Environment Impact Assessment For Expansion of Speciality Chemicals

Transcription

1 Environment Impact Assessment For Expansion of Speciality Chemicals Manufacturing Unit 0f M/s Galaxy Surfactants Ltd. Plot no: G-59, Tarapur MIDC Boisar, District: Palghar, Maharashtra. Plot No. A-95, Road No. 16, Kisan Nagar road, MIDC Wagle Estate Area, Thane (W) Tel. (022) /22/23/24 prs@sadekarenviro.com / psadekar5@gmail.com

2 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY EXECUTIVE SUMMARY ES-1 Introduction The proposal is an expansion project. As per the Environment Impact Assessment notification, 2006 & its latest amendments, the project falls under the schedule 5 (f) Cat B-1 for Synthetic Organic Chemicals Manufacturing Unit. The company is classified as Large Scale Industries and it is categorized under Red category industry by the Maharashtra Pollution Control Board. The salient features of the project are listed in table ES-1: Table No. ES-1: Salient Features of the Project Sr. No Components Status 1 Name Galaxy Surfactants Ltd. 2 Plot No: G-59, Tarapur MIDC, Boisar,Palghar, Dist : Palghar, Location Maharashtra, India. 3 Product Type Speciality Chemicals 4 Project Type Expansion 5 Schedule 5 (f) 6 Category B-1 7 Area Details Existing (sq.m) Proposed (sq.m) Total (sq.m) Total Plot Area Ground Coverage Area Green Belt Area Parking Area Product Capacity (MT/month) Project cost 5.85 Cr /- 100 Cr / Cr /- 10 EMP cost 10 Lakhs 471 Lakhs 481 Lakhs Power Requirement Water Requirement Existing connected Load 150 KW Existing Demand 143 KVA 30 CMD (As per valid CTO) 20.5 Proposed connected Load 1050 KW Proposed demand 998 KVA Proposed connected Load 1200 KW Proposed demand 1140 KVA 500 CMD CMD Sadekar Enviro Engineers Pvt. Ltd ES 1 1

3 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY Sr. No Components Status (actual) 13 Fuel Requirement i) FO ii) HSD LDO/FO :- 1.2 MT/ D HSD :- 167 L/D FO :- 8 MT/D HSD : 400 M/D FO:- 9.2 MT/D HSD :- 567 L/D Boiler Details Stack Height 1. TFH 6 lakh Kcal/Hr 25 m for TFH. 6 m for existing D.G set. 1. TFH 8 lakh Kcal/Hr 2. Steam Boiler 3.5 MT/Hr 39 m ( For Boiler and TFH) Scrubber 12 m D.G set 10 m. D.G. set details 1*250KVA 1*800 KVA 1. TFH 6 lakh Kcal/Hr 2. TFH 8 lakh Kcal/Hr 3. Steam Boiler 3.5 MT/Hr 25 m for TFH. 6 m for existing D.G set. 39 m ( For Boiler and TFH) Scrubber 12 m D.G set 10 m 1*250KVA, 1*800 KVA 17 ETP Capacity 15 CMD (Primary Treatment). The existing ETP will be demolished. 18 Effluent Generation 1. Domestic Eff. 5.5 CMD CTO 2. Industrial Eff. 15 CMD CTO 3. Domestic Eff. 1.2 CMD Actual 4. Industrial Eff. 11CMD Actual. 80 CMD ( Fully Fledged ETP with MEE followed by ATFD and R.O.) 1. Domestic Effluent 8 CMD 2. Industrial Effluent 127 CMD 80 CMD ( Fully Fledged ETP with MEE followed by ATFD and R.O.)The 15 CMD primary treatment will be demolished. 1. Domestic Effluent 9.2 CMD 2. Industrial Effluent 138 CMD 19 Effluent Quantity discharged to CETP The project is a ZLD unit. Sadekar Enviro Engineers Pvt. Ltd ES 1 2

4 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY Sr. No Components Status 21 Man Power 27 employees 150 employees 177 employees 22 Hazardous Waste Generation (MT/A) Wastes/residue containing oil Cat. Existing (As per valid CTO) Proposed Total MT/A 2 MT/A Spent Solvent MT/A 6 MT/A Distillation residue MT/A 410 MT/A Process Residues & wastes Spent catalyst/spent carbon Discarded containers/barrels/liners contaminated with haz. Wastes/chemicals Spent ion exchange resin containing toxic material Flue gas cleaning residue Chemical sludge from waste water treatment Filters and filter material which have organic fluid MT/A -- 1 MT/A MT/A 2 MT/A MT/A 10 MT/A MT/A 1 MT/A 1.2 MT/A MT/A 0.5 Mt/A 0.6 MT/A MT/A 13 MT/A 14.2 MT/A MT/A 0.5 MT/A MEE Residue MT/A 200 MT/A 23 Non Hazardous Waste (MT/M) Existing Proposed Total PVC and Paper Bags 0.1 MT/M 1.5 MT/M 1.6 MT/Month HDPE/Metal Container 100 nos./month 1200 nos./month 1300 nos./month Wooden Pellets 50 nos./month 500 nos. /Month 550 nos. /Month Sadekar Enviro Engineers Pvt. Ltd ES 1 3

5 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY ES-2 Justification of Project The need of the project is justified through the intentions of the company to develop the drugs in a non-infringing, novel and economical manner so that the drugs are available to the lower community. The company aims to reduce the demand and supply gap by eliminating the cost factor. It desires to manufacture and formulate the essential drugs so that it can tap the international market along with the local merchandise taking into consideration the economic factor & quality of the products. The project contemplates to serve the health sector worldwide by producing qualitative & competitive products. Sadekar Enviro Engineers Pvt. Ltd ES 1 4

6 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra 17/00 EXECUTIVE SUMMARY ES-3 Process Description SEEPL/EIA/F/IND/GSL/001/2016 Fig No ES-1 Process Description Diagram Sadekar Enviro Engineers Pvt. Ltd ES 1 5

7 SEEPL/EIA/F/IND/GSL/001/ /00 ES-4 Baseline Environmental Status EXECUTIVE SUMMARY The study area is 10 km radial distance from centre of existing plant site. All the monitoring has been completed in various locations within the study area during the period of March 2016 May The findings of the baseline environmental status on land (topography, soil quality, land use pattern), micrometeorology (Temperature, Humidity, rainfall, wind speed), air (ambient air quality- PM10, PM2.5, SO2, NOX, CO), noise level, ecological environment (flora and fauna), socio economic conditions, are presented in the report and interpreted with reference to environment standards. ES-4.1 Air Environment PM 10 : The level of PM 10 indicates the level of dust and fugitive emissions in the surroundings. From the above results it can be observed that the maximum concentration of PM 10 was estimated to be in the range of 60 & 92 µg/m 3 respectively. The maximum concentration of PM 10 was recorded at location and A4 whereas the minimum concentration was recorded at location A7 in Umroli. It should be noted that the location A4 is located near open ground in Murbe village. The average concentrations of PM 10 during the study varied between 73µg/m 3 to 86µg/m 3. The highest average concentration of particulate matter recorded at location A4 while the lowest average was recorded at location A7. PM 2.5 : The highest maximum concentration of PM 2.5 (48 µg/m 3 ) amongst the all the monitoring stations was recorded at location A5. At the same time the lowest minimum concentration 14µg/m 3 was recorded at A3. The high concentration at location A5 indicates that the area experiences a high vehicular movement. The reason for these values at Boisar (A5) can be explained by the fact that heavy vehicular activity is noted in the city of Boisar as well the major highway which leads to Tarapur passes through the upwind direction. Therefore as per the conclusions of the meteorological data it be said that the pollutants from the vehicular exhausts are being carried to the monitoring stations. The average concentration of PM 2.5 during the study period was computed to be in the range of µg/m 3 SO 2 : High level of SO 2 in ambient air indicates the presence of combustion fossil fuel and burning of wood and other plant material in the vicinity. The ambient air monitoring results presented above indicate that the highest average concentration of SO 2 is experienced at the project site, i.e. location A6. The Sadekar Enviro Engineers Pvt. Ltd ES 1 6

8 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY constant traffic and regular movement of heavy vehicles (which use diesel as fuel) in and around the MIDC area and the sampling station can be considered as the principle source of emission for SO 2. The minimum of SO 2 recorded at all the monitoring locations during the study period was in the range of 11µg/m 3 & 19µg/m 3 respectively. The maximum concentration was observed in the range of 21 and 32µg/m 3. The highest average value of SO 2 was computed at location A1 while the lowest can be observed at location A8. NO X : The various forms of Nitrogen in NO, NO 2 and N 2 O are collectively called as Oxides of Nitrogen. The maximum concentration of NO X during the monitoring period was observed at location A5 while the minimum concentration was recorded at A2. The average concentrations were in the range of µg/m 3. The maximum value of NO X recorded at the monitoring location was 44µg/m 3. Sadekar Enviro Engineers Pvt. Ltd ES 1 7

9 Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra 17/00 EXECUTIVE SUMMARY SEEPL/EIA/F/IND/GSL/001/2016 Min Avg Max Std. Min Avg Max Std A1 A2 A3 A4 A A1 A2 A3 A4 A5 A5 A6 A7 A8 A6 A7 A8 Fig. No.ES 2: Graphical representation of PM 10 Fig No.ES 3 : Graphical representation of PM A1 A2 A3 A4 A5 Min Avg Max Std. A6 A7 A8 A1 A2 A3 A4 A5 Min Avg Max Std. A6 A7 A8 Fig No.ES 4: Graphical representation of SO 2 Fig No.ES 5 : Graphical representation of NOx Sadekar Enviro Engineers Pvt. Ltd ES 1 8

10 Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapurr MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/ /001/ /00 EXECUTIVE SUMMARY Min Avg Max Std A1 A2 A3 A4 A5 A6 A7 A8 Fig No ES-6: Graphical Representation of CO Carbon monoxide (CO): The source of CO is the presence of vehicle movement or incomplete combustion of fuel wood around the given area. The maximum concentrations of CO at all locations recorded during the study period ranged between 0.8 to 2.6 mg/m 3 respectively. The minimumm concentration at all locations ranged between 0.3 and 1.1mg/m 3. The highest average is calculated at location A5 and the lowest average was estimated to be at location A3 in Pasthal village Sadekar Enviro Engineers Pvt. Ltd ES 1 9

11 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY ES-4.2 Noise Environment Industrial Zone: The day time noise level at the boundary of the plant premises was 65 Leq. db (A) & Night time noise level was observed to be 52 Leq. db (A). Residential Zone: During the baseline study it was observed that in residential zone during day time noise level varies from 45 to 54 Leq. db (A) and in night time 38 to 44 Leq. db (A) Daytime Night Time Day time Std. (Industrial Area) Night time Std. (Industrial Area) Daytime Std. (Residential Area) Night Time Std. (Residential Area) N1 N2 N3 N4 N5 N6 N7 N8 Fig No. ES 7: Graphical Representation of Noise Level The noise levels are well within the prescribed MPCB limits and there will be minimal impact of the proposed project on the site as all noise generating equipments will have acoustic enclosures. The Noise level was observed to be higher in the N1 location i.e Plant Premises as it is in the MIDC area surrounded by many large and medium scale industries which are in operation resulted in higher value of noise level. Sadekar Enviro Engineers Pvt. Ltd ES 1 10

12 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY ES-4.3 Water Environment Surface Water Study The analysis of surface water samples revealed that the ph of all the samples ranged 7.2 to 7.9. It should be noted that the desirable limit for ph was not exceeded in any of the category in which the sources are classified. The total hardness ranged in between 74 to 1586 mg/l. The maximum value of hardness was recorded at SW3. It should be noted that the sampling location is located near a salt pans. The water from the salt pans which drains in to the water body can be said to be containing dissolved calcium compounds. The minimum value of hardness was recorded at SW7 which is a lake, in Alewadi village. The concentration of Total Dissolved Solids was in the range of 208 mg/l to mg/l. The maximum concentration of Total Dissolved Solids (TDS) was observed at SW3 whereas the minimum TDS concentration was observed at SW7. The high value of TDS in at location SW3 indicates the discharge of pollutants from the vicinity and other soluble compounds from the salt pans located in vicinity of the sampling location. The Chemical Oxygen Demand (COD) & Biochemical Oxygen Demand (BOD) values were calculated to be in the range of 4.00 mg/l to 248 mg/l & <3.0 to 116 mg/l respectively. The COD & BOD values at all the locations were well within the CPCB discharge standards except for one location SW3, where the value of BOD was observed to marginally exceed the standard for BOD of 100 mg/lit. All other parameters of all locations were within prescribed limits. It should be noted that in case of the source classified under category B, out of all the parameters BOD was observed to marginally exceed the prescribed limit of 3mg/lit. This can be said due to the ingress of sea water in the river on some ocaasions. Hence it is suggested that the water can be used after treatment if intended for bathing purposes (outdoor) as per IS: Inland Surface Water Standards. The surface water bodies do not come under the polluted stretch of river identified by CPCB, (Reference: Series: MINARS/37 / RIVER STRETCHES FOR RESTORATION OF WATER QUALITY by CPCB, dated Feb 2015.) Sadekar Enviro Engineers Pvt. Ltd ES 1 11

13 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY Analysis of nalla passing through plot area - The analysis of the water quality of the stream reveals that the water is moderately polluted. Also it is important to note that the results cannot be compared with the Inland Surface Water Standards provided by the CPCB. The results suggest that COD of the water was estimated to be 260 mg/lit, while the BOD was estimated to be 82 mg/lit. The value for COD is observed to marginally exceed the limit of 250 mg/lit, as prescribed by the CPCB for fresh water streams. The concentration of Total Dissolved Solids was calculated to be 668mg/lit. The presence of Heavy Metals namely Iron and Zinc was evident during the testing, while the concentration of rest of the heavy metals was observed to be under the detection limit. The sample also indicated the presence of coliforms bacteria(e-coli). It is important to highlight that there will be no discharges into the nallah from any of the activities of the proposed project during its establishment or operational phase. Ground Water Study Ground Water monitoring was carried out at eight different locations. Most of the sampling was done from the open wells located in the near-by villages of the study area. During the baseline data collection it was observed that in some of the cases the water from the ground water sources is used for drinking, domestic and irrigation purposes. The results obtained thereby are compared with the IS 10500:2012standards. It can be observed that the results indicate that ph ranges in between 7.1 to 7.8, which is well within the specified standard of 6.5 to 8.5. The maximum ph of 7.8 was observed at Salwad Village (GW3) and the minimum ph of 6.9 was observed at Umroli village (GW6). Total hardness was observed to be ranging between 208 to mg/l. The maximum hardness (375.6 mg/l) was recorded at Salwad (GW3) and the minimum hardness (208 mg/l) was estimated at Satpati Village (GW4). It should be noted that the values of hardness were found to be exceeded the permissible limit of IS 10500:2012standards at five of the eight sampling locations (GW2 to GW4 and GW7 and GW8). In case of concentration of Total Dissolved Solids (TDS) results Sadekar Enviro Engineers Pvt. Ltd ES 1 12

14 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY ranging in between 356 to 1128 mg/lit were obtained. The highest TDS was estimated at GW8 while the lowest was estimated at GW5. High values exceeding the permissible limit can be said to be a result of ground water pollution. The concentrations of Chlorides at all the locations were estimated to be within the permissible limit, ranging in between 56.7 and mg/l. The concentration of chlorides was also observed to be above the standards at two locations (GW7 and GW8). The amount of Nitrate in the given samples was found to be in the range of from 0.21 mg/l to 2.94 mg/l. It was noted that iron content in all the samples collected were exceeding the IS limit 2012 for drinking water. The concentration of iron found to vary between mg/l. The microbiological analysis for the samples revealed that E-coli were absent in all the locations. Based on the above analysis it can be concluded that the ground water is moderately polluted and the use of the water for drinking, domestic & irrigation purposes can be considered after a basic primary treatment. ES-4.4 Soil Environment It has been observed that the ph of the soil in the study area ranged from which indicates neutral nature in soil. The soil type is mostly in the form of sandy. The potassium value ranges to 963 kg/ha to 819 kg/ha falls under more than sufficient. The nitrogen values range between to Kg/ha which falls under very less category. The phosphates values were in the range of Kg/ha which comes under more than sufficient category. The fertility of the soil is compared according to Hand Book of Agriculture, ICAR, New-Delhi. On the basis of chemical analysis of soil samples, the soils can be classified as per soil classification given by Tondon H.L.S. (2005). S1 and S2 can be classified as fertile soil (Table 3.18 and Table 3.19). The presence of heavy metals like arsenic, cadmium, lead & chromium in both the soil samples were below the detection limit. ES-4.5 Biological Environment The field visits resulted in recording 98 plant species that included 57 trees, 7 shrubs, 24 herbs & 10 climbers. Apart from the somewhat exotic & ornamental plants observed in the green belts Sadekar Enviro Engineers Pvt. Ltd ES 1 13

15 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY (plantations along the roads & human settlements) the majority of the vegetation observed in the potential habitat (Gudale, Padhge & Devkhope hillocks) in the study area was of native deciduous type. Also 7 crop species were observed in the study area off which 3 were fruit varieties, 3 were vegetable varieties which were cultivated on commercial basis & 1 food grain variety (rice) which was mainly cultivated for subsistence farming. The 26 species of avifauna recorded during the field visits are commonest resident species for the region in consideration. The habitat preference of the recorded avifauna was to be open wooded county - light scrub jungle. Apart from birds the other faunal sightings were of Indian Palm Squirrel, Stay dog, Common pig & 2 reptilian species. The IUCN status evaluation of the observed floral & faunal species revealed that none of the floral species belongs to categories of concerns such as Near Threatened (NT), Vulnerable (VU), Endangered (EN), Critically Endangered (CR) & Extent in the wild (EW) defined by the IUCN. Also none of the faunal species belonged to the Schedule - I of the IWPA, hence conservation related aspects for the prevailing flora & fauna are not anticipated. Any of the Ecologically Sensitive Areas such as National Parks, Sanctuaries, Biosphere Reserves, Mass feeding/breeding grounds & migratory routes of fauna does not exist in the study area also the observed & recorded faunal species in the study area are not listed in Schedule - I of IWPA 1972 hence conservation related aspects are not applicable. Sadekar Enviro Engineers Pvt. Ltd ES 1 14

16 SEEPL/EIA/F/IND/GSL/001/ /00 ES-5 Prediction of Impacts & its mitigation EXECUTIVE SUMMARY A) Minor Construction Phase Sr.No Environmental Parameters Aspect Attributes Impact Proposed Mitigation Measures 1. Air Quality Dust due to the The emission would be Water Spraying, construction around Traffic management activity, material tons/month of the for loading and handling, activity. unloading of the transportation etc. Workers getting materials, exposed to the dust pollution generated due to the construction activity can suffer from respiratory problems and prolonged exposure can lead to malfunctioning of lungs. 2. Noise Quality Noise generated Using Acoustic from machinery enclosure for the used for machinery used. construction work & transportation 3. Water Quality Water used for construction activity and domestic use of the temporary workers 4. Solid Waste Demolition work is Management envisaged hence debris will be generated. Other waste like plastic bags, empty drums is envisaged The impacts of high noise level would be Temporary/Permanent hearing loss, Mental disturbance, Increase in heart rate, Decreasing in workers performance. Contamination of the soil and nearby water bodies. Unhealthy Condition Work PPEs will be provided for the workers. Proper Management Water The debris will be used for leveling the ground. The solid waste like plastics will be sold to authorized dealer. Sadekar Enviro Engineers Pvt. Ltd ES 1 15

17 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY B) Operational Phase Sr.No Environmental Aspect Parameters Attributes 1. Air Quality Operation of Boiler & D.G Sets Un-reacted gases from manufacturing process., methane generation from the up-flow anaerobic filter & Transportation Impact The Maximum Incremental concentration of PM μg/m 3 PM μg/m 3 SO μg/m 3 NOx μg/m 3 CO mg/m 3 The Health effects related to particulate matter are majorly respiratory, pulmonary injury & lung cancer etc. Exposure to SO2 and NOx majorly leads to respiratory problems. Carbon monoxide decreases the oxygen carrying capacity of the blood by reducing the hemoglobin. Methane majorly causes asphyxiation when concentration arises can result in suffocation. Proposed Mitigation Measures 1. Appropriate Stack height for boiler, TFH stacks will be provided. 2. Five Alkali Scrubbers ( 3 water and 2 alkali scrubbers in series) and an additional vent scrubber would be provided to scrub the unreacted gases generated from the manufacturing process. 3. The roads within the premises are concreted / paved to avoid vehicular emissions. 4. All transportation vehicles carry a valid PUC (Pollution under Control) Certificate. 5. Proper servicing & maintenance of vehicles is carried out/will be carried out. 6. Regular sweeping of all the roads & floors is being /will be done. 7. Development of the green belt on the plant boundary will help reduce the fugitive emission Sadekar Enviro Engineers Pvt. Ltd ES 1 16

18 SEEPL/EIA/F/IND/GSL/001/ /00 2. Noise Quality D.G sets, Boilers, Reactors, operation of pumps & transportation. 3. Water Quality 1. Effluent from manufacturing process. 2. Blow down water from Boiler and Cooling Tower. 3.Domestic wastewater The impacts of high noise level would be Temporary/Permanent hearing loss Mental disturbance Increase in heart rate Decreasing in workers performance due to psychiatric disorder Workers developing Tinnitus due to high level of noise exposure on regular basis. Contamination of surface and groundwater & polluting the agricultural field in the nearby areas. EXECUTIVE SUMMARY 1. Acoustic Enclosures will be provided to the D.G Sets for reducing the noise level during operation. 2. Boiler is kept in a confined space, the surrounding walls acts as a barrier for noise reduction. 3. Traffic management will be implemented. 4. Green belt developed around the company premises will acts a noise barrier. 5. Appropriate PPE are provided. 1. The effluent generated from the boiler blow down & cooling tower blow down will be sent to R.O, the R.O permeate will be reused for Cooling tower makeup & R.O reject will be sent to MEE followed by ATFD. 2. The effluent generated from process will be treated in full fledged ETP with R.O, the R.O permeate will be reused for cooling tower intake & R.O reject will be subjected to MEE followed by ATFD. 3. The MEE Condensate will be reused for cooling tower and residue will be sent to CHWTDSF. Sadekar Enviro Engineers Pvt. Ltd ES 1 17

19 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY 4. The Domestic effluent will be treated in the biological treatment of the ETP. 4. Hazardous Waste Management 1. Hazardous waste generated from the process. 2.Sludge generated from the ETP operation 3. Residue generated from MEE operations Contamination of the soil & Health Impacts to workers coming in contact like skin allergies, rashes etc. 5. The plant will be a ZLD unit.the proposed project will be Zero Liquid Discharge project. Hazardous waste generated from the process is disposed to the CHWTSDF Taloja. ES-6 Risk Assessment Study Risks likely to pose harm to man, environment or property associated with various activities are addressed in this report. Such activities include transport, storage; handling and usage of hazardous raw materials & fuels etc. To calculate the risk involved in the process of the proposed project; ALOHA is performed for all storage tanks and gas cylinders. The MCLS (maximum credible loss scenario) for the factory works out to about 1900 meter in case of toluene (Toxic Area of vapour cloud Road Tanker rupture scenario). Dow Index has been calculated separately for F.O and HSD Tank area, CCOE U.G Tank area and Non CCOE Tank Area. As per the Degree of Fire and Hazard Index the DOW Index falls in light category for F.O and H.S.D farm area whereas it falls in moderate category for CCOE U.G Tanks and Non CCOE Tank Area. Mond's Index for the toxic material was performed for Sulfuric acid, HCl and TEA. The value of toxicity falls in high category of the Toxicity Index for all the chemicals. Sadekar Enviro Engineers Pvt. Ltd ES 1 18

20 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY Appropriate preventive and mitigation measures have been provided to cater all the hazards. Hazop Study has been prepared for all the products. ES-7 Disaster management plan Onsite and offsite emergency plan has been prepared for the industry. During operational phase surrounding population shall be made aware of safety precautions to be taken in case of any mishap in plant. On-site disaster management and off-site emergency plans, commands communication and controls will be established and maintained. Adequate provisions like emergency response, response organization, response plan, material safety data sheet, command and control, capabilities, transportation, medical facilities, mitigation measures, training, education, public awareness emergency plan review etc. to control any disaster situation will be made available. ES-8 CSR Activity Currently the CSR Process is manned by two direct employees. Mr. Adarsh Nayyar is the Head of the Process and is assisted by an associate. Besides this there are local voluntary steering councils at the locations. As the statutory spend increases, the effort in identifying, evaluating, monitoring the execution and the outcomes of the projects would call for adequate direct manning of the CSR Process at the manufacturing locations. CSR Committee is empowered to review the organization structure and manning and allied needs from time to time and take suitable decisions on the same. CONCLUSION: The CSR policy shall be reviewed once in three years and suitable improvisations be done based on experience. The CSR policy shall be subservient to the provisions of the Companies Act, 2013, and Rules made there under, from time to time. Sadekar Enviro Engineers Pvt. Ltd ES 1 19

21 Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapurr MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/ /001/ /00 EXECUTIVE SUMMARY ES-9 Occupational Health Measures The company will be strictly adhered to the rules of Factories Act 1948 & the Maharashtra Factories Rules, 1963 regarding the occupational healthh facilities to be provided to the workers of the company. As the total man power of the company is 177 workers, the industry is providing occupational health centre having a room with minimumm floor areaa of 15 Sq.m. with floors and walls made of smooth and impervious surface. The industry is also providing decontamination facilities for the workers. The health records of the workers would be maintained. For the continues and continual development, the company will train & educate the operators and workers with the environment health safety rules & regulation, procedure and measures. ES -10 Post project Monitoring Plan Monitoring of environmental samples shall be done as per the guidelines provide by MoEF/CPCB/SPCB. The method followed shall be recommended / standard method approved/recommended by MoEF/CPCB. Sadekar Enviro Engineers Pvt. Ltd ES 1 20

22 SEEPL/EIA/F/IND/GSL/001/ /00 EXECUTIVE SUMMARY Sr. no Activity/Area Pollutant Pollutant Characteristics OPERATION PHASE 1. Vehicular Dust CO, SO 2, NO X, SPM Movement Emission in Ambient Air 2. Diesel power Air CO, SO 2, NO X, SPM Generators, emissions from boiler & Boiler. D.G.Sets 3. Scrubbers Air 3. Boiler Area, D.G Set, ETP, Work Place Area 4. Effluent treatment plant 5. Hazardous Wastes Frequency Intermittent / Periodic Intermittent / Periodic Acid Mist Intermittent / emissions Periodic Sound Noise Level db (A) Intermittent / Periodic All parameters E.T.P sludge residue 6. Work Place Air pollutants, Heavy metals ph, O & G, TDS, TSS, COD, BOD. Heavy Metals & Organic Compounds specific to project H.W. characteristics Volatile Organic Compounds & Heavy Metals in ambient Air specific to project Continuous As per the requirement of CHWTSDF providers Intermittent / Periodic Period Quarterly Quarterly Quarterly Quarterly Daily Once in a Year Quarterly Sadekar Enviro Engineers Pvt. Ltd ES 1 21

23 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION 1.1 Purpose of the report CHAPTER 1: INTRODUCTION M/s Galaxy Surfactants Limited have a Fatty alcohol sulphate in the form of Powder/Needles and Liquid manufacturing facility at Plot no G-59, Tarapur MIDC, Taluka- Palghar, District Palghar. The company currently has consented production capacity of 348 MT/M. The proponent now wishes expansion in its existing facility by introduction of new products namely anionic, cationic, non ionic surfactants, specialty chemicals and sunscreens of capacity 3124 MT/M. The total production capacity will be 3472 MT/M. The total plot area is sq. m.; however at present only 1639 sq. m. of ground area has been built-up, thus there is sufficient space available for the proposed expansion The detailed area statement is given in chapter 2; Table no 2.3. As per the Environment Impact Assessment notification dated 14 th September 2006, the project falls under the Schedule 5 (f) of the EIA Notification of Synthetic Organic Chemicals Industry. The project will be categorized as a B-1 category project as it is located in Tarapur MIDC, a notified Industrial area. Thus the case will be appraised for Environmental Clearance at SEIAA, Maharashtra. Thus, EIA report has been prepared with a view to study the impacts on various components of the environment due the proposed activity and to provide mitigation measures to minimize the impacts. The Objective of the EIA studies is as follows; Assuring usage of environment friendly raw materials and adopting greener technologies for manufacturing processes, efficient use of the resources. Assessment of the background level of the pollutants in the 10 km study area of the project site with respect to various environment components. Ensuring consideration of environmental factors and components in the decision-making process during the planning and designing stage of the project. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 1

24 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION Avoiding serious and irreversible damage to the environment. Identification and ascertaining the various biotic and abiotic components of the environment likely to be affected due to the proposed activity and/or likely to cause adverse impacts to the proposed project. Identification, assessment and specification of methods, measures and standards, to be included in the detailed design, construction and operation of the proposed project which are necessary to mitigate the environmental impacts and reduce them to acceptable levels. Identification and quantification of the emission sources and determination of significant impacts on sensitive receivers. Identification and quantification of potential losses or damage to flora, fauna and natural habitats. Identification any impacts on sites of cultural heritage. Identification and quantification any potential impacts on landscape and visual impacts and evaluate the significance of impacts on sensitive receivers. Identification of impacts and suggest appropriate methods and techniques to minimize pollution, environmental disturbance and nuisance during construction and operation of the developments arising from the study. Identification, prediction and evaluation of the residual (i.e. after practicable mitigation) environmental impacts and the cumulative effects expected to arise during the construction and operation phases of the proposed developments in relation to the sensitive receivers. Delineation of environmental management plan (EMP) outlining prevention and control strategies for minimizing adverse impacts of the project. Formulation of environmental quality monitoring program for construction and operational phases to be pursued by the project proponent so as to ensure the smooth and effective. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 2

25 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION 1.2 Information about Project Proponent The company manufactures large range of specialty including surfactants, mild surfactants, rheology modifiers, Pearlising agents, Conditioning Agents, blends based on innovative concepts, proteins for personal care. Galaxy is Certified Preferred Supplier to Colgate, Star Status Supplier for Unilever, Strategic Mind Partner with Henkel, Green Channel Holder of Reckitt Benckiser. The management team comprises of Sr. No. Name Designation Executive Directors 1 U. Shekhar Managing Director. 2 G. Ramakrishnan Executive Director - Innovation 3 Uday Kamat Director 4 Ravi Venkateshwar Executive Director Finance & CFO Non Executive Directors 5 Mr. Shekhar Ravindranath -- 6 V. Kasturirangan -- 7 Subodh S. Nadkarni -- 8 Sudhir D. Patil -- 9 M.G Parameswaran Nandita Gurjar -- Sadekar Enviro Engineers Pvt. Ltd Chapter 1 3

26 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION The company was initially founded in 1980 and has its headquarters at Navi Mumbai. Galaxy Surfactants is a global leader in supplying innovative products in over 103 countries. The company has regional sales offices at North/South America regional sales office at New Jersey. Latin America Sales Office at Colombia Europe regional sales office at Netherlands. Turkey regional sales office at Turkey. Africa and Middle East regions are serviced through our personnel stationed at Head Quarters in Navi Mumbai, India. Presently the company has various manufacturing facilities throughout the country; the company has manufacturing plants at Tarapur, Taloja and Jhagadia in India, Egypt and USA. They also have a state of art pilot plant at Taloja and Tarapur. The company has a well equipped R & D Centre in Navi Mumbai. Galaxy Surfactants Ltd. has GMP Certified plants at Taloja and Jhagadia. Several manufacturing facilities have been certified by ISO 9001: 2008, EMS and OHSAS. 1.3 Brief description of nature, size, location of the project and its importance to the country, region Nature of the Project The nature of the project is surfactants and specialty chemicals manufacturing Industry. The manufacturing process would involve various chemical reactions like, Reaction, Hydrogenation/Reduction, Amination, Esterification, Substitution, Condensation, Hydrolysis, Salt formation, Acid-base, Rearrangement Reaction and physical operations like separation by filtration and centrifugation, extraction, pulverization, sieving and drying. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 4

27 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION Size of the Project The plant is spread over an area of sq. m. However at present only 1639 sq. m. of ground area has been built-up, thus there is sufficient space available for the proposed expansion. The present built up area is 2419 sq. m. which will be increased to 7681 sq. m. The industry falls in Large Scale Industry based on the investment criteria set for manufacturing industries. The investment for the proposed expansion is 100 Crores. The company currently has consented production capacity of 348 MT/M. The proponent now wishes expansion in its existing facility by introduction of new products namely anionic, cationic, non ionic surfactants, specialty chemicals and sunscreens of capacity 3124 MT/M. The total production capacity will be 3472 MT/M and by-products 505 MT/M with total production capacity 4007 MT/M Location of the Project M/s Galaxy Surfactants Limited is located in the Plot No. G-59, MIDC Tarapur, Taluka - Boisar, District Palghar. The Tarapur MIDC is a notified Industrial Area. Geographically the plant location falls between latitude 19 47'10 to 19 47'17 N and longitude 72 44'12 to 72 44'16 E. The entire study area falls in the Survey of India toposheet nos. E43A9 (47 A/9). The site is well connected by road and rail networks. The MIDC internal road runs parallel to the southern boundary of the company. The site is well connected by internal MIDC roads. NH-8 is located at a distance of 20 km from the project site. Boisar Railway Station is the nearest railway station, located approximately 3.5 km from the project site. The nearest airport to the project site is Chattrapati Shivaji International Airport, Mumbai at the distance of approx. 120 Km from the project site Importance to the Country Galaxy Surfactants Ltd.[GSL] is majorly into the production of Surfactants i.e. GSL supply raw materials, formulation and specialty chemicals to home and personal care industry. These Sadekar Enviro Engineers Pvt. Ltd Chapter 1 5

28 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION chemicals are used in preparing soaps/shampoos/detergents/creams/lotion/dish washer etc. GSL currently is supplying chemicals to both domestic and other countries. GSL has supplied to more than 100 countries. The export to domestic ratio of GSL is about 55:45. The Indian as well as the international market has a great potential for the surfactants and specialty chemicals. The unit at G-59 is majorly intending for expansion of both surfactants and specialty chemicals. The export would increase the foreign exchange returns for the country. With the improvement in the consumption cycle of India, the demand for these personal and home care products will increase which will also increase the demand of chemicals used in these products. This project will also help in the Make In India mission of the government. 1.4 Scope of the Study The application of Environmental Clearance for Galaxy Surfactants Limited was submitted to State Expert Appraisal Committee (SEAC), dated 06/12/2015 along with all necessary documents. The baseline data collection was carried out in the period of March 2016 to May In the 128 th meeting of SEAC-1 held on 2 nd - 4 th of June 2016 additional Terms of References for the preparation of EIA was accustomed. Therefore the Environment Impact Assessment report is prepared based on standard ToR by MOEF & CC dated April 2015 & Additional ToR given by SEAC-1 in its 128 th meeting. 1.5 Details of the EIA Consultant including NABET Accreditation M/s Sadekar Enviro Engineers Pvt. Ltd. established in the year 1998 is a NABET accredited EIA consultant as per Minutes of 71 st Accreditation Committee Meeting held for Reaccreditation Assessment dated 2 nd December, The registered office of SEEPL is at 310, Dempo Towers, EDC Patto, Panaji , Goa State, India. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 6

29 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION M/s SEEPL is accredited by QCI-NABET for the following sectors Sr. No Name of Sectors Project/Activity as per Schedule of EIA Notification 1 Mining of Minerals 1 (a) i A 2 Offshore and onshore oil and gas exploration, development & production 1 (b) A 3 Pesticide Industry and pesticide specific 5 (b) A intermediates (excluding formulations) 4 Synthetic organic chemicals industry (dyes & dye 5 (f) A intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates 5 Sugar industry 5 (j) B 6 Oil & gas transportation pipeline (crude and refinery/ petrochemical products), passing through national parks/ sanctuaries/ coral reefs/ ecologically sensitive Areas including LNG terminal 6 (a) A 7 Industrial estates/ parks/ complexes/areas, export processing Zones(EPZs), Special economic zones(sezs), Biotech Parks, Leather Complexes 8 Ports, Harbours, Jetties, marine terminals, break waters and dredging 9 Common municipal solid waste management facility (CMSWMF) 10 Building and large construction projects including shopping malls, multiplexes, commercial complexes, housing estate 7 (c) A 7 (e) A 7 (i) B 8 (a) B 11 Township and area Development projects (8 (b) B Category M/s SEEPL has a highly qualified team of Subject Expert. SEEPL has full-fledged laboratory recognized by Ministry of Environment and Forest (MoEF) & accredited by National Accreditation Board for Testing and Calibration Laboratories, (NABL). M/s SEEPL is also certified by ISO 9001:2008 and BS OHSAS 18001:2007. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 7

30 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 1: INTRODUCTION M/s SEEPL is engaged in providing Turnkey projects of ETP & STP along with their Operation & Maintenance. Analytical Laboratory Services of various elements and environmental parameters. Fabrication of air & water pollution control device. Annual monitoring as per MoEF / CPCB / SPCB guidelines. Consultancy for Hazardous waste Management etc. Sadekar Enviro Engineers Pvt. Ltd Chapter 1 8

31 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION CHAPTER 2: PROJECT DESCRIPTION 2.1 Type of Project The proposal is a Brownfield project. As per the Environment Impact Assessment notification, 2006 & its latest amendments, the project falls under the schedule 5 (f) Cat B-1 for Synthetic Organic Chemicals Manufacturing Unit. The company is classified as Large Scale Industries and it is categorized under Red category industry by the Maharashtra Pollution Control Board. 2.2 Need for the Project The need of the project is justified through the intentions of the company to develop new chemicals and tap the emerging opportunities in both domestic and international market which is essential for the growth of the company. There is increase in demand of the specialty chemicals in India due to increased per capita income and the consumption cycle is expected to improve in the coming years. This project will help GSL to increase the market share and leadership in the surfactants industry. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-1

32 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 2.3 History of the Project Galaxy Surfactants have recently expanded the Jhaghadia facility with an additional capacity of 7500 TPA. 2.4 Size or Magnitude of Operation Sr. No Components Status 1 Name Galaxy Surfactants Ltd. 2 Plot No: G-59, Tarapur MIDC, Boisar,Palghar, Dist : Palghar, Location Maharashtra, India. 3 Product Type Speciality Chemicals 4 Project Type Expansion 5 Schedule 5 (f) Sadekar Enviro Engineers Pvt. Ltd Chapter 2-2

