Annexure:Document of EIA/EMP - …environmentclearance.nic.in/writereaddata/FormB/EC/EIA_EMP/... · measures. Prakruti Shah Period of involvement : ... 4.3.2.2 Dispersion Modelling

Rapid Environmental Impact Assessment Report

Proposed Project of Panchsheel Intermediates, Located at: Plot No. 8101, GIDC Sachin, Ta: Chorasi, Dist: Surat – 394 23

Prepared By:

Ramans Enviro Services Pvt. Ltd. SF –23 & 24, Camps Corner,Near AUDA Garden, Prahaladnagar Ahmedabad380 015,Phone: 079-26937472. Fax: 079-40064440 E-mail:[email protected]

February, 2014

Panchsheel Intermediates

Annexure:Document of EIA/EMP






mailto:[email protected]

mailto:[email protected]

For compilation of data in the EIA report

Identification & verification of activities

involved in and sources which impart air

pollutants from proposed manufacturing

capacity

Identification of impacts related to air

quality & quantity and suggested mitigation

measures

3

WP*

Mr. Samir C.

Choksi

Period of involvement : December 2011 to

August 2013

Verification of Product wise Water

consumption and effluent generation details


involved in and sources which impart water

pollution from proposed manufacturing

capacity

Identification of impacts related to water

quantity & quality and suggested mitigation

measures.

Prakruti Shah Period of involvement : December 2011 to

August 2013

Finalization of mass balance of various

products

Calculation of Product wise Water

consumption and effluent generation details

Delineation of Effluent treatment scheme

for the project


involved in and sources which impart water

pollution from proposed manufacturing

capacity

Identification of impacts related to water

quantity & quality and suggested mitigation


measures.

4

SHW*

Mr. Samir C.

Choksi

Period of involvement : February 2013 to

August 2013


involved in and sources which imparts

generation of hazardous/solid waste from

proposed manufacturing capacity

Identification of impacts related to

solid/hazardous waste and suggested

mitigation measures

Delineation of management plan of

hazardous waste handling

5

LU*

Mr. Vinay

Kumar &

Sanket Patel

Verification of Secondary data of LU of

CETP of Globe Enviro Care Ltd., GIDC

Sachin, Surat

6

NV*

Mr. Vinay

Kumar

Verification of Secondary data of Noise of

CETP of Globe Enviro Care Ltd., GIDC

Sachin, Surat

7

AQ*

Sanket Patel Period of involvement : December 2011 to

August 2013

Collection and compilation of meteorology

data

Modelling study based on various input

parameters and plotting of GLC

8

RH*

Gopal Shah Period of involvement : June 2013 to

August 2013

Compilation of input data for Risk

assessment study & Risk assessment

study report preparation



SR. NO. TITLE PAGE NO.

I CONTENTS I-IV II LIST OF ANNEXURES IV III LIST OF TABLES V-VI IV LIST OF FIGURES VI-VII V LIST OF ABBREVIATIONS &

SYMBOLS/NOTATIONS VII-VIII

VI Copy of TOR ISSUED & ITS COMPLIANCE IX-XXIV

SR. NO. TITLE PAGE NO.

1.0 INTRODUCTION 1.1 Preface 1.1 1.2 The Project 1.1 1.2.1 The Resources 1.2 1.2.2 Promoters of the Project 1.2 1.3 Project Justification 1.3 1.4 Project Location 1.3 1.5 Regulatory Framework 1.3 1.6 Scope of Study 1.4 1.7 Approach of EIA Study 1.4 1.8 Structure of EIA Report 1.5 2.0 PROJECT DETAILS 2.1 Introduction 2.1 2.2 The Project 2.1 2.3 Project Location & Site Layout 2.3 2.4 Site Selection Criteria 2.6 2.5 The Resources 2.7 2.5.1 Land 2.7 2.5.2 Water 2.7 2.5.3 Energy 2.8 2.5.4 Raw Materials 2.9 2.6 Process Technology 2.25 2.7 Major Equipments & Machineries 2.26 2.8 Sources of Pollution 2.27 2.8.1 Liquid Effluent 2.27 2.8.1.1 Details of Effluent Treatment scheme 2.34 2.8.2 Gaseous Emissions 2.36 2.8.3 Solid & Hazardous Waste 2.37 2.9 Green Belt Development Plan 2.38 2.10 Environment, Health & Safety 2.38 2.11 Compliance to various Statutory Guidelines 2.38 2.12 Corporate Social Responsibility 2.39 2.13 Approach to Cleaner Production 2.39 3.0 BASELINE ENVIRONMENTAL SETTING 3.1 Introduction 3.1


3.2 Location 3.2 3.2.1 Introduction 3.2 3.2.2 Key infrastructure features and settlements 3.2 3.3 Micrometeorology of the area 3.4 3.3.1 Temperature and relative humidity 3.4 3.3.2 Wind rose 3.4 3.4 Air Environment 3.6 3.4.1 Ambient Air Quality 3.6 3.4.1.1 Location of AAQ Monitoring Stations 3.6 3.4.1.2 Baseline Data 3.8 3.5 Water Environment 3.9 3.6 Noise 3.11 3.7 Land-Environment 3.11 3.7.1 Soil Quality 3.11 3.7.2 Landuse 3.13 3.7.2.1 Methods of data preparation 3.13 3.7.2.2 Landuse map analysis 3.14 3.7.2.3 Digital image classification and maps 3.14 4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES 4.1 Introduction 4.1 4.2 Identification of impacts 4.1 4.2.1 Identification of impacting activities 4.2 4.2.2 Identification of Environmental Attributes 4.2 4.3 Impact Assessment 4.3

4.3.1 Impact on Water Environment 4.3 4.3.2 Impact on Air Environment 4.5 4.3.2.1 Sources 4.5 4.3.2.2 Dispersion Modelling 4.7

4.3.2.3 Results 4.8

4.3.2.4 Interpretation 4.17 4.3.3 Impact on Land / Soil quality 4.19 4.3.4 Impact on Noise Environment 4.20 4.3.5 Impact on Biological Environment 4.21 4.3.6 Impact on Socio-economic Environment 4.21 4.3.7 Impact on Occupational Health & Safety 4.22 5.0 ENVIRONMENTAL MONITORING PROGRAM 5.1 Objective 5.1 5.2 Environment Monitoring & Control 5.1 5.3 Proposed Monitoring Program 5.2 5.4 Monitoring Methods & Data Analysis 5.4 5.4.1 Air Quality Monitoring 5.4 5.4.2 Noise Monitoring 5.4 5.4.3 Water quality Monitoring 5.4 5.4.4 Wastewater quality Monitoring 5.5


5.4.5 Data Analysis 5.5 5.5 Reporting schedules of the monitoring data 5.5 5.6 Infrastructural Requirement 5.5

6.0 RISK ASSESSMENT AND DISASTER MANAGEMENT 6.1 Introduction 6.1 6.2 Approach to Study 6.1 6.3 Hazard Identification 6.1 6.3.1 Material Handling and Storage Hazard 6.2 6.3.2 Fire and Explosion Hazard 6.4 6.3.3 Electrical Hazard 6.4 6.3.4 Mechanical Hazard 6.4 6.3.5 Toxic Gas Release Hazard 6.4

6.3.6 6.3.7

Corrosion Hazard Identified Hazards

6.4 6.5

6.4 Hazard Mitigation Measures 6.5 6.4.1 Mitigation Measures for Material Handling

and Storage Hazard 6.6

6.4.2 Mitigation Measures for Fire and Explosion Hazard

6.7

6.4.3 Mitigation Measures for Electrical Hazard 6.9 6.4.4 Mitigation Measures for Mechanical Hazard 6.9 6.4.5 Mitigation Measures for Toxic Gas Release,

and Chemical Hazards 6.9

6.5 Risk Assessment and Mitigation 6.10 6.5.1 Catastrophe Criteria 6.11 6.5.2 Maximum Credible Loss Accident Scenario 6.12 6.5.3 Consequence Analysis Calculations 6.13 6.5.4 Considered Scenarios 6.14 6.5.5 Detailed Summary of ALOHA® 5.4 Results 6.17 6.5.5.1 Release of Methyl Ethyl Glycol (MEG) 6.17 6.5.5.2 Release of Iso Propyl Alcohol (IPA) 6.21 6.5.5.3 Release of Ammonia Solution 6.26 6.5.6 Health & Safety Measures 6.29 6.6 Safety Management System 6.31 6.7 Occupational Health and Safety

Management System 6.34

6.8 Disaster Management Plan 6.36 7.0 PROJECT BENEFITS 7.1 8.0 ENVIRONMENT MANAGEMENT PLAN 8.1 Introduction 8.1 8.2 Administrative aspects for EMP 8.1 8.2.1 Operational philosophy 8.1 8.2.2 Environment Management Cell 8.2


http://en.wikipedia.org/wiki/Isopropyl_alcohol

8.3 Environmental Management Practices 8.2 8.3.1 Water environment 8.3 8.3.2 Air environment 8.3 8.3.3 Land / Soil quality 8.4 8.3.4 Noise environment 8.4 8.4

8.3.5

Occupational Health & Safety Corporate Environmental Responsibility

8.4 8.6

9.0 EXECUTIVE SUMMARY 9.1 – 9.10 10.0 DISCLOSURE OF CONSULTANTS

ENGAGED 10.1 – 10.5

LIST OF ANNEXURES

ANNEXURE NO. DESCRIPTION

A Copy of Consent along with its compliance

B Copy of TOR awarded by SEAC

C Application to Sachin Infra Management Ltd. for water supply

D Undertaking for digging of no bore well

E Process flow diagrams for proposed expansion products

F Membership of Globe Enviro Care Ltd

G Membership of BEIL

H Material Safety Data Sheet of Chemicals being handled


LIST OF TABLES

TABLE NO. TITLE PAGE NO.

2.1A Existing Product Profile 2.1

2.1B Proposed Product profile 2.2

2.2 Landuse Breakup 2.6

2.3 Breakup of Water usages 2.7

2.4 Raw Water Quality 2.8

2.5A Specific Consumption of Raw Materials (Existing) 2.9

2.5B Specific Consumption of Raw Materials (Proposed) 2.18

2.6 List of Equipments & Machineries 2.26

2.7A Summary of Product wise Water consumption and

Wastewater generation for Consented Products

2.28

2.7B Summary of Product wise Water consumption and

Wastewater generation for Proposed Products

2.29

2.8A Details of wastewater generation 2.31

2.8B Representative Quality of Wastewater 2.34

2.8C Anticipated Quality of Wastewater based on Lab

scale study

2.34

2.9 Details of ETP and its adequacy 2.36

2.10 Details of Air Pollution Control Systems 2.37

2.11 Details of Solid / Hazardous Waste 2.38

3.1 Distance of nearest key infrastructure feature from

project area

3.3

3.2 Micrometeorological Data 3.4

3.3 Sampling Locations 3.6

3.4 Ambient Air Quality Status of Study Area 3.8

3.5 Water Quality 3.10

3.6 Noise quality 3.11

3.7 Sampling Location 3.12

3.8 Physico-Chemical quality of soil sample 3.12

3.9 Area statistic of Landuse/Landcover Map 3.16


4.1 Impact Identification Matrix 4.3

4.2 Details of Proposed Flue Gas Emission Sources 4.6

4.3 24 hr incremental increase in GLC of SO2 (µg/m3)

due to proposed project

4.9

4.4 24 hr incremental increase in GLC of NOx (µg/m3)

due to proposed project

4.10

4.5 24 hr incremental increase in GLC of PM (µg/m3) due

to proposed project

4.11

4.6 24 hr incremental increase in GLC of HCl (µg/m3) due

to proposed project

4.12

5.1 Environment Monitoring Schedule 5.2

6.1 Details of Raw Material Storage 6.2

6.2 Principal Hazardous Chemicals Characteristics 6.3

6.3 Possible Accident Scenarios at Panchsheel

Intermediates

6.14

6.4 Considered Worst Case Scenario in Panchsheel

Intermediates.

6.16

LIST OF FIGURES

FIGURE

NO.

TITLE PAGE

NO.

2.1 Key plant of Unit 2.4

2.2 Layout plan of Unit 2.5

2.3 Existing Water Balance Diagram 2.32

2.4 Proposed Water Balance Diagram 2.33

3.1 Site location map 3.3

3.2 Wind rose Diagram for the month of December 2011 to

March 2012

3.5

3.3 Sampling Location Map 3.7

3.4 Satellite image of study area 3.18


3.5 Landuse map (level II) 3.19

3.6 Digitized land use map (level II) 3.20

3.7 Landuse distribution chart of the study area 3.21

4.1 Isopleths for concentration of SO2 4.13

4.2 Isopleths for concentration of NOX 4.14

4.3 Isopleths for concentration of PM 4.15

4.4 Isopleths for concentration of HCL 4.16

LIST OF ABBREVIATIONS

AOI Area of Interest

APC Air Pollution Control

BEIL Bharuch Enviro Infrastructure Ltd.

CC&A Consolidated Consent & Authorization

CPCB Central Pollution Control Board

CREP Corporate Responsibility for Environment Protection

D. G. Diesel Generator

CETP Common Effluent Treatment Plant

DGVCL Dakshin Gujarat Vij Company Ltd.

ECC Environmental Clearance Certificate

EIA Environmental Impact Assessment

EMP Environment Management Plan

ETP Effluent Treatment Plant

GECL Globe Enviro Care Ltd.

GEPIL Gujarat Enviro Protection and Infrastructure Pvt. Ltd.

GIC Gautam Industrial Corporation

GIDC Gujarat Industrial Development Corporation

GLC Ground Level Concentration

GPCB Gujarat Pollution Control Board

HC Hydrocarbon

HDPE High Density Poly Ethylene

ISCST Industrial Source Complex Short Term

KLD Kilo liters per day

NH National Highway


MEE Multiple Effect Evaporator

MoEF Ministry of Environment & Forest

MoU Memorandum of Understanding

MSDS Material Safety Data Sheet

PM Particulate Matter

PPE Personnel Protective Equipment

QC/QA Quality Control / Quality Assurance

SEAC State Level Expert Appraisal Committee

SEIAA State Level Expert Impact Assessment Authority

SH State Highway

SLM Sound Level Meter

SPM Suspended Particulate Matter

TOR Terms of Reference

TPH Ton per Hour

TSDF Treatment, Stabilization and Disposal Facility

USEPA U.S. Environmental Protection Agency

VOC Volatile Organic Carbon

LIST OF SYMBOLS / NOTATIONS

SO2 Sulfur dioxide

NOx Oxides of Nitrogen

CO Carbon monoxide

CO2 Carbon dioxide

ppm Parts per million

dB Decibel







ADDITIONAL TOR COMPLIANCE

TOR issued by SEAC through letter no. : EIA – 10 – 2012 – 1377 – E/172 dated 12th February, 2013

TOR

No.

TOR Description Compliance

1. Need for the proposed expansion

should be justified in detail.

Refer Para 1.3, Chapter 1,

Page no. 1.3

2. Demarcation of proposed expansion

activities in lay out of the existing

premises.


Page no. 2.3

Refer Figure no. 2.2, Page no.

2.5

3. Exact details about additional

infrastructural facilities, plant

machineries etc. required for the

proposed expansion.


Page no. 2.3

4. Technical details of all the plants along

with details of manufacturing process /

operations of each product. Details on

strategy for the implementation of

cleaner production activities.


Page no. 2.26

5. Chemical name of each product and

raw materials along with chemical

reactions of unit processes. Detailed

manufacturing process of each product

along with chemical reactions and mass

balance (including reuse-recycle, if any).


Page no. 2.26 for product

details

Refer Annexure D for mass

balance of proposed

products

Refer Para 2.5.4, Chapter 2,

Table no. 2.5A & 2.5B, Page


no. 2.9 to 2.25 for Raw

materials

6. Assessment of source of the water

supply with adequacy of the same to

meet with the requirements of the

project expansion. Permission obtained

for supply of increased quantity of raw

water. Undertaking stating that no bore

well shall be dug within the premises.


Page no. 2.7

Refer Annexure C1 (request

letter to SIML)

Refer Annexure C2

(undertaking)

7. Water consumption and consumption

of each raw material per MT of each

product.

Refer Para 2.8.1, Table no.

2.7A & 2.7B, Chapter 2, Page

no. 2.29 to 2.32 for product

wise water consumption and

effluent generation


Table no. 2.5A & 2.5B, Page

no. 2.9 to 2.25 for Raw

materials

8. Water balance diagram (including

reuse-recycle, if any) along with

qualitative and quantitative analysis of

the each waste stream to be generated.

A detailed treat ability study vis-á-vis

the adequacy and efficacy of the

treatment facilities proposed for the

wastewater to be generated.


2.3, Chapter 2, Page no. 2.7

for water usage break up

Refer Para 2.8.1, Table 2.8A ,

Chapter 2, Page no. 2.32, for

effluent generation details

9. Detailed effluent scheme and disposal

method. Technical details of the

Refer Para 2.8.1.1, Table no.



proposed ETP including size of each

unit, retention time etc. including

modifications up gradation to be done

in existing ETP to take care of increased

effluent quantity along with adequacy

report. Provision of flow totalizer and

online pH meter & TOC meter at final

outlet of the ETP.

– 2.35 for effluent treatment

details. As the effluent is

being sent to Globe CETP for

further treatment through

tankers, the physical records

of the flow as well as other

parameters will be

maintained. Provision of

flow totalizer and online pH

meter & TOC meter at final

outlet of the ETP is not

feasible.

10. Characteristics of untreated and treated

wastewater. A detailed effluent

treatability study vis-à-vis the adequacy

and efficacy of the treatment facilities

proposed for the wastewater to be

generated. The characteristic on which

treatability is based shall also be stated.

Refer Para 2.8.1, Table No.

2.8B, 2.8C and 2.9, Chapter 2,

Page no. 2.34 - 2.36

11. Plan for management and disposal of

waste streams to be generated from

spillage, leakages, occasional reactor

washing and exhausted media from

scrubber etc.

Refer Para 2.8.1.1, Table no.


– 2.35 for details

12. Explore the possibility of reuse/ recycle

and other cleaner production options

for reduction of wastes. Details of

methods to be adopted for the water


Page no. 8.3 for water

conservation measures



conservation. Page no. 2.38 for cleaner

production details

13. One season site-specific meteorological

data including temperature, relative

humidity, hourly wind speed and

direction and rainfall shall be provided.


Table on. 3.3, Page no. 3.4


3.5 for wind rose diagram for

wind speed and wind

direction

14. One complete season AAQ data (except

monsoon) to be given along with the

dates of monitoring. Parameters to be

considered shall be in accordance with

the revised national ambient air quality

standards. Project specific parameters

shall be considered in addition to

general parameters. The location of the

monitoring stations should be so

decided so as to take into consideration

the pre-dominant downwind direction,

population zone and sensitive

receptors. There should be at least one

monitoring station in the upwind

direction. There should be at least on

monitoring station in the upwind

direction. There should at least one

monitoring station in the pre-dominant

downwind direction at a location where

maximum ground level concentration is

Refer Para 3.5.1.1, Chapter 3,

Table no. 3.4, Page no. 3.6 for

sampling location details


3.7 for Sampling location

map


Table no. 3.5, Page no. 3.8 –

3.9 for Ambient air quality

data


likely to occur.

15. Impact of the project on the AAQ of the

area. Details of the model used and the

input parameters used for modeling

should be provided. The air quality

contours may be plotted on a location

map showing the location of project

site, habitation, sensitive receptors, if

any. The wind roses should also be

shown on this map.


Page no. 4.5 – 4.13 for Air

quality modeling data and

isopleths

16. Specific details of (i) Process gas

emission from each unit process with its

quantification, (ii) Air pollution Control

Measures proposed for process gas

emission, (iii) Adequacy of the air

pollution control measures for process

gas emission measures to achieve the

GPCB norms (iv) Details of the utilities

required (v) Type and quantity of fuel

to be used for each utility (vi) Flue gas

emission rate emission from each utility

(vii) Air Pollution Control Measures

proposed to each of the utility along

with its adequacy (viii) List the sources

of fugitive emission along with its

quantification and proposed measures

to control it.


2.10, Chapter 2, Page no.

2.35 – 2.36

17. Details of solvent recovery system As the solvents are used for


including mass balance, solvent loss,

recovery efficiency etc. for each type of

solvent.

oxidation it becomes the part

of product. Hence solvent

recovery system is not

applicable.

18. Details of management of the

hazardous wastes to be generated from

the project stating detail of storage area

for each type of waste, its handling, its

utilization and disposal etc. How the

manual handling of the hazardous

wastes will be minimized.



2.36 – 2.37

19. Methodology of de-contamination and

disposal of discarded containers and its

record keeping.



2.36 – 2.37

20. Membership of Common

Environmental Infrastructure including

the TSDF / Common Hazardous Waste

Incineration facility along with an

assessment to accommodate the

additional quantity of wastes to be

generated.

Refer Annexure E1 (CETP

membership)

Refer Annexure E2 (TSDF

membership)

21. Data on air emissions, wastewater

generation and solid / hazardous waste

generation and management for the

existing plant should also be

incorporated.

Refer Para 2.8.1 to 2.8.3,

Chapter 2 Page no. 2.27 - 2.36

22. Details of measures proposed for the

noise pollution abatement and its


Page no. 4.15 – 4.16


monitoring. Refer Para 8.3.4, Chapter 8,

Page no. 8.4

23. A detailed EMP including the

prediction and mitigation measures for

impact on human health and

environment as well as detailed

monitoring plan and environmental

management cell proposed for

implementation and monitoring of

EMP. The EMP should also include the

concept of waste – minimization,

recycle / reuse/recover techniques,

every conservation, and natural

resource conservation. Total capital cost

and recurring cost/annum earmarked

for environment pollution control

measures.

Refer Chapter 4 for

mitigation measures for

various environmental

attributes

Refer Para 8.3, Chapter

8,Page 8.3 – 8.5 for

environmental management

practices to be adopted

24. Occupational health impacts on the

workers and mitigation measures

proposed to avoid the human health

hazards along with the personal

protective equipment to be provided to

the workers. Provision of industrialist

hygienist and monitoring of the

occupational injury to workers as well

as impact on the workers. Plan for

periodic medical checkup of the

workers exposed. Details of work place

Refer Chapter 6


ambient air quality monitoring plan as

per Gujarat Factories Rules.

25. Details of hazardous characteristics and

toxicity of raw materials and products

to be handled and the control measures

proposed to ensure safety and avoid the

human health impact.

Refer Chapter 6

26. Details of quantity of each hazardous

chemical to be stored, material of

construction of major hazardous

chemical storage tanks, threshold

storage quantity as per schedules of

Manufacture, Storage & Import of

Hazardous Chemicals Rules of major

hazardous chemicals.

Refer Chapter 6

27. Risk assessment including prediction of

the worst-case scenario and maximum

credible accident scenarios should be

carried out. The worst-case scenario

should take into account the maximum

inventory of storage at site at any point

of time. The risk contours should be

plotted on the map clearly showing

which of the facilities and surrounding

units would be affected in case of an

accident taking place. Based on the

same, proposed safeguard measures

including On-Site /Off-Site emergency

Refer Chapter 6


Plan should be provided.

28. Details of fire fighting system including

provision for flame detectors,

temperature actuated heat detectors

with alarms, automatic sprinkler

system, location of fire water tanks &

capacity, separate power system for fire

fighting, details of qualified and trained

fire personnel & their job specifications,

nearest fire station & time required to

reach to reach the proposed site. Submit

line diagram of the fire hydrant

network.

Refer Chapter 6

29. Submit checklist in the form of Do’s &

Don’ts of preventive maintenance,

strengthening of HSE, manufacturing

utility staff for safety related measures.

Refer Chapter 6

30. Detailed five year greenbelt

development program including annual

budget, types & number of trees to be

planted, area under green development

[with map], budgetary outlay; along

with commitment of the management to

carry out the tree plantation activities

outside the premises at appropriate

places in the nearby areas and

elsewhere.


Page no. 2.37 for green belt

details

31. Copies of, Consent to Establish, Consent Refer Annexure A for copy


to Operate orders obtained in past

along with point wise compliance status

of all the conditions stipulated therein.

of consent and compliance of

its conditions

32. Copies of Environmental Clearance for

the existing project and a certified

report of the status of compliance of the

conditions stipulated in the

environmental clearance for the existing

operation of the project by the Regional

Office of the MoEF.

Not applicable

33. Records of any legal breach of

Environmental laws i.e. details of show

– cause notices, closure notices etc.

served by the GPCB to the existing unit

in last five years and actions taken then

after for prevention of pollution.


Page no. 2.37

No show cause notice /

closure notice has been

issued to unit till date for

any legal breach of

environmental laws

34. Details of fatal / non – fatal accidents,

loss of life of man hours, if any,

occurred in the existing unit in last

three years and measures proposed to

be taken for avoiding reoccurrence of

such accidents in future.

No such accident has been

occurred in the existing plant

since its inception.

35. (a) Does the company have a well laid

down Environment Policy approved by

its Board of Directors? If so, it may be

detailed in the EIA report.

(b) Does the Environment Policy


Page no. 8.6


prescribe for standard operating

process / procedures to bring into focus

any infringement / deviation /

violation of the environmental or forest

norms / conditions? If so, it may be

detailed in the EIA.

36. What is the hierarchical system or

administrative order of the company to

deal with the environmental issues and

for ensuring compliance with the EC

conditions. Details of this system may

be given.


Page no. 8.2

37. Does the company have a system of

reporting of non-compliances /

violations of environmental norms to

the Board of Directors of the company

and / or shareholders or stakeholders at

large? This reporting mechanism

should be detailed in the EIA Report.


Page no. 8.6

38. Certificate of accreditation issued by the

NABET, QCI to the environmental

consultant should be incorporated in

the EIA Report.

