M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PRIVATE LIMITED

Transcription

1 ENVIRONMENTAL IMPACT ASSESSMENT REPORT OF (APPLE ORGANICS DIVISION) FOR MANUFACTURING OF SYNTHETIC ORGANIC PRODUCTS EXPANSION PROJECT PLOT NO. 609/610, 100 SHED AREA, GIDC ESTATE, VAPI , DIST.-VALSAD, GUJARAT. PREPARED BY M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PRIVATE LIMITED Shed No. K-1, 7705/2,3,4 GIDC ESTATE, Ankleshwar Phone: (02646)220293; Fax: (02646) Website: info@jyotiom.com

2 TABLE OF CONTENTS SR. CONTENT PAGE NO. NO. -- LIST OF CONTENTS i to xiv CHAPTER 1 INTRODUCTION 1.1 PURPOSE OF THE REPORT INTRODUCTION OF THE PROJECT & PROJECT PROPONENT IDENTIFICATION OF PROPOSED PROJECT DETAILS OF CONSENT SCREENING CATEGORY ABOUT COMPANY AND PROJECT PROPONENT KEY INFORMATION OF PROJECT IMPORTANCE AND JUSTIFICATION OF PROJECT SIZE AND COST OF THE PROJECT SITE SELECTION LOCATION OF THE PROJECT REGULATORY FRAMEWORK SCOPE OF THE STUDY OBJECTIVES OF THE EIA STUDY STRUCTURE OF EIA REPORT REGULATORY PROVISIONS AND REQUIREMENT GENERAL LEGAL REQUIREMENTS TERMS OF REFERENCE AND ITS COMPLIANCE COMPLIANCE OF TOR APPROVED BY MoEF & CC, NEW DELHI STANDARD TERMS OF REFERENCE (TOR) AS PER ANNEXURE-I FROM SEIAA, GUJARAT 22 CHAPTER - 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT NEED FOR THE PROJECT PRODUCTS AND RAW MATERIAL DETAILS STORAGE & HANDLING OF PRODUCTS AND BY-PRODUCTS RAW MATERIAL STORAGE AND HANDLING PHYSICAL PROPERTY/CHARACTERISTICS OF PRODUCTS & 49 RAW MATERIALS TRANSPORTATION OF RAW MATERIALS AND FINISHED 60 PRODUCTS 2.4 PROCESS DESCRIPTION BEST AVAILABLE TECHNOLOGY USED FOR MANUFACTURING 62 PROCESS AND JUSTIFICATION MANUFACTURING PROCESS OF PRODUCTS MANAGEMENT PLAN FOR BY-PRODUCTS DETAILS OF SOLVENT RECOVERY SYSTEM SOLVENTMONO CHLORO BENZENE RECOVERY FROM PLANT SOLVENT METHANOL RECOVERY FROM PLANT SOLVENT N, N-DIMETHYLFORMAMIDE, SULFOLANE, ACITO 101 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. i

3 SR. NO. CONTENT NITRILE, MDC and THFRECOVERYFROM PLANT PAGE NO. 2.7 RESOURCE REQUIREMENT INFRASTRUCTURE FACILITIES (LAND) DETAILS OF FUEL AND ELECTRICITY CONSUMPTION DETAILS OF ENERGY DISTRIBUTION/UTILISATION DETAILS OF EQUIPMENTS/MACHINERIES WITH UTILITIES MANPOWER WATER REQUIREMENT POLLUTION POTENTIAL SCENARIO DETAILS OF WASTE WATER GENERATION SEGREGATION OF WASTE STREAMS QUALITATIVE AND QUANTITATIVE ANALYSIS PROPOSED EFFLUENT TREATMENT PLANT PROCESS GASEOUS EMISSION AND CONTROL FLUE GAS EMISSION PROCESS GAS EMISSION MANAGEMENT OF AIR ENVIRONMENT DETAILS OF SCRUBBER HAZARDOUS WASTE GENERATION HAZARDOUS WASTE AND SOLID WASTE MANAGEMENT METHODOLOGY FOR DECONTAMINATION PROJECT IMPLIMENTATION SCHEDULE COST PROVISION FOR ENVIRONMENTAL MEASURES PROJECT COST ESTIMATES ECONOMICAL AND TECHNICAL VIABILITY OF THE EFFLUENT TREATMENT SYSTEM ODOUR MANAGEMENT PLAN FUGITIVE EMISSIONS MANAGEMENT PLAN ADEQUACY OF THE PROPOSED EMS 128 CHAPTER - 3 BASELINE ENVIRONMENT STATUS 3.1 INTRODUCTION SALIENT FEATURES OF AREA GEOGRAPHY TOPOGRAPHY NEIGHBORING INDUSTRIES WINDROSE AIR ENVIRONMENT AMBIENT AIR QUALITY (AAQ) LOCATION OF AAQ MONITORING STATIONS BASE LINE DATA WATER ENVIRONMENT GROUND WATER SAMPLING SURFACE WATER SAMPLING NOISE ENVIRONMENT RECONNAISSANCE 149 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. ii

4 SR. CONTENT PAGE NO. NO METHODOLOGY FOR NOISE MONITORING NOISE MONITORING LOCATIONS SOIL ENVIRONMENT BASELINE DATA LAND USE PATTERNS BIOLOGICAL ENVIRONMENT & SOCIO ECONOMIC ENVIRONMENT ECOLOGICAL INFORMATION FOREST FLORA FAUNA SOCIO-ECONOMIC ENVIRONMENT DEMOGRAPHIC DATA WITHIN THE REGION OF INTEREST LITERACY RATE OCCUPATIONAL STRUCTURE EARTHQUAKE VULNERABILITY WIND AND CYCLONE VULNERABILITY TRAFFIC SURVEY 177 CHAPTER - 4 IDENTIFICATION AND ASSESSMENT OF IMPACTS 4.1 IDENTIFICATION OF IMPACT PREDICTION AND ASSESSMENT OF IMPACT WATER ENVIRONMENT AIR ENVIRONMENT DISPERSION MODEL AND OBSERVATION NOISE ENVIRONMENT LAND ENVIRONMENT ECOLOGICAL ENVIRONMENT INFRASTRUCTURE AND SERVICES SOCIO-ECONOMIC IMPACT IMPACT MATRIX 206 CHAPTER - 5 ANALYSIS OF ALERNATIVES (TECHNOLOGY & SITE) 5.1 INTRODUCTION SITE ANALYSIS OF ALERNATIVES TECHNOLOGY ANALYSIS 209 CHAPTER - 6 ENVIRONMENT MONITORING PROGRAM 6.1 INTRODUCTION OBJECTIVES OF ENVIRONMENTAL MONITORING PLAN IMPLEMENTATION SCHEDULE OF MONITORING MEASURES POLLUTION MONITORING AND SURVEILLANCE SYSTEM AMBIENT AIR QUALITY MONITORING STACK MONITORING NOISE MONITORING WATER AND WASTE WATER QUALITY MONITORING MONITORING EQUIPMENT AND CONSUMABLES ENVIRONMENTAL MANAGEMENT CELL 214 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. iii

5 SR. NO. CONTENT PAGE NO. CHAPTER - 7ADDITIONAL STUDIES 7.1 SCOPE OF THIS STUDY METHODOLOGY OF RISK ASSESSMENT OBJECTIVES OF RISK ASSESSMENT DETAILS OF STORAGE FACILITIES RISK ASSESSMENT QUALITATIVE RISK ASSESSMENT ARRANGEMENTS FOR ENSURING HEALTH & SAFETY OF WORKERS ENGAGED IN HANDLING OF HAZARDOUS 232 MATERIALS SAFETY PRECAUTIONS MEASURES FOR FUGITIVE EMISSION CONTROL FIRE CONTROL PLAN RECOMMENDATIONS LDAR DO S & DON TS ANTIDOTES DETAILS ON SITE AND OFF SITE DISASTER PREPAREDNESS & EMERGENCY MANAGEMENT PLAN DEFINING THE NATURE/LEVEL OF EMERGENCY OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM COMMMUNICATION SYSTEM OCCUPATIONAL HEALTH & SAFETY OCCUPATIONAL HEALTH HOSPITAL FACILITIES FACTORY MEDICAL OFFICER/OHC PLAN FOR PERIODIC MEDICAL CHECKUP DETAILS OF OCCUPATIONAL HEALTH IMPACTS AND SAFETY HAZARDS MEASURES ADOPTED BY COMPANY TO KEEP AIR BORNE CONCENTRATION OF HAZARDOUS CHEMICALS BELOW PEL WORKZONE MONITORING ARRANGEMENTS FOR HAZARDOUS CHEMICALS HEALTH STATUS EVALUATION OF WORKERS (EXPOSURE SPECIFIC) ACTION PLANFOR SAFE HANDLING & SAFETY SYSTEM PLAN AND FUND ALLOCATION TO ENSURE THE OCCUPATIONAL HEALTH & SAFETY OF ALL CONTRACT AND CASUAL WORKERS ARRANGEMENTS FOR ENSURING HEALTH AND SAFETY OF WORKERS ENGAGED IN HANDLING OF TOXIC MATERIALS MOCK DRILLS 258 CHAPTER- 8 PROJECT BENEFIT 8.1 CORPORATE ENVIRONMENT RESPONSIBILITY ACTIVITIES OTHER TANGIBLE BENEFITS 260 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. iv

6 SR. CONTENT PAGE NO. NO. 8.3 EMPLOYMENT POTENTIAL ACTION PLAN FOR BUDGETARY ALLOCATIONFOR CER ACTIVITY 260 CHAPTER- 9ENVIRONMENTAL COST BENEFIT ANALYSIS 9.1 COST-BENEFIT ANALYSIS 261 CHAPTER- 10 ENVIRONMENT MANAGEMENT PLAN 10.1 INTRODUCTION AIM AND OBJECTIVE ENVIRONMENT, HEALTH AND SAFETY (EHS) ENVIRONMENTAL MANAGEMENT PLAN ENVIRONMENT MANAGEMENT PLAN FOR CONSTRUCTION PHASE ENVIRONMENT MANAGEMENT PLAN FOR OPERATIONAL PHASE ADDITIONAL MITIGATION MEASURES ENERGY CONSERVATION PROGRAMME WATER CONSERVATION PROGRAMME MANAGEMENT OF TRAFFIC ODOUR CONTROL MANAGEMENT PLAN SAFETY MEASURES TO PREVENT THE OCCUPATIONAL HEALTH HAZARDS SOCIAL WELFARE MEASURES FOR FUTURE PLANNING LEAK DETECTION AND REPAIR (LDAR) PROGRAM INSTRUCTIONS, SHOW-CAUSE NOTICES, CLOSURE NOTICES & ENVIRONMENT AUDIT REPORTS FINDINGS CONCLUSION 283 CHAPTER- 11EXECUTIVE SUMMARY& CONCLUSION 11.1 INTRODUCTION LOCATION INVESTMENT PRODUCT& RAW MATERIALDETAILS PROJECT DESCRIPTION NEED FOR THE PROJECT PRODUCT STORAGE & HANDLING RAW MATERIAL STORAGE & HANDLING RESOURCE REQUIREMENT POLLUTION POTENTIAL SCENARIO BASELINE ENVIRONMENT STATUS STUDY AREA INCLUDED IN ENVIRONMENTAL SETTING CLIMATE OF THE STUDY AREA AMBIENT AIR QUALITY WATER QUALITY NOISE ENVIRONMENT SOIL LAND USE OF THE STUDY AREA 290 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. v

7 SR. CONTENT PAGE NO. NO BIOLOGICAL ENVIRONMENT IDENTIFICATION & ASSESSMENTOF IMPACT WATER ENVIRONMENT AIR ENVIRONMENT NOISE ENVIRONMENT LAND ENVIRONMENT ECOLOGICAL ENVIRONMENT SOCIO-ECONOMIC IMPACT INFRASTRUCTURE AND SERVICES ENVIRONMENT MONITORING PROGRAM RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN PROJECT BENEFITS ENVIRONMENTAL MANAGEMENT PLAN ENVIRONMENT MANAGEMENT CELL ENVIRONMENTAL MANAGEMENT PLAN PUBLIC HEARING CONCLUSION 296 CHAPTER- 12 DISCLOSURE OF CONSULTANT ENGAGED 12.1 SALIENT FEATURES SERVICES PROVIDED BY THE CENTRE OUTSTANDING ACHIVEMENTS STATUS OF NABET ACCREDITATION DECLARATION BY CONSULTANT 301 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. vi

8 LIST OF TABLES TABLE NO. TABLE NAME PAGE NO. CHAPTER -1 INTRODUCTION 1.1-A LIST OF EXISTING PRODUCTS B LIST OF PROPOSED PRODUCTS LIST OF DIRECTORS CAPITAL COST OF PROJECT DETAILS OF CORNERS CO-ORDINATE OF SITE STRUCTURE OF EIA REPORT APPLICABLE REGULATORY PROVISION FOR PROPOSED PROJECT TOR GIVEN BY IMPACT ASSESSMENT DIVISION OF MoEF & CC, NEW DELHI STANDARD TOR AS PER ANNEXURE-I FROM SEIAA, GUJARAT 22 CHAPTER - 2 PROJECT DESCRIPTION 2.1 LIST OF PRODUCT WISE RAW MATERIAL CONSUMPTION DETAILS OF EXISTING PRODUCT STORAGE DETAILS OF PROPOSED PRODUCT AND BY-PRODUCT STORAGE DETAILS OF RAW MATERIAL STORAGE CHARACTERISTICS OF PRODUCT AND RAW MATERIAL DETAILS OF RAW MATERIAL SOURCE AND METHOD OF TRANSPORTATION DETAILS OF SOLVENTS TO BE USED AND RECOVERED LAND USE BREAK UP OF TOTAL PLOT AREA FUEL CONSUMPTION & ELECTICITY CONSUMPTION ENERGY DISTRIBUTION A LIST OF EXISTING EQUIPMENTS B LIST OF PROPOSED EQUIPMENTS MAN POWER REQUIREMENT DETAILS OF WATER CONSUMPTION DETAILS OF WASTE WATER GENERATION QUALITATIVE AND QUANTITATIVE ANALYSIS OF EACH WASTE STREAM CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT EXISTING EQUIPMENT LIST OF EFFLUENT TREATMENT PLANT DETAILS OF FLUE GAS EMISSION DETAILS OF PROCESS EMISSION DETAILS OF EMISSION ESTIMATE DETAILS OF ALL EMISSIONS CONTROL MEASURES A DETAILS OF SCRUBBING AGENTS FOR PLANT-1&2 WITH DIMENSION 116 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. vii

9 TABLE NO. TABLE NAME PAGE NO B DETAILS OF SCRUBBING AGENTS FOR PLANT-3 WITH DIMENSION DETAILS OF HAZARDOUS WASTE GENERATION PROJECT IMPLEMENTATION SCHEDULE BUDGET ALLOCATION FOR ENVIRONMENTAL MONITORING & MANAGEMENT DETAILS OF COST OF ETP PER YEAR PROPOSED FUGITIVE EMISSION CONTROL MEASURES 127 CHAPTER 3 BASELINE ENVIRONMENT STATUS 3.1 LIST OF MAJOR INDUSTRIES IN THE VAPI SALIENT FEATURES OF THE PROJECT SITE DETAILS OF NEIGHBORING INDUSTRIES AT PROJECT SITE METEOROLOGICAL DATA DETAILS OF SAMPLING LOCATION OF AMBIENT AIR QUALITY MONITORING AMBIENT AIR QUALITY STATUS OF STUDY AREA METHOD OF ANALYSIS A DETAILS OF GROUND WATER MONITORING LOCATIONS B WATER QUALITY PARAMETERS (GROUND WATER SOURCES) A DETAILS OF SURFACE WATER MONITORING LOCATIONS B WATER QUALITY PARAMETERS (SURFACE WATER SOURCES) NOISE LEVEL DATA CPCB RECOMMENDATIONS FOR COMMUNITY NOISE EXPOSURE SOIL QUALITY MONITORING WITH RESPECT TO THE PROJECT SITE SOILQUALITY PARAMETERS LAND USE STATISTICS OF THE STUDY AREA LIST OF FLORA LIST OF FAUNA DEMOGRAPHIC DATA LITERACY RATE WITHIN 10 KM RADIAL DISTANCE OF STUDY AREA OCCUPATIONAL STRUCTURE DISTRIBUTION OF WORKERS TRAFFIC SURVEY OF DELHI TO MUMBAI HIGHWAY (NH-8) LEVEL OF SERVICE TRAFFIC SURVEY OF MUMBAI TO DELHI HIGHWAY (NH-8) 178 CHAPTER 4 IDENTIFICATION AND ASSESSMENT OF IMPACTS 4.1 EMISSION DETAILS CONCENTRATION OF SOx & PM 190 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. viii

10 TABLE TABLE NAME PAGE NO. NO. 4.3 CONCENTRATION OF NOx CONCENTRATION OF HCl, HBr, Cl2 & Br CONCENTRATION OF NH ENVIRONMENT IMPACT MATRIX (WITH MITIGATION MEASURES) CUMULATIVE IMPACT CHART 208 CHAPTER 6 ENVIRONMENT MONITORING PROGRAM 6.1 IMPLEMENTATION POLLUTION CONTROL MEASURES ENVIRONMENT MONITORING PLAN LIST OF LAB EQUIPMENTS LIST OF ETP OPERATION EMPLOYEES 215 CHAPTER - 7 RISK ASSESSMENT 7.1 DETAILS OF HAZARDOUS RAW MATERIALS RISK MATRIX FOR QUALITATIVE RISK ASSESSMENT RISK RANGE & ACCEPTABILITY CRITERIA RISKS AND RECOMMENDATIONS FOR SOLID CHEMICALS RISKS AND RECOMMENDATIONS FOR ACIDS RISKS AND RECOMMENDATIONS FOR DRUMS/BARRELS RISKS AND RECOMMENDATIONS FOR FORKLIFT OPERATION SAFETY PRECAUTIONS FIRE HYDRANT SYSTEM MOTOR/PUMPS DETAILS FIRE EXTINGUISHER DETAILS DETAILS OF ANTIDOTES 240 CHAPTER- 8 PROJECT BENEFITS 8.1 BUDGETARY ALLOCATION FOR CER ACTIVITIES 260 CHAPTER- 10 ENVIRONMENT MANAGEMENT PLAN 10.1 CONSTRUCTION PHASE DETAILS DETAILS OF CONTROL MEASURES FOR EFFLUENT AND SEWAGE GENERATION DETAILS OF CONTROL MEASURES FOR NOISE POLLUTION LIST OF PLANT SPECIES TO CONTROL GAS, DUST EMISSION AND NOISE LEVEL BUDGET FOR GREENBELT DEVELOPMENT LDAR PROGRAM DETAILS OF INSPECTION REPORT 282 CHAPTER- 12 DISCLOSURE OF CONSULTANT ENGAGED 12.1 NAME OF EIA TEAM MEMBER 298 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. ix

11 LIST OF FIGURES FIGURE NO. FIGURE NAME PAGE NO. CHAPTER -1 INTRODUCTION 1.1 LOCATION MAP OF PROJECT SITE GOOGLE EARTH OR SATELLITE IMAGE OF PROJECT LOCATION GOOGLE EARTH OR SATELLITE IMAGE OF ALL CORNERS OF THE SITE 15 CHAPTER - 2 PROJECT DESCRIPTION 2.1 FLOW DIAGRAM OF MCB & METHANOL RECOVERY SYSTEM FLOW DIAGRAM OF SOLVENT RECOVERY SYSTEM EXISTING WATER BALANCE DIAGRAM PROPOSED WATER BALANCE DIAGRAM PROPOSED FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT DIAGRAM OF SCRUBBER SYSTEM FOR PLANT-1 & PLANT DIAGRAM OF SCRUBBER SYSTEM FOR PLANT METHODOLOGY OF DECONTAMINATION BAR CHART 124 CHAPTER - 3 BASELINE ENVIRONMENT STATUS 3.1-A WIND ROSE DIAGRAM FOR PERIOD OF MARCH-2017 TO MAY B WIND ROSE DIAGARM ON SATELITE IMAGE WIND CLASS FREQUENCY DISRTIBUTION LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS LOCATION OF GROUND WATER QUALITY MONITORING STATIONS LOCATION OF SURFACE WATER QUALITY MONITORING STATIONS LOCATION OF NOISE MONITORING STATIONS LOCATION OF SOIL MONITORING STATIONS LAND COVER MAP WITH VILLAGE LOCATION EARTHQUAKE VULNERABILITY MAP WIND AND CYCLONE VULNERABILITY MAP 176 CHAPTER - 4 IDENTIFICATION AND ASSESSMENT OF IMPACTS 4.1 IMPACT NETWORK ON AIR ENVIROENMENT IMPACT NETWORK ON NOISE ENVIRONMENT IMPACT NETWORK ON WATER ENVIRONMENT IMPACT NETWORK ON GROUND WATER ENVIRONMENT IMPACT NETWORK ON SOCIO-ECONOMIC AND CULTURAL ENVIRONMENT IMPACT NETWORK ON LAND ENVIRONMENT ISOPLETHS OF NO X (SITE COORDINATES 0,0) ISOPLETHS OF SO 2 (SITE COORDINATES 0, 0) 193 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. x

12 FIGURE FIGURE NAME PAGE NO. NO. 4.9 ISOPLETHS OF PM (SITE COORDINATES 0, 0) ISOPLETHS OF HCl (SITE COORDINATES 0,0) ISOPLETHS OF HBr (SITE COORDINATES 0, 0) ISOPLETHS OF Cl 2 (SITE COORDINATES 0, 0) ISOPLETHS OF Br 2 (SITE COORDINATES 0, 0) ISOPLETHS OF NH 3 (SITE COORDINATES 0, 0) 199 CHAPTER 6 ENVIRONMENT MONITORING PROGRAM 6.1 FLOW DIAGRAM OF ENVIRONMENT MANAGEMENT CELL FLOW DIAGRAM OF EMERGENCY REPORTING SYSTEM 216 CHAPTER -7 RISK ASSESSMENT 7.1 HAZARDOUS CHEMICAL LOCATION IN COMPANY LAYOUT 220 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. xi

13 LIST OF ANNEXURE ANNEXURE ANNEXURE NAME NO. I - A COPY OF TOR LETTER I B COPY OF STANDARD TOR ISSUED BY SEIAA, GUJARAT II- A COPY OF CCA II- B COPY OF CCA II- C COPY OF CCA - AWH-73091, DATED: III COMPLIANCE REPORT OF CCA - AWH IV PLOT ALLOTMENT LETTER FROM VAPI GIDC V TOPO SHEET FROM SURVEY OF INDIA VI VAPI GIDC INDUSTIRAL ESTATE MAP VII PROPOSED PLANT LAYOUT VIII PHOTOGRAPHS OF EXISTING UNIT & GREEN BELT AREA IX WATER PERMISSION LETTER FROM VAPI GIDC X WASTE WATER DISCHARGE LETTER FROM CETP-VGEL, VAPI XI A & G MOU FOR BY-PRODUCTS XII-A GPCB ANALYSIS REPORT XII-B THIRD PARTY ANALYSIS REPORT (ENPRO) XIII HAZARDOUS WASTE MEMBERSHIP CERTIFICATES XIV MONITORING SAMPLING LOCATION AND DATES XV ENVIRONMENT HEALTH & SAFETY POLICY XVI LETTER OF PERFORMANCE FROM CETP-VGEL, VAPI XVII LETTER SUBMITED TO GPCB-GANDHINAGAR FOR DETAIL OF CETP AT VAPI XVIII WORK ZONE MONITORING REPORT (FROM NO. 37) XIX COMPLIANCE OF RECOMMENDATIONS/SUGGESTIONS FOR SAFETY AUDIT REPORT XX- EMPLOYEE MEDICAL FITNESS CERTIFICATE XXI INSPECTION QUERY AND ITS REPLY XXII UNDERTAKING OF CLIENT XXIII UNDERTAKING OF CONSULTANT XXIV COPY OF STAY ORDER FROM GUJARAT HIGH COURT XXV FORMATE FOR EXPANTION PROJECT-5(F) FROM SEAC M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. xii

14 LIST OF ABBREVIATIONS AMSL AAQM BGL BOD CETP CGWA CGWB CH & S COD CPCB CTE CTO Db DFO DG DMP EHS EIA EMP EOT EPA ESP ETP FAE GLC GPS Ha HAZOP HC HDPE HCl HSD H2SO4 IMD INR ISCST-3 KG KLD KVA kw MCLS MoEF & CC MSI HC MSDS MSW MT NA Above Mean Sea Level Ambient Air Quality Monitoring Below Ground Level Biological Oxygen Demand Common Effluent Treatment Plant Central Ground Water Authority Central Ground Water Board Community Health & Safety Chemical Oxygen Demand Central Pollution Control Board Consent to Establish Consent to Operate Decibels Deputy Forest Officer Diesel Generator Disaster Management Plan Environmental Health and Safety Environmental Impact Assessment Environmental Management Plan Electric Overhead Travel Environmental protection Act Exchangeable Sodium Percentage Effluent Treatment Plant Functional Area Expert Ground Level Concentration Global Positioning System Hectare Hazard and Operability Study Hydrocarbon High Density Polyethylene Hydrochloric acid High Speed Diesel Sulphuric Acid Indian Meteorological Department Indian Rupees Industrial Source Complex Short Term-3 Kilo Gram Kilo Liter per Day Kilo Volt Ampere Kilowatt Maximum Credible Loss Scenarios Ministry of Environment and Forest & Climate Change Manufacture, Storage and Import of Hazardous Chemical Material Safety Data Sheet Municipal Solid Waste Metric Tone Not Applicable M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. xiii

15 NABAT NAAQS NH NOC OHS PCU PHC PM PP PPE PPMV PUCC QCI R&R SEAC SEIAA STP SH TDS ToR TPD ZLD National Accreditation Board of Education and Training National Ambient Air Quality Standards National Highway Non Objection Certificate Occupational Health & Safety Passenger Car Unit Public Health Center Particulate Matter Project Proponent Personal Protective Equipments Parts per Million by Volume Pollution Under Control Certificate Quality Council of India Resettlement & Rehabilitation State Expert Appraisal Committee State Environment Impact Assessment Authority Sewage Treatment Plant State Highway Total Dissolved Solids Terms of Reference Tone Per Day Zero Liquid Discharge LIST OF SYMBOLS / NOTATIONS C : Degree Celsius db(a) : Decibels(A-Weighted) Kcal/Hr : Kilo Calorie per Hour KVA : Kilo Volts Ampere KLD : Kilo Liters per Day m : meters m/s : Meters per Second mg/lit : Milligram/ Liters MW : Mega Watt µg/m3 : Microgram/cube meter of air µs : Microgram second NOX : Oxides of Nitrogen PM : Particulate Matter ppm : Parts per Million SCM : Standard Cubic Meter SO2 : Sulphur dioxide Sq.km. : Square kilometer Sq.m. : Square Meter TPM : Ton per Month M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. xiv

16 INTRODUCTION CHAPTER PURPOSE OF THE REPORT M/s. Aarti Industries Ltd. (Apple Organics Division) is an existing unit, located at Plot no. 609/610, 100 Shed Area, GIDC Estate, Pardi, Vapi, Dist.:-Valsad, Gujarat. The unit has first obtained CCA order 3431, issued on 16/08/2004. Further, it was extended by valid CCA order no. AWH-73091, issue on dated 14/09/2015, valid up to 06/07/2020 for manufacturing of synthetic organic products mentioned in below table no.1-a. The proposed products by the unit fall in the Schedule attached to the EIA Notification, i.e. Project No. 5(f), Synthetic organic chemicals industry of EIA Notification dated September 14 th, Since the project will be established in industrial estate, it is classified as Category B project and will be evaluated by the State Level Expert Appraisal Committee (SEAC), Gujarat. Public hearing is not applicable to this expansion project as the unit is located in GIDC notified area. Unit had applied online for TOR application on 21 st December, 2017 to MoEF&CC, New Delhi. TOR issued on 07 th July, 2017 from MoEF&CC, New Delhi. In this connection, we have prepared EIA report. Now, Industrial committee-2, MoEF&CC, New Delhi has suggested submitting EIA report to SEIAA, Gujarat. In this connection, we have prepared EIA report. TOR letter issued by the MoEF & CC, New Delhi as received vide ref F. no. J-11011/384/2016- IA.II (I) dated: - 07 th July, 2017(Proposal No: IA/GJ/IND2/61144/2016) has been duly addressed. The copy of TOR letter is attached as annexure-i-a. The committee prescribed Standard Terms of Reference (TOR) as per annexure-i by SEIAA, Gujarat for preparation of EIA-EMP report is attached as annexure-i-b. The purpose of this report is to: Establish a pre-project baseline with respect to environmental indicators. Identify environment related impacts. Evaluate safety related risk factors associated with project. Propose appropriate mitigation measures for minimizing the adverse impacts to the extent possible. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 1

17 Suggest Environment Management Plan. Recommend Risk Management Plan. This report is also made in the overall frame work of the Environmental Impact Assessment (EIA) Notification dated 14 th September 2006 (and subsequent amendments to the same) issued by the Ministry of Environment, Forest and Climate Change (MoEF & CC), by providing required information with regards to the project as mentioned in the Terms of Reference issued by the Industrial Committee-2 of MoEF & CC, New Delhi. This Report is prepared based on General Structure of EIA given in Appendix III and IIIA of mentioned EIA Notification. 1.2 INTRODUCTION OF THE PROJECT & PROJECT PROPONENT IDENTIFICATION OF PROPOSED PROJECT M/s. Aarti Industries Ltd. (Apple Organics Division) is manufacturing synthetic organic products at plot no.:609/610 & 100 shed area, Phase-II, GIDC Estate, Vapi , and Dist.: Valsad, Gujarat. Existing production capacity as per CCA No: AWH is 18 or 20 MT/Month. Now, the unit wants to go for proposed expansion in same plot. The products are highly influenced by the market demand and market rates. Unit has proposed same production capacity but will be arranging group wise production of new products. The philosophy of the expansion is to provide unit operation based various products. Unit will manufacture products based on various unit operations. After expansion, total group wise proposed production capacity will be 20 MT/Month and total by products quantity in worst case scenario will be MT/Month. The expansion will be carried out at existing plot located in GIDC, Vapi. The expected cost of proposed expansion will be Rs. 500 Lacs. The total plot area of the unit is 1752 sq. m. The existing green belt area is approx. 183 sq. meters. After expansion, the green belt area will be remaining same DETAILS OF CONSENT M/s. Aarti Industries Ltd. (Apple Organics Division) was established in the year The unit has first obtained CCA order no: 3431, issued on 16/08/2004. The unit has valid CCA vide order No.: AWH-73091, issue on dated 14/09/2015, valid up to 06/07/2020 for manufacturing of synthetic organic products. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 2

18 The copy of All CCA order is attached as Annexure-II. Report on the status of compliance of the conditions stipulated in the CCA order no. AWH is attached as Annexure- III. The lists of the existing products and group wise proposed products and byproducts details are provided in table 1.1-A & 1.1-B. TABLE: 1.1-A LIST OF EXISTING PRODUCTS Sr. No. Name of Product Quantity in MT/Month 1. Para Chloro Aniline OR ,4 Di Chloro Aniline OR ,5 Di Chloro Aniline OR Mix of 3,4 DCA & 2,3 DCA OR Ortho Anisidine OR Para Toludene OR 20 TABLE: 1.1-B LIST OF PROPOSED PRODUCTS Sr. List of Process No. 1. CHLORINATED PROCESS AND/OR Mono Chloro Benzene/ Ortho Di Chloro Benzene/ Para Di Chloro Benzene AND/OR 123,124 Tri Chloro Benzene ( Benzene) AND/OR Para Nitro Toluene (2 chloro 4 Nitro toluene) AND/OR CAS No Mono Dichloro Benzene AND/OR Ortho chloro toluene / Para chloro toluene AND/OR Chloro 2-Nitro Toluene/ Chloro 2-Nitro Toluene AND/OR Pivalyl Chloride AND/OR Ethyl Hexanyl Chloride AND/OR Iso Nonyl Chloride AND/OR ,4,6 Trichloro Aniline (TCAN) Quantity (MT/Month) 5 End use of Product Dyes and intermediates M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 3

19 Sr. No. List of Process CAS No. AND/OR , 6 Dichloro-4-nitroaniline (2,6 DCPNA) AND/OR HYDROGENATION/REDUCTION PROCESS AND/OR 2.1 Ortho Toluene AND/OR Meta Chloro Aniline / Ortho Chloro Aniline/ Para Chloro Aniline AND/OR ,4 Dichloro Aniline ,3 Dichloro Aniline ,5 Dichloro Aniline AND/OR ,4 Diamino Diphenyl Ether / 4, Diamino Diphenyl Ether AND/OR Di Fluoro Benzene (1-3) AND/OR Mixing of 2, 4 / 2, 5 DCA AND/OR Mixing of 2, 5 / 2, 6 DCA AND/OR Mixing of 2, 4 / 2, 5 / 2, 6 DCA AND/OR -- 2,4 Dichloro Aniline / ,6 Dichloro Aniline / ,5 Dichloro Aniline AND/OR ,4,5 Trichloro Aniline AND/OR Meta Phenylene Di Amine / Ortho Phenylene Di Amine / Para Phenylene Di Amine AND/OR ,4 Diamino Diphenyl Ether / ,4 Diamino Diphenyl Ether AND/OR Ether AND/OR Meta / Ortho / Para Anisidine Quantity (MT/Month) 5 End use of Product Dyes and intermediates M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 4

