PRE-FEASIBILITY REPORT - Welcome to Environment€¦ · PRE-FEASIBILITY REPORT. ... Above Axis...

[Vide EIA Notification dated 14th

PPRREE--FFEEAASSIIBBIILLIITTYY RREEPPOORRTT

September, 2006 & Subsequent Amendments]

For

PROPOSED EXPANSI ON AND ADDI TI ON OF NEW PRODUCTS

FOR MANUFACTURI NG OF CHEMI CAL FERTI LI ZERS

By

M/s. COROMANDEL INTERNATIONAL LIMITED

Plot no.71/71-A/72/73/74/75/83, GIDC, Nandesari, District: Vadodara, Gujarat, India.

October, 2017

Conducted & Prepared By

GREEN CIRCLE, INC. Integrated HSEQR Consulting Engineers, Scientists & Trainers

(MoEF Recognized Environment Laboratory) (An ISO: 9001, 14001,NABL/ 17025:2005 OHSAS: 18001 Certified Organization & GPCB approved

Environment Auditor – Schedule I I ) Gujarat High Court Stay Order for QCI NABET No. C/ SCA/ 5312/ 2016dated 21.07.2016

Corp. Office & Environmental Research Laboratory:

Green Empire (Anupushpam), Above Axis Bank, Nr. Yash Complex, Gotri Road, Vadodara-390 021 (Gujarat) India |Tel: 0265-2371269

www .greencircleinc.com E: [email protected]

ALSO AT BENGALURU RUDRAPUR NEW DELHI HYDERABAD PUNE RAIPUR KOLKATA GOA

OVERSEAS AUSTRALIA OMAN KUWAIT AFRICA VIETNAM

http://www.greencircleinc.com/�

mailto:[email protected]�

Green Circle, Inc. M/s. Coromandel International Limited.

Project Proponent: M/s. Coromandel International Limited Project: Proposed expansion and addition of new products for manufacturing of chemical fertilizers

TABLE OF CONTENTS

1. EXECUTIVE SUMMARY .............................................................................................................................................. 3 1. EXECUTIVE SUMMARY .............................................................................................................................................. 3 2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ............................................................................. 3 3. PROJECT DESCRIPTION .............................................................................................................................................. 5 4. SITE ANALYSIS .......................................................................................................................................................... 22 5. PLANNING BRIEF ..................................................................................................................................................... 24 6. PROPOSED INFRASTRUCTURE ................................................................................................................................. 25 7. REHABILITATION AND RESETTLEMENT (R & R) PLAN ............................................................................................... 26 8. PROJECT SCHEDULE & COST ESTIMATES.................................................................................................................. 26

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) .......................................................................................... 26

LIST OF TABLES

TABLE 1.1 CONSUMPTION, PRODUCTION AND IMPORTS OF FERTILIZERS FROM 2009-2013 ............................................................. 5TABLE 1.2 EXISTING PRODUCTION DETAILS .............................................................................................................................. 9TABLE 1.3 TOTAL PRODUCTION DETAILS .................................................................................................................................. 9TABLE 1.4 MASS BALANCE OF SSP (600 TPD) ..................................................................................................................... 11TABLE 1.5 MASS BALANCE OF ZINCATED SSP (600 TPD) ....................................................................................................... 13TABLE 1.6 MASS BALANCE OF BORONATED SSP (600 TPD) ................................................................................................... 13TABLE 1.7 LIST OF RAW MATERIAL ...................................................................................................................................... 17TABLE 1.8 WATER CONSUMPTION AND WASTEWATER GENERATION ........................................................................................... 18TABLE 1.9 ELECTRICITY REQUIREMENT ................................................................................................................................. 19TABLE 1.10 FUEL REQUIREMENT ........................................................................................................................................ 20TABLE 1.11 DETAILS OF PROCESS GAS STACKS ....................................................................................................................... 20TABLE 1.12 DETAILS OF HAZARDOUS WASTE ........................................................................................................................ 20TABLE 1.13 DETAILS OF NON-HAZARDOUS WASTE ................................................................................................................ 21TABLE 1.14 ENVIRONMENT SETTINGS ................................................................................................................................. 22TABLE 1.15 AREA BREAK-UP ............................................................................................................................................. 25

LIST OF FIGURES

FIGURE 1.1 LOCATION MAP OF PROPOSED PROJECT ................................................................................................................. 6FIGURE 1.2 PROJECT BOUNDARY OF PROPOSED PROJECT SITE ..................................................................................................... 6FIGURE 1.3 GOOGLE IMAGE OF THE PROJECT SITE (5 & 10 KM RADIUS) ....................................................................................... 7FIGURE 1.4 PLANT LAYOUT ................................................................................................................................................. 8FIGURE 1.5 WATER BALANCE DIAGRAM .............................................................................................................................. 19



