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Expansion of Pesticide, Pesticide Intermediates
and Fine Chemicals manufacturing at PI
Industries Ltd. Plot No.237, GIDC Estate Panoli,
Ankleshwar, Gujarat
Environmental Consultant
EQMS INDIA PVT. LTD. INDIA
304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower,
Community Centre, Karkardooma, Delhi – 11009
Nabet certi: QCI/NABET/ENV/ACO/18/0701
Website: www.eqmsindia.com
E-mail – [email protected]
PI External
CONTENTS 1. EXECUTIVE SUMMARY .................................................................................................................................. 4
2. INTRODUCTION ............................................................................................................................................. 5
2.1 Identification of Project and Project Proponent ............................................................ 5
2.2 Brief Description of the Project ...................................................................................... 6
2.3 Need for the Project and Its Importance to the Country and / or Region .................. 6
2.4 Demand Supply Gap ....................................................................................................... 6
2.5 Import vs. Indigenous Production .................................................................................. 7
2.6 Export Possibility ............................................................................................................ 7
2.7 Domestic / Export Markets.............................................................................................. 7
2.8 Employment Generation (Direct and Indirect) due to the project ................................ 7
3. PROJECT DESCRIPTION .................................................................................................................................. 8
3.1 Type of Project Including Interlinked and Interdependent Projects ............................ 8
3.2 Location (Map Showing General Location, Specific Location and Project Boundary and Project Plant Layout) with co-ordinates ....................................................................... 8
3.3 Details of alternate sites considered and the basis of selecting the proposed site ... 9
3.4 Size or Magnitude of Operation .....................................................................................10
3.5 Technology and Process Description ...........................................................................11
3.6 Raw material required along with estimated quantity & Storage details. ...................15
3.7 Resource optimization / recycling and reuse envisaged in the project, if any. .........15
3.8 Availability of water its source, energy/power requirement and their source. ..........15
3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal ..................................................................................................16
4. SITE ANALYSIS.............................................................................................................................................. 22
4.1 Connectivity ....................................................................................................................22
4.2 Land Form, Land Use and Land Ownership .................................................................22
4.3 Topography (along with map) .......................................................................................22
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ. .............................................................23
4.5 Existing Infrastructure ...................................................................................................26
4.6 Soil classification ...........................................................................................................26
5. PLANNING BRIEF ......................................................................................................................................... 28
5.2 Population Projection ....................................................................................................28
5.3 Land use Planning .........................................................................................................28
5.4 Assessment of Infrastructure Demand .........................................................................28
PI External
5.5 Amenities / Facilities ......................................................................................................28
6. PROPOSED INFRASTRUCTURE .................................................................................................................... 29
6.1 Industrial Area (processing area) ..................................................................................29
6.2 Residential Area (non-processing area) .......................................................................29
6.3 Green belt .......................................................................................................................29
6.4 Social Infrastructure .......................................................................................................29
6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.) ................29
6.6 Drinking water management (source and supply of water) .........................................29
6.7 Sewage system ...............................................................................................................29
6.8 Industrial waste water management .............................................................................29
7. REHABILITATION AND RESETTLEMENTS (R AND R) PLAN .......................................................................... 31
8. PROJECT SCHEDULE AND COST ESTIMATE ................................................................................................. 32
8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given) ........................................................................................................32
8.2 Estimated project cost along with analysis in terms of economic viability of the project. ..................................................................................................................................32
9. ANALYSIS OF PROPOSAL ............................................................................................................................. 33
9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area .......................................................33
PI External
Annexure
Annexure I Site layout map
Annexure II Product wise manufacturing Process
Annexure III Raw materials details
Annexure IV Water balance
Annexure V STP details
Annexure VI ETP Details
PI External
1. EXECUTIVE SUMMARY PI Industries Ltd (PI) is undertaking an expansion project of manufacturing facility at its existing
site located at Plot No. 237, GIDC-Panoli, Bharuch, Gujarat.
The Proposed Expansion Project falls under S.N. 5 (b) & 5(f) “Category “A”. Pesticide & pesticide
intermediates 5(b) and synthetic Organic Chemicals 5(f).
1. Name of the Industry PI Industries Ltd (PI)
2. Products to be manufactured Pesticides Technical & pesticides
intermediates and Synthetic Organic
Chemicals at 83250 MTPA capacity &
By Products 1,08,000 MTPA
3. Total Plot Area 56868 Sq.mt
4. Water Requirement Total Fresh Water requirement = 1200 KLD Industrial = 1020 KLD Domestic = 60 KLD Gardening = 120 KLD Source of Water- GIDC
5. Power Requirement Current requirement 40,800 KVA,
Proposed 61,200 KVA
6. Manpower Requirement Existing: 700
Proposed: 850
7. Total Project cost Rs 95 crores
PI External
2. INTRODUCTION
2.1 Identification of Project and Project Proponent
2.1.1 Project Proponent – PI Industries
PI Industries Ltd (PI) was incorporated in 1947 (as Mewar Oil & General Mills Ltd.) with its
registered office in Udaipur, Rajasthan. The company has three manufacturing facilities in Gujarat
and a Research & Development Centre at Udaipur. The manufacturing facilities include 4 multi-
purpose plants at Panoli and 5 multi-purpose plants at Jambusar.
