m/s punjab acid-chem pvt. ltd. -...
TRANSCRIPT
FORM-I
&
PREFEASIBILITY REPORT
for
M/S PUNJAB ACID-CHEM PVT. LTD.
Village Behra, Behra-Gulabpur Road, Distt- Mohali
Punjab.
Prepared by:
C P T L ENVIROTECH (S.No. 95, of List of Consultant by MOEF)
Pollution Control Consultants H.O. # 2093, Sector – 15C, Chandigarh. 160015.
Works: E-126 Phase-VII, Industrial Area, Mohali.-160055.
Phone : 0172-4668664,4669295, 2781307, Fax : 0172-4669295.
September-2012
INDEX
Chapter. Description Page No.
FORM-I
PROJECT AT A GLANCE
1. INTRODUCTION 1
2. PROFILE OF THE COMPANY’ & PROMOTERS 2
3. BASELINE ENVIRONMENTAL SETTING 3
3.1 Project Site 3
3.2 Climate 7
3.3 Temperature 7
3.4 Rainfall 7
3.5 Humidity 7
3.6 Cloudiness 9
3.7 Winds 9
3.8 Drainage 11
3.9 Land Use 11
3.10 Forest 11
3.11 Flora & Fauna 11
3.12 Demography & Socio-economics 12
3.13 Study Area 13
4. PROJECT DESCIRPTION 14
4.1 General 14
4.2 Raw Material 14
4.3 Finished Products 14
4.4 Installed Capacity 16
4.5 Manufacturing Process 17
4.6 Facilities at the Plant 22
4.7 Machinery 23
4.8 Power 23
4.9 Water Supply 23
4.10 Manpower 23
4.11 Waste Handling 25
4.12 Pollution Control 25
5. ENVIRONMENT IMPACT ASSESSMENT 28
5.1 Present Environment 28
5.2 Probable Impact on Environment 28
5.3 Development Stage 28
5.4 Operational State 30
6. ENVIRONMENT MANAGEMENT PLAN 32
6.1 General 32
6.2 Air Environment 32
6.3 Water Environment 32
6.4 Land Environment 33
6.5 Solid Waste 33
6.6 Noise Environment 33
6.7 Green Belt 34
7. EXPENDITURE ON ENVIRONMENTAL 35
MEASURES
LIST OF FIGURES:
3.1 Location Plan 4
3.2 Location on Google Image 5
3.3 Site Plan 6
3.4 Wind-rose Diagram 10
4.1 Water Balance 24
4.2 Process Chart of APCS 26
LIST OF TABLES:
3.1 Metrological Data 8
3.2 Summary of Key Demographic Statistics 12
4.1 Plant Site & Location 15
ANNEXURES
I. Existing Consents 36
II. Land Papers 42
III. Memorandum of Article 48
IV. Approval of Site 60
PROJECT AT A GLANCE
Name of Project : Punjab Acids-Chem Pvt. Ltd.
Location : Village Behra, Behra-Gula, Tehsil- Derabassi,
Distt- Mohali, Punjab
Product : Sulphuric Acid, Alum, Olem, Di-Methyl
Sulphate, Sodium, Bi-Sulphite, Sulphamic Acid &
Liquid SO3
Capacity (TPD) :
Existing Proposed Total
Sulphuric Acid 75 125 200
Alum 200 Nil 200
Oleum Nil 70 70
Di-Methyl Sulphate Nil 30 30
Sodium Bi-Sulphite Nil 30 30
Sulphamic Acid Nil 30 30
Liquid SO3 Nil 30 30
Type of Project : Industrial Chemicals
Cost of the Project : Rs. 4426 Lakhs
Total Land : 10 Acres
Power Requirement : 699 KW
Source of power : From Pb. State Power Corporation Ltd
Source of Water Supply : Own Tube well
Quantity of Water(KLD) : Existing Additional Total
60 185 245
Effluent Quantity : Nil
Effluent treatment : Domestic = STP
Process = Nil
Alternate source of power : 1 No. DG Set (700KVA), 1 No. DG Set (325KVA)
Air Pollution Control : Multi-cyclones, Stack
Solid Waste : Solids from APCD, Ash from Boiler Furnace
Hazardous : Used oil from DG Set,
Rain Water Harvesting : 670m3/annum
1
1.0 INTRODUCTION
M/s Punjab Acids-Chem Pvt. Ltd. is proposing to enhance capacity of the unit & addition of
chemical products like Oleum, Di-Methyl Sulphate, Sodium Bi-sulphite, Sulfamic Acid &
Liquid SO3 at Village Behra, Tehsil Derabassi, Distt. Mohali, Punjab. As per G.O.I
Notification dated 14/09/2006 they have to submit Form-I alongwith Pre-Feasibility Report
and other relevant documents for getting Environmental Clearance. This prefeasibility report
has, therefore, been prepared by the consultants to assess the likely impact of the proposed
expansion on various factors which may be affected with the implementation of the
programme and to suggest remedial / precautionary measures, if any.