Part of the EIA report


CHAPTER – 1


CHAPTER -1

INTRODUCTION

1.1 PREFACE

India is a developing country and one of the most industrialized countries in the world

map. The industrial segment of the country is versatile consisting of various industrial

sectors viz. chemicals, petrochemicals, metallurgical, textile, engineering, power etc. The

chemical industrial sector has played a vital role in its economic development. Gujarat is

one of the developed states in the country having major chemical industrial companies.

Amongst the chemical industrial sector, the major development has been occurred in

field of Dyes & Dyes intermediates. Dyes and dyes intermediates products have major

application in textile and food industries as colour additives.

Panchsheel Intermediates is in existence at Plot no 8101, GIDC Sachin, Surat since year

1978. The unit is involved in manufacturing of various acid and solvent dyes @ 6 MT/M at

the premises.

1.2 THE PROJECT

Panchsheel Intermediates is involved in manufacturing of various acid and solvent dyes

@ 6 MT/M and having the valid consent from GPCB for production of the same. The copy

of the consent along with its compliance is attached as Annexure A.

Considering the growing market demand of the various dyes in the national and global

market, the unit has decided to expand its production capacity along with inclusion of

new alternative products.

Company has commenced its operations with capacity of @ 6 MT/Month which has been

planned to expand upto @ 34.5 MT/Month by way of inclusion of additional alternative

products. The estimated cost of proposed expansion project will be Rs. 300 Lakhs. Out of

this, @Rs. 25 Lakhs will be capital cost towards Environmental management system.


1.2.1 The Resources

The total land area of @ 3000 sq.m. is being owned by the unit at the location. There is

no need of acquisition of additional land for expansion project, as no additional

construction work has to be carried out on site for the expansion phase. For the

proposed expansion, there will be installation of new reaction vessels and Hot air

generators.

The unit has connected power load of @ 110 KW, which is being supplied by Dakshin

Gujarat Vij Company Ltd. There is no need of additional power load for proposed

expansion, as the existing connected power load is adequate for proposed expansion

also.

The unit has also installed L.D.O. based D.G. set (75 KVA capacity) in the existing

manufacturing activity, which will be also utilized during proposed expansion, in case of

power supply failure from the Grid. L.D.O. will be consumed @ 20 L/hour in case of its

operation during emergency.

At present, the unit has installed natural gas fired small industrial boiler of 1500 Kg/hour

capacity, which consumes natural gas @ 35 SCM/hour (i.e. running at 20-25% of its

capacity). The unit has planned to install 4 nos. of natural gas fired Hot Air Generators for

proposed expansion, which will utilized additional natural gas @ 12 - 15 SCM/hour for

each.

At present, the unit is utilizing water @8.5 KLD, which is being supplied by Sachin Infra

Management Ltd. The water consumption will increase upto 23.00 KLD at ultimate phase

of expansion, availing from existing water source only.

1.2.2 Promoters of the Project

Panchsheel Intermediates is established in GIDC Sachin, since year 2000 and engaged in

manufacturing of various Acid & Solvent Dyes with production capacity of @ 6 MT/M.

The partners of the company are well qualified and well experienced persons having

educational qualification B.Sc. (technology) and more than 15 years of experience in the

field of production and trading of dyes and dyes intermediates.


1.3 PROJECT JUSTIFICATION

The unit has commenced the production with the rate of 6 MT/M of Solvent and Acid

dyes in year 2000. With the growing of company after a decade time alongwith assured

customers as well as increasing need of the various dyes and dyes intermediates in

national and international market, the unit has planned to expand its production capacity

from 6 MT/M to 34.5 MT/M with addition of new alternative products. These products

have its applications in industrial sectors viz. Textile, Food etc. as colour additives.

For the expansion project, the unit has to install few new reaction vessels only, wherein

no additional civil work is anticipated.

1.4 PROJECT LOCATION

The proposed expansion project is to be executed within existing premises, where

infrastructure is already in place. The location of the unit is within well established area

of GIDC Sachin, Surat. GIDC Sachin is on approach road of NH-8. The site is located at 72°

50' 45.68" E and latitude 21° 05' 57.10" N. The site is well connected by rail and road. The

nearest railway station is Sachin, which is about 3 km away. The location of the proposed

project is given at Figure no. 1.

1.5 REGULATORY FRAMEWORK

Panchsheel Intermediates is involved in manufacturing of various acid and solvent dyes

@ 6 MT/M and having the valid consent from GPCB for production of the same. The copy

of the consent alongwith its compliance is attached as Annexure A.

The major Environmental Acts & Rules applicable for the proposed project are :

1. The Environmental Protection Act,1986[as amended] and the rules there under,

2. EIA Notification-2006[as amended],

3. The Water Act,1974 and the rules there under,

4. The Air Act, 1981, and the rules there under.

The proposed expansion project falls under the Item 5 (f) of Schedule I of Environmental

Impact Assessment Notification dated 14/09/2006 under the provisions of Environmental


Protection Act, 1986. The location of the proposed project being within notified industrial

estate; it will be treated as Category B project.

As per Notification, for Category B Project, it is necessary to obtain Environmental

Clearance Certificate (ECC) from the State Level Expert Impact Assessment Authority

(SEIAA). As a procedural part it is necessary to carry out Environmental Impact

Assessment (EIA) Study as per Terms of Reference (ToR) approved by State Level Expert

Appraisal Committee (SEAC) of the state.

1.6 SCOPE OF STUDY

Panchsheel Intermediates had applied to State level Expert Appraisal Committee (SEAC)

in prescribed Form -1 for obtaining Environmental Clearance and were called for the

scoping meeting on 27th September, 2012. Based on the application submitted and

discussion held during the scoping meeting, TOR was issued by SEAC vide letter no. EIA-

10-2012-1377-E/172 dated 12th February, 2013. The copy of TOR awarded by SEAC is

attached as Annexure B. Compliance status of additional TOR awarded by SEAC is the

part of the report.

In a view of procedure to be followed for obtaining Environmental clearance, Panchsheel

Intermediates has appointed M/s. Ramans Enviro Services Pvt. Ltd. (RESPL), Ahmedabad

to carry out EIA study to assess the impacts to be generated from the proposed

expansion project and to propose its mitigation measures.

1.7 APPROACH OF EIA STUDY

Present EIA study has been conducted to fulfill the following objectives:

1. To delineate the project activities along with anticipated sources of pollution as

well as Environmental Management System (EMS) to be adopted.

2. To describe the prevailing baseline environmental quality within the impact zone

(study area) based on field studies.

3. To identify and predict the likely impacts due to proposed expansion project


4. To outline EMP describing control technologies to be adopted for mitigation of

adverse impacts

To suggest environmental quality monitoring programme to be pursued

by the management to evaluate the effectiveness of mitigative measures

5. To carry out risk assessment studies and suggest risk mitigation and disaster

management plan

6. To describe the measures to be adopted for occupational health and safety of the

workers

1.8 STRUCTURE OF EIA REPORT

The present EIA report has been prepared considering the Generic structure of EIA

Report as described in EIA notification dated 14th September, 2006 and its various

amendments as per its applicability for the proposed project.

CHAPTER 1 : Includes brief outline of the project and its promoters, brief description of

project and its location, project justification, regulatory framework as well as scope and

approach towards the study.

CHAPTER 2 : Provides details regarding project which includes requirement of resources

& infrastructure, process description, pollution potential along with Environmental

management system in place for existing activity and to be adopted for proposed

expansion.

CHAPTER 3 : Delineates the existing environmental scenario in the vicinity of the project

site, i.e. in study area of @ 5Km considering site of Globe Enviro Care Ltd., as center.

CHAPTER 4 : Deals with the identification and prediction of impacts along with Mitigation

measures for adverse impacts. This has been developed based on the Chapter 2 and

Chapter 3, by correlating the activities under the proposed expansion project and their

impacts on the receiving environmental attributes.

CHAPTER 5 : Delineates the post project environmental monitoring programme along

with its budgetary provision.


CHAPTER 6 : Describers about the study on risk assessment and occupation health safety

aspects of the proposed expansion project.

CHAPTER 7 : Describes about the benefits of the proposed project.

CHAPTER 8 : Delineates the environment management plan inclusive of the mitigation

measures and roles and responsibilities of the management.

CHAPTER 9 : Attempts to summarize the entire report and conclude the outcome of

the study.

CHAPTER 10 : Provides the brief profile of the EIA consultant organization and the

team of functional area experts.


CHAPTER – 2


CHAPTER -2

PROJECT DETAILS

2.1 INTRODUCTION

Panchsheel Intermediates is in existence at Plot no 8101, GIDC Sachin, Surat since year

1978. The unit is involved in manufacturing of various acid and solvent dyes @ 6 MT/M at

the premises.

Company has commenced its operations with capacity of @ 6 MT/Month which has been

planned to expand upto @ 34.5 MT/Month by way of inclusion of additional alternative

products.

2.2 THE PROJECT

The unit is involved in manufacturing of various acid and solvent dyes @ 6 MT/M and

having the valid consent from GPCB for production of the same. The list of existing

products for which consent has been obtained is presented at Table no. 2.1A. The unit

intends to expand its production facility from 6 MT/M up to @ 34.5 MT/Month (increase

of 28.5 MT/M) by way of inclusion of additional alternative products. The list of proposed

products for expansion has been presented at Table no. 2.1B. The name Acid dyes and

Solvent dyes indicate the solubility of dyes in acid and solvent respectively.

Table No. 2.1A EXISTING PRODUCT PROFILE

SR. NAME OF PRODUCT PRODUCTION

A ACID DYES

6 MT/MONTH

1 Acid Brown – 14

2 Acid Orange – 24

3 Acid Black – 1

4 Acid Yellow – 73

5 Acid Red – 42

6 Acid Blue – 113

7 Acid Black - 58

8 Acid Black - 64

9 Acid Brown - 45

10 Acid Dark Brown - 48


11 Acid Orange - 80

12 Acid Orange - 86

13 Acid Violet - 78

14 Acid Yellow - 114

B SOLVENT DYES

1 Solvent Black - 27



4 Solvent Blue - 48

5 Solvent Brown - 43

6 Solvent Dark Brown - 5R

7 Solvent Fire Red - 119

8 Solvent Orange - 58

9 Solvent Orange - 99

10 Solvent Red - 89

11 Solvent Red - 122



14 Solvent Yellow - 62



(Source : PIS)

Table No. 2.1B PROPOSED PRODUCT PROFILE

Sr. No. Group of Product Product name Quantity (MT/M)

A Oxidation based

products

Solvent blue 35, Solvent blue 36,

Solvent blue 45, Solvent violet

13, Solvent green 3, Solvent

green 28, Solvent violet 37

9.0

B Sulfonation based

products

Solvent blue 70, Solvent blue

122, Solvent blue 104

5.0

C Metallization based Solvent orange 114, Solvent Red 7.5


products 270, Solvent Red 52, Solvent

Red 23, Solvent Red 24, Solvent

Violet 14, Solvent orange 54

D Condensation based

products

Solvent orange 63, Solvent

orange 60, Solvent yellow 93,

Solvent red 235, Solvent red

111, Solvent yellow 160, Solvent

yellow 43, Solvent red 195,

Solvent red 196, Solvent green

5, Solvent green 7

7.0

TOTAL 28.5

(Source : PIS)

2.3 PROJECT LOCATION & SITE LAYOUT

The proposed expansion of manufacturing facility will be carried out within existing

premises of 3000 sq.m. land area, at plot no. 8101, GIDC Sachin, Surat, Gujarat. The

nearest railway station is Sachin @ 3.5 Km whereas nearest airport is Surat @ 10 Km

distance. The National Highway no. 8 is passing adjacent to the location of GIDC Estate of

Sachin. The unit is @ 1 KM away from the National Highway. The location of the unit is

shown at Figure no. 2.1 The layout of the manufacturing facility is shown at Figure no.

2.2.

For the proposed expansion, no additional civil work is to be carried out. However,

increase in production capacity will be achieved through full capacity utilization of

existing equipments and machineries alongwith addition of reaction vessels within

existing structure. Hence, there will not be any change in land utilization pattern from the

existing condition. The landuse break up is shown at Table no. 2.2.


Figure no. 2.1 Key Plan of Unit


Figure no. 2.2 Plant Layout of Unit


Table No. 2.2 LAND USE BREAK UP

Sr.

No.

Particular Land Area

(sq. m.)

% of Land Use at

Ultimate Stage

1 Manufacturing facility 1220 40.67

2 Storage (Raw materials and

Products)

145 4.83

3 Storage (Hazardous wastes) 30 1.00

4 Administrative building &

other facilities- lab.

210 7.00

5 Green belt / Space / Area 100 3.33

6 Approach roads 400 13.33

7 Open to Sky 895 29.84

TOTAL 3000 100

(Source : PIS)

2.4 SITE SELECTION CRITERIA

For the proposed expansion project, the specific site selection criteria considered are as

under :

1. Existing plot size and infrastructure is suitable to meet the requirement of the

expansion project.

2. The site is well connected by road and rail.

3. No prime agriculture land / waste land is required to be converted for industrial use.

4. Availability of Uninterrupted power supply.

5. Does not require additional establishment of basic infrastructure facilities.


2.5 THE RESOURCES

2.5.1 Land

The total land area under possession of the unit is @3000 sq. m. The land area being

utilized for various purpose at the ultimate phase of expansion of the project is given at

Table No. 2.2.

2.5.2 Water

For manufacturing of Acid and Solvent dyes @ 6 MT/M, water is being utilized @ 8.5 KLD.

The breakup of water usages is shown at Table no. 2.3. The water is being supplied by

Sachin Infra Management Ltd. (SIML). Based on the mass balance of the various

alternative products and considering the worst case scenario, the requirement of water

will be @23 KLD at the ultimate phase. The unit has requested the SIML for supply of

additional water requirement. The copy of the request letter is attached as Annexure C.

The undertaking in respect of not withdrawing ground water is also attached as

Annexure D. The detailed breakup of water requirement for various purpose is shown at

Table no. 2.3. The quality of water being supplied from the SIML is given at Table no.

2.4.

Table No. 2.3 BREAK UP OF WATER USAGES

Sr.

No.

Usage Water consumption

Existing (KLD) Proposed

Expansion (KLD)

Ultimate (KLD)

1 Domestic 1.50 1.50 3.00

2 Industrial

a. Processing 5.00 10.50 15.50

b. Boiler feed 0.30 0.70 1.00

c. Cooling make up 0.20 0.30 0.50

d. Washing 1.50 1.50 3.00

e. Others Nil Nil Nil

Total of (2) – Industrial 7.00 13.00 20.00

Total of (1) & (2) – Domestic

& Industrial

8.50 14.50 23.00


Table No. 2.4 Raw Water Quality

Sr. No. Parameter Unit Result

1 Colour Hazen < 1

2 Odour -- Unobjectionable

3 Taste -- Agreeable

4 Turbidity NTU 1.37

5 pH -- 7.93

6 Total Hardness as CaCO3 mg/L 110

7 Iron as Fe mg/L 0.011

8 Chloride as Cl mg/L 16.99

9 Residual free chlorine mg/L <0.1

10 Fluoride mg/L N.D.

11 Total Dissolved Solids mg/L 208

12 Calcium as Ca mg/L 26

13 Magnesium as Mg mg/L 10.8

14 Copper as Cu mg/L N.D.

15 Manganese as Mn mg/L N.D.

16 Sulphate as SO4 mg/L 3.05

17 Nitrates as NO3 mg/L 0.54

18 Phenolic compounds mg/L N.D.

19 Mercury as Hg mg/L N.D.

20 Cadmium as Cd mg/L N.D.

21 Selenium as Se mg/L N.D.

22 Arsenic as As mg/L N.D.

23 Cyanide as CN mg/L N.D.

24 Lead as Pb mg/L N.D.

25 Zinc as Zn mg/L 0.01

26 Anionic detergent as MBAS mg/L N.D.

27 Hexavalent Chromium as Cr+6 mg/L N.D.

28 Oil & Grease mg/L N.D.

29 Alkalinity mg/L 102

30 Boron as B mg/L N.D.

31 Pesticides mg/L N.D.

32 Coliform Per 100 ml Absent

33 E-coli Per 100 ml Absent

34 Aluminium as Al mg/L N.D.

(Source: Pollucon Laboratories)

2.5.3 Energy

The unit has connected power load of 110 KW from Dakshin Gujarat Vij Co. Ltd., which is

sufficient to cater the need of power even for expansion phase of the project. Hence,

there will not be any additional power requirement. The unit has installed D.G. set of 75


KVA for emergency operations in case of power failure, which consumes L.D.O. @ 20

L/hour.

The unit is utilizing Natural gas @ 10850 SCM/M for Industrial Boiler of 1500 Kg/hour

(having utilization rate of 20 – 25% of the capacity) for satisfying the steam requirement

for the production activity. The same boiler will utilized for expansion phase having full

utilization capacity with gas consumption rate of @ 120 SCM/hour at the ultimate.

The unit intends to install Hot Air Generator (4 Nos.) of 1,00,000 Kcal which will also

utilize natural gas as fuel having consumption rate of @ 12 – 15 SCM/hour for each HAG.

2.5.4 Raw Materials

The details of raw material consumption / requirement for existing products as well

proposed products has been given in Table no. 2.5A and Table no. 2.5B. The figure given

in column 3 of the table is consumption of raw material for each batch, whereas the

figure given in column 4 of the table is monthly consumption considering the maximum

(consented and proposed) production of the product.

Table no. 2.5A SPECIFIC CONSUMPTION OF RAW MATERIALS (Existing)

Sr. No.

PRODUCT / Raw Material Quantity (Kg /Kg of product)

A ACID DYES

1. Acid Brown 14 (Batch size : 1000 Kg)

2 – Amino Phenol – 4 – Sulfonamide 0.120

Phenyl Methyl Pyrazolene 0.130

Sodium Dichromate 0.035

Sodium Bisulphite 0.040

Salicylic Acid 0.040

Sodium Nitrite 0.050

Hydrochloric Acid 0.070

Liquid Ammonia 0.025

Caustic Soda Lye 0.020

Light Diesel Oil 0.70 L

Salt 0.550

2. Acid Orange – 24 (Batch size : 1000Kg)









Soda Ash 0.030

Light Diesel Oil 0.75L

Sodium Acetate 0.100

Salt 0.500

3. Acid Black –1 (Batch size : 1000 Kg)


Aceto Acetanilide 0.030

1 – Amino Carbo Methoxy – 7 – Naphthol

0.095









Salt 0.450

4. Acid Yellow – 73 (Batch size : 1000 Kg)

Aniline 0.110





1:4 Sulpho Phenyl Methyl Pyrazolene 0.080





Sodium Acetate 75

Salt 450

5. Acid Red – 42 (Batch size : 1000 Kg)

4 – Nitro – 2 – Amino Phenol 0.115

Phenyl Methyl Pyrazolene 0.070









Soda Ash 0.030


Salt 0.500

6. Acid Blue – 113 (Batch size : 1000 Kg)

Copper Phthalo Cyanine 0.105

Sodium Acetate 0.085










Salt 0.350

7 ACID BLACK – 58 (Batch size : 315 Kg)

OAPSAMIDE 0.320

HCl 0.320

Sodium Nitrite Solution 0.600

Ice 5.079

Carbonyl A. Naphthol 0.413

Liq. Ammonia 0.400

S.C.S. 0.200

8 ACID BLACK – 64 (Batch size : 325 Kg) OAPSAMIDE 0.310 HCl 0.310 Ice 4.900 Sodium Nitrite Solution 0.570 Carbonyl A. Naphthol 0.340 Acetic Anthranilide 0.080 Liq. Ammonia 1.230 S.C.S. 0.620

9 ACID BROWN – 45 (Batch size : 340 Kg) OAPSAMIDE 0.300 Sodium Nitrite Solution 0.470 Ice 4.705 Water 7.350


HCl 0.265 MCPMP 0.210 Liq. Ammonia 0.620 Carbonyl A. Naphthol 0.100 Sodium Bisulfite 0.300 Ice + Salt 3.230 Sodium Dichromate 0.175 Salicylic Acid 0.340

10 ACID DARK BROWN – 48 (Batch Size : 375 Kg) 4 NAP 0.300 HCl 0.930 Sodium Nitrite Solution 0.535 Water 5.600 Ice 3.730 Di Methyl Phenol 0.225 Caustic Lye 0.107 Soda Ash 0.270 S.C.S. 0.670 Liq. Ammonia 0.270

11 ACID ORANGE – 80 (Batch Size : 335 Kg) OAPSAMIDE 0.300 Caustic Lye 0.300 HCl 0.900 Water 6.860 Ice 4.775 Sodium Nitrite Solution 0.400 MCPMP 0.300 Salt 0.820 Acetic Acid 0.150 Cobalt Chloride 0.225

12 ACID ORANGE – 86 (Batch Size : 375 Kg) OAPSAMIDE 0.270 HCl 0.530 Water 8.530 Ice 3.730 Sodium Nitrite Solution 0.490 MCPMP 0.270 Caustic Lye 0.135 S.C.Salicylate 0.530 Salt 0.800 Acetic Acid 0.106


13 ACID VIOLET – 78 (Batch Size : 370 Kg) OAPSAMIDE 0.270 HCl 0.675 Water 6.480 Ice 4.320 Sodium Nitrite Solution 0.405 B-Naphthol 0.190 Caustic Lye 0.135 Salt 0.675 S.C.S. 0.540

14 ACID YELLOW – 114 (Batch Size : 360 Kg) Amino Benzoic Sulfamide 0.280 Water 7.500 Ice 4.170 HCl 1.111 Sodium Nitrite Solution 0.420 Liq. Ammonia 0.695 MCPMP 0.305 S.C.S. 0.555 Salt 0.695

B SOLVENT DYES

1 SOLVENT BLACK – 27 (Batch size : 320 Kg) 4 NAP 0.250 5 NAP 0.310 HCl 2.500 Water 7.340 Ice 5.625 Sodium Nitrite Solution 1.070 B-Naphthol 0.580 Caustic Lye 0.560 Sodium Bisulfite 0.080 Liq. Ammonia 0.470 Salicylic Acid 0.500 Sodium Dichromate 0.450 Formic Acid 0.125 Amine 0.345 Acetic Acid 0.470

2 SOLVENT BLACK – 29 (Batch Size : 251 Kg) 4 NAP 0.090 5 NAP 0.120 Amyl NAP 0.150


Water 15.930 Naphthaline Sulfonic Acid 0.955 Caustic 0.320 B-Naphthol 0.320 Ice 1.195 Sodium Bisulfite 0.200 Sodium Dichromate 0.200 Salicylic Acid 0.400 Liquor Ammonia 0.180 N-Butyl Amine 0.060

3 SOLVENT BLACK – 34 (Batch Size : 340 Kg) 4 NAP 0.530 HCl 2.350 Water 6.765 Ice 6.175 Sodium Nitrite Solution 1.000 B- Naphthol 0.560 Caustic Lye 0.590 Liq. Ammonia 0.440 S.C.S. 0.940 Amine 0.325 Formic Acid 0.150 4 SOLVENT BLUE – 48 (Batch Size : 215 Kg) Chloro Sulfonilic CPC 0.930 N-Butyl Amine 0.255 Primene 0.115 Water 7.440 Ice 6.975 Sodium Bicarbonate 0.165 5 SOLVENT BROWN – 43 (Batch Size : 362 Kg) 2 Amino Phenol 4 Methyl Sulfonamide 0.275 Sodium Nitrite 0.375 Ice 6.900 HCl 0.525 Water 6.765 MCPMP 0.200 Ammonia 0.275

Carbonyl Phenyl 7 Naphthol 0.095 Liq. Ammonia 0.070 Sodium Bisulfite 0.195 Sodium Dichromate 0.165 Salicylic Acid 0.345


6 SOLVENT DARK BROWN - 5R (Batch Size : 370 Kg) 4-NAP 0.405 Water 9.190 Ice 4.050 Sodium Nitrite Solution 0.810 HCl 1.620 Di Methyl Phenol 0.350 Caustic Lye 0.150 Soda Ash 0.270 Sodium Dichromate 0.230 Salicylic Acid 0.405 Sodium Bisulfite 0.270 Liquor Ammonia 0.270

7 SOLVENT FIRE RED – 119 (Batch Size : 310 Kg) 4 NAP 0.320 5 NAP 0.095 Anthranilic Acid 0.115 Sodium Nitrite Solution 0.970 Water 14.510 Ice 5.480 HCl 1.450 PMP 0.645 Caustic Lye 0.160 Sodium Acetate 0.485 MEG 4.830 Chrome Formate 0.080 Rhodamine 0.435

8 SOLVENT ORANGE – 58 (Batch Size : 295 Kg) 2 Amino Phenol 4 Methyl Sulfate 0.340 HCl 2.375 Water 6.780 Sodium Nitrite 0.680 Ice 5.425 MCPMP 0.390 Caustic Lye 0.170 Sodium Dichromate 0.170 Salicylic Acid 0.265 Sodium Bisulfite 0.100 Acetic Acid 0.120 Primene 0.155

9 SOLVENT ORANGE – 99 (Batch Size : 380 Kg)


4 NAP 0.265 HCl 0.790 Sodium Nitrite Solution 0.660 Water 7.895 Ice 5.000 PMP 0.395 Acetate 0.475 Caustic Lye 0.105 MEG 1.580 Chrome Formate 0.160 Amine - P 0.130 Formic Acid 0.130

10 SOLVENT RED – 89 (Batch Size : 210 Kg) Sovent Yellow - 62 0.550 Caustic Lye 0.145 Water 3.810 Rhodamine 0.310 HCl 0.475

11 SOLVENT RED - 122(Batch Size : 330 Kg) 5 NAP 0.300 4 NAP 0.006 Water 8.785 Ice 5.455 Sodium Nitrite 0.760 HCl 0.910 PMP 0.455 Sodium Acetate 0.545 Caustic Lye 0.120 MEG 1.820 Chrome Formate 0.120 Amine - P 0.150 Formic Acid 0.150

12 SOLVENT RED – 127 (Batch Size : 290 Kg) 1 Diazo 2 Naphthol 4 Sulfonic Acid 0.220 Water 7.755 PMP 0.160 Caustic Lye 0.085 HCl 0.070 Ammonia 0.035 Chrome Formate 0.025 MEG 0.865 Ice 1.040


Rhodamine 0.415 Primene 0.180

13 SOLVENT RED – 132 (Batch Size : 286 Kg) Amyl NAP 0.195 Nitro Amino P.C. 0.155 Caustic Lye 0.105 Naphthalene Sulfonic Acid 0.700 Water 16.610 Ice 4.900 Sodium Nitrite 0.600 PMP Sulfonamide 0.455 Soda Ash 0.070 Sodium Bisulfite 0.105 Liquor Ammonia 0.140 HCl 0.175 Salicylic Acid 0.280 Sodium Dichromate 0.150 N-Butyl Amine 0.070 Acetic Acid 0.090

14 SOLVENT YELLOW – 62 (Batch Size : 550 Kg) 2 Amino Phenol Sulfate 0.365 Caustic Lye 0.290 HCl 1.090 Water 5.275 Ice 4.545 Sodium Nitrite 0.490 MCPMP 0.335 Acetic Acid 0.165 Cobalt Chloride 0.265

15 SOLVENT YELLOW – 82 (Batch Size : 380 Kg) Anthranilic Acid 0.265 Water 14.865 HCl 0.342 Nitrite Solution 0.525 Ice 3.420 Caustic + Ammonia 0.880 Sodium Acetate 0.355 PMP 0.355 MEG 1.895 Chrome Formate 0.066 EHA 0.160 Primene 0.080


16 SOLVENT YELLOW – 90 (Batch Size : 540 Kg)

2 Amino Benzoic Sulfonamide 0.370 Water 6.480 Ice 4.170 Sodium Nitrite Solution 0.555 Liquor Ammonia 0.370 HCl 1.205 PMP 0.335 Sodium Bisulfite 0.205 Sodium Dichromate 0.170 Salicylic Acid 0.295

Table no. 2.5B SPECIFIC CONSUMPTION OF RAW MATERIALS (Proposed)

Sr.

