rapid environmental impact assessment & environmental management plan of proposed

RAPID ENVIRONMENTAL IMPACT ASSESSMENT &

ENVIRONMENTAL MANAGEMENT PLAN

OF

PROPOSED EXPANSION OF ORGANIC CHEMICAL

MANUFACTURING PLANT

OF

KUTCH CHEMICAL INDUSTRIES LIMITED.

PLOT NO. 166/1-3, 171/1, 172,167,168, VILL: PADANA, GANDHIDHAM,

DI: KUTCH, GUJARAT

PREPARED BY

ECO-CARE SOLUTIONS

FIRST FLOOR, 40-A, MIRA SOC.DIWALIPURA.

VADODARA-390007

ECS

REIA of Kutch Chemical Industries Limited Table of Content

April - 2010 1

TABLE OF CONTENTS

EXECUTIVE SUMMARY ________________________________________________________ 9

1.0 INTRODUCTION__________________________________________________________ 17

1.1 SITE LOCATION _____________________________________________________________ 20

1.2. NEED FOR REIA _____________________________________________________________ 24

1.3 INDIAN POLICIES REQUIRING REIA ___________________________________________ 24

1.4 THE REIA CYCLE AND PROCEDURES _________________________________________ 25

1.5 METHODOLOGY & SCOPE OF REIA ___________________________________________ 25

1. 6 APPLICABLE ENVIRONMENTAL REGULATIONS AND STANDARDS ______________ 29

1. 6 APPLICABLE ENVIRONMENTAL REGULATIONS AND STANDARDS ______________ 30

1. 7 STRUCTURE OF THE REIA REPORT ___________________________________________ 30

2.0 PROJECT DESCRIPTION_____________________________________________ 31

2.1 SITE SETTINGS ______________________________________________________________ 31

2.2. PRODUCT PROFILE __________________________________________________________ 31

2.3. LAND DISTRIBUTION AT SITE ________________________________________________ 33

2.4. CAPITAL COST OF THE PROJECT _____________________________________________ 36

2.5. MANUFACTURING DETAILS__________________________________________________ 37 2.5.1 RAW MATERIALS ________________________________________________________________ 37 2.4.2 PROCESS DESCRIPTION ___________________________________________________________ 41

2.4.2.1 Vinyl Sulphone & Vinyl Sulphone Condense: _______________________________________ 41 2.4.2.3 Benzene Sulphonyl Chloride ____________________________________________________ 46 2.4.2.4 DASDA_____________________________________________________________________ 48 2.4.2.5 Dimethyl Sulphate ____________________________________________________________ 50 2.4.2.6 Dimethyl Aniline _____________________________________________________________ 51 2.4.2.7 Diethyl Sulphate ______________________________________________________________ 52 2.4.2.7 Diethyl Sulphate ______________________________________________________________ 53 2.4.2.8 Sulfamic Acid ________________________________________________________________ 55 2.4.2.9 Power Plant __________________________________________________________________ 56 2.4.2.9 Power Plant __________________________________________________________________ 57 2.4.2.10 Sulphuric Acid As_____________________________________________________________ 59 2.4.2.11 Chloro Sulphonic Acid ___________________________________________________________ 65 2.4.2.11 Chloro Sulphonic Acid ___________________________________________________________ 66 2.4.2.12 Thionyl Chloride________________________________________________________________ 66


April - 2010 2

2.4.2.12 Thionyl Chloride________________________________________________________________ 67 2.4.2.13 Sodium Bisulphite_____________________________________________________________ 69 2.4.2.14 Calcium Chloride _______________________________________________________________ 70 2.4.2.15 Di Calcium Phosphate___________________________________________________________ 71 2.4.2.16 Sulphur Monochloride _________________________________________________________ 73 2.4.2.17 Slphuryl Chloride_____________________________________________________________ 74 2.4.2.18 Aluminium Sulphate (ALUM) ___________________________________________________ 75

2.5. SOLVENT RECOVERY AND ITS MANAGEMENT ________________________________ 77

2.6. RESOURCE REQUIREMENTS__________________________________________________ 77 2.6.1 FUEL / ENERGY REQUIREMENTS __________________________________________________ 77

2.6.1.1 ENERGY ___________________________________________________________________ 77 2.6.1.2 FUEL ______________________________________________________________________ 78

2.6.2 WATER & WASTEWATER ________________________________________________________ 80

2.7 WASTEWATER MANAGEMENT _______________________________________________ 85 2.7.1 EFFLUENT TREATMENT PLANT____________________________________________________ 87 2.7.2 INCINERATOR PLANT_____________________________________________________________ 90 2.7.3 SEPTIC TANK & SOAK PIT _________________________________________________________ 91 2.7.4 QUANTITY OF WATER RECYCLED AND RECYCLING MECHANISM ____________________ 91

2.8 ATMOSPHERIC EMISSIONS ___________________________________________________ 92 2.8.1 FLUE GAS DETAILS_______________________________________________________________ 92 2.8.2 PROCESS EMISSION ______________________________________________________________ 93 2.8.3 QUANTIFICATION OF EMISSION ___________________________________________________ 94

2.8.3.1 Flue Gas Emission ____________________________________________________________ 94 2.8.3.2 Process Gas Emission __________________________________________________________ 95

2.8.4 FLUE GAS EMISSION/FUGITIVE EMISION CONTROL _________________________________ 95

2.9 HAZARDOUS WASTE MANAGEMENT_________________________________________ 96

2.10 SAFETY & OCCUPATIONAL MEASURE FOR STORAGE & HANDLING OF THE RAW

MATERIAL & PRODUCT ____________________________________________________________ 97

2.11 GREENBELT DEVELOPMENT _________________________________________________ 98

2.12 WATER RESOURCE & RAIN WATER HARVESTING _____________________________ 98

2.13 COMPLIANCE TO THE RECOMMENDATIONS MENTIONED IN THE CREP

GUIDELINES. ______________________________________________________________________ 99

2.14 PROJECT SUMMARY ________________________________________________________ 100

3.0 BASE LINE ENVIRONMENTAL STATUS ______________________________ 102

3.1 DEMOGRAPHIC & SOCIO ECONOMIC PROFILE (CENSUS OF INDIA 2001) _ 105


April - 2010 3

3.1.1 POPULATION ___________________________________________________________________ 105 3.1.2 LITERACY LEVELS ______________________________________________________________ 106 3.1.3 OCCUPATIONAL STRUCTURE. ____________________________________________________ 108 3.1.4 LAND USE PATTERN (CENSUS HANDBOOK-2001) ___________________________________ 112 3.1.5 PUBLIC AMENITIES _____________________________________________________________ 114

3.1.5.1 WATER SUPPLY ___________________________________________________________ 114 3.1.5.2 TRANSPORTATION & COMMUNICATION _______________________________________ 114 3.1.5.3 ELECTRICITY______________________________________________________________ 114 3.1.5.4 HELATH & MEDICAL FACILITY _____________________________________________ 114 3.1.5.5 EDUCTION FACILITIY ______________________________________________________ 114 3.1.5.6 PLACES OF HISTORICAL IMPORTANCE,/SENSITIVE AREAS ____________________ 114

3.2 GEOLOGICAL STRUCTURE __________________________________________________ 117 3.2.1 TOPOGRAPHY __________________________________________________________________ 118 3.2.2 HYDROLOGY ___________________________________________________________________ 118

3.3 WATER QUALITY___________________________________________________________ 120 3.3.1 DISCUSSION ____________________________________________________________________ 125

3.4 AIR MONITORING __________________________________________________________ 125 3.4.1 SELECTION OF SAMPLING LOCATIONS____________________________________________ 125 3.4.2 DETAILS OF THE SAMPLING LOCATIONS __________________________________________ 126 3.4.3 METHODOLOGY ADOPTED FOR AIR QUALITY SURVEY_____________________________ 129

3.4.3.1 FREQUENCY AND PARAMETERS FOR SAMPLING _____________________________ 129 3.4.3.2 DURATION OF SAMPLING: ____________________________________________________ 129 3.4.3.3 METHOD OF ANALYSIS: ____________________________________________________ 129 3.4.3.4 SAMPLING AND ANALYTICAL TECHNIQUES _________________________________ 129 3.4.3.5 SELECTION OF INSTRUMENTS FOR AIR QUALITY SAMPLING 8. & CALIBRATION 129

3.4.4 GENERAL OBSERVATIONS _______________________________________________________ 132

3.5 SOIL QUALITY _____________________________________________________________ 134 3.5.1 GENERAL OBSERVATIONS _______________________________________________________ 136

3.6 NOISE MONITORING ________________________________________________________ 136

3.7 METEOROLOGY ____________________________________________________________ 139 3.7.1 SITE SPECIFIC METEOROLOGICAL DATA __________________________________________ 139 3.7.2 PRESENTATION OF DATA ________________________________________________________ 142

3.8 FLORA & FAUNA ___________________________________________________________ 143

4.0 ENVIRONMENTAL IMPACT ASSESSMENT____________________________ 147

4.1 INTRODUCTION ____________________________________________________________ 147

4.2 IMPACT ASSESSMETN MATRIX______________________________________________ 147


April - 2010 4

4.3 OVERALL IMPACTS_________________________________________________________ 154

4.3 OVERALL IMPACTS_________________________________________________________ 154 4.3.1 IMPACT ON LAND/SOIL __________________________________________________________ 154 4.3.2 IMPACT ON AIR QUALITY. _______________________________________________________ 154 4.3.3 IMPACT ON GROUNDWATER _____________________________________________________ 157 4.3.4 IMPACT ON NOISE LEVELS _______________________________________________________ 157 4.3.5 IMPACT ON DEMOGRAPHY AND SOCIO-ECONOMICS _______________________________ 158