2
2. PROFILE OF THE COMPANY & PROMOTORS
M/s Punjab Acids-Chem (Pvt.) Ltd is a Private Limited Company. The Directors of
the company are as under:
1. Sh. Inderjit Singh Bal
2. Mrs. Inderpal Kaur
3. Mrs. Jagvinder Kaur
4. Mr. Harvinder Singh
3
3.0 BASELINE ENVIRONMENTAL SETTING
3.1 Project Site
The Plant site is in FEZ (Free Enterprises Zone) Derabassi, Dist. S.A.S. Nagar
Mohali of Punjab. It is on Chandigarh-Ambala Highway. Dera Bassi block has
number of small scale and medium scale units. Chemical paints, Steel tubes,
plywood, handlooms knitting and dairy are some of the industries which have
offered good employment to a number of persons. It lies near Long 76° 53' 17"
East and Lat: 30° 34' 07" North and is at an Altitude of about 315 m. above mean
sea level. It is well connected with Mohali, Chandigarh & Zirakpur through well
maintained metalled roads. It is about 26 K.M. from Mohali. Chandigarh Bus
stand is at a distance of about 26 K.M. by road. The nearest rail head is Lalru,
which is at a distance of about 7 km from the site. Location & Layout Plan of the
unit is given in Fig. 3.1 & 3.2
4
FIGURE – 3.1
LOCATION – PLAN
5
FIGURE – 3.2
LOCATION – ON GOOGEL IMAGE
6
FIGURE – 3.3
SITE – PLAN
7
3.2 Climate:
There is a meteorological observatory at Chandigarh which is at a distance of
about 15 km from the site. Its data is fairly representative of the conditions in the
District in general. The climate of the district is generally dry except in the brief
monsoon season and is very hot in summer and cold in winter. The cold season is
from middle of November to early part of March. Succeeding period upto the end
of June is hot season. July, August and September are the South West monsoon
season.
3.3 Temperatures
The area is fairly plain. December and January are the coldest months whereas in
May and June the heat is quite intense. The wettest months of the seasons are July,
August and September. The temperature varies from 6oC minimum to 40
oC
maximum during the year. Monthly average temperatures of the area are given in
Table-3.1
3.4 Rainfall
The rainfall in the Zone is caused by the South-West monsoon. It starts in the
month of July and extends up-to the end of September. During this period the
monsoon rain-fall contributes about 75 to 80% of the total annual rainfall. The
average annual rain fall is in the range of 1000 to 1100 mm. The annual number
of rainy days on a average are about 51 in a year, out of which about 31 fall in the
monsoon period of July to September. Monthly rainfall data for this zone is given
in Table-3.1
3.5 Humidity
In summer months of April, May and June, which is the driest part of the year, the
afternoon humidity comes down to 23% to 25% while the relative humidity
during monsoon months goes up-to 75% to 80%. Monthly humidity is given in
Table-3.1
8
Table 3.1
METROLOGICAL DATA
Month Average Temperature Rainfall Humidity %
Max oC Min.
oC
mm Av. No. of
Rainy Days
08.30 hrs. 17.30 hrs.
January 20 6 44 3 70 44
February 23 10 41 2.5 63 41
March 28 14 30 2 50 33
April 34 20 12 0.1 38 25
May 38 24 24 2 35 23
June 40 26 110 5 10 25
July 34 25 290 12 75 64
August 32 24 295 13 81 69
September 33 17 184 6 76 58
October 32 17 43 2 57 40
November 27 11 7 1 58 40
December 22 7 20 2 67 45
TOTAL 1000 51
Source: IMD Chandigarh (2004-2009)
9
3.6 Cloudiness
During monsoon season skies are over cast with moderate to heavy clouds.
During rest of the year, the sky is mostly clear. It is lightly clouded occasionally
during winter season.
3.7 Winds
The Wind direction in the area is mostly from North-West to South-East. During
January to May the winds are quite strong while July to October is calm months.
The general trends of various meteorological data from meteorological
observatory at Chandigarh and field observations are used to draw Wind Rose
Diagram. The Wind rose diagram is shown in Figure-3.4
10
FIGURE-3.4
WIND-ROSE DIAGRAM
Source: IMD Chandigarh (2004-2009)
11
3.8 Drainage
The area is fairly plain and has good slope from North-East to South-West. The
area is well drained and takes the entire rain water flows to local Choes.
