[Vide EIA Notification dated 14th
PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT
September, 2006 & Subsequent Amendments]
For
PROPOSED EXPANSI ON AND ADDI TI ON OF NEW PRODUCTS
FOR MANUFACTURI NG OF CHEMI CAL FERTI LI ZERS
By
M/s. COROMANDEL INTERNATIONAL LIMITED
Plot no.71/71-A/72/73/74/75/83, GIDC, Nandesari, District: Vadodara, Gujarat, India.
October, 2017
Conducted & Prepared By
GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers
(MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001,NABL/ 17025:2005 OHSAS: 18001 Certified Organization & GPCB approved
Environment Auditor – Schedule I I ) Gujarat High Court Stay Order for QCI NABET No. C/ SCA/ 5312/ 2016dated 21.07.2016
Corp. Office & Environmental Research Laboratory:
Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India |Tel: 0265-2371269
www .greencircleinc.com E: [email protected]
ALSO AT BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA
OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM
Page 2 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
TABLE OF CONTENTS
1. EXECUTIVE SUMMARY .............................................................................................................................................. 3 1. EXECUTIVE SUMMARY .............................................................................................................................................. 3 2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ............................................................................. 3 3. PROJECT DESCRIPTION .............................................................................................................................................. 5 4. SITE ANALYSIS .......................................................................................................................................................... 22 5. PLANNING BRIEF ..................................................................................................................................................... 24 6. PROPOSED INFRASTRUCTURE ................................................................................................................................. 25 7. REHABILITATION AND RESETTLEMENT (R & R) PLAN ............................................................................................... 26 8. PROJECT SCHEDULE & COST ESTIMATES.................................................................................................................. 26
9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) .......................................................................................... 26
LIST OF TABLES
TABLE 1.1 CONSUMPTION, PRODUCTION AND IMPORTS OF FERTILIZERS FROM 2009-2013 ............................................................. 5TABLE 1.2 EXISTING PRODUCTION DETAILS .............................................................................................................................. 9TABLE 1.3 TOTAL PRODUCTION DETAILS .................................................................................................................................. 9TABLE 1.4 MASS BALANCE OF SSP (600 TPD) ..................................................................................................................... 11TABLE 1.5 MASS BALANCE OF ZINCATED SSP (600 TPD) ....................................................................................................... 13TABLE 1.6 MASS BALANCE OF BORONATED SSP (600 TPD) ................................................................................................... 13TABLE 1.7 LIST OF RAW MATERIAL ...................................................................................................................................... 17TABLE 1.8 WATER CONSUMPTION AND WASTEWATER GENERATION ........................................................................................... 18TABLE 1.9 ELECTRICITY REQUIREMENT ................................................................................................................................. 19TABLE 1.10 FUEL REQUIREMENT ........................................................................................................................................ 20TABLE 1.11 DETAILS OF PROCESS GAS STACKS ....................................................................................................................... 20TABLE 1.12 DETAILS OF HAZARDOUS WASTE ........................................................................................................................ 20TABLE 1.13 DETAILS OF NON-HAZARDOUS WASTE ................................................................................................................ 21TABLE 1.14 ENVIRONMENT SETTINGS ................................................................................................................................. 22TABLE 1.15 AREA BREAK-UP ............................................................................................................................................. 25
LIST OF FIGURES
FIGURE 1.1 LOCATION MAP OF PROPOSED PROJECT ................................................................................................................. 6FIGURE 1.2 PROJECT BOUNDARY OF PROPOSED PROJECT SITE ..................................................................................................... 6FIGURE 1.3 GOOGLE IMAGE OF THE PROJECT SITE (5 & 10 KM RADIUS) ....................................................................................... 7FIGURE 1.4 PLANT LAYOUT ................................................................................................................................................. 8FIGURE 1.5 WATER BALANCE DIAGRAM .............................................................................................................................. 19
Page 3 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
1. EXECUTIVE SUMMARY M/s. Coromandel International Limited is located at Plot no.71/71-A/72/73/74/75/83, GIDC, Nandesari, District: Vadodara, Gujarat, India. M/s. Coromandel International limited has proposed for expansion and addition of new products for manufacturing of chemical fertilizers and Proponent for the proposed expansion project is Mr. Tarun Kumar Bandhyopadhyay. As per the EIA Notification, 2006 & subsequent amendments, the proposed expansion project falls under category ‘B’ listed at item 5(a). The site is well connected with road and railway, nearest city Vadodara is located at a distance of 10 km and Mahi River passing through NW direction at a distance of 2.1 km and Mini river passing through East direction at a distance of 1.35 Km. There is no reserved forest, national park, eco sensitive areas in surrounding 10 km radius. The detail related to the proposed expansion project is discussed in the upcoming section.
