1 scoping s. item details -...

NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING

LAB PLANT AT NIRMA LTD., ALINDRA FORM - 1

1

1 SCOPING

The scoping for the project has been done based on FORM 1, as per EIA Notification, dated September 14, 2006 amended as on date. The scoping details are as follows:

I. Basic Information

S. No.

Item Details

1 Name of the Project EC Amendment for alternate fuel (from FO/NG to FO/NG/Coal) by installing coal

based Thermic fluid Heaters in existing LAB plant

2 S. No. in the Schedule Project or Activity: 5(e): Petrochemical based processing (processes other than

cracking & reformation and not covered under the complexes)

3

Proposed capacity / area / length / tonnage to be

handled/ command area / lease area / no. of wells to

be drilled

There is no change in Production capacity. Existing production capacity is as under:

Sr. No. Product Name Quantity (MT / Month)

1. Liner Alkyl Benzene (LAB) 10,417

2. Detergent Cake 12,500

3. Detergent Powder 12,500

4. Heavy Alkylate (By product) 250

Alternate fuel mix as under:

Sr. No. Fuel Consumption

Existing Proposed Total

1.

Natural Gas

& / or

10.86 KMN3/Hr.

-- 10.86 KMN3/Hr.

Furnace Oil/LSHS

& / or

9.26 MT/Hr. -- 9.26 MT/Hr.

Coal -- 15 MT/hr. 15 MT/hr.

LDO 9.17 MT/Hr. -- 9.17 MT/Hr.

2. HSD 0.15 MT/Hr. -- 0.15 MT/Hr.

3. Naphtha 0.2 MT/Hr. -- 0.2 MT/Hr.

4 New / Expansion /

Modernization

Consumption Proposed Fuel (Coal):

Sr. No.

Unit Capacity

(mnkcal/hr) Fuel Consumption

Indonesian Coal (kg/hr)

1. TFH - 1 12 2,672

2. TFH - 2 12 2,672

3. TFH – 3

(As Stand By) 12 2,672

4. TFH - 4 12 2,672

5. TFH - 5 12 2,672

6. TFH - 6 12 2,672

7. TFH – 7

(As Stand By) 12 2672

TFH: Thermic Fluid Heater

Notes:

a) There is no increase in production quantities.

b) Water Consumption & wastewater generation shall not exceed consented



2

S. No.

Item Details

quantity.

c) Only addition of Coal as a Fuel is requested.

d) Seven (7) new Coal Based Thermic Fluid Heaters are proposed to be provided. Out of these, Two (2) would be as a Stand By

e) When the proposed Coal Fired Thermic Fluid Heaters will be in operation, existing FO / NG based Hot Oil Heaters will be in stand-by mode and when existing FO/NG based Hot Oil Heaters will be in operation, proposed Coal based Thermic Fluid Heaters will be in stand-by mode. So, in no case existing FO/NG based Hot Oil Heaters and proposed Coal Fired Thermic Fluid Heaters will be in operation in parallel.

f) GCV of Indonesian coal is 5,307 kcal/kg.

5 Existing Capacity / Area

etc. Mentioned in Table vide Sr. No. 3

6 Category of Project (A or

B) A

7 Does it attract the general conditions? If yes, please

specify. No

8 Does it attract specific

condition? If yes, please specify

No

9

Location Village Alindra

Plot Survey / Khasra No. 167-173,181,183, 185-195, Block no. 3/P, 3/A of Chandranagar, Block no. 90, 132/2,

135/2 of Khokhar

Village Alindra

Tehsil / Taluka / Mandal Savli

District Vadodara

State Gujarat

10 Nearest railway station /

airport / along with distance in km.

Nearest Railway Station

Vadodara: ~24 km towards SW (~Road distance)

~17.8 km towards SW (Aerial distance)

Samlaya: ~18 km towards ENE (~Road distance)

~7.21 km towards ENE (Aerial distance)

Nearest Airport:

Vadodara: ~ 20.7 km towards SSW (~Road distance)

~ 14.61 km towards SSW (Aerial distance)



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S. No.

