M/s. Exide Industries Limited, Hosur

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Pre – Feasibility Report

M/s. Exide Industries Limited, Hosur Survey No. 203/1B2, 204PT, 225/2B, 237 PT, 242 PT, 243 PT, 244 PT, 245 PT & 246 PT, Chichurakanapalli Village, Sevangapalli Panchayath, Hosur Taluk, Krishnagiri District, Tamilnadu. 1. Executive Summary

Exide Industries Limited is in the business of manufacturing Lead Acid batteries for various applications at Hosur from 1996 at Survey No. 203/1B2, 204PT, 225/2B, 237 PT, 242 PT, 243 PT, 244 PT, 245 PT & 246 PT, Chichurakanapalli Village, Hosur taluk, Krishnagiri District in Tamilnadu in an area of 73.6 acres.

Project Summary 1 Name of Company Exide Industries Ltd, Hosur 2 Proposed Product Proposed expansion of existing

consented products Valve regulated Lead Acid Batteries (VRLA) & Automotive Batteries.

3 Location Survey No. 203/1B2, 204PT, 225/2B, 237 PT, 242 PT, 243 PT, 244 PT, 245 PT & 246 PT, Chichurakanapalli Village, Hosur taluk, Krishnagiri District in Tamilnadu.

4 Name of the project Manufacturing Capacity - Enhancement of Lead Acid Batteries production.

5 Total land area of the plot 73.6 acres 6 Total proposed green

area after expansion Green area: 24.2 acres

7 Major raw material Lead and Sulphuric Acid 8 Water Existing - 350 KLD + Proposed

Addition - 650 KLD (Total - 1000 KLD)

9 Power Existing 14 MW Proposed 7 MW After Expansion 21 MW

10 Proposed manpower Existing: 1100 Nos. + Proposed 1900 Nos. (Total 3000 Nos.)

11 Waste water quantity (estimate and disposal pathway

Existing: Sewage 100 KLD Effluent 70 KLD Proposed Addition: Sewage 100 KLD Effluent 60KLD

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Total after expansion:

Sewage 200 KLD Effluent 130 KLD (Zero Liquid Discharge System)

12 Air emissions Existing & after expansion - Enclosed annexure

13 Solid Waste Enclosed Annexure 14 Project cost estimate Proposed expansion entails Capital

cost of Rs. 113.49 crores

2. Introduction of the Project

2. 1 Identification of Project and Project Proponent: Exide industries limited, Hosur is India's flagship storage battery industry and is also the largest power storage solutions company in south and south east asia. Exide industries limited, Hosur started operations in 1997. The Proposal is to increase the lead acid battery manufacturing capacity in the existing land. The advent of electric vehicles and solar energy parks has increased the market demand for additional manufacturing capacity in this sector. 2.2 Brief Description of Nature of the Project: The industry has proposed to increase the production capacity of vale regulated lead acid batteries (VRLA) from 100 MAh/Month to 210 MAh/month and Automotive batteries from 3, 00,000 Nos/month to 4,50,000 Nos/Month. The estimated cost of the proposed expansion project is Rs.113.49 Crores. The details of the resource requirements like land, raw materials, power, water and manpower for the proposed project is described in this section.

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2.3 Need for the project and its importance to the country and or region: The increasing demand for power storage solutions due to electric vehicles, battery driven vehicles, solar parks, telecom sector in addition to conventional automotive batteries, industrial batteries necessitated the expansion proposal. 2.4 Demands-Supply Gap: The project is envisaged to meet the demand supply gap in both domestic market and export market due to government focus on solar energy utilization and battery-operated vehicles (Pollution free transport). 2.5 Imports Vs. Indigenous Production: Production enhance the foreign exchange reserves in view of the proposed exports of few types. 2.6 Export Possibility: There is increase in demand globally for Lead Acid Batteries due to the growing concern to reduce Air Pollution by promoting green transport. 2.7 Domestic/export Markets: The products shall cater to both domestic and export markets.

2.8 Employment Generation (Direct and Indirect) due to the project: It is expected to generate employment for nearly 2000 Persons.

3. Project Description

3.1 Type of Project including interlinked and interdependent projects, if any: The project is expansion of the battery manufacturing plant. The major plant facilities proposed for the project are increase in the total production capacity of VRLA (Valve regulated lead acid) batteries of 100MAh/Month to 210 MAh/Month and automotive batteries of 3 Lakh batteries/month to 4.5 lakhs batteries/month in the existing premise of land area of 73.6 acres. Total land area after expansion is 73.6 acres. Expansion includes addition of production blocks, facility for utility proposed and ZLD system for entire effluent. 3.2 Size or magnitude of operation: The Manufacturing Capacity before & after expansion are presented in Table A-1.