2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of project and project proponent
2.1.1 Identification of project M/s. Coromandel International Limited, India’s second largest Phosphoric fertilizer industry, is in the business segments of Fertilizers, Specialty Nutrients, Crop Protection and Retail. The Company manufactures a wide range of fertilizers and markets around 3.2 million tons making it a leader in its addressable markets. M/s. Coromandel international limited, is situated at Plot No. 71, 71- A, 72, 73, 74, 75 & 83 GIDC Nandesari, Distt.: Vadodara, Gujarat, and engaged in manufacturing of Single super phosphate and Granular single super phosphate. In its endeavour to be a complete plant nutrition solutions Company, Coromandel has also introduced a range of Specialty Nutrient products including Organic Fertilizers. Coromandel has also ventured into the retail business setting up more than 750 rural retail centres in the States of Andhra Pradesh and Karnataka. 2.1.2 Project Proponent The proponent for the proposed expansion project of M/s. Coromandel International Limited is
Mr. Tarun Kumar Bandhyopadhyay, working as Manager-Operations at Nandesari plant. He is
having 30 years of experience in chemical fertilizer Industry.
2.2 Brief description of nature of project
The proposed expansion project is covered under the category ‘B’ of 5(a) in schedule “Chemical fertilizers” of EIA Notification-2006 & subsequent amendments. M/s. Coromandel International Limited has obtained Environmental Clearance and CC&A for manufacturing of Single Super Phosphate (SSP) 18,000 MT/M and out of which 12,000 MT/M of SSP is converted to Granular Single Super Phosphate (GSSP). The company has proposed for expansion of production capacity of SSP from 18000 MT/M to
24000 MT/M, and addition of new products, Zincated SSP/GSSP, Boronated SSP/GSSP
Page 4 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
(fortified) and NPK. A single product or group of products will not exceed 24,000 MT/M
production capacity, in case of SSP, GSSP, Zincated SSP/GSSP, Boronated SSP/GSSP
(fortified) and NPK.
2.3 Need of project and its importance to the country and/or region
Single Super Phosphate (SSP) Fertilizer industry is the pioneering fertilizer in the country and the first SSP plant is said to have been established by EID Parry in the year 1906. Manufacturing of SSP is based on perhaps the simplest chemical reaction amongst chemical fertilizer industry. 0. SSP is a poor farmer's fertilizer (price-wise), is an option to optimize the use of phosphatic fertilizer. It also helps to treat Sulphur deficiency in soil (40% Indian soil Sulphur deficient) as well for further enhancement of yields at the least cost. In various crops, which require more of Sulphur and phosphate like oilseeds, pulses, sugarcanes, fruits and vegetables, tea etc. SSP is an essential fertilizer. S.S.P. is cheapest among phosphoric fertilizer and essential for cultivation of Sugarcane, Pulses, Oil seeds, Fruits and vegetables etc. The DOF has indicated that 40% of Indian soil is deficient of Sulphur, which needs use of SSP. The production of SSP recorded a sharp increase from 3.093 million tons in 2009-10 to 3.631 million tons in 2010-11 showing 17.4% over the previous year. All India capacity utilization of SSP increased from 46.2% during 2009-10 to 49.5% in 2010-11. Out of 66 operating plants, 25 operated above 60% capacity utilization and 41 plants below 60%. Total dispatches of SSP during 2010-11 stood at 3.596 million tons recorded an increase of 29.2% over 2009-10. There was a marginal fall in inventory. Stock of SSP reduced from 523.6 thousand tons as on March 2011.
2.4 Demand Supply gap
Farmers are now hard pressed to procure SSP to fertilize the top soil. Though SSP has been in short supply for preceding 5 to 6 years, the continuous decline in its production has further tightened its supply in the current Rabi season. The gap in SSP’s supply and demand further widen this season because against the requirement of 15 Lac tons, not more than 10 Lac tons will be available from the indigenous producers. Usually, this phosphate fertilizer is much in demand in the Rabi season when potato is being cultivated. But the way SSP’s production is sinking every crop season, not even 70% of the requirement would be met from the domestic production.
