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Environmental Impact assessment of proposed expansion project of technical grade pesticides at Behror, Distt Alwar, Rajasthan

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EIA/EMP & RA/DMP Report of Proposed Expansion Project of Technical Grade Pesticides at Behror, Distt Alwar,

Rajasthan

Project Proponent

M/S AMBEY LABORATORIES PVT LTD

September 2015

Environmental Consultant

EQMS India Pvt. Ltd.

304-305, Rishabh Corporate Tower

Community Centre, Karkardooma

Delhi - 110092

Email: [email protected]

Phone: +91 11 3000 3200

Fax: +91 11 2237 4775

mailto:[email protected]


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Table of Contents

Chapter 1. Introduction ............................................................................................... 7 1.1. Project Proponent – M/S Ambey Laboratories Pvt. Ltd (Ambey) ....................... 7 1.2. Proposed Project .............................................................................................. 7 1.3. Need of the Proposed Project ........................................................................... 7 1.4. Purpose of the Study ........................................................................................ 8 1.5. Project Location ................................................................................................ 8 1.6. Regulatory Norms ........................................................................................... 10 1.7. Scope and Methodology of the Study ............................................................. 11 1.8. Approved ToR for EIA Study by EAC .............................................................. 13 1.9. Structure of the Report .................................................................................... 22 1.10. List of major industries within 10km radius ...................................................... 24 Chapter 2. Project Description .................................................................................. 25 2.1. The Site .......................................................................................................... 25 2.2. Manufacturing Activity [Existing Products] ....................................................... 28 2.3. Manufacturing Process in Brief [New Products] .............................................. 33 2.4. Major equipment and machinery required: ...................................................... 63 2.5. Basic Requirements of the Project .................................................................. 65

2.5.1. Land ............................................................................................................ 65 2.5.2. Raw Material Requirement .......................................................................... 65 2.5.3. Water Requirement ..................................................................................... 68 2.5.4. Fuel ............................................................................................................. 69 2.5.5. Steam Generation ....................................................................................... 69 2.5.6. Power Requirement .................................................................................... 70 2.5.7. Man Power .................................................................................................. 70

2.6. Generation of Pollutants ................................................................................. 70 2.6.1. Liquid Effluent ............................................................................................. 70 2.6.2. Solid Hazardous Wastes ............................................................................. 72 2.6.3. Air Emissions .............................................................................................. 73 2.6.4. Noise Pollution ............................................................................................ 75

2.7. Management of Fly Ash .................................................................................. 75 2.8. OHS System and Safety Measures ................................................................. 76 2.9. RESOURCE RECOVERY ............................................................................... 81 2.10. SOLVENT MANAGEMENT PLAN .................................................................. 81 2.11. Project Cost and Cost towards Environmental Protection ............................... 82 2.12. CSR Activities [Existing / Proposed] ................................................................ 82 2.13. CREP Compliance .......................................................................................... 84 Chapter 3. Description of the Environment ............................................................... 86 3.1. Method of Data Generation ............................................................................. 86 3.2. Site description ............................................................................................... 87

3.2.2. Topography ................................................................................................. 87 3.2.3. Geology ...................................................................................................... 89

3.3. Land use ......................................................................................................... 95 3.4. Meteorology .................................................................................................... 97 3.5. Ambient Air Quality ....................................................................................... 100 3.6. Noise Environment........................................................................................ 103 3.7. Water Quality ................................................................................................ 104 3.8. Soil Quality ................................................................................................... 108 3.9. Biological Environment ................................................................................. 112 3.10. Socioeconomic Environment ......................................................................... 117 Chapter 4. Impacts Assessment and Prediction ...................................................... 124 4.1. General ......................................................................................................... 124


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4.2. Construction Phase....................................................................................... 124 4.3. Operation Phase ........................................................................................... 125 4.4. Noise Environment........................................................................................ 132 4.5. Water Environment ....................................................................................... 133

4.5.2. Land Diversion .......................................................................................... 134 4.5.3. Land Deterioration .................................................................................... 134

4.6. Biological Environment ................................................................................. 134 4.7. Socio – Economic Environment .................................................................... 136 Chapter 5. Environment Management Plan ............................................................ 137 5.1. Introduction ................................................................................................... 137 5.2. Objectives of EMP ........................................................................................ 137 5.3. Components of EMP ..................................................................................... 137 5.4. CREP Guide Lines for Pesticides Industry .................................................... 138

5.4.4. Resource Conservation Measures ............................................................ 139 Chapter 6. Risk Assessment& DISASTER MANAGEMENT PLAN ......................... 142 6.1. Introduction ................................................................................................... 142 6.2. Risk Assessment .......................................................................................... 142 6.3. Risk Screening Approach.............................................................................. 144 6.4. Hazardous Materials Storage ........................................................................ 158 6.5. QRA Approach .............................................................................................. 158 6.6. Thermal Hazards .......................................................................................... 159 6.7. Damage due to Explosion ............................................................................. 160 6.8. Toxic Release ............................................................................................... 161 6.9. Data Limitations ............................................................................................ 161 6.10. Likely Failure Scenarios ................................................................................ 161 6.11. Weather Effect .............................................................................................. 161 6.12. Incidents Impacts .......................................................................................... 161 6.13. Occupational Health and Safety .................................................................... 167 6.14. Emergency Management Plan ...................................................................... 168 6.15. Objectives 169 6.16. Emergency Management Plan ...................................................................... 170 6.17. Responsibilities & Role of Key Personnel ..................................................... 171

6.17.1. Over all In-charge –President (Operation) ................................................. 171 6.17.2. Chief Site Coordinator- Manager (Prod.) ................................................... 171 6.17.11. Fire Supervisor should also ensure the following: .................................. 175

6.18. Post Emergency Recovery ............................................................................ 175 Chapter 7. Summary and Conclusion ..................................................................... 178 7.1 Prelude.....................................................................................................174 7.2. Regulatory Compliance ................................................................................. 178 7.3. Baseline Conditions ...................................................................................... 178 7.4. Environmental Impacts and Mitigation Measures .......................................... 179 7.5. Recommendations ........................................................................................ 179 Chapter 8. Disclosure of Consultants ...................................................................... 180 8.1. Prelude ......................................................................................................... 180


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List of Tables

Table 1.1 : ToR Compliance Status ......................................................................... 14 Table 1.2 : List of major industries within 10km radius of site .................................. 24 Table 2.1 : Connectivity and Surrounding Area Profile ............................................ 25 Table 2.2 Existing and Proposed Products .............................................................. 25 Table 2.3 Emission scrubbing system details:- ........................................................ 29 Table 2.4 : Emission scrubbing system details:- ...................................................... 36 Table 2.5 : Emission scrubbing system details:- ...................................................... 42 Table 2.6 : Emission scrubbing system details:- ...................................................... 44 Table 2.7 : Emission scrubbing system details:- ...................................................... 50 Table 2.8 : Emission scrubbing system details:- ...................................................... 55 Table 2.9 : Emission scrubbing system details:- ...................................................... 59 Table 2.10 : Emission scrubbing system details:- .................................................... 61 Table 2.11 : Laboratory‘s Equipment ....................................................................... 63 Table 2.12 :Plant Machineries: ................................................................................ 63 Table 2.13 Land Distribution .................................................................................... 65 Table 2.14 Raw Materials ........................................................................................ 65 Table 2.15 Water Balance (Existing/After proposed Expansion) .............................. 68 Table 2.16 Existing and proposed waste water generation ...................................... 70 Table 2.17 Details of Hazardous/ Solid Wastes Generation, Storage and Disposal . 72 Table 2.18 Stacks of Boiler and DG set ................................................................... 73 Table 2.19 Process and Utility Stacks: .................................................................... 73 Table 2.20 Emission Load ....................................................................................... 74 Table 2.21 Transportation, Unloading and handling procedure ............................... 78 Table 2.22 CREP Guidelines Compliance ............................................................... 84 Table 3.1 Location Details, Period and Methodology of Baseline Data Generation . 86 Table 3.2 Salient feature of the project .................................................................... 87 Table 3.3 Geological Sequence of the Study Area as per GSI ................................ 89 Table 3.4 Land Use Distribution of the Study Area (10 km Radius) ......................... 95 Table 3.5 Monthly Rainfall in Alwar District .............................................................. 98 Table 3.6 Summary of Climatic Condition at the Site ............................................... 99 Table 3.7 Ambiant Air Quality Monitoring Locations .............................................. 100 Table 3.8 Summery of Ambient Air Quality Monitoring Results (24-hour average) 100 Table 3.9 Ambiant Air Quality Monitoring Locations .............................................. 103 Table 3.10 Ambient Noise Quality in the Study Area ............................................. 103 Table 3.11 Ground Water Sampling Locations ...................................................... 104 Table 3.12 Ground Water Quality in the Study Area .............................................. 105 Table 3.13 Soil sampling Locations ....................................................................... 110 Table 3.14 Analysis Result of Soil Sampling ......................................................... 110 Table 3.15 Details of Environmental Setting .......................................................... 113 Table 3.16 List of Flora observed in the study area .............................................. 113 Table 3.17 List of Agricultural Crops Grown in the Study Area .............................. 115 Table 3.18 List of Fauna ........................................................................................ 116 Table 3.19 Tehsil wise Rural& Urban Demographic Profile .................................. 118 Table 3.20 Village wise Population in Study Area .................................................. 118 Table 3.21 : Distribution by size of population ...................................................... 119 Table 3.22 : Tehsil wise SC & ST Population ....................................................... 119 Table 3.23 Village wise SC & ST Population ......................................................... 119 Table 3.24 Literacy Rate of Study area (within 10 km radius) ................................ 120 Table 3.25 : Occupation Pattern in Study Area (10 km Area) ............................... 121 Table 3.26 :Classification of Main Workers in Study Area ..................................... 122 Table 4.1 : Contribution to GLCs (maximum) due to proposed AMBEY plant stacks

....................................................................................................................... 132 Table 4.2 CREP Guidelines Compliance ............................................................... 134


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List of Figures

Figure 1.1 : Location of the Project Site ................................................................... 10 Figure 1.2 : Methodology of EIA Study .................................................................... 13 Figure 2.1 : Locationof Project Site .......................................................................... 26 Figure 2.2 : Site Layout Plan ................................................................................... 27 Figure 2.4 : Air Pollution Control System [Dust Extraction System for Hot Air

Generator (Dryer of Sodium Salt Plant ............................................................. 75 Figure 3.1 Map Showing Site and Surrounding Environment Features within 10 km

area .................................................................................................................. 88 Figure 3.2 Drainage Map of Study Area .................................................................. 90 Figure 3.3 Water Level Trends of Alwar district ....................................................... 91 Figure 3.4 Seismic Zones of India ........................................................................... 92 Figure 3.5 Graph Showing Land Use of the Study Area (10 km Radius) ................. 95 Figure 3.6 Digital Elevation Map of Study area ........................................................ 93 Figure 3.7 Contour map of Study Area .................................................................... 94 Figure 3.8 Land Use Map of the Study Area (10 km Radial Zone) ........................... 96 Figure 3.9 Average Annual Rainfall in Alwar 1990-2004 .......................................... 97 Figure 3.10 Rainfall Pattern of Alwar district during the period of 2010-2014 ........... 98 Figure 3.11 Wind Rose (Dec- March) ...................................................................... 99 Figure 3.12 Wind Frequency Distribution ................................................................. 99 Figure 3.13 Map Showing Environmental Monitoring Locations ............................ 102 Figure 3.14 Soil Map of Alwar District .................................................................... 108 Figure 3.15 : Soil Composition of the Alwar District .............................................. 109 Figure 4.1 PM ISOPLETHS FROM PLANT EMISSION SOURCES ...................... 128 Figure 4.2 SO2ISOPLETHS FROM PLANT EMISSION SOURCES ...................... 129 Figure 4.3 HCl ISOPLETHS FROM PLANT EMISSION SOURCES ...................... 130 Figure 4.4 HBr ISOPLETHS FROM PLANT EMISSION SOURCES .................... 131


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List of Annexure

Annexure I: NABET Certificate

Annexure II: TOR Letter

Annexure III: Raw material MSDS

Annexure IV: Land document

Annexure V: Existing EC copy

Annexure VI: Existing monitoring report

Annexure VII: TSDF Membership


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CHAPTER 1. INTRODUCTION

1.1. Project Proponent – M/S Ambey Laboratories Pvt. Ltd (Ambey)

Ambey is a part of renowned Ambey Group of Industries that was established in the year 1977. The group began its operations manufacturing home hygiene products under the brand name TRISHUL. The growth of this company was marked throughout India as the brand soon became a national recognized within few years of its commencement. The success story of this company encouraged to develop and expand manufacturing capabilities to agrochemical division producing various technical and formulated herbicides, insecticides, and weedicides.

The company started its first largest selling technical herbicide named 2,4-D and producing the complete range. Exclusive range of 2,4-D herbicide with the lowest unit acreage rates, are among the most economical of crop protection solution available in the world. Ambey Laboratories Pvt Ltd emerged as the largest manufacturer of 2,4-D series in India capturing more than 30% of the domestic market share and also marking global presence in many countries of the world.

1.2. Proposed Project

M/s Ambey Laboratories Pvt.Ltd intends to expand Technical grade Pesticides manufacturing under its Modernization Project at its existing site Plot No. SP1-5, RIICO Industrial Area, Sotanala, Behror Dist. Alwar, Rajasthan.

The company is presently operating existing unit at their facilities and have incorporated changes to the process scheme during the course of their R&D efforts. The commercial unit will be a scale-up version of the existing and considering all changes incorporated during the development phase, till date. The scaled up will be 13000 MT per annum on an average.

The new plant is designed with the basic concept of existing unit with modifications to optimize energy utilization and with significant reduction of manual interface. To meet the target production rate, all equipment‘s

capacities and their sizes are optimized. An equipment list is prepared which includes the capacities and equipment sizes with minimum other details required to finalize the overall plot area.

1.3. Need of the Proposed Project

The role of the pesticides in the well-being of human race needs no emphasis. Pesticide usage has become essential in order to maximize agriculture production and reduce public health pestilence. The rapid changes in cropping patterns, increased fertilization and adoption of programs for high yielding varieties have all contributed to increased use of pesticides. Further, pest problems keep on changing with the changing environment. New physiological kinds evolve as a result of mutations to withstand new conditions in nature. Many pest species develop resistant strains when the


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same Pesticide is used far too often. The problems of pest resurgence and secondary pest out-breaks crop up with the indiscriminate use of pesticides. These associated problems offer a great scope for revolutionizing the use of pesticides. However, in India though the overcall pesticide growth figures may appear impressive, the rate of consumption per hectare of cultivated land is very low in comparison per hectare of cultivated land is very low in comparison to other countries. India used 180 g of pesticides/ha. as against 10,790g, 1870 g and 1490 g/ha used in Japan, Europe and U.S.A. respectively. India spent just Rs. 2.15/ha. on pesticides while Japan and U.S.A spent Rs.110/ha and Rs.35/ha respectively during the same period. India consumed 12 gm. of pesticides per kg. of fertilizer used against 146 gm. in Japan in and 19 gm in U.S.A in . This is one of the major factors that can be attributed to low per hectare yields in our country since the crops and especially the high yielding varieties cannot manifest their production potential in absence of proper pest protection. That the production potential remains suppressed for want of protection can be exemplified by considering how in wheat, a crop comparatively resistant to insect pestilence, we have had a ―revolution‖ where as in paddy which is one of the most heavily infested

crops, we have had no break-through. In case of wheat, the per hectare yield in India rose from 827 kg.in to 1338 kg. Corresponding yields of paddy in India on the other hand was 1826 kg. as against 6185 kg. 5326 kg. , 5105 kg.and 4000 kg.in Japan, Egypt, USA and USSR respectively.

Within the country itself, there is a great imbalance between different regions with regard to the use of pesticides. Of the total of approximately Rs.5000 million spent on pesticides in at the farm level, south contributed for about 45 per cent of the total consumption in the rest of the country.

1.4. Purpose of the Study

The environmental study undertaken is aimed at identifying existing environmental conditions, predicting environmental impacts associated with the proposed expansion of Ambey unit at RIICO Industrial Area, Sotanala, Behror dist. Alwar,.and suggesting mitigation measures to mitigate the adverse environmental impacts. The different activities that are likely to take place have been analyzed and proposed mitigation measures are assessed for their adequacy. Further mitigation measures have been proposed where considered necessary. The study also aims at reflecting the acceptability of the project to different stakeholders, and at incorporating the concerns raised by them into impact assessment and of the subsequent Environmental Management Plan.

1.5. Project Location

The Ambey proposed expansion project is located at latitude 30.8°61' 75.95‖

N and longitude 76.9°31' 12.3‖ E. The existing project site is situated at Plot

No. SP 1 - 5, RIICO Industrial Area, Sotanala, Behror, Dist. Alwar.

The unit is located in notified industrial Area of RIICO. The copy of notification of Rajasthan Government notifying this industrial Area is given in Annexure I.


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Topographically the area is flat terrain and the elevation of the plant site is between 203m above Mean Sea Level.

The location of RIICO Industrial Area with respect to its position in the State and Region is shown in Figure 1.1.

(A) Google Map


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(B) Approach towards Project Site

Figure 1.1 : Location of the Project Site

1.6. Regulatory Norms

The proposed expansion project of Ambey is for manufacturing pesticides. The project falls under Category 'A' of the Schedule in project activity no. 5(b) of EIA Notification dated September 14, 2006 as amended up to December 1, 2009 and requires prior environmental clearance from the Ministry of Environment and Forests (MoEF), New Delhi.

Therefore, as part of its EC processAmbey submitted relevant documents, namely Form-1 (as per the EIA Notification 2006, as amended) along with a copy of Pre-Feasibility Report (PFR) and proposed Terms of References (ToRs) for carrying out Environmental Studies, to the EAC, MoEF, New Delhi vide letter No. J-11011/296/2013 – IA II(I) dated 11 December 2014.

Other Statutory Requirements/ approval are as below:

S. No.

Permit / Clearance/Standards

For Existing Project

For Proposed Expansion Project

Current Status for Expansion Project

1

No Objection Certificate / Consent to Establish from Rajasthan Pollution Control Board (RPCB) for the expansion

Available Mandatory, prior to establishment of expansion project

Shall be applied


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S. No.

Permit / Clearance/Standards

For Existing Project

For Proposed Expansion Project

Current Status for Expansion Project

project

2 Factory License Available

Mandatory approvals required for drawings prior to commencement off construction and issue of modified license after completion of expansion

Being applied

3 Water linkage From existing bore well

Approval required for increasing capacity Shall be applied

4

Environmental Clearance from Expert Appraisal Committee, Impact assessment Authority(IAA)

Not Required Required Under Process

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The Hazardous Waste (Management, Handling and Trans boundary Movement) Rules 2008 amended to date.

Available

Required since there will be an increase in air emissions, waste water quantities and hazardous wastes

Shall be applied

10 Water (Prevention and Control of Pollution) Act,1974

11 Air (Prevention and Control of Pollution) Act, 1980

Like all other industries, the proposed project being a pesticides manufacturing unit, will also contribute significantly to the agricultural and economic growth through industrialization. In addition, they bring associated ills of environmental imbalance by creating pollution. To reduce the adverse impacts of pollution, the plant activities must co-exist satisfactorily with its surrounding environment. This requires sound environmental management plan (EMP) to be implemented by the plant management, which makes environmental protection as essential requirement, equal in status with production and profit requirements.

1.7. Scope and Methodology of the Study

The scope of the EIA study is based on the generic structure of environmental impact assessment document as stated in the Appendix III of the EIA Notification 2006 (S.O. 1533), Ministry of Environment and Forests, Government of India.

The scope of the study includes a detailed characteristic of environment in the study area associated with the proposed development on various environmental components. The proposed project is currently in the design


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preparation stage. For the purpose of environmental assessment, areas within 10 km radius of the project have been studied and the following methodology will be adopted:

Generation and collection of baseline data for valued environmental components as per the EIA guidelines.

Identification and quantification of significant environmental impacts due to the project and associated activities.

Evaluation of impacts due to proposed activities and preparation of an environmental impact statement

Preparation of appropriate Environmental Management Plan (EMP) encompassing strategies for minimizing identified adverse impacts along with budgetary provisions to be made by the project authorities for implementation of mitigation measures.

Delineation of post Environmental Quality Monitoring Programme (EQMP) along with organizational setup required for monitoring the effectiveness of mitigation measures.


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Figure 1.2 : Methodology of EIA Study

1.8. Approved ToR for EIA Study by EAC

The MoEF has finalized the Terms of References (ToRs) for carrying out Environmental Studies vide letter 11th December 2014 (Annexure II).

The EIA study has been conducted in-line with the approved ToR by MoEF and taking into consideration the structure of the report given in the EIA Notification 20061. The compliance to the approved ToR has been presented in Table 1.1.

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Appendix III (Generic Structure of Environmental Impact Assessment Document) of EIA Notification, 2006 (http://envfor.nic.in/divisions/iass/notif/notif.htm) – S.O. 1533, dated 14th September 2006, as published in the Gazette of India, Extraordinary, Part II, and Section 3, Sub-section (ii), Ministry of Environment and Forests.

http://envfor.nic.in/divisions/iass/notif/notif.htm


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Table 1.1 : ToR Compliance Status

S.no ToR Compliance

1.

Executive Summary(maximum 2-3 sheets in A4 size paper) of the project covering project description, description of the environment, anticipated environmental impacts & its mitigation measures, environmental management plan, environmental monitoring programme, public consultation, project benefits, Social impacts including R&R

Complied

2.

Site Details:

i. Location of the project site covering village, Taluka/Tehsil, District and State on Indian map of 1:1000,000 scale.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25.000 scale on an A3/A2 sheet.

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

iv. Google map-Earth downloaded of the project site.

v. A map showing environmental sensitivity and from critically/severaly polluted area and Eco-sensitive Areas within 10km radius of the project site vis-à-vis shortest (aerial) distance from the project. If the project is located within 10km of CPAs/severely Polluted Areas, confirm whether moratorium has been imposed on the area.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. in addition, if located within an industrial area/Estate/Complex, layout of industrial area and location of unit within the Industrial area/Estate/Complex, layout of Industrial Area.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, in addition to site map, provide photographs of plantation/greenbelt in the existing project. If fresh EC application, photographs.

Location detail of the project site given in Section 1.5 and Figure 1.1. Existing EC copy attached as Annexure.

3.

Landuse break-up of total land of the project site (identified and acquired) – agriculture, forest, wasteland, water bodies, settlements, etc shall be included.

Detail of the Landuse given in Section 3.3.

4. A copy of the mutual agreement for land acquisition signed with land oustees.

Site situated in RIICO industrial area, the Land document attached as Annexure


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S.no ToR Compliance

5.

Proposal shall be submitted to the Ministry for environmental clearance only after acquiring at least 60% of the total land required for the project. Necessary documents indicating acquisition of land shall be included

Expansion of Project at its existing location , The RIICO land allocation document attached as Annexure

6.

Forests and wildlife related issues:

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

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

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

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

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

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

No Forest land Involved. Landuse of the study area given in Section 3.3. Detail of project location given in Section 3.3. Wild life clearance not applicable because there is no National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals with in 10 km radius.

7.

Expansion/modernization proposals:

i. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments should be provided. In addition, status of compliance of Consent to Operate for the ongoing/existing operation of the project from SPCB shall be attached with the EIA-EMP report.

Copy of existing environmental clearance attached as Annexure


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S.no ToR Compliance ii. In case the existing project has not obtained

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

8. A list of major industries with name and type within study area (10km radius) shall be incorporated.

A list of major industries with name and type within study area given in Section 1.10

9.

Details of proposed raw materials and products along with production capacity. If expansion project, details for existing unit, separately for existing and new (proposed) unit.

Detail of raw material of the expansion project given in Section 2.5.2.

10.

Details of manufacturing process, major equipment and machinery. If expansion project, details for existing unit, separately for existing and new (proposed) unit.

Details of manufacturing process, major equipment and machinery given in Section 2.2 and 2.3.

11.

List of raw materials required and its source along with mode of transportation shall be included. All the trucks for raw materials and finished product transportation must be ―Environmentally Compliant‖.

List of raw materials required and its source given in Section 2.5.2.

12.

Quantity of fuel required, its source and characteristics and documentary evidence to substantiate confirmed fuel linkage shall be furnished.

Fuel required, its source given in Section 2.5.4.

13.

Project site layout plan to scale using AutoCAD showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1Km) dumping, waste disposal, green areas, water bodies, rivers/drainage passing through the project site shall be included.

Site detail given in Section 2.1 and Plant layout of the plant given in Figure 2.2.

14. Manufacturing process details of all the plants including captive power plant if any along with process flow chart shall be included.

Manufacturing process details given in Section 2.2 and 2.3.

15. Mass balance for the raw materials and products shall be included. Attached as Annexure

16. Energy balance data for all the components of the plant shall be incorporated.

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

Geological features and Geo-hydrological status of the study area given


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S.no ToR Compliance in Section 3.2

18.

Details of Drainage of the project upto 5Km radius of study area. If the site is within 1km radius of any major river, peak and lean river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of RL of the project site and mRL of the river should also be provided

Details of Drainage of the project upto 5Km radius of study area given in Section 3.2

19.

One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOx, CO and HC (methane & non-methane) should be collected. The monitoring stations should be take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) at 8 locations given in Section 3.5

20. Surface water quality of nearby River (60m upstream and downstream) and other surface drains at eight locations to be provided.

Section 3.7

21. Ground water monitoring minimum at 8 locations shall be included. Section 3.7

22. Noise levels monitoring at 8 locations within the study area. Section 3.6

23.

Traffic study of the area for the proposed project in respect of existing traffic, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangements etc.

Section 4.2

24.

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

Detailed description on flora and fauna (terrestrial and aquatic) exists in the study area given in section 3.9

25. Emissions (g/second) with and without the air pollution control measures.

Section 2.6.2 and Section 4.3

26.

Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be well assessed. Details of the model used and the input data used for modelling shall also be provided. The air quality contours should be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.

Details of the model used and the input data used for modelling given in Section 4.3 and Figure 4.1 to 4.1

27.

Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products

Impact of the transport of the raw materials and end products on the surrounding


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S.no ToR Compliance and wastes (large quantities) by rail-cum road transport or conveyor-cum-rail transport shall be examined.

environment given in Section 2.6.3.

28. Details of water requirement, water balance chart for new unit or for existing unit as well as proposed expansion (in case of expansion).

Water requirement, water balance chart for new unit or for existing unit as well as proposed expansion given in Section 2.5.3.

29.

Source of water supply and quantity and permission of withdrawal of water (surface/ground) from Competent Authority.

Ground water Acknowledgement copy attached.

30.

Details regarding quantity of effluents generated, recycled and reused and discharged to be provided. Methods adopted/to be adopted for the water conservation shall be included. Zero discharge effluent concepts to be adopted.

Detail of Resource recovery and Zero discharge effluent given in Section 2.9.

31.

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

Complete scheme of effluent treatment given in section 2.6.1. and Figure 2.3.

32.

Action plan for control of ambient air quality parameters as per NAAQES Standards for PM10, PM2.5, SO2, and NOx, etc as per GSR 826 (E) dated 16th November 2009.

Section 2.6.3.

33.

An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R 414 (E) dated 30th May 2008.

Section 2.6.3.

34.

Action plan for solid/hazardous waste generation, storage utilization and disposal. Copies of MOU regarding utilization of solid waste shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Action plan for solid/hazardous waste generation, storage utilization and disposal given in Section 2.6.2. and TSDF Membership attached as Annexure

35.

Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 1999 and subsequent amendment in 2003 and 2009. A detailed plan of action should be provided.

Action plan for Fly ash management given in section 2.7.

36.

Action plan for the green belt development plan in 33% area i.e. land with not less than 1500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the

Action plan for the green belt development plan given in Section 5.4.5.


19

S.no ToR Compliance roads used for the project shall also be incorporated. All rooftops/terraces shall have some green cover.

37.

Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to converse fresh water and reduce the water requirements from the other sources. Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayat and Village Heads to augment the ground water level. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well.

Rainwater harvesting should be taken up where ever possible.

Four peizeometric wells should be installed to monitor ground water around the plant (to ensure hazardous material leachate in the ground).

38.

Environment Management Plan (EMP) to mitigate the adverse impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Detail Environmental Management plan given in Chapter 5

39.

Details of Rehabilitation & Resettlement (R&R) involving the project. R&R shall be as per policy of the State Govt. and a detailed action plan shall be included.

Not Applicable

40. Action plan for post-project environmental monitoring shall be submitted. Chapter 5

41.

Disaster Preparedness and Emergency Management Plan including Risk Assessment and damage control needs to be addressed and included.

Detailed study of Disaster Preparedness and Emergency Management Plan including Risk Assessment given in Chapter 6

42.

Occupational Health:

i. Details of existing Occupational & Safety Hazards. What are the exposure levels of above mentioned hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved.

ii. Details of exposure specific health status evaluation of worker. If the worker‘s health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular defect) ECG, during pre-placement and periodical examinations give the details of the

Details of existing Occupational & Safety Hazards given in Section 2.8 and section 6.13


20

S.no ToR Compliance same. Details regarding last month analysed data of abovementioned parameters as per age, sex, duration of exposure and department wise.

iii. Annual report of health status of workers with special reference to Occupational Health and Safety.

iv. Action plan for the implementation of OHS standards as per OSHAS/USEPA.

v. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers.

43.

Corporate Environment Policy:

i. Does the company have a well laid down Environment Policy approves by its Board of Directors? If so, it may be detailed in the EIA report.

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

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

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

Detail Environmental Management plan given in Chapter 5

44.

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

Details regarding infrastructure facilities given in Section 2.5

45.

At least 5% of the total cost of the project shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Detail of Project cost and CSR given in Section 2.11.

46.

Any litigation pending against the project and/or direction/order passed by any Court of Law against the project. If so, details thereof shall also be included. Has the unit received any notice under the section 5 of Environment (Protection) Act, 1986

Not Applicable


21

S.no ToR Compliance or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

47. The questionnaire for industry sector (available on MoEF website) shall be submitted as an Annexure to the EIA-EMP report.

Attached as Annexure

48. Manufacturing process details along with the chemical reactions and process flow chart. Section 2.2 and 2.3

49. Name of all the solvents to be used in the process and details of solvent recovery system. Section 2.10

50. Design details of ETP, incinerator, if any along with boiler, scrubbers/bag filters etc. Section 2.6.3.

51.

The details of solid and hazardous wastes generation, storage, utilisation, and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristics of the hazardous waste. Action plan for the disposal of fly ash generated from boiler shall be included.

Section 2.6.2.

52. Precautions to be taken during storage and transportation of hazardous chemicals shall be clearly mentioned and incorporated.

Section 2.6.2

53.

Material Safety Data Sheet for all the Chemicals are being used/will be used. CAS No./RTECS No./DOT/UN etc to be mentioned against each chemicals.

Attached as Annexure

54. Details of VOC monitoring in the working zone environment, and other hazardous emissions such as Chlorine, HCl, etc if any.

Existing Monitoring report attached as Annexure

55. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.

TSDF certificate Attached as Annexure.

56. Risk assessment for storage for chemicals/solvents. Action plan for handling & safety system.

Chapter 6

57.

Details of occupational health programme.

i. To which chemicals, workers are exposed directly or indirectly.

ii. Whether these chemicals are within Threshold Limit Values (TLV)/Permissible exposure Levels as per ACGIH recommendation.

iii. What measures company has taken to keep these chemicals within PEL/TLV.

iv. How the workers are evaluated concerning their exposure to chemicals during pre-placement and periodical medical monitoring.

Chapter 6


22

S.no ToR Compliance v. Liver function tests (LFT) during pre-placement

and periodical examination.

58. A toxic management Plan shall be prepared. Chapter 6

59. A write up on ―Safe Practice‖ followed for handling, storage, transportation and unloading of chemicals to be submitted.

Chapter 6

60. What are onsite and offsite emergency plan during chemical disaster. Chapter 6

61. A write up on ―Treatment of workers affected by accidental spillage of chemicals‖. Chapter 6

62. A tabular chart with index for point wise compliance of above ToRs. Complied

1.9. Structure of the Report

This EIA report has been prepared on the basis of available on-site primary data (survey/ monitoring) and secondary/literature data. The EIA report contains project features, baseline environmental setup, assessment of environmental impacts, and formulation of mitigation measures, environmental management and monitoring plan with risk & disaster management plan.