20 Sr. No. List of Process CAS No. AND/OR Chloro Fluoro Aniline AND/OR Ortho/Para/Meta Cumidine AND/OR Para /Meta Amino Phenol AND/OR Toludiene AND/OR Aniline AND/OR Para / Meta / Ortho Floro Aniline AND/OR Di Floro Aniline (1:3) AND/OR Floro-N-Isopropyl Aniline AND/OR Chloro-N-Isopropyl Aniline AND/OR 2 Methoxy 4 Nitro Aniline (Scarlet R - from partial hydrogenation of 24 Dinitro Anisole) AND/OR ,4 Di Amino Anisole AND/OR N-N Disec Butyl PPDA AND/OR Meta Xilidine AND/OR Chloro 2,5 Dimethoxy Aniline AND/OR N-N Disec tertiary butyl para phenylene Diamine AND/OR DCBH (Dichloro benzene Hydro chloride) AND/OR ,5/2,6 DFA (Di Fluoro Aniline) AND/OR Di Anisidine AND/OR OT Base AND/OR Quantity (MT/Month) End use of Product M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 5

21 Sr. No. List of Process 3. NITRATION PROCESS AND/OR /2-3/2-5/2,4 Dichloro N Benzene AND/OR CAS No Di Chloro Di Fluoro Nitro Benzene AND/OR Ortho Nitro Chloro Benzene/ Para Nitro Chloro Benzene/ Meta Nitro Chloro Benzene AND/OR ,4 Di Nitro Chloro Benzene AND/OR ,4,5 Tri Chloro Nitro Benzene/ ,3,4 Tri Chloro Nitro Benzene AND/OR Nitro N-methyl Phthalimide AND/OR EHN (Ethyl Hexanol Nitration) AND/OR NITRO ANISOLE PROCESS AND/OR 4.1 Ortho Nitro Anisole AND/OR Para Nitro Anisole AND/OR ,4-Di Nitro Anisole AND/OR Methoxy 5 Chloro Nitro Benzene (from 25 DCNB) AND/OR 5. FLUORINATION PROCESS AND/OR 5.1 Para Fluoro Nitro Benzene AND/OR Di Fluoro Nitro Benzene AND/OR DE-NITRO CHLORINATION PROCESS AND/OR 6.1 2,6 Di Chloro Fluoro Benzene AND/OR ,6 Di Chloro Benzonitrile AND/OR Di Chloro Di Fluoro Benzene AND/OR 6.4 Meta Dichloro Benzene AND/OR Quantity (MT/Month) End use of Product Dyes and intermediates Dyes and intermediates Dyes and intermediates Dyes and intermediates M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 6

22 Sr. No. List of Process CAS No ,4 Di Fluoro Chloro Benzene AND/OR ,4 Di Chloro Fluoro Benzene AND/OR ,3 Dichloro 4,6 Difluoro Benzene AND/OR Para Fluoro Chloro Benzene AND/OR Ortho Fluoro Chloro Benzene AND/OR AMMONIATION PROCESS AND/OR Di Chloro Ortho Nitro Aniline AND/OR Ortho Nitro Aniline-Para Nitro Aniline AND/OR BROMINATION&DEAMINATION PROCESS AND/OR 8.1 3, 4, 5 Tri Fluoro Bromo Benzene AND/OR Bromo 4 Fluoro Acetanilide AND/OR Di Chloro Bromo Benzene AND/OR SULPHANATION PROCESS AND/OR 9.1 4B Acid ALKYLATION PROCESS AND/OR 10.1 Methyl Ethyl Aniline DEHALOGENATION PROCESS AND/OR ,3 Di Fluoro Benzene CONDENSATION PROCESS AND/OR 12.1 Di Nitro Di Phenyl Ether 13. CYCLIZATION PROCESS AND/OR 13.1 Di Amino Phenyl Benzimidazole AND/OR Quantity (MT/Month) End use of Product Dyes and intermediates Dyes and intermediates Dyes and intermediates Dyes and intermediates Dyes and intermediates Dyes and intermediates Dyes and intermediates M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 7

23 Sr. No. List of Process CAS No Para Fluoro Anisole AND/OR Quinalphose (TECH) (Diethyl 2- Hydroxy Thiophosphoryl Chloride)AND/OR 14. ESTERFICATION AND/OR Ester DIAZOTISATION PROCESS AND/OR &23Di Chloro Phenol AND/OR ,5 Di Chloro Nitro Benzene AND/OR Para Fluoro Phenol (PFP) AND/OR ACETYLATION & HYDROLYSIS PROCESS 16. AND/OR 16.1 Meta Nitro Para Anisidine AND/OR Meta Nitro Para Toludiene AND/OR Total 17. BY PRODUCTS Quantity % Hydrochloric Acid Spent Sulphuric Acid Aluminum Oxide (Al2O3) Sodium Chloride (NaCl) Ortho Nitro Phenol (ONP) Calcium Chloride solution (CaCl2) Potassium Chloride (KCl) Acetic Acid (CH3COOH) Total (MT/Month) MT/Month MT/Month End use of Product Dyes and intermediates Dyes and intermediates Dyes and intermediates Organic Chemicals Manufacturing Note: Proposed product table as per TOR Letter. By products will be consider as hazardous waste generation. Hence, also mention in the hazardous waste generation table. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 8

24 1.2.3 SCREENING CATEGORY As per EIA Notification dated 14 th September, 2006, as amended from time to time; this project falls under Category B, Project or Activity-5 (f) and requires Environmental Clearance from SEIAA, Gujarat. Public hearing is not applicable to this expansion project as the unit is located in GIDC notified area. Environment Clearance will be evaluated by the Industrial committee of SEIAA, Gujarat ABOUT COMPANY AND PROJECT PROPONENT M/s. Aarti Industries Ltd. (Apple Organics Division) is one of company of Aarti Group. Aarti had started its operations in the year 1975 in the name of Alchemie labs in a small of way with a single product namely Dimethyl sulphate. Today Aarti is one of the leading suppliers to global manufacturers of Dyes, Pigments, Agrochemicals, Pharmaceuticals & rubber chemicals. Aarti has acquired world-class expertise in the development & manufacture of these chemicals. Aarti is amongst the largest producers of Benzene based basic and intermediate chemicals in India. It has corporate office in Mumbai & representatives in U.S.A and Europe. Aarti has 16 manufacturing units spread across Gujarat & Maharashtra and a strong Research & Development with sophisticated instruments and pool of scientists. Aarti has customers spread across the globe in 60 countries with major presence in USA, Europe, Japan & India. 80% of our products from this division are exported globally. The proposed expansion will act as scale up facility for Aarti group. This will be a link between R&D and full commercial facility. The Aarti group has developed strong environment management cell and possess in house capabilities to undertake implementation of cleaner production technologies, green chemistry, zero liquid discharge systems, etc. besides carrying out environment impact assessments. The directors of the company have good experience in handling the production management, financial management and all the allied areas. Details regarding Directors are given in Table 1.2. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 9

25 TABLE: 1.2 LIST OF DIRECTORS Sr. Name of No. Director 1. Shri. Rajendra V. Gogri 2. Shri. Rashesh C. Gogri 3. Shri. Parimal H. Desai 4. Shri. Manoj M. Chheda 5. Shri. Kirit R. Mehta 6. Smt. Hetal Gogri Gala 7. Shri. Renil R. Gogri Designation Address Telephone No. Chairman& 1401, Antriksh Managing Director Murar road, Mulund (w), Mumbai Vice chairman & Managing Director Whole-Time Director Whole-Time Director Whole-Time Director Whole - Time Director Whole - Time Director 601,Antriksh Murar Road, Mulund (W) Mumbai A/ TH Floor, Runwal Heights, L.S.B. Marg, Mulund (W) Mumbai Dunhill Villa CO.OP. HSG. SOC. Ltd., Besant Road, Santa Cruz (W), Mumbai , Pushpendra Mension, Phiroj shah Mehta Road, Santa Cruz (W), Mumbai B, Gopal Sadan, Block no. 801, 8 TH Floor, Jamshed Road, Matunga (E), Mumbai , Antriksh. Murar Road Mulund (W) Mumbai KEY INFORMATION OF PROJECT IMPORTANCE AND JUSTIFICATION OF PROJECT A pilot plant is a pre-commercial production system that employs new production technology and/or produces small volumes of new technology-based products, mainly for the purpose of learning about the new technology. The knowledge obtained is then used for design of full-scale production systems and commercial products, as well as for identification of further research objectives and support of investment decisions. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 10

26 The unit does contribute towards improving the performance of the company since the end users of products are industries ranging from agrochemicals and dyes to specialty chemicals and pharmaceuticals - markets that are critical to long-term sustainability. By supplying high quality and good value products to our customers, the unit indirectly helps people to have access to better medicines, fertilizers and diverse items of daily use. In other words, facilitating the supply chain management plays a significant role in the unit s business strategy. The products are highly influenced by the market demands and market rates. Various products listed in Table 1B are used in manufacturing of Intermediates for Dyes industry & Pigments industry, Pharmaceuticals industry and Rubber chemicals industry. The Golden corridor of Gujarat from Dahej to Vapi has presence of lots of industries manufacturing Organic chemicals. Hence, local market is already available. AARTI has privilege of catering to its export customers in countries such as USA, UK, Germany, Spain, Italy, Switzerland, Belgium, Japan, Korea, China, Russia, etc SIZE AND COST OF THE PROJECT The expansion will be carried out at existing plot located in GIDC, Vapi. The expected cost of proposed expansion will be Rs. 500 Lacs. The total plot area of the unit is 1752 sq. m. The existing green belt area is approx. 183 sq. meters. After expansion, the green belt area will be remaining same. The cost break up is provided in Table 1.3. TABLE: 1.3 CAPITAL COST OF PROJECT Sr. No. Purpose Existing (Rs. In Lacs) Proposed (Rs. In Lacs) 1. Land Building Plant and Machinery Env. Protection & Safety Effluent treatment Plant Safety Equipment (PPE, fire extinguishers, Ventilation, etc.) Green belt development Total Total (Rs. In Lacs) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 11

27 1.3.3 SITE SELECTION The project proponent did not consider any other alternative site for proposed expansion. The unit has proposed expansion of existing plot because existing plot area is sufficient for proposed expansion. Letter of existing plot allotment from GIDC of industrial plot no. 609/610, 100 shed area is attached as Annexure IV LOCATION OF THE PROJECT M/s. Aarti Industries Ltd. (Apple Organics Division) is located at Vapi, Gujarat. It is approximately km distance from Dist.: Valsad. The geographical positioning of the project site is at Latitude 20 20'55.194'' N, Longitude 72 56' ''E. Vapi is a very important industrial center having the advantage of close proximity to Mumbai, the commercial capital of India. Due to NH-8 and Vapi railway station, GIDC is well connected by road and rail to rest parts of the country. Communication facility available in the area is good. Water is available from GIDC. The proposed plant layout are attached as Annexure VII. The photograph of existing plant area and proposed plant area are attached as Annexure-VIII. The location of the project site can be identified from the location map shown in Figure 1 and satellite image or Google earth image shown in Figure-2. All four corners of the site Co-ordinates latitude and Longitude are given in Table 1.4 and shown in Figure-3. TABLE 1.4 DETAILS OF CORNERS CO-ORDINATE OF SITE Direction Corners Latitude Longitude SW 1 st - Gate 20 20' 55"N 72 56' 16.26"E NE 2 nd - Gate 20 20' 56.16"N 72 56' 17.45"E SE 3 rd 20 20' 55.15"N 72 56' 17.47"E WN 4 th 20 20' 56.08"N 72 56' 16.12"E M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 12

28 FIGURE: 1.1 LOCATION OF THE PROJECT SITE INDIA MAP N GUJARAT MAP VAPI, DISTRICT-VALSAD MAP M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 13

29 FIGURE 1.2 GOOGLE EARTH OR SATELLITE IMAGE OF PROJECT LOCATION M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 14

30 FIGURE 1.3 GOOGLE EARTH OR SATELLITE IMAGE OF ALL CORNERS OF THE SITE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 15

31 1.4 REGULATORY FRAMEWORK To keep the environment congenial for better standard of living, the provisions have been made in the constitution of India and many Enactments have taken place, so that, Industrialization may not have adverse impact on the environment. There are many Acts/ Rules/Notifications issued by MoEF & CC in this regard, few of the mare mentioned below: Environment(Protection)Act, 1986; Environment(Protection)Rules, 1986; Water(Prevention & Control of Pollution) Act, 1974; Air(Prevention & Control of Pollution) Act, 1981; Environmental Imp act Assessment (EIA) Notification, dated 14th September2006 as amended from time to time. 1.5 SCOPE OF THE STUDY The Disciplines covered under the study are pre-requisite in formation of the proposed site, process technology, effluent generation, treatment and its proper disposal, hazardous waste management, impacts and management plans. This report contains data of ambient air quality monitoring as well as the ecological studies noise environment, socio-economic study carried out during Winter Season (March-2017 to May-2017). Application (Appendix I/Form I/ToR and Pre Feasibility Report) for obtaining Environmental Clearance for this proposed project was submitted online proposal no.ia/gj/ind2/61144/2016; Dated: 21 st December, TOR issued on 07 th July, 2017 from MoEF & CC (IA Division), New Delhi. 1.6 OBJECTIVES OF THE EIA STUDY This EIA Report is prepared to comply with the requirements of the SEAC as per the guideline for the Clearance. The objectives of this EIA are: To describe the Project and associated works together with the requirements for carrying out the Project. To identify and describe the elements of the community and environment likely to be affected by the Project, and / or likely to cause impacts upon the Project, including both the natural and man-made environment. To identify and quantify emission sources and determine the severity of impacts on sensitive receivers and potential affected uses. To recognize and quantify any environmental impacts associated with the Project and recommend appropriate mitigation measures. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 16

32 To study existing landscape and visual quality in the study area so as to evaluate the landscape and visual impacts of the project. To propose mitigation measures to minimise pollution, environmental disturbance and nuisance during construction and operation of the project; To identify, predict and evaluate the residual (that is, after practicable mitigation) environmental impacts and cumulative effects expected to arise during the construction and operation phases of the project in relation to the sensitive receivers and potential affected uses. To identify, assess and specify methods, measures and standards, to be included in the detailed design, construction and operation of the project which are necessary to mitigate these impacts and reduce them to allowable levels within established standards / guidelines. To investigate the extent of side-effects of proposed mitigation measures that may lead to other forms of impacts. To identify constraints associated with the mitigation measures recommended in this EIA. To identify any additional studies necessary to fulfil the objectives to the requirements of this EIA Study. 1.7 STRUCTURE OF EIA REPORT The generic structure of the EIA report, as per the guideline provided by MoEF&CC is illustrated in the following tabulated format. TABLE: 1.5 STRUCTURE OF EIA REPORT Sr. EIA Structure Contents No. 1. Introduction Purpose of the report and regulatory frame work Identification of the project and project proponent Key Information of project Regulatory Frame work Scope & Objective of EIA study Structure of EIA report Terms of reference & Its Compliance 2. Project Description Condensed description of those aspects of the project (based on project feasibility study), likely to cause environmental effects. Description contains M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 17

33 Sr. No. EIA Structure Contents the details of the following: Type of project Need for the project Location details showing general location, specific location, project boundary & project site layout) Technology and process description Project description. Including drawings showing project layout, components of project etc. Schematic representations of the feasibility drawings which give information important for EIA purpose Description of mitigation measures incorporated into the project to meet environmental standards, 3. Description of the Environment Study area, period, components & methodology Establishment of baseline for valued environmental components, as identified in the scope Base maps of all environmental components 4. Anticipated Environmental Impacts & Mitigation Measures Details of Investigated Environmental impacts due to project location, possible accidents, project design, project construction, regular operations, final decommissioning or rehabilitation of a completed project Measures for minimizing and / or offsetting adverse impacts identified Irreversible and Irretrievable commitments of environmental components Assessment of significance of impacts (Criteria for determining significance, Assigning significance) Mitigation measures M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 18

34 Sr. EIA Structure No. 5. Analysis of alternatives (technology & site) Contents Need for alternatives with respect to technology and site selection, give details of each alternative, summary of adverse impact of each alternative and propose mitigation measures for each alternative. 6. Environmental Monitoring Program Technical aspects of environmental monitoring for the effectiveness of mitigation measures (incl. Measurement methodologies, frequency, location, data analysis, reporting schedules, emergency procedures, budget & procurement schedules) 7. Additional Study: Risk Assessment & Disaster Management Plan Hazard Identification Risk Assessment & control/prevention Measures Disaster Management 8. Project Benefits Detail of the Socioeconomic & other tangible benefits of the project 9. Environmental Cost Benefit Analysis Environmental cost benefit analysis to be carried out if required. 10. Environment Management Plan Description of the administrative aspects of ensuring that mitigation measures are implemented and their effectiveness monitored, after approval of the EIA. The Chapter consist of: Mitigation measures for impacts Pollution Prevention Plan Greenbelt Development Plan Mangrove Management Plan Dredging management Plan Waste management plan Environment Management Cell Budgetary Provisions for EMS 11. Summary & Conclusion Description of brief of EIA report 12. Disclosure of Consultant Engaged Detail of the EIA Consultant M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 19

35 1.8 REGULATORY PROVISIONS AND REQUIREMENT The proposed project is for the manufacturing of Synthetic Organic Chemicals and is covered under EIA Notification of MoEF & CC, New Delhi. It is obligatory for the proponent to obtain prior EC from State Environment Impact Assessment Authority (SEIAA), Gujarat and Consent to Establish (CTE/NOC) and Consent to Operate (CTO/CCA) from GPCB for the proposed project, under the various Environmental laws GENERAL LEGAL REQUIREMENTS The general legal statutory requirements applicable to the proposed project are tabulated in below table. TABLE: 1.6 APPLICABLE REGULATORY PROVISION FOR PROPOSED PROJECT Sr. Legal Instrument Concern Authority or Bodies No. 1. Air (Prevention and Control of Pollution) CPCB and SPCB/UTPCC. Act, 1981 amended Air (Prevention and Control of Pollution) CPCB and SPCB/UTPCC. (Union Territories) Rules, Water (Prevention and Control of CPCB and SPCB/UTPCC. Pollution) Act, 1974 amended Water (Prevention and Control of CPCB and SPCB/UTPCC. Pollution) Rules, The Environment (Protection) Act, 1986, Ministry of Environment, Forests & Climate amended Change, CPCB and SPCB/UTPCC. 6. Environmental (Protection) Rules, 1986 Ministry of Environment, Forests & Climate (Amendments in 1999, 2001, 2002, 2002, Change, CPCB and SPCB/UTPCC. 2002, 2003, 2004) 7. Hazardous & Other Wastes (Management MoEF&CC, CPCB, SPCB/UTPCC, DGFT, and Transboundry Movement) Rules 2016 Port Authority and Customs Authority. 8. Manufacture Storage and Import of Ministry of Environment & Forests, Chief Hazardous Chemicals Rules, 1989 Controller of Imports and Exports, CPCB, amended SPCB/UTPCC, Chief Inspector of Factories, Chief Inspector of Dock Safety, Chief Inspector of Mines, AERB, Chief Controller of Explosives, District Collector or District Emergency Authority, CEES under DRDO. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 20

36 Sr. No. Legal Instrument Concern Authority or Bodies 9. Chemical Accidents (Emergency Planning, CCG, SCG, DCG, LCG and MAH Units. Preparedness and Response) Rules, Ozone Depleting Substances (Regulation and Control) Rules, Ministry of Environment, Forests & Climate Change. 11. EIA Notification, 2006 as amended timely MoEF&CC, SPCB/UTPCC. (2009, 2011) 12. Batteries (Management and Handling) SPCB/UTPCC, CPCB and MoEF. Rules, Public Liability Insurance Act, 1991 amended Ministry of Environment, Forests & Climate Change, District Collector. 14. Public Liability Insurance Rules, 1991 amended Ministry of Environment, Forests & Climate Change, District Collector. 15. Factories Act, Ministry of Labour, DGFASLI and Directorate of Industrial Safety and Health/Factories Inspectorate. 16. The Explosives Act, Ministry of Commerce and Industry (Department of Explosives). 17. The Explosive Rules, Ministry of Commerce and Industry and Chief Controller of Explosives, port conservator, customs collector, railway administration. 18. The Gas Cylinder Rules, 2004 * Ministry of Commerce and Industry and Chief Controller of Explosives, port conservator, customs collector, DGCA, DC, DM, Police (sub inspector to commissioner) 19. The Static and Mobile Pressure Vessels (Unfired) Rules, 1981 Ministry of Commerce and Industry and Chief Controller of Explosives, port conservator, customs collector, DGCA, DC, DM, Police (sub inspector to commissioner) 20. The Motor Vehicle Act, 1988 Ministry of Shipping, Road Transport and Highways. 21. The Central Motor Vehicle Rules, 1989 Ministry of Shipping, Road Transport and Highways. 22. The Custom Act, 1962 CBEC, Ministry of Finance. (Note: * the rules are not directly applicable to the proposed project but during operation it may be applicable timely depending up on allied operations like welding, fabrication & shipping of raw materials & products.) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 21

37 1.9 TERMS OF REFERENCE AND ITS COMPLIANCE COMPLIANCE OF TOR APPROVED BY MoEF & CC, NEW DELHI. As per TOR letter issued by the MoEF& CC, New Delhi as received vide ref no. J /384/2016-IA.II (I) dated: - 07 th July, 2017 has been sent duly addressed Point wise summary of compliance is given below Table. TABLE: 1.7 TOR GIVEN BY IMPACT ASSESSMENT DIVISION OF MoEF & CC, NEW DELHI. Sr. TOR Points Compliance No. (Reference in EIA report) A. Additional TOR i. Public hearing is exempted under the Noted by the unit. provisions as per para 7 (i) Stage III (3) Unit is located in GIDC area Vapi. So, (i) (b) of the EIA notification, Public hearing is exempted STANDARD TERMS OF REFERENCE (TOR) AS PER ANNEXURE-I FROM SEIAA, GUJARAT. Unit has considered also Standard Terms of Reference (TOR) as per Annexure-I by SEIAA, Gujarat and its point wise summary of compliance is given below table. TABLE: 1.8 STANDARD TOR AS PER ANNEXURE-I Sr. Terms of Reference No. 1. A tabular chart with index for point-wise compliance of below mentioned TORs. 2. Executive summary of the project giving a prima facie idea of the objectives of the proposal, use of Resources, justification, etc. In addition, it should provide a compilation of EIA report, including EMP and the Post-project monitoring plan in brief. 3. Justification for selecting the proposed product and unit size. Compliance (Reference in EIA report) Instruction followed. Details for point wise compliance of all of TOR is covered under Chapter-1 in section no. 1.9 from page no 22 to 35. Details are covered under Chapter-11 from page no. 285 to 297. Justification for selecting the proposed product and unit size are covered under Chapter-1 in section no on page no Land requirement for the project including Details about land requirement are M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 22

38 Sr. Terms of Reference No. its break up for various purposes, its availability and Optimization. 5. Land possession documents. Copy of NA order showing permission to use the project land for industrial purpose. If located in GIDC, copy of plot holding certificate obtained from GIDC Authority. 6. Location of the project site and nearest habitats with distances from the project site to be demarcated on a toposheet (1:50000 scale). Compliance (Reference in EIA report) covered under Chapter-2 in section on page no Copy of Land possession documents obtained from Vapi GIDC Authority is attached as an Annexure-IV. Toposheet is attached as an Annexure- V. Layout of industrial area / Estate map is attached as Annexure VI. 7. Topography details of the project area. Details are covered under Chapter-3 in 8. Geological features and geo-hydrological status of the study area. 9. In case of project located outside notified area: Legal Undertaking stating that unit is complying the three conditions [i.e. water consumption less than 25 M3/day; Fuel consumption less than 25 TPD; and not covered in the category of MAH units as per the Management, Storage, Import of Hazardous Chemical Rules (MSIHC Rules), 1989] as per the amendment to EIA Notification, 2006 vide SO 1599 (E) dated 25/06/ Present land use pattern of the study area shall be given based on satellite imagery. 11. Layout plan of the factory premises clearly demarcating various units within the plant. Provision of separate entry & exit and adequate margin all-round the periphery for unobstructed easy movement of the emergency vehicle / fire tenders without reversing back. Mark the same in the plant layout. 12. Technical details of the plant/s along with details on best available technologies (BAT), proposed technology and reasons for selecting the same. 13. Product spectrum (Proposed products along with production Capacity) and processes. section 3.1 from page no.132 to 134. Details are covered under Chapter-3 in section 3.1 from page no.132 to 134. Not Applicable. Project located in GIDC Notified area, Vapi, Dist: Valsad. Details are covered under Chapter-3 in section no. 3.7 from page no. 152 to 154. Details are covered under Chapter-2 in section no on page no Plant Layout marking the same is attached as an Annexure-VII. Unit is pilot plant for the R & D products. So, unit will be use best technology in proposed plant. Details are covered under Chapter-2 in section no on page no.62. Details are covered under Chapter-1 in table no. 1.1A&B on page no. 2 to 7. Manufacturing process is given M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 23

39 Sr. No. Terms of Reference 14. Chemical name of each proposed product to be manufactured. Details on end use of each product. (Provide CAS number of all the products & raw materials. In case of Dyes, CI number). 15. Details on raw materials, source and storage within the premises. 16. Details of complete manufacturing process / operations of each product along with chemical reactions, process flow diagram describing each unit processes and unit operations along with material balance, consumption of raw materials etc. 17. Details on strategy for the implementation of cleaner production activities. 18. Assessment of source of the water supply with adequacy of the same to meet with the requirements for the project. Permission obtained from the concern authority for supply of raw water. 19. Undertaking stating that no bore well shall be dug within the premises (If project is located within the Industrial estate). 20. Details on water balance including quantity of effluent generated, recycled & reused. Details of methods to be adopted for the water conservation. 21. Efforts to minimize effluent discharge and to maintain quality of receiving water body. Compliance (Reference in EIA report) under Chapter-2 in section no from page no 62 to 98. Details of chemical name, CAS number and end use of each product are covered under Chapter-1 in table no. 1.1-B on page no. 3 to 8. Details of CAS number of each raw material are covered under Chapter- 2 in table no. 2.1 from page no. 37 to 40. Details are covered under Chapter-2 in section & on page no. 46 to 61. Manufacturing process along with material balance is given under Chapter-2 in section no from page no 62 to 98. Implementation of cleaner production activities is followed by unit. Details are covered under Chapter- 10 in section on page no 277. Vapi GIDC water supply letter is attached as an Annexure-IX. Undertaking stating no bore well to be dug is attached as an Annexure- XXII. Water balance is given in Chapter-2 in section from page no. 106 to 107. Methods to be adopted for water conservation is given in Chapter-10 in section from page no. 278 to 279. Details are covered under Chapter- 10 in section on page no Explore the possibilities for Zero Liquid Details are covered under Chapter- M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 24

40 Sr. No. Terms of Reference Discharge (ZLD) or Efforts to minimize effluent discharge and to maintain quality of receiving water body. 23. Segregation of waste streams, characterization and quality with specific treatment and disposal of each stream including action plan for maximum recycle of treated waste water and minimum discharge for effluent. 24. Capacity of ETP in KL/day. Details of ETP including dimensions of each unit along with schematic flow diagram. Inlet, transitional and treated effluent qualities with specific efficiency of each treatment unit in reduction in respect of all concerned/regulated environmental parameters. Inlet effluent quality should be based on worst case scenario considering production of most polluting products that can be manufactured in the plant concurrently. 25. In case of discharge into GIDC drainage / Pipeline: 1.Copy of permission letter with quantity (KL/day) from the concern authority of drainage network /pipeline with confirmation for spare capacity available to take additional effluent. 2.Characteristics of the combined effluent and treated water to be sent to Common pipeline with reference to the MoEF&CC/CPCB/GPCB discharge norms. 26. In case of waste water sent to Common Facilities (CF) like CETP, MEE, Spray Dryer etc. (a)details of Common facilities including (1) Total capacity of the CF (2) Copy of CC&A of the CF. (3) Actual load at present (Qualitative and Quantitative KL per day) (4) Booked quantity & Spare capacity of CF (5) Copies of XGN generated Inspection reports with analysis reports of the water/air/hazardous samples collected by GPCB (Last 2 year). Copies of instructions issued by GPCB in last 2 year and point wise compliance thereof. (6) Compliance (Reference in EIA report) 10 in section on page no 271. Segregation details are covered in chapter 2 under section 2.8 from page no 108 to 111. Capacity of ETP will be 20 KLD. Details are covered in chapter-2 under section 2.8 from page no 108 to 111. Details are covered under: 1. Treated effluent discharge permission letter from VGEL, Vapi is attached as annexure- X. 2. Details are covered in chapter 2 under section 2.8 from page no 108 to 111. We had asked CETP-Vapi Green Enviro Limited, Vapi to all the details required in ToR. CETP-Vapi Green Enviro Limited, Vapi suggested the unit to directly ask for CETP performance from GPCB, Gandhinagar as they are monitoring agency. Letter from VGEL, Vapi is attached as annexure XVI. The unit have submitted letter to GPCB, Gandhinagar regarding performance of CETP-Vapi Green M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 25

41 Sr. No. Terms of Reference Copies of Show- cause notices, closure notices etc. served by the GPCB and its compliance (7) Recommendations and suggestions of the last two Environment Audit reports of CETP and its compliance report. (8) Common Facility Up gradation scheme, if any. (b)status of compliance to the 18(1) (b) direction issued by the CPCB with respect to CETP compliance & CEPI area action plan along with relevant supportive document. (c)give status of compliance of Environmental norms of existing Common Infrastructure i.e. CETP, MEE & Spray Dryer (Whichever is applicable) in which you are a member. (d)submit adequacy of Common Infrastructure i.e. CETP, MEE & Spray Dryer for additional load (Whichever is applicable) along with written confirmation/membership certificate mentioning the same (Total consented quantity, total quantity booked so far, quantity booked for the unit, spare quantity available). Compliance (Reference in EIA report) Enviro Limited, Vapi. Copy of letter is attached as annexure XVII. 27. In case of Zero Liquid Discharge (ZLD) : 1. Action plan for Zero discharge of effluent shall be included. Notarized undertaking for assuring that underground drainage connection will not be taken in the unit. 2. Economical and technical viability of the effluent treatment system to achieve Zero Liquid Discharge (ZLD). 3. Certification of adequacy of proposed ZLD scheme through credible institutes of National repute. 4. To estimate & monitor ground water quality & its contamination status, piezometer wells, one on up gradient of the groundwater flow and other three on the down gradient side of the ground water flow of the proposed project at different depth based on available ground water depth shall be established and all the parameters mentioned in IS Not applicable. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 26

42 Sr. Terms of Reference No. 10:500 for potable water standard shall be monitored. 28. In case of in-house MEE for waste water treatment: Capacity of MEE in KL/hr. Technical details of MEE including evaporation capacity, steam required for evaporation, adequacy of the proposed boiler to supply steam for evaporation in addition to the steam required for the process etc. Techno-economical viability of the evaporation system. Control measures proposed for the evaporation system in order to avoid/reduce gaseous emission/voc from evaporation of industrial effluent containing solvents & other chemicals. 29. Technical details of ATFD/ Crystallizer/ Dryer, RO/NF system etc. (If any). 30. Undertaking stating that a separate electric meter will be provided for the waste water treatment system viz.etp, RO, MEE, Spray dryer etc. (Whichever is applicable) 31. Economical and technical viability of the effluent treatment system. 32. Plans for management, collection and disposal of waste streams to be generated from spillage, leakages, vessel washing, used container washing etc. Measures proposed for preventing effluent discharge during unforeseen circumstances. 33. Action plan for reuse of waste streams like Spent acids, Poly Aluminium Chloride etc. within premises to convert into valuable products instead of sending outside to actual end-users. 34. Adequacy of the proposed EMS with respect to the pollution load envisaged in terms of Air, Water and hazardous waste. 35. One season Site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be incorporated. 36. Anticipated environmental impacts due to the proposed project/production may be evaluated for significance and based on corresponding likely impacts VECs (Valued Compliance (Reference in EIA report) Not applicable. Not applicable. Undertaking is attached as an Annexure- XXII. Details are covered in chapter-2 under section 2.11 on page no.126. Details are covered in chapter 2 under section from page no 121 to 122. Unit will generated by products and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-A to G. Details are covered in Chapter-2 in section no from page no. 128 to 129. Details are covered in Chapter-3 in section no. 3.2 from page no. 134 to 136. Anticipated environment impacts due to the proposed projects are covered in chapter 4 under section M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 27

