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Environmental Impact Assessment of the Proposed Expansion in Existing Capacity of Pesticides Technical, Intermediate & Pesticides Formulation Products & Addition of New Pesticides Technical Product within Existing Premises at M/s UPL Limited, UNIT # 02, Plot No. 3405/ 3406/3460A, Notified Industrial Estate, GIDC Ankleshwar, Bharuch, Gujarat

Final EIA Report

January 2019

www.erm.com

FINAL EIA REPORT

UPL Limited

Environmental Impact Assessment of the Proposed Expansion in Existing Capacity of Pesticides Technical, Intermediate & Pesticides Formulation Products & Addition of New Pesticides Technical Product within Existing Premises at M/s UPL Limited, UNIT # 02, Plot No. 3405/ 3406/3460A, Notified Industrial Estate, GIDC Ankleshwar, Bharuch, Gujarat

Environmental Consultant: ERM India Private Limited, Gurgaon NABET Accredited as per certificate No. NABET/EIA/1619/RA 0055, valid up to 31 October 2019

27 January 2019

Reference # I12655 0426521

Project Manager (signature, designation and date) Sankalp Anand

Senior Consultant, ERM

Client Review (signature, designation and date)

Initial Review: Purvesh Soni, Manager Environment, UPL

Final Review: Dr. Mritunjay Chaubey, Vice President, UPL

NABET Approved EIA Coordinator for Pesticide Sector

Subir Gupta Senior Advisor, ERM

Environmental Resources Management Group of companies, with all reasonable skill, care and diligence within the terms of the Contract with the client, incorporating our General Terms and Conditions of Business and taking account of the resources devoted to it by agreement with the client.

We disclaim any responsibility to the client and others in respect of any matters outside the scope of the above.

This report is confidential to the client and we accept no responsibility of whatsoever nature to third parties to whom this report, or any part thereof, is made known. Any such party relies on the report at their own risk.

Declaration by Experts contributing to the EIA of Proposed Expansion in Existing Capacity of Pesticides Technical, Intermediate & Pesticides Formulation Products & Addition of New Pesticides Technical Product within Existing Premises at M/s UPL Limited, UNIT # 02, Plot No. 3405/ 3406/3460A, Notified Industrial Estate, GIDC Ankleshwar, Bharuch, Gujarat

EIA Coordinator

I, hereby, certify that I was a part of the EIA team in the following capacity that developed the above EIA. EIA coordinator : Subir Gupta

Signature and Date: 27 January 2019

Period of involvement : From December 2017 – January 2019

Contact information : ERM India Private Limited, 4th Floor, Tower A, Building 10, DLF Cyber City, Gurgaon. Tel: 91-124-4170300 Email: [email protected]

Functional Area Experts

SN. Functional Areas Name of the Experts (FAE) & Dates

Involvement Signature & Date

1. Air Pollution Control

Naval Chaudhary (FAE)[Mar. to Dec. 2018]

Sankalp Anand (Team Member) [Mar. to Dec. 2018]

Selection of Air quality monitoring stations, discussion with client on various air pollution control aspects and changes in the impacts from the proposed project and development of EMP.

2. Water Pollution Control

Dr. Koel Kumar (FAE)[Mar. to Sep. 2018]

Selection of water monitoring stations, interpretation of analysis results, discussion with client on initiatives for water and wastewater management, inputs for impact assessment and development of EMP.

Left Organisation

3. Air Quality Modelling

Naval Kishore Chaudhary (FAE) [Jun 2018. to Jan. 2019]

Sankalp Anand (FAE)[Jul 2018. to Jan. 2019]

Undertaking Air Quality &Noise Quality Modelling.

Inputs related to givenfunctional area –model inputdata related to emissions andmicrometeorological data

Interpretation of modellingresults and discussion withclient on mitigationmeasures.

4. Noise Naval Kishore Chaudhary (FAE) [Mar2018. to Jan. 2019]

Undertaking Noise QualityModelling;

SN. Functional Areas Name of the Experts (FAE) & Dates

Involvement Signature & Date

Sankalp Anand (FAE)[Feb2018. to Jan. 2019]

Selection of noise samplinglocations for baselinemonitoring

Interpretation of modellingresults and mitigationmeasures.

5. Solid & Hazardous Waste

Dr. Koel Kumar (FAE)[Mar. to Sep. 2018]

Review of existing SHW management and details provided by the client and support for impact assessment, and development of EMP.

Left Organisation

6. Socioeconomics Neena Singh (FAE) [Mar.to Dec. 2018)

Rutuja Tendolkar (FAE) [Mar. 2018 to Jan. 2019]

Pranalee Balsaraf(Team Member) [Mar.2018 to Jan. 2019]

Socio economic baseline survey, data collection, stakeholder consultations and impact assessment.

7. Ecology and Biodiversity

Dr. Abhishek Roy Goswami (FAE) [Mar. to Dec. 2018]

SaumabhaBhattacharya (Teammember) [Mar. to Dec.2018]

Ecological survey and assessment of flora and fauna and related impact assessment and development of EMP

8. Geology Samrat Basak (FAE) [Mar. 2018]

Inputs related to the given functional area – Geology related baseline and impact assessment.

Left theOrganization on Apr. 3rd 2018

9. Hydrogeology Kiran Kesireddy (FAE)[Jul. to Sep. 2018]

Inputs related to Hydrogeology related baseline and impact assessment.

10. Land use Kiran Kesireddy (FAE)[Jun. to Dec. 2018]

Jayakrishna Vasam(Team Member) [Jun. toDec. 2018]

Preparation of all maps including LULC and impact assessment.

11. Soil Conservation Rajesh Mohanan (FAE)[Apr. 2018 to Jul. 2018]

Review of baseline soil quality and soil contamination impacts in impact assessment.

12. Risk and Hazards DebanjanBandyopadhyay (FAE) [Aug. 2018to Jan. 2019]

Subhradeb Pramanik(Team Member) [Aug.2018 to Jan. 2019]

Consequence modelling and Quantitative Risk Assessment for the project.

I, Neena Singh, hereby, confirm that the above mentioned experts prepared the EIA of Proposed Expansion in Existing Capacity of Pesticides Technical, Intermediate & Pesticides Formulation Products & Addition of New Pesticides Technical Product within Existing Premises at M/s UPL Limited, UNIT # 02, Plot No. 3405/ 3406/3460A, Notified Industrial Estate, GIDC Ankleshwar, Bharuch, Gujarat. I also confirm that the consultant organization shall be fully accountable for any misleading information mentioned in this statement.

Signature:

Name: Designation:

Neena Singh Managing Partner

Name of the EIA consultant organization: ERM India Private Limited Date: 27.01.2019

NABET Certificate No. & Issue Date: NABET/EIA/1619 /RA 0055 dated Jun 21, 2017 valid up to 31 October 2019

ERM's Accreditation from NABET

CONTENTS

0.1 EXECUTIVE SUMMARY I

1 INTRODUCTION 1

1.1 BACKGROUND 1 1.1.1 Location of the Project 1 1.2 ENVIRONMENTAL SETTING OF THE PROJECT 1 1.3 BRIEF OF EXISTING & PROJECT PROJECT FACILITIES 10 1.3.1 Existing Facilities 10 1.3.2 Proposed Expansion Facilities 10 1.4 PESTICIDE CONSUMPTION PATTERN IN INDIA 10 1.5 DEMAND SUPPLY GAP 11 1.6 EXPORT POSSIBILITY & DOMESTIC EXPORT MARKETS 12 1.7 NEED FOR THE PROJECT, ITS IMPORTANCE TO THE COUNTRY & BENEFITS OF THE

PROJECT 13 1.8 EMPLOYMENT OPPORTUNITIES 14 1.9 PURPOSE OF THE EIA STUDY 14 1.9.1 Banned Pesticides 15 1.10 SCOPE OF EIA STUDY 16 1.11 METHODOLOGY ADOPTED FOR CONDUCT OF THE EIA STUDY 16 1.11.1 Step I: General Screening 16 1.11.2 Step II: Scoping Exercise involving ToR Approval by EAC for conducting EIA

Study 16 1.11.3 Step III: Project Description 17 1.11.4 Step IV: Environmental Baseline Data Compilation 17 1.11.5 Step V: Impact Assessment & Development of Analysis of Alternatives 17 1.11.6 Step VI: Environment Management Plan 18 1.12 LIMITATIONS 18 1.13 CONTENTS OF THE EIA REPORT 19

2 PROJECT DESCRIPTION 21

2.1 DETAILS OF PROPOSED EXPANSION 21 2.2 MANUFACTURING PROCESS DETAILS 30 2.2.1 Devrinol (Existing and Proposed) 30 2.2.2 D-Devrinol (Existing) 32 2.2.3 Clomazone (Existing and Proposed) 35 2.2.4 Metobromuron (Existing) 41 2.2.5 Terbuphos (Existing) 45 2.2.6 Metasystox (Existing) 47 2.2.7 Acephate (Existing and Proposed) 49 2.2.8 Metamitron (Existing) 53 2.2.9 Surflan (Oryzalin) (Existing) 56 2.2.10 Azoxystrobin (Existing & Proposed) 59 2.2.11 Ethofumesate (Existing & Proposed) 63 2.2.12 Mesotrion (Existing) 65 2.2.13 Pyrazosulfuran Ethyl Technical (Existing): 69

2.2.14 Monochrotophos (Existing & Proposed) 75 2.2.15 2-4 D Technical (2, 4 – Dichloro Phenoxy Acetic Acid.) (Existing) 77 2.2.16 Acetamiprid (Existing & Proposed) 79 2.2.17 Imidacloprid (Existing & Proposed) 82 2.2.18 Imidacloprid (Proposed- New Route) 84 2.2.19 Metribuzin Process Description - (Existing) 86 2.2.20 Metribuzin (New Route) 88 2.2.21 Imazapic Technical (Proposed) 90 2.2.22 Diethyl Thiophosphoryl Chloride (DETCL) (Existing) 93 2.2.23 Amino Aceto Nitrile Sulphate (AANS) (Existing) 95 2.2.24 Myristyl Amine Oxide (MO) (Existing) 96 2.2.25 Parachloro Ortho Cresol (PCOC) (Existing ) 98 2.2.26 Dimethyl Phosphoro Amidothioate (DMPAT) (Existing & Proposed) 99 2.2.27 Dimethyl Phosphoro Amido Thioate (DMPAT) – Proposed New Route 100 2.2.31 Dimethyl Methyl Phosphonate (DMMP) (Existing & Proposed) 103 2.2.32 Di Ethyl Thiophosphoryl Chloride (DETA) (Existing & Proposed) 104 2.2.33 Zinc Di Thio Phosphate (ZnDTP) (Existing & Proposed) 105 2.2.34 Absolute Alcohol (Existing) 107 2.2.35 NOFLAN (EXISTING) 107 2.3 RESOURCE REQUIREMENT 110 2.3.1 Land 110 2.3.2 Water 110 2.3.3 Power 111 2.3.4 Raw Materials 113 2.4 POLLUTION CHARACTERIZATION, SOURCES AND THEIR CONTROL 121 2.4.1 Air Emissions 121 2.4.2 Solid Waste Management 124 2.4.3 Wastewater Management 125 2.4.4 Hazardous Chemicals Management 133 2.4.5 Water Conservation Measures 136 2.4.6 Solvent Recovery Management 138 2.5 GREENBELT DEVELOPMENT 138 2.6 LITIGATION DETAILS 140 2.7 REGULATORY FRAMEWORK 140 2.8 PROJECT SCHEDULE AND COST 143

3 DESCRIPTION OF THE ENVIRONMENT 144

3.1 OVERVIEW 144 3.2 BASELINE – PHYSICAL ENVIRONMENT 144 3.2.1 Topography 144 3.2.2 Geology and Hydrogeology 146 3.2.3 Meteorology 149 3.2.4 Ambient Air Quality 152 3.2.5 Stack Emissions Monitoring 162 3.2.6 Ambient Noise Quality 162 3.2.7 Traffic Survey 166 3.2.8 Water Quality 168 3.2.9 Land use/ Land Cover 179 3.2.10 Soil Quality 180 3.3 BASELINE – ECOLOGICAL ENVIRONMENT 184 3.3.1 Objective 185

3.3.2 Approach and Methodology 185 3.3.3 Habitat Assessment 190 3.3.4 Floral Assessment 192 3.3.5 Faunal Assessment 196 3.3.6 Protected Area 201 3.4 BASELINE – SOCIAL ENVIRONMENT 202 3.4.1 Approach and Methodology 202 3.4.2 State & District Profile 203 3.4.3 Study Area Profile 206 3.4.4 Livelihood profile 211 3.4.5 Civic infrastructure 214 3.4.6 Industrial outreach programmes 216

4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 217

4.1 INTRODUCTION 217 4.2 IMPACT EVALUATION CRITERIA 217 4.2.1 Determining Magnitude of an Impact 217 4.2.2 Determining Sensitivity / Importance/Vulnerability of Receptors 221 4.2.3 Evaluating Significance of Impacts 222 4.3 IDENTIFICATION OF POTENTIAL IMPACTS FOR UNIT 2 EXPANSION 223 4.4 POTENTIAL IMPACTS AND MITIGATION MEASURES DURING CONSTRUCTION

PHASE 226 4.4.1 Impacts on Land Environment 227 4.4.2 Impacts on Air Quality 228 4.4.3 Impacts on Noise Quality 230 4.4.4 Impacts on Water Resource 232 4.4.5 Impact on Ecology during Construction Phase 234 4.4.6 Socioeconomic Impacts 236 4.4.7 Impacts due to Change in Land Use 236 4.4.8 Impacts on Community Health and Safety 238 4.5 POTENTIAL IMPACTS AND MITIGATION MEASURES DURING OPERATION

PHASE 239 4.5.1 Impacts on Land Environment from Project Components 239 4.5.2 Impacts on Air Quality 245 4.5.3 Impacts on Noise Quality due to Proposed Expansion Project 263 4.5.4 Impacts on Water Quality 265 4.5.5 Impact on Ecology during Operation Phase 269 4.5.6 Impacts of Socioeconomic Environment 271 4.6 NON-ROUTINE IMPACTS/RISKS 272

5 ANALYSIS OF ALTERNATIVES 273

5.1 BACKGROUND 273 5.1.1 Alternate Source of Land 273 5.1.2 Additional Wastewater treatment facilities 273 5.1.3 Additional Power Sourcing 273 5.1.4 Addition Manpower sourcing 274

6 ENVIRONMENTAL MONITORING PROGRAM 275

6.1 APPROACH 275

6.2 SCOPE 275 6.2.1 Monitoring parameters and frequency 275 6.2.2 Guidelines for External Agency 276 6.2.3 In-house Laboratory at UPL 277 6.2.4 Odour Monitoring 277 6.2.5 Leak Detection Monitoring 277

7 ADDITIONAL STUDIES – RISK ASSESSMENT AND EMERGENCY RESPONSE PLAN 279

7.1 PUBLIC CONSULTATION 279 7.2 RISK ASSESSMENT 279 7.3 RA STUDY OBJECTIVE 280 7.4 RA METHODOLOGY 280 7.5 PROJECT – FLAMMABLE AND TOXIC MATERIAL STORAGE DETAILS 281 7.6 HAZARD IDENTIFICATION 284 7.6.1 Hazards from Flammable Chemical Storages 284 7.6.1 Hazards from Toxic Chemical Storages 285 7.7 FREQUENCY ANALYSIS 289 7.7.1 Frequency Analysis – Flammable Fuel & Chemical Storage Tankages 289 7.8 CONSEQUENCE ANALYSIS 290 7.8.1 Consequence Analysis – Tankages 292 7.9 RA OUTCOME 298 7.10 EMERGENCY PREPAREDNESS AND RESPONSE PLAN 300 7.10.1 Classification of Emergency 300 7.10.2 Emergency Response Personnel 301 7.10.3 Emergency Control Centre 302 7.10.4 Other companies/ external organizations to be involved in on-site

emergency 303 7.10.5 List of Emergencies 303 7.10.6 Identification and Assessment of Hazards 303 7.10.7 Emergency due to Natural Calamities 304 7.10.8 Communication Arrangements for On-site and Off-site Emergencies 304 7.11 OCCUPATIONAL HEALTH AND SAFETY 305 7.11.1 In-Plant Safety Precautions Employed 305 7.11.2 Approach for Safety Management 306 7.11.3 Occupational health programs 307

8 PROJECT BENEFITS 308

8.1 DEMAND SUPPLY GAP 308 8.2 SOCIAL BENEFITS 308 8.3 EMPLOYMENT GENERATION 313

9 ENVIRONMENTAL COST BENEFIT ANALYSIS 315

10 ENVIRONMENTAL MANAGEMENT PLAN 316

10.1 INTRODUCTION 316 10.2 ELEMENTS OF EMP 316 10.2.1 Commitment & Policy 316 10.2.2 Planning 318 10.2.3 Implementation 321

10.2.4 Checking 322 10.2.5 Management Review 323 10.3 MANAGEMENT ACTION 324 10.4 BUDGET ALLOCATION FOR THE ENVIRONMENTAL MANAGEMENT PLAN 325

11 SUMMARY AND CONCLUSION 340

12 DISCLOSURE OF CONSULTANT 342

13 TERMS OF REFERENCE FOR EIA STUDY 343

List of Tables

Table 1.1 State-wise Consumption of Pesticides (Technical Grade) 11 Table 1.2 Employment Generation from the Proposed Project 14 Table 1.3 Contents of the EIA Report 19 Table 2.1 Product List for the Proposed Expansion of Unit 2 23 Table 2.2 List of By-Products 28 Table 2.3 Land Area Break-up Details 110 Table 2.4 Details of Water Requirement (Existing and after Proposed Expansion) 111 Table 2.5 Raw Materials Detail for Existing and Proposed Project 113 Table 2.6 Details of Flue Gas Emissions (as on July 2018) 122 Table 2.7 Details of Process Emissions 122 Table 2.8 Fugitive Emissions Monitoring (as per January - June 2018 report) 124 Table 2.9 Details of Wastewater Generation (Existing and after Proposed Expansion) 126 Table 2.10 PESO Licenses Details 134 Table 2.11 Hazardous Chemicals Storage Details 135 Table 2.12 Plantation at Unit 2 139 Table 2.13 Environmental Clearance (EC) Details 141 Table 2.14 Applicable Regulatory Framework UPL Unit 2 142 Table 2.15 Details of Estimated Project Cost 143 Table 3.1 Climatological Data of Bharuch IMD Station (1951 - 1980) 149 Table 3.2 Summary of Meteorological Conditions in the Study Area 149 Table 3.3 Testing Methods used for Ambient Air Quality Monitoring 152 Table 3.4 Ambient Air Quality Monitoring Locations 153 Table 3.5 Ambient Air Quality Monitoring Results 154 Table 3.6 Unit 2 Stack Emissions Detail 162 Table 3.7 Ambient Noise Quality Monitoring Locations 163 Table 3.8 Noise Level in the Study Area 165 Table 3.9 Traffic Survey Locations surrounding the project area 166 Table 3.10 Analysis of Traffic volumes in the study area 167 Table 3.11 Composition of Traffic 167 Table 3.12 Details of Water Sampling Locations 168 Table 3.13 Surface Water Quality in the Study Area 174 Table 3.14 Groundwater Quality in the Study Area 176 Table 3.15 Land use Classification of 10km area surrounding the Project Site 179 Table 3.16 Soil Quality Monitoring Locations 180 Table 3.17 Soil Quality within Study Area 182 Table 3.18 Soil Remediation Intervention Values as per Dutch Standards 184 Table 3.19 Standard Soil Classification 184 Table 3.20 Details of the Vegetation Sampling Plots 188 Table 3.21 Water Bodies in the Study Area 191 Table 3.22 Different types of Habitat in the Study Area 191 Table 3.23 Tree Species Used for Green Belt Development 192 Table 3.24 Trees Used for Avenue Plantation 193 Table 3.25 Phytosociological Characteristics of Tree Species in Homestead Plantation 193 Table 3.26 Phytosociological Characteristics of Shrub and Herb Species in Homestead

Plantation 194 Table 3.27 Phytosociological Characteristics of Tree Species in Agricultural Fields 194 Table 3.28 Phytosociological Characteristics of Shrub and Herb Species in Agricultural

Fields 195

Table 3.29 Phytosociological Characteristics of Tree Species in Scrub lands 195 Table 3.30 Phytosociological Characteristics of Shrub and Herb Species in Scrub

Lands 196 Table 3.31 Species Richness and Species Diversity Index of the surveyed habitats 196 Table 3.32 Fish Diversity of the Study Area 197 Table 3.33 Herpetofauna reported and observed in the Study Area 198 Table 3.34 Avifaunal Species observed in the Study Area during primary survey 199 Table 3.35 Mammals Reported from the Study Area 201 Table 3.36 Stakeholders consulted during site visit 203 Table 3.37 Key demographic features of Gujarat State 204 Table 3.38 Key demographics of the Study Area 207 Table 3.39 Percentage of Working Population in the Study Area 212 Table 3.40 Water Sources in the Study Area 215 Table 3.41 Health Care Facilities in the Study Area 215 Table 4.1 Assessing Magnitude of Impact 220 Table 4.2 Sensitivity/ Importance/ Vulnerability Criteria 222 Table 4.3 Project Activities, Related Events & Likely Resources / Receptors Affected 224 Table 4.4 Typical Peak Noise Levels Expected at a Construction Site 231 Table 4.5 Hazardous Waste Details - Existing and Proposed 242 Table 4.6 Inputs for Air Dispersion Modelling Using AERMOD Model 246 Table 4.7 Flue gas and process gas Emissions Sources from the Proposed Expansion

Project 247 Table 4.8 Maximum Predicted Incremental Ground Level Concentrations 248 Table 4.9 Projected Ambient Air Quality Concentrations from the Proposed Project 249 Table 4.10 Additional Traffic Due to the Proposed Expansion Project 257 Table 4.11 Emissions from Vehicular Traffic 257 Table 4.12 Maximum Predicted GLC from the Additional Traffic in the Proposed

Project 257 Table 4.13 Predicted Noise Level from the Proposed Project 264 Table 4.14 Details of Water Requirement (Existing and after Proposed Expansion) 266 Table 4.15 Details of Wastewater Generation (Existing and after Proposed Expansion) 266 Table 6.1 Environmental Monitoring Plan for Construction and Operation Phase 276 Table 7.1 Flammable and Toxic Chemical Storage Details –Existing and Proposed 282 Table 7.2 Hazard Summary of Toxic Chemicals 287 Table 7.3 Frequency Categories and Criteria 289 Table 7.4 Tank Failure Frequency – Flammable and Toxic Chemicals 289 Table 7.5 Ignition Probabilities from Cox, Lees and Ang 290 Table 7.6 Severity Categories and Criteria 291 Table 7.7 Risk Matrix 292 Table 7.8 Risk Criteria and Action Requirements 292 Table 7.9 Flammable & Toxic Chemical Storages– Risk Modelling Scenarios 293 Table 7.10 Hazardous Chemical Storages – Risk Modelling Results 296 Table 7.11 List of Emergencies identified at UPL 303 Table 8.1 CSR Initiatives by UPL in Sourrounding Villages of Unit 2 314 Table 10.1 Break-up of Five- year CSR budget 325 Table 10.2 Environmental Management Plan for the Project 326

List of Figures

Figure 1.1 Layout of GIDC Ankleshwar Estate, Ankleshwar 2 Figure 1.2 Location Map of the Project Site 3 Figure 1.3 Project Site Location on Toposheet 4 Figure 1.4 Geographical Coordinates of the Project Site 5 Figure 1.5 Environmental Setting of UPL Limited Unit 2 6 Figure 1.6 Physical Features of the Study Area 7 Figure 1.7 Photographs of the Project Site 9 Figure 1.8 Pesticide (Technical Grade) Consumption in India 11 Figure 1.9 Comparison of Pesticide Consumption (kg/ha) 12 Figure 1.10 Export and Import of Major Agro-chemicals in 2016-17 13 Figure 2.1 Plot Plan for the Proposed Unit 2 Expansion Project 22 Figure 2.2 Process Flow Diagram 31 Figure 2.3 Process Flow Diagram with Quantity 34 Figure 2.4 Process Flow Diagram 37 Figure 2.5 Process Flow Diagram for Clomazone 40 Figure 2.6 Process Flow Diagram for Clomazone (Step 1: PIC to PHU) 43 Figure 2.7 Process Flow Diagram Clomazone (Step 2: PHU to PMMU) 43 Figure 2.8 Process Flow Diagram - Clomazone (Step 3: PMMU to MBN) 44 Figure 2.9 Process Flow Diagram for Terbuphos (Existing) 46 Figure 2.10 Process Flow Diagram Metasystox (Existing) 48 Figure 2.11 Process Flow Diagram (Acephate (Existing) 51 Figure 2.12 Process Flow Diagram (Metamitron (Existing) 55 Figure 2.13 Process Flow Diagram Surflan (Oryzalin) (Existing) 58 Figure 2.14 Process Flow Diagram Azoxystrobin (Existing & Proposed) 61 Figure 2.15 Process Flow Diagram (Ethofumesate (Existing & Proposed) 64 Figure 2.16 Process Flow Diagram Mesotrion (Existing) (STEP I: MSNBA to MSNBC) 66 Figure 2.17 Process Flow Diagram Mesotrion (Existing) (STEP II&III: MSNBC to EST to

Me-328) 67 Figure 2.18 Process Flow Diagram - Tea Recovery 67 Figure 2.19 Process Flow Diagram Pyrazosulfuran Ethyl Technical (Step-I) 71 Figure 2.20 Process Flow Diagram Pyrazosulfuran Ethyl Technical (Step II) 72 Figure 2.21 Process Flow Diagram – Pyrazosulfuron Ethyl 74 Figure 2.22 Process Flow Diagram 76 Figure 2.23 Process Flow Diagram 78 Figure 2.24 Process Flow Diagram 81 Figure 2.25 Process Flow Diagram 83 Figure 2.26 Process Flow Diagram: 85 Figure 2.27 Process Flow Diagram 87 Figure 2.28 Process Flow Diagram 89 Figure 2.29 Stochiometric Balanced Chemical Reaction 91 Figure 2.30 Imazipic Preparation 91 Figure 2.31 Process Flow Diagram 92 Figure 2.32 Process Flow Diagram 94 Figure 2.33 Process Flow Diagram 96 Figure 2.34 Process Flow Diagram 97 Figure 2.35 Process Flow Diagram 98 Figure 2.36 Process Flow Diagram 99 Figure 2.37 Process Flow Diagram 102

Figure 2.38 Process Flow Diagram 103 Figure 2.39 Process Flow Diagram 104 Figure 2.40 Process Flow Diagram 106 Figure 2.41 Process Flow Diagram 109 Figure 2.42 Water Balance for the Proposed Project 112 Figure 2.43 Scrubbers for Gaseous Emissions at Unit 2 123 Figure 2.44 Hazardous Waste Storage Facility as per MoEF/CPCB Guidelines at Unit 2 125 Figure 2.45 Schematic of Zero Liquid Discharge (ZLD) from Unit 2 126 Figure 2.46 Effluent Treatment Plant (ETP) at Unit 2 128 Figure 2.47 Schematic of ETP 129 Figure 2.48 Existing RO Plant at Unit 2 130 Figure 2.49 Schematic of Proposed STP 132 Figure 2.50 Snapshot of Hazardous Chemical Storage 133 Figure 2.51 Implementation of Rooftop Rainwater Harvesting at Unit 2 137 Figure 2.52 Greenbelt Development at Unit 2 139 Figure 2.53 Additional Greenbelt Development by UPL Unit 2 140 Figure 3.1 Topography of Study Area 145 Figure 3.2 Hydrogeological Map: District Bharuch 147 Figure 3.3 Depth to Water Levels of Bharuch District as per CGWB 148 Figure 3.4 Windrose- (Wind Blowing from) March 2018 to May 2018 151 Figure 3.5 Map Showing AAQ Monitoring Locations in the Study Area 156 Figure 3.6 Graphical Presentation of Observed PM10 Concentration 157 Figure 3.7 Graphical Presentation of Observed PM2.5 Concentration 158 Figure 3.8 Graphical Presentation of Observed SO2 Concentration 158 Figure 3.9 Graphical Presentation of Observed NO2 Concentration 159 Figure 3.10 Graphical Presentation of Observed CO Concentration 159 Figure 3.11 Graphical Presentation of Observed NH3 Concentration 160 Figure 3.12 Photographs of Ambient Air Quality Sampling 161 Figure 3.13 Location of Noise Monitoring Stations 164 Figure 3.14 Noise Quality at Monitoring Locations 165 Figure 3.15 Location of traffic survey stations 166 Figure 3.16 Traffic Survey Photographs 168 Figure 3.17 Photographs of Water Sampling 171 Figure 3.18 Map Showing Surface Water Monitoring Locations within the Study Area 172 Figure 3.19 Map Showing Ground Water Monitoring Locations within the Study Area 173 Figure 3.20 Landuse of 10 km radius study area surrounding the Project site 179 Figure 3.21 Soil Quality Monitoring Locations within the Study Area 180 Figure 3.22 Photographs of Soil Sampling 181 Figure 3.23 Location Map of Vegetation Survey 189 Figure 3.24 Protected Area 202 Figure 3.25 Population Density in the Study Area 205 Figure 3.26 Population Density Across the Study Area 209 Figure 3.27 Percentage of Working Population in the Study Area 211 Figure 4.1 Impact Significance 222 Figure 4.2 Incremental Noise Levels during Construction Phase 231 Figure 4.3 Plantation Undertaken by UPL at Mandva Village 235 Figure 4.4 Predicted 24-hourly Maximum PM10 Concentration in Study Area 250 Figure 4.5 Predicted 24-hourly Maximum SO2 Concentration in Study Area 251 Figure 4.6 Predicted 24-hourly Maximum NO2 Concentration in Study Area 252 Figure 4.7 Predicted 24-hourly Maximum VOC Concentration in Study Area 253

Figure 4.8 Predicted 24-hourly Maximum HCl Concentration in Study Area 254 Figure 4.9 Predicted 24-hourly PM from Additional Traffic 259 Figure 4.10 Predicted 24-hourly NO2 from Additional Traffic 260 Figure 4.11 Predicted 8-hourly CO from Additional Vehicular Traffic 261 Figure 4.12 Predicted 24-hourly HC from Additional Traffic 262 Figure 4.13 Incremental Noise Level due to the Proposed Project 264 Figure 4.14 Zero Liquid Discharge (ZLD) Plant at Unit 2 267 Figure 7.1 Risk Assessment Methodology 281 Figure 7.2 Map showing Existing and Proposed Tanks in UPL Plant 283 Figure 7.3 IRT Organizational Support Matrix 301 Figure 7.4 Arrangement for off-site emergency plan and communication 305 Figure 8.1 UPL Vasudha Programme 311 Figure 8.2 Skill development of youths of nearby community 312 Figure 10.1 UPL’s HSE Policy 317 Figure 10.2 UPL’s Corporate Social Responsibility Policy 318 Figure 10.3 UPL’s HSE Organization Chart 320

List of Annexures

Annexure A: Copies of Previous Environmental Clearances

Annexure B: Copy of Certified EC Compliance Report for the Period January to June 2018 Received from Regional Office, MoEF&CC Bhopal.

Annexure C: Copy of CC&A/CTO Compliance Report submitted to GPCB

Annexure D: Site Specific Meteorological Data (February 2018 – May 2018)

Annexure E: Onsite Ambient Air Quality (AAQ), Noise and Traffic data for the Study Period (February – May 2018) & NABL Accreditation for CEG Test House & Research Centre Private Limited (3rd Party Environmental Baseline Monitoring Agency)

Annexure F: Copy of Material Safety Data Sheet of Products and Raw Materials

Annexure G: Risk contours for flammable and toxic chemical storages

Annexure H: Existing Onsite Emergency Response Plan

Annexure I: Onsite Annual Medical Check-up and Medical Examination Record

Annexure J: Membership Certificate for Common Solid/Hazardous Waste Disposal Facility and Common Incineration Facility of Bharuch Enviro Infrastructure Limited (BEIL), GIDC, Ankleshwar

Annexure K: Copy of Approval for Additional Water from Gujarat Industrial Development

Corporation (GIDC)

Annexure L : Copy of CC&A and Renewal Application for CC&A as Submitted to GPCB

Annexure M : Copy of FETP Membership

Annexure N : Action Plan for Solvent Recovery Submitted to MoEF&CC as part of EC Compliance

Annexure O : Commitment on No Banned Pesticides Production

Abbreviations

AAQ Ambient air Quality ACF Activated Carbon Filter AEGL Acute Exposure Level Guidelines AERMOD AMS EPA Regulatory Model AIE Ankleshwar Industrial Estate ALARP As Low As Reasonably Practicable ALOHA Areal Locations of Hazardous Atmospheres ANQ Ambient Noise Quality APCD Air Pollution Control Device APCM Air Pollution Control Measures APHA American Public Health Association API American Petroleum Institute ASTM American Society for Testing and Materials BDL Below detectable limit BEIL Bharuch Enviro Infrastructure Ltd bgl Below ground level BOD Biological Oxygen Demand CA Contract Agreement CAS Chemical Abstracts Service CBEC Central Board of Excise and Customs CC& A Consolidated Consent of Authorization CCD Closed Circuit Desalination CCR Central Control Room CER Corporate Environmental Responsibility CFM Cubic Feet per Minute CGWB Central Ground Water Board CIMAH Control of Industrial Major Accident Hazards COD Chemical Oxygen Demand CPCB Central Pollution Control Board CSO Central Statistic Office CSR Corporate Social Responsibility CTE Consent to Establish CTO Consent to Operate DDMP Di Methyl Phosphate DDVP Dichlorovos DEA Di ethanolamine DEAA Diethyl Acetyl Acetoacetemide DETCL Diethyl Thiophosphoryl Chloride DG Diesel Generator DGVCL Dakshin Gujarat Vij Company Limited DMF Dual Media Filter DMP Disaster Management Plan EAC Expert Appraisal Committee EDC Ethylene di chloride EDG Emergency Diesel Generator EHS Environmental, Health and Safety EIA Environmental Impact Assessment

EMP Environmental Management Plan EMS Environmental Management System ENVIS Environmental Information System EPA Environmental Protection Agency ERM Environmental Resource management ERP Emergency Response Plan ERPG Emergency Response Planning Guidelines ESIC Employees State Insurance Corporation ETA Event Tree Analysis ETP Effluent Treatment Plant FICCI Federation of Indian Chambers of Commerce and Industry FRU First Referral Units GCA Gross Crop area GDP Gross Domestic Product GIDC Gujarat Industrial Development Corporation GIDR Gujarat Institute of Development Research GLC Ground Level Concentrations GPCB Gujarat Pollution Control Board GPS Geographical Positioning System GWQ Ground Water Quality GWRDC Gujarat Water Resources Development Corporation HAZOP Hazard and Operability Study HMV Heavy Motor Vehicles HP High Pressure HS& E Health , Safety and Environmental Policy HSD High Speed Diesel HSE Health, Safety and Environment HSEMS Health ,Safety and Environmental Management System HWA Hazardous Waste Authorization IBA Indian Boiler Association ICAR Indian Council for Agricultural Recearch ICC Indian Chemical Council IUCN International Union for Conservation of Nature IVI Important Value Index LC Least Concern LDAR Leak Detection and Repair LISS Linear Imagine and self Scanning LMV Light Motor Vehicles LOC Level of Concern LPG Liquid Petrolieum gas MCF Micro-cartridge filter MCLS Maximum Credible Loss Scenario MEE Multiple Effect Evaporator

MGNREG Mahamta Gandhi National Rural Employment Guarantee Scheme

MHV Mobile Health Van MLSS Mixed Liquor Suspended Solids MLVSS Mixed Liquor Volatile Suspended Solids MoEF & CC Ministry of Environment, Forests and Climate Change MSDS Material Safety Data Sheet

MSIHC Manufacture, Storage and Import of Hazardous Chemicals MSME Micro, Small and Medium Enterprises MSW Municipal Solid Waste MTPM Metric Tons Per Month N.G. & F.O Natural Gas and Furnace Oil NAAQS National Ambient Air Quality Standards NABL National Accredition Board for Testing and Calibration NaSH Sodium Hydrogen Sulphide NG Natural gas NGT National Green Tribunal NI 2-nitro imino imidazolidine NMHC Non -methane Hydrocarbon NOC No Objection Certificate NRSC National Remote Sensing Centre NT Near Threatened ONSEMP Onsite Emergency Preparedness Plan PESO Petroleum Explosive Safety Organization PPE Personal Protective Equipment PSV Pressure Shutdown Valve QA Quality Assurance QC Quality Control RA Risk Assessment RO Reverse Osmosis ROSOV Remote Operated Shut off valve RVI Relative Value Index SHG Self Help Groups SIL Safety Integrity Level SPCB State Pollution Control Board SPL Sound Pressure levels SQ Soil Quality SRB Sex Ratio at Birth STP Sewage Treatment Plant TDS Total Dissolved solids TERI The Energy and Resource Institute TLV Threshold Limit Value ToR Terms of Reference TPA Tons per Annum TPH Tons per Hour TSDF Treatment, Storage and Disposal Facility TWA Total weighted Average UNDP United Nations Development Programme VCE Vapour Cloud Explosion VFD Variable Frequency Device VOC Volatile Organic Compound WGS World Geographic System WPA Wildlife Protection Act, 1972 WPR Worker Participation Rate ZLD Zero Liquid discharge ZnDTP Zinc Di Thio Phosphate

ERM EIA STUDY FOR THE PROPOSED EXPANSION IN EXISTING CAPACITY OF UNIT 2, GIDC ANKLESHWAR PROJECT # 0426521 UPL LIMITED, JANUARY 19

ES - I

0.1 EXECUTIVE SUMMARY

0.2 Introduction

UPL Ltd. is a global generic crop protection, chemicals and seeds company, headquartered in India (Mumbai). UPL Limited is engaged in manufacturing of wide range of pesticides (technical), intermediates of pesticides and other inorganic chemicals. UPL LIMITED (UNIT-02) is an operational pesticides & intermediates manufacturing unit located at Plot No. 3405/3406/3460A, Notified Gujarat Industrial Development Corporation (GIDC) estate, Ankleshwar, Dist. Bharuch, Gujarat. The geographical coordinates of Unit 2 site are located within Latitude 21°37'43.31"N to 21°37'42.81"N and 21°37'35.24"N to 21°37'34.18"N and Longitude 73° 2'2.35"E to 73° 2'9.66"E and 73° 2'1.66"E to 73° 2'16.27"E. The UPL’s Unit 2 is an ISO 14001: 2015, ISO 9001:2008, OHSAS 18001: 2007, ISO 50001: 2011 Certified Company. The UPL’s Unit 2 Project Site is well connected by National Highway NH-8, State Highways SH-64 and SH-13. Ankleshwar Railway Station is located at ~3.5 km while Surat Airport is located at 66 km and Vadodara Airport is located at ~81 km. Existing Facility UPL Limited Unit 2 was commissioned in 1993 with the manufacture of Quinalphos, Phosphamidon, Dichlorovos and Paraquate dichloride. In addition to this, UPL started manufacturing pesticides Phorate and Turbophose and substituted the then existing product Paraquate dichloride with Acephate between January 1994 to 1996. The Unit is currently manufacturing Technical Pesticides - Metribuzin, Terbuphos, Metasystox, Mesotrion, Pyrazosulfuron Ethyl, Ethofumisate, Azoxystrobin, Surflan, Devrinol, D-Devrinol, Clomazone, Metobromuran, Acephate, Metamitron, Acetamiprid, Imidacloprid, Acephate, etc. Pesticide Intermediates – Di Ethyl Thio Phsphory Chloride (DETCL), Amino Aceto Nitrile Sulphate, Myrisyl Amineoxide, Di Methyl Phosphorous Amido Thionate (DMPAT), Di Methyl Phosphonate (DDMP), Para Chloro O Cresol (PCOC), Diethyl Thio Phosphoric Acid(DETA), Zinc Dithio Phosphoric Acid (ZnDTP), Noflan, Absolute Alcohol etc. and pesticides formulation products and maintaining Zero Liquid Discharge (ZLD) since May-2014. Proposed Expansion Unit 2 now proposes to expand the existing few pesticides technical and intermediate products and plans to add few new pesticide technical and intermediate products at the existing site. The total production after expansion will be - pesticides (technical) products from 2,175 MT/month to 5,580 MT/month and intermediate products from 1,894 MT/month to 3,984 MT/month. The development will require augmentation of existing facilities and development of new ones. A. Project Proposal

UPL Ltd. Unit 2 is not manufacturing any banned pesticide products and shall not manufacture, store or import any such products. The pesticide technical and intermediate products proposed as part of the proposed expansion shall be manufactured after having valid consents and CIB registration after expansion. The product list has been revised based on the Pesticide (Prohibition) Order, 2018 as published vide S.O. 3951 (E), dated 8th August, 2018. The proposed expansion project is planned within the existing Unit 2 due to the following:


ES - II

The availability of most of the existing plant’s infrastructure which will help in minimising both the economical and environmental impacts;

Availability of supply chain logistics which can be extended to the proposed expansion and will help in economical and environmental impacts;

Re-engineering capabilities and relatively low cost of production; It will provide a boost to the local economy by providing employment generation; Continuous growth of exports and increase in the Indian market demand off set the

local competitions; The export opportunities will help in generating foreign currency; The proposed expansion project is based on the market surveys and in house

captive consumption; The CSR Activities of UPL will enhance an improved quality of life to the local

community.

Post this Project, the product and by-product slate of UPL Unit 2 will be as below:

Plant No

S.N. Product Name

Existing Capacity (TP/M)

Proposed Capacity (TP/M)

After Expansion Product Name

Total Capacity (TP/M)

CAS Number

A

1

D-Devrinol OR Devrinol OR Clomazone (combined capacity)

300 NIL D-Devrinol 300 15299-99-7

OR OR OR OR OR OR

2 Metobromuron

60 NIL Metobromuron

60 3060-89-7

3 Devrinol NIL 400 Devrinol 400 15299-99-7

4 Imazapic Technical

NIL 500 Imazapic Technical

500 104098-48-8

5 Ethofumesate NIL 100 Ethofumesate 100 26225-79-6

B

6

Terbuphos OR

500 NIL

Terbuphos OR

500

13071-79-9 OR

Phorate OR

Phorate OR

298-02-2 OR

Metasystox (combined capacity)


2674-91-1

7

Acetamiprid OR 10

OR 5

40 (Combined Capacity)

Acetamiprid OR


135410-20-7 OR

Imidacloprid Imidacloprid 138261-41-3

C 8 Acephate 1,225 NIL Acephate 1,225 30560-19-1

9 OR Metamitron

OR 60

NIL OR Metamitron

OR 60

41394-05-2

D

10

Phosphamidon (PD) OR Azoxystrobin

100 OR

NIL

Phosphamidon (PD) OR

100 OR 40

13171-21-6 OR

Surflan OR

40 Surflan 19044-88-3

11 Azoxystrobin NIL 200 Azoxystrobin 200 131860-33-8

12 Clomazone NIL 300 Clomazone 300 81777-89-1

13 OR

Monocrotophos OR

10 (Combine

90 (Combine

Monocrotophos OR

100 6923-22-4 OR


ES - III

Plant No

S.N.

Product Name Existing Capacity (TP/M)




CAS Number

13

2-4 D technical (2, 4- Dichloro Phenoxy Acetic Acid) (Combined Capacity)

d Capacity)

d Capacity)


94-75-7

14

Dichlorvos (DDVP) OR

85 OR

NIL Mesotrion

85

104206-82-8

Ethofumesate OR

50 OR

NIL

Mesotrion OR 85 OR NIL OR Pyrazosulfuron Ethyl (Combined Capacity)

OR 93697-74-6

Pyrazosulfuron Ethyl

85 NIL

15 Dichlorvos (DDVP)

NIL 170 Dichlorvos (DDVP)

170 62-73-7

16 Metribuzin 5 NIL Metribuzin 5 21087-64-9

E 17 Acephate NIL 1,775 Acephate 1,775 30560-19-1 TOTAL A - Submitted in PFR & Form 1

2,235 3,575 5,810 -

Product List as per EC Application submitted to MoEF&CC dated 31/12/2017 TOTAL A1 - Revised After Exclusion of Prohibited Pesticides

2,175 3,405 -- 5,580 -

Based on The Pesticide (Prohibition) Order 2018 dated 8th August 2018 by Ministry of Agriculture and Farmers Welfare the Products - Dichlorovos, Phorate & Phosphamidon are Prohibited for Manufacture, Formulate, Import with effect from the 1st January, 2019. Note: The strikethrough items are no longer manufactured or produced at Unit 2 from January 01st 2019

(B) Intermediate Chemicals - Existing and Proposed capacity

A 1

Di Methyl Methyl Phosphonate (DMMP)

100 200


300 756-79-6

B 2

Di Ethyl ThioPhosphoryl Chloride (DETCL) OR

50 OR

NIL


50 OR

2524-04-1 OR

Amino Aceto Nitrile Sulphate (AANS) OR

160 OR


160 OR

5466-22-8 OR

Myristyl amine oxide (MO)

160

Myristyl amine oxide (MO) (Combined capacity)

160 3332-27-2


ES - IV

Plant No

S.N.

Product Name Existing Capacity (TP/M)




CAS Number

3 Para Chloro O Cresol (PCOC)

96 NIL Para Chloro O Cresol (PCOC)

96 59-50-7

4

Di Ethyl Thio Phosphoric Acid (DETA) OR 1,000 1,000

Di Ethyl Thio Phosphoric Acid (DETA) OR 2,000

298-06-6 OR

ZnDTP (Combined Capacity)


19210-06-1

5 Absolute alcohol

420 NIL Absolute alcohol

420 64-17-5

6 Noflan 8 NIL Noflan 8 --

C 7

Di Methyl Phosphorus Amido Thionate (DMPAT)

110 890


1000 17321-47-0

TOTAL B - Submitted in PFR & Form 1

1,894 2,090 3,984 No changes in Quantities since The Applicability of The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare does not covers Intermediate chemicals.

TOTAL B1 - Revised After Exclusion of Prohibited Pesticides

1,894 2,090 3,984

Grand Total (A + B) As per PFR Submission

4,129 5,665 9,794

The Product List Total as per EC Application submitted to MoEF&CC dated 31/12/2017 i.e. before the publication of The Pesticide (Prohibition) Order 2018 dated 8th August 2018.

Grand Total (A1 + B1) After Exclusion of Prohibited Pesticides

4,069 5,495 9,564

Based on consideration of Applicability of The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Fa rmers Welfare the Products - Dichlorovos, Phorate & Phosphamidon are Prohibited for Manufacture, Formulate, Import with effect from the 1st January, 2019.

WHO Class Details - Ia = Extremely hazardous; Ib = Highly hazardous; II = Moderately hazardous; III = slightly hazardous; U = Unlikely to present acute hazard in normal use; FM = Fumigant, not classified; O = Obsolete as pesticide, not classified.


ES - V

Existing and Proposed Production Capacity of by-products

S.N. By Product Name Source/Plant

Existing Generation (MT/Month)

Additional Generation (MT/Month)

Total Generation after Expansion (MT/Month)

1 30% HCL

D-Devrinol, Surflan, Mesotrion,DETCL,PCOC, DMPAT, Imazapic

68.72 4,079.40 4148.12

2 Sodium Sulphite D-Devrinol, Mesotrion

563 353.9 916.9

3 Sodium Sulphate Metobromuron, Clomazone

60 125.61 185.61

4 Sodium Bromide Metobromuron, Metribuzin

114 24.44 138.44

5 NaSH (30%) Terbuphos, Phorate, DETCL, DETA, ZnDTP

331.5 1310 1641.5

6 Ammonium Acetate (35%) OR

Acephate

1,907 3,493 5,400

7 Acetic Acid (30%) OR

1,735 2,458.22 4193.22

8 Acetic Acid (45%) OR

1,157 1,935.64 3092.64

9 Acetic Acid (99%) AND

526 879.05 1405.05

10 Ammonium Sulphate (90%)

636 1,509.57 2145.57

11 Sodium Acetate (27%)

2,634 3,663.87 6,297.87

12 Spent Acid Metamitron 145.8 0 145.8

13 HCl (28%) Phosphamidon 0 0 0

14 Methyl Chloride* Phosphamidon, DDVP, Monocrotophos

15.3 46.2225 61.5225

15 Ammonium Chloride

Surflan, DMPAT 50 314.48 364.48

16 Methyl Acetate Azoxystrobin 36.4 36.4 72.8

17 Sodium Bi-Sulphate (17%)

Mesotrion 96 83.6 179.6

18 KHCO3+KCl Salt Imidacloprid 0 56.75 56.75

19 Di Methoxy Methane-DMM (95%)

AANS 115.84 0 115.84

20 Ethanol Acetamiprid 0.084 10.416 10.5

21 Methanol Noflan 11.84 0.539 12.379

22 POCl3 (98%) Noflan 20.46 0 20.46

23 Phenol Pyrazosulfuron Ethyl 18.19 0 18.19

24 Ammonium Chloride Solution

Surflan 50 17.52 67.52

25 Ammonia (20%) DMPAT 0 158 158 TOTAL A (As per PFR/Form 1 Submitted to MoEF&CC)

4,481.134 10,374.965

14,856.099

Total A1 (After Delist of Prohibited Pesticides as per The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare

4,331.13 10,281.15 14,612.28

Note: The strikethrough items are no longer manufactured or produced at Unit 2 from January 01st 2019.


ES - VI

i) Project Schedule and Cost The proposed projects will be implemented in a phased manner. The project will start execution after obtaining all the necessary approvals. The tentative plan to start the project will be from the Financial Year 2019 – 2020. The total project cost is estimated around INR 445.89 Crores. ii) Resource Requirements Land : The proposed expansion is planned within the existing premises

admeasuring 65,625 m2 area. The existing premise is already in Gujarat Industrial Development Corporation (GIDC) estate of Ankleshwar and adjacent to many industries. No additional land is required for the proposed expansion.

Water : The water requirement for the proposed expansion shall be met

from the existing GIDC water supply. No ground water is/shall be used as per Gujarat Pollution Control Board (GPCB) restriction. Total fresh water consumption after proposed Project expansion will be 4,056 m3/day, out of which ~1,031 m3/day is existing and ~3,722 m3/day is proposed.

Raw materials : The raw materials required for the proposed production will be

either imported or procured from domestic market and transported by road.

Power : Total power requirement after the proposed expansion will be

~16,799 kW, out of which 6,895 kW is existing and 9,904 kW is proposed which is/will be supplied from Dakshin Gujarat Vij Company Limited (DGVCL). For power back-up an additional DG Set of capacity ~2,000 kVA is proposed along with existing three (3) nos. of capacities 1,250 kVA, 500 kVA and 2,000 kVA.

Greenbelt : UPL has developed greenbelt as an integral part of development

of its facilities. Till date ~13,911.58 m2 (21.19%) out of total area of 65,625 m2 of Unit 2 area is developed as green belt and additional greenbelt area of 315 m2 is proposed for the expansion Project. The additional area is identified within existing GIDC area and the unit has signed agreement with GIDC for development and maintenance of green belt. During 2017-18, ~2,250 of native trees have been planted. In addition, the unit has signed agreement for development of 45 acres (182,108.54 m2) of land for greenbelt development from ~3 km distance at survey no 611/613/614/615 & 616 located at village – Mandva.

B. Baseline Environment Primary baseline environmental monitoring in 10-km radius study area was conducted through an NABL approved laboratory (CEG Test House & Research Centre Pvt. Ltd.). This study period was from February 26 -May 21, 2018. Topography - The topography of the Ankleshwar is relatively flat terrain with series of deeply incised creeks of River Narmada. There are generally levee deposits on the bank of river. The project site is located at ~7 km from River Narmada in south-west direction. The terrain is relatively flat with gentle slope towards Arabian Sea.


ES - VII

Geology - The predominant geological formations in Bharuch District are Deccan Trap, Sandstone and Alluvium. The study area falls under alluvial plain. Landuse & its Classification - The land use and land cover of the study area based on multispectral satellite imagery. Analysis of the land use pattern shows that out of total 326.4 km2, 66% of land is under agriculture, 12% of land is barren, 10% under settlements, 6% under industries and less than 6% is covered under roads, river, waterbody, canal and railway line. Soil - The soil quality was monitored at eight (08) locations within the study area. Soil texture in samples of most locations was observed to be loamy, silty loamy and silty clay loamy except at SQ3 (Jitali) where in the soil texture was observed to be sandy. pH of the soil samples ranged from 8.31 to 8.56. The values for metals namely Cadmium and Mercury (inorganic) were observed to below detectable limit whereas the values for Zinc, Arsenic, Lead, Copper, and Nickel, in absence of corresponding Indian Standards, were found to be much below the soil remediation intervention values specified in Soil Remediation Circular 2009 of Netherlands. Weather and Climate - The study area experiences a sub-humid climate. Project specific micro-meteorological data was collected for the study period (from February 2018 to May 2018). The automatic weather monitoring station was installed at UPL Unit 2 Site Ankleshwar (21°37’39.46”N 73°02’04.06”E). The ambient temperature varied from 21.1°C to 43.0°C with an average temperature of 33.1°C. Relative humidity (RH) varied from 9.0% to 98.5% with an average RH of 41.2%. The predominant winds during the study period mainly blown from SSW, SW, WSW & W and wind speeds varying from calm conditions (0 m/s for 2% of time) to 10.0 m/s with an average of 3.9m/s. There was no rainfall observed during the study period. Ambient Air Quality - The Ambient Air quality was monitored for PM10, PM2.5, NOx, SO2, CO, NH3, HC (Methane and Non-methane), C6H6, HCl, Cl2, H2S, HBr and VOCs at nine (9) locations in the study area

AAQ Parameters

Unit Minimum Maximum Average 98th Percentile

NAAQS

PM10 (μg/m3) 35.5 121.0 67.5 100.0 100 PM2.5 (μg/m3) 15.8 64.2 42.7 58.9 60 SO2 (μg/m3) 7.3 25.4 15.2 22.4 80 NOx (μg/m3) 11.5 45.4 25.2 39.2 80 CO (mg/m3) 0.3 1.8 0.9 1.6 2† H2S (μg/m3) BDL (DL: 10) BDL BDL BDL NS Cl2 (μg/m3) BDL (DL: 15) BDL BDL BDL NS HCl (μg/m3) BDL (DL: 10) BDL BDL BDL NS HBr (μg/m3) BDL (DL: 1) BDL BDL BDL NS NH3 (μg/m3) 8.8 26.9 14.2 20.7 400 C6H6 (μg/m3) BDL (DL: 1) BDL BDL BDL 5* HC (Me) (mg/m3) BDL (DL: 1.3) BDL BDL BDL NS HC (NMe) (mg/m3) BDL (DL: 1.3) BDL BDL BDL NS VOC (μg/m3) BDL (DL: 1) BDL BDL BDL NS

HC (Me) – Methane Hydrocarbon; HC (NMe) – Non-methane Hydrocarbon; NS – Standard not specified; *annual average; †8-hourly average In general, the ambient air quality is satisfactory with respect to all major pollutants except particulate matter at a few locations. Non-Methane HCs, VOC, C6H6, H2S, HCl, HBr and Cl2 were found below their respective detection limits.


ES - VIII

Noise Quality - The noise quality was monitored at nine (9) locations in the study area during the study period.

Category Leq daytime Leq night time Daytime Standard

Night time standard

Min Max Min Max Residential 50.1 54.3 41.1 49.7 55 45 Commercial 62.5 66.9 57.2 61.5 65 55 Industrial 74.5 68.8 75 70

The noise quality in the study area was found mostly within the prescribed statutory limits except the daytime noise levels for commercial area and nighttime noise levels for residential area. Traffic - Traffic survey was conducted at three major intersections within the study area for 24 hours, once during the study period. The hourly traffic pattern at the surveyed locations indicated peak vehicular traffic of 1,257 and 1,739 vehicles per hour during morning (0800 to 1100 hrs) at Junction near Unit 2 and Junction of GIDC flyover and 14th E road respectively. The peak vehicular traffic at the junction of SH-64 and 14th E road was 804 vehicles per hour during evening (1700 to 1800 hrs) at the junction of SH-64 and 14th E road. The peak hourly traffic at these junction was primarily represented by two wheelers (31%) and four wheelers (24%) followed by heavy vehicles (20%). Water Quality - Surface water samples were collected once during the study period at four (4) locations. The pH varied from 6.5 to 8.3 while dissolved oxygen varied from 5.8 mg/l to 7.1 mg/l. The results also showed presence of total coliform. The suface water quality conformed to CPCB D criteria (propagation of wildlife and fisheries) as per CPCB standards. Ground water samples were collected from eight (08) locations to assess the existing groundwater quality of the study area during the study period. The samples compared as per the requirements of IS10500:2012 standards. The pH varied from 7.4 to 8.3 showing it slightly to moderately alkaline with total dissolved solids ranged from 821 mg/l to 1,395 mg/l. Total hardness ranged from 323.2 mg/l to 888.8 mg/l and total alkalinity ranged from 285.0 mg/l to 606.9 mg/l. Sulphates varied from 21 mg/l to 128 mg/l. Heavy metals viz. Cd, Cr, Cu, Pb, Hg were found in concentrations below detection limits. Biological Environment – The quantitative analysis of flora was conducted by transect and quadrate surveys in identified terrestrial habitats. Twelve (12) sampling plots were laid in the study area covering the terrestrial habitats. Azadirachta indica (Neem) was found to be most dominant tree species in homestead plantations and Prosopis julifora in agricultural landscape. Among shrubs and herbs, Ocimum sanctum (Tulsi) a native species as well as Parthenium hysterophorus and Lantana camara (invasive species) was found to be most dominant species. Two (2) species of amphibians belonging to two (2) families and eight (8) species of reptiles belonging to six (6) families were observed and reported based on primary and secondary survey. One (1) bird species i.e. Black kite (Milvus migrans) from Accipitridae family was identified under Schedule I of the WPA, 1972. No migratory bird species was recorded from the ecological survey conducted. No species of mammal was found under Schedule I of the WPA, 1972 or listed in IUCN Red List of Threatened Species.