The report includes 9 Chapters. The executive summary has been at the beginning of the report. The structure of the EIA Report with necessary tables, drawings and annexure is as follows:

Chapter 1: Introduction

This chapter provides background information on need of project, need of EIA study and brief of the project. The scope and EIA methodology adopted in preparation of EIA report have also been described in this Chapter. It also covers the identification of project & project proponent, brief description of nature, size, location of the project and its importance to the country and the region. Scope of the study details about the regulatory scoping carried out as per the generic structure given in the EIA Notification, 2006.

Chapter 2: Project Description

This chapter deals with the project details of the proposed Pesticide Manufacturing Plant, with type of project, need for the project, location, size & magnitude of operation including associated activities required by and for the project, proposed schedule for approval and implementation, including technical details of raw material, quality and quantity etc.

Chapter 3: Description of the Environment

This chapter presents the existing environmental status of the study area around the proposed project including topography, drainage pattern, water environment, geological, climate, transport system, land use, flora & fauna,


23

socio-economic aspects, basic amenities etc. Environmental assessment of the proposed project site in regard to its capability to receive the proposed new development is also discussed in this Chapter.

Chapter 4: Anticipated Environmental Impacts and Mitigation Measures

This chapter describes the overall impacts of the proposed project activities and underscores the areas of concern, which need mitigation measures. It predicts the overall impact of the proposed project on different components of the environment viz. air, water, land, noise, biological, and socio-economic.

Chapter 5: Environmental Management Plan

This chapter details the inferences drawn from the environmental impact assessment exercise. It describes the overall impacts of the proposed activities during construction and operation phases and underscores the areas of concern, which need mitigation measures. It also provides mitigation and control measures for environmental management plan (EMP) for minimizing the negative environmental impacts and to strengthening the positive environmental impacts of the proposed project.

Chapter 6: Environmental Monitoring Program

Technical aspects of monitoring the effectiveness of mitigation measures have been given in this Chapter.

Chapter 7: Risk Assessment & Disaster Management Plan

This chapter deals with the risk assessment carried out for the proposed Pesticide manufacturing plant and disaster management plan.

Chapter 8: Summary & Conclusion

This chapter provides the summary and conclusions of the EIA study of the proposed project with overall justification for implementation of the project and also explanation of how, adverse effects will be mitigated. This chapter also includes the conclusions of the Public Hearing.

Chapter 9: Disclosure of Consultants Engaged

This chapter provides the disclosure of consultants engaged to carryout the EIA study along with other additional studies.


24

1.10. List of major industries within 10km radius

Table 1.2 : List of major industries within 10km radius of site

Sr. No Name of Industry Type of Industry 1 Mehta Stone Pvt. Ltd. Tiles 2 Jagatjit Industries Ltd. Wine 3 S.R. Foils Ltd. Tissue paper 4 Globus Spirits Pvt. Ltd. Spirit 5 Mount Shivalik Breweries Pvt. Ltd. Beer 6 Shri Krishna paper Mills Paper Industry 7 Otsuka Chemicals Pvt. Ltd. Pharmaceuticals 8 Jaipur Distilleries Spirit 9 Bar Malt India Pvt. Ltd. Malt

10 Ramco Industries Ltd. Silicon Board 11 ShriNath Life Sciences Pvt Ltd Active Pharma

Ingredients 12 Shree jee Laboratory Pvt Ltd Pharma Intermediates 13 Sarika Life Sciences Pvt Ltd Pharma Intermediates


25

CHAPTER 2. PROJECT DESCRIPTION

2.1. The Site

M/s Ambey Laboratories Pvt. Ltd, intends to expand Technical grade Pesticides manufacturing under its Modernization Project. The locations details of the project are placed below:

Table 2.1 : Connectivity and Surrounding Area Profile

Longitude 76°15'56.69"E Latitude 27°49'56.24"N Altitude 324 m above MSL Topography Plain Nearest State highway Jaipur highway (NH-8,0.73Km West) Nearest Railway station Narnaul [Distance 26.4 Kms NW] Nearest Airport IGI Delhi 114Kms,NE Nearest River No river exist Nearest Habitation Behror– 1.41 SE Nearest Seaport None in 25 Kms Nearest Sanctuary None in 25 Kms Nearest Historical Place None in 25 Kms Nearest National Park None in 25 Kms Nearest Hill None in 25 Kms Interstate Boundary Rajasthan – Haryana boundary 3.82 KM in

West

The proposed pesticides manufacturing facility is being set up for enhancing manufacturing of pesticides (existing products as well as 12new products) as given below:

Table 2.2 Existing and Proposed Products

S.No Product Name (Existing) Capacity Approved (MT/Annum)

Capacity Proposed (MT/Annum)

1 2,4 D Sodium Salt 1040 4000 2 2,4 D Acid 845 2000 3 2,4 D Ethyl Ester 600 800 4 2,4 D Amine Salt 600 3000 1 Clodinafop -- 50 2 Hexaconazol -- 250 3 Atrazine -- 300 4 Buprofezine -- 100 5 Lambda Cyhalothrin -- 50 6 Cypermethrin -- 250 7 Alphamethrin -- 50 8 Deltamethrin -- 50 9 Cypermethrin Acid Chloride

(CMAC) -- 1000

10 Meta phenoxybenzaldehyde (MPB)

-- 720

11 Fipronil -- 200 12 Glyphosate -- 200

Total 3085 13020


Figure 2.1 : Locationof Project Site


Figure 2.2 : Site Layout Plan


2.2. Manufacturing Activity [Existing Products]

2.2.1. 2,4-D Sodium Salt |Batch Size: 1000 Kg | Batch Time: 128Hrs

Step1: Phenol neutralisation

The neutralisation step refers to the neutralisation of DCP with caustic soda. Sufficient caustic soda is added to create alkaline conditions although not all of the DCP is neutralisedduring this step. The neutralisation is exothermic with heat removed through a cooling jacket on the reactor. The product from this neutralisation is sodium dichlorophenol (NaDCP).

Step 2:NaMCA production

NaMCA is produced by the neutralisation of monochloroacetic acid (MCA) with caustic soda, which is an exothermic reaction. The heat of reaction is removed by reacting these two chemicals in a heat exchanger prior to adding the NaMCA to the reactor.

Step 3: Condensation

The NaMCA then condenses the NaDCP to produce 2,4-D Sodium Salt. This reaction is highly exothermic with the heat of reaction removed through a cooling jacket on the reactor.

Step 4: Final ageing

As the raw materials are used up, the speed of reaction slows because the unreacted material is at a low concentration in the reaction mass. An ageing period is required to ensure the phenol content of the 2,4-D Sodium Salt is below 0.5 w/w %. During the ageing step, caustic soda is slowly added to the reaction mass to react with any remaining phenol. The addition rate is controlled so that alkaline conditions are maintained in the reactor. The crude is filtered through Agitated Nutsche Filter (Filter) and then dried.


Process Flow Diagram and Mass Balance:

Emissions:-

The HCL gas are liberated slowly as the reaction progresses; and first HCL gas is scrubbed by water in condenser column and then scrubbed by NaOH Solution in Ventury Scrubber. The resulting 30% HCL Solution are obtained in the scrubbing system.

Table 2.3 Emission scrubbing system details:- Type of Scrubbing System

Scrubbing Media

Stack Height

Stack Dia

Flow in Nm3/hr

Pollutant Concentration in mg/Nm3

Multistage Ventury

Water and Caustic

15 m 0.12 m 50 Less than 20 mg/Nm3

Liquid Pollutants:-

Mother Liquor from process filter washings sent to ETP after detoxification by caustic solution.

Solvent Recovery Plan:-N/A

2.2.2. 2,4-D Acid | Batch Size: 1000 Kg |Batch Time: 24 Hrs

Charge water in the reactor then add 2,4-D Sodium Salt under stirring to make slurry form. Adjust pH less than 1 by adding HCL. Agitate the mass at 40 – 45oC for


2-3 hours. The mass is filtered through ANF/Centrifuge. Then dry the obtained wet cake.


Emissions:- N/A

Liquid Pollutants:-Mother Liquor from process filter washings sent to ETP after detoxification by caustic solution.


2.2.3. 2,4-D Ethyl Ester | Batch Size: 1000 Kg | Batch Time: 36 Hrs

Charge Ethanol in the reactor then add 2,4-D Sodium Salt and sulphuric acid simultaneously. Cook the mass at temperature 80-85 0C for 4 hours. Give 1st washing with water and agitate for 30 min then separate the spent sulphuric acid from bottom. Again give 2nd washing with water and 10% caustic lye to maintain pH


-7 at 80-850C. After that concentrate the mass at 95oC under vacuum – 730 mm/Hg for 2-3 hours. Filter the material and pack in the drums.


Emissions:-N/A

Liquid Pollutants:-Aqueous Layer from process washings sent to ETP.



2.2.4. 2,4-D Amine Salt | Batch Size: 1000 Kg |Batch Time: 24 Hrs

Charge DMA in the Reactor then add 2,4-D Acid under stirring. Agitate the mass for 2 hours. Cook the mass at 50-52oC for 4 hours, adjust the pH to 7. Filter the material by Filter Press or Notch Filter and then pack it.


Emissions:-N/A

Liquid Pollutants:-Aqueous Layer from equipment washing sent to ETP.


Packing


2.3. Manufacturing Process in Brief [New Products]

2.3.1. Clodinafop - Propargyl Technical | Batch Size: 1000 Kg |Batch Time: 104 Hrs

Charge Acetonitrile/dimethylformamidein the reactor. Start stirring and heat the solvent to 500C. Charge slowly Weighted quantity of R-HPPA [(R)-(+)-2-(4-Hydroxyphenoxy) propionic acid] in to the reactor under stirring in 1 to 2 hrs. Charge catalyst at the above temperature. Further heat the mass to 55 to 60 0C. Start charging the Potassium carbonate powder in the reaction mass in 2 to 3 hrs. Heat the mass to 70 -72 0C and maintained it for 2 hr for competition of the reaction. Heat the mass to 82 to 84 0C. Start addition of CDFP [5-chloro-2, 3-difluoro pyridine] at 82 to 840C temp. and add the weighted quantity in 4 hrs. Maintain the reaction temp 82 to 840C for 24 hrs. Check forwarding of reaction of by HPLC in 20 and 24 hrs. If found unreacted, R-HHPA maintained the reaction more times. Cool the RXN mass to 70 to 73 0C. Start addition of propargyl chloride and add the weighted qty in 4 to 5 hrs. at the 70 to 73 0C Maintained the reaction mass for 8 hrs. at the same temperature. Check sample for the conversion of CDFPPA into Clodinafop -propargyl. Cool the reaction mass to room temperature by applying cooling. Filter the salt at RT. Wash the salt with ACN/DMF. Collect the washing, filtrate, and transfer it in to Distillation reactor. Distilled out the solvent up all traces to be removed by applying full vacuum. Cool and add Hexane and Isopropyl alcohol at 45 deg. and add seeds. Apply chilling to further cooling. Cool to 03 to 0 0C. Under stirring. Cook the mass at 0 deg. for 2 hrs. Filter the cake on NF. Dry the technical.

Re-cycle of the Spent Solvents (Acetonitrile/ dimethylformamide, Hexane and Isopropyl alcohol)



Emissions:-N/A

Liquid Pollutants:-Aqueous Layer from process washings sent to ETP after detoxification by caustic solution.

Solvent Recovery Plan:

The Clodinafop-propargyl technical is manufactured on the basis of batch process. There are three solvents used in the manufacturing of Clodinafop-propargyl technical, the Acetonitrile/ dimethylformamide used to provide the reaction medium for the key reactants when reaction completed the Acetonitrile/ dimethylformamide recovered from the reaction mass through the distillation process as per the batch


quantity. The recovered Acetonitrile/ dimethylformamide is used in next batch by mixing with fresh qty up to three batch cycles completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility in built in the reactor where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste is periodically dispose through RSWMB, a Govt. authorized agency as per RSPCB norms.

The two solvents IPA and Hexane are used for the purpose of purification and re-crystallization process of the Clodinafop-propargyl technical, and are recovered through filtration process. The recovered mixture of IPA + Hexane is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.2. Hexaconazole | Batch Size: 1000 Kg |Batch Time: 96 Hrs

Charge water, Dimethyl Sulfide, DCVP in the reactor, agitate the mass for 15 min. Heat the reflux at 40o C. Add Dimethyl Sulphate at 40o C. Maintain 40o C for four hours. After that add water and remove Dimethyl Sulfide atmospherically. Again add water and agitate the mass at 70o C for 30 min and then kept it for settling. Separate the organic layer from bottom. Then extract the aqueous layer by petroleum ether, separate ether layer from Top & Discard the Bottom Aqueous layer. After that distilled out Ether and Concentrate the mass under vacuum at 950C. Charge DMF and 1,2,4 triazole, heat up to 70o C and maintain for 30 min. Then after cool it to 50o C then charge Potassium Carbonate and agitate for 30 min. Charge Oxirane and heat up to 140o C, maintain for 5 hours. After oxirane<1%, remove DMF under vacuum up to 95o C. After DMF recovery cool the mass to 50o C then add petroleum ether and water. Then cool the mass up to 20o C and filter it. Wash the mass twice by petroleum ether and then dry it.



Mass Balance:

Inputs in Kgs Outputs in Kg Name of Raw

material Per MT Name of Product Per MT

Valeric acid 465 SO2 (gas) 280.16 Thionyl chloride 570 HCL 159.84

NaOH 325 Poly Aluminium Chloride

1520

MDCB 670 MDC (Loss) 320 AlCI3 820 MDC (Recovered) 6680 MDC 7000 DMS (Loss) 200

DMSO4 660 DMF (Recovered) 8600 KOH 650 Effluent 10380 DMF 9000 Solid waste 145

1,2,4 – Triazole 280 Hexaconazole Technical

1000

K2CO3 145 Water 8900

Total Input 29685 Total Outputs 29685

Emissions:-The SO2gas are liberated slowly as the reaction progresses; and SO2 is scrubbed by NaOH solution. The resulting Sodium Bisulfateare obtained in the scrubbing system.

Table 2.4 : Emission scrubbing system details:-

Type of Scrubbing

System

Scrubbing Media

Stack Height

Stack Dia

Flow in Nm3/hr

Pollutant Concentration in

mg/Nm3 Glass Column

Packed Scrubber for

SO2

Caustic 15 m 0.12 m 50 Less than 10 mg/Nm3


Liquid Pollutants:-Aqueous Layer from process washings sent to ETP after detoxification by

caustic solution.


There are two solvents used in the manufacturing of Hexaconazole technical. The DMS used to provide the reaction medium for the key reactants when reaction completed the DMS recovered from the reaction mass through filtration process. The recovered DMA is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

The solvent DMF is used for the purpose of purification and re-crystallization process, and are recovered through the distillation process as a pure solvent. The impurities isolated in the form of solid waste is periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.3. Atrazine | Batch Size: 500 Kg |Batch Time: 36 Hrs

Carbon Tetra Chloride is taken in to the reactor to which added cyanuric chloride, after addition is complete ethylamine and caustic soda solution are added simultaneously other than Iso Propyl Amine and caustic soda are added. After reaction is over, aqueous layer is separated and solvent is distilled off to get Atrazine.



Emissions:N/A



The solvent IPA used in the manufacturing of Atrazine technical. The IPA used to provide the reaction medium for the key reactants when reaction completed the IPA recovered from the reaction mass through the distillation process as a pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.4. Buprofezin Batch Size: 500 Kg

Batch Time: 48 Hrs

Buprofezin technical is manufactured in three operational stages as below.

Stage 1: Reaction Stage

N-chloromethyl N-Phenyl Carbamoyl chloride (CMPC) is reacted with N-Ter Butyl N-Isopropyl Thiourea (BITU) in presence of solvent Mono Chlorobenzene (MCB) at a specified temperature. The resultant mass is then neutralized and washed with water.

Stage 2: Solvent Recovery and Crystallization

Solvent MCB is recovered by removal with aid of reduced pressure. The recovered solvent is recycled for use by necessary make up.

Stage 3: Crystallization

The residual mass is then crystallized in Methanol to achieve product Buprofezin.




Emissions: N/A



The solvent MCB used in the manufacturing of Buprofezin technical. The MCB used for the purpose of purification and re-crystallization process, the MCB recovered from the reaction mass through filtration process. The recovered MCB is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.5. Lambda Cyhalothrin | Batch Size: 1000 Kg |Batch Time: 250 Hrs

The process for the manufacturing of Lambda Cyhalothrin is divided into the following steps:

Acid Chloride Preparation

Lambda Cyhalothric Acid is reacted with Thionyl Chloride in presence of n-Hexane at low temperature over a period of time. The SO2 and HCl gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then SO2 is scrubbed by NaOH solution. The resulting 30% HCl solution and also Sodium Bisulfate are obtained in the scrubbing system. After the reaction, Hexane is distilled off and recycled back to the next batch. The resulting Acid Chloride is sent for the Condensation step.

Condensation & Work-up

In the solution of water and sodium cyanide, MPB and Acid Chloride are added at low temperature. After the addition, the reaction mass is cooled at low temperature for the fixed period. Then phase separation carried out and the organic phase washed with hypo solution. The organic phase is subjected to distillation at low temperature to remove Hexane which is recycled. Hexane – free reaction mass which is Crude Lambda Cyhalothrin is sent for the Epimerization step. The aqueous phase is sent for Cyanide Effluent Treatment.

Epimerization & IPA Recovery

The crude lambda cyhalothrin is washed with IPA and DIIPA in presence of solvent. Then again washed with acidic water. The phases are separated. The IPA & Hexane are recovered and the reaction mass sent for crystallization.

Crystallization

The Epimerized mass is extracted with the solvent and then dried. The dried mass which is Lambda Cyhalothrin packed.




Emissions: The SO2 and HCl gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then SO2 is scrubbed by NaOH solution. The resulting 30% HCl solution and also Sodium Bisulfate are obtained in the scrubbing system.


Type of Scrubbing System

Scrubbing Media

Stack Height

Stack Dia

Flow in Nm3/hr


Multistage Jet Ventury For HCL

Water 15 m 0.12 m 50 Less than 20 mg/Nm3

Glass Column PackedScrubber for SO2


Liquid Pollutants:-Aqueous phase from process washings sent to ETP after detoxification by Hypo Solution.


There are two solvents used in the manufacturing of Lambda Cyhalothrin technical. The Hexane used to provide the reaction medium for the key reactants when reaction completed the Hexane recovered from the reaction mass through distillation process. The recovered Hexane is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

The solvent IPA is used for the purpose of purification and re-crystallization process, and are recovered through the filtration process. The recovered IPA is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste is periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.6. Cypermethrin | Batch Size: 1000 Kg |Batch Time: 36 Hrs

Solution of CMAC and Meta phenoxybenzaldehyde reacts with solution of sodium cyanide in water in presence of phase transfer catalyst at 25 to 300C to give cypermethrin. After reaction water & cyanide layer is separated. The organic mass is washed with water to remove traces of cyanide. Water layer contain sodium cyanide and is treated with Sodium hypochlorite to destroy sodium cyanide the obtain purity of Cypermethrin is minimum 92%.




Emissions: The SO2 and HCl gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then SO2 is scrubbed by NaOH solution. The resulting 30% HCl solution and also Sodium Bisulfate are obtained in the scrubbing system.



Scrubbing Media

Stack Height

Stack Dia

Flow in Nm3/hr



Water 15 m 0.12 m 50 Less than 20 mg/Nm³

Glass Column Packed Scrubber for SO2

Caustic 15 m 0.12 m 50 Less than 10 mg/Nm³



There are one solvent used in the manufacturing of Cypermethrin technical. The Hexane used to provide the reaction medium for the key reactants when reaction completed the Hexane recovered from the reaction mass through distillation process. The recovered Hexane is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.7. Alphamethrin | Batch Size: 1000 Kg |Batch Time: 200 Hrs

The cypermethrin prepared using the above method (Manufacturing of Cypermethrin) is subjected to Epimerization at 250C in presence of tri Ethyl Amine in solvent n-hexane to obtain Alphamethrin. Then it is filtered & dried under vacuum. n-Hexane & TEA is recovered & recycled. The purity of Alphamethrin obtain will be minimum 95%.



Emissions:N/A



There are two solvents used in the manufacturing of Alphamethrin technical. The Hexane and TEA used to provide the reaction medium for the key reactants when reaction completed the Hexane and TEA recovered from the reaction mass through distillation process. The recovered Hexane and TEA is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.8. Deltamethrin | Batch Size: 1000 Kg |Batch Time: 120 Hrs

Step I: Resolution of Mix CMA to RR CMA

Mix CMA is converted to its sodium salt along with Catalyst EPH. The RR CMA sodium salt along with EPH precipitates under alkaline condition, while SS CMA remains soluble in the aqueous medium. The precipitates are filtered and wash with water. The filtrates are collected and worked up for recovery of SS CMA [Ref – 2].

The solids [wet cake of RR CMA Sodium Salt along with EPH] is further taken in solvent MDC along with water and acidified to pH 2 by HCl solution. The RR CMA


gets extracted in MDC while EPH in aqueous medium. The layers are separated. The aqueous is collected separately for catalyst recovery and recycle [Ref – 1]. The organic layer is further washed with water and taken for further process. The washing

water is taken to ETP.

Ref – 1: Recovery of Catalyst

The main aqueous layer obtained from acidification of RR CMA sodium is further adjusted for its pH to 3.5 – 4.0 by NaOH and is directly recycled as catalyst with necessary make up.

Ref – 2: Recovery of SS CMA

The highly alkaline aqueous filtrates from step I is taken along with solvent MDC and acidified by HCl solution. The SS CMA thus formed is extracted in MDC. The layers are separated. The acidic aqueous layer is taken for treatment, while organic layer is further subjected to MDC distillation. The residual molten mass is SS CMA and is used for Cypermethrin manufacturing.

Step II: Bromination of RR CMA

The organic mass consisting of RR CMA obtained from previous step is subjected to Bromination with HBr generated from HBr System [Ref – 3]. Bromination of RR CMA results into unsaturated bromo RR CMA. Unsaturated RR CMA is further Dehydrohalogenated by treatment with Sodium Hydroxide to give saturated Bromo RR CMA Sodium, which in turn is further acidified to obtain saturated Bromo RR CMA. The organic mass is subjected to distillation for removal of solvent leaving pure Bromo RR CMA as distillation residual.

Ref – 3: HBr generation and its work up

Benzene is brominated with bromine using Ferric chloride as catalyst. The Hbr generated in passed to Bromination set up of unsaturated RR CMA as shown above. The bromo benzene obtained is further purified by distillation for recovering of benzene which is recycled. The pure cut of Bromobenzene is sold out as it is a by – product.

Step III: Preparation of Bromo RR CMAC

The Bromo RR CMA obtained from previous step is taken along with Toluene as solvent and DMF as catalyst and is chlorinated by aid of Thionyl chloride, which yields Bromo RR CMAC and HCl and SO2 as off gas which are scrubbed in water and dilute alkali respectively and are by – product.

Step IV: Preparation of Deltamethrin from Bromo RR CMAC

Bromo RR CMAC is reacted with meta-PhenoxyBenzaldehyde and sodium Cyanide in Toluene to give Deltamethrin. The reaction mass is subjected to layer separation and washing with water. The aqueous layer obtained is detoxified with Hypo solution


[Ref – 5]. The washed organic mass obtained is subjected for toluene recovery by distillation leaving crude Deltamethrin as residual mass.

The crude Deltamethrin obtained is further epimerized in Isopropyl Alcohol along with Triethyl Alcohol. The epimerized product is filtered and washed with Isopropyl Alcohol. The Filtrate is collected for recovery of Isopropyl Acohol [Ref – 4]. The wet cake obtained is further recrystallized in Isopropyl Alcohol to obtain purified Deltamethrin. In this case also the filtrate obtained is taken for Isopropyl recovery [Ref – 4].

Ref 4: Isopropyl Recovery

All the filtrate obtained [IPA filtrate] are taken collectively and subjected to distillation under slightly acidic condition. The residual obtained is sent for incineration.

Ref 5: Detoxification of Deltamethrin Aqueous stream

Total aqueous mass obtained from Deltamethrin reaction stream is collectively detoxified using Hypo solution.

Chemical Reaction:





Emissions: The SO2, HCl and HBr gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then SO2 and HBr is scrubbed by NaOH solution. The resulting 30% HCl solution and also Sodium Bisulfate are obtained in the scrubbing system.



Scrubbing Media

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Glass Column Packed Scrubber for HBr



Liquid Pollutants:-Total aqueous mass obtained from Deltamethrin reaction stream is collectively detoxified using Hypo solution.


There are two solvents used in the manufacturing of Deltamethrin technical. The Toluene used to provide the reaction medium for the key reactants when reaction completed the Toluene recovered from the reaction mass through distillation process. The recovered Toluene is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

The solvent IPA is used for the purpose of purification and re-crystallization process, and are recovered through the filtration process. The recovered IPA is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste is periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.9. Cypermethrin Acid Chloride (CMAC) |Batch Size: 1000 Kg |Batch Time: 164 Hrs

Stage 1: Preparation of Tetra ChloroButyro Nitrile (TBN)

Reaction of Carbon tetra chloride (CTC) with acrylonitrile (ACN) at 100o C to 125o C in presence of cupric chloride catalyst, DEA HCl as buffer & acetonitrile (AN) solvent gives tetra chlorobutyro nitrile (TBN). Crude TBN is washed with water to remove catalyst complex, DEA, HCl Salt, Solvent AN & excess CTC is distilled out. Crude TBN is proceeded further. The purity of basic R/M CTC & ACN is above 99% where as crude TBN is above 97%.

Stage 2: Preparation of Tetra Chloro Butyric Acid (TBA)

Acid hydrolysis of crude TBN using 30% of HCl solution at 800C gives tetra Chloro butyric acid (TBA). After reaction TBA is separated from the bottom & dehydrated upto the moisture level of 0.1% & Ammonium chloride solution from top layer is stored in storage tank for sell. The purity of TBA is above 98%.

Stage 3: Preparation of Tetra ChloroButyric Acid Chloride (TBAC)

Reaction of TBA with thionyl chloride in presence of Dimethyl formamide (catalyst) at 60 0C gives tetra chloro butyric acid chloride (TBAC). During reaction of HCl& SO2 gas is evolved which is scrubbed in water & caustic solution respectively. Crude TBAC is further distilled out at high vacuum. The purity of distilled TBAC is 98%.


Stage 4: Preparation of 2-Chloro Butanone Derivative (2CB)

TBAC is reacted with isobutylene gas in presence of TEA (tri ethyl amine) at 700C under 5.0 kg/cm2 pressures. n-Hexane is used as solvent. After reaction excess Isobutylene gas is recovered. The whole mass is washed with water & Tri-ethylamine hydrochloric acid is separated & further preceded for TEA recovery. The organic mass is neutralized with sodium bicarbonate & organic mass is transferred for further process.

Stage 5: Preparation of Sodium Salt of Cypermethrin Acid (Na-CMA)

2CB is isomerized to 4CB in presence of Boron tri fluoride etherate solution (BF3) & TEA at 1200C . 4CB is directly reacted with caustic solution gives Na-CMA. This intermediate is not getting isolated.

Stage 6: Preparation of Cypermethrin Acid (CMA)

Na-CMA is acidified with dilute Sulphuric Acid at room temperature. CMA is extracted in n-Hexane Aqueous layer (Sodium sulphate Solution) is sent for triple effective evaporator. Organic mass (n-Hexane+CMA) is taken for next process.

Stage 7: Preparation of Cypermethrin Acid Chloride (CMAC)

n-Hexane is recovered from CMA solution. Crude CMA is reacted with thionyl chloride in presence of DMF catalyst to give crude CMAC. HCl& SO2 gas generated is scrubbed in water & caustic solution respectively. Crude CMAC is distlled out under high vacuum to get pure CMAC (Cypermethric Acid Chloride). The purity of distilled CMAC is above 99%.




Emissions:The SO2 and HCl gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then SO2 is scrubbed by NaOH solution. The resulting 30% HCl solution and also Sodium Bisulfate are obtained in the scrubbing system.



Scrubbing Media

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There are two solvents used in the manufacturing of CMAC technical. The Hexane and TEA used to provide the reaction medium for the key reactants when reaction completed the Hexane and TEA recovered from the reaction mass through distillation process. The recovered Hexane and TEA is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.10. Meta Phenoxy Benzaldehyde (MPB) Batch Size: 1000 Kg

Batch Time: 90 Hrs

Metabromobenzaldeyde (MBB) Preparation:-

Benzaldehyde is reacted with Chlorine and Bromine in the presence of EDC (as solvent) and Aluminium Chloride as catalyst. Then the reaction mass is drowned in chilled water containing HCl and Formic acid; and then washed with Sodium Thiosulphate solution. Crude MBB, thus obtained is further purified by distillation.

MetabromobenzaldehydeAcetal (MBBA) Preparation:-

MBB is reacted with MEG in the presence of PTSA (as catalyst) and water formed is distilled off and pure MBBA is obtained.

MetaphenoxybenzaldehydeAcetal (MPBA) Preparation:-

First, Potassium Phenoxide is prepared by reacting Phenol with Potassium Hydroxide (KOH) in presence of Toluene. Then Potassium Phenoxide is reacted with MBBA and MPBA is formed. Crude MPBA is purified by water washings.


Hydrolysis:-

MPBA is hydrolysed to MPB in presence of water and Sulphuric acid. Crude MEG so obtained is purified by distillation and recycled to MBBA preparation. The crude MPB is sent for final purification.

MPB Distillation/ Purification:-

The crude MPB is subjected to high vacuum distillation and pure MPB is obtained, which is packed as Finished Product.


Hdrolysis



Emissions: The HCl and HBr gas are liberated slowly as the reaction progresses; and, first HCl gas is scrubbed in water and then HBr is scrubbed by NaOH solution. The resulting 30% HClsolution are obtained in the scrubbing system.




Scrubbing Media

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Aqueous phase from process washings sent to ETP after detoxification by Caustic Solution. Solvent Recovery Plan:

The solvent MEG is used to provide the reaction medium for the key reactants when reaction completed, the MEG recovered from the reaction mass through filtration process. The recovered MEG is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste is periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.

2.3.11. Fipronil | Batch Size: 200 Kg |Batch Time: 36 Hrs

Step 1:

Fipronil is a phenylpyrazole type insecticide.

It is manufactured by reaction of Fipronilpyrazole with Bromothiocyanate at -50C to 00C using MDC as solvent. The reaction mass is maintained at 0o C for 6 hrs. Check for unreacted pyrazole, if more than 2% continue cooking for 2 more hours. After completion of reaction MDC is recovered to give Fipronilthiocyanate.

Step 2:

Fipronilthiocyanate thus obtained from step -1 is dissolved using DMF solvent. Stir the reaction mass at RT till complete dissolution. Start addition of prior scrubbed SO2 gas in DMF to the reaction mass at around 10 – 150C. Ensure that the reactor is properly blancketed with nitrogen atmosphere during the whole course of reaction. Then start simultaneous addition of CF3Br gas and sodium formate at around 0 – 50C within 5 hrs. The pressure in the reactor is maintained at around 10 – 11 kg/cm2. The reaction pressure subdues as CF3Br is consumed. Maintain the reaction for 5 hrs. The excess gas is vented/ scrubbed and finally the reaction mass is taken for solvent (DMF) recovery. Fipronil sulphide thus obtained is taken for the next step.

Step 3:


Finally fipronil sulphide reacts with trichloroacetic acid (TCAA) and dichloroacetic acid (DCAA) in presence of hydrogen peroxide at 10 – 150C . The reaction mass is maintained for 7 hrs. The reaction mass is subjected to water wash. The solids are dissolved in methanol and purified, dried till constant weight to yield Fipronil technical. In process and finished product samples are analysed of HPLC.