33 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Sr. No Components Status 6 Category B-1 7 Area Details Existing (sq.m) Proposed (sq.m) Total (sq.m) Total Plot Area Ground Coverage Area Green Belt Area Parking Area Product Capacity (MT/month) Project cost 5.85 Cr /- 100 Cr / Cr /- 10 EMP cost 10 Lakhs 471 Lakhs 481 Lakhs Power Requirement Water Requirement Fuel Requirement i) FO ii) HSD Existing connected Load 150 KW Existing Demand 143 KVA 30 CMD (As per valid CTO) 20.5 (actual) LDO/FO :- 1.2 MT/ D HSD :- 167 L/D Proposed connected Load 1050 KW Proposed demand 998 KVA Proposed connected Load 1200 KW Proposed demand 1140 KVA 500 CMD CMD FO :- 8 MT/D HSD : 400 M/D FO:- 9.2 MT/D HSD :- 567 L/D Boiler Details Stack Height 1. TFH 6 lakh Kcal/Hr 25 m for TFH. 6 m for existing D.G set. 1. TFH 8 lakh Kcal/Hr 2. Steam Boiler 3.5 MT/Hr 39 m ( For Boiler and TFH) Scrubber 12 m D.G set 10 m. D.G. set details 1*250KVA 1*800 KVA 1. TFH 6 lakh Kcal/Hr 2. TFH 8 lakh Kcal/Hr 3. Steam Boiler 3.5 MT/Hr 25 m for TFH. 6 m for existing D.G set. 39 m ( For Boiler and TFH) Scrubber 12 m D.G set 10 m 1*250KVA, 1*800 KVA Sadekar Enviro Engineers Pvt. Ltd Chapter 2-3

34 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Sr. No Components Status 17 ETP Capacity 15 CMD (Primary Treatment). The existing ETP will be demolished. 18 Effluent Generation 1. Domestic Eff. 5.5 CMD CTO 2. Industrial Eff. 15 CMD CTO 3. Domestic Eff. 1.2 CMD Actual 4. Industrial Eff. 11CMD Actual. 80 CMD ( Fully Fledged ETP with MEE followed by ATFD and R.O.) 1. Domestic Effluent 8 CMD 2. Industrial Effluent 127 CMD 80 CMD ( Fully Fledged ETP with MEE followed by ATFD and R.O.)The 15 CMD primary treatment will be demolished. 1. Domestic Effluent 9.2 CMD 2. Industrial Effluent 138 CMD 19 Effluent Quantity discharged to CETP The project is a ZLD unit. 21 Man Power 27 employees 150 employees 177 employees 22 Hazardous Waste Generation (MT/A) Wastes/residue containing oil Cat. Existing (As per valid CTO) Proposed Total MT/A 2 MT/A Spent Solvent MT/A 6 MT/A Distillation residue MT/A 410 MT/A Process Residues & wastes Spent catalyst/spent carbon Discarded containers/barrels/liners contaminated with haz. Wastes/chemicals Spent ion exchange resin containing toxic material Flue gas cleaning residue MT/A -- 1 MT/A MT/A 2 MT/A MT/A 10 MT/A MT/A 1 MT/A 1.2 MT/A MT/A 0.5 Mt/A 0.6 MT/A Sadekar Enviro Engineers Pvt. Ltd Chapter 2-4

35 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Sr. No Components Status Chemical sludge from waste water treatment MT/A 13 MT/A 14.2 MT/A Filters and filter material which have MT/A 0.5 MT/A organic fluid MEE Residue MT/A 200 MT/A 23 Non Hazardous Waste (MT/M) Existing Proposed Total PVC and Paper Bags 0.1 MT/M 1.5 MT/M 1.6 MT/Month HDPE/Metal Container 100 nos./month 1200 nos./month 1300 nos./month Wooden Pellets 50 nos./month 500 nos. /Month 550 nos. /Month 2.5 Location of the Project M/s Galaxy Surfactants Ltd. is located at Plot No. G-59, MIDC Tarapur, Boisar, Palghar district, State Maharashtra. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-5

36 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Figure No. 2.1: Google Earth Image of Galaxy surfactants Limited Corners Latitude Longitude N 72 44'11.48"E '10.86"N 72 44'15.32"E '16.49"N 72 44'16.64"E '17.16"N 72 44'12.68"E The project site is surrounded by MIDC roads from the front side. The immediate surroundings to the project site is depicted in the below table no Sadekar Enviro Engineers Pvt. Ltd Chapter 2-6

37 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Table No. 2.1: Immediate Surroundings to the Project Site Sr. No Component Direction 1 Darshan Creation Pvt. Ltd. & Hartex Silk North mills 2 MIDC Open Road South 3 D Décor Dicitex Furnishing East 4 Nahar Textiles West List of Major Industries within the 10 km study area. The List of Major Industries in the study area is depicted in the below table no. 2.2 Table No. 2.2: List of Major Industries Sr.No Name of the Industry Type of Industry 1 JSW steel Ltd. Forging 2 Tata wire and ropes Ltd. Forging and fabrication 3 Viraj steels Ltd. Forging and fabrication 4 Aarti industries Ltd. Synthetic organic chemicals 5 Lupin Pharmaceuticals Ltd. Pharmaceuticals 6 Bombay Rayon Textile fiber Land Use Details of the Study Area M/s Galaxy Surfactants Ltd. is located at Plot No. G-59, MIDC Tarapur, Boisar, Palghar district The company is spread over an area of sq. m. Table No. 2.3: Area Details of the Project Site Area Details Existing (sq.m) Proposed (sq.m) Total (sq.m) Total Plot Area Total Built Up Area Green Belt Area Parking Area Sadekar Enviro Engineers Pvt. Ltd Chapter 2-7

38 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Galaxy Surfactants Ltd. Plot No. G-59, MIDC Tarapur Figure No. 2.2: Location of Galaxy Surfactants Ltd. on TOPO sheet. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-8

39 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Figure No. 2.3: Location of Galaxy Surfactants Ltd. on Tarapur MIDC layout Sadekar Enviro Engineers Pvt. Ltd Chapter 2-9

40 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Existing units Proposed expansion units Green belt ETP area Parking area Utility Scrubber area Manufactu ring unit Manufacturing unit Fire hydrant tank 6 m wide road 6 m wide road Gate no. 2 Gate no. 3 Gate no. 1 Figure No. 2.4: Plot Layout of Galaxy Surfactants Ltd. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-10

41 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Main building Assembly point and green belt Road inside plant and green belt ETP area Figure No. 2.5: Existing manufacturing plant photographs of Galaxy Surfactants Ltd. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-11

42 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 2.6 Proposed Schedule for Approval and Implementation The said project is an expansion project. The total cost of the project after expansion including the land and machinery sums up to be nearly 106 Cr. The budget for the environmental management plan of the project is 4.81 Cr. & recurring cost is around 18.5 Lakh/year. The completion period of the project is tabulated below, Table No.2.4: Schedule for Approval and Implementation Sr. No. Description Time Cost in % 1. Obtaining all statutory permission with 7 Months 10% respect to industry 2. Design and Engineering Plan 6 Months 20% 3. Factory Set Up 18 Months 60% 4. Testing and Commissioning 1 Months 5% 5. Actual Starting 1 Months 5% Status of Acquisition of Land. The industry is a brown field project, which is located in Tarapur MIDC, Boisar, Palghar. The expansion will be done at existing plant site. No new land will be purchased in MIDC. 2.7 Technology & Process Description The process description for each and every product is briefly explained below representing the reaction scheme followed by the process flow diagram and mass balance. The list of the products and raw materials that would be need is listed in the below table along with its source and mode of transportation. Major equipments that would be required for the manufacturing of the products are also mentioned. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-12

43 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Sr. No Name of Raw Material Table No. 2.5: List of Major Raw Materials Existing Proposed Total quantity (MT/m) Physical State Source Mode of Transpo rtation 1 Lauryl Alcohol Liquid Local Road 2 Dextrose Solid Local Road Import/ Caustic Lye -- Liquid Local Ship 4 Hydrogen Peroxide Liquid Local Road 5 Magnesium oxide Solid Local Road Rapeseed Oil -- Liquid Local Road 7 Tung Oil Liquid Local Road 8 Alpha-tocopherol Local Road 9 Behenyl Alcohol Liquid Local Road 10 Thionyl Chloride Liquid Local Road methyl/ethyl p methoxy cinnamate -- Local Road 12 NaOH Pellets Solid Local Road Conc HCl solution[30%] -- Liquid Local Road Dimethylaminopropyl amine [DMAPA] Local Road 15 Methylene dichloride Liquid Local Road 16 p-nitro benzoic acid Liquid Local Road 17 2 Ethyl hexanol Liquid Local Road 18 Methanol Liquid Import Ship 19 Raney Ni Solid Local Road 20 Hydrogen Gas Gas Local Road 21 Cyanuric chloride Solid Local Road 22 Ethyl Acetate Liquid Local Road Sadekar Enviro Engineers Pvt. Ltd Chapter 2-13

44 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 23 Sodium carbonate Solid Local Road 24 Trimethylamine Gas Gas Local Road 25 Dipropylene glycol Liquid Local Road 26 Cetyl Alcohol Liquid Local Road 27 Polyphosphoric acid Liquid Local Road Phosphorous pentoxide -- Solid Local Road 29 KOH Flakes Solid Local Road 30 Isopropyl alcohol Liquid Local Road 31 Milcoside Solid Local Road 32 Glycerin Liquid Local Road Sodium Cocoyl Taurate -- Solid Local Road 34 EDTA Solid Local Road 35 Cathon CG liquid Local Road Sodium Cocoyl Isethionate -- Solid Local Road 37 Caprylic Acid Liquid Local Road 38 Undecylenic acid Liquid Local Road 39 Glycine Liquid Local Road 40 2 Phenoxy ethanol Liquid Local Road 41 Caprylic Capric Acid Liquid Local Road 42 Sodium Bicarbonate Solid Local Road 43 Sodium Isethionate Solid Local Road 44 Glutamic Acid Liquid Local Road Potassium hydroxide Solution [50%] -- Liquid Local Road Sodium dihydrogen orthophosphate -- Solid Local Road 47 Avobenzone Solid Local Road 48 Benzophenone Solid Local Road Butylated Hydroxy Toluene (BHT) -- Liquid Local Road 50 Salicylic Acid Solid Local Road Sadekar Enviro Engineers Pvt. Ltd Chapter 2-14

45 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 51 Toluene Liquid Local Road 52 Homomenthol Solid Local Road 53 Myristic acid Solid Local Road 54 Palmitic Acid Solid Local Road 55 Myristyl alcohol Liquid Local Road 56 Epichlorohydrin Solid Local Road 57 Sodium metabilsulfite Solid Local Road 58 Sodium sulphite Solid Local Road 59 Methyl paraben Solid Local Road 60 Propyl paraben Solid Local Road Mono potassium phosphate 0.5 Solid Local Road Amide of DMAPA (Cocofatty acid) -- Solid Local Road Sodium salt of mono chloro acetic acid solution -- Solid Local Road 64 Phosphoric acid Liquid Local Road Amide of DMAPA Plus (coconut oil) -- Liquid Local Road Citric acid (MONOHYDRATE) -- Solid Local Road Dimethyl lauryl Liquid amine (c 1214) -- Local Road 68 Formaline solution Liquid Local Road Coconut Fatty Acid (HCFA C818) -- Solid Local Road 70 Diethanol amine Liquid Local Road 71 Sodium Methylate Solid Local Road 72 Cocodiethanolamide Solid Local Road Cocomonoethanol amide -- Solid Local Road 74 TEFAS 6872 (2 M) Solid Local Road Sadekar Enviro Engineers Pvt. Ltd Chapter 2-15

46 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 75 Sodium Sulfate Solid Local Road Ethyleneglycol distearate -- Liquid Local Road 77 Sodium Chloride Solid Local Road Fatty alcohol ethoxylate -- Solid Local Road 79 LA-MME C Solid Local Road Potassium Sulfite solution -- Liquid Local Road Dimethyl palmityl amine (c16) -- Liquid Local Road Dimethyl stearyl amine (c18) -- Liquid Local Road Amide of DMAPA Lauric Myristic Acid -- Solid Local Road 84 Propylene Glycol Liquid Local Road 85 Stearic acid (C1845 ) Solid Local Road 86 Sugar Solid Local Road 87 Codex DS Liquid Local Road 88 Cocoyl chloride Solid Local Road Hi flow supercel powder -- Solid Local Road 90 Lauroyl Chloride Solid Local Road 91 Benzyl Chloride Solid Local Road Acryl Amide Liquid solution Local Road Di-Methyl Di-Allyl Ammonium Chloride Solid Local Road Coconut Fatty Acid (DCFA C818) Solid Local Road Liquid Methyl Cyanoacetate Local Road 96 Ammonium Acetate Liquid Local Road 97 Benzophenone Solid Local Road 98 Cyclo-hexane Liquid Local Road 99 Glacial Acetic acid Liquid Local Road Sadekar Enviro Engineers Pvt. Ltd Chapter 2-16

47 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION 100 p-anisaldehyde Liquid Local Road 101 Reagent W Liquid Local Road 102 Reagent HP Liquid Local Road 103 Reagent E Liquid Local Road 104 Reagent S Liquid Local Road 105 Lauric Acid Liquid Local Road Coco Fatty Acid [CFA8-16] Solid Local Road 107 Myristic Acid Solid Local Road Fatty alcohol sulphates/fatty Alcohol sulfosuccinate (Liquid) Liquid Local Road Ammonium bicarbonate/ammonia 1 Solid Local Road 110 Sulphuric Acid (98%) Liquid Local Road Cosmenyl Green 2 Liquid GLS gran Local Road Cosmenyl Blue A 4 R Solid 112 LP 3214 Local Road Cosmenyl Carmine Solid 113 FB 01-IN Local Road Liquitint Red ST & Solid 114 Liquitint Yellow LP Local Road 115 Sodium Benzoate Solid Local Road 116 Glycerine Ethoxylate Solid Local Road 117 Sorbitol Solid Local Road 118 Milcoside Liquid Local Road 119 Titanium dioxide Solid Local Road 120 Coconut oil Liquid Local Road 121 Mono ethanol amine Liquid Local Road Dimethyl myristyl amine Liquid Local Road TOTAL Sadekar Enviro Engineers Pvt. Ltd Chapter 2-17

48 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Table No. 2.6: List of Products Sr. No Product Name Fatty Alcohol Sulphate / Sulfosuccinate (powder/needles) on 100% basis Fatty Alcohol Sulphate (Color Needles) on 100% basis Existing (MT/A) Propose d (MT/A) Total (MT/A) Fatty Alcohol Sulphate (Liquid) on 100% basis Active preparations including anionic, cationic, amphoteric, non ionic surfactants such as fatty alcohol sulphates/ Quatternary ammonium compounds/ alkanol amides/ Glycinates/ Amineoxides/ betaines/ Quaternary ammonium compounds and surfactant blends Specialty chemicals such as polymeric conditioners, polyquats, preservatives, fatty acid esters Sunscreens Total (A) By-Products Rec. Acetic Acid [ on 100% basis] Rec. Methanol HCl solution [~30%] Sodium bisulfite solution/sodium bisulfate/sodium sulphite [~30%] Sodium Chloride [on 100% basis] Sadekar Enviro Engineers Pvt. Ltd Chapter 2-18

49 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Total (B) Total (A + B) 4007 Sadekar Enviro Engineers Pvt. Ltd Chapter 2-19

50 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Table No. 2.7: List of Major Equipments & Machineries S. no. Equipment name Capacity TYPE MOC 1 R1 1 KL Reactor GLR 2 R2 3 KL Reactor GLR 3 R3 5 KL Reactor GLR 4 R4 8 KL Reactor GLR 5 R5 1 KL Reactor SS 6 R6 2 KL Reactor SS 7 R7 3 KL Reactor SS 8 R8 3 KL Reactor SS 9 R9 5 KL Reactor SS 10 R10 5 KL Reactor SS 11 R11 5 KL Reactor SS 12 R12 10 KL Reactor SS 13 R13 20 KL Reactor SS 14 R14 Distillation SS 15 R15 Distillation SS 16 R16 3 KL Reactor Duplex 17 R17 5 KL Reactor Duplex 18 R18 3 KL Reactor PPFRP 19 R19 5 KL Reactor PPFRP 20 R20 10 KL Reactor PPFRP 21 C1 3 KL Scrubber PPFRP 22 C2 3 KL Scrubber PPFRP 23 C3 3 KL Scrubber PPFRP 24 C4 3 KL Scrubber PPFRP 25 C5 3 KL Scrubber PPFRP 26 C6 3 KL Scrubber PPFRP 27 C7 3 KL Scrubber PPFRP 28 C8 3 KL Vent PPFRP scrubber 29 Agitated Nutche filter SS 30 Flaker SS 31 RVD SS 32 TFE SS 33 Centrifuge 1 & 2 SS 34 Nauta mixer SS Sadekar Enviro Engineers Pvt. Ltd Chapter 2-20

51 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Details of Manufacturing Process. Brief Description Step i) Synthesis of Behenyl Chloride (Chlorination) In a clean and dry reactor behenyl alcohol and Catalyst is added and heated to C. Now thionyl chloride is added and gases (HCL and SO 2 ) are removed by scrubber. Step ii) Synthesis of p-methoxycinnamic acid (Hydrolysis) In reactor, Base-500 and Methanol is charged along with NaOH pallets and heated to C. Then reaction mass is cooled and Salt of Sodium p-methoxycinnamate will precipitate out which is goes for filtration. Filtered cake is charged into reactor along with addition of concentrated HCL to adjust ph. The mass in the reactor sent for filtration Step iii) : Synthesis of p-methoxycinnamoyl Chloride i.e. RB-650 (Chlorination) The p-methoxycinnamic acid powder & Catalyst is charged in the reactor along with addition of Thionyl chloride. The SO 2 and HCl gases formed during reaction simultaneously are removed with the help of gas scrubber. The reaction mass is kept for digestion up to C.Thenthe crude mass is sent for distillation. Step iv) : Synthesis of p-methoxycinnamidopropyldimethylamine i.e. RB-700 (Amidification) The MDC and DMAPA are charged in the reactor. Now solution of RB-650 dissolved in MDC is added slowly. Then water wash is given to MDC layer. The aqueous layer is charged to reactor for recovery. Caustic lye is added to the aqueous layer maintaining temperature C. The product is taken for filtration and finally to packing. Step v) : Synthesis of GalHueShield HCS (Quaternization) The RB-700, Behenyl chloride, Distilled water and GalHueShield HCS are charged to the reactor and it is heated slowly to C. Reaction Scheme For GalHueShield HCS Sadekar Enviro Engineers Pvt. Ltd Chapter 2-21

52 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Step i) : Synthesis of Behenyl Chloride (Chlorination) Step ii) : Synthesis of p-methoxycinnamic acid (Hydrolysis) Sadekar Enviro Engineers Pvt. Ltd Chapter 2-22

53 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Step iii) : Synthesis of p-methoxycinnamoyl Chloride (Chlorination) Step iv) : Synthesis of p-methoxycinnamidopropyldimethylamine (Amidification) Step v) : Synthesis of GalHueShield HCS (Quaternization) Sadekar Enviro Engineers Pvt. Ltd Chapter 2-23

54 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Mass Balance ofgalhueshield HCS Behenyl Alcohol Thionyl Chloride Catalyst Water TOTAL Reactor Reaction BehenylChoride Next step Water washing Effluent HCl Gas 0.02 SO2 Gas Bottom Residue Incineration TOTAL To scrubber system to make HCl solution To scrubber system to make SBS solution p-methoxycinnamic Acid 0.09 Thionyl Chloride Catalyst TOTAL Reactor RB650 Bottom Residue HCl Gas SO2 Gas TOTAL Next step Incinration To scrubber system to make HCl solution To scrubber system to make SBS solution RB Solvent DMAPA 0.05 Caustic Lye Water 0.55 TOTAL Reactor Reaction RB Next step Rec. Solvent 0.32 Recycle Rec. Water Recycle Washing Water To MEE Washing Water Effluent Evaporation loss 0.01 TOTAL RB Behenyl Chloride Water TOTAL 1 Reactor Reaction GalHueShield 1 Product Fresh Water Usage: 1.79 kg/kg of product Total Production Capacity: 1200 TPA Sadekar Enviro Engineers Pvt. Ltd Chapter 2-24

55 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Waste Type Quantity/kg Quantity in Quantity in MT/month MT/day Treatment Effluent Liquid To ETP By-Product Liquid To MEE By-Product Gases To HCL Scrubber By-Product Gases To SO2 Scrubber Distillation Waste Solid Incineration Solid Waste Solid Nil Nil Nil Nil FugitiveEmissions Gas Nil Nil Nil Nil Manufacturing Process: SCG Brief Description Water, glycine are taken in the reactor and then neutralized with caustic lye. Cocoyl chloride is added to the reaction mass along with caustic lye solution. After the reaction is completed, the material is cooled and packed Reaction Scheme For SCG R O C O CL +H 2N CH 2 COOH + 2NaOH R C NH CH 2 COONa+ NaCL+2H 2 O MW= g MW = 75 g MW= 40 g Mass Balance of SCG Water 0.6 Glycine 0.07 Caustic Lye 0.14 Cocoyl Chloride 0.18 Additives 0.01 Reactor Reaction SCG 1 Product Fresh Water Usage: 0.6 kg/kg of product Sadekar Enviro Engineers Pvt. Ltd Chapter 2-25

56 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION Total Production Capacity: 2300 MT/A Waste Type Quantity/kg Quantity in MT/month Quantity in MT/day Treatment Effluent Liquid Nil Nil Nil Nil Distillation Waste Liquid Nil Nil Nil Nil By-Product Liquid Nil Nil Nil Nil Solid Waste Solid Nil Nil Nil Nil Fugitive Emissions Gas Nil Nil Nil Nil 2.8 If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any. The unit is a brown field project. The land is allotted to M/s Galaxy Surfactants Ltd. Tarapur MIDC. The existing unit is situated at plot no. G-59 at Tarapur MIDC. Area of the existing plot is sq. m. The expansion will be done at existing plot, no new land will be purchased for the expansion activity. 2.9 Description of Mitigations Measures. Sr. No. A) Minor Construction Phase Environmen tal Parameters 1. Air Quality Minor dust emissions from handling & transportation of cement/concrete/st one aggregates. 2. Noise Quality Noise generated from construction equipments/machi nery like spade, Aspect Attributes Impact Proposed Mitigation Measures The emission would be around tons/month of the construction activity. Workers getting exposed to the dust pollution generated due to the construction activity can suffer from respiratory problems and prolonged exposure can lead to malfunctioning of lungs. The impacts of high noise level would be Temporary/Permanent hearing loss, Traffic management for loading and unloading of the materials. Regular sprinkling of water on the working site, Avoiding Cement dust emission, Managing stockpiles. Creating wind barrier for controlling the dust emissions. Appropriate PPEs will be provided to the workers. Implementation of Sadekar Enviro Engineers Pvt. Ltd Chapter 2-26

57 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION shovel, dabber, drill, hammer, concrete mixer etc. Transportation of construction materials. Mental disturbance, Increase in heart rate, Affecting worker's performance. Traffic management. Development of Green belt. 3. Water Quality 4. Solid Waste Management Water used for construction activity mainly for concrete mixing, sprinkling etc. Construction wastes such as left off concrete, stone, aggregates, wooden piles, excavated material etc. Contamination of the soil and nearby water bodies due to the surface runoff. Unhealthy Work Conditions at project site. Proper surface water runoff management would be implemented. Storm water drain should be provided. The solid waste generated in the construction phase would be disposed off through local Municipal Corporation. The excavated soil will be used for green belt development activities within the premises. B) Operational Phase Sr. No. Environmental Parameters Aspect Attributes 1. Air Quality Operation of Boiler, Thermopack & D.G Set Gaseous emission from manufacturing process, Non spontaneous emissions from transportation of Impact The Maximum Incremental concentration of PM g/m 3 PM g/m 3 SO g/m 3 NOx g/m 3 CO mg/m 3 The Health effects related to particulate Proposed Mitigation Measures 1. Common stack of 39 m high will be provided for new boiler & thermopack. 2. Proposed D.G Set will be provided with a stack height of 7.12 m from ground level. 3. Three water scrubbers, two alkali scrubbers & one vent scrubber will be provided to mitigate the Sadekar Enviro Engineers Pvt. Ltd Chapter 2-27

58 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION raw materials & finished goods. VOC emission generated due to the handling and storage of the solvents & other raw materials. 2. Noise Quality Operation of D.G set, Boiler, Reactors, ancillary utilities & transportation matter are majorly respiratory, pulmonary injury & lung cancer etc. Exposure to SO 2 and NOx majorly leads to respiratory problems. Carbon monoxide decreases the oxygen carrying capacity of the blood by reducing the hemoglobin. The health effects related to VOC emission are eye, nose and throat irritation headaches, loss of coordination and nausea, damage to liver, kidney and central nervous system etc. The air emissions in long course of time may affect the immediate surrounding vegetation stature physically (leaf senescence, hampered growth etc.) & biologically thus may affect the overall surrounding ecology. The impacts of high noise level would be Temporary/Permanent hearing loss, Mental disturbance process emissions. 4. The roads within the premises are concreted / paved to avoid the dust generation from vehicular activity. 5. It will be ensured that all the transportation vehicles have a valid PUC (Pollution under Control) Certificate. 6. Proper servicing & maintenance of vehicles is carried out. Same practice will be continued in future. 7. Regular sweeping of all the roads & floors is being /will be done. 8. Development of the green belt along the plant boundary will help to capture the fugitive emission. 9. To control VOC emission carbon adsorption system can be implemented. 10. Industry to ensure that at no point of time the air emission concentrations does not exceed the prescribe standards. 1. Acoustic enclosure will be provided to D.G set for attenuation of noise level during operation. 2. Boiler & Thermopack Sadekar Enviro Engineers Pvt. Ltd Chapter 2-28

59 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION activity. 3. Water Quality 1. Effluent from manufacturing process. 2. Effluent from Scrubber operations 3. Blow down water from Boiler and Cooling Tower. 4.Domestic wastewater Increase in heart rate Decreasing in workers performance due to psychiatric disorder Workers developing Tinnitus due to high level of noise exposure on regular basis. The increased noise level may induce locale level disturbances/ temporary migration of fauna in the immediate vicinity of the project area. Indiscriminate release/discharge of effluents may contaminate the surrounding surface and groundwater & there by affecting the overall ecology & agricultural productivity. will placed in a confined space viz. boiler house where the surrounding walls acts as a barrier for noise propagation. 3. Isolation of high intensity noise generating equipments. 4. Appropriate traffic management to be implemented. 5. Green belt developed around the company premises will acts a noise barrier. 6. Appropriate PPE should be provided to workers. 1. The effluent generated from the boiler blow down & cooling tower blow down will be sent to R.O, the R.O permeate will be reused for Cooling tower makeup & R.O reject will be sent to MEE followed by ATFD. 2. The effluent generated from process will be treated in full fledged ETP with R.O, the R.O permeate will be reused for cooling tower intake & R.O reject will be subjected to MEE followed by ATFD. 3. The MEE Condensate will be reused for cooling tower and residue will be Sadekar Enviro Engineers Pvt. Ltd Chapter 2-29

60 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION sent to CHWTDSF. 4. The Domestic effluent will be treated in the biological treatment of the ETP. 4. Solid Waste Management - Hazardous Waste 1. Hazardous waste generated from the manufacturing process. 2. Sludge generated from the ETP operation. 3. Residue generated from the MEE operation. Unscientific handling & disposal may lead to contamination of surrounding soil, water sources & there by affecting the ecology & health of the workers coming in direct contact with the hazardous waste like skin allergies/rashes/burns etc. 5. The plant will be a ZLD unit.the proposed project will be Zero Liquid Discharge project. 1. Hazardous waste generated from the manufacturing process is disposed to Mumbai Waste Management Limited - CHWTSDF, Taloja. 2. Sludge generated from the ETP operations are disposed to Mumbai Waste Management Limited - CHWTSDF, Taloja. Solid Waste Management - Non Hazardous waste 1. Scrap Metal 2. Scrap Plastic 3. Office Waste 4.Food Waste 5. Carboys & wooden pellets 1.Hap-Hazard handling & storage may lead to inadequate open space in plant premises & it may lead to rodent 3. MEE residue generated from MEE operation will be sent to Mumbai Waste Management Limited - CHWTSDF, Taloja. The mixed solvent recovered from the process will be reused for in-house purpose. Designated area for Scrap materials will be provided in the plant. Scrap materials will be recycled through Sadekar Enviro Engineers Pvt. Ltd Chapter 2-30

61 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER NO- 2: PROJECT DESCRIPTION breeding registered scrap vendors. Daily housekeeping waste and food waste will be disposed through municipal waste management facility. Sadekar Enviro Engineers Pvt. Ltd Chapter 2-31

62 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Chapter 3 DESCRIPTION OF ENVIRONMENT 3.1 Methodology In order to avail Environmental Clearance a methodology for Environmental Impact Assessment (EIA) and Environmental Clearance is necessary to be followed. The steps for the same are depicted in Fig. 3.1 below. Out of the aspects mentioned in Fig. 3.1 the present section focuses on describing the present scenario of environmental conditions such as air quality, water quality, soil quality and noise pollution levels during a period of three months around the project site. This will also include the collection of onsite meteorological data. The Standard Operating Procedures (SOPs) for all the functional areas applicable in this section of the study are followed as per the Quality Management System of the organization and are mentioned in detail in SEE-METH-EIA-01 to SEE-METH-EIA-12. It is known that meteorological conditions around us influence not only the levels of pollution but also their dispersion on local, regional, national as well as global scale. Moreover these meteorological conditions also vary spatially and temporally. Hence it is important to study the meteorological conditions around the study area in order to estimate their level of influence in dispersion of pollutants. 3.2 Site Specific Meteorological Data Study of Meteorology is an important part in Environmental Impact Assessment. In order to determine the prevailing micro-meteorological conditions during the study period, an automatic weather monitoring station was installed at the project site. The station was installed at a height of 10 m above the ground level and away from obstructions in the vicinity of the sensors. The crucial Micro meteorological parameters like wind speed; wind direction, rainfall, temperature and relative humidity were monitored continuously on hourly basis. The meteorological data was monitored for a period of 3 months from March 2016 to May The summary of the meteorological data is provided in Table 3.1. Sadekar Enviro Engineers Pvt. Ltd Chapter3-1

63 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Figure 3.1 Methodology For EIA Sadekar Enviro Engineers Pvt. Ltd Chapter3-2

64 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Temperature Ambient temperature is important part of meteorology for living organisms as it has direct as well as indirect effects on their survival. Also it plays an important part in influencing in the rate of atmospheric chemical reactions. The monitoring of ambient air temperature was carried out at the present site for duration of three months (March to May, 2016). During the monitoring period minimum hourly average temperature was observed in the month of March (19.8 O C) whereas the maximum hourly average temperature was recorded in the month of May (37.4 O C). The following section describes variations relative humidity Relative Humidity Relative humidity can be explained as the ratio of the partial pressure of water vapor to the equilibrium vapor pressure of water at a given temperature. Relative humidity depends on temperature and spatial distribution of the given area. It is known to vary spatially and temporally. Based on the available data it can be said that relative humidity during the study period varied between 40 to 86 %. The highest value for humidity was recorded in the month of May. The minimum Relative Humidity was recorded during the month of March. It is important to note that the highest average value for relative humidity was computed for the month of May (75 %) Wind Speed and Wind Direction The wind speed and wind direction are the parameters which indicate the extent and direction where the pollutants can disperse. Hence critical observations of wind speed and wind direction are necessary to be carried out. These values are further useful for the preparation of wind rose and dispersion modeling. The readings for wind speed and wind direction were recorded on hourly basis. The wind rose diagram of study period is shown in Fig. 3.2 to Fig The wind rose for each month is plotted in Fig 3.2 to 3.4 and a combine wind rose for the study period is depicted in Fig A review of wind rose diagram shows that predominant wind is mostly from South-West to South-East. The minimum wind speed is 0.5 Km/hr & maximum is 28.6 Km/hr. Sadekar Enviro Engineers Pvt. Ltd Chapter3-3

65 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table 3.1 Summary of Site Specific Meteorological Data from March to May, 2016 Month Rainfall (mm) Temperature ( C) Relative Humidity (%) Wind Speed (Km/hr) MIN MAX AVG MIN MAX AVG MIN MAX AVG Dominant Wind Direction (Blowing from) March SW April SWW May SSW Figure 3.2 Wind rose March, 2016 Figure 3.3Wind rose April, 2016 Figure 3.4 Wind rose May, 2016 Figure 3.5 Wind rose March to May, 2016 Sadekar Enviro Engineers Pvt. Ltd Chapter3-4

66 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Interpretation The site specific wind rose is prepared as per the micro meteorology data collected from the site. The analysis of the wind rose of the study period reveals that the pre-dominant wind direction during the study period was South-West. Moreover based on the above observations it can be inferred that, 24% of the time the wind was blowing from west direction during the study period. By further examination it can be estimated that only 5% of the total sampling duration the wind was blowing at speed greater than 10.0 m/s. Sadekar Enviro Engineers Pvt. Ltd Chapter3-5

67 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.3 Ambient Air Quality Monitoring The Ambient Air Quality Monitoring was carried out within an aerial radius 10 Km from the center of the project site. The study area is classified under MIDC, Tarapur. The various sources that can contribute to the air pollution are highlighted as under: Sources of Pollution in the vicinity: As mentioned earlier since the area is located inside MIDC, the surrounding industries and their emissions are one of the most important sources of ambient air pollution. Adjoining to the industrial belt is residential town of Boisar. Along with this numerous small towns like Pasthal, Salagaon, Saravali are located in the vicinity. The activities from residential which are mostly linked with transportation area can be considered as significant contributors towards air pollution. The transportation activities other than that of the residential area another major source of air pollution. A major Highway (Boisar-Tarapur Highway) passes near the site which has traffic density of heavy vehicles Sampling Details The period contemplated for the baseline data collection of the study area was from March to May Based on the inferences of the meteorological data an ambient air quality monitoring network of 8 locations was designed to study the ambient air quality of the study area. The sampling frequency was twice a week as per the NAAQM Notification of November As mentioned in earlier section the sampling locations were selected after considering the predominant wind direction. Thus one location each was selected on the west and southwest side of the project site in the up wind direction of the project site. Three locations were selected on the North-East side and one location was selected in the East, which is in down wind direction. Considering the predominant wind conditions of March one location was selected on the South-East of the project site. The criteria for selection of site are highlighted in the next section. Sadekar Enviro Engineers Pvt. Ltd Chapter3-6

68 3.3.3 Criteria for Selection of Site CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Along with selection of direction of sampling location, the selection site for monitoring is also important. Selection of poor site conditions may lead to inappropriate results and will end up in incorrect inferences which may hamper the outcomes of the purpose of the study. Hence the major aspects for site selection for ambient air quality monitoring are highlighted below: 1 Prevailing prominent wind direction in the study area as examined form the Windrose distribution prepared from the secondary data. 2 Location of sensitive receptors such as reserved forests, national Parks, hospitals, archeological sites, etc. in the vicinity of the study area. 3 Topography of the study area. 4 Site feasibility related to accessibility, security, distances from nearest obstructions such as shades and trees, etc. 5 Availability of electrical supply and supplementary arrangements. The sampling locations based on the aforesaid criteria are noted in Table 3.2. It should be noted that since the MIDC area is surrounded with residential area in the North-East and North side, an additional sampling location is identified in the area under a radius of 4.0 Km. For the ease of understanding the sampling locations are plotted on Google Earth maps and presented in Fig It should be noted that except the project site all the sites selected for the study are classified as residential areas. Table 3.2 Details of the sampling lcoations Sr. Location Code & Distance Coordinates No. Name (Km) Type of Site Direction 1 A1 Project Site 19 47'14.97"N 72 44'14.08"E - Industrial - 2 A2 Pam Tembhi 19 47'25.43"N 72 42'54.04"E 4.97 Residential WWW 3 A3 Pasthal 19 49'13.95"N 72 43'46.11"E 3.77 Open Scrub NNN 4 A4 Murbe 19 44'34.38"N 72 42'32.03"E 5.74 Residential SW 5 A5 Boisar 19 48'24.03"N 72 45'21.05"E 2.90 Residential NE 6 A6 Shirgaon 19 50'19.96"N 72 47'40.56"E 8.29 Residential NE 7 A7 Umroli 19 45'9.73"N 72 45'32.64"E 4.46 Residential SSE 8 A8 Maan village 19 46'49.04"N 72 47'35.01"E 5.90 Residential EEE Sadekar Enviro Engineers Pvt. Ltd Chapter3-7

69 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT After sampling for ambient air quality, the analysis of the said parameters is also necessary to be conducted in a standard manner. The methodologies for the analysis are detailed in section Methodology Used for Ambient Air Analysis The sampling was carried out at selected locations according to the CPCB guidelines. The standard methodology used for analysis is presented in Table 3.3. The details of the detection limits as per the standard methods are also provided. It should be noted that Ambient Air Quality Monitoring was carried out for 12 parameters at the project site (notified by CPCB) whereas, the monitoring of criteria pollutants namely PM 2.5, PM 10, NO X, SO 2 & CO were monitored at remaining stations. Table 3.3 Methodology for Selected Parameters Sr. No Parameters Standard Method Minimum Detection Limit 1 PM 10 IS 5182( Part 23): g/m 3 2 PM 2.5 USEPA Quality assurance handbook VOL-II part II 2.0 g/m 3 3 SO 2 IS 5182 (Part 02): 2001 Reaff g/m 3 4 NOx IS 5182 (Part 06): g/m 3 5 CO Based On Instrument ACE 9000XT 0.02 mg/m 3 6 Ozone (O 3 ) Lab SOP No.-SEE/LD/SOP-AA g/m 3 7 Lead (Pb) EPA Inorganic Compendium method IO ng/m 3 8 Ammonia (NH 3 ) Method 401,Air Sampling and analysis, 3 rd edition 20.0 g/m 3 9 Benzene (C 6 H 6 ) IS 5182 (Part 11) : g/m 3 10 Benzo( )pyrene (BaP) 11 Arsenic (As) Unit IS 5182 (Part 12): 2004 Reaff ng/m 3 Based On CPCB guidelines for measurement of ambient air pollutant Vol. I May ng/m 3 12 Nickel (Ni) EPA Inorganic Compendium method IO ng/m 3 13 Hydrochloric Acid OSHA ID-174SG 0.05 mg/m 3 a. Equipment used for sampling: The sampling of PM 10 was conducted using Envirotech make sampler (model no.: APM-460), while the sampling of PM 2.5 was carried out using Envirotech make sampler (model no. APM550). The monitoring of carbon Sadekar Enviro Engineers Pvt. Ltd Chapter3-8