3.9 Land Use
The total area of the District is 1092.64 sq km. 68% is net sown area and 32% is
under non-agricultural use. Agriculture is mostly dependent on tube-wells. Rice
and wheat are the main crops in the area.
3.10 Forest
There are no notified reserved forests near the site of the project. In the entire
district area under forest is about 18,000 Ha. The company also proposes to plant
about 300 trees and shrubs within the project area.
3.11 Flora And Fauna
Ecological system consists of varieties of interrelationship between both biotic and
abiotic components. Biotic components comprise of both plant and animal
communities, which interact not only within and between them but also within the
abiotic physical. Animal plant communities in their natural habitat exist in a well
organized manner. The project does not disturb any natural setting and is coming
up in an already existing FEZ area. The main species of trees found in these
jungles are Kikar (Acacia Arabic), Neem (Azardirachta indica), Peepal (Ficus
religiosa) and Bargad (Ficus bengalensis). Among the species which have been
introduced recently include Mango, Khair, Safed siris, Kala siris, Amaltas, Jamun,
Arjun, Bahera and Zizyphus which are commonly grown in the area. Prolific wild
life is not observed in the study area as there is no thick forest/ vegetation.
Lizards, snakes, hare, pigeon, mongoose and peacock are noticed in the study
area.
12
3.12 Demography And Socio-Economic Scenario
Quite a good and Residential development has taken place in and around Mohali,
Zirakpur and Dera Bassi. The socio-economic profile has been studied through
random sample primary surveys and secondary data. The significant demographic
and socio economic statistics of the district are summarized and given in Table-
3.2
TABLE-3.2
SUMMARY OF KEY DEMOGRAPHIC STATISTICS
Punjab Mohali Dist.
Particulars 2001 2001
Male Population 1,29,85,045 3,79,533
Female Population 1,13,73,954 3,18,784
Total Population 2,43,58,994 6,98,317
Sex Ratio 876/1000 840/1000
Density of Population/Km2
484 635
Literacy Rate: Total 69.7 % 78.4%
Male 63.4% 83.8%
Female 75.2% 72.1%
OCCUPATIONAL STRUCTURE IN THE AREA
Occupation 2001 (No.) Percentage in
the District
Agriculture Labour 21,638 8.0 %
Cultivators 40,445 14.9 %
House Hold Industry 6,539 2.5 %
Others covering:
Transport and
Communication
Trade & commerce
Govt. Services
Construction
Industry
2,01,401
74.6 %
Total 2,70,023 100%
13
3.13 Study Area
In order to establish bench mark conditions near the unit an area of 10 km around
the site will be selected for study of Ambient Air, Ground water, Surface Area-
wide and noise monitoring after issuing of TORs.
14
4.0 PROJECT DESCRIPTION
4.1 General
The Punjab Acids-Chem (P) Limited located at Village Behra, Tehsil Dera Bassi,
Dist. S.A.S. Nagar Mohali, Punjab is about 6 Kms from Dera Bassi Bus Stand and
about 26 Kms from Chandigarh Bus Stand (U.T). It is about 6 km from
Chandigarh – Ambala Highway. The unit has 10 acres existing land. No additional
land is required for expansion. Location details are given in Table 4.1. The total
cost of the project is 4426 lacs.
4.2 Raw Materials
(1) Sulphur
(2) Sulphuric Acid
(3) Sulphur Trioxide
(4) Liquid SO3
(5) Methanol
(6) Urea
(7) Caustic Soda
4.3 Finished Product
The unitwill manufactures following Product:
i. Sulphuric Acid
ii. Alum
iii. Oleum
iv. Sulphur Trioxide (SO3)
v. Di-Methyl Sulphate
vi. Sulphamic Acid
vii. Sodium Bi-sulphite
15
Plant Site and Location
TABLE 4.1
S.No Particulars Details
1 Location
a Village/ Town/Plot No. Behra
b Tehsil Dera Bassi
c District S.A.S. Nagar Mohali
d State Punjab
e Latitude 30º34’17” North
d Longitude 76º53’07” East
2 Elevation 315 mts.
3 Land use at the project site Industrial
4 Climatic Conditions
Temperature
Rainfall
Relative Humidity, %
Wind speed, Kms/hour
Min: 6oC, Max:40
oC
1000-1100 mm (average)
Min: 23%, Max:80%
10 Km (approx.)
5 Nearest highway National Highway-22
(Chandigarh – Ambala about 6 km)
6 Nearest railhead Lalru (about 7 km)
7 Nearest airport Chandigarh (about 20 km)
8 Nearest major city Mohali (about 26 km)
9 Nearest major settlement Dera Bassi (about 6 km)
10 Features with 10 km :
i) Defence installations Nil
ii) Archaeological important
places
Nil
iii) Wild life sanctuaries Nil
Iv) Reserved/Protected forest Bir Kheri PF about 3 km, Bir Dadrala PF
about 4km, Bir Baqarpura PF about 7 km
from site.
