Project No: AESPL/IND-E/17-18/EIA/012

Environmental Impact Assessment Report

Proposed Establishment of Synthetic Organic

Chemicals & Intermediates to serve

Agrochemicals, Pharmaceuticals, Polymer, and

Specialty Chemicals

By

Reshmika Minerals and Chemicals Private

Limited

Plot No. 23, GIDC Industrial Estate, Panoli, Tal.

Ankleshwar, Dist. Bharuch, Gujarat- 394116 B

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August - 2018

Environmental Consultant:

Aditya Environmental Services Pvt. Ltd., Mumbai

QCI- NABET Accredited EIA Consultant

www.aespl.co.in

Declaration by Experts contributing to the EIA “Proposed Establishment of Synthetic Organic Chemicals & Intermediates to serve Agrochemicals, Pharmaceuticals, Polymer, and Specialty Chemicals by Reshmika Minerals and Chemicals Private Limited at Plot no 23, GIDC Industrial Estate Panoli, Dist Bharuch, Gujarat”. I, hereby, certify that I was a part of the EIA Team in the following capacity that developed the above EIA. EIA Coordinator: Name: Mr. Rajiv V Aundhe

Signature & Date: 17th August 2018 Period of involvement: since October 2017 Contact information: Mob. 09821513367, E-mail: rajivpers@yahoo.com Functional Area Experts:

S.N. Functional Areas

Name of the Expert/s

Involvement (Period &

Task**)

Signature & Date

1 AP* Rajiv Aundhe (FAA Swapnil Ubale)

Since October 2017

2 WP* Rajiv Aundhe (FAA Swapnil Ubale)

Since October 2017

3 SHW* Rajiv Aundhe Since October 2017

4 SE* Ms. Anju Chawhan March- May 2018

5 EB* Dr. Shobha Kamat March- May 2018

6 HG* -- -- -- 7 GEO* -- -- -- 8 SC* -- -- -- 9 AQ* Sudhir Verma March- May

2018

10 NV* Rajiv Aundhe Since October 2017

11 LU* Ms. Bela Pharate March- May 2018

12 RH* D. K. Joshi March- May 2018

NOTE: (*) Full forms of abbreviations given on Next Page (**) Tasks for each Functional Area Expert given on Next Page

Environmental Baseline monitoring and analysis for this project was carried out by in-house, environmental analytical laboratory, registered by MoEFCC, approved under Environment Protection Act 1986, vide MoEFCC Notification S.O. no. 1190 (E), dated 1st May 2014. The duration of recognition is from 1st May 2014 to 30th April 2019

Declaration by the Head of the Accredited Consultant Organization

I, Rajiv V. Aundhe, hereby, confirm that the above mentioned experts prepared the EIA “Proposed Establishment of Synthetic Organic Chemicals & Intermediates to serve Agrochemicals, Pharmaceuticals, Polymer, and Specialty Chemicals by Reshmika Minerals and Chemicals Private Limited at Plot no 23, GIDC Industrial Estate Panoli, Dist Bharuch, Gujarat’’. I also confirm that Aditya Environmental Service Pvt. Ltd. shall be fully accountable for any mis-leading information mentioned in this statement.

Name: Rajiv V. Aundhe

Designation: Director

Name of the EIA Consultant Organization: Aditya Environmental Service Pvt. Ltd.

NABET Certificate No. & Issue Date: NABET/EIA/16 17/RA 0032 dated 14th Feb 2017

S.N. Functional Area Code

Complete Name of the Functional Areas

Tasks

1 AP Air Pollution Prevention, Monitoring & Control

Assessing baseline ambient air quality, stack emission, possible impacts and control measures

2 WP Water Pollution Prevention, Control & Prediction of Impacts

Assessing baseline surface/ ground water quality, possible impacts and control measures

3 SHW Solid Waste and Hazardous Waste Management

Assessing solid/hazardous waste generation, treatment and disposal

4 SE Socio-Economics Assessing baseline Socioeconomic, demographic situation, impacts and CSR plan/ measures for upliftment

5 EB Ecology and Biodiversity Assessing baseline biodiversity situation in study area, impacts and Biodiversity management plans

6 HG Hydrology, ground Water & Water Conservation

Assessing baseline hydrological situation in study area, impacts and management plans

7 GEO Hydrogeology Assessing baseline hydrogeological situation in study area, impacts and management plans

8 SC Soil Conservation Assessing baseline soil quality, possible impacts & control measures

9 AQ Meteorology, Air Quality Modeling & Prediction

Assessing nature and scale of impacts on ambient air quality through modeling and management plans

10 NV Noise/ Vibration Assessing baseline ambient noise quality, possible sources, impacts and control measures

11 LU Land Use Assessing baseline Land use Land cover possible impacts and control measures

12 RH Risk Assessment & Hazard Management

Assessing safety measures taken up by company modeling to assess scale of impacts, disaster management and control measures

ADITYA ENVIRONMENTALSERVICES PVT. LTD. Recognized by MOEF as “Environmental Laboratory” vide S.O.No. 983 valid up to 30.04.2019

ISO 9001:2008, OHSAS 18001:2007 Certified

Accredited by QCI-NABET as ‘A’ Category EIA Consultancy Organization

Reg. Office: 107, Hiren Light Indl. Estate, Mogul Lane, Mahim, Mumbai -400016Tel: 022 42127500 E-mail: adityaenviro@vsnl.com

Central Lab : P-1, MIDC Mohopada, P.O. Rasayani, Dist. Raigad Pin 410207 Tel : 02192 252008 E-mail : aespvtltd@yahoo.com

Branches : Goa 08322652456 Ahmedabad : 079 40063271 Pune : 915802585 Delhi : 01164595949 Baroda : 02652331790

CIN: U74999MH2001PTC132091

TO WHOMSOEVER IT MAY CONCERN

This is to confirm that the EIA/ EMP for the project “Proposed Establishment of

Synthetic organic chemicals and intermediates to serve agrochemicals,

pharmaceuticals, polymer, and specialty chemicals” to be located at Plot No. 23,

Panoli GIDC, Tal. Ankleshwar, Dist. Bharuch, Gujarat by Reshmika Minerals and

Chemicals Private Limited has been prepared by me in the capacity of EIA coordinator.

The Standard ToR’s prescribed by MoEF & CC vide Notification dated 10th April 2015 and

additional ToR’s prescribed by EAC -II committee vide letter no. IA-J-11011/535/2017-

IA-II(I) dated 22nd March 2018 have been fully complied with in preparing the EIA/ EMP.

A point wise compliance to the ToR’s prescribed as above has been presented in Chapter

1 of this report.

We also confirm that the EIA prepared is based on factual data and all due diligence has

been followed in preparing the same.

For Aditya Environmental Services Pvt. Ltd.

Rajiv Aundhe EIA coordinator Date: 17th August 2018 Place: Mumbai

Table of Contents

INTRODUCTION ....................................................................................................................................................... 20

Purpose of Environmental Impact Assessment (EIA) Report ...................................................................... 20 Identification of project & project proponent ...................................................................................................... 20

1.2.1 Project Proponent & Background of Promoters ......................................................................................... 21 Brief Description of Nature, Size, Location of the Project & Its Importance in the Country, Region

21 1.3.1 Nature & Size of Project ........................................................................................................................................ 21 1.3.2 Project Location ....................................................................................................................................................... 22 1.3.3 Importance of the Project to the Country, Region ...................................................................................... 23 1.3.4 Export Possibilities .................................................................................................................................................. 24 1.3.5 Import vs Indigenous production ...................................................................................................................... 24 1.3.6 Demand supply gap ................................................................................................................................................ 24 1.3.7 Employment generation (direct/indirect) due to project: ...................................................................... 24 Regulatory framework of the proposed expansion ........................................................................................... 24

1.4.1 General clearances and other related permissions .................................................................................... 24 1.4.2 Applicability of EIA Notification 2006 ............................................................................................................ 25 1.4.3 Regulatory framework .......................................................................................................................................... 26 1.4.4 Scope ............................................................................................................................................................................. 26 1.4.5 Process of EIA study ................................................................................................................................................ 26 1.4.6 Methodology adopted for EIA study ................................................................................................................. 27 1.4.7 Structure of EIA Report ......................................................................................................................................... 29 1.4.8 Scope of the EIA Study ........................................................................................................................................... 31 1.4.9 Regulatory Scoping & Its Compliance ............................................................................................................. 32

PROJECT DESCRIPTION ........................................................................................................................................ 40

Type of Project ................................................................................................................................................................... 40 Location of the Project ................................................................................................................................................... 41 Size/ Magnitude of Operation ..................................................................................................................................... 41 Proposed Schedule for Approval & Implementation ........................................................................................ 44 Technology & Process Description, Environmental & Safety Aspects ...................................................... 44

2.5.1 Diethyl Ketone (DEK) ............................................................................................................................................. 44 Process Chemistry – Diethyl Ketone ..................................................................................................................................44 Process block diagram – Diethyl Ketone (DEK) ...........................................................................................................44 Plant Process description – Diethyl Ketone(DEK) ......................................................................................................45 Material balance – Diethyl Ketone (DEK) ........................................................................................................................45

2.5.2 Propiophenone ......................................................................................................................................................... 45 Process Chemistry – Propiophenone ................................................................................................................................45

Process block diagram – Propiophenone ..............................................................................................................................................46 Plant Process description – Propiophenone ..................................................................................................................46 Material balance – Propiophenone.....................................................................................................................................46

2.5.3 4-Nitro-o-Xylene and 3 Nitro O xylene ............................................................................................................ 47 Process Chemistry – 4 Nitro O Xylene & 3 Nitro O Xylene ......................................................................................47 Process block diagram – 4 Nitro O Xylene & 3 Nitro O Xylene .............................................................................47 Plant Process description – 4 Nitro O Xylene & 3 Nitro O Xylene .......................................................................48 Material balance – 4 Nitro O Xylene & 3 Nitro O Xylene ..........................................................................................49

2.5.4 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene .......................................................... 49 Process Chemistry – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene ............................49 Process block diagram – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene ...................50 Plant Process description – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene ............50 Material balance – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene ...............................51

2.5.5 3,4-Xylidine (3,4 –Dimethyl Aniline) ................................................................................................................ 51 Process Chemistry –3,4-Xylidine (3,4 –Dimethyl Aniline) ......................................................................................52 Process block diagram –3,4-Xylidine (3,4 –Dimethyl Aniline) .............................................................................52 Material balance – 3,4-Xylidine (3,4 –Dimethyl Aniline) .........................................................................................52

2.5.6 2,6-Xylidine (2,6 –Dimethyl Aniline) ................................................................................................................ 53 Process Chemistry –2,6-Xylidine (2,6 –Dimethyl Aniline) ......................................................................................53 Process block diagram –2,6-Xylidine (2,6 –Dimethyl Aniline) .............................................................................54

Material balance – 2,6-Xylidine (2,6 –Dimethyl Aniline) .........................................................................................54 2.5.7 2,4-Xylidine (2,4 – Dimethyl Aniline) ............................................................................................................... 55

Process Chemistry –2,4-Xylidine (2,4 – Dimethyl Aniline) .....................................................................................55 Process block diagram –2,4-Xylidine (2,4 – Dimethyl Aniline) ............................................................................55 Plant Process description – General ..................................................................................................................................55 Material balance – 2,4-Xylidine (2,4 – Dimethyl Aniline) ........................................................................................56

2.5.8 N-(1-Ethylpropyl)-3,4-Xylidine .......................................................................................................................... 57 Process Chemistry –N-(1-Ethylpropyl)-3,4-Xylidine ................................................................................................57 Process block diagram –N-(1-Ethylpropyl)-3,4-Xylidine ........................................................................................57

....................................................................................................................................................................................................................................57 Plant Process description – N-(1-Ethylpropyl)-3,4-Xylidine .................................................................................57 Material balance –N-(1-Ethylpropyl)-3,4-Xylidine .....................................................................................................58

2.5.9 2-Cynophenol ............................................................................................................................................................ 58 Process Chemistry – 2-Cynophenol ...................................................................................................................................59 Process block diagram – 2-Cynophenol ...........................................................................................................................59 Plant Process description – 2-Cynophenol .....................................................................................................................59 Material balance – 2-Cynophenol ........................................................................................................................................61

2.5.10 1-Octanoic acid......................................................................................................................................................... 61 Process Chemistry – 1-Octanoic acid ...........................................................................................................................61 Process block diagram – 1-Octanoic acid ..................................................................................................................62 Plant Process description – 1-Octanoic acid ............................................................................................................62 Material balance – 1-Octanoic acid ...............................................................................................................................63

2.5.11 Styrene oxide ............................................................................................................................................................. 63 Process Chemistry – Styrene oxide ...............................................................................................................................63 Process block diagram – Styrene oxide ......................................................................................................................64 Plant Process description – Styrene oxide ................................................................................................................64 Material balance – Styrene oxide ...................................................................................................................................65

2.5.12 Phenyl ethyl alcohol ............................................................................................................................................... 65 Process Chemistry – Phenyl ethyl alcohol .................................................................................................................65 Process block diagram – Phenyl ethyl alcohol ........................................................................................................66 Plant Process description – Phenyl ethyl alcohol ..................................................................................................66 Material balance – Phenyl ethyl alcohol .....................................................................................................................67

2.5.13 Phenyl ethyl alcohol methyl ether..................................................................................................................... 68 Process Chemistry – Phenyl ethyl alcohol methyl ether ....................................................................................68 Process block diagram – Phenyl ethyl alcohol methyl ether ............................................................................68 Plant Process description – Phenyl ethyl alcohol methyl ether ......................................................................69 Material balance – Phenyl ethyl alcohol methyl ether ........................................................................................70

2.5.14 Phenyl acetaldehyde............................................................................................................................................... 70 Process Chemistry – Phenyl acetaldehyde ................................................................................................................71 Process block diagram – Phenyl acetaldehyde .......................................................................................................71 Plant Process description – Phenyl acetaldehyde .................................................................................................71 Material balance – Phenyl acetaldehyde ....................................................................................................................72

2.5.15 Phenyl acetaldehyde di-methylacetal ............................................................................................................. 72 Process Chemistry – Phenyl acetaldehyde di-methylacetal .............................................................................72 Process block diagram – Phenyl acetaldehyde di-methylacetal .....................................................................73 Plant Process description – Phenyl acetaldehyde di-methylacetal ...............................................................73 Material balance – Phenyl acetaldehyde di-methyl acetal ................................................................................74

2.5.16 Phenyl ethyl acetate ............................................................................................................................................... 75 Process Chemistry – Phenyl ethyl acetate .................................................................................................................75 Plant Process description – Phenyl ethyl acetate ..................................................................................................75 Material balance – Phenyl ethyl acetate .....................................................................................................................76

2.5.17 Raw material consumption and sourcing and mode of transport ....................................................... 76 Pollution generation aspects ...........................................................................................................................................77

2.5.18 Proposed Onsite Bulk Storage ............................................................................................................................ 81 Utilities .................................................................................................................................................................................. 81

2.6.1 Energy Requirements ............................................................................................................................................. 81 Electricity ........................................................................................................................................................................................81 Steam and other Energy ..........................................................................................................................................................81 Existing Water requirement and waste water generation .....................................................................................82 Proposed additional water requirement and waste water generation ............................................................83 Total water requirement and waste water generation ............................................................................................83

Manpower requirement ................................................................................................................................................ 84 Environmental Aspects .................................................................................................................................................. 84

2.8.1 Effluent Generation, Treatment and Disposal.............................................................................................. 84

2.8.2 Solid Waste & Hazardous waste Treatment and Disposal ...................................................................... 84 2.8.3 Environmental Monitoring & Management ................................................................................................. 85

Proposed In-house Monitoring Capabilities ..................................................................................................................86 Management System .................................................................................................................................................................86

2.8.4 Risk of Technological Failure ............................................................................................................................. 86

DESCRIPTION OF THE ENVIRoNMENT ............................................................................................................ 87

Land Environment ........................................................................................................................................................... 87 3.1.1 Description of study area ..................................................................................................................................... 87 3.1.2 Topography and Climate ...................................................................................................................................... 89 3.1.3 Salient Features of site and Surrounding ...................................................................................................... 89 3.1.4 LULC Classes .............................................................................................................................................................. 90 3.1.5 Survey of India- Open series map ...................................................................................................................... 91 3.1.6 Statistics of LULC classes ...................................................................................................................................... 92 3.1.7 Drainage map ........................................................................................................................................................... 93 3.1.8 Soil Quality Monitoring ......................................................................................................................................... 94

Methodology of Soil Monitoring ..........................................................................................................................................94 Soil Monitoring Locations .......................................................................................................................................................95 Solid/Hazardous Waste Generation, Treatment and Disposal .............................................................................98

Climate and Meteorology .............................................................................................................................................. 98 3.2.1 Wind ............................................................................................................................................................................. 98 3.2.2 Micrometeorology ................................................................................................................................................... 99 Air Environment.............................................................................................................................................................. 101

3.3.1 Reconnaissance Survey ...................................................................................................................................... 101 3.3.2 Onsite Air Environment ...................................................................................................................................... 101 3.3.3 Methodology for Selection of Monitoring Locations .............................................................................. 101 3.3.4 Baseline Ambient Air Monitoring Studies ................................................................................................... 102 Noise Environment ........................................................................................................................................................ 106

3.4.1 Noise Level Monitoring ...................................................................................................................................... 106 Water Environment ....................................................................................................................................................... 107

3.5.1 Onsite Water Environment ............................................................................................................................... 107 3.5.2 Reconnaissance survey ....................................................................................................................................... 107 3.5.3 Baseline water quality ........................................................................................................................................ 107

Ground Water .......................................................................................................................................................................... 107 Observation of Ground water result: .................................................................................................................................................... 110

Surface Water ............................................................................................................................................................................ 110 Biological Environment ............................................................................................................................................... 113

3.6.1 Project Location and Surroundings .............................................................................................................. 113 3.6.2 Biological Components in the Immediate Boundary of Project Site ................................................ 113 3.6.3 10 km Impact Boundary .................................................................................................................................... 115 3.6.4 Survey Methodology ............................................................................................................................................ 118 3.6.5 Habitats in the Survey Area.............................................................................................................................. 118

Water Bodies .............................................................................................................................................................................. 118 Human Habitations ................................................................................................................................................................. 121 Agricultural Fields ................................................................................................................................................................... 122

3.6.6 Qualitative and Quantitative Characteristics of the Ecosystem ........................................................ 123 3.6.7 Greenbelt and Plantation at the Site ............................................................................................................ 130 3.6.8 Summary and Conclusion .................................................................................................................................. 131 3.6.9 Recommendations ................................................................................................................................................ 131 Socio Economic Environment ................................................................................................................................... 132

3.7.1 Reconnaissance ..................................................................................................................................................... 133 3.7.2 Methodology ........................................................................................................................................................... 133 3.7.3 Demographic Structure of the Study Area ................................................................................................. 136 3.7.4 Infrastructural Facilities or Civic Amenities .............................................................................................. 139 3.7.5 Occupational Pattern/ Economic Resource Base .................................................................................... 140

Anticipated Environmental Impacts & Mitigation Measures .............................................................. 145

Introduction ...................................................................................................................................................................... 145 Identification of Impacts ............................................................................................................................................. 145 Prediction of Impacts during Construction Phase and Mitigation Measures ...................................... 146

4.3.1 Land Environment ............................................................................................................................................... 146 Anticipated Impacts ................................................................................................................................................................ 146 Mitigation Measures ............................................................................................................................................................... 146

4.3.2 Water Environment ............................................................................................................................................. 147 Anticipated Impacts ................................................................................................................................................................ 147 Mitigation Measures ............................................................................................................................................................... 147

4.3.3 Air Environment ................................................................................................................................................... 147 Anticipated Impacts ................................................................................................................................................................ 147 Mitigation Measures ............................................................................................................................................................... 147

4.3.4 Ecological & Biological Environment ........................................................................................................... 147 Anticipated Impacts ................................................................................................................................................................ 147 Mitigation Measures ............................................................................................................................................................... 148

4.3.5 Noise & Vibration Environment ...................................................................................................................... 148 Anticipated Impacts ................................................................................................................................................................ 148 Mitigation Measures ............................................................................................................................................................... 148

4.3.6 Occupational Health and Safety ..................................................................................................................... 148 Anticipated Impacts ................................................................................................................................................................ 148 Mitigation Measures ............................................................................................................................................................... 148

4.3.7 Socio-economic Environment .......................................................................................................................... 148 Anticipated Impacts ................................................................................................................................................................ 148 Mitigation Measures ............................................................................................................................................................... 148

Prediction of Impacts during commissioning and operation phase and mitigation Measures ... 149 4.4.1 Anticipated Impacts ............................................................................................................................................ 149 4.4.2 Mitigation Measures ........................................................................................................................................... 149 4.4.3 Innovative technological measures proposed to be adopted .............................................................. 149 4.4.4 Land Environment ............................................................................................................................................... 150

Anticipated Impacts ................................................................................................................................................................ 150 Mitigation Measures ............................................................................................................................................................... 150

4.4.5 Water Environment ............................................................................................................................................. 151 Anticipated Impacts: Additional Water use & Wastewater Generation ........................................................ 151 Mitigation Measures Water Environment ................................................................................................................... 152 Storm water collection and disposal .............................................................................................................................. 153 Total Water balance diagram ............................................................................................................................................. 153

4.4.6 Air Environment ................................................................................................................................................... 155 4.4.7 Process emission ................................................................................................................................................... 155

Quantitative Assessment of Impacts due Fuel Burning......................................................................................... 155 Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed activity .................. 157 Modelling Impacts on PM10 ............................................................................................................................................... 160 Modelling Impacts on SO2 ................................................................................................................................................... 162 Modelling Impacts on NOx .................................................................................................................................................. 163 Observations from dispersion modeling studies ...................................................................................................... 164 Other Air Pollution Impacts ................................................................................................................................................ 164 Mitigation Measures ............................................................................................................................................................... 164 Proposed Process Stacks ...................................................................................................................................................... 164

4.4.8 Ecological & Biological Environment ........................................................................................................... 165 Anticipated Impacts ................................................................................................................................................................ 165 Mitigation Measures ............................................................................................................................................................... 165

4.4.9 Noise & Vibration Environment ...................................................................................................................... 168 Anticipated Impacts ................................................................................................................................................................ 168 Mitigation Measures ............................................................................................................................................................... 168

4.4.10 Solid and Hazardous Waste ............................................................................................................................. 168 Anticipated Impacts .......................................................................................................................................................... 168 Mitigation Measures ......................................................................................................................................................... 170

4.4.11 Occupational Health and Safety ..................................................................................................................... 170 Anticipated Impacts .......................................................................................................................................................... 170 Mitigation Measures ......................................................................................................................................................... 170

4.4.12 Socio-economic Environment .......................................................................................................................... 172 Anticipated Impacts .......................................................................................................................................................... 172 Corporate Social Responsibilities & Socio-Economic Welfare ..................................................................... 174 CER Fund Provision ........................................................................................................................................................... 174

Prediction of Impacts during De Commissioning Phase and Mitigation Measures........................... 175 4.5.1 Anticipated Impacts ............................................................................................................................................ 175 4.5.2 Mitigation Measures ........................................................................................................................................... 175

Environmental Impact matrix ................................................................................................................................... 175 Observations and Conclusions .................................................................................................................................. 180

aNAlysis of Alternatives (Technology & Site)............................................................................................ 181

Analysis of Alternative Sites ...................................................................................................................................... 181 Analysis of Alternative Technologies ..................................................................................................................... 181

Environmental Monitoring PROGRAMME .................................................................................................. 182

Objective of Environmental Monitoring Program ........................................................................................... 182 Environmental Monitoring Program ..................................................................................................................... 182

6.2.1 Measurement Methodologies ........................................................................................................................... 186 6.2.2 Reporting Schedules ............................................................................................................................................ 186 Budgetary Provisions for EMP .................................................................................................................................. 187

Additional Studies (Risk Assessment, Public Hearing) ......................................................................... 189

Introduction ...................................................................................................................................................................... 189 7.1.1 Approach to the Study ........................................................................................................................................ 189 7.1.2 Methodology ........................................................................................................................................................... 189 Hazard Identification............................................................................................................................................................... 191 7.1.3 Identification of Hazardous areas ................................................................................................................. 191 7.1.4 Identification of Failure cases for Hazardous areas ............................................................................... 191 7.1.5 Major Hazardous Areas ..................................................................................................................................... 191 Consequence Analysis .................................................................................................................................................. 200

7.2.1 Operating parameters ........................................................................................................................................ 201 7.2.2 Inventory .................................................................................................................................................................. 201 7.2.3 Loss of Containment ............................................................................................................................................ 201 7.2.4 Damage Criteria ................................................................................................................................................... 201 7.2.5 Source strength parameters ............................................................................................................................ 202 7.2.6 Consequential Effects .......................................................................................................................................... 202 7.2.7 Selection of Damage Criteria ........................................................................................................................... 202 7.2.8 Maximum credible loss accident scenarios ................................................................................................ 204 7.2.9 Consequence Analysis Calculations ............................................................................................................... 204 Quantitative risk assessment based on ALOHA ................................................................................................ 205 HAZOP Study..................................................................................................................................................................... 222

7.4.1 Objective ................................................................................................................................................................... 222 7.4.2 Purpose of HAZOP ................................................................................................................................................ 222 Dow Fire and Explosion Index .................................................................................................................................. 222 Disaster preparedness and Emergency Management Plan ......................................................................... 230

7.6.1 Defining nature of Emergency ........................................................................................................................ 231 7.6.2 Emergency classification ................................................................................................................................... 231 7.6.3 Emergency handling priority ........................................................................................................................... 232 7.6.4 Elements of planning .......................................................................................................................................... 232

Legal Authority and Responsibility / On Site Emergency Planning ................................................................ 232 7.6.5 Organization Structure – Duties and Responsibilities ........................................................................... 232 7.6.6 Infrastructure ........................................................................................................................................................ 237 7.6.7 Operational systems during emergencies ................................................................................................... 237

Communication system......................................................................................................................................................... 237 Warning system and control .............................................................................................................................................. 237

7.6.8 Following plans of work to illustrate are to be made ............................................................................ 237 7.6.9 Mutual Aid ............................................................................................................................................................... 238 7.6.10 Disaster management Plan .............................................................................................................................. 238 7.6.11 Earthquake ............................................................................................................................................................. 239 7.6.12 Hazard Control Measures ................................................................................................................................. 240

Fire ............................................................................................................................................................................................ 240 7.6.13 Natural Disasters .................................................................................................................................................. 240 7.6.14 Electrical accidents .............................................................................................................................................. 241

Prevention of Electrical accidents .............................................................................................................................. 241 First aid and emergency procedures ........................................................................................................................ 243

Public Consultation ........................................................................................................................................................ 244 7.7.1 Public Hearing ....................................................................................................................................................... 244

Social Impact Assessment, R & R (Relocation and rehabilitation) action plan ................................... 244

Project Benefits .................................................................................................................................................... 245

Improvement in Infrastructures .............................................................................................................................. 245 Improvement in Social Infrastructure ................................................................................................................... 245 Employment Potential .................................................................................................................................................. 245 Other Tangible & Intangible Benefits .................................................................................................................... 245

Environmental Cost Benefit Analysis ........................................................................................................... 246

Environmental Management Plan ............................................................................................................ 247

Introduction ...................................................................................................................................................................... 247 10.1.1 Objective & Scope of EMP .................................................................................................................................. 247

Environmental Management systems ................................................................................................................... 248 Environment, Health and Safety (EHS) Cell ........................................................................................................ 248 EMP for water environment management .......................................................................................................... 249

10.4.1 Water consumption ............................................................................................................................................. 249 10.4.2 Water conservation measures ......................................................................................................................... 249 10.4.3 Waste water generation, treatment and disposal ................................................................................... 250

EMP for impact on noise levels ................................................................................................................................. 251 EMP For Impact on Land Environment ................................................................................................................ 251

10.6.1 Hazardous/Non Hazardous Waste Management ................................................................................... 251 10.6.2 EMP for impacts on Air, water, social environment ............................................................................... 252

EMP for socio economic environment .................................................................................................................. 252 EMP for impacts on ecological environment ...................................................................................................... 253 Environment management though housekeeping ........................................................................................... 253

Occupational safety and hazard management .............................................................................................. 253 10.10.1 Onsite Medical treatment .................................................................................................................................. 254 10.10.2 Medical examination practice ......................................................................................................................... 254 10.10.3 Fund allocation for Occupational Health and Safety measures......................................................... 255

Environment Budget Allocation .......................................................................................................................... 257 Energy Conservation measures ........................................................................................................................... 257

10.12.1 Financial Provisions for EMP Implementation ......................................................................................... 257 10.12.2 Authorities Responsible for EMP Implementation .................................................................................. 257 10.12.3 EMP Implementation Schedule ....................................................................................................................... 257

Reporting ....................................................................................................................................................................... 258

EXECUTIVE Summary and ConclusioN .................................................................................................... 259

Introduction ...................................................................................................................................................................... 259 Company and Project proponent ............................................................................................................................. 259 Project Description ........................................................................................................................................................ 259 Description of the Environment ............................................................................................................................... 261

11.4.1 Study period and area ........................................................................................................................................ 261 11.4.2 Land use and Land cover ................................................................................................................................... 261 11.4.3 Meteorology ............................................................................................................................................................ 262 11.4.4 Soil .............................................................................................................................................................................. 262 11.4.5 Ambient Air Quality ............................................................................................................................................. 262 11.4.6 Noise .......................................................................................................................................................................... 263 11.4.7 Water Quality......................................................................................................................................................... 263 11.4.8 Surface Water Quality ........................................................................................................................................ 263 11.4.9 Biological Environment ..................................................................................................................................... 263 11.4.10 Socio economic environment ........................................................................................................................... 264

Anticipated Environmental Impacts and mitigation measures ................................................................. 264 11.5.1 Air environment .................................................................................................................................................... 264 11.5.2 Noise .......................................................................................................................................................................... 265 11.5.3 Water requirement & wastewater generation ......................................................................................... 266 11.5.4 Land ........................................................................................................................................................................... 266 11.5.5 Biological environment ...................................................................................................................................... 267 11.5.6 Socio economic environment ........................................................................................................................... 268 11.5.7 Environmental monitoring program ............................................................................................................ 268

Additional Studies .......................................................................................................................................................... 268 11.6.1 Risk Assessment, Hazard identification and consequence analysis .................................................. 268

Project benefits ................................................................................................................................................................ 268 Environmental monitoring plan .............................................................................................................................. 269 Conclusion.......................................................................................................................................................................... 269

Disclosure of Consultants Engaged ........................................................................................................... 270

List of Tables Table 1.1 Proposed products and its capacities ..................................................................................................................... 21 Table 1.2 Statutory Clearances / Permissions required ..................................................................................................... 24 Table 1.3 Compliance to Model ToR Prescribed by EAC-II (5(b) & 5(f) activity) .................................................... 32 Table 2.1 Proposed Products and is capacities ....................................................................................................................... 40 Table 2.2 Land broad break up of plot ........................................................................................................................................ 41 Table 2.3 Major raw material requirement, source and transport mode ................................................................... 76 Table 2.4 Occupational health and safety precautions to be taken (for major chemicals) ................................. 79 Table 2.5 Bulk liquid storages (Proposed)................................................................................................................................ 81 Table 2.6 Consolidated Estimated Fuel Requirement .......................................................................................................... 82 Table 2.7 Existing water requirement ........................................................................................................................................ 82 Table 2.8 Existing waste water generation and disposal ................................................................................................... 82 Table 2.9 Proposed additional water requirement (Fresh + recycle) .......................................................................... 83 Table 2.10 Proposed additional water generation and disposal .................................................................................... 83 Table 2.11 Total water requirement after expansion .......................................................................................................... 83 Table 2.12 Total waste water generation after expansion ................................................................................................ 83 Table 2.13 Expected manpower details ..................................................................................................................................... 84 Table 2.14 Proposed waste generation and disposal pathway (Non hazardous) ................................................... 84 Table 2.15 Proposed waste generation and disposal pathway (Hazardous) ............................................................ 85 Table 3.1 Definition of LULC Classes ........................................................................................................................................... 90 Table 3.2 Landuse/ Landcover Statistics of the 10 km radius Area .............................................................................. 92 Table 3.3 LULC Statistics of the 1 km angular distance around project site .............................................................. 93 Table 3.4 Soil Analysis report ......................................................................................................................................................... 96 Table 3.5 Standard Soil Classification ......................................................................................................................................... 97 Table 3.6 Temperature and Humidity Summer 2018 ........................................................................................................ 100 Table 3.7 Details of Ambient Air Monitoring Stations ....................................................................................................... 102 Table 3.8 Summarized AAQM Results- Summer season 2018 ....................................................................................... 104 Table 3.9 National Ambient Air Quality Standards (CPCB, 2009) ................................................................................ 105 Table 3.10 Noise Monitoring Results (Summer 2018) ...................................................................................................... 106 Table 3.11 Ground water analysis results ............................................................................................................................... 108 Table 3.12 Surface water analysis results ............................................................................................................................... 111 Table 3.13 Survey Locations within 10 km radius of Site ................................................................................................ 118 Table 3.14 Quadrat Study for Trees within the Project Site ........................................................................................... 124 Table 3.15 Quadrat Study for Shrubs in the Vicinity of the Project Site .................................................................... 125 Table 3.16 Quadrat Study for Grasses and Herbs within the Project Site ................................................................. 126 Table 3.17 List of Bird Species observed during the Survey .......................................................................................... 128 Table 3.18 List of Sensitive and Tolerant Species to Pollution ...................................................................................... 132 Table 3.19 List of Sampling locations for SE Primary Survey ........................................................................................ 134 Table 3.20 Summary of Demographic Parameters in the Study Area ........................................................................ 136 Table 3.21 Occupational Structure of the Study Area ........................................................................................................ 140 Table 3.22 Economic Category wise Distribution of Workers ....................................................................................... 141 Table 4.1 Environmental Aspects and Impacts of the Project ........................................................................................ 145 Table 4.2 Fuel Requirements for proposed Boilers / TFH & DG sets .......................................................................... 155 Table 4.3 Air Pollution Sources : Proposed Operations .................................................................................................... 156 Table 4.4 Top 10 incremental concentrations ...................................................................................................................... 160 Table 4.5 Prediction of GLC of PM10 ......................................................................................................................................... 161 Table 4.6 Prediction of GLC of SO2 ............................................................................................................................................. 162 Table 4.7 Prediction of GLC of NOx ........................................................................................................................................... 163 Table 4.8 Suggested Species for Green Belt – Outer pheriphery ................................................................................... 166 Table 4.9 Suggested Species for Green Belt – Inner pheriphery .................................................................................. 167 Table 4.10 Non hazardous Waste Generation & Disposal Proposed ........................................................................... 168 Table 4.11 Hazardous Waste Generation & Disposal Proposed .................................................................................... 169 Table 4.12 Activities proposed for CER .................................................................................................................................... 174 Table 4.13 Budgetary Allocation for CER ................................................................................................................................ 175 Table 4.14 Environmental Impact Matrix Evaluation without Mitigation Measures .......................................... 178 Table 4.15 Environmental Impact Matrix Evaluation with Mitigation Measures ................................................. 179 Table 6.1 Environment Monitoring Plan for the Proposed Facilities.......................................................................... 183

Table 6.2 Reporting Schedule ....................................................................................................................................................... 186 Table 6.3 Budgetary Provisions for EMP ................................................................................................................................. 188 Table 7.1 Proposed Onsite Storages (OSBL) .......................................................................................................................... 192 Table 7.2 Hazard Identification & Risk Assessment at Different Project Stages .................................................... 193 Table 7.3 Other Hazards and control......................................................................................................................................... 194 Table 7.4 Hazardous properties of the chemicals, special hazards ............................................................................. 196 Table 7.5 Consequence Analysis studies carried out ......................................................................................................... 205 Table 7.6 Failure Frequency Data ............................................................................................................................................... 205 Table 7.7 Findings of Consequence Analysis Studies ......................................................................................................... 206 Table 7.8 Hazard Category for Storage Tanks as per FETI study ................................................................................. 223 Table 7.9 F & EI / Mond index calculations ............................................................................................................................ 224 Table 7.10 Planned & Suggested Measure based on Fire and Explosion index ...................................................... 230 Table 7.11 First aid for burns ....................................................................................................................................................... 243 Table 10.1 Proposed Medical Examination Plan .................................................................................................................. 254 Table 11.1 Proposed products and its capacity .................................................................................................................... 259 Table 11.2 Total Water requirement ......................................................................................................................................... 260 Table 11.3 Waste water generation and disposal ................................................................................................................ 261

List of Figures Figure 1.1 Location of Panoli GIDC ............................................................................................................................................... 23 Figure 1.2 Flow chart of EIA study ............................................................................................................................................... 27 Figure 2.1 Map showing location of RMPCL at GIDC Panoli .............................................................................................. 41 Figure 2.2 Plant layout ....................................................................................................................................................................... 43 Figure 3.1 Image showing site & 1 km study area ................................................................................................................ 88 Figure 3.2 Image showing site & 10 km study area .............................................................................................................. 88 Figure 3.3 Survey of India OSM showing study area around project site ................................................................... 91 Figure 3.4 Landuse/landcover statistics of 10 km radius area around Project Site .............................................. 92 Figure 3.5 LULC statistics of 500 m angular distance around Project Site ................................................................. 93 Figure 3.6 Drainage map of 10 km radius area around Project Site.............................................................................. 94 Figure 3.7 Soil sampling locations in 10 km study area ...................................................................................................... 95 Figure 3.8 Wind Rose for summer 2018 season..................................................................................................................... 99 Figure 3.9 Temperature variation at Bharuch ...................................................................................................................... 100 Figure 3.10 Monthwise temperature and rainfall profile at Bharuch ......................................................................... 101 Figure 3.11 AAQ sampling locations .......................................................................................................................................... 103 Figure 3.12 Photographs of AAQ monitoring ........................................................................................................................ 103 Figure 3.13 Ground water sampling location ........................................................................................................................ 107 Figure 3.14 Surface water sampling locations ...................................................................................................................... 110 Figure 3.15 Immediate Neighbourhood of the Project Site (500m boundary) ...................................................... 114 Figure 3.16 Project Site and Biological Components in the Immediate Surroundings ....................................... 115 Figure 3.17 OSM of the Study Area ............................................................................................................................................. 117 Figure 3.18 Extent of Study Area with Locations Surveyed ............................................................................................ 117 Figure 3.19 View of GIDC Reservoir, Ankleshwer .............................................................................................................. 119 Figure 3.20 Plantation surrounding the Reservoir Area .................................................................................................. 120 Figure 3.21 Waterbody at Bakrol ................................................................................................................................................ 121 Figure 3.22 Pond near Panoli Village ........................................................................................................................................ 121 Figure 3.23 Human Habitations in the Impact Area ........................................................................................................... 122 Figure 3.24 Agriculture Field near Project Site .................................................................................................................... 122 Figure 3.25 Ground Flora .............................................................................................................................................................. 123 Figure 3.26 Greenbelt Plantation at Site. ................................................................................................................................. 131 Figure 3.27 Ratio of Workers & Non Workers in the Study Area ................................................................................. 140 Figure 3.28 Economic Category wise Distribution of Workers in the Study Area ................................................ 141 Figure 3.29 Number of Factories and Average Number of Workers in Bharuch District from 2008 to 2011 .................................................................................................................................................................................................................... 142 Figure 4.1 Proposed Effluent Treatment scheme ................................................................................................................ 153 Figure 4.2 Total Water balance .................................................................................................................................................... 154 Figure 4.3 Windrose – Summer 2018 ....................................................................................................................................... 159 Figure 4.4 Isopleths for PM10 ...................................................................................................................................................... 161 Figure 4.5 Isopleths for SO2 .......................................................................................................................................................... 162 Figure 4.6 Isopleths for NOx .......................................................................................................................................................... 163 Figure 4.7 Sample template for Occupational health of the workers ......................................................................... 172 Figure 7.1 QRA Methodology ........................................................................................................................................................ 190 Figure 7.2 Flow Chart for QRA Methodology ......................................................................................................................... 190 Figure 10.1 Proposed Environment, Health and Safety (EHS) Cell .............................................................................. 249

LIST OF ANNEXURES

Number Contents

1.1 Project cost breakup

1.2 Granted TOR from MoEF & CC

1.3 Existing Consent to Operate

2.1 Layout plan

2.2 Letter from GIDC for green belt development

2.3 Letter to GIDC for additional Water requirement

2.4 Application for CHWTSDF membership

3.1 Open series map of 10 km study area

3.2 Land use Land cover report

3.3 Datewise AAQM report & Accreditation of Laboratory

3.4 Socio economic environment

4.1 Proposed ETP scheme

4.2 Copy of CER plan submitted to District authority

7.1 Confirmation for HAZOP compliance recommendation

7.2 ALOHA study & it’s results

7.3 Qualitative risk assessment

7.4 Fire load calculation

7.5 Fire detection & protection

LIST OF ABBREVIATIONS

Abbreviation Full form

AAQ Ambient Air Quality

ACGIH American Council for Governmental Industrial Hygienists

API Active Pharmaceutical Ingredient

BDL Below Detectable Limit

BOD Biological Oxygen Demand

CETP Common Effluent Treatment Plant

CGWA Central Ground Water Authority

CHWTSDF Common Hazardous Waste Treatment Storage and Disposal Facility

CMD Cubic Meter Per Day

COD Chemical Oxygen Demand

CPCB Central Pollution Control Board

CREP Corporate Responsibility for Environment Protection

DISH Directorate of Industrial Safety and Health

EC Environment Clearance

EIA Environment Impact Assessment

EMP Environment Management Plan

ERPG Emergency Response Planning Guidelines

ISO International Organization for Standardization

GLC

GIDC

GPCB

Ground Level Concentration

Gujarat Industrial Development Corporation

Gujarat Pollution Control Board

HW Hazardous Waste

LULC Land Use Land Cover

MOEF Ministry of Environment and Forest

MOEF&CC Ministry of Environment and Forest & Climate Change

MSDS Material Safety Data Sheet

NAAQS National Ambient Air Quality Standard

NOC No Objection Certificate

OHSAS Occupational Hazard and Safety

O & M Operation and Maintenance

PM Particulate Matter

Abbreviation Full form

PM10 Particulate Matter < 10 µg/cum

PM2.5 Particulate Matter < 2.5 µg/cum

PPE Personal Protective Equipment

RWH Rain Water Harvesting

SOCMI Synthetic Organic Chemicals Manufacturing Industry

STEL Short Term Exposure Limit

SEAC State Expert Appraisal Committee (SEAC-I)

SEIAA State Environmental Impact Assessment Authority

TPA Ton Per Annum

TLV Threshold Limiting Value

TOR Term of Reference

TPD Ton Per Day

TPH Ton Per Hour

TPM Ton Per Month

TWA Time Weighted Average

UTM Universal Transverse Mercator coordinate system

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INTRODUCTION

Purpose of Environmental Impact Assessment (EIA) Report

The purpose of this Environmental Impact Assessment report is to investigate the principal environmental concerns, assess magnitude of impact and suggest a suitable Environmental Management Plan for Proposed Establishment of Synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals, polymer, and specialty chemicals by Reshmika Minerals & Chemicals Pvt. Ltd. at its existing Plot No. 23, Panoli GIDC, District - Bharuch, Gujarat.

Identification of project & project proponent

M/s Vansum Industries is a group of companies having head quarter at Pune, Maharashtra. It is a group of experienced Chemical Industry professionals providing original manufacturing services on Manganese products. It carries out rigorous and immense production with the help of our extensive in-house knowledge base and its highly qualified staff of chemical engineers. It manufactures quality manganese products in bulk quantity.

The chemical manufacturing operations are simultaneously managed at two locations viz. M/s. Kemtech Solutions Pvt. Ltd.(KSPL) at Pune, Maharashtra and M/s. Reshmika Minerals & Chemicals Pvt. Ltd. (RMCPL) at GIDC Panoli, Gujarat.

Company is regularly producing chemicals from raw Ore Manganese compounds at both locations and has increased its market share over last 47 years.

RMCPL started its operations in the year 2010 by acquiring 89,632.72 square meter land in the year 2008 at GIDC Panoli, Gujarat. RMCPL is now producing ~ 60,000 TPA of Manganese Sulphate Solution to customers in and around Panoli. The local authorities require that RMCPL should utilize surplus land at Panoli by expanding activities.

RMCPL has now developed in-house green technologies for some organic Chemicals / intermediates. The initial lab and pilot scale studies are successfully completed and company is now ready for commercial operations.

RMCPL wish to establish its manufacturing operation of Organic Chemicals and intermediates at its site at GIDC, Panoli, Gujarat. The products identified are not only based on green technologies but also have potentials to substitute imports, which are sourced at present from China. Also, some of the intermediates in-spite of imports shows a gap in demand against supply and hence the market potentials for products are very encouraging. These observations are based on data obtained by RMCPL by conducting market survey from reputed agencies. This proposal envisages the details required in order to obtain environmental clearance from authorities so that the expansion activities at Panoli can be undertaken.

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Reshmika Minerals and Chemicals believe in quality of its every product. With a vision to become the number one manufacturer in India, and to be known throughout the country as a diversified, socially responsible group. A leading company in the field of chemicals, the RMCPL Group has established itself as a force to be reckoned with.

More than just a slogan, this philosophy has been the key to RMCPL’s success in building mutually beneficial long-term relationships with all its customers, suppliers and the public, and has helped the company fulfill its commitments over the years. The most ambitious and successful conglomerates in India. RMCPL group has over hundred employees - the best in the industry who constantly strive to maintain the high standards that we are known for. We have been able to attract the most skilled workers for our manufacturing plants, the most efficient executives at our corporate office and the best managers who strive to put RMCPL at the top.

The RMCPL Group has registered consistent growth over the past 35 years. Its two manufacturing plants are strategically located across India. Its headquarter is at Pune, India. RMPCL has a group of experienced Chemical Industry professionals providing original manufacturing services on Manganese products in bulk quantity.

RMPCL run a production for Manganese Sulphate solution, which started in the year 1977 and the high demand made us produce the solution in large quantity by which its production from 400 MT/ annum went up to 60,000 MT/ annum. The present manufacturing capacity for Manganese Sulphate stands at 5,000 MT per month. RMCPL has set up an integrated manufacturing facility for Manganese Dioxide, Manganese Oxide and Manganese Sulphate - solution and powder.

State of Art Technology and innovative techniques utilize to setup the production processes with the help of custom built plant and machinery. Long term contracts have already been entered into with customers for purchase of Manganese Sulphate in large volumes.

Brief Description of Project & Its Importance in the Country, Region

The company proposes to set up manufacturing facility for synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals, polymer, and specialty chemicals etc. at the site as below:

Table 1.1 Proposed products and its capacities

No Product / By Product CAS No Proposed Capacity, TPM

Products 1 Di-Ethyl Ketone (DEK) 96-22-0 250 2 Propiophenone 93-55-0 50 3 4-Nitro-o-Xylene 99-51-4 500

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Note: Currently RMCPL is having valid CCA No 75308 from GPCB for manufacturing inorganic chemicals Manganese dioxide (2000 Mt/Month), Manganese Oxide (700 Mt/Month) and Manganese sulphate solution (12000 Mt/month), Bricks (using own nonhazardous waste generated from manufacturing process) (36,00,000 Nos/Month).

The total plot area of the site is 89,632.72 sq m.

The estimated project cost is about Rs. 130 Crores. The project execution will be carried out in phases (Phase I- Rs. 30 Cr & Phase II- Rs. 100 Cr). During TOR application, project cost given in Form- I & PFR is only for Phase- I. Detailed project cost breakup given in

Annexure 1.1.

The proposed establishment shall be carried out at its plot 23, GIDC Industrial estate Panoli, Tal Ankleshwar, Dist Bharuch Gujarat. GIDC Industrial estate, Panoli is located at about 13 km from Ankleshwar city and is about 0.6 km away from National highway No 8. Nearest railway station is Ankleshwar. The Geographical Location of this plot is at 210 32’ 42.30’’ N Latitude and 720 59’ 59.64” E Longitude with an elevation of 34 meter above sea level MSL. Geographical plant site coordinates are as below:

Direction Latitude Longitude North east corner 210 32’ 47.69’’ N 730 00’ 10.00” E North west corner 210 32’ 44.48’’ N 720 59’ 56.28” E

4 3-Nitro-o-Xylene 83-41-0 600 5 1,3-Dimethyl-2-Nitrobenzene 81-20-9 20 6 2,4-Dimethyl-1-Nitrobenzene 89-87-2 80 7 3,4-Xylidine (3,4 –Dimethyl Aniline) 95-64-7 100 8 2,6-Xylidine (2,6 –Dimethyl Aniline) 87-62-7 10 9 2,4-Xylidine (2,4 – Dimethyl Aniline) 95-68-1 40

10 N-(1-Ethylpropyl)-3,4-Xylidine 56038-89-2 500 11 2-Cynophenol 611-20-1 100 12 1-Octanoic acid 124-07-2 300 13 Styrene oxide 96-09-3 200 14 Phenyl ethyl alcohol 60-12-8 200 15 Phenyl ethyl alcohol methyl ether 3558-60-9 50 16 Phenyl acetaldehyde 122-78-1 20 17 Phenyl acetaldehyde di-methylacetal 101-48-4 20 18 Phenyl ethyl acetate 103-45-7 20

Subtotal (Products) 3060 By Products

19 Methyl Ethyl Ketone 78-93-3 5 20 Dilute Sulfuric acid 7664-93-9 230 21 Dilute nitric acid 7697-37-2 800

Grand Total (Products+ by Products) 4095

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South east corner 210 32’ 38.56’’ N 730 00’ 8.86” E South west corner 210 32’ 40.09’’ N 720 59’ 55.82” E

Figure 1.1 Location of Panoli GIDC

India is leading manufacturer of technical material for Agro / Pharma / Polymer / Specialty chemical etc. industry. Most of the chemical industry in India is dependent on intermediate supplies through imports particularly from China. In spite of that industry has faced severe shortages for chemical intermediates due to factors beyond local controls. RMCPL has identified organic intermediates imported in country in large quantities in-spite of some local production. Some of the technical intermediates are short in supply since timely imports cannot be managed. The intermediates identified by RMCPL will be mainly produced to bridge the gap between demand and supply. Also, the innovative technologies when commercialized will also give an opportunity to substitute imports so that valuable foreign exchange can be saved. The proposal will also generate job opportunities for locals. The initiative taken up by RMCPL is mainly due to strategic direction of Govt. of India viz. Make in India.

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At present country is not exporting intermediates identified by RMCPL mainly due to non-availabilities of production capacities. RMCPL objective is initially to meet local demand and export opportunities are not explored at this juncture. However, RMCPL will create in future more capacities if export opportunities are available.

Some of the intermediates identified by RMCPL for production are totally imported in the country whereas, for others the dependency for imports is upto 70-80%. Only one or two intermediates are locally produced and it is observed that production capacities over last 5 years are stagnant and not increasing.

