PROJECT PRE-FEASIBILITY REPORT...PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09,HALDIA 3 4 SITE ANALYSIS 53 4.1 CONNECTIVITY 53 4.1.1 Road Connectivity 53 4.1.2 Rail Connectivity 53

PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09,HALDIA

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PROJECT PRE-FEASIBILITY REPORT

For

THE PROPOSED EXPANSION PROJECT FOR THE MANUFACTURING OF PESTICIDE TECHNICALS

Category: 5(b)

Of

M/s UPL Limited, UNIT # 09

Located at:

Haldia Industrial Area; Durgachak, Haldia, East Midnapur, West Bengal, India


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CONTENTS

1 EXECUTIVE SUMMARY 1

1.1 PROJECT PROPONENT 1 1.2 ABOUT PROJECT 1 1.3 SYNOPSIS OF THE REPORT 3

2 INTRODUCTION 7

2.1 BACKGROUND 7 2.1.1 CSR Activity at Haldia 7 2.1.2 Key Personnel 7 2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT. 8 2.3 JUSTIFICATION FOR THE PROJECT: 11 2.3.1 Need for the Project and its Importance to the Country and or Region, 11 2.3.2 Demand-Supply Gap. 11 2.3.3 Imports vs. Indigenous Production. 11 2.3.4 Export Possibility. 11 2.3.5 Domestic / export Markets 12 2.3.6 Employment Generation (Direct and Indirect) due to the Project 12

3 PROJECT DESCRIPTION 13

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY 13 3.2 LOCATION & ACCESSIBILITY 13 3.3 ENVIRONMENTAL SENSITIVITY 17 3.4 SITE ALTERNATIVE STUDY 19 3.5 SIZE OR MAGNITUDE OF OPERATION. 19 3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS 19 3.6.1 Acephate (Existing Route) 19 3.6.2 Acephate (Proposed New Route – After Expansions) 22 3.6.3 Di Ethyl P-Tosyloxym Ethylphosphonate ( DESMP - New) 25 3.6.4 Metamitron ( Existing – No Expansion) 27 3.6.5 Di Methoate (Existing – No Expansion) 31 3.6.6 ETHION (Existing – No Expansions) 33 3.6.7 Methyl Sulfenilyl Caramate (ASULAM - EXISTING – No Expansions) 35 3.6.8 PRETILACHLOR (EXISTING – No Expansions) 37 3.6.9 Methoxy Ethyl Mercuric Chloride (BAGALOL - EXISTING – No

Expansions) 41 3.7 RAW MATERIAL REQUIREMENT 44 3.8 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE 47 3.9 RESOURCE REQUIREMENT 47 3.9.1 Land 47 3.9.2 Water 49 3.9.3 Power 49 3.9.4 Fuel 49 3.10 POLLUTION SOURCES, TREATMENT AND DISPOSAL 50 3.10.1 Effluent & Sewage 50 3.10.2 Air Emission 50 3.10.3 Solid Waste / Hazardous Generation 52


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4 SITE ANALYSIS 53

4.1 CONNECTIVITY 53 4.1.1 Road Connectivity 53 4.1.2 Rail Connectivity 53 4.1.3 Air Connectivity 54 4.1.4 Water Connectivity 54 4.1.5 Land Form, Land use and Land Ownership : 54 4.2 TOPOGRAPHY (ALONG WITH MAP) 54 4.3 LAND USE 54 4.3.1 CRZ applicability 55 4.4 EXISTING INFRASTRUCTURE 55 4.4.1 Water 55 4.4.2 Power 55 4.4.3 Telecommunication 56 4.4.4 Drainage 56 4.5 SOIL CLASSIFICATION 56 4.6 CLIMATE 56 4.7 DEMOGRAPHY OF THE PROJECT INFLUENCE AREA 57 4.8 SOCIAL INFRASTRUCTURE AVAILABLE 57

5 PLANNING BRIEF 59

5.1 PLANNING CONCEPT 59 5.2 POPULATION PROJECTION 59 5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC 59 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ( PHYSICAL & SOCIAL) : 61 5.5 AMENITIES/ FACILITIES 61

6 PROPOSED INFRASTRUCTURE 62

6.1 INDUSTRIAL AREA (PROCESSING AREA). 62 6.2 RESIDENTIAL AREA (NON PROCESSING AREA) : 62 6.3 GREENBELT 62 6.4 SOCIAL INFRASTRUCTURE 62 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/ WATER

WAYS ETC) 62 6.6 DRINKING WATER MANAGEMENT ( SOURCE & SUPPLY OF WATER ) : 62 6.7 SEWERAGE SYSTEM 62 6.8 INDUSTRIAL WASTE MANAGEMENT 62 6.9 SOLID/HAZARDOUS WASTE MANAGEMENT 62 6.10 POWER REQUIREMENT & SUPPLY / SOURCE 63

7 REHABILITATION AND RESETTLEMENT (R&R) PLAN 64

7.1 POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF THE PROJECT AFFECTED

PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A

BRIEF OUTLINE TO BE GIVEN): 64

8 PROJECT SCHDULE & COST ESTIMATION 65

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION 65 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT 65


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9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 66

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE

LOCAL PEOPLE INCLUDING TRIBAL POPULATION ANY IN THE AREA 66 9.2 CONCLUSION: 66

List of Tables

Table 1-1 Brief Summary of Project 3 Table 2-1 List of existing Products & Proposed Products with expansion quantities 8 Table 2-2 List of By-products 10 Table 2-3 Manpower Requirement 12 Table 3-1 Environmental Settings of the Site 17 Table 3-2 Mass Balance for Acephate (Existing Route) 20 Table 3-3 Mass Balance for Acephate (Proposed Route) 24 Table 3-4 Mass Balance for DESMP 26 Table 3-5 Mass Balance for Metamitron 29 Table 3-6 Mass Balance for Di-Methoate 32 Table 3-7 Mass Balance – ETHION 34 Table 3-8 Mass Balance for ASULAM 36 Table 3-9 Mass balance for Pretilachlor 39 Table 3-10 Mass Balance for BAGALOL 42 Table 3-11 Raw Material Requirement Details 44 Table 3-12 Solvent Recovery Details 47 Table 3-13 Water Balance Details 49 Table 3-14 Waste Water Balance 50 Table 3-15 Existing and Proposed Air Emissions Details (Flue Gas) 51 Table 3-16 Existing and Proposed Process Stack Emissions 51 Table 4-1 Existing and Proposed Land Use Details 55 Table 4-2 Climatic Condition in the Study Area 56 Table 4-3 Demography of Haldia at a Glance 57 Table 4-4 Working Population of Haldia 57 Table 5-1 Existing and Proposed Land Use Details 60 Table 6-1 Solid/Hazardous Waste Management 63 Table 6-2 Non Hazardous Waste Management 63 Table 8-1 Project Cost Breakup 65

PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09, HALDIA

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1 EXECUTIVE SUMMARY

1.1 PROJECT PROPONENT

UPL Limited (formerly known as United Phosphorous Limited) is an International Company having base operations in about 12 Countries for the manufacture of Agrochemical and intermediates chemicals. UPL of late has made a significant entry in Seed business as well. In Gujarat, UPL Limited, is engaged in manufacturing of wide range of pesticides (technical), intermediates of pesticides, and other inorganic chemicals. United Phosphorus Limited, popularly known as ‘UPL’, started its operation in the year 1969. Since then it has established well equipped 11 Manufacturing units in India i.e. Vapi, Ankleshwar, Jhagadia, Halol, Tarapur (Maharashtra), Jammu & Haldia (West Bengal)] & total global 33 locations of manufacturing. Thus, the company has grown rapidly over the years. The company is a leading Agrochemical and Intermediates Chemicals manufacturing company. The company has marketing network in 130 countries including America, Europe, Africa, besides in all states of India. The product range of the company includes agrochemicals, Industrial Chemicals & Specialty chemicals. UPL Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL are Sanskardeep Vidyalaya (Ankleshwar), Gyandham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). 1.2 ABOUT PROJECT

M/s UPL Limited (Unit: 9) is located in Haldia Industrial area, falling under Medium Scale

category manufacturing products as mentioned under for which the company had obtained

Consent To Establish and Operate from West Bengal State Pollution Control Board.

The company proposes for expansion of capacity from 460 MT/month to 2100 MT/month

under the category “Pesticides technical & Intermediates”

It is categorized under project activity 5(b) and Screening Category “A” (sector- Pesticides

industry and pesticide specific intermediates (excluding formulations)) of the EIA

notification dated 14-09-2006 and therefore requires prior Environmental Clearance from the

Environment Impact Assessment Authority, Ministry of Environment & forests, New Delhi.

Proposed Project Cost: Rs. 165.31 crores.

The unit is manufacturing pesticides product as Pesticides technical like Acephate / Metamitron, Di-Methoate Or Ethion, Asulam and liquid Formulation Products like Ethion 50% EC, Dimethoate 30 %EC, Quinolphos 25% EC, Asulam (Methyl Sulfanilyl Carbamate 40% W/v Solution) , Asulam (Methyl Sulfanilyl Carbamate 50% W/v Solution) , and Solid Formulation Products like Acephate 75%, Metamitron 50% and Bagalol (MEMC 15%).


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The Company now plans to expand the capacity of existing products at pesticide technical grade and also plans to add new product Diethyl P - Toluene Methyl Sulphonyloxy Phosphonate (DESMP) as Pesticides technical product. The Unit is having various infrastructure facilities to take care of effluent generated and control of air pollution. The facility includes effluent treatment plant with primary and secondary and tertiary treatment. Treated effluent is discharged to green belt canal for further disposal to Hooghly River which ultimately meets to Bay of Bengal. The solid/hazardous waste generated is disposed off at TSDF site operated by West Bengal Waste Management Ltd (WBWML). The Company had obtained 01 (One) Environmental Clearance for pesticides & formulations, as follows.

1. Environmental Clearance No.: J.11011/914/2008-IA II(i) dated April 29th ,2009 in name of

United Phosphorous Limited, Durgachak, Haldia – 721602.

The copy of above environmental clearances is attached as Annexure – 01. 1.2.1.1 Applicability of EIA notification – 2006

UPL LIMITED (UNIT#09) is an existing manufacturing facility located at Haldia Industrial Area, West Bengal. The Unit is manufacturing Technical grade pesticides and formulations. Now, the Company proposes to expand the existing products at the existing site. It is categorized under project activity 5(b) and Screening Category “A” (sector- Pesticides industry and pesticide specific intermediates (excluding formulations)) of the EIA notification dated 14-09-2006 and therefore, requires prior Environmental Clearance from the Ministry of Environment Forests and Climate Change (MoEF&CC), New Delhi UPL- Haldia Units (Unit No. 9) had accorded the Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF) for 625 MTPM metric tons per month (MTPM) vide F.No. J-11011/914/2008-IA II(I) dated 29.04.2009. UPL, Haldia has been submitted the six monthly compliance report to Regional Office of MoEF&CC. The Unit has implemented Environmental Management System Standard i.e. ISO 14001, Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo by Indian Chemical Council (ICC). 1.2.1.2 Justification for the Project:

Presently, India is leading in the manufacture of pesticides and pesticide intermediates and is likely to become a world leader in future. Most of the pesticide products become immune to pests in short period and newer types of pesticides are to be replaced to meet the pest control requirements. UPL is having own R&D Division and is able to develop new processes for manufacture of alternative pesticide products. The company also has technology for manufacture of different pesticides and intermediates as they have acquired several units internationally.


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To fulfil the demand supply gap, it is decided to make optimal use of the facilities at UPL Unit#09 site by providing additional supporting infra-structure & hence this project for addition & expansion. 1.3 SYNOPSIS OF THE REPORT

The pre-feasibility report includes a brief introduction of the company, need and justification of the project, manufacturing process description, required and available resources, proposed Environment Management Systems, land-use and proposed infrastructure, project schedule and cost estimate and proposed Terms of reference for conducting the EIA studies. UPL has engaged M/s ERM India limited as an Environmental Consultant to conduct the EIA studies for obtaining Environmental Clearance (EC) for UPL Unit#09, located at Haldia, West bangal. Proposed project at a glance is mentioned in following Table.