5.0 ENVIRONMENTAL MANAGEMENT PLAN ____________________________ 159

5.1 INTRODUCTION ______________________________________________________________ 159

5.2. MITIGATION MEASURES ____________________________________________________ 159

5.3 ENVIRONMENT MANAGEMENT CELL ________________________________________ 166

5.4 GREEN BELT DEVELOPMENT________________________________________________ 167

6.0 ENVIRONMENTAL MONITORING PLAN _____________________________ 168

6.1 EXPENDITURE ON ENVIRONMENTAL MATTERS ______________________________ 169

7.0 CONCLUSION ____________________________________________________________ 170

7.1 SUMMARY OF ENVIRONMENTAL IMPACTS __________________________________ 170

7.2 CONCLUSION ______________________________________________________________ 171

8.0 PROJECT BENEFITS _______________________________________________ 172

9.0 ADDITIONAL STUDIES _____________________________________________ 173

10.0 DISCLOSURE OF CONSULTANTS ENGAGED__________________________ 174


April - 2010 5

LIST OF TABLES

TABLE 1.1A LIST OF THE EXISTING PRODUCTS ________________________________________ 18

TABLE 1.1B LIST OF THE NEW PRODUCST AND EXPANSION REQUIRED _________________ 19

TABLE 2.1 PRODUCT PROFILE ________________________________________________________ 31

TABLE 2.2 LAND DISTRIBUTIONS AT SITE _____________________________________________ 33

TABLE 2.3 CAPITAL COST OF EXISTING & PROPOSED EXPANSION ______________________ 36

TABLE 2.3 PHYSICAL AND CHEMICAL PROPERTIES OF THE RAW MATERIAL & PRODUCTS

38

TABLE 2.4 STORAGE DETAILS OF MAJOR RAW MATERIALS_____________________________ 40

TABLE 2.5 DETAILS OF THE FUELS ___________________________________________________ 78

TABLE 2.6 FUEL CHARACTERISTICS__________________________________________________ 78

TABLE 2.7 FUEL STORAGE DETAILS___________________________________________________ 79

TABLE 2.8 SOURCE AND TRANSPORTATION DETAILS OF FUELS ________________________ 79

TABLE 2.9 TOTAL WATER REQUIREMENTS FOR THE PROJECT _________________________ 80

TABLE 2.10 WASTEWATER GENERATION FROM THE PROJECT________________________ 81

TABLE 2.10 WASTEWATER GENERATION FROM THE PROJECT________________________ 82

TABLE 2.11 SEGREGATION OF WASTEWATER FOR TREATMENT & DISPOSAL __________ 83

TABLE 2.12 CHARACTERISTICS OF VARIOUS STREAMS OF WASTEWATER _____________ 86

TABLE 2.13 CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT ___ 88

TABLE 2.14 SIZING OF ETP UNITS ___________________________________________________ 89

TABLE 2.15 SPECIFICATION OF INCINERATOR_______________________________________ 91

TABLE 2.16 FLUE GAS DETAILS _____________________________________________________ 92

TABLE 2.17 PROCESS EMISSION DETAILS ___________________________________________ 93

TABLE 2.18 EMISSION RATE OF THE POLLUTANTS -EXISTING ________________________ 94

TABLE 2.19 EMISSION RATE OF THE POLLUTANTS -Proposed __________________________ 94

TABLE 2.20 PROCESS EMISSION -EXISTING __________________________________________ 95

TABLE 2.21 PROCESS EMISSION -PROPOSED_________________________________________ 95

TABLE 2.22 HAZARDOUS WASTE GENERTION & DISPOSAL ___________________________ 96


April - 2010 6

TABLE 2.23 GREENBELT DETAILS___________________________________________________ 98

TABLE 3.1 LIST OF VILLAGES AROUND THE PROJECT SITE (10 KM).____________________ 102

TABLE 3.2 IMPORANT FEATURES WITHIN STUDY AREA _______________________________ 104

TABLE 3.3 TOTAL POPULATIONS WITHIN STUDY AREA________________________________ 105

TABLE 3.4 LITERACY WITHIN STUDY AREA ___________________________________________ 106

TABLE 3.5 POPULATION & LITERACY WITHIN STUDY AREA ___________________________ 107

TABLE 3.6 WORKERS CATEGORISATION ______________________________________________ 108

TABLE 3.7 MAIN WORKERS CATEGORISATION ________________________________________ 109

TABLE 3.8 MARGINAL WORKERS CATEGORISATION___________________________________ 110

TABLE 3.9 NON WORKERS CATEGORISATION _________________________________________ 111

TABLE 3.10 LAND USE DISTRIBUTIONS _____________________________________________ 112

TABLE 3.11 AMENITIES AVAILABLE WITHIN STUDY AR _____________________________ 115

TABLE 3.12 HYDROLOGY DETAILS:_________________________________________________ 119

TABLE 3.13 DETAILS OF WATER SAMPLING STATIONS ______________________________ 121

TABLE 3.14 WATER QUALITY ______________________________________________________ 122

TABLE 3.14 WATER QUALITY ______________________________________________________ 123

TABLE 3.15 DETAILS OF AIR MONITORING STATIONS _______________________________ 126

TABLE 3.16 NATIONAL AMBIENT AIR QUALITY STANDARDS _________________________ 128

TABLE 3.17 TECHNIQUES USED FOR AMBIENT AIR QUALITY MONITORING __________ 130

TABLE 3.18 AMBIENT AIR QUALITIES IN THE STUDY AREA __________________________ 131

TABLE 3.19 SOIL SAMPLING LOCATIONS ___________________________________________ 134

TABLE 3.20 SOIL CHARACTERISTICS _______________________________________________ 135

TABLE 3.21 DETAILS OF NOISE SAMPLING STATIONS _______________________________ 137

TABLE3.22 AMBIENT NOISE LEVEL STANDARDS ______________________________________ 137

TABLE 3.23 NOISE LEVEL DATA____________________________________________________ 138

TABLE 3.24 MEAN MICROMETEREOLOGICAL DATA _________________________________ 140

TABLE 3.25 MEAN WEATHER DATA ________________________________________________ 142

TABLE 3.26 AGRICULTURAL CROPS IN THE STUDY AREA ____________________________ 143


April - 2010 7

TABLE 3.27 FLORAL COMPOSITIONS IN THE STUDY AREA ___________________________ 143

TABLE 3.28 LIST OF INVERTEBRATFAUNA IN THE STUDY AREA _____________________ 144

TABLE 3.29 LIST OF VERTEBRATFAUNA IN THE STUDY AREA________________________ 145

TABLE 4.1 IMPACT IDENTIFICATION MATRIX ________________________________________ 148

TABLE 4.2 ENVIRONMENTAL IMPACT ASSESSMENT __________________________________ 149

TABLE 5.1 ENVIRONMENT MANAGEMENT PLAN ______________________________________ 160

TABLE 5.2 ENVIRONMENT MANAGEMENT CELL ______________________________________ 166

TABLE 5.3 GREENBELT DETAILS_____________________________________________________ 167

TABLE 5.4 BUGETARY EXPENDITURE ________________________________________________ 167

TABLE 6.1 ENVIRONMENT MONITORING PLAN _______________________________________ 168

TABLE 6.2 EXPENDITURE ON ENVIRONMENTAL MATTERS ____________________________ 169

TERMS OF REFERENCE (TOR) COMPLIANCE _________________________________________ 175


April - 2010 8

LIST OF MAPS

MAP 1.1 PROJECT LOCATION IN INDIA/GUJARAT MAP

MAP 1.2 PROJECT LOCATION ON KUTCH MAP

MAP 1.3 RAW SATELLITE IMAGE OF STUDY AREA

MAP 2.1 PROJECT LOCATION ON TALUKA MAP

MAP 2.2 PROJECT LAYOUT OF THE UNIT

MAP 3.1 STUDY AREA OF THE PROJECT

MAP 3.2 MAP SHOWING LAND USE OF THE STUDY AREA

MAP 3.3 MAP SHOWING STUDY AREA & SAMPLING LOCATIONS – AMBIENT AIR,SOIL,WATER & NOISE

REIA of Kutch Chemical Industries Limited Executive Summary

April - 2010 9

EXECUTIVE SUMMARY

1.0 INTRODUCTION

M/s. Kutch Chemical Industries Ltd. (herein after referred as “KCIL”) wishes to expand their

existing manufacturing activities at Plot No. 166/1-3, 171/1, 172,167,168, Vill: Padana,

Gandhidham, Di: Kutch, Gujarat. The industry is involved in the manufacture of range of

organic & inorganic chemical and other specialty chemical in other parts of Gujarat. The site

is approximately 15.0 km East of Gandhidham.

1.1 PURPOSE OF STUDY

Environmental Impact Assessment Report has been prepared for obtaining Environmental

Clearance for KCIL production activities, as it involves manufacture of Organic Chemical:

Category: 5(f)) and is included category of the Environmental Impact Assessment

Notification, issued in September-2006 and subsequent amendments.

1.2 EXTENT OF STUDY AND AREA COVERED

This Rapid environment impact assessment (EIA) is prepared, based on studies carried out

during the summer season of Year-2009. The environmental attributes (ambient air, water,

soil, noise selected for study are those, which are likely to be affected by the project. The

study area is defined as an area within 10.0 kms radius around site located at Padana village.

(As per the Terms of Reference approved by MoEF- New Delhi Vide their letter No, F. No.

J-11011/531/2009/IA-II(I) dtd. 12.02.2010.

1.3 METHOD OF STUDY

The study is carried out based on guidelines of MoEF and identifies the nature of activities

involved and their impacts caused on various environmental parameters. It subsequently

suggests mitigation measures to be executed for safeguarding against any environmental

degradation. Finally, it suggests methods of implementing the environmental management

plan.


April - 2010 10

2.0 PROJECT DETAILS

The products manufactured and proposed to be manufactured along with their capacities are

shown in following table.

Sr. No. Name of the Product

Existing Capacity,

MT/Month

Additional Capacity,

MT/Month

Total Capacity,

MT/Month

Product Required Environmental Clearance 1 Vinyl Sulphone 500 4000 4500

2 Sulphonation of PNT,ONT,VS, Tobias & Other

0 1500 1500

3 Benzene Sulphonyl Chloride 0 1500 1500 4 DASDA 0 1000 1000 5 V.S Condense 0 1000 1000 6 Dimethyl Sulfate (DMS) 100 3000 3100 7 Dimethyl Aniline (DMA) 0 1500 1500 8 Diethyl Sulfate (DES) 0 1500 1500 9 Sulfamic Acid 0 1000 1000

10 Power Plant (Coal) 2.5 MW

(FO) 10 MW (Coal)

12.5 MW (FO&Coal)

Product do not required Environmental Clearance 1 Sulphuric Acid (98%) 7500 15000 22500 2 Oleum (23% & 65%) 0 3000 3000 3 Liquid SO3 ( 70-90%) 0 7500 7500 4 Chloro Sulphonic Acid 1200 15000 16200 5 Thionyl Chloride 0 5000 5000 6 Sodium Bisulphite (SBS) 0 3000 3000 7 Calcium Chloride 0 4000 4000 8 Dicalcium Phosphate (DCP) 0 1500 1500 9 Sulphur Monochloride 0 200 200 10 Sulphuryl Chloride 0 200 200 11 Aluminum Sulphate (ALUM) 0 1000 1000

2.1 FUEL/ENERGY REQUIREMENTS

o Source: Paschim Gujarat Vidyut Company Ltd.

o The maximum demand of power is 10,000 KVA , No Additional Power

required

o Proposed : Fuel for Boiler (Power Plant-10 MW) : Coal – 10 MTD

o Existing: Fuel for Boiler (Power Plant- 2.5 MW) : F.O - 850 LIT/HR .

2.2 WATER REQUIREMENT


April - 2010 11

o Total Water Requirement: 1516.5 KLD

o Source: GWIL (Gujarat Water Infrastructure Limited – Narmada Water

Pipeline)

o Wastewater Generation : 486 KLD

o Sewage Generation : 30 KLD

2.3 UTILITY REQUIREMENT

o Cooling Tower

o Boiler for Power Plant 2.5 MW –Existing

o Boiler for Power Plant 10 MW - Proposed

3.0 BASELINE ENVIRONMENT

Baseline Environment incorporates the description of the various existing environmental settings

within the area encompassed by a circle of 10 km radius around the proposed project site. A total of

14 villages fall in the specified study area. The study area comes under Anjar, Bhachau &

Gandhidham Taluka.

3.1 DEMOGRAPHIC & SOCIO ECONOMIC PROFILE

3.1.1 Population

o Total Population : 37717 , Male: 20588 & Female: 17129

o The density of population within 10.0 km radius of the project site per Sq km is 114.

o The percentages of male and female population are 55 %& 45% respectively.

o The population of scheduled castes and scheduled tribes is 7.54 % & 11.19%

respectively.

o Sex Ratio 832 Female / 1000 Male

3.1.2 Literacy

o Total Literacy Level is 29.94%, Male Literacy: 38.04% & Female Literacy: 20.21%

3.1.3 Occupational Structure

This wide diversity in occupational structure may be broadly categorized as working and non-working

population. Total Main Workers: 13101, Total Marginal Workers: 1411 & Total Non Workers:

23205. In Rural, majority of the people are engaged in agricultural activities, forestry and allied

activities.

3.2 LANDUSE


April - 2010 12

The land use within the study area has been determined. The study area contains of forestland,

irrigated agricultural land, unirrigated agricultural land, cultivable wasteland and area not available for

cultivation. 14 villages fall within 10.0 km radius from the project site. The total area studied is about

32964 hectares.

Sr. No. Type Of Land use Area, Ha 1 Forest 23

2 Irrigated by source 391

3 Unirrigated 19446

4 Culturable waste land 4385

5 Area not available for cultivation 8836

Total 33081

3.3 PUBLIC AMNETIES

3.3.1 Water Supply

Most of the villages in the study area are provided with Basic civic amenities. Water supply source in

the villages within the study area is ground water, Water in the form of Well Water, Tap Water, Tank

Water, Tube well, River Water, Nallah, Canal, Hand pumps, etc.

3.3.2 Transportation & Communication

The Study area has a well connected road network. (NH-8A) joining Anjar-Bhachau-Ahmedabad.

Gandhidham is nearest railway station and the city is connected through Western Railway & State

Highway.

3.3.3 Electricity

Electricity is supplied to all main and remote places for various needs such as domestic, industrial and

agricultural requirements

3.3.4 Health, Medical and Educational Facility

Various Health & Medical facilities available within study area are Community Health Worker,

Family Planning Centre, Primary Health Centre, Child Welfare Centre, Dispensary & Subsidized

Medical Practitioner.

3.3.5 Educational Facility


April - 2010 13

The study area has facilities of primary /secondary high school. Gandhidham is the nearest city where

all kind of educational institution is available

3.4 AMBIENT AIR QUALITY

Ambient air was sampled at five locations selected and each station was sampled for 24 hours

continuously twice a week. Parameters monitored were PM10, NOx, SO2, HCl, Cl2 & VOC.

Ambient air was found to be within the prescribed regulatory limits. Within Study area the average

Ambient air quality is shown below:

PM10 : 43.7 – 55.2 µg/m3 , HCl :0.2– 5.3 µg/m3

SOx : 17.7 – 23.2 µg/m3 , Cl2 :0.4– 2.8 µg/m3, NOx : 11.5 – 12.6 µg/m3, VOC :0.1-2.9 µg/m3

3.5 WATER & HYDROLOGY

The source of water for the proposed project is Narmada Pipeline Project ( GWIL). No ground water

will be utilized for the project activities. Water in this area is generally encountered at a depth of 300

feet below the ground level.

3.6 SOIL GEOLOGY & TOPOGRAPHY

The geology of the study area consists of Alluvium, Blown sand, millolite sand, Basalts andesite,

trachyte flows, Laterite, Bauxite, Gypsiferous clays and Sandy limestone, Sandstones and shales.

3.7 NOISE

Noise levels within the site boundary are recorded to be within the limits stipulated by regulatory

agencies for industrial areas. The equivivalent Noise level during day time and Night time within

study area are shown below:

During Day Time: 63.9 – 69.3 dB(A)

During Night time: 55.1 – 61.4 dB(A)

3.8 FLORA & FAUNA

The flora in the study area are Neem, Gulmohur, Babool, Khair, Guava, Bel, Pappaya. Various fruit

giving flora species alike Papaya, Bore are also seen within study area. The predominant agricultural

crops grown in the study area are Bajara, and Castor, Jeera. There are no endangered/endemic flora

species and faunal species within the study area.

4.0 ENVIRONMENT IMPACTS


April - 2010 14

4.1 Ambient air

The sources of Air Emission from the Industrial Boiler & Power Plant Stack, Process

emissions from various plant viz Sulphuric Acid, CSA, CaCl2, DASDA etc. The flue gas

emission from Industrial Boiler will be released through filter bags to stack with adequate

height. The process vents from the reaction tanks are attached to the scrubber before releasing

to the atmosphere

4.2 Water resources

Water requirement will be met from GWIL (Gujarat Water Infrastructure Limited) – Water

Supply. The quantity of water required is to the tune of 1516.5 KLD. The wastewater &

sewage is being treated together in the scientifically designed effluent treatment plant.

4.3 Noise levels

Noise will be generated from the process equipments & Power plant.

4.4 Soil/Land quality

KCIL will take all precautions to make its solid waste areas impervious to water and leachate

migration. This will avoid soil contamination. It follows that soil quality will not be adversely

impacted by proposed production activity. The unit is existing and expansion will be done in the

existing premises only and hence no change in land use.

5.0 ENVIRONMENTAL MANAGEMENT PLAN

An environment management plan has been proposed to implement the mitigation measures.

The plan will ensure that the adverse environmental impacts are minimized and the beneficial

impacts are maximized.

