FINAL REPORT ON
ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED MANUFACTURING OF SYNTHETIC ORGANIC CHEMICALS (PHARMACEUTICAL BULK DRUGS & DRUG INTERMEDIATES) BY
ASCENT PHARMA Survey No. 163/9 & 11, On S.I.D.C. Road, Shapar-Veraval Industrial Area, Village: Veraval (Shapar), Taluka: Kotada Sangani, District: Rajkot, Gujarat.
Prepared By:
3rd Floor, Akashganga Complex, B/s. Suvidha Shopping Centre, Nr. Parimal Underpass, Paldi, AHMEDABAD-380 007, Gujarat. Telefax: (079) 2665 0473, 2665 0878 E-mail:
[email protected]
October, 2014
EIA-EMP REPORT
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
SR. NO.
TITLE
PAGE NO.
2.6
Manufacturing Process
2.7
2.7
Solvent Requirements & Recovery System
2.29
2.8
Details of Raw materials
2.31
2.9
Resource Requirements
2.34
2.9.1 Land
2.34
2.9.2 Machineries & Utilities
2.37
2.9.3 Capital Cost
2.38
2.9.4 Power / Electricity
2.38
2.9.5 Water
2.38
2.9.6 Fuel
2.39
2.9.7 Man Power
2.39
2.10 Pollution Potential & Management
2.40
2.10.1 Water Pollution
2.40
2.10.2 Air Pollution
2.46
2.10.3 Hazardous waste
2.48
2.10.4 Noise & Vibration
2.50
CHAPTER – 3: BASELINE ENVIRONMENTAL STATUS 3.1
Preamble
3.1
3.2
Approach & methodology of baseline study
3.1
3.2.1 Study Area
3.1
3.2.2 Study Period
3.1
3.2.3 Sampling Location
3.2
3.2.4 Frequency of Monitoring
3.4
3.2.5 Method of Sampling & Analysis
3.4
Baseline environment
3.5
3.3.1 Topography & Geology
3.6
3.3.2 Seismology
3.6
3.3.3 Land use Pattern
3.6
3.3
3.3.4 Meteorology 3.3.4.1 Temperature
Table of Contents Page | ii
3.10 3.11
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
SR. NO.
PAGE NO.
TITLE 3.3.4.2 Humidity
3.11
3.3.4.3 Cloudiness
3.11
3.3.4.4 Wind Speed & Wind Direction
3.12
3.3.4.5 Rainfall
3.12
3.3.5 Micrometeorology
3.12
3.3.6 Ambient Air Quality
3.14
3.3.7 Hydrology
3.16
3.3.8 Soil Quality
3.21
3.3.9 Noise Level
3.23
3.3.10 Ecological Status
3.24
3.3.10.1 Flora
3.24
3.3.10.2 Fauna
3.28
3.3.11 Socio-economic Structure
3.32
3.3.11.1 Population Growth
3.32
3.3.11.2 Literacy
3.34
3.3.11.3 Occupational Structure
3.36
3.3.11.4 Availability of Basic Amenities
3.36
CHAPTER- 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 4.1
Preamble
4.1
4.2
Identification of Environmental Impacts
4.1
4.2.1 Construction Phase
4.2
4.2.2 Operation Phase
4.2
4.3
Prediction of Environmental Impacts
4.5
4.4
Impacts During Construction Phase and Its Mitigative Measures
4.7
4.5
Impacts During Operation Phase and Its Mitigative Measures
4.11
4.5.1 Water Environment
4.11
4.5.2 Air Environment
4.13
4.5.3 Land/ Soil Environment
4.23
4.5.4 Noise Environment
4.24
4.5.5 Ecological Environment
4.25 Table of Contents Page | iii
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
SR. NO.
TITLE
PAGE NO.
4.5.6 Aesthetic Environment
4.26
4.5.7 Socio-Economic Environment
4.26
CHAPTER – 5: ENVIRONMENTAL MANAGEMENT PLAN (EMP) 5.1
Preamble
5.1
5.2
Objectives of the EMP
5.1
5.3
Environmental Management Plan (EMP)
5.2
5.4
Greenbelt Development Plan
5.5
5.5
Rainwater Harvesting System
5.6
5.6
Application Of Cleaner Production Technology
5.7
5.6.1 Pollution Prevention
5.8
5.6.2 Water Conservation
5.8
5.6.3 Energy Conservation
5.8
5.6.4 Reuse / Recycle
5.9
5.6.5 Good Housekeeping
5.9
Budgetary Allocation for Environment protection
5.10
5.7
CHAPTER – 6: ENVIRONMENTAL MONITORING PROGRAM 6.1
Preamble
6.1
6.2
Monitoring Program
6.1
6.3
Infrastructural requirement & procurement schedules
6.3
6.4
Corporate Environmental Responsibility
6.3
6.5
Environment management cell
6.4
6.6
Administrative actions & documentation
6.6
6.6.1 Data Analysis
6.6
6.6.2 Reporting Schedules
6.6
6.6.3 Environmental Monitoring Expenditure
6.6
CHAPTER – 7: ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE) CHAPTER – 8: RISK AND SAFETY MANAGEMENT Table of Contents Page | iv
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
SR. NO.
PAGE NO.
TITLE
8.1
Preamble
8.1
8.2
Objective, philosophy and methodology of risk assessment
8.2
8.2.1 Objective
8.2
8.2.2 Philosophy
8.2
8.2.3 Methodology
8.2
Hazardous material, process & safety management
8.3
8.3.1 Hazardous Chemicals
8.3
8.3.2 Safety measures for transportation, storage & handling of
8.5
8.3
chemicals 8.3.3 Safety Measures for Methanol
8.5
8.3.4 Critical safety measures for process units
8.6
8.3.5 Safety Measures For Preventive Maintenance
8.7
8.3.6 Safety measures to prevent spillage / leakage of toxic chemicals
8.8
8.4
Occupational Health & Safety Program
8.9
8.5
Risk assessment study
8.10
8.5.1 Identification of High Risk Areas
8.11
8.5.2 Modes of Failure
8.11
8.5.3 Maximum Credible Accident Analysis and Its Mitigation Measures
8.12
8.5.4 Consequences Analysis
8.13
8.6
8.7
8.5.4.1
Definitions & Explanation of Terms Used
8.13
8.5.4.2
Possible Accident Scenario
8.15
8.5.4.3
Risk Mitigative Measures
8.28
Onsite Emergency Plan And Disaster Management Plan
8.28
8.6.1 Pre - Emergency Activities
8.29
8.6.2 Emergency Time Activities
8.31
8.6.3 Post - Emergency Activities
8.32
Offsite Emergency Plan
8.33
CHAPTER – 9: PROJECT BENEFITS 9.1
Employment Opportunities
9.1
9.2
Corporate Social Responsibility (CSR) & Socio-economic Development
9.1
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Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
SR. NO.
TITLE
PAGE NO.
9.3
Direct Revenue Earning to the National and State Exchequer
9.3
9.4
Infrastructural benefit
9.3
9.5
Other tangible Benefits
9.3
CHAPTER – 10: PUBLIC CONSULTATION CHAPTER – 11: PROJECT SUMMARY & CONCLUSION 11.1 Salient Features of the Project
11.1
11.2 Conclusion
11.2
CHAPTER – 12: DISCLOSURE OF CONSULTANT
[
Table of Contents Page | vi
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
LIST OF TABLES TABLE TITLE NO. 1.1 Promoters & Their Background
PAGE NO. 1.2
1.2
Structure of EIA Report
1.5
1.3
Applicable Regulatory Provision for Proposed Project
1.8
2.1
Salient features of the project site
2.2
2.2
List of Existing Products
2.6
2.3
Details of Proposed Products
2.6
2.4
Details of proposed By-Products
2.7
2.5
Details of Solvent Requirement and Recovery
2.30
2.6
Summary of Solvent Requirement and Recovery
2.30
2.7
List of Raw Materials with Requirement
2.32
2.8
Details of Products storage & Handling
2.33
2.9
Details of Raw Materials Storage & Handling
2.33
2.10
Break up of Area
2.34
2.11
Details of Proposed Machineries and Utilities
2.37
2.12
Capital Cost of the project
2.38
2.13
Details of Fuel requirement
2.39
2.14
Details of Manpower Requirement
2.39
2.15
Product wise Water Consumption & Wastewater Generation
2.41
2.16
Category wise Water Consumption & Wastewater Generation
2.42
2.17
Stage-wise characteristics of effluent
2.44
2.18
Detail of proposed Effluent Treatment Plant
2.45
2.19
Details of Flue Gas Stacks
2.46
2.20
Details of Process Gas Emission
2.47
2.21
Details of Process Gas Stack
2.47
2.22
Details of Air Pollution Control Measures for Process Stack
2.47
2.23
Details of scrubbing system
2.47
2.24
Details of Hazardous waste generation and management
2.49
3.1
Sampling & Monitoring Locations
3.2
3.2
Frequency of Environmental Monitoring and Method of Sampling &
3.4
Analysis Table of Contents Page | vii
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TABLE TITLE NO. 3.3 Land Use Pattern of the Study Area
PAGE NO. 3.7
3.4
Meteorological Parameters
3.10
3.5
Ambient Air Quality Status
3.15
3.6
Physico-Chemical Characteristics of Water
3.19
3.7
Physico-Chemical Characteristic of Soil
3.22
3.8
Noise Level in Study Area
3.24
3.9
Enumeration of Flora in the study area
3.25
3.10
List of Flora in the study area
3.25
3.11
List of Fauna in the study area
3.29
3.12
Socio economic profile
3.33
4.1(a)
Identification of Impacts during Construction Phase
4.3
4.1(b)
Identification of Impacts during Operation Phase
4.4
4.2(a)
Prediction of Impacts during Construction Phase
4.6
4.2(b)
Prediction of Impacts during Operation Phase
4.7
4.3
Impacts & its Mitigative Measures during Construction Phase
4.8
4.4
Details of Stacks emission due to proposed project
4.14
4.5
First Three Highest 24-Hourly Average GLC Values
4.15
4.6
First Highest 24-Hourly Average GLC Values for AAQM Stations
4.15
4.7
Incremental ground level concentration of pollutants
4.17
5.1
Environmental management plan
5.2
5.2
Details of plant species
5.5
5.3
Estimation of availability of yearly runoff
5.7
5.4
Recurring cost for environmental management
5.10
6.1
Environmental Monitoring Program
6.1
6.2
Details of Hospitals Tie-up for Medical Assistance
6.3
6.3
Responsibilities of EMC
6.5
8.1
Details of Hazardous Chemicals per the MSIHC rules 1989 & 2000
8.4
8.2
Storage details of hazardous chemicals
8.13
8.3
Threshold values of the Hazardous Chemicals
8.13
8.4
Atmospheric Conditions Assumed
8.16
8.5
Source Strength considered for Methanol
8.16
8.6
Threat zone of toxic liquid concentration
8.17
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Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TABLE TITLE NO. 8.7 Flammable area of vapor cloud
PAGE NO. 8.17
8.8
Threat zone of thermal radiation from pool fire
8.19
8.9
Threat zone of thermal radiation from BLEVE
8.20
8.10
Source Strength considered for Ammonia Gas
8.22
8.11
Toxic Threat zone
8.23
8.12
Flammable area of vapor cloud
8.24
8.13
Threat zone of thermal radiation from jet fire
8.26
8.14
Threat zone of thermal radiation from BLEVE
8.27
9.1
Employment Opportunity due to the Proposed Project
9.1
LIST OF FIGURES FIGURE NO. 2.1 Location Map of Project Site
TITLE
PAGE NO. 2.3
2.2
Key Infrastructure & Administrative Map of Study Area
2.4
2.3
Google map showing distance from severely polluted area
2.5
2.4
Schematic Diagram of the Solvent Recovery System
2.31
2.5
Key Plan & Plant Lay-out
2.36
2.6
Water Balance Diagram (After Proposed Project)
2.43
2.7
Schematic Diagram of Proposed Effluent Treatment Plant
2.45
2.8
Schematic Diagram of APCM for Process Emission
2.48
3.1
Map of Study Area showing Sampling & Monitoring Locations
3.3
3.2
Satellite Image of the Study Area
3.8
3.3
Land use / Land Cover Map of the Study Area
3.9
3.4
Wind Rose Diagram
3.13
3.5
Map showing hydrology of the study area
3.18
3.6
Map of Study Area Showing Population Distribution
3.35
3.7
Map of Study Area showing population literacy rate
3.37
3.8
Map of Study Area showing workers distribution
3.38
4.1
Contour plot showing highest Incremental GLC for PM 10
4.18
4.2
Contour plot showing highest Incremental GLC for SO 2
4.19
4.3
Contour plot showing highest Incremental GLC for NOx
4.20 Table of Contents Page | ix
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
FIGURE TITLE NO. 4.4 Contour plot showing highest Incremental GLC for HCl
PAGE NO. 4.21
4.5
Beneficial Impacts Due to the Project
4.28
6.1
Environmental management cell
6.4
8.1
Source Strength in case of Methanol escapes
8.17
8.2
Isopleths result of Toxic threat at a point for Methanol
8.18
8.3
Source Strength in case of Methanol escapes (Pool Fire)
8.19
8.4
Thermal radiation at a point in case of Methanol escapes (Pool Fire)
8.20
8.5
Isopleths result of threat zone of thermal radiation from BLEVE
8.21
8.6
Source Strength in case of Ammonia Gas escapes
8.22
8.7
Isopleths result of toxic threat zone for Ammonia Gas escaping
8.23
8.8
Isopleths result of flammable threat zone for Ammonia Gas escaping
8.24
8.9
Isopleths result of Toxic threat at a point for Ammonia Gas
8.25
8.10 Source Strength in case of Ammonia Gas escapes (Pool Fire)
8.25
8.11 Isopleths result of thermal radiation from jet fire
8.26
8.12 Isopleths result of threat zone of thermal radiation from BLEVE
8.27
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Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
LIST OF ANNEXURES ANNEXURE NO.
TITLE
PAGE NO.
1.
Consent To Establish (CTE/NOC) from GPCB for the existing unit
A-2
2.
Consent to Operate (CTO/CC&A) from GPCB for the existing unit
A-6
3.
Compliance report of CTE
A-11
4.
Compliance report of CTO
A-14
5.
Compliance of CREP guidelines
A-19
6.
Land possession documents
A-23
7.
NOC from Forest Department, Rajkot
A-25
8.
Permission of water supply from Veraval (Shapar) Gram
A-27
Panchayat 9.
List of industries in nearby area
A-28
10.
Copy of membership certificate of TSDF/CHWIF
A-32
11.
AAQ monitoring results
A-33
12.
Stack monitoring reports from NABL approved laboratory for
A-39
existing unit 13.
Photographs of the existing unit
A-41
14.
Photographs of the baseline monitoring during EIA study
A-42
15.
National Ambient Air Quality standards
A-43
16.
Drinking Water Specification as per IS:10500:2012
A-45
17.
Ambient Air Quality standards in respects of noise
A-49
18.
MSDS of all products and raw materials
A-50
19.
