pre feasibility report of - welcome to...

Pre – Feasibility Report of

Proposed Expansion of Existing Integrated

Common Hazardous Waste Treatment, Storage and

Disposal Facility (ICHWTSDF) by Mumbai

Waste Management Limited

at P-32 & P-32 (part), MIDC, Taloja, Panvel

Taluk, Raigad District, Maharashtra

Contents

S. No. Description Page No.

1. Executive Summary 1

2. Introduction of the project 2

3. Project Description 6

4. Site Analysis 32

5. Planning Brief 36

6. Proposed Infrastructure 37

7. Rehabilitation & Resettlement Plan 39

8. Project Schedule & Cost Estimates 40

9. Analysis of Proposal 41

PFR for proposed Expansion of ICHWTSDF at P-32 & P-32 (part), MIDC, Taloja, Panvel, Raigad, Maharashtra by MWML

Ramky Enviro Services Private Limited, Hyderabad 1

Pre-Feasibility Report

1. Executive Summary Mumbai Waste Management Limited (MWML), a subsidiary of Ramky Enviro Engineers

Limited is proposing to expand the existing Integrated Common Hazardous Waste

Treatment, Storage and Disposal Facility (ICHWTSDF) along with addition of new units for

the recovery of solvents, recycling of paper, plastics and MS drums as well as facilities for

E-waste management and alternate fuel & raw material recovery. The existing project

activities includes secured landfill (1,20,000 MTPA), two incinerators (combined capacity

of 30,000 MTPA) and bio-medical waste treatment facility (150 TPM with 1X250 kg/hr

incinerator, 2X600 lit/batch autoclaves and 2X100 kg/hr shredders).

The ICHWTSDF, after the proposed expansion, will have the following components:

secured landfill (3,50,000 MTPA), three (3) incinerators (combined capacity of 45,000

MTPA), bio-medical waste treatment facility (250 TPM with 2 X 250 kg/hr incinerators, 2

X 3,000 lit/batch autoclaves and 2 X 200 kg/hr shredders), E-waste Management (5,400

MTPA), Plastics Recycling (5,000 MTPA), Paper Recycling (30,000 MTPA), Solvent

Recovery (9,000 KLPA), AFRF (70 MTPD) and MS Drum Recycling (15 MTPD).

As per the MoEFCC Notification S.O.1533 dated 14.09.2006 and its subsequent

amendments the proposed project falls under Project Activity 7(d) - Common Hazardous

Waste Treatment, Storage and Disposal Facilities (TSDFs), Category ‘A’ - All Integrated

facilities having incineration & landfill or Incineration alone (including 7 (da) Bio-Medical

Waste Treatment Facilities).

The proposed expansion will be developed within the existing Mumbai Waste

Management Limited (MWML) site located at P-32 & P-32 (part), MIDC, Taloja, Panvel

Taluk, Raigad District, Maharashtra (within notified industrial area). The total land area of

the project is 39.40 Ha (97.35 Acres) and the proposed facilities will be developed within

existing area. Greenbelt meeting MoEFCC guidelines will be developed with a minimum

10 m width all around the boundary of proposed site.

The total water requirement of the project is 582 KLD will be sourced from MIDC, which

includes existing requirement of 361 KLD and proposed requirement of 221 KLD. The

total power required for operations is 2220 kVA which is sourced from Maharashtra State

Electricity Distribution Co. Ltd (MSEDCL), which includes existing requirement of 500 kVA

and proposed requirement of 1720 kVA. The DG sets of 875 kVA (existing) and 500 kVA

(proposed) will be used as a power backup for emergency requirement.

The capital cost of the proposed expansion project is Rs.40.05 Crores (Existing project

cost is Rs.155.82 Crores). The capital cost allocated for EMP is around Rs. 3.5 Crores with

a recurring cost of Rs. 35 lakhs/annum. The CSR budget allotted during FY 2017-18 is

around Rs. 20 lakhs.



2. Introduction of the Project

2.1 Identification of Project and Project Proponent

2.1.1 Identification of Project

MWML is an existing Integrated Common Hazardous Waste Treatment, Storage and

Disposal Facility (ICHWTSDF) at Taloja, operational since 2002. Currently, the existing

facility has secured landfill and incinerator for landfillable hazardous & bio-medical

waste. MWML is proposing to expand its existing facilities along with addition of new

units for the recovery of solvents, recycling of paper, plastics and MS drum as well as

facilities for E-waste management and alternate fuel & raw material recovery in

compliance with the statutory guidelines.

2.1.2 Identification of Project Proponent

Ramky Group’s Waste Management Division is leader in the field of waste management

in the country. It is focused in the fields of Industrial Hazardous Waste Management,

Bio-Medical Waste Management and Municipal Solid Waste Management. It’s group of

companies have the credit and distinction of having established first-of-its-kind bio-

medical waste (BMW) and hazardous waste management facilities operating on a

common platform in the country at Hyderabad.

The group today is the leader in waste management in India, with 15 bio-medical waste

management facilities located at Hyderabad, Bangalore, Ludhiana, Ahmedabad,

Mumbai, Chennai, Madurai, Salem, Durgapur, Kalyani, Haldia, Kolkata, Mangalore and

Ghaziabad. Few are under construction. The company is today operating fifteen

hazardous waste management facilities established and operated (some are under

construction stage) under the name of;

Hyderabad Waste Management Project located at Hyderabad (Dundigal)

Mumbai Waste Management Limited located at Mumbai (Taloja)

West Bengal Waste Management Limited located at Haldia

Tamil Nadu Waste Management Limited located at Chennai (Gummidipoondi)

Uttar Pradesh Waste Management Project located at Kanpur

Coastal Waste Management Project located at Visakhapatnam

Rajasthan Waste Management Project located at Udaipur

Punjab Waste Management Project located at Chandigarh (Nimbua)

Karnataka Waste Management Project located at Bangalore (Dobaspet)

Orissa Waste Management Project located at Bhubhaneswar

Balotra Waste Management Project (Balotra)

Madhya Pradesh Waste Management Project Located at Indore (Pithampur)

West Bengal Waste Management Limited located at Saltora

Tamil Nadu Waste Management Limited located at Chennai (Virudhnagar)



Bihar Waste Management Project (Bhojpur).

The hazardous waste management facilities in operation are integrated facilities

catering to over 6000 industrial establishments and catering to over 7,00,000 TPA of

industrial hazardous wastes. All the facilities are equipped with the state-of-the-art

laboratories capable of performing comprehensive and fingerprinting analysis. Ramky’s

experience in Municipal Solid Waste (MSW) is also exhaustive in terms of various

consultancy projects rendered for various cities in India. All the waste management

facilities established are operated and maintained with high priority towards

environment and occupational health and safety aspects. Wherever possible, the

operations have been automated or mechanized and all the staff working with the

waste are provided with adequate and suitable personnel protective equipment (PPE).

Regular health check-ups are also being organized as a matter of employee’s safety

2.2 Brief Description of Nature of the Project

Mumbai Waste Management Limited (MWML), a subsidiary of Ramky Enviro Engineers

Limited is planning to expand the existing Integrated Common Hazardous Waste

Treatment, Storage and Disposal Facility (ICHWTSDF) along with addition of new units for

the recovery of solvents, recycling of paper, plastics and MS drum as well as facilities for

E-waste management and alternate fuel & raw material recovery. The existing facility

consists of secured landfill (1,20,000 MTPA), incineration (30,000 MTPA) and bio-medical

waste treatment facility (150 TPM).

2.3 Need for the Project and its Importance to the Country and Region

The wastes such as hazardous, e-waste, plastic, etc. need to be disposed of in a secured

manner in view of their hazardous nature, environmental pollution and wide range of

health hazards they pose. At present, the waste generated from industries, commercial

and residential activities are either indiscriminately disposed in open areas or within their

units or given to small recyclers. The waste generators find it difficult to dispose their

wastes without causing environmental disturbance, as very few appropriate disposal

facilities are available.