70 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT monoxide was conducting the online instruments of Rave innovations instruments (model no.: COA-109). The monitoring of ambient VOC was carried out using Envirotech make portable sampler with model no.: APM 802. b. Sample Transportation and Sample Preservation: Proper preservation of samples was done after sampling. The Gaseous samples were preserved in an ice box (below 4 C) and transported to the laboratory for analysis. The filter papers were collected using forceps and Figure 3.6 Sampling Locations selected for Galaxy Surfactants on Google Earth Imagery stored in polythene bags and stored in cool and dry containers during transportation. Sadekar Enviro Engineers Pvt. Ltd Chapter3-9

71 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Ambient Air Quality Status As mentioned earlier ambient air quality monitoring was carried out at eight locations including the project site for a period of three months during March, 2016 to May, The results of ambient air quality monitoring presented in Table 3.4. Table 3.4 Results of Ambient Air Quality Monitoring at eight locations. Parameter Location No. A1 A2 A3 A4 A5 A6 A7 A8 PM 10 ( g/m 3 ) PM 2.5 ( g/m 3 ) SO 2 ( g/m 3 ) NO X ( g/m 3 ) CO (mg/m 3 ) Min Max Avg Percentile Min Max Avg Percentile Min Max Avg Percentile Min Max Avg Percentile Min Max Avg Percentile Note: Monitoring & Analysis performed by Sadekar Enviro Engineers Pvt. Ltd, Laboratory. NAAQ Standards 100 g/m 3 (Annual) 60 g/m 3 (Annual) 80 g/m 3 (Annual) 80 g/m 3 (Annual) 4 mg/m 3 (Annual) Sadekar Enviro Engineers Pvt. Ltd Chapter3-10

72 3.3.6 Interpretation of Primary Data CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT a. PM 10 The level of PM 10 indicates the level of dust and fugitive emissions in the surroundings. From the above results it can be observed that the maximum concentration of PM 10 was estimated to be in the range of 82 & 92 µg/m 3 respectively. The maximum concentration of PM 10 was recorded at location and A4 whereas the minimum concentration was recorded at location A7 in Umroli. It should be noted that the location A4 is located near open ground in Murbe village. The average concentrations of PM 10 during the study varied between 73µg/m 3 to 86µg/m 3. The highest average concentration of particulate matter recorded at location A4 while the lowest average was recorded at location A7. b. PM 2.5 The highest maximum concentration of PM 2.5 (48 µg/m 3 ) amongst the all the monitoring stations was recorded at location A5. At the same time the lowest minimum concentration 14µg/m 3 was recorded at A3. The high concentration at location A5 indicates that the area experiences a high vehicular movement. The reason for these values at Boisar (A5) can be explained by the fact that heavy vehicular activity is noted in the city of Boisar as well the major highway which leads to Tarapur passes through the upwind direction. Therefore as per the conclusions of the meteorological data it be said that the pollutants from the vehicular exhausts are being carried to the monitoring stations. The average concentration of PM 2.5 during the study period was computed to be in the range of µg/m 3. c. Sulphur dioxide (SO 2 ) High level of SO 2 in ambient air indicates the presence of combustion fossil fuel and burning of wood and other plant material in the vicinity. The ambient air monitoring results presented above indicate that the highest average concentration of SO 2 is experienced at the project site, i.e. location A5. The constant traffic and regular movement of heavy vehicles (which use diesel as fuel) in and around the MIDC area and the sampling station can be considered as the principle source of emission for SO 2. The minimum of SO 2 recorded at all the monitoring locations during the study period was in the range of 11µg/m 3 & 19µg/m 3 respectively. The maximum concentration was observed in the range of 21 and 32µg/m 3. The highest average value of SO 2 was computed at location A5 while the lowest can be observed at location A8. Oxides of Nitrogen (NO X ) Sadekar Enviro Engineers Pvt. Ltd Chapter3-11

73 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The various forms of Nitrogen in NO, NO 2 and N 2 O are collectively called as Oxides of Nitrogen. The maximum concentration of NO X during the monitoring period was observed at location A5 while the minimum concentration was recorded at A6. The average concentrations were in the range of µg/m 3. The maximum value of NO X recorded at the monitoring location was 44 µg/m 3. d. Carbon monoxide (CO) The source of CO is the presence of vehicle movement or incomplete combustion of fuel wood around the given area. The maximum concentrations of CO at all locations recorded during the study period ranged between 0.8 to 2.6 mg/m 3 respectively. The minimum concentration at all locations ranged between 0.3 and 1.1mg/m 3. The highest average is calculated at location A5 and the lowest average was estimated to be at location A3 in Pasthal village Monitoring of Additional Parameters: The ambient air quality monitoring was conducted for additional parameters like Ozone, Lead, Ammonia, Arsenic, Nickel, Benzopyrene( ) and Hydrochloric Acid were monitored within the project premises (A1 location). The results for the analysis are presented in Table 3.5. Table No. 3.5: Results of additional Ambient Air Quality parameters monitored at project site A1- Premises of Galaxy Surfactants Sr. Parameters Ltd. NAAQ Standards Unit No. Min. Max. Avg. 1. Ozone (O 3 ) (8 Hourly) g/m 3 2. Ammonia (NH 3 ) (24 Hourly) g/m 3 3. Benzene (C 6 H 6 ) <1.0 <1.0 <1.0 5 (Annual) g/m 3 4. Benzo (a) pyrene (BaP) <0.20 <0.20 < (Annual) ng/m 3 5. Arsenic (As) <5.00 <5.00 < (Annual) ng/m 3 6. Nickel (Ni) <5.00 <5.00 < (Annual) ng/m 3 7. Lead (Pb) <0.10 <0.10 < (24 Hourly) ng/m 3 8. HCl mg/m 3 Note: Monitoring & Analysis performed by Sadekar Enviro Engineers Pvt. Ltd, Laboratory. Based on the analysis of additional parameters carried out for ambient air quality at location A1 it can be stated that the NAAQS did not exceed during the sampling period. The highest concentration of Ammonia was observed to be g/m 3, while the minimum Sadekar Enviro Engineers Pvt. Ltd Chapter3-12

74 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT concentration was estimated to be 84.3 g/m 3. The maximum concentration of Ground level ozone was estimated to be 89.4 g/m 3 and minimum concentration was recorded to be 39.8 g/m 3. The concentrations of heavy metals monitored during the sampling period were found to be under the detection limit. The same was observed in the case of Benze ( ) pyrene. It should be noted that the concentration of HCl was determined to minimal. The average concentration of HCl was estimated to be 0.58 mg/m 3 during the monitoring period Conclusion The descriptive statistics of ambient air quality monitoring at all the locations are indicating that pollution levels did not exceed the standards prescribed by the CPCB. It should be noted that 98 th Percentile values computed at all the sampling locations were close to the maximum value observed at the respective locations. This indicates a negligible variance in the observations obtained. Within the Plant premises the results of additional parameters for Ambient Air quality like, benzene, lead, arsenic, nickel & Benzo ( ) Pyrene were found to be below the detection limit. The results for ozone and ammonia indicate that the values did not exceed the permissible limits by CPCB. The readings of PM 10 and PM 2.5 were observed to be higher in the A7 and A5. The high values for PM 10 can be explained by the fact that the location is near the ground and faces problem of fugitive emissions. Another reason for high concentrations can be said to be the proximity of the location close to the shoreline. In case of PM 2.5 high values were observed at A5, in Boisar which is major commercial and residential area. Also a major highway connecting Boisar and Tarapur passes through the city which experiences heavy traffic. These emissions contribute to increased concentration of PM 2.5. Sadekar Enviro Engineers Pvt. Ltd Chapter3-13

75 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.4 Surface water Quality The observations of the study area from Maps (Survey of India) and Satellite Images (Google Earth) reveal that a major surface water body, the Arabian Sea is located on the west side. Due to the presence of Arabian Sea the area experiences ingress of sea water into land leading to formation of creeks and estuaries in some locations. Thus the area has presence of Murbe Creek on South West side, Uchelli creek on North west side and a of Tarapur creek on the North side, etc. It is important to note, that the study area has only one fresh water body named Banganga River, which is seasonal in nature. But presence of small ponds at various places is observed in the study area. The sampling locations for the water bodies were finalized after consultation with the functional area experts. The probable sources of pollution identified by the functional area experts and are listed in section The broad criteria for finalizing the sampling locations are highlighted in section Probable sources of surface water pollution in the study area It was also studied that majority of the study creek area is surrounded with villages and the population is thus rural in nature. The untreated sewage from the major residential area of Boisar and other nearby villages is discharged in the creek. This can be said to be one of the principal sources of water pollution Sampling Details The present section discusses the criteria sampling for the surface water bodies, methodologies for analysis and provides the details of the procedures for sampling, storage and transportation adopted during the study period Selection criteria for water quality sampling locations The locations for collection of representative sample were selected considering the following guidelines:- i. The sampling locations were selected based on upstream and downstream uses of the water body. ii. Drainage Pattern of the water body. iii. Final Discharge points of the CETP and STP drains into the selected rivers which are relevant to the study area if any. iv. Presence of important Lakes, Dams and Reservoirs in the study area. v. Any other water bodies which may be affected due to the proposed activity. Sadekar Enviro Engineers Pvt. Ltd Chapter3-14

76 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT For the ease of understanding the selected sampling locations are represented in Fig. 3.7 on Google maps. A total of eight sampling locations were selected for the present study. The details of the sampling locations are highlighted in Table 3.6. Table 3.6 Details of Sampling Locations for Selected Surface Water Bodies Sr. Location Code & Distance Type of Coordinates No. Name (Km) Sample Direction 1 SW1 Satpati- Arabian Sea 19 43'5.65"N 72 42'1.05"E 8.59 Sea Water SSW 2 SW2 Murbe Creek 19 44'18.43"N 72 42'35.30"E 6.16 Creek Water SSW 3 SW3 Kumbhawali 19 45'41.20"N 72 43'30.84"E 3.17 Creek Water SSW 4 SW4 Saravali 19 46'44.35"N 72 45'3.57"E 1.71 Pond Water SE 5 SW5 Banganga at Pasthal 19 49'25.43"N 72 43'50.59"E 4.06 River Water NNN 6 SW6 Uchelli 19 48'11.35"N 72 41'38.63"E 4.86 Creek Water NWW 7 SW7 Alewadi 19 46'30.03"N 72 41'36.89"E 4.77 Pond Water SWW 8 SW8 Vire 19 51'46.31"N 72 46'18.47"E 9.12 Creek Water NNE Figure No. 3.7: Sampling Locations for Surface Water bodies identified in the Study Area Sadekar Enviro Engineers Pvt. Ltd Chapter3-15

77 3.4.4 Methodology CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT a. Methodology for Sampling The sampling frequency was kept once a season. Grab samples were collected from the identified locations. The surface water samples were collected from the upward and downward stretch of the stream. Sampling was carried out using the standard SOP and guidelines as per the QMS of the organization. b. Sample Collection, Preservation and Transportation: Samples were collected by personnel who had proper training and adequate experience. During transportation the proper storage of samples is vital and hence it is necessary to assure that all storage procedures are followed so as to avoid any significant alterations in the storage conditions. This is useful to keep the samples in a state fit for analysis at the laboratory. The key aspects which were taken care of during transport and storage are highlighted as under: Samples were collected in HDPE containers and packed to avoid breakage and crosscontamination. Sample degradation was reduced through appropriate preservation and 1ml 1N HNO 3 per liter of sample was added for analysis of selected metals. Sample containers were sealed, labeled and carefully packed with an appropriate packing material and stored in chilled containers (around 4 C). The chain of custody records was also maintained as per standard protocol. Microbiology samples were collected in sterile Pyrex-glass bottles The ph and Temperature were monitored at the time of collection and the DO was fixed on site. The details of parameters assessed from the water bodies and the standard methods for analysis of water samples are presented in Table 3.7. The method detection limits for each of the parameters are also provided in the table with respective units of measurement. Sadekar Enviro Engineers Pvt. Ltd Chapter3-16

78 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table 3.7 Methodology for Water Analysis Sr. No. Parameters Standard Method Minimum Detection limit Unit 1 ph APHA 4500 H + - B Total Dissolved Solids APHA C 5.00 mg/lit 3 Chlorides as Cl - APHA 4500 Cl - - B mg/lit 4 - Sulphate as SO 4 APHA 4500 SO E 1.00 mg/lit 5 Total Hardness as CaCO 3 APHA C 2.00 mg/lit 6 Nitrate as NO 3 APHA-4500-NO 3 -B 1.00 mg/lit 7 Fluoride as F - APHA-4500-F - - D 0.02 mg/lit 8 Phosphate APHA-4500-PC 1.00 mg/lit 9 Bicarbonate APHA B 1.00 mg/lit 10 COD APHA-5220-B 4.00 mg/lit 11 BOD APHA-5210-B 3.00 mg/lit 12 DO APHA-4500-C 1.00 mg/lit 13 Arsenic as As APHA B 0.01 mg/lit 14 Calcium as Ca APHA B 1.00 mg/lit 15 Cadmium as Cd APHA B mg/lit 16 Chromium as Cr APHA B 0.05 mg/lit 17 Iron as Fe APHA B 0.3 mg/lit 18 Lead as Pb APHA B 0.01 mg/lit 19 Magnesium as Mg APHA B 1.00 mg/lit 20 Mercury as Hg APHA B mg/lit 21 Nickel as Ni APHA B 0.02 mg/lit 22 Potassium as K APHA B 0.1 mg/lit 23 Sodium as Na APHA B 0.1 mg/lit 24 Zinc as Zn APHA B 0.1 mg/lit 25 Total coliforms at 37 0 C for 48 hrs. APHA-9221-B Absent - 26 Ecoli at C for 24hrs. APHA-9221-G Absent Interpretation of the data It is known that the nature of the water bodies considered for sampling are of different types. As per the guidelines of the IS: (Inland Surface Water). Each category of water body has different set of permissible limits. The criteria for classification of the water bodies (IS: ) are provided in Table 3.8. The result for the analysis of samples for the aforesaid parameters is presented in Table 3.9. Sadekar Enviro Engineers Pvt. Ltd Chapter3-17

79 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Based on the guidelines it can be inferred that locations SW4 SW5 and SW7 fall under the B category as the water from these water bodies is not used for drinking water purpose. The water these water bodies can be used for organizing outdoor bathing only. The water bodies Sw1 to SW3, SW6 and SW8 can be categorized into category E, i.e. the water is fit for purposes such as Irrigation, industrial cooling and controlled waste disposal. These water bodies have sea water which is saline in nature and therefore cannot be used for domestic activities. Table 3.8IS: Inland Surface Water Standards Parameter A B C D E Unit ph EC ms/c Color Hazen Odor Agreeable TSS mg/l TDS mg/l Turbidity mg/l AlkalinityasCaCO mg/l Chloride as Cl mg/l SulphateasSO mg/l NitratesasNO mg/l HardnessasCaCO mg/l CalciumasCaCO mg/l MagnesiumasCaCO mg/l Sodium as Na mg/l Potassium as K mg/l Fluoride as F mg/l Iron as Fe mg/l DO mg/l COD mg/l BODat27 C mg/l Note:- A-Drinking water without conventional treatment but after disinfection B-Outdoor bathing (organized) C-Drinking water source with conventional treatment followed by disinfection D - Propagation of wild life, fisheries E -Irrigation, industrial, cooling, controlled waste disposal The analysis of surface water samples revealed that the ph of all the samples ranged 7.2 to 7.9. It should be noted that the desirable limit for ph was not exceeded in any of the category Sadekar Enviro Engineers Pvt. Ltd Chapter3-18

80 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT in which the sources are classified. The total hardness ranged in between 74 to 1586 mg/l. The maximum value of hardness was recorded at SW3. It should be noted that the sampling location is located near a salt pans. The water from the salt pans which drains in to the water body can be said to be containing dissolved calcium compounds. The minimum value of hardness was recorded at SW7 which is a lake, in Alewadi village. The concentration of Total Dissolved Solids was in the range of 208 mg/l to mg/l. The maximum concentration of Total Dissolved Solids (TDS) was observed at SW3 whereas the minimum TDS concentration was observed at SW7. The high value of TDS in at location SW3 indicates the discharge of pollutants from the vicinity and other soluble compounds from the salt pans located in vicinity of the sampling location. The Chemical Oxygen Demand (COD) & Biochemical Oxygen Demand (BOD) values were calculated to be in the range of 4.00 mg/l to 248 mg/l & <3.0 to 116 mg/l respectively. The COD & BOD values at all the locations were well within the CPCB discharge standards except for one location SW3, where the value of BOD was observed to marginally exceed the standard for BOD of 100 mg/lit. All other parameters of all locations were within prescribed limits. It should be noted that in case of the source classified under category B, out of all the parameters BOD was observed to marginally exceed the prescribed limit of 3mg/lit. This can be said due to the ingress of sea water in the river on some ocaasions. Hence it is suggested that the water can be used after treatment if intended for bathing purposes (outdoor) as per IS: Inland Surface Water Standards. The surface water bodies do not come under the polluted stretch of river identified by CPCB, (Reference: Series: MINARS/37 / RIVER STRETCHES FOR RESTORATION OF WATER QUALITY by CPCB, dated Feb 2015.) The Site Falls near to the polluted stretch of river identified by the CPCB/MoEF& CC. The surface water bodies do not come under the polluted stretch of river identified by CPCB, (Reference: Series: MINARS/37 / RIVER STRETCHES FOR RESTORATION OF WATER QUALITY by CPCB, dated Feb 2015.) (Reference: Series: MINARS/37 / RIVER STRETCHES FOR RESTORATION OF WATER QUALITY by CPCB, dated Feb 2015.) Sadekar Enviro Engineers Pvt. Ltd Chapter3-19

81 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Analysis of Nallah Passing through Site Premises During the survey it was observed that a nallah was passing through the site premises. It is important to note that no discharge of any kind will be released into the nallah. The present status of water quality of the nallah was determined by conducting analysis and testing all the parameters provided in section 3.7. The location of the nallah is depicted on satellite image in Fig Figure 3.8 Sampling Location of Nallah Passing Through Site The results of the parameters are presented in Table 3.10 separately. Sadekar Enviro Engineers Pvt. Ltd Chapter3-20

82 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra Table 3.9 Results for Surface Water Quality at Selected Sampling Locations Sr. No. General Nutrients Organics Total Ions Inorganic Parameter Arabian Sea At Satpati Murbe Creek Stream Annapurna Salt works, Kumbhawali Saravli lake Banganga River at Pasthal CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Uchelli Creek Alewadi Lake Vire Creek SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 1. ph TDS mg/lit 3. NO mg/lit 4. Total PO mg/lit 5. BOD < < <3 <3 mg/lit 6. COD mg/lit 7. Ca++ Hardness mg/lit 8. Ca mg/lit 9. Mg mg/lit 10. Na mg/lit 11. K mg/lit 12. Cl mg/lit 13. SO mg/lit 14. HCO mg/lit Units Sadekar Enviro Engineers Pvt. Ltd Chapter3-21

83 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra Sr. No. Parameter Arabian Sea At Satpati Murbe Creek Stream Annapurna Salt works, Kumbhawali Saravli lake Banganga River at Pasthal CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Uchelli Creek Alewadi Lake Vire Creek SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 15. F mg/lit Total Metals 16. Arsenic as As < <0.01 <0.01 < <0.01 <0.01 mg/lit 17. Cadmium as Cd < <0.005 <0.005 < <0.005 <0.005 mg/lit 18. Chromium as Cr < <0.005 <0.005 < <0.005 <0.005 mg/lit 19. Copper As Cu <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 mg/lit 20. Iron as Fe mg/lit 21. Mercury as Hg <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 mg/lit 22. Zinc aszn mg/lit 23. Nickel as Ni <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < Lead as Pb <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 Bacteriological 25. Total Coliforms >1600 > > Org./100 ml 26. E-Coli Absent Org./100 ml Units Sadekar Enviro Engineers Pvt. Ltd Chapter3-22

84 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table 3.10 Characteristics of Stream Passing through Project Site Sr. No. General Nallah Passing Through Site Units General 1 ph TDS 668 mg/lit 3 Nutrients 4 NO mg/lit 5 Total PO mg/lit Organics 5 BOD 82 mg/lit 6 COD 260 mg/lit Total Ions 7 Ca ++ Hardness mg/lit 8 Ca mg/lit 9 Mg mg/lit 10 Na + 50 mg/lit 11 K mg/lit 12 Cl - 90 mg/lit 13 SO mg/lit 14 HCO mg/lit Inorganic 15 F mg/lit Total Metals 16 Arsenic as As <0.01 mg/lit 17 Cadmium as Cd <0.005 mg/lit 18 Chromium as Cr <0.005 mg/lit 19 Copper As Cu <0.002 mg/lit 20 Iron as Fe 3.68 mg/lit 21 Mercury as Hg <0.001 mg/lit 22 Zinc aszn 2.3 mg/lit 23 Nickel as Ni <0.01 mg/lit 24 Lead as Pb <0.02 mg/lit Bacteriological 25 Total Coliforms 130 Org./100 ml 26 E-Coli 90 Org./100 ml The analysis of the water quality of the stream reveals that the water is moderately polluted. Also it is important to note that the results cannot be compared with the Inland Surface Water Standards provided by the CPCB. The results suggest that COD of the water was estimated to be 260 mg/lit, while the BOD was estimated to be 82 mg/lit. The value for COD is observed to marginally exceed the limit of 250 mg/lit, as prescribed by the CPCB for fresh water streams. The concentration of Total Dissolved Solids was calculated to be 668mg/lit. The presence of Heavy Metals namely Iron and Zinc was evident during the testing, while the concentration of rest of the heavy metals was observed to be under the detection limit. The sample also indicated the presence of coliforms bacteria(e-coli). Sadekar Enviro Engineers Pvt. Ltd Chapter3-23

85 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT It is important to highlight that there will be no discharges into the nallah from any of the activities of the proposed project during its establishment or operational phase. Sadekar Enviro Engineers Pvt. Ltd Chapter3-24

86 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.5 Ground water Quality Ground Water sources in the study area Primarily the study area had bore wells and hand pumps as major as ground water sources. Ground water samples were collected from the 10 km study area from 8 locations. The project proponent does not explore any ground water for any purpose. Although, fresh water is supplied by the municipal authority in the city, ground water is used as an alternate source in some villages for drinking domestic and irrigation purposes. It is important to assess the existing baseline status of the ground water quality Probable sources of ground water pollution in the study area Uncontrolled discharge of effluent or discharge of open and untreated sewerage can be one of the principle sources of ground water pollution in the area Sampling Details The sampling locations and their coordinates are presented in Table The Ground water samples were collected based on the drainage pattern. Table 3.11 Sampling locations to analyze the Ground Water Quality of Study area. Sr. No. Location Code & Name Coordinates Distance Type of (Km) Sample Direction 1 GW1 Satpati 19 43'23.29"N 72 42'10.23"E 7.96 Hand Pump SW 2 GW2 Boisar 19 48'12.25"N 72 45'14.99"E 2.52 Bore well NNE 3 GW3 Salwad 19 48'33.16"N 72 43'14.08"E 2.99 Bore well NNW 4 GW4 Navapur 19 47'18.39"N 72 41'23.90"E 4.95 Bore well WWW 5 GW5 Maan 19 46'53.48"N 72 47'39.95"E 6.03 Bore well EEE 6 GW6 Umroli 19 45'16.31"N 72 45'36.53"E 4.36 Bore well SSE 7 GW7 Saravali 19 46'39.18"N 72 44'57.80"E 1.67 Hand Pump SE 8 GW8 Nandgaon 19 45'52.42"N 72 41'20.60"E 5.86 Bore well SWW The water quality monitoring network of 8 locations was designed to evaluate the prevailing ground water quality in the study area. The sampling frequency was once in as season (study period March to May, 2016). The details of the methodology for ground water sampling is provided in Table No Sadekar Enviro Engineers Pvt. Ltd Chapter3-25

87 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table 3.12 Methodology for Ground Water Analysis Sr. No Parameters Analysis Detection Limit Unit 1 ph APHA 4500 H + - B Total Dissolved Solids APHA C 5.00 mg/lit 3 Chlorides as Cl - APHA 4500 Cl - - B mg/lit mg/lit 4 - Sulphate as SO 4 APHA 4500 SO E 1.00 mg/lit mg/lit 5 Total Hardness as CaCO 3 APHA C 2.00 mg/lit mg/lit 6 Nitrate as NO 3 APHA-4500-NO 3 -B 1.00 mg/lit mg/lit 7 Fluoride as F - APHA-4500-F - - D 0.02 mg/lit mg/lit 8 Phosphate APHA-4500-PC 1.00 mg/lit mg/lit 9 Bicarbonate APHA B 1.00 mg/lit mg/lit 10 COD APHA-5220-B 4.00 mg/lit mg/lit 11 BOD APHA-5210-B 3.00 mg/lit mg/lit 12 Arsenic as As APHA B 0.01 mg/lit mg/lit 13 Calcium as Ca APHA B 1.00 mg/lit mg/lit 14 Cadmium as Cd APHA B mg/lit mg/lit 15 Chromium as Cr APHA B 0.05 mg/lit mg/lit 16 Iron as Fe APHA B 0.3 mg/lit mg/lit 17 Lead as Pb APHA B 0.01 mg/lit mg/lit 18 Magnesium as Mg APHA B 1.00 mg/lit mg/lit 19 Mercury as Hg APHA B mg/lit mg/lit 20 Nickel as Ni APHA B 0.02 mg/lit mg/lit 21 Potassium as K APHA B 0.1 mg/lit mg/lit 22 Sodium as Na APHA B 0.1 mg/lit mg/lit 23 Zinc as Zn APHA B 0.1 mg/lit mg/lit 24 Total coliforms at 37 0 C for 48 hrs. APHA-9221-B Absent Org/100ml 25 E-coli at C for 24hrs. APHA-9221-G Absent Org/100ml Criteria for selection of monitoring site The sites were selected considering the following criteria - 1. Drainage Pattern. 2. Areas which may be affected due to the activity. 3. Based on the above criteria eight sampling locations were selected for the present study. These locations are marked on Google Earth Imagery in Fig Sadekar Enviro Engineers Pvt. Ltd Chapter3-26

88 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 4. Sample Collection, Preservation and Transportation are described in detail in the above section no Figure No. 3.9: Sampling Locations for Ground Water Quality on Google Earth Imagery Analysis of Ground Water The Ground Water quality for the selected samples was tested as per the methods as described in the earlier section. The results for the samples collected are presented in Table These results are compared with the drinking water standards provided by IS. Sadekar Enviro Engineers Pvt. Ltd Chapter3-27

89 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Interpretation Ground Water monitoring was carried out at eight different locations. Most of the sampling was done from the open wells located in the near-by villages of the study area. During the baseline data collection it was observed that in some of the cases the water from the ground water sources is used for drinking, domestic and irrigation purposes. The results obtained thereby are compared with the IS 10500:2012standards. It can be observed that the results indicate that ph ranges in between 7.1 to 7.8, which is well within the specified standard of 6.5 to 8.5. The maximum ph of 7.8 was observed at Salwad Village (GW3) and the minimum ph of 6.9 was observed at Umroli village (GW6). Total hardness was observed to be ranging between 208 to mg/l. The maximum hardness (375.6 mg/l) was recorded at Salwad (GW3) and the minimum hardness (208 mg/l) was estimated at Satpati Village (GW4). It should be noted that the values of hardness were found to be exceeded the permissible limit of IS 10500:2012standards at five of the eight sampling locations (GW2 to GW4 and GW7 and GW8). In case of concentration of Total Dissolved Solids (TDS) results ranging in between 356 to 1128 mg/lit were obtained. The highest TDS was estimated at GW8 while the lowest was estimated at GW5. High values exceeding the permissible limit can be said to be a result of ground water pollution. The concentrations of Chlorides at all the locations were estimated to be within the permissible limit, ranging in between 56.7 and mg/l. The concentration of chlorides was also observed to be above the standards at two locations (GW7 and GW8). The amount of Nitrate in the given samples was found to be in the range of from 0.21 mg/l to 2.94 mg/l. It was noted that iron content in all the samples collected were exceeding the IS limit 2012 for drinking water. The concentration of iron found to vary between mg/l. The microbiological analysis for the samples revealed that E-coli were absent in all the locations. Based on the above analysis it can be concluded that the ground water is moderately polluted and the use of the water for drinking, domestic & irrigation purposes can be considered after a basic primary treatment. Sadekar Enviro Engineers Pvt. Ltd Chapter3-28

90 Sr. No. Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra Table 3.13 Results For Ground Water Samples General Parameters GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 Satpati HandPump Boisar Borewell Salwad HandPump Navapur Borewell Maan Borewell Umroli Borewell Saravli Borewell CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Nandgaon Borewell Units IS desirable Limit (As per IS 10500) ph TDS mg/lit Total Hardness mg/lit 200 Nutrients 4 NO mg/lit 45 5 Total PO mg/lit - Total Organic 6 BOD mg/lit - 7 COD mg/lit - Total Ions 8 Ca mg/lit 75 9 Mg mg/lit Na mg/lit - 11 K mg/lit - 12 Cl mg/lit SO mg/lit HCO mg/lit - Inorganic 15 F - <0.02 < <0.02 <0.02 < mg/lit 1 Sadekar Enviro Engineers Pvt. Ltd Chapter3-29

91 Sr. No. Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra Total Metals Parameters GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 Satpati HandPump Boisar Borewell Salwad HandPump Navapur Borewell Maan Borewell Umroli Borewell Saravli Borewell CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Nandgaon Borewell Units IS desirable Limit (As per IS 10500) Arsenic as As < <0.01 <0.01 < <0.01 <0.01 mg/lit Cadmium as Cd < <0.005 <0.005 < <0.005 <0.005 mg/lit Chromium as Cr < <0.005 <0.005 < <0.005 <0.005 mg/lit - 19 Copper As Cu <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 mg/lit 20 Iron as Fe mg/lit Mercury as Hg <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 mg/lit Zinc mg/lit Nickel as Ni <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 mg/lit Lead as Pb <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 mg/lit 0.01 Bacteriological 25 Total Coliforms Org./100 ml Absent 26 E-Coli Absent Absent Absent Absent Absent Absent Absent Absent Org./100 ml Absent Sadekar Enviro Engineers Pvt. Ltd Chapter3-30

92 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.6 Noise levels monitoring Noise level pollution in the areas with anthropogenic activities is of great concern as high and constant exposure to noise levels are reported to cause deleterious effects on the humans as well as plant and animals. Noise level monitoring provides an insight pertaining to the prevailing conditions of noise levels in the surrounding areas. Based on the understanding of these, monitoring noise levels are calculated in L equvivalent and this helps in deciding the management technologies for abatement of noise pollution. Noise level monitoring was carried out within the aerial distance of 10 km study area for 8 locations Major Sources of Noise generation sources in the study area The major sources of noise in the study area are from various activities carried out in the industrial, commercial and residential area in the study area Monitoring Details Continuous ambient noise monitoring was carried out once for 24 hours during the study period. The daytime noise levels have been monitored during 6 am to 10 pm and night time levels during 10 pm to 6 am at all the locations in the study area. The noise monitoring was carried out as per the NAAQM Standards for noise. As per the Central Pollution Control Board guidelines Continuous ambient noise monitoring was carried out for 24 hours at 8 locations in 10 km radial study area. The locations were decided as per the guidance of the Functional Area Experts and are presented in Fig.3.10 respectively. The noise monitoring was performed by a precision integrated noise meter of baseline technology Model No It is important to note that location A1 is located in the industrial area while remaining locations are categorized as residential areas. The standards used for comparison of the noise levels are therefore used as per the standards prescribed regulations of CPCB Criteria for selection of source The locations for collection of representative sample were selected considering - 1. Identification of probable sources. Sadekar Enviro Engineers Pvt. Ltd Chapter3-31

93 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 2. Individuals/Areas likely to be affected due to the activity. The details of the sampling locations are presented in Table Table 3.14 Details of Ambient Noise Sampling Locations Sr. No. Sampling Location Code & Name Direction Dist. (Km) from the centre Galaxy Surfactants Ltd. Coordinates Type of Area 1 N1 Project Site '14.97"N 72 44'14.08"E Industrial 2 N2 Pam Tembhi NWW '25.43"N 72 42'54.04"E Residential 3 N3 Pasthal NNN '13.95"N 72 43'46.11"E Residential 4 N4 Murbe SW '34.38"N 72 42'32.03"E Residential 5 N5 Boisar NNE '24.03"N 72 45'21.05"E Residential 6 N6 Shigaon NNE '19.96"N 72 47'40.56"E Open Land 7 N7 Umroli SW '9.73"N 72 45'32.64"E Residential 8 N8 Maan village SEE '49.04"N 72 47'35.01"E Residential Note: Monitoring & Analysis performed by Sadekar Enviro Engineers Pvt. Ltd., Laboratory Sadekar Enviro Engineers Pvt. Ltd Chapter3-32

94 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Figure No. 3.10: Sampling locations for Noise Monitoring (Google Earth Imagery) Sadekar Enviro Engineers Pvt. Ltd Chapter3-33

95 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The results for the sampling locations obtained are presented in Table 3.15 along with the NAAQS for Ambient Noise Level. Table No. 3.15: Results of Ambient Noise Monitoring Galaxy Surfactants Ltd. Sr. No Sampling Location Noise in db(a) Leq Day Time Noise in db (A) Leq Night Time 1 Premises of Galaxy Surfactants Pvt. Ltd Pam Tembhi Pasthal Murbe Boisar Shigaon Umroli Maan village NAAQ Noise Limit (Industrial Area) NAAQ Noise Limit (Residential Area) Interpretation As per the guidelines of the CPCB the results for the Noise Levels are compared with the standards prescribed for Industrial and residential zone as applicable. a. Industrial Zone: The average Leq for day time noise levels at the boundary of the plant premises were computed 68.7 Leq db (A) while for the Night time it was measured to be 64.2 Leq. db (A). It should be noted that the noise levels were under the prescribed limits of CPCB during the day time as well as during the Night time. b. Residential Zone: The results of the study indicate that the day time noise level varied between 49.2 to 54.6Leq. db (A) and in night time 40.2to 44.3 Leq. db (A). The values are within the prescribed MPCB limits and it can be concluded that there will be minimal impact of the proposed project on the site as all noise generating equipments will have acoustic enclosures. Among the residential areas highest readings during the day time Sadekar Enviro Engineers Pvt. Ltd Chapter3-34

96 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT and night time were observed at Boisar (N5). As explained earlier the locality is busy commercial as well as residential area where maximum anthropogenic activity is observed as compared to the rest of the locations. The Noise level was observed to be higher in the N1 location i.e. Plant Premises as it is in the MIDC area surrounded by many large and medium scale industries which are in operation resulted in higher value of noise level. Sadekar Enviro Engineers Pvt. Ltd Chapter3-35

97 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.7 Soil Environment Soil Monitoring was carried out in the 10 km study area for 2 locations. The sampling was carried out to assess the baseline status of soil environment Probable sources of soil pollution/contamination in the study area The effluent & hazardous waste generated by various industries located in the Tarapur industrial cluster if not disposed off scientifically may find its way to surrounding soil and thus can affect the soil quality adversely. The problem can also be aggravated by uncontrolled disposal of municipal solid waste or sewage inhabited into vacated land Sampling Details The sampling was conducted as per the standard operating procedures. The key aspects considered while sampling are: The soil samples were collected from 1.5 m depth The samples were stored in 1Kg. HDPE zip-lock bags and transported in cool and dry containers. The samples were analyzed for physical & chemical characteristics. The samples have been analyzed as per the established scientific methods for physico-chemical parameters & heavy metals have been analyzed by Atomic Absorption Spectrophotometry. The criteria for deciding the sampling location is described in the following section Criteria for selection of source The locations for collection of representative sample were selected considering - 1. From agricultural land in downwind direction 2. From comparatively polluted site viz. within industrial area Based on the above understanding the two sampling locations were identified and are depicted in Fig The coordinates of the sampling locations are provided in Table Sadekar Enviro Engineers Pvt. Ltd Chapter3-36

98 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table No. 3.16: Details of Soil Monitoring Locations Galaxy Surfactants Ltd. Sr. No. Sampling Location Direction Dist. (Km) Lat. Long. 1 SS1 Salwad CETP NNW '15.29"N 72 43'30.59"E 2 SS2 Ranishigaon NNE '26.54"N 72 45'49.91"E Figure No. 3.11: Sampling Location for Soil Monitoring (Google Earth Imagery) Sadekar Enviro Engineers Pvt. Ltd Chapter3-37

99 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Sr. No. The methodology for analysis and results obtained are presented in Table Table No. 3.17: Results of Soil Monitoring Parameters S1 Results Location S2 Units 1 ph IS:2720 (PART 26) Moisture Content % 3 Organic matter % 4 Exchangeable Calcium as Ca mg/kg 5 Color Brown Brown - SW Soil texture Sandy Sandy mg/kg 7 8 Electrical Conductivity Water Capacity holding ms/cm IS :14767 : % 9 Arsenic as As <1.00 <1.00 mg/kg EPA Method B 10 Cadmium as Cd ND ND mg/kg EPA Method B 11 Chromium as Cr ND ND mg/kg EPA Method B 12 Lead as Pb ND ND mg/kg EPA Method B 13 Magnesium as Mg mg/kg EPA Method B 14 Iron as Fe mg/kg EPA Method B Method Lab SOP no. SEE/LD/SOP-SA/13 issue dt. 29/03/2014 based on procedure of soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002 Lab SOP no. SEE/LD/SOP-SA/05 issue dt. 29/03/2014 base on procedure of soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002 Lab SOP no. SEE/LD/SOP-SA/18 issue dt. 29/03/2014 based on procedure of soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition Procedure for Soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002 Procedure for Soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002 Sadekar Enviro Engineers Pvt. Ltd Chapter3-38