PI has two business activities namely Agri Inputs and Custom Synthesis & Manufacturing. Agri
Inputs offers plant protection products, and specialty plant nutrient products and solutions. PI has a
strong rural reach and brand equity with millions of Indian farmers duly backed by a robust pipeline
of products, for sustained growth in the sector.
List of Chairman and Board of Directors:
Mr. Salil Singhal Chairman Emeritus
Mr. Narayan K. Seshadri Non-Executive Chairman
Mr. Mayank Singhal Managing Director and CEO
Mr. Rajnish Sarna Executive Director
Mr. Arvind Singhal Non-Executive Director
Mr. Ravi Narain Independent Director
Mrs. Ramni Nirula Independent Director
Mr. Pravin K. Laheri Independent Director
Dr. T.S. Balganesh Independent Director
PI External
2.2 Brief Description of the Project
The proposed expansion project is located within the GIDC wherein M/s PI Industries Limited
operates a plant at Plot No 237 GIDC-Panoli, Bharuch, Gujarat. M/s. PI Industries ltd. proposes to
manufacture Pesticide technical and pesticide intermediates [Category 5 (b)] and synthetic organic
chemicals [Category 5 (f)].
2.3 Need for the Project and Its Importance to the Country and / or Region
Agrochemicals are used to improve crop performance, yield or control pests. As per Indian Journal
of Ecology report, major crop losses due to non-usage of pesticides were about 17.5% of the yield
valued at ~INR 90,000 Cr per annum (FY12 estimated). It is estimated that the present food grain
production can increase from 3 Trillion Ton to 4 Trillion Ton by using appropriate crop protection.
Therefore, right usage of crop protection chemicals is essential in increasing agricultural
production by preventing crop losses before and after harvesting.
Crop losses in the country due to various pests range from 10 to 30 percent each year depending
upon the severity of pest attack. Pesticides play an important role in sustaining agricultural
production of the country by protecting crops from pest attacks and by keeping the pest population
under control. Availability of safe and efficacious pesticides and their judicious use by the farming
community is critical to a sustained increase in agricultural production and productivity. Pesticides
are also useful in health programs for controlling vectors responsible for diseases like malaria.
Pesticides proposed to be manufactured by the project proponent are widely used all over the
world including India. At present, there are only few industries in India manufacturing these
particular products, which have good market potential and will help farmers for better crop yield. By
using appropriate pesticides, up to 90% crop loss can be avoided in various crops. Benefit in terms
of saving of crop output is multifold compared to expenses for buying Agrochemicals.
It is thus, very much justified to manufacture these Pesticides not only to increase the market
availability but also to reduce import burdens of the country.
2.4 Demand Supply Gap
This would thus appear from the above that there is an unabridged major gap between the
demand and supply of pesticides for both public health and agriculture. The investments involved
in setting up of basic manufacturing plants as compared to formulation units are fairly high. It has
been possible for small scale entrepreneurs to go in for formulation business but financially not
PI External
possible to invest in basic manufacturing facilities. In the country basic manufacturing are mostly
with large scale multi-national companies and, in some cases, may be wholly owned by them. In
view of the fact that the present companies of these subsidiaries have sizeable capacities for the
manufacture of basic chemical in their own countries, they are reluctant to invest money for basic
manufacture in India. Also, these companies are reluctant to transfer technology and losing
monopoly sales especially when these products are proprietary.
2.5 Import vs. Indigenous Production
The Indian crop protection industry was estimated to be USD 4.25 billion in FY14 and is expected
to grow at a CAGR of 12% to reach USD 7.5 billion by FY19. Globally, India is fourth largest
producer of crop protection chemicals, after United States, Japan and China. The crop protection
companies in India can be categorized into three types –Multi-National, Indian including public
sector companies
2.6 Export Possibility
Global generic market of pesticides was $45 billion. Export opportunities for Indian companies are
immense with Key markets being USA, France, Netherlands, South Africa, and Bangladesh. All the
products have very high possibilities of Export.
2.7 Domestic / Export Markets
The Indian pesticides industry grew at a rate of 8-9% over the past five years (fy07-fy11). Industry
size is estimated to be $3.8 billion in FY11 with exports accounting for~50% of the market. Over
the XIIth plan period, the segment is expected to grow at 12-13%per annum with domestic demand
growing at 8-9% per annum and export demand growing at 15-16% per annum. Based on the
Export Potential and Potential for increased penetration in the domestic market, the Indian
agrochemical industry target a size of US $7.7 billion by FY17. 6 The technical grade pesticides
will be sold to many formulators all over the country. At the same time export will be done to Middle
East, Latin America and south Asian countries.
2.8 Employment Generation (Direct and Indirect) due to the project
PI Industries Ltd, Gujarat generates the employment on various levels time to time and gives the
priority to local persons. After expansion additional 150 vacancies will be created. The total
employment at the site post expansion will be 850.