This ineffective hazardous waste management can be attributed to the following factors:

Absence of systematic qualitative and quantitative assessment (inventory) of

wastes generated

Improper storage and disposal practices of wastes

Absence of proper treatment, storage and disposal facilities (TSDFs)

The Government of India has promulgated the Hazardous Waste (Management

&Handling) Rules in 1989 through the Ministry of Environment and Forests, Climate

Change (MoEFCC) under the aegis of Environment (Protection) Act, 1986. Also in order to

encourage the effective implementation of these rules, the MoEFCC has further



amended the rules several times. Since then, there is a growing concern on disposal of

hazardous wastes generated from anthropogenic sources all over the country. The

Government of India during 2016 has issued rules to handle e-waste, plastic waste, etc.

Having an integrated facility would minimize the risk involved in waste transportation

and waste movement. This project will also cater the needs of industries, commercial

establishments, etc situated in various districts of Maharashtra by facilitating a one stop

solution for management of all types of wastes at a common treatment facility. At this

ICHWTSDF, the wastes would be collected from the waste generators, treated as per

their characteristics and finally disposed of.

2.4 Demand Supply Gap

Due to rapid industrialization, the generation of waste all over the country including the

state of Maharashtra is growing exponentially. Mumbai, being a business capital of the

country, the waste generation in and around the Mumbai is considerably high. In this

connection, the existing facility will be strengthened to handle the waste in scientific

manner meeting the new guidelines issued by Govt.of India.

Figure 1

Increasing Waste Demand for Waste Management

2.5 Imports vs. Indigenous Production

The proposed project is for treatment and disposal of various wastes generated by

industries, commercial establishments, etc. hence, imports vs. indigenous production is

not applicable for this project. On the contrary, the recycling units proposed can reduce

the demand for virgin materials (paper, plastic, solvent, etc.).

2.6 Export Possibility

The proposed project being a treatment and disposal facility of various wastes generated

by industries, commercial establishments, etc. does not generate any products suitable

for export.

2.7 Domestic/Export Markets

The recycled materials (paper, plastic, solvent, etc.) produced from the proposed project

can meet the demand of domestic market to a certain extent.



2.8 Employment Generation (Direct and Indirect) due to the Project

The employment details of the existing project and projected employment from the

proposed activity is given in Table 1.

Table 1

Manpower Details

S.No Description Existing Proposed Total

1 Skilled Manpower 70 61 131

2 Unskilled Manpower 200 245 445

Total 270 306 576

In addition to the above there will be indirect employment of around 100.



3. Project Description

3.1 Type of Project including Interlinked and Independent Projects, if any

The proposed project is an expansion of the existing Integrated Common Hazardous

Waste Treatment, Storage and Disposal Facility (ICHWTSDF) by additional development

of the recycling, alternate fuel & E-waste management facilities. There are no interlinked

projects.

3.2 Location (Map showing general location, specific location, project boundary and

project site layout) with coordinates

The site is located at P-32 & P-32 (part), MIDC, Taloja, Panvel Taluk, Raigad District,

Maharashtra State. The site coordinates are 19° 05' 48.28" N latitude and 73° 06' 52.07"

E longitude. The location map of the site is shown in Figure 2 and site layout is shown in

Figure 3.

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations gone into should be highlighted.

It is an existing project located within the MIDC industrial area, Taloja going for the

expansion hence no alternate sites were considered.

3.4 Size or Magnitude of Operation

The area allocated for ICHWTSDF facility is 39.40 Ha (97.35 Acres). Land possession

document is attached as Annexure I. Details of existing and proposed capacities are given

in Table 2.

Table 2

Proposed and Existing Project Capacities

S.No Name of the Facility Existing** After Proposed Expansion

1 Secured Landfill * 1,20,000 MTPA 3,50,000 MTPA 2 Incinerator 1 15,000 MTPA 15,000 MTPA

Incinerator 2 15,000 MTPA 15,000 MTPA Incinerator 3 - 15,000 MTPA

3 Bio medical waste 150 TPM 250 TPM Incinerator 1X250 kg/hr 2X250 kg/hr Autoclave 2X600 lit/batch 2X3000 lit/batch Shredder 2X100 kg/hr 2X200 kg/hr

4 E-waste - 5400 MTPA 5 Plastic Recycling - 5000 MTPA 6 Paper Recycling - 30000 MTPA 7 Solvent Recovery - 9000 KLPA 8 Alternate Fuel & Raw Material Facility - 70 MTPD 9 MS Drum Recycling - 15 MTPD

*Stabilization & land fillable hazardous waste & incinerated ash at the rate of 20% of hazardous waste incinerated Existing incinerator capacity is 30,000 MTPA with two operating incinerators. One new incinerator is proposed with a capacity of 15,000 MTPA. With this the total capacity of the incinerator will become 45,000 MTPA. Autoclave from 1200 lit/batch to 6000 lit/batch. Shredder from 200 kg/hr to 400 kg/hr. ** CFO copy is attached as Annexure II.



Figure 2

Location Map



Figure 3

Site Layout



3.5 Project Description with Process Details (A schematic diagram/ flow chart showing

the project layout, components of the project etc. should be given)

3.5.1 Hazardous Waste Management Facility

Hazardous wastes handled in the project area are comprised of the following groups:

ETP sludges

Iron sludges

Still Bottom residues and process sludges

Spent Carbon

Evaporation salts/ other process salts

Incineration ash

lags

Asbestos and glass fibers

Spent catalysts and resins

Other hazardous wastes

Depending on the nature and characteristics of hazardous waste, pre-treatment is given

to the waste and disposal methods are as given below:

ETP sludges can go directly to landfill either directly or after stabilization.

Depending on the characteristics of the impurities, bottom residues, process

residues and other organic wastes including spent carbon can be sent for

incineration.

Incineration ash, slags, asbestos and glass fibers are essentially inorganic in nature

and can go to landfill directly or with simple stabilization techniques.

Spent catalysts and resins would have to be characterized on a case-by-case basis

to assess their nature and characteristics. However, the percentage of wastes

generated through these sources is likely to be very small as most of it is taken

back by the manufacturers.

Salts will have to be bagged and land filled.

Based on the above compiled information wastes have been classified by their pathway

of disposal:

Wastes going to direct landfill

Wastes that require stabilization prior to landfill

Wastes requiring storage until alternate economically viable techniques are made

available.

Wastes requiring incineration

The following general guidelines shall relate to daily activities associated with the

operations of TSDF:

The facility especially, incinerators will work round the clock.

The landfill will be filled progressively, cell wise and capped to minimize

infiltration of wastes.



The weigh bridge at the main entrance will record all movements and weights and

receive waste tracking receipt as required by the waste manifest system.

The standpipe forming part of the leachate collection system shall be checked

regularly for the presence of leachate. Once leachate is detected it shall be

regularly pumped out and transferred to the leachate treatment facility on-site.

The level of leachate in the standpipe shall not be allowed to rise above the level

of the leachate collection system.

Materials Safety Data Sheets (MSDS) for every chemical used or handled at the

landfill shall be provided on the premises.

Monitoring and auditing of the facility is performing on a periodic basis as per CFE

issued by CPCB.

Met-station shall be installed with continuous recording system.

A security system shall be maintained to avoid trespassing of public.

Once a waste is received at the TSDF, a sample of waste shall be collected, at the

sampling bay/temporary storage facility and shall undergo laboratory analysis

based on which its pathway of treatment/ disposal shall be determined.

A waste manifest system shall be developed in accordance with the requirement

of the regulatory agencies to cover the transportation of the waste to TSDF and to

provide for record of waste manifestation. The manifest system shall include

details of the waste generator, waste transporter, quantity of waste,

characteristics of waste, physical description, consistency of waste in terms of

physical state and waste category number as per HW (M&H) Rules, 2016 and

subsequent amendments

Each load of waste arriving at the facility shall be located properly and logged to

identify its pathway of treatment/ storage/ disposal.

An inventory shall be maintained at the arrival and departure dates of waste

loads in and out of the intractable waste storage area.

