FLOW CHART & DESCRIPTION OF SINGLE SUPER PHOSPHATE POWDER (S.S.P.):

(A) MAIN REACTION:

(1) 3Ca3 (PO4)2 +6 H2SO4 + 3 H2SiF6.H2O 6 CaSO4 + 3Ca (H2PO4)2.H2O + 3 SiF4

(932) (588) (486) (817) (756) (313) (120)

+

6HF

SIDE REACTION:

(2) CaF2 + H2SO4 2HF + CaSO4

(78) (98) (40) (136)

(3) 4HF +SiO2 SiF4 + 2H2

(80) (60) (104) (36)

O

(4) 3SiF4 + 3H2O 2H2SiF6 + SiO2.H2

(312) (54) (288) (78)

O

Upon Getting Reuse in Process for

15%-17% Concentration Reduction of Water

in Scrubber Consumption as per Reaction No.1

(Quantity: 22 MT/month)

Sellable in Market

(Quantity: 12 MT/month)


[2-22]

(B) MASS BALANCE & MFG. PROCESS FLOW CHART :

BASE: MT/ MONTH

FLUOROSILISILIC ACID (H2SiF6

H) (22)

2SO4

ROCK PHOSPHATE (600) WATER (30)

ACID (70 %) (500)

WATER (15) EVAPORATION (0.2) THICK SLURRY (1160) SiF4

SILICA (1)

REUSE (22)

LOSSES (32)

SELL AS A BY PRODUCT (12)

PACKING OF POWDER S.S.P. (1000) OVER SIZE MATERIAL

TO N.P.K. PRODUCT

SECTION (100)

MIXER

DEN

CUTTER

CURING YARD

POWDER PLANT

ROTARY SCREEN

WATER SCRUBBER

FLUOROSILISILIC ACID


[2-23]

(C) Mfg. Process description :

The company is intending to manufacture single super phosphate the plant will have 120 M.T.

per day manufacturing capacity. The storage facilities for raw material system the plant

designs will be based on broad field system. The manufacturing process of SSP can be sub

divided in

Raw material Section

Acidulation Section

Acid Section

Curing & Storage

Product Packing & Storage

Pollution Control

Raw Material Section:

Main raw material rock phosphate is available in the form fine powder / coarse chips. The

proposed plant is based on the use of fine powder, which is shipped and stored in loose

condition in the go down. The go down is land yard having retaining walls on both sides.

Rock phosphate is heaped in the yard. A hopper and conveyor will be provided in the go

down for mechanical handling of material.

The rock phosphate of required fineness will be obtained from the source, hence grinding will

not be required. The ground rock powder will be fed into G.R. feed hopper, for feeding the

rock to acidulation section through rock train.

Rock train consisting of Rotary valve Screw conveyors, Elevator, Surge hopper and Rotary

feeder is used for feeding ground Rock phosphate to the Acidulation Section


[2-24]

Acidulation Section

In this section processing takes place. This section consists of mixer and den (Main &

R.P.) and acid feeder. The mixer is a horizontal blending machine having mixing and knee

ding section. Ground rock phosphate and dilute Sulphuric acid is continuously fed into

Mixer in fixed proportion. Due to continuous agitation by rotating paddles. First two stage

of reaction take place over here and the mass is converted into thick slurry. A particular

temperature and suction is maintained over here, for proper reaction. The slurry is

discharged by mixer directly into the other slow moving machine called den. Den retains

the slurry for advancement of reaction. Retention time of material in this section can be

changed based on the process need. A slow speed cutter is installed at the discharge end of

den. The den cutter chops the solid material into fine pieces, before discharging it from

den. The material is discharged by den continuously & slowly up to 85-90 % of reaction is

completed at this stage.

The material being discharged by den is Green Super Phosphate. The balance reaction

continues & is completed slowly, in heap in next few days. Den discharged is shifted &

heaped in Curing yard. The material is directly discharged over rubber conveyer. A set of

conveyer belts is installed in go down for shifting heaping of Green Super Phosphate at

different location in go down for curing. The Green Super reshuffled 2 to 3 times & cured.

Acid Section

Dilute Acid is required for reaction with rock phosphate. Hence dilute Sulphuric acid (an

industrial waste of various chemical plants) or concentrated Sulphuric Acid is procured

from the nearby industries. Simple diluter may be installed for diluting conc. Acid if

required. This section will consist of acid storage & acid service tank which will be

installed in tank form area. Acid feed tank will be kept in plant area Brought out acid will

be unloaded in service tank & then transferred into the storage tank acid will be

transported to acid feed tank form service tank thought pump & pipe line acid will be

pumped from acid feed tank to acid feeder which will feed the required quantity into the

mixer as per ratio and excess quantity will be returned to the feed tank through respective

pipe line scrubber liquor feed tank and inlet / discharge pipeline will be provided to feed

Scrubber liquor into the mixer in preset proportion.


[2-25]

Curing and Storage

The semi-finished goods, Green Super Phosphate will be kept in green SSP curing yard.

The material is directly discharged over green super belt, be den A set of cross and

inclined belt conveyors is installed for conveying the discharge of green super belt over

the shuttle belt conveyor. The shuttle belt is used for heaping green super Phosphate at

deferent locations in curing go down. The green super is reshuffled 2 to 3 times and cured

with in 12-15 days.

Cured material is heaped and checked for quality after approval from QCD material

required for captive consumption is shifted to N.P.K. plant/granulation plant or powder

packing section.

Product Packing Storage & Shipment

The material for direct sale as single super Phosphate in granular or powder from is further

processed material is shifted to granulation plant for converting the powder into granules

of desired size and packed in HDPE bags and kept in go down for dispatch to dealers.

Material to be sold in powder from is screened in a rotary screen and fine powder is fed

into packing hopper for packing. The oversize grid is shifted to granulation plant for use

after crushing in chain / hammer mill.

The screened material is filled in bags & stitched after weighment and kept in day stores.

The day store’s material is shifted to product after quality check. Batch number is also

marked over here before shifting.


[2-26]

Pollution Control

In Process:

During acidulation fluorine content of rock phosphate is evolved as SiF4 gas. Fluorine

bearing gases are evolved during the reaction are to be removed before discharge to

atmosphere. The gases evolved during reaction in mixer and den is sucked by a high

suction blower & is scrubbed in circulating water. This section consists of H.V. jet

scrubber, Ventury scrubber, cyclone separator, I.D. fan & Chimney for sucking the gases

from point of generation & discharging to atmosphere at height of thirty Five meter, from

ground level after due cleaning. All the specially designed equipment of the section is

lined with different anti-corrosive materials. This scrubber liquor, namely H2SiF6, is kept

in lined pits for settling. The solid silica in the liquor is separated here & kept. The clear

liquor is kept in storage tanks & is used in process for manufacturing of Green Super

Phosphate.

The H2SiF6 liquor can also be used for manufacturing other Fluorine based chemicals,

such as Sodium Silico Fluoride. The silica can be sold or used as filler after sun drying.

As the liquor generated is recycled & used in process hence there will not be any liquid

discharge from the plant.

In Hot Air Generator:

Flue gas generated due to burning of bio-coal will be allowed in to Multi Cyclone Dust

separator, where mostly Dust particle will be settled down due to gravitational flow &

only clean Gas will be generated after ID fan & Chimney.


[2-27]

(2) MANUFACTURING PROCESS FLOW CHART & DESCRIPTION OF “SINGLE SUPER PHOSPHATE GRANULATED”

(A) Mass Balance & Manufacturing Process Flow Chart of “Single Super Phosphate Granulated”

BASE: MT/ MONTH

SINGLE SUPER PHOSPHATE POWDER (1000) SINGLE SUPER PHOSPHATE GRANULATED (100)

WATER (15)

RECYCLED MATERIAL (100) EVAPORATION (100) HOT AIR LOSS (15) AMBIENT AIR OVER SIZED MATERIAL (50) UNDER SIZED MATERIAL (50)

ROTARY DRUM GRANULATOR

ROTARY DRYER

ROTARY COOLER

SCREENER

FINISHED PRODUCT (GRANULATED S.S.P.) PACKING (1 TO 5 MM)

1000 MT.

CRUSHER


[2-28]

(B) Manufacturing Process Description of “Single Super Phosphate Granulated” The granulated fertilizers technology which is basically developed by tenancy valley

authority know as TVA design is adopted in our plant where in the different fertilizer

materials in solid form are stored in the different process bins from which proportionate

quantities are drawn by volumetric method & delivered to rotary drum granulator through

bucket elevator. Injecting about 10 to 12 % moisture moistens the materials. Due to

moistening & rolling action of the material in the rotary drums granular are formed. The

move excess moisture the material is fed to Co-current rotary dryer. Hot air evaporates the

excess moisture & some is carried away to atmosphere through dust collector.

The hot granular coming out from the dryer are fed to rotary collars where the temperature

of the granular are brought down to ambient temperature by outer air draught the dried &

called granulate screened to separate out over size, under size & finished product material.

The over sized material is crushed & returned to the granulator along with under sized

recycled material for reprocessing. Finished product material that is in the range of 1 mm to

5 mm is taken to the bagging go down by graving chute. The material is packed in 50 Kg

HDPE bags & duly machine stitched.


[2-29]

(3) Manufacturing Process Flow Chart & Description of “N.P.K – GRANULATED MIX FERTILISER”

(A) Mass Balance & Manufacturing Process Flow Chart of “N.P.K – Granulated Mix Fertilizer”

BASE: MT/ MONTH

PADDLE MIXER

ROTARY DRUM

ROTARY DRYER

ROTARY COLLARS

SCREENER

FINISHED PRODUCT PACKING

(GRANULATED N.P.K.) (1 TO 5 MM) (1000 MT)

CRUSHER

SINGLE SUPER PHOSPHATE

UNDER SIZED MATERIAL (50)

OVER SIZED MATERIAL (50)

LOSS (15)

EVAPORATION (171)

WATER (15)

RECYCLED MATERIAL (100)

AMBIENT AIR

HOT AIR

MOP (POTASH)

FILLER (300)

D.A.P. (60)

UREA (460)


[2-30]

(B) Manufacturing Process Description of “N.P.K. Granulated” Mix Fertilizers”

The granulated fertilizers technology which is basically developed by tenancy valley

authority know as TVA design is adopted in our plant where in the different fertilizer

materials in solid form are stored in the different process bins from which proportionate

quantities are drawn by volumetric method & delivered to common belt conveyer which is

turn delivers to paddle mixture where the material is delivered to rotary drum granulator

through bucket elevator. Injecting about 10 to 12 % moisture moistens the materials. Due to

moistening & rolling action of the material in the rotary drums granular are formed. To

remove excess moisture, the material is fed to Co-current rotary dryer. Hot air evaporates

the excess moisture & some is carried away to atmosphere through dust collector.

The hot granular coming out from the dryer are fed to rotary collars where the temperature

of the granular are brought down to ambient temperature by outer air draught the dried &

called granulate screened to separate out cover size, under size & finished product material.

The over sized material is crushed & returned to the granulator along with under sized

recycled material for reprocessing. Finished product material that is in the range of 1 mm to

5 mm is taken to the bagging go down by graving chute. The material is packed 50 Kg

HDPE bags & duly machine stitched.


[2-31]

2.5 WATER BALANCE

Water requirement for the project will be met from the bore well. The details of water

requirement are given below. The details include purpose, type of water required, peak demand

and avg. demand for different categories. For Water Balance diagram refer Figure 2.1. For

quality analysis report of the waste water generated please refer Table 2.8

Water Consumption (KL/Day)

Effluent Generation (KL/Day)

Existing Proposed Total Existing Proposed Total

(A) Domestic 1.0 3.0 4.0 1.0 1.5 2.5

(B) Industrial

I. Process 7.0 16 23 Nil Nil Nil

II. Utility

(For Scrubber)

Nil 5 5 Nil Nil Nil

III. Washing 0.5 Nil 0.5 Nil Nil Nil

Total (B) 7.5 21 28.5 Nil Nil Nil

Total (A+B) 8.5 24 32.5 1.0 1.5 2.5


[2-32]

FIGURE 2.1 WATER BALANCE DIAGRAM Basis: KL/ day

Total Water Required 32.5 28.5 Industrial

Domestic Process Utility 4.0 23.5 (Scrubber) 5.0

2.5 Septic Tank Nil Scrubbed Liquid

(H2SiF6

for reuse)

There shall be no generation of trade effluent, only domestic sewage will be generated, which will be allowed to dispose in an existing septic tank.


[2-33]

2.6 SOURCES OF ENERGY

The main sources of power of M/s. T.J. Agro Fertilizers Pvt. Ltd. will be utilized energy

from existing provider M/s. Madhya Gujarat Vij Company Limited. The total existing

connected load of the energy is about 80 HP.

Additional 600 HP will require for expansion project which would be applied to MGVCL

as & when required.

In case of power failure the unit proposed to install D.G set (125 KVA) as the backup

power supply.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011

CHAPTER 3 DESCRIPTION OF THE ENVIRONMENT

[3-1]

3.1 BASELINE ENVIRONMENTAL STATUS The baseline status of the environment quality in the vicinity of the project site serves as

the basis for identification, prediction and evaluation of the impacts. The baseline

environmental quality is assessed through field studies within the impact zone for various

components of the environment, viz. air, noise, water, and land and socio-economic. The

baseline environmental quality has been assessed in the winter season (December 2010 –

February 2011) in a study area of 10 km radial distance from the project site.

Knowledge of baseline environmental status of the study area is useful for Impact

Assessment Process of assessing and predicting the environmental consequences of the

significant actions. Significant action depicts direct adverse changes caused by the action

and its effect on the health of the biota including flora, fauna and human being, socio-

economic conditions, current use of land and resources, physical and cultural heritage

properties and biophysical surroundings.

Baseline data generation of the following environmental attributes essential in EIA studies

have been studied and included in the report.

1. Meteorology

2. Ambient Air Quality

3. Ambient Noise Quality

4. Surface and Ground water Quality

5. Soil Quality & Geological Features

6. Land use pattern

7. Biological Information

8. Socio-economic status survey

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 3 DESCRIPTION OF THE ENVIRONMENT

[3-2]

3.2 ESTABLISHMENT OF IMPACT ZONE

Deciding whether a proposed action is likely to cause significant adverse environmental

effects is central to the concept and practice of EIA. Before proceeding for baseline data

generation, it is important to know the boundary limits and framework, so that the data

generated can be utilized for the effective and accurate prediction of the environmental

impact assessment of the proposed project.

3.3 METEOROLOGY

Air borne pollutants is dispersed by atmosphere motion. Knowledge of these motions,

which range is scale from turbulent diffusion to long-range transport by weather systems,

is essential to simulate such dispersion and quality of impacts of air pollution on the

environment. The purpose of EIA is to determine whether average concentrations are

likely to encounter at fixed locations (Know as the receptor), due to the given sources

(locations and rates of emission known), under idealized atmospheric conditions. It is

imperative that one should work with idealized condition and all analysis pertaining to air

turbulence and ambient air or noise pollution should be done with meteorological

conditions, which can at best be, expected to occur.

3.4 MICRO-METEOROLOGY OF THE AREA

The climate of the district is characterized by hot summer and general dryness except in the

coastal region. The year is divided into four seasons. The cold season December to

February followed by the hot season from March to May, June to September is South-West

Monsoon season and October and November form the post monsoon season. The Arabian

Sea and the Gulf of Cambay in the west and the forest-covered hills in the east soften the

rigors of climatic extremes, consequently reducing the temperature and render the climate

more pleasant and healthy.


[3-3]

3.4.1 Temperature Details:

Mean daily maximum temperature is recorded in the month of May at 40.9 °C. Highest

mean temperature, recorded in May is 44.5 °C. From October to December, both day and

night temperatures begin to decrease rapidly. January is generally the coldest month, with

mean morning temperature of 13.8 °C. Mean daily minimum temperature of about 12.0 °C

is recorded in January.

During the post monsoon months of October and November, day temperatures remain

between 20.4 – 25.0 °C. In winters, i.e. December, January and February, average day

temperature remain between 13.8 – 16.2 °C.

3.4.2 Relative Humidity:

Most humid conditions are found in the monsoon, followed by post monsoon, winter and

summer in the order. Mornings are more humid than evenings and humidity ranges from a

high of 76-90% in monsoon mornings to a low of 20-27% in summer evenings. During

post monsoon season, in morning humidity remains between 64-72 % and in the evening it

remains between 41-44 %.

Nearest IMD station from the project site is Harni Aerodrome, Vadodra.


[3-4]

3.4.3 Rainfall:

The total rainfall in year is observed to be 922.7 mm. Distribution of rainfall by season

is 7.5 mm in winter (December, January, February), 7.5 mm in summer (March, April,

May), 870.8 mm in monsoon (June, July, August, September) and 38.2 mm in post

monsoon (October, November)

3.4.4 Wind:

The predominant wind direction during the period of April-10 to March-11 is as

mentioned in the Table 3.1.

Predominant

Month

Table 3.1 Predominant Wind Direction

First Second Third

Morning Evening Morning Evening Morning Evening

April-10 Calm NW SW W NW SW

May-10 SW SW W W Calm NW

June-10 SW SW W W S S

July-10 SW SW Calm W W Calm

August-10 SW SW W W Calm Calm

September-10 SW SW Calm W W Calm

October-10 Calm Calm NW NW SW NE

November-10 Calm Calm NE NE N NW

December-10 NE Calm Calm NE N N

January-11 NE NE Calm NW N Calm

February-11 Calm NW NE NE N Calm

March-11 Calm NW SW W NE SW

The predominant wind direction during the study period (Dec-10 to Feb-11) is observed

to be from NE direction.

3.4.5 Cloud Cover:

The area remains cloudy between June- Septembers, which is the active period of the

monsoon season. Generally cloud cover ranges from 4 to 7 Oktas during this monsoon

season.


[3-5]

3.5 SITE SPECIFIC METEOROLOGICAL DATA

(PERIOD – Dec. 1, 2010 to Feb. 28, 2011)

Site- specific meteorological data shows that average wind speed in the winter season is

1.8 km/hr.

Wind rose prepared for winter season is shown in Fig: 3.1. It can be observed that in the

winter season, wind blows mostly from NNE direction. Calm wind contributes to about

42.4 %.

Average temperature recorded for winter season was 22.8 °C with maximum

temperature of 37.4 °C and minimum of 11.2 °C, which is a characteristic of this study

area.

The average humidity recorded was 55.0 % with maximum humidity of 85.0 % and

minimum of 26 %.

The data obtained has then been complied to obtain average data. Complied mean

meteorological data is represented in Table: 3.2.


[3-6]

Hour

Table 3.2 Mean Meteorological Data During Study Period

Temp. °C Relative Humidity %

Wind Speed Km/hr

Wind Direction

01 24.1 45.1 1.1 NNE 02 17.1 47.8 1.1 NE 03 18.1 50.7 1.0 NNE 04 19.0 53.3 0.8 NNE 05 20.2 56.2 0.8 NNE 06 21.4 58.9 0.9 NNW 07 22.9 62.0 0.9 NNW 08 24.2 64.7 1.9 NNW 09 25.6 66.6 2.7 NW 10 27.1 66.8 4.9 NE 11 28.4 67.5 5.7 NE 12 29.7 67.9 2.8 NNE 13 29.9 64.4 2.8 NNE 14 29.2 61.1 2.4 NW 15 27.9 57.9 2.5 NW 16 26.2 54.8 2.3 NW 17 24.4 52.5 1.8 NW 18 22.7 49.9 1.1 NNE 19 21.2 48.0 0.8 NE 20 19.6 47.3 1.0 NNE 21 18.5 45.5 1.0 NNE 22 17.4 44.3 1.1 NNE 23 16.5 43.5 1.0 NNE 24 15.9 42.2 1.0 NNE

AVERAGE/ PREDOMINANT 22.8 55.0 1.8 NNE

The wind rose diagram processed by Lake Environment software from data collected at

site is shown below.


[3-7]

Figure 3.1 Wind Rose Diagram


[3-8]

3.6 AIR ENVIRONMENT

3.6.1 Design of Network for Ambient Air Quality Monitoring Locations

The air quality status in the impact zone is assessed through a network of ambient air

quality monitoring locations. The tropical climatic conditions mainly control the

transport and dispersion of air pollutant emissions during various seasons. The baseline

studies for air environment include identification of specific air pollutants prior to

implementation of the project. The Environmental Impact Assessment (EIA) study

requires monitoring of baseline air quality during one season. Accordingly, air quality

monitoring was carried out in the winter season from Dec. 1, 2010 to Feb. 28, 2011. The

baseline status of the air environment is assessed through a systematic air quality

surveillance programme, which is planned based on the following criteria:

• Topography / terrain of the study area • Regional synoptic scale climatologically normal • Densely populated areas within the region • Location of surrounding industries • Representation of regional background • Representation of valid cross-sectional distribution in downwind direction

3.6.2 Reconnaissance

Reconnaissance was undertaken to establish the baseline status of air environment in the

study region. Five nos. of Ambient Air Quality Monitoring (AAQM) locations were

selected based on guidelines of network sitting criteria. All AAQM locations were

selected within the study area of 10 km radial distance from the project site.

3.6.3 Methodology for Ambient Air Quality Monitoring

The ambient air quality monitoring was carried out in accordance with guidelines of

Central Pollution Control Board (CPCB) of June 1998 and National Ambient Air

Quality Standards (NAAQS) of CPCB of May 1994. Ambient Air Quality Monitoring

(AAQM) was carried out at five locations during winter season. The maximum numbers

of sampling locations were selected close to the project site and in the study area of 10

km radial distance around the plant site. The monitoring was carried out 24 hours a day

twice a week per location in the study area except the project site, where continuous

monitoring was carried out. Twelve numbers of observations were taken at each

monitoring location except the project site. The locations of the different stations with

respect to its distance and direction from project site are shown in Table- 3.3 and

Figure-3.2 respectively.


[3-9]

Sr. No.

Table 3.3 Details of Ambient Air Quality Monitoring Locations

Name of village bearing W.R.T. Project site

Approximate Radial distance From project

Site (km)

Direction From project

Site

1. Project Site (A1) 0.0 -

2. Bahidhara Village (A2) 2.16 NNE

3. Anjesar (A3) 3.06 ESE

4. Mahapura (A4) 2.97 WWS

5. Raniya (A5) 4.67 WWN


[3-10]

Figure 3.2 Location of Ambient Air Quality Monitoring Stations


[3-11]

The conventional and project specific parameters such as Suspended Particulate Matter

(PM10), Respirable Suspended Particulate Matter (PM2.5), Sulphur Dioxide (SO2),

Oxides of Nitrogen (NOx) and Hydrogen Fluoride (HF) were monitored at site.

The values for mentioned concentrations of various pollutants at all the monitoring

locations were processed for different statistical parameters like arithmetic mean,

minimum concentration, and maximum concentration and percentile values. The

existing baseline levels of PM10, PM2.5, SO2, NOx and HF are expressed in terms of

various statistical parameters as given in Tables-3.4(A-F).

Table 3.4 (A): Ambient Air Quality Status (December, 2010 to February, 2011)

Unit: µg/m3

Period: 24 Hours

Sr. No.

Sampling Location

PM PM10 SO2.5 NO2 HF X

Average (min-max)

1. Project Site

(A1)

82.5 (98.6-44.3)

40.9 (59.0-11.4)

13.9 (20.6-5.4)

17.4 (24-13.6)

0.1 (0.6-0.0)

2. Bahidhara

(A2)

70.2 (97.6-30.2)

36.6 (58.9-8.7)

14.0 (19.8-5.2)

17.4 (28.6-8.9)

0.1 (0.2-0.0)

3. Anjesar (A3) 71.5 (98.6-40.2)

43.3 (56.5-16.5)

17.5 (33.5-8.9)

17.2 (30.2-9.1)

0.1 (0.3-0.0)

4. Mahapura

(A4)

70.5 (98.5-26.3)

42.1 (58.9-10.1)

13.7 (19.2-7.2)

17.1 (26.5-10.2)

0.1 (0.3-0.0)

5. Raniya (A5) 73.2 (98-30.6)

36.0 (58.9-10.3)

14.8 (26.4-3.6)

19.1 (46.8-5.0)

0.1 (0.2-0.0)


[3-12]

Table 3.4 (B): Cumulative Percentiles of PM10

Unit: µg/m

Sr. No.

3

Period: 24 Hours

Sampling Location Min Percentile

Max 25 50 75 98

1. Project Site (A1) 44.3 75.20 89.20 95.22 98.32 98.6

2. Bahidhara Village

(A2)

30.2 55.33 71.35 88.96 97.03 97.6

3. Anjesar (A3) 40.2 55.73 75.85 86.50 97.28 98.6

4. Mahapura (A4) 26.3 56.23 74.05 89.00 98.05 98.5

5. Raniya (A5) 30.6 63.13 72.60 86.95 96.75 98.0

NAAQ Standard of CPCB (98th percentile): 100 µg/m3 (for residential areas)

NAAQ Standard of CPCB (98th percentile): 100 µg/m3 (for industrial areas)

Table 3.4 (C): Cumulative Percentiles of PM2.5

Unit: µg/m3

Sr. No.

Period: 24 Hours

Sampling Location Min

Percentile Max 25 50 75 98

1. Project Site (A1) 11.4 30.17 43.16 51.33 56.89 59.0


(A2)

8.7 20.50 39.04 51.63 57.71 58.9

3. Anjesar (A3) 16.5 39.14 45.76 50.03 56.04 56.5

4. Mahapura (A4) 10.1 35.30 46.50 50.65 58.55 58.9

5. Raniya (A5) 10.3 25.37 33.70 48.80 58.51 58.9




[3-13]

Table 3.4 (D): Cumulative Percentiles of SO2

Unit: µg/m3

Sr. No.

Period: 24 Hours

Sampling Location Min

Percentile Max

25 50 75 98

1. Project Site (A1) 5.4 11.55 13.20 16.20 20.40 20.6


(A2)

5.2 12.03 14.25 16.20 19.07 19.8

3. Anjesar (A3) 8.9 14.73 17.50 19.73 29.82 33.5

4. Mahapura (A4) 7.2 11.79 14.22 15.98 18.67 19.2

5. Raniya (A5) 3.6 11.58 15.30 18.51 22.55 26.4



Table 3.4 (E): Cumulative Percentiles of NOX

Unit: µg/m3

Sr. No.

Period: 24 Hours


Max 25 50 75 98

1. Project Site (A1) 5.4 16.20 16.88 18.90 22.29 24.0


(A2)

8.9 14.00 17.50 20.18 26.89 28.6

3. Anjesar (A3) 9.1 14.60 16.55 19.20 28.89 30.2

4. Mahapura (A4) 10.2 14.53 16.50 19.80 24.14 26.5

5. Raniya (A5) 5.0 12.0 18.90 22.30 45.16 46.8




[3-14]

Table 3.4 (F): Cumulative Percentiles of HF

Unit: µg/m3

Sr. No.

Period: 24 Hours


Max 25 50 75 98

1. Project Site (A1) 0.0 0.07 0.11 0.17 0.29 0.6


(A2)

0.0 0.08 0.13 0.18 0.21 0.2

3. Anjesar (A3) 0.0 0.08 0.15 0.19 0.23 0.3

4. Mahapura (A4) 0.0 0.09 0.14 0.17 0.22 0.3

5. Raniya (A5) 0.0 0.07 0.11 0.18 0.21 0.2

3.6.4 Techniques Used for Ambient Air Quality Monitoring:

The technique used for ambient air quality monitoring of the above mentioned

parameters are as mentioned in Table 3.5.

Table 3.5 Technique Used For AAQM

Sr. No. Parameter Instrument used for analysis

1 Hydrogen Fluoride High Volume Gaseous Sampler-Colorimeter

2. Sulphur dioxide High Volume Gaseous Sampler-Colorimeter

3. Nitrogen Oxide High Volume Gaseous Sampler- Colorimeter

4. Particulate Matter (PM10 High Volume Air Sampler ) 5 Particulate Matter (PM2.5 High Volume Air Sampler with PM) 2.5

Attachment (Cyclone)


[3-15]

3.6.5 Flue Gas Characteristics The details regarding characteristics of the various flue gases generated at the site are

given in Table 3.6(A&B). The details include:

- Pollutant parameter

- Source of emission

- Emission concentration

- Emission Rate

FLUE GAS CHARACTERISTICS

Table 3.6 (A): Proposed Details of Stack, APCS & Its Emission Estimate

Stack Attached To

Height & Top Dia. of Stack

Type of Fuel & Qty.

Source of Fuel Proposed

Air Pollution Control System

Final Concentration

Existing

Proposed

Hot Air Generator 1 & 2

11 Meter &

500 mm

Nil Bio Coal 16 MT/day

Local Traders Multi Cyclone Separator

& Bag Filter in series

SPM < 150 mg/NM3

SO2 < 100 ppm NOx < 50 ppm

D. G. Set (Stand By)

(Capacity: 125 KVA)

8 Meter Nil HSD 15 Lit/hr

Local Petroleum Product Supplier

Not Applicable SPM < 150 mg/NM3


Evaluation for Stack Height:

(1) For Hot Air Generator H = 14 (Q)0.3 Where, H = Stack Height in meters Q = Emission rate of SO2

H = 14 (0.15)0.3

= 7.92 m ≈ 8 m

NOTE: The stack height of Hot Air Generator will be 11 m which is above the statutory requirement (8 m) as per the Environmental Standards set by CPCB.


[3-16]

Sr. No. Stack Attached to Parameter

Emission Estimate in Kg/hr

Existing Proposed Total

1. Hot Air Generator 1&2

(Flow: 3000 M3

PM

/Hr.)

Nil 0.225 0.225

SOx Nil 0.15 0.15

NOx Nil 0.075 0.075

Table 3.6 (B): Proposed Details of Process Vent , APCS & Its Emission Estimate

Process Vent Attached To


Air Pollution Control System Final Concentration

Den & Mixture 35 Meter &

600 mm

Ventury Water Scrubber

SPM < 150 mg/NM3

SO2 < 40 mg/NM3 NOx < 25 mg/NM3

Fluorine < 0.5 mg/NM3

The minimum stack height should be either 30 m or as per the equation H = 14 (Q)0.3

(2) For Den & Mixture

(whichever is greater) as per Environmental Standards set by CPCB.

H = 14 (Q)0.3 Where, H = Stack Height in meters Q = Emission rate of SO2

Since, the emission rate of SO2

Sr. No.

will be Nil, minimum stack height should be 30 m. the unit proposed to keep the stack height to be 35 m, which is above the statutory requirement.

Stack Attached to Parameter Emission Estimate in Kg/hr

Existing Proposed Total

1. Den & Mixture (Process Vent)

(Flow: 7500 M3

PM

/Hr.)

Nil 0.40 0.40

SOx Nil Nil Nil

NOx Nil 0.05 0.05

HF Nil 0.01 0.01

Fluorine Gas Nil 0.001 0.001


[3-17]

3.6.6 Scrubber System Details

The unit have already available Water scrubber of adequate capacity to handle proposed

qty. of SiF4 gas to be generated.

Fluorine bearing gases are evolved during the reaction are to be removed before

discharge to atmosphere. The gases evolved during reaction in mixer and den is sucked

by a high suction blower & is scrubbed in circulating water. This section consists of H.V

jet scrubber, Ventury scrubber, cyclone separator, I.D. fan & chimney for sucking the

gases from point of generation & discharging to atmosphere at height of 35 meter, from

ground level after due cleaning. All the specially designed equipment of the section is

lined with different anti-corrosive materials. This scrubber liquor, namely H2SiF6

• Source of fugitive emission from the unit along with its quantification and

Proposed measures to control it.

, is

kept in lined pits for settling. The solid silica in the liquor is separated here & kept. The

clear liquor is kept in storage tanks & is used in process for manufacturing of Green

Super Phosphate.

In Hot Air Generator:

Flue gas generated due to burning of biocoal will be allowed to Multi Cyclone Dust

separator & Proposed Bag Filter, where mostly dust particles will be settled down and

only clean gas will be generated after ID fan & Chimney. Design details of proposed

Bag Filter is attached as per Fig 3.3

Following are the sources of fugitive emission

- Material Storage - During process - Material Handling

In material storage & material handling, when fugitive emission occurred to its threshold

limit, automatic censor alarms and operator in shift will immediate start blower to suck

fugitive gases and simultaneously start scrubber also.