43 Sr. No. Terms of Reference Environmental Components) may be identified. Baseline studies may be conducted within the study area for all the concerned/identified VECs and likely impacts will have to be assessed for their magnitude in order to identify mitigation measures. 37. One complete season base line ambient air quality data (except monsoon season) to be given along with the dates of monitoring. The parameters to be covered shall be in accordance with the revised National Ambient Air Quality Standards (NAAQS) as well as project specific parameters like NH3, HCl, CL2, HBr, VOC etc. Locations of the monitoring stations should be so decided so as to take into consideration the pre-dominant downwind direction, population zone and sensitive receptors. There should be at least one monitoring station in the upwind direction. There should be at least one monitoring station in the predominant downwind direction at a location where maximum ground level concentration is likely to occur. 38. Modeling indicating the likely impact on ambient air quality due to proposed activities. The details of model used and input parameters used for modeling should be provided. The air quality contours may be shown on location map clearly indicating the location of sensitive receptors, if any, and the habitation. The wind rose showing pre-dominant wind direction should also be indicated on the map. Impact due to vehicular movement shall also be included into the prediction using suitable model. Results of Air dispersion modeling should be superimposed on satellite Image / geographical area map. 39. Base line status of the noise environment, impact of noise on present environment due to the project and proposed measures for noise reduction including engineering controls. 40. Specific details of 1. Process gas emission from each unit Compliance (Reference in EIA report) 4.2 from page no 186 to 208. Baseline studies are covered in chapter 3 under section 3.3 from page no 136 to 141. Details are covered in Chapter-3 in section 3.3 from page no 136 to 141. Dates of monitoring are attached as annexure- XIV. Details are covered in chapter 4 under section 4.2 from page no 186 to 208. Details are covered in Chapter-3 in section no. 3.5 from page no 149 to 150. Details of following points are under: 1. Details are covered in chapter-2 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 28

44 Sr. No. Terms of Reference process with its quantification. 2. Air pollution Control Measures (APCM) proposed for process gas emission. Adequacy of the air pollution control measures (APCM) for process gas emission measures to achieve the GPCB norms. 3. Details of the utilities required. 4. Type and quantity (MT/hr& MT/Day) of fuel to be used for each utility. 5. Flue gas emission rate emission from each utility. 6. Air Pollution Control Measures (APCM) proposed to each of the utility along with its adequacy. 7. List the project specific sources of fugitive emission along with its quantification and proposed measures to control it. 8. Details on tail gas treatment.(if any) 41. Provision of CEMS (Continuous Emission Monitoring system). 42. Action plan for odour control to be submitted. 43. Management plan for solid/hazardous waste including storage, handling, utilization and safe disposal as per the Hazardous and Other Wastes (Management and Transboundry Movement) Rules CPCB guidelines in respect of specific treatment, such as solar evaporation, incineration, etc., need to be followed. 44. How the manual handling of the hazardous wastes will be minimized. Methodology of decontamination and disposal of discarded containers and its record keeping. 45. Management of by-products which fall under the purview of the Hazardous and Other Wastes(Management and Transboundry Movement) Rules 2016 as per the said rules and necessary permissions from the concern authority. Compliance (Reference in EIA report) under section no from page no 112 to Details are covered in chapter-2 under section no from page no 116 to Details are covered in chapter-2 under section no from page no. 104 to Details are covered in chapter-2 under section no on page no Details are covered in chapter-2 under section on page no Details are covered in chapter-2 under section on page no Details are covered in chapter-2 under section from page no. 113 to No Such treatment necessary. Unit will be Provision of online meter for Chlorine, HCl, Br 2, HBr & NOx. Details are covered in chapter-10 under section no from page no. 282 to 283. Details are covered in chapter-2 under section no from page no. 119 to 123. TSDF membership certificates are attached as Annexure-XIII. Details are covered in chapter-2 under section no from page no. 121 to 123. Details are covered in chapter-2 under section no. 2.5 from page no. 99 to 100. MOU with end users are attached as Annexure XI-A to G. 46. Membership of Common Environmental Membership certificates are attached as M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 29

45 Sr. Terms of Reference No. Infrastructure like TSDF, Common Incineration Facility (CHWIF)etc. 47. Name and quantity of each type of solvents to be used for proposed production. Details of in-house solvent recovery system including mass balance, solvent loss, recovery efficiency (% recovery), feasibility of reusing the recovered solvents etc. for each type of solvent. 48. Appropriate monitoring network has to be designed and proposed, to assess the possible residual impact son VECs. 49. A detailed EMP including the protection and mitigation measures for impact on human health and environment as well as detailed monitoring plan and environmental management cell proposed for implementation and monitoring of EMP. The EMP should also include the concept of waste-minimization, recycle/reuse/recover techniques, energy conservation, and natural resource conservation. Total capital cost and recurring cost/annum earmarked for environment pollution control measures. 50. Details of in-house monitoring capabilities and the recognized agencies if proposed for conducting monitoring. 51. Permission from PESO, Nagpur for storage of solvents, other toxic chemicals, if any. 52. Occupational health impacts on the workers and mitigation measures proposed to avoid the human health hazards along with the personal protective equipment to be provided. Provision of industrial hygienist and monitoring of the occupational injury to workers as well as impact on the workers. Plan for periodic medical checkup of the workers exposed. Details of work place ambient air quality monitoring plan as per Gujarat Factories Rules. 53. Details on volatile organic compounds (VOCs) from the plant operations and occupational safety and health protection Compliance (Reference in EIA report) an Annexure- XIII. Name: MCB, MeOH, N, N- DIMETHYLFORMAMIDE, ACITO NITRILE, MIBK, and THF. % Recovery: 95 to 99% Details are covered in chapter-2 under section no. 2.6 on page no. 100 to 102. Details are covered in chapter-6 under table no. 6.2 from page no. 212 to 214. A detailed EMP including all aspect is covered in chapter-10 under section 10.4 & 10.5 from page no. 263 to 281. Total Capital Cost: 99 Lakhs Recurring Cost: 37 Lakhs/Annum Total capital cost and recurring cost are covered in chapter- 2 under section 2.10 from page no 124 to 126. Every three month by external approved monitoring agency. Not Applicable. All solvents and other toxic chemicals storage will be within the limit. Details are covered in chapter-7 under section no. 7.6 from page no. 255 to 258. Work zone monitoring arrangements for hazardous chemicals are coved in chapter 7 under section from page no. 254 to 255. Work place ambient air quality monitoring is attached as annexure- XVIII. Details of VOCs from the plant operations are covered under topic no of chapter-7 from page M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 30

46 Sr. No. Terms of Reference measures. Proposal for Leak Detection and Repair (LDAR) program as per the CPCB guidelines. 54. Risk assessment including prediction of the worst-case scenario and maximum credible accident scenarios should be carried out. The worst-case scenario should take into account the maximum inventory of Storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly showing which of the facilities would be affected in case of an accident taking place. Based on the same, proposed safeguard measures including On- Site / Off-Site Emergency Plan should be provided. Compliance (Reference in EIA report) no. 240 to 241. Details are covered in chapter-7 under section no. 7.2 & 7.3 from page no. 218 to 301. On-Site / Off-Site Emergency Plan is covered under chapter-7 under section no. 7.5 from page no. 240 to MSDS of all the products and raw materials. Material Safety Data Sheet is provided in soft copy. 56. Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health Details are covered in chapter-2 under table no.2.5 from page no. 49 to 59. Details of Antidotes are covered in impacts. This shall include the details of chapter-7 under section no Antidotes also. from page no. 239 to Details of quantity of each hazardous chemical (including solvents) to be stored, Material of Construction (MoC) of major hazardous chemical storage tanks, dyke details, threshold storage quantity as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardous chemicals, size of the biggest storage tank to be provided for each raw material & product etc. How the manual handling of the hazardous chemicals will be minimized? 58. Details of the separate isolated storage area for flammable chemicals. Details of flame proof electrical fittings, DCP extinguishers and other safety measures proposed. Detailed fire control plan for flammable substances and processes showing hydrant pipeline network, provision of DG Sets, fire pumps, jockey pump, toxic gas detectors etc. Details of quantity of each hazardous chemical to be stored are covered in chapter-7 under table no. 7.1 on page no Details of minimized the manual handling are covered in chapter-7 under section from page no. 255 to 256. Details of the separate isolated storage area are covered in chapter- 7 under section , 2 & 3 from page no. 224 to 228. Detailed fire control plan are covered in chapter-7 under section from page no. 234 to Submit checklist in the form of Do s & Details are covered in chapter-7 under M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 31

47 Sr. No. Terms of Reference Don ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures. 60 Specify safety precautions to be taken for Chemical storage, process, and handling& transportation hazard. Compliance (Reference in EIA report) section no from page no. 238 to 239. Details are covered in chapter-7 under section no on table no: 7.8 from page no. 232 to Details on workers training before engaging work, periodical, in-house, outside etc. Details are covered in chapter-7 under section from page no. 255 to Details on various SOP to be prepared. Details are covered in chapter-7 under section no on table no: 7.8 from page no. 232 to Details on safety audit to be carried out and their compliance status. Not Applicable. Unit will be carried out Third Party Safety Audit as per IS: after proposed expansion. 64 Specific safety measures to be taken for general Public living in the vicinity. Details are covered in chapter-7 under section no from page no Details on hazard identification i.e. Details are covered in chapter-7 under HAZOP, HAZAN, Fault tree analysis, Event tree analysis, Checklist, Audit etc. to section no. 7.3 & 7.4 from page no. 222 to 240. be adopted for the safety operation of the plant. 66. Detection and monitoring of VOC s / gases. Details are covered in chapter-6 under table no. 6.2 from page no. 212 to Detailed five year greenbelt development program including annual budget, planning schedule, species, width of plantations, number of trees to be planted, area under Details are given in chapter 10 under section from page no. 274 to 277. green belt development [with map],budgetary outlay etc. along with commitment of the management to carry out the tree plantation activities outside the premises at appropriate places in the nearby areas and elsewhere. 68. Action plan for the greenbelt development species, width of plantations, planning schedule, etc., in accordance to CPCB published guidelines. 69. Detailed socio-economic development measures including community welfare program most useful in the project area for the overall improvement of the environment. Submit a detailed plan for social corporate responsibilities, with appropriate budgetary provisions for the next five years and activities proposed to be carried out; specific to the current Details of action plan for greenbelt development are given in chapter 10 under section from page no. 274 to 277. Detailed CER plan is covered in Chapter-8 from page no. 259 to 260. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 32

48 Sr. Terms of Reference No. demographic status of the area. 70. (a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. (b). Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA. 71. What is the hierarchical system or administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. 72. Does the company have a system of reporting of non-compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA Report. 73 Phase wise project implementation schedule with bar chart and time frame, in terms of site development, infrastructure provision, EMS implementation etc. 74 Certificate of accreditation issued by the NABET, QCI to the environmental consultant should be incorporated in the EIA Report. 75 An undertaking by the Project Proponent on the ownership of the EIA report as per the MoEF&CC OM dated 05/10/2011 and an undertaking by the Consultant regarding the prescribed TORs have been complied with and the data submitted is factually correct as per the MoEF&CC OM dated 04/08/ All documents to be properly referenced with index and continuous page numbering. 77 Where data are presented in the Report especially in Tables, the period in which the data were collected and the sources should be indicated. 78 Project Proponent shall enclose all the analysis/testing reports of water, air, soil, noise etc. using the MoEF & CC/NABL Compliance (Reference in EIA report) Environment Policy approved by its Board of Directors is attached as an Annexure-XV. Details are covered under Chapter-6 in section no. 6.6 from page no. 214 to 216. Details are covered under Chapter-6 in section no. 6.6 from page no. 214 to 216. Details are covered under Chapter-2 in section no. 2.9 from page no. 123 to 124. The consultant has got the stay order from Hon ble Gujarat High Court and copy is attached as an annexure - XXIV. Undertaking of project proponent is attached as an Annexure- XXII. Undertaking of Consultant is attached as an Annexure- XXIII. Noted by the unit and Complied. Noted by the unit and Complied. Noted by the unit. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 33

49 Sr. Terms of Reference No. accredited laboratories. All the original analysis/testing reports should be available during appraisal of the Project. 79 In case of Expansion of the project a. Need for the proposed expansion should be justified in detail. b. Adequacy of existing EMS. c. Explore the possibility to achieve Zero Liquid Discharge (ZLD) for existing as well as proposed activity. d. Records of any legal breach of Environmental laws i.e. details of showcause notices, closure notices etc. served by the GPCB to the existing unit in last five years and actions taken then after for prevention of pollution. e. Copies of Environmental Clearances obtained for the existing plant, its point wise compliance report. f. Environmental audit reports for last 3 years and compliance of its recommendations/suggestions. (Include latest audit report and its compliance.) g. Copy of Consent to Operate (CC&A) obtained along with point wise compliance status of all the conditions stipulated therein. h. Compliance of MoEF&CC circulars vide No: J-11011/618/2010-IAII (I) dated 30/05/2012 and J-11013/41/2006-IA-II(I) dated 20/10/2009. Compliance (Reference in EIA report) a) Detail of the justification of proposed expansion is covered in chapter 1 under section from page no 10 and 11. b) Details are covered in chapter 2 under section 2.14 on page no.128 to 129. c) Details are covered in chapter 2 under section & 2.8 from page no.106 to 111. d) Details of are covered in chapter 10 under section 10.7 on page no.282 to 283. Copy of instructions reply are attached as annexure XXI. e) Not applicable. Unit is applying for 1st time for EC. f) Environmental audit is not applicable. Existing unit is pilot plant. g) Copy of valid CC&A obtained along with point wise compliance status is attached as annexure-ii & III. h) Unit has applied for first time EC. So, this point is not applicable. i) Copies of XGN generated Inspection reports is attached as annexure-xxi. Analysis reports are attached as annexure XII-A. i. Copies of XGN generated Inspection reports with analysis reports of the water/air/hazardous samples collected by GPCB (Last 2 year). Copies of instructions issued by GPCB in last 2 year and point wise compliance thereof. 80. In case of project is located in Ankleshwar- Ankleshwar, Vatva-Narol & Vapi GIDC. (A) Compliance of MOEFCC s OM no. J /5/2010-IA.II (I) dated 25/11/2016 regarding lifting of moratorium on the consideration of projects for environmental A) The unit will be located at GIDC, Vapi. The Moratorium Period was lifted on due to CEPI figure reduced less than 70. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 34

50 Sr. No. Terms of Reference clearance. (B) Compliance of direction under section 18 (1) (b) of the Water (Prevention and Control of Pollution) act, 1974 issued by CPCB dated 31/03/2016 regarding compliance of CETP. a) Action initiated by GPCB, if any, against proposed unit regarding non-compliance of prescribed standards under the various environmental laws. b) Performance of CETP with respect to current hydraulic load & prescribed standards with No Objection Certificate of CETP regarding incorporation of the proposed unit for acceptance of waste water. c) Performance of TSDF site with respect to current load & prescribed standards with No Objection Certificate of TSDF site regarding incorporation of the proposed unit for acceptance of hazardous waste to the common infrastructure. d) Copies of quarterly action report taken for the above points submitted to the CPCB. e) Report of GPCB which have conducted monitoring as per the said direction by CPCB dated 31/03/2016. Compliance (Reference in EIA report) The unit is compliance with CETP outlet norms. So, there will be no effect CEPI due to water environment. Unit has proposed to use adequate APCM for process gas & VOC. Thus, Air Environment will also not deteriorate due to this unit. In view of above it can be said that CEPI figure will remain unaltered due to proposed project. B) Unit will be maintaining CETP discharge norms. So, This direction is not applicable. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 35

51 PROJECT DESCRIPTION CHAPTER TYPE OF PROJECT M/s. Aarti Industries Ltd.(Apple Organics Division) located at plot no. 609/610, 100 shed area, GIDC Estate, Vapi, Dist.:-Valsad, Gujarat is manufacturing organic products. The proponent has proposed expansion of existing organic manufacturing activity. The expansion project falls under category 5(f) of the schedule, as per the EIA Notification, September The unit has valid CCA order No.: AWH-73091, issued on dated: 14/09/2015 for manufacturing of organic products like Para Chloro Aniline, 3,4 Di Chloro Aniline, 2,5 Di Chloro Aniline, Mix of 3,4 DCA & 2,3 DCA, Ortho Anisidine and Para Toluidine. The existing production capacity is 20 or 18 MT/Month. Now, the unit has proposed production capacity will be same, 20 MT/month. The unit will be arranging unit operation wise production of new products like chlorinated products, hydrogenation/reduction products, nitration products, ammoniation products, bromination & deamination products, etc. The production capacity of all products and by-products are given in Chapter 1, Table 1.2. The list of raw materials required for each product is provided in Table NEED FOR THE PROJECT In order to adopt newer technology. The products or to be validated in pilot plant facility ones the products gets slandered in the pilot plant the same or taken to scale up for full commercial capacity. Any investment decision is done based on techno economic viability of the project. The project has to be technically feasible and financially viable in nature. The existing units are in export market for several years. They have range of products from various units and catering to the need of industries. The demand for organic products used to be regular feature from several countries as well as from India. The quality of their product is the edge in the international market. To fulfill this requirement, the unit wants to go for expansion. 2.3 PRODUCTS AND RAW MATERIAL DETAILS The list of raw materials with consumption quantity in MT/Month is provided in below table 2.1. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 36

52 TABLE: 2.1 LIST OF PRODUCT WISE RAW MATERIAL CONSUMPTION Sr. No. List of Product Name of Raw Materials CAS Number Quantity in MT/ Month 1. Chlorinated Process and/or Mono Chloro Benzene Benzene AND/OR Chlorine ,124 Tri Chloro Benzene- (Benzene) AND/OR 1.3 Para Nitro Toluene (2 chloro 4 Nitro toluene) AND/OR Total 7.16 Benzene Chlorine Total 8.04 Para nitrotoluene Chlorine Total Hydrogenation/ Reduction Process and/or Ortho Toludiene AND/OR Ortho nitrotoluene Hydrogen Total M- O & Para Chloro Aniline AND/OR 2.3 3,4-2,3-2,5 Dichloro Aniline AND/OR M-O & Para chloro nitro benzene Hydrogen Solvent Total ,4-2,3-2,5 Di Chloro Nitro Benzene Hydrogen Fresh Solvent Total ,4 & 4,4 Diamino Diphenyl 3, 4 Dinitrodiphenyl ether Ether AND/OR Hydrogen Fresh solvent Total Nitration Process and/or , 2-3, 2-5, 2,4 Dichloro N Benzene AND/OR Para di chloro benzene Conc. Nitric Acid Sulphuric Acid Total Di Chloro Di Fluoro Nitro Di Chloro Di Fluoro Benzene AND/OR Benzene Conc. Nitric Acid Sulphuric Acid Oleum Total Nitro Anisole Process and/or Ortho Nitro Anisole AND/OR Ortho and Para Nitro Chloro Benzene Anhydrous Ammonia Lime (Purity-80%) Total 8.25 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 37

53 Sr. No. List of Product Name of Raw Materials CAS Number 5. Fluorination Process and/or Para Fluoro Nitro Benzene AND/OR Para chloro nitro benzene Potassium fluoride (KF) Sulfolane Polyethylene glycol Mono Chloro Benzene Total Quantity in MT/ Month 5.2 Di Fluoro Nitro Benzene 2,4-dichloronitrobenzene AND/OR Potassium fluoride (KF) Polyethylene glycol Fresh Sulfolane Total De nitro Chlorination Process and/or ,6 Di Chloro Fluoro Benzene AND/OR 6.2 2,6 Di Chloro-Benzo Nitrile AND/OR 2,3 Fluorochloronitro Benzene Chlorine % Soda Sulphuric acid Total ,6-CNBn Chlorine gas Mono Chloro Benzene Ammonia 25% Sulphuric acid Total Di Chloro Di Fluoro Benzene DFCNB as is AND/OR Chlorine Caustic lye Sulphuric acid Total Ammoniation Process and/or Di Chloro Ortho Nitro Aniline AND/OR 2,3,4 Tri Chloro Nitro Benzene Anhydrous Ammonia Mono Chloro Benzene Lime (Purity 80%) Total Ortho Nitro Aniline- Ortho/Para nitro chloro Para Nitro Aniline AND/OR benzene Anhydrous Ammonia Lime (Purity 80%) Total Bromination & De Amination Process and/or Tri Fluoro Bromine Benzene AND/OR 2,3,4 Trifluoro acetic acid (TFA) Bromine Hydrogen peroxide (50%) Sodium bisulfite (20%) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 38

54 Sr. No. List of Product Name of Raw Materials CAS Number Quantity in MT/ Month Hydrochloric Acid (30%) Methylene Dichloride (MDC) Hypo phosphorous acid (50%) Sodium nitrite Soda solution (10%) Total Sulphonation Process and/or B Acid Para Toluidine Sulphuric Acid Ortho dichlorobenzene (ODCB) Total Alkylation Process and/or Methyl Ethyl Aniline Fresh O-Toluidine Aluminium Aluminium chloride Ethylene Methanol fresh Total Dehalgenation Process and/or ,3 Di Fluoro Benzene Di Fluoro Chloro Benzene Triethyl amine Catalyst Hydrogen Hydrochloric Acid (30%) Caustic flakes Total Condensation Process and/or Di Nitro Di Phenyl Ether Para nitrochlorobenzene PNP Na N,N-Dimethylformamide Solvent Catalyst Total Cyclization Process and/or Di Amino Phenyl TABA Benzimidazole Sulphuric Acid (98%) Total Esterification and/or Ester Methanol Para-Tert-Butyl benzoic acid (PTBBA) Sulphuric Acid (98%) Recovered Methanol Total Diazotisation Process (Sand Mayer reaction ) and/or 5 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 39

55 Sr. No. List of Product Name of Raw Materials CAS Number Quantity in MT/ Month & 23Di Chloro Phenol 2,5-dichloroaniline Nitro sylsulfuric acid Sulphuric Acid Spent acid Sodium bicarbonate solution (10%) Total Acetylation & Hydrolysis Process and/or Meta Nitro Para Anisidine Ortho Anisidine AND/OR Acetic Anhydride Hydrogen Methylene dichloride (MDC) Recovered MDC Nitric Acid Sodium Nitrate Caustic Total Meta Nitro Para Toluidine AND/OR Para Toluidine Acetic Anhydride Hydrogen Methylene dichloride (MDC) Recovered MDC Nitric Acid Sodium Nitrate Caustic Total STORAGE & HANDLING OF PRODUCTS AND BY-PRODUCTS The monthly products & by-products storage is given in below table. Products & by products are stored in HDPE woven bag with PP liner & HDPE drums. Storage area of both solid products & liquid products are separate. The storage area will be designed in such a way that the floor level is 150 mm above the maximum floor level with 2.5 mm thickness of HDPE geo membrane and two layers of RCC in storage is proposed. The quality of products are checked properly and stored in the close shed with due consideration of compatibility of chemicals. Details of existing & proposed product & by- product Storage and handling are given in Table 2.2 & 2.3. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 40

56 TABLE 2.2 DETAILS OF EXISTING PRODUCT STORAGE Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC 1. Para Chloro Aniline Solid Bag 50 kg 2 HDPE Bag OR 2. 3,4 Di Chloro Aniline Solid Bag 50 kg 2 HDPE Bag OR 3. 2,5 Di Chloro Aniline Solid Bag 50 kg 2 HDPE Bag OR 4. Mix of 3,4 DCA & 2,3 Solid Bag 50 kg 2 HDPE Bag DCA OR 5. Ortho Anisidine OR Liquid Drum 200 Liter 2 HDPE 6. Para Toludiene OR Liquid Drum 200 Liter 2 HDPE TABLE 2.3 DETAILS OF PROPOSED PRODUCT AND BY-PRODUCT STORAGE Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC 1. CHLORINATED PROCESS AND/OR 1.1 Mono Chloro Benzene, Liquid Drum 200 Liter 2 HDPE Ortho Di Chloro Benzene, Para Di Chloro Benzene AND/OR ,124 Tri Chloro Liquid Drum 200 Liter 2 HDPE Benzene-(Benzene) AND/OR 1.3 Para Nitro Toluene Liquid Drum 200 Liter 2 HDPE (2chloro 4 Nitro toluene) AND/OR 1.4 Mono Dichloro Benzene Liquid Drum 200 Liter 2 HDPE AND/OR 1.5 Ortho chloro toluene / Liquid Drum 200 Liter 2 HDPE Para chloro toluene AND/OR Chloro 2-Nitro Toluene/ 4-Chloro 2-Nitro Toluene AND/OR Liquid Drum 200 Liter 2 HDPE 1.7 Pivalyl Chloride AND/OR Liquid Drum 200 Liter 2 HDPE Ethyl Hexanyl Chloride Liquid Drum 200 Liter 2 HDPE AND/OR 1.9 Iso Nonyl Chloride AND/OR Liquid Drum 200 Liter 2 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 41

57 Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC ,4,6 Trichloro Aniline Solid Bag 50 kg 2 HDPE (TCAN) AND/OR , 6 Dichloro para- nitro aniline (2,6 DCPNA) AND/OR Solid Bag 50 kg 2 HDPE 2. HYDROGENATION/REDUCTION PROCESS AND/OR 2.1 Ortho Toluidine AND/OR Liquid Drum 200 Liter 2 HDPE 2.2 M- O & Para Chloro Solid Bag 50 kg 2 HDPE Aniline AND/OR 2.3 3,4-2,3-2,5 Dichloro Solid Bag 50 kg 2 HDPE Aniline AND/OR 2.4 3,4 & 4,4 Diamino Diphenyl Ether AND/OR Solid Bag 50 kg 2 HDPE 2.5 Di Fluoro Benzene (1-3) Liquid Drum 200 Liter 2 HDPE AND/OR 2.6 Mixing of 2, 4 / 2, 5 DCA Solid Bag 50 kg 2 HDPE AND/OR 2.7 Mixing of 2, 5 / 2, 6 DCA Solid Bag 50 kg 2 HDPE AND/OR 2.8 Mixing of 2, 4 / 2, 5 / 2, 6 Solid Bag 50 kg 2 HDPE DCA AND/OR 2.9 2,4 Dichloro Aniline / 2,6 Solid Bag 50 kg 2 HDPE Dichloro Aniline / 3,5 Dichloro Aniline AND/OR ,4,5 Trichloro Aniline Solid Bag 50 kg 2 HDPE AND/OR 2.11 Meta / Ortho / Para Solid Bag 50 kg 2 HDPE Phenylene Di Amine AND/OR ,4 Diamino Diphenyl Solid Bag 50 kg 2 HDPE Ether / 4,4 Diamino Diphenyl AND/OR 2.13 Ether AND/OR Liquid Drum 200 Liter 2 HDPE 2.14 Ortho / Para / Meta Liquid Drum 200 Liter 2 HDPE Anisidine AND/OR 2.15 Chloro Fluoro Aniline Solid Bag 50 kg 2 HDPE AND/OR 2.16 Ortho / Para /Meta Liquid Drum 200 Liter 2 HDPE Cumidine AND/OR 2.17 Para /Meta Amino Phenol Solid Bag 50 kg 2 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 42

58 Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC AND/OR powder 2.18 Toluidine AND/OR Liquid Drum 200 Liter 2 HDPE 2.19 Aniline AND/OR Liquid Drum 200 Liter 2 HDPE 2.20 Para / Meta / Ortho Fluoro Liquid Drum 200 Liter 2 HDPE Aniline AND/OR 2.21 Di Fluoro Aniline (1:3) Liquid Drum 200 Liter 2 HDPE AND/OR Floro-N-Isopropyl Liquid Drum 200 Liter 2 HDPE Aniline AND/OR Chloro-NIsopropyl Liquid Drum 200 Liter 2 HDPE Aniline AND/OR Methoxy 4 Nitro Aniline Liquid Drum 200 Liter 2 HDPE (Scarlet R - from partial hydrogenation of 2 4 Dinitro Anisole) AND/OR ,4 Di Amino Anisole Solid Bag 50 kg 2 HDPE AND/OR 2.26 N-N Disec Butyl PPDA Solid Bag 50 kg 2 HDPE AND/OR 2.27 Meta Xilidine AND/OR Solid Bag 50 kg 2 HDPE Chloro 2,5 Dimethoxy Solid Bag 50 kg 2 HDPE Aniline AND/OR 2.29 N,N Di Sec tertiary butyl Solid Bag 50 kg 2 HDPE para phenylene Diamine AND/OR 2.30 DCBH (Di Chloro Solid Bag 50 kg 2 HDPE Benzene Hydro chloride) AND/OR ,5/2,6 DFA (Di Fluoro Liquid Drum 200 Liter 2 HDPE Aniline) AND/OR 2.32 Di Anisidine AND/OR Solid Bag 50 kg 2 HDPE 2.33 OT Base AND/OR Liquid Drum 200 Liter 2 HDPE 3. NITRATION PROCESS AND/OR ,2-3,2-5,2,4 Dichloro Solid Bag 50 kg 2 HDPE N Benzene AND/OR 3.2 Di Chloro Di Fluoro Nitro Solid Bag 50 kg 2 HDPE Benzene AND/OR 3.3 Ortho Nitro Chloro Benzene/ Para Nitro Chloro Benzene/ Meta Solid Bag 50 kg 2 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 43

59 Sr. No. Name of product State Storage Mode Nitro Chloro Benzene AND/OR 3.4 2,4 Di Nitro Chloro Benzene AND/OR 3.5 2,4,5 Tri Chloro Nitro Benzene/ 2,3,4 Tri Chloro Nitro Benzene AND/OR Nitro N-methyl Phthalimide AND/OR EHN (Ethyl Hexanol Nitration) AND/OR Capacity Max. storage capacity (MT/Month) MOC Solid Bag 50 kg 2 HDPE Solid Powder Bag 50 kg 2 HDPE Solid Bag 50 kg 2 HDPE Powder Liquid Drum 200 Liter 2 HDPE 4. NITRO ANISOLE PROCESS AND/OR 4.1 Ortho Nitro Anisole Liquid Drum 200 Liter 2 HDPE AND/OR 4.2 Para Nitro Anisole Solid Bag 50 kg 2 HDPE AND/OR 4.3 2,4-Di Nitro Anisole Solid Bag 50 kg 2 HDPE AND/OR Methoxy 5 Chloro Nitro Benzene (from 25 DCNB) AND/OR Solid Bag 50 kg 2 HDPE 5. FLUORINATION PROCESS AND/OR 5.1 Para Fluoro Nitro Liquid Drum 200 Liter 2 HDPE Benzene AND/OR 5.2 Di Fluoro Nitro Benzene AND/OR Liquid Drum 200 Liter 2 HDPE 6. DE-NITRO CHLORINATION PROCESS AND/OR 6.1 2,6Di Chloro Fluoro Solid Bag 50 kg 2 HDPE Benzene AND/OR 6.2 2,6 Di Chloro- Solid Bag 50 kg 2 HDPE Benzonitrile AND/OR 6.3 Di Chloro Di Fluoro Liquid Drum 200 Liter 2 HDPE Benzene AND/OR 6.4 Meta Dichloro Benzene Liquid Drum 200 Liter 2 HDPE AND/OR 6.5 2,4 Difluoro Chloro Liquid Drum 200 Liter 2 HDPE Benzene AND/OR 6.6 2,4 Dichloro Fluoro Liquid Drum 200 Liter 2 HDPE Benzene AND/OR 6.7 1,3 Dichloro 4,6 Difluoro Benzene AND/OR Liquid Drum 200 Liter 2 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 44

60 Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC 6.8 Para Fluoro Chloro Liquid Drum 200 Liter 2 HDPE Benzene AND/OR 6.9 Ortho Fluoro Chloro Benzene AND/OR Liquid Drum 200 Liter 2 HDPE 7. AMMONIATION PROCESS AND/OR 7.1 Di Chloro Ortho Nitro Solid Bag 50 kg 2 HDPE Aniline AND/OR 7.2 Ortho Nitro Aniline-Para Nitro Aniline AND/OR Solid Bag 50 kg 2 HDPE 8. BROMINATION&DEAMINATION PROCESS AND/OR 8.1 3,4,5, Tri Fluoro Bromine Liquid Drum 200 Liter 2 HDPE Benzene AND/OR Bromo 4 Fluoro Solid Bag 50 kg 2 HDPE Acetanilide AND/OR 8.3 Di Chloro Bromo Benzene AND/OR Solid Bag 50 kg 2 HDPE 9. SULPHONATION PROCESS AND/OR 9.1 4B Acid AND/OR Solid Bag 50 kg 2 HDPE 10. ALKYLATION PROCESS AND/OR 10.1 Methyl Ethyl Aniline AND/OR Liquid Drum 200 Liter 2 HDPE 11. DEHALOGENATION PROCESS AND/OR ,3 Di Fluoro Benzene AND/OR Liquid Drum 200 Liter 2 HDPE 12. CONDENSATION PROCESS AND/OR 12.1 Di Nitro Di Phenyl Ether AND/OR Solid Bag 50 kg 2 HDPE 13. CYCLIZATION PROCESS AND/OR 13.1 Di Amino Phenyl Solid Bag 50 kg 2 HDPE Benzimidazole AND/OR 13.2 Para fluoro Anisole Liquid Drum 200 Liter 2 HDPE AND/OR 13.3 Quinalphose (TECH) (Diethyl 2-Hydroxy Thiophosphoryl Chloride)AND/OR Liquid Drum 200 Liter 2 HDPE 14. ESTERIFICATION AND/OR 14.1 Ester AND/OR Liquid Drum 200 Liter 2 HDPE 15. DIAZOTISATION PROCESS AND/OR &23Di Chloro Phenol AND/OR Solid Bag 50 kg 2 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 45

