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ENVIRONMENTAL CLEARANCE FOR PROPOSED INSTALLATION OF POLYURETHANE (PU)

INSULATION UNIT IN THE EXISTING COMPLEX BY M/S CELLO INDUSTRIES.

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4.0 ENVIRONMENT MANAGEMENT:

The Cello Plant is designed with Zero Discharge concept. No waste water generation is

envisaged from the proposed PU Foaming Process. Bleed water from CT will be reused

into green belt. Waste water generated (6.10 KLD) from Domestic & miscellaneous

Purpose i.e. floor/equipment washings will be treated in the CETP.

Little quantity of solid waste (Approx. 10.0 Kg/day) will be generated during material

sampling, dispensing, handling, production, processing and packing & eventually reuse

into process.

Approx. 5.0 kg / day solid waste will be generated from the proposed production process

such as cutting waste of Puff shall be sold to authorized recyclers for safe disposal.

Approx. 30.0 Kg/day solid waste will be generated as scrap of Empty sacs, Boxes, Plastic

Utensils, and Cans, which will be sold to the respective Dealers.

5.0 SITE ANALYSIS:

5.1 Connectivity:

The plant is located about 9.5 Kms from Haridwar City, just outside Municipal limits, in a

Integrated Industrial Estate of SIDCUL. The existing land area is 20265.00 Sq. M with

plenty of green land. However land area required for installation of proposed Polyurethane

(PU) insulation Unit– 150.00 Sq. m in the vacant space of existing complex. The nearest

National Highway NH-58 is 3.45 km away from the site. The nearest Railway station

Haridwar is about 8.59 km away from the site.

5.2 Land Use:

Proponent has acquired Land about 20265.00 Sq. m at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand. Proposed Polyurethane (PU) insulation Unit

will be installed in the part vacant land i.e. 150.0 Sqm of the existing plot.

The land break-up details are shown in Table – 06

Table – 06: Land break-up details

S. No. Construction Area (Sq m.)

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1. Total Ground cover area for Plant & Facilities 8752.22

2. Greenbelt 6688.00

3. Open Area 2289.78

4. Parking area 2185.00

5. Loading /unloading area 350.00

Total Land 20265.00

5.3 Topography:

The Existing Plant is located at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand – 249 403. The area is situated in the survey of India Topo Sheet

No. 53 K and Coordinates Latitude: 290 57’ 02.20” N, Longitude: 780 03’58.52” E. The

nearest National Highway NH-58 is 3.45 km away from the site. The nearest Railway

station Haridwar is about 8.59 km away from the site.

The main features of the site including environmental considerations that make it suitable

for PU Insulation plant are given below:

Availability of sufficient stretch of land with flat terrain

No habitation in the plant site, hence no direct R&R issues

Sparsely populated surroundings

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

Nearness to source of main raw materials

Location of consumer center

Convenient Rail & Road links.

Adequate sources of water supply

Availability & closeness to source of adequate power supply

The site lies in seismic zone IV as per Seismic zonation & intensity Map of India and has

the lowest seismic potential.

There is no Capable Fault within the study area. The seismic zone map of Uttarakhand is

shown in the Fig. – 10.

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Fig – 10: Seismicity Map of Uttarakhand State

5.4 EXISTING LAND USE PATTERN:

Proponent has acquired Land about 20265.00 Sq. m at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand. The products of Cello Industries are having a

wide range of Kitchen wares. Presently the company is producing Plastic house hold goods

2244.00 MTPA, Plastic Moulded Parts (PMP) 480.00 MTPA and Pet Preforms & Bottles

48.00 MTPA.

Proposed Polyurethane (PU) insulation Unit will be installed in the part vacant land i.e.

150.0 Sqm of the existing plot.

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5.5 EXISTING INFRASTRUCTURES:

The proposed PU insulation installation is in existing complex so infrastructure such as

storage facility, Drinking water facility, First-aid facility, Toilet facility is already

available. Internal roads are developed inside the plant premises once all the statutory

clearances are obtained.

Land:

Proponent has already acquired Land about 20265.00 Sq. m, whose building is converted

through modifications to suit to various Products at Plot No. – 1, Sector No. – 2, IIE,

SIDCUL, Ranipur, Haridwar, Uttarakhand.

Power:

The total connected load for smooth operation of the Unit is being sourced from UPCL

(1400 KVA). However just 20 KVA power will be required for the proposed unit.