Item Details

11 Nearest town, city, district headquarters along with

distances in kms

Nearest Town/City

Savli: ~16.1 km towards NNW (~Road distance)

~11.19 km towards NNW (Aerial distance)

District Headquarters

Vadodara: ~24.6 km towards SSW (~Road distance)

~18.12 km towards SSW (Aerial distance)

12

Village Panchayat, Zilla Parishad, Municipal

Corporation, Local Body (complete postal address with telephone nos. to be

given)

Taluka Panchayat

Seva Sadan Savli, Muval Road, Tal: Savli, Dist. Vadodara.

13 Name of the applicant NIRMA LTD.

14 Registered address

NIRMA LTD.

Nirma House, Ashram Road, Nr. Income Tax office,

Ahmedabad - 380009

15

Address for correspondence

Same as Above

Name Mr. Ashish Desai

Designation Project Coordinator

Address

Nirma Ltd.

Nirma House, Ashram Road, Nr. Income Tax office,

Ahmedabad

Pin Code 380009

E-mail [email protected]

Telephone No. Ph: +91-79-27549319+91-79-27546603 / 05

Fax No. -

Mobile No. +91-9825320090

16

Details of alternative sites examined, if any. Location of these sites should be

shown on the Toposheet.

Alternative sites are not identified since the existing facility possesses sufficient Infrastructure for the proposed establishment of New Thermic Fluid Heaters

17 Interlinked Projects No Interlinked Projects

18

Whether separate application of interlinked

project has been submitted?

Not Applicable



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S. No.

Item Details

19 If yes, date of submission Not Applicable

20 If no, reason Not Applicable

21

Whether the proposal involves approval /

clearance under: if yes, details of the same and their status to be given:

The Forest (Conservation) Act, 1980

The Wildlife (Protection) Act, 1972

The C.R.Z Notification, 1991

No

22

Whether there is any Government order / policy, relevant / relating to the

site

No

23 Forest land involved (ha.) Not Applicable

24

Whether there is any litigation pending against

the project and / or land in which the project is

proposed to be set up?

Name of the Court Case No. Order / directions of the Court, if any and its

relevance with the proposed project

No

25 Project Cost (in Lacs) INR 8000 lakhs

II Activity 1. Construction, operation or decommissioning of the project involving actions, which will cause

physical changes in the locality (topography, land use, changes in water bodies, etc.)

S. No. Information/Checklist

Confirmation

Yes/

No

Details thereof (with approximate quantities / rates, wherever possible) with source of information data

1.1

Permanent or temporary change in land use, land

cover or topography including increase in

intensity of land use (with respect to local land use

plan)

No The proposed Coal based Thermic fluid heaters would be constructed in

vacant land available within existing premises of Nirma – LAB plant at Savli

1.2 Clearance of existing land, vegetation and buildings?

No Land clearance is not involved. The land is already available and earmarked

for the proposed activity within existing plant.



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Confirmation

Yes/

No


1.3 Creation of new land uses? No The proposed Coal based Thermic fluid heaters will be constructed on vacant land available in existing LAB plant, hence no new land use will be created.

1.4 Pre-construction

investigations e.g. bore houses, soil testing?

Yes Prior to commencement of construction activities, essential studies such as

soil testing will be conducted to ensure a safe structural design.

1.5 Construction works? Yes Additional construction work will be carried out as per the plant requirements.

1.6 Demolition works? No No demolition work would be undertaken because land is plain and proposed

expansion is to be carried out within the existing factory premises.

1.7

Temporary sites used for construction works or

housing of construction workers?

No

The proposed site has sufficient availability of land for development of construction activities whenever required. Local workers will be hired during construction phase. Hence, no temporary housing facilities will be created for

construction workers.

1.8

Above ground buildings, structures or earthworks

including linear structures, cut and fill or excavations

Yes Above ground buildings includes, structures for Coal fired Thermic fluid

heaters, Coal storage yard etc. cut, fill or excavation activities are part of the project.