Table 1-1 Brief Summary of Project

S. No.

Description Proposed Project Details

1 Name of project & Address Expansion of Manufacturing Capacity of existing products and manufacturing of new pesticides by M/s. UPL Limited Unit#09. Durgachak, Haldia. State – West Bengal.

2 Project Category The proposed project categorized under project activity 5(b) and Screening Category “A” (Pesticides industry and pesticide specific intermediates (excluding formulations)) of EIA notification dated 14-09-2006.

3 Project capital cost The Proposed project is for the expansion of the manufacturing capacity for existing unit. The capital cost of the Proposed project shall be approx. Rs. 16531 Lacs.

4 Products Sr. No

Product Category

Existing Production Capacity in MT/Month

Additional Capacity in MT/Month (Proposed in EC) in MT/Month

Total Production Capacity after Expansion (Including new products)in MT/Month

1 Pesticide Technical

460 1640 2100

2 Intermediate Products

NIL NIL NIL

3 Liquid Formulation*

950 NIL 950

4 Solid Formulation*

330 NIL 330

*The pesticide solid/liquid formulation products are excluded from Environmental Clearance as per EC Notification SO 1543 dated 14th September 2006. The product quantities (existing & proposed) details are given in Table 2-1 of Chapter 2.

5 By-products Total 3 no’s of by products are proposed to be generated after expansion. All by-products will be sold to market or disposed as per rule 9 of Hazardous and other wastes (Management & Transboundary Movement) Rules 2016 based on applicability. The total quantities generation is tabulated below.


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S. No.


Sr. No

Existing By Product Generation Quantity in MT/Month

Additional By Product Generation Quantity in MT/Month

Total By Product Generation Quantity in MT/Month

1 26 2767.4 2793.4

All details about By-product are given in Table 2-2 of Chapter 2.

6 Raw Materials The major raw materials consists of following items.

Organic Chemicals

In Organic Chemicals

Solvents and

Catalysts The product wise consumption details of raw materials have been given in Table 3-11.

7 Resource Requirement

a. Land The unit has total Land area 60702.82 sq. m (15 acre) sq.m. The area details are tabulated as below.

Sr. No

Existing Land Area in Sq.m

Additional Land Area Requirement in Sq m

Total Land Area Requirement in Sq m

Land Use Type

1 60702.82 Existing site, No additional new land required

60702.82 Industrial

b. Water The entire water requirement is proposed to be met through Haldia Development Authority (HDA) supply.

Existing Total water requirem ent in KLD

Additional Water requirement in KLD

Total Water requirement in KLD

Water Sources (Existing & Proposed)

60 271 331

Haldia Development Authority (HDA) supply

The unit is having valid EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009 having approval of 453 KLD, which will not be increased. Hence no additional water will be sourced as per previous EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009. Additionally, Unit is having One existing bore well as per EC letter no J-11011/914/2008-IA II(I) dated 29th April 2009 for which the approval from State Water Investigation Directorate, Kolkata has been obtained for 30 KL/hr with maximum 02 Hours withdrawal period. The copy of certificate is also attached as Annexure 02. The unit will not supplement any additional water requirement from Existing bore well for proposed expansions in construction & operational phase. No proposal for additional bore well for proposed expansions hence No ground water will be used for proposed expansions. Water quantity Details are given in a Table 3-13 of Chapter 3.

c. Electricity & Fuel Requirements

The power requirement details for existing & proposed expansion are given below. The power requirement will be met through West Bengal State Electricity Distribution Company Limited (WBSEDCL).


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S. No.


Existing Power Requirement in KW

Additional Power Requirement in KW

Total Power Requirement in KW

4250 43530 47780

The Fuel requirements for operation of Boilers, and DG sets is given below.

Sr No

Fuel Name

UOM Existing Qty.

Additional Proposed Quantity

Total after Expansion

Consumption Area

1 Coal MT/Day

60 225 285 Boiler

2 HSD Lit/ Day

250 455 705 DG Sets

d. Backup power The DG sets are installed at existing plant premises for emergency power back up only. The details of existing and proposed DG sets are tabulated as below.

Sr. No

Existing DG Set Capacity (KVA)

Additional DG Set Capacity (KVA)

Total Power Back up Capacity in KVA

1 1 X 500 KVA 1X2000 KVA

1 X 500 KVA 1 X 600 KVA 1 X 2000 KVA

2 1 X 600 KVA

The fuel for all DG sets : High Speed Diesel (HSD)

e Steam Requirements The steam generation capacity expansion is proposed as follows.

Sr. No

Existing Boiler Capacity in TPH

Additional Boiler Capacity for proposed expansion in TPH

Total Boiler Capacity after expansion in TPH

1 1 X 8 TPH Coal Fired Boiler

2 X 15 TPH Coal Fired Boilers

1 X 8 TPH 2 X 15 TPH Coal fired boilers

f. Man power Total required Manpower would be around 2046 and the details are given below:-

Sl. No. Particulars Manpower Details

Existing Proposed Total after Expansion

1 Staff 54 100 154

2 Contract 80 225 280

Total 134 325 459

The company will encourage local employment for proposed expansion.

8 Source of Pollution

a. Waste Water Generation The total existing and proposed waste water generation rates in KLD are tabulated below.

Source Total Existing waste water generation

Additional waste water generation

Total waste water generation after expansion

Industrial & Domestic

20 KLD 200 KLD 220 KLD

The details of waste water generation are given in Table 3-14 of Chapter 3.

b. Air Emission The point source emissions will be from Process and Flue stacks. The emission parameters for Flue stacks and Process stacks have been tabulated below.


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S. No.


Source of Emissions (Point Source)

Existing Parameters Proposed Parameters

Flue Gas PM, SO2 , NOx & CO

PM, SO2 , NOx & CO

Process HCl, NH3, H2S, HC. HCl, NH3, H2S, HC.

The details of stack emissions are given in Error! Not a valid result for table. & Table 3-16 of Chapter 3.

c. Solid Waste / Hazardous Generation

The Major Waste Generation from Proposed Expansion is from following sources. Organic distillation residues Toxic and High COD Aqueous waste Expired / Off Specific Products ETP Sludge Used Oil Packaging Materials Lead Acid Batteries Details of all waste with generation quantity and disposal method are given in Table 6-1 & Table 6-2.

9 Mode of Treatment

a. Waste water

Existing effluent treatment facility: The company has existing adequate effluent treatment plant (25 KLD) with Primary, secondary & tertiary treatment facility. Additional Capacity of Proposed ETP : Approx. 200 KLD. Total Capacity of ETP After Expansion: 220 KLD. Final Disposal Facility: Treated effluent will be discharged to green belt canal for further disposal to hooghly river which ultimately meets to bay of bengal. Recycling Proposed : The unit has proposed recycle/reuse of treated effluent part in cooling and green belt development before discharge to green belt canal. The details of Effluent generation & disposal are given in Table 3-14 of Chapter 3.

b. Air Existing APCM: company has adequate Air pollution control devices for control of Flue gas & Process gas emission like process scrubber, bag filter. Proposed APCM: company will provide adequate APCM like process scrubber, bag filter to achieve WBPCB norms. The details of air pollution sources and control devices are given in Table 3-16 of Chapter 3.

c. Hazardous/Solid Waste/municipal solid waste

Hazardous Waste /Solid Waste - Collection, storage and disposal to be carried out as per hazardous and other waste (management & transboundary movement) rules 2016. The details of solid/ hazardous waste generation and disposal method are given as Table 6-1 of Chapter 6.

10 Resource Recovery

a. Solvent The solvent used in Production Process are recycled / recovered during production process and UPL has maintained minimum recovery of 95 % for solvents. Detail of solvent usage and solvent recovery are given in Table 3-12 of Chapter 3.


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2 INTRODUCTION

2.1 BACKGROUND

UPL Limited (formerly known as United phosphorous Limited), popularly known as ‘UPL’, is an International company started its operation in the year 1969. It`s almost 48 years ago, they had started as a small scale unit to manufacture Red Phosphorus. Since then it has established well-equipped manufacturing units with corporate office at Mumbai. Through backward and forward integrations respectively, today they are a leading global producer of crop protection products, intermediates, specialty chemicals and other industrial chemicals. Being the largest manufacture of agrochemicals in India, they offer a wide range of products that includes Insecticides, Fungicides, Herbicides, Fumigants and Rodenticides. UPL of late has made a significant entry in Seed business as well. M/s UPL Limited have major manufacturing facilities at Vapi, Ankleshwar, Jhagadia, Haldia and major products are Pesticides, Caustic Soda, Chlorine, Intermediate Chemicals, Phosphorus based chemicals and Specialty Chemicals. UPL Limited started operations at Vapi Estate in 1969 with manufacturing of Red Phosphorus first time in India. Mr Rajnikant D Shroff, an industrialist, is the Chairman of the Company. The Company has acquired several Units in India and abroad, and modernized them; and are in operation. UPL Limited have a strong manufacturing base supported by engineers and scientists. The R&D team of the Company develops various products as per the market requirements. Most of the products manufactured are agrochemicals used by the farmers. UPL have 25 manufacturing sites and customer base in 123 countries all over the world. The company has marketing network in 25 countries including America, Europe, Africa, besides in all states of India. They rank amongst the top 5 post patent agrochemical industries in the world. The Unit has implemented Environmental Management System Standard i.e. ISO 14001, Occupational Health & Safety Assessment Standards i.e. OHSAS 18001 and Quality management System Standards i.e. ISO 9001. UPL voluntarily adopted the Codes of Practice of Responsible Care (RC) initiatives. UPL is one among the few industries permitted to use Responsible Care logo by Indian Chemical Council (ICC). UPL Limited Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL Limited are Sanskardeep Vidyalaya (Ankleshwar), Gyam Dham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). 2.1.1 CSR Activity at Haldia

The CSR activity in the UPL Haldia unit are providing infrastructure and facilities in schools like (i) toilets, (ii) computers and (iii) school uniforms. 2.1.2 Key Personnel

Mr Rajnikant D Shroff, Chairman & Managing Director


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Mrs Sandra R Shroff, Vice Chairman

Mr Jaidev R Shroff, Group CEO- Director

Mr Vikram R Shroff, Executive Director

Mr Kalyan Banerjee, Director

Mr Arun C Ashar, Director

Mr Raj K Tiwari, Global SCM Director

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT.

UPL Limited (Unit-09) is an operational manufacturing unit, located at leased land of Kolkata Port Trust, Haldia, East Midnapur District, West Bengal. The Unit is manufacturing pesticides technical, and pesticides formulation products. UPL- Haldia Units (Unit No. 9) had accorded the Environmental Clearance (EC) from Ministry of Environment and Forests (MoEF) for 460 metric tons per month (MTPM) vide F.No. J-11011/914/2008-IA II(I) dated 29.04.2009. Now UPL has proposed to expand the Pesticide technical, Intermediate & Formulation products to 1980 MTPM. The existing and proposed product and by-products is provided in following table.

Table 2-1 List of existing Products & Proposed Products with expansion quantities

Sl. No

.

Building Status (No of

Buildings)

Products

Production Quantity in (Metric Tonne Per Month)

CIB Status

EC Notification 2006, category

Change in

Production

Process (Yes / NO)

Existing Capacity as per EC Granted

Additional

Capacity

Total Capacity

after Expansio

n

A) Pesticide Technical Grade

1 1

(Existing + Proposed in New Plant

Adjacent to Existing Plant)

Acepate 100 1400 1500 Not

Banned 5(b) Yes, New

Route

OR OR OR OR OR OR OR

Metamitron 100 NIL 100 Not

Banned 5(b) No

2

Di-Methoate

60 NIL 60 Not

Banned 5(b) No

OR OR OR OR OR OR OR

Ethion 60 NIL 60 Not

Banned 5(b) No

3

1 (No

Expansions Proposed)

Methyl Sulfanilyl Caramate (Asulam)

200 NIL 200

Not Banned

5(b) No

4 Not

Implemented

Pretilachlor 50 NIL 50 Not

Banned 5(b) No


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Sl. No

.