Public Hearing Proceeding
A-184
Table of Contents Page | xi
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
LIST OF ABBREVIATIONS AAQM
: Ambient Air Quality Monitoring
APHA
: American Public Health Association
APCM
: Air Pollution Control Measure
APTI
: Air Pollution Tolerance Index
BDL
: Below Detectable Limit
CP
: Cleaner Production
CPCB
: Central Pollution Control Board
CHWIF
: Common Hazardous Waste & Incineration facility
CSR
: Corporate Social Responsibility
EAC
: Expert Appraisal Committee
EIA
: Environmental Impact Assessment
EC
: Environment Clearance
EHS
: Environment, Health & Safety
EMP
: Environment Management Plan
EMS
: Environment Management System
EPA
: Environmental Protection Act
ETP
: Effluent Treatment Plant
DMP
: Disaster Management Plan
GLC
: Ground Level Concentration
GOI
: Government of India
GPCB
: Gujarat Pollution Control Board
HAZOP
: Hazard & Operability Study
IMD
: Indian Metrological Data
IS
: Indian Standard
ISCST
: Industrial Source Complex Short term
ISO
: International Standard Organization
MOC
: Material Of Construction
MoEF
: Ministry of Environment & Forest
MSL
: Mean Sea Level
MSDS
: Material Safety Data Sheets
NH
: National Highway
NOC
: No Objection Certificate
Table of Contents Page | xii
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
OSHA
: Occupational Safety And Health Administration
PAC
: Poly Aluminum Chloride
PM
: Particulate Matter
PPEs
: Personal Protective Equipments
RA
: Risk Assessment
TOR
: Terms of Reference
TSDF
: Treatment, Storage and Disposal Facility
TDS
: Total Dissolved Solid
LIST OF SYMBOLS / NOTATIONS °C
:
Degree Celsius
dB(A)
:
Decibels(A-Weighted)
gm/cc
:
Gram per Cubic Centimeter
Kcal/ Hr
:
Kilo Calorie per Hour
KVA
:
Kilo Volts Ampere
KLD
:
Kilo Liters per Day
KW
:
Kilo Watt
m
:
meters
m/s
:
Meters per Second
mg/lit
:
Milligram/ Liters
mg/m3
:
Milligram/cube meter of air
MW
:
Mega Watt
µg/m
:
Microgram/cube meter of air
µs
:
Microgram second
NO X
:
Oxides of Nitrogen
ppm
:
Parts per Million
SO 2
:
Sulphur dioxide
Sq.km
:
Square kilometer
Sqm
:
Square Meter
TPM
:
Ton per Month
3
Table of Contents Page | xiii
COPY OF TOR ISSUED BY MoEF
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Terms of Reference (TOR) Page | xiv
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Terms of Reference (TOR) Page | xv
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Terms of Reference (TOR) Page | xvi
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Terms of Reference (TOR) Page | xvii
TOR COMPLIANCE
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
COMPLIANCE OF TOR TOR TOR Points No. 1 A separate chapter on status of compliance of Environmental Conditions granted by State/Centre to be provided. As per circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA/EMP report 2 Executive summary of the project 3 4 5 6
7 8 9 10
Compliance Status Not Applicable because presently unit is manufacturing inorganic products for which EC is not required
Separately provided with the EIA report Justification of the project Chapter-2, Section -2.2 Promoters and their back ground Chapter-1, Section -1.2 Regulatory framework Chapter-1, Section -1.7 Environment clearance for the existing unit issued by the Presently unit is Ministry (reasons, if not obtained), Consent to Operate and manufacturing inorganic Authorization accorded by the GPCB. products for which EC is not required. For Consent to Operate and Authorization accorded by the GPCB, please refer Annexure-2. Copy of NOC/Consent to Establish for the existing unit. Annexure-1 Compliance to the conditions stipulated in the NOC Annexure-3 granted by the SPCB. Has the unit received any notice under the Section 5 of Unit does not have receive Environment (Protection) Act, 1986 or relevant Sections of such notice in last two years Air and Water Acts? If so, compliance to the notice(s). Data for the stack emissions, fugitive emissions; water Please refer Annexure-12 requirement and water balance chart; wastewater for stack emission report. generation, treated effluent quality, re-utilization and There is no any process disposal of solid/hazardous waste for the existing unit. emission from the existing unit. For the water and wastewater details, please refer Chapter-2, Section2.10.1 Activated carbon is utilized for color removal during the process, if any as per the product quality & customer requirement. Till date no such quantity of activated carbon is used & hence no generation of any spent carbon which is required to be disposed of. Compliance of TOR Page | xviii
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TOR TOR Points Compliance Status No. 11 A map indicating location of the project and distance from Chapter-2, Figure 2.3 severely polluted area. 12 Project location and plant layout. Chapter-2, Section-2.3, Figure 2.5 13 Infrastructure facilities including power sources. Chapter-2, Section-2.9.2 & 2.9.4 14 Total cost of the project along with total capital cost and Chapter-2, Section-2.9.3; recurring cost/annum for environmental pollution control Chapter-5, Section-5.7 measures. 15 Project site location along with site map of 10 km area and Chapter-2, Figure 2.1, 2.2; site details providing various industries, surface water Chapter-3, Figure 3.3 & 3.5 bodies, forests etc. 16 Present land use based on satellite imagery for the study Chapter-3, Figure 3.2 & area of 10 km radius. Details of land availability for the 3.3 project along with supporting document. This is an existing unit having a total land area of 2292 sqm and proposed project will take place within the same premises. No additional land is required for the proposed project. Refer Annexure-6 for land possession documents of existing plot 17 Location of National Park/Wild life sanctuary/Reserve Figure 2.2 & 3.3 forest within 10 km radius of the project. Table 2.1, Sr. No. 5 18 Permission from the State Forest Department regarding Annexure-7 the impact of the proposed plant on the surrounding reserve forests. 19 Details of the total land and break-up of the land use for Chapter-2, Section-2.9.1 green belt and other uses. 20 List of products along with the production capacities. Chapter-2, Section-2.5 21 Detailed list of raw material required and source, mode of Chapter-2, Section-2.8 storage. 22 Manufacturing process details along with the chemical Chapter-2, Section-2.6 reactions and process flow chart. 23 Action plan for the transportation of raw material and Chapter-5, Section-5.3 products. 24 Site-specific micro-meteorological data using temperature, Chapter-3, Section-3.3.5, relative humidity, hourly wind speed and direction and Figure-3.4 rainfall is necessary. 25 Ambient air quality monitoring at 6 locations within the Chapter-3, Section-3.3.6 study area of 5 km., aerial coverage from project site as per NAAQES notified on 16th September, 2009. Location of one AAQMS in downwind direction. 26 One season site-specific micro-meteorological data using Chapter-3, Section-3.2, temperature, relative humidity, hourly wind speed and 3.3.5, 3.3.6, 3.3.7, 3.3.9 Compliance of TOR Page | xix
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TOR No.
27 28 29 30
31 32 33 34
35 36
37
38
TOR Points
Compliance Status
direction and rainfall and AAQ data (except monsoon) for PM 10 , PM 2.5 , SO 2 , NO x , CO, NH 3 including VOCs shall be collected. The monitoring stations shall take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring shall also be included. Details of water and air pollution and its mitigation plan Chapter-2, Section-2.10.1, 2.10.2 Air pollution control measures proposed for the effective Chapter-2, Section-2.10.2 control of gaseous/process emissions within permissible limits. An action plan prepared by SPCB to control and Chapter-4, Section-4.5.2.C monitor secondary fugitive emissions from all the sources. Determination of atmospheric inversion level at the Chapter-4, Section-4.5.2.B project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modeling for proposed plant. Name of all the solvents to be used in the process and Chapter-2, Section-2.7 details of solvent recovery system. Design details of ETP, incinerator, if any along with Chapter-2, Section-2.10.1, boiler, scrubbers/bag filters etc. 2.10.2 Action plan to control ambient air quality as per NAAQS Chapter-4, Section-4.5.2.C Standards notified by the Ministry on 16th September, 2009. Permission from Competent Authority for the drawl of 12 Refer Annexure-8 for m3/day water. Water balance chart including quantity of permission of water. effluent generated recycled and reused and effluent For water details refer discharge. Chapter-2, Section-2.10.1 Complete scheme of effluent treatment. Characteristics of Chapter-2, Section-2.10.1 untreated and treated effluent to meet the standard. Zero discharge effluent concepts to be adopted. Only 1.7 KLD industrial effluent will be generated which will be treated in ETP and treated effluent conforming to the discharge norms will be utilized for greenbelt development within the premises. Refer Chapter-2, Section-2.10.1 Ground water quality monitoring minimum at 6 locations Chapter-3, Section-3.3.1, shall be carried out. Geological features and Geo- 3.3.7, 3.3.10 hydrological status of the study area and ecological status (Terrestrial and Aquatic). The details of solid and hazardous wastes generation, Chapter-2, Section-2.10.3 storage, utilization and disposal particularly related to the Unit is using Furnace oil as hazardous waste calorific value of hazardous waste and a fuel and for the proposed Compliance of TOR Page | xx
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TOR No.
39 40 41 42 43
44
45 46 47
48 49 50
TOR Points
Compliance Status
detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler shall be included. Material Safety Data Sheet for all the Chemicals are being used/will be used. Authorization/ Membership for the disposal of solid/ hazardous waste in TSDF. Risk assessment for storage for chemicals/solvents. Action plan for handling & safety system. An action plan to develop green belt in 33 % area. Layout plan for green belt shall be provided. Action plan for rainwater harvesting measures at plant site shall be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water. Details of occupational health programme. i) To which chemicals, workers are exposed directly or indirectly. ii) Whether these chemicals are within Threshold Limit Values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation. iii) What measures company has taken to keep these chemicals within PEUTLV. iv) How the workers are evaluated concerning their exposure to chemicals during pre-placement and periodical medical monitoring. v) What are onsite and offsite emergency plan during chemical disaster. vi) Liver function tests (LFT) during pre-placement and periodical examination. vii) Details of occupational health surveillance programme. Socio-economic development activities shall be in place. Note on compliance to the recommendations mentioned in the CREP guidelines. Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure shall be provided. EMP shall include the concept of waste-minimization, recycle / reuse / recover techniques, Energy conservation, and natural resource conservation. Total capital cost and recurring cost/annum for environmental pollution control measures. Corporate Environmental Responsibility (a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. (b) Does the Environmental Policy prescribes for standard
project FO/LDO will be utilized. Thus, no question of disposal of fly ash. Annexure-18 Annexure-10 Chapter-8, Section-8.3 & 8.5 Chapter-5, Section-5.4, Figure-2.5 Chapter-5, Section-5.5
Chapter-8, Section-8.4, 8.6 & 8.7; Chapter-6, Section6.2
Chapter-9, Section-9.2 Annexure-5 Chapter-2, Section-2.10; Chapter-5, Section-5.3; Chapter-6, Section-6.2 Chapter-5, Section-5.6 Chapter-2, Section-2.9.3; Chapter-5, Section-5.7 Chapter-6, Section-6.4, 6.5 & 6.6
Compliance of TOR Page | xxi
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
TOR No.
TOR Points
Compliance Status
operating process / procedures to bring into focus any infringement/ deviation/violation of the environmental or forest norms/ conditions? If so, it may be detailed in the EIA report. (c) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. (d) Does the company have a system of reporting of noncompliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report. 51 Any litigation pending against the project and/or any No litigation is pending and direction/order passed by any Court of Law against the no direction has been project, if so, details thereof. passed by any Court against the project/unit 52 Public hearing issues raised and commitments made by Will be incorporated after the project proponent on the same should be included completion of the public separately in EIA/EMP Report in the form of tabular chart hearing process with financial budget for complying with the commitments made. 53 A tabular chart with index for point wise compliance of Noted & Complied above TORs. The following general points shall be noted: Noted & Complied i. All documents shall be properly indexed, page numbered. ii. Period/date of data collection shall be clearly indicated. iii. Authenticated English translation of all material provided in Regional languages. iv. The letter/application for EC shall quote the MOEF file No. and also attach a copy of the letter. v. The copy of the letter received from the Ministry shall be also attached as an annexure to the final EIA-EMP Report. vi. The final EIA-EMP report submitted to the Ministry must incorporate the issues in this letter. The index of the final EIA-EMP report must indicate the specific chapter and page no. of the EIA-EMP Report. vii. Certificate of Accreditation issued by the QCI to the environmental consultant shall be included.
Compliance of TOR Page | xxii
CHAPTER 1 INTRODUCTION
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
CHAPTER – 1 1.1
INTRODUCTION
PREAMBLE
M/s. Ascent Pharma is an existing small scale unit located at Survey No. 163/9 & 11 on S.I.D.C. Road in Shapar-Veraval Industrial Area of Village Veraval (Shapar) in Kotada Sangani Taluka of Rajkot District in Gujarat state. At present the unit is manufacturing various Inorganic Chemicals with the total production capacity of 50 TPM. Now, considering the market demand, the unit intends to manufacture various Bulk Drugs & Drugs Intermediates (Synthetic Organic Chemicals) with total production capacity of 55 TPM within the existing premises by utilizing existing infrastructure facilities with the addition of new machineries. The unit believes in sustainable development and equally concern about environment preservation and pollution control. Since the foundation the unit has already provided adequate Environmental Management System in existing plant. The unit also proposes to provide adequate Environmental Management System to meet desired norms of effluent discharge (Water + Air + Solid) for their proposed project as per the statutory recruitments and also prepared to put its continuous endeavor for the pollution prevention and betterment of environment. 1.2
PROMOTERS & THEIR BACKGROUND
M/s. Ascent Pharma has been promoted by three Managing Partners; 1. Mr. R. M. Ghonia 2. Mr. Vipul Baldha 3. Mr. G. G. Gajipara Details about the promoters are given below: 1. Mr. R. M. Ghonia aged about 41 years, a postgraduate in organic chemistry from Saurashtra University having rich experience of 17 years in the Pharmaceutical Industry. He was with Ficom Organic Ltd., Ankleshwar for 2.5 years and United Phosphorus Ltd., Ankleshwar for 6.5 years and since last 9 years he is associated with Ascent Pharma as managing partner. He was looking after production, process scale up, plant erection and regulations. His vast knowledge and experience about Chapter-1: Introduction Page | 1.1
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
the Pharma Industry will be of immense help in production and factory administration of their proposed project. 2. Mr. Vipul Baldha aged 35 years has done Post Graduate in Analytical chemistry from Saurashtra University having 12 years of experience in Quality Control. He has worked with Gujarat Organic, Ankleshwar for 3 years and since last 9 years he is associated with Ascent Pharma as managing partner. He was looking for Quality Control and other regulatory aspects. 3. Mr. G. G .Gajipara aged 44 years a graduate in chemistry from Saurashtra University having 20 years of vast experience in Production, Maintenance in Pharma industry. He has worked with Ficom Organic Ltd., Ankleshwar for 8 years and with H. N. Dyechem, Ankleshwar for 3 years. Since last 9 years he is associated with Ascent Pharma as managing partner. He was looking after maintenance and production. Table 1.1: Promoters & Their Background Sr. Name of Partners & No. Designation 1. Mr. Ramesh M. Ghonia [Managing Partner] 2.
Mr. Vipul R. Baldha [Managing Partner]
3.