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Table A-1 Manufacturing Capacity – Existing and Expansion

Products Existing After Expansion Automotive Batteries (12V, 40AH/M)

3,00,000 Nos/Month 4,50,000 Nos/Month

VRLA Batteries (12V, 40AH/M)

100 MAh /Month 210 MAh /Month

By products Nil Nil Intermediate Products Nil Nil

3.3 Process Description with process details (a schematic diagram/flow chart)

Grid Casting & Ageing: Blended alloys of specified composition are machine cast by gravity flow into grids (structured lattices). These serve as conductive pathways for the current to and from the active material. These also act as supporting framework, grids cast are aged before subsequent processing to reach sufficient hardness levels. Oxide Manufacture: Lead is partly oxidized to form grey oxide, a finely divided admixture of the metal and its monoxide; this is carried out through attrition process in Ball Mills and Super micron mills. Paste Mixing, Pasting and Curing: Grey oxide is mixed with specified quantities of additives, acid and water to form a pliable paste. Positive and Negative plates are made by machine pasting the paste onto the grids. The pasted plates are quick dried (for better handling) and stored in warm and humid cubicles to convert the paste largely to tribasic lead sulphate, which enhances adhesive and cohesive properties and facilitates the next step of Formation.

Forming: Cured positive and negative plates are arranged alternately in tanks containing dilute sulphuric acid and subjected to the passage of a specified current for a specified duration, when the positive material is converted largely to lead dioxide and the negative to spongy lead.

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Drying: The formed plates are dried at elevated temperature in a stream of hot air. Plate Parting and Lug Brushing (‘Plate-Cleaning’ or ‘Plate-Finishing’) Plates, if processed in multiple configurations, are separated into individual ones: their lugs (tops protrusions for connection) are brushed cleaned. Assembly: The finished plates of each type-positive and negative are assembled into groups by fusing their lugs top a common group bar, and vertical strap. This process is carried out manually using a jig Positive and Negative groups are interleaved separated by Separators in the form of Glass Fibre Mats. The cell/battery is finally finished by the correct sequence of inter cell connector/terminal burning and lid sealing operations. Charging: After lid sealing operation, each battery is filled with dilute sulphuric acid and then battery charging process is carried out as per the process specification for a specific duration. At the end of the charging schedule, only passed batteries go to successive operation. Final Assembly: The passed charged batteries are sent to final assembly after fixing the safety valve. Tests for Internal Resistance and High Rate Discharge and Ultrasonic Welding process take place. Cosmetics are also checked at the point. After screen-printing, all batteries go to dispatch yard; batteries are packed and shipped to customers.

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Process Flow Chart of Batteries Production

3.4 Raw material required along with estimated quantity likely source, marketing area of final product/s, mode of transport of raw material and finished product.

All the raw materials required for manufacturing mostly available in India or from abroad. There are no banned chemicals or products which are proposed to be used. It is proposed to enter into long term arrangements with some of the raw material suppliers both in India and overseas to avoid shortages at any time.

Raw materials Requirement

S. No.

Material Quantity (MT/M)

Existing After

Expansion 1 Pure Lead Ingots 3450 6334 2 Alloy Lead Ingots 3198 7657 3 Alloy strip (Outsourcing) 744 0 4 Red Lead 90 180 5 Barium sulphate 165 297 6 Vanespersc 3 5.4 7 Carbon Black 4.5 8.1 8 Sulphuric acid 1140 2052

3.5 Availability of water its source, energy/power requirement and source should be given Water is required for process, wet scrubbers, washing, cooling tower makeup and domestic purposes. The required water shall be drawn from ground water sources

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and rain water harvesting in addition to reuse of treated wastewater. Tamilnadu water and drainage board as agreed to provide 1000 KLD water from Dakshina Pinakini River. This will reduce the ground water abstraction. The total water requirement after expansion is 1000 KLD consisting of 875 KLD fresh water and the remaining 125 KLD of recycled water. Total water balance is presented in Table below.