1. EXECUTIVE SUMMARY M/s. Coromandel International Limited is located at Plot no.71/71-A/72/73/74/75/83, GIDC, Nandesari, District: Vadodara, Gujarat, India. M/s. Coromandel International limited has proposed for expansion and addition of new products for manufacturing of chemical fertilizers and Proponent for the proposed expansion project is Mr. Tarun Kumar Bandhyopadhyay. As per the EIA Notification, 2006 & subsequent amendments, the proposed expansion project falls under category ‘B’ listed at item 5(a). The site is well connected with road and railway, nearest city Vadodara is located at a distance of 10 km and Mahi River passing through NW direction at a distance of 2.1 km and Mini river passing through East direction at a distance of 1.35 Km. There is no reserved forest, national park, eco sensitive areas in surrounding 10 km radius. The detail related to the proposed expansion project is discussed in the upcoming section.

2. INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of project and project proponent

2.1.1 Identification of project M/s. Coromandel International Limited, India’s second largest Phosphoric fertilizer industry, is in the business segments of Fertilizers, Specialty Nutrients, Crop Protection and Retail. The Company manufactures a wide range of fertilizers and markets around 3.2 million tons making it a leader in its addressable markets. M/s. Coromandel international limited, is situated at Plot No. 71, 71- A, 72, 73, 74, 75 & 83 GIDC Nandesari, Distt.: Vadodara, Gujarat, and engaged in manufacturing of Single super phosphate and Granular single super phosphate. In its endeavour to be a complete plant nutrition solutions Company, Coromandel has also introduced a range of Specialty Nutrient products including Organic Fertilizers. Coromandel has also ventured into the retail business setting up more than 750 rural retail centres in the States of Andhra Pradesh and Karnataka. 2.1.2 Project Proponent The proponent for the proposed expansion project of M/s. Coromandel International Limited is

Mr. Tarun Kumar Bandhyopadhyay, working as Manager-Operations at Nandesari plant. He is

having 30 years of experience in chemical fertilizer Industry.

2.2 Brief description of nature of project

The proposed expansion project is covered under the category ‘B’ of 5(a) in schedule “Chemical fertilizers” of EIA Notification-2006 & subsequent amendments. M/s. Coromandel International Limited has obtained Environmental Clearance and CC&A for manufacturing of Single Super Phosphate (SSP) 18,000 MT/M and out of which 12,000 MT/M of SSP is converted to Granular Single Super Phosphate (GSSP). The company has proposed for expansion of production capacity of SSP from 18000 MT/M to

24000 MT/M, and addition of new products, Zincated SSP/GSSP, Boronated SSP/GSSP



(fortified) and NPK. A single product or group of products will not exceed 24,000 MT/M

production capacity, in case of SSP, GSSP, Zincated SSP/GSSP, Boronated SSP/GSSP

(fortified) and NPK.

2.3 Need of project and its importance to the country and/or region

Single Super Phosphate (SSP) Fertilizer industry is the pioneering fertilizer in the country and the first SSP plant is said to have been established by EID Parry in the year 1906. Manufacturing of SSP is based on perhaps the simplest chemical reaction amongst chemical fertilizer industry. 0. SSP is a poor farmer's fertilizer (price-wise), is an option to optimize the use of phosphatic fertilizer. It also helps to treat Sulphur deficiency in soil (40% Indian soil Sulphur deficient) as well for further enhancement of yields at the least cost. In various crops, which require more of Sulphur and phosphate like oilseeds, pulses, sugarcanes, fruits and vegetables, tea etc. SSP is an essential fertilizer. S.S.P. is cheapest among phosphoric fertilizer and essential for cultivation of Sugarcane, Pulses, Oil seeds, Fruits and vegetables etc. The DOF has indicated that 40% of Indian soil is deficient of Sulphur, which needs use of SSP. The production of SSP recorded a sharp increase from 3.093 million tons in 2009-10 to 3.631 million tons in 2010-11 showing 17.4% over the previous year. All India capacity utilization of SSP increased from 46.2% during 2009-10 to 49.5% in 2010-11. Out of 66 operating plants, 25 operated above 60% capacity utilization and 41 plants below 60%. Total dispatches of SSP during 2010-11 stood at 3.596 million tons recorded an increase of 29.2% over 2009-10. There was a marginal fall in inventory. Stock of SSP reduced from 523.6 thousand tons as on March 2011.