v) Industries Industrial Focal Point Dera Bassi
vi) Rivers Dangri Nadi about 6 km in Haryana State &
Ghaggar Nadi about 8 km in punjab.
vii) Hill ranges Nil
viii) State Boundary Haryana State (about 2 km)
16
4.4 Installed Capacity:
The total installed capacity of the plant for the product will be as per details given
below:-
NAME OF PRODUCT EXISTING PROPOSED TOTAL
(TPD) (TPD) (TPD)
Sulphuric Acids = 75 125 200
Alum = 200 NIL 200
Oleum = NIL 70 70
Di-Methyl Sulphate = NIL 30 30
Sodium Bi-Sulphite = NIL 30 30
Sulphamic Acid = NIL 30 30
Liquid SO3 = NIL 30 30
The unit will operate for an effective period of 300 days in a year on three shift
basis of 8 hrs each.
17
4.5 Manufacturing Process
1) Sulphuric Acid Manufacturing Process:
The manufacturing process for Sulphuric Acid as practiced in the plant at the
present time is described as under:
(a) Sulphur: Solid sulphur of 99% purity from sulphur storage yard is charged
by wheel-barrows to the sulphur melter-cum-settler. The molten sulphur
from the melter compartment flows to the sulphur settler compartment. The
melter has capacity equivalent to more than two days consumption at the
rated sulphur utilization. The melter chamber is divided into three
compartments for removal of any ash particles (suspended solids) by
settling. With an initial ash content of 0.2% in the dirty molten sulphur, the
ash content in the sulphur in the last compartment of sulphur settler will not
exceed 0.02% (200ppm).
From the last pumping compartment molten sulphur at about 1350C. is
pumped by means of one of the submerged centrifugal sulphur pumps to
the sulphur burner. The molten sulphur is pumped to the burner through a
steam jacketed and insulated pipe line and is controlled by a flow
regulating valve. The sulphur burner is of a horizontal type lined with
refractory and insulating material. The combustion of molten sulphur is
fully completed in the burner.
(b) Air and Gas System: The combustion air for burning of the sulphur and
for conversion of SO2 to SO3 is provided by the air blower via the drying
chamber. The air blower after the filtration of air on its suction side forces
clean air through a drying tower where 98.4% sulphuric acid is circulated.
The filtered and dried air goes to the sulphur burner.
The gases leaving the sulphur burner have around 11% SO2 at a
temperature of around 980 deg. C. These gases pass through waste heat
boiler No. 1 where saturated steam is produced at a pressure of about
32kg/cm2. The waste heat boiler no. 1 and super heater are designed
according to the process requirement and the temperature control of the
outlet gases is achieved through by-passing of a part of the hot gases
leaving the burner through a refractory lined duct line fitted with heat
18
resisting valve. It is thus possible to control the temperature of the gases
entering the first bed of the converter at the desired level.
Before entering the converter the gases pass through a special type of pad
bed type HGF filter which removes minor quantities of dust which might
reach this point. The filter is loaded with crushed and cleaned filter media
and is completely insulated. The gases leaving the HGF filter enter the first
bed of the converter at around 430 deg. C and come out at around 600 deg.
C. Vanadium pentoxide (V205) catalyst is used for the conversion of SO2 to
SO3. These gases are cooled in a waste heat boiler No. 2 where steam is
raised at around 32 kg/cm2 and superheated to 370 deg. C. For proper
control of temperature, gas entering the second bed of the converter at
around 525 deg. C. is cooled to around 440 deg. C before entering the third
pass by passing the gas on the tube side of the hot heat exchanger which in
turn heats the gases coming from the cold heat exchanger. A by-pass valve
is provided on the tube side of the hot heat exchanger for proper control of
the gases entering the third bed of the converter. The gases come out of the
third bed of the converter at around 4650
C. are cooled on the tube side of
the cold heat exchanger to a temperature of around 2500 C which after
further cooling enter the interpass absorption tower where SO3 is absorbed
by means of sulphuric acid (98.4%) and the remaining gases coming out of
the interpass absorption tower at about 700
C are first heated on the shell
side of cold heat exchanger where the temperature is raised to around 3300
C. the gases then pass through the shell side of the hot heat exchanger
where the temperature is raised to around 425 deg. C. before entering the
fourth bed of the converter. For proper control of temperature of the gases
entering the fourth bed of the converter, a by-pass on the tube side of the
cold heat exchanger is provided.