RMCPL has conducted market survey to identify the organic intermediates to be produced in-house so that not only the demand supply gap is adequately covered but also, to ensure that import substitution can be achieved. The market survey conducted clearly shows a gap of almost 20-30% of Indian requirement. In addition to this, considering the potentials of import substitution and further export opportunities the project looks attractive.

Project envisaged by RMCPL is from basic stage involving procurement of raw material, storage, commercial production in-house analytical backup, finished products warehousing and supply chain management. Since present activities are running at its peak wherein no existing manpower can be released for new project, RMCPL proposes to recruit manpower for all the functions explained above. The head count will cover skilled as well as unskilled labour which will be managed by a highly experienced and talented seniors. The operations at Panoli will also generate job opportunities for indirect labour to support activities such as transport, maintenance, fabrication, civil jobs at site, canteen and food suppliers and security etc. RMCPL foresees around 100 to 110 jobs for direct employment. Also there is great potential for employment in the downstream industries.

Regulatory framework of the proposed expansion

RMPCL shall obtain required statutory permission and clearances from concerned authorities. Indicative permits and clearance as applicable to this project are provided in table below.

Table 1.2 Statutory Clearances / Permissions required

No Legal requirement 1 Environmental Impact Assessment Notification, 2006 as amended to date

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2 Factory License 3 The Factories Act 1948 & Rules therein 4 The Water (Prevention and Control of Pollution) Act, 1974 and Rules, 1975, as

amended to date. 5 The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules, 1978,

as amended to date. 6 The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982, as

amended to date. 7 The Manufacture, Storage and Import of Hazardous Chemical rules, 1989, as

amended to date. 8 The Hazardous Waste (Management, Handling and Trans boundary Movement)

Rules, 2016 as amended to date. 9 The Environment (Protection) Act, 1986 and Rules, 1986, as amended to date

10 Chemical accidents (Emergency Planning, preparedness and response) Rules, 1996

11 The Motor Vehicles Act, 1988 & The Central Motor Vehicle rules, 1989 12 The Petroleum Act, 1934 & Rules, 2002. 13 The Gas Cylinders Rules, 2004 14 The Static and Mobile Pressure Vessels (Unfired) Rules, 1981 15 The Batteries (Management and Handling) Rules, 2001, as amended to date 16 The Noise Pollution (Regulation and Control) Rules, 2000 as amended to date 17 E-waste (Management and Handling) Rules, 2011 as amended to date 18 Electricity Rule, 2005 19 Consents from GPCB 20 The Bureau of Indian Standards Act 21 Public Liability Insurance Act, 1991 and Rules, 1991 as amended to date 22 Chemical Accidents (Emergency planning, Preparedness and Response) Rules,

1996 23 The Central Motor Vehicle Rules, 1989

Note: Above list is indicative and not exhaustive.

As a part of Environmental Clearance process, RMPCL uploaded and submitted relevant documents, namely Form – 1 (as per the EIA Notification, 2006, as amended), along with a Pre-feasibility Report and Proposed Terms of Reference (ToRs) for carrying out Environmental Studies, to the Central Expert Appraisal Committee (EAC -II) MoEF&CC on 11th April 2017. Based on the information contained in the documents submitted, the project has been awarded proposal number IA/GJ/IND2/70788/2017. ToR has been finalized by EAC-II vide letter IA-J-11011/535/2017-IA-II(I) dated 22nd March 2018 for conducting the Environmental Impact Assessment (EIA) & Environmental Management Plan (EMP) studies (Refer Annexure 1.2).

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For conducting EIA, the project proponent RMPCL has retained the services of M/s. Aditya Environmental Services Private limited; Mumbai who are NABET accredited EIA Consultant Organization for the 5(b) and 5(f) sector. Own Laboratory of Aditya Environmental Services Private limited (Recognized by MOEF&CC as “Environmental Laboratory” vide SO no 983 valid till 30.04.2019) and Laboratory of M/s. ENPRO Enviro Tech and Engineers Pvt. Ltd, Surat (Recognized by MOEF&CC as “Environmental Laboratory” vide letter No. Q 15018/45/2015-CPW dated August 18th 2016 valid for 5 years) has been utilized for various analytical activities of the EIA study.

Objectives

The objectives of EIA for the proposed establishment of project are listed below:

• Characterization and benchmarking of existing environmental status.

• To identify and quantify significant impact on the environmental parameters during construction, commissioning and operation phases of the proposed project.

• To identify and quantify any environmental impacts associated with the project

and recommend appropriate mitigation measures to avoid/minimize pollution, environmental disturbance and nuisance.

• Preparation of an environmental management plan to minimize adverse impacts of proposed project.

• Recognize the scope and requirement of the ToR and comply with the same.

The EIA study of proposed project is limited to the project site, study area of 10 km

surrounding the project site and in accordance with the Terms of Reference (ToR) issued

by EAC-II vide letter no. IA-J-11011/535/2017-IA-II(I) dated 22nd March 2018.

Base line data collection and environmental monitoring of the study area is carried out during the period of summer 2018 (March-May 2018).

EIA is a management tool to identify, frame and prioritize the environmental issues in such a way as to work out the mitigation measures to allow the negative impacts to be minimized or to be avoided during the construction and operation phase of the proposed establishment project.

EIA process passes through the following phases:

• Screening, Scoping and consideration of alternatives

• Study of the project details

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• Application with environmental pre-feasibility study for approval of ToR.

• Collection of baseline data for study area

• Impact identification, prediction and evaluation

• Assessment of alternatives and delineation of Environment Management Plan

• Risk Assessment (RA) and Disaster Management Plan (DMP)

• Review and finalization of EIA report

• Final EIA report and EC Application.

Flow chart of various activities to be carried out for EIA report preparation is depicted in figure below.

Figure 1.2 Flow chart of EIA study

The methodology adopted for conducting the EIA is mentioned below:

• Screening and scoping: Screening is done to see whether a project requires clearance as per the statutory notifications. Scales of investment, type and location of

development are the main criteria for screening the project activity. Scoping is carried out in close association with the project proponent and guidance by the Impact Assessment Agency. The MoEF & CC has published guidelines for different

Project initiation

Preliminary scan of Existing environment

Preliminary scan of Proposed environment

Select Environmental indicators

Describe Environmental Indicators

Select Environmental setting

Impact evaluation (modeling)

Environmental Impact Assessment

Environmental Management Plan

Hazard and Risk

Analysis

Risk assessment and

DMP

EIA Report

Field survey / sampling

Rescanning of proposed Environment

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sectors, which outline the significant issues to be addressed in the EIA studies. Quantifiable impacts are assessed on the basis of magnitude, prevalence, frequency, duration and significance of non-quantifiable impacts is commonly determined through the socio-economic criteria. After the areas where the project can have significant impact are identified, the baseline status of these are to be monitored and then the likely changes in these on account of the construction and operation of the proposed project are predicted.

• Desk top study: Desktop study has been conducted to establish an environmental information database for the EIA. Reference materials such as textbooks, articles,

maps, internet, photographs and past EIA reports of similar industries have been used for the preparation of EIA report.

• Field study: One season field study for the period of summer 2018 has been carried out to verify and complement information gathered from desktop study. Baseline data describes the existing environmental status of the identified study area. The study covers all the relevant components of ambient air monitoring; noise, water quality, soil monitoring, ecological, and socio-economic and health components of the environment. The site-specific primary data has been monitored for the identified parameters and supplemented by secondary data if available.

Air environment

Monitoring of the existing status of ambient air quality and analysis has been carried out as per revised National Ambient Air Quality Standard. Maximum numbers of sampling stations have been selected considering the pre-dominant downward wind direction, population zone and sensitive receptor of the region. Micro-meteorological data like hourly wind speed and direction, temperature, relative humidity, rain fall, etc., have been collected by using wind monitor. Air Modeling was done to envisage the likely impact on ambient air quality due to proposed establishment of the project.

Noise environment

Noise level monitoring has been carried out for day and night times by noise meter to

assess the present scenario of the noise environment.

Land Environment

Soil samples have been collected from selected locations within the impact zone and analyzed for relevant parameters. Studies on soil characteristics are carried out. Existing land use, topography, landscape and drainage patterns within the study area is analyzed.

Water environment

Ground & Surface Water samples have been collected from various locations within 10 km radius from the project. Analysis is carried out for physio-chemical, heavy metal,

microbiological and biological parameters. Results have been compared to assess the water quality.

Ecology & Socio-Economic Environment

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Secondary data of flora and fauna have been collected by site survey and from various literatures published by Forest Department. Data have also been verified by primary data collected. Collection of demographic and related socio-economic data. Projection of anticipated changes in the socio-economic aspect due to the project related activities, are also studied.

Laboratory Analysis

Samples collected during the field sampling are analyzed in an established, recognized and NABL accredited laboratory.

• Impact Prediction and Evaluation: Impact prediction is a way of ‘mapping’ the

environmental consequences of the significant aspects of the project and its alternatives. Evaluation of all associated and potential impacts of the proposed project are carried out using required models. Impact evaluation was carried out using the matrix method.

• Mitigation Measures and Environmental Management Plan: Efficient mitigation plan has been drawn up for the selected option and is supplemented with an Environmental Management Plan (EMP) to guide the proponent towards environmental improvements. Depending on nature, location and scale of the project, all significant risks and hazards and their mitigation measures shall be incorporated

in the risk report. Risk report contains hazard identification by taking recourse to hazard indices, inventory analysis, natural hazard probability, consequence analysis of failures and accidents resulting in fire, explosion, hazardous releases etc. Assessment of risk on the basis of the necessary evaluations and preparation of an Onsite /Off site Emergency Plan and Disaster Management Plan are also mentioned in the risk report.

• EIA Report: Based on the field survey visit primary & secondary data collection, compilation of data and technical details are done by the project team and reviewed by the EIA study team and EIA Coordinator. Draft EIA report is prepared after incorporation of all the technical data, maps, drawings, FAEs comments and inputs

from Environmental IA study team and EIA Coordinator. Quality check is conducted by a QA/QC team and their comments are incorporated in the report. After final confirmation from the project proponent EIA report is submitted to MoEF&CC.

No Chapter Content 1 Introduction • Purpose of the report

• Identification of project & project proponent • Brief description of nature, size, location of the

project and its importance to the country, region • Scope of the study – details of regulatory scoping

carried out.

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No Chapter Content 2 Project

Description • Condensed description of those aspects of the

project (based on project feasibility study), likely to cause environmental effects. Description contains the details of the following:

• Type of project • Need for the project • Location details showing general location, specific

location, project boundary & project site layout • Technology and process description including

drawings showing project layout, components of project etc.

• Description of mitigation measures incorporated into the project to meet environmental standards.

3 Description of the Environment

• Study area, period, components & methodology. • Establishment of baseline for valued environmental

components, as identified in the scope. • Study Period • Base maps of all environmental components. • Frequency of monitoring

4 Anticipated Environmental

Impact and mitigation measures

• Details of Investigated Environmental impacts due to project location, possible accidents, project design, project construction, regular operations.

• Measures for minimizing and / or offsetting adverse impacts identified.

• Irreversible and Irretrievable commitments of environmental components

• Assessment of significance of impacts (Criteria for determining significance, Assigning significance)

• Mitigation measures. 5 Analysis of

Alternatives (Site and

Technology)

• Analysis of alternatives site considered for siting the project.

• Analysis of alternatives technologies considered for the project

6 Environmental monitoring programme

• Technical aspects of environmental monitoring for the effectiveness of mitigation measures (incl. Measurement methodologies, frequency, location data analysis, reporting schedules, emergency procedures, budget &

• procurement schedules) 7 Additional

studies (Public hearing and Risk

assessment)

• Hazard Identification • Risk Assessment & control/prevention Measures • Disaster Management • Results of public hearing and recommendations

8 Project benefits • Details of the Socio-economic & other tangible / intangible benefits of the project.

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No Chapter Content 9 Environmental

cost benefit analysis

• Details of the environmental benefits of the project.

10 Environmental management plan

• Description of the administrative aspects of ensuring that mitigation measures are implemented and their effectiveness monitored, after approval of the Clearance. The Chapter consist of :

• Mitigation measures for impacts • Pollution Prevention Plan • Greenbelt Development Plan • Waste management plan • Environment Management Cell • Budgetary Provisions for EMS

11 Summary and conclusions

• Brief description of EIA content, summary and conclusion

12 Disclosure of consultant engaged

• Details of EIA Consultant

RMCPL is proposing to establish production facility of synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals, polymer, and specialty chemicals manufacturing facility by installation of plants and infrastructure at the site.

The proposal falls under category 5(f) and 5(b) – A as per EIA notification 2006 and needs environmental clearance from Central Expert Appraisal Committee (EAC-II)

According the EIA is prepared as per Model TOR prescribed (MOEFCC document April 2015) and specific TOR granted as per letter no. IA-J-11011/535/2017-IA-II(I) dated 22nd March 2018.

Any development project is likely to impact surrounding environment. The nature and magnitude of impact on different components of the environment will depend on the nature and size of project as well as location aspects of the project site and steps taken for mitigating the environmental impact. The final net impact due to the proposed project on environmental components can be evaluated through Environmental Impact Assessment (EIA) studies within the study area prior to its implementation. The results of EIA Studies form the basis for preparation of a viable Environmental Management Plan (EMP).

The EIA Studies can be broadly divided in to three phases.

➢ 1stPHASE: The first phase involves identification of significant environmental components and assessing their baseline (Pre-project) status within the study area.

➢ 2ndPHASE: The second phase involves prediction of impacts on various identified significant environmental parameters due to proposed project. Data regarding the

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proposed construction activities, design capacity of the individual units, water consumption, solid / hazardous waste, sewage / effluent generation, characteristics of disposal medium and topography of the study area is also taken into consideration to evaluate project related environmental features.

➢ 3rdPHASE: The third phase covers the evaluation of final impacts and delineation of an Environmental Management Plan to mitigate adverse impacts on the quality of surrounding environment.

For the purpose of assessing the impacts Study area of 10 km radius around project site was identified for the EIA study as per MOEF guidelines.

The scope of work for the EIA covers the following covers following details:

• Assessment of environmental features of project and evaluation of pollution control measures.

• Assessment of environmental features of the project.

• Establishment of present status of land, air, noise, water, biological and socioeconomic and cultural components of the environment.

• Identification and quantification of likely impacts due to implementation of proposed plant on the environmental components during the construction and

operation phases.

• Study of existing activities in the project area.

• Evaluation of proposed eco-friendly and pollution control measures.

• Assimilation of collected and generated data during the course of EIA studies.

Delineation of an Environmental Management Plan (EMP) outlining measures to

be adopted by the project proponents for mitigation of adverse impacts.

Compliance to various TOR items as per the Model TOR (MOEFCC document - April 2015) and Project specific TOR prescribed as per letter no. IA-J-11011/535/2017-IA-II(I) dated 22nd March 2018, are given in tables below.

Table 1.3 Compliance to Model ToR Prescribed by EAC-II (5(b) & 5(f) activity)

Sr. No.

Particulars Compliance

A Standard terms of reference 1. Executive Summary Included as part

of EIA Report. Refer Chapter 11

2. Introduction i Details of the EIA Consultant including NABET accreditation Please refer

Chapter 12 ii Information about the project proponent Please refer

Chapter 1

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iii Importance and benefits of the project Please refer Chapter 1

3. Project Description i Cost of project and time of completion Please refer

Chapter 2 ii Products with capacities for the proposed project. Please refer

Chapter 1 & 2 iii If expansion project, details of existing products with

capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Not applicable. Proposed project is establishment

of SOCMI manufacturing

iv List of raw materials required and their source along with mode of transportation

Please refer Chapter 2

v Other chemicals and materials required with quantities and storage capacities

Please refer Chapter 2

vi Details of Emission, effluents, hazardous waste generation and their management

Please refer Chapter 2 & 4

vii Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

Please refer Chapter 2

viii Process description along with major equipments and machineries, process flow sheet (quantitative) from raw material to products to be provided

Please refer Chapter 2

ix Hazard identification and details of proposed safety systems. Please refer Chapter 2

x Expansion/modernization proposals

a Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to Operate for the ongoing existing operation of the project from SPCB shall be attached with the EIA-EMP report.

Not applicable

b In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish/No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted.

Not applicable. Existing facility is not covered

under EIA notification,

2006. (Refer

Annexure 1.3 for valid CTO)

4 Site Details

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i Location of the project site covering village, Taluka / Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

Please refer Chapter 3

ii A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

Please refer Chapter 3 &

Annexure 3.1.

iii Details w.r.t. option analysis for selection of site Please refer Chapter 3

iv Co-ordinates (lat-long) of all four corners of the site. Please refer Chapter 3

v Google map-Earth downloaded of the project site. Please refer Chapter 3

vi Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/ Estate/ Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate

Please refer Chapter 3

vii Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular

Please refer Chapter 3

viii Land use break-up of total land of the project site (identified and acquired), government/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)

Please refer Chapter 3

ix A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area

Please refer Chapter 3

x Geological features and Geo-hydrological status of the study area shall be included

Please refer Chapter 3

xi Details of Drainage of the project up to 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river shall also be provided. (mega green field projects)

Please refer Chapter 3

xii Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land

Not applicable

Xiii R & R details in respect of land in line with state Government policy.

Not applicable

5. Forest and wildlife related issues (if applicable) I Permission and approval for the use of forest land (forestry

clearance), if any, and recommendations of the State Forest Department. (if applicable)

Not applicable

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Ii Land use map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)

Not applicable

Iii Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

Not applicable

Iv The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon.

Not applicable

V Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in the study area.

Not applicable

vi Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife.

Not applicable

6 Environmental Status i Determination of atmospheric inversion level at the project

site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Please refer Chapter 3

ii AAQ data (except monsoon) at 8 locations for PM 10, PM 2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

Please refer Chapter 3

iii Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Please refer Chapter 3

iv Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/ MoEF &CC guidelines.

Please refer Chapter 3

v Whether the site falls near to polluted stretch of river identified by the CPCB/ MoEF & CC, if yes give details.

There is no polluted stretch of river identified by the CPCB/ MoEF & CC near the site.

vi Ground water monitoring at minimum at 8 locations shall be included

Please refer Chapter 3

vii Noise levels monitoring at 8 locations within the study area. Please refer Chapter 3

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viii Soil Characteristic as per CPCB guidelines Please refer Chapter 3

ix Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

Not applicable. Site is well

connected by Road, Rail.

x Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

Please refer Chapter 3

xi Socio-economic status of the study area Please refer Chapter 3

7 Impact and Environment Management Plan i Assessment of ground level concentration of pollutants from

the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modeling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.

Please refer Chapter 4

ii Water Quality modeling - in case of discharge in water body Not applicable. Proposed project

will maintain ZLD facility.

iii Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyor cum- rail transport shall be examined.

Please refer Chapter 6

iv A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E(P) Rules.

Please refer Chapter 4

v Details of stack emission and action plan for control of emissions to meet standards.

Please refer Chapter 4

vi Measures for fugitive emission control Please refer Chapter 4

vii Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding

Please refer Chapter 4

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utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/ reuse/ recover techniques, Energy conservation, and natural resource conservation.

viii Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Not applicable

ix Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated.

Please refer Chapter 4.

x Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.

Not applicable.

xi Total capital cost and recurring cost/ annum for environmental pollution control measures shall be included.

Please refer Chapter 6

xii Action plan for post-project environmental monitoring shall be submitted.

Please refer Chapter 6

xiii Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Please refer Chapter 6

8 Occupational Health i Plan and fund allocation to ensure the occupational health &

safety of all contract and casual Workers Please refer

Chapter 6 ii Details of exposure specific health status evaluation of

worker. If the workers' health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, color vision and any other ocular defect) ECG, during pre-placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.

New proposed unit. The health monitoring shall

be carried out once unit is established.

iii Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved.

New proposed unit. The health monitoring shall

be carried out once unit is established.

iv Annual report of health status of workers with special reference to Occupational Health and Safety.

New proposed unit. The health monitoring shall

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be carried out once unit is established.

9 Corporate Environment Policy i Does the company have a well laid down Environment Policy

approved by its Board of Directors? If so, it may be detailed in the EIA report.

Please refer Chapter 10

ii Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA.

Please refer Chapter 10

iii What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Please refer Chapter 10

iv Does the company have system of reporting of non compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report

New proposed unit.

10 Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labor force during construction as well as to the casual workers including truck drivers during operation phase.

Sanitation, fuel, Restroom etc will be provided to the labors during construction as well as casual workers including truck drivers during operation phase.

11 Enterprise Social Commitment (ESC) Adequate funds (at least 2.5 % of the project cost) shall be

earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Detailed CER plan is attached

in Annexure 4.2.

12 Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

Not applicable

13 A tabular chart with index for point wise compliance of above TOR.

Please refer Chapter 1

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Sr. No

Additional ToR as specified by MOEFCC vide letter dt 22.03.2018

Compliance/ Company’s reply

1. Details on solvents to be used, measures for solvent recovery and for emissions control

Refer Chapter 2 & 4

2. Details of process emissions from the proposed unit and its arrangement to control

Refer Chapter 2 & 4

3. Ambient air quality data should include VOC, other process-specific pollutants* like NH3*, Chlorine*, HCl*, HBr*, H2S*, HF*, CS2 etc. (* - as applicable)

Refer Chapter 3 and Annexure 3.3

4. Work zone monitoring arrangements for hazardous chemicals.

Refer Chapter 3 and 4

5. Detailed effluent treatment scheme including segregation of effluent streams for units adopting 'Zero' liquid discharge

Detailed effluent treatment scheme is given in Chapter 4 & Annexure 4.1

6. Action plan for odor control to be submitted. Chemicals used are not odorous however number of VOC control measures proposed – please Refer Chapter 4

7. Copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated

Not Applicable. Hazardous waste shall be sent to CHWTSDF. Refer Chapter 4

8. Authorization/Membership for solid/ hazardous waste in TSDF, if any.

Refer Annexure 2.4.

9. Action plan for utilization of MEE/dryers salts. MEE/ Dryer salts will be disposed off to CHWTSDF.

10. Material Safety Data Sheet for all the Chemicals are being used/will be used.

Yes, All MSDS available

11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF are being used/will be used

Refer Annexure 3.2

12. Details of Incinerator if to be installed Not applicable. 13. Risk assessment for storage and handling of

hazardous chemicals/solvents. Action plan for handling & safety system to be incorporated.

14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

Refer Chapter 4 & 7

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PROJECT DESCRIPTION

Type of Project

As per EIA Notification dated 14 September 2006, the enhancement / establishment in production capacity of Pestcide intermediates and Synthetic Organic Chemical Manufacturing Industry (SOCMI) falls in 5(b) and 5(f)- A category needs prior environmental clearance from central EAC-II.

The proposed production quantities of the various products / by-products at Reshmika Minerals and Chemicals Private Limited at Panoli GIDC site shall be as below:

Table 2.1 Proposed Products and is capacities

Currently RMCPL is having valid CCA No 75308 from GPCB manufacturing inorganic chemicals Manganese dioxide (2000 Mt/Month), Manganese Oxide (700 Mt/Month) and Manganese sulphate solution (12000 Mt/month), Bricks (using own nonhazardous waste generated from manufacturing process) (36,00,000 Nos/Month).

No Product / By Product CAS No Proposed Capacity, TPM

Products 1 Di-Ethyl Ketone (DEK) 96-22-0 250 2 Propiophenone 93-55-0 50 3 4-Nitro-o-Xylene 99-51-4 500 4 3-Nitro-o-Xylene 83-41-0 600 5 1,3-Dimethyl-2-Nitrobenzene 81-20-9 20 6 2,4-Dimethyl-1-Nitrobenzene 89-87-2 80 7 3,4-Xylidine (3,4 –Dimethyl Aniline) 95-64-7 100 8 2,6-Xylidine (2,6 –Dimethyl Aniline) 87-62-7 10 9 2,4-Xylidine (2,4 – Dimethyl Aniline) 95-68-1 40

10 N-(1-Ethylpropyl)-3,4-Xylidine 56038-89-2 500 11 2-Cynophenol 611-20-1 100 12 1-Octanoic acid 124-07-2 300 13 Styrene oxide 96-09-3 200 14 Phenyl ethyl alcohol 60-12-8 200 15 Phenyl ethyl alcohol methyl ether 3558-60-9 50 16 Phenyl acetaldehyde 122-78-1 20 17 Phenyl acetaldehyde di-methylacetal 101-48-4 20 18 Phenyl ethyl acetate 103-45-7 20

Subtotal (Products) 3060 By Products

19 Methyl Ethyl Ketone 78-93-3 5 20 Dilute Sulfuric acid 7664-93-9 230 21 Dilute nitric acid 7697-37-2 800

Grand Total (Products + by Products)

4095

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Location of the Project

The proposed project of RMCPL will be be located at Plot No. P- 23, GIDC Industrial Estate Panoli, Tal Ankleshwar, Dist Bharuch, Gujarat.

Figure 2.1 Map showing location of RMPCL at GIDC Panoli

Size/ Magnitude of Operation

Total plot area is 89,632.72 m2. The land area utilization shall be as follows:

Table 2.2 Land broad break up of plot

Description Land requirement

Exiting plant area 6547.295

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Proposed area 25283.94 Total road and free space 33748.005

Green belt area (within plot) 14447.06

Parking area 9606.42

Green belt area (GIDC Lease adjacent land) 14973.37

Total green belt 29420.43

Total plot area 89632.72

Detailed plant layout showing proposed plants, utilities, storage and other details are as

given in Figure below. Refer Annexure 2.1.

Note: Project proponent has acquired adjacent area of 14973.37 sq m for green belt development from GIDC. Refer Annexure 2.2.

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Figure 2.2 Plant layout

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Proposed Schedule for Approval & Implementation

It is expected that the project shall be completed within 6 – 18 months from date of grant of environmental clearance.

Technology & Process Description, Environmental & Safety Aspects

It is proposed to establish plant capacity of 250 TPM.

Process Chemistry – Diethyl Ketone

Reaction Mechanism

Process block diagram – Diethyl Ketone (DEK)

2

Catalyst , Heat

+ +

H2O

Propionic acid De-Ethyl ketone Carbon di-

oxide

Water

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Plant Process description – Diethyl Ketone(DEK)

The fixed bed or stirred tank reactor having solid catalyst is heated to 375 to 400 Deg C. The propionic acid is fed through the hot catalyst bed continuously. The reaction products (DEK, water vapor and carbon di-oxide) are fed to the distillation column in a continuous mode. The top of distillation column water and DEK are condensed, whereas the excess propionic acid is collected at distillation column bottom. The excess propionic acid is recycled to the catalytic reactor. The DEK and water are subjected to distillation to separate water and pure DEK. The water is used for gardening purpose. The carbon di-oxide generated is passed through the scrubber the scrubbed water is recycled within process.

Material balance – Diethyl Ketone (DEK)

It is proposed to establish plant capacity of 50 TPM.

Process Chemistry – Propiophenone

Reaction Mechanism

Input kg Output kgPropionic acid 1,810 To distillation I 567

Propionic acid(recycle) 550 1,000

2,360 793

2,360

Input OutputFron reactor 2,360 Carbon di oxide 583

Disti. bottom recycle 550

MEK distillation II 17

2,360 To distillation II 1,210

2,360

Input OutputFrom distillation I 1,227 Product DEK 1,000

MEK 17

1,227 Water recycle/reuse 210

1,227

Distillation II

(Basis:- 1000 kg output product)

Reactor

Distillation I

Schematic Flow Chart for Manufacturing Process of

Product : Diethyl Ketone

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Process block diagram – Propiophenone

Plant Process description – Propiophenone

The fixed bed or stirred tank reactor having catalyst is heated to 375 to 400o C. Mean time propionic acid and benzoic acid solution (around 10 to 20% by wt of benzoic acid) is prepared as a feed stock. The propionic and benzoic acid solution is fed through the hot catalyst bed continuously. The reaction products (DEK, Propiophenone, water vapor and carbon di-oxide) are fed to the distillation column. The top of column water and DEK are condensed, whereas; propiophenone with the excess propionic acid is collected at distillation column bottom. The bottom product containing excess propionic acid and propiophenone is subjected to distillation. Initially excess propionic acid is collected, which is recycled to reactor. Then the pure propiophenone is collected as product. The DEK and water are subjected to distillation to separate water and pure DEK. The water is used for gardening purpose.

Material balance – Propiophenone

Catalyst , Heat

H2O

Benzoic acid Propionic acid De-Ethyl

ketone

Propiophenone Carbon

di-oxide

Water

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It is proposed to establish plant capacity of 500 TPM of 4 NOX and 600 TPM of 3 NOX.

Process Chemistry – 4 Nitro O Xylene & 3 Nitro O Xylene

Reaction Mechanism

Process block diagram – 4 Nitro O Xylene & 3 Nitro O Xylene

Input kg Output kgPropionic acid 1,875 To distillation I 2,700

Benzoic acid 200

Propionic acid(recycle) 625

2,700 2,700

Input Outputfrom reaction 2,700 Carbon di oxide 600

To distillation II 1,475

To distillation III 625

2,700 2,700

Input OutputFrom distillation I 1,475 Distilled water reuse 250

Product DEK 1,000

Product Priopiophenone 225

1,475 1,475

Distillation II & Distillation III

(Basis:- 1000 kg output product)

Reactor

Distillation I

Schematic Flow Chart for Manufacturing Process of

Product : Propiophenone

Catalyst, Stir

o-Xylene Nitric acid 3-NOX 4-NOX

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Plant Process description – 4 Nitro O Xylene & 3 Nitro O Xylene

In a stirred reactor n-hexane / or suitable solvent (n-hexane and catalyst are stirred at room temperature). The jacket of reactor is supplied with cooling / chilled water. Then to it O-Xylene and nitric acid is added continuously over the period of 6 to 8 hours. The addition is done slowly with careful control of temperature. The addition is completed in 6 to 8 hours and then stirred further for 8 hours. The reaction mixture is filtered, the catalyst is recovered. The reaction mixture is washed with water. The aqueous layer contains dilute nitric acid. The organic layer is subjected to fractional distillation initially under atmospheric pressure to recover n-hexane, which is recycled to reaction zone. Then the fractional distillation under vacuum is carried out to recover un-converted o-Xylene, which is recycled to reaction zone. The 3-NOX is first distilled out and recovered as product. The material in the distillation still is finally recovered using short path distillation unit to recover 4-NOX product. At the bottom of short path distillation heavies are collected, which are send for disposal.

Process Block Diagram : 4-NOX AND 3-NOX

Reactor

Distillation - I

3 NOX Product /Incineration

o Xylenerecycle

Distillation - II

Short path distillation

Filtration

Extraction with water

Distillation III

Distillation IV 4 NOX Product

Residue & Others

Discard - For Incineration

n Hexane recycle

catalyst

o Xylene + n HexaneCatalyst + Nitric acid

water Spent acid

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Material balance – 4 Nitro O Xylene & 3 Nitro O Xylene

It is proposed to establish plant capacity of 20 TPM of 1,3 Dimethyl 2 Nitrobenzene and 80 TPM of 2,4 Dimethyl 1 Nitrobenzene.

Process Chemistry – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene

Reaction Mechanism

Input kg Output kgRecycle Hexane 1,800 To filtration 9,020

Fresh n Hexane 200

Recycle O xylene 3,256

Fresh O Xylene 1,544

Nitric acid+water 1,960

Water 20

Recycle Catalyst 240

9,020 9,020

Input OutputFrom reactor 9,020 To extraction 8,780

Catalyst recycle 240

9,020 9,020

Input Outputfrom filtration 8,780 To distillation I 7,560

water 400 Spent acid 1,620

9,180 9,180

From above 7,560 Recycle n Hexane 1,800

To distillation II 5,760

7,560 7,560

From above 5,760 Recycle O xylene 3,256

to distillation III & IV 2,504

5,760 5,760

From above 2,504 Product 4 NOX 1,000

Product 3 NOX 1,000

Distilation residue 504

2,504 2,504

Schematic Flow Chart for Manufacturing Process of

Product : 4-NOX AND 3-NOX

Distillation III and Distillation IV

Extraction with water

Distillation I

Distillation II and short path distillation

(Basis:- 1000 kg output product)

Reactor

Filtration

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Process block diagram – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene

Plant Process description – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene

In a stirred reactor 80% sulfuric acid solution in water along with m-Xylene is charged. The jacket of reactor as well as the internal cooling coil of reactor is supplied with cooling / chilled water. The reaction mixture is cooled to 20 to 22o C. Then to this reaction mixture 50 to 55% dilute nitric acid is added continuously over the period of 4 to 6 hours. The addition is done slowly with careful control of temperature. The addition is completed in 4 to 6 hours and then stirred further for 1 hour. The reaction mixture is

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allowed to settle and separate in two layers. Two layers are separated, lower heavy layer of dilute sulfuric acid is separated and stored in dilute sulfuric acid. Then to the crude nitro mass, DM water is charged and stirred, allowed to settle in two layers. The heavier crude nitro mass is separated and stored in crude nitro-mass storage tank. The water washing is transferred and mixed with dilute sulfuric acid. This aqueous layer contains dilute sulfuric acid which is sold in market or used elsewhere in the existing plant. The organic layer is subjected to fractional distillation initially under vacuum to recover un-reacted m-Xylene, which is recycled to reaction zone in next batch. Then the fractional distillation under vacuum is carried out to recover product 1,3-Dimethyl-2-Nitro benzene is first distilled out and recovered at boiling point of product. The material in the distillation still is finally recovered using short path distillation unit to recover 2,4-Dimethyl-1-Nitrobenzene as the top distilled product. At the bottom of short path distillation heavies / higher boiler are collected, which are sent for disposal.

Material balance – 1,3-Dimethyl-2-Nitrobenzene and 2,4 Dimethyl 1Nitrobenzene

It is proposed to establish plant capacity of 100 TPM.

Input Outputm Xylene (fresh) 2,864 To decanter 10,199

m Xylene (recycle) 286

Sul Acid 2,775

Nitric acid 1,790

DM water 2,484

10,199 10,199

Input OutputFrom reactor 10,199 To distillation I 4,390

Water (washing) 3,000 Aq layer 8,809

13,199 13,199

Input OutputFrom decanter 4,390 Recovered m Xylene 286

Distillation II 4,104

4,390 4,390

From above 4,104 1,3-Dimethyl-2-Nitrobenzene 800

2,4-Dimethyl-1-Nitrobenzene 3,200

Distillation residue 104

4,104 4,104

Distillation I

Distillation II

(Basis:- 800 kg & 3200 kg output product respectively)

Reactor

Decanter washing (with water)

Schematic Flow Chart for Manufacturing Process of

Product : 1,3-Dimethyl-2-Nitrobenzene & 2,4-Dimethyl-1-Nitrobenzene

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Process Chemistry –3,4-Xylidine (3,4 –Dimethyl Aniline)

Reaction Mechanism

Process block diagram –3,4-Xylidine (3,4 –Dimethyl Aniline)

Material balance – 3,4-Xylidine (3,4 –Dimethyl Aniline)

3, 4-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

3,4-Dimethyl-1-

Nitrobenzene

3,4-Dimethylaniline Water of reaction

Process Block Diagram : 3,4-DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

4 NOX Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle

Distillation - II Distilled water for reuse

Product

Solvent Recycle

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It is proposed to establish plant capacity of 10 TPM.

Process Chemistry –2,6-Xylidine (2,6 –Dimethyl Aniline)

Reaction Mechanism

Input Output4 NOX 2,500 To filtration 5,150

Catalyst recycle 50

Methanol (Fresh) 125

Methanol (Recycle) 2,375

Hydrogen 100

5,150 5,150

Input OutputFrom above 5,150 Catalyst recycle 50

To Distillation I 5,100

5,150 5,150

Input OutputFrom filtration 5,100 Methanol recycle 2,375

Processing loss 125

To distillation II 2,600

5,100 5,100

From distillation I 2,600 Product 2,000

Water for reuse 600

2,600 2,600

(Basis:- 2000 kg output product)

Hydrogenator (Hydrogenetion)

Catalyst Filtration

Schematic Flow Chart for Manufacturing Process of

Product : 3,4 Dimethyl Aniline

Distillation I

Distillation II

2,6-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

1,3-Dimethyl-2-

Nitrobenzene

2,6-Dimethylaniline Water of reaction

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Process block diagram –2,6-Xylidine (2,6 –Dimethyl Aniline)

Material balance – 2,6-Xylidine (2,6 –Dimethyl Aniline)

Process Block Diagram : 2,6 -DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

1,3-Dimethyl-2-Nitrobenzene

Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle

Distillation - II Distilled water for reuse

Product

Solvent Recycle

Input kg Output kg1,3 Dimethyl 2 nitrobenzene 1,250 To filtration 3,200

Catalyst recycle 25

Methanol (Fresh) 94

Methanol (Recycle) 1,781

Hydrogen 50

3,200 3,200

Input OutputFrom above 3,200 Catalyst recycle 25

To Distillation I 3,175

3,200 3,200

Input OutputFrom filtration 3,175 Methanol recycle 1,781

Processing loss 94

To distillation II 1,300

3,175 3,175

From distillation I 1,300 Product 1,000

Water for reuse 300

1,300 1,300

(Basis:- 1000 kg output product)

Hydrogenator (Hydrogenetion)

Catalyst Filtration

Schematic Flow Chart for Manufacturing Process of

Product : 2,6 Dimethyl Aniline

Distillation I

Distillation II

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It is proposed to establish plant capacity of 40 TPM.

Process Chemistry –2,4-Xylidine (2,4 – Dimethyl Aniline)

Reaction Mechanism

Process block diagram –2,4-Xylidine (2,4 – Dimethyl Aniline)

Plant Process description – General

General brief Process Description (to reduce nitro compounds to corresponding amino compound) In a stirred high pressure hydrogenation reactor having good mixing, internal cooling coil and external limpet coil for heating is first thoroughly checked for tightness by applying nitrogen at high pressure. Once this testing is done, transfer dry methanol to the reactor. Then transfer the corresponding nitro mass (viz. 1, 3-Dimethyl-2-Nitrobenzene or 2, 4-Dimethyl-1-Nitrobenzene or 3, 4-Dimethyl-1-Nitrobenzene). The agitator of reactor is started. Then the reaction mass is flushed with nitrogen. Once the nitrogen flushing is over, then solid catalyst viz. Pd/C or Pt/C is charged in the reaction mixture under nitrogen environment and mixing of reaction mass. Once all the raw materials are

2,4-DIMETHYLANILINE

Methanol, Hydrogen

gas

Catalyst, Heat

2 H2O

2,4-Dimethyl-1-

Nitrobenzene

2,4-Dimethylaniline Water of reaction

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charged, the reactor is evacuated with the help of vacuum pump. The vacuum is released by nitrogen gas and the reactor is pressurized to 3 kg-g/cm2 with nitrogen and the excess nitrogen pressure is vented after holding the pressure for 5 minutes. The operation is repeated for five times to expel out air completely. Reactor is completely closed, all safety gadgets are checked like pressure control loop, safety relief valve, rupture disc, hydrogen gas leak sensors etc. Then the reaction mixture is heated to desired temperature by passing medium pressure steam pressure through the limpet coil of the reactor. Once the reaction temperature is attained, the reactor is pressurized to the desired pressure with the help of hydrogen gas through auto loading loop through hydrogen gas mass flow controller. Once the desired hydrogen gas consumption attains desired value, the reactor is cooled by passing cooling tower water through the internal cooling coil of the reactor. The reaction mass is further digested so that no nitro-mass is left unconverted and the minimum hydrogen gas is present in the reactor. The excess hydrogen is gas vented along with low pressure steam and nitrogen gas diluent. The reaction mixture is filtered through the catalyst filter. The catalyst filter cake is washed with methanol followed by DM water. The washings are taken in the reaction mixture. The catalyst is recycled in next batch. The filtrate is subjected to recovery by distillation. Initially the methanol and reaction water are recovered by distillation at atmospheric pressure. The recovered methanol is recycled in next batch. The distilled water partly send to cooling water make-up. The finished product is (amino compounds) recovered by distillation under vacuum. The product is stored in nitrogen atmosphere. The distilled product is packed in the drums.

Material balance – 2,4-Xylidine (2,4 – Dimethyl Aniline)

Input kg Output kg2,4-Dimethyl-1-Nitrobenzene 2,500 To filtration 5,150

Catalyst recycle 50

Methanol (Fresh) 125

Methanol (Recycle) 2,375

Hydrogen 100

5,150 5,150

Input OutputFrom above 5,150 Catalyst recycle 50

To Distillation I 5,100

5,150 5,150

Input OutputFrom filtration 5,100 Methanol recycle 2,375

Processing loss 125

To distillation II 2,600

5,100 5,100

From distillation I 2,600 Product 2,000

Water for reuse 600

2,600 2,600

(Basis:- 2000 kg output product)

Hydrogenator (Hydrogenetion)

Catalyst Filtration

Schematic Flow Chart for Manufacturing Process of

Product : 2,4 Dimethyl Aniline

Distillation I

Distillation II

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It is proposed to establish plant capacity of 500 TPM.

Process Chemistry –N-(1-Ethylpropyl)-3,4-Xylidine

Reaction Mechanism

Process block diagram –N-(1-Ethylpropyl)-3,4-Xylidine

Plant Process description – N-(1-Ethylpropyl)-3,4-Xylidine

In a reactor, the reactor is first flushed with nitrogen for three to four times. Then to the reactor enough quantity of IPA or Methanol solvent is charged followed by hydrogenation catalyst (Pd/Carbon). Then to this mixture 4-NOX and DEK are charged to desired quantity. The reactor is closed and the reactants are flushed thoroughly with nitrogen

Catalyst, Stir

Hydrogen , Heat

H2O

4-NOX DI-ETHYL

KETONE

N-(1-ETHYL

PROPYL)-3,4-

XYLIDINE

Process Block Diagram : N-(1-ETHYL PROPYL)-3,4-DIMETHYL ANILINE

Hydrogenator

Hydrogenation

Distillation - I

DEK + 4 NOX Catalyst + Solvent

Hydrogen

Catalyst Filtration

CatalystRecycle

Distillation - II Distilled water for reuse

Product

Solvent Recycle

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gas. The reaction mass is heated under agitation till 75 to 80o C. Then to it the hydrogen gas is passed to reactor, hydrogen gas is allowed to consume. If required the reaction mass is occasionally cooled by passing water through the jacket of the reactor. Hydrogenation is continued till no more hydrogen gas is consumed. After the reaction is over reaction mixture is digested for further 30 to 45 minutes. Then the reaction mixture is cooled and the catalyst is filtered through sparkler filter. The catalyst is washed with small quantity of solvent. The catalyst is preserved for recycle in next hydrogenation batch. The filtrate and washings are charged to distillation vessel. The product is subjected to complete solvent recovery under vacuum. The product is cooled and is taken in drum. The product drum is flushed with nitrogen. The distillate obtained in the above-mentioned flash distillation operation is subjected to solvent recovery to recover and recycle the solvent. The water recovered by distillation is subjected to gardening application or cooling tower application.

Material balance –N-(1-Ethylpropyl)-3,4-Xylidine

It is proposed to establish plant capacity of 100 TPM.

Input, Kg Output, kgDEK 230 To filtration 1,596

4 NOX 396

Catalyst recycle 10

IPA / Methanol (Fresh) 47

IPA / Methanol (recycle) 892

Hydrogen 21

1,596 1,596

Input OutputFrom above 1,596 Catalyst recycle 10

To Distillation I 1,586

1,596 1,596

Input OutputFrom filtration 1,586 Solvent recycle 892

Processing loss 47

To distillation II 647

1,586 1,586

From distillation I 647 Product 500

Water for reuse 147

647 647

(Basis:- 500 kg output product)

Hydrogenator (Hydrogenetion)

Catalyst Filtration

Schematic Flow Chart for Manufacturing Process of

Product : N-(1-Ethylpropyl)-3,4-Dimethyl Aniline)

Distillation I

Distillation II

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Process Chemistry – 2-Cynophenol

Reaction Mechanism

Process block diagram – 2-Cynophenol

Plant Process description – 2-Cynophenol

The reactor is flushed with nitrogen, then reactor is charged with toluene. Desired amount of salicylic acid is then charged to the reactor followed by desired amount of liquor ammonia solution is charged. The reaction mixture is stirred for 1 hour. The reaction mixture is slowly heated till the boiling point, the excess water and reaction water is removed by azeotropic distillation with toluene. The distilled water is send for disposal. The toluene is recovered by distillation. The salicyl amide is stored in molten condition.

Ammonia solution ,

Toluene, Heat

2H2O

Salicylic acid Salicyl amide Water of reaction

Vapor phase ,

Catalyst

H2O

Salicyl amide 2-Cynophenol Water of reaction

Process Block Diagram : 2 Cyanophenol

Reactor-Neutralizer

Dehydration Reactor

Catalytic Reactoration

Toluene + Salicylic acidLiquor Ammonia

Distilled water with ammoniaTraces - disposal

Solvent Distillation

Distilled solvent recycle

Dehydration ReactorDistilled water- disposal

Crystallization

CentrifugeVacuum

DryerProduct

Mother Liquor Distillation

Distilled Toluene recycle

Residue -Disposal

Toluene

Toluene

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The molten salicyl amide is continuously charged to fixed bed catalytic reactor along with small amount of nitrogen. The reaction product 2-cyanophenol and reaction water is collected by cooling. This product i.e. crude 2-cyanophenol and reaction water is charged along toluene to the azeotropic distillation facility. The reaction water is recovered by azeotropic distillation, which is send for treatment. The dehydrated 2-cyanophenol is cooled by applying chilled water through the jacket of reactor. The crystallized purified 2-cyanophenol is centrifuged in the centrifuge. The crystalline 2-cyanophenol is then dried in a vacuum drier. The mother liquor is subjected to recovery of second crop 2-cyanophenol. Finally the toluene is recovered by distillation and recycled. The residue of distillation column is sent for solid waste disposal facility.

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Material balance – 2-Cynophenol

It is proposed to establish plant capacity of 300 TPM.

Process Chemistry – 1-Octanoic acid

Reaction Mechanism

Input, Kg Output, kgToluene Fresh 150 To dehydration reactor 5,517

Toluene Recycle 2,850

Salycylic acid 1,657

Ammonia 215

Water 645

5,517 5,517

Input OutputFrom above 5,517 To solvent distillation 4,645

Water to ETP 872

5,517 5,517

Input Outputfrom above 4,645 Distilled Toluene(recycle) 2,850

Processing loss 150

4,645 To catalytic reactor ation 1,645

4,645

From distillation 1,645 Distillate water (disposal) 216

Toluene (recovered) 3,290 To Crystallisation 4,719

4,935 4,935

From dehydration 4,719 M/L to distillation 3,849

Toluene(recovered) 200 To vacuum drier 1,070

4,919 4,919

From centrifuge 3,849 Recovered toluene(recycle) 3,420

Distillation residue 429

3,849 3,849

From centrifuge 1,070 Product 1,000

Processing losses 70

1,070 1,070

Vacuum Drier

Schematic Flow Chart for Manufacturing Process of

Product : 2 Cynophenol

Solvent distillation

Dehydration reactor

Crystalliser / centrifuge

(Basis:- 1000 kg output product)

Reactor - Neutraliser

Dehydration reactor

M/ Distillation

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Process block diagram – 1-Octanoic acid

Plant Process description – 1-Octanoic acid

The reactor is charged with desired amount 1-Octanol. Then to the reactor is charged with the catalyst. The agitator of the reactor is started with high intensity for better mixing of catalyst and 1-Octanol. Then the reactor is heated to desired temperature by passing steam through the jacket of reactor. Then the reactor is pressurized with oxygen gas to the desired pressure and allowed to consume the pressure. The operation is repeated by pressurizing with oxygen till desired consumption takes place. The reaction temperature is continuously maintained by cooling the reaction mixture by passing cooling water through the jacket of reactor. Once the reaction is complete, the reaction mass is cooled, depressurized and filtered through the filter. The crude 1-Octanoic acid distilled under reduced pressure, the water

Process Block Diagram : 1- Octanoic acid

Reactor

Catalyst Filter

Vacuum Distillation

Filtrate and washing

Catalyst Cakerecycle

Reaction WaterResidue/Polymeric bodies

Product1- Octanoic acid

1 Octanol

1 Octanol + CatalystOxygen

1 Octanol

1 OctanolRecycle

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of reaction is recovered and disposed followed by excess 1-Octanol is recovered and recycled. Finally 1- Octanoic acid is recovered and the distillation residue is subjected to incineration.

Material balance – 1-Octanoic acid

It is proposed to establish plant capacity of 200 TPM.

Process Chemistry – Styrene oxide

Reaction Mechanism

Input, kg Output, kg1 Octanol 923 To filtration 1,404

1 Octanol(recycle) 103

Catalyst (recycle) 100

Oxygen 278

1,404 1,404

Input OutputFrom reactor 1,404 Catalyst recycle 100

1 Octanol 100 Loss of dissolved gas 26

To Vac distillation 1,378

1,504 1,504

Input OutputFrom Filtration 1,378 Product 1,000

Recycle water 130

Recovered octanol 103

Residue 145

1,378 1,378

Vacuum distillation

(Basis:- 1000 kg output product)

Reactor

Catalyst filtration and washing

Schematic Flow Chart for Manufacturing Process of

Product : 1 Octanoic acid

+ H2O2

Catalyst

NaHCO3, Cool

+ H2O

Styrene Hydrogen

Peroxide

Styrene Oxide Water of

reaction

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Process block diagram – Styrene oxide

Plant Process description – Styrene oxide

In a stirred tank vessel the feed comprising of DM water or distilled recycled water is taken to it desired amount of sodium bi-carbonate is charged along with catalyst. The feed is made homogeneous by good mixing.

The continuous plug-flow reactor is kept ready. The cooling water to the reactor is started. Initially the metering pump for the above catalyst feed is started to the reactor at desired rate. Then the styrene feed to the reactor at desired rate is started followed by the hydrogen peroxide feed is started to the reactor at the desired rate. The reaction mixture emerges out enters in to the continuous high speed decanter to separate organic layer (product layer) from the aqueous layer. The organic layer is washed in to continuous extractor with DMW and the organic layer is taken for further processing whereas the washed water layer is mixed with the above aqueous layer which goes for the recovery through the ETP treatment.

The organic layer of crude styrene oxide is mixed with small amount of nitroso-naphthol, and subjected to recovery by distillation. The bottom residue of styrene oxide distillation still is subjected to sell or given for co-processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Process Block Diagram : Styrene Oxide

Feed Preparation

Reactor

Organic Layer

Residue

DM Water /Process water Reaction Water

Styrene + H2O2+O2

Continuous Decanter

Aqueous Layer +Washing

Water

MEE for water

recovery

Water as CT make up

washings

Vacuum distillation

ProductStyreneOxide

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Material balance – Styrene oxide

It is proposed to establish plant capacity of 200 TPM.