Method of purification and recovery:

Fipronil is purified using methanol as solvent at 20 – 250C. The material is then dried at 60 – 650C till constant weight. Second crop is isolated from the methanol filtrate. Lastly methanol is distilled and recycled for next batch. (The ratio of Fipronil : Methanol is 1:3)

Process Flow and Mass Balance


Emissions: The HBrgas are liberated slowly as the reaction progresses; and HBr is scrubbed by NaOH solution.



Scrubbing Media

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Liquid Pollutants:-Aqueous phase from process washings sent to ETP after detoxification

by Caustic Solution.


There are two solvents used in the manufacturing of Fipronil technical. The TFA and MCB used to provide the reaction medium for the key reactants when reaction completed the TFA and MCB recovered from the reaction mass through distillation process. The recovered TFA and MCB is used in next batch by mixing with fresh qty up to three batch cycle completed. After three times use, the spent solvent is sent to recovery storage tank. From the recovery solvent tank, the spent solvent is transferred to distillation facility where it is distilled and recovered to the storage tanks as pure solvent. The impurities isolated in the form of solid waste are periodically dispose through RSWMB a Govt. authorized agency as per RSPCB norms.


2.3.12. Glyphosate | Batch Size: 1000 Kg | Batch Time: 44 Hrs

Step 1:The process of manufacture involves the reaction of Paraformaldehyde with Phosphorous tri Chloride to yield chloromethylphosphonic acid.

Step 2:This is further with glycine and sodium hydroxide to give sodium salt of glyphosate. This is further reacted with hydrochloric acid to give Glyphosate.

Step 3:The crystalline salt thus formed are filtered/ centrifuged by washing many time to remove excess acid/ alkali. This is dried and then tested and packed.


Emissions:N/A


Liquid Pollutants:-Aqueous phase from process washings sent to ETP after detoxification by Caustic Solution.

Solvent Recovery Plan:N/A

2.4. Major equipment and machinery required:

2.4.1. Laboratory Equipment’s:

Table 2.11 : Laboratory’s Equipment

Sr.No. MACHINE DESCRIPTION MAKE MODEL NO. NO. 1 HPLC WITH SOFTWARE WATERS 2489 2 2 GAS CHROMATOGRAPH

WITH SOFTWARE NUCON 5700 2

3 U.V. SPECTROPHOTOMETER

ELICO SL159 2

4 Ph METER TOSHNIWAL 3 5 POLARIMETER RAJDHANI

SCIENTIFIC INSTRUMENT CO.

12 SPI 2

6 OVEN POPULAR TRADERS

2

7 VACCUM OVEN TOSHIBA - 1 8 ANALYTICAL BALANCE OHAUS PAG-214C 2 9 ANALYTICAL METLER TOLEDO AB1045 2 10 WRIST ACTION SHAKER PR SCIENTIFIC - 1 11 VACCUM PUMP PROMIVAC - 2 12 VACCUM PUMP LOCAL - 1 13 WATER BATH SM INDUSTRIES - 1 14 MAGNETIC STIRER REMMI - 2 15 FLASH POINT

APPARATUS ASHIAN SCIENTIFIC

- 1

16 REFRIGERATOR BPL, GODREJ - 2 17 BOD INCUBATOR CALTON - 2 18 MELTING POINT

APPARATUS LOCAL - 1

19 TITRATION APPARATUS 10 20 DISTILLATION UNIT BOROSIL 2 21 FLASK, BEAKER,

BURETTE, PIPETTE BOROSIL 15 Each

22 VISCOSITY METER 2 23 LAB STIRRER REMMI 4

Table 2.12 :Plant Machineries:

S.NO. MACHINE DESCRIPTION CAPACITY No. 1 S.S.REACTOR 3 KL 2 2 S.S.REACTOR 4 KL 6


3 S.S.REACTOR 5 KL 10 4 S.S.REACTOR 8 KL 5 5 S.S.REACTOR 10KL 10 6 GLASS LINED REACTOR 6 KL 5 7 GLASS LINED REACTOR 10 KL 10 8 GLASS LINED REACTOR 20 KL 2 9 GLASS LINED REACTOR 25 KL 4 10 M.S.REACTOR 25KL 4 11 M.S.T.L REACTOR 25KL 4 12 RUBBER LINED REACTOR 3 KL 3 13 FILTER PRESS 23*18 1 14 FILTER PRESS 23*18 1 15 AGITATED NUTSCHE FILTER 5 KL 4 16 AGITATED NUTSCHE FILTER 7 KL 2 17 AGITATED NUTSCHE FILTER 9 KL 4 18 CENTRIFUGE 48 Inch 5 19 CENTRIFUGE 60 Inch 15 20 RUBBER LINED CENTRIFUGE 60 Inch 5 21 SPIN FLASH DRYER 1 Ton/Hr 3 22 ROTATORY VACCUM DRYER 760 Kg. 3 23 ACM (AIR CLASSIFYING MILL) 30 1 20 RIBBON BLENDER 600 Kg. 4 21 SPARKLER FILTER 1000 Ltr/Hr 10 22 GLASS COLUMN &

CONDENSER 20

Utilities:

S.NO. MACHINE DESCRIPTION MAKE CAPACITY 1 TUBEWELL PUMP ROCKWELL 200 LTR./MIN 2 FIRE PUMP KIRLOSKAR 18 LPS/90M/30HP

RPM2830 3 BLOWER (AIR POLLUTION) AIR TECH 100CFM 4 BLOWER (AIR POLLUTION) AIR TECH 100 CFM 5 GEN-SET CUMMINS 500 KVA

250 KVA 6 AIR COMPRESSOR ELGI 75 CFM 7 AIR COMPRESSOR ELGI 75 CFM 8 AIR COMPRESSOR ELGI 75 CFM 9 AIR COMPRESSOR ELGI 140 CFM 10 AIR COMPRESSOR ELGI 140 CFM 11 FIRE SIREN EXPRESS 1 KM 12 SOLVENT PUMP-1 KIRLOSKAR 2.0 KL/Hr 13 SOLVENT PUMP-2 KIRLOSKAR 2.0 KL/Hr 14 SOLVENT STORAGE TANK SAIFA ENGG. 25 KL 15 SOLVENT STORAGE TANK SAIFA ENGG. 25 KL 16 WATER COOLER SHRI RAM 80LTR/Hrs/60/120 17 COOLING TOWER PALTACK 500 TR 18 COOLING TOWER DELTA 250 TR 19 CHILLING UNIT (WATER) VOLTAS 48 TR 20 CHILLING UNIT (BRINE) EXCEL 25 TR& 50 TR


21 CHILLING UNIT (WATER) 200 TR 22 SOFTENER THERMAX 23 BOILER THERMAX 2 MT/hr 24 BOILER LALSONS 400 Kg/Hr 25 VACCUM EJECTOR 730 mm/hg 26 STEAM EJECTOR 740 mm/hg 27 OXYGEN FEEDER 10 cylinder 28 OIL VACCUM PUMP 730 mm/hg 29 SCRUBBER SYSTEM 1500 rpm 30 LATHE MACHINE. 14‘ 14‘ 31 DRILL MACHINE BOSCH 32 GRINDER MACHINE

2.5. Basic Requirements of the Project

2.5.1. Land

The project will be set up in an approved/ existing industrial zone where all required infrastructure is available. In addition all arrangements will be made to ensure environment protection inside the factory & surroundings

Total Plot Area: 20183 sq. m. The total area requirements for manufacturing facility are given below in the table.

Table 2.13 Land Distribution

Facility Area, m2 Remarks Manufacturing 12000 120m x 100m space in the manufacturing Solvent Recovery System

300 30m x 10 m space towards north of New Manufacturing facility

Tank Farm 300 30m x 10m space near existing area Total 12600 Non Processing Area 7500 Empty Space Grand Total 20100

2.5.2. Raw Material Requirement

The basic raw materials required for the formation of various pesticides proposed in this project are given in Table 2.14 along with source, mode of transport and storage capacity.

Table 2.14 Raw Materials

Sr. No

Name of Raw Material

Source/ Mode of Transport

Storages (MT) Remarks Existing Proposed

1 Phenol Import&Domestic/ By Road

40 KL -- Storage Tank – 4 No‘s Capacity – 10 kl each

2 Chlorine Domestic/ By Road

43.2 MT 86.4 MT Cylinders Storage Capacity – 900 Kg

3 Mono Chloro Acetic Acid (MCA)

Domestic/ By Road

20 MT -- Bags in Storage Yard Size of Bag – 25 kg

4 Sodium hydroxide (Caustic Soda)

Domestic/ By Road

65 KL -- Storage Tank – 4 No‘s Capacity – 16 Kl each

5 Hydrochloric Acid In-house/ Domestic

50 KL -- Storage Tank – 5 No‘s Capacity – 10 kl each


6 Dimethyl Amine Domestic/ By Road

32 KL -- Storage Tank – 2 No‘s Capacity – 16 Kl each

7 Sulphuric Acid Domestic/ By Road

20 KL -- Storage Tank – 1 No Capacity – 20 Kl

8 Ethanol Domestic/ By Road

28 KL -- Underground Storage Tank, Capacity – 28 Kl

9 RHydroxy- phenoxyPropoinic Acid

Domestic/ By Road

-- 10 MT Corrugated Drums in Storage Yard Size of Drum – 25 Kg

10 Chloro Di-Flouro Pyridine

Domestic/ By Road

-- 10 KL Drums in Storage Yard Size of Drum – 200 Ltr

11 Propargyl Chloride Domestic/ By Road


12 Tetra Butyl Ammonium Bromide

Domestic/ By Road


13 Acetonitrile Domestic/ By Road


14 Isopropyl Alcohol Domestic/ By Road


15 2,4 – DichloroVelorophenone

Domestic/ By Road


16 1,2,4 Triazole Domestic/ By Road

-- 10 MT Bags in Storage Yard Size of Bag – 25 kg

17 Petroleum Ether Domestic/ By Road


18 Di Methyl Sulphide Domestic/ By Road


19 Di Methyl Sulphate Domestic/ By Road


20 Di Methyl Formamide

Domestic/ By Road


21 Cyanuric Chloride Domestic/ By Road

-- 10 MT Jumbo Bags in Storage Yard Size of Bag – 500 kg

22 Potassium Carbonate

Domestic/ By Road


23 Ethyl Amine Domestic/ By Road


24 Carbon Tetrachloride

Domestic/ By Road


25 Toluene Domestic/ By Road

-- 28 KL Underground Storage Tank, Capacity – 28 Kl

26 1-Tetra Butyl Domestic/ By Road


27 n-chloro n-phenyl carbamye chloride (MPC)

Domestic/ By Road


28 Mono Chloro Benzene (MCB)

Domestic/ By Road


29 Methanol Domestic/ By Road


30 Cyhalothric Acid Domestic/ By Road

-- 10 MT Corrugated Drums in Storage Yard


Size of Drum – 25 Kg

31 Metaphenoxybenzaldehyde (MPB)

Domestic/ By Road


32 Sodium Cyanide Domestic/ By Road


33 Hexane Domestic/ By Road


34 Thionyl Chloride Domestic/ By Road


35 Sodium Bicarbonate Domestic/ By Road


36 Sodium Carbonate Domestic/ By Road


37 Di Isopropyl Amine Domestic/ By Road


38 Sodium Hypochloride

Domestic/ By Road


39 Triethyl benzyl amine (TEBA)

Domestic/ By Road


40 Cypermithric Acid Chloride

Domestic/ By Road


41 Acrylonitrile Domestic/ By Road


42 Cupric Chloride Domestic/ By Road


43 Iso Butylene Domestic/ By Road

-- 10 MT Bullet Tank – 1 No Capacity – 10 MT

44 Triethylamine Domestic/ By Road


45 n-PhosphonomethylIminodiacetic Acid (PMIDA)

Import &Domestic/ By Road

-- 10 MT Jumbo Bags in Storage Yard Size of Bag – 500 kg

46 Hydrogen Peroxide Domestic/ By Road

-- 10 MT HDPE Carboy in Storage Yard Size of Drum – 25 Kg

47 Sodium Tungstate Domestic/ By Road


48 Ferrous Sulphate Domestic/ By Road


49 Sodium Bi Meta Sulphate

Domestic/ By Road


50 Triflouro Acetic Acid Domestic/ By Road

-- 10 KL Storage Tank – 1 No Capacity – 10 Kl

52 ThioPyrazole Domestic/ By Road


53 Dichloromethane Domestic/ By Road

-- 10 KL Storage Tank – 1 No Capacity – 10 Kl


54 Benzene Domestic/ By Road


55 Bromine Domestic/ By Road

-- 1 MT Bottles in Storage Yard Size of Bag – 5 kg

56 Ferrous Chloride Domestic/ By Road


57 Sodium ThioSulphate

Domestic/ By Road


58 Formic Acid Domestic/ By Road


59 DMPAT Domestic/ By Road


60 Acetic Anhydride Domestic/ By Road


61 Ethyl Acetate Domestic/ By Road


2.5.3. Water Requirement

Process water requirement will be mainly for washing, scrubber, boiler, cooling, flushing, gardening and sanitary purposes. The unit has a tube well to supply water. The ground water requirement shall be approximately 8 KLD. Groundwater is not used for irrigation purpose in the vicinity. Canal water is available in the area for irrigation. Only drinking water shall be taken from groundwater in the industries and villages. Water generated in the process shall be separated in distillation unit and will be treated in ETP and reused to meet water requirements for horticulture and greenery in the plant premises.

Existing Water Consumption: 20 KLD

After Proposed Expansion: 28 KLD

Table 2.15 Water Balance (Existing/After proposed Expansion)

Sr. No.

Water Consumption Area Existing, KLD Proposed Expansion,

KLD 1. Domestic 2.5 - 2. Industrial

i. Processing 10 6.5

ii. Boiler / Cooling 2.2 0.5

iii. Washing 2.0 1.0

iv. Horticulture 3.3 -

TOTAL 20 KLD 8 KLD Grand Total 28 KLD

Water Balance [Existing Operation]


Water Balance (after Expansion)

2.5.4. Fuel

HSD is used in DG Sets. Fuel consumption in the plant is as given below:

S. No.

Equipment Type of Fuel used

Fuel consumption (~ per Day) Existing Proposed

(additional) Total

1 DG Set (On during Power

failure)

HSD 300 Litre 200 Litre 500 Litre

2 Boiler Coal 2 Ton 3 Ton 5 Ton

2.5.5. Steam Generation


Boiler of 2 TPH capacity will be used to supply steam in the process.

2.5.6. Power Requirement

The power supply shall be from JVVNL (1000 KVA). In addition there is one DG set capacity 500 KVA (to be used in case of no supply from JVVNL) and 250 KVA for lighting in the night.

2.5.7. Man Power

The project is intended to use skilled manpower. At present the unit is operating in batch mode. After the proposed expansion unit will operate more or less on 24 hrs.Continuous basis.

Project will provide direct & indirect benefit to more than 200 people

2.6. Generation of Pollutants

The generation of pollutants associated with the Ambey proposed expansion of pesticide manufacturing plant can be in the form of liquid effluent, solid waste, hazardous waste, emissions and noise pollution.

2.6.1. Liquid Effluent

The process for formulation of Pesticides is very simple as mentioned the sub head manufacturing process above. It is normally a batch process. However during manufacturing process no effluent in the form of solid, liquid and gaseous state is discharged in this process. Hence there is no pollution in any form during the manufacture of above quoted items. More over unit will install suction hoods to control the fume and dust if discharged at the time of manufacturing. In addition to these measures, the unit holder shall comply with the instructions of the board from time to time. The system is technically feasible and it would also not affect the viability of the project. Necessary provision for soakage pit/ septic tank has been made towards human waste treatment as per the accepted.

Table 2.16 Existing and proposed waste water generation

S No. Waste Water Generation Existing, KLD Proposed Expansion,

KLD

1. Domestic - -

2. Industrial

i. Processing 2.0 1.0

ii. Boiler / Cooling -

iii. Washing 1.0 0.5

iv. Horticulture -

TOTAL 3.0 KLD 1.5 KLD

Grand Total 1.5 KLD

Process Description of Effluent Treatment Plant:


Existing ETP consisting of primary, secondary and tertiary treatment facility to effluent to

be generated. Detail of the ETP plant is as below:

First all biodegradable streams (Stream II) of wastewater (low TDS) shall passed through Screen Chamber where Then effluent shall be collected in Collection tank. Pipe grid is provided at bottom of the tank to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1 stand‐ by) shall supply air through diffusers to pipe grid.

All biodegradable streams (Stream I) with high TDS shall collected in Collection Tank. Pipe grid is provided at bottom of the tank to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1 stand‐ by) shall supply air through diffusers to pipe grid. Then effluent will be sent for further treatment.

Then after, equalized wastewater shall be pumped to Neutralization Tank where the continuous addition and stirring of lime solution is done to maintain the pH of wastewater from Lime Dosing Tanks as per requirement by gravity. Then after, neutralized wastewater shall go to Flash Mixer by gravity. Alum and Polyelectrolyte shall be dosed to carry out coagulation by using a Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Clarifier. Clear supernatant from Primary Clarifier shall be passed in Aeration Tank‐ 1. Here, biodegradation of organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the AT‐ 1 and for that oxygen shall be supplied by 2 nos. of air blowers through diffusers. Air blowers also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Clarifier from AT‐ 1. Here the suspended solids shall be settled. Sludge shall be removed from bottom and pumped to AT‐ 1 to maintain MLSS and excess activated sludge shall be sent to Sludge tank. Clear supernatant from AT‐ 1 shall go to Aeration Tank‐ 2. Here, further biodegradation of organic matter of the wastewater shall be carried out by bacteria (suspended growth) and for that oxygen shall be supplied by 2 nos. of air blowers (B‐ 02) through diffusers.

Thereafter, the wastewater shall be passed through Pressure Sand Filters to remove left out TSS and Activated Carbon Filters for final effluent polishing. After tertiary treatment, effluent shall be collected in Treated Effluent tank. Treated effluent will be sent to solar cum forced evaporation tank.


Figure 2.3 : Effluent Treatment Facilities at Ambey

Further, we proposed to upgrade the ETP system for reutilization of treated water. The system is attached with photo oxidation, ultra filtration and further Nano filtration. The photo oxidation is the unique feature of the system where liquid oxygen dosing will takes place by means of oxygen concentrator. This is electro – mechanical device which can minimize BOD & COD load of the trade effluent almost Nil. The system is based on latest & modern technology available. The system is based on the ―Physico – Chemical Nature‖ where consistent chemical dosing is the heart of the system & it is done by means of AUTO – DOSING MECHANISM.

2.6.2. Solid Hazardous Wastes

The solid and hazardous wastes generated from the plant operations is of one category as per the Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2008. The hazardous waste category along with quantity and mode of storage and disposal have been presented in the Table below.

Table 2.17 Details of Hazardous/ Solid Wastes Generation, Storage and Disposal

S. No.

Hazardous Waste

Category No.

Quantity MT/Annum

Mode of storage and disposal

Existing Proposed Total after proposed expansion

1 Used oil 5.1 -- 1.0 1.0 Disposal through approved vendor / agency

2

Solid Waste

19.1 2.4 2.6

5.0

HDPE Bags in Sludge Store room. Disposal through approved vendor /


agency (Rajasthan Hazardous waste Management Project Udaipur)

The company has provided adequate separate storage area/ space for the storage of hazardous/ solid wastes generated in the plant.

The sewage generated presently sent to the septic tank. It is proposed to install a small package Sewage Treatment Plant (STP) of 5 KLD capacity within the plant premises in order to manage the sewage generated within the plant. The treated water and cake from the STP shall be used in the horticultural activities within the plant site. The Municipal waste generated shall be collected in the waste bins separately and shall be disposed off in the Municipal bins from where it shall be take further for landfill as per the Municipal norms.

2.6.3. Air Emissions

The equipment which can generate air emissions, are mainly boiler and process emissions from reactors through scrubbers. The DG set will be used only in case of power failure. The details of flue gas stack and process stack and DG stack have been presented in Table 2.4.

In addition to that fugitive emissions can also occur due to various process emissions. Movement of vehicles will also generate some air emission.

Table 2.18 Stacks of Boiler and DG set

Sr. NO.

Stack Attached to

Type of Fuel

Stack Height in m

Fuel consumption

No. of Operating Hours

1 Boiler– 2 Ton/Hr Coal 30 2Ton per day 15 2 D.G- 500KVA Diesel 8 300 Ltr per day Depends on Power Failure 3 D.G- 250 KVA Diesel 8 200 Ltr per day Depends on Power Failure

Table 2.19 Process and Utility Stacks:

Sr. NO.

Process Vent Attached to

Air Pollution Control Measure

Stack Height in m

Emission Parameters

1

Hot Air Generator with Dust Extraction System (Dryer)

Multi Cyclone 15

Particulate Matter – Less Than 50 mg/Nm3

2 2,4-D Sodium Salt Reactor for HCL

Water and Caustic Multistage Scrubber

15

Hydrochloric Acid Vapour – Less than 20 mg/Nm3 Chlorine – Less than 9 mg/NM3

3 Lambda Cyhalothrin Reactor for HCL

Water and Caustic Multistage Scrubber 15

Hydrochloric Acid Vapour – Less than 20 mg/Nm3

4 Lambda Cyhalothrin Reactor for SO2

Glass Column Packed Scrubber

(Caustic) 15

SO2 Vapour less than 10 mg/Nm3


5 Cypermethrin Reactor for HCL

Water and Caustic Multistage Scrubber 15

Hydrochloric Acid Vapour – Less than 20 mg/Nm3

6 Cypermethrin Reactor for SO2


(Caustic) 15

SO2 Vapour less than 10 mg/Nm3

7 Deltamethrin Reactor for HBr


(Caustic) 15

HBr Vapour less than 5 mg/Nm3

8 MPB Reactor for HBr Glass Column

Packed Scrubber (Caustic)

15 HBr Vapour less than 5 mg/Nm3

9 Boiler

Adequate Stack Height 30

Particulate Matter – < 75 mg/Nm3

SO2 ---<200 mg/Nm3

Table 2.20 Emission Load

Particulars Details for the Source Source / Stack No.

1 2 3 4 5 6 7 8 9

Emission height, m

15 15 15 15 15 15 15 15 30

ID of Stack at top, m

0.25 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.5

Volume flow, Nm3/hr

1225 1000 900 900 900 900 900 1000 1200

Exhaust Temp, 0C

160 80 95 95 100 100 100 90 160

Efflux Velocity, m/s

11.0 5.0 4.0 4.0 4.0 4.0 4.0 5.0 6.7

Emission Load Kg/hr

Particulate matter

0.612 --- --- --- --- 0.009 --- --- 0.09

SO2 --- --- --- 0.009 --- --- --- --- 0.24 NO2 --- --- --- --- --- --- --- --- --- HCl --- 0.02 0.018 --- 0.018 --- --- --- --- HBr --- Cl—

0.009

--- --- --- --- 0.0045 0.005 ---

Well-designed counter current absorption system in scrubber will be used for scrubbing of process generated emissions. The gases will be scrubbed with dilute caustic as scrubbing media before releasing in atmosphere. The brief of two scrubbing system are as given below. The schematic diagram of scrubber system has been presented in Figure 2.5.


Figure 2.4 : Air Pollution Control System [Dust Extraction System for Hot Air Generator (Dryer of Sodium Salt Plant

Figure 2.5 Air Pollution Control Measures [Scrubbing System]

2.6.4. Noise Pollution

Major sources of noise generation in the plant will be equipment, pumps, DG set blowers, compressors etc. The major equipment will be fitted with noise abatement systems. The personnel will be exposed to noise for short periods during which they will wear noise protection devices. Acoustic enclosure will be installed to control the noise.

2.7. Management of Fly Ash

In proposed Boiler, coal will be used as fuel as a result fly ash will be generated around 0.5 MT/day. Fly ash can be used for the commercial applications in cement industry, brick making industry, etc.


Recommendation

Probable Areas for Ash Utilization

The probable areas of fly ash utilization can be categorized in to bulk utilization and value added products.

Category 1: Utilization in bulk

Land Levelling Construction of pavements, road and associated infrastructure

Category 2: Value added Products

Manufacturing of Portland Pozolona Cement Fly ash bricks Fly ash concrete blocks Thermal insulation bricks Ceramic products

To considering the low volume of Fly ash, we recommended to utilize it by local brick

manufacturer working in 25 km radius from project site. Unit will provide it to brick

manufacturer with no cost.

2.8. OHS System and Safety Measures

2.8.1. Process Safety:

Flameproof equipment‘s and fittings are provided for handling of hazardous chemicals.

Tanks and all pump motors are earthed. Road tanker earthing lines have been provided near the unloading pumps. Dykes have been provided for hazardous chemicals storage to contain

leakages. Floors of the dyke area have impervious finish. Housekeeping of the plant is as per prescribed norms. Floors, platforms,

staircases, passages are kept free of any obstruction. All hazardous operations are explained to the workers. They are periodically

trained on the hazardous processes. Dedicated supply of firewater is available in the plant. Only authorized persons are allowed inside the plant. All instrument and safety devices are checked and calibrated during installation.

They are also calibrated, checked at a frequent interval. Calibration records are maintained.

All electrical equipment‘s are installed as per prescribed standards. All the equipment‘s of the plant are periodically tested as per standard and

results are documented. All equipment‘s undergo preventive maintenance

schedule. Hydrant system is pressured with a Jockey Pump. Flame arrestor is provided on each tank. Pressure gauge is provided on each tank.


In addition to fire hydrant system, nos. of fire extinguishers is also installed at different locations within premises.

Retention basin is provided to collect the contaminated water used during firefighting.

Adequate ventilation arrangement has been provided for safe and better working in the plant as per the standard.

Process, equipment, plant involving serious fire hazards are designed as per prescribed guideline.

2.8.2. For Underground and above ground storage tank farm:

Class A petroleum products will be received through road tanker and stored in underground storage tank as per petroleum rules.

Tank farm will be constructed as per explosive department requirement and separation distance will be maintained.

Static earthing provision will be made for road tanker as well as storage tank.

Flame arrestor with breather valve will be provided on vent line.

Road tanker unloading procedure will be prepared and implemented.

Fire load calculation will be done and as per fire load Hydrant System will be provided as per NFPA std. and Fire extinguishers will be provided as per fire load calculation.

Spark arrestor will be provided to all vehicles in side premises.

Flame proof type equipment‘s and lighting will be provided.

Lightening arrestor will be provided on the top of chimney.

Trained and experience operator will be employed for tank farm area.

NFPA label (hazard identification) capacity and content will be displayed on storage tank.

Solvents will be transferred by pump only in plant area and day tank will be provided. Overflow line will be return to the storage tank or Pump On-Off switch will be provided near day tank in plant.

Jumpers will be provided on solvent handling pipe line flanges.

Flexible SS hose will be used for road tanker unloading purpose and other temperature connection.

2.8.3. For Drum Storage area:

Some chemicals will be received at plant in drums by road truck and stored in a separate

drum storage area.

FLP type light fittings will be provided.

Proper ventilation will be provided in godown.

Proper label and identification board /stickers will be provided in the storage area.

Drum handling trolley / stackers/fork lift will be used for drum handling.


Separate dispensing room with local exhaust and static earthing provision will be made.

Materials will be stored as per its compatibility study and separate area will be made for flammable, corrosive and toxic chemical drums storage.

Smoking and other spark, flame generating item will be banned from the Gate.

2.8.4. Transportation:

Class A petroleum products will be received through road tanker and stored in underground storage tank as per petroleum Act & Rules.

Road tanker unloading procedure will be in place and will be implemented for safe unloading of road tanker.

Static earthing provision will be made for tanker unloading.

Earthed Flexible Steel hose will be used for solvent unloading from the road tanker.

Fixed pipelines with pumps will be provided for solvent transfer up to Day tanks/reactors.

Double mechanical seal type pumps will be installed.

NRV provision will be made on all pump discharge line.

Table 2.21 Transportation, Unloading and handling procedure

ACTIVITY TYPE OF POSSIBLE HAZARD

MITIGATION MEASURES

Transportation of Chemicals like HCl, Formic Acid, NitricAcid, Bromine andH2SO4 &Solventsby road tanker

Leakage& Spillage Fire,& explosion, Toxic release

• Check the source of leakage point. • Do not touch damaged containers or spilled material unless wearing appropriate protective clothing. • Stop leak if you can do it without risk. • Use water spray to reduce vapors; do not put

water directly on leak, spill area or inside container. • Keep combustibles (wood, paper, oil, etc.) away from spilled material. • Isolate the area • Isolate the container • Training will be provided to driver and cleaner

regarding the safe driving, hazard of Flammable chemicals, emergency handling. • TREM card will be kept with TL. • Fire extinguishers will be kept with TL. • Flame arrestor will be provided to TL exhaust. • Instructions will be given not to stop road

tanker in populated area. • Clear Hazard Identification symbol and


emergency telephone number will be displayed as per HAZCHEM CODE. • Appropriate PPEs will be kept with TL.

HCl, Formic Acid, Nitric Acid, Bromine and H2SO4 & Solvents Road tanker unloading at project site.

Leakage& Spillage Fire,& explosion, Toxic release

• Check the source of leakage point. • Do not touch damaged containers or spilled material unless wearing appropriate protective clothing. • Stop leak if you can do it without risk. • Use water spray to reduce vapors; do not put

water directly on leak, spill area or inside container. • Keep combustibles (wood, paper, oil, etc.) away from spilled material. • Isolate the area • Isolate the container • Check the source of leakage point. • Spray the water on leakage • Priority will be given to Tanker to

immediatelyenter the storage premises at site and will not be kept waiting near the gate or the main road. • Security person will check License, TREM

CARD, Fire extinguisher condition; Antidote Kit, required PPEs as per SOP laid down. • Store officer will take sample as per sampling

SOP from sampling point. • After approval of QC department unloading procedure will be allowed be started. Following precautions will be adopted during unloading • Wheel stopper will be provided to TL at

unloading platform. • Static earthing will be provided to road tanker. • Tanker unloading procedure will be followed according to check list and implemented. • Flexible SS hose connection will be done at TL

outlet line. • The quantity remaining in the hose pipeline will

be drained to a small underground storage tank, which will be subsequently transferred by nitrogen pressure to the main storage tank thus ensuring complete closed conditions for transfer from road tanker. • All TL valves will be closed in TL. • Only day time unloading will be permitted.

HCl, Formic Acid, Nitric Acid,

Leakage& Spillage,

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


Bromine and H2SO4 & Solvents Storage tank safety

Fire, Explosion Toxic release.

material unless wearing appropriate protective clothing. • Stop leak if you can do it without risk. • Use water spray to reduce vapors; do not put

water directly on leak, spill area or inside container. • Keep combustibles (wood, paper, oil, etc.)

away from spilled material. • Isolate the area • Isolate the container • Check the source of leakage point. • Spray the water on leakage • SS storage tank will be provided as per IS

code. • Dyke wall will be provided to storage tank. • Level transmitter will be provided with lowlevel

high level auto cut-off provision. • Vent will be connected to water trap and vent of water trap will be provided with flame arrestor. • Water sprinkler system will be provided to

storage tank. • Fire hydrant monitor with foam attachment

facility will be provided. • Dumping / Drain vessel/alternate vessel will be provided to collect dyke wall spillage material. • FLP type pump will be provided. • Nitrogen blanketing will be provided to storage

tank. • Double static earthing will be provided to

storage tank. Double Jumper clip will be provided to all Solventhandling pipeline flanges.

HCl, Formic Acid, Nitric Acid, Bromine and H2SO4 & Solvents transfer from storage tank to Day tank.

Leakage& Spillage due to Line rupture, Flange Gasket failure, Fire, Explosion, Toxic release.

• Double mechanical seal type FLP type pump will be provided. • Double on / off switch will provided at tank farm

and process area near day tank. Pump auto cut off with day tank high level will be provided. • Flame arrestor will be provided on day tank

vent. • Over flow will be provided for additional safety and it will be connected to main storage tank. • NRV will be provided on pump discharge line. • Double Jumper clip will be provided to all

solvent handling pipeline. Double static earthing will be provided to day tank.

Transportation of Leakage, Spillage • Gravity transfer.


Chemicals like HCl, Formic Acid, Nitric Acid, Bromine and H2SO4 & Solvents transfer from Day tank to reactor.

due to Line rupture, Flange Gasket failure, Fire, Explosion, Toxic release.