100 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Sr. No. Parameters S1 Results Location S2 Units 15 Potassium as K mg/kg EPA Method B 16 Total Nitrogen mg/kg Phosphate PO4- as Cation exchange capacity mg/kg mg/kg 19 SAR mg/kg Interpretation Method Lab SOP No. SEE/LD/SP-SA/04 (Based on procedure for Soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002) Lab SOP no. SEE/LD/SOP-SA/09 issue dtd. 29/03/2014 based on procedure of soil Analysis by Food and Agriculture Organization of United nations /International soil reference & information center compiled under Edited by LP Vanreeuwijk 6 Edition 2002 Handbook of Methods in Environmental Studies Vol.2 by S K Maiti Handbook of Methods in Environmental Studies Vol.2 by S K Maiti It has been observed that the ph of the soil in the study area ranged from which indicates neutral nature in soil. The soil type is mostly in the form of sandy. The potassium value ranges to 963 kg/ha to 819 kg/ha falls under more than sufficient. The nitrogen values range between to Kg/ha which falls under very less category. The phosphates values were in the range of Kg/ha which comes under more than sufficient category. The fertility of the soil is compared according to Hand Book of Agriculture, ICAR, New-Delhi. On the basis of chemical analysis of soil samples, the soils can be classified as per soil classification given by Tondon H.L.S. (2005). S1 and S2 can be classified as fertile soil (Table 3.18 and Table 3.19). The presence of heavy metals like arsenic, cadmium, lead & chromium in both the soil samples were below the detection limit.. Sadekar Enviro Engineers Pvt. Ltd Chapter3-39

101 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table No Chemical Classification of Soil Quality Sr. No. Soil Test Classification 1 ph 2 Salinity Electrical Conductivity (mmhos/cm) (1ppm = 640 mmho/cm) 3 Organic Carbon (%) 4 Nitrogen (Kg/ha) <4.5 Extremely acidic Very strongly acidic moderately acidic slightly acidic Neutral slightly alkaline moderately alkaline strongly alkaline 9.01 very strongly alkaline Upto 1.00 Average harmful to germination harmful to crops (sensitive to salts) Upto 0.2: very less : less medium, : on an average sufficient : sufficient >1.0 more than sufficient Upto 50 very less less good Better >300 sufficient Upto 15 very less less 5 Phosphorus (Kg/ha) medium on an average sufficient sufficient >80 more than sufficient 6 Potash (Kg/ha) very less less Sadekar Enviro Engineers Pvt. Ltd Chapter3-40

102 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Sr. No. Soil Test Classification medium average better >360 more than sufficient Source: Hand Book of Agriculture, ICAR, New Delhi Table No. 3.19: Levels of Soil Fertility Soil Fertility Level Organic Carbon (%) Available N kg/ha Available P2O5 kg/ha Available K2O kg/ha Very high > 1.00 > 700 > 80.0 > 360 High Medium Medium Low Low Very Low < 0.20 < 140 < 16.0 < 120 Source : Tondon H. L. S. (2005) 3.8 geology & Hydrogeology of the study area The geological & hydrogeology aspects are often associated with larger areas hence the geomorphologic aspects of entire Palghar District are considered as described below Geology of Palgar District A major part of district is covered with basalt lava flows generally called as Deccan trap. This volcanic activity was confined mainly to Upper Cretaceous to Lower Eocene age. Besides Deccan traps the formation like local alluvium, beach sand, coastal alluvium, laterites, trachytes & rhyolite cover very small area of the district. The main topographic features of this lava flows are flat topped hills and steps like terrace Statigraphic sequences of the geological formation in the district is shown as below:- Sadekar Enviro Engineers Pvt. Ltd Chapter3-41

103 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Table No. 3.20: Statigraphic sequences of geological formation in Palghar District Formation Age Lithology Alluvium Recent clay, silt and sand Beach sand Recent sand and silt Laterite Pleistocene Laterite Dykes Basic intrusion Deccan traps basalt Eocene to upper cretaceous Amygdularbasalt Rhyolite Eocene to upper cretaceous Rhyolite Trachyte Eocene to upper cretaceous Trachyte Deccan Traps: The Deccan trap has been divided into three major groups, i.e. upper, middle and lower. The Bombay basalt flows have been grouped into upper traps on the basis of the inter-trappean and ash beds present in them. Being in the contiguous area, the Deccan traps in the district can also be grouped with the upper flows. There are number of dykes crisscrossing the area. The general trend is however, north-northwest south-southeast and northnortheast south-southwest, dipping steeply to the east. The thickness seldom exceeds six meters. The dykes send out offshoots of different sizes, at places enclosing lenticular wedges of country rock. Chilled margins are seen along dykes flow contact. The dykes vary from coarse dolerite to fine grained basalts. Most of the dykes are porphyritic of feldspars. Laterite: Few high basalt plateaus of the district are capped by laterites. These are Boundongri ( N: E) and Bombassadongri ( N: E) 430 meters, Kanheri ( N: E) 510 meters, and Tungar ( N: E) 665 meters hills. The Kanheri and Tungar laterites have conspicuous development of bauxite. Shore Sands: The sea coast of the district stretching several kilometers along the western boundary is covered by sands. Sadekar Enviro Engineers Pvt. Ltd Chapter3-42

104 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Figure No. 3.22: Geology of Maharashtra Hydrogeology of Palghar District Hydro geologically the basaltic terrain has aquifers in the form of jointed and fractured trap. The occurrence of ground water in deccan trap is governed by its degree of weathering, concentration of joints & fractures planes, porosity & permeability of geological units. The Sadekar Enviro Engineers Pvt. Ltd Chapter3-43

105 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT movement & storage of ground water are mainly controlled by physical & geological set up of the terrain. The lava flows have no primary porosity. Only after weathering the cracks develop which allow ground water to store. However due to adverse morphological conditions, the availability of ground water is mainly restricted to plains & valley fill. The irrigation based on ground water is seen only in the parts of Dahanu, Talasari, Vasai, & Palghar Tahsils. The irrigation is mainly of horticultural crops. The coastal sandy aquifers are sufficiently good yielding, but even a marginal over exploitation causes intrusion of saline water. Figure No. 3.33: Ground Water Level Source: Groundwater Survey & Development Agency Sadekar Enviro Engineers Pvt. Ltd Chapter3-44

106 3.9 Traffic Study CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The purpose of this study is to assess the local transportation connectivity to the project site and to estimate the current traffic scenario for assessing whether the existing infrastructure viz. local road network &access ways in the project affected corridors are sufficient or not to bear with the additional vehicular mobility due to the proposed project & is also able to have access to infrastructures needed for the future developments & its functionality Objective The objective of the study is to review & study the present traffic pattern on the main access roads to the project site to estimate the traffic flow pattern on completion of the proposed project Methodology Generally traffic surveillance study involves one or other survey technique either by manual observation or automatic method by using instruments. The traffic survey methodology adopted for current study is Classified Traffic Volume Count Survey Method of Counting The counting of vehicles was achieved by following two methods: i) Manual Method : The survey by this method mainly involves visual counts by the survey team Equipments used 1) Garmin GPS Garmin e-trex 10 GPS was used to locate the pre decided observation points. 2) Measuring Tape A measuring tape was used to measure the road breadth. Sadekar Enviro Engineers Pvt. Ltd Chapter3-45

107 3) Nikon Digital Camera CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Nikon COOLPIX P510 Full HD digital camera with 42x optical zoom was used to record the traffic flow during peak hours. The camera was mounted on a tripod at a proper elevation & angle such that the whole square (and particularly one direction of inflow and outflow) of the traffic movement was recorded. The zoom was set in such a manner that all the vehicles were easily distinguished. 4) Nikon tripod A light & sturdy Nikon tripod was used to fix the digital camera at desired angle & elevation. The height was adjusted in such a manner that all the vehicles were easily distinguished Data Collection The transport roads for the proposed project have been identified; transportation of material carrying vehicles will mainly take place through NH 48 to Boisar and further Boisar- Tarapur MIDC road leading to project site. The important traffic junctions identified on the above road are i) Entrance to Tarapur MIDC from Boisar city ii) Major Junction in Tarapur MIDC Area (Boisar- Navapur Road) Table No.3.21: Traffic study observation locations Sr. No. Observation Point Code Observation Point Details 1 TS1 Entrance to Tarapur MIDC from Boisar city 2 TS2 Major Junction in Tarapur MIDC Area (Boisar- Navapur Road) Distance from project site (km) Sadekar Enviro Engineers Pvt. Ltd Chapter3-46

108 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Figure No.3.14: Observation locations Categorization of Traffic To establish effective vehicle count during the survey the traffic was categorized into Heavy Vehicles (Multi Axle Vehicles), Truck, Tempo, Bus, Car, Auto (Three Wheelers), Motorcycle (Bike) & Cycle. The results of vehicle count are converted into Passenger Car Units (PCU s) as per the equivalent PCUs prescribed by Indian Road Congress (IRC) guidelines. The equivalency factor for various types of vehicles is as given in the below table. Table No.3.22: Recommended PCU factors for various types of vehicles on urban roads Equivalent PCU s Type of Vehicle 5% 10% & above Two Wheelers, Motor Cycle or Scooter etc Passenger Car, Pick-up Van Sadekar Enviro Engineers Pvt. Ltd Chapter3-47

109 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Type of Vehicle Equivalent PCU s 5% 10% & above Auto-Rickshaw Light Commercial Vehicle Truck or Bus Agricultural Tractor Trailer Cycle Cycle Rickshaw Tonga (Horse drawn vehicle) Hand Cart Source IRC: Observation & Assessment A) Traffic scenario at Entrance to Tarapur MIDC from Boisar city The traffic flow pattern observed Entrance to Tarapur MIDC from Boisar city during morning& evening peak hours is as shown in the following figures. Traffic scenario during morning peak hours (8: 00 AM to 10: 00 AM) Percentage of vehicle count - (TS1) Entrance to Tarapur MIDC from Boisar (8 AM to 9 AM) Heavy Truck 9% Tempo 15% Motorcycle 26% Truck 16% Bus 5% Car 13% Auto 13% Cycle 3% Figure No.3.15: Percentage of vehicle count at study point (TS1) Tarapur MIDC from Boisar city during 8 AM to 9 AM Sadekar Enviro Engineers Pvt. Ltd Chapter3-48

110 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Percentage of vehicle count - (TS1) Entrance to Tarapur MIDC from Boisar (9 AM to 10 AM) Heavy Truck 5% Tempo 16% Motorcycle 15% Cycle 5% Truck 22% Bus 7% Car 19% Auto 11% Figure No.3.16: Percentage of vehicle count at study point (TS1) Tarapur MIDC from Boisar city during 9 AM to 10 AM Traffic scenario during evening peak hours (04: 00 PM to 06: 00 PM) Percentage of vehicle count - (TS1) Entrance to Tarapur MIDC from Boisar (4 PM to 5 PM) Heavy Truck 11% Tempo 9% Truck 15% Bus 2% Car 21% Motorcycle 26% Auto 13% Cycle 3% Figure No.3.17: Percentage of vehicle count at (TS1) during 04 PM to 05 PM Sadekar Enviro Engineers Pvt. Ltd Chapter3-49

111 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Percentage of vehicle count - (TS1) Entrance to Tarapur MIDC from Boisar (5 PM to 6 PM) Heavy Truck 9% Motorcycle 14% Cycle 3% Tempo 22% Auto 15% Truck 14% Bus 4% Car 19% Figure No.3.18: Percentage of vehicle count at (TS1) during 05 PM to 06 PM Table No 3.23 Summary of traffic in terms of PCUs observed at observation point (TS1) - (08: 00 to 10: 00 AM) & (04: 00 to 06:00 PM) Observation Time No. of PCUs Morning hours 08: 00 Am to 09: 00 AM : 00 AM to 10: 00 AM 2419 Average 2896 Evening hours 04: 00 PM to PM : 00 PM to PM 3871 Average 3463 Estimated Total PCUs per day Sadekar Enviro Engineers Pvt. Ltd Chapter3-50

112 Interpretation CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The maximum & minimum traffic passing through Boisar-Tarapur MIDC road during morning & evening peak hours is 3372 & 2419 PCUs & 3871& 3055 PCUs respectively. Total PCUs passing through the road during the study period were The average traffic during morning & evening peak hours is 2896 & 3463 PCUs respectively. B) Traffic scenario at Junction at Tarapur MIDC road- Navapur road The traffic flow pattern observed at Tarapur MIDC road- Navapur road Junction during morning & evening peak hours is as shown in the following figures. Traffic scenario during morning peak hours (08: 00 AM to 10: 00 AM) Percentage of vehicle count - (TS2) 8 AM to 9 AM Heavy Truck Tempo 7% 8% Motorcycle 8% Cycle 10% Truck 23% Auto 22% Bus 4% Car 18% Figure No.3.19: Percentage of vehicle count at (TS2) Junction on Tarapur MIDC road during 08 AM to 09 AM Sadekar Enviro Engineers Pvt. Ltd Chapter3-51

113 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Percentage of vehicle count - (TS2) 9 AM to 10 AM Heavy Truck Tempo 6% 9% Motorcycle 13% Cycle 7% Truck 20% Auto 17% Bus 3% Car 25% Figure No.3.20: Percentage of vehicle count at (TS2) Junction on Tarapur MIDC road during 09 AM to 10 AM Traffic scenario during evening peak hours (04: 00 PM to 06: 00 PM) Percentage of vehicle count - (TS2) 4 PM to 5 PM Heavy Truck 4% Motorcycle 17% Truck 21% Tempo 15% Bus 5% Car 17% Cycle 10% Auto 11% Figure No.3.21: Percentage of vehicle count at (TS2) Junction on Tarapur MIDC road during 04 PM to 05 PM Sadekar Enviro Engineers Pvt. Ltd Chapter3-52

114 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Percentage of vehicle count - (TS2) 5 PM to 6 PM Tempo 10% Heavy Truck 4% Truck 15% Motorcycle 20% Cycle 9% Bus 3% Car 20% Auto 19% Figure No.3.22: Percentage of vehicle count at (TS2) Junction on Tarapur MIDC road during PM to PM Table No. 3.24: Summary of traffic in terms of PCUs observed at observation point (TS2) - ) Junction on Tarapur MIDC road during (08: 00 to 10: 00 AM) & (04: 00 to 06:00 PM) Observation Time No. of PCUs Morning hours 08: 00 Am to 09: 00 AM : 00 AM to 10: 00 AM 1869 Average 2413 Evening hours 04: 00 PM to 05 PM : 00 PM to 06 PM 2454 Average 2214 Estimated Total PCUs per day 9255 Interpretation Sadekar Enviro Engineers Pvt. Ltd Chapter3-53

115 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The maximum & minimum traffic passing through Junction at Tarapur MIDC road- Navapur road junction during morning & evening peak hours is 2957 & 1869 PCUs & 2454 & 1973 PCUs respectively. The average traffic during morning & evening peak hours is 2413 & 2214 PCUs respectively Increased traffic scenario due to proposed project The transportation of raw materials & finished goods from the existing unit in operation and the proposed production enhancement activity will be mainly done by trucks/tempos & it is envisaged that 03 trucks/tempos will make to and fro trip and 6 auto rikshaws, 2 cars and 13 motorcycles will be used after expansion. Proposed project will involved transportation of materials and personnel s. During operational phase traffic condition will be controlled by doing proper traffic management As described in the above section the transportation activity will mainly take place from NH 48 to Boisar city and then Road from which further access to MIDC. The exit from MIDC area will be done from same road. As an initiative for efficient traffic management the project proponent will ensure that transportation activity will be done mainly after 10 AM avoiding the morning peak hour traffic. Due to the proposed project the increase in traffic would be 17.95~ 18 PCUs. Table No. 3.25: Summary of increased traffic in terms of PCUs due to proposed project (TS1) Boisar- Tarapur road during (08: 00 to 10: 00 AM) Average PCUs per hour (08: 00 to 10: 00 AM) 2896 PCUs scenario after considering the increase in traffic due to proposed project 2914 Increase in PCUsper hour due to proposed project 18 Table No. 3.26: Summary of increased traffic in terms of PCUs due to proposed project (T2) at Tarapur MIDC- Navapur road junction (08: 00 to 10: 00 AM) Sadekar Enviro Engineers Pvt. Ltd Chapter3-54

116 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Average PCUs per hour (08: 00 to 10: 00 AM) 2413 PCUs scenario after considering the increase in traffic due to proposed project 2431 Increase in PCUs per hour due to proposed project 18 Table No. 3.27: Summary of increased traffic in terms of PCUs due to proposed project (TS1) Boisar- Tarapur road during (04: 00 to 06: 00 PM) Average PCUs per hour (04: 00 to 06: 00 PM) 3463 PCUs scenario after considering the increase in traffic due to proposed project 3481 Increase in PCUsper hour due to proposed project 18 Table No. 3.28: Summary of increased traffic in terms of PCUs due to proposed project (T2) at Tarapur MIDC- Navapur road junction (04: 00 to 06: 00 PM) Average PCUs per hour (04: 00 to 06: 00 PM) 2214 PCUs scenario after considering the increase in traffic due to proposed project 2232 Increase in PCUs per hour due to proposed project 18 Sadekar Enviro Engineers Pvt. Ltd Chapter3-55

117 3.10 Land use - Land cover study CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The prevailing Land Use & Land Cover (LULC) pattern in the 10 km radial study area are assessed based on remote sensing technique using satellite imagery. The interpretation of satellite image was done in succession stages as described below: i) Visual Interpretation: The land use/ land cover classes were established by processing the satellite imagery by using IDRISI SELVA image processing software to obtain various land use land cover classless & analyzing the resultant output based on image characteristics/elements such as Color, Tone, Texture, Pattern, Size, Shape, Association etc. ii) Ground Truth Survey Ground truth verification of the doubtful elements/classes encountered during the visual analysis & interpretations were confirmed by deploying ground truth survey & the findings of the same were incorporated during finalizing the LULC map of the study area. The LULC map of the study area is shown in the following figure Prevailing LULC in the study area Sadekar Enviro Engineers Pvt. Ltd Chapter3-56

118 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Fig No 3.23: Land Use Land Cover Map of the Study Area Observation & Assessment of Land use & Land Cover Land Use Based on the image analysis land use/ land cover classes in the study area can be categorized as presented in Table Table No. 3.29: Prevailing land use & land cover classes in study area Sr. No. Level - I Land Use Classes Level - II Classification Area in Sq.km. Sadekar Enviro Engineers Pvt. Ltd Chapter3-57

119 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Classification 1 Built up Habitation/Settlement & Developmental Setups (Roads, Educational Institutes, Offices etc.) Industrial Area Agricultural land Crop land, Cultivations Fallow land Temporary & permanent land Salt pans Mining Stone quarries Artificial water Surface Water Tanks/Ponds/Reservoir 0.21 reservoirs Land Cover Classes 1 Barren land Barren areas, open rocky land without scrub, desert 1.85 patches near shore 2 Water bodies Rivers/Creeks/Streams & Sea Vegetation Terrestrial: Trees planted along the road, gardens, industrial green belt, naturally occurring vegetation, scrub Mangrove vegetation Wetlands Mudflats, Water logged area, Rocky submerged patches Total Sadekar Enviro Engineers Pvt. Ltd Chapter3-58

120 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Fig No 3.24: Percentage wise Land Use classification of the study area Land use interpretation The study area prevailed 6 types of land use classes off which Agricultural land was the major land use type with 62% followed by Built up 28%, Fallow land 5%, & Salt pans 4% Land Cover Sadekar Enviro Engineers Pvt. Ltd Chapter3-59

121 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Fig No 3.25: Percentage wise Land Cover classification of the study area The study area prevailed 4 types of land cover classes off which Vegetation was the predominant class with 55% followed by Water bodies 32%, Wetlands 12% & Barren land 1% Drainage Pattern of the Study Area The drainage pattern of the study area has been determined by using remote sensing technique. Satellite imagery has been processed by using IDRISI SELVA software to obtain drainage pattern map of the study area Assessment of drainage pattern in study area The south westerly running hills & hillocks along the Gundale, Padghe & Devkhope villages are the prominent features in the study area along with undulating terrain in East. Sadekar Enviro Engineers Pvt. Ltd Chapter3-60

122 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The presence of hills & hillocks in the study area has effected in large number of lineaments & fractures thus resulting in dendritic type of drainage pattern, also the westerly meandering Banganga & Jununa River forms the prominent features of the surface drain in the study area as depicted in the following drainage map of the study area. Fig No 3.26: Map depicting Drainage Pattern of the study area Sadekar Enviro Engineers Pvt. Ltd Chapter3-61

123 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT 3.11 Prevailing Ecology of the Study Area Figure 3.27: Google Earth Imagery depicting 10 km radial study area Sadekar Enviro Engineers Pvt. Ltd Chapter3-62

124 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Ecology in essence is the study of interaction of living and non-living components, interaction of community and the environment and exchange of material (energy and nutrient) between living and non-living parts. The ecological study has been conducted to establish the prevailing baseline ecological data in terms of terrestrial biodiversity status in the project influenced area in order to identify, quantify the impacts associated with the proposed project on the prevailing ecology & to advocate suitable mitigation measures for the same Study Area The study area was 10 km radial distance from the project site considering inner 5 km radial distance as core area & outer 10 km radial distance as the buffer study area. To assess the implications of the proposed project on the surrounding ecology within study area following attributes were considered & executed: Identification of important/potential habitats in the study area Identification of mass feeding/breeding grounds for fauna Identification of important migratory routes used by fauna Comprehensive floral & faunal inventory in the identified potential habitats Status evaluation of flora & fauna as per International Union for Conservation of Nature (IUCN) for flora & fauna & as per Indian Wildlife Protection Act, 1972 & Amendments (IWPA) for fauna to address the conservation aspects if any in the study area To assess the impacts of project related activities on the surrounding ecology within study area & to advocate suitable mitigation measures Primary Baseline Data Sadekar Enviro Engineers Pvt. Ltd Chapter3-63

125 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The primary baseline data collection period was March - May 2016, however to ensure the representativeness of biotic data during other seasons viz. post monsoon & pre monsoon seasons (seasonality of data), published secondary data for the study area was resorted Prominent features of the prevailing terrestrial ecosystem in the study area The study area viz. Tarapur MIDC & surrounding 10 km radial study area comes under the Palghar District. The 10 km radial study area is a part of the coastal plains on the west coast of India. The inner 5 km (core) radial study area was subjected to multiple land use forms such as industrial area, human habitations with associated commercial establishments, small scale salt panning activities & subsistence farming. The outer 5 km (buffer) radial is moreover a scrubland with somewhat prominent vegetation along the hillocks at Gundale, Padghe & Devkhope villages. The observed vegetation stature in and around these hillocks was of semi evergreen deciduous forest formations. The remaining major part of the study area is characterized by natural presence of uneven sporadic patches of scrub, gregarious vegetation & clusters of trees. Also in and around the human inhabited pockets in the study area, by virtue of plantations & green developmental activities, orchards & avenue plantations etc. were seen Prominent features of the prevailing aquatic ecosystem in the study area The prominent aquatic/wetland ecosystem in the study area is represented by the estuarine environment prevailing along the creek lets near Murbe, Ucheli & Satpati villages which prevailed mangrove strands & associated mudflats. Note: Since any of the project related activities during commissioning & operation phase were not associated with the prevailing surface water bodies in the study area in terms of withdrawal or disposal/discharge hence no impact is envisaged on the water bodies so the studies pertaining to aquatic ecology such as Plankton, Chlorophyll, Benthos & Ichtyofauna have been kept out the purview of this study. Sadekar Enviro Engineers Pvt. Ltd Chapter3-64

126 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Identification of important/potential habitats, mass feeding/breeding grounds, migratory routes used by fauna in the study area Following important/potential habitats were identified in the study area: i) Prominent vegetation existing along the hillocks at Gundale, Padghe & Devkhope villages. ii) Mangrove vegetation & associated wetlands along the creek lets near Murbe, Ucheli & Satpati villages Floral diversity & status in the study area As discussed earlier, the floral diversity in the study area is mainly represented by the prominent vegetation along the Gundale, Padghe & Devkhope hillocks, avenue plantations along the roads, green belt developmental activities in the industrial area, intermittent patches of scrub along the entire expansion of the study area & mangroves along the creeklets. The comprehensive floral inventory along with habit form & IUCN assessment is depicted in the Table No. 1 of Annexure Status evaluation of flora To identify any floral species of conservation importance existing in the study area, the status evaluation of the observed flora has been done as per the IUCN (International Union for Conservation of Nature and Natural Resources) assessment. Off the observed 98 species in the study area 76 species were not assessed indicating them to be extremely common in abundance & distribution, 13 species were assessed as Least Concern ver 3.1, 2 species were assessed as Lower Risk/least concern ver 2.3, 2 species as Data Deficient ver 2.3 & Data Deficient ver 3.1 respectively, 1 species as Vulnerable B1+2ac ver 2.3 & since 3 genera could not be identified up to species level & 1 species being not in IUCN database there assessment could not be established Faunal diversity & status in the study area Sadekar Enviro Engineers Pvt. Ltd Chapter3-65

127 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT The field survey for primary baseline data collection resulted in recording 20 avifaunal species belonging to aquatic & terrestrial habitat dwelling, 3 mammalian species & 2 reptilian species. The detailed faunal inventory is given in Table No. 2 & Table No. 3 of the Annexure Status evaluation of fauna To identify any faunal species of conservation importance existing in the study area, the status evaluation of the observed fauna & as recorded in the secondary data has been done as per the IWPA 1972 (Indian Wildlife Protection Act) & amendments & as per the IUCN. Off the observed 20 species of birds 11 are listed as Schedule - IV, 1 as Schedule - V & 8 species were not listed in the Schedule indicating theme to be extremely common in abundance & distribution also the IUCN assessment for 19 species is as Least Concern ver 3.1 & 1 species as Not Assessed. Off the observed 3 mammalian species one being common pig & one being stray dog their assessment could not be established, however the IUCN assessment of Indian Palm Squirrel is as Least Concern ver 3.1 & amongst the two observed reptilian species 1 is assessed as Least Concern ver 3.1. None of the observed faunal species are listed in any of the Schedule in the IWPA Secondary data There is tremendous paucity of the documented literature for the region (study area) in consideration; hence the only source of secondary data available was the interactions held with the locals during the EB study. Reference I - Interactions held with the locals during EB study Interactions with locals were held to know the presence/activity of any other wild fauna all year around. The interactions revealed that locals were largely unaware of presence of any wild animals. However locals had occasional sightings of some mammal in the study area, on Sadekar Enviro Engineers Pvt. Ltd Chapter3-66

128 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT the basis of description provided by them the presence of 1 species of mammals could be concluded as given in Table No. 4 of the Annexure 3.1. The IUCN assessment of the mammalian species is Least Concern ver 3.1 & is listed as Schedule - II species as per the IWPA Interpretation of primary & secondary data The field visits resulted in recording 98 plant species that included 57 trees, 7 shrubs, 24 herbs & 10 climbers. Apart from the somewhat exotic & ornamental plants observed in the green belts (plantations along the roads & human settlements) the majority of the vegetation observed in the potential habitat (Gudale, Padhge & Devkhope hillocks) in the study area was of native deciduous type. Also 7 crop species were observed in the study area off which 3 were fruit varieties, 3 were vegetable varieties which were cultivated on commercial basis & 1 food grain variety (rice) which was mainly cultivated for subsistence farming. The 26 species of avifauna recorded during the field visits are commonest resident species for the region in consideration. The habitat preference of the recorded avifauna was to be open wooded county - light scrub jungle. Apart from birds the other faunal sightings were of Indian Palm Squirrel, Stay dog, Common pig & 2 reptilian species. The IUCN status evaluation of the observed floral & faunal species revealed that none of the floral species belongs to categories of concerns such as Near Threatened (NT), Vulnerable (VU), Endangered (EN), Critically Endangered (CR) & Extent in the wild (EW) defined by the IUCN. Also none of the faunal species belonged to the Schedule - I of the IWPA, hence conservation related aspects for the prevailing flora & fauna are not anticipated Applicability of forest & wildlife related clearances The proposed production capacity enhancement project of Galaxy Surfactants Ltd. is a brown field project which will be executed within the existing factory premises at Plot No. G - 59, Sadekar Enviro Engineers Pvt. Ltd Chapter3-67

129 CHAPTER NO- 3: DESCRIPTION OF ENVIRONMENT Tarapur MIDC, Boisar, Palghar, Dist. - Palghar. Now since the proposed project activity does not envisage any new land acquisition, hence any sort of habitat loss will not occur. Also project being located in Notified Tarapur MIDC exclusively meant for industrial developmental activities does not attract any sort of Forest Clearance. Any of the Ecologically Sensitive Areas such as National Parks, Sanctuaries, Biosphere Reserves, Mass feeding/breeding grounds & migratory routes of fauna does not exist in the study area also the observed & recorded faunal species in the study area are not listed in Schedule - I of IWPA 1972 hence conservation related aspects are not applicable. Sadekar Enviro Engineers Pvt. Ltd Chapter3-68

130 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES This chapter deals with the environmental impacts due to various activities carried out at the project site, which could affect the various biotic and abiotic factors of the surrounding environment and suggesting mitigative measures to minimize the impact as far as possible. For understanding the impact and its severity on the environment it becomes necessary to identify all the probable sources of pollutants, type of releases and characteristics of the pollutants, quantification of the pollutants. Accordingly, Pollution Control Equipments and mitigation measures are suggested to minimize the impacts of the project activity on the environment. 4.1 Air Environment Construction Phase: Identification of Source The proposed expansion project will be achieved by adding manufacturing plant and supporting utilities and infrastructure within its existing premises. The ground built up area will be increased by 4223 sq. m. whereas the total built-up area will be 7681 sq. m. Demolition of the existing ETP will be done which may result in dust emissions, ETP comprises only of primary treatment. No other demolition work will be done for the proposed project. During these construction activities like demolitions, site clearances, wind erosion, stockpiling, heavy machinery activities & material handling dust emissions are expected to be the major sources of air pollution. SO 2 & NO x will be emitted from the diesel powered heavy machineries and equipment. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-1

131 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Predicted Impact Dust emissions generally differ from day to day, depending on the level of activity, the specific operation and the prevailing meteorological conditions. Therefore for predicting the quantitative value of TSPM that would be generated due to the construction activity an emission factor from AP-42 Section (U.S.EPA,1995) has been used. The emission factor is E = 1.2 tons/acre/month of activity. The mentioned value is most applicable to construction operations with a) medium activity level, b) moderate silt contents and 3) semi-arid climate. The Total plot area of the project is sq. m. The construction work will be carried out only in that part which is allotted for built up purpose i.e., 4223 sq. m. The construction activity will not take place simultaneously on the entire allotted plot. Also, the construction activity is assumed to be carried out for all 30 days of the month (24 Hours). Hence, the estimated value will be conservatively high for TSPM for worst case scenario. The emission would be around tons/month of the activity. But the emission would be reduced to around 90 to 95 % as control measures will be adopted. There would be around 100 temporary workers appointed for construction activity who may be affected by the dust pollution. Workers getting exposed to the dust generated due to the construction activity can suffer from respiratory problems, and prolonged exposure to dusty environment can lead to malfunctioning of lungs. The TPM concentration will increase during the construction phase however it can be controlled to a greater extent by implementing mitigative measures Mitigation Measures Control measures like temporary wind barrier, proper traffic management during loading and unloading of the construction materials, regular sprinkling of water on the working site, Avoiding Cement dust emission, Managing stockpiles (sand, gravel) by using water sprays (when emptying cement bags into mixer) will be implemented to ensure minimum dust generation. It is anticipated that the existing paved roads will be utilized for transportation of Sadekar Enviro Engineers Pvt. Ltd Chapter 4-2

132 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES construction materials hence dust generation at the project site due to haulage within the project site shall be minimal Operational phase: Identification of Sources The company presently has two stacks attached to a 6 lakh Kcal/Hr thermic fluid heater and spray drier of 25 meters height (f.g.l) each, whereas one stack of height 15 meters (f.g.l) is attached to D.G set of 250 KVA capacity. An additional common stack of height 39 meters (f.g.l) will be provided for thermic fluid heater of 8 lakh Kcal/Hr capacity and 3.5 MT/Hr steam boiler is proposed & an additional stack D.G Set of 800 KVA is proposed. These sources are said to be point sources of air emissions for the expansion project. The Thermic fluid heater and boiler are F.O fired whereas the D.G sets are HSD fired. The D.G Sets are operative only during power failure are not continually operating, thus they are not considered for air dispersion studies. Gases generated from manufacturing processes mainly SO2 and acid mists will be subjected to three water scrubbers and two alkali scrubbers in series. An additional vent scrubber will be provided to scrub the process emissions. There will be two stacks for scrubbers of height 12 m each. One of the major sources of fugitive emission generation can be due to the handling and storage activity of the solvents, raw materials from the raw material storage area of the company premises. The sources of VOC emissions from the project would be from the storage area due to handling & operating the solvent drums, manufacturing plant area from the activity like addition & recovery of the solvent. The vehicle used for transporting the raw materials & finished products also contributes to the dust generation & emissions of gases like SO2 and NOx due to fossil fuel burning escaping from the combustion chamber. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-3

133 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Prediction of Impacts For the quantitative impact analysis on the air quality due to the expansion project, air dispersion modeling is performed. The criteria pollutants like PM 10, PM 2.5, SO 2, NOx & CO generated from operation of steam boiler & two thermopacks were considered for air modeling. D.G set is not considered for impact prediction as it will be used only during the power failure. Aermod 8.2 developed by USEPA and authorized by CPCB is used for air modeling simulation which is based on the steady state Gaussian plume equation Model Options Used for Computation The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of the mixing layer; Stack tip down-wash is not considered; Point Source Modeling is considered; Calms processing routine is used by default; Wind profile exponents is used by default; Flat terrain is used for computations; It is assumed that the pollutants do not undergo any physico-chemical transformation and that there is no pollutant removal by dry deposition; Washout by rain is not considered; and Cartesian co-ordinate system has been used for computations. Uniform polar receptor grid is used. The grid consists of 180 receptors each assumed to be at ground level Modeling Procedure The prediction of the Ground Level Concentrations (GLC s) due to activity has been computed by AERMOD version 8.2 as per CPCB guidelines. While performing the model the rural dispersion and regulatory defaults options were selected as per guidelines on air quality models (PROBES/70/ ). Sadekar Enviro Engineers Pvt. Ltd Chapter 4-4

134 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Meteorological Data Processing The surface synoptic meteorological data of Thane District for the year were obtained from the Indian Meteorological Department, Mumbai. The meteorological observation station of IMD for Thane District is located at Dahanu (Station Index: 43001, anemometer height of 10 m). The quality assurance process was undertaken as required by the EPA (EPA- 454/R ) to identify and fill the missing data for preparation of hourly surface meteorological data. The surface and profile met data were prepared for use in AERMOD using the AERMET meteorological data preprocessor of Lakes Environmental. Processing the surface file indicated more than 90 % data availability. Onsite meteorological data collected for three months were used to process the AERMET file and not the upper air meteorological data. Meteorological inputs required are hourly wind speed and direction, ambient temperature, pressure, precipitation, cloud cover, stability class and mixing height. The atmospheric inversion level at Thane for 12 hours from 7:00 hour to 7:00 hour is represented in the below table No 4.1. The data has been compiled from IMD manual. Table 4.1: Atmospheric inversion level at Tarapur, Palghar, Maharashtra. Sr. Time Mixing height, m 1 7: : : : : : : : : : : : : Source: (Hourly Mixing Height &Assimilative capacity of Atmosphere in India) by IMD Sadekar Enviro Engineers Pvt. Ltd Chapter 4-5

135 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Model Input Data The emission factor used in the air dispersion modeling for estimating the pollutants from the boiler & thermic fluid heater operation is calculated using the document (EPA) AP-42 chapter no. 1 External Combustion Sources, Section 1.3 for Fuel Oil Combustion. The table no. 4.2 represent the input data required for describing the sources in the model. Table No. 4.2: Model Input Parameters for 6 Lakh Thermic Fluid Heater Stack. Sr. No Parameters Values 1 Source 6 lakh Kcal/Hr. 2 Fuel Used Furnace Oil 3 Base Elevation (m) 7 m 4 Stack Height (m) 25 m 5 Stack exist velocity of gas (m/s) 6.72 m/sec. 6 Exit Temp O C 192 O C 7 Stack inside diameter (m) 0.45 m 8 Gas quantity m 3 /sec 0.67 m 3 /sec. 9 Emission Factors g/s PM g/s PM g/s SO g/s NOx g/s CO g/s Table No. 4.3: Model Input Parameters for Boiler & Thermic Fluid Heater Stack Modeling Sr. No Parameters Values 1 Source 8 lakh Kcal/Hr and 3.5 MT/Hr 2 Fuel Used Furnace Oil 3 Base Elevation (m) 7 m 4 Stack Height (m) 39 m 5 Stack exist velocity of gas (m/s) m/sec. 6 Exit Temp O C 180 O C 7 Stack inside diameter (m) 0.6 m 8 Gas quantity m 3 /sec 1.25m 3 /sec. 9 Emission Factors g/s PM g/s PM g/s SO g/s NOx g/s CO g/s Sadekar Enviro Engineers Pvt. Ltd Chapter 4-6

136 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES The total workers in the factory premises will be around 177 Nos. who may be affected due to the unscientific operation of boiler & thermic fluid heater. Mostly the health effects associated with particulate matter are respiratory, pulmonary injury, lung cancer etc. Exposure to SO 2 and NOx also lead to respiratory problems. Carbon monoxide decreases the oxygen carrying capacity of blood by reducing the hemoglobin. Since the company is handling some highly volatile solvents the VOC emission can have an adverse affect on the workers health if present in higher concentration. The health effects related to VOC emission are eye, nose and throat irritation headaches, loss of coordination and nausea, damage to liver, kidney and central nervous system etc. The air emissions in long course of time may affect the immediate surrounding vegetation stature physically (leaf senescence, hampered growth etc.) & biologically thus may affect the overall surrounding ecology. The incremental values at various monitoring stations were predicted and integrated with the baseline value for PM 10, PM 2.5, SO 2, NOx & CO is tabulated in the below table no 4.3. The output image of the dispersion modeling describing the incremental predictive values for the selected pollutants is attached as Annexure : 4.1 Sadekar Enviro Engineers Pvt. Ltd Chapter 4-7

