Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

PRE FEASIBILITY REPORT For Proposed Expansion of Common Effluent Treatment Plant At 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka

M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Prepared By

SMS Envocare Limited 301, Pentagon P3, Magarpatta city, Hadapsar, Pune- 411028 Ph.: 020-66801111 Website: www.smsenvocare.co.in

1

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

INDEX Sr. No. 1 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 4 4.1 4.1.1 4.1.2 4.1.3 5 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 7.4 8 8.1 9 10 11 11.1 12

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Particular EXECUTIVE SUMMARY INTRODUCTION OF PROJECT/BACKGROUND INFORMATION Identification of Project and Project Proponent Project Proponent Nature of the Project Need of the Project Importance of the Country and Region PROJECT DESCRIPTION Type of Project Alternative Site Consideration SIZE/MAGNITUDE OF THE PROJECT Project Details Process Disposal of Sludge Design Basis and Design Calculation PROCESS DESCRIPTION & FLOW DIAGRAM REQUIREMENT OF THE PROJECT Chemical Requirement Water Requirement & Distribution Power and Fuel Requirement Area Requirement Regulatory Framework SITE ANALYSIS Connectivity Landform, Land Use and Land Ownership Topography Climatology PLANNING BRIEF Planning Concept SAFETY PROVISION IN THE PROPOSED EXPANSION PROJECT REHABILITATION AND RESETTLEMENT (R&R) PLAN PROJECT IMPLEMENTATION SCHEDULE Project Cost Estimation PROJECT BENEFIT

Prepared By M/s SMS Envocare Limited ,Pune

Page 1 1 1 1 5 5 5 6 6 9 9 10 10 11 12 12 12 12 12 13 13 13 13 13 13 14 14 15 15 15 17 17 17 18

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

1.

EXECUTIVE SUMMARY

S.N

Details

Information

1

Name of the Project

Expansion of Common Effluent Treatment Plant (CETP)

2

Regulatory Framework

3

Location

4

Capacity

The Proposed Project is Expansion of Existing CETP Project from 40 KLD to 160 KLD

5

Name of Project Proponent

Pai & Pai Chemicals (I) Pvt. Ltd.

6

Area Requirement

Total Plot Area = 1Acre Building Area – 7500 Sq. Ft.

7

Water Requirement

This is a, Effluent Treatment Plant. Treated water will be fit for re-use for non potable uses viz; Gardening, Flushing Toilets, and Vehicle washing or any other nonpotable industrial uses etc.

8

Power Requirement

Proposed : 89.5 Kw

9

Man Power

Existing: 4 Proposed:7 Total: 11

10

Project Cost

Proposed:318.80 Lakhs

Activity of 7(h), namely “Common Effluent Treatment Plants”, as per EIA Notification, 2006 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka

2. INTRODUCTION OF PROJECT /BACKGROUND INFORMATION 2.1 Identification of the Project and Project Proponent M/s. Pai & Pai Chemicals (I) Pvt. Ltd. proposes to expand the existing Common Effluent Treatment Plant from 40 KLD to 160 KLD at Plot no. 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka. 2.2 Project Proponent M/s. Pai & Pai Chemicals (I) Pvt. Ltd. was established in the year 1992 to cater the need of the treatment of effluents from metal finishing industries of small, medium and large sizes. During the course of operation of this unit, the industry received number of inquiries from the Pharma sector, herbal extraction units and other chemical industries having problems with high BOD and COD 3

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

effluents. The only solution then available was solar evaporation, which was a failure in Bangalore due to the climatic condition. Hence this 2nd unit was established in the year 2003. The CFE was obtained on 06.11.2003. The unit became functional from January 2004. The CFO was obtained on 02.03.2012. The specialty of this plant is the anaerobic degradation of concentrated COD and BOD. This mechanism is highly popular in developed countries as it is environmental friendly and is a potential source of energy. This unit has tankers of different capacity to collect and transport wastewater from different industries. We also have full-fledged lab facility to analyze the inflow and the out flow of treated water. Day to day analysis is carried out at each level by trained and qualified chemist for various effluents and the necessary treatment is carried out as per KSPCB norms. •

Total Environmental Audit

•

Consultancy on handling / disposal of solid , liquid and gaseous and oil waste

•

Air and Sound Pollution consultancy

•

Techno-economic feasibility for common effluent treatment plants

•

Design and fabrication of custom built effluent , metal finishing , phosphating, pickling and waste water recovery plants

•

Auditing of metal finishing processes

•

Auditing of waste water treatment plants

•

Environment impact assessment

•

Analysis of effluents and drinking water

•

Segregation and storage of Scrap

•

Training all our employees and contract employees on the processer and performance in quality of environment