• Total quantity of day tank material will be charged in to reactor at a time. • Static earthing will be provided to storage tank. • Double Jumpers will be provided to pipeline

flanges.

2.9. RESOURCE RECOVERY

2.9.1. GREEN BELT DEVELOPMENT

The unit have existing green belt in 4500 sqm and Ambey will do extensive plantation in 2160sqm areas. The total green belt area will be 6600 sqm out of total 20183 sqm. So greenbelt will be in 33% of total area.

2.9.2. RAIN WATER HARVESTING

Rain Water Harvesting is a method of utilizing rain water for domestic and agricultural use is already widely used throughout the world. It is a method which has been used since ancient times and is increasingly being accepted as a practical method of providing potable water in development projects throughout the world. Improve the ground water in Industrial area is one of the main problems which is being faced by developed countries of the world. In Industrial area, charging of underground water in natural way like rural areas is not taking place due to large sprawl of Industrial activities. But it is feasible by injecting the water by percolating wells. To considering the Industrial area and various types of activities may contaminate the rain water, recharging the rain water by injecting the rain water to underground aquifers is not advisable. Ambey will partial reuse the rain water collect from rooftop during the rainy season.

2.10. SOLVENT MANAGEMENT PLAN

All the solvents shall be directly distilled from product mixes and purified in packed column with the help of reflux.

The solvent distillation system shall be designed so as to achieve minimum 93 ‐ 98 % recovery of solvent.

Pure solvent, crude solvent and distilled (recovered) solvent shall be stored only in storage tanks and we shall not be using drums at any stage in the Solvent Management System.

Wherever required, the solvents shall be directly pumped into day tanks from the storage tanks and shall be charged into the reactors without involving any manual handling.

All the pumps shall be mechanical seal type to avoid any leakage of solvent. All necessary fire fighting systems shall be provided with alarm system. Flame

proof wiring and flame proof electrical accessories shall be provided to avoid any mishap.

All the storage tank and day tank shall be connected to a vent system through chilled water and chilled brine condensers to prevent loss of solvents in the atmosphere.


All the distillation column vents are also connected to chilled water/ chilled brine condensers for maximum possible recovery of the solvents.

All the vents will be connected to a common carbon Absorber for removing traces of solvent from vent gases.

Residue generated from the distillation will be incinerated sent to common incinerator site.

Coolant to be used Primary Condensers Cooling Water Secondary Condensers Chilled water up to +5o C Vent Condensers Brine up to ‐10o C

2.11. Project Cost and Cost towards Environmental Protection

The total project investment will be about Rs. 12Crores, out of which Rs. 0.5 Crores will be allocated for pollution control equipment including scrubbers, effluent treatment plant, etc.

2.12. CSR Activities [Existing / Proposed]

We at Ambey are committed to the prosperity of India's agricultural community. We are dedicated to the well-being of not only the individual farmer but his family and his community as well.

We undertake several social service activities that better the lives of the agricultural community as a whole. This includes providing public utility services, sponsoring rural sports. We provide scholarships to farmers' children so that they may attain professional degree courses in engineering and agriculture.


Renovation of Govt. High School, Goonti, Behror.

Ambey Laboratories Pvt. Ltd. Provided financial assistance to renovate the Government High School in the Mutage village of Behror. The company provided aid in constructing toilets for girls; it also provided cemented tiles for the Assembly Hall and ceiling fans for classrooms.

Development of Nearby Village “Jainpurwas”

Jainpurwas is located at a distance of 2 km in SE Direction from Ambey‘s Site. We

Ambey adapt the village for its development.In order to provide better living conditions for inhabitants of Jainpurwas village, Ambey helped in levelling the roads with truckloads of soil and making the main road made up of tar, Drainage gutters and Street Lights etc.

Sponsoring Rural Sports

Competition is part and parcel of life. Ambey seeks to instil the spirit of competition in the young and the young at heart by sponsoring various rural sports competitions. These sports activities range from Cricket and kabaddi tournaments to popular rural sports such as bullock cart racing. Ambey conduct these activities at nearby village ―Jainpurwas‖ by inviting numerous villages of Behror City to participate in the

Competition.

Traffic sign board display

For proper regulation of traffic control in Behror city, the Company has supplied and displayed various types of traffic sign boards such as Entry, No Entry, and Two Wheeler Parking, Four Wheeler Parking etc. in all important roads and by lanes. In all the Company has supplied / displayed 120 such boards in Behror.

Public Utilities

In order to improve the quality of life of the Indian farmer, Ambey has undertaken numerous welfare programs. The activities undertaken as part of this program include providing facilities for drinking water, toilet facilities, etc.

The company has even undertaken planting of trees along highways.

The activities that can be undertaken by the Company on CSR shall be as specified in Schedule VII to the Companies Act, 2013, as amended from time to time and shall include the following:

Eradicating hunger, poverty and malnutrition, promoting preventive health care and sanitation.

Promoting education, including special education and employment enhancing vocation skills especially among children, women, elderly and the differently abled and livelihood enhancement projects.

Promoting gender equality, empowering women, setting up homes and hostels for women and orphans; setting up old-age homes, day care centers and such other facilities for senior citizens and measures for reducing inequalities faced by socially and economically backward groups.


Ensuring environmental sustainability, ecological balance, protection of flora and fauna, animal welfare, agro forestry, conservation of natural resources and maintaining quality of soil, air and water.

Protection of national heritage and art and culture including restoration of buildings and sites of historical importance and works of art; setting up public libraries; promotion and development of traditional arts and handicrafts.

Measures for the benefit of armed forces, veterans, war widows and their dependents.

Training to promote rural sports, nationally integrated sports, Paralympic sports and Olympic sports.

Contribution to Prime Minster Relief fund or any other fund set up by the Central Government for socio-economic development and relief and welfare of the Scheduled Castes, Scheduled Tribes, Other Backward Classes, minorities and women.

Contributions or funds provided to technology incubators located within academic Institutions which are approved by Central Government.

Rural development projects.

2.13. CREP Compliance

The guidelines enunciated by CPCB are very helpful to mitigate environment pollution, improve human health and benefit of cost savings by cutting cost of valuable solvent by efficient recovery system. We (Ambey) will adopt all the guide lines as stated here under.

Table 2.22 CREP Guidelines Compliance

Sr. No CREP Point Ambey Compliance 1

Segregation waste streams: Waste streams should be segregated into COD waste, toxic waste, low COD waste, inorganic waste etc, for the purpose of providing appropriate treatment.

Generated and segregated inorganic toxic waste for the safe disposal through approved vendor / agency (Rajasthan Hazardous waste Management Project Udaipur)

2

Detoxification and treatment of high COD waste streams: Streams should be detoxified and treated in CTP or thermally destroyed in incinerator, as per CPCB guidelines. The waste streams should be treated suitably before taking to evaporationponds.

We have improved our ETP System to treat Effluent before taking to evaporation ponds.

3

Improvement in solvent recovery: – Solvent recovery should be improved and attempts should be made to achieve at least 90% recovery wherever possible. – Rest of the solvents which cannot be recovered shall be incinerated.

We have improve the cooling and chilling efficiency to get better recovery. Residue will arrange to send for incineration to approved vendor / agency (Continental Petroleum‘s Ltd Behror).

4

Hazardous air pollutant control: – For air pollution control from processes, scrubber efficiency will be improved and

Installed scrubber and stacks for reducing the Air pollution


maintained as per the best practicable technology for control of HCI, CI2, Methyl Chloride, Phosphorus Pentoxide, Ammonia, H2S and VOCs.– An incinerator will be installed, where necessary.

of High efficiency.

5

Control of fugitive emissions/ VOCs: For control of fugitive emissions (particularly for hazardous air pollutions). The industries will adopt standard engineering practices. System of leak detection and repair (LDAR) programme especially for solventsshould be developed industries.

Installed the water vacuum ejector to prevent and collect the toxic vapor. These vapor dissolved into water which neutralize in scrubber system.

6

Upgrade of incinerators: Incinerators will be upgraded to meet CPCB norms hazardous waste incinerators. This is necessary for Halogenated compound and POPs.

Not Applicable

7

Replacement of Bio Assay test by toxicity Factor: The present bio-assay test will be replaced by Toxicity Factor test method developed by CPCB. Toxicity factor of four (TF-4) will be achieved and industries will improve their system to achieve TF- 2. TF test method will be implemented by PCBs/CPCB/ MoEF. The CPCB will organize workshops on ―Toxicity Factor‖ for industry.

Not Applicable

8

Minimum scale of production to afford cost of pollution load: To be decided, as industries view point is that this cannot be done as few products are costly and made in small volume. The matter will be studied in detail by MoEF/ CPCB.

Presently our production load is very low. We are keeping more budget to control the increased the pollution load.

9

Non-complying Units (as identified by SPCB) should meet the notified standards

Not Applicable

10

Bank guarantee to be submitted to SPCB by Non-complying units: The submissions from pesticides industry regarding speedy clearance and other will be considered by MoEF/CPCB for examination.

Not Applicable


CHAPTER 3. DESCRIPTION OF THE ENVIRONMENT

3.1. Method of Data Generation

The baseline environmental quality has been collected during the period of 1st Dec -2014 to 28th Feb 2015 within a study area of 10 km radial distance around the proposed Plant site. M/s Kamal Enviro & Food Lab (P) Ltd., Manesar along with EQMS Team, carried out sampling and testing. The study period and methodology for various environmental components is discussed in Table 3.1.

Table 3.1 Location Details, Period and Methodology of Baseline Data Generation

Component Study Location Study Period Methodology

Meteorology

Online monitoring station was established at Plant Site

1st Dec -2014 to 28th Feb - 2015

Hourly wind speed, wind direction, humidity, temperature, solar radiation, atmospheric pressure, rainfall were recorded.

Ambient Air Quality

AAQ monitoring was done at 8 locations

1st Dec -2014 to 28th Feb – 2015

AAQ monitoring was done by following the CPCB methods. Sampling locations were established at villages around the site at various upwind and downwind directions.

Noise Quality At 8 locations around project site

1st Jan to 8th Jan 2015

Noise monitoring was done using integrated sound level meter, as per CPCB method.

Surface water quality

At 1 locations around project site.

5th Jan 2015

Sampling was done and the samples were preserved and analyzed for relevant parameters following the methods prescribed by IS 2296:1998.

Ground water quality

At 8 location around Project Site

5th Jan 2015

Grab sampling was done and the samples were preserved and analyzed for relevant parameters following the methods prescribed by APHA.

Soil Quality

4 samples were collected from surrounding agriculture fields

10th Jan 2015

Samples were collected and analyzed for all relevant parameters by following IARI Methods.

Flora & Fauna Around study area

Winter season 2015

Secondary Data collected from Forest Department and checked during field surveys.

Landuse

Project area and 10 km area around the project site

Liss III Image - 2014

Latest Satellite Imagery (IRS P6, LISS-III) was used and analysed for land use cover

Socioeconomic scenario - Winter season

2015

Secondary Data was collected from Primary Census of India 2011


3.2. Site description

The proposed project site is located at Plot No.SP1-5, RIICO Industrial Area, Sotanala, Behror Dist. Alwar, Rajasthan. The site is very well connected to National Highway No-8 located at a distance of 0.73 Km in W direction. Nearest Railway station is Narnaul located about 26.4 km (NW) from site. Nearest Airport is IGI Airport, New Delhi located at a distance of 114 Km (NE) from the site. Map showing site and surrounding environment features within the 10 km area is provided in Figure 3.1. The salient feature of the project is given in the Error! Reference source

ot found..

Table 3.2 Salient feature of the project

Longitude 76°15'56.69"E Latitude 27°49'56.24"N Altitude 324 m above MSL Topography Plain Nearest State highway Jaipur highway (NH-8,0.73Km West) Nearest Railway station Narnaul [Distance 26.4 Kms NW] Nearest Airport IGI Delhi 114Kms,NE Nearest River No river exist Nearest Habitation Behror– 1.41 SE Nearest Seaport None in 25 Kms Nearest Sanctuary None in 25 Kms Nearest Historical Place None in 25 Kms Nearest National Park None in 25 Kms Nearest Hill None in 25 Kms Interstate Boundary Rajasthan – Haryana boundary 3.82 KM in West

Source: Field investigation

3.2.2. Topography

The district is fairly regular quadrilateral in shape. Ridges of rocky and precipitous hills for the most part parallel to each other are a feature observable throughout the district which however is generally open to the North and East. The district is characterised by north eastern part of Aravali range which runs uninterruptedly for about 81 kms intersecting the district in two parts. Major rivers of the district are Sabi, Ruparel and the tributaries of Banganga river. Different types of soils viz. Sandy loamy, sandy loam and clayey loam are found in the district. The district covers an area of 8380 sq. kms comprises 10 tehsils, namely Bahror, Mandawar, Kishangarh Bas. Tijara, Bansur, Alwar, Ranlgarh, Thanaghaji, Rajgarh, Lacchmangarh.

The region is characterized by topography of more or less flat-topped hills, which become predominant and precipitous in the south-western parts of it forming the north continuation of the main Aravalli Ranges. The most conspicuous feature of the study area is the Aravalli range. The ridges of rocky and precipitous hills for most part are parallel and are observable throughout the district.


Figure 3.1 Map Showing Site and Surrounding Environment Features within 10 km area


3.2.3. Geology Unconsolidated sediments such as alluvium and wind blown sand occupy the maximum area covering largely the older rocks formations of Delhi super group represented by Alwar and Ajabgarh groups and post Delhi intrusive covered by Quaternary Alluvium. The general geological sequence of the area established by GSI. The Geological sequence of the study area as per GSI shown in Table 3.3.

Table 3.3 Geological Sequence of the Study Area as per GSI

Recent to Sub-recent Alluvium and Wind blown sand Unconformity Post Delhi Intrusive Quartz veins, Pegmatite,

granites, and amphibolites Delhi Super group Ajabgarh group Quartzite, phyllites, mica schist,

calc schist, limestone. Alwar Group Quartzites, mica schist with

quartzites, micaceous quartzites.

Source: Secondary data (CGWB)

Alwar Group: The rocks of Alwar group are predominantly arenaceous and are represented by ortho quartzites, quartz sericite schist with minor phyllites intercalation. This group of meta sediments forms NNE SSW strike ridges. Joints are best developed in quartzites; foliation plane parallel to strike of the formation is also developed at places. These rocks are not present in the study area.

Ajabgarh Group: This group of rocks occur in the study area and is represented by a large portion of argillaceous rocks. Main rock types are phyllites, quartzites, mica schist and calc schist. Limestone is reported near Huriyan Kalan at depth of 145.3 m bgl in drilling of Central Ground Water Board. The quartose phyllite exposed around Neemrana, Nimbhar, Gunti, Tasing forms NNE SSW striking ridges running for several kilometres. Carbonaceous phyllite is noticed near Neemrana and Tasing. The meta-sediments are light grey to greyish brown in colour fine grained and exhibit slaty cleavage at places. Quartzites occur interbedded with phyllites.

3.2.4. Drainage Pattern

Because of the Semi arid climate characterized by hot summer and low to insufficient rainfall, the area do not have good drainage network, however, the Sahibi is the main river draining the area. Other than Sahibi, there are small seasonal or ephemeral streams seen during the rainy season. Following the general direction of slope, these streams have a general flow direction towards north east. The river Sahibi originates from Sawar hills in south and flows in north east direction and enters Behror block of Alwar district in which the project site is also located. The bed of river is sandy and banks are high. The other streams which are at distant from the project area are Karnali nadi, Banganga, Chaondi nala. Many small streams originating from the hills and isolated hills ranges do not join the main river system and disappear in plains and in turn acts as inland drainage. The drainage in and around the project site area is of the similar type. Some localized discontinuous drains are often seen during the rainy season, however, they do not join any major drainage system. The drainage pattern shown in Figure 3.2.


Figure 3.2 Drainage Map of Study Area

http://210.212.96.131/rpcb/Notifications/Environmental_Master_Plan_Alwar.pdf

3.2.5. Hydrogeology

The Alwar district, nestled among the hill ranges in northeastern Rajasthan, falls in the semi-arid zone with an average rainfall measuring 620 mm. The temperatures fluctuate from 0oC in winters to 490C in summers. The region was hard hit by one of the worst droughts in 1985-86. The water table receded below critical levels and rivers and wells dried up. Crop failure became common, the lack of vegetation led to soil degradation and monsoon run off caused soil erosion.

The Aravali mountain range (one of the oldest in the world) in western India runs approximately 482 km from northeast to southwest across the State of Rajasthan. Until the 1930s and 1940s, the Aravali range had verdant forest cover. A multitude of traditional water-harvesting systems ensured that the low rainfall was optimally utilised to provide an adequate water supply to the village community throughout the year. However, due to large-scale logging in later years, surface runoff increased every year, resulting in considerable depletion of groundwater recharge. The complete transfer of water management from community to government created a cycle of neglect and scorn for time-tested traditions and a dependency-syndrome among the village community. The synergy between humankind and nature that was the legacy of centuries of tradition was destroyed in a matter of decades. Drought became a recurring and grim reality in the region (Kishore, 2003).


3.2.6. Groundwater Scenario

The main aquifer around Alwar is contained within unconsolidated quaternary formations of silt, sand kankar and boulder, and is reported to have a potential yield of 20-30 m3/h. According to the GOI Central Ground Water Board (CGWB 2006 2), groundwater occurs under unconfined conditions at shallow depth (18-28 m below ground level) and in a semi-confined condition at deeper levels (around 65 m), and is tapped by a number of tube-wells, which discharge at a rate of between 25 and 68 m3/h. Seasonally the aquifer declines between November and May and recharge begins with the monsoon rains in mid-June. However there has been an alarming decline over the past 20 years from over-extraction and low rainfall, and CGWB reports that the water table in Alwar town has fallen from 9 m in 1984 to 27 m in 2004, at an average rate of 0.91 m per year. Agriculture accounts for more than 80% of the use, and major reductions occur during Rabi crop irrigation in October-April. Groundwater quality has also declined as a result of urbanization, disposal of untreated domestic and industrial wastewater and excessive usage of fertilizers. The water level trends shown in Figure 3.3

Source: http://www.indiawaterportal.org/sites/indiawaterportal.org/files/alwar-grndwater.pdf

Figure 3.3 Water Level Trends of Alwar district


3.2.7. Seismicity of the Study Area

According to the seismic-zoning map of India, the project area falls in Zone IV of seismicity. It thus lies among the high-risk earthquake areas. For pockets with high rise buildings, specific consideration of earthquake resistance shall be incorporated. IS 4326:1993 ‗Earthquake Resistant Design and Construction of Buildings – Code of Practice‘ and IS 13920:1993 ‗Ductile Detailing of Reinforced Concrete Structures subjected to Seismic Forces – Code of Practice‘ shall be followed as per the

requirement. The seismic study shown in Figure 3.4.

(Source: Amateur Seismic Centre, Pune, 2011)

Figure 3.4 Seismic Zones of India

3.2.8. DEM & Contour Map

Digital elevation map and contour map of the study area is provided in Figure 3.5 and Figure 3.6.


Figure 3.5 Digital Elevation Map of Study area


Figure 3.6 Contour map of Study Area


3.3. Land use

The proposed project is Industrial area development Project being developed by RIICO. The plant site is surrounded by small patches of green areas as well as barren land. There is around 62 % agricultural land in the vicinity of plant area. Further, the project is at considerable distance from any sensitive locations. The proposed project will not require conversion of any agricultural land or forest area as land is already available within designated industrial area. Land use distribution of the study area within 10 km radial zone is shown in Table 3.5 and Landuse map is shown below in Figure 3.7. and Figure 3.8 respectively.

Table 3.4 Land Use Distribution of the Study Area (10 km Radius)

Land use Category Area( sq km) Percentage Agricultural land 195.3 62.04 Agri fallow land 55.34 17.59 Vegetation/shrubs 52.24 16.60 Settlement 11.81 3.75 Waterbody 0.04 0.01 Total 314.7 100

Figure 3.7 Graph Showing Land Use of the Study Area (10 km Radius)

Landuse

Agricultural land Agri fallow land Vegetation/shrubs Settlement Waterbody


Source: Interpretation of Satellite image

Figure 3.8 Land Use Map of the Study Area (10 km Radial Zone)


3.4. Meteorology

3.4.1. Climate and Rainfall

The climate is semi-arid and mostly dry, with a hot summer period in April to July, followed by a short monsoon in July to September, and a cool dry winter period between October and March. Average daily temperatures peak at around 41 °C in June (when the minimum is 28 °C at night), and in January the temperature falls to an average of 23 °C during the day and 8 °C at night. The long term average annual rainfall is 638 mm, of which around 85% falls during the monsoon. In Table 3.5 shows the annual rainfall in the district. However rainfall is highly variable, and has been generally low in most recent years (Figure, 3.9 & 3.10).

Relative humidity is around 70% during the monsoon, but is much lower throughout the rest of the year, falling to 20-25% in the summer. Winds are generally light and variable during the cool winter period, and mainly from the north and north-west, and the strongest winds are the south-western lies that bring the monsoon in June and July.

Figure 3.9 Average Annual Rainfall in Alwar 1990-2004 (Source: http://ruidp.rajasthan.gov.in/IEE%20PDF/IEE%20Alwar%20Water%20Supply.pdf)


Figure 3.10 Rainfall Pattern of Alwar district during the period of 2010-2014

Table 3.5 Monthly Rainfall in Alwar District

Year Particulars Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

2010 Monthly rainfall 0 0 0 0 0 25 147 163 160 0 0 0 Rainy days 0 0 0 0 0 1 7 10 12 0 0 0 No. of observation 31 28 31 30 31 30 31 31 30 31 30 31





Source: http://waterresources.rajasthan.gov.in/Daily_Rainfall_Data/Rainfall_Index.htm

3.4.2. Site Specific Meteorology

Meteorological study exerts a critical influence on air quality as it is an important factor in governing the ambient air quality. The meteorological data recorded during the study period is used for interpretation of the baseline information as well as input for air quality simulation models. Meteorological data was collected during winter season 1st Dec 2014 to 28thFeb 2015. All care was taken to see that the station is free from obstructions to free flow of winds. Wind speed, wind direction, temperature and relative humidity data was collected daily on hourly basis during the study period. The summary of site specific met data is given in Table 3.6.


Table 3.6 Summary of Climatic Condition at the Site

Month Parameters Temp. (0C)

Wind Dir Wind speed (km.h)

Humidity

Dec‘14 Max 25 337 25.9 98 Min 2 0 0 15 Average 13 165 7.2 75

Jan‘15 Max 22 337 161 97 Min 5 0 0 37 Average 12 184 8 86

Feb‘15 Max 26 337 26 98 Min 9 0 0 20 Average 21 189 9 61

(Source: Field Survey)

The windrose diagram for the study area is shown in Figure 3.11 and the wind class frequency distribution is shown in following Figure 3.12. The analysis of the average wind pattern shows predominant wind direction is from W, WNW and NW with wind frequencies of 20%, 12% and 10%, respectively. Calm conditions were prevailed for 22.3% of the total time.

Figure 3.11 Wind Rose (Dec- March)

Figure 3.12 Wind Frequency Distribution


3.5. Ambient Air Quality

CPCB guidelines were applied for selecting the appropriateness of monitoring locations. The location and height of the stations were so selected (>5 m from base) to avoid the capture of re-suspended road dust and fugitive domestic emissions due to burning of domestic fuels. All the ambient air analysis with respect to each parameter were analysed as per CPCB guidelines. Details of monitoring locations are shown in Table 3.7. Monitoring Location map is shown in Figure 3.13.. The summary of Ambient Air quality results is presented in Table 3.8

Table 3.7 Ambient Air Quality Monitoring Locations

Location Code

Name of Location

Distance& Direction from

site Direction Terrain Features

AAQ-1 Project Site 00 00 Flat terrain, Industrial area

AAQ-2 Jainpurwas 1.16 SE Rural, flat terrain, surrounded by Agricultural land

AAQ-3 Shimla 2.55 NE Rural, flat terrain, located in downwind direction

AAQ-4 Mordha 2.60 S Rural, flat terrain, surrounded by agricultural land, located in upwind direction.

AAQ-5 Morodi 6.17 SE Rural, flat terrain, surrounded by agricultural land

AAQ-6 Paniyala 4.37 SSW Rural, flat terrain, surrounded by agricultural land, crosswind direction.

AAQ-7 Malpura 1.80 W Rural, flat terrain, surrounded by agricultural land, located in downwind direction.

AAQ-8 Gandoj 5.61 NW Rural, flat terrain, surrounded by agricultural land, located in downwind direction.

Table 3.8 Summary of Ambient Air Quality Monitoring Results (24-hour average)

Location/Parameters (µg/m³) PM10 PM₂.₅ SO₂ NOx CO HC Methane Non-methane

Project Site Max 102 43 13.7 23.6 1060 BDL (1) BDL (1) Min 71 27 8.0 10.8 650 BDL (1) BDL (1) Mean 88 34 10.0 17.2 869 BDL (1) BDL (1) 98 Percentile 100 42 13.2 22.2 1037 BDL (1) BDL (1)

Jainpurwas Max 96 41 15.6 24.3 890 BDL (1) BDL (1) Min 61 24 9.3 12.3 470 BDL (1) BDL (1) Mean 79 35 12.2 17.9 633 BDL (1) BDL (1) 98 Percentile 96 41 15.4 23.6 858 BDL (1) BDL (1)

Shimla Max 95 41 14.7 23.5 930 BDL (1) BDL (1) Min 65 29 9.4 10.6 430 BDL (1) BDL (1)


Mean 81 35 11.7 16.8 612 BDL (1) BDL (1) 98 Percentile 94 41 14.4 23.0 866 BDL (1) BDL (1)

Mordha Max 90 36 13.9 24.1 1140 BDL (1) BDL (1) Min 69 28 8.5 11.9 730 BDL (1) BDL (1) Mean 78 32 11.5 17.3 915 BDL (1) BDL (1) 98 Percentile 90 36 13.9 23.5 1126 BDL (1) BDL (1)

Morodi Max 86 35 13.6 23.8 1070 BDL (1) BDL (1) Min 67 28 8.3 11.5 640 BDL (1) BDL (1) Mean 77 31 11.4 16.8 828 BDL (1) BDL (1) 98 Percentile 86 35 13.5 23.0 1038 BDL (1) BDL (1)

Paniyala Max 83 38 13.5 25.7 1070 BDL (1) BDL (1) Min 60 28 8.0 16.2 610 BDL (1) BDL (1) Mean 75 32 11.0 21.1 846 BDL (1) BDL (1) 98 Percentile 83 37 13.2 25.1 1038 BDL (1) BDL (1)

Malpura Max 85 36 13.0 24.8 920 BDL (1) BDL (1) Min 65 26 7.9 15.0 460 BDL (1) BDL (1) Mean 76 31 11.2 19.6 713 BDL (1) BDL (1) 98 Percentile 84 36 12.9 23.7 915 BDL (1) BDL (1)

Gandoj Max 89 37 12.8 23.0 1090 BDL (1) BDL (1) Min 65 27 7.6 12.6 770 BDL (1) BDL (1) Mean 77 31 10.2 17.9 942 BDL (1) BDL (1) 98 Percentile 88 37 12.8 22.4 1081 BDL (1) BDL (1)

Source: Primary Data Collection and analysis during study period by Laboratory

3.5.2. Observations on Ambient Air Quality:

Particulate Matter (PM10): The average highest PM10 level observed at project site i.e. 102µg/m3 while lowest level was observed at Paniyala Village 83 µg/m3. The PM10 levels are equal to NAAQMS level of 100µg/m3. The PM10 level in the study area is on higher side this is contributed mainly due to industrial zone and vehicular movement.

Particulate Matter (PM2.5):PM2.5 levels were found ranging from 35 to 43 µg/m3 the highest PM2.5 level were found at Project site 43 µg/m3 while the lowest PM2.5 level were found at Village Morodhi 35 µg/m3 . The PM2.5 level in the monitoring location are within permissible limit i.e. NAAQMS level 60µg/m3

Sulphur Dioxide (SO2): SO2 levels were found ranging from 12.8 to 15.6 µg/m3. the highest SO2 level were found at Jainpurwas village (15.6 µg/m3) and lowest SO2 level were observed at Gandoj village (12.8µg/m3). The SO2 level in all the monitoring locations is within permissible limit i.e. NAAQMS level 80µg/m3

Oxides of Nitrogen (NOx): NOx levels were found ranging from 23.5 to 25.7 µg/m3. The highest NOx level were found at Paniyala village (25.7 µg/m3) and lowest NOx level were observed at Shimla village (23.5 µg/m3). The NOx level in all monitoring location are under permissible limit i.e. NAAQMS level 80µg/m3


Figure 3.13 Map Showing Environmental Monitoring Locations


3.6. Noise Environment

Noise after a certain level can have a very disturbing effect on the people and animals exposed to it. Hence, it is important to assess the present noise quality of the area in order to predict the potential impact of future noise levels due to the proposed project. Ambient noise measurements were taken at 8 locations, represented in Table 3.9. Location wise result for day time and night time is presented in Table 3.10.

The monitored levels were compared against the Noise Pollution (Regulation and Control) Rules 2000, as amended through the Noise Pollution (Regulation and Control) Amendment Rules 2010 dated 11th January 2010. The project site falls in designated industrial area and the noise levels at all the locations were found within the ambient noise standards.

Table 3.9 Ambient Air Quality Monitoring Locations

Location Code Name of Location Distance (KM) Direction from site

N-1 Project Site (near NH-8) 00 00 N-2 Jainpurwas 1.16 SE N-3 Shimla 2.55 NE N-4 Mordha 2.60 S N-5 Morodi 6.17 SE N-6 Paniyala 4.37 SSW N-7 Malpura 1.80 W N-8 Gandoj 5.61 NW

Table 3.10 Ambient Noise Quality in the Study Area

Location Project Site Jainpurwas Shimla Mordha Morodi Paniyala Malpura Gandoj

Time Noise Level (dBA)

Hourly Leq 6:00 46.2 49.3 44.2 44.7 45.3 44.3 43.3 44.0 7:00 52.3 51.4 46.5 51.4 50.5 47.2 47.2 51.1 8:00 50.7 51.8 46.8 55.3 53.6 51.4 52.5 53.8 9:00 55.2 49.5 50.5 50.4 55.2 57.5 53.7 55.2 10:00 56.5 50.7 51.2 46.2 53.6 57.8 52.9 53.5 11:00 54.6 47.2 48.9 45.2 51.5 58.4 51.2 52.4 12:00 56.8 51.0 46.2 50.6 48.3 56.5 45.1 49.3 13:00 50.9 48.9 52.4 52.5 51.7 51.2 46.9 47.8 14:00 52.0 49.8 54.7 51.3 48.9 49.5 47.4 48.6 15:00 51.3 60.2 51.6 55.5 42.3 50.6 48.7 51.2 16:00 50.2 52.6 53.2 54.2 46.2 52.2 49.4 52.6 17:00 53.7 58.1 54.0 53.3 52.3 53.4 51.3 49.3 18:00 47.6 51.3 55.5 58.3 54.2 51.3 51.6 52.0 19:00 51.5 56.3 46.9 52.5 51.1 52.1 52.9 50.7


20:00 55.4 49.3 45.1 50.6 53.5 48.6 50.4 49.1 21:00 51.6 50.0 44.0 45.7 51.7 44.8 49.0 47.9 22:00 45.9 46.7 41.2 43.1 44.6 43.2 45.4 45.7 23:00 43.2 39.9 40.8 42.5 43.8 42.1 43.9 42.3 0:00 45.0 41.8 42.1 41.4 43.2 43.5 40.7 41.0 1:00 40.6 47.7 40.3 41.9 42.5 41.2 38.2 40.2 2:00 38.4 40.5 40.4 41.0 41.8 42.6 36.8 37.2 3:00 37.6 46.9 41.6 40.3 41.6 43.3 34.6 36.5 4:00 38.5 41.6 42.0 42.1 42.5 41.0 37.0 37.5 5:00 39.8 42.0 42.5 43.2 42.3 43.4 39.5 43.6

Leq Day 53.2 53.5 51.0 52.7 51.7 53.6 50.4 51.3 Leq Night 42.2 44.4 41.4 42.0 42.9 42.6 40.9 41.6

Observation on Ambient Noise Quality: The sources of noise in the villages of study area are motorcycle and car/jeep, bus and truck movement. The ambient noise quality of the study area is within the prescribed National Ambient Noise Quality Standard. No instance of violation has been observed in the study area.