The fourth bed of catalyst is the largest of all the beds. The relative higher
contact time (lower space velocity) with negligible initial SO3
concentration causes a very high deg. of SO2 conversion to SO3. The
overall conversion of SO2 to SO3 obtain in the converter is more then
19
99.7%. The gasses pass through an economizer where they are cooled to
around 200 deg. C. These gases after further cooling enter the final
absorption tower then SO3 in the gases gets absorbed in the tower. The
remain gases containing mostly N2 (93%) and O2 (7%^) is passes through
demister and are vented through the stack. The condition is of operation are
controlled in such a manner that this remaining gases escaping through the
chimney are kept as per MINAS standard.
A caustic alkali scrubber has been installed before the vent to chimney, for
absorbing any excessive quantity of unconverted SO2 gas that may other
wise be released during the start-up for shutdown of such units as well as
during any plant disturbances.
(c) Acid System: 98.4% sulphuric acid is circulated in the air drying tower,
interpass absorption tower and final absorption tower. This ensures
optimum drying in case of drying tower and maximum absorption
efficiency of SO3 in the absorption towers. All the towers have common
acid pump tank. The air drying tower is used for drying of air coming from
the main air blower so that the moisture content in the dried air is removed
as per the process requirements. Interpass absorption tower removes SO2
coming from the third bed of the converter so that the gases entering the
fourth and final bed is free of SO3. This enhances the conversion of SO2 to
SO3 in such a way that the exhaust gases coming from the final absorption
tower are free of SO2.
The circulating acid is collected in a common acid pump tank. The acid
strength in the pump tank is controlled automatically by feeding the
required quantity of water through automatic control valve. The acid pump
tank is fitted with a vertical submerged acid circulation pump which feeds
acid to the towers via respective acid coolers. These acid coolers cool the
acid before feeding the towers. The acid is cooled by using sprays over
trombone type coolers, fed with circulation cooling water. The tapping for
the product acid is taken from the outlet of the acid coolers.
20
2) Oleum:
Oleum is a dense colorless liquid which is formed by absorbing sulphur
trioxide gas in sulphuric acid. Oleum reacts like a mixture of sulphur
trioxide and Sulphuric acid but contains Pyro-sulphuric Acid (H2S2O7), the
composition of which corresponds to 45% sulphur trioxide. The sulphur
Trioxide gas is to be taken after the 3rd
pass of converter of existing
Sulphuric acid plant to the Oleum absorption Tower from the bottom &
concentrated 98.4% Sulphuric Acid is to be fed from the top of the Oleum
absorption tower. The feed of sulphuric acid in the Oleum absorption tower
is to be maintained through Rota Meter, Oleum strength Monitor &
continue circulation of Oleum in the absorption tower. During the proper
Mixing/absorption of SO3 gas with H2SO4, the temperature will also
increased with exothermic reaction, to cool down the Oleum and maintain
the proper required temperature, the Oleum is to be cooled through Plate /
Shell type Oleum cooler.
3) Sulphur Trioxide (Liquid):
The Oleum Liquid is to be fed to SO3 Generator through Oleum Heater.
The evaporation with the help of steam is to be achieved to get the pure
gaseous vapours, which will be condensed in the SO3 condenser. The cold
water will be fed to SO3 condenser to get the proper production of liquid
sulphur trioxide & which will be stored in the jacketed Storage Tanks. The
liquid sulphur trioxide (24%) SO3 will be supplied to DMS plant from these
tanks only.
4) Di-Methyl-Sulphate
1. Methanol is Vaporized & the pre-heated Vapors are fed
continuously in a Catalyst Bed Reactor (Temp 240 to 250oc) to
convert the methanol into Di-Methyl-Ether (DME)
2. Di-Methyl-Ether thus formed is Sulphonated with Liquid SO3 to get
crude Di-Methyl-Sulphate (DMS) which is further purified by
Vacuum distillation to get pure DMS.
21
REACTION:
CAT
1. 2CH3OH > CH3OCH3+H2O
2. CH3OCH3+SO3 > (CH3)2 SO4 {DMS}
1) Methanol is pumped from main storage tank continuously into
methanol vaporizer, vapors of methanol is passed thru two nos. heat
exchangers to superheat the methanol vapors which then fed
continuously into catalytic reactor containing alumina catalyst temp.
of 250-260o C. is maintained in the reactor for conversion of
methanol to Di-Methyl-Ether, unconverted methanol is 15-20%.