Mr. G. G. Gajipara [Managing Partner]
1.3
Address
Qualification Experience
Village: Bandra, M. Sc. Ta: Gondal, Dist: Rajkot, (Org. Chem.) Gujarat Village: Ambaradi, M.Sc. Ta: Gondal, Dist: Rajkot, (Anal.Chem.) Gujarat At. Virpur (Jalaram), Ta: B.Sc. Jetpur, Dist: Rajkot, Chemical Gujarat
17 Years 12 Years 20 Years
NEED OF THE EIA STUDY
The proposed project is covered under Category ‘5(f)-A’ as per new EIA Notification of Ministry of Environment & Forest (MoEF), dated 14-Sep-06. Therefore, the unit requires to obtain Environmental Clearance (EC) from Ministry of Environment & Forest (MoEF), New Delhi. The purpose of the Environmental Impact Assessment study and report is to comply with the ToR issued by the MoEF as a part of the process to obtain Environmental Clearance. Most importantly the purpose of EIA study is to identify and mitigate environmental impacts in a timely manner. Ascent Pharma has appointed Envisafe [[
Chapter-1: Introduction Page | 1.2
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Environment Consultants (Envisafe), Ahmedabad as an EIA Consultant for the proposed project. Envisafe is an EIA Consultant accredited by the National Accreditation Board for Education and Training (NABET), an organization working under the Quality Council of India (QCI), which is mandatory for carrying out EIA Projects as per the MoEF’s Office Memorandum dated 02-Dec-09. 1.4
OBJECTIVES OF EIA STUDY
Environmental Impact Assessment (EIA) is a planning tool to give the environment its due place in the decision making process by clearly evaluating the environmental consequences of a proposed activity before action is taken. Thus, the main objective of EIA is to determine as precisely as possible, within the present limits of knowledge and expertise, the likely environmental impacts of a planned development activity and incorporate efficient environmental protection measures right at the planning stage of project in such a way that the residual adverse effects becomes acceptable or almost none. The objectives of the present environmental impact assessment study briefly described below: To support the goals of environmental protection and sustainable development. To integrate environmental protection and economic decisions at the earliest stages of planning an activity. To identify and assess environmental, social, economic, and cultural consequences of a proposed activity and to delineate plans for the mitigation of adverse impacts resulting from the proposed activity. To provide for the involvement of the public, Government department and Government agencies in the review of the proposed activities. Thus, by using EIA tool both environmental and economic benefits can be achieved, such as reduced cost & time of project design & implementation, avoided treatment/clean-up costs, impacts of laws and regulations, etc.
Chapter-1: Introduction Page | 1.3
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
1.5
PURPOSE OF EIA STUDY
The concept of EIA has corollaries in the long run for almost all development activity because sustainable development depends on protecting the natural resources which is the foundation for further development. The main purposes of doing environmental impact assessment study are: To assess the prevailing environmental status within the study area around the project site. To critically analyze the various activity of the proposed project and identify potential source of environmental pollution. To assess the impacts of the proposed project on the environment. To identify and assess significant impacts of proposed project on environmental components through matrix method. To suggest preventive and mitigation measures to minimize or avoid the adverse impacts on the environment and to maximize the beneficial impacts. To prepare Environmental Management Plan (EMP) and delineate post-project environmental monitoring program to be pursued by the industries. To prepare an EIA Study report and utilize it for applicable statutory clearances for proposed project and/or any other management purpose. Thus, the present EIA study will help the proponent in their planning of effective control measures to avoid or minimize the likely adverse impacts on environment due to their proposed project. 1.6
STRUCTURE OF REPORT
The EIA report has been structured covering various aspects like project description, baseline conditions, environmental impacts, mitigation measures, environmental management plan as directed by MoEF vide letter of awarded ToR. Copy of ToR and its compliance is provided at the beginning of this report. Further, the present EIA report has been prepared chapter-wise in accordance with generic structure suggested by MoEF in EIA notification.
[[
Chapter-1: Introduction Page | 1.4
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
The present report of the EIA study for the proposed project of manufacturing of synthetic organic chemical (Bulk Drugs & Drugs Intermediates) of M/s. Ascent Pharma has been prepared in the following structure; Table 1.2: Structure of EIA Report Sr. No. 1.
EIA Structure Introduction
Contents Identification of project & project proponent Need, Objectives & Purpose of EIA study EIA structure & Regulatory Frame work
2.
Project description
Description & Justification of the project Project Location and Salient features of the project site Maps showing Project Location, plant layout & administrative map of study area Proposed Product and process description Description of facilities, infrastructure need, resource requirement, pollution potentials & management
3.
Baseline Environmental status
Approach & methodology of baseline study Establishment of baseline status for valued environmental parameters as identified in scope Maps of Study Area showing Sampling & Monitoring Locations and land use pattern.
4.
Anticipated Environmental Impacts & Mitigation Measures
Identification & prediction of environmental impacts during construction as well as operation phases of the proposed project Evaluation of Impacts on air environment using mathematical model. Mitigation measures for minimizing and / or avoiding adverse impacts during construction as well as operation phases
5.
Environmental Management Plan
Environmental Management Plan for various project Activities Illustration of greenbelt development plan, rainwater harvesting system and application of cleaner production technology Budgetary allocation for environment protection
6.
Environmental Monitoring Program
Technical aspects of monitoring the effectiveness of mitigation measures including measurement methodologies, frequency, location, data analysis, Chapter-1: Introduction Page | 1.5
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Sr. No.
EIA Structure
Contents reporting schedules Description of the administrative & managerial aspects of ensuring that mitigation measures are implemented and their effectiveness monitored
7.
Analysis of site alternatives (technology & site)
Justification of sites selection & technology for the manufacturing of proposed products
8.
Risk and safety management
Details of hazardous chemicals and Safety measures for the transportation, loading/unloading, Storage/handling etc. Risk Assessment Safety measures for the manufacturing process and preventive maintenance Occupational Health & Safety Management Onsite / Offsite Emergency Plan
9.
Project Benefits
Employment opportunity and Corporate social responsibility (CSR) Socio-economic development and Improvements in the physical & social infrastructure Employment & Other tangible benefits
10. Public Consultation / Public hearing
Draft EIA report will be submitted for public hearing and Minutes of Public Consultation / Public Hearing will be incorporated in the final EIA report
11. Summary & Conclusion
Salient features of the project covering project description, location, mitigation measures, costing etc. Overall Conclusion for the proposed project
12. Disclosure of Consultants Engaged 1.7
Details of the EIA consultants, experts & Laboratory engaged engaged
REGULATORY FRAMEWORK
Unit has obtained Consent to Establish (CTE/NOC) from GPCB vide letter no. PC/CCA/CCA-RJ-1344/ID-37336/108102
dated
23-Mar-12
(Copy
enclosed
as
Annexure-1) and Consent to Operate (CTO/CC&A) from GPCB vide Consent Order no. AWH-49497, which is valid up to 17-May-17 (Copy enclosed as Annexure-2) for the existing plant. Unit is complying with all the conditions prescribed in the CTE &
[[
Chapter-1: Introduction Page | 1.6
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
CTO. Compliance reports of CTE and CTO are enclosed as Annexure-3 and Annexure-4 respectively. The proposed project is covered under Category ‘5(f)-A’ as per new EIA Notification of Ministry of Environment & Forest (MoEF), dated 14-Sep-06. Therefore, the unit requires to obtain EC from Ministry of Environment & Forest (MoEF), New Delhi. The application & proposal for the proposed project was submitted on 28-Jun-13 to the Ministry of Environment & Forest (MoEF), New Delhi. The said application was considered in 11th reconstituted Expert Appraisal Committee meeting held on 26-Aug13 and approved TOR for the EIA study was issued by MoEF vide letter No. J11011/210/2013- IA II (I), dated 07-Nov-13. During the manufacturing, unit intend to utilize some chemicals having flammable & toxic hazards; hence the regulatory framework related with the hazardous or toxic chemicals as well as regulatory provision of risk, emergency & safety management are applicable to the proposed project. The regulatory provision related with hazardous material handling, manufacturing, storage & transportation are also applicable to the proposed project. Also, the proponent has proposed for export through direct or indirect shipping of finished products; hence the regulatory provisions related with export are also applicable. The transportation & export is proposed through road network & shipping and so the applicability of road transport as well as Port & dock related regulations are required to confirm. Thus, the proposed project may be required to comply with many regulatory provisions. The proponent shall follow the regulatory frame work as listed below and additional applicable provision shall also be referred timely as cited as mandatory provision for proposed project. In any case, proponent shall comply with the regulatory provision as directed through particular regulatory provision. The special regulatory provisions like exemption from excise & custom duty, services tax etc. shall be referred by the proponent in their planning & operations. The main regulatory provisions applicable to the proposed project area tabulated below.
Chapter-1: Introduction Page | 1.7
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 1.3: Applicable Regulatory Provision for the Proposed Project Sr. Legal Instrument Concern Authority or Bodies No. 1 Air (Prevention & Control of CPCB and SPCB Pollution) Act, 1981 amended 1987 2
Air (Prevention & Control of CPCB and SPCB Pollution) (Union Territory) Rules, 1983
3
Water (Prevention and Control of CPCB and SPCB Pollution) Act, 1974 amended 1988
4
Water (Prevention and Control of CPCB and SPCB Pollution) Rules, 1975
5
The Environment (Protection) Act, Ministry of Environment and Forests, CPCB 1986, amended 1991 and SPCB
6
Environmental (Protection) Rules, Ministry of Environment and Forests, CPCB 1986 (Amendments in 1999, 2001, and SPCB 2002, 2002, 2002, 2003, 2004)
7
Hazardous Waste (Management MoEF, CPCB, SPCB, DGFT, Port Authority and Handling) Rules, 1989 and Customs Authority amended 2000 and 2003
8
Manufacture Storage and Import of Ministry of Environment & Forests, Chief Hazardous Chemicals Rules, 1989 Controller of Imports and Exports, CPCB, amended 2000 SPCB, Chief Inspector of Factories, Chief Inspector of Dock Safety, Chief Inspector of Mines, AERB, Chief Controller of Explosives, District Collector or District Emergency Authority, CEES under DRDO
9
Chemical Accidents (Emergency CCG, SCG, DCG, LCG and MAH Units Planning, Preparedness and Response) Rules, 1996
10
EIA Notification, 2006 as amended MoEF, SPCB timely (2009, 2011)
11
Batteries (Management Handling) Rules, 2001.
12
Public Liability Insurance Act, 1991 Ministry of Environment & Forests, District amended 1992 Collector
13
Public Liability Insurance Rules, Ministry of Environment & Forests, District 1991 amended 1993 Collector
14
Factories Act, 1948
[[
Chapter-1: Introduction Page | 1.8
and SPCB, CPCB and MoEF
Ministry
of
Labour,
DGFASLI
and
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Sr. No.
Legal Instrument
Concern Authority or Bodies Directorate of Industrial Safety Health/Factories Inspectorate
and
15
The Custom Act, 1962
CBEC, Ministry of Finance
16
The Merchant Shipping Act, 1958 Ministry of Shipping, Road Transport and amended in 2002 and 2003 & rules Highways there under [Merchant Shipping (carriage of Cargo) Rules 1995] *
(Note: * the rules are not directly applicable to the proposed project but during operation it may be applicable timely depending up on allied operations like welding, fabrication & shipping of products.)
Chapter-1: Introduction Page | 1.9
CHAPTER 2 PROJECT DESCRIPTION
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
CHAPTER – 2 2.1
PROJECT DESCRIPTION
PREAMBLE
M/s. Ascent Pharma is an existing small scale unit located at Survey No. 163/9 & 11 on S.I.D.C. Road in Shapar-Veraval Industrial Area of Village Veraval (Shapar) in Kotada Sangani Taluka of Rajkot District in Gujarat state and involved in the manufacturing of various Inorganic Chemicals with the production capacity of 50 TPM. Now the unit proposes to manufacture various Bulk Drugs & Drugs Intermediates (Synthetic Organic Chemical) with total production capacity of 55 TPM. The stated project will be carried out within the existing premises. Thus, this is a brown field project where unit intends to manufacture products covered under Category 5(f)-A as per new EIA Notification of Ministry of Environment & Forest (MoEF), dtd. 14-Sep06. 2.2
JUSTIFICATION OF THE PROJECT
India's pharmaceutical industry is now the third largest in the world in terms of volume and 14th in terms of value. Being a ‘Life Saving Drug’, there is a huge demand and potential of marketing in Gujarat, India and around the world. In fact, bulk drugs/ API’s are normally not used in their basic form, so the demand for basic drugs emanates from formulation industries manufacturing medicines in various forms. As medicines are highly consumed in all seasons, there are thousands of companies in India, which are manufacturing tablets, capsules & syrups of the proposed products. In India, it is highly demanded in the states like Gujrat, Uttarakhand, Punjab, Haryana, Uttar Pradesh, Andhra Pradesh, Tamilnadu, Maharashtra, West Bengal, etc. These states are the hub of the Pharmaceuticals markets. Looking the anticipated demand of healthcare sector in domestic as well as global market and growing volume of pharmaceuticals industry, the proposed project to manufacture Pharmaceutical Bulk Drugs and & Drugs Intermediates, have no doubt for the guarantee of the product and its acceptability in the local and international market. There is huge demand for Export in countries like Sri Lanka, Iran, Bangladesh, Pakistan, Bhutan, Vietnam, Africa, Nigeria, Singapore, Malaysia, Jordan etc.
Chapter-2: Project Description Page | 2.1
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.3
PROJECT LOCATION
The proposed project will be carried out in existing industrial premises located in the Shapar-Veraval Industrial area. Location map of the project site and key infrastructure map are given as Figure 2.1 & Figure 2.2 respectively. Google map showing the distance of project site from severely polluted area (Aaji GIDC) is given in Figure 2.3. The salient features of the projects are described in Table 2.1. Table 2.1: Salient Features of the Project Site 1
2 3
4 5
: SOI Toposheet No. F42-K16 Altitude - 196 m above MSL Latitude 22° 8' 54.73" N Longitude 70°47' 54.57" E Land use of Plant site : 100% Industrial Land Minimum Distances From Plant Site a) City : Rajkot : @ 13.33 km North b) Village : Veraval : @ 2.2 km, North East Shapar : @ 4.0 km, North West c) Railway Station : Ribda : @ 4.2 km South d) Highway : National Highway No. 8B @ 1.5 km East e) Sea Coast : Arabian Sea: @ 179 km West f) Domestic Airport : Rajkot : @ 10.83 km NNE g) International Airport : Ahmedabad : @ 207 km ENE h) Sea Port : Kandla: @ 190 km NW Distance from severly polluted area : Aaji Industrial Area: @ 15 km NNE Places of Interest within 10 Km radius from the Plant Site (if, any): Geographical Details
There is no protected area notified under the Wild Life (Protection) Act (1972) & Eco - sensitive area notified under Section 3 of the Environment (Protection) Act – 1986 exists within 10 Km radius areas from the Plant Site. As per census 2001, Naranka Reserve Forest falls with in the study area and unit has obtained No Objection Certificate from the Forest Department, Rajkot for the proposed project and same is enclosed as Annexure-7. 6 7
Displacement of population Seismic Zone
Chapter-2: Project Description Page | 2.2
: None : As per the earthquake sensitivity index, the unit is situated in Zone- III having moderate Damage Risk Zone (MSK- VII).
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.1: Location Map of Project Site
Chapter-2: Project Description Page | 2.3
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.2: Key Infrastructure & Administrative Map of Study Area
RF
RF Reserve Forest
Chapter-2: Project Description Page | 2.4
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.3: Google map showing distance of project site from Severely Polluted Area
2.4
JUSTIFICATION OF SITE SELECTION
Proposed project will be carried out in existing industrial premises located in the Shapar-Veraval Industrial Area. Site selection was guided by many factors like infrastructure, availability of land, water sources, fuel transportation, power availability etc. Specific site selection criterias for the proposed project are given below; Total plot area acquired by the unit is 2292 sqmt and alongwith the existing plant unit has sufficient spare area as required for the proposed project. Shapar-Veraval Industrial Area is the well-developed industrial area comprises of more than 80 industries (List of the industries of nearby area is enclosed as Annexure-9), which are mainly pharmaceutical, chemical, cement industries, foundries etc. and having all basic infrastructure facilities like availability of water supply, natural gas, electricity, transport, telecommunication systems etc. Chapter-2: Project Description Page | 2.5
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Plant site is only 13.33 km away from Rajkot City which is well connected by rail and road through National Highway-8B to rest of India. There is no protected area notified under the Wild Life (Protection) Act (1972) & Eco-sensitive area notified under Section 3 of the Environment (Protection) Act1986 exists within 10 Km radius areas from the Plant Site. Availability of trained and skilled manpower nearby because of the proximity to various industrial areas and city/town. 2.5
PRODUCT PROFILE
The company is presently involved in the manufacturing of various inorganic chemicals with total production capacity of 50 TPM. Now, the unit proposes to manufacture various Bulk Drugs & Drugs Intermediates with the production capacity of 55 TPM. The details of exisiting and proposed products & by products along with the capacity are listed below in Table 2.2, 2.3 & 2.4. Table 2.2: List of Existing Products Sr. No. 1.