137 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Table No. 4.3: Interpretation of the Incremental Values BV: Baseline Value IV: Incremental Value RV: Resultant Value. Sr. No. Sampling Location Code & Name Premises of Galaxy Surfactants Ltd. Pam 1 *A1 2 A2 PM 10 (μg/m 3 ) PM 2.5 (μg/m 3 ) SO 2 (μg/m 3 ) NO X (μg/m 3 ) CO (μg/m 3 ) BV IV RV BV IV RV BV IV RV BV IV RV BV IV RV Tembhi 3 A3 Pasthal A4 Murbe A5 Boisar A6 Shirgaon A7 Umroli Maan 8 A Village NAAQS Standards 100 (24hrouly) 60 (24hrouly) 80 (24hrouly) 80 (24hrouly) 4000 (1 hourly) Sadekar Enviro Engineers Pvt. Ltd Chapter 4-8

138 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Interpretation The incremental value of the specific pollutant at the particular monitoring station is added to the baseline value of that specific pollutant measured during the monitoring period of the project. The resultant value thus calculated used for predicting the impacts of the expansion project on the air environment in the study area. In the study area there is a highly sensitive receptor i.e. mangroves & associated mudflats all along the banks of Surya river. The nearest distance at which the mangrove is located to the project site is 5 km. The predominant wind direction is towards northwest direction as per micro metrological data. The location of the mangroves is towards eastern side Mitigation Measures The prominent pollutants like PM 10, PM 2.5, SO 2,NOx & CO will be generated due to the fuel combustion for operation of units like Boiler, Thermic Fluid Heater & D.G Set. The mitigation measure that will be adopted is providing an appropriate stack height for dispersion of pollutants. The stack height calculation is shown below, Sadekar Enviro Engineers Pvt. Ltd Chapter 4-9

139 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Stack Height Calculation for existing stack of Thermic Fluid Heater ( 6 Lakh Kcal/Hr) H=14(Q) 0.3 Where, H= Stack height Q= Emission rate for SO 2 (Kg/hr) Now, FO consumption = 77.7 lit/hr. Total FO consumption = 77.7 l/hr. = 70 kg/hr. The Sulphur content of FO is 4.5% Hence 70 kg of FO will contain 3.15 kg of Sulphur Now stoichiometric conversion of Sulphur to SO 2 = 3.15 * 2 = 6.3 H = 14*(6.3) 0.3 = 14 x 1.73 = m (Reference CPCB Guidelines) Sadekar Enviro Engineers Pvt. Ltd Chapter 4-10

140 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Stack Height Calculation for proposed stack of 8 lakh Kcal/Hr Thermic Fluid Heater and 3.5 MT/Hr Boiler. H=14(Q) 0.3 Where, H= Stack height Q= Emission rate for SO 2 (Kg/hr) Now, FO consumption = lit/hr. Total FO consumption = l/hr. = 310 kg/hr. The Sulphur content of FO is 4.5% Hence 310 kg of FO will contain kg of Sulphur Now stoichiometric conversion of Sulphur to SO 2 = 13.95* 2 = 27.9 H = 14*(27.9) 0.3 = 14 x 2.71 = m (Reference CPCB Guidelines) Sadekar Enviro Engineers Pvt. Ltd Chapter 4-11

141 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Stack Height Calculation for D.G Set H= h+0.2 X Sq. Root of kva Where, H= Height of stack from ground in meter h= Height of the building in meter H= h +0.2X kva = X 250 = x = 7.16 meter from ground level (Reference CPCB Guidelines) Stack Height Calculation for D.G Set H= h+0.2 X Sq. Root of kva Where, H= Height of stack from ground in meter h= Height of the building in meter H= h +0.2X kva = X 800 = x = = 9.65 meter from ground level (Reference CPCB Guidelines) Sadekar Enviro Engineers Pvt. Ltd Chapter 4-12

142 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES As per the CPCB guideline the stack height required for Thermic Fluid Heater is m and for the proposed Thermic Fluid Heater and Steam Boiler required stack height is m. For D.G sets of capacities 250 KVA and 800 KVA the stack height is 7.16 m and 9.65 m. The company has an existing stack of 25 m for the existing stack, however for the proposed stack the height will be 39 metres for Thermic Fluid Heater and steam boiler. The stack heights are sufficient for dispersion of the pollutants as per the CPCB guidelines. For dealing with the process emissions from the manufacturing process 3 water scrubbers and 2 alkali scrubbers in series and an additional vent scrubber will be installed. Packed bed scrubbers are installed. The alkali scrubbers are sufficient to mitigate the emissions due to proposed production enhancement activity. Certain measures can be established to reduce the VOC emission in the plant premises like design changes, operation and maintenance controls as leak prevention etc. Control measures for dust emission control. The following measures will be adopted for controlling the dust emission. Fig No. 4.1: Scrubber Design The roads within the premises shall be sprinkled with water at a regular interval to avoid the dust generation. To be ensured that all transportation vehicles carry a valid PUC (Pollution under Control) Certificate. Proper servicing & maintenance of vehicles is being carried out. Adequate green belt >33% of total open area shall be developed in the project plot. Green belt act as surface for settling of dust particle and thus will reduce the particulate matter in air. Ambient air quality shall be regularly monitored to ensure the air pollution devices are working efficiently. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-13

143 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES From the above, it can be concluded that after the operation of the project and implementation of mitigation measures in an appropriate manner, the Ambient Air Quality will not exceed NAAQ Standards. 4.2 Water Environment Construction phase Probable Sources: Construction runoff and drainage including dewatering operations: Potentials sources would be wash water from dust suppression sprays, wheel washing facilities, runoff and erosion from the site surfaces & stockpiles and fuel oil & lubricants from the maintenance of construction vehicles and equipments. Runoff from general construction activities: The construction activity like foundation lying & concrete mixing etc, involve high amount of water consumption. The source of water supply would be from water tankers. The runoff can be caused due to the improper handling of the construction equipment. Sewage effluents generated from the construction workforce: Around 200 numbers of temporary workers will be engaged for the construction activity. According to the NBC (National Building Code of India) 45 lit/d/person is considered for domestic water consumption i.e. 9 CMD. Sewage effluent will be generated by the on-site construction workforce these have the potential to cause water pollution if not controlled. The existing facilities of sewerage system of the industries will be utilized by the temporary workers Impact predicted The site has a nalla flowing through the plot area which may get affected due to the runoff from construction area which may result in increased loads of suspended solids (SS) and other related Sadekar Enviro Engineers Pvt. Ltd Chapter 4-14

144 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES parameters. The construction runoff and debris may settle in the nalla and affect the flow of the nalla. The analysis of the nalla show effluent releases in the nalla characterizing of high COD values with a typical solvent odour, before passing through the industry premises. The analysis resuts are given in Chapter- 3. Untreated sewage if enters the nalla during the construction phase may affect the water quality and characteristics. The sewage wastewater is characterized by high level of biochemical oxygen demand, ammonia & E-coli counts. Therefore release of such runoffs to the water bodies will have a significant negative impact on the water quality. Since the water requirement during construction phase will be extremely minimal & construction activity being project plot specific does not involve release/discharge of water outside the plant premises Proposed Mitigation It is important that appropriate measures are implemented to control the runoff & drainage water from entering the nearby water courses. Construction runoff and drainage: The flow of the nalla will be entirely sent through hume pipes of surplus capacity considering the peak flow during the monsoon season covered by hume pipes.the runoff during the construction phase will be connected to the existing storm water drain to the MIDC drains and will not be let into the nalla, it is highly recommended to arrange for temporary drainage pipes & culverts of adequate capacity for controlled release of storm flows from the site. Proper site management is essential to minimize the surface water runoff & soil erosion. Sewage effluents generated from the construction workforce: The existing sewer facility will be utilized by the temporary construction workforce. The domestic wastewater generated will be treated in septic tank followed by soak pit. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-15

145 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Operational Phase Probable Source During the project in operational phase, wastewater generation will be through multiple sources such as manufacturing process, scrubbers, domestic activities & utilities. The water supply demand will be met through Tarapur MIDC water supply. The effluent generated will be segregated into three broad streams i.e. effluent stream from utilities will be treated separately in R.O. plant and effluent stream from the manufacturing process from reactor/product washing and domestic activity will be treated in ETP. The stream constituting of quaternary ammonium compounds will be treated separately as quaternary ammonium compounds may affect the degradability of the ETP. The existing & total water balance for the project is depicted in Table No. 4.9 & 4.10 respectively. Table No. 4.9: Existing Water Balance Components Consumption (As per consent) Actual Consumption Losses (CMD) Effluent (CMD) Domestic Domestic Industrial Process Boiler (TFH is used for heating the reactors) Cooling tower Garden Total The consented quantity for sewage discharge is 5.5 m 3 /Day. The consented quantity for industrial effluent is 15 m 3 /Day. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-16

146 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Table No. 4.10: Total Water Balance Effluent Components Consumption Recycle Loss Domestic Effluent Domestic Process Water Cooling Tower Boiler Gardening Total Effluent Streams After expansion the total effluent generated would be 20.2 CMD and 7.6 CMD for the project. 1. Streams from utilities constituting of dissolved solids of 61 CMD from Boiler and cooling Tower 27 CMD and 34 CMD respectively having 0.12 % TDS will be subjected to a two stage R.O treatment. Considering a ratio of 4:1 for permeate water: reject water approx. 49 CMD of permeate will be recovered for cooling tower make-up and 12 CMD will be reject water which will be sent to MEE followed by ATFD. 2. Process Stream: The streams from effluent ie 71 CMD will be treated in ETP, stream comprising of quaternary ammonium compounds approx. 4 CMD will be passed through clay/carbon filter for removal of quarternary ammonium compounds, before entering into the ETP. About 71 CMD of effluent will be treated in the ETP where domestic effluent of 7.3CMD will be connected to Aeration tank of ETP, followed by R.O out of which 3 % will be process loss in ETP. The R.O permeate will be approximately 61 CMD and 15.24CMD will be R.O reject which will be sent to MEE followed by ATFD CMD R.O Reject from utilities and CMD R.O Reject from process resulting in total capacity of CMD will be sent to MEE with ATFD CMD effluent will be sent to MEE out of which MEE condensate will be CMD. 4. The treated effluent will entirely be used for cooling tower make-up. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-17

147 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Reuse and Recycle of treated waste water The boiler condensate would be recovered to the extent of 30 % i.e. 25 CMD. The condensate water will be recycled for Boiler Make up water. Out of the CMD treated effluent around CMD will be reused in plant operations like feed water for cooling tower or gardening. After the maximum recycle and reuse of treated wastewater the overall water consumption will reduce to = CMD. Around 73.8% water reduction is observed in dry season. During the wet season 20 KL of fresh water from rain water harvesting tank will be reuse for Cooling tower makeup. During wet season, by recycling the condensate from boiler & utilization of harvested rain water & reuse of treated wastewater, the total fresh water requirement from MIDC will get reduced by 69 % in the wet season. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-18

148 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Tarapur MIDC Domestic: 9.5 CMD Loss: 1.9 CMD Effluent : 7.6 CMD Raw Water CMD Process: 145 CMD Loss: 74 CMD Quats containing streams 4 CMD. Industrial Effluent: 71 Evaporation Loss: 25 CMD CMD to ETP Boiler: 84 CMD Blow down: 34 CMD & Condensate: 25 CMD Condensate Reuse: 25 CMD CMD to ETP followed by R.O CMD to R.O. C.T. : 266 CMD Recycled : CMD Garden: 18.0 CMD Loss: 239 CMD Losses : 18.0 CMD Blow Down. : 27 CMD R.O Reject CMD to MEE Figure No.4.2: Proposed water balance for Dry Season MEE Condensate: CMD Sadekar Enviro Engineers Pvt. Ltd Chapter 4-19

149 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Tarapur Loss: 1.9 CMD MIDC Domestic: 9.5 CMD Effluent : 7.6 CMD Raw Water CMD Process: 145 CMD Loss: 74 CMD Quats containing streams 4 CMD. Industrial Effluent: 71 Evaporation Loss: 25 CMD CMD to ETP RHW : 20 CMD Boiler: 84 CMD Blow down: 34 CMD & Condensate: 25 CMD Condensate Reuse: 25 CMD CMD to ETP followed by R.O CMD to R.O. C.T. : 266 CMD Recycled : CMD Garden: Nil Loss: 239 CMD Losses : Nil Blow Down. : 27 CMD R.O Reject CMD to MEE Figure No.4.3: Proposed water balance for Wet Season MEE Condensate: CMD Sadekar Enviro Engineers Pvt. Ltd Chapter 4-20

150 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Impact predicted There will no effluent releases in the nalla, The project is projected as a Zero Liquid Discharge unit. The effluent will be treated and entirely reused and recycled. There will be no effluent discharges outside the site. If untreated effluent is passed through the nalla. Also, if untreated waste water is by passed to the drains it may lead to permanent damage to the water characteristics and the residing flora and fauna. The effluent may percolate and damage the ground water table results in the contamination or polluting the water body at final discharge point. The nalla flows through fields on its path and if this stream is used as a water source it will severely affect the soil quality and may result leaching of the soil. The prolonged unscientific discharge of the untreated waste water would lead to the contamination of the nearby surface water bodies, soil in the near vicinity, ultimately resulting in polluting the underground water table reserve through percolation from soil. The release of untreated effluent will ultimately affect the overall ecology & agricultural productivity in the surrounding area. Table No. 4.11: Characteristics of the Wastewater Sr. No. Details Units Composite Raw effluent Characteristics of mix blowdown effluent Characteristics of Domestic effluent 1. ph Total Dissolved solids mg/lit Chemical Oxygen Demand mg/lit Biochemical Oxygen mg/lit Demand, 3 day, 27 C 5. Total Suspended Solids mg/lit Sadekar Enviro Engineers Pvt. Ltd Chapter 4-21

151 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Table No. 4.12: Characteristics of the Treated Effluent Sr. No. Details Units Treated Effluent Concentration Standards to discharge effluent in CETP 1. ph Total Dissolved solids mg/lit <63.45 < Chemical Oxygen Demand mg/lit <16.1 < Biochemical Oxygen Demand, 3 day, 27 C mg/lit <7.90 <100 Sadekar Enviro Engineers Pvt. Ltd Chapter 4-22

152 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Proposed Mitigation Flow Chart & Design Specification of the Effluent treatment plant for High & Low streams of effluent. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-23

153 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Sadekar Enviro Engineers Pvt. Ltd Chapter 4-24

154 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES The detailed treatability report describing the stage wise reduction in the different unit of the effluent treatment plant along with the calculation design details is attached as Annexure Water quality modeling The project is an expansion project which will be designed as a Zero Liquid Discharge unit. As it is evident that the wastewater generated will not be discharged into any river/water channel/surface water body, the water quality modeling is not mandatory for this project as per the Model TOR prescribed by MoEF&CC. 4.3 Noise Environment Construction Phase Probable Sources The dominant source of noise from the construction equipments is the diesel engine without sufficient muffling. The activities like piling or pavement breaking are other dominant source of noise generated during construction. Consideration of probable sources, for the current scenario can be in two modes, stationary and mobile. Stationary equipment operates in one location for one or more days at a time with either a fixed power operation (pumps, generators). Mobile equipments like transportation and haulage carrying construction material may result in noise pollution. The time varying noise level which are converted into a single number for stationary & mobile sources are taken from the the database for noise generations in custic which are depicted in the below table. Table No.4.15: Noise Level Generated from Construction Equipments Sr. No Equipments Typical Noise Level db(a) 1 Power Generators Compressor Trucks 90 4 Pneumatic Equipment 95 (Source: Custic 3.2 Database for Noise Generating Equipments) Sadekar Enviro Engineers Pvt. Ltd Chapter 4-25

155 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Impact Prediction Construction activities are characterized by variation in power expended by equipment, with resulting variation in noise levels with time. Variation in the power is expressed in terms of the usage factor of the equipment, the percentage of time during the workday that the equipment is operating at full power. Time varying noise levels are converted to a single number for each piece of equipment during the operation. Besides having daily variation in activities, major construction project are accomplished in several different phases. Each phase has a specific equipment mix depending on the work to be accomplished during that phase. Each phase has its own noise characteristics some have higher continuous noise level than others; some have high impact noise levels. The purpose of the assessment is to determine the combined noise level generated from different equipments & its drop in db (A) level as it propagates. Custic 3.2 developed by Canarina Environment software is used for noise pollution modeling simulation. The noise dispersion is a complex physical phenomenon that involves turbulences & non linear dynamics of the irreversible processes which is simplified in a simple equation Model Options Used for Computation Flat terrain is assumed Point Source emission is computed Atmospheric sound attenuation is considered Barrier are not used for computation for worst case scenario Solid angle of the propagation is contemplated as 2 pi Temporal average is not considered Simulation calculation is done at surface height The isolines are used as output interphase Classic custic model (Linear sound propagation equation) is used for simulation Sadekar Enviro Engineers Pvt. Ltd Chapter 4-26

156 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Modeling Procedure The propagation of the noise generated due to proposed expansion has been made by CUSTIC version 3.2. The step wise method subjected in the user manual is followed for performing the model Model Input Data Table No.4.16: Noise Model Input Data Sr. No Parameters Values 1 Number of Sources 4 Nos. 2 Number of calculation point in the x-axis X 80 Nos. 3 Solid angle 2 pi 4 Relative Humidity 70 % 5 Air Temperature 30 O C 6 Attenuation coefficient 0.98 db(a)/100m Interpretation Noise negatively affects human health and well being. Problems related to noise pollution include stress, sleep loss, distraction and a general reduction in the quality of life. Noise pollution can also be harmful to animals in the vicinity. High enough level of noise pollution may interface with the natural cycle of animals. The noise level dissipated as it travels the distance. The drop down in the decibels is calculated by the modeling software. The Noise level at the plant boundary in the north direction is observed to be 56 db(a) & in the east direction it is 52 db (A). Towards the south boundary of the plant the noise dissipates up-to 53 db (A) & 55 db (A) in the west direction of the plot boundary. The drop down level of noise as it travels away from the project site is depicted in the below table- Sadekar Enviro Engineers Pvt. Ltd Chapter 4-27

157 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Table No.4.17: Drop down of Noise level in Construction Phase Sr. No Noise level db (A) Distance (m) The noise contour plotted by the Custic 3.2 is graphically represented in Annexure : Mitigation The noise control approaches which can be implemented to curb the noise level in the construction phase are as follows, 1. Design consideration and project layout: Constructing noise barrier, such as temporary walls of piles of excavated material, between noisy activities and noise sensitive receivers. Construct walled enclosure around especially noisy activities or clusters of noisy equipment. Existing green belt around the plot boundary will act as a noise barrier. 2. Sequence of operations: Combining noisy operations to occur in the same time period. The total noise level produced will not be significantly greater than the level produced if the operations were performed separately. Avoid nighttime activities. Thus, noise from construction would have minor negative impact. However by implementing appropriate mitigation measures suggested above, these effects are expected to become insignificant. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-28

158 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Operational phase Probable Sources Any industrial plant in general consists of various sources of noise in clusters or single. These clusters/single sources may be housed in buildings of different dimensions made of different materials or installed in open or under sheds. Generally the plant noise sources include Air Compressors, Feed Pumps, Condensate Pumps, D.G sets, Recycle Pumps, Boiler ID Fans, air blowers, cooling towers etc. Table 4.18: Noise level generated from Operational Phase Sr.No Equipment Noise in db (A) 1 ETP/ Waste/ Wastewater Pumps & Compressor Air Compressor DG Set Boiler 80.1 (Source: Noise monitoring carried out by SEEPL Laboratory) Impact Prediction In order to predict noise levels due to the plant operations, which will be contributing to the ambient noise levels, a sound propagative modeling has been carried out. For predicting the noise levels at various distances with respect to the plant site, noise levels propogation is predicted using a model Custic 3.2 the details of which are elaborated above. The noise modeling is performed considering the values obtained from the sound level meter during the monitoring phase of the project. The modeling parameters & procedure is explained in the above section. Same methodology is adopted for simulating the model considering 4 nos. of point source. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-29

159 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Effects/Impacts of High Noise Level on Workers during the operational phase Temporary/Permanent hearing loss Irritations and thus decrease in performance. Increased heart rate Workers developing Tinnitus due to high level of noise exposure on regular basis Interpretation The noise level gets propogated as it travels the distance. The drop down in the decibels is calculated by the modeling software. The Noise level at the plant boundary during the operational phase in the north direction will be db (A). Towards the east boundary it will be db (A). The propagating noise dissipates up to db (A) & db (A) levels respectively in the south & east directions of the project plot. The drop down in the level of noise as it travels away from the project site is tabulated in the below table- Table No.4.19: Drop down of Noise level in Operational Phase Sr. No Noise level db (A) Distance (m) The noise contour plotted by the Custic 3.2 is graphically represented in Annexure: 4.4. The area is developed as an industrial area. There are no sensitive receptors within 500 m from the plot premises. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-30

160 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Vibration: As the project is an expansion project construction activities like piling, and operation of other heavy machineries may generate vibrations. The vibration is envisaged due to above mentioned activities, it could result in damage to infrastructure & health of the worker. To overcome such impacts, the grouting of these instruments shall be made free from vibration by providing shock absorbing pads and firmly mounted on the surface. Routine maintenance shall be practiced Proposed Mitigation To reduce the Noise level in the company premises following mitigation is/will be provided. Thick green belt or shelter belt will act as a barrier for preventing the noise propagation out of the factory premises. To curb the noise levels the company is recommended to develop the green belt area around the four boundaries of the company. However company has already developed the requisite amount of green belt as per the existing MPCB consent. Isolation of the high noise generating equipments. Workers should work in shifts to avoid the long durations of exposure to high noise level. Implementation of noise absorbing sheets on the walls of building/facilities hosting high noise generating equipments/machinery. Acoustic enclosures to be provided to DG set, Compressor & high noise generating equipments. Anti vibration pads to be installed for high NV generating machines. Enclosure wherever necessary. Regular/routine maintenance of various equipments should be carried out. Regular Oiling and greasing for equipments should be done. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-31

161 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES The proposed equipments would be provided with proper enclosure, anti vibration pads, acoustic enclosure wherever required. 4.4 Details of hazardous and non-hazardous waste generation and their storage, utilization and management Construction phase Construction and demolition activities create solid wastes which includes contaminated earth, concrete, brick, stone etc. construction material waste sand, concrete, gravel, stone, bricks and other types of waste material like plastic, wood, steel bars, roofing waste, cartons and metal waste which need to be disposed properly. In the present scenario of expansion work the construction and demolition work will be negligible because the expansion will be done only by equipment capacity augmentation, no other significant demolition and construction activities will be carried out. The construction waste will be used for landfill and leveling activities within the plant premise. The scrap metal and insulation waste which will generate from equipment replacement and re-arrangement will be disposed through the authorized scrap vendors. The solid waste generated by labor as municipal waste will be collected and segregated and disposed appropriately Operational phase The manufacturing of the API and Intermediate products will generate hazardous waste. The manufacturing process consists of unit operations listed as, Table No Sources of hazardous waste generation Industrial activity Storage and handling of chemicals Distillation Waste Unit operation Handling and material transfer loss (spillage) Solid residue Sadekar Enviro Engineers Pvt. Ltd Chapter 4-32

162 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES filtration Solid waste Unit processes hydrogenation, Chlorination, Sulphonation etc. Wet residue containing by-product and catalyst Neutralization Wet sludge ETP primary treatment process Wet Chemical sludge ETP secondary treatment process Mixture of wet chemical and biological sludge Multiple Effect Evaporator coupled with Dry chemical sludge ATFD Other type of solid hazardous waste includes empty drums, carboys, polymer bags and cardboard cartons used for raw material storage. The hazardous waste generated will be stored and handle as per the Hazardous Wastes (Management, Handling and Trans-boundary Movement) Rules, Biodegradable office waste (paper) and canteen waste will be disposed off through Local Administration (Municipal Waste Disposal Site). The MPCB authorized vendors for recycling of hazardous waste are identified are listed below, 1. Laxmi Organics and Turmaline Acetic acid recovery. 2. Champion Scrap Trader Recovered Methanol. Solid non hazardous waste includes paper waste from office and food waste generated from canteen. It will be recycled through municipal waste collection system. Details of waste generation and disposal method are listed in following table - Sadekar Enviro Engineers Pvt. Ltd Chapter 4-33

163 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/001/ /00 Table No.4.21: Solid waste generation and disposal method Sr. No. Hazardous Waste Generation (MT/A) Cat. Existing (As per valid CTO) CHAPTER NO 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Proposed Total Disposal 1 Wastes/residue containing oil MT/A 2 MT/A Disposed to CHWTSDF 2 Spent Solvent MT/A 6 MT/A 3 Distillation residue MT/A 410 MT/A Disposed to CHWTSDF 4 Process Residues & wastes MT/A -- 1 MT/A Disposed to CHWTSDF 5 Spent catalyst/spent carbon MT/A 2 MT/A Disposed to CHWTSDF 6 Discarded containers/barrels/liners 33.1 MPCB authorized recycler - 10 MT/A 10 MT/A contaminated with haz. Wastes/chemicals 7 Spent ion exchange resin containing toxic 34.2 Disposed to CHWTSDF 0.2 MT/A 1 MT/A 1.2 MT/A material 8 Flue gas cleaning residue MT/A 0.5 Mt/A 0.6 MT/A Disposed to CHWTSDF 9 Chemical sludge from waste water 34.3 Disposed to CHWTSDF 1.2 MT/A 13 MT/A 14.2 MT/A treatment 10 Filters and filter material which have Disposed to CHWTSDF MT/A 0.5 MT/A organic fluid 11 MEE Residue MT/A 200 MT/A Disposed to CHWTSDF Non Hazardous Waste Existing Proposed Total 12 Sent through local municipal PVC and Paper Bags MT/M 1.5 MT/M 1.6 MT/A facility Sent to Approved recyclers HDPE/Metal Container -- nos./month nos./month nos./month 14 Wooden Pellets 50 nos./month 500 nos. /Month 550 nos. /Month Sent through local municipal facility Sadekar Enviro Engineers Pvt. Ltd Chapter 4-34

164 4.4.3 Conclusion The industry will follow the Hazardous Waste Management practices as per the Hazardous Waste Management Rules, 2016 and amendments. It will provide a separate area for the storage of hazardous waste and empty drums with proper segregation and identification. Adequate PPE will be provided for workers handling and transporting hazardous waste. Regular training will be provided by the EHS Dept. to increase the awareness among the employee and contractors regarding generation and management of Hazardous Waste. 4.5 Soil environment The surrounding soil quality can be adversely affected if the treated/untreated effluent enters the ground through disposal/spillage/leakage. Also accidental spillage of chemicals (raw material/product) & hazardous waste during storage, handling, gland leakage of pumps, flange leakage in pipelines has potential of soil contamination. ETP for primary treatment is provided at site, after primary treatment the effluent is carried in tankers at Plot M-3, also owned by Galaxy surfactants where the primary treated effluent is treated for secondary treatment. The treated effluent is reused at maximum potential and the surplus is sent to CETP. For the proposed expansion a full fledged ETP will be installed with MEE with ATFD and R.O plant to ensure Zero Liquid Discharge. The entire quantity of domestic waste water will be treated in septic tank followed by aeration of the ETP. The industry will precisely execute the day to day operations of chemical handling & carry out periodic inspection/maintenance of transfer pumps/flanges so as to avoid leakages. In case of any spillage, the same will be collected and transferred to ETP. The unit has a demarcated hazardous waste storage area thus, there will not be any chances of contamination of soil due to the storage of chemicals and hazardous waste. Hence, there will not be any impact on soil environment due to effluent disposal, chemical handling and storage & handling of hazardous wastes after proposed expansion. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-35

165 4.6 Biological environment Nevertheless the impacts associated with any kind of proposed activity on the environment cannot be completely nullified however the severity of such impacts can be minimized to a great extent by advocating suitable mitigation measures Construction phase The proposed project is a brown field project wherein the production capacity enhancement will be achieved by adding a manufacturing unit and supporting utilities and infrastructure. All these activities will be executed within the premises of existing plant located at plot of Galaxy Surfactants. Since the proposed activity does not involve any new land acquisition & moreover for construction of above mentioned utilities no tree felling activity/habitat loss will occur. Hence during the construction phase no impact is envisaged on the prevailing ecology Operational phase Impact identification The proposed project will be a zero liquid discharge project & disposal of hazardous waste to Mumbai Waste Management - CHWTSDF at Taloja. Hence any sort of liquid/solid waste disposals are not envisaged on land or in water bodies. The only direct impacts envisaged dune to the proposed project will be from following activities: i) Noise, vibrations generated due to the transport activity for transportation of raw materials & products. ii) Air emissions from fuel burning for operation of utilities like boiler, D.G set & vehicular movement for transport related activities Impact prediction i) Generally the augmented noise level & vibrations leads to faunal disturbances compelling locale region level faunal migration. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-36

166 i) Generally the augmented noise levels & vibrations leads to faunal disturbances compelling locale level faunal migrations/movements. ii) Prolonged air emissions may adversely affect the vegetation stature physically (leaf senescence, hampered growth etc.) & biologically in the immediate vicinity of the project eventually affecting the overall ecology. iii) The continuous industrial emissions from the Tarapur MIDC area if considered as a cumulative source may adversely affect the prevailing potential habitat in the study area viz. prominent vegetation along the Gundale, Padghe & Devkhope hillocks & mangrove vegetation & associated wetlands along the creek lets near Murbe, Ucheli & Satpati villages mpact assessment i) It is estimated that due the proposed project expansion activity, on an average additional 3 trucks/heavy vehicles daily will move to and from the project site which is insignificant considering the present traffic scenario in and around the Tarapur industrial cluster. Also transportation is a non continuous & non stationery activity hence no significant impact is anticipated due to the transport related activities. Moreover MIDC area is exclusively meant for industrial developmental activities & the surroundings being subjected to tremendous developmental activities no prominent fauna exists in the immediate surroundings of the project affected area as evidenced during the baseline data collection studies. ii) The potential habitat viz. prominent vegetation along the Gundale, Padghe & Devkhope hillocks & mangrove vegetation & associated wetlands along the creek lets near Murbe, Ucheli & Satpati villages. are situated in the upward wind direction, hence the continuous air emissions from the Tarapur industrial area considered as cumulative source will be dispersed away from this potential habitat Mitigation measures Sadekar Enviro Engineers Pvt. Ltd Chapter 4-37

167 i) Industry should provide stack of minimum 39 m height as per CPCB guidelines so that the air emissions are dispersed at sufficient height in the environment. ii) As suggested in the post project environment monitoring program through continuous monitoring industry should ensure that at no point time during the operational phase the concentrations of air emissions should not exceed the prescribed standards. iii) Industry should ensure the efficiency of pollution control devices on a timed frequency basis so that in case of any deviation corrective actions can be taken. iv) In order to arrest the fugitive emissions within the project premises & maintain ecological equilibrium with the surroundings, green belt should be developed around the project plot boundary with native species as mentioned in Table No of Chapter 10. v) As a part of Corporate Social Environment Responsibility (CSER) initiative it is recommended to project proponent to allocate dedicated budget towards environmental awareness/preservation of potential habitat in the study area. 4.7 Land Use - Land Cover i) Developmental activities depending on the size & magnitude generally tend to change the prevailing land use - land cover aspects of the project site & surroundings directly. ii) Influx of people associated with such project activities has the potentiality of altering the surrounding land use - land cover aspects by way of new habitations/settlements & thus promoting various other infrastructural activities there by inducing new land use - land cover classes indirectly Impact identification i) The proposed project is a production capacity enhancement brown field activity which will be executed within the premises of the existing unit located at plot no. G - 59, Tarapur MIDC, Boisar, Palghar - District, Maharashtra, India. Hence, the decreased open area admeasuring 7681 Sadekar Enviro Engineers Pvt. Ltd Chapter 4-38

168 sq.m. will be converted into built up area within the existing area. However the land use type will remain same as industrial Impact prediction i) The proposed project is a production capacity enhancement brown field activity which will be executed within the premises of the existing unit located at plot no. G - 59, Tarapur MIDC, Boisar, Palghar - District, Maharashtra, India. Hence, the decreased open area admeasuring 7681 sq.m. will be converted into built up area within the existing area. However the land use type will remain same as industrial Impact assessment i) Since the proposed project plot & the Tarapur MIDC industrial area already prevail industrial type of land use by virtue of which no new type of land use will be generated. Moreover the project activity in consideration does not involve influx of people & ancillary developmental activities hence there is no possibility of change in land use/land cover aspects even indirectly. ii) Also any new/additional land is not required for the proposed project hence the prevailing land cover classes in the study area will not be altered. Hence mitigation measures related aspects are not applicable. 4.8 Socio economic environment It is envisaged that the existing project & the proposed activity will help to some improvements in the locale specific socio-economic aspects in the project affected area. Since the proposed expansion will be carried out within the existing plant area and hence no impact on external human settlements is envisaged also project will not have any major impact on the local level population growth, since only a nominal 150 no. man power will be required for the expansion project. Hence increase in the population and related strain on infrastructure of the study area is not envisaged. Better literacy rates are possible due to assumed better economic conditions of the people in the project concerned area. Better literacy means better social status and thereby Sadekar Enviro Engineers Pvt. Ltd Chapter 4-39

169 improved lifestyle. This will be a positive impact due to the existing and proposed capacity expansion. 4.9 Odour Identification of source Odour sources can be continuous or intermittent, point sources (for example chimneys, stacks or building vent/exhaust pipes), area sources (for example stockpiles, ponds or open-topped tanks) or volume sources (for example, a building with many openings from which odour escapes). The sources within the site boundary and any nearby sources beyond the boundary they could contribute to cumulative odour impacts. It is important to include fugitive sources as these often make an important contribution to the odour impacts. In the operational phase the component which will contribute to the odour generations are working of waste water treatment plant, raw materials and chemicals handling in the industry, working emission of the solvents storage tanks etc. Sources which will lead to the generation of odour are leakage of solvent/chemical from the storage drums/pipeline/reactors, evaporation of acid as acid fumes, domestic waste, handling of raw materials, also handling of sludge and reaction waste etc Impact prediction Exposure to odors could result in health effects ranging from none, to mild discomfort, to more serious symptoms. Some chemicals with strong odors may cause eye, nose, throat or lung irritation. Strong odors may cause some people to feel a burning sensation that leads to coughing, wheezing or other breathing problems. Workers/People coming in contact who smell strong odors may get headaches or feel dizzy or nauseous. If an odor lasts a long time or keeps occurring, it also could affect mood, anxiety and stress level Mitigation measures Mitigation measures that can be implemented for controlling the odour are given below, Sadekar Enviro Engineers Pvt. Ltd Chapter 4-40

170 Increasing Air Exchange: The exchange of air surrounding an odorous process is large the emitted odorants will be diluted. But if the odour comes from evaporated material, the emission may increase. In normal circumstances it is best to reduce the amount of air which gets in contact with odorous materials. In this way odour control equipment will be required. Supervision and maintenance: If equipment is supervised and maintained frequently, leakages in joints, pump gaskets, boilers etc. can be avoided and odour nuisances be prevented. Ordinary operational practice should include maintenance of equipment to prevent uncontrolled escape of odour. Odour emissions are often a result of plant overloading or chemicals spill. It is therefore essential that processes operate correctly and chemicals are handled carefully. Odour emitted in connection with tank filling operations can be minimized by means of floating covers or smell charcoal filters at ventilation outlets. Good Housekeeping: Decay Evaporation of odorants from stored decaying material may often lead to odour emission. Good housekeeping may eliminate the problems. Provision of Containment: The preventive measures or changed process parameters are not enough to avoid annoying emissions of odorous compounds from a plant, it must be placed in a building equipped with ventilation and, where required, air cleaning equipment. It may be necessary to have non-opening windows and automatic gate and door closing devices, and to provide a negative pressure in the building. Odour nuisances can be prevented either by cleaning of exhaust air or by dilution in outlets. Sadekar Enviro Engineers Pvt. Ltd Chapter 4-41

171 SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 5: ANALYSIS OF ALTERNATIVE CHAPTER 5: ANALYSIS OF ALTERNATIVE 5.1 Introduction M/s Galaxy Surfactants Ltd. is located at Plot No. G-59, MIDC Tarapur, Boisar, Palghar District, State Maharashtra. The Tarapur MIDC has been established before the year It is a notified industrial area. The MIDC has made its own arrangements to supply filtered and disinfected water to the industrial units. The water is sourced from the Surya dam which is at a distance of 45Km. The said project is a ZLD unit; no effluents will be discharged outside the Plant boundary. MIDC has constructed a fire station which has the following units: i ) Engine room with a fire station office and officers quarters ii) Fireman quarters iii) Smoke room tower iv) Service pit and suction tank MIDC has provided asphalt roads with widths varying from 3.75 to 16 m; these are mainly two lane roads with a central verge of bougainvillea and raised footpaths on either side of the roads. Other facilities provided by the Tarapur, MIDC are appropriate connectivity, streetlights facility, Common facility Centre, Parks & Banks etc. MIDC is strategically located and is easily accessible from Mumbai Ahmadabad highway NH-8, This Estate is well connected with Mumbai- Ahmadabad rail network and Mumbai port is near for sea transport. The nearest city is Mumbai is about 65 km from project site. Overall it can be said the location of Tarapur MIDC is optimum for setting up a Synthetic Organic Chemicals Industry. 5.2 Analysis of Alternative Site. The process of industrial site-selection begins with the recognition of projected need to meet new or growing markets. M/s Galaxy Surfactants Ltd. is an existing unit in Tarapur MIDC since June, Hence analysis of any additional site was not envisaged. The area of the plot is sq. m. The existing site is sufficiently large to house the infrastructure needed for the expansion of the manufacturing capacity. Sadekar Enviro Engineers Pvt. Ltd Chapter 5 1

172 SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 5: ANALYSIS OF ALTERNATIVE 5.3 Analysis of Alternative Technology The unit is a specialty and fine chemicals Industry. The manufacturing process involves various chemical reactions like, Oxidation Reduction Reaction, Hydrogenation/Reduction, Amination, Esterification, Substitution, Condensation, Hydrolysis, Salt formation, Acid-base, Ethoxilation, Rearrangement Reaction and physical operations like filtration, separation, extraction, pulverization, sieving and drying. The unit has adopted latest and best technology available so far in the market for the manufacturing of such products. Sadekar Enviro Engineers Pvt. Ltd Chapter 5 2

