Repor t No. Mr. Kamlesh Bagul & Mr. Rakesh Suryawanshi

Transcription

1 M/s. BHARAT CHEMICALS PFR for Environmental Clearance (EC) of proposed expansion project at existing unit at Plot No.: L 13, L-28, L-29 & L-30, MIDC Tarapur, District: Palghar, Maharashtra Goldfinch Environmental Engineering Systems Private Limited ( Goldfinch ), February 2017 This report is released for the use of the M/s Bharat Chemicals (Bharat). Regulators and relevant stakeholders solely as part of the subject EC of Proposed expansion at existing manufacturing facility located at plot No- L 13, L-28, L-29 & L-30, MIDC Tarapur, Palghar, Maharashtra. Information provided (unless attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of Goldfinch/Bharat. QUALITY CONTROL Name Publication of Bharat Chemicals Proposed expansion project of Manufacturing Synthetic organic chemicals at Plot No. L 13, L-28, L-29 & L-30, MIDC Tarapur, Palghar , Maharashtra Project Number GEC/BCT/201 6/12/03 Repor t No. 1 Version 1 Release d February, 2017 Prepared By Reviewed By Released By Mr. Kamlesh Bagul & Mr. Rakesh Suryawanshi Mr. K. N. Sharma Mr. Anand Apte DISCLAIMER Goldfinch has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Goldfinch also believes that the facts presented in the report are based on information submitted by Bharat and based on the technical expertise of Goldfinch as on the date it was written. However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Goldfinch therefore specifically disclaims any liability resulting from the use or application of the information contained in this report. The information is not intended to serve as legal advice related to the individual situation. PFR for Bharat Chemicals Tarapur Page 1

2 Contents EXECUTIVE SUMMARY INTRODUCTION OF THE PROJECT Introduction of the Project Introduction of the Project Proponent Brief description of nature of the project Need for the project and its importance to the country and or region Demands-Supply Gap Imports vs. Indigenous Production Domestic /Export Markets Employment Generation due to the project PROJECT DESCRIPTION Type of Project ProjectLocation Details of alternate sites considered and the basis of selecting the proposed site Size or Magnitude of Operation Process Description Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product Resource optimization/recycling and reuse envisaged in the project Availability of water its source, energy/power requirement and source Water Requirement and Source Power Requirement Emergency power Utility Existing Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal Gaseous Emissions Effluent Details of Hazardous wastes Schematic representations of the feasibility drawing which give information of EIA purpose SITE ANALYSIS PFR for Bharat Chemicals Tarapur Page 2

3 3.1 Connectivity Land Form, Land use and Land ownership Topography Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ Soil classification Climatic data from secondary sources Social Infrastructure Availability Planning In Brief Planning Concept Land Use Planning Assessment of Infrastructure Demand (Physical & Social) Amenities/Facilities Population Projection Existing infrastructure Industrial area Residential Area Green Belt Social Infrastructure Drinking Water Management Sewage System Industrial Water Management Solid Waste Management Power Requirement & Supply / source Rehabilitationand Resettlement (R & R) Plan Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless PROJECT SCHEDULE & COST ESTIMATES Likely date of start of construction and likely date of completion The modernization/product mix activity is likely to start after getting Environmental Clearance and PFR for Bharat Chemicals Tarapur Page 3

4 NOC/CTE from the authorized committee Estimated project cost along with analysis in terms of economic viability of the project 32 Economic Viability ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) PFR for Bharat Chemicals Tarapur Page 4