Total Water Balance - After Expansion INPUT (KLD) OUTPUT (KLD)

Purpose Fresh water Recycled

water Gets

Evaporated Goes with

Product Sewage Effluent

Process 45 125 150 20 M/C /Floor Washings

75 75

Scrubber 25 25 DM plant 10 10 Jar formation 40 40 Domestic 230 30 200 Cooling, Curing, Ventilation

450 450

Gross Total 875 125 520 150 200 130 * Total 1000 1000

* From 130 Kl effluent, 125 Kl recycling through ZLD & 5 Kl goes to Evaporation

3.5.1 Electricity: The required energy shall be drawn from TNEB and Solar power plant. Stand by DG set of 2 x 1500 KVA are proposed in addition to existing 5 x 1000 KVA DG set. 3.5.2 Fuel Requirement:

Name of fuel Point of use Quantity (Tons/Day) Existing After expansion

Diesel Diesel Generator (Stand By)

2.5 3.5

LPG Lead melting 5.5 9.5 3.6 Quantity of wastes generated (liquid and solid) and Scheme for their Management/disposal: Sewage Treatment & Disposal: The existing STP having treatment capacity 100KL/day has been designed based on Advanced Sequential Batch Reactor (SBR) Technology which consists of both aerobic & an oxidation Phases. The process of BOD removal, nitrification, phosphorous

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removal and sludge separation are achieved continuously in a single SBR tank. The process operates on the continuous in flow & batch out flow principle. The process of aeration, settling and decanting occur sequentially and are controlled by PLC. The treated water is filtered through a pressure sand filter and disinfected using sodium hypochlorite. The waste sludge is being used as manure after dewatering using sludge drying beds. Entire sewage transfer from source of generation to treatment plant is by gravity hence pumping of raw sewage is eliminated. Sewage from security office & administrative building is being treated in septic tank based on anerobic method. After expansion, the sewage generation will be 200 KLD, the generated sewage 1 and sewage 2 are 190 KLD and 10 KLD respectively. The sewage 1 is treated using aerobic process same as that of existing (Sequential batch Reaction) whereas sewage 2 by anerobic process using septic tank. Treated water will be used for Green belt development & maintenance. Effluent Treatment & Disposal: Effluent generation in battery manufacturing industry is mainly due to the floor and machine cleaning and also from electro forming operation. Another source is the regeneration of water treatment plant. Schematic diagram of source of generation is enclosed. Effluent after filtration is neutralized using hydrated lime. Neutralized effluent is fed into clarifier. Sludge from the clarifier is vacuum dried and disposed for co processing cement manufacturing. Clarified water is treated in RO. RO permeate is used in back in process and cooling whereas reject is evaporated in multiple effect evaporator.

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Quantity of Effluent Generated and Mode of Treatment Description Quantity as per

consent KLD Quantity After Expansion KLD

Mode of Treatment in ETP

Process, Machine Washing, Cooling Tower Scrubber Bleed off Effluent DM Plant Regeneration

47 15 8

95 25 10

Effluent is neutralized using hydrated lime & filtered. Filtrate is passed through RO. RO permeate is used in process & Reject is evaporated. Solid waste from ETP ( Gypsum) is sent for Co processing in Cement.

Total 70 130

Total Solid Waste Generated and Mode of Disposal S.no Nature of Solid waste Quantity Mode of disposal

Existing (Tons/Month)

After Expansion (Tons/Month)

1 Wooden pellets 1 10 Sold to scrap vendor 2 Waste paper and carton 0.5 2 Sold to scrap vendor 3 Metal straps 0.25 0.5 Sold to scrap vendor 4 Garden waste 3.0 2.0 Composting 5 Food waste 1.0 2.0 Bio methanation 6 Used/spent oil 7 7 Sold to CPCB authorized

recycler 7 Waste/residue

containing oil 3 3 Sold to CPCB authorized

recycler 8 Lead slag/bearing

residue 4400 7625 Recover and reuse CPCB

authorized recycler 9 Lead ash/particulate

from flue gas 100 175 Recover and reuse CPCB

authorized recycler 10 Chemical sludge from

waste water treatment 300 600 Co-processing in cement kilns

11 E- Wastage 33 67 Sold to CPCB authorized recycler

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4. Site Analysis 4.1 Plant Location

S. No Particulars Details 1

Site co-ordinates Corner

Latitude Longitude

A 12o50'23.34”N

77o47'58.49” E

B 12o50'23.35” N

77o47'58.70” E

C 12o50'23.22” N 77o47'58.49” E

D 12o50'23.25” N

77o47'58.71” E

2 Elevation above Mean Sea Level

895m

3 Climatic conditions (Based on IMD, Bangalore)

Annual max temp - 35.2oC Annual min temp - 14.8oC Annual total rainfall - 979.8 mm

4 Land use at the project site

Unclassified Dry Land

5 Nearest Highway NH-207 (2.0 km, North) NH-7 (7.0 km, SSW)

6 Nearest Railway Station Hosur R.S. (14.0 km, SSE) 7 Nearest Air Port Bangalore (30.0 km, NW)

Hosur (19.7 km, SW) 8 Nearest village Chichurakanapalli (0.5 km, NE) 9 Nearest major city Hosur (12.0 km, SSE) 10 Hills and Mountains No major hills and mountains within 10-km radius. 11 Ecologically sensitive

zone No wild life sanctuaries within 15-km radius.