173 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM 6.1 Introduction Environmental monitoring Program is an essential tool for sustainable development. The Program helps to provide a delivery mechanism to address the adverse environmental impacts of a project during its execution, to enhance project benefits, and to introduce standards of good practice to be adopted for all project works. An environmental monitoring program is important as it provides useful information and helps to: Assist in detecting the development of any unwanted environmental situation, and thus, provides opportunities for adopting appropriate control measures. Monitoring & tracking the effectiveness of Environment Management Plan & implementation of mitigation measures planned. Define the responsibilities of the project proponents, contractors and environmental monitors and provides means of effectively communicating environmental issues among them. Define monitoring mechanism and identify monitoring parameters. Evaluate the performance and effectiveness of mitigation measures proposed in the Environment Management Plan (EMP) and suggest improvements in management plan, if required. Identify training requirement at various levels. Identification of any significant adverse transformation in environmental condition to Plan additional mitigation measures 6.2 Monitoring points /locations and components Environmental monitoring plan shall be decided considered the environmental impact likely to occur due to operation of the project as the main scope of monitoring program is to track timely and regularly change in the environmental condition and to take timely action to protect the environment. Sadekar Enviro Engineers Pvt. Ltd Chapter 6 1

174 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM Table No. 6.1 Pre Project Monitoring Parameter Sr. No. Components Environmental Monitoring Points/Location 1. Ambient Air Ambient air quality at minimum 8 Location, including the plant premises 2. Water & Waste Water Minimum 8 location of ground water and 8 location of surface water should be taken around the project site. 3 Noise At all internal sources and outside the plant area which can be locus to the air monitoring stations. At least 8 locations should be taken near/around the site 4 Soil At least 2 point near the Project site. Sadekar Enviro Engineers Pvt. Ltd Chapter 6 2

175 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM 6.3 Post Project Monitoring Parameters & Frequency Table No. 6.2 Post Project Monitoring Parameters & Frequency SEEPL/EIA/F/IND/GSL/001/ /00 Sr. no Activity/Area Pollutant Pollutant Characteristics Frequency Period OPERATION PHASE 1. Vehicular Movement Dust Emission CO, SO 2, NO X, SPM in Intermittent / Periodic Quarterly Ambient Air 2. Diesel power Air emissions CO, SO 2, NO X, SPM from Intermittent / Periodic Quarterly Generators, Boiler. boiler & D.G.Sets 3. Scrubbers Air emissions Acid Mist Intermittent / Periodic Quarterly 3. Boiler Area, D.G Sound Noise Level db (A) Intermittent / Periodic Quarterly Set, ETP, Work Place Area 4. Effluent treatment plant All parameters ph, O & G, TDS, TSS, COD, BOD. Heavy Metals & Organic Continuous Daily 5. Hazardous Wastes E.T.P sludge residue 6. Work Place Air pollutants, Heavy metals Compounds specific to project H.W. characteristics Volatile Organic Compounds & Heavy Metals in ambient Air specific to project As per the requirement of CHWTSDF providers Intermittent / Periodic Once in a Year Quarterly Sadekar Enviro Engineers Pvt. Ltd Chapter 6 3

176 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM 6.4 Monitoring Methodologies: Monitoring of environmental samples shall be done as per the guidelines provide by MoEF/CPCB/SPCB. The method followed shall be recommended / standard method approved/recommended by MoEF/CPCB. 6.5 Documentation and Reporting The records of the monitoring program shall be kept on regular basis for all aspects of the monitoring. Separate records for water, wastewater, solid wastes (Slag & Collected Dust, Recycled Dust-Scales etc.), air, emission, soil & manure/compost shall be prepared and preserved regularly. Immediately upon the completion of monitoring as per the planned schedule, report shall be done & necessary documents shall be forwarded to the concern person. Methodology of monitoring (sampling & analysis) shall be prepared as separate documents as SOP (standard Operating Procedure) wherever required. The records showing results/outcome of the monitoring programs shall be prepared as per the requirement of the schedule mentioned above. Regularly these documents & records shall be reviewed for necessary improvement of the monitoring plan/mitigation measures/environmental technologies as well as for necessary. Actions of environmental management cell. 6.6 Budget & Procurement Schedule On regular basis, Environment Management Cell shall inspect the necessity & availability of the materials, technologies, services & maintenance works. The Cell shall made appropriate budget for the purpose. Regular record review for change in financial requirement of environment management shall be done and appropriate budgetary provisions shall be made. Along with other budgets, Budget for environmental management shall be prepared and revised regularly up on requirement. The budget shall include provisions for: Environmental Monitoring Program Operation & Maintenance of environmental Technologies/Equipments Laboratory works for Environmental management activities Sadekar Enviro Engineers Pvt. Ltd Chapter 6 4

177 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER 6: ENVIRONMENTAL MONITORING PROGRAM Emergency Purchase of necessary material, equipments, tools, services, protective equipment. Greenbelt development Social & Environmental Welfare & Awareness programs/training & Health related issues. Annual Environmental Audit Sadekar Enviro Engineers Pvt. Ltd Chapter 6 5

178 CHAPTER 7: ADDITIONAL STUDIES CHAPTER 7: ADDITIONAL STUDIES 7.1 Public Hearing Public Consultation refers to the process by which the concerns of local affected persons and others who have plausible stake in the environmental impacts of the project or activity are ascertained with a view to taking into account all the material concerns in the project or activity design as appropriate. M/s Galaxy Surfactants Ltd. will commence the project activity Tarapur MIDC at plot no. G-59. As per the OM No. J-11013/36/2014-IA-I dated 10 th December 2014 public hearing is not mandatory for the industries which are established in industrial estate or parks notified prior to i.e. the EIA notification, 2006 coming into force. 7.2 Risk Assessment Introduction As indicated in the earlier chapter the proposed facility to manufacture Specialty chemicals poses various types of hazards due to storage, handling and manipulation of different chemicals, which are indicated in Chapter no. 2 In order to study the risks envisaged by the activities, the following methodology was adopted Detailed study of all manufacturing activities The factory would be manufacturing about 29 different products with total production quantity of 3472 MT/A. The hazop studies have been carried out for the products A detailed scrutiny of various chemicals which would be stored on the site was done. Aloha is performed for the raw materials which are mentioned below, Table No. 7.1: List of Tanks in CCOE Area Sr.No Name of the Raw Qty Area MOC Materials Capacity Nature 1 Cyclohexane 20 MT Underground 1 Tank CCOE SS316L Sadekar Enviro Engineers Pvt. Ltd Chapter 7-1

179 CHAPTER 7: ADDITIONAL STUDIES Toluene 15 MT Underground Methanol 15 MT Underground Ethyl Acetate 15 MT Underground IPA 15 MT Underground 1 Tank CCOE SS316L 1 Tank CCOE SS316L 1 Tank CCOE SS316L 1 Tank CCOE SS316L The Gas Storage Details are tabulated below - Sr. No. Gas Type Storage pressure bar Table No 7.2: Gas Storage Details Diameter, m Length / height, m Capacity, 1 Hydrogen Cylinder 150 atm. 0.2 m 1.6m 45 lit CCOE (150 ) 2 Trimethylamine Gas Tank 4 bar 2.2 m 3 m 10 MT CCOE Area Table No. 7.1: List of Tanks in Non CCOE Area (Considered for Aloha) Raw materials Proposed Max. Sr.No consumption Storage State Storage type TPM MT 1. Thionyl Chloride Liquid Above ground Storage tank Above ground Storage tank 2. 2-Ethyl hexanol Liquid Above ground Storage tank 3. Benzyl Chloride Liquid 4. Acetic Acid Liquid Above ground Storage tank 5. HCl solution Liquid Above ground Storage tank M.S.D.S.s Sadekar Enviro Engineers Pvt. Ltd Chapter 7-2

180 CHAPTER 7: ADDITIONAL STUDIES Brief M.S.D.S.s of all the above chemicals and other raw materials which would be used in the manufacturing processes of products are used as reference for preparation of hazop & risk assessment study A Quantitative Risk Assessment based on the software ALOHA Areal Locations of Hazardous Atmospheres was carried out. The criteria failure scenarios considered for ALOHA depend on the type of storage whether above ground/ underground, physical state of the chemical stored, chemical properties of the chemical. The summary of the ALOHA footprints are attached as Annexure 7.1 Table No 7.3: Summary of Aloha Footprints Substance Failure Scenario No. Effects considered Tri methyl Direct Source Tri methyl Toxic area of Amine Amine/01 vapor cloud LOC Distance, m AEGL ppm 351 meters AEGL ppm 659 meters AEGL-1 8 ppm 2.7 kilometers Tri methyl Amine/02 Flammable Area of Vapor Cloud ppm = 60% LEL = Flame Pockets 2000 ppm = 10% LEL 42 meters 126 meters Tri methyl Amine/03 Overpressure (blast force) from vapor cloud explosion 8.0 psi LOC was never exceeded 3.5 psi 29 meters 1.0 psi 54 meters Flammable chemical escaping from tank (not Tri methyl Amine/04 Toxic Area of Vapor Cloud AEGL ppm 1.1 kilometers Sadekar Enviro Engineers Pvt. Ltd Chapter 7-3

181 CHAPTER 7: ADDITIONAL STUDIES burning) AEGL ppm 1.7 kilometers AEGL-1 8 ppm 4.4 kilometers Tri methyl Amine/05 Flammable Area of Vapor Cloud ppm = 60% LEL = Flame Pockets 2000 ppm = 10% LEL 330 meters 624 meters Tri methyl Amine/06 Overpressure (blast force) from vapor cloud explosion 8.0 psi LOC was never exceeded 3.5 psi 288 meters 1.0 psi 368 meters Flammable chemical is burning as it escapes from tank Tri methyl Amine/ kw/(sq m) 5.0 kw/(sq m) 2.0 kw/(sq m) 80 meters 124 meters 201 meters BLEVE of flammable liquid in vertical cylindrical tank Tri methyl Amine/ kw/(sq m) 5.0 kw/(sq m) 2.0 kw/(sq m) 136 meters 193 meters 301 meters Sadekar Enviro Engineers Pvt. Ltd Chapter 7-4

182 CHAPTER 7: ADDITIONAL STUDIES Hydrogen Catastrophic failure of cylinder Hydrogen/01 Toxic area of vapor cloud AEGL ppm AEGL ppm AEGL ppm Hydrogen / 02 Flammable area of vapor cloud ppm = 60% LEL 4000 ppm = 10% LEL Hydrogen / 03 Blast area of vapour cloud explosion 8.0 psi < psi < psi < 10 failure of outlet pipeline, pig tail (Chemical not burning) Hydrogen / 04 Toxic area of vapor cloud AEGL ppm AEGL - 2 AEGL ppm ppm 119 Hydrogen/ 05 Flammable area of vapor cloud ppm = 60% LEL 4000 ppm = 10% LEL < Hydrogen / 06 Blast area of vapour cloud explosion failure of outlet pipeline, pig tail (Chemical Hydrogen / 07 Thermal radiation from jet fire 10 kw/sq m. < 10 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-5

183 CHAPTER 7: ADDITIONAL STUDIES burning) 5 kw/sq m. < 10 2 kw/sq m. < 10 Iso propanol Direct Source 20% leakage through transfer pump Isoproponal /01 Toxic area of vapor cloud PAC ppm 20 PAC ppm 146 PAC ppm 146 Isoproponal / 02 Flammable area of vapor cloud ppm = 60% LEL 2000 ppm = 10% LEL Isoproponal / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 22 Road Tanker rupture Isoproponal / 04 Toxic area of vapor cloud PAC ppm PAC ppm 112 PAC ppm 112 Isoproponal / 05 Flammable area of vapor cloud ppm = 60% LEL 2000 ppm = 10% LEL < Isoproponal / 06 Blast area of vapour cloud explosion -- Ethyl Acetate Direct Source 20% leakage Ethyl Acetate /01 Toxic area of vapor cloud PAC ppm 20 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-6

184 CHAPTER 7: ADDITIONAL STUDIES through transfer pump PAC ppm 127 PAC ppm 127 Ethyl Acetate / 02 Flammable area of vapor cloud ppm = 60% LEL 2150 ppm = 10% LEL Ethyl Acetate / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 30 Road Tanker rupture Ethyl Acetate / 04 Toxic area of vapor cloud PAC ppm PAC ppm 134 PAC ppm 134 Ethyl Acetate / 05 Flammable area of vapor cloud ppm = 60% LEL 2150 ppm = 10% LEL Ethyl Acetate / 06 Blast area of vapour cloud explosion 8.0 psi psi psi 15 Methanol Road Tanker rupture Methanol /01 Toxic area of vapor cloud AEGL ppm 624 AEGL ppm 1100 AEGL ppm 1800 Methanol / 02 Flammable area of vapor cloud ppm = 235 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-7

185 CHAPTER 7: ADDITIONAL STUDIES 60% LEL 7180 ppm = 10% LEL 679 Methanol / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 192 Direct Source 20% leakage through transfer pump Methanol / 04 Toxic area of vapor cloud AEGL ppm 42 AEGL ppm 82 AEGL ppm 170 Methanol / 05 Flammable area of vapor cloud ppm = 60% LEL 7180 ppm = 10% LEL Methanol / 06 Blast area of vapour cloud explosion 8.0 psi psi psi 14 Toluene Road tanker rupture Toluene /01 Toxic area of vapor cloud AEGL ppm 520 AEGL ppm 869 AEGL ppm 1700 Toluene / 02 Flammable area of vapor cloud 6600 ppm = 60% LEL 1100 ppm = 10% LEL Sadekar Enviro Engineers Pvt. Ltd Chapter 7-8

186 CHAPTER 7: ADDITIONAL STUDIES Toluene / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 455 Direct Source 20% leakage through transfer pump Toluene / 04 Toxic area of vapor cloud AEGL ppm 36 AEGL ppm 75 AEGL ppm 215 Toluene / 05 Flammable area of vapor cloud 6600 ppm = 60% LEL 1100 ppm = 10% LEL Toluene / 06 Blast area of vapour cloud explosion 8.0 psi psi psi 13 Cyclohexa ne Road tanker Cyclohexane /01 Toxic area of vapor cloud AEGL ppm 363 AEGL ppm 567 AEGL Cyclohexane / 02 Flammable area of vapor cloud 7200 ppm = 60% LEL 1200 ppm = 10% LEL Cyclohexane / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 411 Direct Source Cyclohexane / Toxic area of AEGL ppm 23 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-9

187 CHAPTER 7: ADDITIONAL STUDIES 20% leakage through transfer pump 04 vapor cloud AEGL ppm 43 AEGL Cyclohexane / 05 Flammable area of vapor cloud 7200 ppm = 60% LEL 1200 ppm = 10% LEL Cyclohexane / 06 Blast area of vapour cloud explosion 8.0 psi psi psi 37 Acetic acid Direct Source 20% leakage through transfer pump Acetic acid/ 01 Toxic area of vapor cloud AEGL ppm 164 AEGL-2 35 ppm 459 AEGL-1 5 ppm 1300 Acetic acid / 02 Flammable area of vapor cloud ppm = 60% LEL 4000 ppm = 10% LEL Acetic acid / 03 Blast area of vapour cloud explosion 8.0 psi psi psi 34 The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Acetic acid / 04 Toxic area of vapor cloud AEGL ppm 23 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-10

188 CHAPTER 7: ADDITIONAL STUDIES Chemical not burning AEGL-2 35 ppm 96 AEGL-1 5 ppm 264 Acetic acid / 05 Flammable area of vapor cloud ppm = 60% LEL 4000 ppm = 10% LEL -- < 10 Acetic acid / 06 Blast area of vapour cloud explosion -- The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical burning. Acetic acid /07 Thermal radiation from pool fire. 10 kw/sq m kw/sq m kw/sq m. 29 Hydrochlo ric acid The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical not burning HCl / 01 Toxic area of vapor cloud AEGL ppm 54 AEGL-2 22ppm 129 AEGL ppm 467 Benzyl Chloride Direct Source 20% leakage through transfer pump Benzyl Chloride/01 Toxic area of vapor cloud ERPG-3 50 ppm 175 meters Sadekar Enviro Engineers Pvt. Ltd Chapter 7-11

189 CHAPTER 7: ADDITIONAL STUDIES ERPG-2 10 ppm 411 meters ERPG-1 1 ppm 1.4 kilometers Benzyl Chloride/02 Flammable Area of Vapor Cloud 6600 ppm = 60% LEL = Flame Pockets 1100 ppm = 10% LEL Benzyl Chloride/03 Overpressure (blast force) from vapor cloud explosion 8.0 psi psi psi 29 The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical not burning Benzyl Chloride/04 Toxic area of vapor cloud ERPG-3 50 ppm 10 ERPG-2 10 ppm 22 ERPG-1 1 ppm 82 Benzyl Chloride/05 Flammable Area of Vapor Cloud 6600 ppm = 60% LEL = Flame Pockets 1100 ppm = 10% Sadekar Enviro Engineers Pvt. Ltd Chapter 7-12

190 CHAPTER 7: ADDITIONAL STUDIES Benzyl Chloride/06 Overpressure (blast force) from vapor cloud explosion LEL The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical burning Benzyl Chloride/07 Thermal radiation from pool fire 10.0 kw/(sq m) 5.0 kw/(sq m) 2.0 kw/(sq m) ETHYL HEXANO L Direct Source 20% leakage through transfer pump 2-ETHYL HEXANOL /01 Toxic area of vapor cloud ERPG ppm 73 meters ERPG ppm 105 meters ERPG ppm 3.9 kilometers 2-ETHYL HEXANOL /02 Flammable Area of Vapor Cloud 5280 ppm = 60% LEL 880 ppm = 10% LEL ETHYL HEXANOL /03 Overpressure (blast force) from vapor 8.0 psi -- Sadekar Enviro Engineers Pvt. Ltd Chapter 7-13

191 CHAPTER 7: ADDITIONAL STUDIES cloud explosion 3.5 psi psi 32 The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical not burning 2-ETHYL HEXANOL /04 Toxic area of vapor cloud ERPG ppm <10 ERPG ppm <10 ERPG ppm ETHYL HEXANOL /05 Flammable Area of Vapor Cloud 5280 ppm = 60% LEL 880 ppm = 10% LEL <10 <10 2-ETHYL HEXANOL /06 Overpressure (blast force) from vapor cloud explosion The entire contents of the storage tank getting accumulated in the dyke enclosure because of failure of the tank Chemical burning 2-ETHYL HEXANOL /07 Thermal radiation from pool fire 10.0 kw/(sq m) 18 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-14

192 CHAPTER 7: ADDITIONAL STUDIES 5.0 kw/(sq m) 2.0 kw/(sq m) THIONYL CHLORID E Direct Source 20% leakage through transfer pump THIONYL CHLORIDE/ 01 Toxic area of vapor cloud AEGL AEGL Km AEGL THIONYL CHLORIDE/ 02 Toxic area of vapor cloud AEGL AEGL Km AEGL Interpretation The probability of failure of the entire tank etc, which is considered in the above scenario is very less. However to further reduce the same, following precautions would be taken, A) For Underground Solvent Storage Tanks & Above ground tanks The tanks will be fabricated taking into account the corrosion resistance properties of the material of construction. The tank will be provided with water sprinkler arrangement so as to cool the same in summer season The tanks will be provided with breather valves and will have nitrogen blanketing arrangement wherever required Dyke wall of adequate volume (110%) capacity of the tank will be constructed around the tanks. The dyke enclosure will be lined with impervious coating Sadekar Enviro Engineers Pvt. Ltd Chapter 7-15

193 CHAPTER 7: ADDITIONAL STUDIES Regular inspection of the tank, transfer pipelines and dyke will be done visually and records maintained. Wherever required, the tanks would be covered under a license under Petroleum Rules from PESO. It is recommended to establish foam monitor in the solvent tank yard farm. B) For Hydrogen Cylinders 1. The licensed premises shall not be used for any purpose other than for keeping of compressed gas filled in cylinders. 2. Compressed gas cylinders shall be stored only in the storage shed, which shall be constructed of suitable non-flammable materials provided that, when only non-flammable gas filled in cylinder is stored, the beams, rafters, columns, windows and doors may be of wood. 3. The storage shed shall be adequately ventilated near the ground level and near or in the roof. 4. As far as possible, different types of gases should not be stored in the same shed. Where different types of gas cylinders are stored in the same shed, cylinders may be grouped together depending on the nature of the gas contained therein e.g. flammable gas cylinders shall be separated from cylinders containing oxidizing gases by an intervening space of one meter or by a fire resisting partition wall in between them and cylinders containing toxic gases shall be segregated from the cylinders containing non-toxic gases by a suitable partition wall. 5. The following distances shall be kept clear at all times, between any building, public place, public road or any adjoining property which may be built upon and the storage shed used for the storage of liquefied petroleum gas cylinder: Quantity of compressed gas in Minimum distance to be Cylinder kept clear Kg. Metres over Provided that the distance specified above may be reduced by the Chief Controller (i) where Sadekar Enviro Engineers Pvt. Ltd Chapter 7-16

194 CHAPTER 7: ADDITIONAL STUDIES screen walls are provided or other special precautions taken, or (ii) where there are special circumstances which in the opinion of the Chief Controller would justify such reduction. 6. Notwithstanding anything contained in condition 5 above, cylinders containing liquefied petroleum gas exceeding 100 Kg. but not exceeding 500 Kg. may be kept in a storage shed forming part of, or attached to a building, provided that it is separated there from by a substantial partition and the only means of access to it is from outside air, such a storage shed shall not be situated under any staircase or near other entrances to, or exits from the rest of the building or other buildings. 7. A shed used for storage of liquefied petroleum gas cylinders shall be surrounded by a suitable brick masonry compound wall of 1.8 meters high with a 1.2 meter wide gate to prevent unauthorized person from having access to the shed and its safety zone. 8. Thin wall cylinders shall not be stacked in a horizontal position, provided that in case of liquefied petroleum gas cylinders, the following method of stacking may be permitted:- (i) filled cylinders shall be stored vertically and not be stacked more than 2 high; (ii) empty cylinders if stored vertically, shall not be stacked more than 3 high and; if stored horizontally, shall not be stacked more than 5 high; (iii) the pile of the cylinders shall be kept stable by using chocks at the ends; (iv) at least 60 centimet er wide gangway, to permit access and maneuvering of cylinders, shall be left between stacks of single or double rows and between stacks and walls, 9. True chemical name(s) of the gases shall be prominently displayed in the storage shed. 10. The storage shed shall be in the charge of a competent person. 11. Any accident, fire, explosion or untoward incident occurred within the licensed premises shall be immediately reported to the Chief Controller (Gram EXPLOSIVES, Nagpur, E - mailexplosives@explosives.gov.in), Controller, District Magistrate and the Officer-in-Charge of the nearest Police Station and by quickest mode of communication. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-17

195 CHAPTER 7: ADDITIONAL STUDIES 13. No shed used for storage of flammable gases shall be opened and no handling of the gas cylinders shall be permitted between the hours of sunset and sunrise, except where approved electric lighting is exclusively used. 14. The storage shed and the area surrounding it shall at all times be kept clean and free from all flammable materials, waste vegetation and, rubbish. 15. (a) No fire, furnace or other source of heat or light other than flameproof electric light and fittings shall be allowed in the storage shed and within the safety zone required to be maintained under condition 5. (b) No person shall smoke in the storage shed or carry matches, fuses, mobile phones or other appliances producing ignition in the premises. Conspicuous No smoking signs in Hindi, English and the regional language shall be pasted or hung up at prominent places outside the storage shed. 16. The licensee shall provide at the licensed premises a minimum of two potable foam type/ordinary chemical type fire extinguishers of 10 kg. Each BIS marked or approved which shall be kept ready at a convenient location for immediate use in the event of any fire in addition to other fire fighting for other mitigating facilities required for flammable or toxic gases DOW INDEX The Dow index has been calculated for chemicals stored in tank farm. Dow Index has been calculated separately for F.O and HSD Tank area, CCOE U.G Tank area and Non CCOE Tank Area. Sr.No Table No. 7.4 Storage details of Furnace Oil and LDO Tank. Raw Material Tank/ Drum Capacity KL. Quantity at any given time No. of Tanks Flash Point O C 1 Furnace Oil 40 KL 40 KL LDO 20 KL 20 KL 1 66 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-18

196 CHAPTER 7: ADDITIONAL STUDIES Since, the flash point of Furnace Oil & LDO is the same, the DOW Index is performed for FO considering total volume is 60 KL of FO. Tank No. -- Equipment Name FO 60 KL Basic Material for Material MS Drums Density, kg/l 0.97 Properties of material N h 0 N f 2 N r 0 M.F. 10 Boil. -- 0F -- 0C Flash pt F 66 0C pt. HC = Heat of BTU / lb Quantity of the l kg Lb Storage conditions Temp 30 0C Pressure 1.0 bar Penalty factor Penalty factor 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to 0.80 inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in contact of Flame Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage 0.6 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-19

197 CHAPTER 7: ADDITIONAL STUDIES 3. Combustible Solids in Storage, Dust in Process 0.00 Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.9 Process Unit Hazard Factor ( F3 = F1 x F2) 2.66 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 26.6 Degree of Hazard Light The calculations for Dow Fire and Explosion Index is given and from the calculations it is seen that the storage will have a Dow Index of 26.6 indicating Light hazard potential. Preventive & Protective Features Table No. 7.5 Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light Moderate Intermediate Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX 0-20 Fire & Explosion Index Number Index for the present case > Suggested Recommended Feature required 1) Fireproofing ) Water spray a) directional b) area c) curtain Sadekar Enviro Engineers Pvt. Ltd Chapter 7-20

198 CHAPTER 7: ADDITIONAL STUDIES 3) Special instrumentation a) temperature b) pressure c) flow control ) Dust, blowdown, spill control ) Internal examination ) Combustible gas monitors a) signal alarm b) actuate equipment ) Remote operation ) Diking, (Not Applicable as barrel storage) ) Blast & barrier walls separation ) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required Dow index for chemicals stored in non CCOE storage tanks Sr. No Raw Material Tank/ Drum Capacity MT. No. of Tanks Flash Point O C 1 Acetic acid Epichlorohydrin Acetic acid Tank No. -- Equipment Name Acetic acid 30 MT Basic Material for Material MS Tank Sp. gravity factor Properties of material N h 3 N f 2 N r 0 M.F. 14 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-21

199 CHAPTER 7: ADDITIONAL STUDIES Boil. -- 0F -- 0C Flash pt F 39 0C pt. HC = Heat of 5600 BTU / lb Comb. Quantity of the -- l kg -- Lb Storage conditions Temp 30 0C Pressure 1.0 bar Penalty factor Penalty factor 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to 0.80 inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in contact of Flame Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust in Process 0.00 Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 2.5 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-22

200 CHAPTER 7: ADDITIONAL STUDIES Process Unit Hazard Factor ( F3 = F1 x F2) 3.5 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 49 Degree of Hazard Light The calculations for Dow Fire and Explosion Index is given and from the calculations it is seen that the storage will have a Dow Index of 49 indicating light hazard potential. 2. Epichlorohydrin Tank No. -- Equipment Name Epichlorohydrin drums Basic Material for Material factor HDPE Density, g/cc 1.18 Drums Properties of material N h 3 N f 3 N r 2 M.F. 24 Boil. pt F 116 0C Flash pt. 88 0F 31 0C HC = Heat of Comb BTU / lb Quantity of the material -- l kg -- Lb Storage conditions Temp 32 0C Pressure 1.0 bar Penalty factor Penalty factor used range 1.General Process Hazard Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Hazard Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Hg) Operation in or near flammable range 0.00 to 0.80 inerted noninerted 0.00 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-23

201 CHAPTER 7: ADDITIONAL STUDIES 1. Tank farm storage flammable liquids Process upset or purge failure Always in contact of Flame process Dust Explosion 0.25 to Pressure Operating pressure psig Relief setting psig 0.0 Low temperature 0.20 to Quantity of flammable / unstable material 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust in Process 0.00 Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.9 Process Unit Hazard Factor ( F3 = F1 x F2) 3.04 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) Degree of Hazard Moderate Radius of exposure 18.6 m Area of exposure sq. m. The calculations for Dow Fire and Explosion Index is given and from the calculations it is seen that the storage will have a Dow Index of indicating moderate hazard potential. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-24

202 CHAPTER 7: ADDITIONAL STUDIES RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX Preventive & Protective Features Fire & Explosion Index Number Index for the present case > Suggested Recommended Feature 1) Fireproofing required 2) Water spray a) directional b) area c) curtain ) Special instrumentation a) temperature b) pressure c) flow control ) Dust, blowdown, spill control 5) Internal examination ) Combustible gas monitors a) signal alarm b) actuate equipment ) Remote operation ) Diking, (Not Applicable as barrel storage) 9) Blast & barrier walls separation Sadekar Enviro Engineers Pvt. Ltd Chapter 7-25

203 CHAPTER 7: ADDITIONAL STUDIES 1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required MONDS INDEX Introduction The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index is a series of papers by lewis (1979). The main development made to the DOW Index in the Mond Index are: 1. It covers a wider range of process and storage installation 2. It covers the processing of chemicals with explosive properties 3. A calculation procedure is included to allow for the off-setting effects of good design and control and safety instrumentation 4. The procedure has been extended to cover plant layout 5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial explosion. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-26

204 CHAPTER 7: ADDITIONAL STUDIES Sr. Raw Materials Table No. 7.6: Monds Toxicity index of toxic chemicals Quanti ty MT Flash Point, 0 C UN Classifi cation Health Hazard Thresh old Limit Value Flammabi lity/ Reactivity Mond index Degree 1 Phosphorus 20 NA Corrosive/ 7.37 Moderate pentoxide mg/m 3 Toxic 2 Cautic lye 50 NA Corrosive 7.00 Moderate solution mg/m 3 3 epichlorohydrin NA Corrosive 8.12 Moderate 4 50 Corrosive 7.25 Moderate Con. Hydrochloric acid NA Acetic acid Corrosive/ 4.63 Light Toxic 6 Acrylamide mg/m 3 Toxic 7.7 Moderate 7 Thionyl chloride 40 NF mg/m 3 Corrosive/ Toxic 8.7 Moderate Monds Index Calculation Toxicity Index : Th + Ts (1+GPH+SPH) 100 Where, SPH = Special Process Hazard GPH = General Process Hazard Th = Toxicity factor based on the NFPA hazard index (0 4) Ts = Correction factor (additional penalty) for toxicity based on Maximum Allowable Concentration (MAC) value in ppm Th (Toxicity Factor): For TEA will be 250 from the table no. 6.6 as the Nh factor for TEA is 3 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-27

205 CHAPTER 7: ADDITIONAL STUDIES Ts (Correction Factor): For TEA will be 125 from the table no. 6.7 as the MAC is 2 ppm Table No. 7.7 Toxicity factor Index NFPA Index Number Toxicity Factor (Th) Table No. 7.8 Correction factor for Toxicity MAC (in ppm) Ts 5 and below 125 Between 5 and and more 50 Table No. 7.9 Toxicity Index The resulting TI values are ranked into three categories: 1-5 Light 6-9 Moderate 10-up High 1. Monds Index Calculation for Phosphorus pentoxide T h (Toxicity Factor): For Phosphorus pentoxide will be 250 from the table as the N h factor for Phosphorus pentoxide is 3 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-28

206 CHAPTER 7: ADDITIONAL STUDIES T s (Correction Factor): For Phosphorus pentoxide will be 125 from the table as the MAC is 2 ppm. General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.6 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-29

207 CHAPTER 7: ADDITIONAL STUDIES Therefore from the above table the GPH and SPH is coming to be around 1.3 and 1.6 respectively. Calculation of Toxicity Index: Toxicity Index : T h + T s *(1+GPH+SPH)/ 100 Toxicity Index : [ * ( )]/100 Toxicity Index : 7.00 The Toxicity Index for phosphorus pentoxide is calculated to be around 7.00 which indicate that the degree of hazard is moderate. 2. Monds Index Calculation for caustic lye solution T h (Toxicity Factor): For caustic lye will be 250 from the table as the N h factor for caustic lye is 3 T s (Correction Factor): For caustic lye will be 125 from the table as the TLV is 2 mg/m 3. General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Sadekar Enviro Engineers Pvt. Ltd Chapter 7-30

208 CHAPTER 7: ADDITIONAL STUDIES Operation in or near flammable range inerted noninerted 0.00 to Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.6 Therefore from the above table the GPH and SPH is coming to be around 1.0 and 1.6 respectively. Calculation of Toxicity Index: Toxicity Index : T h + T s *(1+GPH+SPH)/ 100 Toxicity Index : [ * ( )]/100 Toxicity Index : 7.00 The Toxicity Index for caustic lye is calculated to be around 7.00 which indicate that the degree of hazard is moderate. 3. Monds index for epichlorohydrin drums Sadekar Enviro Engineers Pvt. Ltd Chapter 7-31

209 CHAPTER 7: ADDITIONAL STUDIES T h (Toxicity Factor): For TEA will be 250 from the table as the Nh factor is 3 T s (Correction Factor): T s will be 125 from the table as the MAC is 2 ppm Tank No. -- Equipment Name Epichlorohydrin 10 MT Basic Material for Material HDPE Drums Density, g/cc 1.18 Properties of material N h 3 N f 2 N r 3 M.F. 29 Boil. -- 0F 116 0C Flash pt. 87 0F 31 0C pt. HC = Heat of Comb BTU / lb Quantity of the material l kg Lb Storage conditions Temp 30 0C Pressure 1.0 bar 1.General Process Base Factor Penalty factor range Penalty factor used Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in contact of Flame Dust Explosion 0.25 to Pressure Operating pressure psig 0.0 Low temperature 0.20 to Quantity of flammable / unstable material 1. Liquids or gases in process 0.0 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-32

210 CHAPTER 7: ADDITIONAL STUDIES 2. Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.9 The Toxicity Index for epichlorohydrin is calculated to be around which indicate that the degree of hazard is Moderate from above table. 4. Monds Index Calculation for Acetic acid T h (Toxicity Factor): For Acetic acid will be 250 from the table as the N h factor for Acetic Acid is 3 T s (Correction Factor): For Acetic acid will be 50 from the table as the MAC is 100 ppm General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to inerted noninerted Sadekar Enviro Engineers Pvt. Ltd Chapter 7-33

211 CHAPTER 7: ADDITIONAL STUDIES 1. Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 2.46 Therefore from the above table the GPH and SPH is coming to be around 3.3 and 2.46 respectively. Calculation of Toxicity Index: Toxicity Index : T h + T s *(1+GPH+SPH)/ 100 Toxicity Index : [ ( )]/100 Toxicity Index : 4.63 The Toxicity Index for Acetic Acid is calculated to be around 4.63 which indicate that the degree of hazard is light. 5. Monds Index for Hydrochloric acid Th (Toxicity Factor): For HCl will be 250 from the above table as the N h factor for HCl is 3 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-34

212 CHAPTER 7: ADDITIONAL STUDIES Ts (Correction Factor): For HCl will be 125 from the table as the MAC is 2 ppm. General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to 0.80 inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.8 Therefore from the above table the GPH and SPH is coming to be around 1.00 and 1.8 respectively. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-35

213 CHAPTER 7: ADDITIONAL STUDIES Calculation of Toxicity Index: Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [ ( )]/100 Toxicity Index : 725 The Toxicity Index for HCl is calculated to be around 7.25 which indicate that the degree of hazard is moderate. 6. Monds Index for Acrylamide T h (Toxicity Factor): For acrylamide will be 250 from the table as the N h factor for acrylamide is 3 T s (Correction Factor): For acrylamide will be 125 from the table as the MAC is 2 mg/m 3 General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to inerted noninerted Sadekar Enviro Engineers Pvt. Ltd Chapter 7-36

214 CHAPTER 7: ADDITIONAL STUDIES 1. Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Rotating Equipment Special Process Hazard Factor ( F2 ) 1.96 Therefore from the above table the GPH and SPH is coming to be around 1.2 and 1.96 respectively. Calculation of Toxicity Index: Toxicity Index : T h + T s *(1+GPH+SPH)/ 100 Toxicity Index : [ ( )]/100 Toxicity Index : 7.7 The Toxicity Index for acrylamide is calculated to be around 7.7 which indicate that the degree of hazard is moderate. 7. Monds Index for Thionyl chloride Sadekar Enviro Engineers Pvt. Ltd Chapter 7-37

215 CHAPTER 7: ADDITIONAL STUDIES T h (Toxicity Factor): For thionyl chloride will be 325 from the table as the N h factor for thionyl chloride is 4. T s (Correction Factor): For thionyl chloride will be 125 from the table as the MAC is 5 ppm General & Special Process Hazard 1.General Process Base Factor Exothermic Chemical Reaction 0.30 to Endothermic Processes 0.20 to Material handling and transfer 0.25 to Enclosed or Indoor Process Units 0.25 to Access 0.20 to Drainage and Spill Control 0.25 to General Process Hazard Factor ( F1 ) Special Process Base Factor Toxic material(s) 0.20 to Sub atmospheric pressure (< 500 mm Operation in or near flammable range 0.00 to inerted noninerted 1. Tank farm storage flammable Process upset or purge failure Always in Flammable range Dust Explosion 0.25 to Pressure Operating pressure psig 0.00 Low temperature 0.20 to Quantity of flammable / unstable 1. Liquids or gases in process Liquids or gases in storage Combustible Solids in Storage, Dust 0.00 in Process Corrosion & Erosion 0.10 to Leakage - Joints & Packing 0.10 to Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to Sadekar Enviro Engineers Pvt. Ltd Chapter 7-38

216 CHAPTER 7: ADDITIONAL STUDIES Rotating Equipment Special Process Hazard Factor ( F2 ) 2.16 Therefore from the above table the GPH and SPH is coming to be around 1.2 and 2.16 respectively. Calculation of Toxicity Index: Toxicity Index : T h + T s *(1+GPH+SPH)/ 100 Toxicity Index : [ ( )]/100 Toxicity Index : 8.7 The Toxicity Index for thionyl chloride is calculated to be around 8.7 which indicate that the degree of hazard is moderate. Recommendations for storage: MSDS of all the raw materials will be provided in the storage area. Raw material will be segregated and stored by compatibility. The material will be stacked in cabinets away from the source of ignition & heat. Spill kit will be provided. Training will be given to employees to handle hazardous and toxic chemicals. PPEs like full body suit, glove, goggles, mask will be provided to employees for handling toxic & hazardous raw materials. Storage area will be provided with sufficient ventilation. Earthing will be provided to eliminate risk of fire. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-39