PI External
3. PROJECT DESCRIPTION 3.1 Type of Project Including Interlinked and Interdependent Projects
3.1.1 Type of Project
The proposed project is for manufacturing pesticide technical, pesticide intermediate and synthetic
organic chemicals that is covered under S.N. 5 (b) & 5(f) respectively “Category A” projects of
MoEF&CC as per the new EIA notification vide gazette no. S.O. 1533 dated 14th September,
2006.
3.1.2 Interlinked and Interdependent Project
There is no interlinked project.
3.2 Location (Map Showing General Location, Specific Location and Project Boundary and
Project Plant Layout) with co-ordinates
The proposed facility is located at GIDC-Panoli. The total plot area of the unit is 56868 Sq.mt.
Coordinates of the proposed project is 21°34’ 52.74” N and 72°59’42.61” E Google map showing
coordinates of the site is given as Figure 3.1. Location map of proposed site is given as Figure
3.2. Site layout map of proposed site is given as Figure 3.3
Figure 3.1 Site Location Map
PI External
Table 3-1: Co-ordinates of GIDC Area
Points Latitude Longitude
A 21.583056 72.994208
B 21.583101 72.995232
C 21.579519 72.996627
D 21.579215 72.994540
Figure 3.2 Location Map in Google Image
Site Layout Map is given as Annexure-I
3.3 Details of alternate sites considered and the basis of selecting the proposed site
No alternate sites were evaluated as the proposed site is operating at GIDC with all infrastructure
including land, water, power supply, common treatment facility and other infrastructure is readily
available.
PI External
3.4 Size or Magnitude of Operation
PI plans to produce Pesticides and its intermediates, Fine Chemicals, Formulation, R&D products
& Synthetic Organic Chemicals at 83250 MTPA capacity & By-products of 108000 MTPA capacity
at its plant, located at plot No. 237, GIDC Estate, Panoli, District Bharuch.
Table 3.2 Product list of Pi Industries site-I
S.No. Groups Quantity
(TPA)
EC
Category
1 Insecticides and Intermediates 10000 5 (b)
2 Herbicides and Intermediates 8000
3 Fungicides and Intermediates 8000
4 Acaricide & Intermediates 2000
5 Synthetic Organic Chemicals 10000 5 (f)
6 Pharma intermediates 1000
7 R&D Products for pilot scale 250
8 Formulation 44000
Total 83250
Table 3.3 List of By-Products
S.No. By Products Revised (MT)
1 SMM 8000
2 NaSH/Na2s 5000
3 NaBr/Hbr/MgBr 50000
4 Distilled Solvent 15000
5 HCl 12000
6 Ammonia Solution 1500
7 H2SO4 5000
8 Sodium Propionate 3000
9 Acetic Acid 1500
10 Ortho Cresol 1000
11 Propionic Acid 1500
12 Sodium hypochloride 2000
PI External
S.No. By Products Revised (MT)
13 Ammonium Chloride 2500
Total 108000
3.5 Technology and Process Description
Attached below is the general process flow diagram and description for the manufacturing process.
Depending on the type of product produced suitable operation will be employed.
Figure 3-4: Typical Flow Diagram for PI Products
PI External
Description of Manufacturing Process
Raw Material Preparation: Various types of organic and inorganic chemicals are used in the
manufacturing process. In the raw material preparatory stage, the desired raw materials are
weighed and mixed together in proportion. The type of raw materials depends on the product being
manufactured. For e.g. in the manufacturing of product Orysastrobin raw materials like MIPD-
Ketal, Methoxy Amine Hydrochloride, Sodium Methylate etc. is utilized in various proportions.
Reaction in Reactor System:
The next step in manufacturing process involves various types of chemical reactions that take
place in reactors. The MOC of the reactors are either SS-316 or MS Glass Lined reactor. The
major chemical reactions involved in production are: alkylation, carboxylation, acetylation,
condensation, cyclization, dehydration, halogenation, oxidation, sulphonation, nitration and
amination.
Fractionation:
Fractionation is a separation process in which a certain quantity of a mixture (gas, solid, liquid,
enzymes, suspension, or isotope) is divided during a phase transition, into a number of smaller
quantities (fractions) in which the composition varies according to a gradient. Fractions are
collected based on differences in a specific property of the individual components.
Crystallization:
Crystallization is the (natural or artificial) process by which a solid forms, where the atoms or
molecules are highly organized into a structure known as a crystal. The crystallization process
consists of two major events, nucleation and crystal growth which are driven by thermodynamic
properties as well as chemical properties. In Crystallization, nucleation is the step where the solute
molecules or atoms dispersed in the solvent start to gather into clusters, on the microscopic scale
(elevating solute concentration in a small region), that become stable under the operating
conditions. These stable clusters constitute the nuclei. Therefore, the clusters need to reach a
critical size in order to become stable nuclei. Such critical size is dictated by many different factors
(temperature, supersaturation, etc.). It is at the stage of nucleation that the atoms or molecules
arrange in a defined and periodic manner that defines the crystal structure — note that "crystal
structure" is a special term that refers to the relative arrangement of the atoms or molecules, not
the macroscopic properties of the crystal (size and shape), although those are a result of the
internal crystal structure.