Facilities Provided by Company Everyday, a fleet of specially lined tankers fitted with GPRS collect effluents from various companies across Bangalore and adjoining areas. Each tanker is of capacity varying from 6,000 liters - 20,000 liters and are specially designed with PVC or MSRL leak proof linings. Collected effluents are carefully transferred from the tankers to specially lined impervious collection tanks which have a capacity ranging from 65,000 to 200,000 liters and are designed to handle alkali, acids, cyanide, chrome and biological effluents. 4

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Figure No. 1.1: Existing Treatment Facility provided at site Specific treatments are carried out in batch and continuous process depending on the nature of effluent by automated systems. The plant has been designed to use the natural gradient for flow of effluents by gravity thus achieving a saving in consumption of power. Automatic sequential process 5

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

control is achieved through continuous indication of PH and RH levels at every stage of the treatment. The plant is fully equipped with a tertiary treatment facility backed by RO and multistage evaporator for removal of excess dissolved solids. Treated water is thereafter used for non potable purposes like gardening and in-house processes. Multi stage de-watering process is adopted to ensure compacting of the sludge generated during the process and thereafter transported to TSDF as per KSPCB guidelines. With a total storage capacity of over 750,000 liters, Pai and Pai is committed to the concept of recycling and reuse with the objective of waste minimization. Get in touch with us today for a comprehensive and effective environmental control and protection programme. 2.3 Nature of the Project The proposed project is an expansion of common effluent treatment plant for effluent generated from Kumbalgodu Industrial Area. 2.4 Need for the project Disposal of treated effluent and sludge becomes more organized Reduced burden of various regulatory authorities in ensuring pollution control requirements. Small scale Industries cannot afford fully fledged treatment facility Saving in operating and capital cost of treatment plant Neutralization and equalization of heterogeneous waste makes its treatment techno-economically viable. Availability of land is difficult for individuals units to set ETP Professional and trained staff can be made available at CETP 2.5 Importance to the Country and Region Pai and Pai Chemicals was set up with a socio – economic vision to bring the much needed awareness amongst industries to check industrial Pollution. Pai and Pai collect effluents from across a vast spectrum of the industry for treatment at its state-of –the art plant. Spread over 3 acres of land in Kumbalgudu, Bangalore, Pai and Pai collects effluents from several small, medium and large scale industries around Bangalore for treatment of CETP facilitate better management of the industrial waste waters Acids, Alkalis, Cyanide, Chrome, Rinse and Biological waste. Proposed expansion of 6

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

the existing unit will also help to the upcoming industries to treat the effluent and safe disposal of the treated Effluent. Following are the major benefits of the project: It will minimize the pollution load on environment. Compliance with prescribed regulatory norms which in turn avert the risk of closure on account of violation of rules Waste Water can be neutralized by waste water itself where ever feasible The management of Waste water is relatively easier & economically viable at CETP facility. Cost of Laboratory analysis is less at common facility In absence of expertise or availability of less expertise this route is confirmed to be most viable and easy to monitor Operational cost is less compare to individual unit Better occupational health and safety at individual industry level

3. PROJECT DESCRIPTION 3.1 Type of Project Proposed Project is an Expansion of Existing Common Effluent Treatment Plant from 40 KLD to 160 KLD at 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd. The proposed project is for treatment of the Effluent generated from Kumbalgodu Industrial area and nearby location. Project location of the proposed expansion project is given below:

7

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Figure No. 1: Project Location-A

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Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Figure No. 1: Project Location-B

9

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

3.2 Alternative Site Consideration Proposed Expansion of CETP Project is situated in Notified Industrial area under Karnataka Industrial Area Development Board. The project site is situated in 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka. The site is already allotted to M/s. Pai & Pai Chemicals (I) Pvt. Ltd. for development of CETP Project. As the project site already identified for Industrial development, no alternative sites were considered.

4. SIZE/MAGNITUDE OF THE PROJECT Proposed Expansion project is for design, construction, erection, commissioning and operation & maintenance of CETP from 40 KLD to 160 KLD Capacity. Total plot area allotted for proposed expansion project is 1 Acre. Total Buildup area will be 7500 Sq. Fit (697 Sq. m). 33 % of total plot area shall be secured for Green Belt Development. Total 10 different industries contributing to Proposed CETP is given below: Table No. 1: List of Industries contributing to Proposed CETP Project Sl. No.

