PROJECT PRE-FEASIBILITY REPORT - Welcome to …€¦ · 5.4 Assessment of infrastructure Demand 21...

PROJECT PRE-FEASIBILITY REPORT ON

PROPOSED PROJECT FOR

INSTALLATION OF 6 MW

CO-GEN UNIT

AT

M/s. Aarti Industries Limited (Unit-I) Located at:

Plot No. 758/1, 2 & 3

GIDC Jhagadia,

Dist. Bharuch,Gujarat

CONTENTS

SR. NO. PARTICULARS PAGE NO.

1 EXECUTIVE SUMMARY 1

2 INTRODUCTION 5

2.1 The Project 5

2.2 Project Proponent 5

2.3 Nature of project 6

3 PROJECT DESCRIPTION 7

3.1 Type of Project 7

3.2 Project Location 7

3.3 Site selection 9

3.4 Neighboring Industries 9

3.5 Size of project 9

3.6 Process Technology 9

3.7 Resource optimization/recycling and reuse 9

3.8 Resource requirements 9

3.8.1 Land 9

3.8.2 Building 10

3.8.3 Power & Fuel 10

3.8.4 Water 10

3.8.5 Man power 11

3.9 Mitigation Measures &Environment Management

plan 11

3.9.1 Waste water Management 11

3.9.1.1 Waste water generation 11

3.9.1.2 Waste water characteristics 12


3.9.1.3 Waste water treatment and disposal 12

3.9.2 Gaseous emission & Control 15

3.9.2.1 Flue gas emission 15

3.9.2.2 Process emission 16

3.9.3 Hazardous /non hazardous waste management 16

3.9.4 Noise control& odour 18

3.9.5 Storage ,handling and transport of Hazardous

chemical 18

3.9.6 Health & Safety measures 18

4 SITE ANALYSIS 19

4.1 Connectivity 19

4.2 Land use and land ownership 19

4.3 Topography 19

4.4 Existing land use 19

4.5 Existing infrastructure 19

4.6 Social Infrastructure 21

5 PLANNING BRIEF 21

5.1 Planning concept 21

5.2 Population projection 21

5.3 Land use planning 21

5.4 Assessment of infrastructure Demand 21


5.5 Amenities 22

6 PROPOSED INFRASTRUCTURE 22

6.1 Processing area 22

6.2 Non processing area 22

6.3 Green belt area 22

6.4 Social Infrastructure 23

6.5 Connectivity 23

6.6 Drinking water management 23

6.7 Sewerage system 23

6.8 Industrial waste management 23

6.9 Solid waste management 23

7 REHABILITATION & RESETTLEMENT (R & R)

PLAN 24

8 PROJECT SCHEDULE & COST ESTIMATES 24

8.1 Project Implementation Schedule 24

8.2 Estimated project cost 24

9 ANALYSIS OF PROPOSAL 24

LIST OF TABLES

TABLE

NO.

TOPIC PAGE NO.

1 List of Existing Products 1

2 List of Proposed Product 2

3 Salient features of the of the project site 7

4 Details of neighbouring industries 9

5 Approximate requirement of Construction Materials 10

6 Power and Fuel Requirement 10

7 Category wise Water requirement 11

8 Man Power Requirement 11

9 Category wise Wastewater Generation 12

10 Flue gas emissions 15

11 Process emissions and control measures 16

12 Details of Hazardous waste 16

13 Details of Micrometeorological data 20

14 Project implementation schedule 24

LIST OF FIGURES

FIGURE

NO.

DESCRIPTION PAGE NO.

1. Aerial view of the project site 8

2. Existing Water Balance Diagram 13

3. Proposed Water Balance Diagram 14

4. Wind Rose 20

M/S. AARTI INDUSTRIES LIMITED (UNIT-I)

Jyoti Om Chemical Research Centre Pvt. Ltd. 1

1.0 EXECUTIVE SUMMARY

M/s. Aarti Industries Ltd. (Unit-I), Jhagadia is an existing organic chemical manufacturing

unit. They have got boilers with total 57 MT/Hr. capacity. Now the unit has proposed

installation of co-gen unit for generating electricity of 6 MW with 60 MT/Hr. boiler

capacity at Plot No 758/1, 2 & 3 P.B. No. 23 GIDC Jhagadia, Dist. Bharuch-393110. The unit

has also obtained environment clearance for the expansion of their production capacity in

April 2013. The copy of environment clearance is attached as an Annexure-X. The details

of products are given below in table-1.

TABLE: 1

LIST OF EXISTING PRODUCTS WITH THEIR PRODUCTION CAPACITY (AS PER CCA NO. AWH-50364, 59708)

Sr. No.