Name of Product
Capacity TPM
Potassium Nitrate
10.0 10.0
3.
Potassium Sulphate Magnesium Hydroxide
10.0
4.
Potassium Chloride
10.0
5.
Potassium Iodide
10.0
2.
Total
50.0
Table 2.3: Details of Proposed Products Sr. Name of No. Product
Capacity CAS TPM No.
1
Oxyclozanide
25
2
Glibenclamide
20
3-A 1,2,4 Triazole
10
Chapter-2: Project Description Page | 2.6
IUPAC Name
2,3,5-Trichloro-N- (3,52277dichloro-292-1 hydroxyphenyl)-6hydroxybenzamide 5-chloro-N-(4-[N10238- (cyclohexylcarbamoyl) 21-8 sulfamoyl]phenethyl)2-methoxybenzamide 28888-0
1H-1,2,4-triazole
Synonyms / Generic name
Use of product
---
Anthelmintic drug
Glyburide
Antidiabetic drug
• Pyrrodiazole Intermediate • 1,2,4-triazole for API pyrrodiazole
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Sr. Name of No. Product 3-B
Capacity CAS TPM No.
4-Amino 1,2,4 Triazole Total
58413-4
IUPAC Name 4-Amino-4H-1,2,4triazole
Synonyms / Use of Generic name product 4H-1,2,4Intermediate Triazol-4for API amine;
55
Table 2.4: Details of Proposed By-Products Sr. Quantity Name of By-Product Source No. (TPM) 15.5 APCE-Oxyclozanide 1. Hydrochloric Acid (30%) 26.0 APCE-Oxyclozanide 2. Sodium Bi-Sulphite 3. Phosphorous Acid Aq. Total
2.6
3.3
Oxyclozanide (Route-2; using PCL3-Stage-I)
44.80
MANUFACTURING PROCESS
The unit proposes to manufacture all the products as mentioned in Table-2.3, which involves various chemical reaction like, chlorination, dechlorination & Reductive Amination and physical operations like Filtration, drying, centrifugation, distillation, evaporation, separation and condensation. The manufacturing process is briefly described in this section along with brief process description, chemical reaction, mass balance and water balance. 1: OXYCLOZANIDE 1(a) (Route-I- Using Thionyl Chloride) a) Manufacturing Process: Stage: 1 [Crude Oxyclozanide] Charge Mono Chloro Benzene, 3, 5, 6-Trichloro Salicylic Acid and Thionyl dichloride into the reactor. Start Scrubber pump and Heat to 60o in 2 hrs than heat 80oC in 2 hrs, Distilled out excess Thionyl dichloride. Transfer the material in to another reactor contain mixture of 2, 4, Di chloro – 6- Amino phenol and Mono Chloro Benzene, HCl scrub through Scrubber. Reflux Material for 3 hrs. Cool the reaction mass and filter it. Dry the wet cake in Dryer. Unload the product as Crude Oxyclozanide.
Chapter-2: Project Description Page | 2.7
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 [Oxyclozanide] Charge Acetone, Crude Oxyclozanide and Activated Carbon into the reactor. Heat the reaction mass to 60~65°C. Stir & reflux the reaction mass at 60~65°C. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass Stir the reaction mass and filter it. Wash the wet cake with Chilled Acetone. Dry the wet cake in Dryer. Unload the product as OXYCLOZANIDE. b) Reaction Chemistry:
Chapter-2: Project Description Page | 2.8
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
c) Material balance Diagram - Process: Stage: 1
3,5,6 Tri chloro salicylic Acid: 153.5 Thionyl chloride:75.75 Mono chloro benzene: 410
SO2 Gas: 40.75 HCl Gas: 46.5 Reactor
HCl (30%) & NaHSO3 as By Product
Scrubber
552 2,4 Di chloro-6-Amino Phenol: 113.25 Mono chloro benzene: 410
Reactor SO2 Gas: 40.75 1075.25
Mono chlorobenzene:205
Centrifuge
275.25
Drying
Distilled MCB: 980
Distillation
Distillation & Evaporation Loss: 20.0
Distillation Residue: 5
Drying Loss: 20.0
255.25 255.25 kg Crude Oxyclozanide
•
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.9
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 Crude Oxyclozanide: 255.25 Acetone: 786 Activated Carbon:10.25
Reactor
Filter
Spent Carbon to CHWIF: 10.5
Acetone Distilled: 697.5
Acetone: 4.75
Centrifuge
Distillation
Distillation Loss: 30.25
Distillation Residue: 5.0
Drying
250 kg Oxyclozanide •
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.10
Drying Loss: 63.0
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
d) Summary of Mass Balance: Capacity, TPM
:
25.0
Batch Size, Kg
:
250
Working Days
:
26
Stage: 1 Sr. No.
Name of Raw Material
Quantity Remarks
Kg/Batch
Kg/Kg of Product
153.5
0.614
15.350
Reactant
75.8
0.303
7.575
Reactant
113.3
0.453
11.325
Reactant
45.0
0.180
4.500
980.0
3.920
98.000
1367.5
5.470
136.750
255.25
1.021
25.525
980.0
3.920
98.000 Recovered Solvent
40.8
0.163
4.075
46.5
0.186
4.650
5.0
0.020
0.500
TPM
Input 1 2 3 4 5
3, 5, 6-Trichloro Salicylic Acid Thionyl Chloride 2, 4-Dichloro-6-Amino Phenol Mono Chloro Benzene (Fresh) Mono Chloro Benzene (Recovered) Total
Solvent
Output 1
Crude Oxyclozanide
3
Mono Chloro Benzene (Recovered) SO2 Gas
4
HCl Gas
5
Distillation Residue
6
Distillation loss
20.0
0.080
2.000
7
Drying (Solvent) loss
20.0
0.080
2.000
1367.5
5.470
136.750
2
Total
Intermediate product / crude
To scrubber HW to CHWIF for Incineration To Atmosphere
Chapter-2: Project Description Page | 2.11
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 Sr. No.
Name of Raw Material
Kg/Batch
Quantity Kg/Kg of Product
TPM
Remarks
Input 1
Crude Oxyclozanide
255.25
1.021
25.525
2
Acetone (Fresh)
93.25
0.373
9.325
3
Acetone (Recovered)
697.5
2.790
69.750
4
Activated Carbon
10.25
0.041
1.025
1056.3
4.225
105.625
Total
Reactant Solvent Catalyst
Output 1
Oxyclozanide
250.0
1.000
25.000
2
Acetone (Recovered)
697.5
2.790
69.750
3
Spent Carbon
10.5
0.042
1.050
4
Distillation Residue
5.0
0.020
0.500
5
Distillation loss
30.3
0.121
3.025
6
Drying (Solvent) loss
63.0
0.252
6.300
1056.3
4.225
105.625
Total
Chapter-2: Project Description Page | 2.12
Finished product Recovered Solvent HW to CHWIF for Incineration To Atmosphere
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
1(b) (Route – 2- Using Phosphorus Trichloride) a) Manufacturing Process: Stage: 1 [Crude Oxyclozanide] Charge Mono Chloro Benzene, 3, 5, 6-Trichloro Salicylic Acid and Phosphorus Trichloride in to the reactor. heat 80oC in 4 hrs, Add Water and separate out aqueous layer (phosphoric acid) and Transfer organic layer in to another reactor contain mixture of 2, 4, Di chloro – 6- Amino phenol and Mono Chloro Benzene, HCl scrub through Scrubber. Reflux Material for 3 hrs. Cool the reaction mass and filter it. Dry the wet cake in Dryer. Unload the product as Crude Oxyclozanide. Stage: 2 [Oxyclozanide] Charge Acetone/Methanol Crude Oxyclozanide and Activated Carbon into the reactor. Heat the reaction mass to 60~65°C. Stir& reflux the reaction mass at 60~65°C. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass Stir the reaction mass and filter it. Wash the wet cake with Chilled Acetone. Dry the wet cake in Dryer. Unload the product as OXYCLOZANIDE. b) Reaction Chemistry: OH
OH COOH
Cl
1/3
+
Cl
P
o
Cl
Cl
80 C
C
4 hrs
Cl
Cl
+
HO
P
OH OH
Cl
3,5,6 -Trichloro Salicylic Acid or 2,3,5-trichloro-6-hydroxybenzoic acid M.W. 241.456
M.W. 137.33
+
Cl
2,3,5-trichloro-6-hydroxyben zoyl chloride
phosphorous acid
Cl Cl
Cl Cl
2,3,5-trichloro-6-hy droxybenzoyl chloride M.W. 259.901
phosphorous trichloride
O
Cl
M.W. 259.901
Cl
Cl
Cl
OH
O
OH
HO
H2N
o
130 C Cl
O
Cl
HO
N H
3 hrs
Cl
+
HCl
Cl Cl
2,4 - Dichloro -6 -Amino Phenol or 4,6 - Dichloro -2 -Amino Phenol
Oxyclozanide M.W. 401.456
M.W. 178.016 Chapter-2: Project Description Page | 2.13
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
c) Material balance Diagram - Process: Stage: 1 3, 5, 6 Tri Chloro Salicylic Acid: 153.5 Phosphorus Tri chloride: 29.12 Mono Chloro Benzene: 500 Water: 15.0
Reactor
Aq. Layer H3PO3: 32.37 Organic Layer
665.25 2, 4 Dichloro-6-Amino Phenol: 113.25 Mono Chloro Benzene: 500
Reactor
Scrubber
Water: 54.25 HCl: 77.50 sale as byProduct
HCl Gas: 23.25
1255.25 MCB ML 1005 Mono Chloro Benzene: 25
Centrifuge
Distillation
275.25 Drying Evaporation Loss: 20
255.25 Crude Oxyclozanide
•
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.14
Distilled MCB: 980 Distillation & Evaporation Loss: 25
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 Crude Oxyclozanide : 255.25 Acetone /Methanol : 766 Activated Carbon : 10.25
Reactor
Filter
Spent carbon to TSDF: 10.5
1021 Filtrate
Cooling
Acetone/Methanol: 25
1021
Acetone Recover ML: 796
Distillation
Centrifuge 250
250
Acetone/ Methanol Distilled 698
Evaporation Loss: 63 Distillation Loss: 30.0
Distillation Residue: 5
Oxyclozanide
•
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.15
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
d) Summary of Mass Balance: Capacity, TPM
:
25.0
Batch Size, Kg
:
250
Working Days
:
26
Stage: 1 Sr. No.
Name of Raw Material
Quantity Kg/Batch
Kg/Kg of Product
TPM
Remarks
Input 1 2 3 4 5 6
3, 5, 6 Tri Chloro Salicylic Acid Phosohorus Tri chloride 2, 4 –Di chloro – 6Amino Phenol Mono Chloro Benzene (Fresh) Mono Chloro Benzene (Recovered) Water Total
153.5
0.614
15.350
Reactant
29.1
0.116
2.912
Reactant
113.25
0.453
11.325
Reactant
45.0
0.180
4.500 Solvent
980.0
3.920
98.000
15.0
0.060
1.500
1335.87
5.343
133.587
255.25
1.021
25.525
Intermediate product / crude Recovered Solvent
Output 1
Crude Oxyclozanide
2
Mono Chloro Benzene (Recovered)
980.0
3.920
98.000
3
Aq. H3PO3
32.37
0.129
3.237
4
HCl Gas
23.3
0.093
2.325
Sale as By Product To Scrubber
5
Drying (Solvent) loss
45.0
0.180
4.500
To Atmosphere
Total
1335.87
5.343
133.587
Chapter-2: Project Description Page | 2.16
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 Sr. No.
Name of Raw Material
Quantity Kg/Kg of Kg/Batch Product
Remarks
TPM
Input 1 2 3 4
Crude Oxyclozanide Acetone/Methanol (Fresh) Acetone/Methanol (Recovred) Activated Carbon Total
255.25
1.021
25.525
Reactant
93
0.372
9.300
698
2.792
69.800
10.25
0.041
1.025
1056.5
4.226
105.650
250.0
1.000
25.000
698.0
2.792
69.800 Recovered Solvent
10.5
0.042
1.050
5.0
0.020
0.500
Solvent Catalyst
Output 1
3
Oxyclozanide Acetone/Methanol (Recovered) Spent Carbon
4
Distillation Residue
5
Distillation loss
30.0
0.120
3.000
6
Drying (Solvent) loss
63.0
0.252
6.300
1056.5
4.226
105.650
2
Total
Finished product
HW to CHWIF for Incineration To Atmosphere
2: GLIBENCLAMIDE a) Manufacturing Process: Stage: 1 [CHIC SALT] Charge Acetone & Sulphonamide of Glibenclamide into the reactor. Start addition of caustic flack’s solution. Chill to 5~10°C. Charge Cyclo Hexyl Iso Cynate. Stir the reaction mass between 10~15°C. Raise the temperature to 25~30°C. Charge Liq. Ammonia and heat the reaction mass to 50~55°C. Stir the reaction mass between 50~55°C. Cool to 25~30°C. Filter the product. Wash the product with Acetone. Dry the product in Dryer. Unload the product as Chic Salt of Glibenclamide Stage: 2 [GLIBENCLAMIDE] Charge Methanol, Chic Salt of Glibenclamide and Charcoal into the reactor. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass to 10~15°. Start purging of HCl gas up to 2.0 pH. Stir the reaction mass and Chapter-2: Project Description Page | 2.17
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
filter it. Wash the wet cake with Methanol. Dry the wet cake in Dryer. Unload the product as GLIBENCLAMIDE. b) Reaction Chemistry: Synthesis of Glibenclamide :-
O S
NH2
O Cl
O
NH OCH3
Sulphonamide of Glibenclamide or
M.W. 368.835
5-chloro-2-methoxy-N-[2-(4-sulfamoyl phenyl)ethyl]benzamide N NaOH Acetone Methanol
C
O
+
Cyclo hexyl isocynate M.W. 125.168 O O O S NH
O Cl
NH OCH3
Chapter-2: Project Description Page | 2.18
Glibenclamide M.W. 494.003
NH
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
c) Process Flow Diagram: Stage: 1 Acetone : 400 Sulphonamide: 76.2 Caustic soda flakes: 8.3 Cyclo hexyl iso cyanate: 26 Liq. Ammonia : 7 Acetone: 25
Reactor
Acetone Distilled: 375
517.5
Centrifuge
Acetone ML Recover 390.5
152
Drying
Distillation
Distillation Loss: 8.20
Inorganic Salt/Residue: 7.3
Drying Loss: 45.0
107
107 Kg CHIC Salt •
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.19
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 CHIC Salt : 107 Methanol : 1200 Activated Carbon: 2.0
Reactor 1309
Spent carbon to TSDF: 2
Filter 1307 HCl Gas: 7.5
Filtrate
Methanol Recover ML: 1244.5
1314.5
Methanol Distilled 1175
Distillation Methanol: 50
Centrifuge
Distillation Loss: 55
120
Drying 100
Drying Losses: 20
100 kg Glibenclamide •
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.20
Inorganic Salt 14.5
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
d) Summary of Mass Balance: Capacity, TPM
:
20.0
Batch Size, Kg
:
100
Working Days
:
26
Stage: 1 Sr. No.