Than after he remove that material from that area and send to repacking or use in process. In process: operator Incharge will handle unit processes & its operation to minimize risk

of fugitive emission.


[3-18]

FIG: 3.3 SCRUBBER DETAILS Stack Height: 35 m Stack Dia: 600 mm Water In 900

1100 mm mm

600 mm Scrubbed Water 35m 1500 1500 mm mm H2SiF6

Absorption Tower

750 mm Blower Rock Phosphate

Storage Tank H2SiF6

Recycle


[3-19]

DESIGN DETAILS OF H2SiF6 SCRUBBER

Unit already have installed water scrubber to absorb H2SiF6

Sr. No.

gas to be generated during

manufacturing process of SINGLE SUPER PHOSPHATE.

The details of Scrubber & its flow diagram are attached herewith.

Description Capacity

1. Diameter : 0.5 m 2. Height : 31.9 m 3. Water Pump Capacity : 1 M3/hr 4. Water Storage tank Capacity : 1000 lits 5. Scrubbing Efficiency : 90 % 6. Scrubbing water Temperature : 25-30 °C 7. Type of packing media : Lessing ring 8. MOC of packing media : Plastic & Ceramic 9. Water- HCL solubility at ambient temperature : Infinite 10. Quantity of scrubbed gas : H2FiS6 1.5 kg/ day

Due to manufacturing of SINGLE SUPER PHOSPHATE, H2SiF6

• Unit scrubber water storage capacity = 1000 lit.

gas will be

generated, which will be absorbed in existing water scrubber to recovered valuable

Fluorosilisilic acid as a product. The same will be utilized as a raw material again in the

process as well as resale.

Note:

• Average ambient temperature of scrubber water in is 25 – 43°C.

• As per MSDS, H2FiS6

• Thus, scrubbing capacity of our scrubber is 0.1 kg/hr of H

gases will be soluble in water at temperature 25°C is @ of

infinite.

2FiS6

.

Name of the gas Total gas generated at max. production Kg/

hr.

Scrubbing capacity of H2SiF6 Scrubber

Kg/hr

H2FiS 0.02 6 0.1


[3-20]

DESIGN DETAILS OF PROPOSED BAG FILTER

(1) Basis of Design:

Name of equipment : Hot Air Generator Designed Gas Flow : 2500 M3

Media Type : Hot air /hr.

Max. Air Temp. : 80-90 o

Inlet Dust Load : 6-8 gm/MC

Outlet Emission : < 150 mg/Nm

3

Flue Gas particle size : Assumed-10>% (90% Microns)

3

Inlet Pressure : (-)140-180 mm WG Quality of Pulse Air Required : Moisture < 50 ppm , 6-7 Kg/cm2

Pressure

(2) Technical Specification of Bag Filter:

Bag Filter Designed Capacity : Approx. Weight : 1-2 MT Type : Reverse online Pulse jet type,

Self Supported MOC : M.S. with two coat Red oxide. Gas Flow : 2500 M3/hr. Pressure drop : 125 - 150 mm WG (max.) Air to cloth ratio : 1.15 meter3/minute/m2

Bag Filtration area : 1.48 M)

2

Total Filtration area : 47.36 M/ Bag,

Type of Bag Filter : Nomex Woven

2

Bag dimensions : 118 Ø x 4000 mm L ,700 gm/M2 Total No. of Bag : 24 Max. Bag Operating Temperature : < 150 o

Min. Bag Operating Temperature : >50 C

o

MOC of Bag Cage : G.I, Fabricated with 3 mm Ø wire

C

MOC of Ventury : M.S. Bag Permeability : 18-20 m3/m2/min Dust outlet : Through C.S. rotary air lock valve

(01 Nos.-100TPH, 150NB) with Gearbox (15 RPM) & Motor (1 HP)

Timer: 10 Channel, Input Voltage : 230 Volt AC Output Voltage: 230 Volt AC Operating Temperature : 160oC – 250 o

Bag filter hopper thick : 3mm C

Tube sheet thick : 5 mm Tope Cover thick : 3 mm Casing thick : 5 mm


[3-21]

Compressed clean air required : Moisture Free, 6 -7 Kgs/cm2 pressure (By Unit)

Type & Qty. of Solenoid valve : 04, Diaphragam, Integral Solenoid valve Size & Op. Pressure : 1.5 inch, 5-7 Bar Insulation : Mineral wool, 50mm thick,

Aluminium 24 SWG (By Unit) Accessories : Inbuilt Damper, Hopper Heater,

Manometer Temp. Gauge, Self supporting structure (1 mtr ht. from bottom Flange) & one open able door (Top Side) for Maintenance services.

(3) Operation: The dust laden gases enter the pre- separation plenum

1. Where they meet the low baffle plate 2. The baffle wall protects the sleeves against the direct flow. The air velocity is

reduced in the pre- separation plenum. The coarse dust fraction leaves the air flow and falls into the dust collection hopper.

3. The gas laden with the fine remaining dust enters the filter plenum. 4. After deflection by the baffle plate. 5&6. The sleeves (6) fitted over supports (5) receive the flow in the outside. The fine

dust is deposited on the outside of the filter sleeves. 7. The air penetrates through the filter fabric into the inside of the sleeves and rises

into the clean air plenum. 8. From here it can either be led out of the doors. 9. Or returned to the workshop. The control of the cleaning process for the filter

sleeves depends either on the differential pressure or an infinitely electronic timer. The dust particles clinging to the filter sleeves are removed through short, sharp compressed air impacts. Compressed air at 5-7 bar shoots out of electronically activated diaphragm valves into the corresponding opened distribution line and from there into the nozzles. The cleaning stream causes a strong counter pressure in the sleeve.

10. The sleeve, which until then was passed against its support, is suddenly

extended to its full size. The particles of dust are blown off. Small dust is blown off. Small dust particles, which had penetrated the filter fabric, are loosened by the short, but strong cleaning flow, and pressed back to the dust- laden side.


[3-22]

When the diaphragm valves have closed, the cleaned filter sleeves are once

again ready for the normal filter process. All rows of sleeves are cleaned in a fixed sequence. The cleaning time is so short that practically always the whole filter surface of the filter is available. Moreover the necessary compressed air quantity in relation to the flow volume is the same up- and down- line of the filter.

The compressed air impacts are controlled by an electronic timer. Impacted regularity can be continuously set with the electronic timer, depending on the type and amount of dust.

3.6.7 General Observations

The observations based on the study results are summarized in Table-3.4 (A-F):

PM10 & PM2.5

The average values for PM

:

10 were observed to be between 98.6 µg/m3 to 26.3 µg/m3

against a maximum permissible limit of 100 µg/m3 for industrial as well as for

residential areas. While average value for PM2.5 were observed to be between 59.0

µg/m3 to 8.7 µg/m3 against a maximum permissible limit of 60 µg/m3 for residential

areas & 60 µg/m3 for industrial areas which is well within the permissible limits of

NAAQS.

SO2 & NOX:

The average values for SO2 were observed to be between 19.2 µg/m3 to 3.6 µg/m3

against a maximum permissible limit of 80 µg/m3 for residential areas & 80 µg/m3 for

industrial areas. The average values for NOX

• We have used guassian plume model for gases to be generated from our stack /

vents on nearby our area attached as per the data mentioned below in Table

No. 3.7 (A-E) . The Plume model is as shown in Fig 3.4- 3.8(A)

are observed to be between 46.8 µg/m3

to 5.0 µg/m3 against a maximum permissible limit of 80 µg/m3 for residential areas &

80 µg/m3 for industrial areas, which is well within the permissible limits of NAAQS.

HF:

The average values for HF are observed to be between 0.6 µg/m3 to 0.0 µg/m3 against

a maximum permissible limit of 4.0 µg/m3 for residential areas & 4.0 µg/m3 for

industrial areas, which is well within the permissible limits of NAAQS.

• The air quality contour is prepared as per latest available IMD data & its

impact area on satellite map is attached as per Fig 3.4-3.8(B)


[3-23]

TABLE NO. 3.7 (A) RESULT FOR FUGITIVE GAS

DIRECTION DISTANCE (Meters) (DEGREES) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

360 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

10 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 20 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 30 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 40 0.000 0.000 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 50 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 60 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 70 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 80 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 90 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 100 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 110 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 120 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 130 0.002 0.002 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 140 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 150 0.003 0.005 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 160 0.005 0.006 0.005 0.004 0.003 0.003 0.002 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 170 0.007 0.009 0.005 0.004 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 180 0.010 0.012 0.009 0.007 0.006 0.005 0.004 0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 190 0.014 0.016 0.011 0.008 0.006 0.004 0.004 0.003 0.002 0.002 0.001 0.000 0.000 0.000 0.000 200 0.017 0.021 0.020 0.020 0.018 0.016 0.014 0.013 0.011 0.010 0.004 0.003 0.002 0.001 0.001 210 0.020 0.023 0.017 0.014 0.011 0.009 0.008 0.007 0.006 0.005 0.002 0.001 0.001 0.000 0.000 220 0.020 0.023 0.017 0.015 0.012 0.011 0.009 0.008 0.007 0.006 0.002 0.001 0.001 0.001 0.000


[3-24]

DIRECTION (DEGREES)

DISTANCE (Meters)

100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000 230 0.018 0.021 0.016 0.014 0.012 0.010 0.009 0.008 0.007 0.006 0.002 0.001 0.001 0.001 0.000 240 0.015 0.017 0.012 0.009 0.007 0.006 0.005 0.004 0.004 0.003 0.001 0.001 0.000 0.000 0.000 250 0.011 0.014 0.012 0.011 0.010 0.008 0.007 0.006 0.006 0.005 0.002 0.001 0.001 0.001 0.000 260 0.009 0.010 0.007 0.005 0.004 0.003 0.003 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 270 0.007 0.009 0.008 0.008 0.007 0.007 0.006 0.005 0.005 0.004 0.002 0.001 0.001 0.001 0.000 280 0.005 0.006 0.004 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 290 0.003 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 300 0.001 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 310 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 320 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 330 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 340 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 350 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000


[3-25]

Figure 3.4 (A): Guassian Plume Model for Fugitive Gas


[3-26]

Figure 3.4(B) Air Quality Contour for Fugitive Gas:


[3-27]

TABLE NO. 3.7 (B) RESULT FOR HF GAS:


360 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

10 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 20 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 30 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 40 0.000 0.000 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 50 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 60 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 70 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 80 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 90 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 100 0.000 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 110 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 120 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 130 0.002 0.002 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 140 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 150 0.003 0.005 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 160 0.005 0.006 0.005 0.004 0.003 0.003 0.002 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 170 0.007 0.009 0.005 0.004 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 180 0.010 0.012 0.009 0.007 0.006 0.005 0.004 0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 190 0.014 0.016 0.011 0.008 0.006 0.004 0.004 0.003 0.002 0.002 0.001 0.000 0.000 0.000 0.000 200 0.017 0.021 0.020 0.020 0.018 0.016 0.014 0.013 0.011 0.010 0.004 0.003 0.002 0.001 0.001 210 0.020 0.023 0.017 0.014 0.011 0.009 0.008 0.007 0.006 0.005 0.002 0.001 0.001 0.000 0.000 220 0.020 0.023 0.017 0.015 0.012 0.011 0.009 0.008 0.007 0.006 0.002 0.001 0.001 0.001 0.000


[3-28]

DIRECTION (DEGREES)

DISTANCE (Meters) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

230 0.018 0.021 0.016 0.014 0.012 0.010 0.009 0.008 0.007 0.006 0.002 0.001 0.001 0.001 0.000 240 0.015 0.017 0.012 0.009 0.007 0.006 0.005 0.004 0.004 0.003 0.001 0.001 0.000 0.000 0.000 250 0.011 0.014 0.012 0.011 0.010 0.008 0.007 0.006 0.006 0.005 0.002 0.001 0.001 0.001 0.000 260 0.009 0.010 0.007 0.005 0.004 0.003 0.003 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 270 0.007 0.009 0.008 0.008 0.007 0.007 0.006 0.005 0.005 0.004 0.002 0.001 0.001 0.001 0.000 280 0.005 0.006 0.004 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 290 0.003 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 300 0.001 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 310 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 320 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 330 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 340 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 350 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000


[3-29]

Figure 3.5 (A): Guassian Plume Model for HF gas


[3-30]

Figure 3.5(B) Air Quality Contour for HF gas:


[3-31]

TABLE NO. 3.7 (C) RESULTS FOR NOx GAS:


360 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

10 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 20 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 30 0.003 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 40 0.004 0.003 0.003 0.003 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.000 0.000 0.000 50 0.005 0.004 0.004 0.003 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.000 0.000 0.000 60 0.005 0.004 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 70 0.004 0.004 0.003 0.003 0.002 0.002 0.002 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 80 0.003 0.004 0.003 0.002 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 90 0.003 0.004 0.003 0.003 0.002 0.002 0.002 0.002 0.002 0.002 0.001 0.001 0.000 0.000 0.000 100 0.003 0.004 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 110 0.004 0.006 0.005 0.004 0.004 0.003 0.003 0.003 0.002 0.002 0.001 0.001 0.000 0.000 0.000 120 0.007 0.009 0.007 0.005 0.004 0.003 0.002 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 130 0.011 0.015 0.013 0.011 0.009 0.008 0.007 0.007 0.006 0.005 0.003 0.001 0.001 0.001 0.000 140 0.016 0.021 0.017 0.013 0.011 0.009 0.008 0.007 0.007 0.006 0.003 0.002 0.001 0.001 0.000 150 0.022 0.029 0.022 0.016 0.013 0.011 0.009 0.008 0.007 0.006 0.002 0.001 0.001 0.001 0.000 160 0.031 0.040 0.031 0.024 0.020 0.017 0.015 0.013 0.012 0.011 0.005 0.003 0.002 0.002 0.001 170 0.045 0.054 0.038 0.026 0.019 0.014 0.011 0.009 0.008 0.007 0.003 0.001 0.001 0.001 0.000 180 0.066 0.079 0.058 0.043 0.034 0.029 0.025 0.022 0.020 0.018 0.009 0.006 0.004 0.003 0.002 190 0.092 0.105 0.074 0.052 0.038 0.030 0.024 0.020 0.017 0.015 0.005 0.003 0.002 0.002 0.001 200 0.119 0.142 0.118 0.103 0.094 0.087 0.080 0.074 0.069 0.064 0.033 0.021 0.015 0.012 0.005 210 0.138 0.152 0.111 0.084 0.068 0.057 0.049 0.043 0.038 0.033 0.014 0.007 0.005 0.003 0.001 220 0.143 0.156 0.115 0.089 0.074 0.063 0.055 0.049 0.044 0.039 0.018 0.011 0.007 0.005 0.002


[3-32]

DIRECTION (DEGREES)

DISTANCE (Meters) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

230 0.131 0.142 0.106 0.083 0.069 0.060 0.053 0.047 0.042 0.038 0.017 0.010 0.007 0.005 0.002 240 0.107 0.114 0.081 0.059 0.046 0.037 0.031 0.027 0.024 0.021 0.008 0.005 0.003 0.002 0.001 250 0.083 0.093 0.073 0.060 0.052 0.046 0.042 0.038 0.035 0.032 0.016 0.010 0.007 0.005 0.002 260 0.064 0.070 0.050 0.036 0.027 0.022 0.018 0.015 0.013 0.011 0.004 0.002 0.001 0.001 0.000 270 0.051 0.059 0.049 0.043 0.039 0.036 0.033 0.031 0.028 0.026 0.014 0.009 0.007 0.005 0.002 280 0.035 0.038 0.028 0.021 0.016 0.013 0.011 0.010 0.008 0.007 0.003 0.001 0.001 0.001 0.000 290 0.020 0.023 0.017 0.013 0.011 0.009 0.008 0.007 0.006 0.006 0.003 0.002 0.001 0.001 0.000 300 0.011 0.012 0.009 0.007 0.005 0.004 0.004 0.003 0.003 0.003 0.001 0.001 0.000 0.000 0.000 310 0.005 0.006 0.004 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 320 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 330 0.001 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 340 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 350 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000


[3-33]

Figure 3.6 (A): Guassian Plume Model for NOx:


[3-34]

Figure 3.6(B) Air Quality Contour for NOx:


[3-35]

TABLE NO. 3.7 (D) RESULTS FOR SO2

DIRECTION

GAS

DISTANCE (Meters) (DEGREES) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

360 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000

10 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 20 0.003 0.002 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 30 0.005 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 40 0.007 0.005 0.004 0.005 0.004 0.004 0.003 0.003 0.003 0.002 0.001 0.001 0.000 0.000 0.000 50 0.008 0.006 0.005 0.005 0.004 0.004 0.004 0.003 0.003 0.003 0.001 0.001 0.000 0.000 0.000 60 0.009 0.005 0.004 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 70 0.008 0.006 0.004 0.004 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 80 0.006 0.005 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 90 0.005 0.005 0.004 0.004 0.003 0.003 0.003 0.002 0.002 0.002 0.001 0.001 0.000 0.000 0.000 100 0.006 0.005 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 110 0.009 0.008 0.006 0.006 0.005 0.004 0.004 0.003 0.003 0.003 0.001 0.001 0.000 0.000 0.000 120 0.014 0.012 0.008 0.006 0.004 0.003 0.003 0.002 0.002 0.002 0.001 0.000 0.000 0.000 0.000 130 0.021 0.020 0.016 0.014 0.012 0.011 0.009 0.008 0.007 0.006 0.003 0.001 0.001 0.001 0.000 140 0.031 0.028 0.020 0.017 0.014 0.012 0.010 0.009 0.008 0.007 0.003 0.002 0.001 0.001 0.000 150 0.043 0.037 0.026 0.019 0.015 0.012 0.010 0.009 0.007 0.006 0.002 0.001 0.001 0.001 0.000 160 0.060 0.052 0.037 0.030 0.025 0.021 0.018 0.016 0.014 0.012 0.005 0.003 0.002 0.002 0.001 170 0.086 0.069 0.042 0.028 0.020 0.015 0.012 0.010 0.008 0.007 0.002 0.001 0.001 0.001 0.000 180 0.126 0.101 0.067 0.051 0.041 0.034 0.029 0.025 0.022 0.020 0.009 0.006 0.004 0.003 0.002 190 0.175 0.133 0.082 0.057 0.042 0.033 0.026 0.021 0.018 0.015 0.005 0.003 0.002 0.001 0.001 200 0.225 0.187 0.156 0.143 0.130 0.116 0.103 0.092 0.082 0.074 0.033 0.020 0.014 0.011 0.005 210 0.258 0.194 0.133 0.103 0.083 0.069 0.058 0.049 0.042 0.037 0.013 0.007 0.004 0.003 0.001


[3-36]

DIRECTION (DEGREES)

DISTANCE (Meters) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

220 0.268 0.200 0.139 0.110 0.092 0.078 0.066 0.057 0.050 0.044 0.018 0.010 0.007 0.005 0.002 230 0.245 0.183 0.130 0.105 0.088 0.075 0.064 0.056 0.049 0.043 0.017 0.010 0.006 0.005 0.002 240 0.200 0.145 0.093 0.069 0.054 0.043 0.036 0.030 0.026 0.022 0.008 0.004 0.003 0.002 0.001 250 0.156 0.122 0.091 0.078 0.068 0.059 0.052 0.046 0.041 0.036 0.016 0.010 0.007 0.005 0.002 260 0.122 0.090 0.057 0.041 0.031 0.024 0.020 0.016 0.014 0.012 0.004 0.002 0.001 0.001 0.000 270 0.097 0.079 0.065 0.059 0.053 0.048 0.043 0.038 0.034 0.031 0.014 0.009 0.006 0.005 0.002 280 0.066 0.050 0.033 0.025 0.019 0.016 0.013 0.011 0.009 0.008 0.003 0.001 0.001 0.001 0.000 290 0.038 0.029 0.020 0.016 0.013 0.011 0.009 0.008 0.007 0.006 0.003 0.002 0.001 0.001 0.000 300 0.021 0.016 0.011 0.008 0.006 0.005 0.004 0.004 0.003 0.003 0.001 0.001 0.000 0.000 0.000 310 0.010 0.008 0.005 0.004 0.003 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 320 0.005 0.004 0.003 0.002 0.002 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 330 0.003 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 340 0.002 0.002 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 350 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000


[3-37]

Figure 3.7 (A): Guassian Plume Model for SO2

:


[3-38]

Figure 3.7(B) Air Quality Contour for SO2:


[3-39]

TABLE NO. 3.7 (E) RESULTS FOR PM GAS


360 0.003 0.006 0.005 0.004 0.004 0.004 0.003 0.003 0.003 0.003 0.002 0.001 0.001 0.001 0.000

10 0.003 0.005 0.004 0.003 0.002 0.002 0.001 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000 20 0.006 0.008 0.006 0.004 0.004 0.004 0.003 0.003 0.003 0.003 0.001 0.001 0.001 0.000 0.000 30 0.012 0.013 0.009 0.006 0.005 0.004 0.003 0.003 0.002 0.002 0.001 0.000 0.000 0.000 0.000 40 0.019 0.022 0.017 0.016 0.016 0.016 0.016 0.015 0.014 0.014 0.007 0.004 0.003 0.002 0.001 50 0.022 0.027 0.021 0.018 0.018 0.017 0.017 0.016 0.015 0.014 0.007 0.004 0.003 0.002 0.001 60 0.022 0.028 0.020 0.014 0.012 0.010 0.009 0.008 0.007 0.006 0.003 0.002 0.001 0.001 0.000 70 0.018 0.027 0.021 0.017 0.015 0.014 0.013 0.012 0.011 0.010 0.006 0.004 0.003 0.002 0.001 80 0.014 0.023 0.017 0.012 0.009 0.008 0.006 0.005 0.005 0.004 0.001 0.001 0.000 0.000 0.000 90 0.012 0.022 0.019 0.016 0.015 0.014 0.013 0.012 0.012 0.011 0.006 0.004 0.003 0.002 0.001 100 0.012 0.024 0.019 0.014 0.011 0.009 0.007 0.006 0.005 0.005 0.002 0.001 0.000 0.000 0.000 110 0.018 0.037 0.032 0.026 0.023 0.020 0.019 0.017 0.016 0.015 0.008 0.005 0.004 0.003 0.001 120 0.029 0.057 0.046 0.034 0.026 0.020 0.017 0.014 0.012 0.011 0.005 0.003 0.002 0.001 0.000 130 0.045 0.093 0.080 0.066 0.058 0.052 0.047 0.043 0.040 0.037 0.019 0.011 0.008 0.006 0.002 140 0.065 0.132 0.110 0.087 0.072 0.062 0.055 0.049 0.045 0.041 0.020 0.012 0.008 0.006 0.002 150 0.091 0.183 0.148 0.111 0.087 0.072 0.061 0.053 0.047 0.042 0.019 0.010 0.007 0.005 0.002 160 0.128 0.252 0.206 0.159 0.131 0.113 0.101 0.091 0.084 0.077 0.041 0.026 0.019 0.014 0.006 170 0.186 0.349 0.268 0.188 0.137 0.105 0.084 0.069 0.059 0.051 0.020 0.012 0.008 0.006 0.003 180 0.278 0.507 0.397 0.294 0.233 0.196 0.171 0.152 0.138 0.127 0.067 0.044 0.032 0.026 0.013 190 0.394 0.685 0.518 0.366 0.273 0.214 0.175 0.147 0.126 0.110 0.043 0.024 0.016 0.012 0.005 200 0.513 0.895 0.745 0.631 0.577 0.545 0.518 0.491 0.464 0.437 0.246 0.160 0.116 0.090 0.040 210 0.599 0.986 0.756 0.565 0.454 0.384 0.334 0.296 0.265 0.238 0.103 0.057 0.036 0.025 0.008


[3-40]

DIRECTION (DEGREES)

DISTANCE (Meters) 100 200 300 400 500 600 700 800 900 1000 2000 3000 4000 5000 10000

220 0.625 1.009 0.777 0.591 0.484 0.418 0.371 0.334 0.304 0.278 0.134 0.080 0.054 0.039 0.013 230 0.571 0.917 0.711 0.546 0.452 0.394 0.353 0.319 0.291 0.267 0.129 0.077 0.052 0.038 0.013 240 0.464 0.745 0.559 0.406 0.314 0.258 0.219 0.190 0.168 0.150 0.063 0.035 0.023 0.016 0.005 250 0.354 0.596 0.476 0.379 0.328 0.297 0.275 0.255 0.238 0.222 0.120 0.077 0.055 0.042 0.018 260 0.272 0.453 0.344 0.247 0.189 0.151 0.126 0.107 0.092 0.081 0.030 0.016 0.010 0.008 0.003 270 0.216 0.367 0.308 0.261 0.239 0.225 0.213 0.202 0.190 0.179 0.102 0.067 0.050 0.039 0.019 280 0.148 0.246 0.190 0.140 0.110 0.091 0.078 0.067 0.059 0.052 0.020 0.011 0.007 0.005 0.002 290 0.087 0.146 0.113 0.086 0.070 0.060 0.053 0.048 0.044 0.040 0.021 0.013 0.009 0.007 0.003 300 0.045 0.078 0.061 0.045 0.036 0.030 0.026 0.023 0.020 0.018 0.008 0.004 0.003 0.002 0.001 310 0.022 0.038 0.029 0.021 0.017 0.014 0.012 0.011 0.009 0.008 0.004 0.002 0.002 0.001 0.000 320 0.010 0.020 0.016 0.012 0.010 0.009 0.008 0.007 0.007 0.006 0.003 0.002 0.001 0.001 0.000 330 0.005 0.010 0.008 0.006 0.005 0.004 0.003 0.003 0.002 0.002 0.001 0.000 0.000 0.000 0.000 340 0.003 0.007 0.006 0.005 0.004 0.004 0.003 0.003 0.003 0.002 0.001 0.001 0.001 0.000 0.000 350 0.003 0.006 0.005 0.003 0.003 0.002 0.002 0.001 0.001 0.001 0.000 0.000 0.000 0.000 0.000


[3-41]

Figure 3.8 (A): Guassian Plume Model for PM:


[3-42]

Figure 3.8(B) Air Quality Contour for PM:


[3-43]

3.7 WATER ENVIRONMENT

3.7.1 Design of Network for Water Sampling Locations

The water quality status in the impact zone is assessed through a network of water quality sampling

locations. The baseline studies for water environment include identification of specific parameters

of the pollutants prior to implementation of the project. The Environmental Impact Assessment

(EIA) study requires monitoring of baseline water quality during one season. Physico-chemical

parameters have been analyzed to ascertain the baseline status of fresh water in the existing surface

water and ground water bodies. Samples were collected once during the study period for winter

season on December 2010 & February 2011.

The baseline status of the water environment is assessed through a systematic water quality

surveillance program, which is planned based on the following criteria:

• Densely populated areas within the region.

• Location of the surrounding industries.

• Representation of regional background.

3.7.2 Reconnaissance

Reconnaissance was undertaken to establish the baseline status of the air environment in the study

region. Six nos. of water sampling locations were selected within the study area of 10 Km radial

distance from the project site.

3.7.3 Methodology for Ground Water and Surface Water Sampling:

The ground and surface water sampling was carried out as per the prescribed sampling guidelines

and analysis standards of CPCB for water sampling and analysis. Ground water sampling was

carried out at 6 different locations & surface water sampling was carried out from 5 different sites

out of which 4 sampling locations were nearby pond and 1 sample was taken of river Mahi.


[3-44]

There will be only domestic waste water generation which will be allowed in u/g soak pit system.

There shall be no industrial waste water generation. Thus, there shall be no any possibility towards

contact of waste water with soil or land neither it impacts ground water strata.

The details of surface and ground water sampling locations are given in Table 3.8. And sampling

locations of water quality monitoring are shown in Figure 3.9. The Physico-chemical

characteristics of the different water samples are present in the Tables 3.9 (A-C)

Table 3.8 DETAILS OF WATER MONITORING LOCATIONS

Sr. No.


Approximate Radial distance From project

Site (km)

Direction From project

Site

1. Project Site (W1) 0.0 -

2. Bahidhara Village (W2) 2.16 NNE

3. Anjesar (W3) 3.06 ESE

4. Mahapura (W4) 2.97 WWS

5. Raniya (W5) 4.67 WWN

6. Mahi River, Jalampura (W6) 7.01 WWS


[3-45]

Figure 3.9 LOCATION OF WATER SAMPLING STATION


[3-46]

Table 3.9 (A): GROUND WATER QUALITY

Sr. No. Parameters Units

IS 10500 Standard Limits for drinking water Locations

Desirable limit

Permissible limit

Project Site

(W1) Bahidhra

(W2) Anjesar

(W3) Mahapura

(W4) Raniya (W5)

Mahi River (W6)

1. pH pH Scale 6.5-8.5 6.5-8.5 7.31 7.13 7.44 7.47 7.53 7.37 2. Temperature °C NS NS 28 30 28 30 29 29 3. Turbidity NTU 5 10 5.6 49.8 20.5 4.5 4.8 5.7 4. Mg. Hardness mg/lit NS NS 320 780 162 238 535 732 5. Tot. Alkalinity mg/lit 200 600 223 545 284 298 320 438 6. Chloride mg/lit 250 1000 40.3 22.85 383.4 283 440.3 212.3 7. Sulphate mg/lit 200 400 7.54 7.38 48.9 36 38.3 14.12 8. Nitrate mg/lit NS NS 0.033 0.03 0.042 0.02 0.02 0.014 9. Fluoride mg/lit 1.0 1.5 0.51 0.61 0.79 0.96 0.84 0.61

10. Sodium mg/lit NS NS 265 324 565 238 328 294 11. Potasium mg/lit NS NS 38 42 24 38 48 32 12. Salinity mg/lit NS NS 74.3 110.8 142.3 96.4 68.9 112.7 13. Total Nitrogen mg/lit NS NS 14.4 21.0 16.2 19.3 22.0 12.2 14. Total Phosphorus mg/ lit NS NS 0.88 1.23 1.8 1.33 0.92 0.81 15. DO mg/ lit NS NS 3.02 1.13 2.58 2.05 3.88 3.98


[3-47]

16. BOD mg/ lit NS NS 03 04 5 2 5 8 17. COD mg/ lit NS NS 12 12 16 8 16 28 18. Phenol mg/ lit 0.001 0.002 Absent Absent Absent Absent Absent Absent 19. Lead mg/ lit 0.05 0.05 Absent Absent Absent Absent Absent Absent 20. Total Chromium mg/ lit 0.05 0.05 Absent Absent Absent Absent Absent Absent 21. Iron mg/ lit 0.3 1.0 0.08 1.16 1.32 0.63 0.88 1.1 22. Copper mg/ lit 0.05 0.05 Absent Absent Absent Absent Absent Absent 23. Zinc mg/ lit 5 15 0.14 0.12 0.18 0.20 0.11 0.07 24. TDS mg/ lit 500 2000 832 812 296 398 1170 586 25. Conductivity µmhos/cm NS NS 1184 2022 2454 3265 1280 920


[3-48]

Table 3.9 (B): SURFACE WATER QUALITY

Parameters Unit Locations

Bahidhara Pond

Anjesar Pond

Mahapura Pond

Raniya Pond

Mahi River

pH pH scale 7.8 7.6 7.5 7.5 8.08

DO mg/lit 5.1 4.6 4.5 5.1 7.17

COD mg/lit 14.3 10.2 16.0 12.6 8.0

BOD mg/lit 5 4 6 3 2

Free NH4 mg/lit 0.62 0.48 0.59 0.66 0.56

Boron mg/lit -- -- -- -- --

Sodium

Absorption

Ratio

--

1.12 1.53 1.36 1.16 1.20

Conductivity µmhos/cm 890 942 755 435 535

TDS mg/lit 580 650 548 355 464


[3-49]

Table 3.9 (C): LIMITS FOR SURFACE WATER

Sr. No.