Buildings)

Products


CIB Status


Change in

Production

Process (Yes / NO)


Additional

Capacity

Total Capacity

after Expansio

n

5 Not

Implemented

Methoxy Ethyl

Mercuric Chloride

(Bagalol)*

50 NIL NIL

Banned except

The use of

MEMC is banned

completely except for seed treatmen

t of potato

and sugarcan

e S.O.681

(E) dated 17thJuly,

2001

5(b) No

6

New Plant – 1 No for DESMP +

ACEPHATE

Expansions

Diethyl P -toluene Methyl

Sulphonyloxy

Phosphonate (DESMP)

0 240 240 Not

Banned 5(b)

New Product

Total Capacity 460 1640 2100

B) Pesticide Formulation – Solid – No Expansions Proposed

1 Existing Plant No

Expansion

Acepate – 75% (Stthene)

130 MT/Mon

th NIL

130 MT/Mon

th

Not Banned

Not Applicabl

e

Not Applicabl

e

2 Existing Plant No

Expansion

Metamitron—50%

100 MT/Mon

th NIL

100 MT/Mon

th

Not Banned

Not Applicabl

e

Not Applicabl

e

3 Existing Plant No

Expansion

Bagalol (MEMC 15%)

100 MT/Mon

th NIL

100 MT/Mon

th

Not Banned

Not Applicabl

e

Not Applicabl

e

Total in MT/Month 330

MT/Month

NIL 330

MT/Month

Not Applicabl

e

Not Applicabl

e

C) Pesticide Formulation – Liquid – No Expansion Proposed

1 Existing Plant No

Expansion

Asulam (Methyl Sulfanilyl Caramate- 50 w/v solution)

250 KL/Mont

h NIL

250 KL/Mont

h

Not Banned

Not Applicabl

e

Not Applicabl

e


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Sl. No

.


Buildings)

Products


CIB Status


Change in

Production

Process (Yes / NO)


Additional

Capacity

Total Capacity

after Expansio

n

2 Existing Plant No

Expansion

Asulam (Methyl Sulfanilyl Caramate- 40 w/v solution) Asulox

320 KL/Mont

h NIL

320 KL/Mont

h

Not Banned

Not Applicabl

e

Not Applicabl

e

3 Existing Plant No

Expansion

Qninolphos- 25% EC (Starlux)

30 KL/Mont

h NIL

30 KL/Mont

h

Not Banned

Not Applicabl

e

Not Applicabl

e

4 Existing Plant No

Expansion

Dimethoate – 30 EC (TARA 909)

200 KL/M

NIL 200

KL/M

Not Banned

Not Applicabl

e

Not Applicabl

e

5 Existing Plant No

Expansion

Ethion -50% EC (MIT 505)

150 KL/M

NIL 150

KL/M

Not Banned

Not Applicabl

e

Not Applicabl

e

Total in KL/Month 950

KL/Month

NIL 950

KL/Month

Not Applicabl

e

By-products like Methanol, Acetic Acid and Ammonium Sulphate will be generated from the process. However, for Formulation products, Environmental Clearance is not required as per the EIA Notification 2006. The list of by-products has been shown in the following table.

Table 2-2 List of By-products

Sl. No.

By Product Name Source/Plant Existing Generation (MTPM)

Additional Generation (MTPM)

Total Generation after expansion (MTPM)

1 Methanol Asulam 26 0 26 2 Acetic Acid Acephate 0 2025 2025 3 Ammonium

Sulphate Acephate 0 742.4 742.4

Total 26 2767.4 2793.4

The Following By Products are expected from existing process which are not implemented. Sl. No.

By Product Name Source/Plant Existing Generation (MTPM)

Additional Generation (MTPM)

Total Generation after expansion (MTPM)

1 Ammonium Bromide

Ethion 132.7 0 132.7

2 Ethanol Metamitron 96.4 0 96.4 3 Sodium Bi

sulphide Pretilachlor 193.8 0 193.8

4 HCl Pretilachlor 14.95 0 14.95 Total 437.85 0 437.85


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2.3 JUSTIFICATION FOR THE PROJECT:

2.3.1 Need for the Project and its Importance to the Country and or Region,

Proposed expansion in project is needed to serve increasing demand from export market. Benefits of the project are many fold: The proposed expansion project for manufacturing of various products are based on the market surveys. India imports Diethyl P -toluene Methyl Sulphonyloxy Phosphonate (DESMP) -2800 MT per year. Its current price is $7/kg and total value for import is around 150 Cr. There are no manufacturers in India. Therefore producing 120 MT/ month; i.e. 1440 MT per year will reduce the import cost of Diethyl P -toluene Methyl Sulphonyloxy Phosphonate (DESMP). 2.3.2 Demand-Supply Gap.

Indian Pesticides is one of the rapidly growing markets and has emerged a strong export oriented business. Out of the present business of 180 Billion markets, the export accounts 100 billion and is steadily growing at a rate of 6.7%. This is 2.5 times more than the world market. With the introduction of genetically modified crops in India, the consumption of Insecticides decreased marginally. But the other sectors such as weedicides & herbicides, fungicides etc. are rapidly growing. UPL is focuses on the sectors of Fungicides and herbicides and strong in export of these group molecules (Source: India Pesticide Industry Analysis to 2018; Ken Research]. 2.3.3 Imports vs. Indigenous Production.

Company is always focusing on manufacturing all products locally with backward integration so that Country will get benefits like Growth, employment, infrastructure etc. UPL Limited R & D team is constantly engaged in identifying & evaluating new molecules. After a very careful scrutiny of the developments of R & D, the company is ready to enhance the production capacity. Company is importing only such products for which, either the technology is not available in India or, the manufacturing cost is higher than the import cost. 40% Raw materials will be imported to manufacture proposed products. 2.3.4 Export Possibility.

Pesticide Product- The products of UPL Limited are mainly for rice, wheat, cotton, vegetables, fruits, tea, tobacco etc., which are the main crops in India and in many countries as well. That’s why these products have worldwide market. The global marketing network of UPL Limited is mainly, America sales 37%, Europe & Africa 28.%, Indian subcontinent & Asia Pacific 35 %. Intermediates & specialty Chemicals - Indian Specialty Chemicals poised to be $ 80-100 billion industry by 2020. Asia-Pacific region now is nearly 42 % of the global market for chemicals. India is emerging as manufacturing and export hub for specialty and knowledge chemicals. Key advantages include re-engineering capabilities and relatively low cost of production. Innovation and Scale will be the key differentiators, going forward. The continuous growth of this sector saw demand – supply gap and sometimes, molecules are not available both for the domestic and export market. Like the above many products are made in India and exported to all the European Countries and all other countries. Continuous growth of exports and increase in the Indian market demand off set the local competitions. Some


12

manufacturing capacities cleared for the manufacture are neither installed nor operated. Some products are not available at the peak demand time of the local season. To support the above projections, promoters have propelled to set up new manufacturing facility in chemical zone. 2.3.5 Domestic / export Markets

Rest of the approx. 20-30 % of total production will be sold to domestic market. 2.3.6 Employment Generation (Direct and Indirect) due to the Project

For proposed project direct & indirect employment generation will be as follows:

Table 2-3 Manpower Requirement

Sl. No. Particulars Manpower Details

Existing Proposed Total after Expansion

1 Staff 54 100 154

Contract 80 225 280

Total 134 325 459

Locally employed manpower shall be utilized.


13

3 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY

The focus of the company is on the development of agriculture and better products through use of pesticides so essential for growth and prosperity of agriculture economy for that company wishes to manufacture various Fungicides, Herbicides, Insecticides, Specialty Chemicals and Intermediates Products and Formulations (Solid / Liquid). 3.2 LOCATION & ACCESSIBILITY

The proposed expansion unit is located at Haldia. Haldia is an industrial town located in the Purba Medinipur District of West Bengal. The region has been developed with the Haldia port as the focal point in the District. The Regional setting map of the site is provided in Figure 3.1. The site is located in the Survey of India Toposheet No. F45K4. The site location has been indicated on topographic map of 1:50000 scale (Refer Figure 3.2). The google imagery map with geographical coordinates of the site is shown in Figure 3.3. The site can be accessed from Kolkata through Vidyasagar Setu then Kona Express Way which ultimately joins with NH-6 up to Kolaghat. The site can be accessed from NH 6 via. Kolaghat- Haldia road (NH 41) to Rani Chowk (Haldia). From Rani Chowk, the site can be accessed by Link Road to Durgachak and site. Haldia is well connected with Kolkata through rail also; daily trains are available from Haldia to Howrah via. Panskura. The nearest Railway Station is Durgachak, 0.6 km from the site. The nearest Airport of Netaji Subhas Chandra Bose, Kolkata is approximately 140 km from site. The capital city Kolkata is approximately 130 km from site.


14

Figure 3-1 Regional Setting Map of the Site


15

Figure 3-2 Site Location Map on Topomap


16

Figure 3-3 Site Location of Satellite Imagery with Geographical Coordinates


17

3.3 ENVIRONMENTAL SENSITIVITY

The UPL Haldia site is located on the southern side of the Haldia Industrial area. The proposed expansion unit will be constructed within the existing plant area. The environmental setting of the site has been provided in following table.

Table 3-1 Environmental Settings of the Site

Sl. No. Component Location and Distance

1. Industries South Bharat Petroleum Corporation Limited Oil Terminal- adjacent

North Exide Industries Ltd- 0.2 km

Hindustan Petro-chemical Limited – NW, 2.3 km

Reliance MCT East Indorama Chemical Limited- 1.0 Km

Green Belt Canal

Mitsubishi Chemicals-3.5 km West Himadri Chemicals;

Tata Power

Indian Oil Corporation- 2.7 km

Haldia Port- 5.5 km 2. River South Hooghly River- 0.45 km

West Haldi River- 10 km

3. Settlement/ Town

North Durgachack town- 0.6 km

Chaul Khola – NW- 6.5 km

Jamal Chak- 5.7 km West Baishnabchak – 4.5 km

4. Forest No natural forest in the 10 km of the study area

5. Mangrove vegetation Nayachar- Riverine Island of Hooghly River is located 4.2 south of the site has mangrove plantation area;

Mangrove plantation along the Hooghly River side- BPCL oil Terminal to Hooghly Met Coke ; which is approximately 0.4 km from site

6. Ecological Sensitive area like National Park, Wildlife Sanctuary, Biosphere Reserve, etc

No ecological sensitive area in the 10 km radius of the proposed site

7. Estuary Hooghly estuary- 0.45 km from the site

The environmental settings of the site is presented in Figure 3-4


18

Figure 3-4 Environmental Setting Map of the site


19

3.4 SITE ALTERNATIVE STUDY

No alternative site study will be carried out as proposed project will be located in a well-developed Industrial Estate, Haldia. Following points are considered for proposed project site selection. The proposed expansion will be constructed in the available land of existing plant. No additional land will be required for proposed expansion unit. The existing unit is located in the Haldia Industrial area. The existing unit is well connected through Port (Haldia), Railway (nearest station Durgachak), Road (NH-41) for transport of raw material and finished products. Same facilities will be utilised for the proposed expansion unit. The existing water requirement and additional required water will be supplied from Haldia Development Authority (HDA). The power requirement for the existing unit is being sourced from West Bengal State Electricity Distribution Company Limited (WBSEDCL); the additional power requirement for proposed expansion unit will be sourced from WBSEDCL. 3.5 SIZE OR MAGNITUDE OF OPERATION.