5.1 Cooling Tower & Boiler:

The requirement of cooling water (make up -740 KLD) and Boiler make-up( make-up: 60

KLD). The blow down will be directly taken to the effluent treatment plant for treatment and

disposal.

5.2 Domestic Utilities

The sewage will be treated in the Effluent Treatment Plant together with the effluent.

5.3 Industrial Effluent


April - 2010 15

The industrial effluent is being given treatment in the well designed effluent treatment plant

within premises and finally utilized for fire fighting, greenbelt and other use. .

5.4 Air Pollution Management

The source of emission i.e. Flue Gas Emission from Industrial Boiler (Power Plant), The flue

gas emission will be released through fiber glass filter bags to contain particulate matter and

then stack having adequate stack height. The process emission from the various reaction

vessel of the man tanks will be taken to the scrubber before releasing it to the atmosphere.

5.5 Solid and hazardous waste management

The solid and hazardous wastes requiring management are listed in the following table. These

wastes will be stored separately in Hazardous waste storage area.

Existing Additional Total Sr. No.

Type of Hazardous

Waste MT/Month MT/Month MT/Month

Hazardous Waste

Category

Storage &

Disposal 1 ETP Sludge 5 40 45 34.3 Collection, Storage ,

Transporation & Disposal to TSDF

2 Process Sludge from DCP

0 50 50 - Collection, Storage , Transporation & Disposal to TSDF

3 Process Sludge from CaCl2


4 Distillation Residue 2.4 1 3.4 20.3 Collection, Storage, Incineration

5 Incineration Ash 144 0 144 36.2 Collection, Storage , Transporation & Disposal to TSDF

6 Used Oil/Spent Oil 2 0.5 2.5 5.1 Collection, Storage, Transporation & Sell to Authorised Reprocessors

7 Empty Drums/Container

25 Nos. 175 Nos. 200 Nos. 33.3 Collection, Storage, Transporation & Sell to Authorised Vendor

5.6 Green Belt Development


April - 2010 16

Green belt development (Total Area Available= 24750 m2) within & outside the industrial

premises is planned. This will reduce noise levels and dust levels by acting as a barrier

between the outside environment and the inside environment of the premises.

5.7 Monitoring schedule

A detailed monitoring schedule has been prepared to ensure effectiveness of the

environmental management plan.

5.8 Expenditure for environmental activities

KCIL proposed to spend 60.2 lacs as capital expenditure on environmental management. The

recurring cost shall be Rs. 19 lacs per annum.

6.0 CONCLUSION

The study brings out the following points:

1. The flue gas emission from Industrial Boiler will be passed through Cyclone and

Dust bags and finally released in to the atmosphere. The stack with adequate height

as per CPCB norms will be provided .

2. The wastewater generated is being treated in scientifically designed Effluent

Treatment Plant. The treated wastewater will be finally utilized for greenbelt,

firefighting and other reuse option as discussed in Chapter 3..

3. The noise generation will be reduced due to the measure provided in Environmental

Management Plan.

4. The Risk associated have been identified by conducting Risk Assessment, HAZOP

and recommendations of the same will be implemented. Moreover On Site

Emergency Plan has also been prepared to tackle the emergency when it arises.

5. Socio-economic benefits due to creation of direct / indirect employment. An

additional of 100 nos. of person is likely to get employment due to the project.

Moreover due to the project other direct and indirect business will get benefited.

Thus, it can be concluded on a positive note that after the implementation of the mitigation

measures and Environmental Management Plan the normal operation of M/s. Kutch Chemical

Industries Limited, will have negligible impact on environment and will benefit the local

people.

REIA of Kutch Chemical Industries Limited Chapter 1 Introduction

April - 2010 17

1.0 INTRODUCTION

The SLG group of industries started in the year 1979, Kutch Chemical Industries

Limited.(herein after referred as “KCIL”) has grown to become one of the modern and

leading Producer of Organic Chemicals in India. The company started manufacturing activity

in May 1979. Ever since, a wide range of products have been manufactured and marketed

successfully.

Due to increased demand of the existing product. The unit is intent to expand their existing

manufacturing by increasing their product capacities and addition of other organic and

inorganic chemicals. The proposed manufacturing capacity of the various products are as

follows:

KCIL proposed expansion of manufacture products mentioned in Table 1.1


April - 2010 18

TABLE 1.1A LIST OF THE EXISTING PRODUCTS

Sr. No.

Product Capacity, MT/Month

Existing Products GROUP -I

A Nitroderivatives of Hydrocarbon such as Nitro Chloro Benzene, Nitro Toluene, Nitro Cumene, Nitro Xylene, Nitro Benzene

2400

Amino Hydrocarbon such as Chloro Aniline, Toludine, Cumidine, Xylidine, Aniline

2000

B Methoxylation of Nitro Chloro Compound & Hydrolysis such as Ortho Anicidine, Para Anicidine

100

C Amonolysis of Nitro Chloro Compound & Hydrolysis such as Ortho Nitro Aniline, Para Nitro Aniline, Ortho Phylinine Di Amine, Para Phylinine Di Amine

100

GROUP -II 1 Mono Chloro Benzene 1000 2 Di Chloro Benzene 500 3 Chlorinated Paraffin Wax 550

GROUP -III 1 Acetanilide 1000 2 Vinyl Sulphone & Its Derivatives 500 3 CSA (Chlro Sulphonic Acid) 1200 4 Formaldehyde 50 5 DASA 30 6 Sulfanilic Acid 30 7 2-4 DNCB 30 8 2-6 DCNB 30 9 Woven Bags 5000 Kg/Day 10 ASC 30 11 Equivalent Sulphuric Acid Such as Sulphuric

Acid, Liq. SO3, Oleum 65%, Oleum 23% 250

12 Dimethyl Sulphate 100 13 Power Plant 2.5 MW


April - 2010 19

TABLE 1.1B LIST OF THE NEW PRODUCST AND EXPANSION REQUIRED


Existing Capacity,

MT/Month


MT/Month

Total Capacity,

MT/Month


2 Sulphonation of PNT,ONT,VS, Tobies & Other

0 1500 1500



(FO) 10 MW (Coal)

12.5 MW (FO&Coal)

Product do not required Environmental Clearance 1 Sulphuric Acid (98%) 7500 15000 22500 2 Oleum (23% & 65%) 0 3000 3000 3 Liquid SO3 ( 70-90%) 0 7500 7500 4 Chloro Sulphonic Acid 1200 15000 16200 5 Thionyl Chloride 0 5000 5000 6 Sodium Bisulphite (SBS) 0 3000 3000 7 Calcium Chloride 0 4000 4000 8 Dicalcium Phosphate (DCP) 0 1500 1500 9 Sulphur Monochloride 0 200 200 10 Sulphuryl Chloride 0 200 200 11 Aluminum Sulphate (ALUM) 0 1000 1000

The REIA study has been conducted to study the baseline environment of the study area &

Impact Assessment and to prepare an Environmental Management Plan.

ECO-CARE SOLUTIONS, VADODARA have been assigned the job to conduct the study

and prepare the Rapid Environmental Impact Assessment Report (REIA) report as per the

guidelines laid down by the Ministry of Environment and Forests (MoEF), Government of

India for the proposed project. The studies were conducted for various environmental

attributes, which are likely to be affected due to the activities of the proposed project.


April - 2010 20

1.1 SITE LOCATION

The site is located at Plot No. Plot No. 166/1-3, 171/1, 172,167,168, Vill: Padana,

Gandhidham, Di: Kutch, Gujarat. Other locational details are as follows:

The site is located:

o Approximately 15.0 km East of Gandhidham

o The site is near to the National Highway – 8A

o Geographical Location & Area of the Premises are displayed below:

o Latitude : 21°41'42.14"N Longitude: 72°35'12.18"E

o The total area of the site is 75,000 m2

Map 1.1 shows location of project site on India, Gujarat State map


April - 2010 21

Project Location

PROJECT: RAPID EIA FOR KUTCH CHEMICAL INDUSTRIES LTD.

M-1.1: PROJECT LOCATION ON INDIA/GUJARAT MAP


April - 2010 22

PROJECT: RAPID EIA FOR KUTCH CHEMICAL INDUSTRIES LTD -

M-1.2: PROJECT LOCATION ON KUTCH MAP


April - 2010 23

N

SCALE

0 1 2 3 4 5km

MAP: 1.3Date : 15/05/10 APP. BY : HB

Client:KUTCH CHEMICAL INDUSTRIES LTD.

RAW SATELLITE IMAGE OF STUDY AREA

SCALE : AS SHOWN

REVISION : 0

CHD BY : DRAWN BY :

Title :

DRAWING NO.

RAPID ENVIRONMENTAL IMPACT ASSESSMENT

PADANA

Project :

ECO-CARE SOLUTIONS

FOR PROPOSED SECONDARY NON-FERROUS METAL UNIT

JHGP

ECS

0265-2356752, 94260-74416, 94275-06362


April - 2010 24

1.2. NEED FOR REIA

Every anthropogenic activity has some impact on the environment. More often it is harmful

to the environment than benign. However, mankind as it is developed today cannot live

without taking up these activities for his food, security and other needs. Consequently, there

is a need to harmonize developmental activities with the environmental concerns.

Environmental impact assessment (REIA) is one of the tools available with the planners to

achieve the above-mentioned goal.

It is desirable to ensure that the development options under consideration are sustainable. In

doing so, environmental consequences must be characterized early in the project cycle and

accounted for in the project design.

The objective of REIA is to foresee the potential environmental problems that would arise out

of a proposed development and address them in the project's planning and design stage. The

REIA process should then allow for the communication of this information to:

o The project proponent;

o The regulatory agencies; and,

o All stakeholders and interested groups.

REIA integrates the environmental concerns in the developmental activities right at the time

of initiating for preparing the feasibility report. In doing so it can facilitate the integration of

environmental concerns and mitigation measures in project development. REIA can often

prevent future liabilities or expensive alterations in project design.

1.3 INDIAN POLICIES REQUIRING REIA

Environmental Impact Assessment Report has been prepared for obtaining Environmental

Clearance for KCIL’s proposed expansion of organic chemical and addition of new organic

as well as inorganic chemical manufacturing activities at Padana. The manufacturing of

organic chemical falls under EIA Notification issued in September – 2006.


April - 2010 25

1.4 THE REIA CYCLE AND PROCEDURES

The REIA process comprises of the following phases:

o Screening

o Scoping and consideration of alternatives (ToR)

o Baseline data collection

o Impact prediction

o Assessment of alternatives, delineation of mitigation measures and environmental

impact statement

o Environment Management Plan

o Decision making

o Monitoring the clearance conditions

1.5 METHODOLOGY & SCOPE OF REIA

The methodology of EIA adopted for KCIL is based on the guidelines of MoEF. Actions

carried out were as follows:

o The MoER has approved ToR vide EIA-10-2008-330-E

Dated :12.02..2010. Baseline information with respect to air, water, noise, and land

quality in study area was collected by conducting sampling / field studies during

summer of year 2009. Information was collected as per the requirements of the MoEF,

New Delhi.

o The characteristics of baseline status of study area with respect to the following

environmental parameters were studied:

Air Environment Land Environment

Noise Environment Environmental Impacts

Water Environment Environment Management Plan

These studies were carried out in summer season of year 2009 through in-situ sampling / field

studies and secondary data sources.

o Identification of Impacts / Mitigation measures of proposed expansion activities of

KCIL were identified and analyzed for their impacts on environmental parameters.

o An Environmental Management Plan was prepared for monitoring the activities that

impact the environment. Subsequently, an environmental management cell, an

environmental management plan and a statement of current expenditure (capital /


April - 2010 26

operational) on environment was prepared.

The Scope of the approved Terms of Reference is as follows:


April - 2010 27


April - 2010 28


April - 2010 29


April - 2010 30

1. 6 APPLICABLE ENVIRONMENTAL REGULATIONS AND STANDARDS

With respect to prevention and control of environmental pollution, the following Acts and

Rules of MoEF govern the proposed project:

o Water (Prevention and Control of Pollution) Act, 1974 as amended in 1978 and 1988:

o Air (Prevention and Control of Pollution) Act, 1981 as amended in 1987:

o Environment (Protection) Act, 1986 amended 1991 and Environment (Protection) rules, 1986 and amendments thereafter

o Hazardous Waste (Management & Handling) Rules, 1989, as amended in 2000 and 20.05.2003.

o The Noise Pollution (Regulation and Control) Rules, 2000 and as amended in 22.11.2000.

1. 7 STRUCTURE OF THE REIA REPORT

Executive Summary: Summary of REIA Report

Chapter 1: Introduction and Objective of the Study

Chapter 2: Project Description

Chapter 3: Baseline Environmental Setting

Chapter 4: Environmental Impacts

Chapter 5: Environmental Monitoring Plan

Chapter 6 : Environmental Management Plan

Chapter 7 : Conclusion

Chapter 8: Projects Benefit

Chapter 9 : Additional Studies

Chapter 10 : Disclosures of Consultants Engaged

REIA of Kutch Chemical Industries Limited Chapter 2 Project Description

October - 2008 31

2.0 PROJECT DESCRIPTION

M/s. Kutch Chemical Industries Limited (KCIL) wishes to have an expansion in the existing

manufacturing plant located at Plot No. 166/1-3, 171/1, 172,167,168, Vill: Padana,

Gandhidham, Di: Kutch, Gujarat. The industry involved in the manufacture of Organic

Chemical. The SLG group has other units at Jhagadia, Nandesari, Padra for the

manufacturing of various organic chemical, dye intermediate. The site is approximately 15.0

km East of Gandhidham.

