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M/s. Bromchem Laboratories Pvt. Ltd. Environmental Impact & Risk Assessment Report

8‐ 1

CHAPTER – 8 EXECUTIVE SUMMARY OF PROJECT

8.1 Introduction

M/s. Bromchem Laboratories Pvt. Ltd. has proposed for expansion of Chemicals

manufacturing unit at survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat.

Proposed project will be carried within the existing unit having land area of 6981 m2.

Total project cost is Rs. 4.5 Crores.

8.2 Title of the project

Proposed Specialty Chemical Plant in Existing Premises

M/s. Bromchem Laboratories Pvt. Ltd.

Survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat. 8.3 Land acquired Yes 8.4 Land Break‐up

1 Parking 5 x 6 30 2 Office 10 x8 80 3 D.G. Set 5 x 5 25 4 Cooling Tower 10 x 10 100 5 Tank Farm Area 10 x 12 120 6 Raw Materials & Products Storage Area 18 x 12 216 7 Boiler 5 x 5 25 8 Coal/Agro Waste Storage Area 5 x 5 25 9 Existing Manufacturing Unit 18 x 9 162 10 Proposed Manufacturing Unit‐1 29 x 15 435 11 Proposed Manufacturing Unit‐2 40 x 30 1200 12 Green Belt 45 x 51.17 2303 13 ETP 10 x 10 100 14 Road & Open Area 2160 Total 6981


8‐ 2

8.5Cost of the project & Capital and recurring cost towards environment protection

measures

Total Project Cost for proposed project activity is Rs. 4.5 Crore. Capital cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 0.4 Crore.

8.6 Proposed facilities and production capacities in tabular form Project Details

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

Sr. No.

Product Existing Capacity (MT/Month)

After Proposed Expansion Capacity (MT/Month)

1. Potassium chloride

2. Calcium chloride

3. Barium chloride

4. Zinc chloride

400 Max. 1 product

400 Max. 1 product

5. Potassium bromate

6. Sodium bromate

100 Max. 1 product

100 Max. 1 product

7. Potassium bromide

8. Sodium bromide

9. Calcium bromide

10. Ammonium bromide

70 Max. 1 product

70 Max. 1 product

11. Sodium carbonate

12. Potassium carbonate

100 Max. 1 product

100 Max. 1 product

13. Sodium phosphate

14. Potassium phosphate

15. Dicalcium phosphate

16. Tricalcium phosphate

300 Max. 1 product

300 Max. 1 product

17. Sodium sulphate

18. Potassium sulphate

19. Copper sulphate

20. Zinc sulphate

200 Max. 1 product

200 Max. 1 product

21. Chloroacetyl chloride ‐‐ 80

22. Benzoyl chloride ‐‐ 310

23. Pivaloyl chloride ‐‐ 40

24. Propionyl chloride ‐‐ 80


8‐ 3

25. 2‐chloropropionyl chloride ‐‐ 40

26. Butyryl chloride ‐‐ 40

27. Isobutyryl chloride ‐‐ 40

28. 4‐Chlorobenzoyl chloride ‐‐ 40

29. 2‐chlorobenzoyl chloride ‐‐ 40

30. Velaryl chloride ‐‐ 40

31. 3‐chloropropionyl chloride ‐‐ 40

32. 4‐chlorobutyryl chloride ‐‐ 40

33. 4‐methoxybenzoyl chloride ‐‐ 25

34. 3‐methoxybenzoyl chloride ‐‐ 25

35. 3‐chlorobenzoyl chloride ‐‐ 25

36. 2,3‐Dichlorobenzoyl chloride ‐‐ 25




40. 4‐methylbenzoyl chloride ‐‐ 25

41. 2‐methylbenzoyl chloride ‐‐ 25

42. Isophthaloyl chloride ‐‐ 20

43. N‐butyl chloride ‐‐ 20

44. Isobutyl chloride ‐‐ 20

45. N‐Hexyl chloride ‐‐ 20

46. Propiophenone ‐‐ 20

47. 3‐chloropropiophenone ‐‐ 20

48. Benzophenone ‐‐ 20

49. 4‐chlorobenzophenone ‐‐ 20

50. 2,4‐dichloroacetophenone ‐‐ 20

51. Valarophenone ‐‐ 20

52. Trityl chloride ‐‐ 50

53. Acetanilide ‐‐ 20

54. Triethylamine hydrochloride ‐‐ 21

55. 2,4,6‐Trichloropyrimidine ‐‐ 20

Total 1170 2536


8‐ 4

8.7 List of Raw Materials

Sr. No.