5 EXECUTIVESUMMARY BHARAT CHEMICALS established in 1982 and is one of the leading manufacturers of PARACETAMOL in India and has a significant global presence. They have head office located in Mumbai, the commercial capital of India. Bharat have state of the art facility located in TARAPUR MIDC in Maharashtra on the leading commercial hub in India. Bharat proposed expansion project manufacturing of synthetic organic chemicals at existing manufacturing unit at Plot No. L-13, L-28, L-29 & L-30, MIDC Tarapur, Palghar, Maharashtra. The proposed project falls under classification 5(f) of schedules listed in EIA notification SO1533 dated 14/09/2006. Its appraisal category is B-1. Project Synopsis: Sr. Parameters No. 1. Category as per EIA Notification 5 (f) B 2. Longitude N 3. Latitude E 4. Total Production Capacity after expansion 5. Total Plot Area sq. m. 6. Green Belt Area 500 sq. m. 7. Fresh Water Requirement 507 CMD 8. Effluent Quantity (Trade + Domestic) 9. Trade Effluent Treatment 10. Domestic Waste water Treatment 11. Fuel requirement at full load Description Total = 1435 MT/Month (Existing = 270 MT/M & Proposed = 1165 MT/M) 88 CMD +08 CMD = 96 CMD Existing effluent 23 CMD will be discharged to CETP and proposed effluent 65 CMD after treatment will be reuse for utilities. High TDS stream will be fed to MEE followed by ATFD. Low TDS stream along with condensate from MEE will be treated in conventional ETP consisting of primary, two stage secondary and tertiary treatment. This will be further treated by RO for permeate recycled and effect zero liquid discharge (ZLD). Sewage treatment plant of capacity 10 CMD will be proposed. Existing Boiler: 2 TPH X 1 no Proposed Boiler 6 TPH X 1 no (2 TPH will by replaced by 6 TPH) Total Boiler 1 no. Total fuel required 30 TPD PFR for Bharat Chemicals Tarapur Page 5

6 Sr. No. Parameters Description (Type Fuel: Coal) Existing D G set = 125 KVA X 1 no Proposed D G Set = 800 KVA X 1 no Fuel Required = 500 lit/day (Type Fuel: HSD) 12. Power Requirement Existing : 600 KW, Proposed : 400 KW 13. Dispersion of emission for Boiler Stack Height:20 m stack for (2 TPH) boiler and For 6 TPH boiler stack height is 55 m 14. Dispersion of emission DG Sets, Stack Height: 6m above enclosure 15. Work Force Total 175 nos. Existing = 115 nos.& Proposed 60 nos. 16. Total Capital Cost the project (Cr) Rs Cr. 1.0 INTRODUCTION OF THE PROJECT 1.1 Introduction of the Project Bharat Chemicals (Hereafter being referred as Bharat for brevity in this text) intends to expansion of existing projects in the category of synthetic organic chemicals. The existing manufacturing unit is in Tarapur MIDC; which is approved chemical manufacturing zone of MIDC. Bharat is located at plot no.- L-13, L-28, L-29 & L-30. Existing manufacturing capacity of the unit is 270 MT/M. After expansion the total quantities of products and by-products will become 1165 MT/M and 900 MT/M respectively. As per the EIA Notification S.O dated 14 th September 2006, proposed activity is covered under Synthetic Organic Chemical Industry 5 (f) and needs prior environmental clearance. Further, as the proposed industry is under category B. Since it is located in a notified industrial area the project will not need public approval and is under category B. PFR for Bharat Chemicals Tarapur Page 6

7 1.2 Introduction of the Project Proponent Table No 1.1 List of Directors and their designations Sr.No. Name Designation 1 Mr. Shantibhai Vora Partner 2 Mr. Santosh Vora Partner 3 Mr. Paresh Shah Partner 1.3 Brief description of nature of the project Existing manufacturing capacity of the unit is 270 MT/M. After expansion the total quantities of products and by-products will becomes 1165 MT/M and 900 MT/M respectively. 1.4 Need for the project and its importance to the country and or region India's pharmaceutical industry is the third largest in the world in terms of volume. Its rank is 14th in terms of value. India is also one of the top five active pharmaceutical ingredients (API) producers (with a share of about 6.5%). The ever-increasing demand for Bulk Drugs and Intermediated in India and abroad as well as changing market conditions requisite Indian pharmaceutical industries to grow further. Bharat aims to maximize their existing project in order to cater to Domestic & International markets. These products will serve to cut the supply of imports from foreign countries thus saving currency and at the same time will earn valuable foreign currency by export of the proposed products. 1.5 Demands-Supply Gap The population of India as well as internationally is increasing at an alarming rate. This has created a huge gap between demand & supply of API & finally the finished dosage form globally. To fulfill this gap, Bharat is proposing to increase the range and production capacity to meet the market requirement. The products manufactured will be sold both in domestic & Export markets. The major thrust in Export market will earn foreign currency for the country. The foreign currency earned will be utilized to import PFR for Bharat Chemicals Tarapur Page 7