3.5.2 Waste Disposable Operations

3.5.2.1 Waste Stabilization

Waste stabilization is designed to convert industrial wastes in the form of liquids, semi-

solids or reactive solids into low leachable materials that can be deposited into a secure

landfill. The stabilization operation is carried out for all waste that requires this to

minimize their contaminant leaching potential. This will change the nature of these

wastes to a less hazardous category. Stabilization involves the immobilization of

leachable materials by fixation as non-reactive solids. The treated wastes shall be

assessed for compatibility with other wastes before being landfill and for compatibility

with the HDPE and the pipe network. Stabilization covers a number of mechanisms

including:

Immobilization / Chemical Fixation – Chemical binding of contaminants within a

cementing structure to reduce the mobility or leachability of the waste

Encapsulation – Entrapment of contaminant particles within a solid matrix.



Solidification – Conversion of slurries that do not readily de-water, into solids by

addition of adsorption agents.

Treatment facility utilizes a range of techniques and processes designed to change the

physical, chemical or biological characteristics of the waste. This may include changing

the composition so as to neutralize the waste, recover energy or natural resources from

the waste, render the waste non-hazardous or less hazardous, safer to transport, store,

dispose of or to reduce its volume. Typical reagents used, the infrastructure and

operations for waste stabilization unit are presented in Table 3.

Table 3

Reagents, infrastructure and operations for waste stabilization unit

Typical reagents Infrastructure Typical operations

Cement, lime, fly ash, bentonite clay, saw dust Sodium silicate solution would be used as an additive binding agent wherever required

Storage facilities for regents

Tanks/Drums for storage of reagents as required

Stabilization bins for mixing the wastes

Earth moving equipment for movement of wastes and mixing.

Place for curing the treated waste

Trucks for hauling the wastes.

Receiving the waste

Addition of reagents

Mixing

Curing

Analysis of the stabilized wastes

Approval by laboratory for disposal

Transfer of waste materials to the truck

Disposal in landfill

Application criteria: A study of the waste characteristics carried out as an integral part of

the project indicates the following applicability to the process described below in Table 4

Table 4

Stabilization Mechanism based on Waste Characteristics

Mechanism Applicability

Immobilization / Chemical Fixation

Heavy metal and metal plating sludge Copper-chromium-arsenic wood preservative

wastes Mercury waste Bag house dust Tannery wastes Spent catalysts and others

Solidification

Effluent treatment plant sludge Oil and paint sludge Bitumen wastes Textile industry sludge Wool scouring slurries

Encapsulation

Aluminum powder Asbestos Filer aids



3.5.2.2 Landfill

The landfill is designed and constructed as a secure facility to contain the waste material

and any leachate, which is formed by the entrapped moisture or by infiltration of rainfall.

To meet these requirements the base of the landfill has been designed as an engineered

liner constructed prior to the placement of waste and also an engineered capping over

the surface after completion of filling to minimize the infiltration of rainfall.

The base liner of the landfill containment system is a double composite liner with

synthetic geo-membrane plus clay. Adequate leachate collection system is incorporated

at the base to collect and remove the leachate. HDPE pipes embedded in drainage layers

of sand/ gravel and /or geonet/ geotextile. The composite liner (Secondary liner)

comprise of a 450 mm thick clay compacted to a permeability less than 10 –9 m/s and

above this a HDPE liner with permeability less than 10 –14 m/s above which a complete

drainage system is placed. Above the secondary base liner primary liner is placed

comprising of primarily clay layer and HDPE membrane which prevents infiltration into

the secondary layer. A leachate collection and removal system is also placed over the

primary liner to collect and remove any leachate generated by infiltration of precipitation

or by the moisture entrapped in the waste. This makes the secondary system to serve as

a leak detection system and an early warning of potential future liabilities to necessitate

action for remediation. Above the drainage system of the primary liner a geo-textile

filter is placed to act as a filter/ barrier between the waste and the drainage system. This

entire system would make the base liner a double composite liner meeting the national

laws.

Clay Liner consists of a varying proportions of hydrated aluminum silicates (e.g. kaolnite,

bentonite, illite and montmorillonite) which, when properly compacted, form a soil mass

with a very low hydraulic conductivity. The clay material for use as the liner at this landfill

is analyzed and permeability testing has been carried out to ascertain its low

permeability. Design permeability of the clay liner has been fixed at 10 –9 m/s and with

availability of clay liner; we are able to achieve better results than the design values.

Placement of clay liner is most critical in terms of its efficiency of functioning. Clay should

be placed in layers not exceeding 600 mm and compacted to attain the required

permeability. The clay layer after attaining the 450 mm thickness should be then checked

for its permeability. Further to this, clay shall be kept moist to ensure that it does not dry

up and cause cracks to the lining system. To ensure this we intend to keep the clay for

the purpose at +4% wet of optimum moisture content.

Synthetic liners consist of various synthetic flexible membrane liners have been

considered for use as the primary liner at the landfill. Both Poly-Vinyl Chloride (PVC) and

High – Density Polyethylene (HDPE) liners are generally suitable for this landfill. Tensile

strength is a fundamental design consideration in order to assess the ability of the liner

to resist uniaxial and biaxial strains, which occurs in the landfill. Another stress strain

consideration is the coefficient of thermal expansion.



Considering various membrane properties it is decided to use HDPE liner with

appropriate thickness as primary liner for the base of the landfill. HDPE was selected for

the following reasons:

Adequate strength to withstand mechanical strength during construction,

placement and operations.

Acceptable weathering performance.

Superior physical properties under chemical and environmental exposure to

wastes capability to withstand the seaming process.

The hydraulic conductivity of HDPE is of the order of 0.5 * 10 –16 m/sec, which is

effectively impermeable. Construction of the seam welding process shall be

subjected to strict QA/QC measures to ensure the integrity of the liner.

Secure landfill is the final placement area for land fillable hazardous wastes which are

treated or wastes does not require treatment. Waste directly or after treatment is

disposed in the landfill as per the laboratory advice. Waste spread in the landfill using

heavy earth machinery and then compacted using vibro compactor. At the end of the

landfill operations 10 – 15 cm soil cover will be placed as a daily cover. During rainy season

a flexible geo-membrane cover shall be placed over the uncapped area of the landfill

minimize infiltration of rainfall into the landfill; the rain water shall be diverted to join the

surface water drains. At the end of the total landfill operations the final capping shall be

done using composite liner with clay and synthetic geo-membrane, with vegetative soil

cover grass cover.

3.5.2.3 Leachate Collection/Treatment and Disposal

Leachate collection and removal is provided above the geo-membrane in two layers viz.,

the primary and the secondary liners. The primary liner shall serve as leachate collection

and removal system, while the secondary liner shall serve as leak detection system and a

signal of potential liabilities in terms of environmental pollution. Leachate is collected by

a network of lateral and header pipes embedded in a drainage layer, all of which shall

eventually drain into a leachate collection sump. The collected leachate is transferred to

a leachate treatment system.

The leachate collection system in an engineered landfill takes the form of an under-drain

beneath the waste material it is required to ensure there is no more than a limited head

of pressure above the base liner to cause leakage of liquid from the base of the landfill.

The design maximum pressure head in the landfill shall be limited to 300mm. the

detailed landfill cross section is given in Figure 4



Figure 4

Landfill Cross Section

Drainage is affected by a layer of about 300 mm thick of graded sand/gravel having a high

permeability. Within this layer a network of HDPE pipes are placed to collect leachate

and conduct it quickly to the collection sump for removal from landfill. The pipes are

typically perforated only over the upper half to allow the leachate to enter the pipe and

thereafter to be contained within the pipe network system. The layout of the pipe

network generally includes sufficient redundancy to ensure that if a blockage occurs

somewhere in the network the leachate simply backs-up a little then flows into the

system a little further up-gradient. Two layers of the leachate collection system shall be

provided one over the other. Slotting area of the pipe shall be done only on the top 120

portion of the pipe and to an extent of 100 cm2 per running meter of the pipe.

The key design features of the leachate collection system at the landfill comprise the

following:

A network of semi perforated HDPE pipes laid out directly over the primary and

secondary liners and graded towards the collection sump at no less that 2% slope, with a

slotting area of 100 cm2 per running meter of the pipe.

A drainage layer 300 mm thick of graded sand/gravel placed over the entire base of the

landfill, covering the pipe network.