2.4 Demand Supply gap

Farmers are now hard pressed to procure SSP to fertilize the top soil. Though SSP has been in short supply for preceding 5 to 6 years, the continuous decline in its production has further tightened its supply in the current Rabi season. The gap in SSP’s supply and demand further widen this season because against the requirement of 15 Lac tons, not more than 10 Lac tons will be available from the indigenous producers. Usually, this phosphate fertilizer is much in demand in the Rabi season when potato is being cultivated. But the way SSP’s production is sinking every crop season, not even 70% of the requirement would be met from the domestic production.

2.5 Imports v/s indigenous production

Raw materials purchase from indigenous as well as import production. The department of fertilizer report on consumption production and imports (in thousand tones of nutrients) of Phosphatic Fertilizer clearly indicates the deficiency of production against the consumption. The increase in production capacity will be beneficial in saving the foreign currency.



Table 1.1 Consumption, Production and Imports of fertilizers from 2009-2013

Year Consumption Production Imports

2009-10 72.7 43.21 27.6

2010-11 80.5 42.23 38

2011-12 79.1 41.04 44.3

2012-13 66.5 35.41 26.3

Source: Department of Fertilizers

2.6 Export Possibility

If there is any opportunity or demand M/s. Coromandel International Limited, will also export the products.

2.7 Domestic/ export markets

If there is any opportunity or demand M/s. Coromandel International Limited, will also export the products.

2.8 Employment Generation (Direct and Indirect) due to project

The proposed project will generate direct employment in both construction and operation phase locally or regionally. It is expected that direct employment opportunities at the time of construction phase will be provided approximately 20 unskilled and semi skilled workers from the nearby village. During the operation phase, direct employment opportunities will be provided approximately to 80 persons, comprising of 50 unskilled or semi skilled workers. Around 30 persons (unskilled contract workers) will be required for loading and unloading operations.

3. PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any. The project is neither an interlinked project nor an interdependent project. It is the proposed

expansion and addition of new products for manufacturing of chemical fertilizers. The project

falls under category ‘B’, section 5(a) of EIA notification 2006 and amendment thereof.

3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates.

Coordinates of project site: 22˚ 24’ 36.79” N and 73˚ 05’ 34.66” E



Map showing general location:

Figure 1.1 Location Map of Proposed Project

Project boundary of project site

Figure 1.2 Project Boundary of proposed project site



Co-ordinates of the corners of project site:

Corner Coordinates A 22°24'39.81" N, 73°05'32.47" E

B 22°24'38.51" N, 73°05'31.26" E

C 22°24'34.88" N, 73°05'32.32" E

D 22°24'33.89" N, 73°05'33.36" E

E 22°24'34.15" N, 73°05'35.47" E

F 22°24'36.03" N, 73°05'37.31" E

Figure 1.3 Google Image of the project site (5 & 10 Km radius)



Project site layout:

Figure 1.4 Plant Layout

3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.

Alternative site study is not carried out as existing plant and proposed expansion project is located in a well developed industrial Area (GIDC Nandesari). Major factors involved in the selection of site are listed below:

• Project site is within the Nandesari GIDC, which on NH 8 (3 km, E) has inherent location advantage of National Highway connecting to Vadodara, Ahmedabad and Surat.

• The project site is located on level ground, which does not require any major land filling for area grading work.

• Proximity to Raw Material suppliers. • Strategic location – proximity to Vadodara (10 km), the commercial city of Gujarat and

well connected by rail and road. It has direct inter-city trains to Vadodara, Ahmedabad and Surat. Its nature as a fast growing developing city, combined with its proximity to Vadodara and Ahmedabad, make ideal for sourcing human resources.



• Availability of Power, Water, etc.

3.4 Size or Magnitude of Operation

3.4.1 Existing production details

As per the existing EC and CC&A, the total production capacity of SSP is 18,000 MT/M, out of which 12,000 MT/M is being converted to GSSP.

Table 1.2 Existing production details Sr. No.

Product Name Quantity, MT/M

1 SSP 18000

2 GSSP 12000

3.4.2. Proposed production details

The company has proposed for expansion of production capacity of SSP from 18000 MT/M to 24000 MT/M, and addition of new products, Zincated SSP/GSSP, Boronated SSP/GSSP (fortified) and NPK. A single product or group of products will not exceed 24,000 MT/M production capacity, in case of SSP, GSSP, Zincated SSP/GSSP, Boronated SSP/GSSP (fortified) and NPK.