The Company proposes for installation of Green Insulated DG Set for Alternate Power of

arrangement (350.0 KVA) for continuous supply of power in the manufacturing of

existing/proposed Products during Failure / Shutdown of power at any point of time will

adversely affect the production and quality of Finished Product.

Water:

Total water requirement for PU insulation Unit shall be 9.0 KLD, which shall be sourced

from existing bore wells. Necessary provision for storage of water and water supply has been

made in project cost.

Storage:

Company has already developed storage facility for raw material & finished goods by

providing adequate safety measures.

Transportation:

Promoters have adequate resources for transportation of Raw Material and Finished Goods.

Connectivity:

The Project site is well connected with road as well as Rail route.

All the other infrastructural facilities are expected to be adequately available to the Unit.

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5.6 SOIL CLASSIFICATION:

The topography is undulating in the northern part and more or less plain towards south.

The altitude ranges from 869 to 232 m. In the vicinity of Siwalik Hills, the gradient is steep.

Geomorphologically Hardwar district can be divided into four geomorphic units. These are

flood plain, lower piedmont plain, upper piedmont plain and structural hills.

The flood plain area is relatively flat, low lying and adjacent to Solani River. It comprises

unconsolidated, coarse to fine sand with silt and clay. The area is repeatedly inundated

during the floods. The lower piedmont plain is flat to undulating with gradient towards

southwest having micro relief. The sediments vary from fine clastic to coarse clastic

manifesting in variable runoff and infiltration.

The upper piedmont zone is narrow, southerly sloping upland adjoining the Siwalik Hills in

varying lateral and areal extent formed at the foot hills by the coalescence of several alluvial

fans comprising unsorted coarse clastic sediments (boulders, pebbles, gravels sand and clay).

It has high gradient (about 10 m/km) in the northern part to about 0.4 m/km in the

southern part close to Tarai. In this zone, most of the ephemeral rivers draining the area

disappear. There is high moisture content in upper piedmont zone which support dense

forest and lies to the south of Bhabar zone.

Structural hills show high relief and deep incised drainage with steep and sharp hill slopes

and well defined crest line (northern boundary of the block). This unit shows rugged

topography and homogenous lithology. The vegetation is dense indicating the presence of

loose alluvial material.

Soils play an important role in ground water recharge and the agriculture production of the

area. The land of Bhagwanpur block is highly fertile. The northern part, paleochannels and

active floodplain of rivers have soils of sandy loam, where as remaining part of the block is

covered by silty loam soils. Important soils are Ultisols, which are the brown hill soil,

occurring all through the northern part of the block. These are the soils with a horizon of

clay accumulation and low base supply. Entisols are the soils (also called the Bhabar soil)

occurring all along the foothills of Siwaliks and extends up to Tarai. These soils are without

pedogenic horizons. Though these soils consist of boulders, pebbles, sand, silt and clay, they

are highly fertile. Mollisols, also called the Terai soil, occur in the southern part of the block.

They consist mainly of fine-grained sand, silt and clay. These are the soils with a nearly

black, organic-rich surface horizon and high base supply. These three types of soils are

mineral soils with organic matter less than 25%. These are the most fertile soils of the block.

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5.7 CLIMATIC DATA:

District Hardwar experiences moderate subtropical to humid climate with three distinct

seasons viz. summer followed by rainy and winter seasons. Temperature begins to rise from

March (29.10 C) and reaches to its maximum in May (39.20 C), with the commencement of

monsoon season by mid-June, the temperature begins to fall. During the winter season in

the month of November to February the temperature ranges between 10.50 C and 6.10 C.

The relative humidity is highest in monsoon season (85% in the morning and 79% in the

evening). The lowest humidity is observed during the month of April and May i.e. 24% (in

evening) and 40% in May (in morning).

The mean monthly wind speed is highest in the summer season when it goes up to 7.4 and

7.2 km/hour in the month of May and June and the minimum wind speed is observed

during winter when it is 2.6 km/hour in the month of October. The potential

evapotranspiration is maximum in the month of May 198.9 mm and minimum 38.5 mm in

the month of December.

The average normal annual rainfall in Hardwar district is 1174.3 mm, out of which 84% is

received during monsoon season and only 16% occurs during non-monsoon period. The

district receives heaviest rainfall in northern part. The rainfall gradually decreases towards

south.

5.8 SOCIAL INFRASTRUCTURE:

The Project site comes under the Integrated Industrial Estate, “SIDCUL” Haridwar

District. Project area has education, drinking water facilities, transport facilities, School etc.