A geo-textile placed over the primary liner serving the purpose of filter/ barrier between

the waste and the drainage media.



The pipe shall have sufficient strength to withstand the load imposed by the overlying

waste and the earth moving activities associated with the placement and the compaction

of the waste (Min 6 kg/ Sq.cm).

Drainage of Surface Runoff

Network of open channels shall be designed and constructed around the landfill to

intercept surface runoff of rainwater and divert it around the facility or collect it for the

use at the facility or for disposal. Storm water collected on the landfill site will be

directed to a first flush retention pond which shall be designed for a sufficient capacity to

cover a 1 in 100 years 10 minutes storm event. In particular the storm water system will

be designed and implemented to prevent surface runoff entering the landfill and thus

minimizing the leachate.

Wastewater Treatment Plant

Leachate collected from secured landfill and other wastewater including vehicle and

container washing, recycling plants are treated together (excluding domestic

wastewater). Leachate from the landfill and all other places of generation like storage

sheds, vehicle wash, and wheel wash etc., will be treated and recycled back into the

process. The dry residue from the solar evaporation pond / incinerator will be handled as

a solid waste and will be disposed in the landfill.

3.5.2.4 Incinerator

Incineration is an ultimate treatment process, applied to certain wastes that cannot be

recycled, reused or safely deposited into a landfill. It is a high temperature, thermal

destruction oxidation process in which hazardous wastes are converted in the presence

of oxygen in air into gases and incombustible solid residue. The gases are vented into the

atmosphere with cleaning as deemed necessary while the solid residue is sent to landfill

for disposal. The incinerator is facilitating the treatment of the following wastes.

Bio medical wastes

Spent solvents residues

Waste oils, oil emulsions and oil mixtures

Pesticide wastes

Refinery wastes

Pharmaceutical wastes

Phenolic wastes

Grease and wax wastes

Organic wastes containing halogens, sulphur, phosphorous or nitrogen

compounds

Solid materials contaminated with oils.

Organics with high calorific value



Wastes which are not suitable for disposal in the landfill and are candidates for

incineration are disposed in the incinerator. The primary objective of incinerator is to

destroy the wastes as completely as possible, to have end products (solids and gases)

that are harmless when released from the incinerator and to minimize the formation of

new hazardous organic compounds. To achieve the same the incinerator is designed with

a sufficient temperature, time and turbulence and in presence of excess air. The waste is

pre-processed to make it uniform in calorific value and maintain the norms of halogen

concentrations less than 1% and all.

Wastes are fed through cart dumper and ram feeder into the rotary kiln and the hot

gases are sent to the secondary combustion chamber. The residence time and the

desired temperatures are maintained at both primary and secondary combustion

chambers for complete combustion as per CPCB guidelines for hazardous and biomedical

waste incineration. The gases after complete combustion shall be sent to spray drier /

evaporative cooler for cooling followed by gas cleaning equipment.

The gases are passed through multi cyclones for removal of particulates. Then dry lime

and activated carbon are injected for neutralization of acidic gases and removal of

organic constituents if any. The flue gases then passed through bag filters for complete

removal particulates and then through wet alkaline scrubber for neutralization. The flue

gases after completely cleaned in all respects shall be sent out through a 40 m stack. The

ash generated during the combustion process and collected at the bottom of the hopper

will be send to landfill facility. The typical layout of the Incinerator is shown in Figure 5

below

Figure 5

Typical Layout of Incinerator



3.5.3 Bio Medical Waste

In order to regulate the environmental threat due to mismanagement of BMW, the

MoEFCC, Government of India, has notified the Bio-medical waste (Handling &

Management) Rules in 1998, which were amended in 2003, 2011 and 2016. But, all

Health Care Units (HCUs) cannot afford to set up treatment and disposal facilities due to

the high costs involved. Therefore the need for a centralized system for treatment was

felt. Accordingly, in September 2003, the Central Pollution Control Board enunciated the

“Guidelines for Common Bio-Medical Waste Treatment Facility” which in addition to

providing common facilities discouraged the setup of individual incineration facilities by

health care establishments (hospitals, clinics, laboratories etc).

3.5.3.1 Bio Medical Waste Categories as per BMW rules

According to the BMW Management Rules 2016, the waste is classified in to four

categories. A brief description of different categories of BMW, type and colour coding of

bags/container along with treatment and disposal are given in Table 5.

Table 5

Categories of Bio Medical Waste

Category Type of Waste Type of Bag or Container to be used

Treatment and Disposal options (as per Bio-Medical Waste

Management Rules, 2016)

Yellow (a)Human Anatomical Waste Human tissues, organs, body parts and fetus below the viability period (as per the Medical Termination of Pregnancy Act 1971, amended from time to time).

Yellow coloured non-

chlorinated plastic bags

Incineration or plasma pyrolysis or deep burial

(b)Animal Anatomical Waste Experimental animal carcasses, body parts, organs, tissues, including the waste generated from animals used in experiments or testing in veterinary hospitals or colleges or animal houses.

(c)Soiled Waste Items contaminated with blood, body fluids like dressings, plaster casts, cotton swabs and bags containing residual or discarded blood and blood components.

Incineration deep burial or plasma pyrolysis or in absence of above facilities, autoclaving or micro-waving/ hydroclaving followed by shredding or mutilation or combination of sterilization and shredding. Treated waste to be sent for energy recovery.

(d)Expired or Discarded Medicines Pharmaceutical waste Like antibiotics, cytotoxic drugs including all items contaminated with cytotoxic drugs along with glass or plastic ampoules, vials etc

Yellow coloured non-chlorinated plastic bags containers

Expired cytotoxic drugs and items contaminated with cytotoxic drugs to be returned back to the manufacturer or supplier for incineration at temperature>12000C or to common bio-medical waste treatment facility or hazardous waste treatment, storage and disposal facility for incineration at >12000C or encapsulation or plasma pyrolysis at >12000C. All other discarded medicines shall be either sent back to manufacturer or disposed by



incineration.

(e)Chemical Waste Chemicals used in production of biological and used or discarded disinfectants.

Yellow coloured containers or non-chlorinated plastic bags

Disposed of by incineration or plasma pyrolysis or encapsulation in hazardous waste treatment, storage and disposal facility.

(f)Chemical Liquid Waste: Liquid waste generated due to use of chemicals in production of biological and used or discarded disinfectants, Silver X-ray film developing liquid, discarded Formalin, infected secretions, aspirated body fluids, liquid from laboratories and floor washings, cleaning, house-keeping and disinfecting activities etc.

Separate collection system leading to effluent treatment system

After resource recovery, the chemical liquid waste shall be pre-treated before mixing with other wastewater. The combined discharge shall conform to the discharge norms

(g)Discarded linen, mattresses, beddings contaminated with blood or body fluid.

Non-chlorinated yellow plastic bags or suitable packing material

Non- chlorinated chemical disinfection followed by incineration or plasma pyrolysis or for energy recovery. In absence of above facilities, shredding or mutilation or combination of sterilization and shredding. Treated waste to be sent for energy recovery or incineration or plasma pyrolysis.

(h)Microbiology, Biotechnology and other clinical laboratory waste: Blood bags Laboratory cultures, stocks or specimens of microorganisms, live or attenuated vaccines, human and animal cell cultures used in research, industrial laboratories, production of biological, residual toxins, dishes and devices used for cultures.

Autoclave safe plastic bags or containers

Pre-treat to sterilize with non- chlorinated chemicals on-site as per National AIDS Control Organisation or World Health Organisation guidelines thereafter for incineration.

Red Contaminated Waste (Recyclable) (a) Wastes generated from disposable items such as tubing, bottles, intravenous tubes and sets, catheters, urine bags, syringes (without needles and fixed needle syringes) and vacationers with their needles cut) and gloves.

Red coloured non-chlorinated plastic bags or containers

Autoclaving or micro-waving/ hydroclaving followed by shredding or mutilation or combination of sterilization and shredding. Treated waste to be sent to registered or authorized recyclers or for energy recovery or plastics to diesel or fuel oil or for road making, whichever is possible. Plastic waste should not be sent to landfill sites.