This DME+UN converted methanol +water of reaction is taken into
stripping col. To get pure DME vapors, methanol + water mix. Is fed
to methanol recovery col. To get pure methanol which is reused?
2) DME from DME STRIPPING COL. Is fed into a sulphonater where
it reacts with liq. SO3 to get crude DMS.
3) Crude DMS from storage tank is fed into DMS distillation unit
continuously to get pure DMS which is stored in storage tanks as
finished product.
4) Bottom residue of distillation kettle containing some DMS and spent
acid is taken into another DMS recovery unit to recover left over
DMS, spent acid & small quantity of water is to be used alum plant
and for cooling in sulphuric acid plant.
5) Sulphamic Acid (SMA)
Chemical Reaction:
NH2CO2 + H2SO4 = 2NH3SO3H + CO2
(Urea + Sulphuric Acid) = (SMA)
98%
Urea is reacted with mixture of 98% Sulphuric Acid & 65% Oleum at
elevated temp. SMA thus formed is separated by diluting the reaction mass
& then filtering the slurry of SMA Thus formed wet cake of SMA is dried
and packed.
CO2 formed during reactions is vented out after scrubbing. Spent dilute
Sulphuric Acid is used in the manufacture of Alum etc.
22
6) Sodium bi-sulphite:-
Sulphur dioxide gas is purged in a Reactor containing Caustic solution
under agitating and circulation. Reaction takes place and crystallization
started after saturation of Mother Liquor. Than entire material is
centrifuged to separate solid wet cake of Sodium bi-sulphite which is dried
in Flash Dryer get dry Sodium bi-sulphite pure product. The Mother liquor
collected and recycled to prepare next batch.
Chemical Reaction:-
NaOH + SO2 NaHSO3
4.6 Facilities at the Plant
The firm has already acquired 10 acres of land where factory building,
boundary wall and some other ancillary structures are proposed to be
constructed for expansion. It provides adequate space for the following
areas of working:-
1. Storage for raw material and finished goods.
2. Plant and Machinery
3. Store
4. Offices
5. Toilets
6. Water storage tanks
Open space will be landscaped and trees will be planted in due course of
time.
4.7 Machinery
Following machinery will be finally in position within the unit:
S.NO. EQUIPMENT NAME
1 Reaction Vessels
2 Condensers
3 Decanters
23
4 Cooling Tower
5 Storage Tanks
6 Steam Boiler (6 TPH)
4.8 Power
The requirement of Power for the unit is 699 KW which will be supplied
by PSPCL.
4.9 Water Supply
The water requirement of the unit will be met from ground water through
existing tube-well. The daily requirement of water for existing unit is 60 &
after expansion totaled water requirement will be about 245 m3. About 85
KLD water will be required in process & make up water required for cooling
purpose will be 30 KLD. Water required for boiler will be 120 KLD and for
domestic purpose 10 KLD. The capacity of storage tank for cooling purpose
is about 500.0 m3. Another tank of about 50 m
3 has also been provided for
fire fighting which shall be kept always full. Flow chart of water use is given
in fig. 4.1
4.10 Manpower
Unit will work on single shift basis and manpower needed will be about
100-125 persons.
24
Figure: 4.1
WATER BALANCE FLOW DIAGRAM
(KLD)
WATER TANK
245
BOILER
120
COOLING
1500
PROSESS
85
DOMESTIC
10
EVAPORATION
30
CONSUMTION
2
STP
8+2 RE-USE
470
USE IN PROCESS
85
IRRIGATION
STEAM
GENERATION
BLOW DOWN
2
25
4.11 Waste Handling
4.11.1 Liquid waste
There will be no generation of waste from manufacturing process. The domestic
effluent shall be treated through STP. The domestic treated water will be used for
plantation.
4.11.2 Solid waste
Solid wastes in the unit are from the following sources.
i) Solids from APCD.
ii) Ash from the Boiler furnace
Solids from APCD will be disposed off at designated land filling site.
4.11.2 Hazardous waste
The Hazardous wastes generated from the unit are Sulphur Sludge, Catalyst dust and
used DG Set oils. The Sulphur sludge & Catalyst Dust will be sent to TSDF site
Nimbuan Dera Bassi for final disposal & used oil from D.G. Set shall be sold to
recyclers. There are no other hazardous wastes.