PI External
The crystal growth is the subsequent size increase of the nuclei that succeed in achieving the
critical cluster size. Crystal growth is a dynamic process occurring in equilibrium where solute
molecules or atoms precipitate out of solution, and dissolve back into solution. Supersaturation is
one of the driving forces of crystallization, as the solubility of a species is an equilibrium process
quantified by Ksp. Depending upon the conditions, either nucleation or growth may be predominant
over the other, dictating crystal size.
Filtration:
Filtration is any of various mechanical, physical or biological operations that separate solids from
fluids (liquids or gases) by adding a medium through which only the fluid can pass. The fluid that
passes through is called the filtrate. For filtration Agitated Nutsche Filter (ANF) is utilized. Agitated
Nutsche filters are fabricated in materials like Hastelloy & stainless steel. A typical unit consists of
a dished vessel with a perforated plate. The entire vessel is kept at the desired temperature by
using a limpet jacket, jacketed bottom dish and stirrer (blade and shaft) through which heat transfer
media flows. The vessel is made completely leak-proof for vacuum or pressure service. In Filtration
the following five steps are followed:
1. Filling/Charging
The first step involves the transferring of the product to be filtered, usually an aqueous or solvent
based solid/liquid slurry, from the reactor to the filter. The filter is sized appropriately to handle the
solids volume that is being charged
2. Filtering
The second step involves the use of pressure and/or vacuum to force liquid through the solid bed
and filter media. The process is stopped when solids are visible, or can be continued until all the
liquid is pushed out. There are various types of filter media available in nutsche filters – cloth,
single layer metal screen, or multi-layer sintered metal. The media is determined based on the
characteristics of the slurry including particle size and shape, cake porosity, and, will determine
filtration rate).
3. Displacement Washing
Here, fresh wash liquid is sprayed on top of the solid cake taking care not to disturb the surface of
the cake. The liquid is forced through with pressure or vacuum. Displacement washing serves
several purposes – it removes the liquid and its impurities while keeping the cake intact and it
PI External
replaces the previous liquid with fresh liquid. There is also the opportunity prior to this step to try
and close cracks if the cake has any via smoothing.
4. Reslurry Washing
As an additional washing option, a re-slurry washing is sometimes performed if additional
extraction or dissolving of impurities is necessary. This is executed by the addition of fresh wash
liquid that is mixed with the solids. The agitator is stopped and raised before filtering the wash
liquid. The re-slurry process is also used when a long contact time is needed between the wash
fluid and the solids or the displacement wash does not provide the required wash quality.
5. Smoothing
This next step is used after any filtration or wash, especially after the final wash, when gas is blown
through the cake. The agitator is used to close cracks and compress the cake to reduce residual
moisture level. This function helps to achieve uniform flow of liquid or gas through the filter cake,
while helping to eliminate liquid and gas channelling that reduces the efficiency of displacement
washing and gas blow through.
Drying:
Drying is carried out with the aid of Rotary Vaccum Dryer (RVD) or Pan Dryer.
Rotary Vacuum Dryers (RVD) also known as Vanuleuth Dryer is a cylindrical jacketed vessel with
a central agitator having specially designed blades. The drying in a rotary vacuum dryer is a batch
operation under vacuum. It is done to dry heat sensitive materials at well below boiling points of
water and solvents. Drying time depends on material being dried, amount of solvent or water to be
removed, desired final moisture content, permissible jacket temperature etc. The volume of wet
material loaded into the dryer is usually restricted to 50% of gross volume.
The blades of this Rotary Vacuum Paddle Dryer (RVPD) are so designed that they sweep the
entire internal surface and at the same time turn the material so that all the particles come in
contact with the heated surface. The central agitator shaft is supported on the two end bearings
housed in bearing housing in such a way that the alignment remains always intact. This central
agitator is driven by means of a Motor & Gear box through the bull Gear. Cooling is provided by
cold water / brine refrigerant through the jacket. The horizontal shell is jacketed to heat the shell
with steam/hot water. Limpet coil is provided instead of jacket if the heating media is thermic fluid.
A Vacuum Pump of adequate capacity is provided & fitted to the receiver of rotary vacuum dryers
to create the vacuum in the dryer shell through the Receiver, Condenser and Dust Catcher.
PI External
Rotary Vacuum Dryer gives drying, mixing and breaking effects simultaneously. Wet cake or slurry
is fed through charging door, while the agitator is rotating in clockwise direction, vacuum is applied
in the dryer and heating media is circulated in the jacket. Evaporation of moisture takes place
under vacuum and vapours passes through the dust catcher into the condenser, where it is
condensed and collected in the receiver. Dried material is discharged through discharge valve. The
lump breaker rods are provided to achieve good drying effect.
Pan Drier: The atmospheric pan drier has a jacketed round pan in which a stirrer revolves slowly,
driven from below. The slow moving stirrer exposes fresh surfaces and thereby raises the rate of
evaporation and, hence, of drying. The pan drier is a batch machine and is limited to small
batches.