Table 1.3 Total production details Sr. No.

Name of products Total production capacity after

expansion, MT/M 1 Single Super Phosphate (SSP)

24,000

2 Granular SSP (GSSP)

3 Zincated SSP

4 Zincated GSSP

5 Boronated SSP

6 Boronated GSSP

7 NPK-GSSP

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 Single super Phosphate Manufacturing Process:

The manufacturing process of single phosphate (SSP) is basically conversion of insoluble P2O5

to soluble P2O5 by chemical reaction between phosphate ore and dilute sulphuric acid in

definite proportion. The reactants originally thin slurry set to a solid mass during the reaction.

After initial production to completion of the reaction i.e. product SSP it may take up to 15 days.



Dryer Rock phosphate contains moisture from 2 to 8%, which is dried up to 1 % through the co-

current operation with hot air. The inlet temperature of the hot air will be 250 to 3000C and outlet

temperature will be 60 to 700C. Only 15 % material remains in dryer during drying. Mill The first unit operation in the SSP production is the Ball mill. In the ball mill the rock phosphate

is crushed about 92 to 97% is passing through 100 mesh, for better efficiency of reaction. Fine

rock phosphate particles are collected through pulse jet collector system with cyclone separator

system attaches with blower. Grind rock is collected in silo through separator.

Mixer The name itself suggests the function of the equipment. In the mixer the rock phosphate, 98%

H2SO4 acid and water are mixed to form slurry. The optimum ratio is

Rock phosphate 52.00 to 57.5% depending on Rock quality.

98% H2SO4 0.345 to 0.36 MT/Ton of SSP production

Water 3.70%

About 67 to 69% acid concentration is used for getting the better conversion of P2O5

1. Major reaction:

. The slurry

is thicker than the discharged to den.

Den The Den is horizontal tunnel through which the slurry of acid and rock phosphate proceeds on a

slowly moving slatted conveyor, which is also known as Broadfield / Belt Den. The retention

time is 40 to 45 Minutes. During this time cake formation takes place. The gases are evolved in

the process of SSP production, which are scrubbed with the help of three stage scrubbing

system.

Chemical Reaction: Single super phosphate is made by the reaction of phosphate rock with sulphuric acid to

connect the insoluble (tribesic) form of calcium phosphate to a soluble (monobasic) form. This

reason can be represented by the following chemical reaction, which is the major reaction.

Ca3 (PO4) 2 + 2H2SO4 + H2O CaH4 (PO4) 2. H2O + 2CaSO4 The calcium sulphate remains in the product. SSP contains about 16% water soluble of

Phosphorous Pentaoxide (P2O5

2. Minor reactions:

) equivalent to the chemical impact of acid on phosphate rock

librates a large amount of steam, which entrains fine particulates of phosphate rock and acidic

gas and fumes, most of which originates from impurities in the rock.

2CaO+2F2 2CaF2 + O

3CaO + P2

2O5 Ca3 (PO4) 2

CaO+SO

3 CaSO

MgO+H4

2SO4 MgSO4 + H2

Fe

O

2O3+3H2SO4 Fe2 (SO4) 3 + 3 H2O



Al2O3+3H2SO4 Al2 (SO4) 3 + 3 H2

CaO+H

O

2SO4 CaSO4 + H2

3. Pollution reaction: O

CaF2+H2SO4 CaSO4

4HF+ SiO

+ 2HF

2 SiF4 + H2

3SiF

O

4+2H2O 2H2SiF6 + SiO

H2SiF6 SiF4 + 2 HF

Both SiF4 and HF are gases at ambient temperature and pressure and collected in the Den by

scrubbing system. The fluorine evolution is about 25% of 3% fluorine in the rock; Evolution of

the silica is about 30% of 8% in the rock.

2

The evolution of fluorine and Silica containing gases is a major problem in the SSP production

process. These evolved from the fluoride and silica contained as impurities in the rock. These

elements combine with the water to form flurosilic acid (H2SiF6). Excess silica dissolves

Flurosilic acid to form silicic acid (SiO2-H2O). Typical rock phosphate contains about 8% Silica

and 3% Fluorine by weight.

The temperature condition in the den causes a partial dissociation of fluorosilic acid, according

to following chemical equation.