3.7. Water Quality

The water samples were examined for physico-chemical parameters and bacteriological parameters. There is no perennial river in the Alwar district. The Seasonal Rivers, which flow through the Alwar district and carry the run off from the hills, are Sabi, Rupavel, Chuhar Sidh and Lohdoha. There is no natural surface water body containing water during the study period (Winter season). Most of the surface water bodies present in the study area were dry, hence only one surface water sample (Pond) were collected from the study area. Eight groundwater samples were collected from the study area and assessed using the IS10500 criteria. The name of sampling locations is presented in Table 3.11. Analysis results of groundwater are provided in Table 3.12.

Table 3.11 Ground Water Sampling Locations

Location Code

Name of Location

Distance & Direction from site

Source

GW -1 Project Site 00 00 Hand pump GW -2 Jainpurwas 1.16 SE Hand pump GW -3 Shimla 2.55 NE Hand pump GW -4 Mordha 2.60 S Hand pump GW -5 Morodi 6.17 SE Hand pump GW -6 Paniyala 4.37 SSW Hand pump GW -7 Malpura 1.80 W Hand pump GW -8 Gandoj 5.61 NW Hand pump


Table 3.12 Ground Water Quality in the Study Area

Parameters Project Site

Jainpurwas

Shimla

Mordha

Morodi

Paniyala

Malpura

Gandoj

Desirable Limits

Permissible limits

Test Protocol

Colour (Hazen Units)

Less Than 5

Less Than 5

Less Than 5

Less Than 5

Less Than 5

Less Than 5

Less Than 5

Less Than 5

5 25 IS: 3025 Part -4

Conductivity (µmhos/cm)

1401 1365 1816 1925 952 1105 1735 1488 - - IS: 3025 Part -14

Turbidity (NTU) 0.3 1.8 1.3 0.6 2.1 1.9 1.8 0.7 5 10 IS: 3025 Part -10

pH 7.57 7.15 7.08 7.19 7.48 7.05 7.55 7.18 6.5 to 8.5 No Relaxation

IS: 3025 Part -11

Total dissolved Solids (mg/ Liter) 883 859 1144 1213 599 696 1093 937

500 2000 IS: 3025 Part -16

Total Suspended Solids (mg/ Liter)

22 18 12 16 21 21 18 15 - - IS: 3025 Part -17

Total hardness (mg/liter)

383 401 344 360 278 322 375 332 300 600 IS: 3025 Part -21

Chlorides (as CL) mg/ liter

249 302 512 360 345 198 416 388 250 1000 IS: 3025 Part -32

Sulphate (as SO4) mg/ liter)

42 53 52 49 42 39 48 41 200 400 IS: 3025 Part -24

Nitrate (as NO3) (mg/ Liter)

2.4 1.54 2.5 1.74 2.05 1.98 1.88 1.76 45 100 IS: 3025 Part -34

Phosphate (as PO4) (mg/ Liter)

3.6 2.4 1.7 2.67 1.76 2.4 1.53 1.48 - - IS: 3025 Part -31

Fluorides (as F) (mg/ Liter)

4.8 1.62 0.8 2.12 2.1 2.03 1.8 1.4 1 1.5 IS: 3025 Part -60

Iron (as Fe) (mg/ Liter)

2.5 1.09 1.58 9.37 1.46 1.2 1.76 1.22 0.3 1 IS: 3025 Part -53

Lead (as Pb) (mg/ Liter)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

0.05 No Relaxation

IS: 3025 Part -47


Copper (as Cu) (mg/ Liter)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

0.05 1.5 IS: 3025 Part -42

Sodium (as a Na) (mg/ Liter)

298 408 584 385 318 295 385 324 - - IS: 3025 Part -45

Potassium (as K) (mg/ Liter)

132 98 162 244 144 37 157 109 - - IS: 3025 Part -45

Nickel(as Ni) (mg/ Liter)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

- - IS: 3025 Part -54

Zinc (as Zn) (mg/ Liter)

BDL (0.1)

BDL (0.1)

BDL (0.1)

BDL (0.1)

BDL (0.1)

BDL (0.1)

BDL (0.1)

BDL (0.1)

5 1.5 IS: 3025 Part -49

Total chromium (as Cr) (mg/ Liter)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

0.05 No Relaxation

IS: 3025 Part -52

Manganese (as Mn) (mg/ Liter)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

BDL (0.01)

0.1 0.3 IS: 3025 Part

oil&grease (mg/ Liter)

BDL (1)

BDL (1)

BDL (1)

BDL (1)

BDL (1)

BDL (1)

BDL (1)

BDL (1)

- - IS: 3025 Part -39

Calcium (as Ca) (mg/ Liter)

57 70 42 52 55 53 71 62 75 200 IS: 3025 Part -40

Magnesium(as Mg) (mg/ Liter)

58 55 58 56 34 46 48 43 30 100 IS: 3025 Part -46

Total Alkalinity(mg/ Liter)

493 162 172 240 144 170 155 132 200 600 IS: 3025 Part -23

Total Coliform(MPN/100

ml)

Nil Nil Nil Nil Nil Nil Nil Nil 10 10 IS: 3025 Part -2

COD(mg/ Liter) BDL (5)

BDL (5)

BDL (5)

BDL (5)

BDL (5)

BDL (5)

BDL (5)

BDL (5)

- - IS: 3025 Part -58

Source: Water Analysis during study period


EQMS INDIA PVT. LTD. 107

Observation on Ground water Quality:

The pH value of drinking water is an important index of acidity or alkalinity. pH value of the sample vary from 7.05 to 7.57 in all locations. Electric Conductivity levels vary from 952 to 1925 µmho/cm. Total dissolved solids ranges from 564 to 1145 mg/l which is within permissible limit. Sulphate ion values in all the sample ranges from 39 to 53 mg/l and found within the permissible limit. The total hardness is an important parameter of water quality. The hardness values in ground water of the study area ranges between 278 to 401 mg/l which is well within the limit. No biological and metallic contamination has been found in any of the ground water sample of the study area. All the parameters in ground water sample were well within the permissible limit of Indian Standard IS: 10500-2012.

Surface Water Resource

There are about 7-8 small ponds in the project area, however due to harsh climate of the area, they have become dry. Also, there is no perennial river in the Alwar district. The Seasonal Rivers, which flow through the Alwar district and carry the run off from the hills, are Sabi, Rupavel, Chuhar Sidh and Lohdoha. There is only one surface water body found within 10 km radius of the study area.

Parameters Pond (Village Rai Malikpur) Parameters Pond (Village Rai

Malikpur) Colour Pale Yellow Nickel (as Ni) mg/liter BDL (0.01)

Conductivity (µmho/cm) 3368 Sodium (as Na) mg/ liter

825

Turbidity (NTU) 115.8 Potassium (as K) mg/liter

363

pH 8.10 Zinc (as Zn) mg/liter BDL (0.1) Total Dissolved Solids (mg/ liter)

2015 Total Chromium (as Cr) mg/liter

BDL (0.01)

Total suspended solids (mg/ liter)

821 Manganese (as Mn) mg/liter

BDL (0.01)

Total Hardness (as CaCO3) mg/liter

1824 Oil & grease (mg/liter) BDL (1)

Chlorides (as Cl) mg/ liter

688 Calcium (as Ca) mg/ liter

284

Sulphate (as SO4) mg/liter

241 Magnesium (as Mn) mg/liter

270

Nitrate (as NO3) mg/liter 6.21 Total Alkalinity (mg/liter) 1150 Phosphate (as PO4) mg/ liter

4.5 COD (mg/liter) 39

Fluoride (as F) mg/liter 6.2 BOD (for 3 days at 27oC) (mg/liter)

11

Iron (as Fe) mg/ liter 5.1 DO (mg/liter) 4.5 Lead (as Pb) mg/liter BDL (0.01) Total coliform NIL Copper (as Cu) mg/liter BDL (0.01) E.Coli Absent

Discussion:

Surface water in the region has been compared with respect to the Water Quality Standards as per IS: 2296:1992 and reveals that these are having TDS levels and Total Coliform. All the other parameters were found well within the standards. Thus, study shows the water Quality comes under designated Class-C (Drinking water sources with conventional treatment followed by disinfection) of IS



2296:1982 and can be used for Domestic/Drinking use after conventional treatment and Disinfection.

3.8. Soil Quality

As per the district soil conservation office-Alwar, the soils of the district can broadly be divided into three classes, viz., older alluvial soil, Red Grey-valley soil and red sandy soil. Older alluvial soil are found in Tijara tehsil, large parts of Laxmangarh tehsil and some parts of amgarh, Kherli, Behrod, Rajgarh, Itarana and Kishangarh tehsils. Red Grey-Valley soil are found in large part of Alwar and Thanagaji tehsil, small patches in Kishangarh and Ramgarh tehsils, north-east part of Rajgarh and north-west part of Laxmangarh tehsil. Red sandy soil found in large part of Bansur tehsil, mid part of Thanagaji and some parts of Rajgarh. Light & medium textured soils are observed in the district. In the most parts of the District, loam and sandy loam soil are found. In Panchayat Samities of Bansur, Bahrod, Kotaksim & partly Tijara and Mundawar mostly sandy soils are observed. Potash content in soil is good & Nitrogen is in poor stage and Phosphorous is medium. Water level is observed between 80 to 150 feet‘s deep bgl. Soil Map of

Alwar District is shown in Figure-3.14.

Source: (http://atmaalwar.com/dist-soil-conservation-office.php)

Figure 3.14 Soil Map of Alwar District

In Alwar region, agriculture is mainly the livelihood of the people and for good harvest the soil must be of very good quality. The region in general has a fertile alluvial soil in almost all the areas outside the forest boundary where agriculture is done and two to three crops have been taken by the farmers in a year. Nearly all types of soils are found in this area viz. sandy, loamy, sandy-loam and clayey.



Graphical representation of soil composition for Alwar district provided in Figure-3.19.The soil types found in Alwar district in general and the 10-m radius of the study zone in particular are as follows:

Recent Alluvium

Aravalli Pediment

Soils of Aravalli Hills

Old Alluvium

Fluvioaeolian

Figure 3.15 : Soil Composition of the Alwar District Source: http://210.212.96.131/rpcb/Notifications/Environmental_Master_Plan_Alwar.pdf)

Methodology

The samples collected were homogeneous representatives of each location. Soil samples were collected from 5 to15-cm below the surface. Soil was uniformly mixed before homogenizing the soil samples. The samples about 500-gms were packed in polythene bags labelled in the field with location & number and sent to the laboratory for the analysis of physicochemical parameters.

Soil sampling locations

Soil sampling was conducted once during the study period. Eight soil samples were collected from selected locations in the vicinity of the proposed expansion project. For studying soil quality in the study area, sampling locations were selected to assess the existing soil conditions in and around the existing plant area representing various land use conditions. The homogenized samples were analyzed for physicochemical characteristics. Soil sampling locations with their distance & directions with respect to the project site is provided in Table 3.13. Soil test results are presented in Table 3.14.



Table 3.13 Soil sampling Locations

Location Code

Name of Location Distance (KM) Direction from

site Source

S-1 Project Site 00 00 Agriculture Field S-2 Jainpurwas 1.16 SE Agriculture Field S-3 Shimla 2.55 NE Agriculture Field S-4 Mordha 2.60 S Agriculture Field S-5 Morodi 6.17 SE Agriculture Field S-6 Paniyala 4.37 SSW Agriculture Field S-7 Malpura 1.80 W Agriculture Field S-8 Gandoj 5.61 NW Agriculture Field

Table 3.14 Analysis Result of Soil Sampling

S. No.

Paramete

rs

Unit

Project Site

Jainpurwas

Shimla

Mordha

Mordhi

Paniyala

Malpura

Gandoj

Physical Characteristics 1 Color/

Appearance

- Creamy Brown

Yellowish Brown

Yellowish Brown

Yellowish Brown

Creamy Brown

Yellowish Brown

Brown

Yellowish Brown

2 Texture - Sandy

Sandy Loam

Sandy Sandy Sandy Loam

Sandy Loam

Sandy

Sandy

Particle Size Distribution i) Sand % 57 56 54 62 53 57 51 54 ii) Silt % 21 20 28 18 21 24 25 31 iii) Clay % 22 24 18 20 26 19 24 15 4 Porosity % 46.4 48.7 47.9 47.2 47.9 50.9 45.7 48.7 5 Bulk

Density gm/c

c 1.42 1.36 1.38 1.40 1.38 1.30 1.44 1.36

6 Water Holding Capacity

% 30.1 32.8 30.5 31.4 33.6 32.5 29.8 30.0

Chemical Characteristics 7 pH 20%

Slurry 7.58 7.46 7.15 7.88 7.45 7.82 7.42 7.24

8 Conductivity (EC)

µmhos/cm

158 187 183 178 175 169 165 176

9 Organic Matter

% 0.62 0.84 0.71 0.67 0.79 0.90 0.59 0.55

10 Organic Carbon

% 0.36 0.49 0.41 0.39 0.46 0.52 0.34 0.32

11 Cation Exchange Capacity

meq/100g

m

8.8 13.5 6.6 5.9 11.8 14.5 9.5 7.5

12 Zinc as Zn

mg/kg

0.50 0.55 0.48 0.56 0.63 0.51 0.48 0.55



13 Copper as Cu

mg/kg

0.45 0.39 0.56 0.50 0.46 0.35 0.55 0.48

14 Manganese as Mn

mg/kg

<0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

15 Boron as B

mg/kg

<0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Available Nutrients 16 Nitrogen

as N kg/ha 256.

2 276.5 266.8 288.2 296.

6 299.5 277.4 286.5

17 Phosphorus as P

kg/ha 10.5 17.4 12.2 15.6 17.8 12.4 15.7 16.3

18 Potassium as K

kg/ha 112.5

156.2 138.1 152.7 146.4

168.2 144.1 135.8

19 SAR % 1.51 1.75 1.68 1.47 1.62 1.38 1.42 1.44 Source: Soil Analysis during study period

According to Soil Survey Manual (IARI,1970), the soils are grouped under different soil reaction classes viz extremely acidic (pH<4.5), very strongly acidic (pH 4.5-5.0 ), strongly acidic (pH 5.1-5.5), moderately acidic (pH 5.6-6.0), slightly acidic (pH 6.1-6.5), neutral (pH 6.6- 7.3), slightly alkaline (pH 7.4-7.8), moderately alkaline (pH 7.9-8.4), strongly alkaline (pH 8.5-9.0).The soils are rated as low (below 0.50 %), medium (0.50-0.75 %) and high (above 0.75 %) in case of organic carbon, low (<280-kg/ha-1), medium (280 to 560-kg/ha-1) and high (>560-kg/ha-1) in case of available nitrogen, low (<10-kg/ha-1), medium (10 to 25-kg/ha-1) and high (>25-kg/ha-1) for available phosphorus, low (< 108-kg/ha-1), medium (108 to 280-kg/ha-1) and high (> 280-kg/ha-1) for available potassium and low (<10-mg/kg-1), medium (10-20-mg/kg-1) and high (>20-mg/kg-1) for available Sulphur (Singh et. al. 2004, Mehta et. al.1988). Critical limits of Fe, Mn, Zn, Cu and B, which separate deficient from non-deficient soils followed in India, are 4.5, 2.0, 0.5, 0.2 and 0.5-mg/kg-1 respectively. (Follet & Lindsay-1970 and Berger & Truog-1940)

Therefore, as per U.S. Bureau of Soil and Chemistry Textural System (Triangular Classification System), the soils in the Study area can be described as different categories of soil texture, viz. Sandy and Sandy Loam is commonly observed soil in the vicinity of the proposed project.

Bulk density of soil relates to the combined volumes of the solids and pore spaces. Soil with a high pore space with loose solid particles will have lower bulk density than those that are more compact and have less pore space. This is directly related to the movement of air and water through soil thus affecting the productivity. The bulk density of the soils was found in the range of 1.30 to 1.44 - gm/cm3.

Soil porosity is described in terms of air filled pore spaces is indicative of storage and movement of gases for the inherent moisture and development of root systems, soil strength etc. The porosity and water holding capacity were found in the range of 45.7 to 50.9 % and 29.8 to 33.6 % respectively.



The soil samples collected from the project site and study area reveals that soils are texturally Sandy and Sandy Loam. The soils are neutral to slightly alkaline (7.15 to 7.88) in nature.

3.9. Biological Environment

Ecology (Flora and Fauna)

Flora

Ecological studies are one of the important aspects of Environmental Impact Assessment with a view to conserve environmental quality and biodiversity. Ecological systems show complex inter-relationships between biotic and abiotic components including dependence, competition and mutualism. Biotic components comprise of both plant and animal communities, which interact not only within and between themselves but also with the abiotic components viz. physical and chemical components of the environment.

Generally, biological communities are good indicators of climatic and edaphic factors. Studies on biological aspects of ecosystems are important in Environmental Impact Assessment for safety of natural flora and fauna. The biological environment includes terrestrial and aquatic ecosystems. The animal and plant communities co-exist in a well-organized manner. Their natural settings can get disturbed by any externally induced anthropological activities or by naturally occurring calamities or disaster. So, once this setting is disturbed, it sometimes is either practically impossible or may take a longer time to come back to its original state. Hence changes in the status of flora and fauna are an elementary requirement of Environmental Impact Assessment studies, in view of the need for conservation of environmental quality and biodiversity.

Flora of Alwar District:

Most of the forests present inAlwar district fall under the ―II-Dry Tropical Forests‖

as per Champion and Seth‘s revised classification of forest types. As per the Forest Working Plan of Alwar district there are about 87 species of trees, 74 species of shrubs and herbs, 14 species of climbers, 20 species of grasses, 2 species bamboo and two species of parasites in Alwar district. Complete list of the Flora obtained from the Forest Working Plan of Alwar District is attached as Annexure.

Vegetation of Study Area

The study area has been marked as 10 Km radial distance from the proposed site which is located at village Sotanala, Tehsil Behror, District Alwar, Rajasthan. The study area around the project site mainly comprises of terrestrial ecosystem (agriculture).Topography of the study area is generally flat. Three small hillocks are present within the study located about a distance of 3.0 km W, 8.0 km NW and 8.5 km SE respectively. The hillocks have scanty vegetation dominated by neem, acacia, shisam etc. species and commonly found herbs and shrubs. There is no protected and reserved forest present within 10 km area of the project site. Most of the land around the project site is under agriculture, industrialand settlements. The study area mainly supports Agro ecosystem because of its widespread agricultural activities. Vegetation is restricted along the road side,



along the margins of agricultural fields. Environmental setting of the study area is given in Table 3.15.

Table 3.15 Details of Environmental Setting

S. No. Particulars Details 1 Project Location RIICO Industrial area,

SotanalaBehror, Dist. Alwar, RJ 3 Archaeologically important places None 4 Protected areas as per Wildlife Protection Act

1972 None

5 Reserved / Protected Forest None 6 Open Forest None 7 Seismicity Zone-III 8 Defence Installation None 9 Archaeologically important places None 10 Nearest Water Bodies None

The study area (10 km around site) is dominated by rural, urban and commercial activities. It includes some agricultural areas, where chemical fertilizers and pesticides are used. The study area lies in a deciduous type of vegetation. Most of the land around project site is occupied by agro ecosystem.

Agro ecosystem is defined as a spatially and functionally coherent unit of agricultural activity and the living and non-living components involved in that unit as well as their interactions. Acacia nilotica, Azadirachtaindica, Delbergisissotrees are predominantly observed every part of the study area. The flora of the study area is characterized by the arborescent species such as Acacia nilotica (babul), Acacia catechu, Neem (Azadirachtaindica),Bad (Ficusbengalensis), Peepal (Ficusreligiosa), Siris (Albizzialebbek), Arjun (TerminaliaArjuna),Amaltas (Cassia fistula), Aam (Mangiferaindica) and herb &shrubby species such as Xanthium strumarium,Nariumindicum, Calotropisprocera, Bougainvillea spp Lantana camara,Casiatora,Vitexnegundo,Zizyphusmauritiana,Tulsi (Ocimum sanctum), Canabissativa, Parthenium grass (exotic species), Argemonmaxicana and few grasses species. List of Plant species observed in the study area is given in Table 3.16.--.

Table 3.16 List of Flora observed in the study area

S. No. Local / Hindi Name Botanical name Family 1 Acacia Acacia auriculiformis Mimosaceae 2 Arjun Terminaliaarjuna Combretaceae 3 Aam Mangiferaindica Anacardiaceae 4 Ambta Bauhinia recemosa Fabaceae 5 Amla/ Aunla Emblicaofficinalis Euphorbiaceae 6 Peepal Ficusreligiosa Moraceae 7 Babul Acacia nilotica Mimosaceae 8 Bad Ficusbengalensis Moraceae 9 Bilayati babul Prosopisjuliflora Mimosaceae 10 Baikan Meliaazadiratch Meliaceae



11 Shisham Dalbergiasisoo Fabaceae 12 Ber Ziziphusmauritiana Rhamnaceae 13 Bel Aeglemarmelos Rutaceae 14 Siris Albiziaprocera Mimosaceae 15 Eucalyptus Eucalyptus sp. Myrtaceae 16 Gohira Acacia leucophloea Mimosaceae 17 Gulmohar Denonixregia Fabaceae 18 Imli Tamarandusindica Fabaceae 19 Jamun Syzygiumcumini Myrtaceae 20 Jungle jalebi Pithocelobiumdulce Fabaceae 21 Kachnar Bauhinia variegata Fabaceae 22 Kadamb Mitragynaparvifolia Rubiacaea 23 Kalasiris Albizialebbeck Mimosaceae 24 Khair Acacia catechu Fabceae 25 Karanja/kanji Pongamiapinnata Fabaceae 26 Neem/Limbo Azadirachtaindica Meliaceae 27 Nimbu Citrus aurantifolia Citraceae 28 Palas Buteamonosperma Fabaceae 29 Sajana Moringaoleifera Moringaceae 30 Sahtut Morus alba Moraceae 31 Simal/Simili Bombaxceiba Bombacaceae 32 Shishum Dalbergialatifolia Fabaceae 33 Amaltas Cassia fistula Caesalpinaceae 34 Sahtut Morus alba Moracea B. Shrubs / Herbs 35 Besharm Ipomeacornea Acanthaceae 36 Night shade Solanumxanthocarpum Solanaceae 37 Aak Calotropisprocera Asclepiaceae 38 Aragha Adhathodavasica Convolvulaceae 39 Lantana Lantana camara Verbenaceae 40 Ber Zizyphusmauritiana Rhamnaceae 41 Gandhela Murrayakoenigii Rutaceae 42 Begunia Vitexnegundo Verbenaceae 43 Bisalyakarani Tridaxprocumbens Asteraceae 44 Kaner Nariumindicum Apocynaceae 45 Bougainvillea Bougainvillea spp. Nyctainaceae 46 Tulsi Ocimum sanctum Lamiaceae 47 Congress grass Partheniumhesterophorus Asteracea 48 Neel Indigoferahirsuta Fabaceae 49 Pavar Cassia tora Fabaceae 50 Bhang Cannabis sativa Cannabaceae 51 Bathua Chenopodium album Chenopodiaceae E. Grasses 52 Dhanwantary/Khara Cymbopogon martini Poaceae 53 Dub Cynodondactylon Poaceae



55 Nut grass Cyperusrotundus Cyperaceae 56 -- Heteropogoncontortus Poaceae

Agriculture: Economy of study area is mainly agrarian in character. The main occupation of the people in the region is agriculture and industrial workers. Wheat is the main crop growing in the study area. The other crops grown in the study area are maize, bajara, jowar, arhar,gram, vegetables and fruits. List of agricultural crops grown in the study area are given in Table 3.17.

Table 3.17 List of Agricultural Crops Grown in the Study Area

A. Cereals S.No. Local Name English Name Botanical Name 1. Dhan Paddy Oryzasativa 2. Makka Maize Zea mays 3. Gehu Wheat Triticumsativum. 4. Jowar Sorghum Sorghum vulgare 5. Bajara Millet Pennisetumglaucum

B. Pulses and Oil 1. Arhar Pigeon Pea CanjanusCajan 2. Urd Black gram Vignamungo 3. Mung Mung gram Phaseolusmungo 4. Sarson Mustard Brassica campestris 5. Matar Pea Pisumsativum 6. Mungphali Ground Nut Arachis hypogeal

C. Fruit crops 7. Aam Mango Mangiferaindica 8. Nibbu Lime Citrus aurantifolia 9. Amrud Guava Psidiumguajava 10. Papita Papaya Carica papaya 11. Ber Jujube Ziziphusmauritiana

D. Vegetables 12. Tamatar Tomato Lycopersicumesculantum 13. Baigan Brinjal Solanummelongena 14. Pattagovi Cabbage Brassica oleracea 15. Phulgovi Cauliflower Brassica oleracea 16. Bhindi Lady‘s Finger Abelmoschusesculentus 17. Aloo Potato Solanumtuberosum 18. Muli Radish Raphanussativas 19. Karela Bitter gourd Momordicacharantia 20. Torai Ridge gourd Luffaacutangula 21. Khira Cucumber Cucumissativus 22. Lauki Bottle gourd Lagenariasiceraria 23 Chichinda Snake gourd Trichosanthesanguina 24. Dhaniya Coriander Coriander sativum

Threatened Plant Species

Threatened taxa are those species which are vulnerable to endangerment in the near future. Threatened status of any taxa is not a single category but is a group of categories, critically endangered, endangered and vulnerable. On the application of different criteria of IUCN for the assessment of conservation status



of taxa, no taxa were found threatened in the study area. The reported taxa have also not been enlisted in the Red Data Book of Indian plants (Nayar and Shastry, 1988).

Rare and Endangered Plant Species in the Study Area: No rare and endangered plant species was observed in the study area (Source: Red Data Book of Indian Plants, N.P Nayar and A. P. K. Sastry, B.S.I. 1988).

Fauna

There is no forest present in the study area. The carnivore of the study area is restricted to commonly found mammals comprise Langur, Neola, Porcupine and other smaller species. Among reptiles poisonous snakes are common and include several kinds of cobra, the Karait and the deadly Russell's viper. The common avifauna of the study area are jungle crow, house crow, common babbler, red-vented babul, Indian robin, black drongo, weaver bird, common mayna, house sparrow, Koel, bee-eater, kingfisher, hoopoe, owl, pigeon and dove, lapwing, and several varieties of egret and heron. List of fauna observed in the study area is given in Table 3.18.

Table 3.18 List of Fauna

Sr. No Scientific Name Common Name Schedule as per WPA (1972)

A: Aves 1 Phlacrocoraxniger Little Cormorant Sch-IV 2 Ardeolagrayii Paddy bird Sch-IV 3 Ardea alba Large Egret Sch-IV 4 Bubulcus ibis Cattle Egret Sch-IV 5 Milvusmigrans Common pariah kite Sch-IV 6 Vanellusindicus Lapwing Sch-IV 7 Eudynamysscolopacea Indian Koel Sch-IV 8 Meopsphilippinus Bee-eater Sch-IV 9 Acridotherestristis Common Myna Sch-IV 10 Corvussplendens house Crow Sch-V 11 Nectarinia minima Small Sunbird Sch-IV 12 Passer domesticus Indian house Sparrow Sch-IV 13 Copsychussaularis Magpie-robin Sch-IV 14 Ardeolagrayii Indian pond heron Sch-IV 15 Pycnonotuscafer Bulbul Sch-IV 16 Columba libia Blue Rock pigeon Sch-IV 17 Psittaculakrameri Rose ringed parakeet Sch-IV 18 Centrophussinensis Coucal Sch-IV 19 Corvusmacrorhynchos Jungle crow Sch-IV 20 Pericrocotuscinnamomaus Small minivet Sch-IV 21 Turdoidesstriatus Babbler Sch-IV 22 Ploceusphilippinus Weaver bird Sch-IV 23 Bubo bubo Owl Sch-IV 24 Upupaepops Indian Hoopoe Sch-IV 25 Dinopimbenghalensis Woodpeaker Sch-IV 26 Dicrurusadsimilis Black drongo Sch-IV 27 Motacillacaspica Waigtail Sch-IV



B: Amphibians 28 Ranatigriana Common frog Sch-IV 29 Bufomelanosticus Toad Sch-IV C: Reptiles 30 Calotesversicolor Common garden Lizard Sch-IV 31 Bangarus sp. Krait Sch-II 32 Najanaja Indian Cobra Sch-IV 33 Vipera sp. Russels viper Part-II of Sch-II D: Mammals 34 Rattusratus Rat Sch-V 35 Lepusnigricollis Hare Sch-IV 36 Presbytis entellus Langur Part-I of Sch-II 37 Funambuluspalmarum Squirrel Sch-V 38 Rattusnorvegicus Field mouse Sch-V 39 Rhinolopus sp. Bat Sch-V 40 Herpestesedwardii Common mongoose Sch-IV 41 Vulpusbengalensis Fox Part-II of Sch-II 42 Boselaphustragocamelus Blue bull Sch-IV

Wildlife Sanctuary / National Park- No wildlife sanctuary or national park exists within a radius of 10 km of the site of the Project.

Endangered, Rare and threatened Species- With reference to the list of endangered species prepared by Zoological Survey of India (ZSI), Ministry of Environment and Forests, Government of India, none of the faunal species present in the study area belonged to the 'endangered' category.

Schedule-I Fauna: With reference to the list of schedule-I fauna listing of wildlife Protection Act 1972, No schedule-I fauna is present within 10 km area of the project site.

Ecological Sensitive Areas- There is no major ecologically sensitive areas present within the study area of 10 km from the plant site. There are no migratory routes for birds and animals.

3.10. Socioeconomic Environment

Demography and Socio-economics

Impact on the socio-economic environment in the vicinity of any industry revolves around the modes of change that are likely to occur due to beneficial and adverse effects arising out of proposed industrial activity. These pertain to economic output, job opportunities and strain on the existing basic amenities as well as overall impact on the quality of the environment of the region. Therefore, assessment of such an impact calls for detailed baseline information and impact on the socio-economic environment and to suggest environmental management plan in order to minimise the adverse impacts.

The study area has been marked as 10 Km radial distance from the proposed site which is located at village Sotanala (RIICO Industrial area), Tehsil Behror, District Alwar, Rajasthan State. 10 km area of the project site has been considered as study area. Administratively, the villages and settlement within this area falls in Behror and Basur Tehsil of Alwar District. Small portion of the study area



covering one revenue village falls in Bhiwadi district of Rajasthan. There is one town (Behror, Mincipality) and 22 villages fall within 10 km Area of the plant site. According to 2011 census the total population of the study area is 73573 comprising 38705 male and 34868 female. Male female ratio of the study area is 900 female / 1000 male. Total no. of households is 12897. The demographic status of Behror, Bansur Tehsil and Alwar district is given in Table 3.19. Village wise population of the study area is given in Table 3.20

Table 3.19 Tehsil wise Rural& Urban Demographic Profile

Level TRU House holds

Total Population

Total Male

Total Female

Population -06

Male -06

Female -06

Alwar District

Total 639720 3674179 1939026 1735153 587959 315270 272689 Rural 511517 3019728 1589508 1430220 502526 269105 233421 Urban 128203 654451 349518 304933 85433 46165 39268

Behror Sub-

District


Bansur Sub-

District


Source: Primary Census of India 2011

Table 3.20 Village wise Population in Study Area

S.N. Name

Total Households

Total populaion

Total male

Total Female

1 Manchal 409 2319 1176 1143 2 Shahzadpur

Nangaliya 266 1411 745 666 3 Kalyanpura 337 1855 990 865 4 Nareda Kalan 230 1121 596 525 5 Khapariya 219 1141 610 531 6 Kherki 260 1353 710 643 7 Gokalpura 306 1648 844 804 8 Sherpur 415 2404 1229 1175 9 Gadoj 580 3146 1673 1473 10 Dhidhor 208 1297 718 579 11 Goonti 703 4055 2103 1952 12 Shimla 149 870 459 411 13 Mosampur Kankara 213 1520 804 716 14 Jainpurbas 666 4222 2210 2012 15 Pahari 630 4027 2174 1853 16 Behror (Muncipality) 5484 29531 15570 13961 17 Dangiwas 239 1421 731 690 18 Baberi 351 2196 1168 1028 19 Isra Ka Bas 206 1524 801 723 20 Morodi 296 1737 907 830 21 Nangal Lakha 277 1860 980 880



22 Babera 302 2047 1069 978 23 Keharpura 151 868 438 430 Total within 10 km area 12897 73573 38705 34868 Source: Primary Census of India 2011

Distribution by Size of Population: As per 2011 census only 18% of the Villages have population more 3000. 18% of the villages in study area have population in the range of 2000-3000. About 54% of the villages in study area have population in between 1000-2000. There is one town in the study area having population of 29531. There are only 2 villages having population less than 1000. It is concluded from the table below that population size of the villages of study area is between 1000-2000. The distribution of the population by size in study area is given in Table 3.21

Table 3.21 : Distribution by size of population

Around 10 km radius from Proposed Plant site.