ES - IX

Protected areas: There are no protected areas such as National Parks or Wildlife Sanctuaries within 10 km of UPL Unit II. Nearest Protected area is Shoolpaneshwar Wildlife Sanctuary, located about 60 km east, aerial distance from the Project site. Socioeconomic Environment - As per Census 2011 & primary survey, the socio-economic aspects of the study area covers 33 villages and 3 towns. Ankleshwar industrial notified area (INA) is located within 2 km from the Unit 2 boundary while 33 villages and 2 towns are located beyond 2km to 10 km radius from the Project site. The study area covers a total population of 33,482 covering 6,206 (with population density of 1,781 persons/km2) within 2 km and 27,276 (with population density of 366 persons/km2) between 2 km and 10 km from the Project site. Sex ratio of population in study area is 852 females per 1000 males. Within 2 km, the Scheduled cast population has been reported as 1.3%; while that of scheduled tribes it is 2.4%. Between 2 km to 10 km, the Scheduled cast population has been reported as 4.4%; while that of scheduled tribes it is 29.6%. The literacy rate of population within 2 km has been reported as 84.6% for males and 83.4% for females while beyond 2 km to 10 km, the literacy rate has been reported as 75.7% for males and 70.6% for females. C. Anticipated Environmental Impacts

Construction Phase - The proposed expansion Project will involve modifications in existing equipment, reactors and setting up of new plants. The new plants will involve certain constructions like foundations, control rooms, utilities etc. The construction of facilities for the proposed expansion will be established in a phased manner. As the expansion will happen at existing facility, there is no requirement for additional land. The impacts from construction activities will be limited as construction activities will be facilitated with resources (i.e. water, waste disposal, power supply and storage of facilities) available at the existing plant. With the mitigation measures in place, the impacts during construction phase are assessed to be short term, reversible, localised and are not expected to contribute significantly. Operation Phase – The potential impacts during operation phase from the augmented / new facilities will be mainly from different processes, storages, material handling and their disposal. Land environment Potential Impacts - The potential of impacts on land environment from the expansion project includes potential soil contamination from the following sources: 1) Improper handling and storage of hazardous and non-hazardous wastes; 2) Spillage of oil, solvents and other hazardous chemicals; and 3) Discharge of untreated domestic and industrial wastewater on land. The hazardous waste generated from the process units consists of ETP sludge, salt from evaporation system, process liquid waste (organic liquid), solid waste from Ammonium Acetate in-house processing etc. Spillage of these hazardous waste will have potential to cause subsurface contamination. However, hazardous waste from both the existing as well as proposed expansion Project shall be temporily collected in covered shed provided with impervious surface and disposal will be done as per requirement of the Hazardous and Other wastes (Management and Transboundary) Handling Rules, 2016 with prior HW authorization from GPCB. Therefore, likelihood of subsurface impacts is assessed as low. UPL is using closed loop feed system to transfer the material. Solvent recovery system will be operative for spent solvent. Unit


ES - X

2 is a zero liquid discharge unit and will continue to maintain it post expansion. No effluent will be subject to any land application. Only treated sewage will be disposed of in watering the plants of greenbelt. Therefore, likelihood of land contamination by discharge is expected to be low. Mitigation Measures i. UPL shall continue to maintain the inventory of all hazardous and non-hazardous

wastes generated at site including that from the proposed expansion project. ii. All the wastes shall be segregated at the source of generation and disposed in the

legally acceptable manner. iii. All recyclable hazardous wastes such as used oil, empty containers etc. shall be

disposed to GPCB/ CPCB/ MoEF&CC authorized vendors. iv. All hazardous wastes will be stored in covered sheds provided with impervious

surface. v. All recyclable non-hazardous waste such as metals and non-metals (paper,

cardboard, wood, plastic etc.,) will be sold to local scrap dealer; vi. The existing spill management and solvent recovery shall be extended to the

proposed Project as well. Air environment Potential Impacts - Potential additional impacts on air quality due to proposed expansion Project will include from the following activities: 1. Point source flue gas emissions from process stacks, vents, boilers and diesel

generators; 2. Fugitive emission including odour nuisance; 3. Vehicular emission The emissions from flue gas stacks and process vents have been modelled using ISC-AERMOD model for Particulate matter (PM), Oxides of Nitrogen (NOx) Sulphur Dioxide (SO2), Hydrogen Chloride (HCl), Hydrogen Sulphide (H2S) and Volatile Organic Compound (VOC). The maximum predicted Ground Level Concentrations (GLC) from the proposed expansion Project was within the prescribed NAAQS for PM10, SO2 and NO2. Currently there are no NAAQS for H2S, VOCs and HCl. The prediction of transportation related air quality impacts was made using the ISCT3 line volume source model. The predicted 24 hour max. GLC of PM, NO2, CO (8-hourly) and HC for proposed Project was found to be within the prescribed limits. Mitigations Mitigations of atmospheric emissions impacts caused by combustion, process and vehicular emissions shall be achieved through the following measures: All emission sources to be monitored regularly to ensure compliance. Green belts and landscaping should be strengthened to act as an effective means to

control air pollution. Performance evaluation of the pollution control systems will be undertaken at

planned regular intervals; The efficacy of the existing detectors installed will be checked with respect to the

proposed projects activities and or new sensors to detect hydrocarbons will be installed;

Provision of continuous emissions monitoring systems for the stacks; LEL detectors and alarms will be installed for odourous compounds; Sensors and breather valves will be provided at hazardous chemicals storages; UPL shall ensure periodic preventive maintenance of all of its vehicles including

that of the subcontractors;


ES - XI

LDAR program shall be extended to proposed expansion; Workplace monitoring shall be extended for the proposed expansion; Maintaining optimum vehicle speed. Speed breakers are commonly used to ensure

speed limitations.

Noise Environment Potential Impacts - Major noise generating sources from the proposed expansion at UPL will be operation of various equipment’s machineries, instruments such as boilers, reactors, scrubbers, pumps, compressors, DG Set etc. The prediction of ambient noise from the proposed Project was carried out using Sound PLAN 7.2. The resultant noise levels due to the project operations shall not exceed the prescribed noise standards for daytime and nighttime and will attain background levels within the boundaries.

Mitigation The following are the suggested mitigation measures to minimise/reduce the impacts due to noise during this phase: Efficient engineering control during installation of new equipment and machineries

shall be ensured to reduce noise emission levels at source. Maintaining adequate offset distances from noise generating equipments; The machinery deployed in the plant should be designed with the sufficient noise

and vibration controls for minimizing noise at source and purchased through reputed manufacturers and vendors;

Periodic audiometric tests for employees working close to high noise levels, such as compressors, DG sets, the loading and unloading sections shall be conducted;

Periodic job rotation shall be provided to the employees, who are working continuously in the high noise areas;

Ambient noise levels shall conform to statutory limits; Workplace noise levels for workers shall be as per statutory limits.

Water Environment Potential Impacts- The following impacts are anticipated during this phase on water resources and quality: Fresh water consumption; Storm water runoff; Wastewater generation, treatment and disposal.

The net water demand after proposed Project expansion will be 4,751.7 m3/day, out of which ~1,030.5 m3/day is existing and ~3,721.7 m3/day is proposed. The water requirement for the proposed expansion shall be met from the existing GIDC water supply. No ground water is/shall be used. The wastewater generated from process, boiler, cooling tower etc. is and will continue to be treated in existing effluent treatment plant (ETP) of capacity 550 m3/day having primary, secondary & tertiary treatment. The unit is Zero Liquid Discharge (ZLD) since May-2014 and will continue as ZLD. Moreover, the Unit has also installed online CCTV camera and magnetic flow meter at ETP outlet line and online CCTV footage is being transmitted to CPCB website. The Treated domestic waste water from proposed sewage treatment plant will be recycled/ reused in toilet flushing / green belt and there will not be any discharge from UPL Unit 2. The Unit 2 will be maintained as ZLD even after proposed expansion. UPL proposes to install additional Reverse Osmosis (RO) plant of capacity 650 m3/day, Multiple Effect Evaporator (MEE) of capacity 450 m3/day and a sewage treatment plant (STP) of capacity 40 m3/day to maintain zero liquid discharge. Mitigation Maintaining records of water consumption and wastewater generation


ES - XII

Regular monitoring of wastewater inlet and outlet parameters Ensuring maintenance of wastewater treatment plants and storm water drain Treatment of storm water runoff from first rainfall of the season in the wastewater

treatment plant Develop spill prevention plans in case of hazardous chemical discharges and spills Ensure secondary containment system for storage of hazardous chemicals and oils. Wherever possible, use equipment wash down waters and other process waters to

be used as makeup solutions for subsequent batches Storage areas should be secure and covered, preventing exposure to rain and

unauthorized access.

Land Environment Potential Impacts - The following impacts are anticipated on the land environment during operation phase: Improper handling and storage of hazardous and non-hazardous wastes; Spillage of oil, solvents and other hazardous chemicals; and Discharge of untreated domestic and industrial wastewater on land. Various categories of solid waste (both hazardous and non-hazardous) are generated at different stages of pesticide technical and intermediate chemicals manufacturing processes. The hazardous waste generated from the process units consists of ETP sludge, salt from evaporation system, process liquid waste (organic liquid), solid waste from Ammonium Acetate in-house processing etc. Spillage of these hazardous waste will have potential to cause subsurface contamination. UPL is using closed loop feed system to transfer the material. Solvent recovery is above 96% from spent solvent and will be improved further. Mitigation All the wastes are segregated at the source of generation and is disposed in the

legally acceptable manner; Hazardous waste storage area has been constructed as per Central Pollution

Control Board (CPCB) guidelines for temporary storage of hazardous wastes before disposing.

The collection, storage and disposal from the proposed solid wastes – hazardous, non-hazardous, municipal wastes are carried out as per applicable waste management rules notified by MoEF&CC;

All hazardous wastes will be stored in covered sheds provided with impervious surface.

Secondary containment is provided around bulk storage of hazardous chemicals and oils;

All reactor vents are connected to common Condenser or fume incinerator to reduce fugitive/VOC emission.

Ecological Environment Potential Impacts - 1. Reduced safety of straying animals and low flying birds due to road traffic; 1. Terrestrial habitat loss due to ambient air quality; 2. Habitat disturbance due to noise from the Project. Indirect impacts like fragmented or modified habitats due to air emissions from the stack and fugitive emissions from the proposed project. The process emissions (H2S, NH3, VOC etc.) for the existing and proposed project are provided with appropriate control measures like scrubbing media for minimising their impacts and to be compliant with regulatory norms. The performance of these air pollution control


ES - XIII

devices are also monitored periodically. Therefore, considering the background air quality levels within the acceptable levels with small impact magnitude but with medium receptor sensitivity, impacts on terrestrial ecology is considered as Minor. It is less likely that any adverse impact due to noise outside the boundary of plant will be experienced during the operation phase. Mitigation Strengthening the existing greenbelt to the maximum possible extent; Use of native species for greenbelt plantation; Options should be explored to adopt advance technologies for pollution reduction

from process and utilities; Recycled water should conform to the standards before using in the greenbelt The offset plantation site at Village Mandwa should be aimed to develop as forest

habitat with gap plantation after maturation of trees planted in first phase; Sufficient water arrangements should be provided for watering the aforesaid

plantation. Implementation of the Wildlife Conservation plan Socioeconomic Environment The proposed project is planned within the existing premises and does not require any additional land. An additional employment of about 253 (permanent and contractual) is proposed as part of the Project. Preference in employment shall be given to local people indicating positive impacts from the proposed Project. UPL has reportedly invested 9.7% of company’s total profit in social development activities across its different units. Some of the activities undertaken by Unit 2 reportedly include – social forestry plantation, organising health camps, providing seeds for agricultural breed improvement, as well as skill based training for Self Help Groups (SHG). As reported, their beneficiaries also include persons from scheduled caste (SC) and scheduled tribes (ST) communities. D. Analysis of Alternatives Alternate source of land: The proposed project being an expansion project within the existing project site, there were no alternatives considered for the production and or processing facilities. This would also give benefits in utilizing the existing utilities and infrastructure within the project site to have minimal environmental and social footprints. Additional wastewater treatment facilities: The existing project facility is operating as zero liquid discharge (ZLD) unit and to continue operating as ZLD unit after expansion. UPL proposes to install additional Multiple Effect Evaporator (MEE) of capacity 450 m3/day, an RO plant of capacity 650 m3/day and a sewage treatment plant (STP) of capacity 40 m3/day to maintain zero liquid discharge. E. Risk assessment and emergency response plan The consequence scenarios associated with the proposed Project were modelled to determine their potential exposure impacts. The RA results for storage tanks indicates that in most of the scenarios involving leakages leading to Pool/Jet Fire, the risk significance is assessed as “Low”. For scenarios with low risk significance, the effective distance for damage in terms of radiation intensity is likely to remain up to 53m. For medium risk significance, catastrophic failures of highly flammable chemical and fuel storage tanks were found to result in VCEs. For VCEs, the maximum blast overpressure of 8.0 psi, which may cause destruction of building, did not exceed the


ES - XIV

LOC in all cases except for triethyl amine (TEA) which will be up to ~19m within the Plant premises. While the blast overpressure of 3.5 psi (which may cause serious injury) is expected to remain up to a radial distance of 53m. Hence, damaging effects from thermal radiation and VCE are expected to remain limited within the plant premises to nearby process equipment and machineries. The damaging effects may result in occupation injuries/fatalities to site personnel and workers operating in the immediate vicinity, requiring adequate risk mitigation measures be in place together with strict use of adequate PPEs by personnel working in nearby areas. The potential threat from toxic releases were found to be particularly significant with respect to chlorine tonners wherein the life threatening health effects are likely to be experienced up to a distance of 233 m from source. The release scenario leading to irreversible or other serious, long lasting adverse health effects are expected up to 769 m due to catastrophic rupture of a chlorine tonner (i.e. maximum credible leak scenario). The RA results show requirement of implementation of appropriate engineering and administrative controls together with strict risk mitigation measures to minimize potential exposure risks. Adequate fire protection system is required to be in place and supplemented by implementation of focussed training and awareness sessions and organizing periodic Onsite and occasional Offsite Emergency Preparedness drills to check effectiveness of existing risk management system. UPL’s emergency preparedness and response plan will comply with requirement of the Gujarat Factories Rules 1963 & MSIHC Rules, 1989 as amended. UPL is to conduct a detailed process hazard analysis and HAZOP at two stages i.e. as part of the Front End Engineering and Design (FEED) study and prior to commissioning of each process of the proposed expansion to assess associated risks and implement recommendation for safe operations. F. Environmental Management Plan The existing Unit 2 is certified for internationally accepted Environmental Management System based on ISO-14001:2015, Quality Management ISO 9001: 2008, energy management system ISO 50001: 2011 and Occupational Health & Safety Management Systems OHSAS 18001: 2007. An established environmental monitoring program in place, periodic review and audits are carried out for effective environmental management and the same shall be strengthen and extended for the proposed Project activity as well. The identified environmental and risk mitigation measures will be implemented by the existing Environment Management and Safety Departments of Unit 2, which ensures overall effective implementation of the management plan. A Safety Committee has been operative as per requirements of Factories Act with defined role and responsibilities and defined framework covering all aspects of plant and personnel safety. UPL’s Unit-2 being part of the group division, it follows all the group HSE policies and the same shall be extended to the proposed Project as well. G. Project Benefits The following benefits are expected from the proposed development program:


ES - XV

The availability of most of the existing plant’s infrastructure which will help in minimising both the economical and environmental impacts;

Availability of supply chain logistics which can be extended to the proposed expansion and will help in economical and environmental impacts;

Re-engineering capabilities and relatively low cost of production; It will provide a boost to the local economy by providing employment generation; Continuous growth of exports and increase in the Indian market demand off set

the local competitions; The export opportunities will help in generating foreign currency; The proposed expansion project is based on the market surveys and in house

captive consumption; The CSR Activities of UPL will enhance an improved quality of life to the local

community. H. Conclusions This impact assessment study indicates that the overall adverse impact will be minimized to acceptable levels with the implementation of the proposed embeeded and additional pollution controls together with strengthening of the existing environment management measures. Risk mitigation measures (outlined in Sectiton 7.9 including hazard analysis and HAZOP studies for each process) will help minimize potential hazards from the proposed expansion Project. UPL will also ensure that the environmental performances of activities are monitored throughout execution of various project activities during both construction and operation phases. UPL will continue to report environmental performance reports regularly to statutory authorities. Over the years, Unit 2 has developed systems and procedures for effective environmental management. The effective management system coupled with monitoring of environmental components and efforts for continual improvements will result in exemplary environmental performance.

ERM EIA STUDY FOR THE PROPOSED EXPANSION IN EXISTING CAPACITY OF UNIT 2, GIDC ANKLESHWAR, GUJARAT PROJECT # 0426521 UPL LIMITED, JANUARY 19

I

COMPLIANCE OF APPROVED TERMS OF REFERENCE (TOR) FOR THE EIA STUDY STANDARD TERMS OF REFERENCE ISSUED FOR EIA STUDY The standard terms of reference issued by Expert Appraisal Committee (Industry-2) of MoEF&CC are included at the end of this report in Section 12 for conduct of EIA study. The TOR requirement and its inclusion in the EIA study is given below in Table 1.1

Table 1.1 MoEF&CC Approved Standard Terms of Reference for EIA Study

S.N. TOR Conditions/Requirements Compliance – Reference Section Page nos.

Remarks

1. Executive summary of Project Refer to Section 0.1

Included as part of this report

2. Introduction i. Details of the EIA Consultant

including NABET accreditation Refer to

Section 12 ERM India Pvt. Ltd. Is the EIA Consultant having valid Category A accreditation till Oct. 31, 2019 (No.NABET/EIA/1619/0055)

ii. Information about the project proponent

Refer to Section 1.1

UPL is a global generic crop protection, chemicals and seeds company, headquartered in India (Mumbai).

iii. Importance and benefits of the project

Refer to Section 1.7, Section 1.8, Section 8

Importance and benefits of Project are outlined in Section 1.7, Section 1.8 and is included in detail in Section 8.

3. Project Description i. Cost of project and time of

completion. Refer to

Section 2.8 The total Project cost is about INR 445.89 Crores and shall be implemented in phased manner.

ii. Products with capacities for the proposed project.


Products with capacities for the proposed Project are included in Section 2.1

iii. If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Refer to Section 2.1, Table 2.1 & Table 2.2

The proposed expansion is planned within the existing premises. No additional land is required for the proposed project. The details of existing and proposed product and by-product list is included in Section 2.1.

iv. List of raw materials required and their source along with mode of transportation.

Refer to Section 2.3.4 & Table 2.5

List of raw materials, their source and mode of transportation is included in Section 2.3.4 and Table 2.5

v. Other chemicals and materials required with quantities and storage capacities

Refer to Section 2.3.4 & Table 2.5

Refer to Section 2.3.4

vi. Details of Emission, effluents, hazardous waste generation and their management.


Details of air emissions, wastewater, solid and hazardous waste management, water conservation measures and solvent recovery management are included in Section 2.4


II


Remarks

vii. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)


Section 1.8, Table 1.2

Details of water, power requirement is included in Section 2.3. The manpower requirement details are included in Table 1.2, Section 1.8.

viii. Process description along with major equipments and machineries, process flow sheet (quantitative) from raw material to products to be provided


The details of manufacturing processes including material balance is included in Section 2.2

ix. Hazard identification and details of proposed safety systems.

Refer to Section 7.6, Section 7.10

Details of hazard identification are included in Section 7.6 and details of proposed safety systems are included in Section 7.10

x. Expansion/modernization proposals:

a. 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 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall 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.

Refer to Annex A, Annex B and Annex C

Copy of all Environmental Clearances (EC) is included in Annex A, Copy of Certified EC compliance report is included as Annex B and Copy of status of compliance of Consent to Operate (CTO) for the ongoing /existing operations is included as Annex C The copy of latest (January-June 2018) EC Compliance report is alo available at https://www.uplonline.com/people-environment-compliances-policies

b. 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 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 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the

Refer to Annex A and Annex C

Existing Project has obtained EC from MoEF on 17th July, 2003 and 15th April, 2008. The details of approvals like EC & Consent from GPCB and the details are included in Annex A and Annex C.


III


Remarks

conditions of consents from the SPCB shall be submitted.

4. Site Details i. Location of the project site

covering village, Taluka/Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

Refer to Section 1.1.1 & Figures 1.1 to 1.4, Section 5.1.1

Location of the project site is described in Section 1.1.1 and Figures 1.1 to 1.4. There were no alternatives for land considered as the proposed project is an expansion project within the existing project site.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

Refer to Figure 1.3

Section 1.2, Figures 1.5 and 1.6

Study area in open series map is included in Figure 1.3. Details of environmentally setting of the proposed Project is included in Section 1.2 and Figures 1.5 and 1.6 in the report.

iii. Details w.r.t. option analysis for selection of site

Refer to Section 5

There were no alternatives for land considered as the proposed Project is an expansion project within the existing project site.

iv. Co-ordinates (lat-long) of all four corners of the site.

Refer to Figure 1.4

The geographical coordinates of Unit 2 is Latitude 21°37'43.31"N to 21°37'42.81"N and 21°37'35.24"N to 21°37'34.18"N and Longitude 73° 2'2.35"E to 73° 2'9.66"E and 73° 2'1.66"E to 73° 2'16.27"E. Refer to Figure 1.4

v. Google map-Earth downloaded of the project site.

Refer to Figure 1.4

Google Earth Pro image accessed on June 23rd 2018 is provided in Figure 1.4.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

Refer to Figure 2.1

Refer to Figure 1.1

Layout maps indicating existing unit as well as proposed unit is included in Figure 2.1. A map of Gujarat Industrial Development Corporation (GIDC) indicating location of existing unit within the Industrial area is included in Figure 1.1.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.

Refer to Figure 1.7

Photographs of the existing plant site is included in Figure 1.7.

viii. Landuse break-up of total land of the project site (identified and acquired), government/ private - agricultural, forest, wasteland, water bodies, settlements, etc. shall be included. (not required for industrial area)

Refer to Section 2.3.1, Table 2.3

The break-up of land area is included in Table 2.3 in Section 2.3.1

ix. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area

Refer to Section 1.2 and Section 3.2.9

List of major industries within study area is included in Section 1.2. Land use details of the study area is included in Section 3.2.9.

x. Geological features and Geo-hydrological status of the study area shall be included.


Geological features and Geo-hydrological status of the study are included in Section 3.2.2


IV


Remarks

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river shall also be provided. (mega green field projects)

Refer to Figure 3.2

Hydrogeological map of Bharuch district is included in Figure 3.2.

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.


The proposed expansion is planned within the existing premises. No additional land is required for the proposed Project.

xiii. R&R details in respect of land in line with state Government policy


The proposed expansion is planned within the existing premises. No additional land is required for the proposed Project.

5. Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)

Refer to Section 1.1.1, Section 1.2, Section 3.3

The proposed Project will be expanded within existing Unit 2 premises which is is located within notified industrial estate GIDC Ankleshwar and does not involve any permission and/or approval of forest land.

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)


The proposed Project is located within notified industrial estate GIDC Ankleshwar. Land use details of the study area is included in Section 3.2.9 of the report.

iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

Refer to Section 1.1.1, Section 1.2, Section 3.3

The proposed Project will be expanded within existing Unit 2 premises which is is located within notified industrial estate GIDC Ankleshwar and does not involve any permission and/or approval of forest land.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, 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


There are no protected areas such as National Parks or Wildlife Sanctuaries within 10 km of UPL Unit 2. Nearest Protected area is Shoolpaneshwar Wildlife Sanctuary, located about 60 km east, aerial distance from the Project site.

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State


There are no protected areas such as National Parks or Wildlife Sanctuaries within 10 km of UPL Unit 2. Black kite,


V


Remarks

Government for conservation of Schedule I fauna, if any exists in the study area

Schedule I species common in the landscape outside GIDC area, was found 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.


There are no protected areas such as National Parks or Wildlife Sanctuaries within 10 km of UPL Unit 2.

6. Environmental Status i. Determination of atmospheric

inversion level at the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Refer to Section 3.2.3, Annex D

The site specific micrometeorological data is included in Section 3.2.3 and Annex D.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.


Ambient air monitoring for 9 locations covering all parameters is included in Section 3.2.4.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Refer to Annex E

Raw data of all ambient air quality monitoring for 12 weeks at all 9 locations with min, max, average nd 98percentile values for each parameter is provided in Annex E.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.


Surface water quality monitoring data collected from 4 locations in the surrounding area is provided in Section 3.2.8.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if yes give details.


The nearest distance of UPL Unit 2 is about 4 km from the polluted stretch of Amla Khadi, a tributary of Narmada river.

vi. Ground water monitoring at minimum at 8 locations shall be included.


Ground water quality monitoring data collected from 8 locations in the study area is provided in Section 3.2.8.

vii. Noise levels monitoring at 8 locations within the study area.


Noise level monitoring at 9 locations in the study area is provided in Section 3.2.6.

viii. Soil Characteristic as per CPCB guidelines.


Soil quality monitoring details at 8 locations within the study area is included in Section 3.2.10


VI


Remarks

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.


Traffic study results for 3 locations within the study area is included in Section 3.2.7.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing 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.


Description of flora and fauna existing in the study area is included in Section 3.3.

xi. Socio-economic status of the study area.


Details on socio-economic status of the study area is included in Section 3.4.

7. Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modelling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modelling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.


The assessment of ground level concentration of pollutants from the flue gas stack and process emissions based on site-specific meteorological data is included in Section 4.5.2. isopleths of various pollutants such as PM10, SO2, NO2, HCl, H2S, VOC have also been provided in this section.

ii. Water Quality modelling - in case of discharge in water body

Refer to Section 2.3.2 and Section 4.5.4

UPL Unit 2 is a zero liquid discharge unit and no treated effluent is discharged outside the Plant. The water balance is included in Section 2.3.2. The water resource related impacts is included in Section 4.5.4

iii. 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 conveyor cum-rail transport shall be examined.


Transportation related impacts is included in Section 4.5.2.


VII


Remarks

iv. 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.


The details of Effluent Treatment, Reverse Osmosis, Multi Effect Evaporator and Sewage Treatment Plant for the existing and proposed Project is included in Section 2.4.3.

v. Details of stack emission and action plan for control of emissions to meet standards.

Refer to Section 2.4.1, Section 4.5.2

Details of stack emission is given in Section 2.4.1 and details of action plan to control emissions so as to meet standards is given in Section 4.5.2.

vi. Measures for fugitive emission control


Measures for fugitive emission control is included in Section 2.4.1 and Section 4.5.2.

vii. Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Refer to Section 2.4.2, Section 4.5.1, Table 4.5, Annex J

Details of hazardous waste generation and its management and waste minimization is included in Section 2.4.2, Section 4.5.1 and Table 4.5. Copy of MOU with CHWTSDF of BEIL, Ankleshwar is included as Annex J

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Section 2.4.1 and Table 2.6

Natural gas is used as fuel in boilers. The same will be used for proposed project as well. Hence, no fly ash generation and handling is expected.

ix. Action plan for the green belt 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.


Till date ~13,911.58 m2 (21.2%) of Unit 2 is developed as green belt and additional greenbelt area of 315 m2 is proposed for the expansion Project. The greenbelt details is included in Section 2.5

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains 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.


Refer Section 2.4.5

xi. Total capital cost and recurring cost/annum for environmental

Refer to Section 2.8, Table 2.14

The details on total capital and recurring cost is included in Section 2.8 and Table 2.15.


VIII


Remarks

pollution control measures shall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

Refer to Section 6

The Environmental Monitoring Plan for the operation phase of the project is included in Section 6.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.


Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control is included in Section 7.10.

8. Occupational Health i. Plan and fund allocation to ensure

the occupational health & safety of all contract and casual workers


Refer Section 7.11 for occupational health and safety programme at UPL.

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, colour vision and any other ocular defect) ECG, during pre- placement and periodical examinations give the details of the same. Details regarding last month analysed data of above-mentioned parameters as per age, sex, duration of exposure and department wise.

Refer to Section 7.11.3, Annex I

Refer Section 7.11.3 for details on exposure specific health status evaluation of worker. The annual medical record is provided in Annex I.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of 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,


The details of existing occupational & safety hazards is included in Section 7.11 in the report.

iv. Annual report of health status of workers with special reference to Occupational Health and Safety.

Refer to Section 7.11.3, Annex I

Annual medical check-up details and annual medical report of health status of worker with special reference to Occupational Health and Safety is provided in Section 7.11.3 and Annex I respectively.

9. Corporate Environmental 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.

Refer to Section 10.2.1, Figure 10.1 and Figure 10.2


ii. Does the Environment Policy prescribe for standard operating

Refer to Section 10.2.1,



IX


Remarks

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.

Figure 10.1 and Figure 10.2

iii. What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Refer to Section 10.2.2, Figure 10.3

Refer to Section 10.2.2, Figure 10.3

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

Refer to Section 10.2.3 to Section 10.2.5

UPL has defined a management system based on planning, implementing, reviewing and taking action. Details of management and reporting mechanism is included in Section 10.2.3 to Section 10.2.5.

10. 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.



11. Enterprise Social Commitment (ESC)

1. Adequate funds (at least 2.5 % of the project cost) 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.


Public hearing is not applicable to this project as the site is located in notified GIDC Ankleshwar area. However, Unit has identified ESC and its related requirements with budgetary allocations whose details are included in Section 10

12. 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.


The details of pending litigation against the existing project is included in Section 2.6.


X


Remarks

13. A tabular chart with index for point wise compliance of above TOR.

Refer to Table 1.1

B SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FOR PESTICIDES INDUSTRY AND PESTICIDE SPECIFIC INTERMEDIATES (EXCLUDING FORMULATIONS)

1. Commitment that no banned pesticides will be manufactured

Section 1.9.1 UPL’s commitment is included in Section 1.9.1.

2. Details on solvents to be used, measures for solvent recovery and for emissions control.


Details on solvents to be used is included in Section 2.3.4. Measures for solvent recovery and for emissions control is included in Section 2.4.6.

3. Details of process emissions from the proposed unit and its arrangement to control.


Details of process emissions from the proposed unit and its arrangement to control is included in Section 2.4.1.

4. Ambient air quality data should include VOC, other process- specific pollutants* like NH3*, chlorine*, HCl*, HBr*, H2S*, HF*, CS2 etc., (*-as applicable)


Ambient air quality data for 9 location including parameters VOC, other process- specific pollutants like NH3, chlorine, HCl, HBr, H2S is included in Section 3.2.4.

5. Work zone monitoring arrangements for hazardous chemicals.

Refer to Table 6.1

Details of work zone monitoring arrangement for hazardous chemical is included in Table 6.1.

6. Detailed effluent treatment scheme including segregation for units adopting 'Zero' liquid discharge


Details of Effluent Treatment Plant is included in Section 2.4.3.

7. Action plan for odour control to be submitted.

Refer to Section 6.2.4 & 6.2.5

Action plan for odour control is included in Section 6.2.4 & 6.2.5.

8. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated.

Table 4.5 and Annex J

The hazardous waste is being sent to common hazardous waste treatment disposal facility (TSDF) - BEIL Ankleshwar. BEIL Ankleshwar sends the high calorific value waste to cement industry for coprocessing.

9. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste in TSDF, if any.

Refer to Section 2.6.3, Annex M

Unit-2 is a zero liquid discharge (ZLD) plant and will continue to be ZLD after the expansion. However, it also has authorization for disposing in Final Effluent Treatment Plant operated by Narmada Clean Tech Ltd. Ankleshwar. The copy of membership is included as Annex M.

10. Material Safety Data Sheet for all the Chemicals are being used/will be used.

Refer to Annex F

MSDS for chemicals to be used in the proposed project is included in Annex F.

11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.

Refer to Annex J

UPL has taken membership of Bharuch Enviro Infrastructure Limited (BEIL) for disposal of solid/hazardous waste.

12. Details of incinerator if to be installed.

Refer to Table 2.6

No Incinerator is proposed to be installed. Please refer Refer to Table 2.6 for existing and proposed air emission details.

13. Risk assessment for storage and handling of hazardous chemicals/solvents. Action plan

Refer to Section 7.2 to Section 7.10

Details on risk assessment for storage and handling of hazardous chemical/solvents and action plan for


XI


Remarks

for handling & safety system to be incorporated.

handling and safety system is included in Section 7.2 to Section 7.10.

14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.


Arrangements for ensuring health and safety of workers engaged in handling of toxic material is details in Section 7.11

1.5.2 Compliance of Amended Specific ToR during 36th Expert Appraisal Committee (Industry-2) held on held during 24-26 April 2018

The proposal was considered by EAC (Industry-2) for amendment in the Standard

Terms of Reference granted by the Ministry vide Letter No. J-11011/180/2016- I A II(I) dated 31st January 2018 for the project ‘Proposed Expansion in Existing Capacity of Pesticides Technical, Intermediate & Pesticides Formulation Products & Addition of New Pesticides Technical Product within Existing Premises at M/s UPL Limited, UNIT # 02, Plot No. 3405/ 3406/3460A, Notified GIDC Industrial Estate, Ankleshwar, Bharuch, Gujarat’ proposed by M/s UPL Limited Unit 2.

UPL requested for amendment in the ToR with the details are as under: Proposal Details Essential Details Sought

(EDS) Response

Proposal No.: IA/GJ/IND2/71948/2017 File No.: J-11011/180/2016-IA II (I)

Please refer to the Minutes of the 36th Expert Appraisal Committee (Industry-2) meeting held during 24-26 April 2018 at Indira Paryavaran Bhawan, Ministry of Environment, Forest and Climate Change and Ministry’s Office Memorandum dated 27th April, 2018, providing exemption from public consultation/hearing for the projects/activities located within the industrial areas/estates/parks. You are required to submit the proposal for environmental clearance accordingly to the concerned authority (SEIAA/MoEF&CC).

We would like to bring to your kind attention that our Unit (Unit 2) - Plot No # 3405/3406/3460 A is located within Notified GIDC Ankleshwar Industrial Estate having area of 6.56 ha (65,625 m2) was allotted to UPL by GIDC Ankleshwar in 1992 i.e., prior to 14th September 2006 i.e., before EIA Notification 2006 coming into force. The said plot is a part of GIDC Notification dated 1st February 1978 (Attachment-1) allotted to UPL in 1992. The land allotment by GIDC Ankleshwar (Attachment-2) and copy of deed of rectification with mention of all survey numbers and plot details is attached herewith (Attachment-3). Also, kindly refer Minutes of 36th EAC (Industry2) meeting held on 24th May at MoEF&CC wherein our matter was included and EAC (Industry) has agreed to exempt us from Public Hearing condition. In view of above details, we request you to kindly issue amended Terms of Reference (ToR) with exemption from Public Consultation/Hearing.


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1 INTRODUCTION

1.1 BACKGROUND

UPL Ltd. (hereinafter referred to as UPL) is a global generic crop protection, chemicals and seeds company, headquartered in India (Mumbai). It started its operation in the year 1969 as a small-scale unit to manufacture Red Phosphorus at Vapi, Gujarat. It now focusses on emerging as a premier global provider of total crop solutions to secure the world’s long-term food supply. UPL has established its footprint in more than 133 countries across six continents with a visible presence in key agro-based economies like India and Brazil. UPL have manufacturing facilities at Vapi, Ankleshwar, Jhagadia, Halol in Gujarat, One Unit at Tarapur in Maharashtra and One unit at Haldia in West Bengal and major products are pesticides, caustic soda, chlorine, intermediate chemicals, phosphorus based chemicals and specialty chemicals. Through backward and forward integrations respectively, today UPL is a leading global producer of crop protection products, intermediates, specialty chemicals and other industrial chemicals. It offers a wide range of products that includes insecticides, fungicides, herbicides, fumigants and rodenticides. UPL’s Unit 2 is an operational pesticides & intermediates manufacturing unit located at Plot No. 3405/3406/3460A, Notified Gujarat Industrial Development Corporation (GIDC) estate, Ankleshwar, Dist. Bharuch, Gujarat. UPL Unit 2 is an ISO 14001: 2015, ISO 9001:2008, OHSAS 18001: 2007, ISO 50001: 2011 Certified Company.

1.1.1 Location of the Project

The existing Unit 2 is located at Plot no. 3405/3406/3460A, Notified Industrial estate, GIDC Ankleshwar, Bharuch District. The Project Site is well connected by National Highway 8 (NH-8), State Highway 64 (SH-64) and SH-13. The nearest rail station is Ankleshwar, which is ~3.5 km from the site, there are periodic trains connecting Ankleshwar to Ahmedabad, Delhi, Mumbai etc. and nearest town is Ankleshwar is ~3.6 km. Surat and Vadodara are the two nearest commercial airports connected to the site with the distance of ~66 km and ~81 km respectively. The location map of Unit 2 in GIDC Ankleshwar is depicted in Figure 1.1 and Figure 1.2 and in Survey of India open series map in Figure 1.3. The geographical coordinates of Unit 2 site are located within Latitude 21°37'43.31"N to 21°37'42.81"N and 21°37'35.24"N to 21°37'34.18"N and Longitude 73° 2'2.35"E to 73° 2'9.66"E and 73° 2'1.66"E to 73° 2'16.27"E as shown in Figure 1.4.

1.2 ENVIRONMENTAL SETTING OF THE PROJECT

The environmental setting of the Project site and physical features of the study area is shown in Figure 1.5 and Figure 1.6.


2

Figure 1.1 Layout of GIDC Ankleshwar Estate, Ankleshwar

Source: UPL

UPL Unit 2


3

Figure 1.2 Location Map of the Project Site


4

Figure 1.3 Project Site Location on Toposheet

Source: Survey of India Open Series Map (OSM No. F43M14 and F43N2)

ERM EIA STUDY FOR THE PROPOSED EXPANSION IN EXISTING CAPACITY OF UNIT 2, GIDC ANKLESHWAR, GUJARAT PROJECT # 0426521 BY UPL LIMITED, JANUARY 19

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Figure 1.4 Geographical Coordinates of the Project Site

Source: Google Earth Pro as accessed on June 23rd 2018 (Satellite Imagery Dated 26/11/2017)


6

Figure 1.5 Environmental Setting of UPL Limited Unit 2

Source: Google Earth Pro as accessed on 23rd June 2018; Imagery Date: 26.11.2017


7

Figure 1.6 Physical Features of the Study Area

ERM EIA STUDY FOR THE PROPOSED EXPANSION IN EXISTING CAPACITY OF UNIT 2, ANKLESHWAR GIDC, ANKLESHWAR PROJECT # 0426521 UPL LIMITED, JANUARY 19

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The environmental setting of area sourrounding UPL’s Unit 2 covers the following: There are no ecologically sensitive areas such as Wildlife

Sanctuary/National Park/Wetlands/Reserve Forests/Protected Forests within 10-km radius from the Unit 2 facility;

The facility is located in the Notified Industrial Estate, GIDC Ankleshwar; The Narmada River flows through North part of the study area. Small non-

perennial rivers like Amravati (East of study area), Kondhki Khadi (Southeast of study area) and Amla Khadi (West of study area) also lies in the study area. These Rivers finally drain into Narmada River;

There are no archaeological monuments and defence establishments within the study area;

Major habitations in the study area are Ankleshwar city and villages like Mandva, Dadhal, Jitali, Motali, Uchhali, Andada, Kosambdi, Kondh etc.

Following are major industries within GIDC Ankleshwar in study area:

S.N. Name and Address of Industries 1. Abbott Laboratory (I) Ltd., GIDC, Ankleshwar. 2. Alpaine Ceramics Industries, Plot No. 100/101, GIDC, Ankleshwar. 3. Ambeshwar Paper Mills Ltd., Plot No. 140/3, GIDC Ind. Estate, Ankleshwar. 4. Anal Products Ltd., 39/137, GIDC Estate, Ankleshwar. 5. Ashok Organics Inds. Ltd., 318-319, GIDC, Ankleshwar. 6. Asian Paints (India) Limited, 2602- GIDC Estate, Ankleshwar. 7. Atul Ltd., 297 GIDC Ankleshwar. 8. Aventis Crop Science India Ltd., Plot No.6301-10 A, GIDC Ankleshwar. 9. Binayakia Synthetics Ltd., Plot No.2, GIDC Ankleshwar. 10. Bombay Drugs & Pharmas Ltd., 26, GIDC Estate, Ankleshwar. 11. Cadila Healthcare Limited, Plot No.291, GIDC Estate, Ankleshwar. 12. Coromandel International Limited, Plot No: 3204, Ficom Chowkdi, GIDC,

Ankleshwar GIDC, Ankleshwar, Gujarat 393002 13. Cadila Pharmaceuticals Limited, 294, GIDC, Ankleshwar. 14. Deepak Synthecs (p) Ltd., 2A, GIDC, Ankleshwar. 15. Diamond Dye-Chem, Lt. (Unit-II), Plot No.6216, GIDC, Ankleshwar. 16. Eldee Velvets & Industries Lim. Shed No. A1/381, GIDC, Ankleshwar. 17. Enviro Technology Limited, 2413/14, GIDC, Ankleshwar. 18. Ewac Alloys Ltd., Plot No. 79/7, GIDC, Ankleshwar. 19. Ficom Organics Limited, Plot No.3201, Ankleshwar. 20. Gharda Chemicals Limited, Plot No.3525-26-27, GIDC, Ankleshwar. 21. Glaxo India Limited, 3102-3109, GIDC Estate, Ankleshwar. 22. Gravier Packaging Ltd., GIDC, Ankleshwar. 23. Gujarat Insecticides Limited, 805/806, GIDC, Ankleshwar. 24. Gujarat Organics Limited, 327/1, GIDC Ind. Estate, Ankleshwar. 25. Gujarat Reclaim & Rubber Production, Plot No. 8, Ankleshwar. 26. Haryana Sheet Glass ltd., Plot No. 9208-B, GIDC, Ankleshwar. 27. Hemani Organics & Chemicals, 3208, GIDC, Ankleshwar. 28. Heubach Colour Ltd., Plot No. 9003-9010, GIDC, Ankleshwar. 29. Hoechest Mariou Roussel ltd., 3501/3503-15, 63108-14, GIDC, Ankleshwar. 30. Ifiunik Pharmaceuticals Limited, Plot No. 128/1/1, GIDC, Ankleshwar. 31. Indokem Limited, Plot No. 2900, GIDC, Ankleshwar. 32. Indosol Drugs Ltd., 501, GIDC, Ankleshwar. 33. Industrial Solvants & Chemicals, GIDC, Ankleshwar. 34. Kanoria Chemicals & Industries, 3407, GIDC, Ankleshwar, 3208. 35. Kanoria Dychem Ltd., Plot No. 6101/1-2, GIDC, Ankleshwar. 36. K.A. Malle Pharmceuticals Ltd., Plot No. 6005, GIDC, Ankleshwar.


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S.N. Name and Address of Industries 37. Keshvani Synthic (I) Ltd., Plot No. 3307, GIDC, Ankleshwar. 38. L.D. Textile Industries Ltd., Plot No. 2802/3, GIDC, Ankleshwar. 39. Laffans Petrochemicals Ltd., Plot No. 321, GIDC, Ankleshwar. 40. Luna Chemicals Indu. Pri. Ltd., Plot No. 23/6, GIDC, Ankleshwar. 41. Lupin Laboratories Limited, 124-125, GIDC, Ankleshwar. 42. Overseas Synthetics Ltd., Plot No. 5054 to 5056, GIDC, Ankleshwar. 43. Oxford Induestries Ltd., Plot No. 8809, GIDC, Ankleshwar. 44. Panama Petrochem Ltd., Plot No. 3303, GIDC, Ankleshwar. 45. Pesticides India Industries Ltd. GIDC, Ankleshwar 46. R.P.G. Life Science Ltd., 3102/A, GIDC, Ankleshwar. 47. Rallis India Ltd., Plot No. 3301, GIDC, Ankleshwar. 48. Rapicut Carbides Ltd., Plot No. 119, GIDC, Ankleshwar. 49. Rishiroop Rubber (Int.) Ltd., 5807, GIDC, Ankleshwar. 50. RPG Life Science Limited, 3102/A, GIDC, Ankleshwar. 51. RPG Life Science Limited, Plot No. 640, GIDC, Ankleshwar. 52. Sajjan India Ltd., 6102/3, GIDC, Ankleshwar. 53. Schenectady-Back India Ltd., Plot No. 1 & 122, GIDC Estate, Ankleshwar. 54. Shri Dinesh Mill Ltd., Bharkodara, Ankleshwar. 55. Suzlon Fibres Limited, 330-A, GIDC, Ankleshwar. 56. SVM Cera Tea Build Ltd., 4802/B, GIDC, Ankleshwar. 57. Sun Pharma Plot No: 4708, GIDC, Industrial Estate, GIDC, Ankleshwar 58. Tonira Pharma Ltd., Plot No. 4722, GIDC, Ankleshwar. 59. Unique Pharmaceuticals Labs. Ltd., Plot No. 128/1, GIDC, Ankleshwar. 60. UPL Ltd., Unit #1, 117/118, GIDC, Ankleshwar. 61. UPL Ltd., Unit #2, 3405/6, GIDC, Ankleshwar, , 393002 Gujarat 62. UPL Ltd., Unit #3, 3101/2, Ankleshwar GIDC, Ankleshwar, Gujarat 393001 63. Wockhardt Ltd., Plot No. 138, GIDC, Ankleshwar. 64. Yagnik Synthetics Ltd., A-1/5240, GIDC, Ankleshwar.

Figure 1.7 Photographs of the Project Site


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1.3 BRIEF OF EXISTING & PROJECT PROJECT FACILITIES

1.3.1 Existing Facilities

UPL’s Unit 2 was commissioned in 1993 with the manufacture of Quinalphos, Phosphamidon, Dichlorovos and Paraquate dichloride. In addition to this, UPL started manufacturing pesticides Phorate and Turbophose and substituted the then existing product Paraquate dichloride with Acephate between January 1994 to 1996. The Unit is currently manufacturing Technical Pesticides - Metribuzin, Terbuphos, Metasystox, Mesotrion, Pyrazosulfuron Ethyl, Ethofumisate, Azoxystrobin, Surflan, Devrinol, D-Devrinol, Clomazone, Metobromuran, Acephate, Metamitron, Acetamiprid, Imidacloprid, Acephate, etc. Pesticide Intermediates – Di Ethyl Thio Phsphory Chloride (DETCL), Amino Aceto Nitrile Sulphate, Myrisyl Amineoxide, Di Methyl Phosphorous Amido Thionate (DMPAT), Di Methyl Phosphonate (DDMP), Para Chloro O Cresol (PCOC), Diethyl Thio Phosphoric Acid(DETA), Zinc Dithio Phosphoric Acid (ZnDTP), Noflan, Absolute Alcohol etc. products. The Unit 2 has been maintaining Zero Liquid Discharge (ZLD) since May-2014.

1.3.2 Proposed Expansion Facilities

To fulfil the demand – supply gap, UPL is proposing expansion of manufacturing of its products at Unit 2, Ankleshwar as following: a) Existing and new pesticide (technical) from 2,175 metric tonnes per month

(MTPM) to 5,580 MTPM; and b) Intermediate chemicals from 1,894 MTPM to 3,984 MTPM. The proposed expansion will require augmentation of existing facilities and development of new ones.

1.4 PESTICIDE CONSUMPTION PATTERN IN INDIA

Insecticides, fungicides and herbicides are commonly used for pest control in agriculture. Both total as well as per hectare consumption of pesticides in India show significant increase after the year 2009-10 as shown below in Figure 1.8. In the year 2014-15, pesticide consumption was 0.29 kg/ha gross cropped area (GCA), which is roughly 50% higher than the use in 2009-10. The recent increase in pesticide use is because of higher cost of manual weed control due to increase in agricultural wages (FICCI, 2015).


11

Figure 1.8 Pesticide (Technical Grade) Consumption in India

Source: Technical Report entitled “Pesticide Use in Indian Agriculture: Trends, Market Structure and Policy”, by Subhash S.P., Balaji, S.J., Indian Council for Agricultural Research (ICAR), January 2017

Table 1.1 State-wise Consumption of Pesticides (Technical Grade)

State/UTs Total consumption (tonnes) Per ha (kg) 2003-04 2008-09 2015-16 2016-17* Punjab 6,780 5,760 5,743 0.74 Haryana 4,730 4,288 NR 0.62 Maharashtra 3,385 2,400 11,665 0.57 Kerala 326 273 1,123 0.41 Uttar 6,710 8,968 10,457 0.39 Tamil 1,434 2,317 2,096 0.33 West Bengal 3,900 4,100 3,712 0.27 Chhattisgarh 332 270 1,625 0.26 Andhra Pradesh 2,034 1,381 2,713 0.24 Odisha 682 1,156 723 0.15 Gujarat 4,000 2,650 1,980 0.13 Bihar 860 915 831 0.11 Karnataka 1,692 1,675 1,434 0.1 Rajasthan 2,303 3,333 2,475 0.05 Madhya Pradesh 62 663 732 0.03 All India 41,020 43,860 54,121 0.29

Source: Technical Report entitled “Pesticide Use in Indian Agriculture: Trends, Market Structure and Policy”, by Subhash S.P., Balaji, S.J., Indian Council for Agricultural Research (ICAR), January 2017 Note: NR – Not Reported; *GCA based on 2014-15

1.5 DEMAND SUPPLY GAP

The Indian pesticides industry is characterized by low capacity utilization. The present total installed capacity is 146,000 tonnes and has a low capacity utilization of less than 60%1. The industry suffers from high inventory owing to seasonal and irregular demand on account of monsoons. There is a marked

1 Indian Chemical Industry, XIIth Five Year Plan – 2012-2017


12

difference in the consumption pattern of pesticides in India vis-à-vis the rest of the world as shown below in Figure 1.9.

Figure 1.9 Comparison of Pesticide Consumption (kg/ha)

Source: Agrochemicals Sub Group, Indian Chemicals Council (ICC), XIIth Five Year Plan (2012-2017) Insecticides account for 76% of the total domestic market. On the other hand, herbicides and fungicides have a significantly higher share in the global market. Crops like cotton, wheat and rice together account for 70% of total agrochemical consumption. India is at an inflection point on food consumption with the domestic demand likely to grow at 4% per annum in the next 15 to 20 years. An independent analysis1 suggests that this growth could be much higher (5 to 6%) across high value food items like animal products, fruits and vegetables and processed food (6 to 8%).

1.6 EXPORT POSSIBILITY & DOMESTIC EXPORT MARKETS

Globally, India is the thirteenth (13th) largest exporter of pesticides. Most of the exports are off-patent products. The major exports from India happen to Brazil, USA, France and Netherlands. The key growth drivers are India’s capability in low cost manufacturing, availability of technically trained manpower, seasonal domestic demand, overcapacity, better price realization globally and strong presence in generic pesticide manufacturing. The total export of agrochemicals in 2016-17 stood at ~378,000 tonnes with the share of fungicides being the largest in terms of export quantity (~46%) and herbicide accounting for the largest share in terms of value of exports (28.19%) as shown below in Figure 1.10. As per data provided by Central Board of Excise and Customs (CBEC) for the year 2016-17, top five pesticides exported from India were Mancozeb, Cypermethrin, Sulphur, Acephate and Chlorpyriphos, while the major products imported were Glyphosate and Atrazine.

1 India as an agriculture and high value powerhouse: A new vision for 2030, Food and Development Action 3, April 2013 by CII and McKinsey & Company


13

Figure 1.10 Export and Import of Major Agro-chemicals in 2016-17

Source: Technical Report entitled “Pesticide Use in Indian Agriculture: Trends, Market Structure and Policy”, by Subhash S.P., Balaji, S.J., Indian Council for Agricultural Research (ICAR), January 2017 Domestic pesticide market is expected to grow steadily as the farmers have learnt modern techniques of farming which has led to increased dependence on pesticides to enhance crop production. With strong global demand for pesticides and India being the low cost producer, exports of pesticides from the country are expected to remain buoyant. As per FICCI report in 2016, Indian agrochemical industry, which is estimated at $ 4.4 billion in FY15, is expected to grow at 7.5% annually to reach $ 6.3 billion by FY20, with domestic demand growing at 6.5% per annum and export demand at 9% per annum. Further, pesticides worth $ 4.1 billion are expected to go off-patent by 2020. This provides significant export opportunities for Indian players. Globally in regulated markets, patented products constitute about 20-22% share of the total pesticide market which is expected to decrease to around 13-15% by 2020 as a result of the patent cliff. The Indian crop protection industry is dominated by generic products with more than 80% of molecules being non-patented. Exports currently constitute almost 50% of the industry turnover.

1.7 NEED FOR THE PROJECT, ITS IMPORTANCE TO THE COUNTRY & BENEFITS OF THE

PROJECT

As described by UPL, India being the second most populous country in the world, it faces a critical challenge of ensuring adequate food availability for its burgeoning population. The role of crop protection chemicals is not limited to protection; they help in yield enhancement as well. Use of crop protection chemicals can increase crop productivity by 25-50%1, by mitigating crop loss due to pest attacks. It is estimated that almost 25% of world's agricultural production is lost due to

1 A report on Agrochemical Industry, July 2016 by FICCI and Tata Strategic Management


14

postharvest pest attacks. Thus, crop protection chemicals are also very essential to ensure food and nutritional security. The expansion project will also be beneficial due to the following: The availability of most of the existing plant’s infrastructure which will help

in minimising both the economical and environmental impacts; Availability of supply chain logistics which can be extended to the proposed

expansion and will help in economical and environmental impacts; Re-engineering capabilities and relatively low cost of production; It will provide a boost to the local economy by providing employment

generation to the local man power; Continuous growth of exports and increase in the Indian market demand

off set the local competitions; The export opportunities will help in generating foreign currency; The proposed expansion project is based on the market surveys and in

house captive consumption; The CSR activities of UPL will enhance an improved quality of life to the

local community.

1.8 EMPLOYMENT OPPORTUNITIES

As per Indian Chemicals Industry’s five year plan (2012-2017) report, pesticides manufacturing sector provides direct and indirect employment to approximately 60,000 people, nearly 10,000 of these working in pesticides manufacturing units. The industry envisaged employment increase to the extent of 7% as per XIIth five year plan. For the proposed Project the direct and indirect employment generation will be given in Table 1.2. UPL will utilize labor that is locally available.

Table 1.2 Employment Generation from the Proposed Project

S.N. Particulars Manpower (nos.) Existing Proposed Total (After Expansion)

1 Staff 253 103 356 2 Contract 240 150 390 Total 493 253 746

Source: UPL

1.9 PURPOSE OF THE EIA STUDY

The proposed expansion Project falls under activity no. 5(b) of Category ‘A’ of Schedule to EIA notification 2006 and its amendments thereof wherein all “Pesticides industry and pesticide specific intermediates (excluding formulations)” require prior Environmental Clearance from Ministry of Environment, Forests and Climate Change (MoEF&CC), Government of India. The EIA study was based on Standard Terms of Reference (ToR) for EIA study as approved by Expert Appraisal Committee (EAC) of MoEF&CC.


15

This EIA study has been prepared to address the potential impacts as per the Standard ToR approved by MoEF&CC on 31st January 2018. The study forms a guiding tool for decision making by the EAC (Industry Committee-2) of MoEF&CC for appraisal of proposed expansion Project and for UPL to implement agreed mitigation measures under its environmental management system for the proposed Project. The EIA study has been prepared with the following considerations: • Determination of existing environmental and social baseline conditions

based on primary information collected during the course of the EIA study, environmental monitoring data available with UPL as part of the ongoing environmental monitoring of the Plant and secondary information from government and other recognized sources within the 10-km radius study area;

• Detailed description of existing facilities that include control measures for preventing / reducing environmental impacts, and their adequacy for the proposed expansion;

• Identification and assessment of environmental and social impacts, if any due to the proposed expansion;

• Assessment of risks from storage and handling of hazardous substances; • Adequacy check of existing environment management measures and

additional recommendations, if any.

1.9.1 Banned Pesticides

As per the recent Gazzette Notification [S.O. 3951(E)] by Ministry of Agriculture and Farmers Welfare, Department of Agriculture, Co-Operation and Farmers Welfare, published on August 08th, 2018 a total of eighteen (18) pesticides are banned or restricted under section 5 of the Insecticides Act, 1968 (46 of 1968). As per this order, referred to as Pesticides (Prohibition) Order, 2018, no person shall manufacture, import, formulate, transport, sell, use of any pesticide specified under column (2) of the Schedule to this Order from the date specified under column (3) thereof. Out of 18 prohibited pesticides, three (3) existing pesticides as manufactured by UPL Unit 2 namely – Dichlorovos, Phorate and Phosphamidon shall be prohibited for import, manufacture or formulation with effect from January 01, 2019 as per Schedule of this Order. In line with the Pesticide (Prohibition) Order, 2018, UPL Unit 2 shall withdraw its existing facility for manufacture of Dicholorovos, Phorate and Phosphamidon from its technical product and formulation product list.

NOTE: As the application Form-1, prefeasibility report (PFR) for the proposed expansion for the existing and new products was submitted on December 30, 2017, these products were shown as part of the proposed Project. In view of this latest Order, the technical product list has been revised and Dicholorovos, Phorate and Phosphamidon has been taken out. Refer to Section 2 on details of product list.


16

1.10 SCOPE OF EIA STUDY

The scope of work is to conduct the EIA study as per terms of reference issued by the Expert Appraisal Committee (EAC) of MoEF&CC for the proposed expansion in existing capacity of pesticides technical and intermediate products and addition of new pesticides technical product within existing premises at M/s UPL Limited, Unit # 02, Plot No. 3405/ 3406/3460A, Notified Industrial Estate, GIDC Ankleshwar, Bharuch, Gujarat. The scope covers the following key elements: • Conduct EIA study as per the standard terms of reference issued by EAC

(Industry-2) of MoEF&CC; • Compile primary environmental and social baseline data as collected during

the EIA studies as well as through ongoing baseline assessment quality monitoring. Use available secondary information to supplement the baseline data;

• Identify and assess potential environmental impacts from the proposed increase in production capacity and associated facilities development. The scope also comprise use of available information on risk and disaster management by UPL; and

• Develop appropriate mitigation measures and environmental management plan with required environmental management systems in place for effective implementation of suggested mitigation measures.

1.11 METHODOLOGY ADOPTED FOR CONDUCT OF THE EIA STUDY

1.11.1 Step I: General Screening

• Reviewing the Project information and activities and identifying their potential impacts on the various environmental parameters;

• Reviewing of compliance status of the environmental approvals; • Compiling available baseline data for the 10-km radius study area and other

relevant information; and • Developing a list of the environmental requirements as recommended

through terms of reference for EIA study by EAC and environmental issues identified related to this Project.

1.11.2 Step II: Scoping Exercise involving ToR Approval by EAC for conducting EIA

Study

Scoping is a process of identifying the content and extent of social and environmental information and impact assessment required to be included in an EIA study. The purpose of scoping is to identify the matters, which should be covered in the environmental and social information submitted by the developer to the regulatory agency (Ministry of Environment, Forests and Climate Change in this case) and, in particular to identify the matters which are of most importance so that these can be addressed in most detail. Scoping process determines terms of reference for environmental studies to be conducted for a developmental activity or its expansion or modernization. The


17

terms of reference for environmental studies helps in ensuring that all the relevant issues are identified and addressed in an appropriate manner in the EIA studies. As per the requirement of the EIA Notification, 2006, an application for terms of reference (covering checklists as per Form 1, draft terms of reference and Project prefeasibility report) for the EIA study was submitted by UPL Ltd. Unit 2 to MoEF&CC on December 30, 2017. The MoEF&CC issued the standard terms of reference for EIA study for the proposed Project on January 31, 2018 [vide Letter No. J-11011/180/2016- I A II(I)].

1.11.3 Step III: Project Description

Section 2 of this report covers detailed Project description. The information provided in Section 2 becomes the basis for impact and risk assessment and to minimize adverse impacts environmental and risk mitigation measures have been proposed.

1.11.4 Step IV: Environmental Baseline Data Compilation

Environmental baseline study for summer season (26th February to 26th May 2018) was conducted by ERM as part of the ongoing EIA study. The baseline section is further supplemented with the available secondary information for the study area covering Unit 2 and its surrounding area (Section 3).

1.11.5 Step V: Impact Assessment & Development of Analysis of Alternatives

The general process for assessing impacts associated with the proposed increase in production is presented in Section 4 on Impact Assessment. The section covers identification, prediction and quantification of potential impacts due to the proposed Project on the physical, biological and social components of the environment. The impacts have been identified and quantified/determined for the intensity using modelling and/or matrix or qualitative techniques and evaluated as major, medium, minor or insignificant impacts on the environment. Mitigation measures have been suggested for significant adverse impacts likely to be caused, during construction and operation phases of the Project. The Impact Assessment section discusses the outcomes of the environmental impact /risk assessment and outlines mitigation measures that are recommended to control the identified environmental impacts. Risk assessment for the proposed expansion has been included in Section 7 of this report. The impacts have been assessed based on available Project information and existing environmental baseline conditions. The accuracy of predictions depends upon methods used and quality of the input data available at the EIA stage on the Project and the environment conditions. In this EIA, impact assessment has been done using methods ranging from qualitative assessment and expert judgment to quantitative modelling output and subjective judgment


18

of experts engaged for the study. It is to be noted that where details of the Project information is not fully defined at the EIA stage, certain assumptions are required to be made. Worst case scenarios have been assumed where uncertainty prevailed and mitigation measures have been developed accordingly.

1.11.6 Step VI: Environment Management Plan

Based on the findings from the impact assessment process, an Environmental Management Plan (EMP) (Section 10) has been updated for the proposed expansion of Unit 2 production programme. Mitigation measures to counter the identified impacts have been highlighted in the EMP. The EMP includes the following: • Introduction to the purpose and aims of the EMP; • Institutional framework for implementation of the EMP; • Summary of potential adverse impacts and mitigation measures to minimise

impacts on physical, social and biological environment; • Monitoring, Training, Auditing and Reporting requirements. The EMP details the existing specific actions with updated information for the proposed increase in production including information.

1.12 LIMITATIONS

This report is based on certain scientific principles and professional judgement to certain facts with resultant subjective interpretation. Professional judgement expressed herein is based on the available data and information. Baseline information compiled as part of the previous EIA studies and available environmental baseline being collected as part of the ongoing environmental performance monitoring of the Project has been assumed as part of the current baseline information without proposed expansion. This report has been developed with the assumption that the information gathered and provided by UPL. If information to the contrary is discovered, the findings in this EIA may need to be modified accordingly. The impact assessment for the Project is based on the Project capacity as described in Project description (Section 2). The Section 7 on risk assessment has been developed based on certain scientific principles and professional judgement applied to certain facts with resultant subjective interpretation. Professional judgement expressed herein is based on the available data and information provided by UPL on Consequence Analysis to meet the requirements for the Project approval. ERM is not engaged in the impact assessment, consequence analysis and reporting for the purposes of advertising, sales promotion, or endorsement of any client's interests, or other publicity purposes. The client acknowledges that


19

any report prepared by ERM are for the exclusive use of the client and agrees that ERM's reports or correspondence will not be used or reproduced in full or in part for such promotional purposes, and may not be used or relied upon in any prospectus or offering circular.