12 Resettlement and Rehabilitation.

The industry is operating for more than 20 years. There is no displacement of local people due to the project.

13 Nearest River Daksnina Pinakini River (5.3 km, NE) 14 Seismic zone Zone-II (IS: 1893, Part-I – 2002) 15 Defense installations Nil within 15 km

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5. Planning Brief: The project is envisaging to be completed in Phase wise as it involves installation of higher capacity processing equipment’s besides improving of yield and the production shall be initiated thereon.

6. Proposed Infrastructure:

6.1 Power Requirement and Supply/Source

The required energy shall be drawn from TNEB and Solar power plant. Stand by DG set of 2 x 1500 KVA are proposed in addition to existing 5 x 1000 KVA DG set. 6.2 Utilities

List of Utilities S.No Utility Permitted Proposed After Expansion

2 DG Sets (KVA)* 5 x 1000 2 x 1500

5 x 1000 2 x 1500

* DG set will be used during load shut down.

Equipments There will be additional Grid casting machines, Oxide mills, Paste mixtures, Curing ovens and Assembly equipment as part proposed expansion.

6.3 Waste management

Air Pollution The sources of air pollution from the plant are from utilities existing and proposed. The stack heights are provided as per the guidelines of CPCB for effective stack heights.

In the battery plant, the main sources for air pollution are the emissions from stacks attached to various parts of the processing sections and standby DG sets. Bag filters blower & chimney are connected to Lead dust generating points like oxide mill, Grid Casting, Plate cutting &Assembly. Wet Scrubbers, blower and chimney are connected to acid fume generating operation charging. Electrostatic filters are connected to battery container sealing area to capture oil fumes. DG sets are connected with stacks of adequate height. Stack height of 30 mt is ensured in all Lead dust emitting stacks. Periodic stack emission test is carried out by Sate Pollution Control Board & NABL accredited Lab.

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S.No Stack Connected to Stack

Ht (m)

Dia of Stack at top

(m)

Temp of

Exhaust gases (°C)

Exit Velocity

Pollutant Emission rate mg/Nm3

SPM Lead SO2 NOx

Existing

1 Grid casting Scrubber

30 0.9 41 12.8 4.8 0.19 6.2 17

2 Oxide mill Bag filter

30 0.45 75 14.2 1.4 0.45 - -

3 Assembly Bag filter 30 0.9 35 15.1 1.1 0.34 - - 4 Diesel Generator 30 0.3 196 19 55 - 4.8 45.5 5 Charging Scrubber 30 0.6 29 18 - - 6 -

Proposed

1 Grid casting Scrubber 30 0.9 35 16.5 4.5 0.15 5.8 16.2

2 Oxide mill Bag filter

30 0.45 70 15.8 1.2 0.4 - -

3 Assembly Bag filter 30 0.9 32 16.5 1 0.3 - - 4 Diesel Generator 30 0.5 185 18.5 45 - 5 44.2 5 Charging Scrubber 30 0.9 29 19.5 - - 5.6 -

Solid waste:

S.no Nature of Solid waste Quantity Mode of disposal Existing (Tons/Month)

After Expansion (Tons/Month)

1 Wooden pellets 1 10 Sold to scrap vendor 2 Waste paper and carton 0.5 2 Sold to scrap vendor 3 Metal straps 0.25 0.5 Sold to scrap vendor 4 Garden waste 3.0 2.0 Composting 5 Food waste 1.0 2.0 Bio methanation 6 Used/spent oil 7 7 Sold to CPCB

authorized recycler 7 Waste/residue

containing oil 3 3 Sold to CPCB

authorized recycler 8 Lead slag/bearing 4400 7625 Recover and reuse

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residue CPCB authorized recycler

9 Lead ash/particulate from flue gas

100 175 Recover and reuse CPCB authorized recycler

10 Chemical sludge from waste water treatment

300 600 Co-processing in cement kilns

11 E- Wastage 33 67 Sold to CPCB authorized recycler

7. Rehabilitation and Resettlement (R&R) Plan Not applicable as the land area is in the existing plant premises. 8. Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (Time

schedule for the project to be given) Within twelve months as it involves installation of higher capacity processing equipment’s besides improving of yield and the production shall be initiated there upon. 8.2 Estimated project cost along with analysis in terms of economic viability of the project The estimated cost of the project is approximately Rs. 113.49 crores Project Cost

Rs. In Crores

Plant& machinery 53.00 Civil buildings 16.00 ETP, STP and Air Pollution Control 10.30 Other Assests 12.86

Total 113.49 Project Cost 113.49