White (Translucent)

Waste sharps including Metals: Needles, syringes with fixed needles, needles from needle tip cutter or burner, scalpels, blades, or any other contaminated sharp object that may cause puncture and cuts. This includes both used, discarded and Contaminated metal sharps

Puncture proof, Leak proof, tamper proof containers

Autoclaving or dry heat sterilization followed by shredding or mutilation or encapsulation in metal container or cement concrete, combination of shredding cum autoclaving, and sent for final disposal to iron foundries (having consent to operate from the State Pollution Control Boards or Pollution Control Committees) or sanitary landfill or designated concrete waste sharp pit.



Blue (a)Glassware: Broken or discarded and contaminated glass including medicine vials and ampoules except those contaminated with cytotoxic wastes.

Cardboard boxes with blue colored marking

Disinfection (by soaking the washed glass waste after cleaning with detergent and sodium hypochlorite treatment) or through autoclaving or microwaving or hydroclaving and then sent for recycling.

(b)Metallic Body Implants Cardboard boxes with blue colored marking

3.5.3.2 Collection and Transportation

Collection and transportation is done in accordance with the BMW Management Rules

2016. In brief, bio medical waste is collected from each healthcare establishment on a

regular basis. It is the duty of the operator of common bio-medical waste treatment

facilities (CBMWTF) to transport BMW from the premises of HCUs to any offsite

CBMWTF. Only the vehicles complying as per the existing rules carry secured load, clearly

marked with the name and address of the waste carrier and bio-hazard sign. BMW is

transported through designated route, with colour coded, covered and leak proof trolleys

to avoid spillage on road.

3.5.3.3 Bio Medical Waste Incineration

A separate incinerator is used for incineration of all incinerable Bio-medical waste coming

to the facility.

3.5.3.4 Autoclave

The primary purpose of autoclave is to sterilize/disinfect the waste with steam. MoEFCC

has stipulated a temperature of 120oC with 15 psi pressure and 60 min duration to

ensure distribution of temperature. At this temperature and pressure, microorganisms

are completely destroyed and thus render the wastes infection free. The dis-infected

waste shall then be segregated into HDPE, PP, rubber, latex, glass and metal. The

segregated materials are then shredded completing the process of disinfection and

ensuring non-recycling of the waste materials for medical / food grade purposes. All the

process control conditions are as per the applicable bio medical rules.

Autoclave Features

A vacuum type (programmable) autoclave which can operate at all the specifications

mentioned by MoEFCC is being used. The autoclave have continuous and automatic

recording of temperature, pressure, date, time and batch of loading. Every batch is

monitored with a strip chart recorder and once in a month the spore validation test

and/or spore monitoring is done. The Layout of typical autoclave process is given in

Figure 6



Figure 6

Layout of Autoclave Sterilization Process

3.5.4 E Waste Recycling

The assessment of E-waste recycling sector in India indicates that E-waste trade starts

from formal dismantling sector and moves to informal recycling sector. There are no

large scale organized e-waste recycling facilities in India at present except a few in some

states of India. Hence, this will be an opportunity to serve the industries by handling their

E-waste. The main objective of the proposed E-Waste facility is given below.

To provide safe and secured destruction services at project site to ensure

intellectual property assurance.

To provide innovative and pollution-free technology for recycling of E-waste.

To provide environmental management system and solutions.

To recover up to 99% of total waste received

To enhance customer service through online account access.

To conserve natural resource & ensuring working towards global warming

The proposed project consists of the following facilities

Fully integrated state- of - art E-Waste management facility

World class security systems

Certified, safe and secured destruction services

Comprehensive EHS practices

Logistics, warehousing facility

Highly skilled manpower

Methodology

The methodology proposed to be followed at the E-Waste facility is as follows.



Upon client’s request, project management shall arrange a suitable and secured

transport to collect the material from his premises.

Delivery order will be issued by client prior to collection from their premises. If

desired, the collected material shall be weighed at client’s premises using their

own weighing machine and witnessed by both the parties.

The transportation of E-waste shall be carried out as per the manifest system

whereby the transporter shall be required to carry a document (three copies)

prepared by the sender as per Form-6, EWM Rules 2016.

Collected material has to be provided in good packaging condition and thereafter

will be transported to the facility.

After inspection by project security guard, material shall be weighed at site

weighbridge to determine the gross weight of the material and will then be sent

to its warehouse for acceptance.

Goods Receive Note (GRN) for the gross weight will be issued upon receiving the

material at the warehouse.

Material will then be sent for dismantling section under IDO (Internal Delivery

Order) for dismantling. If required, destruction process can be witnessed by

client.

Upon data destruction, official destruction certificate will be issued to client for

records. Finally the dismantled material will then be sent to suitable recycling

process.

Process Description

The process involved in proposed integrated E Waste recycling management facility is

basically physical destruction and shredding to downsize and recovery of plastics, glass,

metals and other valuable products. The steps of proposed process are described in

following paragraphs and the process flow chart is given in Figure 7.

The e-waste received from generator shall be stored at earmarked covered shed

having concrete floor and leak proof roof. Wooden or plastic pallets shall be

provided to store the waste.

Waste which may contain mainly electronic and electrical material like monitors

of computer or TV’s, shall be shifted to manual dismantling section in hand

trolleys

The reusable/salable components will be sold after refurbishment.

A set of 8 to 10 no. of work stations are proposed with a suction hood for any

dust particle coming out of the dismantling process. A team of experts in

dismantling shall be deputed for dismantling purpose with all the required tools

and tackles. The tools and tackles shall be identified with best available brand to

ensure optimization in working and to avoid small accidents in the process. The

employees at this section shall be provided with all the required PPE’s i.e. apron,

safety shoes, gloves, dust mask etc. Fire extinguishers shall be provided in the

working area.



The team deputed shall dismantle all the waste articles like computer CPU box,

hard drive, CD ROM, cables, PCB’s etc. and monitor into back cover and picture

tube. The hard drive, PCB’s shall be further dismantled into components attached

and naked PCB’s.

The dismantled PCB’s shall be sent for shredding followed by crushing and

pulverizing. The product shall be powder of PCB from which metal and nonmetal

part which shall be segregated by physical process. Both the products shall be

stored in bags for disposal for recovery (metal part) and for making of toys and

monuments (nonmetal part). In case the nonmetal part fails to be recycled, the

same shall be disposed into incinerator as this consists of residue with high C.V.

The dismantled picture tube shall send to Cathode Ray Tube (CRT) cutting m/c,

which is a closed chamber attached with a hood connected to cyclone and bag

house.

The CRT shall be put into the control panel connected automatic CRT cutting

frame. The CRT shall be cut into two pieces i.e. front glass and funnel glass.

The glass which is free from all coating etc. shall be crushed further and stored in

bags to be dispatched for recycling. The components removed from PCBs shall be

segregated and stored in bags for further disposal and/or reuse.

The ferrous material i.e. cabinet, body of monitor etc. shall be baled and disposed

for recycling

Plastic from cabinet, monitor shall be shredded in the shredder and sold out for

recycling to authorized recyclers.

The waste generated from above process shall be stored at earmarked area and

not allow the waste to be exposed to the environment.



Figure 7

E Waste Flow Chart

3.5.5 Recycling Facilities

The recycling facilities proposed for the site are

Spent Solvent recovery

Alternative fuel and raw material facility

Waste plastic recycling

Waste paper recycling

MS drum recycling

Plastics

Collection

Storage

Data Destruction

Segregation

Dismantling Testing Storage

Disposal

Shredding

Delaminating

Sale to

Recyclers

Ferrous Metal

Separator

CRT

Store

Sale to Recyclers

PCB & Components

Precious Metals

Sieving

Density Separator

Copper Lead Aluminum

Sale to

Recyclers

Sale to

Recyclers Sale to

Recyclers

Recyclables

Refurbishing Sale to users



3.5.5.1 Solvent Recovery

Spent solvents are recovered using a distillation methodology. A few solvents proposed

to be separated /distilled initially are Isopropyl alcohol, Butanol, Dimethyl formamide,

Toluene and Ortho dichloro benzene

Storage of spent solvents

The waste solvent shall be received in drums (MS/Plastic) and shall be stored in

shed which will be provided with garland drain, fire hydrant system, lined floor

etc.