1.9 Underground works including mining or

tunnelling? No Not Applicable

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore Structures No Not Applicable

1.13 Production and

manufacturing processes? Yes

Proposed Coal based Thermic Fluid heaters (07 nos. including 02 no. on standby) would be installed. Please refer Annexure 7, Pg. 23 for process

description of Thermic Fluid Heaters – FO / NG (existing) & Coad fired (Proposed)

1.14 Facilities for storage of

goods or materials? Yes

Additional storage facility in the form of New Coal Storage yard is proposed. Covered coal storage area would be ~3,500 m2 (13,000 MT)

1.15 Facilities for treatment or disposal of solid waste or

liquid effluents? Yes

Solid waste:

Fly ash & Bottom Ash would be generated due to combustion of coal in proposed Thermic Fluid heaters (as and when these are in operation). The

expected quantities of these generated would be:

Fly Ash = 16 MT/Day

Bottom Ash = 72 MT/Day

Scrubber Solid=4 MT/Day

Storage method: The ash (bottom & fly) would be stored in Silos.

Disposal method: These would be utilised in Brick and Cement manufacturing as well as for Road construction. Scrubber Solid is used as a filler material in detergent plant.



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Confirmation

Yes/

No


Liquid effluents:

3 KL/day would be generated in the form of Scrubber effluent. This would be treated in existing ETP location within the LAB plant premises. Please refer

Annexure 4, Pg. 18 for details of existing ETP

1.16 Facilities for long term housing of operational

workers? No

Most of the workers are locally employed who reside in nearby villages / town. A colony for labourers is also constructed beside Nirma-LAB plant premises on

land belonging to Nirma Ltd.

1.17 New road, rail or sea traffic

during construction or operation?

Yes Some traffic is likely to be generated due to additional road trips during

construction and operation but the same will not be significant.

1.18

New road, rail, air waterborne or other

transport infrastructure including new or altered

routes and stations, ports, airports etc?

No As the site is well connected with access road and state highways, no

additional transportation infrastructure will be required.

1.19

Closure or diversion of existing transport routes or

infrastructure leading to changes in traffic

movements?

No As there is no major increase in traffic due to construction and then operation

activity, closure or existing routes in traffic movement is not foreseen.

1.20 New or diverted

transmission lines or pipelines?

No No transmission lines / pipelines pass inside the plant premises

1.21

Impoundment, damming, culverting, realignment or

other changes to the hydrology of watercourses

or aquifers?

No These activities will not be carried out.

1.22 Stream crossings? No There is no stream crossing through the project site.

1.23 Abstraction or transfers of

water from ground or surface waters?

No

Surface water:

There is no incremental consumption above the consented quantities. The total water consumption quantity as per GPCB Consent is 1706.5 KLD.

Nirma Ltd. has permission from State Government to draw water from River Mahi, through the intake facility near village Bhadarwa and as per agreement, Nirma Ltd. is allowed to draw 0.5 MGD (2250 KLD) of water from Mahi river.

Letter is attached as Annexure 9.

Ground Water:

No abstraction or transfer of water from ground due to proposed activity is envisaged.

1.24 Changes in water bodies or the land surface affecting

drainage or run-off? No

There would be no changes in Water bodies or land surface in the facility. The Run-off water will continue to flow in the existing pattern after the proposed

project is commissioned.



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Confirmation

Yes/

No


1.25

Transport of personnel or materials for construction,

operation or decommissioning?

Yes During the construction and implementation of the project period, transport of

materials and personnel would take place through existing roads.

1.26 Long-term dismantling or

decommissioning or restoration works?

No Not Applicable

1.27

Ongoing activity during decommissioning which could have an impact on

the environment?

No No decommissioning work is envisaged, hence no impact on the environment.

1.28 Influx of people to an area

either temporarily or permanently?

No There would be movement of labourers during construction phase but will not

cause any permanent influx of people.

1.29 Introduction of alien

species? No Not Applicable

1.30 Loss of native species or

genetic diversity? No Not Applicable

1.31 Any other actions? No Not Applicable

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials

or energy, especially any resources which are non-renewable or in short supply):

S. No.

Information/Checklist confirmation

Yes / No


2.1 Land especially

undeveloped or agricultural land (ha)

No Not required since the proposed Coal based Thermic Fluid heaters would be established on land within the existing premises of Nirma – LAB plant.