217 CHAPTER 7: ADDITIONAL STUDIES 7.3 HAZOP Study Hazop study has been carried out for all hazardous operations and process. It is attached as Annexure DISASTER MANAGEMENT PLAN Objectives of Disaster Management Plan [DMP] The Disaster Management Plan (DMP) is aimed to ensure safety of life, protection of environment, protection of installation, restoration of production and salvage operations in the same order of priorities. For effective implementation of the DMP, it should be widely circulated and personnel training through rehearsals/drills should be organized. Further, the management should be able to demonstrate that its assessment of the consequences as good supporting evidence. To tackle the consequences of a major emergency inside the factory or immediate vicinity of the factory, a DMP has to be formulated and this planned emergency document is called "Disaster Management Plan". The objective of the Industrial Disaster Management Plan is to make use of the combined resources of the plant and the outside services to achieve the following: Effect the rescue and medical treatment of causalities Safeguard other people Minimize damage to property and the environment Initially contain and ultimately bring the incident under control Identify any dead Provide for the needs of relatives Provide authoritative information to the news media Secure the safe rehabilitation of affected area Preserve relevant records and equipment for the subsequent inquiry into the cause and circumstances of the emergency. In effect, it is to optimize operational efficiency to rescue rehabilitation and render medical help and to restore normalcy Onsite Emergency Plan Salient Features of the Project Name of Project M/s Glaxy surfactants Ltd. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-40

218 CHAPTER 7: ADDITIONAL STUDIES Address (Plant) Plot No: G-59, Tarapur MIDC, Boisar, Palghar, Dist : Palghar, Maharashtra, India Nature of the Project Production of specialty chemicals Capacity 4132 MT/month Man Power 177 Name of Site Head Mr. Milind Patil Key Persons in the Emergency Plan Site Manager Corporate EHS Head EHS Manager Sr. Executive Safety Officer Fire Officer Chemist OBJECTIVES OF THE PLAN On-Site emergency preparedness plan has the following objectives: 1. Safeguard lives and property at site and in its vicinity area. 2. Contain the incident and bring it under control; 3. Minimize damage to lives, property and environment; 4. Rescue and treat casualties; 5. To train the people to act efficiently and with confidence in an emergency. 6. Evacuate people to safe areas; 7. To minimize its occurrence Pre Emergency Plans - Pre Emergency means the preparatory stage of the plan. It should be ensured that the prepared plan contains all required provisions and details of facility to handle and to contain the emergency situation successfully. The unit has to consider maximum and possible worst scenario for emergency purpose while planning. The unit has to develop and maintain the essential facilities, so that the emergency can be controlled and the damages are minimized in the shortest period with proper use of all available resources. The unit should be duly prepared and ready all the time to encounter any possible emergency, while it may strike or not. Being a specialty chemicals Manufacturing unit various type of Sadekar Enviro Engineers Pvt. Ltd Chapter 7-41

219 CHAPTER 7: ADDITIONAL STUDIES chemicals are used possessing varied types of hazards and knowing the hazards of the chemical, stored, handled or processed in the factory, the quick response action must be created within unit. The structure of the plan may vary depending on the number of employees, materials, process, and availability of recourses, location of site, size and complexity of the unit. It should ensure to work out a plan with possibilities of various emergencies with likely to arise within unit. Further the periodical rehearsal is also to be carried out to check and examine the effectiveness, awareness and preparedness of the plan as well as services. The emergency planning is not a substitute for good design, plant operating and maintenance practices. Therefore, the Onsite Emergency Action Plan must be followed to avoid emergency Periodic Checking Schedule- To check availability, work ability and take necessary actions for replacement and maintenance, if required. Check resources of water. Keep all emergency and essential Telephone Nos. with contact persons, suppliers for the same handy. Contact details may be displayed on the boards installed at prominent locations in the plant and offices. Maintain the co- ordination with other fire services. Also the Firefighting system and PPE should be checked if they are in working condition and proper maintenance should be done Preventive Maintenance (To Avoid Emergency) A scheduled periodical preventative maintenance and inspection of the plants, Reactors, centrifuges, equipment s, storage tanks, air compressors, D.G. Sets etc. are as per laid down procedures and check that records are maintained properly. Check the test, examination and certification have been carried out within reasonable period Training By imparting an effective training to the plant supervisors, inspectors, and education and training of the workers from time to time, the awareness is to be kept alive all the time to ensure safety awareness, preparedness for emergency situations, good housekeeping, discipline, etc. Display of safety slogans, operative instructions and motivation for safety should be made part of the company s normal activities. All the persons earmarked for the emergency services are to be trained to respond to the emergency. The company conducts internal & external training for Environment Health & safety. The training is conducted at a documented frequency. The external training is conducted six monthly and internal training is conducted every month. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-42

220 CHAPTER 7: ADDITIONAL STUDIES Monitoring the Environment Continuous and periodic monitoring of environment is required for detection of a possible damage or a risky situation arises Mock Drill Organize the periodical mock drill / rehearsal as per suggested format by creating an emergency situation so as to verify preparedness and awareness as well as shortcomings on the part of the person to overcome the same. Provide sufficient time prior to mock drill to the emergency services and public for proper response to exercise and provide training also. Record the deficiencies of the system during the trial and take appropriate actions to improve the efficiency of the plan in terms of preparedness and response Maintenance of Records Keep the records of the monitoring conditions, safety systems, storage levels, process condition, etc. and maintain the log- books, registers etc. Keep the M.S.D.S. and onsite emergency plan with required details. The solvent and trimethyl amine tanker unloading and handling sheet is prepared. It will be duly filled by the workers and SOP for unloading shall be followed strictly. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-43

221 CHAPTER 7: ADDITIONAL STUDIES Sadekar Enviro Engineers Pvt. Ltd Chapter 7-44

222 CHAPTER 7: ADDITIONAL STUDIES Work Instructions for Unloading Of Solvents (Ethyl Acetate / Toluene / 2-Ethyl hexanol/ LDO) A. Precautions: Check level of the tank in which you are planning to unload the tanker Check vents line of storage tank. It must be open through flame arrestor. Unloading hose must be metallic. Check whether safety instruments e.g. fire extinguishers are in place. Check for muffler (flame arrester to tanker flue gas exhaust) B. Procedure: 1. Before entering the tanker into the UG tank area ask the driver for his driving license, cleaner, Spark arrestor, Trem card etc. 2. After receiving the tanker slowly in tank area park the vehicle at required position with providing stopper & remove the key. 3. Wear the required the PPEs(safety Goggle, safety shoes, helmet & gloves. 4. Connect tanker to the earth. 5. Take a clean & dry bucket; Keep it below the outlet valve of the vehicle. 6. Start opening the blind flange fitted to tanker outlet valve. 7. While opening blind flange, first open ground side bolt about 2-3 threads. 8. Make loose any other adjacent bolt, so that the contents of the line will be drain into the bucket. 9. Remove the blind flange, connect one end of the SS hose to the receiver line and other to the tanker. 10. Check all the connections are properly fitted & provide the jumpers to all required places. 11. Start unloading into the UG tank by slowly opening unloading valve of the tanker. 12. If there are compartments, open all the valves slowly. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-45

223 CHAPTER 7: ADDITIONAL STUDIES 13. Keep safe distance (around 3 meters) while unloading into UG tank & keep watch on level of the storage tank. 14. After complete unloading, remove the hose connected to the tanker first & then from the receiver line by repeating procedure Remove the earth connection of the tanker. 16. Solvent which is collected in bucket is pour into Solvent tank. 17. Take care of no spillages of the solvent; If spillage occurs then spreading sand on it. Ask driver to remove tanker slowly out of the UG tank area by removing stopper & Retuning vehicle key Protocols of handling TMA gas 1. The storage tank will be stainless steel 2. The TMA gas in the storage tank will be kept under nitrogen pressure of about 3-4 kgf/cm2 3. The temperature of the TMA gas in the storage tank will be maintained between <20 C. 4. The handling area of TMA gas will be flameproof 5. The storage tank and pipelines will be properly earthed using jump-overs over flanges to prevent generation of static charges 6. The vent of the TMA gas will be connected to the scrubber system Level transmitter, 2- pressure transmitter and 2- temperature transmitter will be provided over storage tank of TMA gas to control and monitor the parameters through DCS system 8. Control valve will be provided on chilled water line to control the temperature of the storage tank 9. The pipe line to transfer TMA gas to reactor will be insulated to avoid increase in temperature 10. The reaction will be controlled through DCs system with adequate interlocks to avoid human error. Reactor will be equipped with Pressure transmitter, level transmitter and temperature transmitter to control the process parameters through DCS system. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-46

224 CHAPTER 7: ADDITIONAL STUDIES 11. Gas concentration monitors will be installed in the gas storage section as well as near reactor to monitor the concentration of TMA gas in the area 12. Emergency vent will be connected to the stack with diluents 13. The electrical equipments in the reactor area will also be of flameproof type 14. Showers and eye washers will be provided in the storage area as well as near to reactor area Emergency Control Room The equipped Emergency Control Room should be in working order. The plant layout maps, drawing, storage details, Material safety Data Sheets (MSDS), emergency operations, manuals etc. should be kept and should be updated continuously. List of essential telephone Nos. is also maintained up to date. The senior and expert person should be posted as in charge of the control room Command & Control The organization chart, for the emergency plan has been given which explains the chart of command, channel of information flow, and actions as required during the emergency. The single organizational structure has been created on striking emergency and the same shall be continued till the emergency over. The Shift Supervisor shall take the initial charge as incident controller; he will be coordinating with various agencies effectively to combat the situation. The security office room will be used as emergency control Room. The security gate will be used as Assembly point. The Factory Manager will act as site main controller for the unit. On arrival, he will supervise all activities with the help of asst. Plant in- charge. The duties & responsibilities have been defined as per below. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-47

225 CHAPTER 7: ADDITIONAL STUDIES Identification of Hazards The type of hazards have been identified in the previous section accordingly and risk quantification is also been done for all the raw materials List of fire extinguishers & fire buckets provided Type of extinguishers and location Sr. Type Units no. 1 ABC type Fire Extinguishers 6 kg 12 9 kg 10 2 FOAM type Fire Extinguishers 9 L 5 50 L 4 3 CO 2 type Fire Extinguishers 2 kg kg kg 6 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-48

226 CHAPTER 7: ADDITIONAL STUDIES Table 7.10 Type of Fire Extinguishers Sadekar Enviro Engineers Pvt. Ltd Chapter 7-49

227 CHAPTER 7: ADDITIONAL STUDIES SR NO Fire Hydrant details DESCRIPTION LOCATI MATERIAL QTY REMARK ON 1. Fire Hydrant in plant G-59 plant Fire Hydrant hose box 21 Fire Hydrant site 2. ' ' Fire Hydrant box keys 21 '' 3. ' ' Fire Hydrant hose box hammer 21 '' 4. ' ' Fire Hydrant nozzels 21 '' 5. ' ' Fire Hydrant TPB nozzel 0 '' 6. ' ' Fire Hydrant box ( F ) Spanner 0 '' 7. ' ' Fire Hydrant hose pipe 7.5M 12 '' Fire Hydrant hose pipe 15M 27 '' 8. ' ' 9. ' ' Singal door hose box 10 '' 10. ' ' Double door hose box 16 '' 11. ' ' Fire Hydrant stand post 21 '' Fire Hydrant site Hose reel drums 7 '' 12. ' ' 13. ' ' Fire Hydrant spinkler 71 '' 14. ' ' Old MCP ( siten) ' ' Old MCP pannel ' ' New MCP ' ' Water release point ' ' Hooter ' ' 20. ' ' New Fire hydrant detection pannel 2 Fire Hydrant air release valve ' ' Deluge valve ' ' Heat Detector 20 '' 23. ' ' Smoke Detector 48 '' 24. ' ' Emergency Safety Shower 2 Fire Hydrant site Sadekar Enviro Engineers Pvt. Ltd Chapter 7-50

228 CHAPTER 7: ADDITIONAL STUDIES 25. ' ' Fire sand bucket ' ' Etp In line Inductor (Foam generation) ' ' Fire Hydrant etp site foam troly ' ' (foam trolly foam ore-40 lit ) 29. ' ' sv 2' 2' 0 Fire Hydrant site 30. ' ' sv 2' 4' 0 '' 31. ' ' sv 2' 6' 0 '' 32. ' ' P.G. 2' 9 '' 33. ' ' P.G. 2' 0 '' 34. ' ' P.G. 2' 0 '' 35. ' ' NRV 2' 0 '' 36. ' ' NRV 2' 0 '' 37. ' ' NRV 2' 0 '' 38. ' ' B.FLY all 0 '' 39. ' ' pressure guage ' ' '' 0 Table No : Location of fire hydrants points and quantity Fire Fighting Systems Please fill the following information Fire Fighting Tank Details Capacity of Fire Fighting tanks 400 m 3. Type of tank Overhead/ Below head overhead Material of Construction RCC Sadekar Enviro Engineers Pvt. Ltd Chapter 7-51

229 CHAPTER 7: ADDITIONAL STUDIES Pump Capacity of fire fighting tank Jockey Pump-10.8 m3/hr. Main Pump-171 m3/hr. Diesel Pump-171 m3/hr. No of assembly points 1 No of exit points for emergency 10 evacuation Fire Hydrant system Yes Flow Diagram showing Key Persons involved in Emergency Situation and their hierarchy. PLANT HEAD ASSISTANT MANAGER (EHS) EXECUTIVE EHS EHS OFFICER ` ETP CHEMIST ETP OPERATOR FIRE OFFICER Sadekar Enviro Engineers Pvt. Ltd Chapter 7-52

230 CHAPTER 7: ADDITIONAL STUDIES Emergency Responsibilities The responsibilities of the key personnel are appended below. Sr. Executive On knowing about emergency, rushes to ECC. Helps the Incident Controller in containment of the emergency. Ensures fire pumps in operating conditions and instructs pump house operator to be ready for any emergency with standby arrangement. Guides the fire fighting crew i.e. firemen, trained plant personnel and security staff. Organizes shifting the fire fighting facilities to the emergency site, if required. Takes guidance of the Incident Controller for firefighting as well as assesses the requirements of outside help. Arranges to control the traffic at the gate and the incident area. Directs the security staff to the incident site to take part in the emergency operations under his guidance and supervision. Evacuates the people in the plant or in the nearby areas as advised by Site Controller. Searches for casualties and arranges proper aid for them. Assembles a search and evacuation team. Arranges for safety equipment for the members of this team. Decides which paths the evacuated workers should follow. Maintains law and order in the area and, if necessary, seeks the help of police EHS Manager - Medical, Mutual Aid, Rehabilitation, Transport and Communication In the event of failure of electric supply and thereby internal telephone, sets up communication point and establishes contact with the Emergency Control Centre (ECC). Organizes medical treatment to the injured and, if necessary, arrange to shift the injured to nearby hospitals. Mobilizes extra medical help from outside, if necessary. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-53

231 CHAPTER 7: ADDITIONAL STUDIES Keeps a list of qualified first aiders of the factory and seeks their assistance. Maintains first aid and medical emergency requirements. Makes sure that all safety equipment is made available to the emergency team. Assists Site Controller with necessary data and to coordinate the emergency activities. Assists Site Controller in updating the emergency plan, organizing mock drills, verification of inventory of emergency facilities and furnishing report to Site Controller. Maintains liaison with Civil Administration. Ensures availability of canteen facilities and maintenance of rehabilitation centre. He will liaise with Site Controller/Incident Controller. Ensures transportation facility. Ensures availability of necessary cash for rescue/rehabilitation and emergency expenditure. Controls rehabilitation of affected areas on discontinuation of emergency. Makes available diesel/petrol for transport vehicles engaged in emergency operation EHS Manager - Essential Services He would assist Site Controller and Incident Controller. Maintains essential services like Diesel Generator, Water, Fire Water, compressed Air/Instrument Air and power supply for lighting. He would plan alternate facilities in the event of power failure, to maintain essential services such as lighting, refrigeration plant etc. He would organize separate electrical connections for all utilities and emergency services so that in the event of emergency or fires, essential services and utilities are not affected. Gives necessary instructions regarding emergency electrical supply, isolation of certain sections etc. to shift in charge and electricians. Ensures availability of adequate quantities of protective equipment and other emergency materials, spares etc. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-54

232 CHAPTER 7: ADDITIONAL STUDIES General Responsibilities of Employees during an Emergency During an emergency, it becomes more enhanced and pronounced when an emergency warning is raised; the workers, if they are in charge of process equipment, should adopt safe and emergency shut down and attend to any prescribed duty as essential employee. If no such responsibility is assigned, he should adopt a safe course to assembly point and await instructions. He should not resort to spread panic. On the other hand, he must assist emergency personnel towards objectives of DMP Emergency Facilities Emergency Control Centre (ECC) M/s Galaxy surfactants Ltd has established an Emergency Control Centre. It has external telephone, telefax and telex facility. All the Site Controller/ Incident Controller Officers, Senior Personnel would be located here. The following information and equipment will be provided at the Emergency Control Centre (ECC): Intercom, telephone P and T telephone Safe contained breathing apparatus Fire suit/gas tight goggles/gloves/helmets Hand tools, wind direction/velocities indicators Public address megaphone, hand bell, telephone directories (Internal, P and T) factory layout, site plan Emergency lamps/torch lights/batteries Plan indicating locations of hazard inventories, plant control room, sources of safety equipment, work road plan, assembly points, rescue location, vulnerable zones, and escape routes Hazard chart Sadekar Enviro Engineers Pvt. Ltd Chapter 7-55

233 CHAPTER 7: ADDITIONAL STUDIES Emergency shut-down procedures Nominal roll of employees List of key personnel, list of essential employees, list of Emergency Co-ordinators Duties of key personnel Addresses with telephone numbers of key personnel, emergency coordinator, and essential employees. Important addresses and telephone numbers including Government agencies, neighboring industries and sources of help, outside experts, chemical fact sheets, population details around the factory Assembly Point Number of assemblies depending upon the plant location would be identified wherein employees who are not directly connected with the disaster management would be assembled for safety and rescue. Emergency breathing apparatus, minimum facilities like water etc. would be organized. In view of the size of plant, different locations are earmarked as assembly points. Depending upon the location of hazard, the assembly points are to be used Emergency Power Supply Plant facilities would be connected to Generator and would be placed in auto mode. Thus, water pumps, plant s lighting and emergency control centre, administrative building and other auxiliary services are connected to emergency power supply. In all the blocks, flameproof type emergency lamps would be provided Fire Fighting Facilities First Aid and Firefighting equipment suitable for emergency are maintained well in each section in the plant. This would be developed according to the statutory requirements. However, fire hydrant line covering major areas has been laid. Fire alarms have been located in the bulk storage areas. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-56

234 CHAPTER 7: ADDITIONAL STUDIES Location of Wind Sock Windsocks exist in the plant Emergency Medical Facilities Stretchers, gas masks and general first aid materials for dealing with chemical burns, fire burns etc. will be maintained in the medical centre as well as in the emergency control room. Private medical practitioners help would be sought. Government hospital would be approached for emergency help. Apart from plant first aid facilities, external facilities would be augmented. Names of medical personnel and medical facilities in the area would be Prepared and updated. Necessary specific medicines for emergency Treatment of burns patients and for those affected by toxicity would be maintained. Breathing apparatus and other emergency medical equipment would be provided and maintained. The help of nearby industrial managements in this regard would be taken on mutual support basis Emergency Actions Emergency Warning Communication of emergency will be made familiar to the personnel inside the plant and people outside. An emergency warning system has already been established in the plant Emergency Shutdown There are a number of facilities which can be provided to help deal with hazardous conditions, when a tank is on fire. The suggested arrangements are: Stop feed Dilute contents Remove heat Deluge with water Transfer contents. Whether a given method is appropriate depends on the particular case. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-57

235 CHAPTER 7: ADDITIONAL STUDIES Cessation of agitation may be the best action in some instances but not in others. Stopping of the feed may require the provision of bypass arrangements. Methods of removing additional heat include removal through the normal cooling arrangements or use of an emergency cooling system. Cooling facilities, which use vaporizing liquid, may be particularly effective, since a large increase in vaporization can be obtained by dropping pressure Evacuation of Personnel There could be more number of persons in the storage area and other areas in the vicinity. The area would have adequate number of exits and staircases. In the event of an emergency, unconnected personnel have to escape to assembly point. Operators have to take emergency shutdown procedure and escape. Time Office maintains a copy of deployment of employees in each shift. If necessary, persons can be evacuated by rescue teams All Clear Signal Also, at the end of an emergency, after discussing with Incident Controllers and Emergency Cocoordinators, the Site Controller orders an all clear signal. When it becomes essential, the Site Controller communicates to the District Emergency Authority, Police, and Fire Service personnel regarding help required or development of the situation into an Off-Site Emergency General Employee Information During an emergency, employees would be warned by raising siren in specific pattern. Employees would be given training of escape routes, taking shelter, protecting from toxic effects. Employees would be provided with information related to fire hazards, antidotes and first aid measures. Those who would be designated as key personnel and essential employees should be given training in emergency response. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-58

236 CHAPTER 7: ADDITIONAL STUDIES Public Information and Warning The industrial disaster effects related to this plant may mostly be confined to the plant area. The detailed risk analysis has indicated that the pool fire effects would not be felt outside. However, as an abundant precaution, the information related to chemicals in use would be furnished to District Emergency Authority (normally the Collector) for necessary dissemination to general public and for any use during an offsite emergency Co-ordination with Local Authorities Keeping in view the nature of the emergency, two levels of co-ordination are proposed. In the case of an On Site Emergency, resources within the organization would be mobilized and in the event of an extreme emergency, local authorities help should be sought. In the event of an emergency developing into an offsite emergency, local authority And District Emergency Authority (normally the Collector) would be apprised and Under his supervision, the Off Site Disaster Management Plan would be exercised. For this purpose, the facilities that are available locally, i.e. medical, transport, personnel, rescue accommodation, voluntary organizations etc. would be mustered. Necessary rehearsals and training in the form of mock drills should be organized. 7.5 Off-Site Emergency Preparedness Plan The off-site plan will be prepared with the help of the local district authorities. The proposed plan will be based on the following guidelines Introduction Off-site emergency plan follows the on-site emergency plan. When the consequences of an emergency situation go beyond the plant boundaries, it becomes an off-site emergency. Off-site emergency is essentially the responsibility of the public administration. However, the factory management will provide the public administration with the technical information relating to the nature, quantum and probable consequences on the neighboring population. The off-site plan in Sadekar Enviro Engineers Pvt. Ltd Chapter 7-59

237 CHAPTER 7: ADDITIONAL STUDIES detail will be based on those events, which are most likely to occur, but other less likely events, which have severe consequence, will also be considered. Incidents, which have very severe consequences yet have a small probability of occurrence, should also be considered during the preparation of the plan. However, the key feature of a good off-site emergency plan is flexibility in its application to emergencies other than those specifically included in the formation of the plan. The roles of the various parties who will be involved in the implementation of an off-site plan are described below. Depending on local arrangements, the responsibility for the off-site plan should either rest with the works management or, with the local authority. Either way, the plan should identify an emergency coordinating officer, who would take the overall command of the off-site activities. As with the on-site plan, an emergency control centre should be set up within which the emergency coordinating officer can operate. An early decision will be required in many cases on the advice to be given to people living "within range" of the accident; in particular, whether they should be evacuated or told to go indoor. In the latter case, the decision can regularly be reviewed in the event of an escalation of the incident. Consideration of evacuation may include the following factors: In the case of a major fire but without explosion risk (e.g. an oil storage tank), only houses close to the fire are likely to need evacuation, although a severe smoke hazard may require this to be reviewed periodically If a fire is escalating and in turn threatening a store of hazardous material, it might be necessary to evacuate people nearby, but only if there is time; if insufficient time exists, people should be advised to stay indoors and shield themselves from the fire For release or potential release of toxic materials, limited evacuation may be appropriate downwind if there is time. The decision would depend partly on the type of housing "at risk". Conventional housing of solid construction with windows closed offers substantial protection from the effects of a toxic cloud, while shanty house, which can exist close to factories, offers little or no protection Sadekar Enviro Engineers Pvt. Ltd Chapter 7-60

238 CHAPTER 7: ADDITIONAL STUDIES Aspects Proposed to be considered in the Off-Site Emergency Plan The main aspects, which should be included in the emergency plan, are: Organization Details of command structure, warning systems, implementation procedures, emergency control centers. Names and appointments of incident controller, site main controller, their deputies and other key personnel Communications Identification of personnel involved, communication centre, call signs, network, lists of telephone numbers Specialized knowledge Details of specialist bodies, firms and people upon whom it may be necessary to call e.g. those with specialized chemical knowledge, laboratories Voluntary organizations Details of organizers, telephone numbers, resources etc Chemical information Details of the hazardous substances stored or processed on each site and a summary of the risk associated with them Meteorological information Arrangements for obtaining details of weather conditions prevailing at the time and weather forecasts Humanitarian arrangements Transport, evacuation centers, emergency feeding treatment of injured, First aid, ambulances, temporary mortuaries Public information Arrangements for: (a) dealing with the media press office; (b) informing relatives, etc. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-61

239 CHAPTER 7: ADDITIONAL STUDIES Assessment Arrangements for: (a) collecting information on the causes of the emergency; (b) reviewing the efficiency and effectiveness of all aspects of the emergency plan Role of the Emergency Co-ordinating Officer The various emergency services should be co-ordinated by an emergency co-ordinating officer (ECO), who will be designated by the District Collector. The ECO should liaise closely with the Site Controller. Again, depending on local arrangements, for very severe incidents with major or prolonged off-site consequences, the external control should be passed on to a senior local authority administrator or even an administrator appointed by the central or state government Role of the Local Authority The duty to prepare the off-site plan lies with the local authorities. The emergency planning officer (EPO) appointed should carry out his duty in preparing for a whole range of different emergencies within the local authority area. The EPO should liase with the works, to obtain the information to provide the basis for the plan. This liaison should ensure that the plan is continually kept up to date. It will be the responsibility of the EPO to ensure that all those organizations, which will be involved off site in, handling the emergency, know of their role and are able to accept it by having for example, sufficient staff and appropriate equipment to cover their particular responsibilities. Rehearsals for off-site plans should be organized by the EPO Role of Police Formal duties of the police during an emergency include protecting life and property and controlling traffic movements. Their functions should include controlling bystanders, evacuating the public, identifying the dead and dealing with casualties, and informing relatives of dead or injured. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-62

240 CHAPTER 7: ADDITIONAL STUDIES Role of Fire Authorities The control of a fire should normally be the responsibility of the senior fire brigade officer who would take over the handling of the fire from the site incident controller on arrival at the site. The senior fire brigade officer should also have a similar responsibility for other events, such as explosions and toxic release. Fire authorities in the region should be apprised about the location of all stores of flammable materials, water and foam supply points, and fire-fighting equipment. They should be involved in on-site emergency rehearsals both as participants and, on occasion, as observers of exercises involving on-site personnel Role of Health Authorities Health authorities, including doctors, surgeons, hospitals, ambulances, and similar other persons/institutions should have a vital part to play following a major accident, and they should form an integral part of the emergency plan. For major fires, injuries should be the result of the effects of thermal radiation to a varying degree, and the knowledge and experience to handle this in all but extreme cases may be generally available in most hospitals. For major toxic releases, the effects vary according to the chemical in question, and the health authorities should be apprised about the likely toxic releases from the plant, which will enable them to deal with the aftermath of a toxic release with treatment appropriate to such casualties. Major off-site incidents are likely to require medical equipment and facilities in additional to those available locally, and a medical "mutual aid" scheme should exist to enable the assistance of neighboring authorities to be obtained in the event of an emergency Role of Government Safety Authority This will be the factory inspectorate available in the region. Inspectors are likely to want to satisfy themselves that the organization responsible for producing the off-site plan has made adequate arrangements for handling emergencies of all types including major emergencies. They may wish to see well documented procedures and evidence of exercise undertaken to test the plan. In the event of an accident, local arrangements regarding the role of the factory inspector will apply. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-63

241 CHAPTER 7: ADDITIONAL STUDIES These may vary from keeping a watch to a close involvement in advising on operations. While the industry will activate the DMP and take necessary alleviating measures and arrange to extend all medical and security support, the factory inspectorate may be the only external agency with equipment and resources to carry out appropriate tests to assess the impact External agencies contact details involved during emergency Off site Emergency Plan 1. No. and names of nearest Hospitals from the industry, their address, telephone no and distances from industry. ( Minimum 3 hospitals) Sr. No. Name of Hospit al 1 TIMA Hospita l TMRC T Hospita l Sai Leela Hospita l Address Telephone Distanc es MIDC Tarapur, Near Khaira Fate Boisar, Dist. Palghar , J-70,MIDC Tarapur, Boisar, Dist. Palghar Ground Floor, Satyam Building, Opp. Balaji Sweets, Otaswal, Boisar, Dist. Palghar 2.5km 2.0km km 2. No. and names of nearest Police Station from the industry, their address, telephone no and distances from industry. Sr No Name of Police Station Address Telephone Distances 1 MIDC Police Station MIDC Police Station, Navapur Rd., Camlin Naka, MIDC Tarapur, Boisar, Dist. Palghar km Sadekar Enviro Engineers Pvt. Ltd Chapter 7-64

242 CHAPTER 7: ADDITIONAL STUDIES 3. No. and names of nearest Fire Station from the industry, their address, telephone no and distances from industry. Sr No Name of Fire Address Telephone Distances Station 1 Boisar Fire Station Boisar Fire Station, Navapur Rd, Camlin Naka, MIDC Tarapur, Boisar, Dist. Palghar km 4. Names of nearest MIDC from the industry, their address, telephone no Sr No Name of MIDC Address Telephone Distances 1 Maharashtra Industrial Development Corpn.Tarapue MIDC Tarapur,Takinaka, Navapur Rd.,Dist.Palghar km 5. Names of nearest Municipality from the industry, their address, telephone no Sr No Name of Municipality Address Telephone Distances 1 Gram Panchyat Kolawade Gram Panchyat Kolawade,PO.TAPP, Boisar,Tal. Palghar,Dist.Palghar km 6. Names of nearest Pollution Control Department from the industry, their address, telephone no Sr No Name of PCD Address Telephone Distances 1 Maharashtra Pollution Control Board, MIDC Tarapur MPCB Tarapur, Chitralaya, Boisar Tarapur Rd. Boisar, Dist. Palghar km 7.6 Socio Economic status of the study area Introduction Social Impact Assessment (SIA) is an integral part of project planning and policy evaluation and part of EIA report due the importance that social considerations must be included in the decision Sadekar Enviro Engineers Pvt. Ltd Chapter 7-65

243 CHAPTER 7: ADDITIONAL STUDIES process. Social Impact Assessment (SIA) is understood as a pr ocess of assessing and managing the impacts of a project, plan, program or policy on people. Social impacts include all social and cultural consequences to human populations of any public or private actions that alter the ways in which people live, work, play, relate to one another, organize to meet their needs, and generally cope as members of society. Cultural impacts involve changes to the norms, values, and beliefs of individuals that guide and rationalize their cognition of themselves and their society. In general, the SIA process includes: 1. Understanding, managing, and controlling change. 2. Predicting probable impacts from change strategies or development projects that are to be implemented. 3. Identifying, developing, and implementing mitigation strategies in order to minimize potential social impacts 4. Developing and implementing monitoring programs to identify unanticipated social impacts that may develop as a result of the social change. 5. Developing and implementing mitigation mechanisms to deal with unexpected impacts as they develop. 6. Evaluating social impacts caused by earlier developments, projects, technological change, specific technology, and government policy. Aim of the study: 1. The present endeavour is to understand the socio-economic situation in the vicinity of the proposed plant and assess the impact on the socio-economic factors of the proposed plant. 2. Secondary data were collected through various sources namely:- 3. Census of India, Economic Survey of Maharashtra District Social and Economic Survey of Palghar District Table 7.12: Palghar Taluka, Palghar District, population figures for 2011 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-66

244 CHAPTER 7: ADDITIONAL STUDIES 2011 Male Female Person Urban 86,842 69,608 1,56,480 Rural 1,65,149 1,59,637 3,24,786 Total 2,51,991 2,29,245 4,81,236 Source: Census of India, 2011& 2001 From the secondary data it is evident that male population was comparatively high in both the rural & urban areas in Palghar Taluka Table 7.13: Palghar Taluka, Palghar District child population in the age group 0 to 6 figures for Boys Girls Total Urban 10,57 9,724 20,298 Rural 20,736 20,381 41,117 Total 31,310 30,105 61,415 Source: Census of India, 2011 Off the total 61,415 child population (in age group of 0 to 6) of Palghar Taluka, the population of girl child was observed to be slightly lower than that of boys. Table 7.14: Literacy rates by residence and sex Palghar Tehsil Literacy rate Rural Person Male Female Urban Rural Total Source: Census of India, 2011 As per the data published by Census of India, it is observed that literacy rate amongst the males was comparatively higher in both the urban & rural areas. Table 7.15: Basic Amenities Sadekar Enviro Engineers Pvt. Ltd Chapter 7-67

245 CHAPTER 7: ADDITIONAL STUDIES Palghar Tehsil Facilities/Amenities No. of villages Total number of inhabited villages in the CD block 200 No. of villages with electrification 200 No. of villages with S.T bus facility 179 No. of villages with commerce bank office 17 No. of villages with primary school 193 No. of villages with health related facilities Primary health entre 9 Primary health sub centre 61 Maternity & child welfare 9 centre T.B centre 9 Hospital - allopathic 9 Dispensary 30 Veterinary hospital 9 Mobile health clinic 6 Family welfare centre 9 Medical practioner (with 5 MBBS degree) Medical practioner (with 116 other degree) Medicine shop 20 No. of villages with anganwadi 199 No. of villages with post office Post office 20 Sub post office 35 Post & telegraph office 20 No. of villages with primary agricultural supply institutes 130 Source: Census of India 2011 Sadekar Enviro Engineers Pvt. Ltd Chapter 7-68

246 CHAPTER 7: ADDITIONAL STUDIES As per the Census of India 2011, 200 villages in Palghar, Tehsil are inhabited off which all villages have electric supply, 179 villages have facilities of State Transport, 193 villages have pre primary schools/aanganwadis. It is observed that medical/health related & post office facilities are present only in selective villages. Industrial profile of Palgahr District Palghar Districts have one MIDC (Maharashtra Industrial Development Corporation) industrial area, three Government Cooperative industrial colonies which host 5757 small registered industries, 1883 small temporary registered industries & 427 large/medium scale industries. The industries belong to textile, chemical, engineering & steel production categories. Table 7.16: Taluka wise industrial profile Sr. No. Taluka No. of industries Investment (Lakhs) Employment (No. of people) 1 Palghar 276 2,65,267 22,012 2 Vasai 45 29,130 2,197 3 Talasri 19 7,219 8,05 4 Vikramgad Wada 80 4,00,897 9,195 6 Jawhar Dahanu 7 1,597 7,69 8 Mokhada Source: Official website of Collector Office Palghar : Social Commitments Sadekar Enviro Engineers Pvt. Ltd Chapter 7-69

247 CHAPTER 7: ADDITIONAL STUDIES It is anticipated that the proposed project & related activities will generate further employment for the local people which will help to increase income of the local people to some extent. The project proponent is also actively involved in CSR activities & in continuation with same Project Proponent will undertake locale specific CSR activities such as distribution of school stationery in nearby schools at the project area. R&R details in respect of land in line with state Government policy. The project is located in the MIDC area hence R & R scheme is not applicable for this project. Sadekar Enviro Engineers Pvt. Ltd Chapter 7-70

248 CHAPTER 8: PROJECT BENEFITS CHAPTER 8: PROJECT BENEFITS M/s Galaxy Surfactants Ltd. is located at Plot No. G-59, MIDC Tarapur, Boisar, Palghar district, State Maharashtra. Expansion of the project will become beneficial to the surrounding area or community in terms of employment, social development and other benefits. Expansion of this project will also reduce the demand & supply gap of different types of surfactants in local as well as in international market. The proposed expansion of speciality chemicals manufacturing unit in Tarapur MIDC will result in improvement of infrastructure as well up-liftment of social structure in the nearby area. The people residing in nearby areas will be benefited directly and indirectly as well. It is anticipated that the proposed plant will provide benefits in both construction phase as well as during operational phase of the unit. Overall benefits of the project are as follows: 1) The plant is located at Notified Industrial Area, therefore no human displacement or clearance of vegetation is envisaged. 2) Proposed expansion will create new job opportunities to the locals, during both construction and operational phase of the unit which will also improve economic status of people residing in nearby areas. 3) It will help in improving of infrastructural facilities 4) Development in communication facilities in the surrounding area. 5) The employed people will be benefited financially and this will fulfill their requirements, which will increase their standard of living. 6) Company will employ around 150 more persons out of which number of supervisor will be 30 persons; skilled workers will be 80 persons & workers - 40 persons. The company would try to employ the local people under skilled workers and worker section to boost the economic condition of the surrounding area. Sadekar Enviro Engineers Pvt. Ltd Chapter 8-1

249 CHAPTER 8: PROJECT BENEFITS 7) In CSR activities, there will be education & skill development, Health awareness to the people, water and sanitation and various social activities. Education & Skill development: Provisions of uniform, books, and stationary, necessary equipments etc, to the schools of nearby areas. Conduction of trainings for youth & women empowerment. Health Awareness: Organize free medical checkup camp for the villagers Health Awareness campaigns will be organized. 8) This project will also contribute in increase in revenue in the form of various taxes which will be paid to the government from time to time. Company will also export their products to other countries, which in turn will benefit the country by increase in excise and vat revenues. 9) The proposed project will also have trading opportunities as construction activity will be done. 10) The CSR activities planned by company can be considerably very beneficial for health, education, development of poor people, welfare of women & labour and support to disabled persons etc. Thus a significant benefit to the socio-economic environment is likely to be created due to the expansion project and the project will help in developing the national income. Sadekar Enviro Engineers Pvt. Ltd Chapter 8-2