61 Sr. No. Name of product State Storage Mode Capacity Max. storage capacity (MT/Month) MOC ,5 Di Chloro Nitro Solid Bag 50 kg 2 HDPE Benzene AND/OR 15.3 Para Fluoro Phenol (PFP)AND/OR Liquid Drum 200 L 2 HDPE 16. ACETYLATION & HYDROLYSIS PROCESS AND/OR 16.1 Meta Nitro Para Anisidine Solid Bag 50 kg 2 HDPE AND/OR 16.2 Meta Nitro Para Toluidine Liquid Drum 200 Liter 2 HDPE AND/OR 17. BY PRODUCTS % Hydrochloric Acid Liquid Drum 200 Liter 2 HDPE 17.2 Spent Acid Liquid Drum 200 Liter 2 HDPE 17.3 Aluminum Oxide (Al 2O 3) Solid Bag 50 kg 2 HDPE 17.4 Sodium Chloride (NaCl) Solid Bag 50 kg 2 HDPE 17.5 Ortho Nitro Phenol (ONP) Solid Bag 50 kg 2 HDPE 17.6 Calcium Chloride (Cacl2) solution 17.7 Potassium Chloride (KCL) Liquid Drum 200 Liter 2 HDPE Solid Bag 50 kg 2 HDPE 17.8 Acetic Acid (CH3COOH) Liquid Drum 200 Liter 2 HDPE Note: Raw material will be procured on a campaign basis and not more than 20 ton raw material will be stored within the premises RAW MATERIAL STORAGE AND HANDLING The monthly raw material storage is given in Table 2.3. Raw materials are stored in HDPE Drums, HDPE Carboys, HDPE bags, fibre drums. The quality of raw material is checked properly and store in the close shed storage area as per characteristic of raw material. The storage area are designed in such a way that the floor level is 150 mm above the maximum flood level with 2.5 mm thickness of HDPE geo membrane and two layers of RCC in storage is proposed. Hazardous flammable substances are separately stored in (solvent) farm area within premises. All liquid chemicals are store in MS/HDPE drums. Ammonia, Hydrogen & Chlorine gas is storage are separate in cylinder with all pre-cautionary process instrumentation and safety appliances. Bromine storage tanks will be fitted with appropriate controls to avoid any leakages and bund/dyke walls will be provided 1.5 times higher than storage tanks. Flame arrester cum M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 46

62 breather valve and flame proof fittings are provided at storage area. The solvent storage area is restricted for unauthorized persons. Proper earthling is provided in all electrical equipment whenever solvent handling is done. Details of quantity of Raw Material Storage are given in Table. TABLE: 2.4 DETAILS OF RAW MATERIAL STORAGE Sr. No. Name of Raw Material State Storage Mode Capacity Max. storage capacity (Existing) MT Max. storage capacity (Proposed) MT MOC 1. Benzene Liquid Drum 200 Liter 3 3 HDPE/MS 2. Chlorine Gas Cylinder 930 kg or 6 6 MS /Tonner 100 kg 3. Ortho Nitro Liquid Drum HDPE/MS Toluene 4. Hydrogen Gas Cylinder 0.5 kg 4 kg 4 kg MS 5. Meta Chloro Liquid Drum 200 Liter 7 7 HDPE/MS Nitrobenzene 6. N,N- Liquid Drum 200 Liter 1 1 HDPE/MS Dimethylform amide 7. 3,4 Di Chloro Solid Bag 200 Liter 6 6 HDPE Nitro Benzene 8. 3,4DNDPE Solid Bag 50 kg 7 7 HDPE 9. PDCB Solid Bag 200 / HDPE kg 10. Conc. Nitric Liquid Drum 2 Ton / HDPE/MS Acid L 11. Sulphuric Liquid Drum 50 Liter 2 2 HDPE/MS Acid 12. DCDFB Solid Bag 100 kg Oleum Liquid Drum 50 Liter 9 9 HDPE/MS 14. ONCB/ Solid / Drum / 50 kg 6 6 HDPE/MS PNCB Liquid Bag 15. Anhydrous Gas Cylinder 200 Liter 1 1 MS Ammonia 16. Lime Solid Bag 50 kg 2 2 HDPE (Purity 80%) 17. PCNB Solid Bag 50 kg 7 7 HDPE 18. KF Solid Bag 10 kg 3 3 HDPE 19. PEG-400 Liquid Drum 200 Liter 1 1 HDPE/MS 20. Mono Chloro Liquid Drum 200 Liter 1 1 HDPE/MS benzene M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 47

63 Sr. No. Name of Raw Material State Storage Mode Capacity Max. storage capacity (Existing) MT Max. storage capacity (Proposed) MT MOC 21. 2,4-DCNB Solid Bag 200 Liter 8 8 HDPE 22. Sulfolane Liquid Drum 200 Liter 3 3 HDPE/MS 23. 2,3-FCNB Solid Bag 200 Liter 7 7 HDPE % Soda Liquid Drum 25 kg 1 1 HDPE/MS 25. 2,6-CNBn Solid Bag 50 kg 7 7 HDPE 26. Ammonia Liquid Drum 200 Liter 1 1 HDPE/MS 25% 27. DFCNB as is Solid Bag 200 Liter 8 8 HDPE 28. Caustic lye Liquid Drum 200 Liter 1 1 HDPE/MS 29. 2,3,4 - TFA Liquid Drum 200 Liter 4 4 HDPE/MS 30. Bromine Liquid Tank / Bottles 2 Ton / 3 L 3 3 Glass Bottle/ SS Tanker 31. Hydrogen Liquid Drum 50 Liter 2 2 HDPE peroxide-50% 32. Sodium Liquid Drum 200 Liter 1 1 HDPE/MS bisulfite-20% 33. Hydrochloric Liquid Drum 200 Liter 8 8 HDPE acid - 30% 34. Methylene Liquid Drum 200 Liter 4 4 HDPE/MS dichloride (MDC) 35. Hypo Liquid Drum 50 Liter 4 4 HDPE phosphorous acid-50% 36. Sodium nitrite Solid Bag 200 Liter 2 2 HDPE % soda Liquid Drum 50 Liter 1 1 HDPE solution 38. Ortho Liquid Drum 200 Liter HDPE dichlorobenze ne (ODCB) 39. OT Liquid Drum 200 Liter 5 5 HDPE/MS 40. Aluminium Solid Bag 25 kg 1 1 HDPE Powder 41. Aluminium Solid Bag 25 kg 1 1 HDPE chloride 42. Ethylene Gas Cylinder 80 kg 2 2 MS 43. Di Fluoro Chloro Benzene 44. Triethyl amine Solid Bag 200 Liter 7 7 HDPE Liquid Drum 200 Liter 1 1 HDPE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 48

64 Sr. No. Name of Raw Material State Storage Mode Capacity Max. storage capacity (Existing) MT Max. storage capacity (Proposed) MT MOC 45. Catalyst Solid Bag 25 kg 1 1 HDPE 46. Caustic flakes Solid Bag 50 kg 3 3 HDPE 47. Para-nitro chloro benzene Solid / Liquid Bag / Liquid 50 kg 4 4 HDPE 48. PNP Na Solid Bag 50 kg 5 5 HDPE 49. TABA Solid Bag 50 kg 4 4 HDPE 50. Methanol Liquid Drum 200 Liter 1 1 HDPE/MS 51. PTBBA Solid Bag 50 kg 5 5 HDPE DCA Solid Bag 50 kg 6 6 HDPE 53. NSA Liquid Drum 200 Liter HDPE 54. Sodium Liquid Drum 200 Liter 1 1 HDPE bicarbonate solution-10% 55. Ortho Liquid Drum 200 Liter 5 5 HDPE Anisidine 56. Acetic Liquid Drum 200 Liter 5 5 HDPE Anhydride 57. Hydro Solid Bag 50 Liter 1 1 HDPE 58. Nitric Acid Liquid Drum 2 Ton / 3 L 9 9 Glass Bottle 59. Sodium Solid Bag 25 kg 1 1 HDPE Nitrate 60. Para Toluidine Liquid Drum 50 kg 5 5 HDPE As per the Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 issued by the Ministry of Environment and Forests (MoEF), Govt. of India, All the Hazardous chemicals and storage are within the threshold quantities. So, there will be no Storage permission required from PESO PHYSICAL PROPERTY/CHARACTERISTICS OF PRODUCTS & RAW MATERIALS: The characteristics of Products & Raw material are given in Table 2.5. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 49

65 TABLE: 2.5 CHARACTERISTICS OF PRODUCT AND RAW MATERIAL Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 1. CHLORINATED PROCESS AND/OR 1.1 Mono Chloro Benzene Liquid & ,2-Dichlorobenzene Liquid & ,124 Tri Chloro Benzene- (Benzene) 1.3 Para Nitro Toluene (2 chloro 4 nitro toluene) 1.4 Ortho chloro toluene / Para chloro toluene Chloro 2-Nitro Toluene, 4-Chloro 2-Nitro Toluene 1.6 Pivalyl Chloride Liquid Vapour Density (Air =1) Liquid & Liquid NA NA NA 4.72 Liquid NA NA 3227 NA NA 159 Liquid NA NA -- NA NA & 7.4 NA 638, >1.43 NA > Ethyl Hexanyl Chloride Liquid NA NA 1500, 1.2 NA NA 1.8 Iso Nonyl Chloride Liquid NA NA NA NA NA NA NA NA 1.9 2,4,6 Trichloro Aniline (TCAN) Liquid NA NA NA 1180 NA NA , 6 Dichloro para nitro aniline (2,6 DCPNA) Solid NA NA NA NA 2400 NA NA 2. HYDROGENATION/REDUCTION PROCESS AND/OR 2.1 Ortho Toluidine Liquid M- O & Para Chloro Aniline Solid >104.4 NA NA NA open cum M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 50

66 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 2.3 3,4-2,3-2,5 Dichloro Aniline Solid >110 NA NA 1600 NA NA 2.4 3,4 & 4,4 Diamino Diphenyl Solid NA NA NA NA NA Ether Diflorobenzene (1-3) Liquid NA NA NA NA NA >1 2.6 Mixing of 2, 4 / 2, 5 DCA Solid NA NA NA NA NA NA NA NA 2.7 Mixing of 2, 5 / 2, 6 DCA Solid NA NA NA NA NA NA NA NA 2.8 Mixing of 2, 4 / 2, 5 / 2, 6 DCA Solid NA NA NA NA NA NA NA NA 2.9 2,4 Dichloro Aniline / 2,6 Dichloro Aniline / 3,5 Dichloro Aniline Solid NA NA NA NA NA NA ,4,5 Trichloro Aniline Solid >110 NA NA NA NA > Meta / Ortho / Para Phenylene Solid NA NA 3.71 Di Amine ,4 Diamino Diphenyl Ether / Solid NA NA NA NA NA 4,4 Diamino Diphenyl Ether Ether Liquid Ortho / Para / Meta Anisidine Liquid NA NA NA 3200 NA NA 2.15 Chloro Fluoro Aniline Solid >110 NA NA 356 NA > Ortho / Para /Meta Cumidine Liquid NA NA NA 1180 NA NA 2.17 Para /Meta Amino Phenol Solid 186- NA 195 NA NA 375 NA NA powder Toluidine Liquid NA NA NA NA NA NA Aniline Liquid & 11 2 or 10 NA NA 3.2 Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 51

67 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 2.20 Para / Meta / Ortho Fluoro Liquid NA 2.5 NA NA >1 Aniline Di Fluoro Aniline (1:3) Liquid NA NA NA NA NA NA Floro-N-Isopropyl Aniline Liquid < NA NA 356 NA > Chloro-NIsopropyl Aniline Liquid NA NA NA NA NA NA NA Methoxy 4 Nitro Aniline (Scarlet R - from partial hydrogenation of 24 Dinitro Anisole) Liquid NA NA NA NA NA NA > ,4 Di Amino Anisole Solid NA NA NA NA NA NA NA NA 2.26 N-N Disec Butyl PPDA Solid NA 148 NA NA 2.27 Meta Xilidine Solid & 6.9 NA 840 NA NA Chloro 2,5 Dimethoxy Aniline Solid NA NA 5 or 19 NA ~630 NA 2.29 N,N Di Sec tertiary butyl para Solid NA NA NA NA phenylene Diamine DCBH (Di Chloro Benzene Solid NA NA NA NA NA NA NA Hydro chloride) ,5/2,6 DFA (Di Fluoro Aniline) Liquid NA NA NA NA NA NA 2.32 Di Anisidine Solid 268 NA NA NA NA NA NA NA 2.33 OT Base Liquid NA NA NA NITRATION PROCESS AND/OR , 2-3, 2-5, 2,4 Dichloro N Solid NA NA NA NA NA Benzene Di Chloro Di Fluoro Nitro Solid NA NA NA NA NA NA NA NA Benzene 3.3 Ortho Nitro Chloro Benzene/ Solid & NA 5.4 Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 52

68 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) Para Nitro Chloro Benzene/ Meta Nitro Chloro Benzene 3.4 2,4 Di Nitro Chloro Benzene Solid & NA > ,4,5 Tri Chloro Nitro Benzene/ Solid >110 NA 2.3 NA NA >1 2,3,4 Tri Chloro Nitro Benzene Powder Nitro N-methyl Phthalimide Solid 177- NA NA NA NA 2800 NA NA Powder EHN (Ethyl Hexanol Nitration) Liquid NA NA NA NA NA NA NA NA 4. NITRO ANISOLE PROCESS AND/OR 4.1 Ortho Nitro Anisole Liquid NA NA NA NA 4.2 Para Nitro Anisole Solid NA NA NA NA 4.3 2,4-Di Nitro Anisole Solid NA NA NA NA 198 NA NA Methoxy 5 Chloro Nitro Benzene (from 25 DCNB) Solid >110 NA NA 379 NA >1 5. FLUORINATION PROCESS AND/OR 5.1 Para Fluoro Nitro Benzene Liquid NA NA 23.56mg/L NA >1 5.2 Di Fluoro Nitro Benzene Liquid NA NA NA NA NA NA 6. DE-NITRO CHLORINATION PROCESS AND/OR 6.1 2,6 Di Chloro Fluoro Benzene Solid NA NA 2.28mg/L NA > ,6 Di Chloro-Benzonitrile Solid 143- NA NA NA NA NA NA NA Di Chloro Di Fluoro Benzene Liquid NA NA NA 4.39 mg/l NA >1 6.4 Meta Dichloro Benzene Liquid NA NA NA 2.90 mg/l ,4 Difluoro Chloro Benzene Liquid NA NA NA 4.39 mg/l NA >1 Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 53

69 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 6.6 2,4 Dichloro Fluoro Benzene Liquid NA NA 2.28 mg/l NA > ,3 Dichloro 4,6 Difluoro Liquid 101- NA NA NA NA NA NA NA Benzene Para Fluoro Chloro Benzene Liquid NA NA NA NA NA Ortho Fluoro Chloro Benzene Liquid NA NA NA NA NA 7. AMMONIATION PROCESS AND/OR 7.1 Di Chloro Ortho Nitro Aniline Solid NA NA NA 0.56 mg/l NA >1 7.2 Ortho Nitro Aniline/ Para Nitro Aniline Solid NA NA NA NA 8. BROMINATION & DEAMINATION PROCESS AND/OR 8.1 3, 4, 5 Tri Fluoro Bromine Liquid NA ~47-45 NA NA 2.90 mg/l NA >1 Benzene Bromo 4 Fluoro Acetanilide Solid 117- NA NA NA NA NA NA NA Di Chloro Bromo Benzene Solid NA NA NA NA NA 9. SULPHONATION PROCESS AND/OR 9.1 4B Acid Solid NA NA NA NA NA >2000 NA >1 10. ALKYLATION PROCESS AND/OR 10.1 Methyl Ethyl Aniline Liquid NA NA 885 NA >1 11. DEHALGENATION PROCESS AND/OR ,3 Di Fluoro Benzene Liquid NA NA NA CONDENSATION PROCESS AND/OR mg/l/2hr NA >1 Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 54

70 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 12.1 Di Nitro Di Phenyl Ether Solid NA NA NA NA NA NA NA 13. CYCLIZATION PROCESS AND/OR 13.1 Di Amino Phenyl Benzimidazole Solid 231 NA NA NA NA NA NA NA 13.2 Para fluoro Anisole Liquid NA NA NA NA NA 13.3 Quinalphose (TECH) (Diethyl 2- Liquid NA NA NA 26 NA NA Hydroxy Thiophosphoryl Chloride) 14. ESTERIFICATION AND/OR 14.1 Ester (Avobenzone) Liquid NA NA NA NA NA NA NA 15. DIAZOTISATION PROCESS AND/OR & 23 Di Chloro Phenol Solid NA NA 47 NA > ,5 Di Chloro Nitro Benzene Solid NA NA NA NA NA 588 NA > Para Fluoro Phenol (PFP) Liquid NA 2.5 NA NA >1 16. ACETYLATION & HYDROLYSIS PROCESS AND/OR 16.1 Meta Nitro Para Anisidine Solid NA NA NA NA NA > Meta Nitro Para Toluidine Liquid 115- NA NA NA NA mg/l NA > BY PRODUCTS 17.1 Hydrochloric acid (30%) Liquid >-74 >50 NA NA Dilute sulfuric acid Liquid NA NA mg/m Aluminum Oxide (Al2O3) Solid NA NA NA >2000 NA NA 17.4 Sodium Chloride (NaCl) Solid NA NA NA NA Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 55

71 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) 17.5 Ortho Nitro Phenol (ONP) Solid NA 2.1 NA 1.48 NA mg/m Calcium Chloride (Cacl2) Liquid 772 >160 NA NA NA NA solution 0 mg/m Potassium Chloride (KCl) Solid 773 Subli NA NA NA mes at mg/m Acetic Acid (CH3COOH) Liquid & ppm RAW MATERIALS 1. Benzene Liquid & Chlorine Gas Non- NA 1 > Fla. 3. Ortho Nitro toluene Liquid & Hydrogen Gas & NA NA Meta Chloro Nitrobenzene Liquid NA NA >1 6. N,N-Dimethylformamide - Liquid & NA Solvent ,4 Di Chloro Nitro Benzene Solid NA NA > >1 8. 3,4DNDPE Solid (Dinitro Diphenyl ether) ,4-Dichlorobenzene (PDCB) Solid & Conc. Nitric Acid Liquid NA NA Sulphuric Acid Liquid DCDFB Solid Oleum Liquid NA NA >3 14. ONCB/ PNCB Solid / OC-127 U Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 56

72 Sr. No. Name of product Physical State M.P O C B.P O C Liquid 15. Anhydrous Ammonia Gas Lime (Purity 80%) Solid 580 Deco mpose 17. Para-nitro chloro benzene (PCNB) F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) Vapour Density (Air =1) & NA NA 1 >2000 NA NA Solid NA NA 420 NA Potassium fluoride (KF) Solid NA NA 2.5 >2000 NA NA 19. polyethylene glycol Liquid 4-10 Deco > & 6.9 NA 600 NA NA (PEG-400) mpose 20. Mono Chloro benzene Liquid & (2,4-DCNB) Solid >110 NA NA 379 NA >1 2,4-dichloronitrobenzene 22. Sulfolane Liquid NA NA NA ,3-FCNB Solid NA NA NA NA Soda (25%) Liquid 851 NA NA NA NA NA 25. 2,6-CNBn Solid 116- NA NA NA NA NA NA NA Ammonia (25%) Liquid NA NA NA 25 NA NA NA 27. DFCNB as is Solid NA NA NA NA NA NA NA 28. Caustic lye Liquid NA NA NA >90000 NA NA 29. 2,3,4 - TFA Liquid NA NA NA 699 NA NA 30. Bromine Liquid NA NA NA 2600 NA Hydrogen peroxide-50% Liquid NA M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 57

73 Sr. No. Name of product Physical State M.P O C 32. Sodium bisulfite-20% Liquid Decomp ose@150 B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) NA NA NA NA 33. Hydrochloric acid - 30% Liquid > -74 >50 NA NA NA 900 NA Methylene dichloride (MDC) Liquid NA 13 & Hypo phosphorous acid-50% Liquid NA 100 NA NA NA NA Sodium nitrite Solid NA NA NA NA % soda solution Liquid 851 NA NA NA NA NA 38. Ortho dichlorobenzene (ODCB) Liquid & 9.2 NA 500 NA O-Toluidine Liquid Aluminium Powder Solid NA NA NA NA NA NA 41. Aluminium chloride Solid NA 0.1 NA Ethylene Gas & 36 NA NA NA Di Fluoro Chloro Benzene Solid NA NA NA NA NA >1 44. Triethyl amine Liquid & 8 NA 730 NA Catalyst (Palladium) Solid NA NA 6 NA NA NA 46. Caustic flakes Solid NA NA Para-nitro chloro benzene Solid / >110 NA NA 5.4 (PNCB) Liquid 48. PNP Na Solid >300 NA 90 NA NA 320 NA NA 49. TABA Solid NA NA NA 1.38 NA Methanol Liquid & >1187 NA PTBBA Solid NA >80 NA NA 473 NA NA Vapour Density (Air =1) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 58

74 Sr. No. Name of product Physical State M.P O C B.P O C F.P O C LEL UEL % TLV ppm or mg/m 3 LD50, mg/kg LC50, mg/l Sp. Gravity (Water=1) DCA Solid >110 NA NA 1600 NA NA 53. NSA Liquid 73.5 NA NA NA 1.2 NA NA >1 54. Sodium bicarbonate solution- 10% Liquid NA NA NA 2 or NA NA Decomp Ortho Anisidine Liquid NA 0.1 or >870 NA NA Acetic Anhydride Liquid & 5 or Hydro Solid 52 - NA NA NA NA NA NA NA Decomp oses 58. Nitric Acid Liquid NA NA 2 or mg/l Sodium Nitrate Solid NA NA NA NA 60. Para Toluidine Liquid & NA Vapour Density (Air =1) NA- Not Available/ Not Applicable M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 59

75 2.3.4 TRANSPORTATION OF RAW MATERIALS AND FINISHED PRODUCTS The raw materials and finished goods are transported through tankers and trucks. There is well developed road structure in GIDC, Vapi as well as within premises also. No additional road infrastructure will be required for transportation. All the trucks/tanker for raw material and finished product transportation will be environmentally compliant. Safety training is given to driver and cleaner regarding the safe driving, hazards of chemicals, emergency handling and use of SCBA sets. TREM card, SCBA set & Fire extinguishers are kept with TL. Trucks/tanker will not be use 10 year old. Trucks/tanker will not be use overloading. The number of trucks per day for raw material and finished product transportation will be approx. 2 to 5 Tempo/tanker/trucks. The raw material source will be standard manufacturer or supplier. Indicative list along with mode of transportation is included in Table 2.6. TABLE: 2.6 DETAILS OF RAW MATERIAL SOURCE AND METHOD OF TRANSPORTATION Sr. No. Name of Raw Material State Source (Name of Seller Company) Mode of transportation 1. Benzene Liquid Aarti Industries Tempo 2. Chlorine Gas Vadilal / Aarti Tempo 3. Ortho Nitro Toluene Liquid Aarti Industries Tempo 4. Hydrogen Gas Vadilal Tempo 5. Meta Chloro Nitrobenzene Liquid Aarti Industries Tempo 6. Solvent Liquid Aarti / RCF Tempo 7. 3,4 Di Chloro Nitro Benzene Solid Aarti Industries Tempo 8. 3,4DNDPE Solid Aarti Industries Tempo 9. PDCB Solid Aarti Industries Tempo 10. Conc. Nitric Acid Liquid Aarti Industries Tempo 11. Sulphuric Acid Liquid Aarti Industries Tempo 12. DCDFB Solid Aarti Industries Tempo 13. Oleum Liquid Aarti Industries Tempo 14. ONCB/ PNCB Solid / Aarti Industries Tempo Liquid 15. Anhydrous Ammonia Gas Vadilal Tempo 16. Lime (purity 80%) Solid Suvidhi Industries Tempo 17. PCNB Solid Transpek India Tempo 18. KF Solid Aarti Industries Tempo 19. PEG-400 Liquid Aarti Industries Tempo 20. MCB Liquid Aarti Industries Tempo 21. 2,4-DCNB Solid Aarti Industries Tempo 22. Sulfolane Liquid Aarti Industries Tempo 23. 2,3,FCNB Solid Aarti Industries Tempo %Soda Liquid Suvidhi Industries Tempo 25. 2,6-CNBn Solid Aarti Industries Tempo 26. Ammonia 25% Liquid Vadilal Tempo M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 60

76 Sr. No. Name of Raw Material State Source (Name of Seller Company) Mode of transportation 27. DFCNB as is Solid Aarti Industries Tempo 28. Caustic lye Liquid Suvidhi Industries Tempo 29. 2,3,4 - TFA Solid Aarti Industries Tempo 30. BROMINE Liquid A B enterprise Tempo 31. H2O2 50% Liquid Suvidhi Industries Tempo 32. NaHSO3 20% Liquid Suvidhi Industries Tempo 33. HCl - 30% Liquid Aarti Industries Tempo 34. MDC Liquid Aarti Industries Tempo % H3PO2 Liquid Suvidhi Industries Tempo 36. NaNO2 Solid Suvidhi Industries Tempo % soda solution Liquid Suvidhi Industries Tempo 38. ODCB Liquid Aarti Industries Tempo 39. OT Liquid Aarti Industries Tempo 40. Al Powder Solid Nataraj Aluminium Tempo 41. AlCl3 Solid Triveni Chemicals Tempo 42. CH2=CH2 Gas Vadilal Tempo 43. Di Fluoro Chloro Benzene Solid Aarti Industries Tempo 44. Triethyl amine Liquid Aarti Industries Tempo 45. Catalyst Solid Arrora Mathey / Tempo Jhonson Mathey / Aarti Industries 46. Caustic flakes Solid Suvidhi Industries Tempo 47. PNCB Solid / Aarti Industries Tempo Liquid 48. PNP Na Solid Aarti Industries Tempo 49. TABA Solid Aarti Industries Tempo 50. Methanol Liquid Aarti Industries Tempo 51. PTBBA Solid Aarti Industries Tempo DCA Solid Aarti Industries Tempo 53. NSA Liquid Aarti Industries Tempo % NaHCO3 solution Liquid Suvidhi Industries Tempo 55. Ortho Anisidine Liquid Aarti Industries Tempo 56. Acetic Anhydride Liquid Aarti Industries Tempo 57. Hydro Solid Aarti Industries Tempo 58. Nitric Acid Liquid Aarti Industries Tempo 59. Sodium Nitrate Solid Suvidhi Industries Tempo 60. Para Toluidine Liquid Aarti Industries Tempo M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 61

77 2.4 PROCESS DESCRIPTION BEST AVAILABLE TECHNOLOGY USED FOR MANUFACTURING PROCESS AND JUSTIFICATION: This is a Pilot Plant. R&D is best technology developed and testing. All the technology trials in the pilot scale. The manufacturing process is based on Best Available Technology as it involves minimum opex and based on closed loop technology. It uses minimum solvent and maximum recover 95% solvent. Minimum effluent generation is result as compared to conventional manufacturing process. Unit has already standardized the manufacturing process. This indicates the unit has selected best available technologies (BAT). So, the unit has adopted latest and best technology available so far in the market. Moreover, the unit is very conscious about the product quality and equally about the environmental protection and resource conservation; and hence they put their efforts for replacing/upgrading their plant and machineries from time to time with the best available technology. The unit s processes are efficient and are tailor made to reduce the effluent as well as are based on green chemistry wherever possible. All the technology trials in the pilot scale MANUFACTURING PROCESS OF PRODUCTS I) CHLORINATED PROCESS: MCB, ODCB & PDCB: 1. MONO CHLORO BENZENE Manufacturing Process: The chlorine in the gaseous form is reacted with benzene to form mono Chloro benzene in the chlorinator reactor, reaction is followed by benzene recovery. Chemical Reaction: Cl + Cl 2 + HCl benzene chlorine mono chloro bezene hydro chloric acid M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 62

78 Material Balance: Input Kg Output Kg Fresh benzene 46.4 HCl Chlorination Recovered benzene Reaction mass Chlorine Total Total Reaction mass Benzen recovery Benzene Mix products Total Total Mix products Distillation Crude MCB Crude DCB Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 63

79 MCB pure Crude MCB Fractionation Residue 0.03 Total Total P-DCB pure Crude DCB Crystalizer Crude DCB 33.7 Total Total P-DCB pure Crude DCB 33.7 Fractionation Crude DCB Total 33.7 Total 33.7 O-DCB Crude DCB Fractionation Residue Total Total HCl HCl HCl loss 0.07 Water SCRUBBER 30% HCl TOTAL TOTAL ) 123, 124 TRICHLORO BENZENE: Manufacturing Process: The chlorine in the gaseous form is reacted with either benzene or ortho di chloro benzene in the chlorinator; Reaction is followed by benzene or Ortho di chloro benzene recovery then separation of crude tri chloro benzene. Crude product is then subjected to Flash Distillation to get pure product. Chemical Reaction: Cl + 3 Cl HCl Cl Cl benzene chlorine Tri chloro bezene hydro chloric acid M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 64

80 Mass Balance: Input Kg Output Kg Benzene 42.9 HCl Recovered Benzene Chlorination Reaction mass Chlorine Total Total Reaction mass ODCB recovery Recovered Benzene Mix products Total Total TCB Mix products Distillation Reaction mass Total Total TCB Reaction mass Distillation Residue 0.26 Total Total HCL HCl HCl loss SCRUBBER Water % HCl TOTAL TOTAL ) 2-CHLORO 4-NITRO TOLUENE Manufacturing Process: The chlorine in the gaseous form is reacted with Para nitro toluene in the chlorinator, Reaction is followed by Para nitro toluene recovery then separation of crude chloro nitro toluene. Crude product is then subjected to Flash Distillation to get pure products Chemical Reaction: CH 3 CH 3 Cl + Cl 2 + HCl NO 2 NO 2 Para Nitro Toluene chlorine 2Chlror4Nitro toluene hydro chloric acid M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 65

81 Mass Balance: Input Kg Output Kg Fresh PNT HCl Recovered PNT Chlorination Reaction mass Chlorine Total Total Reaction mass Toluene recovery PNT Reaction Mass Total Total Product Reaction mass Distillation Residue 1.99 Total Total HCl HCL HCl loss 0.12 Water SCRUBBER 30% HCl TOTAL TOTAL II) HYDROGENATION/REDUCTION PROCESS ORTHO TOLUDIENE Manufacturing Process: Here ortho nitro toluene is reacted in an Autoclave reactor with the Hydrogen gas in the presence of a metal powder catalyst. The reaction mixture contains solvent. The reaction is followed by Catalyst Filtration, Solvent Recovery, Layer Separation and Drying. Crude product is than subjected to Flash Distillation to get the pure product. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 66

82 Chemical Reaction: Mass Balance: Input Kg Input Kg Ortho nitrotoluene 130 Hydrogen (Vent) 0.29 Hydrogen 6 Hydrogenation Cr. Ortho toludene TOTAL TOTAL Cr. Ortho toludene Reaction water Vac. Drying Cr. Ortho toludene TOTAL TOTAL Cr. Ortho toludene Fractionation Ortho toluedene Residue 0.41 TOTAL TOTAL M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 67

83 META CHLORO ANILINE / PARA CHLORO ANILINE / ORTHO CHLORO ANILINE Manufacturing Process:: Here Meta Nitrobenzene is reacted in an autoclave reactor with hydrogen gas in presence of metal powder catalyst to produce Meta chloro aniline. The reaction mixture contains solvent. The reaction is followed by catalyst filtration, solvent recovery, layer separation and drying. Crude product is then subjected to flash distillation to get the pure product. Product is either sold as liquid or flakes depending on the market requirement. For production of Para Chloro aniline and Ortho Chloro aniline, same above manufacturing process is applied by taking Para Chloro nitrobenzene and Ortho Chloro Nitrobenzene respectively instead of Meta Chloro nitro benzene. Reference material balance is given for one product. Chemical Reaction: C 6 H 4 NO 2 Cl + 3H 2 C 6 H 4 NH 2 Cl + 2H 2 0 Mass Balance: INPUT Kg OUTPUT Kg Vent MCNB 124 Hydrogen 5 Fresh Solvent 3.06 Hydrogen Loss (1%) 0.05 Reaction Recovered 1.53 Solvent Loss(2%) solvent Catalyst Crude Total Total Catalyst Crude 204 Filter Crude Total 204 Total 204 Vent Crude 204 Solvent Recovery Solvent Loss(2%) 1.53 Solvent Recovery(96%) Crude Total 204 Total 204 Effluent Phase Crude Crude Separator Total Total Crude Distillation Meta Chloro aniline Residue 0.54 Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 68