No.

PRODUCT / Raw Material Quantity Kg/Kg of Product

A Oxidation based Products : 9 MT/M

1. SOLVENT BLUE 35 (BATCH SIZE : 650 Kg)

Quanizarine 0.380

Leuco quanizarine 0.190

IPA 3.700

N butyl amine 0.460

Nitrobenzene 0.050

Piperidine 0.005

2. SOLVENT BLUE 36 (BATCH SIZE : 700 KG)

Quanizarine 0.360


IPA 3.425

N butyl amine 0.360

Nitrobenzene 0.050

Piperidine 0.005

3 SOLVENT BLUE 45 (BATCH SIZE : 750 KG)


Quanizarine 0.210


IPA 1.330

N butyl amine 0.250

Caustic lye 0.070

Hydrogen Peroxide 0.030

4 Solvent Violet 12 (BATCH SIZE: 425 KG)

Quanizarine 0.370


IPA 3.530

Boric acid 0.100

P Toluedine 0.350

Xylene 2.825

Caustic lye 0.175


5. Solvent Green 3 (BATCH SIZE : 800 KG)

Quanizarine 0.220


IPA 3.375

Boric acid 0.075

P Toluedine 0.500

Diethyl Glycol 0.075

Caustic lye 0.250


6. Solvent Green 28 (BATCH SIZE : 1200 KG)

Quanizarine 0.125


IPA 1.700


Boric acid 0.040

P Toluedine 0.270

Diethyl Glycol 0.040

Caustic lye 0.190


7. Solvent Violet 37 (BATCH SIZE : 450 KG)

Quanizarine 0.310


IPA 2.700

Boric acid 0.077

P Toluedine 0.290

Nitro benzene 0.180

Caustic lye 0.500


Xylene 2.700

B Sulfonation based Products : 5 MT/M

1. Solvent Blue 70 (BATCH SIZE : 800 Kg) Copper Pthalo Cyanine 0.190

Chloro sulphonic acid 3.750

Sodium bicarb 0.625

N butyl amine 0.090

2 ethyl hexyl amine 0.100

Ice 2.500

2. Solvent Blue 122 (BATCH SIZE : 750 Kg)

Copper Pthalo Cyanine 0.200


Ammonia 0.095



Ice 2.000

3. Solvent Blue 104 (BATCH SIZE : 800 Kg) Copper Pthalo Cyanine 0.190


N butyl amine 0.100

Primene 0.050

Ice 3.125

C Metallization based Products : 7.5 MT/M

1 Solvent Orange 114 (BATCH SIZE : 800 Kg)

2 Amino benzoic acid 5 Sulphonamide 0.250

HCl 0.812

Sodium nitrite 0.103

Phenyl methyl Pyrazolone (PMP) 0.217

Caustic lye 0.145

Sodium Chromium Salicylate (SCS) 1.875

2 Solvent Red 270 (BATCH SIZE : 600 Kg)

4 nitro amino phenol (4 NAP) 0.208

HCl 0.741


Ice 0.500

Caustic lye 0.050



2 Ethyl hexyl amine 0.183

3. Solvent Red 52 (BATCH SIZE : 600 Kg)


4 nitro amino para sulphonic acid (4

NAPSA)

0.330

HCl 0.490


Ice 0.333

Meta chloro PMP 0.275

Caustic lye 0.050

Sodium acetate 0.267



4. Solvent Red 23 ( BATCH SIZE : 450 Kg)


HCl 0.530


Ice 0.445

Caustic lye 0.067





5. Solvent Red 24 (BATCH SIZE : 550 Kg)

1 Diazo 2 Naphthol Sulphonic acid 0.227

HCl 0.236


Ice 0.727

Meta chloro PMP 0.172

Caustic lye 0.082



Methyl Ethyl Glycol (MEG) 0.909


Chromium Format 0.127

6. Solvent Violet 14 (BATCH SIZE : 450 Kg)


HCl 0.955


Ice 1.333

Caustic lye 0.089

Beta napthol 0.173



C Condesation based Products : 7.0 MT/M


IPA 2.400

Chloro anthra quinine 0.140


N Butyl amine 0.65


IPA 1.500

Pthalic anhydride 0.210

1 : 8 Diamino Napthalene 0.133

Ortho Dichloro Benzene 0.333

3 Solvent Yellow 93 (BATCH SIZE : 330 Kg)

Quanizarine 0.390

Pthalic anhydride 0.606

Ortho Dichloro Benzene 0.606

IPA 3.030



Quanizarine 0.555

IPA 1.835

Mono Ethyl Glycol 2.460


1 Sulphoa anthra quinine 0.925

Resist salt 0.175

Mono methyl amine 0.925

6 Solvent Yellow 160 (BATCH SIZE : 500 Kg)

Ortho dichloro benzene 0.400

1 chloro anthra quinine 0.450


IPA 2.400


2.6 PROCESS TECHNOLOGY

At present, the unit is manufacturing Acid dyes and Solvent dyes product at the location

having cumulative consented capacity of 6 MT/M. The unit intends to expand its

manufacturing facility for additional production of 28.5 MT/M for the products

mentioned at Table no. 2.1 B. The proposed products have been categorized into groups

based on the major reaction to be carried out. Mass balance of the proposed products

have been given at Annexure E.

The products have been divided into following groups:

(A) Oxidation based products

(B) Sulfonation based products

(C) Metallization based products

(D) Condensation based products

The mass balance diagram of the various products alongwith its process is given in the

foregoing section:

(A) OXIDATION BASED PRODUCTS :

(A1) Solvent Blue 35



(A4) Solvent Violet 13

(A5) Solvent Green 3

(A6) Solvent Green 28

(A7) Solvent Violet 37

(B) SULFONATION BASED PRODUCTS :

(B1) Solvent Blue 70



(C) METALLIZATION BASED PRODUCTS :

(C1) Solvent Orange 114

(C2) Solvent Red 270

(C3) Solvent Red 52

(C4) Solvent Red 23


(C5) Solvent Red 24

(C6) Solvent Violet 14

(C7) Solvent Orange 54

(D) CONDENSTAITON BASED PRODUCTS :

(D1) Solvent Orange 63

(D2) Solvent Orange 60

(D3) Solvent Yellow 93

(D4) Solvent Red 235






(D10) Solvent Green 5

(D11) Solvent Green 7

2.7 MAJOR EQUIPMENTS & MACHINARIES

The list of equipments and machineries being installed for existing production and to be

installed for proposed products has been given at Table no. 2.6.

Table No. 2.6 List of Equipments & Machineries

Sr.

No.

Name of

Equipment /

Machineries

Capacity Existing

Nos.

Proposed

Nos.

Type

1 Diazo Vessel 10 KL 2 -- MSRL

20 KL 2 1 MSRL

2 Coupling Vessel 10 KL 2 -- MSRBL

20 KL 1 -- MSRBL

30 KL -- 1 MSRBL

3 Drowning Vessel 10 KL 3 -- MSRL

20 KL 1 1 MSRL

30 KL 1 -- MSRL

4 SS Vessel 2.5 KL 1 -- SS

5.0 KL 1 -- SS

8.0 KL 2 -- SS


10 KL 1 1 MS

5 Sulphonator Vessel 4.0 KL -- 1 MS

6 Tray Dryers 7.5 Kg/hr 8 2 --

7 Filter Press 600 mm X 600 mm 40 Plates

5 -- --

900 mm X 900 mm 45 Plates

2 2 --

8 MEG Storage Tank 6.0 KL 2 -- MS

9 Ammonia Storage Tank

5.0 KL 1 -- HDPE

10 Caustic Lye Storage Tank

5.0 KL 1 -- HDPE

11 HCl Storage Tank 7.0 KL 1 -- HDPE

12 Chloro Storage Tank

15 KL 1 -- MS

13 Ice Crusher 2000 Kg/hr 3 0 MS

14 Boiler 1500 Kg/hr 1 --* Gas Fired

15 Hot Air Generator 100000 Kcal/hr -- 4 Gas Fired

16 Pulverizer 50 Kg/hr 6 2 MS

*Note: to be utilized at its fullest capacity, against present utilization of 20 – 25% of the

capacity.

2.8 SOURCES OF POLLUTION

2.8.1 Liquid Effluent

The water consumption and effluent generation for consented products, for maximum

production capacity (i.e. consented) has been given at Table no. 2.7A.

From the Table No. 2.7B mentioned below, considering the maximum production

capacity of a particular product in a worst case scenario (i.e. considering the monthly

production capacity of each product group for the product generating maximum effluent)

the maximum wastewater generation at any point of time is not likely to exceed 12.7

Kl/D for 28.5 MT/M production for proposed expansion.


Table No. 2. 7A Summary of Product wise Water Consumption and Wastewater

Generation for Consented Products

Sr.

No.

Product

Group

Product Water

Consumption

KL/D

Wastewater

Generation

KL/D

Remarks

A Acid Dyes : 6 MT/M

Acid Brown 45 1.25 4.47 Considering the

production of

Acid Brown 45

@ 6 MT/M, the

average daily

effluent

generation will

be 4.47 KLD.

Acid Yellow 114 1.58 3.61

Acid Orange 80 1.25 3.70

Acid Orange 86 1.52 3.84

Acid Dark Brown 48 1.20 3.12

Acid Black 64 1.69 4.30

Acid Violet 78 1.36 3.35

Acid Black 58 1.74 4.44

B Solvent Dyes : 6 MT/M

Sovlent Black 34 1.51 4.94 Considering the

production of

Solvent fire red

119 @ 6 MT/M,

the average

daily effluent

generation will

be 6.65 KLD.

Solvent Red 122 1.87 4.94

Solvent Orange 99 1.68 4.37

Solvent fire red 119 3.05 6.65

Solvent Black 27 2.25 5.87

Solvent Black 29 2.23 4.62

Solvent orange 58 2.18 5.25

Solvent Red132 3.41 6.15

Solvent Yellow 62 1.49 3.45


Solvent Dark Brown

5R

1.96 4.76

Solvent Blue 48 1.49 2.98



Solvent Brown 43 1.41 3.87


Solvent yellow 82 1.16 5.74

Note: Total cumulative production capacity of all these products is 6 MT/M as per the

consent granted.

Table No. 2. 7B Summary of Product wise Water Consumption and Wastewater

Generation from proposed production capacity

Sr.

No.

Product

Group

Product Water

Consumption

(Including

ICE) KL/D

Wastewater

Generation

KL/D

Remarks

A Oxidation based products : 9 MT/M

Solvent Blue 35 0.92 2.05 Considering the

production of

Solvent Violet 37

@ 9 MT/M, the

average daily

effluent

generation will be

2.58 KLD.



Solvent Violet 13 1.41 1.11

Solvent Green 3 1.12 2.57



B Sulfonation based products : 5 MT/M

Solvent Blue 70 1.46 2.08 Considering the

production of

Solvent Blue 104

@ 5 MT/M, the

average daily

effluent

generation will be

2.80 KLD.



C Metallization based products :7.5 MT/M

Solvent Orange

114

0.37 0.97 Considering the

production of

Solvent Orange Solvent Red 270 0.66 1.26


Solvent Red 52 0.63 1.15 54 @ 7.5 MT/M,

the average daily

effluent

generation will be

2.30 KLD.





D Condensation based products : 7.0 MT/M

Solvent Orange 63 1.02 1.57 Considering the

production of

Solvent Red 111

@ 7.0 MT/M, the

average daily

effluent

generation will be

4.97 KLD.


Solvent Yellow 93 0 0.14

Solvent Red 235 0 0.57








(Source : PIS)


Details of the wastewater quantity from different sources have been given at Table

no. 2.8A. Total effluent generation for the production has been considered for the

worst case scenario (i.e. maximum effluent generation from product(s) of each

group), the maximum water generation for proposed expansion will be 12.7 KLD.

Table No. 2.8A Details of Waste Water Generation

Sr. No. Source Waste Water Generation in KL/day

Existing Proposed Ultimate

A Domestic 1.4 0.9 2.3

B Industrial

1 Process 6.7 12.7 19.4

2 Boiler blow down 0.1 0.2 0.3

3 Cooling bleed off 0.1 0.1 0.2

4 Washing 1.4 1.4 2.8

5 Others Nil Nil Nil

TOTAL of Industrial 8.3 14.4 22.7

TOTAL of Domestic & Industrial

9.7 15.8 25.0

The water balance diagrams for present and proposed conditions are shown at Figure No.

2.3 and 2.4.


Figure No. 2.3 Existing Water Balance Diagram

Water

7.0

Domestic

1.5

Washing

1.5 Process

(5.0)

Utility

Boiler

(0.3)

Cooling

(0.2)

(1.4) (1.4) (6.7)

(0.1) (0.1)

To E.T.P

(8.3+1.4)

Ice (1.7)


Figure No. 2.4 Proposed Water Balance Diagram

Notations:

--- Existing water consumption and wastewater generation

--- Proposed water consumption and wastewater generation

--- Ultimate water consumption and wastewater generation

Water

20.0

Domestic

(1.5+1.5)

Washing

(1.5+1.5) Process

(5.0+10.5)

Utility

Boiler

(0.3+0.7)

Cooling

(0.2+0.3)

(2.3) (1.4+1.4)

(6.7+12.7)

(0.1+0.2) (0.1+0.1)

To E.T.P

(22.7+2.3)

Ice (4.3)


The unit has got membership of GECL for disposal of 25 KLD effluent in to GECL CETP. The

present disposal of industrial effluent will from 8.3 KLD to 22.7 KLD after proposed

expansion. At present unit sending its effluent to CETP through tankers after resorting to

required treatment, so as to meet with inlet norms of CETP. The analysis of the raw &

treated effluent being send to CETP is given in below Table No. 2.8B

Table No. 2.8B Representative Quality of Wastewater

Sr. No. Parameters Unit Raw Effluent Treated Effluent

1 pH -- 3.36 7.2

2 TSS mg/L 101 BDL

3 TDS mg/L 8404 8326

4 COD mg/L 18080 3289

The anticipated characteristics for each stream from various products are not available in

absence of any production of such products. However the representative characteristics

provided by the unit based on their lab scale study is given in Table No. 2.8C

Table No. 2.8C Anticipated Quality of Wastewater based on Lab scale Study

Sr. No. Product Group pH COD (mg/L) TDS (mg/L)

1 Oxidation based products 3.0 – 5.0 15,000 – 20,000 5000 – 9000

2 Sulfonation based products 4.0 – 6.0 17,000 – 23,000 4500 – 8200

3 Metallization based products 3.5 – 6.5 12,000 – 18,000 5500 – 8900

4 Condensation based products 4.4 – 7.5 8000 – 12,000 3300 – 8000

(Source: PIS)

2.8.1.1 Details of Effluent Treatment Scheme

The domestic sewage alongwith industrial effluent from the various stages of the process

is collected and treated in the effluent treatment plant having primary treatment facility.

The raw effluent from different streams of the process is being taken to oil & grease trap

prior to equalization of the effluent. The effluent is being fed to equalization cum

neutralization tank, where pH correction is carried out using lime and ferrous sulphate.

The neutralized effluent is pumped to primary settling tank for removal of suspended

particles. Neutralization tank as well as primary settling tank will be operated in

sequential batch manner (i.e. fill and draw type).


The sludge from PST is dewatered and dried in nutch filter and filtrate collected is sent to

neutralization tank for further treatment.

The details of ETP alongwith its dimension and adequacy is given at Table no. 2.9.

Primary treated effluent will be sent to CETP of Globe Enviro Care Ltd. for further

treatment and its ultimate disposal. The copy of membership of CETP of GECL is attached

herewith as Annexure F.

Any occasional spillages or leakages from the raw materials storage and handling will be

also diverted to ETP for further treatment.


Table No. 2.9 Details of Effluent Treatment Plant and its Adequacy

Note : *These units will be operated in sequential batch manner.

2.8.2 Gaseous Emission

The sources of gaseous emission identified are from the Boiler, Hot air generators and

in the form of fugitive emissions from handling of raw materials.

The unit has installed gas fired boiler of 1500 Kg/hour capacity, which will be utilized at

its fullest capacity to cater the need of steam for expansion project.

The fugitive emissions due to handling and storage of chemicals will be managed by

suitable engineering and administrative practices.

The details on the Air Pollution Control Measures are shown along with the other

details at Table no. 2.10.

Sr. No.

ETP Units Nos. Dimension / Capacity

MOC & Type

Remarks

1 Collection Tank - 3.05 m x 1.82 m x 1.52 m

RCC (U/G) Considering retention time of 8 hours can handle flow of 25 KL/day

2 Equalization cum Neutralization tank*

1 3.05 m dia. x 3.66 m

RCC (U/G) Considering retention time of 12 hours, can handle flow of 53 KL/day

3 Chemical dosing tanks

2 0.91 m (dia) x 3.66 m

MS --

4 Primary settling tank *

1 4.26 m x 2.43 m x 2.43 m

MS (Over head)

Considering retention time of 12 hours, can handle flow of 50 KL/day

5 Settler Tank 1 1.52 m (dia.) X 2.43 m

HDPE Considering retention time of 4 hours, can handle flow of 26 KL/day

6 Treated effluent collection tank

1 2.59 m (dia) x 2.43 m

HDPE Considering retention time of 6 hours, can handle flow of 51 KL/day

7 Sludge Bed 1 7.31 m x 3.65 m RCC --


Table No. 2.10 Details of Air Pollution Control System

Sr. No.

Attached To Fuel used

Fuel Consumption

Stack Height in m

Pollution control measures

Remarks

Consented

1

Stack Attached to Small Industrial Boiler (1500 Kg/hour)

Gas

10850 SCM/M* (ultimate expansion phase : 120 SCM/hour)

11 m

Fuel being liquid / gas, Not required

*At present utilization rate is @20 -25 % of the capacity.

2 Stack attached to D G Set (75 KVA)

LDO 6 L/hour 5 m

Proposed

1

Stack attached to Hot Air generator (4 Nos. 1,00,000 KCal each)

Gas 12 – 15 SCM/hour for each HAG

12 m --

Fuel being gas, Not required

2

Two stage Scrubber attached to sulphonator

-- -- 15 m

Water scrubber followed by alkali scrubber

Process emission from expansion phase products

2.8.3 Solid & Hazardous Waste

The details of solid and hazardous waste generation and its handling and

management have been presented in Table no. 2.11. Approximately 30 sq. m. area

has been earmarked for storage of hazardous waste covered with pucca roof top. The

unit has obtained membership of Bharuch Enviro Infrastructure Ltd. (BEIL) (copy

attached as Annexure G) for disposal of hazardous waste.


TABLE NO. 2.11 Details of solid waste/Hazardous Waste

2.9 GREEN BELT DEVELOPMENT PLAN

Considering the structure of the plant, there is availability of area for green zone

development @100 sq.m. However, the unit will participate in road side plantation drive

as well as community and social forestry programme being organized by the Local

authority / Government agencies.

2.10 ENVIRONMENT, HEALTH & SAFETY

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

provided adequate number of first aid boxes at strategic locations and give training to

designated person for the emergency purpose. The unit has also appointed part-time

medical officer for medical assistance and for ensuring the better health of workers.

The details of occupational health and safety of the workers is part of Chapter 6. No

fatal / non-fatal accident has been reported in the unit in last 3 years of operation. The

unit has not been issued any show cause notices / closure directions for breach of any

Environmental laws and / or Compliance of CC&A conditions. The compliance of

conditions of CC&A issued by GPCB is given at Annexure A.

2.11 COMPLIANCE TO VARIOUS STATUTORY GUIDELINES

Sr.

No. Description Category

Quantity Per Annum

Method of Storage

and Disposal Authorized Ultimate

1 ETP Sludge/ Gypsum

34.3 of Sch I 15.6 MT 25 MT Being Disposed to

authorized TSDF site.

2 Used Oil 5.1 of Sch I

0.022 MT 0.05 MT Selling out to Registered recyclers

3 Discarded Containers/ Bag Liners

33.3 of Sch I 10.56 MT 25 MT Sent back to suppliers / to GPCB approved recyclers


Being committed towards the environment protection, sustainable development and

industrial development, the promoter will follow and implement the guidelines issued

under Charter for Corporate Responsibility for Environment Protection (CREP) for

Chemical industry.

2.12 CORPORATE SOCIAL RESPONSIBILITY

The unit will contribute towards social welfare programmes being conducted by GIDC

Sachin as well as Dyes Manufacturing Association. The unit will allocate @ Rs. 1 Lakh /

annum towards the social welfare activities. The unit in consultation with industrial

association will promote initiative for the educational and health awareness amongst

the weaker sections of the society and nearby communities.

2.13 APPROACH TO CLEANER PRODUCTION

All the products are yield based and on commencement of production material mass

balance for every product will be studied sequentially and based on data the cleaner

production alternative will be implemented so as to reduce water consumption, energy

consumption, raw material consumption along with maximization of yield.


CHAPTER – 3


Chapter 3

Baseline Environmental Setting

3.1 INTRODUCTION

Baseline data collection of Environmental Quality is an essential part of

Environmental Impact Assessment study for superimposing anticipated pollution load, so

as to assess the possible environmental impact. These anticipated environmental impacts

can be either positive or negative. The environmental impacts are assessed mainly for the

environmental attributes like Water, Air, Soil, and Noise etc.

The impact from an existing industrial project on its surrounding environment are

mainly regulated by the nature of the pollutants, their quantities discharged to the

environment, existing environmental quality, assimilative capacity of the surrounding

environment and topography and terrain of the project site (its location) as well as the

surrounding area. In order to identify and establish the extent of likely impacts, it is

essential to gather information on existing environmental quality with regard to various

components of the environment.

For collecting the baseline information, following primary data were obtained

from the Globe Enviro Care Ltd. (in the Sachin GIDC). The study period for the same is

December, 2011 to February, 2012.

For the primary data study area was selected that included towns and villages

within 10 km buffer of the project site as a center. Hence, the following Secondary

baseline data from the GECL are going to be included in this chapter.

1. Three months Ambient Air Quality (December 2011 to February - 2012) of six location

in around the project.

2. Water sampling from the raw water quality being supplied by Sachin Infra

Management Ltd

3. Secondary metrological data from the GECL.

4. Land Use study for 10 km buffer area secondary data obtained from the GECL.


In addition to the Data of GECL, following industry specific data will be generated:

1. Ambient air quality station at the industry (PM2.5, PM10, SO2, NOx, VOC) : Once in a

week for 4 weeks

3.2 LOCATION

3.2.1 Introduction

The data under all categories, except for the administrative boundary and key

infrastructure features, landuse / landcover and soil characteristics, is provided for an area

of approximately 10 km buffer around the project area located at longitude 72°51'14.20"E

and latitude 21° 6'4.00"N.

The area statistics has been extracted for the region falling within a 10 km buffer around

the project area and has been provided in tabular form along with this report. A map

showing the site location has been attached as Figure 3.1.

3.2.2 Key Infrastructure Features and Settlements

A map depicting boundary up to taluka level, showing National and State highways, major

and medium roads is presented as Figure 3.6. The map also shows the water bodies and

major landmarks for better understanding of project area. The map marks the area within

10 km buffer around the project area. Distance of nearest key infrastructure features from

project area has been provided in tabular form as Table 3.1.


Table 3.1 Distance of Nearest Key Infrastructure Features from Project Area

Sr. No.

Nearest

Infrastructure

Feature

Distance (km) Project

Area

Direction from

Project Area

1 Village Budia 3.35 W

2 NH-06 9.98 NE

3 NH-08 12.44 E

4 SH-06 0.98 NE

5 SH-168 2.35 SE

6 SH-195 6.85 S

7 Railway line 1.04 E

8 Bhestan RS 3.26 NE

10 Mindhola River 4.87 SE

11 Reserve Forest 22.28 SW

12 Surat Airport 11.45 WNW

Figure 3.1 Site location map


3.3 MICROMETEROLOGY OF THE AREA

3.3.1 Temperature and Relative humidity:

The maximum, minimum & average temperatures and relative humidity for study area,

for the period of December ’11 to March’12 are presented at Table 3.2.