Raw Material Required

Existing Consumption (MT/Month)

Proposed consumption (MT/Month)

1. Potassium hydroxide 818 818 2. 30% Hydrochloric acid 1570 1570 3. Calcium oxide 222 222 4. Calcium hydroxide 743 743 5. Barium oxide 294 294 6. Zinc oxide 339 339 7. Bromine 202 202 8. Sodium hydroxide 460 460 9. 50% Hydrobromic acid 226 226 10. Ammonium carbonate 25 25 11. 30% Phosphoric acid 2262 2262 12. 50% sulfuric acid 990 990 13. Copper oxide 100 100 14. Monochloroacetic acid (MCA) ‐‐ 84 15. Benzotrichloride ‐‐ 509 16. Pivalic acid ‐‐ 34 17. Thionyl chloride ‐‐ 640 18. Sodium hydroxide ‐‐ 1434 (15%) 19. Propionic acid ‐‐ 64 20. 2‐Chloropropionic acid ‐‐ 34 21. Butyric acid ‐‐ 33 22. Isobutyric acid ‐‐ 33 23. 4‐Chlorobenzoic acid ‐‐ 36 24. 2‐Chlorobenzoic acid ‐‐ 36 25. Valeric acid ‐‐ 34 26. Acrylic acid ‐‐ 23 27. Gamma‐butyrolactone ‐‐ 25 28. 4‐Methoxybenzoic acid ‐‐ 22 29. 2‐Methoxybenzoic acid ‐‐ 22 30. 3‐Chlorobenzoic acid ‐‐ 22 31. 2,3‐Dichlorobenzoic acid ‐‐ 23 32. 2,4‐Dichlorobenzoic acid ‐‐ 23 33. 3,4‐Dichlorobenzoic acid ‐‐ 23 34. 3,5‐Dichlorobenzoic acid ‐‐ 23 35. 4‐Methylbenzoic acid ‐‐ 18


8‐ 5

36. 2‐Methylbenzoic acid ‐‐ 18 37. Isophthalic acid ‐‐ 16 38. N‐Butanol ‐‐ 16 39. Isobutanol ‐‐ 16 40. N‐Hexanol ‐‐ 17 41 Aluminium chloride ‐‐ 104 42. Benzene ‐‐ 65 43. Propionyl chloride ‐‐ 14 44. 3‐Chloropropionyl chloride ‐‐ 15 45. Benzoyl chloride ‐‐ 28 46. 1,3‐Dichlorobenzene ‐‐ 16 47. Acetyl chloride ‐‐ 21 48. Valeryl chloride ‐‐ 15 49. Aniline ‐‐ 14 50. Triethylamine ‐‐ 15 51. Barbituric acid ‐‐ 14

8.8 Site specific meteorological data

(PERIOD–JANUARY 1, 2014 TO MARCH 31, 2014)

MONTH METEOROLOGICAL PARAMETER

January February March

Temperature (0C) Min. Max. Avg.

8.5 33

20.9

12.5 36.1 21.8

14 39

23.3

Relative Humidity (%) Min. Max. Avg.

21 90

55.8

18 87

54.19

13 92

60.55

Wind Speed (m/s) Min. Max. Avg.

0

5.00 1.89

0

5.56 2.20

0

4.44 1.4


8‐ 6

8.9 Air Environment

Air pollution control measures proposed

There are sources of air pollution at M/s. Bromchem Laboratories Pvt. Ltd., flue gas through boiler &

Thermopack stack, vent attached to process reactor.

