Draft Environmental Impact Assessment Report

Transcription

1 Draft Environmental Impact Assessment Report For proposed expansion of Formaldehyde and manufacturing of Paraformaldehyde & Reprocessing Silver (Purification of Silver) Category: 5(f) of Balaji Formalin Pvt. Ltd. Plot No. 1398, Village: Moti Bhoyan, Taluka: Kalol, Dist.: Gandhinagar, Gujarat Prepared by: San Envirotech Pvt. Ltd. 424, Medicine Market, Paldi Cross Road, Ahmedabad (March, 2016) Accreditation as per MOM of MoEF, No. is 136, dated 8 th February, 2016

2 Contents San Envirotech Pvt. Ltd., Ahmedabad Particulars Page No. Contents 1-8 List of Tables 9-11 List of Figures 12 List of Annexures 13 Index Chapter 1 Introduction Page No. 1.1 Preface Purpose of the Report Identification of Project & Project Proponent Identification of Project site with site specific 1-3 criteria Project Identification with respect to category Project Proponent Brief Description of Project Nature of the project Size of the Project Location of the project Regulatory Framework Scope of the Study Compliance to Terms of Reference Objectives of EIA Methodology for EIA Details of Industries 1-24 Chapter 2 Project Description 2.1 Introduction Type of project Need for the expansion Capital Investment Land Requirement Location of the project Size or Magnitude of Operation Proposed schedule for approval and implementation 2-3 EIA report of Balaji Formalin Pvt. Ltd. 1

3 2.9 Details of Major Equipment and Machinery (Existing & Proposed) 2.10 Manufacturing process, chemical reaction and mass balance Formaldehyde Production Technique Process of making Para-formaldehyde from 2-9 Methanol using rake type drying method Process of Silver Refining Project Components Input Requirements (a) Raw Material Requirement 2-14 (b) Water Requirement 2-14 (c) Fuel 2-14 (d) Power 2-14 (e) Manpower Utilities Requirement Generation of Pollutants Wastewater Generation Gaseous Emissions Hazardous/Solid Waste generation Noise pollution Pollution Control measures Effluent Management Air Pollution Control Hazardous/Solid Waste Management Noise Control Measures Fugitive Emission Control Resource Conservation Heat Recovery Rain Water Harvesting System Green Belt Development Odour control Health & Safety 2-19 Chapter 3 Baseline Environmental Status 3.1 Prelude Study area Period of the study area 3-1 EIA report of Balaji Formalin Pvt. Ltd. 2

4 3.1.3 Basic Component of the Environment Methodology Establishment of baseline for Valued 3-6 Environmental Components 3.3 Air Environment Design of Network for Ambient Air Quality 3-7 Monitoring Stations Reconnaissance Micrometeorology of the area Ambient Air Quality Survey Baseline Status Hydro-geological status of the study area Water Environment Ground Water Quality (Primary data) Noise Environment (Primary data) Introduction Methodology Day-Time and Night-Time Noise Levels Ambient Air Quality Standards in Respect of 3-13 Noise Ambient Noise Levels in the Study Area Conclusions Soil Environment (Primary data) Introduction Soil Characteristics Corollaries Ecology (Primary data) Period of the study Study methodology Floral Diversity in the study area Cultivated plants in the study area Faunal Diversity in the study area Socio Economic & Land use (Secondary data) Land use pattern and infrastructure Demographic and Socio-Economic Environment Living Standard and Infrastructure 3-18 EIA report of Balaji Formalin Pvt. Ltd. 3

5 Chapter 4 Anticipated Environmental Impacts & Mitigation Measures 4.1 General Impact on Topography Air Environment Prediction of Impact during Construction Phase Prediction of Impact during Operational Phase Sources of Air Pollution Dispersion Modelling of Emissions from the plant Micrometeorology Air Quality Modeling and Predictions using the 4-5 Gaussian model Details of Air Dispersion Model Predicted GLCs Water Environment Noise Level Impact Prediction of impact During Construction Phase Prediction of impact During Operational Phase Land/soil Environment Prediction of impact during Construction Phase Prediction of impact during Operation Phase Ecological Impacts (Flora and Fauna) Socio-Economic Impact Mitigation Measures during Construction Mitigation Measures during the Operational phase Measures for Air Environment Measures for Water Environment Measures for Hazardous/Solid Waste Measures for Noise Health & Safety Measures 4-14 Chapter 5 Analysis of Alternatives 5.1 Prologue Project Details Site Alternative Alternative For Technologies 5-2 Chapter 6 Environmental Monitoring Programme 6.1 Prelude 6-1 EIA report of Balaji Formalin Pvt. Ltd. 4

6 6.2 Environment Monitoring Program Objective of Monitoring Plan Schedules for Environment Monitoring Ambient Air Quality Monitoring 6-2 Chapter 7 Risk Assessment Report 7.1 Introduction Scope of Study Study Objective The Study Approach System Description Identification of Hazards Risk Reduction Measures Probable Hazards & Risk Hazardous Identification Hazardous Substances to be handled at Balaji Formalin Pvt. Ltd. 7.5 Hazardous Materials Classification Raw Materials Occupational Health Risk Assessment Risk Screening Approach QRA Approach Thermal Hazards Damage due to Explosion Toxic Release Likely Failure Scenarios Consequence Analysis Pro-active Safety Measures Action plan for handling & safety system Safety Measures for Transportation and Unloading of Hazardous Chemicals Safety Measures for Storage/Handling of 7-23 Hazardous Chemicals Safety Measures for Process Units Safety Measures for Preventive Maintenance Safety measures to prevent spillage/leakage of 7-25 toxic chemicals 7.15 Safety management plan for acutely toxic 7-25 EIA report of Balaji Formalin Pvt. Ltd. 5

7 chemicals Hazard Summary Special Handling Procedures and Storage 7-26 Requirements Personal Protective Equipment Spill and Accident Procedures Fire and Emergency Evacuation Procedures Arrangements for ensuring Health and safety of workers engaged in handling of toxic materials On-site emergency plan General Statutory Requirement Preparedness of On Site Emergency Plan Emergency Time Activities Sequential actions during emergency Incident Responding Actions Site Crisis Messages Discipline Emergency Actions Shut Down Procedure Post Emergency Activities Training, rehearsal and records Need of Training & Rehearsal Off-site emergency plan Need of Off-Site Emergency Plan Role of the Factory Management Role of the Emergency Co-ordination Office (ECO) Role of the Local Authority Role of the Fire Authorities Role of the Police and Evacuation Authorities Role of the Health Authorities Role of the Mutual Aid Agencies Role of the factory Inspectorate Disaster management Plan/emergency management plan 7-44 EIA report of Balaji Formalin Pvt. Ltd. 6

8 Objectives Emergency Management Plan Responsibilities & Role of Key Personnel Post Emergency Recovery Accident Investigation Damage Assessment Cleanup and Restoration 7-53 Chapter 8 Project Benefits 8.1 Introduction Improvements in the physical infrastructure 8-1 including technical facility aspects 8.3 Improvement in Social Infrastructure Employment potential Other tangible benefits 8-3 Chapter 9 Environmental Cost Benefit Analysis 9.0 Environmental Cost Benefit Analysis 9-1 Chapter 10 Environment Management Plan 10.1 Introduction Objective of Environmental Management Plan Components of EMP Environmental Management systems Environmental, Health and Safety Management 10-2 System Environmental Management Cell Environmental Management during construction 10-3 phase 10.5 Environmental Management during operational phase Air Environment Measures for fugitive emissions Water Environment Hazardous/Solid Waste Management Noise Control Technique Green Belt Development Resource Conservation/Waste Minimization Action Plan for Transportation of Raw Material and Products Safety Instructions for transportation of EIA report of Balaji Formalin Pvt. Ltd. 7

9 hazardous materials Instructions for drivers & Responsibilities of drivers Manner of display of class labels Health & Safety Possibility of occupational health hazard & its control Possibility of occupational health hazard, its control & Occupational surveillance Preventive Measures Occupational Health Programme Occupational Health and First aid measures Socio-Economic activities Post-Project Environmental Monitoring Environment Management cost estimate Environment Policy Reporting System of Non Compliances/Violations of Environmental Norms Chapter 11 Summary & Conclusion Project Description Location of Project Product Profile Investment of the Project Description of Environment Baseline Environmental Study Air Environment Water Environment Noise Environment Anticipated Environmental Impacts and 11-5 mitigation Measures 11.4 Environment Monitoring Programme Additional Studies Risk Assessment Environmental Management Plan Project Benefits Conclusion 11-9 Chapter-12 Disclosure of Consultant engaged 12-1 EIA report of Balaji Formalin Pvt. Ltd. 8

10 List of Tables San Envirotech Pvt. Ltd., Ahmedabad Table No. Name Page No. 1.1 Product details Details of four corners Co-Ordinate of Site List of major industries Structural facilities along with land break up Location Details List of Products Plant Machineries (Existing & Proposed) Utility Details Details of raw materials along with source & mode of transportation Breakup of water consumption (a) Wastewater Generation Details of stacks with air emission quality (a) Sources of fugitive emission with its quantification (Estimated) Technical Details of forced evaporator Details of Hazardous waste Noise Survey of existing plant Methodology of Ambient Air Monitoring Surface Water Sampling Locations Ground Water Sampling Locations Surface Soil Sampling Locations Soil Sample Analysis Methodology Monitoring Methodology of Noise Ambient Air Quality Monitoring Locations Ambient Air Quality Status Ambient Air Quality Status (PM 10 ) Ambient Air Quality Status (PM 2.5 ) Ambient Air Quality Status (SO 2 ) Ambient Air Quality Status (NO x ) Ambient Air Quality Status (CO, HC, VOCs) National Ambient Air Quality Standards Results of Groundwater Quality in the Study Area Results of Surface water Quality in the Study Area 3-30 EIA report of Balaji Formalin Pvt. Ltd. 9

11 3.17 Indian Standard Specification for Drinking Water Ambient Noise Levels in the Study Area Ambient Air Quality Standards with respect to Noise Soil Analysis of Study area Traffic Survey Floral Diversity Faunal Biodiversity Land use statistics base of satellite imaginary Land Use Pattern Summary of Socio-Economic Status (Demography) Basic Amenities in the Study Area Input data for air quality modeling Existing/Estimated Air emission Quality (Before & After 4-15 APCM) 4.3 Cumulative Concentrations at various locations The 24-hourly average GLC Concentration Values for SPM The 24-hourly average GLC Concentration Values for SO The 24-hourly average GLC Concentration Values for NOx Environment Monitoring Plan Budget for implementation of Environmental Monitoring 6-5 Plan 7.1 Liquid Raw Materials Storage Hazardous Raw Materials Sr. No. (MSHIC) & 7-5 Characteristics 7.3 Risk Classification Effects due to Incident Radiation Intensity Thermal Radiation Impact to Human Tolerable Intensities for Various Objects Damage due to Overpressure Different Failure Scenarios Distances of Occurrence of Various Thermal Radiation Intensities [Storage Tank on Fire Plant Area Instantaneous Spill (Single Tank, Methanol)] 7.10 Distances of Occurrence of Various Thermal Radiation Intensities [Catastrophic Rupture Storage Facility Continuous Spill - Methanol] 7.11 Distances of Occurrence of Various Thermal Radiation Intensities [Storage Tank on Fire Plant Area Instantaneous Spill (Single Tank, Formaldehyde)] 7.12 Distances of Occurrence of Various Thermal Radiation Intensities [Catastrophic Rupture Storage Facility EIA report of Balaji Formalin Pvt. Ltd. 10

12 Continuous Spill- (Formaldehyde)] 10.1 Budgetary provisions for the next five years (Every Year) Environment Management Cost Estimate Design features for minimization of fugitive emissions Environment Monitoring along with Frequency details EIA report of Balaji Formalin Pvt. Ltd. 11

13 List of Figures San Envirotech Pvt. Ltd., Ahmedabad Figure No. Name Page No. 1.1 Location of the project site Google map of 10 km radius Image showing all four boundaries coordinates of the 1-27 site 2.1 Water Balance Diagram (Existing) Water Balance Diagram (after proposed Expansion) Plant Layout Drawing of Evaporator Graphical representation of Ambient Air quality Graphical representation for PM Graphical representation for PM Graphical representation for SO Graphical representation for NO X Location of AAQM Wind Rose Diagram Water sampling Locations Locations of Noise monitoring station Locations of Soil Sampling Land use pattern with 10 km radius (Satellite Image) Topo sheet of location with site location map of 10 km radius (1:25,000 scales) 3.13 Topo sheet of location with site location map of 10 km radius (1:50,000 scale) 3.14 Topo sheet of location with site location map of 10 km radius (1: scale) Isopleths for Ground Level Concentration for SPM Isopleths for Ground Level Concentration for SO Isopleths for Ground Level Concentration for NO x Hierarchical system or Administrative order of the company EIA report of Balaji Formalin Pvt. Ltd. 12

14 List of Annexures San Envirotech Pvt. Ltd., Ahmedabad Annexure No. Annexure Name Page No. Annexure-I Membership certificate of approve TSDF site A-1 Annexure-II MSDS of haz. Chemicals A-2 Annexure-III Request letter to RO-MoEF, Bhopal A-12 Annexure-IV Photographs of existing plant site including existing A-15 greenbelt Annexure-V Land documents A-19 Annexure-VI Copy of Environmental Clearance (EC) A-23 Annexure-VII Narmada water usage permission A-29 Annexure-VIII Health checkup record of workers A-30 Annexure-IX Questionnaire for industry sector A-42 Annexure-X NABET/QCI certificate A-62 Annexure-XI Terms of Reference (TOR) letter A-64 EIA report of Balaji Formalin Pvt. Ltd. 13

15 Chapter-1 Introduction 1.1 PREFACE An Environmental Impact Assessment (EIA) is an assessment of the possible positive or negative impact that a proposed project may have on the environment, together consisting of the environmental, social and economic aspects. It is an assessment and management tool that evaluates the possible positive or negative impact that a proposed project may have on the environment. EIA systematically examines both beneficial and adverse consequences of the project and ensures that these effects are taken into account during project design. The purpose of the assessment is to ensure that decision makers consider the ensuing environmental impacts when deciding to proceed with a project. As India is a developing country, lots of industrialization has been came in focus since last few decades that ultimately leads the bigger issues related the environmental quality of the country. Hence, it is needful for Government of India to control the haphazard industrial development by providing sustainable development under the legislation. In India, Ministry of Environment and Forests has defined elaborated Environmental Clearance (EC) framework along with requirements for preparing Environmental Impact Assessment (EIA) under the Environmental (Protection) Act, 1986 (Environmental Impact Assessment Notification, 2006) for establishing/expanding and industry/development projects although it supports development but only if the development does not hamper the environment over a defined threshold limit. 1.2 PURPOSE OF THE REPORT Industrial development in India has increased economic growth and improved living standards of people. These growths are achieved through industrialization, infrastructure development. The industrialization has played a major role in development of the country. This industrialization is also has many other benefits. Although the industrial development EIA report of Balaji Formalin Pvt. Ltd. 1-1

16 leads to rapid consumption of natural resources, fuel etc. in day to day operational activity. These will deteriorating resources and increase emissions of waste in terms of solid, liquid and gaseous. To control the pollutions from industrial activity, government has framed regulations which are governed by Ministry of Environment and Forest in India. Environment Impact analysis is mandatory as per the Environment Impact Assessment (EIA) Notification issued by Ministry of Environment and Forests (MoEF&CC), New Delhi, dated 14 th September 2006, its subsequent amendment, for setting up a new projects or activities, or expansion or modernization of existing projects or activities based on their potential environmental impacts as indicated in the Schedule to the notification, being undertaken in any part of India, unless prior environmental clearance has been accorded. Proposed activity of M/s. Balaji Formalin Pvt. Ltd. falls under the schedule of 5(f) of schedule of EIA Notification, 2006 Synthetic Organic Chemical Industries (dyes & dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates) and categorized under A. Therefore, unit requires Environmental Clearance for proposed expansion of project. EIA Consultant In view of the above, legal aspect and monitoring work has been carried out for all the environmental attributes by M/s. San Envirotech Pvt. Ltd., Ahmedabad. Draft Environment Impact Assessment (EIA) and Environmental Management Plan (EMP) have been prepared after obtaining Terms of References (TORs) from Ministry of Environment, Forests& Climate Change, New Delhi. The public hearing will be held on the basis of the draft EIA/EMP incorporating the Terms of References. EIA/EMP Report will be finalized after incorporating the comments and suggestions by the public during pubic consultation/public hearing. Final EIA/EMP will be submitted to MoEF&CC for Environment Clearance. EIA report of Balaji Formalin Pvt. Ltd. 1-2

17 1.3 IDENTIFICATION OF PROJECT & PROJECT PROPONENT Identification of project site with site specific criteria: Balaji FormalinPvt. Ltd. is an existing unit at Plot No. 1398, Village: Moti Bhoyan, Taluka: Kalol, Dist. Gandhinagar, Gujarat (India). The products details are given in Table 1.1. Unit now proposed to expand its existing production capacity with addition of new products. Features justifying the location are summarized below: Availability of suitable and adequate land for proposed expansion; Availability of all basic facilities like infrastructure, communication, medical facilities, fuel, water, power, unskilled & skilled manpower, raw materials, road network etc. Considering market demand and economic viability, proponent has decided to expand capacities of its existing products. Nearest city is Ahmedabad, which is 21.2 km away from the location, and having good connectivity with other parts of the country by road, rail & air. Availability of good communication and transportation facilities. No National park or wildlife habitat falls within 10 km radial distance from proposed project site. No critically polluted area falls within 10 km radius. No R & R will be required Project identification with respect to category As per the EIA Notification, 2006 and amendment thereof; proposed activity is covered under 5(f) category- Synthetic organic chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates) Project proponent M/s. Balaji Formalin Pvt. Ltd. is well known and leading and flagship manufacturing company of formaldehyde.this is a manufacturing company established in the year The management of the organization is in the hands of Board of Directors of the company. EIA report of Balaji Formalin Pvt. Ltd. 1-3

18 Mr. Mahendra R. Gupta is the Director of the company. He is the senior member, promoter of the company. He has wide and deep experience of planning, designing and implementation of business. He provides all the necessary directions of various aspects of developing the business. Mr. Mukesh R. Gupta is also the Director of the Company. He too is a senior member and promoter of the company with very good knowledge and practical experience in private sector. Further he has good administrative power to provide inter discipline and co-ordination as well as to develop the business. 1.4 BRIEF DESCRIPTION OF PROJECT Nature of the project: Unit proposed for expansion of existing capacity of formaldehyde with addition of new products. So the project covered under schedule 5(f), - Synthetic organic chemicals industry as per the EIA Notification-2006 and its amendment thereof, category A. Hence prior EC is required for proposed expansion. List of raw materials to be used in the project are given in Table 2.6 of chapter-2. Generated wastewater will be directly sent to forced effect evaporator & then sent to mechanical evaporator. Condensate from evaporator will be reused for utility. So, there will no effluent discharge outside industry premises. Hazardous waste generation from the proposed project is given in Table Size of the project: Balaji Formalin Pvt. Ltd. proposed to expand capacity of existing product with introduction of new products. Production details are given in below table: Sr. No. Products Table 1.1 Product details Existing Production (MTPM) Additional Production (MTPM) Total production after expansion (MTPM) 1 Formaldehyde Para formaldehyde Reprocessing of Silver (Purification of Silver) EIA report of Balaji Formalin Pvt. Ltd. 1-4

19 1.4.3 Location of the project: The unit is located in village Moti Bhoyan, Kalol Taluka, Gandhinagar District of Gujarat state. The geographical co-ordinates of the proposed site are 23 09'44.69"N Latitude and 72 26'45.54"E Longitude. The location of the project site can be identified from the location map shown in Figure 1.1 and satellite image/google earth image is shown in Figure 1.2. Boundary co-ordinates latitude and Longitude of all four corners of the site are given in Table 1.2 and shown in Figure 1.3. Table 1.2 Details of four corners Co-Ordinate of Site Point Latitude Longitude A 23 09'45.44"N 72 26'44.63"E B 23 09'44.73"N 72 26'47.64"E C 23 09'43.06"N 72 26'47.19"E D 23 09'43.64"N 72 26'44.47"E 1.5 REGULATORY FRAMEWORK The MoEF&CC, CPCB and SPCBs together form the regulatory and administrative core of the sector. Legislation for environmental protection in India for chemical industry is mainly EIA Notification-2006, Water (Prevention & Control of Pollution) Act-1974, Air (Prevention & Control of Pollution) Act-1981, Water (Prevention and Control of Pollution) Cess Act, 1977; Hazardous Waste (Management, Handling and Transboundary Movement) Rules 2008, amended time to time, are major Act/Rules/ Notification applicable to industry. 1.6 SCOPE OF THE STUDY The scope of the EIA study is based on the guideline provided by Ministry of Environment, Forests& Climate change, Government of India for structure of environmental impact assessment document. The scope of the study broadly includes: Field sampling of environmental attributes at various representative locations in the study area to establish the baseline status; Collect & compile secondary data including socio-economic data; EIA report of Balaji Formalin Pvt. Ltd. 1-5

20 Identification, assessment and evaluation of the beneficial and adverse impacts on surrounding environment due to proposed project activities considering the existing baseline status along with compilation of other information; Analysis of project proposal and data analysis; Assessment of pollution potential due to proposed project; Predict the incremental levels of pollutants in the study area due to the proposed project; Evaluate the predicted impacts on the various environmental attributes by using scientifically developed and widely accepted models; Identification and assessment of risks associated with the proposed project and their appropriate management through proper Risk Assessment (RA) and Disaster Management Plan (DMP); Prepare an Environmental Management Plan (EMP) to mitigate the predicted impacts; and Identify critical environmental attributes required to be monitored during the project execution and to suggest post project monitoring. The scope also includes all the conditions outlined in the TOR issued by MoEF&CC and the compliance to the TOR is given in below. 1.7 COMPLIANCE TO TERMS OF REFERENCE Based on the documents submitted and presented before 38 th Reconstituted Expert Appraisal Committee (Industry-2) held during 20 st - 21 st April, 2015; Terms of Reference (TOR) was issued by MoEF&CC; vide TORs letter no. J-11011/67/2015-IA II (I), dated and directed to prepare detailed EIA/EMP including following terms of reference. Compliance of TORs for preparation of EIA/EMP is as below: Sr. No. A Specific ToR Conditions 1. Details on solvents to be used, measures for solvent recovery and for emissions control. Compliance We are not going to use any solvent in our process. Methanol is use as a raw material in process and not as a solvent. So EIA report of Balaji Formalin Pvt. Ltd. 1-6

21 2. Details of process emissions from the proposed unit and its arrangement to control. 3. Ambient air quality data should include VOC, etc. 4. Work zone monitoring arrangements for hazardous chemicals. 5. Detailed effluent treatment scheme including segregation of effluent streams for units adopting 'Zero' liquid discharge. 6. Action plan for odour control to be submitted. 7. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/ hazardous waste generated. 8. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste in TSDF, if any. 9. Action plan for utilization of MEE/dryers salts. 10. Material Safety Data Sheet for all the Chemicals are being used/will be used. 11. Authorization/Membership for the disposal of solid/hazardous waste in no need to install solvent recovery system. There are chances of emit traces of methanol and formaldehyde as air pollutants and it will be treated in tail gas treatment plant (Incinerator). Pls. refer table 2.8, page no of chapter-2 for its details. Pls. refer table 3.9 to table 3.13, page no to 3-26 of chapter-3 for details of ambient air quality including VOCs. Pls. refer table 6.1, page no. 6-4 for monitoring of work zone. There will be only 1.0 KLD process effluent which is generates from purification of silver and other source is water treatment & utility. So need to segregate it. Pls. refer sec , page no of chapter- 2 for zero discharge scheme. Pls. refer sec. 2.17, page no of chapter-2 for details of odor control. There is no generation of high calorific solid waste which is generally used in co processing. So need to make MoU with any cement manufacturer. Unit is zero discharge unit hence CETP membership is not required in our case. Membership certificate of approve TSDF site is enclosed as Annexure-I. MEE salt may not reuse anywhere in our process and no marketable quality generation hence we are directly disposed at TSDF site. MSDS of all the major chemicals are attached as Annexure-II. Membership certificate of approved TSDF site is enclosed EIA report of Balaji Formalin Pvt. Ltd. 1-7

22 TSDF are being used/will be used. 12. Authorization/Membership for the disposal of solid/hazardous waste in TSDF. 13. Risk assessment for storage and handling of hazardous chemicals/ solvents. Action plan for handling & safety system to be incorporated. 14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials. B Additional ToR 1. Public Consultation to be conducted and issues raised and commitments made by the project proponent on the same should be included in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made. 2. Copy of Certified Compliance Report to the environmental condition prescribed in the existing environmental clearance dated San Envirotech Pvt. Ltd., Ahmedabad as Annexure-I. Membership certificate of approved TSDF site is enclosed as Annexure-I. Pls. refer chapter-7 for details of risk assessment for storage and handling of hazardous chemicals. Pls. refer sec. 7.14, page no of chapter-7 for action plan for handling & safety system. Pls. refer sec. 7.16, page no of chapter-7. Public hearing is yet to be done so we will incorporate it after public hearing. We have requested to RO, MoEF&CC, Bhopal for issuing of certified compliance report. Request letter is enclosed as Annexure-III. Generic Terms of Reference (TOR) in respect of Industry Sector 1. Executive Summary (maximum 2-3 sheets in A4 size paper) of the project covering project description, description of the environment, anticipated environmental impacts & its mitigation measures, environmental management plan, environmental monitoring programme, public consultation, project benefits, social impacts including R&R. 2. Site Details: i. Location of the project site covering village, Taluka/Tehsil, District and State on Indian map of 1:1000,000 scale. Executive Summary of the project is included as Chapter-11. Pl. refers figure-1.1, page no. 1.25, of Chapter-1 of EIA report for location of the project site covering village, Taluka/Tehsil, District and State on Indian map. ii. A topo sheet of the study area of Topo sheet of study area with EIA report of Balaji Formalin Pvt. Ltd. 1-8

23 radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. iii. Co-ordinates (lat-long) of all four corners of the site. iv. Google map-earth downloaded of the project site. v. A map showing environmental sensitivity [land use/land cover, water bodies, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc.] and from critically/severely polluted area(s) and Eco-sensitive Areas within 10km radius of the project site vis-à-vis shortest (aerial)distance from the project. If the project is located within 10km of CPAs/severely Polluted Areas, confirm whether moratorium has been imposed on the area. vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. In addition, if located within an Industrial area/estate/complex, layout of Industrial Area and location of unit within the Industrial Area/Estate/Complex, layout of Industrial Area. San Envirotech Pvt. Ltd., Ahmedabad site location on 1:25,000 scale followed by 1:50,000 scale of a circle of a radius of 10 kms is incorporated in EIA/EMP report. Pls. refer figure no. 3.12, 3.13, 3.14 on page no to 3-55 of chapter-3. Coordinates (Lat long) of all four corners of the site is given in sec , page no. 1-5 of chapter-1. Google map of 10 km radius is given as figure 1.2 on page no of chapter-1. Pl. refer figure 3.11, page no of Chapter-3 of EIA report for land use map covering environmental sensitivity including land use/land cover, water bodies, reserved forests, wildlife sanctuaries, national parks, tiger reserve etc. As per the Notification of MoEF&CC published dated , Central Government notifies Thol Wild Life Sanctuary in the State of Gujarat, as Ecosensitive Zone, up to kilometers from the boundary of the Thol Wild Life Sanctuary. Our Industrial location is 3.8 km away from the boundary of Thol Wild Life Sanctuary. In addition to this, there is no critically/severely polluted area falls within 10km radius of the project site. Pls. refer figure 2.3, page no of chapter-2 for layout map with demarcation. Old building will be removed & paraformaldehyde plant is to be erected. Formaldehyde capacity enhancement is only through modification of current machineries. So no new space is required for the same. vii. Photographs of the proposed and Photographs of existing plant site EIA report of Balaji Formalin Pvt. Ltd. 1-9

24 existing (if applicable) plant site. If existing, in addition to site map, provide photographs of plantation/greenbelt in the existing project. If fresh EC application, photographs. 3. Land use break-up of total land of the project site (identified and acquired) agricultural, forest, wasteland, water bodies, settlements, etc. shall be included. 4. A copy of the mutual agreement for land acquisition signed with land oustees. 5. Proposal shall be submitted to the Ministry for environment clearance only after acquiring at least 60% of the total land required for the project. Necessary documents indicating acquisition of land shall be included. 6. Forest and wildlife related issues: i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. ii. Land use map based on High resolution satellite imagery (GPS) of the proposed site delineating the forest land (in case of projects involving forest land more than 40 ha). iii. Status of application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted. iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, including existing greenbelt area are attached as Annexure-IV. Old building will be removed & paraformaldehyde plant is to be erected. Formaldehyde capacity enhancement is only through modification of current machineries. So no new space is required for the same. Pls. refer table 2.1, page no. 2-2 of chapter-2 for details of acquired land. Plant is existing and land is owned by the company. Land documents are enclosed as Annexure-V hence no need of mutual agreement for land acquisition signed with land oustees. Proposed project is expansion of existing activities and land is already in possession since Land documents are enclosed as Annexure-V. No forest land is involved hence permission from State Forest Department is not required. Not applicable as no forest land is involved in proposed project site. No forest land is involved hence Forest Clearance is not required. There is not any National Parks, Sanctuaries, Biosphere Reserves; Migratory Corridors of Wild EIA report of Balaji Formalin Pvt. Ltd. 1-10

25 Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon. v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in the study area. vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife. 7. Expansion/modernization proposals: i. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from MoEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30 th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments should be provided. In addition, status of compliance of Consent to Operate for the ongoing/existing operation of the project from SPCB shall be attached with the EIA-EMP report. ii. In case the existing project has not obtained environmental clearance, reasons for not taking EC Under the provisions of the EIA Notification, 1994 and/or EIA Notification, 2006 shall be San Envirotech Pvt. Ltd., Ahmedabad Animals falls within 10 km radius of the project hence map duly authenticated by Chief Wildlife Warden is not required. Not any Schedule I fauna is exist within study area of 10 km radius hence Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government is not required. There is not any National Parks, Sanctuaries, Biosphere Reserves falls within 10 km radius of the project hence clearance under the Wildlife (Protection) Act, 1972 is not required. Copy of Environmental Clearance is enclosed as Annexure-VI. We have requested to RO, MoEF&CC, Bhopal for issuing of certified compliance report. Request letter is enclosed as Annexure-III. Unit has obtained Environmental Clearance (EC), for existing activities, which is enclosed as Annexure-VI. EIA report of Balaji Formalin Pvt. Ltd. 1-11

26 provided. Copies of Consent to Establish/No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY ) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted. Details of Industrial Operations 8. A list of major industries with name and type within study area (10 km radius) shall be incorporated. 9. Details of proposed raw materials and products along with production capacity. If expansion project, details for existing unit, separately for existing and new (proposed) unit. 10. Details of manufacturing process, major equipment and machinery. If expansion project, details of existing unit, separately for existing and new (proposed) unit. 11. List of raw materials required and its source along with mode of transportation shall be included. All the trucks for raw material and finished product transportation must be Environmentally Compliant. 12. Quantity of fuel required, its source and characteristics and documentary evidence to substantiate confirmed fuel linkage shall be furnished. 13. Project site layout plan to scale using AutoCAD showing raw materials, fly ash and other storage plans, bore well or water storage, aquifers (within 1 km) dumping, waste disposal, green areas, water bodies, Pls. refer table 1.3, page no of chapter-1 for name and type of major industries working within the study of 10 km radius. List of products & raw materials (existing & proposed) are given in table 2.3 & 2.6; page no. 2-3 & 2-20 of chapter-2. Pls. refer sec. 2.10, page no. 2-6 of chapter-2 for details of manufacturing process. List of major equipment & machineries for existing and proposed expansion is given as sec. 2.8, page no. 2-3 of chapter-2. List of required raw materials, source along with mode of transportation is given in table 2.6; page no of chapter-2. All hazardous chemicals are transport through approved vehicle by concerned authority. No fuel is used for existing manufacturing because exothermic reaction. Methanol is being used as starting fuel for 30 to 60 minutes when reaction initiated. Pls. refer figure 2.3, page no of chapter-2 for project layout plan. EIA report of Balaji Formalin Pvt. Ltd. 1-12

27 rivers/drainage passing through the project site shall be included. 14. Manufacturing process details of all the plants including captive power plant if any along with process flow chart shall be included. 15. Mass balance for the raw material and products shall be included. 16. Energy balance data for all the components of the plant shall be incorporated. Environmental Status 17. Geological features and Geohydrological status of the study area shall be included. 18. Details of drainage of the project up to 5 km radius of study area. If the site is within 1 km radius of any major river, peak and lean river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of RL of the project site and mrl of the river should also be provided. 19. One season site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) at 8 locations for PM 10, PM 2.5, SO 2, NO X, CO and HC (methane & non-methane) should be collected. The monitoring stations should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. 20. Surface water quality of nearby River (60m upstream and downstream) and other surface drains at eight locations to be provided. Pls. refer sec. 2.10, Page No. 2-6 of chapter-2 for details of manufacturing process. We are not going set up captive power plant hence not applicable. Pls. refer sec. 2.10, Page No. 2-6 of chapter-2 for mass balance for the raw material and products. Our is small scale unit and energy balance data for all the components of plant may not technically feasible and may not correct in our case. Hydrogeological status of the study area is given in sec. 3.4; page no of chapter-3. There is not any river & flood Hazard zone within 1 km radius from the site hence this point is not applicable. One season site-specific micrometeorological data are given in sec on page no. 3-7 and AAQ data are tabulated in table no. 3.9 to 3.13 on page no to Figure 3.6 shows Air monitoring stations on page no The monitoring locations have beenselected on the basis of predominant wind direction, population zone andsensitive receptors. We are not going to disposed off our treated effluent into river hence, 60 m upstream and downstream sampling may not require in our case. EIA report of Balaji Formalin Pvt. Ltd. 1-13

28 21. Ground water monitoring minimum at 8 locations shall be included. 22. Noise levels monitoring at 8 locations within the study area. 23. Traffic study of the area for the proposed project in respect of existing traffic, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, Parking arrangement etc. 24. Detailed description on flora and fauna (terrestrial and aquatic) exists in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule- I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished. 25. Emissions (g/second) with and without the air pollution control measures. 26. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be well assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours should be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any. However, we have collected samples from surface water sources like pond, canal & Thol lake. Result of same is tabulated in table 3.16, page no of chapter-3. We have carried out ground water monitoring at 8 locations in the study area. Results are tabulated in Table 3.15, page no of chapter-3. We have carried out noise level monitoring at 8 locations in the study area. Monitoring results with locations are tabulated in Table 3.18, page no of chapter-3. Pls. refer table 3.21, page no of chapter-3 of EIA report for traffic survey. Pls. refer table 3.22 and 3.23 on page no & 3-37 for details of flora and fauna. Pl. refers table no. 4.2, page no of chapter-4 for emissions (g/second) with and without air pollution control system. Pl. refer table no. 4.3, page no of chapter-4 for cumulative impact along with 24 hrs. maximum GLC. Pls. sec , page no. 4-7 and table 4.1, page no of chapter-4 for details of model used and input data used for modeling. Pls. refer figure 4.1 to 4.3, page no to 4-22 for the air EIA report of Balaji Formalin Pvt. Ltd. 1-14

29 27. Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyorcum-rail transport shall be examined. 28. Details of water requirement, water balance chart for new unit or for existing unit as well as proposed expansion (in case of expansion). 29. Source of water supply and quantity and permission of withdrawal of water (surface/ground) from Competent Authority. 30. Details regarding quantity of effluents generated, recycled and reused and discharged to be provided. Methods adopted/to be adopted for the water conservation shall be included. Zero discharge effluent concepts to be adopted. 31. A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E(P) Rules. 32. Action plan for control of ambient air quality parameters as per NAAQES Standards for PM 10, PM 2.5, SO 2 and NO X, etc. as per GSR 826(E) dated 16 th November, quality contours plotted on a location map. Estimated nos./day of trucks/ tankers will be in and out from our factory premises. There is no nearby railway line so entire materials are transport through road from port or factory. Water balance diagram for existing unit as well as proposed expansion is given as figure 2.1 & 2.2, page no & 2-27 of chapter-2. Source of water supply is Narmada Water supply. Permission obtained for usage of Narmada water is enclosed as Annexure-VII. Pls. refer figure 2.1 & 2.2, page no & 2-27 for quantity of water requirement. Pls. refer water balance diagram figure 2.1 & 2.2, page no & 2-27 for detailed water balance including quantity of effluent generated, recycled/reused & discharge. Pls. refer sec , page no for complete scheme of wastewater treatment, reuse /recycle details. Major source of effluent is water treatment & utility and we are achieving zero discharge so no major difference of raw & treated effluent and practically no need to give the treatment. Following steps will be taken to control the air quality as per the NAAQES standards notified by the Ministry on 16 th September, Paved road will be made. EIA report of Balaji Formalin Pvt. Ltd. 1-15

30 33. An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30 th May, Action plan for solid/hazardous waste generation, storage, utilization and disposal. Copies of MOU regarding utilization of solid waste shall also be included. EMP shall include the concept of waste minimization, recycle/reuse/recover techniques, Energy conservation and natural resource conservation. 35. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 1999 and subsequent amendment in 2003 and A detailed plan of action should be provided. 36. Action plan for the greenbelt development plan in 33% area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated. All rooftops/terraces shall have some green cover. 37. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains Pneumatically transfer of raw materials. Adequate implementation of APCM. Effective implementation of air pollution monitoring. Development of greenbelt. All liquid raw materials and finished products shall be transport pneumatically. Solid materials are handling in close manner. Pls. refer table 2.10, page no of chapter-2 for hazardous waste details. There is no generation of high calorific solid waste which is generally used in co processing. So need to make MoU with any cement manufacturer. Pls. refer sec , page no for heat recovery details. Pls. refer sec of Chapter-10 on page no for resource conservation/waste minimization details. There is no use of any type of fuel hence no generation of fly ash. Pls. refer sec. 10.6, page no of chapter-10 for greenbelt development plan. Design details along with methodology and type of species are covered under this section. Pls. refer sec , page no of chapter-2 for rain water harvesting details. EIA report of Balaji Formalin Pvt. Ltd. 1-16

31 to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources. Rain water harvesting and groundwater recharge structures may also be constructed outside the plant premises in consultation with local Gram Panchayats and Village Heads to augment the ground water level. Incorporation of water harvesting plan for the project is necessary, if source of water is bore well. 38. Environment Management Plan (EMP) to mitigate the adverse impacts due to the project along with item wise cost of its implementation. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included. 39. Details of Rehabilitation & Resettlement (R & R) involving the project. R&R shall be as per policy of the State Govt. and a detailed action plan shall be included. 40. Action plan for post-project environmental monitoring shall be submitted. 41. Disaster Preparedness and Emergency Management Plan including Risk Assessment and damage control needs to be addressed and included. 42. Occupational health: i. Details of existing Occupational & Safety Hazards. What are the exposure levels of above mentioned hazards and whether they are within Permissible Exposure Level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved. Pls. refer chapter-10 for detailed EMP. Pls. refer table 10.2, page no of chapter-10. No Rehabilitation & Resettlement (R & R) is involved in this project. Pls. refer sec , page no and table 10.4, page no of chapter-10 for details of environmental monitoring plan. Pls. refer chapter-7 for risk assessment. Pls. refer sec. 7.19, page no of chapter-7 for Disaster Management Plan (DMP). Estimated work area quality with TWA limit is summarized in Table 2.8(a), page no of Chapter- 2 which is well within the limit. Pls. refer sec , page no of chapter-10 of EIA report for proposed activity carry out by the industry for occupation health. EIA report of Balaji Formalin Pvt. Ltd. 1-17

32 ii. Details of exposure specific health status evaluation of worker. If the workers health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, color vision and any other ocular defect) ECG, during preplacement and periodical examinations give the details of the same. Details regarding last month analyzed data of abovementioned parameters as per age, sex, duration of exposure and department wise. iii. Annual report of health status of workers with special reference to Occupational Health and Safety. iv. Action plan for the implementation of OHS standards as per OSHAS/USEPA. v. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers. 43. Corporate Environment Policy i. 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. ii. 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. iii. What is the hierarchical system or Administrative order of the company to deal with the Activity proposed in sec , page no of chapter-10 of EIA report. Unit is frequently done health checkup of workers and records are maintained in health register. Copy of reference health checkup report of workers is enclosed as Annexure-VIII. Noted the point and prepare action plan for the implementation of OHS standards. Unit is follow OSHAS standard and will obtain certification from competent agency. It is already proposed in EMS plan. Our is a proposed unit and there will be an Environment Policy approved by Director. Pls. refer sec on page no of chapter-10 for environment policy. Environment Policy includes standard operating process including commitment from management. Pls. refer figure 10.1 of chapter- 10 on page no EIA report of Balaji Formalin Pvt. Ltd. 1-18

33 environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given. iv. Does the company have 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 shall be detailed in the EIA report. 44. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase. 45. At least 5% of the total cost of the project shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon. 46. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/atr to the notice(s) and present status of the case. 47. The questionnaire for industry sector (available on MoEF website) shall be submitted as an Annexure to the EIA- EMP Report. San Envirotech Pvt. Ltd., Ahmedabad Pls. refer sec of chapter- 10 on page no This is an existing plant. So all the facilities are already provided. Unit has allocated 2.5% of the total cost of the project for CSR activities. Pls. refer sec & table 10.1, page no & of chapter-10 for budget of CSR activities. Detail scope of CSR activity will be finalized after suggestions obtained during the public hearing. No Pls. refer Annexure-IX for questionnaire for industry sector. 48. TORs prescribed by the Expert EIA report is prepared based on EIA report of Balaji Formalin Pvt. Ltd. 1-19

34 Appraisal Committee (Industry) shall be considered for preparation of EIA- EMP report for the project in addition to all the relevant information as per the Generic Structure of EIA given in Appendix III and IIIA in the EIA Notification, Where the documents provided are in a language other than English, an English translation shall be provided. The draft EIA-EMP report shall be submitted to the State Pollution Control Board of the concerned State forconduct of Public Hearing. The SPCB shall conduct the Public Hearing/public consultation, districtwise, as per the provisions of EIA notification, The issues raised in the Public Hearing and during the consultation process and the commitments made by the project proponent on the same shall be included separately in EIA-EMP Report in the form of tabular chart with financial budget (capital and revenue) along with time-schedule of implementation for complying with the commitments made. The final EIA report shall be submitted to the Ministry for obtaining environmental clearance. 49. A tabular chart with index for point wise compliance of above TORs. 50. The TORs prescribed shall be valid for a period of two years for submission of the EIA-EMP reports along with Public Hearing Proceedings (wherever stipulated). The following general points shall be noted: i. All documents shall be properly indexed, page numbered. ii. iii. Period/date of data collection shall be clearly indicated. Authenticated English Translation of all material in Regional languages shall be provided. San Envirotech Pvt. Ltd., Ahmedabad TOR as well as generic structure given in Appendix-III of EIA Notification, Public Hearing is yet to done and we will incorporate it in our final EIA report, if any. Done Noted the point Noted and complied Noted and complied Noted and complied iv. The letter/ application for Noted and complied EIA report of Balaji Formalin Pvt. Ltd. 1-20