Table 3.2 Micrometeorological Data

Month Temperature, °C Humidity, %

Max. Min. Max. Min.

December 2011 34 12 86 19

January 2012 30 12 94 13

February 2012 36 10 98 07

March 2012 39 16 94 06

(Source: GECL)

3.3.2 Wind Rose:

Meteorological data was processed in WRPLOT and windrose diagram for the period of

December 2011 to March 2012 has been generated and it was observed that the Pre-

dominant wind direction is from North East direction with 23.30 % calm condition and

the average wind speed is 0.81 m /sec.

Based on meteorological data wind rose prepared for the period of December’11 to

March’12 is shown at Figure 3.2.


(Source: GECL)

Figure 3.2 Wind Rose Diagram for December 2011 to March 2012


3.4 AIR ENVIRONMENT

3.4.1 Ambient Air Quality (AAQ)

The basic objective of collection of base line data for air environment is to identify project

specific air pollutants being released into the atmosphere, which will have significant

impact on air environment of immediate vicinity of the proposed project site. For

assessment of the baseline data it is important to specify the study area in respect of the

location of the project at plot no 8101 GIDC, Sachin, Surat Gujarat. It was decided to

study ambient air quality at 7 locations in different directions in the probable impact zone

including the project site.

3.4.1.1 Location of AAQ monitoring Stations

Ambient air quality stations were chosen considering various factors like the most

prevailing wind direction, terrain of the area, pockets of habitation, available

infrastructure facilities like power supply, accessibility etc. The location of AAQ

monitoring stations is tabulated at Table 3.3 and shown at Figure no. 3.3.

Table 3.3 Sampling Locations

Sr. No. Location Direction from Site (km)

Direction from site

1 Site -- --

2 Bamroli 5.52 NW

3 Pardi Kanade 2.88 ESE

4 Pali 3.22 SE

5 Talangpor 3.10 S

6 Saniya Kanade 5.18 NE

7 Umber 3.87 SSW

(Source: GECL)


(Source: GECL)

Figure 3.3 Sampling Location Map


3.4.1.2 Baseline Ambient Air Quality Data:

The frequency of monitoring was twice in a week for a period of 12 weeks (commencing

from 20 Dec 2011) to assess the existing sub regional air quality status. Analytical methods

prescribed by CPCB were used for carrying out air quality monitoring. At all these

monitoring locations PM10, PM2.5, SO2 and NOx were monitored on 24 hourly, to enable

the comparison with ambient air quality standards prescribed by the Central Pollution

Control Board (CPCB).

Based on data obtained through ambient air quality survey the maximum, minimum,

average concentration, 98 percentile and 75 percentile values at different monitoring

locations in the study area have been computed and presented at Table 3.4.

Table 3.4 Ambient Air Quality Status of Study Area

Location Max. Value Min. Value Avg. Value Standard Deviation

98 Percentile Value

PM10 µg/m3(Permissible Limit :100 µg/m3)

Site 284.00 108.00 194.64 58.92 283.48

Umber 156.63 79.13 119.55 19.50 150.97

Pardi Kanade

111.92 64.63 93.60 12.95 111.58

Pali 145.49 71.97 118.23 18.06 143.82

Saniya 97.45 46.78 59.55 11.25 89.75

Talangpor 138.04 76.13 117.70 13.55 136.67

Bamroli 91.94 53.96 62.13 9.42 86.53

SO2 µg/m3(Permissible Limit :80 µg/m3)

Site 30.35 14.36 23.08 5.03 30.31

Umber 11.94 5.39 7.84 2.28 11.89

Pardi Kanade

22.79 5.39 10.94 5.76 22.79

Pali 21.55 5.36 10.48 4.51 21.14

Saniya 23.88 5.43 9.69 3.75 18.87

Talangpor 21.45 5.43 9.62 3.33 18.08

Bamroli 24.97 7.54 17.15 6.59 24.90

NOx µg/m3 (Permissible Limit :80 µg/m3)

Site 48.25 26.19 37.27 7.73 47.72

Umber 34.44 25.37 30.46 2.83 34.30

Pardi Kanade

49.29 25.24 32.68 7.51 48.91

Pali 46.53 25.37 31.49 5.94 46.29


Location Max. Value Min. Value Avg. Value Standard Deviation

98 Percentile Value

Saniya 47.32 24.84 30.13 4.74 41.65

Talangpor 35.10 26.03 30.24 3.27 34.74

Bamroli 50.04 25.05 38.06 9.82 49.90

PM2.5 µg/m3(Permissible Limit :60 µg/m3)

Site 126.00 48.34 85.32 27.02 124.96

Umber 79.57 31.51 59.12 11.90 78.91

Pardi Kanade

68.75 47.18 56.29 6.69 67.59

Pali 74.12 41.87 55.16 12.20 73.80

Saniya 61.90 30.00 49.67 11.58 61.90

Talangpor 80.13 46.12 62.63 9.91 78.87

Bamroli 63.73 35.91 50.28 10.47 63.65

(Source: GECL)

It is evident from the data presented have remained that, during the study period the

average concentrations values remain well below the prescribed NAAQS norms at all AAQM

locations for NOx and SO2, except PM10 and PM2.5 found to be above permissible limits

irrespective at some monitoring locations, which may be due to heavy industrial activity

surrounding those locations.

The average concentration of all pollutants at all 7 ambient air locations are found to

varying in the following range:

PM10: 59.55 to 194.64 µg/m3

PM2.5: 49.67 to 85.32 µg/m3

SO2: 7.84 to 23.08 µg/m3

NOx : 30.13 to 38.06 µg/m3

Data on Hydrocarbons (HC) and Volatile Organic Carbons (VOCs) were also collected for the

industry location, once in a week for Month of February & March 2012. All the results were

found BDL for the location.

3.5 WATER ENVIRONMENT

The water requirement for the proposed project will be for process, utility (Boiler &

Cooling), washing and domestic purpose. At present the water consumption is 7.0KLD and

after the expansion phase the water consumption will be @20KLD and it will be satisfied


through the water supply from Sachin Infra Management Ltd. The raw water quality being

supplied by Sachin Infra Management Ltd. is given at Table no. 3.6.

Table 3.5 Water Quality

Sr. No.

Parameter Unit Result

1 Colour Hazen < 1

2 Odour -- Unobjectionable

3 Taste -- Agreeable

4 Turbidity NTU 1.37

5 pH -- 7.93

6 Total Hardness as CaCO3 mg/L 110

7 Iron as Fe mg/L 0.011

8 Chloride as Cl mg/L 16.99

9 Residual free chlorine mg/L <0.1

10 Fluoride mg/L N.D.

11 Total Dissolved Solids mg/L 208

12 Calcium as Ca mg/L 26

13 Magnesium as Mg mg/L 10.8

14 Copper as Cu mg/L N.D.

15 Manganese as Mn mg/L N.D.

16 Sulphate as SO4 mg/L 3.05

17 Nitrates as NO3 mg/L 0.54

18 Phenolic compounds mg/L N.D.

19 Mercury as Hg mg/L N.D.

20 Cadmium as Cd mg/L N.D.

21 Selenium as Se mg/L N.D.

22 Arsenic as As mg/L N.D.

23 Cyanide as CN mg/L N.D.

24 Lead as Pb mg/L N.D.

25 Zinc as Zn mg/L 0.01

26 Anionic detergent as MBAS mg/L N.D.

27 Hexavalent Chromium as Cr+6 mg/L N.D.

28 Oil & Grease mg/L N.D.

29 Alkalinity mg/L 102

30 Boron as B mg/L N.D.

31 Pesticides mg/L N.D.

32 Coliform Per 100 ml Absent

33 e-coli Per 100 ml Absent

34 Aluminium as Al mg/L N.D.

(Source: GECL)


3.6 NOISE ENVIRONMENT

In order to establish the background noise level, 7 noise monitoring statistics were

established within the study area. The noise levels were measured using sound level meter

made of Envirotech (SLM 100). The results are presented at Table 3.6 and the location of

noise monitoring stations is shown at Figure no. 3.3.

Table 3.6 Noise quality

Sr. No

Location (Category of Area)

Noise Level leq dB(A)

Day time Night Time

1. Site (Industrial) 72 67

2. Bamroli (Residential) 70 65

3. Pardi Kanade (Residential) 63 55

4. Pali (Residential) 66 64

5. Talapor (Residential) 61 58

6. Saniya Kanade (Residential) 62 60

7. Umber (Residential) 67 60

(Source: GECL)

During monitoring period, the noise levels varied between 61 leq dB (A) to 72 leq dB

(A) during day time and 55 leq dB (A) to 67 leq dB (A) during night time for whole study area.

Category of site area is industrial where, all other village location falling under residential

category. The noise level varied at the same place at different times due to fluctuations in

traffic movements as well as commercial and domestic activities going on in the study area.

3.7 LAND ENVIRONMENT

3.7.1 Soil Quality:

The soil samples from depth (0-20 cm) have been collected from identify sampling locations.

Physico-chemical parameters have been analysing to ascertain the baseline status of soil in

the study area. Four soil samples have been collected once during the study period. The

details about the sampling points is given in Table no. : 3.7 and figure is shown in Figure.3.1.


Table No. 3.7 Sampling Locations

Sr. No. Location Direction from Site

(km) Direction from site

1 Talangpor 2.97 S

2 Pardi Kanade 3.00 ESE

3 Bamroli 5.47 NW

4 Saniya Kanade 5.42 NE

Source: RESPL

Results :

The results of physico-chemical analysis, carried out as per standards procedure is given in

Table no: 3.8.

Table 3.8: Physico-Chemical quality of Soil Samples

Parameters Location

Talangpor Pardi kanade Bamroli Saniya Kanade

Permeability (mm/sec) 0.9*10-6 1.0*10-6 1.9*10-7 0.8*10-7

Porosity (%) 29.9 34.1 43.2 40.8

Water Holding Capacity (%) 19.7 23.5 38.4 33.6

Cation Exchange Capacity (meq/100 g) 40.60 43.74 49.46 59.44

pH @ 25° C 8.23 7.86 7.32 7.3

Conductivity @ 25°C (μmhos/cm) 191 328 1479 923

Sodium Absorbing Ratio (meq/kg) 1.48 1.49 2.57 1.03

Gravel(%) (> 4.75 mm) 5 4 0 3

Sand(%) (75 μm – 4.75 mm) 26 21 19 14

Silt + Clay (%) (2 μm - 75 μm)+ (<2 μm) 69 75 81 83

Interpretation

Some significant finding of soil qualities are listed below

1. The texture of the soil Silt loam, percent of clay of soil varies between 69 μm and 83 μm.

2. The porosity and water holding capacity of soil is in the range of 29.9 to 43.2 % and 19.7

to 38.4 respectively. Soil porosity is the major of air fild pore spaces and gives


information about movement of gases, inherent moisture and development of root

system and strength of soil.

3. pH of soil in the study area varies between 7.30 to 8.23 is presenting slightly alkaline

nature of soil. Such soils are conducive for agricultural purposes.

4. Cation exchange capacity that affects the productivity and adsorbtivity of the soil is found

in the range between 40.60 meq/100 g to 59.44 meq/100 g.

3.7.2 Land Use

3.7.2.1 Method of Data Preparation

Remote sensing technology has emerged as a powerful tool in providing reliable

information on various natural resources at different levels of details in a spatial form. Land

use distribution in the study area has been estimated using remote sensing technique. The

land use pattern of the study area has been studied by satellite imaginary picture obtained

from National Remote Sensing Center, Govt. of India. Details about satellite imagery are

given below.

Satellite Data Path Row Date Format Description

IRS LISS IV 093 057 29-OCT-2010 TIFF Orbit no. 26173

For the Land use secondary data were obtained from the Globe Enviro Care Ltd. in the

Sachin GIDC located at a distance of 0.73 km in SW direction from the Panchsheel

Intermediates.

The overall methodology adopted and followed to achieve the objectives of the present

study involves the following steps:

Satellite data of IRS P6 LISS IV sensor is geometrically corrected and enhanced using

principal component method and Nearest Neighborhood resampling technique.

Preparation of basic themes like layout map, transport & settlement map and from the

satellite image by visual interpretation.

Essential maps (related to natural resources) like Land use / Land cover map are

prepared by visual interpretation of the satellite imagery. Visual interpretation is carried out

based on the image characteristics like tone, size, shape, pattern, texture, location,

association, background etc. in conjunction with existing maps/ literature.


Preliminary quality check and necessary corrections are carried out for all the maps

prepared.

All the maps prepared are converted into soft copy by digitization of contours and

drainages. In that process editing, labeling, mosaicing, quality checking, data integration etc

are done, finally Land use areas are measured in Square Kilometers.

3.7.2.2 Land use Map Analysis

Land use Map Analysis done based on the image color, texture, Tone etc. Following steps

are used to analyze the Land use pattern of project site:

Collection of IRS LISS IV images and made fused and blended the images for color

combinations using Image interpreter-Utilities and Layer stack option available in ERDAS.

Identification AOI and made a buffer of 10km radius.

Enhance the Fused and blended LISS IV image using the Spatial, Radiometric and

Temporal options in ERDAS.

Rectified the LISS IV image using Georeferencing technique, Toposheet to get UTM

coordinate system.

Subset the LISS images and Toposheet using 10Kms buffer AOI.

Automatic classifications done for LISS IV images using maximum iterations and number

of options in unsupervised classification options.

Created the signature file by selecting the more samples of different features with AOI

on Unsupervised classification image.

Export to Vector layer from supervised classification image.

Gone through the QC / QA and finalized the data.

3.7.2.3 Digital Image Classification and maps:

Overview of Classifications: Digital Image classification procedures were applied to the

mosaiced images of LISS-IV. In order to do a Land use classification of the area that comes

under a 10km buffer radius of the study area, IRS-P6 images were used.


Since all the data of the study area were georeferenced to UTM 43N, WGS84 projection

system, the satellite images were also obtained with the same georeferencing from NRSA

who provided the GeoTIFFs of the scenes. Before a classification could be performed,

however, the satellite images needed to be pre-processed. All the processing and

classification of the satellite images were performed in the ERDAS Imagine 9.1 software. The

data was delivered in separate bands of 2, 3 and 4. As such, the first step was to stack the

data layers together to get a composite. The scenes were then mosaiced together since the

study area covered parts of both the scenes. Once a satisfactory mosaic was done whereby

the joins were no longer visible and the radiometric resolution of both the scenes matched,

the satellite image was then subset using a vector of the 10 kms buffer radius of the study

area. This subset of the original images was then run through the unsupervised classification

tool of the software to finally create the grouping of classes present in the study area.

The villages situated within the 10 km radius of the proposed site have been considered for

the study of the land use pattern. Figure no. 3.4 showing the project location along with the

Satellite image of site area. The land use pattern (level-2) classification of the study area

within 10 km buffers is shown at Figure no. 3.5.

In order to have more clear understanding of land use of proposed project area, a digitized

land use maps was prepared using the satellite image and topographical information.

Digitized landuse map is shown at Figure no. 3.6. Based on digitized landuse map (level II) it

shows that major part of the study area about 40% is covered by crop land. The north part is

occupied by a major populated area, whereas, the south part is scattered village habitation.

The north part of the project site is the city Surat. NH is dividing to the entire study area as

well as it is so close to the project site. The Existence of the Air port in the west and proper

connectivity of road network is also shown in the map.

The land use classification of the satellite image yielded the following classes as shown at

Table no.3.9 and the distribution chart of the study area is shown at Figure no 3.7.


Table 3.9 Area Statistic of Landuse / Landcover Map

Sr No Classes Area in Sq. Kms. Percentage

1 Transportation 4.56 1.44%

2 Scrub Area 18.77 5.97%

3 Crop Land 41.21 13.11%

4 Habitation 8.76 2.79%

5 Industrial Waste 2.43 0.77%

6 Land Without Scrub 6.70 2.14%

7 Litchen Cover Area 8.21 2.62%

8 Industrial Area 6.03 1.91%

9 Salt Farming 19.51 6.21%

10 Marshy Land 10.97 3.50%

11 Continental Shelf 31.61 10.06%

12 Water Bodies 155.53 49.48%

Total 314.29 100%

(Source: GECL)

Scrub_Area : Area occupied by scanty scrubs. 5.97% is the occupancy of it.

Crop_Land : It is a good agricultural land and the best way to make full use of the land. It is

occupied13.11%.

Land_Without_Scrub : The absence of scrub covers 2.14% of total area.

Transportation: The area is occupied by roads, railways and other transportation media. The

occupancy is 1.44%

Habitation: It is defined as an area of human habitation developed due to nonagricultural

use. Settlement and Industrial area in the study area constitutes 2.79%of the total study

area.

Industrial Waste: The dumping zone of industrial Waste covers 0.77% of total area.

Litchen Covered Area: Part of Marshy Land covered by litchens occupied 2.62% of the total

area.


Industrial Area: The activities of Industrialization occupied 1.91% of total area.

Salt Farming: The area, lying near to sea is used by salt farming occupied by 6.21% of total

area.

Marshy Land: The Marshy Land occupied 6.76% of total area.

Water Bodies: The part of the earth's surface covered with water. It is a natural or man-

made enclosed water body with a regulated flow of water. It occupies 49.48%in this study

area.


Figure 3.4 Satellite image of study area considering GECL at center of map


Figure 3.5 Landuse map (level-II) considering GECL at center of map


Figure 3.6 Digitized Landuse map (level-II) considering GECL at center of map


Figure No. 3.7 Land use Distribution Chart of the study area


CHAPTER – 4


CHAPTER – 4

ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 INTRODUCTION

As a part of present EIA study, anticipated environmental impacts associated with the activity

to be carried out for proposed expansion project of manufacturing of various acid and solvent

Dyes. Various activities during the construction & operation phase of the project, which are

likely to cause an impact on various environmental components, have been identified. For

evaluation of impacts due to proposed expansion of manufacturing activities of the unit, the

baseline data generated for environmental parameters presented at chapter - 3 of this report

has been utilized. Changes in the environmental parameters and their impact, whether short

term or long term, positive or negative are identified & predicted and described in this chapter.

All necessary mitigative measures to combat the likely environmental impacts associated with

the project activities have been listed in this chapter.

Of the various techniques available for the impact identification like checklists, matrices

networks, cause-effect diagrams, computer simulation models etc., Matrix method has been

used for the impact identification of the project.

4.2 IDENTIFICATION OF IMPACTS

An attempt has been made to identify the environmental impacts associated with the different

components of the project by establishing cause-effect relationship through impact

identification matrix as presented at Table no. 4.1. This method uses a matrix format to relate

project actions with environmental components. The column of the matrix consists of all the

project actions (short-listed as per specific project) against rows of the matrix of environmental

components (attributes). If a project action is likely to make an impact on environmental

component, the appropriate cell is marked.


4.2.1 IDENTIFICATION OF IMPACTING ACTIVITIES

Various activities involved in the proposed expansion project are divided viz.:

A. Commissioning phase activities

B. Operation phase activities

For the expansion phase of the project, there is no need of construction / civil work, as the new

vessels / machineries has to be installed in existing structure having available space. In absence

of any construction activity required for the expansion, no impact for construction phase has

been identified.

The activities identified for the proposed project under each phase are :

A. Commissioning Phase

1. Transportation of equipments & machineries

2. Installation of equipments & machineries

B. Operation phase

1. Plant operation

2. Material storage and handling

3. Utilities & Services

4. Green belt development

4.2.2 IDENTIFICATION OF ENVIRONMENTAL ATTRIBUTES

Environmental attributes likely to be affected due to activities involved in different components

of different phases are:

1. Water environment

2. Air environment

3. Noise environment

4. Ecology

5. Socio-economic Environment

a) Employment generation

b) Occupational Health & Safety


Table No. 4.1 IMPACT IDENTIFICATION MATRIX

4.3 IMPACT ASSESSMENT

4.3.1 Impact on Water Environment

Water is essential for human, agriculture, industry and commercial use. The water environment

broadly covers the following points for consideration of impacts:

a) Industrial operations, their effect on water quality and quantity.

b) Identifying potential sources of pollutants focusing specifically on discharge of

wastewater.

PROJECT

ACTIVITY

ENVIRONMENTAL ATTRIBUTES

Water

quantity

Water

quality

Air quality Noise Terrestrial

Ecology

Socio-economic Environment

Employment

Generation

Occupation-

al Health &

Safety

COMMISSIONING PHASE

Transportation of

equipments /

machineries

X X X

Installation of

machineries /

equipments

X X

OPERATION PHASE

Plant operations X X X X X X

Material storage &

handling

X X X

Utilities & Services X X X X X

Green belt

development

X X X X X X


The ultimate water requirement for the proposed expansion of manufacturing plant has been

presented at Table no. 2.7. The source of water supply is Sachin Infra Management Ltd.

The anticipated quantity of effluent generated from the industrial plant is @ 25 KLD in the

worst case scenario of alternative products. The effluent will be treated in Treatment plant

having primary and secondary treatment units. The treated effluent confirming to the norms

will be sent to CETP of Globe Enviro Care Ltd. for further treatment as per present practice. The

quantity of effluent being sent to CETP will be 5% of the present treatment capacity of CETP

capacity which is going to expand further, leading to decrease in total contribution. As there is

no direct withdrawal of ground water as well as no direct disposal into environmental sink,

impact of water environment due to proposed expansion project is insignificant in nature.

Some of the mitigation measures to minimize the likely environmental impacts on water

environment, due to operation of the proposed project are described below :

Sr. No.

Environmental Attribute

Mitigation Measure

1 Water Record of water consumption to be maintained through providing water meter at strategic location

Proper handling of spillages if any will be ensured by introducing spill control procedures for various chemicals.

Proper facilities for storage of raw materials (i.e. with roof and pucca floor) will be provided to prevent storm water contamination during the storage of various raw materials.

ETP Operation shall be done efficiently to meet the CETP inlet norms and any deviation shall be subjected root cause anlaysis.

Monitored data will be analyzed and reviewed at regular intervals and compared with the operating standards so as to take necessary corrective actions.

Enough care will be taken to prevent any leakages / accidental spillages from ETP units in order to avoid any ground water resource contamination.

The regular environment monitoring will be carried out through established laboratory.


4.3.2 Impact on Air Environment

The unit has installed natural gas fired boiler of 1.5 TPH capacity, which is being utilized at 20 –

25% capacity at present. For the expansion phase, full capacity utilization of boiler will be

carried out alongwith installation of gas fired Hot air generators (4 Nos.). Hence, no air pollution

control measure is required for the control of flue gas emissions, There will be process emission

from sulfonation vessel which will be controlled by installing water scrubber followed by alkali

scrubber with the reaction vessel.

Vehicular traffic associated with the commissioning as well as operation phase of the proposed

expansion project for transportation of raw materials and finished products lead to increased

concentration of SPM, NOx, CO etc., through exhaust gases from their original concentration in

the surrounding environment, affecting the ambient air quality of surrounding areas. However,

this effect remains localized near to the plant site during the time of vehicular movement only.

Increased level of concentration associated with exhaust gases will return to its original state

with the passage of time. Hence, this impact is envisaged as short term negative and reversible

in nature. Air quality will be adversely affected for small period of time, during transportation,

loading & unloading of various materials etc. This impact will be negative in nature for

prevailing ambient air quality but it will last for short period of time and will remain confined

within the plant premises.

4.3.2.1 Sources:

The identified air pollution sources along with the control systems are given at Table no. 4.5 &

4.5[a]. The impacts on the air quality have been assessed for the operation of the boiler, hot air

generator and sulphonator. The major air pollutants anticipated, due to boiler and hot air

generator operation, are Particulate Matter, Sulphur Dioxides and Oxides of Nitrogen and

Sulphur dioxides and HCL for Sulphonator. The emission rate of conventional air pollutants,

during operation phase, have been calculated based on the emission factors given in USEPA

Factor Information Retrival System. The other relevant data for running of the model such as

stack height, stack top & internal diameter, stack gas velocity, flue gas temperature, etc. have

been selected based on the standard practices of design and construction of boilers and

practical experience.


Table No. 4.5 Details of Proposed Flue Gas Emission Sources

For Flue Gas Emission

Sr No

Stack Attached To

Emission Load (gm/sec) Type

of Fuel Total Fuel (Scm/hr)

Height of Stack

(m)

Gas exit Temp (K)

Velocity (m/s)

Inside Dia of Stack (m)

Pollution Control

PM Sox NOx

1 Boiler 0.0041 0.0003 0.053 Natural

Gas 120 11 413.15 5 0.45

As Natural Gas is to be used as fuel, APC is not applicable, Stack sampling facility will

be provided 2

Hot air generator

0.0005 0.00004 0.007 Natural

Gas 15 12 413.15 5 0.45

For Process Gas Emission

Sr No

Stack Attached To

Emission Load (gm/sec) Production

(tpy)

Height of Stack

(m)

Gas exit Temp (K)

Velocity (m/s)

Inside Dia of Stack (m)

Pollution Control Sox HCL

1 Sulphonator 0.0008 0.0002 60 15 323.15 1.25 0.5 water scrubber

followed by alkali scrubber


4.3.2.2 Dispersion Modelling :

The impact on air quality due to emissions from single source or group of sources is

evaluated by use of mathematical models. When air pollutants are emitted into the

atmosphere, they are diffused into atmosphere, transported and diluted due to winds. The air

quality models are designed to simulate these processes mathematically and to relate

emissions of primary pollutants to the resulting downwind air quality. The inputs include

emissions, meteorology and surrounding topographic details to estimate the concentration of

conservative air pollutants. The Industrial Source Complex – Short Term Version 3 (ISCST-3)

AERMOD model has been developed to simulate the effect of emissions from point sources on

air quality. The ISCST-3 model was adopted from the USEPA guideline models and routinely

used as a regulatory model to simulate plume dispersion and transport. ISCST–3 (Steady-state

Gaussian Plume Dispersion Model) is the state of the art model with USEPA and extensively

used for predicting the Ground Level Concentrations (GLCs) of conservative pollutants from

point, area and volume sources. The impacts of primary air pollutants are predicted using this

air quality model keeping in view the plain terrain at the project site. The maximum ground

level concentrations of PM10, SO2 and NOx were computed using hourly meteorological data

during the study period.