250 SEEPL/EIA/F/IND/GSL/001/ /00 CHAPTER 9: ENVIRONMENTAL COST BENEFIT ANALYSIS CHAPTER 9: ENVIRONMENTAL COST BENEFIT ANALYSIS The project falls under the schedule 5 (f), category B-1 as per the EIA notification, The environmental cost benefit analysis was not made mandatory in the project specific terms of references accorded to M/s Galaxy Surfactants Ltd. by the state expert appraisal committee - I dated 2 nd -4 th June 2016 in its 128 th meeting. The standard terms of references published by the MOEF & CC / CPCB on April 2015 also does not include the environmental cost benefit analysis in the general & specific TOR prescribed for Synthetic Organic chemicals industry which falls under schedule 5 (f). Sadekar Enviro Engineers Pvt. Ltd Chapter 9 1

251 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 10.1 Introduction Every industrial development is associated positive and negative impacts on environmental components. Possible negative impacts cannot possibly rule out scientific development; however these negative impacts cannot be neglected. Environmental Impact Assessment helps in identifying potentially environmental impacts of a proposed project activity. Based on the finding of the impact assessment, Environment Management Plan is devised to minimize adverse impacts and enumerated various steps to be taken for improvement of the environment. Environmental Management Plan helps in formulation, implementation and monitoring of environmental parameters during & commissioning of project. Environment Management Plan (EMP) is the tool to ensure a safe and clean environment. A project may have identified proper mitigation measures but without a management plan to execute it, the desired results may not be obtained. The Environment Management Plan envisages proper implementation of mitigation measures to reduce the adverse impacts arising out of the project activities. Some of the major objectives of the EMP are: Ensure the project implementation with minimal impacts on all environmental components Minimize the impacts on socio- economic indicators of local and adjoining regions Maintain the highest level of readiness for meeting the needs of any deviation in sustainability practices Systematic implementation with adequate manpower, budget and action plan for EMP To demonstrate the effectiveness of EMP workability along with the project proponent s commitment. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-1

252 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 10.2 ORGANIZATIONAL STRUCTURE OF ENVIRONMENTAL MANAGEMENT Organizational Chart Plant Head Dy. Manager Tech Transfer Asst. Manager Production Asst. Manager Electrical & Maintenance Asst. Manager EHS Executive Instrumen tation Supervisor Production Executive Electrical & Maintenance Executive EHS Associate Production Figure No. 10.1: Schematic Representation of organizational structure of environment management The proposed capital investment of the company is envisaged to be Cr. and the proposed capital investment for Environmental Pollution Control Measures is around 4.71 Cr. The cost details for Environmental Management are as below Table No.10.1: Cost details for Environmental Management Sr. Recurring Cost per Parameters Capital Cost (Rs.) No. Annum (Rs.) 1 Air Pollution Control 3,00,000/- 55,50,000/- Sadekar Enviro Engineers Pvt. Ltd Chapter 10-2

253 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 2 Water Pollution Control 4,00,000/- 3,75,00,000/- 3 Noise Pollution Control 2,00,000/- 15,00,000/- 4 Environment Monitoring and 3,00,000/- Management - 5 Occupational Health 1,50,000/- 3,00,000/- 6 Green Belt 1, 00, 000/- 2,50,000/- 7 Solid Waste Management 3,00,000/- 5,00,000/- 8 Rain Water Harvesting 1,00,000/- 15,00,000/- Total (Rs.) 18,50,000/- 4,71,00,000/ Details of EMP Budgetary Allocation The proposed budgetary allocation has been made with a view to install new pollution control devices & management of overall environment during the operational phase the basis and estimated costing of the EMP budget is as depicted in the following table. Table No.10.2: Justification of EMP budgetary allocation Sr. No. 1 Air Component 2 Water 3 Occupational Health Particulars New stack of 39 m height for boiler Installation of 3 water scrubbers & 2 alkali scrubbers & 1 vent scrubber Up gradation of ETP to 180 CMD capacity comprising of primary, secondary & tertiary treatment along with installation of MEE & R.O. Glares, Breathing Masks, Gloves, Boots, Helmets, Ear Plugs etc. & annual health-medical checkup of workers Estimated Cost Budgetary Allocation Capital Investment Budgetary Allocation Recurring Expenditure 50,00,000/- 55,50,000/- 3,00,000/- 3,60,00,000/- 3,75,00,000/- 4,00,000/- 2,20,000/- 3,00,000/- 1,50,000/- Sadekar Enviro Engineers Pvt. Ltd Chapter 10-3

254 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 4 Noise 5 Solid Waste Management Installation of anti-vibration pads, & Enclosures for DG set & Boiler. Purchase of additional containers for storage of solid waste 12,00,000/- 15,00,000/- 2,00,000/- 3,50,000/- 5,00,000/- 3,00,000/- 6 Green Belt Maintenance of green belt 90, 000/- 2,50,000/- 1,00,000/- 7 8 Rain Water Harvesting Environment Monitoring & Management Installation of RWH system & annual cleaning of RWH tank 85,000/- 15,00,000/- 1,00,000/- Quarterly Environment Monitoring 2,40,000/- -- 3,00,000/- Ambient Air Monitoring Work Place Air Monitoring Boiler & DG Set Monitoring Effluent (Treated & Untreated) Total (Rs.) PM10, PM2.5, SO 2, NOx, CO VOCs & Fugitive Emissions TPM, SO 2, NOx ph, COD, BOD, TSS, TDS, Oil & Grease 4,31,85,000/- 4,71,00,000/- 18,50,000/ Details of Environmental Mitigation Measures The probable impacts identified & the mitigation measures envisaged for protection of Environmental Components during the construction and operational phase are as tabulated in the table below. Table No.10.3: Overview of probable environmental pollution & mitigation measures during A) Minor Construction Phase construction phase Sr. No. Environmen tal Parameters Aspect Attributes Impact Proposed Mitigation Measures Sadekar Enviro Engineers Pvt. Ltd Chapter 10-4

255 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 1. Air Quality Minor dust emissions from handling & transportation of cement/concrete/st one aggregates. 2. Noise Quality Noise generated from construction equipments/machi nery like spade, shovel, dabber, drill, hammer, concrete mixer etc. Transportation of construction materials. The emission would be around tons/month of the construction activity. Workers getting exposed to the dust pollution generated due to the construction activity can suffer from respiratory problems and prolonged exposure can lead to malfunctioning of lungs. The impacts of high noise level would be Temporary/Permanent hearing loss, Mental disturbance, Increase in heart rate, Affecting worker's performance. Traffic management for loading and unloading of the materials. Regular sprinkling of water on the working site, Avoiding Cement dust emission, Managing stockpiles. Creating wind barrier for controlling the dust emissions. Appropriate PPEs will be provided to the workers. Implementation of Traffic management. Development of Green belt. 3. Water Quality 4. Solid Waste Management Water used for construction activity mainly for concrete mixing, sprinkling etc. Construction wastes such as left off concrete, stone, aggregates, wooden piles, excavated material etc. Contamination of the soil and nearby water bodies due to the surface runoff. Unhealthy Work Conditions at project site. Proper surface water runoff management would be implemented. Storm water drain should be provided. The solid waste generated in the construction phase would be disposed off through local Municipal Corporation. The excavated soil will be used for green belt development Sadekar Enviro Engineers Pvt. Ltd Chapter 10-5

256 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN activities within the premises. Table No.10.4: Overview of probable environmental pollution & mitigation measures during operational phase B) Operational Phase Sr. No. Environmental Parameters Aspect Attributes 1. Air Quality Operation of Boiler, Thermopack & D.G Set Gaseous emission from manufacturing process, Non spontaneous emissions from transportation of raw materials & finished goods. VOC emission generated due to the handling and storage of the solvents & other raw materials. Impact The Maximum Incremental concentration of PM g/m 3 PM g/m 3 SO g/m 3 NOx g/m 3 CO mg/m 3 The Health effects related to particulate matter are majorly respiratory, pulmonary injury & lung cancer etc. Exposure to SO 2 and NOx majorly leads to respiratory problems. Carbon monoxide decreases the oxygen carrying capacity of the blood by reducing the hemoglobin. The health effects related to VOC emission are eye, nose and throat irritation headaches, loss of coordination Proposed Mitigation Measures 1. Common stack of 39 m high will be provided for new boiler & thermopack. 2. Proposed D.G Set will be provided with a stack height of 7.12 m from ground level. 3. Three water scrubbers, two alkali scrubbers & one vent scrubber will be provided to mitigate the process emissions. 4. The roads within the premises are concreted / paved to avoid the dust generation from vehicular activity. 5. It will be ensured that all the transportation vehicles have a valid PUC (Pollution under Control) Certificate. 6. Proper servicing & maintenance of vehicles is carried out. Same Sadekar Enviro Engineers Pvt. Ltd Chapter 10-6

257 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 2. Noise Quality Operation of D.G set, Boiler, Reactors, ancillary utilities & transportation activity. and nausea, damage to liver, kidney and central nervous system etc. The air emissions in long course of time may affect the immediate surrounding vegetation stature physically (leaf senescence, hampered growth etc.) & biologically thus may affect the overall surrounding ecology. The impacts of high noise level would be Temporary/Permanent hearing loss, Mental disturbance Increase in heart rate Decreasing in workers performance due to psychiatric disorder Workers developing Tinnitus due to high level of noise exposure on regular basis. The increased noise level may induce locale level disturbances/ practice will be continued in future. 7. Regular sweeping of all the roads & floors is being /will be done. 8. Development of the green belt along the plant boundary will help to capture the fugitive emission. 9. To control VOC emission carbon adsorption system can be implemented. 10. Industry to ensure that at no point of time the air emission concentrations does not exceed the prescribe standards. 1. Acoustic enclosure will be provided to D.G set for attenuation of noise level during operation. 2. Boiler & Thermopack will placed in a confined space viz. boiler house where the surrounding walls acts as a barrier for noise propagation. 3. Isolation of high intensity noise generating equipments. 4. Appropriate traffic management to be implemented. 5. Green belt developed around the company premises will acts a noise Sadekar Enviro Engineers Pvt. Ltd Chapter 10-7

258 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 3. Water Quality 1. Effluent from manufacturing process. 2. Effluent from Scrubber operations 3. Blow down water from Boiler and Cooling Tower. 4.Domestic wastewater temporary migration of fauna in the immediate vicinity of the project area. Indiscriminate release/discharge of effluents may contaminate the surrounding surface and groundwater & there by affecting the overall ecology & agricultural productivity. barrier. 6. Appropriate PPE should be provided to workers. 1. The effluent generated from the boiler blow down & cooling tower blow down will be sent to R.O, the R.O permeate will be reused for Cooling tower makeup & R.O reject will be sent to MEE followed by ATFD. 2. The effluent generated from process will be treated in full fledged ETP with R.O, the R.O permeate will be reused for cooling tower intake & R.O reject will be subjected to MEE followed by ATFD. 3. The MEE Condensate will be reused for cooling tower and residue will be sent to CHWTDSF. 4. The Domestic effluent will be treated in the biological treatment of the ETP. 5. The plant will be a ZLD unit.the proposed project will be Zero Liquid Discharge project. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-8

259 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 4. Solid Waste Management - Hazardous Waste 1. Hazardous waste generated from the manufacturing process. 2. Sludge generated from the ETP operation. 3. Residue generated from the MEE operation. Unscientific handling & disposal may lead to contamination of surrounding soil, water sources & there by affecting the ecology & health of the workers coming in direct contact with the hazardous waste like skin allergies/rashes/burns etc. 1. Hazardous waste generated from the manufacturing process is disposed to Mumbai Waste Management Limited - CHWTSDF, Taloja. 2. Sludge generated from the ETP operations are disposed to Mumbai Waste Management Limited - CHWTSDF, Taloja. Solid Waste Management - Non Hazardous waste 1. Scrap Metal 2. Scrap Plastic 3. Office Waste 4.Food Waste 5. Carboys & wooden pellets 1.Hap-Hazard handling & storage may lead to inadequate open space in plant premises & it may lead to rodent breeding 3. MEE residue generated from MEE operation will be sent to Mumbai Waste Management Limited - CHWTSDF, Taloja. The mixed solvent recovered from the process will be reused for in-house purpose. Designated area for Scrap materials will be provided in the plant. Scrap materials will be recycled through registered scrap vendors. Daily housekeeping waste and food waste will be disposed through municipal waste management facility. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-9

260 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 10.6 Fly Ash utilization as per Fly Ash Notification, The manufacturing plant & MEE along with stripper column would require steam, to obtain this steam company will operate two thermopacks of 6 lakh Kcal/Hr & 8 lakh Kcal/Hr respectively & one boiler of 3.5 MT/hr. The fuel used for boiler & thermopack will be LDO/FO. The maximum ash percentage in LDO/FO is around 0.05% i.e. 4.6 kg/d through combustion of 9.2 MT LDO/FO per day. Therefore fly ash generation will be extremely minimal hence no utilization of fly ash is envisaged, as per Fly Ash Notification, Action Plan for Green Belt Development Generally a green belt is developed with a view to minimize the air pollution & noise pollution at the project site. Development of green belt not only minimizes these impacts but also improves the aesthetics of the project site. However company has already developed the requisite green belt (33% of the open plot area) as specified in the Consent to Operate granted by MPCB Design and development of green belt Green belt development planning has to be done with the ecological perspective of the immediate surrounding environment taking into consideration nature of pollutants, availability of space and prominent wind directions. The project is located at Plot No. G-59, Tarapur MIDC, Boisar, Palghar, Dist. - Palghar, Maharashtra, India Guidelines & Technique for green belt development The structure & composition of vegetation in the study area as observed during the baseline study, edaphic characteristics in the study area & CPCB guideline (PROBES/75/ ) for development of green belt were the basis for selection of plant species along with the following considerations: Local/Native fast growing preferably non fruiting trees & shrubs should be used for plantation Plants should have preferably large leaf area Sadekar Enviro Engineers Pvt. Ltd Chapter 10-10

261 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Plants having comparatively higher Air Pollution Tolerance Index should be used Project plot area breakup details Table No.10.5: Project plot area break up details Area Details Existing (sq. m.) Proposed (sq. m.) Total (sq. m.) Total Plot Area 20, , Built up Area 2, , , Green Belt Area 1, , , Parking Area 1, , , Details of existing green belt The industry has developed green belt in an area of 1,500 sq. m. mainly with a view to improve the aesthetics of project premises comprising of large perennial trees along the plant boundary & shrubs along the internal roads. Table No.10.6: Site/Block wise details of existing green belt Sr. No. Site/Block Area in sq. m. Location 1 A 1500 Along the eastern boundary of the project plot Total Table No.10.7: Existing green belt plant list Sr. No. Botanical Name Habit Family Local Name Total no. of plants planted at the project site 1 Alstonia scholaris Tr Apocynaceae Saptaparni 2 Mangifera indica Tr Anacardiaceae Amba Sadekar Enviro Engineers Pvt. Ltd Chapter 10-11

262 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 3 Lysiloma latisiliquum Tr Fabaceae -- 4 Cycas sp. Sh Cycadaceae -- 5 Platycladus Sh Cupressaceae Mayurpankhi orientalis 6 Duranta sp. Sh Verbenaceae -- 7 Peltophorum Tr Caesalpinaceae Tambadsheng pterocarpum 8 Dypsis lutescens Tr Arecaceae -- 9 Araucaria sp. Tr Araucariaceae Ficus ps. Tr Moraceae Bauhinia sp. Tr Apocynaceae Nerium oleander Sh Apocynaceae Kaner 13 Polyalthia longifolia Tr Annonaceae Ashok 14 Bougainvillea sp. Sh Nyctaginaceae Ixora coccinea Sh Rubiaceae Bakavli Proposed green belt Reconnaissance survey was conducted along with project proponent to identify sites for additional green belt development in & around the project site Area calculations for plantation Area required for tree/shrub is as follows: 1. Area required for Small Tree or Shrub = 2 meter x 2 meter 2. Area required for Large tree = 3 meter x 3 meter Sadekar Enviro Engineers Pvt. Ltd Chapter 10-12

263 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Suggested plant species In order to maintain ecological equilibrium with the immediate surroundings of the project area, some of the native plant species thriving naturally in the study area are suggested for green belt development as tabulated in the below table. Table No.10.8: List of suggested plant species Sr. No. Botanical Name Family Common name Habit 1 Ixora coccinea Rubiaceae Rugmimi Sh 2 Heterophragma quadriloculare Bignoniaceae Waras Tr 3 Oroxylum indicum Bignoniaceae Tetu Tr 4 Nerium oleander Apocyanceae Kaner Sh 5 Schleichera oleosa Sapindaceae Kusum Tr 6 Terminalia elliptica Combretaceae Ain Tr 7 Terminalia paniculata Combretaceae Kinjal Tr 8 Catunaregum spinosa Rubiaceae Ghela Tr 9 Butea monosperma Fabaceae Palash Tr 10 Erythrina variegata Fabaceae Panghara Tr 11 Cassia fistual Caesalpiniaceae Bahava Tr 12 Helicteres isora Sterculiaceae Murudsheng Sh 13 Tabernaemontana alternifolia Apocyanaceae Naagkuda Tr 14 Macaranga peltata Euphorbiaceae Chandwar Tr 15 Albizia lebbeeck Mimosaceae Neem Tr 16 Azadirachta indica Meliaceae Neem Tr 17 Bridelia retusa Phyllanthaceae Asana Tr 18 Bombax ceiba Bombacaceae Sawar Tr 19 Pterospermum acerifolium Sterculiaceae Muchkund Tr 20 Cordia dichotoma Boraginaceae Shelu Tr Sadekar Enviro Engineers Pvt. Ltd Chapter 10-13

264 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 21 Neolamarckia cadamba Rubiaceae Kadamba Tr 22 Sterculia urens Sterculiaceae Sardol Tr 23 Firmiana colorata Sterculiaceae Kaushi Tr Budgetary Allocation & Action plan for green belt development plan Table No.10.9: Action plan for proposed plantation Phase Plantation on 1800 sq. m. block along the northern boundary of the project plot Estimate for plantation around the project premises Total area: sq. m. Estimated Expenditure Total no. of plants: Saplings of small Trees/Shrubs: 225 Saplings of large Trees: 125 Sr. Rate ( Rs.) per Amount Particulars of work Magnitude No. plant (Rs.) 1 Alignment & Digging of pits , Provide good Soil and Fertilizers for the plants , Purchase of plants Small Trees/Shrubs (Saplings) Large Trees (Saplings) , , Transportation of plants , Plant Loading/Unloading& planting in pits , Total 1,45, Table No.10.11: Recurring cost for maintaining green belt Estimate for maintaining the Green Belt Estimated Expenditure Recurring cost for maintain the Green Belt Sr. No. Particular of work Sadekar Enviro Engineers Pvt. Ltd Chapter 10-14

265 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN 1 Removing weeds twice a year 6, Caretaker 1 No. for 12 1x7,000/month 36, Total 84, Action plan for rain water harvesting measures at plant site Rain Water Harvesting Details As the ground water table of the Palghar is lower than 10 mbgl, Roof top rain water harvesting system is adopted. An impervious surface / underground storage tank of required capacity may be constructed in the setback or other open space and the rain water may be channeled to the storage tank. The storage tank would be provided with ventilating covers and shall have draw-off taps suitably placed so that the rain water may be drawn off for domestic, washing, gardening and such other purposes. The storage tank will be backed with filter media comprising the following materials: 40 mm stone aggregate as bottom layer upto 50% of the depth; 20 mm stone aggregate as lower middle layer upto 20% of the depth; Coarse sand as upper middle layer upto 20% of the depth ; A thin layer of fine sand as top layer. Project Site Specific details Level of the Ground water table in Palghar Taluka (Pre Monsoon Water Level) mbgl Level of the Ground water table in Thane Taluka (Post Monsoon Water Level) mbgl (Source: Report On The Dynamic Ground Water Resources Of Maharashtra, ) Hence the proponent is opting for Roof top Rain water harvesting tank and not for artificial recharge of groundwater. Amount of Rain water collected (Approx): Annual rainfall (mm) X Roof Area (sq.m.) X 0.9 (Run off Coefficient) = 1861X 1862 X 0.9 = l/annum Size and no of RWH tank(s) and Quantity = 1x 20 KL RWH Tank Sadekar Enviro Engineers Pvt. Ltd Chapter 10-15

266 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Location of the underground RWH tank(s) is near the proposed parking area & existing tank farm. The rain water harvested will be used for flushing, make up water for boiler & cooling tower. The water intake will be reduced as the RHW water will be totally used in the plant premises. Company has made budgetary allocation of Rs. 15,00,000/- for setting up RWH system (Rain water collection pipes & HDPE 20 KL tank for storage of harvested water) & Rs. 1,00,000/- recurring expenditure for annual cleaning of RWH tank Storm Water Management In developed area like Industrial estate or company premises, impervious surface such as pavements in factory premises prevents precipitation from naturally soaking to the ground, instead of that water runs into storm drains. Managing the quantity and quality of storm water is termed, "Storm water Management." Storm water quantity can be estimated by three methods. 1. SCS Technique: Curve number method of USDA 2. Commercial Software: Storm water management model (SWMM) or STORM 3. Rational Method. In this section of the report rational method will be used to quantify the amount of storm water runoff per hour in the plant premises. Rational Method Q = 10 CiA Q= Runoff in m 3 /hr C = Coefficient of runoff i = intensity of rainfall in mm/hr A = Area of drainage in hectares. Q = 10 x 0.9 x 0.86 x Q = m 3 /hr Sadekar Enviro Engineers Pvt. Ltd Chapter 10-16

267 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Conclusion: The maximum water that can be received during rainy season on the plant is calculated to be around m 3 /hr. Currently the surface runoff directly drains into the MIDC drain. Hence for proper surface runoff management, it is advised to develop internal storm water drains of adequate capacity Solvent Management System Solvents are one of the costly raw materials which get utilized in API & Chemical Industries; these solvents are very hazardous in nature, which may cause harm to environmental components. The main requirement in the industry is minimum inventory maintenance, safe working environment and accurate dispensing. The solvent dispensing system integrates various operations at solvent yard and production blocks like unloading, dispensing etc. solvent management start right from solvent unloading, storage, charging, recovery & reuse of the used solvent. The solvent utilization, recycling and reuse for proposed project are envisaged as follows: 1) Chemicals will be stored in drums & solvent tank farm yard to avoid handling losses closed feed system will be provided for filling and unloading of chemicals from the drums. 2) Products will be purified by using various solvents and use solvents will be collected and recycled or sold to authorized vendors. 3) To avoid leakages from drums & pipelines, regular inspection & maintenance will be done. 4) Closed feed system will be adopted for reactor charging 5) Flame proof equipments will be used during maintenance 6) Earthing will be provided wherever solvent to be handled. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-17

268 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Table No.10.12: Solvent use & recovery summary Product Name Solvent Name Solvent Used in MT Solvent Recovered % Recovery Product 1 MDC % Product 2 Methanol % Ethyl Acetate % Product 3 Toluene % Product 4 Cyclohexane % The recovered solvent would be reused up-to extent of 70 % and remaining i.e. 30 % will be sold to the MPCB authorized vendors. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-18

269 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN CSR Activity (Enterprises Social Commitment) 1. PREAMBLE: At Galaxy Surfactants Ltd. (hereinafter referred to as Company / GALAXY), we act in accordance with the principles of responsible care and sustainable development to safeguard our employees, customers, stakeholders, society and environment. In doing so, we ensure compliance with globally & nationally accepted social and ethical standards and values. As an organization, GALAXY is committed to operate in accordance with the demands of economics, ecology and society. Consequently, the Company makes decisions based not only on financial parameters, but also taking into consideration the social and environmental impact arising out of the actions of the Company. The resultant CSR policy guidelines are also prepared in line with our Corporate Strategy and our commitment to Corporate Responsibility. GALAXY strongly believes that Corporate Social Responsibility (CSR) is connected with the principles of sustainability and recognizes that its business activities have wide impact on the society in which it operates. Therefore, the Company endeavors to make CSR a key business process for sustainable development, through its integration in the overall business approach. GALAXY is committed to its stakeholders to conduct its business in a responsible manner that creates a sustained positive impact on society. We further believe that our Corporate Responsibility lies in embracing core corporate values through commitment to grow in a socially and environmentally responsible way, while meeting the interests of all relevant stakeholders. 2. APPROACH: Approach of the Company is based on the following: i. At least 60% CSR initiatives to focus in the areas around where the Company has its operations and presence. These initiatives shall be fairly distributed amongst various locations, where Galaxy carries on its operations. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-19

270 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN ii. iii. iv. CSR initiatives to create awareness amongst employees and encourage their active involvement in the various CSR activities. Towards this direction, the CSR efforts will aim personal enrolment of about 10% of the work force to dedicate a targeted hours of direct CSR work for the community / projects taken up by the Company. The involvement of the Company shall be more towards participation on the ground rather than only administering the expenditure To obtain expertise to carry out the CSR activities by engaging with agencies of repute, if such need arises. We shall endeavor to drive on our own implementation of at least 50% of CSR project/programmes. For the balance, we may engage with other agencies/ngos of repute 3. OBJECTIVES OF CSR POLICY: The objectives of this policy are as follows: i. To demonstrate commitment to the common good through responsible business practices and placing high value on good corporate governance standards; ii. To actively support the national development initiatives to ensure sustainable change; iii. To set high standards of quality in the delivery of services in the social sector by creating processes and replicable models; iv. To create a sense of empathy and equity among employees of GALAXY to motivate them to give back to the society 4. APPLICABILITY: i. GALAXY CSR policy has been developed pursuant to Section 135 of the Companies Act, 2013 (referred to as the Act in this policy) and in accordance with the Companies (Corporate Social Responsibility Policy) Rules, 2014, (hereby referred to as the Rules) notified by the Ministry of Corporate Affairs, Government of India, in Sadekar Enviro Engineers Pvt. Ltd Chapter 10-20

271 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN ii. iii. The Policy shall apply to all CSR projects/programmes undertaken by the Company in India as per Schedule VII of the Act Depending upon the nature of the project, these CSR programmes shall be implemented through in-house or non-governmental organizations, institutions, municipalities, panchayats, schools and agencies, as may be approved by the CSR Committee. 5. RESPONSIBILITIES OF THE BOARD OF DIRECTORS: The Board of Directors of GALAXY will be responsible for: i. Nominating a CSR Committee comprising of minimum three Directors ii. Approving the CSR policy after taking into account the recommendations made by the CSR Committee iii. Ensuring that the Company shall, in each financial year spend at least the amount on CSR initiatives as has been prescribed by the Companies Act, 2013 and the rules made thereunder from time to time. iv. Ensuring that primarily the activities as included in CSR Policy of the Company are undertaken by the Company. v. Monitoring that in every financial year, funds committed by the Company for CSR activities are utilized effectively and implementation is regularly reviewed. vi. Reporting / providing the details as may be prescribed by the Act and the rules made thereunder. 6. CSR COMMITTEE: i. The Committee to be established by Resolution of the Board of Directors of the Company (the Board ) and is to be known as the CSR Committee. ii. The CSR Committee shall consist of three or more Directors out of which one will be independent director. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-21

272 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN iii. The CSR Committee may invite any other person as they may deem fit to attend meetings of the CSR Committee when required, notwithstanding that they are not members of the CSR Committee. iv. Quorum shall be two members personally present at the meeting. A duly convened meeting of the CSR Committee at which a quorum is present shall be competent to exercise all or any of the authorities, powers and discretions vested in or exercisable by the CSR Committee. v. The Company Secretary / Assistant Company Secretary shall act as the secretary of the CSR Committee and shall keep a record of the membership of and the dates of any changes to the membership of the CSR Committee. He / She shall be responsible to record the minutes of the Meeting. vi. Meetings shall be held at such times as the CSR Committee deems appropriate, and in any event shall be held not less than two times in a financial year. vii. CSR Committee will be governed by the Companies Act, 2013 and rules made there under and Company s Articles of Association regulating the meetings and proceedings of the Directors. viii. Meetings of the CSR Committee shall be convened by the Company Secretary / Assistant Company Secretary at the request of the Chairman or any member thereof. ix. CSR Activities shall be Activities as specified in Schedule VII of the Companies Act, 2013, and as amended by the Ministry of Corporate Affairs from time to time x. The CSR Committee may at the expense of the Company investigate any matter within its terms of reference. It is authorized to seek any information that it requires from any employee in order to perform its duties and all employees are required to cooperate with any requests made by the CSR Committee. xi. The CSR Committee may at the expense of the Company secure external professional advice and attendance of third parties with relevant experience and expertise at meetings of the CSR Committee, if it considers this necessary. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-22

273 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN xii. xiii. xiv. xv. The CSR Committee shall have all necessary authority to carry out its duties and responsibilities. Without limitation to the generality of the foregoing, the Committee shall have the authority to engage (including authority to approve fees and other retention terms) and terminate the engagement of any Social Responsibility consulting firm to provide data or recommendations with respect of CSR projects. The Company shall provide and make available to the Committee, as it may determine, funds for undertaking CSR activities and to pay compensation to any advisers engaged by the Committee. The CSR Committee is empowered to frame, review and modify the criteria / processes for selecting the projects, laying down the criteria for performance evaluation of the projects, selecting the implementation entities / partners and decide on any matter that it may deem pertinent to effectively discharge its responsibilities. GALAXY CSR Committee shall monitor the implementation of the CSR Policy through periodic reviews of the activities of the external agencies / NGOs in compliance with the Act and ensure that funds spent on CSR programmes are creating the desired impact. 7. DELEGATION: i. The suggested structure of delegated powers for approving the CSR projects is as under: a. Head CSR is authorized to approve projects for value up to Rs 2 lakhs per project with cumulative approval in the year capped to 15% of the statutory spend. b. Any one member of the CSR Committee is authorized to sanction a single project upto rupees twenty lakh; c. Any two members are required for sanction of projects above twenty lakh but less than fifty lakh. d. Projects above fifty lakh can only be sanctioned unanimously by all the members of CSR Committee. ii. The above delegation powers for approving the CSR projects are subject to the following: Sadekar Enviro Engineers Pvt. Ltd Chapter 10-23

274 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN iii. a. Any amount in excess of the Statutory Obligation of 2% of the average PBT for past three years (discretionary spend) shall require prior approval of the Board for the allocation of the excess. b. Single project, geography, implementation partner allocation shall be restricted to 25% of the statutory CSR spend for the year. Any allocation in excess shall need Board approval. c. The scroll of the projects approved, the disbursements made and pending shall be placed before the CSR committee at every meeting and shall be appended to the minutes of the CSR Committee. Should a project be spread beyond one year, then any allocation for the period beyond the current year will be subject to the following: a. The projects shall be for a period of maximum 5 years. b. Expression of inclination to support the project for its tenor beyond the current year will be subject to availability of the statutory spend and the project meeting the performance criteria laid down. c. Cumulative expression of inclination to support the CSR projects beyond the current year shall not exceed the statutory spend for the current year i.e., if the statutory spend for is Rs 160 lakhs, then for the period of next 4 years (five year block of ) a cumulative expression of inclination to support the ongoing projects cannot exceed Rs 160 lakhs. 8. CRITERIA FOR IDENTIFYING THE THIRD PARTY IMPLEMENTATION BODIES: It is the responsibility of the CSR Committee, while the implementation modality of a CSR project/programme is defined, to ensure that the external body that would execute the said project/programme is clearly identified. In case the external body is a NGO or an Agency other than an NGO, it shall meet the following criteria: Sadekar Enviro Engineers Pvt. Ltd Chapter 10-24

275 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN i. Have a permanent office/address in India; Be a registered society under Societies Registration Act or a Sec 25 Company (Registered under the Companies Act, 1956) or a Sec 8 Company (Registered under the Companies Act,2013). ii. Have a track record of at least three financial years iii. Have verifiable antecedents and verifiable credentials iv. Maintains duly audited annual accounts v. Preferably possess a valid Income tax Exemption Certificate; 9. FOCUS/THRUST AREA PROJECTS: CSR Committee has identified the thrust area projects around which the Company shall be focusing its CSR initiatives and channelizing the resources on a sustained basis. There will be alignment of CSR programmes across all locations to ensure common focus and synergy in efforts: i. Health & Hygiene (AAROGYA VARDHEENI): Primary healthcare through diagnosis and treatments, promoting preventive healthcare, building awareness about hand, oral & personal hygiene, sanitation and providing monetary support for constructing toilets in particular for girls, supporting rehabilitation centers, medical camps and blood donation camps, providing additional nutrition to eradicate malnutrition children & women, providing water purifier for potable drinking water, awareness about ill-effects of tobacco. ii. Education (GYAAN SANJEEVANI): To contribute to improving and facilitating the literacy levels including e-learning in various sections of the society, by providing support at every stage of a child s educational cycle including but not limited to developing infrastructure for schools/educational centers, conducting education programmes on how to lead a happy & safe life, engaging with students, teachers Sadekar Enviro Engineers Pvt. Ltd Chapter 10-25

276 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN and parents leading to development of a better community, livelihood enhancement projects, vocational skills for differently abled iii. Environment Protection (VATAVARAN SURAKSHA): Tree plantation, cleanliness drives, awareness for energy/ water conservation & solid waste reduction, promoting solar and other non conventional renewable energy projects. iv. Women Empowerment (STREE UNNATI): Girl child & women education & development, income generation, knowledge about relevant statutes, self defense training. v. Community Development (SAAMAJEEK UTTHAAN): Support to orphans, destitute & old age homes, undertaking community sanitation projects, water harvesting (check dams), setting up public libraries, safe drinking water, community utilities, promoting sports through community connect mahotsav, providing hand washing stations, borewells. vi. Calamity Relief (AAPDA RAHAT): Contribution to PM Relief Fund or providing relief articles directly or through NGOs vii. CSR Capacity Building & Personnel Cost: Capacity building cost of own personnel or those of implementation agencies will qualify as a CSR expenditure within the permissible limits allowed by the Companies Act 2013 or Rules made there under. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-26

277 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN viii. Suggestive Allocations: Table No.10.13: Percentage wise budgetary allocation for various CSR activities Sr. % of No. Schedule VII Areas Spend Coverage/ Scope 1. Health & Hygiene (AAROGYA VARDHINI) 30 % As listed above in point 9 (i) 2. Education (GYAN SANJEEVANI) 30 % As listed above in point 9 (ii) 3. Environment Protection (VATAVARAN SURAKSHA) 5 % As listed above in point 9 (iii) 4. Women Empowerment (STREE UNNATI) 5 % As listed above in point 9(iv) 5. Community / Rural Development (SAMAJEEK UTTHAAN) 20 % As listed above in point 9(v) 6. Calamity Relief (AAPDA RAHAT) 5 % As listed above in point 9(vi) 7. CSR Capacity Building & CSR Personnel Cost 5 % As listed above in point 9(vii) Sadekar Enviro Engineers Pvt. Ltd Chapter 10-27

278 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN ix. Above allocation guidelines are suggestive and will be followed based on availability of duly identified & evaluated projects & programmes across the locations. However these guidelines will not restrict the allocation of funds to other projects for lack of worthy projects in respective focus areas or geographies. x. Further this will not act as a constraint on CSR Committee to allocate funds for worthy projects in non focus areas but listed under approved purposes defined in schedule VII of the Act. Any how such allocation for non focus areas shall not exceed 10% of the statutory spend in a financial year. xi. Further, whenever necessary intra and inter geography swapping of budget allocation would be allowed, subject to availability of creditable beneficiary, as long as it is within the overall geography or corporate budget of that specific financial year including justifiable + 5% cost variances in the ongoing projects. 10. GEOGRAPHY / REGION: i. To meet administrative needs, the State in which Company has presence shall be regarded as local presence. Galaxy is present in Maharashtra, Gujarat, Delhi, Bengal and Tamil Nadu. CSR project spend covering these states shall be categorized as local spend and any projects outside these States will be regarded as a corporate spend. ii. Suggestive allocation between local spend and corporate spend on CSR projects is 60:40 in favor of local spend. While preference will be for local spend, there is no obligatory stipulation made under the Rules. Hence in case there is paucity of identified good projects, discretion is vested in the CSR Committee to increase the corporate spend to a maximum of up to 60% of the total Statutory spend. 11. CSR ORGANISATION: Sadekar Enviro Engineers Pvt. Ltd Chapter 10-28

279 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN i. Currently the CSR Process is manned by two direct employees. Mr. Adarsh Nayyar is the Head of the Process and is assisted by an associate. Besides this there are local voluntary steering councils at the locations. ii. As the statutory spend increases, the effort in identifying, evaluating, monitoring the execution and the outcomes of the projects would call for adequate direct manning of the CSR Process at the manufacturing locations. iii. CSR Committee is empowered to review the organization structure and manning and allied needs from time to time and take suitable decisions on the same. 12. CONCLUSION: i. The CSR policy shall be reviewed once in three years and suitable improvisations be done based on experience. ii. The CSR policy shall be subservient to the provisions of the Companies Act, 2013, and Rules made there under, from time to time. Note: Above CSR Policy incorporates approved modifications, reviewed by Board CSR Committee Meeting held on March 5, Occupational Health Plan & fund allocation to ensure the occupation health and safety of all contract and casual workers. The objective of occupational health environment is to provide safe working environment to the employees of the company. Good occupational health management keeps workers physical conditions healthy or non-deteriorating in work environment which keeps the worker physically and psychologically sound. It results in High productivity Sadekar Enviro Engineers Pvt. Ltd Chapter 10-29

280 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN improvement of work efficiency work satisfaction Less medical expenses toward employees thereby less recurring cost. The company has planned all the necessary control measures to prevent air pollution, water pollution and degradation of soil of the project surrounding areas. Since all the pollution control measures are planned. Minor accidents, noise, poor ventilation and accidental chemical exposure are the only possible occupational health hazards from the manufacturing activities. For the prevention of it, the company will educate the operators and workers for the safety rules, procedure and preventive measures and to use personnel protective measures. Galaxy Surfactants Ltd. s Safety, Health & Environment Policy as follows: Sadekar Enviro Engineers Pvt. Ltd Chapter 10-30

281 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Figure No. 10.2: Safety Health & Environment Policy Sadekar Enviro Engineers Pvt. Ltd Chapter 10-31

282 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Figure No. 10.3: Cardinal Rules Sadekar Enviro Engineers Pvt. Ltd Chapter 10-32

283 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Details of exposure specific health status evaluation of worker. The company conducts regular health medical checkups of workers on periodic intervals Corporate Environmental Policy The company has a well established sustainability policy (Environmental policy) which as follows. Sadekar Enviro Engineers Pvt. Ltd Chapter 10-33

284 Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/D/IND/GSL/001/ /00 CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN Figure No. 10.4: Sustainability Policy Sadekar Enviro Engineers Pvt. Ltd Chapter 10-34