Parameters Unit

Minimum Quality specified by CPCB for Qualification of a Particular River Stretch to

Satisfy The Use Classifications

A B C D E

1. Total Carbon mg/l NS NS NS NS NS

2. pH pH scale 6.5 to 8.5

6.5 to 8.5

6.0 to 9.0

6.5 to 8.5

6.5 to 8.5

3. Dissolved Oxygen mg/l 6.0 5.0 4.0 4.0 NS

4. BOD at 20°C mg/l 2.0 3.0 3.0 NS NS

5. Sodium Absorption Ratio (SAR)

mg /gm NS NS NS NS 26 (Max)

6. Boron as B mg/l NS NS NS NS 2

7. Electrical conductivity µ mhos /cm NS NS NS NS 2250

8. Free Ammonia as N mg/l NS NS NS 1.2 NS

9. Total Coliform MPN/100 ml 50 500 5000 - -

Classification of river waters as per their intended use:

A- Drinking water source without conventional treatment but after disinfection B- Out door bathing (organised) C- Drinking water source with conventional treatment followed by disinfection D- Propagation of wildlife, fisheries E- Irrigation, industrial cooling, controlled waste disposal


[3-50]

3.7.4 Baseline Ground Water Quality pH of ground water samples varies from 7.13 – 7.53 DO are found in the range of 1.13 –

3.98 mg/L. Mg. hardness (as CaCO3) varies from 162 - 780 mg/L. Chloride and Sulfates

are found in the range of 22.8 – 440 mg/L and 7.38 – 48.9 mg/L respectively. TDS are

found in the range of 296 – 1170 mg/L.

3.8 AMBIENT NOISE MONITORING

Industrialization, urbanization, construction activities etc., have a direct bearing on the

noise level of the surrounding environment pertaining to such activities. Noise intensity

beyond certain tolerable limits may interfere with communication in work, apart from

causing annoyance and health hazards. Impact of noise on environment depends on

various factors such as intensity distance from source, time of exposure and nature of

activities, machineries, traffic etc. Hence, it is necessary to measure the ambient noise

levels in order to determine the environmental impact so that appropriate measures could

be adopted if needed to abate noise pollution.

The main objective of noise monitoring in the study area is to establish the baseline

noise levels, and assess the impact of the total noise that is expected to be generated

during the construction, and operation of the proposed project activities. Noise

monitoring has been undertaken for 3 hr interval at each location.

Noise monitoring was carried out to establish ambient noise levels in the study area. The

details of the sampling stations are given below in the Table 3.10 and their locations

area are shown in Figure 3.10


[3-51]

Table 3.10 DETAILS OF NOISE MONITORING LOCATIONS

Sr. No.


Approximate radial distance from project

site (km)

Direction from project site

1. Project Site (N1) 0.0 -

2. Bahidhara Village (N2) 2.16 NNE

3. Anjesar (N3) 3.06 ESE

4. Mahapura (N4) 2.97 WWS

5. Raniya (N5) 4.67 WWN


[3-52]

Figure 3.10 LOCATION OF NOISE MONITORING


[3-53]

The noise level data at various locations are as mentioned in Table 3.11. From the noise

level data recorded from the study area it is observed that the average noise level

recorded at Station N1 (Project site) is higher than that recorded at other stations. This

can be attributed towards noise created due to vehicle movement on the road and other

domestic activity in the area.

Table 3.11 NOISE LEVEL DATA

Unit: dB (A): 3 Hours

Sr. No. Sampling Location

Recording Time(Recording interval – 3hrs)

Sound Level

dB(A)

Avg. dB(A)

1. Project Site (N1) Day 66.1 65.3 65.1 63.4 64.9

Night 60.1 59.3 58.4 61.2 59.7

2. Bahidhara (N2)

Day 62.3 63.1 61.0 60.2 61.6

Night 54.4 53.6 52.1 56.2 54.0

3. Anjesar (N3) Day 51.1 53.9 61.0 50.8 59.8

Night 46.3 44.8 43.9 42.6 45.7

4. Mahapura (N4)

Day 55.0 51.7 50.7 55.2 50.8

Night 40.3 43.8 40.2 49.0 42.3

5. Raniya (N5) Day 59.0 54.1 51.9 52.0 52.7

Night 54.4 43.1 42.9 41.6 42.0


[3-54]

3.9 SOIL QUALITY MONITORING

Soil samples were collected from nine different locations during winter season on

December 18, 2010 in the study area (0-20 cm depth). The locations selected for

collection of soil samples are shown in Figure 3.11 and presented in Table 3.12. The

analysis results of soil samples are given in Table 3.14.

3.9.1 Soil Classification Following Table 3.13 provides the soil type and area under different soils within the

project area.

Table 3.12 DETAILS OF SOIL MONITORING LOCATIONS

Sr. No.


Approximate radial distance

from project site (km)

Direction from project site

1. Project Site (S1) 0.0 -

2. Bahidhara Village (S2) 2.16 NNE

3. Anjesar (S3) 3.06 ESE

4. Mahapura (S4) 2.97 WWS

5. Raniya (S5) 4.67 WWN


[3-55]

FIGURE - 3.11 LOCATION OF SOIL SAMPLING STATION


[3-56]

Table 3.13 SOIL CLASSIFICATION

Category Remarks Area_sqkm

Description

Taxonomy1

Taxonomy2 Class Sub_class

Category D 4.48

Moderately deep, moderately well drained, fine soils on nearly level alluvial plain with slight erosion and moderate salinity; associated with very deep, moderately well drained, calcareous, fine soils with slight erosion and slight salinity

Fine, montmorillonitic, isohyperthermic

Typic Chromusterts

Fine, montmorillonitic,

(calcareous), isohyperthermic

Udic Chromusterts

Soils of West Coast (Soils of Gujarat Plain)

Soils of Alluvial Plains

Category E 97.80

Very deep, moderately well drained, calcareous, very fine soils on nearly level plain with slight erosion and slight salinity; associated with very deep, moderately well drained, calcareous, fine soils on very gently sloping lands with slight erosion and slight salinity

Very-fine, montmorillonitic


Typic Chromusterts

Fine, montmorillonitic

(calcareous), hyperthermic,

Vertic Ustochrepts

Soils of west coast (soils of Gujarat plain)

Soils of alluvial plains

Category F 9.41

Very deep, moderately well drained, calcareous, very fine soil on nearly level plain with slight erosion and moderate salinity associated with very deep, moderately well drained, calcareous, very fine soils on very gently sloping lands with slight erosion

Very-fine, montmorillonitic


Udic Chromusterts



Udic Chromusterts


Soils of alluvial plains


[3-57]

(Courtesy: Environmental Information Centre, New Delhi)

Category H 74.76

Very deep, imperfectly, drained, calcareous fine soils, nearly level coastal plain with slight erosion and very strong salinity; associted with very deep moderately well drained, calcareous, fine soils with slight erosion and moderate salinity

Fine, mixed (calcareous),

isohyperthermic Typic Halaquepts



Typic Chromusterts


Soils of coastal plains

Category I 58.06

Deep, poorly drained, calcareous, fine soils on nearly level coastal plain with slight erosion and very strong salinity; associated with very deep, poorly drained, calcareous, fine soils with slight erosion and strong salinity



Vertic Halaquepts



Typic Halaquepts


Soils of coastal plains

Category J 53.52

Very deep, moderately well drained, calcareous fine soils on nearly level coastal plain with slight erosion and very strong salinity; associated with very deep, moderately well drained, calcareous fine loamy soils on very gently sloping lands with modera

Fine, mixed (calcareous),

isohyperthermic Typic Ustropepts

Fine-loamy mixed (calcareous),

isohyperthermic Typic Ustropepts

soils of west coast (soils of Gujarat plain)

soils of coastal plains

Category K Sea Beach Or River Bed

7.43 Fine, montmorillonitic, isohyperthermic Typic Chromusterts

Category L Mud 8.48

Very-fine, montmorillonitic (calcareous), isohyperthermic Typic Chromusterts


[3-58]

Table 3.14 PHYSICO CHEMICAL CHARACTERISTIC OF SOIL

Sr. No. Parameter Unit Locations

Project site Bahidhara Anjesar Mahapura Raniya

1. pH pH Unit 6.75 7.5 7.6 7.4 7.2

2. Calcium mg/kg 126 135 122 155 87

3. Magnesium mg/kg 37 46 41 46 45

4. Potassium mg/kg 29 31 34 34 24

5. Sodium mg/kg 87 80 67 71 57

6. Zinc mg/kg Trace Trace Trace Trace Trace

7. Copper mg/kg Trace Trace Trace Trace Trace

8. Lead mg/kg ND ND ND ND ND

9. Iron mg/kg 0.03 0.18 0.06 0.08 0.05

10. Nickel mg/kg Trace Trace Trace Trace Trace

11. Phosphate mg/kg 0.11 0.15 0.18 0.12 0.16

12. Porosity % 47.37 41.3 41.7 42.9 42.5

13. Water handling capacity % 39 42 44 41.0 38

14. Chloride mg/kg 95 75 112 95 85

15. Sulphate mg/kg 81 57 45 55 60

16. Nitrate mg/kg 12 16 26 20 14


[3-59]

17. Organic Matter mg/kg 1.75 1.28 1.13 1.19 1.15

18. Bulk Density g/cc 1.45 1.42 1.42 1.44 1.41

19. Gravel % 13 11 14 16 17

Coarse Sand % 8 9 5 9 9

Medium sand % 5 7 5 11 9

Fine Sand % 9 8 10 9 10

Silt % 38 26 32 30 28

Clay % 27 32 29 26 30

Sp. Gravity % 2.564 2.678 2.220 2.500 2.430

20. Conductivity µmhos/sec

21. Sodium Absorption Ratio -- 0.82 1.74 1.29 1.24 1.51

22. Permeability Cm/hr 2.95 3.1 3.15 3.25 3.2


[3-60]

3.9.3 Baseline Soil Quality PH varies from 6.75 – 7.6. TDS varies from 257 – 1248 mg/kg. Calcium and Magnesium

are found in the range of 87 – 155 mg/kg and 37 – 46 mg/kg respectively. Potassium and

Sodium are found in the range of 24 – 34 mg/kg and 57 – 87 mg/kg respectively. Zinc,

Copper and Lead are found BDL mg/kg respectively. Iron and Nickel are found in range

of 0.03 – 0.18 mg/kg and BDL mg/kg respectively. Lead is not detectable in any sample.

Phosphates are found in the range 0. – 0.18 mg/Kg Porosity and Water Holding Capacity

are found in the range of 41.3% - 47.3% and 38% - 42% respectively. Chloride, sulphates

and Nitrate are found in the range 75 – 112 mg/Kg, 45-81 mg/Kg and 12-26 mg/Kg

respectively. Organic Matter was found in the range of 1.13-1.75. Bulk Density varies

from 1.41 – 1.45 gm/cm3.


[3-61]

LAND USE PATTERN, BIOLOGICAL ENVIRONMENT AND SOCIO-ECONOMIC ENVIRONMENT

3.10 LAND USE PATTERN

As per the statistical record of census handbook the extent of land area under use for various activities in study area can be summarized as follows

The likely landuse within the study area is determined. The study area contains

forestland, irrigated agricultural land, unirrigated agricultural land, cultivable wasteland

and area not available for cultivation. There are total of 15 villages’ falls within 5.0 km

radius from the project site. The total area studied is about 28889 hectares.

Land use, in general, reflects the human beings activities on land, whereas the word land

cover indicates the vegetation, agricultural and artificial manmade structures covering the

land surfaces. Identification and periodic surveillance of land uses and vegetation covers,

in the vicinity of any developmental activity is one of the most important components for

an environmental impact assessment, which would help determine the impact of the

project development activity on the land use pattern.

The land use classification within a distance of ten kilometers from the project location and

the areas falling under the respective classifications are as per the following Table 3.15 &

Figure 3.12 shows its graphical representation.

Table 3.15 AREAS UNDER DIFFERENT LANDUSE

Sr. No.

Land use classification Area (ha), within 10 km of project location

Percentage of total area

1. Forest 00 00

2. Irrigated by source 10802.2 37.4

3. Unirrigated 12196.8 42.2

4. Culturable waste land 2207.6 7.6

5. Area not available for cultivation 3676.9 12.7

6. Urban Area 5.8 0.1

Total 28889 100


[3-62]

Figure 3.12 LAND USE PATTERN WITHIN STUDY AREA

LAND USE PATTERN

0%

37%

42%

8%

13%

0%Forest

Irrigated by source

Unirrigated

Culturable waste land

Area not available forcultivationUrban Area


[3-63]

3.11 GEOLOGICAL STRUCTURE

The geology of the entire Gujarat has been shown in Figure 3.13 Figure 3.13GEOLOGY OF GUJARAT

FIGURE 3.13: GEOLOGY OF GUJARAT The geology of the study area consists of Alluvium, Blown sand, millolite sand, Basalts andesite, trachyte flows, Laterite, Bauxite, Gypsiferous clays and Sandy limestone.


[3-64]

3.12 HYDROLOGY

Ground water is mainly in the sand sections. Underground water level is comparatively

low in the area. The groundwater depth is 20.0-25.0 m below ground level in the Study

area. The Figure 3.14 shows the ground water level of Gujarat state.

Figure 3.14 GROUND WATER LEVEL OF GUJARAT STATE

FIGURE 3.14: GROUND WATER LEVEL IN GUJARAT

3.13 PHYSIOGRAPHY

The district Vadodra is a part of Gujarat plain and is subdivided into seven sub- micro

regions, namely, Khambhat Silt, Mahi plain, Vadodra plain, Orsang Heran plain,

Vindhyan hills, Narmada Gorge and lower topography, climate, geology, soils and

natural vegetation.


[3-65]

3.14 FOREST BOUNDARIES

The forest cover is classified based on Forest Survey of India into Dense (> 40% crown

density), open (between 10 to 40 % crown density) and Scrubs (shrubby bush of less than

10 % crown density). The vegetation classification criterion used for this study area is

given as follows:

Dense Vegetation is the lands with forest cover with canopy density of equal or more

than 40 percent.

Medium Vegetation is the land with forest cover with canopy density of 10 to 40 percent.

Open Vegetation is the land with forest cover with canopy density less than 10 percent.

Scrubs are the lands generally in and around forest areas, having bushes and/or poor tree

growth chiefly of small or stunted trees with a canopy density less than 10 percent.

3.14.1 Method of Preparation

The vegetation cover for the area of interest has been prepared by extracting the areas under four different vegetation classification provided by the Forest Survey of India (FSI) based on IRS-ID LISS III data for the past two years for the State of Gujarat. There is no Reserved Forests and Protected Forests within the 10 km radius area from project site. The project site and area of interest have been added for ease of special reference.

3.14.2 Map of Vegetation Classification and Forest Boundaries

A digital map comprising layers of vegetation classification, and town and village

locations to facilitate ease of reference and the Area Statistic is given in Table 3.16


[3-66]

Table 3.16 AREA STATISTIC OF FOREST MAP

Area Statistics of Forest Map

Sr. No. Class Name Area (In

Hectares) Area (In Sq.

Km.) Percentage

1. Water Body 23998.81 239.99 12.24 2. Non Vegetation Area 152894.59 1528.95 78

3. Mangrove(Sparse) 2.88 0.03 0.0015 4. Mangrove(Dense) 19.53 0.20 0.01

5. Open/Degraded Vegetation 4410.66 44.11 2.25 6. Vegetation Low Density 11376.46 113.76 5.8 7. Vegetation High Density 450.89 4.51 0.23

8. Scrubs 2792.6208 27.93 1.42

Total 195946.44 1959.46 100


[3-67]

3.15 FLORA Table 3.17 Flora Found in the Savli Area


Common Name Botanical Name Al Cassia auriculata Amla Emblica officinalis Amli Tamarindus indicus Asotri Bauhinia racemosa Aval Cassia auriculata Babul Acacia arabica Baheda Terminalia belerica Beo Pterocarpus marsupium Bondara Lagerstroemia parviflora Bor Zizyphus mauritiana Bordi Zizyphus jujuba Charoli Buchanania lanzan Garmala Cassia fistula Ghatbor Zizyphus xylopyra Gorad Acacia senegal Goradio Acacia senegal Haladwan Adina cordifolia Indrajav Wrighatia tinctoria Jheribaval Acacia farnesiana Kado Holarrhena antidysenterica Kakad Garuga pinnata Kalamb Mitragyna parviflora Karanj Holoptelea integrifolia Kerdo Capparis deciduas Khair Acacia catechu Khakharo Butea frondosa Khakhra Butea monosperma Limbda Melia azadirchta Limbdo Azadirachta indica Mahuda Madhuka indica Palpal Acacia senegal Patrali Dalbergia paniculata Pipal Ficus religiosa Ratobaval Acacia jacquenmonti Sadad Terminalia tomentosa Sag Tectona grandis Sarero Streblus asper Shivan Gmelina arborea Sisam Dalbergia latifolia Tad Phoenix sylvestris Talbaval Acacia farnesiana Teak Tectona grandis Timru Diosphyros melanoxylon Timru Diospyros Montana Umbh Sacconetaluma tomentosum Umro Ficus giomerata Vad Ficus bengalensis Velantro Dichrostachys cinera


[3-68]

3.16 FAUNA

Some Common Fauna of the project area are given Below in Table 3.18

Common Name Scientific Name Fauna

Common Langur Presbestis entellus Common Mongoose Herpestes edwardsi Common Palm Civet Paradoxurus hermaphrohditus Desert hare Leptus dayanus Flying Fox Pteropus giganteus Grey Musk Shrew Suncus murinus Indian Fox Vulpes bengalensis Indian Gerbille Tatera indica Indian Porcupine Hystrix indica Indian Tree Shrew Anathana ellioti Indian Wild Boar Sus scrofa Jackal Canis aureus Longtailed Tree Mouse Vandelura oleracea Nilgai Boselphus tragocamelus Pale Hedgedog Paraechinus micropus Pangolin Manis crassicauda Ratel Melivora capenies Sambar Cervus Unicolor Small Indian Civet Vivericula indica Smooth Indian Otter Lutrogale perspicillata Striped Hyaena Hyaena Hyaena Striped squirrel Funambulus pennant

Avi-Fauna Black Ibis Pseudibis papillosa Blacknecked Grebe P.caspicus Blue Rock Pigeon Columba livia Cattle Egret Bubulcus ibis Cinnereous Vultureq Aegypius monachus Comb Duck Sarkidornis melanots Common Indian Nightjar Caprimulgus asiaticus Common Pochard Anas ferrina Common Quail Coturnix coturnix Common Teal Anas crecca Coot Fulica altra Cormorant Phalacroccrax carbo Cotton teal Nettapus coromandelianus Demoiselle Crane Antcropoides virgo Dusky Horned Owl B.coromandus Fantail Snipe Capella gallinago Flamingo Phoenicopetrus reseus Glossy Ibis Plegadis falcinellus Great Crested Grebe P.cristatus Great Horned Owl Bubo bubo Green Pigeon Treron phoenicoptera Grey Heron Ardea cinerea Grey Patridge Francolinus pondicerianus Grey Pelican P. philippensis Houbara Chlamydotis undulate


[3-69]

Indian Ring Dove Streptopelia decaocto Indian Sandgrouse Pterocles exustus Indian Skimmer Rynchops albicollis Koel Eudynamys scolopacea Large Egret Egretta alba Large Indian Parakeet P.eupatria Lesser Flamingo Phoeniconais minor Lesser Floriken Sypheotides indica Lesser Whistling Teal Dendrocygna javanica Little Brown Dove S.senegalensis Little Grebe Podiceps ruficollis Little Green Heron Bautorides striatus Mottled Wood Owl Strix ocellata Night Heron Nycticorax nycticorax Open billed Stork Anastomus oscitans Painted Sandgrouse Pterocles indicus Painted Snipe Rostratula benghalensis Painted Stork Ibis leucocephalus Peafowl Ibis leucocephalus Peafowl Pavo cristatus Pied Crested Cuckoo Clamator jacobinus Pink Flamingo Phoenicopterus roseus Red Turtle Dove S.tranquebarica Redwattled Lapwing Vanellus indicus Rose ringed Parakeet Psittacula krameri Rosy Pelican Pelicanus onocrotalus Sarus Crane Grus antigone Shikra Accipiter badius Shorteared Owl Asio flammeus Shovellor Anas cylpeata Snake bird Anhinga rufa Spotbill duck Anas poecilorhynchos Spotted Dove S.chinensis Stone Curlew Burhinus oedicnemus White breasted waterhen Amaurornis phoenicurus White Ibis Threskiorsis melenocephala White Pelican Pelecanus onocrotalus White Stork Ciconia ciconia White Vulture Neophron percnopterus White-necked Stork Ciconia episcopus



[3-70]

3.17 DEMOGRAPHIC & SOCIO ECONOMIC PROFILE (CENSUS 2001)

There are total 40 villages (Rural and Urban) falls within 10 km radius of the project site. The demographic and socio economic profile has been presented below. The four major indicators viz. demography, civic amenities, economy and social culture. The baseline status of the above indicators is compiled in forthcoming sections.

3.17.1 Method of Data Preparation

The Census District Book, Map has been used to identify the settlements at various

distances from the project site and compile the demographic data as per the requirement of

environmental clearance questionnaire for different distance bands from the project site.

3.17.2 Demographic Data within the Region of Interest

Table 3.19 provides the data on inhabitations falling within 500m, between 500m and 5

km, between 5 km and 10 km distance from the project site.

On an average, Taluka Savli has population density of about 300 persons per sq. km.

(2001 Census data) & Taluka Vadodra has population density of about 2460 persons per

sq. km. (2001 Census data), compared to the Vadodra District, which has a population

density of about 482 persons per sq. km. (2001 Census data), Population density within

10 km radius of the site is only 473 persons per sq. km. (2001 Census data), while

population density within 5 km radius of site is 435 persons per sq. km. (2001 Census

data). The population details (i.e. population distribution and population density) of the

Taluka Savli & Vadodra and District Vadodra and the study area within 10 km radius and

5 km radius are given in Table 3.20. And their graphical representations are shown in

Figure 3.15 & 3.16.


[3-71]

Table 3.19 DEMOGRAPHIC DATA (CENSUS – 2001)

SR. NO. TOWN / VILLAGE NO. OF

HOUSEHOLD POPULATION

MALE FEMALE TOTAL WITHIN 500 M FROM PROJECT SITE 0 None Nil Nil Nil Nil WITHIN 500 M TO 5 KM FROM PROJECT SITE

1 Ranchhodpura 220 692 623 1315 2 Bahidhara 546 1684 1438 3122 3 Bhadarva 1190 3182 2900 6082 4 Parthampura 173 436 397 833 5 Jalampura 147 376 347 723 6 Khandi 306 852 690 1542 7 Poicha (Raniya) 638 1722 1462 3184 8 Raniya 594 1617 1476 3093 9 Mahapura 140 375 318 693 10 Ranipura 163 423 343 766 11 Namisara 396 1114 970 2084 12 Bautha 304 783 670 1453 13 Anjesar 456 1310 1151 2461 14 Moksi 1173 3046 2722 5768 15 Kunpad 576 1485 1307 2792

WITHIN 5 KM TO 10 KM FROM PROJECT SITE (TALUKA SAVLI) 16 Poicha (Kanoda) 931 2478 2274 4752 17 Sardarpura 90 256 242 498 18 Savli 3449 9382 8555 17937 19 Wankaner 1379 4118 3659 7777 20 Gothada 1477 4316 3901 8217 21 Manjusar 986 2720 2258 4978 22 Lamdapura 131 468 369 837 23 Zumkal 54 111 93 204 24 Alindra 119 296 280 576 25 Pilol 582 1512 1462 2974 26 Khokhar 207 552 530 1082 27 Dodka 458 1603 1374 2977 28 Rayaka 326 927 793 1720 29 Sankarda 1161 3397 3052 6449 30 Vasna 665 1855 1595 3450 31 Sokhda 2295 6459 5889 12348 32 Padamla 1067 2700 2413 5113 33 Fazalpur 745 2104 1900 4004 34 Ajod 488 1224 1169 2393 35 Asoj 797 1925 1709 3634 36 Lasundra 213 578 522 1100 37 Pasva 193 478 458 936 38 Subhelav 113 243 252 495 39 Tundav 951 2856 2600 5456 40 Paldi 133 362 329 691

URBAN AREA (TALUKA SAVLI) 1 Savli 3449 9382 8555 17937 2 Wankaner 1379 4118 3659 7777 3 Tundav 951 2856 2600 5456

URBAN AREA (TALUKA VADODRA) 1 Sankarda 1161 3397 3052 6449 2 Sokhda 2295 6459 5889 12348 3 Padamla 1067 2700 2413 5113

(Courtesy: Census Dept., GOI, Census Book)


[3-72]

Table 3.20 POPULATION DENSITY

Name Population (Persons)

Population Density

(Person / sq. km.)

Sex ratio (No. of females per

1000 males) Within 5 km Radius 35911 435 880

Within 10 km Radius 136509 473 895

Taluka Savli 237929 300 899

Taluka Vadodra 1705989 2460 907

District Vadodra 3641802 482 919


Figure 3.15 MALE & FEMALE WITHIN STUDY AREA

MALE- FEMALE

53%47% MALE

FEMALE


[3-73]

Figure 3.16 POPULATION DENSITY & SEX RATIO

POPULATION DENSITY

435 473300

2460

482

0

500

1000

1500

2000

2500

3000

POPU

LATI

ON D

ENSI

TY

Series1

Series1 435 473 300 2460 482

Within 5 km

Within 10 km

Taluka Savli

Taluka Vadodra

District Vadodra

Sex ratio (No. of females per 1000 males)

880

895 899907

919

860

880

900

920

940

SEX

RATI

O

Series1

Series1 880 895 899 907 919

Within 5 km

Within 10 km

Taluka Savli

Taluka Vadodra

District Vadodra


[3-74]

3.17.3 Literacy Rate

The literacy rate is a major factor, which influences the socio-cultural condition of a

particular place. Details of literacy rate in District-Vadodara, Taluka-Vadodara, Taluka-

Savli and within 10 km radius and 5 km radius of project site are given in Table 3.21

while their graphical representation is shown in Figure 3.17. It is observed that the

literacy rate in Vadodara District as per 2001 Census data is 70.8 as percentage of literate

population to the total population, with 80.0 % among male and 60.7 % among female.

Literacy rate in Taluka-Vadodara as per 2001 Census data is 64.22 % with 74.19 %

among males and 53.10 % among females. Literacy rate in Taluka-Savli as per 2001

Census data is 58.99 % with 68.94 % among males and 47.33 % among females.

Within 10 km radius of the study area, the literacy rate is observed 60.61 % having 70.56

% among males and 49.49 % among females, whereas literacy rate within 5 km radius of

study area is 58.39 % having 68.2 % among males and 47.24 % among females.

Table 3.21 LITERACY RATE

Name Male Literacy (%)

Female Literacy (%)

Total Literacy (%)

Within 5 km Radius 68.20 47.24 58.39

Within 10 km Radius 70.56 49.49 60.61

Taluka Vadodra 74.19 53.10 64.22

Taluka Savli 68.94 47.88 58.99

District Vadodra 80.0 60.7 70.8



[3-75]

Figure 3.17 LITERACY RATE

3.17.4 Occupational Structure There is a large diversity in the occupational pattern in the study area. In Rural, majority

of the people are engaged in agricultural activities, forestry and allied activities.

Major activities in Urban areas include industrial employment, Trade and Commerce,

Livestock, Business, Construction, Transport and Communication network, Engineering

profession, Service centers, Technical and Medical services and others.

This wide diversity in occupational structure may be broadly categorized as working and

non-working population. The Table 3.22 shows total culturer, agriculturer, household,

main workers, marginal workers and non-workers and the Figure 3.18 is the graphical

representation of the total numbers of workers in each category.

LITERACY RATE

0

50

100

LITE

RA

CY

%

MALEFEMALETOTAL

MALE 68.2 70.56 74.19 68.94 80

FEMALE 47.24 49.49 53.1 47.88 60.7

TOTAL 58.39 60.61 64.22 58.99 70.8

Within 5 Within Taluka Taluka District


[3-76]

Table 3.22 OCCUPATIONAL STRUCTURE (2001 DATA)

OCCUPATIONAL PATTERN IN VILLAGES FALLING UNDER AREA OF INTEREST - 2001

Sr. No.

Name of Village

Occupational Pattern

Cultivator Agriculture Household Industries

Other Worker

Marginal Workers

Non Workers

Taluka Savli 1 Poicha

(Kanoda) 901 168 04 119 726 2439

2 Sardarpura 95 49 00 04 110 240 3 Savli 865 1174 130 2912 1575 11281 4 Wankaner 1051 1048 79 676 659 4264

5 Gothada 1008 1022 11 375 924 4877 6 Ranchhodpura 286 272 03 45 155 554 7 Bahidhara 426 370 08 149 91 2078

8 Bhadarva 538 720 24 739 400 3661 9 Parthampura 58 275 02 46 38 414

10 Jalampura 45 393 02 21 19 243

11 Khandi 108 83 02 247 333 769 12 Poicha (Raniya) 245 302 44 341 352 1900 13 Raniya 174 315 01 439 322 1842

14 Mahapura 59 319 00 35 06 274 15 Ranipura 11 03 02 05 483 262

16 Namisara 235 257 02 147 101 1342 17 Bautha 221 169 04 177 76 806 18 Lasundra 104 148 00 101 36 636

19 Pasva 107 182 00 97 00 550 20 Subhelav 33 95 01 86 50 230 21 Tundav 444 803 13 329 226 3641

22 Paldi 28 73 00 94 14 482 23 Anjesar 248 77 21 156 567 1388 24 Moksi 565 480 38 474 621 3590

25 Kunpad 175 82 26 312 778 1414 26 Manjusar 235 721 13 1063 38 2908

27 Lamdapura 63 144 00 48 104 478


[3-77]

28 Zumkal 06 05 00 14 81 98 29 Alindra 26 09 00 49 172 320 30 Pilol 373 129 00 294 543 1635

31 Khokhar 141 61 02 154 81 643

Urban Area- Taluka Savli 1 Savli 865 1174 130 2912 1575 11281 2 Wankaner 1051 1048 79 676 659 4264

3 Tundav 444 803 13 329 226 3641

Tauka Vadodra 1 Dodka 372 122 06 214 480 1783

2 Rayaka 111 175 07 394 120 913 3 Sankarda 383 483 91 778 412 4302

4 Vasna 405 439 18 278 338 1972 5 Sokhda 779 1594 42 1404 1540 6989 6 Padamla 203 581 26 845 174 3284

7 Fazalpur 276 296 05 554 826 2047 8 Ajod 173 230 01 393 83 1513 9 Asoj 191 420 12 490 121 2400

Urben Area Tauka Vadodra 1 Sankarda 383 483 91 778 412 4302 2 Sokhda 779 1594 42 1404 1540 6989

3 Padamla 203 581 26 845 174 3284


[3-78]

Figure 3.18 WORKERS CATEGORISATION

3.18 PUBLIC AMENITIES Infrastructure resource base of the surveyed villages with reference to education, medical,

water resources, post and telegraph, communication, power supply is presented in Table

3.23. There are 40 villages within study area of 10 km radius of plant site. Significant

observations with respect to availability of amenities in study area are as follows.

Most of the villages have primary schools; within the distance of 10 km radius we have

total 83 number of primary school, 02 College, 16 Higher secondary education schools.

05 Senior Secondary School, 05 Other educational Institute, 2 Industrial School.

Within the 10 km Radius apart from the Education Facilities there is also the Medical

facilities which Include 03 Hospital, 10 Primary Health Centre, 06 Maternity and Child

Welfare, 24 number of Primary health sub-centre, 39 registered private practitioners

while 08 family welfare centre, 06 Community Health worker, 03 Dispensary, 02 T.B.

Clinic, 05 maternity home, 1 nursing home, 05 Ayurvedic dispensaries and others are

also available in the impact zone.