Process Chemistry – Phenyl ethyl alcohol

Reaction Mechanism

Input, kg Output, kgWater 1,000 To Reactor 1,150

Sod bicarbonate 100

Catalyst 50

1,150 1,150

Input OutputFrom prep. 1,150 Reaction product 3638

Styrene 1,105 Processing loss(vent) 33

H2O2 425

Water 991

3,671 3,671

Input OutputFrom reactor 3,638 Organic layer 1,271

Aq layer 2,367

3,638 3,638

Org layer 1,271 To vac distillation 1,271

Water 636 Washings 636

1,907 1,907

From washing 1,271 Product 1,011

Dist. Residue 260

1,271 1,271

From Org layer wash636 to MEE for recovery 3,003

From decanter 2,3673,003 3,003

from above 3,003 Recycle in next cycle 1,150

Condensate for reuse 1,853

3,003 3,003

(Basis:- 1000 kg output product)

Feed Preperation

Reaction

Continuous decanter

Organic layer washing

Vacuum distillation

Aq Layer & Washing

MEE for water recovery

Schematic Flow Chart for Manufacturing Process of

Product : Styrene Oxide

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Process block diagram – Phenyl ethyl alcohol

Plant Process description – Phenyl ethyl alcohol

In a stirred high pressure hydrogenation reactor having good mixing, internal cooling coil and external limpet coil for heating is first thoroughly checked for tightness by applying nitrogen at high pressure. Once this testing is done, transfer dry methanol to the reactor. The agitator of reactor is started. Then the reaction mass is flushed with nitrogen. Once the nitrogen flushing is over, then solid catalyst viz. Pd/C or Pt/C or Rani Nickel is charged in the reaction mixture under nitrogen environment and mixing of reaction mass.

Once all the raw materials are charged, the reactor is evacuated with the help of vacuum pump. The vacuum is released by nitrogen gas and the reactor is pressurized to 3 kg-g/cm2 with nitrogen and the excess nitrogen pressure is vented after holding the pressure for 5 minutes. The operation is repeated for five times to expel out air completely. Reactor

+ H2

Catalyst

Methanol

Styrene Oxide Hydrogen gas Phenyl ethyl

alcohol

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is completely closed, all safety gadgets are checked like pressure control loop, safety relief valve, rupture disc, hydrogen gas leak sensors etc.

Then the reaction mixture is heated to desired temperature by passing medium pressure steam pressure through the limpet coil of the reactor. Once the reaction temperature is attained, the reactor is pressurized to the desired pressure with the help of hydrogen gas through auto loading loop through hydrogen gas mass flow controller. Then simultaneously styrene oxide pumping is charged using high pressure metering pump and hydrogenation is continued. The desired amount of styrene oxide is pumped in the reactor. Once hydrogen gas consumption attains desired value; the reaction mass is

further digested so that no styrene oxide is left unconverted and the minimum hydrogen gas is present in the reactor., the reactor is cooled by passing cooling tower water through the internal cooling coil of the reactor. The excess hydrogen is gas vented along with low pressure steam and nitrogen gas diluent.

The reaction mixture is filtered through the catalyst filter. The catalyst filtered cake is washed with methanol followed by small amount of DM water. The washings are taken in the reaction mixture. The catalyst is recycled in next batch. The filtrate is subjected to recovery by distillation. Initially the methanol and water are recovered by distillation at atmospheric pressure. The recovered methanol is recycled in next batch. The distilled water is recycled in next batch for catalyst washing. The finished product is (phenyl ethyl

alcohol) recovered by fractional distillation under vacuum. The distilled product is stored in nitrogen atmosphere. The distilled product is packed in the drums.

The distillation column bottom residue of phenyl ethyl alcohol distillation still is subjected to sell to perfumery industry / agarbatti industry or given for co-processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Material balance – Phenyl ethyl alcohol

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It is proposed to establish plant capacity of 50 TPM.

Process Chemistry – Phenyl ethyl alcohol methyl ether

Reaction Mechanism

Process block diagram – Phenyl ethyl alcohol methyl ether

Input, kg Output, kgStyrene oxide 1,093 To catalyst 3,477

Fresh Methanol 116 filtration

Recycle methanol 2,223

Catalyst 28

Hydrogen gas 18

3,477 3,477

Input OutputFresh Methanol 100 Catalyst recycle 28

from above 3,477 To distillation I 3,549

3,577 3,577

Input OutputFrom Distillation I 3,433 MeOH recycle 2195

Processing loss 116

3,433 To Distillation II 1123

3433

From Dist. I 1,123 Product 1012

Dist. Residue 111

1,123 1,123

(Basis:- 1000 kg output product)

Hydrogenerator

Catalyst filtration

Distillation I

Distillation II

Schematic Flow Chart for Manufacturing Process of

Product : Phenyl Ethyl Alcohol

+

Caustic lye

+

Na2SO4

Phenyl ethyl

alcohol

Di-methyl

sulfate

Phenyl ethyl alcohol

methyl ether

Sodium sulfate

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Plant Process description – Phenyl ethyl alcohol methyl ether

In a stirred tank reactor having limpet coil for cooling, reflux condenser and nitrogen flushing arrangement, is taken desired amount of 47 to 48% caustic lye, which is diluted under agitation to the desired strength with the help of DM water under agitation. The solution temperature is controlled by passing cooling water through the limpet coil of the

reactor.

In a metering vessel desired amount of phenyl ethyl alcohol is charged which is then transferred to the reactor having dilute caustic solution. The reaction mixture is stirred well. Then to the dimethyl sulfate metering vessel desired amount dimethyl sulfate is taken. The dimethyl sulfate is slowly charged to the reactor containing phenyl ethyl alcohol and caustic lye solution. After complete charging of dimethyl sulfate solution the reaction mass is further digested for additional one hour. At the end of reaction, the pH of aqueous solution was checked and it was adjusted to 6 to 7.5. Once the pH adjustment is done the reaction mixture is allowed to settle. The lower aqueous layer of sodium sulfate is taken for recovery to ETP.

The upper layer of crude phenyl ethyl alcohol methyl ether is subjected to fractional distillation under vacuum. The distilled product is stored in nitrogen atmosphere. The distilled product is packed in the drums.

The distillation column bottom residue of phenyl ethyl alcohol methyl ether distillation still is subjected to sell to perfumery industry / agarbatti industry or given for co-

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processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Material balance – Phenyl ethyl alcohol methyl ether

It is proposed to establish plant capacity of 20 TPM.

Input, kg Output, kgPhenyl Ethyl Alcohol 950 To 5,905

Dimethyl Sulphate 1,030 Seperator

Caustic solution 1,363

DM Water 2,562

5,905 5,905

Input OutputFrom Reactor 5,905 Org Layer 1,065

Aq Layer/washing 4,840

5,905 5,905

Input OutputOrganic layer 1,065 Aq layer / washing 500

DM Water 500 To distillation 1,065

1,565 1,565

from washing 1,065 Product 1,000

Residue 65

1,065 1,065

Aq layer / washing from above5,340 Water recovered for

reuse (CT make up)

3,149

Solid waste disposal 2,191

5,340 5,340

(Basis:- 1000 kg output product)

Reaction and pH adjustment

Decantor seperator

Organic layer washing

Vacuum distillation

MEE for water recovery

Schematic Flow Chart for Manufacturing Process of

Product : Phenyl Ethyl Alcohol Methyl Ester (PEME)

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Process Chemistry – Phenyl acetaldehyde

Reaction Mechanism

Process block diagram – Phenyl acetaldehyde

Plant Process description – Phenyl acetaldehyde

Catalyst and Solvent

Heat

Styrene Oxide Phenyl acetaldehyde

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In a stirred tank vessel the feed comprising of styrene oxide is taken to it desired amount and solvent is charged to it in desired amount. The feed is made homogeneous by good mixing. The fixed bed catalyst set-up made ready, the catalyst bed is heated to desired temperature continuously under nitrogen. The above solution of styrene oxide is passed over the catalyst bed in a continuous manner at desired rate. The converted material is stored under nitrogen pressure. The solution of crude phenyl acetaldehyde is distilled under reduced pressure to recover the solvent, the solvent is recycled in the reaction zone. The distilled phenyl acetaldehyde is distilled under reduced pressure and is stored under reduced pressure. The distilled product is packed in the drums.

The distillation column bottom residue of phenyl acetaldehyde distillation still is subjected to sell to perfumery industry or given for co-processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Material balance – Phenyl acetaldehyde

It is proposed to establish plant capacity of 20 TPM.

Process Chemistry – Phenyl acetaldehyde di-methylacetal

Reaction Mechanism

Input, kg Output, kgStyrene oxide 1,087 5,116 5,116

Fresh Toluene (Makeup) 192

Recycle solvent 3,645

Recovered styrene oxide 192

5,116 5,116

Input OutputFrom Preperation 5,116 To Distillation 5,116

5,116 5,116

Input OutputFrom reactor 5,116 Product 1,000

Recovered Toluene 3,645

Recovered styrene oxide 192

Distillation residue 87

Processing losses 192

5,116 5,116

(Basis:- 1000 kg output product)

Feed Preperation

Catalytic reactor

Vacuum distillation

Schematic Flow Chart for Manufacturing Process of Product : Phenyl Acetaldehyde

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Process block diagram – Phenyl acetaldehyde di-methylacetal

Plant Process description – Phenyl acetaldehyde di-methylacetal

In a vessel the feed phenyl acetaldehyde solution in dry methanol is prepared under agitation and is maintained under nitrogen pressure. Meantime, in a stirred tank reactor having limpet coil for heating / cooling is charged anhydrous methanol followed by catalyst. The reactor is flushed with nitrogen, and the mild nitrogen stream is maintained continuously. Once all the above mentioned condition is achieved, the reactor under

Catalyst and Methanol

Heat, Remove water

Phenyl acetaldehyde Phenyl acetaldehyde di-methyl

acetal

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distillation condition is fed continuously phenyl acetaldehyde solution in a desired flow rate and the methanol is allowed to distill taking out water continuously, the wet methanol is dehydrated in second fractional distillation column, the anhydrous methanol is recycled in the reaction zone and the water recovered is send for cooling tower make-up.

The reaction in above-mentioned manner is continued till the desired conversion is achieved. Then the reaction mixture is cooled, the catalyst is filtered under nitrogen pressure, washed with methanol and is recycled in next batch.

The solution of product in methanol is subjected to recover methanol by distillation,

which is recycled in next batch. The residue i.e. crude phenyl acetaldehyde dimethyl acetal is distilled under reduced pressure using short path distillation unit under vacuum and is stored under nitrogen. The product is packed in the drums.

The distillation column bottom residue of phenyl acetaldehyde dimethyl acetal distillation still is subjected to sell to perfumery industry or given for co-processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Material balance – Phenyl acetaldehyde di-methyl acetal

Input OutputPhenyl Acetaldehyde 1,021 To catalytic reactor 3,952

Methanol (Fresh) 477

Recovered MeOH 2,454

3,952 3,952 0

Input OutputFrom feed preperation 3,952 MeOH dehydration column 2,588

Recovered MeOH 2,722 Filtration 4,220

Recovered Catalyst 134

6,808 6,808 0

Input OutputFrom catalytic reactor 4,220 Filtrate 4,086

Recovered catalyst 134

4,220 4,220 0

From Filtration 4,086 Recovered MeOH 2,722

Recovered Phenyl acetaldehyde 128

Distillation column bottom 236

Product PADMA 1,000

4,086 4,086 0

From catalytic reaction 2,588 Recovered MeOH (recycle) 2,454

Recovered water as CT make up 134

2,588 2,588 0

Filtration

Schematic Flow Chart for Manufacturing Process of

Product : Phenyl Acetaldehyde Dimethyl Acetal

(Basis:- 1000 kg output product)

Feed Preperation and Reaction

Catalytic Reaction

Atmospheric and vacuum distillation

Methanol Dehydration column

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It is proposed to establish plant capacity of 20 TPM.

Process Chemistry – Phenyl ethyl acetate

Reaction Mechanism

Process block diagram – Phenyl ethyl acetate

Plant Process description – Phenyl ethyl acetate

The reactor having agitator and fractional distillation column is used in this process. The reactor is provided with limpet coil for heating or cooling of reaction mass. Initially the reactor is flushed with nitrogen, then to it desired amount of acetic acid is charged, followed by catalyst and then phenyl ethyl alcohol is charged. The reaction mixture is maintained under reflux for three to four hours. Then slowly the reaction water along with small amount of acetic acid is removed under reflux, till the vapor temperature

+ CH3COOH

Catalyst

Heat

+ H2O

Phenyl ethyl

alcohol

Acetic acid Phenyl ethyl acetate Water of

reaction

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attains the acetic acid boiling point. The distilled aqueous acetic acid is sold in the market as dilute acetic acid.

Then at this temperature reaction mixture is refluxed for one more hour with small withdrawal so as to drive the reaction to completion. Then the excess acetic acid is recovered under reduced pressure. The reaction mixture is cooled and catalyst is removed by filtration, which is recycled in the reaction. The crude phenyl ethyl alcohol acetate is then washed with 10% solution of sodium bi-carbonate solution and then it is washed with DM water. The aqueous layer is recycled till it is exhausted. The organic layer is subjected to fractional distillation under reduced pressure. The product phenyl

ethyl alcohol acetate is packed in the drums.

The distillation column bottom residue of phenyl ethyl alcohol acetate distillation still is subjected to sell to perfumery industry or given for co-processing in cement industry or will be send for incineration at hazardous solid waste disposal facility.

Material balance – Phenyl ethyl acetate

Overall raw materials used for proposed operations are listed below. (The majority of

raw materials are transported by tankers and trucks).

Table 2.3 Major raw material requirement, source and transport mode

No Raw Material Estimated

Quantity

Ton/Month

Likely source

of supply

Mode of transport of Raw

material to site.

(Tanker/Drums/Carboys/…

Input, Kg Output, kgFresh Acetic acid 447 Aq acetic acid (sale) 178

Recycle acetic acid 323 Crude ester for recovery 1,414

Phenyl ethyl alcohol 783

Catalyst 39

1,592 1,592

Input OutputFrom reactor 1,414 Recovered AcOH 323

To filtration 1,091

1,414 1,414

Input OutputFrom AcOH recovery 1,091 Recovered catalyst 39

To alkali treatment 1,052

1,091 1,091

From Filtration 1,052 Aq layer recycle 1,100

Sodium bi carbonate solution 1,100 Organic layer 1,052

2,152 2,152

From seperation 1,052 Product 1,000

Distillation residue 52

1,052 1,052

Filtration

Alkali treatment and seperation

Vacuum distillation

Crude ester AcOH recovery

Schematic Flow Chart for Manufacturing Process of

Product : Phenyl Ethyl Acetate

(Basis:- 1000 kg output product)

Esterification Reactor

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(Local /

Imported)

1 Propionic acid 510 Imported ISO Tank

2 o-Xylene 850 - 875 Local Tanker

3 Fuming HNO3 700 - 725 Local Tanker

3 n-Hexane 20 Local Tanker

4 m - Xylene 75 Local Tanker

5 Conc Sulphuric acid

75 Local Tanker

6 Conc./ Dilute

Nitric acid (60%

acid)

75 Local Tanker

7 4-Nitro-o-Xylene 525 Indigenous Tanker

8 Hydrogen Gas 35 Local Trolley

9 Methanol 75 Local Tanker

10 1,3-Dimethyl-2-

Nitrobenzene

13 Indigenous Drum / Tanker

11 2,4-Dimethyl-

Nitrobenzene

52 Indigenous Drum / Tanker

12 Diethyl Ketone (DEK)

225 Indigenous Drum / Tanker

13 Salicylic acid 165 Local Drum

14 Liquor ammonia, 25%

90 Local Tanker

15 Toluene 20 Local Tanker / Drum

16 1-Octanol 310 Imported ISO Tank

17 Oxygen 85 Local Cylinder

18 Benzoic acid 50 Local Bags

19 Styrene 500 Imported Tanker

20 Hydrogen

peroxide,

70%/50%/30%

400 Local ISO Tank / Tanker

21 Acetic acid 20 Local Tanker / Drums

22 Di-methyl sulfate 20 Local Tanker / Drums

Pollution generation aspects

• Gaseous emission

o From boiler / TFH stacks in the form of NOx, SO2 and PM o From operation of DG set in the form of NOx, SO2 and PM o VOC emission due to storage and handling of solvents o Process emission from stack

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• Liquid o Sewage waste o Waste water from processes o Used oil

• Solid o Waste paper, metal scrap, plastic waste, wooden waste o Discarded containers, bags, liners o Used catalyst o Distillation column residue o ETP sludge

Management and handling of various wastes will be dealt as per statutory rules.

Occupational Hazards & Safety Precautions to be taken while handling chemicals is given below.

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Table 2.4 Occupational health and safety precautions to be taken (for major chemicals)

No Chemical State color Odor Sp Gr at 20 deg C

Melting point Deg C

Boiling

point, Deg C

Flash point, Deg

C

Explosive limit

TLV ppm

Water solubili

ty

NFPA code Hazard

% LEL

% UEL

H F R

1 Propionic acid

Liquid Colorless

Not available 0.995 -20.8 141 53 2.9 12.1 10 ppm

Soluble 3 2 0 H,F

2 Benzoic acid

Solid White powder

Not available 1.26 122.4 249.2 121 NA NA NA Slightly soluble

2 1 0 H,F

3 N Hexane Liquid Colorless

Gasoline like 0.66 - 95 68 -22.5 1.15 7.5 176 mg/m

3

insoluble

1 3 0 H,F

4 O Xylene Liquid Colorless

Aromatic 0.88 -25 144.4 17 0.9 6.7 150 ppm

Insoluble

2 3 0 H,F

5 M Xylene Liquid Colorless

Not available 0.86 -47.8 139.3 25 1.1 7.0 100 ppm

Insoluble

2 3 0 H,F

5 Methanol (67-56-1)

Liquid Colorless

Alcohol like. Pungent when

crude

0.7915 -97.8 64.5 12 6 36.5 250 ppm

Soluble 1 3 0 H,F

6 Hydrogen (1333-74-

0)

Gas colorless

Odorless 0.07 -259 -253 NA 4 76 NA Not soluble

0 4 0 F

7 Toluene (108-88-3)

Liquid Colorless

sweet, pungent, benzene like

0.8636 -95 110.6 4.44 1.1 7.1 50 Soluble 2 3 0 H,F

9 Salicylic acid

Solid White Odorless 1.44 159 211 157 1.1 - Not availa

ble

Slightly soluble

0 1 0 F

10 IPA Liquid Colorles Ethanol like 2.07 -88.5 82.5 11.6 2 12.7 200 ppm

soluble 1 3 0 H,F

11 1 Octanol Liquid Colorless

Not available 0.83 -16.5 194.5 81.1 1.1 7.4 Not availa

ble

Insluble 1 2 0 H,F

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No Chemical State color Odor Sp Gr at 20 deg C

Melting point Deg C

Boiling

point, Deg C

Flash point, Deg

C

Explosive limit

TLV ppm

Water solubili

ty

NFPA code Hazard

% LEL

% UEL

H F R

12 Styrene Liquid Clear viscous

Aromatic 0.906 -30.6 145.2 31.1 1.1 6.1 50 ppm

Slightly soluble

2 3 4 H,F,R

13 Di methyl sulphate

Liquid Clear Faint 1.33 -32 188 83 3.6 23.2 0.1 ppm

Slightly soluble

3 2 0 H,F

14 Caustic lye Liquid colorless

odorless 2.1 318 1390 NA NA NA NA Soluble 3 0 1 H,R

15 Hydrogen Peroxide

Liquid colorless

Odorless 1.1 - 33 108 NA NA NA 1 ppm Soluble 2 0 1 H,R

16 Acetic acid Liquid colorless

Pungent 1.05 16.6 118.1 39 4 19.9 10 ppm

Soluble 3 2 0 H,F

17 Liquor ammonia

Liquid Colorless

Strong ammonia like

0.898 -69.2 Not availa

ble

NA NA NA 25 ppm

Soluble 2 0 0 H

18 Sulphuric acid

(7664-93-9)

Liquid Colorless

Odorless, choking odor

when hot.

1.84 -35 270 NA - - 1 Soluble 3 0 2 C,R

19 Nitric acid (7697-37-

2)

Liquid Colorless to light yellow

Acrid, disagreeable and chocking

1.408 -41.6 121 NA NA NA 4 Soluble 4 0 0 T,C

20 Caustic Lye (1310-73-

2)

Liquid Colorless

Odorless 1.53 12 140 NA NA NA 2 mg/m

3

Soluble 3 0 1 C , T

Note: For handling all above bulk chemicals, solvents & products suitable hand gloves, Full suit, Splash goggles, Dust respirators, safety shoes shall be used.

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Following onsite bulk storages are proposed at site.

Table 2.5 Bulk liquid storages (Proposed)

No Chemical Capacity of each

tank (m3)

Tank MOC

Tank ID,m

Tank height, m

1 Propionic acid 50 SS316 3.25 6.00 2 Diethyl ketone 50 SS316 3.25 6.00 3 o-Xylene 50 MS 3.25 6.00 4 Conc. Sulfuric Acid 50 MS 3.25 6.00 5 Conc. Nitric Acid (98%) / FNA 25 Aluminum 3.00 4.00 6 Spent acid sulfuric 50 MS 3.25 6.00 7 Spent acid dilute nitric 50 SS304 NAG 3.25 6.00 8 4-Nitro-o-Xylene 50 MS 3.25 6.00 9 3-Nitro-o-Xylene 50 MS 3.25 6.00

10 25% Liquor ammonia 25 MS 3.00 4.00 11 Methyl Ethyl Ketone (MEK) 5 SS316 1.65 2.45 12 m-Xylene 25 MS 3.00 4.00 13 1-Octanol / n-Octanol /1-Octene 50 MS 3.25 6.00 14 n-Octanoic acid 50 SS316 3.25 6.00 15 Styrene 50 SS316 3.25 6.00 16 Hydrogen Peroxide, 50% 25 HDPE 3.00 4.00 17 Styrene Oxide 50 SS304 3.25 6.00 18 Phenyl ethyl alcohol 50 SS304 3.25 6.00 19 Methanol 25 SS316 3.00 4.00 20 Caustic lye 25 MS 3.00 4.00 21 Toluene 50 MS 3.25 6.00

Note: All tanks will be vertically mounted.

Utilities

Electricity

RMCPL at present has sanctioned quota of 275 KVA of electrical supply which is just adequate. The proposed project will require additional 1000 KVA. The additional power requirement will be catered from DGVCL. There is one 315 KVA DG set at site for emergency requirement.

There will addition of 3 DG set of 500 KVA each for emergency power requirement.

Steam and other Energy

Boiler required to produce steam for heating / reactions / product distillation / to operate MEE for ETP, steaming jet ejectors, supporting other utility machinery. 3 No x 5 TPH of steam with dryness fraction >0.97, steam pressure at 10 kg/cm2 and temperature 1800C. 2 operational and 1 as standby Gas fired boiler is proposed.

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• General Hot oil unit Hot oil unit required for heating / reactions / product distillation / to operate MEE for ETP / ZLD unit having ATFD. 3 No x 5 million kcal/hr unit capable of producing Hot oil at 3000 C. Hot oil circulation rate at 150 m3/h. 2 operational and one as standby Gas fired hot oil unit is proposed. • High Temperature Hot oil unit Hot oil unit required for heating / carrying out reactions using fixed bed catalytic reactors. 2 No x 1.5 million kcal/h unit capable of producing Hot oil at 3600 C. Hot oil circulation rate at 100 m3/h. 2 operational Gas fired hot oil units are proposed. Estimated fuel requirement shall be as follows:

Table 2.6 Consolidated Estimated Fuel Requirement

Fuel for No of units Type of Fuel Estimated fuel quantity

Steam generation boiler (5 TPH each at 10 barg)

2 + 1 = 3(2 operational

and one standby)

Natural Gas 2 x 338 Nm3/hr

General Hot oil generator (5 Million Kcal/hr each) (Hot oil at 300 deg C with 150 m3/hr circulation)

2 + 1 = 3(2 operational

and one standby)

Natural Gas 2 x 692 Nm3/hr

High temperature Hot oil generator (1.5 Million Kcal/hr each) (Hot oil at 360 deg C with 100 m3/hr circulation)

2 (2 operational)

Natural Gas 2 x 194 Nm3/hr

Emergency power generation set (500 KVA x 3 Nos)

3 (Emergency use only)

Natural Gas 3 x 150 Nm3/hr

Existing Water requirement and waste water generation

Existing water requirement as per Consent order number (AWH-75308 dated 01.02.2016 valid till 05.10.2020) is as follows,

Table 2.7 Existing water requirement

No Description Proposed (cmd) 1 Domestic 7 2 Industrial Processing and other ancillary operations 374.5 3 Gardening 24 Total 405.5

Table 2.8 Existing waste water generation and disposal

No Description Proposed (cmd) Treatment and Disposal 1 Domestic effluent 5.58 Sewage effluent is treated/disposed

through septic tank/soak pit system. 2 Trade effluent 0 There is no waste water generation at

site.

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Total 5.58 -

Proposed additional water requirement and waste water generation

Water requirement for proposed expansion is about 508 cmd for domestic, process, cooling tower, and boiler and for green belt maintenance purpose. It will be sourced from GIDC (and partly by recycle). The source is dependable and reliable.

Fresh water requirements and waste water generation for proposed production is presented in table below.

RMCPL has applied for water assurance letter from GIDC for its water requirement. Copy of water application made from GIDC is attached (Refer Annexures -2.3).

Computation of water requirement for proposed establishment is summarized below

Table 2.9 Proposed additional water requirement (Fresh + recycle)

No Description Proposed (cmd) 1 Domestic 16 2 Industrial Processing 86 3 Cooling Tower and Boiler 278 4 Gardening 128 Total 508

Table 2.10 Proposed additional water generation and disposal

No Description Proposed (cmd) Treatment and Disposal 1 Domestic effluent 12 It will be treated at STP and treated

waste water will be used for gardening. 2 Trade effluent 147 It will be treated and will be reused;

There will be no discharge outside. Total 159 -

Total water requirement and waste water generation

Water requirement and waste water generation post expansion shall be as follows,

Table 2.11 Total water requirement after expansion

No Description Existing (cmd)

Proposed (cmd)

Total (cmd)

1 Domestic 7 16 23 2 Industrial Processing 374.5 86 738.5 3 Cooling Tower and Boiler 278 4 Gardening 24 128 152 Total 405.5 508 913.5

Table 2.12 Total waste water generation after expansion

No Description Existing (cmd)

Proposed (cmd)

Total (cmd)

Treatment and Disposal

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1 Domestic effluent

5.58 12 17.58 It will be treated at STP and treated waste water will be used for gardening.

2 Trade effluent

0 147 147 It will be treated and will be reused; There will be no discharge outside.

Total 5.58 159 164.58 -

Manpower requirement

Expected manpower requirement for the site shall be as follows

Table 2.13 Expected manpower details

Description Existing, No Proposed, No Total, No Permanent 23 25 48

Contract 35 75 110 Total 58 100 158

Environmental Aspects

Effluent generation from the proposed project shall be from domestic, processing, cooling tower /Boiler blow down, equipment washing, floor wash etc. The effluent generated shall be treated in effluent treatment plant facility and treated effluent shall be used as cooling tower make up or for gardening use. There will be no discharge outside.

Proposed effluent treatment scheme and details are described in Chapter 4 under “Water environment”

Nonhazardous and hazardous waste generation from the proposed activity is given below:

Table 2.14 Proposed Non hazardous waste generation and disposal

Sr No

Type of Waste Quantity UOM Mode of Disposal

1 Waste paper / corrugated boxes

1 TPA Sale to scrap dealer / recycler

2 Metal scrap 3 TPA

3 Plastic waste 2 TPA 4 Wooden waste 2 TPA

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Table 2.15 Proposed Hazardous waste generation and disposal

No Waste Type

Category Existing quantity

as per CCA No

AWH 75308

Proposed quantity

Quantity after

expansion

Mode of disposal

1 Used or spent Oil

5.1 1000 Kg/Year

1000 Kg/Year

2000 Kg/year

Disposal by sale to registered

refiners 2 Discarded

container bags

/Liners

33.1 6.03 MT/Year

10.0 MT/Year

16.03 MT/Year

Collection, storage, reuse

and decontamination.

3 Used Catalyst

29.5 - 1.25 Ton/Month

1.25 Ton/Month

Used catalyst will be sent to solid waste disposal

facility or can be used for

preparation of bricks.

4 Used / Spent

Catalyst (Transition

metal)

29.5 - 5000 Kg/year

5000 Kg/year

Used catalyst will be send to

supplier for re-activation of

catalyst. 5 Process

waste /Distillation

column residue

29.1 - 95 Tons/Month

95 Tons/Month

Will be sent to common

hazardous waste incineration

facility 6 Chemical

sludge from waste water

treatment

35.3 - 100 MT/Year

100 MT/Year

CHWTSDF

7 Used Empty Barrels /

Liners

33.1 - 1000 Nos/Year

1000 Nos/Year

Sale to Authorized party

RMCPL will formulate system for monitoring of stacks, ambient air quality, work place monitoring, untreated and treated effluents through third party laboratory recognized by MOEF&CC.

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Proposed In-house Monitoring Capabilities

The facility will establish in-house quality control lab for waste water quality parameter monitoring and other environmental related parameter monitoring.

Management System

This unit will adopt good manufacturing practices and other management systems such as ISO 14001 & ISO 18001 so as to identify safety, health and environment aspects and impacts as per the standard.

The processes of manufacture intended chemicals are well established and hence risk of technological failure is minimal for proposed product manufacturing.

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DESCRIPTION OF THE E NVIRONMENT

Every anthropogenic activity has some impact on the environment. More often it is harmful to the environment than individual. Consequently, there is a need to harmonize developmental activities with the environmental concerns. Environmental Impact Assessment (EIA) 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 baseline data on the pre-installation status of the terrestrial environment covering Land environment, biological environment (flora & fauna) & socio-economic environment in the study area is collected by undertaking Primary surveys through field visits, monitoring and laboratory analysis. Secondary data is collected from relevant agencies, such as Bharuch district town Planning, Forest Department and Directorate of Census Operations. The baseline data collected and generated, together with the relevant project activities will be considered for predicting the likely impacts of the project on the environment. Subsequently, an appropriate environmental management plan (EMP) will be presented to enable the project proponent to run the project within acceptable level of environmental impact and meet the compliance of the regulatory criteria (MOEF&CC’s Guidelines). An Environmental Impact Statement (EIS) will be ultimately made to summarize the post project status of the terrestrial environment, with the project proponent incorporating the suggested EMP measures. For the purpose of assessing the impacts, study area of 10 km radius around project site is identified for the EIA as per MOEFCC guidelines.

Land Environment

The geographical location of this Industry is at 210 32’ 43.19” N Latitude and 730 0’ 1.81’’ E Longitude.

The proposed expansion is on the existing location at plot no. 23 of GIDC Panoli, Dist Bharuch.

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Figure 3.1 Image showing site & 1 km study area

Figure 3.2 Image showing site & 10 km study area

The site has good connectivity due to NH8 which is only 0.4 km away from project site. The western railway is also well connected to the Panoli station. A part of the Panoli Industrial Estate is a Special Economic Zone for the pharmaceutical industry. The industrial estate has direct access to the Port of Dahej and Hazira Port.

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This proposal envisages establishment of synthetic organic chemicals manufacturing by M/s. Reshmika Minerals & Chemicals Pvt. Ltd. (RMCPL) at Panoli, Gujarat.

RMCPL has conducted a market survey and based on recommendations thereof it is proposed to undertake an establishment project wherein manufacture of organic intermediate can be produced.

The district has a tropical savanna climate (under Köppen's Climate classification), moderated strongly by the Arabian Sea. The summer begins in early March and lasts until June. April and May are the hottest months, the average maximum temperature being 40 °C (104 °F).

Monsoon begins in late June and the area receives about 800 mm (31 inch) of rain by the end of September, with the average maximum temperature being 32°C (90°F) during those months. October and November see the retreat of the monsoon and a return of high temperatures until late November.

Winter starts in December and ends in late February, with average temperatures of around 23°C (73 °F).

Very often heavy monsoon rain brings floods in the Narmada basin area.

Panoli GIDC estate is set up by Gujarat Industrial Development Corporation to boost the industrial growth in this region. The estate is spread over approximately 1057 hectares and various types of industries like chemicals, pharmaceuticals, pesticides, Dyes and Intermediates, Textiles, Engineering etc. comprise the texture of the estate.

A huge water reservoir with a complete set of filtration plant, water pumps, distribution lines etc. is provided to cater the water requirement of the industries. A well planned effluent conveying system is also established in this GIDC estate which is a unique and environmentally safe mode of disposal of the effluent generated by Chemical industries.

A common effluent treatment plant – Panoli Enviro Tehcnology Ltd., is in operation since 2001 to cater the needs of comprehensive treatment of effluent for the small scale chemical industries. For safe disposal of solid and hazardous waste generated by the industries, a secured land fill site is also planned which awaits environmental clearance from GPCB. All other required infrastructures are in place with well-connected roads and Notified Area Authority.

The expansion will come up in existing complex of the company situated on GIDC land. Initially RMCPL will produce at least 2 products at a time depending upon market needs. The tonnage involved could be 200 – 400 TPM which may go upto 1000 TPM. The project is envisaged on16,500 sq.mtr. of area out of 89632.72 sq.mtr. of total plot area. The intermediates identified by RMCPL will be mainly produced to bridge the gap between demand and supply. Also, the innovative technologies when commercialized will also give an opportunity to substitute imports so that valuable foreign exchange can be saved. The proposal will also generate job opportunities for locals.

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The initiative taken up by RMCPL is mainly due to strategic direction of Govt. of India viz. Make in India.

Definition of LULC Classes as per the Ministry of Statistics and Programme Implementation (MOSPI) is given in the following table.

Table 3.1 Definition of LULC Classes

No Class Class Definition

1. Dense

Vegetation

It is an area (within the notified forest boundary) bearing an association predominantly of trees and other vegetation types capable of producing timber and other forest produce.

2.

Semi-evergreen /

Moderate Dense

vegetation

It is described as a forest, which comprises of thick and dense canopy of tall trees, which predominantly remain green throughout the year. It includes both coniferous and tropical broad-leaved evergreen trees. Semi-evergreen forest is a mixture of both deciduous and evergreen trees but the latter predominate

3. Degraded

Vegetation It is described as a forest where the vegetative (crown) density is less than 30% of the canopy cover.

4. Secondary Vegetation

It is described as openings amidst forests without any tree cover. It includes openings of assorted size and shapes as seen on the imagery.

5. Scrub Land Scrub is a stunted tree or bush/shrub.

6. Agriculture It is defined as the land primarily used for farming and for production of food, fiber, and other commercial and horticultural crops. It includes land under crops (irrigated and un-irrigated), fallow, plantation, etc.

7. Fallow Land

It is described as agricultural land which is taken up for cultivation but is temporarily allowed to rest un-cropped for one or more seasons, but not less than one year. These lands are particularly those which are seen devoid of crops at the time when the imagery is taken of both seasons.

8 Plantation

It is described as an area under agricultural tree crops, planted adopting certain agricultural management techniques. It includes tea, coffee, rubber, coconut, areca nut, citrus, orchards and other horticultural nurseries.

9. Quarry Mine / quarry areas subject to removal of different earth material (both surface and sub-surface) by manual and mechanized operations.

10. Open land It is described as openings amidst forests without any tree cover. It includes openings of assorted size and shapes as seen on the imagery.

11. Residential Area (Urban/Rural)

It is defined as an area of human habitation developed due to non-agricultural use and that which has a cover of buildings, transport, communication utilities in association with water vegetation and vacant lands.

12. Industrial Area

It is defined as an area of industrial activities.

13. Mangrove It is described as a dense thicker or woody aquatic vegetation or forest cover occurring in tidal waters near estuaries and along the confluence of delta in coastal areas.

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No Class Class Definition

14. Water body/ River

It is a course of flowing water on the land along definite channels. It includes from a small stream to a big river and its branches. It may be perennial or non-perennial.

15. Reservoir It is a natural or man-made enclosed water body with a regulated flow of water. Reservoirs are larger than tanks/lakes and are used for generating electricity, irrigation and for flood control.

A Survey of India (SOI) Open series map with 1:50,000 scale is used to identify topographic features within 10 km radius around project site is shown in figure below, (Refer Annexure 3.1)

Figure 3.3 Survey of India OSM showing study area around project site

A detailed study area map for the study area is prepared (See above figure) that indicates roads, railways, major settlements, rivers and tehsil boundaries. The project site is located in the Ankleshwar Tehsil, 10.0 km south of Ankleshwar. This site has good connectivity due to NH8 which is only 0.4 km away from Panoli GIDC. The western railway is also well connected to the Panoli station. A part of the Panoli Industrial Estate

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is a Special Economic Zone for the pharmaceutical industry. The industrial estate has direct access to the Port of Dahej and Hazira Port. The site is well connected.

The area distributions along with percentage distribution of the different LULC classes within the study area are shown in table and figure below.

Agricultural Plantation (32.53%) and Agricultural Crop Land (27.03%) dominate the land use pattern within the 10 km angular distance around project site.

It is followed by Fallow Land contributing 18.31%. Barren/ Unculturable waste/ Scrub Land is about 9.52% and Built up Land is 5.10% whereas part of land is Industrial Land (6.9%) and part is Waterbody (0.61%).

Table 3.2 Landuse/ Landcover Statistics of the 10 km radius Area

Sr. No. LULC Class Area (Sq. Km)

Distribution (%)

1 Agricultural Plantation 102.19 32.53 2 Agricultural Crop Land 84.90 27.03 3 Fallow Land 57.51 18.31 4 Barren/ Unculturable waste/ Scrub

lands 29.92 9.52

5 Builtup Land 16.02 5.10 6 Industrial Land 21.68 6.90 7 Waterbody 1.93 0.61 Total 314.30 100.00

Figure 3.4 Landuse/landcover statistics of 10 km radius area around Project Site

A landuse landcover map covering 500 m angular distance around project site is shown in Figure below. The map shows 3 different landuse classes. The area distributions along with percentage distribution of the different LULC classes within the study area of 1 km surrounding the site are given in table below.

Most of the area around the site is Built Up land which is about 54.9% and dominates the landuse pattern around 500 m angular distance from the project site. Scrub land is about 40.4% whereas area under Tree Plantation is about 4.7%.

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Table 3.3 LULC Statistics of the 1 km angular distance around project site

Sr. No.

LULC Class Area (Sq. Km)

Distribution (%)

1 Industrial Land 1.82 57.96 2 Crop Land 0.93 29.62 3 Barren/ Unculturable waste/ Scrub

lands 0.39 12.42

Total 3.14 100.00

Figure 3.5 LULC statistics of 500 m angular distance around Project Site

Drainage layer is generated after scanning the thematic manuscripts which is further edited for line errors. Two different layers are made separately for line drainage. Drainage order was given to all the drain lines in the layer.

Strahler’s method of ordering is used for giving order to drainage, wherein the smallest permanent streams are designated as the first order and the confluences of two first order streams give rise to second order stream and so on. The order of trunk stream is not altered by the addition of lower order. The order of the stream will increase only by the addition of streams of same order.

It can be seen from the Drainage Map of 10 km surrounding the site and the DEM with the drainage map of 10 km surrounding the site that first, second and third order streams and small rivulets run from around the site. The Narmada canal runs from the west of the site.

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nn

Figure 3.6 Drainage map of 10 km radius area around Project Site

Refer Annexure 3.2 for detailed LULC report.

Soil quality reflects how well a soil performs the functions of maintaining biodiversity and Productivity, partitioning water and solute flow, filtering and buffering, nutrient cycling, and providing support for plants and other structures. Soil management has a major impact on soil quality. Representative soil samples are collected from the study area to assess the quality of soil. For studying the soil types and the soil characteristics, different sampling locations are selected to assess the existing soil condition representing various land use condition and geological features.

Methodology of Soil Monitoring

A number of parameters are determined, which are indicative of physical, chemical and fertility characteristics. Sampling and analysis is conducted as per established standard methods and procedures prescribed in IS 2720 and ASTM standards. Soil samples are collected by ramming a hand auger into the soil upto a depth of 90 cm. At each of the sampling location, soil samples are collected from three different depth viz. 30 cm, 60 cm and 90 cm below the surface and homogenized. The homogenized samples are then packed in a polythene plastic bag, sealed and the sealed samples were sent to the Laboratory for analysis.

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The project will be located within GIDC Panoli. Most of the land is back filled & leveled at site. The sampling locations are chosen based on their proximity to the project site. The parameters selected give basic information on type of soil, particle size distribution and water retention.

Soil Monitoring Locations

Figure below shows the soil sampling locations in the impact area map.

Figure 3.7 Soil sampling locations in 10 km study area

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Table 3.4 Soil Analysis report

Parameters

Location Analysis Method

Project

Onsite

Umarwada

village

Alonj

village

Panoli

village

Borsara

village

Kharod

village

Bhadi

village

Bakrol

village

Particle size

(%)

Clay 9.0 12.64 18 20 10.20 13.50 14 10 IS-2720 (part 4) 1985

Silt 30.08 29.51 33.20 29.80 39.30 30.50 33.80 28

Fine sand 60.20 41.12 51.25 49.80 49.50 44.2 48 64

pH 7.82 8.09 8.14 7.78 8.02 8.22 8.06 7.22 IS-2720 (part 26) 1987

Moisture content % 9.57 2.9 12.92 11.34 8.73 11.69 6.20 13.16 IS-9235-2005

Texture Sandy

Loam Silt Loam Loam Loam Silt Loam

Silt

Loam

Silt

Loam

Sandy

Loam

IS-2720 (part 4) 1985

Water holding capacity (%) 57.71 49.28 62.76 54.62 74.01 58.21 42.62 59.24 IS-14765-2000

Chloride (mg/Litre) 2 1.6 1.2 1 1.6 1.8 2.2 1 IS-3025 (Part 32) 1988

Sulphate (mg/kg) 48.62 109.87 12.25 12.37 32.25 31.25 99.12 109.12 IS-2720 (part 27) 1977

K (kg/Hectre) 220 260 300 310 240 190 240 230 IS-3025 (Part 45) 1993

TKN % 4.9 6.16 4.48 3.36 5.04 6.44 8.12 4.62 IS-14684-2008

Phosphorus (kg/Hectre) 21.25 31.06 22.89 26.16 34.33 29.43 22.07 24.52 IS-3025(Part 31)2009

TOC (%) 0.36 0.26 0.32 0.39 0.30 0.47 0.64 0.70 IS-2720(part 22)2010

Conductivity µS/cm 283 363.8 279.2 308.2 436.8 280.3 368.5 530 IS-14767-2000

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Table 3.5 Standard Soil Classification

No Soil Test Classification

1 pH Less than 4.5 : Extremely acidic

4.51 – 5.50 : Very strongly acidic

5.51 – 6.00 : Moderately acidic

6.51 – 7.30 : Neutral

7.31 – 7.80 : Slightly alkaline

7.81 – 8.50 : Moderately alkaline

8.51 – 9.00 : Strongly alkaline

9.01 and above: Very strongly alkaline

2 Salinity Electrical

conductivity (µmhos/cm)

(1 ppm = 640 µmhos/cm)

Up to 1.00 : Average

1.01 to 2.00 : Harmful to germination

2.01 to 3.00 : Harmful to crops (sensitive to salts)

3 Organic Carbon (%) Up to 0.2 : Very less

0.21 to 0.40 : Less

0.41 to 0.50 : Medium

0.51 to 0.80 : On an average sufficient

0.81 to 1.00 : Sufficient

> 1.0 : More than sufficient

4 Nitrogen (Kg/Ha) Up to 50 : Very less

51 – 100 : Less

101 – 150 : Good

151 – 300 : Better

More than 300 : Sufficient

5 Phosphorous (Kg/Ha) Up to 15 : Very less

16 – 30 : Less

31 – 50 : Medium

51 – 65 : On an average sufficient

66 – 80 : Sufficient

More than 80 : More than sufficient

6 Potash (Kg/ha) 0 – 120 : Very less

121 – 180 : Less

181 - 240 : Medium

241 - 300 : Average

301 – 360 : Better

More than 360: More than sufficient

Source: Handbook of Agriculture, Indian Council of Agricultural Research

Observation and interpretation from results:

• Soil at Project site and Bakrol is sandy loam in nature, At Alonj and Panoli village Loam in nature and at Umarwada, Barsara, Bhadi and Kharod village is slit loam in nature.

• Water holding capacity varies from 42.62 % to 62.76 %.

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• pH of soil varies from 7.22 to 8.22 which is “Neutral” to “Moderately alkaline” in nature.

• Conductivity of soil is observed within range of “Average” i.e. from 280.3 µS/cm to 530 µS/cm.

• Potassium content in the soil samples varies from 220 kg/Ha to 310 kg/Ha which is in range of “average” to “better” range.

• % TOC is observed in range of 0.26% to 0.70% which is from “less” to on an average sufficient.

• Phosphorus content in the soil is varies from 21.25 kg/Ha to 34.33 kg/Ha which is from “Less” to “medium” range.

Solid/Hazardous Waste Generation, Treatment and Disposal

At site there is inorganic chemicals manufacture as per Consent authorization. Hazardous waste generation and disposal during 2017-18 as per form 4 is as follows,

No Waste Type Category Existing quantity as per CCA No

AWH 75308

Quantity during 2017-

18

Mode of disposal

1 Used Oil 5.1 1000 Kg/Year

Nil Disposal by sale to registered refiners

2 Discarded container

bags /Liners

33.3 6.03 MT/Year

Nil Collection, storage, reuse and

decontamination. 3 Discarded

bags - - 21005 kg Sold to authorized

recycler

Ref : Form 4 and RMCPL letter dated 20.06.2018

The project is proposed establishment and currently there is no Solid/Hazardous Waste Generation, Treatment and Disposal at the site as per Consent condition for existing

inorganic product.

Climate and Meteorology

The meteorology of the site and nearby areas is affected primarily by the presence of Coast line about 43 km to the west of site. The prevailing micrometeorology at project site plays a vital role in transport and dispersion of air pollutants released into atmosphere. The persistence of the predominant wind direction and wind speed class during a particular time period at the project site will decide the direction and extent of

the worst impact zone at that time. The prominent wind direction at project site during the study period (Summer 2018) was from west, North West and southwest with 76.1 % calm conditions.

The wind speed in the project site remained high with drifting directions. The wind direction also has variations during daytime and nighttime.

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Maximum wind speed was 6.2 m/sec in the month of March 2018, while the average wind speed was 1 m/sec. Maximum wind speed was 4.8 m/sec in the month of April 2018, while the average wind speed was 0.7 m/sec. Maximum wind speed was 4.6 m/sec in the month of May 2018, while the average wind speed was 1 m/sec. Wind roses for the study period indicate the average predominant wind direction was found to be SW and W during the study period.

Wind rose diagram for project site is presented in Figure below, (which shows predominant wind direction at site during the summer season)

Figure 3.8 Wind Rose for summer 2018 season

The weather of Bharuch district is hot and dry-starting from mid-march till mid-June, during summer season weather remains hot and dry. While from mid-June till end of September weather remains humid and can be considered pleasant. From October-November weather is bit hot. From December to February climate remains cool. May is the warmest month of the year. The temperature in May averages 33.1 °C. At 21.9 °C on average, January is the coldest month of the year. (Ref : https://en.climate-data.org/location/24419/)

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Figure 3.9 Temperature variation at Bharuch

Monitored temperature data for the summer season 2018 is presented below,

Table 3.6 Temperature and Humidity Summer 2018

Month Temperature in 0C Humidity %

Minimum Average Maximum Minimum Average Maximum March 19.6 29.0 41.8 14 52 98 April 22.1 30.5 42.6 14 65 96 May 25.5 31.5 42.7 25 70 91

Rainfall The climate here is tropical. When compared with winter, the summers have much more rainfall. This climate is considered to be Aw according to the Köppen-Geiger climate classification. The average temperature in Bharuch is 27.9 °C. The average annual rainfall is 873 mm. The driest month is February, with 0 mm of rain. In July, the precipitation reaches its peak, with an average of 299 mm. (Ref: https://en.climate-data.org/location/24419/)

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Figure 3.10 Monthwise temperature and rainfall profile at Bharuch

Air Environment

The prime objective of this AAQ study is to establish the existing regional background levels within study zone of proposed project. Major sources of air pollution are identified as Large, medium and small-scale units spread over surrounding 10 km area (parts of Industrial Area) & traffic on GIDC Road and other roads near site.

Other miscellaneous sources are identified as Fuel burning and dust from movement of traffic along roads and brick kilns.

GIDC Panoli is a notified chemical industrial and has large/ medium and small scale industries.

The baseline environment monitoring is carried out onsite and surrounding area within 10 km for summer 2018 season.

The datewise AAQ data presented in Annexure 3.3.

Currently there is no fuel burning source at proposed project site.

Ambient air quality status within the study area forms the baseline information over which the predicted impacts due to the proposed activities are to be superimposed the

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ambient air quality is assessed through a scientifically designed ambient air quality monitoring network based on the following considerations:

• Meteorological conditions on synoptic scale.

• Topography of the study area.

• Representations of regional background levels.

• Representations of plant site.

• Representations of predominant and cross sectional distribution in the downward direction.

• Inclusion of population zone and sensitive receptors including reserve forests to collect baseline.

Ambient Air Quality Monitoring (AAQM) stations are set up at 8 locations with due consideration of above mentioned points. Table below and Figure overleaf give details of AAQM stations selected.

The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, CO, nMHC, and NH3 at 8 locations in Summer 2018(March, April, and May). PM10, PM2.5, SO2, NOx, are

monitored on 24 hourly basis & NH3 is monitored on 8 hourly basis using respirable High Volume Sampler and standard methods prescribed by APHA/IS.

CO is monitored using hand held electronic meter (electro-chemical sensor).

Table and Figure below give locations of air monitoring stations bearing w.r.t. the site.

Table 3.7 Details of Ambient Air Monitoring Stations

Sr.

No.