6.0 PLANNING BRIEF:

6.1 Planning Concept (Type of Industries, Facilities and Transportation etc.) Town

and Country Planning/ Development Authority Classification:

The Existing Plant is located at Plot No. – 1, Sector No. – 2, IIE, SIDCUL, Ranipur,

Haridwar, Uttarakhand. The area is situated in the survey of India Topo Sheet No. 53 K

and Coordinates Latitude: 290 57’ 02.20” N, Longitude: 780 03’58.52” E. The nearest

National Highway NH-58 is 3.45 km away from the site. The nearest Railway station

Haridwar is about 8.59 km away from the site.

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6.2 Population Projection:

Total Manpower engaged during operation of the PU insulation unit is 155. Apart

from this, 775 – 800 persons are indirectly benefited by this project during the

operation phase.

Employment Status:

Sl. No. Category No. of Employees

Proposed

01. Plant Head --

02. Production Manager 02

03. Supervisors 07

04. Semiskilled Workers 140

05. Unskilled Workers 06

Total 155

6.3 Land Use:

The Project is over an area of 20265.00 Sq. m there is no forest land was involved in the

project site. The entire land is in the name of the plant and situated as Plot No. – 1, Sector

No. – 2, IIE, SIDCUL, Ranipur, Haridwar, Uttarakhand.

Green Belt Development

Local native species suitable for this region are planted in compliance of conditions of

environmental clearance. With a view to attenuate air pollutants, to resist noise propagation

from power generation units and uptake of treated effluent to some extent, the green belt all

around the periphery of project sites and in vacant areas (33% of the total acquired land) is

being developed. Tree plantation has been undertaken in a large scale on land vacated after

cessation of construction activities. Open spaces, where tree plantation is not possible are

planted with flowering herbs and grass which act as soil binders and also helpful in

preventing erosion of topsoil. Existing green belt is being strengthened regularly.

6.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL):

The social infrastructure likes Malls, Hotels and Primary Health Centre are developed in

this area. However, the following facilities are installed within the plant site;

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a. Electricity supply

b. Water supply

c. Administrative Building, Service Building

d. Construction offices and stores

e. Time and security offices

f. First Aid and firefighting station

g. Canteen

h. Toilets and change rooms

i. Car parks and cycle/ scooter stands

6.4.1 System Design for High Productivity:

The productivity of the Unit and associated auxiliary objectives are achieved by adopting

the following principles;

Use of equipment and systems of design, performance and high availability which has been

fully established by a considerable record of successful operation for similar service

conditions in all plant facilities. Use of only proven design concepts and conservative

designs. Strict implementation of quality assurance norms during design, manufacture as

well as installation and commissioning stage. Strict compliance with the project company

approved pre-commissioning and commissioning procedures as well as standard checklists

forming a part of commissioning documents for the project.

6.4.2 Sizing of Critical Equipment- Margins & Redundancy/Standby:

Adequate margins are provided while sizing all important auxiliaries and sub-systems to

ensure operation of the Unit at ultimate capacity under the worst conditions and taking into

consideration normal wear & tear.

6.4.3 Design for Efficient Operation:

Centralized maintenance system is followed. All repairs of capital nature, heavy

maintenance jobs, and plant civil maintenance are done by engaging specialized external

agencies.

Implementation of computer systems including local area network (LAN) with standard

user friendly software’s in the field of financial management, personnel management,

materials management, order scheduling, sales and marketing management, management

information systems (MIS), production planning and control, maintenance and spares

planning, etc. has been considered to increase work efficiency and to reduce manpower

requirement.

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6.4.4 Operation Performance Management System (OPMS):

The operation of the plant will be optimized by implementation of OPMS. This system will

clearly define the responsibilities of all key O & M personnel including the shift-in-charge.

This will also cover the system of daily reporting to the project company Corporate Office

and monthly O&M review meetings.

6.4.5 Operation & Maintenance Philosophy:

Most of the key positions in operation and maintenance of the proposed plant at different

categories are manned by the qualified persons having experience in the similar field.

However, depending on the type of equipment /facilities along with the degree of

automation contemplated, the operation and maintenance personnel of the plant so

recruited will require specific need based training which is carried out on site by the

respective equipment supplier during equipment erection, start up and commissioning of

different plant units.

6.5 AMENITIES/FACILITIES:

6.5.1 In-Plant Facilities:

The following facilities are provided in the existing plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and firefighting station

e. Canteen

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training Centre

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in relevant factories act. The above facilities shall also be

adequately furnished and equipped.