Name of Product Total Quantity(MT/M)

I Group A: Mono Nitro Derivatives of Benzenes and Chloro Benzene

1. Para Nitro Chloro Benzene 6000 (Sr.no. 1 to 11)

(Either one or more than one product ) (Total production shall not exceed 6000

MT/Month)

2. Ortho Nitro Chloro Benzene

3. Ortho /Para/Meta –Nitro Cumene

4. Nitro Benzene

5. 2,5-Dichloro Nitro Benzene

6. 3,4- Dichloro Nitro Benzene

7. Ortho Nitro Toluene

8. Para Nitro Toluene

9. Meta Nitro Toluene

10. Meta Nitro Chloro Benzene

11. 2,4-Dichloro Nitro Benzene

Group B: Di Nitro Derivatives of Benzenes and MCB

1. Di Nitro Benzenes 3000

2. Di Nitro Chloro Benzenes III Group C:

Diethyl Sulphate 100

IV Group D: Hydrogenated products: (Reduction)

1. Meta Chloro Aniline 5000 (Sr.no. 1 to 35) (In DCA product unit will manufacture 2,3/2,4/2,5/2,6/3,4/3,5 DCA & mixture of 2:3,2:4 / 2:4,2:5 / 2:5, 2:6/ DCA & 2:3,2:4, 2:5, 2:6 DCA.

2. Para Chloro Aniline

3. 3,4 Di Chloro Aniline



6. Meta Phenylene diamine



Sr. No.

Name of Product Total Quantity(MT/M)

7. Para Phenylene diamine In Cumidine category unit will manufacture Ortho, Para & Meta cumidine).

8. Ortho Phenylene diamine

9. Ortho Anisidine

10. Para Anisidine

11. Chloro Fluoro Aniline

12. Para Cumidine

13. Para Amino Phenol

14. Meta Amino Phenol

15. Toludines

16. Ortho Chloro Aniline




20. Mixer of 2,4 / 2,5 DCA

21. Mixer of 2,5 / 2,6 DCA

22. Mixer of 2,4 / 2,5 /2,6 DCA

23. Ortho Cumidine

24. Meta Cumidine

25. Meta anisidine

26. 2,4,5 Trichloro Aniline

27. Aniline

28. Para Floro Aniline

29. Meta Floro Aniline

30. Ortho Floro Aniline

31. Di Floro Aniline (1:3)

32. Di Floro Benzene (1:3)

33. 4-Floro-N-Isopropyl Aniline

34. 4-Chloro-N-Isopropyl Aniline

35. Other reduction products

Total from Group A,B,C & D(Excluding By products)

14100

V Group D: Only Physical Separation

1. Ortho / Para / Meta Chloro Toluene 450

2. 2:3 DCNB / 3:4 DCNB 550 Total of group 1000

TABLE: 2

LIST OF PROPOSED PRODUCTS WITH THEIR PRODUCTION CAPACITY

Sr.no. Name of product Total quantity

VI Group E: Power Generation

1 Co-Generation Power plant 6 MW



COST OF PROJECT

The expected cost of proposed project is Rs. 40 Crores. The plot had been purchased by

M/s. Aarti Industries Ltd. (Unit-I) from GIDC. The total plot area of the unit is 51071 sq.

m. The green belt area is 11815 sq. m.

FUEL & ELECTRICITY CONSUMPTION

The unit is using Imported Coal as fuel for boilers. The connected electricity load is 4000

KW.

WATER CONSUMPTION AS PER CCA AWH-59708 AND 50364

The unit is using 867 KL/Day fresh water + 158 (Recycled water) KL/Day for industrial

purpose and 25 KL/Day fresh water for domestic purpose.

WATER CONSUMPTION AS PER PROPOSED INSTALLATION

The unit will use 301 KL/Day fresh water + 69 (Recycled water) KL/Day for industrial

purpose.

Thus the total water consumption will be 1168 KL/Day (Fresh water) + 227 KL/Day

(Recycled water) and 25 KL/Day fresh water for domestic purpose.

WASTE WATER GENERATION AS PER CCA AWH-59708 AND 50364

The waste water generation from process is going to ETP is 91 KL/Day. The sewage

generation is 5 KL/Day. The industrial waste water is being treated in units own ETP

followed by RO. And the domestic wastewater of 05 KL/Day is also treated in unit’s own

ETP followed by RO. The total wastewater going to ETP followed by RO is 96 KL/Day.

The wastewater generation from utilities is going to separate RO of utilities which is 72

KL/Day. The reject of both RO systems is sent to MEE from where the condensate of 42

KL/Day is sent to cooling tower for reuse.

