Npl Industries Kh Exe Summ Eng and Guj

NPL Industries Private Limited

Executive Summary of REIA Report

Proposed Project of Manufacturing of Textile Binders & Auxiliaries Location at: S.No. 748/P, 750/P,777/B/P, 780/P, Village : Bidaj, Kheda, Gujarat

Prepared By:

Ramans Enviro Services Pvt. Ltd. SF –23 & 24, Camps Corner, Near AUDA Garden, Prahaladnagar Ahmedabad 380 015 Phone: 079-26937472. Fax: 079-40064440 E-mail:[email protected], [email protected]

AUGUST 2012

ExEcutivE summary : maNuFacturiNG PLaNt OF tExtiLE BiNDErs aND auxiLariEs

By NPL iNDustriEs Pvt. LtD. at viLLaGE : BiDaJ, Dist. : khEDa, GuJarat

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1. For growing market demand of the textile binders and auxiliaries

Chiripal Group has intended to establish the manufacturing unit

named M/s NPL Industries Private Limited.

EXECUTIVE SUMMARY

INTRODUCTION :

2. NPL Industries Pvt. Ltd. intends to serve the customers through

production of textile binders, textile auxiliaries, adhesive etc. through

innovative technology. NPL is looking for service driven business, to

work closely with customers to meet their specific needs and hence,

delivering satisfying and efficient solutions

3. The unit intends to engage itself in manufacturing of synthetic

adhesives and acrylic based emulsions for the paint and textile

industries in commitment to world class standards.

4. The proposed establishment falls under the Item 5 (f) of Schedule I of

Environmental Impact Assessment Notification dated 14/09/2006 under

the provisions of Environmental Protection Act, 1986. The location of the

proposed project is not within the any notified industrial estate; hence it

will be treated as Category A project.

PROJECT DESCRIPTION 5. The proposed project is coming up in the vicinity of Textile Park located

near village Bidaj, District Kheda, Gujarat State. National Highway – 8 is

@ 500 m distance from the project site.

6. The cost for the proposed manufacturing plant will be @ Rs. 1737 lacs,

which includes cost of land, building and machineries. Out of this,

approximately Rs. 50- 55 Lacs will be toward implementation of Env.

Pollution control measures.

7. Land area acquired by M/s. NPL Industries Pvt. Ltd. for the proposed

project is @ 9500 sq.m., out of which @1250 sq.m. will be for plant



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facilities, whereas @ 2500 sq.m. will be developed in form of green

area.

8. The unit intends to engage itself in production activities of Textile

binders, Textile polysols, Adhesives, Paint binder, Leather binder,

Auxiliaries & Plasticizers @ 5000 MT/M.

9. The power requirement @ 200 KW will be satisfied Captive power plant

of Vraj Integrated Textile Park Ltd. There will be installation of D.G. set of

100KVA, which will be operated in case of emergency during power

failure.

10. The water requirement @ 163 KLD for the proposed project will be for

process, utility (Boiler & Cooling), washing and domestic purpose,

which will be satisfied through an integrated textile park - VITPL which is

being developed just adjacent to the site.

11. As the major quantity of process water goes as part of product, hence,

the quantity of process wastewater generated is less in compare to

process water consumption. The main source wastewater generation

from utilities such as RO plant, DM plant, Boiler and Cooling is RO reject,

DM regeneration, Boiler blow down and Cooling bleed off.

12. Wastewater from process and utilities will be resorted to primary

treatment followed by tertiary treatment of two stage Reverse osmosis

plant. Reject from the second stage of RO plant will be thermally

destructed through Jacketed evaporator of @ 300 L/hour.

13. The sources of gaseous emission identified are from the Boiler as well as

fugitive emissions from handling of raw materials. No process emissions

have been envisaged from the proposed manufacturing facility.

14. Gaseous emission from solid fuel based 3 TPH boiler will be controlled

by Multicyclone with stack height of 30 m.

15. The sources of hazardous waste generation are process waste, ETP

sludge, used oil, discarded containers which will be handled as per

HWM Rules, 2008 and its amendment.



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16. The unit is committed towards the Health and Safety of workers. The

unit has provided adequate number of first aid boxes at strategic

locations and given training to designated person for the emergency

purpose. The unit has also appointed part-time medical officer for

medical assistance and for ensuring the better health of workers.

17. All the workers are provided with required personal protective

equipments as and when required as per the nature of job.

BASELINE ENVIRONMENTAL SETTING 18. Study period for the baseline data generation work Winter season

(December 2011 to February 2012) and study area was considered as 6

Km radius considering site as center.