1.13 CONTENTS OF THE EIA REPORT

The EIA report comprises of eleven (11) sections as described below in Table 1.3

Table 1.3 Contents of the EIA Report

Section Description Section 1: Introduction Covers Background, Project proponent, brief description

of nature of Project, demand supply gap, need for the Project, employment generation, purpose of the EIA study, scope of the EIA study, approach and methodology for the EIA study, limitations and contents of the EIA report.

Section 2: Project Description Presents a description of the Project activities for the proposed expansion of pesticides technical and intermediates products.

Section 3: Description of the Environment

Includes a description of the environment within and surrounding the Project activities in the study area of 10-km radius.

Section 4: Anticipated Environmental Impacts & Mitigation Measures

Includes impact assessment, mitigation measures and evaluation of significance of residual impacts.

Section 5: Analysis of Alternatives Includes description of alternatives considered and reasons for selecting the alternatives for the proposed expansion of pesticides technical and intermediate products

Section 6: Environmental Monitoring Program

Includes requirement of environmental monitoring including the frequency, location, parameters etc.

Section 7: Additional Studies –Risk Assessment

Includes Risk Assessment and Disaster Management Plan. (Note: no statutory public consultation is required as the Project is located within notified industrial estate of GIDC).

Section 8: Project Benefits Includes benefits from the Project like CSR benefits, financial benefits to the country.

Section 9: Environmental Cost Benefit Analysis

This section covrers environmental cost benefit analysis.

Section 10: Environmental Management Plan (EMP)

This section covers introduction and elements of EMP i.e. planning, implementation, checking and management review. The section includes the following: Reference of UPL’s commitments and policies Institutional arrangements for effective

implementation of proposed environmental management plan

Mitigation measures (specific actions and management plans) and

Mechanism of self-monitoring for compliance with environmental regulations.

Section 11: Conclusions Presents the overall findings from the EIA Section 12: Disclosure about Consultant

Provides brief information about ERM and professionals who were engaged for completion of this study


20

Section Description Section 13: Standard Terms of Reference

Standard Terms of Reference as issued by MoEF&CC

Annexes Annex A Copies of previous Environmental Clearances Annex B Latest (January 2018 to June 2018) Certified EC

Compliance report from Regional Office, MoEF&CC Annex C CC&A/CTO Compliance report as submitted to GPCB Annex D Onsite Meteorological Data for the Study Period Annex E Onsite Ambient Air, Noise Quality and Traffic Quality

for the Study Period and NABL Accreditation for CEG Test House (3rd Party Environmental Baseline Monitoring Agency)

Annex F Material Safety Data Sheet of Product & Raw Materials Annex G Risk Contours for maximum credible loss scenarios

(MCLS) for Flammable and Toxic Storages Annex H Onsite Emergency Response Plan Annex I Medical Examination Records and Annual Medical

check-up details Annex J BEIL Membership Certificate for hazardous waste

disposal Annex K Copy of GIDC Approval to Unit 2 for additional water

supply Annex L Copy of latest CC & A granted by GPCB & Application

letter for Renewal submitted to GPCB. Annex M Copy of FETP Membership Annex N Action plan for Solvent Recovery submitted to

MoEF&CC as part of EC Compliance


21

2 PROJECT DESCRIPTION

This section describes UPL’s Unit 2 operation philosophy of the existing and proposed expansion Project together with additional resources required.

2.1 DETAILS OF PROPOSED EXPANSION

M/s. UPL Limited, Unit # 02 proposes to expand their Pesticide Technical and Intermediates products at Plot no 3405/3406/3460A, Notified Industrial Estate, GIDC Ankleshwar-393002, Bharuch District, Gujarat, India. The proposed expansion comprises of existing and new Pesticides (Technical) from 2,135 MT/month to 5,580 MT/month and Intermediate chemicals from 1,894 MT/month to 3,984 MT/month. The plot plan for the existing proposed Project is shown below in Figure 2.1. The land break-up is detailed in Section 2.5 in Table 2.3. A summary of the existing and proposed production capacity for the products and by-products is provided below in Error! Reference source not found. and Table 2.2. The product list has been revised based on the Pesticide (Prohibition) Order, 2018 as published vide S.O. 3951 (E), dated 8th August, 2018. Kindly refer Section 1.9.1 for details.

1) COMMON PLOT SHOWN IN

3) DRAINAGE SHOWN IN

2) G.I.D.C. ROAD SHOWN IN

NOTE.

4) WATER SUPPLY LINE

5) PERCOLATING BORE WELL (SEALED)

WATER RECHARGING FACILITIES

26A

E-520.000

N-10

0.00

0

N-16

2.500

H.T YARD

OPEN

H-1000

AM-800

PLANT

PLANT

PH-5000

PLANT

29

UP-300

31

37

38

39

31A

50

ST. AREA

DMMP

PLANT

40

41

33A

33B

2

45

10

9

11

21

26

32

33

44

30

23

23A

28

STORAGE TANK

METHYL CHLORIDE RECOVERY PLANT

29A

38A

8

38D

23B

24

18.0 m

W

I D

E

R

O

A

D

WELFARE

3.0m

W

ID

E R

OA

D

4.5m WIDE ROAD

GREEN BELT

4.5m WIDE ROAD

O.H.C

WORKER'S

9.0m

W

I D

E

R

O

A

D

9.0m WIDE ROAD

6.0 m W I D E R O A D


6.0

m W

ID

E R

OA

D

4.5m NEW WIDE ROAD


52

1312

1817

18A

14.29

9.83

19

CANTEEN

18.46

51

54

38B/C

38F

55

18

.2

3

18

.2

3

18

.2

3

36.2330.0030.23

PH-5000

9.00

10.25

9.00

7.40

6.30

12.2

3

11.00

4.50 18.00 18.50 19.50 7.00 3.50

12.00

15.00

4.50

9.00

10.0

0

4.55

27.95

9.00

10.40

12.50 12.50 4.0010.15

4.50

2.40 19.330 11.28

9.00

5.50 10.28

10.22

6.00

30.0 m W I D E G I D C R O A D

6.00

12.00

B

PARKING AREA

C

A

48.50

6.00

12.00

11.43

6.40

7.66

32.00

16.00

7.41

16.41

16.40

8.70

7.04

30.45

12.23

33.63

7.00

19.00

21.00

XX

XX

XX

X

XX

XX

XX

XX X

XX X

22

3.16

3.16

20.00

10

.00

12.45

2.5

0

2.00

4.23

4.50

6.00 12.45

18.45

18.25

8.90

4.5

0

9.0

0

7.00

7.00

4.90

34.00

18.25

UP

UP

2.50

16.29

6.375

8.06 5.04

15.00

18.0

0

23.54

N

29.49

8.72 24.00

17.00

21.00

10.50

15.50

20

15.23

15.23 9.00

62.50

20

9.75

187.00

250.00

1.95

3.17

4.50

10

.0

0

17.77

18.46

37.09

14

12.10

8.10

7.00

48.50 3.50

16.00

20.00

20.00

17.00

7.21

4.50

2.0

6.00

21.50

35.00

9.4

6

12.00

PARKING AREA

12.00 7.00

15A

25A

2.0

2.0

3.00

1.20

8.39

17.88

6.23

14.23

16.23

6.62

1.90

53

.5

0

59.50

7.4

8

9.00

6.38

6.00

4.75

7.45

5.00

4.50

4.97

8.00

6.006.00

5.40

9.93

9.4

6

6.00

25

2.00

3.03

5.8

33.01

9.00

16.50

42

0.00

21

0.0

0

17.00

P

8.00

8.7024.08

48.57

12.47

17.87

30.90

54.57

21.00

5.8

06

.5

03

.8

06.50

10.50 6.25

6.70

3.55

12.3

0

3.5

5

7

34

7

22.00

10

.0

0

PARKING AREA

D

26.59

34.48

PARKING AREA

F

30.90

108.00

7.00

28.00

9.0

0

PLANT

4.50

4.5

0

27.54

7

8.40

56

12

.6

3

5.60

3.9

0

AM

-8

00

P

LA

NT

EX

TE

NS

IO

N

25.39

11.00

G

17

.50

7.77

9.0

0

8.73

13.73

3.00

9.8

0

19

.73

6.73

9.73 4.50

MCC ROOM

CHEMICAL

6.933

19.0

0

41

.1

0

UP

UP

UP

UP

50.70

7.30

6.67

2.72

23.315

D

D

18550

4.40STORAGE

9.0

0

2.7

1

3.00

13.00

2.50

1.20

4.90

10.00

9.00

7.0

0

57

5.21

6.3

0

10

.20

20

.23

2.00

13.0035.50

23.0

47

4.5

0

17

.7

4

29.36

28

.8

7

27.0

0

15.34

21.00

13.00

53

5.00

4.50

9.50

6.50

8.33

7.97

26.43

47.12

4.50

4.50

32.74

41.40

WATER RECHARGING (SEALED)

FACILITES


FACILITES


FACILITES


FACILITES

4.05

1.45

10.3

0

GREEN BELT

3409

R O

A

D

R

O

A

D

U P L

UNIT NO.-2

UPL LTD, UNIT-02

KEY PLAN

3102 3102C

30.0m W

IDE

G.I.D

.C. R

OA

D

3406

3102B

SEARLE

3102A 3205

3412

3307

3416

3306

3417

3418

3413

3414

3415

3405

3411

3410

3305

3460B

3461

3407

KANORIA CHEMICALS & IND.

M.J.PHARMA

N

R O A D

34

60

A

3304

3408

3303

3302

B

3302

12.17

37.69

GREEN BELT

12 x 37 = 444m2

GREEN BELT

12 x 33 = 396m2

GREEN BELT

11 x 30 = 330m2

GREEN BELT

11 x 30 = 330m2

GREEN BELT

6 x 95 = 570m2

USABLE

EQUIPMENT

YARD

S.S.

SCRAP

GLASS

SCRAP

RUBBER

SCRAP

COPPER

SCRAP

PAPER&WOOD

SCRAP

PP/FRP

SCRAP

ELECTRICAL

SCRAP

ALUMINIUM

SCRAP

MS

SCRAP

6.0 M

W

I D

E

R

O

A

D

5370X8200

3150XX5180

3150XX5180

2600X33602580X3360

5180X2800

2600X2800

2580X2800

5180X3000

5180X3300

5180X3100

5180X2800

8110X8950

TOILET

BLOCK

10.0 m x 6.0 m

GARDEN

SEPTIC

TANK

CONTRACT WORKMAN

DINING AREA

10.0 m x 10.0 m

MCS-1

10.0 m x 12.0 m

MCS-2

10.0 m x 12.0 m

MCS-3

10.0 m x 12.0 m

EL-1

10.0 m x 5.0 m

10.0 m x 5.0 m

EL-2

GARDEN

PR

OP

OS

ED

G

RE

EN

B

ELT

9 x 35 =

315m

2

9.89

35

.6

2

57.00

101

.8

6

44

.9

7

15.0 M W I D E R O A D


9.0 M

W

I D

E

R

O

A

D

9.0 M

W

I D

E

R

O

A

D

PLANT NO.-C

PLANT NO.-E

PLANT NO.-BPLANT NO.-A

PLANT NO.-D


UNIT

REV

2

0

SHEET

PLANT

DRAWING No.

TITLE

SCALE

CAD No.

No.OF

DATE

ISSUED DETAILSFORMAT No.

PROJECT No.

-APPD.CHED.

R.C.PATEL

DRAWNBYBY

ISSUED

0

DATE

13.11.17

REV DESCRIPTION

NEW PLAN LOCATION

COPYTO

-

UPL LIMITED

PLOT NO -3405,3406,3460A G I D C ANKLESHWAR [ UNIT-02 ]

TA- ANKLESHWAR , DIST-BHARUCH ,STATE - GUJRAT

2017

NMSJ

NEW PLAN LOCATION MARKINGSITE PLAN [UNIT-2]

MARKING

6) GREEN BELT

7) PROCESS PLANT BUILDING

17

.50

13.50

34.00

38E

3

3

GREEN BELT AREA

8) PROCESS PLANT BUILDING

GREEN BELT

43.73

GREEN BELT

1357.16m2

11

.91

13.50

& TONNER STORAGE SHED

GREEN BELT

GREEN BELT

GREEN BELT

20007398

Typewritten Text

Figure 2.1 :Plot Plan for the Proposed Unit 2 Expansion Project


23

Table 2.1 Product List for the Proposed Expansion of Unit 2

Plant No S.N. Product Name


Proposed Additional Capacity (TP/M)


Total Capacity After Expansion (TP/M)

CAS Number LD50 Biodegradability Toxicity class Use/ Application

Category As per the EIA Notification 2006

CIB Status

(A) Pesticide Technical Products-Existing and Proposed capacity

A

1

D-Devrinol OR Devrinol OR Chlomazone (Combined Capacity)

300 NIL D-Devrinol 300 15299-99-7

Oral- rats >5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In aerobic laboratory soil, degradation is slow, DT50 230-670 days (30 °C); however, in the field, DT50 is 46-131 days. Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) U Ref : Pesticide Manual (Fifteenth Edition)

Pre-emergence control of annual grasses and broad leaved weeds in oilseed rape, tomatoes, capsicums, potatoes, peas, nuts, fruit trees and bushes, vines, strawberries, sunflowers, safflowers, ornamentals, tobacco, olives, figs, mints, turf, and other crops Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide (Herbicides)

Not Banned

OR OR OR OR OR OR OR OR OR OR OR OR

2 Metobromuron 60 NIL Metobromuron 60 3060-89-7

Acute Oral - rats 2603 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

DT50 in soil 30 d; strongly bound to soil, indicating low leaching potential Ref : Pesticide Manual (Fifteenth Edition)


Pre emergence control of annual broad-leaved weeds and grasses in beans, potatoes, tomatoes, tobacco, soya beans, maize, cornsalad, artichokes and sugar beet. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

3 Devrinol NIL 400 Devrinol 400 15299-99-7

Oral- rats >5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In aerobic laboratory soil, degradation is slow, DT50 230-670 days (30 °C); however, in the field, DT50 is 46-131 days. Ref : Pesticide Manual (Fifteenth Edition)


Pre-emergence control of annual grasses and broad leaved weeds in oilseed rape, tomatoes, capsicums, potatoes, peas, nuts, fruit trees and bushes, vines, strawberries, sunflowers, safflowers, ornamentals, tobacco, olives, figs, mints, turf, and other crops Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

4 Imazapic Technical

NIL 500 Imazapic Technical

500 104098-48-8

Acute Oral - rats > 5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

The primary route of degradation in soil is via microbial activity; DT 50 is 31-410 days, depending upon soil and climatic conditions Ref : Pesticide Manual (Fifteenth Edition)

EPA (Formulation) III Ref : Pesticide Manual (Fifteenth Edition)

For post and pre-emergence residual control of a wide range of annual and perennial weeds in pasture rangeland and non-cropland areas. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

5 Ethofumesate NIL 100 Ethofumesate 100 26225-79-6

Acute oral - rats and mice > 5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

It is biologically degraded in soil to transient degradates which are rapidly converted to soil-bound residues and mineralised to CO2 Ref : Pesticide Manual (Fifteenth Edition)


Used pre- and/or post-emergence in sugar and other beet crops, turf, ryegrass and the other pasture grasses. It is effective in controlling a wide range of important grasses and broad-leaved weeds, with a good persistence of activity in the soil. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

B 6 Terbuphos OR

500 NIL Terbuphos OR

500 13071-79-9 OR

Oral for male albino rats 1.6 mg tech./kg Ref : Pesticide Manual (Fifteenth Edition)

Oxidative and hydrolytic degradation occurs in soil. No accumulation. DT50 in soil 9-27 days. Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) Ia Ref : Pesticide Manual (Fifteenth Edition)

Has effective initial and residual activity against soil-dwelling arthropods like maize, sugarbeat,cabbages & onions. Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide Not Banned


24








CIB Status


Phorate OR

Phorate OR

298-02-2 OR

Oral LD50 for male rats 3.7 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In soil metabolic oxidation gives the sulfoxide and sulfone, and their phosphorothioate analogues, and then undergo hydrolysis. DT50 c. 7-10 days. Ref : Pesticide Manual (Fifteenth Edition)


Control of Agromyzidae, Aleyrodidae, Aphididae, Chrysomelidae, Noctuidae, Pyralidae, Tetranychidae and certain nematodes in brassicas, beetroot, sugar beet, fodder beet, carrots, field beans, broad beans, celery, maize, sorghum, wheat, potatoes, tomatoes, hops, soya beans, sunfloers, sugar cane, alfalfa, cotton, coffee, rice, peanuts, and some ornamentals Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide (Insecticide)

Prohibition for import, manufacture or formulate Phorate with effect from the 1st January, 2019 as per as per The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare.



2674-91-1

Oral rats 89 mg/kg Ref :Wako Pure Chemical Industries, Ltd.Japan MSDS

No Inofrmation Available Ref - Wako Pure Chemical Industries, Ltd.Japan MSDS




Not Banned

7

Acetamiprid OR

10 OR 5


Acetamiprid OR


135410-20-7 OR

Oral for male rats 217 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

It is moderately to highly mobile in most soils but is not expected to be peristent in the environment. The primary degradation pathway is aerobic soil metabolism. DT50 is 0.8-5.4 days. Ref : Pesticide Manual (Fifteenth Edition)

No Inofrmation Available Ref : Pesticide Manual (Fifteenth Edition)

Control of Hemiptera, especially aphids, Thysanoptera and Lepidoptera, by soil and foliar application, on a wide range of crops, especially vegetables, fruit and tea. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

Imidacloprid Imidacloprid 138261-41-3

Oral- rats 450 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In lab. studies the most important metabolic steps were oxidation at the imidazolidine ring, reduction or loss of the nitro group, hydrolysis to 6-chloronicotinic acid and mineralisation; these processes were strongly accelerated by vegetation. Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) II Ref : Pesticide Manual (Fifteenth Edition)

Control of sucking insects, including rice-, leaf- and planthoppers, aphids, thrips and whiteflies. Used as a seed dressing, as soil treatrment and as foliar treatment in grains, vegetables & fruits. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

8 Acephate 1,225 NIL Acephate 1,225 30560-19-1

Oral - male rats 1,447 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Readily biodegraded and non-persistent; soil DT50 2 days (aerobic) to 7 days (anaerobic) Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) III Ref : Pesticide Manual (Fifteenth Edition)

Control of a wide range of chewing and sucking insects, e.g., aphids, thrips, lepidopterous, larvae, sawflies, leaf miners, leafhoppers, cutworms, etc., in fruit (including citrus), vines, hops, olives, cotton, soya beans, peanuts, macadamia nuts, beet, brassicas, celery, beans, potatoes, rice, tobacco, ornamentals, forestry and other crops.


Not Banned


25








CIB Status


Ref : Pesticide Manual (Fifteenth Edition)

9 OR Metamitron

OR 60

NIL OR Metamitron

OR 60

41394-05-2

Oral - rats 2,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In soil, it is degraded very rapidly, 20% of the applied material was detectable after 4-6 weeks. No leaching into groundwater occurred. Ref : Pesticide Manual (Fifteenth Edition)


Used against grass and broad-leaved weeds in sugar and fodder beets. Applied pre-drilling incorporated, pre- or post- emergence. Also used in mangold, red beet and certain strawberry varieties. Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide (Herbicide)

Not Banned

D

10

Phosphamidon (PD) OR Azoxystrobin

100 OR

NIL

Phosphamidon (PD) OR

100 OR 40

13171-21-6 OR

Oral - rats 17.9 - 30 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Metabolism and breakdown in plants, animals and soil has been reviewed. Ref : Pesticide Manual (Fifteenth Edition)


Control of sucking, chewing and boring insects, and spider mites, on a wide range of crops. Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide (Insecticide) OR

Prohibition for import, manufacture or formulate Phosphamidon with effect from the 1st January, 2019 as per as per The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare.

Surflan OR

40 Surflan 19044-88-3

Oral rats > 10,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In soil, microbial degardation occurs rapidly, aerobic metabolism being slower than anaerobic. Ref : Pesticide Manual (Fifteenth Edition)


Pre - emergence control of many annual grasses and broad - leaved weeds in cotton, fruit trees, nut trees, vines, ornamentals, soya beans, berries, rice, amenity turf and non-crop areas. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

11 Azoxystrobin NIL 200 Azoxystrobin 200 131860-33-8

Oral Rat: >5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

In soil, DT50 (lab.) 70 days; it is classified as moderately mobile in soil. Ref : Pesticide Manual (Fifteenth Edition)


Control of pathogens at grains, vegitables, fruits and nuts. Ref : Pesticide Manual (Fifteenth Edition)

5 (b) Pesticide (Fungicide)

Not Banned

12 Clomazone NIL 300 Clomazone 300 81777-89-1

Oral-Rat 2077 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Moderately persistent in soil, DT50 30-135 days. Ref : Pesticide Manual (Fifteenth Edition)


Control of broad leaved and grass weeds in soya beans, peas, maize, oil seed rape, sugar cane, cassava, pumpkins, potatoes and tobacco. Applied pre-emergence or pre-plant incorporated. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned


26








CIB Status


13 OR

Monocrotophos OR



Monocrotophos OR

100

6923-22-4 OR

Oral male rats 18 mg/kg, female rats 20 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Rapidly degraded in soil, DT50 1-5 days Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) Ib Ref : Pesticide Manual (Fifteenth Edition)

Control of broad spectrum of pests, including sucking, chewing and boring insects, and spider mites on cotton, citrus, olives, rice, maize, sorghum, sugarcane, sugar beet, peanuts, potatoes, soya beans, vegetables, ornamentals and tobacco. Ref : Pesticide Manual (Fifteenth Edition)


Banned for use on vegetables as per S.O.1482 (E) dated 10th Oct, 2005)

13



94-75-7

For rats 639 - 764 mg/Kg Ref : Pesticide Manual (Fifteenth Edition)

In Soil microbial degradation involves hydroxylation, decarboxylation, cleavage of acid side-chain, and ring opening. DT50 in Soil <7 Days. Ref : Pesticide Manual (Fifteenth Edition)


Post emergence control of annual and parannial broad leaved weeds in serials, fruits and on non crop land. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

14

Dichlorvos (DDVP) OR

85 OR

NIL Mesotrion OR


104206-82-8

Oral-Rat >5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

DT50 (lab., anaerobic) 4 days (first order) DT50 (lab., aerobic) 6-27 days Ref : Pesticide Manual (Fifteenth Edition)

No Inofrmation Available Ref : Pesticide Manual (Fifteenth Edition)

Under Development fpr pre-emergence and post-emergence control of broad leaved weeds. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

Ethofumesate OR

50 OR

NIL

Mesotrion OR 85 OR NIL OR Pyrazosulfuron Ethyl (Combined Capacity)

OR 93697-74-6

OR Oral-Rat >5,000 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

OR In soil, DT50 < 15 days. Ref : Pesticide Manual (Fifteenth Edition)

OR WHO (a.i.) U Ref : Pesticide Manual (Fifteenth Edition)

OR Control of annual and perennial broad leaved weeds and sedges, pre or post emergence in wet-sown and transplanted rice crops Ref : Pesticide Manual (Fifteenth Edition)


Not Banned


85 NIL

15 Dichlorvos (DDVP)

NIL 170 Dichlorvos (DDVP)

170 62-73-7

Oral-Rat : 50 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Non-persistent in the environment, with rapid decomposition in the atmosphere Ref : Pesticide Manual (Fifteenth Edition)

WHO (a.i.) Ib Ref : Pesticide Manual (Fifteenth Edition)

Control of household and public health insect pests and also use as a veterinary anthelmintic Ref : Pesticide Manual (Fifteenth Edition)


Prohibition for import, manufacture or formulate Dichlorovos with effect from the 1st January, 2019 as per as per The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare.

16 Metribuzin 5 NIL Metribuzin 5 21087-64-9

Oral-Rat 510 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Rapidly degraded in soil, microbial breakdown is the major mechanism of loss; DT50 in soil 1-2 months. Ref : Pesticide Manual (Fifteenth Edition)


Pre and post emergence control of many grasses and board-leaved weeds in soya beans, potatoes, tomatoes, sugar cane, maize and cereals Ref : Pesticide Manual (Fifteenth Edition)


Not Banned


27








CIB Status


E 17 Acephate NIL 1,775 Acephate 1,775 30560-19-1

Oral - male rats 1,447 mg/kg Ref : Pesticide Manual (Fifteenth Edition)

Readily biodegraded and non-persistent; soil DT50 2 days (aerobic) to 7 days (anaerobic) Ref : Pesticide Manual (Fifteenth Edition)


Control of a wide range of chewing and sucking insects, e.g., aphids, thrips, lepidopterous, larvae, sawflies, leaf miners, leafhoppers, cutworms, etc., in fruit (including citrus), vines, hops, olives, cotton, soya beans, peanuts, macadamia nuts, beet, brassicas, celery, beans, potatoes, rice, tobacco, ornamentals, forestry and other crops. Ref : Pesticide Manual (Fifteenth Edition)


Not Banned

TOTAL A - Submitted in PFR & Form 1

2,235 3,575 5,810 The Product List Total as per EC Application submitted to MoEF&CC dated 31/12/2017 i.e. before the publication of The Pesticide (Prohibition) Order 2018 dated 8th August 2018.

TOTAL A1 - Revised After Exclusion of Prohibited Pesticides 2,175 3,405 5,580

Based on consideration of Applicability of The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare the Products - Dichlorovos, Phorate & Phosphamidon are Prohibited for Manufacture, Formulate, Import with effect from the 1st January, 2019.

(B) Intermediate Chemicals - Existing and Proposed capacity

A 1 Di Methyl Methyl Phosphonate (DMMP)

100 200


300 756-79-6

Oral Rat 8,210 mg/kg Ref: MSDS - Thermofischer Scientific

No Information Available Ref: MSDS - Thermofischer Scientific

No Information Available Ref: MSDS - Thermofischer Scientific

In Heavy Metal Extraction & Solvent Separation; Pre-Ignition Additive For Gasoline; Antifoam Agent; Plasticizer & Stabilizer; Textile Conditioner & Antistatic Agent; Additive In Solvents & Low Temp Hydraulic Fluids Ref: https://toxnet.nlm.nih.gov/cgi-bin/sis/search/a?dbs+hsdb:@term+@DOCNO+2590

5 (b) Intermediate Chemicals

Not Applicable

B

2


50 OR

NIL


50 OR

2524-04-1 OR

Oral Rat > 1,340 mg/kg Source - MSDS of Fluorochem

No Information Available Ref: MSDS of Fluorochem




Not Applicable


160 OR


160 OR

5466-22-8 OR

No data Available Ref: SDS ThermoFisher Scientific

No further relevant information available Ref: SDS ThermoFisher Scientific

No Information Available Ref: SDS ThermoFisher Scientific

No Information Available Ref: SDS ThermoFisher Scientific


Not Applicable


160

Myristyl amine oxide (MO) (Combined capacity)

160 3332-27-2

No data Available Ref: SDS Sigma Aldreach

No data Available Ref: MSDS Sigma Aldreach

No data Available Ref: SDS Sigma Aldreach

Laboratory chemicals, Manufacture of substances Ref: SDS Sigma Aldreach


Not Applicable

3 Para Chloro O Cresol (PCOC)

96 NIL Para Chloro O Cresol (PCOC)

96 59-50-7

Oral Rat – 1,830 Mg/Kg - Source Thermo Fisher Scientific MSDS

Persistence is unlikely Ref: Thermofischer Scientific

No data Available Ref: Thermofischer Scientific

Laboratory Chemicals Ref : SDS of Thermifischer Scientific


Not Applicable


28








CIB Status


4

Di Ethyl Thio Phosphoric Acid (DETA) OR

1,000 1,000

Di Ethyl Thio Phosphoric Acid (DETA) OR

2,000

298-06-6 OR

Oral Rat 4,510 mg/kg Ref: MSDS of Chemwatch

Biodegradation modeling demonstrates that DEA is biodegradable. Ref: MSDS

No Information Available

Reagent. Intermediate. 0,0-diethyl dithiophosphate is used as an intermediate in the production of an agricultural insecticide Ref: MSDS


Not Applicable



19210-06-1

Oral Rat 4,170 mg/kg Ref: https://www.lookchem.com/ZINC-DITHIOPHOSPHATE/

No Information Available No Information Available

Used in anti-wear additives to lubricants such as greases, gear oils, and motor oils, which contain about 1%. The same compounds serve also as corrosion inhibitors and antioxidants. Ref: https://www.lookchem.com/ZINC-DITHIOPHOSPHATE/


Not Applicable

5 Absolute alcohol 420 NIL Absolute alcohol

420 64-17-5

Oral Rat 3450 mg/kg Ref: MSDS

Persistence is unlikely based on information available. Ref: MSDS

-- Laboratory Chemicals Ref: MSDS


Not Applicable

6 Noflan 8 NIL Noflan 8 -- No Information Available

No Information Available No Information Available

No Information Available 5 (b) Intermediate Chemicals

Not Applicable

C 7


110 890


1000 17321-47-0

Oral Rat 980 mg/kg Ref: MSDS from Clearsynth

No Information Available Ref - MSDS from Clearsynth




Not Applicable

TOTAL B - Submitted in PFR & Form 1

1,894 2,090 3,984

No changes in Quantities since The Applicability of The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare does not coveres Intermediate chemicals. TOTAL B1 - Revised After

Exclusion of Prohibited Pesticides

1,894 2,090 3,984

Grand Total (A + B) As per PFR Submission

4,129 5,665 9,794 The Prodcut List Total as per EC Application submitted to MoEF&CC dated 31/12/2017 i.e. before the publication of The Pesticide (Prohibition) Order 2018 dated 8th August 2018.

Grand Total (A1 + B1) After Exclusion of Prohibited Pesticides 4,069 5,495 9,564

Based on consideration of Applicability of The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Fa rmers Welfare the Products - Dichlorovos, Phorate & Phosphamidon are Prohibited for Manufacture, Formulate, Import with effect from the 1st January, 2019.

WHO Class Details - Ia = Extremely hazardous; Ib = Highly hazardous; II = Moderately hazardous; III = slightly hazardous; U = Unlikely to present acute hazard in normal use; FM = Fumigant, not classified; O = Obsolete as pesticide, not classified.

Source: UPL; The strikethrough items are no longer manufactured or produced at Unit 2 from January 01st 2019

Table 2.2 List of By-Products

S.N. By Product Name Source/Plant Existing Generation (MT/Month)



1 30% HCL D-Devrinol, Surflan, Mesotrion,DETCL,PCOC, DMPAT, Imazapic

68.72 4,079.40 4148.12

2 Sodium Sulphite D-Devrinol, Mesotrion 563 353.9 916.9

3 Sodium Sulphate Metobromuron, Clomazone 60 125.61 185.61


29

S.N. By Product Name Source/Plant Existing Generation (MT/Month)



4 Sodium Bromide Metobromuron, Metribuzin 114 24.44 138.44

5 NaSH (30%) Terbuphos, Phorate, DETCL, DETA, ZnDTP 331.5 1310 1641.5

6 Ammonium Acetate (35%) OR

Acephate

1,907 3,493 5400

7 Acetic Acid (30%) OR 1,735 2,458.22 4193.22

8 Acetic Acid (45%) OR 1,157 1,935.64 3092.64

9 Acetic Acid (99%) AND 526 879.05 1405.05

10 Ammonium Sulphate (90%) 636 1,509.57 2145.57

11 Sodium Acetate (27%) 2,634 3,663.87 6297.87

12 Spent Acid Metamitron 145.8 0 145.8

13 HCl (28%) Phosphamidon 0 0 0

14 Methyl Chloride* Phosphamidon, DDVP, Monocrotophos 15.3 46.2225 61.5225

15 Ammonium Chloride Surflan, DMPAT 50 314.48 364.48

16 Methyl Acetate Azoxystrobin 36.4 36.4 72.8

17 Sodium Bi-Sulphate (17%) Mesotrion 96 83.6 179.6

18 KHCO3+KCl Salt Imidacloprid 0 56.75 56.75

19 Di Methoxy Methane-DMM (95%) AANS 115.84 0 115.84

20 Ethanol Acetamiprid 0.084 10.416 10.5

21 Methanol Noflan 11.84 0.539 12.379

22 POCl3 (98%) Noflan 20.46 0 20.46

23 Phenol Pyrazosulfuron Ethyl 18.19 0 18.19

24 Ammonium Chloride Solution Surflan 50 17.52 67.52

25 Ammonia (20%) DMPAT 0 158 158

TOTAL A (As per PFR/Form 1 Submitted to MoEF&CC) 4,481.134 10,374.965 14,856.099 Total A1 (After Delist of Prohibited Pesticides as per The Pesticide (Prohibition) Order 2018 dated 8th August 2018 published by Ministry of Agriculture and Farmers Welfare

4,331.13 10,281.15 14,612.28



30

2.2 MANUFACTURING PROCESS DETAILS

2.2.1 Devrinol (Existing and Proposed)

1. Manufacturing Process

STEP –1 Preparation of CPAM from 2-CPC DEA and 2CPC are reacted in Caustic solution to give CPAM. 37 – 40°C temperature is maintained during reaction. Reaction mixture is washed with water. Aqueous layer is separated and send to Evaporator. Excess unreacted DEA is stripped off from organic. The recovered DEA is re-cycled to next batch. The HCL & 2CPC emission control provided caustic scrubber. STEP – 2 Preparation of Devrinol from CPAM CPAM is reacted with Alpha Naphthol and Caustic Lye in presence of Toluene at 90°C. The reaction mass is cooked at 102 – 103°C under continuous reflux. After completion of reaction, it is washed twice with hot water and aqueous layer is separated for further treatment. Toluene, residual water is evaporated in flash vessel and thin film evaporator at 125 – 130°C at 710 to 730 mmHg vacuum. The product from thin film evaporator is further treated with steam in a steam stripper to remove impurities. The product is further crystallized in hollow filter flakers and crushed in a crusher and finally packed.

2. Chemical Reaction

STOCHIOMETRIC BALANCED CHEMICAL REACTION C3H4Cl2O

+

C4H11N

C7H14ClNO +

HCl

2-CPC DEA Alpha CPAM Hydrochloric acid

MW 127 73 163.5 36.5

STEP -1 PREPARATION OF CPAM FROM 2-CPC HCl

+

NaOH

NaCl +

H2O

Hydrochloric acid Sodium Hydroxide Sodium Chloride Water

MW 36.5 40 58.5 18

STEP –2 PREPARATION OF DEVRINOL FROM CPAM C7H14ClNO

+

C10H8O

C17H21NO2 +

HCl

Alpha CPAM Naphthol Devrinol Hydrochloric acid

MW 163.5 144 271 36.5 HCl

+

NaOH

NaCl +

H2O

Hydrochloric acid Sodium Hydroxide Sodium Chloride Water

MW 36.5 40 58.5 18


31

Figure 2.2 Process Flow Diagram

Source: UPL


32

3. Mass Balance:

INPUT Quantity (kg/MT)

Devrinol (1,000 kg)

OUTPUT Quantity (kg/MT)

2CPC 521.8 PRODUCT

DEA 289 Devrinol 1,000

Toluene 537 BY-PRODUCT

Caustic (48%) 377 Nil 0

Washwater-(1) 567 TO RECOVERY

EDTA (50%) 1.9 Un. DEA + Toluene 803.475

Napthol 523.29 Toluene 1303

Toluene 822 TO ETP

Wash water (II) 708.3 Waste 22.42

Un. DEA + Toluene 803.475 TO AIR (From Scrubber)

Caustic (48%) 393.75 Toluene 0.0001

Water + Caustic for Scrubber

21.42 FUGITIVE EMISSIONS

Toluene 5 TO HAZARDOUS WASTE (Incinerator) Organic Residue 56

TO HAZARDOUS WASTE (TSDF)

Salt from Eva.-1 203.55 Salt from Eva.-2 194.7 LOSSES

Water (Evaporator) 1,978.45

TOTAL 5,566 TOTAL 5,566

2.2.2 D-Devrinol (Existing)


STEP-1: Preparation of 2-Chloropropionoyl Chloride from 2-Chloro Propionic Acid 2-Chloro propionic acid (L-CPA) is reacted with thionyl chloride (gradual addition of thionyl chloride) gives 2- choro propionyl chloride. During the process, HCl and SO2 gases are evolved which were absorbed in the water scrubber & sodium hydroxide scrubber, respectively. This gives 30% liquid HCl & sodium sulphite solution as by-products. STEP-2: Preparation of N,N-Diethyl-2-Chloropropionamide from 2- Chloropropionoyl Chloride. In the second step, 2-Chloro propionoyl chloride is reacted with diethyl amine. After completion of the reaction, the aqueous phase was separated and organic phase containing product is proceed further. STEP-3: Preparation of N,N-Diethyl-2-(- Naphthoxy) Propionamide From N,N-Diethyl-2-Chloropropionamide [Crude]


33

In the third step, sodium salt of - naphthol is reacted with N,N-Diethyl-2-chloropropionamide gives N, N-diethyl- 2- (- napthoxy). The solvent is recovered by distillation that gives crude product. The product is further isolated by purification of crude D-devrinol in IPA solvent, followed by filtration and drying. The solvent IPA is recovered by distillation and recycle. The residue is considered for incineration.


STOCHIOMETRIC BALANCED CHEMICAL REACTION:

STEP -1 C3H5ClO2

+

SOCl2

C3H4Cl2O

+

SO2

+

HCl

L 2-Chloro propionic

Thionyl Chloride

2-Chloropropionic acid Chloride

Sulphur Dioxide

Hydrochloric Acid

MW 108.5 119 127 64 36.5

2NaOH

+

SO2

Na2SO3

+

H2O

Caustic Sulphur Dioxide Sodium Sulphite Water

MW 80 64 126 18

STEP –2 C3H4Cl2O

+

C4H11N

C7H14ClNO

+

HCl

2-Chloropropionic acidChloride

DEA CPAM Hydrochloric Acid

MW 127 73 163.5 36.5

HCl

+

NaOH

NaCl +

H2O

Hydrochloric acid

Sodium Hydroxide

Sodium Chloride

Water

MW 36.5 40 58.5 18

STEP –3

C7H14ClNO

+

C10H8O +

NaOH

C17H21NO2

+

NaCl H2O

CPAM Alpha Naphthol

Sodium hydroxide

D-devrinol Sodium chloride

Water

MW 163.5 144 40 271 58.5 18


34

Figure 2.3 Process Flow Diagram with Quantity

Qty, Kg Qty,Kg

520 SOCl2 371 Water

490 L- CPA HCl (g) 159 HCl scrubber HCl (30%) 530

11 Catalyst SO2 Na2SO3 soln 2331

279 SO2 Scrubber

2051 NaOH solution

340 DEA Aqueous Layer-1

500 NaOH solution(32%) 1148 27.65% NaCl (Evoperation )

1100 Toluene

300 Water

265 Water Aqueous layer-2 1194

600 Alpha Napthol

812 NaOH solution( 32%)

Toluene 1068

943 IPA : Water

( 90:10 )843 + 100

IPA :Water 779

Mother liquor Residue 32

Recovery For incinerration

D Devrinol dry cake 1000

Recovered solvent 118

Filtration

IPA recovery

Drying

Solvent recovery

Amidation

Purification

CPC Preparation

D-Devrinol preparation

20-21 % NaCl ( Evoperation )


35

3. Mass Balance:


D-Devrinol 1,000 kg


L-2-Chloropropionic acid 490 PRODUCT Thionyl Chloride 520 D-Devrinol (95%) 1,000 Catalyst 11 BY-PRODUCT Water for HCl scrubber 371 Liquid HCl (30%) 530 NaOH solution (17%) for SO2 scrubber

2,051 Sodium sulphite (17%) solution

2,331

DEA 340 RECYCLE NaOH Lye (32%) solution 500 Recovered Toluene 1,068

Water 300 Recovered IPA

+Water ( 90:10) 897

Toluene 1,100 TO Evaporator

Alpha Naphthol 600 Recovered water

(Evaporation) 1,841

NaOH lye(32%)solution 812

Water 265 To AIR (From

Scrubber)

IPA 843 HCl 0.01 Water 100 SO2 0.01 Salt (Land filling )

Salt from Aq-1

Evaporation 233

Salt from Aq-2

Evaporation 258

TO HAZARDOUS

WASTE (Incinerator)

Residue 32 LOSSES Water 35 IPA 46 Toluene 32 TOTAL 8,303 TOTAL 8,303

2.2.3 Clomazone (Existing and Proposed)


STEP-1: 3-Chloro –N-Hydroxy 2,2-Dimethyl Propanamide Charge water and hydroxylamine HCl and adjust pH to 7-8 with caustic lye. Add 3CPC and caustic lye simultaneously. Filter solid and use for next step. STEP-2: 4, 4 Dimethyl Isoxazolidinone. Charge water and step-1 solid and under stirring add caustic lye &adjust pH 8-9, maintain for 4-5. Use 4, 4 DMI solutions for step-3. STEP-3: Clomazone Charge 4,4 DMI solution and add OCBC and maintain for 5-6 hrs. Cool reaction mass and separate aqueous layer and organic mass.


36

Dry HCl gas is passed in organic mass and maintains for 4-5 hrs, add sodium carbonate and caustic lye and heat mass and add water and maintain temperature of 70-90°C for 30 minute, separate organic and aqueous layer. Dehydrate organic mass by distillation to get Clomazone Tech.


Stochiometric Balanced Chemical Reaction

STEP -1 C5H8Cl2O

+

NH2OH.HCl

+

2NaOH

C5H10ClNO2

+

2NaCl

+

2H2O

MW

3Chloro-2,2-Dimethylpropanoyl Chloride

Hydroxylamine Hydrochloride

Caustic

3Chloro-N-Hydroxy 2,2-Dimethyl propanamide

Sodium Chloride

Water

STEP –2

C5H10ClNO2

+

NaOH

C5H9NO2

+

NaCl

+

H2O

3Chloro-N-Hydroxy 2,2-Dimethylpropanamide

Caustic 4,4-Dimethyl isoxazolidin -3-one(4,4-DM)

Sodium Chloride

Water

MW 151.5 40 115 58.5 18

STEP –3 C5H9NO2

+

C7H6Cl2

+

NaOH

C12H14NO2Cl

+

NaCl

+

H2O

4,4-Dimethyl isoxazolidin-3-one (4,4-DM)

O-Chloro Benzylchloride

Caustic Clomazone isomer

Sodium Chloride

Water

MW 115 161 40 239.5 58.5 18

STEP-4 C12H14NO2Cl

+

HCl +

NaOH

C8H5Cl2NaO3 +

NaCl +

H2O

MW Clomazone isomer

Hydrochloric Acid Caustic Clomazone

Sodium Chloride Water


37


Mass Balance: INPUT Quantit

y (kg/MT)

Clomazone (1,000 kg)


Caustic Flakes 375 PRODUCT

Water for Caustic 875 Clomazone 1,000


830 BY-PRODUCT


460 Nil 0

Water 50 TO RECOVERY

Caustic Flakes 225 Nil 0

Water for Caustic 525 TO ETP

Water 50 Nil 0

Catalyst 8 TO AIR (From Scrubber)

O-Cgloro Benzylchloride

705 Nil 0

Caustic Flakes 173 TO HAZARDOUS WASTE (TSDF)

Water for Caustic 403 Salt from Eva.-1 699

HCl Gas (Dry) 200 Salt from Eva.-2 898

Caustic Flakes 195 TO HAZARDOUS WASTE (INCINERATOR)

Water for Caustic 455 Organic residue 216

Na2CO3 19 LOSSES


38

Water 50 Evaporation Losses-1 1,075

Evaporation Losses-2 1,708


OR Clomazone (Proposed Route) STEP-1: 3-Chloro –N-Hydroxy 2,2-Dimethyl Propanamide Charge water and hydroxylamine HCl and adjust pH to 7-8 with caustic lye. Add 3CPC and caustic lye simultaneously. Filter solid and use for next step. STEP-2: 4, 4 Dimethyl Isoxazolidinone. Charge water and step-1 solid and under stirring add caustic lye &adjust pH 8-9, maintain for 4-5. Use 4, 4 DMI solutions for step-3. STEP-3: Clomazone Charge 4,4 DMI solution and add OCBC and maintain for 5-6 hrs. Cool reaction mass and separate aqueous layer and organic mass. Dry HCL gas is passed in organic mass and maintains for 4-5 hrs, add sodium carbonate and caustic lye and heat mass and add water and maintain temp 70-900C for 30 minute, separate organic and aqueous layer. Dehydrate organic mass by distillation to get Clomazone Tech. STOCHIOMETRIC BALANCED CHEMICAL REACTION: STEP -1

STEP –2

STEP –3

C5H8Cl2O

+

NH2OH.HCl

+

2NaOH

C5H10ClNO2

+

2NaCl

+

2H2O


Hydroxy- lamine Hydrochloride

Caustic

3Chloro-N-Hydroxy 2,2-Dimethyl propanamide

Sodium Chloride

Water

MW 155 69.5 80 151.5 117 36

C5H10ClNO2

+

NaOH

C5H9NO2

+

NaCl

+

H2O

3Chloro-N-Hydroxy 2,2-Dimethylpropanamide

Caustic 4,4-Dimethyl isoxazolidin -3-one (4,4-DM)

Sodium Chloride

Water

MW 151.5 40 115 58.5 18


39

STEP-4

C5H9NO2

+

C7H6Cl2

+

NaOH

C12H14NO2Cl

+

NaCl

+

H2O

4,4-Dimethyl isoxazolidin-3-one (4,4-DM)

O-Cgloro Benzylchloride

Caustic Clomazone isomer

Sodium Chloride

Water

MW 115 161 40 239.5 58.5 18

C12H14NO2Cl

+

HCl

+

NaOH

C8H5Cl2NaO3

+

NaCl

+

H2O

Clomazone isomer

Hydrochloric Acid Caustic Clomazone


MW 239.5 36.5 40 239.5 58.5 18


40

Figure 2.5 Process Flow Diagram for Clomazone


41

Mass Balance


Clomazone

OUTPUT Quantity (Kg/MT)

Caustic (32%) 1,248 PRODUCT

Water for Caustic 2,652.00 Clomazone 1,000


915 BY-PRODUCT

Hydroxylamine Sulphate 631 Na2SO4 420

Water 7,076.98 TO RECOVERY

Catalyst 17 MDC 2,700.00

O-Chloro Benzylchloride 705 METHANOL 3,225.25

METHANOL 3,395

H2SO4 (98%) 241.68 TO AIR

SOCl2 50.21 (From Scrubber)

Na2CO3 32.27 MDC 32

MDC 2832 TO HAZARDOUS WASTE (INCINERATOR)

TOLUENE 49.86 Organic residue 216

To Evaporator

Water (Evaporator)

12,252.75

TOTAL 19,846 TOTAL 19,846.00

2.2.4 Metobromuron (Existing)


Stage I: PIC to PHU preparation Charge water and HAS in the reactor and cool the mass to below 0°C. Neutralize the mass by adding 49% NaOH, charge solvents Toluene & EDC in agitated mass and maintain the temperature between 10-20°C. Now start addition of (PI + Toluene) solution and maintain temperature between 5 to 10°C. Cook the reaction mixture for 4-5 hours. Then filter the mass & dry the wet cake separate the organic and aqueous layer from filtrate and send the organic layer for EDC and Toluene recovery. Stage II : PHU to PMMU preparation Charge water and PHU powder in the reaction start addition of DMS and 48% NaOH simultaneously and maintain the pH between 8-9. Cook the mass for 4-5 hours and cool to 5-10°C then filter the mass & dry the wet cake.


42

Stage III : PMMU to Metabromuron Charge Methanol and PMMU powder in the reaction cool the reaction mass to 18-20°C start addition of (Bromine + Methanol) solution for 3-4 hours. Cook the mass for 5-6 hours. Neutralize the mass by 30% Soda Ash so that pH will be 7-8. Then recover the methanol & cool the reaction mixture to form crystals of Metobromuron. Then filter the crystals, wash it with water and dry to get product.


C7H5NO + ½(N2H8O6S)

+ NaOH TOLUENE

C7H8N2O2 + H2O +

1/2Na2SO4

PIC Hydroxylamine Sulfate

Caustic Lye

3-Phenyl-1-Hydroxy

Water

MW 119 82 40 152 18 71

C7H8N2O2 + C2H6SO4 + 2NAOH C9H12N2O2 + Na2SO4 + 2H2O

(PHO) DMS Caustic Lye

3-Phenyl-1 Methyl 1-Methoxy (PMMU)

Urea Water

MW 152 126 80 180 142 36


43

Figure 2.6 Process Flow Diagram for Clomazone (Step 1: PIC to PHU)

Figure 2.7 Process Flow Diagram Clomazone (Step 2: PHU to PMMU)

Qty, Kg Qty,Kg

500 PIC

3626 Toluene

1554 EDC

422 NaOH lye

1446 Water

362 HAS

Toluene 3555

Organic EDC

1065 Water wash ML + WL 1523.5

Water 2765

Aqueous

Na2SO4 383PHU dry cake 636

Filtration

PHU Prepaqration

Distillation

Evoperation

DRYING


44

Figure 2.8 Process Flow Diagram - Clomazone (Step 3: PMMU to MBN)

3. Mass Balance


45

2.2.5 Terbuphos (Existing)


Phosphorous pentasulphide and ethyl alcohol are reacted at 70° mixture. The gas is scrubbed with caustic lye. It gets converted to disodium sulphide and sodium hydrogen sulphide which is a saleable product. After the completion of reaction, the product is charged in another reactor through a sparkler filter. The product of Step I is reacted with formaldehyde and t-butyl mercaptan at room temperature and atmospheric pressure. The reaction mass is neutralized with caustic lye. The neutralized product is Terbophos. The organic mass is distilled under vacuum and filled in the drums.


P2S5 + 4C2H6O 2C4H11O2S2P + H2S

P-Psulphide Ethanol DETA Hydrogen Sulphide

MW 222 184 372 34

C4H11O2S2P + H2CO C5H13O3S2P

DETA Formaldehyde Product-A

MW 186 30 216

C5H13O3S2P + C4H10S C9H21O2S3P + H2O

Product-A Tert butyl mercaptan Terbuphos Water

MW 216 90 288 18

H2S +

NaOH NaSH + H2O

Hydrogen Sulphide Caustic Lye Water

MW 34 40 56 18


46

Figure 2.9 Process Flow Diagram for Terbuphos (Existing)

3. Mass Balance

INPUT Quantity (kg/t) TERBUPHOS OUTPUT Quantity (kg/t)

P2S5 462 Manufacturing PRODUCT

ALCOHOL 497 TERBUPHOS 1,000

CSLYE 32% 294.56 RECOVERY

TEA 1.09 Nil 0

FM 347.9 BY PRODUCT

TERTIARY BUTYL MERCATON

366 NaSH (30%) 289

H2O2 76.71 EFFLUENT GENERATION

WATER 686.27 Stream I: To ETP

From Terbuphos reaction &Purification: 847.53

effluent – Water (2,347.5)

AIR POLLUTION

Traces of tertiary mercaptan to

0.0001


47

INPUT Quantity (kg/t) TERBUPHOS OUTPUT Quantity (kg/t)

fume incinerator

HAZARDOUS WASTE (To Incinerator)

Stream I: To Incinerator

Terbuphos aqueous from reaction & washing

595

TOTAL 2,731.53 TOTAL 2,731.53

2.2.6 Metasystox (Existing)


Ethyl Thio Ethanol and Phosphorus tri chloride are reacted at 45-50°C to get CTA. Caustic lye and O, O-dimethyl thio phosphoryl chloride (Diester) are mixed to form Thiosalt. CTA and Thiosalt are reacted at 45-50°C to form Meta- I. The product is reacted with Hydrogen peroxide in presence of Xylene at 38-42°C under 730 mm vacuum. This is a condensation reaction. The reacted mass is neutralized with Sodium Bisulphite & H2SO4, then neutralized by dilute ammonia and distilled to get pure product as a bottom product. Distillate is burnt in the incinerator. The product is dilute with Monochlorobenzene.


CTA PREPARATION 3 (C4H10OS) + PCl3 3(C4H9SCl) + H3PO3

Ethyl thio Ethanol Phosphorous Trichloride

CTA Phosphorous Acid

MW 318 137.5 373.5 82

THIO SALT PREPARATION

C2H6O2SPCl + 2NaOH C2H6O3SPNa + NaCl +

O-O dimethyl thio phosphoryl chloride

Sodium Hydroxide

Thio Salt Sodium Chloride

MW 160.5 80 164 58.5

META – I PREPARATION

C4H9SCl + C2H6O3SPNa C6H15O3S2P + NaCl

CTA Thio Salt Meta – I Sodium Chloride

MW 124.5 164 230 58.5

META - R PREPARATION C6H15O3S2P + H2O2 C6H15O4S2P + H2O

Meta - I Hydrogen Peroxide

Meta –R Water


48

MW 230 34 246 18

Figure 2.10 Process Flow Diagram Metasystox (Existing)

3. Mass Balance


49

INPUT Quantity (kg/Ton)

METASYSTOX (1000 kg)

OUTPUT Quantity (kg/Ton)

OODMTPC (Diester) 527 PRODUCT

PCl3 176.25 METASYSTOX 1,000 ETE 365.42 RECOVERY

Caustic 32% 512.67 Recovered Xylene 77.59

Water of Caustic 1,089 TO ETP

Xylene 81.09 Effluent 1390 H2O2 196.49

Water 20 TO INCINERATOR

1000

H2SO4 10 Stream:1 SBS 6 NaCl Ammonia 9.37 H2O M CB 383.3 Un. OODMTPC H2O2 91 Un NaOH H3PO3 Un PCl3 Un ETE Caustic 48% water of caustic Stream:2 H2O2 H2SO4 SB Ammonia Xylene Un. OODMTPC Un ETE

AIR POLLUTION

Solvent Traces 0.0001 TOTAL 3,467.59 TOTAL 3,467.59

2.2.7 Acephate (Existing and Proposed)


Dimethyl PhosphorousAmidoThionate (DMPAT) is isomerized to Methamediphos by catalytic reaction at 50°C and atmospheric pressure in the presence of Dichloro methane as solvent. After isomerisation, the mass is reacted with acetic anhydride at 40°C and neutralized with aqueous ammonia. Ammonia vapour is scrubbed through scrubber and all scrubber mass reused in the neutralizer. The layers are separated and aqueous layer is extracted from Acephate which react with H2SO4 to generate ammonium sulphate & acetic acid. The organic layer is fed to FFE for dichloromethane recovery and concentrated Acephate+MDC is then taken for vacuum recovery. Recovered dichlormethane is distilled and recycled back to the process. After vacuum recovery of all MDC crude Acephate is dissolved in ethyl acetate is


50

crystalized and slurry is feed into agitated nutche filter. Ethyl acetate is recovered from the mother liquor of crude. Acephate cake is fed to spin flash dryer for purification. The dry Acephate is filled in bags as final packing.

2. Chemical Reactions

STOCHIOMETRIC BALANCED CHEMICAL REACTION

C2H8O2SPN ISOMERISATION MDC SOLVENT C2H6O4S DMS (164)

C2H8O2NPS

DMPAT MMD

141 141

C2H8O2NPS + C4H6O3 Acetylation C4H10O3SPN + C2 H4O2

MMD Acetic Anhydride

Acephate Acetic Acid

141 102 183.2 60

CH3COOH + NH4OH H2SO4

CH3COONH4 + H2O

Acetic Acid Ammonium Hydroxide

Ammonium Acetate

Water

60 35 77 18

2NH4OH + H2SO4

(NH4)2SO4 + 2H2O

Ammonium Hydroxide

Sulphuric Acid Ammonium Sulfate

Water

70 98 132 36

2NH4CH3CO2 + H2SO4

(NH4)2SO4 + CH3COOH Ammonium Acetate

Sulphuric Acid Ammonium Sulphate

Acetic Acid

154 98 132 120

CH3COOH + NaOH

C2H3NaO2 + H2O Acetic Acid Sodium

Hydroxide Sodium Acetate Water

120 40 82 18


51

Figure 2.11 Process Flow Diagram (Acephate (Existing)

3. Mass Balance

INPUT QUANTITY kg/Ton

Acephate (1,000 kg)

OUTPUT QUANTITY kg/Ton

PRODUCT MDC 5,581 Acephate DMPAT 1,075 RECOVERY

DMS 133 Ethyl Acetate Solvent

2,433

H2SO4 (98%) 25 MDC Solvent 5,531 Acetic Anhydride 766 BY-PRODUCT

NH3 Solution (17%) 808 Ammonium Acetate (35%)

1,800

H2SO4 (98%) 408 OR

Ethyl Acetate 2,483 Acetic Acid (30%) OR

1,397.74


52

Water 230 Acetic Acid (45%) OR

1,048.88

Water for scrubber 1 20 Acetic Acid (99%) 468.35 Water for scrubber 2 5 AND

H2SO4 for Scrubber 2 1 Ammonium Sulphate (90%)

715.19

Caustic (48%) for Sodium Acetate conversion

785.48 OR

Ammonium Sulphate (90%)

715.19

Sodium Acetate (27%)

2,099.29

EFFLUENT GENERATION

Stream:1 Organic waste to incinerator

DMS + DMPAT + MDC + Acetic Anhydrate

420

AIR POLLUTION NH3 Vapour 12 MDC Solvent Traces 5

Ethyl Acetate Solvent Traces

5

SOLID WASTE GENERATION Nil Nil TOTAL 12,320.48 TOTAL 12,320.48

OR Acephate by Ketene Process – Old Route (Existing and Proposed) Dimethyl Phosphoro Thio Amine (DMPAT) is isomerised to Methamediphos by catalytic reaction at 49-52°C and atmospheric pressure. After isomerisation, the mass is reacted with Ketene at 45°C in the presence of Dichloro methane as solvent. Ketene vent is scrubbed with water to give 42% acetic acid solution. It is neutralized with aqueous ammonia at 30 – 32°C. The layers are separated and aqueous layer is taken in another reactor and reacted with caustic lye to form Ammonium Sulphate. Ammonium sulphate is sold in market as a By-Product. The organic layer is taken in another reactor for dichloromethane recovery and acephate separation. Recovered dichloromethane is recycled in the next batch and acephate is dissolved in ethyl acetate to make it crude acephate solution. It is crystallized at 5°C and slurry is filtered in agitated nutsche filter. Cake is dried in rotary vacuum dryer. The dry acephate is filled in bags as a final Product. Ethyl acetate is recovered from the mother liquor of crude acephate cake and is recycled. The residue shall be incinerated. Acephate (Ketene Route)


53

C2H8O2SPN ISOMERISATION MDC SOLVENT C2H6O4S DMS (164)

C2H8O2NPS DMPAT MMD

MW 141 141

C2H8O2NPS + C2H2O Acetylation C4H10O3SPN

MMD KETENE Acephate MW 141 42 183

2NH3 + (CH3)2SO4 2 H2O Neutralisation 2CH3OH (NH4)2SO4

Ammonia Dimethyl Sulphate

Water Methanol Ammonium Sulphate

MW 2 X 17 126 2 X 18 2 X 32 132

Ketene Generation: Ketene is generated by catalytic cracking of acetic acid in presence of Triethyl Phosphate as Catalyst at 700 – 1,000°C in furnace and used for the Acetylation reaction. C2H4CO2

Cracking Δ

C2H2O H20 Acetic Acid Ketene Water

MW 60 42 18

2.2.8 Metamitron (Existing)


Benzaldehyde, NaCN solution and HCI solution are reacted at low temperature and atmospheric pressure to get Mendelonitrile in presence of solvent and water. Aqueous layer of this stage is sent for De-Toxification. Then after Mendelonitrile of organic layer is reacted at around room temperature along with Methanolic HCI (Methanolic HCl generated by addition of H2SO4 and HCl which produces spent acid) and water to give Methyl Mendolate. Aqueous layer of this stage is separated out. In the next stage, oxidation of Methyl Mendolate with Sodium Hypochlorite is carried out at low temperature and atmospheric pressure in the presence of catalyst to give Methyl Ester (MPG). Aqueous layer from this stage is separated and solvent recovery is done under vacuum. Recovered solvent is recycled back to the process. Acetyl Hydrazine is prepared by reaction between Methyl Acetate and Hydrazine Hydrate separately and this Acetyl Hydrazine reacts with MPG and Hydrazine Hydrate at high temperature and atmospheric pressure in presence of Catalyst and solvent to give MMZ. This MMZ is filtered and dried in the next step. Dry MMZ is dissolved in the solvent and at high temperature and atmospheric pressure, in presence of Catalyst. Dehydrolysis results in the product MMT. Liquid product MMT is filtered and dried to give dry product.