Packing:
The final stage of the manufacturing process is packaging of the finished product. The packaging
of the finished product is carried out in a closed room. Packaging is done using 400 Kg Jumbo
Bags or 50/100 Kg cardboard drum. The packed product is appropriately labelled and stored in the
finished good godown for shipment to various parts of the country and abroad.
Product wise manufacturing process is given in Annexure- II
3.6 Raw material required along with estimated quantity & Storage details.
List of raw material given in Annexure-III
3.7 Resource optimization / recycling and reuse envisaged in the project, if any.
The solvent distillation system shall be designed so as to achieve minimum 92% - 95% recovery of
solvent. Energy efficient equipment will be installed at all locations. The company has full-fledged
effluent treatment plant in its premises with primary, secondary and tertiary treatment systems. The
treated waste water is transferred to guard pond where its final analysis is done. From here the
treated waste water is discharged to Panoli pumping station. From Panoli pumping station treated
waste water is discharged into FETP through pipeline and ultimately discharges into deep sea
through NCT pipeline.
3.8 Availability of water its source, energy/power requirement and their source.
3.8.1 Water consumption
Total Fresh Water requirement = 1200 KLD
Industrial = 1020 KLD
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Domestic = 60 KLD
Gardening = 120 KLD
Source of Water- GIDC Supply
Water balance is given as Annexure- IV
3.8.2 Power Requirement
Current requirement 40,800 KVA, proposed 61,200 KVA. The power requirement is met via captive
power plants (CPP-1 & CPP-2) & the power sourced from DGVCL. In addition, the plant is
proposing an additional captive power plant to meet the energy demands arising out of the
proposed expansion. Also the company plans to install a 66 KVA substation at the site. As an
emergency back-up the plant has proposed 1 DG set of 1250 KVA capacity and 4 D.G. Sets of
1500 KVA capacity with common stack.
3.8.4. Fuel Requirement
Table 3-4: Fuel Consumption
S.No. Equipment Present
Equipment
status
Fuel Existing
Quantity
Proposed
1
Boiler + Gas
Turbine +
Thermic
Fluid Heater
Existing Natural
Gas
40000 SM3/day 100000
SM3/day
LDO 250 Lit/Day 1000 Lit/day
FO 731 Lit/hr 2500 Lit/hr
2 D.G. Sets (5
Nos.)
Proposed HSD - 45000 Lit/Day
3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management
/disposal
The generation of pollutants associated with the proposed expansion will be in the form of gaseous
emissions, liquid effluent, solid waste, and hazardous waste.
3.9.1 Process Stack Emission
The PI plant will have following sources of emission namely,
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Table 3.5 Process Stack Emission and Control Measures
Sr. No.
Stack attached to
Stack Height (Mtr.)
Current Status
Probable Pollutants
Air Pollution Control Measures
Permissible Limit
1 Process Stack MPP-1
26.5 Existing HBr Hypo scrubber followed by alkali scrubber
30 mg/Nm3
Br 02 mg/Nm3
SO2 40 mg/Nm3
H2S 45 mg/Nm3
Pesticide compound in the form of Particulate matter
20 mg/Nm3
2 Process Stack MPP-2
26.5 Existing HCl Alkali Scrubber
20 mg/Nm3
Cl2 9 mg/Nm3
HC 15 mg/Nm3
3 Process Stack MPP-3
26.5 Existing HCl Alkali scrubber
20 mg/Nm3
Cl2 05 mg/Nm3
NH3 30 mg/m3
Mercaptan 0.5 PPM
4 Process Stack MPP-4
26.5 Existing HCl Alkali scrubber
20 mg/Nm3
5 Process stack– 4 A
26.5 Proposed NH3 Acid scrubber
30 mg/Nm3
6 Process Stack
MPP-4B
26.5 Proposed HCl Alkali scrubber
20 mg/Nm3
Cl2 9 mg/Nm3
NH3 30 mg/Nm3
SO2 40 mg/Nm3
Pesticide compound in the form of particulate matter
20 mg/Nm3
PI External
3.9.2 Flue Gas Emission
3.9.3 Waste Water Treatment and Disposal
Sr. No.
Stack attached to
Stack Height (Mtr.)
Current Status
Probable Pollutants
Air Pollution Control Measures
Permissible Limit
7 Process Stack
MPP-4C
26.5 Proposed HCl Alkali scrubber
20 mg/Nm3
Cl2 9 mg/Nm3
SO2 40 mg/Nm3
NH3 30 mg/Nm3
Pesticide compound in the form of particulate matter
20 mg/Nm3
8 Fume Incinerator
40 (Common Stack for
fume incinerator & Rotary
Kiln incinerator)
Existing
PM Quencher & Caustic Scrubber
50 mg/Nm3
SO2 200 mg/Nm3
9 Rotary Kiln
incinerator
PM Caustic Scrubber, Multi-cyclone, Ventury followed by packed bed scrubber & demister
50 mg/Nm3
HCl 50 mg/Nm3
SO2 200 mg/Nm3
CO 100 mg/Nm3 (30 mins)
TOC 20 mg/Nm3
Total dioxin and furan 0.1 ng TEQ/Nm3
Sb+As+Pb+ Cr+CO+Cu+Mn+Ni+V+their compound
0.5 mg/Nm3
Sr. No.