Table 1.4 Mass Balance of SSP (800 TPD)

Raw materials Consumption Kg/kg of product MT/day

Input Rock Phosphate 0.565 452 Sulphuric Acid (100%) 0.345 276 Water 0.180 144 Total 1.090 872

Output Single Super Phosphate 1.00 800.00

Losses due to evolution of CO2 etc. 0.020 16.0 Water loss due to evaporation during acidulation 0.050 40.0

Water losses during curing 0.020 16.00

Total 1.090 872.00



Process flow diagram:

3.5.2 Zincated Single Super Phosphate Manufacturing Process: The SSP manufacturing process will comprise of two basic steps: grinding and acidulation.

Rock Phosphate which is the major raw material of the product will be fed through grinding

section. The next stage is acidulation. Sulphuric acid and ground rock phosphate will be fed to

the mixing unit where they will be thoroughly mixed. The output of the mixer which is in slurry

form will then be discharged to the Den. The Den output which is in a dry crumbling state will be

conveyed to the SSP covered storage area and dumped there for curing. The curing will take

10-15 days during which time the SSP will be reshuffled and aerated to aid the process.

The cured SSP than will be mixed with 200 mesh powder of Zincated powder as per required

%age in finished product. This mixing is by crane in most of the plant but a mechanized system

can be used for proper control & mixing. The Zincated SSP powder will then be bagged for

sale.



Table 1.5 Mass Balance of Zincated SSP (800 TPD)

Raw materials Consumption

Kg/kg of product MT/day Input

SSP Powder 0.9925 794 Zinc Oxide 0.0075 6

Total 1 800 Output

Fortified SSP with zinc 1 800

Total 1 800

3.5.3 Boronated Single Super Phosphate (BSSP)

Manufacturing Process: The SSP manufacturing process will comprise of two basic steps: grinding and acidulation.

Rock Phosphate which is the major raw material of the product will be fed through grinding

section. The next stage is acidulation. Sulphuric acid and ground rock phosphate will be fed to

the mixing unit where they will be thoroughly mixed. The output of the mixer which is in slurry

form will then be discharged to the Den. The Den output which is in a dry crumbling state will be

conveyed to the SSP covered storage area and dumped there for curing. The curing will take

10-15 days during which time the SSP will be reshuffled and aerated to aid the process. The

cured SSP than will be mixed with 200 mesh powder of Boron powder as per required %age in

finish product. This mixing is by crane in most of the plant but a mechanized system can be

used for proper control & mixing. The Boronated SSP powder will then be bagged for sale.

Table 1.6 Mass Balance of Boronated SSP (800 TPD)

Raw materials Consumption

Kg/kg of product MT/day Input

SSP Powder 0.988 790.4

Di-Sodium Tetra Borate Pentahydrate 0.012 9.6

Total 1 800 Output

Fortified SSP with Boron 1 800

Total 1 800



3.5.4 NPK

Brief manufacturing process:

The process is in four stages:-

1. Material handling & granulation

2. Drying & Cooling

3. Size Grading

4. Dust Scrubbing

1) Feeding of volumetric hoppers:

NPK nutrients such as Urea, Potash fertilizer, DAP/MOP/TSP, Gypsum, Filler, are fed

separately into individual Volumetric Hoppers. These nutrients, depending on the grade of NPK

Granulated Mixtures that are to be produced, are fed into conveyor belt in required ratio and

conveyed to nutrient mixer/blender along with recycle material thorough mixing of all the

nutrients.

2) Feeding of blended mix of NPK to granulation drum: The blended mix of nutrients from Nutrient Mixer/Blender is fed into Granulation Drum by

Double chain Bucket elevator.

3) Granulation of NPK nutrient mixture: Continuously required quantity of water and scrubber water from Single super phosphate plant

is sprayed over the nutrient mix in the Granulator Drum to facilitate formation of granules. Entire

Blended Mix gets converted into granules in the Granulator Drum. Thus obtained granules are

wet in nature due to addition of water in the process. There are no chemical reactions involved

in the process.

4) Drying of wet granules: The wet granules of NPK from granulator drum are then gets continuously transferred to rotary

drier drum equipped with internal flights and lifters for showering the material and are dried by a

stream of hot air generated from coal fired furnace.

5) Cooling of dried and hot granules: The NPK granules after draying at Drier drum are hot and are to be cooled before packing to

avoid and eliminate caking. The hot and dried NPK granules are transferred to cooler drum

continuously by conveyor belt from Drier drum. The cooler drum is also to provide with internal

flights and lifters for showering the material for better cooling effect. The hot granules are

cooled by stream of atmospheric air pulled by induced Draft Fan. The cooled granules are then

conveyed to screeners by a set of Conveyor belt and Bucket elevator for separation of over size

and under size grains.