6.5.2 Employment Generation:

Total Manpower engaged during operation of the PU Insulation Unit is 155.

Establishment of small and medium scale engineering ancillaries, with cascading

employment opportunities;

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Increased revenue to the state by way of taxes and duties;

Improved green cover;

Better communication and transport facilities;

The project has enhanced the prospects of employment. Recruitment for the unskilled

workers for the plant is from the nearby villages. The basic amenities viz. roads,

transportation, electricity, drinking water, proper sanitation, educational institutions,

medical facilities, entertainment, etc. are developed as far as possible.

6.5.3 Peripheral Developmental Activities:

M/s Cello Industries has undertaken various activities already made around the plant as a

mark of their Corporate Social Responsibilities viz. Education, Water Supply, including

Drinking Water, Health Care, Environment, Social Empowerment and Sports and

Culture.

7.0 PROPOSED INFRASTRUCTURE:

Not Applicable

8.0 REHABILITATION & RESETTLEMENT (R & R) PLAN:

Not Applicable

9.0 PROJECT COST ESTIMATES:

Initiated Project cost was estimated as under:

Table – 07: Cost of Project

Details Rs. in Lakh

Land : 0.00

Plant & Machinery : 80.00

Electrical installation 10.00

Furniture & Fixtures 2.00

Moulds & Dies 8.00

Others : 0.00

Total : 100.00

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Means of Finance:

Details Rs. in Lakh

Internal Accrual (Self) : 100.00

Total : 100.00

10.0 ANALYSIS OF PROPOSAL:

Project will create direct & indirect employment opportunities within the surrounding

region. Unit will use good faith efforts to employ local people from the nearby villages

depending upon the availability of skilled & un-skilled man-power surrounding the project

site.

In operation phase, the proposed project would require significant workforce of non-

technical and technical persons. Migration of highly education and skilled experience will

result in increase of literacy in the surrounding villages. In addition, the proposed project

shall enhance the prospects of employment.

Additional government revenue expected from royalty, taxes, duties and other fees. An

added benefit to the proposed project will result in considerable growth of stimulating the

industrial and commercial activities in the state.

11.0 STORM WATER/SEWER DETAILS:

The Factory Land is small with Plot area of just 20265.00 Sq. m. The open land

surrounding the building is paved with concrete, except for green belt & garden.

Being a small land, there is no storm water drain, as the rain water flows out into the

SIDCUL drain.

11.1 Sewer Drainage System:

The Company has provided the adequate sewerage facilities. Domestic effluent is being

treated in CETP, operated in SIDCUL.

11.2 Rain Water Harvesting:

Rainwater harvesting in the present scenario holds vast potential in controlling runoff and

resulting water logging problems besides assuring an alternative source of water and a

supplement to existing natural resources in a wide variety of circumstances.

A rainwater harvesting system comprises components of various stages namely-

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Transporting rainwater through pipes or drains.

Filtration

Storage in tanks for reuse or recharge.

\

Fig – 11: Design of Typical Recharge Pit

Two major systems that are ideal for industrial developed areas of are artificial ground

water recharge, and roof top rainwater harvesting (The mode NBC-2005). The mode of

harvesting are basically site specific and depends the amount of precipitation, availability of

total number of rainy days, nature of storage structures, nature of aquifers etc.

In general CGWB norm suggest not to artificially recharging if water table is less than 05 M.

Also recharging is not recommended for aquifers with TDS levels higher than 4000 mg/L or

high levels of chemical composition like Nitrate, Fluoride, and Arsenic etc.

In this project it has been planned to provide 02 Nos. rainwater harvesting recharge pit

(Trench) and 02 No. rain water harvesting tank. Rainwater collected from the rooftop

would be diverted by drain pipes to a settlement / filtration tank, from which it would flow

into the recharge pit. Water filters would be provided prior to the chamber to arrest and

separate any suspended matter present in the rain water. The recharge pits are designed with

three concentric circular chambers in which the outer chamber is filled with sand, the

middle one with coarse aggregate and the inner most layer with pebbles.

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Fig – 12: Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the unpaved

areas and allowed to get absorbed. Also there would be proper storm water drainage

network to collect the excess storm water runoff.