54

2. Chemical Reaction STOCHIOMETRIC BALANCED CHEMICAL REACTION:

Step – 1 C7H6O + NACN + HCl

Toluene

C8H7ON + NaCl Benzaldehyde Sodium

cyanide Hydro- Chloric acid

Mendelonitrile Sodium chloride

106 49 36.5 133 58.5

Step – 2

C8H7ON + CH5OCl

Toluene

C9H12O2NCl Mendelonitrile Methanolic HCL Amodohydrauchloride

133 68.5 201.5

Step – 3

C9H12O2NCl + H2O

Toluene

C9H10O3 + NH4Cl Amodohydrauc

hloride

Water Methyl mendelate

Ammonium

chloride

201.5 18 166 53.5

Step – 4

C9H10O3 + NaOCl

TBAD

C9H8O3 + NaCl + H2O Methyl mendelate

Sodium hydrochloride

Methyl Ester

Sodium chloride

Water

166 74.5 164 58.5 18

Step – 5 C9H8O3 + C3H6O2 + 2N2H6O

C10H12O2N4 + 2CH4O 3H2O Methyl ester

Methyl acetate

Hydrazine hydrate

MMZ Methanol Water

164 74 100 220 64 54

Step – 6

C10H12O2N4 DMAC & TOL NaAC (CAT)

C10H10ON4 + H2O

MMZ Metamitron Water

220 202 18


55

Figure 2.12 Process Flow Diagram (Metamitron (Existing)

3. Mass Balance

INPUT (kg/MT)

Metamitron (1000 Kg)

OUTPUT (kg/MT) Benzaldehyde 547 PRODUCT NaCN 494 Metamitron 1,000 NaOH 32% 11 RECOVERY HCl 30% 613 Recovery Toluene 5,297 Process Water (I) 236 Methanol from MMZ mfg. 267 Toluene 136 Recovery DMAC 2,218 Methanol 170 BYPRODUCT HCl 30% 589 Spent Acid 2,430 H2SO4 98% 2,422 TO ETP NH3 17% 247 Stream – 1 Process Water (II) 730 NaCl + Benzaldehyde +

NaCN + Water 2,025

NaOCl 12% 370 Stream – 2 Methyl Acetate 839 NH3 + Water 888 Hydrated Hydrate 644 Stream – 3 NaOCl 12% 3,642 NH4Cl + Water + NaOCl +

NaCl 3,900

DMAC 39 To Incinerator Catalyst 8 Stream – 4 Recovery DMAC 2,218 Methyl Acetate + Hydrazine

hydrate + water Generated 889

Recovery Toluene 5,297 Stream – 5 Methanol from MMZ mfg.

267 Residue 405


56

Stream – 6

Mixed Solvent Residue + Water

200

To Air 0.0001 Solid Waste Generation Nil Nil TOTAL 19,519 TOTAL 19,519

2.2.9 Surflan (Oryzalin) (Existing)


Step-1: OKS Salt to DNSA salt OKS salt is reacted with iso-propyl amine in toluene and water in presence of sodium bi carbonate at high temperature and atmospheric pressure to give DNSA. Reaction mass kept under total reflux condition for few hours. Aqueous layer then separated and considered for batch evaporation. DNSA mass in toluene is proceeded for further step. Step-2: DNSA salt to DNS chloride Afterwards DNSA salt organic mass reacted with POCl3 to give DNSCI. Then after reaction mass cooled to lower the temperature. This reaction mass is quenched in water of low temperature followed by separation of that organic and aqueous layer separates. Aqueous layer is considered for evaporation. The salt KH2PO4 is considered for salt disposal. DNS Chloride mass in toluene is considered for next step.

Step-3: DNS chloride to Surflan Organic layer then reacts with Ammonia solution at lower temperature in Acetone and water to give product Surflan. Excess Ammonia is neutralized with H2SO4 Solution. Aqueous layer containing 17% NH4Cl is sold to end users as by-product. Acetone is recovered at high temperature and under vacuum and recycled back. The product is then filtered out, wash with hot water followed by drying. Solvent toluene is recovered from mother liquor and recycled back Residue of its diverted to Incinerator.


Step-1: OKS Salt to DNSA salt C6H2ClN207

SIK + C6H15N + NaHCO

3 Toluene

C12H16

N2O7KS + NaCl + H2O + CO2


57

OKS Salt Dipropyl Amine

Sodium bicarbonate

DNSA Salt Sodium Chloride

Water

Carbon Dioxide

320.7

101.2 84 385.4 58.5 18 44

Step-2: DNSA salt to DNS chloride

C12H16

N2O7KS + POCl3 + 2H2

0 Toluene

C12H16 ClN3O6S + 2 HCl + KH2PO4

DNSA Salt Phosphorus Oi-Chloride

Water

DNS Chloride Hydrogen Chloride

Potassium dihydrogen phosphate

385.4 153.5 2*18 365.8 2*36.5 136.1

Step-3: DNS chloride to Surflan

C12H16 ClN3O6S + 2NH3 Acetone+Water

C12 H18 N4O6S

+ NH4CI

DNSA Chloride Ammonia Surflan Ammonium Chloride

365.8 2*17 346.3 53.5


58

Figure 2.13 Process Flow Diagram Surflan (Oryzalin) (Existing)

3. Mass Balance

INPUT Quantity (kg/ton)

1,000 kgSurflan

OUTPUT Quantity (kg/ton)

OKS 1,246 PRODUCT

Catalyst D 50

Toluene 5,107 Surflan/Oryzalin Technical 1,000

DPA 438 BY-PRODUCT

NaHCO3 364 Liquid HCl (30%) 902

Water 1,095 NH4Cl Solution/ NH4Cl Solid (17%)

1,688/ 287

POCl3 610 TO RECOVERY

Water for quenching 2,480 Toluene 4,998

Water for scrubber 630 Acetone 1,408

Water for washing 986 To AIR ( From Scrubber)

Acetone 1,438 HCl 2

Water 533 TO ETP

Liq. Ammonia [17%] 812 ETP

Qty, Kg Qty,Kg

438 Diisopropyl amine

1246 OKS

5107 Toluene

1095 Water

50 Catalyst D364 NaHCO3

Aqueous Layer-11235

NaCl ( 16-18% )

610 POCl3 HCl to Air 0.2Kg

630 Water

2480 Water HCl (G) 272 Liquid HCl 902

HCl to Air 1.8Kg

Aqueous Layer-2 3434 ( 15-16% KH2PO4 )

986 Water Wash Layer 940

533 Water

1438 Acetone

812 Ammonia Soln(17%)

180 Sulfuric acid (50%)

Aqueous Layer -3 1688

17% NH4Cl

Rec Acetone 1408 Recovered tolune 4910

Toluene loss 90

500 Hot water wash Mother Liquor 5180 Residue 210

Wash liquor For incinerration

513

Surflan dry cake 1000

Recovered Toluene 88

Filtration

Scrubber

Toluene recovery

Drying

Quenching

Layer seperation

Chlorination

Solvent Recovery

OKS to DNSA

Layer seperation and washing

Amination and Neutralization

Layer seperation


59

Sulphuric acid (50%) 180 Wash layer 940

Hot water wash 500 Wash liquor 513

Aqueous Water after NH4Cl recovery

1,401

ETP :Batch evaporation

Aqueous Layer -1 1,235

Aqueous Layer-2 3,434

TO HAZARDOUS WASTE (Incinerator)

Solvent Residue 210

LOSSES

Toluene 109

Acetone 30


2.2.10 Azoxystrobin (Existing & Proposed)


STEP 1: PREPARATION OF 3-(Α-METHOXY) METHYLENEBENZOFURAN -2(3H)-ONE (MMBF): 2-Coumaranone and Trimethylorthoformate are reacted in the presence of acetic anhydride under controlled conditions to get MMBF. Methyl acetate and water are formed as by product. Methyl acetate is sold as by product after purification. STEP 2: PREPARATION OF ACETAL: MMBF is reacted with 4,6-Dichloro-pyrimidine in the presence of 30% sodium methoxide solution to get acetal. Sodium chloride formed during the reaction is filtered and acetal is isolated by removal of solvent. STEP 3: PREPARATION OF METHYL-2-[2-(6-CHLOROPYRIMIDINE-4-YLOXY) PHENYL)]-3-METHOXY PROPENOATE (MDCPP): Acetal is dehydrated in the presence of a catalyst to get MDCPP. Methanol formed during the reaction is purified and recovered. STEP 4: PREPARATION OF AZOXYSTROBIN: In this step, MDCPP is reacted with 2-cyanophenol in the presence of K2CO3 and DMF as solvent. After reaction, the potassium chloride formed is filtered off, and from filtrate the DMF is distilled off to get crude Azoxystrobin Technical.


Step I:

C8H6O2 + C4H10O3

+ (CH3CO)2O C10H8O3

+ 2CH3COOCH3

+ H2O


60

2-Coumaranone

Trimethylotho formate

Acetic Anhydride

MMBF

Methyl Acetate

Water

134 106 102 176 148 18

Step II:

C10H8O3 +

C4H2N2

Cl2 + NaOCH3 +

CH3OH C16H17N2O5Cl + NaCl

MMBF 4,6 DCP Sodium

Methoxide Methanol

Acetal Sodium Chloride

176 149 54 32 352.5 58.5

Step III:

C16H17N2O5Cl C15H13N2O4Cl + CH4O Acetal MDCPP Methanol 352.5 320.5 32

Step IV:

C15H13N2O4Cl + C6H5OCN + ½ K2CO3

C22H17N3O5 + KCl + ½ CO2 + ½

H2O

MDCPP Orthocyano Phenol

Potassium Carbonate DMF Azoxystrobin

Potassium Chloride

Carbon Dioxide

Water

320.5 119 69 403 74.5 22 9


61

Figure 2.14 Process Flow Diagram Azoxystrobin (Existing & Proposed)

3. Mass Balance:

INPUT QUANTITY

AZOXYSTROBIN 1,000 kg

OUTPUT QUANTITY

(kg/ton) (kg/ton) 2Coumaranone 358 PRODUCT TMOF 450 Azoxystrobin 1,000

Note : All Quanties are in KG

MeOH 1030.5

Acetic anhydride 773.245TMOF 4502Coumaranone 358

MeOH Recy 979Resd To LF 81

Sod Methoxide 149TMOF 1480

DCP 400

Catalyst 2.25

TMOF Recy 1834

KOH 31Tol 2200Water 4043.36

Acetic anhydride 161.755

AQ Ly Recy 2021.68Aq Kayer to ETP 2071.6

Acetic Anhyd Recy 647

Tol Recy 2156Tol Loss 44

EA 539EA Loss 11Res To LF 98

Catalsyt 2.25DMF 2655 Cat Recy 5Pot carb 250O-Cyanophenol 316

Cake LF

DMF 2522

MeOH 1220 MeOH 1159Resd To LF 98

Azoxytrobin 1000

Cryst MeOH Dist

Wahing & Sep

Tol Dist

Cystalization EA Dist

Reaction

Heat & Sep

Dehydration

Demehanolysis

Filtration

Dist DMF

Reaction

Filtration MeoH Dist

Reaction

TMOF Dist


62

30% Acetic anhydride

935 BY-PRODUCT

Methanol 600 Methyl acetate 364 4,6 DCP 400 RECOVERY Sodium Methoxide 149 Methanol 2,138 Methanol 430.5 TMOF 1,834 TMOF 1,480 DMF 2,522 Orthocyanophenol 316 Acetic Anhydride 647 Potassium carbonate

250 Catalyst 5

DMF 2,655 Toluene 2,156 Aq Layer Recy 2,021.68 Ethyl Acetate 539 Methanol 1,220 TO ETP Toluene 2,200 Stream – 1

Catalyst 5 Water + Methyl Acetate+ Acetic Anhydride

2,071.6

Ethyl Acetate 550 TO AIR KOH 31 Carbon dioxide 55

Water (2021.6 X 2) 4,043.36 HAZARDOUS WASTE TO INCINERATOR

Stream – 1

Methanol+ Acetic Anhydride+2 Coumaranone+ Trimethyl Formate

81

Stream – 2

Methanol+ 4, 6 DCP + Sodium Methoxide

54

Stream – 3

Methanol + DMF+ Orthocyanophenol

98

HAZARDOUS WASTE TO TSDF

Stream – 1 NaCl 145 Stream – 2

Potassium Carbonate+ Potassium Chloride + Water

286

Loss Toluene 44 Ethyl Acetate 11 TOTAL 16,072 16,072

For process stabilization & quality improvement, toluene & ethyl Acetate (as solvent) are added


63

2.2.11 Ethofumesate (Existing & Proposed)


PURIFICATION / WASHING: A. Charge required quantity of process water to purification reactor. Then

charge Ethofumisate powder & heat it & agitation for 5–7 hrs. for remove impurity.

B. Separate the bottom organic layer & transfer it into organic hold tank under hot condition & transfer the aqueous layer to the second stage recovery reactor.

C. Charge the organic layer from hold tank to purification reactor & charge process water for the washing.

D. After layer separation transfer the organic layer to stripping/flaking reactor.

E. Transfer the aqueous layer to the second stage recovery reactor.

STRIPPING / FLAKING REACTOR: A. Collect the organic layer from the purification reactor & kept under full

vacuum & heat it up to 75-90°C B. Remove the water traces under vacuum & heating by maintaining the 75 -

90°C temperature. C. After receiving the moisture less than 0.5% w/w, start flaking by drum

Flaker. Flakes transferred to grinding mill & jumbo bag filled from the same.

SECOND CROP RECOVERY: A. Receive the aqueous layers from purification reactor & cool it to 35°C &

recover the second crop Ethofumisate by centrifuging & circulate the recovered water through sparkler filter & sent it for pre-treatment before it goes to ETP for final treatment.


This is being a purification process and hence no chemical reaction takes place.

Molecular Formula : C13H18O5S Molecular Weight : 286


64

Figure 2.15 Process Flow Diagram (Ethofumesate (Existing & Proposed)

3. Mass Balance

INPUT Quantity (kg/Ton)

Ethofumesate Purificati-on 1,000 kg

OUTPUT Quantity (kg/Ton)

PRODUCT

Ethofumesate 96% (1052.00 Product + 43.84 Impurities)

1,095.84 Ethofumesate (970 Product + 30 Impurities)

1,000.00

Water 2,157.72 RECOVERY

Na2CO3 2

Ethofumesate (78.14 Product + 3.68 Impurities) From Second Crop Recovery

81.82

Water from stripper

32.86 Water from Stripping Reactor

32.86

EFFLUENT GENERATION Stream I: To ETP

Total wastewater (2157.72)from Sparkler Filter + Ethofumesate (1.50) & Impurities (8.50)

2,167.72

HAZARDOUS SOLID WASTE GENERATION


Process Waste from Sparkler Filter (0.02) + Ethofumisate (3.84) + Impurities (0.16) +Na2CO3(2.0)

6.02

AIR POLLION Nil Nil TOTAL 3,288.42 TOTAL 3,288.42


65

2.2.12 Mesotrion (Existing)

Mesotrion is a pre emergence herbicide. The manufacturing process involved in 3 steps. 1. Manufacturing Process

STEP 1: MSNBA to MSNBC This step involves formation of (MSNBC) 4-(methylsulfonyl)-2-nitro benzoyl chloride from (MSNBA) 4-(methylsulfonyl)-2-nitro benzoic acid. Reaction is carried out slightly at elevated temperature. Thionyl chloride reacts with (MSNBA) in presence of solvent EDC using dimethyl formamide as a catalyst. During process SO2 & hydrogen chloride gas is generated. Hydrogen chloride gas is scrubbed in water to make 30% liquid HCl solution. SO2 Gas is scrubbed in 17% NaOH solution. 17% Na2SO3 aqueous solution is considered as by-product. Solvent EDC is recovered. STEP 2: MSNBC to EST In this step 4-(methylsulfonyl)-2-nitro benzoyl chloride (MSNBC) is treated with 1, 3 Cycloheaxanedione (CHD) in presence of triethyl amine (TEA) using solvent EDC to give (3-(2- nitro -4-methylsulfonyl-phenylcarbonyloxy)-cyclohex-2-en-1-one (Enol ester). STEP 3: EST to Me-328 In this step 3-(2-nitro-4-methylsulfonyl-phenylcarbonyloxy)-cyclohex-2-en-1-one (Enol ester) is converted to 2-[4-(methylsulfonyl)-2-nitrobenzoyl]-1, 3-cyclohexanedione (Mesotrione) in presence of catalyst and TEA. Reaction mass is maintained and further treated with 30 % HCl solution & proceeding for layer separation. Organic layer is washed with water. Solvent EDC is recovered and product is isolated by purification using methanol solvent. Methanolic ML is proceeding for methanol recovery and residue is considered for Incineration. Aqueous layer-1 generated as triethyl amine hydrochloride (TEA.HCl) layer is proceeded for TEA recovery. The aqueous layer obtained after TEA recovery is further treated with NaOCl and consider for ETP.


Step I:

C8H7NO6S + SOCl2 C8H6ClNO5S

+ HCl + SO2

MSNBA Thionyl Chloride

MSNBC Hydrogen

Chloride Sulphur

Dioxide

245 119 263.5 36.5 64

Step II: C6H8O2 + C8H6ClNO5S + C6H15N C14H13O7NS + C6H16NCl

CHD MSNBC TEA ENOL

ESTER TEA.HCl

112 263.5 101 339 137.5


66

Step III: C14H13O7NS

C14H13NO7S ENOL ESTER MESOTRIONE 339 339

Scrubber Reaction (Step I):

SO2 + 2 NaOH

Na2SO3 + H2O

Sulphur dioxide Sodium hydroxide Sodium sulphite Water 64 2*40 126 18

Figure 2.16 Process Flow Diagram Mesotrion (Existing) (STEP I: MSNBA to MSNBC)

QTY in Kg RM Product / Stream QTY in Kg

496 SOCl2 NaOH Lye (17%) 2339

SO2 (Air) 0.4

856MSNBA

SO2 (g) 221 17% Na2SO3 2559.6solution

4280 EDC

3 DMF HCl (g) 125 Liquid HCl 417

HCl ( Air ) 0.6

Water 292

EDC + SOCl2 4343Recycling

935-945 Kg MSNBC

2140 EDC MSNBC in EDC 3085For next step

Dilution

INPUT

MSNBC preparationScrubber

OUT PUT

EDC Recovey

Scrubber


67

Figure 2.17 Process Flow Diagram Mesotrion (Existing) (STEP II&III: MSNBC to EST to Me-328)

Figure 2.18 Process Flow Diagram - Tea Recovery

QTY ,Kg RAW Materials Product / Streams QTY Kg

430 CHD

2170 EDC

435 TEA

3085 MSNBC+EDC Soln.

5 TEBA-Cl

4.0 Acetone cyanohydrin

435 TEA

2500 EDC Aq layer-1 4319

3190 HCl ( 7 %)

2226 Water wash Wash layer 2237

Rec EDC 6611

3500 Methanol

Methanol 4058

700 Methanol wash MeOH ML 3533 Methanol recovery Residue 165

MeOH WL 690

Dry Me-328 1000Recovered Methanol 90

Drying

OUT PUT

EST Preparation Temp : 45-50C

FILTRATIONTemp : 0-5 C

INPUT

EDC Recovery

Preparation of ME-328Temp : 40-45C

Work up & Layer seperation

Water washing

Purification

Qty ,Kg INPUT OUT PUT Qty ,Kg

4319 TEA.HCl Layer

1105 Caustic Lye (48%)

Stirr for 1hr. NaOCl (8-10%) 3100

Aq.Layer-1 4457

7557

TEA 840 to ETP for draining

Water 29

Residue 37For incinerration

Neutralization

Layer Seperation

Distillation Temp : 25-30 C

Detoxification


68

3. Mass Balance

INPUT QUANTITY (kg/ton)

MESOTRION (1000 kg)

OUTPUT QUANTITY (kg/ton)

MSNBA 856 PRODUCT Thionyl Chloride 496 Mesotrion 1,000

DMF 3 BY-PRODUCT

EDC in step-1 4,280 Sodium bisulphate (17%)

2,113

OR

Sodium Sulphite Solution (17%)

2,560

AND EDC for MSNBC solution 2,140 Liquid HCl (30%) 417 Water for HCl scrubber(Step-2)

292 RECYCLE

NaOH lye (17%) for SO2 scrubber (Step-2)

2,329 Recycle in step-1

CHD 430 Recovered EDC 4,286 TEA 870 SOCl2 in Rec EDC 57 TEBA.Cl 5 Recycle in step-2

Acetone cyanohydrin 4 TEA 840

EDC for step-2 4,670

Recovered Methanol 4,148

Recovered EDC 6,611

HCl (7%) 3,190 Water wash

2,237

Water for washing 2,226 Methanol 4,200 TO Air HCl Gas 0.6 SO2 Gas 0.4 NaOH lye(48%) for TEA recovery

1,105 TO ETP

NaOCl (8-10%) for detoxification

3,100 Water from TEA recovery 29

Aqueous layer after detoxification 7,557

HAZARDOUS WASTE TO INCINERATOR

Residue after methanol recovery

165

TEA residue 37

LOSS (SOLVENT) Methanol 52 EDC 199 TOTAL 30,196 TOTAL 30,196


69

2.2.13 Pyrazosulfuran Ethyl Technical (Existing):

1. Manufacturing Process:

Pyrazosulfuran Ethyl Technical manufacturing involves following 3 steps:

Step I: Reaction of 4, 6-Dimethoxy pyrimidine-2-amine reacts with Phenyl Chloroformate to form Phenyl (4, 6-dimethoxypyrimidine-2-yl) carbamate

Brief Procedure: 1. ADMP, 1, 4- Dioxane and N,N-Dimethyl aniline are charged to the reactor

with stirring and cool . 2. Add phenyl chloroformate gradually 3. Reaction mass stirred and check ADMP < 0.5%. 4. Distill Dioxane under vacuum. 5. Reaction mass is quenched in ice water, stirred & solid is filtered & washed

with water. 6. Sodium hydroxide is added to the filtrate to adjust pH 8-9 and then separate

the layers and aqueous layer further extract with fresh MDC. 7. Aqueous layer sent to effluent treatment plant. 8. Combined organic layer is distilled to recover N,N-Dimethyl aniline and

MDC for recycle in next batch. 9. Wet solid washed with isopropyl alcohol. 10. Solid is dried.

Step II: Reaction of Phenyl (4, 6-dimethoxypyrimidine-2-yl) carbamate with Ethyl-1-methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate to form Pyrazosulfuran Ethyl Technical. Brief Procedure: 1. Ethyl-1- methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate, Phenyl (4, 6-

dimethoxypyrimidine-2-yl) carbamate & Acetonitrile are charged and cooled.

2. Add catalyst then reaction mass stirred . Acetonitrile is distilled under vacuum.

3. Residue is quenched in ice water and precipitated Solid product is filtered & washed with water.

4. Filtrate is extracted by using MDC two times to recover phenol and combined organic layer is distilled to recover MDC and phenol for recycle.

5. Aqueous layer sent to effluent treatment plant. 6. Product is purified from methanol & dried .

2. Chemical Reaction:

Step I:

C6H9N3O2 + C7H5ClO2 → C13H13N3O4

+ HCl


70

4,6-dimethoxy pyrimidin-2-amine

Phenyl chlorocarbonate

phenyl (4,6-dimethoxy pyrimidin-2-yl) carbamate

Hydrochloric Acid

155 156.5 275 36.5

Step II:

C7H11N3O4S + C13H13N3O4 → C14H18N6O7S + C6H5OH

Ethyl 1-methyl 5-Sulfamoyl 1-Hpyrazole 4-carboxylate

Phenyl(4,6-dimethoxypyrimidin-2-yl) Carbamate

Pyrazosulfuran Ethyl Technical

Phenol

233 275 414 94


71

Figure 2.19 Process Flow Diagram Pyrazosulfuran Ethyl Technical (Step-I)


72

Figure 2.20 Process Flow Diagram Pyrazosulfuran Ethyl Technical (Step II)

3. Mass Balance

Input Quantity (kg/ton)

Pyrazosulf-Uran Ethyl Technical (1000 Kg)

Output Quantity (kg/ton)

4,6-dimethoxy pyrimidin-2-amine 374

Product


73

Phenyl chlorocarbonate 390

Pyrazosulfuran Ethyl Technical 980

Impurity with Product 20

N,N Dimethyl Aniline 588

Recovery

1,4 dioxane 1250 1,4 dioxane 1188 Water 530 MDC 288 48% NaOH 408 N,N Dimethyl Aniline 570 MDC 100 Isopropyl Alcohol 955 Isopropyl Alcohol 1000 Acetonitrile 1200 Methanol 1045 Ethyl 1-methyl 5-Sulfamoyl 1-Hpyrazole 4-carboxylate 577

Byproduct

Acetonitrile 1250 Phenol 214 Catalyst 2 To ETP Ice Water 300 Stream – 1

Methanol 1100

NaOH+Water+1,4 dioxane+MDC+NaCl+ N,N Dimethyl Aniline+ Phenyl chlorocarbonate+ 4,6-dimethoxy pyrimidin-2-amine 867

MDC 200 Losses(To Air) 1,4 dioxane 25 MDC 6 N,N Dimethyl Aniline 6 Isopropyl Alcohol 20 Water(Drying) 235 Ice Water 90 Methanol 33 Hazardous Waste To Incinerator Stream – 1 Isopropyl Alcohol 25 Stream – 2

Acetonitrile+Methanol+Water+MDC+ Phenol+ Ethyl 1-methyl 5-Sulfamoyl 1-Hpyrazole 4-carboxylate+Catalyst 302

Total 8069 Total 8069

OR Pyrazosulfuran Ethyl (New Route) 1. Manufacturing Process - Pyrazosulfuron Ethyl


74

Pyrazosulfonyl Isocyanate solution added in 2-Amino-4,6-Dimethoxy Pyrimidine solution in Toluene and maintain for few hours to prepare Pyrazosulfuron Ethyl. Filter reaction mass and dry it.

Chemical Reaction - Pyrazosulfuron Ethyl

C8H9N3O5S + C6H9N3O2 → C14H18N6O7S

Pyrazosulfonyl Isocyanate

2-Amino-4,6-dimethoxy Pyrimidine


MW 259 155 414

Figure 2.21 Process Flow Diagram – Pyrazosulfuron Ethyl

Mass Balance - Pyrazosulfuron Ethyl

Input Quantity (kg/ton) Pyrazosu-

lfuron Ethyl (1000kg)



775 Product

Pyrazosulfuron reaction

Pyrazosulfonyl Isocyanate- 775 Kg

2-Amino 4,6-Dimethoxy Pyrimidine -394 Kg

Toluene – 2275 Kg

Filtration &washing Toluene ML+WML

Recycle Toluene

Residue- 237 kg Pyrazosulfuron Ethyl

drying (1000 Kg)

Toluene wash

RE

CY

CL

E- 2

161

kg


75


394 Pyrazosulfuron Ethyl

1000

Toluene 2275 Recovery/Recycle Toluene 2161

To Incineration Residue 237

Losses Toluene 46


2.2.14 Monochrotophos (Existing & Proposed)

1. Manufacturing Process Step I: Manufacturing process for Monochloro Monomethyl Aceto Acetamide (MMACL) Take aqueous solution of salt and monomethyl aceto acetamyde (MMA) 71% aq. solution in the reactor. Cool the reaction masses to up to –18°C and stir it. Start addition of chlorine to the reaction mass, stir and cool. During chlorination maintain temperature around -12 to –18°C. Chlorination time is about 2.75–3 hrs. After completion of chlorination, neutralize the whole mass to pH 6 to 7 using 16% caustic solution. Now add ethylene dichloride to extract MMACI. Then separate the aqueous from the organic phase. That is partially goes to chlorination stage & remaining goes for evaporation. The generated NaCl salt will treated for landfilling. This MMACI in EDC is taken for second step Perkow reaction.

Step II: Manufacturing process of Monocrotophos-Tech Take solution of MMACI and EDC (of IST step) into reactor and heat it to 60°C. Then add Tri methyl phospite to the reaction mass & maintain temp around 45-55°C. Addition period is about 4–5 hrs. After completion of addition of TMP, further maintain the temperature for about 2 hrs. After completion of reaction EDC is recovered under vacuum to get Monocrotophos Tech. The generated low boiler after TFE will goes to incinerator.

Step III: Methyl chloride recovery system Methyl Chloride vapors along with EDC vapors are chilled in a Heat exchanger where brine is circulated at –35°C. Liquefied Methyl chloride, which is obtained as a top product from distillation column is cooled and stored in a product tank. Finally it is filled in tonners. The generated MeCl residue from MeCl recovery will goes to incinerator.


Step I: C5H9O2N + Cl2 → C5H8O2NCl + HCl

MMAA Chlorine MMACl Hydrogen Chloride

115 71 149.5 36.5


76

HCl + NaOH → NaCl + H2O Hydrogen chloride

Sodium Hydroxide

Sodium chloride Water

36.5 39.94 58.5 18

Step II:

C5H8O2NCl + C3H9O3P → C7H14O5NP + CH3Cl

MMACl TMP Monocrotophos Methyl Chloride

149.5 124 223 50.5

Scrubber Reaction:


Cl2 + 2NaOH → NaCl + H2O + NaOCl 71 80 58.5 18 74.5

5072 Kgs Recycle Aqua. (15 %) 55 Kgs Urea

(4311 kgs water+761 kgs salt)

720 Kgs MMAA

0.023 Kgs Cl2 from scrubber vent

340 Kgs Chlorine Note : Scrubber is using for Emergency only.

190 Kgs 32% Caustic

1410 Kgs Water

700 Kgs EDC

1459 kgs vapour loss to air

5535 Kgs EDC 400 Kgs solid

6931 Kgs Aqua. Waste for land filling

2000 Kgs EDC

2500 Kgs EDC

6 Kgs in Air

226 Kgs MeCL 210 Kgs Pure MeCL

600 Kgs TMP 1240 Kgs EDC 10 Kgs for incineration

Waste

605 Kgs EDC+TMP

(425 Kgs EDC+180 Kgs TMP)

50 Kgs Lowboiler

To Incineration

1000 Kgs MCP (Tech.)

MeCL For

recoveryPerkow

WFE

TFE

Neutralization

1859 Kgs Auqa. To

Evaporation

Chlorination

Extraction

EDC+TFE

Before Perkow


77

3. Mass Balance

Input Quantity

MONOCROTOPHOS 1000 kg

Output Quantity

(Kg/ton) (Kg/ton) MMAA 71% 720 Product Chlorine 340 Monocrotophos 1000

Hot Water 4311 By Product

NaCl as Media 761 Methyl Chloride 210 Urea as catalyst 55 Recovery

Caustic lye 32% 190 EDC 6165

Water as media 1410 TMP 180

EDC as solvent 6235 Aq. ML recycle in to Chlorination stage

5072

TMP 600 Effluent stream

Stream 1 To Evaporator

1859

To Air

Cl2 from scrubber vent

0.023

MeCl to air 6

Solvent Losses EDC 70

Hazardous Waste

MeCl high boiler for incineration

10

MCP Low boiler for incineration

50

Total 14,622 Total 14,622

2.2.15 2-4 D Technical (2, 4 – Dichloro Phenoxy Acetic Acid.) (Existing)

1. Manufacturing Process NaOH Solution is charged in glass lined reactor. The reactor temperature is around 80 to 100 ° C. than 2,4-Di Chloro Phenol is also gradually added in to the solution In the same reaction after completion of addition of 2,4- DiChloro Phenol gradually Mono Chloro Acetic Acid is added. At the same temperature. At same temperature maintaining done for around 2 hours, after completion of reaction, Reaction mass is taken for work up.

In the reaction mass HCl and water is added. Separate the solids by doing filtration. To wet cake of product give water wash to get desired product 2, 4 – Dichloro Phenoxy Acetic Acid.

2. Stochiometric Balanced Chemical Reaction:

Step -I

C6H4Cl2O +

2NaOH +

C2H3O2Cl →

C8H5Cl2NaO3 +

NaCl +

2H2O 2,4-

Dichloro phenol

Sodium Hydroxide

Mono Chloro AceticAcid

2,4- Dichloro phenoxy acetate

Sodium Chloride

Water

MW 163 80 94.5 243 58.5 36


78

Step- 2


3. Mass Balance:


2,4- Dichloro-phenoxy acetic acid 1000 kg


2,4-Dichlorophenol 795 PRODUCT Sodium Hydroxide 30% Soln. 1500

2,4- Dichlorophenoxy acetic acid 1000

Mono Chloro Acetic Acid 80% 600 BY-PRODUCT

Water 200 Nil 0

30% HCl 750 TO RECOVERY

Water 200 Nil 0

Water 300 TO ETP

Stream :1

Water 300

To Air (From Scrubber)

Nil 0

C8H5Cl2NaO3 +

HCl → C8H6Cl2O3 +

NaCl

2,4- Dichloro phenoxy acetate

Hydrochloric Acid

2,4- Dichloro phenoxy acetic acid

Sodium Chloride

MW 243 36.5 221 58.5


79

Losses

Stream:1 Evaporation Losses 2258

Hazardous Waste (To TSDF)

Salt from Eva.-1 787


2.2.16 Acetamiprid (Existing & Proposed)

1. Reaction Chemistry and Process Description

Preparation of Acetamiprid involves following two steps:-

Step I: Preparation of 2-chloro-5-(methylaminomethyl) pyridine (2) In this step 2-chloro-5-chloromethyl pyridine (CCMP) (1) is reacted with excess of 40% aqueous methyl amine in the presence of toluene as solvent to give 2-chloro-5-(methylaminomethyl) pyridine (CMAMP) (2).

+

- CH3NH2.HCl

2-chloro-5-(chloromethyl)pyridine (CCMP) (M.Wt.162)

2-chloro-5-(methylaminomethyl)pyridine (CMAMP) (M.Wt. 156.5)

(1) (2)

40% Methylamine solution and toluene are taken in the reaction vessel. A solution of 2-chloro-5-chloromethyl pyridine (CCMP) (1) in toluene is gradually added. The reaction mixture is stirred for desired time hrs for completion of reaction. After completion of reaction layers are separated and toluene layer containing 2-chloro-5- (methylaminomethyl) pyridine (CMAMP) (2) is taken for next step. Aqueous phase containing methylamine is taken for recovery of methylamine.

Step II: Preparation of Acetamiprid In the second step, 2-chloro-5-(methylaminomethyl) pyridine (CMAMP) (2) obtained in the first step is reacted with Ethyl N-cyano-acetimidate (ECAI) (3) to give Acetamiprid (4).

NCl

Cl CH3NH22

NCl

NH

CH3


80

2-chloro-5-(methylamino methyl) pyridine solutions in toluene are fed to the reactor and Ethyl N-cyanoacetamidate (ECAI) is added gradually maintaining the reaction temperature. The reaction mixture is further stirred for needed time to complete the reaction. At the end of reaction water is added and slurry is filtered to get Acetamiprid cake which is dried to get Acetamiprid Technical.

+

Toluene -C2H5OH

2-chloro-5-(methylaminomethyl)pyridine (CMAMP) (M.Wt. 156.5)

Ethyl N-cyano acetamidate (ECAI) M.Wt. 112

Acetamiprid (M.Wt. 222.5)

(2) (3) (4)

NCl

NH

CH3N

CH3

CN

NCl

N

CH3

O

N

C H 3 C H 3

C N


81


2. Mass Balance


Acetamiprid


40% CH3NH2 1928 Product

Toluene 1200.00 Acetamiprid 1000

CCMP 806 By-Product

ECAI 531 Ethanol 210

48% NaOH 500 To Recovery

WATER 1575 40% CH3NH2 for recycle

1544.00

Toluene 1140

Water 156

To ETP


82

Aqueous layer 590

To Evaporator

Aqueous layer 1810

To Hazardous Waste (Incinerator)

Organic residue 80

Losses

Toluene 10


2.2.17 Imidacloprid (Existing & Proposed)


2. Charge NII and DMF, cool to 20°C. Add NaOH under stirring. 3. Start addition of CCMP at 20-25°C in 2-3 hrs. 4. After completion of addition, maintain for 6-8 hr at same temperature till CCMP

< 0.5 % 5. Remove DMF at 70°C / 755 mm/Hg vacuum and add water at 70°C. 6. Cool the mass to RT and filter it 7. Dry the cake at 70 ºC. 8. Crude Imidacloprid is crystalised with Methanol at reflux temperature and cool

to 20 ºC. 9. Filter the cake and dry in Oven. Chemical Reaction:

C6H5Cl2N + C3H6N4O2 + NaOH → C9H10N5ClO2 +

NaCl + H2O

2-chloro-5-(chloromethyl)pyridine (CCMP)

2 – NitroIminoimidazolidine

Sodium Hydroxide

Imidacloprid Sodium Chloride

Water

162 130 40 255.5 58.5 18


83


Mass Balance

Input Quantity (Kg/T)

Imidacl-Oprid (1000 Kg)

Output Quantity (Kg/T)

CCMP 1079 Product

2 – Nitro Iminoimidazolidine 909 Imidacloprid 1000.0 NaOH 291 By-Product DMF 5952 Nil Nil Catalyst 6 Recovery Washwater 6909 DMF 5653.94 Methanol 9885 Methanol 9390.61 To ETP Washwater 6651.09 NaCl 228.96 H2O 70.45 NaOH 134.35 CCMP 4.45

2 – Nitro Iminoimidazolidine 4.00

Catalyst 6.00 Residue To Incinerator CCMP 440.29

2 – Nitro Iminoimidazolidine 396.28

DMF 178.55 Methanol 297 Loss DMF 119.03 Water (Drying) 258.00


84

Methanol 197.70 Total 25030 Total 25030

Or

2.2.18 Imidacloprid (Proposed- New Route)


Step-I: CCMP to Imidacloprid. 2-Chloro 5-chloromethyl pyridine (CCMP) is reacted with 2-nitro imino imidazolidine (NI) using potassium carbonate (K2CO3) in dimethyl formamide solvent in presence of phase transfer catalyst. The solvent DMF is recovered by vacuum distillation and crude product is isolated by dilution with water followed by filtration. The aqueous mother liquor is considered for ETP. The product is further purified using methanol solvent. Methanolic mother liquor is proceeding for methanol recovery by distillation. Recovered methanol is recycle and residue is considered for incineration.


C6H5Cl2N + C3H6N4O2 + K2CO3 → C9H10N5ClO2 +

KCl + KHCO3

2-chloro-5-(chloromethyl) pyridine (CCMP)

2 – Nitro Imino imidazolidine

Potassium carbonate

Imidacloprid Potassium chloride

Potassium carbonate

162 130 138 255.5 74.5 100


85

Figure 2.26 Process Flow Diagram:

3. Mass Balance:


Imidacloprid (1000 Kg)


Dimethyl formamide(DMF)

6,549 Product

Potassium carbonate

779 IMIDACLOPRID

1,000

2-Nitroamino imidazolidine(NI)

700 By-Product

2-Chloro 5-chloromethyl pyridine (CCMP) (65% )

763.75

KHCO3+KCl salt cake 1,135

DMF for CCMP (35%)

411.25

Catalyst 6

DMF for washing 874 Recycle

Acetic acid 25 DMF 7,730

Water 11,963 Methanol 1,730

Water for washing 1,123 To ETP

Methanol 1,800 Aqueous layer 13,012

Qty, Kg Qty,Kg

6549 DMF

700 NII

779 K2CO3

6 Catalyst

1175 CCMP(65%) solutionin DMF

874 DMF for washing KCl + KHCO3 1135

25 Acetic Acid Re. DMF 7730

11963 Water

1123 Water for washing Aq. M.L + W.L 13012

TO ETP

1800 Methanol

Methanol ML 1990 Methanol 1730

water 29

Imidacloprid Technical 1000 142 Residue for incinerration

Filtration

DMF Recovery

Drying

Filtration MeOH Recovery

Purification

Filtration

Condensation reaction (Preparation of Imidacloprid)


86

Recovered water 29

Hazardous Waste To Incinerator

Residue after

methanol recovery 142

Loss (Solvent)

Methanol 70

DMF (to fume incinerator) 104

Water loss 42

Total 24,994 Total 24,994

2.2.19 Metribuzin Process Description - (Existing)


Charge Water in reactor and Start the stirring and Charge Triazinone under stirring and cool upto 14-150c.Charge C.S.Lye [ 48%] gradually by maintaining temperature 15-200c and Stir for 30 Mints till clear solution is observed. Check the pH by pH meter it should be 12 .Start Nitrogen purging and charge Sodium Bisulphite& Ethyl hexanol. Stirr for 30 – 40 Minutes.

Preparation of Methyl Bromide: Charge Methanol and start stirring and add sulfur powder under stirring and heat up to 65-700c.During heating circulate process water in condenser. Charge bromine slowly by maintaining temperature upto 65-700c during 6 to 8 hrs and generated methyl bromide gas to be purged to solution of sodium salt of triazinone at 15-20 degree.Maintain pH of reaction mass to 11.5 to 12 by adding continuously 10% C.S.Lye solution during Methyl Bromide purging.

After completion of Methyl Bromide addition maintain at 200c Charge 160 Gms 10% C.S.lye and raise temperature upto 500c and maintain. Cool upto 150c and filter the slurry. Wash the solid with water till free from inorganic salt.Dry the solid at 60 to 650c under vacuum till the moisture content less than 0.5%.


Step – 1 6 CH3OH + 3Br2 + S → 6CH3Br +

H2SO4 + H2O

Methanol Bromine Sulphur Methyl Bromide Sulphuric Acid

Water

192 480 32 570 98 36

Step – 2

C8H13N3OS + NaOH → C7H11N4OSNa +

H2O

Triazinone Sodium Hydroxide Salt of Triazinone Water

200 40 222 18


87

Step – 3 C7H11N4OSNa + CH3Br → C8H14N4OS +

NaBr

Salt of Triazinone Methyl Bromide Metribuzin Sodium Bromide

222 95 214 103


Mass Balance: Input Quantity

(kg/t) Metribuzin (1000 kg)

Output Quantity (kg/t)

Sulfur 34.00 Product

Bromine 572.00 Metribuzin 1000 MeOH 120.00 By-Product Water 5120.00 NaBr 3079.98 Sodium bisulfate 11.00 Recovery

Triazinone 1134.00 Methanol 116.79 Caustic lye 446.00 To ETP 2 ethyl hexanol 7.00 Stream:1

Water 550.00

Water+ Un. Methanol+ H2SO4+ Un. Sulphur + Un.Troazionone +Un. Caustic +Sodium 5714.57


88

bisulfate+ 2 ethyl hexanol

Caustic for Bromine Scrubbing (10%) 2400.00

Hazardous Waste To Incinerator

MeOH (as raw material) 160 Residue 204.66

Vapour Losses

Water 438.00 To Air

Un. Bromine (from Scrubber) 0.98


Or

2.2.20 Metribuzin (New Route)

1. Manufacturing Process Triazinone to Metribuzin Charge water and Triazinone in reaction kettle with stirring and chilling. Charge 32% C.S.Lye & stir. Charge bleaching agent and defoamer. pH of mass is adjusted as required adding 10% C S Lye.

Methyl Bromide Generation: Charge methanol and Sulfur powder & apply heating start addition of Bromine. Purge the generated Methyl bromide gas continuously into the above reaction kettle & add 10% C.S Lye to adjust the pH. Complete addition of bromine. Filter the slurry, wash & dry the wet cake

Stochiometric Balanced Chemical Reaction

6CH3OH S 3 Br2 → 6CH3Br H2SO4 2H2O

Methanol Sulfur Br MeBr Sulphuric acid

Water

6*32 32 3*160 6*95 103 2*18

C7H12N4OS NaOH CH3Br → C8H14N4OS NaBr H2O

Triazinone C.S lye MeBr Metribuzin Sodium bromide

Water

200 40 95 214 103 18


89


2. Mass Balance:

Input Quantity (Kg/ton)

Metribuzin (1000 kg)


Bromine 162 Product

Methanol 207 Metribuzin 1000

Sulphur 36 By-product

Water 8200 NaBr 5000

Recovery & Recycled

Triazinone 1069 Spent Acid 200

C. S. Lye 485 Wash ML 3774

SBS 15 Methanol 201

2-Ethyl Hexanol 7 HW to CHWTSDF

Chlorine 305 Incineration 200 *Methanol as Raw material 195

Evaporation salt for landfilling

300

Vent to Air

Methanol 6 Total 10,681 Total 10,681


90

*We shall produce Metribuzin either through old route OR new route process.

2.2.21 Imazapic Technical (Proposed)

1. Manufacturing Process: Stage-I: Process for the Preparation of 2-ethoxy-3-oxo –diethyl succinate

Start addition of Ethyl chloroacetate drop in Ethanol and Sodium ethoxide mixture maintaining the temperature 35-40°C during addtion. Maintain reaction mass at 45°C. Filter the above reaction mass through hyflo-bed followed by Ethanol washing. Stage-II: Process for Diethyl 2-ethoxy-3-oxosuccinate Charge diethyl oxalate, EEA, and ethyl alcohol. Add sodium ethoxide in lots by maintaining temperature 25-35 °C. Maintain reaction mass at 60°C. After completion of reaction, distill out the ethanol and add water and acidify with 2N HCl to pH 2-3 and extract with MDC. Separate the MDC layer and distill out the MDC, initially at atmospheric pressure and then under vacuum to get the intermediate2-ethoxy 3-oxo diethyl succinate. Stage-III: Diethyl 5-methylpyridine-2,3-dicarboxylate Charge 2-ethoxy-3-oxo diethylsuccinate, methyl acrolein, ammonium acetate and ethanol and maintain at 78-80°C. After completion of the reaction, distil out the ethanol under vacuum and cool residue to room temperature. Add water. And extract with toluene. Separate the layer and distil out toluene under vacuum to get the intermediate 5-MDCP. Process for the preparation of 2-METHYL ACROLEIN Charge formaldehyde (37%) and propionaldehyde. Add half the quantity of butyric acid and Di-n-butyl amine Heat the mix to 70°C. Stop heating and cool the reaction mixture to 50°C and add remaining quantity of butyric acid. Heat the mass to reflux for about 1 hr. Cool the reaction mass to 30°C and separate the aqueous layers and distil out the organic layer and collect the product Stage-4: IMAZAPIC Charge Toluene and distil out azeotropically to remove moisture. Cool toluene to 25 degree and add sodium hydride. Maintaining temperature to 25-30°C during addition. Add 2-amino 2,3 dimethyl butanamide at 25-30°C temperature. Add 5-MPDC drop wise maintaining temperature 25- 30°C. Add water to reaction mass at 25-30°C and allow to settle and separate aqueous layer. Cool the aq. Layer to 5-10°C and acidify with hydrochloric acid 30% to pH 2.6. Filter the solid and wash with water, dry at 60-70°C.


91

Figure 2.29 Stochiometric Balanced Chemical Reaction

Figure 2.30 Imazipic Preparation

Methyl Acrolein Chemistry

CH 3

O

H

propanal

Formula Weight = 58.07914

+O

H H

form aldehyde


Butyric Acid

(CH 3CH 2CH 2CH 2)2NH

O

C H 2CH 3

2-m ethy lp rop-2-enal


+ H 2O

Stage IV IMAZAPIC

N

CH 3

O

O

O

O

C 2H 5

C 2H 5

diethy l 5-m ethy lpyrid ine-2 ,3-d icarboxylate


+NH 2

O C H 3

N H 2

C H 3

C H 3


2-am ino-2,3-d im ethy lbutanam ide

Na H N

C H 3

NO

O H

N

O C H 3

C H 3

C H 3

N a + + C 2H 5OHH 22

HCI

N

C H 3

NO

O H

NH

C H 3

C H 3

C H 3

O

+NaCI


IMAZAPIC

M.W. 18

M.W. 24

m.w. - 2 2*(46)

m.w.- 36.5

m.w. - 58.5

O

O

C H 3

C l


e th y l c h lo ro a ce ta te

+CH 3

ONaCH 3 O

O

O

C H 3


+ NaCl

M.W.-58.5

so d iu m e th a n o la te

M.W.- 132

e th y l e th o x y a c e ta te

Stage 1 Ethyl Ethoxy Acetate

Stage II Diethyl - 2 - Ethoxy - 3 Oxosuccinate

H 5 C 2

O

O

O

C 2 H 5

M.W.- 132

e th y l e th o x y a c e ta te

+O

O

C 2 H 5

C 2 H 5

O

O


d ie th y l e th a n e d io a te

1] NaOEt m.w. 68

2] 30 - 45 oC

3] 55-60 oC

4] HCL m.w. - 36.5O

O

O

O

O

O

H 5 C 2

C 2 H 5

C 2 H 5

d ie th y l 2 -e th o x y -3 -o x o b u ta n e d io a te


+ 2 EtOH + NaCL

Chemistry of UPH - 05/IPIC - 218

Stage - III Diethyl 5 - Methylpyridine -2,3 -dicarboxylate

O

C H 2

CH 3


2 -m e th y lp ro p -2 -e n a l

+

O

O

O

O

O

O

H 5 C 2

C 2 H 5

C 2 H 5

N

CH 3

O

O

O

OC 2 H 5

C 2 H 5


d ie th y l 5 -m e th y lp y r id in e -2 ,3 -d ica rb o x y la ted ie th y l 2 -e th o x y -3 -o x o b u ta n e d io a te


+ 2H 2 O + EtOH

2*(46) M.W. 58.5

2*(18) M.W. 46

CH3COONH4

(m.w.77)

+ CH 3 COOH(M.W.60)


92


2. Mass Balance:


Imaz

apic

(100

0 kg

)


Ethyl Chloro Acetate 1,224 Product sodium ethoxide 1,409 Imazapic Technical 1,000 By-Product HCL 4,277 Ethanol 7,395 Recycle Diethyl oxalate 1,419 Ethanol 7,226 HCL (30%) 2,396 MDC 6,856 Toluene 13,865 Water Step 1 & 2 1,340 Water Step 3 1,998 water 0 Water Step 4 7,447 MDC 6,996 To air Ammonium acetate 560 Hydrogen 11 Toluene 13,974 Water 100 2% sodium bicarbonate 2,498 To landfilling

formaldehde 898 Sodium chloride wet cake

640

Propanaldehyde 643 Butyric acid 66 To ETP Di-n-butyl amine 44

Hydroquinone 1 AQ.layer-2 3,241


93

20% NaOH for scrubber 95 AQ.layer-3 1,875

2-Amino-2,3-dimethyl-butyramide

745 AQ.layer-4 886

NaH 447 AQ.layer-5 5,762

Water Step 1 & 2 (1340 X 2)

2,680 Scrubber solution 117

Water Step 3 (1998.5 X 2)

3,997 To incineration

Water Step 4 (3723.33 X 3)

11,170 Residue-Methyl Acrolein stg

234

Residue-toluene distillation

718

Emulsion from Layer Sep-Stg 2

700

Loss Toluene 110 Ethanol 114 MDC 140

Input 58,657 Output 58,657

2.2.22 Diethyl Thiophosphoryl Chloride (DETCL) (Existing)

1. Manufacturing Process Phosphorus Pentasulphide mixed with Ethyl Alcohol & the mass require under nitrogen blanket. Scrub Hydrogensulphide gas evolved from the reaction in caustic scrubber & recovered NASH as a By-Product. Maintain reaction temperature while addition of Ethanol. After completion of reaction, purge nitrogen in the mass to remove dissolve hydrogen sulphide gas. After removing hydrogensulphide gas, cool the reaction mass upto 10°C. Start addition of chlorine gas (1:1 mole ratio) in the reaction mass. Reaction is exothermic. Maintain reaction temperature up to 10°C while chlorination by controlling chlorine flow rate as well as by circulating chilled water into the jacket of the reactor. Generated HCL send to water scrubber & Caustic scrubber. 30% HCl is recovered as a By-Product After completion of the reaction recover solvent by distillation under vacuum. Purify crude product by fractional distillation under vacuum. Sulphur contain residue sends to Incineration. Store Diethyl Thiophosphoryl Chloride in air-tight container and keep it in dry area.


C10H9NO6S2 +

NaNO2 + 2HCl →

C10H7N2O6S2Cl +

NaCl + 2H2O

C-ACID Sodium Nitrite

Diazo1

MW 303 69 73 350.5 58.5 36


94

STEP - II

STEP III


H2S +

NaOH →

NaSH +

H2O

Hydrogen Sulfide

Sodium Hydroxide

Water

MW 34 40 56 18

C4H11O2PS2 +

Cl2 →

C4H10O2PSCl +

S

DETA Chlorine DETCl Sulphur

MW 186 71 188.5 32

Cl2 +

2NaOH →

NaOCl +

H2O

Chlorine Sodium Hydroxide

Sodium Hypochlorite

Water

MW 71 80 74.5 18


95

3. Mass Balance

Input Quantity

(kg/ton)

Diethyl Thio phosphoryl Chloride (DETCL) 1000 kg


Phosphorus Pentasulphide 595

Product

Ethyl Alcohol as raw material 490

DETCl 1000

Lutidine 1 By-Product

Caustic for H2S scrubber 110 NaSH 700

30% HCl 594

Water for caustic scrubber 500

To Recovery

Chlorine 384 Ethyl Alcohol 106

Water for HCl recovery 400 TO ETP

Caustic for Cl2 scrubber 130 Scrubber Liq. 728 Water for caustic scrubber 591


Ethyl Alcohol as solvent 110 H2S 0.09

Chlorine 0.01

Fugitive Emissions

Ethyl Alcohol 3


Organic layer 180 Total 3311 Total 3311

2.2.23 Amino Aceto Nitrile Sulphate (AANS) (Existing)


H2SO4 is added with agitation to aqueous solution of methanol. The solid MAAN powder added with agitation. The reaction is mild exothermic, cooling being employed for temperature control. Now crude AANS Purified by Methanol water washing & filtrate as a wet cake. Mother liquor from Filter is neutralized by NaOH & distilled, DMM (Di Methoxy Methane) & Methanol recovered. Now Wet cake of AANS is dried in Dryer.


C3H4N2 +

0.5H2SO4 + 2CH3OH + H2O → (C2H4N2)0.5H2SO4+

C3H8O2 + H2O

MAAN Sulphuric Acid Methanol Water AANS DMM Water

MW 68 49 64 18 105 76 18


96


3. Mass Balance:

Input Quantity

(kg/ton)

AANS 1000 kg


MAAN 665 Product

Sulphuric Acid 500 AANS 1000

Methanol as Solvent 1910 By-Product

Water 410 DMM 724

Methanol for Reaction 400 To Recovery

Caustic flakes 90 Methanol 1852 Fresh Methanol (washing) 90 To ETP

Nil 0


Nil 0

Losses

Methanol from fugitive emissions 54

Moisture 20% from drying 258


Organic Layer 177


2.2.24 Myristyl Amine Oxide (MO) (Existing)

1. Manufacturing Process : Myristyl amine reacts with H2O2 in presence of DM water, Citric acid & sodium bicarbonate & forms Myristyl amine oxide.



97

Step I:

C16H35N + H2O2 → C16H35NO + H2O

Myristyl amine Hydrogen Peroxide

Myristyl amine Oxide Water

241 34 257 18


3. Mass Balance:


Myristyl Amine Oxide (1000 Kg)


Myristyl Amine 970 Product

Hydrogen Peroxide 43.5 Myristyl Amine Oxide 980

Water of Hydrogen Peroxide 43.5

Impurity With Product

Citric Acid 3 Myristyl Amine 8 Sodium Bicarbonate 2 Hydrogen Peroxide 4

DM Water 619 Water of Hydrogen Peroxide 44

Citric Acid 3 Sodium Bicarbonate 2 DM Water 640 TO ETP Nil Nil Losses(To Air) Nil Nil Hazardous Waste To Incinerator


98

Nil Nil Total 1681 Total 1681

2.2.25 Parachloro Ortho Cresol (PCOC) (Existing )


O-Cresol and Sulphural Chloride are reacted in a glass lined reactor at 45°C. The product of this reaction is crude Para Chloro Ortho Cresol with the evaluation of sulphur-dioxide crude and hydrogen chloride gases. The gases are scrubbed with water and hydrogen chloride is separated in the form of 30% hydrochloric acid. Pure sulphur di-oxide gas is made to react with chlorine in a packed column to form Sulphuryl Chloride which is recycled for the next batch. Crude Para Chloro Ortho Cresol is charged to a distillation system. The top product is pure Para-Chloro-Ortho-Cresol. The residue is discharged from the reactor and is sent for incineration. Pure Para Chloro-Ortho Cresol is filled in drums which get solidified later.


C7H8O + SO2Cl2 C7H7OCl + HCl + SO2

108 135 142.5 36.5 64

O – Cresol Sulphural Chloride Para Chloro Ortho Cresol

SO2 + Cl2 SO2Cl2

64 + 71 135


Mass Balance:

Input Quantity (kg/t)

PCOC Manufacturing 1000 kg


O-CRESOL 798 Product


99

sulphural chloride

998

PCOC 1000

WATER 630 Recovery

CL2 525 sulphural chloride 988

By-Product

HCL 30% 900


Organic residue 53

Air Loss

To Air 10


2.2.26 Dimethyl Phosphoro Amidothioate (DMPAT) (Existing & Proposed)


Dimethyl Thio Phosphoryl Chloride (DMTCL) is reacted with Aqueous Ammonia (Aq.NH3) at 0ÍC and PH= 7.0 in presence of Methylene Dichloride (MDC) as solvent. Once the reaction gets completed, the mass is kept for layer separation. The upper layer, which is aqueous ammonium chloride, is drawn off. From the organic layer, Methylene Dichloride is distilled and reused in the next batch, whereas the left over is pure DMPAT, which is used in existing Acephate plant, as an 'intermediate'.


C2H6O2PSCl + 2 NH3 C2H8O2PSN + NH4Cl 143.5 + 2 ( 17) 124 + 53.5


3. Mass Balance:

Input Quantity DMPAT

(1000

kg)

Output Quantity

(kg/t) (kg/t)

DMTCL 1218 Product

Aq. Ammonia 1698 DMPAT 1000

MDC 2000 Recovery


100

MDC 1900

By-Product

NH4CL 1996

Effluent Generation

(To ETP) Nill

Air Pollution

MDC 20

Hazardous Waste

(To Incinerator) Nill


Or

2.2.27 Dimethyl Phosphoro Amido Thioate (DMPAT) – Proposed New Route

1. Manufacturing Process: STEP-I: Phosphorus Thiochloride Preparation: Phosphorus tri chloride and Sulphur react in an inert atmosphere at higher temperature in presence of catalyst and produce Phosphorus thiochloride. STEP-II: DMPAT Preparation Part A-Phosphorus thiochloride is added in Methanol at lower temperature. Dimethyl thiophosphonyl separate from monoester mass. Hydrochloric acid and unreacted methanol form during process is separate out in aqueous layer. From aqueous layer is recovered 30% HCl & excess methanol. The excess methanol recovered is recycle to process. Remaining aqueous layer send to ETP. The water is added in reaction mass to remove hydrochloric acid from organic mass and unreacted methanol from product & generated effluent taken to ETP. Part B-Ammonia are added in Dimethyl thiophosphonyl chloride along with Dichloromethane to get DMPAT. Ammonium chloride form during process is separate out in aqueous layer. Extract aqueous layer with Dichloromethane to recover DMPAT from aqueous layer. Distilled out Dichloromethane under reduce pressure to get pure final DMPAT. Recovered Ammonium Chloride sold as a By-product. STEP-III: Packing Final DMPAT pack in suitable container under inert atmosphere.