Existing: 1. Details of Flue Gas Stack; Stack Attached To Furnace

SOURCES OF GASESOUS EMISS STACK

Fuel Used Agro Waste/Coal

Type of Emissions SO2 NOx SPM Permissible Limits 262 mg/Nm3 94 mg/Nm3 150 mg/Nm3 Stack Height 10 meters

Proposed Flue Gas Emission 2. Details of Flue Gas Stack; Stack Attached To Thermopack Boiler

SOURCES OF GASESOUS EMISSION STACK

Capacity 6 Lack KCal /Hr


Type of Emissions SO2 NOx SPM Permissible Limits 262 mg/Nm3 94 mg/Nm3 150 mg/Nm3 Stack Height 30 meters

Stack Diameter at the Top 600 mm Control Measures Cyclone Separator with dust collector

3. Details of Flue Gas Stack; Stack Attached To Steam Boiler SOURCES OF GASESOUS EMISSION STACK

Capacity 1 TPH


Type of Emissions SO2 NOx SPM Permissible Limits 262 mg/Nm3 94 mg/Nm3 150 mg/Nm3

Stack Height 30 meters

Stack Diameter at the Top 600 mm

Control Measures Cyclone Separator with dust collector


8‐ 7

4. Details of Process Vent ; Vent Attached To Process Sr. No. Stack attached to Stack Height Air Pollution

Control System Parameter Permissible Limit

Proposed 1 Process Vent

(Chlorination Plant) 11 m HCl

SO2 20 mg/Nm3 40 mg/Nm3

2 Process Vent

11 m

Three StageScrubber

HCl

20 mg/Nm3

Ambient Air Quality Status

SPM – 112 to 152 µg/m3, PM10 – 57 to 75 µg/m3, PM2.5 – 40 to 52 µg/m3, SO2‐ 10 to 13

µg/m3, NOx – 8 to 12 µg/m3, O3 – 10.8 to 12.8 µg/m3, Pb – BDL, NH3 – BDL, CO – BDL, C6H6‐

BDL, BaP – BDL, As – BDL, Ni – BDL, HC – BDL.

Note: BDL‐ Below Detectable Limit

8.10 Water Environment Water Consumption and Waste Water Generation

Daily water consumption of M/s. Bromchem Laboratories Pvt. Ltd. is 4 m3/day for existing

scenario. Water consumption is primarily for processing, washing, boiler, cooling and

domestic purposes. In existing scenario source of water is ground water. Daily 1.3 m3/day of

wastewater is generated. After Proposed expansion water consumption will be 45 m3/day

and wastewater generation will be 8.8 m3/day. Water source will be same after proposed

project.


8‐ 8

WATER CONSUMPTION AND WASTEWATER GENERATION

Existing

Proposed (Total)

Existing Scenario (m3/day) Sr.

No.

Category

Water Consumption Waste Water Generation

1. Industrial

Process 1.7 ‐‐

Boiler ‐‐ ‐‐

Cooling ‐‐ ‐‐

Washing 0.3 0.3

2. Gardening 1 ‐‐

3. Domestic 1.0 1.0

Total (Industrial) 3.0 0.3

Total 4.0 1.3

Proposed (Total)

Proposed Scenario (m3/day) Sr.

No.

Category

Water Consumption Waste Water Generation

2. Industrial

Process 21.7 ‐‐

Boiler 6.0 1.5

Cooling 8.0 2.0

Washing 2.8 2.8

2. Gardening 3.0 ‐

3. Domestic 3.5 2.5

Total (Industrial) 38.5 6.3

Total 45 8.8


8‐ 9

WATER BALANCE DIAGRAM

Reused to dilute the HCL (30%), this will be used to produce the calcium chloride (Own Consumption) – Option ‐1

Raw Water: 45 KL/Day

Domestic:3.5 KL/Day

Process: 21.7 KL/Day

Boiler: 6 KL/Day

Cooling Tower: 8 KL/Day

Gardening: 3.0 KL/Day

Septic Tank & Soak Pit: 2.5 KL/Day

1.5 KL/Day 2.0 KL/Day

ETP: 6.3KL/Day

Washing:2.8 KL/Day

2.8 KL/Day

CETP: 6.3KL/Day for further Treatment (Option ‐2) in


8‐ 10

ETP Details

M/s. Bromchem Laboratories Pvt. Ltd. shall have an Effluent Treatment Plant consisting of primary

and tertiary treatment unit. The effluent confirming the GPCB standards shall be reused into plant

premises. The details of ETP are as follows.