WASTE WATER GENERATION AS PER PROPOSED INSTALLATION

There will be no increase in waste water generation from process and sewage. The

wastewater generation from utilities will be going to separate RO of utilities which is 71

KL/Day. The reject of both RO systems is sent to MEE from where the condensate of 15

KL/Day is sent to cooling tower for reuse.

Thus the total waste water generation from process and sewage going to ETP followed by

RO will be 96 KL/Day. The total waste water from utilities going to separate RO will be



143 KL/Day. The total reject of both RO systems is sent to MEE from where the

condensate of 57 KL/Day is sent to cooling tower for reuse and residue of 30 MT/Month

is sent to land fill site.

GASEOUS EMISSION

FLUE GAS EMISSION AS PER CCA AWH-59708 AND 50364

There are 3 stack attached to boiler (17 TPH) with multi cyclone separator followed by

ESP, boiler (30 TPH) with attached ESP and thermopack (20 Lakh Kcal/hr) attached with

bag filter. There are total 5 stand by stacks. Also there is one stack of stand by Boiler (10

TPH) and four stacks of stand by D.G. Set (1010 KVA Each).

FLUE GAS EMISSION AS PER PROPOSED INSTALLATION

There will be 1 stack attached to boiler (60 TPH) attached with ESP as APCM. After

installation of co-generation unit, all existing boilers will become stand-by boilers.

PROCESS GAS EMISSION AS PER CCA AWH-59708 AND 50364

There are 2 stacks of process emission. One stack is attached to nitration plant and HNO3

storage tank which is attached to sulphuric acid scrubber followed by caustic scrubber.

And one stack is attached to incinerator followed by double chamber scrubber.

PROCESS GAS EMISSION AS PER PROPOSED INSTALLATION

There will be no new process stack due to proposed installation of co-gen unit.

HAZARDOUS WASTE MANAGEMENT AS PER CCA AWH-59708 AND 50364

There is generation of ETP waste (Gypsum) from Waste Water Treatment (100

MT/Month), Discarded Containers/barrels/Liners used for HW/Chemicals (1225 Nos.

/Month), Spent Carbon (3.4 MT/Month), Incinerated ash & Evaporated salt (1.04

MT/Month), Organic Residue (40 MT/Month), Spent Sulphuric Acid (68 % - 72 %)(7200

MT/Month), Used/Spent Oil (0.184 MT/Month), Spent catalyst (Dry Basis) (620

KG/Month).

HAZARDOUS WASTE MANAGEMENT AS PER PROPOSED INSTALLATION

There will be additional generation of spent oil (0.007 MT/Month), Residue from MEE (30

MT/Month) and Fly ash (840 MT/Month).



Thus the total generation will be ETP waste (Gypsum) from Waste Water Treatment (100

MT/Month), Discarded Containers/barrels/Liners used for HW/Chemicals (1225 Nos.

/Month), Spent Carbon (3.4 MT/Month), Incinerated ash & Evaporated salt (1.04

MT/Month), Organic Residue (40 MT/Month), Spent Sulphuric Acid (68 % - 72 %)(7200

MT/Month), Used/Spent Oil (0.191 MT/Month), Spent catalyst (Dry Basis) (620

KG/Month), Residue from MEE (30 MT/Month) and Fly ash (840 MT/Month).

2.0 INTRODUCTION

2.1 THE PROJECT

M/s. Aarti Industries Ltd. (Unit-I), Jhagadia is an existing organic chemical manufacturing

unit. They have got boilers with total 57 MT/Hr. capacity. Now the unit has proposed

installation of co-gen unit for generating electricity of 6 MW with 60 MT/Hr. boiler

capacity at Plot No 758/1, 2 & 3 P.B. No. 23 GIDC Jhagadia, Dist. Bharuch-393110. The unit

has also obtained environment clearance for the expansion of their production capacity in

April 2013.

Aarti Industries Ltd. has a strong research and development which is focused on bringing

in continual improvements on process and products, backward integration and

developing innovative products".

The details of products are given in table -1.

2.2 PROJECT PROPONENT

The list of directors is attached as Annexure-II.

M/s. Aarti industries Ltd. is a steady growing company incorporated in 1975. It is a

registered as Small Scale industrial unit. Aarti Industries Limited (AIL) is a dynamic

organization, continuously investing in innovative products and processes, as well as

cleaner technologies.

The plant is of international standards. The plant boasts of contemporary infrastructure

facilities with advanced machinery and automated processes.

Roots of the company are backed by the strong technical expertise.

Generous & ambitious management.



Well-equipped plants with adoption of modern technology & runs under close

observation by trained technocrats.

Expertise to enrich quality product by breakthrough innovations.