2) Chemical Reaction: DMPAT

Stage-I PCl3 + S → PSCl3

Phosphorous Trichloride Sulfur

Phosphorous Thio-Chloride

MW 137.5 32 169.5


101

Chemical reaction of Excess Phosphorous Trichloride PCl3 +

3H2O →

H3PO3 +

3HCl

Phosphorous Trichloride

Water Phosphorus Acid

Hydrogen Chloride

MW 137.5 54 82 109.5

Stage-II PSCl3

+

2CH3OH → C2H6ClO2PS

+

2HCl

Phosphorus thiochloride

Methanol Dimethyl thiophosphenylchloride

Hydrogen Chloride

MW 169.5 64 160.5 73

3NaOH +

H3PO3 →

Na3PO3 +

3H2O

Sodium Hydroxide

Phosphorus acid

Sodium Phosphite Water

MW 120 82 148 54

Chemical reaction at Scrubber HCl +

NaOH → NaCl +

H2O

Hydrochloric Acid

Sodium Hydroxide


MW 36.5 40 58.5 18

Stage-III C2H6ClO2PS +

2NH3 →

C2H8NO2PS +

NH4Cl

Dimethyl thiophosphenylchloride

Ammonia DMPAT Ammonium Chloride

MW 160.5 34 141 53.5


102


Mass Balance


DMPAT

(1000 kg)


Phosphorus trichloride

931 Product

Sulfur 258 DMPAT 1,000 Methanol 652 By Product Water 163 NH4Cl 353 48% NaOH 41 30% HCl 1,663 20% NH3 158 Water for HCl Scrubber

1,168 Recovery

NaOH Soln for Scrubber

80 Methanol 218

Ammonia 251 Dichloromethane (MDC)

2,241 Dichloromethane (MDC)

2129

Water for NH3 scrubber

132 TO ETP

Stream-1 Scrubbing liquor 85 Stream-2:


103

Methanol 7 Na3PO3 25 Water 163 Un. NaOH 21 To Air (From Scrubber) HCl 0.01 NH3 0.03 To Hazardous Waste Nil Nil Fugitive Emissions Methanol 5 Dichloromethane 90 Total 5,917 Total 5,917

2.2.31 Dimethyl Methyl Phosphonate (DMMP) (Existing & Proposed)

1. Manufacturing Process Trimethyl Phosphite is charged in a reactor and Methyl Iodide is added as the catalyst. The temperature is maintained at 90 ÍC. At this juncture TMP gets converted to DMMP by isomerisation. This is the final product, which is filled in the drum.


C3H9O3P Isomerization C3H9O3P

TMP DMMP

MW 124 124


Mass Balance

Input Quantity (kg/t) DMMP Manufacturing 1000 kg

Output Quantity (kg/t) CH3I CATALYST

2 ProDUCT

DMMP 220 DMMP 1000 TMP 1000 Recovery


104

DMMP 220 CH3I 2 Total 1222 Total 1222

2.2.32 Di Ethyl Thiophosphoryl Chloride (DETA) (Existing & Proposed)

1. Manufacturing Process Phosphorus penta sulphide is reacted with ethanol and made to react at 65C to get DETA which is used as intermediate for Phorate and Turbophos. Hydrogen sulphide gas evolved in this process is scrubbed with caustic solution and NaSH is recovered as a by-product.

2. Stochiometric Balanced Chemical Reaction

P2S5 + 4C2H5OH → 2(2(C2H5O) PSSH) + H2S

Phosphorus(V) sulfide

Ethyl Alcohol

DETA Hydrogen Sulfide

MW 222.27 184.28 372.46 34.08


Mass Balance: Input Quantity

kg/ton DETA (1000 kg)

Output Quantity kg/ton

P2S5 596 Product Alcohol 500 Deta 1000 Lutidine 1 Recovery Caustic Lye(32%) 187 Nil Nil Water 152

H2S +

NaOH →

NaSH +

H2O Hydrogen

Sulfide Sodium Hydroxide

Sodium Hydrosulfate Water

MW 34 40 56 18


105

By-Product NASH 436 Effluent Generation Nil Nil Air Pollution Nil Nil Solid Waste Generation Nil Nil Total 1436 Total 1436

2.2.33 Zinc Di Thio Phosphate (ZnDTP) (Existing & Proposed)

1. Manufacturing Process Phosphorus Penta Sulphide (P2S5) is reacted with mixture of Secondary Butanol (SBA) and Methyl Iso Butyl Carbinol (MIBC) to produce Di Thio Phosphoric Acid (DTPA) at atmospheric pressure and 85 degree tempreture. A by-product of the reaction is Hydrogen Sulphiade (H2S) gas which is scrubbed in the Caustic scrubber to produce Sodium Hydrogen Sulphide (NaSH) – a saleable by-product.

DTPA thus produced, is mixed with Zinc Oxide to produce Zinc Di Thio Phosphate (ZnDTP) at atmospheric temperature and pressure. The crude ZnDTP s filtered to remove the sediment before it is pumped to product storage. The sediment is sent to incinerator for incineration.

P2S5 +

4 R- OH →

2 R O2 P S2 H +

H2S

Penta Sulphide Methyl Iso Butyl Carbinol

Di Thio Phosphoric Acid

Hydrogen Sulphiade

MW 222 34

H2S +

NaOH →

NaSH H2O

Hydrogen Sulphiade Caustic lye

Sodium Hydrogen Sulphide Water

MW 34 40 56 18

6 R2 O2 P S2 H +

( 3+n)ZnO

→

(3-3n ) R4 P2ZnO4S4

n R12 Zn4O16S12 +

H2O

Di ThioPhosphoric Acid Zinc Oxide

Zinc Di ThioPhosphate

+ Water

MW 18


106


Mass Balance:


ZnDTP Output Quantity (kg/t)

P2S5 315 Manufacturing 1000 kg

Product

SBA 354 ZnDTP 1000

MIBC 153.97 Recovery

CSLYE 32% 72 Nil 0

LUBE OIL 244 By Product

ZINC OXIDE 121 NaSH 295

ACETIC ACID 1 Effluent Generation

FW14 22 Stream I: To ETP

WATER 173

Nil Nil

Air Pollution

Traces of ethyl mercatan to fume incinerator

0.0001

Hazardous Waste (To Incinerator)


ZNDTP WASTE 160.97

Total 1455.97 Total 1455.97


107

2.2.34 Absolute Alcohol (Existing)

1. Manufacturing Process Denatured rectified spirit (Ethyl Alcohol/ assay - 93-95%) is purified to 99.9% pure absolute alcohol by azeotropic distillation method. Cyclohexane is used as entrainer. Pure ethyl alcohol is the bottom product. Water & cyclohexane are collected from top. Cyclohexane is separated by layer separation method and recycled in the system. Water is charged in the second distillation column to separate the traces of ethyl alcohol and cyclohexane which are recycled in first distillation system. Pure water is drained to the effluent treatment plant. This is a continuous distillation system.

2.2.35 NOFLAN (EXISTING)


A. Heel making stage :

Charge sufficient quantity of DMP in reactor and start nitrogen passing slowly. Increase the mass temperature upto 250-260º C under stirring and maintain it upto certain hours. B. Isomerisation :

Slowly start addition of DMP at 245-250º C. Raise the mass temperature to 255-260º C and maintain for some hours. Check the acid value, take out required heel fork subsequent Batch. C. Hydrolysis :

Cool and isomerised quantity to 110-130º c and charge sufficient quantity of water with maintaining temperature. Reflux the mass for certain hours. Start distillation of water methanol mixture. After distillation check the Acid Number and moisture of reaction mass. D. Chlorination :

Cool the mass upto 20º C, charge sufficient quantity of PoCI3 maintaining inside temperature under stirring and liquid stage. Charge sufficient quantity of PcI3 under stirring. Start addition of C12 by maintaining certain temperatures. Start scrubbing of liberated HCL in water. Charge the sufficient quantity of PCI3 and C12 as above. Raise the mass temperature upto 60º C and maintain for some hours.

E. POCI3 recovery:

Increase the mass temperature upto 110º C with scrubbing system in ON condition. Remove sufficient quantity of First cut. Increase the mass temp and remove the sufficient quantity of Second Cut. Start the vacuum system and recover the excess POCI3 at 60-85º C. Check the chloride and GC for the mass (MPDC).


108

Amination of Crude MPDC

Cool the mass to 20º C and charge sufficient quantity of MDC and ammonia gas simultaneously till the PH becomes>9.0. Maintain the same PH for some time. Filter the mass and send the finished product to dryer for drying.


Stage -1 – Isomerisation

3(C2H7O3P) → C2H8O5P2 + C2H8O5P1 + C2H6O

DMP

DME

MW 3(110) 174 110 46 330 330

Stage 2 – Hydrolysis

C2H8O5P2 C2H8O5P1 2 H2O → 3CH5O3P + CH30H

MPA

MW 174 110 36 288 32 320 320

Stage – 3

CH5O3P + PCl3 + 2Cl2 → CH3OCl2P + 2HCl + 2POCl3

MPA

Phosphorus Trichloride

Chlorine

Methyl Phosphoric Dichloride

Hydrochloric Acid

Phosphorus Oxi-chloride

MW 96 275 142 133

73 307

Stage – 4

Cl3H3OCl2P + 4NH3 → PCN4OH15Cl2

Methyl Phosphoric Dichloride

Ammonia Noflan

MW 133

68 201


109


Mass Balance:

Input Quantity

NOFLAN (1000 kg)

Output Quantity

(kg/ton) (kg/ton) DMP 707.87 Product Water 149.81 NOFLAN 1,000 POCl3 610.49 By-Product PCl3 1,760.30 Methanol (Stream-1) 67.42

Chlorine 906.37 POCL3 (Stream-2) 2,558.05

MDC 4,516.85

Ammonia 382.02 Effluent Generation

No Effluent Generation Recovery MDC 4,303.37

Water (Stream-1) 71.91 TO Air Fumes from Stream-1 through fume incinerator

104.87

HCL (to HCL Scrubber) 464.42

PCL3 (to HCL Scrubber)

14.98

Chlorine (to HCL Scrubber

3.75

Qty, Kg Qty,Kg

707.8 DMP Water + Methanol 74.91 +67.42

149.8 Water By product

610.5 POCl3 POCl3 byproduct2558.1

1760.3 PCl3

Low boiler impurities for Incineration 183.5

906.4 Chlorine HCl (Gas ) Scubber 464.4

PCL3 to HCL Scrubber 14.98

382.0 NH3

4516.9 MDC NH3 to scrubber 44.9

MDC ML Recovered MDC 4303.37

Residue 217.23

Incinerration

Noflan 1000

AMINATION

Vacuum drying

Filtration

Isomerisation and hydrolysis

CHLORINATION

NH3 Scrubber

MDC Recovery

HCL Scrubber


110

Ammonia (to NH3 Scrubber

44.94

Hazardous Waste To Incinerator Residue MDC recovery 217.23 Unreacted DMP 183.52

Total 9,034

Total 9,034

2.3 RESOURCE REQUIREMENT

2.3.1 Land

The proposed expansion is planned within the existing premises admeasuring 65,625 m2 area. The existing premise is already in Gujarat Industrial Development Corporation (GIDC) estate of Ankleshwar and adjacent to many industries. No additional land is required for the proposed expansion. The land break-up is detailed below in Table 2.3

Table 2.3 Land Area Break-up Details

S.N. Particulars Existing Area (m2)

Proposed Area (m2)

Total Area (m2)

1. Admin block 2,610.00 0.00 2610.00 2. Plant facility 2,697.06 1,402.00 4,099.06 3. Utility facility 2,642.00 934.00 3,576.00 4. Explosive tank farm 761.00 242.00 1,003.00 5. Chemical tank farm 566.00 326.00 892.00 6. Raw material warehouse 751.00 296.00 1,047.00 7. Finish goods tank farm 691.00 96.00 787.00 8. Quality control (QC) lab 494.00 0.00 494.00 9. Chlorine tonner shed 130.00 0.00 130.00 10. Methyl Chloride (MeCL) recovery plant

including Tonner shed for MeCl 129.94 76.48 206.42

11. Compressed cylinder area 15.00 0.00 15.00 12. Approach road/drains 13,894.98 71.20 13,966.18 13. Others (change rooms, washrooms,

internal passages etc.) 3,298.00 106.80 3,404.80

14. Effluent Treatment Plant (ETP) 2,831.00 0.00 2,831.00 15. Sewage Treatment Plant (STP) Area 0.00 160.78 160.78 16. Hazardous waste storage area 623.00 0.00 623.00 17. Parking Area 1,409.31 0.00 1,409.31 18. Open area 18,170.13 -4,026.26 14,143.87 19. Greenbelt 13,911.58 315.00 14,226.58 TOTAL Plot Area 65,625.00 0.0 65,625.00

Source: UPL

2.3.2 Water

The water requirement for the proposed expansion shall be met from the existing GIDC water supply. No ground water is/shall be used as per Gujarat Pollution Control Board (GPCB) restriction. Total fresh water consumption after proposed Project expansion will be 4,056 m3/day, ~1,031 m3/day is existing, ~3,722 m3/day is proposed and ~695 m3/day is recyled. The details of the water requirement is provided below in Table 2.4


111

Table 2.4 Details of Water Requirement (Existing and after Proposed Expansion)

S.N.

Particulars Existing (m3/day)

Proposed (m3/day)

Total (m3/day)

Recycled Water (m3/day)

Net Fresh Water Demand (m3/day)

1 Processing & Washing 265.5 397.2 662.7 100.0 562.7 2 Boiler & Cooling 704.5 3,309.5 4,014.0 563.0 3,451.0 3 Domestic Purpose 35.0 10.0 45.0 2.4 42.6 4 Gardening 25.0 5.0 30.0 30.0 0.0 Total 1,030.5 3,721.7 4,751.7 695.4 4,056.0

Source: UPL The water balance for the proposed Project is shown below in Figure 2.42

2.3.3 Power

Total power requirement after the proposed expansion will be ~16,799 kW, out of which 6,895 kW is existing and 9,904 kW is proposed which is/will be supplied from Dakshin Gujarat Vij Company Limited (DGVCL). For power back-up an additional DG Set of capacity ~2,000 kVA is proposed along with existing three (3) nos. of capacities 1,250 kVA, 500 kVA and 2,000 kVA.


112

Figure 2.42 Water Balance for the Proposed Project

Source: UPL


113

2.3.4 Raw Materials

The raw materials required for the proposed production will be either imported or procured from domestic market and transported by road. The details of the raw materials is illustrated below in Table 2.5

Table 2.5 Raw Materials Detail for Existing and Proposed Project

S.N.

Product name

Existing Cap MTM

Tot CapAfter Expansion MTM

Raw Material Name

Consumption (kg/MT of product)

Existing Consumption MTM

Total consumption after Expansion MTM

1 Devrinol 300 400

Cetylpyridinium chloride (2CPC)

521.8 156.54 208.72

Diethanolamine (DEA)

289 86.7 115.6

Toluene 56 16.8 22.4

Caustic (48%) 596.17 178.851

238.468

Ethylenediaminetetraacetic acid (EDTA) (50%)

1.9 0.57 0.76

Napthol 523.29 156.987

209.316

2 D-Devrinol 300 300

2-Chloropropionic acid

490 147 147

Thionyl Chloride 520 156 156

Catalyst 11 3.3 3.3

Caustic solution for SO2 scrubber (17%)

2331 699.3 699.3

Diethanolamine (DEA)

340 102 102

Caustic (32%) solution

1312 393.6 393.6

Toluene 32 9.6 9.6

Alpha Naphthol 600 180 180

Isopropyl alcohol (IPA)

35.5 10.65 10.65

3 Clomazone 300 NIL

Caustic (32%) 968 290.4 --


830 249 --

Catalyst 8 2.4 --


705 211.5 --

Na2CO3 19 5.7 --


460 138 --

HCL Gas (dry) 200 60 --


114

S.N.

Product name

Existing Cap MTM


Raw Material Name




Clomazone (Proposed Route)

NIL

300

Caustic (32%) 1248 -- 374.4


915 -- 274.5

Hydroxylamine Sulphate

631 -- 189.3

Catalyst 17 -- 5.1


705 -- 211.5

Methanol 250 -- 75

Sulfuric acid (H2SO4)(98%)

241.68 -- 72.504

Thionyl chloride (SOCl2)

50.21 -- 15.063

sodium carbonate (Na2CO3)

32.27 -- 9.681

Methylene dichloride (MDC)

132 -- 39.6

Toluene 49.86 -- 14.958

4 Metobromuron 60 60

Phenyl Isocyanide 500 30 30

Hydroxylamine Sulphate

362 21.72 21.72

Sodium Hydroxide (48%)

1040 62.4 62.4

Toluene 71 4.26 4.26

Ethylene Dichloride (EDC)

30.5 1.83 1.83

Dimethyl sulfide (DMS)

525 31.5 31.5

Bromine 665 39.9 39.9

Sodium Bi-Carbonate 214 12.84 12.84

Methanol 81 4.86 4.86

5 Terbuphos 500 500

Phosphorus pentasulfide (P2S5)

462 231 231

Alcohol 497 248.5 248.5

CSLYE 32% 94.26 47.13 47.13

Triethylamine (TEA) 1.09 0.545 0.545

Fermium (FM) 347.9 173.95 173.95

Tertiary Butyl Mercatan

366 183 183

Hydrogen peroxide (H2O2)

76.71 38.355 38.355

6 Metasystox 500 500

OODMTPC (Diester) 527 263.5 263.5

Phosphorous trichloride (PCl3)

176.25 88.125 88.125

Ethyl thio Ethanol (ETE)

365.42 182.71 182.71


115

S.N.

Product name

Existing Cap MTM


Raw Material Name




Caustic 32% 512.67 256.335

256.335

Xylene 3.5 1.75 0.875

Hydrogen peroxide (H2O2)

287.49 143.745

143.745

Sulfuric acid (H2SO4) 10 5 5

Sodium bisulfite(SBS)

6 3 3

Ammonia 9.37 4.685 4.685

monochlorobenzene (MCB)

383.3 191.65 191.65

7 Acephate 1225

3000


50 61.25 150

O,O-DimethylPhosphoramidothionate (DMPAT)

1075 1316.875

3225

Dimethyl sulfide (DMS)

133 162.925

399


434 531.65 1302

Acetic Anhyd 766 938.35 2298

NH3 Solution(17%) 808 989.8 2424

Casutic (48%) for sodium acetate conversion

785.48 962.213

2356.44

Ethyl Acetate 50 61.25 150

8 Metamitron 60 60

Benzaldehyde 547 32.82 32.82

Sodium cyanide (NaCN)

494 29.64 29.64

Sodium hydroxide (NaOH 32%)

11 0.66 0.66

hydrochloric acid (HCl 30%)

1202 72.12 72.12

Toluene 136 8.16 8.16

Methanol as Raw Material

170 10.2 10.2


2422 145.32 145.32

Ammonia (NH3 17%) 247 14.82 14.82

Sodium hypochlorite (NaOCl 12%)

4012 240.72 240.72

Methyl Acetate 839 50.34 50.34

Hydrated Hydrate 644 38.64 38.64

catalyst 8 480 480

Dimethylacetamide (DMAC)

39 2.34 2.34

9 Surflan 40 40 OKS salt 1246 49.84 49.84


116

S.N.

Product name

Existing Cap MTM


Raw Material Name




Catalyst D 50 2 2

Toluene 109 4.36 4.36

Diphenylamine (DPA)

438 17.52 17.52

Sodium bicarbonate (NaHCO3)

364 14.56 14.56

Phosphoryl chloride (POCl3)

610 24.4 24.4

Acetone 30 1.2 1.2

Liq.Ammonia[17%] 812 32.48 32.48

Sulfuric acid (50%) 180 7.2 7.2

10

Azoxystrobin 100 200

2Coumaranone 358 35.8 71.6

Trimethylotho formate

96 9.6 19.2

30% Acetic anhydride

288 28.8 57.6

Methanol 112.5 11.25 22.5

Dichlorophenol (4,6 DCP)

400 40 80

Sodium Methoxide 149 14.9 29.8

Orthocyanophenol 316 31.6 63.2

Potassium carbonate 250 25 50

Dimethylformamide (DMF)

133 13.3 26.6

Toluene 44 0 8.8

Potassium hydroxide (KOH)

31 3.1 6.2

Ethyl Acetate 11 1.1 2.2

11

Ethofumesate 50 100 Ethofumisate 96%

1095.84

54.792 109.584

Sodium carbonate (Na2CO3)

2 0.1 0.01

12

Mesotrion 85 85

4-(methylsulfonyl)-2-nitro benzoic acid (MSNBA)

856 72.76 72.76

Thionyl Chloride 496 42.16 42.16

Dimethylformamide (DMF)

3 0.255 0.021675

ethylene dichloride (EDC)

193 16.405 16.405

NaOH lye (17%) for SO2 scrubber

2329 197.965

197.965

1, 3 Cycloheaxanedione (CHD)

430 36.55 36.55

Triethylamine (TEA) 30 2.55 2.55


117

S.N.

Product name

Existing Cap MTM


Raw Material Name




Triethyl Benzyl Ammonium Chloride (TEBA.Cl)

5 0.425 0.425

Acetone cyanohydrin 4 0.34 0.34

Hydrochloric acid (HCl) (7%)

3190 271.15 271.15

Methanol 52 4.42 4.42

Sodium hydroxide (NaOH lye(48%)) for TEA recovery

1105 93.925 93.925

Sodium hypochlorite (NaOCl)(8-10%) for detoxification

3100 263.5 263.5

13


85 85

4,6-dimethoxy pyrimidin-2-amine

374 31.79 --

Phenyl chlorocarbonate

390 33.15 --

N,N Dimethyl Aniline

18 1.53 --

1,4 dioxane 62 5.27 --

Sodium hydroxide (48% NaOH)

408 34.68 --


12 1.02 --

Isopropyl Alcohol 45 3.825 --

Ethyl 1-methyl 5-Sulfamoyl 1-Hpyrazole 4-carboxylate

577 49.045 --

Acetonitrile 50 4.25 --

methanol 55 4.675 --

Catalyst 2 0.17 --

Pyrazosulfuron Ethyl- Proposed

85 85


775 -- 65.875


394 -- 33.49

Toluene 114 -- 9.69

14

Monocrotophos 10 100

Monomethyl Aceto Acetamide (MMAA 71%)

720 7.2 72

Chlorine 340 3.4 34

Urea as catalyst 55 0.55 5.5

Caustic lye 32% 190 1.9 19

ethylene dichloride (EDC) as solvent

70 0.7 7

Tri methyl phosphate (TMP)

420 4.2 42


118

S.N.

Product name

Existing Cap MTM


Raw Material Name




15

2-4 D technical (2, 4- Dichloro Phenoxy Acetic Acid)

10 100

2,4-Dichlorophenol 795 7.95 79.5

Sodium Hydroxide 30% Soln.

1500 15 150

Mono Chloro Acetic Acid 80%

600 6 60

Hydrochloric acid (30% HCl)

750 7.5 75

16

Acetamiprid 10 50

Methylamine (40% CH3NH2)

384 3.84 19.2

Toluene 60 0.6 3

2-Chloro 5-chloromethyl pyridine (CCMP)

806 8.06 40.3

Ethyl N-cyano- acetimidate (ECAI)

531 5.31 26.55

Sodium hydroxide (48% NaOH)

500 5 25

17

Imidacloprid 5 Nil

Dimethyl formamide(DMF)

119.51 0.59755

--


909 4.545 --

2-Chloro 5-chloromethyl pyridine (CCMP) 65% solution in DMF

1079 5.395 --

Catalyst 6 0.03 --

Methanol 197.39 0.98695

--

Imidacloprid Nil 50

Dimethyl formamide (DMF)

104.25 -- 5.2125

Potassium carbonate 779 -- 38.95


700 -- 35

2-Chloro 5-chloromethyl pyridine (CCMP) 65% solution in DMF

763.75 -- 38.1875

Catalyst 6 -- 0.3

Acetic acid 25 -- 1.25

Methanol 70 -- 3.5

18

Metribuzin 5 Nil

Sulfur 34 0.17 --

Bromine 572 2.86 --

Methanol 163.21 0.81605

--

Sodium bisulfate 11 0.055 --


119

S.N.

Product name

Existing Cap MTM


Raw Material Name




Triazinone 1134 5.67 --

Caustic lye (48%) 446 2.23 --

2 Ethyl Hexanol 7 0.035 --

Caustic for Bromine Scrubbing (10%)

240 1.2 --

Metribuzin- New Route

Nil 5

Bromine 162 -- 0.81

Methanol 6 -- 0.03

*Methanol as Raw Material

195 -- 0.975

Sulphur 36 -- 0.18

Triazinone 1069 -- 5.345

C. S. Lye 485 -- 2.425

Sodium bisulfite (SBS)

15 -- 0.075

2-Ethyl Hexanol 7 -- 0.035

Chlorine 305 -- 1.525

19

Imazapic Technical Nil 500

Ethyl Chloro Acetate 1224 -- 612

sodium ethoxide 1409 -- 704.5

Ethanol 169 -- 84.5

Diethyl oxalate 1419 -- 709.5

Hydrochloric acid (HCl (30%))

2396 -- 1198

Methylene Dichloride (MDC)

140 -- 70

Ammonium acetate 560 -- 280

Toluene 109 -- 54.5

2% sodium bicarbonate

2498 -- 1249

formaldehyde 898 -- 449

Propanaldehyde 643 -- 321.5

Butyric acid 66 -- 33

Di-n-butyl amine 44 -- 22

Hydroquinone 1 -- 0.5

20% NaOH for scrubber

95 -- 47.5

2-Amino-2,3-dimethyl-butyramide

745 -- 372.5

Sodium hydride (NaH)

447 -- 223.5

20

Di Ethyl ThioPhosphoryl Chloride (DETCL)

50 50

Phosphorus Pentasulphide

595 29.75 29.75

Ethyl Alcohol 494 24.7 24.7

Lutidine 1 0.05 0.05


120

S.N.

Product name

Existing Cap MTM


Raw Material Name




Caustic for Scrubber 240 12 12

Chlorine 384 19.2 19.2

21

Amino Aceto Nitrile Sulphate (AANS)

160 160

Methylene Aminoacetonitrile (MAAN)

665 106.4 106.4

Sulphuric Acid 500 80 80

*Methanol as a raw material

490 78.4 78.4

Methanol as Solvent 58 9.28 9.28

Caustic flakes 90 14.4 14.4

22


160 160

Myristyl Amine 970 155.2 155.2

Hydrogen Peroxide 43.5 6.96 6.96

Citric Acid 3 0.48 0.48

Sodium Bicarbonate 2 0.32 0.32

23

Para Chloro O Cresol (PCOC)

96 96

O-Cresol 798 76.608 76.608

sulphural chloride 10 0.96 0.96

Chlorine (Cl2) 525 50.4 50.4

24

Di Methyl Phosphorus AmidoThionate (DMPAT)

110 Nil

Dimethoxytrityl chloride (DMTCL)

1218 133.98 --

Aqueous Ammonia 1698 186.78 --


100 11 --

Di Methyl Phosphorus AmidoThionate (DMPAT)- Proposed

Nil 1000

Phosphorus trichloride

931 -- 931

Sulfur 258 -- 258

Methanol 434 -- 434

48% NaOH 41 -- 41

NaOH Soln for Scrubber

80 -- 80

Ammonia 93 -- 93

Dichloromethane (MDC)

112 -- 112

25

Di Methyl MethylPhosphonate (DMMP)

100 300

Methyl iodide (CH3I Catalyst)

2 0.2 0.6

Tri methyl phosphate (TMP)

1000 100 300

26

Di Ethyl Thio Phosphoric Acid (DETA)

1000

2000 Phosphorus pentasulfide (P2S5)

596 596 1192

Alcohol 500 500 1000


121

S.N.

Product name

Existing Cap MTM


Raw Material Name




Lutidine 1 1 2

Caustic Lye (32%) 187 187 374

27

ZnDTP (Zinc Di Thio Phosphate)

1000

2000

Phosphorus pentasulfide (P2S5)

315 315 630

Secondary Butanol (SBA)

354 354 708

Methyl isobutyl carbinol (MIBC)

153.97 153.97 307.94

CSLYE 32% 72 72 144

Lube Oil 244 244 488

Zinc Oxide 121 121 242

FW14 22 22 44

Acetic Acid 1 1 2

28

Absolute Alcohol 420 420 Denatured Rectified Spirit

1071 449.82 449.82

29

Noflan 8 8

Dimethyl pimelimidate (DMP)

707.87 5.66296

5.66296

Phosphoryl chloride (PoCl3)

610.49 4.88392

4.88392

Phosphorus trichloride (PCl3)

1760.3 14.0824

14.0824

Chlorine 906.37 7.25096

7.25096

Ammonia (NH3) 382.02 3.05616

3.05616


213.48 1.70784

1.70784

Source: UPL

2.4 POLLUTION CHARACTERIZATION, SOURCES AND THEIR CONTROL

2.4.1 Air Emissions

Process emissions (H2S, NH3, HCl, HC, VOC etc.) are provided with appropriate scrubbing media for compliance. The performance of the scrubbers are also monitored periodically. UPL have added one more stage in the H2S scrubbing system of Phorate plant to meet new norms. The existing point source emissions (flue gas and process) for Unit 2 as on July 2018 are detailed below in Table 2.6 and Table 2.7 respectively. In addition, grid power will be drawn Dakshin Gujarat Vij Company Ltd. (DGVCL), and only emergency power will be generated from diesel generators.


122

Table 2.6 Details of Flue Gas Emissions (as on July 2018)

S.N. Stack attached to

Height (m) Diameter (m)

Fuel Parameters GPCB Permissible Limits

Existing Unit 2 1. Boilers

B1 (10 TPH) B2 (10 TPH) B3 (5 TPH)

30 0.9 Natural gas

/LSHS & FO

PM, SO2 and NOx

150 mg/Nm3 100 ppm 50 ppm

2. DG Set – 2 nos. (1,250 kVA and 500 kVA)

9 0.2

HSD

PM, SO2 and NOx


3. DG Set – 1 no. (2,000 kVA) 18 0.2

PM, SO2 and NOx


Proposed Expansion 4. Boilers

B4 (20 TPH) B5 (20 TPH)

55 0.9 Natural gas

/LSHS & FO

PM, SO2 and NOx


5. DG Set – 1 no. (2,000 kVA) 30 0.2 HSD

PM, SO2 and NOx


Source: UPL

Table 2.7 Details of Process Emissions

S.N. Vents attached to Height (m)

Vent Dia in mm

Air pollution Control Measures (APCM)

Parameters Permissible Limit

Existing Unit 2 1. Fume incinerator 30 1,800 Thermal

destruction PM HCl SO2 NOx

150 mg/Nm3 20 mg/Nm3 40 mg/Nm3

25 mg/Nm3 2. Scrubber for

Phosphamidon and Surflan HCL generated Reactor/DDVP/Mesotrion

30 400 Water scrubber OR two-stage Alkali scrubber

HCl Cl2 OR SO2 HCl

20 mg/Nm3 5 mg/Nm3 40 mg/Nm3 20 mg/Nm3

3. Local vent to Carbon Filter

30 150 Carbon filter H2S 5 mg/Nm3

4. H2S generating Reactor of DETCL / DETA OR ZDTP

30 450 Alkali scrubber H2S 5 mg/Nm3

5. Reactor of Devrinol Plant

30 400 Alkali scrubber HCl Cl2

20 mg/Nm3 5 mg/Nm3

6. Acephate plant process reactor OR Metamitron Mendelonitrile reactor

20 400 Water scrubber NH3

OR HCl Cl2

30 mg/Nm3 OR 20 mg/Nm3 5 mg/Nm3

7. Solid Formulation Plant stack attached to dust collector

20 150 Dust collector PM 20 mg/Nm3


123

S.N. Vents attached to Height (m)

Vent Dia in mm

Air pollution Control Measures (APCM)

Parameters Permissible Limit

8. Flaring System for DME at Noflan Plant

30 300 Flaring system PM SO2 NOx HC

150 mg/Nm3 40 mg/Nm3 25 mg/Nm3

20 mg/Nm3 9.

HCl + PCl3 / Cl2 Scrubber at Noflan Plant

30 300 Two stage scrubber (water + alkali)

HCl Cl2

20 mg/Nm3

5 mg/Nm3

10. Ammonia Scrubber at Noflan Plant

30 300 Water scrubber NH3 175 mg/Nm3

11. Acephate Plant ketene process

30 400 Water scrubber PM SO2 NOx NH3 HC

150 mg/Nm3 100 mg/Nm3 50 mg/Nm3 30 mg/Nm3 20 mg/Nm3

12. Metribuzin Plant 30 300 Caustic scrubber HC 20 mg/Nm3 Proposed (Additional) 13.

D-Devrinol Plant 30 300 Water scrubber Caustic scrubber

HCl SO2

20 mg/Nm3

40 mg/Nm3 14. Clomazone 30 300 Caustic scrubber VOC 20 mg/Nm3 15. Monocrotophos OR

DDVP(Emergency Only)

30 600 Caustic scrubber VOC 20 mg/Nm3

16. PCOC 30 300 Water scrubber HCl 20 mg/Nm3 17.

DMPAT 30 300 Water + Caustic scrubber

HCl 20 mg/Nm3

18. Imazapic 30 400 Caustic scrubber VOC 20 mg/Nm3 19.

Phosphamidon OR Surflan

30 600 Water scrubber OR 2-stage Caustic scrubber

HCl 20 mg/Nm3

20. Mesotrion 30 600

2-stage Caustic scrubber

SO2 HCl

40 mg/Nm3

20 mg/Nm3 21. DETA OR ZnDTP 30 600 Caustic scrubber H2S 5 mg/Nm3 22. Devrinol Plant 30 600 Caustic scrubber VOC 20 mg/Nm3


Figure 2.43 Scrubbers for Gaseous Emissions at Unit 2

Source: UPL


124

Fugitive emission monitoring for workplace environment, product and raw material storage areas using portable monitors for Total Mercaptan (TM), hydrogen sulphide (H2S), ammonia (NH3), and volatile organic compounds (VOCs) is carried out by internal team and external laboratory and data being maintained. The same will be extended to the proposed expansion as well. In addition, vent scrubbers have been provided for hazardous chemical storage tanks vents. The fugitive emissions from the existing plant for the period January to June 2018 is given in Table 2.8.

Table 2.8 Fugitive Emissions Monitoring (as per January - June 2018 report)

S.N. Parameters Result (ppb) 1. Ethyl Acetate (EA) BDL – 102 2. Toluene BDL – 62 3. Total Mercaptan (TM) BDL – 52 4. Ethylene Di-Chloride (EDC) BDL – 21 5. Hydrogen Sulphide (H2S) 4 – 48 6. Ammonia (NH3) BDL - 82

Source: UPL; BDL – Below Detection Limit; DL – Detection Limit; DL – 1 ppb for all parameters

For chlorine, ammonia and hydrogen sulphide, continuous monitors are provided at the existing plant site. For odour control, vapour incinerator has been installed. For H2S, a three (3) stage scrubber have been installed.

2.4.2 Solid Waste Management

Various categories of solid waste (both hazardous and non-hazardous) are generated at different stages of pesticide technical and intermediate stages manufacturing processes. UPL is generating three (3) types of solid wastes; (1) ETP sludge, (2) salt from evaporation system and (3) solid waste from Ammonium Acetate in house processing All these solid wastes are being disposed off at the secured landfill facility operated by Bharuch Enviro Infrastructure Ltd (BEIL) at Ankleshwar. The Company is internally processing ammonium acetate at UPL Jhagadia Unit to recover acetic acid / sodium acetate / ammonium acetate. The generated wastes are sent to BEIL Ankleshwar. Hazardous waste storage area has been constructed as per Central Pollution Control Board (CPCB) guidelines. The collection, storage and disposal from the proposed solid wastes – hazardous, non-hazardous, municipal wastes are and will be carried out as per Hazardous & Other Wastes (Management and Transboundary Movement) Rules, 2016. All the wastes are segregated at the source of generation and shall be disposed in the legally acceptable manner. The details of the solid waste management shall be as below: The discarded drums are detoxified by using water/caustic/Hypo and will

be sold to scrap processors. The contaminated drums will be sent to Treatment, Storage and Disposal Facility (TSDF) – BEIL Dahej for decontamination and disposal.

Used oil shall be sold to CPCB/GPCB authorized recycler / re-processor.


125

Effluent treatment plant (ETP) sludge; Multi effect evaporator (MEE) salts shall be sent to TSDF site at BEIL, Ankleshwar for final disposal.

Organic waste / distillation residue, aqueous waste, off specification product / date expired product, is/will be sent to common incineration site; or organic waste sent to cement Industry for co-processing.

After expansion, total landfilling waste generation will be 3,151 metric tons per month (MTM) (Existing: 1,034 MTM + Proposed: 2,117 MTM) which will be sent to BEIL, Ankleshwar for landfilling.

After expansion, the incineration waste generation will be 3,404 MTM (Existing: 1,437.77 MTM + Proposed: 1,966.25 MTM) which will be sent for co-processing first and remaining quantity will be sent to BEIL, Ankleshwar for incineration.

Figure 2.44 Hazardous Waste Storage Facility as per MoEF/CPCB Guidelines at Unit 2

Source: UPL

2.4.3 Wastewater Management

The existing wastewater generated from process, boiler, cooling tower, domestic etc. is being treated in existing effluent treatment plant (ETP) of capacity 550 m3/day. The treated water is then sent to reverse osmosis (RO) system from which the reject from RO is sent for forced evaporation while the permeate is being recycled back in to the process/cooling tower/plantation. The unit is Zero Liquid Discharge (ZLD) since May-2014 and will continue as ZLD for the proposed expansion. The schematic of ZLD is shown below in Figure 2.45


126

Figure 2.45 Schematic of Zero Liquid Discharge (ZLD) from Unit 2

Source: UPL The details of the wastewater generated from the existing plant and post expansion is given below in Table 2.9

Table 2.9 Details of Wastewater Generation (Existing and after Proposed Expansion)

S.N. Source Existing (m3/day)

Proposed(m3/day)

Total (m3/day)

Mode of Treatment

1 Process effluent 207 118 324 In existing ETP of capacity 550 m3/day followed by RO & MEE

2 Boiler and cooling tower blowdown

278 21 299 In RO system for recycling

3 Domestic effluent 28 8 36 In STP having capacity of 40 m3/d 4 MEE condensate 0 170 170 Will be recycled back TOTAL 513 317 829

Source: UPL Although the existing Unit 2 operates as a ZLD plant, GPCB has given certain relaxation for ZLD conditions under Section 3 of The Water Act in the Consent letter (and included as Annex L). Some of these are as below: No # 1: Unit 2 shall incorporate water recycling system for recovering or

recycling of effluent, hence unit shall strictly adhere to ZLD. It shall keep the discharge to the GIDC conveyance system blocked.

No # 6: The treated effluent confirming to the inlet standard of final effluent treatment plant (FETP) shall be discharge only after getting permission of GPCB when Ankleshwar comes out of critically polluted region.

No # 7: The unit shall operate as Zero Discharge unit; Unit may be permitted to retain the permissible effluent quantity as reserve and allowed to discharge the same as per prevalent Board policy.

2.4.3.1 Existing Effluent Treatment Plant (ETP)

The existing ETP of capacity 550 m3/day is adequate for treatment of effluent from the operational plant. The dilute waste streams generated from the process, utilities covering blow downs of cooling towers and boilers and waste


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from softening plant and domestic sewage are treated. The ETP covers the primary, secondary and tertiary treatment systems, as described below: In the primary treatment, the equalized raw effluent neutralized with lime

and flocculent is added. The clear overflow from the primary clarifier is taken to the secondary treatment. The sludge from clarifier bottom is taken to filter press for sludge dewatering. Generated sludge is being sent to common TSDF at BEIL, Ankleshwar.

The unit has also provided a chemical treatment section where small quantity of certain stream containing high chemical oxygen demand (COD) and biological oxygen demand (BOD) can be treated chemically, so that further treatment is possible in the effluent treatment plant. In the chemical treatment section, effluent streams containing more than 5,000 mg/l COD are taken and treated with hydrogen peroxide. After bringing down the COD level to less than 3,000 mg/l, the effluent is taken to the equalization tank of effluent treatment Plant for further treatment along with the normal streams.

In the secondary treatment three (03) aeration tanks are provided in series. In aeration tank mixed liquor suspended solids (MLSS) in the range of 3,000 – 5,000 mg/l is maintained with mixed liquor volatile suspended solids (MLVSS) / MLSS ratio of approximately 0.6. The treated effluent coming out of the secondary treatment is collected in the sump and passed through activated carbon filter. Treated effluent is collected in a tank and taken to water re-cycling system. The permeate of RO is being recycled back in to process/cooling tower and reject is being sent to single stage evaporation.

The high TDS effluent stream is taken for evaporation. There is small quantity of high COD stream which is taken for chemical treatment. In the Unit, some quantity of aqueous effluent is generated which is having high COD and high TDS and is containing trace pesticides. This stream is sent for incineration at BEIL.

The treated effluent is finally sent to the 400 m3/day capacity Guard pond. The photograph of existing ETP and its schematic is provided below in Figure 2.46 and Figure 2.47


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Figure 2.46 Effluent Treatment Plant (ETP) at Unit 2

Source: UPL


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Figure 2.47 Schematic of ETP

Source: UPL

Existing RO Plant Process Description

Treated effluent from ETP is pumped to receiving cum pH adjustment tank at a uniform rate. As per effluent feed parameters, pre-treatment is required to treat effluent for removal of organic matter, oil & grease& suspended solids before feed to RO system. For pre-treatment, chemical dosing, settling, precipitation of impurities followed by filtration & chlorination enhance life of RO membrane significantly. The photograph of RO Plant is shown below in Figure 2.48.


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Figure 2.48 Existing RO Plant at Unit 2

Source: UPL Chemical dosing of ferrous sulphate at an acidic pH is carried out to take care of COD shock load expected rarely. pH is lowered by addition of HCl in the effluent stream and pH is again elevated to 8-9 by addition of NaOH, for removal of reactive silica by addition of magnesium sulphate/dolomite. For conversion to iron sulphate effluent is aerated by means of blower air. Chemically treated & aerated effluent is fed to tube settler to clarify the precipitate formed during chemical dosage & coagulation with MgSO4 solution. Tube settler unit is provided with hopper bottom & from here, separated & settled sludge is periodically withdrawn to sludge sump under hydrostatic pressure. Clarified effluent shall then be collected into filter feed sump from where it is fed to activated carbon filter with filter feed /backwash pumps. One pump is used during filtration mode and both pumps are used during backwash mode. Activated carbon filter is removing organic matter by carbon adsorption process and removing suspended solids by filtration. Backwashing is done by same feed water. Dirty backwash water from backwash cycle is collected in sludge sump. Filtered water is fed to chlorine contact tank with NaOCl solution dosing for disinfection. Tank is provided with baffle wall for mixing. Disinfected water is collected to treated water collection tank. Filtered &chlorinated effluent is pumped to Micro-filter (MF) for removal of very fine particles before it fed to RO system. Filtered water from MF system is collected at MF permeate collection tank. Same permeate water is used for cleaning of MF system. Necessary pumping arrangement and clean in place (CIP) system with chemical injection points are provided. MF permeate is pumped to proposed RO system. There are two streams of RO system, each designed to handle 100 m3/day flow. For this, dedicated feed pump to feed MF permeate to micro-cartridge filter (MCF) of each stream is


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provided. MCF pumps are variable frequency driven (VFD). Sodium Metabisulphite (SMBS) dosing for removal of residual chlorine are provided before cartridge filter. The RO system is designed with closed circuit desalinization (CCD) technology having single stage RO and having maximum permeate recovery with lowest possible total dissolved solids (TDS) in permeate. Filtrate out from MCF is then be feed to RO system through high pressure (HP) pump. Before high pressure pump, feed pH is adjusted and anti-scalant is dosed. There are two independent RO streams each comprising dedicated MCF, high pressure pump, circulation pump as well as dedicated acid & anti-scalant dosing pump and control panel. RO Permeate from each stream is fed to degassing arrangement for removal of acidity and collected at permeate holding tank. Permeate pumps are provided near the permeate tank. As described above, dirty backwash water from activated carbon filter (ACF) under pressure, wastewater from MF and settled sludge from Tube-settler bottom under hydrostatic pressure are collected at sludge cum backwash water collection sump. Accumulated sludge is pumped to existing sludge handling section of ETP. Chemical wastewater from MF and RO system is diverted to drain pit. Whereas RO reject / brine water from proposed CCD-RO skid is fed to reject sump. Chemicals dosing facilities for chemicals required for pre-treatment and RO section are located nearby system. Proposed ETP Scheme

No expansion in the existing ETP capacity (550 m3/day) is required as after the proposed expansion, total 324 m3/day of effluent will be generated from the process which will be fed to existing ETP system. The treated effluent will be sent to the RO system followed by RO reject to Multiple Effect Evaporator (MEE). Kindly refer Figure 2.42 and Table 2.9 for further details. The generated condensate (170 m3/day) from MEE plant will be recycled back in to process/utility. Proposed RO System

The capacity of the existing RO system will be upgraded from 100 m3/day to 750 m3/day by addition of 650 m3/day additional capacity. The treated effluent from ETP (324 m3/day) will be sent to the RO system (750 m3/day). The boiler & cooling tower blow down (299 m3/day) will be sent to RO system (750 m3/day) directly along with ETP treated water. The RO permeate will be recycled back to process/utility. Kindly refer Figure 2.42 and Table 2.9 for further details.


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Proposed MEE System

The high TDS effluent from process & RO reject will be sent to MEE having a capacity of 450 m3/day. The salt /solid generated from the MEE shall be sent to common TSDF facility at BEIL, Ankleshwar. MEE feed parameters are as follows:

Parameter MEE Feed Water Characteristics pH 6.5 to 8.5 TDS 10% TSS 200 mg/l COD 2,000 mg/l Chloride/Sulphates 8% Low Volatile Negligible High Volatile 0.2% Ammoniacal Nitrogen 50 mg/l

Proposed Sewage Treatment Plant

A new sewage treatment plant (STP) of capacity 40 m3/day is proposed to be installed for the expansion project based on activated sludge process as shown below in . The sewage collected from the various streams is taken into a septic tank where it undergoes an anaerobic treatment. From there the sewage is taken into aeration tank where it is treated with the help of aerobic bacteria and then it is passed to settling tank. From settling tank the mixed liquor is allowed to set and the supernatant liquid is overflowed into the holding tank. The water in the holding tank is passed through a dual media filter (DMF) and is taken in treated water collection tank. From where it is pumped for gardening and drum washing etc.

Figure 2.49 Schematic of Proposed STP

Source: UPL


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The domestic effluent (Existing: 28 m3/d + Proposed: 8 m3/d; Total: 36 m3/d) from the proposed expansion will be sent to the proposed STP (capacity @ 40 m3/d) and treated sewage water will be utilized for gardening.

2.4.4 Hazardous Chemicals Management

The hazardous chemicals within Unit 2 are stored as per the prescribed guidelines and provisions under Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 2000. These rules apply to the activities, which involve handling, storage and import of hazardous chemicals as specified in Part 2 of Schedule 1 of the Rules. Refer Table 2.11 for details of chemical consumption for the pesticide technical and intermediate grade for the proposed capacity augmentation. The storage tanks are kept under negative pressure to avoid any leakages. Nitrogen blanketing has been provided for chemicals such as Ethyl Mercaptan, Tertiary Butyl Mercaptan storage etc. The vents from these storages are connected to fume incinerator. Closed handling system is followed for all hazardous chemicals. Pumps are provided with mechanical seals. For certain chemicals like Ethyl Mercaptan and seal-less pumps (magnetic pumps). Solvent traps are provided and chilled brine condensers are in operation.

Figure 2.50 Snapshot of Hazardous Chemical Storage

Source: UPL Most of these chemicals are procured from domestic or global suppliers through competitive bidding process. Necessary approvals have been obtained by UPL Limited Unit 2 from Petroleum Explosives Safety Organization (PESO) for the storage and handling of Class A, B and C chemicals within the site as given below in Table 2.10


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Table 2.10 PESO Licenses Details

S.N. Consent Description License No. Expiry Date

Class A (in KL)

Class B (in KL)

Class C (in KL)

1. Methanol and Toluene P/HQ/GJ/15/1042(P10593)

31.12.2018 (applied for renewal)

150 - - 2. High Speed Diesel (HSD) - 40 - 3. Furnace Oil (FO) - - 40

4. Sodium Hydroxide 322/756/304/2018

31.12.2018 (applied for renewal)

- 40 - 5. Recovered Methanol (50%) - 40 - 6. Fresh Methanol - - 50

Source: UPL The Chemical Management Services will be extended for procuring the chemicals for the proposed expansion project. The following requirements for storage, handling and management of hazardous chemicals/materials at Unit 2 as per MSIHC Rules, 2000 shall be further strengthened: Classification and Labelling - Under the MSIHC Rules, UPL shall be

responsible to classify and properly label all the hazardous substances being handled at its factory premises. The classification codes used for labelling purpose should include corrosive, explosive, reactive, flammable or toxic;

Safety Audit and its Reporting – UPL should undertake safety audit at least once in a year and comply to the requirements of MSIHC Rules, 2000;

Labeling of Drums Containing Chemicals - Adequate labeling of containers and display of signs showing the hazards associated with the chemicals and the need for PPE per the MSIHC Rules, 2000, as amended.

Secondary Containment - UPL shall ensure that storage of chemicals are properly maintained with impervious flooring surface within the warehouse or stored in a spill containment system of sufficient capacity.

Storage of Petroleum in Bulk – Ensure compliance with all the license conditions such as capacity of enclosures to the tank farms is as per the license conditions, permanent marking of direction for opening and shutting of each valve, changes in the contents of the tanks are informed to the department and requisite permission/NOC is obtained.

Storage of Petroleum in Quantities which are not in Bulk – For other chemicals whose on-site storage exceed the threshold, UPL shall ensure that either the quantity can be reduced below the threshold requiring license or obtain a license to store otherwise, as appropriate.

Accident Reporting Procedure (Rule 5 - Notification of Major Accidents) - Where a major accident occurs within the factory premises, the occupier shall (within 48 hours notify) the concerned authority as identified in Schedule 5, of that accident, and furnish thereafter to the concerned authority a report relating to the accidents in installments, if necessary, in Schedule 6.

Display of material safety data sheet (MSDS) – UPL shall display all the MSDS of the new chemicals at the storage and handling locations and provide training to the people involved in handling these as well.

Update of Onsite Emergency Response and Disaster Management Plan – UPL shall appropriately include specific requirements with respect to


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handling of the proposed new chemicals and update their emergency response and disaster management plans. UPL shall also plan to conduct periodic mock drill regarding chemical spillage and related possible incidents.

The hazardous chemicals storage details is shown below in Table 2.11

Table 2.11 Hazardous Chemicals Storage Details

S.N. Hazardous Chemical Name

Physical State

Storage mode

Existing Storage Capacity (KL/MT)

Proposed Storage Capacity (KL/MT)

Maximum storage capacity after Expansion

1. Toluene Liquid Tank 50 0 50 2. Caustic (48%) Liquid Tank 50 250 300

Caustic (32%) Liquid Tank 40 50 180 Caustic (32%)-

Clomazone Liquid Tank 40 50

Caustic (30%) Liquid Tank 20 0 20 Caustic (20%) Liquid Tank 10 0 10

3. Thionyl chloride (SOCl2)

Liquid Drums 15 35 50

4. Isopropyl alcohol (IPA)

Liquid Drums 5 0 5

5. Methanol Liquid Tank 50 20 70 6. Sulphuric Acid

(H2SO4-98%) Liquid Tank 15 165 180

7. Ethylene Dichloride (EDC)

Liquid Tank 20 0 20

8. Bromine Liquid

Glass Line Tank

NIL 5 5

9. Triethylamine (TEA)

Liquid Drums NIL 1 1

10. Hydrogen peroxide (H2O2)

Liquid Carbouys NIL 30 30

11. Ethyl Mercaptan Liquid Tank 40 0 40 12. Ammonia Gas Cylinder 5 Cylinders 10 Cylinders 10

Ammonia (30%) Liquid Tank 40 220 260 13. Acetic Anhydride Liquid Tank 100 270 370

Acetic Anhydride (30%)


14. Ethyl Acetate Liquid Tank 20 20 40 15. Sodium cyanide

(NaCN) Solid Drums NIL 4 4

16. Chlorine Liquid Tonner NIL 5 5 17. Monochlorobenze

ne (MCB) Liquid Drums 1 29 30

18. Phosphorous Oxy chloride (POCl3)

Liquid Tank NIL 10 10

19. Acetone Liquid Drums 0 2 2 20. Acetone

cyanohydrin Liquid Carbouys 0 1 1

21. 2,4-Dichlorophenol


22. Methylamine (40% CH3NH2)

Liquid Drums 3 0 3


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S.N. Hazardous Chemical Name

Physical State

Storage mode

Existing Storage Capacity (KL/MT)

Proposed Storage Capacity (KL/MT)

Maximum storage capacity after Expansion

23. Acetic acid Liquid

Carbouys/Drums

2 0 2

24. Ethanol (Absolute Alcohol)

Liquid Tank 50 150 200

25. Formaldehyde Liquid Tank 40 10 50 26. Hydroquinone Liquid Drums 0.2 0 0.2 27. O-CRESOL Liquid Drums 0 10 10 28. Phosphorus

Trichloride Liquid Tank 8 102 110

29. High Speed Diesel Liquid Tank 40 0 40 30. Furnace Oil Liquid Tank 40 20 60 31. Terbuphos Liquid Drums 40 0 40 32. Monocrotophos Liquid Drums 10 40 50 33. Methyl Chloride

(MeCL) Liquid Tonner NIL 24 Cylinder 24 Cylinder

Source: UPL

2.4.5 Water Conservation Measures

Rain Water Harvesting Structures at Unit 2 The rainwater harvesting system consists of collection of rainwater from the total surface area of approximately 1,400 m2. The total rainwater collection (considering 24” rainfall) comes to 840 m3 in a year. The collected rainwater is used in cooling tower make up. Also, part of the rain water collected is taken to storage tanks. The storage tank capacity is 650 m3. The implementation of rainwater harvesting at Unit 2 is shown below in Figure 2.51


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Figure 2.51 Implementation of Rooftop Rainwater Harvesting at Unit 2

Source: UPL


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2.4.6 Solvent Recovery Management

UPL Unit 2 has solvent recovery internally integrated with manufacturing process. The solvents namely ethylene di chloride (EDC), methyl chlorobenzene (MCB) and ethyl acetate are recovered during process with average monthly recovery of more than 90%. However, since none of the products which require EDC or MCB as solvent are produced in the period of January-June 2018, EDC or MCB recovery is currently not in operation. The details of solvent recovery is as follows: Unit 2 has installed primary & secondary condensation. The unit has supplied chilled water at primary stage for condensation of

solvents and chilled brine for secondary condensation. Unit 2 has proper monitoring of solvent recovery and generation of VOCs. Organic residue from distillation system after recovery of solvent is sent for

incineration at BEIL, Ankleshwar. The solvent recovery is more than 95% and trying to improve further. As cleaner production technique, the recovery of by-products from the

waste stream such as dilute acetic acid and sodium acetate from Acephate plant is implemented.

Unit has provided fume incinerator for thermal destruction of odorous compounds.

Implemented leak detection system and repair of pump/pipeline based on preventive maintenance with Integration with SAP.

Solvent management shall be as follows: Reactor shall be connected to chilled brine condenser system Reactor and solvent handling pump shall have mechanical seals to prevent

leakages The condensers shall be provided with sufficient HTA and residence time

so as to achieve more than 95% recovery Solvents shall be stored in a separate space specified with all safety

measures Proper earthing shall be provided in all the electrical equipment wherever

solvent handling is done Entire plant shall be flameproof. The solvent storage tanks shall be provided

with breather valve to prevent losses. Please refer Annex N for action plan for solvent consumption reduction as submitted to MoEF&CC and its status of compliance.

2.5 GREENBELT DEVELOPMENT

Greenbelt is developed for containment of air pollution in the environment, especially in industrial zone. UPL has developed greenbelt as an integral part of development of its facilities. Till date ~13,911.58 m2 (21.19%) out of total area of 65,625 m2 of Unit 2 area is developed as green belt and additional greenbelt area of 315 m2 is proposed for the expansion Project. The additional area is identified within existing GIDC area and the unit has signed agreement with


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GIDC for development and maintenance of green belt. During 2017-18, ~2,250 of native trees have been planted. The greenbelt development at the Plant is shown below in Figure 2.52 and the existing list of dominant species planted at Plant in Figure 2.52

Figure 2.52 Greenbelt Development at Unit 2

Source: UPL

Table 2.12 Plantation at Unit 2

S.N. Local Name Scientific Name 1 Gulmohor Delonix regia 2 Indian Badam Terminalia catappa 3 Mango Mangifera indica 4 Karan Millettia pinnata 5 Ashok Polyalthia longifolia 6 Banyan Ficus benghalensis 7 Peepal Ficus religiosa 8 Jamun Syzygium cumini 9 Neem Azadirachta indica 10 Bottle Palm Hyophorbe lagenicaulis

Source: UPL In addition, the unit has signed agreement for development of 45 acres (182,108.54 m2) of land for greenbelt development from ~3 km distance at survey no 611/613/614/615 & 616 located at village – Mandva as shown below in Figure 2.53. The cost of this development is ~INR 64.0 lakh.


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Figure 2.53 Additional Greenbelt Development by UPL Unit 2

Source: UPL

2.6 LITIGATION DETAILS

At Hon’ble Supreme Court, one matter is ‘Pending’ with respect to post-facto Environmental Clearance obtained by the Unit in 2003. Hon’ble Supreme Court has stayed NGT Order. The case number at Hon’ble Supreme Court is “Civil Appeal No. 003175/2016” registered on 29.03.2016.

2.7 REGULATORY FRAMEWORK

UPL Unit 2 has obtained two Environmental Clearances (EC) for manufacturing of Pesticides technical, intermediate products as follows:

GPS Location of Site

Before Clearing After Clearing

Planting of Trees Current Status of Greenbelt


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Table 2.13 Environmental Clearance (EC) Details

S.N. MoEF&CC File No. Issue Date EC Details 1 J-11011/77/2002-IA II 17th July,

2003 Manufacture of the following pesticides: 1. Phorate / Turbophos – 3,600 TPA 2. Acephate – 960 TPA

The land area for the project was 65,625 m2 The project does not involve forestland and

displacement of people. Water requirement was 340.1 m3/day from

GIDC Solid waste –

ETP sludge – 7.5 MTPM; Incinerator ash – 9.0 TPM and Inorganic salts from evaporation system – 30 TPM disposed off in common secured landfill.

2 J-11011/1281/2007-IA (II) 15th April, 2008

Expansion of the following: 1. Pesticides – from 685 to 2,235 MTM (max.) 2. Intermediate chemicals – 1386 to 1,894 MTM

(max.) 3. Pesticide formulation – 60 MTM 4. By-products – 928.2 to 1,281.25 MTM (max.)

The land area for the project was 65,625 m2 The project does not involve forestland and

displacement of people. Water requirement was 1,043 m3/day from

GIDC. The wastewater to be treated into an ETP of capacity 550 m3/d.

Stack height with all the reactors, incinerators and boilers shall be 30 m.

Source: UPL UPL obtained separate Consent to Establish (CTE), Consent to Operate (CTO) and Hazardous Waste Authorization (HWA) from GPCB. The first No Objection Certificate (NOC) from GPCB was granted for 300MTPM of Phorate (Tech)/Turbophos (Tech) on 17th November, 1995 and 80 MTPM of Acephate on 2nd April, 1996. Recently, UPL was issued the Consolidated Consent and Authorization (CC&A) from GPCB vide CC & A No AWH-85575 dated 27/4/2017 valid till 2/8/2018. The Unit has applied to Gujarat Pollution Control Board before expiry of consent vide inward no 141314 dated 04/07/2018. The renewal is pending with GPCB. All the Consent Orders and Authorization were issued by GPCB Bharuch office based on the site visit report of the Regional officer at Bharuch district of Gujarat. The copy of status of latest CC & A and copy of CCA renewal application is included as Annex L. The UPL Unit 2 has obtained additional water quantity of 3,722 m3/d from Notified Area Office Ankleshwar vide letter no NTA/ANK/DEE(WS)/1781 dated 29/10/2018. The copy of letter is attached as Annex K.


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UPL Unit 2 plant is operated under the compliance of applicable environmental acts, rules & regulations, which have been formulated and amended time to

time as given below in Table 2.14

Table 2.14 Applicable Regulatory Framework UPL Unit 2

Sn. Activity Aspects Compliance of Regulations 1. Manufacturing/

operational Boiler Process unit Cooling

tower D.G. Set

Gaseous emission

Factory License The Factories Act, 1948 and the Gujarat

Factories Rules, 1963 The Water (Prevention and Control of

Pollution) Act, 1974 and Rules, 1975, as amended to date.