8 Raw materials used to manufacture these products and save valuable foreign exchange for the country. 1.6 Imports vs. Indigenous Production The proposed products have high in demand in the export market. Also their demand is increasing in the domestic market. Production of these chemicals domestically reduces the need to import these in future along with significant scope for export in these products. 1.7 Domestic /Export Markets The finished goods will be sold in domestic market and would be largely exported to the Regulated International Market as per demand all over the world. 1.8 Employment Generation due to the project Existing employees are 115 nos. and additionally 60 nos. required, so total 175 nos. of employees will be required for this expansion. PFR for Bharat Chemicals Tarapur Page 8

9 2.0 PROJECT DESCRIPTION 2.1 Type of Project Proposed project is expansion of existing products in the category of synthetic organic chemicals in existing manufacturing facility located at MIDC Tarapur. It is included in category 5(f) B of EIA notification Project Location Existing manufacturing unit is located at Plot No.L-13, L-28, L-29 & L-30 MIDC Tarapur, District- Palghar, State-Maharashtra. Major factories adjacent to the manufacturing unit are open plot located on west side and Bright star textile on south side, Surchem polymers Pvt Ltd. is located on east side & Nutraplus India ltd. on north side. The site is well connected by road to Mumbai Ahmadabad Highway at 20 Km. The nearest railway station is Boisar 3.5 km. The nearest airport is at Mumbai 110 km. Figure 1 Google image of the site PFR for Bharat Chemicals Tarapur Page 9

10 The project site is situated in MIDC Tarapur. It is a notified industrial area where the land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity. The detailed plant lay out is attched as Annexure-I Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the Company for 99 years. 2.3 Details of alternate sites considered and the basis of selecting the proposed site The proposal is for expansion of existing products in the same manufacturing unit using existing infrastructure only hence consideration of alternate site is not required. 2.4 Size or Magnitude of Operation The products manufactured and their capacities proposed are shown in below: Table 2.2. Size/Magnitude of Proposed Production & By-product Sr. No. List of Products Capacity Tons / Month Existing Proposed Total 1 Paracetamol Para Nitro Phenol and salt Caffeine Mefanamic Acid Chlorozoxasone Hydrochloride Albendazole Other Bulk Drug Product Mix Total List of Proposed By-Products Sr. No. List of Products Capacity Tons / Month Existing Proposed Total 1 Dil. Acetic Acid Total PFR for Bharat Chemicals Tarapur Page 10

11 2.5 PROCESS DESCRIPTION 1. Paracetamol Chemical Reaction: Process: Para Amino Phenol is reacted with acetic anhydride to give Crude Paracetamol. This Crude Paracetamol is purified with water or mother liquor to give Paracetamol. This is dried, pulverized & packed. Material Balance: PRODUCT : PARACETAMOL (1MT) Sr. No. INPUT OUTPUT Stage I : ACETYLATION RAW MATERIAL Quantity Quantity FINISHED PRODUCT (Kgs) (Kgs) 1 Para Amino Phenol 800 Wet Crude Paracetamol Acetic Anhydride 775 Dilute Acetic Acid Soda Ash 100 Air Emission Water /ML 700 Recovery Paracetamol 50 Solid Waste ( Sodium Acetate) Washing Water 200 Recycle water 150 Evaporation 100 Total 2575 Total 2575 Stage II : PURIFICATION, CENTRIFUGING,DRYING & PACKING 1. Wet Crude Paracetamol 1120 Paracetamol Dry ML/WATER 2500 ML (to be recycle) Activated Carbon 05 Losses (Evaporation) 215 Wet Carbon Sludge 10 Total 3625 Total 3625 PFR for Bharat Chemicals Tarapur Page 11

12 2. Para Nitro Phenol and salt Chemical Reaction: Process Description: Para Nitro Chloro Benzene is hydrolyzed with caustic soda lye & Water at the temperature of about 155 C 160 C and to get sodium salt of Para Nitro phenol. After acidification with sulphuric acid gives Para Nitro phenol. Material Balance: PRODUCT : PARANITRO PHENOL & SALT (1MT) Para Nitro Chloro Benzene 1150 Para Nitro Phenol 1000 Caustic Soda 750 Waste Water 4700 Sulphuric Acid 500 Air Emission 200 Water 3500 Waste Water Total 5900 Total 5900 PFR for Bharat Chemicals Tarapur Page 12

13 3. Caffeine Chemical Reaction: Stage I: Stage II: PFR for Bharat Chemicals Tarapur Page 13