35 environmental clearance shall quote the MoEF file no. and also attach a copy of the letter. v. The copy of the letter received from Ministry shall be also attached as an annexure to the final EIA-EMP Report. San Envirotech Pvt. Ltd., Ahmedabad Complied ToR letter received from MoEFCC is attached as Annexure XI. ADDITIONAL TORs FOR SYNTHETIC ORGANIC CHEMICALS INDUSTRY 1. Manufacturing process details along with the chemical reactions and process flow chart. 2. Name of all the solvents to be used in the process and details of solvent recovery system. 3. Design details of ETP, incinerator, if any along with boiler, scrubbers/bag filters etc. 4. The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste, calorific value of hazardous waste and detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler shall be included. 5. Precautions to be taken during storage and transportation of hazardous chemicals shall be clearly mentioned and incorporated. 6. Material Safety Data Sheet for all the Chemicals are being used/will be used. CAS No./RTECS No./DOT/UN etc to be mentioned against each chemicals. 7. Details of VOC monitoring in the working zone environment and other hazardous emissions such as Chlorine, HCl, etc. if any. 8. Authorization/Membership for the disposal of solid/hazardous waste in TSDF. Pls. refer sec. 2.10, page no. 2-6 of chapter-2 for of manufacturing process details along with the chemical reactions and process flow chart. We are not going to use any solvent in our process. Methanol is use as a raw material in process and not as a solvent. So no need to install solvent recovery system. Refer table 2.9, page no for technical specification of forced effect evaporator. Pls. refer table 2.10, page no of chapter-2 for details of hazardous waste. There is only salt generation from MEE and no Hazardous characteristics envisage in recover salt from MEE. There is no use of any fuel hence no generation of fly ash. Pls. refer sec , page no of chapter-7. MSDS of all the Haz. Chemicals are given as Annexure-II. Pls. refer chapter-6 of EIA report. Membership certificate of approved TSDFsite is enclosed as Annexure-I. EIA report of Balaji Formalin Pvt. Ltd. 1-21

36 9. Risk assessment for storage for chemicals/solvents. Action plan for handling & safety system. 10. Details of occupational health programme. i) To which chemicals, workers are exposed directly or indirectly. ii) Whether these chemicals are within Threshold Limit Values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation. iii) What measures company has taken to keep these chemicals within PEL/TLV. iv) How the workers are evaluated concerning their exposure to chemicals during pre-placement and periodical medical monitoring. v) Liver function tests (LFT) during pre-placement and periodical examination. 11. A Toxic management Plan shall be prepared. 12. A write up on Safe Practice followed for handling, storage, transportation and unloading of chemicals to be submitted. 13. What are onsite and offsite emergency plan during chemical disaster. 14. A write up on Treatment of workers affected by accidental spillage of chemicals. Pls. refer chapter-7 for risk assessment. Pls. refer sec on page no of chapter-10 for occupational health programme details. Refer sec on page no for list of chemicals, and measures, details of Preplacement and periodical medical monitoring of workers, LFT. Pls. refer table 2.8(a), page no of chapter-2 for threshold limit & estimated results of Haz. Chemicals. Pls. refer sec. 7.16, page no of chapter-7. Pls. refer sec. 7.14, page no of chapter-7. Pls. refer section 7.17 & 7.18, page no & 7-38 respectively of chapter-7 for onsite & offsite emergency plan. Pls. refer sec , page no of chapter OBJECTIVE OF EIA EIA is a policy and management tool for both planning and decision making. EIA assists in identification, prediction and evaluation of the foreseeable environmental consequences of proposed developmental and industrial projects. The objectives of the present EIA Study is to assess the impacts on various environmental components due to the proposed project activity, EIA report of Balaji Formalin Pvt. Ltd. 1-22

37 identify potential source of pollution, evaluate impact on environment and to recommend appropriate environmental management system and environment management plan for the unit to ensure that the adverse impacts if any will be minimized. Moreover, to prepare an Environmental Statement to indicate conclusively if the overall impacts are positive or negative. 1.9 METHODOLOGY FOR EIA Environmental Assessment (EA), another term used in the environmental studies, refers to an understanding of the present status of environment and a study of how to manage them. Keeping in view the nature and size of the proposed project and industrial area and various guidelines available, it was decided to cover an area of 10-km radius from the center of proposed plant site for the purpose of environmental impact assessment study. The methodology is briefly reported below and has been described in this section. Baseline data Collection The baseline data for the impact zone have been generated for the following environmental parameters: Ambient Air Quality Micrometeorology Noise Levels Surface and ground water quality Soil Quality Flora and fauna Land use pattern Socio-economics The baseline status of the above environmental parameters has been worked out based on the rapid monitoring/analysis carried out during the study period of October-2015 to December-2015 supplemented by data collected from various government departments, census publications etc. The data is collected and analyzed as per the standard methods for establishing the baseline data and to determine the impact of proposed activity on the same. EIA report of Balaji Formalin Pvt. Ltd. 1-23

38 Evaluation of Impact from Project Activities San Envirotech Pvt. Ltd., Ahmedabad The environmental Impact resulting from the various project activities, have been identified, predicted and evaluated based on the study of manufacturing process and other project related activities as well as correlating the same with existing base line status. Preparation of Environmental Management Plan Environmental Management plan has been prepared covering pollution prevention measures at source in terms of air and water pollution control measures, solid waste/hazardous waste management, safety management, green belt development, environmental surveillance and environmental management team. Finally, the detailed assessment of the resultant environmental impacts have been made based on the impacts identification and evaluated from the activities over the baseline status of various environmentalcomponents to reduce the pollution and to delineate a comprehensive environment management plan along with recommendations and suggestions to improve environment management system DETAILS OF INDUSTRIES Sr. No. Table 1.3 List of major industries Name of Industry Type of Industry Distance 1. Kothari Techno Tex Mfg. of Drop wire, Healds for Quality Fabric Weaving 2. Shree Rama Multi-Tech Ltd. 3. Gujarat Dyestuff Industries Pvt. Ltd. 4. Singhal Industries Pvt. Ltd. Mfg. of Lami Tubes, Labels, Cups, Flexible Mfg. of PP/PE Woven Fabric, Sacks, Antiblock Master Batches Mfg. of PP/HDPE Leno Bags, Jumbo Bags, Woven Sack Bags. 5. CRI Ltd. Manufacturer of ball pen tips, nozzle trader and exporter of ball pen tips, nozzle supplier of ball pen tips & nozzle 300 Mtrs 200 Mtrs 250 Mtrs 500 Mtrs 100 Mtrs 6. Arvind Mills Ltd. Mfg. of Clothes 2 Kms EIA report of Balaji Formalin Pvt. Ltd. 1-24

39 Figure 1.1 Location of the project site San Envirotech Pvt. Ltd., Ahmedabad Project Location EIA report of Balaji Formalin Pvt. Ltd. 1-25

40 Figure 1.2 Google map of 10 km radius San Envirotech Pvt. Ltd., Ahmedabad EIA report of Balaji Formalin Pvt. Ltd. 1-26

41 Figure 1.3 San Envirotech Pvt. Ltd., Ahmedabad Image showing all four boundaries coordinates of the site EIA report of Balaji Formalin Pvt. Ltd. 1-27

42 Chapter-2 Project Description 2.1 INTRODUCTION M/s. Balaji Formalin Pvt. Ltd. is a working unit at Plot No. 1398, Nr. Rama Multi Tech Ltd., Village: Moti Bhoyan, Taluka: Kalol, Dist.: Gandhinagar for manufacturing of Formaldehyde of 5000 MTPM capacity. Now, looking to the market demand, unit intends to enhance its production capacity of Formaldehyde up to MTPM along with Para Formaldehyde MTPM and Reprocessing Silver (Purification of Silver) MTPM. Expansion will be done in existing plant premises. Unit has obtained EC from MoEF&CC vide its letter no. J-11011/625/2009-IA II (I), dated and have valid consent to operate issued by GPCB vide order no. AWH-71755, date of issue 13/07/2015 and valid up to 15/04/ TYPE OF PROJECT Unit proposed to expand production capacity of Formaldehyde and going to add new products Para Formaldehyde manufacturing activity. Production of Formaldehyde and going to add new products Para Formaldehydeis covered under the basic organic chemicals. The project activity falls under item 5(f) of Schedule of Environment Clearance Notification dated 14 th September, 2006 and its subsequent amendment. Considering the project location and itscapacity, as per notification, it falls under Category A project. Hence, it is necessary to obtain Environmental Clearance from Central level before start the expansion work. 2.3 NEED FOR THE EXPANSION Unit is established in the year 2003 for manufacturing of Formaldehyde with capacity of 1500 MTPM and currently produces 5000 MTPM Formaldehyde. The end use of this product is mainly for Resins, disinfectant & other industrial uses. Due to increasing market demand, unit proposes to increase its production activity by expansion of existing production and adding some new products. EIA report of Balaji Formalin Pvt. Ltd. 2-1

43 The promoters of the company have more than 15 years of experience in the same business. The chemicals-formaldehyde offered by the unit is appreciated throughout the local markets for their accurate composition and quality, which has been a reason for the steady growth of the company over the years. With the increasing market demand, unit proposes to increase its production activity by adding some new products. 2.4 CAPITAL INVESTMENT Existing cost of project is Rs crores. The estimated cost of the proposed expansion will be around Rs. 8.0 crores. So after expansion, it will be tune around Rs crores. Out of this, around Rs. 1.0 crore will earmark for pollution control measures as capital investment and Rs. 20 lakhs will be recurring cost per annum. Unit is using excess steam generate from exothermic process reaction resulted to reduce the operational cost. 2.5 LAND REQUIREMENT Proposed expansion will be carried out in existing plant premises admeasuring total area of the premises as 4281 m 2. The area use in the unit is for plant/machinery, raw material & finished product storages, office etc. Detailed break-up of land is given in below table: Table 2.1 Structural facilities along with land break up Sr. No. Particular Land Occupied, sqm 1. Process Area Raw Material Storage Utilities Final Product Storage Office Building Green Belt Parking Internal Road 438 Total LOCATION OF THE PROJECT: Project site details are given in following table: EIA report of Balaji Formalin Pvt. Ltd. 2-2

44 Table 2.2: Location Details Sr.No. Particulars Details 1. Plant location Plot No Village Taluka District State Moti Bhoyan Kalol Gandhinagar Gujarat 2. Co-ordinates Latitude Longitude 23 09'44.69"N 72 26'45.54"E 3. Nearest Habitat Moti Bhoyan-1.45 km 4. Nearest Railway Station Kalol-10.6 km 5. Nearest Airport Ahmedabad-21.2 km 6. Nearest City Ahmedabad-12.0 km 7. Nearest Highway SH km Note: Aerial distances are presented in above table. 2.7 SIZE OR MAGNITUDE OF OPERATION Unit is involved in the manufacturing of Formaldehyde and now, proposed for expansion in existing production capacity by adding some new products. Production details are as under: Sr. No. Products Table 2.3: List of products Existing Production (MTPM) Additional production (MTPM) Total production after expansion (MTPM) 1 Formaldehyde Para Formaldehyde Reprocessing of Silver (Purification of Silver) PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION Specifics EC for Expansion of Project Applied under the Act Under Environment Protection Specifics for approval or legal procedure Environment Clearance for the expansion project Related recent Status Submitted Form-I, TOR presentation, Implementation Project will expand after obtaining EC from MoEF&CC. EIA report of Balaji Formalin Pvt. Ltd. 2-3

45 Operation of the Expansion Project Act, 1986 Under Air, Water, Haz. Waste & Environment (Protection) Act, 1986 from MoEF&CC as per the guideline of EIA Notification-2006& amended time to time. CTE & CTO/CCA from GPCB. San Envirotech Pvt. Ltd., Ahmedabad TORs awarded on Will apply for CTE/CCA to GPCB. After obtaining CC&A. 2.9 DETAILS OF MAJOR EQUIPMENT AND MACHINERY (EXISTING & PROPOSED) The proposed expansion project will be carried out within the existing plant premises. Building construction will be done as per requirement. Restructure of the plant building will be done if required considering safety point of view. For the manufacturing of the products, required Raw materials are available nearby and can be transported to the project site with ease because of good road connectivity. The details about existing infrastructural facilities and plant machineries for proposed expansion are shown in Table 2.4. Table 2.4 Plant machineries (Existing & Proposed) Sr. No. Formaldehyde Particulars Qty. Status (Existing/Proposed) 1. Reactor 2 Existing & Refurnished 2. Evaporator 2 Existing 3. Absorber-1 2 Existing 4. Absorber-2 2 Existing 5. Air Washer 1 Existing 6. Steam Filter 2 Existing 7. Methanol Filter 4 Existing 8. Steam Drum 3 Existing 9. Steam Distributor 2 Existing 10. Hot Water Tank 2 Existing 11. Plate Type Heat Exchange 10 Existing 12. DCS System 2 sets Existing 13. Other Field Instruments 2 Lot Existing 14. Air Compressor 4 Existing 15. Pump & Motors 2 Lot Existing 16. Roots Blower 5 Existing EIA report of Balaji Formalin Pvt. Ltd. 2-4

46 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Particulars Qty. Status (Existing/Proposed) 17. Air Filter 2 Existing 18. Super Heater 1 Existing 19. Gas Filter 1 Existing 20. Bubble Cap Tank 1 Existing 21. Incinerator 1 Existing Paraformaldehyde 1. 1 st Stage, Falling Film Evaporator with Separator 2. 1 st Stage, Condenser for Falling Film Evaporator 3. 2 nd Stage, Thin Film Evaporator with rotating wiper system, drive for rotation & motor 1 Proposed 1 Proposed 1 Proposed 4. 2 nd Stage, Concentrate Buffer Tank 1 Proposed 5. 2 nd Stage, Condenser for Thin Film Evaporator 1 Proposed 6. Feed Tank with Agitator (Drying Unit) 1 Proposed 7. Pressure Nozzle System (Atomizing System) 1 Proposed 8. Steam heated gas heater (Inlet Gas) 1 Proposed 9. Steam heated gas heater (Hot Gas) 1 Proposed 10. Roof Air Disperser (Spray Chamber) 1 Proposed 11. Congealing Chamber (Spray Chamber) 12. Fluid Bed System consisting of 1 stationary fluid bed unit divided into 2 drying sections and 1 cooling section 1 Proposed 1 Proposed 13. Cyclones (Outlet Gas) 1 Proposed 14. Scrubber/Condenser with buffer tank 1Lot Proposed 15. Heat Exchanger 1 Proposed 16. Oxygen Analyzer 1 Proposed 17. Other Field Instruments 1Lot Proposed 18. PLC with SCADA 1 Proposed 19. Packing Machine 1 Proposed 20. Structure supply & Installation 1Lot Proposed Silver catalyst plant 1. Electrolysis Tub 3 Proposed 2. Current Rectifier 3 Proposed 3. Electric Oven 1 Proposed 4. Muffle Furnace 1 Proposed 5. Agitated Tank 1 Proposed 6. Vacuum Filter 1 Proposed EIA report of Balaji Formalin Pvt. Ltd. 2-5

47 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Particulars Qty. Status (Existing/Proposed) 7. Vacuum Pump 1 Proposed 8. Melting Furnace 1 Proposed 9. Sieving Machine 1 Proposed 10. Circulation Pump 1 Proposed 11. Scrubber 1 Set Proposed 12. Different Tubs [Plastic & SS] 1 Set Each Proposed 2.10 MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE Formaldehyde Production Technique: a) Feed Methanol, air, water vapour Catalyst: Silver/Metal oxide b) The methanol in the measuring storage tank is pumped up to an elevated tank by a methanol pump. After being controlled by measuring, the methanol coming out from the elevate tank flows into an evaporator for vaporization of which the temperature is controlled within 44 0 C ~ 47 0 C and the liquid level is controlled as 50%,then the vaporized methanol gets into a super heater. The heat for the vaporization of methanol is provided by the 70 0 C circulating fluid in the 1# formaldehyde absorber. c) The air is filtered by a filter before being delivered to the evaporator by a blower. It mixes with the methanol in the evaporator and enters into then super heater together. The air flow is regulated by the blower through frequency conversion to control the flow ratio of air to methanol (A/M=1.8 ~1.95). d) When the pressure gets stable, the vapour (0.3MPa) gets into a mist eliminator for dehumidification through the pipeline before entering into the superheat. The flow ratio of air to methanol shall be controlled at desired level. In the formaldehyde production technique using silver as catalysis, the water vapor is an inert gas which does not participate in chemical reactions. The added water vapor changes the explosive range of the methanol and air, the production of formaldehyde thereby becomes far from the explosive area and stays safe and reliable. e) After the flow rates are regulated and proportioned, the methanol, air and water vapor enter into the super heater and the superheating EIA report of Balaji Formalin Pvt. Ltd. 2-6

48 temperature shall be controlled at C. Then, these materials enter into a reactor. f) In the reactor, under the catalysis of silver of C, the methanol is dehydrated and oxidised, generating Formaldehyde. Dehydration reaction is an endothermic reaction and oxidation reaction is an exothermic reaction, but the heat release is more than that can adsorbed, therefore the reaction system is a state of heat energy surplus. The water vapour is not involved in reactions but it can absorb a lot of heat of reaction, maintaining the temperature at C. Chemical Reaction CH 3 OH CH 3 OH + ½ O 2 CH 2 O + H 2-20Kcal CH 2 O + H 2 O + 38 Kcal =18Kcal The C reaction gas leaves the reaction and gets into heat exchanger. For the heat exchanger, the medium is water. The outlet temperature of heat exchanger is C. The water absorbs heat, forming the water vapour of 0.35 MPa which will be used to arranging the raw materials for production in the super heater after its pressure stabilized. g) The generated gas of about C enter into 1# and 2# formaldehyde absorber in proper order and gets absorbed by the cooled circling fluid through spraying. The temperature of the circulating fluid at the bottom of 1# absorber shall be control at 70 0 C and fluid is pumped to the evaporator by circulating pump to supply the heat for the evaporation of methanol. In the 1# absorber, the concentration shall be controlled as 37%, and temperature of the top shall be controlled at 45 0 to 50 0 C. The circulating fluid is also a composition of the Formaldehyde product by this technique. The temperature of the top of 2# absorber shall be controlled at 30 0 to 35 0 C and keep adding water by kg/h from top to reduce the release of formaldehyde. The tail gas is discharged from the top of the absorber and sent to a tail gas treatment unit. The tail gas contain 18 to 20% hydrogen and small amount of Formaldehyde, methanol and methane, which will generate EIA report of Balaji Formalin Pvt. Ltd. 2-7

49 heat after burning to produce 0.6 MPa water vapor for the application of other devices. Through tail gas treatment unit, the pollution of formaldehyde, methanol and methane to atmosphere is reduced and the recycling of combustion heat is very effective to reduce pollution discharge and take advantage of wasted energy. Flow diagram EIA report of Balaji Formalin Pvt. Ltd. 2-8

50 Process of making Para-formaldehyde from Methanol using rake type drying method First step process of Para Formaldehyde is production of formaldehyde from Methanol with above mentioned process. Formaldehyde is firstly concentrated and dehydrated until the formaldehyde concentration is increased 65%. Then it is sent to the vacuum type dryer for further dehydration and drying to make powder/prills. The whole drying process is operated under vacuum condition. The evaporation condensate contains 10-15% of formaldehyde fumes, which is condensate and collect as diluted formaldehyde for recycling in formaldehyde plant. Condenser 1: The vapor, which contains formaldehyde & water vapor from evaporator and concentrated receiving vessel pump into 1#condenser for cooling. The condensate is dilute formaldehyde solution which is finally discharged into dilute formaldehyde storage tank, which is return back to formaldehyde plant. Condenser 2: The vapor, which contains formaldehyde & water vapor from dryer into 2# condenser for cooling. The condensate is dilute formaldehyde solution which is finally sent to dilute formaldehyde storage tank, which is return back to formaldehyde plant. Absorber: Off gas of 1# condenser, 2# condenser and vent of Dryer are taken into absorber tower where water circulates from circulation tank. Formaldehyde whichever in off gas is absorb in water and convert into dilute formaldehyde. When absorption liquid formaldehyde solution reaches certain concentration, then it is taken into dilute formaldehyde storage tank and it is used in formaldehyde plant. All source of dilute Formaldehyde from Condenser 1 & 2 + Absorber are collected into Dilute formaldehyde storage tank which have around (4 to 4.5%) concentration of Formaldehyde which is recycled in formaldehyde plant. EIA report of Balaji Formalin Pvt. Ltd. 2-9

51 Process Flow Diagram: Heat out Packing Powder form FM solution Evaporator (65-75%) Concentrate receiving vessel Dryer Off gas Heat in Off gas Off gas Cooling water in Cooling water out Condenser 1 Condenser 2 Cooling water in Cooling water out Absorber Circulation tank Dilute formaldehyde storage tank (4 to 4.5%) EIA report of Balaji Formalin Pvt. Ltd. 2-10

52 Process of Silver Refining Stage-I Process of making silver nitrate In a vessel 50 Ltr of water/dilute solution of Silver Nitrate is taken to which 16 Kg of silver is Degree C, under constant stirring. Nitric Acid 9.3 Kg is added in the same to convert silver to silver nitrate. During reaction nitrous fumes are evolved which is absorbed in scrubber. Stage-II In a tank containing refining cells with hood, connected to scrubber, which can hold silver. Silver nitrate solution is added to tank in which current from 20 to 200 Amp & DC voltage of 2 to 20 Volts is applied. Silver crystals are deposited on silver cathode plate. Silver crystals are removed from cathode plate by scrapping, then collected and washed with DM water to remove silver nitrate. Water used in washing is recycled back to electrolysis tank. Wet crystals are dried and sieved to obtain different sizes. The fumes generated are absorbed in a scrubber. In scrubber NaOH solution is circulated to absorb nitrous fumes. Neutralize solution is taken to common Evaporator. Stage-III Melting Process Silver crystals to be reprocessed are melted in electric/gas 900 Degree C and converted into ingots/small pieces. EIA report of Balaji Formalin Pvt. Ltd. 2-11

53 Flow Diagram San Envirotech Pvt. Ltd., Ahmedabad Stage 1 process (silver refining process) Silver metal AgNO 3 Preparation HNO 3 Silver plate D.C. current AgNO 3 Solution Silver electrolysis Recovered silver Dilute AgNO 3 reused D.M. water Washing Drying Silver Catalyst EIA report of Balaji Formalin Pvt. Ltd. 2-12

54 Stage 2 process Silver recovery from AgNO 3 Reducing agent AgNO 3 from silver refining process NaOH Silver recovery unit Filtration To effluent Water To evaporator Silver Washing Drying Melting Ingots/small process 2.11 PROJECT COMPONENTS Components of the project include all facilities required for the operation of the project with legal necessity. a) Input requirements: Raw materials, water, fuel, power etc. b) Utility requirements: Re-Boiler, cooling tower, D. G. Set etc. c) Pollution control facilities: Water Treatment Facilities: Forced effect evaporator and mechanical evaporator. Air Pollution Control Facilities: Tail gas treatment units. Hazardous/Solid waste facilities: It includes sludge storage and final disposal facility at approved TSDF site by GPCB. d) Other facilities: It includes greenbelt area, rain water harvesting system etc. EIA report of Balaji Formalin Pvt. Ltd. 2-13

55 2.12 INPUT REQUIREMENTS (a) Raw material requirement: The details of the raw material requirement are given in Table 2.6. (b) Water requirement: At present, total water requirement (Industrial + Domestic + Greenbelt) is 129 KLD (104 KLD freshwater + 25 KLD recycle water). After expansion; water requirement will be increased up to 610 KLD, out of which 535 KLD is fresh water & 75 KLD is recycle water (condensate from evaporator). Fresh water consumption is mainly for domestic, process, utilities, greenbelt development. Source of fresh water is Narmada Water supply and it will be same after expansion. Detailed breakup of the waterconsumption is given in Table 2.6. Water balance diagram is given in Figure 2.1. (c) Fuel: No fuel is used for existing manufacturing because exothermic reaction. Methanol is being used as starting fuel for 30 to 60 minutes when reaction initiated. After expansion, same technology will be used hence no need of fuel. Only HSD is used for stand-by D. G. set, which is used in case of emergency/power failure only. (d) Power: Electricity is supply from Gujarat Electricity Board (GEB-UGVCL). At present, power requirement is 400 kva. There will be increase in power consumption. Additional requirement will be 950 kva. Hence, total 1350 kva will be required after expansion. There is also provision of stand by D. G. Set of 400 kva (Existing) and proposed addition of 1000 kva to meet the power requirement in case of power failure. (e) Manpower: After expansion, total manpower will be 55; i.e. existing 30 nos. and proposed 25 nos. which include manpower at all levels (i.e. chemists, supervisors, operators, miscellaneous etc.) UTILITIES REQUIREMENTS Utilities facilities are tabulated below: EIA report of Balaji Formalin Pvt. Ltd. 2-14

56 Table 2.5: Utility details San Envirotech Pvt. Ltd., Ahmedabad Sr. No. Particulars Qty. Capacity 1. Cooling towers TR each [Existing] 2. D. G. Sets kva( Existing) kva (Proposed) 3. Air Compressor 4 22 CFM x 1 [Existing] 39 CFM x 2 [Existing] 39 CFM x 1 [Existing] 2.14 GENERATION OF POLLUTANTS The sources of pollution will be as below; Wastewater generation: Source of water pollution is mainly from process, RO/DM reject, utilities i.e. cooling bleed off and from domestic use. Currently, 30 KLD wastewater is generated from raw water treatment and utilities. After expansion, it will be increased up to 121 KLD. Wastewater generated from the inter-reaction is retained with the product. RO/DM reject, wastewater generated from silver refining & cooling bleed off will be directly sent to force effect evaporator & then sent to mechanical evaporator. Condensate from evaporator will be reused for utility i.e. for cooling. Thus unit will achieve zero discharge after proposed expansion. Generated Domestic wastewater will be sent to soak pit Gaseous Emissions: There will not be any process emission except tail gas, which will be emitted after proper burning/incineration in tail gas treatment plant. Tail gas treatment plant is integral part of process plant. It will be updated/modify along with process plant after expansion. The tail gas treatment plant will be adequate to reduce the pollution of formaldehyde, methanol and methane to atmosphere. There will also be recycling of combustion heat which is very effective to reduce pollution discharge and take advantage of wasted energy. Unit has installed one D G Set (400 kva) and going to install additional one D G Set with capacity of 1000 kva. Both the D G Sets are used as standby in absence of power supply from state grid. HSD will be used as EIA report of Balaji Formalin Pvt. Ltd. 2-15

57 fuel. Most probable pollutants will be SPM, SO 2 and NO x. The details of the flue gas stacks and process gas stacks are given in Table Hazardous/Solid Waste generation: Main source of hazardous waste generation is Evaporation Salt, used oil & discarded containers/barrels. After expansion, source of Haz. waste generation will remain same but there will beincrease in the quantity of hazardous waste generation. The details of hazardous waste generation are given in Table Noise Pollution: At present, the main source of noise generation is process plant, vehicular transportation & other machineries. There will be slight increase in noise level due to proposed manufacturing activities, due to installation of some new additional mechanical equipment required for the proposed expansion. The noise level in the unit is well within the prescribed limit. Noise monitoring for existing plant activities are given in Table POLLUTION CONTROL MEASURES The details of pollution control strategy for various parameters are given hereunder: Effluent Management As discussed in earlier section of this chapter, main source of water pollution is from silver refining process, RO/DM reject, utilities i.e. cooling bleed off. Wastewater generated from water treatment, silver refining & cooling bleed off will be directly sent to forced effect evaporator & then sent to mechanical evaporator. Condensate from evaporator will be reused for utility i.e. for cooling. Thus, unit will achieve zero discharge after proposed expansion. Generated Domestic wastewater will be sent to soak pit. Technical details of forced effect evaporator and mechanical evaporator are given in table Table-2.9 and Figure Air Pollution Control There will not be any process emission except tail gas, which will be emitted after proper burning/incineration in proposed tail gas treatment plant. After expansion, it will be modify along with process plant. The tail EIA report of Balaji Formalin Pvt. Ltd. 2-16

58 gas treatment plant will be adequate to reduce the pollution of formaldehyde, methanol and methane to atmosphere. There will also be recycling of combustion heat which is very effective to reduce pollution discharge and take advantage of wasted energy. The flue gas emission from D. G. set will be well within gaseous emission norms and there is no need of any air pollution control measures. Adequate stack height will be provided to control & disperse the air pollutants within the satisfactory levels and facility for sampling such as ladder and sampling point will be provided as per the GPCB guidelines. The details of the flue gas stacks and process gas stacks are given in Table Hazardous/Solid Waste Management Entire quantity of hazardous waste will be handled and disposed as per Hazardous Waste (Management, Handling & Transboundary Movement) Rules 2008 (amended time to time). Salt from evaporator will be disposed to secured TSDF site for landfilling; discarded containers/barrels will be sold to authorized recyclers. Used oil will be sold to CPCB approved recyclers. The unit has provided isolated area with impervious flooring for the storage of hazardous waste. Thus, hazardous waste management system provided by the unit is adequate. The details of hazardous waste generation are given in Table Noise control measures: Following steps will be taken by industry to control noise: Proper maintenance ofequipment and oiling to avoidincrease in noise. Provide PPEs like ear puff, ear plugs etc. to workers. Rotate the workers from noise generating area to other. Develop the green beltadequately Fugitive Emission Control Fugitive emission of VOCs is likely to emit from production activities. There are also chances of the fugitive emission due to handling of raw materials and from process. However, to prevent the same the unit takes all the precautionary measures like to carry out entire process in the closed pipeline and EIA report of Balaji Formalin Pvt. Ltd. 2-17

59 reactors with practically zero leakages. As major raw material & finished products are in liquid form, practice of pneumatically transfer is adopted to avoid generation of fugitive emission. All raw materials are stored in closed conditions to minimized fugitive emission. Frequent work area monitoring will be done to check fugitive emissions level RESOURCE CONSERVATION Heat Recovery The unit introduces modernized techniques so that generated heat from exothermic reaction is utilized for steam generation. Unit has installed tail gas treatment plant.therefore, wasted heat energy will be recovered in recycled for various industrial activities. Thus, there will not be any additional fuel requirement which will step towards resource recovery and conservation. With tail gas treatment plant there will also be reduction in pollutant concentration and better quality of air emission will be obtained. Better quality water from Mechanical Evaporator will be recovered and reused in process. This resulted in conservation of fresh water requirement. There will also be recycling of combustion heat which is very effective to reduce pollution discharge and take advantage of wasted energy Rain Water Harvesting System The unit has provided Rain water harvesting system within the plant, for capacity of 100 Kl underground tank. During the rainy days, they will first use rain water for process and utilities and only balance water use form ground water source. Further, unit is using this water for manufacturing process Green Belt Development The unit has developed greenbelt area around 1500m 2 in its existing unit and some more area will be added for greenbelt development outside the plant boundary. The greenbelt area is around 35% of total land area. Local spices are planted and survival rate is more than 70% Odour control: The only source of odour is Methanol & Formaldehyde handling and storage which will be in minor quantity. Both the chemicals are EIA report of Balaji Formalin Pvt. Ltd. 2-18

60 pneumatically transferred to the reactor as well as packing containers with practically zero leakages. However, proper personal protective equipment will be provided to the workers which are handling odorous materials Health& Safety: M/s. Balaji Formalin will be followed occupational health program right from the start of production. The following check-ups shall be carried out regularly to avoid occupational hazards: Pre-employment medical check-up at the time of employment Provision of periodic medical check-up for all the employees To provide necessary first aid facilities, the first aid training shall also be given to the employees The unit has appointed doctor for the examination and treatment of the employee. EIA report of Balaji Formalin Pvt. Ltd. 2-19

61 Table 2.6 Details of raw materials along with source & mode of transportation Sr. No. Name of Raw Materials Consumption (MTPM) Source Mode of transport Existing Proposed Total Formaldehyde (37%) MTPM 1 Methanol Indigenous /Imported Para Formaldehyde MTPM Through Tankers from Kandla/ Mundra/ Dahej Port 1 Formaldehyde (37%) Purified Silver MTPM Own manufacturing -- 1 Silver Metal (98%) Indigenous Road 2 HNO 3 (98%) Indigenous Road EIA report of Balaji Formalin Pvt. Ltd. 2-20

62 Table 2.7 Breakup of water consumption Description Water Consumption (KLD) Existing Proposed addition Total Domestic Gardening Industrial Process Water Treatment Boiler Cooling 10+25* * * Total Industrial Total D + G + I Recycle water Fresh Water Requirement * Condensate water Table 2.7(a) Wastewater Generation Description Wastewater generation (KLD) Existing Proposed addition Total Domestic Industrial Water Treatment Process Cooling Boiler * Total Industrial Total (D +I) * Use of re-boiler for steam generation to utilize energy from exothermic reaction and no chances of generation of blow down. EIA report of Balaji Formalin Pvt. Ltd. 2-21

63 Table 2.8 Details of stacks with air emission quality Sr. No. Stack attached to Existing Stack 01 Tail gas treatment incinerator 02 D.G. Set (400 kva) Stack Temp. In 0 K Proposed additional stack 01 D. G. Set (1000 kva) Velocity m/s Stack Height in m Dia. of Stack (m) Fuel Used Waste gas HSD- 45 lit/hr HSD- 110 lit/hr. SPM mg/ Nm 3 SO 2 mg/ Nm 3 NO X mg/ Nm 3 -* -* -* Tail gas* Quality of tail gas Unit % V/V CO 2 CO CH 4 O 2 H 2 O N 2 H 2 CH 2 O CH 3 OH Table 2.8(a) Sources of fugitive emission with its quantification (Estimated) Sr. No. Pollutants Location Results (μg/m 3 ) TLV/TWA Limit (mg/m 3 ) 1. Methanol Process Area Formaldehyde Process Area PM Packing Area EIA report of Balaji Formalin Pvt. Ltd. 2-22

64 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Table 2.9 Technical specification of forced evaporator Description Specification 1 Feed Quantity 1500 kg/hr. 2 Feed temperature 30 0 C 3 Feed ph Water Evaporation Capacity 1388 kg/hr. 5 Total Solids in Product Feed 3.0% 6 Concentrate 40% 112 kg/hr. 7 Steam requirement 850 kg/hr. 8 Steam Pressure 1.5 Kg/cm 2 (g) 9 Power requirement 25 KW PROCESS/PLANT EQUIPMENT 1 Calandria I 1 no. 2 Vapor Separator 1 1 no. 3 Primary Surface Condenser 1 no. 4 Effect Recirculation Pump with Mechanical Seal and Non flame Proof Electric Motor 5 Condensate Pump with Mechanical Seal and Non flame Proof Electric Motor 6 Water Ring Vacuum Pump with Non flame Proof Electric Motor 1 no. 1 no. 1 no. 7 Feed Tank 1 no. 8 Condensate Collection Pot 1 no. Instruments Pressure Gauges will be provided in discharge of all Centrifugal Pumps Vacuum Gauges will be provided to all Vapour Separator, Primary Condenserof Evaporator. Temperature Indicators will be provided to Feed Inlet to First Preheater andfeed Outlet to Last Preheater. Temperature Indicators will be provided to all Recirculation Liquid Inlet andoutlet of Calandrias. Temperature Indicators will be provided to All Vapour Separator Top. Temperature Indicator will be provided on Condensate Pot. Flow meter will be provided at the feed and condensate outlet dischargepump. EIA report of Balaji Formalin Pvt. Ltd. 2-23

65 Sr. No. Name of Waste 1 Evaporation Salt 2 Discarded Containers Category of waste Existing MT/month Nos./yr. San Envirotech Pvt. Ltd., Ahmedabad Quantity Proposed addition 10 MT/month 500 Nos./yr. Table 2.10 Details of Hazardous waste Total 15 MT/month 1000 Nos./yr. Method of Disposal Collection, Storage, transportation, disposal at TSDF- SEPPL. Collection, Storage, decontamination, transportation, disposal by selling to authorized recycler or reuse. 3 Used Oil lit./yr lit./yr. Collection, Storage, transportation, disposal by selling to registered reprocessor or reused as lubricant. EIA report of Balaji Formalin Pvt. Ltd. 2-24

66 Table 2.11 Noise Survey of existing plant Sr. No. Locations Noise Level db(a) 1. Nr. Main Gate Backside of plant Inside Plant Building Nr. Methanol storage tanks Nr. Ejector Nr. D. G. Set 67.4 EIA report of Balaji Formalin Pvt. Ltd. 2-25

67 Figure2.1 Water Balance Diagram (Existing) Water consumption 104 m 3 /d Domestic 3.5 m 3 /d Process 63 m 3 /d Utilities 35 m 3 /d Greenbelt 2.5 m 3 /d Evop loss 5.0 m 3 /d Water generation from reaction 47 RO treatment Reject 10m 3 /d Soak pit 2.5 m 3 /d Retained with product 105 m 3 /d Boiler 15 m 3 /d Cooling m 3 /d Condensate 25m 3 /d Multi Effect evaporator 30 m 3 /d EIA report of Balaji Formalin Pvt. Ltd. 2-26

68 Figure2.2 Water Balance Diagram (after proposed Expansion) Water consumption m 3 /d Domestic 8.0 m 3 /d RO/DM 298 m 3 /d Utilities 225 m 3 /d Greenbelt 4 m 3 /d RO/Softening Soak pit 7.0 m 3 /d Product water 268 m 3 /d Reject 30* m 3 /d Product water 205 m 3 /d Reject 20 m 3 /d Water with RM 42 m 3 /d PF 0+40m 3 /d Formaldehyde 0+40m 3 /d Steam 267 m 3 /d Silver 1 m 3 /d Cooling m 3 /d Water scrubber for PF ( % of Formaldehyde 40 m 3 /d Water retain with Formaldehyde = 255 m 3 /d Water generation from interreaction68 m 3 /d Live steam147 Effluent 1.0* m 3 /d 75 m 3 /d Bleed of 70 m 3 /d Force effect evaporator *+1* = 121 m 3 /d Mechanical Evaporator 78 m 3 /d Salt 500 kg System loss 43 m 3 /d System loss 3 EIA report of Balaji Formalin Pvt. Ltd. 2-27

69 Figure 2.3 Plant Layout Old building is to be removed & paraformaldehyde plant is to be created here Formaldehyde capacity enhancement is only through modification of current machinery. No new space required for same EIA report of Balaji Formalin Pvt. Ltd. 2-28

70 Figure 2.4 Drawing of Evaporator EIA report of Balaji Formalin Pvt. Ltd. 2-29

71 Chapter-3 Baseline Environmental Status 3.1 Prelude To assess environmental impacts from proposed project at a specific location, it is essential to monitor the environmental quality prevailing in the surrounding area prior to implementation of the proposed project. The environmental status within the impact zone could be used for identification of significant environmental issues to be addressed in the impact assessment study. In order to identify and establish the extent of likely impacts, it is essential to gather information on existing environmental quality with regard to various components of the environment Study area M/s. Balaji Formalin Pvt. Ltd. is an existing unit located at Plot No. 1398, Village: Moti Bhoyan, Taluka: Kalol, Dist.: Gandhinagar. The baseline study was carried out within 10 km radius (as per TOR) from the center of the proposed project Period of the Study area The baseline study of the proposed project was carried out during October-2015 to December-2015 within 10 km radius from the center of the proposed project Basic Component of the Environment The basic component of study of the present environment is obligatory to predict the environmental impact on the study area; therefore it is necessary to discriminate the various components of which Environment made. Environment consists of Atmosphere, Hydrosphere, Lithosphere and Biosphere. These Environment components have been considered for the study of the Existing environment. They are as follows: (I) Lithosphere: It includes the terrain and landscape study. Such as a) Topography and Geology of the study area EIA report of Balaji Formalin Pvt. Ltd. 3-1

72 (II) Hydrosphere or Water Environment: It includes water quality of the study area by means of - a) Surface water quality b) Ground water quality (III) Atmosphere or Air Environment: Atmospheric condition mainly depend upon the a) Climatic condition, and b) Micrometeorological data such as wind, temperature, humidity, Rainfall etc. of the project area. (IV) Biosphere: Ecological systems consist of varieties of interrelationship between both abiotic and biotic components including dependence, competition and mutualism. Biotic components comprises of both plant and animal communities, which interact not only within and between themselves but also with the abiotic physical and chemical components of the environment. Whereas biotic component includes study of a) Fauna: Study of the animal b) Flora: Study of the Plant (V) Other Component: Other component of the surrounding area includes Socio- Economic data and noise level data of the surrounding area. Survey for above all components of the study area and data collected by means of Primary and Secondary data are described from Sec: 3.3 to Methodology (a) AIR ENVIRONMENT MONITORING: Process: Reconnaissance Design of Network for AAQM Stations (fig: 3.6 shown all eight Air monitoring stations counting project site) Air quality monitoring or data collection Sample analysis Methodology: To understand the Air environment in the study area, monitoring of the air quality was done by setting up reconnaissance and using Respirable Dust EIA report of Balaji Formalin Pvt. Ltd. 3-2

73 Sampler (RDS) & Fine Particulate Sampler for monitoring of PM 10, PM 2.5, SO 2, NOX. Details of methodology for AAQ monitoring are given in below table. Sampling Parameters PM 10 PM 2.5 SO 2 NO x Table 3.1: Methodology of Ambient Air Monitoring Sampling equipment Respirable Dust Sampler with cyclone & flow measurement Fine Particulate Sampler Gaseous flow attachment with RDS Sampler Gaseous flow attachment with RDS Sampler Analytical Equipment Electronic Balance Electronic Balance Spectro Photometer Spectro Photometer VOC Grab sample Gas Chromatograph CO Grab sample Gas Chromatograph HC Grab sample Gas Chromatograph (b) WATER ENVIRONMENT MONITORING: Process: Reconnaissance Sensitivity Methodology /Detection Limit 1 μg/m 3 Gravimetric IS: 5182 (Part 23) μg/m 3 Guideline for the measurement of ambient air pollutant Volume-1 by CPCB, 2011, Gravimetric ppm Colorimetric IS: 5182: (Part II) ppm Colorimetric IS: 5182: (Part VI) ppm As per equipment manual - As per equipment manual - As per equipment manual Design of network stations for collection of water sample (fig: 3.8 shows all eight water sample stations) Sample collection & preservation Analysis of water quality by using following methodology Methodology for water sample collection: Water sampler was use for collection of surface water sample. Sampling locations with source & date of sampling is given in table below: Table 3.2: Surface Water Sampling Locations Sample Location Date of Source Taluka District Code Sampling SW1 Piyaj village 04/12/2015 Pond Kalol Gandhinagar SW2 Hajipur 04/12/2015 Pond Kalol Gandhinagar SW3 Lapkaman 05/12/2015 Pond Daskroi Ahmedabad SW4 Thol 06/12/2015 Lake Kadi Mahesana SW5 Narmada Canal 06/12/2015 Canal Kalol Gandhinagar EIA report of Balaji Formalin Pvt. Ltd. 3-3