The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982, as amended to date.

The Noise Pollution (Regulation & Control) (Amendment) Rules, 2010

Noise Water Pollution

The Manufacture, Storage and Import of Hazardous Chemicals Rules, 2000 (as amended).

The Indian Boiler Act, 1923 & Rules Bureau of Indian Standards (IS) The Environment Impact Assessment

Notification, dated 14th September 2006, as amended on 1st December 2009.

The Environment (Protection) Act & Rules 1986 as amended

The Hazardous & Other Wastes (Management & Trans-Boundary Movement) Rules 2016

The E-Waste (Management) Rules, 2016 The Plastic Waste Management Rules, 2016 The Construction and Demolition Waste

Management Rules, 2016 2. Storage of

product and raw material

Dust Generation



The Explosive Act, 1884 and rules, 1983 amended to date

The Petroleum Act, 1934 & Rules, 2002 Chemical Accidents (Emergency Planning,

Preparedness and Response) Rules, 1996. The Public Liability Insurance Act, 1991 and

Rules, 1991 as amended to date.

Gaseous Emission Noise Accidents

3. Transportation of raw material and products

Dust Generation

Chemical Accidents (Emergency Planning, preparedness and response) Rules, 1996

The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982, as amended to date

The Motor Vehicles Act, 1988 & The Central Motor Vehicle rules, 1989

The Environment (Protection) Act, 1986 and Rules, 1986, as amended to date

Noise Pollution (Regulation and Control) (Amendment) Rules, 2010.

Gaseous Emission Noise Accidents


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Sn. Activity Aspects Compliance of Regulations 4. Treatment

Technology ETP MEE STP Scrubber

Sludge generation

VOC Generation

The Water (Prevention and Control of Pollution) Cess Act, 1977 and Rules, 1978, as amended to date.



The Hazardous and Other Wastes (Management and Transboundary Movement) Rules, as amended in 2016

The Environment Protection Act 1986 & Rules made under.

5. Recruitment / Labour Welfare

Social The Factories Act, 1948 and Rules 1963

The Employment Relations Amendment Act 2016

The Employees Provident Funds and Miscellaneous Provisions Act, 1952

The Companies Act, 2013 and Rules 2014 (on CSR provisions).

The copies of the ECs and CC&As are included in Annex A and Annex L. The latest EC Compliance Report for the period January to June 2018 for previous ECs and compliance to latest CC&A is included in Annex B and Annex C.

2.8 PROJECT SCHEDULE AND COST

The proposed expansion Project will be implemented in a phased manner. The expansion Project will start execution after obtaining all the necessary approvals. The tentative plan to start the Project will be from the Financial Year 2019 – 2020. The total Project cost is estimated INR 445.89 Crores as per the details given in Table 2.15.

Table 2.15 Details of Estimated Project Cost

S.N. Description Cost (INR in Crores 1 Equipment Cost 206.46 2 Piping Cost 32.59 3 Electrical Cost 12.86 4 Instrumentation Cost 17.16 5 Civil & structure Cost 54.04 6 Insulation Cost 4.34 7 Painting Cost 2.20 8 Safety Equipment Cost 2.29 9 Utility Cost 42.25 10 Miscellaneous Cost ( HAZOP, Service) 45.67 11 Cost of Environment Management System (APCM, Waste

Management cost, RO, MEE, MeCL recovery plant, STP) 26.02

TOTAL 445.89

Source: UPL


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3 DESCRIPTION OF THE ENVIRONMENT

3.1 OVERVIEW

This section outlines the baseline of the physical, biological and socio-economic conditions prevailing within the study area of 10 km radius from the existing UPL Unit 2 plant premises. The baseline information has been collected through primary and secondary sources with specific reference to project aspects which may influence the surrounding environment from the proposed expansion activitiesand as covered in ToR issued by MoEF&CC. The methodology adopted for baseline information collection covers the following: Stakeholder consultations with local people, government departments; and Review of published documents and literature on the environmental and

social aspects of study area.

3.2 BASELINE – PHYSICAL ENVIRONMENT

3.2.1 Topography

The topography of the Ankleshwar and sourrounding area is relatively flat terrain with series of deeply incised creeks of Narmada River. There are generally levee deposits on the bank of river. The project site is located at ~7 km from Narmada River in south-west direction. The terrain is relatively flat with gentle slope towards Arabian sea. The topography of the study area is shown in Figure 3.1.

ERM EIA STUDY FOR THE PROPOSED EXPANSION IN EXISTING CAPACITY OF UNIT 2, ANKLESHWAR GIDC, ANKLESHWAR PROJECT # 0426521 BY UPL LIMITED, JANUARY 19

145

Figure 3.1 Topography of Study Area


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3.2.2 Geology and Hydrogeology

The predominant geological formations in Bharuch District are Deccan Trap, Sandstone and Alluvium. The study area falls under alluvial plain. The alluvial plain, which is nearly flat, constitutes a huge pile of alluvium, deposited during the Holocene and Pleistocene times. Narmada flood plain has conspicuous recent disposition of its own. The hydrogeology of Bharuch District as reported by the Central Ground Water Board (CGWB) presents a complex hydrogeological pattern. It comprises of hard rocks, the semi-consolidated Cretaceous, and Tertiary formations and unconsolidated alluvial deposits, all comprise multi – aquifer systems thereby presenting unconfined as well as confined groundwater conditions in the entire district. Tertiary formations, are inherently saline and contain poor quality of groundwater. Groundwater occurs under unconfined conditions in the limestone and sandstone aquifers of Bagh beds. Occurrence and movement of groundwater is restricted mainly to the fractures and joints in the limestones and sandstones. The bagh beds, where overlain by Deccan Trap are likely to yield groundwater under confined conditions. The alluvium formations in the western most part of the area (close to our study area) do not constitute potential aquifers on account of inferior quality of water. The hydrogeological map of Bharuch district is shown below in Figure 3.2. Ankleshwar Taluka located in the southern part of the Bharuch district has soft rock aquifer formation suitable for dug well with 10m to 25 m depth as well as tubewells with depth of 50m to 100m depth. Dugwells in the study area tapped to around 10 m to 25 m below ground level (bgl) are capable of yielding 200 to 300 litres per minute (LPM). Tubewells tapping deeper down to 50 m to 100 m below ground level (bgl) yields around 400 to 600 LPM. (1) The premonsoon depth to water level by Gujarat Water Resources Development Corporation Ltd. (GWRDC) (as per data collected in 2016) indicates shallow water level i.e., less than 5 m below ground level (bgl) while the post-monsoon levels during the same year indicated an average rise of ~2m over the premonsoon levels from monsoon rainfall of 707 mm during the year in the study area. The premonsoon and postmonsson depth to water levels of the district is shown below in Figure 3.3

(1) Groundwater Brochure, Bharuch District as published by Government of India, Ministry of Water Resources Central

Ground Water Board West Central Region Ahmedabad, March 2014


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Figure 3.2 Hydrogeological Map: District Bharuch

Source: Groundwater brochure Bharuch District, March 2014 by CGWB

Unit 2


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Figure 3.3 Depth to Water Levels of Bharuch District as per CGWB

Source: http://www.gwrdc.gujarat.gov.in/maps.htm

Unit 2 Unit 2


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3.2.3 Meteorology

Bharuch District witnesses semi arid climate. Extreme temperatures, erratic rainfall and high evaporation are the characteristic features of this type of climet. The annual average minimum temperature is 20.7 °C and annual average maximum temperature is 34.7 °C. The annual average rainfall during the years 2003 to 2012 was about 707 mm. The climatic condition of area sourrounding the Unit 2 is being analysed using the meteorological data of nearest India Meteorological Department (IMD) weather station at Bharuch as shown below in Table 3.1.

Table 3.1 Climatological Data of Bharuch IMD Station (1951 - 1980)

Month Max. Temp. (°C)

Min. Temp. (°C)

Humidity (%)

Sunshine (hours)

Rainfall (mm)

Wind Speed (kmph)

January 31.3 11.9 51.5 9.0 1.2 5.9 February 33.8 14.4 45.0 9.2 1.0 6.2 March 37.6 19.0 44.0 9.8 0.8 7.0 April 40.0 23.3 45.0 10.4 1.0 8.8 May 39.6 26.2 55.5 10.8 12.5 12.4 June 35.6 26.5 69.5 7.6 121.0 14.7 July 32.0 25.5 81.0 4.4 307.6 13.2 August 31.2 25.0 83.5 4.2 243.1 11.5 September 32.6 24.4 76.0 6.3 197.6 8.6 October 35.9 22.0 59.5 7.9 35.2 5.7 November 34.8 16.9 52.5 8.0 3.7 4.7 December 32.2 13.2 53.5 8.9 0.1 5.2 Average 34.7 20.7 59.7 8.0 - 8.6

Source: Groundwater Brochure Bharuch District, March 2014

As per the above table, the maximum temperature is 40.0 °C (Jun) while the minimum temperature is 11.9 (Jan.). The humidity varies in the region from 44% in March to 83.5% in August while the wind speed varies from 4.7 kmph in n 14.7 kmph in June. The total rainfall during the period was 924.8 mm. Project Specific - Project specific micro-meteorological data has been collected for the study period (from 26 February 2018 to 21 May 2018), using an automatic weather monitoring station. The automatic weather monitoring station was installed at UPL Unit 2 Site Ankleshwar (21°37’39.46”N 73°02’04.06”E) at a height of about 10 m above the ground level, ensuring that there were no obstructions to the free flow of winds. The summary of the recorded data is provided below in presented below in Table 3.2.

Table 3.2 Summary of Meteorological Conditions in the Study Area

Parameters Feb-2018

Mar-2018 Apr-2018 May-2018 Period (end Feb.-May)

Temperature (°C) Maximum 38.6 41.0 43.0 43.0 43.0 Minimum 22.4 21.1 24.9 28.4 21.1 Average 31.1 30.2 34.4 36.9 33.1

Relative Humidity (%)

Maximum 59.4 92.9 98.5 86.5 98.5 Minimum 19.7 13.1 9.0 11.0 9.0 Average 38.0 41.5 48.0 37.3 41.2


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Parameters Feb-2018

Mar-2018 Apr-2018 May-2018 Period (end Feb.-May)

Wind Speed (m/s)

Maximum 5.6 7.7 8.6 10.0 10.0 Minimum 0.0 0.0 0.3 0.3 0.0 Average 3.2 3.4 4.1 4.9 3.9

Wind Direction Predominant WD

W NW & NNE

SW, WSW & WNW

SSW & SW SSW, SW, WSW & W

Rainfall (mm) Maximum

No rainfall -

Minimum - Average -

Source: Automatic Weather Station Data installed for baseline monitoring

As per above table, the temperature during the study period varied between 21.1°C (March) and 43.0°C (May). The average temperature during the period was recorded as 33.4°C. Minimum and maximum relative humidity during the stuy period was noted as 9% and 98.5% in April. The average humidity was 42.7% during the study period. The wind speed during the study period varied from 0.0m/s (March) to 10.0m/s (May). The average wind speed during the period was 4.0m/s. The predominant wind direction was SSW, SW, WSW and W during the study period. The percentage of calm winds was 1.63% during the study period. There was no rainfall during the study period. The site specific hourly meteorological data is included as Annex D.


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Figure 3.4 Windrose- (Wind Blowing from) March 2018 to May 2018


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3.2.4 Ambient Air Quality

The objective of the ambient air quality monitoring program is to establish the baseline ambient air quality in the study area for the proposed project and to assess its conformity with the National Ambient Air Quality Standards (NAAQS), 2009. ERM India contracted the environmental baseline monitoring to M/s CEG Test House & Research Centre Private Limited (CEG) which is National Accreditation Board for Testing and Calibration (NABL)/MoEF accredited. The accreditation details of CEG is attached as Annex D. The baseline monitoring was carried out during the period February 26, 2018 to May 21, 2018. Techniques Used For Sampling and Analysis Ambient air quality samples were collected and analysed as per the Guidelines for the measurement of Ambient Air Pollutant Volume – I & II published by Central Pollution Control Board (CPCB) in May 2011. List of key parameters monitored, and their analytical method is given below in Table 3.3.

Table 3.3 Testing Methods used for Ambient Air Quality Monitoring

S.N. Parameter Testing Method 1. Particulate Matter (PM10) (μg/m3) IS:5182 (P-23), 2006 2. Particulate Matter (PM2.5) (μg/m3) TP/C/9.7,CPCB Guidline (Vol-

I,May,2011) 3. Sulphur Dioxide (SO2) (μg/m3) IS:5182 (P-2), 2001 4. Nitrogen Dioxide (NO2) (μg/m3) IS:5182 (P-6), 2006 5. Carbon Monoxide (mg/m3) IS:5182 (P-10), 1999 6. Ammonia (NH3) (μg/m3) CPCB Guidline (Vol-I,May,2011) 7. Benzene (C6H6) (μg/m3) IS: 5182 (Part 11), 2006 8. Volatile Organic Compound (VOC) (μg/m3) IS:5182 (P-11), 2006 9. Methane Hydrocarbon (ppm) USEPA 18: 1996 10. Non-Methane Hydrocarbon (ppm) USEPA 18: 1996 11. Hydrogen Chloride (HCl) OSHA-7907 12. Chlorine (Cl2) OSHA-7907 13. Hydrogen Sulfide (H2S) IS 5182 (P-7), 1973 14. Hydrogen Bromide (HBr) OSHA-7907

Source: Quality Assurance (QA) and Quality Control (QC) Plan, CEG

AAQ Monitored Locations The ambient air quality monitoring was carried out at nine (9) locations within the 10 km radius from the existing Unit # 2 premises as described in Table 3.4 and as shown in Figure 5.7. The sampling locations were selected taking into considerations factors such as: Predominant wind direction for the representative season; Settlement’s spread; Existing air pollution sources; Air monitoring stations from previous EIA study.


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Table 3.4 Ambient Air Quality Monitoring Locations

S. N. Location Code

Monitoring Location

Distance Direction Latitude Longitude

1 AAQM – 1 Project Site - - 21°37’39.4”N 73°02’04.0”E 2 AAQM – 2 Dadhal 1.7 km ENE 21°37’57.8”N 73°03’41.0”E 3 AAQM – 3 Jitali 3.3 km ESE 21°37’13.2”N 73°03’49.0”E 4 AAQM – 4 Sanjali 9.3 km SW 21°33’21.1”N 72°59’42.8”E 5 AAQM – 5 Azad Nagar 4.3 km SW 21°36'20.0"N 73°0'0.0"E 6 AAQM – 6 Ankleshwar 4.4 km E 21°37’22.1”N 72°59’36.2”E 7 AAQM – 7 Kondh 6.9 km SE 21°35’18.0”N 73°02’16.3”E 8 AAQM – 8 Bhorbhata Bet 6.4 km NNW 21°40’52.6”N 73°00’14.4”E 9 AAQM – 9 Mandvabuzarg 6.2 km NNE 21°40’38.0”N 73°03’43.3”E

AAQ Results Ambient air quality monitoring was conducted for thirteen weeks (twice a week) 24 hourly at nine (9) locations as listed above in Table 3.3. In nutshell, all the fourteen parameters monitored at the nine (9) AAQ monitoring locations were found to be satisfactory for all pollutants except particulate matter at few locations. Analysis of ambient air quality monitoring results is presented in Table 3.5.


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Table 3.5 Ambient Air Quality Monitoring Results

Parameter Results AAQM-1 AAQM-2 AAQM-3 AAQM-4 AAQM-5 AAQM-6 AAQM-7 AAQM-8 AAQM-9

PM10

(µg/m³) 24 hourly

NAAQS 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 98th Percentile 94.04 92.30 70.74 83.13 112.85 111.84 98.50 66.04 70.56 Average 65.05 61.39 56.79 62.28 81.93 86.31 83.36 51.56 59.06 Min 35.49 46.83 41.79 41.19 59.62 71.28 65.28 36.81 47.07 Max 95.06 95.91 72.18 85.83 119.80 121.01 100.40 67.13 72.05

PM2.5

(µg/m³) 24 hourly


SO₂ (µg/m³) 24 hourly


NOx (µg/m³) 24 hourly


CO (mg/m³) 8-hourly


NH₃ (µg/m³) 24 hourly


C₆H₆ (µg/m³) 24 hourly

NAAQS 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 98th Percentile BDL BDL BDL BDL BDL BDL BDL BDL BDL Average BDL BDL BDL BDL BDL BDL BDL BDL BDL Min BDL BDL BDL BDL BDL BDL BDL BDL BDL Max BDL BDL BDL BDL BDL BDL BDL BDL BDL

VOC (µg/m³) 24 hourly

NAAQS - - - - - - - - - 98th Percentile BDL BDL BDL BDL BDL BDL BDL BDL BDL Average BDL BDL BDL BDL BDL BDL BDL BDL BDL Min BDL BDL BDL BDL BDL BDL BDL BDL BDL Max BDL BDL BDL BDL BDL BDL BDL BDL BDL

MHC (mg/m³) 24 hourly


NMHC (mg/m³) 24 hourly


Cl₂ (µg/m³) 24 hourly

NAAQS - - - - - - - - - 98th Percentile BDL BDL BDL BDL BDL BDL BDL BDL BDL Average BDL BDL BDL BDL BDL BDL BDL BDL BDL


155

Parameter Results AAQM-1 AAQM-2 AAQM-3 AAQM-4 AAQM-5 AAQM-6 AAQM-7 AAQM-8 AAQM-9 Min BDL BDL BDL BDL BDL BDL BDL BDL BDL Max BDL BDL BDL BDL BDL BDL BDL BDL BDL

H₂S (µg/m³) 24 hourly


HCl (g/m³) 24 hourly

NAAQS - - - - - - - - - 98th Percentile 0.50 BDL BDL BDL BDL BDL BDL BDL BDL Average BDL BDL BDL BDL BDL BDL BDL BDL BDL Min BDL BDL BDL BDL BDL BDL BDL BDL BDL Max 0.50 BDL BDL BDL BDL BDL BDL BDL BDL

HBr (g/m³) 24 hourly

NAAQS - - - - - - - - - 98th Percentile 1.09 1.77 1.42 0.11 BDL BDL 1.78 0.22 BDL Average BDL 1.57 0.90 BDL BDL BDL 1.23 BDL BDL Min BDL 1.36 0.36 BDL BDL BDL BDL BDL BDL Max 1.09 1.78 1.44 0.11 BDL BDL 1.80 0.22 BDL

Note: NAAQS = National Ambient Air Quality Standards; BDL = Below Detection Limit; DL = Detection Limit; DL for C6H6 = 1 μg/m3; DL for VOC = 1.0 μg/m3; DL for MHC and NMHC= 1.3 mg/m3; DL for Cl2 = 15 μg/m3; DL for H2S= 10 μg/m3; DL for HCl= 10 g/m3; and DL for HBr=10 g/m3;


156

Figure 3.5 Map Showing AAQ Monitoring Locations in the Study Area


157

1) PM10 The 24-hourly PM10 concentrations ranged from 35.5 μg/m3 to 121 μg/m3 being minimum at AAQ1 (Project Site) and maximum at AAQ6 (Ankleshwar). The seasonal average PM10 concentration in the study area varied from 51.6 μg/m3 (AAQ8) to 86.3 μg/m3 (AAQ6) and the 98th percentile ranged from 66.0 to 112.9 μg/m3. The PM10 concentrations marginally exceeded at AAQ5 (Azad Nagar) and AAQ6 (Ankleshwar) due to dust from vehicular movement, construction /renovation works near to these stations. The PM10 was observed to be within the prescribed NAAQS (100 μg/m3) at most times during the monitoring period except three of 26 monitoring days. The presentation of PM10 values is shown in Figure 3.6.

Figure 3.6 Graphical Presentation of Observed PM10 Concentration

2) PM2.5 The 24-hourly PM2.5 concentrations ranged from 15.8 μg/m3 to 64.2 μg/m3 being minimum at AAQ1 (Project Site) and maximum at AAQ6 (Ankleshwar). The seasonal average PM2.5 concentration in the study area varied from 34.9 μg/m3 (AAQ8) to 54.9 μg/m3 (AAQ6) and the 98th percentile ranged from 47.5 to 63.4 μg/m3. The PM2.5 concentrations marginally exceeded at AAQ5 (Azad Nagar) and AAQ6 (Ankleshwar) due to vehicular movement, construction /renovation works near to these stations. The PM2.5 was observed to be within the prescribed NAAQS (60 μg/m3) at most times during the monitoring period. The graphical presentation of PM2.5 values is shown in Figure 3.7.

0

20

40

60

80

100

120

140

AAQ1 AAQ2 AAQ3 AAQ4 AAQ5 AAQ6 AAQ7 AAQ8 AAQ9

Con

cent

rati

on (µ

g/m

3 )

PM10 (µg/m3)

Min Avg Max NAAQS


158

Figure 3.7 Graphical Presentation of Observed PM2.5 Concentration

3) Sulphur di-Oxide (SO2) The 24-hourly SO2 concentrations ranged from 7.3 μg/m3 to 25.4 μg/m3 being minimum at AAQ1 (Project Site) and maximum at AAQ5 (Azad Nagar). The seasonal average SO2 concentration in the study area varied from 13.1 μg/m3 (AAQ4) to 19.2 μg/m3 (AAQ5) and the 98th percentile ranged from 16.7 to 24.9 μg/m3. The SO2 was observed to be within the prescribed NAAQS (80 μg/m3) at all locations at all times during the monitoring period. The graphical presentation of SO2 concentrations is shown in Figure 3.8

Figure 3.8 Graphical Presentation of Observed SO2 Concentration

4) Nitrogen Di-Oxide (NO2) The 24-hourly NO2 concentrations ranged from 11.5 μg/m3 to 45.4 μg/m3 being minimum at AAQ1 (Project Site) and maximum at AAQ6 (Ankleshwar). The seasonal average NO2 concentration in the study area varied from 17.1 μg/m3 (AAQ1) to 32.5 μg/m3 (AAQ6) and the 98th percentile ranged from 22.4 to 42.9 μg/m3. The NO2 was observed to be within the prescribed NAAQS (80 μg/m3) at all locations at all times during the monitoring period. The graphical presentation of NO2 concentrations is shown in the Figure 3.9.

0

20

40

60

80


Con

cent

rati

on (µ

g/m

3 )

PM2.5 (µg/m3)

Min Avg Max NAAQS

0

20

40

60

80

100


Con

cent

rati

on (µ

g/m

3 )

SO2 (µg/m3)

Min Avg Max NAAQS


159

Figure 3.9 Graphical Presentation of Observed NO2 Concentration

4) Carbon Monoxide (CO) The 8-hourly CO concentrations ranged from 0.3 mg/m3 to 1.8 mg/m3 being minimum at AAQ8 (Bhorbhata bet) and maximum at AAQ6 (Ankleshwar). The seasonal average CO concentration in the study area varied from 0.5 mg/m3 (AAQ8) to 1.4 mg/m3 (AAQ6) and the 98th percentile ranged from 0.9 to 1.7 mg/m3. The CO was observed to be within the prescribed NAAQS (2 mg/m3) at all locations at all times during the monitoring period. The graphical presentation of CO concentrations is as shown below in Figure 3.10.

Figure 3.10 Graphical Presentation of Observed CO Concentration

5) Ammonia (NH3) The 24-hourly NH3 concentrations ranged from 8.8 μg/m3 to 26.9 μg/m3 being minimum at AAQ9 (Mandvabuzurg) and maximum at AAQ8 (Bhorbhata bet). The seasonal average NH3 concentration in the study area varied from 13.0 μg/m3 (AAQ3) to 16.3 μg/m3 (AAQ8) and the 98th percentile ranged from 17.4 to 24.3 μg/m3. The NH3 was observed to be within the prescribed NAAQS (400 μg/m3) at all locations at all times during the monitoring period. The graphical presentation of NH3 concentrations is shown in the Figure 3.10.

0

20

40

60

80

100

AAQ1 AAQ2 AAQ3 AAQ4 AAQ5 AAQ6 AAQ7 AAQ8 AAQ9Con

cent

rati

on (µ

g/m

3 )

NO2 (µg/m3)

Min Avg Max NAAQS

0

1

2

3

AAQ1 AAQ2 AAQ3 AAQ4 AAQ5 AAQ6 AAQ7 AAQ8 AAQ9Con

cent

rati

on (m

g/m

3 )

CO (µg/m3)

Min Avg Max NAAQS


160

Figure 3.11 Graphical Presentation of Observed NH3 Concentration

6) Other Parameters The concentrations for Benzene (C6H6), Volatile Organic Compound (VOC), Methane Hydrocarbon (MH), Non-methane Hydrocarbon (NMHC), Chlorine (Cl2), Hydrogen Sulphide (H2S), Hydrogen Chloride (HCl) and Hydrogen Bromide (HBr) were observed to be below detectable limit at all locations. Currently there are no national ambient air quality standards (NAAQS) for VOC, MH, NMHC, Cl2, H2S, HCl and HBr. The photograph of ambient air quality sampling is shown below in Figure 3.12. The detailed ambient air quality data for the study period is included as Annex E

0

100

200

300

400

500


Con

cent

rati

on (µ

g/m

3 )

NH3 (µg/m3)

Min Avg Max NAAQS


161

Figure 3.12 Photographs of Ambient Air Quality Sampling

Based on Ambient Air Quality monitoring results, average values of most parameters were found to be within the permissible NAAQS at all monitoring


162

locations except particulate matter at a few locations on three of 26 monitoring days.

3.2.5 Stack Emissions Monitoring

The major stack emission sources at the existing Unit 2 plant are three boilers, emergency diesel generator set (DG Set) and process vents. The details of these stacks are provided in Section 2.4.1 and the emissions from these sources is given in

Table 3.6 Unit 2 Stack Emissions Detail

Parameter Emission results (UPL in-house

monitoring) GPCB Permissible Limit Min. Max.

Flue Gas Stack Emissions Stack attached to Boiler 1

PM 3.5 mg/Nm3 18.4 mg/Nm3 150 mg/Nm3 SO2 5.5 ppm 13.8 ppm 100 ppm NOx 1.1 ppm 5.1 ppm 50 ppm

Stack attached to Boiler 2 PM 18.4 mg/Nm3 18.4 mg/Nm3 150 mg/Nm3 SO2 6.4 ppm 6.4 ppm 100 ppm NOx 0.5 ppm 0.5 ppm 50 ppm

Stack attached to Boiler 3

PM 5.2 mg/Nm3 12.2 mg/Nm3 150 mg/Nm3 SO2 9.4 ppm 12.2 ppm 100 ppm NOx 1.0 ppm 3.3 ppm 50 ppm

Process Stack Emission Stack attached to Fume Incinerator in Phorate Plant

PM 3.3 mg/Nm3 11 mg/Nm3 150 mg/Nm3 SO2 26.08 mg/Nm3 32.6 mg/Nm3 40 mg/Nm3 NOx 7.67 mg/Nm3 16.6 mg/Nm3 25 mg/Nm3 HCl BDL BDL 20 mg/Nm3 Cl2 BDL BDL 5 mg/Nm3 H2S BDL BDL 5 mg/Nm3 NH3 BDL BDL 30 mg/Nm3

Stack attached to Water Scrubber (Acephate Plant)

NH3 2 12 30 mg/Nm3 Stack attached to H2S generating reactor (DETA/DETCL/ZDTP - Phorate Plant) H2S BDL 2 5 mg/Nm3 Stack attached to P2S5 Charging Reactor (Phorate Plant) H2S 1 4 5 mg/Nm3 Stack attached to HCl Scrubber (Devrinol Plant) HCl 6 16 20 mg/Nm3 Cl2 BDL BDL 9 mg/Nm3 Stack attached to Local Vent to Carbon Filter (Alkali Scrubber) H2S BDL BDL 5 mg/Nm3

Note: Refer to Tables 2.6 & 2.7 in Section 2 for stack characteristics.

3.2.6 Ambient Noise Quality

Monitoring of noise levels around the study area has been carried out to assess the existing noise levels in the study area. Noise standards have been designed for different types of land use i.e. residential, commercial industrial areas and silence zones as per ‘The Noise Pollution (Regulation and Control) Rules, 2000,


163

Notified by Ministry of Environment and Forests, New Delhi, February 14, 2000’. Instrument Used for Ambient noise Monitoring Sound Pressure Level (SPL) measurements were measured by integrated noise meter at all locations. Noise level monitoring was carried continuously for 24 hours using sound level meter manufactured by Envirotech Instruments, New Delhi (Model SLM -100). Noise Levels Noise monitoring was carried out once at nine (9) locations in the study area in May 2018 as shown below in Figure 3.13. Noise levels were continuously recorded at each location for 24 hours and the noise quality is reported as Leq (day and night time) for each location. Daytime is considered for 06:00 to 22:00 hours and night from 22:00 hours to 06:00 hours. The details of ambient noise quality (ANQ) monitoring locations are given below in Table 3.7 and Figure 3.13

Table 3.7 Ambient Noise Quality Monitoring Locations

Location Code

Location Name Distance Direction Latitude Longitude

1 ANQ – 1 Project Site - - 21°37’39.4”N 73°02’04.0”E 2 ANQ – 2 Dadhal 1.7 km ENE 21°37’57.2”N 73°03’40.0”E 3 ANQ – 3 Jitali 3.3 km ESE 21°37’12.7”N 73°03’48.3”E 4 ANQ – 4 Sanjali 9.3 km SW 21°33’20.2”N 72°59’41.1”E 5 ANQ – 5 Azad Nagar 4.3 km SW 21°36'20.0"N 73°0'0.0"E 6 ANQ – 6 Ankleshwar 4.4 km E 21°37’21.3”N 72°59’35.6”E 7 ANQ – 7 Kondh 6.9 km SE 21°35’17.2”N 73°02’15.4”E 8 ANQ – 8 Bhorbhata Bet 6.4 km NNW 21°40’51.4”N 73°00’13.6”E 9 ANQ – 9 Mandvabuzarg 6.2 km NNE 21°40’37.2”N 73°03’42.6”E


164

Figure 3.13 Location of Noise Monitoring Stations


165

The summarized results of noise levels as Leq day (Leq D) and Leq night (Leq N) are given below in Table 3.8 and shown below in Figure 3.14. The noise levels are compared with Ambient Air Quality Standards in respect of Noise as per The Noise Pollution (Regulation and Control) Rules, 2000 stipulated for daytime and night time for industrial, commercial and residential land use.

Table 3.8 Noise Level in the Study Area

S.N.

Location Code

Location Name Category of Area

Leq D dBA

Leq N dBA

Applicable Standard

Daytime Nighttime

1 ANQ 1 Project Site Industrial 74.5 68.8 75 70 2 ANQ 2 Dadhal Residential 52.4 42.7 55 45 3 ANQ 3 Jitali Residential 50.7 49.7 55 45 4 ANQ 4 Sanjali Residential 52.5 43.0 55 45 5 ANQ 5 Azad Nagar Commercial 66.9 61.5 65 55 6 ANQ 6 Ankleshwar Commercial 62.5 57.2 65 55 7 ANQ 7 Kondh Residential 51.7 42.2 55 45 8 ANQ 8 Bhorbhata Bet Residential 50.1 46.8 55 45 9 ANQ 9 Mandvabuzurg Residential 54.3 41.1 55 45

Figure 3.14 Noise Quality at Monitoring Locations

The equivalent ambient noise levels was observed to be varying from 50.1 dBA (ANQ8-residential) to 74.5 dBA (ANQ1-industrial) during daytime and from 41.1 dBA (ANQ9-residential) to 68.8 dBA (ANQ1-industrial) during nighttime within the study area. The noise levels exceeded the corresponding limits for commercial area at ANQ5 (Azad Nagar) during day time (Leq day) and at ANQ6 (Ankleshwar) during night time (Leq night) mainly due to vehicular movement and some construction/renovation activities near to the monitoring location. Leq day and night values at Dhadal, Jitali, Sanjali, Kondh, Bhorbhata Bet and Mandvabuzurg was observed to be within the corresponding limits for residential areas. The detailed ambient noise quality data for the study period is included as Annex E.

0

10

20

30

40

50

60

70

80

NQ-1 NQ-2 NQ-3 NQ-4 NQ-5 NQ-6 NQ-7 NQ-8 NQ-9

Leq

dB

A

Leq Day Daytime Standard Leq Night Nighttime Standard


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3.2.7 Traffic Survey

Assessment of the existing traffic characteristics within a study area was undertaken to evaluate the traffic movement and to identify best suitable solution for vehicle movement required for material and personnel movement during project’s construction and operational phase. Method of Traffic Counting Field data were collected for 24 hours duration in May 2018 on major network of road junctions in the study area. Data were collected on each side of the roads on a typical working day. The survey locations are presented below in Table 3.9 and Figure 3.15.

Table 3.9 Traffic Survey Locations surrounding the project area

S.N. Code Location Name Coordinates 1 TR1 Junction near Unit 2 21°37’31.4”N 73°01’57.3”E 2 TR2 Junction of GIDC Flyover &14th E Road 21°37’20.2”N 73°00’48.3”E 3 TR3 Junction of SH-64 and 14th E Roads 21°38’20.2”N 73°02’54.5”E

Figure 3.15 Location of traffic survey stations

Traffic Flow and Composition Traffic volume counts collected from above locations have been used to assess the traffic characteristics in terms of average daily traffic, peak hour traffic and traffic composition. The summary of traffic volumes at the surveyed locations in terms of average, minimum and maximum number of vehicles are given in the Table 3.10.


167

The detailed traffic data for the study period is included as Annex E.

Table 3.10 Analysis of Traffic volumes in the study area

S.N. Particulars Monitoring Locations T-1 T-2 T-3

1 Total Vehicles to and fro (veh./day)

9,469 18,459 10,805

2 Max. Traffic Flow to and fro (veh./hr)

1,257 1,739 804

3 Min. Traffic Flow to and fro (veh./hr)

12 99 30

4 Average Traffic Flow to and fro (veh.)/hr

395 769 450

5 Max. Traffic Flow to and fro (Time) 08:00-09:00 10:00 - 11:00 17:00 - 18:00 6 Min. Traffic Flow to and fro (Time) 01:00-02:00 02:00 - 03:00 04:00 - 05:00

Analysis of the survey undertaken indicates that maximum number of vehicles are 1739 vehicles per hour as observed during 10:00 – 11:00 hrs at Junction of GIDC Flyover &14th E Road i.e., T2. Accordingly, minimum number of vehicles are 12 vehicles per hour as observed during 1:00-2:00 hrs at Junction near Unit 2 i.e., T1. The monitored vehicles were categorized into heavy vehicles (truck, tanker, trailer, dumpers etc.), four wheelers (car, mini bus, mini trucks, tractors etc.), three wheelers (auto, tempo etc.), two wheelers (motorcycle etc.) and non-motorized vehicles (cycles, cycle rickshaws, bullock carts, other carts etc.). Composition of traffic in these categories is presented in Table 3.11.

Table 3.11 Composition of Traffic

S.N. Particulars No. of Vehicles

T1 T2 T3 To Fro To Fro To Fro

1 Heavy Vehicle 386 430 1,917 1,899 1,233 1,183 2 Four Wheelers 888 880 2,296 2,289 1,413 1,340 3 Three Wheelers 522 449 1,812 1,798 945 785 4 Two Wheelers 1,992 1,943 2,647 2,559 1,588 1,617 5 Non Motorized Vehicle 1,032 947 621 621 344 357 Subtotal 4,820 4,659 9,293 9,166 5,523 5,282 Grand Total 9,469 18,459 10,805

Analysis of the summarized data of category-wise traffic counts at these survey points indicates that out of the total vehicles observed: 20% of vehicles were heavy vehicles 24% of vehicles were four vehicles 17% of vehicles were three wheelers 31% of vehicles were two wheelers 9% of vehicles were non-motorized vehicles The traffic data indicates that preference to Junction near Unit 2 (T-1) should be given for vehicle movement required for material and personnel movement during construction phase to avoid congestion and preferable early morning or late evening hours. The photographs of traffic survey are shown below in Figure 3.16.


168

Figure 3.16 Traffic Survey Photographs

3.2.8 Water Quality

Water Sampling Locations For the purpose of baseline assessment, total twelve (12) locations were identified for ground and surface water samples covering the study area. These samples were examined for physico-chemical, heavy metals and bacteriological parameters to assess the current status of water quality in the study area during the monitoring period. The water sampling location details are presented below in Table 3.12, Figure 3.18 and Figure 3.19.

Table 3.12 Details of Water Sampling Locations

Location Code

Location Name Distance Direction Coordinates

Surfacewater samples SW-1 Narmada River near NH

bridge 8.9 km N

21°42’53.6”N 73°02’26.9”E


169

Location Code


SW-2 Narmada River near Borbathabet

8.4 km NW 21°40’15.2”N 73°00’09.5”E

SW-3 GIDC Reservoir 3.5 km SW 21°36’25.9”N 73°00’43.8”E SW-4 Pond near Gadkhol Patiya 3.3 km NW 21°38’56.9”N 73°00’45.7”E Ground water samples GW-1 Dadhal 1.7 km ENE 21°37’53.6”N 73°03’33.6”E GW-2 Jitali 3.3 km ESE 21°38’03.2”N 73°03’51.5”E GW-3 Azad Nagar 9.3 km SW 21°37’55.1”N 73°00’18.8”E GW-4 Ankleshwar 4.3 km SW 21°37'35.0"N 72°59'57.0"E GW-5 Bhorbhata Bet 4.4 km E 21°42’53.7”N 73°02’26.9”E GW-6 Mandvabuzarg 6.9 km SE 21°40’37.4”N 73°03’43.2”E GW-7 Kondh 6.4 km NNW 21°34’51.0”N 73°04’32.3”E GW-8 Sanjali 6.2 km NNE 21°41’13.1”N 73°00’14.2”E

The results from the surface water and ground water monitoring have been shown below in Table 3.13 and Table 3.14 Discussion of Results for Surface Water Quality The surface water samples were collected from four (4) different locations in the study area. The analysis results for all of these locations have been compared with CPCB water quality criteria and is discussed as below: Physical parameters: The pH of water samples was within 6.5 – 8.3 and alkaline in nature. The color of samples were found to vary from less than 1 hazen to 3 hazen with agreeable odour and taste. Dissolved oxygen was found to be varying from 5.8 mg/l (at SW-2) to 7.10 mg/l (at SW-1). The Total dissolved solids (TDS) was found to be varying from 134 mg/l (at SW-3) to 11,200 mg/l (at SW-2). Turbidity varied from 1 NTU to 9 NTU at SW-1 and SW-4. Total Suspended Solids (TSS) varied from below detection level (DL-10 mg/l) at SW-4 to 168 mg/l at SW-1. Inorganic Parameters: The Total hardness (as CaCO3), total alkalinity (as CaCO3), chloride (as Cl) and magnesium (as Mg) in water samples varied from 80.8 mg/l (at SW-4) to 3,030 mg/l (at SW-2); 81.6 mg/l (at SW-4) to 229.5 mg/l (at SW-3); 31.2 mg/l (at SW-4) to 7,747.2 mg/l (at SW-2) and 13.7 mg/l (at SW-4) to 639.4 mg/l (at SW-2) respectively. Other Parameters: Boron was found to be less than 2 mg/l at all locations. Total coliform was found to be present in all four surface water samples whereas Faecal coliform were found to be absent in all four water samples collected from the study area. The presence of coliform bacteria indicates increased risk of contracting water borne illness. Although total coliforms can come from sources other than fecal matter, presence of total coliform bacteria can be considered an indication of pollution. The overall surface water quality was found to comply with only with Class D criteria (propagation of Wild life and fisheries) as per CPCB standards. The presence of total coliform suggests sewage disposal in the surface water bodies. Discussion of Results for Ground Water Quality


170

The ground water samples were collected from eight (8) different locations in the study area to obtain understanding of the quality of ground water in the area. The results obtained have been compared with drinking standards IS 10500:2012 and are discussed below. Physical Parameters: The pH of water samples was within 7.4 – 8.3 and hence was observed to be alkaline in nature. The color of samples were found to be less than 1 hazen with agreeable odour and taste. The water samples collected from GWQ-3 (3.0 NTU) and GWQ-4 (4.0 NTU) respectively were found to be high in turbidity as compared to rest of samples which were found to be less than 1 NTU. Values of Total dissolved solids (TDS) in samples of all eight locations were found to exceed the desirable limit of 500 mg/l but was well below the permissible limit of 2,000 mg/l. Total suspended solids in all samples were observed to be below detectable limit (BDL). Inorganic Parameters: The values of total alkalinity, total hardness and magnesium in samples of all locations were found to be higher than the desirable limit as per IS 10500:2012. However, the values were found to be lower than the permissible limit at most locations except exceedance noted in total alkalinity at GWQ-1 (606.9 mg/l), in total hardness at GWQ-2 (666.6 mg/l) and GWQ-6 (888.8 mg/l), and in magnesium at GWQ-5 (108.2 mg/l) and GWQ-6 (157.4 mg/l). Values of calcium in samples of GWQ-2, GWQ-4 and GWQ-6 was observed to be exceeding the desirable limit of 75 mg/l but was lower than permissible limit of 200 mg/l. The samples collected from GWQ-1, GWQ-7 and GWQ-8 indicated chloride concentration within the desirable limit wherease that from rest of locations indicated chloride concentration higher than desirable limt of 250 mg/l but lower than the permissible limit of 1000 mg/l. Values of boron in samples collected from GWQ-1, GWQ-2 and GWQ-7 showed higher than desirable concentrations but were well below the permissible limit of 1.0 mg/l. The concentration of other inorganic parameters and heavy metals in all samples were found to be below the desirable limit of IS 10500:2012. Nutrient and Demand Parameters: Feacal coliform were found to be absent in all the water samples whereas the total coliform content was found to be present in samples collected from GWQ-2, GWQ-4, GWQ-5, GWQ-6 and GWQ-8. The photographs of water sampling are shown below in Figure 3.17.


171

Figure 3.17 Photographs of Water Sampling


172

Figure 3.18 Map Showing Surface Water Monitoring Locations within the Study Area


173

Figure 3.19 Map Showing Ground Water Monitoring Locations within the Study Area


174

Table 3.13 Surface Water Quality in the Study Area

S.N. Parameters Unit Narmada River Upstream

Narmada River Downstream GIDC Reservoir

Pond near Gadkhol Patiya CPCB Water Quality Criteria Class

SW-1 SW-2 SW-3 SW-4 A B C D E 1 pH Value (at 25°C) - 6.5 6.9 7.5 8.3 6.5-8.5 6.5-8.5 6.0-9.0 6.5-8.5 6.5-8.5 2 Odour - Agreeable Agreeable Agreeable Agreeable NS NS NS NS NS 3 Colour Hazen 3 2 <1.0 <1.0 NS NS NS NS NS 4 Taste - Agreeable Agreeable Agreeable Agreeable NS NS NS NS NS 5 Turbidity NTU 20 6 5 1 NS NS NS NS NS 6 Total Suspended Solids (TSS) mg/l 168 109 15 BDL (DL-10) NS NS NS NS NS 7 Total Dissolved Solids (TDS) mg/l 9,346 11,200 343 134 NS NS NS NS NS 8 Biological Oxygen Demand (BOD) mg/l BDL (DL-10) BDL (DL-10) BDL (DL-10) BDL (DL-10) ≤ 2 ≤ 3 ≤ 3 NS NS 9 Total Alkalinity (as CaCO3) mg/l 158.1 132.6 229.5 81.6 NS NS NS NS NS 10 Total Hardness (as CaCO3) mg/l 2,424 3,030 187.9 80.8 NS NS NS NS NS 11 Calcium (as Ca) mg/l 161.9 161.9 36.43 9.72 NS NS NS NS NS 12 Chloride (as Cl) mg/l 6,449.5 7,747.2 57.32 31.27 NS NS NS NS NS 13 Fluoride (as F) mg/l 0.5 0.8 0.4 0.3 NS NS NS NS NS 14 Free Residual Chlorine mg/l BDL (DL-0.05) BDL (DL-0.05) BDL (DL-0.05) BDL (DL-0.05) NS NS NS NS NS 15 Nitrate (as NO3) mg/l 12.5 10.5 1.5 BDL (DL-0.5) NS NS NS NS NS

16 Phenolic Compounds (as C6H5OH) mg/l BDL (DL-0.001) BDL (DL-0.001) BDL (DL-0.001) BDL (DL-0.001) NS NS NS NS NS

17 Cyanide (as CN) mg/l BDL (DL-0.1) BDL (DL-0.1) BDL (DL-0.1) BDL (DL-0.1) NS NS NS NS NS

18 Anionic Detergent (as MBAS) mg/l BDL (DL-0.05) BDL (DL-0.05) BDL (DL-0.05) BDL (DL-0.05) NS NS NS NS NS 19 Sulphate (as SO4) mg/l 130 110 33.6 15.3 NS NS NS NS NS 20 Ammonia (as total ammonia-N) mg/l BDL (DL-0.28) BDL (DL-0.28) BDL (DL-0.28) BDL (DL-0.28) NS NS NS NS NS 21 Chloramines (as Cl2) mg/l BDL (DL-0.5) BDL (DL-0.5) BDL (DL-0.5) BDL (DL-0.5) NS NS NS NS NS 22 Magnesium (as Mg) mg/l 491.87 639.4 23.61 13.78 NS NS NS NS NS

23 Mineral Oil mg/l BDL (DL-0.5) BDL (DL-0.5) BDL (DL-0.5) BDL (DL-0.5) NS NS NS NS NS

24 Sulphide (as H2S) mg/l BDL (DL-0.02) BDL (DL-0.02) BDL (DL-0.02) BDL (DL-0.02) NS NS NS NS NS

25 Dissolved Oxygen (DO) mg/l 7.10 5.80 6.68 6.85 ≥ 6 ≥ 5 ≥ 4 ≥ 4 NS

26 Aluminium (as Al) mg/l 0.25 0.03 BDL (DL-0.01) BDL (DL-0.01) NS NS NS NS NS

27 Boron (as B) mg/l 0.4 0.37 0.22 0.04 NS NS NS NS Max. 2 28 Copper (as Cu) mg/l 0.01 0.008 BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 29 Iron (as Fe) mg/l BDL (DL-0.1) BDL (DL-0.1) BDL (DL-0.1) BDL (DL-0.1) NS NS NS NS NS 30 Manganese (as Mn) mg/l BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 31 Selenium (as Se) mg/l 0.05 0.05 BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 32 Zinc (as Zn) mg/l BDL (DL-0.005) 0.05 0.01 BDL (DL-0.005) NS NS NS NS NS 33 Cadmium (as Cd) mg/l BDL (DL-0.001) BDL (DL-0.001) BDL (DL-0.001) BDL (DL-0.001) NS NS NS NS NS 34 Lead (as Pb) mg/l BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 35 Mercury (as Hg) mg/l BDL (DL-0.0005) BDL (DL-0.0005) BDL (DL-0.0005) BDL (DL-0.0005) NS NS NS NS NS 36 Arsenic (as As) mg/l 0.009 0.008 BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS

37 Molybdenum (as Mo) mg/l BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS


175

S.N. Parameters Unit Narmada River Upstream

Narmada River Downstream GIDC Reservoir

Pond near Gadkhol Patiya CPCB Water Quality Criteria Class

SW-1 SW-2 SW-3 SW-4 A B C D E 38 Nickel (as Ni) mg/l 0.007 0.008 BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 39 Chromium (as Cr) mg/l BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) BDL (DL-0.005) NS NS NS NS NS 40 Barium (as Ba) mg/l 0.04 0.04 0.02 0.01 NS NS NS NS NS 41 Silver (as Ag) mg/l BDL (DL-0.01) BDL (DL-0.01) BDL (DL-0.01) BDL (DL-0.01) NS NS NS NS NS

42 Total Coliform MPN per 100ml

Present Present Present Present ≤ 50 ≤ 500 ≤ 5000 NS NS

43 Faecal Coliform MPN per 100ml

Absent Absent Absent Absent NS NS NS NS NS

Note: BDL = Below Detection Limit; ND = Not Detectable; DL = Detection Limit


176

Table 3.14 Groundwater Quality in the Study Area

S. N. Parameters Units

Dadhal Jitali Azad Nagar

Ankleshwar Bhorbhata Bet

Mandvabuzarg

Kondh Sanjali Limit as per IS 10500:2012 Method of Analysis

GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 GW-8 Desirable Permissible

(I) Physical Parameters 1 pH Value (at 25°C) - 8.3 7.5 8.3 8.2 8.1 7.6 7.4 7.9 6.5-8.5 No relaxation IS 3025 (P-11) 2 Odour - Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable IS 3025 (P-5)

3 Colour Hazen <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 5 (Max.) 15.0 IS 3025 (P-4)

4 Taste - Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable IS 3025 (P-8)

5 Turbidity NTU <1.0 <1.0 3.0 4.0 <1.0 <1.0 <1.0 <1.0 1 (Max.) 5.0 IS 3025 (P-10)

6 Total Suspended Solids (TSS)

mg/l BDL (DL-10)

BDL (DL-10)

BDL (DL-10)

BDL (DL-10) BDL (DL-10)

BDL (DL-10)

BDL (DL-10)

BDL (DL-10)

Not Specified

Not Specified IS 3025 (P-17)

7 Total Dissolved Solids (TDS)

mg/l 920 1252 851 1395 913 1326 821 960 500 (Max.) 2000 IS 3025 (P-16)

(II) Chemical Parameters

8. Total Alkalinity (as CaCO3)

mg/l 606.9 479.4 244.8 387.6 285 357 515.1 423.3 200 (Max.) 600 IS 3025 (P-23)

9. Total Hardness (as CaCO3)

mg/l 484.8 666.6 323.2 505 565.6 888.8 383 404 200 (Max.) 600 IS 3025 (P-21)

10. Calcium (as Ca) mg/l 56.67 121.44 40.5 105.3 48.6 97.15 56.67 64.77 75 (Max.) 200 IS 3025 (P-40)

11. Chloride (as Cl) mg/l 185.86 456.53 420.37 609.7 323.1 656.6 168.5 248.88 250 (Max.) 1000 IS 3025 (P-32)

12. Fluoride (as F) mg/l 0.6 0.5 0.8 0.8 0.4 0.7 0.7 0.7 1.0 (Max.) 1.5 IS 3025 (P-60)

13. Free Residual Chlorine

mg/l BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

0.2 (Min.) 1.0 IS 3025 (P-26)

14. Nitrate (as NO3) mg/l 15 18 2 18 20.5 21 14.5 13 45 (Max.) No relaxation IS 3025 (P-34)

15. Phenolic Compounds (as C6H5OH)

mg/l BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

0.001 (Max.)

0.002 IS 3025 (P-43)

16. Cyanide (as CN) mg/l BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

0.05 (Max.) No relaxation IS 3025 (P-27)

17. Anionic Detergent (as MBAS)

mg/l BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

BDL (DL-0.05)

0.2 (Max.) 1.0 Annex K of IS 13428

18. Sulphate (as SO4) mg/l 21 72 88 92 40 29 28 128 200 (Max.) 400 IS 3025 (P-24)

19. Ammonia (as total ammonia-N)

mg/l BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)

BDL (DL-0.28)


20. Chloramines (as Cl2)

mg/l BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)



177


Dadhal Jitali Azad Nagar Ankleshwar Bhorbhata

Bet Mandvabuzarg Kondh Sanjali Limit as per IS 10500:2012 Method of

Analysis GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 GW-8 Desirable Permissible

21. Magnesium (as Mg)

mg/l 83.62 88.54 54.10 59.00 108.2 157.4 59 59 30 (Max.) 100 IS 3025 (P-46)

22. Mineral Oil mg/l BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

BDL (DL-0.5)

0.5 (Max.) No relaxation Clause 6 of IS 3025 (P- 39)

23. Sulphide (as H2S) mg/l BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

BDL (DL-0.02)

0.05 (Max.) No relaxation 4500, APHA 23rd Ed.2017

24. Dissolved Oxygen (DO)

mg/l 7.3 7.4 6.8 6.2 7.8 7.6 7.1 7.9 Not Specified

Not Specified IS 3025 (P-38)

(III) Trace/ Heavy Metals

25. Aluminium (as Al) mg/l BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

0.03 (Max.) 0.2 3125 APHA

26. Boron (as B) mg/l 0.57 0.64 0.47 0.33 0.24 0.4 0.58 0.35 0.5 (Max.) 1.0 3125 APHA

27. Copper (as Cu) mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

0.05 (Max.) 1.5 3125 APHA

28. Iron (as Fe) mg/l BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

BDL (DL-0.1)

0.3 (Max.) No relaxation 3125 APHA

29. Manganese (as Mn)

mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

0.01 0.04 BDL (DL-0.005)

BDL (DL-0.005)

0.1 (Max.) 0.3 3125 APHA

30. Selenium (as Se) mg/l BDL (DL-0.005)

BDL (DL-0.005)

0.01 BDL (DL-0.005)

BDL (DL-0.005)

0.01 0.007 0.01 0.1 (Max.) No relaxation 3125 APHA

31. Zinc (as Zn) mg/l 0.28 0.01 BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

0.05 5.0 (Max.) 15 3125 APHA

32. Cadmium (as Cd) mg/l BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

BDL (DL-0.001)

0.003 (Max.)

No relaxation 3125 APHA

33. Lead (as Pb) mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)


34. Mercury (as Hg) mg/l BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

BDL (DL-0.0005)

0.001 (Max.)

No relaxation 3125 APHA

35. Arsenic (as As) mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

0.01 (Max.) 0.05 3125 APHA

36. Molybdenum (as Mo)

mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)


37. Nickel (as Ni) mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)


38. Chromium (as Cr) mg/l BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)

BDL (DL-0.005)



178


Dadhal Jitali Azad Nagar Ankleshwar Bhorbhata

Bet Mandvabuzarg Kondh Sanjali Limit as per IS 10500:2012 Method of

Analysis GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 GW-8 Desirable Permissible

39. Barium (as Ba) mg/l BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

0.02 BDL (DL-0.01)

0.02 BDL (DL-0.01)

BDL (DL-0.01)


40. Silver (as Ag) mg/l BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)

BDL (DL-0.01)


(IV) Bacteriological Parameters

(i) Total Coliform mg/l Absent Present Absent Present Present Present Absent Present Absent/ 100ml

Absent/100ml IS 1622

(ii) Faecal Coliform mg/l Absent Absent Absent Absent Absent Absent Absent Absent Absent/ 100ml

Absent/100ml IS 1622

Note: BDL = Below Detection Limit; ND = Not Detectable; DL = Detection Limit Note: Mostly, the ground water samples were collected from borewells with depth varying from 80 - 250 ft. as per information gathered upon consultation with villagers while collecting the samples


179

3.2.9 Land use/ Land Cover

The land use of the area surrounding 10 km from the centre of the study area is shown in Figure 3.20. The land use pattern of the block in the study area is presented as per Table 3.15

Figure 3.20 Landuse of 10 km radius study area surrounding the Project site

Table 3.15 Land use Classification of 10km area surrounding the Project Site

S. N. Land use Class 10 km radius area

km2 % 1 Agriculture Land 215.3 66.0 2 Settlements 32.5 9.9 3 Industires 18.8 5.8 4 Barren Land 38.6 11.8 5 River 11.0 3.4 6 Waterbody 3.7 1.1 7 Roads 4.2 1.3 8 Canal 1.2 0.4 9 Railway Line 1.0 0.3 Total Study Area 326.4 100.0

Analysis of the land use pattern shows that out of total 326.4 km2, 66% of land is under agriculture, 12% of land is barren, 10% under settlements, 6% under industries and less than 6% is covered under roads, river, waterbody, canal and railway line.


180

3.2.10 Soil Quality

The general classification of soil is based on the soil texture and origin of the soil. Accordingly, The soil of the region varies from sandy to silty clay loamy soil types. Details of Soil Quality Monitoring locations are presented in Table 3.16 and Figure 3.21. Analysis results of soil samples are presented in Table 3.17 and the relevant Soil Remediation Intervention Values (Dutch standards) are presented in Table 3.18.

Table 3.16 Soil Quality Monitoring Locations

Location Code


SQ-1 Project Site - - 21°37'36.7"N 73°2'3.4"E SQ-2 Dadhal 1.7 km ENE 21°37’53.3”N 73°03’.37.6”E SQ-3 Jitali 3.3 km ESE 21°38’03.2”N 73°03’51.5”E SQ-4 Azad Nagar 4.3 km SW 21°36’25.6”N 73°00’43.3”E SQ-5 Ankleshwar 4.4 km E 21°36’20.3”N 73°59’59.9”E SQ-6 Kondh 6.9 km SE 21°34’51.0”N 73°04’32.3”E SQ-7 Bhorbhata Bet 6.4 km NNW 21°42’53.7”N 73°02’26.9”E SQ-8 Sanjali 9.3 km SW 21°41’13.1”N 73°00’14.2”E

Figure 3.21 Soil Quality Monitoring Locations within the Study Area

The photographs of soil sampling are shown below in Figure 3.22.


181

Figure 3.22 Photographs of Soil Sampling


182

Table 3.17 Soil Quality within Study Area

S.N. Parameters UoM SQ-1 SQ-2 SQ-3 SQ-4 SQ-5 SQ-6 SQ-7 SQ-8

1. Soil Texture … Loam Silty Clay Loam

Sand Silty Loam Loam Silty Loam Silty Clay Silty Clay Loam

2. Clay % 44.68 59.24 17.23 53.69 35.96 31.98 42.29 45.60 3. Silt % 18.22 22.06 2.97 13.61 24.64 18.22 40.11 30.20 4. Sand % 28.50 18.20 74.80 32.30 370 47.70 17.50 23.40

5. pH - 8.46 8.56 8.31 8.38 8.34 8.39 8.31 8.43

6. Moisture % 3.79 3.92 2.00 3.60 4.20 4.02 6.52 5.7

7. Specific gravity … 2.62 2.60 2.65 2.66 2.62 2.63 2.64 2.63

8. Bulk Density gm/cc 1.32 1.43 1.62 1.45 1.41 1.47 1.33 1.36

9. Porosity % 0.50 0.45 0.39 0.45 0.46 0.44 0.50 0.48

10. Water holding capacity % 44.11 53.08 32.87 49.09 57.71 55.27 48.40 59.71

11. Permeability Test by Falling Head Method (at 27 °C)

cm/sec 3.74×10-6 5.5x 10-6 3.91x10-4 2.3x10-5 6.91x10-7 3.82x10-6 1.12x10-7 5.02x10-7

12. Infiltration capacity inch/hr 0.30 0.32 0.65 0.29 0.30 0.62 0.40 0.18

13. Electrical Conductivity µS/cm 432 2075 923 235 241 446 546 248

14. Alkalinity % 0.04 0.04 0.03 0.06 0.06 0.05 0.07 0.03

15. Acidity % ND ND ND ND ND ND ND ND

16. Calcium Carbonate % 18.7 32.16 16.92 7.02 5.34 13.75 12.46 5.04

17. Total Organic Carbon % 0.15 0.23 0.32 0.44 0.16 0.78 0.14 0.28

18. Nitrogen as Nitrate mg/kg 1.50 1.83 2.22 1.24 1.57 1.96 1.76 2.87 19. Phosphorous as p mg/kg 0.894 1.751 0.895 0.896 0.894 0.895 0.894 0.894

20. Chloride mg/kg 0.03 0.09 0.01 0.03 0.02 0.02 0.01 0.04

21. Sulphate mg/kg 0.05 0.16 0.06 0.05 0.07 0.12 0.1 0.05

22. Boron mg/kg ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

ND (DL-5.0)

23. Potassium mg/kg 0.07 0.86 0.26 0.13 0.11 0.3 0.14 0.11

24. Calcium mg/kg 3.02 2.52 2.00 10.84 3.63 2.86 1.90 0.67

25. Magnesium mg/kg 0.51 0.39 0.18 0.36 0.26 0.26 0.40 0.23

26. Sodium mg/kg 0.17 0.57 0.03 0.03 0.05 0.1 0.16 0.14

27. CEC meq./ 100 ml 0.74 2.49 0.11 0.55 0.20 0.43 0.71 0.63

28. Sodium Absorption Ratio …. 0.59 1.25 0.05 0.07 0.08 0.57 0.50 0.50


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S.N. Parameters UoM SQ-1 SQ-2 SQ-3 SQ-4 SQ-5 SQ-6 SQ-7 SQ-8

29. Total Hexavalent Chromium (as Cr +6)

mg/kg 3.11 2.91 1.19 2.32 1.70 1.70 2.52 3.43

30. Arsenic mg/kg 1.40 ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

1.55 ND (DL-1.0)

ND (DL-1.0)

31. Cadmium mg/kg ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

32. Mercury mg/kg ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

ND (DL-1.0)

33. Nickel mg/kg 18.80 17.61 7.20 14.01 10.30 16.35 15.26 20.77

34. Manganese mg/kg 445.86 404.61 240.55 291.36 283.33 504.75 348.17 0.11

35. Zinc mg/kg 39.40 24.19 72.90 15.91 11.83 27.01 13.91 20.19

36. Lead mg/kg 8.84 4.88 5.60 4.61 4.49 6.97 6.31 7.25

37. Iron mg/kg 0.72 0.54 0.24 0.49 0.24 0.48 0.58 0.62 38. Copper mg/kg 50.50 21.75 11.78 15.80 12.27 18.02 16.26 16.95

ND = Not Detectable; DL = Detection Limit


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India does not have any specific concentration based soil contamination standards. In absence of any existing standards for safe heavy metals contents, Dutch standards have been considered for the purpose of analysis.