Location X UTM

Co

ordinate,

m

Y UTM

co ordinate,

m

Distance &

Direction

w.r.t site

Reason for

selection

1 Project site 292865 2383803 - Project Site

2 Sanjali Village 292909 2384820 1.5 km to NW Village near site

GIDC

3 Bakrol Village 294002 2386637 3 km to NE Downwind

4 Bhadi village 296135 2384472 3.2 km to E Downwind

5 Borsara village 292110 2381672 2.3 km to S Upwind

6 Alonj village 288355 2384883 4.7 km to W Upwind

7 Umarwada

village

290557 2387383 4.3 km to NW Upwind

8 Kharod village 294762 2383299 1.8 km to E Downwind

UTM: Universal Transverse Mercator co ordinates

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Figure 3.11 AAQ sampling locations

Figure 3.12 Photographs of AAQ monitoring

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Table 3.8 Summarized AAQM Results- Summer season 2018

Note: Detection limit for nMHC is 0.1 ppm

Sampling Location

Parameter PM10 (μg/m3)

PM2.5 (μg/m3)

SO2 (μg/m3)

NOx (μg/m3)

CO (mg/m3)

NH3

(µg/m3) nMHC (ppm)

Project site

Min 80.5 28.4 10.0 16.0 0.90 18.0 BDL

Average 87.1 35.0 15.8 21.7 1.14 22.3 BDL

98th Percentile 95.0 42.8 22.1 28.2 1.4 27.1

BDL

Max 95.3 43.1 22.3 28.6 1.39 27.1 BDL

Sanjali village

Min 76.0 32.0 5.0 8.0 0.21 3.12 BDL

Average 82.3 39.1 9.5 12.6 0.35 6.09 BDL

98th Percentile 89.2 46.0 14.1 17.3 0.5 8.7

BDL

Max 89.4 46.1 14.2 17.8 0.47 9.01 BDL

Bakrol village

Min 68.0 21.0 9.3 13.2 0.33 7.2 BDL

Average 75.4 27.9 14.5 18.4 0.45 10.1 BDL

98th Percentile 84.3 37.1 19.7 24.1 0.6 12.6

BDL

Max 84.6 37.4 20.1 24.2 0.59 12.7 BDL

Bhadi village

Min 64.0 18.6 3.2 6.1 0.28 9.2 BDL

Average 75.1 31.7 7.2 10.1 0.42 12.0 BDL

98th Percentile 88.0 43.5 11.9 15.0 0.5 15.0

BDL

Max 90.4 43.7 12.1 15.7 0.53 15.2 BDL

Borsara village

Min 75.2 26.1 14.1 20.2 0.63 10.3 BDL

Average 82.2 32.9 19.7 25.7 0.70 13.9 BDL

98th Percentile 89.7 41.0 25.9 32.0 0.8 17.3

BDL

Max 90.1 41.4 26.1 32.4 0.78 17.3 BDL

Alonj village

Min 79.2 22.5 12.2 18.1 0.25 5.2 BDL

Average 85.0 28.1 17.9 23.8 0.37 7.7 BDL

98th Percentile 91.0 35.2 24.1 30.6 0.5 10.2

BDL

Max 91.4 35.6 24.1 30.6 0.50 10.2 BDL

Umarwada village

Min 55.0 14.2 15.2 19.2 0.17 3.52 BDL

Average 65.7 23.8 19.3 23.4 0.26 5.74 BDL

98th Percentile 77.8 30.9 24.0 27.6 0.3 8.1

BDL

Max 78.5 31.6 24.6 27.9 0.35 8.21 BDL

Kharod village

Min 73.1 24.6 10.2 15.1 0.41 8.32 BDL

Average 79.8 30.1 13.8 18.7 0.52 11.57 BDL

98th Percentile 87.8 37.0 17.0 22.1 0.6 14.3

BDL

Max 88.3 37.8 17.1 22.4 0.65 14.75 BDL

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Table 3.9 National Ambient Air Quality Standards (CPCB, 2009)

Sr. No.

Pollutant Time

weighted Average

Concentration in ambient air

Industrial, Residential,

Rural and other area

Area

Ecologically sensitive

Area (Notified by

Central Government

Method of measurement

1 Sulphur Dioxide (SO2), µg/m3

Annual * 50 20 - Improved West & Gaeke - Ultraviolet fluorescence 24

Hours** 80 80

2 Nitrogen Dioxide (NO2), µg/m3

Annual * 40 30 -Modified Jacob & Hochheiser

(Na- Arsenite) - Chemiluminescence

24 Hours**

80 80

3 Particulate Matter (PM10, µg/m3)

Annual * 60 60 - Gravimetric - TOEM - Beta attenuation

24 Hours**

100 100

4 Particulate Matter (PM2.5, µg/m3)

Annual * 40 40 - Gravimetric - TOEM - Beta attenuation

24 Hours**

60 60

24 Hours**

1.0 1.0

5 Carbon monoxide (CO), (mg/m3)

8 hours** 2 2 - Non-Dispersive Infra-Red (NDIR) spectroscopy

1 hours* 4 4

6 Ammonia (NH3), µg/m3

Annual * 100 100 - Chemiluminescence - Indophenol blue method

24 Hours**

400 400

7 Benzene (C6H6), µg/m3

Annual* 5 5 -Gas Chromatography (GC) based continuous analyzer -Adsorption & desorption followed by GC analysis

(*) Annual arithmetic mean of 104 readings (**) 24 hourly or 8 hourly or 1 hourly reading to be complied 98% time

Observations from results:

Results are compared with National Ambient Air Quality Standards (NAAQ) in respect of monitored parameters as shown in above table.

• Average concentration of PM10 ranges from 65.7 μg/m3 to 87.1 μg/m3. It is noted that the PM10 results are within permissible limit of 100 μg/m3 for 24 Hrs.

• Average concentration of PM2.5 ranges from 23.8 μg/m3 to 39.1 μg/m3. It is noted that the PM2.5 results are within permissible limit of 60 μg/m3 for 24 Hrs.

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• Average concentration of SO2 ranges from 7.2 μg/m3 to 19.7 μg/m3. It is noted that the SO2 results are within permissible limit of 80 μg/m3 for 24 Hrs.

• Average concentration of NOx ranges from 10.1 μg/m3 to 25.7 μg/m3. It is noted that the NOx results are also within permissible limit of 80 μg/m3 for 24 Hrs.

• Average concentration of CO ranges from 0.26 mg/m3 to 1.14 mg/m3. It is noted that the CO results are also within permissible limit of 4 mg/m3 for 24 Hrs.

• Average concentration of ammonia ranges from 5.74 μg/m3 to 22.3 μg/m3. It is noted that the ammonia results are also within permissible limit of 400 μg/m3 for 24 Hrs.

• Average concentration of nMHC is found to be below detectable limit.

With Comparison of NAAQ standards, Ambient Air monitoring results are below the specified norms.

Noise Environment

Noise levels are monitored at proposed project site and nearby villages to judge impact of industrialization and transportation on ambient noise levels.

The reports are as below:

Table 3.10 Noise Monitoring Results (Summer 2018)

Sr. No.

Location/ Date of survey Noise Level dB(A)

Day Time Norms* Night Time

Norms*

Land Use: Industrial 1 On site 73.1 75 68.6 70

Land Use: Residential 2 Sanjali Village 52.7

55

43.2

45

3 Bakrol Village 51.9 41.0 4 Bhadi village 48.6 42.1 5 Borsara village 50.8 44.5 6 Alonj village 52.3 44.7 7 Umarwada village 47.4 42.9 8 Kharod village 49.5 43.8

(*) Standard as prescribed in Schedule II of the Environment Protection Act, 1986.

Note: Day Time: 06.00 am to 10.00 pm, Night Time: 10.00 pm to 06.00 am

Observations from results:

Industrial area: From above results it is observed that noise level at project site location

is within standards.

Residential area: From above results it is observed that noise level at villages monitored are within standards.

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Water Environment

The proposed project is establishment of organic chemicals manufacturing facility. Presently the plant facility at site is for manufacture of in organic chemicals and water for that is sourced from GIDC. During construction & operation phase water will be sourced from existing supply at site i.e. from GIDC.

The project is to be located in notified chemical zone of GIDC Panoli area, Dist Bharuch.

The fresh water will be sourced from GIDC’s water works.

Fresh water available in the study area is from Tap water, Borewells, Dug well.

Selected physico-chemical characteristic along with biological indicators of pollution are used to describe the baseline status of water environment and assessing impacts due to proposed project activities.

Ground Water

Ground water monitoring was done during summer 2018 period. The sampling locations & results presented below,

Figure 3.13 Ground water sampling location

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Table 3.11 Ground water analysis results Sr. No Parameter Locations Limits as per IS

10500:2012 Borewell water Drinking water Desirable Permissible

Panoli Village

Alonj Village

Umarwada village

Kharod village

Bhadi village

Bakrol village

Borsara GIDC

Onsite GIDC

1 Colour, Hazen < 5 < 5 < 5 < 5 < 5 < 5 < 5 < 5 5 15 2 Conductivity,µS/cm 610 1455 3624 495 2100 2293 451.3 260.8 -- -- 3 Odour Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 4 pH 7.92 8.36 8.24 8.18 8.14 7.7 7.78 7.46 6.5 - 8.5 No Relaxation 5 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 6 Turbidity, NTU BDL BDL BDL BDL BDL BDL BDL BDL 1 5 7 TDS, mg/l 380 930 2270 280 1240 1220 300 170 500 2000 8 Aluminium, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.03 0.2 9 NH3(as N), mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.5 No Relaxation

10 Detergents, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.2 1 11 Barium, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.7 No Relaxation

12 Boron, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.5 1

13 Calcium, mg/l 41.6 120 160 60 232 200 37.2 8.8 75 200 14 Chloramines, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 4 No Relaxation

15 Chlorides, mg/l 280 440 BDL 220 480 450 220 120 250 1000 16 Copper, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 1.5

17 Fluoride, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 1 1.5

18 Free Res Cl2, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.2 1

19 Iron, mg/l 0.09 0.09 0.1 0.06 0.04 0.09 0.05 0.01 1 No Relaxation

20 COD mg/l 39 68 157 38 40 29 60 40 -- --

21 Magnesium, mg/l 13.9 43.2 37.6 19.6 67.3 67.2 15.8 4.32 30 100 22 Manganese, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.1 0.3 23 Mineral oil, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.5 No Relaxation

24 Nitrate, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 45 No Relaxation

25 Phenolic com, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.001 0.002

26 Selenium, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01 No Relaxation

27 Silver, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.1 No Relaxation

28 Sulphate, mg/l 58 180 374 48 196 123 58 32 200 400 29 Sulphide, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 No Relaxation

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Sr. No Parameter Locations Limits as per IS 10500:2012

Borewell water Drinking water Desirable Permissible Panoli Village

Alonj Village

Umarwada village

Kharod village

Bhadi village

Bakrol village

Borsara GIDC

Onsite GIDC

30 Alkalinity, mg/l 462 500 360 240 560 304 336 108 200 600 31 Hardness, mg/l 162 480 640 232 860 780 318 40 200 600

32 Zinc, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 5 15 33 Cadmium, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.003 No Relaxation

34 Cyanide, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 No Relaxation

35 Lead, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01 No Relaxation

36 Mercury, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.001 No Relaxation

37 Molybdenum, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.07 No Relaxation

38 Nickel, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.02 No Relaxation

39 Arsenic, mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01 0.05

40 Coliforms (MPN/100 ml)

Present Present Present Absent Present Present Present Absent Absent No Relaxation

41 Fecal Coliform (MPN/100ml)

Absent Absent Absent Absent Absent Absent Absent Absent Absent No Relaxation

Note: All parameters in mg/L except where specifically indicated (pH has no units) (NS: Not specified)

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Observation of Ground water result:

It is observed that all parameters of samples meet Drinking water standards except presence of coliform at 6 borewell samples. Presence of coliform can be mainly due to contamination of sewage/ human interference.

Surface Water

Surface water monitoring was done for mainly lakes at seven locations. The sampling locations & results presented below,

Figure 3.14 Surface water sampling locations

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Table 3.12 Surface water analysis results

Parameter Panoli village

Panoli Lake

Panoli GIDC

Kharod lake

Bhadi lake

Bharan Lake

Amla Khadi

Classification for inland surface water

A B C D E

*pH 8.31 7.5 8.35 7.28 8.36 7.12 7.5 6.5 to 8.5 6.5 to

8.5 6.5 to

8.5 6.5 to

8.5 6.5 to

8.5 Dissolved Oxygen, mg/l, 6.1 7.1 8.2 7.1 7.5 7.1 7.2 6 5 4 4 NS *BOD @20°C 5days 20 28 40 34 42 30 44 2 3 3 NS NS Colour, Hazen units < 5 < 5 < 5 < 5 < 5 < 5 25 10 300 300 NS NS

Odour Unobjectio

nable Unobjectio

nable Unobjectio

nable Unobjectio

nable Unobjectio

nable Unobjectio

nable Unobjectio

nable Unobjectio

nable NS NS NS NS

Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable NS NS NS NS *TDS, mg/l 150 80 190 580 360 260 790 500 NS 1500 NS 2100 Electrical Conductance at 25 °C, μS

251.2 145 336.6 914.5 549.3 394.5 1180 NS NS NS 1000 2250

Hardness as CaCO3 mg/l 110 150 64 430 202 100 590 300 NS NS NS NS Ca as CaCO3, mg/l 42 64 42 310 182 82 350 200 NS NS NS NS Mg as CaCO3, mg/l 68 86 22 120 20 18 48 100 NS NS NS NS Copper as Cu, mg/l BDL BDL BDL BDL BDL BDL BDL 1.5 NS 1.5 NS NS Iron as Fe, mg/l, 0.3 0.4 0.1 1.3 0.2 0.2 0.2 0.3 NS 50 NS NS Manganese as Mn, mg/l BDL BDL BDL BDL BDL BDL BDL 0.5 NS NS NS NS *Chlorides as Cl, mg/l 73 45 107 461 175 190 496 250 NS 600 NS 600 *Sulphate as SO4, mg/l 73 24 66 108 174 35 279 400 NS 400 NS 1000 Nitrates as NO3, mg/1 BDL BDL BDL BDL BDL BDL BDL 20 NS 50 NS NS Fluorides as F, mg/l BDL BDL BDL BDL BDL BDL BDL 1.5 1.5 1.5 NS NS Phenolic comp, mg/l BDL BDL BDL BDL BDL BDL BDL 0.002 0.05 0.005 NS NS Mercury (as Hg), mg/l BDL BDL BDL BDL BDL BDL BDL 0.001 NS NS NS NS Cadmium as Cd, mg/ BDL BDL BDL BDL BDL BDL BDL 0.01 NS 0.01 NS NS Selenium as Se, mg/l BDL BDL BDL BDL BDL BDL BDL 0.01 NS NS NS NS Arsenic as As, mg/l BDL BDL BDL BDL BDL BDL BDL 0.05 0.2 0.2 NS NS Cyanides as CN,mg/l BDL BDL BDL BDL BDL BDL BDL 0.05 0.05 0.05 NS NS Lead as Pb, mg/l BDL BDL BDL BDL BDL BDL BDL 0.1 NS 0.1 NS NS Zinc as Zn, mg/l, BDL BDL BDL BDL BDL BDL BDL 15 NS 15 NS NS Hexavalent Chromium, mg/l BDL BDL BDL BDL BDL BDL BDL 0.05 1 0.05 NS NS Anionic detergents, mg/l BDL BDL BDL BDL BDL BDL BDL 0.2 1 1 NS NS

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Parameter Panoli village

Panoli Lake

Panoli GIDC

Kharod lake

Bhadi lake

Bharan Lake

Amla Khadi

Classification for inland surface water

A B C D E PAH, mg/l BDL BDL BDL BDL BDL BDL BDL 0.2 NS NS NS NS Mineral oil, mg/l BDL BDL BDL BDL BDL BDL BDL 0.01 NS NS NS NS Barium as Ba, mg/l BDL BDL BDL BDL BDL BDL BDL 1 NS NS NS NS Silver as Ag, mg/l BDL BDL BDL BDL BDL BDL BDL 0.05 NS NS NS NS Pesticides Absent Absent Absent Absent Absent Absent Absent Absent NS NS NS NS Selenium (as Se), mg/l BDL BDL BDL BDL BDL BDL BDL NS NS 0.05 NS NS Insecticide BDL BDL BDL BDL BDL BDL BDL NS NS Absent NS NS Oil and Grease mg/l BDL BDL BDL BDL BDL BDL BDL NS NS 0.1 0.1 NS Free Ammonia (as N), mg/l BDL BDL BDL BDL BDL BDL BDL NS NS NS 1.2 NS Sodium Adsorption Ratio,% 0.29 0.48 0.78 0.19 0.24 0.31 0.18 NS NS NS NS 26 Boron (as B), mg/l BDL BDL BDL BDL BDL BDL BDL NS NS NS NS 2 Sodium Percentage 1.2 2.35 2.6 1.68 1.48 1.34 1.62 NS NS NS NS 60 Coliforms >1600 >1600 >1600 >1600 >1600 >1600 >1600 50 500 5000 NS NS

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Classification of River Water as per their intended use is described in below table: Classification Type of use Class A Drinking water source without conventional treatment but after

disinfection Class B Outdoor bathing Class C Drinking water source with conventional treatment followed by

disinfection. Class D Fish culture and wild life propagation Class E Irrigation, industrial cooling or controlled waste disposal

Ref: IS 2296 – 1982 Inland surface water standard. Observation of surface water results:

Moderate to heavy eutrophication was observed in all ponds. The ponds are also used for animal bathing and clothes washing.

From analysis results, it is observed that surface water mainly fall under Class C & E.

Biological Environment

The establishment for manufacturing of proposed chemicals is planned in Plot No. 23, Panoli GIDC, Gujarat where the company is already manufacturing a single product, Manganese Sulphate to the tune of approx. 60,000 TPA. The existing manufacturing facility occupies only 8,351.7 sq.m (approx. 9.25%) of the total plot area of 90,204.3 sq.m. The rest of the area is largely a scrub land except for the roads and peripheral greenbelt area.

The southern and western boundary of the project site is shared by two industrial units of which one is non-operational. The Panoli – Kharod village road is on the north and joins with the NH 8 on the east. A 30 m wide service road developed by industrial estate is on the east. There are no surface water bodies, canals or other water supply sources,

habitations immediate to the project site that could have immediate impact due to setting up of new project.

Biological environment was studied by undertaking detailed primary survey on 3rd May, 2018 and a second site visit on 17th May 2018, peak summer season. The immediate impact area of 500 m from the project site is with intense industrial growth and has limited biodiversity comprising mostly of hangers-on species. Typical plant species were found in areas which are intentionally planted for the purpose of greenbelt obligatory by the regulatory authorities or for beautification, shade, protection from stray/grazing

animals etc. In open spaces/ waste areas, plants exists naturally, supporting dependent fauna and constitutes part of biodiversity.

Proposed site is under planted trees of diverse species predominantly Azadirachta indica, Casuarina equisetifolia, Annona squamosa, Ficus benghalensis, Cassia fistula, Michellia champaca, Mitragyna parvifolia, Bauhinia purpurea etc. A large part of the land is under

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wild growth of Calotropis sp., Tridax procumbens, Achyranthes aspera, other annual herbs and grasses. Being hot summer, the ground flora was almost dry. Birds such as Red vented bulbul, Red Wattle Lapwing and Indian Robin were observed near the Greenbelt area where water was available. Animals like wild boars, dogs were observed near the plant boundary. A nesting site of (Red Wattled Lapwing) was seen near the scrub land next to the site as shown in Figure below. There were no agriculture fields adjacent to the site.

Figure 3.15 Immediate Neighbourhood of the Project Site (500m boundary)

Casuarina Plantation

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Bushy Area at Site

Nesting of Lapwing Wild Boar at site

Irrigation Facility at Site

Drinking Water for Birds

Figure 3.16 Project Site and Biological Components in the Immediate Surroundings

Ecology & Biodiversity study pertaining to Environmental Impact Assessment for proposed project was carried out in the 10 km Impact area from the project site. The 10

km impact area encompasses parts of Bharuch and Surat Districts. According to Bio-Geographic Zone Classification of India, entire study area falls under ‘Semi Arid’ zone. None of the villages from study area falls within Ecologically Sensitive Area, National Park, Wild Life Sanctuary, Bio-Sphere Reserve as per the draft ESA notification of MoEF & CC dated 27th February, 2017. Figures below shows site and extent of study area.

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The terrain of the study area in general is flat. In addition to the industrial establishments in Ankleshwer and Panoli Industrial Estates, the impact area covers agriculture fields/ fruit orchards, isolated eucalyptus plantation etc. Besides these different habitats observed in the study area were water bodies and human settlements. These habitats possesses different characteristic features which support typical composition of flora and fauna within them.

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Figure 3.17 OSM of the Study Area

Figure 3.18 Extent of Study Area with Locations Surveyed

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The study was carried out by visiting the representative locations of all habitats. Geographical coordinates were marked at important locations and geo-tagged photographic evidences were collected. Listing of species was done based on actual sighting, indirect evidences and literature survey.

During survey, total 11 locations (including project site, 2 within 500m impact zone and rest within 10km study area) were visited for phyto-sociological studies as shown in Table below. 10 m X 10 m quadrat for trees, 5 m X 5 m for Shrubs & 1 m X 1 m for herbs were established. Data collected was used to determine species richness and composition

by standard methods.

Table 3.13 Survey Locations within 10 km radius of Site

Location

no. Location Name (as on map) Latitude Longitude

1 Project Site 21°32'43.06"N 73° 0'4.18"E

2 Piraman Village 21°37'17.03"N 72°59'53.03"E

3 GIDC Water Reservoir 21°36'35.30"N 73° 0'26.32"E

4 Near Shafaqat Farm 21°33'52.28"N 73° 0'2.65"E

5 Pond near Bakrol Village 21°34'21.08"N 73° 0'57.13"E

6 Kosamdi Talav (pond) 21°34'46.46"N 73° 2'13.29"E

7 Near Gujarat Guardian Township 21°34'58.86"N 73° 3'45.50"E

8 Panoli Village 21°32'9.03"N 72°57'56.55"E

9 Outside Cheminova Ltd., Panoli GIDC 21°32'43.97"N 72°59'45.33"E

10 Pond near Panoli Post office 21°32'1.29"N 72°58'19.84"E

11 Open field between Nana Borsara and

Panoli

21°31'40.73"N 72°58'57.34"E

Various Habitats observed in the study area and supporting biological components are summarized as follows.

Water Bodies

The largest water body in the study area is the GIDC Water Reservoir, 2 km away from Ankleshwer town. The reservoir beautified with introduced tree species and ornamental plants with walkway all around is a habitat for aquatic as well as the dependent terrestrial biota. The reservoir and surroundings did not show any visible characteristics of stressed ecosystem such as foul smell or foaming or discoloration though floating dry leaves.

Plastics were found floating towards the edges. The observed bird species includes, little egret, pond heron, common kingfisher, white stork, jacana, babbler. The planted trees include, Pithecellobium dulce, Casuarina equisetifolia, Cassia fistula, Samanea saman, Peltophorum pterocarpum, Pongamia pinnata, Delonix regia, Ficus benghalansis, Ficus religiosa and many others with large canopies. The flowering shrubs like Hibiscus sp., Ixora coccinea, Tabernaemontana, along the walk way attracted many butterflies and

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dragon flies. Lawsonia sp., Bombax ceiba, Bauhinia racemosa are planted in the surroundings of the reservoir.

Figure 3.19 View of GIDC Reservoir, Ankleshwer

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Figure 3.20 Plantation surrounding the Reservoir Area

Other water bodies included ponds near Bakroli village, Kosamdi village and Panoli railway station. Except for the pond near Panoli village, the rest were healthy through the water was less due to peak summer. Species like Polygonum glabrum, Cyperus sp., Ipomoea aquatic, Ipomoea carnea, Typha sp etc. were observed commonly in areas of stagnant water or inside the ponds. Covey of Cattle Egrets, Storks, Red wattle lapwing etc. were observed during survey. The view of the ponds sheltering cattle and egrets pecking the parasites from directly off the skin that bothering the cattle and other birds are shown below. The pond at Panoli was polluted and clearly had visible indications as seen in the figure.

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Figure 3.21 Waterbody at Bakrol

Figure 3.22 Pond near Panoli Village

Human Habitations

Ankleshwer, Panoli, and Kosamba constitute major urbanized area, rest Human habitation in study area is rural in nature. Villages in study area are found scattered in various hamlets called “Falia”.

Typical plant species were found in habituated areas which are intentionally planted for the purpose of beautification, shade, protection from stray/grazing animals and for food

value. Similarly, faunal species of interest such as cattle were noticed. In open spaces/ waste areas, plants exists naturally, both supports respective fauna and constitutes part of biodiversity. For the purpose of listing the species; open/waste area adjacent to human settlement, road side plantation etc. are also considered in this habitat. At almost all places, Mango/Coconut/Sapota plantations were noticed in addition to agriculture.

Ansar market, located on the NH 8 between Panoli and Ankleshwer, has series of godowns dealing with metal and plastic scraps and drum decontamination. This area was found to be highly polluted with solid wastes such as solvent drums, plastics, thermocol, metals etc.

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Figure 3.23 Human Habitations in the Impact Area

Agricultural Fields

Major crop in the region during the study period was Sugarcane. However secondary crops like jowar and bajra were seen in dry soils. Azadirachta indica, Mangifera indica, Cocos nucifera, etc. were observed along the boundaries of agriculture fields. Agriculture flora supports corresponding members of fauna in the study area.

Figure 3.24 Agriculture Field near Project Site

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It involved measurements of various characters in sample plots, commonly known as quadrats. Measurements made in sample plots (quadrats) in the study area were scientifically processed to reflect the characteristics of the entire community. Species composition and major quantitative characters include frequency, abundance and density was studied. Two quadrates were laid at the site as there were no much vegetation due to peak summer as seen in the photographs of ground flora. The character defining species of the ecosystem is given in the following tables.

Figure 3.25 Ground Flora

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Table 3.14 Quadrat Study for Trees within the Project Site

Sr. No.

Name of Plant Species

Number of individuals in each quadrat (10x10)

Total No. of

Individual

No. of Quadrate in which species

occurred (Y)

Total Quadrate

studied (Z)

% freq. (Y/Z X 100)

Abundance

Density

Q1 Q2 Q3 Q4 Q5 1 Acacia auriculiformis 1 0 0 0 0 1 1 5 20 1.0 0.2 2 Acacia catechu 1 0 0 0 1 2 2 5 40 1.0 0.4 3 Acacia nilotica 0 1 1 0 1 3 3 5 60 1.0 0.6 4 Acacia lebbeck 1 0 0 0 0 1 1 5 20 1.0 0.2 5 Acacia procera 0 0 0 0 1 1 1 5 20 1.0 0.2 6 Adina cordifolia 0 1 1 1 0 3 3 5 60 1.0 0.6 7 Aegle marmelos 0 0 1 1 1 3 3 5 60 1.0 0.6 8 Ailanthus excelsa 1 1 0 1 1 4 4 5 80 1.0 0.8 9 Alangium salvifolium 1 0 1 0 1 3 3 5 60 1.0 0.6

10 Albizia odoratissimus 0 1 0 1 1 3 3 5 60 1.0 0.6 11 Annogeissus latifolia 1 0 0 0 0 1 1 5 20 1.0 0.2 12 Annona squamosa 1 1 0 1 2 5 4 5 80 1.3 1 13 Azardirachta indica 2 1 3 1 2 9 5 5 100 1.8 1.8 14 Bahuania purpurea 0 1 2 0 3 6 3 5 60 2.0 1.2 15 Bombax ceiba 0 1 0 0 2 3 2 5 40 1.5 0.6 16 Butea monosperma 1 0 0 0 1 2 2 5 40 1.0 0.4 17 Bridelia retusa 0 0 0 0 1 1 1 5 20 1.0 0.2

18 Callistemon lancealatus 0 0 1 0 2 3 2 5 40 1.5 0.6

19 Casuarina

equisetifoier 1 0 1 2 2 6 4 5 80 1.5 1.2 20 Cassia fistula 2 1 2 3 1 9 5 5 100 1.8 1.8 21 Cestrum noctusnum 0 1 0 1 0 2 2 5 40 1.0 0.4 22 Cordia dichotoma 1 0 0 0 0 1 1 5 20 1.0 0.2 23 Murraya koenigii 0 1 0 1 0 2 2 5 40 1.0 0.4 25 Delonix elala 1 0 1 0 1 3 3 5 60 1.0 0.6

26 Diosphyros

melanoxylon 0 0 1 0 0 1 1 5 20 1.0 0.2

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Sr. No.

Name of Plant Species

Number of individuals in each quadrat (10x10)

Total No. of

Individual

No. of Quadrate in which species

occurred (Y)

Total Quadrate

studied (Z)

% freq. (Y/Z X 100)

Abundance

Density

Q1 Q2 Q3 Q4 Q5 27 Emblica officinalis 1 0 0 0 0 1 1 5 20 1.0 0.2 28 Erithina uliginosa 0 1 1 0 0 2 2 5 40 1.0 0.4 29 F. benghalensis 0 1 2 1 1 5 4 5 80 1.3 1 30 Griwia teliaefolia 0 0 0 0 1 1 1 5 20 1.0 0.2 31 Haidwickia bipinnata 0 0 1 0 1 2 2 5 40 1.0 0.4 32 Holoptelia intigrifolia 0 1 1 0 0 2 2 5 40 1.0 0.4

33 Lagerstroemia

lanceolata 2 0 1 0 0 3 2 5 40 1.5 0.6 34 Michellia champaca 1 0 2 0 2 5 3 5 60 1.7 1 35 Madhuca indica 1 0 0 0 1 2 2 5 40 1.0 0.4 36 Mangifera indica 0 1 1 0 1 3 3 5 60 1.0 0.6

37 Milligntonia

hortensis 1 0 0 0 0 1 1 5 20 1.0 0.2 38 Mitragyna parvifolia 1 1 1 1 1 5 5 5 100 1.0 1 39 Moringa oliefera 0 0 0 0 1 1 1 5 20 1.0 0.2 40 Pongamia pinnata 1 0 1 0 0 2 2 5 40 1.0 0.4 41 Pisidium guajava 0 1 0 1 0 2 2 5 40 1.0 0.4 42 Tectona grandis 0 1 0 0 0 1 1 5 20 1.0 0.2 43 Muntingia calabura 0 0 1 0 0 1 1 5 20 1.0 0.2 44 Pithecellobium dulce 1 0 1 1 0 3 3 5 60 1.0 0.6

Table 3.15 Quadrat Study for Shrubs in the Vicinity of the Project Site

Sr. No.

Name of Plant Species

Number of individuals in each quadrat

Total No. of Individual

No. of Quadrat in which species occurred (Y)

Total Quadrat

studied (Z)

% frequency

(Y/Z X 100)

Abundance

Density

Q1 Q2 1 Calotropis procera 5 6 11 2 2 100 5.5 5.5 2 Carissa carandas 2 1 3 2 2 100 1.5 1.5

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3 Clerodendrum

multiflorum 1 0 1 1 2 50 1 0.5 4 Lantana camera 6 4 10 2 2 100 5 5 5 Opuntia dillenii 1 0 1 1 2 50 1 0.5 6 Euphorbia neriifolia 1 1 2 2 2 100 1 1 7 Datura fastuosa 7 5 12 2 2 100 6 6 8 Vitex negundo 2 0 2 1 2 50 2 1 9 Ziziphus nummularia 0 2 2 1 2 50 2 1

Table 3.16 Quadrat Study for Grasses and Herbs within the Project Site

Sr. No.

Name of Plant Species

Number of Individuals in each Quadrat

Total No. of

Individual

No. of Quadrat in which species

occurred (Y)

Total Quadrat

studied (Z)

% freq. (Y/ZX100)

Abundance Density

Q1 Q2

I Grasses

1 Tridax procumbens 13 16 29 2 2 100 14.5 14.5

2 Cynodon dactylon 15 18 33 2 2 100 16.5 16.5

3 Heteropogon

contortus 16 12 28 2 2 100 14 14

4 Chloris barbata 0 8 8 1 2 50 8 4

II Herbs

1 Indigofera tinctoria 5 7 12 2 2 100 6 6

2 Achyranthes aspera 11 12 23 2 2 100 11.5 11.5

3 Amranthus spinosus 13 8 21 2 2 100 10.5 10.5

4 Mollugo pentaphylla 7 0 7 1 2 50 7 3.5

5 Acalypha indica 0 14 14 1 2 50 14 7

6 Aerva lanata 0 6 6 1 2 50 6 3

7 Vernonia cinerea 4 0 4 1 2 50 4 2

8 Ipomoea batatas 0 3 3 1 2 50 3 1.5

9 Boerhavia diffusa 2 1 3 2 2 100 1.5 1.5

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Sr. No.

Name of Plant Species

Number of Individuals in each Quadrat

Total No. of

Individual

No. of Quadrat in which species

occurred (Y)

Total Quadrat

studied (Z)

% freq. (Y/ZX100)

Abundance Density

Q1 Q2

10 Abutlion indicum 0 3 3 1 2 50 3 1.5

11 Datura stramonium 2 0 2 1 2 50 2 1

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Among the trees, Azadirachta indica and Cassia fistula had maximum abundance and density. Plants like Lantana camera, Calotrpis procera, Cassia tora, Achyranthus aspera, Ameranthus spinosus, Acalypha indica were in abundance at the project surroundings. Among animals, common domestic animals like cattle, dogs and wild boar were spotted, however, foxes and other animals are also seen in this area. The bird species observed during the survey are enlisted in the following table.

Table 3.17 List of Bird Species observed during the Survey

Sr. No.

Scientific Name Common Name

Order Appearance* Conservation Status

1 Acridothers tristis

Common Myna

Passeriformes

Least Concern

2 A. ginginianus Bank Myna Passeriformes

Least Concern

3 Ardeola grayii Pond Heron

Pelecaniformes

Least Concern

4 Babulcus ibis Cattle Egret

Pelecaniformes

Least Concern

5 Centropus sinensis

Crow-Phesant

Cuculiformes

Least Concern

6 Columba livia Blue Rock Pigeon

Columbiformes

Least Concern

7 Corvus splendens

House Crow

Passeriformes

Least Concern

9 Dicrurus adsimilis

Black Drongo

Passeriformes

Least Concern

10 Eudynamys scolopacea

Koel Cuculiformes

Least Concern

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Sr. No.

Scientific Name Common Name

Order Appearance* Conservation Status

11 Halcyon rustica White brested

Kingfisher

Coraciiformes

Least Concern

12 Merops orientalis

Little green Bee-eater

Coraciiformes

Least Concern

13 Elanus caeruleus Black-winged

Kite

Accipitriformes

Least Concern

14 Cinnyris asiaticus

Purple Sunbird

Passeriformes

Least Concern

15 Orthotomus Tailor bird Passeriformes

Least Concern

16 Copsychus saularis

Oriental Magpie-

Robin

Passeriformes

Least Concern

17 Copsychus fulicatus

Indian Robin

Passeriformes

Least Concern

18 Vanellus indicus Red-wattled Lapwing

Charadriiformes

Least Concern

19 Turdoides striata

Jungle Babbler

Passeriformes

Least Concern

20 Ciconia ciconia

White Stork

Ciconiiformes

Least Concern

21 Microcarbo niger

Little Cormorant

Pelecaniformes

Least Concern

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*From published source

A greenbelt of more than 500 trees of various forest species are grown at the site. More than 60% of the trees at the site are more than 3 m of height and 20cm girth as seen in the photographs below.

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Figure 3.26 Greenbelt Plantation at Site.

During the survey, 87 trees, 108 shrubs, 46 herbs observed in the impact area. None of the observed species is listed in “Red List of Threatened Vascular Plant Species in India” published by MoEF, 2003. None of the fauna observed were among “vulnerable’ or threatened species.

The well grown greenbelt and ground flora at the site can be considered as the baseline

environment for the biological features. The indicator species (sensitive and tolerant) given in the following table should be planted at the site so that the impact can be studied over a period of time in terms of various parameters related to growth and productivity.

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Table 3.18 List of Sensitive and Tolerant Species to Pollution

Sr. No. Sensitive Tolerant

1 Delonix regia Abutilon indicum

2 Mangifera indica Acacia auriculiformis

3 Millingtonia hortensis Acacia catechu

4 Moringa oleifera Achras sapota

5 Morus alba Adina cordifolia

6 Commelina benghalensis Aegle marmelos

7 Brassica oleraceae Ailanthus altissimo

8 Chenopodium album Alangium chinense

9 Cicer arietinum Albizia lebbeck

10 Dolichos lablab Ficus benghalensis

11 Sonchos asper Butea monosperma

12 Withania somnifera Clerodendrum inerme

13 Tabernamontana coronaria Diospyros melanoxylon

14 Calotropis gigantea Emblica officinalis

15 Melilotus alba Gardenia jasminoides

16 Helianthus annuus Holoptelia integrifolia

17 Crotalaria juncea Ixora chinensis

18 Cyamopsis tetragonoloba Lagerstroemia parviflora

19 Pongamia glabra Mimusops elengi

20 Polyalthia longifolia Nerium indicum

Source: PROBES/75/1999-2000 CPCB - Guideline for Developing Greenbelts

Periodic assessment of the health of these plants in the campus and supporting fauna will

determine the impact of the pollutants from the proposed activities on ecology and

biodiversity of this area. Nature of pollutants and visible impact on species can be

mentioned to make it comprehensive.

Socio Economic Environment

As a part of EIA the socio-economic study includes demographic structure, population dynamics, infrastructure resources, status of human health and economic attributes like employment, per-capita income, agriculture, trade, industrial development, tourist

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attraction, historic and cultural monuments etc. in the study area. The study of these parameters helps in identification, prediction and evaluation of likely impacts on socioeconomics and parameters of human interest due to proposed project.

The socio economic data was collected & generated through both sources i.e. primarily by field survey in sampling locations & it has been substantiated with relevant socio economic data from secondary sources i.e. concerned office’s documented records. The latest available primary & secondary data have been complied & amalgamated to delineate the existing baseline scenario of socio economic environment in study area.

The Proposed Establishment of Synthetic organic chemicals and intermediates to serve agrochemicals, pharmaceuticals, polymer, and specialty chemicals by Reshmika Minerals & Chemicals Pvt. Ltd, at Plot No. 23, Panoli GIDC, District - Bharuch, Gujarat.

Panoli is a village located near Ankleshwar city famous for its large industrial area developed by GIDC as an independent body wholly owned by Gujarat Government, to boost the industrial growth in this region. Various types of industries like chemicals, pharmaceuticals, pesticides, Dyes and Intermediates, Textiles, Engineering etc. comprise the texture of the Panoli GIDC estate. NH 8 offers excellent connectivity & the most important method of transport is the western railway, which is connected by the Panoli

station. The industrial estate also has direct access to the Port of Dahej and Hazira Port.

Primary Data: Primary socio economic data collection through intensive field survey in selected sampling locations i.e. villages & town/ wards in study area as well as the observations by the survey team.

Primary socio economic survey is very essential in order to assess and evaluate likely impacts arising out of any developmental projects on socio economic environment, it is necessary to gauge the apprehensions of the people in the project area.

20% - 30% percent sampling location i.e. areas it may be village or urban areas were selected located in all distance & directions of total areas falls within the study area of 10 km. Judgmental & purposive sampling method applied for selection of respondents (representatives of local Gram Panchayat i.e. Sarpanch, members etc. & adult male & female groups, senior citizen, cultivators, fishermen, business men etc.) Data collection processing includes field survey and observations are made at each sampling areas and the socioeconomic status of that region is studied. At each sampling locations group discussions or group interviews were carried out with different sections of community which representing the study area. Structured interviews involve the use of a set of predetermined questions that includes fixed and alternative questions. The

questionnaire mainly highlights the parameters such as income and employment, housing, water supply, sanitation, health, energy, transportation and communication, education, environment and pollution etc. to assess the standard of living of that particular region and general awareness, opinion and expectation of the respondents about the proposed project or industrial development activity

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Socio-economic survey was conducted in 16 villages & 1 census town of the study area located in all directions & distances with reference to the proposed project site.

Table 3.19 List of Sampling locations for SE Primary Survey

Sr. No.

Surveyed Village / Urban Areas

Distance from project site (km) (approximate)

Direction from site (approximate)

1 Sanjali (CT) 1.00 NW

2 Kharod 1.30 NE

3 Panoli 4.00 SW 4 Alonj 5.40 NW

5 Bakrol 3.00 NE 6 Dhamdod 5.00 S

7 Ravidra 6.00 SW 8 Umarwada 4.65 NW

9 Kapodara 5.70 N

10 Dinod 6.80 SE 11 Hathuran 5.85 SW

12 Adadara 10.00 SW 13 Hajat 9.53 NW

14 Kosamadi 5.75 NE

15 Kondh 8.00 NE

16 Kantva 9.70 SE 17 Nandav 7.35 S

Snapshots showing the socio economic sampling team members are filling the questionnaire scheduled by interviewing a local resident & Gram Panchayat official members at selected sampling locations are illustrated below:

Village: Kantva

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Village: Kondh

Village: Panoli

Village: Bakrol Village: Hajat

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Census Town: Sanjali Village: Kharod

Secondary Data: Secondary source of data includes official / documented records such as census records of 2011 & 2001 CDs from Directorate of Census Office, district statistical abstracts, health statistics from health offices etc.

Details of various facets of socioeconomic environment including salient observations recorded during the field survey are described below & detailed village & town wise or sampling locations wise Tables pertaining to each of the aspects are presented in

Annexure 3.4. Details of various facets of socioeconomic environment are described below:

The Socio economic study spans a radius of 10 km around the proposed project site and is located in Anklesvar Tehsil & Valia tehsil of Bharuch District & Mangrol Tehsil of Surat District. The number of rural & urban areas falls under these three tehsils is given below:

Districts Names of Talukas No. of Villages No. of Towns Total

Bharuch Ankleshwar 21 5 26

Valia 3 ---- 3

Surat Mangrol 12 1 13

Total 36 6 42

There are 36 villages and 6 towns falling under the study area, Out of these, 21 villages & 5 towns are in Anklesvar tehsil of Bharuch district and 13 villages & 1 town in Mangrol tehsil of Surat district.

Demographic structure of the study area was studied in terms of selected parameters

such as households, population, sex ratio, scheduled caste, scheduled tribes, literacy etc. Summarized information of demographic details of study area is shown below:

Table 3.20 Summary of Demographic Parameters in the Study Area

Demographic Parameters Details No. of Household 49662

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Total Population 224479 Male Population 118232 Proportion of Male population 53 Female Population 106247 Proportion of Female Population 47 Child Population 0 - 6 years 26929 Proportion of Child Population 12.0 Sex Ratio (No. of females per 1000 males) 899 Family Size (person per household) 4.5 Scheduled Castes 7923 Proportion of Scheduled Castes 3.5 Scheduled Tribes 49508 Proportion Of Scheduled Tribes 22.1 Literate Population 171214 Proportion of Literate Population 76.3

Source: Primary Census Abstract CD 2011 Bharuch & Surat District, Gujarat State

The significant features of the demographic structure are given below:

Population & Households & Avg. Family Size: Total population of the study area is 224479 out of which 118232 (53 per cent) are males and 106247 (47 per cent) are females with

average sex ratio 899 female per 1000 male. There are 49662 households in the study area with average family size is 4.5 persons per household as per 2011 census.

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The study area is divided into four radial zones, the zones wise distribution of villages &

towns with population within the study area as per 2011 census is shown below.

Zones of Study Area Villages Towns Population Number Ratio

0 – 3 km 3 1 15192 6.8 3 km – 5 km 4 1 8316 3.7 5 km – 7 km 10 1 35002 15.6

7 km – 10 km 19 3 165969 73.9 Total 36 6 224479 100

Source: Primary Census Abstract CD 2011 Bharuch & Surat District, Gujarat State

From the proposed project site there are 3 villages & Sanjali census town come under radius of 3 km compromising 6.8% population of total study area population. And in the radius of 3 km - 5 km, 4 villages & Panoli (Industrial Notified Area) town are falling which comprises 3.7% population of total study area population. Highest percent i.e. 73.9 population found in the 7km – 10km zone of the study area.

Child Population: The child population 0 - 6 years account for about 12.0% of the total

population.

Scheduled Cates & Scheduled Tribes Population: As per 2011 census, about 3.5% of the population in the study area belonged to Scheduled Castes (SC) and 22.1% to Scheduled Tribes (ST), thus indicating that socially backward castes constitute about 25.6% of the total population.

The sex ratio of study area is 899 per 1000 males.

Literacy: As per 2011 census study area literacy rate (76.3 %) is higher as compared with Bharuch District (72.1 %), Surat District (75.2 %) & Gujarat State (68%) average literacy rate. The male and female literacy rates are 79.7% and 72.4% respectively of the total

male & female population.

Majority of the households are living at their own houses except very few villages & urban area i.e. Sanjali (CT) - 72.5%, Bakrol - 42.2%, Kapodara - 43.7%, Bhadkodara (CT) - 30.4 & Kosamba (CT) - 33.3 here above thirty percent population are living on rent.

76.372.1

75.2

68

60

64

68

72

76

80

StudyArea

BharuchDistrict

SuratDistrict

GujaratState

Literacy RateSC4%

ST22%

Other Castes74%

SC & ST POPULATION: STUDY AREA

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The structure of majority of the household is pucca i.e. fully concretely made permanent house & the quality of household is good however at some towns & villages (Panoli (INA, Alonj, Bhadi, Karmali, Boridara, Mahuej, Utiyadara, Nangal, Boidara, Kondh, Siludi, Kantva & Kathvada) above forty percent households condition is Livable not good. While very few shelters conditions are Kucchha i.e. totally temporary or dilapidated where BPL families reside i.e. approximately 2 percent households are covered under BPL at majority of the villages in the study area.

Hindu population is high in majority of the sampling villages except few villages such as

Alonj, Ravidra, Umarwada & Kapodara here above fifty percent population belongs to

Muslim Community. While caste wise distribution shows that majority of the population

comes under Other Castes category except at some surveyed villages Scheduled Tribes

population in high i.e. in Bakrol, Adadara, Kantva, Nandav & Hajat villages.

The infrastructure resources base of the villages coming within the study area with reference to education, medical facility, water supply, post and telegraph, transportation and communication facility and power supply etc. have been abstracted from District

Census Handbook CD 2011 of Gujarat State & from field visit at sampling location which is enclosed in Annexure 3.4. Availability & satisfaction of population within the study area regarding civic amenities is described below:

Educational Facilities: As per 2011 census data there are total 113 primary school, 35 secondary school and 18 senior secondary school are available in both rural & urban region while degree college facility arts & commerce & professional educational institution like Engineering College, Management Institute and Polytechnic are found to be functional in the towns Panoli, Bhadkodara, Anklesvar & Kosamba.

Health / Medical Facilities: As a part of rural health care system primary health centre & primary health sub centre are running in 1 & 14 number of villages respectively in the

study area. Medical facilities are quite ok in urban region i.e. 2 Govt. hospitals with 95 beds facility, 19 non-Government outpatient clinics & 51 Non Government medicine shops are functional in towns falls under study area.

Water: Tap water facility is available in all the 36 villages & all 6 towns with overhead tanks but all the houses not drawn water from treated sources. Rural region also have other sources of water such as well, Tube Wells/Borehole, Hand Pump, Tank/Pond/Lake & River/Canal.

Sanitation: All the households not having toilet facility within their premises / houses. Alternative source i.e. public toilets are also not available in most of the villages so the

open defecation is common in the region. Closed & open drainage system is available in the study area but all the houses in most of the villages are not connected with public drainage for disposed of household waste water. Solid waste disposal facility in the form of house to house garbage collection facility & availability of dustbin in the villages or areas not available in all the villages in the study area.

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Communication & Transportation & Approach Roads: The main mode of public transport is Govt. bus service available in all the 36 villages & all towns in the study area. Railway station facilities is available in Anklesvar, Sanjali & Kosamba towns. Postal facility is available in 18 villages (2 post offices & 16 sub post offices) & almost all villages have phone as well as internet facility because all the villages have an mobile phone coverage. All the villages in the study area is connected with both Pucca (Paved) Road & Kacchha (Gravel) road. Pvt. means of transport i.e. Auto/Modified Autos, Tractors & Carts Drivens by Animals are also available in most of the villages in the study area.

Sources of Electricity & Fuel used for Cooking: The primary source of energy in the study

area is electricity, and the entire study area has electricity and it is available for all purposes i.e. domestic, agriculture & commercial. LPG is the main fuel used for cooking by majority of the household & other fuel includes fire wood & kerosene which is used by some percent of households in the study area.

Firefighting services is available at Panoli (INA), Bhadkodara (CT), Anklesvar (M + OG) & Anklesvar (INA) towns.

Summarized Information on Occupational Structure i.e. numbers of workers & non workers population details & economic category wise distribution of workers population

in the study area is shown in Tables while its percentage is presented in Figures.

Table 3.21 Occupational Structure of the Study Area

Persons Workers Non Worker Main Workers Marginal Workers Total Workers

Total 74725 5707 80432 144047 Male 63606 3116 66722 51510 Female 11119 2591 13710 92537

Source: Primary Census Abstract CD 2011 Bharuch & Surat District, Gujarat State

Figure 3.27 Ratio of Workers & Non Workers in the Study Area

As per 2011 census data the work participation rate in the study area is 36% among which the main workers constitutes 33.3% & marginal worker constitutes 2.5%. It means higher share of population i.e. 64.2% recorded under non worker of the total population.

33.353.8

10.5

2.5

2.6

2.4

64.243.6

87.1

0%

20%

40%

60%

80%

100%

Total Male Female

Main Workers Marginal Workers Non Workers

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Among the main workers, male participation rate is 53.8 percent while that of female is only 10.5 percent it means proportion of main workers is higher in male population than in female population while in non-workers the percentage of female population is 87.1% shows higher than of male population i.e. 43.6% in the study area.

Table 3.22 Economic Category wise Distribution of Workers

Workers Cultivators Agricultural Labourer

Household Industry Workers

Other Workers

Main Worker 4773 11796 666 57490 Marginal Worker 336 1524 174 3673 Source: Primary Census Abstract CD 2011 Bharuch & Surat District, Gujarat State

Figure 3.28 Economic Category wise Distribution of Workers in the Study Area

3 census towns (Sanjali, Bhadkodara & Kosamba), 2 industrial notified areas (Panoli & Anklesvar) & 1 Anklesvar Municipal Corporation & outgrowth covered under the study area consisting 67% population of the total population in the study area. Due to urbanized areas & good employment opportunities in GIDC at Panoli & Anklesvar percent of other workers for both main workers (76.9%) & marginal workers (64.4%) are more as compared to other three economic activities. Other workers includes all government

servants, municipal employees, teachers, factory workers, plantation workers, those engaged in trade, commerce, business, transport, banking, mining, construction, political or social work, priests, entertainment artists, etc. all those workers other than cultivators or agricultural labourers or household industry workers. Agricultural is an important economic activity in the study area as supported by the fact that 6.4 percent cultivators and 15.8 percent agricultural labourers together constitutes 22.2 percent of the total main worker in the study area. As concerned with marginal workers 32.6 percent (5.9 percent cultivators & 26.7 percent agricultural labourer) are engaged in agriculture sector.

Cultivation: As agriculture is one of the important main source of subsistence for the

significant number of people in the study area. The main crops produce in the study area are rice pigeon pea, paddy, wheat, sorghum, bajra, banana, sugarcane and cotton. By considering the land fertility and irrigation facilities the different cropping pattern i.e. kharif, rabi & summer are being followed in the study area. Government canals and wells are the main source of irrigation in the study area. Out of the total irrigated land canal

6.4 15.8 0.9

76.9

5.9 26.7 3

64.4

0

20

40

60

80

100

Cultivators Agricultural Labourer Household IndustryWorkers

Other Workers

Main Worker Marginal Worker

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irrigation contributes about 65.1 percent land in hectare by covering 25 villages and 28 percent area in hectare under Wells/Tube Wells irrigation which covers 21 villages of the total 36 villages in the study area. There are 3 Sugar factories, 2 rice mills, 12 ginning & pressing factories and 1 mango pulp mill agro based industries exist in the Bharuch district.