2.5 Imports v/s indigenous production
Raw materials purchase from indigenous as well as import production. The department of fertilizer report on consumption production and imports (in thousand tones of nutrients) of Phosphatic Fertilizer clearly indicates the deficiency of production against the consumption. The increase in production capacity will be beneficial in saving the foreign currency.
Page 5 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Table 1.1 Consumption, Production and Imports of fertilizers from 2009-2013
Year Consumption Production Imports
2009-10 72.7 43.21 27.6
2010-11 80.5 42.23 38
2011-12 79.1 41.04 44.3
2012-13 66.5 35.41 26.3
Source: Department of Fertilizers
2.6 Export Possibility
If there is any opportunity or demand M/s. Coromandel International Limited, will also export the products.
2.7 Domestic/ export markets
If there is any opportunity or demand M/s. Coromandel International Limited, will also export the products.
2.8 Employment Generation (Direct and Indirect) due to project
The proposed project will generate direct employment in both construction and operation phase locally or regionally. It is expected that direct employment opportunities at the time of construction phase will be provided approximately 20 unskilled and semi skilled workers from the nearby village. During the operation phase, direct employment opportunities will be provided approximately to 80 persons, comprising of 50 unskilled or semi skilled workers. Around 30 persons (unskilled contract workers) will be required for loading and unloading operations.
3. PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects, if any. The project is neither an interlinked project nor an interdependent project. It is the proposed
expansion and addition of new products for manufacturing of chemical fertilizers. The project
falls under category ‘B’, section 5(a) of EIA notification 2006 and amendment thereof.
3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates.
Coordinates of project site: 22˚ 24’ 36.79” N and 73˚ 05’ 34.66” E
Page 6 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Map showing general location:
Figure 1.1 Location Map of Proposed Project
Project boundary of project site
Figure 1.2 Project Boundary of proposed project site
Page 7 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Co-ordinates of the corners of project site:
Corner Coordinates A 22°24'39.81" N, 73°05'32.47" E
B 22°24'38.51" N, 73°05'31.26" E
C 22°24'34.88" N, 73°05'32.32" E
D 22°24'33.89" N, 73°05'33.36" E
E 22°24'34.15" N, 73°05'35.47" E
F 22°24'36.03" N, 73°05'37.31" E
Figure 1.3 Google Image of the project site (5 & 10 Km radius)
Page 8 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Project site layout:
Figure 1.4 Plant Layout
3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.
Alternative site study is not carried out as existing plant and proposed expansion project is located in a well developed industrial Area (GIDC Nandesari). Major factors involved in the selection of site are listed below:
• Project site is within the Nandesari GIDC, which on NH 8 (3 km, E) has inherent location advantage of National Highway connecting to Vadodara, Ahmedabad and Surat.
• The project site is located on level ground, which does not require any major land filling for area grading work.
• Proximity to Raw Material suppliers. • Strategic location – proximity to Vadodara (10 km), the commercial city of Gujarat and
well connected by rail and road. It has direct inter-city trains to Vadodara, Ahmedabad and Surat. Its nature as a fast growing developing city, combined with its proximity to Vadodara and Ahmedabad, make ideal for sourcing human resources.
Page 9 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
• Availability of Power, Water, etc.
3.4 Size or Magnitude of Operation
3.4.1 Existing production details
As per the existing EC and CC&A, the total production capacity of SSP is 18,000 MT/M, out of which 12,000 MT/M is being converted to GSSP.
Table 1.2 Existing production details Sr. No.
Product Name Quantity, MT/M
1 SSP 18000
2 GSSP 12000
3.4.2. Proposed production details
The company has proposed for expansion of production capacity of SSP from 18000 MT/M to 24000 MT/M, and addition of new products, Zincated SSP/GSSP, Boronated SSP/GSSP (fortified) and NPK. A single product or group of products will not exceed 24,000 MT/M production capacity, in case of SSP, GSSP, Zincated SSP/GSSP, Boronated SSP/GSSP (fortified) and NPK.
Table 1.3 Total production details Sr. No.
Name of products Total production capacity after
expansion, MT/M 1 Single Super Phosphate (SSP)
24,000
2 Granular SSP (GSSP)
3 Zincated SSP
4 Zincated GSSP
5 Boronated SSP
6 Boronated GSSP
7 NPK-GSSP
3.5 Project Description with process details (a schematic diagram/flow chart showing the project layout, components of the project, etc. should be given)
3.5.1 Single super Phosphate Manufacturing Process:
The manufacturing process of single phosphate (SSP) is basically conversion of insoluble P2O5
to soluble P2O5 by chemical reaction between phosphate ore and dilute sulphuric acid in
definite proportion. The reactants originally thin slurry set to a solid mass during the reaction.