4.12 Pollution Control Measures
The main sources of pollution from the unit are discussed as under:
4.12.1 Air Pollution
i) Exhaust from Boiler
The source of emissions at the Plant is Boiler of capacity 6.0 TPH. There will be 4
No. stacks in the industry. In which one no. stack will be attached with boiler,
second stack on alum plant, third stack on acid plant and the fourth stack with DG
set. The fuel used for boiler will be biomass and Diesel for DG set. The main
pollutants are particulate matter and gaseous emissions.
26
Fig: 4.2
PROCESS FLOW CHART OF AIR POLLUTION CONTROL SYSTEM
Boiler
ducts
Multi –Cyclone
ID Fan
Stack
27
4.12.2 Water Pollution
Water will be used for Process, cooling, Boiler and domestic purposes. Waste
water from the toilets will be treated through septic tank. The domestic
effluent shall mainly be used for plantation.
4.12.3 Noise Pollution
There is some noise producing machineries such, as ID Fan, Blowers etc.
All these machines are spread at different places within the covered sheds.
Thus no noise of significant level shall go out side the working area which
may disturb the general noise environment. DG set installed shall be noise
free & with canopy.
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5.0 ENVIRONMENT IMPACT ASSESSMENT:
5.1 Present Environment:
Various Environment factors as existing in the project area which possibly
could be affected by the activities have been assessed & identified as
below:
(i) Ambient Air
(ii) Water Quality
(iii) Noise
(iv) Land use pattern
(v) Soil and Agricultural
(vi) Demography and socio-economic pattern.
5.2 Probable Impact on Environment:
The above factors will be checked after the implementation of the project to
cross check the probable impact discussed hereunder and remedial
measures taken wherever necessary. Broadly the impacts may be classified
in two categories as under:-
i) Short term - during construction/development stage
ii) Long term - during operational stage.
Both these categories have been considered while predicting and evaluating
the impacts as given herein after:-
5.3 DEVELOPMENT STAGE: - (SHORT TERM)
This is a construction phase of the project and the impacts are temporary
due to construction related activities which are as under:-
i) Air Environment:
There is no point source of air pollution. The only source will be the dust
generation due to excavation, construction and plying of vehicles within
unit. Some emission may be expected from vehicles plying in the area for
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transportation of material etc. Kerosene oil shall be provided to the labour
so that they do not burn wood for cooking etc.
ii) Water Environment :
Requirement of water during construction activity will be about 1.0 m3/day
and there will be no waste discharge as the same will be used completely.
However, during monsoon some malba etc may get washed due to run off
from the site. There is a natural ‘nallah’ near the land which takes the entire
run off from the area.
Labour during construction is not very large. Hardly about 10 persons may
be working daily on an average who may be using water for drinking and
bathing etc. Toilet facilities with septic tank will be provided to labour @ 1
toilet for 20 persons who will be used by the labour.
In view of this there is no likelihood of any significant impact on the
general environment of water in the area.
iii) Noise Environment:
Some noise may be expected from the working of the machinery for
replacement and repair purposes and movement of vehicles. Steps will be
taken to reduce its effect by resorting to staggering of various operations.
Even otherwise since there will not be any large scale machinery, the
activity is not likely to have any significant effect on the over all noise
environment.
iv) Land Environment:
It is an approved FEZ area; the land at site is leveled as such no leveling is
required. Natural drainage will not be disturbed. Solid waste from
construction activities will be used within the premises under roads &
refilling. There will not be any significant impact on land in general.
v) Socio Economic:
The project does not involve any displacement of population or
rehabilitation of any kind. Rather it will provide employment to local
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people in the shape of additional man power required for the units, & will
and boost the economy of the area. It will have some positive impact,
although not to a large extent.
5.4 OPERATIONAL STAGE: - (LONG TERM)
After completion, when the unit starts production, the operational impacts
on the various parameters are considered as under:-
i) Air Environment:
There is only one source of likely pollution which is PM emission from the
Boiler furnaces & mist from Sulphuric Acid plant/Alum Plant. All the
processes are closed circuits as such emissions to the open atmosphere will
be minimum. However, APCD, Multi –Cyclone on boiler & Alkali
Scrubber on Sulphuric Acid/Alum plant will be provided at the exit point to
arrest particulate matter & to neutralize Acid mist. Whatever solid waste
goes out the same will be disposed off at low lying areas.
ii) Water Environment:
The domestic use of water will generate about 8 m3/day of effluent, which
will be treated through STP. There is no discharge of water from industrial
process. Treated domestic water will be discharged on land for irrigation.