Industry: Bharuch is a fierce industrial base in sectors as diversified as drugs & pharmaceuticals, chemicals & petrochemicals, ports & ship building and textiles. Several private business groups and public sector companies have their presence in Bharuch. Bharuch has few prestigious industrial projects and certain renowned economic

activities such as Oil and natural Gas Commission at Ankleshwar. Chemical port of India at Dahej port; Gujarat Chemical Port Trust Private Limited at Dahej. Active presence of Corporate giants like Gujarat Narmada Valley Fertilizers Co. Ltd., Gujarat Mineral Development Corporation, IPCL, Grasim Birla, Videocon Group and Multi-National Companies Such As Hoechst, Borosil, Asian Paints, Bayers, Glaxo, Avantis, Wockhardt, etc. and Two co-operative sugar Factories. Over 11,500 units of small and medium enterprises, involved in different sectors, such as chemicals and petrochemicals, textiles etc. are present in the district. With over 70 medium and large scale industries, Ankleshwar is the major industrial center in Bharuch witnessing a large number of business activities. Ankleshwar being a major industrial center, has shown substantial contribution in the development of the District Presence of over 625 Major industrial

units in Bharuch.

Figure 3.29 Number of Factories and Average Number of Workers in Bharuch District from 2008 to 2011

Reference: Bharuch District 2011 DCHB (Industries in Gujarat Statistical information 2013)

There are total registered numbers of industrial units in 2008 & 2009 is 1544 & 2695 employs 72866 & 73276 average numbers of workers and in 2010 & 2011 years there is 1608 & 1662 units provided employment to 76350 & 85990 person respectively in all

types of units i.e. micro & small scale industries & large & medium scale industries at all types of works i.e. skilled, semi-skilled & unskilled labour work.

Animal Husbandry (Livestock & Poultry): Farmers of Bharuch district have a long tradition of rearing animals for milk production. Dairy farms provide employment to large number of landless families of rural areas. Livestock particularly buffalo, cattle and

1544 2695 1608 1662

72866 7327676350

85990

65000

70000

75000

80000

85000

90000

0

500

1000

1500

2000

2500

3000

2008 2009 2010 2011

Ave

rage

No

. of

Wo

rker

s

Reg

iste

red

Wo

rkin

g Fa

cto

ries

Registered Working Factories Average No. Workers

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goats constitute the main animal husbandry component in the farming system of the district. This sector’s vast potential can be harnessed for growth in generating employment, income and restoring soil health. Cattle wealth occupies a pivotal place in the rural economy of the district. According to the livestock census of 2007, the livestock population in the district are 4,23,353 (Cattle (cross breed) - 18,750, Cattle (Indigenous) - 1,03,119, Buffaloes - 1,53,814, Sheep - 6,896, Goats - 1,33,671, Horses and Pines – 596, Camels – 836, Pigs – 267 & Other Livestock - 5,404) and poultry was 2,71,136.

Out of 16 surveyed villages 4 villages not involved in dairy farm activities while in balanced all the villages, varying between 1% - 20% families are involved in dairy farm

activities as their major source of income.

Retail Trade / Business: Retail trade is carried on by a large number of establishments in the urban and rural areas and caters to the needs of local inhabitants. These traders usually obtain their goods on credit generally from local wholesalers and settle bills periodically. Their stock in trade is limited and generally depends upon their financial condition and local demand. Retailers quickly replenish items which are much in demand among the people.

As per field survey adjacent sampling locations i.e. Kharod village & Sanjali town with Panoli GIDC is highly populated & developed areas that’s why approximately 20 percent population of both these sampled areas involved in business activities while in balanced

all the sampling villages 1% - up to 5% population are engaged in business activities such as small shops like general stores, fair price shops, tea stalls, food hotels, fruits, vegetables, chicken & mutton shops, clothes & tailoring shops etc. While wholesale market facilities, malls & multiplexes all are available in towns.

Perception Regarding Industrial Development: Due to industrial zone primarily a bulk drugs & chemical manufacturing zone with tag of critically polluted area that has put a blanket ban in January 2010 by the Ministry of Environment & Forest on the existing industries in the region to undertake any expansion activities. But as per recent assessment by senior officials of GPCB the area can no longer be categorized as critically polluted. As people are getting employment as well development of area & improvement

in their standard of living but along with these positive impacts people continuously suffered with pollution problems so they mostly response either negatively or neutrally regarding further development of industries in the region. People opined industrial development only take place in a condition when full fledge precautionary pollutions control measures should be compulsorily adhered on a regular basis without any lackness so any operational, expansion as well as any upcoming companies would not deteriorate the environment quality & health of locals & agriculture activities by polluting the area. Plus people want along with industrial development, local populations must be recruit & action should be taken for the overall development of natives & villages located nearer with Panoli GIDC within the study area. The villages are mostly lacking in the

areas namely sanitation facilities – drains, toilets & garbage disposal facility, health facilities, educational facilities, potable drinking water, approach roads both main & internal, tribal areas / padas located within the villages not having a potable drinking water, internal roads etc. Emphasis should be given for more development of farming & its allied activities i.e. irrigation facility & agriculture market facility & animal husbandry

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development activities - dairy farm development & assistance for development of small scale business to self-help groups & skill enhancement programs for youth etc.

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ANTICIPATED ENVIRONM ENTAL IMPACTS & MITIGATION MEASURES

Introduction

Any Organic Chemical manufacturing has various impacts during construction commissioning, operation phase and at end of project life on environmental parameters like land environment, water quality, air quality of surrounding area and due to

generation of solid and hazardous wastes.

Identification of Impacts

Environmental impact identification is based on stage of project and the type, scale and

location of proposed project activity. Environmental components that may be affected

negatively and positively due to proposed activity are identified for construction and

operation phase and presented below:

Table 4.1 Environmental Aspects and Impacts of the Project

Sr. No.

Step/Activity Environmental Aspect

Impact Type Severity

1.0 Construction of buildings and Erection of Plant

Emission to air (dust) Air Pollution Temporary Use of water, energy and materials

Natural resources, conservation

Temporary

Use of manpower Employment Temporary Hazardous and nonhazardous Waste Disposal on land

Land pollution Permanent

Cutting of Trees Biodiversity loss Temporary 2.0 Commissioning Use of water, energy

and materials Air Pollution Temporary

Use & storage of hazardous chemicals

Safety, Occupational Hazards

Temporary

Waste Water discharge

Water Pollution Temporary

Hazardous and nonhazardous Waste Disposal on land

Land Pollution Temporary

3.0 Operation Use of Water Natural resources/ conservation

Permanent

Wastewater discharge

Water Pollution Permanent

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Sr. No.

Step/Activity Environmental Aspect

Impact Type Severity

Hazardous and nonhazardous waste for disposal

Land Pollution Permanent

Use of manpower Employment Permanent Use of material, energy and resources

Air Pollution Permanent

Use & storage of materials

Safety, Occupational Hazards

Permanent

Production of goods Revenue Generation

Permanent

Operation of Plant and machinery

Noise Pollution Permanent

4.0 Closure and Decommissioning

Stoppage of New product

Revenue & employment loss

Permanent

Decommissioning Land pollution Permanent

Prediction of Impacts during Construction Phase and Mitigation Measures

Anticipated Impacts

Plant erection involves leveling of land and excavation. Solid waste generated will include demolition rubble, substratum removed during foundation, broken concrete, glass, bricks and scrap iron pieces, insulation, packaging materials, plastic drums etc. Hazardous waste generated includes paint drums, glass wool insulation, etc. Improper waste disposal can lead to unhygienic conditions and hazards to nearby populace.

Construction material (concrete, iron sheets, plant and machinery etc) transport will lead

to increase in number of vehicles plying on GIDC roads by about 4 – 5 nos/ day. However existing service road is tarred by GIDC and hence no traffic congestion is expected.

Mitigation Measures

• Separate area will be earmarked for storage of solid wastes generated while hazardous wastes will be stored in existing covered area earmarked for the purpose

• Substratum removed during foundation, broken pieces of concrete, bricks will be given for leveling of nearby plots for other industries as directed by GIDC

• wastes like broken glass, plastic drum/ bags / iron scrap etc will be sold to scrap

dealers for recycle

• Waste paint cans, brushes and filters, glass wool material and packing will be stored separately and disposed of to CHWTSDF facility.

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• Separate space shall be earmarked for parking of construction trucks so that they do not clog GIDC road. Heavy material will be brought in during night time only.

Anticipated Impacts

Water (15 - 20 cmd) required will be supplied from GIDC supply line. About 50-100 workers from nearby villages will be employed during construction. Additional Sewage generation will be treated in soak pit during construction phase.

Mitigation Measures

• Temporary arrangement of clean drinking water will be provided for workers

• Toilets will be provided and connected to septic tanks discharging to soak pits (during construction phase).

Anticipated Impacts

Impact on air environment will be due to dust generation and will be highly localized and confined to plant boundaries. Also, there are no human settlement upto 1 km from site, hence impact will be localized and temporary in nature. Particulate emissions may cause

occupational health like respiratory problems i.e. allergic asthma and watering of eyes etc.

Mitigation Measures

• Provision of PPE (dust masks, goggles) for onsite workers.

• Screening of construction area at boundary with tin sheets

• Periodic water sprinkling in the construction area.

Anticipated Impacts

There is no wild life sanctuary/national park located within study area. There is considerable agricultural fallow and urban area in study area. The proposed expansion is in part of notified industrial area of GIDC. Construction phase involves leveling, removal of herbaceous vegetation within plot, civil construction, plant erection etc.

Species of existing herbs within plot that need to be cleared are found commonly in the region and does not have conservation concern. Clearing herbs does not pose significant impact on flora. No mass nesting was observed within site during site visit, owing construction activity there will be insignificant adverse impact on fauna also.

Particulate emissions during construction will have some impact on trees located near construction site. However, since the particulate are non-toxic in nature and emission is temporary thus no serious impacts are considered.

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Mitigation Measures

• Provide barriers around site with water sprinkling to reduce particulate dust generation

• About 100 numbers trees will be planted around new plant boundary and on road sides adjoining plot.

Anticipated Impacts

Noise and vibrations will be generated in construction phase. The project site is part of

GIDC and there is no human settlement in 1 km vicinity of the site, thus the noise

generated will not have any major impact in the study area. As the phase of construction

and plant erection will be of temporary nature, noise pollution will be confined to plant

boundaries only.

Mitigation Measures

• Adequate PPE (ear muffs, ear plugs) for construction workers.

• Adequate barrier will be provided to prevent noise propagation.

• Use construction machinery meeting in EP Act norms for noise.

Anticipated Impacts

Health of workers may be affected due to dust and noise and possibility of accidents.

Mitigation Measures

• Adequate provision of PPE (helmets, safety shoes, harness, ear plugs, muffs, dust masks) for construction workers.

• Insurance for construction workers and extending medical facilities to all concerned.

Impacts on socio-economic environment due to proposed project during construction phase are envisaged due to direct and indirect employment which will be beneficial.

Anticipated Impacts

There will be temporary employment for about 100 persons over about 8 - 12 months. It will create business opportunities to suppliers of construction material, fabricators, manpower suppliers, civil contractors etc Local labors will be employed during construction phase.

Mitigation Measures

• Engage local contractors for non-specialized work

• Provide adequate water supply and sanitation for onsite workers.

• Employ local labors and youth for construction work

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Prediction of Impacts during commissioning and operation phase and mitigation Measures

Impacts during commissioning and operation phase will be due to:

Use of water: Additional water requirement for plant operation will be ~ 508 cmd and will be sourced from GIDC and from recycle.

Similarly, electricity required will be sourced from DGVCL. During commissioning stage the water and energy demands will be fluctuating as plant and machineries will be

commissioned in phased manner.

Use of materials, hazardous chemicals Industry will be using Methanol, Toluene, Sulphuric acid, nitric acid, styrene, o xylene, m xylene, propionic acid, 1 octanol, hydrogen peroxide, and many more chemicals for the first time at the site.. Incorrect procedures followed during initial stages can lead to accidental exposure to employees, leakage of chemicals thereby polluting land and water bodies.

Waste water generation during plant operation will result in estimated ~ 159 cmd of effluent (including sewage) for expansion project. Total effluent generation post expansion project is 164.58 cmd.

During commissioning phase risks of water pollution are enhanced since in plant pollution control facility such as effluent treatment plant will also be under commissioning and there might be shock load to effluent treatment plant.

Waste generation: As the plant operation shall not be stabilized immediately, there is possibility of failed batches which will need to be stored and recycled and disposed safely so as not to cause land pollution.

• Proper training to employees in handling chemicals mentioned by hiring trained

personnel well versed in handling such chemicals and processes.

• Personal supervision by Senior executive staff and HSE staff to ensure that there is no shock load to Effluent treatment plant. Active support from technology supplier and Quality control staff to ensure that the plant process is stabilized as soon as possible to ensure that loads to ETP remain at the predicted levels.

• Have a documented procedure to ensure waste generated during commissioning is collected separately, segregated and sent to CHWTSDF site.

• DCS controlled / PLC controlled Automated closed circuit process control will be

provided. Due to advanced control system, with multiple check points where

hazards are involved, and additional backup system to make the system fail safe,

and the latest system adoption will ensures better control over process and

mitigate any hazards.

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• Double Mechanical seals will be provided to all pressure reactors/pumps

involving hazardous operation. All safety precaution will be taken to ensure safe

operations. The use of Double mechanical seal helps in environment, plant, and

personal safety, so that in case, one mechanical seal fails, there is no exposure of

any hazardous gas to atmosphere, as the other seal takes over. The reactors will

be provided with safety valve and rupture disk, for safety purpose, and the vent of

which will be collected in suitably sized enclosed vessel.

• Interlocks will be provided at appropriate place for safety purpose. This interlocks

help in ensuring plant, environment, human, and process safety.

• Close loop process from unloading of Raw material to packing, no exposure to

atmospheric condition, and to avoid any hazards.

• Multi Tier communication includes Walkie Talkie, Mobile phone, paging systems,

and intercoms. Due to effective communication, action can be taken immediately

when needed.

• Smoke detectors, Gas detectors, safety showers, will be provided at appropriate

locations.

• Assembly point, safety evacuation, Mock drill, breathing apparatus to be provided

at various locations for environmental safety and human safety.

Anticipated Impacts

Major concern in land environment during operation phase is contamination of land by:

• Disposal of ETP sludge / MEE salts

• Spill and leak during transport, handling, storage activity of chemicals

• Spill of oil and greases during maintenance of equipment, machineries and vehicles

• Improper storage/dumping of hazardous wastes, resulting in leachate contaminating the soil

• Contaminated runoff from site and contaminated drain from storage areas of hazardous wastes and chemical storages, tanker loading/unloading areas draining to land

• Transportation in tanker or drums through national highway, which may have considerable impacts on environment of the area falling in the route of the transportation. During the incidence of major accident, the hazardous materials being transported can have serious impacts on land where on it spilled or leaked.

Mitigation Measures

• ETP sludge & MEE salts shall be disposed to CHWTSDF facility

• Production, maintenance area and warehouses for storage of raw materials, finished products and hazardous wastes will be provided with impervious flooring.

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• All bulk storage tanks will be provided with adequate dyke walls to prevent spreading of spill or leaked chemicals causing contamination of soil.

• Necessary cleanup procedures (SOPs) for the specific area will be designed and implemented.

• Used oil from machineries/equipment etc. will be collected in drums & stored in designated storage area.

• ETP facilities for management of effluents will be provided as planned during erection and commissioning phase and untreated effluents will not be disposed off on land.

• The chemicals used will be transferred through closed pipelines by DCS control system to avoid/prevent spill/leak of the materials.

• Hazardous waste management will be done as per statutory guidelines & requirements. ETP sludge generated is dried in mechanical dewatering system and stored on sludge drying beds or kept in sacks in covered godowns, with impervious flooring sloping so that any leachate will be collected and taken back for treatment.

• Empty Chemical drums will be decontaminated and reused/recycled or sent back to supplier or sold to GPCB authorized party.

• All transportation of hazardous wastes will be done in closed truck/tanker by GPCB approved agencies

• HAZMAT guidelines will be followed for transport of all hazardous materials. All required safety & emergency equipment & materials will be provided on the transport vehicles.

• Proponent will maintain a good spill or leak control action plan to cope up with such incidents.

• Monitoring of soil samples in areas near hazardous waste storage will be done as

per Environmental monitoring plan.

• No waste will be stored on open barren land under any condition

Anticipated Impacts: Additional Water use & Wastewater Generation

As seen in chapter 2, additional water requirement during operation phase will be ~ 508 CMD.

The proposed project will result in generation of effluents from process, cooling tower/ boiler, equipment / floor wash, and domestic sewage.

The Effluent Treatment facility will also have to be fail safe since there is no discharge permitted. And the treated effluent has to be recycled within the site.

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Impacts on water resources may also occur as secondary impacts of soil contamination as well as runoff of contaminated water from premises resulted due to the spill/ leak of hazardous chemicals or from leachates from hazardous waste storage areas.

Mitigation Measures Water Environment

RMCPL is proposing to establish a full-fledged ETP facility with tertiary treatment facility for treatment of effluents followed by RO & MEE so as to recycle entire treated effluent.

Proposed ETP scheme

Trade effluent from existing activity is NIL while wastewater generation sources from

proposed activity are Domestic sewage, Plant processing/ washings, Reaction water, Cooling Tower blow down, Boiler blow down, DM / Water softening plant – Backwash and regeneration water

• It is proposed to first segregate High TDS wastewater from Low TDS Low COD wastewater and treat these two sources separately.

• High TDS wastewater will be treated in a well designed Multi Effect Evaporate (MEE).

• Condensate from MEE will be further treated in the effluent treatment plant while the inorganic salt paste will be disposed of by selling to respective industries.

• Low COD Low TDS wastewater will be treated in a well designed effluent treatment

plant including MEE Condensate and Domestic Effluent in conventional primary, secondary and tertiary treatment followed by Disinfection, Sand filtration and AC Adsorption.

• Equalized and homogenized treated effluent shall be further treated through a suitably designed UF/RO system.

• RO Permeate shall be recycled to cooling tower or for suitable use and the Reject from this unit shall be subjected to evaporation either by MEE or ATFD system of MEE so as to recover separately condensate and inorganic salt paste.

• Recovered condensate from the MEE will be either reused / recycled within facility or

will be treated in the Effluent Treatment Plant.

• Recovered salt paste shall be disposed by selling to respective industry or will be sent for Landfill at Common Hazardous Waste Treatment Storage Disposal Facility.

Figure below shows the Proposed Effluent Treatment Process:

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Figure 4.1 Proposed Effluent Treatment scheme

Storm water collection and disposal

Appropriate care will be taken while designing the storm water network so that Storm water from the entire plot will be collected through network of storm drains. Storm water from plot area will be channeled to outside GIDC provided drain.

Total Water balance diagram

As mentioned above, with effluent treatment scheme, overall water balance shall be as follows,

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Figure 4.2 Total Water balance

Following mitigation measures will be adopted to reduce impacts on water environment:

• Implementation of scheme of in plant pollution control system for process effluents generated (as described in chapter 2) comprising

• segregation of process effluent and treatment

• Implementation of measures for management of hazardous chemicals/wastes as given under land environment

• Regular monitoring of effluents for statutory purpose and to gauge the functioning of ETP and in plant effluent treatment system to be carried out as given in Chapter 6

• Proper preventive and breakdown maintenance of ETP units from civil, mechanical, electrical and instrumental angle will be undertaken

• Regular log book of ETP and in plant effluent treatment system will be maintained to indicate chemical consumption and operational status of equipment

• Regular records of energy consumption for ETP units will be maintained

• Close monitoring of effluents will be undertaken to ensure proper functioning of ETP to meet GPCB norms

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• The treated effluent shall be reused on site as CT make up/used for gardening on site

• Online monitoring of effluents streams will be undertaken including flow measurement

Impact on air environment is anticipated due to proposed fired boilers and Thermic Fluid heaters.

Fuel Requirement- Proposed

Fuel requirement for proposed Boilers, Thermic Fluid heaters & Emergency DG sets shall be as follows:

Table 4.2 Fuel Requirements for proposed Boilers / TFH & DG sets

No Capacity Nos Fuel (natural Gas) requirement

1 Boilers (5 TPH each) 2 (running)+ 1 (standby)

2 x 338 Nm3/hr

2 TFH’s (Low temp) (5 Mkcal/hr) 2 (running)+ 1 (standby)

2 x 692 Nm3/hr

3 TFH’s (High temp) (1.5 Mkcal/hr)

1 (running)+ 1 (standby)

1 x 194 Nm3/hr

4 3 x 500 KVA 3 (Emergency requirement)

3 x 150 Nm3/hr

There will 2 process stacks followed by scrubbers installed for process emissions.

Quantitative Assessment of Impacts due Fuel Burning

Impact on air environment is anticipated due to emissions from fuel burning (NG)

(though very low) leading to emission of sulfur dioxide and NOx.

The proponent is proposing to provide adequate stack heights for Boilers, TFH’s and DG sets as per CPCB norms.

Details of stacks proposed are given in table below:

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Table 4.3 Air Pollution Sources : Proposed Operations

Stack number (proposed) Unit 1 2 3 4 5 6 7 8

Attached to - Boiler Boiler Boiler TFH1 TFH2 TFH3 HT TFH1 HT TFH2

Capacity / Duty - 5 TPH 5 TPH 5 TPH 5 Mkcal/hr 5 Mkcal/hr 5 Mkcal/hr 1.5 Mkcal/hr 1.5 Mkcal/hr

Fuel type - NG NG NG NG NG NG NG NG

Sulphur content in NG (assumed)

mg/nm3 30 30 30 30 30 30 30 30

Fuel quantity Nm3/hr 338 338 338 692 692 S/B 194 194

Sulphur content in NG kg/hr 0.01014 0.01014 0.01014 0.02076 0.02076 - 0.00582 0.00582

SO2 emission kg/hr 0.02028 0.02028 0.02028 0.04152 0.04152 - 0.01164 0.01164

Material of construction - CS CS CS

Shape (round/rectangular) - Round Round Round

Calculated stack height, m (above ground level)

meter 30 30 30

Diameter/size, in meters at top meter 0.8 1.0 0.5

Cross sectional area at top m2 0.50272 0.7855 0.196375

Flue Gas quantity Nm3/hr 15342 20940 5870

Flue Gas temperature Deg C 150 150 150

Flue Gas quantity m3/hr 23772 32445 9095

Flue gas exit velocity meter/sec 13.14 11.47 12.87

Particulate Matter grams/sec 0.639 0.873 0.245

SO2 grams/sec 0.017 0.083 0.006

NOx grams/sec 0.430 0.587 0.165

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a) Stack height calculation for Boiler (as per CPCB guidelines)

Fuel consumption (Natural gas) = 2 x 338 Nm3/hr

Sulphur content in NG = 30 mg/nm3

Sulphur oxide generation= 2 x 0.02028 = 0.04056 kg/hr

Minimum calculated stack height = 14 x (0.04056)^0.3 = 6 meters

30 m stack height will be provided for boiler.

b) Stack height calculation for Low Temperature Thermic Fluid Heater (as per CPCB guidelines)

Fuel consumption (Natural gas) = 2 x 692 Nm3/hr

Sulphur content in NG = 30 mg/nm3

Sulphur oxide generation= 2 x 0.04152 = 0.08304 kg/hr

Minimum calculated stack height = 14 x (0.08304)^0.3 = 7 meters

30 m stack height will be provided for Low Temperature TFH.

c) Stack height calculation for High Temperature Thermic Fluid Heater (as per CPCB guidelines)

Fuel consumption (Natural gas) = 2 x 194 Nm3/hr

Sulphur content in NG = 30 mg/nm3

Sulphur oxide generation= 2 x 0.01164 = 0.02328 kg/hr

Minimum calculated stack height = 14 x (0.02328)^0.3 = 5 meters

30 m stack height will be provided for High Temperature TFH.

Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed activity

In order to compute air quality impacts due to proposed additional sources, dispersion modeling studies are carried out using the AERMOD model, assumptions of which are as given below:

• Steady state conditions & uniform emission rates

• No removal/ transformation of pollutants

• Pollutant material

• Averaging time 24 hours

The AERMOD is steady state advanced Gaussian plume model that simulates air quality

and deposition fields up to 50 km radius. It is an advanced version of Industrial Source

Complex (ISCST3) model, utilizes similar input and output structure to ISCST3 sharing

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many of the same features, as well as offering additional features. The model is applicable

to rural and urban areas, flat and complex terrain, surface and elevated releases and

multiple sources including point, area, flare, line and volume sources. AERMOD is

approved by USEPA and is widely used software for air dispersion modelling studies. For

prediction of maximum Ground Level Concentrations (GLC’s), the air dispersion

modelling software, AERMOD have been used.

Model overview

The AERMOD model features include:

• The ability to model dispersion of primary pollutants, toxic and hazardous waste

pollutants;

• The ability to handle multiple sources in an industrial complex (point, area,

volume and pit types) with no buildings or single or multiple buildings with

building downwash;

• Constant or time-varying emissions;

• Gas and particle depositions;

• Concentration estimates for all terrain locations, except in lee areas;

• Predictions at distances up to 50 km from the source;

• Specification of receptors locations as gridded and/or discrete receptors in

Cartesian or polar coordinates; and

• Use of real-time meteorological data to account for the atmospheric conditions

that affect the dispersion of air pollutants.

Dispersion modelling using AERMOD requires hourly site specific meteorological data

which include wind direction, wind speed, temperature etc. AERMET is integral software

of AERMOD. AERMET provides a general purpose meteorological pre-processor for

organizing available meteorological data into a format suitable for use by the AERMOD

air quality dispersion model. Site specific data is used for executing current modelling

studies. The site specific meteorological data is processed using AERMET processor and

resultant output (pfl file) is used for air pollutant modelling study.

Model Set up

The model set-up details are presented in Table below.

# Parameter Details

1 Model Name AERMOD

2 Model Type Steady state Gaussian Plume Air Dispersion

model

3 Topography Flat

4 Averaging Time 24 hours

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# Parameter Details

5 Source Type Point Source

6 Boundary Limits 10 km X 10 km

7 Co-ordinate System Uniform Polar Grid

8 Receptor Height 2 m

9 Surface meteorological data Pre-processed from Site Data

10 Upper air Data Pre-processed from Site Data

11 Anemometer Height 10 m

Model input

Site specific meteorological data for a period of three months (March 2018 to May 2018) has been processed using AERMET. Site specific wind rose generated is shown in Figure below. As per the wind rose, it can be observed that the predominant wind direction is from southwest and west direction.

Figure 4.3 Windrose – Summer 2018

Emission rates considered for modeling of SO2, NOx and PM10 are given in table above.

Results

The model simulations have been carried out to evaluate the pollutant emissions from

the project that are likely to contribute to the ambient air environment. For the short-

term simulations, the concentrations are estimated and evaluated to obtain an optimum

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description of variations in concentrations over the site within 10 km radius covering all

the directions. The predicted results for pollutants are presented in Table below and

isopleths showing the incremental concentrations are presented in Figures below.

Based on the modeling results, the highest incremental increase in concentration of Pollutants are summarized in the table below:

Table 4.4 Top 10 incremental concentrations

Highest

Values

X Coordinate (UTM)

Y Coordinate (UTM)

PM10, Concentration

in µg/m3

SO2, Concentration in µg/m3

NOx, Concentratio

n in µg/m3 mts mts

1st 294065 2383803 0.3 0 0.2

2nd 294165 2383803 0.3 0 0.2

3rd 294046 2384011 0.3 0 0.2

4th 294145 2384029 0.3 0 0.2

5th 293965 2383803 0.3 0 0.2

6th 294265 2383803 0.3 0 0.2

7th 294243 2384046 0.3 0 0.2

8th 293948 2383994 0.3 0 0.2

9th 294440 2384081 0.3 0 0.2

10th 284365 2383803 0.3 0 0.2

Note: though there will not be any emission of PM due to natural gas firing, however modeling is carried out based on PM emission norm.

The concentration of incremental GLC is added to the baseline concentration at locations in the study area to indicate predicted the ground level concentrations.

Modelling Impacts on PM10

Based on the modeling results, isopleths for incremental increase in concentrations for PM10 are drawn and is shown below:

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Figure 4.4 Isopleths for PM10

Based on the modeling results, the highest incremental increase in concentration of PM10 occurs at coordinates in the west direction at a distance of 1200 m and the incremental increase is 0.30 µg/m3.

The maximum concentration of GLC is added to the baseline concentration at locations in

monitoring areas in the study area to indicate the predicted ground level concentrations.

Table 4.5 Prediction of GLC of PM10

AAQM location Back Ground value (µg/cum)

Predicted GLC (µg/cum)

Net Impact (µg/cum)

Norms* (µg/cum)

Project site 87.1 0.3 87.4 100 Sanjali village 82.3 0.3 82.6 100 Bakrol village 75.4 0.3 75.7 100 Bhadi village 75.1 0.3 75.4 100 Borsara village 82.2 0.3 82.5 100 Alonj village 85.0 0.3 85.3 100 Umarwada village 65.7 0.3 66.0 100 Kharod village 79.8 0.3 80.1 100

(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazzette Notification dated 16th November 2009.

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Modelling Impacts on SO2

Based on the modeling results, isopleths for incremental increase in concentrations for SO2 are drawn and are shown below using aerial view of the site using google earth which is shown below:

Figure 4.5 Isopleths for SO2

Based on the modeling results, the highest incremental increase in concentration of SO2

occurs at coordinates in the west direction at a distance of 1200 m and the incremental

increase is nil µg/m3.

The maximum concentration of GLC is added to the baseline concentration at locations in monitoring areas in the study area to indicate the predicted ground level concentrations.

Table 4.6 Prediction of GLC of SO2

AAQM location Back Ground value (µg/cum)

Predicted GLC (µg/cum)

Net Impact (µg/cum)

Norms* (µg/cum)

Project site 15.8 0 15.8 80 Sanjali village 9.5 0 9.5 80 Bakrol village 14.5 0 14.5 80 Bhadi village 7.2 0 7.2 80 Borsara village 19.7 0 19.7 80 Alonj village 17.9 0 17.9 80 Umarwada village 19.3 0 19.3 80 Kharod village 13.8 0 13.8 80

(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazzette Notification dated 16th November 2009.

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Modelling Impacts on NOx

Based on the modeling results, isopleths for NOx are drawn and are superimposed on an aerial view of the site using maps from Google Earth which is shown in the figure below:

Figure 4.6 Isopleths for NOx

Based on the modeling results, the highest incremental increase in concentration of NOx occurs at coordinates in the west at a distance of 1200 m and the incremental increase is 0.2 µg/m3.

The maximum concentration of GLC is added to the baseline concentration at locations in monitoring areas in the study area to indicate the predicted ground level concentrations.

Table 4.7 Prediction of GLC of NOx

AAQM location Back Ground value (µg/cum)

Predicted GLC (µg/cum)

Net Impact (µg/cum)

Norms* (µg/cum)

Project site 21.7 0.2 21.9 80 Sanjali village 12.6 0.2 12.8 80 Bakrol village 18.4 0.2 18.6 80 Bhadi village 10.1 0.2 10.3 80 Borsara village 25.7 0.2 25.9 80 Alonj village 23.8 0.2 24.0 80 Umarwada village 23.4 0.2 23.6 80 Kharod village 18.7 0.2 18.9 80

(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazette Notification dated 16th November 2009.

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Observations from dispersion modeling studies

From the dispersion modeling studies conducted, it is observed that the maximum ground level concentration occurs in the west direction.

It is concluded that the predicted incremental increase will have negligible impact on the air environment.

Other Air Pollution Impacts

1. VOC Emissions from Process:

The chemicals being proposed for manufacture are organic chemicals and will lead

to increased emissions of volatile organic chemicals during handling, storage and from process and emergency vents.

VOCs are harmful to human health and cause secondary air pollutants on emission into atmosphere. This will lead to increased odor nuisance for neighboring populace and industrial environment.

Mitigation Measures

Following mitigation measures are planned and suggested in view of air environment during operation phase:

1. Controlling VOC emissions:

• Transportation must be done in closed approved vehicles only. All safety & control measures shall be provided to prevent spill, leak and accident during transportation.

• All transport vehicles must comply with HAZMAT guidelines & statutory requirements.

• It is essential that best practicable control measures and practices are introduced to control VOC emissions from plant. This shall include:

• Providing vent condensers to control VOC emissions

- Ensure that cooling water/chilled water supply to the condensers is always maintained by providing standby pumps and DG power

- Having a preventive maintenance program

- Providing mechanical seals on agitators, pumps, etc

- Training for staff in fitting out seals, packings etc so as to ensure that they are properly fitted and do not “leak”

2. General:

Provide green belt all around the factory to ensure that site is screened from

surroundings and air impacts are reduced.

Proposed Process Stacks

Two process stacks are proposed to be added for emission control.

The gaseous emission from process will be scrubbed.

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Water circulation pumps of scrubber shall be provided with dedicated DG power supply in addition to normal power supply.

The impacts during operation phase of the establishment are mentioned below:

Anticipated Impacts

Operation phase involves transportation of raw material, work force and finished goods; operation of plant and machineries, this leads to increase in noise levels at site; however industrial area has several other noise sources, which overall establishes background noise level of GIDC area.

Propose project activity envisage insignificant adverse impact on fauna due to noise generation. Gaseous and particulate matter emission from stacks and other process related sources are predicted to increase levels of particulate matters, SO2 & NOx.

Threshold limit of SO2 for sensitive species is 1820 µg/m3 for 1 hour exposure. Visible injury caused in the form of development of interveinal necrotic blotches. Similarly, threshold limit of NOx for sensitive species is 38000 µg/m3 for 1 hour exposure. Visible injury is seen same as in case of SO2.

Considering baseline environmental conditions, air dispersion modeling has been done, which indicates, incremental concentrations of gaseous pollutants together with existing baseline concentrations are lower than threshold limit specified in CPCB publication, March 2000 for Green belt Development.

Operation phase of project activity envisage insignificant adverse impact on flora and fauna, provided suitable pollution control equipment’s are efficiently working.

Mitigation Measures

Impacts of proposed establishment of organic chemicals at RMCPL is discussed in earlier

chapter; these impacts can be minimized by adopting following mitigation measures.

For particulate and noise abatement, two rows of trees will be planted all around the boundary of site.

Green belt will be developed in two levels i.e. tall, native and evergreen broad leaved species towards outer periphery whereas dwarf and native species towards inner side of it. This arrangement provides better screening effect. Objectives and principles of green belt development are listed below. In practice, green belt will be developed in consultation with horticulture expert, as per available species nearby. Indicative species list for green belt is given in Tables below.

Objectives of Green belt development

• Partial check on air pollution

• Partial check on noise level

• Increase in esthetic value of surrounding

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• Indirect partial help to maintain biodiversity

Principles of Green belt development

- Green belt will be composed of native species

- Species will be suitable for agro-climatic zone

- Species will be selected according to soil type, climate, rain fall etc.

- Taller plants will be planted towards outer periphery

- Shorter plants will be planted towards inner periphery

- Evergreen species will be selected as far as possible to have least litter fall

- Plant will be tolerant to air pollution

- Green belt will have indicator species with respect to air pollution

- Species may have quick growing ability

There shall be monitory provision made for development of green belt. Plantation of species must be started prior to commencement of construction phase. There shall be separate monitory provision made for maintenance of green belt. A gardener shall be appointed for the same. Maintenance shall include watering and manuring plats at appropriate time, weeding out unwanted plants, cleaning, replacing wilted/died plants etc. Polyalthia longifolia and Millingtonia hortensis are sensitive species. Therefore these species will be planted as a part of green belt and serves as indicator for concentration of gaseous pollutants emitted from stack.

Area proposed under green belt is about 29420.43 m2 Green belt lay out is presented in Annexure 2.1.

In operation phase, yearly monitoring will be conducted to assess any sort of impact due to project activity on flora and fauna, for first three years. Frequency of monitoring may be reduce to once in three years from forth year. Reports prepared based on monitoring,

primary surveys will be conserved as record and made available on demand. Monitoring will be conducted by QCI-NABET approved Functional Area Expert for Ecology & Biodiversity or department of Botany/Zoology, Mumbai University or officials of forest department.

Table 4.8 Suggested Species for Green Belt – Outer pheriphery

Sr. No.

Scientific name

Common name Height

(m) Growth

rate Evergreen/ Deciduous

Crown Shape

1. Anona

squamosa Custard apple 10

Fast Growing

Evergreen Round

2. Mimusops

elengi Bakuli 10

Fast Growing

Evergreen Oblong/ Round

3. Lagerstroemia

speciosa Queen Crape

Myrtle 10

Fast Growing

Evergreen Oblong

4. Polyalthia longifolia

Ashok 10 Fast

Growing Evergreen

Conical/ Rounded

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5. Careya arborea Kumbhi 8 Fast

Growing Evergreen Spreading

6. Mangifera

indica Mango 15

Fast Growing

Evergreen Round/ oblong

7. Ficus

glomerata Umber 15

Fast Growing

Evergreen Spreading

8. Hardwickia

binata Anjan 8

Fast Growing

Evergreen Spreading

9. Aegle marmelos Bel 10 Fast

Growing Evergreen

Round/ oblong

10. Feronia

elephantum Kawath 12

Fast Growing

Evergreen Round/ oblong

11. Azadirachta

indica Neem 8

Fast Growing

Evergreen Spreading

12. Cochlospermum

religiosum Ganeri 10

Fast Growing

Evergreen Spreading

13. Holoptelea integrifolia

Ainsadada/ Vavla

10 Fast

Growing Evergreen Spreading

14. Balaniles

roxburghii Hinganbet/Hingu 10

Fast Growing

Evergreen Spreading

Table 4.9 Suggested Species for Green Belt – Inner pheriphery

Sr. No.

Scientific name

Common name

Height (m)

Growth rate

Evergreen/ Deciduous

Crown Shape

1. Helicteris

isora Murad sheng

5 Fast

Growing Evergreen

Round/ oblong

2. Gymnosporia

montana Henkal 3

Fast Growing

Evergreen Spreading

3. Holarrhena puboscens

Pandhra-Kuda

3 Fast

Growing Evergreen Oblong

4. Bauhinia purpurea

Butterfly Tree

7 Fast

Growing Deciduous Oblong

5. Bauhinia racemosa

Astha 5 Fast

Growing Deciduous Oblong

6. Gardenia

jasminoides Anant 5

Fast Growing

Evergreen Oblong

7. Hibiscus rosa-

sinensis Chinese Hibiscus

3 Fast

Growing Evergreen

Round/ oblong

8. Nyctanthus arbor-tristis

Parijatak 5 Fast

Growing Deciduous

Oblong/ Round

9. Psidium guava

Guava tree 5 Fast

Growing Evergreen Oblong

10. Calycopteris floribunda

Ukshi 3 Fast

Growing Evergreen Spreading

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Anticipated Impacts

Noise & vibrations generated from the equipment & machineries including pumps, motors, blowers etc. can add to occupational noise level, exposing on site workers to hearing loss. The project is part of GIDC and 1 km away from nearest village. Thus, impacts of the noise sources of the project will be restricted within the premises only and will be within the prescribed norms of industrial area as well as occupational exposure.

Mitigation Measures

• Low noise generating equipment and working methods for production unit shall be selected to reduce noise generation in plant areas.

• Proper mounting of equipment & machinery on strong non-vibrating foundation & fitted by proper shunting & rubber padding to avoid vibration and thereby noise.

• Provision of ear protection equipment (ear plug/ ear muff) for activities that are likely to create noise in excess of 75 dB (A) to protect worker’s health and safety.

• Undertake in plant audit to identify high noise level generating equipment

• Preventive maintenance including regular lubrication of machineries and equipment to reduce noise level

• Static & dynamic balancing of all rotating equipment & machineries shall be done on regular basis starting from the installation time to reduce the vibration & noise.

• Regular noise monitoring shall be done as per environment monitoring plan chapter 6

• The impacts of noise on occupational health would be mitigated by proper shift timing & annual audiological checkup of concern employees. Workers showing hearing loss, if any, will be shifted to other less noisy areas.

• Dense Greenbelt development around the noise source area and along the boundary

of premises shall be done.

Anticipated Impacts

During operation phase, following nonhazardous and hazardous waste generation is expected. Waste if not stored properly may cause short term, temporary impact on the environment, particularly during monsoon season due leachate formation. Hazardous waste generation quantities from proposed operation are as follows:

Table 4.10 Non hazardous Waste Generation & Disposal Proposed

Sr No

Type of Waste Quantity UOM Mode of Disposal

1 Waste paper / corrugated boxes

1 TPA Sale to scrap dealer / recycler

2 Metal scrap 3 TPA

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3 Plastic waste 2 TPA

4 Wooden waste 2 TPA

Table 4.11 Hazardous Waste Generation & Disposal Proposed

No Waste Type

Category Existing quantity

as per CCA No

AWH 75308

Proposed quantity

Quantity after

expansion

Mode of disposal

1 Used or spent Oil

5.1 1000 Kg/Year

1000 Kg/ Year

2000 Kg/ year

Disposal by sale to registered

refiners 2 Discarded

container bags

/Liners

33.1 6.03 MT/Year

10.0 MT/ Year

16.03 MT/ Year

Collection, storage, reuse

and decontamination.

3 Used Catalyst

29.5 - 1.25 Ton/ Month

1.25 Ton/ Month

Used catalyst will be sent to solid waste disposal

facility or can be used for

preparation of bricks.

4 Used / Spent

Catalyst (Transition

metal)

29.5 - 5000 Kg/ year

5000 Kg/ year

Used catalyst will be send to

supplier for re-activation of

catalyst. 5 Process

waste /Distillation

column residue

29.1 - 95 Tons/ Month

95 Tons/ Month

Will be sent to common

hazardous waste incineration

facility 6 Chemical

sludge from waste water

treatment

35.3 - 100 MT/ Year

100 MT/ Year

CHWTSDF

7 Used Empty Barrels /

Liners

33.1 - 1000 Nos/ Year

1000 Nos/ Year

Sale to Authorized party

Hazardous Wastes will be stored in impervious lining/ flooring in covered shed. The chemical sludge from waste water treatment will be stored in bags and will be stored in shed and then disposed of to Common Hazardous Waste Treatment, Storage and Disposal

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Facility (CHWTSDF) periodically through trucks owned by GPCB authorized contractors or sold to GPCB authorized recyclers.

No impacts are envisaged on the 10 km surrounding study area in case above disposal methodologies are adhered to. However, close monitoring and control over waste disposal contractors/transporters by use of manifest system is essential to ensure that the waste reaches the designated waste disposal site and is not dumped in undesignated areas impacting agricultural areas, soil and ground water adversely.

Mitigation Measures

• Adequate use of PPE for onsite workers.

• Disposal through authorized recycler/ re-processor or to designated CHWTSDF site

• Follow of Manifest system scrupulously to ensure waste reaches designated site

• Disposal through GPCB authorized transport contractor

• Waste storage in designated covered area having impervious flooring and epoxy lining wherever necessary

• Maintenance of records as required under HW Rules 2016 and subsequent amendments

Anticipated Impacts

The proposed project involves use of hazardous raw materials as per MSIHC Rules, 2000 having fire and toxic hazards. O xylene, n Hexane, Nitric acid, sulphuric acid, m Xylene, Methanol, Toluene, IPA, Hydrogen, Styrene, Hydrogen peroxide, Acetic acid etc are of major concern for impacts on occupational health.

Continuous exposure of employee to the chemical beyond permissible limit (TWA/TLV) may result in acute or chronic toxic or lethal effects. A detailed Quantitative Risk Assessment (QRA) for the proposed project is conducted and it is noticed that the

hazardous condition causing serious effects on occupational health may occur only during the catastrophic incident as described in Chapter 7 Additional Studies. However, minor continuous exposure to toxic chemicals may lead to health issue in long term. Hence, it is necessary to monitor the health status of all employees on regular basis.

Further, impacts on occupational health may also occur due to works like manual lifting of heavy good, continuous working in single position, working in improper ergonomic conditions etc. Such condition or operations may lead to health problems like back ache etc. Considering these, proponent plans for closed automated transfer system for major raw materials as well as forklift & trolley for other handlings.

Mitigation Measures

• Proponent will make efforts to get & implement management systems such as ISO 9001, ISO 14001 & ISO 18001.

• Provision of facilities like safe drinking water & dining rooms etc. and good sanitation including proper waste disposal.

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• Isolation of drinking water & refreshment area including canteen etc. from the area of hazardous materials storage & handling.

• Chemical Safety Booklet/Documents for hazardous chemicals will be prepared and made available well before commissioning to all employees handling the chemicals.

• Strict Prohibition of edibles & potables in the area of hazardous materials storage & handling.

• Strict Prohibition of match box, lighters, and clothes having potential of static charges as well as smoking in plant & storage area.

• Proponent will ensure implementation of Emergency action plan including on-site & off-site emergency management plan.

• Proponent undertakes to do regular safety audit and necessary improvement suggested by auditor will be done on regular basis as required.

• Necessary emergency facilities including firefighting equipment, medical facilities, evacuation facilities etc will be provided within premises.

• Properly designed & designated storage area and provision of good handling equipment and procedures will be ensured before commissioning.

• Proper shift planning of workers exposed to hazard prone areas to manage the

total exposure level as per stipulated standards & / or statutory norms.

• Company will train a group of employee for comprehensive first-aid and basic fire-fighting training and ensure trained staff availability in all three shifts.

• Mechanical handling system will be provided wherever feasible to reduce the stress of pulling -pushing and lifting.

• Ergonomic design of all facilities wherever possible (e.g. chairs, tables, working platforms, self and position & height of display screens & panel etc).

• Management will provide all necessary PPEs, safety tools, equipment/tackles to

ensure healthy & safe work conditions.

• Workplace monitoring will be carried out on regular basis and corrective actions initiated as needed

• Necessary training programs & audit will be done on regular basis to improve workplace condition & provide safe work system.

• Company will continue to undertake Pre employment medical checkup and Periodic medical examination (once in a six month) and will maintain records in Form No-32 & 33 as per Factories Act.

• PFT & LFT test will be carried out during pre-placement and periodical

examination considering the toxic effects of various chemicals handled.

• Company follows all statutory guidelines related with occupational health & safety which will be extended to the proposed expansion also.

• Safety committee will be to ensure worker participation

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• Sample template for maintaining health records is as given below for information.

Figure 4.7 Sample template for Occupational health of the workers

Anticipated Impacts

Employment Opportunities

• The proposed project will have positive effect on socio – economic environment as there will be growth in employment i.e. about 100 new workers. During employment, local populace will be given preference considering their skills & suitability.

• The operational activities of propose project will also generate job opportunities for indirect labor to support activities such as transport, maintenance, fabrication, civil jobs at site, canteen and food suppliers and security etc.

Other Impacts

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• Due to pollution there may be certain health problems if adequate pollution control measures are not undertaken. Project proponent is committed to implement adequate precautionary measures from design stage onwards to mitigate/control the environmental pollution from proposed project to comply all emissions/discharges as well as manage/treat/dispose off the wastes as prescribed by MoEFCC/ CPCB with the objective of environment protection. Project proponent will use natural gas as fuel for boiler which has negligible pollution potential.

• Waste water generated from proposed establishment will be plan to treated onsite

& reused so there will not be any type waste water generate outside the plant. The unit will operate as zero liquid discharge unit.

• The industry proposes to manufacture organic chemicals which may be hazardous and/or might be toxic in nature. The industry will formulate a health and safety policy for the employee that governs working practices and priority to human life at the shop floor level and in the production plant as whole. Various provisions such as grant of personnel protective equipment, safety shoes, ear plugs etc. will be made available by the Project proponent. RMCPL has practice of periodic medical check-up and has arrangement with Doctors for the same. Impact of project on health of workers and local populace is deemed to be negligible only

with the implementation of proper schemes for containment of emissions and chemicals and proper provision of personal protective equipment to the workers.

• There is likely to be growth in the revenue generation and economy at local, regional and state levels.

• There will certainly be improvement in standard of living due to required facilities provided or upgraded by management under CSR. Like the insanitary conditions causes number of health problems and sanitary facilities are inadequate in rural area so project authority will take action for enhancing cleanliness and reducing insanitary conditions by constructions of drains, toilets, close open drains, construction of underground drains, provision of solid waste disposal facility etc.

• The proposed project establishment is at vacant land of RMCPL at GIDC Panoli (which is notified industrial area) so there is no land acquisition, rehabilitation & resettlement issues are not envisaged.

• The project is located in a well-developed zone, which have all essential facilities such as well-connected road network with ease of transportation, arrangement for supply of water and power to industries, effluent disposal facilities etc. So there will be no additional pressure on existing infrastructural facilities in the study area, in fact the villages falls within the study area will be more developed than earlier because lacking infrastructural facilities will be upgrade by the RMCPL

under proposed CSR activities

• The income of benefitted local population would increase by getting employment directly or indirectly, further it would improve the consumption pattern of employed houses which will definitely have a positive impact on the standard of living of the population.

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Corporate Social Responsibilities & Socio-Economic Welfare

In order to mitigate adverse impact likely to arise in social, cultural and economic aspects in the surrounding region the proposed project is expected to contribute towards upliftment of local people quality of life. The proposed project will help in improving socio – economic status of surrounding area as there will be direct employment generation 100 people. Preference will be given to local people at the time of man power recruitment. Preventive measures will be taken to control pollution, which may arise from the proposed project. Communication with local community will be institutionalized & done on regular basis by the project authorities.

Reshmika Minerals and Chemicals Private limited propose following social development activities / CSR activities under CER (Corporate Environment Responsibility) in the study area:

Table 4.12 Activities proposed for CER

Proposed Activities as per Specific Needs Frequency Selected Areas or Villages

Tree Plantation - Plantation of trees in village road side, formal

institution like Gram Panchayat office, local school area & health Centre area etc.

Need Based Nearby villages located within study area

Infrastructure development for sanitation - Construction of toilets or assistance to Govt.

programs for construction of toilets - Construction of drains - Construction of underground Drainage Line - Closed open drains - Development of Well-planned storm water

drainage system - Garbage Disposal Facility

Need Based Nearby villages located within study area (Sanjali (CT), Kharod, Panoli, Nana Borsara, Alonj, Bakrol & Dhamdod, Dinod, Hathuran & Adadara etc.)