After initial production to completion of the reaction i.e. product SSP it may take up to 15 days.
Page 10 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Dryer Rock phosphate contains moisture from 2 to 8%, which is dried up to 1 % through the co-
current operation with hot air. The inlet temperature of the hot air will be 250 to 3000C and outlet
temperature will be 60 to 700C. Only 15 % material remains in dryer during drying. Mill The first unit operation in the SSP production is the Ball mill. In the ball mill the rock phosphate
is crushed about 92 to 97% is passing through 100 mesh, for better efficiency of reaction. Fine
rock phosphate particles are collected through pulse jet collector system with cyclone separator
system attaches with blower. Grind rock is collected in silo through separator.
Mixer The name itself suggests the function of the equipment. In the mixer the rock phosphate, 98%
H2SO4 acid and water are mixed to form slurry. The optimum ratio is
Rock phosphate 52.00 to 57.5% depending on Rock quality.
98% H2SO4 0.345 to 0.36 MT/Ton of SSP production
Water 3.70%
About 67 to 69% acid concentration is used for getting the better conversion of P2O5
1. Major reaction:
. The slurry
is thicker than the discharged to den.
Den The Den is horizontal tunnel through which the slurry of acid and rock phosphate proceeds on a
slowly moving slatted conveyor, which is also known as Broadfield / Belt Den. The retention
time is 40 to 45 Minutes. During this time cake formation takes place. The gases are evolved in
the process of SSP production, which are scrubbed with the help of three stage scrubbing
system.
Chemical Reaction: Single super phosphate is made by the reaction of phosphate rock with sulphuric acid to
connect the insoluble (tribesic) form of calcium phosphate to a soluble (monobasic) form. This
reason can be represented by the following chemical reaction, which is the major reaction.
Ca3 (PO4) 2 + 2H2SO4 + H2O CaH4 (PO4) 2. H2O + 2CaSO4 The calcium sulphate remains in the product. SSP contains about 16% water soluble of
Phosphorous Pentaoxide (P2O5
2. Minor reactions:
) equivalent to the chemical impact of acid on phosphate rock
librates a large amount of steam, which entrains fine particulates of phosphate rock and acidic
gas and fumes, most of which originates from impurities in the rock.
2CaO+2F2 2CaF2 + O
3CaO + P2
2O5 Ca3 (PO4) 2
CaO+SO
3 CaSO
MgO+H4
2SO4 MgSO4 + H2
Fe
O
2O3+3H2SO4 Fe2 (SO4) 3 + 3 H2O
Page 11 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Al2O3+3H2SO4 Al2 (SO4) 3 + 3 H2
CaO+H
O
2SO4 CaSO4 + H2
3. Pollution reaction: O
CaF2+H2SO4 CaSO4
4HF+ SiO
+ 2HF
2 SiF4 + H2
3SiF
O
4+2H2O 2H2SiF6 + SiO
H2SiF6 SiF4 + 2 HF
Both SiF4 and HF are gases at ambient temperature and pressure and collected in the Den by
scrubbing system. The fluorine evolution is about 25% of 3% fluorine in the rock; Evolution of
the silica is about 30% of 8% in the rock.
2
The evolution of fluorine and Silica containing gases is a major problem in the SSP production
process. These evolved from the fluoride and silica contained as impurities in the rock. These
elements combine with the water to form flurosilic acid (H2SiF6). Excess silica dissolves
Flurosilic acid to form silicic acid (SiO2-H2O). Typical rock phosphate contains about 8% Silica
and 3% Fluorine by weight.
The temperature condition in the den causes a partial dissociation of fluorosilic acid, according
to following chemical equation.
Table 1.4 Mass Balance of SSP (800 TPD)
Raw materials Consumption Kg/kg of product MT/day
Input Rock Phosphate 0.565 452 Sulphuric Acid (100%) 0.345 276 Water 0.180 144 Total 1.090 872
Output Single Super Phosphate 1.00 800.00
Losses due to evolution of CO2 etc. 0.020 16.0 Water loss due to evaporation during acidulation 0.050 40.0
Water losses during curing 0.020 16.00
Total 1.090 872.00
Page 12 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Process flow diagram:
3.5.2 Zincated Single Super Phosphate Manufacturing Process: The SSP manufacturing process will comprise of two basic steps: grinding and acidulation.