The existing capacity (Pesticide technical, Intermediate & Formulation products) of UPL- Haldia is 460 MTPM. It is proposed to expand the Pesticide technical to 1980 MTPM. As per the proposed project cost, the project is covered under Medium Scale category of manufacturing industries. 3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS

Detailed project description with process details has been provided in the following section. 3.6.1 Acephate (Existing Route)

3.6.1.1 Process Description

Step 1 : Isomerization (Preparation of O, S, dimethyl Phosphoramidothioate) O, O - dimethyl phosphoramidothioate is isomerised in presence of catalyst, dimethyl sulphate. Dichloroethane is used as solvent.

Step 2 : Acetylation O, S, dimethyl phosphoramidothioate is reacted with acetic anhydride in presence of sulphuric acid as catalyst to produce Acephate.

CH3O S (CH3)2 SO4 CH3O O

P P

CH3O NH2 CH3S NH2

CH3O O CO-CH3 CH3O O

P + O P + CH3COOH

CH3S NH2 COCH3 CH3S NH-C-CH3

O


20

Step 3 : Neutralization The acetic acid formed during acetylation in Step 2 and the sulphuric acid, which was used as catalyst, are neutralized with ammonia and water. The aqueous phase and organic phase are separated. Step 4 : Extraction of Aqueous Phase The aqueous phase after neutralization is extracted with dichloro methane to extract the dissolved Acephate. Extraction is a batch process and the process is repeated 8 to 9 times till all the Acephate is being taken out. Step 5 : Stripping The organic phase after neutralization and the extract of aqueous phase is stripped to remove excess dichloro methane and to maintain desired concentration. Step 6 : Crystallisation

The stripped mass in Step 5 is chilled to produce acephate crystals.

Step 7 : Centrifugation

The crystallized mass of Step 6 is centrifuged to produce wet acephate cake.

Step 8 : Drying The Acephate cake as obtained in Step 7 is dried in screw drier by Fluidised Bed drier to produce final product dried Acephate.

3.6.1.2 Mass Balance- ACEPHATE

Mass balance of Acephate has been provided in following Table

Table 3-2 Mass Balance for Acephate (Existing Route)

INPUT Kg/MT

Acephate

Output in Kg/MT

Methylene di Chloride 10774 PRODUCT

DMPAT 1113 Acephate 1000

DMS 133 WASTE WATER TO ETP

Sulphuric Acid 98% 25 WASTE WATER 2223

Acetic anhydride 777 WASTE TO INCINERATION

Ammonia Solution 25% 808 INCINERABLE WASTE 10

Water 980 WASTE TO LAND FILLING

LAND FILLING WASTE 0

SOLVENT RECOVERY

SOLVENT RECOVERY(MDC) 10235

BY PRODUCT


21

RECYCLE / REUSE

Centrate + MDC 1137

EMISSION TO AIR

Vapour loss 5

TOTAL 14610 TOTAL 14610

Figure 3-5 Acephate Process Flow Diagram with Existing Route

Acephate Technical

MDC

Organic Part

Effluent

MDC to

Recycle

Centrate Wash NH3

H2O

MDC

H2SO4

DMS

AC2O

MDC

Isomerization

Acetylation

Centrifugation

Neutralization

Organic Part

Extraction

Drying

.

Stripping

Crystallisation

Aqueous Part

DMPAT

Centrate to Recycle


22

3.6.2 Acephate (Proposed New Route – After Expansions)


Dimethyl Phosphorous Amido Thionate (DMPAT) is isomerized to Methamediphos by catalytic reaction at 50 degree C and atmospheric pressure in the presence of Dichloro methane as solvent. After isomerisation, the mass is reacted with acetic anhydride at 40 degree C. It is then neutralized with aqueous ammonia. Ammonia vapour Scrubbed through scrubber & all scrubber mass reuse in neutralizer. The layers are separated and aqueous layer is extracted from Acephate and react with H2SO4 which generate Ammonium sulphate & acetic acid. The organic layer is feed to FFE for dichloromethane recovery and concentrated Acephate + MDC is then taken for vacuum recovery. Recovered dichlormethane is Distilled and recycled in process. After vacuum recovery of all MDC crude Acephate is dissolved in ethyl acetate .After then it is crystalized and slurry is feed into agitated nutche filter. Ethyl acetate is recovered from the mother liquor of crude. Acephate cake is feed to spin flash dryer for purification. The dry Acephate is filled in bags as final packing.


23

Figure 3-6 Stoichiometric Balanced Chemical Reaction

3.6.2.2 Raw Material & Mass Balance

Raw material requirement and mass balance of Acephate has been provided in following Table


24

Table 3-3 Mass Balance for Acephate (Proposed Route)

INPUT QUANTITY Kg/Ton

Acephate (1500 kg)

OUTPUT QUANTITY Kg/Ton

PRODUCT

MDC 8371.5 Acephate 1500

DMPAT 1612.5 RECOVERY

DMS 199.5 Ethyl Acetate Solvent 3649.5

H2SO4 (98%) 37.5 MDC Solvent 8296.5

Acetic Anhyd 1149 BY-PRODUCT

NH3 Solution(17%) 1212 Ammonium Acetate(35%)

H2SO4 (98%) 612 OR

Ethyl Acetate 3724.5 Acetic Acid (30%)OR

Water 345 Acetic Acid (45%) OR

Water for scrubber 1 30 Acetic Acid (99%)

Water for scrubber 2 7.5 AND

H2SO4 for Scrubber 2 1.5 Ammonium Sulphate (90%)

Caustic (48%) for Sodium Acetate conversion

1178.22 OR

Ammonium Sulphate (90%) 1072.785

Sodium Acetate (27%) 3148.935

EFFLUENT GENERATION

Stream:1 Organic waste to incinerator

DMS+DMPAT+MDC+Acetic Anhydrate

780

AIR POLLUTION

NH3 Vapour 18

MDC Solvent Traces 7.5

Ethyl Acetate Solvent Traces 7.5

SOLID WASTE GENERATION

Nil Nil

TOTAL 18480.72 TOTAL 18480.72


25

Figure 3-7 Acephate Process Flow Diagram

3.6.3 Di Ethyl P-Tosyloxym Ethylphosphonate ( DESMP - New)


Diethyl Phosphite(DEP) react with formaldehyde in presence of catalyst under nitrogen atmosphere at temp 15 degree centigrade to produce DEHMP. Then this DEHMP react with PTSCL in presence of caustic lye solution by maintaining pH 10-11 and mass temperature 0-5 degree centrigrade. After reaction water addition and layer separation. Then again water addition followed by Hydrochloric acid addition by maintaining pH 6-6.5.Proper stirring,


26

settle the mass and separate organic layer that is finally fed for removal of solvent and moisture by vacuum 725-730 mm Hg and temperature 60-65 degree centigrade. Stoichiometric Balanced Chemical Reaction for DESMP

Diethylphosphite

P

OO

OH

+

Formaldehyde

C HH

O

Diethyl p-tosyloxymethylphosphonate

P

O

O

OOS

O

O

P OO

O

OH

Hydroxymethyl-phosphonic acid diethyl ester

+

p-TolueneSulphonyl Chloride

S

O

O

Cl

Table 3-4 Mass Balance for DESMP

INPUT KgMT

DESMP

Output in Kg/MT

Di Ethyl Phosphite 538 PRODUCT

Formaldehyde 372 DESMP 1000

Catalyst 34 WASTE WATER TO ETP

PTSCL 671 WASTE WATER 4020

C.S.Lye 566 WASTE TO INCINERATION

Toluene 2692 No incinerable waste 0


Hydrochloric Acid 39 No land filling waste 0

SOLVENT RECOVERY

Solvent recovery (Toluene) 2584

BY PRODUCT

No By Product Recovery 0

RECYCLE / REUSE

No Recycling 0

EMISSION TO AIR

No Emissions 0



27

Figure 3-8 DESMP Process Flow Diagram

3.6.4 Metamitron ( Existing – No Expansion)

3.6.4.1 Manufacturing Process

Step 1 : Preparation of Acetyl Hydrazine

Acetyl Hydrazine is prepared by reacting ethyl acetate with Hydrazine Hydrate under refluxing temperature. Ethanol and water so produced during reaction is removed by distillation.

O CH3 – COO.C2H5 + H2N – NH2.H2O CH3–C–NH–NH2+C2H5OH+ H2O (Ethyl Acetate) (Hydrazine Hydrate) (Acetyl Hydrazine) (Ethanol)

Step 2 : Preparation of Hydrazone

Hydrazone is prepared by reacting acetyl hydrazine with EPG in presence of ethanolic HCl medium. This reaction is carried out at low temperature for long time. Wet cake of Hydrazone is recovered through filtration and mother liquor is recycled till it has rejected and sent for recovery.


28

N-NH-C-CH3 CH3 – C – NH – NH2 + C6H5 – CH – C C6H5 – C – C – OC2H5 + H2O OC2H5 O (Acetyl Hydrazine) (EPG) (Hydrazone)

Step 3 : Preparation of MMZ (Phenyl Glyoxylic Acid Hydrazide Acetyl Hydrazone)

MMZ is prepared by reaction of Hydrazone with hydrazine hydrate at low temperature in alkaline medium. Here ethanol is used as carrier / solvent. Wet cake so obtained is dried under vacuum at 70oC.

N – NH – C – CH3 N – NH – C – CH3 C6H5–C–C–OC2H5 + H2N–NH2.H2O C6H5–C–C–HN–NH2 + HOC2H5 + H2O (Hydrazone) (MMZ)

Step 4 : Preparation of Metamitron

Metamitron (MMT) is prepared by dehydrating MMZ in presence of sodium acetate under refluxing temperature. Here ethanol is used as medium / solvent. After completion of reaction the mass is cooled at 0oC centrifuged to get wet cake of MMT. Then final product is dried under vacuum at 65oC.

N – NH – C – CH3 N – N C6H5 – C – C – HN – NH2 + CH3 – COONa C6H5 – C C – CH3 + H2O O = C – N - NH2 (MMZ) (Metamitron)

O

O

OO

OO

OO

OO

OO

OO

O

O


29

Table 3-5 Mass Balance for Metamitron

INPUT Kg/MT

Metamitron

Output in Kg/MT

Ethyl Phenyl Glyoxalate 1271 PRODUCT

Ethyl Acetate 844 Metamitron 1000

Hydrazine Hydrate 1043 WASTE WATER TO ETP

Ethanol Solvent 4348 WASTE WATER 0

Hydrochloric Acid 117 WASTE TO INCINERATION

Acetic Acid 15 WASTE 1604

Sodium Acetate 43 WASTE TO LAND FILLING

Water 322 NO LAND FILLING WASTE 0

Ammonia Solution 25% 247 SOLVENT RECOVERY

SOLVENT RECOVERY(ETHANOL) 4174

BY PRODUCT

ETHANOL 964

RECYCLE / REUSE

CONDENSATE WATER 507

EMISSION TO AIR

VAPOUR LOSS 1



30

Figure 3-9 Process Flow Diagram for Metamitron

MMZ Preparation

Reaction Mass

Metamitron

Wet Cake

EtOH (F/R)

Reaction Mass

EtOH (F/R)

Na Acetate

MMZ

H2O

EtOH (F/R)

EPG

HCl

EtOH (F/R)

NH3

EtOH (F/R)

Ethyl Acetate

Hydrazine Hydrate

Acetyl Hydrazine

Preparation

MMZ Preparation

Filtration

Alcohol

Recovery

Acetyl Hydrazine

Hydrazine Hydrate

Wash H2O

Alcohol

Recovery

MMZ

Meta

am

mm

ami

tro

nmi

tro

nmi

tro

n

Pre

par

atio

n

MMT Reaction

Crystallization

Alcohol

Recovery

FBD Drying

Centrifugation

Aqueous

Effluent


31

3.6.5 Di Methoate (Existing – No Expansion)

3.6.5.1 Manufacturing Process of Dimethoate

Step 1 : Neutralization

The dimethyl dithio phosphoric acid is neutralized with diluted ammonium hydroxide solution. The aqueous layer

containing the ammonium salt of dimethyl dithio phosphoric acid is taken in another reactor for condensation

reaction and organic phase sent for toluene recovery.