Stack attached To
Current status
Fuel Stack Height (Mtr.)
Parameters
1 Boiler 1 & Boiler 2. (Common Stack)
Existing NG/FO 54 PM 150 mg/Nm3 SO2 100 PPM NOx 50 PPM 2 Thermic Fluid Heater Existing NG/FO 20
3 Power Plant -1 (2.4 MW) Existing NG 30
4 Power Plant -2 (2.4 MW) Existing NG 30
5 Power Plant-3 (2.5 MW) Proposed NG 30
6 D.G. (4 Nos. of 1500 KVA + 1 No. of 1250 KVA
capacity) Common stack
Proposed HSD 30
PI External
Current waste water generation 208 KLD and proposed generation will be 650 KLD. The current
treated effluent disposal from the site is 143.575 KLD and the proposed quantity is 250 KLD. The
treated effluent conforming to the statutory standards shall be discharged into final pumping station
at Panoli and conveyed to FETP of NCT for ultimate disposal in deep sea. Toxic effluent of 35 KLD
shall be incinerated in house or in approved common incineration facility or sent for co-processing.
High TDS waste of 205 KLD shall be treated in MEE in in-house facility or any other approved
common facility.
Sewage System
Domestic wastewater treated in sewage treatment plant will be treated and used in gardening and
for any other appropriate use deemed fit. Detail of Sewage Treatment Plant is given as Annexure-
V
Effluent Treatment Plant
Industrial effluent is treated in the state of the art effluent treatment plant which comprises of
primary and secondary treatment units. The treated waste water is transferred to guard pond
before disposal to FETP of NCT. Before the discharge of treated waste water online TOC meter is
available which is connected to CPCB server. Detail of Effluent Treatment Plant is given as
Annexure-VI
3.9.4 Solid / Hazardous Waste
PI being an environmentally conscious Organization has always emphasized on pollution
prevention rather than pollution Control. To strengthen the waste management system, different
types of wastes are identified along with proper disposal / recycling / reuse mechanisms.
Basically the following types of solid wastes are generated at PI:
Table 3.6 Hazardous Waste Generation and disposal Details
Sr.No.
Type of Hazardous Waste
Unit Category Total Quantity
Method of Disposal
1a Sludge ( ETP)
MT/Annum
34.3 24000 Collection, storage, transportation and disposal in approved common TSDF
1b Sludge (MEE)
MT/Annum
34.3 26000 Collection, storage, transportation and disposal in approved common TSDF
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Sr.No.
Type of Hazardous Waste
Unit Category Total Quantity
Method of Disposal
2 Incinerator Ash
MT/Annum
36.2 7000 Collection, storage, transportation and disposal in approved common TSDF
3 Process solid wastes /residues
MT/Annum
29.1 22000 Collection, storage, & Incineration in house or in approved common incineration facility or co-processing
4 Spent oil/other spent lube oil/ system
KL/Annum 5.1 18000 Collection, storage, & Incineration in house or in approved common incineration facility or Sale to Authorized recyclers
5 Packing waste
MT/Annum
33.3 3600 Tons or 6,00,000 Nos./Annum
Recycled or sold to authorized end users or disposal in approved common TSDF
6 Spent Solvent
MT/Annum
20.2 18000 Collection, storage, & Incineration in house or in approved common incineration facility or Co-processing or reuse by in-house solvent distillation or Sale to GPCB Authorized recyclers/ distillators/re-processor for recovery
7 Solvent Distillation Residue
MT/Annum
20.3 6000 Collection, storage, & Incineration in house or in approved common incineration facility or co-Processing
8 Spent catalyst
MT/Annum
35.2 500 Collection, storage, & Incineration in house or in approved common incineration facility or Send to Authorized recyclers/ re-processors for recovery
9 Spent Carbon
MT/Annum
35.3 500 Collection, storage, & Incineration in house or in approved common incineration facility or Send to Authorized recyclers/ re-processors for recovery or co-processing
10 Spent Resin
MT/Annum
34.2 100 Collection, storage, transportation and disposal in approved common TSDF
11 Filter & Filter cake
MT/Annum
35.1 100 Collection, storage, & Incineration in house or in approved common incineration facility/Co-processing
12 Date Expired off specification products
MT/Annum
29.3 1000 Collection, storage, & Incineration in house or in approved common incineration facility/co-processing
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Sr.No.
Type of Hazardous Waste
Unit Category Total Quantity
Method of Disposal
13 Contaminated cotton rags or other cleaning materials
MT/Annum
33.2 500 Collection, storage, & Incineration in house or in approved common incineration facility/co-processing
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4. SITE ANALYSIS
4.1 Connectivity
The plant site is well connected by road to the major national and state highway network.