WORKERS CATEGORIZATION

8.65%

10.50%

0.47%

11.10%

10.13%

59.15%

CULTIVATORAGRICULTUREHOUSE HOLD IND.OTHER WORKERMARGINAL WORKERNON WORKER


[3-79]

In the study area drinking water facilities are good as tap water and well water is

available almost in all the villages, 37 Tap water facilities are available around the

Village, 34 hand pumps, 27 Well water, 20 Tube well Water, 24 Tank water is available

around the 10 Km Radius, 6 from River and from other resources.

There are 34 Post office facilities, 1053 telephone Connection, 04 post and telegraph

facility.

Villages are well connected through a network of Pucca road and Kaccha approach road.

Bus is the main mode of transportation and railway is another important mode of

transportation.

Most of the villages get electricity for all purpose i.e. domestic, agriculture and industrial.

The Table 3.23 below shows the details of amenities available in study area.


[3-80]

Table 3.23 DETAILS OF AMMENITIES AVAILABLE IN STUDY AREA

TALUKA VILLAGE EDUCAT- IONAL MEDICAL DRINKING

WATER POST &

TELEGRAPH COMMUNICATION APPROACH

TO VILLAGE

NEAREST TOWN

POWER SUPPLY

SAVLI

POICHA (KANODA) P(6) C(<5)

PHS MCW(<5) RMP PHC(<5) H(<5)

T TK HP R W

PO PH(5)

BS RS(<5)

PR MR FP

VADODRA (40) EA

SARDARPURA P C(<5)

H(<5) MCW(5) PHC(<5)

T W HP TK TW

PO(<5) PH(<5)

BS RS(<5)

MR FP

VADODRA (40)

ED EAG

SAVLI

P(5) C(2) S(5) O(2) PUC(2)

H(3) FWC D(3) TB MCW RMP(11) MH(3) O HC PHC(5-10) PHS(2)

T HP TW W

PO PTO

PH(700)

BS RS (10+)

PR MR FP

VADODRA (32) EA

WANKANER P(4) S

PUC C(<5)

DA FWC MCW RMP MH H(<5) PHS PHC(<5)

T TK HP R W

PO PH(12)

BS RS(<5)

PR MR FP

VADODRA (38) EA

GOTHADA P(5) S O

C(<5)

PHS MCW(<5) RMP PHC(5) H(<5)

T W HP TK TW

PO PH(23)

BS RS(<5)

PR MR FP

VADODRA (30) EA

RANCHHODPURA P

C(<5)

CWC PHC(5-10) H(<5) MCW(<5)

T W HP TK TW

PO(<5) PH(7)

BS RS(<5)

PR

VADODRA (40) EA

BAHIDHARA P(2) C(10+)

PHS PHC(10+) H(10+) MCW(10+)

T W HP TK TW R

PO PH(4)

BS RS(5-10)

PR MR

VADODRA (32)

ED EAG


[3-81]

BHADARVA P(2) S

PUC O

C(5-10)

MCW TB PHC NH PHS(2) RMP(3) FWC H(5-10)

T TK HP TW W

PO PTO

PH(35)

BS RS(5-10)

PR

VADODRA (22) EA

PARTHAMPURA

P C(10+)

H(10+) MCW(<5) PHC(<5)

T TK HP W

PO PH(3)

BS RS(10+)

PR MR FP

VADODRA (30)

ED EAG

JALAMPURA P C(10+)

H(10+) MCW(<5) PHC(<5)

T R HP TW

PO PH(<5)

BS RS(10+) PR VADODRA

(30) ED

EAG

KHANDI P C(10+)

H(10+) MCW(<5) PHC(<5)

T HP

PO PH(<5)

BS RS(10+)

PR MR

VADODRA (28)

ED EAG

POICHA (RANIYA) P S

C(10+)

RMP H(10+) MCW(<5) PHC(<5)

T R HP TW TK

PO PH

BS RS(10+)

PR MR

VADODRA (25) EA

RANIYA P C(10+)

RMP H(10+) MCW(<5) PHC(<5)

T TK HP TW W

PO PTO PH

BS RS(10+)

PR MR FP

VADODRA (25) EA

MAHAPURA P C(10+)

H(10+) MCW(<5) PHC(<5)

T TK TW W

PO(<5) PH(<5)

BS RS(10+)

PR MR FP

VADODRA (24) EA

RANIPURA P C(5-10)

H(5-10) MCW(5-10) PHC(5-10)

T W HP TK TW

PO(5-10) PH(5-10)

BS RS(5-10) PR VADODRA

(24) EA


[3-82]

NAMISARA P(2) C(5-10)

PHS PHC(5-10) H(5-10) MCW(5-10)

T W HP TW

PO PH(5)

BS RS(5-10)

PR MR

VADODRA (21) EA

BAUTHA P C(<5)

PHS H(<5) MCW(<5)

HP TK

PO PH(18)

BS RS(<5)

PR MR FP

VADODRA (30) EA

LASUNDRA P C(5-10)

PHS PHC(5-10) H(5-10) MCW(5-10)

T TK HP W

PO PH(2)

BS RS(5-10)

PR MR FP

VADODRA (25) EA

PASVA P C(5-10)

H(5-10) MCW(5-10) PHC(5-10)

T TK HP W

PO PH(2)

BS RS(<5)

PR MR FP

VADODRA (45)

ED EAG

SUBHELAV P C(5-10)

H(5-10) MCW(<5) PHC(<5)

T HP W

PO PH

BS RS(5-10)

PR MR FP

VADODRA (19) EA

TUNDAV

P S

AC C(10+)

MCW FWC PHC RMP(2) PHS H(10+)

T W HP TK TW

PO PTO PH

BS RS(10+) PR VADODRA

(21) EA

PALDI P C(5-10)

H(5-10) MCW(<5) PHC(<5)

T HP W

PO(<5) PH(<5)

BS RS(10+)

PR MR FP

VADODRA (20) EA

ANJESAR P S

C(10+)

RMP(2) PHC(<5) H(10+) MCW(<5)

T W HP TK TW

PO PH(25)

BS RS(10+)

PR MR

VADODRA (25) EA

MOKSI P(2)

S C(10+)

PHS H(10+) FWC MCW(<5) RMP PHC(<5)

T W HP TK TW

PO PH

BS RS(10+)

PR MR FP

VADODRA (25) EA


[3-83]

KUNPAD P(2) C(10+)

CHW PHC(<5) H(10+) MCW(<5)

T TW

PO PH(<5)

BS RS(<5) PR VADODRA

(23) ED

EAG

MANJUSAR P C(10+)

PHS MCW(<5) RMP(2) PHC(<5) H(10+)

T W HP TW

PO PH(35)

BS RS(5-10) PR VADODRA

(18) EA

LAMDAPURA P S

C(10+)

H(10+) MCW(<5) PHC(<5)

T W HP TK TW

PO PH(4)

BS(<5) RS(5-10)

PR MR

VADODRA (30) EA

ZUMKAL P C(10+)

H(10+) MCW(<5) PHC(<5)

HP W TK

PO(<5) PH(<5)

BS(<5) RS(<5)

MR FP

VADODRA (25) EA

ALINDRA P(2) C(10+)

H(10+) MCW(5-10) PHC(5-10)

T W HP TK TW

PO PH(4)

BS RS

MR FP

VADODRA (25) EA

PILOL P(4) AC

C(5-10)

CHW PHC(<5) H(5-10) MCW(<5)

T TK HP R W

PO PH

BS RS PR VADODRA

(10) EA

KHOKHAR P(2) C(10+)

PHS PHC(<5) H(10+) MCW(<5)

HP W TK

PO PH(5)


(22) EA


[3-84]


VADODRA

DODKA P(2)

S C(10+)

PHS PHC(10+) MCW(10+) FWC H(10+)

T HP

PO PH(6)

BS RS(5-10) PR RANOLI

(9) EA

RAYAKA P(3)

S C(10+)

RMP MCW(5-10) CHW PHC(5-10) H(10+)

T W R

PO PH(3)


(20) EA

SANKARDA P(5) C(10+)

DA FWC MCW RMP(3) PHC CHW PHS H(10+)

T HP

PO PH(50)

BS RS(5-10)

PR FP

VADODRA (14) EA

VASNA P C(10+)

CWC(3) PHS MCW(<5) CHW(2) H(10+) PHC(<5)

T HP TW TK

PO PH(6)

BS RS(5-10)

PR

RANOLI (10) EA

SOKHDA

P(5) S

PUC C(10+)

MCW RMP(5) MH H(10+) PHC PHS(2)

T PO PH(50)

BS RS(<5) PR RANOLI

(8) EA

PADAMLA P C(10+)

PHS MCW(<5) RMP(3) H(10+) PHC(<5)

T HP

PO PH(5)

BS RS(<5) PR

FERTILIZER NAGAR

(5) EA

FAZALPUR P(4) C(10+)

PHS PHC(5-10) H(10+) MCW(<5)

T HP

PO PH(2)


(20) EA

AJOD P C(10+)

PHS MCW(<5) RMP(3) PHC(<5) H(10+)

T PO PH(16)

BS RS(<5) PR

FERTILIZER NAGAR

(2) EA

ASOJ

P S O

C(10+)

PHC CHW PHS H(10+) FWC MCW(<5) RMP(2)

T PO PH(16)


(14) EA

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 4 ANTICIPATED ENVIRONMENTAL IMPACT & MITIGATION MEASURES

[4-1]

ENVIRONMENTAL IMPACT ASSESSMENT

4.1 Introduction

Impact assessment describes identification and appraisal of various impacts due to the

proposed project.

"Environmental Impact" can be defined as any alteration of environmental conditions or

creation of a new set of environmental conditions, adverse or beneficial, caused or induced by

the action or set of actions under consideration.

Generally, the environmental impacts can be categorized as either primary or secondary.

Primary impacts are those, which are attributed directly by the project, secondary impacts are

those, which are indirectly induced and typically include the associated investment and

changed patterns of social and economic activities by the proposed action.

The impacts have been predicted for the proposed project assuming that the pollution due to

the existing activities has already been covered under baseline environmental monitoring.

4.2 Impact Assessment Matrix

From the Table-4.1 significant impacts are identified. They are further elaborated with

characterization and assessment in Table-4.2 and Table-4.3.


[4-2]

TABLE 4.1 IMPACT IDENTIFICATION MATRIX

Activities

Environmental Attributes

Air Noise Water Land & Soil Ecology Socio-

Economic Aesthetics

Handling & Charging of Raw Material

Operation of Hot air generator

Operation of Den & Mixer

Operation of Compressor

Operation of Cutter

Operation of Scrubber

Operation of Bag Filter & MCS

Operation of Domestic Utilities

Operation of Conveyer


[4-3]

Operation of Grinding Mill

Operation of Granulator (Rotary Drum)

Operation of Dryer & Cooler

Storage facilities for Liquid Raw Material/

Product

Storage facilities for Solid Raw Material/

Product

Transportation of Raw Material/ Product

Development of Green Belt

Employment Generation


[4-4]

TABLE 4.2 ENVIRONMENTAL IMPACT ASSESMENT

Activity Environmental

Attribute Cause

Impact Characteristic

Nature Duration Reversibility Significance, Mitigative

Measure

Manufacturing of SINGLE SUPER PHOSPHATE POWDER

Handling & Charging of Raw Material / Product

Air, Noise, Land & Soil

Charging of dilute Sulphuric acid

Direct Negative

Long Term Reversible The Management should Ensure Proper usage if PPE’s

Charging of Fluorosilisilic acid

Direct Negative

Long Term Reversible The Management should Ensure Proper usage if PPE’s

Operation of conveyer, Mixer, powder plant, Rotary Screen, – Dust Emission & Noise Generation

Direct Negative

Long Term Reversible The Management should Ensure Proper usage of PPE’s and explore method of reducing dust emission and also noise generation.

Operation of Hot Air Generator

Air, Noise Charging of biocoal Operation of high speed blower

Direct Negative

Long Term Reversible The Management should explore method of reducing dust emission and also noise generation.

Operation of Mixer & Den

Air, Noise Operation of high speed blower

Direct Negative

Long Term Reversible The Management should explore method of reducing process emission and also noise generation.


[4-5]

Manufacturing of SINGLE SUPER PHOSPHATE GRANULATED

Handling & Charging of Raw Material / Product

Air Handling Operation for Transfer Charging of Raw Materials Final Product – Manually or through Pipeline, Conveyer.

Direct Negative

Long Term Reversible Low, The management should Ensure Proper handling of the spillage during transfer charging operation and provision of temporary hood to trap the vapour emission wherever applicable.

Air, Noise Operation of Dryer – Dust Emission & Noise Generation

Direct Negative

Long Term Reversible The Management should Ensure Proper usage if PPE’s and explore method of reducing dust emission and also noise generation.


[4-6]

Operation of AIR COMPRESSOR Operation & Maintenance of Air Compressor

Air Quality (Noise)

Noise generation due the operation of Air Compressor

Direct Negative

Long Term Reversible The management should ensure proper usage of ear plugs/muffs by workers and explore methods for dampening the noise generated, after identifying the particular equipment generating noise. Besides, regular preventive maintenance of Air Compressor is to be carried out.

Land Maintenance of the air compressors , lube oil replacement - generation of old lube oil

Direct Negative

Long Term Reversible The used lube oil should be sent for reprocessing and documentation of the same as per regulatory requirements to be done.

Maintenance of the air compressors (frequency - monthly) - lube oil spillage

Direct Negative

Long Term Reversible The contaminated cotton waste/sand should be either incinerated or sent for disposal into landfill, after accumulation.


[4-7]

Operation of SCRUBBER

Operation & Maintenance of Scrubber

Air Quality Noise

Noise generation due the operation of Blower

Direct Negative

Long Term Reversible The management should ensure proper usage of ear plugs/muffs by workers and explore methods for dampening the noise generated, after identifying the particular equipment generating noise. Besides, regular preventive maintenance of Blower is to be carried out.

Land Replacement of used Packing with a new one. - Waste/used Packing Material

Direct Negative

Long Term Reversible The used Packing should be sent for disposal into landfill, after accumulation or explore opportunities for reuse of the same.

Water Backwash of the packed bed – Waste water generation due to backwash operation.

Direct Negative

Long Term Reversible The H2SiF6 liquor generated will be again reused in the process. The silica will be reused as filler after sun drying.

Operation & Maintenance of Bag filter & MCS

Air Quality Noise

Noise generation due the operation of Blower Dust Generation near the Valve

Direct Negative

Long Term Reversible The management should ensure proper usage of ear plugs/muffs by workers and explore methods for dampening the noise generated, after identifying the particular equipment generating noise. Besides, regular preventive maintenance of Blower is to be carried out. Proper maintenance of welding joints, proper collection system at the bottom of rotatory valve


[4-8]

Operation of DOMESTIC UTILITIES

Operation & Maintenance of Domestic Utilities

Water Operation of Washroom, toilets - Wastewater generation

Direct Negative

Long Term Reversible The wastewater is disposed into soak pit

Land Generation of Domestic solid waste. .

Direct Negative

Long Term Reversible The solid domestic waste is stored within the premises temporarily and then sent to Municipal Drainage Lines.

Storage facilities for all the solid raw materials:

Storage facilities for all the solid raw materials

Land, Water Storage of all the solid raw materials in the plant area in HDPE bags and transfer to the operational / processing area - spillage, disposal of used bags.

Direct Negative

Long Term Reversible The management should improve the storage conditions, by taking necessary measures to reduce contamination of rain water during rainy season and ensure safe disposal/reuse of the empty bags (to end-users only) after decontamination. Adequate records to be Maintained


[4-9]

Storage facilities for all the Liquid raw materials: Storage Land, Water Storage of all the liquid raw

materials within the plant area and transfer to the operational / processing area - spillage, disposal of used drums.

Direct Negative

Long Term Reversible The management should improve the storage conditions, by taking necessary measures to reduce contamination of rain water during rainy season and ensure safe disposal/reuse of the empty drums (to end-users only) after decontamination. Adequate records to be Maintained.


[4-10]

Transportation of all the raw materials, finished products and hazardous wastes Transportation of all the raw materials, finished products and hazardous wastes

Land Water

Transportation of all the raw materials, finished products and hazardous wastes

Direct Negative

Long Term Reversible The truck drivers should be trained in transportation of hazardous materials, spill control and other emergency actions. MSDS of all the raw materials and finished products should be made available to the Off-site Emergency team as and when required. The vehicles used for transporting hazardous materials should follow the applicable guidelines given in The Motor Vehicles Act. PPE's such as goggles, gumboots & face-masks should be made available in the vehicle used for transportation.

Development and maintenance of Green Belt

Development and maintenance of Green Belt

Air, Noise Development of green belt for mitigation of pollution, Plantation of trees within premises

Direct Positive

Long Term Reversible Very High Positive Impact due to development of a good green belt inside as well as at the periphery of the premises



Socio Economic

Direct & Indirect Employment of 8 managerial, skilled and unskilled workers, out of whom 6 locals are employed

Direct Positive

Long Term Reversible Very High Positive Impact due to hiring of manpower.


[4-11]

4.3 OVERALL IMPACTS

The impacts arising out of the said projects have been listed.

4.3.1 Impact on Land/Soil

T. J. Agro Fertilizers Pvt. Ltd. will take all reasonable precautions to make its solid waste

storage / treatment areas impervious to water and leachate migration. This will prevent soil

contamination.

The land is having fairly flat terrain. The construction activities may result in loss of topsoil

to some extent in plot area where the development has to be made. The topsoil will be

conserved and will be reutilized for gardening/landscaping.

Only roof type shed required for additional products including process machinery. Only

ground structure will be constructed for roof type shed. Thus, soil quality is not adversely

impacted by T. J. Agro Fertilizers Pvt. Ltd. plant operations.

Further, it is emphasized that all precautionary measures have to be strictly controlled as

mentioned in the mitigation measures discussed in Table 4.3 of this chapter and summarized

in the Environmental Management Plan given to prevent soil contamination in the future.

The land acquired is of non- notified Industrial Estate and will be utilized for Industrial

Purpose. As our unit is zero discharge units, soil quality is not adversely impacted by T. J.

Agro Fertilizers Pvt. Ltd. plant operations.

4.3.2 Impact on Air Quality

The baseline status of the Ambient Air Quality shows that PM- Due to the development

activities of the proposed project there would be increase in the particulate matter as well as

some increase in the SO2 and NOx levels due to the vehicular movement inside the premises.

Location and distance of ambient air monitoring stations were selected as already mentioned

in Chapter-3. Ambient air monitoring carried out in winter season shows that the ambient air

quality for PM2.5, PM10, SO2, and NOx are within the limits specified by CPCB.


[4-12]

Impact on ambient air due to T. J. Agro Fertilizers Pvt. Ltd. Plant operations will be due to

only operation of Hot Air Generator and the process gas. The consumption of Industrial

wood (Bio Coal) will be only 16 Ton/Day. Hence, it can be concluded that T. J. Agro

Fertilizers Pvt. Ltd. Emissions are causing negligible impacts on air quality.

Further, it is emphasized that all the emissions have to be strictly controlled as mentioned in

the mitigation measures discussed in Table 4.3 of this chapter and summarized in the

Environmental Management Plan given in Chapter 8, to maintain ambient air quality within

norms in the future.

4.3.3 Impact on Groundwater

Water requirement for the project will be met through the Borewell. The water required will

be 32.5 Kiloliters/Day. There will be no effluent generation. Hence,

a. Impact on receiving surface water body:

There will be no adverse impact on receiving water body.

b. Impact on ground water quality:

Ground water consumption per year will be: 32.5 KL× 300 = 9,750 KL/year.

Ground water recharged due to proposed Rain water Harvesting System will be 11,837.79 KL/year which will be more than the expected water consumption.

Thus there will be positive impact on ground water. Moreover ground water quality was

tested at five different locations in the study area. Most of the parameters are within limits

prescribed by C.P.C.B standard.

T. J. Agro Fertilizers Pvt. Ltd., will take all necessary precautions to make its solid waste

storage / treatment areas impervious to water and leachate migration.

It follows from the above that ground water quality will not adversely impact by T. J. Agro

Fertilizers Pvt. Ltd.’s activities.

Further, it is emphasized that all precautionary measures have to be strictly controlled as

mentioned in the mitigation measures discussed in Table 4.3 of this chapter and summarized

in the Environmental Management Plan given in Chapter 8, to maintain ground water quality

within norms in the future.


[4-13]

4.3.4 Impact on Noise Levels

The noise level within the plant premises has been tabulated in chapter 3.

As per observations undertaken the Ambient Noise Level is within norms of Residential Area

and well below the norms of Industrial Area.

With the implementation of the mitigation measures proposed, the noise levels at plant

boundaries will be well below the limits specified for industrial areas.

The major sources contributing to Noise pollution during the plant operation will be

Compressor, and Pumps etc. The operation of the equipment will generate noise ranging

between 70-80 dB (A).

It follows that noise levels are not adversely impacted by T. J. Agro Fertilizers Pvt. Ltd. plant

operations.

4.3.5 Impact on Terrestrial Ecology

As the surrounding has mixed land use i.e. residential, industrial and commercial, no loss of

flora & fauna is envisaged during any phase. Some trees existing on the plot area to be

developed need to be trimmed, this is not an impact. However more trees will be planted

within the plot area.

Flora

The prediction of impacts on the floristic components of the environment is as follows:

Analysis of biotic factors reveals that ambient air and fresh water quality will remain,

practically, unaffected. Thus, indirect adverse impact on flora is ruled out.

The floristic component of the study area does not include any rare or endangered species.

Thus, impact on rare and endangered species of flora is ruled out.


[4-14]

Fauna

The prediction of impacts on the faunal components of the environment is as follows:

The quality of ambient air and fresh water system will remain, practically, unaffected. Thus

indirect impact due to these abiotic factors is ruled out.

The Industry does not envisage destruction of habitat and feeding or breading area of fauna

species. No rare or endangered species of fauna are reported to exist in the area. Thus, no

impacts on rare / endangered species are envisaged due to normal operations.

Thus direct adverse impact on faunal species is ruled out due to normal operation of the T. J.

Agro Fertilizers Pvt. Ltd. industry.

4.4. Mitigation Measures

Each of the activities during production phase is critically reviewed for suggestion of

mitigation measures. Based on this the Table 4.3 gives the mitigation measures for the

activities considered to be causing significant environmental impacts during production

phase.

In general the best housekeeping practices are incorporated in the design as well as in

production phase to reduce the short terms impacts due to the proposed activities.


[4-15]

TABLE 4.3 MITIGATION MEASURES

Activity Environmental Impact Mitigations Remarks

Manufacturing of Single Super Phosphate Powder

Air Land Water

Ensure proper handling of all spillages by introducing spill control procedures for various chemicals.

Implementation responsibility: Plant Incharge

Strictly follow the appropriate spill control procedures.

Provide a temporary hood attached to scrubber to handle the entire vapor/gaseous and powder emissions. Explore methods for reducing fugitive emissions of HF and Fluorine Gas during Acidulation operation.

Ensure proper disposal of solid waste generation.

Manufacturing of Single Super Phosphate Granulated.

Air Land Water




Provide a temporary hood attached to a common scrubber to handle the entire vapor/gaseous and powder emissions. Explore methods for reducing fugitive emissions of HF and Fluorine Gas during Acidulation operation. Ensure proper disposal of solid waste generation.


[4-16]

Manufacturing of N.P.K- Granulated Mix Fertilizers

Air Land Water




Provide a temporary hood attached to a common scrubber to handle the entire vapor/gaseous and powder emissions.

Explore methods for reducing fugitive emissions of HF and Fluorine Gas during Acidulation operation. Ensure proper disposal of solid waste generation.

Manufacturing of Diluted Fluorosilisilic Acid

Air Land Water



Strictly follow the appropriate spill control procedures. Provide a temporary hood attached to a common scrubber to handle the entire vapor/gaseous and powder emissions.

Explore methods for reducing fugitive emissions of HF and Fluorine Gas during Acidulation operation.

Ensure proper disposal of solid waste generation.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 5 ENVIRONMENTAL MONITORING PROGRAM

[5-1]

ENVIRONMENTAL MONITORING

5.1 DETAILS OF MEASURES PROPOSED FOR THE ONLINE MONITORING OF THE POLLUTANTS FROM THE PROCESS STACKS AND ITS MONITORING PLAN.

• Unit will provide handy monitoring instrument to monitor H2SiF6 having alarm

system to identify concentration of H2SiF6

gases.

• Details of the online H2SiF6

Sensor type online detector will be installed on process vent having minimum

traceability value of 0.01 mg/m

detector:

3. As and when HF value reach the limit 25% below

the permissible limits of the mg/m3

prescribed by GPCB alerts will be given

through alarm to minimize or take preventive actions against it to limit it to statutory

norms.

• Routine maintenance & periodical calibration of it will be carried out.

• Unit will also carry out monthly environmental monitoring from third party and will

submit analysis results for the same to R.O. GPCB.

5.2 DETAILS OF PROVISIONS FOR THE WORK AREA AIR QUALITY MONITORING AS PER GUJARAT FACTORIES RULES.

• Unit will carry out indoor work environment monitoring on quarterly basis to check

working condition of our employees. If any abnormalities observed, we will take

corrective actions for the same.

• Moreover unit proposes to install LUX meter for the monitoring of the illumination

level as well Noise Level Meter for monitoring the Noise level within the premises.

5.3 WASTEWATER MANAGEMENT

• T. J. Agro will not generate any wastewater from the process.

• Sewage (domestic wastewater and sanitary waste water)

Domestic wastewater will be generated from domestic requirements. It will be

disposed through soak pits.


[5-2]

5.4 SOLID WASTE MANAGEMENT

5.4.1 Details of Solid Waste Generated

With respect to the mfg. process to be carryout, Unit process & operation to be involved

from the proposed Project, there will be a Solid Waste to be generated. The source of the

waste generation will be from the process. The solid waste generated during the

manufacturing of each product for the each batch is summarized below in Table 5.1.

Quantity of Hazardous and Solid wastes disposed by various methods is shown in Table.

5.1(A&B)


[5-3]

TABLE 5.1 (A) TOTAL SOLID WASTE GENERATION

Sr. No. Waste Stream Waste Cat. No.

As per- 2008

Qty. Total

Qty. Produce Source Existing

Proposed

1. Used oil

5.1 150 lit/year 50 lit/year 200 lit/year Air Compressor

2. Discarded containers/barrels/

Liner

33.3 60 Kg/Month 240 Kg/Month 300 Kg/Month Raw material & Finished product packing material

3. Silica/Sand -- Nil 10 Kg/month 10 Kg/month Process


[5-4]

TABLE 5.1 (B) DETAILS OF HAZARDOUS WASTE MANAGEMENT

Sr. No

Waste Stream

Waste Cat. No. As per-

2008

Total Qty.

Produce

Total Qty.

Recycled/ Reused

Total Qty.

Disposed

Method of packing

Method of recycling /Reuse Disposal Method

1. Used oil

5.1 200 lit/year

100 lit/year

100 lit/year

PP Carba / Drum

Lubrication in machineries & Lift

Collection, Storage, Transportation and disposal by selling to registered refiners enlisted by GPCB /MoEF.

2. Discarded containers/

barrels/Liner

33.3 300 Kg/Month

150 Kg/Month

150 Kg/Month

PP Bag

Good quality packing material will be reused in finished product packing - Teared liners will be stitched & reused for packing.

Collection, Storage, Transportation and disposal by selling to registered refiners enlisted by GPCB /MoEF.

3. Silica/Sand -- 10 Kg/month

10 Kg/month

--- PP Bag

Collection, storage & Reuse as filler in product

--


[5-5]

• Following steps shall be adopted during handling of hazardous chemicals.

o For powder material, the material allowed in a vessel through closed loop.

o Transportation from raw material storage to process plant shall be carried out

by trolly.

o Each activity shall be improved/done in such a way that minimum risk of gas

exposure to be occurred.

• The unit has provided scientifically designed H.W.S.A. having impervious layer .We

will store each type of hazardous waste separately in this storage area. The capacity

of our storage area is 15 M

5.4.2 Methodology of De-Contamination and Disposal of Discarded Containers and Its

Record Keeping.

3

• The unit will send back maximum quantity of drums / carboys to its actual supplier.


[5-6]

5.5 SUMMARY OF THE ENVIRONMENTAL MONITORING PROGRAM

Environmental Monitoring program shall be as mentioned in Table 5.2

Table 5.2: Environment Monitoring Plan

Sr. No. Activity Schedule

Air Pollution Monitoring 1. Ambient air monitoring of parameters specified

by GPCB in their air consents from time to time within the T. J. Agro Fertilizers Pvt. Ltd. premises

Once every Quarter

2. Ambient air monitoring of parameters specified by GPCB in their air consents from time to time at four stations outside T. J. Agro Fertilizers Pvt. Ltd. premises

Once every season at each station

Flue Gas Emission Monitoring 3. Stack monitoring of prescribed parameters as

given in air consent from time to time Once every month

Ground Water Monitoring 4. Sampling & Analysis of the ground water of bore

well within premises will be done. Once in Six months

Solid Waste Generation Monitoring / Record Keeping

5. Records of generation of used liner, bags and records of their dispatch to suppliers for refilling

Daily To be comply as per Haz. Waste [MPH] rules, 2003

6. Records of generation of waste oils and their treatment

Daily

7. Records of generation, handling, storage, transportation and disposal of other solid, aqueous and organic hazardous wastes as required by hazardous waste authorization

To be updated daily

Environmental Audit & Annual return

8. Environmental statement under the EP (Act) 1986 & annual return of hazardous waste generation, handling & disposal.

Once in a year

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 6 ADDITIONAL STUDIES

[6-1]

SAFETY & RISK ANALYSIS

6.1 OBJECTIVES An emergency is considered to be a situation of process deviation that may lead to or

actually leads to a major accident/disaster with potential short term and/or long term risk

and damage consequences to life and property in and/or around the factory.

A Disaster is a catastrophic consequence of a major emergency/accident that leads to, not

only extensive damage to life and property but also disrupts all normal human activity for a

pretty long time and requires a major national and international effort for rescue and

rehabilitation of those affected.

Since the occurrence of a disaster is very remote for this project, the report focuses on

emergency situations and discusses the contents of an Emergency Plan (EP).

EP is a guide, giving general considerations, directions and procedures for handling

emergencies likely to arise from deviations to planned operations.

6.2 EMERGENCY PLAN: STRUCTURE The EP is supposed to be a dynamic, changing, document focusing on continual

improvement of emergency response planning and arrangements. A structure working on a

Plan, Do, Check & Review (PDCR) cycle has been therefore suggested. Another advantage

of doing this is to have a system that is in synchronicity with commonly used EHS systems

such as ISO 14001 and OHSAS 18000.

6.3 POLICY M/s. T. J. Agro Fertilizers Pvt. Ltd. will have Environment, Health and Safety Policies

which guides the Emergency Response Plan. These policies will be made accessible to all

at site. The policies have been framed considering legislative compliance, stakeholder

involvement, continual improvement, and management by objectives.


[6-2]

6.4 PLANNING

6.4.1 Event Classification and Modes of Failure Hazards that can lead to accidents in operations are discussed in this section. Important

hazardous events are classified in below Table 6.1.

Table 6.1: Event Classification

Type of Event Explanation

Spill Release ‘Loss of containment’. Release of fluid or gas to the surroundings from unit’s own equipment / tanks causing (potential) pollution and / or risk of explosion and / or fire

Structural Damage Breakage or fatigue failures (mostly failures caused by weather but not necessarily) of structural support and direct structural failures

6.4.2 Methodology of Risk Assessment

The scope of work has been framed as per standard requirements for risk and safety studies and includes the following:

• General description of project. Level 1: Hazard Identification

• Study of operational information, including safety concepts used in design of plant, equipment and storages

• Listing of key plant equipment • Listing of hazardous inventory and identification of key hazardous substances to be

used. • Identification of Maximum Credible Loss Scenarios (MCLS) using standard

techniques. Level 2: Hazard Assessment • Estimate loss quantities for given scenarios and conditions. • Analysis and quantification of primary effects (consequences) of identified MCLS, in terms of distances to toxic endpoint. • Analysis and quantification of secondary effects (damages) of identified MCLS in terms of fatalities, injuries and property damage. • Estimation of probability of occurrence of MCLS’ based on standard techniques for the purpose.