14 Process Description: Step No. I: Theophylline Crude reacts with Sodium Hydroxide which results in in-situ formation of Sodium Theophyllinate / Sodium Theophyllinate which further reacts with Di methyl Sulphate [(CH 3 ) 2 SO 4 ] at controlled ph 8.0 to 8.5 results in formation of Caffeine Crude. Step No. II: Caffeine Crude dissolved in water and charcoalised with Activated charcoal then filtered crystallized and Slurry filtered in Agitated nutsche filter to get Caffeine Pure. Drying of caffeine pure done in SFD and mixing done in Homonizer and further packed as per party requirements. Material Balance: PRODUCT : CAFFEINE (1MT) STAGE-I REACTION 1. Theophylline Crude/ Soda salt of Theophylline 1500 Reaction Mass Recycle ML/Water Di- methyl Sulfate 1130 Spent Carbon Activated Carbon 40 Total 4050 Total 4050 STAGE-II :CRUDE FILTERATION 1. Reaction Mass 3990 Wet Caffeine Crude Chloroform ML 2650 Total 3990 Total 3990 STAGE-III :PURIFICATION 1. Caffeine Crude 1340 Caffeine Wet Cake Water 1056 ML Recycle Activated Carbon Washing Water 124 Spent Carbon 75 Total 2570 Total 2570 STAGE-IV :DRYING Caffeine Pure Caffeine Wet Cake 1176 Losses 126 Total 1176 Total 1176 PFR for Bharat Chemicals Tarapur Page 14

15 2.6 Raw material required along with estimated quantity, likely source, marketing area of final Product/s, mode of transport of raw material and finished product. Raw Materials: The detailed raw material list for product mixed products as per selected capacity is detailed below for all reactants, solvents and support chemicals. Source for Raw Material Procurement: Raw Materials are easily available in the local market, from Mumbai and Gujarat. Part of the raw materials are generated In-house and used internally and some raw material will be imported. Mode of Transport of Raw Materials: Raw Materials will be transported through Trucks/ Tankers from suppliers factories or traders go-downs. Those which are in house will be transported through internal pipelines as per the requirements. Storage at the site: Raw Materials are stored in storage yard at the project site. Location of storage yard is demarcated in Layout Plan. Table 2-2: List of Raw material Sr. No. Name of the product Para Nitro Phenol & Salt Existing Qty. (MT/Month) Proposed Qty. (MT/Month) Total Qty. (MT/Month) 1 Para nitro Chloro benzene Caustic soda 100% basis Sulphuric acid Paracetamol 4 Para amino phenol PFR for Bharat Chemicals Tarapur Page 15

16 5 Acetic Anhydride / Acetic acid Soda ash Activated carbon Caffeine 8 Theophylline Crude/Soda salt of Theophylline Caustic soda 100% basis Dimethyl sulphate Hydrochloric acid Activated carbon Resource optimization/recycling and reuse envisaged in the project To conserve the water, various recycle/ reuse schemes will be implemented. Most energy efficient technology is selected. 2.8 Availability of water its source, energy/power requirement and source Water Requirement and Source Fresh water requirement of the project for domestic and industrial activity during operation phase will be 507 CMD. The water supply is from MIDC. The details of water requirement are given below Table 2-3: Details of Raw water consumption Sr. No. Units Raw Water Qty.(CMD) 1 Domestic 11 2 Industrial Process Cooling tower & Boiler Gardening 5 Total 507 PFR for Bharat Chemicals Tarapur Page 16

17 2.8.2 Power Requirement Existing power requirement is 600 KW and additionally 400 KW will be required for expansion. Total power requirement will be 1000 KW. Source is State Electricity Board Emergency power Existing 1 no. of D. G. set having capacity 125 KVA (1 no.) & additionally 800 KVA (1 no.) are required to meet emergency power requirement Utility Existing& Proposed Sr. No. Item Quantity Capacity Type Fuel Quantity 1 Boiler 1 (Existing) 1 2 TPH Furnace Oil 2.40 TPD 2 Boiler 1 (Proposed) 1 6 TPH Coal TPD 3 D G Set (Existing) KVA HSD 0.10 TPD 4 D G Set (Proposed) KVA HSD 0.30 TPD 2.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal GaseousEmissions Details of gaseous emissions from Process and Flue gas are given in Table 2-4 Table 2-4: Details of emissions from process and flue gas Sr. No. Pollutant Source of Emission Concentration in flue gas 1. SPM Boiler (Coal) <150 mg/nm 3 PFR for Bharat Chemicals Tarapur Page 17