Winning against competition with the weapons of quality, commitment & service.

Optimum utilization of man, machine, materials and money.

Customer's satisfaction is our best reward.

Devoted to keep safe environment & ecology.

Quality Policy

The company’s commitment is to manufacture quality products through systematic

operations in pursuit of meeting and enhancing their customer satisfaction level.

The company has in house testing facility with modern testing equipments to ascertain

the quality of raw materials as well as finished products. Continued emphasis towards

process and technology up gradation is being done effectively to enrich the product

quality. R & D with initiative & innovative ideas had resulted into excellent

performance in respect of quality products.

As a means of achieving these, the unit pledge to company with the legal & other

requirements to their core and focus on continually improving their products, systems

& operations.

Environmental Policy

The unit is committed to execute all operations, products and services by

environmental protection activities to the extent possible.

As a recycling plant, the unit understand the need of maintaining and improving the

environmental quality through controlled solid waste disposals and safe working

conditions.

As a means of achieving these, the unit pledge to company with the legal & other

requirements to their core and focus on continually improving products, systems &

operations.

2.3 NATURE OF PROJECT

The unit is manufacturing organic products 14100 MT/Month of 5(f) category product and

physical separation : 1000 MT/Month as per CCA NO. AWH-50364 valid up to 7/6/2017



and amended CCA no. AWH 59708 issued on 1/2/2014. As per EIA notification 2006 and its

amendment, the existing is Organic Chemical Manufacturing unit falling in 5(f) category

project. Proposed expansion is for Co-gen unit which is falling under 1(d) category.

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is not including any interlinked and interdependent projects.

3.2 PROJECT LOCATION

The proposed project site is located at plot no758/ 1, 2 & 3, GIDC Estate, Jhagadia, Dist. Bharuch

in the state of Gujarat. It is approximately 16 km distance from district head quarter Bharuch. The

approximate geographical positioning of the project site is at Latitude: 21°39'23.73"N, Longitude:

73° 7'39.97"E. The location of the project site can be identified from the location map shown in

Figure-1 &2 .

TABLE: 3

SALIENT FEATURES OF THE PROJECT SITE

Particulars Details

Village Jhagadia

Taluka/ Tehsil Jhagadia

District Bharuch

Approx. Geographical

positioning

Latitude: 21°39'23.73"N

Longitude: 73° 7'39.97"E

Nearest City Bharuch

Nearest Town Bharuch

Nearest Highway National Highway No. 8

Nearest State highway State Highway No.6

Nearest Railway line/ Railway

station

Bharuch

Nearest Airport/ Airbase Vadodara



FIGURE: 1

AERIAL VIEW OF THE PROJECT SITE

Project site



3.3 SITE SELECTION

3.4 NEIGHBOURING INDUSTRIES

TABLE: 4

DETAILS OF NEIGHBOURING INDUSTRIES

3.5 SIZE OF PROJECT

The unit has proposed installation of co-gen unit. Environment Protection and safety

systems have also been considered in planning the Cost Projection. The unit proposed to

set up effluent treatment plant which will be maintained as per requirements. The total

project cost will be Rs. 40 Crores.

3.6 PROCESS TECHNOLOGY

Process details like process description for co-gen unit are covered separately in

Annexure-V.

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE

3.8 RESOURCE REQUIREMENTS

3.8.1 LAND

The plot had been purchased by M/s. Aarti Industries Ltd. (Unit-I) from GIDC. The total

plot area of the unit is 57017sq. m.

Sr.

No.

Name of Industry Address

1. United Phosphorus

Limited

Plot no.750,GIDC,Jhagadia

2. Endica Ceramics Plot no. 756-8,9, GIDC, Jhagadia

3. Star Oxoform Plot no.756-10A/B, GIDC, Jhagadia

4. Janta Paper Mills Plot no.778,GIDC,Jhagadia

5. Panoli Intermediates Ltd Plot no.778-1,GIDC,Jhagadia



3.8.2 BUILDING

The new foundations will be constructed.

TABLE: 5

APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS

Sr.

No.

Material Qty. Source

1 Bricks 5 Cu. Mt. From local

supply

2 Cement 100 MT

3 Sand 75 Cu. Mt.

4 TMT Steel 40 MT

5 Gravel 150 Cu. Mt.

6 Kapchi 35 Cu. Mt.

7 Stone 50 Cu. Mt.

3.8.3 POWER AND FUEL

TABLE: 6

POWER AND FUEL REQUIREMENT AS PER CCA AWH-59708 AND 50364

Sr.

No.