Treated effluent will not be thrown in any water body. Thus water
environment is not likely to be affected. Further, ground water will be
balanced through recharge by rain water harvesting from the roof top to the
of extent about 670 m3/annum through recharge wells. Thus pressure on
underground water will be reduced.
iii) Land Environment:
The Project is coming up in an existing focal point. Thus there will not be
any significant adverse effect on the existing general land environment
with the coming up of the project.
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iv) Noise Environment:
There will be no noise producing machinery or equipment except ID fans
& Blower etc. which will be placed at different places within the closed
sheds causing least disturbance in the area. There is no likelihood of any
significant change in noise environment.
v) Socio Economic Pattern
The project will provide employment to local people in the field of running
plants and maintenance of machinery, APCD & security etc. Thus it will
have positive effect on the employment potential in the area.
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6.0 ENVIRONMENTAL MANAGEMENT PLAN:
6.1 General
Environment Management Plan (E.M.P) in a project is prepared to mitigate
the possible adverse effect of various activities on the existing
environmental factors, during construction as well as in operational stages,
to avoid their deterioration, if any. It is desirable that necessary steps are
taken right from the beginning of the project to be more effective. As a
social and moral obligation on the part of every body it becomes our
bounden duty to leave our environment to the next generation in a state at
least what we inherited from our ancestors, if not in a better condition.
E.M.P. for this project has been prepared keeping in view the existing
conditions and likely changes which may occur due to the proposed project.
The implementation and monitoring of different control measures have also
been covered. These are discussed as under:-
6.2 Air Environment
During construction stage water will be sprinkled on the soil to avoid dust
generation, if any. The debris and unused construction malba shall be
removed immediately for recycling, if any, or for land fill. Cyclone &
Alkali Scrubber shall be provided to arrest SPM from flue gases to keep it
within permissible limits. All vehicles for service activities at the project
site shall be checked for vehicular emission. The agencies will be asked to
keep them within prescribed limits. They will also be asked to maintain
them properly.
Tree plantation shall be resorted to for further improving the air
environment in general and minimize noise levels, if any.
6.3 Water Environment:
Water shall be drawn from existing tube well. During construction toilet
facilities shall be provided to labour with septic tank. Finally, waste water
from the toilets shall be taken to septic tank through underground delivery
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system and treated to tertiary level. The treated water will be discharge into
land for irrigation. It will not be thrown outside either on land or in any
water body. Roof top rain water shall be harvested and used for ground
water recharge to minimize effect of withdrawal of water from the
underground.
6.4 Land Environment:
To avoid erosion of the top soil the development is planned in the shortest
possible time and land-clearing activity shall be kept to the absolute
minimum by working at the specific sites one by one where construction is
to take place so as to increase detention and infiltration. Natural
waterways/drainage pattern shall be maintained by providing culverts
where needed. The requirements of sand and aggregates for the
construction works will be met through venders. The land use is thus so
planned that there is minimum adverse impact.
6.5 Solid Waste
The solid waste generated from the construction activities shall be
effectively recycled within the project. The other solid wastes from the
APCD shall be dumped in a dumping pit of R.C.C. and disposed off in the
designated land fill places.
6.6 Noise Environment
During Construction stage “NO HORN” signs will be displayed at prominent
places. The drivers shall be directed not to blow horn unnecessarily. Vehicle
owners will be asked to maintain them in proper condition. During
operational stage noise creating machinery such as blower, ID Fans etc will
be housed different places within closed sheds so as not to disturb the noise
level in the area.
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6.7 Green Belt:
The main objective of the green belt is to provide a barrier between the
source of pollution and the surrounding areas. The green belt helps to
capture the fugitive emission and to attenuate the noise generated, apart
from improving the aesthetics. Development of green belt and other forms
of greenery shall also prevent soil erosion and washing away of topsoil
besides helping in stabilizing the functional ecosystem and further, to make
the climate more conducive and to restore water balance. It is planned that
the selected plants will be grown as per normal horticultural (or forestry)
practice and authorities responsible for plantation will also make sure that
adequate provision for watering and protection of the saplings exists at site.
Species of trees shall be selected in consultation with the forest Department
officers. In all about 200 trees & shrubs are proposed to be planted within
the unit premises.
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7. EXPENDITURE ON ENVIRONMENTAL MEASURES
Cost of environment protection measures
S.No Title Capital Cost
Lacs
Recurring Cost
- Lacs
(Annum)
1 Air Pollution Control 15.0 2.0
2. Noise Pollution Control
(Including cost of
Landscaping, Green Belt)
4.0 ---
3. Solid Waste Management 2.0 0.5
4. Environment Monitoring
and Management (Including
Establishment of
Laboratory)
8.0 0.5
Total 29.0 3.0