Rock Phosphate which is the major raw material of the product will be fed through grinding
section. The next stage is acidulation. Sulphuric acid and ground rock phosphate will be fed to
the mixing unit where they will be thoroughly mixed. The output of the mixer which is in slurry
form will then be discharged to the Den. The Den output which is in a dry crumbling state will be
conveyed to the SSP covered storage area and dumped there for curing. The curing will take
10-15 days during which time the SSP will be reshuffled and aerated to aid the process.
The cured SSP than will be mixed with 200 mesh powder of Zincated powder as per required
%age in finished product. This mixing is by crane in most of the plant but a mechanized system
can be used for proper control & mixing. The Zincated SSP powder will then be bagged for
sale.
Page 13 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Table 1.5 Mass Balance of Zincated SSP (800 TPD)
Raw materials Consumption
Kg/kg of product MT/day Input
SSP Powder 0.9925 794 Zinc Oxide 0.0075 6
Total 1 800 Output
Fortified SSP with zinc 1 800
Total 1 800
3.5.3 Boronated Single Super Phosphate (BSSP)
Manufacturing Process: The SSP manufacturing process will comprise of two basic steps: grinding and acidulation.
Rock Phosphate which is the major raw material of the product will be fed through grinding
section. The next stage is acidulation. Sulphuric acid and ground rock phosphate will be fed to
the mixing unit where they will be thoroughly mixed. The output of the mixer which is in slurry
form will then be discharged to the Den. The Den output which is in a dry crumbling state will be
conveyed to the SSP covered storage area and dumped there for curing. The curing will take
10-15 days during which time the SSP will be reshuffled and aerated to aid the process. The
cured SSP than will be mixed with 200 mesh powder of Boron powder as per required %age in
finish product. This mixing is by crane in most of the plant but a mechanized system can be
used for proper control & mixing. The Boronated SSP powder will then be bagged for sale.
Table 1.6 Mass Balance of Boronated SSP (800 TPD)
Raw materials Consumption
Kg/kg of product MT/day Input
SSP Powder 0.988 790.4
Di-Sodium Tetra Borate Pentahydrate 0.012 9.6
Total 1 800 Output
Fortified SSP with Boron 1 800
Total 1 800
Page 14 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
3.5.4 NPK
Brief manufacturing process:
The process is in four stages:-
1. Material handling & granulation
2. Drying & Cooling
3. Size Grading
4. Dust Scrubbing
1) Feeding of volumetric hoppers:
NPK nutrients such as Urea, Potash fertilizer, DAP/MOP/TSP, Gypsum, Filler, are fed
separately into individual Volumetric Hoppers. These nutrients, depending on the grade of NPK
Granulated Mixtures that are to be produced, are fed into conveyor belt in required ratio and
conveyed to nutrient mixer/blender along with recycle material thorough mixing of all the
nutrients.
2) Feeding of blended mix of NPK to granulation drum: The blended mix of nutrients from Nutrient Mixer/Blender is fed into Granulation Drum by
Double chain Bucket elevator.
3) Granulation of NPK nutrient mixture: Continuously required quantity of water and scrubber water from Single super phosphate plant
is sprayed over the nutrient mix in the Granulator Drum to facilitate formation of granules. Entire
Blended Mix gets converted into granules in the Granulator Drum. Thus obtained granules are
wet in nature due to addition of water in the process. There are no chemical reactions involved
in the process.
4) Drying of wet granules: The wet granules of NPK from granulator drum are then gets continuously transferred to rotary
drier drum equipped with internal flights and lifters for showering the material and are dried by a
stream of hot air generated from coal fired furnace.
5) Cooling of dried and hot granules: The NPK granules after draying at Drier drum are hot and are to be cooled before packing to
avoid and eliminate caking. The hot and dried NPK granules are transferred to cooler drum
continuously by conveyor belt from Drier drum. The cooler drum is also to provide with internal
flights and lifters for showering the material for better cooling effect. The hot granules are
cooled by stream of atmospheric air pulled by induced Draft Fan. The cooled granules are then
conveyed to screeners by a set of Conveyor belt and Bucket elevator for separation of over size
and under size grains.
6) Size grading: The dried and cooled granules are passed over “over size separation screen” to remove
granules of over 4 mm size. The oversize grains are crushed in chain mill to crush them and are
Page 15 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
recycled back in the process of granulation. Thus screened material having size 4 mm and
below are then sent for further screen over “under size separation screen”. The under size
material of 1 mm and below gets separated during screening and the same is recycled back in
the process granulation. The material of size varying between 1 mm and 4 mm are then
transferred by conveyor belt to “product hopper” for bagging.