19. For Winter season (December 2011 to February 2012), primary data on

wind speed, wind directions, temperature and humidity were obtained

from the project site by installing Weather Monitoring Station.

20. The maximum temperature recorded during study period was in the

month of December 2011, i.e. 34o C, whereas the minimum

temperature recorded was in the month of January 2012, i.e. 4o

21. Total 6 ambient air quality stations were selected in the radius of 6 km

from the project site as centre considering the various factors.

C. The

relative humidity has varied from 15% to 90% during study period.

22. At all these sampling locations PM10, PM2.5, SO2, NOx

were monitored

to enable the comparison with ambient air quality standards

prescribed by the Central Pollution Control Board (CPCB).

PARAMETERS MINIMUM VALUE

(µg/m3

MAXIMUM VALUE

(µg/m) 3)

PM 39.72 10 83.02



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PM 28.00 2.5 50.50

Sulfur dioxide 9.42 21.64

Oxides of Nitrogen 14.16 35.40 23. As per additional TOR conveyed by EAC, Volatile organic compounds

were monitored at all AAQM sampling locations and the minimum and

maximum result has been presented at below table.

PARAMETERS MINIMUM VALUE

(mg/m3

MAXIMUM VALUE

(mg/m) 3)

VOCs < 0.002 1.25

24. For characterization of water sources, Ground water samples (from 4

locations) and surface water samples (from 2 locations) were

collected and analyzed for drinking water quality parameters i.e.

physico-chemical parameters and heavy metals. All parameters were

found within permissible limit of IS 10500: 2000 (drinking water

standards). No heavy metals were found in any of the samples.

25. The noise levels were measured once during the study period at all

study locations for day time and night time. Noise levels were varied

between 56.17 to 71.66 during daytime and 41.09 to 64.33 at night time

during the study period.

26. Total 6 sampling locations within study area were identified for

characterization of soil. Physical characteristics of soil have been

delineated through specific parameters, viz. particle size distribution

(grain size analysis), porosity, water holding capacity and permeability

whereas data for chemical characterization of soil, selected

parameters viz. pH, electrical conductivity, cation exchange capacity,

and alkali matter and sodium absorption ratio have been analyzed.

27. Land use pattern of the study area have been obtained through LISS IV

satellite imaginary. Out of total 31428 Ha land, majority of the land area

i.e. @ 39% Crop land, followed by @ 12.93 % Water bodies including



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river. Approximately 17 % land is covered with open as well as dense

scrub where as @ 8.8% land is covered with plantation.

28. A detailed on-site survey on flora and fauna existing in study area was

carried out. The study area does not have any identified

endangered species and also does not have any designated

forest, national park, sanctuaries.

29. The general observation of the site visit is that none of the plant and

animal species recorded is rare or endangered. The species of flora

and fauna found in the study area are common as anywhere and

everywhere.

30. Total population of study area is 96,683 with sex ratio of 911 and

average literacy rate of 61%.

31. At present, the study area has an average employment of 42.5%. Out

of which 35.5% are main workers and 7% are marginal workers. Out of

main and marginal workers, 50% workers depend on agriculture and

cultivation.

32. All villages have electric supply available for all purpose. All the villages

are having education facilities upto Primary education.

33. Medical facilities are found satisfactory. All villages have community

health workers. Some of the villages have Hospital facility also.

34. Tap and well, Tube well and Hand pump are prime sources of water in

all villages. For communication purpose, post office and phones are

available in most of the villages.

35. Villages are connected with paved roads. Bus is the main source of

transportation for all villages. Kanij, Sarsa and Geratpur villages have

availability of railway facility.

IMPACT ASSESSMENT 36. Impacts are identified due to proposed project in two phases:

Construction & Operation.



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37. Impacts for construction phase will be short term temporary in nature

either positive or negative.

38. The negative impact will be on air quality and noise level due to

identified activities of proposed project during construction as well as

operation phases.

39. Green belt development will be the activity revealing beneficial

impacts on surrounding environment.

40. Employment generation will contribute positively to the local people

due to proposed project.

41. As the amount of ground water to be withdrawn for proposed project

is insignificant to the amount withdrawn by VITPL for its textile park,

there is no adverse impact anticipated on ground water quantity.

42. The anticipated quantity of effluent generated from the industrial plant

is @ 57.5 KLD, which will be treated in Treatment plant having primary

and tertiary treatment to achieve the quality of treated effluent so as

to recycle /reuse in the plant. As the treated effluent will be reused /

recycled in the plant, no direct impact on any environmental sink is

anticipated.

