Reply of POINT NO. 1 :

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Christal Lang
5 years ago
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4 Reply of POINT NO. 1 : Net energy consumption for the plant and the energy balance should be submitted and details regarding Heat recovery system from the exhaust gas and other plant operations should be submitted.

PROPANE GAS SAVING DUE TO INGOT PREHEATING 92 Ki data CONSUMPTION AREA EQUIPMENT NAME FUEL TYPE FUEL CONSUMPTION (METER CUBE) CALORIFIC VALUE (KCAL/KG) WASTE HEAT RECOVERY (YES/NO) REMARKS MELTING

5 PROPANE GAS SAVING DUE TO INGOT PREHEATING 92 Ki data CONSUMPTION AREA EQUIPMENT NAME FUEL TYPE FUEL CONSUMPTION (METER CUBE) CALORIFIC VALUE (KCAL/KG) WASTE HEAT RECOVERY (YES/NO) REMARKS MELTING FURNACE Melting Furnace Total PROPANE YES Waste heat used for preheating the ingots SL NO Total aluminum melting in Tons With pre heating Propane Gas consumption-92ki in m3 Propane gas saved for preheating -92Ki in m TOTAL PROPANE GAS SAVINGS FOR 92KI IS 57603metre cube

6 Fuel Consumption data from Paint 180 K_FUEL CONSUMPTION AREA EQUIPMENT NAME FUEL TYPE FUEL CONSUMPTION (SCM) CALORIFIC VALUE (KCAL/SCM) TOTAL REQUI. MKCAL WASTE HEAT (EXHAUST) MKCAL WASTE HEAT RECOVERY (YES/NO) WASTE HEAT RECOVERY (MKCAL) FUEL CONSERVATION (MKCAL) PAINT SHOP PAINT SHOP TOTAL CNG YES K_POWER CONSUMPTION AREA EQUIPMENT NAME POWER TYPE POWER CONSUMPTION (KWH) POWER CONSERVATION (YES/NO) POWER CONSERVATION (KWH) PAINT SHOP PAINT SHOP TOTAL GRID YES Power Conservation back up sheet Sl No Title of Energy Saving project implemented POWER CONSERVATION (KWH) Status 1 Control Flow of High Pr. Pump through VFD in RO Plant In progress 2 Replace ED Chiller Condenser pump from 25M to 20M Head In progress 3 Overhead light automation Completed 4 Cooling tower eff. improvement by controlling the fan opration on temp. controller Completed 5 Energy wastage reduction in ED chiller system during winter season by using cooling tower Completed 6 Installation of LED Lights in non process area in place of ordinary lights In progress 7 Sludge pit : replace 10 existing pumps from 30M to 15M Head In progress Fuel Conservation back up sheet Sl No Title of Energy Saving project implemented FUEL CONSERVATION (SCM) Status 1 Flue gas heat recovery In progress 2 Magnetic resonator ovens burner Completed 3 Flue gas analysis and control motor adjustment in HWG 3000 In progress

7 Reply of POINT NO. 2- Submission of Details Paint Sludge disposal Paint Sludge Disposal Process - HCIL Paint Sludge generation from Paint shop & POPA Shop Collection of Paint Sludge (hazardous waste in nature) in the containers Drying of paint sludge on the drying beds for the period of 7 to 10 days Storage of the dried paint sludge into HDPE bags Sent to CPCB & RSPCB approved, authorized party for Co-processing

REPLY Point No. 3 & 4 : VOC Emission data in Plant Location Paint Shop S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, 1948 1 VOC (toluene+ Xylene+ Benzene) 245.

9 REPLY Point No. 3 & 4 : VOC Emission data in Plant Location Paint Shop S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, VOC (toluene+ Xylene+ Benzene) mg/m mg/m3 OSHA Test Protocol VOC is with in Govt. specified limit.

10 Location Paint Shop S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, VOC (toluene+ Xylene+ Benzene) 259 mg/m mg/m3 OSHA Test Protocol VOC is with in Govt. specified limit.

11 Location Paint Shop S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, 1948 Test Protocol 1 VOC (toluene+ Xylene+ Benzene) mg/m mg/m3 OSHA VOC is with in Govt. specified limit.

12 Location PO Location POPA S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, VOC (toluene+ Xylene+ Benzene) Test Protoco l NT mg/m3 OSHA S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, VOC (toluene+ Xylene+ Benzene) Test Protoc ol NT mg/m3 OSHA VOC is with in Govt. specified limit.

13 Location POPA S. No. Parameters Result Permissible limit of Exposure, As per Factories Act, VOC (toluene+ Xylene+ Benzene) Test Protocol NT mg/m3 OSHA VOC is with in Govt. specified limit.