Rain Water Harvesting (RWH) System Calculation

Based on the area statement, the total roof/surface area receiving the rainfall is as follows:

Total Plot Area: 20265.00 m2

Ground coverage area of the unit receiving: 8752.22 m2

Paved area of the Unit 2289.78 m2

As per data available, the annual rainfall in Dehradun: 1174.30 mm

Total rainy days in a year: 80 days

Average rainfall per day: 1174.30/80 = 14.67 mm/day

The intensity of rainfall considered is 14.67 mm/hr, (Heavy rain fall) which generally occurs

in one hour (for the purpose of calculations, the higher value of rainfall intensity is being

considered in view of unpredictable nature of rainfall for arriving at total storage volume)

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Therefore, intensity of rainfall: 14.67 mm/hr

RUN-OFF (Discharge)

Q = 10*C*I*A

Where:

Q: run off in cubic meters/hr

C: Co-efficient/Impermeability factor of the surface

I: Intensity of rainfall (14.67 mm/hr)

A: Total drainage area in hectare

Co-efficient of Run off/Impermeability Factor [C]

S. No. Description of Surface Value of run off coefficient

factor of the surface (C)

1. Terraces, Hard paved surfaces 0.9-0.95

2. Paved Surfaces, roads 0.85-0.90

3. Gravel path, loosely paved walk, rocky surface 0.70-0.85

4. Brick paved, Compact ground 0.50-0.70

5. General Ground 0.50-0.60

6. Natural Ground, sloping ground 0.20-0.50

Run Off Calculation:

(i) Run off from ground coverage area of the unit

Q1 = 10*0.8*14.67*8752.22/10000 (since 1 hectare = 10000 m2)

= 102.71 m3/hr

Q2 = 10*0.9*14.67*2289.78/10000 (since 1 hectare = 10000 m2)

= 30.23 m3/hr

Total run off discharge (Q): = 132.94 m3/hr

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Considering the first flush of rainwater after a dry period shall be allowed to run to waste as

it will be contaminated with dust, bird droppings etc.

Total run off = 0.9 * 132.94 = 119.65 m3/hr

Considering retention storage of rain water harvesting is 30 min

Total capacity of RWH storage: 119.65 *30/60 = 59.82 m3

The total no. of RWH proposed: 2

Capacity of each RWH: 29.91 m3 (approx. 30 kl)

12.0 WASTE WATER MANAGEMENT:

The manufacturing Process doesn’t generate any effluent. Bleed water from CT will be

reused into green belt. Waste water generated (6.10 KLD) from Domestic Purpose &

Miscellaneous i.e. Equipment/floor washings etc. will be treated in the CETP. Company

has already made a contract between SK UEM Water Projects Pvt. Ltd.

13.0 AIR / NOISE POLLUTION CONTROL MEASURE:

As Green insulated DG Set will be installed, although an acoustic enclosure will be

provided on the DG Set.

All noise producing equipment are enclosed in Acoustic hoods.

Ambient air quality and stack emissions will be regularly monitored to ensure ambient air

quality standards.

Dense Green belt is available and being strengthening around the boundary to reduce the

noise escape in surrounding area.

14.0 SOLID WASTE MANAGEMENT:

Little quantity of solid waste (Approx. 10.0 Kg/day) will be generated during material

sampling, dispensing, handling, production, processing and packing & eventually reuse into

process.

Approx. 5.0 kg / day solid waste will be generated from the proposed production process

such as cutting waste of Puff shall be sold to authorized recyclers for safe disposal.

Approx. 30.0 Kg/day solid waste will be generated as scrap of Empty sacs, Boxes, Plastic

Utensils, and Cans, which will be sold to the respective Dealers.

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15.0 HAZARDOUS WASTE MANAGEMENT:

Empty Barrels approx. 1500 Nos. / Annum will be generated and shall be manage as per

Hazardous & Other Waste (Management, Handling & Transboundary movement) Rule,

2016. Waste / Used Oil from Proposed DG Set will be sold to the authorized recyclers only.

16.0 SAFETY MEASURES:

Company will provided full proof fire hydrant system & all kinds of fire extinguishers to

ensure the safe working environment. The workers shall be provided with face-mask, hand

gloves, moreover the production halls shall be fitted with exhaust fans etc.

On site emergency management plan has been made. MSDS instruction shall be followed

while dealing with the raw materials. All Safety measures will be taken to ensure that there

would be no wastage of any manufactured or By - product. Due care & precautions would

be taken at every stage to ensure that no material will go down to the drain.

The Organization will establish, implement & maintain documented Occupational health &

safety objectives, at relevant functions & levels within the organization and training /

awareness program will be conducted on regular basis.