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.

28

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