CH3O S CH3O S

P + NH4OH P + H2O

CH3O S – H CH3O S – NH4

STEP 2 : PREPARATION OF METHYL CHLORO ACETATE

It is an ester and prepared by reacting mono chloro acetic acid with methanol in presence of catalyst

at required temperature.

Cl – CH2 – COOH + CH3OH Cl – CH2 – CO – CH3 + H2O

Step 3 : Condensation

Salt of dimethyl dithio phosphoric acid, is condensed with methyl chloro acetate formed in Step 2.

CH3O S CH3O S

P + Cl.CH2.COOCH3 P + NH4Cl

CH3O S – NH4 CH3O S – CH2 – CO – CH3

Step 4 : Amidation

O

O


32

Table 3-6 Mass Balance for Di-Methoate

INPUT KgMT

Dimethoate

Output in Kg/MT

Di Methyl Di thio phosphoric Acid

1159 PRODUCT

Ammonia Solution 25% 76 Dimethoate 1000

Mono chloroacetic Acid 382 WASTE WATER TO ETP

Methanol 127 WASTE WATER 1647

Sodium Bi Carbonate 13 WASTE TO INCINERATION

Water 1480 INCINERABLE WASTE 0

Monomethyl Amine 276 WASTE TO LAND FILLING


SOLVENT RECOVERY

SOLVENT RECOVERY 0

BY PRODUCT

BY PRODUCT 0

RECYCLE / REUSE

Mother Liquor 642

Organic Part for Recycle 225

EMISSION TO AIR

NO VAPOUR LOSS 0


Step 4 : Amidation

The condensed produced formed in Step 3 is amidated by reacting with mono methylamine to produce

Dimethoate. This dimethoate is then filtered, washed and transferred to drier.

CH3O S CH3O S

P + CH3NH2 P + CH3OH

CH3O S – CH2 – CO – CH3 CH3O S-CH2-C-NH-CH3

Step 5 : Drying

Dimethoate is then dried under vacuum to remove moisture and Dimethoate technical is obtained.

O O


33

Figure 3.10: PROCESS FLOW DIAGRAME FOR DI METHOATE

3.6.6 ETHION (Existing – No Expansions)

3.6.6.1 PROCESS DESCRIPTION FOR ETHION

STEP 1 - NEUTRALISATION

The diethyl dithio phosphoric acid is neutralized with diluted ammonium hydroxide

solution. The aqueous layer containing the ammonium salt of diethyl dithio

phosphoric acid is taken in another reactor for condensation reaction and sent for

toluene recovery.

Dry Dimethoate

Mother Liquor for

Recycle

H2O

H2O

MMA

CP

H2O

Effluent

Effluent

Effluent

Effluent

H2O N3HCO3

MCA

H2O

Neutralization

Layer Separation Neutralization

Condensation

MCA Preparation

Amidation

Drying

.

Filtration

Washing &

Layer Separation

MCAA BOUNDARY

MeOH

Layer Separation

NH3

Organic part for

Toluene Recovery

and Recycle

Effluent

DMTA


34

Step 2 : Condensation

Ammonium salt of diethyl dithio phosphoric acid is condensed with methylene dibromide to

get ethion.

Step 3 : Drying

Ethion produced in Step 2 is dried under vacuum to get Ethion Technical.

Table 3-7 Mass Balance – ETHION

INPUT KgMT

ETHION

Output in Kg/MT

Di Ethyl thio phosphoric acid 1309 PRODUCT

Ammonia 25% 512 ETHION 1000

Water 1785 WASTE WATER TO ETP

Toluene 17 WASTE WATER 879

Methylene Di Bromide 495 WASTE TO INCINERATION

INCINERABLE WASTE 10

WASTE TO LAND FILLING


SOLVENT RECOVERY

SOLVENT RECOVERY (TOLUENE) 16.5

BY PRODUCT

AMMONIUM BROMIDE 2212

RECYCLE / REUSE

RECYCLE OR REUSE

EMISSION TO AIR

WATER VAPOUR 0.5


C2H5O S C2H5O S

P + NH4OH P + H2O

C2H5O S – H C2H5O S- NH4

C2H5O S

P

C2H5O S-NH4

C2H5O S

P

C2H5O S - CH2

S OC2H5

P

- S OC2H5

+ CH2Br2 + 2NH4Br


35

Figure 3-10PROCESS FLOW DIAGRAM FOR ETHION

3.6.7 Methyl Sulfenilyl Caramate (ASULAM - EXISTING – No Expansions)

3.6.7.1 Process description of Asulam :

Raw materials Dimethyl carbonate, Sodium methoxide and Sulfanilamide are charged in the

reaction vessel at room temperature. And then the mass are heated to reflux temp of 68°c

slowly and is being maintained at reflux temperature for some time. After completion of the

reaction, the mass which contains methanol are recovered by steam and vacuum distillation.

The recovered methanol along with water is sent for methanol distillation where methanol is

purified and the waste water is sent for treatment.

The product from the reaction vessel are sent for mixing vessel where required quantities of

hydrochloric and caustic are added to achieve the product quality specified and then it is

stored in the final storage tank from there it shall be loaded in tankers.

Reaction chemistry:

1st stage C6H8N2SO2 + NaOCH3 --------- C6H7N2SO2Na + CH3OH 172 54 194 32 Sulfanilamide sodium methoxide methanol

CH2Br2

H2O

Condensate

Effluent

Effluent

H2O

DDPA

Neutralization

Layer Separation

Condensation

Drying

Stripping

NH3

Organic part for

Toluene Recovery

and Recycle

Ethion Technical


36

2nd stage C6H7N2SO2Na + C3H6O3------- C8H9O4N2SNa + CH3OH 194 90 252 32 Di methyl ASULAM

carbonate

Table 3-8 Mass Balance for ASULAM

INPUT KgMT

ASULAM

Output in Kg/MT

Sodium Methoxide 130 PRODUCT

Sulphanilamide 313 ASULAM 1000

Di methyl carbonate 192 WASTE WATER TO ETP

Caustic 11 WASTE WATER NOT GENERATED 0

Water 605 WASTE TO INCINERATION

Hydrochloric acid 89 INCINERABLE WASTE 0

Solvent Methanol 301 WASTE TO LAND FILLING

LANDFILLING WASTE 0

SOLVENT RECOVERY

Recovered Solvent(Methanol) 286

BY PRODUCT

Methanol 125

RECYCLE / REUSE

WATER +Methanol TO PROCESS 228

EMISSION TO AIR

HCl 2



37

Figure 3-11 PROCESS FLOW DIAGRAM FOR ASULAM

3.6.8 PRETILACHLOR (EXISTING – No Expansions)

3.6.8.1 Manufacturing Process of Pretichlor

1st stage : PEC

1 Ready a MSGL Reactor provided with a agitator, condenser, Feed tank, TP etc.

2 Check whether the equipment is clean and free of any extraneous matter.

3 Check whether all utilities required for the process is available with the Utilities department.

4 Charge n - Propoxy Ethanol and DMF

5 Heat the mass to 110ºC

6 Feed Thionyl Chloride at110ºC through dip tube over a period of 3 Hrs such that the temperature of the reaction mass is maintained around 110ºC and scrubber can take the load.

8 Maintain the temperature of the reaction mass at 120ºC for a period of 1 Hr

9 Submit a sample for unreacted n - Propoxy Ethanol and Chlorosulfite ( < 1.0%)

(Take out an aliquot in test tube , add MDC,such that 10% solution is obtained)

10 If EOR is OK then proceed for the next step , otherwise continue the reaction

till PEA and Chloro sulfite is in desired limit.

11 Distill out the reaction mass at atmos. pressure and collect first cut upto 125 deg C and

then the main cut between 125 to 135º C

12 Analyze all the cuts for Area Profile and note the quantities of each.

13 The residue left over after distillation is to be disposed off.

14 The yield of the Main cut is about 92.0%

2ND STAGE PEDA

1 Charge DEA, NMP

2 Heat the mass to 150ºC over a period of 1 Hr

3 Feed PEC via the additional tank to the reaction mass over a period of 3 Hrs at a temperature between 148 - 152 ºC (Not to exceed 155 deg C)

4 If the EOR is OK , proceed for work up. If not OK, then continue cooking for further 2.0 Hrs.

Sodium Methoxide

Solution

Sodium Methoxide Powder

Methanol

Asulam Reaction

Sulphanilamide

Dimethyl Carbonate

Methanol Generation

ASULAM TECHNICAL


38

5 Cool the reaction mass to 100 ºC, and distill out NMP and DEA (part) at 10 mmHg vacuum

at max pot temp. 140 deg C

6 Transfer contents to SS wash vessel and cool to RT

7 add 15% Caustic solution, agitate the mass for 20 to 30 mins to attain pH 10-11.

8 Pass this through hyflow bed or body feed and allow to settle and separate the layers at RT

9 HETP of 9 stages. After the 2nd cut, the mass is preferably taken to smaller vessel for the 3rd cut

10 Distill off the crude organic mass under 10 to 1 Torr during the first cut to third cut

11 First cut 110-122º C Vapor Temp DEA (6 mmHg)

12 Middle cut 122-142ºC Vapor Temp Mixture of DEA + PEDEA (6 mmHg)

12 Main cut 133-142 ºC Vapor Temp PEDEA (2 mmHg)

14 And mid cut to next distillation batch. The yield of the PEDEA is around 78%

3rd stage Pretichlor

1 Ready the SS reactor for the step

2 Charge PEDEA

3 Charge toluene

4 Heat the contents to 80 deg C

5 Feed CAC via the additional tank to the reaction mass over a period of 3 - 3.5 Hrs at a temperature

between 80 ºC

6 Submit a sample of the reaction mass for absence of PEDEA (< 0.5%)

7 If the EOR is OK , cool mass to 30°C. proceed for work up. If not OK, then continue cooking for further 1.0 to 2.0 Hrs.

Add fresh water (200ml/mol) and stir and allow the layer to separate

8 Allow to settle and separate the bottom aqueous layer

9 Wash the organic layer with 5% NaHCO3 soln (100 ml/mol), separate the layers.

10 Allow to settle and separate the bottom aqueous layer

11 Wash the organic layer with water again (100 ml/mol), separate the layers.

12 Organic layer is taken for solvent recovery

13 Distill out the Toluene from reaction mass at 10 torr

14 Towards the end subject the organic layer at maximum vacuum and remove all traces of the solvent.

Chemical Reactions 1st stage C5H12O2 + SOCL2 --------- HCL + SO2 + C5H11CLO 104 119 36.5 64 122.5 PEA TC PEC 2nd stage C5H11CLO + C10H13N ------- HCL + C15H25NO 122.5 149.5 36.5 235.5 PEC Aniline PEDEA 3rd stage C15H25NO + C2H2CL2O + NAOH -------- C17H26NCLO2 + NaCL + H2O 235.5 113 40 312.5 58.5 18 PEDEA CAC Pretilachlor


39

Table 3-9 Mass balance for Pretilachlor

INPUT Kg/MT

Pretilachlor

Output in Kg/MT

PEA 495 PRODUCT

DMF 5 Pretilachlor 1000

SOCL2 571 WASTE WATER TO ETP

DEA 3368 WASTE WATER 2808

NMP 1408 WASTE TO INCINERATION

Sodium Hydroxide 15% 1299 INCINERABLE WASTE 77

CAC 432 WASTE TO LAND FILLING

Toluene 1356 LAND FILLING WASTE 0

Water 1016 SOLVENT RECOVERY

Sodium Bi Carbonate 339 NMP 1338

Sodium Hydroxide 10% 3605 DEA 3199

Toluene Recycle 1296

BY PRODUCT

Sodium Bi Sulphite 3877

HCL 299

RECYCLE / REUSE

RECYCLE OR REUSE 0

EMISSION TO AIR

Vapour loss (Water) 0.6



40

Figure 3-12 PROCESS FLOW DIA FOR PRETILACHLOR

NaOH 10% 3605

ALL QUANTITY IN KGS

PEA 495 SO2

Sodium Sulphide

DMF 5.4 271.5 3876.5 By product

water 699

SOCL2 571

175 30% HCL (By-Product)

PEC 998

624

77

547

DEA 3368

NMP 1408

3780

15% NAOH 1299 Aq effluent to ETP

1471

PEDEA

3608

2543

DEA RECYCLE

796

CAC 432 124

HCL

Toluene 1356

2460

Water 1016 1459

Aq effluent

NAHCO3 339 ETP

5%

2356

loss atm 60

Toluene recy

1296

1000

Product

Residue for Incineration

NMP +DEA RECYCLE

1543

PEA

to

PEC

PEC

Distillation

PEC

to

PEDEA

Separation

Caustic Scrubber

HCl

scrubber

Distillation

of DEA

Condensation

Washing

Ist water

2nd NaHCO3

Toluene

Distillation


41

3.6.9 Methoxy Ethyl Mercuric Chloride (BAGALOL - EXISTING – No Expansions)

3.6.9.1 Process description of Bagalol

Take Methanol and Acetic acid in 2KL cap Glass lined Reactor.