Table 3.18 Soil Remediation Intervention Values as per Dutch Standards

Parameter Intervention Values (mg/kg dry matter)

Zinc 720

Arsenic 76

Lead 530

Cadmium 13

Copper 190

Mercury (inorganic) 36

Nickel 100

Source: Soil Remediation Circular 2009, Minister of Housing, Spatial Planning and Environment, Netherlands. Note: Concentrations are shown for standard soil (10% organic matter and 25% clay)

Soil texture in samples of most locations was observed to be loamy, silty loamy and silty clay loamy except at SQ3 (Jitali) where in the soil texture was observed to be sandy. pH of the soil samples ranged from 8.31 to 8.56. The pH of samples collected from most locations were moderately alkaline, whereas the soil samples collected from SQ2 (Dadhal) was analysed to be strongly alkaline, as per the standard soil classification as given in Table 3.19.

Table 3.19 Standard Soil Classification

pH Classification Sampled Soil Classification <4.5 Extremely acidic 4.51- 5.00 Very strong acidic 5.01- 5.50 Strongly acidic 5.51- 6.00 Moderately acidic 6.01- 6.50 Slightly acidic 6.51- 7.30 Neutral 7.31- 7.80 Slightly alkaline

7.81- 8.50 Moderately alkaline SQ-1, SQ-3, SQ-4, SQ-5, SQ-6, SQ-7, SQ-8 8.51- 9.00 Strongly alkaline SQ-2 > 9.00 Very strongly alkaline

Source: Handbook of Agriculture, Indian Council of Agricultural Research, New Delhi

The values for metals namely Cadmium and Mercury (inorganic) were observed to below detectable limit whereas the values for Zinc, Arsenic, Lead, Copper, and Nickel were found to be much below the soil remediation intervention values specified in Soil Remediation Circular 2009.

3.3 BASELINE – ECOLOGICAL ENVIRONMENT

The UPL Unit 2 Plant, located within Ankleshwar GIDC Industrial Estate, Ankleshwar in Bharuch District, Gujarat. An ecological survey was undertaken from May 8 to 10, 2018 covering the Unit 2 Plant and the study area up to 10km radius from the Plant (designated as the study area), to establish the ecological baseline of the study area and to assess likely impacts of the Project on species and habitats in surrounding areas.


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3.3.1 Objective

The ecological surveys were conducted with following objectives: Flora Identification of sensitive habitats, and forest land falling within the

determined study areas (Project area + study area of 10 km from the Plant); Classification of flora for any threatened, protected or endemic floral

species prevailing in the study areas based on field surveys; Identification of areas protected under international conventions, national

or local legislation and those recognized nationally and internationally for their ecological, landscape, cultural or other related value; and

Identification of aquatic flora in the water bodies falling in the study areas.

Fauna Identification of fauna (specifically amphibians, birds, mammals and

reptiles) based on direct sightings, calls, pug marks, droppings, nests, etc.; Identification and classification of any species recognized as threatened (in

accordance with the IUCN Red List V 2017.3 and according to the schedules of the Indian Wildlife (Protection) Act 1972 and amendments);

Identification of areas which are important or sensitive for ecological reasons including their breeding, nesting, foraging, resting, over wintering areas including wildlife migratory corridors /avian migratory routes; and

Identification and assessment of aquatic ecological resources within the study areas.

3.3.2 Approach and Methodology

Desktop Review Prior to site visit, a desktop review (published document) was carried out to determine the land use and land cover (Toposheet, Satellite imagery), vegetation type (Champion and Seth, 1962) and floral and faunal species assemblage in the study area. Baseline Ecological Survey A baseline survey was carried out to determine the existing ecological conditions and to facilitate an adequate assessment of the project’s impacts upon ecology and development of appropriate mitigation measures. The baseline covers two parts- (i) Secondary data collection and (ii) Primary data collection

(i) Secondary Data Collection

Secondary baseline data regarding sensitive ecological habitat (National Park,

Sanctuary, Ecological Sensitive Area, Migratory Corridor, habitat of

endangered, vulnerable and range restricted species etc.), flora & fauna in the

study area, forest cover was collected from reliable sources like published

documents, the ENVIS portal on Wildlife and Protected areas in India, wetland

atlas, Important Bird Areas (IBA). Consultations were carried out with local


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people to understand major flora & fauna in the study area, presence of any

Schedule I species or other species having conservation value and pressures on

forest resources.

Consultation was carried out with the Range Forest Officer at Ankleshwar and

Forest Circle Office at Bharuch, to understand the prevailing flora & fauna of

the area, ecological sensitivities and extent of forest and their vegetation types

in the area. Community consultations were also conducted at Dadhal, Mandwa,

Kondh and Piraman villages to identify the faunal species in the area.

(ii) Primary Data Collection

a. Habitat survey

Different habitats identified through desktop review were visited. Data

regarding the type and quality of habitat with reference to flora and fauna

supported, were collected.

b. Floral Survey

Major floral species in different types of habitats were visually identified using

published manuals and recorded.

For quantitative analysis of vegetation – frequency, density, abundance, IVI and

diversity index, targeted vegetation survey was conducted by transect and

quadrate surveys in identified terrestrial habitats. The sampling plot size was

10 m x 10 m for trees, 5 m x 5 m for shrubs and 1 m x 1 m for herbs and grasses.

Twelve (12) sample plots were laid in the study area covering the terrestrial

habitats. The details of the sample plots studied are given in Table 3.20 and

Figure 3.23. Species diversity is calculated based on Shannon Weiner Index (1)

for the trees, shrubs and herbs.

Phyto-sociological Analysis: Phytosociology provides frequency, abundance,

density and Importance Value Index (IVI) of plant species Formulae used for

calculating IVIs are provided below:

Frequency refers to the degree of dispersion of individual species in an area and

usually expressed in terms of percentage occurrence. It was studied by

sampling the project influence area at several places at random and recorded

the name of the species that occurred in each sampling units. It is calculated by

the equation:

Frequency %Numberofquadratesinwhichspeciesoccurredx100

Totalnumberofquadratesstudied

(1) Shannon CE & W Weaver 1949. The Mathematical Theory of Communication. University of Illionis Press. Urbana, IL

USA.


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Relative Frequency is the degree of dispersion of individual species in an area

in relation to the number of all the species occurred. It is calculated by the

equation;

RelativeFrequencyNumberofocurrenceofspeciesx100Numberofoccurencesofallspecies

Density indicates numerical strength of plants in a community and implies

number of plants in a unit area. The total number of individuals encountered

in the zone studied is converted into individuals per hectare (10,000 sq. m) for

trees and per one square meter for shrubs, climbers and herb species.

DensityTotalnumberofindividualsofaspeciesinallquadrats

Totalnumberofquadratesstudied

Relative density is the study of numerical strength of a species in relation to the

total number of individuals of all the species and can be calculated as:

RelativeDensityNumberofindividualsofspeciesx100Numberofindividualsofallspecies

Abundance is the study of the number of individuals of different species in the

community per unit area. By quadrats method, samplings are made at random

at several places and the number of individuals of each species was summed

up for all the quadrats divided by the total number of quadrats in which the

species occurred. It is represented by the equation:

AbundanceTotalnumberofindividualspeciesinallquadrates

Totalnumberofquadratesinwhichindividualspeciesoccurred

The formulae used for calculation of the three parameters are based upon

Misra(1).

Species richness (N) is the primary measure of biodiversity. It is simply the

number of species observed in the area.

Shannon Diversity Index (H’) (2) has been used for estimating the diversity

between the sampled habitats (for this study the study area was divided into

four habitats) in order to highlight the most diverse zone. Diversity index is a

ratio between number of species and number of individuals present in a sample.

Shannon index (H’) is expressed by the formula:

HniN

LogniN

Where, H’ = Shannon index, ni= number of individuals of each species

N = total individuals of each species, (Log to the base 2 is used)

(1) Misra, R. 1974. Manual of Plant Ecology, Oxford and IBH Publishing Company, New Delhi (2) Shannon CE & W Weaver 1949, the Mathematical Theory of Communication, University of Illionis Press, Urbana, IL,

USA.


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Importance Value Index (IVI): gives an overall estimate of the influence of

importance of a plant species in the community. It is the sum of relative density,

relative frequency and relative coverage or relative basal area of tree species.

Relative Value Index (RVI): Status of woody shrub was assessed based on

Relative Value Index (RVI). Relative value indexes are the added value of only

the Relative Frequency and Relative Density.

Description of Quadrates

Details of quadrates are provided below in Table 3.20.

Table 3.20 Details of the Vegetation Sampling Plots

Location Code

Location/ Nearest Village

Latitude Longitude Habitat Type

Q1 Dadhal 21°37'31.7"N 73° 4'22.3"E Scrub Q2 Dadhal 21°38'0.2"N 73° 3'38.8"E Homestead Plantation Q3 Dadhal 21°37'37.4"N 73° 3'39.5"E Agricultural land Q4 Mandwa 21°39'51.6"N 73° 3'25.5"E Scrub Q5 Mandwa 21°40'27.2"N 73° 3'42.1"E Homestead Plantation Q6 Mandwa 21°41'28.5"N 73° 3'46.2"E Agricultural land Q7 Kondh 21°34'16.3"N 73° 4'7.0"E Scrub Q8 Kondh 21°34'40.6"N 73° 4'45.6"E Homestead Plantation Q9 Kondh 21°33'19.4"N 73° 4'4.5"E Agricultural land Q10 Piraman 21°36'42.1"N 72°59'21.5"E Scrub Q11 Piraman 21°36'54.8"N 72°59'47.5"E Homestead Plantation Q12 Piraman 21°36'20.7"N 72°59'4.7"E Agricultural land


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Figure 3.23 Location Map of Vegetation Survey

c. Faunal Survey

Faunal species from the study areas were recorded based on direct sightings,

indirect evidences such as dung, droppings, scats, pugmarks, scratch signs,

burrows, nests etc. Consultations with local communities were carried out to by

displaying pictorial representations of species anticipated in the area to confirm

their presence. The species occurring within the study area were surveyed using

the below methods:

Amphibians: Amphibians are often restricted to natural and constructed ponds

during the hottest parts of the day (1). All such water bodies were visited during

the hottest parts of the day to determine the presence of amphibians along the

shaded ledges of the water body.

Reptiles: Reptile presence was determined through the use of Intensive Time

Constrained Search Methods (2) (3). The method was adapted for the terrain by

targeting rocks and logs located around water bodies or recently dried streams,

hedges and along the trunks of higher vegetation.

(1) Knutson et. al. 2004. Agricultural ponds support amphibian populations. Ecological Applications. 14 (3): 669-684 (2) Welsh, H.H., jr. 1987. Monitoring herpetofauna in woodlands of north western California and south west Oregon: a comparative strategy. Pp. 203-213. In. Multiple – Use Management of Califirnia’s hardwood resources. T.R. Plumb, N.H.

Pillisbury (eds. Gen. Tech. Regional Environmental Planning. PSW – 100) US Department of Agriculture, Forest Service. (3) Welsh, H.H. Jr. and Lind, A. 1991. The structure of the herpetofaunal assemblage in the Douglas-fir/hardwood forests

of northwestern California and south western Oregon. Pp: 395-411. In: Wildlife and vegetation of unmanaged Douglas-fir forests. (Tech. Coords). L.F. Ruggiero, K.B. Aubry, A.B. Carey and M.H. Huff. Ge. Tech. Rep. PNW-GTR-285. Portland, OR:

US. Department of Agriculture, Forest Service.


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Avifauna: Any avifaunal species that was identified by visually sighting or

hearing bird calls was recorded. Birds were identified along motorable roads,

around water bodies and in clumps of higher vegetation during the hottest

parts of the day. Binoculars and standard field guides (1) were used for avifaunal

identification.

Mammals: Mammal surveys were conducted along motorable roads, near

water bodies and in grassy terrain. Individuals were identified through direct

(visual sighting) and indirect (pellets, tracks, paw marks and scat) methods.

Species were then identified using standard literature (2) (3).

3.3.3 Habitat Assessment

According to the Biogeographic Provinces of India published by Wildlife Institute of India (Rodgers, Panwar and Mathur, 2002), the project site falls under the Biogeographic Province – 4B-Semi-Arid-Gujarat Rajputana. The project site is chemical industry located in Ankleshwar GIDC (Gujarat Industrial Development Corporation) area, an industrial cluster of chemical plants, producing products such as pesticides, pharmaceuticals, chemicals and paints etc. Rest of the study area is a mosaic of urban area, villages, agricultural fields and scrublands. No forest land is located within the Study Area of 10-km from UPL’s Unit 2. The project site is located within Notified Industrial Estate, GIDC in the south bank of Narmada River, approximately at a distance of 7 km. Topography of the study area is mostly flat, with very little undulation. Types of habitat in the study area Industrial Cluster: The project site and surrounding area up to 1.5 km to 2.0 km from the Project site is the GIDC Ankleshwar area. It is more than 30 years old industrial area, established in 1978. In this predominantly industrial landscape trees are mostly found along the green belts developed by the industries. Scrub vegetation has developed in few empty plots within the industrial area. Urban Area and Settlement: The Ankleshwar urban area along with small suburban areas are located within 2.0 km to 5.0 km from the Project site. Bharuch Town is located about 8.5 km north west of the study area, beyond Narmada River. These are densely populated areas characterised by low rise domestic as well as commercial buildings (2 to 5 storey), roads and few parks. Apart from these urban areas some villages are present in the study area.

(1) Grimmet, R. Inskipp, C. and Inskipp, T. 2013. Birds of the Indian Subcontinent - Second Edition. Published by Christopher Helm, 49-51 Bedford Square, London. (2) Prater, S.H. 2005. The Book of Indian Animals. Bombay Natural History Society and Oxford University Press - 12th Edition. pp 316 (3) Menon, V. 2003. A field guide to Indian Mammals. Dorling Kindersley (India) Ltd. New Delhi, 201 p


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Vegetation is mostly concentrated within homestead plantation within and around the village and along the road, as roadside plantation. Agricultural lands: Agricultural lands dominates the rural area in the study area. Mostly wheat, Rice, Wheat, Gram, Perlmillets, Sorghum, Maize, Kodra, Ragi, Pigeonpea, groundnut, Sesamum, Castor, Cotton, Sugarcane, Chillies etc. Occasionally vegetation patches or single tree are associated with the agricultural fields. Scrub Lands: Scrub vegetation has covered government lands or community lands where agriculture is not practiced. Scrublands are mostly found between stretches of agricultural fields or along the dry natural drainage channels. Aquatic Habitat: Narmada River is flowing east to west along the north, north western part of the study area, about 7km from the project site. Section of river Narmada falling within the study area is located about 50km upstream of the river mouth, draining in the Gulf of Khambhat. Apart from Narmada River, few water bodies are located in the study area and studies during the ecological survey.

Table 3.21 Water Bodies in the Study Area

S.N. Water Body Name

Coordinate Location

1 GIDC Water Reservoir

21°36'45.2"N, 73° 0'25.4"E

Located in Ankaleshwr, about 3.3km south west of UPL Unit 2

2 GNFC Lake 21°38'58.9"N, 73° 0'47.2"E

Located in Ankaleshwr, about 3km north west of UPL Unit 2

3 Small Swamp Near UPL Unit 2

21°37'48.5"N, 73° 1'58.6"E

Located in Ankaleshwr, about 200m north west of UPL Unit 2

4 Pond at Kondh Village

21°34'19.4"N, 73° 4'23.8"E

Located in Kondh Village, about 5km south of UPL Unit 2

5 Pond at Kosamdi Village

21°34'50.3"N, 73° 2'17.5"E

Located in Kosamdi Village, about 7.2km south east of UPL Unit 2

Table 3.22 Different types of Habitat in the Study Area

Agricultural Fields near Mandwa village Scrubland near Dadhal


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GIDC reservoir Homestead Plantation near Kondh VIllage

Pond near Kondh Village River Narmada

3.3.4 Floral Assessment

Floral assessment was carried out in different types of habitats following the aforementioned techniques (Section 3.3.2). Habitat wise floral assessment is provided below: Industrial Cluster: In this predominantly industrial landscape trees are mostly found along the green belts developed by the industries. Trees that are in use for development of green belt are listed below:

Table 3.23 Tree Species Used for Green Belt Development

S.N. Common Name Scientific Name 1 Gulmohar / flame tree Delonix regia 2 Indian-almond Terminalia catappa 3 Mango Mangifera indica 4 Karan Millettia pinnata 5 Ashok Polyalthia longifolia 6 Banyan Tree Ficus benghalensis 7 Peepal Tree Ficus religiosa 8 Jamun Syzygium cumini 9 Neem Azadirachta indica 10 Bottle palm Hyophorbe lagenicaulis

Urban Area and Settlement: Vegetation is urban area is mostly restricted to avenue plantation. Trees that are commonly found along the avenues of Ankleshwar are listed in Table 3.24.


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Table 3.24 Trees Used for Avenue Plantation

S.N. Common Name Scientific Name 1 Gulmohar / flame tree Delonix regia 2 Tamarind Tamarindus indica 3 Radhachura / Yellow Flame Tree Peltophorum pterocarpum 4 Palash Butea monosperma 5 Ashok Polyalthia longifolia 6 Banyan Tree Ficus benghalensis 7 Peepal Tree Ficus religiosa 8 Jamun Syzygium cumini 9 Neem Azadirachta indica 10 Golden rain tree Cassia fistula 11 Rain Tree Albizia saman

Homestead Plantation: Apart from these urban areas some villages are present in the study area. Vegetation is mostly concentrated within homestead plantation within and around the village. Floral sampling of homestead plantation were done in four sample plots located in four villages, Dadhal, Mandwa, Kondh and Piraman. During the sampling, total twenty six (26) plant species were record from four quadrats. Twelve (12) tree species, eight (8) shrubs and six (6) herbs were recorded from the homestead plantations. Phytosociological analysis of homestead plantation is provided below in Table 3.25 and Table 3.26:

Table 3.25 Phytosociological Characteristics of Tree Species in Homestead Plantation

Species Frequency Relative Frequency (RF)

Density

Relative Density (RD)

Abundance

Relative Abundance (RA)

IVI [RF+RD+RA]

Azadirachta indica

100.0 0.5 1.3 17.86 1.25 0.18 18.54

Ficus benghalensis

75.0 0.4 0.5 7.14 0.50 0.07 7.59

Prosopis juliflora

100.0 0.5 0.5 7.14 0.50 0.07 7.71

Acacia nilotica 25.0 0.1 0.3 3.57 0.25 0.04 3.73

Ficus religiosa 75.0 0.4 0.5 7.14 0.50 0.07 7.59

Delonix regia 50.0 0.3 0.5 7.14 0.50 0.07 7.46

Salvadora persica

50.0 0.3 0.3 3.57 0.25 0.04 3.86

Peltphorum pterocarpum

100.0 0.5 1.0 14.29 1.00 0.14 14.93

Thespesia populnea

50.0 0.3 0.3 3.57 0.25 0.04 3.86

Casuarina equisetifolia

75.0 0.4 0.8 10.71 0.75 0.11 11.20

Leucaena leucocephala

50.0 0.3 1.0 14.29 1.00 0.14 14.68


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Density


Abundance


IVI [RF+RD+RA]

Mangifera indica

50.0 0.3 0.3 3.57 0.25 0.04 3.86

Azadirachta indica (Neem) was found to be most dominant tree species in homestead plantations, with IVI value of 18.54. It is followed by Peltphorum pterocarpum (yellow flame tree) with IVI value of 14.93. Laucaena leucocephala is third most dominant species with IVI value of 14.68.

Table 3.26 Phytosociological Characteristics of Shrub and Herb Species in Homestead Plantation


Density Relative Density (RD)

RVI [RF+RD]

Shrubs

Calotropis gigantea 0.25 9.1 0.3 1.4 10.5 Cassia sophera 0.25 9.1 0.3 1.4 10.5

Datura metel 0.5 18.2 0.8 4.2 22.3 Hibiscus rosa-sinensis 0.25 9.1 0.3 1.4 10.5 Lantana camara 0.5 18.2 1.8 9.7 27.9 Lawsonia inermis 0.25 9.1 0.3 1.4 10.5 Ricinus communis 0.25 9.1 0.5 2.8 11.9 Zizyphus nummularia 0.5 18.2 0.5 2.8 21.0 Herbs Argemone mexicana 25 10.0 0.25 0.07 10.1 Canna indica 25 10.0 0.25 0.07 10.1 Cassia tora 25 10.0 0.25 0.07 10.1 Ocimum sanctum 75 30.0 1.00 0.29 30.3 Parthenium hysterophorus 75 30.0 1.00 0.29 30.3 Sida cordata 25 10.0 0.75 0.21 10.2

Among shrubs and herbs, most dominant species was found to be Ocimum sanctum (Tulsi) a native species as well as Parthenium hysterophorus, an invasive species, both having RVI value of 30.3. Agricultural lands: Apart from crops that are grown in the agricultural fields, other tree and shrub species grows along the edge of agricultural fields and fallow land associated with agricultural fields. Total thirteen (13) such plant species were recorded from the agricultural fields. Out of 13, six (6) were tree species, four (4) were shrub species and three (3) were herbaceous species. Phytosociological analysis of agricultural field is provided below in Table 3.27 and Table 3.28:

Table 3.27 Phytosociological Characteristics of Tree Species in Agricultural Fields

Species Frequency

Relative Frequency (RF)

Density


Abundance


IVI [RF+RD+RA]

Prosopis juliflora 100.0 1.6 3.5 70.00 3.50 0.70 72.30


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Species Frequency


Density


Abundance


IVI [RF+RD+RA]

Acacia nilotica 25.0 0.4 0.3 5.00 0.25 0.05 5.45 Azadirachta indica 50.0 0.8 0.5 10.00 0.50 0.10 10.90

Ficus religiosa 25.0 0.4 0.3 5.00 0.25 0.05 5.45 Peltophorum pterocarpum 25.0 0.4 0.3 5.00 0.25 0.05 5.45

Mangifera indica 25.0 0.4 0.3 5.00 0.25 0.05 5.45

Prosopis juliflora, an invasive species, was found to be the most dominant tree in agricultural landscape, with IVI value of 72.3. It is followed by species like Azadirachta indica (IVI=10.9), rest of the four species have IVI of 5.45.

Table 3.28 Phytosociological Characteristics of Shrub and Herb Species in Agricultural Fields



RVI [RF+RD]

Shrubs

Calotropis gigantea 0.5 25.0 0.5 5.6 30.6 Hyptis suaveolens 0.5 25.0 0.5 5.6 30.6

Lantana camara 0.75 37.5 1.0 11.1 48.6 Zizyphus nummularia 0.25 12.5 0.3 2.8 15.3 Herbs Argemone mexicana 100 50.0 1.25 0.50 50.5 Cassia tora 25 12.5 0.25 0.10 12.6 Parthenium hysterophorus 75 37.5 1.00 0.40 37.9

Argemone mexicana, an invasive species was found to be dominant among shrubs and herbs in the agricultural fields, with RVI value of 50.5. It is followed by another invasive species Lantana camara (RVI=48.6). Scrub Lands: Sixteen (16) species of plants were recorded from the scrublands during the phytosociological survey. Total four (4) species of trees, Seven (7) species of shrubs and five (5) Species of here recorded. Phytosociological analysis of scrub lands is provided below in Table 3.29 and Table 3.30:

Table 3.29 Phytosociological Characteristics of Tree Species in Scrub lands

Species Frequency


Density


Abundance


IVI [RF+RD+RA]

Prosopis juliflora 100.0 1.8 4.3 65.38 4.25 0.65 67.82 Acacia nilotica 50.0 0.9 1.5 23.08 1.50 0.23 24.20 Azadirachta indica 50.0 0.9 0.5 7.69 0.50 0.08 8.66 Salvadore parsica 25.0 0.4 0.3 3.85 0.25 0.04 4.33


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Most of the scrub lands was found to be covered by Prosopis juliflora, an invasive species, with IVI value of 67.82. It is flowed by Acacia nilotica (IVI=24.2), Azadirachta indica (IVI=8.66) and Salvadore parsica (IVI=4.33).

Table 3.30 Phytosociological Characteristics of Shrub and Herb Species in Scrub Lands



RVI [RF+RD]

Shrubs

Calotropis gigantea 0.5 15.4 0.5 2.6 18.0 Calotropis procera 0.25 7.7 0.3 1.3 9.0

Cassia sophera 0.5 15.4 0.5 2.6 18.0 Datura metel 0.5 15.4 0.5 2.6 18.0 Lantana camara 0.75 23.1 1.8 9.2 32.3 Ricinus communis 0.5 15.4 1.0 5.3 20.6 Zizyphus nummularia 0.25 7.7 0.3 1.3 9.0 Herbs Calotropis gigantea 50 0.9 0.75 0.19 1.1 Calotropis procera 50 0.9 0.50 0.13 1.0 Cassia sophera 25 0.4 0.50 0.13 0.6 Datura metel 25 0.4 0.25 0.06 0.5 Lantana camara 75 1.3 2.00 0.50 1.8

Among shrubs and herbs, Lantana camara was found to most dominant with RVI value of 32.3. Lantana camara is also an invasive species. Floral Diversity Highest species richness as recorded from homestead plantation, having twenty six (26) species, followed by Scrub land having sixteen (16) species and then agricultural lands, having thirteen (13) species. Highest diversity was recorded in homestead plantation with Shannon Diversity Index Value of 2.11219. It is followed by scrub land, with diversity index of 1.52205. Agricultural lands had least diversity index value of 1.25299. Species richness and species diversity indices of the surveyed habitats are presented in Table 3.31.

Table 3.31 Species Richness and Species Diversity Index of the surveyed habitats

S.N. Habitat Species Richness Species Diversity Index 1 Homestead Plantation 26 2.11219 2 Agricultural Fields 13 1.25299 3 Scrub Lands 16 1.52205

3.3.5 Faunal Assessment

A faunal assessment was carried out based on the aforementioned search techniques (3.3.2) for each of the target fauna – herpetofauna (amphibians and reptiles), avifauna and mammals. The subsequent sections describe the fauna found on the site.


197

Ictheofauna: Total forty (40) fish species, from nineteen family were reported (1) from the river and other waterbodies of the study area. Cyprinidae family (Barbs and Carps) had the largest representation in the study area with nine (9) species, followed by Bagridae family (Catfish), with seven (7) species. No species of fish is listed under Schedule I of the Indian Wildlife Protection Act, 1972 or listed in IUCN Red List of Threatened Species. List of Ictheofauna reported from the study area is provided in the Table 3.32.

Table 3.32 Fish Diversity of the Study Area

S.N. Family Scientific Name Common Name IUCN Status

1 Notopteridae Notopterus notopterus Grey featherback LC 2 Clupeidae Corica soborna Ganga river-sprat LC 3 Tenualosa ilisha Hilsa LC 4 Engraulidae Setipinna taty Scaly Hairfin Anchovy LC 5 Cyprinidae Amb/ypharyngodon mola Mola carplet LC 6 Catla catla Catla Carp LC 7 Cirrhinus mriga/a Mrigal Carp LC 8 Labeo bata Bata LC 9 Labeo rohita Rohu LC 10 Labeo calbasu Kalbasu LC 11 Puntius sarona Olive barb LC 12 Puntius sophore Spotfin swamp barb LC 13 Puntius ticto Ticto barb LC 14 Cobitidae Lepidocepha/us guntea Guntea loach LC 15 Bagridae Mystus bleekeri Tengra LC 16 Mystus cavasius Gangetic Mystus LC 17 Mystus gulio Long-whiskered cat fish LC 18 Mystus vittatus Striped dwarf catfish LC 19 Rita rita Rita LC 20 Sperata aor Long-whiskeerd catfish LC 21 Sperata seenghala Giant river- catfish LC 22 Schilbeidae Clupisoma garua Garua Bachcha LC 23 Eutropiichthys murius Murius vacha LC 24 Eutropiichthys vacha Murius vacha LC 25 Ariidae Arius gagora Gagora catfish NT 26 Belonidae Strongylura strongylura Spottail needlefish NE 27 Aplocheilidae Aplocheilus panchax Blue panchax LC 28 Ambassidae Chanda nama Eongate glass-perchlet LC 29 Pseudambassis ranga Indian glassy fish LC 30 Scatophagidae Scatophagus argus Spotted Scat LC 31 Nandidae Nandus nandus Mottled Nandus LC 32 Mugilidae Liza macrolepis Largescale mullet LC 33 Gobiidae Glossogobius giuris Tank Goby LC 34 Anabantidae Anabas testudineus Climbing perch DD 35 Belontiidae Colisa fasciatus Stripled Gourami LC 36 Colisa lalia Dwarf Gourami LC 37 Channidae Channa marulius Giant snakehead LC 38 Channa striatus Banded snakehead LC 39 Mastacembelidae Mastacembelus armatus Tire-track spiny eel LC

(1) M.K. Das, M.K. Bhandhopadhya, A.P. Sharma, S.K. Paul, S.Bhhowmick. 2013. Fishes of River Narmada, A Field

Identification Manual. Central Inland Fisheries Research Institute.


198

S.N. Family Scientific Name Common Name IUCN Status

40 Macrognathus pancalus Stripped spiny eel LC

Source: M.K. Das, M.K. Bhandhopadhya, A.P. Sharma, S.K. Paul, S.Bhhowmick. 2013. Fishes of River Narmada, A Field Identification Manual. Central Inland Fisheries Research Institute. Notes: Conservation Status: IUCN: LC-Least Concern, DD- Data Deficit, NE-Not Evaluated

Herpetofauna: Two (2) species of amphibians belonging to two (2) families and eight (8) species of reptiles belonging to six (6) families were observed and reported based on primary survey and community consultation and consultation with forest department. The details of the species recorded are provided in Table 3.33.

Table 3.33 Herpetofauna reported and observed in the Study Area

S.N. Common Name Scientific Name

Family Source IUCN Status

WPA, 1972 Schedule

A. Amphibians 1 Common Indian

Toad Duttaphrynus melanostictus

Bufonidae PS LC -

2 Skittering frog Euphlyctis cyanophlyctis

Dicroglossidae PS LC IV

B. Reptiles 1 Oriental Garden

Lizard Calotes versicolor

Agamidae PS NA -

2 House gecko Hemidactylus fluviviridis

Gekkonidae PS LC -

3 Fan-throated lizard

Sitana ponticeriana

Gekkonidae CC +PS LC -

4 Russell’s Viper Daboia russelii Viperidae CC LC II 5 Indian Rat

snake Ptyas mucosus Colubridae CC+FD LC II

6 Indian Cobra Naja naja Elapidae CC+FD LC II 7 Common Indian

Krait Bungarus caeruleus

Elapidae CC+FD LC II

Source: PS- Primary Survey, CC- Community Consultation, FD- Consultation with Forest Department Officials Notes: IUCN Conservation Status: LC-Least Concern, NA-Not assessed NL-Not listed; Source: http://envfor.nic.in/legis/wildlife/wildlife1.html

Avifauna: Forty eight (48) birds species belonging to thirty two (32) families were observed with proper evidence of their presence in the study area during primary survey. As per the WPA, 1972, one (1) bird species was identified as Schedule I species - Black kite (Milvus migrans) of Accipitridae family during the primary survey. From the IUCN Red List of Threatened Species V 2017-3, two species, viz., River Tern (Sterna aurantia) and Painted Stork (Mycteria leucocephala) and are classified as Near Threatened (NT). No Migratory bird species were recorded from the study conducted during May, 2018.


199

Out of forty eight (48) species from the study area, nineteen (19) species use aquatic habitats and twenty nine (29) species use terrestrial habitats. The details of birds are provided below in Table 3.34.

Table 3.34 Avifaunal Species observed in the Study Area during primary survey

S.N.

Common Name

Scientific Name

Family Migratory Status

Habitat

IUCN

WPA, 1972 Schedule

Remarks

1. Black Kite Milvus migrans

Accipitridae R T LC I Recorded adjacent to GIDC reservoir on the water tank (Lat. 21°36'20.82"N, Long. 73°0'26.45"E)

2. Indian Spot-billed Duck

Anas poecilorhyncha

Anatidae R A LC IV -

3. Lesser Whistling Duck

Dendrocygna javanica

Anatidae R A LC IV -

4. Ashy crowned Sparrow Lark

Eremopterix griseus

Alaudidae R T LC IV -

5. Common Kingfisher

Alcedo atthis Alcedinidae R A LC IV -

6. Pied Kingfisher

Ceryle rudis Alcedinidae R A LC IV -

7. Common Swift

Apus apus Apodidae R T LC IV -

8. House Swift

Apus nipalensis

Apodidae R T LC IV -

9. Cattle Egret

Bubulcus ibis

Ardeidae R A LC IV -

10. Indian Pond Heron

Ardeola grayii


11. Intermediate Egret

Mesophoyx intermedia


12. Little Egret Egretta garzetta


13. Red-wattled Lapwing

Vanellus indicus

Charadriidae R A LC IV -

14. Black-winged Stilt

Himantopus himantopus

Charadriidae R A LC IV -

15. Painted Stork

Mycteria leucocephala

Ciconiidae R A NT IV -

16. Tailor Bird Orthotomus sutorius

Cisticolidae R T LC IV -

17. Laughing Dove

Spilopelia senegalensis

Columbidae R T LC IV -


200

S.N.

Common Name

Scientific Name


Habitat

IUCN

WPA, 1972 Schedule

Remarks

18. Common Pigeon

Columba livia


19. Spotted Dove

Spilopelia chinensis


20. House Crow

Corvus splendens

Corvidae R T LC V -

21. Indian Jungle Crow

Corvus macrorhynchos

Corvidae R T LC IV -

22. Asian Koel Eudynamys scolopaceus

Cucculidae R T LC IV -

23. Black Drongo

Dicrurus macrocercus

Dicruridae R T LC IV -

24. Indian Silverbill

Lonchura malabarica

Estrildidae R T LC IV -

25. White Throated Kingfisher

Halcyon smyrnensis

Halcyonidae R A LC IV -

26. River Tern Sterna aurantia

Laridae R A NT IV -

27. Coppersmith Barbet

Megalaima haemacephala

Megalaimidae R T LC IV -

28. Green Bee-eater

Merops orientalis

Meropidae R T LC IV -

29. Indian Robin

Saxicoloides fulicatus

Muscicapidae R T LC IV -

30. Purple Sunbird

Nectarinia asiatica

Nectariniidae R T LC IV -

31. Indian Golden Oriole

Oriolus kundoo

Oriolidae R T LC IV -

32. House Sparrow

Passer domesticus

Passeridae R T LC IV -

33. Little Cormorant

Microcarbo niger

Phalacrocoracidae

R A LC IV -

34. Grey Francolin

Francolinus pondicerianus

Phasianidae R T LC IV -

35. Baya Weaver

Ploceus phillipinus

Ploceidae R T LC IV -

36. Little Grebe

Tachybaptus ruficollis

Podicipedidae R A LC IV -

37. Rose ringed Parakeet

Psittacula krameri

Psittaculidae R T LC IV -

38. Red vented Bulbul

Pycnonotus cafer

Pycnonotidae R T LC IV -

39. White-breasted Waterhen

Amaurornis akool

Raliidae R A LC IV -

40. Purple Swamphen

Porphyrio porphyrio

Raliidae R A LC IV -

41. Eurasian Coot

Fulica atra Raliidae R A LC IV -


201

S.N.

Common Name

Scientific Name


Habitat

IUCN

WPA, 1972 Schedule

Remarks

42. Common Myna

Acridotheres tristis

Sturnidae R T LC IV -

43. Bank Myna Acridotheres ginginianus

Sturnidae R T LC IV -

44. Large Grey Babbler

Turdoides malcolmi

Sylviidae R T LC IV -

45. Red naped ibis

Pseudibis papillosa

Threskiornithidiae

R A LC IV -

Notes: Migratory Status:- R-Resident, M-Migratory, Habitat Status:- A-Aquatic, T-Terrestrial, Conservation Status : IUCN: -NT-Near Threatened, LC-Least Concern Source: http://envfor.nic.in/legis/wildlife/wildlife2s1.html

Mammals: Information about six (6) mammals belonging to six (6) families were collected from the study area. No species of mammal is listed under Schedule I of the Indian Wildlife (Protection) Act, 1972 or listed in IUCN Red List of Threatened Species. Mammals like Nilgai (Blue Bull) (Boselaphus tragocamelus), Jackal (Canis aureus) and Common Hare (Lepus nigricollis) were reported from the agricultural land and scrublands of the study area. The details of the species recorded/reported from the study area are provided in Table 3.35.

Table 3.35 Mammals Reported from the Study Area

S.N. Common Name

Scientific Name Family Source IUCN Status

WPA, 1972 Schedule

1 Nilgai (Blue Bull)

Boselaphus tragocamelus

Bovidae FD+CC LC III

2 Jackal Canis aureus Canidae FD+CC LC II 3 Southern

Plains Gray Langur

Semnopithecus dussumieri

Cercopithecidae FD+CC LC II

4 Common Hare Lepus nigricollis Leporidae FD+CC LC IV 5 Five-Striped

Palm Squirrel Funambulus pennati

Sciuridae PS+CC LC IV

6 Indian Grey Mongoose

Herpestes edwardsii

Herpestidae PS+CC LC IV

Source: PS- Primary Survey, CC- Community Consultation, FD- Discussion with Forest Department Notes: Conservation Status: IUCN: LC-Least Concern, NT-Near Threatened

3.3.6 Protected Area

There are no protected areas such as National Parks or Wildlife Sanctuaries within 10 km of UPL Unit II. Nearest Protected area is Shoolpaneshwar Wildlife Sanctuary, located about 60 km east, aerial distance from the Project site.


202

Figure 3.24 Protected Area

3.4 BASELINE – SOCIAL ENVIRONMENT

This section presents a socio-economic profile of the study area demarcated for M/s UPL Unit II located in Ankleshwar taluka of Bharuch district in Gujarat. It aims to provide the reader with key information about the study area including demographic features, land use, changing livelihood patterns, income and expenditure profile, status of social infrastructure etc.

3.4.1 Approach and Methodology

The baseline is prepared with the help of secondary information as well as primary data collected through consultations with various stakeholders. Secondary information review A review of information available in the public domain and secondary data sources was undertaken in order to substantiate and add value to the primary data collected. The following data sources were used for this purpose: Primary Census Abstract, Census of India, 2011; Village Directory, Census of India, 2011; District Census Handbook of Bharuch 20011; District industrial potentiality survey report of Bharuch district 2016-172, Socio-economic review 2017-2018 Gujarat state3,

(1) https://gujecostat.gujarat.gov.in/sites/default/files/23%20DANG%20ENG.pdf (2) http://dcmsme.gov.in/dips/2016-17/9.%20Bharuch%202016-17.pdf (3) https://gujecostat.gujarat.gov.in/sites/default/files/socio-economic-review-2017-18-part-i-iii.pdf


203

Cluster Profile Report of Ankleshwar Chemical Cluster 20121, District Human Development Report of Bharuch district 2015, Research papers on importance of Narmada, Agriculture and

Industrialisation in Bharuch, news articles on local governance, provision of basic amenities, cases of accidents and incidents in Ankleshwar causing damage to property and humans etc.

Research papers on importance of Narmada, Agriculture and Industrialisation in Bharuch,

News articles on local governance, provision of basic amenities, Cases of accidents and incidents in Ankleshwar causing damage to property

and humans etc. Stakeholder consultations A person, group, or entity under influence of the project and with potential to have effects on project activities were consulted at this stage. List of stakeholders consulted are presented below in Table 3.36.

Table 3.36 Stakeholders consulted during site visit

Date Stakeholders 8th May 2018 Community representatives from neighbouring villages and towns 8th May 2018 Representatives of Non-government Organisation (NGO) working in the area 8th May 2018 Block Development Officer 8th May 2018 Shopkeepers in the Ankleshwar Industrial Area 9th May 2018 Doctors at Primary Health Care (PHC) centres 9th May 2018 Medical staff at Employees State Insurance (ESI) Hospital 9th May 2018 Range Forest Officer etc.

As part of these consultations, an attempt was made to develop an understanding of key concerns of stakeholders related to health, water, livelihood etc. and their perception about the project and expectations from the project proponent.

3.4.2 State & District Profile

The state of Gujarat is situated in the westernmost corner of India and stands bordered by state of Rajasthan in the north east, Madhya Pradesh in the east, and Maharashtra and the Union territories of Diu, Daman, Dadra and Nagar Haveli in the south. It also shares north western border with neighbouring country Pakistan. The Arabian Sea borders the state both to the west and the south west. Gandhinagar is the capital of Gujarat. As per the website of Gujarat State Finance commission, there are 5 divisions in Gujarat viz., Kutch, Central Gujarat, North Gujarat, Saurashtra and South Gujarat. There are 33 districts in Gujarat, which have been further subdivided into 249 sub-districts or tehsils2.

(1) https://www.sidbi.in/files/Cluster%20Profile%20Report%20-%20Ankleshwar%20%28Chemical%29%20Cluster.pdf (2) Tehsil also tahsil is an administrative divisions of India denoting a sub-district. Tehsils are also referred to as "talukas" or "mandal" in some states. Tehsils can consist of multiple villages and a few towns. The Panchayat samitis are usually the

administrative governing bodies of the tehsils.


204

Figure Administrative divisions in Gujarat

Source: Gujarat State Finance Commission website Gujarat covers an area of 196,024 square km1, which forms 10.41% of the total geographical area of India and Bharuch district admeasuring 6,509 sq.km. forms 3% of the total geographical area of Gujarat. Key demographic features of Gujarat State is presented below in

Table 3.37 Key demographic features of Gujarat State

Attributes Gujarat % of India Bharuch % of Gujarat Area (sq. km) 1,96,244 10.41 6,509 3.32 Total population 6,04,39,692 5.66 15,51,019 2.57 Males 3,14,91,260 5.71 8,05,707 2.56 Females 2,89,48,432 5.62 7,45,312 2.57 Sex ratio 919 NA 925 NA Percentage of rural Population 57.40 NA 66.15 NA Percentage of urban population 42.60 NA 33.84 NA Population density (individuals per sq. km.)

308 NA 238 NA

Source: Census of India, PCA, 2011

The population of Gujarat that is 6,04,39,692 forms 5% of the total population of India and the population of Bharuch district that is 15,51,019 forms 3% of total population living in Gujarat. The population density in Gujarat (328 persons per sq.km.) is higher than the population density in Bharuch district (238 persons per sq.km.). More than half of the population in Gujarat (57%) as well as in Bharuch (66%) live in rural areas. When compared to the rural population of India (68.84%), the rate of urbanisation in Gujarat seems to be relatively high.

(1) http://www.gujaratindia.com/about-gujarat/fact-file.htm

Gujarat state

South Gujarat Division

Bharuch district

Ankleshwar tehsil

34 Villages, 1 Town


205

The population density in the study area is 738.6 inhabitants per sq.km. It is significantly higher than the population density of 238 persons per sq.km in Bharuch district. The average population density in the buffer zone is 441.1 persons per sq.km; whereas in the core zone with majority of migrant population, it is 1958.05 persons per sq.km. The core zone is the closest locality to the project site. In the buffer zone, the closest two villages are Jitali and Dadhal. Some of the villages with significantly high population density include Kapodara (1555.9) and Dadhal (1539.6). Population density across the study area is described below and is shown in Figure 3.26 : a) 13 villages with population density of less than 300 persons per sq.km; b) 5 villages with population density ranging between 300 persons and 500

persons per sq.km; and c) 8 villages that have more than 500 persons living per sq.km of distance.

Figure 3.25 Population Density in the Study Area


Scheduled caste and Scheduled tribe population In the tehsil, the Scheduled Caste population is 3.7% and the Scheduled Tribe population a 23.6%. Out of total population in the study area, 29.6% is comprised of Scheduled Tribes whereas merely 4.4% is comprised of Scheduled Caste. The tehsil does not fall under Schedule V area1. Apart from these, the highest population in the study area belongs to OBC community. Sex ratio

(1) http://pesadarpan.gov.in/en_US/fifth-schedule-areas/-/asset_publisher/LmZ9LplaCh7b/content/scheduled-areas-

in-gujarat?inheritRedirect=false&redirect=http%3A%2F%2Fpesadarpan.gov.in%2Fen_US%2Ffifth-schedule-areas%3Fp_p_id%3D101_INSTANCE_LmZ9LplaCh7b%26p_p_lifecycle%3D0%26p_p_state%3Dnormal%26p_p_mode%3D

view%26p_p_col_id%3Dcolumn-1%26p_p_col_count%3D1

13

5

8

0

2

4

6

8

10

12

14

180-300 persons sq.km 300-500 persons sq.km 500 and above personssq.km

Population Density

No. of Villages


206

The sex ratio in Bharuch district has shown an increasing trend in the successive decade, from 921 females per thousand males in 2001 to 925 females per thousand males in 2011. In the study area average sex ratio is 852 females per 1000 males, which is much lower than the district average. Specifically in the core zone, the sex ratio is higher at 855 females per 1000 males whereas in the buffer zone it is 851 females per 1000 males. Considering the continuously increasing population of migrant working class in the core zone and neighbouring villages to the core zone largely comprises of males compared to females, could be one of the reasons behind this difference in the study area vis-à-vis district sex ratios. Migration The district, till before the advent of industrial growth sector, was marked by high incidence of inter-district migration. They key reasons being - (i) adverse agro-climatic conditions with a large proportion of land affected by salinity; and (ii) substantial tribal population with marginal landholdings with limited access to the forest resources within the region1.

3.4.3 Study Area Profile

The study area for the social baseline is demarcated to be 10 km of radius around the proposed Project site. The study area is divided into two zones –core and buffer. The core zone starts from the site boundary and stretches up to 2 km of radius around the unit. This is estimated as the direct impact zone of the project activities. The buffer zone starts from the outer boundary of core zone and stretches 8 km further. The total study area comprises of 33 villages and 3 towns (Ankleshwar INA, Andada and Gadkhol), covering sections of three tehsils viz. Ankleshwar, Jhagadia, and Valia (also known as a sub-district or a block). The core zone falls under Ankleshwar tehsil and consists of Ankleshwar INA. The Ankleshwar INA comprises of various residential colonies including, Hifazat Nagar, Patel Nagar, Laxman Nagar, Padmavat Nagar, Miranagar, and Valia Chowkdi. The buffer zone comprises of 33 villages and remaining 2 towns under the three tehsils. Key demographics The study area is spread across 31,400 ha. The total population of the study area is 1,45,259; out of which 17% lives in the core zone whereas 83% lives in the buffer zone. Key demographics of core zone and buffer zone as per 2011 census data have been shown below in Table 3.38.

(1) http://gidr.ac.in/pdf/WP-125.pdf


207

Table 3.38 Key demographics of the Study Area

Tehsils Villages Total Population

No. of Households

Population density

Sex Ratio Literacy Rate (%)

Female Literacy rate (%)

Scheduled Caste Population (%)

Scheduled Tribe Population (%)

Tehsils Ankleshwar - 315596 70782 48.5 113.4 75.4 70.7 3.7 23.6 Core zone Ankleshwar Ankleshwar INA 24789 6206 NA* 855.6 84.6 83.4 1.3 2.4 Total (core) - 24789 6206 NA* 855.6 84.6 83.4 1.3 2.4 Buffer zone Ankleshwar Taluka

Amrutpura 943 182 410.00 878.49 65.6 60.1 0.0 98.8 Andada (CT) 16730 4076 NA 877.03 79.2 75.5 13.3 15.0 Dadhal 3695 758 1539.58 1010.34 73.3 68.5 0.8 35.9 Gadkhol (CT) 25332 6100 NA 746.19 76.9 70.9 4.8 7.5 Jitali 4225 921 320.08 956.02 68.6 63.1 2.2 49.8 Kansiya 3686 755 277.14 926.82 71.3 62.6 0.3 48.3 Kapodara 4512 956 1555.86 871.42 71.0 66.6 2.0 34.0 Kosamadi 12287 2817 835.85 902.60 72.3 67.9 2.3 16.0 Motali 895 180 526.47 949.89 60.9 53.2 0.6 82.0 Surwadi 2739 643 782.57 924.81 77.1 73.6 7.6 29.9

Uchhali 895 198 198.9 984.5 66.7 62.4 3.4 56.3 Borbhatha 1176 252 317.8 973.2 66.9 57.9 0 73.3 Bobhata Bet 4680 996 793.2 941.1 68.5 58.4 0.7 30.8 Avadar 1333 291 272.0 885.4 72.2 68.1 0.0 65.4 Kararvel 1526 329 214.9 943.9 68.1 60.6 1.2 43.1 Pardi Mokha 586 118 279.0 1006.8 79.7 74.1 0.0 37.0 Piprod 607 127 242.8 1036.9 59.3 54.4 0.0 67.9 Bhadi 2831 529 358.4 1050.0 63.8 60.1 0.5 35.5 Kharod 4658 802 548.0 775.8 80.5 77.2 1.5 25.2 Bakrol 1591 393 221.0 869.6 74.4 65.4 5.2 55.9 Umarwada 3711 761 255.9 980.3 67.8 62.8 5.0 52.0 Amboli 1072 214 397.0 988.9 72.9 69.0 11.3 69.6 Pungam 2017 448 530.8 946.9 65.6 62.6 2.3 61.8 Boidara 1644 371 293.6 968.9 74.6 68.1 1.4 29.3 Divi 581 125 187.4 1010.4 78.8 72.6 1.9 79.3 Surwadi 2739 643 782.6 924.8 77.1 73.6 7.6 29.9


208

Tehsils Villages Total Population

No. of Households

Population density

Sex Ratio Literacy Rate (%)

Female Literacy rate (%)

Scheduled Caste Population (%)

Scheduled Tribe Population (%)

Chhapra 1335 287 834.4 940.4 60.5 53.0 6.1 68.8 Sanjali 5344 1560 685.1 431.2 80.9 68.6 2.0 20.3 Boridara

(Dumala) 960 203 282.4 939.4 72.5 69.5 9.1 32.1 Mulad 1043 211 306.8 971.6 72.7 65.4 5.6 58.6 Kharchi Bhilwada 998 217 499.0 992.0 64.1 53.3 0.0 93.1 Kharchi 1068 238 267.0 857.4 80.4 74.0 2.2 38.2 Untia 752 174 289.2 989.4 68.1 62.6 0.0 56.8 Sardarpura 456 102 240.0 846.2 84.2 84.2 0.0 44.7 Kondh 4562 942 236.3 923.3 70.3 63.7 3.6 50.1 Total (buffer) - 120470 27276 654.7 851.4 73.9 68.0 4.4 29.6 Grand total/ Average of core and buffer

-

145259.0 33482.0 Limited Information 852.1 75.7 70.6 3.9 25.0

Source: Census of India, PCA, 2011 Note**: NA = Not Available.


209

Population density The population density in the study area is 789.4 inhabitants per sq.km. It is significantly higher than the population density of 238 persons per sq.km in Bharuch district. Although, buffer zone has population density of 366 persons per sq.km; core zone has shown higher population density of 1,781 persons per sq.km. indicating larger proportion of inhabitants living in the immediate vicinity of the industrial area compared to villages at further distance (beyond 2km). Some of the villages with significantly high population density include Kapodara (1,555.9), Dadhal (1,539.6), Kosamadi (835.9). Population density across the study area is described below and is shown in Figure 3.26 : d) 15 villages with population density of less than 300 persons per sq.km; e) 7 villages with population density ranging between 300 persons and 500

persons per sq.km; and f) 10 villages that have more than 500 persons living per sq.km of distance.

Figure 3.26 Population Density Across the Study Area


3.4.3.1 Migration trends

According to a paper published by Gujarat Institute of Development Research (GIDR), Ankleshwar had majority of in-migrants in the district in 2001 and all of them migrated for non-agricultural purposes. There is no data available on present migration trends; however, as per consultations with the locals there has not been substantial change in the proportion of migrants in the last one decade in the core zone. Moreover, the seasonal out-migration for temporary work, to other tehsils within Bharuch district and to other districts within Gujarat has also reportedly reduced significantly because of availability of employment opportunities within Ankleshwar tehsil.

02468

10121416

180-300 personsper sq.km

300-500 personsper sq.km

500 and abovepersons per

sq.km

Villages


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Social groups Both Jhagadiya and Valia tehsils, covering the buffer zone of the study area, fall under Schedule V areas1 and have predominant schedule tribe population of 68.7% and 78.2% respectively. However, Ankleshwar tehsil occupying the major section of the study area has comparatively lesser population (23.6%) of Scheduled Tribes. The Schedule Caste population is 3.7% in Ankleshwar tehsil, 2.1% in Jhagadiya tehsil and 0.7% in Valia tehsil. Out of total population in the study area, 25.5% comprises of scheduled tribes whereas merely 4% is comprised of Scheduled Caste.

(1) http://pesadarpan.gov.in/en_US/fifth-schedule-areas/-/asset_publisher/LmZ9LplaCh7b/content/scheduled-areas-

in-gujarat?inheritRedirect=false&redirect=http%3A%2F%2Fpesadarpan.gov.in%2Fen_US%2Ffifth-schedule-areas%3Fp_p_id%3D101_INSTANCE_LmZ9LplaCh7b%26p_p_lifecycle%3D0%26p_p_state%3Dnormal%26p_p_mode%3D

view%26p_p_col_id%3Dcolumn-1%26p_p_col_count%3D1


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3.4.4 Livelihood profile

The Worker Participation Rate (WPR) i.e. number of people engaged in some or the other work in the study area is 39.13%, which is equivalent to the WPR at the Ankleshwar taluka at 37.4%; however, lesser than the WPR at Jhagadiya and Valia block that is 45.8% and 50% respectively. The total workers are divided into two groups viz. main (those who work for more than 6 months a year) and marginal (those who work for 6 months or less in a year). The proportion of main workers in the study area is significantly higher at 91% than marginal workers that are merely 9% of the total working population. In other words, the working population in study area, has availability of work for major part of the year.

Industrial sector The largest group of workers (64.9% from main workers and 4.3% from marginal, total of 69%) are ‘other workers’ mainly engaged as industrial labourers, as reported. The other workers also include construction workers, shopkeepers, school teachers etc. Based on the community consultations it is understood that persons belonging to Modi community (OBC category) mainly run small shops of grocery items in the study area; whereas those belonging to ST community are industrial labourers. The distribution of working population in the study area under different categories is presented in Table 3.39 and is shown below in Figure 3.27.

Figure 3.27 Percentage of Working Population in the Study Area


6.3

18.4

1.0

64.9

0.94.1

0.34.3

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

maincultivator

main agri main HH main other marginalcultivators

marginalagri

marginalHH

marginalother

% of Workers


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Table 3.39 Percentage of Working Population in the Study Area

Talukas Village names

(A) Total Working Population (%)

(a) Main Workers (%)

Distribution of Main Workers (b) Marginal Workers (%)

Distribution of Marginal Workers

Cultivators

Agricultural Labourers

Household Industry Workers

Other workers

Cultivators



Other workers

Ankleshwar Taluka

- 37.4 91.4 7.1 20.6 1.0 71.3 8.6 7.6 39.1 2.7 50.6

Jhagadia Taluka

- 45.8 78.0 17.4 60.0 1.4 21.3 22.0 7.5 73.5 2.5 2.5

Valia Taluka - 50.1 77.6 14.2 64.6 1.2 20.0 22.4 7.5 76.5 1.9 1.9

Core zone

Ankleshwar INA

34.3 96.6 0.5 0.4 0.4 98.7 3.4 4.2 0.7 4.2 91.0

Buffer zone

Andada (CT)

34.4 95.4 2.7 11.2 1.2 84.9 4.6 3.8 29.2 3.8 63.3

Kansiya 192.3 87.8 11.7 77.3 0.3 10.6 12.2 11.3 76.9 0.0 11.8 Gadkhol (CT)

36.9 91.2 0.9 2.5 1.7 95.0 8.8 2.8 6.8 6.7 83.8

Motali 9.1 90.1 19.3 53.9 0.3 26.5 9.9 21.1 65.8 0.0 13.2

Uchhali 55.3 91.7 16.5 59.9 0.0 23.6 8.3 11.1 74.1 0.0 14.8

Dadhal 10.6 88.5 11.9 33.4 3.4 51.3 11.5 5.4 42.3 6.0 46.3

Jitali 211.6 86.0 9.1 46.4 2.5 42.1 14.0 4.9 85.0 0.9 9.3

Kapodara 99.4 97.0 7.4 15.4 3.4 73.8 3.0 14.9 53.2 0.0 31.9

Kosamadi 98.4 93.8 7.1 6.6 1.4 84.9 6.2 17.3 13.4 3.2 66.1

Amrutpura 10.5 64.9 15.1 58.3 0.8 25.8 35.1 23.5 64.0 1.5 11.0

Ankleshwar Taluka

Borbhatha 46.6 92.3 11.1 74.7 0.0 14.2 7.7 16.7 31.0 0.0 52.4 Borbhatha Bet

49.4 91.2 14.2 42.6 0.7 42.5 8.8 9.8 38.7 1.0 50.5

Chhapra 16.3 92.5 7.2 65.8 0.0 27.0 7.5 20.0 62.2 2.2 15.6

Surwadi 110.5 90.3 9.7 18.9 0.9 70.4 9.7 31.3 42.7 4.2 21.9

Divi 23.7 99.1 22.9 60.0 0.0 17.1 0.9 50.0 50.0 0.0 0.0

Pungam 68.1 89.1 17.1 56.6 0.4 26.0 10.9 7.1 87.9 0.0 5.1


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Talukas Village names

(A) Total Working Population (%)

(a) Main Workers (%)

Distribution of Main Workers (b) Marginal Workers (%)

Distribution of Marginal Workers

Cultivators



Other workers

Cultivators



Other workers

Boidara 40.7 80.8 12.0 33.9 2.2 52.0 19.2 7.6 52.1 5.9 34.5

Kararvel 89.6 74.1 17.4 29.0 0.5 53.1 25.9 14.9 34.8 0.7 49.6

Amboli 21.1 46.1 10.9 54.9 3.3 30.9 53.9 8.1 73.3 5.0 13.7

Umarwada 30.7 97.2 11.7 57.2 0.0 31.1 2.8 12.5 55.0 0.0 32.5

Piprod 24.6 95.1 8.4 58.6 0.0 33.1 4.9 15.4 53.8 0.0 30.8

Avadar 30.1 59.5 22.7 9.1 1.4 66.8 40.5 2.4 95.5 0.0 2.0 Pardi Mokha

12.1 96.0 18.3 35.6 0.0 46.1 4.0 12.5 50.0 0.0 37.5

Bakrol 134.6 70.8 14.6 14.6 2.9 67.9 29.2 5.3 65.4 2.2 27.2

Kharod 47.1 95.8 18.0 34.2 0.2 47.6 4.2 37.0 11.1 0.0 51.9

Bhadi 67.3 96.7 20.9 37.0 0.2 41.9 3.3 13.3 36.7 0.0 50.0

Sanjali 59.4 90.5 0.7 5.4 0.2 93.6 9.5 0.0 13.6 0.0 86.4

Jhagadia Taluka

Boridara (Dumala)

42.8 91.7 37.4 37.9 2.7 22.0 8.3 14.7 32.4 0.0 52.9

Mulad 41.9 89.9 19.3 54.2 1.8 24.7 10.1 27.3 54.5 4.5 13.6 Kharchi Bhilwada

38.3 62.6 25.1 27.2 0.8 46.9 37.4 4.2 58.7 0.0 37.1

Kharchi 50.4 73.8 22.4 29.2 0.3 48.1 26.2 14.2 60.3 2.1 23.4

Untia 67.3 79.4 24.1 30.8 0.5 44.5 20.6 42.3 47.1 0.0 10.6

Sardarpura 44.3 52.5 26.4 11.3 0.9 61.3 47.5 5.2 81.3 3.1 10.4

Valia Taluka Kondh 39.1 87.7 6.5 35.3 0.8 57.5 12.3 8.2 50.9 0.9 40.0 Source: Census of India, VD, 2011


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Agriculture and allied activities The second largest group of workers in the study area is of ‘agricultural labourers’. They form 11.7% of main workers and 2.1% of marginal workers. This is a primary occupation mainly for the landless households and marginal land holding households. Based on community consultations they largely comprised of ST community. It is understood that both men and women are engaged in any type of labour work for industrial or agricultural work. Amongst agricultural labourers, the general daily wage rate paid to a male workers is INR 150/- while for females, it is INR 120/-. The proportion of ‘cultivators’ is significantly low than the persons engaged in other work and agricultural labour work. The cultivators form 3.6% of the main workers and 0.5% of the marginal workers. Moreover, the proportion of cultivators is higher in the buffer zone (11% of total workers) as compared to core zone (3.6% of total workers). It is understood that although the largest part of land in the study area is comprised of cultivated land, the proportion of workers dependent on agriculture (including main and marginal) are 4.1% that is significantly lower than ‘other workers’ that primarily include industrial labour. This indicates that even with lower area of land occupied, industry has generated higher employment opportunities in the study area. In terms of agriculture, the average land holding in the study area is 5-6acres. Reportedly, cultivation in one bigha (1 bigha = 1.5acres) of land per season provides for INR 30,000-40,000/- profit. Some of the key crops cultivated in the core zone include Toor (pulse) and Sorghum (millet) that are primarily rain-fed crops; whereas in the buffer zone, paddy continues to be the key crop since last 3-4 decades that required higher amount of water for irrigation. As reported by the locals, farmers in the core zone have reduced the use of groundwater sources (bore well, tube well) for irrigation. However, there are some villages in the northern side of the industrial cluster such as Kansiya that continue to use groundwater sources for irrigation. This is related to closer proximity to Narmada river tributaries that helps maintain the ground water levels.