Educational - Computers supply in school Need Based Nearby villages Schools

located within study area

CER Fund Provision

For the execution of propose social welfare activities Reshmika Minerals and Chemicals Private limited has earmarked budget of Rs. 97.5 lakhs. The mentioned budget allocation is as per recent OM F. No. 22-65/2017-IA. III issued by MoEF & CC on 1st May 2018 on Corporate Environment Responsibility (CER) the fund allocation for the CER is based on criteria such as % of capital investment for green field / brown field projects. For Brownfield projects, fund allocation is 0.75% of project capital investment (for Investment Rs. 100 Crores to Rs. 500 Crores). Reshmika Minerals and Chemicals Private limited is allocating Rs. 97.5 Lakhs (0.75% of project investment) for CER. The year wise allocated amount may vary time to time based on the needs and priorities in discussions with NGOs/Local Government authorities in vicinity of the study area.

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Table 4.13 Budgetary Allocation for CER

Activities Year

1st Year

2nd Year

3rd Year

4th Year

5th year

6th Year

7th year

Total

Tree Plantation - 3.0 3.0 - - - - 6.0

Infrastructure development for water and sanitation

- 10.0 10.0 15.0 15.0 15.0 14.0 79.0

Educational aid (computers) supply to schools

- 2.0 2.0 2.0 2.0 2.0 2.5 12.5

Total (Rs in Lacs) - 15.0 15.0 17.0 17.0 17.0 16.5 97.5

Letter submitted to District collector is enclosed at Annexure 4.2.

Prediction of Impacts during De Commissioning Phase and Mitigation Measures

This section examines impacts during decommissioning of project, should the need arise.

Impacts during de commissioning phase will be due to:

Stoppage of new production facilities The stoppage of production facilities will lead to having a stockpile of chemicals at the site, which will need to be safely disposed of. Decommissioning if not undertaken in a safe way may lead to catastrophic incidents which may have effects within/outside the factory. In addition, decommissioning will cause revenue loss to company and loss of employment to workers.

Waste generation there is possibility that failed batches will need to be stored and disposed safely so as not to cause land pollution

• Proper procedure for safe decommissioning shall be established as part of project development with training to employees

• Wastes generated will have to be identified and disposed of safely and site will not be considered shut down unless all wastes are safely disposed

• Have a designated procedure to ensure that workers do not suffer in this eventuality

Environmental Impact matrix

The possible impacts of various constructional and operational activities as identified above have been denoted in a matrix form. A quantitative matrix rating has been devised to give severity of impacts in the following manner:

• Highly Negative Overall Impacts: Total Score= above -353

• Moderately Negative Overall Impacts: Total Score= -176 to - 352

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• Slightly Negative Overall Impacts: Total Score= -1 to -176

• Neutral overall Impacts: Total Score = 0

• Slightly Positive Overall Impacts: Total Score= 1 to 176

• Moderately Positive Overall Impacts: Total Score= 176 to 352

• Highly Positive Overall Impacts: Total Score = above 353

The matrix system assumes the environmental indices into the following:

➢ Physical Parameters: Surface water quality

• Ground water quality

• Air quality & Climate

• Soil Quality

• Land use pattern & Topography

➢ Ecological Parameters:

• Forests/Parks/Sanctuary

• Flora & Fauna

• Aquatic ecosystem

➢ Social Parameters: Aesthetics

• Local Housing structure

• Services

• Health & Safety

➢ Economic Parameters: Agriculture

• Fisheries

• Industries

• Employment

The assessment of the impact of the general impacting activities on the above parameters

of environmental indices can be done by establishing a co-relation by “Cause and effect

relationship” with the help of impact matrices. The matrices for construction as well as

operation phase are presented below for two conditions:

• Without mitigation/control measures.

• With proposed mitigation measures for adverse / beneficial effects.

The criteria for evaluation of qualitative matrix are presented herewith:

1. No Impact (0): This indicates that the project activity is unlikely to have any impact on an environmental attribute.

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2. Negligible Adverse Impact (-1) / Negligible Beneficial Impact (+1): It signifies that the actions have minor effect, adverse or beneficial, on the environmental parameters concerned.

3. Significant Adverse Impact (-2) / Significant Beneficial Impact (+2): The activities and their environmental Impacts are judged to be significant if they create, or have the potential to create concern in the public or professional community.

4. High Adverse Impact (-3) / High Beneficial Impact (+3): The action that can create or have a potential to create controversy in the public or professional

community due to its long-term effect. They may be at times irreversible.

The environmental Impact matrix without mitigation / control measures during the construction phase and operation phase is given below, which shows the slightly negative impact of the project is (-)123 i.e no significant impact. The matrix with proposed mitigation measures during the operation phase is given below, which shows the overall impact with environmental controls is reduced to (-) 30 i.e. slightly negative.

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Table 4.14 Environmental Impact Matrix Evaluation without Mitigation Measures

Impact Source Parameters

Construction Phase Operation Phase

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Physico-chemical parameters: Surface water quality 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Ground water quality 0 -1 0 0 -1 0 0 0 0 -2 0 -3 0 0 -3 -2 -3 -3 -2 -16 Air quality & climate -1 0 -1 0 0 -1 -1 0 0 -4 -3 0 -3 0 0 -2 -2 -3 -2 -14 Soil quality 0 -1 0 0 -1 0 0 0 0 -2 -1 -3 0 0 -3 -2 -2 -2 -1 -14 Land use pattern 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Ecological parameters: Forest/ park/ sanctuary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Flora & fauna 0 -1 -1 0 0 0 0 0 +1 -1 -2 -2 -2 -1 -2 -1 -2 -2 +3 -11 Aquatic ecosystem 0 0 0 0 0 0 0 0 0 0 -2 -2 -2 0 -2 -1 -2 -2 +2 -11 Social parameters: Aesthetics -2 0 -2 0 -1 -1 -2 -1 0 -9 -2 -2 -2 -1 -2 -2 -2 -2 +1 -14 Local housing structure 0 -1 -1 -1 -1 -1 -1 -1 0 -7 0 -1 -1 0 -1 -1 -1 -1 0 -6 Service 0 -1 -1 0 0 -1 -1 -1 0 -5 0 -1 -1 0 0 -1 -2 -2 0 -7 Health & safety -2 -1 -1 -1 -1 -1 -1 -1 0 -9 -2 -1 -3 0 -2 -2 -1 -1 +2 -10 Economic parameters: Agriculture 0 -1 0 0 -1 -1 0 0 0 -3 -2 -3 -3 0 -2 -1 -2 -1 -2 -16 Fisheries 0 -1 0 0 -1 -1 0 0 0 -3 0 -2 0 0 -2 0 0 -1 -1 -6 Industries 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0 0 0 0 0 +2 +2 Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 0 0 0 -1 +1 Total -4 -8 -7 -2 -7 -7 -6 -4 +4 -41 -12 -20 -17 -2 -19 -15 -19 -20 +1 -123

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Chapter 4 – Anticipated Environmental Impact and Mitigation Measures

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Table 4.15 Environmental Impact Matrix Evaluation with Mitigation Measures

Impact Source Parameters

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Physico-chemical parameters:

Surface water quality 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Ground water quality 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 -1 -2 Air quality & climate 0 0 0 0 0 0 0 0 0 0 -1 0 -1 0 0 -1 -1 -2 -1 -7 Soil quality 0 0 0 0 0 0 0 0 0 0 -1 -3 0 0 -3 -2 -2 -2 -1 Land use pattern 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Ecological parameters: Forest/ park/ sanctuary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Flora & fauna 0 0 0 0 0 0 0 0 +1 +1 -1 0 -1 0 0 -1 -1 -1 +2 -3 Aquatic ecosystem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Social parameters: Aesthetics 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 -1 -1 0 -3 Local housing structure 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Service 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Health & safety 0 0 0 0 0 0 0 -1 0 -1 -1 0 -1 0 0 -1 -1 -1 +2 -3 Economic parameters: Agriculture 0 0 0 0 0 0 0 0 0 0 -1 0 -1 0 0 0 0 0 0 -2 Fisheries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Industries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 +2 +2 Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 0 0 0 0 +2 Total +1 0 0 0 0 0 0 -1 +3 +3 -3 -3 -4 0 -3 -6 -6 -8 +3 -30

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Chapter 4 – Anticipated Environmental Impact and Mitigation Measures

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Observations and Conclusions

The study for the proposed project of RMCPL has revealed that the upcoming activities of manufacturing will have negligible impacts which would mainly occur only upon Improper discharge of effluent/ release of untreated gaseous pollutant to air/ Improper disposal of solid waste/ accidental spill/ leak of volatile/ gaseous chemicals/ materials.

Risk assessment study has been conducted for the proposed project and the suggestions made in the report shall be implemented strictly to prevent any chances of environmental contamination and employee health & safety. By the efficient implementation of

Hazard/Risk control/Prevention measures the negative impacts would be avoided.

Besides, the hazardous waste generated from the production process & utility operation will be managed as per MoEF/CPCB/GPCB Guidelines. Hence issues of air & land contamination are not envisaged. The water requirement will be met by GIDC & through recycle of treated effluent hence no impact on ground water availability envisaged.

The proponent will plant varieties of trees & shrubs in the premises. The Greenbelt will be maintained in excellent condition giving visual of dense vegetation. The proponent will manage the greenbelt with all possible care & attention to improve environmental condition. Thus, the beneficial impacts due to the dense greenbelt are envisaged.

It is also found that the high noise generation sources are not part of proposed project. Hence noise levels are not expected to go up. The noise level out of the premises is envisaged to be <65-70 dB(A) in day and 55-60 dB(A) in night as maximum. Thus, looking to the source, potential noise level generation & planned mitigation measures; impacts due to noise are not envisaged.

Company intends to conduct the CER activities around the project area for social welfare & upliftment. Necessary documents & records of all activities shall be maintained.

All aspects of safety will be adequately managed and required safety material, equipment and facilities will be provided to all employees, contractor & visitors. Thus, issue of

impacts due to probable hazards/ risk/ disaster would be minimal.

Thus looking all the management intent, procedures/actions, proposed environmental management activities and other allied functions of management system, it is concluded that there will not be any major considerable impacts on environment.

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Chapter 5 – Analysis of Alternatives

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ANALYSIS OF ALTERNAT IVES (TECHNOLOGY & SITE)

Analysis of Alternative Sites

The proposed establishment will be located at Plot No 23, GIDC Industrial estate, Panoli, Tehsil Ankleshwar, Dist. Bharuch which comprises of total 89632.72 sq. m of land. Following aspects are considered during the site selection:

• Located in well-developed GIDC Industrial estate

• Availability of major raw material from nearby industries

• Availability of adequate land, utilities and infrastructure

• Synergy with RMCPL’s manufacturing activities

• Availability of technically skilled staff

• Availability of unskilled workers in the area

• Proximity to end users.

• Land is part of GIDC, doesn’t involve R&R issues.

• No water body i.e. river or Nallah flowing through the project site.

• Port facilities at Dahej and Mumbai.

• Well connectivity by road and Rail (Bharuch and Ankleshwar station)

• No human habitation in the project vicinity

• Availability of medical, educational facility, transportation and other infrastructure

• Fuel availability (NG from Gujarat Gas Company Limited)

• No reserved forests or sanctuaries or archeological sites are located in the vicinity of the area

• Common CHWTSDF facility of BEIL Ankleshwar

Analysis of Alternative Technologies

Various technologies are analyzed and are under considerations for manufacture of the proposed chemicals.

Well experienced and vibrant R&D program and expertise in process design and

development is actively engaged in developing best and safe process technologies globally approved and proven. RMCPL is committed to employ best available technology for manufacturing of proposed products. Latest design and instrumentations shall be used in process equipment selection. Best technology is selected based on various considerations including Environmental aspects.

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Chapter 6 – Environmental Monitoring Programme

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ENVIRONMENTAL MONITO RING PROGRAMME

Based on the predicted & assessed impacts as well as the baseline environmental status of the project area, an environmental monitoring program is suggested for implementation during various stages of the project cycle.

Objective of Environmental Monitoring Program

For tracking of the effectiveness of mitigation measures & EMP at specific interval, regular monitoring of the necessary environmental parameters is required. With this vision, an environment monitoring program is prepared with due consideration of the baseline status of the expansion project area, various components of project & environmental attributes likely to be affected.

Major objectives of the Environmental Monitoring Program are as under:

• To comply with the statutory requirements of monitoring for compliance with conditions of EC, Consent to operate and provisions under Factory Act & Environmental Protection Act provisions

• Assessment of the changes in environmental conditions, if any, during the project operation/activities.

• Monitoring & tracking the effectiveness of Environment Management Plan & implementation of mitigation measures planned.

• Identification of any significant adverse transformation in environmental condition to plan additional mitigation measures; if & as required.

RMPCL will implement the environment monitoring programs in line with the planned schedule. The company shall ensure that the necessary requisite facilities are made

available and budgetary provision is made as & when required to ensure regular efficient environmental monitoring activities.

Environmental Monitoring Program

Environmental monitoring parameters and frequencies of monitoring are given in below table. In case of accidental spill & leak of hazardous chemicals, monitoring of the environment for detection of the spilled/leaked chemical shall be done in the affected area. In such case, soil & groundwater sample of the affected area shall be collected and analyzed for detection of the spilled / leaked chemicals at regular interval for the period as required to ensure safe level of contamination.

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Chapter 6 – Environmental Monitoring Programme

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Table 6.1 Environment Monitoring Plan for the Proposed Facilities

Sr. No.

Project Phase Environmental Component

Parameters Frequency Locations Conducted by

1 Construction Air Environment Ambient air PM10 / PM2.5/ SO2/

NOx/CO Once/Month Adjacent to new

construction site MoEF approved Laboratory

Ambient Noise Level

Leq day and night time or over one work shift

Once/Month At new construction site

Water Quality Drinking Water

Quality Microbiological parameters as per IS 10500: 2012

Once/month Construction site -each drinking

water locations.

MoEF approved Laboratory

2 Commissioning Stage

Air Environment Ambient air PM10 / PM2.5/ SO2/ NOx/

CO/ nMHC Once/Month Adjacent to new

plant MoEF approved Laboratory

Ambient Noise Level

Leq day and night time or over one work shift

Once/Month Adjacent to new plant

MOEF approved lab

Water Quality Drinking Water

Quality Microbiological (as per IS 10500: 2012)

Once/month At each drinking water location.

MOEF approved lab

In plant ETP pH, TDS, COD, BOD and Oil and Grease, MEE solids, permeate and reject analysis

Once/shift ETP at intermediate stages and MEE

In house lab and periodically through MOEF approved lab

Waste Generated ETP sludge, MEE salts/sludge

As per Schedule II of HW Rules, 2008 and parameters for identifying disposal pathway as per CPCB

Once ETP / MEE CHWTSDF or MOEF approved lab for identifying disposal pathway

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Chapter 6 – Environmental Monitoring Programme

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Sr. No.

Project Phase Environmental Component

Parameters Frequency Locations Conducted by

3 Operation Phase

Air Environment

Stacks – Boiler/ TFH’s/ DG sets/Process stacks

TPM/ SO2/ NOx/ Acid mist

Once/ month

Respective stacks MoEF approved Laboratory + Online continuous Monitoring

Ambient Air PM10 / PM2.5/ SO2/ NOx/ CO/ nMHC/

once/month At 3 locations within site

MoEF approved Laboratory

Workroom environment

Ammonia, TPM, VOC Once/ 6 months

Plant / Storage/ handling Area

Oxygen Content/LEL Once per shift

Before vessel / confined space entry

Own laboratory

Water Environment ETP ETP Operational

parameters like pH, TSS, COD, TDS, MEE solids, Permeate and reject quality parameters

Daily Equalization, after primary clarifier, after secondary treatment, RO & MEE

Own QC lab

Parameters as per GPCB Consent.

Once/month At inlet and outlet of ETP

MoEF recognized laboratory + Online continuous Monitoring

Drinking water Microbiological parameters as per IS 10500: 2012

Once/ month

at each drinking water locations.

MoEF recognized laboratory

Noise Environment

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Chapter 6 – Environmental Monitoring Programme

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Sr. No.

Project Phase Environmental Component

Parameters Frequency Locations Conducted by

Ambient Noise Leq (day & night) Once/ month

At fence level and at nearest habitats.

MoEF approved Laboratory

Workroom noise Leq (8 hours) Once/ month

near noise producing sources like DG set, Boiler house etc.

Biological Environment Ecological survey Study growth of trees at

site as per plan and identify new species for plantation

Once every 3 years

At site QCI NABET approved Biological expert

Land Contamination

Soil /Ground water Quality

For specific contaminants of spilled chemicals

Regularly until no traces noticed

At/near site of spillage

MOEF approved laboratory

4 Decommissioning Stage

Ambient air PM10 / PM2.5/ SO2/ NOx/ CO/ nMHC

Once/Month Adjacent to project site

MoEF approved Laboratory

Ambient Noise Level

Leq day and night time or over one work shift

Once/Month Adjacent to project site

MOEF approved lab

Soil /Ground water Quality

For specific contaminants of spilled chemicals

Regularly until no traces noticed

At/near site of spillage

MOEF approved laboratory

ETP pH, TSS, TDS, COD, BOD, Oil and Grease

Daily until effluent stops completely

At various stages of in plant effluent treatment system as in 2 above

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Chapter 6 – Environmental Monitoring Programme

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Monitoring of environmental samples shall be done as per the methods/guidelines provided by MoEF&CC/CPCB and/or relevant Indian Standards or methods as specified by Standard Methods for Water and Wastewater Treatment by American Public Health Association (APHA). Methodology of monitoring (sampling & analysis) shall be documented as SOP (standard Operating Procedure) for parameters analyzed through in house laboratory and shall be subjected to Internal audit and review.

For monitoring of workplace area, methods suggested / published by National Institute

of Occupational Safety and Health (NIOSH), USA or as specified in Standard Methods for Air Analysis published by APHA shall be adopted.

The records of the monitoring program viz water, wastewater, solid waste, air, emission, soil shall be prepared and preserved properly. The records showing results/outcome of the monitoring programs will be submitted as per the schedule below.

Monitoring reports will be reviewed regularly by Factory Management along with Environmental Consultant for necessary improvement of the monitoring plan/mitigation measures/environmental technologies as well as for necessary actions of environmental

management cell.

Table 6.2 Reporting Schedule

Sr. No.

Monitoring During

Reporting Schedule

Applicable Statute

Compliance Reporting To

1 Construction

Phase 1st June and 1st December of each year till end of construction

EIA Notification Clause 10

a) SEIAA, Gujarat b) GPCB – Regional

Office c) MOEF&CC - Western

Zone office and Monitoring Cell

2 Commissioning Phase

1st June and 1st December of each year till end of construction

EIA Notification Clause 10

d) SEIAA, Gujarat e) GPCB – Regional

Office MOEF&CC - Western Zone office and Monitoring Cell

3 Operation Phase

1st June and 1st December of each year

EIA Notification Clause 10

f) SEIAA, Gujarat g) GPCB – Regional

Office MOEF&CC - Western Zone office and Monitoring Cell

Before 10th of next Month in respect of stack/ vents,

Combined Consent &

GPCB – Regional Office

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Chapter 6 – Environmental Monitoring Programme

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AAQ, ETP inlet/outlet, Noise levels

Authorization (CC & A)

4 Decommissioning Phase

1st June and 1st December of each year

EIA Notification Clause 10

h) SEIAA, Gujarat i) GPCB – Regional

Office MOEF&CC - Western Zone office and Monitoring Cell

Company will also file returns under HW Rules (yearly), Cess Act (monthly) and annual Environmental statements &/or performance report/compliance report/audit report as per conditions of EC and CC&A and submit to GPCB within the stipulated timeframe. CC&A and other statutory permission/consents must be obtained & renewed timely as per legal provision & guidelines. Similarly, all necessary report & forms will be prepared and submitted to the concern authority as per the statutory requirement of Environmental Acts/rules, Factory Act & MSIHC rules. Reporting of accident & other requirements will be made in prescribed format well within stipulated time frame as per statutory requirements & guidelines.

Budgetary Provisions for EMP

On regular basis, environment management cell shall inspect the necessity & availability of the materials, technologies, services & maintenance works. The cell shall make appropriate budget for the purpose. Regular record review for change in financial requirement of environment management shall be done and appropriate budgetary provisions shall be made. Budget for environmental management shall be prepared and revised regularly. The budget shall include provisions for:

• Environmental Monitoring Program

• Operation & Maintenance of environmental Technologies/Equipment

• Laboratory works for Environmental management activities

• Emergency Purchase of necessary material, equipment, tools, services

• Greenbelt development

• Social & Environmental Welfare & Awareness programs/training

• Annual Environmental Audit.

The company has made budgetary provision for the proposed expansion project along with existing plant facilities as a part of their initial planning. The same is presented below.

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Chapter 6 – Environmental Monitoring Programme

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Table 6.3 Budgetary Provisions for EMP

No Particular Capital

Cost in Rs. Lakhs (*)

Basis of cost estimation

Recurring cost (Rs.

Lakhs) per year (*)

Basis of cost estimation

1 Air pollution

control 50

scrubber system for process emissions, odor control, etc

10 Maintenance of APC systems

2 Water pollution

control 450

Construction of STP, ETP, RO, MEE, construction of storm water network etc

40 Treatment cost including chemicals, manpower, power consumption

3 Environment monitoring & Management

15

Installation of online monitoring, in house monitoring, analytical facilities,

5 Third party monitoring, EMS activities, Env audits, statutory compliances etc

4 Occupational

Health & Safety 100

Construction of OHC and its facilities

5 OHC and safety expenses

5 Green Belt

enhancement & maintenance

30 Plantation, irrigation, fertilizers, pesticides

5 Hiring agency for maintenance, irrigation, fertilizers, pesticides

6 Solid waste

management 100

Construction of storage area for different types of wastes in compliance with HW rules, necessary infrastructure, equipment’s for collection and transport

70 Disposal cost, manpower cost, transportation cost etc

7 Social Welfare &

upliftment 30

Infrastructure development for sanitation

0 --

Total 775 135

*Note above is preliminary estimates.

Environmental Impact Assessment Reshmika Minerals & Chemicals Private Limited

Chapter 7 – Additional studies (Risk Assessment, Public Hearing)

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ADDITIONAL STUDIES ( RISK ASSESSMENT, PUBLIC H EARING)

In order to support the environment impact assessment and environment management plan, following additional studies have been included in the report.

✓ Risk assessment ✓ Disaster Management Plan ✓ On site and off site emergency action plan ✓ Occupational Health and Safety Management System

Introduction

Hazard analysis involves the identification and quantification of the various hazards (unsafe conditions) associated with establishment of proposed chemicals manufacturing facility which is to be located at Plot No. 23, GIDC Panoli,Tehsil Ankleshwar, District Bharuch, Gujarat.

The risk analysis deals with recognition and computation / quantification of risk to the plant equipment, personnel and neighboring population, due to accidents

resulting from hazards present in the plant.

Risk assessment follows an extensive hazard analysis. This requires a thorough knowledge of Plant processes, failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate. Consequently, the risk assessment is often confined to maximum credible accident studies.

It provides basis for what should be type and capacity of its on-site and offsite emergency plan also what types of safety measures shall be required.

Risk involves the occurrence or potential occurrence of some accidents consisting of an event or sequence of events. The risk assessment study covers the following:

- Identification of potential hazard area; - Identification of representative failure cases; - Visualization of the resulting scenarios in terms of fire and explosion; - Assess the overall damage potential of the identified hazardous events and the - Impact zones form the accidental scenarios; - Furnish the recommendations on the minimization of the worst accident

possibilities - Preparation of Disaster Management Plan; - Emergency Plan, which includes Occupational and Health Safety Plan;

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the

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Chapter 7 – Additional studies (Risk Assessment, Public Hearing)

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risks from hazardous activities, and forming a rational evaluation of their significance, in order to provide input to a decision-making process. The term ‘quantitative risk assessment’ is widely used, but strictly this refers to the purely numerical assessment of risks without any evaluation of their significance. The study has been conducted based on the premises of a traditional Quantitative Risk Assessment. The key components of a QRA are explained below, and illustrated in figures below,

Figure 7.1 QRA Methodology

Figure 7.2 Flow Chart for QRA Methodology

QRA METHODOLOGY

HAZARD IDENTIFICATION

CONSEQUENCE MODELING

RISK ASSESSMENT

FREQUENCY ANALYSIS

RISK COMPUTATION

RISK REDUCING MEASURES

DEFINING THE SYSTEM

RISK AREA IDENTIFICATION

FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT

RISK AREA SELECTION

FAILURE CASE IDENTIFICATION

START

SELECT FAILURE CASE

IDENTIFY CONSEQUENCE OUTCOME

SELECT CONSEQUENCE OUTCOME

DETERMINE FREQUENCY

ESTIMATE CONSEQUENCE

RECORD CONSEQUENCE AND FREQUENCY

HAVE ALL CONSEQUNECE OUTCOMES STUDIED ?

HAVE ALL FAILURE CASES STUDIED

HAVE ALL RISK AREAS BEEN STUDIED

DRAW RISK CONTOUR FINISH YES

NEXT

NEXT

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Chapter 7 – Additional studies (Risk Assessment, Public Hearing)

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Identification of hazards in the proposed expansion project activity is of primary significance of the analysis, and quantification. Hazard states the characteristics of system/plant/process that presents potential for an accident. All the components of a system/plant/process need to be thoroughly examined to assess their potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an accident.

The procedure for QRA starts with identification of major risk areas in the proposed plant set up. At RMCPL, major risk areas are as follows:

o Bulk liquid storage area for Raw Materials at ambient temperature o Warehouse (Drums, carboys, solid RM storage) o Natural gas handing o Process Plant involving pumping, transportation, reactors, distillation,

heating, cooling, etc. o Bulk loading and unloading from road tankers to storage and vice versa.

▪ Release due to catastrophic failure of storage tanks or process vessels. ▪ Rupture of connected pipe with storage tank or process vessels. ▪ Continuous release at significant rates for long durations transfer pipelines caused by

sudden, major break of the pipeline. ▪ Continuous release at low rate through small holes or cracks in piping and vessels,

flange leaks, and leakage from pump glands and similar seals.

It is to be noted that for Quantitative Risk Assessment, worst case scenarios has been considered, though their frequency of occurrence is much lower than the cases of small leaks.

The major Hazardous chemicals to be stored, transported, handled and utilized within the plot area are summarized in the table below.

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Chapter 7 – Additional studies (Risk Assessment, Public Hearing)

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Table 7.1 Proposed Onsite Storages (OSBL)

Chemical No of tanks

KL for each tank

MOC Dia (Mts)

Ht (Mts)

1 Propionic acid 1 50 SS316 3.25 6.00

2 Diethyl ketone 1 50 SS316 3.25 6.00

3 o-Xylene 1 50 MS 3.25 6.00

4 Conc. Sulfuric Acid 1 50 MS 3.25 6.00

5 Conc. Nitric Acid (98%) / FNA

1 25 Aluminum 3.00 4.00

6 Spent acid sulfuric 1 50 MS 3.25 6.00

7 Spent acid dilute nitric 1 50 SS304 NAG 3.25 6.00

8 4-Nitro-o-Xylene 1 50 MS 3.25 6.00

9 3-Nitro-o-Xylene 1 50 MS 3.25 6.00

10 25% Liquor ammonia 1 25 MS 3.00 4.00

11 Methyl Ethyl Ketone (MEK) 1 5 SS316 1.65 2.45

12 m-Xylene 1 25 MS 3.00 4.00

13 1-Octanol / n-Octanol or will be used for 1-Octene

1 50 MS 3.25 6.00

14 n-Octanoic acid 1 50 SS316 3.25 6.00

15 Styrene 1 50 SS316 3.25 6.00

16 Hydrogen Peroxide, 50% 1 25 HDPE 3.00 4.00

17 Styrene Oxide 1 50 SS304 3.25 6.00

18 Phenyl ethyl alcohol 1 50 SS304 3.25 6.00

19 Methanol 1 25 SS316 3.00 4.00

20 Caustic lye 1 25 MS 3.00 4.00

21 Toluene 1 50 MS 3.25 6.00 *The dimensions are indicative and preliminary. It will be finalized during detail engineering stage. Dyke dimension shall be maintained as per good engineering practice / norms/standards.

Other hazards and control measures during different project stages are summarized in table below.

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Table 7.2 Hazard Identification & Risk Assessment at Different Project Stages

Sr. No.

Step/Activity Hazard identification

Typical Areas /activities

Possible causes Safety Measures Required

Risks

1.0 Erection of Plant Physical Hazards - Fall from height

- Working at ht> 2m - Formwork - Ramps - Unprotected sides

and edges - Roofing - Overhead brick

laying

- Untrained workers

- Wearing loose clothes

- No safety gear

Fall protection - guardrail - safety net/PPEs - harness - warning lines - appropriate clothes - supervision to

identify hazards

Accidental injury (personal)

- Electrocution

Entire site - Temporary connections

- Cables running across site

Supervision to identify hazards

Accidental injury (personal)

- Struck by falling objects

Entire site walking below loading or working equipment

Supervision Warning ribbons and signs

Accidental injury (personal)

2.0 Commissioning Electrocution Use of Energy Temporary connections

Tagging & Lock out Warning signs

Electrocution (personal injury)

Chemical exposure Use & storage of chemicals

Improper handling

Safety Gear/PPEs Training

Personal injury (Chemical burn, organ damage)

Instrumental failure

Complying HAZOP recommendations

On/offsite Accident injuries

Noise exposure

Entire plant Commissioning activities

Ear Muffs/plugs Oiling and greasing Vibration dampening

Personal injury (noise induced hearing loss)

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Sr. No.

Step/Activity Hazard identification

Typical Areas /activities

Possible causes Safety Measures Required

Risks

3.0 Operation Electrocution Use of Energy Temporary connections

Tagging & Lock out Warning signs

Electrocution (personal injury)

Chemical exposure Use & storage of chemicals & hazardous wastes

Improper handling

Safety Gear/PPE’s Training

Personal injury (Chemical burn, organ damage)

Instrumental failure

Regular HAZOP & audits & complying recommendations

On/offsite Accident injuries

Noise generation Entire plant Improper maintenance

Ear Muffs/plugs Preventive maintenance, oiling and greasing

Personal injury (noise induced hearing loss)

4.0 Closure and Decommissioning

Chemical exposure Use & storage of chemicals & hazardous wastes

Improper handling

Safety Gear/PPE’s Training

Personal injury (Chemical burn, organ damage)

Table 7.3 Other Hazards and control

No Possible hazard / Emergency

Its source and possible reason

Effect on person, property and environment

Place of its effect

Control measures suggested.

1 Natural calamity Nature Injury / Death to persons, damage to property

Within & outside the unit

Emergency preparedness, Alarm, Evacuation rescue & shelter/ Welfare

2 Toxic release from outside the premises

Outside the factory Injury/Death Within & outside the unit

Emergency preparedness, Alarm, Evacuation rescue & shelter/ Welfare

3 Structural failure Inside the factory (Corrosion)

Injury/Death to persons, damage to

Within the factory

Inspection and Maintenance practices / Automatic operation

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property Periodic Testing of safety valves / systems

4 Pipe line leakages / Spillages. (1) Corrosion (2) Toxic gas release

Leaking of pipe line due to corrosion, Loose contact etc

Physical / Chemical Thermal Burn Injury (Major / Minor)

Plant area Proper maintenance, Proper Selection of Material for pipe lines, Immediate attention, Earthing, flame proof fitting, No Smoking display Boards.

5 Electricity (burning, fire, shock)

Loose Contacts, Weak earthling Short Circuit Improper Insulation

Burning, Shock, Death

Surrounding the accident area

Proper Earthing, Periodical Checking of joints, proper insulations of Equipment’s, etc. Flame proof fitting in solvent storage area, bonding and jumpers to all solvent barrier lines to be provided.

6 Boiler (burning, physical injury, explosion)

Over pressure in the boiler if safety valve not working. Water level indicator not working. Low water level indicator fail. High temp. System fails.

Minor/Major Injury Loss of human life Loss of property (Loss of Main/ Machine Material)

Boiler House and surrounding places

Lower & Upper Level Indication System provision. Safety valves for pressure control fixed temp. & pressure indicator provided. Blow down & blowing system provided for cleaning tube and shell. Soft water used. Inter locking provided on pumps, FD fan, ID fan. Periodical checking & inspection maintenance done. Yearly inspection done by Boiler Inspector

7 Housekeeping (physical, Fire, burning, exposure to chemicals)

Bad House keeping Physical / Chemical Thermal Burn Injury (Major / Minor)

In all surrounding areas i.e. Storage, Plants

Proper Handling, regular cleaning, Proper placement of material (RIGHT THING AT THE RIGHT PLACE)

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Table 7.4 Hazardous properties of the chemicals, special hazards

No Chemical State color Odor Sp Gr at 20 deg C

Melting

point Deg C

Boiling

point, Deg C

Flash

point,

Deg C

Explosive limit

TLV ppm

Water solubil

ity

NFPA code

Hazard

% LEL

% UEL

H F R

1 Propionic acid

Liquid Colorless

Not available 0.995 -20.8 141 53 2.9 12.1 10 ppm

Soluble 3 2 0 H,F

2 Benzoic acid

Solid White powder

Not available 1.26 122.4 249.2 121 NA NA NA Slightly soluble

2 1 0 H,F

3 N Hexane Liquid Colorless

Gasoline like 0.66 - 95 68 -22.5 1.15 7.5 176 mg/m3

insoluble

1 3 0 H,F

4 O Xylene Liquid Colorless

Aromatic 0.88 -25 144.4 17 0.9 6.7 150 ppm

Insoluble

2 3 0 H,F

5 M Xylene Liquid Colorless

Not available 0.86 -47.8 139.3 25 1.1 7.0 100 ppm

Insoluble

2 3 0 H,F

5 Methanol (67-56-1)

Liquid Colorless

Alcohol like. Pungent when

crude

0.7915 -97.8 64.5 12 6 36.5 250 ppm

Soluble 1 3 0 H,F

6 Hydrogen (1333-74-

0)

Gas colorless

Odorless 0.07 -259 -253 NA 4 76 NA Not soluble

0 4 0 F

7 Toluene (108-88-3)

Liquid Colorless

sweet, pungent,

benzene like

0.8636 -95 110.6 4.44 1.1 7.1 50 Soluble 2 3 0 H,F

9 Salicylic acid

Solid White Odorless 1.44 159 211 157 1.1 - Not available

Slightly soluble

0 1 0 F

10 IPA Liquid Colorles

Ethanol like 2.07 -88.5 82.5 11.6 2 12.7 200 ppm

soluble 1 3 0 H,F

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No Chemical State color Odor Sp Gr at 20 deg C

Melting

point Deg C

Boiling

point, Deg C

Flash

point,

Deg C

Explosive limit

TLV ppm

Water solubil

ity

NFPA code

Hazard

% LEL

% UEL

H F R

11 1 Octanol Liquid Colorless

Not available 0.83 -16.5 194.5 81.1 1.1 7.4 Not available

Insluble

1 2 0 H,F

12 Styrene Liquid Clear viscous

Aromatic 0.906 -30.6 145.2 31.1 1.1 6.1 50 ppm

Slightly soluble

2 3 4 H,F,R

13 Di methyl sulphate

Liquid Clear Faint 1.33 -32 188 83 3.6 23.2 0.1 ppm

Slightly soluble

3 2 0 H,F

14 Caustic lye Liquid colorless

odorless 2.1 318 1390 NA NA NA NA Soluble 3 0 1 H,R

15 Hydrogen Peroxide

Liquid colorless

Odorless 1.1 - 33 108 NA NA NA 1 ppm

Soluble 2 0 1 H,R

16 Acetic acid Liquid colorless

Pungent 1.05 16.6 118.1 39 4 19.9 10 ppm

Soluble 3 2 0 H,F

17 Liquor ammonia

Liquid Colorless

Strong ammonia like

0.898 -69.2 Not availa

ble

NA NA NA 25 ppm

Soluble 2 0 0 H

18 Sulphuric acid

(7664-93-9)

Liquid Colorless

Odorless, choking odor

when hot.

1.84 -35 270 NA - - 1 Soluble 3 0 2 C,R

19 Nitric acid (7697-37-

2)

Liquid Colorless to light

yellow

Acrid, disagreeable and chocking

1.408 -41.6 121 NA NA NA 4 Soluble 4 0 0 T,C

20 Caustic Lye

Liquid Colorless

Odorless 1.53 12 140 NA NA NA 2 mg/m3

Soluble 3 0 1 C , T

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No Chemical State color Odor Sp Gr at 20 deg C

Melting

point Deg C

Boiling

point, Deg C

Flash

point,

Deg C

Explosive limit

TLV ppm

Water solubil

ity

NFPA code

Hazard

% LEL

% UEL

H F R

(1310-73-2)

E = EXPLOSIVE, R = REACTIVE, BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT, UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY, H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS, R = REACTIVE HAZARD, TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-USA, C = CORROSIVE, T=TOXIC

Facilities / System for process safety, transportation, and emergency capabilities to be adopted are stated below.

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Precautions during storage and transportation of hazardous chemicals / liquids

▪ Ensure and use the road tankers having authorization for transporting the said liquids.

▪ Ask all vendors to provide MSDS of the chemical transported to Tanker Driver. ▪ Tankers will have to be clearly marked identification of material being contained

with mentioning Safety Card (TREM card). ▪ Driver to have concerned Safety Officer’s contact details to contact him in case of

Emergency. ▪ Provide muffler on exhaust while entering tanker within premises. ▪ Ensure Earthing connection before starting any transferring.

▪ SOP to cover routine checking of Tank farm area to be carried out for checking any spillage / leakage.

▪ Physical inspection of tanks daily for having any visual abnormality. ▪ Readings of Temperature & Pressure will be noted, recorded & reported

immediately for any abnormality. ▪ Safety instruments like rupture disc, safety valves will be checked at defined

duration for intactness.

▪ Scheduled testing of tanks to be done for thickness testing. ▪ Tanks to be painted on regular interval defined as per laws to protect them from

atmospheric corrosion.

▪ Barrels to be checked for proper fixing of bungs before sending it outside the premises.

▪ Barrels to be monitored physically daily for developing any pressure or vacuum within it on long storage.

▪ Concerned persons will be trained properly to use spill kit in case of observing any spillage inside warehouse.

The major hazards at RMCPL are described below,

o Toxic hazard due to leakage of hazardous chemicals e.g. Toluene etc. from storage

tank.

o Corrosive hazard due to leakage of chemicals like HCl, Sulphuric acid etc. from storage tank or Carboys.

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

Welding, motors, and heavy lift devices, cabling, human intervention (short circuit possibility), maintenance work (due to machinery breakdown etc.), plant lighting related electrical hazards.

o Possibility of human injury due to working with mechanical machines, manual handling etc.

o Possibility of injury during chemicals handled, during operations and due to intoxication.

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

Operations involved with crane/ overhead lifting/ hoisting equipment.

o Fires in any part of the plant working areas – there is a possibility of rapid escalation if it is not brought under control quickly.

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o Possibilities of fire hazards at transformers, switchgear and other electrical equipment etc.

o Fire hazard at natural gas handling facility

Transportation, unloading, and handling procedures for hazardous chemicals No Activity Type of

possible hazard

Proposed mitigation measure

1 Transportation of chemicals like, Propionic acid, o & m xylene, Nitric acid, sulphuric acid, Methanol, styrene oxide, Octanoic acid, hydrogen peroxide, Toluene, etc. by road tanker / Unloading at site / transfer from storage to day tank/reactor system

Leakage / Spillage

Check the source of leakage point. Do not touch damaged containers or spilled material unless wearing appropriate protective clothing. Stop leak if you can do it without risk.

Fire,& explosion Use water spray to reduce vapors; do not put water Directly on leak, spill area or inside container. Keep combustibles (wood, paper, oil, etc.) away from spilled material.

Toxic Release Isolate the area Isolate the container Training to be provided to driver and cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling. TREM card with tanker Fire extinguishers will be kept with Tanker Flame arrestor will be provided to tanker exhaust. Instructions will be given not to stop road tanker in populated area. Clear Hazard Identification symbol and emergency telephone number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with tanker.

Consequence Analysis

In a plant while handling hazardous chemicals, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or vapor clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits.

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Potential vapor release for the same material depends significantly on the operating conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential. If we take up an example of ammonia, if it is stored at ambient temperature, say 30 Deg C, and then the vapor release potential of the inventory is much higher as compared to the case if it is stored at 0 Deg C.

Inventory Analysis is commonly used in understanding the relative hazards and short listing of release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a vessel or a system, larger the quantity of potential release. The potential vapor release (source strength) depends upon the quantity of liquid release, the properties of the materials and the operating conditions (pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source strength estimated for each release case, a ranking should become a credible exercise.

Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all significant release cases and then to short list release scenarios for a detailed examination. Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden appearance of such a major crack that practically all of the contents above the crack shall be released in a very short time. The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is depending on the size of the hole as well as on the pressure, which was present, in front of the hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The vaporization of released liquid depends on the vapor pressure and weather conditions. Such consideration and others have been kept in mind both during the initial listing as well as during the short listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the largest potential hazard inventories have been considered for consequence estimation.

In consequence analysis, use is made of a number of calculation models to estimate the physical effects of an accident (spill of hazardous material) and to predict the damage (lethality, injury, material destruction) of the effects. The calculations can roughly be divided in three major groups:

▪ Determination of the source strength parameters; ▪ Determination of the consequential effects; ▪ Determination of the damage or damage distances.

The basic physical effect models consist of the following.

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▪ Calculation of the outflow of liquid, vapor or gas out of a vessel or a pipe, in case of rupture. Also two-phase outflow can be calculated.

• Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of the dimensions of the remaining liquid pool.

• Calculation of the evaporation rate, as a function of volatility of the material, pool dimensions and wind velocity.

• Source strength equals pump capacities, etc. in some cases.

o Dispersion of gaseous material in the atmosphere as a function of source strength, relative density of the gas, weather conditions and topographical situation of the surrounding area.

o Intensity of heat radiation [in kW/ m2] due to a fire or a BLEVE, as a function of the distance to the source.

o Energy of vapor cloud explosions [in N/m2], as a function of the distance to the distance of the exploding cloud.

o Concentration of gaseous material in the atmosphere, due to the dispersion of evaporated chemical. The latter can be either explosive or toxic.

It may be obvious, that the types of models that must be used in a specific risk study strongly depend upon the type of material involved:

▪ Gas, vapor, liquid, solid ▪ Inflammable, explosive, toxic, toxic combustion products ▪ Stored at high/low temperatures or pressure ▪ Controlled outflow (pump capacity) or catastrophic failure?

The damage criteria give the relation between extent of the physical effects (exposure) and the percentage of the people that will be killed or injured due to those effects. The knowledge about these relations depends strongly on the nature of the exposure. For instance, much more is known about the damage caused by heat radiation, than about the damage due to toxic exposure, and for these toxic effects, the knowledge differs strongly between different materials. In Consequence Analysis studies, in principle three types of exposure to hazardous effects are distinguished:

✓ Toxic effects, from toxic materials or toxic combustion products. ✓ Heat radiation, from a jet, pool fire, a flash fire or a BLEVE. ✓ Explosion

In the next paragraphs, the chosen damage criteria are given and explained.

Intoxication

The consequences from inhalation of a toxic vapor/gas are determined by the toxic dose. This dose is basically determined by:

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o Concentration of the vapor in air; o Exposure duration.

Furthermore, of course, the breathing rates of the victim, as well as the specific toxic mechanism unto the metabolism play an important role.

Heat Radiation

The consequence caused by exposure to heat radiation is a function of:

o The radiation energy onto the human body (kW/m2) o The exposure duration [sec]; o The protection of the skin tissue (clothed or naked body). o The limits for 1% of the exposed people to be killed due to heat radiation,

and for second-degree burns are given in the table herein:

Damages to Human Life Due to Heat Radiation

Exposure duration

Radiation for 1% lethality (kW/m2)

Radiation for 2nd degree burns (kW/m2)

Radiation for first degree burns (kW/m2)

10 seconds 21.2 16 12.5 30 seconds 9.3 7 4

Since in practical situations, only the own employees will be exposed to heat radiation in case of a fire, it is reasonable to assume the protection by clothing. It can be assumed that people would be able to find a cover or a shield against thermal radiation in 10 sec. time. Furthermore, 100% lethality may be assumed for all people suffering from direct contact with flames, such as the pool fire, a flash fire or a jet flame. The effects due to relatively lesser incident radiation intensity are given below.

Effects Due To Incident Radiation Intensity

Incident radiation in kw/m2

Type of damage

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.

9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are likely)

1.6 No discomfort for long exposure 0.7 Equivalent to Solar Radiation

Explosion

In case of vapor cloud explosion, two physical effects may occur:

▪ flash fire over the whole length of the explosive gas cloud; ▪ blast wave, with typical peak overpressures circular around ignition source.

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As explained above, 100% lethality is assumed for all people who are present within the cloud proper. For the blast wave, the lethality criterion is based on:

o A peak overpressure of 0.1 bar will cause serious damage to 10% of the housing/structures.

o Falling fragments will kill one of each eight persons in the destroyed buildings.

The following damage criteria may be distinguished with respect to the peak overpressures resulting from a blast wave:

Damage Due to Overpressures

Peak overpressure Type of damage 0.83 bar Total Destruction 0.30 bar Heavy Damage 0.10 bar Moderate Damage 0.03 bar Significant Damage 0.01 bar Minor Damage

A Maximum Credible Accident (MCA) can be characterized as the worst credible accident. In other words: an accident in an activity, resulting in the maximum consequence distance that is still believed to be possible. A MCA-analysis does not include a quantification of the probability of occurrence of the accident. Another aspect, in which the pessimistic approach of MCA studies appears, is the atmospheric condition that is used for dispersion calculations. As per the reference of the study, weather conditions having an average wind speed of 1.85 m/s have been chosen. The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The MCL cases considered, attempt to include the worst “Credible” incidents- what constitutes a credible incident is always subjective. Nevertheless, guidelines have evolved over the years and based on basic engineering judgment, the cases have been found to be credible and modeling for assessing vulnerability zones is prepared accordingly. Only catastrophic cases have been considered and not partial or small failures (as is the case in Quantitative Risk Assessment where contributions from low frequency - high outcome effect as well as high frequency - low outcome events are distinguished). The objective of the study is emergency planning, hence only holistic & conservative assumptions are used for obvious reasons. Hence though the outcomes may look pessimistic, the planning for emergency concept should be borne in mind whilst interpreting the results.

The Consequence Analysis has been done for selected scenarios. This has been done for weather conditions having wind speed 1.85 m/s. In Consequence Analysis, geographical location of the source of potential release plays an important role. Consideration of a large number of scenarios in the same geographical location serves little purpose if the dominant scenario has been identified and duly considered.

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Quantitative risk assessment based on ALOHA

ALOHA (Arial Locations of Hazards Atmosphere) is an atmospheric dispersion model used for evaluating releases of hazardous chemical vapors. ALOHA is a part of software called CAMEO (Computer Aided Management of Emergency Operation). CAMEO is one of the tools developed by EPA’s Chemical Emergency Preparedness and Prevention Office (CEPPO) and the National Oceanic and Atmospheric Administration Office of Response and Restoration (NOAA), to assist front-line chemical emergency planners and responders.

CAMEO consists of three parts viz. CAMEO (which is basically a data base), ALOHA and

MARPLOT (Mapping Applications for Response, Planning, and Local Operational Tasks).

ALOHA allows the user to estimate the downwind dispersion of a chemical cloud based on the toxicological/physical characteristics of the released chemical, atmospheric conditions, and specific circumstances of the release. Graphical outputs include a "cloud footprint" that can be plotted on maps with MARPLOT to display the location of other facilities storing hazardous materials and vulnerable locations, such as hospitals and schools. Specific information about these locations can be extracted from CAMEO

information modules to help make decisions about the degree of hazard posed.

Systematic study based on ALOHA has been carried out for critical tanks and gas leakage scenarios. The details of consequence analysis studies carried out are presented at

Annexure 7.2 for various accident and consequence scenarios like:

Table 7.5 Consequence Analysis studies carried out

Failure Scenarios Accident Scenario Effects Catastrophic failure of tank

vapor cloud formation and dispersion

Toxic area of vapor cloud

Flammable area of vapor cloud Explosion of vapor cloud Overpressure effects of VCE Vapor cloud catching fire Radiation Effects from pool fire Radiation effect from fireball Leakage from pump discharge valve

vapor cloud formation and dispersion

Toxic area of vapor cloud

Flammable area of vapor cloud Explosion of vapor cloud Overpressure effects of VCE

Failure frequency data as given in Loss Prevention in Process Industries by Frank P Lees is presented below for information.

Table 7.6 Failure Frequency Data

SR. NO. ITEM FAILURE FREQUENCY (No. per 106 years)

1 Shell

2 Process / Pressure Vessel 1.0 3 Atmospheric Pressure Storage 0.1 4 Full Bore Vessel Connection

25 30.0 40 10.0 50 7.5

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SR. NO. ITEM FAILURE FREQUENCY (No. per 106 years)

100 4.0 150 3.0

5 Full Bore Process Pipeline (Diameter in mm) Less Than 50 0.30* >50, <150 0.09* More than 150 0.03* (*Failure frequency expressed in No. per met length per 106 years)

The Maximum Credible Accident scenario likely identified is leakage of pump discharge line due formation of pin hole/leakage (20% flow). The damage distances worked out for

these scenarios indicates that for most of the effects the damage will not be confined to the plant boundary.

The above table indicates that probability of occurrence of this scenario is very low (<0.5 x 106 years), which is within the acceptable limits. However, various preventive and protective measures are required to ensure that the above accident scenarios do not occur. These are presented in section below.