Charge Mercury Oxide slowly with continuous agitation for 2 Hrs.

After mixing, purge ethylene gas in the mixture. Ethylene gas is generated in Silver Cracker Unit. Total conversion is required min 40 to 56 Hrs.

Maintain the reaction mass at room temperature by circulating cool water in Jacket. Distillation

Take reaction mass in Distillation vessel. Distilled out excess methanol under vacuum at low temp.

Neutralize the remaining mass after distillation with NaOH solution.

Take reaction mass in wooden tub and cool it using Ice.

Slowly add NACL solution in reaction mass and precipitate it.

Filter reaction mass in centrifuge.

Mix MEMC cake with soda ash and soda bicarbonate to get 15% MEMC in Ballmill.

Recover Mercury from Mother liquor.

HgO + 2 CH3COOH (CH3COO)2Hg + H2O

(216.6) (60) (318.6) (18)

Mercury Oxide Acetic Acid

2) H H

Hg(OOC-CH3)2 + H-C = C-H + CH3OH CH3OC2H4CH3COOHg + CH3COOH

(318.6) (28) (32) (318.6) (60)

3) H H

CH3OC2H4CH3COOHg + NaCl CH3O C C HgCl + CH3 COONa

H H

(318.6) (58) (294.6) (82)


42

Table 3-10 Mass Balance for BAGALOL

INPUT Kg/MT

Bagalol

Output in Kg/MT

Methanol 2857 PRODUCT

Acetic Acid 371 Bagalol 1000

Mercury Oxide 571 WASTE WATER TO ETP

Ethylene Gas 234 WASTE WATER 1434

Sodium Hydroxide 57 WASTE TO INCINERATION

Sodium Chloride 143 INCINERABLE WASTE 0


Ice 514 LAND FILLING WASTE 0

SOLVENT RECOVERY

NO SOLVENT RECOVERY 0

BY PRODUCT

BY PRODUCT 0

RECYCLE / REUSE

EXCESS METHANOL + ACETIC ACID 2457

EMISSION TO AIR

NO EMISSION 0



43

Figure 3-13 Process Flow Diagram For BAGALOL

INPUT Consumption/MT OUTPUT Generation/MTMethanol 2857

Acetic Acid 371

Mercury Oxide 571

Ethylene Gas 234

Sodium Hydroxide 57

Methanol and Acetic Acid

Sodium Chloride 143

Water 143

Ice 514

Centrifuge Mother Liquor to ETP 3863

Drying Evaporation Loss 29

Yield 1000Bagalol

Technical

Reactor

Distillation

Precipitation

(pH = 7.0)


44

3.7 RAW MATERIAL REQUIREMENT

Raw materials required for existing project, proposed expansion project, transport and storage facility is provided in following table.

Table 3-11 Raw Material Requirement Details

Sr no Product name Raw material Name Existing Consumption in MT/ Month

Additional Consumption in MT/Month

Total consumption

after Expansion in MT/Month

Existing Product (Pesticide Technical Grade)

1 Acephate (Existing

Route)

Methylene di Chloride 1077.4 0 1077.4

DMPAT 111.3 0 111.3

DMS 13.3 0 13.3

Sulphuric Acid 98% 2.5 0 2.5

Acetic anhydride 77.7 0 77.7

Ammonia Solution 25% 80.8 0 80.8

1 Acephate (Proposed

New Route)

MDC 0 8371.5 8371.5

DMPAT 0 1612.5 1612.5

DMS 0 199.5 199.5

H2SO4 (98%) 0 37.5 37.5

Acetic Anhyd 0 1149 1149

NH3 Solution(17%) 0 1212 1212

H2SO4 (98%) 0 612 612

Ethyl Acetate 0 3724.5 3724.5

H2SO4 for Scrubber 2 0 1.5 1.5

Caustic (48%) for Sodium Acetate

conversion

0 1178.22 1178.22

OR OR OR OR OR

2 Metamitron

Ethyl Phenyl Glyoxalate 127.1 0 127.1

Ethyl Acetate 84.4 0 84.4

Hydrazine Hydrate 104.3 0 104.3

Ethanol Solvent 434.8 0 434.8

Hydrochloric Acid 11.7 0 11.7

Acetic Acid 1.5 0 1.5

Sodium Acetate 4.3 0 4.3


3 Di-Methoate

Di Methyl Di thio phosphoric Acid 69.6 0 69.6


Mono chloroacetic Acid 22.9 0 22.9

Methanol 7.6 0 7.6

Sodium Bi Carbonate 0.8 0 0.8

Monomethyl Amine 16.6 0 16.6

OR OR OR OR OR

4 Ethion Di Ethyl thio phosphoric

acid 78.5 0 78.5


45

Sr no Product name Raw material Name Existing Consumption in MT/ Month

Additional Consumption in MT/Month

Total consumption

after Expansion in MT/Month

Ammonia 25% 30.7 0 30.7

Toluene 1.0 0 1.0

Methylene Di Bromide 29.7 0 29.7

5 Methyl Sulphenilyl

Carbamate (Asulam)

Sodium Methoxide 26.0 0 26.0

Sulphanilamide 62.6 0 62.6

Di methyl carbonate 38.4 0 38.4

Caustic 2.2 0 2.2

Hydrochloric acid 17.8 0 17.8

Solvent Methanol 60.2 0 60.2

6 Pretilachlor

PEA 24.8 0 24.8

DMF 0.3 0 0.3

SOCL2 28.6 0 28.6

DEA 168.4 0 168.4

NMP 70.4 0 70.4

Sodium Hydroxide 15% 65.0 0 65.0

CAC 21.6 0 21.6

Toluene 67.8 0 67.8

Sodium Bi Carbonate 17.0 0 17.0

Sodium Hydroxide 10% 180.3 0 180.3

7

Methoxy Ethyl Mercuric Chloride

(Bagalol)

Methanol 142.9 0 142.9

Acetic Acid 18.6 0 18.6

Mercury Oxide 28.6 0 28.6

Ethylene Gas 11.7 0 11.7

Sodium Hydroxide 2.9 0 2.9

Sodium Chloride 7.1 0 7.1

8

Di Ethyl P-Tosyloxym

Ethylphosphonate (DESMP)

Di Ethyl Phosphite 0 129.1 129.1

Formaldehyde 0 89.3 89.3

Catalyst 0 8.2 8.2

PTSCL 0 161.0 161.0

C.S.Lye 0 135.8 135.8

Toluene 0 646.1 646.1

Hydrochloric Acid 0 9.4 9.4


47

3.8 RESOURCE OPTIMIZATION/ RECYCLING AND REUSE

Resource optimization/recycling and reuse envisaged in the project (solvent recovery system) in detail are as mentioned below.

The raw materials will be stored in closed containers and will be handled through closed system to avoid the handling losses.

The solvents are reused in the manufacturing of pesticides. Details of solvent use & recovery are as under.

Condensate from Boiler will be recycled in the process to minimize the water consumption.

Recovery of valuable by-products like MDC. Toluene, and Methanol.

The UPL has maintained standard of solvent recovery more than 95% for solvents used in production of Acephate & DESMP.

The Recovery details of Solvents are Tabulated below.

Table 3-12 Solvent Recovery Details

Sr. No

Name of Product Name of Solvent Consumed

Quantity of Consumption in Kg/MT

Recovered Quantity in Kg/MT

% Solvent Recovery

1 Acephate (Existing Route)

MDC 10774 10235 95

Acephate (Proposed Route)

Ethyl Acetate 3724.5 3649.5 98

MDC 8371.5 8296.5 99

2 DESMP Toluene 2692 2584 96

3 Asulam Methanol 301 286 95

4 Ethion Toluene 17 16.5 97

5 Metamitron Ethanol 4348 4174 95

6 Pretilachlor

NMP 1408 1338 95

DEA 3368 3199 95

Toluene 1356 1296 96

3.9 RESOURCE REQUIREMENT

3.9.1 Land

The total land of the plant is 60702.82 sq. m (15 acre). This land has been taken long term lease from Kolkata Port Trust Haldia Dock Complex; the possession letter is attached in Annexure -3. The total build-up area of the plant is 23986.557 sq. m. and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. The site layout plant with proposed expansion unit has been provided in following figure.


48

Figure 3-14 Plant Layout Map


49

3.9.2 Water

The existing fresh water requirement of the plant is 60 KLD. The additional water requirement for the proposed expansion unit is 211 KLD; therefore total fresh water requirement after expansion will be 271 KLD. Water is being sourced from Haldia Development Authority (HDA), the future required water will be sourced from HDA. The detailed water balance is given below.

Table 3-13 Water Balance Details

Sr No

Source of Water Consumption Existing Water Consumption

(KLD)

Additional Water Consumption (KLD)

Total water Consumption

After Expansion (KLD)

1 Domestic 10 42 52

2 Industrial

2.a Process Water including Scrubber and R & D & Washing

12 62 74

2.b Boiler Feed Water

20 45 65

2.c Cooling, DM Plant, Chilling Water

8 52 60

2.e Gardening* 10 10 20

Total 60 211 271

3.9.3 Power

The existing power requirement is 4250 KW. Additional power requirement for proposed expansion unit is 43530 KW. Therefore, total power requirement will be 47780 KW. The power is being sourced from West Bengal State Electricity Distribution Company Limited (WBSEDCL); additional required power will be sourced from WBSEDCL. There are two (2) diesel generator (DG) sets having capacity of 1 x 500 KVA and 1 x 600 KVA. Additional 2000 KVA DG set will be installed for proposed expansion unit. 3.9.4 Fuel

Coal fired boiler (8 TPH capacity) is being utilised for generation of steam for the process. The existing coal requirement is 60 Mt/Day Exported coal is being used for boiler and is being sourced from Haldia Port through truck. For proposed expansion unit additional 2 x 15 TPH capacity boiler will be required and additional coal requirement will be 225 Mt/Day. Exported coal will be sourced from the Haldia port for proposed expansion unit. The existing HSD requirement is 250 lit/Day; additional requirement will be 455 lit/Day. HSD is being sourced from nearest oil terminal. 26 days HSD storage facility has been provided within the plant.


50

3.10 POLLUTION SOURCES, TREATMENT AND DISPOSAL

3.10.1 Effluent & Sewage

Effluent has been generated from the process as well as boiler and cooling tower blowdown. The total effluent generated from the plant is 20 KLD. The effluent is being treated through effluent treatment plant (ETP) of 25 KLD capacity. After expansion, approximately, 200 KLD effluent will be generated from the plant. The effluent will be treated through 230 KLD capacity ETP. Part of the treated effluent will be used as cooling tower makeup water and remaining treated water will be discharged into Green Canal after meeting the discharge standard. Sewage is being generated from the office and plant area. Sewage generated from the existing plant is 5.8 KLD. After expansion, 17.8 KLD sewage will be generated from the plant. Sewage is presently being treated through ETP; same system will be continued for proposed expansion project. The Waste Water Balance is given in a Table Below.