Particulars Consumption

as per CCA

AWH-59708

& 50364

Proposed

Consumption

Total Remark

Electricity

1. Electricity

connected load

4000 KVA -- 4000 KVA DGVCL

company

Fuel

1. Imported Coal 9 MT/Hr. 9 MT/Hr. 18 MT/Hr. --

2. Furnace Oil 850 L/Hr -- 850 L/Hr Local Supplier

3. Diesel 880 L/Hr -- 880 L/Hr Local Supplier

3.8.4 WATER

The category wise bifurcation of the water requirement is given in below table-7. The

source of water will be from GIDC water supply scheme.



TABLE: 7

CATEGORY-WISE WATER REQUIREMENT

Sr. No.

Particulate

Water Consumption in KL/Day

As per CCA order no. AWH 59708

Proposed quantity

Total quantity

1 Domestic 25 0 25

2 Industrial

Process & washing 40 (fresh) 0 40 (fresh) DM Plant 301(fresh) 301(fresh) 602 (fresh)

Boiler 263 (DM permeate)

263 (DM permeate)

526 (DM permeate)

Softner 506(fresh) 0 506(fresh)

Cooling 501 (softner permeate) +

158 (recycled)

69 (recycled) 501 (softner permeate) +

227 (recycled)

Gardening 20(fresh) 0 20(fresh) Total 892 (fresh)

+ 158 recycled 301

+69 (recycled) 1193 (fresh)

+ 227 recycled

3.8.5 MANPOWER

The manpower required for the project as well as during the construction/ commissioning

activities will be employed from the local area. The preference will be given to local

people.

TABLE: 8

MAN POWER REQUIREMENT FOR PROPOSED CO-GEN PLANT

Phase of Project Type of Labor No. of Worker

During operations Managerial 2

Skilled 8

Un-skilled 10

3.9 MITIGATION MEASURES & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been

proposed by the company for the control of the anticipated pollution load.

3.9.1 WASTEWATER MANAGEMENT

3.9.1.1 WASTEWATER GENERATION



The category-wise bifurcation of the anticipated wastewater generation details is given in

below table-9.

TABLE: 9

CATEGORY-WISE WASTEWATER GENERATION

Sr. No.

Particulate Waste water generation in KL/Day

As per CCA order no. AWH 59708

Proposed quantity

Total quantity

1 Domestic 5 0 5

2 Industrial

Process & washing

91 ( 40 from process + 51

due to reaction)

0 91( 40 from process+ 51 due to

reaction)

Total waste water to ETP

96 (to ETP followed by Process RO)

0 96 (to ETP followed by Process RO)

DM Plant 38 38 76

Boiler 11 19 30

Softner 5 0 5

Cooling 18 14 32

Total waste water from utility

72 (to utility R.O.) 71(To Utility RO)

143 (to utility R.O.)

Condense water from MEE

42(to cooling tower) 15 57(to cooling tower)

Residue from MEE

1.5 (landfill site or incinerator)

1.5 3(landfill site or incinerator)

3.9.1.2 WASTEWATER

The unit is zero liquid discharge unit treating effluent in ETP followed by RO and MEE.

3.9.1.3 WASTEWATER TREATMENT & DISPOSAL

The unit has already proposed ETP. The domestic waste water of 05 KL/Day will be

treated in ETP.

The industrial waste water & sewage will be treated in units own ETP having primary,

secondary and tertiary treatment facilities.

Details of Effluent Treatment Plant and Flow Diagram are attached as Annexure-VII.



FIGURE: 2

EXISTING WATER BALANCE DIAGRAM

Water Coming from GIDC 892

Process

40

DM water

Plant

301

Boiler

263

Cooling Tower

501

ETP

96

Softner

506

Boiler blow

down

11

Cooling Tower

blow down

18

Effluent

from the

process

91

Water due to the reaction

51

Regeneration

water

38.0

Regeneration

water

5.0

R.O.

72

MEE

52

Reject 18

Domestic

25

Gardening

20

Option: 2

Crystallizer 10

158

Soak pit

5

Treated effluent sent to R.O.

96

Note: All units are in KL/day

Flash steam

54.0

198

54

Condensate 42

Filtration 10

Salt (sent to landfill or incineration) 1.5

62

Reject 34

8.5

Option :1

Incineration

10



FIGURE: 3

PROPOSED WATER BALANCE DIAGRAM

Water Coming from GIDC 1193

Process

40

DM water

Plant

602

Boiler

526

Cooling Tower

728

ETP

96

Softner

506

Boiler blow down

30

Cooling Tower

blow down

32

Effluent

from the

process 91

Water due to the reaction

51

Regeneration water

76

Regeneration

water

5

R.O. 143

MEE

69

Reject 35

Domestic

25

Gardening

20

Option: 2

Crystallizer 12

227

Soak pit

5

Treated effluent sent to R.O.