43. Stream containing high TDS (reject of second stage R.O.) will be

thermally destructed in evaporator.

44. The air quality will be affected moderately during construction phase

of proposed project. The unit has proposed to install lignite / agro

briquettes based boiler of 3 TPH capacity, Hence, for the control of flue

gas emissions, multi – cyclone will be provided. No process emissions

have been envisaged from the proposed production facility.

45. There will be minor significant adverse impact on air quality during

operation phase of the project due to material handling, operation of

utilities. Development of Green belt of different species will absorb and

confine the pollutants within the premises.



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46. The dispersion modeling was done as per the general guidelines of

CPCB vide their publication “Assessment of Impact to Air Environment:

Guidelines for conducting Air Quality Modeling”, 1998 and using ISCST-3

model of USEPA. From the dispersion model, it is observed that the

predicted ambient air quality due to proposed plant operations is well

within limits specified by the CPCB.

47. Incremental increase within the study area due to proposed project will

be as follow :

a. Particulate matter : 0 – 1.97 µg/m3

b. SO2 : 0 – 1.77 µg/m3

c. NOx : 0 – 0.66 µg/m3

Thus it can be concluded that proposed plant operations will not

adversely impact the air quality. Further, it is emphasized that all the

emissions have to be strictly controlled as mentioned in the mitigation

measures and summarized in the Environmental Management Plan, to

maintain ambient air quality within norms in the future.

48. The proposed project land has been taken on lease from the VITPL, for

industrial purpose, hence, there will not be any conflict in change of

landuse pattern. So, there is no impact envisaged on existing land use

pattern of the project site.

49. Placement and fixation of heavy machineries and vessels will have

moderate impact on noise for particular time period only. There will be

continuous generation of noise during plant operations, operation of

boiler having minor significant impact on the environment.

50. As the proposed project is to be developed near the premises of

industrial park, no significant impact associated with displacement of

prevailing floral & faunal species is envisaged on surrounding biological

environment due to proposed project activity.

51. The proposed project is anticipated to have positive socio-economic

impact as it will generate employment during construction as well as



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operation phase. The generation of employment will improve the

Quality of Life (QoL) of people of the region due to improvement in

income.

RISK ASSESSMENT STUDY 52. Risk assessment study has been carried out for the storage of identified

hazardous and toxic chemicals which will be used for manufacturing of

proposed products. The characteristic of the potential hazardous

material to be stored are identified for deciding preventive measures

required during storage, handling and transportation.

53. The chemicals to be hazardous or toxic in nature to be utilized are

identified and are acrylamide , ammonia, formaldyhyde , vinyl acetate

monomer , acrylonitrile , methanol, Epichlorohydrine, Acetic Acid,

styrene , formic acid.

54. Effect and consequence for the hazardous chemicals are carried out

specifically for thermal radiation, overpressure effect in case of

explosion and for toxic release scenario for IDLH concentration.

55. Most of the chemicals stored in container or drum and the

consequence analysis is carried out for rupture of 200 liter drum of

methanol , 1250 liter container of vinyl acetate monomer, 200 liter drum

of styrene and rupture of 200 liter drum of acrylonitrile and the pool fire

and thermal radiation distance are calculated based on the available

software of PHAST(Version 6.53.1) Software of DNV. The various

concentration foot prints are plotted and shown in detail in report.

56. For the worst case scenarios and Maximum credible accident scenario,

rupture of the drum/ container is considered and the distance for

thermal radiation concerning first degree burn, second degree burn

and third degree burn are evaluated. This will help in deciding the

appropriate control measures to be provided for minimizing the effect

in case of emergency.



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57. The maximum damage distance for various chemicals is summarized as

follow.

Sr

no

Name of chemicals

and condition

Atmospheri

c condition

Maximum distance in m

37.5

kw/m2

12.5

kw/m2

4

kw/m2

1 Rupture of 200 liter

drum of Methanol

3 m/s – D Not

reache

d

6.32 11.77


vinyl acetate

container

3 m/s – D 12.41 32.34 51.24

3 Rupture of 200 l

styrene drum

3 m/s – B 5.10 16.24 26.16


acrylonitirle drum

3 m/s – D 5.59 15.19 23.67

58. However in event of release as a result of rupture in drum /container of

above chemical, explosive mass will not be formed in any stability class

and wind speed. Hence, no overpressure hazard due to both early and

late explosion is possible in any case.

59. Statutory guidelines have been followed for preparation of risk

mitigation measures on basis of risk analyzed. Fire fighting system as per

guideline will be installed and maintained.