2.1 SITE SETTINGS

The topography of the land is flat. The site falls in village: Padana, Ta: Gandhidham, Di:

Kutch The major land use of the study area consists mainly of Industries, Agriculture and

Residential. The site is on the National Highway -8A.

2.2. PRODUCT PROFILE

The quantum of expansion required in the existing facility has been depicted in the Table 2.1

with their respective capacities.

TABLE 2.1 PRODUCT PROFILE


Existing Capacity,

MT/Month


MT/Month

Total Capacity,

MT/Month


2 Sulphonation of PNT,ONT,VS, Tobias & Other

0 1500 1500



(FO) 10 MW (Coal)

12.5 MW (FO & Coal)

Product do not required Environmental Clearance 1 Sulphuric Acid (98%) 7500 15000 22500 2 Oleum (23% & 65%) 0 3000 3000


April - 2010 32


Existing Capacity,

MT/Month


MT/Month

Total Capacity,

MT/Month

3 Liquid SO3 ( 70-90%) 0 7500 7500 4 Chloro Sulphonic Acid 1200 15000 16200 5 Thionyl Chloride 0 5000 5000 6 Sodium Bisulphite (SBS) 0 3000 3000 7 Calcium Chloride 0 4000 4000 8 Dicalcium Phosphate (DCP) 0 1500 1500 9 Sulphur Monochloride 0 200 200 10 Sulphuryl Chloride 0 200 200 11 Aluminum Sulphate (ALUM) 0 1000 1000


April - 2010 33

2.3. LAND DISTRIBUTION AT SITE

Project Location on Taluka Map Plan M - 2.1

Detailed factory layout is enclosed vide Plot Plan M - 2.2

The area (actual and as a percentage), allocated at site for various manufacturing and other

plant facilities are provided in Table No 2.2.

TABLE 2.2 LAND DISTRIBUTIONS AT SITE

Title

Area in m2 Area as % of

total area

1. Plant Facilities 3000 4

2. Plant Area 25000 33.33

3. Utilities

• Fuel

• Water

• Raw Material Storage

• Boiler

• Cooling Tower

20000 26.67

4. Other Raw material Storage 2250 3

5. Green belt + Open Spaces 24750 33

Total 75000 100


April - 2010 34

KCIL – Vill: Padana

M-2.1: PROJECT LOCATION ON TALUKA MAP

PROJECT: RAPID EIA FOR KUTCH CHEMICAL INDUSTRIES LTD - PADANA


April - 2010 35

Map 2.2 : LAYOUT OF THE

PROJECT


April - 2010 36

2.4. CAPITAL COST OF THE PROJECT

The capital investment made to the existing project and to be done proposed expansion has

been depicted in the following table. The capital investment required for the proposed

expansion is to the tune of INR 80.5 Cr.

TABLE 2.3 CAPITAL COST OF EXISTING & PROPOSED EXPANSION

Sr. No Description Existing

Cr.

Additional

Cr.

Total

Cr.

A Land & Site Development 0.6 1.0 1.6

B Building 5.0 8.0 13.0

C Plant & Machineries 0.0 0.0

1 Vinyl Sulphone & VS Condense 1.0 8.0 9.0

2 Sulphonation - 1.5 1.5

3 Benzene Sulphonyl Chloride - 1.0 1.0

4 DASDA - 3.0 3.0

5 DMA, DES - 4.0 4.0

6 DMS 3.0 2.0 5.0

7 Sulfamic Acid - 1.0 1.0

8 H2SO4, Oluem, SO3, CSA 20 12 32

9 Sodium Bisulphite - 0.5 0.5

10 TC, SMC, Sulphuryl Chloride - 3.0 3.0

11 DCP - 0.3 0.3

12 Calcium Chloride - 0.2 0.2

13 Power Plant 7.5 35 42.5

Total 37.1 80.5 117.6


April - 2010 37

2.5. MANUFACTURING DETAILS

The capacity along with the product to be manufactured has been shown in Table 2.1. The

detailed manufacturing process has been described in this chapter along with the mass

balance diagram.

2.5.1 RAW MATERIALS

o The physical and chemical properties of the raw materials to be used for the

manufacture of various products at Kutch Chemical Industries Limited. – Padana

has been depicted in Table 2.3.

o Storage details of raw materials to be used for the manufacturing and the products

has been shown in Table 2.4


April - 2010 38

TABLE 2.3 PHYSICAL AND CHEMICAL PROPERTIES OF THE RAW MATERIAL & PRODUCTS


April - 2010 39


April - 2010 40

TABLE 2.4 STORAGE DETAILS OF MAJOR RAW MATERIALS

Sr. No.

Raw Material Storage Quantity,

MT

MOC No. of Vessel

Capacity, MT

Type of Hazard

Raw Material 1 Acetanilide 600 Solid Flakes HDPE

Bags 600 R/C

2 Chloro Sulphonic Acid 600 MS 6 100 R/C 3 Caustic Lye 600 MS 3 200 R/C 4 Sodium bycarbonate - Solid HDPE

Bags - -

5 Sulfuric Acid 2000 MS 2 1000 R/C 6 Sluphur 5000 - - 5000 R/C 7 Sulfur Trioxide MS 2 100 C 8 Hydrochloric Acid 450 MS 3 150 R/C 9 o-Nitro Toluene 250 MS 1 250 R 10 p-Nitro Toluene 200 MS 1 200 R 11 Tobias Acid R 12 Oluem (65%) 200 MS 2 100 R/C 13 Sodium Chloride 50 - - 50 - 14 Benzene 250 MS 1 250 F 15 Chlorine 200 200 T 16 Soda Ash 200 - - 200 - 19 Ammonium Chloride 100 MS - 100 F/T 20 Sodium Carbonate - - 21 Sulfur Dioxide - R/T 22 Methanol 960 MS 4 240 F 23 Aniline 100 SS 1 100 R/C 24 Ethanol 200 MS 1 200 R/T 25 Ammonia 50 MS 1 50 R/T 26 Calcium Carbonate 50 - - 50 - 27 Rock Phosphate 50 - - 50 - 28 Coal 200 - - 200 F


April - 2010 41

2.4.2 PROCESS DESCRIPTION

2.4.2.1 Vinyl Sulphone & Vinyl Sulphone Condense:

Process Description:

Chloro Sulphonation:

Chloro Sulphonic Acid is charged into the sulphonation reactor. Acetanilide is then

slowly added to maintain the temperature below 80° C. The temperature is then

maintained between 50-60 °C. The batch thus prepared is transferred to the storage

tank.

Dumping:

Sulphonated mass is charged into the Reactor cooled with brine. Ice water is then

added slowly to remove all the HCl formed due to decomposition of excess Chloro

Sulphonic Acid. The HCl is scrubbed and absorbed in water to make HCl. Further Ice

water is added to dilute the concentrated Sulfuric Acid formed due to the

decomposition of Chloro Sulphonic Acid. Here we get of Sulfuric Acid of strength

30-40%.

The mass is then filtered out (ASC Cake).

Reduction:

Sodium Bi Sulphite slurry is added to the reactor. The pH is maintained neutral by

adding Caustic Lye. The ASC wet cake is then charged under controlled temperature

and pH. After addition is over the temperature is raised up to 50 °C. The mass is then

filtered and transferred to condensation vessel.

Condensation:

The reduction mass in condensation vessel is maintained at 50°C. Ethylene Oxide is

slowly added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The

material after condensation is transferred to the Nutsch Filter. The Mother liquor is

stored in storage tank. The condensed product is then washed and dried.


April - 2010 42

NHCOCH3

+ 2Cl.SO3H

ACETANILIDE

NHCOCH3

+

SO2Cl

HCl + H2SO4

CHLORO SULPHONIC ACID

NHCOCH3

+

SO2Cl

NaOH + NaHSO3

NHCOCH3

+

SO2Na

Na2SO4 + NaCl

NHCOCH3

+

SO2Na

H2SO4 + H2O

O

H2C CH2

+

NHCOCH3

SO2CH2CH2OH

+ Na2SO4

ETHYLENE OXIDE

NHCOCH3

SO2CH2CH2OH

+ H2SO4

NH2

SO2CH2CH2OSO3H

+ CH3COOH

VINYL SULPHONE

Esterification:

The condensed product is charged in esterification reactor. Concentrated Sulphuric

Acid is added. The temperature is then raised and maintained at 160°C for 4 hours.

Vacumm is applied to take out acetic acid vapors and being condensed. The product

is then collected a tank. The dried Vinyl Sulphone is pulverized and packed in PVC

bags.

Chemical Reaction:


April - 2010 43

Process Flowchart:

Acetanilide 2182CHLOROSULPHONIC ACID 10182

12364

Ice 14545 DUMPING(ICE)

26909

FILTERATION(Nutch) H2SO4 (35-40%)

12364 14545

SOD. BISULPHITE SLURRY(30%) 6545

CAUSTIC LYE 218221091

PRODUCT FROM FILT

ETHYLENE OXIDE 1018H2SO4 2269.00

24378.00

Salt

FILTER 17753SODIUM SULPHITE

SALT (BYPRODUCT)

8299

6625.00

ETP

CONDENSED PRODUCT 9454

6625.00

2262 MOISTURE LOSS

DRYER

4363.00

PRODUCT FROM Dryer

H2SO4 1455 ESTERIFICATION

5818.00ACETIC ACID

1818

VINYL SULPHONE

4000.0

CHLOROSULPHONATION

REDUCTION

ETHOXYLATION

MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE


April - 2010 44

2.4.2.2 Sulphonated o/p-NT & Tobias Acid


Take o-NT/p-NT in as sulfonator and charge 98% Sulphuric Acid and 65% Oluem in

it slowly. After completion of reaction blow sulfomass in another vessel containing

water, charge common salt, mix it, cool it and filter in neutsch. Material is then

centrifuge. Collect filterate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT

from centrifuge is then packed in HDPE bags and sent for sale.

For Tobias, Take Oleum (65%) in sulfonator, charge Tobias Acid slowly and after

completion of charging raise temperature and maintain it. Now cool the sulphonated

mass and blow it in Brine water. Allow for mixing, filter and give wash of brine

water. Centrifuge the mass and collect the wet cake as product and packed in HDPE

bags.

Chemical Reaction: Sulphonated o/p-NT

98

178

o-Nitro Toluene Sulphonated Sulfuric Acido-NT

137 217 98

CH3NO2 H2SO4

H2S2O7

CH3NO2

SO3H

+ H2SO4


April - 2010 45

+ H2S2O7 + H2SO4

Tobias Acid (TA) STA (Sulfo Tobias Acid)223 178 303 98

NH2

SO3H SO3HNH2

SO3H

ONT 137H2SO4 98H2S2O7 178

413

Water 18Common Salt 117(NaCl) 548

Spent Acid (25%)Filteration (Water+Salt+Sulfuric Acid)

217 331

Centrifuge 2(Recycle to Drawning Vessel)

Wet Cake215

Sulfonator

Drawning Vessel

MASS BALANCE OF SULPHONATION ONT/PNT

Chemical Reaction: Sulphonated Tobias Acid

Process Flowchart: Sulphonated o/p-NT


April - 2010 46

Tobias Acid 223

H2S2O7 178401

Brine Water 18

419Spent Acid (25%)

Filteration (Water+Salt+Sulfuric Acid)305 114

Centrifuge 2(Recycle to Drawning Vessel)

Wet Cake303

Drawning Vessel

MASS BALANCE OF SULPHONATION TOBIAS ACID

Sulfonator

Process Flowchart: Sulphonated Tobias Acid

2.4.2.3 Benzene Sulphonyl Chloride


Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low

temperature at about 20 -25 °C. Chloro Sulphonic Acid is used in excess for the

reaction. The reacted mass is then kept under agitation for some time. It is then

transferred to another vessel containing chilled water. During the addition, the vessel

is cooled up to desire temperature till the addition complete. The contents are kept

under agitation for some time. The mass is then separated. The acid layer is

transferred to the storage tank for sale. The organic layer is washed, dried & distilled

under vacuum to get the product. The HCl gas evolved during the reaction & isolation

is send to CAS plant for making Chloro Sulphonic Acid.


April - 2010 47

663 Benzene HCl gas

1980 CSA 310

2333

Isolation Dilute H2SO4

1500 833

DistillationCrude

Dimethyl Sulphone

1485 15

Benzyl Sulphonyl Chloride

MASS BALANCE OF BENZYL SULPHONYL CHLORIDE

Reactor

Chemical Reaction:

C6H6 + HOSO2Cl C6H5SO2Cl + HCl

Benzene CSA BSC Hydrochloric Acid Gas(l) (l) (l) (g)

M.W 78 116.5 176.5 36.5

Process Flowchart:


April - 2010 48

PNT(137) 98 178 PNTSA (217)

+ 2HCl + 3H2O2NaOCl +H2O

217 149 18 474 73 54

Fe/HCl

NH4Cl

(DNSDA) Di-Sodium Salt (Nitro form) Di-Sodium Salt (Amino form)414

+ H2SO4

414 370DASDA

CH3

+

NO2

H2SO 4 + H2S2O7 2H2SO4

CH3

NO2

+SO3H

O2N

SO3Na

- C = C

H H

SO

3N

NO2 H2N

SO3Na

- C = C

H H

SO3N

NH2

H2N

SO3Na

- C = C

H H

SO

3N

NH2 H2N

SO3H

- C = C

H H

SO3H

NH

CH3

NO2

+SO3H

2 O2N

SO3Na

- C = C

H H

SO3N

NO2

2.4.2.4 DASDA


Sulfuric Acid & Oluem (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is

then charged. The mass in then dumped in to the water, cooled and filtered in Neutsch

filter. The acid is then separated, The mass (PNTOSA) is then oxidized with sodium

hypochloride. After completion of the reaction common salt is charged at the room

temperature the mass is then filtered in Neutsch Filter.