2.2 Water (expected source & competing users) unit: KLD

Yes

Source: Existing intake facility from River Mahi. There is no incremental consumption above the consented quantities. The total

water consumption quantity as per GPCB Consent is 1706.5 KLD. Additional fresh water requirement in scrubber will be 4 KLD. Water requirement in KLD is as per

table below:

Existing (KLD) Proposed (KLD)

Total (KLD)

1702.5 4 1706.5

Note:

Sprinkling water on coal stockpile will be source from the existing ETP treated water. Nirma Ltd. has permission from State Government to draw water from River

Mahi, through the intake facility near village Bhadarwa and as per agreement, Nirma Ltd. is allowed to draw 0.5 MGD (2250 KLD) of water from Mahi river.

2.3 Minerals (MT) No Imported Coal would be used in the proposed Coal Based Thermic Fluid Heaters.

2.4 Construction material

stone, aggregates, sand / soil (expected source, MT)

Yes Construction materials like stones, aggregates, sand, brick, steel, cement, rubble, etc. would be procured from the local market of the region, which are available

locally.

2.5 Forests and timber (source, No Not Applicable



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S. No.

Information/Checklist confirmation

Yes / No


MT)

2.6

Energy including electricity and fuels (source,

competing users) unit: fuel (MT), energy (MW)

Yes

Electricity Source: MGVCL

Existing consumption = 170000 KWH/Day Proposed Consumption = 120000 KWH/Day

2.7

Any other natural resources (use appropriate standard

units)

None No other natural resources would be used

3. Use, storage, transport, handling or production of substances or materials, which could be harmful

to human health or the environment or raise concerns about actual or perceived risks to human health.

S. No. Information / Checklist confirmation Yes /

No Details thereof (with approximate quantities / rates, wherever possible) with source of information data

3.1

Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna,

and water supplies)

Yes

As per MSICHR, Sodium Hydroxide (NaOH) is the only hazardous chemical used in proposed project as scrubbing

media.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne

diseases)

No

Suitable OH & EMS, proper drainage and waste management measures will be adopted in construction and operation phase,

which will restrict the growth and reproduction of disease vectors.

3.3 Affect the welfare of people e.g. by

changing living conditions? No -

3.4 Vulnerable groups of people who could be

affected by the project e.g. hospital patients, children, the elderly etc.,

No No Vulnerable groups reported in the study area

3.5 Any other causes No Not envisaged

4. Production of solid wastes during construction or operation or decommissioning (MT/month)


confirmation Yes/ No


4.1 Soil, overburden or mine wastes No Not Applicable

4.2 Municipal waste (domestic and or

commercial wastes) Yes

Municipal waste:

Waste paper from administration building, waste metals, kitchen waste etc.

Disposal method:

Waste paper and metal will be given to recyclers and kitchen waste will be converted into manure.

4.3 Hazardous wastes (as per

Hazardous Waste Management Rules)

Yes Hazardous wastes generated from existing & proposed operations are as

per Annexure 10,Pg. 31

4.4 Other industrial process wastes

Yes Fly Ash & Bottom ash will be generated during operation of proposed Coal based thermic fluid heaters, the quantities of which are as Annexure 10,

Pg. 31

4.5 Surplus product No No Surplus product

4.6 Sewage sludge or other sludge

from effluent treatment No

Sewage is treated in existing Sewage treatment plant (STP) at the site. The sewage from toilet blocks of proposed coal based thermic fluid

heater plant would be conveyed to this STP for treatment



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4.7 Construction or demolition wastes Yes

Minimal quantity of debris, scrap, excavated soil, used cement bags, iron / steel scrap and cardboard waste could be generated during

construction.

Demolition activity is not applicable.

4.8 Redundant machinery or

equipment No

None

4.9 Contaminated soils or other

materials No

Not Applicable

4.10 Agricultural wastes No Not Applicable

4.11 Other solid wastes No Fly ash and Bottom Ash would be generated as per details in Sr. No. 4.4

above.

5. Release of pollutants or any hazardous, toxic or noxious substances to air(kg/hr)




5.1

Emissions from combustion of fossil fuels from stationary or

mobile sources

Yes Due to combustion of Coal in proposed Coal based Thermic Fluid heaters

(as and when these are operational)

5.2 Emissions from production

processes

No Emissions from Existing and Proposed sources are vide Annexure 5, Pg. 20. Emission Estimate and Pollution Load table is given in Annexure 6.