84 3, 4/2, 3/2, 5 DICHLORO ANILINE Manufacturing Process: Here 3, 4 Dichloro nitrobenzene is reacted in an autoclave reactor with hydrogen gas in presence of metal powder catalyst to produce 3, 4 Dichloro aniline. The reaction mixture contains solvent. The reaction is followed by catalyst filtration, solvent recovery, and layer separation and drying. Crude product is then subjected to flash distillation to get the pure product. Product is either sold as liquid or flakes depending on the market requirement. For production of 2, 3 chloro aniline and 2, 5 Dichloro aniline, same above manufacturing process is applied by taking 2, 3 Dichloro nitrobenzene and 2, 5 Dichloro benzene instead of 3, 4 dichloronitro benzene. Reference material balance is given for one product. Chemical Reaction: C 6 H 3 NO 2 Cl 2 + 3H 2 C 6 H 3 NH 2 Cl 2 + 2H Mol. Wt.(kg/kmol) Feed (kg/hr) Material Balance: Input Kg Output Kg DCNB Hydrogen 3.72 Hydrogen 0.04 Fresh Solvent 0.84 Reaction Loss(1%) Recovered 0.08 Solvent Solvent Loss Catalyst Reaction mass Total Total Vent 0.02 Catalyst Reaction mass Filter Reaction mass Total Total Vent Solvent 0.84 Loss(2%) Reaction mass Solvent Recovery Solvent Recovery(96%) Reaction mass Total Total Effluent to ETP Phase Reaction mass Crude(DCA) Total Seperator Total pure DCA Crude Distillation 0.50 Residue Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 69

85 3, 4 DIAMINO DIPHENYL ETHER / 4, 4 DIAMINO DIPHENYL ETHER Manufacturing Process: 3, 4-Di nitro biphenyl ether is reacted in an Autoclave reactor with Hydrogen gas in presence of metal powder catalyst. The reaction mixture contains solvent. The reaction followed by Catalyst Filtration, Crystallization, solvent recovery and drying. For production of 4, 4 Di Amino Diphenyl Ether same above manufacturing process is applied by taking 4, 4-Di nitro biphenyl ether. Chemical Reaction: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 70

86 Material Balance: Input Kg Output Kg Recovered 3,4 DNDPE 1.3 Fresh 3,4DNDPE 130 Hydrogen loss(1%) 0.06 Hydrogen 6 Solvent loss 2 Fresh solvent 3.36 Reaction Crude Recovered solvent Catalyst Total Total Crude Catalyst Catalyst recovery Filteration Crude Total Total Crystalisati 3,4DADPE +solvent 110 Crude on & Filtration Solvent +water Total Total ,4DADPE 100 3,4DADPE +solvent 110 Drying Solvent loss 1 Recovered solvent 9 Total 110 Total 110 Solvent loss 0.36 Solvent +water Distillation Recovered solvent Recovered Water 36 Recovered 3,4DNDPE 1.3 Total Total III) NITRATION PROCESS 2, 5 /3, 4 /2, 3DICHLORONITROBENZENE Manufacturing Process: Mixed acid containing concentrated nitric acid and concentrated sulphuric acid is reacted with 2, 5 Di Chloro benzene to produce 2, 5 Di Chloro nitro benzene. The reaction gets completed in series of nitrators with cooling coils and jackets. Reaction is followed by spent acid separation, washing by water and soda ash, drying to get a 2, 5 Di Chloro nitro benzene and unreacted 2, 5 Di Chloro benzene. Un-reacted 2, 5 Di Chloro Benzene is recovered by steam distillation and recycled. For 3, 4 Di Chloro Nitro benzene and 2, 3 Di Chloro Nitro Benzene same above process is used. Used 3, 4 Di Chloro Benzene and 2, 3 Di Chloro Benzene instead of 2,5 Di Chloro Benzene. Reference Material balance is given for one product. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 71

87 Chemical Reaction: C 6 H 4 Cl 2 + HNO 3 = C 6 H 3 Cl 2 NO 2 + H 2 O Material Balance: Input Kg Kg Output pdcb Conc. Nitic Acid Nitration Sulphuric Acid Reaction Mass Spent Acid 125 Total Total 100 Crude 2,5 DCNB Reaction Mass Seperation 125 Spent Acid 38.6 Spent Acid Total Total Reaction Mass 100 Washing Water Reaction Mass Total Total Seperation Water to ETP Reaction Mass ,5 DCNB Crude Total Total 1.66 Water 2,5 DCNB Drying Crude ,5 DCNB Crude Total Total DCDFNB: Manufacturing Process: DCDFB reacts with sulphuric acid, nitric acid and oleum to give Reaction mass. Separation and Washing of reaction mass gives DCDFNB. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 72

88 Chemical Reaction: NO 2 Cl + 2KF Cl Cl Cl 1,2,3,4-tetrachloro-5-nitrobenzene Manufacturing Process: Solvent / Catalyst NO 2 F + Cl Cl F 2KCl 1,3-dichloro-2,4-difluoro-5-nitrobenzene Input Kg Kg Output DCDFB Conc. Nitic Acid Sulphuric Acid Nitration Reaction Mass Water Oleum Total Total Reaction Mass Reaction Mass Separation Spent Acid Total Total Reaction Mass Washing 100 DCDFNB Water Aq Layer Total Total IV) NITRO ANISOLE PROCESS ORTHO NITRO ANISOLES Manufacturing Process: Here we are adding ortho nitro chloro benzene, methanol and Caustic soda flakes in the methoxylation type reactor. From that we will get reaction mass and its transfer to filter for filtration. After that we will get reaction mass sodium chloride. Again reaction mass passed through distillation columns and here we are adding require quantity of water. After finishing distillation procedure we will get crude ONA, ONP, water. Here methanol is also recovered and some methanol will be loss. Crude ONA with water adding in evaporation than finally we get ONP &NaCl salt. Evaporated water will be used in cooling tower make-up. Reference material balance is given for one product. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 73

89 Chemical Reaction: Material Balance: Input Kg Output Kg ONCB Methanol Reaction mass Recovered Methoxylation methanol 133 Caustic Flakes Total Total Reaction mass Filteration Reaction mass Sodium Chloride Total Total Crude ONA Reaction mass Distillation Recovered Methanol Recycled Crude Water ONP+Water Methanol Loss 7.91 Total Total Crude ONA Washing ONA 100 Water Water for Recycle Total Total Crude ONP+Water Sulphuric Acid ONP 3.41 By product Recovery through Evoporation Salt for disposal Evaporated Water will be used for Cooling tower make up Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 74

90 V) FLOURINATION PROCESS PFNB Manufacturing Process: PCNB reacts with KF in the presence of Sulfolane and catalyst to give PFNB and KCL. Chemical Reaction: N O 2 N O 2 + K F + K C l C l F Material Balance: Input Output pcnb Loss Rec pcnb 36.4 KF Recovered sulfolane Fluorination Sulfolane Reaction mass Rec Sulfolane PEG Total Total Reaction mass Reaction mass MCB 2.84 Filtration ML for MCB recovery Rec MCB Salted cake Total Total PFNB 10.9 Loss Distillation Reaction mass PCNB Recycle Sulfolane Recycle 1.51 Residue Total Total ML for MCB re Rec MDC Distillation 6.63 Residue 1.2 Loss Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 75

91 DFNB Charge DMSO followed by dried KF and Chloro Fluoro Nitrobenzene in the reactor to form DFNB and by product KCl. Chemical Reaction: NO 2 NO 2 Cl F + KF DMSO F F + KCl Material Balance: Input Output 2,4-DCNB Loss KF Recovered Sulfolane DCNB Recycle 9.39 Mono Recycle Fluorination Rec Sulfolane Reaction Mass PEG Total Total Reaction Mass Reaction Mass Fresh Sulfolane Filtration Rec Sulfolane Salted cake Total Total Loss Reaction Mass DFNB Mono Recycle Distillation 9.39 DCNB Recycle 177 Sulfolane Recycle Residue Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 76

92 VI) NITRO CHLORINATION PROCESS: 2, 6 DI CHLORO FLORO BENZENE Manufacturing Process: Chlorination of 2, 6 fluoro chloro benzene give us 2, 6 dichloro fluoro benzene and No2 is also generated. Chemical Reaction: NO 2 F Material Balance: INPUT KG KG OUTPUT 2,3,FCNB NO 2 gas Recovered 2,3,FCNB Chlorination Disstilled 1 st Cut Chlorine Disstilled 2 nd Cut Total Total Cl + 1/2Cl 2 + Cl F Cl NO Disstilled 1 st st Cut Cut nd Cut Distilation Disstilled Recovered 2 nd Cut ,3 FCNB Total Total Water %Soda 1.8 Washing 1 st Cut Washing Water 2 nd Cut ,6 DCFB Total Total Sulphuric ac NSA Scrubbe r No Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 77

93 2, 6 DC BENZO NITRILE Manufacturing Process: Chlorination of 2 Chloro, 6 Nitro Benzo Nitrile give us 2, 3 Di chloro Benzo Nitrile and No 2 is also generated. Chemical Reaction: N O 2 C l C N C N + 1 /2 C l 2 + N O 2 C l C l Material Balance: INPUT KG KG OUTPUT 2,6-CNBn Chlorination NO 2 gas Chlorine gas Reaction mass Total Total Fresh MCB Reaction Mass Recovered MCB Dumping Ammonia 25% loss Reaction mass Total Total Recovered MCB for Wet Cake-1 washing Filter ML for MCB Reaction Mass recovery 5.93 Loss Total Total Wet Cake Dry Cake -1 Drying 9.08 Loss Total Total 0.18 Loss ML for MCB MCB Recovery recovery Recover MCB Residue Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 78

94 Recovered MCB for washing Wet Cake -2 Filteration 3.64 Loss ML for MCB Residue recovery Total Total Wet Cake Dry Cake -2 Drying 0.1 Loss Total Total 0.23 loss ML for MCB MCB Recovery recovery Recover MCB Residue Total Total 1.93 Wet Cake -3 Recovered MCB for Filteration washing Loss ML for MCB Residue recovery Total Total Wet Cake Dry Cake -3 Drying Loss Total Total 0.15 loss ML for MCB MCB Recovery recovery Recover MCB Residue Total Total Sulphuric acid NSA Scrubber No Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 79

95 DI CHLORO DI FLORO BENZENE Manufacturing Process: Chlorination of Di fluoro Chloro nitrobenzene gives Di Chloro, Di fluoro Benzene. Chemical Reaction: NO 2 F + 1/2 Cl F Cl 2 (gas) Cl Cl F F + NO Material Balance: INPUT KG KG OUTPUT DFCNB asis Chlorination NO 2 gas Distilled aqueous spent to ETP Distilled organic layer Chlorine Residue Total Total Water for washing Effluent to ETP Caustic lye 2.08 Washing Organic layer Distilled organic layer Total Total 0.92 loss Distilled pure Distilation Organic layer DFDCB 1.52 Residue Total Total Sulphuric acid NSA Scrubbe r No Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 80

96 VII) AMMONIATION PROCESS DCONA Manufacturing Process: Trichloro Nitro Chloro Benzene, recycled liquor Ammonia & anhydrous Ammonia are taken together in an autoclave for manufacturing of Di Chloro Ortho Nitro Aniline. Desired temperature and pressure maintain are 15 to 16 hours to complete then reaction. When reaction is over &excess of Ammonia is blown off through vent valve and scrubber in water to from 32% w/w Ammonia solution. Chemical Reaction: NO2 Cl NO2 NH2 Cl Cl Cl + 2 NH3 Cl + NH4Cl 2, 3, 4 Tri Chloro Nitro Benzene (TCNB) M. W , 3 Di Chloro Ortho Nitro Aniline (DCONA) M.W.207 Material Balance: Input Kg Output Kg 2,3,4 Tri Chloro Nitro Ben OCPNA -product 100 Anhydrous Ammonia 16.7 MCB Recovery MCB Recovery AUTOCLAVE MCB Loss 5.8 MCB 5.8 Water 73 Aqueous Layer Total Total Aqueous Layer Lime(purity 80%) 25 Treatment and FILTRATION Solid waste(to TSDF 11.5 Calcium Chloride soln(23-25%)(sales By Product) Ammonia connected to scrubber 0.5 Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 81

97 ORTHO NITRO ANILINE /PARA NITRO ANILINE Manufacturing Process: Para Nitro Chloro Benzene, recycled liquor Ammonia & anhydrous Ammonia are taken together in an autoclave for manufacturing of Para Nitro Aniline. Desired temperature and pressure maintain are 15 to 16 hours to complete then reaction. When reaction is over &excess of Ammonia is blown off through vent valve and scrubber in water to from 32% w/w Ammonia solution. Chemical Reaction: Material Balance: Input Kg Output Kg ONCB/ PNCB AUTOCLAVE ONA/PNA -product 100 Anhydrous Ammonia 12.7 Ammonia solution % Ammonia Solution Aqueous Layer Total Total Ammonia solution Autoclave Ammonia 5 14% Ammonia solution Scrubber 32% Ammonia solution (reuse in next batch) Total Total Aqueous Layer Treatment and FILTRATION Solid waste(to TSDF 19.9 Calcium Chloride soln(23-25%)(sales By Product) Lime(purity 80%) 37 Ammonia 12.3 Total Total Ammonia 12.3 Scrubber 2-5% Ammonia solution % Ammonia solution (reuse in autoclave scrubber) Total Total Ammonia 5 Secondary Water Scrubber 2-5% Ammonia solution (reuse in scrubber) Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 82

98 VIII) BROMINATION&DEAMINATION PROCESS 3, 4, 5 TRI FLUORO BROMO BENZENE Manufacturing Process: 1) Tri Fluoro aniline reacts with Sulphuric acid to form Tri Fluoro aniline sulphate. 2) Tri Fluoro aniline sulphate reacts with sodium nitrate to form dizo mass. 3) These dizo mass reacts with hydrogen bromide solution & cuprous bromide to form crude trifluorobromo benzene & dilute sulphuric acid. 4) After separation & distillation get pure Tri Fluoro Bromo benzene. Chemical Reaction: Step-1 (Bromination): Step-2 (Deamination): M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 83

99 Material Balance: Input Qty. Output Qty. 2,3,4 - TFA BROMINE H2O2 50% Bromination Reaction mass water BROMINE 1.49 NaHSO3 20% 1.20 Total Total Reaction mass HCl - 30% Spent acid to ETP water Org. layer Deamination MDC % H3PO NaNO Total Total Org. layer aq layer Water Washing org. layer % soda solution 7.46 Total Total Loss 6.72 org. layer Recovered MDC Distillation 3,4,5TFBrB 100 Residue 3.72 Total Total IX) SULPHONATION PROCESS 4B Acid Manufacturing Process: ODCB, PT is reacted with H2SO4 to form reaction mass. From reaction mass separate ODCB and Water. Recycle back ODCB into the reaction mass. After completion of Reaction; no more water will be observed. Then cool and filtered. Dry the wet cake to get 4B Acid. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 84

100 Chemical Reaction: C H 3 C H 3 + H 2 S O 4 (9 8 % ) H E A T C SO 3 H + H 2 O N H 2 p -T o lu id in e N H 2 4 -a m in o to lu e n e -3 -s u lp h o n ic a c id (4 B a c id ) Material Balance: Input Kg Output Kg ParaToludiene 60.5 Sulphuric Acid 59.3 Reaction mass Sulphonation ODCB 43.1 Rec.ODCB Rec Water Total Total Reaction mass ODCB Rec Water ML to ETP Water 60.5 Filtration Wet Cake Total Total Loss 11.8 Drying Wet Cake B Acid 100 Total Total X) ALKYLATION PROCESS METHYL ETHYL ANILINE Manufacturing Process: The ortho Toluidine is reacted with ethylene in the presence of aluminium and aluminium chloride. Reaction is followed by catalyst filtration, distillation of excess Toluidine. Crude product is than subjected to Flash Distillation to get the pure product. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 85

101 Chemical Reaction: A lc l3 + 3 H 2O A l(o H )3 + 3 H C l ( ) (5 4 ) (7 8 ) ( ) A l 2 7 ) + 3 H 2O A l(o H )3 + (54) (78) 3 /2 H 2 (3 ) 2 A l(o H )3 A l2o H 2O (156) (102) (54) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 86

102 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 87

103 Material Balance: Input Kg Output Kg Fresh OT Recovered OT CATALYST H Al 1.65 PREPARATION Reaction mass AlCl TOTAL TOTAL Reaction mass ETHYLATION Ethylene Vent to flare CH 2 =CH Reaction mass TOTAL TOTAL Water 4.14 H HYDROLISIS Reaction mass Reaction mass TOTAL TOTAL Reaction mass OT+MEA+MBA FILTRATION Reaction mass TOTAL TOTAL Reaction mass Al(OH) 3 to furnace 5.98 MeOH fresh 3.45 FILTRATION Reaction mass MeOH recovered TOTAL TOTAL MeOH recovered MeOH loss 3.38 DISTILLATION Reaction mass HCl to scrubber 1.69 MEA 5 TOTAL TOTAL MEA 5 OT 1.65 DISTILLATION OT+MEA+MBA MEA+MBA TOTAL TOTAL MEA+ MBA MEA 100 DISTILLATION 1 MBA 2.6 TOTAL TOTAL Water % HCl 5.56 HCl Scrubber HCl 1.69 HCl loss 0.01 TOTAL 5.57 TOTAL 5.57 Al(OH) Al 2 O FURNACE H 2 O 2.07 Total 5.98 Total 5.98 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 88

104 XI) DEHALOGENATION PROCESS 1, 3 DIFLORO BENZENE (1, 3 DFB) Manufacturing Process: Here Di Fluoro Chloro benzene is reacted in an autoclave reactor with hydrogen gas in presence of metal powder catalyst to produce di fluoro benzene. The reaction mixture contains solvent. The reaction is followed by catalyst filtration, solvent recovery, and layer separation and drying. Crude product is then subjected to flash distillation to get the pure product. Product is either sold as liquid or flakes depending on the market requirement. Chemical Reaction: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 89

105 Material Balance: Input Kg Output Kg Di Flouro Chloro Benzene 135 Fresh Triethyl amine 5 H 2 Loss 0.4 Recovered Triethyl Hydogenation Amine 103 Reaction Mass Water Catalyst 0.18 Hydrogen 2.7 Total Total Reaction Mass Filtration Catalyst for recovery 0.35 Crude DFB Total Total Crude DFB Crude TEA Acidification HCl 30 % 22 Crude DFA Total Total Crude TEA TEA loss 5 Caustic flakes 45 Laye sepration TEA for recycle 103 Wate to ETP Total Total Crude DFA Pure DFA 100 Distillation Residue 0.93 Total Total XII) CONDENSATION PROCESS DNDPE Manufacturing Process: PNCB and PNA react in the presence of catalyst to form Reaction Mass. After filtration and Distillation of Reaction mass we can get DNDPE. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 90

106 Chemical Reaction: N0 2 Cl + Na0 N0 2 N0 2 0 N0 2 + NaCl Material Balance: Input Kg Output Kg PNCB 67.3 PNP Na 84.4 Reaction mass Solvent 14.7 Condensation Water layer Rec Solvent Catalyst 4.2 Rec Solvent 97.8 Total Total Reaction mass SALT Solvent 41 Filteration Organic layer Total Total Organic layer Rec Solvent Distillation Reaction Mass Total Total Reaction Mass ML Filteration Water 20.5 DNDPE 100 Total Total XIII) Cyclization Process DAPBI (Di amino phenyl Benzimidazole) Manufacturing Process: Charge water 98% H2SO4 and TABA (Triamino benzamide) in reactor. Heat the reaction mass up to C and maintain for 2 hrs. Cool the reaction mass up to RT. Filter the reaction mass in centrifuge and send to drying to get final DAPBI (Di amino phenyl Benzimidazole) Chemical Reaction: C 13 H 14 N 4 O+H 2 SO 4 +H 2 O C 13 H 18 N 4 SO 6 +H 2 O+H 2 SO 4 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 91

107 Input Kg Output Kg Rec.Methanol EIA REPORT 25 OF M/S. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Methanol 12 Reaction Mass Esterification PTBBA % H2SO4 Material Balance: 3 Total Input Kg Total Output Kg TABA 154 Reaction Mass Separation Reaction Reaction Mass % H2SO4 66 CYCLIZATION Mass 445 Spent acid 9.6 Total Water Total Total 445 Total 445 Reaction Mass 445 Spent acid 210 Centrifugation DAPBI Wet Cake 235 Total 445 Total 445 Water loss 10 DAPBI Wet Cake 235 Drying DAPBI Dry 225 Total 235 Total 235 XIV) ESTERIFICATION Ester Manufacturing Process: Charge Methanol kg, PTBBA kg and 98 % H2SO4 3 kg. Heat the reaction mass up to C and maintain for 1 Hrs. Then cool the reaction mass at RT and separate out H2SO4 from bottom. Chemical Reaction: C 11 H 14 O 2 +CH 3 OH+H 2 O H 2SO 4 C 12 H 16 N 4 SO 6 +H 2 O+H 2 SO 4 Material Balance: Input Kg Output Kg Rec.Methanol 35 Methanol 2 Reaction Mass Esterification PTBBA % H2SO4 3 Total Total Reaction Mass Separation Reaction Mass Spent acid 9.6 Total Total Reaction Mass Product 58 Loss 0.85 Distillation Rec.Methanol 35 Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 92

108 XV) DIAZOTISATION PROCESS 2, 3/2, 5 DCP (DI CHLORO PHENOL) Manufacturing Process: 1) Di Chloro aniline reacts with sulphuric acid to for Di chloro aniline sulphate. 2) Di Chloro aniline sulphate reacts with mix acid to for dizo mass. 3) Dizo mass reacts with dilute sulphuric acid to form crude Di Chloro phenol. In 4) These reaction N2 gas evolved & spent acid generate. 5) Crude Di Chloro phenol separate out & distilled to get pure di chloro phenol. Chemical Reaction: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 93

109 Material Balance: Input Qty. Output Qty. 25DCA NSA Diazotization Reaction mass H2SO Reaction mass Spent acid Decomposition Aq Layer water Org. layer Org. layer % NaHCO3 solution 7.62 Washing Org. layer org. layer Water Distillation 2,5-DCP 100 Residue 1.69 Total Total XVI) ACETYLATION & HYDROLYSIS PROCESS META NITRO PARA ANISIDINE: Manufacturing Process: Conversion of Para Anisidine to Meta Nitro Para Anisidine is carried out in unit process namely Acetylation, Nitration, Hydrolysis. In Acetylation Para Anisidine is acetylated with Acetic acid + Acetic Anhydride to obtain acetylated Para Anisidine. Acetic acid is recovered after reaction completion. The Nitration of acetylated Para Anisidine is done with Nitric acid & Sodium bi sulphite as catalyst. The nitro body thus obtained is hydrolyzed with caustic soda to get the hydro body, which contains Meta nitro Para Anisidine. This hydro body is filtrate in nutch filter & caustic spent is taken out as a filtrate &filtrate is taken for further treatment. The wet cake Meta nitro Para Anisidine is then dried, blended, pulverized and packed in drums and bags for dispatch. The caustic spent taken out from filter of hydro body as a filtrate taken for neutralization. It is neutralized with recovered Acetic acid from acetylation. Then carbon treatment is given to this and then followed evaporation in another vessel. After completion of evaporation the liquid mass M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 94

110 called as liquid sodium acetate can be dispatch able or make cool and centrifuge it. This solid sodium acetate is a by-product. Chemical Reaction: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 95

111 Material Balance: Input Kg Output Kg Para Anisidine 90 Acetic Anhydride 81 Reaction mass Hydrogen 0.18 Acetylation Acetic Acid MDC 22.5 Rec MDC 85.5 Total Total Reaction mass Nitric Acid 162 Reaction mass Nitration Rec MDC 342 Sodium Nitrate 0.18 Total Total Reaction mass Layer Seperation Nitro Mass MDC Layer 450 Total Total Nitro Mass Nitro Mass Washing Water 810 Water for ETP Total 1100 Total 1100 Nitro Mass Reaction Mass 127 Water 567 Aqueous layer for Hydrolysis Sodium Acetate and washing Recovery Caustic 36 Total Total Reaction Mass 127 MNPA Wet 108 Water 135 Centrifuge Wash Water to ETP Total 262 Total 262 MNPA 100 MNPA Wet 108 Drying loss 8 Total 108 Total 108 Recovered MDC MDC Layer 450 MDC MDC Loss 22.5 Water 135 Recovery Wash Water to ETP 135 Total 585 Total 585 Sodium Acetate 99.9 Sodium Aqueous layer for Acetate Sodium Acetate Water to ETP Recovery Recovery Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 96

112 META NITRO PARA TOLUDIENE: Process Description: Conversion of Para Toluidine to Meta Nitro Para Toluidine is carried out in unit process namely Acetylation, Nitration, Hydrolysis. In Acetylation Para Toluidine is acetylated with Acetic acid + Acetic Anhydride to obtain acetylated Para Toluidine. Acetic acid is recovered after reaction completion. The Nitration of acetylated Para Toluidine is done with Nitric acid & Sodium bi sulphite as catalyst. The nitro body thus obtained is hydrolyzed with caustic soda to get the hydro body. Which contains Meta nitro Para Toluidine, This hydro body is filtrate in nutch filter &caustic spent is taken out as a filtrate & filtrate is taken for further treatment. The wet cake Meta nitro Para Toluidine is then dried, blended, pulverized and packed in drums and bags for dispatch. The caustic spent taken out from filter of hydro body as a filtrate taken for neutralization. It is neutralized with recovered Acetic acid from acetylation. Then carbon treatment is given to this and then followed evaporation in another vessel. After completion of evaporation the liquid mass called as liquid sodium acetate can be despatch able or make cool and centrifuge it. This solid sodium acetate is a by-product. Chemical Reaction: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 97

113 Material Balance: Input Kg Output Kg ParaToludiene Acetic Anhydride Acetylation Reaction mass Hydro 0.17 Acetic Acid Total Total Reaction mass Nitric Acid 113 Recovered MDC Nitration Reaction mass MDC Sodium Nitrate Total Total Nitro Mass Layer Seperation Reaction mass MDC Layer 435 Total Total Nitro Mass Nitro Mass Washing Water 609 Water for ETP Total Total Nitro Mass Reaction Mass Water Aqueous layer for Hydrolysis and Sodium Acetate washing Recovery Caustic 34.8 Total 1097 Total 1097 Reaction Mass 153 MNPT wet Centrifuge Water 174 Wash Water to ETP Total 327 Total 327 MNPT 100 Drying MNPT wet Water loss 9.09 Total Total Recovered MDC MDC Layer 435 MDC Recovery MDC Loss Water Wash Water to ETP Total Total Sodium Acetate Aqueous layer for Sodium Acetate Recovery Sodium Acetate Recovery Water to ETP Total Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 98

114 2.5 MANAGEMENT PLAN FOR BY-PRODUCTS MANAGEMENT PLAN FOR HYDROCHLORIC ACID (30%): Hydrochloric acid is generated as By-product from chlorination process. The total quantity generated is MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-A MANAGEMENT PLAN FOR SPENT SULPHURIC ACID: Spent acid is generated as by-product from Bromination, Nitration, Cyclization and Diazotisation process. The total quantity generated is MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-B MANAGEMENT PLAN FOR ALUMINIUM OXIDE (Al2O3) : Aluminium oxide is generated as by-product from Alkylation process. Aluminium oxide is separate from filtration system. The total quantity generated is 0.20 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as annexure XI-C MANAGEMENT PLAN FOR SODIUM CHLORIDE (NaCl): Sodium chloride is generated as by-product from Nitro Anisoles, Acetylation & Hydrolysis process. The total quantity generated is 7.52 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-D MANAGEMENT PLAN FOR ORTHO NITRO PHENOL (ONP): Ortho nitro phenol is generated as by-product from Nitro Anisoles process. Crude ONP with water is generated from distillation column after ONP recovered from evaporation system with the help of sulphuric acid. The total quantity generated is 0.2 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-E MANAGEMENT PLAN FOR CALCIUM CHLORIDE SOLUTION (CaCl2) : Calcium chloride is generated as by-product from ammoniation process. Calcium chloride is maximum generated from PNA/ONA product. The total quantity generated is 7.43 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-G MANAGEMENT PLAN FOR POTASSIUM CHLORIDE (KCl): Potassium Chloride is generated as by-product from fluorination & de nitro chlorination process. The total quantity generated is 16.2 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-H. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 99

115 2.5.8 MANAGEMENT PLAN FOR ACETIC ACID (CH3COOH) Acetic acid is generated as by-product from Acetylation & Hydrolysis process. Acetic acid is maximum generated from MNPT product. The total quantity generated is 2.44 MT/Month and sold to actual end users having rule 9 permission. MOU with end users are attached as Annexure XI-G. 2.6 DETAILS OF SOLVENT RECOVERY SYSTEM A solvent like MCB, MeOH, N, N-DIMETHYLFORMAMIDE, ACITO NITRILE, MIBK, and THF is used in the process SOLVENT MONO CHLORO BENZENE RECOVERY FROM PLANT Mono Chloro Benzene (MCB) is the solvent to be used in the process. Solvent is recovered completely under condenser from vacuum Distillation Column. Solvent recovery plant is designed to recover the solvent from the process. The unit will be using solvent mono chloro benzene. It will be steam distilled during the process. The MCB will come along with water. It will be collected in receiver and used in next batch. Plant will work efficiently with approx 96 to 98 % recovery. There will be no escape of solvent or VOC in the atmosphere. Diagram for MCB recovery system is shown in Figure 2.1. FIGURE: 2.1 FLOW DIAGRAM OF MCB & METHANOL RECOVERY SYSTEM M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 100

116 2.6.2 SOLVENT METHANOL RECOVERY FROM PLANT Methanol is the solvent to be used in the Esterification process. Methanol is recovered completely under simple distillation column. Solvent recovery plant is designed to recover the methanol from the mother liquor. Plant will work efficiently with above 95 % recovery. Recovered methanol will be reused in next batch. There will no loss in the atmosphere. The 1 to 2 % solvent remains with waste water and finds its way in the effluent. Diagram for Methanol recovery system is shown in Figure SOLVENT N, N-DIMETHYLFORMAMIDE, SULFOLANE, ACITO NITRILE, MDC and THF RECOVERY FROM PLANT N, N-Dimethyl formamide, Sulfolane, Aceto nitrile, MIBK and THF is the solvent to be used in the hydrogenation/reduction and condensation process. Solvent is charged from storage tank to autoclave at starting of batch. After the reaction is complete, crude product along with solvent is passed through Agitated Nutch Filter for separating solvent. Separated solvent is distilled. There are two H.E. in series to cool down the solvent vapours. Hence, recovery of solvent above 97% and remaining 3% going with residue. Stream ejector is used for creating vacuum & all the volatile vapours if any is getting condense with the water. Over a period of time solvent is condensed and reused. Thus, there is no escape of VOC. Diagram for solvent recovery system is shown in Figure 2.2. FIGURE: 2.2 FLOW DIAGRAM OF SOLVENT RECOVERY SYSTEM Solvent Storage Tank/Drum Day Tank Vessel Reactor ANF/ Centrifuge Vessel (Mixed) Solvent Receiver Distillation Vessel (DH-01) Residue + Loss M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 101

117 TABLE: 2.7 DETAILS OF SOLVENTS TO BE USED AND RECOVERED Sr. No. Name of Product Name of Solvent Total Quantity of solvent in MT/Month Quantity of solvent recovered in MT/Month % Recovery M- O & Para Chloro Aniline AND/OR 3,4-2,3-2,5 Dichloro Aniline AND/OR 3,4 & 4,4 Diamino Diphenyl Ether AND/OR Para Fluoro Nitro Benzene AND/OR Methyl Ethyl Aniline AND/OR Di Nitro Di Phenyl Ether AND/OR Mono Chloro Benzene Mono Chloro Benzene Mono Chloro Benzene Mono Chloro Benzene Methanol N,N-Dimethyl formamide Ester AND/OR Methanol Meta Nitro Para Anisidine AND/OR Meta Nitro Para Toluidine AND/OR Methylene Dichloride Methylene Dichloride M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 102

118 2.7 RESOURCE REQUIREMENT INFRASTRUCTURE FACILITIES (LAND) Expansion will be carried out at existing plot no. 609/610, 100 Shed Area, GIDC Estate, Vapi , Dist.: Valsad, Gujarat. Letter of plot allotment from GIDC of industrial plot no. 609/610, 100 Shed Area is attached as Annexure IV. The total plot area of the unit is 1752 sq. m. The green belt area is 183 sq. meter. Layout plan of the factory premises clearly demarcating various units within the plant. Provision of separate entry & exit and adequate margin all-round the periphery for unobstructed easy movement of the emergency vehicle / fire tenders without reversing back. Mark the same in the plant layout. The proposed plant layout is attached as Annexure - VII. The photographs of existing plant area are attached as Annexure - VIII. Details of breakup of plot area are covered under following Table 2.7. Expansion is carried out at plot no. 609/610, 100 Shed Area and there will be no proposed plant constructed and only addition new machinery will be installed. TABLE: 2.8 LAND USE BREAK UP OF TOTAL PLOT AREA Sr. No. Particular Land Area in sq.m. Land Area in % 1. Pilot plant Pilot plant Pilot plant -3 (Proposed) Utility area Cooling Tower (Chilling plant) Instrument & Compressed air area 7 Panel room & AHU area Office, Lunch room & security area 10 ETP Area Warehouse Raw material, Packing store & Finish Good store 13 Blower & DG area Laboratory area Work shop area Fire water storage tank Passage 17 Green Belt area (1 to 4) Open area Total 1752 sq. meter 100 % M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 103