Then reduction of PNTOSA is carried out with Fe, HCl and NH4Cl. Filter the

reduction mass & isolate the filterate using dilute H2SO4 & filter it in Neutsch filter.

Material thus prepared is DASDA. Which is then centrifuged and packed in the

HDPE bags.

Chemical Reaction:


April - 2010 49

PNT 63H2SO4 45Oleum 82

190Water 20Salt 15

225

Neutsch Filter 58 To ETP

167

Centrifuge 30 ML(Recycle)137 Drawning

Common Salt 15Soda Ash 18NaOCl 69Water 25

264

Neutsch Filter 58 To ETP206

Centrifuge 5 ML(Recycle)201 Drawning

Fe 5HCl 8NH4Cl 15

229

Filter Press 27 To ETP202

Isolation Vessel

202

Neutsch Filter 26 To ETP176

Centrifuge 6 ML(Recycle)170 Isolation Vessel

Product

DASDA

MASS BALANCE OF DASDA

Sulfonator

Drawning Vessel

Oxidation

Reduction Vessel

Process Flow chart

Process Flow Chart:

Mass Balance: MT/Month


April - 2010 50

2.4.2.5 Dimethyl Sulphate


Methanol from day tank in the plant is taken through metering pump passed

through heat exchanger and condenser in gas cycle. The methanol gas is passed

through the aluminum catalyst, further it is reacted with liquid SO3. The ration of

consumption of methanol + SO3 for DMS produced is as follows:

SO3 = 0.70 MT

Methanol = 0.55 MT.

The moisture shall be collected out of Methanol and sent to ETP. After reaction of

SO3 + Methanol gas in a closed reaction , Which will have chilled water circulation

in jacket. The crude DMS formed is having a high acidity. The distilled and acid

thus produced is 98% Sulphuric Acid. This is a by product and will be sold.

Chemical Reaction:

260°C2 CH3OH CH3-O-CH3 + H2O

Catalyst(Al2O3)Methanol Dimethyl Ether

2 x 32 46 18

CH3-O-CH3 + SO3 (CH3)2SO4

Dimethyl Sulphate46 126

SO3 + H2O H2SO4

80 18 98


April - 2010 51

1979 Liq SO3DME Gas

1138

1524 Methanol Day Tank Heat Exchanger

Reactor Containing

Al2O3 Catalyst(260°C)

Reactor

386 Water To ETP Condensation Tank

Pure Dimethyl Sulphate 3000 Distillation

11798% Spent Sulfuric Acid

MASS BALANCE OF DIMETHYL SULPHATE

Process Flow Chart:

2.4.2.6 Dimethyl Aniline


Methanol from day tank in the plant is taken through metering pump passed

through heat exchanger and condenser in gas cycle. The methanol gas is passed

through the aluminum catalyst, further it is reacted with Aniline. The product is

then distilled to get Dimethyl Aniline

The moisture shall be collected out of Methanol and sent to ETP.


April - 2010 52

260°C2 CH3OH CH3-O-CH3 + H2O

Catalyst(Al2O3)Methanol Dimethyl Ether2 x 32 46 18

CH3-O-CH3 + C6H5NH2 (CH3)2C6H5NH2

Dimethly Aniline46 93 123

DME GasAniline1134

560

780 Methanol Day Tank Heat Exchanger

Reactor Containing Aluminium Catalyst

Reactor

220 Water To ETPCondensation

Tank

1694

1500 Pure Dimethyl Aniline Distillation

194Wastewate to ETP

MASS BALANCE OF DIMETHYL ANILINE

Chemical Reaction:

Process Flow Chart:


April - 2010 53

2C2H5OH + 2SO3 2C2H5OSO3HCatalyst

Ethyl Alcohol Ethyl Hydrogen Sulfate92 160 228

2C2H5OSO3H + NH3 (C2H5)2SO4 + NH4SO4

EHS Ammonia Diethyl Sulfate Ammonium Sulfate228 17 154 114

2.4.2.7 Diethyl Sulphate


Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea

and formed Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by

ammonia and EHS gets converted into Diethyl Sulfate. Ammonia is passed in Ethyl

Hydrogen Sulfate mass. The product thus formed is crude Diethyl Sulphate.

Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric

Acid.

Distillation of crude EHS takes place under vacuum. The pure DES is produced

and transported to the storage tanks.

Chemical Reaction:


April - 2010 54

896 Ethyl Alcohol

1558 SO3

3542100

NH3166

2266

Spent ST Tank766

1500Pure Diethyl Sulfate

MASS BALANCE OF DIETHYL SULFATE

Reactor (Catalyst: Urea+Sod. Sulfate)

Cooler

Ammoniation Reactor

Distillation

Process Flow Chart:


April - 2010 55

2.4.2.8 Sulfamic Acid

Process Description :

Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by

chilled water/brine and cooling water. The reaction products are diluted by mixing

with recycled mother liquor (available after separation of crystals of sulfamic acid).

Temperature is controlled during mixing by chilled water/brine. Dilute acid streams

(70% sulfuric acid) is separated after the mixing operation and is sold to SSP/Alum

manufacturer.

Chemical Reaction:

NH2CONH2 + SO3 NH2CONHSO3H + CO2

NH2CONHSO3H + H2SO4 2NH2SO3H + CO2

Overall Reaction

NH2CONH2 + SO3 + H2SO4 2NH2SO3H + CO2

60 80 98 2 x 97 44


April - 2010 56

350 Urea Reactor3300 SO3/Oleum

(23-25%) 3650R/C Mother Liquor

Mixing

5150

Separation Spent Acid2400 2750

100 Water Make -Up

2500

Cyrstallisation1500

1000

Packing/Bagging

Figure are in Ton/Month

MASS BALANCE OF SULFAMIC ACID

Process Flow Chart:


April - 2010 57

2.4.2.9 Power Plant


(2.5 MW – Existing)

For power generation steam is generated from the boiler, which is then sent to

steam turbine to generate the power. At the outlet of the turbine steam goes to

condenser to recover the water utilized and further sent back to the boiler. The fuel

utilized for the boiler will be Coal.

To generate 2.5 MW, a steam of 8 MTD required, which is generated from the FO

based boiler. The FO consumption for the required steam would be approximately

1700 Lit/Day. Total Consumption

(10 MW –Proposed)

For power generation steam will be generated from the boiler, which is then sent to

steam turbine to generate the power. At the outlet of the turbine steam goes to

condenser to recover the water utilized and further sent back to the boiler. The fuel

utilized for the boiler will be Coal.

To generate 10 MW, a steam of 40 MTD required, which is generated from the coal

based boiler. The coal consumption for the required steam would be approximately

10 MTD.

For Power plant, separate coal yard will be made in which coal will be stored, from

coal yard the coal will be sent to crusher. The crushed coal is then sent to silo for

ultimate feed in to the combustion chamber.


April - 2010 58

Process Flow Chart:

High Pressure Steam45 kg/cm2

410°C

Exhaust0.1 kg/cm2

100 °CCondenser Condensate back to

Boiler feed water

Turbine GeneratorSet


April - 2010 59

2.4.2.10 Sulphuric Acid As

Sulphuric Acid (98%)

Oleum (23 % & 65%)

Liquid SO3


The process for the manufacture of sulphuric acid comprise the following steps:

1. Solid Sulphur after weighment is fed to sulphur melter which is provided with

steam coils. The ash content of the molten sulphur settles in the melter cum settler

and molten sulphur free of impurities is pumped to the sulphur burner where it is

burnt with air. Sulphur is converted in to SO2 in the sulphur burner as per the

following reaction

S + O2 SO2

2. SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in

the converter as per the following reaction:

SO2 + ½ O2 SO3

The conversion of SO2 to SO3 is carried out in stages in all the five pass of the

convertor. The conversion is optimized by intermediate cooling of gases between

the different stages and also by interpass absorption of SO3 after 3rd pass of the

convertor.

3. The gas from the 3rd & 5th pass of the convertor containing SO3 is cooled & then

fed to the interpass & final absorption tower where SO3 is removed by circulating

Sulphuric Acid in the absorption towers. The concentration of sulphuric acid is

controlled by addition of water in the pump tank.

Air for sulphur burner is routed through Air Filter to drying tower and further to

suction side of Centrifugal Air Blower. 98.5% acid is circulated through drying


April - 2010 60

tower at 70°C, thus heating to 125°C before entering sulfur burner. This system

helps to increase generation of steam and hence power generation.

4. SO2 emission during start up of the plant is controlled by a Venturi Scrubber

using alkali as scrubbing medium. The plant therefore does not cause any

pollution either during start up or during normal operation.

The process as described above has been divided into five main sections described as

follows:

1. Sulphur Circuit

The weighed quantity of sulphur of about 99.5% purity is fed to the first

compartment of sulphur melter. The heat for melting sulphur is provided

through steam coils. The optimum pressure to be maintained for melting

sulphur in the first compartment is upto 7 kg/cm2 G.

The molten sulphur flows from compartment no. 1 to pumping compartment

through underflows/overflows. The sulphur pumps for feeding sulphur are

fitted in pumping compartment. The total time of retention in the

compartments corresponds to more than 72 hrs at normal rated production

capacity of the plant. In order to achieve optimum results, it is necessary that

the feeding of sulphur to the melter should be maintained at specified

temperature of 135 °C. All compartments are fitted with steam coil to provide

the necessary heat for maintaining the temperature of molten sulphur at the

desired level. Molten sulphur from the pumping compartment is pumped to

the sulphur burner through one of the submersible type sulphur pumps

through specially designed sulphur feeding gun. The rate of feed of sulphur to

the sulphur burner is controlled by operation of sulphur feed control valve.


April - 2010 61

Drain lines have been provided in the molten sulphur discharge line at two

different points.

The optimum steam pressure for coils located in 2nd, 3rd , 4th through pumping

compartments of the sulphur melter is around 4 kg/cm2 G. This regulated

steam pressure is achieved through pressure reducing valve. Molten sulphur

line starting from the discharge flange of the sulphur pump to the inlet of the

sulphur burner is suitably steam jacketed to maintain correct temperature of

molten sulphur fed to the sulphur burner.

2. SO2 Scrubber

It is very important that SO2 emission during plant startup is controlled within

persmissible limits. This is achieved by use of a alkali scrubber located after

the final absorption tower where gas is scrubbed with circulating alkali

solution.

3. DM and Water Softening Plants

For generation of steam of high quality DM water is required for this purpose

RO plant and DM plant will be installed.

4. The plant is provided with data logging system through DCS control circuits for

control of parameters like Acid concentration control, pump tank level control, Boiler

feed water level control, boiler feed water from deaerator temperature control. All

the output signals are fed to a computer and output data is collected based on reports

to be prepared including log sheets.


April - 2010 62

S + O2 SO2

SO2 + 1/2O2 SO3

SO3 + H2O H2SO4

OverallS 3/2O2 + H2O H2SO4

M.W 32 48 18 98

Chemical Reaction:


April - 2010 63

Processs Description

Oleum & Liquid SO3

Oleum (23%)

Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid.

H2SO4 + SO3 H2S2O7

Oleum 23% means free SO3 in the product is 23%, which is equivivalent to 105.17%

Sulphuric Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid.

The sulphur required for 1 ton of 23% oleum is 0.326 x 1.07 = 0.349 ton.

Oleum (65%)

Oleum 65% means, the free SO3 in this product is 65% which is equivivalent to

114.626% sulphuric acid. This way the oleum 65% is equivalent to 1.17 times of 98%

sulphuric acid.

The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 = 0.381 ton

Liquid SO3

Liquid SO3 is = 1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of

liquid SO3 = 0.326 x 1.25 = 0.41 ton.


April - 2010 64

Sulphur Metler (135°C)

163.25 MT

904341 M3 Air Drying Tower Furnace (1100°)

(Oxygen: 245 MT)

Water

WHB Steam Steam Turbine to Generate

4 MW Power

Convertor (upto 3rd pass)

100 MTDM Water

H2SO4 (98.5%)

Acid Pump Tank PIPAB(Inter Pass

Absorption Tower

99% H2SO4

Convertor (4th pass)

Oleum Storage

(23% or 65%)

99% H2SO4

H2SO4 (98.5%) Storage

Final Absorption Tower

Alkali Scrubbe

r

Vent to Atmosphere

Wastewater 500 MT/Day 0.8 KLD

Oleum Tower

Oleum Pump Tank (Oleum 23%

or 65%)

PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)

Process Flow Chart:


April - 2010 65

Condenser SO3 Liquid

7500

Oluem Pump Tank (23%)

8070

Oleum Tower (23%)

SO3 Convertor (132 °C)

PROCESS FLOW CHART OF SO3 LIQUID

Process Flow Chart:


April - 2010 66

SO3 + HCl ClSO3H(l) (g) (l)80 36.5 116.5

1567 HCl Chilling

1567Chilled HCl

H2SO4 Gas Cleaning Bleed

1567Dry HCl 99.90%

3433 Liq SO3 Reactor

100.00% Gas to StackCaustic

Scrubber0.8 Castic Solution Wastewate To ETP

10% 0.8 KL/Month

5000Chlorosulphonic Acid

MASS BALANCE OF CHLOROSULPHONIC ACID

2.4.2.11 Chloro Sulphonic Acid


The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is

reacted with liq SO3 to get Chloro Sulphonic Acid. The unconverted gas is

scrubbed in caustic scrubber.

Chemical Reaction:

Process Flowchart:


April - 2010 67

2.4.2.12 Thionyl Chloride


Sulphur is charged in sulfur monochloride reactor along with chlorine in measured

quantity and reacted over a period of 12 hours to Sulphur Monochloride (SMC),

which is stored for further reaction. Thionyl Chloride reacted is fed with SMC, SO3

and Chlorine. Reactor is fitted with fractionating column. TC gas thus produced is

passed through 3 condenser, out of which first condenser used cooling water and

other two condenser use chilled water. Crude TC is then sent to Distillation

column as reflux. A part of crude TC is reacted with sulfur to get pure Thionyl

Chloride.