5.3 Emissions from materials handling

including storage or transport

Yes Minor emissions from Truck movement & coal handling.

5.4 Emissions from construction activities including plant and

equipment

Yes Emission from diesel operated concrete mixers and excavators. However these equipment will be maintained properly to ensure minimum

emissions and vehicles with PUC certificate will be used. Dust emission due to earth moving machinery.

5.5

Dust or odours from handling of materials including construction materials, sewage and waste

Yes

Dust:

Coal Handling: Covered coal storage area, closed conveyor belt as well as water sprinkling system will be provided to control dust emission.

Truck Movement: Coal will be transported in truck covered by tarpaulin and water will be sprinkled on truck movement road.

Dust will be generated during handling of construction materials, this will be controlled by sprinkling of water.

Sewage:

Sewage will be disposed STP for further treatment

5.6 Emissions from incineration of

waste

No Not Applicable

5.7 Emissions from burning of waste in

open air (e.g. slash materials, construction debris)

No Not Applicable

5.8 Emissions from any other sources No None envisaged

6. Generation of Noise and Vibration, and Emissions of Light and Heat:


confirmation Yes /


6.1 From operation of equipment e.g. engines, ventilation plant, crushers

Yes

Noise:

Noise will be generated from operation of coal crushers, boilers, TFH, air blowers, plant machineries, etc. Adequate enclosures and

necessary PPE will be provided to exposed employees

6.2 From industrial or similar processes Yes Noise shall be generated from crushers, fans, etc. during operation



10


confirmation Yes /


phase.

6.3 From construction or demolition Yes During construction phase, noise will be generated due to dumpers,

rollers, truck movement etc.

6.4 From blasting or piling No Not Applicable

6.5 From construction or operational

traffic Yes

During construction and operational phase noise will be generated due to trucks and other vehicles.

6.6 From lighting or cooling systems No No emissions of light or cooling system is envisaged.

6.7 From any other sources No Not Applicable

7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers,

surface waters, groundwater, coastal waters or the sea


confirmation

Yes

/ No


7.1 From handling, storage, use or spillage of hazardous materials

No

Proper care for handling of hazardous material will be taken as per the MSIHC rules & HW management Rules. Moreover all of the

hazardous wastes are disposed as per guidance of State Pollution Control Board. Same will be continued after installation of proposed

Coal based Thermic Fluid Heaters.

7.2

From discharge of sewage or other effluents to water or the land (expected mode and place of

discharge)

No Sewage generated from toilet blocks of proposed Coal based

Thermic fluid heater will be conveyed to existing STP for treatment & further disposal.

7.3 By deposition of pollutants emitted to

air into the land or into water No

As pollutants would be released less than the permitted levels as well as Fly ash would be stored in silos & bottom ash will be

collected in pit having HDPE lining.

7.4 From any other sources No None identified.

7.5

Is there a risk of long term build-up of pollutants in the environment from

these sources? No

Adequate mitigation measures, monitoring and periodic maintenance of equipment’s will ensure no risk of long term build-

up of pollutants in the environment.

8. Risk of accidents during construction or operation of the Project, which could affect human health or

the environment


confirmation Yes /


8.1 From explosions, spillages, fires etc.

from storage, handling, use or production of hazardous substances

Yes The associated hazard from the plant is fire in coal storage yard.

8.2 From any other causes Yes

Common risks in factories such as Electric Shock, Hit by Objects, Fall / Slips, Hot Work such as Welding and Cutting & during

maintenance activities.

8.3

Could the project be affected by natural disasters causing

environmental damage e.g. floods, earthquakes, landslides, cloudburst

etc)?

Yes

Site falls under the seismic intensity Zone III, which is classified as Moderate Damage Risk Zone. Thus, suitable seismic coefficients

accordingly shall be adopted while designing the structures to make it earthquake resistant.