Table 3-14 Waste Water Balance

Waste Water Generation Source Existing Waste

Water Generation in KLD

Additional Waste water

Generation in KLD

Total Proposed Waste water

generation in KLD

Process 7.4 120.6 128

Cooling Water Blow Down from CT 4.8 40.2 45

Boiler Blow Down 2 27.2 29.2

Domestic Waste Water 5.8 12 17.8

Total Waste Water Generation in KLD 20 200 220

3.10.2 Air Emission

3.10.2.1 Flue Gas Emission

At present, the unit is having one number of 8 TPH steam boiler. The proposed expansion unit will install additional two number of Steam Boiler having capacity 15 TPH each. Coal will be utilised as fuel.

The details of Flue gas stack have been given in a Table Below.


51

Table 3-15 Existing and Proposed Air Emissions Details (Flue Gas)

Sr. No

Stack Attached To Dia of Stack in MM

Stack Height in M

Parameters Air Pollution Control Device

Monitoring Device

EXISTING FLUE GAS STACKS

1 Boiler – 8 TPH 1000 30 PM. SO2, NOx Bag Filter Opacity Meter Connected to CPCB Server

2 DG Sets – 1 X 500 KVA

250 10 PM, SO2 & NOx Adequate Stack Height

Only used in Emergency

3 DG Sets – 1 X 650 KVA

250 10 PM, SO2 & NOx

PROPOSED STACK EMISSIONS

1 Boiler 1 X 15 TPH 1875 51 PM, SO2 & NOx Bag Filter Opacity Meter & Flue Gas Analyser

2 Boiler 1 X 15 TPH 1875 51 PM, SO2 & NOx Bag Filter

3 1 X 2000 KVA DG Set

800 30 PM, SO2 & NOx Adequate Stack Height

Only used in Emergency

3.10.2.2 Process Emission The emission from the process are HCl, NH3, H2,S, CH3Cl. The process emission will be controlled through following air pollution control systems. The details of existing and proposed process emissions with stack details are given below.

Table 3-16 Existing and Proposed Process Stack Emissions

Sr. No

Stack Attached To Dia of Stack in MM

Stack Height in M

Parameters Air Pollution Control Device

EXISTING PROCESS GAS STACKS

1 Asulum Plant Vent 80 5 HCL Caustic Scrubber

2 Ethion Vent

25 18 H2S, NH3 Caustic & NaOCl Scrubber

3 Acephate Plant IsoMer Reactor Vent

40 9 CH3Cl Water Scrubber

4 Fluidised Bed Drier – FBD 350 18 PM Bag Filter

5 Spin Flush Drier - SFD 200 19 PM Bag Filter

PROPOSED PROCESS STACK EMISSIONS

1 Asulum Plant Vent 80 5 HCL Caustic Scrubber

2 Ethion Vent 25 18 H2S, NH3 Caustic & NaOCl Scrubber

3 Acephate Plant IsoMer Reactor Vent

560 9 CH3Cl Water Scrubber

4 Fluidised Bed Drier – FBD 350 18 PM Bag Filter

5 Spin Flush Drier - SFD 200 19 PM Bag Filter


52

Presently the unit has installed two numbers of two stage water scrubber followed by alkali scrubber to scrub HCl gas generated from the process. After proposed expansion, the unit will install additional three numbers of two stage water followed by alkali scrubbers to scrub HCl, gas generated from the process. Adequate height of process vent will be provided. 3.10.3 Solid Waste / Hazardous Generation

The discarded drums /bags /Liners are decontaminated, detoxified by using water/caustic/HYPO and will be sold to scrap processors.

Used oil shall be sold to State Pollution Control Board (SPCB) authorized recycler / re-processor.

ETP Sludge; MEE salts shall be sent to Treatment, Storage and Disposal Facility (TSDF) site at Haldia- Ramkey for final disposal

Organic waste / distillation Residue, Aqueous waste, Off specification product / date expired product, is/will be sent for incineration.

After expansion total Landfilling waste generation will be 0 MTM (Existing: 00 MTM + Proposed: 00 MTM). Generated landfilling wastes will be sent to Ramkey, Haldia for landfilling.

After expansion total Incineration waste generation will be 15 MTM (Existing: 1.5

MTM + Proposed: 13.5 MTM). Generated incineration waste will be sent for co-processing first and remaining quantity will be sent to Ramkey, for incineration.


53

4 SITE ANALYSIS

4.1 CONNECTIVITY

The port of Haldia acts as the guiding factor to trade and commerce of vast hinterland comprising the entire Eastern India including Bihar and Eastern Uttar Pradesh and the two land locked Himalayan Kingdoms of Nepal and Bhutan. The near by Aminities to the site have been given in Table 3.1 of PFR Report. 4.1.1 Road Connectivity

The National Highway 41 connects the port city with National Highway 6 (part of Golden Quadrilateral) at Kolaghat. From Kolaghat NH-6 connects Orissa, Jharkhand, Kharagpur, Bankura and Purulia and also Durgapur, through NH-34 to North Bengal, Bangladesh via Petrapole and Bhojadanga.

Figure 4-1 Accessibility Map of the Haldia Industrial Area

4.1.2 Rail Connectivity

Haldia port is connected with the broad-gauge line of the South-Eastern Railways. Panskura-Haldia electrified rail route is highly suitable for the daily commuters. Also a circular railway connecting the core industrial areas to provide additional facilities to the industries are among the plans for the future.


54

4.1.3 Air Connectivity

The Netaji Subhash Chandra Bose International Airport, Kolkata, connects the port city to the rest of the India and world by air. Available road transport from the airport to the port city provides an easy means of communication in spite of the distance. 4.1.4 Water Connectivity

The Allahabad-Haldia stretch of the Ganga-Hooghly River serves as national waterways No 1. With Haldia Dock Complex, the country's 5th largest port with all modern facilities for industrial growth. Bulk cargo-handling facilities, full-fledged container facilities, an oil jetty to handle tankers with liquid cargo are a few of the facilities that the Haldia Dock provides. Along with these the city is also equipped with river ferry services between Kukrahati-Raichak and Kukrahati - Diamond Harbor. 4.1.5 Land Form, Land use and Land Ownership :

The plot of land is located at a land of KoPT – Kolkata Port Trust – A Nodal agency owing a land has given permission to UPL for 30 Years Lease utilisation for Industrial Purpose. The “Haldia Development Authority (HDA) is nodal agency constituted by government of West Bengal who is responsible for support infrastructure development at Industrial area like Water, Road & Other Amenities. Thus, landuse pattern is non-agricultural it is used for industrial activities only and belongs to KoPT. Land possession document is attached as Annexure-03. The total land described above is owned (acquired) by the project proponent and has declared as Industrial zone. The total land of the plant is 60702.82 sq. m (15 acre). This land has been taken long term lease from Kolkata Port Trust Haldia Dock Complex. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. 4.2 TOPOGRAPHY (ALONG WITH MAP)

There is a general gradual slope towards Southern side i.e. towards the 45 meter Service Corridor (Nananjuli), running parallel to the HPL Link Road, on the way to City Centre from Durgachak at Haldia Township area. The most prevalent soil in the region is black cotton soil. However, sandy, light grey, reddish and brown soil also occurs in the area. Major portion of the area is black and red sandy loam soil. Geological formations are of Khodalites, Chamockites, Quartzite and quartz veins origin occurring in elongated bands. 4.3 LAND USE

The total land used UPL Haldia unit is 60702.82 sq. m (15 acre. The total build-up area of the plant is 23986.557 sq. m. (39.5%) and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant. The identified land was built-up area. Therefore, land filling and tree felling would not be required. The detailed land use table for existing site and proposed expansions is given as below.


55

Table 4-1 Existing and Proposed Land Use Details

Sr. No

Particulars Existing m2 Proposed area in m2 Remarks

A Production Plant Area with

Utility 23987 25187

No Additional Land Requirement since

Expansion is proposed within

existing plant premises.

B Rain Water Harvesting

Pond Area 11476 11476

C Circulation Areas (Roads) 3500 3500

D Green belt /Land scrapings 18,211 20,032

E Open Areas /Non Processing Areas

3,529 508

TOTAL AREA IN Sq. M 60702.82 60702.82

The Proposed Land has already been defined as a classified Industrial zone by Haldia Development Authority. Hence, there is no change in the character of the land to be used for the Industry. 4.3.1 CRZ applicability

The proposed expansion site is approximately, 450 m from high tide line. As per CRZ Notification 2011, CRZ is applicable up to 100 m from HTL. Therefore proposed project does nor attract CRZ. 4.4 EXISTING INFRASTRUCTURE

The details on the existing core infrastructure facilities are dealt in the above paragraph some additional important aspects are dealt below 4.4.1 Water

Water at Haldia is served by rivers like Rupnarayan, Haldi and Hooghly that ensure abundant water supply for irrigation of the agricultural farms. The Authority has made requisite arrangements to ensure treated industrial and domestic water supply round-the-clock. Due to current water demand of industries, HDA augmented 25 MGD Water Treatment Plant beside its existing 25 MGD Water Treatment Plant at Geonkhali. For fulfillment of future demand to a tune of 25 MGD the treatment plant has been started operating recently on BOT basis. 4.4.2 Power

West Bengal State Electricity Distribution Corporation Ltd. (WBSEDCL) is primarily responsible for a stable and quality power supply to the Haldia Planning Area.


56

4.4.3 Telecommunication

For instantaneous communication to any part of the globe, Haldia port city is well equipped with the latest telecom facilities provided by BSNL, Reliance, Airtel, Vodafone etc. and postal services. 4.4.4 Drainage

The Irrigation and Waterways Department of West Bengal plays a significant role in the planning and execution of the comprehensive drainage scheme for Haldia. To supplement, this scheme HDA has undertaken a number of projects like construction of drainage culverts and RCC Box type culverts over Manasatala Canal. Also some secondary drainage schemes for Storm Water Drainage have been taken. 4.5 SOIL CLASSIFICATION

General soil classification of the area is as under : Soil Characteristics & Land use classification: The study area is located at Haldia Industrial area. Major part of the study area has been developed for industrial use and township. The quality of East Midnapur district area soil had been identified as coastal alluvial type. Proposed expansion project is within existing site and located in Kolkata Port Trust industrial Area Haldia, where land is already developed for industrial purpose. Quality of soil is not considerably fertile for agriculture activities and no evidence of any influence of soil contaminant has been noticed. 4.6 CLIMATE

The climate of Haldia is a typical moderate one with winter temperatures ranging from a low of around 9.6 degrees Celsius to a high of 29.3 degrees Celsius. Summers on the other hand can be very hot and humid. Usual summer temperatures in May range from a low of 24 degrees to highs around 42 degrees. Rainfall is heavy during monsoons, and the rainy months are between May and September.

Table 4-2 Climatic Condition in the Study Area

Sl. No. Parameter

1. Temperature

Summer 41.7 C to 24.0 C

Winter 29.3 C to 9.6 C

2. Humidity 68 to 80%

3. Rainfall (Annual average) 1580 mm

4. Wind speed Mean speed – 5.5 to 9.9 km per hour

5. Wind Direction

Predominant From South & south west

Winter season From North & North-West

[IMD, Haldia]


57

4.7 DEMOGRAPHY OF THE PROJECT INFLUENCE AREA

In the 2011 census, Haldia had a population of 200,827, out of which 104,841 were males and 95,986 were females. The 0–6 year’s population was 21,945. Effective literacy rate was 79%.