The approach road to the site is suitable for movement of heavy loads involved including the
construction materials.
S. No Location Distance in KM
1 Nearest Railway Station Ankleshwar Junction (4.9 Km, N)
2 Nearest Air Port Surat International Airport (57.34 Km, SSW)
3 Nearest Highway NH 8
4.2 Land Form, Land Use and Land Ownership
Land Form: GIDC Land
Land Use: Industrial
Land ownership: It will be incorporated in EIA Studies.
4.3 Topography (along with map)
Bharuch district is located in the Sourthern part of Gujarat, near the Gulf of Khambhat in Arabian
Sea. In 1997, Bharuch district is bifurcated into two parts (1) Narmada District and (2) Bharuch
District. The newly formed Bharuch District has 5253.30 Sq.km. area and situated between 21.30’
to 22.00’ North Latitude and 72.45’ to 73.15’ East Longitude Bharuch District comes under Seismic
Zone- III. Bharuch District is bounded by Baroda and Anand District on the North, Narmada District
on the East, Surat District is on the South and on its west lies the Gulf of Cambay. The Eastern
strip of the district is a hilly and forest area. Main rivers in Bharuch District are Narmada, Dhadhar
and Kaveri. The rivers flow throughout the year.
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Figure 4-2: Location Map in Topo Map)
(SOURCE India and Pakistan series U.S Army Map series 1955)
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including
area under CRZ)), shortest distances from the periphery of the project to periphery of the
forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from
the HFL of the river), CRZ.
● Existing Land use pattern: Industrial
1 Areas protected under
international
conventions, national or
local legislation for their
ecological, landscape,
cultural or other related
value
No
There are no Areas protected under international
conventions, national or local legislation for their
ecological, landscape, cultural or other related value
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2 Areas which are
important or sensitive for
ecological reasons -
Wetlands, watercourses
or other water bodies,
coastal zone,
biospheres, mountains,
forests
Yes There is Amlakhadi Creek at a distance of 1.70km(E)
3 Areas used by protected,
important or sensitive
species of flora or fauna
for breeding, nesting,
foraging, resting, over
wintering, migration
No
There are no Areas used by protected, important or
sensitive species of flora or fauna for breeding, nesting,
foraging, resting, over wintering, migration
4 Inland, coastal, marine or
underground waters
Yes There is Amlakhadi Creek at a distance of 1.70km(E)
5 State, National
boundaries No There are no state or National boundaries
6 Routes or facilities used
by the public for access
to recreation or other
tourist, pilgrim areas
Yes NH-8,0.38km(E)
7 Defense installations No There are no Defense installations
8 Densely populated or
built-up area Yes Sanjali,3.27km(S)
9 Areas occupied by
sensitive man-made land
uses (hospitals, schools,
places of worship,
community facilities)
Yes
Shree Gattu Vidhalaya(3.85km,NE)
Shree Rang Childerns Hospital(4.34km,NE)
10 Areas containing
important, high quality or
scarce resources
No
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(ground water resources,
surface resources,
forestry, agriculture,
fisheries, tourism,
minerals)
11 Areas already subjected
to pollution or
environmental damage.
(Those where existing
legal environmental
standards are exceeded)
No -
12 Areas susceptible to
natural hazard which
could cause the project
to present environmental
problems (earthquakes,
subsidence, landslides,
erosion, flooding or
extreme or adverse
climatic conditions)
Project area falls in the seismic zone-III (Moderate Risk Zone)
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Figure 4.6 Environment Sensitivity Map of Pi Industries Site I
4.5 Existing Infrastructure
This is a proposed expansion project within existing site, hence there is already infrastructure
available at the site. The Project proponent has available infrastructure like water, electricity,
roads, transportation, storage sheds, parking, availability of raw material and drainage system.
4.6 Soil classification
The soil in the study area is deep black clayey soil.
4.7 Climatic data from secondary sources
The climate of region is moderate with greater humidity on its coastal side. The weather of
Bharuch district is hot and dry-starting from mid-march till mid-June, mid during summer season
weather remains hot and dry. While from mid-June till end of September weather remains humid
and can be considered pleasant. From October-November weather is bit hot. From December to
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February climate remains cool. The Climatological data of nearest India Meteorological
Department (IMD) station - Bharuch is given below:
Month Temp. Humidity Wind
speed
Solar
Radiation
Rainfall
Max. (C) Min. (C) (%) kmph (MJ/m2 /d) mm
Jan 31.3 11.9 51.5 5.9 17.3 1.2
Feb 33.8 14.4 45.0 6.2 19.6 1.2
Mar 37.6 19.0 44.0 7.0 22.7 0.8
Apr 40.0 23.3 45.0 8.8 25.2 1.0
May 39.6 26.2 55.5 12.4 26.2 12.5
Jun 35.6 26.5 69.5 14.7 21.3 121.0
Jul 32.0 25.5 81.0 13.2 16.5 307.6
Aug 31.2 25.0 83.5 11.5 15.9 243.1
Sep 32.6 24.4 76.0 8.6 18.1 197.6
Oct 35.9 22.0 59.5 5.7 18.5 35.2
Nov 34.8 16.9 52.5 4.7 16.5 3.7
Dec 32.2 13.2 53.5 5.2 16.5 0.1
Average 34.7 20.7 59.7 8.7 19.5 Total 924.8
Source: Groundwater Brochure, Bharuch Dist., Central Ground Water Board (CGWB), Ahmedabad, March
2014
4.8 Social infrastructure available
Educational facilities in project area are quite good because all nearby villages/town have
primary schools.