60. The manual handling of chemical will be avoided as far as possible

and required safety measures will be provided for handling and

transportation of this chemical. Risk mitigation measures are specifically

provided for major and minor spills from drum and containers.

61. Occupational health surveillance program will be planned and

implemented during operational stage.



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62. DMP will be prepared for the proposed manufacturing plant and

implemented.

ENVIRONMENTAL MANAGEMENT PLAN 63. Optimum use of water will be done for construction phase as well as for

labours with adequate water supply to labours for drinking water and

sanitation facilities.

64. Dust will be the main pollutant affecting the ambient air quality during

construction phase alongwith gaseous emissions during transportation

of required materials. For suppression of dust during construction

activities, water will be sprinkled.

65. The performance of ETP will be monitored continuously. Any deviation

in performance will be subjected to corrective measures through root-

cause analysis.

66. The regular environment monitoring shall be done through established

laboratory.

67. For proposed project, all transferring and feeding areas will be well

covered to avoid any fugitive emissions. For the process area of the

plant, proper ventilation will be provided on the shop floor for

proper air circulation to maintain the work area air quality.

68. The segregation and storage of all hazardous solid waste generated

will be done for the proposed project.

69. Proper storage, handling and disposal of all type of hazardous solid

wastes as per the guidelines prescribed will be ensured.

70. Regular maintenance of equipments / machineries will be done by

application of proper lubricating agent. Enclosures and barriers will be

provided to pumps and machineries producing high noise levels for

proposed project.



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71. There will be practice of pre medical checkup and regular medical

checkup of employees and periodical training will be imparted for

better occupational health of workers.

72. Trained workers will be employed for all the hazardous process

operations within the plant and will be supervised by experienced

supervisors.

73. Antidotes as well as MSDS for all the chemicals will be made available

within the factory premises.



E.12

1.

NPL Industries Pvt. Ltd.

.

:

2. NPL Industries Pvt. Ltd. ,

.

NPL

3. Paint Textile Synthetic Adhesive

Acrylic Based Emulsion .

4. ,

1986 14/09/2006 1 5 (f)

;

A .

5. ,

, - 8 @ 500

.

6. @ 1737

. . 50 - 55

.

7. NPL Industries Pvt. Ltd

1250 2500

.



E.13

8. textiles binders,

textiles polysols, adhesives, paint binder, lather binders, Auxiliaries

plasticizers

9. Vraj Integrated Textile Park Ltd 200 KW

100KVA, DG Set

10. 163 KLD ,

Process, Utility ( ),

VITPL

11. ,

R.O. Reject, DM Regeneration, Boiler Blow down

Cooling Bleed off

12.

R.O. Plant

R.O. Plant R.O. Reject 3

Jacketed Evaporator

13.

fugitive emission

14. 3 TPH 30

Multicyclone .

15. ETP sludge HWM ,

2008



E.14

16. .

.

17.

18. (

) 6

. .

19.

( ), ,

.

20. ) 34oc

4o

21. 6 . .

c

15% 90%

22. PM10, PM2.5, SOX, NOX

(CPCB)

( / )

( / )

PM10

PM 2.5



E.15

SO 2

NO x

23. EAC TOR , AAQM VOC

.

( )

( )

VOCs 0,002 < 1.25

24. ( (4 )

(2 )

IS (Drinking water

standards) .

25.

.

.

26.

grain size

analysis), porosity, permeability

.

cation exchange capacity,

.



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27. LISS IV

% %

%

28. .

, .

29.

.

.

30.

% .

31. % . %

% . , 50%

.

32. .

.

33. .

. .

34. ,

. ,

.

35. .

. .

-

36.

37.



E.17

38.

39. .

40.

41. VITPL

42.

R.O. Plant

43. R.O. Plant R.O. Reject

Jacketed Evaporator

44.

3 TPH

–

45.

46. CPCB

"

" 1998 USEPA ISCST-3 .

CPCB

.

47.

– /



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– /

– /

48. VITPL ,

.

49.

.

50.

51.

.

52.

53. , ,

, , , ,

, , .

54.

IDLH

55.

DNV PHAST



E.19

56.

,

.

.

57. .

37.5

kw/m2 12.5

kw/m2 4

kw/m2 1 200

3 m/s – D --

2 1250

3 m/s – D

3 200

3 m/s – B

4 200

3 m/s – D

58.

59.

60.

.

.

61.

.

62. DMP .



E.20

63.

64.

65.

66.

67. ,

,

68.

69.

70.

.

71.

72.

73. MSDS antidotes

Documents

Npl Industries Kh Exe Summ Eng and Guj