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9. Factors which should be considered (such as consequential development) which could lead to

environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality


confirmation Yes /

No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data

9.1

Lead to development of supporting Facilities, ancillary development or

development stimulated by the project which could have impact on the environment e.g.: supporting

infrastructure (roads, power supply, waste or waste water treatment,

etc.) housing development extractive industries supply industries, (other)

Yes

The installation of proposed coal based thermic fluid heater would result in economic plant operations, better / rationalised use of

natural resources

9.2

Lead to after-use of the site, which could have an impact on the

environment No Not Applicable

9.3 Set a precedent for later

developments No

Not Applicable

9.4

Have cumulative effects due to proximity to other existing or planned

projects with similar effects No

Very negligible cumulative effect, as adequate mitigation measures will be provided.

III Environmental Sensitivity

S. No. Areas Name / Identity

Aerial Distance (within 15 km) of the proposed project location boundary

10.1

Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other

related value

None No such areas reported

10.2

Areas which are important or sensitive for ecological reasons - Wetlands, watercourses

or other water bodies, coastal zone, biospheres, mountains, forests


10.3

Areas used by protected, important or sensitive species of flora or fauna for

breeding, nesting, foraging, resting, over wintering, migration


10.4 Inland, coastal, marine or underground waters None No such areas reported

10.5 State, National boundaries None No such areas reported

10.6 Routes or facilities used by the public for

access to recreation or other tourist, pilgrim areas


10.7 Defence installations None No such areas reported

10.8 Densely populated or built-up area None No such areas reported

10.9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship,

community facilities) None

Primary health centres, primary schools, hospitals, worship places etc. are located within

15 km

10.10

Areas containing important, high quality or scarce resources (ground water resources,

surface resources, forestry, agriculture, fisheries, tourism, minerals)


10.11 Areas already subjected to pollution or

environmental damage. (Those where existing legal environmental standards are exceeded)




12

S. No. Areas Name / Identity

Aerial Distance (within 15 km) of the proposed project location boundary

10.12

Areas susceptible to natural hazard which could cause the project to present

environmental problems (earthquakes, subsidence, landslides, erosion, flooding or

extreme or adverse climatic conditions)


NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA FORM - 1

13

Annexure 1: General and Specific Location Map

NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES

14

Annexure 2: Project Boundary Map on Google Earth


15

Co-ordinates of Site Boundary

POINT LATITUDE LONGITUDE

A 22°27'29.47"N 73°14'5.87"E

B 22°27'32.89"N 73°13'57.77"E

C 22°27'34.42"N 73°13'55.93"E

D 22°27'54.39"N 73°13'54.53"E

E 22°27'59.80"N 73°14'29.29"E

F 22°28'5.45"N 73°14'46.11"E

G 22°27'55.02"N 73°14'47.51"E

H 22°27'47.22"N 73°14'47.81"E

I 22°27'36.33"N 73°14'49.00"E

J 22°27'33.67"N 73°14'36.13"E

K 22°27'33.17"N 73°14'17.37"E


16

Annexure 3: Plant Layout map


17

Layout map of Thermic Fluid Heater

NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN

EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES

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Annexure 4: Existing Effluent Treatment Plant (ETP) Details

Brief Description of the Effluent Treatment Plant: - Wastewater coming from the plant including proposed coal fired thermic fluid heater is collected in equalization tank where it is equalized and is transferred to the CPI oil separator tank. This separated oil is collected in oil collection tank and the effluent flows by gravity to the DAF unit. In this DAF unit polyelectrolyte is dosed. The effluent from this unit is taken by gravity to the aeration tank where diffused aeration system is provided. The effluent from aeration tank goes into the secondary clarifier where settling time is given for settling of the sludge. The sludge from the clarifier is taken to the sludge drying bed. The clarified effluent is taken to the polishing sump where DM water regeneration and cooling water blow down is mixed. Here either acid or alkali is dosed. This polished effluent is transferred to guard pond from where this treated effluent is used for gardening and plantation. Details of Effluent Treatment Plant units Name and size of all units:-

Sr. No. Name of unit Size of unit in meters

[(L x B ) / Dia. x SWD x TD]