10

Industry

Flow (m3/day) 18.56

COD (Mg/L) 66,500

BOD5 (Mg/L) 22,200

1

Pharmaceutical

2

Herbal Extraction

24.05

1,01,200

33,700

3

Food/Beverage

39.56

95,000

31,600

4

Animal nutrition

22.96

4,300

1,400

5

Formulations

10.7

17,000

5,500

6

Paint Industry

5.45

16,500

5,300

7

Adhesive Manufacturing

8.40

1,86,500

62,000

8

Resin/Pigment

2.45

48,000

15,800

9

Water Treatment

6.25

11,800

3,900

10

Lens Manufacturing

10.76

2,200

750

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

4.1 Project Details 4.1.1 Process Unloading of the effluent Effluents Collected from the industries are unloaded into the collection tanks. Equalization The effluents are equalized based on their characteristics. The pH is maintained at 8.5- 9.0 Primary clarifier From the Equalization tank the effluent is sent to the clarifier for separation of solids and clear liquid. The overflow is sent to the intermediate sump. Anaerobic Digester From intermediate sump the liquid is pumped into the anaerobic digesters for breakdown of the complex hydrocarbons to simple hydrocarbons. Aerobic Tank The overflow of anaerobic digesters is sent to the aerobic tanks for aeration. Secondary Clarifier 1 The overflow of aerobic tanks is sent to the secondary clarifier for sedimentation of suspended particles and takeout the clear liquid. Extended Aeration Tank The over flow from the secondary clarifier 1 is sent to the extended aeration tank for further aeration. Secondary Clarifier 2 The over flow from the extended aeration tank is sent to the secondary clarifier 2 for further sedimentation of suspended particles and takeout the clear liquid. Flash Mixer The over flow from the secondary clarifier 2 is mixed with Alum and lime in Flash mixer to remove color and maintain pH respectively.

11

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Clariflocculator The over flow from the Flash mixer is sent to the Clariflocculator where sedimentation of suspended particles takes place. The suspended particles settled are sent to sludge sump. Pre Sand Filter Tank The over flow from the clarifloculator is collected in pre sand filter tank before sending it to Sand and Activated carbon filter. Sand filter and activated carbon filter (1) From the Pre sand filter tank the water is sent to the sand filter and activated carbon filter for removal of colloidal suspended solids and Colour. Holding tank Water from sand & carbon filter (1) is stored in Holding tank where Sodium hypo chlorite is added to remove excess color. Aeration is provided in tank for mixing of hypo and to improve treatment process. Sand Filter and Activated Carbon Filter (2) From the holding tank the water is sent to the sand and activated carbon filter (2) for further removal of traces of colloidal suspended solids and colour. Treatment process of proposed expansion unit is enclosed as Annexure-2 4.1.2 Disposal of Sludge Total 2.9 Tonns (2928 Kg/day) of Sludge will be generated from various stages of the treatment. Chemical Sludge will be sent to CHWTSDFs. Biological Sludge will be use back to the treatment process. 732 Kg/day of excess sludge will be sent to Anaerobic Sludge Digester. After treatment into Anaerobic Sludge Digester, treated Sludge will be collected to Sludge drying beds and will be used as manure for plantation and gardening. Layout plan of Sludge drying beds is enclosed as Annexure3.

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Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

4.1.3 Design Basis and Design Calculation Design Basic Table No.2: Raw & Treated Effluent characteristics Sr. No. Parameters Raw Effluent 1 pH 5.29 2 BOD 18,300 mg/l 3 COD 55,000 mg/l 4 Chloride 3,380 mg/l 5 TDS 27,627 mg/l

Treated Effluent 5.5-9.0 100 430 600 2100

5. Process Description & Flow Diagram Process Flow Diagram of Proposed Expansion Project is enclosed as Annexure-2. 6. Requirement of the Project 6.1 Chemical Requirement

Sr. No

Table No.3: Chemical Requirement Name of Raw Materials Quantity (Kg/d)

Quantity (Kg/m)

Source

1

Lime

100

3000

Local Market

2

Alum

0.714

22

Local Market

3

Hypo

6.66L/D

200 L/D

Local Market

4

Flock

1

30

Local Market

5

Deformer

1

30

Local Market

6.2 Water Requirement & Distribution Total water requirement in the project is 12.5 KLD. Existing water requirement is 5 KLD and total water requirement for Expansion project is 7.5 KLD. Treated water will be fit for re-use for non potable uses viz; Gardening, Flushing Toilets, and Vehicle washing or any other non-potable industrial uses/to meet disposal standards for natural Nala. And the sludge disposed as manure in gardening and agricultural use. Water balance for proposed expansion project is given below:

13

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

6.3 Power and Fuel Requirement Total power requirement for proposed project is 89.5 KW. Required power will be sourced from Karnataka Power Distribution Company limited (KPDCL). DG will also be provided for as backup source in case of power failure.