Level 3: Development of DMP • Development of DMP report based using standard procedures for the purpose.


[6-3]

Level 4: Recommendations • Recommendations to reduce the probability or consequence of hazards studied and for

implementation of the DMP. These are given on the basis of the study findings and professional judgment.

6.4.3 Study Methodology The methodology of the study for development conforms to national and international

rules, regulations, standards, guidelines and codes of practices. It involves the following:

• Identification of hazardous material

• MCLS Development

• Development of yardsticks

• Incorporation of results in development of DMP reports

6.4.4 Identification of Possible Emergency Situations Broadly, two situations can arise:

• Emergency situations involving loss of containment of hazardous materials. For the

proposed facility, the following containment loss scenarios may be envisaged:

• Loss of Extremely toxic like Sulphuric Acid & Fluorosilisilic Acid due to catastrophic

rupture of M. S. tank & HDPE tank – an incredible event.

Consequence analysis of all the above mentioned containment loss scenarios has been

discussed as below.

Emergency situations not involving loss of containment are generally more likely to occur

and the following are possible:

• Falls due to working at heights (during construction/repair and maintenance).

• Electric shock caused by contact with faulty electrical equipment, cables, etc.

• Chronic health issues related to inhalation or ingestion of dust.

• Falls on floors made slippery by aqueous solutions.

• Burns by splashes of liquids, by steam or hot vapors, by contact with hot surfaces.

• Exposure to adverse environmental factors (for e.g. high temperature).

With respect to emergencies situations not involving loss of containment, general

recommendations are given at the end of the chapter.


[6-4]

6.4.5 Consequence Assessment Toxic substances released from sources of storage as a result of failures or catastrophes,

can cause losses in the surrounding area in the form of:

• Toxic release.

Toxic releases are caused due to leakage and dispersion of toxic chemicals in air & on soil. Consequences of toxic release are influenced by wind speed, weather condition, leak rate or mass released at particular place.

Consequences of Toxic Release

6.5 CONSEQUENCES OF CONTAINMENT FAILURE AND RELEASE OF MATERIAL INTO ENVIRONMENT

6.5.1 Release of Sulphuric Acid (98%) & Fluorosilisilic Acid into Environment

It is expected that M/s. T. J. Agro Fertilizers Pvt. Ltd. will store sulphuric acid in M.S.

rubber lined storage tanks.

The consequence scenarios considered are loss of Sulphuric acid due to leakage in bottom

valve of storage tank or corrosion of tank, which is an extremely unlikely event.

The consequence scenarios considered for loss of Fluorosilisilic acid in the atmosphere due

to break down of Ventury water scrubber, which is an extremely unlikely event.

In case of leakage in bottom valve (Diameter: 50 mm) of storage tank, Flow rate of

Sulphuric Acid will be 5 Liter/minute.


[6-5]

6.6 INDIVIDUAL RISK ANALYSIS 6.6.1 Introduction The results of the QRA study can be utilized in the effective management of the risks

presented by the facilities to the employees and the surrounding community. In evaluating

these risks to the offsite population, it is important to address the question of whether the

risks are serious enough to warrant concern. Awareness of the approaches by the regulatory

authorities throughout the world has taken to address the issue of risk acceptability as a

useful guide.

HSE (UK) Industrial Criteria

HSE Industrial Criteria

The risk criteria used by the UK Health and Safety Executive (HSE), 1992 was originally

published in 1987 for nuclear power stations, but the 1992 revision of the document

indicates that they should apply to any large industrial plant in any industry.

Individual risk criteria are:

Maximum tolerable risk for workers: 10-3

Maximum tolerable risk for public: 10

per year -4

Broadly acceptable risk: 10

per year -6

per year

INTOLERABLE

TOLERABLE IF ALARP

BROADLY ACCEPTABLE

1 x 10-4 per year

1 x 10-6 per year


[6-6]

To the region between the maximum tolerable and broadly acceptable levels, the ALARP

(As Low As Reasonably Practicable) principle is applied, taking into account of the costs

and benefits of any risk reduction. For the risk levels within ALARP region, it is necessary

to consider further reduction of risk level through review of the following:

a) Selection of the best available technology, design and construction

b) Changes to operating philosophy

c) Additional safety features and protection devices

d) Improved maintenance, inspection and testing schedules.

The HSE appears not to use societal risk criteria, since no upper envelope of acceptable

societal risk emerged from several cases in which QRA was used in a decision making

process.

6.6.2 Acceptability Criteria for Risks in India Acceptability criteria for risks due to industrial activities have not been defined by

regulatory authorities in India. At present acceptability criteria, ALARP, prescribed by

Health and Safety Executive (HSE), U.K.

6.6.3 Assumptions for Fatality Risk Calculations

Since, no pool fire to be occurred, thus it is not required.

6.6.4 Probability of Exposure

No exposure expected to be analyzed.

6.6.5 Vulnerability Analysis

A Vulnerability Analysis gives quantitative estimates of the people, property and

environment in the vicinity of the proposed activity that are vulnerable due to the proposed

activity. It follows the risk and consequence assessment.

Based on the proposed activity and results of the consequence analysis for the modeled

scenarios, vulnerable receptors would include the following:

The summary of the vulnerability analysis is provided in below Table 6.2.


[6-7]

Table 6.2: Vulnerability Analysis

Vulnerable Area Maximum Impact

Distance (mtr) from leakage area

Number of People covered

under area

Occurrence (Frequency)

Sulphuric Acid Storage Area

4 2 Once in three years

6 Nil

Process Vent (H2SiF6

40 ) 07 Once in three years

6.6.6 Safety Measures to be adopted

The following safety measures will be observed at the site:

• All storage tanks will be made out of Boiler quality plates.

• All storage tanks will be stress relieved after fabrication.

• All storage tanks should be hydraulically tested for 72 hours duration and leakage

checked.

• All storage tanks will be kept at separate place having acid proof lining work with high end level to collect spillage acid & no acid over flow on open land.

• All pipelines will be Corrosion resistant having minimum joint and adequate supported.

• All pipeline joints will be stress relieved.

• Regular checking of leakage should be done.

• Regular training will be provided to operators for safe plant operations & emergency shutdown procedures.

• Scheduled regular monitoring of storage tank & pipeline thickness measurements will be done using Ultrasonic thickness measuring instruments.

• Annual inspections of storage tanks will be done.

• Mock drills for handling emergency will be conducted.


[6-8]

6.7 DETAILS OF HAZARDOUS CHARACTERISTICS AND TOXICITY OF RAW MATERIALS AND PRODUCTS

Details of hazardous and toxicity of raw materials and products to be handled and their control measures proposed are as summarized in the Table 6.3.

TABLES 6.3 Details of Hazardous and Toxicity of Raw Materials and Products

Type of Activity Risk Involved Mitigation Measures

Raw Material Storage & Handling

1: Urea • May cause allergic reactions

• Harmful on inhalation

• Causes Eye irritation

• Causes Skin irritation

• Wear appropriate Protective clothing to prevent contact with skin & Eyes

• Wear Dust mask

• Adequate ventilation

• Use PPE’S

2: DAP

3: MOP (potash)

4: Rock Phosphate

5: Filler

6: SSP

7: Fluorosilisilic Acid • Spillages / Leakages

• Harmful on inhalation

• Causes Eye irritation

• Causes Skin irritation

• Stored in closed shed

• For small fire, use dry powder, Carbon Dioxide, Water Spray

• Do not inject

• Wear Safety glasses

• Wear Cotton or Rubber gloves

• Proper collection system will be provided for the leakage & spillage of acids by preparing dyke wall & acid proof RCC flooring with spillage collection tank

8: Diluted Sulphuric Acid (70%) 9: Conc. Sulphuric Acid (98%)


[6-9]

Product Storage & Handling

1: Single super phosphate powder • May cause mild eye irritation

• May cause skin irritation

• Harmful if swallowed

• Skin contact may cause dermatitis

• Stored in well ventilated dry place

• Flush eyes/ Skins with plenty of water for at least 15 minutes

• Remove from exposure and move to fresh

air immediately • Use proper PPE’s while handling & wash

hand properly after handling • Use water spray, dry chemical, carbon

dioxide, or chemical foam. • Vacuum or sweep up material and place

into a suitable disposal container. • Do not breathe dust, vapor, mist or gas

2: Single super phosphate granulated

3: NPK mixed Fertilizer

4: Filler (By product)

5: Magnesium Sulphate

6: Fluorosilisilic Acid (By product)


[6-10]

6.8 DETAILS OF POSSIBILITIES OF OCCUPATIONAL HEALTH HAZARDS

Details of occupational health hazards from the proposed manufacturing activities are summarized below in Table 6.4.

Table 6.4 Details of Occupational Health Hazards

Type of Activity Risk Involved Mitigation Measures

During Production

• Handling Operation for Transfer, Charging of Raw Materials, and Final Product Spillages/leakages

• Inhalation during Top cap remove

• Due to tearing of conveyor belt

• Suffocation due to grinding & acidification

• Regular checking of dosing tank level

• Regular inspection & maintenance of all process equipment

• Proper collection system will be provided for the leakage & spillage collection of acids by preparing dyke wall & acid proof RCC flooring with spillage collection tank

• The Management should Ensure Proper usage of PPE’s

• Use Dust Mask near grinding area

• Process area should be proper RCC flooring

• Adequate ventilation should be provided at top of roof

During Packing • Spillages / Leakages

• Inhalation

• Ensure good quality packing material.

• Use Dust mask

• Proper PPE’s & Apparel shall be provided to the work force.

• Packing area should be well ventilated & illumination should be kept high

• Store product in original containers & clearly labeled


[6-11]

During Handling, Loading & Unloading of Product & Raw Material

• Spillages/ Leakages occurred

• Top cap removed & cause inhalation problem

• Skin irritation

• Proper collection system will be provided for the leakage & spillage of acids by preparing dyke wall & acid proof RCC flooring with spillage collection tank

• Buffer solution shall be used for highly acidic material which will immediately create suffocation problem

• Loading & Unloading equipments should be inspected & maintained regularly

• The cargo tank motor vehicles as well as their attachments including the hose pipes used for loading and unloading the acid should be inspected

• Conduct external and internal visual inspections, leakage and

pressure tests • Adequate PPE’s shall be provided to all employee

• Work job training should be given to employee

• Adequate ventilator shall be provided on top of roof • All the MSDS of raw materials & products should be available &

work force should aware of its nature


[6-12]

During operation of Utility

• Bag Filter & Multi Cyclone Separator

• Working at height

• Dustness at bottom

• Burning of Bags

• Safety belt should be provided to those working at height

• Safety guards shall be provided at bottom of rotary valve

• Use dust mask

• Routine inspection of Bags

• Adequate ventilation should be provided at top of roof

• Check pressure difference of bag filter

• Proper insulation shall be carried out

• Air compressor

• Human injuries in belt

• Safety guards should be provided

• Regular removal of tank oil & keep as a used oil in HWSA

• Pressure tank should be regularly checked

• Scrubber

• Human injuries due to spillages

• Regular inspection & maintenance of all scrubber pipelines & its joints

• Regular inspection & maintenance of scrubber & vent supports


[6-13]

6.9 PLANS FOR PERIODIC MEDICAL CHECKUP

• Monthly local doctors will be hired to check health of each employee. • Records will be maintained in prescribed format as per Gujarat Factory Act Rules.

6.10 DETAIL MSDS OF THE IMPORTANT HAZARDOUS RAW MATERIAL & PRODUCT:


[6-14]


[6-15]


[6-16]


[6-17]


[6-18]


[6-19]


[6-20]


[6-21]


[6-22]


[6-23]


[6-24]


[6-25]


[6-26]


[6-27]


[6-28]


CHAPTER 7 PROJECT BENEFITS

[7-1]

7.1 GREEN BELT DEVELOPMENT

7.1.1 General Principles in Greenbelt Design

Plants grown in such a way so as to function as pollutant sinks are collectively referred as

greenbelts. These plants should also provide an aesthetic backdrop for persons using the site and

for the surrounding community.

7.1.2 General principles in greenbelt design considered for this study are:

• Type of pollution (air, noise, water and land pollution) likely from the activities at the site

• Semi arid to dry sub humid and sub-zone where the greenbelt is located (and hence the

plant species which can be planted in the area).

• Water quantity and quality available in the area

• Soil quality in the area

• Greenbelt is designed to minimize the predicted levels of the possible air and noise pollutants. While designing the scheme the following facilities are considered:

• Site perimeter and approach road

• Along the internal roads

7.1.3 Types & Numbers of Trees to Be Planted:

It is presumed that the selected plants will be grown as per normal horticultural practice and the

authorities responsible for the plantation will make adequate provisions for water and protection

of the saplings. A budgetary cost estimate is also prepared for greenbelt development.

The total area over which the industries is located is 30,831 square meter. The existing

gardening area is approximately about 750 square meters and proposed gardening area will

be about 2969.00 square meters.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 7 PROJECT BENEFITS

[7-2]

TABLE 7.1 TYPES & NUMBERS OF TREES TO BE PLANTED:

Sr. No. Tree Species Existing Proposed Total

1. Neem 02 12 14

2. Asopalav 08 40 48

Layout of the greenbelt has been shown in plot layout attached as FIGURE 1.1

To ensure a permanent green shield around the periphery planting is recommended in two

phases.

• In the first phase one row of evergreen and fast growing trees (which grows up to 10-15 m)

with maturity period of around three years shall be planted at 3.0 meter interval along with

fast growing ground covers to enhance the water holding capacity, improve the organic

content and check the soil erosion.

• In the second phase after eighteen months, second row of trees with large leaf surface area

with large ever green canopy and longer life span shall be planted at 6.0 meters intervals.

• A green belt has been proposed within the premises. Thus, the proposed project will have

significant positive impact on the floristic component.

• The development of proposed green belt will provide habitat, food and breeding areas to

birds, small animals and insects. Thus a positive impact is envisaged on this count.

7.2 Expenditure on Green Belt Development

• The project proponent will incur about Rs.1.5 lacs for the green belt development in and

around units project site.

• We hereby committed that we will born any expenses to be occur in future for green belt

development with our areas by society/association.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 7 PROJECT BENEFITS

[7-3]

7.3 Socio-Economic Benefits

With respect to the Socio Economics this project will result into employment for workers as well

as the staff. Moreover it will result into the improvement in the economy of the local vendors.

About 20 direct jobs and 12 jobs to contracted workers are envisaged. Further, jobs will be

created indirectly. Thus a significant benefit to the socio-economic environment is likely to be

created.

Thus a significant benefit to the socio-economic environment is likely to be created.

• Local people will be employed as much as possible depending on the capabilities & job

requirements.

• 1 computer will be donated to the nearby local school.

• 1 Rain water recharge structure will be constructed in nearby Village.

• Yearly Medical checkup camp will be conducted in nearby Village.


CHAPTER 8 ENVIRONMENTAL MANAGEMENT PLAN

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=

8.1 ENVIRONMENTAL MANAGEMENT PLAN

8.1.1 Introduction

The Environment Management Plan (EMP) is required to ensure sustainable development in

the area of the proposed project. Hence it needs to be an all encompass plan for which the

industry, Government, Regulating agencies like Pollution Control Board working in the

region and more importantly the population of the area need to extend their co-operation and

contribution.

It has been evaluated that the project area will not be affected significantly with proposed

project. Mitigation measures at the source level and an overall Management Plan at the site

level are elicited so as to improve the surrounding environment.

The following mitigation measures are recommended in order to synchronize the economic

development of the project area with the environmental protection of the region. The

construction phase impacts are mostly short term, restricted to the plot area and not

envisaged on the larger scale. In the operational phase the environmental impacts are due to

continuous operation of the project, hence, the emphasis in the Environment Management

Plan (EMP) is to minimize such impacts. The emphasis on the EMP development is on the

following:

• Mitigation measures for each of the activities causing the environmental impact

• Monitoring plans for checking activities and environmental parameters and monitoring responsibilities

• Role responsibilities and resource allocation for monitoring

Following sections describes the environment management plan proposed for construction

and operation phases.

8.1.2 Details of Hazardous Processes & Their Engineering Controls and Details of Alarm Provision with Interlocking DCS System To Control Run Away Reaction:

The unit will adopt following engineering practices during unfavorable process condition

• Each vessel should be equipped with temperature indicator with its sensor, pressure

indicator, pressure relief valve and rupture disc. If any abnormality will occur, than

temperature & pressure sensor will alarm for immediate attention of Incharge, who will

immediately stop steam supply to the vessel to control runaway reaction.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 8 ENVIRONMENTAL MANAGEMENT PLAN

[8-2]

8.1.3 Plans for Management and Disposal of Waste Streams To Be Generated From Spillage, Leakages Etc.

• If any spillages/ leakages occurred than the said material will be collected in such a way

that maximum quantity can be recycled/ reuse and minimum quantity can be disposed for

incineration/ TSDF site.

Note: During above activity, the workers to be engaged after wearing adequate PPE’S & another, kept as a stand by having flame proof material / extinguishers & water sprayer.

8.2 ENVIRONMENT MANAGEMENT CELL

An environment management cell is already created to manage all environmental issues. The

Manager (Operations) will be responsible for environmental issues at plant.

STRENTHENING OF HSE:

For strengthening of HSE following steps will be taken:

• To develop a logbook history of work related accident.

• To conduct a mock drill through another agency once in a year.

• To invite expert to evaluate the policy of HSE and implement it periodically.

• To carry out safety audit once in a year.

The responsibilities of the various members of the environment management cell are given in Table 8.1 as follows:

TABLE – 8.1 ENVIRONMENT MANAGEMENT CELL

Sr. No. Designation Proposed Responsibility

1. Executive Director • Environmental policy and directions

2. Manager (Operations)

• Overall responsibility for environmental management and decision making for all environmental issues

• Ensuring legal compliance by properly undertaking activities as laid down by various regulatory agencies from time to time and interacting with the same

3. Asst.Manager (Utilities) • Secondary responsibility for environmental

management and decision making for all environmental issues

4. Safety Manager

• Conduct mock drill once in a month. • To keep records related to safety/accident. • To aware employees working in manufacturing &

Utility department about the risk involved and precautions to be taken to avoid accidents


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• To identify safety aspects in how to do & what to do manner.

• To identify possibility of risk involved in each activity, prepare plan to mitigate it and take a step to avoid its repetation.

5. Plant Incharge

• Ensure environmental monitoring as per appropriate procedures

• Ensures scrubber efficiency for effective control of emissions

• Ensure correct records of generation, handling, storage, transportation and disposal of solid hazardous wastes.

8.3 FOLLOWING MEASURES WILL BE TAKEN TO CONSERVE WATER

• Use of double nose flushing • Unit will keep a provision to install aerated coke in washbasin, low flush water closet

in toilet and pressure reducing valve in water line. • Rain water harvesting system will be adopted.

The ground water used by the unit will be mitigated through adopting the rain water harvesting technology.

8.3.1 Unit Will Provide Rain Water Harvesting System As Under:

• The net plot area is 30,831 m2

TABLE 8.2 DETAILS OF RAINWATER HARVESTING PITS

. The site will be divided into 08 pockets varying from 4000 square meters depending upon site layout. The details of the rain water harvesting pits are as mentioned in Table 8.

Number of pits 08 Nos.

Size pf pits 4 m x 3 m x 3 m

Size of Bore 350 mm dia

Size of pipe 150 mm dia

• Annual rainfall of the city was observed to be 922.7 mm. • Rainwater recharge calculation using Rational Formula is as under

Rain Water Harvested = Area in m2

• Each pocket will have independent harvesting well. A de-silting chamber and Oil & Grease removal trap will be provided to de-silt and remove floating material through bar screen. The details of the maximum storm water generated are as shown in Table 8.3.

× rainfall (mm/yr) ×run off coefficient.


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TABLE- 8.3 DETAILS OF MAXIMUM STORM WATER GENERATED:

Description Area in m Annual Rainfall in mm

2 Runoff coefficient

Total storm water in l/yr

Roof area 6368.63 922.7 0.8 47,01,067.92 Green & Open area 23142.69 922.7 0.3 64,06,128.01

Paved area 1319.68 922.7 0.6 7,30,601.24 Total 30831 1,18,37,797.17

Depth of bore pipe will kept 5 meter above than U/G water level.

FIGURE 8.1 RAIN WATER HARVESTING PIT


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8.4 WASTE MANAGEMENT

Looking to our product profile, we have think possibilities of recycling/ reuse wastes as

under.

Air: H2SiF6

8.5 EXPENDITURE ON ENVIRONMENTAL MATTERS

gas generated from SSP powder process will be totally scrubbed in water scrubber and recovered as a by-product.

Solid Waste: Solid waste (Silica/Sand) generated will be reused after sun drying as a filler in the process.

The following Table 8.4 gives the expenditure incurred by T. J. Agro Fertilizers Pvt. Ltd. on

environmental matters.

TABLE – 8.4 EXPENDITURE ON ENVIRONMENTAL MATTERS

Sr. No. Topic

Approximate recurring cost per

annum (Rs. In Lacs)

Approximate Capital cost (Rs. in Lacs)

1. Noise pollution control 0.1 2.0

2. Air Pollution Control 2.5 17.0

3. Water Pollution Control -- 0.5

4. Solid and hazardous waste management

0.5 1.0

5. Environment monitoring and management

0.9 0.75

6. Occupational health 0.25 0.25

7. Green belt 0.5 1.5

Total 4.75 23.0


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8.6 DISASTER MANAGEMENT PLAN

The Disaster Management Plan (DMP) is a guide, giving general considerations, directions

and procedures for handling emergencies likely to arise from planned operations. Site

specific documentation contingent to – and demonstrating suitable implementation of the

DMP is described in the annexure to the DMP. The annexure, being site specific, will require

to be updated once the actual site operations are underway.

The DMP must also be revaluated prior to start of operations and it is the responsibility of the

Plant Manager to do this. The DMP has been prepared for M/s T. J. AGRO FERTILIZER

Pvt Ltd on the basis of the consequence assessment and related findings covered in the earlier

chapter of this report.

8.6.1 Disaster Management Plan: Structure

The DMP is supposed to be a dynamic, changing, document focusing on continual

improvement of emergency response planning and arrangements. A structure working on a

Plan, Do, Check & Review (PDCR) cycle has been therefore suggested. Another advantage

of doing this is to have a system that is in synchronicity with commonly used EHS systems

such as ISO 14001 and OHSAS 18000.

The DMP is covered in further detail in the remaining sections of this Chapter.

8.6.2 Policy

The Environment, Health and Safety (EHS) policies are to be made accessible to all at site

and to other stakeholders. The policies must be framed considering legislative compliance,

stakeholder involvement, continual improvement, and management by objectives.

8.6.3 Planning

8.6.3.1 Identification and Prevention of Possible Emergency Situations

Identification of Emergencies

Possible emergency situations can broadly be classified into toxic release, fire or explosion.

While doing so, it is stressed that these results are only for the modeled scenarios and, that

the distances as well as damages can change depending upon the actual development of a

scenario. Additional emergency situations can be developed on the basis of audit / HAZOP

or other procedures prior to commencement of operations.


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Emergency Prevention

Some of the ways of preventing emergencies are as follows:

• Preparation of a Preventive Maintenance Schedule Programme based on

recommendations given and also covering maintenance schedules for all critical

equipments and instruments as per recommendations of the manufacturers user manuals,

• Establishment of a Non Destructive Testing (NDT) system as necessary. This may not be

feasible in-house but there are specialized organizations who undertake the work, and the

same may be used.

• Importantly, it is of great importance to collect and analyze information pertaining to

minor incidents and accidents at the site, as well as for recording near-misses or

emergencies that were averted. This information gives an indication of how likely or

unlikely it is for the site to face actual emergencies and what should be further done to

prevent them from occurring.

• Establishment of an ongoing training and evaluation Programme, incorporating the

development of capabilities amongst employees about potential emergencies and ways

and means of identifying and averting the same. Most emergencies do not occur without

some incident or an abnormal situation. So there is always some time of few seconds to

few minutes to arrest an incident of abnormal situation from turning in to an emergency.

This is the role of the shift in-charge who is the incident controller (IC) along with his

shift team.

8.6.3.2 Identification and Compliance with Legislative Requirements

The following EHS regulatory requirements are applicable to the activities being planned,

and the checklist given in below Table No:8.5 may be taken into consideration prior to

actual commencement of operations. This checklist requires to be reviewed at quarterly

intervals.



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Table 8.5: Applicable EHS regulatory requirements – M/s T. J. Agro Fertilizers Pvt. Ltd.

Sr. No.

Applicable Legislation / Rule / Permit Requirement Action Required / Timing of Action

1. Amendment in Consent to Establish/ NOC from the GPCB

A general permit to establish facilities for adds new product or equipments of plant operations.

NOC to be applied for along with the completed EIA report

2. Authorization to generate, transport and dispose hazardous wastes from the GPCB

Permit to generate and dispose hazardous wastes Application to be filed with the GPCB once the NOC is obtained

3. The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (as

amended till date)

Listing of hazardous materials; thresholds against which Safety Audit and Safety Report has to be

maintained; Requirements of disclosure of information; Availability of MSDS’;

If required, safety audit and safety report to be prepared.

4. The Public Liability Act, 1991 (PLI) Insurance to be taken out Check whether M/s T. J. Agro Fertilizers Pvt. Ltd. insurance under PLI covers the

project under consideration

5. Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996

Preparation of Local/District Level Crisis groups, for management of offsite emergencies.

Identify whether Local or District Level Crisis Groups exist at site and take

proactive part in preparing Offsite DMP.

6. Factory License from the DISH (Department of Industrial Safety Health)

A basic safety license to run the Factory Application prior to construction



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8.6.3.3 Identification of, and Communication with, Relevant Stakeholders

This includes identifying, communicating and developing working relations with relevant

offsite agencies that have an interest (either due to regulatory requirements or otherwise) in the

continued safe operations of the site. Identified Stakeholders are as follows:

On the basis of the Chemical Accidents (Emergency Planning, Preparedness and Response)

Rules, 1996, (referred to as The Chemical Accidents Rules), the following persons may be

considered as relevant stakeholders with regards to the maintenance of M/s T. J. AGRO

FERTILIZERS Pvt Ltd. emergency response at the district level:

• District Collector

• Inspector of Factories

• District Energy Officer

• Chief Fire Officer

• District Information Officer

• Controller of Explosives

• Chief, Civil Defence

• Deputy Superintendent of Police

• District Health Officer/Chief Medical Officer

• Commissioner, Municipal Corporations

• Representative of the Department of Public Health Engineering

• Experts (Industrial Safety & Health)

• Commissioner (Transport)

The following persons may be considered as relevant stakeholders at the local level:

• Sub-divisional Magistrate

• Inspector of Factories

• Representative of Industries in the District

• Transporters of Hazardous Chemicals


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• Fire Officer

• Station House Officer (Police)

• Block Development Officer

• One Representative of Civil Defence

• Primary Health Officer

• Editor of local News paper

• Community leader / Sarpanch / Village

• Non-Government Organization representatives

• Eminent Doctors in the Local area,

The above groups of persons, between themselves, respectively form the District Level Crisis

Group and Local Level Crisis Group for mitigation of chemical accidents as per the Chemical

Accidents Rules. Consequently, it is suggested that M/s T. J. AGRO FERTILIZERS Pvt Ltd

consider opening a dialogue with them and soliciting their assistance in management of onsite

& offsite emergencies associated with its activities. These may be considered as inputs to other

planning activities.

8.6.3.4. Formation of Emergency Plan Objectives

Specific objectives of the Emergency Response Plan are to be clearly listed with regards to the

responses desired for successful management of the possible emergency situations. Suggested

Objectives could, initially include:

• Formulation of suitable onsite / offsite toxic release response

• Formulation of suitable onsite / offsite fire release response

• Improved awareness of safety issues amongst site personnel.

• Training of key persons in cardio-pulmonary resuscitation.

The objectives are suggested currently are generic in nature. However, they will evolve and

become more specific as the project develops further. Responsibilities, resources and

timeframes require to be allocated for implementing the objectives.


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8.7 IMPLEMENTATION

8.7.1 Allocation of Resources

M/s. T. J. Agro Fertilizers Pvt. Ltd. will require allocation of suitable resources for effective

implementation of the DMP. Resources include both human and financial resources.

8.8 EMERGENCY STRUCTURE AND RESPONSIBILITY

8.8.1 Emergency Organization Structure

The emergency organization is a network system with focus on the Emergency Control Centre

(ECC), the Incident Controller (IC), and the Incident Site (IS). The following are office bearers

of the Emergency Organization:

• Site Main Controller: Operations Manager, in-charge of the unit.

• Incident Controller: The respective HOD /shift in-charge. The shift in-charge(s) have to be

present in each shift.

• Essential Workmen: Shift personnel from various operational units within the facility

• Safety Officer: In-charge of controlling fire

• Security officers / guards

Accordingly, the following will have to be done initially:

Identification and appointment of key officials who will take up the roles of Site Main

Controller,

Incident Controller and Essential Workers.

Informing each concerned official of their authorities and responsibilities, which are listed in

the Subsequent paragraphs and keeping records of the same.


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8.8.2 Emergency Organization: Responsibilities of Key Personnel

Immediately being aware of the emergency, the Site Main Controller (SMC) will go to the

Emergency Control Center. His main role is to control emergency in required time. On arrival

he will:

1. Get effective briefing from the Incident Controller and take charge as Site Main

Controller relieving the Incident Controller for concentrating on his role as Incident

Controller.

2. In consultation with the Incident Controller decide whether major emergency exist and

on declaration of a major emergency, ensure that the outside emergency services and

mutual help are called, the off site activated and if necessary, nearby factories and

population are informed.

3. Ensure that key personnel are called in.

4. Exercise direct operational control of those parts of the works outside the affected area

leaving the affected area to be directly controlled by the Incident Controller in close

coordination and direction of the Site Main Controller.

5. Continually review and assess possible developments to determine the most probable

course of events.

6. Coordinate the safe shut down and evacuation of the plant in consultation with the

Incident Controller and key personnel if these decisions and actions have not yet been

taken by the Incident Controller till the arrival of the SMC. If necessary, arrange for

evacuation of neighboring population.

7. Ensure that casualties are receiving adequate attention. Arrange for hospitalization of

victims and additional help if required. Ensure that the relatives are advised.

8. Inform and Liaise with the Chief Officers of the Fire and Police Services, District

Emergency Authority and experts in the field of Health and Safety. Provide advice on

possible effects on areas outside the Site.

9. In the case of prolonged emergencies involving risk to outside areas by wind blown

materials as in case of Toxic gas releases and toxic and volatile liquid spills, contact the

local Meteorological office to receive early notification of impending changes in weather

conditions and alert new onsite/offsite areas likely to be affected by the weather changes

likely in the short span of time of the likely duration of the emergency.

10. Ensure the accounting for personnel and rescue of missing persons.


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11. Control traffic movement within the Site.

12. Arrange for a chronological record of the emergency development and consequences for

later review.

13. Where the emergency is prolonged, arrange for the relief of personnel and the provision

of catering localities.

14. Issue authorized statements to the news media-where necessary and keeps in constant

touch with Head Office.

15. Ensure that proper consideration is given to the preservation of evidence. Arrange

for photographs/video recording as soon as the same is feasible.

16. Control rehabilitation of affected areas and victims on cessation of the emergency. He

will not initiate restart of the work at the worksites unless it is ensured safe to start and

cleared by the authorities.

Role of Incident Controller (IC):

Immediately being aware of the emergency and its location he will proceed to the scene. On

arrival he will:

1. Assess the scale of emergency and decide if a major emergency exists or is likely to

develop into one. On his decision, he will activate the on-site plan and if necessary, the off-

site emergency plan.

2. Assume the duties of the Site Main Controller pending the latter's arrival. For this purpose

he will depute his deputy Incident Controller on the scene and he will go to the control

center. Particularly he will:

3. Direct the shutting down and evacuation of plant and areas likely to be affected by the

emergency,

4. Ensure that the outside emergency services, including mutual aid, have been called, and:

• Ensure that key personnel have been called in.

• Direct all operations within the affected area with the following priorities:

• Secure the safety of the personnel,

• Minimize damage to site, property and environment, and

• Minimize loss of material.