EXISTING:

The existing wastewater 0.3 KL/Day is collected and neutralized in neutralization tank and reused in

HCl dilution or caustic dilution or sulfuric acid dilution or phosphoric acid dilution or any other

manufacturing product at a time.

PROPOSED

PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)

The treatment scheme will be divided in two different stages:

Stage 1‐ Primary Treatment

Stage No ‐2 Tertiary Treatments

1) Primary Treatment:

The waste water from unit will be brought to the treatment plant via a series of underground

pipelines or trenches. The waste water will pass through oil & grease separator and will be collected

in the equalization tank. Two numbers of tanks are proposed. One will in filling mode for

equalization of waste water while the other will be in pumping mode. The equalized wastewater is

pumped to the flash mixer for addition of chemicals like lime. From the flash mixer the waste water

flows into the flocculator where chemical flocs are formed by coagulation and flocculation by

addition of Alum/Ferrous sulphate and polyelectrolyte. These flocs are removed in the primary

settling tank. The underflow (sludge) from the primary settling tank is taken to sludge dewatering

unit (Sludge Drying Bed).

2) Tertiary Treatment:

The treated waste water will further undergo polishing in Tertiary Treatment Unit, which will

comprise of pressure sand filter and activated carbon filter. The tertiary treated water will be

collected in final collection tank.

Option ‐1: Treated effluent will reuse to dilute HCL (30%). This will use to produce the calcium

chloride (Own Consumption).


8‐ 11

Note:

Option‐ 2 for disposal of Treated effluent

The treated effluent will be sent to CETP for further treatment (Option ‐2) as per CETP norms.

The Domestic wastewater is disposed of through septic tank & soak pit.

Effluent Treatment Plant (Dimension):

Sr. No. Name of the Unit Dimension Volume (m3) MOC

1. Oil & Grease Trap 3.0(m) x 2.0(m)x 1.0(m)

6.0 m3 RCC (Acid/Alkali Proof Lining)

2. Collection Tank (2 Nos.) 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

3. Dosing Tank (1 Nos.) 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

4. Flash Mixer 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

5. Flocculator 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

6. Neutralization Tank 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

7. Primary Settling Tank 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

8. Sand Filter ‐‐ 0.5 m3/hr MSEP

9. Activated Carbon Filter ‐‐ 0.5 m3/hr

10. Final Collection Tank 4.0(m) x 4.0(m)x 3.0(m)

48.0 m3 RCC

11. Sludge Dewatering Unit ‐ Sludge Drying Beds

6.0(m) x 3.0(m) x 2.0(m)

‐‐ Brick


8‐ 12

Flow Diagram:

Raw Effluent

Oil & Grease Trap

Collection Tank Neutralization Tank

Primary Settling Tank

Sand Filter Activated Carbon Filter

Final Collection Tank

CETP for further Treatment (Option‐2) in F t re

DST FMT Floc.

Reused to dilute the HCL (30%), this will be used to produce the calcium chloride (Own Consumption) – Option ‐1


8‐ 13

EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT Characteristics (mg/L) CETP Inlet Norms

(mg/L)

Sr.