14 Stack Air Analysis report VOC in all stack monitoring reports is with in Govt. specified limit.

15 REPLY Point No. 5 TDS Management and Calculation should be submitted for the effluent

16 TDS Balance- Fresh water 1774 KLD & Recycle 558 KLD (Total 2332) Ref EIA 660 cars/ day Bore well 1774 KLD Recycle water 1174 Raw water Tank All units in KLD @ ~ 10% Flushing water 60 Domestic Cooling Process 600 (Drinking, Canteen, Toilets) 60 KLD ~20% (Consumed in drinking) 540@ 700 ~ 12% Blow down (Air washer & 5000 WWTP-614 (Waste water treatment plant (Paint) ~ 90% EVP Loss 92 KL~ 15% Loss 460 Process Car Process Power Train 40 ETP Effluent treatment plant (Coolant) 34@ KL~ 15% Loss Flushing water in toilets STP- 600 Sewage treatment plant Horticulture 90 KL~ 15% Loss KLD Recycle Plant 414 < 2000 PPM TDS in PPM

17 REPLY Point No. 6 Worker Health report S no Reports HONDA STATUS LEGAL REQMNT TECHNICAL REQUIRMENT REMARK 1 MEDICAL EXAMINATIONS OF ASSOCIATES 2 AUDIOMETRY Done (including some areas not under legal reqmnt) Done Yes Manpower selection and details of surveillance methods are subject to local requirement Associates working in High Noise areas Periodical PTA with comparative trend analysis for TTS and PTS Technically relevant to the conditions is important Coordinate with Deptt s & Safety 3 SPIROMETRY Expiratory Flow Metry done (PEFR) 4 X-RAYS Not done Not for auto manufacturing for industry like construction, cement industry, cotton mills, asbestos works etc and cause structural damage in addition to functional disease * 5 MUSCULO SKELETAL DISORDERS Planning a comprehensive Ergonomic program In June 2016, 819 employees were subjected to OHS including 220 Audiometry's Not specified PEFR is internationally recognised as the most effective and appropriate method to detect occupational functional lung disease In industries where fine particles of any material enter the lungs of workers during occupation and cause structural and functional damage PEFR iss good enough for Screening Spirometry is detailed diagnostics not necessary for screening X-ray findings could be critical in trend analysis * In auto industry functional lung disease like asthma and bronchitis etc cannot be detected in Xrays In such cases undue exposure to harmful Xrays is not warranted PEFR (Flowmetry) is useful in Auto industry No Yes Important in terms of Occupational Health Work Environment Monitoring and Task hazrd Analysis reports are must for starting the process

18 Worker Health report

19 Worker Health report

20 REPLY Point No. 7 Water Balance for the plant operation should be submitted

21 Water Balance- Fresh water 1774 KLD & Recycle 558 KLD (Total 2332) Ref EIA 660 cars/ day Bore well 1774 KLD Recycle water 1174 Raw water Tank 558KLD 1732 All units in KLD ~ 10% Flushing water 60 Domestic Cooling Process 600 (Drinking, Canteen, Toilets) 60 KLD ~20% (Consumed in drinking) 540 ~ 12% Blow down 1232 (Air washer & CT) ~ 90% EVP Loss 460 Process Car Process Power Train WWTP-614 (Waste water treatment plant (Paint) 92 KL~ 15% Loss ETP Effluent treatment plant (Coolant) 34 6 KL~ 15% Loss STP- 600 Sewage treatment plant ( ) Recycle Plant 558 Flushing water in toilets Horticulture 448 KLD

22 REPLY Point No. 8 Non-methane HC Ambient Air monitoring data for NMHC Sr. No. Parameters Result Standard Limits 1 Non Methane Hydro Carbon(NMHC) NT 0.01 ppm Non Methane Hydro Carbon(NMHC) is not detected in Ambient Area

23 REPLY Point No. 9 Notification for Industrial area

FORM-1 FOR PROPOSED API PLANT AT MADURAI, TAMIL NADU. Name of Products. Products. 1 Metformin Hydrochloride Paracetamol Bronopol 25

FORM-1 FOR PROPOSED API PLANT AT MADURAI, TAMIL NADU. Name of Products. Products. 1 Metformin Hydrochloride Paracetamol Bronopol 25 3 ANNEXURES Annexure 1: Production Details Name of Products Products Production Capacity in MT/Month 1 Metformin Hydrochloride 1000 2 Paracetamol 1200 3 Bronopol 25 By-Products Total 2225 1 Acetic acid