Name of Raw Material
Kg/Batch
Quantity Kg/Kg of Product
TPM
Remarks
Input 1
Sulphonamide
76.2
0.762
15.240
2
Acetone (Fresh)
50.0
0.500
10.000
3
Acetone (Recovred)
375.0
3.750
75.000
4
Caustic Soda Flaks
8.3
0.083
1.660
Reactant
5
Cyclo Hexyl Isocynate
26.0
0.260
5.200
Reactant
6
Liq. Ammonia
7.0
0.070
1.400
Reactant
542.50
5.425
108.500
Total
Reactant Solvent
Output 1
CHIC Salt
107.00
1.070
21.400
2
Acetone (Recovred)
375.00
3.750
75.000
3
Inorganic salt
7.30
0.073
1.460
4
Distillation Evaporation loss
8.20
0.082
1.640
5
Drying loss
45.00
0.450
9.000
542.50
5.425
108.50
Total
Intermediate Product Solvent Recovered To TSDF To Atmosphere
Chapter-2: Project Description Page | 2.21
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Stage: 2 Sr. No.
Name of Raw Material
Quantity Kg/Batch
Kg/Kg of Product
Remarks TPM
Input 1
CHIC Salt
2
Methanol (Fresh) Methanol (Recovred) Hydrochloric Acid gas Activated Carbon
3 4 5
Total
Intermediate Product
107.00
1.070
21.400
75
0.750
15.000
1175
11.750
235.000
7.5
0.075
1.500
For Acidification
2.00
0.020
0.400
Catalyst
1366.5
13.665
273.300
Solvent
Output 1
100.0
1.000
20.000
1175.0
11.750
235.000
3
Glibenclamide Methanol (Recovred) Inorganic salt
14.5
0.145
2.900
4
Spent Carbon
2.0
0.020
0.400
55.0
0.550
11.000
20.0
0.200
4.000
1366.5
13.665
273.300
2
5 6
Distillation Evaporation loss Drying loss Total
Chapter-2: Project Description Page | 2.22
Solvent Recovered To TSDF HW to CHWIF for Incineration To Atmosphere
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
(3-A) : 1, 2, 4 – TRIAZOLE a) Manufacturing Process: Charge Xylene and Hydrazine hydrate into the reactor. Start addition of Formic acid slowly below 60o than purge Ammonia Gas slowly in 2 hrs than heat to reflux at 142145oC for 8 hrs, and continuously distilled out azeotrope of water and Xylene in receiver. Separate out water from bottom and upper layer xylene is continuously transferred in to reactor for 8 hrs. Cool the reaction mass at RT and filter it. Dry the wet cake in Dryer. Unload the product as 1, 2, 4 - Triazole.
b) Reaction Chemistry:
Chapter-2: Project Description Page | 2.23
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
c) Process Flow Diagram: Formic Acid: 408 Hydrazine Hydrate: 142 Ammonia Gas: 76 Xylene (Fresh): 24 Xylene (Recovered): 558
Reactor
Xylene Water:16
320
Condensate Water
Gravity Separation
Xylene Water: 16
304
Water to Cooling tower 304
Distilled Xylene: 588
904 Xylene (Recovered) : 30
Centrifuge
318
Drying
300.0 kg 1, 2, 4-Triazole
•
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.24
Distillation
Distillation Loss: 24.0
Distillation Residue: 4
Drying Loss: 18.0
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
d) Summary of Mass Balance: Capacity, TPM
:
10.0
Batch Size, Kg
:
300
Working Days
:
26
Sr. No.
Name of Raw Material
Kg/Batch
Quantity Kg/Kg of Product
TPM
Remarks
Input 1
Hydrazine Hydrate
142.0
0.473
4.733
Reactant
2
Formic Acid
408.0
1.360
13.600
Reactant
3
Ammonia Gas
76.0
0.253
2.533
Reactant
4
Xylene(Fresh)
24.0
0.080
0.800
5
Xylene (Recovered)
588.0
1.960
19.600
6
Xylene water
16.0
0.053
0.533
1254.0
4.180
41.800
Total
Solvent
Output 1
1,2,4 – Triazole
300.0
1.000
10.000
2
Xylene (Recovered)
588.0
1.960
19.600
3
Xylene water
16.0
0.053
0.533
4
Distillation Residue
4.0
0.013
5
Distillation Evaporation loss
24.0
0.080
6
Condensate water
304.0
1.013
7
Drying (solvent) loss
18.0
0.060
1254.0
4.180
Total
Finished Product Recovered Solvent
HW to CHWIF for Incineration To 0.800 Atmosphere To Cooling 10.133 tower To 0.600 Atmosphere 41.800 0.133
Chapter-2: Project Description Page | 2.25
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
(3-B) 4-Amino - 1, 2, 4 - TRIAZOLE a) Manufacturing Process: Charge Xylene and Hydrazine hydrate into the reactor. Start addition of Formic acid slowly below 600 than heat to reflux at 142-145 0C for 8 hrs, and continuously distilled out azeotrope of water and Xylene in receiver. Separate out water from bottom and upper layer xylene is continuously transferred to reactor for 8 hrs. Cool the reaction mass at RT and filter it. Dry the wet cake in Dryer. Unload the product as 4-Amino -1, 2, 4 - Triazole. b) Reaction Chemistry:
Chapter-2: Project Description Page | 2.26
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
c) Material Balance Diagram - Process:
Formic Acid: 233 Hydrazine Hydrate: 336 Xylene (Fresh): 24 Xylene (Recovered): 618
Reactor
263
Condensate Water
Xylene Water: 13 Gravity Separation
Xylene Water: 13
249
Water to Cooling tower 250
961
Xylene (Recovered) : 30
Centrifuge
Distilled Xylene: 648 Distillation Loss: 24.0
Distillation
Distillation Residue: 4 315
Drying
Drying Loss: 15.0
300.0 kg 4- Amino-1, 2, 4-Triazole •
All quantities are expresses in Kg/Batch.
Chapter-2: Project Description Page | 2.27
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
d) Summary of Mass Balance: Capacity, TPM
:
10.0
Batch Size, Kg
:
300
Working Days
:
26
Sr. No.
Quantity
Name of Raw Material
Kg/Batch
Kg/Kg of Product
1
Hydrazine Hydrate
336.0
1.120
11.200
Reactant
2
Formic Acid
233.0
0.777
7.767
Reactant
3
Xylene(Fresh)
24.0
0.080
0.800
4
Xylene (Recovered)
648.0
2.160
21.600
5
Xylene water
13.0
0.043
0.433
1254.0
4.180
41.800
TPM
Remarks
Input
Total
Solvent
Output 1
4 -Amino-1,2,4 – Triazole
300.0
1.000
10.000
2
Xylene (Recovered)
648.0
2.160
21.600
3
Xylene water
13.0
0.043
0.433
4
Distillation Residue
4.0
0.013
0.133
5
Distillation Evaporation loss
24.0
0.080
0.800 To Atmosphere
6
Condensate water
250.0
0.833
7
Drying loss
15.0
0.050
1254.0
4.180
Total
Chapter-2: Project Description Page | 2.28
Finished Product Recover Solvent HW to CHWIF for Incineration
To Cooling tower 0.500 To Atmosphere 8.333
41.800
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.7
SOLVENT REQUIREMENTS & RECOVERY SYSTEM
The industry proposes to manufacture synthetic organic chemicals (Bulk Drugs & Drugs Intermediates), which require solvents during various unit processes. The unit intends to use various solvents viz. Mono Chloro Benzene, Acetone, Methanol and Xylene. The spent solvent generated during the manufacturing process will be recovered by way of distillation and reused in the process. The process of the solvent recovery system is described hereunder; After the completion of the reaction, the spent solvent/mother liquor will be separated by centrifuge and pumped to distillation reactor. It will be subjected to distillation to separate and recover solvent. Firstly, the mass will be distilled at required temperature where pure solvents will be distilled out depending on their boiler points and it will be collected in the recovered solvent storage tank and reused in the process and then residue will be sent to TSDF site for the disposal by incineration. Vaccum will also be applied during distillation. The overall requirements and mass balance for the solvent based on mass balance of each product has been worked out which is given in Table 2.5. The schematic diagram of the solvent recovery system is shown in the Figure 2.4. Measures for achieving maximum solvent recovery: The entire manufacturing activities & distillation process will be carried out in the totally closed system. Maintenance of the pipeline and valves & fittings will be carried out regularly to avoid any leakages. Reactor will be connected with two numbers of condensers where cooling water and chilled water will be used as media and also equipped with vacuum system as per requirement. The condenser will be provided with the sufficient HTA and residence time to achieve more than 90% recovery. The fresh solvent requirement will be depended on generation of distillation loss. The details of solvent consumption and mass balance are given below in Table 2.5 & Table 2.6.
Chapter-2: Project Description Page | 2.29
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.5: Details of Solvent Requirement and Recovery Fresh, TPM Recovered, TPM Sr. Product Name of Solvent Product Group Product Group No. Code Total Total wise Max wise Max 1(a) 9.33 9.33 69.75 69.75 1 Acetone 19.33 144.75 2 10.00 10.00 75.00 75.00 2
Acetone/ Methanol
1 (b)
9.30
9.30
9.30
69.80
69.80
69.80
3
Methanol
2
15.00
15.00
15.00
235.00
235.00
235.00
4
Mono Chloro Benzene
1 (a)
4.50
1 (b)
4.50
4.50
4.50
98.00
98.00
5
Xylene
3-A
0.80
3-B
0.80
0.80
0.80
21.60
21.60
98.00 98.00 19.60 21.60
Table 2.6: Summary of Solvent Requirement and Recovery Solvent Requirement, TPM Fresh Recovered Total
Solvent Requirement,% Fresh Recovered Total
1 Acetone
19.33
144.75
164.08
11.78
88.22
100.00
2 Acetone/Methanol
9.30
69.80
79.10
11.76
88.24
100.00
3 Methanol
15.00
235.00
250.00
6.00
94.00
100.00
4.50
98.00
102.50
4.39
95.61
100.00
0.80
21.60
22.40
3.57
96.43
100.00
48.93
569.15
618.08
7.50
92.50
100.00
Sr. Name of Solvent No.
4
Mono Chloro Benzene
5 Xylene Total/Average
Chapter-2: Project Description Page | 2.30
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.4: Schematic Diagram of The Solvent Recovery System CHILL ED WATER OUT
CONDENSER - 1 CHILL ED WATER OUT
CHILL ED WATER IN
CONDENSER -2
S T E A M
DISTILLATION COLUMN
REFLUX
CHILL ED WATER IN
VACUUM =752 mm of Hg
Recovered Solvent
RE-BOILER
2.8
DETAILS OF RAW MATERIALS
The various raw materials will be required for the manufacturing of proposed products; details of raw materials requirements for the proposed project are given in Table 2.7. Storage and transportation details of products and raw materials are given in Table 2.8 & 2.9. The convenient transportation medium will be used for the transportation of raw materials and products. In case of export of products, facilities at Kandla port will be used which is about 190 kms from the project site.
Chapter-2: Project Description Page | 2.31
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.7: List of Raw Materials with Requirement Sr. Name of Raw Material No. 2, 4-Dichloro-6-Amino 1 Phenol 3, 5, 6-Trichloro Salicylic 2 Acid
Product Kg/Kg Code 1 (a) 1(b) 1 (a) 1 (b) 1 (a) 2
0.453 0.453 0.614 0.614 0.373 0.500
Requirement, TPM Product Group Total wise Maximum 11.325 11.325 11.325 11.325 15.350 15.350 15.350 15.350 9.325 9.325 19.325 10.000 10.000
3
Acetone
4
Acetone/Methanol
1 (b)
0.372
9.300
5
Activated Carbon
1 (a) 1 (b) 2
0.041 0.041 0.020
1.025 1.025 0.400
0.400
6
Ammonia Gas
3-A
0.253
2.533
2.533
2.533
7
Ammonia Liq.
2
0.070
1.400
1.400
1.400
8
Caustic Soda Flakes
2
0.083
1.660
1.660
1.660
9
Cyclo Hexyl Isocynate
2
0.260
5.200
5.200
5.200
3-A 3-B 3-A 3-B
1.360 0.777 0.473 1.120
13.600 7.767 4.733 11.200
13.600
13.600
11.200
11.200
2
0.075
1.500
1.500
1.500
2
0.750
15.000
15.000
15.000
1 (a) 1 (b)
0.180 0.180
4.500 4.500
4.500
4.500
15 Phosohorus Tri chloride 16 Sulphonamide
1 (b)
0.116
2.912
2.912
2.912
2
0.762
15.240
15.240
15.240
17 Thionyl Chloride
1 (a)
0.303
7.575
7.575
7.575
3-A 3-B
0.080 0.080
0.800 0.800
0.800
0.800
10 Formic Acid 11 Hydrazine Hydrate 12 Hydrochloric Acid gas 13 Methanol 14 Mono Chloro Benzene
18 Xylene
Chapter-2: Project Description Page | 2.32
9.300 1.025
9.300 1.425
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Name of Chemicals
1 Oxyclozanide 2 Glibenclamide 3 1,2,4 Triazole 4
4-Amino -1,2,4 Triazole
Physical form
Packing Size
Sr. No.
Type of packing
Table 2.8: Details of Products storage & Handling
SolidCrystal SolidCrystal SolidCrystal SolidCrystal
HDPE Drum HDPE Drum HDPE Drum HDPE Drum
25, 50 Kg 25, 50 Kg 25, 50 Kg 25, 50 Kg
Max. Storage Storage storage CharacterMarket/ Pressure Temp. capacity istic Source 2 Kg/cm ºC MT Local 5 Toxic ATM At RT /Export NonLocal 5 ATM At RT Hazardous /Export Local 5 Hazardous ATM At RT /Export Local 5 Hazardous ATM At RT /Export
2, 4-Dichloro-6Amino Phenol 3, 5, 62 Trichloro Salicylic Acid 1
3 Acetone 4
Activated Carbon
SolidPowder
Woven Bag
Max. Storage Storage storage CharacteMarket/ Pressure Temp. capacity ristic Source 2 Kg/cm ºC MT 25, Non10 ATM At RT Local 50Kg Hazardous
SolidCrystal
Woven Bag
25, 50Kg
HDPE 170Kg Barrel SolidWoven 25, Granules Bag 50Kg Liquid
5 Ammonia Gas
Gas
6 Ammonia Liq.
Liquid
Caustic Soda Flaks Cyclo Hexyl 8 Isocynate
SolidFlakes
9 Formic Acid
Liquid
7
Hydrazine Hydrate Hydrochloric 11 Acid 10
12 Methanol Mono Chloro Benzene Phosohorus Tri 14 chloride 13
15 Sulphonamide
Packing Size
Name of Chemicals
Type of packing
Sr. No.
Physical form
Table 2.9: Details of Raw Material Storage & Handling
Liquid
Liquid Gas Liquid Liquid Liquid SolidPowder
Cylinder 50 Kg HDPE Barrel Woven Bag HDPE Barrel HDPE Barrel HDPE Barrel
10 10 0.5 0.5
NonHazardous Flammable, corrosive NonHazardous Toxic & Flammable Toxic & Flammable
ATM
At RT
Local
ATM
At RT
Local
ATM
At RT
Local
ATM
At RT
Local
ATM
At RT
Local
50 Kg
0.5
50 kg
2
Hazardous
ATM
At RT
Local
50 kg
0.5
Hazardous
ATM
At RT
Local
2
Hazardous
ATM
At RT
Local
2
Hazardous
ATM
At RT
Local
Cylinder 50 kg
0.5
Hazardous
ATM
At RT
Local
HDPE 170 kg Barrel
10
Toxic, poisonous & flammable
ATM
At RT
Local
10
Flammable
ATM
At RT
Local
0.5
Hazardous
ATM
At RT
Local
1
NonHazardous
ATM
At RT
Local
200 Ltr. 200 Ltr.
HDPE 235 kg Barrel HDPE 100 kg Barrel HDPE 50 kg Drum
Chapter-2: Project Description Page | 2.33
Max. Storage Storage storage CharacteMarket/ Pressure Temp. capacity ristic Source 2 Kg/cm ºC MT
GI 300 kg Barrel HDPE 17 Xylene Liquid 190 kg Barrel ATM: Atmospheric; RT: Room Temperature 16
2.9
Thionyl Chloride
Packing Size
Name of Chemicals
Type of packing
Sr. No.