6.4 Area Requirement Total plot area allotted for proposed expansion project is 1 Acre. Total Buildup area will be 7500 Sq. Fit (697 Sq.m). 33 % of total plot area shall be secured for Green Belt Development.

6.5 Regulatory Framework As per the Schedule attached to the EIA Notification, 2006 and its amendment in 2009 the proposed expansion project is covered under Project or Activity of 7(h), namely “Common Effluent Treatment Plants”, requires prior Environmental Clearance (EC). It is categorized as Category B and requiring Environmental Clearance from the State Environmental Impact Assessment Authority (SEIAA).

7. SITE ANALYSIS 7.1 Connectivity Table No. 4: Connectivity of the Project Site Sr. No

Particulars

Details

1

Nearest Town

Bangalore City: 21 Km at NE

2

Nearest Highway

SH-17 at .30 Km at W Direction

3

Nearest Railway Station

Kengeri Railway Station: 7 km at NE

5

Nearest Airport

Bangalore International Airport 63 KM at NE

6

Location

Kumbalgodu Industrial Area

7.2 Landform, Land use and Land Ownership Proposed expansion project is located in Notified Industrial area i.e. Kumbalgodu Industrial area, Village Kumbalgodu, Taluka and district Bangalore South, Karnatka. Presently the area is plain with few ground floras. As the area already being used for Industrial purpose, no change in land use will be occurred.

14

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

7.3 Topography The district has two unique Topographical terrains—North Bangalore taluka and the South Bangalore taluka. The North Bangalore taluka is a relatively more level plateau and lies between an average of 839 to 962 meters above sea level. The middle of the taluka has a prominent ridge running NNE-SSW. There are gentle slopes and valleys on either side of this ridge. The low-lying area is marked by a series of water tanks varying in size from a small pond to those of considerable extent, but all fairly shallow. The topography of district is flat except for a central ridge running NNE-SSW. The South Bangalore taluka has an uneven landscape with intermingling hills and valleys. The southern and western portions of the city consist of a topology of granite and gneissic masses. The eastern portion is a plane, with rare minor undulations. The rock types prevalent in the district belong to the Saugar, Charnokite and Peninsular Gneissic Complex (PGC) groups. The PGC is the dominant group of rocks and covers two-thirds of the area and includes granites, gneissis and migmatites. 7.4 Climatology Due to its high elevation, district usually enjoys a more moderate climate throughout the year, although occasional heat waves can make summer somewhat uncomfortable. The coolest month is December with an average low temperature of 15.4 °C (59.7 °F) and the hottest month is April with an average high temperature of 36 °C (97 °F). The highest temperature ever recorded in Bangalore is 38.9 °C (102 °F) (recorded in March 1931). However, the suburbs of Bangalore recorded temperatures as high as 41 °C (106 °F) which are now part of present-day Bangalore. The lowest ever recorded is 7.8 °C (46 °F) (recorded in January 1884). Winter temperatures rarely drop below 12 °C (54 °F), and summer temperatures seldom exceed 37 °C (99 °F). Bangalore receives rainfall from both the northeast and the southwest monsoons and the wettest months are September, October and August, in that order. The summer heat is moderated by fairly frequent thunderstorms, which occasionally cause power outages and local flooding.

15

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

8. PLANNING BRIEF 8.1 Planning Concept It has been summarized that a CETP has to be constructed to treat Effluent from Kumbalgodu Industrial Area. The Proposed treatment scheme includes Pre Treatment, physico Chemical Treatment, Biological Treatment, Tertiary Treatment, Ultra filtration & Sterilization by UV sterilizer / Chlorination, and Reverse Osmosis (RO) and finally disposal of treatment effluent and handling of Sludge. They are situated in Kumbalgodu Industrial area, Bangalore South, Karnataka.