Table 7.7 Findings of Consequence Analysis Studies

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Sr

No

Substance Failure Scenerio Effects considered Distanc

e ,

meters

1 Methanol The contents of the tank leaking in

the dyke enclosure and forming a

pool

Methanol 1/

1

Gas not burning – Toxicity

effect

AEGL-3 7200

ppm

< 10

AEGL-2 2100

ppm

< 10

AEGL-1 530 ppm 10

Methanol 1/

2

Flammable area of vapor cloud 60 % LEL 43080

ppm

< 10

10 % LEL 7180

ppm

< 10

Methanol 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Methanol 1/

4

Radiation effect from pool fire Potentially

lethal

10

kw/m2

< 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 <10

Methanol 1/

5

Radiation effect from th fireball Potentially

lethal

10

kw/m2

218

2 nd degree

burn

5 kw/m2 315

severe pain 2 kw/m2 497

1 Methanol Failure of the unloading

pump(full bore leakage)

Methanol 2/

1

Gas not burning – Toxicity

effect

AEGL-3 7200

ppm

63

AEGL-2 2100

ppm

125

AEGL-1 530 ppm 257

Methanol 2/

2

Flammable area of vapor cloud 60 % LEL 43080

ppm

20

10 % LEL 7180

ppm

68

Methanol 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi 18

1 Methanol Failure of the unloading pump

line (20 % flow)

Methanol 3/

1

Gas not burning – Toxicity

effect

AEGL-3 7200

ppm

29

AEGL-2 2100

ppm

55

AEGL-1 530 ppm 111

Methanol 3/

2

Flammable area of vapor cloud 60 % LEL 43080

ppm

11

10 % LEL 7180

ppm

32

Methanol 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi 12

Calculations of affected distances considering various scenarios have been done and summarized results are as below:

Scenerio No Level of concern (LOC)

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Sr

No

Substanc

e

Failure Scenerio Effects considered Distance

, meters

2 Toluene The contents of the tank leaking in

the dyke enclosure and forming a

pool

Toluene 1/

1

Gas not burning – Toxicity

effect

AEGL-3 4500

ppm

< 10

AEGL-2 1200

ppm

< 10

AEGL-1 200 ppm 16

Toluene 1/

2

Flammable area of vapor cloud 60 % LEL 6600

ppm

< 10

10 % LEL 1100

ppm

< 10

Toluene 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Toluene 1/

4

Radiation effect from pool fire Potentially

lethal

10

kw/m2

< 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

Toluene 1/

5

Radiation effect from the

fireball

Potentially

lethal

10

kw/m2

389

2 nd degree

burn

5 kw/m2 550

severe pain 2 kw/m2 859

2 Toluene Failure of the unloading

pump(full bore leakage)

Toluene 2/

1

Gas not burning – Toxicity

effect

AEGL-3 4500

ppm

48

AEGL-2 1200

ppm

144

AEGL-1 200 ppm 473

Toluene 2/

2

Flammable area of vapor cloud 60 % LEL 6600

ppm

34

10 % LEL 1100

ppm

97

Toluene 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 26

Glass shatter 1 psi 49

2 Toluene Failure of the unloading pump

line (20 % flow)

Toluene 3/

1

Gas not burning – Toxicity

effect

AEGL-3 4500

ppm

22

AEGL-2 1200

ppm

65

AEGL-1 200 ppm 198

Toluene 3/

2

Flammable area of vapor cloud 60 % LEL 6600

ppm

16

10 % LEL 1100

ppm

43

Toluene 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 14

Glass shatter 1 psi 32

Calculations of affected distances considering various scenarios have been done and summarized results are as below:

Scenerio No Level of concern (LOC)

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Sr

No

Substanc

e

Failure Scenerio Effects considered Distance

, meters

3 Propionic

acid

The contents of the tank leaking in

the dyke enclosure and forming a

pool

Propion

ic acid

1/

1

Gas not burning – Toxicity

effect

PAC -3 170 ppm < 10

PAC -2 28 ppm 11

PAC -1 15 ppm 16

Propion

ic acid

1/

2

Flammable area of vapor cloud 60 % LEL 17400

ppm

< 10

10 % LEL 2900 ppm < 10

Propion

ic acid

1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Propion

ic acid

1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

Propion

ic acid

1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 269

2 nd degree

burn

5 kw/m2 390

severe pain 2 kw/m2 616

3 Propionic

acid

Failure of the unloading

pump(full bore leakage)

Propion

ic acid

2/

1

Gas not burning – Toxicity

effect

PAC -3 170 ppm 351

PAC -2 28 ppm 890

PAC -1 15 ppm 1200

Propion

ic acid

2/

2

Flammable area of vapor cloud 60 % LEL 17400

ppm

23

10 % LEL 2900 ppm 68

Propion

ic acid

2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 15

Glass shatter 1 psi 35

3 Propionic

acid

Failure of the unloading pump

line (20 % flow)

Propion

ic acid

3/

1

Gas not burning – Toxicity

effect

PAC -3 170 ppm 146

PAC -2 28 ppm 375

PAC -1 15 ppm 519

Propion

ic acid

3/

2

Flammable area of vapor cloud 60 % LEL 17400

ppm

11

10 % LEL 2900 ppm 31

Propion

ic acid

3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 12

Glass shatter 1 psi 26

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

4 DEK The contents of the tank leaking in

the dyke enclosure and forming a

pool

DEK 1/

1

Gas not burning – Toxicity

effect

PAC -3 5000 ppm < 10

PAC -2 830 ppm < 10

PAC -1 300 ppm < 10

DEK 1/

2

Flammable area of vapor cloud 60 % LEL 9600 ppm < 10

10 % LEL 1600 ppm < 10

DEK 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

DEK 1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

DEK 1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 343

2 nd degree

burn

5 kw/m2 488

severe pain 2 kw/m2 763

4 DEK Failure of the unloading

pump(full bore leakage)

DEK 2/

1

Gas not burning – Toxicity

effect

PAC -3 5000 ppm 32

PAC -2 830 ppm 89

PAC -1 300 ppm 164

DEK 2/

2

Flammable area of vapor cloud 60 % LEL 9600 ppm 22

10 % LEL 1600 ppm 60

DEK 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 15

Glass shatter 1 psi 35

4 DEK Failure of the unloading pump

line (20 % flow)

DEK 3/

1

Gas not burning – Toxicity

effect

PAC -3 5000 ppm 13

PAC -2 830 ppm 41

PAC -1 300 ppm 69

DEK 3/

2

Flammable area of vapor cloud 60 % LEL 9600 ppm 11

10 % LEL 1600 ppm 27

DEK 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 13

Glass shatter 1 psi 29

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

5 O Xylene The contents of the tank leaking in

the dyke enclosure and forming a

pool

O

Xylene

1/

1

Gas not burning – Toxicity

effect

IDLH 900 ppm < 10

600 ppm < 10

200 ppm < 10

O

Xylene

1/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm < 10

10 % LEL 1100 ppm < 10

O

Xylene

1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

O

Xylene

1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

O

Xylene

1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 394

2 nd degree

burn

5 kw/m2 557

severe pain 2 kw/m2 869

5 O Xylene Failure of the unloading

pump(full bore leakage)

O

Xylene

2/

1

Gas not burning – Toxicity

effect

IDLH 900 ppm 100

600 ppm 128

200 ppm 247

O

Xylene

2/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 33

10 % LEL 1100 ppm 89

O

Xylene

2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 26

Glass shatter 1 psi 48

5 O Xylene Failure of the unloading pump

line (20 % flow)

O

Xylene

3/

1

Gas not burning – Toxicity

effect

IDLH 900 ppm 44

600 ppm 57

200 ppm 107

O

Xylene

3/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 14

10 % LEL 1100 ppm 40

O

Xylene

3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 14

Glass shatter 1 psi 32

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

6 M Xylene The contents of the tank leaking in

the dyke enclosure and forming a

pool

M

Xylene

1/

1

Gas not burning – Toxicity

effect

PAC -3 2500 ppm <10

PAC -2 920 ppm < 10

PAC -1 130 ppm < 10

M

Xylene

1/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm < 10

10 % LEL 1100 ppm < 10

M

Xylene

1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

M

Xylene

1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

M

Xylene

1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 323

2 nd degree

burn

5 kw/m2 458

severe pain 2 kw/m2 714

6 M Xylene Failure of the unloading

pump(full bore leakage)

M

Xylene

2/

1

Gas not burning – Toxicity

effect

PAC -3 2500 ppm 56

PAC -2 920 ppm 98

PAC -1 130 ppm 306

M

Xylene

2/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 33

10 % LEL 1100 ppm 85

M

Xylene

2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 26

Glass shatter 1 psi 48

6 M Xylene Failure of the unloading pump

line (20 % flow)

M

Xylene

3/

1

Gas not burning – Toxicity

effect

PAC -3 2500 ppm 23

PAC -2 920 ppm 44

PAC -1 130 ppm 127

M

Xylene

3/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 14

10 % LEL 1100 ppm 40

M

Xylene

3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 14

Glass shatter 1 psi 32

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

7 MEK The contents of the tank leaking in

the dyke enclosure and forming a

pool

MEK 1/

1

Gas not burning – Toxicity

effect

AEGL-3 4000 ppm < 10

AEGL-2 2700 ppm < 10

AEGL -1 200 ppm 13

MEK 1/

2

Flammable area of vapor cloud 60 % LEL 10800

ppm

< 10

10 % LEL 1800 ppm < 10

MEK 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

MEK 1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

MEK 1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 164

2 nd degree

burn

5 kw/m2 234

severe pain 2 kw/m2 366

7 MEK Failure of the unloading

pump(full bore leakage)

MEK 2/

1

Gas not burning – Toxicity

effect

AEGL-3 4000 ppm 32

AEGL-2 2700 ppm 41

AEGL -1 200 ppm 178

MEK 2/

2

Flammable area of vapor cloud 60 % LEL 10800

ppm

19

10 % LEL 1800 ppm 52

MEK 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 14

Glass shatter 1 psi 32

7 MEK Failure of the unloading pump

line (20 % flow)

MEK 3/

1

Gas not burning – Toxicity

effect

AEGL-3 4000 ppm 14

AEGL-2 2700 ppm 19

AEGL -1 200 ppm 75

MEK 3/

2

Flammable area of vapor cloud 60 % LEL 10800

ppm

11

10 % LEL 1800 ppm 23

MEK 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 13

Glass shatter 1 psi 28

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

8 Octanol The contents of the tank leaking in

the dyke enclosure and forming a

pool

Octanol 1/

1

Gas not burning – Toxicity

effect

ERPG -3 150 ppm < 10

ERPG -2 20 ppm < 10

ERPG -1 5 ppm < 10

Octanol 1/

2

Flammable area of vapor cloud 60 % LEL 5040 ppm < 10

10 % LEL 840 ppm < 10

Octanol 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Octanol 1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

Octanol 1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 368

2 nd degree

burn

5 kw/m2 521

severe pain 2 kw/m2 814

8 Octanol Failure of the unloading

pump(full bore leakage)

Octanol 2/

1

Gas not burning – Toxicity

effect

ERPG -3 150 ppm 249

ERPG -2 20 ppm 718

ERPG -1 5 ppm 1500

Octanol 2/

2

Flammable area of vapor cloud 60 % LEL 5040 ppm 33

10 % LEL 840 ppm 89

Octanol 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 25

Glass shatter 1 psi 48

8 Octanol Failure of the unloading pump

line (20 % flow)

Octanol 3/

1

Gas not burning – Toxicity

effect

ERPG -3 150 ppm 107

ERPG -2 20 ppm 305

ERPG -1 5 ppm 627

Octanol 3/

2

Flammable area of vapor cloud 60 % LEL 5040 ppm 14

10 % LEL 840 ppm 40

Octanol 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 15

Glass shatter 1 psi 34

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

9 Styrene The contents of the tank leaking in

the dyke enclosure and forming a

pool

Styrene 1/

1

Gas not burning – Toxicity

effect

AEGL- 3 150 ppm < 10

AEGL -2 20 ppm < 10

AEGL -1 5 ppm < 10

Styrene 1/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm < 10

10 % LEL 1100 ppm < 10

Styrene 1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Styrene 1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 < 10

2 nd degree

burn

5 kw/m2 < 10

severe pain 2 kw/m2 < 10

Styrene 1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 392

2 nd degree

burn

5 kw/m2 555

severe pain 2 kw/m2 866

9 Styrene Failure of the unloading

pump(full bore leakage)

Styrene 2/

1

Gas not burning – Toxicity

effect

AEGL- 3 150 ppm 133

AEGL -2 20 ppm 465

AEGL -1 5 ppm 1200

Styrene 2/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 49

10 % LEL 1100 ppm 133

Styrene 2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 41

Glass shatter 1 psi 69

9 Styrene Failure of the unloading pump

line (20 % flow)

Styrene 3/

1

Gas not burning – Toxicity

effect

AEGL- 3 150 ppm 57

AEGL -2 20 ppm 197

AEGL -1 5 ppm 520

Styrene 3/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm 21

10 % LEL 1100 ppm 57

Styrene 3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 15

Glass shatter 1 psi 35

Calculations of affected distances considering various scenarios have been done and summarized results are as below:Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

10 Liquor

Ammonia

The contents of the tank leaking in

the dyke enclosure and forming a

pool

Liquor

Ammoni

a

1/

1

Gas not burning – Toxicity

effect

AEGL- 3 1100 ppm 33

AEGL -2 160 ppm 89

AEGL -1 30 ppm 208

Liquor

Ammoni

1/

2

Flammable area of vapor cloud 60 % LEL 6600 ppm < 10

10 % LEL 1100 ppm < 10

Liquor

Ammoni

a

1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi -

Glass shatter 1 psi -

Calculations of affected distances considering various scenarios have been done and summarized results are as below:

Scenerio No Level of concern (LOC)

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Failure Scenerio Effects considered Distance

, meters

11 Hydroge

n

peroxide

The contents of the tank leaking in

the dyke enclosure and forming a

pool

Hydrog

en

peroxid

e

1/

1

Gas not burning – Toxicity

effect

ERPG- 3 100 ppm < 10

ERPG - 2 50 ppm < 10

ERPG -1 10 ppm < 10

Hydrog

en

1/

2

Flammable area of vapor cloud 60 % LEL - NA

10 % LEL - NA

Hydrog

en

peroxid

e

1/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi NA

Serious injury 3.5 psi NA

Glass shatter 1 psi NA

Hydrog

en

peroxid

e

1/

4

Radiation effect from pool fire Potentially

lethal

10 kw/m2 NA

2 nd degree

burn

5 kw/m2 NA

severe pain 2 kw/m2 NA

Hydrog

en

peroxid

e

1/

5

Radiation effect from the

fireball

Potentially

lethal

10 kw/m2 NA

2 nd degree

burn

5 kw/m2 NA

severe pain 2 kw/m2 814

11 Hydroge

n

peroxide

Failure of the unloading

pump(full bore leakage)

Hydrog

en

peroxid

e

2/

1

Gas not burning – Toxicity

effect

ERPG- 3 100 ppm 1200

ERPG - 2 50 ppm 1700

ERPG -1 10 ppm 3800

Hydrog

en

peroxid

e

2/

2

Flammable area of vapor cloud 60 % LEL - NA

10 % LEL - NA

Hydrog

en

peroxid

e

2/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi -

Serious injury 3.5 psi 25

Glass shatter 1 psi 48

11 Hydroge

n

peroxide

Failure of the unloading pump

line (20 % flow)

Hydrog

en

peroxid

e

3/

1

Gas not burning – Toxicity

effect

ERPG- 3 100 ppm 507

ERPG - 2 50 ppm 727

ERPG -1 10 ppm 1700

Hydrog

en

peroxid

e

3/

2

Flammable area of vapor cloud 60 % LEL - NA

10 % LEL - NA

Hydrog

en

peroxid

e

3/

3

Overpressure effect of vapor

cloud explosion

Bldg.

destruction (no

part above LEL)

8.5 psi NA

Serious injury 3.5 psi NA

Glass shatter 1 psi NA

Calculations of affected distances considering various scenarios have been done and summarized results are as below:

Scenerio No Level of concern (LOC)

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Consolidated recommendations/suggested control measures for all the tanks and recommendations are summarized below:

Mitigation Measures

• Isolate the source if possible without risk. • If leakage is small, dilute with water and mop up, or absorb with an inert dry

material and place in an appropriate waste disposal container. If necessary: Neutralize the residue with a dilute solution of sodium carbonate.

• Absorb with DRY earth, sand or other non-combustible material. • Do not get water inside tanks. Do not touch spilled material. Use water spray

curtain to divert vapor drift. • Use water spray to reduce vapors. • Prevent entry into sewers, basements or confined areas. • Neutralize the residue with a dilute solution of sodium carbonate.

Preventive Measures

o A dike will be provided to accommodate the full quantity stored in all the drums. o Drums will be stored in designated area. o Provide exhaust ventilation or other engineering controls to keep the airborne

concentrations of vapors below their respective TLVs. o Never add water to the product. o In case of insufficient ventilation, wear suitable respiratory equipment. If

ingested, seek medical advice immediately and show the container or the label. o Avoid contact with skin and eyes. Keep away from incompatibles such as

oxidizing agents, organic materials, metals, alkalis, moisture. o Storage: Keep container tightly closed. Keep container in a cool, well-ventilated

area. o While handling always use face shield. Full suit. Vapor respirator. Be sure to use

an approved/certified respirator or equivalent.

o Ensure that eyewash stations and safety showers are proximal to the work-station location.

Measures to control and mitigate emergency

✓ Priority will be given to Tanker to immediately enter the storage premises at site and will not be kept waiting near the gate or the main road.

✓ Security person will check License, TREM CARD, Fire extinguisher condition, required PPEs as per SOP laid down.

✓ Store officer will take sample as per sampling SOP from sampling point.

✓ After approval of QC department unloading procedure will be allowed be started. Following precautions will be adopted during unloading

✓ Wheel stopper will be provided to tanker at unloading platform. ✓ Tanker unloading procedure will be followed according to check list and

implemented. ✓ Flexible hose connection will be done at tanker outlet line and checked for no

leakage. ✓ Every time gasket will be changed.

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✓ The quantity remaining in the hose pipeline will be drained to a small container, which will be subsequently transferred to the main storage tank thus ensuring complete closed conditions for transfer from road tanker.

✓ All tanker valves will be closed. Following precautions will be adopted Storage of such chemicals

✓ Storage tank will be stored away from the process plant. ✓ Tanker unloading procedure will be prepared and implemented. ✓ Caution note and emergency handling procedure will be displayed at unloading

area and trained all operators. ✓ NFPA label will be provided. ✓ Required PPEs like full body protection PVC apron, Hand gloves, gumboot,

Respiratory mask etc. will be provided to operator. ✓ Neutralizing agent will be kept ready for tackle any emergency spillage. ✓ Safety shower, eye wash with quenching unit will be provided in acid storage

area. ✓ Material will be handled in close condition in pipe line. ✓ Dyke wall will be provided to all storage tanks, collection pit with valve

provision. ✓ Double drain valve will provided. ✓ Level gauge will be provided on all storage tanks. ✓ Safety permit for loading unloading of hazardous material will be prepared and

implemented. ✓ TREM CARD will be provided to all transporters and will be trained for

transportation Emergency of ✓ Hazardous chemicals. ✓ Fire hydrant system with jockey pump as per TAC norms will be installed.

Mitigation measures to control Emergency o Safety Shower and eye wash will be provided away from the tank and unloading

station. o Sand bags/ buckets will be provided near tank area. o Neutralizing medium (Lime and dry sand) will be kept ready near tank farm. o Emergency siren and wind sock will be provided. o Tele Communication system and mobile phone will be used in case of emergency

situations for communication. o First Aid Boxes and Occupational health centre will be made at site. o Emergency organization and team will be prepared. o Full body protection suite and other PPEs will be kept ready in ECC at site. o Emergency team will be prepared and trained for scenario base emergency. Like

Toxic control team, Fire control team, First aid team, communication and general administration team, Medical team etc.

SPILL OR LEAK

o Do not touch damaged containers or spilled material unless wearing appropriate protective clothing.

o Stop leak if you can do it without risk.

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o Use water spray to reduce vapors; do not put water directly on leak, spill area or inside container.

o Keep combustibles (wood, paper, oil, etc.) away from spilled material. Small Spill

o Cover with DRY earth, DRY sand or other non-combustible material followed with plastic sheet to minimize spreading or contact with rain.

o Use clean non-sparking tools to collect material and place it into loosely covered plastic containers for later disposal.

o Prevent entry into waterways, sewers, basements or confined areas.

Other Control Measures Suggested for tanks

• Storage tank shall be appropriately dyked for the spill containment as per NFPA guidelines

• Periodic inspection and maintenance program on the tank, pumps and piping shall be ensured.

• Least number of flanged joints to be provided in the pipelines.

• Visual inspection of the pipelines to be done periodically to ascertain external pitting and corrosion.

• Protective equipment such as gloves, lab coat, vapor respirator, splash goggles shall be ensured while handling the chemicals.

• Spill control kit to be made available at location.

• Prominent signage of hazards (such as “Danger”, No smoking”) of the substances shall be provided on the tank and surroundings in addition to the cautionary notice as required under provisions of Schedule XII of MFR 114.

• Comprehensive SOP to be formulated for the unloading and transfer operation indicating sequence of valve operation.

• Periodic inspection of unloading/loading hoses to be included in Preventive maintenance program.

• Ensure that the tankers are regularly checked by the transporter.

• Preventive Maintenance program to ensure tanks inspection, thickness check

• Gas leak Detector to be provided near the pumps (Diesel)

• Training to be provided to both, Field Operator & Panel Operator

• Provision for Earthing of Tanker must be provided near the Tanker unloading point

• SOP to be formulated to ensure

1. Oxygen content should be minimum – purging with Nitrogen

2. Moisture content to be within acceptable limit

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• The flanges on the acid pipelines shall be so covered (Flange guard) that any leakage may not cause spray of fatty acid. For the flanges which are above working and walking surfaces, cachepots with adequate drain pipes shall be provided to avoid dripping of acid on the body.

• Floors of the storage area shall be of acid-resistant material and shall be adequately slope for easy draining of any spilled acid.

• The firefighting system for equipment and vessels in Plant shall be designed conforming to OISD norms. Fire hydrant network should be considered taking into consideration of additional cooling water requirement.

• Health check-up and maintenance of the equipment and pipelines should be done

at regular intervals to avoid any major failure.

• Instruments and trip interlocks should be checked and calibrated at regular intervals to prevent any wrong signaling and consequent failures.

• Storage Tanks should be provided with water sprinklers as per guidelines.

• Firefighting system as well as portable fire-fighting appliances should be always

kept in good working condition. Safety appliances should also be checked and kept in good working condition.

• Mock Drills should be conducted at regular intervals.

• To reduce the failure frequency due care should be taken in design, construction,

inspection and operation. Well-established codes of practices should be followed for design, inspection and construction of the facility.

• The operation of the unit should be done by experienced and trained operating

personnel. They should also have training in firefighting operation.

• Smoking should be strictly prohibited inside the installation.

• Non -sparking tools should be used for maintenance to avoid any spark.

• The equipment’s including storage tanks and pipelines should be properly earthed to avoid accumulation of static electricity.

• Maintenance of moving equipment’s should be done regularly as per instruction of the suppliers as well as by experience of the company.

• Good liaison should be maintained with outside organization and District

Administration, hospitals and nursing homes in the locality as well as in nearby towns.

Proposed fire detection and protection measures are given in Annexure 7.5.

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HAZOP Study

For identifying cause and the consequences of perceived mal operations of equipment and associated operator interfaces in the context of the complete system. It accommodates the status of recognized design standards and codes of practice but rightly questions the relevance of these in specific circumstances where hazards may remain undetected.

It emphasizes upon the operating integrity of a system, thereby leading methodically to most potential and detectable deviations which could conceivably arise in the course of normal operating routine

- including "start-up” and "shut-down" procedures - as well as steady-state operations.

It is important to remember at all times that HAZOP is an identifying technique and not intended as a means of solving problems nor is the method intended to be used solely as an undisciplined means of searching for hazardous scenarios. RMCPL will carry out Detailed HAZOP study, during basic and detail engineering stage once P & ID’s are finalized. Letter from RMCPL regarding Confirmation for HAZOP compliance recommendation is attached as Annexure 7.1.

Dow Fire and Explosion Index

Dow Fire & Explosion Index for the Storage Tanks method is used as a rapid ranking system to classify separate elements of the plants. The method is based on the Fire &

Explosion Index Hazard Classification Guide developed by M/s. Dow Chemical Company (DOW INDEX) and the National Fire Protection Association (NFPA) indices for health hazard.

The Fire and Explosion Index (F & E I) indicates the fire and/or explosion hazard of the particular unit. Though the concept was developed basically for determining the "Risk Insurance", it also provides guidance on the degree of preventive methods to be provided. It also identifies the areas of priority for taking up the proactive control measures.

The calculations of F & E I and Recommendations are done for the Methanol, Toluene, styrene, m xylene, o xylene and MEK. The degree of hazards and hazard severity are given

below. The recommendations based on F & EI index are also summarized below.

The Mond index covers a wider range of process and storage installations, the processing of chemicals with explosive properties and the evaluation of a toxicity hazards index. It also allow for the off-setting effects of good design, and of control and safety instrumentation. The Dow and Mond indexes are useful techniques, which can be used in the early stages of a project design to evaluate the hazards and risks of the proposed

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process. Calculation of the indexes for the various sections of the process will highlight any particularly hazardous sections and indicate where a detailed study is needed to reduce the hazards. Mond Index/Calculation and Classification in Hazard Category for Storage Tanks are given below,

Table 7.8 Hazard Category for Storage Tanks as per FETI study

No Chemical Fire and

explosion index Degree of

hazard Mond index

Hazard category

1 Methanol 190 Severe 7.95 III 2 Toluene 248 Severe 18.1 III 3 Styrene 372 Severe 18.1 III 4 m Xylene 238 Severe 15.5 III 5 o Xylene 238 Severe 15.5 III 6 MEK 164 Severe 7.4 III

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Table 7.9 F & EI / Mond index calculations

Tank No Equipment name

Density 0.79

Nh 1 Nf 3 Nr 0 M.F.

B.P. 147 Deg F Flash Point 52 Deg F 9,838 BHT/Lb

Quantity of material 25,000 Litre 19,750 Kg 43,450

Storage condition Temp 25 Deg C Pressure Atm bar

0.43 x 10 9̂ BTU

Mac value for Methanol

Properties of Material

16

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR METHANOL TANK

- Methanol Tank

Basic material for material factor Methanol Kg/Litre

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.3

E Access 0.20 to 0.35 0.35

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.20

General Process Hazard Factor ( F1 ) Total 3.00

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

2. Liquids or gases in storage 0.9

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

Special Process Hazard Factor ( F2 ) Total 3.95

L Rotating Equipment 0.5 0

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 190

Process Unit Hazard Factor ( F3 = F1 x F2) 11.9

200

Th 50

Ts 50

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

T 7.95

Since T < 10 and F & EI index is 190 It falls under Hazard Category III

GPHt 3.00

SPHt 3.95

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Tank No Equipment name

Density 0.86

Nh 2 Nf 3 Nr 0 M.F.

B.P. 232 Deg F Flash Point 40 Deg F 17,430 BHT/Lb

Quantity of material 50,000 Litre 43,000 Kg 94,600

Storage condition Temp 25 Deg C Pressure atm bar

1.65 x 10 9̂ BTU

Mac value for Toluene

Properties of Material

16

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR TOLUENE TANK

- Toluene Tank

Basic material for material factor Toluene Kg/Litre

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.5

E Access 0.20 to 0.35 0.35

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.40

General Process Hazard Factor ( F1 ) Total 3.20

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

2. Liquids or gases in storage 1.6

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

Special Process Hazard Factor ( F2 ) Total 4.85

L Rotating Equipment 0.5 0

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 248

Process Unit Hazard Factor ( F3 = F1 x F2) 15.5

50

Th 125

Ts 75

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

T 18.1

Since T > 10 and F & EI index is 248 It falls under Hazard Category III

GPHt 3.20

SPHt 4.85

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Tank No Equipment name

Density 0.86

Nh 2 Nf 3 Nr 2 M.F.

B.P. 293 Deg F Flash Point 88 Deg F 17,400 BHT/Lb

Quantity of material 50,000 Litre 43,000 Kg 94,600

Storage condition Temp 25 Deg C Pressure atm bar

1.65 x 10 9̂ BTU

Mac value for Styrene

T 18.1

Since T > 10 and F & EI index is 372 It falls under Hazard Category III

GPHt 3.20

SPHt 4.85

20

Th 125

Ts 75

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 372

Process Unit Hazard Factor ( F3 = F1 x F2) 15.5

Special Process Hazard Factor ( F2 ) Total 4.85

L Rotating Equipment 0.5 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

2. Liquids or gases in storage 1.6

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.40

General Process Hazard Factor ( F1 ) Total 3.20

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.5

E Access 0.20 to 0.35 0.35

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

Properties of Material

24

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR STYRENE TANK

- Styrene Tank

Basic material for material factor Styrene Kg/Litre

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Tank No Equipment name

Density 0.86

Nh 2 Nf 3 Nr 0 M.F.

B.P. 283 Deg F Flash Point 77 Deg F 17,600 BHT/Lb

Quantity of material 25,000 Litre 21,500 Kg 47,300

Storage condition Temp 25 Deg C Pressure atm bar

0.83 x 10 9̂ BTU

Mac value for m Xylene

T 15.5

Since T > 10 and F & EI index is 238 It falls under Hazard Category III

GPHt 3.20

SPHt 4.65

100

Th 125

Ts 50

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 238

Process Unit Hazard Factor ( F3 = F1 x F2) 14.9

Special Process Hazard Factor ( F2 ) Total 4.65

L Rotating Equipment 0.5 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

2. Liquids or gases in storage 1.4

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.40

General Process Hazard Factor ( F1 ) Total 3.20

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.5

E Access 0.20 to 0.35 0.35

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

Properties of Material

16

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR M XYLENE TANK

- m Xylene Tank

Basic material for material factor m Xylene Kg/Litre

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Tank No Equipment name

Density 0.88

Nh 2 Nf 3 Nr 0 M.F.

B.P. 292 Deg F Flash Point 62.6 Deg F 17,600 BHT/Lb

Quantity of material 25,000 Litre 22,000 Kg 48,400

Storage condition Temp 25 Deg C Pressure atm bar

0.85 x 10 9̂ BTU

Mac value for o Xylene

T 15.5

Since T > 10 and F & EI index is 238 It falls under Hazard Category III

GPHt 3.20

SPHt 4.65

100

Th 125

Ts 50

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 238

Process Unit Hazard Factor ( F3 = F1 x F2) 14.9

Special Process Hazard Factor ( F2 ) Total 4.65

L Rotating Equipment 0.5 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

2. Liquids or gases in storage 1.4

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.40

General Process Hazard Factor ( F1 ) Total 3.20

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.5

E Access 0.20 to 0.35 0.35

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

Properties of Material

16

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR O XYLENE TANK

- o Xylene Tank

Basic material for material factor o Xylene Kg/Litre

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Tank No Equipment name

Density 0.86

Nh 1 Nf 3 Nr 0 M.F.

B.P. 175 Deg F Flash Point 22 Deg F 13,500 BHT/Lb

Quantity of material 5,000 Litre 4,300 Kg 9,460

Storage condition Temp 25 Deg C Pressure atm bar

0.13 x 10 9̂ BTU

Mac value for MEK

T 7.4

Since T < 10 and F & EI index is 164 It falls under Hazard Category III

GPHt 3.20

SPHt 3.20

200

Th 50

Ts 50

Degree Hazard Based on F & E I Index Severe

MOND INDEX (Classification in Hazard category)

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 164

Process Unit Hazard Factor ( F3 = F1 x F2) 10.2

Special Process Hazard Factor ( F2 ) Total 3.20

L Rotating Equipment 0.5 0

J Use of Fired Equipment 0.2

K Hot oil heat exchange system 0.15 to 1.15 0.15

H Corrosion & Erosion 0.10 to 0.75 0.1

I Leakage - Joints & Packing 0.10 to 1.50 0.3

2. Liquids or gases in storage 0.15

3. Combustible Solids in Storage, Dust in Process 0

G Quantity of flammable / unstable material --- ---

1. Liquids or gases in process 0

E Pressure Operating pressure ___ psig

Relief setting ________ psig

0.3

F Low temperature 0.20 to 0.30

3. Combustible solids in storage. Dust in

process

0.8 0

D Dust Explosion 0.25 to 2.00 0

1. Tank farm storage flammable liquids 0.5 0.5

2. Process upset or purge failure 0.3 0.3

B Sub atmospheric pressure (< 500 mm Hg) 0.00

C Operation in or near flammable range

_____inerted ______noninerted

--- ---

2. Special Process Hazards Base Factor 1.00 1.00

A Toxic material(s) 0.20

General Process Hazard Factor ( F1 ) Total 3.20

F Drainage and Spill Control 0.25 to 0.50 0.5

D Enclosed or Indoor Process Units 0.25 to 0.90 0.5

E Access 0.20 to 0.35 0.35

B. Endothermic processes 0.20 to 0.40

C. Material handling and transfer 0.25 to 1.05 0.85

1. General Process conditions Base Factor 1.00 1.00

A. Exothermic chemical reactions 0.30 to 1.25

Properties of Material

16

Heat of Combusion

Lb

Penalty factor range Penalty factor used

DOW FIRE & EXPLOSION INDEX CALCULATION FOR MEK TANK

- MEK tank

Basic material for material factor MEK Kg/Litre

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Based on the study on the index, recommendation on planned / suggested measures for risk mitigation are given below.

Table 7.10 Planned & Suggested Measure based on Fire and Explosion index

Sr. No.

Preventive & Protective Features

F & EI Index for for all above 6 tanks > 90

Recommendation* Remarks Range of F & EI >90 1 Fireproofing 4 Required 2 Water Spray

2a Directional 4 Required 2b Area 4 Required 2c Curtain 4 Required 3 Special Instrumentation

3a temperature 4 Required 3b pressure 4 Required 3c flow control 4 Required 4 Dust, blow down, spill

control 4 Required

5 Internal examination 4 Required 6 Combustible gas Monitors

6a Signal alarm 4 Required 6b actuate equipment 4 Required 7 Remote operation 4 Required 8 Diking 4 Required 9 Blast & barrier walls

separation 4 Required

* NOTE: 1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required

Disaster preparedness and Emergency Management Plan

RMCPL will prepare Onsite Disaster Management Plan as per the following broad guidelines. The purpose of this plan is to provide VOL with the means to effectively utilize all the resources at its disposal for the protection of life, environment and property. RMCPL will develop emergency management system to tackle any emergency situation for proposed plants establishment based on following guidelines. The details of Onsite Emergency plan/Disaster management plan (DMP) are discussed in the following section. The disaster management plan (DMP) provides for a framework of actions to handle various emergency situations at the RMCPL. It also provides for on-site resources and appropriate outside assistance in case of any incident at the facility. The ERP will be in

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place before the commencement of operations at site, and all personnel will have undergone a comprehensive training in emergency response. The primary objective of the plan is

• Minimization of the risks to lives and safety of proposed plant personnel and of the neighboring community.

• Containing and minimizing environmental damage, to surroundings, and to site property, and equipment, this could occur from emergency or accidental situations beyond the normal operations of the plant.

• Coordinating appropriate and effective actions with outside regulatory agencies

during and after their involvement in on-site emergencies.

• Maintaining effective trained personnel capable of performing the established emergency response procedures when it is required.

An on-site emergency is caused by an accident that takes place in plant itself and the effects are confined to the factory premises involving only the people working in the factory. On-site emergency plan to deal with such eventualities is the responsibility of the occupier and is mandatory. An on-site emergency plan should contain the following key elements:

• Basis of the plan: Hazard analysis • Accident prevention procedure/measures; • Accident/emergency response procedure/measures and • Recovery procedure.

An Emergency can be defined as an “Occurrence of such magnitude so as to create a situation in which normal pattern of life within a facility is suddenly disrupted, adversely affecting not only the personnel and property within the facility, but also in its vicinity”. Such an occurrence may result in emergency. The following maximum credible accident scenarios may occur,

• Road accident during transportation of chemicals • Ammonia tonner leakage • Tank on fire (e.g. Methanol / Toluene / o xylene/ DEK) • Spillage of chemical etc

Emergency is a general term implying hazardous situation both inside and outside the plant/installation premises. Thus, the emergencies termed “on-site” when it confines itself within the plant/installation even though it may require external help and ‘offsite” when emergency extends beyond its premises. It is to be understood here, that if an emergency occurs inside the plant and could not be controlled properly and timely, it may

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lead to an “off-site” emergency. The emergencies at the plant can be broadly classified into three levels:

Level 1: The incident at site is confined to a small area and does not pose an immediate threat to life or property. Spillage of flammable liquid or solids, small fire of flammable chemical etc can come under this category. Level 2: An incident at the plant involving a greater hazard or larger area which poses a potential threat to life or property. Fire in flammable chemicals / tank can come under this category. Level 3: An incident at plant involving a severe hazard or a large area which poses an extreme threat to life or property.

The general order of priority for involving measures during the course of emergency would be as follows,

• Safeguard life, • Safeguard environment • Safeguard property

Legal Authority and Responsibility / On Site Emergency Planning

The provisions of the Factories Act, 1948 (as amended) requires that every occupier is to draw up an on-site emergency plan with detailed disaster control measures and to educate the workers employed. The obligation of an occupier of hazardous chemicals installation to prepare an emergency plan is also stipulated in Rule 13 of the ‘Manufacture, Storage and Import of Hazardous Chemicals Rule’s, 1989 and subsequent amendments. Off-Site Emergency Planning Under the ‘Manufacture, Storage and Import of Hazardous Chemicals Rules preparation of ‘Off-site Emergency Plan’ is covered in Rule No.14. The duty of preparing and keeping up to date the ‘Off-site Emergency Plan’ as per this rule is placed on the District Emergency Authority. Also, occupiers are charged with the responsibility of providing the above authority with such information, relating to the industrial activity under their control, as they may require for preparing the off-site emergency plan. Off-site emergency response needs actions by various Government agencies over which the operating company has no control. RMCPL’s role and responsibility is to provide material, manpower, and knowledge support under the overall charge of the off-site control administration.

In case of an emergency, the On-site Emergency Plan of the plant will come into action. Effective on-site emergency plan requires that in the event of an accident, nominated

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functionaries be given specific responsibilities, often separate from their day-to-day activities. The emergency organization follows the usual pattern of the hierarchy. The senior-most functionary available during an emergency at the plant takes charge as Chief Emergency Coordinator (CEC) and will locate himself at the designated Primary Command Post. The senior most functionaries for each emergency service will act as coordinator and shall report at the Primary Command Post unless otherwise instructed by the Chief Coordinator. The senior most persons in the shift will be designated as the Site Incident Controller

(SIC). The SIC will take charge of the incident site and take the overall command. He will

be supported by other key persons representing various emergency services. Key

persons are personnel available at the site on round the clock basis. It is to be appreciated

that the key persons remain the front line fighters. The role of various coordinators is to

assess the situation from time to time, take appropriate decisions in consultation with the

CEC and to provide timely resources to the key persons to fight the emergency. Duties

and responsibilities of various emergency functionaries have been described in following

sub sections.

Duties and Responsibilities for Functionaries The duties and responsibilities of the

functionaries for unlikely event of emergency are given below:

Crises Co-coordinator

The Head of Plant will work as Crisis Coordinator: He will assess the situation and

instructs the Chief Emergency Co-coordinator to sound the siren. This will inform the

employee that an emergency situation has siren arisen and that the plant should be shut

down and evacuated. All the personnel/part of the Plant need to be evacuated and

employees other than given responsibility assemble at the assembly points. He will

approve release of information to press, TV and Government agencies as required.

Chief Emergency Coordinator (CEC)

The General Manager of Plant will work as Chief Emergency Coordinator.

He will report at the command post and will assume overall responsibility of the works

and its personnel. His duties will be:

i. To assess the magnitude of the situation and decide whether a major emergency exists

or is likely to develop, requiring external assistance. To inform District Emergency

Authority (DEA) (i.e. District Collector) in case on-site emergency escalates into off-site

emergency.

ii. To contact Crisis Cell of the Ministry and inform about the incident, magnitude of

disaster, combating operations and number of casualties, if any.

iii. To exercise direct operational control over areas in the plant other than those affected.

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iv. To assess the magnitude of the situation and decide if personnel need to be evacuated

to identify safe places.

v. To continuously review in consultation with the other coordinators.

vi. To liaise with senior officials of police, fire brigade, and Factories Inspectorate and pass

on information on possible effects to the surrounding areas outside the factory

premises.

vii. To liaise with various coordinators to ensure casualties are receiving adequate

attention and traffic movement within the plant is well regulated.

viii. To arrange for a log of the emergency to be maintained in control room.

ix. To release authorized information to press through the media officer designated.

x. To control rehabilitation of the affected persons and the affected areas after the

emergency.

xi. To obtain assistance from Mutual Aid partners.

Site Incident Controller

The In-change waste storage will work as Site Incident Controller.

He will take overall control of handling the emergency at the plant. His first task will be

the isolation of the source of containment loss to the extent feasible. Simultaneously, in

case of fire, he will organize appropriate fire response to get the situation under control

and to prevent escalation.

On arrival at the site, he will assess the scale of emergency and judge if a major emergency

exists or is likely to develop and will inform the control room accordingly asking for

assistance and

indicating the kind of support needed. His duties and responsibilities will include:

I. To coordinate the activities of other key persons reporting at the incident site, under

his overall command.

II. To direct all operations within the affected areas giving due priorities for safety of

personnel and to minimize damage to environment, plant and property.

III. To provide advice and information to Fire & Safety personnel and other fire services

as and when they arrive.

IV. To ensure that all non-essential workers and staff within the affected area are

evacuated to appropriate assembly points and those areas are searched for casualties.

V. To organize rescue teams for any casualties and to send them to safe areas/medical

centre for first aid and medical relief.

VI. To setup communication points and establish contact with control room.

VII. To seek additional support and resources as may be needed through the control

room.

VIII. To seek decision support from the control room for decisions such as activation of

mutual aid plan etc.

IX. To preserve all evidence so as to facilitate any inquiry into the cause and circumstance,

which caused or escalated the emergency (to arrange photographs, video, etc.)

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X. To arrange for a head count after the emergency is over with respect to the personnel

on duty in the affected areas.

Fire and Safety Function

The Manager-Fire & Safety along with fire fighting team will work as fire and safety

functionary.

The main responsibilities of fire and safety functionary are:

i. To immediately take charge of all firefighting operations upon sounding of the alarm.

ii. To instruct the telephone operator to immediately inform all essential personnel not

residing within the audible range of the emergency siren.

iii. To guide firefighting crew and provide logistics support for effectively combating the

fire.

iv. To barricade the area at appropriate locations in order to prevent the movement of

vehicular traffic.

v. To assist in rescue and first aid operations.

vi. To operate the Mutual Aid Scheme and call for additional external help in firefighting

via the control room.

vii. To organize relieving groups for firefighting.

viii. To inform the Crises Controller and give "All Clear" signal when the fire emergency

is over.

Media Function

The Human Resource Manager will work as Media Function. He will under the direction

of the CEC, co-ordinate the following:

i. To liaise with various media and release written statements to the press through prior

concurrence of Crises Controller.

ii. To handle media interviews with various media. Make arrangements for televising the

information about the incident, if public interest warrants.

iii. Inform State and Central Governments & statutory bodies of the nature and magnitude

of the incident, the number of casualties, etc.

iv. To locate himself such that media personnel/third parties do not need to go past the

plant security gates and that adequate communication links exist.

v. Media personnel often insist on visiting the incident scene.

vi. To escort media team(s) if the Crises Controller approves such visits.

Communication Function

The Manager - Laboratory will work as communication functionary. He should perform

the following duties:

i. To ensure all available communication links remain functional.

ii. To quickly establish communication links between incident site and the control room

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iii. To ensure that previously agreed inventory of various types of communication

equipment is maintained in working condition and frequent checks carried out and

records maintained.

iv. To maintain voice record of significant communications with timings received/passed

from the primary control room.

Medical Function

The Manager – Occupational Health will look after medical function. He will perform the

following:

i. To arrange for the First Aid team to treat the affected personnel.

ii. To arrange for treatment in the hospital.

iii. To liaise with the local medical authorities and hospitals, if the casualties are more

and the situation demands treatment at more/other medical centers.

iv. To liaise with the transport coordinator for transporting the victims to various

hospitals.

v. To arrange for ambulances.

vi. The Medical Coordinator should ensure the upkeep of agreed medical supplies,

antidotes and equipment that should always be kept in stock for treating victims of

burns.

vii. To liaise with the Media coordinator for release of news to the press.

Transport Function

The Waste Transportation Manger will work as Transport Function. He shall perform

the following duties:

i. Arrange for transport of victims to hospital/dispensaries.

ii. Mobilize all available vehicles available at the plant for emergency use, along-with the

drivers.

iii. Arrange for the duty rotation of the drivers to meet with the emergency situation.

iv. To direct refueling of vehicles, if not topped up.

v. To arrange for vehicles from other sources.

vi. To liaise with the CEC for evacuation of personnel and transportation of victims.

List of Names of Functionaries

List of name of various functionaries with designation and telephone numbers will be

mentioned below. (and will be available with all concerned)

Type of

Coordinator

Name Designation Telephone

Numbers

Office Residential

Crisis Coordinator

Chief Emergency (CEC)

Site Incident Controller

Fire & Safety

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Emergency Control Room- Emergency Control Room is to be set up and marked on the site plan. The Control Room will be the focal point case of an emergency from where the Operations to handle the emergency are directed and coordinated. It will control site activities and should be furnished with external and internal telephone connections, list of essential telephone numbers, list of key persons and their addresses. Assembly Points- Assembly points are to be set up farthest from the location of likely hazardous events where pre-designated persons from the works, contractors and visitors would assemble in case of emergency. Up-to-date list of pre-designated employees of various departments (shift-wise) must be available at these points so that roll call could be taken. Pre-designated persons would take charge of these points and mark presence as the people come into it.

Communication system

There are different types of alarms to differentiate one type of an emergency from other as described below:

Fire or Gas Normal Fire Siren Emergency/Evacuation High-pitched wailing Siren

Alarms should be followed by an announcement over Public Address System (PAS). In case of failure of alarm system, communication should be by telephone operator who will make announcement in industrial complex through Public Address System which should be installed. If everything fails, a messenger could be used for sending the information.

Warning system and control

The Control Centers should be located at an area of the minimum risk or vulnerability in the premises concerned, taking into account the wind direction, areas which might be affected by fire/explosion, toxic releases, etc. For promptness and efficiency, the factory premises/storage sites may be divided into ‘X’ number of zones, which should be clearly marked on the site plan. Emergency services - Under this, each factory should describe the facilities of firefighting, first-aid and rescue. Alternate sources of power supply for operating fire pumps, communication with local bodies, fire brigade, etc. should also be clearly indicated.

• An adequate number of external and internal telephone connections should be installed.

• Areas with large inventories of hazardous material. • Sources of safety equipment. • Fire-hydrant system and alternate supply sources.

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• Stock of other fire-fighting materials. • Assembly points, first-aid centers. • Surrounding habitation within 1/ 2 km distance. • Availability of first-aid equipment.

It is essential to have mutual aid arrangements as it is useful in cases of major fire and other emergencies. Mutual aid arrangements are to be worked out in the plan to facilitate additional help in say, fire-fighting or medical attention which might be beyond the capacity of an individual factory/unit. To make the mutual aid plan a success, the following are considered essential:

• Written procedure which spells out how call for help will be made and how it will be responded.

• The type of equipment which would be used and procedure for making replacement.

• A quick hot-line method of communication. • A brief mention of the type of hazard in each plant and fire-fighting measures. • Orientation and joint training program for staff. • Joint inspections and drills.

Emergency prevention through good design, operation, maintenance and inspection are essential to reduce the probability of occurrence and consequential effect of such eventualities. The overall objective of the DMP/Emergency Response Plan (ERP) is to make use of the combined resources at the site and outside services to achieve the following.

• Localize the emergency on property and people • Minimize effects on property and people • Effective rescue and medical treatment • Evacuation.

A disastrous event strikes suddenly, violently and without warning. Identifying the potential hazards ahead of time and advance planning can reduce the dangers of serious injury, loss of life and damage to environment in the event of an incident occurrence. The first response to a disaster is the job of the local government’s emergency services with the help from the nearby municipalities and the volunteer service agencies. In a catastrophic disaster only the govt. can provide the rescue search on the disaster site, resumption of electric power, food, water, medicines, cloths, shelter and other basic human needs. It is the long term recovery phase of disaster which places the most severe financial strain to govt. in-addition to damage to public facilities and infrastructure. It takes longer time to get aid from the govt. for rescue work when there is a natural calamity because of various constraints such as reaching the site, priority of personnel involved, availability of material, equipment and rescue team personnel etc. It is always advisable to develop teams within the organization for taking immediate rescue action if

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possible. Industry has to prepare a detailed disaster control measures and give information such as the quantity of hazardous material stored, the location of storage, the approximate population living in the vicinity and the detail of the hazardous Characteristic of the material to the Employees, District Collector, Police, Fire service department, Director of Factories, State Pollution control Board and the Public living in the vicinity regularly to enable the government to prepare the disaster management plan. Educate employees and the public living in the vicinity the safety measures required to be taken in the event of an accident taking place.

During site selection stage based on the past seismic metrological data / reports earth quake prone areas have to be avoided. Cover the site with public liability insurance as per the advice of government. Design building to withstand minor shocks of earth quake without damage to structures. Maintain inventory of material and the location of stock on day today basis and submit the report to disaster management authority (district collector) and the state pollution control board weekly / monthly also maintain parallel record at H.O. Maintain MSDS of stored materials toxicity of gases that can emanate due to reactions of stored materials including the landfill material. Provide communication facilities internal and with people living in the vicinity. Educate the employees and the surrounding peoples about the possible dangers in case of an earthquake and the safety measures required to be taken. Take preventive action of stopping work activities, informing and evacuating employees and the public living in the vicinity to safe location as per the advice of government agency if there is an advance earth quake warning from the agencies. After an earth quake (if the site is affected), Inform disaster management authorities and state pollution control board authorities over phone, e-mail or through messenger. Display Phone Numbers of: District Collector, Police S.P, Fire Service Department, Factories Inspectorate and nearby Hospitals. Inform company authorities through phone: Phone numbers: Project Head, EHS Head, HR Head. Inform the insurance authorities about the incident. Phone Numbers: Local Insurance officer and Divisional Manager Test the nearby water sources and soil for contamination and the extent of damage and compare data with the base data. If found contaminated, Inform public of the affected area not to use water from the wells or bore wells through mobile public announcement system and by using media like radio and TV. Arrange supply of drinking water from outside till the condition is normalized. Use the services of the lab and expertise of pollution board and find solutions to arrest the leakage of material and leachate and start remedial measures. Divert material required for lining and transfer skilled employees for new pit construction from other site along with additional number of equipment. Construct new pit and start transfer landfill material / leachate in to the new pit. Test the soil contamination level and find out the level of damage and treat the soil if required or remove the contaminated soil and safely transfer it in the new land fill. Check the water contamination level and advise authorities and public about the usability of water. Asses the expenditure required for implementation of required remedial measures. Prepare cost estimate of the total loss including the transport and remediation cost. Make insurance claim and pay compensation if any advised by the govt. authorities to the affected victims.

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Fire

To increase the level of safety in project, installation of smoke alarms or automatic fire detection /alarm systems will be installed at strategic locations as an early warning of fire to the occupants. To prevent fire mishaps and to manage the emergency situation during fire in the project the following activities and precautions are proposed.

• Emergency evacuation plan is important for all projects, and the same will be prepared as per Fire & Safety rules.

• Regular mock drills will be carried out to create awareness on procedures to be followed in times of emergency situation/evacuation

• It will be advised to keep oxygen cylinders, medical kits and masks to prevent smoke inhalation especially for those with respiratory disorders for whom smoke inhalation can be very dangerous.

• Plant manager will be advised to ensure that the firefighting equipment are in good working conditions.

• The plant will be provided with sufficient firefighting gadgets (water, soil, cylinders, etc).

Simple steps to be followed during emergency are as follows.