Physical form
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Liquid
3
Toxic
ATM
At RT
Local
3
Hazardous
ATM
At RT
Local
RESOURCE REQUIREMENTS
The proposed project requires additional water, power, fuel, human resources, machineries & utilities etc. The details of all major resources required for proposed project are described in subsequent sections under respective headings. 2.9.1 Land Land is 100% Industrial and is located at Survey No. 163/9 & 11, on SIDC road, Veraval (Shapar) village in Kotda Sangani Taluka of District Rajkot in Gujarat State. The total available land area of existing premises is 2,292 sqmt (0.57 acres). Proposed project will take place within the existing premises and thus no additional land would be required for proposed project. Out of total land available, the unit has developed green belt/gardening area in 340 sqmt (14.83 %) for the betterment of the environment. The green belt/ gardening area will be expanded to 760 sqmt (33.16%) during the proposed project. Detailed break-up of the land is given in Table 2.10 and Key Plan & Plant Layout is shown in Figure 2.5.
Chapter-2: Project Description Page | 2.34
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.10: Break-up of Area Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Area (Sqmt) Particular Process Plant Raw Material & Product Storage Utility Storage (Hazardous Chemicals) Storage (Fuel) Hazardous Waste Storage Area Effluent Treatment Plant Scrap yard Parking Area Administrative Building Security, Clock & Eng room Road Green Belt Undeveloped Total
Existing Proposed 353 74 20 5 7 11 38 11 14 57 30 340 1,332 2,292
147 26 45 13 13 62 9 50 420 -785 -
Total 500 100 20 50 20 24 100 20 14 50 57 30 760 547 2,292
% of Total Land 21.82 4.36 0.87 2.18 0.87 1.05 4.36 0.87 0.61 2.18 2.49 1.31 33.16 23.87 100.00
Chapter-2: Project Description Page | 2.35
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.5: Key Plan & Plant Layout
Chapter-2: Project Description Page | 2.36
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.9.2 Machineries & Utilities As the proposed project will be carried out in the existing premises, existing infrastructure facilities will also be utilized with the addition of some new machineries and utilities for the proposed project. The list of plant machineries after proposed project is given in Table 2.11. However, the actual requirements of machineries & equipment are not limited to the basic list below as some additional minor requirements can also be cited depending up on necessity noticed during installation & operations. Table 2.11: Details of Proposed Machineries and Utilities Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Item Name
MoC
Glass Line Reactor R1 SS Reactor R2 SS Reactor R3 Glass Line Reactor R4 SS Reactor R5 SS Centrifuge CF1 SS Centrifuge CF2 Multi mill Pulverizer 5 HP SS Hot air dryer Chemical Process Pump Oil vacuum pump 5 HP Water Jet Ventury 5 HP Sparkler Filter Storage Tank Storage Tank Storage Tank Air Compressor Water Softener Storage Tank Storage Tank Chilling Plant Cooling tower
Glass SS-316 SS-316 Glass SS-316 SS-316 SS-316 SS-316 SS-202 SS-316 SS-316 MS PP SS-316 SS-316 MS PP MS MS PP PP MS Casting
Process/ Size/ Qty. Activity Capacity Chlorination 1 700 Ltr. Condensation 2 750 Ltr. Carbon Treat 1 1100 Ltr. Purification 1 1500 Ltr. Distillation 1 750 Ltr. Crude Filtration 2 0.61 X 0.45 m Pure Filtration 1 0.61 X 0.45 m Sieve 1 50 kg/hr Micronization 1 25 kg/hr Drying 2 48 Tray Solvent Transfer 3 1500 Ltr/hr High Vacuum 1 758 mm Hg Vacuum 1 700 mm Hg Carbon Filtration 1 10.0 Kg Solvent Storage 1 500 Ltr. Solvent Storage 1 1500 Ltr. Solvent Storage 1 1000 Ltr. Air Generation 1 4 Kg Softener 1 1000 Ltr/hr DM Water Storage 1 3000 Ltr. DM Water Storage 1 500 Ltr. Chilling 1 10TR Cooling 1 50TR
Chapter-2: Project Description Page | 2.37
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.9.3 Capital Cost The unit is a small scale unit and has made capital investment of Rs. 48.57 lacs in the existing plant and the estimated cost for the proposed project will be about Rs. 36.50 lacs. The detail break-up of the capital cost is given in Table 2.12. Table 2.12: Capital Cost Sr. No.
Cost (INR In Lac) Proposed Existing Total Project 2.58 2.00 4.58
Description
1
Land & Site Development
2
Building
10.80
7.50
18.30
3
Plant and Machinery
35.19
21.50
56.69
4
Environmental Protection Measures
--
5.50
5.50
48.57
36.50
85.07
Total 2.9.4 Power / Electricity
At present the total connected load of power is about 45 KVA which will be increased up to 60 KVA after proposed project. The power required is procured from Pashchim Gujarat Vij Company Ltd. (PGVCL) and the same source will be utilized after proposed project. 2.9.5 Water Total fresh water requirement for existing unit is 2.7 KLD, which includes domestic, gardening, process, boiler and cooling activities. After proposed project, it will be increased up to 11.51 KLD. Thus, the additional water requirement for proposed Project will be 8.81 KLD. Presently the entire water requirement of M/s. Ascent Pharma is met by water supply by Veraval (Shapar) Gram Panchayat through tanker and same source will be utilized after proposed project. Permission letter is enclosed as Annexure-8. Unit is also bought water from Private water supplier through tankers in case of non-availability of main source. After proposed project also, this will be kept as stand by source. As per Guidelines
issued by Central Ground Water Authority, Ministry of Water
Resources, New Delhi, dated 15/11/2012, the unit falls under White Zone (Safe) and do not covered under the list of critical areas published by CGWA. Also the water requirement of the plant is 11.51 KL/Day which falls within the limit of 100 KLD as per Chapter-2: Project Description Page | 2.38
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
CGWA; therefore the unit does not require obtaining permission from CGWA for the use/abstraction of ground water. 2.9.6 Fuel Presently the unit uses Furnace Oil as fuel for steam boiler of 0.8 TPH. After proposed project, same boiler will be utilized with additional fuel requirement. Unit will use LDO/FO as a fuel after the proposed project. The details of fuel requirement are given in Table 2.13. Table 2.13: Details of Fuel Requirement Sr. No.
Fuel
Used In
1
Furnace Oil
2
LDO
Steam Boiler 0.8 TPH
Fuel Requirement, KL/Month Existing Proposed 1.50
3.00
--
2.9.7 Man Power The manpower is one of the main resource requirements to operate and maintain the plant in a better and efficient way. Total 11 personnel are working in the existing plant and after the proposed project the company has planned to employ about 27 additional personnel at various cadres and in various departments. The details of existing and proposed Manpower are given in Table 2.14. Table 2.14: Details of Manpower Requirement Mgmt. Staff
Description
Supervisory Staff E P 02 02
Administration
E 01
P 02
Production & allied services
01
02
02
Stores & Dispatch
--
01
Others
-02
Total
Workers
Total
E 02
P 03
E 05
P 07
03
02
07
05
12
--
01
01
03
01
05
01
--
--
--
02
--
03
06
04
06
05
15
11
27
Total
38
E-Existing, P-Proposed
Chapter-2: Project Description Page | 2.39
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.10
POLLUTION POTENTIAL AND MANAGEMENT
The proposed project will have potential of pollution mainly due to the wastewater generation & disposal, gaseous emission from process, flue gas emission from utilities and hazardous waste generation & disposal. These potentials of pollution are described below under respective heading with necessary details. 2.10.1 Water Pollution Presently the Industrial fresh water requirement of the unit is 1.70 KLD, which comprises the need for process, boiler and cooling activity. The water requirement for domestic and greenbelt activity is 0.50 KLD for each. After the proposed project, the industrial water requirement will be increased up to 8.21 KLD. The fresh water requirement for domestic and greenbelt activity will also be increased up to 2.00 KLD and 1.30 KLD respectively after proposed project. At present there is no generation of wastewater from industrial activities. The total effluent generation from industrial activity after proposed project will be 2.10 KLD. The wastewater generation from domestic activity is 0.40 KLD which will be increased up to 1.60 KLD after proposed project. The product-wise and category wise water consumption and wastewater generation is given in Table 2.15 & Table 2.16 respectively and water balance diagram after proposed project activity is given in Figure 2.6.
Chapter-2: Project Description Page | 2.40
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Product Code
Table 2.15: Product-wise Water Consumption & Wastewater Generation for Proposed Project
Product
Water Consumption,Liter Wastewater Generation,Liter Batch Capacity, Stream size, Per Per Per TPM Per Kg Per Kg Per Day Kg/batch Batch Day Batch
Oxyclozanide Process HCl Scrubber APCE 1(a) (Oxyclozanide) SO2 Scrubber APCE (Oxyclozanide) Oxyclozanide Process 1(b) HCl Scrubber APCE (Oxyclozanide) Maximum of Product-1 (Process) Maximum of Product-1 (APCE) 2 Glibenclamide Process 3-A 1,2,4-Triazole Process 3-B
4-Amino,1,2,4Triazole
Process
250
25.00
Nil
Nil
Nil
Nil
Nil
Nil
108.50
0.43
417.31
155.00
0.62
596.15
190.58
0.76
733.01
257.32
1.03
989.70
15.00
0.06
57.69
Nil
Nil
Nil
54.25
0.22
208.65
77.50
0.31
298.08
---
---
---
---
57.69
---
---
Nil
---
---
---
---
1150.32
---
---
596.15
100
20.00
Nil Nil
Nil Nil
Nil Nil
Nil 304.00
Nil 1.01
Nil 389.74
300
10.00
Nil
Nil
Nil
250.00
0.83
320.51
---
---
Nil
---
---
389.74
-------
-------
57.69 1150.32 1,208.01
-------
-------
389.74 596.15 985.90
Maximum of Product-3 ----(Process) Total of Process ----Total of APCE ----TOTAL (Process + APCE)
Chapter-2: Project Description Page | 2.41
Remarks -Sale as By-product (HCl) OR To ETP Sale as by-product (Sodium bi sulphite) -Sale as By-product (HCl) OR To ETP Sale as By-product OR To ETP This condensate water will be recovered & reused in cooling make-up
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.16: Category-wise Water Consumption & Wastewater Generation Sr. No.
Water Consumption, KLD Stream E P T
Particulars
I
Domestic
Fresh
0.50
1.50
2.00
II
Gardening
Fresh
0.50
0.80
1.30
Reuse
Nil
1.70**
1.70
III
Wastewater Generation, KLD E P T 0.40
1.20
1.60
Nil
Nil
Nil
Industrial
a
Process
Fresh
0.50
0.06
0.56
Nil
0.40*
0.40
b
APCE
Fresh
Nil
1.15
1.15
Nil
0.60
0.60
c
Boiler
Fresh
1.00
3.00
4.00
Nil
0.40
0.40
d
Cooling
Fresh
0.20
1.80
2.00
Reuse
Nil
0.40*
0.40
Nil
0.20
0.20
e
Washing
Fresh
Nil
0.50
0.50
Nil
0.50
0.50
Total Industrial Consumption/ Fresh+ Generation Reuse
1.70
6.91
8.61
0.00
2.10
2.10
Industrial Reuse Reuse
0.00
0.40*
0.40
0.00
0.40*
0.40
1.70
6.51
8.21
0.00
1.70
1.70**
2.70
8.81
11.51
0.40
2.90
3.30
Total Industrial Fresh Consumption/ Discharge Total (Industrial + Domestic) Fresh Consumption/ Discharge E-Existing, P-Proposed, T-Total
Note: *In case of manufacturing of 1,2,4, triazole and 4-Amino triazole the condensate water generated from the manufacturing process will be recovered and reused in cooling-Makeup. ** The waste water generated from APCM, Boiler, Cooling, Washing @ 1.70 KL/day will be treated into ETP and after achieving GPCB Norms it will be reused in Gardening/irrigation purposes within premises. The unit will increase green belt area up to 760 sqmt within the premises.
Chapter-2: Project Description Page | 2.42
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.6: Water Balance Diagram (After Proposed Project) (1.60)
Domestic (2.0)
Fresh Water (11.51)
To soak pit via septic tank system
Nil
Gardening (1.30) Fresh Industrial (8.21)
(0.56)
(1.15)
(4.00)
(2.0)
(0.40) Reuse Process
(0.50)
(0.40) Boiler (Make up)
APCE
(0.60)
(0.40)
Cooling (Make up)
Washing
(0.20)
(0.50)
(1.70) To ETP (1.70) For gardening/irrigation purposes within the premises
• All quantities are expressed in KLD.
Chapter-2: Project Description Page | 2.43
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Presently there is no effluent generation form the existing unit and unit maintains the Zero Effluent Discharge. The industrial effluent generation from the proposed project will be @ 2.10 KLD, from which 0.40 KLD of condensate water from process will be recovered & reused in cooling make-up and for remaining 1.7 KLD effluent, the unit has proposed to install an effluent treatment plant (ETP) comprising of primary, secondary & tertiary treatment which will be adequate to achieve the discharge norms prescribed by GPCB. After treatment into ETP, the total quantity of effluent will be used for gardening and plantation within the premises. The Domestic wastewater after the proposed project will be increased from 0.40 KLD to 1.60 KLD, which will be discharged in to soak pit through septic tank as per the current practice. The stage wise characteristics of effluent are given hereunder in Table 2.17. The detail of proposed effluent treatment plant is given hereunder in Table 2.18 and schematic flow diagram is given in Figure 2.7. Table 2.17: Stage-wise Characteristics of Effluent Sr. No. 1 2 3 4 5
Parameter pH TSS TDS COD BOD
Unit pH unit mg/l mg/l mg/l mg/l
Chapter-2: Project Description Page | 2.44
Raw Effluent 5.0 – 8.0 200 1200 650 200
Primary Outlet 6.5 - 8.5 100 1300 400 120
Secondary Outlet 6.5 - 8.8 80 1300 100 30
Tertiary Outlet 6.5 - 8.5 < 100 < 2100 < 100 < 30
GPCB Norms 6.5-8.5 100 2100 100 30
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Liquid Volume, m3
Retention Time, hrs
0.50
4.11 0.42 0.42 0.05 0.28
12.34 0.83
1.00
2.00
2.00
6.00
1.50
1.50
2.50
5.63
67.50
1
1.20
1.20
2.00
2.88
8.64
1 1 1 2
1.10
1.10 1.70 2.06 0.3 Dia. X 1.5 HOS 0.3 Dia. X 1.5 HOS 1.00 0.50 1.00
6.17
Sr. No.
Units
Nos.
Width, m
1.70 0.75 0.75
Length, m
Liquid Depth, m
Table 2.18: Detail of Proposed Effluent Treatment Plant
1 2 3 4 5
Collection cum Treatment Tank Lime Solution Tank Alum Solution Tank Polyelectrolyte Solution Tank Flocculation Channel
2 1 1 1 1
1.10 0.75 0.75
1.10 0.75 0.75 50 Liter 1.10 0.50
6
Primary Settling Tank (Hopper Bottom)
1
1.00
1
7 8 9 10 11 12
Aeration Tank Secondary Settling Tank (Hopper Bottom) Treated Water Collection Sump Pressure Sand Filter Activated Carbon Filter Sludge Drying Beds
1.00
--
Figure 2.7: Schematic Diagram of Proposed Effluent Treatment Plant
Chapter-2: Project Description Page | 2.45
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.10.2 Air Pollution The main source of air pollution will be flue gas emission and process gas emission from the proposed project. There will be also chances of fugitive emission due to manufacturing activities and storage, handing & transportation of raw materials & products. Various potential of air pollution are described hereunder; 2.10.2.1 Flue Gas Emission Unit has installed steam boiler of 0.8 TPH wherein Furnace Oil is used as fuel. The same boiler will be utilized after the proposed project with additional fuel requirement as given in Table 2.13. Unit will use LDO/FO as a fuel after the proposed project. Stack with adequate height of 12 m is provided for proper dispersion of pollutant from the steam boiler and same will be adequate after proposed project also. The details of flue gas stack is given hereun
der in Table 2.19.