Alkali Scrubber is provided to absorb SO2 when required; similarly chlorine

scrubber removes traces of chlorine. Byproduct is recycled back to sulfuric acid

plant, where it is converted to Sulphur Trioxide for reuse in TC Plant.

Chemical Reaction:

2S + Cl2 S2Cl2

Sulphur Chlorine Sulphur Monochloride (SMC)

64 70 134

S2Cl2 + 2SO3 + Cl2 2SOCl2 + 2SO2

134 160 70 236 128

SMC Sulphur Trioxide Chlorine TC

Overall Chemical Reaction:

2S + 2Cl2 + 2SO3 2SOCl2 + 2SO2

64 140 160 236 128


April - 2010 68

818 Sulphur890 Chlorine

17082044 SO3 To Sulfuric Acid & SBS plant (Recycle)890 Chlorine 1627

3015

2400Product

600Product

15Total Product 3000

MASS BALANCE OF THIONYL CHLORIDE

SMC Reactor

TC Reactor

Condenser

Distillation Column

Process Flowchart:


April - 2010 69

2.4.2.13 Sodium Bisulphite


Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then

passed slowly to the reactor. The mass is then allowed for continuous mixing. The

material thus prepared is Sodium Bi Sulphite.

Chemical Reaction:

Na2CO3 + 2SO2 + H2O 2NaHCO3 + CO2106 64 18 208 28

Sodium SBSCarbonate

Process Flowchart:

CO2Sodium Carbonate 106 28SO2 64Water 18

160

Reactor

MASS BALANCE OF SODIUM BI SULPHITE


April - 2010 70

0.2Water

5 Lime Stone Ventury Scrubber (Alkali)ETP

4 HCl 0.29

Sludge to ETP1

8 CaCl2 Clear Liquid

Mosture Loss

5Dry CaCl2

Product

Reactor

Filter Press

MASS BALANCE OF CALCIUM CHLROIDE

Evaporator

2.4.2.14 Calcium Chloride


Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.

Chemical Reaction:

2CaCO3 +4 HCl 2CaCl2 + 2 HCO3

Process Flowchart:


April - 2010 71

2.4.2.15 Di Calcium Phosphate


Rock Phosphate is reacted with Hydrochloric Acid to generated Phosphoric Acid,

which is further reacted with Lime stone to get DCP which separated and

crystallized.

Chemical Reaction:

Ca F2 3 ( Ca3(PO4)2) + 14 HCl 7 CaCl2 + 3Ca H(PO4)2 + 2HF

3Ca (OH)2

6CaHPO4 (DCP)

Process Flowchart:


April - 2010 72

Rock Phosphate 1800

HCl (30%) 36005400

Lime 200

5600

Hydrated Lime 200

Sodium Silicate 105810

Filteration Process Sludge5310 500

Recycle to Reactor to recover DCP 1500 Centriguge

3810

Dryer Mositure Loss3000 810

Finished Product

Reactor

Neutralisation

Separation

MASS BALANCE OF DI CALCIUM PHOSPHATE


April - 2010 73

95.5 Sulphur104.5 Chlorine

200

MASS BALANCE OF SULPHUR MONOCHLORIDE

SMC Reactor

2.4.2.16 Sulphur Monochloride


Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a

reactor.

Chemical Reaction:

2S + Cl2 S2Cl2

Sulphur Chlorine Sulphur Monochloride (SMC)

64 70 134

Process Flowchart:


April - 2010 74

16 Sulphur17.5 Chlorine

33.580 SO3

89.5 Chlorine203

190Product

13

Residue Product 103

Reactor

Reactor

Condenser

Distillation Column

MASS BALANCE OF SULPHURYL CHLORIDE

2.4.2.17 Slphuryl Chloride


Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl

Chloride.

Chemical Reaction:

S + 3Cl2 + 2SO3 3SO2Cl2

32 210 160 402

Sulphuryl Chloride

Process Flowchart:


April - 2010 75

2.4.2.18 Aluminium Sulphate (ALUM)


Aluminium Sulphate is manufactured by the reaction of Aluminia Hydrate and

Bauxite with Sulphuric Acid.

Bauxite is ground in the pulveriser to 90% passing through 200 mesh and elevated

to batch hopper through bucket elevator. Measure quantity of water is added in the

lead bonded reactor and slowly sulphuric acid is to be added in the reactor.. After

getting the required temperature in the reactor, slowly ground bauxite i.e added.

After the addition of measure quantity of bauxite/alumina hydrate, the agitator is

kept on for about 45 minutes, solution is then dumped in to the settling tank.

The decanted solution of Aluminium Sulphate is then taken to the reactor and the

required quantity of sulphuric acid is added after getting the required temperature

Hydrated Alumina is added slowly. After addition, Aluminum Sulphate is moulded

in the trays with the help of tray filling arrangements. The slabs after cooling are to

be taken out from the trays and stacked in the store.

Chemical Reaction:

2Al(OH)3 + 3H2SO4

Al2(SO4)3 + 6H2O

156 294 342 108


April - 2010 76

Water

860 Alumina Hydrate/Bauxite

456 Sulphuric Acid1316

1316

456 Sulphuric Acid

Mouldingin to Slab

Reactor

Settling Tank

Reactor

MASS BALANCE OF ALUM

Process Flowchart:


April - 2010 77

2.5. SOLVENT RECOVERY AND ITS MANAGEMENT

The only solvent, which is recycled in the process, is in the manufacturing of Sulphonated

Products. The butanol used is separated in the filter and then sent for distillation unit for the

recovery of the same. The recovered Butanol is reused back into the process. The mass

balance diagram has been given the 2.4.2.7.

2.6. RESOURCE REQUIREMENTS

2.6.1 FUEL / ENERGY REQUIREMENTS

2.6.1.1 ENERGY

1. PGVCL

Existing:

Source : Paschim Gujarat Vidyut Company Ltd. – 3000 KVA

Proposed:

Source : Paschim Gujarat Vidyut Company Ltd. – 7000 KVA

Total Power Required for the project : 10000 KVA

1. CAPTIVE POWER PLANT

Existing : Power Plant : 2.5 MW

Proposed: Power Plant : 10 MW

Total : 12.5 MW


April - 2010 78

2.6.1.2 FUEL

The details of fuels used for the project are given in Table 2.5

Existing Requirements

TABLE 2.5 DETAILS OF THE FUELS

Sr. No. Utility (Existing) Nos. Fuel Consumption

MT/Day

1 Boiler (5 TPH) 1 F.O 1700 Lit/Day

Proposed Requirement

Sr. No. Utility (Proposed) Nos. Fuel Consumption

MT/Day

1

Boiler (5 TPH)

For Power Plant 1 Coal 10

TABLE 2.6 FUEL CHARACTERISTICS Fuel Consumption Calorific Value

(Kcal/Kg)

% Sulphur

content in

the fuel

% Ash

Content

Density, Kg/M3

F.O 1.7 KL/Day 9650 4.5 0.1 950

COAL 10 MT/Day - 5% 10% -

The storage details of the fuel used for the project are given in Table 2.7.


April - 2010 79

TABLE 2.7 FUEL STORAGE DETAILS

Operating Condition

Capacity of

Vessel

Storage Capacity

Fuel Method of storage

Press. Kg/cm2

Temp. 0C

KL

No. of Vessels

KL

Control Measures Provided

F.O Above Ground

Atm. Room temp

45 1 45 Stored in designated area.

Coal Separate Covered

Area

Atm. Room temp

- - 150 MT

Stored in designated area.

Table 2.8 provides the details regarding transportation of the fuel from the source.

TABLE 2.8 SOURCE AND TRANSPORTATION DETAILS OF FUELS

Fuel Source of Supply Means Of Transportation Distance of supplier from

Padana (Km)

F.O IOCL,ESSAR Tanker (by road) Gandhidham

COAL Kandla Truck (by Road) Kandla


April - 2010 80

2.6.2 WATER & WASTEWATER

Water requirement for the project is supplied by the GWIL (Gujarat Water Infrastructure

Limited) Narmada Pipeline Project. Presently the company has agreement with GWIL for

supply of maximum of 1210 KLD. The copy of the same is enclosed herewith. The unit is

also in process for obtaining permission of maximum supply of 1520 KLD. The details of

water requirement are given in Table No.2.9. The details include purpose, peak consumption

for different categories.

TABLE 2.9 TOTAL WATER REQUIREMENTS FOR THE PROJECT

Sr.

No Category

Type of

Water

Existing Water

Consumption,

KLD

Additional

Water

Consumption,

KLD

Total Water

Consumption,

KLD

1 Process Raw Water 413 226 639

2

Power Plant

Steam

Generation

DM Water 10 50 60

3 Cooling Tower Raw Water 500 240 740

4 Washing Raw Water 5 5 10

5 Gardening & Fire Raw Water 10 20 30

6 Regeneration Raw Water 2.5 5 7.5

7 Domestic Raw Water 25 5 30

Total 965.5 551 1516.5

Total Gardening Water Requirement as per the area available for gardening (24750 Square

Meter) is 124 KL. Out of which 30 KLD will be utilized freshwater and 94 KLD will be

utilized treated water from effluent treatment plant.


April - 2010 81

AGREEMNE WITH GWIL


April - 2010 82

TABLE 2.10 WASTEWATER GENERATION FROM THE PROJECT

Sr. No Category

Existing

Wastewater

Generation,

KLD

Additional

Wastewater

Generation,

KLD

Total

Wastewater

Generation,

KLD

Industrial

1 Process 65 400 465

2 Power Plant Steam

Generation 1 5 6

3 Cooling Tower 5 2.5 7.5

4 Regeneration 2.5 5 7.5

Total Industrial 73.5 412.5 486

Domestic

Domestic 20 4 24


April - 2010 83

TABLE 2.11 SEGREGATION OF WASTEWATER FOR TREATMENT & DISPOSAL

Sr. No Category

Existing

Wastewater

Generation,

KLD

Additional

Wastewater

Generation,

KLD

Total

Wastewater

Generation,

KLD

A. Industrial Wastewater To ETP

1 Process (Vinyl

Sulphone) 59 256 315

B. Industrial Wastewater to ETP

1 Process (Others) 1 139 140

2 Cooling Tower 1 5 6

3 Boiler Blowdown 5 2.5 7.5

4 Regeneration 2.5 5 7.5

5 Washing 5 5 10

Total 14.5 156.5 171

C. Domestic Wastewater to Septic Tank & Soak Pit

1 Domestic 20 4 24


April - 2010 84

Total Water consumption 1516.5 KLD

1516.5

10 639 740

Evaporation & Drift Losses

133.5 60 Losses 30 7.5 30

Washing Process Cooling Boiler 73 Domestic Regeneration

Gardening & Fire Fighting

24V.S. Stream Septic Tank

Blow down Blow Down &10 140 7.5 6 Soak Pit 7.5

ETP171

Figure are given in Kilolitres/Day For Reuse, Gardening & Firefighting Make-up Tank

315 Incinerator

TOTAL WATER BALANCE AFTER PROPOSED EXPANSION ALL Figures are in KLD


April - 2010 85

2.7 WASTEWATER MANAGEMENT

The wastewater generated will be segregated and treated separately. After proposed

expansion a total of 486 KLD of Industrial & 24 KLD of domestic wastewater will be

generated. The industrial wastewater will be further segregated considering its pollution load

and finally be treated within premise.

SEGREGRATION OF THE WASTE STREAMS:

The Various Streams generated from the industrial activity will be as follows:

Stream A: Process wastewater from Vinyl Sulphone, which will have high concentration of

COD & BOD.

Stream B: Process wastewater from Sulphuric Acid Plant, TC Plant, Chloro Sulphonic Acid

Plant, DASDA Plant, DMS Plant, DMA Plant.

Stream C: Utility wastewater (viz Boiler blow down, Cooling water blow down,

Regeneration & Washing

Stream D: Domestic wastewater.

The streams from the process will be conveyed to the equalization/ collection tank and is

given a primary treatment. The utility wastewater will be directly taken into the final

collection tank after the physical screening of the wastewater. The domestic wastewater will

be directly fed in to the aeration tank of the Effluent Treatment Plant. Hence only wastewater

which required the full treatment is process water i.e 64 KLD.


April - 2010 86

CHARACTERISTICS OF THW WASTEWATER STREAMS

The characteristics of wastewater of different streams and final outlet would be as follows:

TABLE 2.12 CHARACTERISTICS OF VARIOUS STREAMS OF WASTEWATER

Sr. No

Parameters Unit Characteristic of Process Streams- Vinyl Sulphone

Characteristics of Other Process Streams

Characteristics of Sewage

Characteristics of Cooling Tower Blow down

Characteristics of Boiler Blow down

Analysis Results After treatment

Permissible Limits

1 Color pt Co.

units

- Turbid –Light

Yellow

Turbid Colorless Colorless Colorless 100 units

2 pH - 3.5-6.5 3.5-6.5 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5

3 COD mg/lit 6500-8500 500-750 500 50 50 <250 <250

4 BOD mg/lit 2000-4200 100-300 200 15-20 15-20 <50 <500

5 TDS mg/lit 2500-3500 1000-2000 400 1500 2500 <2500 N.S


April - 2010 87

The detail of the wastewater management to be done within the premises has been described below.

2.7.1 EFFLUENT TREATMENT PLANT

Stream B & Stream C containing lesser pollution load will be collected in collection &

equalization tank and physico chemical treatment followed with Tertiary Treatment. The

treatment scheme is as under.

The raw effluent from all the sections will be collected in to the collection sump. The effluent

from the collection sump will be pumped to the oil & grease trap. The effluent free of oil &

grease and floating matter will be taken to the equalization cum neutralization tank.