119 2.7.2 DETAILS OF FUEL AND ELECTRICITY CONSUMPTION The energy requirement in terms of power and fuel for proposed unit is shown in following Table 2.9. TABLE: 2.9 FUEL CONSUMPTION & ELECTICITY CONSUMPTION Sr. Name Requirement Source No. Existing Proposed Total FUEL CONSUMPTION 1. Diesel* 0 75 Lit/Hr 75 Lit/Hr Local Market 2. Natural Gas SCM/hr 894 SCM/hr GSPC ELECTRICITY CONSUMPTION 1. Electricity 125 KVA 125 KVA 250 KVA DGVCL Note: Diesel for DG Sets DETAILS OF ENERGY DISTRIBUTION/UTILISATION Details of energy distribution are given in below Table TABLE: 2.10 ENERGY DISTRIBUTION Sr. No. Name of Equipment Existing Connected Energy in KVA Proposed Connected Energy Total Connected Energy in KVA in KVA 1. Reactors and other equipments 2. Boiler Thermo pack Compressors ETP Domestic Total 125 KVA 125 KVA 250 KVA DETAILS OF EQUIPMENTS/MACHINERIES WITH UTILITIES Details of existing & proposed equipment s are given in below Table 2.11-A & 2.11-B. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 104

120 TABLE: 2.11-A LIST OF EXISTING EQUIPMENTS Sr. Capacity Size Quantity Name of the equipment MOC No. KL Dia. Height in No. 1. R -104 Autoclave SS316 D x H R -203 Reactor SS316 D x H R-106 Reactor SS316 D x H R-102 Reactor SS316 D x H R-101 Reactor MSGLR D x H CF-102 Centrifuge 15 kg SS CF103 Centrifuge 15 kg SS CF-201 Centrifuge 50 kg MSRL RVD-101 Dryer SS316 D x 280 H CT TR PPFRP L-2000 x 2000 x 1200 H R-211 Reactor MSGLR D x H R-210 Autoclave SS316 D x H R-205 Reactor 2 SS316 D x H R-204 Reactor 1.5 SS316 D x H R-212 Reactor SS316 D x H 01 TABLE: 2.11-B LIST OF PROPOSED EQUIPMENTS Sr. Capacity Size Quantity Name of the equipment MOC No. KL Dia. ht. in mm in No. 1. R-202 Autoclave 0.02 SS316 D x H R-206 Reactor 6 PPFRP D x H R-207 Reactor 6 HDPE D x H R-208 Reactor 0.25 MSGLR D x H R-209 Distillation Column SS316 D x H R-216 Reactor MSPTFE D x H R-218 Autoclave 0.02 SS316 D x H V Receiver 8 m3 MS 2000x2000x V Receiver 0.6 MS D - 800x H V Receiver 0.100L MS D x H V Receiver 1.6 MS D x H V Receiver 0.125L MS D x H V Receiver 1.4 MS D x H CH-501 Chilling plant 30 TR MS L-2000xB-2000x HE Condenser 5 m3 MS D x H 01 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 105

121 2.7.5 MAN POWER The manpower required for the proposed project as well as during the construction/ commissioning activities will be employed from the local area. Details of existing and proposed man power requirement are given in below Table TABLE: 2.12 MAN POWER REQUIREMENT Phase of project During construction During commissioning During operations Type of No. of workers No. of workers No. of workers worker (Existing) (Proposed Scenario) (Total) Contractual Contractual Managerial Skilled Un-skilled Total WATER REQUIREMENT Water is used primarily for processing, washing, boiler, cooling, gardening and domestic purpose. The existing fresh water requirement for domestic and industrial purpose is met through GIDC water supply. GIDC has its own water reservoir and distribution network throughout the GIDC Estate. As per CCA order no.: AWH-73091, average daily fresh water consumption of the unit is 18 KL/day. Now, proposed average daily total fresh water consumption of the unit will be 43 KL/day. A letter from GIDC stating that the proposed additional quantity of water will be provided is attached as Annexure-IX. Stream wise bifurcation of water consumption is given in Table 2.13 and existing and proposed water balance diagram are given in Figure 2.4 & 2.5. TABLE: 2.13 DETAILS OF WATER CONSUMPTION Sr. Section Water Consumption KL/Day No. Existing Proposed Total after Expansion A Domestic B Gardening C Industrial Process Washing Boiler Cooling Total (B+C) Total (A+B+C) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 106

122 FIGURE: 2.3 EXISTING WATER BALANCE DIAGRAM G.I.D.C (18 KL/day) PROCESS 4 KL/day GARDENING 3 KL/day COOLING 3 KL/day BOILER 5 KL/day DOMESTIC 3 KL/day TO ETP 3 KL/day BLOW DOWN 0.5 KL/day BLOW DOWN 1 KL/day SOAKPIT 2 KL/day FIGURE: 2.4 PROPOSED WATER BALANCE DIAGRAM E.T.P 6.5 KL/day C.E.T.P FRESH WATER CONSUMPTION 43 KLD GARDENING 5 KLD PROCESS+ SCRUBBER 9 KLD COOLING 6 KLD BOILER 15 KLD WASHING 3 KLD DOMESTIC 5 KLD Drying loss 1.15 KLD 30% HCl generated from Scrubber 0.35 KLD Effluent to ETP 7.5 KLD Blow-down 2 KLD Blow-down 2 KLD To ETP 3 KLD Soak Pit 4 KLD Effluent Treatment Plant 18.5 KL/day Overflow Treated effluent will be sent to C.E.T.P. of M/s. Vapi Green Enviro Ltd. for further treatment & for final disposal 18.5 KL/Day M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 107

123 2.8 POLLUTION POTENTIAL SCENARIO The details of pollution generation in terms of effluent generation, sewage generation, flue gas emission, process emission and hazardous waste generation are covered in this section DETAILS OF WASTE WATER GENERATION As per CCA order no.: AWH-73091, the effluent generation is 6.5 KL/Day. After proposed expansion, total effluent generation will be 18.5 KL/Day (Existing: 6.5 KL/Day + Proposed: 12 KL/Day). Total 18.5 KL/Day of sewage & industrial effluent generated will be treated in ETP. The final treated effluent will be discharged to C.E.T.P. of M/s. Vapi Green Enviro Ltd. for further treatment. Permission letter is attached as Annexure-X. The details of waste water generation are given in below Table TABLE: 2.14 DETAILS OF WASTE WATER GENERATION Waste Water Generation in KL/Day Sr. Section Existing As Per CCA As Per Proposed No. Total No. : AWH Expansion 1. Domestic Industrial 2.1 Process Washing Boiler Cooling Total (Industrial) Total (Domestic + Industrial) Note: Our group company M/s. Aarti Industries Limited (Alchemie Organic Division) having discharge of 90 KLD and M/s. Aarti Industries Limited (Amine Division) having discharge of 55 KLD are in the process of achieving zero liquid discharge, already an EC is granted which will reduce the load of CETP SEGREGATION OF WASTE STREAMS: QUALITATIVE AND QUANTITATIVE ANALYSIS: The details of waste water generation and qualitative and quantitative analysis of each waste stream are given in following Table no M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 108

124 TABLE: 2.15 QUALITATIVE AND QUANTITATIVE ANALYSIS OF EACH WASTE STREAM BASED ON WORST CASE SCENARIO Sr. No. Source of Waste Water Generation Quantity in KL/Day Quality Final load at ETP in Kg/day 1. Boiler blow down 2 ph: TSS: mg/l 0.2 COD: mg/l 0.2 TDS: mg/l 5 2. Cooling Tower blow down 2 ph: TSS: mg/l 0.2 COD: mg/l 0.4 TDS: mg/l 5 3. Washing 3 ph: TSS: mg/l 0.75 COD: mg/l 0.75 TDS: mg/l Process 7.5 ph: TSS: mg/l 1.5 COD: mg/l 3.75 TDS: mg/l Domestic waste water 4 ph: TSS: mg/l 2.0 COD: mg/l 3.6 TDS: mg/l 6.0 TOTAL 18.5 Effluent treatment plant has been designed considering following parameters or characteristics of wastewater before treatment & after treatment are given in Table TABLE: 2.16 CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT Sr. No Parameters Units Before Treatment After Treatment Inlet norm of CETP 1 ph Total Suspended Solids mg/l < Ammonical Nitrogen mg/l <10 <50 4 B.O.D. 3 days at 27 C mg/l < C.O.D. mg/l < M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 109

125 2.8.3 PROPOSED EFFLUENT TREATMENT PLANT PROCESS: The waste water from process, washing, cooling, steam condensates, floor washing, etc. is coming through drain line from plant to the oil and grease traps. Here oil and grease is trapped floating on the water, which is to be removed manually. Through this trap, water flows to neutralization cum primary settling tank. Here all different quality water ph is adjusted to 7.5. In this tank an agitation is provided by stirrer. Sulphuric acid, caustic lye, hydrated lime, alum and polyelectrolyte or the chemicals used in the primary treatment. Neutral water from this tank is settled out and clear effluent overflows to collection tank. The settled sludge from bottom of the settling tank will be taken in sludge drying bed where the sludge is dried. The dry sludge is packed in plastic bags and stored in storage area. Collected effluent of collection tank is continuously feeded to the aeration tank. Aeration tank contains huge qty. of biomass and a diffuser system to provide sufficient oxygen required for biodegradation of the organic matters. Water treated in this aeration tank then continuously flows to secondary setting tank, where the bio sludge settles at the bottom. Thick slurry of this bio-sludge from the bottom tank is pump backed to aeration tank to maintain MLSS. If it is an excess then it is transferred to sludge drying beds. Overflow of effluent from the secondary settling tank to collection tank by gravity. Collected effluent of collection tank is taken to high pressure sand filter where filter the effluent after that effluent is taken to carbon column. Where reduce the colour and decrease the COD value. All the unit operation will have primary effluent treatment plant facility mainly phantom treatment to achieve less than 5000 COD. A general facility of Hydro cavitation will be also be installed. The final treated effluent will be discharged to GIDC underground drainage system, which will be ultimately disposed to CETP for further treatment. Details of Existing and Proposed ETP equipment are given in Table TABLE: 2.17 EXISTING EQUIPMENT LIST OF EFFLUENT TREATMENT PLANT Sr. No. Particular Existing Capacity in M 3 Proposed Capacity in KL 1. Oil & Grease Trap Neutralization cum settling tank Equalization Tank Filter press Collection Tank Aeration Tank Secondary Settling Tank 5 15 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 110

126 6. Collection Tank Sand Filter Carbon Column Lime Preparation Tank Sludge Drying Bed FIGURE 2.5 PROPOSED FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT Inlet of Process & Washing water water Oil & Grease Trap (11 KL) Dosing Neutralizer cum settling Tank (6.6 KL) Inlet of CT & Boiler Blow Down Collection Tank No: 1 (3 KL) Equalization Tank (15 KL) Filter Press Sludge To TSDF site Aeration Tank (40 KL) Settling Tank (15 KL) Collection Tank No: 2 (3.0 KL) Sand Filter (1.5 KL) Carbon Filter (0.5 KL) Treated effluent will be sent to C.E.T.P. of M/s. Vapi Green Enviro Ltd. for further treatment. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 111

127 2.8.4 GASEOUS EMISSION AND CONTROL The source of air pollution will be in a form of flue gas emission and process emission. To control the emission of pollutants from these sources stacks are installed of appropriate height and diameter FLUE GAS EMISSION The existing sources of flue gas emission are one Boiler. The unit will install additional one D.G. set due to proposed expansion. Details of stack height, fuel consumption, air pollution control system etc. are shown in below Table TABLE: 2.18 DETAILS OF FLUE GAS EMISSION Sr. No Stack attached to Stack Height APCM Fuel & Quantity Probable Pollutants Permissible Limit in meter Existing 1. Boiler (2TPH) 11 Adequate Natural Gas: SPM 150mg/Nm3 stack height 894 SCM /hr SOx 100 PPM Proposed NOx 50 PPM 2. DG Set 11 Adequate LDO (250 KVA) stack height (75 Lit/hr.) Note: DG sets will be run only in case of electricity failure PROCESS GAS EMISSION The process gas emissions from the existing and proposed manufacturing activities are given in the Table TABLE: 2.19 DETAILS OF PROCESS EMISSION Sr. No. Stack attached to Stack Height in meter APCM Proposed 1 Plant-1 11 m Water Scrubber followed by Alkali Scrubber Probable Pollutants HCl NO x Br 2 HBr Permissible Limit 20 mg/nm 3 25 mg/nm 3 09 mg/nm 3 20 mg/nm 3 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 112

128 2 Plant-2 11 m Water Scrubber followed by Alkali Scrubber 3 Plant-3 11 m Water Scrubber followed by Acidic Scrubber Cl2 09 mg/nm 3 HCl 20 mg/nm 3 NOX 25 mg/nm 3 Br2 09 mg/nm 3 HBr 20 mg/nm 3 Cl2 09 mg/nm 3 NH3 175 mg/nm 3 TABLE: 2.20 DETAILS OF OVERALL EMISSION ESTIMATE Sr. No. Gases Come out from process Vent Before Quantity in MT/MT APCM After Quantity with APCM in MT/MT As per GPCB Analysis Report 1. HCl, excess Cl 2, Br 2, HBr 0.60 Water Scrubber followed by Two Alkali Scrubber BDL 2 NH Two stage water BDL 3. NOX 0.54 scrubber by Acid Scrubber BDL BDL: Below Detectable Limit MANAGEMENT OF AIR ENVIRONMENT The possible sources of flue gas emission and process emission and fugitive emission are as under. TABLE: 2.21 DETAILS OF ALL EMISSIONS CONTROL MEASURES Sr. No. Source FLUE GAS EMISSION Probable Pollutant Emission Control Measures/ APCM 1. Boiler (Natural Gas) (2 TPH) 2. D.G. set (Diesel) (250KVA) Air polluant (SPM, SOX, NOX) Air polluant (SPM, SOX, NOX) Adequate stack height. Acoustic encloser, Engineering control, Provision of PPE, Green belt. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 113

129 Sr. Source No. PROCESS EMISSION Probable Pollutant Emission Control Measures/ APCM Plant - 1 Plant - 2 Air pollutant (HCl, NOX, Br2, HBr, NO 2, Cl 2) 3. Plant - 3 Air pollutant (NH 3) FUGITIVE EMISSION 1. Acid storage area Air pollutant (Acid fumes) 2. Solvent storage area Air pollutant (VOC) 3. Solvent recovery Air pollutant system (VOC) 4. Handling of raw Air pollutant material bags in (PM) storage area 5. Flange joints of Air pollutant pipeline, pump & (VOC) Water scrubber followed by alkali scrubber. Adequate stack height. Water scrubbers followed by acid scrubber Adequate stack height. Close handling system. Provision of exhaust ventilation. Carry out work place monitoring to find out concentration level in ambient air Carry out work place area monitoring to find out concentration level in ambient air. Connected with vent condensers with child brine circulation. Close handling system. Provision of breather valve cum flame arrester. Vaccum distillation. Close handling system. There will be recovery of more than % solvent. Provision of exhaust ventilation. Provision of PPE. Provision of Job rotation to reduce exposure. Routine & periodic inspection to M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 114

130 Sr. Source No. motors 6. Solid raw material transferring to reactor 7. Liquid raw material transferring to reactor 8. Gaseous raw material transferring to reactor 9. Loading /unloading at storage area Probable Pollutant Emission Air pollutant (PM) Air pollutant (VOC, Acid fumes) Air pollutant (VOC, gaseous fumes) Air pollutant (VOC) Control Measures/ APCM check leakage. Preventive maintenance, follow SOP for maintenance. Pumps & motors mechanical seal type. Leak Detection and Repair (LDAR) program is followed. Hopper is provided with powder transfer system. Feeding of liquid raw material is carried out by closed pipeline and mechanical seal pump. Transfer of gaseous raw material is carried out by closed pipeline. Unloading through pipeline to tank in a close system. Regular ambient air quality monitoring will be carried out within premises and nearby area for PM 10, PM 2.5, SO X, NO X, NH 3, HCl, Br 2, HB r, Cl 2 and VOC in the downwind directions as well as where maximum ground level concentration are anticipated and record of the same shall be maintained. Action plan for other control process & fugitive emissions following measures are recommended: A. Provision of mechanical seal in pumps. B. Regular inspection of tank roof seals & Drums. C. Adequate measures for the minimization/prevention of the fugitive emission. D. Regular maintenance of valves, pumps and other equipment to prevent leakage. E. Entire processes to be carried out in the closed reactors with proper maintenance of temperature. F. Regular periodic monitoring of work area to check the fugitive emission. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 115

131 G. Adequate stack heights as per the CPCB estimation will be provides at all locations to reduce GLCs of pollutants. H. Air Pollution Control System will be installed in the plant. Third party monitoring report is attached as Annexure XII DETAILS OF SCRUBBER 1. Scrubber system for Plant-1 & Plant-2 HCl, NO X, Br 2, HBr, NO 2 and Cl 2 are generated from Plant -1 reactor & Plant -2 rector through common line and send to the scrubbers are shown in the below diagram/figure 2.6. Water scrubber: Excess gases coming from plant-1 & 2 reactors through common line are scrubbed in primary water scrubber. Here most of Hydrogen chloride gas is scrubbed through recirculation of water and remaining un-reacted gas goes to primary lime water scrubber. Primary lime water scrubber: In lime water scrubbing system sucked un-reacted gases like nitric from water scrubbing system and gases is scrubbed through re-circulation of lime water solution and un-reacted gas goes to caustic scrubber. Secondary caustic scrubber: In caustic scrubbing system sucked all un-reacted gas from lime water scrubbing system and gases is scrubbed through re-circulation of spent caustic solution and remaining fresh air goes to environment. Details of scrubbing agent shown in below Table: 2.3. TABLE: 2.22 DETAILS OF SCRUBBING AGENTS FOR PLANT-1&2 WITH DIMENSION Sr. No. Name of Air Pollutant Water scrubber I. HCl, excess Cl 2 Caustic scrubber II. Excess Br 2, HBr Quantity of Air Pollutant MT/MT of product Name of Scrubbing Agent Quantity of Scrubbing Agent MT/MT of product Quantity of Scrubbed Product of MT/MT Name of Scrubbed Product 0.60 Water % HCl Solution -- Lime + water III. -- Caustic + water Lime water to ETP Caustic solution to ETP Scrubber Dimension Tank: 2 KL (Dia-1.53 X ht-1.05 mtr) Colum: Packed Colum (Dia- 0.6 X ht-5 mtr) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 116

132 FIGURE: 2.6 DIAGRAM OF SCRUBBER SYSTEM FOR PLANT-1 & PLANT-2 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 117

133 2. Scrubber system for Plant-3 Ammonia gas is generated from autoclave reactor & ONA day tank and rector through common line and send to the Primary scrubber and Secondary scrubber are shown in the below diagram/figure. Primary water scrubber: Un-reacted ammonia gas coming from plant-3 reactor is scrubbed in primary water scrubber. Here most of gas is scrubbed through re-circulation of water and unreacted gas goes to secondary water scrubber. Secondary water scrubber: Ammonia gas from plant intermediate vessels vent and un-reacted gas is scrubbed though re-circulated water and un-reacted gas goes to acid scrubber. Acid scrubber: In acid scrubbing system sucked all un-reacted gas from water scrubbing system and gas is scrubbed through re-circulation of spent acid solution and remaining fresh air goes to environment. The schematic diagram of the scrubbing system is shown in the below Figure 2.7. Details of scrubbing agent shown in below Table. TABLE: 2.22-B DETAILS OF SCRUBBING AGENTS FOR PLANT-3 WITH DIMENSION Sr. No. Name of Air Pollutant Quantity of Air Pollutant MT/MT of product Name of Agent Two stage water scrubber I. NH % NH3 solution Quantity of Scrubbed Product of MT/MT Name of Scrubbed Product 1.08 NH3 solution (14%) to autoclave scrubber II NH Water NH3 solution (5%) to I st Acid scrubber III. NO X 0.54 Dilute sulphuric acid scrubber 1.55 Spent sulphuric Acid Quantity of Scrubbed Product of MT/MT Scrubber Dimension Tank: 2 KL (Dia. 1.5 X ht 1.05 mtr) Colum: (Dia. 0.6 X ht 3 mtr) Tank: 2.2 KL (Dia. 0.5 X ht 3 mtr) Colum: Packed Colum M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 118

134 FIGURE: 2.7 DIAGRAM OF SCRUBBER SYSTEM FOR PLANT HAZARDOUS WASTE GENERATION The following type of hazardous waste will be generated from the operational activities. The collection, treatment and disposal of hazardous waste will be as per Hazardous waste (Management and Handling) Rules 2016, and hence no adverse impact on land environment is envisaged. It will be stored separately in dry & covered place with RCC plat form. There will be provision of separately storage in ETP area. Hazardous waste will be stored in proper storage room and handed over to authorized vendor for final disposal. Details of Hazardous Waste generation, storage and disposal facility are shown in Table TABLE: 2.23 DETAILS OF HAZARDOUS WASTE GENERATION Category Quantity in MT/Year Sr. Type of Treatment and as per No. hazardous waste Existing Proposed Total disposal 2016 Collection, Storage, transportation, 1. ETP Waste disposal at TSDF, Vapi. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 119

135 2. Distillation residue Discarded containers/bags Used oil Spent carbon Spent catalyst Hydrochloric Acid (30%) Spent Sulphuric Acid Acetic Acid (CH3COOH) Aluminium Oxide (Al2O3) Ortho Nitro A Collection, Storage, transportation, disposal at TSDF at RSPL, Panoli & GSPL, Palsana. Collection, Storage, Decontamination, transportation and sell it to authorized dealers. Collection, Storage, Transportation disposal by reuse in plant & machinery for lubricating purpose. Collection, Storage, transportation, sent for co-processing to RSPL, Panoli & GSPL, Palsana. Collection, Storage, transportation, sent to supplier or regenerator for regeneration. Collection, storage, Transportation and sale to authorized industry having permission under rule-9 of Hazardous & other wastes (Management & Transbouandry M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 120

136 Phenol (ONP) Sodium Chloride (NaCl) Calcium Chloride solution (CaCl2) Potassium Chloride (KCl) Ammonia Solution B A NON- HAZARDOUS WASTE GENERATION 15. Insulation Waste Movement) rule-2016 OR in-house treatment. Collection, storage and used back in process. Collection, Storage, tr ansportation, disposal at TSDF Site. Hazardous waste membership certificate from VWEMCL, GSPL & RSPL is attached as annexure-xiii HAZARDOUS WASTE AND SOLID WASTE MANAGEMENT Waste is an unavoidable by-product of human activity. Economic development, rapid urbanization & improved living standards have led to the increase in quantity & complexity of the waste generated. Proper disposal of waste is essential for preservation and improvement of public health. Solid waste management is one of the most essential services for maintaining the quality of life in the plant and for ensuring better standards of health and sanitation. Solid waste generated in the plant area can be handled under two main categories, namely domestic wastes and industrial wastes. Effective measures shall be taken to effectively implement the solid waste management systems in the plant. Solid waste will be handed over to authorized vendor for disposal. The Hazardous wastes shall be handled and disposed as per Hazardous Waste (Management and Handling) Rules, The Waste Management plan includes: Waste Inventory Classification of waste Packaging, Storing and Transporting Wastes to Disposal site Data Management and Reporting -Personnel Training Waste Minimization M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 121

137 General Guidelines for Waste Management: 1. Solid waste The solid waste shall be segregated as bio-degradable and non-biodegradable. The organic waste shall be segregated and handed over to outside authorized agency for disposal. The non-biodegradable (inorganic) waste shall be handed over to authorized recycler for further handling and disposal. Reuse of paper and plastic waste. Planned system for waste collection, segregation and disposal. E-waste will be disposed as per E-Waste (Management) Rule, Hazardous waste Hazardous waste will be stored as per the guidelines in proper storage room and handed over to authorized vendor for final disposal. The collection, treatment and disposal of hazardous waste will be as per Hazardous waste (Management and Handling) Rules 2016, and hence no adverse impact on land environment is envisaged. It is proper management it will be stored separately in dry & covered place with RCC plat form. There will be provision of separately storage area. Forklift truck will be used in shifting, loading and unloading operation for hazardous waste to minimize manual handling of hazardous waste. Necessary PPE s shall be provided to workers while handling of hazardous waste METHODOLOGY FOR DECONTAMINATION For disposal of discarded bags and containers, the guideline provided by the Gujarat Pollution Control Board will be followed. It will be ensured that containers are empty before taken for disposal. As per the guidelines all the containers will be washed properly, the washings will be checked for ph and COD. The ph should be neutral and COD should be NIL. This will ensure that the containers are cleaned before taken for disposal. Removal or defacing of all labelling and content of all product and waste material will be regular practice. The sticker will be put on individual container as "cleaned". The container will be deposited in the area marked for disposal. Then the containers will be inspected by the certifying agency approved by the GPCB. In confirmation of the quality of the cleaning they will issue the stickers for identification. After receiving stickers, that should be pasted on to the containers. Then the containers are disposed of to actual raw material supplier. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 122

138 FIGURE: 2.8 METHODOLOGY OF DECONTAMINATION Contaminated contained area Water Decontamination area Effluent to ETP Clean Container area 2.9 PROJECT IMPLIMENTATION SCHEDULE Implementation of Project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. The project implementation schedule is given in table no This will start immediately after getting Environment Clearance. From the date of start, the implementation schedule envisages completion of project in 12 months. It is considered that preliminary activities such as obtaining necessary statutory clearance for proposed project and financial arrangements for the implementation of the project will be made at proper dates. The major activities to be carried out at site during project work are as follows: TABLE: 2.24 PROJECT IMPLEMENTATION SCHEDULE Project implementation schedule after getting NOC from GPCB Sr. No. Activity Required Period 1. Civil work Immediately after getting NOC-6 Months 2. Procurement of machinery 3 month after getting NOC 3. Eraction & installation of machinery Immediately after competition of activity no.2-1 month 4. Trial of machinery & Within 1 month after competition of activity no.3 equipment 5. Commercial activity 1 month after competition of activity no.4 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 123

139 FIGURE 2.9 BAR CHART Commercial Activity Trial of machinery & equipment Erection & installation of machinery Procurement of machinery Civil Work Civil Work Procurement of machinery Erection & installation of machinery Trial of machinery & equipment Commercial Activity Year After Getting NOC from GPCB COST PROVISION FOR ENVIRONMENTAL MEASURES For environment protection, management and pollution control and treatment and monitoring systems, appropriate budgetary provision would be made and provision for recurring expenditure for environment management of the project would be made. The details of budget allocation during construction phase and operation phase are given in Table PROJECT COST ESTIMATES A Budget allocation for effective Environmental Management Plan (EMP) is proposed during operation phase is given in below table. TABLE 2.25 BUDGET ALLOCATION FOR ENVIRONMENTAL MANAGEMENT PLAN CONSTRUCTION PHASE Sr. No. Pollution Control Measures Capital Cost (Rs. In Lakhs) 1. Dust suppression during construction 1 Lakh 2. Green Belt development 2 Lakhs 3. Solid waste management facility 2 Lakhs 4. Environment Monitoring 2 Lakhs (Monitoring charges for air, water, noise) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 124

140 5. Occupational Health TOTAL (Includes cost of medical check-up, PPE & first aid kit and PPE, first aid facility, safe drinking water plant & sanitation measures) OPERATION PHASE Sr. No. Pollution Control Measures 3 Lakhs 10 Lakhs Approximate Total Capital Cost (Rs. In Lakhs) Air Pollution Control 15 5 a. Water + Two stage caustic scrubber b. Two stage water + Acid scrubber Water Pollution Control a. Effluent Treatment Plant Noise Pollution Control 10 1 a. Acoustic Barrier b. Noise filters c. Noise Muffler Environment Monitoring and Management a. Online TOC meter b. Online Monitoring system with ph & flow meter c. Environment monitoring by external approved monitoring agency Occupational Health Green Belt (Premises and outside premises.) Haz. Waste Management Fire Safety & Equipment 20 3 Approximate Recurring Cost (Rs. In Lakhs/ Annum) Total 89 Lakhs 37 Lakhs/ Total EMP cost (Construction + Operation phase): 99 Lakhs Annum M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 125

141 2.11 ECONOMICAL AND TECHNICAL VIABILITY OF THE EFFLUENT TREATMENT SYSTEM TABLE: 2.26 DETAILS OF COST OF ETP PER YEAR Sr. No. Detail Approx. Expenses in Monthly Approx. Expenses in Yearly 1. ETP - O & M 85,000/ Lakhs 2. VGEL (effluent generation) bill (Rs. 20/KL) 15,000 /- 1.8 Lakhs TOTAL Rs. 1,00,000/- 12 Lakhs This unit is a pilot plant so, irrespective of financial viability ETP will be operated. The costing is normally loaded on commercial manufacturing unit ODOUR MANAGEMENT PLAN Odour Problem and Sources of Emissions: Causes of odour can be bad sanitation, bacterial growth in the interconnecting pipes & unattended drains etc. Remedial Measures: Better management to avoid staling. Use of sanitation biocides to minimize the growth of aerobic/anaerobic microorganisms. Steaming of major pipe lines. Proper cleaning of drains. Following Additional methods can also be used to reduce odour nuisance: Green belt development in the buffer zone may help at least partially to mitigate / obfuscate the Odour. Ensuring that the operation is carried out under the best management practices. If still the Odour persists, nozzles, sprayers and atomizers that spray ultra-fine particles of water or chemicals can be used along the boundary lines of area sources to suppress odour. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 126

142 2.13 FUGITIVE EMISSIONS MANAGEMENT PLAN Fugitive emission sources and their control measures are shown in below table. TABLE: 2.27 PROPOSED FUGITIVE EMISSION CONTROL MEASURES Sr. Probable Source Proposed Control Measures No. 1. Pump handling odorous chemicals and pressured gases Use of mechanical seals of pumps and compressor. All pipeline and pipe fitting shall be well maintain, wear and tear shall be attended promptly. 2. At reactor during charging of liquid and solids chemicals Liquid raw material will be charged by pumping and closed loop. 3. Pressure release valve emission from pipeline For highly pressurized lines, vent lines of PRVs to air pollution control device in case of toxic gases. 4. Release from sampling lines Using a close loop sampling system. 5. Emission from bulk storage tank during unloading Breather valve, PSVs, Rupture disc will be provided. Vapour recovery system will be installed for process and storage vent tank. 6. Leak from valves, flanges, plugs and instrument connection. Welded pipes will be used wherever feasible. Suitable gasket material to be used. Suitable gland packing will be used in valves. Periodic inspection and maintenance of pipes and pipe fittings. 7. Chemical vapors from wet cake in filtration and drying area Filtration will be done out in Agitated Neutch filter. Transfer and drying of wet-cake done in system shall be adopted, worker shall be provided PPEs, fume extraction system shall be provided, whenever require. 8. Warehouse storing drums and Spillages shall be strictly prevented by bags providing dip pans, proper handling equipment, M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 127

143 Sr. No. Probable Source Proposed Control Measures minimum manual operation, local exhaust and roof top ventilators. Spill control procedures and equipment shall be provided ADEQUACY OF THE PROPOSED EMS AIR: The unit will use natural gas in Boiler (2 TPH) and LDO will be used in D.G. Set (250KVA) adequate stack height. The fugitive emission of VOC will be from solvent recovery plant, VOC will be control as per the CPCB Guidelines. WATER: The unit will use total 43 KLD (Domestic: 5 KLD+ Gardening: 5KLD+Industiral: 33KLD) of fresh water consumption. Total effluent generation will be 18.5 KLD (Domestic: 4 KLD + Industrial: 14.5 KLD). Total 18.5 KLD of sewage & industrial effluent water will be treated in ETP. The final treated effluent will be discharged to C.E.T.P. of M/s. Vapi Green Enviro Ltd. for further treatment. HAZARDOUS WASTE: There will be total generation of ETP sludge (60 MTA), Discarded container and bags (1 MTA), Used oil (0.2 MTA), Distillation residue (30 MTA), Spent carbon (180 MTA), Spent catalyst (5 MTA), Hydrochloric acid (124.2 MTA), Spent Sulphuric Acid ( MTA), Acetic Acid (29.28 MTA), Aluminum Oxide (2.4 MTA), ONP (2.4 MTA), Sodium chloride (90.24 MTA), Calcium Chloride (89.16 MTA) and Potassium Chloride (194.4 MTA). Hazardous waste will be stored in dedicated closed areas. ETP sludge will be sent to TSDF site for disposal. Discarded containers and bags will be sold to authorized dealers after proper decontamination. Used oil will be disposed to registered re-processors. Spent catalyst will be sent to supplier or regenerator for regeneration. Distillation residue and spent carbon will be sent to TSDF at RSPL, Panoli & GSPL, Palsana for disposal. Hydrochloric acid, Spent Sulphuric Acid, Acetic Acid, Aluminum Oxide, ONP, Sodium chloride, Calcium Chloride and Potassium Chloride will be sold out to actual authorized users/under rule-9 with MOU or in-house treatment. The unit will first give preference to Co-processing over TSDF site for better environment management. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 128