74 Methodology for water sample Analysis: San Envirotech Pvt. Ltd., Ahmedabad To understand the water quality of the study area, analysis of sample collected from all eight locations including the plant site was conducted as per IS: 10500: 2012 of drinking water or APHA (American Public Health Association). Details are given in below table: Table 3.3: Ground Water Sampling Locations Sample Locations Date of Taluka District Code Sampling GW1 Project Site 04/12/2015 Kalol Gandhinagar GW2 Moti Bhoyan 04/12/2015 Kalol Gandhinagar GW3 Hajipur 04/12/2015 Kalol Gandhinagar GW4 Khatraj 05/12/2015 Kalol Gandhinagar GW5 Sherisa 05/12/2015 Kalol Gandhinagar GW6 Vadsar 05/12/2015 Kalol Gandhinagar GW7 Karoli 06/12/2015 Kalol Gandhinagar GW8 Ganapatpura 06/12/2015 Kalol Gandhinagar (c) LAND ENVIRONMENT MONITORING: Reconnaissance Design of network stations for collection of soil sample (fig: 3.10 shows all six soil sample collection stations counting project site) Sample collection Physico-Chemical analysis of soil based on following methodology Methodology for soil sample collection: Undisturbed top soil samples were collected manually. Sampling locations with date of sampling is given in table below: Sample code Table 3.4: Surface soil sampling locations Locations Date of sampling Tehsil District S1 Project site 04/12/2015 Kalol Gandhinagar S2 Hajipur 04/12/2015 Kalol Gandhinagar S3 Moti Bhoyan 04/12/2015 Kalol Gandhinagar S4 Khatraj 05/12/2015 Kalol Gandhinagar S5 Sherisa 05/12/2015 Kalol Gandhinagar S6 Ganpatpura 06/12/2015 Kalol Gandhinagar EIA report of Balaji Formalin Pvt. Ltd. 3-4

75 Methodology for analysis: To understand the soil quality of the study area, analysis of all six locations including the plant site was conducted by making suspension of soil sample and analysis were done by using following methodology. Sampling Parameters Porosity Table 3.5: Soil Sample analysis methodology Sample collection Manual sample collection using hammer and container tube for collecting undisturbed top soil Analytical Equipment Methodology - IS: 2720 Part 7 Water holding - - capacity Permeability - IS: 2720 Part 17 Moisture Electronic IS: 2720 Part 2 content Balance Texture - IS: 2720 Part 4 Particle size Distribution Cation Exchange Capacity SAR Glass wares IS: 2720 Part 4 Centrifuge IS: 2720 Part 24 (1976) F. Photometer (Na, K) Titration (Ca & Mg) Calculation ph ph Meter 4500 H+B Electrical Conductivity Conductivity Meter As per IS Calcium Glass wares 3500 Ca B Magnesium Glass wares 3500 Mg B Sodium (Na) Potassium Flame Photometer Flame Photometer (d) NOISE ENVIRONMENT MONITORING: Reconnaissance 3500 Na B 3500 K B Remarks Trial pit method for topsoil sample collection; disturbed samples 5% Leachate to be made and analyzed as per APHA, Standard Methods All method numbers are as per APHA Standard Methods (22 nd edition) Design of network stations for noise monitoring (fig: 3.9 shows all ten noise monitoring stations counting project site) Methodology: To understand the noise environment in the study area, a survey was conducted using Sound Level Meter at each of the ten locations including the plant site. EIA report of Balaji Formalin Pvt. Ltd. 3-5

76 Monitoring methodology of noise is given in below table. San Envirotech Pvt. Ltd., Ahmedabad Table 3.6: Monitoring Methodology of Noise Environment Component Ambient Noise levels Sampling Location 08 Locations Sampling Parameter Decibels db (A) Sampling Frequency Once during the study Hourly reading for 24 hours at each location Sampling Equipment Noise Level Meter Detection Limit 0.1 db (A) 3.2 Establishment of baseline for valued environmental components Environmental Impact Assessment (EIA) studies need a significant amount of primary and secondary baseline environmental data. The primary baseline environmental data are those which need to be collected in the field to define the status of environment (like air quality data, water quality data, noise quality etc.). The secondary baseline environmental data are those data which have been collected over the years and can be used to understand the existing environmental scenario of the study area by any recognized agencies. (Such as Used IMD data for micrometeorological data- rainfall, humidity and Census data for Socio Economic etc.) The environmental impact assessment (EIA) studies are conducted over a short period of time and therefore the understanding the environmental trends based on few months of primary data has its own limitations. Ideally, the primary data has to be considered along with the secondary data for complete understanding of the existing environmental status of the area. 3.3 Air Environment The impact on air environment would depend and has been identified on the basis of identification of sources of air pollution from various process operations; the nature of pollutants and their quantities likely to be discharged to the atmosphere; and the baseline data on air quality. The baseline data on air quality and micrometeorological conditions of the area surrounding the project site have been generated through an appropriately designed network for monitoring of Ambient Air Quality (AAQ) within the zone of likely impacts. EIA report of Balaji Formalin Pvt. Ltd. 3-6

77 3.3.1 Design of Network for Ambient Air Quality Monitoring Stations The following criteria were taken into account while designing the ambient air quality-monitoring network: Topography/Terrain of the study area Populated areas within the region Prediction of maximum concentrations and distances of their likely occurrence under prevailing meteorological conditions Representation of regional background Representation of valid cross sectional distribution in downwind direction Reconnaissance Reconnaissance was undertaken to establish the baseline status of air environment in the study region. The prime objective of the NAAQ survey, within 10 km radial study area around the plant was to establish the existing ambient air quality levels. Eight Ambient Air Quality Monitoring (AAQM) stations including project site were selected based on the criteria used for designing the network. The locations (relative directions and distances) of these stations with respect to project site are given in Table 3.7 and details of these stations are shown in Figure 3.6. The Particulate Matter (PM 10 ), Particulate Matter (PM 2.5 ), Sulphur Dioxide (SO 2 ) and Oxides of Nitrogen (NO x ), CO, HC (methane & non-methane) and VOCs were identified as significant parameters for ambient air quality monitoring, particularly because these are likely to be emitted from the industries and for which ambient air quality standards are prescribed. The micrometeorological data on wind speed, wind direction, temperature and relative humidity were collected through a weather monitoring station for the study period. The baseline status of air quality was monitored within the study area i.e. 10 km radial distance from project site as per the latest regulatory guidelines Micrometeorology of the area The micrometeorological conditions at the project site will regulate the transport and diffusion of air pollutants released into the atmosphere. The principle meteorological variables are horizontal convective transport EIA report of Balaji Formalin Pvt. Ltd. 3-7

78 (average wind speed and direction), vertical convective transport (atmospheric stability, mixing height) and topography of the area. The data on surface meteorological parameters (hourly average wind speed and direction) in the study area were collected during the October-2015 to December-2015 using portable weather monitoring station placed at industry site. The sensors of this equipment were kept at about 10 m above ground level with free exposure to the atmosphere all through the study period. In addition, data on temperature as well relative humidity were also recorded simultaneously using a data logger. Wind Rose (Secondary data) The 24 hourly wind rose was prepared using the data on wind direction and speed collected during October-2015 to December-2015 in the study area. The same, as depicted in Figure 3.7, shows the predominant wind directions are ENE, NE, NNE, N, NNW implying that wind comes from these directions for most of the time during the period. The wind speed class 1-5 kmph occurred for 9.47%, 6-10 kmph about 31.70%, kmph 33.33% and above 15 kmph and below 30 kmph occurred for 15.64% of the study duration and of the time. The calm condition (below 1 kmph) prevails 9.9% of time. The wind data generated at site were also compared with the climatologically data obtained from the nearest Indian Meteorological Department station. The local prevailing wind pattern during the study period is in conformity with the climatologically normal of the region. Temperature (Primary data) During the study period, the maximum temperature was recorded as 40.0 C and minimum was 13.0 C. Relative Humidity (Primary data) During study period, the maximum relative humidity was recorded as 78% and min. was 11%. Rainfall (Primary data) No rainfall during the study period at project site. EIA report of Balaji Formalin Pvt. Ltd. 3-8

79 3.3.4 Ambient Air Quality Survey The ambient air quality monitoring was carried out at eight AAQM locations, with a frequency of twice a week to assess the existing sub-regional air quality status during the period of October-2015 to December The Respirable Dust Sampler and Fine Particulate Sampler along with the analytical methods prescribed by CPCB were used for carrying out air quality monitoring. At all these sampling locations; PM10, PM 2.5, SO 2, NO x, CO, HC (methane & non-methane) and VOCs were monitored on 24-hourly basis to enable the comparison with ambient air quality standards prescribed by the Central Pollution Control Board. The data on concentrations of various pollutants were processed for different statistical parameters like arithmetic mean, standard deviation, minimum and maximum concentration and various percentile values Baseline Status The existing baseline levels with respect to PM 10, PM 2.5, SO 2, NO x, CO, HC (methane & non-methane) and VOCs are presented in Tables 3.9 to 3.13 with interpretation of statistical analysis of observed ambient air quality data for eight locations. Presented results, represent the cross sectional distribution of baseline air quality status of the study region. Particulate Matter (PM 10 ) An average and 98 th percentile value of 24-hourly PM 10 values at all the locations varied between g/m 3 and g/m 3, which are well within the stipulated standard of CPCB, 100 g/m 3. Particulate Matter (PM 2.5 ) An average and 98 th percentile value of 24-hourly PM 2.5 values at all the locations varied between g/m 3 and g/m 3, which are well within the stipulated standard of CPCB, 60 g/m 3. Sulphur Dioxide (SO 2 ) An average and 98 th percentile value of 24-hourly SO 2 value of arithmetic mean at all the locations ranged between g/m 3 and g/m 3 respectively, which are well within the stipulated standards of 80 g/m 3. EIA report of Balaji Formalin Pvt. Ltd. 3-9

80 Oxides of Nitrogen (NO x ) An average and 98 th percentile value of 24 hourly NO x value of arithmetic mean at all the locations ranged between g/m 3 and g/m 3 respectively, which are much lower than the standards stipulated by CPCB, i.e. 80 g/m Hydro-geological status of the study area Gandhinagar district is situated in the central part of Gujarat and has four talukas (Mansa, Kalol, Dahegam and Gandhinagar) with 302 villages. Total area of the district is 2140 Sq. Km. and total population, as per 2001 census is 13,34,731 souls. Average rainfall of last decade is 698 mm in the district. Main Rivers of the Gandhinagar district are Sabarmati, Meshwo and Khari, which originate from Aravalli hills and meet in the Gulf of Cambay. The topography of the district is almost even. General flow of district is north to South. Geologically the Gandhinagar district is covered with quaternary alluvium formation of Cambay basin. Rocky area is not found in this district. The alluvial formation is made up of multi-layer sand, silt and clay formation. Alluvium thickness is more in western side of the district, while less in eastern side. Silt, clay dominates alluvium found in the northwest side while coarse-grained sand with gravels is common in the eastern part. Tertiary clay (Blue clay) occurs at different depths in the area. It demarcates the potable water boundary, below which water quality deteriorates. In the eastern part it occurs at very shallow depth i.e. at 40 to 50 mts restricting drilling depth up to that depth. Ground water occurs in semi-confined to confined and in un-confined conditions. Total depth of the bore in east side is ranging from 50 to 180 Mts., while in northwest side, depth of the bore varies from 200 to 350 Mts. Presently village water supply schemes are mainly based on ground water through tubewells. Water level of the district is depleting very fast due to less recharge and un-controlled withdrawal. Rainfall in the study area: The study area receives maximum rainfall from mid-june to September from southwest monsoon. The annual average rainfall in Gandhinagar for EIA report of Balaji Formalin Pvt. Ltd. 3-10

81 last ten years is around 698 mm. Thus, Rainfall in the study area can therefore be termed as moderate. 3.5 Water Environment Water is one of the essential requirements of living elements. Also it is an essential requirement for many of the industrial activities. The change in quality of water may bring about an adverse impact on the entire environment. Due to their physical, chemical and biological interrelations, change in water quality parameter may trigger changes in other variables. Physico-chemical parameters have been analyzed to ascertain the baseline status of fresh water. There are mainly two types of water available in the region: surface water and ground water. Surface Water: There are surface water bodies like lakes, village pond/reservoir in the study area. Surface water samples were collected from pond of Piyaj, Hajipur, Lapkaman, Thol Lake & from Narmada Canal near project site. Table: 3.16 show the analysis of the same. Ground water: Ground water is the major/important source of water supply in the study area. Water samples have been collected from project site and different seven villages (Moti Bhoyan, Khatraj, Hajipur, Sherisa, Vadsar, Karoli, Ganapatpur). Table: 3.15 show the analysis of the same Ground Water Quality (Primary data) Collected water samples were analyzed for various desirable characteristics of ground water. Sampling location is shown in Figure 3.8. The results are shown in Table Color: All the samples were colorless meeting desirable norms. ph: All the samples meet the desirable standards (ph ranges from 7.59 to 7.83). Total Dissolved Solids (TDS): TDS in samples ranges from 998 mg/l (Project Site) to 1346 mg/l (Sherisa). All the samples meet the permissible limit of 2000 mg/l (If alternate sources of potable water are not available). EIA report of Balaji Formalin Pvt. Ltd. 3-11

82 Calcium: Calcium contents in the water ranges from 49 mg/l (Karoli) to 65 mg/l (Moti Bhoyan), all the samples meet the permissible limit of 200 mg/l (If alternate sources of potable water are not available). Magnesium: Magnesium content in the water ranges from 39 mg/l (Hajipur) to 61 mg/l (Sherisa). All the samples meet even the permissible limit of 100 mg/l (if alternate source of potable water in not available). Sulphate: Sulphate content in the water ranges from 18 mg/l (Project site) to 36 mg/l (Sherisa). All the samples meet the permissible limit of 400 mg/l for drinking water. Fluoride: Fluoride content in the water ranges from 0.57 mg/l (Moti Bhoyan) to 0.75 mg/l (Sherisa). All the samples meet the permissible limit (1.5 mg/l). Total Alkalinity: Total alkalinity in the water samples ranges from 362 mg/l (Khatraj) to 485 mg/l (Project Site). All the samples are within the permissible limit of drinking water (600 mg/l) (if alternate source of portable water is not available). Other Parameters: Potassium (ranges from 13 mg/l to 22 mg/l), Sodium (ranges from 289 mg/l to 423 mg/l) and Chloride (ranges from 382 mg/l to 602 mg/l). Heavy metals like copper, lead, chromium and zinc are found below detectable limit in all samples. Conclusions: Ground water samples from villages meet the permissible limit set by the authority (BIS). Indian Standard specification for drinking water is given in Table Noise Environment (Primary data) Introduction Noise can be defined as an unwanted sound. It interferes with speech and hearing and is intense enough to damage hearing or is otherwise annoying. The definition of noise as unwanted sound implies that it has an adverse effect on human beings and their environment. Noise can also disturb natural wildlife and ecological system. EIA report of Balaji Formalin Pvt. Ltd. 3-12

83 Sound is mechanical energy from a vibrating surface, transmitted by cyclic series of compression and rarefaction of molecules of the materials through which it passes. Sound can be transmitted through gases, liquids and solids. The number of compressions and refractions of the air molecules in the unit of time is described as its frequency. Frequency is expressed in hertz (Hz), which is the same as the number of cycles per second Methodology To understand the noise environment in the study area, a survey was conducted using Sound Level Meter at each of the ten locations including the plant site as shown in Figure Day-Time and Night-Time Noise Levels Noise survey was carried out once at each of the ten locations in the day and night time during the study period. Table 3.18 depicts average L eq (day) and L eq (night) noise levels for all locations Ambient Air Quality Standards in Respect of Noise Ministry of Environment and Forest has notified the ambient standards in respect of noise in Gazette of India dated 14 th February, Table 3.19 depicts these standards in respect of noise Ambient Noise Levels in the Study Area The L eq values of noise levels during day-time varied from 48.1 db(a) to 62.2 db(a). Highest L eq daytime value was recorded at Bus stop Ganpatpura due to transportation of vehicles. The L eq values of noise levels during night time varied from 38.5 db(a) to 54.6 db(a). Highest L eq value during night time was recorded at Near Project Site Conclusions The hourly L eq noise levels recorded at various locations in the study area show considerable fluctuations because of changes in traffic movement, commercial and domestic activities in the study area. In the study area higher Noise value during day time was noted at Bus stop Ganpatpura, due to the movement of vehicles and it is within the Ambient standards of Commercial area for day time {65 db (A)} and highest results in night EIA report of Balaji Formalin Pvt. Ltd. 3-13

84 time was recorded at Project Site, which is within the prescribed limit of Industrial area for night time {70 db (A)}. 3.7 Soil Environment (Primary data) Introduction Soils may be defined as a thin layer of earth s crust that serves as a natural medium for the growth of plants. It is the unconsolidated mineral matter that has been subjected to and influenced by genetic and environmental factors. Soils serve as a reservoir of nutrients for plants and crops and provide mechanical anchorage and favorable tilth. The study area has more or less flat topography. The soil analysis results show that the soil is a fertile land. The study area has soil with the following physical and chemical characteristics Soil Characteristics Samples of soil were collected from 6 locations (Nr. Project site, Ganpatpura, Moti Bhoyan, Khatraj, Hajipur, Sherisa) during the study period and these locations are shown in Figure The values of important physical and chemical parameters of these soil samples are depicted in Table From the tabulated values, the following conclusions can be made about the physical and chemical characteristics of these soil samples Corollaries Physical Parameters Particle Size: A Particle size of the different constituents (clay, silt, sand and gravel) controls the porosity and water holding characteristic of the soil. Clay (size < mm) amount in the soil samples ranges from 26% to 32%; Silt (size to mm) in the soil samples is 16% to 30% and Sand (size to mm) in the soil samples is 19% to 33%; while Gravel (size > 4.75 mm) in the soil samples is 16% to 26%. Analysis shows that the soil has moderate water holding capacity. Porosity: Porosity is a measure of space in between soil particles caused by structural conditions and determined under identical conditions. Porosity of soil samples of the study area ranges from 42.9 to 45.7%. EIA report of Balaji Formalin Pvt. Ltd. 3-14

85 Water Holding Capacity (WHC): Water holding capacity (WHC) of soil samples of the study area ranges between 40.4% to 42.8% and these being sandy soils are not capable of retaining sufficient water during irrigation for facilitating the plant growth. Bulk Density: Bulk Density of soils in the study area is found to be in the range from 1.34 to 1.41 g/cm 3. Bulk density is of greater importance for characterizing the physical behavior of soils. Generally, soils with low bulk density have favorable physical conditions (porosity and permeability) whereas those with high bulk density exhibit poor physical conditions. Chemical Parameters ph: ph of soils in the study area is found to be in the range of 7.35 to Chloride: Chloride content in soils of the study area is found to be in the range of 138 to 242 mg/kg. Soluble Calcium: The soluble calcium as CaCO 3 in soil samples is found to be in the range of 21 to 98 mg/kg. Magnesium: Magnesium content in soil samples of the study area ranges from 16 to 37 mg/kg. Available Phosphorus: Available Phosphorus content in soil samples of the study area ranges from 34 to 82 mg/kg. Available Nitrogen: Available nitrogen content in soil samples of the study area is found to be in the range from 116 to 149 mg/kg. Potassium: Potassium content in soil samples of the study area is found to be in the range from 24 to 39 mg/kg. Sodium: Sodium content in soil samples of the study area is found to be in the range from 103 to 185 mg/kg. Total Organic Matter (TOM): Total organic matter content in soil samples of the study area is found to be in the range of 1.19 to 1.42 mg/kg. 3.8 Ecology (Primary data) A detailed flora fauna study was carried out in 10 km radius area of the site. The structure and type of vegetation depends on climatic conditions and physiography of an area. It provides goods and services essential to EIA report of Balaji Formalin Pvt. Ltd. 3-15

86 support human livelihoods and aspirations and enables societies to adapt to change needs and circumstances. In addition, biodiversity maintains the ecological balance necessary for planetary and human survival. Climate of the study area is suited for the variety of vegetation. The contents of this subsection are based primarily on reconnaissance survey carried out by the team of San Envirotech Pvt. Ltd. & through secondary sources Period of the study The baseline study, for the assessment of the floral and faunal biodiversity of the terrestrial environment of the study area, within 10 km radius of the site was conducted during October-2015 to December Study methodology The study region was earmarked for 10 km radius area and its relevant baseline data was collected from the Census data book. The survey methodology was based on the flora and fauna species identification in personal and recently recorded and found in the region by the localities. Sampling of grass species was carried out by quadrat sampling method to examine the species distribution and its frequency in the region. Quadrat Sampling Method: A quadrat (or plot-based) survey is a quantitative examination of species distribution and abundance. Quadrats are more likely to detect inconspicuous or threatened species because a smaller area is sampled in a concentrated search. This survey technique also provides a basis for subsequent monitoring. The survey was carried out for the vegetation ground cover found in the road edges by 1 m 2 quadrat and study on the edge effect due to rapid industrialization and urbanization. The results and findings of the same are discussed in the following sections Floral diversity in the study area The vegetation of this area was represented by very tall trees, middle layer trees and shrubs, ground layer of herbaceous and twiners and climbers. The various terrestrial plants available in the study area are reported in Table EIA report of Balaji Formalin Pvt. Ltd. 3-16

87 3.8.4 Cultivated plants in the study area Almost all the villages in the study area were actively engaged in agriculture practices. For irrigation in the non-monsoon season the villagers were depending up on the village lakes/ponds. The agriculture crops practiced in this area are Arando, Kapas and Jower, Bajra, Guvar are generally cultivated immediately after summer. Wheat is cultivated as major crop in winter season Faunal Diversity in the study area For the documentation of the faunal biodiversity of the study area with respect to birds, reptiles, amphibians sps.; a baseline survey had been conducted for the study area of 10 km radius. A faunal biodiversity with their scientific names and common names is presented in Table Socio Economic & Land use (Secondary data) Land use pattern and infrastructure The land use pattern indicates the manner in which different parts of land in an area is being utilized or non-utilized. It is an important indicator of environmental health; human activity and a degree of inter play between these two. Even though the soil quality, water availability and climate have strong influence on agriculture and vegetation, the human activity may alter the natural environment to a large extent to suit human needs. Unnatural land use often triggers rapid environmental deterioration and disturbs ecological balance. In census records, major land use classifications are; Forests, Culturable land, culturable wasteland and area not available for cultivation. Culturable land is further classified as: irrigated and unirrigated. Area not available for cultivation includes lands put to non-agriculture uses as well as barren and uncultivable lands. The main land use in area is for dwellings, infrastructure and related activities. However, the land use pattern for rural areas is discussed below. The information is preliminary based on 2001 Census as depicting in Table Total land area is ha, out of that Irrigated area is ha. It constitutes 58.82% of the total land area. Land has got irrigation facilities from tube well with electricity ha are unirrigated by source and it constitutes 24.48% of total land area. The EIA report of Balaji Formalin Pvt. Ltd. 3-17

88 study area consist of Cultivable wasteland is ha (7.02%). Area not available for cultivation is ha & it constitute 9.67% Demographic and Socio-Economic Environment The demographic and Socio-economic details of the study area are discussed below. These are primarily based on census data of Data on number of households, population as well as literacy and employment pattern in the study area have been presented in Table The employment pattern in the area is indicator of number of persons employed in various sectors. It also indicates the various categories of employment flourishing in the area. The Study area in 10 km radius has 39 villages including project site. The total no. of household in the villages are and the total population is (53.10% men & 47.88% women) % of are literate while literacy rate among women & men is 20.96% & 37.00% respectively % of male population is part of main worker, while only 10.31% of female population is a part of main workers. 2.52% of male workers are marginal workers, while 8.77% of female workers are engaged in such type of activities % of male population and 28.80% of female population are non-workers Living Standard and Infrastructure In India it is not possible to setup a primary standard of living because of wide variations in terms of income, economic conditions, social custom, employment opportunity, pattern of spending, etc. However, availability of amenities like education, medical, water supply, communication, road network, electricity, etc. significantly reflects the level of development of the area. Information on available amenities in the study area has been extracted from census record of Total numbers of village in study area are 39. On the basis of data presented in the Table-3.27, the status of available amenities is discussed in following sub-sections: Educational Facilities As per 2001 census, there are 44 primary schools, 10 Higher Secondary schools, 3 Higher Secondary/Intermediate/Pre-University/Junior College or Senior Secondary and 9 colleges in all 39 villages. EIA report of Balaji Formalin Pvt. Ltd. 3-18

89 Medical Facilities 39 villages in the study area have 22 Registered Private Medical Practitioner, 22 Community Health Worker/Health Worker, 25 Hospitals, 21 Maternity and Child Welfare Centre, 19 Primary Health Centre, 14 primary health sub centers, 3 Dispensary, 13 Family Welfare Centre, 2 Maternity Home and 1 Child Welfare Centre in study area of 10 km. Drinking Water Supply All the villages in the study area have two or more sources of drinking water. Most of the villages in study area have Well water supply in addition to Tap water (almost all). Moreover all villages have facility of Tube Well water facility, 11 have Tank water facility, 1 have canal and 2 have hand pump facilities. Communication and Transport The main mode of public transport available in the study area is by bus service. All villages have approach to railway station as western railway meter gauge line is passing through nearby. Majority of villages in the study area is connected with pucca road. Post and Telegraph As per 2001 census record out of 39 villages in study area, almost all the villages have post office facility at doorstep & phone facility. Power Supply As per 2001 census record almost all the villages are getting power supply for all purposes. EIA report of Balaji Formalin Pvt. Ltd. 3-19

90 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Table 3.7: Ambient Air Quality Monitoring Locations (Period of Monitoring: October-2015 to December-2015) Sampling Location Direction w.r.t. center of Industry Distance km Type of Area 1 Project Site (A1) Industrial 2 Moti Bhoyan (A2) NNE (Upwind) 1.45 Residential 3 Khatraj (A3) W (Downwind) 2.92 Residential 4 Ganapatpura (A4) ENE (Up Wind) 5.17 Residential 5 Karoli (A5) W (Downwind) 1.40 Residential 6 Bhimasan (A6) WSW (Downwind) 3.75 Residential 7 Sherisa (A7) NNE (Up Wind) 4.06 Residential 8 Jethlaj (A8) SSW (Downwind) 3.78 Residential EIA report of Balaji Formalin Pvt. Ltd. 3-20

91 Table 3.8: Ambient Air Quality Status San Envirotech Pvt. Ltd., Ahmedabad (Period: October-2015 to December-2015) Sr. No. Sampling Station PM 10 ( g/m 3 ) 1 Project Site (A1) 70.7 ( ) 2 Moti Bhoyan (A2) 73.0 ( ) 3 Khatraj (A3) 65.4 ( ) 4 Ganapatpura (A4) 73.9 ( ) 5 Karoli (A5) 69.9 ( ) 6 Bhimasan (A6) 67.9 ( ) 7 Sherisa (A7) 74.6 ( ) 8 Jethlaj (A8) 72.5 ( ) PM 2.5 ( g/m 3 ) SO 2 ( g/m 3 ) Average (Min-Max) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) NOx ( g/m 3 ) 22.2 ( ) 19.2 ( ) 21.1 ( ) 18.6 ( ) 21.2 ( ) 22.6 ( ) 21.5 ( ) 20.8 ( ) Figure 3.1 Graphical representation of Ambient Air quality EIA report of Balaji Formalin Pvt. Ltd. 3-21

92 Table 3.9: Ambient Air Quality Status (PM 10 ) (Period: October-2015 to December-2015) Average - 24 Hours Unit - g/m 3 Station Name Max Min 98 th Percentile 75 th Percentile 50 th Percentile 25 th percentile Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) Avg. SD Figure 3.2 Graphical representation for PM 10 EIA report of Balaji Formalin Pvt. Ltd. 3-22

93 Table 3.10: Ambient Air Quality Status (PM 2.5 ) (Period: October-2015 to December-2015) Average - 24 Hours Unit - g/m 3 Station Name Max Min 98 th Percentile 75 th Percentile 50 th Percentile 25 th percentile Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) Avg. SD Figure 3.3 Graphical representation for PM 2.5 EIA report of Balaji Formalin Pvt. Ltd. 3-23

94 Table 3.11: Ambient Air Quality Status (SO 2 ) (Period: October-2015 to December-2015) Average-24 Hours Unit- g/m 3 Station Name Max Min 98 th Percentile 75 th Percentile 50 th Percentile 25 th percentile Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) Avg. SD Figure 3.4 Graphical representation for SO 2 EIA report of Balaji Formalin Pvt. Ltd. 3-24

95 Table 3.12: Ambient Air Quality Status (NOx) (Period: October-2015 to December-2015) Average-24 Hours Unit- g/m 3 Station Name Max Min 98 th Percentile 75 th Percentile 50 th Percentile 25 th percentile Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) Avg. SD Figure 3.5 Graphical representation for NO X EIA report of Balaji Formalin Pvt. Ltd. 3-25

96 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Table 3.13: Ambient Air Quality Status (CO, HC, VOCs) (Period: October-2015 to December-2015) Station Name Concentration ( g/m 3 ) VOCs VOCs as BTX Methanol Formaldehyde Benzene Toluene Xylene Total 1 Project Site (A1) BDL Moti Bhoyan (A2) BDL BDL BDL BDL BDL BDL 3 Khatraj (A3) BDL BDL BDL BDL BDL BDL 4 Ganapatpura (A4) BDL BDL BDL BDL BDL BDL 5 Karoli (A5) BDL BDL 1.04 BDL BDL Bhimasan (A6) BDL BDL 1.01 BDL BDL Sherisa (A7) BDL BDL BDL BDL BDL BDL 8 Jethlaj (A8) BDL BDL BDL BDL BDL BDL Sr. No. Station Name Concentration ( g/m 3 ) CO HC MHC NMHC 1 Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) EIA report of Balaji Formalin Pvt. Ltd. 3-26

97 Pollutants San Envirotech Pvt. Ltd., Ahmedabad Table 3.14: National Ambient Air Quality Standards (EP, 7 th amendment rules-2009) Time-weighted average Industrial, Residential, Rural and others area Concentration in ambient air Ecologically Sensitive area (Notified by Central Government) Method of Measurement Sulphur Dioxide Annual Average* Improved west and (SO 2 ) µg/m 3 24 hours** Gaeke Ultraviolet fluorescence Oxides of Annual Average* Modified Jacob Nitrogen as 24 hours** &Hochheiser (NO 2 ) µg/m 3 (Na-Arsenate) Chemiluminescence Particulate Matter Annual Average* Gravimetric (Size less than 10 µm or PM 10 ) µg/m 3 24 hours** TOEM Beta attenuation Particulate Matter (Size less than 2.5 µm or PM 2.5 ) µg/m 3 Ozone (O 3 ) Annual Average* Gravimetric 24 hours** TOEM Beta attenuation 8 hours ** UV photometric µg/m 3 1hours** Chemiluminescence Chemical Method Lead (Pb) Annual Average* AAS/ICP method µg/m 3 24 hours** after sampling on EPM 2000 or equivalent filter paper ED-XRF using Teflon filter Carbon Monoxide 8 hours** Non Dispersive (CO) mg/m 3 Infra Red (NDIR) 1 hour** spectroscopy Ammonia (NH 3 ) Annual Average* Chemiluminescence µg/m 3 24 hours** Indophenol Blue Method Benzene (C 6 H 6 ) Annual* Gas µg/m 3 chromatography based continuous analyzer Adsorption and desorption followed by GC analysis Benzo(a)Pyrine (BaP)-particulate phase only, µg/m 3 Annual* Solvent extraction followed by HPLC/GC analysis Arsenic (As), µg/m 3 Annual* AAS/ICP method after sampling on EPM 2000 or equivalent filter paper EIA report of Balaji Formalin Pvt. Ltd. 3-27

98 Nickel (Ni) µg/m 3 Annual* AAS/ICP method after sampling on EPM 2000 or equivalent filter paper Annual Arithmetic mean of minimum 104 measurements in a year taken * twice a week 24 hourly at uniform interval. 24 hourly/8 hourly or 01 hourly values, as applicable, shall be complied ** with 98% of the time in a year. 2% of the time the time, they may exceed the limits but not two consecutive days of monitoring. EIA report of Balaji Formalin Pvt. Ltd. 3-28

99 Table 3.15: Results of Groundwater Quality in the Study Area (Date of Monitoring: 04/12/15 to 06/12/15) San Envirotech Pvt. Ltd., Ahmedabad Parameters Unit CONCENTRATION Method of Test Project Motibhoyan Hajipur Khatraj Sherisa Vadsar Karoli Ganapatp (Ref. to IS) site (GW2) (GW3) (GW4) (GW5) (GW6) (GW7) ura (GW1) (GW8) ph ph Unit (Part 11) Color Co-Pt Colorless Colorless Colorless Colorless Colorless Colorless Colorless Colorless 3025(Part 4) Unit Taste --- Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 3025 (Part 7&8) Odour --- Unobjecti- Unobjecti- Unobjecti- Unobjecti- Unobjecti- Unobjecti- Unobjecti- Unobjecti- 3025(Part 5) onable onable onable Onable onable onable onable onable Conductivity μmhos (Part 14) /cm Turbidity NTU (Part 10) TDS mg/l (Part 16) Total Hardness as mg/l (Part 21) CaCO 3 Total Alkalinity mg/l (Part 23) Calcium as Ca +2 mg/l (Part 40) Magnesium as Mg +2 mg/l (Part 46) Chlorides as Cl - mg/l (Part 32) -2 Sulfates as SO 4 mg/l (Part 24) Fluoride as F - mg/l (Part 60) -3 Nitrates as NO 3 mg/l (Part 34) Sodium as Na + mg/l (Part 45) Potassium as K + mg/l (Part 45) Phenol mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < (Part 43) Cadmium as Cd mg/l <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 <0.003 < (Part 41) Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < (Part 54) Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < (Part 42) Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < (Part 47) Manganese as Mn mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 < (Part 59) Iron as Fe mg/l (Part 53) Chromium mg/l <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 < (Part 52) Zinc as Zn mg/l <0.004 <0.004 <0.004 <0.004 <0.004 <0.004 <0.004 < (Part 49) EIA report of Balaji Formalin Pvt. Ltd. 3-29

100 Table 3.16: Results of Surface water Quality in the Study Area (Date of Monitoring: 04/12/15 to 06/12/15) San Envirotech Pvt. Ltd., Ahmedabad Parameters Unit Concentration Test Method Piyaj Pond (SW1) Hajipur Pond (SW2) Lapkaman pond (SW3) Thol Lake (SW4) Narmada Canal (SW5) (Ref to IS) ph ph Unit (Part 11) Colour Co-Pt Unit Colorless Colorless Colorless Colorless Colorless 3025(Part 4) Odour --- Unobjecti- Unobjecti- Unobjecti- Unobjecti- Unobjecti- 3025(Part 5) onable onable onable onable onable Temperature 0 C Conductivity Micro mhos/cm (Part 14) Turbidity NTU (Part 10) TDS mg/l (Part 16) Dissolved Oxygen mg/l Total Hardness as CaCO 3 mg/l (Part 21) Total Alkalinity mg/l (Part 23) Sodium as Na+ mg/l (Part 45) Potassium K+ mg/l (Part 45) Calcium Ca+2 mg/l (Part 40) Magnesium Mg+2 mg/l (Part 46) Chlorides as Cl- mg/l (Part 32) Sulfates as SO4-2 mg/l (Part 24) Nitrates as NO3-3 mg/l (Part 34) Fluoride as F- mg/l (Part 60) Phenol as C 6 H 5 OH mg/l <0.01 <0.01 <0.01 <0.01 < (Part 43) Cadmium as Cd mg/l <0.003 <0.003 <0.003 <0.003 < (Part 41) Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 < (Part 42) Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 < (Part 47) Manganese as Mn mg/l <0.01 <0.01 <0.01 <0.01 < (Part 59) Iron as Fe mg/l <0.01 <0.01 <0.01 <0.01 < (Part 53) Total Chromium mg/l <0.001 <0.001 <0.001 <0.001 < (Part 52) Zinc as Zn mg/l <0.004 <0.004 <0.004 <0.004 < (Part 49) Nickle as Ni mg/l <0.01 <0.01 <0.01 <0.01 < (Part 54) EIA report of Balaji Formalin Pvt. Ltd. 3-30

101 Table 3.17: Indian Standard Specification for Drinking Water Sr. No. I Parameters Desirable Limit Permissible Limit in the Absence of Alternate Source Essential Characteristics 1. Colour, Hazen Units, Max Odour Unobjectionable - 3. Taste Agreeable - 4. Turbidity, NTU, Max ph value No Relaxation 6. Total Hardness (as CaCO 3 ) mg/l, Max Iron (as Fe) mg/ l, Max Chlorides (as Cl) mg/l, Max Residual Free Chlorine, mg/l, Min. 0.2* - II Desirable Characteristics 10. Dissolved Solids, mg/l, Max Alkalinity (as CaCO 3 ), mg/l, Max Sulphate (as SO 4 ) mg/l, Max Nitrate (as NO 3 ) 50 No Relaxation 14. Fluoride (as F) mg/l, Max Calcium (as Ca) mg/l, Max Magnesium (as Mg) mg/l, Max Copper (as Cu) mg/l, Max Manganese (as Mn) mg/l, Max Mercury (as Hg) mg/l, Max No Relaxation 20. Cadmium (as Cd) mg/l, Max No Relaxation 21. Selenium (as Se) mg/l, Max No Relaxation 22. Arsenic (As As) mg/l, Max No Relaxation 23. Lead (as Pb) mg/l, Max No Relaxation 24. Zinc (as Zn) mg/l, Max Aluminium (as Al) mg/l, Max Boron (as B) mg/l, Max Chromium (as Cr) mg/l, Max No Relaxation 28. Cyanide (as CN) mg/l, Max No Relaxation 29. Phenolic Compounds (as C 6 H 5 OH) mg/l, Max. 30. Anionic Detergents (as MBAS) mg/l, Max. mg/l, Max. 31. Mineral Oil mg/l, Max Pesticides Absent Radioactive Materials a. Alpha Emitters, Bq/I, Max. b. Beta Emitters, Pci/I, Max *Applicable only when water is chlorinated Source: IS: EIA report of Balaji Formalin Pvt. Ltd. 3-31

102 Sr. No. San Envirotech Pvt. Ltd., Ahmedabad Table 3.18: Ambient Noise Levels in the Study Area Noise Monitoring Locations Date of Monitoring CPCB Limits in db (A) L eq (Day) db A L eq (Night) db A Average Noise levels in db (A) L eq (Day) db A L eq (Night) db A 1. Near Project Site 04/12/ Village Hajipur 04/12/ Village Moti Bhoyan 04/12/ Village Khatraj 05/12/ Temple Khatraj 05/12/ Village Sherisa 05/12/ Village Vadsar 05/12/ Primary School 05/12/ Vadsar 9. Village Ganpatpura 06/12/ Bus stop Ganpatpura 06/12/ Table 3.19: Ambient Air Quality Standards with respect to noise Category of Area Limits L eq, db(a) Day Time Night Time Industrial Commercial Residential Silence EIA report of Balaji Formalin Pvt. Ltd. 3-32

103 S. No. San Envirotech Pvt. Ltd., Ahmedabad Table 3.20: Soil Analysis of Study area (Date of Sampling: 04/12/15 to 06/12/15) Parameters Unit Nr. Project site (S1) Hajipur (S2) MotiBho yan (S3) Khatraj (S4) Sheris a (S5) Ganpa tpura (S6) 1. ph (5%) Solution Moisture % Loss of Ignition % Particle Size Clay (<0.002 % mm) Silt (0.002 to % mm) Sand ( % mm) gravel (size > % mm) Texture -- Sandy Loam Sandy Loam Sandy Loam Sandy Loam Sandy Loam Sandy Loam 5. Water Holding % Capacity 6. Permeability cm/hr Bulk Density g/cm Porosity % Sodium Absorption Ratio Meq/ 100 gm Sodium mg/kg Potassium mg/kg Calcium mg/kg Magnesium mg/kg Chlorides mg/kg Sulphates mg/kg Organic Matter mg/kg Total Nitrogen mg/kg Total Phosphorus mg/kg Iron mg/kg Cation Exchange Capacity mg/ 100 gm EIA report of Balaji Formalin Pvt. Ltd. 3-33

104 Table 3.21 Traffic Survey San Envirotech Pvt. Ltd., Ahmedabad TRAFFIC SHEET LOCATION Near plant site Khatraj-Kalol Road TIME to DATE 05/12/2015 TOTAL PCU calculation Total PCU/hr BUSES* 32 PCU x 3 96 CARS/VANS 170 PCU x MOTORCYCLES / BICYCLES 392 PCU x Total 457 TIME to DATE 05/12/2015 TOTAL PCU calculation Total PCU/hr BUSES* 37 PCU x CARS/VANS 163 PCU x MOTORCYCLES / BICYCLES 402 PCU x Total 475 Note: *Mini-bus, Chartered Bus, School Bus, have been collectively classified as Buses. Additional traffic from our project will be estimated 144 PCU/day [24-48 trucks/tankers (in & out) x 3] and 12 PCU/day from car and motorcycle, which have insignificant impact on existing traffic load. EIA report of Balaji Formalin Pvt. Ltd. 3-34

105 Table 3.22: Floral Diversity San Envirotech Pvt. Ltd., Ahmedabad (i) Trees Sr. No. Family Scientific name Local name 1. Fabaceae Pongamia pinnata Karanj 2. Myrtaceae Eucalyptus globules Nilgiri 3. Mimosaceae Acacia nilotica Subsp. Indica Acacia auriculiformis Prosopis juliflora Leucaena leucoephala Acacia caiechu Albizzia indica Prosopis spicigera Baval Australian Baval Gandobaval Pardesi Baval Khair Siris Khijado 4. Salvadoraceae Salvadora aleoides Pilvo 5. Meliaceae Azadirachta indica Limbado Melia azedarah Bakan Limdo 6. Arecaceae Roystonea regia Royal Palm 7. Moraceae Ficus benghalensis Vad Ficus religiosa Piplo 8. Caesalpiniaceae Parkinsonia aculeate Rambaval Peltophorum pterocarpum Tamarafali (ii) Shrubs Sr. No. Family Scientific name Local name 1. Euphorbiaceae Euphorbia nivulia Buch Thor Ham 2. Capparidaceae Cadaba indica Telio hemkand Capparis sepiaria Kerdo Capparis sepiaria Kanthar 3. Apocgnaceae Thevetia peruviane Merr Pili karen Nerium indicum Mill Lal Karen 4. Convolvulaceae Ipomoea fistulosa Nafatio 5. Rhamnaceae Zizgphus mummularia Chanibor Zizgphus glabrata Hegne Bor 6. Asclepiadaceae Calotropis gigantea Akado Calotropis procera Akado EIA report of Balaji Formalin Pvt. Ltd. 3-35

106 (iii) Herbs Sr. No. Family Scientific name Local name 1. Acanthaceae Hygrophila auriculata (Schum.) 2. Solanaceae Solanum indicum Rigni Kanatashelio, Akaro 3. Amaranthaceae Amarantus paniculatus Rajagro 4. Papilionaceae Phaseolus aureus Roxb. Mag Phaseolus aconitifolius,jacquin Cyamopsis psoralioides Math Guvar 5. Lamiaceae Ocimum sanctum Tulsi O. Canam Sims Ramtulsi O. Basilicum Damro 6. Liliaceae Aloe barbadensis mill Kunvarpato 7. Rutaceae Citrus aurantifolia, Swingle Limbodi 8. Poaceae Triticum aestivum Ghau Sorghum bicolor Zea mays Pennisetum typhoides Cynodon doctylon Chloris barbata Heteropogon contortus Jowar Makai Bajra Darbh Mindadin Dabhsuliu (iv) Climbers and Twiners Sr. Family Scientific name Local name No. 1. Cuscutaceae Cuscuta reflexa Roxb Amarvel 2. Menispermaceae Cocculus hirsutus Vevdi 3. Convolvulaceae Ipomea aquatic Forsk Nadanivel EIA report of Balaji Formalin Pvt. Ltd. 3-36