The equalization cum neutralization tank with adequate residence time has been provided for

equalizing the organic as well as hydraulic load. There will be two compartments in the

equalization cum neutralization tank so as to have the ease of operation and saving the

chemical consumption for neutralization. The effluent will be checked for the pH and it will

be neutralized with the chemicals. The chemicals will be mixed with the coarse aeration

provided at the bottom. After the chemical treatment is over, the effluent will be pumped to

the primary clarifier where sludge settles at the bottom & clarified effluent overflows to next

stage. The sludge settled at the bottom of the primary clarifier will be taken to the sludge

drying bed. The overflow of the primary clarifier is taken to intermediate collection tank.

Tertiary treatment in the form of Sand Filteration & Carbon Treatment will be followed. The

treated wastewater from the tertiary treatment is collected in final collection tank and finally

utilized for gardening and firefighting use. The biological treatment comprises of activated

sludge process The ETP will be designed for treating 200 KL/day of effluent.

The quantity of wastewater to be treated is 171 KLD.


April - 2010 88

TABLE 2.13 CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT

The characteristics of before & after treatment will be as follows:

Sr. No Category of Wastewater Before Treatment After Treatment

1 pH 3.5-6.5 6.5-8.5

2 COD 500-750 50-100

3 BOD 100-300 10-30

4 TDS 1000-2000 1500-200

The method of treatment followed will be as follows:

Collection Tank

Equalisation Tank

Neutraliser Tank

Clarifier

Tertiary Treatment (Sand & Charcoal)

Intermediate Collection Tank

Lime Tank

Reuse in Fire Fighting, Gardening


April - 2010 89

EFFLUENT TREATMENT PLANT UNITS:

TABLE 2.14 SIZING OF ETP UNITS

Sr No. UNITS Nos. SIZE Total Unit

Volume, KL

1 Raw Effluent Collection Tank 2 5.0 m x 5.0 m x 4.0 m + 0.5

SWD 100

2 Oil & Grease Trap 1 - -

3 Equalisation cum

Neutralisation Tank

2 2.0 m x 2.0 m x 2.5 m 20.00

4 Primary Clarifier 1 3.0 m Dia x 2.5 m SWD 17.66

5 Intermediate Collection Tank 1 3.5 m x 3.5 m x 2.5 m 30.65

6 Sand Filter 1 - 20 M3

7 Carbon Filter 1 - 20 M3

6 Final Collection Tank 1 5.0 m x 5.0 m x 4.0 m + 0.5

SWD 100

7 Chemical Dosing Tank 2 1.5 m x 1.5 m x 1.5 m 6.75

8 Sludge Drying Bed 4 8.0 m x 6.0 m x 1.1 m 211.20

9 Chemical House 1 7.0 m x 5.0 m 35 m2


April - 2010 90

PROCES & WASHINGEFFLUENT COLLECTION TANK CRYSTALLISER COLLECTION TANK

GLAUBER SALT

SOLID WASTE FILTER PRESS

FILTERATE COLLECTION TANK

INCINERATION CONCENTRATED WASTE EVAPORATOR

2.7.2 INCINERATOR PLANT

Stream A containing high COD & BOD concentration will be processed for effluent

reduction by crystallization , evaporation process. The concentrated and reduced effluent

will be incinerated. The flow scheme of the same has been described below:

The ML is first collected in collection tank and then it is pumped to crystallizer for recovery

of Glauber Salt. The effluent is then neutralized in the neutralization tank. The neutralized

effluent is pumped to filter press. The filterate is collected in collection tank from where it

is pumped to the multi effect evaporator for reduction in volume.

The concentrated ML is collected in other collection tank from where it is pumped to the

incinerator.

The total volume of effluent to be passed through effluent reduction process is 315 KLD.

The reduced mass after the evaporation will be 70 KLD, which will be sent to incinerator

for the final incineration process.


April - 2010 91

The details of the Incinerator & Flow Scheme are given as below.

TABLE 2.15 SPECIFICATION OF INCINERATOR

The details of the incinerator are as follows:

Sr. No. Description Details

1 Type Vertical

2 Capacity 3000 Lit/Hr

3 Size - Diameter 1.0 meter

4 Height 6.0 meter

5 Inlet feed rate 3000 Lit/Hr

6 Fuel Consumption 250 Lit/Hr

7 Fuel LDO

8 LDO Feed System Pumping

9 Nozzle

LDO

Mother liquor

Lap – 1 (2 Nos.)

Lap – 2 (2 Nos.)

10 Operating Temperature 700-1000 °C

11 Scrubber Ventury Scrubber

2.7.3 SEPTIC TANK & SOAK PIT

Domestic waster will be generated to the tune of 24 KLD. The entire sewage will be

disposed off in to the septic tank and soak pit.

2.7.4 QUANTITY OF WATER RECYCLED AND RECYCLING MECHANISM

The treated wastewater from the process will be utilized for the gardening, firefighting.

Total Gardening Water Requirement as per the area available for gardening (24750 Square

Meter) is 124 KL. Out of which 30 KLD will be utilized freshwater and 94 KLD will be

utilized treated water from effluent treatment plant. Balance 71 KLD will be utilized for

firefighting mock drill.


April - 2010 92

2.8 ATMOSPHERIC EMISSIONS

2.8.1 FLUE GAS DETAILS

The details regarding characteristics of the various flue gases generated at the site are given in Table 2.14.

TABLE 2.16 FLUE GAS DETAILS

Sr. No. Stack attach to Dia. at topmt

Height, m Type of Fuel

Rate of Fuel consumption per day

Air Pollution Control Measures

Pollutants Expected

• Existing

1 Boiler-1 (5 TPH) 1.2 m 30 m FO 850 Lit/Hr Adequate stack height is provided

2 Incinerator 1.2 m 30 m LDO 250 Lit/Hr Adequate stack height is provided

3 Power Plant 1.8 m 20 m - - Adequate stack height is provided

PM, SOx, NOx

• Proposed 1 Boiler – 2 (5 TPH)

1.2m 30 m

Coal 10 MT / day Cyclone & Bag Filters, Adequate Stack Height

2 Power Plant (Steam Turbine) 1.8m

20 m - - Adequate stack height will beprovided

PM, SOx, NOx


April - 2010 93

2.8.2 PROCESS EMISSION

The Details of the process gas emission has been depicted in the Table 2.15

TABLE 2.17 PROCESS EMISSION DETAILS

Sr. No. Stack Attach to Air Pollutant Scrubbing Media

Capacity of Scrubbing tank, KL

Pump Capacity KL/Hour

Stack Height meter

Stack Diameter, meter

Existing 1 Alkali Scrubber – Sulfuric

Acid & Oluem Plant SO2 Caustic Solution 2 2 20 0.2

2 Alkali Scrubber – CSA Plant HCl., SO2 Caustic Solution 2 2 20 0.2

Proposed

3 Alkali Scrubber – DASDA Plant SO2 Caustic Solution 2 2 20 0.2

4 Alkali Scrubber – CaCl2Plant HCl Caustic Solution 2 2 20 0.2


April- 2010 94

2.8.3 QUANTIFICATION OF EMISSION

2.8.3.1 Flue Gas Emission

The various pollutants viz. PM, SO2 & NOx have been quantified based on the characteristics

of the fuel depicted in Table 2.7 Fuel Characteristics. For NOx quantification emission factor

has been taken from the software FIRE.

The total emission from the F.O operated Boiler, Coal Operated Boiler and Incinerator have

been calculated and depicted in the following table.

The details of the emission rate have been depicted in the Table 2.16.

TABLE 2.18 EMISSION RATE OF THE POLLUTANTS -EXISTING

Pollutants Emission Rate, gms/sec Utility

PM SO2 NOx Boiler - FO 0.2 1.12 0.07 Incinerator - LDO 0.02 0.08 0.01 0.22 1.20 0.08

TABLE 2.19 EMISSION RATE OF THE POLLUTANTS -Proposed

Pollutants Emission Rate, gms/sec Utility

PM SO2 NOx Incinerator - LDO 0.04 0.22 0.02 Boiler - Coal 0.12 0.52 0.09 0.16 0.74 0.11


April- 2010 95

2.8.3.2 Process Gas Emission

The various pollutants viz. SO2, HCl & Cl2 have been identified, considering the permissible

norms of the pollutants the quality of gaseous emission has been depicted in Table 2.18 &

2.19. The process emission for various plant will be connected to the alkali scrubber and then

only released in to the atmosphere. The existing and proposed emission rates calculated have

been tabulated in the following table.

TABLE 2.20 PROCESS EMISSION -EXISTING

Emission Concentration, mg/m3 HCl SO2 H2SO4 & Oluem Plant - 20 H2SO4 & CSA Plant 20 20

TABLE 2.21 PROCESS EMISSION -PROPOSED

Emission Rates, gms/sec HCl SO2 DASDA Plant - 20 CaCl2 Plant 20 -

2.8.4 FLUE GAS EMISSION/FUGITIVE EMISION CONTROL

The volatile matters getting released from the storage tanks, process piping, reactors, fuel

storage & combustion will be handled by various preventive measures mentioned below:

1. Coal during combustion is completely burnt by providing sufficient air for combustion and

is released to atmosphere through high-rise stack. Keeping in mind the CPCB guideline for

controlling flue gas/fugitive emission following arrangement will been done.

2. Each & Every process emission will be passed through scrubber and finally released in to

atmosphere through adequately designed stack height.

3. Preventive maintenance will be done so as to prevent any leakage and spillage and thereby

reducing the fugitive emission sources.

4. Storage tank will be provided with level gauge, dyke wall, automated loading and unloading

for the chemicals to avoid human contact.

5. All storage tank will be designed and placed according to the Industrial Safety & Health

Department.


April- 2010 96

2.9 HAZARDOUS WASTE MANAGEMENT

Details of Solid waste generated

The Quantity of Hazardous and Solid wastes generation & disposal by various methods have

been shown in Table. 2.17. All the solid/hazardous wastes generated do not contain any

toxic/radioactive substances. However, precautionary measures will be provided in the form

of Safety Management/Risk Management.

TABLE 2.22 HAZARDOUS WASTE GENERTION & DISPOSAL


Type of Hazardous Waste

MT/Month MT/Month MT/Month

Hazardous Waste

Category

Storage &

Disposal

1 ETP Sludge 5 40 45 34.3 Collection, Storage , Transporation & Disposal to TSDF










The empty drums generated are basically from dry powder raw material. The drums are then

stored at separate hazardous waste storage are and finally be given to the approved vendor.

Hence no decontamination is required at the site.


April- 2010 97

2.10 SAFETY & OCCUPATIONAL MEASURE FOR STORAGE &

HANDLING OF THE RAW MATERIAL & PRODUCT

To prevent any spillage, accident and impacts of human health for safety measure will be

taken while handling the raw material and products:

♦ Separate storage area for the raw material & product.•

♦ Solid Raw Material Stored in Separate Storage area with proper identification

labeling.

♦ Liquid Raw Material is stored in suitable tanks at separate demarcated space.

♦ Separate area for packing of the product.

♦ Storage area with separate Bunds for separate chemicals to contain any kind of

leakage and to avoid mixing of the chemicals in case of leakages.

♦ Liquid Raw material charging will be done with utmost care and by mechanical

seal type of pump to avoid any leakages.

♦ Personal Protective Equipment (viz. dust mask, gloves, goggles & gum boots)

are being provided to the workers and plant operators.

♦ Gas Detectors with alarm system for Hydrogen, Ammonia..

♦ Occupational Health Centre with Male Nurse is provided within the company

premises. First Aid kit has been provided at various locations within the plant.

♦ Fire Hydrant has been installed within the premises.

♦ Fire Extinguisher has been provided at the vulnerable points within the premises.

♦ Medical Check-up for workers and employee at pre-employment and periodical

stages.

The characteristics, handling of the raw material and product and first aid measure has been

given in the MSDS.


April- 2010 98

2.11 GREENBELT DEVELOPMENT

The company has a total land of 75,000 sq. meter, out of which green belt to develop is

24750 sq. meter.. The unit has already provided a land area of 15000 Sq. meter for green belt

development. The trees will be grown within plant boundary and at the periphery of the

company premises. These will be utilized for gardening and landscaping. Thus, the proposed

project will have significant positive impact on the floristic component.

The details regarding the tree are based on the guidelines for developing greenbelts by the

CPCB. The details about the trees planted are given as follows:

TABLE 2.23 GREENBELT DETAILS

Name of the Trees Sensitive / tolerant to air pollution

Height No. of Trees to bePlanted

Neem Tolerant 5-10 m 1500 Saru Tolerant 5-10 m 1500 Cassia Fistula (Yellow Flower Tree)

Tolerant 5-10 m 1500

Eucalyptus Tolerant 10-15 m 1500

A Total of 6000 trees will be planted within & at the periphery of the premises. Apart form

the tree a bogunvelia and other ornamental plant will be grown within the premises.

2.12 WATER RESOURCE & RAIN WATER HARVESTING

The source of water for the project is GWIL (Gujarat Water Infrastructure Limited) a

Narmada pipeline project. The unit have also proposed to design & implement rain water

harvesting scheme within premises. The parameter considered for designing the Rain water

harvesting is as follows:

The average rainfall of the area considered for the design is 300 mm/year (peak rain fall: 50

mm/hr). The paved area available in front is 15000 Square Meter. The amount of water

collected from the run off would be 375 m3/hr. The roof top area available is 500 Square

Meter. The amount of water collected from the roof top would be 20 m3/hr. Considering one

hour of peak rainfall total rain water to be collected would be 395 m3/hr. Hence rain water

harvesting pit of 400 KL will be made to collect the rain water from roof top and paved area.