The drums shall be stacked as per the best practices. The leakages shall be

avoided at any point of time.

A separate storage shed is proposed adjacent to facility to store the solvent

drums.

The stacking of drums shall be in the manner that mixing of solvent drums shall

be avoided at maximum extent.

Recovery of spent solvents

Distillation process is suitable for the recovery of most of the spent solvents which can be

either batch or continuous operation. However, it is proposed to adopt batch process in

the proposed facility. Flow chart for Spent Solvent recovery is shown in Figure 8.

Figure 8

Flow Chart of Spent Solvent Recovery

Incinerator

Cooling Tower

Chiller

Main Product

receiver

Solvent received in

Drums

Pre - Treatment

( Adjusting pH,

removal of SS etc.)

Pump

Feed Tank

Pump

Agitated Vessel

Sludge

Column

Condenser

Cooler

Trail product receiver

Collection Tank Collection Tank

Pump

Feed Tank/

Incinerator

Pump

Drums



Process Description

The process involves pre-treatment, followed by neutralization and separation of spent

solvent feed mixture in a reactor. After layer separation, the spent solvent mixture will be

sent to distillation connected to distillation column. The solvent mixture is heated by

steam and the distillation column will be under total reflux for a specific period.

Fractionation of solvent takes place solvent / water as the case may be are separated

initially under atmospheric pressure and later under vacuum (if required). Distilled

solvents are analyzed, stored and recycled, liquid effluent which is mostly condensate will

be recycled back into system and solid residue sent for incineration / landfill. Steam for

heating will be donor from the boiler.

3.5.5.2 Alternative Fuel and Raw Material Facility

Alternative fuel platforms will be developed within the site as below:

“S” Type

Alternative fuel preparation facility

“L”Type

Alternative fuel preparation Facility

‘L’ Type Alternative Fuels Area

‘L’ type alternative fuels are basically liquid type incinerable waste which are more than

2500 Kcal.

Common neutralization tank to maintain pH level 7

25 KL mixing tank with cooling coil and external jacket to control the heat for exothermic

liquid waste

25 KL mixing tank for the non-exothermic liquid waste

Agitator set up made by stainless steel

Pump

‘S’ Type Alternative Fuels Area:

‘S’ type alternative fuels are basically solid type incinerable waste which are more than

2500 Kcal

Common neutralization tank to maintain pH level 7

Mixing pit of 5 x 5 m

Jaw mixer for premixing of the solid and semisolid Waste.

Blender

Solid blend is prepared through mixing in an appropriate quantity of solid/ semi solid

waste with binders. The first step of preparing solid blend is to selection of waste. The

segregation of waste according to their pH & calorific value helps in it. Source materials

for solid substitute fuel include paint sludge, oily filter cake, spent carbon, organic waste,

tarry waste, biomass, resin, distillation residues, grease, ETP sludge, and alumina sludge

etc.

Assortment of waste is done according blending norms. A general waste selection criteria

for high calorific value fuel is Low moisture content, high LOI & TOC, High calorific value,



good compressibility, less ash content, non-toxic, less pollutant, sustainable combustion.

Schematic diagram for the alternative fuel recovery is shown in Figure 9.

Figure 9

Alternative Fuel and Raw Material Facility

3.5.5.3 Waste Plastic Recycling

A plastic recycling plant uses several steps to turn plastic trash into recycled plastic. The

process flow sheet of waste plastic recycling is given in Figure 10. Following is a brief

explanation of recycling.

Segregation: The plastic shall be segregated manually into two major components

i.e. dirty plastic not suitable for granulation and plastic can be used for

granulation.

Mechanized Cleaning: Mechanized cleaning is done with some cleaning agents to

remove any types of hazardous substances in the drum. The cleaned drums can

be re-used or further processing based on the requirement.

Chopping: The washed drums are chopped into flakes for further processing.

Drying: The plastic flakes are dried in a tumble dryer.

Melting: The dried flakes are fed into an extruder, where heat and pressure melt

the plastic. Different types of plastics melt at different temperatures.

Filtering: The molten plastic is forced through a fine screen to remove any

contaminants that slipped through the washing process. The molten plastic is

then formed into strands

Pelletizing: The strands are cooled in water and chopped into uniform pellets.

Manufacturing companies buy them from recyclers to make new products.



Was te P las tic

Was te P las tic

S torag eS torag e

S eg reg ationS eg reg ation

Was hingWas hing

DryingDrying

G ranulationG ranulation

P las tic G ranules

P las tic G ranules

Dirty P las tic for P yrolys is

Dirty P las tic for P yrolys isDus t & dirtDus t & dirt

Exit Gases

Inert waste

Figure 10

Process flow sheet of plastic recycling

3.5.5.4 Waste Paper Recycling

Waste paper recycling is the process of recovering waste paper and remaking it into new

paper products. There are three categories of paper that can be used as feedstock for

making recycled paper:

Mill broke: Paper trimmings and other paper scrap from the manufacture of

paper, and is recycled internally in a paper mill.

Pre-consumer waste: Material which left the paper mill but discarded before it

was ready for consumer use.

Post-consumer waste: Post-consumer waste are the material discarded after

consumer use such as old magazines, old newspaper, office wastes, old telephone

directories, residential mixed paper, industrial packaging, waste multi-wall

cement paper bags.

3.5.5.5 Processing of waste paper for recycling

Waste paper recycling facility focuses on recovering waste paper and sending to paper

manufacturing industry. It is proposed to carryout waste paper processing in the

following steps:

Waste Paper Collection: Collection of waste paper material shall be done through

special color coded recycling bins (segregated directly at Generator’s premises).

However, at some locations all kinds of papers may be collected in a single bin.

Manual Segregation: The waste paper (newspaper, office stationary, packaging

paper, card boards) collected is segregated according to variety/thickness of

paper.

Compaction and Baling: The waste paper is manually fed to the Baling press. It is

Equipment which utilizes Hydraulic pressure on the loose paper in an enclosed



chamber to compact them into Bales. The bale weight can be varied from 40 – 60

kg, making them very convenient to handle manually.

Transportation: Transportation of bales to paper mills and other paper related

product manufacturing units.

The schematic of waste paper recycling is given in Figure 11 below.

Figure 11

Schematic of Wastepaper Recycling

3.5.5.6 MS /HDPE/Plastic drums recycling

Different types of used drums (MS, HDPE, Plastic) in various industries and commercial

establishments after reaching their end life will be cleaned for any waste present and

segregated as per the type of the material, cut into small pieces and sent for further

recycling process for making end use products. Recycling of various scrap materials helps

in reducing the consumption of fresh raw materials and prevents excess consumption of

power and energy.

Metal Recovery Process

Collection of metal drums

Cleaning of the drums

Shredding

Baling

Storage of baled material

If the waste is opaque, the drums with waste shall be pyrolysed.

Selling it for further processing.

3.6 Raw Material Required along with Estimated Quantity, likely Source, Marketing

Area of Final Products, Mode of Transport of Raw Material and Finished Product.

The proposed project is a treatment, storage and disposal facility of hazardous waste

generated from different types of industries located in MIDC Taloja and other parts of

the Maharashtra. Hence there are no major raw materials required for the proposed

activities. However, small quantities of chemicals such as cement, lime, fly ash, bentonite

clay, saw dust and others will be required for waste stabilization which will be procured

form local market as per the requirement.



3.7 Resource Optimization/Recycling and Reuse Envisaged in the Project, if any, should

be briefly outlined.

The proposed facilities are mainly based on the concept of material recovery and reuse

from the different types of waste collected from various sources. The recyclable

materials such as paper, plastic, e-waste, etc. will be given to authorized agencies for

further use.

3.8 Availability of Water its Source, Energy/Power Requirement and Source should be

given

The source of total water requirement of the existing and proposed expansion is MIDC.

The detailed breakup required for various activities is given in Table 6. The power

required for the existing and proposed expansion activities will be sourced from MSEDCL.

The details of power requirement are given in Table 7.