6) Size grading: The dried and cooled granules are passed over “over size separation screen” to remove

granules of over 4 mm size. The oversize grains are crushed in chain mill to crush them and are



recycled back in the process of granulation. Thus screened material having size 4 mm and

below are then sent for further screen over “under size separation screen”. The under size

material of 1 mm and below gets separated during screening and the same is recycled back in

the process granulation. The material of size varying between 1 mm and 4 mm are then

transferred by conveyor belt to “product hopper” for bagging.

7) Dust scrubbing: The dust particles that are carried out by stream of hot and cool air from drier and cooler drums

are passed through “cyclone separator” and dust collecting chambers to remove all dust

particles from the system and air along with flue gases from hot air coal fired furnace are let out

into atmosphere through a chimney of 30 meters height from the ground level for better

disbursement.

8) Weighing and packing: The screened NPK Granulated fertilizers from product hopper are filled in 50 Kgs net capacity

LDPE lined HDPE oven bags, weighed and stitched by stitching machine. Thus weighed and

stitched bags are then transferred to finished product storage godown.



Process flow chart:

3.6 Raw Material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and Finished product. All raw materials will be transported through roadways. Details of raw materials are given in below table|:

Table 1.7 List of Raw Material

Sr. No.

Name of Product

Name of Raw Materials Existing Quantity,

MT/M

Proposed Quantity,

MT/M

Total Quantity,

MT/M Source Storage Condition

1

SSP

Rock phosphate 10,170 3,390 13,560 Imported/Indigenous Storage yard

Sulphuric acid/Spent acid 6,210 2,070 8,280 Imported/Indigenous 2 Nos. x 1000 MT MS Tank

2 GSSP SSP Powder 12,000 12,000 24,000 Self made Storage yard 3

Zincated SSP

SSP Powder - 23,820 23,820 Self made Storage yard Zinc Oxide - 180 180 Indigenous Storage yard

4 Zincated

GSSP Zincated SSP - 24,000 24,000 Indigenous Storage yard

5

Boronated

SSP

SSP Powder - 23,712 23,712 Self made Storage yard Di-Sodium Tetra Borate

Pentahydrate - 288 288 Indigenous Storage yard

6 Boronated

GSSP Boronated SSP - 24,000 24,000 Self made Storage yard

7

NPK

SSP - Self made Storage yard Di-ammonium phosphate - Imported/Indigenous Storage yard

Urea - Imported/Indigenous Storage yard Murate of potash - Imported Storage yard

3.7 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.

There is no generation of industrial waste water from the manufacturing process. However, the liquid waste generated from scrubber which is reused in for dilution of Sulphuric acid and the sludge generated in the scrubber is reused for product SSP blending as filler. The domestic waste water is sent to the common STP, Nandesari for further treatment.

3.8 Availability of water its source, energy/power requirement and source

3.8.1 Water requirement The source of water for the proposed expansion project will be GIDC water supply. Total water requirement after the expansion will be 207.2 KLD. Generated sewage will be sent to the common STP, Nandesari for further treatment. Wastewater generated from venturi scrubber will be reused in acid dilution. Hence, no industrial effluent is anticipated from the project.

Table 1.8 Water consumption and Waste water generation

Sr. No.

Type of activity

Water requirement, KLD

Wastewater generation, KLD Remark

Existing Proposed Total Existing Proposed Total

1 Domestic 10 5 15 8 4 12 Sent to the common STP, Nandesari

2 Gardening 5 0 5 0 0 0 - 3 Industrial

i Venturi Scrubber 108 36 144 108 36 144

15.84 KLD will be evaporation losses and remaining 128.16 KLD will be reused in Acid dilution for SSP product

ii Process water for GSSP/NPK

21.6 21.6 43.2 0 0 0

36.72 KLD Evaporation losses 6.48 KLD water with Product

Total Industrial 129.6 57.6 187.2 108 36 144 - Total (1+2+3) 144.6 62.6 207.2 116 40 156 -

*Note: 6.48 KLD water with product



Figure 1.5 Water Balance Diagram

3.8.2 Electricity Requirement Electricity shall be obtained from GEB (Gujarat Electricity Board). Diesel will be used as a fuel for D.G set. The total power requirement is given in below table:

Table 1.9 Electricity requirement

S. No.

Particulars Existing Power

requirement (KVA)

Proposed Power requirement

(KVA)

Total Power requirement

(KVA)

1.