The additional considerations made in the prediction are as under :

The flue gas volumetric rates & source strength was calculated based on the ultimate

analysis of the fuel and its loading rate. Excess air has also been added to the actual air

requirement for combustion. Details about proposed stack are presented at Table No. –

4.5.

The terrain of the study area was considered as FLAT with no flag pole.

Emission rates from the point sources were considered as constant during the entire

period.

The mixing height for the region from CPCB’s publication “Atlas of Hourly Mixing Height

& Assimilative capacity of Atmosphere in India” has been considered in the model.


Stability class has been determined based on solar insolation as obtained from using

Longitude and Latitude of the project site and cloud cover.

Meteorological data for the project area has been obtained for a period starting from

December 2011 to February 2012.

4.3.2.3 Results:

The ISCST-3 model AEROMOD-View software has been run considering the conditions as

mentioned above. The maximum 24 hourly average GLC values for SOx, NOx, PM10 and HCL for

proposed scenario are given in Table No. 4.6, Table No. 4.7 Table No. 4.8 and Table No 4.9

respectively. Isopleths for 24 hourly predicted values for SOx, NOx, PM and HCL for proposed

scenario are generated which are shown in Figure No. 4.1, Figure No. 4.2, Figure No. 4.3 and

Figure 4.4 respectively.


Table No. 4.6 : The Max 50 (24-Hr) Average Concentration values For SOx

Discrete Receptor ID (Group

Name)

X Y Avg. Conc. [ug/m^3]


Name)


1 -34.2 -93.97 0.16193 26 50 86.6 0.04076

2 -50 -86.6 0.15545 27 34.2 -93.97 0.03807

3 -76.6 -64.28 0.13999 28 50 -86.6 0.035

4 -64.28 -76.6 0.13972 29 -684.04 -1879.39 0.03353

5 -86.6 -50 0.13923 30 0 -1000 0.03087

6 -17.36 -98.48 0.12801 31 -939.69 -342.02 0.028

7 -93.97 -34.2 0.10878 32 -86.6 50 0.02796

8 0 -100 0.08901 33 34.2 93.97 0.02469

9 -98.48 -17.36 0.07876 34 -1000 0 0.02252

10 100 0 0.07156 35 -985.02 -2706.31 0.02179

11 98.48 17.36 0.07049 36 -1026.06 -2819.08 0.0207

12 -100 0 0.06896 37 -642.79 -766.04 0.02027

13 86.6 -50 0.06317 38 -1060.26 -2913.05 0.01986

14 93.97 34.2 0.06312 39 -1101.3 -3025.81 0.01892

15 -342.02 -939.69 0.06178 40 -766.04 -642.79 0.01837

16 17.36 -98.48 0.06101 41 0 -2000 0.01661

17 76.6 64.28 0.06035 42 1000 0 0.01632

18 86.6 50 0.06026 43 -939.69 342.02 0.01553

19 76.6 -64.28 0.05943 44 939.69 342.02 0.01522

20 98.48 -17.36 0.05897 45 -1323.62 -3636.61 0.01488

21 -98.48 17.36 0.05762 46 -1879.39 -684.04 0.01476

22 64.28 76.6 0.05438 47 -1368.08 -3758.77 0.01423

23 93.97 -34.2 0.054 48 -76.6 64.28 0.01369

24 64.28 -76.6 0.04719 49 -500 -866.03 0.01267

25 -93.97 34.2 0.04395 50 -2000 0 0.01261


Table No. 4.7: The Max 50 (24-Hr) Average Concentration values For NOx


Name)

X Y Avg.

Conc. [ug/m^3]


Name)


1 -64.28 -76.6 3.84578 26 -985.02 -2706.31 0.99917

2 -34.2 -93.97 3.67975 27 93.97 -34.2 0.97725

3 -50 -86.6 3.53911 28 64.28 -76.6 0.97473

4 -76.6 -64.28 3.43247 29 -939.69 -342.02 0.96945

5 -17.36 -98.48 3.33832 30 -1026.06 -2819.08 0.9554

6 -86.6 -50 3.09179 31 -1060.26 -2913.05 0.92111

7 -93.97 -34.2 2.61558 32 50 86.6 0.9081

8 0 -100 2.35595 33 -1101.3 -3025.81 0.88238

9 -342.02 -939.69 2.05128 34 -642.79 -766.04 0.87969

10 -98.48 -17.36 1.99277 35 34.2 -93.97 0.81489

11 100 0 1.60166 36 -766.04 -642.79 0.77964

12 98.48 17.36 1.56929 37 50 -86.6 0.75653

13 -100 0 1.54598 38 0 -2000 0.72911

14 -684.04 -1879.39 1.43181 39 -86.6 50 0.71171

15 93.97 34.2 1.39138 40 -1000 0 0.7109

16 17.36 -98.48 1.38106 41 -1323.62 -3636.61 0.71053

17 76.6 64.28 1.36132 42 -1368.08 -3758.77 0.68246

18 -98.48 17.36 1.34811 43 -500 -866.03 0.65695

19 86.6 50 1.34027 44 -1879.39 -684.04 0.64831

20 98.48 -17.36 1.30784 45 939.69 342.02 0.56723

21 64.28 76.6 1.22641 46 -939.69 342.02 0.55786

22 86.6 -50 1.20139 47 34.2 93.97 0.54317

23 76.6 -64.28 1.19723 48 -2000 0 0.53334

24 -93.97 34.2 1.07751 49 1000 0 0.53172

25 0 -1000 1.04378 50 -866.03 -500 0.52851


Table No. 4.8: The Max 50 (24-Hr) Average Concentration values For PM


Name)

X Y Avg.

Conc. [ug/m^3]


Name)


1 -64.28 -76.6 0.29511 26 -985.02 -2706.31 0.07662

2 -34.2 -93.97 0.28239 27 93.97 -34.2 0.07502

3 -50 -86.6 0.2716 28 64.28 -76.6 0.07481

4 -76.6 -64.28 0.2634 29 -939.69 -342.02 0.07436

5 -17.36 -98.48 0.25618 30 -1026.06 -2819.08 0.07326

6 -86.6 -50 0.23728 31 -1060.26 -2913.05 0.07063

7 -93.97 -34.2 0.20076 32 50 86.6 0.06969

8 0 -100 0.1808 33 -1101.3 -3025.81 0.06766

9 -342.02 -939.69 0.15735 34 -642.79 -766.04 0.06746

10 -98.48 -17.36 0.15292 35 34.2 -93.97 0.06254

11 100 0 0.12292 36 -766.04 -642.79 0.05979

12 98.48 17.36 0.12044 37 50 -86.6 0.05806

13 -100 0 0.11865 38 0 -2000 0.05592

14 -684.04 -1879.39 0.1098 39 -86.6 50 0.05462

15 93.97 34.2 0.10678 40 -1000 0 0.05453

16 17.36 -98.48 0.10599 41 -1323.62 -3636.61 0.05448

17 76.6 64.28 0.10447 42 -1368.08 -3758.77 0.05233

18 -98.48 17.36 0.10346 43 -500 -866.03 0.05037

19 86.6 50 0.10286 44 -1879.39 -684.04 0.04972

20 98.48 -17.36 0.10037 45 939.69 342.02 0.04351

21 64.28 76.6 0.09412 46 -939.69 342.02 0.0428

22 86.6 -50 0.09222 47 34.2 93.97 0.04169

23 76.6 -64.28 0.09189 48 -2000 0 0.0409

24 -93.97 34.2 0.08269 49 1000 0 0.04079

25 0 -1000 0.08007 50 -866.03 -500 0.04052


Table No. 4.9: The Max 50 (24-Hr) Average Concentration values For HCL


Name)

X Y Avg.

Conc. [ug/m^3]


Name)


1 -34.2 -93.97 0.03529 26 50 86.6 0.0089

2 -50 -86.6 0.03385 27 34.2 -93.97 0.00836

3 -76.6 -64.28 0.03059 28 50 -86.6 0.00768

4 -64.28 -76.6 0.03047 29 -684.04 -1879.39 0.00635

5 -86.6 -50 0.03043 30 0 -1000 0.00625

6 -17.36 -98.48 0.02727 31 -86.6 50 0.00598

7 -93.97 -34.2 0.02377 32 -939.69 -342.02 0.00563

8 0 -100 0.01891 33 34.2 93.97 0.0054

9 -98.48 -17.36 0.01724 34 -1000 0 0.00462

10 100 0 0.01562 35 -985.02 -2706.31 0.00403

11 98.48 17.36 0.0154 36 -1026.06 -2819.08 0.00382

12 -100 0 0.01505 37 -642.79 -766.04 0.00382

13 86.6 -50 0.01409 38 -1060.26 -2913.05 0.00366

14 93.97 34.2 0.01381 39 -766.04 -642.79 0.00349

15 17.36 -98.48 0.0133 40 -1101.3 -3025.81 0.00348

16 86.6 50 0.01317 41 1000 0 0.00333

17 76.6 64.28 0.01316 42 0 -2000 0.00316

18 76.6 -64.28 0.01316 43 -939.69 342.02 0.00309

19 98.48 -17.36 0.01289 44 939.69 342.02 0.003

20 -342.02 -939.69 0.01254 45 -76.6 64.28 0.00293

21 -98.48 17.36 0.0125 46 -1879.39 -684.04 0.00277

22 93.97 -34.2 0.01212 47 -1323.62 -3636.61 0.00271

23 64.28 76.6 0.01186 48 17.36 98.48 0.00268

24 64.28 -76.6 0.01042 49 -1368.08 -3758.77 0.00259

25 -93.97 34.2 0.00946 50 -2000 0 0.0024


Figure No. 4-1: Isopleths for Concentration of SO2 due to emission from stacks for proposed scenario


Figure No. 4-2: Isopleths for Concentration of NOx due to emission from stacks for proposed scenario


Figure No. 4-3: Isopleths for Concentration of PM due to emission from stacks for proposed scenario


Figure No. 4-4: Isopleths for Concentration of HCL due to emission from stacks

for proposed scenario


4.3.2.4 INTERPRETATION:

It may be noted from the computed results for the proposed scenario that the maximum 24

hourly average GLC’s value for proposed scenario as 0.16 g/m3 for SO2, 3.84 g/m3 for Nox

and 0.29 g/m3 for Particulate Matter and 0.03 forg/m3 HCL. These GLC’s are expected to

occur at a distance of 100 m from the source towards the South South West (SSW) direction.

For the purpose of the impact assessment, the more relevant determination for anticipated

pollutants is the incremental increase in the background concentration rather than the

determination of maximum GLC values. In the present study, an attempt has been made to

determine the increase in the concentration of PM10, SO2 and NOx for villages where the

ambient air quality stations were established through a substitution of relevant data in the

ISCST-3 model. The resultant concentration thus obtained along with the background levels are

present in Table no. – 4.9.

Table No. 4.9 Resultant Concentration Value

Location Background Average

Conc. Incremental Conc. Resultant Conc.

Particulate Matter µg/m3 (Permissible Limit :100 µg/m3)

Site 130.89 0.29 131.18

Umber 119.55 0.006 119.56

Pardi Kanade 93.60 0.008 93.61

Pali 118.23 0.007 118.24

Saniya 59.55 0.004 59.55

Talangpor 117.70 0.007 117.71

Bamroli 62.13 0.003 62.13

SO2 µg/m3 (Permissible Limit :80 µg/m3)

Site 10.46 0.16 10.62

Umber 7.84 0.02 7.86

Pardi Kanade 10.94 0.002 10.94

Pali 10.48 0.001 10.48

Saniya 9.69 0.001 9.69


Talangpor 9.62 0.002 9.62

Bamroli 17.15 0.009 17.16

NOx µg/m3 (Permissible Limit :80 µg/m3)

Site 31.47 3.84 35.31

Umber 30.46 0.07 30.53

Pardi Kanade 32.68 0.11 32.79

Pali 31.49 0.09 31.58

Saniya 30.13 0.05 30.18

Talangpor 30.24 0.10 30.34

Bamroli 38.06 0.05 38.11

Although the incremental concentration due to proposed project for Particulate Matter

is negligible, as it ranges between 0.003 – 0.29 µg/m3, but the resultant values at 4 sites exceed

the permissible limit due to the high background values. While, as far as SO2 and NOx,

incremental concentrations are concerned, the contribution from the proposed source is

negligible and the resultant concentration values remain well below the permissible limits.


As part of precautionary measure, to minimize the likely environmental impacts on air

environment due to the proposed project, necessary mitigation measures are described below:

Sr.

No.

Environmental

Attribute

Mitigation Measures

All transferring and feeding areas will be well covered to avoid

any fugitive emissions.

For the plant area, proper ventilation will be provided on the

shop floor for proper air circulation to maintain the work area

air quality.

Proper preventive maintenance of fuel firing system will be

ensured.

Efficient working of proposed APC system will be ensured with

its periodical monitoring.

It will be ensured that the vehicles to be deployed at the site

should have PUC certification.

4.3.3 Impact on Land / Soil quality

The proposed expansion project is to be carried out within existing premises, which is located in

notified industrial estate, hence, there will not be any conflict in change of landuse pattern. So,

no impact has been envisaged on existing land use pattern of the project site.

Solid / hazardous waste generated from production activity will be stored separately in

Hazardous Waste storage area within the factory premises. The hazardous waste storage area

will have non-percolating RCC floor and covered roof. Hence, no significant negative impact has

been envisaged on the surrounding soil quality due to presence of solid / hazardous waste

within the plant premises.

Necessary mitigation measures to minimize the likely environmental impacts on soil quality /

land environment due to operation of the proposed unit is described below :


Sr.

No.

Environmental

Attribute

Mitigation Measures

1

Soil quality / Land

environment

There will be adoption of practice of segregation and storage

of all hazardous solid waste generated from the production

plant.

Regular record keeping of volumes / weights of wastes

generated and disposed will be maintained.

Proper storage, handling and disposal of all type of hazardous

solid wastes as per the guidelines prescribed will be ensured.

Any spillage of hazardous chemicals on land area of plant

premises should be avoided.

4.3.4 Impact on Noise Environment

Vehicular movement for transportation of various raw materials and finished products is one of

the sources of noise generation during operation phase of the project. Noise generation

associated with vehicular movement within the plant premises will increase ambient noise

levels for shorter period of time and the negative impact generated due to this will get reversed

with the passage of time. Operation of manufacturing plant and machineries, will be

contributing to noise generation during operative phase.

Necessary mitigation measures to minimize the likely environmental impacts on noise

environment due to operation of the proposed project are described below:

Sr.

No.

Environmental

Attribute

Mitigation Measures

1

Noise

High noise generating machines and processes will be enclosed

and insulated.

Insulation of ventilation pipes and use of dampers will be made at

all possible places.

Implementation of management control on site for limiting

transportation timing by adopting mechanical and technological

ideas.

Preventive maintenance schedule will be followed for all

instruments and machineries to maintain good working condition.

Enclosures and barriers will be provided to pumps and


machineries producing high noise levels, required for proposed

project.

There will be periodical noise level measurements for verifying

compliance with relevant laws.

Workers exposed to high noise generating operations will be

provided with suitable ear protection devices.

4.3.5 Impact on Biological Environment

As project location is within notified industrial estate, no significant impact associated with

displacement of prevailing floral & faunal species is envisaged on surrounding biological

environment due to proposed project activity.

There will not be any discharge of effluent from the plant directly into any water body; hence

there will not be any impact on aquatic ecology of the surrounding area.

There is no forest / national park / sanctuary / protected area within 10 km radius from the

project site.

Air emissions generated within the plant premises will be always kept within the prescribed

limit and hence no significant impact on terrestrial ecology is expected.

4.3.6 Impact on Socio-economic Environment

Unit will provide employment opportunity to locally available skilled and un-skilled labours

within its manufacturing facility as per the requirement, which is a positive impact on prevailing

socio-economic environment.

Impact in terms of displacement of habitation and settlements due to the proposed project

is totally absent as the unit is within industrial estate.

Increased vehicular movement associated with the project operation phase will have short

term negative impact on noise and air environment surrounding the plant site.

No loss or disturbance of any historic and cultural heritage is associated with the proposed

project.

Proposed project will provide the surrounding region business potential as well as

subsequent employment opportunities.


Existence of proposed project will lead to increase in the job opportunities for the qualified

and skilled as well as unqualified and unskilled people in project region.

This industrial development along with employment potential poses long-term positive impact

on the socio-economic environment as it provides benefits in terms of economics to the people

employed with it.

Actions for Socio - Economic Environment

Locally available man-power will be employed by the management in the manufacturing

activity. A full-fleged emergency preparedness plan will be prepared to deal with fire fighting,

evacuation and local communication. Organization will provide basic amenities viz. safe

drinking water, sanitation facility & medical treatment for workers of the unit.

4.3.7 Impact on Occupational Health & Safety

In the operation phase of the project, various effects on occupational health and safety of the

employees working in the plant are envisaged. Major health and safety issues encountered will

be physical hazards, respiratory hazards, electrical hazards, noise, fire & explosion hazards

associated while working within manufacturing plant. Also, chemical industry poses risks such

as accidents due to spillage, fire and explosion. Preventive safety measures taken to minimize

the risk of accident with respect to chemical handling will be as follows :

Sr.

No.

Environmental

Attribute

Mitigation Measures

1

Occupational

Health & Safety

All reasonably practical measures will be adopted by the unit to

minimize the risk of accidents within the manufacturing unit.

Trained workers will be employed for all the hazardous process

operations within the plant and will be supervised by experienced

supervisors.

Safety features such as fire extinguishers at strategic locations

and suitable personal protective equipments will be provided.

Flame-proof electrical fittings, flame arrestors etc., will be

installed.

All the raw materials will be stored in designated storage area

equipped with necessary safety features.


Periodic inspection & testing of pressure vessels, equipments,

machineries will be done.

Good house-keeping will be ensured within the factory premises.

Training will be provided to the designated staff & workers for fire

fighting, work permit system, first aid & safe handling of


Incident / accident reporting system will be developed and all the

employees will be made aware for the same.

Suitable notices / boards will be displayed at designated locations

indicating appropriate hazard warnings.

Antidotes as well as MSDS for all the chemicals will be made

available within the factory premises.

With effective implementation of the mitigative measures and keeping the workers well

equipped with necessary personal protective equipments and training for the safety aspects to

be followed during working hours, the occupational health and safety impacts can be

controlled.


CHAPTER – 5


CHAPTER – 5

ENVIRONMENTAL MONITORING PROGRAM

5.1 OBJECTIVE

Regular monitoring program of the environmental parameters is essential to take into

account the changes in the environment. The objective of environmental monitoring

program is:

To verify the results of the impact assessment study with regards to the

development

To follow the evolution of parameters which have been identified as critical

To check the effectiveness of the environment management system in operation

To confirm statutory compliance

To establish a data base for future impact assessment studies

5.2 ENVIRONMENT MONITORING & CONTROL

To implement midterm corrective measures as well as to achieve effective

implementation of the same, environment monitoring and control program is essential.

Regular monitoring of environmental parameters is of immense importance to assess the

status of environment during project operation. With the knowledge of baseline

environmental status, monitoring program will serve as a tool to assess any deterioration

in environmental conditions due to operation of the project.

Generally the EIA study for any project is carried out over a short period of time and the

data generated cannot bring out all variations induced by natural or human activities.

Hence, regular monitoring program is essential to take into account the changes in the

environment quality.

Scope of the monitoring program generally focuses on various environmental parameters

viz., Air quality, Water quality, Noise, Soil characteristics, Ecology, Land use pattern and

socio-economic environment. However, location of the proposed expansion project being


within a notified industrial estate, monitoring of various environmental parameters will

be required to assess proper functioning and efficiency of all the proposed pollution

control systems. For the proposed project, monitoring activity is mainly envisaged for

stack emissions to analyze the performance of APC system, to check treated wastewater

quality to analyze the performance of ETP and to measure the prevailing noise levels due

to plant operation.

5.3 PROPOSED MONITORING PROGRAM

With the knowledge of baseline environmental status and anticipated impacts,

monitoring programme will serve as a tool to assess any deterioration in environmental

condition due to operative phase of the project. Scope of the monitoring programme

generally focuses on various environmental attributes / indicators. Proposed monitoring

program for the unit is shown at Table No : 5.1.

Table No : 5.1 Environment Monitoring Schedule

Sr.

No.

Particulars Frequency of

Monitoring

Duration of

Monitoring

Parameters for

Monitoring

1 Air Quality

a. Ambient Air Quality

Monitoring

Plant premises and at

three locations within 5

km radius

Once in quarter One 24 hourly

sample

PM10, SOx, NOx

b. Stack Monitoring (flue gas

and process emissions)

Once in a

month

-- PM10, PM2.5, SOx,

NOx

2 Water and Wastewater Quality


2a. Raw water quality Once in a

month

Grab General

parameters such

pH, TDS, Chlorides

2b. Wastewater quality

(i) Quality of raw effluent Daily -- For parameters

issued through

consent by GPCB (ii) Quality of treated effluent

3 Noise Quality

a. Within plant premises at

identified locations

Once in three

months

-- Leq Levels

b. At the periphery of plant

premises at least 5

locations

-- Day and night time

Leq levels

4 Work zone monitoring Once in three

months

8 hourly SPM

5 Solid waste generation Records of quantity of generation, handling, storage and

transportation of solid and hazardous waste to be

maintained and updated daily

6 Employee Health Pre-employment and periodical health check-up of

every employee at least once in six months


5.4 MONITORING METHODS & DATA ANALYSIS

5.4.1 Air Quality Monitoring

Stack Monitoring

Emissions from all the stacks should be monitored regularly. Exit gas temperature,

velocity and pollutant concentration shall be measured. Air blowers should also be

checked for any drop in exit gas velocity.

Work zone Monitoring

Concentration of air-borne pollutants in the work-space / work zone should be monitored

periodically. Work zone monitoring should be carried out in respect of particulate matter

concentration. If concentrations beyond threshold limits are observed than the source

should be immediately identified and necessary corrective measures should be taken.

Ambient Air Quality Monitoring

Ambient concentrations of PM2.5, PM10, SOx, NOx should be monitored at regular

intervals. Any abnormality should be investigated to identify the causes and appropriate

action should be initiated.

5.4.2 Noise Monitoring

Work zone noise at high noise generating work areas within the plant premises and

ambient noise in surrounding areas of project site should be measured at periodical

intervals. Periodical audiometric tests should be conducted for the workers working at

high noise generating areas.

5.4.3 Water quality Monitoring

For strict control over water consumption, flow meters should be installed at water inlets.

All leakages shall be identified and rectified. Methods prescribed by APHA should be

adopted for monitoring of water quality.


5.4.4 Wastewater quality Monitoring

Wastewater stream shall be monitored for flow rate and physical and chemical

characteristics. Monitoring shall be carried out for raw & treated effluent. Such analysis is

required for wastewater at the source of generation and to explore the possibility for re-

use of the same.

5.4.5 Data Analysis

All environmental monitoring data should be stored as a computer database for proper

storage, retrieval and interpretation of the same. A regular database format should be

maintained to keep a track of monitored parameters and causes should be identified in

case of non-conformity with the permissible limits.

5.5 REPORTING SCHEDULES OF THE MONITORING DATA

Voluntary reporting of environmental performance with reference to EMP will be

undertaken. The in-charge of environment, health and safety department of the unit has

to co-ordinate all monitoring programmes at site and data generated shall be submitted

regularly to the statutory agencies. Frequency of reporting shall be once every six months

to concern Authority.

5.6 INFRASTRUCTURAL REQUIREMENT

MoEF / GPCB recognized agencies should be deployed for carrying out regular

environment monitoring. The recurring cost towards environment pollution control and

environmental monitoring will be @ Rs. 5 Lakhs / month.


CHAPTER – 6


CHAPTER – 6

RISK ASSESSMENT AND DISASTER MANAGEMENT

6.1 INTRODUCTION :

M/s. Panchsheel Intermediates is in existence at Plot No. 8101, GIDC Sachin, Surat,

Gujarat. The unit is involved in manufacturing of acid dyes and solvent dyes @ 6 MT/M

at the premises.

Company has commenced its operations with capacity of @ 6 MT/Month which has

been planned to expand upto @ 34.5 MT/Month by way of inclusion of additional

alternative products.

6.2 APPROACH TO STUDY :

Present study has been carried out to assess the risk involved in the proposed project.

The study specifically focuses on the followings :

1. Hazard Identification.

2. Hazard Mitigation Measures.

3. Risk Assessment & Mitigation.

4. Safety Management System.

5. Occupational Health and Safety Management System.

6. Disaster Management Plan.

6.3 HAZARD IDENTIFICATION :

Risk is a probability that damage to life, health and or the environment, will occur as a

result of the hazard.

Hazard is an inherent property of a substance, agent, and source of energy or situation

having potential of causing undesirable consequences.

The following two methods of hazard identification have been employed in the study :

Identification of major hazards based on Manufacture, Storage, and Import of

Hazardous Chemicals Rules, 1989, Government of India, as amended till date.

Primary Hazard Analysis.


Following are the various hazards considered during proposed project :

Material Handling and Storage Hazard.

Fire ad Explosion Hazard.

Electrical Hazard.

Mechanical Hazard.

Toxic Gas Release Hazard.

Corrosion Hazard.