144 CONCLUSION: The environment management plan given by M/s. Aarti Industries Limited (Apple Division). for air, water and hazardous waste is adequate as per the worst-case scenario. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 129

145 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. BASELINE ENVIRONMENT STATUS CHAPTER INTRODUCTION It is essential to monitor the environment quality prevailing in the surrounding area before implementation of the any project for assessing the environmental impacts. The Environment status within the study area could be used for identification of significant environmental issues to be addressed in the impact assessment study. The impact from an existing industrial project on its surrounding environment are mainly regulated by, The nature of the pollutants, Their quantities discharged to the environment, Existing environment quality Assimilative capacity of the surrounding environment and Topography and terrain of the project site. In order to identify and establish the extent of likely impacts, it is necessary to gather information on existing environmental quality relating to various components of the environment. Primary data were collected for baseline collection. Secondary data were also gathered for remaining information like meteorological data, Socio-economic data, Ecological data and Land use data. For the purpose of collection of primary data, study area was selected within 10 km radius taking project site as a center which also included towns and villages. The main factor of local, sub-regional and regional meteorology that influence the air quality in area of the proposed project are diurnal and seasonal wind pattern and wind direction, humidity,temperature etc. Vapi is a very important industrial center having the advantage of close proximity to Mumbai, the commercial capital of India. Due to NH-8 and Vapi railway station, GIDC is well connected by road and rail to rest parts of the country. Communication facility available in the area is good. Water is available from GIDC. Vapi is a large industrial estate with a number of chemical plants, paper mills, textile processing plants and other allied industries totaling to about more than 705 units. At present there are several industries located in this area. Lists of major industries in the Vapi are given in Table 3.1. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 130

146 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. TABLE: 3.1 LIST OF MAJOR INDUSTRIES IN THE VAPI Sr. Name Of The Company Type Of Industry No. 1. K.V. Arochem Limited Organic chemicals 2. Aegis Chemicals Limited Chemical 3. Amantech Chemicals Pvt. Limited Chemical 4. Arochem Industries Chemical 5. Aarti Industries Ltd. (Alchemie Division) Organic chemicals 6. Aarti Industries Ltd. (Amine Division) Organic chemicals 7. Aarti Industries Ltd. (Organic Division) Organic chemicals 8. Ganesh Polychem Limited Chemical 9. Bhageria Dye-Chem Limited Chemical 10. Brighton Inorganic Pvt. Limited Chemical 11. Manglam organics Limited Chemical 12. Phthalo colours & chemicals Pvt. Ltd. Pigment 13. Sarna Chemicals Pvt. Limited Dye intermediates 14. Hindustan inks & organics pigments Ltd. Chemicals 15. A- One Phthalo Colours Pvt. Ltd. (Unit II) Pigments 16. Mangalam drugs Limited Bulk drugs and intermediated 17. Dhiraj Intermediates Pvt. Limited (Unit II) Dyes Intermediates 18. Dhiraj Intermediates Pvt. Limited(Unit I) Pigments 19. Makwell Plasticizer Pvt. Limited Chemical 20. Makwell Organics Pvt. Limited Chemical 21. Mitsu Limited Agrochemicals 22. Nascent Chemicals Limited Chemical 23. Nath Industrial hem Limited Chemical 24. Numet Industries Chemical 25. Pidilite Industries Chemical 26. Rishiroop Organics Pvt. Limited Chemical 27. Supreet Chemicals Pvt. Limited Chemical 28. United Phosphorous Limited Agrochemicals 29. Vadilal Chemicals Chemical 30. Perstorp Aegis Limited Chemical 31. Amoli Organics Limited Bulk drugs 32. Essel Mining and industries Chemicals 33. Duphar interfran Limited Pharmaceutical 34. MM Labs Pharmaceutical 35. Sun Pharmaceuticals Ind. Ltd. Pharmaceutical 36. Umedica Laboratories Limited Pharmaceutical 37. Supreme Non wovens Limited Roof liners 38. Daman Ganga Boards Limited Paper 39. Nathani Paper Mills Limited Paper M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 131

147 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Sr. Name Of The Company Type Of Industry No. 40. NR Paper Mills Limited Paper 41. Ruby Macons Limited Paper 42. Prayag tex prints Limited Textiles 43. Navin Chemicals Dyes 44. Techno Colour Corporation Dyes 45. Pramanik tex fab Pvt. Ltd. Textile 46. Gujarat Axles and forgins pvt. Ltd. Engineering 47. Gujarat Electromag Industries Pvt. Ltd. Engineering 48. Kabra Extru- Technics Limited Engineering 49. Pragati Engineering Engineering 50. Bilag Industries Agrochemicals 51 Micro Inks Inks & Organic Pigments 52. Themis Medicare Limited. Pharmaceutical 53. Ritcher Themis Ltd. Pharmaceutical 54. Perstrop Industries Ltd. Agrochemicals SALIENT FEATURES OF AREA GEOGRAPHY: Valsad, located in the northern part of Valsad district of the state of Gujarat, is officially spread over an area of 4.54 sq. km. However, due to rapid urbanization, the town now occupies a much larger area. Geologically Valsad district is a northern extension of Deccan Plateau of Central India, belonging to late Cretaceous early Eocene age and here, it is followed by Quaternary sediments. Map showing major geological formations and tectonic features are shown in figure. Vapi is the largest city in Valsad district in Gujarat. Best known for Vapi Industrial Estate, the City is a municipality that falls under the administration of Pardi Taluka. Over the recent years, Vapi has seen massive industrial and economic growth. It contributes a major share in the revenue of the state. Today, Vapi is one of the leading industrial cities of the country. It is well connected to neighboring regions like Umbergaon, Sanjan, Udavada, Bhilad and Pardi by rail and roadways TOPOGRAPHY: Valsad town has a flat topography, which slopes towards the west. The average elevation of the town is 13 meter (43 feet) above the sea level. The Arabian Sea lies to its West. The plant is located in a well-developed industrial zone, which has all essential facilities such as internal roads, arrangement for supply of water and power to industries, effluent disposal facilities etc. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 132

148 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. The Vapi GIDC falls at Pardi Taluka of Gujarat. It is positioned on the bank of River Daman Ganga. It is situated to the East of Daman (Central Territory) and to the West of Dadra and Nagar Haveli (Central Territory). Vapi is largely an industrial area dominated by small scale industries, especially chemical plants. Water is available from G.I.D.C. water supply. G.I.D.C. Vapi is large industrial estate with a number of chemical plants, paper mill, textile processing plants and other allied industries total to about more than 705 units. Vapi industrial association (VIA) has set up a disaster management cell to take care of any disaster in the vicinity. A common effluent treatment plant (CETP) and Common Hazardous Waste Storage Site are established and operated by M/s. Vapi Green Enviro Ltd. The treated effluent from CETP is discharged in to sea. The present unit will utilize TSDF facility. The salient features of project site are given in Table 3.2. TABLE: 3.2 SALIENT FEATURES OF THE PROJECT SITE Particulars Details Taluka/ Tehsil Pardi 19 km, NEN District Valsad 28 km, WNN Geographical positioning Latitude N Longitude E Nearest City Valsad 28 km, WNN Nearest Town Vapi 4.5 km, WN Nearest Highway NH8 2.5 km, WN Nearest Railway line/ Railway station Nearest Domestic Airport/ Airbase Nearest International Airport/ Airbase Vapi Surat Daman Mumbai Distance from project site (Approximately kilometer ) km, WN 88.5 km, WNN 12.5 km, WN km, SWS Nearest water body Daman Ganga River 2.9 km, SWW There are no metropolitan cities. The industrial housing sector is located at approx. 3 km distance from the site. There is no defense installation. There are no ecological sensitive areas such as tropical forests, biosphere reserve, and important lakes or coastal areas rich in coral formation. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 133

149 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. There is no national park of wild life sanctuary. There are no sensitive places of archaeological, historical, cultural and religious or tourist importance NEIGHBORING INDUSTRIES The lists of neighboring industries are given in below table. TABLE 3.3 DETAILS OF NEIGHBORING INDUSTRIES AT PROJECT SITE Name of Industry Direction w.r.t project site Address Amarjyot Chemicals Pvt. Ltd. North Plot No 286/2, Phase II, GIDC, Vapi. Ratna Paper Mill South Plot No. 322/22, Phase II, GIDC, Vapi. GIDC Road East GIDC Road. GIDC Road West GIDC Road. For Baseline study, the monthly meteorological data for study period from March-2017 to May-2017 is shown at below Table WINDROSE Based on the meteorological data, wind rose have been prepared for the summer season period between the March-2017 to May The wind rose diagram prepared from same data is shown at Figure 3.1(A), Figure 3.1(B) Figure 3.2. TABLE: 3.4 METEOROLOGICAL DATA Month Temperature Wind speed Rain Humidity ( o C) (kmph) fall (%) Max. Avg. Min. Max. Avg. (mm) March April May M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 134

150 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. FIGURE: 3.1(A) WIND ROSE DIAGRAM FOR PERIOD OF MARCH-2017 TO MAY FIGURE: 3.1(B) WIND ROSE DIAGARM ON SATELITE IMAGE M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 135

151 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. FIGURE: 3.2 WIND CLASS FREQUENCY DISRTIBUTION It was observed that wind is blowing mainly towards the East direction. Average wind speed was 5.02 m/s with calm winds recorded to be 0.14% AIR ENVIRONMENT AMBIENT AIR QUALITY (AAQ) The basic objective of collection of base line data for air environment is to identify project specific air pollutants being released into atmosphere, which will have significant impact on air environment of immediate locality of the proposed project site. For assessment of the baseline data it is important to specify the study area in respect of the location of the proposed project. It was decided to the study ambient air quality at 9 locations in the different direction in probable impact zone including the project site LOCATION OF AAQ MONITORING STATIONS Ambient air quality stations were chosen considering the various factors like the most prevailing wind direction, pockets of habitation, available infrastructure facilities like power supply, accessibility etc. The location of AAQ monitoring stations are shown in Figure 3.3 and Table 3.3. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 136

152 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. FIGURE: 3.3 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS TABLE: 3.5 DETAILS OF SAMPLING LOCATION OF AMBIENT AIR QUALITY MONITORING Sr. No. Location Sample ID Distance & Direction w.r.t project site Latitude Longitude 1. Project Site A ' '' N 72 56' ''E 2. Karvad A KM, NE 20 21'21.91"N 72 57'25.53"E 3. Kocharva A KM, NEE 20 22'1.85"N 72 58'6.62"E 4. Chanod A KM, W 20 20'48.08"N 72 55'43.11"E 5. Dungrifalia A KM, E 20 20'52.37"N 72 56'35.98"E 6. Chandor A KM,W 20 20'58.93"N 72 54'22.90"E 7. Rata A KM, NNE 20 22'59.03"N 72 57'22.40"E 8. Balitha A KM, NNW 20 23'19.10"N 72 54'53.34"E 9. Valwada A KM, SW 20 19'14.60"N 72 54'18.04"E BASE LINE DATA For Baseline study, the ambient air quality monitoring was carried out during period of March to May Monitoring details like location, monitoring date are attached as Annexure- XV. The frequency of monitoring was twice in a week for a period of 12 weeks to assess the existing the sub regional air quality status. All the sampling locations were monitored for M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 137

153 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. PM 2.5, PM 10, SO 2, NO X, CO, NH 3, HCl, HBr, Br 2, Cl 2 and VOC on 24 hr basis to enable the comparison with ambient air quality standards prescribed by the CPCB. Based on the data obtained through ambient air quality survey statement showing maximum, minimum average concentration values of different monitoring location in the study area have been computed and presented at below table. TABLE: 3.6 AMBIENT AIR QUALITY STATUS OF STUDY AREA Location Min. Value Max. Value Avg. Value PM 10 (Permissible Limit (CPCB standard) : 100 µg/m 3 ) Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) PM2.5 (Permissible Limit (CPCB standard) : 60 µg/m 3 ) Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) SO2 µg/m 3 (Permissible Limit (CPCB standard):80 µg/m 3 ) (24 hr) Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) NO X (Permissible Limit (CPCB standard): 80 µg/m3) (24 hr) Project Site (A1) Karvad (A2) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 138

154 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Location Min. Value Max. Value Avg. Value Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) HCl - µg/m3 Project Site (A1) BDL BDL BDL Karvad (A2) BDL BDL BDL Khacharva (A3) BDL BDL BDL Chanod (A4) BDL BDL BDL Dungrifalia (A5) BDL BDL BDL Chandor (A6) BDL BDL BDL Rata (A7) BDL BDL BDL Balitha (A8) BDL BDL BDL Valwada (A9) BDL BDL BDL HBr - µg/m3 Project Site (A1) BDL BDL BDL Karvad (A2) BDL BDL BDL Khacharva (A3) BDL BDL BDL Chanod (A4) BDL BDL BDL Dungrifalia (A5) BDL BDL BDL Chandor (A6) BDL BDL BDL Rata (A7) BDL BDL BDL Balitha (A8) BDL BDL BDL Valwada (A9) BDL BDL BDL Br2 - µg/m3 Project Site (A1) BDL BDL BDL Karvad (A2) BDL BDL BDL Khacharva (A3) BDL BDL BDL Chanod (A4) BDL BDL BDL Dungrifalia (A5) BDL BDL BDL Chandor (A6) BDL BDL BDL Rata (A7) BDL BDL BDL Balitha (A8) BDL BDL BDL Valwada (A9) BDL BDL BDL Cl 2 - µg/m3 Project Site (A1) BDL BDL BDL Karvad (A2) BDL BDL BDL Khacharva (A3) BDL BDL BDL Chanod (A4) BDL BDL BDL M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 139

155 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Location Min. Value Max. Value Avg. Value Dungrifalia (A5) BDL BDL BDL Chandor (A6) BDL BDL BDL Rata (A7) BDL BDL BDL Balitha (A8) BDL BDL BDL Valwada (A9) BDL BDL BDL VOC- µg/m3 Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) <1 <1 <1 Balitha (A8) Valwada (A9) NH 3 (Permissible Limit(CPCB standard): 400 µg/m3) (24 hr) Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) CO (Permissible Limit (CPCB standard): 2 mg/m3) (8 hr) Project Site (A1) Karvad (A2) Khacharva (A3) Chanod (A4) Dungrifalia (A5) Chandor (A6) Rata (A7) Balitha (A8) Valwada (A9) BDL: Below Detectable Limit OBSERVATION: Based on data obtained, it could be stated that, during the study period the values of PM 10 at monitored locations is ranged between µg/m 3 while the values PM 2.5 fluctuates in the range of µg/m 3. The values of SO2 and NOx were observed to be in the range of µg/m 3 and µg/m 3 respectively. The values of VOC were observed to be in the M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 140

156 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. range of µg/m 3 respectively. The values of HCl, Br 2 & Cl 2 were found Below Detectable Limit. The values of CO & NH 3 observed are within prescribed limit at all locations. The average concentration of PM10, PM2.5, SO2, NOx, VOC, HCl, Br2, Cl2 CO & NH3 are within prescribed limit at all locations. PM was carried out. It was found that, it is visibly due to transport activity in the study area. These concentrations at all AAQM locations were primarily caused by local phenomena including vehicular movement and natural dusting due to human activities and wind movement. 3.4 WATER ENVIRONMENT There are two categories of water environment: 1) Ground water: - accumulation in deeper strata of ground and 2) Surface water: - river, drains, cannals, ponds etc. Sampling Method The samples were collected as per Indian standard IS: 3025 (part-1) for ground water and surface water quality assessment. Analysis Method The analysis method followed for the measuring different parameters to evaluate water quality is given in below table. TABLE: 3.7 METHOD OF ANALYSIS Sr. No. Parameters Applicable Standard Method of Analysis 1. Color in Pt. Co. Sc. APH (22 nd Edition) Spectrophotometer (analogous to APHA 2120 C) (Platinum Cobalt Method) 2. ph APHA(22 nd Edition) 4500 H + B Electrometric Method 3. Total hardness APHA(22 nd Edition) 2340 C: Page 2 37 EDTA (as CaCO 3) in mg/l Titrimetric Method 4. Chloride (as Cl) in APHA(22 nd Edition) 4500-Cl-B-Argentometric mg/l method 5. TDS in mg/l APHA (22 nd Edition) 2540 C Total Dissolved Solid Dried at 180 C Detection Limit M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 141

157 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. 6. TSS in mg/l APHA (22 nd Edition) 2540-D-Total Suspended 4 Solids Dried at C 7. Calcium (as Ca) in mg/l 8. Magnesium (as Mg) in mg/l 9. Sulphate (as SO4) in mg/l 10. Alkalinity (as CaCO 3) in mg/l APHA (22 nd Edition) Ca : B Page EDTA Titrimetric Method APHA(22 nd Edition) Mg : B Page Calculation Method APHA (22 nd Edition) 4500 SO4-2 E: Page Turbid metric Method/ IS 3025 (Part 24) 1986 (Reaffirmed 1986) Gravimetric Method APHA (22 nd Edition) 2320 B: Page Titration Method 11. COD in mg/l APHA(22 nd Edition) 5220 B Open Reflux Method BOD in mg/l IS: 3025 (Part 44) (Reaffirmed 1999) 13. MPN Coliform APHA C -- Count 14. E.coli APHA D (Presence Absence Test) Nitrate in mg/l Spectrophotometer Iron (as Fe) in mg/l By NOVA 60 spectrophotometer (Triazine) Fluoride (as F) in By NOVA 60 spectrophotometer 0.1 mg/l 18. Residual Free Iodometric method 1 Chlorine in mg/l 19. Sodium in mg/l Flame photo meter Potassium in mg/l Flame photo meter Ammonical Nitrogen in mg/l APHA-4500 N ORGBnC macro and semi-micro KJELDHAL GROUND WATER SAMPLING Eight locations were selected for ground water sampling and six locations were selected for surface water sampling. Collected samples were analyzed for drinking water quality parameters like physic-chemical parameters and heavy metals. During study period, the sampling was done for one time. The map viewing location for sampling points is shown at Figure 3.4 and Figure 3.5. The analysis results are presented at Table 3.8-B & 3.9-B. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 142

158 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. FIGURE: 3.4 LOCATION OF GROUND WATER QUALITY MONITORING STATIONS TABLE: 3.8-A DETAILS OF GROUND WATER MONITORING LOCATIONS Sr. No. Sampling locations Sample ID Distance & Direction w.r.t project site Latitude Longitude 1. GIDC water supply GW ' 55.19'' N 72 56'16.551''E (Project Site) 2. Kocharva GW KM, NEE 20 22'7.23"N 72 58'5.06"E 3. Chanod GW KM, SWW 20 20'44.36"N 72 55'44.92"E 4. Rata GW KM, NNE 20 23'12.62"N 72 57'6.82"E 5. Balitha GW KM, NNW 20 23'20.97"N 72 54'57.50"E 6. Sulpade GW KM, WN 20 21'7.94"N 72 55'38.06"E 7. Chanod Colony GW KM, SSE 20 20'35.61"N 72 56'5.83"E 8. Shanthi Nagar GW KM, WN 20 22'31.25"N 72 54'4.11"E 9. Vapi GW KM, WNW 20 22'5.22"N 72 53'46.20"E M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 143

159 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. TABLE: 3.8-B WATER QUALITY PARAMETERS (GROUND WATER SOURCES) Parameter Unit IS : 2012 Sampling Location Desirable Limit Permissible Limit Project site (GW1) Kocharva (GW2) Chanod (GW3) Rata (GW4) Balitha (GW5) Sulpad (GW6) Chandon Colony (GW7) ph Color Hazen 5 25 <5 <5 <5 <5 <5 <5 <5 <5 Turbidity NTU <4 <4 <4 <4 <4 <4 <4 <4 TDS mg/l TSS mg/l Total mg/l hardness Chloride mg/l Calcium mg/l Magnesium mg/l Iron mg/l < <1 Fluoride mg/l Sodium mg/l Potassium mg/l Sulphate mg/l ND Nitrate mg/l Alkalinity mg/l Shanthi Nagar (GW8) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 144

160 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Parameter Unit IS : 2012 Sampling Location Desirable Limit Permissible Limit Project site (GW1) Kocharva (GW2) Chanod (GW3) Rata (GW4) Balitha (GW5) Sulpad (GW6) Chandon Colony (GW7) COD mg/l 4 -- ND <4 12 <4 20 <4 <4 <4 BOD mg/l 1 -- ND <4 <4 <2 <4 <2 <4 <2 Free Residual Chloride MPN Colifrom mg/l ND ND ND ND ND ND ND ND CFU/ 100 ml Observation: Quality of Ground Water It was observed from the analysis report that: 1 10 ND ND ND ND ND ND ND ND Shanthi Nagar (GW8) *ND-Not Detected Detectable limit for Free Residual Chlorine- 1 mg/l Though the area is found to be of rocky terrain but the TDS content of the sample is observed to be maximum up to 975 mg/l in Shanthi nagar (GW8). Magnesium content of the sample is observed to be in 120, 240, 140, 382 and 710 mg/l in Kocharva (GW2), Rata (GW4), Balitha (GW5), Sulpad (GW6) and Shanthi nagar (GW8) respectively which is more than the permissible limit. Sulphate content of the sample is observed to be maximum up to 65 mg/l in project site which is under the acceptable limit. Analysis of collected samples reveals that rest of the parameters satisfy the permissible limits as per IS 10500:2012 specified for drinking water and hence are suitable for drinking, however it is suggested that the water may be disinfected by boiling or by use of chlorine tablets before use. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 145

161 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI SURFACE WATER SAMPLING FIGURE: 3.5 LOCATION OF SURFACE WATER QUALITY MONITORING STATIONS TABLE: 3.9-A DETAILS OF SURFACE WATER MONITORING LOCATIONS Sr. Sampling Sample Distance & Type Latitude Longitude No. locations ID Direction w.r.t project site of Area 1. Kocharva SW KM, NEE Pond 20 22'2.46"N 72 57'49.21"E 2. Rata SW KM, NNE Pond 20 23'17.61"N 72 57'8.00"E 3. Karvad SW KM, NE Pond 20 21'22.24"N 72 57'7.52"E 4. Balitha SW KM, NNW Pond 20 23'48.23"N 72 55'38.80"E 5. Daman SW5 3 KM. SSW River 20 20'21.14"N 72 54'45.44"E Ganga River 6. Namdha SW6 5.0 KM, W Pond 20 21'34.52"N 72 53'37.48"E Note: Out of eight location two ponds (Chanod colony & Valwada) where found dried here, six locations have been considered. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 146

162 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. TABLE: 3.9-B WATER QUALITY PARAMETERS (SURFACE WATER SOURCES) Parameter Unit IS 10500: 2012 Sampling location Desirable Limit Permissible Limit SW1 Kocharva SW2 Rata SW3 Karvad SW4 Balitha SW5 Daman Ganga River SW6 Namdha ph Color Hazen <5 <5 Odour -- Unobjecti onable -- Unobjectio nable Unobjecti onable Unobjection able Unobjectiona ble Unobjectiona ble Unobjectiona ble Turbidity NTU <4 <4 2 <4 Total mg/l hardness Chloride as mg/l Cl TDS mg/l TSS mg/l ND ND Calcium as mg/l Ca Magnesium mg/l as Mg Iron as Fe mg/l Fluoride mg/l Sodium mg/l Potassium mg/l Sulphate mg/l as SO4 Nitrate mg/l Alkalinity mg/l COD mg/l <4 BOD mg/l <2 < <2 <2 M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 147

163 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. E.Coil (MPN/ Absent Absent Absent Absent Absent Absent 100 ml) FaecalConl (MPN/ Absent Absent Absent Absent Absent Absent ifrom 100 ml) Phenol mg/l <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Pesticides (P/A) Absent Absent Absent Absent Absent Absent Dissolved Mg/l Oxygen Observation: Quality of Surface Water It was observed from the analysis report that: Though the area is found to be of rocky terrain but the TDS content of the sample is observed to be maximum up to 780 mg/l in Rata (SW2). Calcium & Magnesium content of the sample is observed to be maximum in 252 & 134 mg/l in Rata (SW2) which is over the permissible limit. Analysis of collected samples reveals that rest of the parameters satisfy the permissible limits as per IS 10500:2012 specified for drinking water and hence are suitable for drinking, however it is suggested that the water may be disinfected by boiling or by use of chlorine tablets before use. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 148

164 3.5 NOISE ENVIRONMENT Noise can be defined as an unwanted sound. It interferes with speech and hearing. If intense enough, it can damage hearing, or is otherwise irritating. Noise can also disturb natural wildlife and ecological system RECONNAISSANCE In order to measure the existing noise sources and to identify the background noise levels, the noise pollution survey around the proposed site was carried out METHODOLOGY FOR NOISE MONITORING Noise standards have been designated as per the Noise Pollution (Regulation & Control) Rules, 2000 Notified by Ministry of Environment and Forests, New Delhi, February 14, The ambient noise standards are presented in Equivalent noise levels (Leq). The measurements were carried out at each monitoring location during day time and night time. Noise survey was conducted using Sound Level Meter NOISE MONITORING LOCATIONS A total of nine locations were identified for ambient noise monitoring in the study area. The noise monitoring locations are shown in Figure 3.6 and listed in Table FIGURE: 3.6 LOCATION OF NOISE MONITORING STATIONS M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 149

165 TABLE: 3.10 NOISE LEVEL DATA Sr. Location Sample ID Area Category LEQ (db (A)) No. Day Time Night Time 1. Project Site N1 Industrial Karvad N2 Residential Kocharva N3 Residential Chanod N4 Residential Dungrifalia N5 Residential Chandor N6 Residential Rata N7 Residential Balitha N8 Residential Valwada N9 Residential TABLE: 3.11 CPCB RECOMMENDATIONS FOR COMMUNITY NOISE EXPOSURE Area Code Category of area Leq. (dba) (Daytime) (06:00 to 21:00hrs.) A Industrial area B Commercial Area C Residential Area D Silence Zone Leq. (dba) (Night time) (21:00 to 06:00hrs.) Note : 1 Silence zone is defined as areas up to 10 meters around such premises as hospitals, education, institutions and courts. The silence zones are to be declared by the Component Authority. Note : 2 Mixed categories of areas should be declared as one of the four above-mentioned categories by the Component Authority and the corresponding standard has apply. (Source: The Noise Pollution (Regulation & Control) Rules, 2000) OBSERVATION & DISCUSSION The noise levels during daytime varied from db (A) Leq to db (A) Leq in the study area. The noise level in the study area is within the permissible Limits as per Noise rules The night time noise level in the study area is in the range of db (A) Leq to db (A) Leq. The night time noise was also within stipulated standards of CPCB. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 150

166 3.6 SOIL ENVIRONMENT BASELINE DATA Description of soil environment has become vital particularly when the treated effluent is to be discharged on land for disposal or treatment. The soil environment is usually described by determining the physical and chemical characteristics of soil samples collected from site with the help of auger/spade. The composite soil sample was collected from project site and the villages Within 5 km radius. The samples were collected to determine physical and chemical characteristic of soil. The selected soil sampling locations are given in Table 3.12 and shown in Figure 3.7. TABLE: 3.12 SOIL QUALITY MONITORING WITH RESPECT TO THE PROJECT SITE Sr. Location Sample ID Direction from the site Distance in Km District No. 1. Project Site S Valsad 2. Vapi S2 WN 4.5 Valsad 3. Chirri S3 NNE 3.36 Valsad 4. Karwad S4 NE 1.96 Valsad 5. Dungri falia S5 SEE 0.5 Valsad 6. Chandor S6 WWN 3.7 Valsad FIGURE: 3.7 LOCATION OF SOIL MONITORING STATIONS M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 151

167 TABLE: 3.13 SOIL QUALITY PARAMETERS Sr. Paramete Unit Sampling Locations No. rs Project site (S1) Vapi (S2) Chirri (S3) Karwad (S4) Dungri falia (S5) Chandor (S6) 1. ph EC Us Sodium ppm Potassium ppm Nitrogen mg/ 100 gm 3.7 LAND USE PATTERNS The land use pattern of the study area has been studied by satellite imaginary picture of National Remote Sensing Centre, Govt. of India. Details are covered in Table TABLE: 3.14 LAND USE STATISTICS OF THE STUDY AREA Sr. Class Name Area (Hectares) Area(Sq. km) Area (%) No. 1. Water Body Open/Barren Land Agriculture Land Fallow Land Open/Degraded vegetation Vegetation Medium Density Vegetation High density Plantation/orchards Grass Land Scrubs Ravenous/Gullied Land River & Canal Marshy Land Salt affected Land Settlement & Habitation Mud flat Sand/Beach M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 152

168 Sr. Class Name Area (Hectares) Area(Sq. km) Area (%) No. 18. Jetty Salt pans Mangrove (Sparse) Mangrove (Dense) Marshy Vegetation Mines Stony waste/rocky Area Industrial Area Miscellaneous Sea Snow River Bed Seasonal Water Body Total M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 153

169 FIGURE: 3.8 LAND COVER MAP WITH VILLAGE LOCATION M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 154

170 3.8 BIOLOGICAL ENVIRONMENT & SOCIO ECONOMIC ENVIRONMENT ECOLOGICAL INFORMATION The study of the environmental components like flora and fauna is required to assess the biological diversity of the region. Flora and fauna can be used for biological surveillance in assessing the environmental status. The ecological interpretation of study area is based on secondary sources of information. Water is the basic and essential resource for the survival of flora and fauna. The flora being the primary producer influences the fauna of the region. The characteristic flora existing in a region depends upon the existing conditions such as intensity of sunlight, type of soil, quality of air, including the quality and quantity of water available, etc FOREST There are patches of reserved forest and protected forests within 10 Kms radial periphery of the study area. The map of reserved forest is shown in Figure 3.8. The entire zone of Valsad district that comprises of maritime coastal environment and also the upland forest in the North-East has been classified as Tropical Moist Deciduous Forest. The reserved forest is having also maritime climate and the habitat serves as an ecological niche several plant species of terrestrial realm, and form important nature conservation sites FLORA The list of flora found during field survey is given in Table TABLE: 3.15 LIST OF FLORA Sr. Scientific Name Common Name No. 1. Psilostachya seriea Lannea coromandelica Wodier 3. Mangifera indica Aam 4. Calotropis procera Ak 5. Nerium indicum Kaner 6. Rauvolfia tetrafylla Bara Chand 7. Tabernaemontana coronaria Tagar 8. Vernonia anthelmintica Kaliziri 9. Millingtonia hortensis Akashneem 10. Bombax ceiba Silk cotton 11. Casuarina equisetifolia Saru 12. Garcinia xanthochymus Bottle brush 13. Anogeissus latifolia Axle wood M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 155

171 Sr. Scientific Name Common Name No. 14. Terminalia arjuna Arjun 15. Terminalia bellerica Behda 16. Terminalia catappa Desshibadam 17. Terminalia tomentosa Terminalia paniculata Flowering murdah 19. Cyperus esculentus Yellow nustsedge 20. Diospyros chloroxylon Ninai 21. Diospyros melanoxylum Tendu 22. Ricinus communis Eranda 23. Acacia auriculiformis Australian acacia 24. Acacia catechu Khair 25. Acacia nilotica Babul 26. Alibizia lebbeck Shirish 27. Bauhinita tomentosa Kachnar 28. Cassia fistula Amaltash 29. Cassia siamea Karamala 30. Dalbergia latifolia Pahari sheesham 31. Dalbergia sissoo Sheesham 32. Delonix elata Gamhar 33. Desmodium heterocarpum Ougeinia dalbergioides Tiwas 35. Pithecellobium Saman Raintree 36. Pongamia pinnata Kanji 37. Prosopis juliflora Vilayati babul 38. Pterocarpus marsupium Indian Kino tree 39. Saraca indica Asoka 40. Tamarindus indica Imli 41. Vitex nequndo Shivarii 42. Parkinsonia aculeata Keerar 43. Lagerstroemia parviflora Dhuara 44. Hibiscus sabdariffa Lalambadi 45. Hibiscus schizopetalus Jaswand 46. Thespesia populnea Jaswand 47. Azadirachta indica Neem 48. Mimosa hamata Pithacellobium duice Jangli Jilebi 50. Artocarpus heterophyllus Jacktree 51. Ficus bengalensis Bargad 52. Ficus religiosa Peepal 53. Moringa oleifera Shevga 54. Eucalyptus Nilgiri 55. Syzygium cumini Jamun 56. Boerhavia diffusa Lalsata 57. Bougainvillea glabra Bougainvillea 58. Oxalis corniculata Nalvari 59. Emblica officinalis Amla M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 156