107 Table 3.23: Faunal Diversity San Envirotech Pvt. Ltd., Ahmedabad (i) Birds Sr. No. Family Scientific name Local name 1. Threskiornithidae Pseudibis papillosa Black Ibis 2. Accipitridae Elanus caerwleus Black winged kite Accipitel nisus Sparrow hawk 3. Anhingidae Anhinga melanogaster Darter or Snake Birds 4. Charadriidae Himantopus himantopus Black-winged Stilt Vanellus indicus Red-wattled Lapwing 5. Apodidae (Swifts) Apus apus Common Swift 6. Ardeidae Bubulcus ibis Cattle egret Ardeola grajii Pond Heron 7. Alcedinidae Alcedo atthis Common kingfisher 8. Dacelonidae Halcyon smyrnensis White brested Kingfisher 9. Columbidae Columba livia Blue Rock Pigeon Streptopelia orientalis Streptopelia chinensis 10. Meropidae Merops persicus Merops superciliosus Oriental Turtle Dove Spotted Dove Blue-cheeked Beeeater 11. Corvidae Corvus splendens House crow 12. Muscicapidae Saxicoloides fulicata Indian Robin 13. Passeridae Passer domesticus House Sparrow 14. Pycnonotidae Pycnonotus cafer Red-vented Bulbul 15. Sturnidae Acridotheres tristis Common Myna 16. Sylviidae Turdoides striatus Jungle Babbler 17. Ciconiidae Mycteria leucocephala Painyed Strok 18. Rallidae Amaurornis phoenicurus White breasted water hen (ii) Butterflies Sr. No. Family Scientific name Local name 1. Papilionidae Papilio polgtes Linnaeus Common Mormon Pachliopta aristolochiae 2. Pieridae Eurema hecabe Linnaeus Catopsilia Pomona Fabricius Common Rose Common Grass yellow Common Emigrant EIA report of Balaji Formalin Pvt. Ltd. 3-37

108 3. Nymphalidae Melanitis leda Linnaeus Common evening Brown Junonia hierta Fabricius Yellow Orange tip Mycalesis perseus Common bush Brown (iii) Reptiles Sr. No. Scientific name Local name 1. Ptyas mucosus (Linn.) Common rat snake 2. Calotes versicolor (Daudin) Common garden lizard 3. Nanja Naja (Linn.)* Indian cobra 4. Hemidactylus flaviviridis House Gecko * Not sighted but included as per the information provided by villagers. (iv) Mammals Sr. No. Scientific name Local name 1. Herpestes edwardsi (Geoffory) Common Mongoose 2. Funambulus palmarum (Linnaeus) Three striped palm Squirrel 3. Rattus rattus (Linnaeus) Common House rat EIA report of Balaji Formalin Pvt. Ltd. 3-38

109 Sr. No. Table 3.24 San Envirotech Pvt. Ltd., Ahmedabad Land use statistics base of satellite imaginary Category Area (in Hectares) Area in % 1 Agricultural Land Barren Land Industrial Built-up Land (Residential & storage yard) Forest Land (Green cover) Water Body Wetland (Non-forested Wetland) Total EIA report of Balaji Formalin Pvt. Ltd. 3-39

110 Name of Village Total Area of the Village (ha) Table 3.25 Land Use Pattern Irrigated by source (ha) San Envirotech Pvt. Ltd., Ahmedabad Unirrigated (ha) Culturable waste (ha) Area not available for cultivation (ha) Pratappura Piyaj Ramnagar Ranchhodpura Vansajada Santej , Karoli Khatraj Bhimasan Vayana Adhana Nasmed Sanavad Jethlaj Dantali Vadsar Jaspur Bhoyan Moti , Sabaspur Ganpatpura Usmanabad Palsana Borisana Himmatpura Dhanaj Sherisa Hajipur , Fuletra Vamaj Vansol Adraj Ambliyara Sedfa Thol Vadavi Lapkaman Lilapur Khodiyar Bhadaj EIA report of Balaji Formalin Pvt. Ltd. 3-40

111 Name of the Village/ Town/ Ward No. of Occupied Residential House Table 3.26: Summary of Socio-Economic Status (Demography) Total Population (Including institutional and houseless population) Literates Total main Workers Marginal Workers San Envirotech Pvt. Ltd., Ahmedabad Cultivators Agricultural Laborer Non-Worker P M F M F M F M F M F M F M F Pratappura Piyaj Ramnagar Ranchhodpura Vansajada Santej Karoli Khatraj Bhimasan Vayana Adhana Nasmed Sanavad Jethlaj Dantali Vadsar Jaspur Bhoyan Moti Sabaspur Ganpatpura Usmanabad Palsana Borisana Himmatpura Dhanaj Sherisa Hajipur Fuletra EIA report of Balaji Formalin Pvt. Ltd. 3-41

112 Name of the Village/ Town/ Ward No. of Occupied Residential House Total Population (Including institutional and houseless population) Literates Total main Workers Marginal Workers San Envirotech Pvt. Ltd., Ahmedabad Cultivators Agricultural Laborer Non-Worker P M F M F M F M F M F M F M F Vamaj Vansol Adraj Ambliyara Sedfa Thol Vadavi Lapkaman 382 1, Lilapur Khodiyar Bhadaj EIA report of Balaji Formalin Pvt. Ltd. 3-42

113 Table 3.27: Basic Amenities in the Study Area San Envirotech Pvt. Ltd., Ahmedabad Name of Village Educational Facility Medical Facility Pratappura P(2), C(5-10) RMP(2), CHW, H (5-10), MCW(5-10), PHC(5-10) Piyaj P, C(5-10) PHS, RMP(3), CHW(3), H(5-10), MCW(5-10), PHC(5-10) Ramnagar P, C(5-10) RMP, CHW, H(5-10), MCW(5-10), PHC(5-10) Ranchhodpura P, C(10+) H(10+), MCW(10+), PHC(10+) Vansajada P, C(10+) H, D, RMP, CHW, MCW(5-10), PHC(5-10) Santej P(3), S, C(10+) D, PHS, FWC, RMP(2), CHW(2), H(10+), MCW(10+), PHC(5-10) Karoli P, C(10+) H, D, RMP, CHW, MCW(5-10), PHC(5-10) Khatraj P, C(10+) RMP, CHW, H(10+), MCW(10+), PHC(10+) Bhimasan P, C(10+) RMP, CHW, H(10+), MCW(10+), PHC(<5) Vayana P, C(10+) H(10+), MCW(5-10), PHC(10+) Adhana P, C(10+) H(10+), MCW(10+), PHC(5-10) Nasmed P(2), C(10+) PHS, FWC, CHW(2), H(5-10), MCW(5-10), PHC(10+) Sanavad P, C(10+) H(10+), MCW(10+), PHC(<5) Jethlaj P(2), C(10+) H(2), PHS, FWC, RMP, CHW, MCW(5-10), PHC(5-10) Dantali P, C(<5) H(10+), MCW(10+), PHC(5-10) Drinking Water Facility Communication (Post or Telegraph) Transportation Facility (Bus etc.) Approach to Village Nearest town and Distance (Kms.) Power Supply T PO, PH(17) BS, RS(5-10) PR, MR, FP Kalol (5) EA T PO, PH(10) BS, RS(5-10) PR Kalol (5) EA T, TW, TK, C PO, PH(20) BS, RS(5-10) PR Kalol (7) EA T, TW, TK PO, PH(15) BS, RS(10+) PR, MR, FP Ahmadabad EA (19) T, HP, TW, PO, PH(10) BS, RS(10+) PR, MR, FP Kalol (13) EA W, TK T, TW PO, PH(150) BS, RS(10+) PR, MR, FP Ahmadabad EA (15) T, HP, TW, PO, PH(15) BS, RS(10+) PR, MR, FP Kalol (12) EA W, TK T, TW PO, PH BS, RS(10+) PR Kalol (15) EA T, TW, W, TK PO(<5), PH(10+) BS, RS(10+) PR, MR, FP Kalol (25) ED EAG T, TW, TK PO(5-10), PH(5- BS, RS(10+) PR, MR, FP Kalol (25) EA 10) T, W, TK PH(5), PO(<5) BS, RS(10+) PR, MR, FP Kalol (28) EA T, TW PH(5), PO(<5) BS, RS(10+) PR Sanand (12) EA T, TW PH(4), PO(<5) BS, RS(10+) PR Kalol (18) EA T, TW PO, PH(5) BS, RS(10+) PR, MR, FP Kalol (17) EA TW PO, PH BS, RS(10+) PR, MR, FP Kalol (12) EA EIA report of Balaji Formalin Pvt. Ltd. 3-43

114 Name of Village Educational Facility Vadsar P(2), S, C(10+) Medical Facility H(3), D(3), MH, CWC, PHS, FWC, RMP, CHW, MCW(10+), PHC(10+) Jaspur P, S, C(5-10) PHS, FWC, RMP(2), CHW(2), H(5-10), MCW(<5), PHC(<5) Bhoyan Moti P, C(5-10) RMP, CHW, H(5-10), MCW(5-10), PHC(5-10) Sabaspur P, C(5-10) H(5-10), MCW(5-10), PHC(5-10) Ganpatpura P, C(5-10) H(5-10), MCW(5-10), PHC(5-10) Usmanabad P, C(10+) RMP, CHW, H(10+), MCW(10+), PHC(10+) Palsana P, S, C(<5) RMP, CHW, H(<5), MCW(<5), PHC(<5) Borisana P(4), S, C(<5) HC, H(<5), MCW(<5), PHC(<5) Himmatpura P, C(10+) RMP, CHW, H(<5), MCW(<5), PHC(<5) Dhanaj P(2), C(<5) H(<5), MCW(<5), PHC(<5) Sherisa P(2), S, C(5-10) PHS, FWC, RMP(2), CHW, H(5-10), MCW(5-10), PHC(5-10) Hajipur P, S, C(10+) MH, PHC, FWC, CHW(3), H(10+), MCW(10+) Fuletra P, C(10+) PHS, FWC, H(10+), MCW(<5), PHC(<5) Vamaj P(2), S, PUC, PHS, FWC, H(10+), C(10+) MCW(<5), PHC(<5) Vansol P, C(10+) MCW, PHS, FWC, H(10+), PHC(10+) Adraj P, S, PUC, C(10+) MCW, PHC, PHS, FWC, H(10+) Drinking Water Facility Communication (Post or Telegraph) Transportation Facility (Bus etc.) Approach to Village Nearest town and Distance (Kms.) Power Supply T, TW PO, PH(20) BS, RS(10+) PR, MR, FP Kalol (13) EA T, TW, W, TK PO, PH(30) BS, RS(5-10) PR, MR, FP Kalol (7) EA T, TW, TK PO, PH(14) BS, RS(5-10) PR, MR, FP Kalol (8) EA T, TW PO(<5), PH(5-10) BS, RS(5-10) PR, MR, FP Kalol (7) EA T, TW, W, TK PO, PH BS, RS(5-10) MR, FP Kalol (7) EA T, W PO(10+), BS, RS(10+) PR, MR, FP Kalol (10) EA PH(10+) T, TW PO, PH(18) BS, RS(<5) PR, MR, FP Kalol (4) EA T, TW, W, PO, PH(108) BS, RS(<5) PR, MR, FP Kalol (4) EA TK T, TW, TK, PH(15), PO(<5) BS, RS(5-10) PR Kalol (23) EA T, TW PO, PH(3) BS, RS(<5) PR, MR, FP Kalol (3) EA T, TW PO, PH(29) BS, RS(5-10) PR Kalol (7) EA T, TW PO, PH BS, RS(10+) PR Kalol (13) EA T, TW PO, PH BS, RS(5-10) PR Kadi (14) EA T, TW PO, PH(60) BS, RS(10+) PR Kalol (9) EA T, TW PO(<5), PH(<5) BS, RS(5-10) PR Kalol (16) EA T, TW PO, PH(75) BS, RS(10+) PR, MR Kalol (12) EA EIA report of Balaji Formalin Pvt. Ltd. 3-44

115 Name of Village Educational Facility Medical Facility Ambliyara P, C(10+) H(10+), MCW(<5), PHC(<5) Sedfa P, C(10+) H(10+), MCW(<5), PHC(<5) Thol P, S, PUC, C(10+) MCW, PHS, FWC, RMP, O, H(10+), PHC(5-10) Vadavi P, C(10+) RMP, H(10+), MCW(<5), PHC(<5) Lapkaman P, C(10+) RMP, CHW, H(10+), MCW(<5), PHC(<5) Lilapur P, C(10+) RMP, CHW, H(<5), MCW(5-10), PHC(5-10) Khodiyar P, C(10+) PHS, RMP, CHW, H(10+), MCW(10+), PHC(10+) Bhadaj P, C(10+) PHS, RMP, CHW, H(<5), MCW(<5), PHC(<5) Drinking Water Facility Communication (Post or Telegraph) Transportation Facility (Bus etc.) Approach to Village Nearest town and Distance (Kms.) Power Supply T PH, PO(<5) BS, RS(10+) MR Kadi (15) EA TW, W PO(<5), PH(<5) BS, RS(10+) PR, MR Kadi (23) EA T, TW PO, PH(128) BS, RS(10+) PR Sanand (12) EA T, TW PO, PH(5) BS, RS(10+) PR Kadi (14) EA T, TW, W PO, PH(9) BS, RS(10+) PR Kalol (15) EA T, TW PH(7), PO(5-10) BS, RS(10+) PR Kalol (13) EA T, TW PH(11), PO(5-10) BS, RS PR, MR Ahmadabad (18) T, TW, TK PO, PH(17) BS, RS(<5) PR Ahmadabad (18) EA EA EIA report of Balaji Formalin Pvt. Ltd. 3-45

116 Abbreviations: Educational P - Primary School S - Higher Secondary schools C - College, Any college (Graduate level & above) like Arts, Science, Commerce PUC - Higher Secondary/Intermediate/Pre-University/Junior College or Senior Secondary Medical Facility RMP - Registered Private Medical Practitioner CHW - Common Health Worker H - Hospitals MCW- Maternity & Child welfare Centre PHC - Primary Health Centre PHS - Primary Health Sub-Centre D - Dispensary FWC - Family Welfare Centre MH - Maternity Home CWC - Child Welfare Centre Drinking Water T - Tap Water W - Well Water TW - Tube well Water TK - Tank Water HP - Hand Pump Post and Telegraph PO - Post Office PH - Telephone Connection Transportation BS - Bus RS - Railway Station Approach to Village PR - Paved Road MR - Mud Road FP - Foot Path Power Supply EA - Electricity for all Purposes ED - Electricity for domestic use EAG - Electricity for agricultural use EIA report of Balaji Formalin Pvt. Ltd. 3-46

117 Figure 3.6 Location of AAQM San Envirotech Pvt. Ltd., Ahmedabad Project Site 10 km Indicating AAQM stations EIA report of Balaji Formalin Pvt. Ltd. 3-47

118 Figure 3.7 Wind Rose Diagram San Envirotech Pvt. Ltd., Ahmedabad EIA report of Balaji Formalin Pvt. Ltd. 3-48

119 Figure: 3.8 Water sampling Locations San Envirotech Pvt. Ltd., Ahmedabad Project Site 10 km Indicating Ground Water sampling location Indicating Surface Water Sampling location EIA report of Balaji Formalin Pvt. Ltd. 3-49

120 Figure: 3.9 Locations of Noise monitoring station San Envirotech Pvt. Ltd., Ahmedabad Project Site 10 km Indicating Noise Monitoring location EIA report of Balaji Formalin Pvt. Ltd. 3-50

121 Figure: 3.10 Locations of Soil sampling San Envirotech Pvt. Ltd., Ahmedabad 10 km Project Site Indicating Location of Soil sampling EIA report of Balaji Formalin Pvt. Ltd. 3-51

122 Figure 3.11 Land use pattern with 10 km radius (Satellite Image) Project Site EIA report of Balaji Formalin Pvt. Ltd. 3-52

123 Figure 3.12 Topo sheet of location with site location map of 10 km radius (1:25,000 scales) EIA report of Balaji Formalin Pvt. Ltd. 3-53

124 Figure 3.13 Topo sheet of location with site location map of 10 km radius (1:50,000 scale) EIA report of Balaji Formalin Pvt. Ltd. 3-54

125 Figure 3.14 Topo sheet of location with site location map of 10 km radius (1:1,00,000 scale) EIA report of Balaji Formalin Pvt. Ltd. 3-55

126 Chapter-4 Anticipated Environmental Impacts & Mitigation Measures 4.1 GENERAL Environmental Impact can be defined as any change in environmental conditions which may be adverse or beneficial; occurred due to action or set of actions under consideration. Environmental impact can be assessed by identifying the sources of the impact and predicting the same. The identification of environmental impacts has been made by co-relating the relationship between project activity and environmental parameters. The project activities of the proposed project are usually divided into two phases: Construction Phase and Operation Phase. The activities like building construction, transportation of construction material, etc. are usually considered in the construction phase. While in the operation phase, the activities like manufacturing process, transportation and storage of raw materials and finished products, resource consumption, emergency, disaster and greenbelt development has been considered. The next step is prediction of impacts, which is an important component in environmental impact assessment process. Several techniques and methodologies are in vogue for predicting the impacts due to existing and proposed industrial development on physical, chemical, biological and socio-economic components of environment. Such predictions delineate contribution in existing baseline condition for the proposed project. The additional impacts due to proposed expansion activities are analyzed by keeping in mind the baseline status. This helps to assess the assimilative capacity of the environment and in turn the gravity of the impacts. The third important component of the environmental assessment is the evaluation. Based on the identification and prediction of the nature of impact the environment, the impact can be evaluated qualitatively and quantitatively. EIA report of Balaji Formalin Pvt. Ltd. 4-1

127 As such it becomes important to estimate the peak incremental concentrations of gaseous pollutants caused due to the emissions from the proposed expansion activities. Chapter 2 of this report discusses the details of pollution sources from the plant. There are various types of impacts which may arise due to the proposed expansion activities. The impact assessment has been addressed for the following attributes, which may get affected due to the proposed expansion activities of the project. Impact on Topography Impact on Air Environment Impact on Water Environment Impact on Noise Environment Impact on Land Environment (Hazardous waste generation) Impact on Ecology (Flora and Fauna) Impact on Socio-Economic Environment 4.2 IMPACT ON TOPOGRAPHY Since the proposed expansion will be carried out in the existing premises, very less construction work will be required for the installation of new/additional machineries. The area of the plant is almost flat terrain. During the construction, excavated soil will be restored to its original shape. Thus, the impact during the construction is reversible, for short terms and insignificant. During the operational phase of the project, no impact is envisaged on the topography. 4.3 AIR ENVIRONMENT Sources of Impact There are chances of impact on the air environment due to installation of new machinery during construction phase and due to gaseous emission from the Tail Gas Treatment unit during operational phase Prediction of impact during Construction Phase Since the proposed expansion will be carried out within the existing premises, construction activities will be required only for the installation of new plant & machineries. Hence; there will be some minor impacts on the quality of the air but this will not cause any adverse effects on the surrounding atmosphere. There will be chances of dust emission from site EIA report of Balaji Formalin Pvt. Ltd. 4-2

128 cleaning and construction activity. This will be limited up to working area only. Dust and other emissions are not likely to spread in wider area, which would affect homes and other properties. Dust will generate within working areas and measures will be taken to protect workers. However, to mitigate the impact due to Suspended Particulate Matter (SPM), regular sprinkling of the water will be done along with the construction activities Prediction of Impact during Operational Phase Mathematical models are used for predictions of impact during Operational Phase includes steady state Gaussian Plume Dispersion model designed for multiple point sources. The impacts on air quality from project depend on various factors like design capacity, configuration, process technology, raw material, fuel to be used, air pollution control measures, operation and maintenance. Apart from the above, other activities associated with any project, viz., transportation of fuel, raw materials and finished products, storage facilities and material handling within the plant premises may also contribute to air pollution Sources of Air Pollution The unit propose to adopt modernized techniques of the process, the process along with proposed expansion in the production capacity. Tail gas treatment plant is installed where there is no use of fuel. This is resulted in no air pollution. Tail gas treatment plant will be updated/modify along with process plant after expansion. The estimated tail gas quality is given in Table-2.8 of Chapter-2 of EIA report. Other source of flue gas emission is from standby existing D. G. Sets with power generation capacity of 400 kva & proposed will have capacity of 1000 kva. HSD with fuel consumption is 45 lit/hr. for 400 kva & 110 lit/hr. for proposed D G Set with capacity of 1000 kva. Adequate stack height to the stack has been provided for proper dispersion of gaseous emission. Existing/estimated emission levels of stacks are given in Table: 4.1. The results show that all parameters are well within the stipulated norms. EIA report of Balaji Formalin Pvt. Ltd. 4-3

129 Fugitive Emission The fugitive pollutants such as RPM, VOCs are likely to emit from process area. However it will be within acceptable level. To minimize fugitive emission; the unit has adopted the practice of carrying out entire manufacturing process into closed vessel as well as tail gas treatment plant will also be established, which reduces the concentration of the pollutants. Special care is also taken while material handling and storage. To reduce the pollutant emitted during transportation, the unit has adopted the practice of regular check-up and maintenance of vehicular engines for complete combustion of the fuel. To mitigate the impact due to Suspended Particulate Matter (SPM), following control measures will be implemented: Paved road will be developed inside the plant premises. Regular housekeeping will be carried out. Construction material will be stored separately and covered to control dust emission due to wind. Regular maintenance of vehicles and machinery will be carried out. PUC certified vehicles will be used. Ambient air quality monitoring will be done at strategic location Dispersion Modeling of Emissions from the plant In the present study, the mathematical model that has been used for prediction on air quality includes steady state Gaussian Plume Dispersion model designed for multiple point sources. The objective of dispersion modeling is to predict the ground level concentration during the operation of proposed expansion activities and its impact on ambient air quality of the area. The ground level concentrations of pollutants have been computed using computer simulation model Industrial Source Complex Short Term (ISCST-3) of United State Environmental Protection Agency (USEPA) and considering guidelines stipulated by CPCB for air pollution dispersion modeling. The key emitted pollutants will be Suspended Particulate Matter (SPM), Sulphur Dioxide (SO 2 ), Nitrogen Oxide (NOx). EIA report of Balaji Formalin Pvt. Ltd. 4-4

130 4.3.5 Micrometeorology The hourly wind speed, solar insolation and total cloudiness during day time and wind speed and total cloudiness during night time were used to determine the hourly atmospheric stability classes (defined by Pasquill and Gifford as A to F, A being most unstable and F being most stable).the hourly stability classes were determined based on the technique suggested by Turner. Turner s system used for determining the stability classes is as follows: - For day or night: If total cloud cover (TC) = 10/10 and ceiling <7000 ft (2134 m), NR=0 - For night-time (defined as period from one hour before sunset to one hour after sunrise): a) If TC<4/10, use NR = -2 b) If TC>4/10, use NR = -1 - For daytime: determine isolation class number (IN) a) If TC<5/10, use NR=IN b) If TC>5/10, modify IN by the sum of the following applicable criteria If ceiling<7000 ft (2134m), modification = -2 If ceiling>7000 ft but <16000 ft (4877 m), modification = -1 - If TC=10/10 and ceiling>7000 ft, modification = -1, and let modified value of IN=NR, except for day-time NR cannot be <+1. During the study period, stability calculated based on above-mentioned Turner method gives average stability as A-B class during Day time and E class during Night time. The mean mixing height considered for prediction is 100 m as mean minimum and 1000 m as mean maximum. Average micro meteorological data of October-15 to December-15 is used Air Quality Modeling and Predictions using the Gaussian Model The impact on air quality due to emissions from single source or group of sources is evaluated by use of mathematical models. When air pollutants are emitted into the atmosphere, they are immediately diffused into surrounding atmosphere, transported and diluted due to winds. The air quality models are designed to simulate these processes mathematically and to relate emissions of primary pollutants to the resulting downwind EIA report of Balaji Formalin Pvt. Ltd. 4-5

131 air quality. The inputs include emissions, meteorology and surrounding topographic details to predict the impacts of conservative pollutants. The impacts of air pollutants were predicted using Gaussian air dispersion model, which is selected on the basis of existence of multiple point sources within the industrial complex and the plain terrain at the project site. The Gaussian air dispersion model has been developed to simulate the effect of emissions from point sources on air quality. Gaussian model is extensively used for predicting the Ground Level Concentrations (GLCs) of conservative pollutants from point, area and volume sources. The impacts of primary air pollutants are predicted using this air quality model keeping in view the plain terrain at the project site. The micrometeorological data monitored at project site during study period have been used in this model. The Gaussian model provides estimates of pollutant concentrations at various receptor locations. It is, an hour-by-hour steady state Gaussian model which takes into account the following: - Terrain adjustments - Stack-tip downwash - Gradual plume rise - Buoyancy-induced dispersion, and - Complex terrain treatment and consideration of partial reflection - Plume reflection off elevated terrain - Building down wash - Partial penetration of elevated inversions is accounted for Hourly source emission rates, exit velocity, and stack gas temperature A Gaussian air dispersion models were used to estimate the ambient air quality levels at the different monitoring stations due to stack emissions. Only two stability conditions based on the meteorology aspects were used to calculate the theoretical maximum ground level concentration is comparing the actual data and data generated from mathematical modeling, it highlights that the stability condition E & A-B were predominant in the region. EIA report of Balaji Formalin Pvt. Ltd. 4-6

132 4.3.7 Details of Air Dispersion Model Prediction of GLC values are made by using Industrial Source Complex Short Term Model Version-3 (ISCST-3) software approved by U.S. Environmental Protection Agency (USEPA). This model uses a steady state, sector-averaged Gaussian plume equation for application in complex terrain (i.e. terrain stack or release height) and is run using stability classes developed by Pasquill and Gifford. Following are the assumptions made while using the model: - No dry and wet depletion of pollutants - Receptors are on flat terrain with no flag pole (a) Input data for air quality modeling Stack emissions data have been used for prediction of short-term incremental GLC values of PM, SO 2, NOx using one season meteorological data collected at site during Oct-15 to Dec-15. Input data is given in Table 4.1. (b) Source Characteristics/Release Characteristics The details of stack emissions (with & without APCM) is given in Table 4.2 and cumulative concentrations at various locations is given as Table 4.3. (c) Meteorological Parameters Hourly meteorological data collected at site for the period of Oct-15 to Dec-15 have been used for computing the meteorological parameters. (d) Dispersion Modeling Results The 24 hourly average ground level concentration (GLC) values from proposed project have been computed for PM, SO 2, NOx & considering topographical features around the proposed plant and applicable stability classes. The maximum 24 hourly average GLC values for PM, SO 2, NOx from proposed expansion are given in Table 4.4 to Table 4.6. Corresponding isopleths plotted are shown in Figure 4.1 to Figure Predicted GLCs It is predicted that highest 24 hourly incremental GLC value for SPM, SO 2 & NO x are g/m 3, g/m 3 and g/m 3 respectively. The point of maximum concentration by unit would be 1.0 km from center of industry in S direction. EIA report of Balaji Formalin Pvt. Ltd. 4-7

133 With this marginal contribution due to the proposal of the project, the levels of PM10, SO2 & NOx will remain well below the 24 - hourly ambient air quality standards for SO 2 & NOx (80 g/m 3 ), PM 10 (100 g/m 3 ), PM 2.5 (60 g/m 3 ) prescribed by CPCB. The 24-hourly average GLC Values for SPM, SO 2 and NO X are reported in Table 4.4 to Table 4.6. The operation of proposed plant is not likely to cause any significant impact on the ambient air quality of the study area. 4.4 WATER ENVIRONMENT (A) Sources of Impacts The main sources of impact on water environment will be due to use of additional fresh water from Narmada Water supply system during construction and operation phase. The unit will be Zero Discharge Unit after proposed expansion therefore; there will not be any impact due to industrial wastewater. Prediction of Impact- During Construction phase Since the proposed expansion will be in the existing premises, construction will be required only for the installation of new plant and machineries. There will not be any adverse impact on the quality of water because very small quantities of water will be used. No disposal of construction waste outside the plant and no leaching are anticipated. Thus, the quality and quantity of ground water will not have any adverse impact during construction phase. During Operational Phase After proposed expansion, water requirement will be satisfied through Narmada Water. Unit has obtained necessary permission for it. The increase in water requirement due to proposed expansion will be from KL/day to KL/day; out of which industrial water requirement will be KL/day only. Unit is reuse 25.0 treated wastewater currently and it will be increased up to 75.0 KL/day after expansion. The unit is engaged in the manufacturing of Formaldehyde, which is continuous process and water also retained with the product. Therefore, there will not any wastewater generation from the process. Since there is EIA report of Balaji Formalin Pvt. Ltd. 4-8

134 no need of plant washing and cleaning hence, the main source of industrial wastewater generation is cooling bleed off and RO reject. Currently, industrial wastewater generation is 30.0 KL/day and it will be increased up to KL/day which will be sent to Evaporator to achieve zero liquid discharge and condensate of evaporator is reuse in utilities. (B) Impact Assessment Fresh water requirement will increase from KL/day to KL/day after proposed expansion. Source of water is Narmada water, a surface water source. However, unit will be recharging ground water during the monsoon season. For that, industry proposes to make khettalavadi in nearby villages to recharge rain water. Thus, there will not be any major impact on the water environment due to proposed expansion. After expansion also unit will continue to achieve zero discharge. Effluent will evaporated in in-house Force effect evaporator & Mechanical evaporator to achieve zero discharge and condensate from Mechanical evaporator will be reuse. Domestic effluent will be discharge through soak pit followed by septic tank. Thus, there will not be any major impact on the water environment due to proposed expansion activities. 4.5 NOISE LEVEL IMPACT Any unwanted sound that creates disturbance in hearing is termed as Noise. Hence, it is important to assess the present noise quality of the area in order to predict the potential impact of future noise levels due to the project Prediction of impact during Construction Phase The impact on noise environment will be due to installation of new mechanical equipments and machineries. The noise produced during construction may have significant impact on the existing ambient noise levels. The impact will be very minor and temporary in nature Prediction of impact during Operational Phase The main sources of noise (at present & after expansion) within the plants are: manufacturing activities, transferring pumps and material handling systems. Suitable noise control system will be provided to ensure that noise does not exceed the limits. The noise level shall, EIA report of Balaji Formalin Pvt. Ltd. 4-9

135 however, exceed the limits for a short period during start-up of equipments. The other sources of noise are the movement of vehicles along the road. However, proper noise preventive measures have been taken to minimize the noise pollution like ear plugs, efficient silencers to the vehicles, etc. The results of monitoring carried out in the region have been presented in Chapter-3. The results are below the standards prescribed for Industrial environment. It can be concluded that, the impact on noise environment will be long term but insignificant. The mitigation measures proposed for minimising impacts on noise quality are provided in Chapter LAND/SOIL ENVIRONMENT The main source of impact on land and soil environment will be due to construction activities and hazardous waste disposal. There will not be any disposable hazardous waste generation from the manufacturing process Prediction of impact during Construction Phase Since the proposed expansion will be carried out in the existing premises, all the existing infrastructure facilities will be utilized with addition of some new machineries and equipment. Therefore, no major construction activities will be carried out. Further, the area of the plant is flat. Leveling would not be required. Thus, topography will also be remained unchanged after proposed expansion. Thus, the impact on the land/soil during the construction is for short terms and insignificant Prediction of impact during Operation Phase Hazardous/solid waste generation will be the main source of impact on the soil environment. No disposable will be generated during the plant operation; therefore, there will not be any impact on the land Environment due to plant operation. The main source of hazardous waste generation will remain same only qty. will be increased after proposed expansion. Generated hazardous wastes will be is Evaporation Salt, used oil & discarded containers/barrels. EIA report of Balaji Formalin Pvt. Ltd. 4-10

136 Evaporation salt will be disposed to secured TSDF site for landfilling; discarded containers/barrels will be sold to authorized recyclers. Used oil will be sold to CPCB approved recyclers. The unit has provided isolated area with impervious flooring for the storage of hazardous waste. Entire quantity of the hazardous waste will be stored in the isolated hazardous waste storage area within premises having leachate collection system and roof cover. Thus, after taking adequate steps for the hazardous waste storage, there will be minor impact on the environment due to proposed project activities. 4.7 ECOLOGICAL IMPACTS (FLORA AND FAUNA) Unit is already in existence. So there will not be any cutting of natural vegetation. On the contrary, the unit proposes to plant more tress in existing greenbelt to make it dense. The area around the premises consists of an adequate growth of vegetation. Various trees, shrubs and herbs are found in and around it. Also, the trees are identified for their sensitivity & pollution tolerance capacity. This concept helps to plan the greenbelt of the area making it less polluted and a pollution absorber. The high Stomatal Index of Azadirachta Indica makes them susceptible to SO 2. However, the SO 2 emissions from the industry will be well within the limits and disperse from the adequate height. Hence, no major adverse impact is expected on these plants with the increased emissions. The high SPM levels may harm leaves by blocking stomata and thus interfering with exchange of gases during photosynthesis and respiration and also cause abrasion of plant surfaces when the wind blows. But the site is not subjected to high-speed winds and the plants can be expected to be free from any major impacts of SPM on plants. Thus, there will not be any significant impact on ecological environment due to proposed expansion activities. 4.8 SOCIO-ECONOMIC IMPACT The proposed expansion will be in the existing premises and no additional land will be required. Therefore, no displacement of person is envisaged. EIA report of Balaji Formalin Pvt. Ltd. 4-11

137 The plant is most modern and will require educated and trained manpower. The surrounding area has got good educational facilities and most of employees will come from the surrounding area. The operation of the existing plant requires a workforce of 30 persons and after expansion it will be increased up to 55. Thus, increasing industrial activity will boost up the commercial and economical status of the locality to some extent. Thus, overall impacts on socio-economic environment are long term and positive in nature. EIA report of Balaji Formalin Pvt. Ltd. 4-12

138 Mitigation Measures for different component 4.9 MITIGATION MEASURES DURING CONSTRUCTION: In order to mitigate the adverse environment impact due to the construction phase are given below: Regular sprinkling of the water will be recommended along with the construction activities. Regular maintenance of machinery and transportation of vehicles during construction to reduce noise pollution. The domestic sewage generated during the construction activity will be routed to septic tanks followed by soak pit. To protect the workers working in noisy area, personal protective equipments like earmuffs/earplugs, safety shoes will be provided. Tree plantation will be increased around periphery of plant premises and along the road sides MITIGATION MEASURES DURING THE OPERATIONAL PHASE: Measures for Air Environment A) Stack Emission Flue gas volume should be checked for amount of air needed for the complete combustion of the fuel. Since, there will be no air pollution from process and utilities except tail gas emission after proper treatments. The unit will also provide adequate APCM & stack monitoring facilities for the periodic monitoring of the stack to verify the compliance of the stipulated norms. In order to minimize the air pollution, unit will also develop greenbelt in and around its premises. B) Measures for fugitive emissions The unit will take following measures: Paved roads make to reduce the fugitive emission. Water sprinkler will be provided to reduce the dusting from road transportation. Regular maintenance of valves, pipes etc. EIA report of Balaji Formalin Pvt. Ltd. 4-13

139 To reduce the pollutant emission during transportation, unit has adopted the practice of regular check-up and maintenance of vehicular engines for complete combustion of the fuel by the transporters. Regular periodic monitoring of work area to check the fugitive emission Measures for water environment Unit proposed to recharge ground water during the whole year and especially in monsoon to balance the water table by making a recharge sump/ structures etc. in own premises. Use of high-pressure hoses for cleaning the floor to reduce the amount of wastewater generated Measures for hazardous/solid waste Classification of waste Collection, Storage, Transportation & disposal at TSDF site & sell to appropriate recycler &/or reuse. Data Management and Reporting Separate storage area Measures for Noise To minimize the noise pollution, the unit proposes the following noise control measures, Noise suppression measures such as enclosures, buffers and/or protective measures should be provided, if required (wherever noise level is more than 90 db (A)). Employees should be provided with ear protection measures like earplugs or earmuffs. Earplug should be provided to all workers where exposure is 85 db (A) or more. Extensive oiling, lubrication and preventive maintenance will be carried out for the machineries and equipments to reduce noise generation Health & Safety measures Provision of periodic medical check-up for all the employees. Protective equipments will be regularly checked and will be kept easily accessible and easily workable during emergency. Various types of fire extinguishers such as (Foam type, water CO 2 type, CO 2 type) will be provided inside the factory premises. EIA report of Balaji Formalin Pvt. Ltd. 4-14

140 Table 4.1 Input data for air quality modeling Sr. No. Stack attached to Existing Stack 1 D.G. set (400 kva) Stack Temp. ( 0 K) Proposed additional stack 1 D G Set (1000 kva) Velocity (m/s) Stack Height (m) Dia. of Stack (m) Fuel Used HSD- 45 lit./hr HSD- 110 lit/hr. SPM (g/s) SO 2 (g/s) NO X (g/s) Table 4.2 Existing/Estimated Air emission Quality (with & without APCM) Sr. No. Stack attached to Without APCM With APCM SPM (g/s) SO 2 (g/s) NO X (g/s) SPM (g/s) SO 2 (g/s) NO X (g/s) 1 D.G. Set (400 kva) D.G. Set (1000 kva) EIA report of Balaji Formalin Pvt. Ltd. 4-15

141 Table 4.3 Cumulative Concentrations at various locations Station Direction Distance (Km) Baseline Concentration ( g/m 3 ) Predicted GLC ( g/m 3 ) Cumulative Concentration ( g/m 3 ) Project Site (A1) Moti Bhoyan (A2) Khatraj (A3) Ganapatpura (A4) Karoli (A5) Bhimasan (A6) Sherisa (A7) Jethlaj (A8) PM SO 2 NO x PM SO 2 NO x PM SO 2 NO x NNE (Upwind) W (Downwind) ENE (Up Wind) W (Downwind) WSW (Downwind) NNE (Up Wind) SSW (Downwind) EIA report of Balaji Formalin Pvt. Ltd. 4-16

142 Table 4.4 The 24-hourly average GLC Concentration Values for SPM RANK CONC RECEPTOR TYPE RANK CONC RECEPTOR TYPE (XR,YR) (XR,YR) (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC ( , ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( ,.00) GC ( , ) GC ( , ) GC (.00, ) GC (.00, ) GC ( ,.00) GC ( , ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC ( ,.00) GC (.00, ) GC ( , ) GC ( , ) GC ( ,.00) GC (.00, ) GC ( ,.00) GC ( ,.00) GC (.00, ) GC ( , ) GC ( ,.00) GC (.00, ) GC Note: Receptor Types: GC = Grid cart, Concentration in µg/m 3 EIA report of Balaji Formalin Pvt. Ltd. 4-17

143 Table 4.5 The 24-hourly average GLC Concentration Values for SO 2 RANK CONC RECEPTOR TYPE RANK CONC RECEPTOR TYPE (XR,YR) (XR,YR) (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC ( , ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( , ) GC ( , ) GC (.00, ) GC (.00, ) GC ( ,.00) GC ( ,.00) GC ( , ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC ( ,.00) GC (.00, ) GC ( , ) GC ( , ) GC ( ,.00) GC (.00, ) GC ( ,.00) GC ( ,.00) GC (.00, ) GC ( , ) GC ( ,.00) GC (.00, ) GC Note: Receptor Types: GC = Grid cart, Concentration in µg/m 3 EIA report of Balaji Formalin Pvt. Ltd. 4-18

144 Table 4.6 The 24-hourly average GLC Concentration Values for NOx RANK CONC RECEPTOR TYPE RANK CONC RECEPTOR TYPE (XR,YR) (XR,YR) (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( , ) GC ( , ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC (.00, ) GC (.00, ) GC (.00, ) GC (.00, ) GC ( , ) GC ( ,.00) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC ( ,.00) GC ( , ) GC (.00, ) GC (.00, ) GC ( , ) GC ( , ) GC (.00, ) GC (.00, ) GC ( ,.00) GC (.00, ) GC ( , ) GC ( , ) GC ( ,.00) GC ( , ) GC ( ,.00) GC ( ,.00) GC (.00, ) GC (.00, ) GC ( , ) GC (.00, ) GC Note: Receptor Types: GC = Grid cart, Concentration in µg/m 3 EIA report of Balaji Formalin Pvt. Ltd. 4-19

145 Figure 4.1: Isopleths for Ground Level Concentrations for SPM EIA report of Balaji Formalin Pvt. Ltd. 4-20

146 Figure 4.2: Isopleths for Ground Level Concentrations for SO 2 EIA report of Balaji Formalin Pvt. Ltd. 4-21

147 Figure 4.3: Isopleths for Ground Level Concentrations for NOx EIA report of Balaji Formalin Pvt. Ltd. 4-22

148 Chapter-5 Analysis of Alternatives 5.1 PROLOGUE: Alternative analysis is the process of analyzing the proposed locating for suitability for basic necessities to operate the plant safely, this analysis also covers the environmental aspect of pollution prevention and improvement in quality of life nearby the project vicinity. The project alternative is the course of action in pace of another, that would meet the same purpose and need, but which would avoid or minimize negative impacts and enhance project benefits. Such projects may result in specific impacts which can be avoided or mitigated by adherence to certain predetermined performance standards, guidelines or design criteria. Alternative approaches may therefore be more effective in integrating environmental and social concerns into the project planning process. 5.2 PROJECT DETAILS: Balaji Formalin is already in existence at Plot No. 1398, Village: Moti Bhoyan, Taluka: Kalol, District: Gandhinagar, Gujarat for manufacturing of Formaldehyde. Unit now proposed to expand its existing production capacity with introducing new products (Para Formaldehyde & Purification of silver). Expansion will be carried out in the existing premises. Proposed expansion activities is falls under 5(f) category - Synthetic organic chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals and chemical intermediates) and therefore prior EC is required. 5.3 SITE ALTERNATIVE: The project is already in existence. It is very well familiar with the surrounding environment; therefore, it becomes easy for the unit to expand the project in the same premises. The other supporting features are briefly summarized hereunder, Availability of adequate land for expansion; EIA report of Balaji Formalin Pvt. Ltd. 5-1

149 Availability of all basic facilities like infrastructure, communication, transportation, medical facilities, water, power, unskilled & skilled manpower, raw materials, road network etc. Proximity of market; Nearest city Ahmedabad is 12.0 km away from the project site which is very well connected with other parts of the country by road, rail & air; No R & R will be required; Easy availability of manpower for proposed expansion activities; So no alternative for site is analyzed. 5.4 ALTERNATIVE FOR TECHNOLOGIES: Particular Proposed Technology Alternatives Water Forced effect evaporator followed Proposed technology is mechanical evaporator. adequate to achieve zero discharge. Domestic w/w will be disposed off in soak pit through septic tank. Air Tail gas treatment plant & Proposed technology is adequate stack height & acoustic adequate to keep emission enclosure to the stand-by D. G. within limit. set. Solid/ Haz. Waste will be stored in As proposed disposal facilities Hazardous separate storage area and finally are safe disposal facilities and waste disposed to approve TSDF site, also guided by authority. No disposal by selling to registered thoughts are required to recycler. switching on other alternative. EIA report of Balaji Formalin Pvt. Ltd. 5-2