96

Note: All units are in KL/day

Flash steam

54.0

198

108

Condensate 57

Filtration 12

Salt (sent to landfill or incineration) 3

62

Reject 34

9

Option :1

Incineration

12

501



3.9.2 GASEOUS EMISSIONS & CONTROL

3.9.2.1 FLUE GAS EMISSIONS

FLUE GAS EMISSION

Details of stacks number, stack height, pollutants emitted are covered in following table-

10.

TABLE: 10

FLUE GAS EMISSIONS

Stack No.

Source of emission

Type of emission

Permissible

limit

Stack heigh

t (m)

Stack diamete

r (mm)

Pollution control

equipment

Fuel used ( fuel

name & quantity

/hour)

Existing as per CCA order no.AWH 59708

1 Boiler- 1(Oil fired stand by boiler) Capacity = 10 TPH

PM

SO2 NOx

150 mg/Nm3 100 ppm 50 ppm

30 750 - F.O 850 L/Hr

2 Boiler-2 (IBR water tube boiler) Capacity= 17 TPH

PM

SO2 NOx


40 1350 Bag filter Coal 3MT/hr

3 Boiler-3 (IBR water tube boiler) Capacity= 30 TPH

PM

SO2 NOx


40 1800 ESP Coal 5 MT/Hr

4 D.G. Set (4 Nos) Capacity= 1010 KVA (Each)

PM

SO2 NOx


11 250 - Diesel 220 L/Hr (Each)

5 Thermopack Capacity= 20 LAKH Kcal/hr

PM

SO2 NOx


30 750 Bag filter CoaL 1MT/Hr

As per proposed quantity

6 Boiler-4 (IBR water tube boiler)

PM SO2 NOx

150 mg/Nm3 100 ppm

40 1800 ESP Coal 17MT/hr



Capacity= 60 TPH

50 ppm

3.9.2.2 PROCESS EMISSIONS

The process emissions from the manufacturing activities are given in following Table. The

details of air pollution control system are also mentioned in table-12.

TABLE: 11

PROCESS EMISSIONS AND CONTROL MEASURES

Stack no.

Source of Emission

Type of Emissio

n

Permissible limit

Stack Height (meter)

Stack diameter

(m)

Air pollution control system

Existing as per CCA order no.AWH 59708

1 Nitration Plant , HNO3 storage tank

NOx 25 mg/Nm3

12 100 Sulphric acid scrubber followed by Caustic Scrubber

2 Incinerator PM SO2 NOx


30 700 Scrubber (Double Chamber)

As per proposed quantity

There will be no new process stack due to proposed CTE-amendment.

3.9.3 HAZARDOUS/ NON-HAZARDOUS WASTE MANAGEMENT

The following type of hazardous waste will be generated from the operational activities.

All the waste will be stored separately in a designated storage area.

TABLE: 12

DETAILS OF HAZARDOUS WASTE

Sr. No.

Hazardous waste

Category

Quantity As per Consent-AWH 50363

Proposed Addition

al Quantity

Total Qty after

expansion

Disposal

1. ETP waste (Gypsum)

34.3 100 MT/Month

0 100 MT/Mon

th

Collection, Storage, Transportation, Disposal at TSDF at BEIL.

2 Spent Oil 5.1 0.184 MT/Month

0.007 0.191 MT/Mon

Collection, storage, Transportation,



th Disposal by selling to registered recyclers.

3 Organic Residue

36.4 40 MT/Month

0 40 MT/Mon

th

Collection, storage, Transportation, Disposal by incineration at CHWIF-BEIL & SEPPL.

4 Spent carbon

35.3 3.4 MT/ Month

0 3.4 MT/ Month

Collection, storage, Transportation, Disposal by incineration at CHWIF-BEIL & SEPPL.

5 Incinerated ash & Evaporated salt

36.2 1.04 MT/Month

0 1.04 MT/Mon

th

Collection, Storage, Transportation, Disposal at TSDF at BEIL

6 Spent Sulphuric Acid (68% -72%)

D-2 7200 MT/Month

0 7200 MT/Mon

th

Collection, Storage, Transportation, Disposal by selling to registered users

7 Discarded Plastic bags, Carboys, drums

33.3 1225 No/

Month

0 1225 No/Mont

h

Collection, Storage, decontamination

8 Spent Catalyst (Dry Basis)

35.3 620 Kg/Month

0 620 Kg/Mont

h

Collection, Storage, Transportation, Disposal by selling to registered supplier for regeneration.