Call the fire rescue department: During fire in plant, leave the premises by nearest available exit. Call fire department and do not assume anyone else has called the fire department. If your cloth catches fire, do not get panic or run, stop, drop and roll. Cover your nose and mouth with a wet clean cloth: Stay calm cover your nose and mouth with a wet, clean cloth to prevent smoke inhalation injury and choking. Never jump off or attempt to climb down the side of a tall structure as it will mean certain death. Do not run: During a fire, smoke containing poisonous gases such as CO tends to rise up. When you run in a smoke filled room, you tend to inhale the smoke faster. CO dulls the senses and prevents clear thinking, leading to panic. To prevent being asphyxiated, dip tissues or cloth in water and cover your noise with it. Head-count of the occupants: During an emergency, make good use of the evacuation procedure and help each other to reach out of plant/building safely. Ensure nobody is left behind by doing a head-count of occupants. Visitors should read and understand the evacuation plan before going into the plant/building area and ensure their safety.

Disasters occur without notice. Most disasters are natural such as earthquake, floods, hurricanes, sandstorms, landslides, tsunamis and volcanoes. We have no way of stopping

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them, but we can learn to deal with the difficult situations that arise due to them. During disasters like floods, fire, earth quake, landslides, rescue beings at site. Even before external help arrives, people affected by the disasters help each other. The government and many voluntary organizations send teams of workers trained in rescue operations to disaster-affected areas. These teams join hands with the local community helpers such as doctors, nurses, social workers and policemen. Temporary shelters are built for displaced people. Doctors and nurses provide medical aid. They treat the wounded and work to control epidemics. Social workers collect food and cloth from all over the country for the disaster-affected people. The police maintain law and order. Media –persons help in spreading news about the victims and their conditions. They also post advertisements that urge people to donate for victims. In extreme conditions, the army and Air force organize rescue operations. They clear roads, send medical teams and help to move people to safer places. The air force drops food, water and clothes in the affected areas. Organization like UN helps in providing aid during massive disasters. Individually, people from all over the world also come forward to help during a disaster. They donate blood while many donate money. Some even reach the disaster affected places to give an extra hand in the rescue operation. Families adopt children who have lost their parents and thus give them a new home.

Electrical hazards can cause burns, shocks, and electrocution which can lead to serious injury and even death. When dealing with potentially serious electrical hazards stop and think! Instead of taking a chance and risking your personal safety, call trained professionals to handle problems. Many times people prefer to take electrical matters into their own hands. Other small aspects of electrical repair in a business setting may be taken care of without needing professional service technicians. If you do decide to take matters into your own hands, safety precautions can avoid injuries and other losses.

Prevention of Electrical accidents

Flexible cords connected to appliance should be wired to confirm to the international color code. Color of insulation wire is

• Brown represents live wire, • Blue represents neutral wire and • Green/yellow stripes represent earth wire.

What you should look for when selecting an electrical appliance are given below

• The appliance should be suitable for operation on local electrical supply of 240

volts AC and frequency of 50 Hz.

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• The appliance should preferably be tested and certified by a national or reputed standards testing authority

• Look for certified plugs on the flexible cords connected to the appliances. If the appliance is double insulated and has a 2-pin plug, then it should be fitted with a suitable certified plug.

• An essential formality when buying any appliances is a duly completed guarantee card with the dealers/retailer's official stamp and details of the appliance (serial number, etc.).

Safety precautions to be taken when using electrical appliances

a. Avoid using handheld appliances when your hand and/or body is wet.

b. Do not use or leave appliances where liquid can splash onto them.

c. Flexible cords connecting the appliance and the plug should be in good condition, if the cord is frayed, chaffed, cut or melted, have the entire cord replaced by a competent person.

d. Check accessories such as plugs attached to appliances for cracks and burnt marks

and have them replaced. If undue overheating occurs or burnt marks appear in any electrical appliance, have it checked.

Some common causes of electrical accidents in the house

a. Faulty wiring: This usually occurs when unauthorized extension or rewiring is done by unqualified persons. Some of the usual faults are the omission of earth wires and the Reversing of the live and neutral wires. Without an earth wire, the exposed metal parts of appliances may deliver a lethal shock to the user when a fault develops.

b. Improper flexible cords: This can be caused by connecting the flexible cord wrongly to the plug. In the case of appliances which have exposed metallic parts, a 2-core instead of a 3-core flexible cord is used. When the appliance is faulty, the exposed metal parts may become live and a fatal accident could result.

c. Faulty appliance: Attempts to repair faults in electrical appliances by people not

trained to do so can result in accidental shock.

To prevent Electrical accidents, the following points should be kept in mind:

• All electrical wiring, rewiring or extension work must be carried out by licensed electrical contractors. On completion, the contractors should test before electricity supply is connected

• Repair of appliances and replacement of flexible cords should be carried out only by competent persons.

• To ensure electrical safety in the facility, a current-operated Earth Leakage Circuit Breaker (ELCB) or Residual Current Circuit Breaker (RCCB) set to operate at a very small leakage current is recommended. (This is usually marked 100mA or

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0.1A on the label). In case of dangerous electrical leakage to earth, it should automatically cur off the supply of electricity.

• DO NOT use multi-way adaptors. Over loading can cause fire. One socket outlet is for one appliance only.

• DO NOT carry out wiring extension, Engage a licensed wiring contractor for the work.

• DO NOT use a two-way lighting adaptor for any extension. • DO NOT connect any electrical appliance to lighting outlets. A lighting outlet does

not have an earth wire to prevent danger.

• DO NOT make joints to lengthen the lead of the electrical appliances. If the lead wire is worn out or too short, replace it with a new wire.

• USE individual socket outlet for every electrical appliance. • KEEP AWAY from danger areas such as a substation for whatsoever reasons. • CHECK before carrying out excavation work to prevent damaging any

underground cable. The operator may receive severe electric shock or even be electrocuted.

• TAKE PRECAUTION when working in the vicinity of overhead lines to avoid any unforeseen incident. DO NOT meddle with any broken overhead wire. Report the matter immediately to the nearest electric office.

• DO NOT climb any electric pole. You may receive an electric shock or get electrocuted.

• NOT throw anything onto the overhead lines. • NEVER attempt to retrieve anything stuck to overhead lines by whatever means. • NOT climb transmission line towers. No one is safe from its high voltage shock. • DO NOT erect any structure close to transmission lines. • TAKE PRECAUTION when working in the vicinity of overhead lines to avoid any

unforeseen incident. • NEVER stand on a damp or wet surface when using electrical equipment. • USE a portable electrical tool, which is properly earthed. • DO NOT tap electrical power without a proper plug. • DO NOT use any electrical tool which has a damaged casing, cap, switch, lead or

plug.

First aid and emergency procedures

Burns can cause due acid spillage and leakage of electricity. Curative measures for any issues of burns and First Aid procedures are given below:

Table 7.11 First aid for burns

Burns covering small area Burns covering extensive area Allow cold tap water to run gently over the area or immerse in cold water.

Allow person to lie down.

It may be necessary to cover with gauze or a clean handkerchief, and bandage.

Cover burned areas with sterile dressing or clean cloth and lightly bandage.

If clothing is adhering, do not disturb; leave the clothing alone.

Keep person warm. If person is not

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nauseated, he may have sips of water. Arrange for immediate medical care.

Public Consultation

“Public Hearing” refers to the process by which the concerns of local affected persons and others who have plausible stake in the environmental impacts of the project or activity are ascertained with a view to taking into account all the material concerns in the project or activity design as appropriate. Since the project of manufacturing is falling under

Category 5(b) and 5(f)- A which is to be located in the well-developed Industrial estate i.e. GIDC Panoli Dist. Bharuch Hence, public hearing is not required. (Refer MOEF OM No. J-11013/36/2014-IA-I dated 10th December 2014). http://www.moef.nic.in/sites/default/files/O.M%20Dated% 2010.12.2014.pdf).

Social Impact Assessment, R & R (Relocation and rehabilitation) action plan

Not Applicable (The project is within plot of the company which is located in notified GIDC industrial area (GIDC Panoli).

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PROJECT BENEFITS

Improvement in Infrastructures

The proposed project establishment is to be located in GIDC Panoli Industrial area and does not require any additional infrastructure as the site is well connected so no major benefits in terms of direct improvement in infrastructure is anticipated.

Improvement in Social Infrastructure

Local youth will be employed during construction stage. During operation phase, locals will be given preference based on qualification and skill. RMCPL as a part of CER also will benefit the community around.

Employment Potential

All recruitments will be done from local area which will be the considerable benefit to the local area considering the demography of the region/project area (5 Km). Further, the indirect employment via increased transportation, ancillary units & local economic

activities will also add in the employment potential of the proposed project.

Other Tangible & Intangible Benefits

Due to establishment of proposed unit the people of nearby areas / villages will be benefited by way of generation of direct as well as indirect employment opportunities.

During construction stage approx. 200 - 250 persons will be hired. The project creates employment to ~ 100 persons (direct and contract workmen) once the plant comes to the operational stage.

With the development of this plant there will be a lot of scope for more ancillary

development, which in turn will benefit the local people and society.

This will uplift financial and social condition of local people leading to overall improvement in the income level of the people.

Need based survey will be carried out in nearby area / villages during baseline data generation and details CER will be outlined accordingly.

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ENVIRONMENTAL COST BENEFIT ANALYSIS

This analysis is not carried out in this study as it is not recommended at scoping stage and not specified in additional TOR. Also it is not considered as necessary as all the environmental costs of the project are committed by the Project Proponent for implementation since they are necessary measures for the environmental management of the project.

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ENVIRONMENTAL MANAGE MENT PLAN

Introduction

Description of the administrative aspects of ensuring the mitigative measures is implemented and their effectiveness monitored, after approval of EIA are presented in this chapter.

Once mitigative measures are identified, an EMP is drafted as a joint activity by project proponent and EIA consultant organization to detail out each activity required to accomplish the proposed mitigation delineated in Impact Assessment section of this report.

o An EMP assures that the desired environmental management is communicated by

the management to the executing teams and members of the EHS cell in a systematic manner without missing any vital / critical information.

o It helps the EHS cell in streamlining the role and responsibilities of the members and their respective departments.

o The EMP also helps in formulating preventive measures in terms of inspections, preventive maintenance, monitoring, etc. so that the performance of equipment and manpower are verified periodically.

The Environmental Management Plan is prepared with the main objective of enlisting all the requirements to ensure effective mitigation of adverse impacts for all the components of the proposed project. The objectives taken into account in preparation of EMP are summarized here as follows:

a. The prevention, control and abatement of pollution, i.e. air pollution, water pollution, hazardous/ non-hazardous wastes and noise pollution,

b. To comply with the stipulated Enviro-legal requirements and standards,

c. To direct the steps to be followed, for effective maintenance and regulation of environmental management system.

d. To ensure the better and safe work environment through pre-meditated planning of prevention and control of hazards,

e. To direct the investments towards sustainable development by considering the cost of effluent treatment, emission control, waste disposal, social development, green belt development and health & safety in the planning stage only,

f. To account for recycling and reusing measures, proposed or required to be

adopted for minimization of consumption of resources and generation of pollutants.

As the proposed project is an establishment at the existing site, the EMP has been prepared to meet the requirements of pollution control from proposed project as an integrated environment management plan. The EMP may not be suitable & feasible for

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any other upcoming activities other than those of the proposed project. The EMP does not cover scope of management of hazardous substance as it forms the key part of RA study (Additional Studies).

Environmental Management systems

RMCPL will establish HSE & Q management system at the site. It will formulate EHS cell before execution of project.

Environment, Health and Safety (EHS) Cell

All the project activities will be monitored to ensure the appropriate implementation of all Environmental mitigation activities and to identify areas where environmental management plan compliance is not satisfied. For effective implementation of the monitoring program, it is also necessary to have a permanent organizational set-up. Unit will set-up permanent environmental management cell (EMC) for the effective implementation and monitoring of environmental management system. The unit will assign responsibility to officer from various disciplines and cadres to perform and co-ordinate the activities concerned with management and implementation of Environmental control measures. In compliance with the requirement of EP Act and Factories Act, the unit will have EHS cell to keep a close watch on the performance of the pollution control equipment, emissions from the sources and the quality of surrounding environment in accordance with the monitoring program. The cell will include safety function/cell for observing, inspecting and regulating the safety measures inside the plant campus. The EHS cell shall report directly to site head for environmental issues including non-compliances and the board of directors are appraised through emails and other communication means.

Responsibilities of EHS cell shall be:

o Collect information from regular monitoring and create database o Analyze the data and decide thrust area. o Carry out “project” in each thrust area to arrive at practical solutions to

environmental problems. o Discuss the reports of study on environment and disseminate the information. o Work out action plan for implementation of the recommendations made in the

report. o Prepare Management Information System (MIS) reports and budget for

Environment management program. o To deal with the environmental issues and for ensuring compliance with the

Conditions prescribed by State pollution control board. o Effluent Treatment plant operation, APCD’s, hazardous waste management, green

belt development, housekeeping, ambient air management, work area monitoring, safety department and OHC / facilities etc. The activities is managed by systematic assignment of responsibilities to each member.

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o Monitor Health, Safety and Environment standards and practices o Maintaining records of all the data, documents and information in line with the

statutory requirements and regularly furnish the same to the State regulatory authorities.

o General prevention and maintenance of pollution control system as proposed to be done by the maintenance department, to achieve optimum efficiency of the control equipment and to maintain the quality of the environment.

Figure 10.1 Proposed Environment, Health and Safety (EHS) Cell

EHS cell shall also act as safety department in compliance with the requirements of section 41 G & 41 H of Factories Act and 68 F & 68 J as per Factories Act with defined role and responsibilities and defined framework covering all aspects of plant and personnel safety.

EMP for water environment management

The total water requirement post expansion project is anticipated to be ~ 913.5 CMD. It shall be fully supplied from GIDC and hence ground water levels shall not be affected.

The process water consumption shall be optimized by the RMCPL team by applying reuse and recycling techniques, wherever possible.

-

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Following measures are suggested to further reduce fresh water consumption

• Water meters should be provided at main areas of consumption to maintain records and to conduct water audit from time to time

• Drip irrigation for watering of green belt within plant premises • Dry sweeping of passages and building floors in place of washing with water • Water saving faucets in toilets and washrooms

Sewage waste will be treated in STP and treated water will be used for gardening. Adequate waste water treatment will be provided with Primary, secondary and tertiary treatment followed by RO and MEE system.

• There shall be sufficient holding capacity for storage of treated and untreated effluent (At least for 3 days)

• Proper housekeeping practices shall be followed in the unit to maintain clean and clear environment and prevent contamination of surface runoffs and storm water.

• The plant shall be provided with well-structured storm water drainage network for preventing surface run-off from mixing into sewers during monsoon.

• During monsoon, periodic monitoring of storm water shall be carried out to ensure that it is not contaminated. Project Proponent is committed for the following:

• To install online pH meters, flow and conductivity meters at strategic locations in the treatment scheme in order to monitor performance of the treatment system.

• For performance monitoring of treatment systems, proponent shall provide and maintain separate electric meter, operational logbook for effluent treatment systems.

• In house analytical laboratory for analysis of basic parameters of raw effluents as well as effluent quality at various treatment stages shall be developed. Third party sampling and analysis shall also be carried out.

• To take utmost care to prevent leakages from pipe fittings, valves etc., drains shall be provided at all plants and tank farms to route such occasional effluents to effluent treatment plant.

• Spill control procedures shall be practiced. • To provide contingency storage capacity for at least 3 days of effluent generation.

Further to above following measures are suggested, Consider EMP for unforeseen waste stream generation due to equipment breakdown or emergency control Causes or source of generation of wastewater stream can be - - Spillage from drums, bags etc. - Leakage from drums, bags, reactors, tanks, vessels, pipelines, valves, etc. - Vessel washing, container washing

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For such effluent generation, following measures should be taken, All plant buildings handling chemicals shall be provided with drains which shall be connected to separate collection tank for storage of such unexpected effluents. This effluent shall be analyzed in laboratory for giving suitable treatment in controlled manner in the ETP. Monsoon preparedness shall be implemented for following compliances

o Gate valves with shall be installed at all storm water outlets o Maintenance of adequate freeboard in all open tanks / containers to prevent

overflow during monsoon o General Housekeeping in chemical storage areas to ensure that there is no spillage

on the ground which can mix with rain water and flow out of the industry

EMP for impact on noise levels

For noise abatement, following measures shall be taken –

▪ Use of acoustic enclosures for high noise equipment’s at boiler, TFH’s and DG sets.

▪ For minimizing and controlling noise levels, following measures are proposed

o Ear muffs and ear plugs to operating personnel / contract workmen o Maintenance of pumps and machinery and all rotating equipment o Maintaining the greenbelt since it also helps in reducing noise

EMP For Impact on Land Environment

o Storm water shall be collected and appropriately treated / routed. o Pre-monsoon maintenance schedule for clearing storm water drain shall be

carried out. o Appropriate precautionary measures to prevent contaminated run-offs from

mixing in storm water by regular analysis and necessary cordoning of process, ETP and storage areas.

o All such areas which pose contamination of storm water should be provided with drains going to ETP.

o Fugitive emissions and fugitive dusts shall be controlled.

Storage RMCPL is committed to provide adequate facilities for collection, storage and disposal of Hazardous and solid wastes in line with the requirements of Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016 and authorization granted by GPCB.

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o Wastes shall be segregated and stored in separate areas having covered roof and concrete flooring.

o Appropriate leachate collection system shall also be provided. Leachate shall be sent to ETP for treatment and recycle.

o It is also planned to explore possibilities for reducing manual handling of hazardous wastes wherever possible – by packing the waste at place of generation, minimum transport distances, transport in closed containers, and minimum inventory of wastes.

o RMCPL shall keep a vigilant check on the characteristics of each waste and review storage and disposal methods periodically.

o Air emissions shall be controlled and monitored o Effluent shall be treated and major recycled within plant site. o Ground water shall not be used. o The plant sections shall be built with proper safety features and safety

equipment and devices at all required locations as per good engineering practice and code.

o Fire hydrant system shall be provided to cover all plant facilities. o Fire extinguishers shall be placed at all required locations of plant facilities. o Safety and health of workers and all contract workmen shall be ensured

through proper SOPs, safety devices, fail-safe instrumentation, interlocks, sound equipment, emergency control systems and procedures.

o Automation shall be used wherever possible and feasible o Noise shall be controlled by –

▪ Placing of noise barriers along noise emitting area ▪ Ear muffs and ear plugs to workers

o Transporters shall be instructed to follow road safety and use well maintained trucks and tankers

o Restrooms shall be provided for truck drivers and assistants o Night time maintenance activities shall be avoided as far as possible

EMP for socio economic environment

o Proposed Man power: 100 nos. company employees and additional on contract basis during operation phase of the project.

o Technical as well as non-technical recruitment shall be generated for skilled and unskilled manpower

o RMCPL is committed to give employment to locals according to skill and academic qualification.

o Project specific training shall be imparted to enhance skills and increase employment of local people.

o It shall also provide opportunities for trade and commerce and development of ancillary businesses for the local people during construction phase and operational phase, such as

▪ mechanical supplies, ▪ machinery services and repair work ▪ spare parts and accessories supplies ▪ canteen services and supplies,

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▪ housekeeping, ▪ security, ▪ green belt maintenance, ▪ Contractual labor for packaging and other activities.

EMP for impacts on ecological environment

The management of air, water and land environment as proposed in the previous sections shall ensure that there is no adverse impact on the terrestrial and aquatic ecology of the area. RMCPL proposes to develop green belt of 29420.43 sq.m. area within and around the plot. Green belt will be developed in scientific manner to give screening effect to surrounding environment from proposed facility.

Environment management though housekeeping

Following are suggested good housekeeping practices,

▪ Prepare a check-list for maintaining good housekeeping in the plant premises. ▪ To regularly inspect the housekeeping in various sections of the plant ▪ The passages, floors and stairways should be kept in good condition ▪ Internal roads and major walkways as well as work areas should be carpeted

either by asphalt or paver blocks to minimize dusting as well as provide ease of transportation and movement.

▪ Walkways should be free from obstructions, as well as marked ▪ All equipment and auxiliaries, piping should be labeled appropriately ▪ Piping Color code to be followed ▪ Wastes to be collected in separate containers with labels and marking in each

department and sent to common waste collection area in the factory for disposal. ▪ Spill Control procedures to be developed and given to shift in charge and all

concerned. ▪ Sweeping to be done in all departments on daily basis. ▪ Electrical wirings should be properly housed/ dressed ▪ Localized extraction and scrubbing facilities for dust and fumes should be

provided wherever required.

Occupational safety and hazard management

The chemicals involved in manufacturing processes are of toxic and flammable nature. The major hazardous materials, their inventories and their hazardous properties are tabulated in Chapter 2 and 7. The unit will be MAH installation in accordance to the schedule 3 of MSIHC rules, 2000. The probable hazards related to the various operations and processes have been assessed and suitable control measures have been proposed. Details are provided in chapter 7 of this report, which are summarized below, Preventive Measures

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Chilled water circulation, Flame proof fittings, Tank level control on DCS, DCS system, CCOE License premises , Earthing and Bonding , Tank insulated with suitable insulation , SOP for tanker unloading , Flame arrester on tank Top, Lightning arrester at tank and building top, Gas Leak Detector etc. Control Measures suggested :- Fire hydrant system, Portable Fire Extinguishers, Foam Trolley, Water Hydrant and Monitor , Self-Contained Breathing Apparatus, Flame proof electrical fittings, Dyke wall for containment, Shower & Eye Washer near Tank Farm Area and at strategic locations within plant premises. Following sections discuss on measures which shall be taken for fulfilling the requirements of applicable statutory rules and regulations related to health aspects: First aid boxes: In all plants / depts., First aid boxes (min. one no. in each plant or building) shall be installed and all the necessary items will be maintained by OHC. They shall be inspected on regular interval of one month.

Visiting doctor shall be appointed as Factory Medical Officer (FMO) who shall visit the unit to attend routine medical illness of workers and employees. FMO shall also be responsible for carrying out pre as well as periodical medical examination. There shall be ready to act preparedness for treating exposure to chemicals as quickly as possible including oxygen administration at OHC.

o Pre-employment medical check-up of all employees and contract labor shall be carried out by FMO and records shall be maintained.

o Full medical checkup of all employees as well as contract workers shall be carried out half yearly and records shall be maintained.

o Health Register in Form No. o Certificate of fitness shall be issued to workers by factory 07 (prescribed under

Rule 68 T and 102) shall be maintained by Medical officer in Form No. 33.

Table 10.1 Proposed Medical Examination Plan

Pre medical employment examination Type of employment

Test to be conducted By (examining agency)

For company employees as

- Physical Examination. - Present complaints / illnesses - Family History - Past History

External Hospital

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as well as contract workmen

- Hematology Profile - Complete Blood Count with Differential Count, E S R & Blood Group & Rh factor.

- Urine Analysis - Liver Profile - S G P T - Kidney Profile - Blood, Urea, Uric Acid & Creatinine. - Lipid Profile - Cholesterol, Trigycerides, HDL -

Cholesterol – VLDL Cholesterol, - LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio

(Risk Factor). - X - Ray Chest - P A View - E C G Signed by Cardiologist - Blood Sugar

Six monthly medical examinations

Type of employment

Test to be conducted By (examining agency)

For company employees as as well as contract workmen

- Physical Examination. - Present complaints / illnesses - Family History - Past History - Hematology Profile - Complete Blood Count with

Differential Count, E S R & Blood Group & Rh factor.

- Urine Analysis - Liver Profile - S G P T - Kidney Profile - Blood, Urea, Uric Acid & Creatinine. - Lipid Profile - Cholesterol, Trigycerides, HDL -

Cholesterol – VLDL Cholesterol, - LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio

(Risk Factor). - X - Ray Chest - P A View - Pulmonary Function Test - E C G Signed by Cardiologist - Blood Sugar - USG – for chemicals which are toxic on liver (once in

a year frequency) - Phenol in urine

Factory medical Surgeon

Appropriate fund allocation shall be done for implementing proposed Occupational Health and Safety measures as delineated in Safety Manual of the company and standard procedures and directions. Towards management of occupational health and safety in the unit, provisions to be made for maintaining an efficient system are described hereunder:

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o Safe and ergonomic design and layout of plant, machinery, tools and control

equipment’s keeping in view the safety and pollution prevention in mind. o In-house Training programs as well as programs with help of outside agencies on

Health hazards and safety for the workers and staff. Trainings shall cover topics on firefighting, awareness training for hazards, first aid etc.

o Proper handling of all spillages by introducing spill control procedures for various chemicals.

o Sufficient lighting, ventilation, drinking water facility, sanitary blocks, firefighting and first aid arrangements.

o SOPs for all operations and critical equipment o Work permit system for specific task o PPE as per operations shall be provided and it shall be ensured that workers make

proper use of PPE o Regular workplace monitoring as per Gujarat Factories rule to be carried out and

records maintained as prescribed. o Material safety data sheet for all the concerned materials to be available at the site. o Adequate firefighting equipment’s provided at relevant areas. o Fire alarms and LEL detectors to be installed in process plants and storage areas. o Emergency telephone numbers displayed at required places. o Planned schedule for inspections of safety devices shall be followed and records

shall be maintained. o On-site emergency plan to be prepared, practiced and upgraded periodically. o Regular emergency mock drills to be carried out

Following suggestions shall be considered by RMCPL,

All aspects of Industrial hygiene and occupational health such as

▪ Noise minimization, ▪ Proper illumination at all floors, ▪ Minimum exposure to fugitive emission while charging, ▪ Proper plant layout and equipment design to provide correct working

postures and body postures, ▪ Suitable platforms and ladders to minimize accidents due to movements, etc

shall be considered at the time of detail engineering of the project.

o Since there are more than one main raw material for many of the products, it is suggested to implement stringent three level permit system for raw material issue from warehouse and tank farms before indenting in process plants so as to minimize mis operation and batch failures due to miscommunication or operator flaws and errors. A good record keeping practice should be maintained. Store activities need to be given due importance and handled by qualified personnel.

o Ensure that the transporters of hazardous chemicals are provided with PPE and carry TREM cards during transportation

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Environment Budget Allocation

RMCPL has committed to allocate ~ Rs. 775 Lakhs towards investment in environmental management and monitoring.

Energy Conservation measures

o Steam condensate shall be returned back as far as possible o Boiler blowdown shall be controlled by automatic system to save heat up losses o Batch processes shall be monitored stringently for heating and cooling operations

so that there is minimum loss of energy and material by way of temperature, pressure and flow controls.

o Level sensors and alarms shall be provided on day vessels to prevent unnecessary pumping energy losses

o Insulations shall be maintained and damaged insulations shall be attended immediately to prevent heat losses

o LED lights shall be provided to conserve electrical energy o Solar panels shall be installed to capture solar energy

Costs for pollution control, monitoring and management will be included in the account

under separate head in CAPEX as well as OPEX provisions.

• Structural measures (such as installation of STP, MEE/ATFD, RO, ETP installation, preventive and protective equipment etc): Directors, Project manager, accounting head/manager, Site Officer & engineers, Contractors.

• Non-Structural (SOP’s, studies, implementing systems etc): Directors, Production manager, accounting head/manager, Plant in-charge, safety & environment Officer & engineers, Contractors & operators.

• Structural measures identified will be provided in construction phase prior to commissioning of plant operation.

• Maintenance will be done throughout the extent of operation phase.

• Proper installation of pumps, motors will be done well before commissioning to prevent wastage & efficient use of water

• The non-structural actions will be initiated with inception of commissioning stage and will be implemented & practiced as routine throughout the project life.

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Reporting

The proponent shall prepare & submit quarterly/half yearly reports regarding implementation of the environmental management program as described in conditions of various licenses/certificate of clearance like EC, CTO, CC etc. which will be submitted to concerned authorities is as listed below:

• Board of Director through MD & General/Production manager.

• Gujarat Pollution Control Boards & other authority as required by regulatory provisions.

Other organizations/firms as directed timely by Board of Directors or General/production Manager or Govt. authority like MoEF, GPCB, CPCB etc.

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EXECUTIVE SUMMARY AND CONCLUSION

Introduction

As per EIA Notification S.O.No 1533 dated 14th Sep 2006 the proposed project falls under Project/Activity 5(b) (Pesticides industry and pesticide specific intermediates (excluding formulations) and 5 (f) (Synthetic organic chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates), Category “A” and requires environmental clearance from EAC, MOEFCC, New Delhi. Project proponent received system auto generated ToR vide letter No.IA-J-11011/535/2017-IA-II(I) dated 22 nd March 2018 for undertaking EIA Study / EMP in accordance with the provisions of the EIA notification dated September 14, 2006.

Company and Project proponent

M/s.Vansum Industries is a group of companies having head quarter at Pune, Maharashtra. It is a group of experienced Chemical Industry professionals providing original manufacturing services on Manganese products. It carries out rigorous and immense production with the help of our extensive in-house knowledge base and its highly qualified staff of chemical engineers. It manufactures quality manganese products in bulk quantity. The chemical manufacturing operations are simultaneously managed at two locations viz. M/s. Kemtech Solutions Pvt. Ltd.(KSPL) at Pune, Maharashtra and M/s. Reshmika Minerals & Chemicals Pvt. Ltd. (RMCPL) at GIDC Panoli, Gujarat. Company is regularly producing chemicals from raw Ore Manganese compounds at both locations and has increased its market share over last 47 years. RMCPL started its operations in the year 2010 by acquiring a 89,632.72 square meter land in the year 2008 at GIDC Panoli, Gujarat.

Project Description

The proposed product to be manufactured at site is given below,

Table 11.1 Proposed products and its capacity

No Product / By Product CAS No Proposed Capacity, TPM

Products 1 Di-Ethyl Ketone (DEK) 96-22-0 250 2 Propiophenone 93-55-0 50 3 4-Nitro-o-Xylene 99-51-4 500 4 3-Nitro-o-Xylene 83-41-0 600 5 1,3-Dimethyl-2-Nitrobenzene 81-20-9 20 6 2,4-Dimethyl-1-Nitrobenzene 89-87-2 80 7 3,4-Xylidine (3,4 –Dimethyl Aniline) 95-64-7 100

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Currently RMCPL is having valid CCA No 75308 from GPCB manufacturing inorganic chemicals Manganese dioxide (2000 Mt/Month), Manganese Oxide (700 Mt/Month) and Manganese sulphate solution (12000 Mt/month), Bricks (using own nonhazardous waste generated from manufacturing process) (36,00,000 Nos/Month).

The total plot area of the site is 89,632.72 sq m and estimated project cost is about Rs. 130 Crores. The project execution will be carried out in phases.

Energy requirement and its management

The steam requirement and process heat requirement for the proposed establishment shall be met from Boilers and Thermic Fluid heaters.

It is proposed to install 3 natural gas fired boilers each of 5 TPH capacity (2 operating and one standby).

It is proposed to install 3 natural gas fired TFH each of 5 mkcal/hr capacity (2 operating and one standby).

It is also proposed to install 2 natural gas fired high temperature TFH each of 1.5 mkcal/hr capacity (one operating and one standby).

Water requirement

Additional water requirement is about 508 cmd (Fresh + recycle) for domestic, process, cooling tower, and boiler and for green belt maintenance purpose. Total water requirement post expansion project is 913.5 cmd.

Fresh water will be sourced from GIDC.

Table 11.2 Total Water requirement

No Description Existing (cmd)

Proposed (cmd)

Total (cmd)

1 Domestic 7 16 23 2 Industrial Processing 374.5 86 738.5

8 2,6-Xylidine (2,6 –Dimethyl Aniline) 87-62-7 10 9 2,4-Xylidine (2,4 – Dimethyl Aniline) 95-68-1 40

10 N-(1-Ethylpropyl)-3,4-Xylidine 56038-89-2 500 11 2-Cynophenol 611-20-1 100 12 1-Octanoic acid 124-07-2 300 13 Styrene oxide 96-09-3 200 14 Phenyl ethyl alcohol 60-12-8 200 15 Phenyl ethyl alcohol methyl ether 3558-60-9 50 16 Phenyl acetaldehyde 122-78-1 20 17 Phenyl acetaldehyde di-methylacetal 101-48-4 20 18 Phenyl ethyl acetate 103-45-7 20

Subtotal (Products) 3060 By Products

19 Methyl Ethyl Ketone 78-93-3 5 20 Dilute Sulfuric acid 7664-93-9 230 21 Dilute nitric acid 7697-37-2 800

Grand Total(Products+by Products)

4095

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3 Cooling Tower and Boiler 278 4 Gardening 24 128 152 Total 405.5 508 913.5

Effluent generation, treatment and disposal

Effluent generation from the proposed establishment project shall be from domestic, process, cooling tower / boiler blow down, equipment washing, floor wash etc.

Total effluent generation from proposed project is estimated to be 159 cmd (12 cmd domestic and 147 cmd trade effluent). Total effluent generation post expansion project is 164.58 cmd.

Effluent shall be treated in ETP / RO/ MEE to meet discharge standards.

Treated effluent will be reused within premises. There will be no discharge outside.

Table 11.3 Waste water generation and disposal

No Description Existing (cmd)

Proposed (cmd)

Total (cmd)

Treatment and Disposal

1 Domestic effluent

5.58 12 17.58 It will be treated at STP and treated waste water will be used for gardening.

2 Trade effluent

0 147 147 It will be treated and will be reused; There will be no discharge outside.

Total 5.58 159 164.58 -

Waste generation and its management

Nonhazardous and Hazardous waste generation from the proposed activity (as mentioned in Chapter 2 and 4) will be dealt with as per statutory norms and good practices.

Description of the Environment

Baseline environmental study/monitoring is carried out during Summer 2018 (March 2018 to May 2018 within 10 km radius of the proposed site to understand ambient air quality, water quality, soil quality, noise level, biological study and socio-economic status of study area.

Soil, AAQM and Noise monitoring is carried out at 8 locations. Water samples are collected from 8 locations (6 borewells and 2 GIDC supply). Surface water locations are collected from 7 locations.

Panoli GIDC estate is set up by Gujarat Industrial Development Corporation to boost the industrial growth in this region. The estate is spread over approximately 1057 hectares and various types of industries like chemicals, pharmaceuticals, pesticides, Dyes and Intermediates, Textiles, Engineering etc. comprise the texture of the estate.

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The area distributions along with percentage distribution of the different LULC classes within the study area are as below.

Agricultural Plantation (32.53%) and Agricultural Crop Land (27.03%) dominate the land use pattern within the 10 km angular distance around project site.

It is followed by Fallow Land contributing 18.31%. Barren/ Unculturable waste/ Scrub Land is about 9.52% and Built up Land is 5.10% whereas part of land is Industrial Land (6.9%) and part is Waterbody (0.61%). Detailed LULC report is given in Annexure 3.2.

GIDC Panoli falls in Bharuch district which has high temperature in summer season (March to May) & low temperature in winter season (December to February). The meteorology of the site and nearby areas is affected primarily by the presence of Coast line about 43 km to the west of site.

Based on the soil analysis for its physical and chemical properties, It is observed that

• Soil at Project site and Bakrol is sandy loam in nature, At Alonj and Panoli village Loam in nature and at Umarwada, Barsara, Bhadi and Kharod village is slit loam in nature.

• Water holding capacity varies from 42.62 % to 62.76 %. • pH of soil varies from 7.22 to 8.22 which is “Neutral” to “Moderately alkaline” in

nature. • Conductivity of soil is observed within range of “Average” i.e. from 280.3 µS/cm to

530 µS/cm. • Potassium content in the soil samples varies from 220 kg/Ha to 310 kg/Ha which

is in range of “average” to “better” range. • % TOC is observed in range of 0.26% to 0.70% which is from “less” to on an

average sufficient. • Phosphorus content in the soil is varies from 21.25 kg/Ha to 34.33 kg/Ha which is

from “Less” to “medium” range.

The broad findings of the ambient air quality monitoring are as follows:

• Average concentration of PM10 ranges from 65.7 μg/m3 to 87.1 μg/m3. It is noted that the PM10 results are within permissible limit of 100 μg/m3 for 24 Hrs.

• Average concentration of PM2.5 ranges from 23.8 μg/m3 to 39.1 μg/m3. It is noted that the PM2.5 results are within permissible limit of 60 μg/m3 for 24 Hrs.

• Average concentration of SO2 ranges from 7.2 μg/m3 to 19.7 μg/m3. It is noted that

the SO2 results are within permissible limit of 80 μg/m3 for 24 Hrs.

• Average concentration of NOx ranges from 10.1 μg/m3 to 25.7 μg/m3. It is noted that the NOx results are also within permissible limit of 80 μg/m3 for 24 Hrs.

• Average concentration of CO ranges from 0.26 mg/m3 to 1.14 mg/m3. It is noted that the CO results are also within permissible limit of 4 mg/m3 for 24 Hrs.

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• Average concentration of ammonia ranges from 5.74 μg/m3 to 22.3 μg/m3. It is noted that the ammonia results are also within permissible limit of 400 μg/m3 for 24 Hrs.

• Average concentration of nMHC is found to be below detectable limit.

With Comparison of NAAQ standards, Ambient Air monitoring results are below the specified norms.

Industrial area: From above results it was observed that noise levels in GIDC location is

within standards.

Residential area: Noise levels were found to be within standards at all monitored locations.

It is observed that all parameters of samples meet Drinking water standards except presence of coliform at 6 borewell samples. Presence of coliform can be mainly due to contamination of sewage/ human interference.

From analysis results, it is observed that surface water mainly fall under Class C & E.(as per surface water use classification of IS standard 2296: 1982).

The 10 km impact area encompasses parts of Bharuch and Surat Districts. According to Bio-Geographic Zone Classification of India, entire study area falls under ‘Semi Arid’ zone. None of the villages from study area falls within Ecologically Sensitive Area. Ankleshwer, Panoli, and Kosamba constitute major urbanized area, rest Human habitation in study area is rural in nature. Villages in study area are found scattered in various hamlets called “Falia”. Typical plant species were found in habituated areas which are intentionally planted for the purpose of beautification, shade, protection from stray/grazing animals and for food value. Similarly, faunal species of interest such as cattle were noticed. In open spaces/ waste areas, plants exists naturally, both supports respective fauna and constitutes part of biodiversity. For the purpose of listing the species; open/waste area adjacent to human settlement, road side plantation etc. are also considered in this habitat. At almost all places, Mango/Coconut/Sapota plantations were noticed in addition to agriculture. Ansar market, located on the NH 8 between Panoli and Ankleshwer, has series of godowns dealing with metal and plastic scraps and drum decontamination. This area was found to be highly polluted with solid wastes such as solvent drums, plastics, thermocol, metals etc.

Major crop in the region during the study period was Sugarcane. However secondary crops like jowar and bajra were seen in dry soils Azadirachta indica, Mangifera indica,

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Cocos nucifera, etc. were observed along the boundaries of agriculture fields. Agriculture flora supports corresponding members of fauna in the study area. The largest water body in the study area is the GIDC Water Reservoir, 2 km away from Ankleshwer town. The reservoir beautified with introduced tree species and ornamental plants with walkway all around is a habitat for aquatic as well as the dependent terrestrial biota. The reservoir and surroundings did not show any visible characteristics of stressed ecosystem such as foul smell or foaming or discoloration though floating dry leaves and plastics were found towards the edges. Other water bodies included ponds near Bakroli village, Kosamdi village and Panoli railway station. Except for the pond near Panoli village, the rest were healthy through the water was less due to peak summer. Species like Polygonum glabrum, Cyperus sp., Ipomoea aquatic, Ipomoea carnea, Typha sp etc. were observed commonly in areas of stagnant water or inside the ponds.

Panoli is a village located near Ankleshwar city famous for its large industrial area developed by GIDC as an independent body wholly owned by Gujarat Government, to boost the industrial growth in this region. Various types of industries like chemicals, pharmaceuticals, pesticides, Dyes and Intermediates, Textiles, Engineering etc. comprise the texture of the Panoli GIDC estate. NH 8 offers excellent connectivity & the most important method of transport is the western railway, which is connected by the Panoli station. Population & Households & Avg. Family Size: Total population of the study area is 224479 out of which 118232 (53 per cent) are males and 106247 (47 per cent) are females with average sex ratio 899 female per 1000 male. There are 49662 households in the study area with average family size is 4.5 persons per household as per 2011 census. Farmers of Bharuch district have a long tradition of rearing animals for milk production. Dairy farms provide employment to large number of landless families of rural areas. Livestock particularly buffalo, cattle and goats constitute the main animal husbandry component in the farming system of the district. As agriculture is one of the important main source of subsistence for the significant number of people in the study area. The main crops produce in the study area are rice pigeon pea, paddy, wheat, sorghum, bajra, banana, sugarcane and cotton. Retail trade is carried on by a large number of establishments in the urban and rural areas and caters to the needs of local inhabitants

Anticipated Environmental Impacts and mitigation measures

Impact on air environment is not anticipated as proponent intend to use clean fuelnatural gas for boilers and TFH’s. However fuel burning will have minor increase in SO2, and NOx.

Mitigation Measures for Air Quality Impacts

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Following mitigation measures are planned and suggested in view of air environment during operation phase:

Boiler & Thermic Fluid Heater:

o Adequate stack height

o Regular monitoring for fuel burning stacks through MOEFCC approved laboratory

Process emission

o Water scrubbers and adequate process stack heights

o Regular monitoring of stack and work room area through MOEFCC approved laboratory

Noise & vibrations generated from the equipment & machineries including pumps, motors, blowers etc. will add to occupational noise level, exposing on site to high noise which can lead to hearing loss.

The project is within Panoli GIDC and away from residential areas. Thus, impacts of the noise sources of the proposed project will be restricted within the premises only and will be within the prescribed norms of industrial area as well as occupational exposure.

Mitigation Measures

• Low noise generating equipment and working methods for production unit shall be selected to reduce noise generation in plant areas.

• Proper mounting of equipment & machinery on strong non-vibrating foundation & fitted by proper shunting & rubber padding to avoid vibration and thereby noise.

• Provision of ear protection equipment (ear plug/ ear muff) for activities that are likely to create noise in excess of 75 dB (A) to protect worker’s health and safety.

• Undertake in plant audit to identify high noise level generating equipment

• Preventive maintenance including regular lubrication of machineries and equipment to reduce noise level

• Static & dynamic balancing of all rotating equipment & machineries shall be done on regular basis starting from the installation time to reduce the vibration & noise.

• Regular noise monitoring shall be done as per environment monitoring plan chapter 6

• The impacts of noise on occupational health would be mitigated by proper shift timing & annual audiological checkup of concern employees. Workers showing hearing loss, if any, will be shifted to other less noisy areas.

• Dense Greenbelt development around the noise source area and along the boundary of premises shall be done.

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As seen in chapter 2, additional water requirement during operation phase will be ~ 508 CMD.

The proposed project is in organic chemicals manufacture will result in generation of 147 cmd effluent. (domestic ~ 12 cmd and from process ~ 159 cmd).

RMCPL is proposing to establish a STP and full-fledged ETP facility with tertiary treatment facility (RO, MEE) for treatment of effluent.

As mentioned, the effluent treatment shall be carried out at site and treated water will be

recycled within site.

Impacts on water resources may also occur as secondary impacts of soil contamination as well as runoff of contaminated water from premises resulted due to the spill/ leak of hazardous chemicals or from leachates from hazardous waste storage areas.

Major concern in land environment during operation phase is contamination of land by:

• Disposal of ETP sludge / MEE salts

• Spill and leak during transport, handling, storage activity of chemicals

• Spill of oil and greases during maintenance of equipment, machineries and vehicles

• Improper storage/dumping of hazardous wastes, resulting in leachate contaminating the soil

• Contaminated runoff from site and contaminated drain from storage areas of hazardous wastes and chemical storages, tanker loading/unloading areas draining to land

• Transportation in tanker or drums through national highway, which may have

considerable impacts on environment of the area falling in the route of the transportation. During the incidence of major accident, the hazardous materials being transported can have serious impacts on land where on it spilled or leaked.

• Mitigation measures

• ETP sludge & MEE salts shall be disposed to CHWTSDF facility

• Production, maintenance area and warehouses for storage of raw materials, finished products and hazardous wastes will be provided with impervious flooring.

• All bulk storage tanks will be provided with adequate dyke walls to prevent

spreading of spill or leaked chemicals causing contamination of soil.

• Necessary cleanup procedures (SOPs) for the specific area will be designed and implemented.

• Used oil from machineries/equipment etc. will be collected in drums & stored in designated storage area.

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• ETP facilities for management of effluents will be provided as planned during erection and commissioning phase and untreated effluents will not be disposed off on land.

• The chemicals used will be transferred through closed pipelines by DCS control system to avoid/prevent spill/leak of the materials.

• Hazardous waste management will be done as per statutory guidelines & requirements. ETP sludge generated is dried in mechanical dewatering system and stored on sludge drying beds or kept in sacks in covered godowns, with impervious flooring sloping so that any leachate will be collected and taken back

for treatment.

• Empty Chemical drums will be decontaminated and reused/recycled or sent back to supplier or sold to GPCB authorized party.

• All transportation of hazardous wastes will be done in closed truck/tanker by GPCB approved agencies

• HAZMAT guidelines will be followed for transport of all hazardous materials. All required safety & emergency equipment & materials will be provided on the transport vehicles.

• Proponent will maintain a good spill or leak control action plan to cope up with

such incidents.

• Monitoring of soil samples in areas near hazardous waste storage will be done as per Environmental monitoring plan.

• No waste will be stored on open barren land under any condition

Operation phase involves transportation of raw material, work force and finished goods; operation of machineries etc. this leads to increase in noise levels at site; however industrial area has several other noise sources, which overall establishes background noise level for GIDC area.

Considering baseline environmental conditions, air dispersion modeling has been done, which indicates, incremental concentrations of gaseous pollutants together with existing baseline concentrations are lower than threshold limit specified in CPCB publication, March 2000 for Green belt Development.

Greenbelt will be developed includes periphery plantation, road side plantation and plantation around various buildings. Well-developed greenbelt off area consisting different species of trees on 29420.43 sq m is proposed.

For particulate and noise abatement, two rows of trees will be planted all around the boundary of site. Green belt will be developed in two levels i.e. tall, native and evergreen

broad leaved species towards outer periphery whereas dwarf and native species towards inner side of it. This arrangement provides better screening effect.

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Impacts on socio-economic environment due to proposed project during operation phase are envisaged due to direct and indirect employment which will be beneficial.

The proposed project will have positive effect on socio – economic environment as there will be growth in employment for direct / indirect workers. During employment, local populace will be given preference considering their skills & suitability.

Environmental monitoring program as mentioned in Chapter 6 shall be implemented.

Additional Studies

Public hearing is exempted as per para 7(i) III Stage (3)(i)(b) of EIA Notification, 2006 for preparation of EIA/EMP Report, being site is located in the Notified industrial area (GIDC).

The principal objective of the risk assessment study is to identify and quantify the major hazards and the risk associated with various operations of the proposed project, which may lead to emergency consequences (disasters) affecting the public safety and health. All necessary measures to minimize the risk due to the proposed project will be taken during design stage and also during operation period viz, Fire & safety control measures, Emergency preparedness plan, Disaster Management plan, etc.

Risk assessment, Hazard identification is carried out for the proposed project during various project phases, Solvents storage and raw material handling. Quantitative risk assessment/consequence analysis based on ALOHA has been carried out during unloading, storage and transfer of chemicals. Dow fire and explosion indexes arrived at

and suggested control measures.

Project benefits

The proposed activity is to be carried out in GIDC Panoli industrial area and does not require any additional infrastructure and the site is well connected so no major benefits in terms of direct improvement in infrastructure is anticipated. However, indirect improvement in public infrastructure may occur due to the CER activities by the company.

Employment Potential

The proposed peak manpower requirement during construction and commissioning will

be around 100 Persons and the operations & activities will require manpower of about 100 numbers.

Recruitments will be done from local area which will be the considerable benefit to the local area considering the demography of the region/project area (5 Km). Further, the indirect employment via increased transportation, ancillary units & local economic

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activities will also add in the employment potential of the proposed project. Thus the potential of employment will be greatly beneficial to the local people.

Other Tangible & Intangible Benefits

Demand of chemicals proposed to be manufactured is increasing in India as well as in foreign countries day by day. Thus the proposed project will help the possibilities of export to many foreign countries. Successful exports by company, will result in benefit to the country in form of foreign revenue, duties etc.

Environmental monitoring plan

The Environmental monitoring plan during various phases is discussed in Chapter 6 & 8.

Conclusion

The study for the proposed establishment project of RMCPL at GIDC Panoli has revealed that the upcoming activities of manufacturing will have not have much impacts in operation phase.

Other impacts of the project will also remain far below acceptable limits after necessary mitigation as described & suggested in EIA report.

The major impacts will also be brought under acceptable limits by implementing the required hazard prevention & control measures as suggested in the report. Thus it has been concluded that there would not be any major impacts on environment due to the proposed project except the impacts of major accident scenarios which may extend out of the plant area.

The EIA study has concluded that the project would be environmentally acceptable, in compliance with environmental legislation and standards, Hence the proposed project may be considered for prior Environmental Clearance.

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DISCLOSURE OF CONSULTANTS ENGAGED

Name : ADITYA ENVIRONMENTAL SERVICES PVT. LTD.

Reg. Office : 107, Hiren Light Indl. Estate, Mogul Lane, Mahim, Mumbai – 400016

Phone No. : 022 42127500 Email id : adityaenviro@vsnl.com

Central Lab : P-1, MIDC Mohopada, P.O. Rasayani, Dist. Raigad Pin 410207

Phone No. : 02192 252008 Email id : aespvtltd@yahoo.com

Branches :

Goa : 08322652456 Ahmedabad : 079 40063271

Pune : 915802585 Delhi : 011 64595949

Baroda : 02652331790

Accreditation Obtained

: 1. ‘A’ Category EIA Consultancy Organization by QCI-NABET

2. Recognized by MoEFCC as “Environmental Laboratory” vide S.O.No. 1190 (E) dt. 01.05.2014 valid up to 30.04.2019

3. ISO 9001:2008 Certified

4. OHSAS 18001:2007 Certified

Services Offered by

AESPL

: Environmental planning studies

Policy planning studies for CPCB, GPCB and other agencies like World Bank.

Environmental Impact Assessment (EIA) & Environment Management Plan (EMP)

Risk Analysis Studies & On Site/Off Site Emergency Management Plan.

Environment Health & Safety audits & Due Diligence audits

Effluent Characterization & Treatability Studies

Project Management Consultancy for Effluent Treatment Plants

Ventilation, work room air quality surveys

Air pollution control system design

Analytical Services covering entire spectrum of environmental analysis

➢ Ambient air monitoring

➢ Ambient noise level monitoring

➢ Ground & Surface water analysis

➢ Soil analysis

➢ Marine water & sediment analysis

➢ Ecological & Biodiversity surveys

➢ Socio-economic surveys

➢ Hydro-geological surveys

Coastal engineering & coastal process studies & management plans

Website : www.aespl.co.in