No. Parameter

Untreated Treated

1. pH 6.5 ‐ 8.5 7‐8 5‐9

2. SS 600 100 600

3. Phenolic Compound 0.8 0.2 5

4. COD 4680 1250 2000

5. BOD3 1960 380 500

6. Ammonical Nitrogen 10 6 50

7. Oil & Grease 32 5 20

Ground Water Quality

pH – 6.88 to 7.11, Turbidity – 0.1 to 0.7 NTU, TDS – 1460 to 1880 mg/l, TSS – 12.0 to 26.0

mg/l, DO – 6.2 to 6.9 mg/l, COD –1.0 to 13.66 mg/l, BOD3 ‐ 0.1 to 0.8 mg/l, Total Hardness –

302.5 to 444.6 mg/l, Chlorides – 430.5 to 1262.3 mg/l, Sulphates – 53.2 to 257.3 mg/l,

Ammonical Nitrogen – 0.005 to 0.1 mg/l

Surface Water Quality

pH – 7.15 to 7.29, Turbidity – 2.4 to 6.2 NTU, TDS – 370 to 1280 mg/l, TSS – 12.0 to 18.0

mg/l, DO – 6.5 to 6.7 mg/l, COD –11.9 to 50.8 mg/l, BOD3 – 4.6 to 7.9 mg/l, Total Hardness –

75.1 to 312.6 mg/l, Chlorides – 48.9 to 401.2 mg/l, Sulphates – 23.3 to 108.0 mg/l,

Ammonical Nitrogen – 0.08 to 0.1 mg/l


8‐ 14

8.11 Noise Environment

The objective of the noise pollution survey around the project site was to identify existing

noise sources and to measure background noise levels. The study was carried out in the

following steps:

• Reconnaissance

• Identification of noise sources and measurement of noise levels

• Measurement of noise levels due to transportation

• Community noise levels

Noise Level

Day time – 46.4‐54.3 dB(A)

Night Time ‐ 39.8‐44.6 dB(A)


8‐ 15

8.12 Land Environment Solid / hazardous waste management and disposal

Type of

Waste

Schedule

Category

Source Quantity Disposal Method

ETP Waste

34.3

ETP 17 MT/ Month Collection, Storage, Transportation &

Disposal to TSDF Site

Used Oil

5.1 Plant & Machinery

5 Liters/ Month Collection, Storage, Transportation &

Sale to GPCB Authorized Recycler

Discarded Containers/

Bags/ Carboys

33.3 Process 500 Nos. Decontamination, Storage & Given to GPCB Registered

Vendor.

Distillation Residue

20.3 Process 12 MT/ Month Collection, Storage, Transportation,

Disposal by Incineration at CHWI

of NECL or Co‐processing in

Cement Industries.

Fly Ash ‐‐ Boiler 17 MT/ Month WILL BE SOLD TO BRICK

MANUFACTURERS

HCl (30 %) ‐‐ Process 872 MT/Month Captive Consumption

Sodium Bisulfite

‐‐ Process 1772 MT/Month

Will be sold to end user.

Aluminum Chloride Solution

‐‐ Process 396 MT/Month Will be sold to end user.


8‐ 16

Soil Quality

pH – 7.31 to 8.10, Moisture – 1.32 to 3.78%, Total Hardness – 900 to 6550.0 mg/kg,

Chlorides –48.9 to 6653.3 mg/kg, Sulphates – 395.0 to 3639.0 mg/kg, Calcium – 200.4 to

1944.0 mg/kg, Specific gravity – 2.3 to 2.8 g/cm3, Porosity – 50.5 to 64.18 %.

8.13 Storage Details of Hazardous Chemicals

Sr.

No.

Name of the

Hazardous

Substance

Maximum

Storage

Mode of

Storage & No.

of tank

Actual

Storage

State &

Operating

pressure &

temperature

Possible

type of

Hazards

1 Sulphuric Acid 30 MT Tank (2 Nos.) 15 MT NTP Corrosive

2 Thionyl Chloride 40 MT Tank (2 Nos.) 20 MT NTP Corrosive

3 N‐Butanol 1 MT Drum (5 Nos.) 200 Lit NTP Flammable

4 Iso‐Butanol 1 MT Drum (5 Nos.) 200 Lit NTP Flammable

5 Benzene 2 MT Drum (5 Nos.) 200 Lit NTP Flammable

6 Aniline 1 MT Drum (5 Nos.) 200 Lit NTP Flammable/

Toxic

7 Tri Ethyl Amine 1 MT Drum (5 Nos.) 200 Lit NTP Flammable

8 Propionic acid 2 MT Drum (10

Nos.)