7) Dust scrubbing: The dust particles that are carried out by stream of hot and cool air from drier and cooler drums
are passed through “cyclone separator” and dust collecting chambers to remove all dust
particles from the system and air along with flue gases from hot air coal fired furnace are let out
into atmosphere through a chimney of 30 meters height from the ground level for better
disbursement.
8) Weighing and packing: The screened NPK Granulated fertilizers from product hopper are filled in 50 Kgs net capacity
LDPE lined HDPE oven bags, weighed and stitched by stitching machine. Thus weighed and
stitched bags are then transferred to finished product storage godown.
Page 16 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Process flow chart:
3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product. All raw materials will be transported through roadways. Details of raw materials are given in below table|:
Table 1.7 List of Raw Material
Sr. No.
Name of Product
Name of Raw Materials Existing Quantity,
MT/M
Proposed Quantity,
MT/M
Total Quantity,
MT/M Source Storage Condition
1
SSP
Rock phosphate 10,170 3,390 13,560 Imported/Indigenous Storage yard
Sulphuric acid/Spent acid 6,210 2,070 8,280 Imported/Indigenous 2 Nos. x 1000 MT MS Tank
2 GSSP SSP Powder 12,000 12,000 24,000 Self made Storage yard 3
Zincated SSP
SSP Powder - 23,820 23,820 Self made Storage yard Zinc Oxide - 180 180 Indigenous Storage yard
4 Zincated
GSSP Zincated SSP - 24,000 24,000 Indigenous Storage yard
5
Boronated
SSP
SSP Powder - 23,712 23,712 Self made Storage yard Di-Sodium Tetra Borate
Pentahydrate - 288 288 Indigenous Storage yard
6 Boronated
GSSP Boronated SSP - 24,000 24,000 Self made Storage yard
7
NPK
SSP - Self made Storage yard Di-ammonium phosphate - Imported/Indigenous Storage yard
Urea - Imported/Indigenous Storage yard Murate of potash - Imported Storage yard
3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.
There is no generation of industrial waste water from the manufacturing process. However, the liquid waste generated from scrubber which is reused in for dilution of Sulphuric acid and the sludge generated in the scrubber is reused for product SSP blending as filler. The domestic waste water is sent to the common STP, Nandesari for further treatment.
3.8 Availability of water its source, energy/power requirement and source
3.8.1 Water requirement The source of water for the proposed expansion project will be GIDC water supply. Total water requirement after the expansion will be 207.2 KLD. Generated sewage will be sent to the common STP, Nandesari for further treatment. Wastewater generated from venturi scrubber will be reused in acid dilution. Hence, no industrial effluent is anticipated from the project.
Table 1.8 Water consumption and Waste water generation
Sr. No.
Type of activity
Water requirement, KLD
Wastewater generation, KLD Remark
Existing Proposed Total Existing Proposed Total
1 Domestic 10 5 15 8 4 12 Sent to the common STP, Nandesari
2 Gardening 5 0 5 0 0 0 - 3 Industrial
i Venturi Scrubber 108 36 144 108 36 144
15.84 KLD will be evaporation losses and remaining 128.16 KLD will be reused in Acid dilution for SSP product
ii Process water for GSSP/NPK
21.6 21.6 43.2 0 0 0
36.72 KLD Evaporation losses 6.48 KLD water with Product
Total Industrial 129.6 57.6 187.2 108 36 144 - Total (1+2+3) 144.6 62.6 207.2 116 40 156 -
*Note: 6.48 KLD water with product
Page 19 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Figure 1.5 Water Balance Diagram
3.8.2 Electricity Requirement Electricity shall be obtained from GEB (Gujarat Electricity Board). Diesel will be used as a fuel for D.G set. The total power requirement is given in below table:
Table 1.9 Electricity requirement
S. No.
Particulars Existing Power
requirement (KVA)
Proposed Power requirement
(KVA)
Total Power requirement
(KVA)
1.
Plant & administration
Plot no:
71,71A,72,73,74,75
800 1500. 2300
2 Plant & administration
Plot no: 83 50 500 550
Total Power requirement 850 2000 2850
4 Proposed: 1 No. x 500 KVA D.G Set (Stand By)
Page 20 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
3.8.3 Fuel requirement Table 1.10 Fuel Requirement
Sr. No Particulars Capacity Name of
Fuel Fuel Quantity
1 D.G. Set Proposed: 1 No. x 500KVA
Diesel 100 L/hr
2 GSSP Drying furnace - Coal 35 kg/Ton
3.8.4 Stack details Table 1.11 Details of Process gas Stacks
Sr. No.