Table 6

Water Requirement Details (KLD)

Description

Existing

Proposed Total

Solvent Recover

y

Plastic Recyclin

g

Paper Recyclin

g

Drum Decontamination

BMW Incinerator

Domestic 10 5 4 4 2 0 1 26

Process 251 50 2 0 2 15 126 446

Floor Washing

0 2 0 2 0 0 4

Cooling 0 1 0 0 0 5 6

Gardening 100 0 0 0 0 0 0 100

Total 361 55 9 4 6 15 132 582

Table 7

Power Requirement Details (kVA)

Description Power Requirement

Existing Power Requirement Plant & Amenities 500

Proposed Power Requirement

Plastic Recycling 300

Paper Recycling 50

E waste 350

Solvent Recovery Plant 300

AFRF 150

MS Drum Recycling plant 100

Bio medical 100

Landfill 50

Incinerator 320

Total 2220

Maximum Demand Sanctioned 500

Proposed 1720



DG set Existing 875

Proposed 500

Transformer Existing 910

Proposed 2000

3.9 Quantity of Wastes to be Generated (Liquid and Solid) and Scheme for their

Management/Disposal.

The quantities of waste water generated along with water requirement are given in Table

8. The waste water will be treated in ETP/LTP, since the project adopts the concept of

“Zero discharge facility”, the treated water will be reused within the facility.

Table 8

Water and Wastewater Details (KLD)

S.No Description Water requirement

Wastewater generation

Remarks

1 Domestic 26 23 Septic tank followed by soak pit

2 Process 446 22 Treated in SEP and will be reused for dust suppression and spraying on landfill/ scrubbing liquid

3 Floor washing 4 0

4 Cooling 6 0 Makeup water

5 Leachate from landfill

0 69 Incineration/forced evaporation/spraying on landfill

6 Greenbelt 100 0

Total 582 114

Note: Process waste water includes E-waste – 0.5 KLD, Solvent recovery – 8 KLD, plastic recycling – 3 KLD, drum decontamination – 2 KLD

Leachate Collection/ Treatment and Disposal

Leachate collection and removal is provided above the geo-membrane in two layers viz.

the primary and the secondary liner. The primary liner serves as leachate collection and

removal system, while the secondary liner serves as leak detection system and a signal of

potential liabilities in terms of environmental pollution.

Leachate is collected by a network of lateral and header pipes embedded in a drainage

layer, all of which eventually drain into a leachate collection sump. The collected leachate

is transferred to a leachate treatment system. Leachate, thus collected is transferred to

the forced evaporation system and the residue after decanting is subjected back to the

land-filling process.

The proposed project is an ICHWTSDF, having major activity of treatment, storage and

disposal of various wastes. In the proposed project the major activity in which the solid

waste generated is from incineration of hazardous waste. The details of the waste

generated and its disposal methods proposed is given in Table 9.



Table 9

Details of Solid Waste Generated

S.No Description Existing Proposed Total Remarks

1 Ash from incinerator

(Hazardous waste)

1500 MTPA 750 MTPA 2250 MTPA Landfill

2 Ash from incinerator (BMW) 64 MTPA 98 MTPA 162 MTPA Landfill

3 Waste oil from DG set 140 LPA 250 LPA 390 LPA Incinerator

4 Municipal solid waste 54 kg/day 64 kg/day 118 kg/day Nearest

municipal bin

5 Solvent sludge - 50 KLPA 50 KLPA Incinerator

3.10 Schematic Representation of the Feasibility Drawing for EIA Purpose

For development of proposed project site screening, pre-feasibility report, environmental

impact assessment (EIA) and environmental management plan (EMP) studies, etc. for

obtaining environmental clearance and consent for establishment from statutory

authorities are the main process.

Submission of Form-1, Prefeasibility report, draft ToR for appraisal to concerned

authority (MoEFCC)

Obtaining official Terms of Reference from MoEFCC

Base data collection for one season, EIA report preparation compliance with ToR

Submission of final EIA report including public hearing minutes and action plan to

MoEFCC

Obtaining EC from MoEFCC

Submission of CFE application to SPCB

Obtaining CFE from SPCB



4. Site Analysis

4.1 Connectivity

The site is well connected with all the transportation facilities from the nearby places.

Taloja bypass road is located at a distance of 1.2 km (E) and NH 4 is located at a distance

of 2.8 km (W) from the project site. The nearest railway station is Taloja Panchnand

railway station is at a distance approximately 2.7 km (W). The nearest airport is

Chatrapati Shivaji International airport, 49 km (W) away from the site.

4.2 Land form, Land Use and Land Ownership

The proposed project is an expansion of the existing ICHWTSDF facility. The new unit

operations proposed are, facilities for the management of E-waste, recycling of spent

solvent, paper and plastic as well as alternative fuel and raw material recycling. The land

use is meant for treatment, storage and disposal of hazardous waste.

4.3 Topography (Along with Map)

Topography of the site is highly even and undulating. The topographical map of the study

area is shown in Figure 12.

4.4 Existing Land Use Pattern (agriculture, non-agriculture, forest, water bodies

(including area under CRZ)), shortest distances from the periphery of the project to

periphery of the forests, national park, wildlife sanctuary, eco sensitive areas, water

bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a

copy of the gazette notification should be given.

The existing facility is located within the MIDC industrial area. The shortest distance from

the project site to eco sensitive areas is given below.

Reserved and Protected Forest – 4.3 km (E), Reserved Forest – 5.1 km (W), Reserved

Forest – 13 km (S), Reserved Forest – 13.1 km (SE) these are few reserved and protected

forests which are present within the study area. There is one mangrove forest located at

10.3 km (NW) and Karnala Bird Sanctuary located at 13 km (S). Bava Malang Nadi –

Adjacent (W), Taloje River – 0.7 km (S), Kasadi River – 3.4 km (S), Lendi River – 8.6 km

(SE), Panvel Creek – 9.6 km (SW), Ulhas River – 12.6 km (NW) and Thane Creek – 13.4 km

(W) are water bodies existing within the study area.

The site is located within the MIDC notified industrial area and the land possession

document dated 24.12.2001 issued by MIDC (Govt. of Maharashtra undertaking) is

attached as Annexure I.



Figure 12

Topographical Map of Site – 10 km Buffer



4.5 Existing Infrastructure

The existing facility has a secured landfill and two incineration plants. Supporting to these

administration buildings consists of relative process departments are available. A well-

established laboratory with NABL accreditation and MoEFCC approval exists to carry out

comprehensive analysis of hazardous wastes.

The site is also well-equipped with all the infrastructure facilities like security room, R&D

building, vehicle maintenance shed, weigh bridge, electrical utility area, toilet block, etc.,

present within the existing ICHWTSDF and the same facilities will be provided within the

block proposed for the establishment of the recycling facilities. The site photographs are

shown in Figure 13.

Figure 13

Site Photographs



4.6 Soil Classification

The district has three physiographic divisions i.e. (i) Coastal zone in west covers about

20% percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting

of fertile land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude

and covered with forest.

The soils in the district are formed from the Deccan Trap which is predominating rock

formation with small out crops of Laterite at a few places in the Poladpur taluka and

Matheran hill. The soils are grouped as Saline, Coastal Alluvium and Laterite as per the

location and topographical situation.

4.7 Climatic Data from Secondary Sources

The climatological data of the proposed project available from secondary sources like

IMD (Mumbai) is given in Table 10.