9. SAFETY PROVISION IN THE PROPOSED EXPANSION PROJECT This is an S.S.I unit spread over 01 acre of land. The main building and staff block occupy around 1/3rd of the area, where as other 2/3rd is covered by green patch. Substantial manpower and money is spend in maintaining the aesthetic beauty of the industry. Special attention is given to the working community to take care of their health and safety aspects. All employees are covered under E.S.I. in the treatment unit they are provided with safety goggles, safety shoes, safety gloves, safety masks, safety belts and safety ear muffs. Monthly training sessions are conducted to educate them about the health hazards, and usage of PPE’s. Each section of the plant is equipped with fire extinguishing device of appropriate nature. In the chemical preparation, workers handling acid or alkali are provided with gloves, masks, goggles in addition to all other equipments. Building & Work Spaces: •

Adequate space will be provided for equipment repair and removal

•

Equipment maintenance slope will be set up with appropriate safety provisions for hazards associated with maintenance activities

•

Laboratory with adequate entry & exit gate

•

Provision for safe collection of samples will be provided

•

Lightning protection will be provided

Electrical: •

Medium and high voltage cables will be completely enclosed in either conduit or covered trays

• 16

Electrical equipment will be grounded adequately

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

•

Wiring will be properly insulated, grounded, and non exposed

•

Emergency shutoff switch, clearly labeled, at all machinery units will be provided

•

DG set will be provided as stand by source of power to keep critical systems operational

•

Maintenance tools with insulated handles will be provided for nonconductive cases

Fire: •

Fire hydrants and fire alarms will be provided

•

Fire extinguishers will be provided

•

Laboratory wall surfaces, ceilings, and furniture will be made of nonflammable or fire resistant materials

First Aid: •

First aid Kits will be provided

Illumination: •

Adequate exterior and interior lighting throughout the plant will be provided

•

Emergency lighting (battery operated lights) will be provided

Laboratory: •

Durable and nonslip floor materials will be used

•

Ventilation with adequate make up air will be provided

Personal Protective and Safety equipment: •

Safety shoes, chemical aprons, work cloths, hard hats and rubber boots will be provided

•

Safety equipment will be located for easy access in an emergency

•

Hard hats and ear plugs will be provided for visitors

Piping & Valves: •

The valves will be accessible and easily operated

•

Head clearance will be provided

•

Piping will be designed in such a way that will not block or restrict access for routine operation or maintenance

Walkway, Ladders and Stairways: •

Nonslip stair treads on landings and stairs will be provided

•

Stair risers of equal height and proper slope will be provided

•

Handrails of type and cross section will be provided such that they can be fully gripped with fingers and thumb

17

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

•

Rest landings on stairways will be provided

Others •

Usage of PPE’s made compulsory in the process unit.

•

Usage of PPE’s made compulsory at the time of loading and unloading of vehicles.

•

Separate drains for collecting spills.

•

First Aid facility.

•

Display of Trem card made compulspory in the vehicles transporting effluents

10. REHABILITATION AND RESETTLEMENT (R & R) PLAN R&R has not been found relevant for the proposed expansion project as there would not be any temporary or permanent displacement of live and goods at the project site located within the notified Industrial area of Kumbalgodu Industrial area. Hence no R & R is applicable for the project.

11. PROJECT IMPLEMENTATION SCHEDULE Table No.5: Project Implementation Schedule SL. No

Project Implementation Work

Time Period

1.

Applicable Clearance work

By June 2016

2.

Equipment Manufacturing

By September 2016

3.

Final Installation

By December 2016

4.

Trials

Up to March 2017

11. 1 Project Cost Estimation Estimated Project Cost for the proposed expansion is given below along with the existing cost will be Rs 318.80 Lakhs. Detail of the same is given below: Table No.6: Project Cost Estimation Sl. No 1

Description

Amount (In Lakhs)

Civil works including construction of shed, Bar Screen Chamber, Effluent Collection Tank, Sludge Drying Beds, Equipment Plat Form and Intermediate sump

18

Prepared By M/s SMS Envocare Limited ,Pune

85.00

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

2

Electro mechanical equipments

3

Inter plant piping

5.8

4

Electrical works

3.5

5

Instrumentation and SCADA

4.0

GRAND TOTAL (Excluding TAX)

220.50

318.80

12. PROJECT BENEFIT Project will create direct & indirect employment opportunities within the surrounding region. Unit will use good faith efforts to employ local people from the nearby villages depending upon the availability of skilled & un-skilled man-power surrounding the project site. In operation phase, the proposed project would require significant workforce of non-technical and technical persons. Migration of highly education and skilled experience will result in increase of literacy in the surrounding villages.

19

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Annexure-1 Plant Layout

20

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Annexure-2 Process Flow Diagram

21

Prepared By M/s SMS Envocare Limited ,Pune

Pre-Feasibility Report For the Proposed Expansion of Common Effluent Treatment Plant (CETP) from 40 KLD to 160 KLD at 25D, 1st Phase, Kumbalgodu Industrial Area, Kumbalgodu, Tehsil & District Bangalore South, Karnataka by M/s. Pai & Pai Chemicals (I) Pvt. Ltd.

Annexure-3 Sludge Drying Beds

22

Prepared By M/s SMS Envocare Limited ,Pune