Population Villages Towns Number % Number %

0-500 0 0 - 500-1000 2 9.0 - 1001-2000 12 54.54 - 2001-3000 4 18.18 - >3000 4 18.18 1 100 Total 22 100 1 100

Scheduled Caste and Schedule Tribe Population: The schedule Caste (SC) and Schedule Tribe (ST) community are considered as socially weak, hence the state and central governments have several welfare schemes for their economic and social development. Tehsil wise SC & ST population is provided in Table 3.22. Village wise SC & ST population provided in Table 3.23.

Table 3.22 : Tehsil wise SC & ST Population

Level Population

SC Male SC

Female SC

Population ST

Male ST

Female ST

Alwar DISTRICT

653036 342938 310098 289249 153397 135852 540412 283680 256732 266880 141505 125375 112624 59258 53366 22369 11892 10477

Behror Sub-district

54152 28342 25810 8663 4551 4112 46665 24460 22205 5582 2946 2636 7487 3882 3605 3081 1605 1476

Bansur Sub-district

38940 20540 18400 12059 6359 5700 38940 20540 18400 12059 6359 5700

0 0 0 0 0 0 Source: Primary Census of India 2011

Table 3.23 Village wise SC & ST Population

S.No. Village Name Population SC

Male SC

Female SC

Population ST

Male ST

Female ST

1 Manchal 237 122 115 7 3 4



2 Shahzadpur Nangaliya 315 169 146 0 0 0 3 Kalyanpura 3 2 1 0 0 0 4 Nareda Kalan 184 99 85 8 6 2 5 Khapariya 124 64 60 0 0 0 6 Kherki 190 97 93 0 0 0 7 Gokalpura 457 241 216 64 33 31 8 Sherpur 445 225 220 139 73 66 9 Gadoj 455 239 216 0 0 0 10 Dhidhor 7 4 3 0 0 0 11 Goonti 981 526 455 532 274 258 12 Shimla 176 92 84 0 0 0 13 Mosampur @ Kankara 181 96 85 0 0 0 14 Jainpurbas 596 322 274 66 36 30 15 Pahari 558 300 258 158 88 70 16 Behror (M) 4466 2325 2141 940 515 425 17 Dangiwas 384 202 182 0 0 0 18 Baberi 344 187 157 0 0 0 19 Isra Ka Bas 178 88 90 0 0 0 20 Morodi 388 193 195 15 9 6 21 Nangal Lakha 508 258 250 0 0 0 22 Babera 160 89 71 116 67 49 23 Keharpura 117 59 58 73 38 35

Total within 10 km area 11454 5999 5455 2118 1142 976 Source: Primary Census of India 2011

There are 12 villages of study area having no ST population. Total SC population in the study area is 11454 comprising of 5999 males and 5455 females. Total ST Population in the study area is 2118 comprising of 1142 males and 976 females. Out of the total population the SC and ST population of the study area is 15.5% and 2.8% respectively.

Education and Literacy: According to Census of India literacy rate is defined as the percentage of literates to the population of age above 6. It is important to study the extent of literacy among the people in the impact area i.e. area covering 10 km radius from the proposed site. Any developmental project will be well understood and appreciated by the literate masses. Further, it will help project proponent in exploring the potential of the locals for future recruitment during the construction and operational phases of the proposed. According to 2011 Census, Literacy rate of the villages in study area is around 65.2% comprising 75.4% male literates and 55.1% Female literates. Details given in following table 3.24:

Table 3.24 Literacy Rate of Study area (within 10 km radius)

Sr. No. Description Number Total/Male/Female Literacy % 1 Total Population 73573 - - 2 Total Literates 48147 Total 65.2 3 Total Male population 38705 - 4 Male Literates 29207 Male 75.4 5 Total Female population 34868 - 6 Female literates 19240 Female 55.1 Source: Primary Census of India 2011



Occupational Structure: According to the Census definition ―work‖ may be

defined as participation, mental or physical, in any economically productive activity. People engaged in such an activity constitute the workforce. Workforce can be classified as main or marginal‖. A person who has worked for more than

183 days in a year is called the main worker. Marginal workers are those who have worked any time in the year preceding the census but have not worked for major part, which is not more than 183 days, of the year.

The proposed Plant involves engaging skilled, semiskilled and unskilled work force. It is generally felt that engaging the locals in the various activities of the proposed project during the construction phase and also during the operational phase wherever possible will increase the work participation rate of the people in the impact area. This is one of the direct benefits accruing to the local people due to the proposed project. Occupational pattern of the study area is given in the Table 3.25

Table 3.25 : Occupation Pattern in Study Area (10 km Area)

Name Total Workers Main Workers Marginal workers Non workers Study Area 33153 25327 7826 40420 Source: Primary Census of India 2011

0

10

20

30

40

50

60

70

80

Male Female Total

Lite

racy

Rat

e in

%Literacy rate in study area



Distribution of Main Worker: The agricultural related activities are the main occupation of the study area. Farming and agricultural activities generates the maximum employment in the study area. Male and female equally counts its growth. Agricultural related activities are generally seasonal. Therefore, these agricultural workers may not be employed during all seasons. The services of agricultural labourers can be potentially utilized for the construction phase of the project. The classification of the main worker of the study area is given in Table 3.26

Table 3.26 :Classification of Main Workers in Study Area

Level Name

Main Workers Cultivators

Agriculture labour

Household workers

Other workers

Study Area 25327 12712 1471 521 10623 Source: Primary Census of India 2011

Infrastructure Facilities:

Basic infrastructure available in the surrounding village of the proposed site is given in following sections

Education facilities

Primary education is available in all the village of the study area. There are 45 Primary School, 20 Middle schools and 6 Secondary Schools available in the villages of the study area. College and other higher education facilities are available in Behror town.

Health facilities

Medical facility is not well developed in the study area. There are only 5 villages have the medical facility. There are 3 dispensaries, and 1 primary health centre and one primary health sub-centre is available in the villages of study Area. Community health workers are available in four villages of the study area. Medical facilities are well developed in Behror town. Several private medical practitioner and community health workers are also available in the study area.



Drinking Water facilities

Drinking water facilities are available in all the villages of the study area. Villagers mostly depend on groundwater resource for drinking/domestic water. Tube well, well, hand pump are the main source of water in the study area.

Communication Facilities

There are 8 villages have the post offices facility. Most of the villagers have mobile phone facility. Village of the study area are well connected with the approached road.

Banking Facilities

Banking facility is available in Jainpura village and Behror town. .

Electricity

All villages of the study area are electrified.



CHAPTER 4. IMPACTS ASSESSMENT AND PREDICTION 4.1. General

The possible impact on various components of environment due to the proposed expansion of existing AMBEY plant can be assessed in terms of: Physical and Biological Environment and Demographic and Socio-economic Environment.

For proper assessment of significance and magnitude of environmental changes due to construction and operational phases of the plant, the impacts are analyzed on the 10 km radius study area around the proposed plant site for each environmental parameter. Impact assessment study for the existing AMBEY unit is carried out by predicting net contribution of pollutants (qualitative as well as quantitative) on overall qualitative assessment of various environmental indicators. Prediction of impacts is an important component in environmental impact assessment process. Several techniques and methodologies are in vogue for predicting the impacts due to existing and proposed industrial development on physico-ecological and socio-economic components of environment. Such predictions delineate contribution in existing baseline data for the operational project and superimpose over the baseline (pre-project) status of environmental quality to derive the ultimate (post-project) scenario of the environmental conditions due to the proposed project. The quantitative prediction of impacts lead to delineation of suitable environmental management plan needed for implementation during the construction, commissioning and operational phases of the proposed project in order to mitigate the adverse impacts on environmental quality.

4.2. Construction Phase

The activities of proposed expansion program will be confined to the project site within the boundary of Plant complex (Plant in RIICO industrial area). The present expansion activities will not cause any significant loss of any important flora.

Gaseous pollution

Due to different vehicular movement and project operation activities, the concentration of air pollutants can be increased. These pollutants can affect the surrounding vegetation and nearby agricultural crops.

Dust Generation

Terrestrial flora can be affected by the dusty environment to be created due to vehicular movement during construction and operation phase. Increment in the density of the dust particles (SPM) in the atmosphere can affect the surrounding plant/ vegetation in following ways:

Blockage and damage to stomata Reduction in chlorophyll content Abrasion of leaf surface or cuticle

All these disturbances ultimately affect photosynthesis process and plant metabolism which leads to reduction in plant growth up to some extent.

Noise Pollution

Noise level of the project area will be increased during construction and operation phase. Although there is no specific noise-sensitive fauna has been recorded near to



project site but limited avifauna and small animals in the industrial area can be affected by increased noise level. In such cases they can change their habitat.

Congregation of Labour

Construction activities often require a considerable workforce and associated support services. The livelihood activities of this increased human population may contribute to local environmental impacts in terms of collecting firewood and food as well as enhancing recreational activities.

Mitigation Measures:

Gaseous pollution

The pollutants in ambient air is reported in this study is low and the levels of other air pollutants are also low. Development of multi-layer plantation (green belt) around the proposed project area will help to mitigate gaseous pollution within and around the project area.

Dust Generation

Dust generation will be managed through:

A periodic plantation of fast growing, evergreen, broad leaved, dust-resistant indigenous plant species (proposed under Greenbelt Development Programme)

Effluent discharge

There will be a negligible discharge of effluent from the proposed plant which will be directly treated inside the plant. Safe guard for rainy season runoff will be taken to prevent any direct discharge from the plant to nearby water body. As such the water ecology will not be affected.

Congregation of Labour

The impacts will be managed through:

No permanent camping in vegetation rich area and riverside

A provision of fuel for laborers engaged in construction activities

Restriction on poaching/hunting and removal of any vegetation

Based on the field observations and interaction with local people and forest officials, it was noticed that the project area is industrial area does not associated with any National Park/Wildlife Sanctuary/Conservation Reserve and there is no wildlife migratory routes present in the project area. Improvement in the green cover under a regular plantation program (Greenbelt Development Program) will not only increase the plant diversity in the area but also enhance the habitat for wildlife especially for avifauna.

4.3. Operation Phase

4.3.1. Micro-Meteorology

The hourly wind speed, solar insulation and total cloudiness during day time and wind speed and total cloudiness during night time were used to determine the hourly atmospheric stability classes (defined by Pasquill and Gifford as A to F, A being most



unstable and F being most stable). The hourly stability classes were determined based on the technique suggested by Turner.

Turner‘s system used for determining the stability classes is as follows:

- For day or night: If total cloud cover (TC) = 10/10 and ceiling <7000 ft (2134 m), NR=0

- For night-time (defined as period from one hour before sunset to one hour after sunrise):

a) If TC<4/10, use NR = -2 b) If TC>4/10, use NR = -1 - For daytime: Determine insolation class number (IN) a) If TC<5/10, use NR=IN b) If TC>5/10, modify IN by the sum of the following applicable criteria If ceiling<7000 ft (2134m), modification = -2 If ceiling>7000 ft but <16000 ft (4877 m), modification = -1 If TC=10/10 and ceiling>7000 ft, modification = -1, and let modified value of IN=NR, except for day-time NR cannot be <+1

During the study period stability calculated based on above mentioned Turner method gives average stability as F class during night, C & D class during morning and evening and A & B class during noon.

4.3.2. Air Quality Modelling and Predictions using the ISCST - 3 Model

The impact on air quality due to emissions from single source or group of sources is evaluated by use of mathematical models. When air pollutants are emitted into the atmosphere, they are immediately diffused into surrounding atmosphere, transported and diluted due to winds. The air quality models are designed to simulate these processes mathematically and to relate emissions of primary pollutants to the resulting downwind air quality. The inputs include emissions, meteorology and surrounding topographic details to predict the impacts of conservative pollutants.

The impacts of air pollutants were predicted using Industrial Source Complex – Short Term (ISCST Version 3) air quality model, which is selected on the basis of existence of multiple point sources within the industrial complex as well as the plain terrain at the project site.

The Industrial Source Complex – Short Term Version 3 (ISCST-3) model has been developed to simulate the effect of emissions from point sources on air quality. The ISCST-3 model was adopted from the USEPA guideline models and routinely used as a regulatory model to simulate plume dispersion and transport from up to 100 point sources and 10000 receptors. ISCST–3 is the state of the art model with USEPA and extensively used for predicting the Ground Level Concentrations (GLCs) of conservative pollutants from point, area and volume sources. The impacts of primary air pollutants are predicted usingthisair quality model keeping in view the plain terrain at the project site. The micrometeorological data monitored at project site during study period have been used in this model.



The ISCST-3 model provides estimates of pollutant concentrations at various receptorlocations. It is, an hour-by-hour steady state Gaussian model which takes into account the following:

Terrain adjustments

Stack-tip downwash

Gradual plume rise

Buoyancy-induced dispersion, and

Complex terrain treatment and consideration of partial reflection

Plume reflection off elevated terrain

Building down wash

Partial penetration of elevated inversions is accounted for hourly source emission rates, exits velocity, and stack gas temperature

In the present case, prediction of impacts has been carried out for the summer season on 24-hourly basis in the entire study area of 10 km radius using the mentioned ISCST–3model.

4.3.3. Predicted GLC due to AMBEY Expansion Project

The contribution to GLCs for the pollutants i.e. particulate matter, SOx, NOx,HCl, Hbr, etc. were predicted over the study area proposed project considering the worst scenario. The emission load from proposed project are given in Table-2.12.The prediction (maximum) is based on the expected total emission rate from each stack and are given in isoplethsFigure-4.1 (A,B,C,D,E,F,G,H and I) for proposed project. The additional contribution to GLC is also given below in Table - 4.1:



Figure 4.1 PM ISOPLETHS FROM PLANT EMISSION SOURCES



Figure 4.2 SO2ISOPLETHS FROM PLANT EMISSION SOURCES



Figure 4.3 HCl ISOPLETHS FROM PLANT EMISSION SOURCES



Figure 4.4 HBr ISOPLETHS FROM PLANT EMISSION SOURCES



The pollutants contribution (maximum) to GLCs due to Proposed project is given below and

the expected contribution shall be in the range as give below –

Table 4.1 : Contribution to GLCs (maximum) due to proposed AMBEY plant stacks

PM SO2 NOx HCl HBr

Emission from process and utility stack (µg/m3) 15.20 0.117 - 0.193 0.054

Distance of Occurrence (km) 2.5 2.4 - 2.5 2.5

Direction of Occurrence E E - E E

4.3.3.1 PM

The modelling results indicate maximum contribution of PM GLCs of 15.20 μg/m3 at a

distance of 2.5 km downstream which will be limited to industrial area only. In the study area. The maximum PM was observed at Project site (102 μg/m3) and with additional

contribution of 15.20 μg/m3 it will be 117.2μg/m3exceeding with respect to residential area norms for PM (100 μg/m3 for residential, rural area and industrial area).

4.3.3.2 SOx

The modeling results indicate maximum contribution of SOx 0.117 μg/m3 at a distance

of 2.5 km downstream which will be limited to industrial area only. The maximum SOx was observed at village Jainpurwas (15.6 μg/m3) and with additional contribution of

0.117 μg/m3 it will be 15.71 μg/m3 well within the prescribed norms for SOx (80 μg/m3

for residential, rural area and industrial area).

4.3.3.3 Other Pollutants

The modeling results indicate maximum contribution of other Pollutants namely HCl ( 0.193 μg/m3 at a distance of 2.5 km down stream), HBr (0.054 μg/m3 at a distance

of 2.5 km down stream) which will be limited to industrial area only. There are no prescribed norms for these pollutants in ambient air.

4.4. Noise Environment

The sources of noise during the operational phase of the plant are mainly small air compressors, blowers, pumps, vacuum pumps, ejectors and furnaces. The other sources of noise are the movement of vehicles along the road. The noise survey of the study area was carried out and the noise level at various locations is given in Table –3.8.

4.4.1. Impacts due to Transportation

Noise level contributed from light medium and heavy vehicles on the roads can be considerable depending upon the traffic density. The heavy commercial vehicles traffic is limited depending upon the material receipt and dispatch of fertilisers through road transport. The major quantity of pesticides will bedispatched through roads.

4.4.2. Impact on Community

Equivalent sound levels for are often used to describe community exposures to noise. Noise survey was also carried out at eight locations outside the plant area but within



the study area. The Leq for these areas is found to be well within the prescribed limits promulgated by CPCB.

The noise level norms in villages of study area are being met with respect to the norms of ‗Ambient Air quality Standards in Respect of Noise‘.

The operation of AMBEY proposed project will have the noise level not exceeding the present noise level and as such will not have any adverse impact on the human settlement around it. The noise will not be audible beyond its boundary limit, particularly due to natural green belt and other attenuators.

4.5. Water Environment

Impact on water environment due to AMBEY proposed project scheme will be in terms of additional water consumption {water demand} and waste water / effluent generation and discharge to environment.

4.5.1. Water Demand

4.5.1.1 Construction Phase

Since the AMBEY expansion project will have water requirement both during construction period as well as during operation. The requirement during construction period will be much less.as compared to that during operationand will be met with the proposed existing borewell. Operational Phase

Water during operational phase is normally required for:

Process

Cooling Water

Boiler Feed Water

Domestic and Green Belt

The requirement during construction period will be much less. as compared to that during operation (additional 8 KLD) and will be met with the proposed existing borewell. Canal water is available in the area for irrigation. Water generated in the process shall be separated in distillation unit and will be treated in ETP and reused to meet water requirements for horticulture and greenery in the plant premises.

4.5.1.2 Effluent Generation and Discharge

AMBEY has existing ETP having primary, secondary and tertiary treatment facility. Ambey also propose to upgrade the ETP. The effluents are segregated into process effluents &non process effluents. These are collected in separate underground tanks. The treated effluents will be sent to solar cum forced evaporation pond. Ambey plant is ZERO effluent plant. The treated sewage effluents are used for green belt development.

Land Environment

Essentially, the two major problems normally faced in impact on land environment due to any development project are:



Diversion of land from designated use to the ‗project use‘.

Deterioration of land / soil in terms of soil fertility and toxicity.

4.5.2. Land Diversion

AMBEY project is being located in the designated industrial area developed by RIICO and as such no diversion of land from other uses is involved.

4.5.3. Land Deterioration

The solid wastes generated in the plant will be are kept in sealed containers for safe disposal in designated vendor / agency(Rajasthan Hazardous waste Management Project Udaipur). As suchAMBEY plant operation will not have any impact, which is likely to affect soil due to solid waste generation or effluents release. As such soil chemistry is not going to be affected with AMBEYproject.

4.6. Biological Environment

4.6.1. Flora

The AMBEY project is small and will have limited highly controlled emission (through scrubbers). The emission (if any) will not adversely affect the flora in the study area. The limited treated effluents generated will be meeting prescribed norms and will also not going to adversely affect the flora.

AMBEY is going to develop green belt in and around the plant. The development of green belt provides habitat, food and breeding areas to birds. The green belt will attenuate the little emission and noise from the plant.

4.6.2. Fauna

The cattle and birds living around the AMBEY proposed plant area are not going to be affected, as the impact due to the plant is very little.

CREP Guidelines: In addition AMBEY as good corporate citizen commited to abide by CREP guide lines for pesticide industry as give below:

The guidelines enunciated by CPCB are very helpful to mitigate environment pollution, improve human health and benefit of cost savings by cutting cost of valuable solvent by efficient recovery system. We (AMBEY) will adopt all the guidelines as stated here under.

Table 4.2 CREP Guidelines Compliance

Sr. No CREP Point Ambey Compliance

1

Segregation waste streams: Waste streams should be segregated into COD waste, toxic waste, low COD waste, inorganic waste etc, for the purpose of providing appropriate treatment.

Generated and segregated inorganic toxic waste for the safe disposal through approved vendor / agency (Rajasthan Hazardous waste Management Project Udaipur)



2

Detoxification and treatment of high COD waste streams: Streams should be detoxified and treated in CTP or thermally destroyed in incinerator, as per CPCB guidelines. The waste streams should be treated suitably before taking to evaporation ponds.

We have improved our ETP System to treat Effluent before taking to evaporation ponds.

3

Improvement in solvent recovery:

– Solvent recovery should be improved and attempts should be made to achieve at least 90% recovery wherever possible.

– Rest of the solvents which cannot be recovered shall be incinerated.

We have improve the cooling and chilling efficiency to get better recovery. Residue will arrange to send for incineration to approved vendor / agency (Continental Petroleum‘s Ltd Behror).

4

Hazardous air pollutant control:

– For air pollution control from processes, scrubber efficiency will be improved and maintained as per the best practicable technology for control of HCI, CI2, Methyl Chloride, Phosphorus Pentoxide, Ammonia, H2S and VOCs.– An incinerator will be installed, where necessary.

Installed scrubber and stacks for reducing the Air pollution of High efficiency.

5

Control of fugitive emissions/ VOCs: For control of fugitive emissions (particularly for hazardous air pollutions). The industries will adopt standard engineering practices. System of leak detection and repair (LDAR) programme especially for solventsshould be developed industries.

Installed the water vacuum ejector to prevent and collect the toxic vapor. These vapor dissolved into water which neutralize in scrubber system.

6

Upgrade of incinerators: Incinerators will be upgraded to meet CPCB norms hazardous waste incinerators. This is necessary for Halogenated compound and POPs.

Not Applicable

7

Replacement of Bio Assay test by toxicity Factor: The present bio-assay test will be replaced by Toxicity Factor test method developed by CPCB. Toxicity factor of four (TF-4) will be achieved and industries will improve their system to achieve TF-

2. TF test method will be implemented by PCBs/CPCB/ MoEF. The CPCB will organize workshops on ―Toxicity Factor‖ for industry.

Not Applicable



4.7. Socio – Economic Environment

AMBEY proposed project will generate employment opportunities some through direct employment and more so indirectly through services for the plant. Pesticides manufactured by AMBEY proposed plant are indirectly going to contribute food grain availability by preventing loss due to insects (to crop) and rodents (during storage) etc.

AMBEY expansion project will have some impacts also on socio – economic

environment of the study area- some are as given below:

Proposed project of the plant would result in handling of more product and raw

material, which will increase manpower requirement at some stages directly, or

indirectly resulting in more income of people.

AMBEY project would increase requirement from ancillary and auxiliary industries in

the vicinity.

With more load on infrastructure facilities – roads and rails; these facilities would need

improvement.

More income to Government through more taxes on higher amount of production.

4.7.1. Negative Impact

Increased traffic on road due to more raw material requirement and more production results in deterioration of road and increase likelihood of accidents.

However these can be handled and safety on roads can be ensured through increased awareness and better management.

8

Minimum scale of production to afford cost of pollution load: To be decided, as industries view point is that this cannot be done as few products are costly and made in small volume. The matter will be studied in detail by MoEF/ CPCB.

Presently our production load is very low. We are keeping more budget to control the increased the pollution load.

9

Non-complying Units (as identified by SPCB) should meet the notified standards

Not Applicable

10

Bank guarantee to be submitted to SPCB by Non-complying units: The submissions from pesticides industry regarding speedy clearance and other will be considered by MoEF/CPCB for examination.

Not Applicable



CHAPTER 5. ENVIRONMENT MANAGEMENT PLAN 5.1. Introduction

Prediction of the potential adverse environmental and social impacts arising from development interventions is at the technical heart of EIA process. An equally essential element of this process is to develop measures to eliminate, offset, or reduce impacts to acceptable levels during implementation and operation of projects. The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental Management Plan (EMP).

Normally, potential impacts are identified early during the initiation of project, and measures to avoid or minimize impacts are incorporated into the alternatives being considered. In this respect, some of the most important measures to protect the environment and local communities become integral to the project design, and may not be reflected in a formal EMP.

AMBEY EIA study proposes to identify all the likely potential impacts, collect data information and incorporate all the measures necessary to avoid or minimize impacts on surrounding environment. Many of the mitigation measures are already being taken care during the design stage (as AMBEY is already in pesticides manufacturing activities and knows its adverse impacts on environment) itself. It is desirable to collect even such information in the EMP to facilitate better assessment and communication as well as improve the systems and technologies to improve mitigation for environmental components having moderate residual impacts.

5.2. Objectives of EMP

Overall objective of EMP:

Prevention: Measures aimed at impeding the occurrence of negative environmental impacts and/or preventing such an occurrence having harmful environmental impacts.

Preservation: Preventing any future actions that might adversely affect an environmental resource or attribute.

Minimization: Limiting or reducing the degree, extent, magnitude, or duration of adverse impacts.

This is achieved by stepwise process of treatment, recovery and reuse/recycle of pollutants (mainly ammonia and urea) and natural resources (mainly water). Various measures taken for these are detailed in the following section. Saving of resources also results in energy conservation.

5.3. Components of EMP

EMP for AMBEYfor the proposed project considers the following aspects:

Description of mitigation measures

Description of monitoring program



Institutional arrangements

Implementation schedule and reporting procedures

Institutional framework includes the responsibilities for environmental

management as well as responsibilities for implementing environmental

measures.

5.4. CREP Guide Lines for Pesticides Industry

MoEF publication ―Technical EIA Guidance Manual (TGM) for Pesticides

Industry‖-has mentioned specific points as ‘CREP guidelines‘for pesticide

industry. AMBEY has committed (Section 4.8 and 2.13) and should follow all the points in letter and spirit.

5.4.1. Air Environment

The emission from Ambey expansion project shall be mainly from the nine stacks, (seven process scrubbers and two of boiler and hot air generator) and very limited fugitive emissions.

In order to mitigate the adverse environmental impact due to the operation due to the proposed plant following measures are recommended:

Close watch and control are to be exercised over the quality of raw material quality.

The control measures (LDAR) and good house keeping will considerably reduce the fugitive emission.

Regular monitoring of shop floor environment / storages of hazardous materials (both raw materials and products) is to be carried out to control the fugitive emission as well as shop floor safety.

Leakages {of gases / liquids/ dust} shallbe checked and promptly attended.

5.4.2. Noise Environment

The statutory national standards for noise levels at the plant boundary and at industrial areas near the plant are being and are to be met. The following mitigation measures are proposed to meet the objectives:

The selection of any new plant equipment is to be made with specification of low noise levels. Noise suppression measures such as acoustic enclosures / cabins, buffers and / or protective measures are be provided if necessary.

Earplug shall be provided to all workers where exposure level is > 85 dB (A). The exposure of employees working in the noisy area should be monitored regularly to ensure compliance with the regulatory requirements.

The green belt around the plant and colony attenuate the noise level. Mixed plantation as well as variability in tree height and shape, to disperse the sound waves more efficiently shall be further strengthened.



5.4.3. Water Environment

AMBEY plant has taken ample precautions to tackle effluents problem. The philosophy of segregation of effluent streams and treatment near the source and ETP will reduce the effluent problem considerably:

Recycle of treated effluents in the system as far as possible or destruction through evaporation.

The treated sewage shall be effectively utilized in the plant for irrigation in green belt.

Water is a precious commodity and it shall be further conserved.

Rainwater harvesting should be taken up where ever possible.

Four peizeometric wells should be installed to monitor ground water around the plant (to ensure hazardous material leachate in the ground).

5.4.4. Resource Conservation Measures

Some of the key measures taken for natural resource and energy conservation are as given below:

Solvents are to be recovered to the maximum extent as far as possible.

Fugitive dust of raw materials and products to be recovered collected and recycled.

All hazardous materials (both raw mateials / products; in packing) are to be stored in covered storages / hard flouring in order to prevalent leaking / leachate in soil/ ground water.

Proper schedule of preventive maintenance and centrifuging of oil on all critical machines is there to minimize used oil generation.

Energy efficient drives / CFL fittings to be used. Reduction of power consumption by optimum use of electrical lights in plants by installing timers.

5.4.5. Green Belt Development

An action plan to develop green belt in 33 % area

AMBEY plan to put wide green belt all around its boundary wall. The green belt and other horticulture program will start along with plant construction. However these activities will take momentum only after the construction activities are over and plant commissioning starts. The plant construction, vehicle movement and other activities may damage the young trees. All the open area will have green cover. The total area under green cover will not be less than 33%.

5.4.6. Rain Water Harvesting

AMBEY realizes the importance of rainwater harvesting however it will be prudent that rain water harvesting is not taken up in AMBEY plant area. This is because if some hazardous dust (in spite of all possible precautions) gets mixed with rainwater and enter the ground water the ground water will get



contaminated. Consultant has recommended the ground water monitoring in the AMBEY premises to ensure no contamination of ground water. If desired AMBEY may do rain water harvesting at alternate place with due approval from authorities.

5.4.7. Land Environment

The proposed project will generate the some solid hazardous wastes, which should be carefully stored and sent to Rajasthan Hazardous waste Management Project Udaipur.

5.4.8. Socio - economic Environment

As a good corporate citizen and major industry,AMBEY may consider adopting few selected villages in developing them as model villages.

Awareness program are to be initiated in immediate neighbouring industries about AMBEY plant activities and the various EHS measures undertaken to make the plant safe and environment friendly.

5.4.9. Environment Management Cell

AMBEYshould have an EHS management cell headed by a senior executive supported by other supporting staff. The plant shall have well equipped quality and environmental control laboratory having sophisticated instruments including:

Gas Chromatograph Water quality checker CO,CO2ppm analyser BOD Incubator Colony Counter Spectrophotometer Naphalometer Stack Monitoring Kits. Drager Pumps and tube kits pH Meter Gas Chromatograph for NG & other associated facilities.

A team of well-trained and experienced staff carries out tests in the laboratory.

5.4.10. Post – Operational Monitoring Program

AMBEY should carry out environment monitoring as per monitoring plan proposed as follows:

Discipline Location Parameter Frequency Remarks Meteorology One Temp.{max.; min.};

Relative humidity; Rain fall; Wind speed and direction.

Daily Being complied

Ambient Air Quality

Five HCl, Cl; HBr, SOx; Particulate matter (with pesticide compounds)

Twice a week Parmaters as applicable /as per products



Discipline Location Parameter Frequency Remarks being manufactured

Stack Emission

All continuous

stacks

HCl, Cl; HBr, SOx;NOx;Particulate matter (with pesticide compounds)

Once a week; Parmaters as applicable /as per products being manufactured

Effluents Final effluents discharge point

--- Once a day. Parmaters as applicable /as per products being manufactured

Sanitary TSS; BOD Weekly Ground Water Quality (Four peizometric wells)

Four peizometric wells

Pesticides- etc. Quaterly Parmaters as applicable /as per products being manufactured

Noise Plant area &periphery

Day & Night time noise level

Monthly

Health Check Up

All Plant Personnel

Diseasesrelated to pesticides

Annually



CHAPTER 6. RISK ASSESSMENT& DISASTER MANAGEMENT PLAN

6.1. Introduction

Industrial plants deal with materials, which are generally hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of these. Fire, explosion, toxic release or combinations of these are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and Quantitative Risk Assessment have now been developed to improve upon the integrity, reliability and safety of industrial plants.

The primary emphasis in safety engineering is to reduce risk to human life, property and environment. Some of the more important methods used to achieve this are:

Quantitative Risk Analysis: Provides a relative measure of the

likelihood and severity of various possible hazardous events by

critically examining the plant process and design.