Plant & administration

Plot no:

71,71A,72,73,74,75

800 1500. 2300

2 Plant & administration

Plot no: 83 50 500 550

Total Power requirement 850 2000 2850

4 Proposed: 1 No. x 500 KVA D.G Set (Stand By)



3.8.3 Fuel requirement Table 1.10 Fuel Requirement

Sr. No Particulars Capacity Name of

Fuel Fuel Quantity

1 D.G. Set Proposed: 1 No. x 500KVA

Diesel 100 L/hr

2 GSSP Drying furnace - Coal 35 kg/Ton

3.8.4 Stack details Table 1.11 Details of Process gas Stacks

Sr. No.

Stack attached to Status Stack

No. Capacity Stack

Ht. (m)

Stack Dia.

(mm)

Stack gas

temp. (˚C)

APCM

1. SSP – Stack Existing 1 36000 CFM 50 900

mm 40 to

80

Four stage Scrubber is provided to control fumes from the mixer.

2. GSSP plant -Stack Existing 1 25000

CFM 30 900 mm

70 to 80

Twin Cyclone separators are provided to control the air emissions.

3. NPK/GSSP plant – Stack Proposed 1 25000

CFM 30 900 mm

70 to 80

Twin Cyclone separators will be provided to control dust emissions.

Table 1.12 Details of flue gas Stacks

Sr. No.

Stack attached to Status Stack

No. Capacity Stack

Ht. (m)

Stack Dia.

(mm)

Stack gas

temp. (˚C)

APCM

1. DG set (stand By) Proposed 1 500 KVA 14 200

mm 90 to

95 Adequate Stack Height.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/Disposal

3.9.1 Waste Water generation & Management plan The total wastewater generation from industrial process will be reused in dilution of sulphuric acid. There is no any industrial wastewater generation. Sewage will be sent to Common STP Nandesari for further treatment. 3.9.2 Solid & Hazardous waste generation & Management plan Details of hazardous wastes and non-hazardous wastes are given in below tables;

Table 1.13 Details of Hazardous Waste



Sr. No.

Type of

waste Category

Waste generating

process

Physical Characteris

tics

Quantity Management

E P T

1.

Used

/spent

oil

5.1 Machinery

& D.G set Liquid 2.4 MT/yr

1.0

MT/yr 3.4 MT/yr

Reuse in gear

and lubricant of

drives.

2. Silica

sludge 36.1 Process

Solid/Semi-

solid

36.1

MT/yr

12.0

MT/yr

48.1

MT/yr

Reuse as a filler

in process.

Note: E=Existing, P=Proposed, T=Total

Table 1.14 Details of Non-Hazardous Waste

Sr. No.

Type of waste

Quantity Management

E P T

1. HDPE

scraps - 100 MT/yr 100 MT/yr Will be sold to authorized vendors



3.10 Schematic representations of the feasibility drawing which give information of EIA purpose.

4. SITE ANALYSIS

4.1 Connectivity

• Site is very well connected by road and railway network.

Table 1.15 Environment Settings

Sr. No. Particulars Details Distance,

Km Direction

1 Nearest Village Nandesari 0.9 NNW

2 Nearest Town/City Vadodara 10 SE

3 Nearest Railway Station Nandesai Railway Station 0.8 NNE

4 Nearest Hospital Deepak Medical Hospital 0.6 NW



Sr. No. Particulars Details Distance,

Km Direction

5 Nearest Highway NH-8 3.4 E

6 Nearest Airport Vadodara Airport 15.5 ESE

7 Nearest Water Body Mahi River 2.1 W

Mini River 1.35 E

8 Nearest School Nandesari Vidhyalaya 0.6 W

9 Nearest Fire station Nandesari Fire station 0.7 NW

4.2 Land Form, Land Use and Land Ownership

Land Form: Proposed project site is within the industrial area (GIDC Nandesari). Land use: Industrial purpose for proposed expansion and addition of new products for manufacturing of chemical fertilizers. Land Ownership: On Lease

4.3 Topography (along with map).

Project site is located almost in the central part of state of Gujarat at an altitude of approximately 150 ft (46 meters) above the sea level.

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, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of the notified industrial area, a copy of the Gazette notification should be given.

The project falls inside the notified industrial area (GIDC-Nandeasri). CRZ is not applicable to the project.

4.5 Existing Infrastructure

There is SSP and GSSP manufacturing unit exists as per the EC and CC&A. Demolition of buildings/structures will be carried out at Plot No. 83 only. 4.6 Soil Classification The Vadodara District and surrounding area consist of “Goradu soil in the North-Eastern part, Bhatha soils with salinity in the north-western part, deep black soils in the southern part.