9 Residue from MEE

34.3 0 30 MT/mon

th

30 MT/mon

th

Collection, Storage, Transportation, Disposal at TSDF at BEIL

10 Fly ash - 0 840 MT/mon

th

840 MT/mon

th

Collection, Storage, Transportation, Disposal at fly ash handlers



In addition to the provision of above, we will ensure proper management for hazardous

waste as below:

Transportation of hazardous waste to the TSDF Site will be governed as per the guidelines

and accompanied with Form-13.

Annual returns of the disposal of wastes in Form-4 will be uploaded online and submitted

regularly to the local office of the GPCB.

3.9.4 NOISE CONTROL & ODOUR

The major noise generating installation will be the D.G. Set. However DG Set will be

provided with Canopy for control of Noise pollution. Ear plugs will also be provided to

the operating personnel in boiler room.

The following steps will be taken for odour control.

Raw-material feeding will be carried out by pumps.

All reactions will be taken in closed reactor loop system.

Roof top ventilation will be provided in the entire plant area.

Regular monitoring will be done of piping and fittings for checking of any leakages.

3.9.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS CHEMICALS

The storage and mode of transport of chemicals is done as per detailed MSDS and

Chemical hazards guide (NIOSH) for the hazardous chemicals.

3.9.6 HEALTH AND SAFETY MEASURES

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release

of large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3

of MSIHC Rules.

Moreover transport activity will be through drums, so there will be manual loading and

unloading and no unloading through pipe at the site. Hence, the risk of static charge

generation during transfer of such chemicals is not significant.

Below mentioned is the summary proposed safety measures to be taken at site for control

of anticipated hazard.



4.0 SITE ANALYSIS

4.1 CONNECTIVITY

Jhagadia GIDC industrial estate (chemical zone, engineer zone, service cum commercial

zone) is spread over large area in close proximity to State Highway No. 6. National

highway 8 passes through the district connecting it with Ahmedabad (182 km) and

Mumbai (402 km). The Jhagadia is located at 20 km distance from Bharuch Railway

station. The nearest domestic airport Vadodara is at an approx distance 116 km from

Jhagadia. The nearest International airport Ahmedabad is at a distance 250 km.

4.2 LAND USE AND LAND OWNERSHIP

The proposed installation of co-gen project site is located at Plot no. 758/1, 2 & 3, GIDC

Estate, Jhagadia, District: Bharuch, Gujarat. The plot had been purchased by M/s. Aarti

Industries Ltd. (Unit-I) from GIDC. The total plot area of the unit is 51,071 sq. m.

4.3 LAND USE

The proposed installation of co-gen project site is located at Plot no. 758/1, 2 & 3, GIDC

Estate, Jhagadia, District: Bharuch, Gujarat. The plot is notified by GIDC for industrial

purpose.

4.4 EXISTING INFRASTRUCTURE

The plant is located in a well-developed industrial zone, which will have all essential

facilities such as internal roads, arrangement for supply of water and power to industries,

effluent disposal facilities etc.

4.5 CLIMATE DATA

Vadodara is the nearest meteorological observatory station to the project site. The various

meteorological details of Vadodara station for the year of March, 2014 to May, 2014 are

given in below table-14.



TABLE: 13

DETAILS OF THE METEOROLOGICAL CONDITIONS (MARCH TO MAY, 2014).

Month

(2014)

Temperature(oC) Humidity (%) Rain fall

(mm)

Maximum Minimum Maximum Minimum Maximum

March 38.2 14.8 84 13 0

April 47.8 22.8 86 14 0

May 42.4 27.2 83 15 0.8

(Data from Indian Meteorological Department, Baroda)

Based on the above metrological data, wind rose has been prepared for the summer

season period from March 2014 to May 2014. As per the metrological data, it shows that

the average wind speed in March, April, and May 2014 is 2.76 m/s with wind direction

blowing to NE.

The wind rose prepared from same data is shown at Figure 4.

FIGURE: 4

WIND ROSE DIAGRAM



4.6 SOCIAL INFRASTRUCTURE

There are 41 villages in Jhagadia Taluka. Population density and sex ratio of Jhagadia

Taluka was reported 212 persons/sq.km. and 937 females per 1000 males respectively in

2001 census report. Total literacy of Jhagadia Taluka was found 65.92 %.The basic

amenities like primary and secondary education schools, community health workers,

primary health sub centre, private practitioners, primary health centre, maternity and

child welfare, dispensaries, T.B clinic, family welfare centre, hospital, drinking water,

transportation facilities, electricity , telephone etc. are available.

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT

Details will be covered in EIA report.