150 Chapter-6 Environmental Monitoring Program 6.1 PRELUDE: Environment monitoring is the sampling and analysis tool to know the environment conditions at particular time. The record of environmental monitoring is most important as the environmental changes are slow in nature and impact appears after many years. Environmental Monitoring is the technical heart of assessment of environmental and social impacts arising due to implementation of the proposed project. An equally essential element of this process is to develop measures to eliminate, offset or reduce impacts to acceptable levels during implementation and operation of projects. The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental Management Plan. Balaji Formalin Pvt. Ltd. is an existing unit for manufacturing of Formaldehyde. Unit now proposed to expand its existing production capacity with addition of new products. Expansion will be carried out in the existing premises. It has proposed adequate environmental monitoring programme. 6.2 ENVIRONMENT MONITORING PROGRAM: The continuous monitoring of Environmental parameters like air, water, noise, soil and performance of pollution control facilities and safety measures in the plant are vital for proper Environmental management of any industrial project. Therefore, the company shall create environmental monitoring facilities by the environmental and safety department to monitor air and water pollutants as per the guideline of GPCB & CPCB. Moreover, air and water shall be monitored by outside agencies authorized by GPCB at regular frequencies. This department shall also carry out periodical checkup of fire and safety equipments. 6.3 OBJECTIVE OF MONITORING PLAN: The basic objective of implementing a monitoring plan on a regular basis is as follows: EIA report of Balaji Formalin Pvt. Ltd. 6-1

151 Know the pollution status within the plant and its vicinity. Generate data for corrective action in respect of pollution. Correlate the production operations with emission and control mechanism. Examine the performance of pollution control system. Assess the Environmental impacts. Remedial measures and environment management plant to reverse the impacts. 6.4 SCHEDULES FOR ENVIRONMENT MONITORING: The environmental monitoring will be scheduled on regular interval to assess the conditions. The record of these monitoring will be compared with the baseline study to know the changes in environmental conditions. The post-project environmental monitoring suggested herewith should be as per the following guideline. The highlights of the integrated environmental monitoring plan are: The stack monitoring facilities like ladder, platform and porthole at all the stacks will be maintained in good condition. Regular monitoring of all gaseous emissions from stacks/vents. The performance of air pollution control equipment evaluated based on these monitoring results. Water consumption will be recorded daily. As far as possible, noise curbed at its source, with the help of acoustic hoods and other such noise reducing equipment. Regular noise level monitoring will be carried out. Greenbelt will be properly maintained and new plantation programmes will be undertaken frequently. Continuous environmental awareness programmes will be carried out for the employees and also in the surrounding villages. 6.5 AMBIENT AIR QUALITY MONITORING Schemes for monitoring ambient air quality, stack emissions and fugitive emissions are proposed. The ambient air quality monitoring systems are recommended for monitoring the ground level concentrations and fugitive emissions around the plant. Unit should install three monitoring stations EIA report of Balaji Formalin Pvt. Ltd. 6-2

152 around its battery limit (at as per guideline) for monitoring PM, SO 2 and NOx. The combined data will provide overall characteristic and emission from the industry. For this, the following equipment is recommended to be procured or can higher the services from Environmental consultant by the project proponent for implementing the above mentioned monitoring schemes: Respirable Dust Sampler Blower m 3 /min capacity with adapter for uniform suction through filter and a properly calibrated manometer assembly for the determination of flow rate through filter paper. Rota meter - For gaseous sampling, calibrated Rota meter (0-5 LPM) for maintaining flow rate should be provided. Main housing - The main housing should be rectangular with a stand of about 1.25 m height. Besides this, stack emissions monitoring as per GPCB guidelines shall be carried out. Water Environment: Wastewater generated from water treatment, silver refining process & cooling bleed off will be directly sent to forced effect evaporator & then sent to mechanical evaporator. Condensate from evaporator will be reused for utility i.e. for cooling. Thus, unit will achieve zero discharge after proposed expansion. Noise Environment: Monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures. A good quality digital sound pressure level meter is essential for this purpose. Transportation: All the necessary precaution will be taken while carrying out transport of the materials as per the Hazardous rules of transportation, central Motor Vehicle Act-1988 & The vehicle for transportation of raw materials, by-products and products will be parked at specified loading facilities where there will be a provision of fire extinguishers. EIA report of Balaji Formalin Pvt. Ltd. 6-3

153 Table: 6.1 Environment Monitoring Plan Nature of Analysis Frequency of analysis with its analyzer Parameters Wastewater analysis Monthly by external agency ph, TDS, SS, Oil & Grease, etc. Stack monitoring of each stack Ambient Air Quality Monitoring Noise level Work zone fugitive monitoring Health check-up of workers Monthly by external agency Monthly for 24 hours or as per the statutory conditions by external agency Monthly as per the statutory conditions by external agency Monthly by external agency As per the statutory guideline PM, SO 2, NO X PM 10, PM 2.5, SO 2, NO X Nr. Main gate, Nr. D. G. Set, Process area, Raw material storage area etc. Dust, VOCs All workers EIA report of Balaji Formalin Pvt. Ltd. 6-4

154 Table: 6.2 Budget for implementation of Environmental Monitoring Plan Particulars No. of location Parameters Methodologies Total Method of Monitoring Method of Analysis Budget (Tentrati ve) Stack Monitoring of each stack Ambient Air Quality Monitoring Waste water Analysis Work zone fugitive monitoring All stacks PM, SO 2, NOx Stack monitoring kit 3 locations Noise Pollution 6 to 8 locations PM 2.5, PM 10, SO 2, NOx 1 sample ph, TDS, SS, Oil & Grease, etc. 2 to 3 Dust, VOCs locations Sound Level Meter RDS, Fine particulate sampler PM: IS 11255: part-1: 1985 SO 2 : IS 11255: part-2: 1985 NOx: IS 11255: part-7: 2005 PM 2.5 : IS 5182: part-23: 2006 PM 10 : IS 5182: part-23: 2006 SO 2 : IS 5182: part-2: 2001 NOx: IS 5182: part-6: APHA-AWWA 22 nd edition Personal sampler, VOC sampler Sound Level Meter 3200/ stack 5500/ station 2500/ Sample Gravimetric, GC 1500/ location Sound Level Meter 1000/ location EIA report of Balaji Formalin Pvt. Ltd. 6-5

155 Chapter-7 Risk Assessment Report 7.1 INTRODUCTION The risk assessment studies have been conducted for identification of hazards, to calculate damage distances and to spell out risk mitigation measures. Balaji Formalin Pvt. Ltd. is a working unit at Plot No. 1398, Nr. Rama Multi Tech Ltd., Post: Moti Bhoyan, Taluka: Kalol, Dist.: Gandhinagar for manufacturing of Formaldehyde of 5000 MTPM capacity and intends to enhance its production capacity of Formaldehydeup to MTPM along with Para Formaldehyde MTPM and Reprocessing Silver (Purification of Silver) MTPM Scope of Study The scope of work is to carry out risk analysis for the proposed expansion of plant covering all the hazardous chemicals to be handled and stored at the plant after expansion Study Objective The objective of the risk analysis includes the following: Identification of hazards Selection of credible scenarios Consequences Analysis of selected accidents scenarios Risk Mitigation Measures The Study Approach The risk assessment study broadly comprised of the following steps: System Description Identification of Hazards Selection of Credible Accident Scenarios Consequence Analysis Risk Mitigation Measures System Description This step comprised the compilation of the location, design and operational information needed for the risk analysis. EIA report of Balaji Formalin Pvt. Ltd. 7-1

156 7.1.5 Identification of Hazards Hazards associated with the plant after expansion was identified. Summary of relevant accident cases was reviewed Risk Reduction Measures Based on hazard identification and consequence analysis, risk reduction measures were suggested to reduce risk and enhance safety at the plant. 7.2 PROBABLE HAZARDS & RISK Hazard identification and risk assessment is carried out through careful study of plant process. Following this various scenarios by which an accident can occur are then determined. Concurrent study of both probability and the consequences of an accident are carried out and the final risk assessment is made. Since chemical & fuel posses different kind of hazard, both have been separately associated. The chemicals poses more of Occupational Health Hazard, while fuel posses more of safety/accidental hazards. Hazard & risk assessment has been carried out for exposure to harmful dust/vapors, liquid pool evaporation or boiling and leakage s in confined space. 7.3 HAZARDOUS IDENTIFICATION Hazard is defined as a chemical or physical conditions those have the potential for causing damage to people, property or the environment. Hazard identification is the first step in the risk analysis and entails the process of collecting information on: the types and quantities of hazardous substances stored and handled, the location of storage tanks & other facilities, Potential hazards associated with the spillage and release of hazardous chemicals. 7.4 HAZARDOUS SUBSTANCES TO BE HANDLED AT BALAJI FORMALIN PVT. LTD. Balaji is having raw materials few of which are hazardous in nature (inflammable, highly toxic). These materials are being stored with full safety and security. EIA report of Balaji Formalin Pvt. Ltd. 7-2

157 Some of the materials will be stored in Tank farms. Some of the safety measures proposed are: Hazardous material (inflammable/ tank farm) will be away from the main plant. Storage area will be cordoned off with barbed wire with restricted entry, safety signs/posters, No smoking/no naked flame sign will be posted all around it. All light fittings/electric installations/equipment in the flammable chemicals storage area will be flame proof type only. Table 7.1: Liquid Raw Materials Storage Sr. No. Existing Name of Chemicals Storage capacity of Chemicals 1 Methanol 3 Nos. of Tank x 95 KL Capacity= 285 KL 1 No of Tank x 79 KL Capacity= 79 KL Total 4 Nos. Tank = 364 KL 2 Formaldehyde 1 No. of Tank x 77 KL Capacity= 77 KL 1 No. of Tank x 92 KL Capacity= 92 KL 1 No. of Tank x 260 KL Capacity= 260 KL 1 No. of Tank x 295 KL Capacity= 295 KL 2 Nos. of Tank x 130 KL Capacity= 260 KL 2 Nos. of Tank x 22 KL Capacity= 44 KL Total 8 Nos. Tank = 1028 KL Proposed 3 Methanol 6 Nos. of Tank x 95 KL Capacity= 570 KL 1 No of Tank x 79 KL Capacity= 79 KL Total 7 Nos. Tank = 649 KL 4 Formaldehyde 1 Nos. of Tank x 77 KL Capacity= 77 KL 1 Nos. of Tank x 92 KL Capacity= 92 KL 1 No of Tank x 260 KL Capacity= 260 KL 1 Nos. of Tank x 295 KL Capacity= 295 KL 2 Nos. of Tank x 130 KL Capacity= 260 KL 2 Nos. of Tank x 22 KL Capacity= 44 KL Total 8 Nos. Tank = 1028 KL 7.5 HAZARDOUS MATERIALS CLASSIFICATION: Material of Construction MS- Underground MS-Above ground MS- Underground MS-Above ground Hazardous materials have been defined under MSIHC Rules (1989) - 2 (e) which means. (i) Any chemical which satisfies any of the criteria laid down in Part I of Schedule I and is listed in Column 2 of Part II of this Schedule; Toxic Chemicals: Chemicals having the following values of acute toxicity and which owing to theirphysical and chemical properties, are capable of producing major accident hazards: EIA report of Balaji Formalin Pvt. Ltd. 7-3

158 S. No. Toxicity Oral Toxicity LD 50 (mg/kg) San Envirotech Pvt. Ltd., Ahmedabad Dermal Toxicity LD 50 (mg/kg) Inhalation Toxicity LC 50 (mg/l) Remarks 1 Extremely >5 < 40 < Toxic 2 Highly Toxic >5 50 > < Toxic > > > Flammable chemicals: (i) Flammable gases; 20 0 C and at standard pressure of KPa are: Ignitable when in a mixture of 13% or less by volume with air, or; Have a flammable range with air of at least 12% regardless of thelower flammable limits. (ii) Extremely flammable liquids: Chemicals which have a flash point lower than or equal to 23 0 C and the boiling point less than 35 0 C; (iii) Very Highly flammable liquids: Chemicals which have a flash point lower than or equal to 23 0 C and the boiling point higher than 35 0 C; (iv) Highly Flammable Liquid: Chemicals which have a flash point lower than or equal to 60 0 C but higher than 23 0 C. (v) Flammable liquids: Chemicals which have a flash point higher than 60 0 C but lower than 90 0 C. Explosives:Explosive means a solid or liquid or pyrotechnich substance (or a mixture of substances) or an article. a. Which is in itself capable by chemical reaction of producing gas at such a temperature and pressure and at such a speed as to cause damage to surroundings; b. That is designed to produce an effect by heat, light, sound, gas or smoke or a combination of these as the result of non-detonative self-sustaining exothermic chemical reaction. Any chemical listed in Column 2 of Schedule 2; Any chemical listed in Column 2 of Schedule 3; Raw Materials Many of the raw materials are defined and listed under MSIHC Rules (1989). The sr. no. as defined under MSIHC Rules (1989) and other hazardous properties of the hazardous raw materials are in Table below. EIA report of Balaji Formalin Pvt. Ltd. 7-4

159 Table 7.2: Hazardous Raw Materials Sr. No. (MSHIC) & Characteristics S. No. Material 1. Methanol CAS No.: Formalde hyde CAS No.: Para Formalde hyde CAS No.: Note: S. No.& Threshold Quantity (TQ in Kg) as per MSHIC Rules Sched ule-1, Part- II Sched ule-2, Part-I Sched ule-3, Part-I Chemicals Hazards Potential Hazards FP-12 0 C ; BP C LEL-6%; UEL-36% Incompatibiliti es with Other Materials: Oxidizing agents, reducing agents, acids, alkali metals, potassium, sodium, metals as powders TQ-1: 5 MT FP-56 0 C ; BP C LEL-7%; UEL-73% May react violently with acids/ alkali/ oxidizing agents etc FP-70 0 C; BP-Not Available, MP C, LEL-7%; UEL- 73% May form carbondioxide, carbon monoxide & formaldehyde when heated to decomposition Oral Toxicity (OT) in LD 50 (mg/kg) Dermal Toxicity (DT) in LD 50 (mg/kg) Inhalation Toxicity in LC 50 (mg/l) [4 hrs.] Toxic LD 50,5628mg/k g LC mg/l LD mg/kg, Inhale Exposure Limit: 0.5 ppm Adequate ventilation needed. TLV: 2 mg/m 3 Remarks May be fatal or cause blindness if swallowed. Vapor harmful. Flammable liquid&vapor. Harmful if swallowed, inhaled, or absorbed through the skin. Causes eye, skin, and respiratory tract irritation. May cause central nervous system depression. Death if inhaled or absorbed; severe eye irritation and burns; allergic dermatitis,skin burns; bronchitis, pulmonary edema; headache, dizziness, nausea, vomiting Toxic formaldehyde gas may be produced if paraformaldehyde decomposes. EIA report of Balaji Formalin Pvt. Ltd. 7-5

160 7.6 OCCUPATIONAL HEALTH Balaji plant deals in someof the highly hazardous chemicals namely formaldehyde and methanol. The occupational hazards due to these chemicals and preventive and remedial measures are as given below: a. Formaldehyde: i. Eye contact: Always use face mask or goggles while handling chemicals. In case of eye contact immediate first aid is needed to prevent eye damage. IMMEDIATELY flush eyes with copious quantities of water for at least 20 minutes holding lids apart to ensure flushing of the entire surface. Seek immediate medical attention. DO NOT use an eye ointment. ii. Skin contact: Always use face mask hand gloves, apron etc. While handling chemicals. In case of skin contact immediate first aid is needed to prevent skin damage. Immediately flush skin with plenty of water for at least 20 minutes while removing contaminated clothing and shoes. Seek immediate medical attention. Wash contaminated clothing before reusing. iii. Inhalation: Remove patient to fresh air. Administer approved oxygen supply if breathing is difficult. Administer artificial respiration or CPR if breathing has ceased. Seek immediate medical attention. iv. Ingestion: If conscious, wash out mouth with water. DO NOT induce vomiting. Seek immediate medical attention. b. Methanol: Danger! Poison! May be fatal or cause blindness if swallowed. Vapor harmful. Liquid and vapor are flammable. Harmful if swallowed, inhaled, or absorbed through the skin. Causes eye, skin, and respiratory tract irritation. May cause central nervous system depression.cannot be made non-poisonous? Target Organs: Eyes, nervous system, optic nerve, Potential Health Effects i. Eye: May cause painful sensitization to light. Methanol is a mild to moderate eye irritant. EIA report of Balaji Formalin Pvt. Ltd. 7-6

161 ii. Inhalation, ingestion or skin absorption of methanol can cause significant disturbance in vision, including blindness. iii. Skin: Causes moderate skin irritation. May be absorbed through the skin in harmful amounts. Prolonged and or repeated contact may cause defatting of skin and dermatitis. Methanol can be absorbed through the skin, producing systemic effects that include visual disturbances. iv. Ingestion: May be fatal or cause blindness if swallowed. Aspiration hazard. Cannot be made non-poisonous. May cause gastrointestinal irritation with nausea, vomiting and diarrhoea. May cause systematic toxicity with acidosis. May cause central nervous system depression, characterized by excitement, followed by headache, dizziness, drowsiness, and nausea. v. Inhalation: Methanol is toxic and can very readily form extremely high vapor concentrations at room temperature. Inhalation is the most common route of occupational exposure and/or snowy vision, and blindness. Depending on the severity of exposure and the promptness of treatment, survivors may recover completely or may have permanent blindness, vision disturbances and/or nervous system effects. First Aid Measures: i. Eyes: In case of contact, immediately flush eyes with plenty of water for a t least 15 minutes. Get medical aid. ii. Skin: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Get medical aid immediately. Wash clothing before reuse. iii. Ingestion: Potential for aspiration if swallowed. Get medical aid immediately. Do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. If vomiting occurs naturally, have victim lean forward. iv. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical aid. EIA report of Balaji Formalin Pvt. Ltd. 7-7

162 v. Antidote: Ethanol may inhibit methanol metabolism c. Para Formaldehyde: Very hazardous in case of skin contact (irritant), of eye contact (irritant). Hazardous in case of skin contact (sensitizer), of ingestion, of inhalation. Slightly hazardous in case of skin contact (corrosive), of eye contact (corrosive). The amount of tissue damage depends on length of contact. Eye contact can result in corneal damage or blindness. Skin contact can produce inflammation and blistering. Inhalation of dust will produce irritation to gastro-intestinal or respiratory tract, characterized by burning, sneezing and coughing. Severe over-exposure can produce lung damage, choking, unconsciousness or death. Inflammation of the eye is characterized by redness, watering, and itching. Skin inflammation is characterized by itching, scaling, reddening or occasionally, blistering. Eye Contact: Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Cold water may be used. Get medical attention immediately. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold water may be used. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention immediately. Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medicalattention. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately. Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waist band. If breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. WARNING: It maybe hazardous to the person providing aid to give mouth-to-mouth resuscitation when EIA report of Balaji Formalin Pvt. Ltd. 7-8

163 the inhaled material is toxic, infectious orcorrosive. Seek immediate medical attention. Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar, tie, belt or waistband. 7.7 RISK ASSESSMENT A three levels risk assessment approach has been adopted for the Balaji s facilities. The risk assessment levels are generally consistent with the practices encountered through various assignments for medium and large chemical complexes. The brief outline of the three tier approach is given below: Level 1 Risk Screening i. This is top-down review of worst- case potential hazards/risks, aimed primarily at identifying plant sites or areas within plant, which pose the highest risk. Various screening factors considered include: Inventory of hazardous materials; Hazardous Materials properties; Storage conditions (e.g. temperature and pressure); Location sensitivity (distance to residential areas/populace). ii. The data/information is obtained from plant. The results provide a relative indication of the extent of hazards and potential for risk exposure. Level 2 Major Risk Survey (Semi - Quantitative) i. The survey approach combines the site inspection with established risk assessment techniques applied both qualitative as well quantitative mode. The primary objective is to identify and select major risks at a specific location in the plant considering possible soft spots/weak links during operation/maintenance. Aspects covered in the risk usually include: Process Hazards; Process Safety Management Systems; Fire Protection and Emergency response equipments and programs. EIA report of Balaji Formalin Pvt. Ltd. 7-9

164 Security Vulnerability; Impact of hazards consequences (equipment damage, business interruption, injury, fatalities); Qualitative risk identification of scenarios involving hazardous materials; Risk reduction measures. ii. Selection of critical scenarios and their potential of damage provide means of prioritising mitigate measures and allocate the resources to the areas with highest risks. Level 3 Quantitative Risk Assessment (Deterministic) This is the stage of assessment of risks associated with all credible hazards (scenarios) with potential to cause an undesirable outcome such as human injury, fatality or destruction of property. The four basic elements include: Hazards identification utilising formal approach (Level 2, HAZOP etc.); i. Frequency Analysis based on past safety data (incidents/accidents); Identifying likely pathway of failures and quantifying the toxic/inflammable material release; ii. Hazards analysis to quantify the consequences of various hazards scenarios (fire, explosion, BLEVE, toxic vapor release etc.). Establish minimum value for damage (e.g. IDLH, over pressure, radiation flux) to assess the impact on environment. iii. Risk Quantification: Quantitative techniques are used considering effect/impact due to weather data, population data, and frequency of occurrences and likely hood of ignition/toxic release. Data are analyzed considering likely damage (in terms of injury/fatality, property damage) each scenarios is likely to cause. QRA provides a means to determine the relative significance undesired events, allowing analyst and the team to focus their risk reduction efforts where they will be beneficial most. Proposed expansion of Balaji plant is a medium level plant but hazardous in nature. Existing plant (similar to proposed expansion project) is in operation. The QRA for this plant is based on Level 1 and Level 2. Details EIA report of Balaji Formalin Pvt. Ltd. 7-10

165 of raw materials and the bulk storages of liquid materials is gives in Table 7.1 & the hazardous nature of raw materials and products are summarized in table Risk Screening Approach Risk screening of Balaji plant was undertaken through process study and study of data/information provided by technical personal of Balaji. Data of major/bulk storages of raw materials, intermediates and other chemicals were collected. MSDS of hazardous chemicals were studied vis a vis their inventories and mode of storage. Balaji plant will have few hazardous chemicals and also producing Formaldehyde and Para Formaldehyde which are in hazardous nature. The chemicals stored in bulk (liquid or gaseous) and defined under MSHIC Rule will be considered for detailed analysis. The solid products powder or granules spillage can results in polluting small area only. The damage to personnel can be through ingress- dermal (if individual come in contact), oral (if individual food gets infected through fugitive dust) or inhalation (fugitive dust). The main route is fugitive dust which incovered area will move to short distance only. The risk is through liquid products which are volatile material. The toxic vapours due to spillage of such material can travel to some distance and cause damage. Considering these aspects only extremely hazardous (ET) liquid have been considered for QRA. The liquid products will be stored in bulk storage tanks QRA Approach Identification of hazards and likely scenarios (based on Level-1 and Level-2 activities) calls for detailed analysis of each scenario for potential of damage, impact area (may vary with weather conditions/wind direction) and safety system in place. Subsequently each incident is classified according to relative risk classifications provided in Table below as Table 7.3 Table 7.3: Risk Classification High Stage (> 10-2 /yr) Description A failure which could reasonably be expected to occur within the expected life time of the plant. EIA report of Balaji Formalin Pvt. Ltd. 7-11

166 Stage Moderate ( /yr.) Low (<10-4 ) Minor Incidents Serious Incident Extensive Incident Description Examples of high failure likelihood are process leaks or single instrument or valve failures or a human error which could result in releases of hazardous materials. A failure or sequence of failures which has a low probability of occurrence within the expected lifetime of the plant. Examples of moderate likelihood are dual instrument or valve failures, combination of instrument failures and human errors, or single failures of small process lines or fittings. A failure or series of failures which have a very low probability of occurrence within the expected lifetime of plant. Examples of low likelihood are multiple instruments or valve failures or multiple human errors, or single spontaneous failures of tanks or process vessels. Impact limited to the local area of the event with potent for knock on- events One that could cause: Any serious injury or fatality on/off site; Property damage of $ 1 million (or equivalent) offsite or $ 5 million (or equivalent) onsite. One that is five or more times worse than a serious incident. Assigning a relative risk to each scenario provides a means of prioritising associated risk mitigation measures and planned actions. 7.8 THERMAL HAZARDS In order to understand the damages produced by various scenarios, it is appropriate to understand the physiological/physical effects of thermal radiation intensities. The thermal radiation due to tank fire usually results in burn on the human body. Furthermore, inanimate objects like equipment, piping, cables, etc. may also be affected and also need to be evaluated for damages. Table 7.4, Table 7.5 & Table 7.7 respectively give tolerable intensities of various objects and desirable escape time for thermal radiation. Thermal hazards could be from fires or explosion. Fire releases energy slowly while explosion release energy very rapidly (typically in micro seconds). Explosion is rapid expansion of gases resulting in rapidly moving shock wave. Explosion can be confined (within a vessel or EIA report of Balaji Formalin Pvt. Ltd. 7-12

167 building) or unconfined (due to release of flammable gases). BLEVE (boiling liquid expanding vapour explosion) occurs if a vessel containing a liquid at a temperature above its atmospheric boiling point ruptures. The subsequent BLEVE is the explosive vaporisation of large fraction of its vapour contents; possibly followed by combustion or explosion of the vaporised cloud if it is combustible. Thermal hazards have been considered for various scenarios including: Catastrophic Formaldehyde tank failure, spillage and Toxic Vapours spread. Table 7.4: Effects due to Incident Radiation Intensity Incident Radiation Damage Type kw/m Equivalent to Solar Radiation 1.6 No discomfort on long duration Exposure Duration Sufficient to cause pain within 20 sec. Blistering of skin (first degree burn are likely). Pain threshold reached after 8 sec. Second degree burn after 20 sec Minimum energy required for piloted ignition of wood, melting of plastic tubing etc. 25 Minimum Energy required for piloted ignition of wood, melting, plastic tubing etc Sufficient to cause damage to process equipment Spontaneous ignition of wood. Table 7.5: Thermal Radiation Impact to Human Radiation Energy {1% lethality; kw/m 2 } Radiation Energy for 2 nd degree burns; kw/m 2 Radiation Energy for 1 st degree burns; kw/m 2 10 sec Table 7.6: Tolerable Intensities for Various Objects Sl. Objects Tolerable Intensities No. (kw/m 2 ) 1 Drenched Tank 38 2 Special Buildings (No window, fire proof doors) 25 EIA report of Balaji Formalin Pvt. Ltd. 7-13

168 3 Normal Buildings 14 4 Vegetation Escape Route 6 (up to 30 secs.) 6 Personnel in Emergencies 3 (up to 30 secs.) 7 Plastic Cables 2 8 Stationary Personnel DAMAGE DUE TO EXPLOSION The explosion of a dust or gas (either as a deflagration or detonation) results in a reaction front moving outwards from the ignition source preceded by a shock wave or pressure front. After the combustible material is consumed the reaction front terminates but the pressure wave continues its outward movement. Damage estimates based on overpressure are given in Table 7.7 below: Sl. No. Table 7.7: Damage due to Overpressure Overpressure (psig/bar) Damage Loud Noise/sonic boom glass failure Typical pressure for glass failure Large and small windows usually shattered Minor damage to house structure 5. 1 Partial demolition of houses, made uninhabitable Lower limit of serious structure damage Nearly complete destruction of houses 8. 9 Loaded train box wagons completely demolished Probable total destruction of houses Limits of crater lip 7.10 TOXIC RELEASE Toxic materials handled in Balaji complex are Formaldehyde and Methanol as defined in MSHIC rules and indicated in Table 7.2. These chemicals are stored in bulk (in tank farm). EIA report of Balaji Formalin Pvt. Ltd. 7-14

169 Damage criteria: For toxic release the damage criteria considered is IDLH concentration (if data are available). In the absence of non-availability of IDLH, Inhalation Toxicity (IT) data for rats are considered LIKELY FAILURE SCENARIOS Few likely failure scenarios have been selected after critical appraisal of raw materials and products properties and storage inventories. Failure scenarios selected are as given in Table 7.8 below: Table 7.8: Different Failure Scenarios Sr. No. Scenario Remark Raw materials 1 Formaldehyde Tank catastrophic Toxic failure, spillage and Toxic Vapours 2 Methanol spillage; Toxic vapours; fire Flammable/Toxic 7.12 CONSEQUENCE ANALYSIS The facilities at the Material Storage Dyke area are mainly comprised of methanoland formaldehyde storage tanks. The hazards posed by them are mainly in the form offire. There is a possibility of flash fire taking place in the event of large spill ofhydrocarbons, mainly major failure scenarios were evaluated to assess the effect onpeople and property inside the plant area as well as outside. a) Tank Fire b) Bund Fire c) Flash fire The effect of fire on people and property outside will chiefly manifest itself in the formof thermal radiation. A criteria was selected for deciding the maximum level of thermalradiation to which the outside population can be subjected. Thermal radiation levelsfrom fire scenarios of each tank are worked out at various distances and their effectsare evaluated against the set criteria. Thermal Radiation Thermal radiation due to pool fire may cause various degrees of burns on exposedhuman bodies. Moreover their effects on inanimate objects like EIA report of Balaji Formalin Pvt. Ltd. 7-15

170 piping, equipment orvegetation also need to be evaluated to assess their impact. For continuous presence of persons, the following thermal radiation intensity levels are usually adopted: -1.6 Kw/m 2 for outside population -4.5 Kw/m 2 for plant operators This is the criteria that are followed in case of flare design where peak load conditionmay occur for a short time but mostly without warning. The operators are usuallytrained and properly clothed; they are expected to run for shelter quickly. For secondary fire, an incident radiation intensity of 12.5 Kw/m 2 is required. This is usuallytaken as the minimum criteria. The facilities at the storage area mainly comprises of vertical cylindrical tanks of structural steel. The hazard posed by them is mainly in the form offire. There is a possibility of tank fire taking place and is evaluated to assess theeffect on people and property. Damage Criteria: Damage estimates due to thermal radiation has been arrived at by correlating recorded incidents. The consequences can then be visualized by super imposing the effects onthe proposed site plan and identifying the elements within the project site as well as the neighboring environment which may be affected. The damage criteria due to accidental release of hydrocarbon arise primarily from fire. Contamination of soil or water is not expected as fuel will vaporize quickly and wouldnot leave any residue as it happens with oil. The vapour of methanol/formaldehyde is not toxic and hence no effects of toxicity are expected. Consequence of Spill: The tank on fire situation would occur if the heat on peripheral surface of the tank leadsto internal tank pressure. Pool fire would occur when solvent collected in the dyke due to leakages get ignited. Thermal Damage The following table presents the damage and effects due to thermal radiation oninanimate objects like piping, equipment or vegetation in addition to effects on humanbeings. EIA report of Balaji Formalin Pvt. Ltd. 7-16

171 Incident radiation Type of damage (in kw/m 2 ) 62.0 Spontaneous ignition of wood. San Envirotech Pvt. Ltd., Ahmedabad 37.5 Sufficient to cause damage to process equipment Maximum thermal radiation intensity allowed on thermallyprotected adjoining equipment 25.0 Minimum energy required to ignite wood at infinitely longexposure (non-piloted) 12.5 Minimum energy required for piloted ignition of wood, melting of plastic 8.0 Maximum thermal radiation intensity allowed on thermallyunprotected adjoining equipment 4.5 Sufficient to cause pain to personnel if unable to reach coverwithin 50 seconds, however blistering of skin (1 st degree burns) 1.6 Causes no discomfort on long exposures 0.6 Equivalent to solar radiation The effect of incident radiation and exposure time on lethality is stated in the followingtable: Radiation Exposure and Lethality Incident radiation (Kw/m 2 ) Methodology Exposure time (seconds) Lethality (%) Degree of burns st st st <1 3 rd <1 3 rd <1 2 nd rd Storage tanks are evaluated to assess the effect in the event of its catching fire. For the present study, the scenarios under consideration assume that the peak level ofradiation intensity will not occur suddenly. Based on the past experience, it is found that minutes time will be required before a tank fire grows to full size. For radiation calculations, full tank fire has been considered. From the above considerations, the EIA report of Balaji Formalin Pvt. Ltd. 7-17

172 criteria of 4.5 kw/m 2 have been selected to judge acceptability of the scenarios. The assumptions for calculations are: -It is not continuous exposure; -There is not enough time available for warning the public and initiating emergencyaction; -Within 10 minutes, plant personnel would attend any eventuality -Secondary fire at public road and building is not likely to happen; -The effect of smoke on reduction of source radiation intensity has not beenconsidered; therefore hazard distances calculated tend to be conservative; and -Shielding effect of intervening trees or other structures has not been considered. Nolethality is expected from this level of intensity although burn injury takes placedepending on time of exposure. Pool Fire Following an accidental release, chemicals will form a confined pool with in the dyke area or an unconfined pool in case liquids were allowed to be stored in the absence of a dyke. Should the vapour above the pool ignite, the liquid will burn as a pool fire. Thepool fire will result in thermal radiation. It could also damage the storage tanks located within the common dyke area. Model Computations Although the interest of this study is to find out the distance from a burning tank to aradiation intensity level of 4.5 Kw/m 2, calculations of the levels of radiation intensity as indicated have been included, the hazard distances for storage tank on fire: (i) Plant area instantaneous spill (Single Tank, Methanol) (ii) Plant area instantaneousspill (Single Tank, Formaldehyde) and (iii) Catastrophic rupture of storage facility Continuous spill (All tanks). Radiation distances shown in above tables are at tank elevations. At ground level theradiation intensity will be comparatively low. CONCLUSION 1. The following arrangements are available for the storage tanks: EIA report of Balaji Formalin Pvt. Ltd. 7-18

173 -Independent high level alarm and trip off liquid inlet-line. -Low level alarm. -Provision of auto deluge water sprinkler system for each bulk storagetank. The auto deluge water sprinkler would be set to start working at atemperature of 66 0 C. 2. The turbine building, switchyard, transformer yard, administrative building, pantry, first aid center, fire stations etc. should be located safely, if viewed inthe light of worst accident scenarios. 3. In case of any tank on fire or fire in the vicinity, the cooling of adjoining tank should be resorted promptly in addition to tank on fire so that the tank shell of neighboring tanks does not give away. 4. The night vision wind sock is mounted on top of administrative building, and the Dyke area with adequate illumination so that people can move in upwind directions in the event of massive spillage. 5. Population growth around the plant and colony should be watched by appropriate authorities. Unauthorized growth of shanty colonies and hutmentsaround the plant should be avoided. 6. No machinery of vital importance like fire-fighting pump house, Hydrant and Fuel oil pump house should be placed within radiation contours of 32.0 kw/m 2 heat intensity. Strict adherence to standards and accepted maintenance and operation of the plant plays a vital role in maintaining the plant. The monitoring of the health of equipment, pipeline and machines, thickness survey will improve plant performance and safety. Table 7.9 Distances of Occurrence of Various Thermal Radiation Intensities Storage Tank on FirePlant Area Instantaneous Spill (Single Tank, Methanol) Radiation Intensity (kw/m 2 ) Distance of Occurrence (metres) Tank Capacity (KL) EIA report of Balaji Formalin Pvt. Ltd. 7-19

174 Table 7.10 San Envirotech Pvt. Ltd., Ahmedabad Distances of Occurrence of Various Thermal Radiation Intensities [Catastrophic Rupture Storage Facility Continuous Spill - Methanol] Radiation Intensity Distance of Occurrence (kw/m 2 ) (metres) Table 7.11 Distances of Occurrence of Various Thermal Radiation Intensities Storage Tank on FirePlant Area Instantaneous Spill (Single Tank, Formaldehyde) Radiation Intensity (kw/m 2 ) Distance of Occurrence (metres) Tank Capacity (KL) Table 7.12 Distances of Occurrence of Various Thermal Radiation Intensities [Catastrophic Rupture Storage Facility Continuous Spill- (Formaldehyde)] Radiation Intensity Distance of Occurrence (kw/m 2 ) (metres) EIA report of Balaji Formalin Pvt. Ltd. 7-20

175 PRO-ACTIVE SAFETY MEASURES Accidents/incidents just don t happen themselves. They are caused due to human failure (mostly) or natural causes (rare). Some of the measures to prevent the incidents/accidents are given below: All employees must receive and understand the locally applicable Workplace Hazardous Materials information guide, safety rules and MSDS of hazardous chemicals (if such a guide exists). In any case, the management is responsible for proper instruction (SOP). Develop a positive attitude toward safety: prevention is better than cure. Good housekeeping is extremely important. Maintain a safe, clean work environment. You may work hard, but never in haste. Follow the safety norms/safe Operating Procedure (SOP) provided by the authorities when operating equipment/machineries. Learn what to do in case of emergencies (e.g., fire, chemical spill). Learn emergency first aid. Seek medical attention immediately if affected by chemicals anduse first aid until medical aid is available. Report all accidents and near-misses to the management. Adopt LDAR (Leak detection and repair) system and sincerely act on the same. Access to emergency exits, eye-wash fountains and safety showers must not be blocked. Fountains and showers should be checked periodically for proper operation. (Safety showers are used for chemical spills and fire victims) EIA report of Balaji Formalin Pvt. Ltd. 7-21

176 Wash hands immediately after contact with potentially hazardous or toxic chemicals. Clean up any spillage immediately. Use appropriate materials for each spillage. Strictly observe No Smoking and other safety rules. Use personal safety equipment as described below. Body protection: Chemical-resistant apron. Hand protection: gloves, particularly when handling concentrated acids, bases, and other hazardous chemicals. Dust mask: when crushing or milling/grinding samples, etc. Gas Masks: When entering an area where toxic gases or vapors are likely to occur. Eye protection: safety glasses with face shields. Persons wearing contact lenses should always wear safety glasses dealing with corrosive chemicals. Foot protection: proper footwear should be used. Read labels before opening a chemical container. Balaji will have a well-equipped first aid post. It will also have staff personnel trained in first aid. Injured personnel will be immediately rushed to hospital after giving first aid. All employees will have regular medical check-up as per norms. An emergency vehicle/ ambulance will always (round the clock) available for meeting any eventuality ACTION PLAN FOR HANDLING & SAFETY SYSTEM Formaldehyde & Methanol are the main Haz. Chemicals to be handled in the project, classified as flammable and poisonous chemical. Flammable chemicals will be stored in open area outside the process plant with all the safety measures. Hazardous chemicals bags/barrels/drums will be stored and handle in dispensing room for taking out sample from the container for quality check-up purpose or for the partial use. This activity for Hazardous material handling will be carried out by using all PPE with proper ventilation & under supervision. EIA report of Balaji Formalin Pvt. Ltd. 7-22

177 Safety Measures for Transportation and Unloading of Hazardous Chemicals Solvent unloading standard procedure will in place and will be implemented for safe unloading of road tanker. Static earthing provision will be made for tanker unloading. Drum handling trolleys will be used for transportation of drums up to plant and internal handling from storage to process area. Display Boards will be provided on all storage tanks which include the name of the chemicals and its major hazardous characteristics. Fire extinguishers will be provided as required. First aids boxes will also be provided at different places wherever required. Water showering system will be provided to the flammable chemicals storage area. Area will be declared as NO SMOKE ZONE Safety Measures for Storage/Handling of Hazardous Chemicals: All Hazardous and flammable chemicals will store separately and away from the strong oxidant & kept it in well ventilated room. Adequate firefighting system will be installed. Safety shower and eye washer will be installed near storage area. Flame proof light fitting will be provided at storage area. Sprinkler system will be installed near storage area. Safety permit system will be followed for loading and unloading. Isolate storage will be provided with wire fencing under lock and key. Caution note, hazardous identification board will be provided. Only authorized person will be permitted in storage area and register will be maintained. NO SMOKING board will be displayed and Wind Indicator and siren will be provided Safety Measures for Process Units Safety measures are the most important aspect of selection of process technology to ensure safety in production unit. For the safety in production area some important critical safety measures will be provided within the process technology/equipment itself & will put continue efforts for developing new technology/equipment. Company will ensure such EIA report of Balaji Formalin Pvt. Ltd. 7-23

178 provision in the technology /equipment /machineries at time of purchase. The details of the critical safety measures for process unit are as below; Any reaction upsets will be confined to the reaction vessel itself as defined quantity of raw materials will be issued to the reaction vessel by metering pumps/load cells. Process parameters control will be provided as per SOP- Standard Operating Procedures. Materials will be transferred by pumping through pipeline or by vacuum from drums. All reaction vents will be connected to vapor condensers system. Hazardous materials will be transferred by pipelines and in control manners. Trained person will be engaged for handling of hazardous materials. Proper safety precautions will be taken during handling of hazardous materials.all solvents and flammable material with required quantity will be charge in reactor by pump or by gravity. All the vessels will be examined periodically by a recognized competent person. All the vessels and equipments will be well earthed appropriately and well protected against Static Electricity. Temperature indicators will be provided near all reactor and distillation systems. Flame proof light fittings will be installed in the plant. All the Plant Personnel will be provided with Personal Protection Equipments to protect against any adverse health effect during operations, leakage, spillages or splash. PPE like Helmets, Safety Shoes and Safety Glasses will be provided to the employees Safety Measures for Preventive Maintenance The safety measures in form of the general Do's & Don'ts for safety in process & other plant area are as below: Do not work on equipments without permission from plant head and maintenance head. Make sure equipment is empty and fluxed with nitrogen and air. Check VOC content for flammable and make sure that no flammable vapour contents. Keep proper and adequate fire extinguisher near work area. Use proper PPE. EIA report of Balaji Formalin Pvt. Ltd. 7-24

179 Do not allow any employment without pre-medical check-up or without checking fitness. Check all motors are disconnected and fuse pulled out before maintenance. Work in any equipment must be conducted in presence of supervisor. Make sure all process lines are disconnected. Additional safety measures in form of the checklist covering Do's & Don'ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures will be updated timely and will be made available to all concern department & personnel Safety measures to prevent spillage/leakage of toxic chemicals The preventive maintenance will be planned and carried out as per plan to avoid the failure of valve, pipe lines and other component of transferring line. The spillage will be confined to the dyke area underneath the vessel. The resultant splash of such chemicals will result in exposure of toxic chemicals to employees. Decontamination facilities (Safety shower and eye wash fountains) will be provided in the plant area, which can be used to decontaminate the affected employees. Suitable decontamination procedure will be used to decontaminate the spilled or leaked material. The SOP for decontamination will be reared with all related department SAFETY MANAGEMENT PLAN FOR ACUTELY TOXIC CHEMICALS Purpose: Develop a reference document that can be used by a Principle Investigator or a designee to assist in the development of Safety Operating Procedures (SOP) for acutely toxic chemicals. The following elements below should be included when developing safety guidelines for acutely toxic chemicals: Hazard Summary These guidelines are intended to provide general guidance on how to safely work with acutely toxic chemicals. Toxic chemicals are defined as those with an LD 50 value for oral exposure in rats of mg/kg, for skin contact in rabbits of mg/kg, or EIA report of Balaji Formalin Pvt. Ltd. 7-25

180 for inhalation exposure in rats of ppm/air. Highly toxic chemicals are defined as those with an LD 50 value for oral exposure in rats of less than mg/kg, for skin contact in rabbits of less than mg/kg, or for inhalation exposure in rats of less than ppm/air. An acutely toxic chemical causes damage in a relatively short time after a single concentrated dose. Irritation, burns, illness, or death may result. These substances may cause severe inflammation, shock, collapse or even sudden death when inhaled in high concentrations. Examples include: Hydrogen Cyanide, Hydrogen Sulfide, Nitrogen Dioxide, Carbon Monoxide, Ammonia Highly toxic gases are a chemical that has a median lethal concentration in air of 200 ppm by volume or less of gas or vapor, or 2mg/L or less of mist, fume or dust, when administered by continuous inhalation for 1 hour. Examples: Nitrogen Dioxide, cyanogen, phosgene, fluorine, nitric oxide, chlorine pentafluoride, arsine, chlorine trifluoride, sulfur tetra fluoride, and hydrogen selenide Special Handling Procedures and Storage Requirements Handling processes should be designed to minimize the potential for splash, splatter, or other likely scenarios for accidental contact. The handling of these materials needs to be conducted in a fume hood. If the process does not permit the handling of such materials in a fume hood, the lab personnel should contact Environmental Health and Safety at x for review the adequacy of ventilation measures. For use of highly toxic materials, a designated area shall be established where limited access, special procedures, knowledge, and work skills are required. A designated area can be the entire laboratory, a specific laboratory workbench, or a laboratory hood. Designated areas must be clearly marked with signs that identify the chemical hazard and include an appropriate warning; for example: WARNING! HYDROFLUORIC ACID WORK AREA HIGHLY TOXIC MATERIAL. Upon leaving the designated area, remove any personal protective EIA report of Balaji Formalin Pvt. Ltd. 7-26