172 Sr. Scientific Name Common Name No. 60. Bambusa arundinaceae Bamboo 61. Dendro calamus strictus Bans 62. Zizyphus mauritiana Ber 63. Adina cordifolia Haldu 64. Mitragyna parvifolia Phaldu 65. Madhuca indica Mahua 66. Lindernia hyssopioides Ailanthus excels Ajan 68. Physalis longifolia Tamarix trupii Jhavnujhada 70. Typha angustata Patera 71. Gmelina arborea Shivan 72. Tectona grandis Sagwan 73. Borassus sp. Tad/Asian Palmyra palm 74. Phoenix sp. Khajoori/Date Palm Ref: FAUNA Some of the fauna found in study area is listed in Table TABLE: 3.16 LIST OF FAUNA Sr. Common Name Scientific Name Family No. Reptiles 1. Common cobra Naja naja Elapidae 2. Common Krait Bungarus caeruleus Elapidae 3. Land monitor Varanus albigularis Varanidae 4. Python Python molrus bivittatus Pythonidae 5. Russell s viper Daboia russelii Viperidae 6. Saw scaled viper Echis carinatus Viperidae 7. Garden lizard Catotes versicolor Agamidae 8. Rat snake Zamenis longissimus Colubridae 9. Indian chameleon Chameleon zeylanicus Chamaeleonidae 10. House qecko Hemidactylus frenatus Gekkonidae Aves 11. Cattle egret Bubulcus ibis Ardeidae 12. Common crane Gruidae Gruiformes Common peafowl Pavo cristatus Phasianidae 14. Crow pheasant Centropus sinensis Cuculidae 15. House Sparrow Passer domesticus Passeridae 16. Gold backed Brachypternus aurantius Picidae woodpecker 17. Green pigeon Treron phoenicoptera Columbidae 18. Grey partridge Perdix perdix Phasianhdae 19. Hoopoo Upupa epops Upupidae M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 157

173 Sr. Common Name Scientific Name Family No. 20. Inian myna Acridotheres tristis Sturnidae 21. Jungle bush quail Perdicula asiatica Phasianidae 22. Jungle crow Corvus macrohynchos Corvidae 23. Red vented bulbul Red wattled lapwing Pycnonotidae 24. Red wattled Vanellus Indicus Charadriidae lapwing 25. Small Green Bee- Merops orientalis Meropidae eater 26. Spotted dove Streptopelia chinensis Corvidae 27. Spotted owlet Athene brama Strigidae 28. Jungle owlet Glaucidium radiatum Strigidae 29. Large egret Ardea Alba Ardeidae 30. Little egret Egretta garzetta Ardeidae 31. Pond heron Ardeola grayii Ardeidae 32. Whitenecked stork Cicinia episcopus Ciconiidae 33. Black ibis Pseudibis papillosa Threskiornithidae 34. Common barbbler Turdoides caudata Timaliidae 35. Marsh harrier Circus aeruginosus Acciptridae 36. Pied crested cuckoo Clamator jacobinus Cuculidae 37. Sugari/Tailor Bird Ortotomus sutorius Sylviidae 38. Vulture Diurnilis Neophron Accipitridae 39. Samadi Milvus migrans Accipitridae 40. Duck Anatidae Anseriformes Anatidae 41. Barking deer Muntiacus Cervidae 42. Langur Semnopithecus entellus Cercopithecidae 43. Jackal Canis aures Canidae 44. Panther Panthera Pardus Felidae 45. Porcupine Hystrix indicus Hystricidae 46. Sambar Rusa unicolor Cervidae 47. Wild Boar Sus scrofa Suidae 48. Wild dog Lycaon pictus Canidae 49. Fox Vulpes vulpes Canidae 50. Bonnet macaque Macaca radiata Cercopithecidae 51. Common Herpestes edwardsii Herpestinae Mongoose 52. Squirrel Rodentia Sciurus Sciuridae 53. Rat Rattus Muridae 54. Indian hare Lepus nigricollis Leporidae 55. Indian bush rat Golunda ellioti Muridae 56. Indian field mouse Mus booduga Muridae Ref: M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 158

174 3.9 SOCIO-ECONOMIC ENVIRONMENT As assessment of socio-economic environment forms an integral part of an EIA study, baseline information for the same was collected during the study period. The baseline socio-economic data collected for the study region, before the proposed expansion is operational, has been identified for the four major indicators viz. demography,civic amenities, economy and social culture. The baseline status of the above indicators is compiled in forthcoming sections. SETTLEMENTS AND DEMOGRAPHIC PATTERN DEMOGRAPHIC DATA WITHIN THE REGION OF INTEREST Demography covers the information related to population density sex ratio and literacy level of the public in the study area. Table no.3.14 provides the data on inhabitations of the Pardi Taluka. TABLE: 3.17 DEMOGRAPHIC DATA Sr. No. Rural /Urban Area Name of area of Pardi Taluka No. of Households Total Population Total Male Total Female 1. Rural Pardi (M) Rural Umarsadi Rural Balda Rural Kumbhariya Rural Sondhalwada Rural Parvasa Rural Kachwal Rural Mota Waghchhipa 9. Rural Nana Waghchhipa 10. Rural Sukhesh Rural Borlai Rural Sukhlav Rural Velparva Rural Khadki Rural Motiwada Rural Palsana Rural Kalsar Rural Udwada Rural Kolak Rural Kikarla Rural Rentlav Rural Dungri Rural Dashwada M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 159

175 Sr. No. Rural /Urban Area Name of area of Pardi Taluka No. of Households Total Population Total Male Total Female 24. Rural Amli Rural Sonwada Rural Varai Rural Nimkhal Rural Panchlai Rural Lakhmapor Rural Nevri Rural Rabdi Rural Asma Rural Tarmaliya Rural Khuntej Rural Sarodhi Rural Tarakpardi Rural Saran Rural Vatar Rural Kunta Rural Morai Rural Bagwada Rural Tighara Rural Paria Rural Rohina Rural Samarpada Rural Dhagadmal Rural Daheli Rural Chival Rural Arnala Rural Pati Rural Goima Rural Barai Rural Dumalav Rural Tukwada Rural Ambach Rural Kherlav Rural Pandor Rural Rata Rural Chharwada Rural Chandor Rural Kocharva Rural Vankachh Rural Koparli M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 160

176 Sr. No. Rural /Urban Area Name of area of Pardi Taluka No. of Households Total Population Total Male Total Female 64. Rural Kaval Rural Karaya Rural Nani Tambadi Rural Degam Rural Moti Tambadi Rural Karamkhal Rural Chibhad Kachchh 71. Urban Pardi (M) Urban Pardi (M) ward no Urban Pardi (M) WARD NO Urban Pardi (M) WARD NO Urban Pardi (M) WARD NO Urban Pardi (M) ward no Urban Pardi (M) WARD NO Urban Pardi (M) WARD NO Urban Vapi (M) Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 161

177 Sr. No. Rural /Urban Area Name of area of Pardi Taluka 85. Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO Urban Vapi (M) WARD NO No. of Households Total Population Total Male Total Female Urban Vapi (M) ward no Urban Vapi (M) ward no Urban Vapi (INA) Urban Vapi (INA) WARD NO Urban Orvad (CT) Urban Orvad (CT) WARD NO Urban Balitha (CT) Urban Balitha (CT) WARD NO Urban Salvav (CT) Urban Salvav (CT) WARD NO Urban Chhiri (CT) Urban Chhiri (CT) WARD NO Urban Chanod (CT) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 162

178 Sr. No. Rural /Urban Area Name of area of Pardi Taluka 105. Urban Chanod (CT) WARD NO No. of Households Total Population Total Male Total Female Urban Karvad (CT) Urban Karvad (CT) WARD NO Urban Lavachha (CT) Urban Lavachha (CT) WARD NO (Source: Census-2011 for Valsad District) LITERACY RATE The literacy rate is a major factor, which influences the socio-cultural condition of a particular place. Details of literacy rate in percentage in district Valsad and Taluka Pardi are given in Table no TABLE: 3.18 LITERACY RATE WITHIN 10 KM RADIAL DISTANCE OF STUDY AREA Sr. No. Village Name CD Block Name Total Population Population < 06 Years Population Literate Literacy (%) 1. Umarsadi Pardi Balda Pardi Kumbhariya Pardi Sondhalwaa Pardi Parvasa Pardi Kachwal Pardi Mota Pardi Waghchhipa 8. Nana Pardi Waghchhipa 9. Sukhesh Pardi Borlai Pardi Sukhlav Pardi Velparva Pardi Khadki Pardi Motiwada Pardi Palsana Pardi Kalsar Pardi Udwada Pardi M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 163

179 Sr. No. Village Name CD Block Name Total Population Population < 06 Years Population Literate Literacy (%) 18. Kolak Pardi Kikarla Pardi Rentlav Pardi Dungri Pardi Dashwada Pardi Amli Pardi Sonwada Pardi Varai Pardi Nimkhal Pardi Panchlai Pardi Lakhmapor Pardi Nevri Pardi Rabdi Pardi Asma Pardi Tarmaliya Pardi Khuntej Pardi Sarodhi Pardi Saran Pardi Tarakpardi Pardi Vatar Pardi Kunta Pardi Morai Pardi Bagwada Pardi Tighara Pardi Paria Pardi Rohina Pardi Samarpada Pardi Dhagadmal Pardi Daheli Pardi Chival Pardi Arnala Pardi Pati Pardi Goima Pardi Barai Pardi Dumalav Pardi Tukwada Pardi Ambach Pardi Kherlav Pardi Pandor Pardi Rata Pardi Chharwada Pardi Namdha Pardi Chandor Pardi M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 164

180 Sr. No. Village Name CD Block Name Total Population Population < 06 Years Population Literate Literacy (%) 61. Kocharva Pardi Vankachh Pardi Koparli Pardi Kaval Pardi Karaya Pardi Nani Tambadi Pardi Degam Pardi Moti Tambadi Pardi Karamkhal Pardi Chibhad Pardi Kachchh 71. Pardi (M) Pardi Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Pardi (M) Pardi WARD NO Vapi (M) Pardi Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) WARD NO Pardi M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 165

181 Sr. No. Village Name CD Block Name Total Population Population < 06 Years Population Literate Literacy (%) 84. Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (M) Pardi WARD NO Vapi (INA) Pardi Vapi (INA) Pardi WARD NO Orvad (CT) Pardi Orvad (CT) Pardi WARD NO Balitha (CT) Pardi Balitha (CT) Pardi WARD NO Salvav (CT) Pardi Salvav (CT) WARD NO Pardi M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 166

182 Sr. No Village Name CD Block Total Population Population Literacy Name Population < 06 Years Literate (%) Chhiri (CT) Pardi Chhiri (CT) WARD NO Pardi Chanod (CT) Pardi Chanod (CT) Pardi WARD NO Karvad (CT) Pardi OCCUPATIONAL STRUCTURE (Source: Census-2011 for Valsad District) In economic development of the region its geographical location, natural resources, business and employment, industries and manpower play vital role. Table 3.19 provides the occupational patterns in all villages of Pardi Taluka. TABLE: 3.19 OCCUPATIONAL STRUCTURE Sr. No. Name of Area Total Population Worker Population Total Main Worker Worker Marginal Worker Total Non worker population Employment Ratio% 1. Pardi Taluka Umarsadi Balda Kumbhariya Sondhalwada Parvasa Kachwal Mota Waghchhipa 9. Nana Waghchhipa 10. Sukhesh Borlai Sukhlav Velparva Khadki Motiwada Palsana M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 167

183 17. Kalsar Udwada Kolak Kikarla Rentlav Dungri Dashwada Amli Sonwada Varai Nimkhal Panchlai Lakhmapor Nevri Rabdi Asma Tarmaliya Khuntej Sarodhi Saran Tarakpardi Vatar Kunta Morai Bagwada Tighara Paria Rohina Samarpada Dhagadmal Daheli Chival Arnala Pati Goima Barai Dumalav Tukwada Ambach Kherlav Pandor Rata M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 168

184 59. Chharwada Namdha Chandor Kocharva Vankachh Koparli Kaval Karaya Nani Tambadi 68. Degam Moti Tambadi 70. Karamkhal Chibhad Kachchh 72. Pardi (M) Pardi (M) WARD NO Pardi (M) WARD NO Pardi (M) WARD NO Pardi (M) WARD NO Pardi (M) WARD NO Pardi (M) WARD NO Pardi (M) WARD NO Vapi (M) Vapi (M) WARD NO M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 169

185 82. Vapi (M) WARD NO Vapi (M) WARD NO Pardi (M) ward no Pardi (M) ward no Vapi (M) Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 170

186 98. Vapi (M) WARD NO Vapi (M) WARD NO Vapi (M) WARD NO Vapi (INA) WARD NO Orvad (CT) Balitha (CT) Salvav (CT) Chhiri (CT) Chanod (CT) Karvad (CT) Lavachha (CT) Kaprada Umbergaon (Source: Census-2011 for Valsad District) Main worker: Who has worked last year for six month or more? Marginal worker: Who has worked last year for less than six months? Non-worker: Who did not work at all during the reference period of one year? Distribution of main worker and marginal worker into further following four categories are shown in Table Cultivators Agricultural labors Household industry Others worker M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 171

187 TABLE: 3.20 DISTRIBUTION OF WORKERS Sr. No. Area Name Pardi Taluka Main worker Cultivators Agricultural Labours Household Industry Marginal worker Others Cultivators Agricultural Labours Household Industry 1 Pardi Umarsadi Badla Kumbhariya Sondhalwada Parvasa Kachwal Mota Waghchhipa Nana Waghchhipa Sukhesh Borlai Sukhlav Velparva Khadki Motiwada Palsana Kalsar Udwada Kolak Kilkara Rentlav Others M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 172

188 Sr. Area Main worker Marginal worker No. Name Cultivators Agricultural Household Others Cultivators Agricultural Household Others Labours Industry Labours Industry 22 Dungri Dashwada Amli Sonwada Varai Nimkhal Panchlai Lakhmapor Nevri Rabdi Asma Tarmaliya Khuntej Sarodhi Saran Tarakpardi Vatar Kunta Morai Bagwada Tighara Paria Rohina Samarpada Dhagadmal M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 173

189 Sr. Area Main worker Marginal worker No. Name Cultivators Agricultural Household Others Cultivators Agricultural Household Others Labours Industry Labours Industry 47 Daheli Chival Arnala Pati Goima Barai Dumalav Tukwada Ambach Kherlav Pandor Rata Chharwada Namdha Chandor Kocharva Vankachh Kaval Karaya Nani Tambadi Degam Moti Tambadi Karamkhal Chibhad Kachchh M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 174

190 Sr. Area Main worker Marginal worker No. Name Cultivators Agricultural Household Others Cultivators Agricultural Household Others Labours Industry Labours Industry 72 Pardi (M) WARD NO WARD NO WARD NO WARD NO WARD NO WARD NO WARD NO Vapi (M) WARD NO WARD NO WARD NO WARD NO WARD NO WARD NO WARD NO (Source: Census-2011 for Valsad District) M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 175

191 3.10 EARTHQUAKE VULNERABILITY Map of Earthquake vulnerability is shown in below Figure. FIGURE: 3.9 EARTHQUAKE VULNERABILITY MAP 3.11 WIND AND CYCLONE VULNERABILITY Map of Wind and cyclone vulnerability is shown in below Figure. FIGURE: 3.10 WIND AND CYCLONE VULNERABILITY MAP M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 176

192 3.12 TRAFFIC SURVEY RECONNAISSANCE The traffic survey, to ascertain the traffic density in the study area was conducted on the road near the project site. The composition of Traffic includes Two Wheelers, Three Wheelers (Goods & Passenger Autos, Four Wheeler (Passenger Cars) and Four Wheeler Heavy Vehicles like Trucks, Lorries, Busses etc TRAFFIC SURVEY OF THE STUDY AREA Data was collected by physically counting the number of vehicles playing in both directions of NH-8: Delhi to Mumbai Highway. The hourly counts were carried out for the different type/ category of vehicles. The variation in the traffic flow at the given road along with the numbers of vehicles during peak hour & lean hour is presented in the table below. While it s graphical representation is done in figure below. TABLE: 3.21 TRAFFIC SURVEY OF DELHI TO MUMBAI HIGHWAY (NH-8) Sr. No. Vehicle Type During Lean Hrs. (No. of Vehicles/Hr) No. of Vehicles In PCU During Lean Hrs During Peak Hrs (No. of Vehicles/Hr) 1. Two Wheelers Three Wheelers Cars Buses/ Mini Buses Trucks/ Lorries 6. 2 Axle Truck Axle Truck No. of Vehicles In PCU During Peak Hrs EXISTING TRAFFIC SCENARIO AND LEVEL OF SERVICES (UP) The road from Delhi to Mumbai is four lane with divider. Capacity of road as per IRC= 2500 PUC s/ hr Total volume during peak hours= 1443 Nos. Existing volume / capacity ratio= 1443/2500= The level of service is C that is good M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 177

193 TABLE: 3.22 LEVEL OF SERVICE Sr. No. Existing volume/ Capacity Ratio Levels of Services to 0.2 A (Excellent) to 0.4 B (Very Good) to 0.6 C (Good) to 0.8 D (fair) to 1.0 E (Poor) Location: From B to A (Down): From Mumbai to Delhi TABLE: 3.23 MUMBAI TO DELHI HIGHWAY (NH-8) Sr. No. Vehicle Type During Lean Hrs. (No. of Vehicles/Hr) No. of Vehicles In PCU During Lean Hrs During Peak Hrs (No. of Vehicles/Hr) 1. Two Wheelers Three Wheelers Cars Buses/ Mini Buses Trucks/ Lorries Axle Truck Axle Truck No. of Vehicles In PCU During Peak Hrs Existing Traffic Scenario and Level of Services (Down) Capacity of road as per IRC= 2500 PUC s/ hr Total volume during peak hours= 1384 Existing volume / capacity ratio= 1384/2500=0.55 The level of service is C that is good Results: The above traffic reveals the LOS (Levels of Service) as C Good for the NH-8 Road, Which are 4 lane roads divider for proposed project scenario. Since adequate parking is provided and increase in traffic due to proposed project has taken care by the 4 lane road. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 178

194 EIA REPORT OF M/S. AARTI INDUSTRIES LIMITED (APPLE ORGANICS DIVISION), VAPI. CHAPTER -5 ANALYSIS OF ALERNATIVES (TECHNOLOGY & SITE) 5.1 INTRODUCTION M/s. Aarti Industries Ltd. (Apple Organics Division) is an existing pilot plant, located at Plot no. 609/610, 100 Shed Area, GIDC Estate, Pardi, Vapi, Dist.:-Valsad, Gujarat. The unit has already engaged with manufacturing of synthetic organic products. Existing production capacity is 18 or 20 MT/Month. Now, the unit wants to go for proposed expansion in existing plot. After expansion, total group wise proposed production capacity will be 20 MT/Month and total by products quantity in worst case scenario will be MT/Month. 5.2 SITE ANALYSIS OF ALERNATIVES The unit has proposed expansion in existing plot area, because existing plot area is sufficient for proposed expansion. The total plot area of the unit is 1752 sq. m. The total green belt area is 183 sq. m. Plot allotment letter from GIDC, Ankleshwar is attached as Annexure IV. The proposed plant layout is attached as Annexure VII. The project proponent did not consider any other alternative site for proposed expansion: The land located in the notified industrial area so there will be no alternative for site. The unit already exists and has procured applicable permissions for existing plant. The project proponent already possess ready infrastructure for existing capacity; where the product would be manufactured with regulate modification. Uninterrupted availability of sufficient water (from GIDC authority). No significant physical displacement of the members of the public. Connectivity of the site via road and train to procure the raw material and to dispatch the products. Vicinity of common environmental infrastructure; like VW&EMCL, VGEL. 5.3 TECHNOLOGY ANALYSIS Well established technology for R & D will be used as pilot scale. Weary trials to optimize the reaction condition will be carried out at pilot plant. All the unit optimize will be continuous instead of batch operation. All the unit operation will have primary effluent treatment plant facility mainly phantom treatment to achieve less than 5000 COD. A general facility of Hydro cavitation will be also be installed. Solvent recovery will be achieve more than 95% using two stage condenser. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR. 209

195 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. CHAPTER 6 ENVIRONMENTAL MONITORING PROGRAM 6.1 INTRODUCTION Environmental monitoring describes the processes and activities that need to take place to characterize and monitor the quality of the environment. Environmental monitoring is used in the preparation of environmental impact assessments, as well as in many circumstances in which human activities carry a risk of harmful effects on the natural environment. All monitoring strategies and programmed have reasons and justifications which are often designed to establish the current status of an environment and Prediction of the impact of future development and/or alteration in the operation and design of existing installations. Environmental Monitoring Network is operation phase of the project for monitoring of various environmental parameters like air, water, noise, soil etc. A well defined environmental monitoring programme would be employed with trained and qualified staff of Environmental Management Cell of the proposed expansion project to monitor the environmental attributes of the area with respect to EMP as well as the guidelines of the GPCB/CPCB. Environment monitoring schedule proposed to be adopted by the project. 6.2 OBJECTIVES OF ENVIRONMENTAL MONITORING PLAN To comply with the statutory requirements of monitoring for compliance with conditions of NOC and CC&A. To comply with the provision of Factory Act & MSIHC Rules. To verify the results of the impact assessment study in particular with regards to new development. Identification of any significant adverse transformation in environmental condition to plan additional mitigation measures; if & as required. To check or assess the efficiency of the controlling measures. To ensure that new parameters, other than those identified in the impact assessment study, do not become critical through the commissioning of new project. To establish a data base for future Impact Assessment Studies for new project. 6.3 IMPLEMENTATION SCHEDULE OF MONITORING MEASURES Monitoring should be done as periodically to understand the environmental condition of the site. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 210

196 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. The mitigation measures suggested in the Chapter-4 should be implementing so as to reduce the impact on environment due to the operations of the proposed project. In order to facilitate easy implementation, mitigation measures are phased as per the priority implementation. The priority of the implementation schedule is given in Table 6.1. TABLE 6.1 IMPLEMENTATION POLLUTION CONTROL MEASURES Sr. No. Required Measures Stage Remarks 1. Air pollution control measures 2. Drinking Water parameter. 3. Waste Water Treatment 4. Greenbelt development 5. Hazardous waste disposal During operation stage. During operation stage. Operation phase of the project. During ooperation stage. Operation phase of the project. Electrostatic precipitator and Scrubber system. As per IS Standard Quarterly monitor quality of water. Treated at effluent treatment plant. Plantation will be done along the boundary and specified sites shown in master plan. Collection /storage /transportation /disposal at TSDF-VWEMCL, Vapi. 6.4 POLLUTION MONITORING AND SURVEILLANCE SYSTEM Regular monitoring of important parameters is of immense importance to assess the status of environment during plant operation. With the knowledge of baseline conditions, a properly planned monitoring program can serve as an indicator for assessment of any deterioration in environment conditions. This will facilitate undertaking suitable measures to mitigate adverse impact during the operation of the plant and further help to protect the environment in the area. The main attributes for which monitoring has carried out are: Ambient Air Quality Stack Emission Effluent water Quality Noise Level The above mentioned sources will be monitored so as to meet the requirements of the State Pollution Control Board. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 211

197 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI AMBIENT AIR QUALITY MONITORING The ambient air quality with respect to PM 10, PM 2.5, SO 2, and NOX & VOC has monitor at ETP area, process area, storage area and one location in downwind direction. The frequency of monitoring will be every three month by external approved monitoring agency STACK MONITORING All the flue gas stacks in the proposed project has monitored with respect to temperature, oxides of nitrogen (NO X), Suspended Particulate Matter (SPM) and Sulphur dioxide (SO 2) level. The process stacks are monitored for NH 3, HCl, NO x, Br 2, HB r, NO 2 and Cl 2. Automatic/online monitoring system will be installing for stack monitoring NOISE MONITORING Monitoring of noise levels is essential to assess the effectiveness of Environmental Management Plan implemented to reduce noise levels. A good quality sound level meter and noise exposure meter may be procured for the same. Audiometric tests have conducted periodically for the employees working close to the high noise sources. The noise levels due to machines/equipments viz. compressor, motors, engines etc has monitored regularly WATER AND WASTE WATER QUALITY MONITORING Daily analysis of effluent stream is recommended. Sampling and analysis of the raw effluent, collection tank, Primary Settling Tank, Pressure Sand Filter, Activated Carbon Filter and Final Collection tank will be conducted regularly. The detailed monitoring plan is tabulated in Table 6.2. TABLE 6.2 ENVIRONMENT MONITORING PLAN Sr. No. Description Location Parameter To Be Monitored 1. Flue gas Existing one Boiler PM, SO 2, NO X emission stacks (Natural gas) monitoring One proposed D.G. PM, SO 2, NO X stacks 2. Process gas Proposed Stack- HCl, NOx, Br2, emission Plant -1 & Plant-2 HB r, NO 2, Cl 2 monitoring plan Proposed Stack NH 3 Plant-3 3. Ambient air monitoring plan One location in upwind direction & PM 10 PM2.5 Frequency of Monitoring Every three month by external approved monitoring agency. 1) Online meter will be provided for Chlorine, HCl, Br 2, HBr & NOx. 2) Every three month by external approved monitoring agency. Every three month by external approved M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 212

198 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. Sr. No. Description Location Parameter To Be Monitored one location in SO 2 downwind direction. NO X Nine location within company premises 4. Noise monitoring 5. Water quality monitoring for EFLUENT TREATMENT PLANT 5.1 Effluent quality before neutralisation Collection tank 5.2 Effluent quality after neutralization 5.3 Effluent quality after PSF & Activated Carbon Filter Neutralization Tank At CETP inlet Frequency of Monitoring monitoring agency. --- Every three month by in house facility monitoring. For TDS, ph, COD,TSS, Ammonical nitrogen, Chlorides, Sulfates For TDS, ph, COD, TSS, Ammonical nitrogen. For TDS, ph, COD. 1) Every three month by external approved monitoring agency. 2) Every day by self analytical facility. 1) Every three month by external approved monitoring agency. 2) Every day by self analytical facility. 1) Flow meter is already installed. 2) Every day by self analytical facility. 6. Water Quantity Monitoring 6.1 Inlet & Outlet ETP Quantity in KL Flow meter 6.2 Inlet Boiler Quantity in KL Flow meter 6.3 Inlet Cooling Tower Quantity in KL Flow meter 6.4 Inlet Process Quantity in KL Flow meter 6.5 Inlet Domestic Quantity in KL Flow meter 7. Hazardous waste monitoring Sludge drying bed ph, Chloride, Alkalinity, CV. Comprehensive analysis every 2 year. 8. Electricity consumption monitoring 8.1 ETP Plant ETP Electricity Separate electricity meter and daily reading will be noted. 6.5 MONITORING EQUIPMENT AND CONSUMABLES A well-equipped laboratory with consumable items will be established for monitoring of important environmental parameter. Alternatively, monitoring can be outsourced from NABL / MoEF recognized laboratory. Details of equipment s and in-house monitoring facilities are shown in below table. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 213

199 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. TABLE 6.3 LIST OF LAB EQUIPMENTS Sr. No. Title A M.E. (MEASURING EQUIPMENT): 1. Automatic Moisture Analyser 2. Bead Strength Tester 3. Conductivity Meter 4. Digital Balance 5. Digital Burette 6. Flame photometer 7. Gas Chromatograph 8. Glass Thermometer 9. Karl Fisher 10. ph Meter 11. Portable Spectrophotometer(Hach) 12. Referactometer 13. Resistivity Meter 14. Sieve 15. Turbidity Meter 16. Viscometer B A.E. (AUXILLARY EQUIPMENT) 1. Centrifuge 2. COD Digester 3. Digital Shaking Machine 4. Electric Stirrer 5. Fume Hood Cupboard 6. Microscope 7. Muffle Furnace 8. Magnetic Stirrer 9. Oven 10. Vacuum Oven 6.6 ENVIRONMENTAL MANAGEMENT CELL Company will ensure to conduct all business operations in compliance with applicable laws, regulations and standards related to occupational Health, Safety and Environment (HSE). An Environmental Management Cell with adequate professional expertise and resources shall be established to discharge responsibilities related to environmental management including statutory compliance, pollution prevention, environmental monitoring, etc. The EMC will be made responsible for all issues related to environmental management of the proposed project facilities. List of employee responsible for operation & maintenance of ETP is given in below table. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 214

200 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. TABLE: 6.4 LIST OF ETP OPERATION EMPLOYEES Sr. No. Name Designation Total Experience 1. Mr. Anil Shah Site Head 28 Years 2. Mr. Dilip Patel Executive-ETP Incharge 16 Years 3. Mr. Ketan Wani Executive 05 Years 4. Mr. Rajnish Kanojia Operator 10 Years 5. Mr. Nimesh Patel Supervisor 10 Years 6. Mr. Hiren B. Patel Operator 11 Years 7. Mr. Harshad Paliwal Operator 08 Years 8 Mr. Gunan Mandal Operator 07 Years There shall be HSE Manager for overseeing all environment and safety responses to ensure the implementation of EMP mentioned during construction and operation phase including findings / recommendations of third party audits and monitoring results as mentioned in the EMP. At least one permanent employee with adequate educational and professional qualification and experience to discharge responsibilities related to environmental management including statutory compliance, pollution prevention, environmental monitoring will be employed by company and will directly report to the director of the organization operations. Environment management cell/ Hierarchical system is shown in below Figure 6.1. The unit has already developed system of reporting of non-compliances/violations of environmental norms to the chairman & directors of the company. Whenever such situations come in, which could be detrimental to environmental in that case Plant Manager directly coordinates with Department head & Division head. This will ultimately lead to the highest chain of command which has authority to take decisions. The unit has developed emergency reporting system is shown in below Figure 6.2. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 215

201 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. FIGURE: 6.1 FLOW DIAGRAM OF ENVIRONMENTAL MANAGEMENT CELL Director (Technical) Vice President General Manager (EHS Corporate) Site head Sr. Manager (Environment) Sr. Manager (Safety) Executive (Environment) Officer (Safety) Shift supervisor (ETP) Shift operator (ETP) FIGURE: 6.2 FLOW DIAGRAM OF EMERGENCY REPORTING SYSTEM Operator Plant Manager Department Head Div. Head Director MD M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 216

202 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. CHAPTER 7 RISK ASSESSMENT ADDITIONAL STUDIES In order to support the environment impact assessment and environment management plan, following additional studies have been included in this report. Risk Assessment Onsite and Offsite Disaster (natural and manmade) Preparedness and Emergency Management Plan Occupational Health Program 7.1 SCOPE OF THIS STUDY: The QRA study in this report has been conducted considering the Terms of References (TORs) given by Expert Appraisal Committee of MoEF for Environment Clearance (EC). The study has been carried out with a view to comply the following TOR points as per Annexure-I by SEIAA, Gujarat: 52. Occupational health impacts on the workers and mitigation measures proposed to avoid the human health hazards along with the personal protective equipment to be provided. Provision of industrial hygienist and monitoring of the occupational injury to workers as well as impact on the workers. Plan for periodic medical checkup of the workers exposed. Details of work place ambient air quality monitoring plan as per Gujarat Factories Rules. 54. Risk assessment including prediction of the worst-case scenario and maximum credible accident scenarios should be carried out. The worst-case scenario should take into account the maximum inventory of Storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly showing which of the facilities would be affected in case of an accident taking place. Based on the same, proposed safeguard measures including On-Site / Off-Site Emergency Plan should be provided. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 217

203 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI. 56. Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health impacts. This shall include the details of Antidotes also. 57. Details of quantity of each hazardous chemical (including solvents) to be stored, Material of Construction (MoC) of major hazardous chemical storage tanks, dyke details, threshold storage quantity as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardous chemicals, size of the biggest storage tank to be provided for each raw material & product etc. How the manual handling of the hazardous chemicals will be minimized? 59. Submit checklist in the form of Do s & Don ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures. 60. Specify safety precautions to be taken for Chemical storage, process, and handling& transportation hazard. 61. Details on workers training before engaging work, periodical, in-house, outside etc. 64. Specific safety measures to be taken for general Public living in the vicinity. 65. Details on hazard identification i.e. HAZOP, HAZAN, Fault tree analysis, Event tree analysis, Checklist, Audit etc. to be adopted for the safety operation of the plant. 7.2 METHODOLOGY OF RISK ASSESSMENT M/s. Aarti Industries Ltd. (Apple Organics Division), Vapi handles various chemicals, some of which are hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of them. Fire, explosion, toxic release or combinations of them are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Identification and Qualitative/Quantitative Risk Assessment have been developed to improve upon the integrity, reliability and safety of industrial plants, the same has been discussed in detail under their respective headings. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 218

204 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI OBJECTIVES OF RISK ASSESSMENT Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of risks the neighbouring populations are exposed to as a result of hazards present. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate. Consequently, the risk analysis is often confined to maximum credible accident studies. Risk assessment is carried out with the following objectives: 1.To identify hazard and risk resulting from the hazards. 2.To study and foresee the effects of such risks on the workers, public, property and environment and to find out necessary control measures to prevent or minimize risk. 3.To comply the legal requirement by various safety and environment laws of the country like The Factories Act, 1948 The Gujarat Factories Act, 1963 The Environment Protection Act and Rules, 1986 Hazardous waste (Management & Handling) Rules, 1989 Public Liability Insurance Act & Rules,1991 Chemical Accident, (Emergency, planning, preparedness and response) Rules, To get the necessary information for Emergency planning and evacuation. M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 219

205 EIA REPORT OF M/s. AARTI INDUSTRIES LTD. (APPLE ORGANICS DIVISION), VAPI DETAILS OF STORAGE FACILITIES The storage facility for major hazardous chemicals has been marked on the company layout given below with Separate Entry & Exit gates. FIGURE: 7.1 HAZARDOUS CHEMICAL LOCATION IN COMPANY LAYOUT M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LIMITED, ANKLESHWAR. 220