6.3.1 Material Handling and Storage Hazard :

Hazards in Manual as well as Mechanical handling of materials are identified as the

chances of accident due to loading, unloading and transportation of hazardous as well as

non-hazardous material.

The following hazardous chemicals are used and stored at Panchsheel Intermediates for

the production of acid dyes and solvent dyes :

Table No. 6.1 Details of Raw Material Storage.

Sr.

No. Raw Material*

Method of

Storage

Maximum Storage Capacity

at a time, (MT)

1 Hydrochloric Acid HDPE Tank 7

2 Ammonia HDPE Tank 5

3 Iso Propyl Alcohol (IPA) HDPE Tank 1

4 Caustic Soda Lye HDPE Tank 5

5 Methyl Ethyl Glycol (MEG) MS Tank 6 (2 Nos.)

6 Chloro Sulphonic Acid MS Tank 15

*Being multiproduct manufacturing industry, inventory of other hazardous materials is

very small which eventually reduces the quantity of potential release. Hence, they are

not considered in the study.

The important characteristics of principal hazardous chemicals used and stored at

Panchsheel Intermediates for the manufacturing of acid dyes and solvent dyes are

shown in Table No. 6.2.


Table No. 6.2 Principal Hazardous Chemicals Characteristics.

The Material Safety Data Sheets of the principal hazardous material are attached as Annexure - H.

SR. NO.

FULL NAME RAW MATERIAL

STATE – SOLID, LIQUID OR GAS

NO. OF CONTAINER

AND SIZE

STORAGE PARAMETERS

MAIN PROPERTIES (REFER MSDS, SCH‐9 OF MSIHC RULES)

No. MT Pressure Kg/cm2

Temp. °C

B.P. °C

F.P. °C

LEL UEL %

TLV Ppm

or mg/m3

LD50

mg/kg LC50

mg/L

Specific gravity

(Water=1)

Vapour density (Air=1)

Odor threshold

ppm or

mg/m3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 Caustic Soda Lye Solid 1 5 1390 318 -- 2 -- 1.51 Not

Available --

2 Ammonia Liquid 1 5 -- -- -- 2000 ppm 0.90 0.59 ‐‐ --

3 Hydro Chloric Acid Liquid 1 7 83 -- ‐‐ ‐‐ 90

mg/kg 1.1 to 1.19 1.267

0.25‐10 ppm

4 Chloro Sulphonic

Acid Liquid 1 15 158 ‐80 -- -- -- 1.76 4.02 --

5 Iso Propyl Alcohol

(IPA) Liquid 1 1 82.5 11.67 -- 3600 mg/kg 0.785 2.07

22 ppm

--

6 Methyl Ethyl Glycol

(MEG) Liquid 2 6 188 -59 -- -- 20800 mg/kg 1.036 2.62 --


6.3.2 Fire and Explosion Hazard :

The condition of events like spillage or leakage of flammable material, equipment

failures, presence of open flame or spark, static charge accumulation, open live cables

and reaction between incompatible materials are some of the reasons which lead to the

fire hazard.

It should be clearly understood that when a liquid is used having flash point below or

close to the normal ambient temperature, it could lead to fire in suitable circumstances,

liberate a sufficient quantity of vapor to give rise to flammable mixtures with air.

The condition of release of energy in a rapid and uncontrolled manner occurs, gives rise

to explosion hazard.

6.3.3 Electrical Hazard :

The circumstance where a worker can or does make electrical contact with any electrical

appliances / equipments, loose wiring, and static electricity could lead to electric hazard.

6.3.4 Mechanical Hazard :

The following mechanical hazards are considered during proposed project :

Handling of cranes, trolleys, construction machineries.

Handling of mechanical equipments like, drilling, shovel, fork lift, etc.

Handling of raw material, metal sheets and various mechanical accessories.

6.3.5 Toxic Gas Release Hazard :

The condition of ingestion, absorption and or inhalation of toxic substances leads to toxic

hazard. The condition of release of toxic gases and or toxic dust in the atmosphere, which

can be poisonous or harmful to personnel and environment, could leads to toxic gas

release hazard.

6.3.6 Corrosion Hazard :

Corrosion is a chemical reaction taking place at the surface of metal. Corrosive chemicals

have their typical hazard when it comes in contact with human tissues. Most corrosive

substances will produce chemical burns, while certain chemical produce deep ulceration.


Other has detailing effect on skin and may cause dermatitis. This has also adverse effects

on weakening the strength of material in contact.

6.3.7 Identified Hazards :

The major identified hazards in the M/s. Panchsheel Intermediates are described below :

Toxic hazard due to leakage of hazardous chemical like hydrochloric acid,

Ammonia, Caustic Soda Lye, Chloro Sulphonic Acid, etc.

Possibility of injury during chemicals handled, during operations, and due to

intoxication.

Fire hazard due to leakage of chemicals like isopropyl alcohol (IPA), Methyl Ethyl

Glycol (MEG), Light Diesel Oil (LDO), etc.

Explosion hazards in solvent tank farm and storage area (warehouse).

Electrical hazards due to the electrical major equipment / machinery, operations,

welding, motors, heavy lift devices, cabling, human intervention (short circuit

possibility), maintenance work (due to machinery breakdown, etc.), plant

lighting related electrical hazards.

Possibility of human injury due to working with mechanical machines.

Major dropped objects hazard due to large number of physical handling steps /

operations involved with crane / overhead lifting / hoisting equipment.

Possibilities of rapid escalation in case of fires in any part of the plant working

areas.

Possibilities of fire hazards at transformers, switchgear, and other electrical

equipment, etc.

6.4 HAZARD MITIGATION MEASURES :

Hazards cannot be eliminated totally in any activity. They can be only controlled and at

the most can be minimized. Risk associated with any activity is directly proportional to

the hazard control procedures and arrangements. The following measures should be

taken to minimize and / or control the hazards in the Panchsheel Intermediates premises.


6.4.1 Mitigation Measures for Material Handling and Storage Hazard :

The following preventive measures should be undertaken for handling and storage of

non-hazardous and hazardous materials :

Prior to working, concerned person has to be trained on proper handling and

storage of materials.

Only adult worker will be appointed for manual handling of hazardous

chemicals.

For lifting weight works, carrying capacity will be considered. Female worker will

be avoided for such type of job.

All tools and tackles used for material handling should be periodically inspected,

checked, and maintained by qualified person.

The records in form no. 10 prescribed under Factory Act’s Rule 60 containing

particulars of examination specifying safe working load should be maintained.

The certified engineers should test the safety valves every year for their

efficiency. The records of certificates should be maintained.

A regulated, marked area should be established where IPA , MEG and LDO is

handled, used, or stored.

Hazardous materials must be stored to avoid contact with even small amounts

of incompatible substances.

Hazardous materials should be stored in tightly closed containers in a cool well

ventilated area away from Heat, Sparks, or Direct Sunlight.

Sources of ignition such as smoking and open flames are prohibited where IPA,

MEG, & LDO are handled, used or stored.

Strictly use of only non sparking tools and equipment, especially for opening

and closing of containers.

Explosion proof electrical equipment and fittings should be use wherever IPA ,

MEG, & Diesel are used, handled, manufactured or stored.


Secondary containment for the storage of hazardous chemical should be

provided.

As part of an ongoing education and training, effort communicate all

information on the health and safety hazards to potentially exposed workers.

6.4.2 Mitigation Measures for Fire and Explosion Hazard :

The Panchsheel Intermediates should strictly follow the safety rules and regulation to

avoid circumstances which lead to fire hazard. Panchsheel Intermediates uses Flammable

chemicals (IPA, MEG, LDO, etc.). All flammable liquid materials having very less inventory

are to be stored in drums, whereas rest will be stored in storage tanks having dyke wall

around them.

The following steps shall be consider to prevent fire consequences during any stage of

material handling, operation or any other unexpected leakage :

Proper earthing connections for the all the equipments and bulk storage tanks

should be provided.

All the pipelines will be providing suitable earthing to handle static charges

safely.

All the electrical connections will do with flameproof fittings.

Hazardous materials are delivered, stored, and used at temperatures below

their flash point. Avoid all naked flames, sparks, cigarettes, etc.

Fire detectors with critical switches and alarms should be installed near those

points which handle large amount of explosives material and operates under

high temperature and pressure.

Fire system & various types (DCP, CO2, etc.) of fire extinguisher will be installed

as per Indian standards IS 7673 : 2004, as per Factories Act, 1948 and as per

Tariff Advisory Committee (TAC) guidelines.

The fire protection equipment shall be kept in good operating condition at all

time and firefighting system should be periodically tested for proper functioning

and logged for record and corrective actions.


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Proper care should be taken by providing remote switches for remote cutoff,

control systems (level indicator, temperature controller, pressure gauge, etc.),

dyke wall, rupture disk, pressure release valve, etc.

Detailed study shall be carried out for finding all the source of ignition while

handling the flammable materials and utmost care will be taken to avoid source

of ignition.

Only stainless steel (S.S.) braided hose will be used for safe transferring of

flammable materials.

The storage tanks will be provided with flame arrester.

The approval will be taken from concerning authority for storage, handling, and

use of hazardous materials.

The following measures shall be taken in case of fire :

In case of fire, immediately alert the fire fighting officials.

Ensure an escape path is always available from any fire.

If gas has ignited do not attempt to extinguish but stop gas flow and allow to

burn out. Use water spray to cool heat-exposed containers, and to protect

surrounding areas and personnel.

Use suitable extinguishing media (dry chemical, CO2, water spray, foam) for fire

extinguishing.

Continuous fire water supply should be available to the fire hydrant and

monitor nozzle.

Every precaution must be taken to keep containers cool to avoid the possibility

of a boiling liquid expanding vapor explosion (BLEVE).

If employees are expected to fight fires, they must be trained and equipped as

per statutory guidelines.

Shut off and isolation valves should be easily approachable in emergencies.

Fist aid appliances should be provided.


6.4.3 Mitigation Measures for Electrical Hazard :

All electrical installation shall be as per The Indian Electricity Act, 1910 and The Indian

Electricity Rules, 1956. The Earth Leakage Circuit Breaker (ELCB) will be installed for

human safety as and when required.

6.4.4 Mitigation Measures for Mechanical Hazard :

The following preventive measures should be undertaken to minimize and or control the

mechanical hazard :

All the installation shall be as per the related standards and codes.

All the rotating parts will be guarded properly.

Regular testing of equipments as per Form no. 9, 10, and 11 prescribed under

Factory Act’s Rule 58, 60, and 61respectively.

Plants should be designed as partly Reinforced Cement Concrete (R.C.C.) and

Steel Structure.

6.4.5 Mitigation Measures for Toxic Gas Release, and Chemical Hazards :

The Panchsheel Intermediates should have adequate provision of safety along with

personal protective equipments like breathing apparatus, gloves, safety glasses, etc. and

emergency kit.

Following are the preventative measures being undertaken to avoid the occurrence of

toxic gas release, explosion and corrosion hazards :

Only trained person should handle hazardous chemicals.

The Material Safety Data Sheet (MSDS) of each chemicals will be referred before

handling and storage.

Regular inspection, testing, and maintenance of hazardous chemical handling

and storage tanks.

Ensure proper and sufficient Personal Protective Equipments are available.


6.5 RISK ASSESSMENT AND MITIGATION :

Risk assessment can be stated as the identification, evaluation, and estimation of the

levels of risks involved in a situation, and determination of an acceptable level of the risk.

In any chemical plant, the various hazards arise due to improper storage & handling of

hazardous chemicals. If these chemicals are released into the atmosphere, they may

cause damage due to resulting fires or vapor clouds.

The following are the important factors which can lead to the consequences of hazard :

1. Operating Parameters :

Potential vapor release for the same material depends significantly on the operating

conditions i.e. Pressure, temperature, etc.

2. Inventory :

Inventory Analysis is commonly used in understanding the relative hazards and short

listing of release scenarios. Inventory plays an important role in regard to the potential

hazard. Larger the inventory of a vessel or a system, larger the quantity of potential

release. The potential vapor release (source strength) depends upon the quantity of

liquid release, the properties of the materials and the operating conditions (pressure,

temperature).

3. Loss of Containment :

Plant inventory can get discharged to environment due to loss of containment. Liquid

release from inventory can be either instantaneous or continuous. Failure of a vessel

leading to an instantaneous outflow assumes the sudden appearance of such a major

crack that practically all of the contents above the crack shall be released in a very short

time. The more likely event is the case of liquid release from a hole in a pipe connected

to the vessel. In the study, Maximum Credible Loss accident methodology is to be used,

therefore, the largest potential hazard inventories have been considered for

consequence estimation.


6.5.1 Catastrophe Criteria :

In consequence analysis, numbers of calculation models are used to estimate the

physical effects of an accident (spill of hazardous material) and to predict the damage

(lethality, injury, material destruction) of the effects. These calculations can be roughly

divided in to three major groups :

1. Determination of the source strength parameters.

2. Determination of the consequential effects.

3. Determination of the damage or damage distances.

The basic physical effect models consist of the following features :

1. Source Strength Parameters :

Calculation of the outflow of liquid, vapor or gas out of a vessel or a pipe, in case

of rupture. Also two-phase outflow can be calculated.

Calculation, in case of liquid outflow, of the instantaneous flash evaporation and

of the dimensions of the remaining liquid pool.

Calculation of the evaporation rate, as a function of volatility of the material, pool

dimensions and wind velocity.

Source strength equals pump capacities, etc. in some cases.

2. Consequential Effects :

Dispersion of gaseous material in the atmosphere as a function of source

strength, relative density of the gas, weather conditions and topographical

situation of the surrounding area.

Intensity of heat radiation [in KW/m2] due to a fire or a BLEVE, as a function of the

distance to the source.

Energy of vapor cloud explosions [in N/m2], as a function of the distance to the

distance of the exploding cloud.

Concentration of gaseous material in the atmosphere, due to the dispersion of

evaporated chemical. The latter can be either explosive or toxic.


The types of models that must be used in a specific risk study strongly depend upon the

type of material involved :

Gas, vapor, liquid, solid.

Inflammable, explosive, toxic, toxic combustion products.

Stored at high / low temperatures or pressure.

Controlled outflow (pump capacity) or catastrophic failure.

3. Selection of Damage Criteria : The damage criteria give the relation between extent of

the physical effects (exposure) and the percentage of the people that will be injured or

killed due to those effects. The knowledge about these relations depends strongly on the

nature of the exposure. For instance, much more is known about the damage caused by

heat radiation, than about the damage due to toxic exposure, and for these toxic effects,

the knowledge differs strongly between different materials.

In Consequence Analysis studies, in principle three types of exposure to hazardous

effects are distinguished :

Heat radiation, from a jet, pool fire, a flash fire or a BLEVE.

Explosion.

Toxic effects, from toxic materials or toxic combustion products.

6.5.2 Maximum Credible Loss Accident Scenario :

A Maximum Credible Accident (MCA) can be characterized as the worst credible

accident. In other words an accident in an activity, resulting in the maximum

consequence distance that is still believed to be possible.

A MCA analysis does not include a quantification of the probability of occurrence of the

accident. Another aspect, in which the pessimistic approach of MCA studies appears, is

the atmospheric condition that is used for dispersion calculations. As per the reference of

the study, weather conditions having an average wind speed of 1.8 m/s have been

chosen.


The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The

MCL cases considered, attempt to include the worst “Credible” incidents i.e. what

constitutes a credible incident is always subjective.

Only catastrophic cases have been considered in this study. Partial or small failures cab

be controlled by proper control mechanism, safety precautions and training. The

objective of the study is emergency planning. Hence, only holistic & conservative

assumptions are used for obvious reasons though the outcomes may look pessimistic,

the planning for emergency concept should be borne in mind whilst interpreting the

results.

6.5.3 Consequence Analysis Calculations :

The Consequence Analysis has been done for selected scenarios. This has been done for

weather conditions having wind speed 1.8 m/s. In Consequence Analysis, geographical

location of the source of potential release plays an important role. Consideration of a

large number of scenarios in the same geographical location serves little purpose if the

dominant scenario has been identified and duly considered.

ALOHA (Areal Locations Of Hazardous Atmospheres) :

ALOHA is a computer program designed especially for use by people responding to

chemical accidents, as well as for emergency planning and training. ALOHA can predict

the rates at which chemical vapors may escape into the atmosphere from broken gas

pipes, leaking tanks, and evaporating puddles. It can then predict how a hazardous gas

cloud might disperse in the atmosphere after an accidental chemical release.

ALOHA is an air dispersion model, which you can use as a tool for predicting the

movement and dispersion of gases. It predicts pollutant concentrations downwind from

the source of a spill, taking into consideration the physical characteristics of the spilled

material. ALOHA also accounts for some of the physical characteristics of the release site,

weather conditions, and the circumstances of the release. Like many computer

programs, it can solve problems rapidly and provide results in a graphic, easy-to-use


format. This can be helpful during an emergency response or planning for such a

response.

ALOHA provides output as amount of chemical discharged from the source as well as its

concentration in air it takes in to account different levels of concentrations for a specified

chemical. Different concentration levels are given below :

ERPG 1 : is the maximum airborne concentration below which it is believed that

nearly all individuals could be exposed for up to 1 hour without experiencing other than

mild transient adverse health effects or perceiving a clearly defined, objectionable odor.


nearly all individuals could be exposed for up to 1 hour without experiencing or

developing irreversible or other serious health effects or symptoms which could impair

an individual's ability to take protective action.


nearly all individuals could be exposed for up to 1 hour without experiencing or

developing life-threatening health effects.

IDLH : The Immediately Dangerous to Life or Health (IDLH) level. A chemical's

IDLH is an estimate of the maximum concentration in the air to which a healthy worker

could be exposed without suffering permanent or escape-impairing health effects.

6.5.4 Considered Scenarios :

The possible accidents scenarios at Panchsheel Intermediates are described below.

TABLE No. 6.3 Possible Accident Scenarios at Panchsheel Intermediates.

Scenario* MCL Pressure Temp. Storage

Quantity Past

history

1. Release of MEG Ambient Ambient 6000 kg (2 nos.)

Nil

2. Release of Iso Propyl Alcohol Ambient Ambient 1000 kg Nil

3. Release of Hydrochloric Acid Ambient Ambient 7000 kg Nil

4. Release of Chloro Sulphonic Acid Ambient Ambient 15000 kg Nil

5. Release of Caustic Soda Lye Ambient Ambient 5000 kg Nil

6. Release of Ammonia Solution Ambient Ambient 5000 kg Nil


*Worst Case Scenario for Methyl Ethyl Glycol, Iso Propyl Alcohol and Ammonia is as per

below, whereas, release of Hydrochloric Acid, Chloro Sulphonic Acid, and Caustic Soda

Lye can be controlled by proper control mechanism, safety precautions and training.


Table No. 6. 4 Considered Worst Case Scenario in Panchsheel Intermediates.

Scenario MCL Red Zone Orange

Zone Yellow Zone

Remarks Potential Chronic

Health Effects Environment

Effects Antidotes

IDLH* (ppm)

1.

Release of

Methyl Ethyl

Glycol

1000m

(500ppm)

1300 m

(250ppm)

3500m

(15ppm)

Direct release

of 6000 liters

at a time.

Toxic to central

nervous system.

Exert high levels of

biochemical oxygen

demand (BOD).

Fomepizole --

2.

Release of

Iso Propyl

Alcohol

326m

(2000ppm)

656m

(400ppm)

656m

(400ppm)

Direct release

of 1000 liters

at a time.

Toxic to kidneys,

liver, skin, central

nervous system,

Reproductive system.

Dangerous to

aquatic life in high

concentration.

Charcoal,

cathartic or

sorbitol

2000

3.

Release of

Ammonia

Solution

< 10m

(750ppm)

< 10m

(150ppm)

23m

(25ppm)

Evaporating

Puddle of 5000

liters.

Extremely corrosive

to the skin, eye,

lungs.

Very toxic to

aquatic life. No Antidote 300

* Immediately Dangerous to Life or Health (IDLH) is a concentration at which a person can escape without the use of any personal protective equipment within 30 minutes.


6.5.5 Detailed Summary of ALOHA® 5.4 Results :

Detailed Results of the consequence analysis of above mentioned worst case scenarios

have been given below :

6.5.5.1 Release of Methyl Ethyl Glycol (MEG) :

A release from the MEG Storage at Storage Tank Area :

TEXT SUMMARY OF MODEL FROM ALOHA® 5.4 :

SITE DATA :

Location : PANCHSHEEL INDUSRIES, GIDC, SACHIN , SURA

Building Air Exchanges Per Hour : 0.46 (unsheltered single storied)

Time : January 1, 2012 1612 hours ST (user specified)

CHEMICAL DATA :

Chemical Name : ETHYLENE GLYCOL MONOETHYL ETHER

Molecular Weight : 90.12 g/mol TEEL-1: 15 ppm TEEL-2 : 250 ppm

TEEL-3 : 500 ppm IDLH : 500 ppm LEL : 17000 ppm UEL : 156000 ppm

Ambient Boiling Point : 133.2°C

Vapor Pressure at Ambient Temperature : 0.0081 atm

Ambient Saturation Concentration : 8.632 ppm or 0.86%

ATMOSPHERIC DATA : (MANUAL INPUT OF DATA)

Wind : 1.8 meters/second from NNE at 3 meters

Ground Roughness : open country Cloud Cover : 5 tenths

Air Temperature : 27°C Stability Class : C No Inversion Height

Relative Humidity : 50%

SOURCE STRENGTH :

Direct Source : 6000 liters Source Height : 0 Source State : Liquid

Source Temperature : equal to ambient Release Duration : 1 minute

Release Rate : 92.4 kilograms/sec Total Amount Released : 5.547 kilograms

THREAT ZONE :

Model Run : Heavy Gas


Red : 1.0 kilometers --- (500 ppm = TEEL-3)

Orange : 1.3 kilometers --- (250 ppm = TEEL-2)

Yellow : 3.5 kilometers --- (15 ppm = TEEL-1)

Source Strength :

Direct Source : 200 pounds Source Height : 0

Release Duration : 1 minute Release Rate : 1.51 kilograms/sec

Total Amount Released : 90.7 kilograms

TOXIC THREAT ZONE OF MODEL FROM ALOHA® 5.4 :




THREAT ZONE :


Red : 1.0 kilometers --- (500 ppm = TEEL-3)

Orange : 1.3 kilometers --- (250 ppm = TEEL-2)

Yellow : 3.5 kilometers --- (15 ppm = TEEL-1)



SOURCE STRENGTH (RELEASE RATE) OF MODEL FROM ALOHA® 5.4 :



SOURCE STRENGTH :



Release Rate : 92.4 kilograms/sec Total Amount Released : 5,547 kilograms

Past History: This type of incident has not occurred in the plants since its inception.

Preventative Measures :

Some of the preventative measures being undertaken to avoid the occurrence of this type

of incident include :

Provide employees with hazard information and training.

Store in ignition source, such as smoking and open flames, prohibited area.

Regular inspection, testing, and maintenance of tanks (mechanical, electrical, etc.).

Provision for remote switches for remote cut-off.

Acid proof lined dyke with slopped ground floor is required, to contain storage

tanks.


To contain spillage, provisions for ample quantity of vermiculite, dry sand, earth,

or a similar material should be provided.

Remedial Actions and Recommendations :

The above results indicates that a distance of 1000m is expected to be vulnerable

in case of a release.

Evacuate personnel and secure as well as control entrance to the storage area.

Eliminate all ignition sources.

Absorb liquids in vermiculite, dry sand, earth, or a similar material and place into

sealed containers for disposal.

Ventilate and wash area after clean-up is complete.

Containers may explode in fire, use water spray to keep fire exposed containers

cool.

Poisonous gases may produced in fire, use appropriate personal protective

equipments for fire extinguishing.

Use dry chemical, CO2, water spray or alcohol resistant foam as extinguishing

agent.

6.5.5.2 Release of Iso Propyl Alcohol (IPA) :

A release from the Iso Propyl Alcohol Drum at Storage Tank Area :


SITE DATA :

Location : PANCHSHEEL INDUSRIES, GIDC, SACHIN , SURA



CHEMICAL DATA :

Chemical Name : ISOPROPANOL Molecular Weight : 60.10 g/mol

TEEL-1: 400 ppm TEEL-2 : 400 ppm TEEL-3 : 2000 ppm

IDLH : 2000 ppm LEL : 20000 ppm UEL : 127000 ppm

Ambient Boiling Point : 80.8°C




Vapor Pressure at Ambient Temperature : 0.067 atm

Ambient Saturation Concentration : 71,710 ppm or 7.17%




Air Temperature : 27° C Stability Class : C No Inversion Height

Relative Humidity : 50%

SOURCE STRENGTH :



Release Rate : 13 kilograms/sec Total Amount Released : 780 kilograms

THREAT ZONE :


Red : 326 meters --- (2000 ppm = TEEL-3)

Orange : 656 meters --- (400 ppm = TEEL-2)

Yellow : 656 meters --- (400 ppm = TEEL-1)



Chemical Name : ISOPROPANOL


THREAT ZONE :


Red : 326 meters --- (2000 ppm = TEEL-3)

Orange : 656 meters --- (400 ppm = TEEL-2)

Yellow : 656 meters --- (400 ppm = TEEL-1)





Chemical Name : ISOPROPANOL

SOURCE STRENGTH :


Source Temperature : equal to ambient Release Duration : 1minute

Release Rate : 13 kilograms/sec Total Amount Released : 780 kilograms

Past History : This type of incident has not occurred in the plants since its inception.



of incident include :

Provide employees with hazard information and training.

Store in ignition source, such as smoking and open flames, prohibited area.

Regular inspection, testing, and maintenance of tanks (mechanical, electrical, etc.).

Provision for remote switches for remote cut-off.

Acid proof lined dyke with slopped ground floor is required, to contain storage

tanks.


To contain spillage, provisions for ample quantity of vermiculite, dry sand, earth,

or a similar material should be provided.