1. Equalization / Panic Pond 15.1 sq. x 15.1 x 3.65

2. CPI Oil Separator Tank 5.0 x 2.50 x 2.6

3. Oil Collection Tank 0.8 Dia. x 1.4 h

4. DAF Unit 2.0 Dia. x 1.5h

5. Aeration Tank 7.0 sq. x 7.0 x 2.8

6. Secondary Tank 4.0 Dia. x 2.7h

7. Polishing Sump 2.6 sq. x 2.6 x 1.8

8. Guard Pond (2 Nos.) 24.8 x 10.5 x 2.8

9. Sludge Drying Bed (4 Nos.) 4.0 x 2.5 x 1.1

NOTE: L – Length TD – Total Depth Dia. – Diameter B – Breadth SWD – Side Water Depth


19

ETP FLOW DIAGRAM:



20

Annexure 5: Air Emission details (Existing and Proposed)

Air emissions from stationary sources are provided below: Table 1-1 Details of Stacks APCM attached to Flue Gas Stacks

Sr.

No. Stack Attached to

Stack Height

(m)

Stack Diameter

(m)

Exit Velocity (m/sec)

Pollutants Air Pollution

Control measures

Flue Gas Stacks (Existing)

1. Boilers (2 nos.) 75 1.85 6.28

Particulate Matter, SOX, NOX

--

2. Pacol Charge Heater & Hot

Oil Heaters 89 5.23 10 --

3. Hot Oil Heaters 76 2.86 9.2 Ultra Low NOX

burners

4. Union Finning Charge

Heaters 35 1.00 8.50 --

5. Reformer Furnace 32 0.65 5.0 --

6. D.G. Set (stand by) 17 0.50 15.0 --

Flue Gas Stacks (Proposed)

1 Thermic Fluid Heater - 1

63.5 1.8 9

PM, SO2, NOX

ESP with minimum three Fields for PM;

Tower type wet scrubber for SO2 &

NOX


3 Thermic Fluid Heater – 3

(stand-by)


70 2.0 10



7 Thermic Fluid Heater –

7(Stand-by)



21

Annexure 6: Pollution Load Statement

In our proposal, there is no increase in production capacity as well as in pollution load in comparison to existing permissible limits. Our proposal is to use coal as alternate fuel along with

FO/NG. As form of fuel is solid, we need to install the solid base Thermic Fluid Heaters (TFH). Details of Thermic Fluid Heaters are given in Annexure-5 of Form-1.

When these proposed coal fired thermic fluid heaters will be in operation, our existing Hot Oil Heaters which are mentioned in Annexure-5 of form-1 will be in standby mode and when our

existing FO/NG based Hot Oil Heaters will be in operation, our proposed Coal based Thermic Fluid Heaters will be in standby mode. So, in no case existing FO/NG based Hot Oil Heaters and

proposed Coal Fired Thermic Fluid Heaters will be in operation in parallel.

Pollution Load - Actual (as per fuel specifications)

S. NO.

Parameter Unit

Fuel (Either FO/LSHS or NG or Coal will be used)

FO/LSHS NG Coal

1 SO2 kg/day 1919 9.9 752

2 PM kg/day 50.1 1.0 235.5

3 NOx kg/day 1670 1670 330

Total kg/day 3639 1681 1318

Total (As per EC dated 03.08.2007) kg/day 4239.11

Pollution Load - As per GPCB Norms

S. NO.

Parameter Unit

Fuel (Either FO/LSHS or NG or Coal will be used)

FO/LSHS NG Coal

1 SO2 kg/day 4712 4712 932

2 PM kg/day 2700 2700 534

3 NOx kg/day 1694 1694 335

Total kg/day 9105 9105 1800



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Seismic Map of Gujarat

Break up of Seismic Zones: Zone II: Least Active Seismic Zone Zone III: Moderate Seismic Zone Zone IV: High Seismic Zone Zone V: Highest Seismic Zone



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Annexure 7: Precess description of Thermic Fluid Heaters

Coal fired Thermic Fluid Heaters (Proposed)

In order to fulfil the heat requirement of the process, there are two hot oil heaters, two process heaters, one reformer and two boilers. One of the process heater viz. Pacol Charge Heater is

connected to hot oil heater, resulting into a common stack.