Table 2.19: Details of Flue Gas Stack Sr. No
Stack Attach to
Fuel Requirement
Stack Ht. & Dia.
FO / LDO 1
Steam Boiler Existing: 1.5 KL/Month (0.8 TPH) Proposed: 3.0 KL/Month
12 m & 0.2 m
Concentration of Polluants
Air Pollution Control Mesures
PM < 150 mg/Nm3 SO2 < 100 ppm
Not required
NOx < 50 ppm 2.10.2.2 Process Gas Emission There is no any process emission from the existing manufacturing unit. The only source of process gas emission from the proposed manufacturing activity will be HCl & SO2 gas generated from the manufacturing of Oxyclozanide. The details of gaseous pollutants liberated due to proposed manufacturing activities are given in Table 2.20 & details of process gas stack are given in Table 2.21. The adequate scrubbing system like water scrubber followed by alkali scrubber will be provided for the control of process gas emission. The details of Air pollution control measures for the process gas emission are given hereunder in Table 2.22 and details of scrubbing system is given in Table 2.23. Schematic diagram of air pollution control measure are given as Figure 2.8. Chapter-2: Project Description Page | 2.46
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.20: Details of Process Gas Emission Product Code 1 (a)
1 (b)
Pollution Reaction Rate of Load Time Generation (kg/Batch) (hr) (kg/hr)
Expected Pollutants
Product Oxyclozanide-stage-I (Using Thionyl Chloride-SOCl2) Oxyclozanide-stage-I (Using Phosphorous tri chloride –PCl3)
HCl
46.50
5 to 6
9.0
SO2
40.75
5 to 6
8.0
HCl
23.25
2 to 3
11.0
Table 2.21: Details of Process Gas Stack Sr. No. 1.
Stack attached To
Height (m)
Dia. (m)
Temp (°C)
Polluant Concentration mg/NM3
15
0.04
40
HCl ≤ 20 mg/Nm3 SO2 ≤ 40 mg/Nm3
Reactors
Table 2.22: Details of Air Pollution Control Measures for Process Stack Sr. No. 1.
Scrubber attached To
Air Pollutant
Reaction Vessels
HCl & SO2
Air Pollution Control Equipment 1st Stage 2nd Stage Water Alkali Scrubber -A Scrubber-B
Table 2.23: Details of Scrubbing System Sr. No.
Size of Scrubber, meter (Ht. and Dia.)
Scrubbing Media
Capacity of Scrubbing Tank, KL
Pump Capacity m3/Hr
A
3.0 X 0.25
Water
0.5
5
B
3.0 X 0.25
Caustic
0.5
5
Output Sale as By-product (HCl) OR To ETP Sodium Bi Sulphate (Sale as By-product)
Chapter-2: Project Description Page | 2.47
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Figure 2.8: Schematic Diagram of APCM for Process Emission
In addition to the control measures of the flue gas emission and process gas emission, the unit has taken all the required precautions and control measures to take care of the fugitive emissions, which are described under Section 4.5.2 of Chapter-4: Anticipated environmental impact and mitigation measures. 2.10.3
HAZARDOUS WASTE
The main sources of hazardous waste generation from proposed manufacturing activity will be process wastes viz. inorganic residue, distillation residue, spent carbon and spent solvent. Dried sludge will be generated from effluent treatment plant. The ancillary source of hazardous waste generation will be discarded bags /liners /drums / Carboys/Containers from storage and handling of raw materials and spent oil generation from plant machinery. The details of hazardous waste generation and handling / Management are given in Table 2.24. Chapter-2: Project Description Page | 2.48
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Table 2.24: Details of Hazardous Waste generation and Management Source
Cat.
Quantity per Annum E P T
28.1
Nil
52.0 MT
Collection, Storage & 52.0 Solid disposal by land filling MT Inorganic at TSDF site.
Distillation Residue 28.1
Nil
14.0 MT
14.0 Semisolid MT organic
12.4 MT
5.6 MT
18.0 Solid MT Inorganic
Type of waste Inorganic Salt
Process
Spent Carbon
Spent Solvent
ETP
Raw Material Storage & Handling
Plant and Machineries
ETP Sludge
28.2
28.5
34.3
Nil
Nil
7400 7400 MT MT
2.0 MT
2.0 MT
PhysicalChemical Form
Liquid & Organic
5.1
0.05 0.05 MT MT
0.1 MT
Collection, Storage, Transportation, Disposal by incineration at nearby CHWIF OR send for the Co-Processing to the GPCB authorized agencies Collection, Storage & Reuse after distillation within process OR Sell to GPCB authorized recycler
Collection, Storage, Transportation, Solid & Disposal by land filling Inorganic at TSDF site
Discarded 300 700 1000 SolidContainers/ 33.3 Nos. Nos. Nos. Inorganic Bags
Spent Oil/ Used Oil
Method of Disposal
LiquidOrganic
Collection, Storage, Decontamination and Disposal by selling to scrap vendors / recyclers. Collection, Storage, Transportation, Reuse as lubricant within the premises OR sell to registered Reprocessor/ MoEF approved recyclers
The unit will provide an adequate designated storage area for the hazardous waste storage within premises having impervious floor and roof cover system and leachate collection system. The unit has obtained membership of GPCB approved TSDF/ CHWIF of M/s. Saurashtra Enviro Projects Pvt. Ltd. for the disposal of hazardous waste and copy of certificate is enclosed as Annexure-10.
Chapter-2: Project Description Page | 2.49
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
2.10.4 Noise & Vibration There is no major source of noise and vibration from the existing as well as proposed manufacturing activity. Also, there is no D.G. set in existing unit and will not provided after proposed project. However, adequate precautionary measure for noise and vibration control measures as described below will be taken by the unit; Proper and timely oiling, lubrication and preventive maintenance will be carried out for the machineries and equipment to reduce noise generation. The noise generation will be mitigated by installing noise barriers/absorbers around stationery noise sources. Adequate noise control measures such as antivibration pad for equipment with high vibration will be provided. All the vibrating parts will be checked periodically and serviced to reduce the noise generation. The equipment, which generates excessive noise, will be provided with enclosures etc. To minimize the adverse effect on the health, ear muffs/ earplugs will be provided to the workers working under high noise area. To reduce the noise generation during the transportation activities; the transport contractor will be instructed kept vehicle periodically serviced and maintain as per the requirement of latest trend in automobile industry. Only those vehicles with PUC’s will be allowed for the transportation. The transport contractor will be informed to avoid unnecessary speeding of vehicles inside the premises. Noise monitoring will be done regularly at different parts of the plant. Increase in greenbelt area will help to prevent the noise pollution outside the factory premises.
Chapter-2: Project Description Page | 2.50
CHAPTER 3 BASELINE ENVIRONMENTAL STATUS
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
CHAPTER – 3 3.1
BASELINE ENVIRONMENTAL STATUS
PREAMBLE
Preparation of EIA needs a datum on which the evaluation can be done. It is necessary to collect data about different environmental aspects that are likely to be affected due to the proposed industrial activity, which in turn defines an existing environmental quality to serve as the datum. Various environmental conditions exist in the area surrounding the project site, which are liable to be affected due to the project activities, have been assessed quantitatively as well as qualitatively. In order to assess the feasibility of the said project, a study related to the present environment condition has been carried out by generating the baseline data. 3.2
APPROACH & METHODOLOGY OF BASELINE STUDY
The baseline environmental study for the EIA of proposed project of M/s. Ascent Pharma has been done by following the guidelines of MoEF. The study was finalized with the ToRs approved by the Ministry of Environment & Forest (MoEF), New Delhi. Copy of ToRs and its compliance is provided at the beginning of this report. The details of the study period, frequency of sampling & method of environmental sampling & analysis are shown below in succeeding chapter under respective titles. 3.2.1 Study Area For the present EIA study, the area falling within 10 km radial distance from project site has been selected for preparing the site map along with infrastructure setup and administrative map, land use/land cover map and socio-economic study whereas the area falling within 5 km was considered to monitor the base line environment quality. 3.2.2 Study Period The baseline study was carried out in Winter Season during December 2013 to February 2014 and all the points/conditions of approved ToRs have been covered in the study.
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3.2.3 Sampling Locations Locations for sampling & monitoring have been selected within the study area of 5 km radial distance from site. The sampling locations were selected on the basis of surface influence, demographic influence and meteorological influence. Total seven sampling locations were selected including project site, out of which two locations were selected in downwind direction. Among all the seven locations, ambient air monitoring, water sampling, noise monitoring & soil sampling were carried out at six locations. Meteorology data of the study area were collected by setting-up the weather station at project site. In addition to six locations, noise levels were also monitored near Shapar Veraval Junction at NH-8A. Details of monitoring locations are given below in Table 3.1. Map of study area showing sampling & monitoring locations are illustrated below in Figure 3.1.
Location Code
Table 3.1: Sampling & Monitoring Locations
Name of Village / Location
GPS Coordinates
Bearing w. r. t project Site
Approx. Aerial Env. Distance Attributes from Monitored* project site (km)
Type of Area
23° 10' 31.9" N A, PW, N, S, --Industrial 70° 09' 17.0" E MET 22° 11' 03.8" N 1°/ N A, GW, N, S2 Pardi Village 4.00 Residential 70° 47' 54.2" E /Upwind S Veraval (Shapar) 22° 09' 22.4" N 18°/NNE/ A, GW, N, S3 1.10 Residential Village 70° 48' 08.8" E Upwind S 22° 6' 55.77" N 154°/SSE/ A, GW, N, S4 Gundasara Village 4.02 Residential 70°48' 57.11" E Downwind S 22° 7' 37.83" N 218°/SW/ A, GW, N, S5 Ribda Village 2.87 Residential 70° 46' 50.42" E Downwind S 22° 8' 57.31" N 257°/WSW A, GW, N, S6 Pipliya Pal Village 4.61 Residential 70° 45' 8.64" E /Crosswind S Shapar Veraval 22° 9' 26.65" N 328°/NNW / S7 1.25 N Commercial Junction at NH-8A 70°47' 29.15" E Upwind *A-Ambient Air, GW-Ground water, PW-Pipe water, S-Soil, N-Noise, MET- Meteorology S1 Project Site
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Figure 3.1: Map of Study Area showing Sampling & Monitoring Locations
S2
S7
S3 S1
S6
S5
S4
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3.2.4 Frequency of Monitoring The frequency of environmental monitoring was determined considering the approved TOR issued by MoEF. The guidelines provided by MoEF in online EIA Manual and other guidelines provided by CPCB was also taken in to consideration while deciding the same. Frequency of environmental monitoring and method of sampling & analysis for various attributes considered for the study are illustrated in Table 3.2. 3.2.5 Method of Sampling & Analysis Selection of method for sampling, preservation and analysis plays very important role in baseline environmental study. Considering the necessity of quality in environmental sampling & analysis, CPCB has issued guidelines and even in the EIA manual published by MoEF necessary guidelines for baseline study have been provided. Considering these guidelines, methods of sampling & analysis for environmental monitoring have been selected/ adopted and same are illustrated in following Table 3.2. Table 3.2: Frequency of Environmental Monitoring and Method of Sampling & Analysis Monitoring Frequency Sampling Method Source / of / Instrument Location Monitoring A. Air Environment Book “Climate Meteorological Once -of Gujarat” Data published by IMD, Government of India-1995 Site Specific Project site Continuous Micro controller Micromonitoring based Automatic Meteorological with hourly Weather station Data data with data logger recording throughout the study period Ambient Air 6 Locations 24 hourly Fine Particulate Quality twice a Sampler (FPS) week and Respirable throughout Dust Sampler the study (RDS) period with attachment for Gaseous Attributes
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Analysis Method Computer Aided Data Analysis
Computer Aided Data Analysis
As per CPCB Guidelines and Manufacture’s Manual for Electronic instrument, IS 5182 [Part –II
Environmental Impact Assessment (EIA) Report Proposed Project for Manufacturing of Synthetic Organic Chemicals
Attributes
B. Noise
C. Water Ground Water
D. Soil Quality
Monitoring Source / Location
7 Locations
Grab samples from 6 locations
Once
6 locations
Once
E. Land Use - Satellite Image : Land Cover (Landsat ETM + Thermal MSS) F. Ecological Data through Data primary survey G. SocioCensus of economic India-2011 Data 3.3
Frequency Sampling Method of Analysis Method / Instrument Monitoring sampling, (2001) & Part – Electronic VI & XXIII instrument with (2006)], PID Sensor Method of air sampling & Analysis Second Edition Published By APHA Once, 24 IS 9989 -1981/ Computer Aided hourly Sound Level Data Analysis Meter With data logger
Once Once Once
As per IS: 3025 ‘Methods for sampling and testing of water and waste water’ and Standard Methods for Examination of Water and Wastewater Analysis published by American Public Health Association (APHA). Handbook of methods in environmental studies.Vol.2: Air, Noise, Soil and Overburden Analysis, Edition: 2011 published by S.K.Maiti & IS: 2720 Arc GIS software and Computer Aided Data Analysis Field survey
Computer Aided Data Compilation Compilation of data from Census of India-2011 and Computer Aided Data Analysis
BASELINE ENVIRONMENT
The baseline study was conducted during study period of December 2013 to February 2014 as mentioned above. All the scope given in the approved TORs were referred and baseline study was conducted to comply all requirements of approved TORs. The study was carried out to determine the prevailing status of topography, land use, meteorology, ambient air, water quality, soil quality, ecology and socioeconomic environment. The sampling, monitoring and analysis related to ambient air, water, soil and noise during the baseline study was carried out by in-house NABL approved Chapter-3: Baseline Environmental Status Page | 3.5
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laboratory of Envisafe Environment Consultants, Ahmedabad. The details regarding the outcomes of the baseline study are described in subsequent sections under respective heading. 3.3.1 Topography & Geology The area is almost flat. The ground gradients are mild and sloping from West to East. In and around the study area comprises of Deccan Trap Basalts. This trap rocks appears gently tilted at places. This Deccan Trap flows comprises massive, hard and tough Amygdaloidal Basalt, Vesicular fine grained basalts; Porphyritic basalts, Geodes with Zeolite, Chalcedony, Agate and Calcite are often in Amygdaloidal types. The traps are invariably jointed by all kinds of joints in Basalt. The most prevalent trap rocks are basalt and dolerites. Some of traps are stated to be ultra basic in composition. The Trap rocks formed due basalts on account of their fluidity spread over wide areas in the form of horizontal sheets and gave rise to the topography so common in the Deccan trap country. In and around the study area is covered by thick Mantle of soil. The recent formation includes Alluvium. 3.3.2 Seismology Study area falls in Zone III as per IS 1893 (Part-I):2002, which is referred as Moderate Damage Risk Zone. The area is liable to earthquakes of Modified Mercalli Intensity Scale VII. 3.3.3 Land Use Pattern Land cover inventories form an essential component in land resource evaluation and environmental studies. Land use in general refers to the various ways land is being utilized for different purposes by man, mainly to generate income as well as for residential purpose. Whereas, the word land cover indicates the vegetation, agricultural, artificial manmade structures and natural creature covering the land surfaces. It may include various landforms, geological features and ecosystems. Identification of land uses & land cover in the vicinity of any developmental activity is one of the most important components for environmental impact assessment, which would help determine the impact of the project developmental activities on the land use pattern. Good and correct compilation of this information helps in deciding the proper use of the land. Optimum economic use in accordance with minimal disturbance of the present ecology should be the prime objective of any industrial activity. Chapter-3: Baseline Environmental Status Page | 3.6
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The land use/land cover in the study area of 10 Kms has been presented in the form of a map prepared by using the satellite image, given below as Figure 3.2. The satellite image/data has been processed using ERDAS Imagine software supported with ground checks and ground truth verification by qualified and experienced professionals. Area and distance calculations have been carried out using GIS software after georeferencing the interpreted data with the help of Sol topographical maps of 1:50,000 scale.) A map depicting major land use/ land cover classes is given here as Figure 3.3 and classification of land use/ land cover is given in Table 3.3. Based on the data it can derived that about 69% of land in the study area is agriculture land utilizing for various crops like Makai, Gehu, Kapas, Ground nut, Kapas, Danger etc. There is only 3.55% land acquired for the industrial purposes in the study area. Table 3.3: Land Use Pattern of the Study Area Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Land use
Area (Ha.)