Metals containers involving the transfer of Isopropyl Alcohol should be grounded

and bonded.


The above results indicates that a distance of 326m is expected to be vulnerable in

case of a release.

Isopropyl Alcohol can reacts with air and oxygen over time to form unstable

peroxides, that can explode. It also forms explosive mixtures, when heated, with

Aluminum.

Evacuate personnel and secure as well as control entrance to the storage area.

Eliminate all ignition sources.

Absorb liquids in vermiculite, dry sand, earth, or a similar material and place into

sealed containers for disposal.

Ventilate and wash area after clean-up is complete.

Containers may explode in fire, use water spray to keep fire exposed containers

cool.

Poisonous gases may produced in fire, use appropriate personal protective

equipments for fire extinguishing.

Use dry chemical, CO2, water spray or alcohol resistant foam as extinguishing

agent.

Vapor is heavier than air and may travel a distance to cause a fire or explosion, far

from the source.

Isopropyl Alcohol may form an ignitable vapor / air mixture in closed tanks or

containers.


6.5.5.3 Release of Ammonia Solution :

This scenario considers release of Ammonia Solution evaporation puddle at Storage Tank

Area :


SITE DATA :

Location: PANCHSHEEL INDUSRIES, GIDC, SACHIN , SURA



CHEMICAL DATA :

Chemical Name : AQUEOUS AMMONIA

Solution Strength : 29% (by weight) Ambient Boiling Point : 26.2°C

Partial Pressure at Ambient Temperature : 0.95 atm

Ambient Saturation Concentration : 1,000,000 ppm or 100.0%

Hazardous Component : AMMONIA Molecular Weight : 17.03 g/mol

ERPG-1 : 25 ppm ERPG-2 : 150 ppm ERPG-3 : 750 ppm

IDLH : 300 ppm LEL : 160000 ppm UEL : 250000 ppm




Air Temperature : 27°C Stability Class : C

No Inversion Height, Relative Humidity : 50%

SOURCE STRENGTH :

Evaporating Puddle (Note: chemical is flammable)

Puddle Diameter : 0.15 meters Puddle Volume : 5 cubic meters

Ground Type : Default soil Ground Temperature : 27°C

Initial Puddle Temperature : 26.2°C

Release Duration : ALOHA limited the duration to 1 hour


Max Average Sustained Release Rate : 28.6 grams/min

(averaged over a minute or more)

Total Amount Hazardous Component Released : 1.69 kilograms

THREAT ZONE :

Model Run : Gaussian

Red : less than 10 meters (10.9 yards) --- (750 ppm = ERPG-3)

Note : Threat zone was not drawn because effects of near-field patchiness make

dispersion predictions less reliable for short distances.

Orange : less than 10 meters (10.9 yards) --- (150 ppm = ERPG-2)



Yellow : 23 meters --- (25 ppm = ERPG-1)





Chemical Name : AQUEOUS AMMONIA

Solution Strength : 29% (by weight)

Hazardous Component : AMMONIA


THREAT ZONE :

Model Run : Gaussian

Red : less than 10 meters (10.9 yards) --- (750 ppm = ERPG-3)



Orange : less than 10 meters(10.9 yards) --- (150 ppm = ERPG-2)



Yellow : 23 meters --- (25 ppm = ERPG-1)






Chemical Name : AQUEOUS AMMONIA Solution Strength : 29% (by weight)

Hazardous Component : AMMONIA

SOURCE STRENGTH :

Evaporating Puddle (Note : chemical is flammable)

Puddle Diameter : 0.15 meters Puddle Volume : 5 cubic meters

Ground Type : Default soil Ground Temperature : 27°C

Initial Puddle Temperature : 26.2°C

Release Duration : ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate : 28.6 grams/min

(averaged over a minute or more)

Total Amount Hazardous Component Released : 1.69 kilograms

Past History : No such incidents have been reported till date.




of Incident include:

Handling by trained experienced personnel only.

Use of safe operating procedures for handling.

Chemical to be stored under adequate safe conditions.

Provision for remote shut-off facility.

Highly controlled and closely monitored operations.


Evacuate the affected area.

Keep material out of water sources and sewers.

Leaks of ammonia should be searched for, preferably with Hydrochloric Acid

solution or with small cylinder of SO2 gas.

Dig a pit, pond, lagoon, holding area to contain liquid or solid material.

Dike surface flow using soil, sand bags, foamed polyurethane, or foamed concrete.

Absorb bulk liquid with fly ash, cement powder, or commercial sorbents.

In case of Fire do not extinguish fire unless flow can be stopped.

Facilities for creating water curtains around the ammonia storage tank should be

created to absorb ammonia vapors if they leak out. However, care should be

taken to not to add water to the liquid ammonia, else it will be worsen the

situation.

6.5.6 Health & Safety Measures :

M/S. Panchsheel Intermediates is handling hazardous chemicals and to take care of

employee’s health, Panchsheel has adopted practice of preventive and predictive

maintenance looking to the nature of hazardous chemicals being handled.

All the equipments in the plant areas are being inspected / tested by an outside agency.

The various safety equipments like breathing apparatus and critical instrumentation

provided on various equipments are inspected and tested frequently to ensure their


operability all the time. Besides, all the first aid fire fighting devices are also inspected,

tested and maintained by a competent third party and kept all the time in ready to use

condition.

Health of all the employees in plant area is being regularly monitored by outside

physician. Necessary history cards, records are also being maintained which is updated

time to time.

Some of the safety measures carried out by Panchsheel to ensure prevention of

occupational hazards is delineated below :

Flameproof equipment’s and fittings are provided for handling and storage of


Proper Earthing is provided to each hazardous chemical storage and handling

tank and pumps motors. Also, earthing is taken care during solvent transfer from

tanker into the underground vessel.

Independent dykes have been provided for hazardous chemicals storage to

contain leakages. Floors of the dyke area have impervious finish.

Housekeeping of the plant is as per prescribed norms. Floors, platforms,

staircases, passages are kept free of any obstruction.

All hazardous operations are explained to the workers. They are periodically

trained on the hazardous processes.

Dedicated supply of firewater is available in the plant.

Only authorized persons are allowed inside the process plant.

All instrument and safety devices are checked and calibrated during installation.

They are also calibrated and checked at a frequent intervals. The records of

calibration and checking are maintained.

All electrical equipments are installed as per prescribed standards.

All the equipments of the plant are periodically tested as per standard and

results are documented. All equipments undergo preventive maintenance

schedule.

Fire hydrant system is pressured with a Jockey Pump.


In addition to fire hydrant system, numbers of fire extinguishers are also installed

at different locations within premises.

Retention basin is provided to collect the contaminated water used during fire

fighting.

Separate Solvent tank farm area is created for storage of Hazardous Solvents.

The area is fenced to isolate the same from all other departments.

Flame arrestor is provided on hazardous chemical storage and handling tank.

Flameproof pumps & motors are provided for solvent transfer.

Pressure gauge is provided on each tank. The solvents are stored at normal

temperature and pressure.

D.G. Sets are also available which can supply power in case of grid power failure.

Adequate ventilation arrangement has been is provided for safe and better

working in the plant as per the standard.

Process and equipments involving serious fire hazards are designed as per

prescribed guideline.

Sufficient access for firefighting is existing in the plant.

Protection against lightning is taken care in the plant.

6.6 SAFETY MANAGEMENT SYSTEM :

The following should be considered for the general precautions to undertake to mitigate

hazard :

1. Factory Layout

2. Medical services

3. Safety services

4. Engineering services


6.6.1 Factory Layout :

All plant building up to 4.5 meter levels will have minimum two exit routes connected by

approach roads from plants. Storage tanks of hazardous chemicals will be located away in

an isolated area called Tank Farm Area.

6.6.2 Medical Services :

Planned to avail the services of nearby hospitals for pre-employment medical

examination as well as biannual medical checkup of the employees to detect any

symptoms of health hazards. Records of all these medical checkups should be properly

maintained.

Also provide sufficient first aid boxes at proper places. The first aid boxes should be

inspect and maintained regularly.

In addition, also Planned to avail the services of nearby hospitals for medical assistance

during any emergency with arrangements for emergency vehicles.

6.6.3 Safety Services :

Safety department should be looked after by Manager or higher plant authority. The Key

Result Areas of the safety department in the safety related activities of the company

planning, organizing, directing, placement, inspections, and implementation of the

company’s safety aspects and strategy.

List of safety appliances should be available with safety department :

Self Contained Breathing Apparatus

Canister Type Gas Masks

Air Line Respirators

Dust Masks

Safety Goggles

Helmets

Acid / Alkali Proof Hand Gloves

Safety Shoes

Face Shield


Apron

Full PVC Suit

Rope Ladders

6.6.4 Engineering Services :

Engineering services comprise mechanical, electrical, civil, and instrumentation areas.

They play a vital role in emergencies arising from material spillages fire or explosion.

Mechanical maintenance group possess all equipments like chain pulley blocks, wire

ropes, tools, and tackles, which will require in handling any emergency situations.

The following are the various methods for mitigation of hazards :

6.6.4.1 Maintenance and Inspection Schedules :

Regular maintenance and preventive maintenance will carried out as per legal

requirements, maintenance schedule, and documented procedures of fire equipment,

machinery, facilities vehicles, tools, spill response equipment and chemical stores. The

high pressure storage tank thickness should be tested by the out side agency after every

six months. The crane system will also be tested by the competent person after every 6

months.

6.6.4.2 Description of Responsibility for Plant Safety :

Safety committee will form which comprises of senior persons with officers & workers

from each fields. This committee will meet minimum once in every three months. The

points raised in the committee will require to be implemented based on the evaluation.

6.6.4.3 Work Permits System :

The meaning of work permit is the permit or approval for the work other than the

manufacturing process or routine manufacturing jobs. This is one type of accident

prevention technique. The main objectives of the work permit systems is to ensure the

safe working place by taking all necessary precautions and by preventing the human

error. The various work permits should be introduced according to the requirement.


6.6.5 Mitigation Measures During Manufacturing Activity :

The key strategy for managing the potential risks associated during manufacturing activity

will be the development and implementation of the following actions, policies, and

procedures :

6.6.5.1 Facilities and Resources :

The fire equipments and chemical storage facilities with sufficient quantities of spill

response equipments should comply with relevant legislation, standards, building codes

as well as codes of practice with regard provision of ventilation and separation

requirements.

6.6.5.2 Management Policies, Plans, & Procedures :

The following management policies, plan, & procedures should be developed and or

implemented :

Incident Reporting Policy

Fire Action Plan (including Preventative Measures)

Environmental Management Plan

Maintenance Schedule

Spill Response Procedures

6.6.5.3 Training :

The following training programs should be developed and or implemented :

Chemical Storage (Separation and Ventilation Requirements)

Chemical Handling (Reading Labels, MSDS, etc.)

Oil Spill Containment and Cleanup

Fire Safety (Identifying and Managing Fire Risks and Suppression Techniques)

Operation of Equipment

Incident Reporting

6.7 OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM :

M/s. Panchsheel Industry is committed towards the Health and Safety of workers and

provided a facility of pre medical and regular medical check-up of employees for


detecting any kind of adverse effect on the health of employee due to the chemical or

work place condition and providing opportunity to improve the working condition.

The workers exposed to fugitive emission will be provided with dust mask to prevent

respiratory disorders. The workers exposed to higher noise level will be provided with ear

muffs/ ear plugs.

The protective devices will be provided to the employees handling hazardous substances.

Proper handling of the hazardous chemicals and the maintenance of Material Safety Data

Sheet (MSDS) will be followed to ensure safety within the plant area.

Drinking water supply for the employees will be provided by the project proponent and

the standard of the drinking water will be per WHO guidelines. Proper sanitary facilities

will be made available by the project proponent so that employees do not suffer from any

health ailments.

The employees will be made aware of general sanitary practices. Periodical training

programme to inform the employees about their task, associated risk, and safe working

practices will be undertaken.

Training will also include information on accident prevention, proper control and

maintenance of equipment and safe material handling practices.

A regular monitoring of the Occupational Health and Safety will reduce the chances of

accidents. Hence, all the records of job related accidents and illness should be maintained

as per the requirements of factory act, 1948. This information will be reviewed and

evaluated to improve the effectiveness of Environmental Health and Safety programme.

The following occupational measures will be adopted :

The workers will be provided with personal protective equipments such as

gloves, goggles, safety shoes, helmets, and dust masks.

Periodic medical checkup of the workers for audiometric, blood tests, physical

examination, etc. as per applicable rules.

First aid medical facility will be made available at the site and medical kit will be

made available at strategic location and plant personnel will be trained for first

aid medical treatment.


Dispensary and medical facility is available in the nearby GIDC area and that will

be utilized in the case of emergency. However. The company will appoint one

doctor for further consultation and treatment in case of emergency.

6.8 DISASTER MANAGEMENT PLAN :

The Disaster Management Plan gives a broad idea of the detailed emergency

preparedness in case of an accidental release of hazardous chemicals in the proposed

project.

The Disaster Management Plan is prepared keeping in view to conform to the

requirements of the provisions of the Factories Act, 1948 under Section 41 B (4) with

guidelines issued by the Ministry of Environment and Forests, Govt. of India and

Manufacture, Import and Storage of Hazardous Chemicals Rules 2000, Schedule 11 under

Environmental Protection Act 1986 as well as the various guideline issued by State Chief

Inspectors of Factories from time to time.

Disaster Management Plan envisages the need for defining appropriate action so as to

minimize loss of life, property and for restoration of normalcy within the minimum time.

Main component of Disaster Management Plan are as follows :

1. Emergency Response Organization.

2. Communication System.

3. Action on the Site.

4. Facilities Available at Site.

6.8.1 Emergency Response Organization :

Emergency Response Organization shall have Site Controller, Incident Controller, and

Other Key Personnel, to take the action in the event of an emergency.

Roles and responsibilities of emergency response organization have been described in

following subsections :


6.8.2 Site Controller :

The General Manager shall have over all responsibility for the plant and its personnel. In

the absence of General Manager, Plant Manager shall assume the responsibility of Site

Controller.

Duties of site controller during emergency shall be :

To assess the magnitude of the situation and decide if employees need to be

evacuated to assembly points.

To maintain continuous review of possible development and assess in

consultation with incident controller as to whether the shutting down the plant

or part of plant, and evacuation of person is required.

To give necessary instructions to Liaison Officer and Head of the Department

(P&A) regarding the help to be obtained from out side agencies like fire brigade,

police and medical.

To advice liaison officer to pass necessary information about the incident to

news media and ensure that the evidences are preserved for inquiries to be

conducted by statutory authorities.

6.8.3 Incident Controller :

The Head of the Department of affected department shall have overall responsibility for

controlling the incident and directing the personnel. Section In-Charge of the affected

department shall assume the responsibility of incident controller in the absence of Head

of the affected Department.

The incident controller duties during emergencies shall be :

To inform communication officer about the emergency, control center and

assembly point.

To direct essential operators within the affected areas with priorities for safety of

personnel, to minimize damage to the plant and environment as well as to

minimize the loss of material.

To ensure that all non-essential persons are sent to the assembly point.


To provide advice and information to safety officer, security officer and other out

side agencies, when they arrive.

To act as Site Controller till the later arrives.

6.8.4 Primary Controller :

The primary controller is the employee who gives the first information about the incident.

He will be responsible for :

To inform the Security Office (Main Gate) & Environment Engineers/ Shift In-

Charges / Head Of the Department of Section of the aforesaid Department /

Section from the nearest available telephone about the location and the nature

of incident.

To assist out side agencies in their operation, and would assist in clearing any

obstruction coming in way of fire extinguishers.

To carry out all instructions from Incident Controller.

6.8.5 Liaison Officer :

The Head Of the Personnel & Administrative Department shall be the Liaison Officer.

Liaison Officer shall be responsible for:

To contact, fire brigade, police and medical facilities on intimation from site

controller and arrange for the rescue operation.

To ensure that the casualties receive attention.

To inform relatives of affected employees at the earliest.

To arrange the additional transport, if required.

To arrange for relief of personnel and organize refreshment / catering facility, in

case the duration of emergency is prolonged.

To issue authorized statements to news media and ensure that evidence is

preserved for inquiries to be conducted.

6.8.6 Section – In Charge (Medical) :

On receiving the information, Section In-charge of Medical will reach hospital

immediately and take following actions :


Section In-charge of Medical will keep necessary first aid medicines and artificial

respiration equipment ready.

Inform doctors at other places to be ready, for attending serious injury and burns

cases.

6.8.7 Communication Officer :

Section In-Charge of the safety shall act as Communication Officer. Communication

Officer shall work from Control Center and maintain communication between relevant

personnel. Communication Officer shall be responsible for :

To apprise the site controller of the situation, based on the information received,

suggest the evacuation of personnel from assembly points, if needed.

To arrange for suitable persons to act as runners / messengers in case of failure

to communication system.

To carry out any other works as assigned by site controller / incident controller.

6.8.8 Section – In Charge (Security) :

Section In-charge of the security shall be responsibly for :

The Section In-charge of the security shall guide the fire crew in fire fighting. He

shall give instruction to Security Guards to cordon off area as required by

Incident Controller. Section In-charge of the security shall render all help to

incident Controller to handle the emergency and carry out the assigned work.

Section In-charge of the security shall be responsible for unauthorized persons

inside the affected section as well as plant during emergency.

6.8.9 Shift In-charge (Security) :

Shift In-charge of Security shall be responsible for:

To arrange the necessary help as requested by Primary Controller.

To inform section In-charge of Security.

To below emergency Siren, if instructed by primary Controller.

To send Ambulance and Fire Brigade to incident site along with available trained

security persons.


6.8.10 Communication System :

Communication system comprehend declaration of major emergency, communication

system, telephone massages, and communication of major emergencies.

6.8.11 Declaring the Major Emergency :

Major emergency will be declared after sufficient and through check because the

declaration of major emergency puts many agencies on action and it may disturb the

running plant, which may be costly or its consequence may be serious. Therefore, major

emergency must not be decided on whims or immature judgment or without proper

thought. Looking to all the above, the plant will take care to nominate the persons who

can declare the emergency, will select them on the basis of their knowledge &

experience.

The joint decision to declare major emergency may be taken but it should be as early as

possible and without wasting the time.

6.8.12 Communication System :

Any person noticing an emergency should be able to raise or cause to be raised the

Emergency Alarm. All employees must be trained to operate such emergency alarms.

There should be an adequate number of points from which the alarm can be raised either

directly, by activating an audible warning of individual signal or message to a preliminary

manned location.

The alarm should be audible in every part of the plant. In areas of high noise levels, it may

be advantageous to provide an alternative to an audible alarm e.g. flashing lights. In case

of total electricity failure and alarms, mobile telephones/telephone and intercom system

not working, help of runners/messengers shall be taken. One (or more) big bell

(independent power) and magnetic telephones with fire and emergency services may also

be useful. Public address system (PAS) or Internal telephones throughout the plant will be

useful for quick communication. Automatic alarms may be appropriate on some sites. To

communicate disaster, hooter will be useful. The alarm system should be checked

periodically to test efficiency.


https://www.google.co.in/search?espv=210&es_sm=122&q=define+comprehend&sa=X&ei=6tnsUvHMEe6ZiAeIlIHIBQ&ved=0CDQQ_SowAA

6.8.13 Telephone Message :

After hearing the emergency alarm during emergency or even while just receiving the

emergency message on phone, a telephone operator has to play an important role.

Telephone operator should be precise, sharp, attentive and quick in receiving and noting

the message and subsequently effective in further Communication. A form to record

emergency telephone calls will be made available with telephone operator or person

available in Emergency Control Center, who will record such calls during emergency.

6.8.14 Communication of Emergency :

The plant will initiate effective system to communicate emergency :

1. Inside the plant i.e. workers including key personnel and essential workers, on

duty & inside during normal working hours.

2. To key personnel and essential workers not on duty and outside during normal

working hours.

3. To the outside emergency services and the Government Authorities.

4. To the neighboring plant & the General Public in the vicinity.

6.8.15 Inside the plant to the workers :

Copy of the manual fulfilling the entire statutory requirement will be distributed to

concerned personnel.

Frequently training and mock drills will be conducted to make the workers aware about

their duties and action to be taken during the emergency.

6.8.16 To key personnel outside daring normal working hours :

As per emergency planning, the key personnel & essential workers will be available in all

shifts or on short call. But due to some reason, if some one is outside the plant premises

or not on duty and if their help is required, an updated list and address of the essential

workers and key personnel will be available in the Emergency Control Center.

6.8.17 To the outside Emergency Services and the Authorities :

Once the emergency is declared, it is essential that the outside emergency services

should be informed in the shortest possible time.


Responsibilities will be fixed as per the Incident/Emergency Command to contact outside

agencies for help and to communicate to the all the Government and other authorities,

such as, Fire Brigade, Police, District Emergency Authorities, Factory Inspectorate &

Hospitals, etc.

6.8.18 To neighboring factories and the General Public :

A major emergency will affect areas outside the works and it is essential that neighboring

plants and general public, should be informed to enable them to take prompt action to

protect their own employees and to take whatever measures may be possible to prevent

further escalation of the emergency due to effects on their own installations, at the same

time, they may be able to provide assistance as part of a prearranged mutual aid plan.

Further responsibilities will be fixed to inform the neighboring plants and the general

public residing in the vicinity.

6.8.19 Action on the Site :

Action on the site comprehend pre-emergencies and post-emergencies activities.

6.8.20 Evacuation & Transportation :

During emergency, personnel may require to be evacuated from the incident area and

also from adjacent areas. Evacuation should to be at pre-determined assembly points in a

safe part of the plant. At the plant, assembly points need to be clearly marked. The plan

should designate someone to record all personnel arriving at assembly point so that the

information can be passed to the emergency control center.

Personnel required to be transported for the purpose of medical care or for better shelter

should be transported with care and facilities.

6.8.21 Assembly Points :

Assembly points should be set up farthest from the location of likely hazardous events,

where pre-designated persons would assemble in case of emergency.



6.8.21.1 Safe Plant Shut-Down :

If necessary, full or partial shut down of the plant should be followed under the judgment

of the incident controller or the site, main controller. For single plant sites, shut down

may be comparatively simple, with the knock-on effects, elsewhere on the site.

6.8.21.1.1 Accounting for Personnel :

It is necessary to know that everyone on the site has been accounted for and that the

relatives of causalities have been informed. The problem of accounting can be particularly

difficult, especially on large works and hinges on being able to know, with any certainty,

which is on site at any one time. It can be exacerbated if an accident occurs, as it

frequently does, at a shift change or at a time when large number of contractor’s

personnel are on the work.

It may be impracticable in many situations, to have an updated list of names of peoples

on site at any one time. Holiday and sickness absence will mean that relief personnel are

present and some others may be off site at the time engaged on the other work.

At the Emergency Control Center, a responsible person should be appointed to collate the

lists, check those against the nominal role of these believed to be missing. Where missing

people could have had cause to be at the affected area, the Incident Controller should be

informed and arrangement made for further search.

6.8.21.2 Post Emergency Activities :

Post emergency activities comprise of steps taken after the emergency is over so as to

establish the reasons of the causation of the emergency and preventive measures. The

steps to be involved are :

Collection of records

Conducting inquiry and concluding preventive measures

Making insurance claims

Preparation of inquiry reports recommendations

Rehabilitate the affected persons within the plant and outside the plant

To restart the plant.


6.8.22 Facilities Available at Site :

It comprehend public address system, telephone, firefighting equipments, first aid and

rescue, medical services available, etc.

6.8.22.1 Public Relations :

Inevitably, major incident will attract the attention of the press, television and radio

services. It is essential to make arrangements of authoritative release of information to

them, preferably at a place remote from the workers to avoid any possible harm to the

people concerned. Senior personnel should be appointed as the sole authoritative source

of information of the news media. All other employees should be instructed not to

divulge information themselves which may, in the event, be misleading or inaccurate.

6.8.22.2 Warning System and Control :

The control centre shall be located at an area of minimum risk or vulnerability in premises

concerned, taking into account the wind direction, areas which might be affected by

fire/explosion, toxic releases, etc.

6.8.22.3 Emergency Services :

This includes fire-fighting system, first aid centre, hospital etc. Alternate sources of power

supply for operating fire-pumps, communication with local bodies, fire-brigade etc. should

also be clearly identified. Adequate number of external and internal telephone

connections should be installed.

6.8.22.4 Fire Protection System :

The fire protection system for the proposed plant is to consist of :

Fire system for all the vulnerable areas of the plant.

Portable carbon-dioxide extinguishers for the control room.

Portable hand appliances of suitable types/ capacities for extinguishing small

fires in selected areas of the plant.

The Disaster Management Plan shall have the key personnel of the organization and

responsibilities assigned to them in case of an emergency and their telephone numbers.

These telephone numbers and persons shall be finalized after commissioning of the plant.



Depending on the severity of the emergency, outside agency will be called for assistance.

The following information shall be included in case outside organizations are involved in

assisting on site emergency :

Type of accidents.

Responsibility assigned to each of the organization.

Liaison arrangement between the organization.


CHAPTER – 7


CHAPTER – 7

PROJECT BENEFITS

Panchsheel Intermediates, is located at Plot No. 8201/2, GIDC Sachin, Dist. : Surat,

Gujarat. The unit intends to expand manufacturing facility for various dyes which will be

used in different industries for various purposes. The unit is located within a notified

industrial estate. All the essential facilities such as power, fuel, post, tele-communication,

bank and roads / transportation etc., is easily accessible to the project.

Water is being supplied by Sachin Infra Management Ltd. The Electricity supply is being

taken from State Electricity Grid. Transportation of raw materials and finished products is

to be carried out by road transport. Looking to the size of the project and its location

within a notified estate, increase in transportation activity due to the project as

compared to traffic load associated with the whole estate will be insignificant.