200 Lit NTP Corrosive

9 Isobutyric acid 1.5 MT Drum (8 Nos.) 200 Lit NTP Corrosive

10 1,3‐

Dichlorobenzene

1 MT Drum (5 Nos.) 200 Lit NTP Flammable


8‐ 17

8.14 Power & Fuel Requirement

S. No. PARTICULARS REQUIREMENT

POWER

1 Power Requirement 150 KVA

2 Source of Supply MGVCL

FUEL

1 Fuel & it’s Consumption Wood/Agro Waste ‐ 5 MT/Day or Coal ‐ 4 MT/Day

Diesel ‐ 150 Liter/Day (Emergency)

2 Source of Supply Nearest Supplier

8.15 Green belt Development The main objective of the green belt is to provide a barrier between the plant and

surroundings areas. M/s. Bromchem Laboratories Pvt. Ltd. has developed green belt within

factory premises. Company is proposing 2303 sq. meter (32 %) for green belt out of 6981 sq.

meter of the total land area.

8-18

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8-22

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8-23

V[DPHLP q V[GPV[DP#

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8-24

! 5|M;[; J[g8 sS,MZLG[XG %,FGf

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SPM - 112.2 to 152.13 µg/m3, PM10 - 57.4 to 75.28 µg/m3, PM2.5 - 40.17 to 52.78 µg/m3,

SO2 - 10.6 to 13.4 µg/m3, NOx - 8.2 to 12.2 µg/m3, O3 - 10.8 to 12.8 µg/m3, Pb - BDL,

NH3 - BDL. CO - BDL, C6H6 - BDL, BaP - BDL, As - BDL, Ni - BDL, HC - BDL.

GM8 ov AL,MJ l08[S8[A, ,LDL8

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8-25

S],L\U v v

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8-26

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J5ZFXDF\ ,[JFDF\ VFJX[P H[ S[,XLID S,MZF.0 AGFJJF DF8[ SFDDF\ ,[JFDF\ VFJX[P s5MTFGM

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8-27

V[OI],g8 8=L8D[g8 %,Fg8 sDF5f o S|D

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12.0 m3 RCC

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6.0(m) x 3.0 (m) x 2.0 (m)

--- Brick

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8-28

E]UE" H/ o

pH - 6.88 to 7.11, Turbidity - 0.1 to 0.7 NTU, TDS - 1460 to 1880 mg/l, TSS - 12.0 to

26.0 mg/l, DO - 6.2 to 6.9 mg/l, COD - 1.0 to 13.66 mg/l, BOD3 - 0.1 to 0.8 mg/l, Total

Hardness - 302.5 to 444.6 mg/l, Chlorides - 430.5 to 1262.3 mg/l, Sulphates - 53.2 to

257.3 mg/l, Ammonical Nitrogen - 0.005 to 0.1 mg/l

;5F8LG]\ 5F6L o

pH - 7.15 to 7.29, Turbidity - 2.4 to 6.2 NTU, TDS - 370 to 1280 mg/l, TSS - 12.0 to 18.0

mg/l, DO - 6.5 to 6.7 mg/l, COD - 11.9 to 50.8 mg/l, BOD3 - 4.6 to 7.9 mg/l, Total

Hardness - 75.1 to 312.6 mg/l, Chlorides - 48.9 to 401.2 mg/l, Sulphates - 23.3 to 108.0

mg/l, Ammonical Nitrogen - 0.08 to 0.1 mg/l

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8-29

DF; V[<I]DLGLID

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pH - 7.31 to 8.10, Moisture - 1.32 to 3.78%, Total Hardness - 900 to 6500.0 mg/kg.

Chlorides - 48.9 to 6653.3 mg./kg, Sulphates - 395.0 to 3639.0 mg./Kg., Calcium - 200.4

to 1944.0 mg/kg, Specific gravit - 2.3 to 2.8 g/cm3, Porosity - 50.5 to 64.18%

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8-30

(P!$ v pHF" VG[ .\36GL H~ZLIFT ov

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