• Direct rescue and fire fighting operations until the arrival of the outside Fire Brigade, when

he will relinquish control to the Head of the Fire Brigade.


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• Search for casualties.

• Evacuate non-essential workers to the assembly points.

• Set up a communications point and establish radio (telephone/messenger) contact as

appropriate with the Emergency Control Center.

• Give advice and information as requested to the Head of the fire Brigade and other

emergency services.

• Brief the Site Main Controller (SMC) on the latter's arrival at site and keeps the SMC fully

informed of the developments.

• Preserve evidences that will be necessary for subsequent inquiry into the cause of the

emergency and concluding preventive measures.

Role of Key Workers, Medical Services:

M/s. T. J. Agro Fertilizers Pvt. Ltd. can have sufficient first-aid centers and first-aiders

properly trained. The staff shall be available round the clock. Tie-up with nearby hospital &

medical shops. It should have sufficient space, capacity and situated in a safe place (avoiding

normal down wind direction). The statutory provisions shall be met with.

8.8.3 Setting up of Emergency Infrastructure

To enable the key persons to implement the DMP, the following infrastructure will require to

be set up:

8.8.4 Site Map with Escape Routes and Safe Assembly Points marked on it

Site layouts have to be put up at key areas where assembly is to be done. These points could

vary depending upon the atmospheric stability and location and intensity of the emergency.

With the onset of emergency, all non-essential workers (those workers not assigned emergency

duty) shall evacuate the area and report to the specified emergency assembly point.


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8.8.5 Wind Sock

It is required to install wind sock at the top of any tall structure in the vicinity of the site. In

case there is a risk of the structure getting damaged during the emergency, it is desirable to

have alternate wind sock(s) as required. At least one wind sock should be visible from any part

of the site. Site personnel have to be trained in reading the atmospheric conditions on the basis

of the status of the wind sock.

8.8.6 Evacuation, Escape and Rescue (EER) Plan

In a major emergency, it will be necessary to evacuate personnel from effective areas and as a

precaution / measure to further evacuate non-essential workers from areas likely to be affected

should the emergency escalate. Whether evacuation is required or not can be decided by the

Incident Controller, and arrangements made to communicate with employees in this regards.

Arrangements could include announcements over the public address system, or through other

suitable means.

On evacuation, employees should be directed to pre-determined assembly points already

explained earlier. If they are required to be evacuated outside the site and at a remote place,

their transportation will be necessary for which vehicles will be required. At remote shelters

their care and welfare will also be through beforehand. Employees should use own vehicles

first and then use, if necessary, the mutual aid system or hired vehicles from elsewhere. The

vehicle may be needed to warn public also.

The safe passages/routes for escape shall be decided and marked by arrows in the plans as

explained in the details of Emergency Control Center in this chapter.

8.8.7 Safe Assembly Points

In affected and vulnerable locations, all non-essential workers (who are not assigned any

emergency duty) shall evacuate the area and report to a specified assembly point. The various

assembly points are shown in the layout plan. The selection is done based on the safety and its

location in downwind direction. The need to evacuate non-essential workers from non-affected

areas will be determined by the foreseeable rate at which the incident may escalate.

Each assembly point must be situated in a safe place, well away from areas of risk and least

affected by down wind direction. It may be in the open or in a building depending on hazard

involved. More than one assembly point is needed:


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• To ensure that employees do not have to approach the affected area to reach the assembly

point;

• In case any assembly point lies in the path of wind-blown harmful materials, e.g. toxic gas,

burning brands, thrown (expected) materials and;

Before reaching an assembly point, or subsequently, if it is required to pass through an effected

area or the release of toxic substance, suitable personal protective equipment (PPE) including

respirator, helmets etc., should be available to the people.

8.8.8 Emergency Control Centre

An Emergency Control Centre (ECC) is the primary area from where emergencies are handled.

An ECC should contain various items as listed. The Main Control Centre, or any structure on

the site, at sufficient distance from the affected area, and that is designed to withstand

overpressure and radiation stress should be designated at the ECC.

For communication:

• Siren, or other suitable alarm system

• Public address system

• Intercom sets

• External phone sets

• Telephone directory

• Company Directory

• List of Important phone numbers

• Mobile phone

Documents for ready reference:

• Site Plan

• Layout plan with hazard zones, assembly points marked and location of siren, safety/fire

system shown (Display)

• Stock list of Fire extinguishers

• Fire-water system and additional sources of water

• Emergency Response Plan


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• Copy of First Aid

• Mutual Aid Members,

• List of employees and addresses and phones

Wall display:

• Site plan

• Layout plan

• Emergency Organization.

Stationary:

• Note pads

• Pens/pencils

• Erasers

8.8.9 Fire Extinguishers

All equipment should be regularly inspected and tested for adequacy. Personnel should be

trained in the use of the same, where special training is required. Records of the same are to be

maintained.

8.8.10 Fire Fighting

These include the following facilities:

• The internal wide road of 6m is constructed around the periphery of the factory for easy

unobstructed movement of fire tender.

• Sufficient water supply

• Dedicated, above ground fire water storage of approximate 100m3

• Dedicated fire pumps to pump the water, connected to the DG Set as well as the GEB

supply.

capacity

• The system should be designed such that when half the aggregate pumping capacity has

been discharged at the hydraulically most remote point and the other half in the most

vulnerable area enroute, a minimum running pressure of 7 kg/cm2

(g) is available at the

former point and the velocity of water does not exceed 5m/sec anywhere in the system.


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The following fire fighting equipment shall be required at the site.

• Water buckets: 9 lit of water buckets for 100 m2

• Shovels: 2 Nos.

of the floor area

• Fire Detection & Alarm system : At key locations

M/s. T. J. Agro Fertilizers Pvt. Ltd. might have fire accidents as mentioned in Table 8.6:

TABLE 8.6 TYPE OF FIRE ACCIDENTS

Sr. No Class Extinguisher

Medium SI code Nos.

1. Type A Water Type

A. Soda Acid 934 5

B. Gas pressure 940 5

2. Type B Chemical Foam 933 3

Carbon Dioxide (CO2

5507, 2878,

10474, 8149 ) 3

Sand Bucket --- 5

3. Type E Carbon Dioxide (CO2

2878 )

4

Dry Chemical Powder

2171,4308 4

Fire Extinguisher Calculation:

Total Area of Fire Hazard: 6368.63 m2

Capacity of fire extinguisher : 600 m

2

Total Nos of fire extinguisher required: 14 nos.

Nearest fire station from the project site is Fire Station of Mandvi, Vadodara which is 31.5 km

away from project site and fire brigade can reach to the site within 40 minutes.

Note: Vadodara is major town near the project site having fire fighting facilities.


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8.8.11 First Aid Basic items in a first aid kit consist of following items.

• First aid leaflet, including CPR

• Sterilized finger dressing

• Sterilized hand or foot dressing

• Sterilized body or large dressing

• Sterilized burns dressing - small

• Sterilized burns dressing - large

• Sterilized burns dressing – extra large

• Sterilized cotton wool (25 gms)

• Cetavolon (28 gms)

• Eye pads

• Adhesive plaster

• Assorted roller bandage

• Triangular bandages

• Safety pins

• Scissors, ordinary, 12.7cms, both sides sharp

• Savlon liquid, 150 ml, or equivalent

• Cotton wool for padding, 100 gms

• Eye Ointment of sulphacetamide preparation

• Loose woven gauze (28”x8”), Compressed pack

• Scribbling Pad, 4”x 6” with a pencil in a plastic cover

• Adhesive dressing strips

• Field dressing of modified army pattern

• Record cards in a plastic cover

• Torch, medium size

• Eye wash

• Wooden splints, small

• Wooden splints, big


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8.8.12 Personnel Protective Equipments (PPE)

• Gloves of different types

• Helmet

• Masks of different types

• Safety Spectacles

• Ear Muff/ Ear Plug/ Caps/ Shocks/ Uniforms

• Eye Showers

8.9 AWARENESS, TRAINING, AND COMPETENCE

8.9.1 Awareness General awareness is to be invoked in all site personnel (including contractor’s employees)

with regards to the importance of safety in general and emergency procedures in particular.

Awareness can be generated in a number of ways, some of which are:

• Awareness of Environment, Health and Safety Policies, and the role of each employee in achieving what are covered under the policies.

• Awareness of the importance of carrying out tasks as mentioned in the Standard Operating Procedures and the potential impacts of not doing so.

• The importance of wearing personal protective equipment • Awareness with regards to relevant recommendations issued in this report • Awareness about relevant portions of the safety instructions covered in equipment manuals

used at site.

8.9.2 Training

Specific training requires to be given to key employees. Examples of such training include:

• Testing of critical equipment and controls • Provision of Cardio-Pulmonary Resuscitation • Use of fire fighting equipment • Emergency Evacuation and Rescue (EER) procedures. • Training in use of communication procedures to be followed in case of emergencies.

Training needs identification exercises should be undertaken prior to commencement of

operations and the same must cover environment, health and safety issues.


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8.9.3 Competence Competence is a function of training, experience and education. Key persons involved in

administering the DMP, should be competent. The level of competence can be decided for each

key task and a clearly defined competence chart should be prepared.

8.10 COMMUNICATION

Communication is vital during emergencies. Under the Factories Act, as well as the MSIHC

Rules, communication is important and it is required to divulge the potential emergencies that

could arise out of the operations related to hazardous units.

After undertaking an assessment of risks and their possible environmental impacts, and setting

up an organization for the preparedness to control the emergency, including related

infrastructure, the next step is operationalizing the communications system. Depending upon

the severity of the event, communications may have to be made with:

• Persons inside the site premises • No person to be allowed enters or exits inside or outside the plant at security gate. • Key personnel outside the site premises during their non-working hours • Outside emergency services and authorities, and • Neighboring businesses, industries and general public.

Requirements pertaining to communication during emergencies are covered in this section.

8.10.1 Levels of Emergency

Three levels of emergencies are to be recognized:

• First level: Confined to a particular unit of the entire site,

• Second level: A spreading emergency, that requires outside help, and

• Third level: A major emergency requiring neighboring population to be alerted.

Suitable alarms require to be made for each of these potential emergencies. The alarm should

be audible in every part of the site. In areas of high noise levels, an alternative to an audible

alarm, such as flashing lights may be installed.


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8.10.2 Raising the First Level Emergency Alarm

Any person noticing an emergency should be able to raise or cause to be raised, the First Level

Emergency Alarm (FLEA). All employees must be trained to operate such emergency alarms.

There should be adequate places within the site, where provision to raise an alarm is available.

This could be an audible warning, individual signal or message to a manned location. Major

emergencies can be avoided by doing this.

8.10.3 Raising the Second and Third Level Emergency Alarms

In case there is a risk of the event spreading beyond the original unit and / or outside the site

premises, then a second level emergency alarm can be raised. This could be across the entire

site, as opposed to the first which could be at a part of the site.

In case a third level or (major) emergency is to be declared, telephonic information to members

of the local crisis group, or in case of failure of power and formal communication systems, and

non-availability of mobile phone signals, a big bell or a messenger can be deployed.

8.10.4 Declaring a major emergency:

Declaration of a major emergency should never be done on whims, immature judgement or

without proper thought. Further, because of the scale of activity that will commence due to

declaration of a major emergency, it is advisable to restrict the authority to declare it, and a

limited number of persons may be invested the authority to declare such an emergency,

although care should be taken to ensure that at least one such person is always at site.

8.10.5 Identifying the Type of Emergency through an Alarm

Alarm systems vary and will depend upon the size of individual sites. The person noticing the

incident should warn all those in the site vicinity to either evacuate or take other immediate

action according to a predetermined plan. Automatic alarms may be considered. Audible

alarms include sirens or other alarms over public address systems.

Alarms for a particular type of emergency (toxic leak or fire) can be raised separately enabling

different emergency plans to be put in motion. However, this must be done after giving due

thought about avoiding confusion in the minds of the site personnel.


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Use of alarms can be carried out to communicate different information such as:

• Declaration of a first level emergency by an alarm in a particular area

• Declaration of an advanced emergency situation by sounding of an alarm in the entire site

• Declaration of a major emergency by sounding of a hooter, alarm or by communication

through phone, bell or messenger.

8.10.6 Communication of Emergency

There should be an effective system to communicate emergency:

Inside the factory, i.e. to the workers including key personnel and essential workers on duty,

and inside normal working hours,

To the key personnel and essential workers not on duty and outside during normal working

hours

To outside emergency services and the government authorities, and

To the neighboring businesses, and public in general

8.10.7 Use of telephones and the role of the telephone operator

After hearing the emergency alarm and emergency declaration, or even while fast receiving the

emergency message on phone, a telephone operator (or communication officer) has to play an

important role. He should be precise, sharp, attentive and quick in receiving and noting the

message and then for immediate subsequent action of further communication.

8.10.8 Communication inside with Personnel inside the Site during the Incident

Relevant statutory information pertaining to the site must be made available beforehand,

preferably in the form of a booklet, to workers so that they can prepare themselves to prevent

or control the emergency. Such information includes:

Statutory requirements under section 41-B, 41-C, and 41-H of the Factories Act

Hazard Information, including

• A list of hazardous processes carried on in the factory • Location and availability of all MSDS’ • Physical and health hazards arising from the exposure to or handling of substances • Measures taken to ensure safety and control of physical and health hazards


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• Measures taken by workers to ensure safe handling, storage and transportation of hazardous substances

• Personal Protective Equipment required to be used by the workers employed in hazardous processes or dangerous operations

• Meaning of various labels and markings used on the containers of hazardous substances • Signs and symptoms likely to be manifested on exposure to hazardous substances and to

whom to report • Measures to be taken by the workers in case of spillage or leakage of hazardous substances • Role of worker vis-à-vis the emergency plans of the site and in particular evacuation

procedures. • Any other important health and safety related information.

In all cases, once the communication of emergency is done, through an alarm, all personnel

should be ready to undertake their roles in the same.

8.10.9 Communication with Personnel outside the Site during the Incident

Because of the suggested planning covered in Section 0, key personnel will typically be

available in all shifts or on short call. But due to some reason, if some are outside or not on

duty and if their help is required, their updated details should be kept in the ECC for

communication.

As far as possible, names should be listed in the order or priority. Communicators should be

told to call in the personnel in the order given, but not to waste time and call the next in line,

returning to those who could not be contacted later.

On making contact, the communicator should give a short pre-arranged message to the effect

that an emergency has been declared at the site. While coming to the site, they should be

instructed to carry with them their identity cards in case they are stopped at road blocks.

8.10.10 Communication inside with external Emergency Services and Relevant

Authorities

Communication with external agencies is important and essential, both to control the

emergency and as per regulatory compliance requirements. This is specially so for reportable

(lost time) accidents. In such cases, it is essential that the outside emergency services as well as

relevant outside agencies be informed in the shortest possible time. Liaison at the local level

will help determine the best means for achieving this.


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Relevant agencies that provide emergency services include the fire brigade, nearby hospitals

and doctors, and the police, besides senior local and district administration personnel. Statutory

information, given to such agencies in advance will help them in arranging emergency

services.

8.10.11 Communication with neighboring firms and the general public

Telephone can be used for contact with industries in the study area with a view of receiving

mutual aid. However, the public in the area, in some circumstances, may require to be

informed about the emergency, which as stated earlier, should be done after careful evaluation.

The general public requires to be informed of the precautions to be taken in case of emergency

situations arising out of hazards posed by units near them.

These include:

• Common names of hazardous substances used which could give rise to an accident likely to affect them, with an indication of their principal harmful characteristics.

• Brief description of the measures to be taken to minimize the risk of such an accident in compliance with its legal obligations under relevant safety requirements

• Salient features of the approved emergency management features of the site • Details of the emergency warning system that will be deployed by the site for emergency

action by the general public • General advise on the steps to be taken by the general public on hearing or becoming aware

of the warning • Brief description of arrangements in the site including liaison with emergency services to

deal with foreseeable accidents of such nature and to minimize their effects • Details of where additional information may be collected.

8.10.12 Communication with District Crisis Group and the Local Crisis Group

• In addition to the general public communication will require being provided to the district

administration and this may be done by liaisioning with different agencies.

8.11 EMERGENCY DOCUMENTATION AND DOCUMENT CONTROL 8.11.1 Documentation Emergency documentation consists of:

• The Disaster Management Plan (this chapter) and its annexure duly completed. • Related Formats and Records showing compliance with these documents.


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The DMP needs to be approved by the Site in-charge prior to use. All documents should be

easily accessible at individual sites.

8.11.2 Document Control

• Documents should be legible. • All documents should be protected against damage, deterioration and loss. • Changes, if any, should also be approved by the Site in-charge. • Copies of the approved DMP are to be kept with the Site in-charge at the office in the

Emergency Control Centre, with the Site Main Controller. • Obsolete documents should be marked as such, and copies of such documents are to be

collected and prevented from being used.

8.11.3 Emergency Control

In case of emergencies, actions can broadly be categorized into the following activities:

• Saving of human lives

• Controlling the spread of the emergency and ultimately stopping it from further developing

On the basis of the issues covered in this chapter, the following are required to be incorporated

into the site’s DMP annexure.

8.11.3.1 Onsite Emergency Control

• Shut down and Isolation: Raising the alarm, followed by immediate safe shut down and

isolation of effected areas.

• Escape, Evacuation and Rescue: Safeguarding human lives at site by commencement of

the Emergency Evacuation and Rescue Plan. Ensuring that all personnel are accounted

for and carrying out a head count of persons evacuated. Notification and commencement

of offsite emergency plan in case offsite impacts are possible.

• Stopping the development of the emergency: Control or response to the emergency

depending upon its nature (fire OR toxic release). Fire can be somewhat better controlled

through fire fighting, while toxic release impacts can be partially controlled through

proper communication with affected population.

• Treatment of injured: First aid and hospitalization of injured persons.

• Protection of environment and property: During mitigation, efforts should be made to

prevent impacts on environment and property to the extent possible.


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• Welfare of the personnel managing the emergency: Changeover, first aid and

refreshments for the persons managing the emergency.

• Informing and collaborating with statutory, mutual aid and other authorities including

those covered in the Local Crisis Group.

• Informing and assisting relatives of the victims.

• Informing the news and electronic media.

• Preserving all evidences and records: This should be done to enable a through

investigation of the true causes of the emergency.

• Investigation and follow up: This requires to be carried out to establish preventive

measures for the future and a review of the DMP & its annexure to fill up the deficiencies

in the emergency planning procedures.

• Ensuring safety of personnel prior to restarting of operations: Efforts require to be made

to ensure that work environment is safe prior to restarting the work.

8.11.3.2 Off-site Emergency Response Plan

An emergency may affect areas offsite of the works as for example, fire can spread burning

brands of gases through wind. Perhaps the most significant risk to the outside areas is that

associated with a large release of toxic vapors. Management will usually need expert advice in

drawing up plans so that if such a release occurs, they will be able to collaborate with

Emergency Services to estimate as far as practicable which downwind areas are at risk. It may

be necessary to prepare in advance simple charts or tables relating the likely spread of the

vapors cloud taking into account its expected buoyancy, the local topography and all possible

weather conditions during the time of release. Advice on all these matters can be obtained

from the Meteorological Office. Any such advice will include the recommendation that if a

release occurs the local Meteorological Office (whose address is in the telephone directory)

should be contacted for the current state of the weather over a somewhat wider area and, in

the case of prolonged emergencies, information on imminent changes in weather which

may alter the areas at risk. Such information is likely to be more specific if prior consultation

has been made.

M/s. T. J. Agro Fertilizers Pvt. Ltd. obligations for generating the Offsite Emergency Plan

Offsite emergency preparedness is covered in the Chemical Accidents (Emergency Planning,

Preparedness and Response) Rules, 1996.


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The following are the responsibilities towards generation of the Offsite Emergency Plan:

• To provide basic information on Risk and Environmental Impact Assessment to the

Local/District Authority, Police, Fire Brigade, Doctors, surrounding industries and the

public and to appraise them on the consequences and the protection/prevention

measures and control plans and seek their help to manage the emergency.

• To assist the District Authorities in preparing the Off-site Emergency Plan.

An off-site emergency plan organization has essentially two parts:

1. Formation of the Local Crisis Group: This Group is headed by the Deputy Collector or the

Magistrate of the Industrial area and is responsible for the management of any industrial

emergency confined to the local area.

2. Formation of the District Crisis Group: This Group is headed by the District Collector of the

District and is responsible for any major Industrial emergency affecting Local and beyond

any industrial area of the District.

The composition of the Off-Site Crisis Group is covered in. Since, the actual offsite plan

requires the participation of outside agencies; this report does not dwell further on the issue.

The typical structure of the offsite emergency planning group is provided vide Table 8.7 given

below.


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Table 8.7: COMPOSITION OF OFFSITE CRISIS GROUP

District Collector

Off-Site EMP Teams

Each Team has:

• A Chair Person / Director • Secretary • Coordinator • Members

Local Crisis Groups

(For each Industrial Area Headed by

the Deputy District Collector or

Magistrate)

Off-Site EMP Teams

1 Fire Brigade Team, 2 Experts, 3 AMC-Team, 4 IC-Team, 5 Toxic Gas Containment team, 6 Communication Team, 7 Transport and Evacuation Team, 8 Traffic Control Team, 9 Medical Team, 10 Mass Media and PR-Team.


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8.12 CHECKING AND CORRECTIVE ACTION

8.12.1 Monitoring and Measurement

Monitoring of the planned arrangements and the implementation of the DMP are essential to

deliver the required output and enhance emergency preparedness. This includes:

• Provisions for NDT, FMECA and other tests to identify failure of critical equipment,

before it actually takes place.

• Monitoring compliance to permits and statutory requirements lay down by regulatory

authorities.

• Conducting mock drills (including fire drills and toxic release drills) to check whether the

planned arrangements are working as per the required norms or not.

• Testing of critical equipment, and

• Identifying minor leaks, accidents, near misses and others incidents that can lead to

emergencies.

A detailed monitoring checklist requires being prepared and the required actions carried out,

prior to start of work.

8.12.2 Records

Records are a means of evaluating performance. Records include (but are not limited to):

1. Regulatory records, such as permits and related documents

2. Monitoring and test records

3. Correspondence with relevant offsite and onsite agencies

Site management will ensure that records are properly maintained and available. It is desirable

to keep copies of all records at the site as well at the project sites, to prevent their loss. The

retention time for these records will depend upon their criticality and an ultimate decision will

require to be taken by Head Office in this regards. Legal records should be kept permanently.

8.12.3 DMP Audit, Non Conformance and Corrective Action and Preventive Action

Since this DMP has been designed as a dynamic document, it is required that its performance

be audited at regular intervals. Ideally, persons auditing the DMP should be external auditors

(i.e. not employed at the site being audited). The audit should result in a set of findings that are

put before the site management for review.


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Audits will be periodic, at intervals that are decided by the Head Office. Audit reports shall

state the exact non-compliance with the particular clause of this DMP, and should include steps

to be taken to attain compliance, through corrective and preventive actions.

8.12.4 Safety Committee and Safety Meeting

Safety committee is an organizational structure where members represent a group. This gives

everyone a voice but keeps the meeting size to an effective number of participants.

8.12.5 Functions of Safety Committee

A safety committee can be very helpful, especially when they are allowed to do the following.

1. Discuss safety polices and recommended adoption

2. Help management to correct unsafe conditions and unsafe acts.

3. Create more disciples of safety

4. Help evaluate safety suggestions

5. Arouse Interest in safety

8.12.6 Safety Committee Procedure

When a committee is formed, a procedure should be written describing its function and

activity.

1. Extent of committee authority

2. Scope of Committee activity

3. Order of business

4. Record Keeping

5. Attendance

8.12.7 Review of Emergency Performance

The site / head office management will review the findings of the audit and the non-

compliances. It will consider whether the DMP is providing adequate safety assurance to the

management, delivering performance as desired, and whether it continues to be in the spirit of

Environment, Health and Safety Policies, and changing requirements. On the basis of these, the

management will record its decisions and consider modifying the DMP, as deemed

appropriate.


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8.12.9 Contents of the Annexures

The contents of the DMP Annexures are listed. The annexure should first be completed in

respect of the names, addresses and contact phone numbers of all the members of the

emergency organization. In addition, the names, addresses and phones numbers of nearest

police station, local authorities, media, doctors, hospitals, fire brigade, voluntary organizations,

and home guards also require to be collected. Once this, (and other) updating of DMP has been

done for the site, the same may be got printed and kept with each officer, work sites and

security, and other relevant persons as may be needed. The items covered in the annexure are:

• Emergency organization

• Siren code

• Site map with escape routes and safe assembly points

• Emergency control centers

• Role of site main controller

• Role of incident controller

• Role of fire safety service

• Medical services

• Engineering services

• Welfare services

• Security services

• Replenishment services

• Mutual aid

• Internal emergency reporting and communication system

• Safe assembly points

• Evacuation, escape and rescue (EER) plan

• MCLS

• Mutual aid organizations

• Mock drill and review procedure

• Offsite plan components


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8.13 RECOMMENDATIONS Recommendations are made for different aspects of the project and are given in subsequent paragraphs.

8.13.1 Hazardous Material Storage and Handling

8.13.1.1 Storage of Hazardous Chemicals in Drums and other Containers • The drums should never be filled full with the liquid chemical. There should be sufficient

space to take care of thermal expansion.

• The drums should preferably be stored in a well ventilated shed (preferably away from

process units) with impermeable floor sloping away from drums.

• Periodic site inspection should be carried out to ensure that there is no leakage from any of

the drums..

8.13.1.2 Storage and Handling of Extremely toxic or highly toxic

• Store in a segregated and approved area. Keep container in a cool, well-ventilated area and

tightly.

• Keep away from heat, from sources of ignition. Ground all equipment containing material.

Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing.

• Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents.

• Avoid all possible sources of ignition (spark or flame).

8.13.1.3 Storage and Handling of Fuel

In case heating is to be provided to HSD in winter, then steam heating is suggested as opposed to

use of heating coils for heating purpose.

• Fuel storage roofs and interface of vapour and liquid levels have shown heavy corrosion and nitrogen bleed helps in preventing corrosion and also fire and explosions. This provision should be kept. Fuel does not statutorily require a flame arrester at the vent line of storage tank, but it is desirable to provide one as fires and explosions have taken place.

• Dyke below the overhead HSD tank be provided to contain spills and for good house keeping around.

• For draining of water from the HSD tank, a drum be kept with bottom and side outlets, instead of draining in the open to maintain good house keeping and draining of water be done


[8-34]

in a jug and throw away the water and the drum should retain any drippings of HSD that can be pumped to overhead tank when filled.

8.14 UNLOADING OF TANK TRUCKS

• Before the tanker enters the industry premises, the tanker is to be inspected for authorized

entry and safe & sound condition of the tanker, its contents and that of the prime mover.

Tankers entering plant are to be fitted with flare arresters on their exhaust.

• The quality of the chemical in the tanker should be ascertained before unloading to avoid

contamination of chemical already at storage.

• Coupling used for connecting hose to tanker must be leak proof.

• For flammable chemicals, the tanker and the hose are to be properly earthed before starting

unloading operation.

• Unloading should be done under personal supervision of responsible staff authorized by the

management.

• Provision of sample quantity of water / neutralizing medium to take care of leakage / spillage

must be made. Also steam and inert gas hose stations must be available at unloading point.

• Fire alarm and fire fighting facility commensurate with the chemical should be provided at

the unloading point.

8.15 HAZARDOUS WASTE TRANSPORT

The occupier of hazardous substance shall prepare six copies of the manifest (transporting

documents) in Form 9 comprising of Colour code indicated below (all six copies to be signed by

the transporter):

• Copy 1 (white): to be forwarded by the occupier to the State Pollution Control Board or

Committee

• Copy 2 (yellow): to be retained by the occupier after taking signature on it from the transporter and rest of the four copies to be carried by the transporter

• Copy 3 (pink): to be retained by the operator of the facility after signature

• Copy 4 (orange): to be returned to the transporter by the operator of facility after accepting

waste


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• Copy 5 (green): to be returned by the operator of the facility to State Pollution Control Board / Committee after treatment and disposal of wastes.

• Copy 6 (blue): to be returned by the operator of the facility to the occupier after treatment and disposal of wastes

The occupier shall forward copy number 1 (white) to the State Pollution Control Board or

Committee and in case the hazardous waste is likely to be transported through any transit State,

the occupier shall prepare an additional copy each for such State and forward the same to the

concerned State Pollution Control Board or Committee before he hands over the hazardous waste

to the transporter.

No transporter shall accept hazardous wastes from an occupier for transport unless it is

accompanied by copy numbers 2 to 5 of the manifest. The transporter shall return copy number

2 (yellow) of the manifest signed with date to the occupier as token of receipt of the other four

copies of the manifest and retain the remaining four copies to be carried and handed over to

respective agencies as specified in sub-rule (4).

8.16 GENERAL SAFETY PRACTICES

8.16.1 Work Permit System

• It is recommended that plot plans of the installation and the operating blocks should be

displayed in the fire and concerned unit control rooms respectively and site of hot jobs under

progress should be indicated on these plot plans with red pins.

• No hot/cold work shall be undertaken without a work permit except in the areas pre-

determined and designated by the owner-in-charge.

• Permit should be issued only for a single shift and its validity should expire at the termination

of the shift. However, where the work has to be continued, the same permit may be

revalidated in the succeeding shift, by authorized person after satisfying the normal checks.

• Equipment or area where work is to be conducted should be inspected to ensure that it is safe

to carry out the work and assess other safety requirements / stipulations.

• Unsafe conditions for performance of work may arise from surrounding area. It should be

cleaned-up to remove flammable material such as oil, rags, grass etc.


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• Other activities (routine / non-routine) being carried out near-by which can create conditions

unsafe for performance of the permit work, should be taken into consideration and the

concerned persons should be alerted accordingly.

• Running water hose and portable fire extinguisher are required respectively to flush / dilute

in case of release of any hazardous chemical or to quench sparks and to put out small fires

immediately.

• In order to meet any contingency, it should be ensured that the fire water system including

fire water pumps, storage, network etc. is checked and kept ready for immediate use

• Equipment / Vessel, on which the work permit is being issued, should be completely isolated

from the rest of the plant with which it is connected during normal operation, in order to

ensure that there is no change in the work environment with respect to presence of toxic /

flammable gases, liquids, hazardous chemicals etc. in the course of the work.

• Equipment under pressure should be depressurized after isolation. This will be followed by

draining / purging / water flushing etc. as the case may be.

• Proper means of exit is required in case of emergencies developed on account of the work or

otherwise. Availability of an alternate route of escape should be considered.

8.16.2 Contractor Safety

Duties & responsibilities of the contractor should include the following:

• To implement safe methods and practices, deploy appropriate machinery, tools & tackles,

experienced supervisory personnel and skilled work force etc. required for execution.

• To prepare a comprehensive and documented plan for implementation, monitoring and

reporting of Health, Safety and Environment (HSE) and implement the same after its

approval.

• To nominate qualified & trained Safety Engineers / Officers reporting to the Site in charge,

for supervision, co-ordination and, liaison for the implementation of the safety plan

• To arrange for fire protection equipment as per the advice of owner

• To ensure that its employees have completed appropriate health and safety training as

required by the statute / regulation and also as per requirements of the Owner / Consultant


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• To comply with all the security arrangements of owner.

• To ensure availability of First Aid boxes and First Aid trained attendant.

• To ensure that all incidents including near misses are reported to all concerned immediately.

• To ensure strict compliance with work permit system by carrying out work only with

appropriate work permits and after ensuring that all safety precautions / conditions in the

permit are complied with and closing the same after job completion.

• To ensure that the workers likely to be exposed to hazardous chemicals/materials have access

to appropriate Material Safety Data Sheets (MSDS), wherever applicable, and provide

necessary mitigation measures.

• To ensure that appropriate warning signboards or tags are displayed.

• To ensure that workers have proper training for their job assignments, including use of

appropriate PPE and first aid fire fighting equipment.

• To comply with all applicable safety and health standards, rules, regulations and orders

issued by competent authority pertaining to the assigned activities.