Work Safety Analysis: The technique discerns whether the plant

layout and operating procedures in practice have any inherent

infirmities.

Safety Audit: Takes a careful look at plant operating conditions, work

practices and work environments to detect unsafe conditions.

Together, these three broad tools attempt to minimize the chances of accidents occurring. Yet, there always exists, no matter how remote, probability of occurrence of a major accident. If the accident involves highly hazardous chemicals in sufficiently large quantities, the consequences may be serious to the plant, to surrounding areas and the populations residing therein.

6.2. Risk Assessment

A three ‗levels‘ risk assessment approach has been adopted for theM/s

Ambey Laboratories Pvt Ltd. (hence forth Ambey) proposed project to be set up at Plot No. SP1-5, RIICO Industrial Area,Sotanala, Behror Dist. Alwar, Rajasthan. The risk assessment levels are generally consistent with the practices encountered through various assignments for medium and large chemical complexes. The brief outline of the three tier approach is given below:

Level 1 – Risk Screening

This is top-down review of worst- case potential hazards/risks, aimed primarily at identifying plant sites or areas within plant, which pose the highest risk. Various screening factors considered include:

Inventory of hazardous materials;



Hazardous Materials properties; Storage conditions (e.g. temperature and pressure); Location sensitivity (distance to residential areas / populace).

The data / information are obtained from plant. The results provide a relative indication of the extent of hazards and potential for risk exposure.

Level 2 – Major Risk Survey (Semi - Quantitative)

The survey approach combines the site inspection with established risk assessment techniques applied both qualitative as well quantitative mode. The primary objective is to identify and select major risks at a specific location in the plant considering possible soft spots / weak links during operation / maintenance. Aspects covered in the risk usually include:

Process Hazards; Process Safety Management Systems; Fire Protection and Emergency response equipment and programs. Security Vulnerability; Impact of hazards consequences (equipment damage, business

interruption, injury, fatalities); Qualitative risk identification of scenarios involving hazardous

materials; Risk reduction measures.

Selection of critical scenarios and their potential of damage provide means of prioritising mitigative measures and allocate the resources to the areas with highest risks.

Level 3 – Quantitative Risk Assessment (Deterministic)

This is the stage of assessment of risks associated with all credible hazards (scenarios) with potential to cause an undesirable outcome such as human injury, fatality or destruction of property. The four basic elements include:

Hazards identification utilising formal approach (Level 2, HAZOP etc.); Frequency Analysis. Based on past safety data (incidents / accidents);

Identifying likely pathway of failures and quantifying the toxic / inflammable material release;

Hazards analysis to quantify the consequences of various hazards scenarios (fire, explosion, BLEVE, toxic vapour release etc.).Establish minimum value for damage (e.g. IDLH, over pressure, radiation flux) to assess the impact on environment.

Risk Quantification: Quantitative techniques are used considering effect / impact due to weather data, population data, and frequency of occurrences and likely hood of ignition / toxic release. Data are analysed considering likely damage (in terms of injury / fatality, property damage) each scenarios is likely to cause.



QRA provides a means to determine the relative significance of a number of undesired events, allowing analyst and the team to focus their risk reduction efforts where they will be beneficial most.

Ambey shall manufacture pesticides chemicals at the proposed site.Table 2.6 in section 2.5.2 gives the list of raw materials and mode of storages/ quantum of storage in the plant. The list of bulk storages of raw materials are as given below:

Table 7.1. Bulk Storages Sr. No.

Name of Chemicals State Storage capacity (MT)

1. Phenol Liquid 4X10 KL each= 40KL 2. Chlorine Gas 86.4 MT (0.9 t tonner) 3. Sodium hydroxide (Caustic

Soda) Liquid 4X16 KL=65 KL

4. Hydrochloric Acid Liquid 5X10 KL each= 50KL 5. Dimethyl Amine Liquid 2X16 KL each= 32KL 6. Sulphuric Acid Liquid 1X20 KL each= 20KL 7. Ethanol Liquid 28 KL underground Tank 8. Toluene Liquid 28 KL underground Tank 9. Methanol Liquid 28 KL underground Tank 10. Hexane Liquid 28 KL underground Tank 11. Iso Butylene Gas 10 MT Bullet

12. Trifluro Acetic Acid Liquid 1X10 KL each= 10KL 13. Dichloromethane Liquid 1X10 KL each= 10KL

6.3. Risk Screening Approach

Proposed Plant: Risk screening of Ambeyproposed project was undertaken through data / information provided by Ambey. Data of major / bulk storages of raw materials, intermediates and other chemicals were collected. MSDS of hazardous chemicals were studied vis a vis their inventories and mode of storage. Ambey plant will be using number of hazardous chemicals and also producing pesticides chemicals – all hazardous in nature. The chemicals stored in bulk (liquid or gaseous) and defined under MSHIC Rule will be considered for detailed analysis.

Hazardous materials have been defined under MSIHC Rules (1989) - 2 (e) which means.

(i) Any chemical which satisfies any of the criteria laid down in Part I of Schedule I and is listed in Column 2 of Part II of this Schedule;

Toxic Chemicals: Chemicals having the following values of acute toxicity

and which owing to their physical and chemical properties, are capable of

producing major accident hazards:

S. No

Toxicity Oral Toxicity

LD50 (mg/kg)

Dermal Toxicity

LD50 (mg/kg)

Inhalation Toxicity

LC50 (mg/l)

Remarks

1 Extremely Toxic >5 < 40 < 0.5 2 Highly Toxic >5 – 50 > 20 – 200 < 0.5 – 2.0



3 Toxic >50 - 200 > 200 - 1000

> 2 - 10

Flammable chemicals:

(i) Flammable gases; 20 0C and at standard pressure of 101.3 KPa are:

Ignitable when in a mixture of 13% or less by volume with air, or; Have a flammable range with air of at least 12% points regardless of

the lower flammable limits. (ii) Extremely flammable liquids: chemicals which have a flash point lower

than or equal to 230C and the boiling point less than 350C;

(iii) Very Highly flammable liquids: chemicals which have a flash point lower

than or equal to 230C and the boiling point higher than 35 0C;

(iv) Highly Flammable Liquid: Chemicals which have a flash point lower

than or equal to 60 0C but higher than 23 0C.

(v) Flammable liquids: chemicals which have a flash point higher than 60 0C but lower than 90 0C.

Explosives: Explosive means a solid or liquid or pyrotechnics substance (or a mixture of substances) or an article.

a) Which is in itself capable by chemical reaction of producing gas at such a temperature and pressure and at such a speed as to cause damage to surroundings;

b) Which is designed to produce an effect by heat, light, sound, gas or smoke or a combination of these as the result of non-detonative self-sustaining exothermic chemical reaction.

I. any chemical listed in Column 2 of Schedule 2; II. any chemical listed in Column 2 of Schedule 3;

Ambeyall 16 (4 existing and 12 new) pesticides products are hazardous in nature. However hazards potential (for damage) of products and other materials to plant personnel, environment and off-site area is different for different materials. Ambey will be storing nearly14liquid/ gaseous raw materials (in bulk) but only 11 are listed under ―List of hazardous and Toxic Chemicals‖ category under MSIHC Rules,

1989.The raw materials coming under hazardous category as specified by MSIHC Rules, 1989 (including subsequent amendments) is given in Table 7.2 below:

Table 7.2. Hazards Analysis –Raw materials

S. No

Material S. No & Threshold Quantity (TQ in Kg) as

Chemicals Hazards Potential

Remarks

per MSHIC Rules Schedul

e-1, Part-II

Schedule-2,

Part-I

Schedule-3,

Part-I

Hazards Toxic

1ortho-Phenol CAS No:106-

481 ---- ---- Flammability: Ignites when

ERPG-1: 10 ppm

Phenol



. 95-2 moderately heated; Yields flammable vapors when heated, which will form explosive mixtures with air; Health Hazards: Will burn eyes and skin. The analgesic action may cause loss of pain sensation. Readily absorbed through skin, causing increased heart rate, convulsions, and death.

UN No: 2821 ERPG-2: 50 ppm

A colorless liquid when pure, otherwise pink or red. Combustible. Flash point 175°F.

ERPG-3: 200 ppm

IDLH: 250 ppm

2.

Chlorine 119 5 108 ERPG-1: 1.0 ppm

CAS No:7782-50-5

TQ-1: 10MT

TQ-1: 10MT

Non Combustible;May ignite other combustible materials (wood, paper, oil, etc.). Mixture with fuels may cause explosion. Container may explode in heat of fire. Chlorine reacts explosively with or supports the burning of numerous common materials. Ignites steel at 100°C in the presence of soot, rust, carbon, or other catalysts. Ignites dry steel wool at 50°C. Hydrogen and chlorine mixtures (5-95%) are exploded by almost any form of energy (heat, sunlight, sparks, etc.). Health Hazards: Poisonous; may

ERPG-2: 3.0 ppm



be fatal if inhaled. Contact may cause burns to skin and eyes. Bronchitis or chronic lung conditions

UN No:1017 TQ-2: 25 MT

TQ-2: 25 MT

ERPG-3: 20 ppm

A greenish yellow gas with a pungent suffocating odor. Toxic by inhalation.

IDLH: 10 ppm

3.

Sulphuric Acid CAS No: 7664-93-9 UN No: 1830

591 ---- ---- Flammability: Will not burn Health Hazard: Extremely hazardous - use full protection; Reactivity: Violent chemical change possible

ERPG-1: 2.0 mg/m3

ERPG-2: 10 mg/m3 ERPG-3: 30 mg/m3 IDLH:15 mg/m3

4.

Hydrochloric acid (Gas) CAS No: 7647-01-0 UN No: 1789

313 ---- ---- Not Flammable; Inhalation of fumes results in coughing and choking sensation, and irritation of nose and lungs. Liquid causes burns

ERPG-1: 3.0 ppm

Plant uses liquid and emits HCl gas

ERPG-2: 20 ppm ERPG-3: 150 ppm IDLH: ---- ppm

5.

Sodium Hydroxide CAS No: 1310-730-2 UN No: 1823

571 ---- ---- Not flammable; Corrosive to metals and tissue. Hazardous.

ERPG-1: 0.5 ppm

ERPG-2: 5.0 ppm ERPG-3: 50 ppm IDLH: ---- ppm

6.

Dimethyl Amine (40%)

--- ---- ---- Acute Flammable.

CAS No:124-40-3 (Pure DMA)

Very hazardous in case of ingestion, of inhalation. Hazardous in case of skin contact (corrosive, irritant, permeator), of eye

toxicity Oral-(LD50): Mouse) Vapor (LC50): 11350 ppm 4 hour(s)

NFPA:

Liquid with strong odour

contact (irritant). (Rat) (Calculated value

Health: 3



for the mixture).

Flammability: 4

Reactivity: 0

7.

Ethyl Alcohol 248 ---- ---- Hazardous in case of skin contact (irritant), of eye contact (irritant), . Slightly hazardous in case of skin contact (permeator), of ingestion. Non-corrosive for skin. Non-corrosive to the eyes. Non-corrosive for lungs

Oral (LD50): 7060 [Rat]. 3450 [Mouse].

Flammable.

CAS No:64-17-5 (200 Proof) (Pure DMA)

Vapor (LC50): 20000 ppm 8 hours [Rat]. 39000 4 hours [Mouse].

NFPA:

Liquid with alcohol/wine like odour

Health: 2

BP: 78.50C Flammability: 3

FP(CC):18.50

C Reactivity:

0 LFL: 3.3%;

UFL: 19%

8.

Toluene 628 ---- ---- Flammability: Ignites at normal temperatures; Vapor is heavier than air and may travel a considerable distance to a source of ignition and flash back; Health Hazard

ERPG-1: 50 ppm

CAS No: 108-88-3 UN No: 1294

Vapors irritate eyes and upper respiratory tract; cause dizziness, headache, anesthesia, respiratory arrest. Liquid irritates eyes and causes drying of skin. If aspirated, causes coughing, gagging, distress, and rapidly developing pulmonary

ERPG-2: 300 ppm



edema. If ingested causes vomiting, griping, diarrhea, depressed respiration.

A clear colorless liquid with a characteristic aromatic odor. Flash point 40°F

ERPG-3: 1000 ppm

IDLH: 500 ppm

9

. Methanol 377 ---- ---- Health Hazards:

Exposure to excessive vapor causes eye irritation, headache, fatigue and drowsiness. 50,000 ppm will probably cause death in 1 to 2 hrs. Swallowing may cause death or eye damage.

ERPG-1: 200 ppm

Highly Flammable; Behavior in Fire: Containers may explode

CAS No:67-56-1

ERPG-2: 1000 ppm

UN No:1230 ERPG-3: 5000 ppm

A colorless fairly volatile liquid with a faintly sweet pungent odor like that of ethyl alcohol.

IDLH: 6000 ppm

1

0. n-Hexane 306 --- --- Health Hazards:

Inhalation causes irritation of respiratory tract, cough, mild depression, cardiac arrhythmias. Aspiration causes severe lung irritation, coughing, pulmonary edema; excitement followed by depression. Ingestion causes nausea, vomiting,.

TEEL-1: 400 ppm

Highly flammable; Vapours may explode;

CAS No:110-54-3

TEEL-2: 3300 ppm

TEEL-3: 8600 ppm

Clear colorless

liquids with a petroleum-like

odor. Flash points -9°F

IDLH 1100 ppm

11.

Toluene CAS No: 108-88-3 UN No: 1294

628 ---- ---- Flammability: Ignites at normal temperatures; Vapor is heavier than air and may travel a considerable

ERPG-1: 50 ppm



distance to a source of ignition and flash back; Health Hazard

A clear colorless liquid with a characteristic aromatic odor. Flash point 40°F

Vapors irritate eyes and upper respiratory tract; cause dizziness, headache, anesthesia, respiratory arrest. Liquid irritates eyes and causes drying of skin. If aspirated, causes coughing, gagging, distress, and rapidly developing pulmonary edema. If ingested causes vomiting, griping, diarrhea, depressed respiration.

ERPG-2: 300 ppm

ERPG-3: 1000 ppm

IDLH: 500 ppm

1

2. Iso Butylene [C4 H8]

---- ---- ---- Product stable; extremely reactive; incompatible with oxidizing agents.

LC50 (Rat)—550000 mg/M3

O-Xylene

CAS No: 115-11-7 UN No: 1055 Extremely Flammable Gas; FP—76.1 0C Explosive Limit- Lower-1.8%; Upper-9.6%

13.

Triflouro Acetic Acid

---- ---- ---- LC50 (Rat)—10000 mg/M3

C2HF3O2 Harmful by inhalation. Causes severe burns.

NFPA RATING

CAS No: 76-05-1

Skin Contact: Causes severe burn

HEALTH: 3

Clear colorless liquid with

organisms, may cause long-term adverse effects

FLAMMABILITY: 0



pungent odor in the aquatic environment.

Hazardous Decomposition Products: Carbon monoxide, Carbon dioxide,

REACTIVITY: 1

Hydrogen fluoride.

14.

Dichloromethane

---- ---- ---- Skin: May be absorbed through the skin. Causes irritation with burning pain, itching, and redness. Prolonged exposure may

ACGIH-50ppm TWA

NFPA Rating: (estimated) Health: 2; Flammability: 1; Instability: 0

CAS No: 75-09-2

result in skin burns.

STEL (15 min)-125 ppm

UN No: 1294 Ingestion: Causes gastrointestinal irritation with nausea, vomiting and diarrhea. May cause kidney damage

A clear colorless liquid with a characteristic Etheralodor.

Inhalation of high concentrations may cause central nervous system effects characterized by nausea,

BP-40 0C headache, dizziness, unconsciousness and coma

Note: TQ-I: Threshold quantity (for application of rules 4,5,7 to 9 and 13

to 15)TQ-II: Threshold quantity (for application of rules 10 to 12)

As detailed in the above table out of 13 materials only tenhave been mentioned in the MSIHC list and only one is toxic gas (Chlorine), one (isobutylene) is extremely inflammable / explosive gas, eight are toxic/inflammable liquid.Four of these liquid (highly inflammable) materials are stored in bulk in underground tanks and rest liquids are received in above ground tanks and stored as such. Isobutylene gas is stored in bullet tank. Chlorine is stored in 900 kg cylinders.

The hazardous nature and properties of the products are given in Table 7.3 below:

Table 7.3. Hazards Analysis – Products



Sr. No. Product/ Formula / [Active Ingredient

(AG) % + Others%]/ CAS / UN No

Properties Toxicity Potential

Remarks / Hazards

1. ` 2,4-D Sodium Salt (95% SP) (Monohydrous sodium salt of 2,4 Dichlorophenoxyacetic acid) C8H5Cl2NaO3 · H2O CAS No: 2702-72-9 Class: 9 Solid Powder

May be harmful if inhaled. May cause respiratory tract irritation. Harmful if swallowed. May be harmful if absorbed through skin. May cause skin irritation. Causes eye burns. Hazardous decomposition products formed under fire conditions. - Carbon oxides, HCl gas, Sodium oxides

No data available TLV – TWA 7mg/m³ ORAL LD50 (Rat) : = 552mg/kg b.w. DERMAL LD50 (Rat) :>5000mg/kg b.w.

Limited Data

2. 2,4-D Acid Technical C8H6Cl2O3 CAS No: 94-75-7 White to browncrystalline Solid; MP: 1380C

Extremely hazardous in case of eye contact (irritant). Slightly hazardous in case of skin contact (irritant), of eye contact (Corrosive). Non-corrosive for skin. Severe over-exposure can result in death. Inflammation of the eye is characterized by Redness, watering, and itching.

ORAL (LD50): Acute: 375 mg/kg [Rat]. 347 mg/kg [Mouse]. 100 mg/kg [Dog]. DERMAL (LD50): Acute: 1400 mg/kg [Rabbit].

Limited Data

3. 2,4-D Ethyl Ester Technical CAS No: 533-23-3 Colourless to amber liquid; does not mix with water

Accidental ingestion of the material may be harmful; animal experiments indicate that ingestion of less than 150 gram may be fatal. f applied to the eyes, this material causes severe eye damage.; Inhalation of vapours or aerosols (mists,

Oral (rat) LD50: 500 mg/kg *

Limited Data



fumes), may be harmful.

4. 2,4-D Amine Salt C10H13Cl2NO3 CAS No: 2008-39-1 UN No: 3082 Clear dark/brown viscous liquid with Mild phenolic odour

Very irritating to eyes. Skin contact: Not irritating to skin. Ingestion: Harmful if large amounts are swallowed. Inhalation: Moderately irritating to respiratory tract.

Acute oral LD50:600. 5 mg/kg in rats. Acute dermal LD50: > 4 347, 73 mg/kg in male rats. Acute inhalation LC50(4h) : 1.60 mg/l [HT]

Limited Data

New Products Proposed ClodinofopPropergyl

C17H13ClFNO4 AG-22.3 % CAS No:105512-06-9

Light to dark brown liquid. With aromatic odour. Dangerous products Flash Point: 143.50F of decomposition at high temperature – Toxic gases Nitrogen oxides (NOx)

DT-4000; OT-2276 IT-3.5; [T] (Rats) NFPA- H-2;F-2;I-0

Causes eye, skin and respiratory passage irritation. May cause sensitation of skin. Exposure to high vapour level may cause dizziness, headache or affect nervous system.

Hexaconazol C14H17Cl2N3O AG-4.96%; CAS No:79983-71-4 UN No:2903

White crystalline odourless solid Combustion Products- Sulphur / phosphorus compounds etc.

DT-> 2000; OT-2189; IT->5.98;[T] (Rats)

Eyes &Skin:Can cause mild irritation; Ingestion may result nausea. Cramps and vomiting; Non Carcinogenic

Atrazine CAS No: 1912-24-9

Active Ingredient: 25% Ethylene Glycol –6% Balance Formulation Aids White coloured liquid; BP-103 0C

DT- 3100mg/Kg (Rabbit) OT-4346; ()Rat IT-NE (Rats)

Buprfezine CAS No: 69327-76-0

Active Ingredient: 43% Ethylene Glycol –6% Balance Formulation Aids Solid

DT- >5000mg/Kg (Rat) OT-2198; (Rat) IT-NE (Rats)

Skin irritation in rabbits: the product is considered none irritating. Eye irritation rabbits: the product is considered none Irritating the product is considered none sensitizing.



Lambda-Cyhalothrin C23H19ClF3NO3 C23H19ClF3NO3

AG: 97% CAS No:91465-08-6

Dark brown/green solid FP: 1850C

DT- 696; OT-79; IT-0.06 [ET]; (Rats)

Mild eye irritant; Not skin irritant; Symptoms that may arise if the product is mishandled and overexposure occurs are nausea, vomiting, diarrhoea, abdominal pain, ataxia, unsteady gait, hyper excitability, salivation, tremors and incontinence

Cypermethrin AG-97% C22H19Cl2NO3 CAS No:52315-07-8 UN No:3349

Appearance:yellow-brown viscous semi-solid at ambient temperatures

DT->4920; OT-187-326; IT-2.5; [T] (Rats)

Skin Hazards –temporary (~ 24 hrs); Ingestion- affects gastrointestinal tract;

Alphamethrin C25H20Cl2NO3 CAS No: 67375-30-8

Active ingredient~ 12 to 15% Rest Aromatic hydrocarbon Appearance: yellow- colour liquid with mild odour at ambient temperatures Inflammable- FP- >62 0C

DT- ---; OT-79 mg/Kg (Rat); IT-2.5; [T] (Rats)

Skin Hazards –temporary (~ 24 hrs); Ingestion- affects gastrointestinal tract;

Deltamethrin C22H19Br2NO3

AG-98% CAS No:52918-63-5

UN No:3349

Colourless and odourless solid

DT->2000; OT-135 - >5000; IT----- NFPA- H-2;F-0;I-0

Toxic by inhalation and if swallowed and breathe dust.

Cypermethrin Acid Chloride

AG: 98.5% CASNo: 52314- 67- 7

Yellow Colour Liquid with aromatic odour; React violently with water with evolution of HCl

------- Can cause temporary irritation, tearing and blurred vision Can cause a slight irritation on more sensitive areas [face, eyes, mouth] Can cause stomach irritation resulting in nausea, cramps and vomiting. Excessive inhalation can cause nasal and respiratory irritation

Meta PhenoxyBeenzaldehyde

Clear light amber liquid;

Not available Causes eye irritation.



AG: 98% CAS No: 39515-51-0

BP: 140 0C Inflammable FP: 112 0 C

May cause chemical conjunctivitis. Skin: Causes skin irritation. Ingestion: May cause gastrointestinal irritation with nausea, vomiting and diarrhea. Inhalation: Causes respiratory tract irritation.. Can produce delayed pulmonary edema. Chronic: Effects may be delayed.

Fipronil

CAS No: 1200068-37-3

Appearance: grey to tan granules Odor: slight musty odor Not inflammable

DT-2000 (Rabbit); OT- > 5000 mg/Kg (Rat) IT- 5.16; mg/L (4 hrs.)(Rats) [T] NFPA- H-1;F-1;R-0

Eye: May causes redness, irritation, tearing. Skin: Harmful if absorbed through skin. May produce symptoms similar to those from ingestion. May cause irritation, redness, swelling. Ingestion: Harmful if ingested. May cause drowsiness, involuntary shaking, shortness of breath, convulsions, excitement.

Glyphosate

CAS No: 38641-94-0

AG: 53.8% Pale yellow viscous liquid with amine odour POTENTIAL PHYSICAL HAZARDS: May react with metals such as galvanized or mild steel to produce hydrogen gas, potentially forming a highly combustible gas mixture

DT-5000 (Rat); OT- > 5000 mg/Kg (Rat) IT- >7.03; mg/L (4 hrs.)(Rats) [T]

EYE – Slight eye irritant. Undiluted product may cause pain, redness and tearing. SKIN - May be slightly irritating to the skin. INGESTION - No more than slightly toxic and no significant adverse health effects are expected to develop if a small amount (less than a mouthful) is swallowed.

Note: 1. Oral Toxicity (OT) in LD50 (mg/kg) 2. Dermal Toxicity (DT) in LD50 (mg/kg) 3. Inhalation Toxicity in LC50 (mg/l) [4 hrs.]



Acute Exposure Guideline Levels (AEGLs)

AEGL-3 is "the airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience life-threatening adverse health effects or death."

AEGL-2 is "the airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape."

AEGL-1 is "the airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience notable discomfort, irritation, or certain asymptomatic no sensory effects.

Emergency Response Planning Guidelines (ERPGs)

The 3 ERPG Emergency Response Planning Guidelines are levels of concern

representing the adverse health effects of a hazardous substance on members of

the general public. ERPGs are developed by the ERPG committee of the American

Industrial Hygiene Association (www.aiha.org). tiers are defined as follows:

ERPG-3 is "the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects."

ERPG-2 is "the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action."

ERPG-1 is "the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing other than mild transient health effects or perceiving a clearly defined, objectionable odor."

Temporary Emergency Exposure Limits (TEELs)

TEELs Temporary Emergency Exposure Limits are levels of concern representing the adverse health effects of a hazardous substance on members of the general public. TEELs are defined by the U.S. Department of Energy for use when ERPGs or AEGLs aren't available (see www.hss.energy.gov/HealthSafety/WSHP/chem_safety/teel.html).are used in similar situations as the 60-minute AEGLs Acute Exposure Guideline Levels are levels of concern representing the adverse health effects of a hazardous substance on members of the general public. AEGLs are developed by the National Research Council's National Advisory Committee on AEGLs (www.epa.gov/oppt/aegl).andERPGs Emergency Response Planning Guidelines are levels of concern representing the adverse health effects of a hazardous substance on members of the general public. ERPGs are



developed by the ERPG committee of the American Industrial Hygiene Association (www.aiha.org).. However, in situations where the concentrationThe amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.varies over time, the TEEL developers recommend using a conservative 15-minute time-weighted average concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.. A chemical may have up to 4 TEEL Temporary Emergency Exposure Limits are levels of concern representing the adverse health effects of a hazardous substance on members of the general public. TEELs are defined by the U.S. Department of Energy for use when ERPGs or AEGLs aren't available (see www.hss.energy.gov/HealthSafety/WSHP/chem_safety/teel.html).values, each of which corresponds to a specific tier of health effects.

The 4 TEEL Temporary Emergency Exposure Limits are levels of concern representing the adverse health effects of a hazardous substance on members of the general public. TEELs are defined by the U.S. Department of Energy for use when ERPGs or AEGLs aren't available (see www.hss.energy.gov/HealthSafety/WSHP/chem_safety/teel.html).tiers are defined as follows:

TEEL-3 is "the maximum concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.in air below which it is believed nearly all individuals could be exposed without experiencing or developing life-threatening health effects."

TEEL-2 is "the maximum concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.in air below which it is believed nearly all individuals could be exposed without experiencing or developing irreversible or other serious health effects or symptoms that could impair their abilities to take protective action."

TEEL-1 is "the maximum concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.in air below which it is believed nearly all individuals could be exposed without experiencing other than mild transient health effects or perceiving a clearly defined objectionable odor."

TEEL-0 is "the threshold concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.below which most people will experience no appreciable risk of health effects."



The National Institute of Occupational Safety and Health (NIOSH National Institute for Occupational Safety and Health (www.cdc.gov/niosh). The federal agency responsible for conducting research and making recommendations for the prevention of work-related disease and injury. NIOSH is part of the Centers for Disease Control and Prevention (CDC).) defines an immediately dangerous to life or health condition as a situation "that poses a threat of exposure to airborne contaminants when that exposure is likely to cause death or immediate or delayed permanent adverse health effects or prevent escape from such an environment."

The IDLH limit Immediately Dangerous to Life and Health limits, levels of concern for adult workers; estimate of the highest concentration from which escape is possible without permanent injury (if their respirators fail). IDLHs ae established by the National Institute for Occupational Safety and Health (www.cdc.gov/niosh).represents the concentration The amount of a chemical present in a given weight or volume of air. Concentration of a gas in air may be expressed in units such as parts per million (by volume) or milligrams per cubic meter.of a chemical in the air to which healthy adult workers could be exposed (if their respirators fail) without suffering permanent or escape-impairing health effects.

6.4. Hazardous Materials Storage

The solid raw materials will be received in bags or drums and will be stored inchemicals go-downs. The products (liquid or solid) will be packed in drums and stored in product go-downs as per market demand. The bulk storages of liquid hazardous materials are given in the Table 7.1.

The solid materials powder or granules spillage can results in polluting small area only. The damage to personnel can be through ingress- dermal (if individual come in contact), oral (if individual food gets infected through fugitive dust) or inhalation (fugitive dust). The main route is fugitive dust which incovered area will move to short distance only.

The risk is through liquid and gaseousmaterials which are volatile material. The toxic vapours due to spillage of such material can travel to some distance (as they are stored in covered go-downs) and cause damage. The liquid products will be packed in drums (50 litres drums).

6.5. QRA Approach

Identification of hazards and likely scenarios (based on Level-1 and Level-2 activities) calls for detailed analysis of each scenario for potential of damage, impact area (may vary with weather conditions / wind direction) and safety system in place. Subsequently each incident is classified according to relative risk classifications provided in Table below asTable 7.3:

Table 7.4. Risk Classification Stage Description

High (> 10-2/yr.)

A failure which could reasonably be expected to occur within the expected life time of the plant.



Stage Description Examples of high failure likelihood are process leaks or single instrument or valve failures or a human error which could result in releases of hazardous materials.

Moderate (10-2 --10-

4/yr.)

A failure or sequence of failures which has a low probability of occurrence within the expected lifetime of the plant. Examples of moderate likelihood are dual instrument or valve failures, combination of instrument failures and human errors, or single failures of small process lines or fittings.

Low (<10-4)

A failure or series of failures which have a very low probability of occurrence within the expected lifetime of plant. Examples of ‗low‘ likelihood are multiple instruments or valve failures or multiple human errors, or single spontaneous failures of tanks or process vessels.

Minor Incidents

Impact limited to the local area of the event with potent for ‗knock – on- events‘

Serious Incident

One that could cause: Any serious injury or fatality on/off site; Property damage of $ 1 million offsite or $ 5 million onsite.

Extensive Incident

One that is five or more times worse than a serious incident.

Assigning a relative risk to each scenario provides a means of prioritising associated risk mitigation measures and planned actions.

6.6. Thermal Hazards

In order to understand the damages produced by various scenarios, it is appropriate to understand the physiological/physical effects of thermal radiation intensities. The thermal radiation due to tank fire usually results in burn on the human body. Furthermore, inanimate objects like equipment, piping, cables, etc. may also be affected and also need to be evaluated for damages.Table 7.5, Table 7.60andTable 7.7(below), respectively give tolerable intensities of various objects and desirable escape time for thermal radiation.

Thermal hazards could be from fires or explosion. Fire releases energy slowly while explosion release energy very rapidly (typically in micro seconds). Explosion is rapid expansion of gases resulting in rapidly moving shock wave. Explosion can be confined (within a vessel or building) or unconfined (due to release of flammable gases).

BLEVE (boiling liquid expanding vapour explosion) occurs if a vessel containing a liquid at a temperature above its atmospheric boiling point ruptures. The subsequent BLEVE is the explosive vaporisation of large fraction of its vapour contents; possibly followed by combustion or explosion of the vaporised cloud if it is combustible.

Thermal hazards have been considered for various scenarios including:

Fire in inflammable chemicals storage tanks.

Table 7.5. Effects due to Incident Radiation Intensity Incident Radiation

kW/m2 Damage Type



0.7 Equivalent to Solar Radiation 1.6 No discomfort on long duration

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn are likely).

9.5 Pain threshold reached after 8 sec. Second degree burn after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting of plastic tubing etc.

25

Minimum Energy required for piloted ignition of wood, melting, plastic tubing etc.