It is intended to add Coal Fired Thermic Fluid Heaters (CFTFH) as a substitute for Hot Oil Heaters

(HOH). Coal fired thermic fluid heaters are available in smaller sizes i.e. 10, 11, 12, & 15 mmKcal/Hr capacity and are used in multiples as per the need. HOH (new) shall require three

units of 12 mmKCal /Hr capacity whereas the other HOH shall require four units of 12 mmKCal/Hr capacity. A total of 7 nos. of coal fired heaters would be required. There will be two stacks taking

care of the flue gases generated.

PROCESS:

Coal fired thermic fluid heaters are used to heat the thermic fluid to the desired temperature. This heated thermic fluid is used as heating medium in various exchangers.

Coal fired thermic fluid heaters unit consist of the following:

1. Coal handling:

i. Crushers ii. Conveyer

iii. Bucket elevator

iv. Vibrating screen 2. Furnace

i. Fuel bunkers ii. Firing & combustion chamber

iii. Radiation & convection section iv. Air pre heater

v. Pollution control equipment vi. ID & FD fan

vii. Stack

3. Ash handling i. Dense phase Pneumatic fly ash handling system.

ii. Ash storage silo

1. Coal handling:

Coal is collected and its size is reduced in crushers & particles are sieved in vibrating

screens and from there it is conveyed to fuel bunkers through bucket conveyors.

2. Furnace: It consists of the following loops,

2.1 Combustion air & flue gas.

2.2 Thermic fluid. 2.3 Fuel firing.

2.1 Combustion air & flue gas. Air is drawn from atmosphere through FD fan and it is preheated in APH and fed to

furnace for fuel fluidization and combustion. Flue gas which is coming from furnace convection section exchange the heat with

cold air in APH and passed through pollution control equipment (Electrostatic precipitator or bag house, etc.,). It is transported from pollution control equipment to

stack through ID fan.



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2.2 Thermic fluid Thermic fluid from thermic fluid circulation pump is passed through furnace (tubes)

and it is heated in furnace to desired temperature and sent to plant. From the plant it returns to thermic fluid surge drum and from thermic fluid surge drum it is pumped to

furnace through thermic fluid pumps.

2.3 Fuel firing Coal is conveyed to fuel bunkers from here it is fed to fluidized bed of furnace and

where combustion takes places. Heat delivered by combustion is absorbed by thermic

fluid flowing through tubes. Further, flue gases travels to convection section and heat is transferred to thermic

fluid flowing through tubes in convection section.

3. Ash Handling:

Dense phase ash is collected by pneumatic dense ash collection system from APH, & ESP. From there it is collected in ash silos.

Bed ash is also collected from fluidized bed.



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Figure 1-1: Block Diagram of Pacol Enhancement Process



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Annexure 8: Analysis of Alternative Sites

Alternative sites are not identified since there is sufficient land available in existing facility of Nirma Ltd. – LAB plant. Further, the proposed Coal based heaters are part of the utilities for the existing LAB plant.



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Annexure 9: Water Supply Agreement Letter from Irrigation Department



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Annexure 10: Hazardous Waste & Solid Waste Details

Hazardous waste Details:



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Sr. No Waste# Category Quantities (MT/Year)

Disposal Existing Proposed Total

1. Adsorbent 1.6 79 0 79

Disposal by selling to registered/ Ms. Nandesari Environment Control Ltd.

(NECL)-TSDF

2. Spent Catalyst 1.6 46.53 0 46.53 Disposal by selling to authorised recyclers

3. Used Spent Oil 5.1 6.8 2.5 9.3 Disposal by selling to authorized recyclers

4. Discarded Container

33.3 5 0 5 Decontamination within

factory premises.

5. ETP Sludge I-34.3 17.04 0 17.04

Disposal to Ms. Nandesari Environment Control Ltd.

(NECL)-TSDF

6. Spent Clay 35.1 10 0 10 Disposal to Ms. Nandesari Environment Control Ltd.

(NECL)-TSDF

7. Inorganic Acid II-B15 12,000 0 12,000 Disposal at M/s. Nirma

Limited, Moraiya, Ta: Sanand

#: As per the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016. Solid Waste Details

Waste Name Quantities Generated (MTPD) Disposal

Fly Ash 16 Will be sold to Brick manufacturing unit/ Block manufacturing unit. Bottom Ash 72

Scrubber Sludge 4 used as a filler material in detergent plant

1 scoping s. item details -...

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