The soils of the region are complex, and highly variable, reflecting a variety of differing parent materials, physiographic land features, range of distribution of rainfall and its effects etc. Quality of the soil in the area is shown a marked diversity in nature depending upon the parent rock and climatic conditions prevailing in different parts of the district.



4.7 Climatic data from secondary sources

The climate of the study area and surrounding region is generally dry except in the southwest monsoon season. The year may broadly be divided into four seasons. Winter season : December to February Pre-monsoon season: March to May Monsoon season : mid June to September Post monsoon season: October and November Temperature: In the months of April and May, it is the period of continuous increase in temperature. May is the hottest month of the year. The climate of the district is characterized by hot summer and general dryness throughout the year except during the south-west monsoon period, i.e. June to September. The mean minimum and maximum temperatures observed are 14.8°C and 40°C respectively. Rainfall: The district gets rainfall from south west monsoon winds. The average annual rainfall over the district is about 584 mm.

4.8 Social infrastructure available

This proposed project is located at notified GIDC of Nandesari, in Vadodarda district, Gujarat. The Site is 10 km from Vadodara city and 0.3 km from Nandesari railway Station. The land and infrastructure is made available by GIDC and the raw materials are easily available through easy transport via road connectivity. The site is well connected by the National Highway-8.

5. PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc) Town and Country

Planning/Development authority classification.

Type of Industry: Chemical fertilizer industry

5.2 Population Projection

The proposed project would require 156 workers and staff during the operation of the project.



5.3 Land use planning (breakup along with green belt etc.)

Table 1.16 Area Break-up

Sr. No Particulars Existing area Proposed area Total area after

Expansion

1 Main plant building

(production area) 2819.2

-

2819.2

2 Raw material storage 2790.5 - 2790.5

3 R/M storage tank

(HDPE/MS tank) 468.8

-

468.8

4 Finished product storage 998.6 - 998.6

5 Chimney 38.2 - 38.2

6 Transformer 124.3 - 124.3

7 Administration & lab 207.7 - 207.7

8 Green area 600.0 - 600.0

9 NPK/GSSP - 5016.8 5016.8

Total Plot Area 8047.2 5016.8 13064.0

5.4 Assessment of Infrastructure Demand (Physical & Social)

On the basis of the preliminary site visit, the infrastructure demand in the villages was assessed on the basis of need and priority. Employment would be as per prevailing norms of state government for skilled and unskilled people for the proposed project activity.

5.5 Amenities/Facilities

Proper site services such as First Aid, Canteen, Drinking Water, Maintenance Workshop, etc. will be provided to the workers. It is proposed to construct one room for labor.

6. PROPOSED INFRASTRUCTURE 6.1 Industrial Area (Processing Area)

Processing Area (Plant facilities, and Utility Services) Developed Area: 7874.2 Sq.m.

6.2 Residential Area (Non Processing Area)

Non Processing Area (Green belt, Raw material storage area, Admin and open area). Area: 5065.6 Sq.m.

6.3 Green Belt

Total 13064.0 sq.mt square meters land area at proposed site; out of this 600 Sq.m. will be used for development of green belt.

6.4 Social Infrastructure

Depending on the growth of the company the required social infrastructure will be provided.



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

Road and railways are very close to the working site. There is no proposal to make any new kind of connectivity.

6.6 Drinking water Management (Source & Supply of water)

Water for drinking and operations will be 7 KLD, which will be met from GIDC water supply.

6.7 Sewerage System

Sewage will be sent to the Common STP, at Nandeasri GIDC for further treatment.

6.8 Industrial Waste Management

Please refer section 3.9.2.

6.9 Solid Waste Management

No solid waste generation.

6.10 Power Requirement & Supply/Source

Electricity shall be obtained from GEB. The total power requirement for the proposed project is 2000 KVA.

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, land oustees and landless labourers

Not Applicable because the proposed project site within the GIDC-Nandesari.

8. PROJECT SCHEDULE & COST ESTIMATES 8.1 Likely date of start of construction and likely date of completion (Time schedule for the project to be given).

We shall start construction after obtaining environmental clearance.

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

Total Project Cost for proposed project activity is Rs. 15 Crores.

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9.1 Financial and social benefits with special emphasis on the benefit to be local people including tribal population, if any, in the area. The project will be prove time by time for beneficial to the people as the company progress and expands its activity. By CSR activity company management will committed to improve infrastructural facilities for the local people like Educational facilities, Medical facilities, Transportation facilities etc. as well the local people especially tribal population will be taken as labours, which will improve the socioeconomic environment of the area.

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