37.5 Sufficient to cause damage to process equipment. 62.0 Spontaneous ignition of wood.

Table 7.6. Thermal Radiation Impact to Human

Exposure Duration

Radiation Energy {1% lethality; kW/m2}

Radiation Energy for 2nd degree burns; kW/m2

Radiation Energy for 1st degree burns; kW/m2

10 sec 21.2 16 12.5 30 9.3 7.0 4.0

Table 7.7. Tolerable Intensities for Various Objects

Sl. No Objects Tolerable Intensities (kw/m2)

1 Drenched Tank 38 2 Special Buildings (No window, fire proof

doors) 25

3 Normal Buildings 14 4 Vegetation 10-12 5 Escape Route 6 (up to 30 sec.) 6 Personnel in Emergencies 3 (up to 30 sec.) 7 Plastic Cables 2 8 Stationary Personnel 1.5

6.7. Damage due to Explosion

The explosion of a dust or gas (either as a deflagration or detonation) results in a reaction front moving outwards from the ignition source preceded by a shock wave or pressure front. After the combustible material is consumed the reaction front terminates but the pressure wave continues its outward movement. Blast damage is based on the determination of the peak overpressure resulting from the pressure wave impacting on the object or structure.

As a safety measure Ambey is storing highly inflammable raw materials in underground tanks. Damage estimates based on overpressure are given in Table 7.8below:

Table 7.8. Damage due to Overpressure Sl. No Overpressure

(psig / bar) Damage

1. 0.04 Loud Noise / sonic boom glass failure



2. 0.15 Typical pressure for glass failure 3. 0.5 - 1 Large and small windows usually shattered 4. 0.7 Minor damage to house structure 5. 1 Partial demolition of houses, made uninhabitable. 6. 2.3 Lower limit of serious structure damage 7. 5 – 7 Nearly complete destruction of houses 8. 9 Loaded train box wagons completely demolished 9. 10 Probable total destruction of houses 10. 200 Limits of crater lip

In Ambey case explosion probability is remote.

6.8. Toxic Release

Hazardous materials handled and stored in bulk in Ambey complex are toxic/ inflammable gases Chlorine / isobutylene andliquids (as detailed in Table 7.1) and many other raw materials as defined in MSHIC rules and indicated in Table 7.2. Some of these chemicals are stored in bulk (in tank farm).

Damage criteria: For toxic release the damage criteria considered is IDLH concentration (if data are available). In the absence of non-availability of IDLH, ‗Inhalation Toxicity (IT) data for rats‘ are considered. ‗IT‘ data are used

for the products as IDLH are not available for these chemicals.

6.9. Data Limitations

It is also observed that very little data or information (regarding physicalproperties required for modelling) is available about the products.

6.10. Likely Failure Scenarios

Few likely failure scenarios have been selected after critical appraisal of raw materials and storage inventories. Failure scenarios selected are as given in Table 7.9 below:

Table 7.9. Different Failure Scenarios S. No. Scenario Remark

Raw materials RM-1 Chlorine Tonner heavy leak Chlorine Down wing toxic effect RM-2 Isobutylene gas heavy leak; Jet Fire BLEVE Inflammable RM-3 Hexane—Heavy Spillage Inflammable RM-4 Toluene—Heavy Spillag Toxic

6.11. Weather Effect

The effect of ambient conditions on the impact of fire / heat radiation and GLC of hazardous / toxic material can be beneficial as well as harmful. A high wind (turbulence) can dilute the toxic material while stable environment can extend the reach of IDLH or IT (inhalation LC50 rats for products) concentration to long distance. Any inflammable gas / vapour release in turbulent weather will soon dilute the hazardous gases below LEL and thus save the disaster.

6.12. Incidents Impacts

The identified failure scenarios (Table 7.9) have been analysed (Using ALOHA and EFFECT Modules) for the impact zones considering damage due



to thermal and toxic impacts. Similar impacts are considered for expansion units. Each incident will have Impact on the surrounding environment which in extreme case may cross plant boundary. The impact zones for various scenarios are given in Table 7.10

Table 7.10. : Hazards Scenario Impact Scenario No.

Scenario Impact Zone (m) Remarks

Scenario Raw Material RM-1 Chlorine Tonner heavy

leak ~ 910

419

IDLH; Stability Class F Template 1 IDLH; Stability Class D Template 2

RM-2 Isobutylene gas leak; Jet fire BLEVE

~10 430

1st degree burn; Template 3 1st degree burn from fireball Template 4

RM-3 Heavy Spillage Hexane 20 1st degree burn Template 5

RM-4 Toluene Heavy Spillage ~13 IDLH; Stability Class D

Templates of Scenario

Template 1: Chlorine Leakage Impact Zone (Stability Class F)



Template 2: Chlorine Leakage Impact Zone (Stability Class D)

Template 3: Isobutylene Leakage Jet Fire Impact Zone



Template 4: Isobutylene Leakage BLEVE Impact Zone

Template 5: Hexane Heavy Spillage Leakage Pool Fire Impact Zone



6.12.1. Consequential Impacts

The consequential impacts from each incident scenario can be though thermal, over pressure wave and toxic route. The damage can be on plant personnel (and neighbouring residents in case incident crosses boundary), property and also loss in production.

6.12.2. Thermal and Explosion Hazards

Incidents involving thermal hazards are mainly due to raw material fire (due to spillage/ BLEVE). The impact (1st degree burn) is limited to 20 m only (i.e. within plant boundary) except due to BLEVE (in case of Isobutylene Bullet explodes) where impact zone can be as large as 430 m from fireball. However the consequences can go to worse if the incidents lead to domino effect to other tanks.

6.12.3. Toxic Hazards

Toxic hazards are mainly due to chlorine gas leakageand its impact can cross the plant boundary (if not controlled in time). The impact due to chlorinewill go to 0.91 km i.e. it will cross the plant boundary limit and affect large areas / nearby populace depending upon wind direction.

Ambey is using chlorine as basic raw material and shall provide following emergency safety measures:

Caustic pit shall beprovided adjoining to chlorine storage for any emergency.

Chlorine hood shall be provided that covers the chlorine cylinder in emergency and necessary connections provided directly connecting to the scrubbing system.

Emergency kit and four sets of breathing apparatus provided to meet any emergency.

6.12.4. Other Hazards

The other hazards in the plant include (but not limited to):

Other toxic hazards due to acids / other toxic spillages (mainly limited to spillage area only.).

Mechanical hazards due to machines / equipment. Hazards due to individual soft spots like walking casually and noticing a

pit and falling or colliding/ stumbling or slipping (not noticing a wet place etc.).

6.12.5. Other Toxic Hazards

Acid spillage-its impact will be limited to spillage area. The spillage if comes in contact with metal parts will produce hydrogen which is highly flammable gas. Any person moving in area and getting splash will get the injury. In addition the spillage will cause pollution problem. The spillage is to be collected and neutralized for toxic contents before disposal.



6.12.6. General Control Measures

Since some of the substances in use at Ambey are hazardous with fire potential and also toxic in nature, it is necessary to use appropriate control measures recommended for such substances:

6.12.7. Flammable Gas Fires

Fire control generally consists of directing, diluting and dispersing the inflammable gas/vapor to prevent contact with persons, to prevent it from infiltrating structures if the leak is out door, and to avoid its contact with ignition sources while, if possible, simultaneously stopping the flow of gas. Water in the form of spray, applied from hoses or monitor nozzles or by fixed water spray system cools the burning vapours / gas.

6.12.8. Commonly Recommended Control Measures

A number of preventive control measures for hazardous occurrences have been analysed and discussed above. Some more salient points are enumerated below:

All storage tanks in the tank farm should be dyked. Other operation and maintenance features shall be based on established best safety practices.

Concentration detectors for hazardous chemical vapours (e.g. Chlorine etc.) fire Smoke / heat detectors and fire alarm should be installed at all strategic locations in the plant.

A schedule for preventive maintenance including health survey of all plant equipment should be adhered to as far as possible.

Ensure the absence of ignition sources in storage area. Ensure placement of fire fighting facilities, such as, carbon dioxide, dry

chemical powder and foam type fire extinguishers in addition to fire hydrant system, at strategic locations. Spill control measures, such as, removal of all ignition sources from the spill area and ventilating the area as well as soaking the spilled material with paper, towel or mud and letting the volatile substance evaporate slowly in a safe area.

Compulsory use of protective clothing, non-sparking tools and warning signs during critical operations and maintenance.

Training / refresher courses on safety information‘s / norms. Eyewash and showers should be put up at strategic places for use

during emergencies.

A group of plant personnel should be trained in first aid, rescue, fire fighting and emergency control measures. These personnel will form core group/emergency squad who will fight the emergency and also act as rescue and first aid team.

In order to ensure communication from isolated places/locations Walkie-Talkie be made available to persons working in these areas. This will considerably improve the effectiveness of emergency management.

There is no substitute for training-mock drills and these must be held at regular interval keeping the following objectives in mind:



Real time mock-drill should be carried out for probable/likely hazardous situation (after the plant is successfully commissioned).

Target to be set up for various tasks and events during an emergency.

Weak links should be marked and corrective action taken to improve effectiveness during emergency.

Ambey team already understand the implication and hazards in fertiliser industry and has implemented most of the measures in the sister organisation existing plants.

6.13. Occupational Health and Safety

Occupational Health and Safety (OHS) are of prime importance more so in hazardous industries. Industries have various types of hazards and QRA is carried out to understand the hazards potential from various incidents. Pre-emptive steps can be planned to safeguards from likely causes. Some of the

Frequent causes of accidents

Fire and explosion: explosives, flammable material Hazards from Toxic Materials Mechanical Hazards such as:

Being struck by falling objects Caught in between machine parts Snapping of cables, ropes, chains, slings Handling heavy objects

Electricity Hazards o Electrocution o Short circuits and consequential fire. o Poor illumination etc.

Other Hazards: Falls from height inside industrial units or on the ground Struck by moving objects;Slipping on wet surfaces Sharp objects

Oxygen deficiency in confined spaces; Lack of personal protective equipment (PPE), housekeeping practices, safety signs

Consequential hazards due to extreme Temperatures; Consequential hazards due to vibration Consequential hazards due to radiation; Many more hazards.

Hazardous substances and wastes

Heavy and toxic metals Lack of hazard communication (storage, labelling, material safety data

sheets) Batteries, fire-fighting liquids Welding fumes Volatile organic compounds (solvents) Inhalation in confined and enclosed spaces



Ergonomic and psychosocial hazards

Many of the hazards are as result of working environment. Repetitive strain injuries, awkward postures, repetitive and

monotonous work,excessive workload Long working hours, shift work, night work, temporary employment

(Long working hours, shift work, night work, temporary employment,Mental stress, human relations) which results in less attention at work place and consequential incidents and accidents.

Lack of education and training / awareness is another prime cause of accidents.

Considering above, QRA analysis and also the nature of activities at Ambey the following steps for OHS activities have been suggested:

Employee‘s health check-up:pre-employment and periodic check-up during employment. The health check-up observations should be informed to employees.

The health should include any impact due to hazards at work place including (but not limited to) due to noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc.

Training and refresher courses on safety to all employees. Employees should be made aware of the hazards in the plant and the

preventive actions to be safe from such hazards.

Response to Injuries:Based on a survey of possible injuries, a procedure for response to injuries or exposure to hazardous substances should be established. All staff should have minimum training to such response and the procedure ought to include the following:

Immediate first aid, such as eye splashing, cleansing of wounds and skin, and Bandage etc.

Immediate reporting to a responsible designated person If possible, retention of the item and details of its source for

identification of possible hazards. Medical surveillance Recording of the incident Investigation, determination and implementation of remedial action

6.14. Emergency Management Plan

Ambey has a Emergency Management Plan (EMP) and regularly carrying out Mock drills to check the effectiveness of the EMP (EMP and report attached). However for reference and review key features of standard EMP are given below.

6.14.1. Ergonomic and psychosocial hazards

Many of the hazards are as result of working environment



Repetitive strain injuries, awkward postures, repetitive and monotonous work,excessive workload

Long working hours, shift work, night work, temporary employment (Long working hours, shift work, night work, temporary employment,Mental stress, human relations) which results in less attention at work place and consequential incidents and accidents.

Lack of education and training / awareness is another prime cause of accidents.

Considering above, QRA analysis and also the nature of activities at AMBEY the following steps for OHS activities have been suggested:

Employees health check-up: pre-employment and periodic check up during employment. The health check-up observations should be informed to employees.

The health should include any impact due to hazards at work place including (but not limited to) due to noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc.

Training and refresher courses on safety to all employees.

Employees should be made aware of the hazards in the plant and the preventive actions to be safe from such hazards.

Response to injuries: Based on a survey of possible injuries, a procedure for response to injuries or exposure to hazardous substances should be established. All staff should have minimum training to such response and the procedure ought to include the following:

Immediate first aid, such as eye splashing, cleansing of wounds and skin, and Bandage etc.

Immediate reporting to a responsible designated person If possible, retention of the item and details of its source for

identification of possible hazards. Medical surveillance Recording of the incident Investigation, determination and implementation of remedial action

6.14.2. Emergency facilities

Emergency Management Planning (EMP) should be developed considering the likely hazards in the plant and sincerely implemented. Mock drills for various scenarios should be carried out and results of the drills should be recorded. Weal links in the mock drills should be strengthened.

6.15. Objectives

The Emergency Management Plan (EMP) is developed to make the best possible use of the resources available at AMBEY and the nearby agencies to



provide help/assistance in case of an emergency in the plant. The activities will include:

Rescue the victims and give them the necessary medical attention in the shortest possible time.

Safeguard other person (evacuate them to a safer place). Contain the incident and control it with minimum damage to human and

life and property. Provide necessary information to families/relatives of affected persons,

outside agencies including media and statutory bodies.

6.16. Emergency Management Plan

The organizational set-up necessary for chain of commands during emergency situation in the plant is as given below..

President (Operations) of the AMBEY is the Chief Emergency Coordinator and he shall be the main guiding person directing the emergency operations. He shall be assisted by:

Chief Site Coordinator.

GM (Production), Coordinate and direct all the activities from Emergency site, In absence of GM (Prod.), DGM (Prod. I/II) will act as Chief Site Coordinator.

Chief Maintenance Coordinator

Manager-Maintenance, Coordinate all the maintenance activities from the Emergency Control Center. In absence of Manager (Maint.), Asst. Manager will act as Chief maintenance Coordinator.

Chief Service Coordinator

Manager (HR), Coordinate with local administration takes care of transport, medical, canteen arrangements, and evacuation of people if required. In absence of Manager (HR), Asst. Manager (P&A) will act as Chief Service Coordinator.

Chief Material Coordinator

Manager (Material), In absence of Manager (Material), Asst. Manager (Material) will act as Material Coordinator.

Operation Coordinator Manager (Prod.) is the Incident, Controller for Vehicle Control & Security Personnel Security Officer, In absence of Security Officer, Security Supervisor will act for Vehicle Control & Security Personnel deployment.

Fire & Safety Controller

\Incharge (F&S), In absence of Incharge (F&S), Supervisor. (F & S) will act as Fire & Safety Controller and also for first aid.

Two ―Assembly Points‖ will be identified (based on wind direction and away

from hazardous areas) and duly marked.

Chief Service Coordinator shall contact the following senior officers stationed at Behror and Alwar.

Format for Telephone Numbers of the Authorities:



Important Phone No’s Establishments Phone No S.D.O Behror 01494-220023 TehsildarBehror 01494-220047 Fire Station Behror 101, 01494-222034 Fire Station Neemrana 01494-246046 Fire Station Sotanala (at 300 mtr distance) 01494-220084 Inspector of Factories & Boiler, Alwar 0144-2341574 Police Station Behror 01494-220022 Pollution Control Board, Alwar 0144-2372996 E.S.I Inspector, Behror 01494-221731 Electricity Board, Behror 01494-230030 PHED Water Works, Behror 01494-222465 Telephone Exchange 01494-221400

Medical Services Name Of Hospital Address Phone No. Capacity Civil Hospital Haminder Road, Behror 01494-230104 More than 100

Beds Kailash Hospital NH-8 Behror 01494-222444/222222 More than 200

Beds VIL Dispensary VIL, Shahjahanpur 9549088572 About 3 Beds E.S.I Dispensary Near panchayatbhawan

Neemrana 01494-221731 About 5 Beds

6.17. Responsibilities & Role of Key Personnel

6.17.1. Over all In-charge –President (Operation)

On getting the information about emergency from GM (Prod.) rush to incident site/ECC. Assess the over all situation and provide guidance in critical decision-making.

6.17.2. Chief Site Coordinator- Manager (Prod.)

On getting the information about emergency from Supervisor Plant, inform over all In-charge P (O).

Rush to the emergency site to assess the situation and decide to: Declare emergency based on amount/extent of hazards and water/air

analysis (toxic / flammable material release) and advise Incharge (F&S) for sounding emergency siren.

Review if plant shutting down is required to contain / control the hazard.

Review, evacuation from affected areas and sending the affected person to a safe place.

Advise Incident Controller and other key personnel to take necessary action.

He will interact with Chief Service Coordinator and advise him on possible effects on areas inside and outside the factory to initiate Off- Site Emergency Response Plan.



Remain in touch with Overall in-charge (P -O) and inform about the situation & actions being taken and seek his advice for the critical decisions.

6.17.3. Chief Maintenance Coordinator- GM (Maintenance)

After getting information about emergency from manager concerned Plant. Inform all concerned personnel to be on alert.

Rush to the ECC, assess the situation and facilitate Chief Site Coordinator-GM (Prod.), Maintenance support needed to tackle the emergency.

Facilitate elect. isolation of the affected area, if required through Supervisor (E&I)

Facilitate lighting arrangements at (a) affected locations and (b) Assembly points if required through Supervisor (E&I)

Facilitate work-shop facilities with adequate manpower if required through Manager (Maintenance). Remain in touch with Chief Site Controller.

6.17.4. Chief Service Coordinator - Manager (HR)

On getting information from the Medical Coordinator rush to the Emergency Control Centre.

Assess the situation in consultation with Chief Site Coordinator and Incident Controller and ensure that casualties get adequate transport / medical help.

Make arrangement to shift all the persons to the safest place if called for.

Assess 'Law and Order' situation. Inform press, TV / Radio, local authorities about the severity of

situation in close co-ordination with Chief site Coordinator and in consultation with Over all In-charge -P (O).

Inform the District Authority / local police station in case their help is required for evacuation of personnel / preserving law and order.

Evacuation of adjoining areas and villages, if required. Remain in touch with over all In-charge - P (O) and seek his advice for

the critical decisions.

6.17.5. Chief Material Coordinator- Manager (Materials)

Rush to the emergency control centre on receipt of the message from Chief Service Coordinator / on hearing the emergency siren and inform Supervisor. (Store) about the emergency.

Get the stores opened for requirement of the Fire fighting/safety and other materials, which may be required during emergency.

Assess the situation in consultation with Chief site coordinator & incident controller for any material requirement /help at the affected site.



He will be responsible for the arrangements of trucks for movement of bulk material if required.

Remain in touch with Chief site coordinator, Incident controller, and Chief maintenance coordinator.

6.17.6. Incident Controller Concerned Plant -Manager Concerned Plant

Rush to the site of emergency after getting information from Shift In-charge assesses the situation and immediately inform

GM – Prod. Take over charge from shift in charge. Ensure that persons working in the area are safe and isolate source of

toxic release if possible. Advise and assist In charge (F&S) for providing water curtains to

contain toxic release with in the plant battery. Remain in touch with Chief Site Controller and other concerned

officers. Coordinate with Chief Maintenance / Chief Material coordinators for

assistance required at site. Depending upon the severity of incident, ensure that adequate

emergency services like Medical/ Laboratory/ Mechanical/ Electrical etc.are summoned.

Preservation of evidence as far as possible without affecting the operation of emergency procedures to facilitate any subsequent inquiries into the causes and circumstances, which led to the emergency.

6.17.7. Shift In charge (Concerned Plant):

Immediately proceed to the site of emergency and assess the situation: Emergency Control Room at 101/123 (with name and location of

emergency) During odd hours/till arrival of Fire shift I/C should act as chief fire

coordinator. Initiate the shutting down operations for controlling the hazard if

unavoidable. Cordon off the area and do not allow any body to enter the affected

area without respiratory protection (In case of toxic gas leakage). Direct rescue operations with the help of fire and safety staff. Open safety Almirah for the use of plant personnel. Have regard to the need for preserving evidence that could facilitate

subsequent inquiry. Advise Supervisor of the plant to take roll call and account for missing

personnel. Hand over charge of the operation to the Manager when he arrives at

site.



Ensure service agencies like Electrical, mechanical, instrumentation are mobilized to handle the emergencies.

6.17.8. Security Officer Vehicle Control and Security Personnel Deployment at the Locations

Rush to the spot of emergency on getting information from Security Officer on duty and inform Manager (HR) about emergency.

Arrange one emergency vehicle immediately for ECC. Keep in touch with Chief Service Coordinator, Chief Site Coordinator

and Incharge (F&S). He will act as a special rescue Coordinator at the time of evacuation of

employees and others if required. Alerts complete staff under his control and make it available at a known

point, as per the guidance of Chief Site Coordinator / Chief Service Coordinator.

Anticipate and arrange vehicles required at emergency site in consultation with Incharge (F&S) and Chief Site Coordinator and Chief Service Coordinator.

On request send vehicles for getting plant personnel / fire personnel required for emergency.

Arrange vehicle in consultation with Medical Coordinator / Chief Service Coordinator for shifting injured to Behror hospital.

During emergency arrange for opening of relevant gates/ barriers foreasy movement of vehicles. Security Guards should be posted on these gates / barriers to prevent unauthorized entry.

Arrange transport and temporary shelters for evacuated personnel and inform the relatives of the affected personnel if required.

6.17.9. Fire & Safety Controller- Incharge (F&S)

Rush to the spot of emergency after getting information from ECC and inform to Supervisor. (F&S).

Direct rescue operations under the guidance of Chief Site Coordinator/ Incident controller if required

Ask additional help from C.S.O. for cordoning off the area and advise fire personnel for rescue / fire fighting if required

Arrange to provide water curtains, water monitors, at affected locations if required.

Organize and supervise fire-fighting operations if called or. Provide necessary respiratory equipment to plant personnel for

emergency use. Advise Chief Site Coordinator to arrange additional help Mutual aid

group / neighbouring industries if required. Give safety precautions to the personnel at rescue work.

6.17.10. Fire Control Room In-Charge



On receiving emergency message from the Incharge(F&S)/ on hearing siren. Rush to ECC and take charge of Fire Control Centre from the fire operator / fire supervisor.

Assess the situation and Call fire staff from fire barrack. Immediately rush fire crew to emergency spot. Inform Medical Centre for sending ambulance to emergency site.

6.17.11. Fire Supervisor should also ensure the following:

Supervisor to look for the wind direction and cordon off the area. Use water monitors/hydrants/water curtains in consultation with

incident/Chief site controller. Provide respiratory equipment‘s to the plant personnel. In case of toxic spillage at site, put foam (HAZMAT)/ sand on the

spillage area. Remain in touch with Incharge(F&S). Chief Site Co-coordinator will instruct Fire Control Room In-charge for

operation of ―All Clear Siren‖ when the disaster is contained /

controlled. However, regular testing of siren & emergency buzzer plant control

rooms for 2 minutes on every Monday at 13.00 hrs is being done .All clear siren will sound for 2 minutes with a continuous sound.

6.18. Post Emergency Recovery

The post-emergency procedures discussed briefly below are designed to successfully manage the damage / losses of an emergency event. The focus of these procedures is to move the plant back into normal operating mode as quickly and efficiently as possible.

Immediately after the ―ALL CLEAR‖ an emergency meeting will be held in

emergency control centre to assess the loss both for men & materials, where in following will be present with attendance records, details of injured, out side situation and preparation of press release (if felt necessary)

Overall In charge

Chief Site Coordinator

Chief Maintenance Coordinator

Chief Service Coordinator

Incident Controller

Material Coordinator

Security

Fire & Safety Controller

6.18.1. Accident Investigation

a. As soon as possible after the emergency is over and plant operation has become normal, the investigation and analysis is to be carried out to determine the cause of the event.

b. Representatives from various disciplines will be members of the



investigation and analysis team. c. The areas of the events are to be sealed off so that tempering or

alterations of the physical evidence are not likely to occur. d. Key components are to be photographed and logged with time, place,

direction etc. e. Statements are to be taken from those who were involved with the

operation or who witnessed the event.

6.18.2. Damage Assessment

This phase of recovery establishes the quantum of replacement machinery considered necessary for bringing back plant to normal operation; property and personnel losses accounted and culminates in a list of necessary repair, replacement and construction work.

Insurance companies will be informed of the damage and requested to pay the compensation as per claim.

6.18.3. Clean-up and Restoration

This phase will only begin once the investigation is complete. Reporting documentations are to be prepared and forwarded to appropriate authorities. Repair, clean up and restoration work to begin.

6.18.4. Conclusion & Recommendations

The hazard analysis and risk assessment of few possible selected incident scenarios indicates that such incidents mostly are not limited to plant battery limits and have impact on adjoining plants. There are possibilities of domino effect and the secondary scenario not predictable can be worse than the primary one. Two scenarios (specifically toxic hazards scenarios) are crossing the Ambey plant boundaries. The direction of impact will be in down wind direction (wind direction and speed varies with season).

Some of the recommendations for Tank farm storage system are as given below:

Provision of flamedetectors/ thermal sensorsat strategic locations

in the tank farm area.

Auto water deluge system on each bulk storage tank for

inflammable liquids. The system should automatically start taking

signal from flame detectors or thermal relay.

Fixed foam system with adequate capacity.

Toxic Hazards are due to Chlorine and all liquid products... Regular ‗Hazard

Survey‘ ensures the detection of leakage in the plant.

Chlorine leakage can have adverse impact in large area and also in areas outside the AMBEY battery limit. AMBEY should have provision for sucking and scrubbing Chlorine in alkali solution. In house ‗capability building‘ to

attend hazardous scenarios is to be taken up through mock drills. Real time exercise with controlled release of Chlorine



to attend the leakage in cylinder

to transfer leaky cylinder near scrubber and absorb chlorine in

alkali solution

To attend leaky cylinder with ‗Chlorine safety Kit‘.

Train staff in attending such scenarios.

Human Factors: AMBEY should have well equipped fire station and also safety department – safety practices. Human factors role in safety cannot be ignored. Odd hours working and over / long hours work can drain out individual. It shows in lack of efficiency and also the lack of apt attention the modern chemical complex demand. They are to be closely looked into and avoided.

‗Safety‘ has unique features:

If no accident has happened so far probability of incident / accident occurring increases.

‗No accident‘ / good safety record develops complacency inertia/ over

confidence in the team. This attitude gives rise to gaps / soft spots in the system giving chances to incidents / accidents.

Safety requires novelty. Routine training practices get stale with no positive results. Look for novel scheme of training/ safety practices to build up fresh impetus in safety. Involvement of employees with refreshed outlook for safety is to be achieved.



CHAPTER 7. SUMMARY AND CONCLUSION

7.1. Prelude

The present study was aimed at identifying the potential environmental impacts due to the various project activities, assessment of impact, mitigation measures, and at developing an environmental management and monitoring plans for proper mitigation of any adverse environmental impact. In this study, the various activities likely to take place during the construction and operation phases of the project have been analyzed in relation to the baseline condition of different environmental components. The mitigation measures proposed for the contractors and the project proponent have also been reviewed and the potential residual impacts discussed. The key points considered in this study are described in the following sections:

7.2. Regulatory Compliance

The project is yet at its technical investigation stage. Prior to its implementation, it will be necessary to acquire all the necessary clearance from the Government of India, as per the applicable national regulations. Key clearances include obtaining No Objection Certificate from the Rajasthan State Pollution Control Board (RSPCB) under The Water (Prevention and Control of Pollution) Act, 1974 and Rules, 1975; The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982. In addition to that Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989 and amendments thereafter, Hazardous Waste (Management, Handling and Trans-boundary Movement) Rules, 2008, Bio Medical Waste (Management & Handling) Rules, 1998 and amendments thereafter, Municipal Solid Waste (Management & Handling) Rules, 2000 and amendments thereafter will also be applicable to the industry.

7.3. Baseline Conditions

The monitoring of the existing environmental conditions of the proposed project site and of its close vicinity have been established with respect to physical, biological and human environment. The air quality of the area meets the prescribed National Ambient Air Quality Standards applicable for the Residential & Rural Areas. The background noise levels were also found well within the standards as at present most of the area is not developed.

The water quality prevails in the study area is not good as it is not meeting the desirable limits of drinking. Ground water quality was compared with the drinking water At project site groundwater exceeding the permissible limit in respect of TDS and total hardness..Ground water from other villages is more or less suitable for drinking purposes (permissible limit in the absence of other source of water‖). Similarly It was observed that Surface water samples from

pond Raj Malikpur were with in the norms of permissible limit in the absence of other source of water‖ in respect of TDS, Cl, Total hardness, Mg and Total Coliform. The geology of the project area is of varied nature. No forest land is falling in the study area. In addition there is no sensitive ecosystem in the vicinity.



7.4. Environmental Impacts and Mitigation Measures

The project entails various impacts on the study area, some negative and some positive. The impacts will be caused by the construction activities as well as by the other industrial activities during the construction and operation phases, respectively. Various impacts identified during the study have been provided mitigation measures for a better environmental management. In addition to that the roles and responsibilities of the developers have also been given in the Environmental Monitoring Program to monitor the implementation of the environmental management plan to ensure the mitigations of adverse impacts.

7.5. Recommendations

Based on the environmental impact assessment conducted, the following recommendations are made:

Since regulations are fast changing in India, the project proponent must keep themselves updated with respect to applicable laws and take appropriate actions in case the provisions in some regulations undergo change.

Most of the impacts envisaged are due to construction activities. Systems of periodic auditing and reporting shall be adopted during the construction period to ensure that the contractors adhere to the EMP.

The project proponent and its team of consultants and contractors are urged to develop a strategy for effective communication with local people. The construction team/ developer should effectively follow the suggestions made in the EMP and/ or any other environmental measures so as not to damage the environment of the project area.



Chapter 8. Disclosure of Consultants

8.1. Prelude

Declaration by Experts Contributing To the EIA/EMP REPORT of Proposed

Expansion Pesticides manufacturing at Behror, Distt Alwar, Rajasthan by M/s Ambay

Laboratories Pvt Ltd. I, hereby, certify that I was a part of the EIA team in the

following capacity that developed the above EIA.

EIA Coordinator:

Name: P K Srivastava Signature & Date:

Period of involvement June 2013 to finalization of report Contact Information: 011-30003200

Functional Area Experts

Functional Areas

Name of the Expert

Involvement (Period and Task**) June 2013 to finalization of report

Signature

Air Pollution Monitoring & Control (AP)

S K Jain

Site visit, assistance in selection of monitoring locations, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM)

Air Quality Modeling and Prediction (AQ)

Sanjeev Sharma

Assistance in air quality modeling and prediction: met file generation and model run

Water Pollution (WP) S K Jain

Site visit, assistance in selection of sampling locations for surface water sampling, water balance for the project and contribution to EIA documentation

Solid and Hazardous Waste Management (SHW)

S K Jain

Identification of waste generated from the industry, studying adequacy of mitigation measures for management of hazardous waste

Socio-Economics (SE)

T G Ekande

Site visit, contribution to Baseline environment and contribution to EIA documentation

Risk and Hazards (RH)

P K Srivastava

Site visit, Identification of modeling scenarios,



Functional Areas

Name of the Expert

Involvement (Period and Task**) June 2013 to finalization of report

Signature

consequence modeling using PHAST, finalization of DMP, contribution to RA / DMP Documentation and contribution to EIA documentation

Team Member Name

Air Pollution Monitoring & Control (AP) Team Member: Om Prakash (AFAE)

Declaration by the Head of the Accredited Consultant Organization/authorized

person I, S.K.Jain, hereby confirm that the above-mentioned experts the EIA/EMP REPORT for Proposed Expansion Pesticides manufacturing at Behror, Distt Alwar, Rajasthan by M/s Ambay Laboratories Pvt Ltd. I also confirm that the consultant organization shall be fully accountable for any mis-leading information mentioned in this statement.

Signature:

Name: S.K.Jain Designation: Director, Technical

Name of the EIA Consultant organization EQMS India Pvt. Ltd. NABET Certificate No. and date NABET/EIA/RA11/007, 19th May, 2014

Documents

EIA/EMP & RA/DMP Report of Proposed Expansion Project of Technical ...environmentclearance.nic.in/writereaddata/EIA/24092015X97M6UI2EIA... · Environmental Impact assessment of proposed