Stack attached to Status Stack
No. Capacity Stack
Ht. (m)
Stack Dia.
(mm)
Stack gas
temp. (˚C)
APCM
1. SSP – Stack Existing 1 36000 CFM 50 900
mm 40 to
80
Four stage Scrubber is provided to control fumes from the mixer.
2. GSSP plant -Stack Existing 1 25000
CFM 30 900 mm
70 to 80
Twin Cyclone separators are provided to control the air emissions.
3. NPK/GSSP plant – Stack Proposed 1 25000
CFM 30 900 mm
70 to 80
Twin Cyclone separators will be provided to control dust emissions.
Table 1.12 Details of flue gas Stacks
Sr. No.
Stack attached to Status Stack
No. Capacity Stack
Ht. (m)
Stack Dia.
(mm)
Stack gas
temp. (˚C)
APCM
1. DG set (stand By) Proposed 1 500 KVA 14 200
mm 90 to
95 Adequate Stack Height.
3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/Disposal
3.9.1 Waste Water generation & Management plan The total wastewater generation from industrial process will be reused in dilution of sulphuric acid. There is no any industrial wastewater generation. Sewage will be sent to Common STP Nandesari for further treatment. 3.9.2 Solid & Hazardous waste generation & Management plan Details of hazardous wastes and non-hazardous wastes are given in below tables;
Table 1.13 Details of Hazardous Waste
Page 21 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Sr. No.
Type of
waste Category
Waste generating
process
Physical Characteris
tics
Quantity Management
E P T
1.
Used
/spent
oil
5.1 Machinery
& D.G set Liquid 2.4 MT/yr
1.0
MT/yr 3.4 MT/yr
Reuse in gear
and lubricant of
drives.
2. Silica
sludge 36.1 Process
Solid/Semi-
solid
36.1
MT/yr
12.0
MT/yr
48.1
MT/yr
Reuse as a filler
in process.
Note: E=Existing, P=Proposed, T=Total
Table 1.14 Details of Non-Hazardous Waste
Sr. No.
Type of waste
Quantity Management
E P T
1. HDPE
scraps - 100 MT/yr 100 MT/yr Will be sold to authorized vendors
Page 22 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
3.10 Schematic representations of the feasibility drawing which give information of EIA purpose.
4. SITE ANALYSIS
4.1 Connectivity
• Site is very well connected by road and railway network.
Table 1.15 Environment Settings
Sr. No. Particulars Details Distance,
Km Direction
1 Nearest Village Nandesari 0.9 NNW
2 Nearest Town/City Vadodara 10 SE
3 Nearest Railway Station Nandesai Railway Station 0.8 NNE
4 Nearest Hospital Deepak Medical Hospital 0.6 NW
Page 23 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
Sr. No. Particulars Details Distance,
Km Direction
5 Nearest Highway NH-8 3.4 E
6 Nearest Airport Vadodara Airport 15.5 ESE
7 Nearest Water Body Mahi River 2.1 W
Mini River 1.35 E
8 Nearest School Nandesari Vidhyalaya 0.6 W
9 Nearest Fire station Nandesari Fire station 0.7 NW
4.2 Land Form, Land Use and Land Ownership
Land Form: Proposed project site is within the industrial area (GIDC Nandesari). Land use: Industrial purpose for proposed expansion and addition of new products for manufacturing of chemical fertilizers. Land Ownership: On Lease
4.3 Topography (along with map).
Project site is located almost in the central part of state of Gujarat at an altitude of approximately 150 ft (46 meters) above the sea level.
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given.
The project falls inside the notified industrial area (GIDC-Nandeasri). CRZ is not applicable to the project.
4.5 Existing Infrastructure
There is SSP and GSSP manufacturing unit exists as per the EC and CC&A. Demolition of buildings/structures will be carried out at Plot No. 83 only. 4.6 Soil Classification The Vadodara District and surrounding area consist of “Goradu soil in the North-Eastern part, Bhatha soils with salinity in the north-western part, deep black soils in the southern part.
The soils of the region are complex, and highly variable, reflecting a variety of differing parent materials, physiographic land features, range of distribution of rainfall and its effects etc. Quality of the soil in the area is shown a marked diversity in nature depending upon the parent rock and climatic conditions prevailing in different parts of the district.