18 Details of stack are given in Table 2-5 Table 2-5: Details stacks along with their mitigation methods Stack Attached Boiler D. G. Set to Existing Proposed Existing Proposed Capacity 2 TPH 6 TPH 125 KVA 800 KVA Fuel type FO Coal Diesel Diesel Fuel qty lit/day 25 T/day 100 lit/day 400 lit/day MOC/Make Nestler Nestler Kirloskar Cummins Shape Round Round Round Round Diameter Height (m) (above ground level) Control equipments Multi cyclone followed by Bag filter Adequate Stack Effluent Generation: The quantity of effluent generated proposed project is given in Table 2.6 Table 2-6: Details of Effluent Generation Sr. No. Units Effluent generation (CMD) A Process 28 B Utilities 60 Trade effluent Total 88 C Domestic 08 Adequate Stack Trade effluent generated from the expansion project will be 88 CMD. High TDS will be treat in MEE followed by ATFD and Low TDS will be treat in ETP plant consisting primary, secondary and tertiary treatment with RO unit for permeate will be recycled and effect Zero Liquid Discharge (ZLD). The sewage generated due to domestic activities will be treated in STP of 10 CMD capacity and treated water will be reused for gardening. PFR for Bharat Chemicals Tarapur Page 18

19 Table 6.1: Design Data & Performance projection High TDS Stream : To MEE Sr. RO Parameters Unit No. Reject Inlet to MEE Condensate of MEE 1. Flow m 3 / Steam d condensate 2. ph TSS mg/l < 100 Nil Nil 4. TDS mg/l < 150 Low TDS Stream (including condensate of Multiple Effect Evaporator) : To ETP Sr. No. Parameters Inlet Effluent Characteristics Characteristics of Effluent to CETP Characteristics of Effluent to RO 1 Flow ph to to TDS mg/l mg/l mg/l 4 BOD mg/l mg/l mg/l 5 COD mg/l mg/l mg/l 6 TSS mg/l mg/l mg/l All values are in mg/l except ph and Flow To RO S.No. Parameters Unit Inlet Permeate Reject 1 Quantity m 3 /day ph to to to TDS mg/l < PFR for Bharat Chemicals Tarapur Page 19

20 The ETP Process Details: ETP shall be installed to treat 123 CMD of waste water. The capacity of the ETP will be 150 CMD and it will treat effluent till tertiary level with RO unit to achieve Zero Liquid Discharge (ZLD). Schematic Flow Diagram of ETP has been presented in below diagram PFR for Bharat Chemicals Tarapur Page 20

21 Standard Operating Procedure of Effluent Treatment Plant Source of effluent generation: High TDS Effluent: The treatment to the high TDS effluent is given the following sequence. 1. Multiple Effect Evaporator 2. Agitated Thin Film Dryer The high TDS effluent arising from the production activities will be collected in separate collection sump tank near the individual plants. The effluent from collection tank shall be collected in collection tank. The effluent will be fed to MEE (capacity 100 CMD) where the effluent will be concentrated up to 50 % w/w by evaporating the water with the high pressure steam. The condensate of the Evaporator will be fed to ETP for removal of volatile organics that will get carried away in the condensate. The concentrated liquor will be pumped to the Agitated Thin Film Dryer for the removal of solids again by evaporation of the water with the help of high pressure steam. Thus the dissolved solids will be completely removed from the liquor and it will also reduce the concentration of other polluting parameters. The solids recovered from ATFD will be sent for disposal to CHWTSDF. The condensate of Multiple Effect Evaporator and ATFD will be pumped to the Effluent Treatment Plant for the removal of organics. Low TDS Stream: ETP is designed to treat 123 m 3 / day of effluent. The treatment to the stream is in the following sequence. Physico-Chemical Treatment: The treatment include the following 1) Oil and Grease trap 2) Equalization cum neutralization tank 3) Acid/Alkali dosing PFR for Bharat Chemicals Tarapur Page 21