• To conduct daily inspections to ensure compliance with safety standards, codes, regulations,

rules and orders applicable to the work concerned.

8.16.3 Static Electricity

• Ensure no metal objects/appurtenances projecting from roof/shell plates, which will attract

highly charged spots in fuel for dissipation.

• Ensure reduced rate of flow initially into tank/vessel until fill point/nozzle is completely

submerged in fluid.

• Ensure periodic checking and recording of earthing test for tanks and piping systems are

maintained.

• Agitation with air, steam gas, jet nozzle or mechanical mixtures should be avoided.

• Ensure no personnel are allowed on tank roof for gauging / sampling during product transfer

unless dip pipes extend to bottom of tanks. Use only mechanical gauges for ascertaining

product transferred during transfer operations otherwise.


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• Protective bonding is required when fill open containers where the product to be handled has

a flash point below 54.5 Deg.C (130 Deg.F) or, in the case of a higher flash point product,

when it is heated to within 6.0 Deg. C (15 Deg.F) of its flash point. The purpose is to keep

the nozzle and container at the same electrical potential, thus avoiding a possible static spark

in the area of a flammable mixture.

• Small containers made up of plastic or other non-conductive materials should not be used for

filling of fuels.

• Water washing is safe from a static electricity stand-point. However, there should be no

insulated conductive objects within the tank.

8.16.4 Lightning Protection

• Measures to control fugitive emission from storage tanks should be given special

consideration.

• Structures of exceptional vulnerability by reason of explosive or highly flammable contents

need special consideration and every possible protection need to be provided even against

the rare occurrence of a lightning discharge.

• A lightning protection system (Conventional Air Terminal System) consists of the following

three basic components - Air terminal, Down conductor and Earth connection

• Non-conducting chimneys whose overall width or diameter at top is upto 1.5m shall be

provided with one down conductor, and chimneys with overall width or diameter at top

more than 1.5m shall be provided with 2 no. down conductors

• Metal stacks shall be properly earthed at the bottom.

• Flammable liquids shall be stored in essentially gastight structures.

• Openings where flammable concentrations of vapour or gas can escape to the atmosphere

shall be closed or otherwise protected against the entrance of flame.

• Structures and all accessories e.g. dip-gauge hatches, vent valves shall be maintained in good

and sound operating conditions.

• Flammable air-vapour mixtures shall be prevented to the greatest possible extent from

accumulating outside storage tanks.


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• Potential spark-gaps between metallic conductors shall be avoided at points where flammable

vapors may escape or accumulate.

• A properly designed / constructed gas tight storage tanks considered to be self-protected

against lightning provided it is properly earthed and bonded. Such a structure may not

require any additional means of lightning protection.

8.17 PERSONNEL SAFETY

8.17.1 Personnel Protective Equipment

• Protective equipment should be inspected frequently to ensure that it is in good condition.

Frequency of checking can be decided depending upon the usage.

• After the use of protective equipment, it should be cleaned and disinfected before being

issued to another person

• Know about MSDS of hazardous chemicals used.

• A person not-familiar with MSDS and trained in use of appropriate shall not commence any

work with hazardous chemicals.

• Frequently refer to the MSDS and use of appropriate PPE

• Display prominently requisite information on MSDS and use of PPE through illustrations

• It is essential that right type of PPE and in sound condition be used.

• All stocks of PPEs should be periodically inspected, serviced and maintained and unusable

ones removed from stock of usable PPEs and sent for disposal.

• All PPEs should be cleaned for personal hygiene and kept packed in poly bags.

• All PPEs should be inspected before and after each use.


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8.17.2 Training and Development

• Participant’s reaction should be obtained in respect of the course content; training

methods/techniques used by the faculty, quality of course material etc.

• It should be ascertained whether participants’ learning in terms of knowledge and skills in

specific areas or activities e.g. safe operating and maintenance procedures, fire prevention

and control etc. have improved after the training.

• It should be checked in what ways and to what degree/extent the attitude of the participants

(values or beliefs) have been influenced by the training programme. An evaluation of their

behavior on the job is necessary for this purpose.

• Change in participants’ performance at their place of work as a result of the training, should

be evaluated.

• The effectiveness of faculty in each training programme should be evaluated and necessary

changes if need be, should be made in subsequent training programmes.

• The impact of the training programmes on the performance standards of the organisation and

attainment of tangible results with respect to safety should be evaluated.

• Records of training should be maintained in respect of every employee indicating the types

and the period of training programmes attended, performance evaluation and the need for

future training.

• The impact of training programmes should be evaluated in terms of overall safety objectives

achieved.

8.18 SAFETY OF PLANT EQUIPMENT

8.18.1 Thermal Insulation

• PUF, Rock wool insulating material will be used.

• Frequency of Visual Inspection shall be once a year for plants and mobile equipment. This

visual inspection shall be preferably carried out before monsoon, to check for any

damage/deterioration, and record the same.


[8-41]

• Like equipment, insulation also shall be checked and maintained at regular intervals.

Preventive maintenance of insulation is very much necessary for safe and economic

operation.

8.18.2 Electrical Equipment

• Before initiating the inspection of electrical equipment and associated circuits, Inspector

should familiarize himself with the complete previous history of the equipment/circuits,

design parameters, service, and likely areas of concern, manufacturer’s recommendations

and such other pertinent data to arrive at the appropriate inspection procedure.

• The field inspection of electrical equipment in an operating unit is classified into following

three types as follows:

8.18.3 OnStream Inspection

• This covers audio visual inspection items (instrument aided or otherwise) for checking of

general equipment conditions, while the equipment is in operation. (e.g. an abnormal nose

or vibration of motor, leakage of transformer oil or overheating of equipment etc., can be

assessed through such inspections).

8.18.4 Shutdown Inspection

• This covers those inspection items for checking conditions of equipment and systems which

cannot be revealed through on-stream inspection (such as internal condition of equipment).

This inspection shall be carried out after taking the shutdown of the related equipment after

obtaining the Electrical Line Clearance and Work Permit requirements

8.18.5 Inspection of Standby Equipment and Spare Parts

• The standby electrical equipment shall be inspected on the same basis and schedule

applicable under shutdown inspection, so that changeover from normal to standby equipment

shall be possible without any downtime of unit operation.


[8-42]

8.19 Reactors

Reactors will be designed such that the safe working pressure of the reactors is never exceeded.

As per the American Society of Mechanical Engineers (ASME), the safe working pressure of a

vessel should always be higher of the two conditions mentioned:

• 10% higher than the maximum operating pressure, or

• 2 kg/cm2

Minimum statutory requirements include:

more than the maximum operating pressure

• Safety relief valves or rupture discs

• Pressure gauges

• Isolation valves or valves to prevent connected equipment over-pressurization

• Drain valve at the bottom to drain of condensates

Vents of pressure relief systems should lead to a surge tank whose vent should lead to a

scrubbing system that should have reserve overhead water tank with interlock with critical

operating parameters such as pressure. Other safety devices that may be considered include:

• High / low pressure alarms, and

• Interlocking equipment to prevent over-pressurization; such as between compressors and

connected equipment.

Pressure relief devices and rupture discs are always the last resort. Engineered design should

include high / low pressure alarms, auto trips that are set up at pressure above the operating

pressure but below the relief systems.

In general, all reactors and pressure vessels will conform to rules laid down in The Static and

Mobile Pressure Vessels (Unfired) Rules 1981.


[8-43]

8.20 Equipment Safety

\

8.20.1 Pumps

Pre-starting procedure • Equipment: Pump shall be thoroughly cleaned.

• Piping: Assembly of all piping shall be checked to ensure that they are as per the design

drawing. Piping shall be thoroughly flushed to remove rust preventive/foreign material.

• Support: Relevant pipe supports shall be checked to ensure that they are as per design

drawing.

• Alignment: Alignment of pump and prime mover shall be carried out.

• Bearing: Bearings shall be lubricated with correct lubricant wherever applicable.

• Prime mover: The prime mover shall be prepared for operation as manufacturer’s instruction.

In case of Electric Drive correct direction of rotation shall be ensured in decoupled

condition. Insulation value of motor and cable shall be checked and recorded.

• Packing: For gland packing and mechanical seal, cooling and flushing shall be ensured.

Mechanical Seals (if applicable) shall be installed as per manufacturer’s recommendations.

• Heating up before startup: Pumps on high temperature service shall be heated up gradually to

an even temperature before putting on service.

• Balancing drum leakage: For pumps equipped with balancing drums, any valve in the line

shall be locked open for ensuring leakage return to pump suction or to the vessel.

Start-up Procedure

• The free rotation of the pump shall be checked.

• Ensure all instruments are installed as per P&I diagram.

• Ensure that strainer is provided in the suction line.

• Discharge valve shall be closed (if not already closed).

• On pumps having externally sealed stuffing boxes, the injection line valves shall be opened

and sealing fluid allowed flowing to the seal cages.

• Pump shall be properly primed.

• Prime mover shall be started as per prescribed recommendation.


[8-44]

Post-start Checks

• All instrument readings shall be checked and recorded periodically.

• Vibration readings shall be checked and signature shall be taken as necessary.

• Stuffing box packing shall be checked for overheating.

• Temperature rise, vibration and any abnormal sound from bearings shall be checked.

• Cooling water flow shall be checked frequently.

• Suction and discharge pressure shall be monitored to ensure proper operating condition.

8.20.2 Diesel Engines

• Fuel, oil, water and exhaust shall be checked for leaks.

• Air cleaner oil level shall be checked.

• Oil level in hydraulic governor shall be checked, if provided.

• The following checks shall be carried out after every 250 hours - condition of entire oil, the

filter elements for metal particles and oil sludging, element holes and tears, oil in aneroid

control, if provided, belts, fan hub and drives.

8.20.3 Fans, blowers, gear boxes and agitators

Fans and Blowers

• Bearing Temperature, Bearing cooling water flow & cooling water temperature and motor

amperage should be checked daily

• After every 2000 hrs, the gear boxes should be inspected for condition of the gear and

bearings, coupling and alignment and oil level

• In the case of side entry or bottom entry agitators the shafts are sealed by using stuffing box

or mechanical seals. In the case of long shafts steady bearings may be used. Therefore,

agitators can be subdivided for the purpose of preventive maintenance schedule into Gear

boxes and sealing arrangements.


[8-45]

Rotating equipment components

• Check the set of belts for exact length ranges i.e. the belts should be in matched sets.

• Check the sheave groove with a template for ensuring the tight fit.

• Always ensure that the set of belts is from one manufacturer only.

• All the bolts must have manufacturers’ original mark imprinted on it.

• Ensure replacement of belt in full set whenever required.

• During operation belts is checked for to see the belts have become loose, the ply threads have

started coming out, the belts are touching the guards, the guards are properly bolted with

main frame or a separate support, black dust started coming off from the belts etc.

8.20.4 Mechanical Seals

Inspection of Seal Components Prior to Installation:

• It should be ensured that all parts are kept clean; especially the running faces of the seal ring

and insert.

• The seal rotary unit should be checked to ensure that the drive pins and/or spring pins are

free in the holes or slots.

• The set screws in the rotary unit collar should be checked to ensure that they are free in the

threads.

• The thickness of all gaskets should be checked against the dimensions shown on the

assemble drawing. Improper gasket thickness will affect the seal setting and the spring load

imposed on the seal.

• The fit of the gland ring to the equipment should be checked to ensure that the gland ring

pilot enters the bore with a reasonable guiding fit for proper seal alignment. It should be

ensured that there is no interference or binding on the studs or bolts or other obstructions.

• It should be ensured that all rotary unit parts of the seal fit over the shaft. ‘V’ ring should be

placed on the shaft individually, and never be installed on the shaft while they are seated in

the seal ring or rotating assembly.


[8-46]

• Both running faces of the seal should be checked to ensure that there are no nicks or

scratches. Imperfections of any kind on either of these faces will cause seal leakage.

Fixing of mechanical seal

• The complete seal assembly drawings and instructions should be carefully studied before

starting installation.

• All burrs and sharp edges should be removed from the shaft or shaft sleeve including sharp

edges on key-ways and threads. Worn shaft or sleeves should be replaced.

• The stuffing’s box bore and stuffing box face should be checked to ensure that they are clean

and free of burrs.

• The shaft or shaft sleeve should be marked with various reference marks required for

installation of seal as per assembly drawings.

• The shaft or sleeve should be oiled lightly prior to seal assembly to allow the seal parts to

move freely over it.

• The rotary units should be installed on the shaft or sleeve in proper sequence.

• The back of the collar should be set at the proper distance from the original reference mark

on the shaft or sleeve. Tighten all set screws firmly and evenly.

• The seal faces should be wiped clean and a thin oil film applied prior to completing the

equipment assembly.

• The gland ring should be inserted with insert over the shaft carefully. Complete the

equipment assembly taking care when compressing the seal into the stuffing box.

• The gland ring and gland ring gasket should be seated to the faces of the stuffing box by

tightening the nuts or bolts evenly and firmly enough to affect a seal at the gland ring gasket.

8.20.5 Rotating equipment (Den & Mixture)

• Maintenance work on any rotating equipment should be started only after obtaining the work permit from the concerned department. Ensure that the equipment is electrically isolated.

• During opening of equipment such as pumps and compressors, it is a good practice to treat

the equipment as if it were under considerable pressure even though all steps have been

taken to relieve the pressure.


[8-47]

• Vehicle entry permit should be obtained from the concerned authority before bringing any crane or

any other equipment for removing the pump.

8.20.6 Inspection of storage tanks

• Inspection of tanks during fabrication shall be carried out as per the requirements of the

applicable codes, specifications, drawings etc. This inspection requires regular checks on

the work at various stages as it progresses. During fabrication, a thorough visual check

should be undertaken and the tank should be checked for foundation pad and slope, slope of

the bottom plates, proper welding sequence and external & internal surfaces etc.

• Roof plates shall be inspected for defects like pin holes, weld cracks, pitting etc., at water

accumulation locations

• Tanks pads shall be visually checked for settlement, sinking, tilting, spalling, cracking and

general deterioration

• Anchor bolts wherever provided shall be checked for tightness, and integrity by hammer

testing.

• All open vents, flame arrestors and breather valves shall be examined to ensure that the wire

mesh and screens are neither torn nor clogged by foreign matter or insects.

• If a tank is insulated, the insulation and weather proof sealing shall be visually inspected for

damage

• Grounding connections shall be visually checked for corrosion at the points where they enter

earth and at the connection to the tank.

• The tanks shall be inspected for any obvious leakage of the product. Valves and fittings shall

be checked for tightness and free operations.

• The tanks shell shall be visually examined for external corrosion, seepage, cracks, bulging

and deviation from the vertical.

8.20.7 Pipes, valves and fittings

• The inspection of piping during fabrication shall be carried our as per the requirement of

applicable codes, specifications, drawings, etc. This inspection requires regular checks on

the work at various stages as it progresses. The inspection shall include Identification and


[8-48]

inspection of material, approval of welding procedures in accordance with code and tender

requirement, carrying out of performance qualification test and hydrostatic testing.

• Visual inspection shall be made to locate leaks. Particular attention should be given to pipe

connections, the packing glands of valves and expansion joints.

• Pipe supports shall be visually inspected for condition of protective coating or fire proofing if any. If fireproofing is found defective, sufficient fireproofing should be removed to determine extent of corrosion.

• If vibrations or swaying is observed, inspection shall be made for cracks in welds,

particularly at points of restraint such as where piping is attached to equipment and in the

vicinity of anchors.

• Line shall be checked for bulging, bowing and sagging in between the supports.

• Conditions of paint and protective coating shall be checked.

• Pipelines shall be inspected for cracks. Particular attention should be given to areas near the

weld joints.

• Externally coverts lined piping shall be visually inspected for cracking and dislodging of

concrete.

• All piping, which cannot be checked on the run, shall be inspected during shutdown. These

are mostly high temperature piping. During shutdown inspection, hammer-testing and

hydrotesting as applicable should be carried out in addition to visual, ultrasonic and

radiographic inspections.

• Pipelines in some of the services like water, phenol and steam are prone to pitting corrosion.

Neither ultrasonic nor radiographic testing will reveal the actual internal condition of the

pipes in such service. In such cases samples shall be cut for thorough internal examination,

at scheduled comprehensive inspections. The samples shall be spilt open in two halves and

internal surfaces inspected for pitting, grooving, etc.

• Piping shall be opened at various locations by removing valves at flanged locations to permit

visual inspection. When erratic corrosion or erosion conditions are noted in areas accessible

for visual examination, radiographic examination or ultrasonic testing shall be performed to

determine thickness.


[8-49]

• The gasket faces of flange joints, which have been opened, shall be inspected visually for

corrosion and for defects such as scratches, cuts and grooving which might cause leakage.

Ring gaskets and joints shall be checked for defects like dents, cuts, pitting and grooving.

• Inspection shall be made for hot spots on internally insulated piping. Any bulging or scaling

shall be noted for further inspection when the equipment is shut down.

8.20.8 Hot Air Generator

At the time of fabrication:

Inspection of new Hot Air Generator at the time of fabrication shall be done as per applicable

codes and statutory requirements and shall include the following:

• Study of the tender document and all the technical specifications.

• Identification and inspection of the materials.

• Approval of the welding procedures.

• Approval of welder’s performance qualification test.

• Check to ensure that the welding is carried out as per approved welding sequence and

procedures with approved electrodes and qualified welders.

• Inspection of the weld joints for proper quality during welding.

• Check for proper insulation over hot metal surfaces.

• Ensure high durability, tensile strength & resistivity to adverse condition.

At the time of operation:

• Hot air lines should be checked for any leakages from flanges, valves and fittings using

foam.

• The hot air generator and the blower should be checked for any abnormal noise and

vibrations.

• Internal inspection of hot air generator and its auxiliary equipment should be done regularly.

• Visual inspection for the external surface of shell column for pitting, corrosion and cracks

shall be done.


[8-50]

• Regular inspection & maintenance of air pollution control equipment like Bag Filter &

Multicyclone Separator attached to hot air generator should be done.

8.20.9 Pressure relieving devices

• All pressure relieving devices shall be bench tested for set pressure, blow down and leakage

as applicable prior to installation.

• The following inspection checks shall be carried out once in every six months for breather

valves on storage tanks - discharge opening should be checked for obstruction, flame arrestor

wherever provided shall be inspected for fouling, bird nests or clogging, element shall be

inspected for mechanical damage, deposits, scaling etc. and cleaned before onset of

monsoon, oil filled type liquid seal valve shall be inspected for oil level, fouling, bird nests,

foreign material etc. and free movement of pallet shall be checked.

• Visual inspection of different parts of safety valve shall be done after dismantling to check

the condition of flanges for pitting, roughening, decrease in width of seating surface etc.

8.21 EMERGENCY MANAGEMENT

8.21.1 Emergency Prevention

• Preparation of a Preventive Maintenance Schedule Programme covering maintenance

schedules for all critical equipments and instruments as per recommendations of the

manufacturers user manuals,

• Establishment of a computerized Failure Modes Effects and Criticality Analysis (FMECA) or

similar procedure to generate data on failures of critical equipments and instruments based

on mode wise failures and their criticality. This requires codification of equipments,

instruments and their modes of failure and their criticality. Consideration may be given to

the use of appropriate software for processing FMECA data for review of the Preventive

Maintenance Schedule and for improvement of the same to ensure critical failures,

• Establishment of a Non Destructive Testing (NDT) system as necessary. This may not be

feasible in-house but there are specialized organizations who undertake the work, and the

same may be used.


[8-51]

• Importantly, it is of great importance to collect and analyze information pertaining to minor

incidents and accidents at the site, as well as for recording near-misses or emergencies that

were averted. This information gives an indication of how likely or unlikely it is for the site

to face actual emergencies and what should be further done to prevent them from occurring.

• Establishment of an ongoing training and evaluation Programme, incorporating the

development of capabilities amongst employees about potential emergencies and ways and

means of identifying and averting the same. Most emergencies do not occur without some

incident or an abnormal situation. So there is always some time of few seconds to few

minutes to arrest an incident of abnormal situation from turning in to an emergency. This is

the role of the shift in-charge who is the incident controller (IC) along with his shift team.

• Material Safety Data Sheets (MSDS) or chemical information sheets (CIS) should be kept

handy.

• Fire and emergency alarms should be provided; alarm recognition training should be given to

every employee.

• Regular mock drills should be conducted on a specific potential disaster scenario as

determined through risk assessment study

• Safe operating procedures including safe emergency and normal shut down procedures and

safe maintenance procedures should be adopted.

• The roles and responsibilities of all responsible for the control of emergency should be

clearly defined.

• List of key personnel and authorities (including police, factory inspector, district magistrate,

state and central level authorities, experts, doctors, village leaders) along with their location

should be kept handy.

• Personal Protective Equipments (PPEs) and safety torches should be made available.

• Liaison with outside agencies, home guards and civic authorities for co-operation in

mitigating the emergency consequences.


[8-52]

8.22 EMERGENCY RESPONSE

8.22.1 Onsite Emergency Response

• Shut down and Isolation: Raising the alarm, followed by immediate safe shut down of the

power supply, and isolation of effected areas.

• Escape, Evacuation and Rescue: Safeguarding human lives at site by commencement of the

Emergency Evacuation and Rescue Plan. Ensuring that all personnel are accounted for and

carrying out a head count of persons evacuated. Notification and commencement of offsite

emergency plan in case offsite impacts are possible.

• Stopping the development of the emergency: Control or response to the emergency

depending upon its nature (fire, toxic release or explosion). Fire can be somewhat better

controlled through fire fighting, while toxic release impacts can be partially controlled

through proper communication with affected population. Impacts of explosions impacts can

not be controlled once they occur, hence efforts will require focusing on provision of relief

or control of secondary impacts (such as property damage or fires) resulting from explosions.

• Treatment of injured: First aid and hospitalization of injured persons.

• Protection of environment and property: During mitigation, efforts should be made to prevent

impacts on environment and property to the extent possible.

• Welfare of the personnel managing the emergency: Changeover, first aid and refreshments

for the persons managing the emergency.

• Informing and collaborating with statutory, mutual aid and other authorities including those

covered in the Local Crisis Group.

• Informing and assisting relatives of the victims.

• Informing the news and electronic media.

• Preserving all evidences and records: This should be done to enable a through investigation

of the true causes of the emergency.

• Investigation and follow up: This requires to be carried out to establish preventive measures

for the future and a review of the DMP & its annexure to fill up the deficiencies in the

emergency planning procedures.


[8-53]

• Ensuring safety of personnel prior to restarting of operations: Efforts require to be made to

ensure that work environment is safe prior to restarting the work.

8.22.2 Off-site Emergency Response Plan

An emergency may affect areas offsite of the works as for example, an explosion can scatter

debris over wide areas and the effects of blast can cover considerable distances, wind can spread

burning brands of gases. In some cases e.g. as the result of an explosion, outside damage will be

immediate and part of the available resources of the emergency services may need to be

deployed in the affected areas. In any case, the possibility of further damage may remain, e.g. as

the result of further explosion or by the effect of wind spreading burning brands of hazardous

material.

It will be necessary to prepare in advance simple charts or tables relating the likely spread of the

vapours cloud taking into account its expected buoyancy, the local topography and all possible

weather conditions during the time of release. It may also be desirable to install instruments

indicating wind speed and direction, which could be done jointly with surrounding industries.

8.22.3 Inspection of firefighting equipment and systems

• The internal and external surfaces of the cylinder body shall be coated with Zinc or lead-tin

alloy

• Material used for the cylinder shell shall be identified to ensure conformity with

manufacturing standard.

• Extinguisher (DCP Vessel) is prone to internal corrosion at the interface between the dry

powder top level and empty space; periodic inspection should therefore be undertaken.

• The shell of the DCP extinguisher shall be visually inspected externally once a month and

internally once every three months to check for any mechanical damage or corrosion.

• A DCP extinguisher body shall be removed from service and destroyed when it is corroded

or damaged to such an extent at repair is required, when the shell threads are damaged, when

it has failed in hydro testing or when the extinguisher has been exposed to high temperatures

due to proximity of fire.


[8-54]

• The internal coating and external painting shall be checked for damage/deterioration once in

three months.

• The safety valve shall be visually inspected for corrosion or damage once every three

months. The safety valve shall be bench tested at rated test pressure once every three years.

• All DCP extinguishers shall be permanently punched at the bottom ring with Manufacturer’s

name, year of manufacture, manufacturer’s Sr. No. and Inspectors stamp.

• Equipment, which will automatically detect heat, flame, smoke, flammable gases, or other

conditions likely to produce fire or explosion and cause automatic actuation of alarm and

protection equipment should be provided.

8.23 DETAILS OF THE SEPARATE ISOLATED STORAGE AREAS FOR TOXIC MATERIALS AND FLAMMABLE CHEMICALS. DETAILS OF FLAME PROOF ELECTRICAL FITTINGS AND OTHER SAFETY MEASURES PROPOSED

• The unit is not using any toxic or flammable material. Only Sulphuric acid is used which

is hazardous material. Unit has provided separate storage area for the same.

• As there is no any use of flammable liquid to be used as a raw material, no flame proof

electrical fittings needed.

• A toxic gas detector will be provided to identify any toxic gas to be released.

• One D.G. set will be provided for alternative power source.

8.24 CHECKLIST IN THE FORM OF DO’S & DON’TS OF PREVENTIVE

MAINTENANCE, STRENGTHENING OF HSE, MFG. UTILITY STAFF FOR

SAFETY RELATED MEASURES.


[8-55]

TABLE 8.8 CHECKLIST OF DO’S & DON’TS

Activity DO’s Don’ts

Mfg. Process

All pump motors are earthen -

Housekeeping of the plant is as per the prescribed norms. Floors, Platforms, staircases and passages are kept free from

any obstruction

- Don’t put any raw material /maintenance part other than its specified place.

All hazardous operations are explained to the workers. They are periodically trained on the hazardous processes. - Don’t use unskilled man power

All the equipments of the plants are periodically tested as per standard and results are documented. All equipments

undergo preventive maintenance schedule.

-

Transportation of raw material Transfer the minimum quantity of material as per requirement.

- Excess quantity should be avoided.

Charging solid material Charging of solid material by closed loop system only - Don’t charge directly.

Stored material Proper labeling shall be done -

Temperature and pressure instrumentation

Calibrated at every six month and maintain records. -

Employee working Monthly health inspection shall be carried out and maintain its records

-


[8-56]

8.25 COMPLIANCE STATUS OF THE EXISTING UNIT WITH RESPECT TO VARIOUS CONDITIONS GIVEN IN NOC (CTE) AND CONSENT OF GPCB.

Compliance report of CTE conditions is attached herewith as per Table 8.9

SR. NO. DESCRIPTION OF CONDITION COMLIANCE

STATUS

CORRECTIVE & PREVENTATIVE ACTION

TAKEN 1.0 Consent Order No. 31288 date of issue : 16/12/2008 Complied valid up to 03/09/2013

2.0 Production Capacity:

Sr. No.

Product Quantity (MT/MONTH)

1. Magnesium Sulphate 600 MT/month 2. Filler 60 MT/month

Complied

----

3.0 CONDITION UNDER WATER ACT 3.1 There shall be no disposal of industrial effluent from the manufacturing

process and other ancillary industrial operations.

3.2 The quantity of sewage effluent from the factory shall not exceed 1000 lit/day.

Complied ----

3.3 TRADE EFFLUENT 3.3.1 Sewage shall be disposed of through septic tank/soak pit system 4.0 CONDITIONS UNDER THE AIR ACT 4.1 There shall be no generation of flue gas emission from the manufacturing

activities and other ancillary industrial operation as you have submitted undertaking dtd. 09/07/2008 for no applicability of Air Act-.

Complied ----


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4.2 There shall be no generation of process emission from the manufacturing activities and other ancillary industrial operation. You have submitted undertaking dtd. 09/07/2008 for no applicability of Air Act.

Complied.

--

4.3 The concentration of the following parameters in the ambient air within the premises of the industry shall not exceed the limits specified hereunder.

Parameter Permissible Limit,g/m3 SPM 200 SOx 80 NOx 80

RSPM 100

Complied.

--

4.4 The industry shall take adequate measures for control of noise levels from its own sources within the premises so as to maintain ambient air quality standards in respect of noise to less than 75dB(a) during day time and 70dB(A) during night time. Daytime is reckoned I between 6a.m. and 10 p.m. and nighttime is reckoned between 10 p.m. and 6 a.m.

Complied --

5.

GENERAL CONDITIONS

5.1 Any change in personnel, equipment or working conditions as mentioned in the consents form/order should immediately be intimated to this Board.

Complied If any change than we will intimate to the board.

5.2 Applicant shall also comply with the general condition given in Annexure-I. Partly Complied. We will try our best to comply it. 6. AUTHORISATION FOR THE MANAGEMENT & HANDLING OF HAZARDOUS WASTES Form-2 [See rule 3 (c) & 5 (5)]

6.1 Number of authorization: 31288, Date of issue : 16/12/2008

Complied


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6.2 M/s. T. J. Agro Fertilizers Pvt. Ltd. is hereby granted and authorization to operate facility for following hazardous wastes on the premises situated S. No. 41, 42, Mahapura, Tal – Savli, Dist – Vadodara.

Sr. No. Waste Quantity Schedule

process No. Facility

1. Process Residue

60 MT/Year

7.2 Collection, storage, transportation, disposal at TSDF

2. Used Oil 150 Lit/Year

5.1 Collection, storage, transportation disposal by selling to registered reprocess.

3. Discarded Container

60000 nos./Year

33.3 Collection, storage, Decontamination

Complied

6.3 The authorization is granted to operate a facility for collection, storage, within the factory premises, transportation and ultimate disposal of Hazardous wastes at nearest authorized TSDF

Complied We will strictly comply all the conditions of H.W. authorization.

6.4 The authorization shall be in force for a period up to 03/09/2013. 6.5 The authorization is subject to the conditions stated below and such other

conditions as may be specified in the rules from time under the Environment (Protection) Act-1986.

6.6 TERMS AND CONDITIONS OF AUTHORIZATION 6.6.1 The applicant shall comply with the provisions of the Environment (Protection)

Act- 1986 and the rules made there under. Complied

--

6.6.2 The authorization shall be produced for inspection at the request of and officer authorized by the Gujarat Pollution Control Board.

Complied

--


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8.26 DETAILS OF FATAL/NON-FATAL ACCIDENTS OCCURRED IN PAST IN THE EXISTING UNIT:

As per the records there is no fatal / non- fatal accidents reported since starting of the unit.

8.27 RECORDS OF ANY LEGAL BREACH OF ENVIRONMENTAL LAWS

Also there is no any legal breach of environmental laws in form of show cause, closure etc reported.


CHAPTER 9 ALTERNATIVES (TECHNOLOGY & SITE)

[9-1]

p

9.1 ALTERNATIVES:

During the scoping period, no necessity for the alternative analysis of the technology was observed as the technology/process mentioned for manufacturing of the proposed product are best suitable.

Moreover the unit is already running production of the existing product has enough space for expansion so the proposed site is best suitable for the manufacturing of the proposed product.


CHAPTER 10 ENVIRONMENTAL COST BENEFIT

[10-1]

10.1 ENVIRONMENTAL COST BENEFIT

During the study period it was revealed that the environmental cost benefit can’t be recommended at the scoping stage.


CHAPTER 11 SUMMARY & CONCLUSION

[11-1]

11.1 INTRODUCTION & PROJECT JUSTIFICATION

T. J. Agro Fertilizers Pvt. Ltd. is a private limited company formed in 1986. The promoters are

highly qualified and have global experience. T. J. Agro Fertilizers Pvt. Ltd. is one of the

renowned fertilizers trading and manufacturing organizations.

Proposed plant is located at Village-Mahapura, Taluka-Savli, Dist. Baroda (Gujarat). Unit is

producing Magnesium Sulphate (MgSO4) & Filler (by product) at above location from 2008.

To expand their business strength in middle of Gujarat, they intend to produce new products

namely NPK Granulated Mixed Fertilizers, Single Super Phosphate Powder, Single Super

Phosphate Granulated & Fluorosilisilic Acid (by product) in addition of old products.