Page 24 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
4.7 Climatic data from secondary sources
The climate of the study area and surrounding region is generally dry except in the southwest monsoon season. The year may broadly be divided into four seasons. Winter season : December to February Pre-monsoon season: March to May Monsoon season : mid June to September Post monsoon season: October and November Temperature: In the months of April and May, it is the period of continuous increase in temperature. May is the hottest month of the year. The climate of the district is characterized by hot summer and general dryness throughout the year except during the south-west monsoon period, i.e. June to September. The mean minimum and maximum temperatures observed are 14.8°C and 40°C respectively. Rainfall: The district gets rainfall from south west monsoon winds. The average annual rainfall over the district is about 584 mm.
4.8 Social infrastructure available
This proposed project is located at notified GIDC of Nandesari, in Vadodarda district, Gujarat. The Site is 10 km from Vadodara city and 0.3 km from Nandesari railway Station. The land and infrastructure is made available by GIDC and the raw materials are easily available through easy transport via road connectivity. The site is well connected by the National Highway-8.
5. PLANNING BRIEF
5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country
Planning/Development authority classification.
Type of Industry: Chemical fertilizer industry
5.2 Population Projection
The proposed project would require 156 workers and staff during the operation of the project.
Page 25 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
5.3 Land use planning (breakup along with green belt etc.)
Table 1.16 Area Break-up
Sr. No Particulars Existing area Proposed area Total area after
Expansion
1 Main plant building
(production area) 2819.2
-
2819.2
2 Raw material storage 2790.5 - 2790.5
3 R/M storage tank
(HDPE/MS tank) 468.8
-
468.8
4 Finished product storage 998.6 - 998.6
5 Chimney 38.2 - 38.2
6 Transformer 124.3 - 124.3
7 Administration & lab 207.7 - 207.7
8 Green area 600.0 - 600.0
9 NPK/GSSP - 5016.8 5016.8
Total Plot Area 8047.2 5016.8 13064.0
5.4 Assessment of Infrastructure Demand (Physical & Social)
On the basis of the preliminary site visit, the infrastructure demand in the villages was assessed on the basis of need and priority. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project activity.
5.5 Amenities/Facilities
Proper site services such as First Aid, Canteen, Drinking Water, Maintenance Workshop, etc. will be provided to the workers. It is proposed to construct one room for labor.
6. PROPOSED INFRASTRUCTURE 6.1 Industrial Area (Processing Area)
Processing Area (Plant facilities, and Utility Services) Developed Area: 7874.2 Sq.m.
6.2 Residential Area (Non Processing Area)
Non Processing Area (Green belt, Raw material storage area, Admin and open area). Area: 5065.6 Sq.m.
6.3 Green Belt
Total 13064.0 sq.mt square meters land area at proposed site; out of this 600 Sq.m. will be used for development of green belt.
6.4 Social Infrastructure
Depending on the growth of the company the required social infrastructure will be provided.
Page 26 Green Circle, Inc. M/s. Coromandel International Limited.
Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers
6.5 Connectivity (Traffic and Transportation Road/ Rail/Metro/ Water ways etc)
Road and railways are very close to the working site. There is no proposal to make any new kind of connectivity.
6.6 Drinking water Management (Source & Supply of water)
Water for drinking and operations will be 7 KLD, which will be met from GIDC water supply.
6.7 Sewerage System
Sewage will be sent to the Common STP, at Nandeasri GIDC for further treatment.
6.8 Industrial Waste Management
Please refer section 3.9.2.
6.9 Solid Waste Management
No solid waste generation.
6.10 Power Requirement & Supply/Source
Electricity shall be obtained from GEB. The total power requirement for the proposed project is 2000 KVA.
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 labourers
Not Applicable because the proposed project site within the GIDC-Nandesari.
8. PROJECT SCHEDULE & COST ESTIMATES 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given).
We shall start construction after obtaining environmental clearance.
8.2 Estimated Project cost along with analysis in terms of economic viability of the project.
Total Project Cost for proposed project activity is Rs. 15 Crores.
9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. The project will be prove time by time for beneficial to the people as the company progress and expands its activity. By CSR activity company management will committed to improve infrastructural facilities for the local people like Educational facilities, Medical facilities, Transportation facilities etc. as well the local people especially tribal population will be taken as labours, which will improve the socioeconomic environment of the area.