22 4) Effluent transfer pump 5) Flash mixture 6) Primary Settling tank 7) Bioreactor I 8) Secondary settling Tank I 9) Bioreactor II 10) Secondary Settling Tank II 11) Sludge Drying bed The low TDS effluent generated from the utility area will be collected in separate collection tanks near individual plants. The effluent from collection tank will be transferred to screening sump for trapping coarse solids. The coarse solids will be manually removed and collected in a drum for disposal. The effluent will be then pumped to the oil and grease trap for trapping oils by virtue of its immiscibility. The oil floats at the surface which will be skimmed out by using oil skimmer and will get collected in drums for disposal. The effluent devoid of oils will flow to the equalization and neutralization tank for equalizing the organic and hydraulic load. Provision of acid / alkali dosing for neutralization of effluent will be made near the tank. The neutralizing agents will be dosed from the respective dosing tanks. The content of equalization tank will be mixed with help of coarse diffused aeration system. The ph will be checked with the help of ph indicator till the ph value of 7.5 to 8 is achieved. The equalized and neutralized effluent will be then pumped to flash mixer for primary clarification. The dosing tanks containing alum will be used for coagulant dosing. The flash mixer will be provided for mixing the coagulants with effluent. The coagulated mass will flow to primary settling tank for settlement of solids. The primary settling tank will be constructed with the hopper bottom for effective removal of solids. The clarifier mechanisms will be fitted on the primary clarifier for effective scraping of the solids from the walls and bottom. The settled sludge will be pumped to the sludge drying pits. The filtrate will be collected in collection tank and pumped back to equalization tank. PFR for Bharat Chemicals Tarapur Page 22

23 BIOLOGICAL TREATMENT The biological treatment, (Activated Sludge Treatment) consists of following units; 1) Secondary clarifier tank-1 2) Secondary clarifier tank-2 The supernatant from the Carifloculator overflows to bio reactor - I for the aerobic treatment. Activated sludge treatment works on the principle of development of microbial culture in the aeration tank. Each bacterium is constituted of C, H, N, O and P. The bacteria assimilate all carbonaceous matter. The oxygen required for the bacterial growth will be supplied through the silicon membrane diffuser. Air will be supplied to the diffuser through air blowers. This system is energy saving and effective as compared to surface aerator. The carbon and hydrogen will be present in the effluent. The microbial culture that will be developed in the aeration tank is called Mixer Liquor Suspended Solids (M.L.S.S), which will be in the range of 3000 to 3500 mg/lit. Mixed Liquor from the aeration tank will flow by gravity to the settling tank-1. The sludge is settled at the hopper bottom of the Secondary Settling tank This sludge will be pumped back to aeration tank-1 for marinating M.L.S.S in the tank with the help of Sludge Recycle pump. Excess Sludge from the settling tank will be pumped to the Sludge drying Beds. The overflow of secondary settling tank-1 will flow to aeration tank-2 and overflow of aeration tank-2 will flow to secondary settling tank-2. The organics which will not be degraded in the 1st stage bio-reactor will be degraded in the 2nd stage bio-reactor. The sludge will be settled at the hopper bottom of the Secondary Settling tank 2. This sludge will be pumped back to aeration tank-2 for marinating M.L.S.S in the tank with the help of Sludge Recycle pump. Excess Sludge from the settling tank will be pumped to the Sludge drying Beds. The recycling of Biomass will be done in both the Bio-reactors from the respective settling tank to maintain MLSS. The biodegradable organics which will be not degraded in Bio-I are degraded in Bio-II. PFR for Bharat Chemicals Tarapur Page 23

24 TERTIARY TREATMENT Tertiary treatment includes following units; 1. Holding tank 2. Pressure Sand Filter 3. Activated Carbon filter The biologically treated effluent flows to effluent holding sump from where will be pumped to pressure sand filter for tertiary treatment. Tertiary treatment consists of pressure Sand Filter and Activated Carbon Filter, which will remove traced suspended solids which have escaped settlement and dissolved organics, color and odor. The treated water will be collected in the final treated water tank from where it is pumped to RO System. RO System: Reverse Osmosis is at present a proven technology used to recover good quality water for process use. The treated effluent from ETP containing TDS is passed through RO where the dissolved solids are separated in the form of Reject & treated effluent free from dissolved solids (Permeate - 81 CMD) is utilized for cooling tower and boiler feed. Reject of RO (19 CMD) shall be feed to the MEE. Treatment Scheme for Domestic Wastewater The sewage generated due to domestic activities will be treated in proposed sewage treatment plant of capacity 10 CMD Details of Hazardous wastes The types of Hazardous wastes generated from the project, method of disposal is shown in below table below: PFR for Bharat Chemicals Tarapur Page 24