April- 2010 99

2.13 COMPLIANCE TO THE RECOMMENDATIONS MENTIONED IN THE CREP

GUIDELINES.

The Ministry of Environment & Forest (MoEF) has launched the Charter on "Corporate

Responsibility for Environmental Protection (CREP)" with the purpose to go beyond the

compliance of regulatory norms for prevention & control of pollution through various

measures including waste minimization, in-plant process control & adoption of clean

technologies. The Charter has set targets concerning conservation of water, energy, recovery

of chemicals, reduction in pollution, elimination of toxic pollutants, process & management

of residues that are required to be disposed off in an environmentally sound manner. The

Charter enlists the action points for pollution control for various categories of highly

polluting industries. The Task Force was constituted for monitoring the progress of

implementation of CREP recommendations/ action points.

The following activities is being undertaken and will be continued in the proposed expansion.

• Sulphuric Acid plant having exothermic chemical reaction generating lots of heat,

which is utilized in waste heat recovery for generation of steam as well as generation

of power plant. Power plant of 2.5 MW is successfully operated using waste heat

recovery.

• In manufacturing of various inorganic chemicals HCl & Spent Sulfuric Acid

generated which is being utilized in the plant for various organic product

manufacturing processes.

• The company following CREP guidelines by adopting reuse/recycle mechanisms and

reduction of pollution at sources.


April- 2010 100

2.14 PROJECT SUMMARY

o Total Land Available: 75000 M2

o Power Requirement: 10000 KVA Source: PGVCL

Power Plant Existing: 2.5 MW, Power Plant Proposed: 10 MW

o Raw Water Requirement: 1516.5 KLD , Source: GWIL

o Industrial Wastewater Generation: 486 KLD

o Domestic Wastewater Generation: 24 KLD

o Air Emission Source

Sr. No. Stack attach to Air Pollutant Stack Height, meter

• Existing � � 1 Boiler-1 (5 TPH) 30 m 2 Incinerator 30 m 3 Power Plant

PM, SOx, NOx 20 m

• Proposed � 1 Boiler – 2 (5 TPH) 30 m

2 Power Plant (Steam Turbine) PM, SOx, NOx 20 m

o Process Emission from the manufacturing activity

Sr. No. Stack Attach to Air Pollutant Stack Height meter

Existing

1 Alkali Scrubber – Sulfuric Acid & Oluem Plant SO2 20

2 Alkali Scrubber – CSA Plant HCl., SO2 20 Proposed

3 Alkali Scrubber – DASDA Plant SO2 20 4 Alkali Scrubber – CaCl2 Plant HCl 20


April- 2010 101

o Hazardous/Solid Waste Generation


Type of Hazardous

Waste MT/Month MT/Month MT/Month

Hazardous Waste

Category

Storage &

Disposal 1 ETP Sludge 5 40 45 34.3 Collection, Storage ,

Transporation & Disposal to TSDF










REIA of Kutch Chemical Industries Ltd. Chapter 3 Baseline Environmental Status

April - 2010 102

3.0 BASE LINE ENVIRONMENTAL STATUS

This Rapid Environmental Impact Assessment (REIA) Study has been conducted to assess the various

environmental impacts likely to occur on the surrounding environment in and around the proposed

project. The study also incorporates the appropriate control measures required to be adopted or

implemented in order to minimize the adverse effects thereof.

In order to carry out the assessment study, it was first necessary to delineate and define the existing

environmental factors in and around the proposed project on the existing environmental scenario

which will include various environmental attributes such as ecology, Flora-fauna, socio economic

profile, environmental quality with respect to air, water, noise & soil etc.

This section incorporates the description of the various existing environmental settings within the area

encompassed by a circle of 10 km radius around the proposed project site. This study area is in Kutch

district, which is surrounded by villages listed in Table 3.1.

The Study area has been shown in Map-3.1

TABLE 3.1 LIST OF VILLAGES AROUND THE PROJECT SITE (10 KM). Sr. No.

Name of village Aerial distance, Km Direction

Villages in Taluka Anjar 1 Pashuda 3 N 2 Tapar 3.5 N 3 Lakhapar 4.5 NW 4 Ajapar 4.5 SW 5 Bhimasar 2.5 N 6 Varsana 3.5 SE 7 Modvadar 2.5 S 8 Varsamedi 5.5 NW

Villages in Taluka Bhachau 9 Chirai Nani 3.5 NE 10 Chirai Moti 5.5 NE

Villages in Taluka Gandhidham 11 Padana 0 - 12 Chudva 5 S 13 Mithi Rohar 6.5 S 14 Galpadar 8.5 SW

REIA of Kutch Chemical Industries Ltd Chapter 3 Baseline Environmental Status

April - 2010 103

282

281

283

299

303

302

300

301

NH 8A

249

248

943

945

944

946

GANDHIDHAM

SCALE

0 1 2 3 4 5km

SR.NO VILLAGE NO. VILLAGE NAME

1

300 BHIMASAR

2

301 VARSANA

3

302 MODVADAR

TALUKA

303 VARSAMEDI

299 AJAPAR

281 PASHUDA

282 TAPAR

283 LAKHAPAR

248 CHIRAI NANI

249 CHIRAI MOTI

943 PADANA

944 CHUDVA

945 MITHI ROHAR

4

5

6

7

8

9

10

11

12

13

ANJAR

GANDHIDHAM

N

MAP: 3.1Date : 15/05/2010 APP. BY :

Client:KUTCH CHEMICAL INDUSTRIES LTD.

FEATURES WITHIN STUDY AREA OF 10 KMS

SCALE : AS SHOWN

REVISION : 0

CHD BY : DRAWN BY :

Title :

DRAWING NO.

RAPID ENVIRONMENTAL IMPACT ASSESSMENT

PADANA

Project :

ECO-CARE SOLUTIONS

FOR ORGANIC & INORGANIC CHEMICALS UNIT

JHGP

STATE HIGHWAY

NATIONAL HIGHWAY

BROAD GAUGE RAIL

METER GAUGE RAIL

ANJAR TALUKA

BACHAU TALUKA

LEGEND

VILLAGE DETAILS

GANDHIDHAM TALUKA

ANJAR

ANJAR

ANJAR

ANJAR

ANJAR

ANJAR

ANJAR

BACHAU

BACHAU

GANDHIDHAM

GANDHIDHAM

MARINE / CREEK

VILLAGE BOUNDARY

TALUKA BOUNDARY

0265-2356752, 94260-74416, 94275-06362

SANU CREEK

GULF OF KUCHCHH

946 GALPADAR14 GANDHIDHAM


April - 2010 104

TABLE 3.2 IMPORANT FEATURES WITHIN STUDY AREA S. No. Features Location Distance(km) Direction

1. National Park/Wildlife

Sanctuary

- - -

2. Tiger Reserve e/Elephant

Reserve / Turtle Nesting G

round

- - -

3. Core Zone of Biosphere

Reserve

- - -

4. Reserved Forest Land - - -

5. Habitat for migratory birds - - -

6. Lakes/Reservoir/Dams Bhimasar Pond 2.5 N

Ajapar Pond 2.0 W

Varsamedi Pond 4.8 SW

7. S tream/Rivers - - -

8. Estuary /S ea Arabian Sea 4.5 S

9. Mangroves - - -

10. Mountains/Hills - - -

11. Notified Archaeological sites - - -

12. Any other Archaeological sites - - -

13. Defense Installation - - -

14. National / State Highway s NH-8A 0.3 S

15. Airports - 10.5 W

16. Railway Line(Meter Gauge) - 0.5 N


April - 2010 105

MALE & FEMALE % WITHIN STUDY AREA

55%45% MALE

FEMALE

3.1 DEMOGRAPHIC & SOCIO ECONOMIC PROFILE

(CENSUS OF INDIA 2001)

A total of 14 villages falls within 10 km radius of the project site. The demographic and socio

economic profile has been presented below.

3.1.1 POPULATION

The density of population within 10.0 km radius of the project site per Sq km is 91.

The percentages of male and female population are 54 %& 46% respectively.

The population of scheduled castes and scheduled tribes is 6.89% & 12.38% respectively.

Sex Ratio: 861 Female / 1000 Male

TABLE 3.3 TOTAL POPULATIONS WITHIN STUDY AREA

Total Population Total Population in the age group(0-6) SC ST

Distance, km

No. Of House Holds Population M F P M F M F M F

0-10 8240 37717 20588. 17129 6244 3222 3022 1471 1374 2231 1988

A figure of Male & Female proportion has been shown in Figure-3.1

A figure of population has been shown in Figure-3.2.

FIGURE 3.1 POPULATIONS OF MALE & FEMALE IN STUDY AREA


April - 2010 106

POPULATION PATTERN WITHIN STUDY AREA

64.72%16.55%

7.54%

11.19%

SC

ST

AGE GROUOP 0-6

OTHERS

FIGURE 3.2

POPULATION OF SC, ST, AGE GROUP 0-6 YRS

3.1.2 LITERACY LEVELS

The literacy rate within the study area amongst the male & female population has been depicted in the

Table 3.4

TABLE 3.4 LITERACY WITHIN STUDY AREA Total Population Literates % Literates

Distance

No. Of

House

Holds Population

M F M F M F Total

0-10 km 8240 37717 20588 17129 7831 3461 38.04 20.21 29.94

The elaborate figures of population, literacy have been depicted in the Table 3.5.


April - 2010 107

TABLE 3.5 POPULATION & LITERACY WITHIN STUDY AREA

Total Area Total Population Total Population in the

age group(0-6) SC ST Literates Sr. No

Name of Village

Ha.

No. Of

House Holds Population M F P M F M F M F M F

1 Chirai Nani 2100.4 1101 4808 2822 1986 679 359 320 132 118 95 71 1249 341 2 Chirai Moti 4835.4 1043 4412 2666 1746 816 414 402 87 67 630 548 1163 315 3 Pashuda 1911.6 146 597 303 294 102 52 50 19 19 33 34 150 89 4 Tapar 5440.8 669 2692 1376 1316 399 206 193 62 63 207 181 694 364 3 Lakhapar 2464.2 310 1254 624 630 183 93 90 59 60 21 18 325 200 4 Ajapar 1272.4 128 708 360 348 107 61 46 0 0 4 1 164 85 5 Bhimasar 1911.6 653 2791 1415 1376 443 222 221 167 149 218 222 780 469 6 Varsana 1120.0 248 1047 614 433 217 121 96 0 0 115 116 282 73 7 Modvadar 694.2 257 1261 630 631 163 84 79 30 29 11 9 344 201 10 Varsamedi 4379.0 492 2143 1094 1049 329 177 152 116 118 50 47 554 308 11 Padana 1164.9 367 1764 905 859 274 137 137 67 52 213 192 371 214 12 Chudva 1407.1 74 293 170 123 61 38 23 28 19 75 55 25 9 13 Mithi Rohar 3601 1680 8409 4383 4026 1674 836 838 391 378 341 298 1512 597 14 Galpadar 780 1072 5538 3226 2312 797 422 375 313 302 218 196 218 196

Total 33082.2 8240.0 37717.0 20588.0 17129.0 6244.0 3222.0 3022.0 1471.0 1374.0 2231.0 1988.0 7831.0 3461.0


April - 2010 108

3.1.3 OCCUPATIONAL STRUCTURE.

There is a large diversity in the occupational pattern in the study area. In Rural, majority of the people

are engaged in agricultural activities, forestry and allied activities.

Major activities in Urban areas include industrial employment, Trade and Commerce, Livestock,

Business, Construction, Transport and Communication network, Engineering profession, Service

centers, Technical and Medical services and others.

This wide diversity in occupational structure may be broadly categorized as working and non-working

population. The Table 3.6 shows total main workers, marginal workers and non-workers. The

elaborate details have been depicted in the Table 3.7, 3.8 & 3.9.

TABLE 3.6 WORKERS CATEGORISATION Sr. No. Category Total

1 Total Main Workers 13101

2 Total Marginal Workers 1411

3 Total Non Workers 23205

Total 37717


April - 2010 109

TABLE 3.7 MAIN WORKERS CATEGORISATION

Total Main Workers Cultivators Agricultural Labourers Household Workers Other Workers

Sr. No.

Name of the Village Total Male Female Total Male Female Total Male Female Total Male Female Total Male Female

1 Chirai Nani 2251 1869 382 103 92 11 18 14 4 31 15 16 2099 1748 351 2 Chirai Moti 2447 1840 607 21 20 1 44 29 15 9 0 9 2373 1791 582 3 Pashuda 259 178 81 110 73 37 32 18 14 31 6 25 86 81 5 4 Tapar 555 511 44 84 76 8 38 34 4 1 0 1 432 401 31 5 Lakhapar 336 321 15 99 97 2 73 63 10 6 6 0 158 155 3 6 Ajapar 195 190 5 1 1 0 123 118 5 1 1 0 70 70 0 7 Bhimasar 842 738 104 125 118 7 42 39 3 28 10 18 647 571 76 8 Varsana 240 234 6 0 0 0 0 0 0 1 1 0 239 233 6 9 Modvadar 346 306 40 24 24 0 10 5 5 3 2 1 309 275 34 10 Varsamedi 546 485 61 58 57 1 106 96 10 36 2 34 346 330 16 11 Padana 584 464 120 14 13 1 159 128 31 0 0 0 411 323 88 12 Chudva 74 72 2 1 1 0 29 28 1 1 1 0 43 42 1 13 Mithi Rohar 2392 2204 188 13 9 4 74 62 12 8 5 3 2297 2128 169 14 Galpadar 2034 1941 93 59 55 4 15 8 7 14 9 5 1946 1869 77

Total 13101 11353 1748 712 636 76 763 642 121 170 58 112 11456 10017 1439

Documents

rapid environmental impact assessment & environmental management plan of proposed