181 equipment worn and wash hands, forearms, face and neck. After each use (or day), wipe down the immediate work area and equipment to prevent accumulation of chemical residue. At the end of each project, thoroughly decontaminate the designated area before resuming normal laboratory work in the area Personal Protective Equipment At minimum, safety glasses, lab coat, long pants, and closed toed shoes are to be worn when entering laboratories having hazardous chemicals. If the use half mask, or full face respirator is requested, the individual and/or their supervisor must first contact Environmental Health & Safety for a consultation to determine if respirator use is necessary. This includes a medical evaluation; respirator fit test, and training. Eye protection in the form of safety glasses must be worn at all times when handling acutely toxic chemicals. Ordinary prescription glasses do not provide adequate protection. Adequate safety glasses must meet the requirements of the Practice for Occupational and Educational Eye and Face Protectionand must be equipped with side shields. Safety glasses with side shields do not provide adequate protection from splashes, therefore, when the potential for splash hazard exist other eye protection and/or face protection must be worn. Disposable nitrile gloves provide adequate protection against accidental hand contact with small quantities of most laboratory chemicals. However, the handling of some acutely toxic chemicals will require chemical resistant gloves. Lab workers should review the MSDS for the acutely toxic agents Spill and Accident Procedures If there is a spill involving an extremely hazardous chemical, emergency responders should be contacted immediately. Building occupants can be notified of a building evacuation through the activation of a fire alarm pull station. Personnel: If lab personnel are exposed to an extremely hazardous chemical, call fire department immediately. Remove any contaminated clothing, and IMMEDIATELY flush contaminated skin with water for at EIA report of Balaji Formalin Pvt. Ltd. 7-27

182 least 15 minutes following any skin contact. For eye exposures, IMMEDIATELY flush eyes with water for at least 15 minutes. Consult MSDS for guidance on appropriate first aid. Where medical attention is required, ensure to bring along MSDS(s) of chemical(s) to aid medical staff in proper diagnosis and treatment Fire and Emergency Evacuation Procedures: In case of fire or emergency situation and campus police. Immediately evacuate the building via the nearest exit when the fire alarm is activated. If unable to evacuate due to a disability, shelter in the area of rescue / refuge, typically a stairwell landing, and wait for assistance from drill volunteers or emergency responders. Instruct visitors and students to evacuate and assist them in locating the nearest exit. Do not use elevators to exit the building during an evacuation as they may become inoperable. Carry only those personal belongings that are within the immediate vicinity. Close doors to limit the potential spread of smoke and fire. Terminate all hazardous operations and power off equipment. Close all hazardous materials containers. Remain outside of the building until the building is released for reentry. Do not restrict or impede the evacuation. Convene in the designated grassy gathering area and await instruction from emergency responders or drill volunteers. Avoid parking lots. Report fire alarm deficiencies, (e.g., trouble hearing the alarm) to facilities personnel for repair. Notify evacuation drill volunteers or emergency responders of persons sheltering in the areas of rescue/refuge. Never assume that an alarm is a false alarm. Treat all fire alarm activations as emergencies. Get out of the building! Proper consideration of safety in handling and disposal of chemicals should be observed. The following points must be observed for this EIA report of Balaji Formalin Pvt. Ltd. 7-28

183 purpose. All hazardous and toxic chemicals must be identified. Material information sheets must be acquired and specific warning sign must be shown for potentially dangerous chemicals. In transport and transfer of chemicals, proper handling precautions provided by manufacturer must be observed. All containers for storage should be chemical resistant, leak free, and with good caps of stoppers. Gloves and goggles should be used while handling chemical of toxic nature. It is preferred that at least two persons should be present at all time while working with chemicals. Heating flammable solvent may cause fire. Such work must be carried out in a well-ventilation fume-cupboard. When your body is contact with the chemical, flush your body with plenty of fresh water and report the accident to the laboratory technician. Waste products and disposals must be discharged with proper neutralization. If the material to be disposed is extremely toxic or poisonous, the material should be kept in closed container and sent to appropriate agency for proper disposal ARRANGEMENTS FOR ENSURING HEALTH AND SAFETY OF WORKERS ENGAGED IN HANDLING OF TOXIC MATERIALS The significance of Safety & Health in chemicalindustries has been a vital issue in achieving productivity and quality standard. Following is an effort for safety and Health of workers working in chemical plant. Numbers of chemicals are used in plant have specific health hazards in nature. Following are basic fundamental principles properly underlie all the workers working in the plant. Occupational health and safety is about preventing people from being harmed by work or becoming ill from work by taking adequate precautions and providing a safe and healthy work environment. Consideration of each should be encouraged before beginning work as part of the culture of safety within the plant. Plan ahead. Determine the potential hazards associated with production. EIA report of Balaji Formalin Pvt. Ltd. 7-29

184 Minimize exposure to chemicals. Do not allow toxic chemicals to come in contact with skin. Provide proper ventilation devices to prevent/minimize airborne. Do not underestimate hazards or risks. Assume that any mixture of chemicals will be more toxic than its most toxic component. Treat all the chemicals as toxic substances. Be prepared for accidents. Before beginning of any batch reaction, know what specific steps to take which cause to accident if any hazardous substance release accidently. Proper follow SOP- Standard Operating procedure to take batch reaction. Unit will assess is careful examination of what, at work, could cause harm to workers. Accidents and ill health. All risks in the workplace must be identified and assessed for control measures to be put in place. Follow the five steps of hazard identification will be taken by unit namely; Identify the hazards Decide who might be harmed and how Evaluate the risks and decide on precaution Record your findings and implement them Review your assessment and update if necessary Following Information workers should know regarding hazardous chemicals We shall ensure that the employee is adequately trained with regard to: The contents of the hazardous chemical substances Potential source exposure to chemicals Potential risks to health caused by exposure Measures taken by the employer to protect employees against any risk from exposure Precautions to be taken by an employee to protect himself against the health risks associated exposure Correct use, maintenance of safety equipment, facilities and engineering controls Importance of good housekeeping at the workplace and personal hygiene EIA report of Balaji Formalin Pvt. Ltd. 7-30

185 Safe working procedures Procedures to be followed in the event of spillages or leakages 7.17 ON-SITE EMERGENCY PLAN General The emergency is an undesirable occurrence of events of such magnitude and nature that adversely affect business, cause loss of human lives and property as well as damage to the environment. Industrial units are vulnerable to various kinds of natural and man-made emergencies. Examples of Natural disasters are flood, cyclone, earthquake, lightening etc. and manmade disasters are major fire, explosion, sudden heavy leakage of toxic/flammable gases, building collapse, human errors, vehicle crash, sabotage, etc. It is impossible to forecast the time and nature of emergency, which might strike the unit. In spite of the fact that every industry is expected to take steps to assess, minimize and, wherever feasible, eliminate risks, accidents may still occur. Risks can only be minimized; it can never be totally eliminated. However, an effective emergency plan helps to minimize the losses in terms of human lives, plant assets and environmental damage and to resume the working condition as soon as possible. In all these steps speed is the essence. Controlling the emergency will require prompt action by the operating staff, the staff of various agencies, emergency teams and the outsiders when called for. Minimizing the effect on people may be achieved by prompt communication, rescue, evacuation etc., if the situation so warrant Statutory Requirement The provisions for preparing the on-site emergency plan are explained below: The Factories Act, 1948: Rules 68J(12), Schedule 8 A of the Gujarat Factories Rules 1963 (Amended 1995) providing that the every occupier, who has control of an industrial activity pertaining to hazardous chemicals shall furnish the On- Site Emergency Plan detailing how major accidents shall be dealt with EIA report of Balaji Formalin Pvt. Ltd. 7-31

186 along with explaining specific responsibilities and actions by various persons. The Environment (Protection) Act-1986: Rule 13(1) under the Manufacture, Storage and Import of Hazardous Chemicals Rule 1989 (amended 1994), rules framed under The Environment (Protection) Act-1986, indicates that the occupier shall prepare and keep up-to-date an on-site emergency plan containing details specified in schedule II and detailing responsibilities and actions by different person and agencies. Chemical Accidents (Emergency Planning, Preparedness and Response) Rule, 1996 Under these rules, framed under The Environment (Protection) Act-1986, the state government has constituted a Local Crisis Group & District Crisis Group to deal with major chemical accidents and to provide expert guidance for handling chemical accidents. Further provision is made that the Major Accident Hazard units have to prepare the on-site emergency plan and submit the plan to the crisis groups. The local emergency plan will dovetail with the District off-site emergency plan Preparedness of On Site Emergency Plan The On-site Emergency Plan describes planning, preparation and training for on-site action in the event of emergency. For On-Site Emergency Plan Advance planning and proper training of each employee s into the emergency function is very essential to make emergency control measure more effective. It is not possible to eliminate emergency but is definitely possible to control them. The scope of onsite emergency plan is to prepare for activate the emergency time activities, to controlled and contained within the shortest time if emergency arise after failure of our pre-emergency control measures. Following stage activities are consider for the purpose, as they are co-related and provide better points for emergency preparedness Emergency Time Activities It is not possible to include and discuss every action, which should be taken first during emergency. It is also not possible to describe entire EIA report of Balaji Formalin Pvt. Ltd. 7-32

187 actions on emergency situation. The basic principle of handling emergency, that may be relied upon, who have the knowledge and experience to assess the situation and give direction as per the objectives as quickly as possible. Sometimes, it is a natural gift and it is an art by heart. However, the aim is to control the situation by safest way in a limited time within existing available resources. Further, it should be handle with such a care that minimum loss of life, property and environment. In short, the objective of the plan should be successfully complied with Sequential actions during emergency Incident There are possibilities of occurrences of various types of the accidents or mishaps in the factory premises or around the factory. Most of the occurrences will be of minor nature, while few occurrences may be of major type. If the factory is fortunate enough, there may not be a single incident or mishap during its lifespan. However, when any incident occurs, it cannot be distinguished immediately whether it is minor or major, the subsequent development, or gravity of situation, or seriousness of such occurrence is required safe handling irrespective of its nature, if it cannot be controlled. It should be general practice that whenever any person notices the accident/fire/explosion/mishap at the site, he should immediately shout FIRE, FIRE or HELP, HELP and such message should reach to the Supervisor/Shift Officer/Senior Person of the unit Responding Actions The root cause of occurrence should be removed immediately if possible. Similarly, if any incident takes place in the premises, using available resources, within the factory as well as nearby, to their optimum, it should be so responded that the incident is contained immediately before spreading. If the incident looks severe and could not be controlled by simple efforts, the Shift Officer or Senior Personnel should rush to the place and make every effort to control the incident using various resources at the site. Further, if the incident is uncontrollable even using EIA report of Balaji Formalin Pvt. Ltd. 7-33

188 own resources, he should immediately call for additional helps form outside resources such as Mutual Aiders, Fire Brigade, etc. He should act the Incident Controller and immediately start the following actions: Sound the siren or ring the emergency bell. Take continuous responding actions with the use of other helps. Call the higher authorities and Site Main Controller Site Crisis On arrival, the Site Main Controller (Factory Manager) will take the charge of Incident site. He will immediately assess the situation and manage the Situation as site crisis. The incident can be said as on-siteemergency. Activate the emergency teams like fire team, first aid team, communication. Team, rescue team, essential workers, key personnel, etc. The Emergency control room will communicate the messages regarding Prevailing situation to requisite authorities, outside resources, agencies, neighbors, etc. Non-essential person will rush to safe shelter and roll call will be taken. He will order to shut down the plant, if situation so warrants. Now, if the situation is uncontrollable by the management of the unit, he will immediately call for the local crisis group to handle the situation Messages While conveying the messages regarding the incident, the following details should be incorporated. Brief description of incident Type of help required & direction Chemical involved & Quantity Action immediately taken Development of the incident EIA report of Balaji Formalin Pvt. Ltd. 7-34

189 Discipline The plan assuming certain discipline at site during emergency, as follows; Do not get panicky. Do not approach the site of incident as an observer. Do not engage telephone unnecessary. Do not move about unnecessary. Do not approach unnecessarily for information or more inquiry. Arrange medical first aid care to the injured. Do not allow unnecessary crowd nearby incident Emergency Actions On receiving information, the Emergency Control Centre will activate and urgently establish the contact with the required persons, agencies and authorities. The essential workers, responsible to carry out certain specific functions, will have to start work immediately. The non-essential workers should go to the assembly center. The cordoning the incident area will be ensured. The water should be sprayed on the flammable storage tank, even if not caught under fire. The experts for the responding to emergency situation will be consulted, if required. vii. Authentic information for incident will be provided to Press/Public by the authorized officer only. Removal the flammable, dangerous material, cylinders, etc. should be arranged along with isolation from fire. The trapped personnel, if any, in incident will be rescued. All assistance will be provided to the Fire Brigade to control spreading of fire. Any remotest possibility of re-ignition or explosion should be looked into and controlled Shut Down Procedure It is advisable to shut down the plant for safety, if situation so warrants. The safe shut down procedure should be adopted during such eventualities. First of all, main electrical supply should be cut-off/switch- EIA report of Balaji Formalin Pvt. Ltd. 7-35

190 off. Similarly, the pipelines supplying flammable gas, liquid or chemicals should be immediately shut-off by valves and should be isolated from the process line. The water shower on flammable storage tank, if installed, to be started to keep it in cool condition, if tank is in vicinity of fire. The shutdown procedure should be laid down in the process manual, which will be useful during such emergency Post Emergency Activities Post emergency activities comprise of step taken after the emergency is over. To Find out the reason of emergency after the investigation and suggest the preventive measure. For the investigation different level personnel from different dept., are selected and an investigation team is formed. The following steps are taken after the emergency is over. Collection of record Conducting the investigation/inquiry committee with the suggestion for preventive measure Making the insurance claim and necessary procedure Implementation of the recommendation of inquiry reports Rehabilitation of the affected persons within the plant and outside the plant. They are in continuous touch with the hospitalized person and give status report of them to the top management. Restart the plant if shut down happened Training, rehearsal and records Need of Training & Rehearsal Extensive experience in the chemical industry with on-site emergency planning has proved the need and value of rehearsal of emergency procedures. When finalized, the major emergency procedure should be set down in clear, concise terms and everyone on-site made aware of them, particularly the key personnel and essential workers. They should then be put to the test. This may best be done by arranging a series of preliminary exercises to test certain system, including the alternative arrangements in cases of failure. The speed of Mobilization of the factory emergency teams, search & rescue and treatment of casualties, emergency isolation and shut down procedures. These exercises will help EIA report of Balaji Formalin Pvt. Ltd. 7-36

191 to define the procedures by identifying deficiencies and difficulties. At this stage, more exercises that are elaborate can be planned to involve the outside services who should be closely involved at the planning stage. Each exercise should at various positions, e.g. At the scene, the emergency control center, work entrance; assemble points or casualty reception area. A following round-the-table discussion between managers, senior officers of the emergency services, factory inspectorate and observers will further assist to develop practical and effective procedures. It is recommended that a major emergency exercises should be conducted at regular intervals with arrangement with the outside agencies. There is much practical advantage to be gained in situations where people required working together in handling emergencies are already known to each other. Close local liaison and combined exercises are invaluable in this respect. At the same time, familiarization visits to works especially of the fire service personnel, will help enormously to acquaint with the works layout and the nature of potential hazards. Emergency plans need to be tested when first devised and thereafter to be rehearsed at suitable intervals. Their normal training and experience in day-to-day operation will generally qualify individual personnel with duties under the plans. Some duties, however, such as firefighting for the works fire team are not routine and special training will be needed. In addition, key personnel will need training in their emergency roles both individually and as a team. For the professional emergency services the general training may be taken for granted. Rehearsals or exercises are important for all personnel likely to be involved in an incident on or off-site because, for example: They familiarize on-site personnel with their roles, equipment and the details of the plans. They allow the professional emergency services to test their parts of the plan and the co-ordination of all the different organizations. They also familiarize them with the special hazards. EIA report of Balaji Formalin Pvt. Ltd. 7-37

192 They prove the current accuracy of the details of the plan [phone no., etc.] and the availability of special equipment. They give experience and build confidence in the team members. In the initial shock and confusion of a real incident, ability to fall back on established initial actions is invaluable. Employers should ensure that the on-site emergency procedures for such process plants, storage facility, etc. are tested regularly and that all employees receive initial and refresher training. Exercises should be arranged to test each part of the emergency plan on each plant, state by state, starting with first immediate action. Emergency isolation and shut down should be rehearsed from the emergency services, the emergency planning officer [EPO] should be invited to attend on-site exercise, and familiarization visits should be encouraged. The complete plan for each site including both on-site and off-site components should be tested. Many organizations now use tabletop exercises to test emergency plans. These are very cost effective because they do not interrupt the day-today running of the plant and because many events can be catered for in one session. However, they are theoretical in nature and should be communications and key personnel working from the locations they would use in an emergency. It is, of course, essential that the exercises be carefully prepared, the results analyzed and the lessons learned, circulated and discussed. Full-scale practices involving all concerned that all reasonably practicable measures have been taken. After each rehearsal of practice, the plan should be reviewed to take account of any shortcomings highlighted by the exercise. In addition, its effectiveness should be reviewed every time it is used to with a real emergency. Fix your periodicity to carry out table tope exercises and real rehearsal of this on-site and off-site emergency plan, including mutual aid agencies and mention here in this chapter OFF-SITE EMERGENCY PLAN Need of Off-Site Emergency Plan A major accident, major emergency and disaster may affect areas outside the works. Explosions can scatter debris over wide areas, the effects of EIA report of Balaji Formalin Pvt. Ltd. 7-38

193 blast can cover considerable distances wild can spread burning brands of toxic gases. In some cases, e.g., as the result of an explosion, outside damage will be immediate and part of the available resources of the Emergency Services may need to be developed in the affected area. In any event, the possibility of further damage any remain, e.g., as the result of further explosion or by the effect of wind spreading burning brands of hazardous materials. Perhaps the most significant risk to outside areas is that associated with a large release of toxic vapors. Management will usually need expert advice in drawing up plans so that if such a release occurs, they will be able to collaborate with Emergency services to estimate as far as practicable which downwind areas are at the risk. It may be necessary to prepare in advance simple charts or tables relating the likely spread of the vapor cloud taking into account its expected buoyancy, the local topography and all possible conditions during the time of release. It may also be desirable to install instruments indicating wind speed and direction. Advice on all these matters can be obtained from the Meteorological office. The fact of the major emergency and the spread or potential spread of its effects outside the work may require that road and rail traffic past the works has to be halted or diverted. The police, taking account of the advice of the Site Main Controller. They will also, where necessary, inform the Rail. The problem is usually exacerbated by members of the public driving to the scene to view the situation. The net effect can be cause problems to those who have a real need to get to the works, including the key personnel who will have been called out. Liaison at local level will help to devise a means whereby key personnel can readily identify themselves to the police controllers. The use of a windscreen sticker of other identify label may be advantageous. All emergency plans should consider the possible effects of incidents on the neighboring population and the remedial measures should be devised in consultation with the local authority and emergency services. The offsite emergency plan should be based on those events identified by the manufacturer, which could affect people and the environment outside his EIA report of Balaji Formalin Pvt. Ltd. 7-39

194 premises. The manufacturer should provide the necessary information on the nature, extent and likely effects of such incidents. The plan should cater in detail for those events identified as being the most likely but should be sufficiently flexible to allow the remedial measures to be able to be extended and increased to deal with extremely adverse combinations of circumstances and consequences. The factory inspectorate and the local authority should be satisfied that the information provided is sufficiently detailed unambiguous and clearly stated to be comprehensible and for the dangers to be provided. Several different planned responses may be necessary at a single site depending on the size and characteristics of the incidents. Thus in brief the two main purposes of the off-site emergency plant are: To provide the local/district authorities, police, fire brigade, doctors, surrounding industries and the public the basic information of risk and environmental impact assessment and to appraise them of the consequences and the protection/ prevention measures and control plans and to seek their help to communicate with the public in case of a major emergency. This information from every industry enable the District Authorities to educate the public that what can go wrong the measures taken to train them of their individual role in case of emergency, and To assist the District Authorities for preparing the off-site emergency (Contingent) plan for the district or particular area and organize rehearsals from time to time and initiate corrective action bases on the lessons learnt. In charge of the on-site Emergency plan of the Site Main Controller will keep liaison, for this purpose, with the District Authorities Role of the Factory Management The on-site and off-site plans should dovetail so that the emergency services are summoned at the appropriate time and are provided with accurate information and a correct assessment of the situation. The responsibility for this should be with the Site Main Controller. The site main controller will provide a copy of this on-site and off-site emergency EIA report of Balaji Formalin Pvt. Ltd. 7-40

195 plans to the District Authorities, the factory inspectorate and the emergency services so that from information from the various annexure, such authorities will make their emergency preparedness to formulate and execute the District/Area off-site Emergency Plan. On their advice, necessary modifications may also be made to make the plan more perfected Role of the Emergency Co-ordination Office (ECO) The various emergency services will be co-coordinated by an emergency co-coordinating officer (ECO) who is likely to be a senior police office, but depending on the circumstances, could be a senior fire officer. The ECO will liaise closely with the Site main controller. Again, depending on local arrangements, for every severe incident with major or prolonged off-site consequences, the external control may pass to a senior local authority administrator or even an administrator appointed by the central or state government. The emergency control Center of the factory or/and any other control centers may be utilized by the ECO to keep liaison with the site main controller Role of the Local Authority Generally, the duty to prepare the off-site plan lies with the local authorities. They may have appointed an Emergency Planning Officer (EPO) to carry out this duty as part of the EPO s role in preparing for a whole range of different emergencies within the local authority area. The EPO will need to liaise with the works to obtain the information to provide the basis for the plan. This liaison will need to be maintained to ensure that the plan is continually kept up to date. It will be the responsibility of the EPO to ensure that all those organizations, which will be involved offsite in handling the emergency, know their role and are able to accept it by having for example, sufficient staff and appropriate equipment to cover their particular responsibilities. Rehearsals for off-site plans are important for the same reasons, as on-site plans will need to be organized by the EPO. It will be the duty of the local authority to inform public, road/rail traffic, news media, etc., while operating off0site plan. It will also announce EIA report of Balaji Formalin Pvt. Ltd. 7-41

196 public protection measures; termination public awareness system will be developed. The ILO suggestion of separation distances is useful for planning (Proposed development) by the local authorities Role of the Fire Authorities The control of a fire is normally the responsibility of the senior fire brigade officer who would take over the handling of the fire from the incident controller on arrival at the site. The senior fire Brigade Officer may also have a similar responsibility for other events, such as explosions and toxic releases. Fire authorities having major hazards works in their area should have familiarized themselves with the location on site of all stores of flammable materials, water and foam supply points, and fire-fighting equipment. They may well have been involved in on-site emergency rehearsals both as participants and, on occasion, as observers of exercises involving only site personnel Role of the Police and Evacuation Authorities The police normally assume the overall control of an emergency, with a senior officer designated as emergency co-coordinating officer. Formal duties of the police during an emergency include protecting life and property and controlling traffic movements. The functions include controlling by standers, evacuating the public, identifying the dead and dealing with casualties, and informing relatives of dead or injured. There may be separate authorities, agencies to carry out evacuation and transportation work. For evacuation, the following criteria are useful: An early decision will be required in many cases on the advice to be given to people living within range of the accident in particular whether they should be evacuated or told to go indoors. In the later case, the decision can regularly be reviewed in the event of an escalation of the incident. Consideration of evacuation may include the following factors: In case of major fire but without explosion risk (e.g. on oil storage tank), only houses close to the fire are likely to need evacuation. Although a severe smoke hazard may require this to be reviewed periodically. EIA report of Balaji Formalin Pvt. Ltd. 7-42

197 If a fire is escalating and in turn threatening a store of hazardous material, if might be necessary to evacuate people nearby, but only if there is time; if insufficient time exists, people should be advised to stay indoors and shield themselves from the fire. This later case particularly applies if the installation at risk could produce a fireball with very severe thermal radiation. For releases or potential releases of toxic materials, limited evacuation may be appropriate downwind if there is time. The decision would depend party on the type of housing at risk Conventional housing of solid construction with windows closed offers substantial protection from the effects of a toxic cloud, while shanty houses which can exist close to factories, particularly in developing countries, offer little or no protection. The major difference between releases of toxic gas is that toxic clouds are generally hazardous down greater distances. Also a toxic cloud drifting at, say, 300 meters per minute covers a large area or land very quickly. Any consideration of evacuation must take this into account. The shelters for evacuated persons and their welfare shall also be arranged Role of the Health Authorities Health authorities, including doctors, surgeons, hospitals, ambulances and so on, have a vital part to play following a major accident, and they should form an integral part of any emergency plan. For major fires, injuries will be the result of the effects of thermal radiation to a varying degree, and the knowledge and experience to handle this in extreme cases may be generally available in most hospitals. For major toxic releases, the effects vary according to the chemical in question, and it is important for health authorities who might be involved in dealing with the aftermath of a toxic release to be familiar with the treatment appropriate to such require medical equipment and facilities additional to those available locally, and a medical mutual aid scheme should exist to enable the assistance of neighboring authorities to be obtained in the event of an emergency. EIA report of Balaji Formalin Pvt. Ltd. 7-43

198 Role of the Mutual Aid Agencies Various type of mutual aid available from the surrounding factories and other agencies should also be utilized, as per need, as a part of the onsite and off-site emergency plan Role of the factory Inspectorate The factory inspectors are likely to want to satisfy themselves that the organization responsible for producing the off-site plan has made adequate arrangements for handling emergencies for all types, including major emergencies. They may wish to see well-documented procedures and evidence of exercises undertaken to test the plan.in the event of an accident, the factory inspector will assist the District Emergency Authority for information and help in getting mutual aid from surrounding factories. In the aftermath, factory inspectors may wish to ensure that the affected areas are rehabilitated safely. In addition, they may require items of plan and equipment essential for any subsequent investigation to be impounded for expert analysis, and may also want to interview witness as soon as practicable. In the state of Gujarat, District Emergency Control (Contingent) plans have been formulated, and some rehearsed, for some districts and the copies are available from the local factory inspectorate. All hazardous factories needing on-site and off-site emergency plans are advised to keep constant liaison with them. The communication system between the factory and various above roleplaying authorities must be effective. Ineffective public telephone system will not be useful in emergencies. Therefore, it should be improved and other effective system like duplex (two way) radio telephone, wireless set, hot line, emergency lead vehicles, etc., should be maintained between important organizations DISASTER MANAGEMENT PLAN/EMERGENCY MANAGEMENT PLAN Balaji plant at Moti Bhoyan is an expansion project. The Risk Assessment report has been prepared based on the risks and hazards identification of the plant. Balaji is a medial scale plant employing only 55 personnel (after expansion) However, basic requirement of emergency EIA report of Balaji Formalin Pvt. Ltd. 7-44

199 planning and subsequent actions (Incase of emergency) will be same. Balaji has to delegate responsibilities to various employees as per plant personnel set up. The EMP proposed is for guidance for preparing EMP as per plant set up and submitting to authorities for approval, mock drill and further improvement. Admittedly, the best way of managing an emergency situation lies in its prevention. This is sought to be achieved by good engineering design and construction, use of latest technology and sophisticated equipment, reliable safety systems, careful personnel selection and training. Adequate knowledge of dangers and appropriate safety training ensures that all hazardous situations will be handled without any panic and controlled by rational actions. This is supplemented with repeated practices through real time exercises (mock drills) and noting the weak spots and taking needful corrective actions. Nevertheless, it is recognized that despite our best efforts, things can go wrong. Therefore, it is essential to plan and develop the support system, required in case an emergency arises Objectives The Emergency Management Plan (EMP) is developed to make the best possible use of the resources available at Balaji and the nearby agencies to provide help/assistance in case of an emergency in the plant. The activities will include: Rescue the victims and give them the necessary medical attention in the shortest possible time. Safeguard other person (evacuate them to a safer place). Contain the incident and control it with minimum damage to human and life and property. Provide necessary information to families/relatives of affected persons, outside agencies including media and statutory bodies Emergency Management Plan The organizational set-up necessary for chain of commands during emergency situation in the plant is as given below. EIA report of Balaji Formalin Pvt. Ltd. 7-45

200 In charge (Operations) of the Balaji is the Chief Emergency Coordinator and he shall be the main guiding person directing the emergency operations. He shall be assisted by: Chief Site Coordinator. In charge (Production) Coordinate and direct all the activities from Emergency site. In absence ofincharge (Prod.), next In charge (Prod.) will act as Chief Site Coordinator. In charge-maintenance Coordinate all the maintenance activities from the EmergencyControlCenter (ECC). In absence of Incharge (Maint.), next personwill act as Chief maintenance Coordinator. Chief Service Coordinator Incharge (HR) Coordinate with local administration take care of transport, medical,canteen arrangements, and evacuation of people if required. In absence of Incharge(HR), next person (P&A) will act as Chief Service Coordinator. Chief Material Coordinator Incharge (Material) In absence of Incharge (Material), next person (Material) will act as Material Coordinator. Fire & Safety Controller Incharge (F&S) In absence of Incharge (F&S), Supervisor. (F & S) will act as Fire & Safety Controller and also for first aid. Two Assembly Points will be identified (based on wind direction and away from hazardous areas) and duly marked. Format for Telephone Numbers of the Authorities: DISASTER MANAGEMENT KEY PERSONNEL - OFFSITE EMERGENCY RESPONSE OFFICERS PLACE OFFICE RES. DIVISIONAL COMMISSIONER EIA report of Balaji Formalin Pvt. Ltd. 7-46

201 COLLECTOR & DISTRICT MAGISTRATE CITY MAGISTRATE DY.I.G. OF POLICE SUPDT.OF POLICE POLICE CONTROL ROOM (CITY) POLICE STATION KALOL INDUSTRIAL AREA DY CHIEF INSPECTOR OF FACTORIES GUJARAT POLLUTION CONTROL BOARD FIRE BRIGADE, KALOL HOME GUARD NEAREST CIVIL HOSPITAL (CHIEF MEDICAL SUPTD) Responsibilities & Role of Key Personnel Over all In-charge Incharge (Operation) On getting the information about emergency from Incharge (Prod.) rush to incident site/ecc. Assess the overall situation and provide guidance in critical decision-making. Chief Site Coordinator- Manager (Prod.) On getting the information about emergency from Supervisor Plant, inform over all In-charge P (O). Rush to the emergency site to assess the situation and decide to: o Declare emergency based on amount/extent of hazards and water/air analysis (toxic/flammable material release) and advise Incharge (F&S) for sounding emergency siren. o Review if plant shutting down is required to contain / control the hazard. o Review, evacuation from affected areas and sending the affected person to a safe place. o Advise Incident Controller and other key personnel to take necessary action. o He will interact with Chief Service Coordinator and advise him on possible effects on areas inside and outside the factory to initiate Off- Site Emergency Response Plan. EIA report of Balaji Formalin Pvt. Ltd. 7-47

202 o Remain in touch with Overall in-charge (P -O) and inform about the situation & actions being taken and seek his advice for the critical decisions. Chief Maintenance Coordinator- Incharge (Maintenance) After getting information about emergency from manager concerned Plant. Inform all concerned personnel to be on alert. Rush to the ECC, assess the situation and facilitate Chief Site Coordinator-Incharge (Prod.), Maintenance support needed to tackle the emergency. Facilitate elect. isolation of the affected area, if required through Supervisor (E&I) Facilitate lighting arrangements at (a) affected locations and (b) Assembly points if required through Supervisor (E&I) Facilitate work-shop facilities with adequate manpower if required through supervisor (Maintenance). Remain in touch with Chief Site Controller. Chief Service Coordinator - Incharge (HR) On getting information from the Medical Coordinator rush to the Emergency Control Centre. Assess the situation in consultation with Chief Site Coordinator and Incident Controller and ensure that casualties get adequate transport / medical help. Make arrangement to shift all the persons to the safest place if called for. Assess 'Law and Order' situation. Inform local authorities about the severity of situation in close coordination with Chief site Coordinator and in consultation with Overall In-charge -P (O). Inform the District Authority/local police station in case their help is required for evacuation of personnel/preserving law and order. Evacuation of adjoining areas and villages, if required. Remain in touch with overall In-charge - P (O) and seek his advice for the critical decisions. EIA report of Balaji Formalin Pvt. Ltd. 7-48

203 Chief Material Coordinator-Incharge (Materials) Rush to the emergency control centre on receipt of the message from Chief Service Coordinator/on hearing the emergency siren and inform Supervisor. (Store) about the emergency. Get the stores opened for requirement of the Firefighting/safety and other materials, which may be required during emergency. Assess the situation in consultation with Chief site coordinator & incident controller for any material requirement /help at the affected site. He will be responsible for the arrangements of trucks for movement of bulk material if required. Remain in touch with Chief site coordinator, Incident controller, and Chief maintenance coordinator. Incident Controller Concerned Plant SupervisorConcerned Plant o Rush to the site of emergency after getting information from Shift Incharge assesses the situation and immediately inform Incharge Prod. Take over charge from shift in charge. Ensure that persons working in the area are safe and isolate source of toxic release if possible. Advise and assist Incharge (F&S) for providing water curtains to contain toxic release with in the plant battery. Remain in touch with Chief Site Controller and other concerned officers. Coordinate with Chief Maintenance / Chief Material coordinators forassistance required at site. Depending upon the severity of incident, ensure that adequate emergency services like Medical/ Laboratory/ Mechanical/ Electrical etc.are summoned. Preservation of evidence as far as possible without affecting the operation of emergency procedures to facilitate any subsequent inquiries into the causes and circumstances, which led to the emergency. EIA report of Balaji Formalin Pvt. Ltd. 7-49

204 Shift In charge (Concerned Plant): Immediately proceed to the site of emergency and assess the situation: o Emergency Control Room (with name and location of emergency) During odd hours/till arrival of Fire shift I/C should act as chief fire coordinator. Initiate the shutting down operations for controlling the hazard if unavoidable. Cordon off the area and do not allow any body to enter the affected area without respiratory protection (In case of toxic gas leakage). Direct rescue operations with the help of fire and safety staff. Have regard to the need for preserving evidence that could facilitate subsequent inquiry. Advise Supervisor of the plant to take roll call and account for missing personnel. Hand over charge of the operation to thesupervisor when he arrives at site. Ensure service agencies like Electrical, mechanical, instrumentation are mobilized to handle the emergencies. Security Officer Vehicle Control and Security Personnel Deployment at the locations Rush to the spot of emergency on getting information from Security Officer on duty and inform Incharge (HR) about emergency. Arrange one emergency vehicle immediately for ECC. Keep in touch with Chief Service Coordinator, Chief Site Coordinator and Incharge (F&S). He will act as a special rescue Coordinator at the time of evacuation of employees and others if required. Alerts complete staff under his control and make it available at a known point, as per the guidance of Chief Site Coordinator/Chief Service Coordinator. EIA report of Balaji Formalin Pvt. Ltd. 7-50

205 Anticipate and arrange vehicles required at emergency site in consultation with Incharge (F&S) and Chief Site Coordinator and Chief Service Coordinator. On request send vehicles for getting plant personnel/fire personnel required for emergency. Arrange vehicle in consultation with Medical Coordinator/Chief Service Coordinator for shifting injured to Kalol hospital. During emergency arrange for opening of relevant gates/barriers foreasy movement of vehicles. Security Guards should be posted on these gates/barriers to prevent unauthorized entry. Arrange transport and temporary shelters for evacuated personnel and inform the relatives of the affected personnel if required. Fire & Safety Controller-Incharge (F&S) Rush to the spot of emergency after getting information from ECC and inform to Supervisor (F&S). Direct rescue operations under the guidance of Chief Site Coordinator/Incident controller if required. Ask additional help from C.S.O. for cordoning off the area and advise fire personnel for rescue/firefighting if required. Arrange to provide water curtains, water monitors, at affected locations if required. Organize and supervise fire-fighting operations if called or. Provide necessary respiratory equipment to plant personnel for emergency use. Advise Chief Site Coordinator to arrange additional help Mutual aid group/neighboring industries if required. Give safety precautions to the personnel at rescue work. Fire Control Room In-Charge On receiving emergency message from the Incharge (F&S)/on hearing siren, rush to ECC and take charge of Fire Control Centre from the fire operator/fire supervisor. Assess the situation and Call fire staff from fire barrack. Immediately rush fire crew to emergency spot. EIA report of Balaji Formalin Pvt. Ltd. 7-51

206 Inform Medical Centre for sending ambulance to emergency site. Fire Supervisor should also ensure the following: Supervisor to look for the wind direction and cordon off the area. Use water monitors/hydrants/water curtains in consultation with incident/chief site controller. Provide respiratory equipment s to the plant personnel. In case of toxic spillage at site, put foam (HAZMAT)/sand on the spillage area. Remain in touch with Incharge (F&S). Chief Site Co-coordinator will instruct Fire Control Room In-charge for operation of All Clear Siren when the disaster is contained/ controlled. However, regular testing of siren & emergency buzzer plant control rooms for 2 minutes on every Monday at hrs. is being done.all clear siren will sound for 2 minutes with a continuous sound Post Emergency Recovery The post-emergency procedures discussed briefly below are designed to successfully manage the damage/losses of an emergency event. The focus of these procedures is to move the plant back into normal operating mode as quickly and efficiently as possible. Immediately after the ALL CLEAR an emergency meeting will be held in emergency control centre to assess the loss both for men & materials, where in following will be present with attendance records, details of injured, outside situation and preparation of press release (if felt necessary) Overall In charge Chief Site Coordinator Chief Maintenance Coordinator Chief Service Coordinator Incident Controller Material Coordinator Security Fire & Safety Controller EIA report of Balaji Formalin Pvt. Ltd. 7-52

207 Accident Investigation a. As soon as possible after the emergency is over and plant operation has become normal, the investigation and analysis is to be carried out to determine the cause of the event. b. Representatives from various disciplines will be members of the investigation and analysis team. c. The areas of the events are to be sealed off so that tempering or alterations of the physical evidence are not likely to occur. d. Key components are to be photographed and logged with time, place, direction etc. e. Statements are to be taken from those who were involved with the operation or who witnessed the event Damage Assessment This phase of recovery establishes the quantum of replacement machinery considered necessary for bringing back plant to normal operation; property and personnel losses accounted and culminates in a list of necessary repair, replacement and construction work. Insurance companies will be informed of the damage and requested to pay the compensation as per claim Cleanup and Restoration This phase will only begin once the investigation is complete. Reporting documentations are to be prepared and forwarded to appropriate authorities. Repair, clean up and restoration work to begin. EIA report of Balaji Formalin Pvt. Ltd. 7-53

208 B) Social Impact Assessment No any negative Social Impact envisaged from the proposed expansion project activities. In fact, positive Social impact was prevail during the study of Sociological data because, necessity for unskilled and skilled person will increase for proposed activities and unit will accord opportunity first prior to the local people. There will be no R & R due to proposed activities. C) Public Consultation The public hearing will be conducted as per the TORs condition and outcome of public hearing will be incorporated. EIA report of Balaji Formalin Pvt. Ltd. 7-54

209 Chapter-8 Project Benefits 8.1 Introduction All industrial projects have positive and negative effects on nearby locations due to its operational activities. This chapter mainly highlights and focuses on those points which will become beneficial to the surrounding area or community in terms of infrastructural development, social development, boosting employment and other tangible benefits due to upcoming or proposed activities. The proposed expansion project has a potential for employment of skilled, semi-skilled and unskilled employees during construction phase as well as operational phase. Followings are the benefits that surrounding area will get due to the expansion activities: 8.2 Improvements in the physical infrastructure including technical facility aspects: Physical infrastructure includes infrastructural & technological facilities of the project, necessary for the operation. Unit is already in existence and has well developed physical infrastructural facilities; however, due to the expansion of the project, minor construction work, modification of plant building will be done. Thus, following infrastructural facilities will be developed due to proposed expansion: Improvement in local amenities facilities Improvement in road link facilities as transportation through truck and other vehicles will increased due to expansion of project Improvement in local civilization Increase income of local population Increase requirement of man power 8.3 Improvement in Social Infrastructure: Due to proposed expansion activity, Social Infrastructure will improve by means of Civilization, Vocational Training and Basic Amenities. EIA report of Balaji Formalin Pvt. Ltd. 8-1

210 Civilization: Due to expansion; employment and other infrastructural facilities will boost up income of surrounding people and improve quality of life. This will indirectly boost up the civilization of the surrounding people. Vocational Training: Moreover, unit will provide vocational training opportunity to the surrounding people and greed for employment will motivate the education activities that will lead the change in life style of the surrounding and affected people hence social infrastructure will be improved. Basic Amenities: Better education facilities, proper health care, road, infrastructure and drinking water facilities are basic social amenities for better living standard of any human being which will further augment the above amenities either by providing or by improving the facilities in the area, which will help in uplifting the living standards of local communities. 8.4 Employment potential Due to the expansion project, infrastructure will get improved and enhance the employment opportunity for both skilled and unskilled person from nearby area. Direct employment as well as indirect employment due to ancillary services will be given to the local people. Therefore, the socio-economic status of the local people will get improved. The details of employment opportunity during Construction and Operation phase are discussed underneath: Increased employment opportunity in Construction phase: Construction work and commissioning will require manpower and resources. The unit has proposed to employ local contractual labor force for this phase. Hence with the inception, project may lead to slight growth in the social status & improvement of the quality of life in the surrounding area. Increased employment opportunity in Operation phase: After expansion, total nos. of employee will be 55 nos. This will ultimately boost the employment opportunity. EIA report of Balaji Formalin Pvt. Ltd. 8-2

211 8.5 Other tangible benefits: Moreover, unit will provide vocational training opportunity to the surrounding people that will provide educational help & increase the knowledge of the surrounding people. EIA report of Balaji Formalin Pvt. Ltd. 8-3

212 Chapter-9 Environmental Cost Benefit Analysis 9.0 ENVIRONMENTAL COST BENEFIT ANALYSIS As per EIA Notification 2006, this Chapter of the Environmental Cost Benefit Analysis is applicable only if it is recommended at the Scoping stage. As per the ToR points issued by MoEF&CC, New Delhi vide File No. J-11011/67/2015-IA II (I) & ToR Letter dated 22 nd June, 2015, the Environmental Cost Benefit Analysis is not applicable and hence has not been prepared. EIA report of Balaji Formalin Pvt. Ltd. 9-1

213 10.1 INTRODUCTION San Envirotech Pvt. Ltd., Ahmedabad Chapter-10 Environment Management Plan Assessment of environmental and social impacts arising due to implementation of the proposed project activities is at the technical heart of EIA process. An equally essential element of this process is to develop measures to eliminate, offset or reduce impacts to acceptable levels during implementation and operation of projects. The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental Management Plan (EMP). From the previous chapter it can be said that the proposed expansion project of M/s. Balaji Formalin Pvt. Ltd. has very less pollution generation in terms of water, air and hazardous waste generation. For abatement of environmental pollution, the unit would adopt several measures, which are summarized in this chapter. M/s. Balaji Formalin Pvt. Ltd. is the existing unit and equally concern for production as well as pollution control. The unit has already done the homework to develop the efficient Environmental Management Plan for existing set up and plan for proposed expansion OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN The objectives of the Environmental Management Planare summarized here under, To limit/reduce the degree, extent, magnitude or duration of adverse impacts. To treat all the pollutants i.e. liquid effluent, air emissions and hazardous waste with adoption of adequate and efficient technology To comply with all the norms and standards stipulated by Gujarat Pollution Control Board/Central Pollution Control Board. To create good working conditions. To reduce any risk hazards and design the disaster management plan EIA report of Balaji Formalin Pvt. Ltd. 10-1