The town has private dispensaries and hospitals in all major branches of medicines and
surgery.
All small villages have postal and telephone connection facilities.
Electricity for all purpose (industrial and residential) is available.
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5. PLANNING BRIEF
5.1 Planning Concept
The entire area is a well-developed industrial area with numerous industrial units.
5.2 Population Projection
During the Construction and Execution phase of the Project, it is estimated that about 100 workers will be involved for a period of about 12 months.
Thereafter during the operation phase at the new plant around 150 person’s positions will be created and employed.
5.3 Land use Planning
S.N. Area Description Area Sq.M
1 Production plants including ware house, utilities 15057
2 Administration, QC, R&D, HSE, Security and
welfare facilities
3444
3 Open Areas, Roads, Pathway & Auxiliary 18186
4 ETP, Laboratory, APCM 2731
5 Green belt/Plantation 14220
6 Other Miscellaneous Facility 3230
Grand Total 56868
5.4 Assessment of Infrastructure Demand
PI Industry 1 is an existing unit located inside Notified GIDC Industrial estate. Well-developed
Infrastructure is already existed as project site is located inside Notified Industrial estate GIDC.
5.5 Amenities / Facilities
Following facilities will be made available at site:
● First Aid Facility/ OHC (occupational health center)
● Hygienic Drinking Water Facility
● Green Area
● Regular Worker Medical Checkup Facility
● Change Room for Workers
● Canteen facilities
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6. PROPOSED INFRASTRUCTURE 6.1 Industrial Area (processing area)
Site located in Notified industrial area developed by GIDC, Ankleshwar.
6.2 Residential Area (non-processing area)
No residential facility will be provided.
6.3 Green belt
The Proposed Project Plant will have 14220 Sq.M Green Belt
6.4 Social Infrastructure
Canteen, Rest shelter / room, Recreation Room is provided and it will be augmented.
6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)
The expansion project will be at existing site only which is located inside Notified GIDC industrial
estate of Ankleshwar. The existing connectivity is convenient for future also.
6.6 Drinking water management (source and supply of water)
Existing unit & the source of drinking water is from GIDC water supply & same will be continue for
proposed expansion.
6.7 Sewage system
Sewage generated will be sent to STP operated by the PI Industries Ltd.
6.8 Industrial waste water management
The company has full-fledged effluent treatment plant in its premises with primary, secondary and
tertiary treatment systems. The treated waste water is transferred to guard pond where its final
analysis is done. From here the treated waste water is discharged to Panoli pumping station. From
Panoli pumping station treated waste water discharge into FETP through pipeline and ultimately
discharges into deep sea through NCTL pipeline.
Domestic wastewater treated in sewage treatment plant will be used in gardening or any other
suitable purpose within the unit.
6.9 Solid waste management
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Hazardous wastes generated will be maintained as per Hazardous Waste (Management, Handling
and Transboundary Movement) Rules, 2016 and will be disposed of as per the details given in
Table 3-6.
6.10 Power requirement and supply/ source
Current requirement 40, 800 KVA, proposed 61,200 KVA. The power requirement is met via
captive power plants (CPP-1 & CPP-2) & the power sourced from DGVCL. The unit has proposed
additional power plant (CPP-3) to meet its energy demands owing to proposed expansion. Also the
Unit will install a 66 KVA substation at the site for power transmission.
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7. REHABILITATION AND RESETTLEMENTS (R AND R) PLAN
Not applicable as rehabilitation and resettlement will not be required, since the project lies in an
Industrial Area, with land acquisition procedures completed by the GIDC.
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8. PROJECT SCHEDULE AND COST ESTIMATE
8.1 Likely date of start of construction and likely data of completion (time schedule for the
project to be given)
The proposed expansion project will start immediately after getting Environmental clearance from
Ministry of Environment, Forest and Climate Change (MoEF&CC) & Consent to Established (CTE)
from State Pollution Control Board (SPCB).
8.2 Estimated project cost along with analysis in terms of economic viability of the project.
The estimated project cost is 95 Crores. The expansion is in terms of capacity enhancement in the
existing multipurpose Plants and setting up of two additional multipurpose plants.
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9. ANALYSIS OF PROPOSAL 9.1 Financial and social benefits with special emphasis on the benefit to the local people
including tribal population, if any, in the area
The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to
be purchased. The project will improve the socio-economic status of the society in the region by
generating direct and indirect employment opportunities and lead to ensure continued employment
to existing workforce without affecting work conditions and hence supporting their families. The
project will contribute additional revenue to the State & Central exchequers in the form of taxes,
cess, etc.