Table 10

Meteorological Data (IMD)

Mumbai (Colaba), Lat:180 54’ N & Lon:720 49’ E, MSL 11 m, Distance from proposed site 28 km (W)

Month Mean Temperature 0C Humidity % Rainfall Mean

Wind

speed

kmph

Pre dominant

direction Min Max Highest Lowest 8.30

Hrs

17.30

Hrs

Monthly

mm

No of

rainy

days 1st 2nd

Jan 19.3 30.2 34.4 16 78 62 0.9 0.1 4.6 NW N

Feb 20.2 30.2 34.9 17.1 76 62 0.2 0 5.4 NW N

Mar 22.7 31.5 35.8 20 78 63 0.4 0.1 5.7 NW N

Apr 25 32.7 35.1 22.9 77 66 0.5 0.1 5.7 NW W

May 27.1 33.8 35.4 25 76 68 20.2 0.7 6 NW W

Jun 26.5 32.2 35 23.3 83 77 530.2 13.8 7.4 W SW

Jul 25.4 30 32.1 23.3 89 85 711.6 21.2 9 W SW

Aug 25.1 29.7 31.7 23.3 89 84 493.8 19.7 8.5 W NW

Sep 25 30.6 32.7 23.1 89 90 330.4 13.4 5.1 W NW

Oct 24.8 33 36.4 22.8 84 72 78.4 3.4 4.3 NW E

Nov 23.2 33.5 36.3 20.7 78 65 14.9 0.5 4.2 NW NE

Dec 20.9 32.2 35.3 17.7 77 63 2.6 0.1 4.2 NW NE

Source: GOI, Ministry of Earth Sciences, IMD, Climatological Tables - 1981-2010

4.8 Social Infrastructure Available

Social infrastructure facilities like Hospital, School, College, Banks, etc., are available in

nearby villages. Taloja and Navi Mumbai are the major developed and nearby urban

areas having all required social infrastructure.



5. Planning Brief

5.1 Planning Concept (Type of Industries, Facilities, transportation, etc.) Town and

Country Planning/ Development Authority Classification

The proposed project is an expansion of the existing ICHWTSDF. The new unit operations

proposed are- facilities for the management of E-waste, recovery of spent solvents,

recycling of paper, plastic as well as alternative fuel and raw material recycling. The

project area is within the MIDC Taloja industrial area.

5.2 Population Projection

There will be an influx of 200 to 300 people to the area due to the proposed project and

majority of them will be from the nearby villages.

5.3 Land Use Planning (Breakup along with Greenbelt etc.).

The total land area of the proposed project is 39.40 Ha (97.35 Acres). The detailed land

breakup of total area is given in Table 11.

Table 11

Land Breakup

Description Land Area

Acres Sq.m Ha

Facility Area 55.60 225005.80 22.50

Roads 9.63 38974.17 3.90

Greenbelt 32.12 130020.00 13.00

Total 97.35 393999.97 39.40

Note: The land allotted by MIDC as per possession document is 39.40 Ha (97.35 Acres)

5.4 Assessment of Infrastructure Demand (Physical & Social)

There will be a minimum influx of people to the area due to the proposed project, as the

major manpower will be employed from the nearby villages. Hence the infrastructure

available is sufficient to accommodate the demand.

5.5 Amenities/Facilities

All the amenities/facilities like security room, administrative building, R&D building,

vehicle maintenance shed, weigh bridge, electrical utility area, toilet block, etc., are

present within the existing ICHWTSDF and the same facilities will be provided within the

block proposed for the establishment of the recycling facilities.



6. Proposed Infrastructure

6.1 Industrial Area (Processing Area)

The existing ICHWTSDF is operational since 2002, which is a part of the MIDC industrial

area at Taloja. The site is established with all facilities/amenities and supporting

infrastructure which will be used for the proposed facilities also and additional

infrastructure if any required will be developed after obtaining all the necessary

approvals from the statutory authorities.

6.2 Residential area (Non-processing Area)

No residential area is proposed within the project site

6.3 Greenbelt

A 10m wide greenbelt will be developed all around the boundary of the proposed site

and the greenbelt will be developed as per MoEFCC guidelines. The list of existing plants

of greenbelt is given in Table 12.

Table 12

List of Existing Plants

S.No Botanical Name Family Name Common Name No.of Trees

1 Azadirachta indica Meliaceae Neem 200

2 Bambusa vulgaris Poaceae Bamboo 30

3 Borassus flabellifer Arecaceae Palmyra Palm 10

4 Catharanthus roseus Apocynaceae Periwinkle 5

5 Cycas revoluta Cycadaceae Sago palm 50

6 Delonix regia Caesalpiniaceae Flame Tree 200

7 Hibiscus rosa-sinensis Malvaceae China Rose 300

8 Jasminum sambac Oleaceae Arabian Jasmine 50

9 Madhuca longifolia Sapotaceae Indian Butter Tree 3

10 Magnolia champaca Magnoliaceae Champa 10

11 Ocimum tenuiflorum Lamiaceae Holy basil 25

12 Plumeria obtusa Apocynaceae White Frangipani 3

13 Rosa x damascena Rosaceae Damask Rose 100

14 Roystonea regia Arecaceae Royal palm 250

Total 1236

6.4 Social Infrastructure

Social infrastructure facilities like hospital, school, college, banks, etc., are available in

nearby villages. Taloja and Navi Mumbai are the major developed and nearby urban

areas having all required social infrastructure.



6.5 Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.)

The site is well connected with all the transportation facilities from the nearby places.

Taloja bypass road is located at a distance of 1.2 km (E) and NH 4 is located at a distance

of 2.8 km (W) from the project site. The nearest railway station is Taloje Panchnand

railway station is at a distance of approximately 2.7 km (W). The nearest airport is

Chatrapati Shivaji International airport, 49 km (W) away from the site.

6.6 Drinking Water Management (Source & Supply of Water)

The drinking water required for the proposed project will be sourced from MIDC

6.7 Sewerage System

The domestic waste water generated from the proposed project will be sent to septic

tank followed by soak pit. The process water will be treated and reused for various other

uses.

6.8 Industrial Waste Management

The proposed project is an ICHWTSDF, having major activity of treatment, storage and

disposal of various wastes. In the proposed project the major activity in which the solid

waste generated is from incineration of hazardous waste. The industrial waste (fly ash)

generated is disposed in landfill as daily soil cover. Used oil from DG sets and solvent

residues from solvent recovery plant is disposed into the incinerator.

6.9 Solid waste management

Domestic solid waste generated from the existing and proposed activities will be sent to

the nearest municipal bin for further disposal.

6.10 Power requirement & supply/ source.

The power required for the existing and proposed expansion activities will be sourced

from MSEDCL. DG sets will be used for emergency power backup during power failure.



7. Rehabilitation and Resettlement

(R&R) Plan

7.1 Policy to be adopted (Central/State) in respect of the project affected persons

including home oustees and landless laborers (a brief outline to be given)

The proposed project is developing within the existing ICHWTSDF which is part of MIDC

industrial area and hence there is no rehabilitation and resettlement is envisaged.



8. Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (Time schedule for

the project should be given).

As per initial estimate around 6 months is required for implementation of the project

considering the starting date i.e. from the date of receiving all the statutory clearances

from concerned departments of state and central government.

8.2 Estimated project cost along with analysis in terms of economic viability of the

project.

As per the initial estimate the cost of the project works out to be around Rs.40.05 Crores

(Existing project cost is Rs.155.82 Crores). After examining the environmental,

commercial and financial feasibility it may be inferred that the project will have a positive

impact. The detailed cost breakup of the proposed expansion is given in Table 13.

Table 13

Detailed Project Cost Breakup

S. No. Project Name Estimated Cost in Rs.Lakhs

1 Recycling of MS Drum/ HDPE 25.00

2 Recycling facility – Waste Paper 220.00

3 Recycling facility – Spent Solvent 1100.00

4 Recycling facility – Waste Plastic 160.00

5 Alternate Fuel and Raw Material 200.00

6 Recycling Facility – E – waste 250.00

7 BMW Incinerator 200.00

8 Incinerator 1400.00

9 EMP cost 350.00

10 Miscellaneous 100.00

Total Amount 4005.00

Note: CSR budget allocated is Rs. 20 lakhs (not included in the project cost)



9. Analysis of Proposal

(Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefit to the local

people including tribal population if any, in the area.

The industries and commercial establishments etc. which generates hazardous waste

cannot afford to treat and dispose scientifically, meeting MoEFCC guidelines. Hence an

integrated common hazardous waste treatment and disposal facility nearer to the source

of generation will solve the many environmental related issues. Hence the proposed

project will be a beneficial to the generators and to the country.

Further, the proposed project will have a positive impact on the people and its

surroundings. Due to the project, employment options to the locals will be increased

which improve their livelihood.



Site Photographs

pre feasibility report of - welcome to...

Documents