214 Continuous development and search for innovative technologies for a cleaner and better environment COMPONENTS OF EMP EMP for the proposed project of Balaji Formalin Pvt. Ltd. covers following aspects: Description of proposed mitigation measures for proposed operation phase only Description of monitoring program Institutional arrangements Implementation schedule and reporting procedures All above aspects and objectives are kept in the view and considering the same EMP is prepared for two major fields Environmental Management systems M/s. Balaji Formalin Pvt. Ltd. is well aware of environmental requirements for planning and implementation of the project and set up a department with trained personnel headed under the qualified manager. As indicated in the Chapter-4 of this report: Environmental Impacts and Mitigation Measures, the environmental impact due to the proposed project is almost negligible Environmental, Health and Safety Management System Chemical Industries prefer an integrated approach and make environmental management a part of overall Environment, Health and Safety (EHS) Management system. This model EHS system suggests and addresses EMS issues such as: Management system expectation Management leadership, responsibilities and accountability Risk assessment and management Compliance and other requirements Personnel, training and contractor services Documentation and communications Facilities design and construction Operation, maintenance and management Community awareness and emergency response EIA report of Balaji Formalin Pvt. Ltd. 10-2

215 EHS performance monitoring and measurement Incident investigation reporting and analysis EHS management system audit Management review and audit With this type of EHS management approach, proposed expansion project would be able to integrate the requirements of ISO & ISO into the overall management system Environmental Management Cell Apart from having an environmental management plan, it is also necessary to have a permanent organizational set up charged with the task of ensuring effective implementation. In this effect, unit has already assigned responsibilities to officers from various disciplines to co-ordinate the activities concerned with management and implementation of environment control measures. An organogram of Environment management is shown in Figure Basically, this department undertake monitoring of environmental pollution level by measuring stack emissions, ambient air quality, effluent quality, Noise level, etc. either departmentally or appointing external agency whenever necessary ENVIRONMENTAL MANAGEMENT DURING CONSTRUCTION PHASE Since the proposed expansion project of M/s. Balaji Formalin Pvt. Ltd. for formaldehyde, Paraformaldehyde and purification of silver matal will be carried in the existing premises, construction activities will be required only for the installation of new plant and machineries. Hence, there will be some adverse impacts on the quality of air and water but, this will not cause adverse effects on the surrounding atmosphere. No disposal of construction waste outside the plant and no leaching are anticipated. The impact will be temporary and negligible. The construction activities for installation work shall generate noise anddust within working areas. Therefore, measures will be taken to protect workers. In order to mitigate the adverse environment impacts during the construction phase, regular sprinkling of the water will be done. EIA report of Balaji Formalin Pvt. Ltd. 10-3

216 10.5 ENVIRONMENTAL MANAGEMENT DURING OPERATIONAL PHASE Air Environment The unit has already adopted modernized techniques for production of Formaldehyde and same successful technology will be used for proposed expansion. Tail gas treatment plant is integral part of process plant. It will be updated/modify along with process plant after expansion. No additional stack/vent to emit air pollution in atmosphere except stack of D. G. set which will not operate regularly. The estimated tail gas quality is given in Table-2.8. However, in order to achieve the reduction, it is suggested that during operational phase, proper air flow will be maintained to ensure proper combustion and subsequent minimization of any unburned combustibles. For this, combustion process may be further improved by adopting following measures. Optimization of combustion aerodynamics should be done using a flame retention device. Re-circulation of flue gas may be considered to achieve the triple goals of low PM emissions, low NO X emissions and high thermal efficiency. Primary flame zone O 2 level should be decreased by decreasing overall O 2 level, controlling (delaying) mixing of fuel and air and use of fuel-rich primary flame zone. The tail gas treatment plant will be adequate to reduce the pollution of formaldehyde, methanol and methane to atmosphere. There will also be recycling of combustion heat which is very effective to reduce pollution discharge and take advantage of wasted energy. The unit has also provided adequate stack monitoring facilities for the periodic monitoring of the stack to verify the compliance of the stipulated norms Measures for fugitive emissions The fugitive emissions may be from leakage through valves, fittings, pumps, etc. Continous processes will furhter help to reduce fugitive emmision because repitally valve on/off is not required which helpful to maitain practically zero leckages. EIA report of Balaji Formalin Pvt. Ltd. 10-4

217 Good house-keeping, proper maintenance and continuous observation will prevent the chances of any fugitive emission from the process plant. However, unit will adopt adequate measures for the minimization/ prevention of the fugitive emission. The unit proposes to adopt following measures, which will be continued after the production starts. Regular maintenance of valves, pumps and other equipments to prevent leakage and thus minimize the fugitive emissions of VOCs. Entire process will be carried out in the closed reactors with proper maintenance of pressure and temperature. Regular periodic monitoring of work area to check the fugitive emission. M/s. Balaji Formalin Pvt. Ltd. will strictly follow design features as suggested in Table 10.3 for new equipment may be considered Water Environment Total water requirement due to proposed expansion will be increased from 129 KLD to 610 KLD (535 KLD fresh water + 75 KLD recycle water) out of which industrial water requirement will be 598 KLD (523 KLD fresh water + 75 KLD recycle water). After proposed expansion water requirement will be satisfied through Narmada Water. The unit proposes to practice of maintaining the records for the total water withdrawal from various resources and consumption at various levels in the plant. As mentioned in the previous chapter, the only source of industrial wastewater generation is RO/DM reject, wastewater generated from silver refining & cooling bleed off. The unit is engaged in the manufacturing of Formaldehyde, which is continuous process and water also retained with the product. Therefore there will not any wastewater generation from the process. Since there is no need of plant washing and cleaning hence, the main source of industrial wastewater generation is cooling bleed off and RO reject. The total quantity of industrial wastewater will be KLD which will be sent to Evaporator to separate out the salts and recover better quality water which will be reused in process. Thus, this steps toward water conservation. EIA report of Balaji Formalin Pvt. Ltd. 10-5

218 The other source of wastewater generation is domestic wastewater of 7.0 KLD quantities which is disposed to soak pit through septic tank. Cleaner production technologies will also be adopted to reduce the quantity of fresh water requirement and industrial wastewater generation. The mitigation measures for minimizing the impacts on water environment in general includes following: Minimization of water use Segregation and collection philosophy for effluent to minimize waste generation and facilitate treatment as well as recycle. Treatment philosophy to achieve mandated standards. Reuse/recycle Some of the measures, which are to be implemented, include: Reducing the actual process water consumption by way of improvement in operation of processing units Hazardous/Solid Waste Management There will be only one source for disposal of hazardous waste namely evaporator salt. This salt is collected properly and store in premises and finally disposal at TSDF-SEPPL. Other Hazardous sources are discarded Containers & Used Oil. Discarded Containers are collected and storage in premises and disposal by selling to authorized recycler or reuse. Same as Used oil is collected and storage in premises and disposal by selling to registered re-processor or reused as lubricant Noise Control Technique The main sources of noise within the plant are: Tai gas treatment unit, air compressors, manufacturing activities, transferring pumps and material handling systems. Additional noise will be generated due to installation of new machineries and equipments however, these impacts will be very minor and temporary in nature. The impact on the environment during the operational phase will be long term but, of insignificant quantity. To minimize the noise pollution, the unit proposes the following noise control measures: EIA report of Balaji Formalin Pvt. Ltd. 10-6

219 Noise suppression measures such as enclosures, buffers and/or protective measures should be provided (wherever noise level is more than 90 db (A)). Employees should be provided with ear protection measures like earplugs or earmuffs. Earplug should be provided to all workers where exposure is 85 db (A) or more. The transportation contractor shall be informed to avoid unnecessary speeding of the vehicles inside the premises. Extensive oiling, lubrication and preventive maintenance will be carried out for the machineries and equipments to reduce noise generation. The selection of any new plant equipment will be made with specification of low noise levels. Areas with high noise levels will be identified and segregated where possible and will include prominently displayed caution boards. The green belt area will be developed within industrial premises and around the periphery to prevent the noise pollution in surrounding area. Monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures. A good quality digital sound pressure level meter is essential for this purpose GREEN BELT DEVELOPMENT Tree plantation is one of the effective remedial measures to control the air pollution and noise pollution. It also causes aesthetics improvement of the area as well as sustains and supports the biosphere. Plantation around the pollution sources control the air pollution by filtering the air particulate and interacting with gaseous pollutant before it reaches the ground. Each plant shows different air pollution tolerance level depending upon number of factors. In green belt area about 1000 trees per acre of land as prescribed by Gujarat Pollution Control Board shall be planted. The EIA report of Balaji Formalin Pvt. Ltd. 10-7

220 selection of tree species suitable for plantation at the industry shall be governed by following factors, The trees should be tolerant to air pollutants present in the area The trees should be able to grow and thrive on soil of the area, be evergreen, inhabitant and having minimum of leaf fall. The trees should be tall in peripheral curtain plantation and with large and spreading canopy in primary and secondary attenuation zone It is also recommended to plant few trees, which are sensitive to air pollution as air pollution indicator. The unit has extensive greenbelt in 1500 sqm, which is around 35% of total land area. Local spices are planted and survival rate is more than 70%. Design of Green Belt As far as possible, following guidelines will be considered in greenbelt development: The spacing between the trees will be maintained as per GPCB guideline i.e. 1 tree/4 sqm. Spaces, so that the trees may grow vertically and slightly increase the effective height of the green belt. Planting of trees in each row will be in staggered orientation. The short trees (< 10 m height) will be planted in the first two rows (towards plant side) of the green belt. The tall trees (> 10 m height) will be planted in the outer three rows (away from plant side). Plantation Programme Plantation of trees in and around the company are meant mainly to reduce air pollution caused by factory emissions, to absorb sound, to prevent soil erosion and to maintain aesthetic value for healthy living. Survival rate of trees and post plantation care Considering the availability of water and general survey of surrounding area, the survival rate is expected to be around 75%. Moreover, the wire net guards will be provided to protect the saplings. The same will be properly manure and watered so that it can grow well. EIA report of Balaji Formalin Pvt. Ltd. 10-8

221 Planting methodology The plantation shall be done in pits. Pits of about 50 cm dia shall be dug in grid of 0.5 m X 0.5 m up to a depth of 0.3 m. The pit shall be refilled with soil after the planting. The sampling of healthy, nursery raised, seedlings in polythene containers shall be transported in baskets. Planting shall be done after first monsoon showers. The level of soil is about 10 cm above of ground level. The soil around the plant shall be pressed to form a low through. About 25 gm chemical fertilizers shall be added in ring of 25 cm radius around the plant. Watering shall be continued after plantation if any dry spells follows. Planted area shall be inspected and mortality rate ensured for each species. The dead and drying plant shall be replaced by fresh seedlings. Protection of plantation site: Protection from grazing will be done by erecting tree guards a rounded planted sapling. Though the tree suggested for plantation will require very less water, however during the first year watering will be done twice in a day. There after watering will be done twice in a week. The manuring will be done when plantation take up. For this propose cow dung will be dump in the pit. No other manuring will require for proposed plantation. Cow dung is easily available in the study area. Damaged plants will be replaced with new plants RESOURCE CONSERVATION/WASTE MINIMIZATION The unit introduces modernized techniques with installation of Tail Gas Treatment Plant. Therefore, wasted heat energy will be recovered in recycled for various industrial activities. Thus, there will not be any additional fuel requirement which will step towards resource recovery and conservation. With tail gas treatment plant there will also be reduction in pollutant concentration and better quality of air emission will be obtained. Energy consumption will be reduced from 40 KW/Tonne of production to 26 KW/Tonne. EIA report of Balaji Formalin Pvt. Ltd. 10-9

222 Main benefit to this technology is conserve resource-raw material around 12% compare to conventional process which resulted to reduced raw material consumption per unit from 0.5 to Better quality water from Evaporator will also be recovered and reused in process. This ultimately results in conservation of fresh water requirement. The units shall also implement the concept of waste minimization circle. Good Housekeeping or proper housekeeping practice makes the system easier and less costly. Some of these are as follows: Rain water harvesting system shall be adopted to reduce the fresh water requirement. Cleaner production technology shall be adopted for the resource conservation and pollution control ACTION PLAN FOR TRANSPORTATION OF RAW MATERIAL AND PRODUCTS The basic raw materials required for the proposed expansion project are given in Chapter-2 along with source, mode of transport. The raw materials and their storage quantities may change (to some extent) depending upon products and market demand. The current practice of transportation of raw materials and products will be continued for the proposed expansion project. Following safety precautions will be taken during transportation: Supplementary operational requirements for loading, transport, storage, unloading, handling and storage. Restrictions, if any, on the mode of transport and any necessary routing instructions. Emergency action plan and an indication of the general nature of risk and safety precautions. Proper parking of vehicle at designated place. During the parking, stop the engine of vehicles. Provide earthing to tanker securely for solvent storage tanker. Ensure that fire fighting system is available near the place of storage of hazardous chemicals. EIA report of Balaji Formalin Pvt. Ltd

223 Liquid transportation should be pneumatically. Before start unloading, check that, there should not be any leakage in the pipeline. In case of leakage, immediately attend the leakages and rectify it and stop the valve of tanker. After unloading, close the cover properly to avoid any fumes. Vehicle to be started only after removal of all pipelines connected with tanker Safety Instructions for transportation of hazardous materials: The name of the chemical along with pictorial sign denoting the dangerous goods are marked on the vehicle and the packing material. The name of the transporter, his address and telephone number are clearly written on the road tanker and on the vehicle. The important safety precautions are mentioned on the tanker as a warning label. Only trained drivers and cleaners are engaged in transport of hazardous chemicals. The transporter and manufacturer must ensure the safe transportation of the material Instructions for drivers & Responsibilities of drivers Before any hazardous substance is transported, the carrier shall - TERM (Transport Emergency) card should be with driver. Copy of the statement give to the driver of the vehicle relating to the substance being transport the hazardous substance. Ensure that the driver is adequately trained to carry out the instructions contained in the statement. A copy of the statement given to him where the information will be available at all times while the substance to which it relates is being transported; and Comply with all instructions contained in the copy of the statement given to him. Designation and quantity of the hazardous substance; EIA report of Balaji Formalin Pvt. Ltd

224 Required approval from the PESO in regard to the transport of the hazardous substance; The tankers are checked for its fitness and safe condition before loading. During loading and unloading, the tanker should be braked and isolated against any movement, while loading/unloading, use safety appliances. Check for leakages from the line connections before starting and stopping the filling operations. Drive the vehicles carefully, especially in crowded localities and on bumpy roads. Do not apply sudden break. The tanker should not be parked for long time on the way and especially in crowded places. Park the vehicle away from residential areas Manner of display of class labels Where a class label is required to be displayed on a vehicle, it shall be so positioned that the size of the class label is at an angle of 45 degrees to the vertical and the size of such label shall not be of less than twenty-five millimeters square which may be divided into two portions, the upper half portion being reserved for the pictorial symbol and the lower half for the text. Provided that in the case of smaller packages a suitable size of the label may be adopted. Where the class label consists of adhesive material, it shall be waterproof and where it consists of metal or other substance on which the pictorial symbol and the text are printed, painted or affixed, they shall be affixed directly on such material and in every case, the surface of the vehicle surrounding the label shall be of a color that contrasts vividly with the background of the class label. Every class label displayed on a vehicle shall be positioned in such a manner that it does not obscure any other markings required to be displayed under any other law. EIA report of Balaji Formalin Pvt. Ltd

225 Every goods carriage carrying any dangerous or hazardous goods shall display the class label on the appropriate places where anyone can see easily HEALTH & SAFETY M/s. Balaji Formalin Pvt. Ltd. will follow occupational health program right from the start of production. Health hazards associated with occupation are called occupational hazards. The following check-ups shall be carried out regularly to avoid occupational hazards: Pre-employment medical check-up at the time of employment. Provision of periodic medical check up for all the employees. To provide necessary first aid facilities, the first aid training shall also be given to the employees. Monitoring of occupational hazards like noise, ventilation, chemical exposure shall be carried out at frequent intervals. The unit will appoint the medical officer for the regular medical examination and treatment of the employee. The following precautions shall be taken to avoid foreseeable accident like spillage, fire and explosion hazards and to minimize the effect of any such accident and to combat the emergency at site level in case of emergency. Various emergency spots in plant area will be identified and kept in sharp and alert watch. Use of protective equipments will be regularly checked and will be kept easily accessible and easily workable during emergency. Safety installations like available quantity of running water will be regularly watched. Fire bucket and hose reels will be provided to withstand the fire or explosion conditions. Various types of fire extinguishers such as (Foam type, water type, CO 2 type) will be provide inside the factory premises. Every pressure vessel will be provided with minimum one or more pressure relief devices. The design of the valve is made in such a way that the breakage of any part will not obstruct force discharge of the liquid under pressure. Moreover, relief valves are tested and a periodic EIA report of Balaji Formalin Pvt. Ltd

226 schedule for their testing shall be maintained. The defective valves will be removed if found unsafe for the operation Possibility of occupational health hazard & its control An occupational hazard is a thing or situation with the potential to harm a worker. Occupational hazards can be divided into two categories: safety hazards that cause accidents that physically injure workers and health hazards which result in the development of disease. Hazards can be rated according to the severity of the harm they cause - a significant hazard being one with the potential to cause a critical injury or death. In case of M/s. Balaji Formalin Pvt. Ltd., methanol and formaldehyde will be handled within premiseswhich can enter in the human body by the way of inhalation of vapour or spray and skin absorption these are the commonest method of entry. Skin absorption usually arises from direct contact of the liquid solvent with the hands and arms of workers who are cleaning objects manually or handling objects recently dipped in or coated with substances. The following precautions shall be taken to avoid foreseeable accident like spillage, fire and explosion hazards and to minimize the effect of any such accident and to combat the emergency at site level in case of emergency. Various emergency spots in plant area will be identified and kept in sharp and alert watch. Protective equipments will be regularly checked and will be kept easily accessible and easily workable during emergency. Safety installations like available quantity of running water will be regularly watched. Fire bucket and hose reels will be provided to withstand the fire or explosion conditions. Various types of fire extinguishers such as (Foam type, water CO 2 type, CO 2 type) will be provided inside the factory premises. Every pressure vessel will be provided with minimum one or more pressure relief devices. The design of the valve is made in such a way that the breakage of any part will not obstruct force discharge of the EIA report of Balaji Formalin Pvt. Ltd

227 liquid under pressure. Moreover, relief valves are tested and a periodic schedule for their testing shall be maintained. The defective valves will be removed if found unsafe for the operation Possibility of occupational health hazard, its control & Occupational surveillance An occupational hazard is a thing or situation with the potential to harm a worker. Occupational hazards can be divided into two categories: safety hazards that cause accidents that physically injure workers, and health hazards which result in the development of disease. Hazards can be rated according to the severity of the harm they cause - a significant hazard being one with the potential to cause a critical injury or death. Chemical agents: There are possibility to generate gases, vapours and aerosols (fumes, mists). We will take care to reduce it at optimum minimum level and advices to workers to use PPE who work in such identify area. Noise: Noise is considered as any unwanted sound that may adversely affect the health and well-being of individuals or populations. Aspects of noise hazards include total energy of the sound, frequency distribution, duration of exposure and impulsive noise. Noise might result in acute effects like communication problems, decreased concentration, and sleepiness and as a consequence interference with job performance. Exposure to high levels of noise (usually above 85 db(a)) over a significant period of time may cause both temporary and chronic hearing loss. Permanent hearing loss is the most common occupational disease in compensation claims. There will be no high noise level issue. However, unit will identify such areas like, utilities area and advice to workers to not enter without PPE. Occupational surveillance involves active programmes to anticipate, observe, measure, evaluate and control exposures to potential health hazards in the workplace. Depending upon the occupational environment and problem, two surveillance methods can be employed: medical and environmental. EIA report of Balaji Formalin Pvt. Ltd

228 Medical surveillance is used to detect the presence or absence of adverse health effects for an individual from occupational exposure to contaminants, by performing medical examinations and appropriate tests. Environmental surveillance is used to document potential exposure to contaminants for a group of employees, by measuring the concentration of contaminants in the air, in bulk samples of materials and on surfaces. Medical surveillance is performed because diseases can be caused or exacerbated by exposure to hazardous substances. So periodic medical check-up will be carried out Preventive Measures The methods of protecting the work force from exposure to toxic agents in the workplace apply to the use of solvents: Segregation of processes using solvents; Enclosures or special ventilator control of processes; Good general ventilation-particularly important if the solvent is used in a confined space; Personal protection-protective clothing should be worn, including gloves, where there is a possibility of absorption through the skin. Suitable respiratory protection is necessary like Panorama gas mask with cartridge suitable for the chemicals we will be handling, Breathing Air Apparatus and Air Hood with instrument air connection. Gas detector with emergency alarm systems in confined area. Emergency preparedness plan OCCUPATIONAL HEALTH PROGRAMME Some of the philosophies underlining the occupational health programme are discussed below. M/s. Balaji Formalin Pvt. Ltd. will employ well qualified and experienced safety Manager and make arrangement for part time doctor for regular checking of health of the employees. Also, plans to become member of any local hospital for emergency need. Annual health check for employees will be carried out and record will be maintained. Regular EIA report of Balaji Formalin Pvt. Ltd

229 training to plant personnel in safety fire fighting and first aid will be provided. Unit will maintain a healthy work environment. This will be accomplished through the identification, evaluation and control of workplace environmental factors which may cause sickness, impaired health or significant discomfort and inefficiency among workers. Environmental factors such as noise, physical hazards toxicity/chemical hazard and ergonomic hazards will be monitored on a periodic basis to assist in maintaining a healthy work environment.workers exposed to noise and toxic materials will be evaluated against applicable recognised exposure levels in the Factories Act. Hearing protection aid will be provided to workers who work in the high noise areas, during construction of the proposed facilities and also to those who will continue through the life of the facility. (A) Exposure of workers with major chemicals Mainly Methanol and Formaldehyde are used from which workers are directly exposed. All workers are directly or indirectly comes in contact with above chemicals, are aware about the hazardousness of such chemicals and all have provide Personnel protective equipments and also provide appropriate training for use it. (B) List of chemicals, their threshold limit and measures Unit are using Methanol and Formaldehyde. Workers are directly or indirectly exposed in work area during the handling of these chemicals. Details of hazardous chemicals characteristics are summarized in Chapter-7 of RA report. Unit will handle above chemicals with proper handling process suggested in MSDS. Estimated work area quality with TWA limit is summarized in Table 2.8(a) of Chapter-2. Measured value indicates that, exposure of such chemicals are within the Threshold Limit Values (TLV)/Permission Exposure Levels as per ACGIH recommendation. (C) Details of Pre-placement and periodical medical monitoring of workers Pre-employment Medical Examinations There are two main purposes of pre-employment medical examinations: EIA report of Balaji Formalin Pvt. Ltd

230 1. To provide base-line health data against which subsequent changes after employment can be evaluated This is important for assessment of the effectiveness of preventive measures at work. For example, where the hearing threshold of a worker, which is normal before employment in a noisy occupation, is found to have increased after employment, this possibly indicates noise-induced hearing loss and a review of the hearing protection measures would be required. On the other hand, if the pre-employment hearing threshold of the workers has not been assessed, it would be difficult to ascertain whether the worker s high hearing threshold after employment is due to excessive noise exposure at work or to his own hearing problem before employment. Pre-employment health data is also important in substantiating or negating employees compensation claims since it provides evidence of the health status of claimants before employment. 2. To ensure medical fitness for work Pre-employment medical examinations identify those persons who are medically unfit for employment in particular occupations. Persons with certain underlying medical conditions are particularly vulnerable to the effects of certain health hazards and are not suitable for employment in particular occupations. Persons with certain underlying medical conditions are particularly vulnerable to the effects of certain health hazards and are not suitable for employment in work with such exposures. For example, workers with thalassemia (a genetic disease of the blood) should not be engaged in work involving lead exposure which may aggravate the anaemia. Workers may fail to meet the specific health requirements for particular job so that they cannot undertake the jobs safely without risks to themselves or others. Periodic Medical Examinations Periodic medical examinations aim to detect susceptible workers for whom corrective actions are required before they develop overt occupational diseases. The frequency of periodic medical examinations EIA report of Balaji Formalin Pvt. Ltd

231 depends on the nature of the occupational hazards. For most hazardous exposures, however, these examinations are conducted annually. Requirements of Medical Examination The requirements of medical examinations depend on the nature of the hazardous exposures of workers. In general, the doctor will take a detailed occupational and medical history, conduct a physical examination and prescribe a range of ancillary laboratory and/or radiological investigations such as urine test, blood test, X-ray, lung function test and audiometric test. Liver Function Test (LFT) Clinical examination and Pre-placement medical examination carried out in every 12 months. Liver function tests including serum bilirubin, alkaline phosphatase estimations every 12 months are required. Measures: Entire materials will be transfer either pneumatically or closed manner and charging the raw materials in reactor with deep charges so that chances of un-reacted materials are minimized Occupational Health and First aid measures Unit is using Methanol and Formaldehyde as main raw materials which if handled in safe ways with all precautions (as detailed in respective MSDS) will not cause harm to employees. However, in rare case of exposures, immediate action is to be taken to save life and reduce the extent of damage. Unit has first aid facilities and calling base ambulance facilities as and when required. Industry will appoint part time doctor for periodically health check-up. Instructions for immediate actions to exposures to some of the chemicals will be given to employees SOCIO-ECONOMIC ACTIVITIES: Socio-economic development activities refers to voluntary actions undertaken by company/organization to either improve the living conditions (economically, socially and environmentally) of local communities or to reduce the negative effects of the project. Socioeconomic development activities is a concept of organization whereby organizations serve the interests of society by taking responsibility for the EIA report of Balaji Formalin Pvt. Ltd

232 impact of their activities on customers, employees, shareholders, communities and the environment in all aspects of their operations. Unit has identified following activities as a part of CSR under different heads: Education Awarding meritorious school students in SSC & HSC Providing utensils to schools and anganwadi for Mid-Day Meal preparation Science Lab - Equipment & books in libraries for schools Supports for sport & cultural competitions in schools Health and family welfare Malaria eradication camps (collection of blood sample & detection of virus & free medicine distribution, Blood donation camp) General Health Camp for men, women & kids Support for Pulse Polio Immunization camp Contribution towards primary Health Services depending on local needs. Preservation of the Environment and to Sustainable Development Water harvesting systems in nearby villages. Landscaping and greenbelt development in and around of the project site. Provide sanitation facilities to villagers. Unit has committed to spend about Rs. 20 Lakhs every year up to five years of the operation towards various rural up-liftman and community development programs. Table 10.1 Budgetary provisions for the next five years (Every Year) Sr. No. Activities Budgetary provision (Lakhs) 1. Educational activities Preservation of the Environment and Sustainable Development Health and family welfare Drinking water and sanitation facilities 7.0 EIA report of Balaji Formalin Pvt. Ltd

233 5. Miscellaneous as per the demand of surrounding villages San Envirotech Pvt. Ltd., Ahmedabad 1.5 Total POST-PROJECT ENVIRONMENTAL MONITORING The post project environmental monitoring suggested herewith should be as per the following guideline. The highlights of the integrated environmental monitoring plan are: The stack monitoring facilities like ladder, platform and porthole of all the stacks maintained in good condition. Regular monitoring of all gaseous emissions from stacks/vents and all fugitive emissions in the process areas. The performance of air pollution control equipment evaluated based on these monitoring results. Water consumption in the complex recorded daily. Analysis of untreated and treated effluent, before discharge into the final disposal pipeline carried out regularly. Performance of effluent treatment plant units evaluated based on these analysis results. As far as possible, noise curbed at its source, with the help of acoustic hood and other such noise reducing equipments. Regular noise level monitoring to be carried out. Green belt properly maintained and new plantation programmes undertaken frequently. Continued environmental awareness programmes carried out within the employees and also in the surrounding villages. Rain water harvesting ponds will be developed within the industrial premises and encouraged in the surrounding villages too. All possible back up and support provided to them. Ambient Air Quality monitoring Schemes for monitoring ambient air quality stack emissions and fugitive emissions are proposed. The ambient air quality monitoring systems are recommended for monitoring the ground level concentrations and fugitive emissions around the plant. Balaji Formalin Pvt. Ltd. should install three EIA report of Balaji Formalin Pvt. Ltd

234 monitoring stations around its battery limit (at as per guideline) for monitoring SPM, SO 2, NO X and HC. The combined data will provide overall characteristic and emission from the industry. For this, the following equipment is recommended to be procured or can higher the services from Environmental consultant by the project proponent for implementing the above mentioned monitoring schemes: Noise Environment Monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures. A good quality digital sound pressure level meter is essential for this purpose ENVIRONMENT MANAGEMENT COST ESTIMATE The management will spend about Rs Lakhs as recurring cost per annum on the pollution control measure, greenbelt development and other environment management. Recurring cost is estimated as below: S. No. Table 10.2 Environment Management Cost Estimate Description Recurring Cost Rs. (Lakh/Annum) Capital Cost Rs. (Lakhs) 1. Air pollution Control Water pollution Control Noise pollution Environment monitoring & management Occupational Health Green belt Development Plan Haz. Waste management Rain water harvesting system ENVIRONMENT POLICY Total cost per annum Balaji is an existing unit and it has already well developed Environment Policy approved by the management. They commit themselves to: EIA report of Balaji Formalin Pvt. Ltd

235 Ensure continuous improvement in environmental performance of works through protective Environmental management system. Comply with applicable legal and other requirements related to environmental aspects. Conserve the resources particularly water, power by fixing and improving consumption norms. Concept of cleaner production is adopted. Ensure involvement of all employees and contractors in effective implementation of Environment Management System through training and awareness. Promote awareness among local surrounding community for preservation and maintaining clean environment. Work procedures and safety instructions are provided to all staff. Unit also conducts the safety seminars, mock drills and training programmes for our staff at regular intervals REPORTING SYSTEM OF NON COMPLIANCES/VIOLATIONS OF ENVIRONMENTAL NORMS Company will develop reporting systems of non-compliances/ violations of environmental norms to the management. The mechanism is summarized below: 1. Identify deviation/non-compliance/violation of environmental norms as lay down in Consent to operate and letter of Environmental clearance. Record to communication/complain received from plausible stake holder. 2. The EHS manager will identify deviation/non-compliance/violation from failure to comply with statutory requirements. 3. Respond from EHS manager within reasonable time limit to concern authorities with c/c mark to Technical head. 4. Technical head will take it in action and give necessary guideline to comply this deviation/ non-compliance/ violation of environmental norms. Parallel arrange budget for necessary action to comply the condition. EIA report of Balaji Formalin Pvt. Ltd

236 5. Communication received from the EHS manager will be discussed in technical management meeting. 6. Board discussion, Decision and Action The Chairperson will review the information available and take a decision depending on the seriousness of the violation. The decision will be taken to ensure the compliance of noncompliance/violation of environmental norms and it s safeguarded. The decision will be taken by consensus and if no consensus is arrived at, voting will be conducted. Enlist measures that would undertake to ensure that deviations/ noncompliance /violations of Environmental norms and take care not to occur same violation in future. EIA report of Balaji Formalin Pvt. Ltd

237 Table 10.3 Design features for minimization of fugitive emissions Sr. Equipments Design Features Control No. Efficiency % 1 Pumps Seal less design 100 Dual Mechanical Seal Valves Seal less Design Compressor Dual Mechanical Seal Connectors Weld together Pressure Relief Rupture Disc 100 Devices 6 Sampling Connection Closed loop sampling 100 EIA report of Balaji Formalin Pvt. Ltd

238 Table 10.4 San Envirotech Pvt. Ltd., Ahmedabad Environment Monitoring along with Frequency details Nature of Analysis Wastewater analysis Stack monitoring of each stack Ambient Air Quality Monitoring Noise level Work zone fugitive monitoring Health check-up of workers Frequency of analysis with its analyzer Monthly by external agency Monthly by external agency Monthly for 24 hours or as per the statutory conditions by external agency Monthly as per the statutory conditions by external agency Monthly by external agency As per the statutory guideline Parameters ph, COD, BOD, NH 3 -N, TDS, SS, Oil & Grease, etc. PM, SO 2, NO X PM 10, PM 2.5, SO 2, NO X Nr. Main gate, Process area etc. Dust, VOCs All workers EIA report of Balaji Formalin Pvt. Ltd

239 Figure-10.1 San Envirotech Pvt. Ltd., Ahmedabad Hierarchical system or Administrative order of the company Director General Manager Office Manager EHS Manager Plant Incharge Chemist Plant operator EIA report of Balaji Formalin Pvt. Ltd

240 11.1 PROJECT DESCRIPTION San Envirotech Pvt. Ltd. Chapter-11 Summary & Conclusion M/s. Balaji Formalin Pvt. Ltd. is a working unit at Plot No. 1398, Post: Moti Bhoyan, Taluka: Kalol, Dist.: Gandhinagar for manufacturing of Formaldehyde (5000 MTPM). Now, looking to the market demand, unit intends to enhance its production capacity of Formaldehyde up to MTPM along with Para Formaldehyde MTPM and Reprocessing Silver (Purification of Silver) MTPM. Expansion will be done in existing plant premises. Unit has obtained EC from MoEF, New Delhi vide its letter no. J-11011/625/2009-IA II (I), dated and have valid consent to operate issued by GPCB vide order no. AWH-71755, date of issue 13/07/2015 and valid up to 15/04/ LOCATION OF PROJECT Details of the project site are as given in following table: Sr. No. Particulars Details 1. Plant location Plot No Village Taluka District State Moti Bhoyan Kalol Gandhinagar Gujarat 2. Co-ordinates Latitude Longitude 23 09'44.69"N 72 26'45.54"E 3. Nearest Habitat Moti Bhoyan-1.45 km 4. Nearest Railway Station Kalol-10.6 km 5. Nearest Airport Ahmedabad-21.2 km 6. Nearest City Ahmedabad-12.0 km 7. Nearest Highway SH km EIA report of Balaji Formalin Pvt. Ltd. 11-1

241 San Envirotech Pvt. Ltd PRODUCT PROFILE Production capacity is given below: Sr. No. Products Existing Production (MTPM) Additional production (MTPM) Total production after expansion (MTPM) 1 Formaldehyde Para formaldehyde Reprocessing of Silver (Purification of Silver) INVESTMENT OF THE PROJECT Existing cost of project is Rs crores. The estimated cost of the proposed expansion will be around Rs. 8.0 crores. So after expansion, it will be tune around Rs crores. Out of this, around Rs. 1.0 crore will earmark for pollution control measures as capital investment and Rs. 20 lakhs will be recurring cost per annum. Unit is using excess steam generate from exothermic process reaction resulted to reduce the operational cost DESCRIPTION OF ENVIRONMENT BASELINE ENVIRONMENTAL STUDY To predict the impact of the proposed activities on the surrounding environment, the current baseline environmental status was studied by collecting the data and carrying out monitoring for the period of October-2015 to December The baseline data for ambient air quality, surface and ground water quality, noise and soil quality was collected and analyzed for various parameters AIR ENVIRONMENT The ambient air quality monitoring was carried out at eight AAQM locations, with a frequency of twice a week, to assess the existing sub-regional air quality status during the period of October-2015 to December Respirable Dust Sampler & Fine Particular Sampler along with the analytical methods, prescribed by CPCB was used for carrying out air quality monitoring. At all these sampling locations; PM 10, PM 2.5, SO 2 and EIA report of Balaji Formalin Pvt. Ltd. 11-2

242 San Envirotech Pvt. Ltd. NOx were monitored on 24-hourly basis to enable the comparison with ambient air quality standards prescribed by the Central Pollution Control Board. The data on concentrations of various pollutants were processed for different statistical parameters like arithmetic mean, standard deviation, minimum and maximum concentration and various percentile values. Particulate Matter (PM 10 ) An average and 98 th percentile value of 24-hourly PM 10 values at all the locations varied between g/m 3 and g/m 3, which are well within the stipulated standard of CPCB, 100 g/m 3. Particulate Matter (PM2.5) An average and 98 th percentile value of 24-hourly PM 10 values at all the locations varied between g/m 3 and g/m 3, which are well within the stipulated standard of CPCB, 60 g/m 3. Sulphur Dioxide (SO 2 ) An average and 98 th percentile value of 24-hourly SO 2 value of arithmetic mean at all the locations ranged between g/m 3 and g/m 3 respectively, which are well within the stipulated standards of 80 g/m 3. Oxides of Nitrogen (NO x ) An average and 98 th percentile value of 24-hourly NO x value of arithmetic mean at all the locations ranged between g/m 3 and g/m 3 respectively, which are much lower than the standards stipulated by CPCB, i.e. 80 g/m Water Environment Surface Water Quality There are surface water bodies like lakes, pond/reservoirs, canal in the study area. Surface water samples were collected from pond of Piyaj, Hajipur, Lapkaman, Thol Lake & from Narmada Canal near project site. Results of the same are given in Chapter-3 of EIA report. Conclusions: Surface water samples are meet the permissible limit set by the authority (BIS) for drinking purpose. EIA report of Balaji Formalin Pvt. Ltd. 11-3

243 San Envirotech Pvt. Ltd. Ground Water Quality Ground water samples have been collected from project site and different seven villages (Moti Bhoyan, Khatraj, Hajipur, Sherisa, Vadsar, Karoli, Ganapatpur). Color: All the samples were colorless meeting desirable norms. ph: All the samples meet the desirable standards (ph ranges from 7.59 to 7.83). Total Dissolved Solids (TDS): TDS in samples ranges from 998 mg/l (Project Site) to 1346 mg/l (Sherisa). All the samples meet the permissible limit of 2000 mg/l, (If alternate sources of potable water are not available). Calcium: Calcium contents in the water ranges from 49 mg/l (Karoli) to 65 mg/l (Moti Bhoyan), all the samples meet the permissible limit of 200 mg/l. Magnesium: Magnesium content in the water ranges from 39 mg/l (Hajipur) to 61 mg/l (Sherisa). All the samples meet even the permissible limit of 100 mg/l (if alternate source of potable water in not available). Sulphate: Sulphate content in the water ranges from 18 mg/l (Project site) to 36 mg/l (Sherisa). All the samples meet the permissible limit of 400 mg/l for drinking water. Fluoride: Fluoride content in the water ranges from 0.57 mg/l (Moti Bhoyan) to 0.75 mg/l (Sherisa). All the samples meet the permissible limit (1.5 mg/l). Total Alkalinity: Total alkalinity in the water samples ranges from 362 mg/l (Khatraj) to 485 mg/l (Project Site). All the samples are within the permissible limit of drinking water (600 mg/l) (if alternate source of portable water is not available). Other Parameters: Potassium (ranges from 13 mg/l to 22 mg/l), Sodium (ranges from 289 mg/l to 423 mg/l) and Chloride (ranges from 382 mg/l to 602 mg/l). Heavy metals like copper, lead, chromium and zinc are found below detectable limit in all samples. EIA report of Balaji Formalin Pvt. Ltd. 11-4

244 San Envirotech Pvt. Ltd. Conclusions: Ground water samples from villages meet the permissible limit set by the authority (BIS) Noise Environment The L eq values of noise levels during day-time varied from 48.1 db(a) to 62.2 db(a). Highest L eq daytime value was recorded at Bus stop Ganpatpura. The L eq values of noise levels during night time varied from 38.5 db(a) to 54.6 db(a). Highest L eq value during night time was recorded Nr. Project site, which is well within the limit of 70 db(a) prescribed for Industry ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES Various sources of pollution and pollution loads were identified. It has also identified the technologies to be adopted for the mitigation and control of the same. The sources of pollution in the proposed expansion project are air emissions from tail gas treatment plant & D G Set; liquid effluents from RO/DM reject, process (silver refining) & cooling bleed off and domestic sources; Hazardous wastes generation and noise pollution from utilities and process equipment. Impacts on Air quality & Mitigation measures: The impacts on air quality shall be due to the emissions from Unit. The impacts are quantified using ISCST3 model. The results indicate marginal increase in the ambient air quality parameters. The predicted values for SPM, SO 2 & NO x are g/m 3, g/m 3 & g/m 3 respectively. The point of maximum concentration for SPM, SO 2, NO x would be 1.0 km from center of industry in S direction. With this marginal contribution due to the proposed expansion activities, the levels of SPM, SO 2 and NO X will remain well below the 24-hourly ambient air quality standards for SO 2 & NOx (80 g/m 3 ), PM 10 (100 g/m 3 ), PM 2.5 (60 g/m 3 ) as prescribed by CPCB. To mitigate the impact due to the proposed expansion project, unit has provided APCM and adequate stack height for proper atmosphere dispersion as per the Pollution Control norms. EIA report of Balaji Formalin Pvt. Ltd. 11-5

245 San Envirotech Pvt. Ltd. Impacts on Water Environment & Mitigation measures: Total water requirement (Industrial + Domestic + Greenbelt) will be increased from 129 KLD up to 610 KLD; out of which 535 KLD is fresh water & 75 KLD is recycle water (condensate from evaporator). Source of fresh water is Narmada Water supply. After proposed expansion, total wastewater generation will be increased from KLD. 7.0 KLD will be domestic wastewater which will be disposed off into soak pit through septic tank. RO/DM reject, wastewater generated from silver refining & cooling bleed off will be directly sent to force effect evaporator & then sent to mechanical evaporator. Impacts on Noise quality & Mitigation measures: The noise levels may increase due to the proposed expansion activities. The impact is found to be insignificant outside the premises. To decrease the noise pollution impact, unit will provide necessary PPEs like earplugs or earmuffs to all workers where exposure is 85 db(a) or more and selection of any new plant equipment will be made with specification of low noise levels. Impacts on Soil & Mitigation measures: The solid/hazardous wastes generated from the unit may have significant negative impacts if disposed unsystematically. Hence, appropriate measures for storage and disposal of solid wastes are adopted as per the regulatory guidelines and it will be continued after expansion also. Impacts on Socio Economy & Mitigation measures: There is a potential for direct/indirect employment for the locals due to the proposed expansion project. Unit will improve infrastructure facilities in the villages ENVIRONMENT MONITORING PROGRAMME The unit has a dedicated Environment, Health and Safety (EHS) department to monitor and evaluate the environmental performance, and to supervise the environment management measures. The details of monitoring are as below. EIA report of Balaji Formalin Pvt. Ltd. 11-6

246 Environment Monitoring Program San Envirotech Pvt. Ltd. Nature of Analysis Wastewater analysis Stack monitoring of each stack Ambient Air Quality Monitoring Noise level Work zone fugitive monitoring Health check-up of workers Frequency of analysis with its analyzer Monthly by external agency Monthly by external agency Monthly for 24 hours or as per the statutory conditions by external agency Monthly as per the statutory conditions by external agency Monthly by external agency As per the statutory guideline Parameters ph, TDS, SS, Oil & Grease, etc. PM, SO 2, NO X PM 10, PM 2.5, SO 2, NO X Nr. Main gate, Nr. D. G. Set, Process area, Raw material storage area etc. Dust, VOCs All workers 11.5 ADDITIONAL STUDIES Risk Assessment Risk analysis and study have been carried out for identification of hazards, selection of credible scenarios, Risk Mitigation measures etc. All the hazardous chemicals will be stored and handled as per MSDS guidelines. The detail study is prescribed in Chapter ENVIRONMENTAL MANAGEMENT PLAN The EMP is covers the impacts identified and mitigation measures suggested. The EMP addresses the impacts identified during construction and operation stages. Impacts during construction stage are temporary and negligible; impacts during operational phase are permanent & management plan of impacts identified is detailed below: Liquid Effluents: After expansion, total quantity of industrial wastewater generation will be KLD which will be sent to force effect Evaporator to separate out the salts and recover better quality water which will be reused for cooling. Thus, this step is towards the water conservation. The other source of wastewater generation is domestic wastewater of 7.0 KLD which is disposed to soak pit through septic tank. EIA report of Balaji Formalin Pvt. Ltd. 11-7