For the manufacturing of the new products the company has applied for the Environmental

Clearance of the project under the latest Notification for EC. Form 1 was submitted to the Sate

Level Expert Appraisal Committee on dated 03.06.2010.

First Presentation for the Terms of Reference was conducted on the 28.09.2010 following

which the terms of reference were issued to us.

This report has been prepared based on the Terms of Reference vide the letter Project No. EIA-

10-2010-700-E, 63217 Dated 16.11.2010 issued to us by the SEAC committee.

The Total Investment for the proposed project will be 1.225 Crores.

Total area of the site is 30,831 m2

11.2 PURPOSE OF STUDY

Environmental Impact Assessment Report & Environmental Management Plan have been

Prepared for obtaining Environmental Clearance for T. J. Agro Fertilizers Pvt. Ltd. for the

proposed project for Manufacturing of Products- NPK Granulated Mixed Fertilizers, Single

Super Phosphate Powder, Single Super Phosphate Granulated & Fluorosilisilic Acid (by

product) in addition of old products.

M/s. T. J. Agro Fertilizers Pvt. Ltd. Envirocare Engineers & Consultant, Surat February-2011 CHAPTER 11 SUMMARY & CONCLUSION

[11-2]

11.3 EXTENT OF STUDY AND AREA COVERED

The baseline status of environmental quality in the vicinity of project site serves as the basis

for identification, prediction and evaluation of impacts. The baseline environmental quality is

assessed through field studies within the impact zone for various components of the

environment, viz. air, noise, water, land and socio-economic. The baseline environmental

quality has been assessed in the winter season (December 2010 – February 2011) in a study

area of 10 km radial distance from the project site.

11.4 METHOD OF STUDY

The study is based on guidelines of MoEF and identifies the nature of activities involved and

their impacts caused on various environmental parameters. It subsequently suggests mitigation

measures to be executed for safeguarding against any environmental degradation. Finally, it

suggests methods of implementing the environmental management plan.

11.5 PROJECT DETAILS

The product proposed to be manufactured along with their capacities is shown in following

Table 11.1.


[11-3]

TABLE 11.1 PROPOSED PRODUCT LIST:

The Raw material proposed to be used along with their consumptions is shown in following

Table 11.2.

Sr. No. Name of Products

Existing Quantity

(MT/Month)

Proposed Quantity

(MT/Month)

Total Quantity

(MT/Month)

1. NPK Granulated Mixed Fertilizers Nil 6,000 6,000

2. Single Super Phosphate Powder Nil 10,000 10,000

3. Single Super Phosphate Granulated Nil 6,000 6,000

4. Fluoro Silisilic Acid (by product) Nil

Total : 340 120 Reuse : 220

Sale : 120

5. Magnesium Sulphate (MgSO4) 600 Nil 600

6. Filler (by product) 60 Nil 60


[11-4]

TABLE 11.2 PROPOSED RAW MATERIAL LIST

11.6 ENVIRONMENTAL SETTING

11.6.1 Landuse of the study area:

Landuse within 10 km radius of the study area is determined with the help of satellite image.

Landuse of study area can broadly be classified in to categories such as habitation, habitation

with dense vegetation, water body, vegetation, land with shrub, land without shrub, industrial

area, sandy area and agricultural land etc.

Sr. No. Name of Raw Material

Existing Quantity

(MT/Month)

Proposed Quantity

(MT/Month)

Total Quantity

(MT/Month) (A) NPK Granulated Mixed Fertilizers

1. Urea Nil 2760 2760 2. DAP Nil 360 360 3. SSP (Single Super Phosphate) Nil 480 480 4. MOP (Potash) Nil 1626 1626 5. Filler Nil 1800 1800

(B) Single Super Phosphate Powder 6. Fluorosilisilic Acid Nil 220 220 7. Rock phosphate Nil 6000 6000 8. Diluted sulphuric acid (70%) Nil 3000 3000 9. Concentrated sulphuric acid (98%) Nil 1562.5 1562.5

(C) Single Super Phosphate Granulated 10. Single Super Phosphate Powder Nil 6000 6000

(D) Magnesium Sulphate (MgSO4)

11. Diluted Sulphuric acid (70%) 375 Nil 375

12. Light Calcined Magnasite 150 Nil 150


[11-5]

11.6.2 Climate of the Study Area:

The general agro-climatic zone of the study area is Semi- arid.

11.6.3 Wind:

The predominant wind direction during the study period is observed to be from NE direction.

11.6.4 Rainfall:

The total rainfall in year is observed to be 922.7 mm. Distribution of rainfall by season is 7.5

mm in winter (December, January, February), 7.5 mm in summer (March, April, May), 870.8

mm in monsoon (June, July, August, September) and 38.2 mm in post monsoon (October,

November).

11.6.5 Cloud Cover:

The area remains cloudy between June-September, which is the active period of the monsoon

season. Generally cloud cover ranges from 4 to 7 Oktas during this monsoon season.

11.6.6 Humidity:

Most humid conditions are found in the monsoon, followed by post monsoon, winter and

summer in the order. Mornings are more humid than evenings and humidity ranges from a high

of 76-90% in monsoon mornings to a low of 20-27% in summer evenings. During post

monsoon season, in morning humidity remains between 64-72 % and in the evening it remains

between 41-44 %.

11.7 FUEL/ENERGY REQUIREMENTS

• The main sources of power of M/s. T. J. Agro Fertilizers Pvt. Ltd. will be utilized energy from existing provider M/s. Madhya Gujarat Vij Company Limited. The total existing connected load of the energy is about 80 HP.

• Additional 600 HP will require for expansion project which would be applied to MGVCL as & when required.

• Fuel for Hot air Generator 1& 2 : Bio Coal @ 16 MT/ day.

• Fuel For Proposed DG Set 125 KVA : HSD – 15 Liters/hr


[11-6]

11.8 WATER REQUIREMENT

• Total Water Requirement: 32.5 KL/day

• Source: Borewell

• Wastewater Generation: Domestic: 2.5 KL/day

Industrial: Nil

TABLE 11.3 (A) TOTAL WATER REQUIREMENTS FOR THE PROJECT:

Categories Existing (KL/day)

Proposed (KL/day)

Total (KL/day)

(A) Domestic 1.0 3.0 4.0

(B) Industrial

(i) Process 7.0 16 23

(ii) Utility (For scrubber )

-- 05 05

(iii) Washing 0.5 -- 0.5

Total (B) 7.5 21 28.5

Total (A+B)

8.5 24 32.5

TABLE 11.3 (B) TOTAL WASTEWATER GENERATIONS FOR THE PROJECT:

Categories Existing (KL/day)

Proposed (KL/day)

Total (KL/day)

(A) Domestic 1.0 1.5 2.5

(B) Industrial

(i) Process Nil Nil Nil

(ii) Utility -- -- --

(iii) Washing -- -- --

Total (B) Nil Nil Nil

Total (A+B) 1.0 1.5 2.5


[11-7]

11.9 BASELINE ENVIRONMENT

Has been displayed in Chapter No. 3 of the EIA Report

11.10 ENVIRONMENT IMPACTS & MITIGATION MEASURES

Has been displayed in Chapter No. 4 of the EIA Report

11.11 ENVIRONMENTAL MONITORING PROGRAMME

TABLE 11.4 ENVIRONMENTAL MONITORING PROGRAMS

Sr. No.

Activity Schedule

Water Pollution Monitoring 1. Ground water quality of borewell within premises Once in six month

Air Pollution Monitoring 2. Ambient air monitoring of parameters specified by GPCB

in their air consents from time to time within the T.J Agro Fertilizers Pvt. Ltd. premises

Once every Quarter

3. Ambient air monitoring of parameters specified by GPCB in their air consents from time to time at four stations outside T.J Agro Fertilizers Pvt. Ltd. premises .

Once every season at each station

4. Stack monitoring of process as given in air consent from time to time

Once every month

Solid Waste Generation Monitoring / Record Keeping 5. Records of generation of used drums, bags and records of

their dispatch to suppliers for refilling Daily

6. Records of generation of waste oils and their treatment Daily 7. Records of generation, handling, storage, transportation

and disposal of other solid, aqueous and organic hazardous wastes as required by hazardous waste authorization

To be updated daily

Environmental Audit & Annual Return 8. Environmental statement under the EP (Act) 1986 and

annual return of hazardous waste generation, handling & disposal.

Once in a year


[11-8]

11.12 AMBIENT AIR

The source of Flue gas Emission from the proposed production activity is from Hot air

Generator. For Hot air Generator Bio Coal will be used as fuel.

Flue gas will be released through stacks of 11 m height. The Hot air Generator will be

provided with Multi Cyclone Separator & Bag Filter.

Another Source is Den & Mixer exhaust gas which will be provided with Ventury Water

Scrubber followed by rock phosphate absorption tank to scrub H2SiF6

Stack Attached To

gas. Hence, it can be

concluded that the production activities will not adversely impact the ambient air quality.

TABLE 11.5 (A) PROPOSED DETAILS OF STACK, APCS & ITS EMISSION

ESTIMATE


Type of Fuel & Qty. Proposed Air Pollution

Control System

Final Concentration

Existing

Proposed

Hot Air Generator

1 & 2

11 Meter &

500 mm

Nil Bio Coal

16 MT/Day Multi Cyclone

Seperator & Bag Filter

in series

SPM < 150 mg/NM3


D. G. Set (Stand By)

(Capacity: 125 KVA)

8 Meter Nil HSD 15 Lit/hr

Not Applicable

SPM < 150 mg/NM3


TABLE 11.5 (B) PROPOSED EMISSION RATE


Emission Estimate in Kg/hr Existing Proposed Total

1. Hot Air Generator 1&2

(Flow: 3000 M3

PM

/Hr.)

Nil 0.225 0.225

SOx Nil 0.15 0.15

NOx Nil 0.075 0.075


[11-9]

TABLE 11.5 (C) PROPOSED DETAILS OF PROCESS VENT, APCS & ITS EMISSION

ESTIMATE

Process Vent Attached To


Air Pollution Control System Final Concentration

Den & Mixture 35 Meter &

600 mm

Ventury Water Scrubber

SPM < 150 mg/NM3

SO2 < 40 mg/NM3 NOx < 25 mg/NM3

Fluorine < 0.5 mg/NM3

TABLE 11.5 (D ) PROPOSED EMISSION RATE


Emission Estimate in Kg/hr Existing Proposed Total

1. Den & Mixture (Process Vent)

(Flow: 7500 M3

PM

/Hr.)

Nil 0.40 0.40

SOx Nil Nil Nil

NOx Nil 0.05 0.05

HF Nil 0.01 0.01

Fluorine Gas Nil 0.001 0.001

The ambient air quality monitoring was carried out in accordance with guidelines of Central

Pollution Control Board (CPCB) of June 1998 and National Ambient Air Quality Standards

(NAAQS) of CPCB of November 2009. Ambient Air Quality Monitoring (AAQM) was carried

out at five locations during winter season. The maximum numbers of sampling locations were

selected close to the project site and in the study area of 10 km radial distance around the plant

site. The monitoring was carried out 24 hours a day twice a week per location in the study area

except the project site, where continuous monitoring was carried out. Twelve numbers of

observations were taken at each monitoring location except the project site.

The conventional and project specific parameters such as PM10, PM2.5, SO2, NOx & HF were

monitored at site.

The values for mentioned concentrations of various pollutants at all the monitoring locations

were processed for different statistical parameters like arithmetic mean, minimum

concentration, and maximum concentration and percentile values.


[11-10]

11.13 WATER RESOURCES

Water will be used from Existing Bore wells in the premises. No new bore wells are to be dug.

Rain water recharging scheme will be incorporated hence the impact on ground water will be

minimized.

11.13.1 Ground Water Quality

• The unit is a Zero Discharge Unit. Sewage will be allowed in Septic Tank.

• M/s. T.J.Agro Fertilizers Pvt. Ltd. will take all precautions to make its solid waste areas impervious to water and leachate migration.

Hence it follows that ground water quality is not adversely impacted by M/s. T. J. Agro

Fertilizers Pvt. Ltd. activities.

11.14 NOISE LEVELS

Noise levels envisaged shall be within prescribed limits of GPCB at plant boundary, after

implementation of the mitigation measures. DG Sets will be Acoustically Enclosed type. Green

belt development will be made. Hence there will be no adverse impacts on existing noise levels

due to the proposed production activities.

11.15 SOIL / LAND QUALITY

M/s. T. J. Agro Fertilizers Pvt. Ltd. will take all precautions to make its Raw Material Storage,

Product Storage, hazardous waste and effluent storage / treatment areas impervious to water

and leachate migration. This will prevent soil contamination.

It follows that soil quality will not be adversely impacted by proposed production activity.

11.16 ENVIRONMENTAL MANAGEMENT PLAN

An environment management plan has been proposed in this report to implement the mitigation

measures. The plan will ensure that the adverse environmental impacts are minimized and the

beneficial impacts are maximized. Detailed plan is discussed in Chapter No-8 of EIA report.


CHAPTER 11 SUMMARY & CONCLUSION

[11-11]

11.17 SOLID & HAZARDOUS WASTE MANAGEMENT

The details of the solid and hazardous waste management is as given in the Table 11.6

TABLE 11.6 SOLID AND HAZARDOUS WASTE MANAGEMENT REQUIREMENT:

Sr. No. Waste Stream

Waste Cat. No.

As per- 2008

Existing Qty.

Proposed Qty.

Total Qty. Source Method of

Packing Disposal Method

1. Used oil

5.1 150 Lit/year

50 Lit/year

200 Lit/year

Air Compressor

PP Carba / Drum

Collection, Storage, Transportation and disposal by selling to registred refiners enlisted by GPCB / MoEF.

Qty. to be Reused

100 Lit/year Qty. to be Disposed

100 Lit/year 2. Discarded

containers / barrels / Liner

33.3 60 Kg/month

240 Kg/month

300 Kg/month

Raw material & Finished

product packing material

PP Bag Collection, Storage, Transportation and disposal by selling to registred refiners enlisted by GPCB / MoEF.

Qty. to be Reused

150 Kg/month Qty. to be Disposed

150 Kg/month 3. Silica / Sand -- Nil 10

Kg/month 10

Kg/month Process PP Bag Collection, Storage &

Reuse as Filler in product


[11-12]

11.18 GREEN BELT DEVELOPMENT

Total plot area of the project is 30,831 m2. Greenbelt & Plantation is proposed in approximately

12% of the plot area. Hence the total Proposed Green Belt will be 3719 m2

• Due to the plant operation no adverse impacts envisaged on Ambient Air, Noise, Ground

water, Land & Soil.

. This development

has been already started. This will attune noise levels and dust levels by acting as a barrier

between the outside environment and the inside environment of the premises.

11.19 MONITORING SCHEDULE

A monitoring schedule has been prepared to ensure effectiveness of the environmental

management plan.

11.20 EXPENDITURE FOR ENVIRONMENTAL ACTIVITIES

M/s. T. J. Agro Fertilizers Pvt. Ltd. will spend Approximately Rs. 23.0 Lacs as capital expenditure on environmental management. The recurring cost is Approximately Rs. 4.75 lacs per annum.

11.21 CONCLUSION

The following can be concluded based on the study:

• Risk to soil is negligible due to effective management and handling of hazardous wastes

and wastewater.

• Socio-economic benefits due to generation of direct / indirect employment.

Thus, it can be concluded on a positive note that after the implementation of the mitigation

measures and Environmental Management Plan the activities of M/s. T. J. Agro Fertilizers Pvt.

Ltd. will have negligible impact on environment and will beneficial to the nearby residents.


CHAPTER 12 DISCLOSURE OF CONSULTANTS ENGAGED

[12-1]

12.1 CONSULTANT ENGAGED

M/s. T. J. Agro Fertilizers Pvt. Ltd. has engaged M/s Envirocare Engineers & Consultant as an

EIA consultant.

12.2 BRIEF PROFILE OF CONSULTANT

M/s. Envirocare Engineers & Consultant (EEC) is one of the leading firms in the field of

environment since last 13 years. EEC is enlisted with Gujarat Pollution Control Board (GPCB)

as well as with Rajasthan Pollution Control Board as Consultant and schedule II auditors.

Acquainted with well experienced and knowledgeable staff EEC accomplished various turnkey

projects, Environmental Monitoring projects as well various EIA Projects of various well

renowned companies as well as various small scale industries. Moreover EEC is engaged with

various consultancy works as well as audit works.

12.3 SCOPE OF WORK

M/s. T. J. Agro Fertilizers Pvt. Ltd. has engaged EEC for studying the Environmental Impact

Assessment of its proposed project at R.S. NO: 41/42, P.O. Mahapura, Tundav Rania Road,

Taluka Savli, District Vadodara of Gujarat State. The scope of work includes study of current

environment status with environmental monitoring, assessing the impact of project on

environment and preparation of EIA report along with technical assistance work consideration

for the approval of the project from the state Level Expert Appraisal Committee.

Compliance of the CREP Guidelines SR. NO. CREP GUIDELINES OUR COMPLIANCE

Wastewater Management 1 Efforts will be made for conservation of water, particularly

with a target to have consumption less than 8.12 and 15 m3 /tone of urea produced for plant based on gas, naphtha and fuel oil, respectively. In case of plants using Naptha and Gas both as feed stocks, water consumption target of less than 10m3

Not Applicable

/ tone will be achieved. An action plan for this will be submitted by June 2003 and targets be achieved by March 2004.

2 Use of arsenic for CO2 Not Applicable absorption in ammonia plants and chromate based chemicals for cooling system, which is still continuing in some industries, will be phased out and replaced with non- arsenic and non- chromate systems by December 2003. In this regard, action plan will be submitted by June 2003.

3 Adequate treatment for removal of oil, chromium (till non- chromate based cooling system is in place) and fluoride will be provided to meet the prescribed standards at the source (end respective process unit) itself. Action plan will be firmed up by June 2003 for compliance by March 2004.

Not Applicable

4 Proper and complete nitrification and de-nitrification will be ensured wherever such process used for effluent treatment, by September 2003.

Not Applicable

5 Ground water monitoring around the storage facilities and beyond the factory premises will be carried out at regular intervals particularly for pH. Fluoride CPCB will finalize the guidelines for groundwater monitoring by December 2003.

Pucca RCC flooring is provided to prevent any percolation of any hazardous contamination. Ground Water Monitoring will be done as per Scheduled of Monitoring Proposed in EIA report Chapter No: 5 Page No.5-6.

Compliance of the CREP Guidelines

6 No effluent arising from process plants and associated facilities will be discharged to the storm water drain. The quality of storm water will be regularly monitored by all the industries.

Strictly Complied Storm water monitoring will be carried out. Unit does not generate any trade effluent.

7 The industries, where waste water/ effluent flows through the storm water drains even during the dry season will install continuous systems for monitoring the storm water quality for pH, ammonia and fluoride. If required, storm water will be routed through effluent treatment plant before discharging. An action plan will be submitted by June 2003 and necessary action will be taken by June 2004.

Not Applicable Unit does not generate any trade effluent

Air Pollution Management 1 All the upcoming urea plants will have urea prilling towers

based on natural draft so at to minimize urea dust emissions.

Not Applicable

2 The existing urea plants particularly, the plants having forced draft prilling towers will install appropriate systems (e.g. scrubber. etc.) for achieving existing norms of urea dust missions. In this regard, industries will submit action plan by June 2003 and completion of necessary actions by June 2004.

Not Applicable

3 The sulphuric acid plants having SCSA system will switch over to DCDA system by March 2004 to meet the emission standard for SO2 as 2 Kg/tone of H2SO4

Not Applicable

produced. An action plan for this will be submitted by June 2003.

4 Sulphuric acid plants having DCDA system will improve the conversion and absorption efficiencies of the system as well as scrubbers to achieve SO2 emission of 2 Kg/ tone of acid produced in case of plants having capacity above 300 TPD and 2.5 Kg/ tone in case of plants having capacity up to 300TPD. An action plan will be submitted by June 2003 and emission

Not Applicable

Compliance of the CREP Guidelines levels will be complied with by September 2004.

5 Stack height for sulphuric acid plants will be provided as per the guidelines and on the basis of normal plant operations (and not when the scrubbers are in use) by June 2003. The scrubbed gases are to be let out at the same height of the stack.

Not Applicable

6 An action plan for providing proper dust control systems rock phosphate grinding unit in phosphoric acid plants/ single super phosphate plants, so as to achieve particulate emission of 150 mg/Nm3

• A Dry dust Type Bag Filter will be installed to recover Phosphate dust & reuse it again in Process. Ventury water scrubber followed by Dry Rock Phosphate bed will be installed to minimize the concentration of H

will be submitted by September 2003 and complied with by March 2004.

2SiF6.

7 Particulate as well as gaseous fluoride will be monitored and adequate control systems will be installed by June 2004 to achieve the norms on total fluoride emissions (25 mg/Nm3

• Particulate & Gaseous fluoride monitoring will be done as per Scheduled of Monitoring Proposed in EIA report Chapter No: 5 Page No.5-6. ).

8 Continuous SO2 Not Applicable emission monitoring systems will be installed in sulphuric acid plants (having capacity 200 TPD and above) by March 2004. Action plan for this will be submitted by June 2003.

9 Regular monitoring of ambient air quality with regard to SO2 NOx, PM, SO3

Regularly Ambient Air Monitoring will be will be done as per Scheduled of Monitoring Proposed in EIA report Chapter No: 5 Page No.5-6.

, fluoride and acid mist will be carried out.

Solid Waste Management 1 Gypsum will be effectively managed by providing proper

lining, dykes with approach roads and monitoring of groundwater quality around storage facilities. Accumulated gypsum will be properly capped. In this regard, action plan will be submitted by June 2003 and for compliance by December 2003.

Not Applicable

Compliance of the CREP Guidelines

2 An action plan for proper handling, storage and disposal of spent catalyst having toxic metals will be submitted by June 2003 and implemented by September 2003. The industry will also explore recovery/buy-back of spent catalyst by September 2003.

Not Applicable

3 Carbon slurry, sulphurmuck and chalk will be properly managed and disposed of in properly designed landfill either within premises or in common facility. Action plan on this will be submitted by June 2003 and implemented by March 2004.

Not Applicable

4 Existing stock of chromium and arsenic bearing sludge will be properly disposed by December 2003. Industries will also explore recovery of chromium from the sludge. CPCB will provide guidelines for proper disposal of the sludge.

Not Applicable

Minutes of the Public Hearing

SR.

NO.

Name & Address ISSUE RAISED DURING PUBLIC

HEARING OUR REPLY /COMMITMENT

1 Shri Vitthalbhai

Dahyabhai Patel,

Vill : Mahapura,

Ta: Savli,

Dist: Vadodara.

He started by saying that although he had

his fields in Mahapura village, he lived in

Chhani and was well aware of the

pollution caused by fertilizer plants since

GSFC caused a lot of pollution near

Chhani area.

Noted

He requested the Company to give

commitment to the farmers that pollution

will not be caused and no damage will be

caused to the fields and crops.

The representative of the Project Proponent welcomed the

suggestion given and gave his commitment that whenever any

farmer had a problem with the unit, they could contact the unit

directly and immediate measures would be taken to resolve the

problem.

He further added that the Company should

be ready to compensate the farmer in case

his land or crops were damaged due to the

air pollution from the unit.

Noted

On hearing this, he asked the Company to

extend the benefit to the smallest farmer

also who may require probably only one

bag of fertilizer for his entire land.

He said that NPK fertilizers would be sold at Rs.40 less than the

market cost to the farmers in the area, as per their requirement.

2 Shri Rajeshbhai

Ambabhai Patel,

Vill : Anjesar,

Ta: Savli,

Dist: Vadodara

He asked where the hazardous waste was

going to be disposed.

He then queried what would happen if it

was not used? Would it be disposed on

some land like other Companies do?

The representative of the Project Proponent replied that the

hazardous waste generated was used as filler for Magnesium

Sulphate Production.

The representative of the Project Proponent replied that their

hazardous waste was actually their raw material and so, there was

no question of disposing it off somewhere else. They further gave


their commitment for the same.

3 Shri Jagdishbhai

Punjabhai Patel,

Vill : Anjesar,

Ta: Savli,

Dist: Vadodara

He asked the Company to put up the plant

such that there was no damage to their

fields.

---

4 Shri Gaurav Patel,

Vill : Anjesar, Ta :

Savli, Dist :

Vadodara.

He stated that The Company has said that

Green Belt will be provided.

He asked the Company to give a

commitment to plant 500-1000 trees for

green belt, which may curb the air & noise

pollution.

The representative of the Project Proponent replied that they

welcomed his suggestion and would certainly involve his inputs

while planning the Green Belt.

5 Shri Ashwinbhai

Kalidabhai Patel,

Deputy Sarpanch,

Vill : Mahapura,

Ta: Savli,

Dist: Vadodara

He said that he had heard everybody raise

their objections and give their suggestions

and had only one thing to say that the

Company should give in writing that they

would take suitable steps to compensate

the damage, if any to the environment due

to their industry in an area of 10Kms

radius.

----

6 Shri Vitthalbhai

Dahyabhai Patel,

Vill : Mahapura,

Ta: Savli,

Dist: Vadodara.

He asked to carry out videography of the

surrounding area and fields for

documentation so that in the years to

come, if the environment would be

degraded in any way by the industry, they

could be held responsible.

The representative of the Project Proponent replied that since

theirs was a fertilizer manufacturing unit, high profile people were

not required and hence they would give first preference to the

local people only.

He added that those interested could leave their names and


He further added that the Company should

give preference to the local people for

employment and not take high profile

people from other parts of the country.

addresses with the management.

He further added that even women were going to be considered

for employment and hence any woman who was needy or wanted

to augment the household earnings could apply.

7 Shri Rajeshbhai

Ambabhai Patel,

Vill : Anjesar,

Ta: Savli,

Dist: Vadodara

He asked how many workers were going

to be employed by the Company.

He told the Company that they only

promise, but seldom take local people.

And added that even if locals were taken,

they had to work too hard, so they had to

leave.

The representative of the Project Proponent replied that 38

personnel were going to be taken.

The representative of the Project Proponent reiterated that they

would be giving preference to locals.

Suggestion/Comment/Recommendation from PARYAVARAN MITRA

8 The project should not be considered as expansion project

because new products with much higher quantity are

proposed to produce. So new consent and Clearance should

be applied.

We have applied for EC.

NOC will be applied in future.

9 What was original mode of land acquisition on such a large

scale?

We have purchased land from liquidator of Hon’ble Gujarat High

court.

10 Why it took one year from approval of TOR to preparation

of EIA report?

Due to our late submission of required data, preparation of EIA is

delayed.

11 Whether Company has valid consolidated Consent and

Authorization of GPCB under various Acts for its existing

unit? Please give copy of it and copy of compliance report

of Consent and Authorization.

Company has valid CC&A for existing unit. Copy of CC&A & its

compliance report were attached in reply.


12 What is the status of NOC application to GPCB? NOC will be applied in future

13 Whether Company has Environmental Clearance for its

existing plant? If yes please give copy of it along with

compliance report.

Company does not have Environmental Clearance for its existing

plant as the existing product does not require environment

clearance.

14 Please give copy of GPCB visit report and air/water/solid

waste sample analysis report for existing unit in last two

years.

Copy of all GPCB visit report during last two year were attached

in reply

As there is not effluent & Air emission source, No sample was

collected by GPCB.

15 Whether company had been issued show cause notice /

closure order / notice under water Act 1974 or Air Act 1981

or Environment protection Act 1986 since starting of

existing unit? If yes give copy of it. Also what remedies had

been taken for restarting operation?

No such notice or order under relevant act is not received yet.

16 Whether unit has submitted Environmental Audit Reports

regularly to GPCB for existing plant? What were

suggestions of Auditor in last two years report?

Our existing product does not fall any Env. Audit scheme as per

guidelines.

17 Whether alternative has been thought of ground water

extraction at time of planning of expansion?

Our total water consumption after expansion will be 32.5 KL/Day

for which we will adopt rain water recharging system to balance

it.

As such no alternative for water supply available in this area.


18 Please justify domestic water use of 4000 L per day. After expansion, there will be total 38 workers will be working

for which they need approx. 2850 lit/day domestic water looking

to our activity. Also same transporters will also use approx. 1150

lit/day water for their requirements. Therefore, we have calculate

4000 lit/day domestic water consumption

19 Why there is no greenbelt in existing factory premises?

There is approx. 750 m2 existing greenbelt.

We will further develop 2969 m2 greenbelt totaling 3719 m

2

20 Why there is no proposal for greenbelt development in

proposed expansion?

We have already proposed 2969 m2

greenbelt in addition of

existing 750 m2 areas.

21 What is the exact source of sulphuric acid from

surrounding industries?

We have two exact source for supply of H2 SO4 acid…

M/s. GNFC Ltd. Bharuch (2) M/s. Indu. Solvent & chemicals Ltd.

Ankleshwar.

22 Why only 5 locations for ambient air monitoring within 5

km radius of factory had been selected?

Looking towards Proposed activity like grinding & curing, the

main Source of Air emission for this type of unit is dust Pollution,

which can be self settled down immediately with wind within 01

to 03 km radius.

Thus, to identify exact impact of dust concentration & its

mitigation measures, only 05 Amb. Air Station was selected

within 06 km radius to comply condition no.: 12 of TOR.

23 Please give name of CPCB authorized recycler / trader to

whom waste oil and other hazardous waste is given for

existing unit.

At present whatever used oil generated is totally reuse for

lubrication purpose within premises.

Whatever plastic bag container generated is totally reuse for

packing of filler (by product).


24 Please give exact date of monitoring for each sample of

ambient air, water, noise and soil sampling.

Annexure for Dates were attached in the reply

25 How many skilled and unskilled people from

surrounding area will get employment in proposed

expansion project?

Following man power expected to be working …..

Status Total workers in all shifts

Male Female Total

(a) Existing 06 - 06

(b)

Expansion

Direct Job 12 8 32

Contracted

job

12

Total 30 8 38

Suggestion/Comment/Recommendation from PRAVIN SHETH

SENIOR CITIZEN, TECHNOCRATE AND ENVIRONMENTALIST,ANKLESHVAR

26 Please encourage timber free construction Noted. Will be implemented as much as possible.

27 Please use solar system for garden lanterns, pumping water to

overhead tanks.

Noted. Will be implemented as much as possible.

28 Please celebrate world environment day each year to create

awareness on environment protection


29 Please try to offer your products (fertilizers) at subsidized rates

as a part of CSR activity to needy farmers residing in study area

so that farmers can be encouraged to carry out farming in

economical way.



Suggestion/Comment/Recommendation from BIRD VIEW OF INDUSTRIES

30 In plant, how many employees will be local to get employment

for existing as well as after expansion?

Thirty two (32) persons will get employment due to the expansion

of our project; six local workers are already working. Due to

expansion, more than 80% local people will get employment.

31 It is surprise that in your unit there shall be no any kind of

effluent or solid waste generation including cleaning activity.

Please specify whether any management proposed for cleaning

effluent.

There shall be no cleaning process included during manufacturing

activity.

32 Please give us copy of any showcause notice issue by GPCB in

the past.

We haven’t received any notice from GPCB.

33 What will be the company’s policy to give more than 80% local

employment?

Unit will provide training to the local people.

34 Please provide us the copy of the company’s commitment and

its compliances submitted during past public hearing for

existing plant?

No public hearing has been carried out before this.

Suggestion/Comment/Recommendation from SARPANCH OF RANIA GRAM PANCHAYAT

35 Employment will be generated Noted Around 32 more employment placement will be generated.

36 Farmers will get cheaper fertilizer compare to costly fertilizer

available in the market which will be beneficial to farmers

Noted NPK fertilizers would be sold at Rs.40 less than the market

cost to the farmers in the area, as per their requirement.

Suggestion/Comment/Recommendation from SARPANCH OF NATVARNAGAR GRAM PANCHAYAT






Suggestion/Comment/Recommendation from SARPANCH OF MOKSHI GRAM PANCHAYAT







Suggestion/Comment/Recommendation from SARPANCH OF BHADARVA GRAM PANCHAYAT






Suggestion/Comment/Recommendation from SARPANCH OF MAHAPURA GRAM PANCHAYAT