5.2 POPULATION PROJECTION

Population of Jhagadia Taluka was reported to be 185337 in 2011, Census. Entire Jhagadia

area is all set for massive industrialization. There is large scale migrant population is

anticipated in this area. The proposed project is relatively small in size and will be

employing Around 300 skilled and unskilled people .Almost 80% of this will be selected

from local people. Even though the population of Jhagadia Taluka will have some increase

due to this project.

5.3 LAND USE PLANNING

Details will be covered in EIA report.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

The M/s. Aarti Industries Ltd.(Unit-I) is getting water from GIDC water supply scheme. So

there will be no additional stress on ground water resources and there will be no adverse

effect on the ground water resources available in the nearby area.

The unit is using 4000 KW connected load from DGVCL The transportation facilities will

also expect to improve due to increase in the movement of workers and raw material and

finished products.



5.5 AMENITIES

All of the villages have primary schools, 4 villages have both primary and secondary

education schools. 10 villages have adult education facility, 1 villages has higher

secondary and intermediate. There is no training school in any village. 10 villages have

other education institution.

35 villages have community health workers, 15 villages have primary health sub

centre, 5 villages have registered private practitioners while 4 villages have family

planning centre, 1 village has primary health centre. 1 maternity home, 1 child welfare

centers, 1 dispensary and one hospital are also available in the impact zone.

Primary source of water in villages are tap and well. Tank and hand pump are also

used in the villages.

Villages are connected with paved road. Bus is the main source of transportation.

Broad guage rail line conversion work is under progress.

Most of the villages have post office and phones.

All the villages have availability of electricity supply.

The villages have connectivity of mobile phone facility.

All the surrounding area is covered with 108 emergency facilities.

Source: 2011, Census.

6.0 PROPOSED INFRASTRUCTURE

6.1 PROCESSING AREA

The process area will cover plant area, raw material storage area, Hazardous waste storage

area, ETP, utilities etc. The process area covered by the unit at ground level will be 25345

sq. m.

6.2 GREEN BELT

Out of the total land area of 51071 sq. m. approximately 23 % will be utilized for green belt

development.

The proposed greenbelt area is 11815 sq. m.

6.3 SOCIAL INFRASTRUCTURE

The availability of basic amenities is covered as under:



Training & Education: All the employees will be trained and educated periodically

about the hazardous nature of chemicals used in the process. Also, training for fire

fighting, work permits system, first aid, safe handling of hazardous chemicals and

integrating safety, in all activities.

Medical facility: Pre-employment medical checkup at the time of employment. In order

to safe guard the health of the employees, all the employees undergo periodic health

checkup.

Drinking water: There will be provision of Aqua Guard/R.O. at different places to

provide purified water for drinking purpose.

Transportation: The unit will provide basic transportation facility for workers.

Telegraph & Post: There will be provision of telephone, mobile, fax & internet facility.

Power supply: There is connected load of 4000 KW from DGVCL.

6.5 CONNECTIVITY

The unit will be connected to main towns- Jhaghadia, Ankleshwar and Bharuch – located

within 20 Km of the site. There will be provision of transportation of workers from

Ankleshwar and Bharuch railway station.

6.6 DRINKING WATER MANAGEMENT

Average daily water consumption of unit will be 10 KL/Day for domestic purpose. The

entire water requirement will be meeting through GIDC water supply system.

6.7 SEWERAGE SYSTEM

Average daily water consumption of unit will be 25 KL/day for domestic purpose. The

entire water requirement will be meeting through GIDC water supply system.

6.8 INDUSTRIAL WASTE MANAGEMENT

The hazardous waste management and disposal is shown in table 12.

6.9 SOLID WASTE MANAGEMENT

The record of non hazardous solid waste like, Fiber board drum, wooden waste etc. will be

mentioned.



7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN

The proposed project is located in Jhagadia, Dist. Bharuch. The project site is barren land.

There will be no any human settlement affected by proposed project. So, there is no

requirement of any Rehabilitation & Resettlement Plan.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT IMPLEMENTATION SCHEDULE

TABLE 14

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule after getting NOC from GPCB

Sr.

No.

Activity Required Period

1. Civil work Immediately after getting NOC

2. Procurement of

machinery

1 month after getting NOC

3. Erection & installation of

machinery

Immediately after competition of activity no.2

4. Trial of machinery &

equipments

Within 1 months after competition of activity no.3

5. Commercial activity 1 months after competition of activity no. 4

8.2 ESTIMATED PROJECT COST

Details are already covered in table -4.

9.0 ANALYSIS OF PROPOSAL

All the manpower is utilized from local region around Jhagadia. Company shall also try to

provide indirect employment opportunities by availing local contract services during

transportation during operational phase.

The company intends to donate 5 % of the profit to agencies like NGOs or social welfare

societies for projects carried out in nearby village for their welfare and upliftment.

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