Built-up Land Settlements Industrial Agriculture Open shrubs Waste land Stony waste Ponds/Lakes River Total
Percentage (%)
1296.28 669.63 1116.16 21663.92 5710.11 34.78 622.28 95.42 206.65 31415.23
4.13% 2.13% 3.55% 68.96% 18.18% 0.11% 1.98% 0.30% 0.66% 100.00%
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Figure 3.2: Satellite Image of the Study Area
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Figure 3.3: Land use / Land Cover Map of the Study Area
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3.3.4 Meteorology Meteorology is the interdisciplinary scientific study of the atmosphere and is important tool in studying environmental phenomena like pollutant dispersion. When the EIA study is planned for any project meteorological data are very important and shall be collected through the entire period of the baseline study. Typically for EIA, micrometeorological data is required to collect as these data are essential to formulate the pollutant dispersion models. Besides, it also helps in understanding the current trend in climatologically variable as well as prevailing ambient air quality issues and forecasting. Details of the various Meteorological parameters analyzed during the study with their importance in EIA are presented in subsequent Table 3.4. Information about these parameters is taken from the Book “Climate of Gujarat” published by Indian Meteorological Department, Government of India-1995. Table 3.4: Meteorological Parameters Sr. Parameters No
1.
Surface Temperature
2.
Relative Humidity
3.
Wind Speed
4.
Wind Direction
5.
Rainfall
Measurement Importance Method Digital Sensor • Temperature affect the plum rise & it capable of giving increase the effective height of release electrical signals e.g. and thereby increase dispersion and thermocouples, thus decreases the maximum ground resistance level concentration of the pollutants. thermometers or • It also influences stability conditions thermistors. and extent of dispersion of pollutants. Moisture provides surface area for suspended particulate matter to coalesce and grow in the size and settle under the influence of gravity. It also enhances the Digital Sensor chemical reactions of the gaseous capable of giving electrical signals e.g. pollutant. High humidity is associated with; hydrometer. • Lowered visibility for water vapour plumes • Possible acid mist formation 3 cup anemometer Determines initial dispersion of air with reed pollution switch/magnet Wind vane with magnetic hall effect Determines downward geometry sensor Tipping Bucket Rainwater scrubs the atmospheric sensor with magnet & pollutants and pollutes surface and reed switch groundwater.
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Sr. Parameters No 6.
Cloud Cover
7.
Solar Radiation
8.
Atmospheric Stability Condition
3.3.4.1
Measurement Method Passive Cloud Cover Detector – PCCD Pyranometer type sensor Determined from surface observations on wind speed, cloud cover and solar radiations
Importance It influences stability conditions and determines the dispersion &/or dilution rate of pollutant. Determines plume spread associated with turbulent motions in the atmosphere
Temperature
The climate of the district is characterized by hot summer and dryness in the non rainy seasons. The year may be divided into four seasons. The cold season from December to February is followed by the hot season from March to May. The southwest monsoon season is from June to September and October and November form the post monsoon season. After mid November both day and night temperatures drop rapidly till January which is the coldest month with the mean daily maximum temperature at 28.1°C and the mean daily minimum at 10.7 ºC. In association with cold waves which sometimes affect the district in the wake of western disturbances which pass across north India during the cold season, minimum temperatures particularly in January may go down to the freezing point of water. The highest maximum temperature recorded at Rajkot was 47.8°C on 1919 May 15 and the lowest minimum temperature was -0.6°C on 1935 January 16. 3.3.4.2
Humidity
During the southwest monsoon season the relative humidities are generally over 60%. In the rest of the year the air is comparatively dry with afternoon humidities ranging between 20 and 30%. 3.3.4.3
Cloudiness
During the southwest monsoon season skies are heavily clouded to overcast on many days. In the rest of the year clear or lightly clouded skies prevail. But on a few days in the winter season skies become cloudy when the district is affected by passing western disturbances across north India.
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3.3.4.4
Wind Speed and Wind Direction
Winds are generally moderate but in summer and the southwest monsoon season they become stronger. Southwesterly to westerly winds prevail in the southwest monsoon season. In October winds are from direction between west and northeast. In November and December winds are mainly from directions between north and east. In January and February winds are again from directions between west and northeast. In the summer season the winds are predominantly from directions between southwest and northwest. Monthly mean wind speed observed in km/hr in months of December, January & March are 11.3, 13.1 & 13.6 respectively. 3.3.4.5
Rainfall
The average annual rainfall in the district is 569.0 mm. About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to September, July being the month with highest rainfall. The rainfall generally decreases from the southwest to the northwest. The variation of rainfall over the district from year to year is large. 3.3.5 Micrometeorology The site-specific micrometeorological data has been collected continuously during the study period by installing automatic weather station at project site. The parameters for which data has been collected are temperature, relative humidity, wind speed, wind direction, cloud cover, rainfall and radiation. Site specific micrometeorological data shows that, during study period; •
Average wind speed was 0.85 m/s and maximum wind speed was 7.1 m/s.
•
Wind blew mostly from NNW. Calm wind contributes to about 40.42%.
•
Average
temperature
recorded
was
20.1°C
with
maximum
temperature of 34.3°C and minimum of 12.1°C. •
The average relative humidity recorded was 46% with maximum relative humidity of 83%.
•
Wind rose diagram is shown as Figure 3.4.
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Figure 3.4: Wind Rose Diagram
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3.3.6 Ambient Air Quality Government of India and concern authorities have consistently ranked air pollution as a major environmental concern. The state of our air is an important factor in the quality of life. It affects the health of the community and directly influences the sustainability of our lifestyles and production methods. The Government seeks to protect and improve urban air quality through national action to reduce emissions of major air pollutants. The Government Department's focus is on those sectors that make the greatest contributions to adverse air quality as well as those pollutants that continue to pose threats to the environment and human health. National action can relate to the implementation of relevant national standards and strategies and a common approach to monitor air quality, research to inform air quality policy and community education on air quality issues. National policies and programmes relate principally to the reduction of emissions mainly from two sectors as detailed below: Transport: National initiatives aim to reduce the impact of road transport on environment quality, urban amenity and human health. People's travel behaviour is also targeted, including promotion of bicycle use for short journeys. Industry: Emissions from larger industries are reported under the National Pollutant Inventory and are subject to State/Territory control programmes. In last few years Government has enacted standards for both of these sectors through CPCB. Recently, Government has also put forwards some findings regarding the critical issues of air quality & critical level of pollution in many part of India. Further, Government through its concern department is continuously trying to improve the environmental quality of the Indian regions. The findings have also noted that the issues of contamination of air have been arising in the region experiencing more industrial development. Hence, while studying the probable impacts of any industrial project, establishment of state of air quality in project area has become very important aspect of EIA study. With such purpose, ambient air quality monitoring has been conducted for the present EIA study at 6 locations as mentioned in earlier section referring the adopted methods. The monitoring was carried out for PM 2.5 , PM 10 , SO 2 , NO x , HCl, CO, NH 3 and VOC.
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The AAQ monitoring results obtained during the entire study are given in Annexure-11 and summary of the results are given in Table 3.5. Table 3.5: Ambient Air Quality Status Parameters Particulate Matter (size less than 10µm) or (PM 10 ,), µg/m3 [100]* 24 Hours Particulate Matter (size less than 2.5µm) or (PM 2.5 ), µg/m3 [60]* 24 Hours
Sulphur Dioxide (SO 2 ), µg/m3 [80]* 24 Hours
Nitrogen Oxide (NO x ), µg/m3 [80]* 24 Hours
Hydrogen Chloride (HCl), µg/m3 [200]** 24 Hours Ammonia (NH 3 ) µg/m3 [400]* 24 Hours
Station Name of Station Code S1 Project Site S2
Min. 96
Concentration Max. Avg. 98 %tile 148 121.5 145.2
61
82
70.9
82.0
60
79
69.5
79.0
S4
Pardi Village Veraval (Shapar) Village Gundasara Village
69
91
80.0
91.0
S5
Ribda Village
81
113
98.2
113.0
S6
Pipaliya Pal Village
76
103
89.5
103.0
S1
Project Site
39
55
47.2
55.0
S2
27
38
32.1
38.0
25
34
29.7
34.0
S4
Pardi Village Veraval (Shapar) Village Gundasara Village
31
42
36.3
42.0
S5
Ribda Village
36
52
44.8
52.0
S6
Pipaliya Pal Village
33
48
40.7
47.1
S1 S2
Project Site Pardi Village Veraval (Shapar) Village Gundasara Village Ribda Village Pipaliya Pal Village Project Site Pardi Village Veraval (Shapar) Village Gundasara Village Ribda Village Pipaliya Pal Village Project Site
27 18
52 36
39.7 26.9
52.0 35.5
26
48
36.5
47.1
14 16 10 33 19
27 29 17 56 33
20.5 22.5 13.3 45.3 26.1
27.0 29.0 17.0 55.1 32.5
21
38
29.2
38.0
16 26 17
25 43 28
21.4 35.7 22.6
25.0 42.5 28.0
19
30
25
30
S3
S3
S3 S4 S5 S6 S1 S2 S3 S4 S5 S6 S1
S2 to S6
Below Detection Limit (18)
S1 to S6
Below Detection Limit (20)
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Parameters
Station Code
VOC (as isobutylene) µg/m3 [NS] Grab
Name of Station
S1 to S6
Min.
Concentration Max. Avg. 98 %tile Below Detection Limit (1)
S1 S2
Project Site 0.91 1.42 1.13 1.41 Carbon Pardi Village 0.45 0.89 0.65 0.87 Monoxide (CO), Veraval (Shapar) S3 0.41 0.99 0.67 0.96 mg/m3 Village [2]* S4 Gundasara Village 0.39 0.79 0.57 0.76 8 Hours, S5 Ribda Village 0.42 0.82 0.61 0.81 Grab S6 Pipaliya Pal Village 0.35 0.81 0.54 0.78 *National Ambient Air Quality Standards published by MoEF, New Delhi vide G.S.R. 826 (E), dated 16/11/2009. **GPCB norms for HCl for industrial area [NS] – No standards prescribed for VOC under NAAQs. All monitoring stations are of the category “Industrial, Residential, Rural & Other Area” as per NAAQs The maximum concentrations of PM 2.5 , PM 10 , SO 2 , NO x , CO and NH 3 at each ambient air monitoring locations were compared with National Ambient Air Quality Standards (NAAQS) for industrial, residential, rural and other areas and following are the observations: •
All the parameters are well within the NAAQS except PM 10 at three locations.
•
PM 10 concentrations at project site, Ribda and Pipaliya Pal Village were found higher than the NAAQS.
•
HCl concentration at project site was also well within the GPCB norms prescribed for industrial area. It was below detectable limit at other locations.
•
VOC and NH 3 concentration (as isobutylene) was below detectable limit (BDL) at all locations.
3.3.7 Hydrology The importance of water can’t be overstated when it comes to life on Earth. Over 70% of the Earth is covered in water and without water there simply is no life. With increasing industrialization & modernization in lifestyle, issue of water crisis either quality &/or quantity of water is being critical day by day. The main source of such crisis is found to be the activities requiring huge quantity of freshwater and generating huge quantity of wastewater. Thus, such activities are posing threat to the life and the Chapter-3: Baseline Environmental Status Page | 3.16
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industrial development is the prime operation of such activities. Hence, while studying the probable impacts of industrial project, it is very important to determine the existing status of water quality & quantity. The water resource for such investigations can be groundwater or surface water or both depending upon the water specific planning of the proposed project. Major source of water available in the area is ground water. There is not any surface water source like perennial river, reservoir etc in the study area. Baseline study for the water quality has been conducted and as a part of study water samples were collected from various locations as described in earlier section once during the study period. The samples were analyzed as per the method described in IS: 3025 ‘Methods for sampling and testing of water and waste water’ and Standard methods for examination of water and wastewater analysis published by APHA. Details of the baseline study for establishment of existing water quality status has been described in subsequent section under respective heading. Map showing the hydrology status of the study area is given as Figure 3.5. The outcome of the study of water quality is presented in subsequent Table 3.6. Ground Water Ground Water is occurring in the zone of Secondary Porosity, under unconfined condition. In order to assess the present status on ground water quality, information of selected wells was collected and studied. During the study well samples were also collected and analyzed to assess the present status of ground water quality. The depth to water level of unconfined aquifer in this area is ranging from 3.0 to 16.0 m. The depth of well in this area is ranging from 16.9 to 21.0 m. From the ground water development point of view this area falls in safe category. Large diameter of well is indicative of slow recovery in water level in well after pumping phases. It indicates low specific yield values. Ground water quality is good, but yield of such wells is not sufficient or inadequate.
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Figure 3.5: Map showing Hydrology of the Study Area
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Table 3.6: Physico-Chemical Characteristics of Water
Sr. No. A 1 2 3 4 5 6 B 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Parameter
Unit
IS: 10500 standard limit for drinking water
Desirable Permissible Organoleptic and physical parameters Hazen Colour 5 15 unit pH -6.5 – 8.5 NR Elec. Conductivity ms/cm --Temperature --⁰C Turbidity NTU 1 5 Dissolved Solids mg/l 500 2000 General Parameters Alkalinity mg/l 200 600 Total Hardness mg/l 200 600 (as CaCO 3) Calcium (as Ca+2) mg/l 75 200 Magnesium (as mg/l 30 100 Mg+2) Chlorides (as Cl-) mg/l 250 1000 Sulphate (as SO4-2) mg/l 200 400 Fluoride (as F ) mg/l 1 1.5 Nitrates (as NO 3 -) mg/l 45 NR Ammonical nitrogen mg/l --Phenolic compound mg/l 0.001 0.002 Alluminium (as Al) mg/l 0.03 0.2 Boron (as B) mg/l 0.5 1.0 Copper (as Cu) mg/l 0.05 1.5 Iron (as Fe) mg/l 0.3 NR
S1
S2
S3 S4 Veraval Gundasara (Shapar) Village Village GW GW
S5
S6
Project Site
Pardi Village
Ribda Village
Pipaliya Pal Village
PW
GW
GW
GW
1.0
1.0
1.0
1.0
1.0
1.0
7.46 0.6 32 0.5 635
7.59 0.8 33 1.0 2245
7.11 1.0 32 2.1 1380
7.98 1.3 32 0.9 505
7.20 0.9 34 1.5 1485
7.83 0.7 32 1.0 845
280
260
228
144
368
324
460
860
675
200
685
535
120
110
132
46.1
60.1
54.1
39.1
142
84.0
20.7
130
97.4
116 21.9 0.30 28.2