Figure 4-2 Decadal Population Growth at Haldia

Table 4-3 Demography of Haldia at a Glance

Demographic parameter Total Male Female

Total No. of Household 44065

Total Population 200827 104841 95986

Sex Ratio 916

In the age group 0-6 years 21945 11194 10751

Child Sex Ratio 960

Literates 158380 87334 71046

79% 55% 45%

Table 4-4 Working Population of Haldia

Workforce Participation Parameter Total Male Female

Total workers 61216 54477 6739

30% 89% 11%

Main Worker 50792 46004 4788

25% 91% 9%

Marginal Worker 10424 8473 1951

5% 81% 19%

Non Worker 139611 50364 89247

70% 36% 64%

4.8 SOCIAL INFRASTRUCTURE AVAILABLE

The infrastructure resource base of the area with reference to education, medical facilities, water supply, post and telegraph, transportation and communication facilities and power


58

supply etc. are briefly described below for 5 km Core Area of Influence around the site (that comprises of Haldia Municipality, Dihsibram Nagar, Anantapur and Kismat Sibramnagar) : Education: The villages and sub-urban towns located within the 10 km study area have access to 86 govt. primary schools, 20 middle schools, 19 secondary schools and 15 senior secondary schools. Other than that, there are several private educational facilities imparting education from primary to higher education lying within the Haldia Municipal Corporation area. Communities within the study area are mostly dependent on Haldia for fulfilling the needs of higher education. Drinking Water: As per Census 2011 data, treated water supply is available from Geonkhali Water Supply Station. Communication and Transportation: The area is well connected with road network. The Kolaghat Nandkumar Road and Haldia Tamluk Mecheda Road connects the core area with other parts of the District. Public transportation such as buses and autos are available. Power Supply: Power supply is available in all of the villages and sub-urban areas within the study area. Medical/Primary Health Care: Primary Health Centre, Block Primary Health Centre and Sub-Divisional Hospital is present within Haldia Municipality Area. Other than that Primary Health Sub Centre is present in Kismat Shibramnagar.


59

5 PLANNING BRIEF

5.1 PLANNING CONCEPT

Planning Concept (Type of industries, facilities, transportation, etc.) Town and Country Planning /Development authority Classification is as follows UPL has a thorough knowledge of worldwide market of Pesticides (Technical & Formulations) as well as organic intermediates and is already exporting these products. After a very careful scrutiny of the developments of R & D, UPL is ready to launch new intermediates as well as several new pesticides. To support the above projections, it is decided to make optimal use of the facilities at existing site by providing additional supporting infra-structure & hence this project for addition & expansion. Land required for the proposed project is already owned by proponent and no additional land is required for proposed project. Additional Power, Fuel and water will also be available through same existing sources. Proposed project activities will address all the applicable rules and regulations. There is a cluster of numerous large-scale, medium-scale and small-scale industries, engaged in the manufacture of variety of products like petro-chemicals, chemicals, oil & gas storage and bottling, thermal power plant. Haldia Dock complex, etc. in the Haldia Industrial area. 5.2 POPULATION PROJECTION

Not applicable 5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC

The existing unit is located in the HDA Industrial area; the proposed expansion unit will be constructed within the existing plant area; hence there will not be any change in Land use of core zone and buffer zone. The total land used UPL Haldia unit is 60702.82 sq. m (15 acre. The total build-up area of the plant is 23986.557 sq. m. (39.5%) and greenbelt area is 18,211 sq. m. (30% of the total plant area). The plant has demarcated 1821 sq. m for greenbelt plantation. The land required for proposed expansion unit is 1200 sq. m and same is available within the plant.


60

Table 5-1 Existing and Proposed Land Use Details

Sr. No

Particulars Existing m2 Proposed area in m2 Remarks

A Production Plant Area with

Utility 23987 25186.557

No Additional Land Requirement since

Expansion is proposed within

existing plant premises.

B Rain Water Harvesting

Pond Area 11476 11476

C Circulation Areas (Roads) 3500 3500

D Green belt /Land scrapings 18,211 20,032

E Open Areas /Non Processing Areas

3,529 508

TOTAL AREA IN Sq. M 60702.82 60702.82

Figure 5-1 Photographs of Existing Greenbelt

While selecting the plants species to be grown in the green belt zone, following points will be taken into account:

Climatic condition and soil characteristics of the region.


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The air pollution emitted by the industry – gaseous and particulate matter. Plant interaction with both gaseous and particulate pollutants and to a great extent absorbs them and thus, removes them from the atmosphere.

Characteristics of plants including shapes of crowns considered necessary for effective absorption of pollutant gases and removal of dust particles.

Height of the plants should not be too high to be lethal.

For absorbance of gases, the duration of the foliage should be longer.

Vegetation controls soil erosion rates significantly. The decrease of water erosion rates with increasing vegetation cover is exponential. This review reveals that the decrease in water erosion rates with increasing root mass is also exponential. Plant species having good root system are selected, so that soil erosion can be checked.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND ( PHYSICAL & SOCIAL) :

There is no need for any infrastructure demand in terms of physical or social needs for the proposed expansion. 5.5 AMENITIES/ FACILITIES

HDA industrial area of Haldia has the available infrastructure like water, electricity, roads, rail, transportation, availability of raw material and drainage system.


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6 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA).

The proposed infrastructure to manufacture products will be built with standard engineering design considering all the relevant parameters related to environment, health and safety. The proposed project is an expansion within existing unit. Approx. 60702.82 Sq. meter land will be used for proposed expansion. 6.2 RESIDENTIAL AREA (NON PROCESSING AREA) :

No residential area is involved in the proposed expansion project. 6.3 GREENBELT

Green belt will be provided and maintained at the tune of 33% of the total land area of factory. 6.4 SOCIAL INFRASTRUCTURE

Not applicable. 6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/ WATER WAYS ETC)

The project site is very well connected by road through National Highway no. 41, eastern railways. 6.6 DRINKING WATER MANAGEMENT ( SOURCE & SUPPLY OF WATER ) :

Source of water is from HDA water supply services for proposed expansions. 6.7 SEWERAGE SYSTEM

HDA has provided drainage facility for disposal of treated effluent and sewage. 6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial liquid effluent generated during the manufacturing of proposed products will be segregated. Concentrated (high TDS) effluent will be treated in the primary, secondary & tertiary ETP and will be discharged through HAD drainage to Hooghly after meeting the discharge standard. Generated domestic liquid waste is being treated through ETP and then disposed off through drainage system. 6.9 SOLID/HAZARDOUS WASTE MANAGEMENT

Generation, treatment and disposal of solid/hazardous waste has been provided in following table.


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Table 6-1 Solid/Hazardous Waste Management

Sl. No.

Type of Solid /Hazardous waste

Quantity in MT/Month

Mode of Disposal Existing as per EC

Actual Generation

Additional Quantity After Expansion

Total Quantity (Actual Generation + Additional)

1 ETP sludge 1.465 0.7 4.9 5.6 Disposed off into TSDF, Haldia

2 Used oil 1.00 0.11 0.64 0.75 Sell to authorized recycler

3

Solid waste from industrial process (Salt from MEE & Process residue

6.5 0 0 0 Disposed off into TSDF, Haldia for Incineration

4 Waste from MMT Process

166.25 4.83 178.18 182.94

Disposed off into TSDF, Haldia for Incineration

5 Asulum formulations

2 2 2 2 No Generation

177.215 7.64 185.72 191.29

Table 6-2 Non Hazardous Waste Management

Sl. No.

Type of Solid /Hazardous waste

Category Quantity TPD Place of Storage

Disposal

Existing as per EC

Actual Generation

Additional After Expansion (Actual +Additional)

1 Fly Ash 34.3 15 2.1 68.1 70.2 HDPE Drums

Disposed off into Low laying area or Given to Local Brick Manufacturers

6.10 POWER REQUIREMENT & SUPPLY / SOURCE

Power requirement for proposed expansion project will be taken from West Bengal State Electricity Distribution Corporation Ltd. (WBSEDCL).


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7 REHABILITATION AND RESETTLEMENT (R&R) PLAN

7.1 POLICY TO BE ADOPTED (CENTRAL/ STATE) IN RESPECT OF THE PROJECT AFFECTED PERSONS

INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO

BE GIVEN):

Proposed expansion will be carried out at existing site located in Industrial zone of Kolkata Port Trust which is developed for industrial purpose and there is no population or local inhabitant at the proposed expansion at existing site. Thus Rehabilitation & Resettlement (R&R) Plan is not applicable to propose expansion


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8 PROJECT SCHDULE & COST ESTIMATION

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

The proposed expansion project will be started after getting Environmental clearance from Ministry of Environment, Forest and Climate Change (MoEF &CC) & Consent to Established (CTE) from State Pollution Control Board (SPCB). 8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF

THE PROJECT

The estimated approx. capital cost of the expansion project shall be INR 165.31 crores & detail

Table 8-1 Project Cost Breakup

Sl. No. Component Amount (INR in Crore)

1 Equipment Cost 47.17

2 Piping Cost 25.47 3 Electrical Cost 10.43 4 Instrumentation Cost 8.68 5 Civil & structure Cost 37.67

6 Insulation Cost 5.15 7 Painting Cost 5.15

8 Safety Equipment Cost 2.00 9 Utility Cost 9.09 10 Miscellaneous Cost ( HAZOP, Service) 14.50 11 Cost of Environment Management System (APCM, Waste

Management cost, Effluent Treatment & Green Belt)

(25.14 crore) included in the project

cost

Total 165.31


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9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL

PEOPLE INCLUDING TRIBAL POPULATION ANY IN THE AREA

The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to be purchased.

From The proposed expansion project, there shall be increase to foreign exchange generated by Exports.

Reduce dependence on Imports hence reducing forex risks.

There shall be direct or indirectly increase in employment generation for the local people and lead to ensure continued employment to existing workforce without affecting work conditions and hence supporting their families.

The company has allocated some budget for CSR activities, which can lead to improved social infrastructure, if planned properly.

The proposed expansion project shall not have any adverse environmental impacts because adequate protection measures will be provided to achieve permissible norms of MoEF&CC /WBPCB.

UPL Management have taken up various CSR activities and major activities are in the field of education, health protection and improvement of infrastructure facilities. The important organizations under the umbrella of UPL are Sanskardeep Vidyalaya (Ankleshwar), Gyan Dham School (Vapi), Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology (Ankleshwar). In CSR, UPL spent 10.62 Crores in the year of 2014-15; 11.56 Crores in 2015.16 and 23.79 Crores in 2016-17.

CSR Activity at Haldia The CSR activity in the UPL Haldia unit are providing infrastructure and facilities in schools like (i) toilets, (ii) computers and (iii) school uniforms 9.2 CONCLUSION:

The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to be purchased. From The proposed expansion project, there shall be increase to foreign exchange generated by exports and reduced dependence on Imports hence reducing forex risks. Moreover, existing site is located inside Industrial zone of Kolkata Port Trust. As summarized in above sections, it has been noticed that the proposed expansion in existing production capacity (Pesticides Technical) and addition of new products (Pesticides Technical products) will not have any major impacts, which can lead to serious issue of environmental pollution or any other hazards. Considering the probability of impacts, proponent has planned adequate mitigation measures and EMP. There shall be direct or indirectly increase in employment generation for the local people which will lead to ensure continued employment to existing workforce without affecting work conditions and hence supporting their families. The company has allocated some budget for CSR activities, which can lead to improved social infrastructure. In addition, UPL Management have taken up various CSR activities and shall continue to do so in the field of education, health protection and improvement of infrastructure facilities.


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Annexure


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Annexure 1: Environmental Clearance


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Annexure 2: Ground water Withdrawal Permission


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Annexure 3: Land Possession Certificate

Documents

PROJECT PRE-FEASIBILITY REPORT...PRE-FEASIBILITY REPORT UPL LIMITED, UNIT # 09,HALDIA 3 4 SITE ANALYSIS 53 4.1 CONNECTIVITY 53 4.1.1 Road Connectivity 53 4.1.2 Rail Connectivity 53