Direct & indirect employment opportunities will be within the surrounding region. Local

people will be employed depending upon the availability of skilled & un-skilled man-

power surrounding the project site. Company shall also try to provide indirect

employment opportunities by availing local contract services during transportation

during operational phase. The company intends to contribute social welfare societies for

carrying out projects in nearby villages for their welfare and upliftment in conjunction

with industrial association.


CHAPTER – 8


CHAPTER – 8

ENVIRONMENT MANAGEMENT PLAN

8.1 INTRODUCTION

An Environmental Management Plan (EMP) is a project and site specific plan developed to

ensure that the project is being implemented / operated in an environmentally sustainable

manner where all stakeholders including the project proponents, contractors, sub-

contractors, consultants understand the potential environmental impacts arising from the

project and take appropriate actions to properly manage the same. Adequate

environmental management measures need to be incorporated during the planning phase

to minimize any adverse impact and assure sustainable development of the area. This plan

helps in formulation and implementation of environment protection measures. It also

helps in development of monitoring programme for environmental parameters during the

operation phase of the project.

8.2 ADMINISTRATIVE ASPECTS FOR EMP

8.2.1 Operational Philosophy

All the activities to be undertaken at the plant shall be in complete compliance with all

applicable laws, regulation, standards and guidelines. In order to achieve this, the unit shall

establish a resource base for the management of health, safety, environmental and social

issues during operation phase of the project. Technically qualified and experienced staff

shall be in-charge of this activity. The HSE objectives for the unit shall consist of no

accidents in plant, no harm to people of surrounding area and no damage to the

environment. Unit shall also be responsible to the community regarding environmental

protection and shall promote all practicable control measures to ensure implementation of

project operation phase in an efficient and environmentally responsible manner.


Success of well formulated Environment Management Plan lies in the following which shall

be fulfilled simultaneously:

1) Management support

2) Efficiency of Environment Management Cell

3) Acceptability of resulting environmental quality

8.2.2 Environment Management Cell

Qualified and experienced person in the field of Environment either environmental

engineer or environmental scientist or in-charge of the plant should be appointed for

overall responsibility for the management of all the issues related to Environment, Health

and Safety within the plant. He/she shall directly report to the owner of the company for

issues related to the Environment Management System of the unit.

To facilitate the Environment Management System, one of the most important aspects is

the organization and personnel.

Environment Management Cell shall perform following duties :

Collect information from regular monitoring and create a database

Analyze the data and decide the critical areas for immediate attention and corrective

actions

Work out action plan for implementation of the recommendations made under

Environment Management Plan

Prepare budget for environment management program and proper allocation of the

funds for the same

8.3 ENVIRONMENTAL MANAGEMENT PRACTICES

Above described environment management cell will implement and co-ordinate the

suggested environmental management practices for mitigation of various impacts


associated with the project activity on different environmental components as described

below :

8.3.1 Water Environment

Any wastages/leakages will be avoided at all possible locations / opportunities.

Proper handling of spillages if any will be ensured by introducing spill control

procedures for various chemicals

Proper facilities for storage of raw materials (i.e. with roof and pucca floor) will be

provided to prevent storm water contamination during the storage of various raw

materials

Performance of the ETP will be monitored so as to meet with the prescribed discharge

norms

Monitored data will be analyzed and reviewed at regular intervals and compared with

the operating standards so as to take necessary corrective actions

Enough care will be taken to prevent any leakages / accidental spillages from ETP units

in order to avoid any ground water resource contamination.

Waste streams to be generated from spillage, leakages, occasional reactor wash etc.,

will be directed to ETP for further treatment of the same.

8.3.2 Air Environment

All transferring and feeding areas will be well covered to avoid any fugitive emissions.

Proper ventilation will be provided on the shop floor for proper air circulation to

maintain the work area air quality.

Proper preventive maintenance of fuel firing system will be ensured.

Efficient working of APC system will be ensured.


8.3.3 Land / Soil Quality

All the hazardous solid waste generated will be segregated properly and will be stored in

identified area for storage and for further disposal

Regular record keeping of volumes / weights of wastes generated and disposed will be done

Proper storage, handling and disposal of all type of hazardous solid wastes as per the

guidelines prescribed will be ensured

8.3.4 Noise Environment

High noise generating machines and processes will be enclosed and insulated.

Insulation of ventilation pipes and use of dampers will be made at all possible places

Implementation of management control on site for limiting transportation timing by adopting

mechanical and technological ideas

Preventive maintenance schedule will be followed for all instruments and machineries to

maintain good working condition.

Enclosures and barriers will be provided to pumps and machineries producing high noise

levels.

There will be periodical noise level measurements for verifying compliance with relevant

laws.

Workers exposed to high noise generating operations will be provided with suitable ear

protection devices

Green belt development will act as a medium for noise absorbance.

8.3.5 Occupational Health & Safety

All reasonably practical measures will be adopted by the unit to minimize the risk of

accidents within a chemical manufacturing unit

All building plans and installations will be as per relevant laws and will be approved by

competent authority

Workers will be trained for all the hazardous process operations within the plant and will be

supervised by experienced supervisors


Safety features such as fire extinguishers at strategic locations and suitable personal

protective equipments will be provided

Flame-proof electrical fittings, flame arrestors etc., will be installed

All the raw materials will be stored in designated storage area equipped with necessary

safety features

Periodic inspection & testing of pressure vessels, equipments, machineries will be done

Good house-keeping will be ensured within the factory premises

Training will be provided to the designated staff & workers for fire fighting, work permit

system, first aid & safe handling of hazardous chemicals

Incident / accident reporting system will be developed and all the employees will be made

aware for the same

Suitable notices / boards will be displayed at designated locations indicating appropriate

hazard warnings

Antidotes as well as MSDS for all the chemicals will be made available within the factory

premises


8.4 CORPORATE ENVIRONMNETAL RESPONSIBILITY

The company has well laid down Environmental policy, which is being implemented. The

policy is communicated to all employees for its effective implementation. The

management ensures the availability of resources essential to implement the corporate

environmental policy across all its activities/projects. The EHS cell to be appointed/framed

will be responsible for compliance with Corporate environmental responsibility.

The planning, implementation and monitoring of the organizational environmental

performance have to be documented meticulously. All achieved milestones should be well

supported by documentary evidence in the form of photographs, monitoring records,

and/or reports, wherever applicable.

EHS statutory compliance team will work towards all the required statutory compliance

associated with the plant operations and will directly report to the top management of the

company for compliance status of the unit on regular basis. Nature and criticality of the

noncompliance reported to the top management will be further reviewed and will be

placed before the Board of Directors either for information along with action taken for non

compliance or for approval for the major actions to be initiated.

The company shall prepare Corporate Environmental Performance Report inclusive of the

major violations / non-conformance occurred in a year. The Environmental Performance

report shall be made a part of the Annual report of the company to inform the

stakeholders / shareholders about the company’s environmental performance.


CHAPTER – 9


CHAPTER – 9

EXECUTIVE SUMMARY

9.1 INTRODUCTION :

1. M/s. Panchsheel Intermediates is proposing expand manufacturing activities at their

unit located at Plot No. 8101, GIDC – Sachin, Village : Sachin, Dist.: Surat, Gujarat.

2. Panchsheel Intermediates is involved in manufacturing of various Acid and Solvent

dyes @ 6 MT/M and having the valid consent from GPCB for production of the same.

3. The new proposed project for addition of solvent based dyes is covered at item 5(f) of

schedule of EIA notification dated 14th September, 2006. Location of the project being

within notified Special Economic Zone, the project is category “B” project.

4. This Environment Impact Assessment (REIA) report has been prepared to take stock of

the existing environmental quality surrounding the plant site and to assess the

environmental impacts associated with the proposed manufacturing activity as well as

to plan and implement environmental control measures to mitigate, if not prevent

completely, the adverse impacts.

9.2 PROJECT DESCRIPTION :

5. At present, the unit is manufacturing various Acid and Solvent dyes @ 6 MT/M and

intends to increase its production capacity by installing additional reaction vessels for

various Solvent dyes @ 28.5 MT/M. Hence, the ultimate production capacity will be @

34.5 MT/M, after proposed expansion.

6. Proposed product profile is as show below :

Sr. No. Group of Product Product name Quantity

(MT/M)

A. Oxidation based

products.


Solvent blue 45, Solvent violet 13,

Solvent green 3, Solvent green 28,

Solvent violet 37.

9.0


B. Sulfonation based

products.


Solvent blue 104.

5.0

C. Metalization based

products.

Solvent orange 114, Solvent Red

270, Solvent Red 52, Solvent Red

23, Solvent Red 24, Solvent Violet

14, Solvent orange 54.

7.5

D. Condensation based

products.

Solvent orange 63, Solvent orange

60, Solvent yellow 93, Solvent red

235, Solvent red 111, Solvent

yellow 160, Solvent yellow 43,

Solvent red 195, Solvent red 196,

Solvent green 5, Solvent green 7.

7.0

TOTAL 28.5

7. The location of the unit is within well-established area of GIDC Sachin, Surat. GIDC

Sachin is on approach road of NH-8. The site is located at latitude 21° 05' 57.10" N and

longitude 72° 50' 45.68" E.

8. The total land area of @ 3000 sq.m. is being owned by the unit at the location. There

is no need of acquisition of additional land for expansion project, as no additional

construction work has to be carried out on site for the expansion phase. For the

proposed expansion, there will be installation of new Reaction Vessels and Hot Air

Generators.

9. The unit has connected power load of @ 110 KW, which is being supplied by Dakshin

Gujarat Vij Company Ltd. There is no need of additional power load for proposed

expansion, as the existing connected power load is adequate for proposed expansion

also.

10. The unit has also installed L.D.O. based D.G. set (75 KVA capacity) in the existing

manufacturing activity, which will be also utilized during proposed expansion, in case


of power supply failure from the Grid. L.D.O. will be consumed @ 20 L/hour in case of

its operation during emergency.

11. The unit has installed natural gas fired small industrial boiler of 1500 Kg/hour

capacity, which consumes natural gas @ 35 SCM/hour (i.e. presently being operated

at 20-25% of its capacity). The unit has planned to install 4 nos. of natural gas fired Hot

Air Generators for proposed expansion, which will utilized additional natural gas @ 12

- 15 SCM/hour for each.

12. At present, the unit is utilizing water @8.5 KLD, which is being supplied by Sachin

Infra Management Ltd. The water consumption will increase upto 23.00 KLD at

ultimate phase of expansion, availing from existing water source only, i.e. Sachin Infra

Management Ltd.

13. The sources of wastewater generation due to existing as well as proposed

manufacturing facility will be from process, utilities & domestic.

14. Considering the maximum production capacity of a particular product in a worst case

scenario (i.e. considering the monthly production capacity of each product group for

the product generating maximum effluent) the maximum wastewater generation at

any point of time is not likely to exceed 12.7 KLD for 28.5 MT/M production for

proposed expansion.

15. The total industrial effluent generation at the ultimate phase of expansion will be not

exceed beyond 22.7 KLD in worst case scenario.

16. The domestic sewage alongwith industrial effluent from the various stages of the

process is collected and treated in the effluent treatment plant having primary

treatment facility.

17. Neutralization tank as well as primary settling tank will be operated in sequential

batch manner (i.e. fill and draw type).

18. The sludge from PST is dewatered and dried in nutch filter and filtrate collected is

sent to neutralization tank for further treatment.


19. Existing boiler being utilized under capacity will be utilized at fullest capacity and

being natural gas fired will not require any air pollution control measures.

20. Proposed natural gas based hot air generators will not have any air pollution control

measures.

21. Sulphonation vessels will be equipped with Water scrubber followed by alkali

scrubber.

22. Hazardous solid waste being generated from the existing activity is being disposed off

as per prescribed guidelines and for which necessary permissions have been

obtained. The same practice will be kept continued for the wastes being generated

from expansion phase.

23. Considering the structure of the plant, there is availability of area for green zone

development @ 100 sq.m. However, the unit will participate in road side plantation

drive as well as community and social forestry programme being organized by the

Local authority / Government agencies.

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

provided adequate number of first aid boxes at strategic locations and give training

to designated person for the emergency purpose.

25. No fatal / non-fatal accident has been reported in the unit in last 3 years of operation.

The unit has not been issued any show cause notices / closure directions for breach

of any Environmental laws and / or Compliance of CC&A conditions.

9.3 DESCRIPTION OF ENVIRONMENT :

26. Primary data collected for CETP of Globe Enviro Care Ltd. was utilized as a part of

baseline data for the project. The baseline data were generated for the period

between December, 2011 to February - March, 2012.

27. The average concentration of all pollutants at all 7 ambient air locations are found to

varying in the following range :


a. PM10 : 59.55 to 194.64 µg/m3

b. PM2.5 : 49.67 to 85.32 µg/m3

c. SO2 : 7.84 to 23.08 µg/m3

d. NOX : 30.13 to 38.06 µg/m3

28. Based on meteorological data, wind roses have been prepared for the winter season.

As per meteorological data, it shows that average wind speed in this season is 0.81

m/s. It can be observed that in this season, wind blows mostly from North East (NE)

direction and during this season total calm wind contributes to about 23.30%.

29. During monitoring period, the noise levels varied between 61.00 to 72 dB during day

time and 55 to 67 dB during night time for whole study area.

30. The texture of the soil in study area found to be Silt loam, percent of clay of soil

varies between 68 μm and 83 μm. pH of soil in the study area varies between 7.11 to

8.23 is presenting slightly alkaline nature of soil. Such soils are conducive for

agricultural purposes.

31. Landuse classification of the study area depicts that major part is covered by water

bodies i.e. 49.48% followed by 13.11% of crop land whereas industrial area is @2%.

9.4 IMPACT IDENTIFICATION :

32. Impact identification has been carried out for various activities involved in

operational phase of the project.

33. The source of water supply for the project will be Sachin Infra Management Ltd.

Hence, there will not be any direct impact of the proposed industrial operation on

the surrounding ground water sources.

34. The anticipated quantity of effluent generated from the industrial plant is @ 25 KLD

in the worst case scenario of alternative products. The effluent will be treated in

Treatment plant having primary and secondary treatment units. The treated effluent

confirming to the norms will be sent to CETP of Globe Enviro Care Ltd. for further

treatment as per present practice. The quantity of effluent being sent to CETP will be


5% of the present treatment capacity of CETP capacity which is going to expand

further, leading to decrease in total contribution. As there is no direct withdrawal of

ground water as well as no direct disposal into environmental sink, impact of water

environment due to proposed expansion project is insignificant in nature.

35. Increased level of concentration associated with exhaust gases of vehicular traffic will

return to its original state with the passage of time. Hence, this impact is envisaged as

short term negative and reversible in nature.

36. Having installation of natural gas fired boiler and hot air generators, no significant

impact on air quality due to flue gas emission is anticipated.

37. Fugitive emissions associated with the various chemicals involved in the proposed

manufacturing activity will also contribute to the prevailing ambient air quality.

38. The only source of process emission will be Sulfonation vessels, which will be

controlled by installing water scrubber followed by alkali scrubber with the reaction

vessel.

39. The incremental concentration due to proposed project for Particulate Matter is

negligible, as it ranges between 0.003 – 0.29 µg/m3, but the resultant values at 4 sites

exceed the permissible limit due to the high background values. While, as far as SO2

and NOX, incremental concentrations are concerned, the contribution from the

proposed source is negligible and the resultant concentration values remain well

below the permissible limits.

40. The predicted GLC values for SO2, NOX, and PM10 have been added to the background

levels to determine the resultant value. The resultant concentration values remain

well below the prescribed NAAQS at all AAQM locations, indicating that the impact

on the ambient air quality will be insignificant at all AAQM locations.

41. The proposed expansion project is to be carried out within existing premises, which is

located in notified industrial estate, hence, there will not be any conflict in change of


landuse pattern. So, no impact has been envisaged on existing land use pattern of the

project site.

42. Solid / hazardous waste generated due to production activity will be stored

separately in Hazardous Waste Storage Area within the factory premises. It will have

non-percolating R.C.C. floor and covered roof. Hence, no significant negative impact

is envisaged on the surrounding soil quality due to presence of solid / hazardous

waste within the plant premises.

43. Operation of manufacturing plant and machineries, will be contributing to noise

generation during operative phase.

44. As project location is within notified industrial estate, no significant impact associated

with displacement of prevailing floral & faunal species is envisaged on surrounding

biological environment due to proposed project activity.

45. There will not be any discharge of effluent from the plant directly into any water

body; hence there will not be any impact on aquatic ecology of the surrounding area.

46. Impact in terms of displacement of habitation and settlements due to the proposed

project is totally absent as the unit is to be located within notified industrial estate.

47. Major health and safety issues encountered will be physical hazards, respiratory

hazards, electrical hazards, noise, fire & explosion hazards associated while working

within manufacturing plant. Also, chemical industry poses risks such as accidents due

to spillage, fire and explosion.

9.6 ENVIRONMENTAL MONITORING PROGRAM :

48. For the proposed expansion project, monitoring activity is mainly envisaged for stack

emissions to analyze the performance of APC system, to check treated wastewater

quality to analyze the performance of proposed ETP and to measure the prevailing

noise levels due to plant operation.


49. The in-charge of environment, health and safety department, of the unit has to co-

ordinate all monitoring programmes at site and data generated shall be submitted

regularly to the statutory agencies.

50. MoEF / GPCB recognized agencies should be deployed for carrying out regular

environment monitoring.

9.7 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN :

51. The proposed plant will be engaged in handling and storage of various hazardous

materials. Hazard identification is carried out to identify the material handling &

storage, fire & explosion, electrical, mechanical, toxic gas release, and corrosion

hazards.

52. Necessary safety measures including inherent safety devices, fire fighting facilities,

and proper training will be provided to attend any emergency due to handling and

storage of hazardous chemicals.

53. Following maximum credible scenarios have been selected for consequence analysis

as a result of accidental releases :

No. Type of Release Worst Case Outcomes Measures

1.

Direct release of

Methyl Ethyl Glycol

from 6000 Liter tank.

May affect nearby area of

1000 meters for the

concentration of 500 ppm.

Absorbent showers with

appropriate absorbent

collection and disposal

system.

Availability of sufficient

quantity of Antidotes.

Proper communication

with nearby area people.

Providing firefighting

facilities.

2.

Direct release of Iso

Propyl Alcohol from

1000 Liter tank.

May affect nearby area of 326

meters for the concentration

of 2000 ppm.

3.

Release of Ammonia

Solution evaporating

puddle of 5000 Liter.

May affect nearby area of less

than 10 meters for the

concentration of 750 ppm.


54. Disaster management plan consisting of emergency response organization,

communication system, action on the site, and facilities available at site has also been

formulated.

9.8 ENVIRONMENT MANAGEMENT PLAN :

55. Any wastages / leakages will be avoided at all possible locations / opportunities.

56. Proper handling of spillages if any will be ensured by introducing spill control

procedures for various chemicals.

57. Performance of the ETP will be monitored so as to meet with the prescribed

discharge norms.

58. Proper preventive maintenance of fuel firing system will be ensured.

59. Efficient working of proposed APC system will be ensured.

60. All the hazardous solid waste generated will be segregated properly and will be

stored in identified area for storage and for further disposal.

61. Proper storage, handling, and disposal of all type of hazardous solid wastes as per the

guidelines prescribed will be ensured.

62. High noise generating machines and processes will be enclosed and insulated.

63. There will be periodical noise level measurements for verifying compliance with

relevant laws.

64. Workers exposed to high noise generating operations will be provided with suitable

ear protection devices.

65. Locally available man-power will be employed by the management in the

manufacturing activity.

66. Workers will be trained for all the hazardous process operations within the plant and

will be supervised by experienced supervisors.

67. Flame-proof electrical fittings, flame arrestors, etc., will be installed.


68. Training will be provided to the designated staff & workers for firefighting, work

permit system, first aid, & safe handling of hazardous chemicals.

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

factory premises.

70. Qualified and experienced person in the field of Environment either Environmental

Engineer or Environmental Scientist or In-charge of the Plant should be appointed for

overall responsibility for the management of all the issues related to Environment,

Health and Safety within the plant. He/she shall directly report to the owner of the

company for issues related to the Environment Management System of the unit.

71. The company shall prepare Corporate Environmental Performance Report inclusive of

the major violations / non-conformance occurred in a year. The Environmental

Performance report shall be made a part of the Annual report of the company to

inform the stakeholders / shareholders about the company’s environmental

performance.


CHAPTER – 10


CHAPTER – 10

DISCLOSURE OF CONSULTANT ENGAGED

(A) Name : Ramans Enviro Services Pvt. Ltd.

(B) Address : 23 & 24 , SF ,Camps Corner ,

Nr. Auda Garden , Prahaladnagar,

Ahmedabad - 380 015

Gujarat

INDIA.

Telephone : 91 – 79 –26937472

Fax : 91 – 79 –40064440

E mail address : [email protected]

(C) Company’s Capabilities :

The company deals with the issues related to environmental pollution

control and also provide better options/solutions for effective control of

environmental pollution i.e. air, water and solid waste disposal. The

company has sufficing infrastructure of its technical staff and has its own

laboratory for analysis of water, wastewater, and solid waste and gaseous

emission.

(D) Company’s Work area:

At present company is capable to undertake following type of assignments:

1. To design the water, wastewater and sewage treatment plant.

2. To carry out rapid as well comprehensive Environmental Impact

Assessment study and report preparation.

3. To undertake work related to CRZ permission and Environmental

Clearance from Ministry of Environment and Forest (MoEF).

4. To carry out Environment audits.


5. To provide advice in respect of statutory obligations related environmental

pollution control (Form-V, Form4, Water Cess Returns) which are required

to be complied by industrial organization as well as techno-legal

environmental issues.

6. To carry out treatability studies for evolving effluent treatment system.

7. To carry out analysis of water, wastewater hazardous waste & gaseous

emission.

8. To operate or assist for efficient operation of effluent/sewage treatment

plants.

9. To design secured landfill site for hazardous waste disposal and to prepare

techno economical feasibility report.

10. To carry out waste minimization study for the industrial pollution control.

(E) List of Laboratory Equipments :

Sr. No. Name of Instrument Sr. No. Name of Instrument

1 Monopan Balance 13 Heating mantle

2 Magnetic Stirrer 14 Hot Plate

3 COD Apparatus of M/s

Spectra Lab Mumbai

capable to carry out COD of

15 samples at a time using

air condenser columns

15 Distillation apparatus.

4 Refrigerator 16 Muffle Furnace

5 Oven 17 Imhoff Cone

6 pH meter 18 Stack Sampling kit for PM &

gaseous emission (2 Nos.)

7 Conductivity meter 19 High volume air samplers /

Respirable dust samplers (3

Nos.)


8 TDS meter 20 Automatic Sampler for

Analysis of CO, O2 & CO2 in

combustion process.

9 Spectrophotometer 21 Two handy Air Samplers

10 BOD incubator 22 Weather monitoring station

11 Jar apparatus for the

treatability studies

23 Integrated noise level meter

12 Kjehdal Assembly 24 Fine particle sample PM2.5

(Envirotech APM 550)

(F)Analytical Capability:

The existing laboratory facilities are capable of estimation of following pollutants.

(1)For waster and wastewater

1. pH 2. Suspended Solids

3. Total dissolved Solids 4. Total Solids

5. Acidity 6. Alkalinity

7. Hardness 8. Chlorides

9. Sulphate 10. Dissolved oxygen

11. Bio Chemical Oxygen Demand 12. Chemical Oxygen Demand

13. Phenol 14. Heavy metals like CU, Ni, Zn etc

15. Residual chlorine. 16. Ammonical nitrogen

17. Oil and Grease

(2)For Process / Flue gas emission

1. Particulate matter – SPM, PM10, PM2.5

2. Sulphur dioxide

3. Oxides of nitrogen

4. Other process gases like HCl, Cl2, NH3 etc.


(3)For Ambient Air

1. Sulphur dioxide

2. Oxides of nitrogen

3. Suspended particulate matter

4. Other gases like HCL, Cl2 etc.

5. Ground level ozone concentration

(G) Details of Technical Persons :

Sr. No.

Name Qualifications Responsibilities in EIA report

Total Experience

1 Mr. Samir C. Choksi

B.E. (Civil), M.E.

(Env. Eng.)

EIA co-ordinator, FAE – AP

20 years with GPCB (1978 – 1998) Since 1998, working as Technical Director of the company

2 Ms. Prakruti Shah

M.E. (Env. Mgmt.),

Diploma in Env. Management & ISO 14000/1,

Diploma in Industrial Safety

FAE – WP 7.5 years

3 Ms. Bhavisha Shah

B.E. (Env. Engg.)

FAE – SHW 11 years

4 Ms. Krupa Oza B.E. (Env. Engg.)

FAE – AQ 5.5 years

5 Prof. A. B. Vora Ph.d. (Botany) FAE – EB 55 years

6 Mr. Ajay Mishra B.Com, Masters in Sociology

FAE – SE 14 years

7 Mr. Sanket Patel M.Sc. (Env. Science),

Masters in Information

System

Landuse Pattern, Baseline data

generation work

4 years

8 Mr. Bhavin Mudiya

M.E. (Env. Mgmt.)

EIA Compilation 1.5 Years

9 Mr. Bhargav Patel

B.E. (Env. Engg.)

EIA Compilation 8 Months

10 Ms. Hiral Mehta M.Sc. (Env. Science)

Baseline data generation work

1 year


Empanelled Experts

1 Dr. N. S. Varandanisir EIA co-ordinator

2 Mr. Vinay kumar FAE – NV, LU

3. Mr. Nirzar Lakhia FAE – GW

4. Mr. B. S. Lolle FAE-GS

5. Mr. Gopal Shah FAE-RH


Documents

Annexure:Document of EIA/EMP - …environmentclearance.nic.in/writereaddata/FormB/EC/EIA_EMP/... · measures. Prakruti Shah Period of involvement : ... 4.3.2.2 Dispersion Modelling