247 San Envirotech Pvt. Ltd. Water Management Unit maintains the records for the total water consumption at various resources. Condensate water from evaporator will be utilized in utility hence there will be reduction in fresh water consumption. Domestic effluent will be disposed off into soak pit through septic tank. Air Pollution control measures: There will not be any process gas emission except tail gas, which will be emitted after proper burning/incineration in tail gas treatment plant. Tail gas treatment plant is integral part of process plant. It will be updated/modify along with process plant after expansion. Hence, after proposed expansion no stack will be added. The tail gas treatment plant will be adequate to reduce the pollution of formaldehyde, methanol and methane to atmosphere. There will also be recycling of combustion heat which is very effective to reduce pollution discharge and take advantage of wasted energy. Unit has installed one D G Set (400 kva) and going to install additional one D G Set with capacity of 1000 kva, which will be treated as stand by and operated only in case of non-availability of power. HSD is used as a fuel. Emitted flue gas pollutants will be SPM, SO 2 and NOx. Adequate stack height is provided for proper dispersion of pollutants. Hazardous/Solid Waste Management: Entire quantity of hazardous waste will be handled and disposed as per Hazardous Waste (Management, Handling & Transboundary Movement) Rules 2008 (amended time to time). Salt from evaporation will be disposed to secured TSDF site for land filling; discarded containers/barrels will be sold to authorized recyclers. Used oil will be sold to CPCB approved recyclers. The unit has provided isolated area with impervious flooring for the storage of hazardous waste. Thus, hazardous waste management system provided by the unit is adequate and continues after expansion also. EIA report of Balaji Formalin Pvt. Ltd. 11-8

248 San Envirotech Pvt. Ltd. There will not be any major impact on the environment due to hazardous waste management. Noise Pollution control measures: Noise is anticipated from process plant & other machineries, D. G. set, reactors & vehicular transportation etc. The D. G. shall be kept in a separate enclosed room with acoustic enclosure. The motors and compressors shall be mounted properly to ensure the reduction of noise and vibration. The employees working in noise generating areas shall be provided with appropriate Personnel Protective Equipments (PPEs). The greenbelt area is developed within industrial premises and around the periphery to prevent the noise pollution in surrounding area. Green Belt Development: The unit has developed greenbelt area around 1500 m 2 in its existing unit and some more area will be added for greenbelt development outside the plant boundary. The greenbelt area is around 35% of total land area PROJECT BENEFITS The proposed project expansion has a potential for employment of skilled, semi-skilled and unskilled employees during construction phase as well as operational phase CONCLUSION Based on the study it is concluded that- There will be no major impact on water environment as effluent will be directly sent to forced effect evaporator & then sent to mechanical evaporator. Condensate from evaporator will be reused for utility i.e. for cooling. Thus, unit will achieve zero discharge after proposed expansion. Domestic wastewater will be disposed in soak pit followed by septic tank. No fuel is used for manufacturing because exothermic reaction. Tail gas treatment plant is installed which reduce the pollution of formaldehyde, methanol and methane to atmosphere. To prevent fugitive emission; various step will taken like regular sprinkling of water and paved road. EIA report of Balaji Formalin Pvt. Ltd. 11-9

249 San Envirotech Pvt. Ltd. Adequate arrangement for handling and disposal of Hazardous/solid waste will be made as per regulatory norms. Fire protection and safety measures will be provided to take care of fire and explosion hazard. Suggestions of qualitative risk analysis study will be followed to minimize accidents and for safe operations. Overall, direct and indirect employment opportunities, improvement in basic infrastructures by development of industry etc. will be observed with negligible impact on environment. It can be concluded that after implementation of mitigation measures and environmental management plan during the construction and operational phase, there will be negligible impact on the environment. EIA report of Balaji Formalin Pvt. Ltd

250 Introduction San Envirotech Pvt. Ltd., Ahmedabad Chapter-12 Disclosure of Consultant engaged San Envirotech Pvt. Ltd. (An ISO 9001:2008, 14001:2008 and OHSAS certified company) is a leading multi-disciplinary testing laboratory in Gujarat. SEPL provides testing services in the areas of environmental assessment and analytical testing. SAN Envirotech Pvt. Ltd. (henceforth SEPL) has started its work in 1990 to serve the environment as a trustee of a next generation with a small infrastructure under the dynamic leadership of Dr. Mahendra Sadaria. During last two decade, SEPL has been taking care of client s unique problems and concerns in order to develop cost effective strategies to meet their regulatory obligations. We focus on strategic planning and comprehensive solutions to address both the short and long term needs of the clients. Consequently we have developed long-term relationship with our clients to provide them the services necessary to meet their changing needs. To protect and preserve the natural resources on earth for future generation, it offers extensive consultancy services in the field of environment. With its rich experience, multidisciplinary expertise and with the support of its state-of theart analytical equipments, the services offered by the division are wide ranging and encompasses entire scope of environment management and monitoring services. With its emphasis on quality services over the years, it has evolved itself into a single reference point in India for comprehensive environmental services. We conduct analytical works pertaining to various Environmental Parameters. We perform Effluent treatability studies also. To conduct the analysis work, we follow National & International Quality Standard and update our process regularly. Quality Assurance Team always welcomes any suggestion and feedback, to improve the Quality, Performance and Standards of the services. These suggestion and feedback are considered for reviewing of the services and complied immediately. EIA report of Balaji Formalin Pvt. Ltd. 12-1

251 Major Milestones and Accreditation SEPL is a recognize schedule-ii Environmental Auditor appointed by Gujarat Pollution Control Board as per the directives of the Honorable High Court of Gujarat. Recognize laboratory under Environment Protection (EP) Act, 1986 by Government of India (GOI). SEPL has listed as accredited EIA consultant organization by NABET/QCI for EIA report preparation. The certificate of same is attached with EIA report. SEPL has necessary manpower and expertise in various fields and also the required infrastructure facilities to carry out work related to EIA. Technical experts involved in the preparation of this EIA/EMP report are given below: EIA Coordinator: Name: Signature & Date: Dr. Mahendra Sadaria Period of involvement December-2014 to finalization of report Contact Information: Functional Area Experts Functional Areas Air Pollution Monitoring & Control (AP) Air Quality Modeling and Prediction (AQ) Name of the Expert Dr. Mahendra Sadaria Team Member: Diti Patel, Henal Mehta Dr. Mahendra Sadaria Team Member: Diti Patel Involvement (Period and Task**) December-2014 to finalization of report Planning of meteorological AAQM baseline monitoring schedule of site visit, site survey, assistance in selection of monitoring locations, data verification & approval, interpretation of baseline condition of air environment. Evaluation of results of Ambient Air Quality Monitoring (AAQM). Contribution of EIA documentation. Assessment of pollutant release source, rate. Meteorology file generation, Assistance in air quality modeling and model (ISCST-3) run using meteorology data, identifying source & receptor, source inventory, worst case scenario. Prediction of GLC & plotting isopleths. Study of GLCs obtained from simulation & calculating cumulative concentration of pollutants in AAQ due to the project. Contribution of EIA documentation. Signature EIA report of Balaji Formalin Pvt. Ltd. 12-2

252 Functional Areas Water Pollution (WP) Ecology and Biodiversity Conservation (EB) Solid and Hazardous Waste Management (SHW) Socio Economy (SE) Land Use (LU) Hydrogeology (HG & Geo) Name of the Expert Dr. Mahendra Sadaria Team Member: Diti Patel, Henal Mehta Dr. Khyati Chanana Team Member: Henal Mehta Dr. Mahendra Sadaria Shobhana Sadaria Satish Borad Hardik Patel Involvement (Period and Task**) December-2014 to finalization of report Site visit, advice in selection of sampling locations, review & interpret GW, SW baseline quality, review & approve water balance calculation for the project, explore reuse/recycle options, prediction of impacts & proposed mitigation measures, explore possibilities for groundwater & surface water conservation and contribution to EIA documentation. Site visit for ecology study, planning & scheduling for baseline ecological survey, determining status of endangered species of flora/fauna, if any, identification of nearest ecologically sensitive area in the study area. Review of Greenbelt development requirement of the project-suggestion for species, type of plantation and contribution to EIA documentation. Review of generation of existing Hazardous waste & ascertain compliance with HW rules for storage facilities, generation qty. & disposal methods, studying adequacy of mitigation measures for management of hazardous waste. Contribution of EIA documentation. Site visit, secondary data collection, evaluation of Socio-Economic status of the study area, assessment of the possible chances to socio-economic issues arising out of the proposed activity, contribution in EIA documentation. Development of land use maps of study area, site visit for ground truth survey, prepare land use classification and determine LULC of the area, prediction of impact on land use pattern & land cover, Suggest mitigation measures, contribution in EIA report. Site visit, understanding and representing ground water conditions, finalization of survey findings, identification of impacts, suggestion of mitigation measures and contribution of EIA documentation. Signature EIA report of Balaji Formalin Pvt. Ltd. 12-3

253 Functional Areas Risk and Hazards (RH) Noise Name of the Expert Prabhat Kumar Srivastva Team Member: Diti Patel Involvement (Period and Task**) December-2014 to finalization of report Determine worst & most credible accident scenarios, Identification of modeling scenarios, consequence modeling, finalization of RA/DMP, documentation and contribution to EIA documentation. Site visit, selection of sampling locations, review baseline noise levels, source & its compliance with permissible limits, contribution to EIA documentation. Signature Declaration by the Head of the Accredited Consultant Organization/authorized person I, Dr. Mahendra Sadaria, hereby confirm that the above-mentioned experts are involved in the preparation of Environmental Impact Assessment Report of Balaji Formalin Pvt. Ltd., Plot No. 1398, Village: Moti Bhoyan, Tal: Kalol, Dist.: Gandhinagar. I also confirm that, the consultant organization shall be fully accountable for any misleading information mentioned in this statement. Signature: Name: Designation: Name of the EIA Consultant organization Dr. Mahendra Sadaria Director, Technical San Envirotech Pvt. Ltd. NABET Certificate No. and date NABET/EIA/327/IA14, dated 12 th May, 2014 CONTACT DETAILS: San Envirotech Pvt. Ltd. 424, Medicine Market, Opp. Shefali Cross Road, Paldi cross Road, Ahmedabad , Gujarat Phone: mahendra.sepl@gmail.com EIA report of Balaji Formalin Pvt. Ltd. 12-4

254 Annexure-I Membership certificate of approve TSDF site

255

256 Annexure-II MSDS of haz. Chemicals

257 Our Main Product is FORMALDEHYDE. SALES SPECIFICATION : CAS Number EINECS Number Chemical Name Formaldehyde Chemical Classification Aldehyde Formula C H2O Molecular Weight Shipping Name Formaldehyde Solution Codes/Label Flammable Liquid, Class Hazardous Waste ID No. 5 Hatchem Code 2 SE / 2T UN Number 1198 Description Colourless liquid with characteristic pungent odour. In the manufacturing of phenolic resins. artificial silk and cellulose esters, dyes, organic chemicals, glass mirrors, explosives, disinfectant for dwellings, ship, storage Product Uses Houses, Utensils, Clothes etc., as a germicide & fungicide for plants & vegetables, improving fastness of dyes on fabrics, tanning & preserving hides;, mordanting & water proofing fabrics; preserving & coagulating rubber latex; in embalming fluids. Specifications Limits Application Packaging Carbon Dioxide, % v/v/ Min Moisture, % v/v max. <1.0 * Acidity (as HCOOH), % w/w max Iron, ppm max. 2.00** PH * Methanol content may vary as per specific customer's requirement. Hence sp. gr. will also vary accordingly. ** Valid for SS containers & HDPE carboy packing. In the manufacture of explosives, photographic materials, antiseptic and fumigants; in treatment of pulp & papers; in cosmetics, fertilizers & fuels; in treatment of fur & hair, mouth wash, germicidal soap, lavender water & cologne; sterilization of surgical instruments; as food preservative. In SS tankers, ISO-containers and in HDPE

258 drums / carboys. This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should therefore, not be construed as guaranteeing specific properties of the products described or their suitability for a particular application. Any existing industrial property rights must be observed. The quality of our product is guaranteed under our General Conditions of Sale. MATERIAL SAFETY DATA SHEET (Accordingto 91/155 EC) 1. IDENTIFICATION OF THE SUBSTANCE / PREPARATION AND OF THE COMPANY / UNDERTAKING: Product Details: Trade Name FORMALDEHYDE, 37% SOLN. IN METHANOL/WATER Manufacturer / Supplier Balaji Formalin Pvt. Ltd., Moti Bhoyan, Khatraj, Kalol Road, Tal. Kalol, North Gujarat. 2. COMPOSITION / INFORMATION ON INGREDIENTS: Description CAS No. EINECS Number Formaldehyde Methanol Water HAZARD IDENTIFICATION: Hazard Description Extremely hazardous product. Harmful if swallowed or inhaled. Causes severe irritation or burns to skin, eyes, upper respiratory tract, gastro-intestinal irritation and burns to mouth and throat Lachrymator at levels from less than 20 ppm upwards. Chronic Exposure Kidney and Lever Damage. Chrcinogen City Yes (NTP/IARC/OSHO) 4. FIRST-AID MEASURES: After inhalation After Skin Contact After Eye Contact After Swallowing Remove to fresh air, restore breathing, get medical attention. Remove contaminated clothing, flush with plenty of water at least for 15 minutes. Immediately flush opened eye with plenty of running water for at least 15 minutes. Induce vomiting of conscious patient by giving plenty of water to drink. Consult physician immediately in case of an unconscious victim. 5. FIRE-FIGHTING MEASURES:

259 Suitable extinguishing Agents CO 2, Dry Chemical Powder, Water Spray and Alcohol foam. 6. ACCIDENTAL RELEASE MEASURES: Person-related Safety Precautions Measures for cleaning/collecting Proper protective equipment and self contained breathing apparatus with full face piece operated in positive pressure mode. Shut off sources of ignition, no flares, smoking or flames in area. Stop leakage if possible. Use water spray to reduce vapour. Take up with sand or other non combustible absorbent and place in to container for disposal according to item HANDLING AND STORAGE: Handling Information for Safe Avoid breathing vapours, avoid contact with handling eyes, skin and clothing. Decontaminate soiled clothing thoroughly before use. Information about fire and Flammable liquid. Closed containers explosion protection exposed to heat may explode. Storage Requirements to be met by store rooms and receptacles Store in tightly closed containers in a dry, cool, well ventilated, flammable liquid storage area. 8. EXPOSURE CONTROLS / PROTECTION: formaldehyde OES Short term value * 3mg/m Long term value **1.5 mg m3 * total inhalable vapour, ** permissible exposure Personal Protective Self contained breathing apparatus and full Equipment protective clothing Respiratory protection Self contained breathing apparatus. Protection of hands Gloves of natural rubber Eye Protection Safety glasses W/face shield. 9. PHYSICAL AND CHEMICAL PROPERTIES: General Information: Form Liquid Colour Colourless Odour Pungent odour Change in Condition: Melting Point -- Boiling Point / Boiling range 960 C Flash Point: (TCC) 590C Flammable Limits Upper 73.0%, Lower 7.0% Auto Ignition Temperature 423oC Specific Gravity 1.08 Vapour Density (Air = 1) 1.0

260 Vapour Pressure (MMHG) at 20 0 C Solubility /Miscibility with water at 20 0 C 1.3 Complete 10. STABILITY & REACTIVITY: This product is stable, strong reducing agent, especially in alkaline solution. Keep away from strong bases and acids, oxidizing agents, aniline, phenol, isocyanates, anhydride. Combustible lightand air sensitive, polymerzes spontaneously. Dangerous reactions Carbon monoxide may form on incomplete combustion. Dangerous Decomposition CO, CO 2 & Vapours of formaldehyde Products 11. TOXICOLIGICAL INFORMATION: Acute toxicity LD/LC50 Values relevant for Oral/LD 50:100 mg/kg (rat) classification SKN LD 50: 270 ul/kg (rabbit) Primary irritant effect: On the Skin Irritating effect (severe) On the eye Irritating effect (Severe) Sensitization Prolonged contact may cause skin sensitization 12. ECOLOGICAL INFORMATION: Environmental Toxicity The product is expectecd to be slightly toxic to aquatic life. The LC 50/96 hrs values for fish are between 10 and 100 mg/l. Environmental Fate The product is expected to be slightly toxic to aquatic life. The LC 50/96 hrs values for fish are between 10 and DISPOSAL CONDITIONS: Whatever cannot be recycled, should be absorbed in sand or other non combustible absorbent, containerized and transferred to appropriate and approved waste disposal facility. Dispose waste, containers and unused contents in accordance with official regulations. 14. TRANSIT INFORMATION: Shipping Name FORMALDEHYDE SOLUTION UN Number 1198 Class : 3,3.3,8 Packing Group III Label : Flammable Liquid 15. REGULATORY INFORMATION: This Product is extremely hazardous. It is listed as an "ACGIH" 'suspected' human carcinogen and a "NTP" anticipated human carcinogen. It may cause (mutagenic) reproductive effects.

261 Material Safety Data Sheet Methyl alcohol MSDS Section 1: Chemical Product and Company Identification He a lt h Fire Re a c t iv it y Pe rs o n a l Pro t e c t io n H Product Name: Methyl alcohol Catalog Codes: SLM3064, SLM3952 CAS#: RTECS: PC TSCA: TSCA 8(b) inventory: Methyl alcohol CI#: Not applicable. Synonym: Wood alcohol, Methanol; Methylol; Wood Spirit; Carbinol Chemical Name: Methanol Chemical Formula: CH3OH Contact Information: Sciencelab.com, Inc Smith Rd. Houston, Texas US Sales: International Sales: Order Online: ScienceLab.com CHEMTREC (24HR Emergency Telephone), call: International CHEMTREC, call: For non-emergency assistance, call: Section 2: Composition and Information on Ingredients Composition: Name CAS # % by Weight Methyl alcohol Toxicological Data on Ingredients: Methyl alcohol: ORAL (LD50): Acute: 5628 mg/kg [Rat]. DERMAL (LD50): Acute: mg/kg [Rabbit]. VAPOR (LC50): Acute: ppm 4 hours [Rat]. Section 3: Hazards Identification Potential Acute Health Effects: Hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (permeator). Severe over-exposure can result in death. Potential Chronic Health Effects: Slightly hazardous in case of skin contact (sensitizer). CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. Mutagenic for bacteria and/or yeast. TERATOGENIC EFFECTS: Classified POSSIBLE for human. DEVELOPMENTAL TOXICITY: Not available. The substance is toxic to eyes. The substance may be toxic to blood, kidneys, liver, brain, peripheral nervous system, upper respiratory tract, skin, central nervous system (CNS), optic nerve. Repeated or prolonged exposure to the substance can produce target organs damage. Repeated exposure to a highly toxic material may produce general deterioration of health by an accumulation in one or many human organs. Section 4: First Aid Measures p. 1

262 Eye Contact: Check for and remove any contact lenses. Immediately flush eyes with running water for at least 15 minutes, keeping eyelids open. Cold water may be used. Get medical attention. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold water may be used.wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention immediately. Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medical attention. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately. Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate medical attention. Ingestion: If swallowed, do not induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. Loosen tight clothing such as a collar, tie, belt or waistband. Get medical attention immediately. Serious Ingestion: Not available. Flammability of the Product: Flammable. Auto-Ignition Temperature: 464 C (867.2 F) Section 5: Fire and Explosion Data Flash Points: CLOSED CUP: 12 C (53.6 F). OPEN CUP: 16 C (60.8 F). Flammable Limits: LOWER: 6% UPPER: 36.5% Products of Combustion: These products are carbon oxides (CO, CO2). Fire Hazards in Presence of Various Substances: Highly flammable in presence of open flames and sparks, of heat. Non-flammable in presence of shocks. Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of mechanical impact: Not available. Explosive in presence of open flames and sparks, of heat. Fire Fighting Media and Instructions: Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use alcohol foam, water spray or fog. Special Remarks on Fire Hazards: Explosive in the form of vapor when exposed to heat or flame. Vapor may travel considerable distance to source of ignition and flash back. When heated to decomposition, it emits acrid smoke and irritating fumes. CAUTION: MAY BURN WITH NEAR INVISIBLE FLAME Special Remarks on Explosion Hazards: Forms an explosive mixture with air due to its low flash point. Explosive when mixed with Choroform + sodium methoxide and diethyl zinc. It boils violently and explodes. Section 6: Accidental Release Measures p. 2

263 Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste disposal container. Large Spill: Flammable liquid. Poisonous liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not get water inside container. Do not touch spilled material. Use water spray to reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Call for assistance on disposal. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities. Section 7: Handling and Storage Precautions: Keep locked up.. Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing. In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and show the container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, metals, acids. Storage: Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep container tightly closed and sealed until ready for use. Avoid all possible sources of ignition (spark or flame). Section 8: Exposure Controls/Personal Protection Engineering Controls: Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value. Ensure that eyewash stations and safety showers are proximal to the work-station location. Personal Protection: Splash goggles. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product. Exposure Limits: TWA: 200 from OSHA (PEL) [United States] TWA: 200 STEL: 250 (ppm) from ACGIH (TLV) [United States] [1999] STEL: 250 from NIOSH [United States] TWA: 200 STEL: 250 (ppm) from NIOSH SKIN TWA: 200 STEL: 250 (ppm) [Canada] Consult local authorities for acceptable exposure limits. Section 9: Physical and Chemical Properties Physical state and appearance: Liquid. Odor: Alcohol like. Pungent when crude. Taste: Not available. Molecular Weight: g/mole Color: Colorless. ph (1% soln/water): Not available. Boiling Point: 64.5 C (148.1 F) Melting Point: C (-144 F) Critical Temperature: 240 C (464 F) p. 3

264 Specific Gravity: (Water = 1) Vapor Pressure: 12.3 kpa (@ 20 C) Vapor Density: 1.11 (Air = 1) Volatility: Not available. Odor Threshold: 100 ppm Water/Oil Dist. Coeff.: The product is more soluble in water; log(oil/water) = -0.8 Ionicity (in Water): Non-ionic. Dispersion Properties: See solubility in water. Solubility: Easily soluble in cold water, hot water. Stability: The product is stable. Instability Temperature: Not available. Section 10: Stability and Reactivity Data Conditions of Instability: Heat, ingnition sources, incompatible materials Incompatibility with various substances: Reactive with oxidizing agents, metals, acids. Corrosivity: Non-corrosive in presence of glass. Special Remarks on Reactivity: Can react vigorously with oxidizers. Violent reaction with alkyl aluminum salts, acetyl bromide, chloroform + sodium methoxide, chromic anhydride, cyanuirc chlorite, lead perchlorate, phosphorous trioxide, nitric acid. Exothermic reaction with sodium hydroxide + chloroform. Incompatible with beryllium dihydride, metals (potassium and magnesium), oxidants (barium perchlorate, bromine, sodium hypochlorite, chlorine, hydrogen peroxide), potassium tert-butoxide, carbon tetrachloride, alkali metals, metals (aluminum, potassium magnesium, zinc), and dichlormethane. Rapid autocatalytic dissolution of aluminum, magnesium or zinc in 9:1 methanol + carbon tetrachloride - sufficiently vigorous to be rated as potentially hazardous. May attack some plastics, rubber, and coatings. Special Remarks on Corrosivity: Not available. Polymerization: Will not occur. Section 11: Toxicological Information Routes of Entry: Absorbed through skin. Eye contact. Inhalation. Ingestion. Toxicity to Animals: WARNING: THE LC50 VALUES HEREUNDER ARE ESTIMATED ON THE BASIS OF A 4-HOUR EXPOSURE. Acute oral toxicity (LD50): 5628 mg/kg [Rat]. Acute dermal toxicity (LD50): mg/kg [Rabbit]. Acute toxicity of the vapor (LC50): hours [Rat]. Chronic Effects on Humans: MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. Mutagenic for bacteria and/or yeast. TERATOGENIC EFFECTS: Classified POSSIBLE for human. Causes damage to the following organs: eyes. May cause damage to the following organs: blood, kidneys, liver, brain, peripheral nervous system, upper respiratory tract, skin, central nervous system (CNS), optic nerve. Other Toxic Effects on Humans: Hazardous in case of skin contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (permeator). Special Remarks on Toxicity to Animals: Not available. Special Remarks on Chronic Effects on Humans: p. 4

265 Passes through the placental barrier. May affect genetic material. May cause birth defects and adverse reproductive effects(paternal and maternal effects and fetotoxicity ) based on animal studies. Special Remarks on other Toxic Effects on Humans: Section 12: Ecological Information Ecotoxicity: Ecotoxicity in water (LC50): mg/l 96 hours [Fathead Minnow]. BOD5 and COD: Not available. Products of Biodegradation: Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise. Toxicity of the Products of Biodegradation: The products of degradation are less toxic than the product itself. Special Remarks on the Products of Biodegradation: Methanol in water is rapidly biodegraded and volatilized. Aquatic hydrolysis, oxidation, photolysis, adsorption to sediment, and bioconcentration are not significant fate processes. The half-life of methanol in surfact water ranges from 24 hrs. to 168 hrs. Based on its vapor pressure, methanol exists almost entirely in the vapor phase in the ambient atmosphere. It is degraded by reaction with photochemically produced hydroxyl radicals and has an estimated half-life of 17.8 days. Methanol is physically removed from air by rain due to its solubility. Methanol can react with NO2 in pollulted to form methyl nitrate. The half-life of methanol in air ranges from 71 hrs. (3 days) to 713 hrs. (29.7 days) based on photooxidation half-life in air. Section 13: Disposal Considerations Waste Disposal: Waste must be disposed of in accordance with federal, state and local environmental control regulations. Section 14: Transport Information DOT Classification: CLASS 3: Flammable liquid. Identification: : Methyl alcohol UNNA: 1230 PG: II Special Provisions for Transport: Not available. Section 15: Other Regulatory Information Federal and State Regulations: Connecticut hazardous material survey.: Methyl alcohol Illinois toxic substances disclosure to employee act: Methyl alcohol Illinois chemical safety act: Methyl alcohol New York release reporting list: Methyl alcohol Rhode Island RTK hazardous substances: Methyl alcohol Pennsylvania RTK: Methyl alcohol Minnesota: Methyl alcohol Massachusetts RTK: Methyl alcohol Massachusetts spill list: Methyl alcohol New Jersey: Methyl alcohol New Jersey spill list: Methyl alcohol Louisiana spill reporting: Methyl alcohol California Directors List of Hazardous Substances (8CCR 339): Methyl alcohol Tennesse Hazardous Right to Know : Methyl alcohol TSCA 8(b) inventory: Methyl alcohol SARA 313 toxic chemical notification and release reporting: Methyl alcohol CERCLA: Hazardous substances.: Methyl alcohol: 5000 lbs. (2268 kg) Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR ). EINECS: This product is on the European Inventory of Existing Commercial Chemical Substances. Other Classifications: WHMIS (Canada): CLASS B-2: Flammable liquid with a flash point lower than 37.8 C (100 F). CLASS D-1B: Material causing immediate and serious toxic effects (TOXIC). CLASS D-2A: Material causing other toxic effects (VERY TOXIC). Class D-2B: Material causing other toxic effects (TOXIC). p. 5

266 DSCL (EEC): R11- Highly flammable. R23/24/25- Toxic by inhalation, in contact with skin and if swallowed. R39- Danger of very serious irreversible effects. R39/23/24/25- Toxic: danger of very serious irreversible effects through inhalation, in contact with skin and if swallowed. S7- Keep container tightly closed. S16- Keep away from sources of ignition - No smoking. S36/37- Wear suitable protective clothing and gloves. S45- In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible). HMIS (U.S.A.): Health Hazard: 2 Fire Hazard: 3 Reactivity: 0 Personal Protection: h National Fire Protection Association (U.S.A.): Health: 1 Flammability: 3 Reactivity: 0 Specific hazard: Protective Equipment: Gloves. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator when ventilation is inadequate. Splash goggles. Section 16: Other Information References: -SAX, N.I. Dangerous Properties of Indutrial Materials. Toronto, Van Nostrand Reinold, 6e ed Material safety data sheet emitted by: la Commission de la Santà et de la Sà curitã du Travail du Quà bec. -Hawley, G.G.. The Condensed Chemical Dictionary, 11e ed., New York N.Y., Van Nostrand Reinold, LOLI, HSDB, RTECS, HAZARDTEXT, REPROTOX databases Other Special Considerations: Not available. Created: 10/10/ :23 PM Last Updated: 05/21/ :00 PM The information above is believed to be accurate and represents the best information currently available to us. However, we make no warranty of merchantability or any other warranty, express or implied, with respect to such information, and we assume no liability resulting from its use. Users should make their own investigations to determine the suitability of the information for their particular purposes. In no event shall ScienceLab.com be liable for any claims, losses, or damages of any third party or for lost profits or any special, indirect, incidental, consequential or exemplary damages, howsoever arising, even if ScienceLab.com has been advised of the possibility of such damages. p. 6

267 Annexure-III Request letter to RO-MoEF, Bhopal

268

269

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271 Annexure-IV Photographs of existing plant site including existing greenbelt

272 Photographs Existing plant photographs

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274 Photographs of Greenbelt

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276 Annexure-V Land documents

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281 Annexure-VI Copy of Environmental Clearance (EC)

282 F. No. J-ll0ll/ IA II (I) Government of India Ministry of Environment and Forests (I.A. Division) Paryavaran Bhawan CGO Complex, Lodhi Road New Delhi ;.! To, Shri Mukesh Gupta M/s Balaji Formalin Pvt. Ltd Devarc Complex, Beside Fun Republic Cinema S. G. Road, Ahmedabad (Gujarat). info@balaiiformalin.com; Fax: pb.rastogi@nic.in Telefax: 011: Dated 24'" August, 2010 Subject: Expansion with Modernization of Formaldehyde (1.500 TPM to 5,000 TPM) Manufacturing Unit at Plot no. 1398, Nr. Rama Multi Tech Ltd., Post Moti Bhoyan, Taluka Kalol, District Gandhinagar, Gujarat by M/s Balaji Formalin Pvt. Ltd.- Environmental Clearance reg. Ref. Your letter no. nil dated 11"' May, Sir, Kindly refer your letter no. nil dated l11h May, 2010 alongwith project documents including Form I. Terms of References, Pre-feasibility Report. EIAfEMP Report alongwith public hearing report regarding above mentioned project. 2.0 The Ministry of Environment and Forests has examined the applir;ation. It is noted that proposal is for expansion with modernization of Formaldehyde manufacturing unit capacity (1500 TPM to 5000 TPM) at Plot no. 1398, Nr. Rama Multi Tecl1 Ltd., Post Moti Bhoyan. Taluka Kalol. District Gandhinagar. Gujaral. No nationa,! parklwild life sanctuary/reserve forest is located within 10 km radius of the project site. Total project area is 4,281 m 2. Total project cost is Rs Crores. No litigation/court case is pending against the project. 3.0 The tail gas containing 18 to 20 % hydrogen and small amount of formaldehyde, methanol and methane will be incinerated and waste gases will be discharged through adequate stack height. Existing boiler will be replaced by tail gas treatment unit. Waste heat will be recovered from process and tail gas treatment and utilized in MEE for evaporation. Water requirement from Narmada canal will be 104 m'/day. Industrial waste water will be evaporated through MEE after treatment. Domestic wastewater (2.5 KLD) will be disposed through septic tank/soak pit. 'Zero' discharge will be adopted and no effluent will be discharged outside the premises. 4,. 4.0 The synthetic organic chemical manufacturing units located out Side the notified industrial areas are listed at serial no. 5(f) of schedule of EtA Notification, 2006 under "A" category and apprised at central level. 5.0 Public hearing of the project was held on 4'h May, fi/".

283 2 6.0 The proposal was considered by the Expert Appraisal Committee-2 (/ncf:jstry) in its 11'" meeting held on 9'" June The Committee recommended the proposal for environmental clearance. 7.0 Based on the information submitted by the project proponent. the Ministry of Environment and Forests hereby accords environmental clearance to above project under the provisions of EIA Notification dated 14'" September 2006 subject to the compliance of the following Specific and General Conditions: A. SPECIFIC CONDITIONS: i) Efforts shall be made to reduce RSPM levels in the ambient air and a time bound action plan shall be submitted. At no time, the emission levels shall go beyond the prescribed standards. In the event of failure of any pollution control system adopted by the unit, the respective unit shall not be restarted until the control measures are rectified to achieve the desired efficiency., ii) iii) iv) Adequate pollution control measures including scrubbers and stacks of adequate height as per CPCB guidelines shall be provided to control gaseous emissions within permissible limits as per norms prescribed by the GPCB or prescribed in the E(P) Rules whichever are more stringent. The National Ambient Air Quality Emission Standards issued by the Ministry vide G.S.R. No. 826(E) dated 16'" November shall be followed. Scrubber shall be installed to' control process emission at project site. In plant control measures for checking fugitive emissions from all the vulnerable sources shall be provided. Fugitive emissions shall be controlled by providing closed storage. closed handling & conveyance of chemicals/materials. multi cyclone separator and water sprinkling system. Dust suppression system including water sprinkling system shall be provided at loading and unloading areas to control dust emissions. v) For further control offugitive emission. following steps shall be followed: vi) vii) 1. Closed handling system shall be provided for chemicals. 2. Reflux condenser shall be provided over reactor. 3. System of leak detection and repair of pump/pipeline based on preventive maintenance. 4. The acids shall be taken from storage tanks to reactors through closed pipeline. Storage tanks shall be vented through trap receiver and condenser operated on chilled water. Cathodic protection shall be provided to the underground solvent storage tanks. The gaseous emissions from DG set s~..l?e dispersed through stack height as per CPCB standards. Acoustic enclosure' shall be provided te. the DG sets to mitigate the noise pollution. Monitoring of Methanol & Formaldehyde alongwith other relevant parameters like PM,o. PM,s, SO,. NO. HC and VOCs in work zone environment, product, raw materials storage area etc. shall be carried out regularly and records maintained. The emissions shall conform to the limits imposed by GPCB. viii) The company shall uploa~ the status of compliance of the stipulated environmental clearance' conditions, including results of monitored data on its website and shall update the same periodically. II shall simultaneously be sent to ~

284 3 the Regional office of MOEF, the respective Zonal office of CPCB and the Gujarat Pollution Control Board. The levels of PM 1O, PM 25, 80 2, NOx and VOCs (ambient levels) shall be monitored and displayed at a convenient location near the main gate of the company and at important public places. ix) Solvent management shall be as follows : a. Reactor shall be connected to chilled brine condenser system b. Reactor and solvent handling pump shall have mechanical seals to prevent leakages. c. The condensers shall be provided with sufficient HTA and residence time so as to achieve more than 95% recovery d. Solvents shall measures. be stored in a separate space specified with all safety e. Proper earthing shall be provided in all the electrical equipment wherever solvent handling is done. f. Entire plant shall be flame proof. The solvent storage t3nksshall be provided with breather valve to prevent losses. x) Total water requirement from Narmada canal shall not exceed 104 m'jday and prior permission shall be obtained from the concerned department Industrial waste water shall be evaporated through MEE after treatment As proposed, 'zero' discharge shall be strictly implemented and no wastewater shall be discharged outside the premises. Domestic wastewater shall be treated in septic tank followed by soak pit. xi) xii) xiii) xiv) xv) xvi) The Company shall harvest rainwater from the rooftops of the buildings and storm water drains to recharge the ground water and use the same water for the process activities of the project to conserve fresh water. High calorific organic residues shall be sent to cement industries for burning In the kiln or disposed off to nearby TSDF site. ~ The Company shall obtain Authorization for collection, storage and disposal of hazardous waste under the Hazardous Waste (ManagE;ment, Handling and Trans boundary Movement) Rules, 2008 and amendments time to time for management of hazardous wastes and prior permission from GPCB shall be obtained for disposal of solid' hazardous waste in the TSDF. The concerned company shall undertake measures for fire fighting facilities in case of emergency. The Company shall strictly comply with the rules and guidelines under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 as amended in October, 1994 <,'lnd January, All transportation of hazardous chemicals shall be as pertlie Motor Vehicle Act (MVA), Hazardous chemicals shall be stored in tanks, drums, carboys etc. Flame arresters shall be provided on tank farm. Solvent transfer shall be done by pumps. During transfer of materials, spillages shall be avoided and garland drains be constructed to avoid mixing of accidental spillages with domestic wastewater and storm water drains. xvii) The company shall undertake following ~ minimization measures : a. Metering and control of quantities of active ingredients to minimize waste. b. Reuse of by-products from the process as raw materials or as raw material substitutes in other processes.v

285 I 4 xviii) xix) xx) xxi) xxii) c. Use of automated filling to minimize spillage. d. Use of Close Feed system into batch reactors. e. Venting equipment through vapour recovery system. f. Use of high pressure hoses for equipment clearing to reduce wastewater generation. The unit stlall make the arrangement for protection of possible fire hazards during manufacturing process in material handling. Fire fighting system should be as per the OISD 117 norms Usage of Personnel Protective Equipments (PPEs) by all employees! workers shall be ensured. Occupational health surveillance of the workers shall be done on a regular basis and records maintained as per the Factories Act. Green belt shall be developed in 1,500 m 2 (35 %) to mitigate the impact of air emissions. Selection of plant species shall be as per the CPCB guidelines. Provision shall be made for the housing for the construction labour within the site with ali necessary infrastructure and facitities such as fuel for cooking, mobile toilets, mobile sewage treatment plant, safe drinking water, medical health care, creliche etc. The housing may be in the form of temporary structure to be removed after the completion of the project. All the construction wastes shall be managed so that there is no impact on the surrounding environment. B. GENERAL CONDITIONS: ii. iii. The project authorities shall strictly adhere to the stipulations made by the Gujarat Pollution Control Board. No further expansion or modifications in the plant shall be carried out without prior approval of the Ministry of Environment and Forests. In case of deviations or alterations in the project proposal from those submitted to this Ministry for. clearance, a fresh reference shall be made to the Ministry to assess the adequacy of conditions imposed and to add additional environmental protection measures required, if any. The locations of ambient air quality monitoring stations shall be decided in consuhation with the State Pollution Control Board (SPCB) and it shall be ensured that at leas! one stations is installed in the upwind and downwind direction as well as where maximum ground level concentrations are anticipated. iv. The overall noise levels In and around the plant area shall be kept well within the standards by providing noise control measures including acoustic hoods, silencers, enclosures etc. on all sources of noise generation. The ambient noise levels shall conform to the standards prescribed under Environment (Protection) Act, 1986 Rules, 1989 viz. 75 dba (da., ẹ) and 70 dba (nigl1ttime). v. Training shall be imparted to all employees on safety and health aspects of chemicals handling. Pre-employment and routine periodical medical examinations for all employees shall be undertaken on regular basis. Training to all employees' on handling of chemicals shall be imparted. vi. The company shall also comply with all the environmental protection measures and safeguards proposed in the documents submitted to the Ministry. All the recommendations made in the EIAIEMP in respect of environmental management, risk mitigation measures and public hearing relating to the project shall also be implemented. V

286 5 vii. viii, ix, The company shall undertake all relevant measures for improving the socio- economic conditions of the surrounding area, CSR activities will be undertaken by involving local villages and administration The company shall undertake eco-developmental measures including community welfare measures in the project area for the overall improvement of the environment A separate Environmental Management Cell equipped with full fledged laboratory facilities shall be set up to carry out the Environmental Management and Monitoring functions, x, The company shall earmark adequate funds to implemeni the conditions stipulated by the Ministry of Environment and ForeSts as well as the State Government along with the implementation schedule for all the conditions stipulated herein. The funds so earmarked for environmerit management! pollution control measures shall not be diverted for any other purpose, xi. xii. A copy of the clearance letter shall be sent by the project proponent to concerned Panchayat, Zila Parisad/Municipal Corporation, Urban local Body and the local NGO; if any, from who suggestions/ representations, if any, were received while processing the proposal. The project proponent shall also submit six monthly reports on the status of compliance of the stipulated Environmental Clearance conditions including results of monitored data (both in hard copies as wei! as by ) to the respective Regional Office of MoEF, the respective Zonal Office of CPCB and the Gujarat Pollution Control Board. A copy of Environmental Clearance and six monthly compliance status report shall be posted on the website of the company, xiii. The environl11ental statement for each financial year ending 31 S1 March in Form-Vas is mandated shall be submitted to the concerned State Pollution Control Board as prescribed under the Environment (Protection) Rules, 1986, as amended subsequently, shall also be put on the website of the company along with the status of compliance of environmental clearance conditions and shall also be senfto the respective Regional Offices of MoEF by a-mail. xiv, xv. The project proponent shall inform the public that the project has been accorded environmental clearance by the Ministry and copies of the clearance letter are available with the SPCB/Committee and may also be seen at Website of the Ministry at shall be advertised within seven days from the date of issue of the clearance letter, at least in two local newspapers that are widely circulated in the region of which one shall be in the vernacular language of the locality concerned and a copy of the same shall be forwarded to the concerned Regional Office of the Ministry. The project authorities shall inform the Regional Office as well as the Ministry, the date of financial closure and final approval of the project by the concerned authorities and the date of start of the project. 8.0 The Ministry may revoke or suspend the clearance, if implementation of any of the above conditions is not satisfactory, 9,0 The Ministry reserves the right to stipulate ~ltional conditions, if found necessary, The company in a time bound manner will implement t~e conditions, Any appeal against this environmental clearance shall :Ue with the National Appellate Authority, if preferred, within a period of 30 daysprescribed under section 11 of the National Environment Appellate Authority Act, 1997,

287 The above conditions will be enforced, inter-alia under the provisions of the Water (Prevention & Control of Pollution) Act, 1974, Air (Prevention &. Control of Water Pollution) Act, 1981, the Environment (Protection) Act, 1986 Hazardous Wastes (Management and Handling) Rules, 2003/ 2008 and the Public Liability Insurance Act, 1991 along with their amendments and rules. ~~ (Dr.? B. Rastogi) Scientist 'F' Copy to : 1. The Secrela~, Environment & Forests Department, Government of GUjarat, Sachivalaya, 8 Floor, Gandhi Nagar , GUjarat. 2. The Chief Conservator of Forests (Westem Zone), Ministry of Environment & Forests, - Regional Office, E-5, Arera Colony, Link Road -3, Bhopal , MP. 3. The Chairman, Central Pollution Control Board Parivesh Bhavan, CBD-cum-Office Complex, East A~un Nagar, New Delhi The Chairman, Gujarat State Pollution Control Board, Paryavaran Bhawan, Sector 10 A, Gandhi Nagar , Gujarat. 5. Monitoring Cell,. Ministry of Environment and Forests, Paryallaran Bhavan, ego Complex, New Delhi. 6. Guard File/Monitoring File/Record File. ~~1>II" (Dr. P. B. Rastogi) Scientist 'F'

288 Annexure-VII Narmada water usage permission

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290 Annexure-VIII Health checkup record of workers

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