25 Table 2-7: Details of Proposed Hazardous Solid waste along with the Category and disposal method Sr. No. Waste Name Cat. Hazardous Waste 1 Activated carbon sludge Existing MT/A Quantity TPA Propose d 384 MT /A Total 504 MT/A 2 ETP Sludge MT/A 2.4 MT/A 4.8 MT/A Non- Hazardous Waste Sr. No. Waste Name Unit Existin g Proposed Total 1 Plastic Bags Nos Disposal Method Disposal to MWML Disposal to MWML Disposal Method Sale to authorized recycler PFR for Bharat Chemicals Tarapur Page 25

26 2.10 Schematic representations of the feasibility drawing which give information of EIA purpose. Project Identification what environmental impacts are normally associated with such type of projects being proposed? Pre-feasibility Analysis Is the Project feasible from an environment point of view? Project Design (a) What negative environmental impacts could arise if the proposed project is implemented with proposed design? (b) Is there alternative design with less environmental impacts? Project Appraisal Have all the environmental concerns associated with the project been eliminated? Project Implementation what environmental concerns might arise at the implementation phase of the project? Preparation of an Environment Monitoring and Evaluation Plan (a) What environment monitoring indicators are required to ensure that the implementation of components of the project will be executed within environmentally sound limits? (b) What is required to ensure that the recommended environmental control PFR for Bharat Chemicals Tarapur Page 26 Post EIA Monitoring and Environment Audit (a) Is the implementation of components of the project being executed in an environmentally sound manner? (b) Are all the recommended environmental control measures being implemented and enforced? Are there any environmental impacts that were earlier not anticipated when EIA was done? ( Identify gaps and corrective action )

27 3.0 SITE ANALYSIS 3.1 Connectivity This unit is at Plot No. L 13, L-28, L-29 & L-30, MIDC Tarapur, Palghar, Maharashtra. The nearest city from the site is Boisar at distance of 3.5 Km The nearest railway station is Boisar at distance of 3.5 Km from the site The nearest airport is at Mumbai 110 km. National Highway Mumbai Ahmadabad highway is at 20 Km from project side. 3.2 Land Form, Land use and Land ownership The proposed land is situated in approved chemical zone of MIDC where land use is industrial. Land is owned by MIDC and is leased for 99 years. 3.3 Topography The proposed industry is located at Latitude N and Longitude E. Elevation above mean sea level is: 15m. Toposheet of the site is shown below. The study area (10 km radius) around the project site exhibits flat terrain in the east and relatively elevated terrain in the west side. Figure 3.1: Toposheet Showing Project site PFR for Bharat Chemicals Tarapur Page 27

28 3.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. Proposed site falls under the Industrial MIDC. The land is reserved for Industrial use. 3.5 Soil classification The basic type of soil found in the area varies from brown & black. The black type of soil is found in the eastern part. The fertility of the soil increases as it goes from red to black. 3.6 Climatic data from secondary sources The climate in proposed area is characterized by hot summer and general dryness throughout the year except the south west monsoon season. Climate Classification: Project site features a semiarid climate. Temperature: Annual maximum and minimum temperature in Tarapur range from max. 38 C and min. 11 C. Rainfall: Most of the rainfall occurs in the monsoon season from June to September. Average annual rainfall is 2488 mm. Humidity: Annually relative humidity ranged from 64% 88% and during summer season the humidity ranged from 64% 75%. 3.7 Social Infrastructure Availability Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. PFR for Bharat Chemicals Tarapur Page 28

29 4.0 Planning In Brief 4.1 Planning Concept MIDC Industrial area, Tarapur provides many basic facilities like uninterrupted water supply, power and road network & solids disposal facility if feasible. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure. 4.2 Land Use Planning Existing land is converted for industrial purpose. The land is located in a designated industrial area. No change in land use. Table 4-1: Land Use Break Up Sr.No. Particular Area in Sq.m 1 Plant area RM & Product storages area ETP & STP 70 4 Office Building Parking Internal road 1412 Total 4008 Green belt Assessment of Infrastructure Demand (Physical & Social) Key infrastructure such as hospitals, schools, bank, places of worship and social/ community facilities such as park, market, playground etc. education, health care, community development, income distribution, employment and social welfare are available in nearby area of Maharashtra Industrial Estate. 4.4 Amenities/Facilities In proposed site many basic facilities like uninterrupted water supply, Power and Road Network & solids disposal facility if feasible are available. This site is inside the campus PFR for Bharat Chemicals Tarapur Page 29

30 of the MIDC and means safe transportation, less need of utilities, less constructing buildings and roads, less fuel, less water with optimization of infrastructure and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal facility), MWML, Taloja in vicinity established with support of MIDC and MPCB. All nearby villages are provided with drinking water from wells or Government Water Supply Schemes RWS. Hence we do not encroach upon their supply. 4.5 Population Projection Palghar District has a population of 454,635 as per census It has more than 99,652 households of Maratha, Aagri, Koli, Muslim, Buddhist, and also includes SC, ST, OBC and open categories community. The village has basically an agrarian economy and industrial workers and farming is the main occupation of the villagers. The local self- Government vests with a Grampanchayat having an elected body of headed by a Sarpanch. Population growth is being increased at alarming rate with their basic requirements. Amongst, Medicine is one of the basic needs, which is very essential for everyone to live happy life. So to fulfil their future basic need of Medicine for social community there is a necessity to promote R & D Centre in each industrial sector. There will be in ratio of population increase in similar way their need also increases so to fulfil their needs we are going to set up a proposed unit which again generates employment. PFR for Bharat Chemicals Tarapur Page 30

31 5.0 Existing Infrastructure 5.1 Industrial area Industrial Area (Processing area) Utilities Cooling towers HSD unloading/storage area Boilers DM water plant Cooling towers Chilling Plants Non- Processing Area Weighbridge Administrative Buildings Security cabins Workers restroom Vehicle Shed Water reservoirs Temporary storage sites Works block etc. For proposed expansion existing infrastructure will be utilized and is sufficient for the proposed activity 5.2 Residential Area There is no any residential area has been proposed. 5.3 Green Belt The project is built on an MIDC plot with plot area of 4008 sq. m. and green belt area sq. m. Green belt is already developed at project site and details will be provided in EIA report. 5.4 Social Infrastructure The basic amenities within the study area include primary schools, dispensaries, water supply, electric supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training institute and entertainment etc. 5.6 Drinking Water Management The source of water supply is from MIDC Tarapur. PFR for Bharat Chemicals Tarapur Page 31

32 5.7 Sewage System The domestic effluent will be treated in proposed sewage treatment plant. 5.8 Industrial Water Management Existing effluent 23 CMD will be discharged to CETP and propose effluent 65 CMD after treatment will be reuse for utilities. High TDS stream will be fed to MEE followed by ATFD. Low TDS stream along with condensate from MEE will be treated in conventional ETP consisting of primary, two stage secondary and tertiary treatment. This will be further treated by RO for permeate recycled and give effect zero liquid discharge (ZLD). 5.9 Solid Waste Management Hazardous solid waste generated from the process will be collected, stored, transported Transboundry Movement) Rules Power Requirement& Supply / source The Total Power required for the proposed expansion project is 1000 KW. 6.0 Rehabilitation and Resettlement (R & R) Plan 6.1 Policy to be adopted (Central/State) in respect of the project affected persons including home oustees, land oustees and landless. Proposed activity will be at existing manufacturing unit located at MIDC area. Hence, there is no any kind of activity of Rehabilitationand resettlement carried out over it. 7.0 PROJECT SCHEDULE & COST ESTIMATES 7.1 Likely date of start of construction and likely date of completion The expansion activity is likely to start after getting Environmental Clearance and NOC/CTE from the authorized committee. 7.2 Estimated project cost along with analysis in terms of economic viability of the project The total investment envisaged is Rs Crore. PFR for Bharat Chemicals Tarapur Page 32

33 Economic Viability The project has been conceived assuming that there will be a growth in demand for the proposed products, leading to a reasonable rate of return in the medium term. The project is considered bankable. 8.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) Proposed expansion activity will provide benefits to the local people in terms of financial and social welfare. Company will contribute in improving education and health facilities in nearby area. Annexure I Plant Lay out PFR for Bharat Chemicals Tarapur Page 33