3.4.5 Civic infrastructure

Water The key sources of water available in the study are in the descending order of availability (most available source being the first) are untreated tap water, hand pumps, tube wells, un-covered wells, rivers and ponds. The sources of water in the Study area distributed in core and buffer zone within the Study area are presented in Table 3.40.


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Table 3.40 Water Sources in the Study Area

Number of villages with availability of following water sources

Tap Water Untreated

Uncovered Well

Hand Pump Tube Wells/Borehole

River/Canal Tank/Pond/Lake

Buffer Zone

32 8 24 22 9 0

Source: Census of India, VD, 2011 Note* - data not available for Andada and Gadkhol towns

Amongst these, tap water and hand pumps are the sources from which drinking water is drawn, whereas the remaining are used mainly for irrigation purposes. The locals reported that there have been water filtration plants being set up in the study area since last five years by both government (through Gram Panchayats) as well as private entities (mostly companies from industrial cluster). Therefore, dependency on hand pumps is anticipated to reduce with increasing number of water filtration plants in the villages. In terms of irrigation water sources, it is understood that since last 2-3 years large farmers (10ha and above) have started using drip Irrigation for cultivation. There has also been increase in the production of crop since this system has been introduced in farming. Health care The details of health care facilities available in the study area as given below in Table 3.41.

Table 3.41 Health Care Facilities in the Study Area

Study area Number of health care facilities Primary Health Centre

PHC Sub Centre

ESIC Hospital

Private hospitals

Buffer zone 2 14 1 1 Source: Census of India, VD, 2011 Note* - data not available for Andada and Gadkhol towns and Ankleshwar INA

As evident in the table above, majority of the health care facilities available in the study area are government facilities. Although the data shows only 1 private hospital, it dates back to 2011 and at present there are 4-5 private clinics for primary consultation and diagnosis in core zone. Similar infrastructure is available in buffer zone as well. The preferred facilities for locals is PHC and Sub centres (government facilities) for minor illnesses like cold and cough. Whereas for major illnesses such as persistent fever, Tuberculosis, Malaria, locals prefer to get treatment from private facilities. There is 1 ESIC hospital in the core zone that has 56,000 insured workers and their families from Ankleshwar industrial cluster.


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Some of the frequently faced illnesses by the workers engaged in the Ankleshwar industrial cluster are reported to include the following: Fungal infection leading to skin problems, Asthama/ bronco asthma – this is specially observed amongst children, Tuberculosis – mostly observed amongst female workers, HIV – T.B. and HIV are mostly inter-linked and patient suffering from HIV

more prone to T.B., Hebatitis B, Malaria and Dengue, Oral cancer – mostly lymphomas that can be linked to air pollution. Cases for treatments with major illnesses are generally referred to Sansthayam Hospotal in Baroda and Jayaben Hospital in Ankleshwar taluka. As reported by medical practitioners working at the ESIC, there have been medical camps organised in multiple industrial units in Ankleshwar cluster. Some of these companies include Asian Paints, J.B. Chemicals, Shyam Dying etc. Electricity The core zone has power supply for 24/7hours for domestic purpose and 8hours per day for agricultural purpose as reported. In the buffer zone, the power supply is for shorter period i.e. for 15hours a day for domestic purpose and 7hours a day for agriculture, as reported. This indicates that villages in closer proximity to the industrial cluster have better provision of electricity. There is a substation of 150MVA installed capacity (132KV) in Ankleshwar circle for power distribution as reported.

3.4.6 Industrial outreach programmes

The villages in the study area are benefited by Corporate Social Responsibility (CSR) interventions carried out by various companies in the Industrial Clusters of Ankleshwar and Jhagadia. The nature of these interventions is reported to be one time activities like monetary donations, distribution of material to schools, construction of temples, provisioning for water filtration plants, social forestry plantation etc. However, some of the companies also provide for primary health care through mobile clinics. The project proponent has reportedly invested 9.7% of its total profit. UPL reportedly has developed a CSR policy and also has a CSR committee at corporate level. Some of the activities undertaken by the unit management reportedly include – social forestry plantation, organising health camps, providing seeds for agricultural breed improvement, as well as skill based training for Self Help Groups (SHG). As reported, their beneficiaries also include persons from SC and ST.


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4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 INTRODUCTION

This section assesses the manner in which the proposed expansion Project will interact with elements of the physical, biological and social environment to produce impacts to resources/ receptors. This section identifies and assesses the potential changes in the environment that could be expected from the proposed increase in manufacturing of existing and new pesticides technical and intermediate products within the study area i.e., the area of influence. The impacts of existing activities has been captured as part of the prevailing environmental baseline conditions and continue to remain the same till the proposed increase of the capacities is taken up by UPL. Qualitative and quantitative (using mathematical/statistical techniques) methodologies have been used for predicting impacts due to the proposed developmental activities on physico-ecological and socio-economic environment. For environmental components (including land, biological and socio-economic environments), where use of mathematical models or statistical techniques are not possible, impact predictions are arrived at through available scientific knowledge and judgments. Scoping exercise initiated for this EIA study as per the requirement of the EIA Notification, 2006 (refer to methodology described in Section 1). The terms of reference for the EIA study were approved by Expert Appraisal Committee (Industry Projects-2) of MoEF&CC as per letter dated January 31, 2018. The scoping exercise included high level assessment of potential impacts and risk due to the proposed expansion Project.

4.2 IMPACT EVALUATION CRITERIA

The criteria that have been developed to evaluate impacts due to the proposed Project, together with existing operations on various environmental components is based on assessment of: Magnitude (severity) of impact i.e. actual change taking place to the

environment; and The sensitivity/importance/ value of receptors or the affected resource.

4.2.1 Determining Magnitude of an Impact

Magnitude i.e. severity of an impact or degree of change caused by a project activity is a function of one or more of the following characteristics: Extent; Duration (including Frequency and Likelihood); and Scale – Intensity. 1) Extent (Context)


218

The extent refers to spatial or geographical extent of a project and related activities. In this EIA study, extent of an impact has been determined as per the following understanding: a. Local (low spread), when impact are restricted within the Project footprints

up to 500 m due to the proposed augmentation of Project facilities. For the planned project components if the activities remain within footprint, these will have low spread i.e., local spread;

b. Subregional (subregional spread) when an impact due to the proposed Project is spread in a larger area of beyond 500 m up to 2 km from the Project footprint when the impacts most likely affects occupants within GIDC industrial estate;

c. Regional (regional spread) when impact/risk due to proposed Project extends beyond up to 10 km and affects communities within 10 km radius from the Project;

d. National and International (national and international spread*) when an impact/risk due to the proposed Project affects nationaly or internationally important environmental resources, such as protected areas or heritage sites of national and international importance including requirements under international conventions to which India is a signatory.

The above extent has been selected based on the understanding of the proposed Project related activities and prevailing environmental baseline conditions within 10km radius of the project within which no known protected areas and known sensitive habitats are located. 2) Duration The duration of an impact is to be determined whether it would be temporary, short-term, long-term or permanent. The impacts have been assessed considering impact duration and time taken by an environmental component to recover back to its best achievable pre-project state. For the proposed expansion project which is extension of already operative plant, impacts have been determined based on their existence in temporal scale as following: a. Temporary, (very low duration) when impact lasts for a limited period of six

(6) months or less and ceases on completion of the activity, or as a result of mitigation measures and natural recovery of resource or receptor;

b. Short-term (low duration) when impact is likely to be restricted for a duration of less than one (1) year; this is based on the understanding that there will be recovery of the effected environmental component to its best achievable pre-project state within three (03) years;

c. Medium -term (medium duration) when impacting 1 to 3 years ; this is based on the understanding that there will be recovery of the effected environmental component to its best achievable pre-project state within five (5) to ten (10) years; and

d. Long-term or Permanent (high duration) when impacting beyond three (3) years; this is based on the understanding that there will be recovery of the effected environmental component to its best achievable pre-project state within ten (10) years or beyond or upon decommissioning after completion of the Project life.


219

Within each of the above categories, the impact assessment (adverse or beneficial) considers impacts of one off or varying frequency as per following classification: a. Remote (R) – one off, when resulting remote or one off chance of an event

due to a an activity on a receptor/resource; b. Occasional (O), when an impact due to an activity is occurring

intermittently from time to time on a receptor/resource; c. Periodic (P), when an impact due to an activity is resulting on periodic basis

say for a week or a month on a resource/ receptor; d. Routine or Continuous (C), when an impact due to an activity is

continuously resulting on a resource/ receptor; and e. Non-routine (NR), when an impact is arising as an unplanned or accidental

events resulting in project related structure/infrastructure breakdown or catastrophic failure or external events (e.g. due to earthquake) causing impact on environment resources or receptors. The impact of non-routine events is assessed in terms of the Risk i.e. taking into account both the consequence of the event and the probability of occurrence (Risk = probability x consequence).

The likelihood of impacts/risks is determined based for unplanned or accidental events even with low probability. The likelihood of an impact/risk has been considered as per the following criteria: a. Unlikely (U), when an event is unlikely but may occur at some time during

normal operating conditions; b. Possible (Po), when an event is likely to occur at some time during normal

operating conditions; and c. Likely (L), when an event will occur during normal operating conditions

(i.e., it is essentially inevitable). 3) Intensity It is important to understand that some impacts results in changes to the environmental baseline that may be immeasurable, undetectable or within the range of normal natural variation. Such changes can be regarded as essentially having negligible intensity. Indicators of the intensity of an impact has been developed based on the understanding that the prevailing environmental and social baseline conditions gets changed or results into harmful effects or injury or damage to ecology due to the Project development as per following understanding: a. Low intensity, when an activity results in slight changes of prevailing

baseline conditions. This is based on the understanding that there will be recovery of the effected environmental conditions within short term;

b. Medium intensity, when an activity results in changes that are within the benchmark norms or shows some signs of stress and prevail for short term. This is based on the understanding that there will be recovery of the effected environmental conditions in long term of three (3) to ten (10) years; and

c. High intensity, when an activity results in changes which affects ecological or health impacts in larger extent or shows signs of stress in larger extent. This is based on the understanding that there will be recovery of the effected


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environmental conditions within ten (10) years or beyond following decommissioning or seizure of project activity causing such impact.

Based on the above understanding, magnitude is assessed as per Table 4.1 by considering the extent, duration and intensity of impacts of the proposed Project activities.

Table 4.1 Assessing Magnitude of Impact

Extent Duration Frequency Likelihood* Intensity Magnitude Local Short R, O, P or C U, Po or L Low Negligible Local Medium

R, O, P or C U, Po or L

Low

Small Local Long Low Subregional Short Low Subregional Medium Low Subregional Long Low Local Short


Medium

Medium

Local Medium Medium Local Long Medium Subregional Short Medium Subregional Medium Medium Subregional Long Medium Regional Short Low Regional Medium Low Regional Long Low Regional Short Medium Regional Medium Medium Regional Long Medium Local Short R, O U High

Large

Local Short P or C Po or L High Local Medium


High Subregional Medium High Subregional Short High Regional Short High Local Long High National/International Short High National/International Medium High Regional Long High National/International Long High

Note: * Applicable only for unplanned events; R = Remote; O = Occasional; P = Periodic; C = Continuous; U = Unplanned; Po = Possible; L = Likely In case of positive impacts, generally no magnitude is assigned. It is usually sufficient to indicate that the Project will result in a positive impact, without characterising the exact degree of positive change likely to occur.

Definition of magnitude for physical, biological and human environmental resources and receptors are given in Box 4.1.


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Box 4.1 Magnitude Definitions for Bio-physical and Human Resources & Receptors

Note: The above is developed based on ERM’s experience in impact assessment.

4.2.2 Determining Sensitivity / Importance/Vulnerability of Receptors

In addition to characterising the magnitude of impact, the other principal step necessary to assign significance for an impact is to define the sensitivity/ vulnerability/importance of the impacted resource/receptor. There are a range of factors to be taken into account when defining the sensitivity/ vulnerability/ importance of the resource/receptor, which may be physical, biological, cultural or human as per the following understanding: Where the resource is physical (for example, a water body) its quality,

sensitivity to change and importance (on a local, regional, national and international scale) are considered.

Where the resource/receptor is biological or cultural (for example, forests), its importance (on a local, regional, national or international scale) and its sensitivity to the specific type of impact are considered.

Where the receptor is human, the vulnerability of the individual, community or wider societal group is considered.

Apart from the above, other factors that are included to ascertain low, medium or high sensitivity/vulnerability/importance includes legal protection, economic value, government policy and stakeholders views. Following table provide further guidance:


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Table 4.2 Sensitivity/ Importance/ Vulnerability Criteria

Sensitivity Contributing Criteria

High

Existing physical environment quality is already under stress; Ecologically sensitive/ protected area, provides habitat for globally protected

species; Profound or multiple levels of vulnerability that undermine the ability to adapt

to changes brought by the project. Human receptors/ vulnerable community are located within the project

footprint and directly affected by the project activities Resource exclusive for community use

Medium

Existing physical environment quality shows some sign of stress; which is sensitive to change in quality or physical disturbance;

Natural habitat provides habitat for wildlife, which are protected under National regulations;

Some, but few areas of vulnerability; retaining an ability to at least in part adapt to change brought by the project.

Human receptors/ vulnerable community are located adjacent the project components footprint and likely to be affected by the project activities

Alternative resource available with community

Low

Existing physical environment quality is good; Alternate habitats are available for common species; Minimal vulnerability; consequently with a high ability to adapt to changes

brought by the Project and opportunities associated with it. Human receptors are located away and are not likely to be affected due to the

project related activities

4.2.3 Evaluating Significance of Impacts

After characterizing, magnitude of impact and sensitivity/ vulnerability/ importance of resource/ receptor the significance was assigned for each impact. Impact significance is designated using the matrix shown in Figure 4.1.

Figure 4.1 Impact Significance

The matrix applies universally to all resources/receptors, and all impacts to these resources/receptors, as the resource/receptor-specific considerations are factored into the assignment of magnitude and sensitivity/ vulnerability/

Sensitivity/Vulnerability/importance of Resource/Receptor

Low Medium High

Mag

nit

ude

of

Imp

act

Negligible Negligible Negligible Negligible

Small Negligible Minor Moderate

Medium Minor Moderate Major

Large Moderate Major Major


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importance designations that enter into the matrix. Box 4.2provides a context of what the various impact significance ratings imply.

Box 4.2 Context of Impact Significances

It is important to note that impact prediction and evaluation takes into account any embedded controls (i.e., physical or procedural controls that are already planned as part of the Project design, regardless of the results of the IA Process).

4.3 IDENTIFICATION OF POTENTIAL IMPACTS FOR UNIT 2 EXPANSION

The project proponent proposes to expand their fungicides, herbicides, specialty chemicals and intermediates technical products. The proposed expansion comprises of existing and new Pesticides (Technical) from 2,175 MT/month to 5580 MT/month and intermediate chemicals from 1,894 MT/month to 3,984 MT/month. All these activities will be implemented in a phased manner after obtaining all necessary approvals. The tentative plan to start the project will be from the Financial Year 2019 – 2020. Environmental impacts during proposed augmentation activities have been identified for each of the potential environmental components viz. air, water, land, biological and human / socio-economic due to relevant proposed project activity. Keeping in mind the proposed expansion project activities as described

An impact of negligible significance is one where a resource/ receptor (including people) will essentially not be affected in any way by a particular activity or the predicted effect is deemed to be ‘imperceptible’ or is indistinguishable from natural background variations. An impact of minor significance is one where a resource/ receptor will experience a noticeable effect, but the impact magnitude is sufficiently small and/or the resource/receptor is of low sensitivity/ vulnerability/ importance. In either case, the magnitude should be well within applicable standards/ guidelines. An impact of moderate significance has an impact magnitude that is within applicable standards/guidelines, but falls somewhere in the range from a threshold below which the impact is minor, up to a level that might be just short of breaching a legal limit. Clearly, to design an activity so that its effects only just avoid breaking a law and/or cause a major impact is not best practice. The emphasis for moderate impacts is therefore on demonstrating that the impact has been reduced to a level that is as low as reasonably practicable (ALARP). This does not necessarily mean that impacts of moderate significance have to be reduced to minor, but that moderate impacts are being managed effectively and efficiently. An impact of major significance is one where an accepted limit or standard may be exceeded, or large magnitude impacts occur to highly valued/sensitive resource/receptors. An aim of IA is to get to a position where the Project does not have any major residual impacts, certainly not ones that would endure into the long-term or extend over a large area. However, for some aspects there may be major residual impacts after all practicable mitigation options have been exhausted (i.e. ALARP has been applied). An example might be the visual impact of a facility. It is then the function of regulators and stakeholders to weigh such negative factors against the positive ones, such as employment, in coming to a decision on the Project.


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in Section 2, identification of impacts has been done as per the matrix given below in Table 4.3

Table 4.3 Project Activities, Related Events & Likely Resources / Receptors Affected

S.N. Activity Aspect Resource / Receptor likely to be affected

Environmental component

Proposed expansion of capacities of manufacturing of Pesticide Technical and Pesticide Intermediates

A Construction Phase A1 Site clearance

and civil construction

Air emission Human and biotic health due to fugitive air and noise emissions

Potential subsurface contamination due to solid waste and domestic waste water generation;

Soil quality of the site and immediate surrounding area;

Loss of habitat and disturbance to fauna at site.

Air Environment Land Environment Water Environment Noise Environment Socioeconomic Environment Ecological Environment

Water consumption Waste water generation Labour influx Solid waste generation Noise emission Soil compaction and loss of top soil Loss of habitat and species

A2 Material and waste handling

Spillage of hazardous substance / material

Potential soil and groundwater contamination due to improper handling of construction material and solid and hazardous wastes;

Human health due to air emissions;

Habitat disturbance at site.

Land Environment Air Environment Ecological Environment

Air emission

Loss of habitat and species

A3 Transportation of men and material

Air emissions Disturbance to residents enroute the transportation of construction material to the Site;

Human and biotic health due to air and noise emissions;

Community health and safety;

Disturbance to fauna at site

Air Environment Noise Environment Socioeconomic Environment Ecological Environment

Noise emissions

Traffic congestion and accidents Hunting or Trapping of Wildlife

B Operation Phase

B1 Process of manufacturing products

Air emissions – changes in air quality

Community health and safety;

Potential subsurface contamination at temporary storage

Air Environment Socioeconomic Environment Land Environment

Noise emissions

Wastewater generation


225



Hazardous waste generation

site before disposal;

Potential subsurface contamination due to spillage during manufacturing and maintenance of plant;

Ambient air quality deterioration affecting biological receptors’ health and crop productivity

Workplace health hazards;

Water Environment

Hazardous chemical/material spillage during manufacturing or maintenance Employment generation and local area development

B2 Handling and storage of hazardous chemicals in UPL

Air emissions, Workplace health hazards;

Community health

Air Environment Occupational hazards

Fugitive VOC emissions from storage tanks, Spillage of hazardous chemicals/materials

Potential subsurface contamination due to improper handling of hazardous materials/ chemicals

Land Environment Occupational hazards Potential non-routine risks

B3 Water requirement for domestic, processing, utilities, etc.

Fresh water consumption

Potential contamination of soil and groundwater

Community health

Water Environment Socioeconomic Environment Air Environment

Possible changes to freshwater resources Loss of water due to leakages/spillage

B4 Waste water generation including from scrubber and manufacturing process

Waste water generated from process

Soil and groundwater contamination

Land Environment Water Environment Sludge generation

during waste water treatment and evaporation

B5 Sewage discharges from the plant, offices, warehouse etc.

Treated sewage reuse in greenbelt development

Soil and groundwater contamination

Land Environment

B6 Hazardous waste generation and disposal

Waste storage and disposal to landfill;

Subsurface contamination due to spillage during handling and storage

Land Environment Water Environment


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Incineration of waste

Ambient air quality deterioration affecting human and biological receptors health

Air Environment

B7 Pumps, and other machinery operations

Noise generation Ambient noise quality

Ambient noise

Air emissions Ambient air quality deterioration affecting human and biological receptors health

Air Environment

Land Environment

Chemical spills Soil and groundwater contamination

B8 Floor and equipment cleaining and washing

Effluent generation Potential subsurface contamination at temporary site before disposal;

Water Environment Land Environment

Hazardous waste disposal

B9 Developing Greenbelt

Planting of native trees

Air emissions Noise emissions Soil erosion

Positive impacts on Air Environment; Noise Environment and Land Environment

B10 Road transportation of raw material and finished good

Accidental release on road Air and noise emission

Air emission Noise emission Water emission Land

contamination Community health

and safety

Physical and Socio-economic Resources

Traffic congestion and accidents

Onsite Risks – Hazards including Occupational Health Hazards have been described in Section 7. The anticipated potential impacts due to the above mentioned activities have been described as following sections.

4.4 POTENTIAL IMPACTS AND MITIGATION MEASURES DURING CONSTRUCTION

PHASE

The construction of facilities for the proposed expansion will be established in a phased manner. As the expansion will happen at existing facility, there is no requirement for additional land for the proposed expansion. The impacts from construction activities will be limited as the construction activities will be facilitated with the resources available at the existing plant, which includes source of water, waste disposal, power supply and storage of facilities. The impact assessment of construction and operation phase related activities as identified in Table 4.1 have been discussed in the following subsection.


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4.4.1 Impacts on Land Environment

Impact Sources The impacts on land environment during construction phase will result from: Disturbance to soil during construction; Spillage of construction materials and wastes on land; Disposal of construction waste/ municipal solid wastes in non-designated

area; Surface runoff from material and waste storage areas Impact Assessment Temporary and short term earth works, and other civil construction activities may result in loss of top soil. These impacts shall be restricted to limited land area within the boundary of existing plant premises. There is a possibility of impacts on land and soil quality due to improper handling and storage of construction related solid and hazardous wastes, lube-oil, diesel, paints and solvents. The general wastes during construction includes debris, concrete (often recycled and reused at the site), steel and other metals, pallets, packaging and paper products, bricks etc. The activity includes storage and handling of petroleum based products such as lubricants, hydraulic fluids, paints etc. Land and soil contamination may also occur due to oil leaks from construction machinery, spills from refueling and run off from these material storage areas to other drains. Thus, any land contamination will impact soil and subsurface groundwater quality, which will directly affect human health. Embedded Control Measures The top soil will be preserved and will be reused after the construction activity for greenbelt. Solid waste generated from the project components will be collected in a systematic manner and will be managed in line with Construction and Demolition Waste (Management & Handling) Rules, 2016 and Hazardous and Other Wastes (Management and Transboundary) Rules, 2016. The existing drains shall be utilised for collecting the surface run-offs. The existing greenbelt shall help in preventing any potential soil erosion. Mitigation Measures All construction material for the proposed expansion will be stored in the

covered area or will be covered with tarpaulin sheets to minimize its erosion due to wind or rain;

Ensure all excavated soil is well bunded and protected to minimize soil erosion through rain or wind;

Adequate provision shall be made for segregation of solid waste, storage of solid waste and for easy access to the dustbins;

All paints, solvents, oils and wastes shall be stored in a dedicated area which shall be weather proof and imperviously floor area with bund wall;

Preventive maintenance of construction equipment and temporary storage areas, to prevent occasional leaks. Drip pans shall be used to collect any oil drips;

UPL will monitor and supervise their contractors for all construction activities to prevent any potential soil and groundwater contamination.


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Impact Significance Impact Impacts on Land Environment

Nature Negative Positive Neutral

Type Direct Indirect Induced

Extent Local Subregional Regional National/International

Duration Temporary Short Term Medium Term Long Term

Frequency Remote – oneoff Occasional Periodic Routine/continuous Non-routine

Intensity Low Medium High

Impact Magnitude Negligible Small Medium Large Resource/Receptor Sensitivity

Low Medium High

Impact Significance (without mitigation measures)

Negligible Minor Moderate Major Without mitigation measures, impact intensity will be medium and impact magnitude will be Medium thus impact significance will be ‘Minor’.

Impact Significance (with mitigation measures)

Negligible Minor Moderate Major With mitigation measures, impact intensity will reduce to low and impact magnitude to Small thus impact significance will reduce to ‘Negligible’.

Residual Impact Implementation of appropriate method or procedure for handling and storage of paints, solvents, lube oils, diesel, solid and hazardous wastes for their effective segregation, storage, transportation and implementation of suggested mitigation measures would assist in minimising impact on land environment. The impact significance with mitigation measures in place is assessed as ‘Negligible’.

4.4.2 Impacts on Air Quality

Impact Sources Deteriorated air quality causes health issues. Potential impacts sources identified from construction activities related to the proposed Project on air quality include the following: 1. Site clearance and civil construction; 2. Material and waste handling; 3. Transportation of men and material; and 4. Emissions from emergency power diesel generators

Impact Assessment 1) Site Clearance and Civil Construction Dust emissions will be generated due to site clearance and construction activities such as earth moving, building foundations for process equipment’s, civil works etc. The proposed project’s facilities will be built in the area of existing plant and therefore land levelling, cut and fill will not be required. Use of DG Sets are restricted to emergency purpose. 2) Material and waste handling Wind-blown dusts will contribute to air quality during handling of construction materials like cement, sand, etc. and construction related wastes. However, the dust emissions will vary from day to day based on the level of activity and prevalent meteorological conditions.


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3) Transportation of men and material Emissions from the movement of ~20 vehicles each day to the site will be generated during transportation of men and material for the construction work at site and also from the operation of construction equipment’s at site. Trailer trucks, road tankers and open trucks will be used for movement of materials, associated equipment, chemicals, water and fuel. Additionally, the plant is well connected to National (NH-8), State Highway (SH-64,) and other internal connecting roads. Further, the entire augmentation will be undertaken in phases, hence the impact will be further minimized. Embedded Control Measures The plant is located in the organized industrial estate of GIDC; UPL has a well-established environmental team and shall supervise and

monitor the performance of all construction contractors during construction;

UPL carries out frequent monitoring of ambient air quality using accredited laboratories;

The vendor management system at UPL will ensure contract work is awarded only to experienced and competent contractors which can then support them in meeting all requirements of compliance;

All contractors to follow the protocols as set by UPL regarding construction management.

Mitigation Measures Enclosures and dust curtains to be provided at all construction sites; Water spray, is an effective way to keep dust under control. Misting systems

and sprinklers are mechanisms that can be employed to deliver continuous moisture to control fine particulate. The size of the water droplet must be comparable to the size of the dust particle so that the dust adheres to the water.

All material storages areas/warehouses to be adequately covered and contained so that they are not exposed to situations where winds on site could lead to dust / particulate emissions.

To use proper loading and unloading procedures for construction materials, and cover them wherever required.

Reducing vehicle speed. Speed bumps are commonly used to ensure speed bumps. In case where speed reduction cannot effectively reduce fugitive dust, it may be necessary to divert traffic to nearby paved areas.

Emergency diesel generators with adequate stack height will be used only in case of power supply interruption from grid supply.

Ensure periodic preventive maintenance of vehicles and construction equipment.

Regular monitoring of ambient air quality during the construction period to ensure compliance and corrective actions in case of any exceedances.

Strengthening of existing greenbelt to act as wind shield and also help in preventing soil erosion.


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Impact Significance Impact Deterioration of Ambient Air Quality during construction activities



Extent Local Subregional Regional National /International


Frequency Remote – oneoff Occasional Periodic Routine/continuous Non-routine



Low Medium High


Negligible Minor Moderate Major With mitigation measures, impact intensity will reduce to low and impact magnitude to Small thus impact significance will reduce to ‘Minor’.



Residual Impact Proper implementation of suggested mitigation measures would assist in minimising impact of air quality on human receptors. The impact significance with mitigation measures in place is assessed as ‘Negligible’.

4.4.3 Impacts on Noise Quality

Impact Sources Deteriorated noise quality causes nuisance. Potential impacts sources identified from construction activities related to proposed expansion Project on noise quality include the following: 1. Site clearance; 2. Transportation of men and material; and 3. Civil construction. Impacts Assessment 1) Site Clearance As the area requiring site clearance is limited to the premises of existing facility which is located in the confines of GIDC, site clearance activities will not require much of the efforts and will not contribute to significant noise generation. 2) Transportation of Men & Construction Materials It is expected there will be daily plying of ~15 heavy motor vehicles (HMVs) and 5 light motor vehicles (LMVs) for transportation of men and construction material at a given site. Considering the range of heavy vehicle movement from ~30 to 40 per day to UPL (based on analysis of traffic in the study area), the addition of project related transportation vehicles are not expected to impact the baseline noise quality levels. 3) Civil Construction Work Depending upon type and stage of construction, the noise levels may vary. The noise generation at a construction site typically would include use of heavy machineries, cement mixers, metal pipes and plates welding, and


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miscellaneous construction activities including lifts/cranes operation as described in Table 4.4

Table 4.4 Typical Peak Noise Levels Expected at a Construction Site

Tools (operations at ground level) Average Noise Level dB(A) at 1 m

Average hours of operations (from 0800 to 1900 hours)

Welding, Cutting Equipment 95 20% Power tools operations 95 5% Screw Gun, Drill Motor 97 5% Hammering 97 5% Compressors operations 95 30% Diesel Generators 75 80% Miscellaneous Construction Activities including use of lifts/cranes etc.

95 80%

Noise propagation model SoundPlan 7.2 was run to assess the spread of peak noise levels from the construction activities based on the above emission levels. The outcome for free propagation (without use of any noise barriers) is shown below in Figure 4.2. The model showed incremental noise level of 65-70 dBA just outside the Project site due to the construction activities. The noise levels at all receptors NQ1, NQ2 and NQ3 (both within and outside the site) was predicted to be within the prescribed noise limits for industrial area (75 dBA) during day time and 70 dBA during night time due to various construction activities.

Figure 4.2 Incremental Noise Levels during Construction Phase

Embedded Control Measures UPL has a well-established environmental team and shall supervise and

monitor the performance of all construction contractors; UPL carries out frequent monitoring of ambient noise quality using

accredited laboratories to maintain compliance to prescribed standards thus to ascertain effectiveness of the mitigation measures.


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Mitigation Measures Barriers will be placed near construction sites, for the continuous noise

sources operating for one hours and beyond with noise levels of more than 85 dB(A);

The maximum noise levels near the construction site will be aimed to limit to 75 dB(A) Leq (5 min) at the Plant boundary;

The construction sites will be protected by providing fencing to control entry of outsiders;

Vehicular speed limit of 40 kmph will be maintained for heavy motor vehicles (HMVs) and 50 kmph of light motor vehicles (LMVs) thus to minimize any disturbance due to noise to any nearby settlements.

Night-time activities shall be restricted to essential activities only. Contractors to provide basic personal protective equipment (PPE) to the

construction workers. Contractors to ensure that construction workers working in high noise areas

follow all the safety protocols. Regular maintenance of machineries used for construction will be carried

out to ensure minimum noise generation. Impact Significance Impact Deterioration of noise quality during construction activities


Type Direct Indirect Induced Cumulative

Extent Local Subregional Regional National / International

Duration Temporary Short Term

Medium Term Long Term

Frequency Remote – one off

Occasional Periodic Routine/continuous Non-routine



Low Medium High


Negligible Minor Moderate Major Without mitigation measures, impact intensity will be medium and impact magnitude medium as well thus impact significance will be ‘Minor’.



Residual Impact Proper implementation of suggested mitigation measures would assist in minimising impact of noise quality on human receptors. The impact significance with mitigation measures in place is assessed as ‘Negligible’.

4.4.4 Impacts on Water Resource

Impact Sources


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The construction related water requirement for the proposed expansion shall be met from the GIDC water supply through a local vendor. No ground water is/shall be used as per Gujarat Pollution Control Board (GPCB) restriction. Impact Assessment Water will be required for various construction activities such as concrete preparation, curing, foundation, hydro-testing of vessels/pipelines etc. and for domestic usage. The quantity of water required for construction of different facilities including domestic water requirement will be generally ~10 to 15 m3/day (peak) and will be met through GIDC supply. During the construction phase of project, domestic wastewater of 5 to 10 m3/day will be generated from construction involving deployment of ~50 to 80 workers. All domestic wastewater generation from construction will be treated in existing effluent treatment plant of UPL. Embedded Control Measures All contractors to follow the protocols as set by UPL regarding construction

water management. The water requirement during construction will be phased to minimise

impacts on the water sources from which it is proposed to be tapped.

Mitigation Measures The construction contractors shall maintain a record of water consumption

and wastewater generation at site. Reuse and recycle treated domestic and construction wastewater to the extent possible.

Water storages will be kept covered and ensure no leakage from them. UPL carries out frequent monitoring of wastewater quality using different

accredited laboratories which helps them maintain compliance to prescribed standards.

The runoff from construction areas should not be allowed to percolate direct into the ground. Separate drains to be provided for domestic wastewater and surface runoff water.

Areas for storage and handling of construction materials should be water protected/waterproofed and have a drainage system, so that any spills and wash waters can be directed to treatments.

Avoidance of construction activity during rainy days. Proper sanitation facilities shall be provided to workers during the

construction stage. Impact Significance Impact Impact on water resources



Extent Local Subregional Subregional Regional National /International



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Frequency Remote – one off

Occasional Periodic Routine/continuous Non-routine



Low Medium High


Negligible Minor Moderate Major Without mitigation measures, impact intensity will be medium and impact magnitude to medium thus impact significance will be ‘Minor’.


Negligible Minor Moderate Major With mitigation measures, impact intensity will reduce to low and impact magnitude to Small thus impact significance will reduce to ‘Minor’.

Residual Impact Implementation of mitigation measures would assist in minimising impact on water resources. The impact significance with mitigation measures in place is assessed as ‘Negligible’.

4.4.5 Impact on Ecology during Construction Phase

Impact Sources Potential sources of impacts anticipated on ecological environment due to construction of proposed expansion project components include the following: 1. Probable habitat disturbance due to site clearance; and. 2. Probable habitat disturbance due to fugitive dust and noise. The UPL-2 plant is situated within Ankleshwar GIDC (Gujarat Industrial Development Corporation) area. Ankleshwar GIDC is more than thirty years old industrial area, primarily producing bulk drug and chemicals. The industrial landscape is spread 1.5 km to 2 km surrounding the UPL plant. The ecological impacts of the construction activities resulting in release of fugitive dust and noise are expected to be limited to the UPL-2 Plant area of 65,625 m2

and immediate vicinity of ~100 m from the plant boundary. No additional land requirement is required for proposed expansion. The likely impacts on faunal species (herpetofauna and avifauna) from the construction activities are expected within the immediate vicinity of the UPL-2 Plant area. Context UPL-2 has proposed to expand within the existing 65,625 m2. land area. 1) Habitat disturbance due to site clearance The proposed expansion of Unit 2 will be carried out within the premises of the existing UPL plant. Pre-construction will not involve any tree felling or site clearance. Therefore, no habitat disturbance or destruction is expected. 2) Habitat disturbance due to fugitive dust and noise Minimal impact is envisaged on the surrounding habitat during construction activity due to fugitive dust and construction noise. The existing greenbelt & water spray at construction sites will help in reducing the carryover of such emissions. Receptors


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The plant area is situated within the Ankleshwar GIDC (Gujarat Industrial Development Corporation) area. The 2 km radial area falls in the industrial landscape does not represent the significant habitat for floral and faunal species. One (01) Schedule I species (Black kite (Milvus migrans) of the Indian Wildlife Protection Act, 1972 was observed during baseline assessment beyond 2 km in the study area of 10 km from UPL-2 Plant. Embedded Control Measures UPL has undertaken various habitat improvement plantation programmes within and outside the Plant to create habitats for wild species. The Unit has signed agreement for development of ~45 acres of land with green belt at village Mandva located ~ 4 km from project site. Solar powered pumps are being used at this site for the development of green belt at this site.

Figure 4.3 Plantation Undertaken by UPL at Mandva Village

Source: UPL

Mitigation Measures 1. Any vegetation to be carefully removed, efforts for replantation of larger

tree species to be explored; 2. Local tree plantation should be undertaken at all avenue locations possible; 3. In case burrowing animal presence is confirmed by the ecologist at the site

clearance location, they should be relocated using assistance from forest department;

4. Usage of sign boards for speed limits @15 km/hr and awareness for drivers for avoiding over speeding on access roads should be carried out to prevent any faunal road kills;

5. UPL should look for more opportunities for afforestation in and around the plant area. Regular monitoring of vegetation survival should be carried out.

6. Control of fugitive dust due to construction activities such as excavation and construction vehicle movement;

7. Training the workers to maintain better housekeeping; 8. Exploring options of vertical green cover in the internal boundary of plant

plantation drive along the outer boundary; 9. Water sprinkling in the roads used for movement of construction vehicles; 10. Use of bird friendly structures such as water fountains, bird baths,

artificial bird nest for habitat improvement in available areas; and 11. Implementation of the Wildlife Conservation Plan. Impact Significance


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Impacts from the construction activities are expected to be confined to the plant area and adjoining 100 m extent. Therefore, it impact of project construction activity not likely to threaten viability of faunal species in the study area. The extent of impact is assessed as Local and nature of the impact is Negative and, the type of impact is assessed as direct and indirect, the Impact duration will be confined to construction period and is assessed as Short term; the frequency of the impact is assessed as Occasional. Intensity is determined as Low. The resource sensitivity for habitat within GIDC industrial area is Low as no protected areas are involved. The impact significance hence is derived as Negligible for Habitats and Minor for faunal Species. Impact Impact on Habitat and Species from Construction Activity



Extent Local Sub regional Regional International

Duration Temporary Short-term Long-term Permanent

Frequency Occasional

Likelihood Unlikely

Intensity Low

Impact Magnitude Positive Negligible Small Medium Large

Resource Sensitivity (Habitat)

Low Medium High

Resource Sensitivity (Species)

Low Medium High

Impact Significance

Negligible Minor Moderate Major

Significance of impact is considered Negligible for Habitats and Minor for Species

Residual Impact Magnitude

Positive Negligible Small Medium Large

Residual Impact Significance


Significance of impacts is considered Negligible

Residual Impact The impact significance during construction phase with mitigation measures in place will be ‘Negligible’.

4.4.6 Socioeconomic Impacts

The social impacts associated with the construction stages have been assessed qualitatively and in some cases quantitatively (subject to availability of data), using professional judgement and based on past experience from similar projects.

4.4.7 Impacts due to Change in Land Use

Context and receptor The land required for the proposed expansion (that is part of the scope for current study) is available within the existing premises admeasuring 65,625 sq.


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m. The existing premise is already located in Gujarat Industrial Development Corporation (GIDC) Notified Industrial estate of Ankleshwar and is adjacent to many other chemical manufacturing and handling industries. No additional land is required for the proposed expansion, as reported. Moreover, the project proponent reported that the labour required for the work will be hired from local areas; therefore, no separate labour camps will need to be set up. Considering there are no additional land requirements for the project’s temporary or permanent components; the impacts linked to change in land use are not envisaged to occur. Embedded/ in-built control The in-built control measures are presently part of the project planning stage their and this is not an assessment of their execution: The temporary storage and other ancillary facilities will be located in the

existing premises of UPL Unit 2 and no additional land will be procured for the same;

Workforce will be hired locally therefore no labour camp will be set up; The access roads to be used for material transportation will be the same as

existing GIDC Ankleshwar road infrastructure used by other companies in the industrial area. Thus there will not be additional land required for construction of new approach roads.

Impact Significance The significance of the impact has been assessed for more than one stakeholder including landowners (large and marginal), agricultural labourers, and pastoralists. It is presented in the table below.

Cms

Impact Change in Land use



Extent Local Subregional

Regional National /International

Duration Temporary Short-term Medium-term Long-term

Frequency The change in land use is likely to be a one-time impact; considering the embedded measures part of the planning process will be implemented.

Intensity Considering the project does not require any additional land; the intensity of impact is assessed to be low.

Magnitude Negligible Small Medium Large

Resource /Receptor Sensitivity

Low Medium High

Significance Negligible Minor Moderate Major

Significance of impact is considered negligible.

Mitigation/Management Measures UPL should sign Contract Agreement (CA) with each of the contractors that will be responsible for providing workers to UPL for the expansion work.


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Through the CA, the Contractors should be obliged to give preference to locally available labour for the work. Significance of Residual impacts The significance of impacts is likely to remain negligible considering the embedded and mitigation measures will be implemented.

4.4.8 Impacts on Community Health and Safety

Context and receptor Location of the factory and distance from community: The UPL Unit 2 is located in a notified Ankleshwar Industrial Zone amidst other factories. On its immediate east are two pharmaceutical drug intermediates manufacturing plants, adjacent to its northern and southern boundaries are two chemical manufacturing plants, and adjacent to its western boundary is another pharmaceutical drug manufacturing plant. Industrial landscape extends approximately 1.5 km to 2.0 km surrounding the UPL plant. The nearest settlement from the Unit 2 is Padmavat Nagar (settlement of in-migrants situated 2-3 decades back) at 800 m of aerial distance towards north. Access roads: The proposed expansion work is anticipated to generate road traffic on the approach roads for transportation of material and labourers. Due to existing road infrastructure developed for the GIDC Ankleshwar, the main route for material transportation (from Unit 2 to National Highway 8) is envisaged to be the internal road of GIDC Ankleshwar. However, in order to reach National Highway 8 it is likely to pass through 1.5 km of stretch of the GIDC road that is commonly used by the locals as well as companies. In this case, unsafe driving practices of the project related drivers (such as rash driving, over-taking, driving of overloaded trucks and uncovered material) pose a major risk of accidents that can result into minor, major injuries or even fatalities to its users. Due to its location and distance, the impacts of the proposed expansion work are less likely to generate direct influence on the community’s health and safety; however, it is likely to add onto the existing impacts of air and noise pollution that is created by the chemical factories in the GIDC. Embedded/ in-built control As an embedded measure, the project will avoid use of any village roads and will use the existing road infrastructure developed by GIDC Ankleshwar for its transportation. Impact Significance The significance of impacts is assessed to be minor.

Table Impact Significance

Cms

Impact Community health and safety




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Extent Local Subregional Regional National / International

Duration Temporary Short-term Medium-term Long-term

Frequency The impacts are likely to be realised once or more throughout the construction phase of the project.

Scale The scale of impact is assessed to be small.

Likelihood Less likely

Magnitude Positive Negligible Small Medium Large


Low Medium High

Impact Significance


Significance of impact is considered minor. However, with embedded controls and mitigation measures the residual impact is considered to be negligible.

Mitigation/Management Measures The project contractors need to ensure the drivers on project vehicles are trained for safe practices to avoid any accidents on access roads. In case migrant workers are hired, they should undergo medical check-ups at the time of joining to ensure they do not suffer from any communicable diseases that may spread to the local community. Residual impacts The residual impacts are likely to be negligible.

4.5 POTENTIAL IMPACTS AND MITIGATION MEASURES DURING OPERATION PHASE

This section describes the anticipated impacts from the operation of new/augmented facilities as proposed in UPL.

4.5.1 Impacts on Land Environment from Project Components

Impact Sources The potential of impacts on land environment from the expansion project includes soil contamination from the following sources: 4) Improper handling and storage of hazardous and non-hazardous wastes; 5) Spillage of oil, solvents and other hazardous chemicals; and 6) Discharge of untreated domestic and industrial wastewater on land. Impact Assessment 1) Improper handling and storage of hazardous and non-hazardous wastes - Various categories of solid waste (both hazardous and non-hazardous) are generated at different stages of pesticide technical and intermediate chemicals manufacturing processes. The hazardous waste generated from the process units consists of ETP sludge, salt from evaporation system, process liquid waste (organic liquid), solid waste from Ammonium Acetate in-house processing etc. Spillage of these hazardous waste will have potential to cause subsurface contamination. After expansion,


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- Total landfilling waste generation is estimated to be 3,151 metric tons per month (MTM) which includes existing 1,034 MTM and proposed 2,117 MTM. These wastes will be sent to BEIL, Ankleshwar for landfilling.

- Total incineration waste generation is estimated to be 3,215.72 MTM which includes existing 1,251.75 MTM and proposed 1,964.55 MTM. These wastes will be first sent for co-processing and remaining quantity will be sent to approved common hazardous waste treatment, storage and disposal facility (CHWTSDF) of BEIL, Ankleshwar for incineration.

- All hazardous waste shall be kept on an impervious surface with arrangements of spill kits.

- All hazardous chemical storages shall be provided with secondary containment to recover and reuse the spillages.

2) Spillage of oil, solvents and other chemicals Extreme care is taken while transferring / charging of any material. Garland drains are provided surrounding the Plant to avoid storm water contamination. These garland drains are connected to the guard pond of ETP. UPL has implemented atomization in material transferring by implementation of closed handling system wherever possible to minimize leakage/spillage and implemented leak detection and repair (LDAR) system. UPL is using closed loop feed system to transfer the material. Solvent recovery is above 96% from spent solvent and will be improved further. 3) Discharge of untreated domestic and industrial wastewater on land Any untreated domestic or industrial wastewater spillage on ground will also have potential to cause subsurface contamination. Unit 2 is a ZLD unit and will continue to maintain it post expansion. Embedded Controls a. All the wastes are segregated at the source of generation and is disposed in

the legally acceptable manner. b. Hazardous waste storage area has been constructed as per Central

Pollution Control Board (CPCB) guidelines for temporary storage of hazardous wastes before disposing.

c. The collection, storage and disposal from the proposed solid wastes – hazardous, non-hazardous, municipal wastes are carried out as per applicable waste management rules notified by MoEF&CC.

d. The details of existing disposal practise for solid waste management is as below and the same shall be extended for proposed expansion as well: - The discarded drums / bags / liners are decontaminated, detoxified by

using water/caustic/Hypo are sold to scrap processors. - Used oil shall be sold to CPCB/SPCB authorized recycler / re-processor. - ETP Sludge; MEE salts, Filter Aids, Used PPEs, Spent Carbon &

Insulation waste are sent to Treatment, Storage and Disposal Facility (TSDF) site at BEIL, Ankleshwar for final disposal.

- Organic waste / distillation residue, aqueous waste, off specification product / date expired product, is sent to common incineration site; or organic waste sent to cement Industry for co-processing.


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- Company is internally processing Ammonium Acetate at UPL Jhagadia Unit to recover Acetic Acid / Sodium Acetate / Ammonium Acetate. The generated wastes are sent to BEIL Ankleshwar for disposal.

The details of hazardous waste from existing and proposed expansion is given below in Table 4.5. e. Secondary containment is provided around bulk storage of chemicals and

oils f. UPL’s Solvent Management Plan –

All rector vents are connected to common Condenser or fume incinerator to reduce fugitive/VOC emission.

All the reactors and pumps are having suitable mechanical seals to prevent any leakages.

The condensers provided for solvent recovery are having 20% excess HTA to achieve more than 96% recovery.

The solvents are stored in separate underground (UG) tanks and required Chief Controller of Explosives (CCOE) license has been taken. All the required safety aspects are being incorporated.

Proper earthing with jumpers, cathodic protection to the UG solvent tanks are provided.

Total plant has flame proof electrical installations. Suitable breather valves are also provided at the vents of the solvent tanks.


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Table 4.5 Hazardous Waste Details - Existing and Proposed

S.N. Type of Waste

Existing Waste Quantity (MT/M)

Additional Quantity after Expansion (MT/M)

Total Quantity after Expansion (MTM)

Schedule Category (as per HWM Rules, 2016)

Chemical Form Method of Disposal

1 ETP Sludge 28 92 120 I 35.3 CaSO4, Ca3(PO4)2, Ca(OH)2

Generation, Collection, Storage, Treatment, Transportation and sending to TSDF at BEIL, Ankleshwar

2 Filter Aid inert

3.25 6.75 10 I 29.1 Filter Aids [Organic/ Cloths]

Generation, Collection, Storage, Treatment, Transportation, & sending for Incineration at BEIL, Ankleshwar

3 *Process liquid / Solid Waste (Organic)

587.43 988.3 1,576 I 29.1 Organic residue contents : Solvents with traces of pesticides and Aqueous Waste Contents : Water, solvent, salt etc.


4 Evaporation system Salt

270 905 1,175 I 35.3 Mixed Salt (NaCl etc.)


5 Packing materials (a) drums

4,000 Nos/M 4,000 Nos/M 8,000 Nos/M I 33.1 Metals/HDPE Decontamination, Detoxi-fication and sale to approved scrap operators OR contaminated drum sent to BEIL, Dahej for decontamination & disposal

(b) plastic waste

10 30 40 I 33.1 Plastic Generation, Collection, Storage, Transportation and sending to TSDF at BEIL, Ankleshwar

6 Process liquid Waste (Aqueous)

659 951 1,610 I 29.1 Aqueous effluent Contents : High COD & toxic


7 Used Oil 1,700 Lit/M 2,000 Lit/M 3,700 Lit/M I 5.1 Oil Sale to CPCB approved recyclers


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S.N. Type of Waste






8 Date expired & off specification pesticide

1.5 8.5 10 I 29.3 Pesticide Generation, Collection, Storage, Transportation, & sending for Incineration at BEIL, Ankleshwar

9 Solid waste from Ammonium Acetate in-house processing

655 949 1,604 I 35.3 Mixed Salt (NaCl etc)


10 Salt from RO rejects evaporation

60 112 172 I 35.3 Mixed Salt (NaCl etc.)


11 Used PPE’s 2 8 10 I 33.2 Rubber / plastic Generation, Collection, Storage, Transportation and sending to TSDF at BEIL, Ankleshwar

12 Spent carbon from ETP/ RO plant

5 5 10 I 35.3 Carbon Generation, Collection, Storage, Transportation and sending to TSDF at BEIL, Ankleshwar

13 Used Batteries

40 Nos/M 60 Nos/M 100 Nos/M II A5 Lead –acid Sale to approved recyclers

14 Insulation Waste

4 16 20 I 33.2 Glass wool / insulation

Generation, Collection, Storage, Transportation and sending to TSDF at BEIL, Ankleshwar

15 Spent Solvent

196.5 250.5 447 I 29.4 Solvents Disposal by sell out to Authorized users who is having authorization with valid CC&A and Rule 9 permission to receive this waste

16 **Spent Acid 146 146 292 MT/M I 29.6 Acids Disposal by sell out to Authorized users who is having authorization with valid CC&A and Rule 9 permission to receive this waste


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S.N. Type of Waste






17 Spent Catalysts

NIL 10 10 MT/M I 29.5 Catalysts Generation, Collection, Storage, Transportation, & sending for Incineration at BEIL, Ankleshwar OR sent to recyclers

Source: UPL Note: - *Organic residue shall sent for co-processing first and remaining quantity shall be sent for incineration at Common incinerator BEIL, Ankleshwar.

**Spent acid is also considered in by-product list.


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Mitigation Measures

vii. UPL shall continue to maintain the inventory of all hazardous and non-hazardous wastes generated at site including that from the proposed expansion project.

viii. All the wastes shall be segregated at the source of generation and disposed in the legally acceptable manner.

ix. All recyclable hazardous wastes such as used oil, waste oil, used containers etc., and recyclable non-hazardous waste such as metals and non-metals (paper, cardboard, wood, plastic etc.,) are disposed to GPCB/ CPCB/ MoEF&CC authorized vendors.

x. The assessment of all temporary storage area for hazardous wastes shall be carried out every quarter to check on its adequacy.

xi. The existing spill management and Solvent recovery shall be extended to the proposed Project as well.

Impact Significance Impact Assessment Subsurface contamination due to handling of hazardous wastes from the

proposed expansion project Nature Negative Positive Neutral Type Direct Indirect Induced Extent Local Subregional Regional National / International Duration Temporary Short Term Medium

Term Long Term

Frequency Remote Occasional Periodic Routine or Continuous Non-Routine

Intensity Low Medium High Magnitude Negligible Small Medium Large Resource/Receptor Sensitivity

Low Medium High

Impact Significance Negligible Minor Moderate Major

With mitigation measures, impact intensity will reduce to low with the result impact magnitude will be Small and impact significance will reduce to ‘Minor’.

Residual Impacts The impact significance with mitigation measures in place will be ‘Minor’.

4.5.2 Impacts on Air Quality

Impact Sources Potential impacts on air quality due to proposed expansion operations have been identified from the following activities: 1. Point source emissions from process, and fuel combustion in boilers and

diesel generators (DG) sets; 2. Fugitive emission and odour nuisance 3. Vehicular emission Impact Assessment The impacts on air quality from point sources including associated utilities depend upon the following factors – process technology, design, capacity, fuel used for combustion, quantity, air pollution control equipment’s installed, operation and maintenance of units. The severity of impacts on air environment


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from any industrial project is also governed by terrain conditions and the prevailing micro-meteorological conditions in the project region. Ambient Air Quality: The background ambient air quality concentrations as monitored at various locations is presented in Table 3.4 in Section 3. Air Quality Model Inputs: Inputs for the air quality modelling of emissions from the flue gas stacks and process gas stacks is provided below in Table 4.6.

Table 4.6 Inputs for Air Dispersion Modelling Using AERMOD Model

S.N. Input Description 1 Modelling Software Used ISC-AERMOD View ver. 9.6.5 2 Control Pathway Dispersion option Non Default Options Dispersion Coefficient Industrial Flagpole Receptors No 3 Meteorology Pathway Met Input Data One year meteorological data (from February

2018 to May 2018) using Default AERMET Format Wind Speed Categories A: 1.54 m/s

B: 3.09 m/s C: 5.14 m/s D: 8.23 m/s E: 10.8 m/s F: no upper bound

Datum UTM Anemometer Height 10 m Base Elevation 181 m above mean sea level 4 Receptor Pathways Uniform Cartesian Grid 1 No. of X and Y axis Receptors 101 Spacing for X and Y axis 200 m Receptor group 10 km radius area from the existing Plant 5 Source Pathway (emission sources) Stationary emission sources considered to be

emitted round the clock on 24 hourly, 365 days a year basis – Refer to emission strengths in Table 4.10

For the purposes of air quality modelling, the likely emissions have considered as inputs for the air quality model as given below in Table 4.7.


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Table 4.7 Flue gas and process gas Emissions Sources from the Proposed Expansion Project

S.N Stack attached to Stack Id Fuel Type

UTM Coordinates (zone 43 Q) Stack Parameters Flow Rate (Nm3/hr)

Emissions (g/s) Easting (m) Northing (m)

Ht. (m) Dia (m) Exit temp.. (°C)

Exit vel. (m/s) PM10 HCl SO2 NOx H2S VOC

1. Boiler B4 - 20 TPH Stk1 Natural

gas/LSHS & FO

296623.23 2392844.53 55 0.9 112 7.5 13296.691 0.55 -- 0.97 0.35 -- --

2. BoilerB5 - 20 TPH Stk2 Natural

gas/LSHS & FO

296617.26 2392845.94 55 0.9 112 7.5 13296.691 0.55 -- 0.97 0.35 -- --

3. DG Set – 2,000 kVA

Stk3 HSD

296552.78 2392926.02 30 0.2 218 6.7 459.989 0.02 -- 0.03 0.01 -- --

4. D-Devrinol Plant Vent1 - 296683.51 2392845.37 30 0.4 40 4.2 1809.023 -- 0.01 0.02 -- -- --

5. Clomazone Vent2 - 296689.72 2392897.39 30 0.3 35 3.8 935.602 -- -- -- -- -- 0.005

6. Monocrotophos Vent3 - 296694.25 2392897.37 30 0.6 35 3.1 3053.017 -- -- -- -- -- 0.017

7. PCOC Vent4 - 296686.51 2392820.43 30 0.3 40 3.8 920.663 -- 0.005 -- -- -- --

8. DMPAT Vent5 - 296699.16 2392921.8 30 0.3 35 3.8 935.602 -- 0.005 -- -- -- --

9. Imazapic Vent6 - 296691.3 2392845.61 30 0.4 40 4.2 1809.023 -- -- -- -- -- 0.010

10. Surflan Vent7 - 296692.35 2392894.52 30 0.6 35 3.1 3053.017 -- 0.017 -- -- -- --

11. Mesotrion Vent8 - 296681.91 2392897.25 30 0.6 40 3.8 3682.654 -- 0.020 0.041 -- -- --

12. DETA OR ZnDTP Vent9 - 296679.38 2392820.28 30 0.6 70 3.1 2741.621 -- -- -- -- 0.004 --

13. Devrinol Plant Vent10 - 296686.12 2392845.85 30 0.6 40 3.8 3682.654 -- -- -- -- -- 0.020

Note: Emissions from Diesel Generator have not been considered in the air quality modelling input as these are meant only for emergency power generation purposes;


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Modelling Output and Discussion of Point Source Emissions Results: The maximum Ground Level Concentrations (GLC) as predicted through air quality modelling for the entire due to emissions from proposed project components is given in Table 4.8.

Table 4.8 Maximum Predicted Incremental Ground Level Concentrations

Pollutant Incre-mental Max GLC (µg/m3)

Coordinates Distance (m) of Max GLC

Observed Max AAQ at Project site

Resultant Max AAQ near Project site

X (m, N) Y (m, E)

Particulate Matter, PM10 3.5 296431.0 2392454.0 450 SSW 95.1 98.6 Hydrochloric Acid, HCl 0.78 296631.0 2392654.0 400 S BDL +0.78 Sulphur Dioxide, SO2 6.41 296431.0 2392454.0 450 SSW 20.7 27.1 Nitrogen Dioxide, NO2 2.23 296431.0 2392454.0 450 SSW 22.9 25.1 Hydrogen Sulphide, H2S 0.07 296631.0 2392654.0 400 S BDL +0.07 Volatile Organic Compounds VOCs

0.76 296631.0 2392654.0 400 S BDL +0.76

The predicted maximum incremental concentrations from the proposed

expansion project are within the prescribed NAAQS for PM10, SO2 and NO2. Currently there are no NAAQS for H2S, VOCs and HCl.

The distance at which the peak concentration attains ground level is within 500 m from the boundary of UPL for all pollutants in south or south-south-west (SSW).

The nearest settlements are located beyond 1.5 km from the boundary of UPL Unit 2, thus incremental concentrations at the settlements will be further reduced.

The results of ambient air quality concentrations monitored at various locations (refer Table 4.9) in the study area has been used as the background/existing concentration. The predicted incremental values of concentration of pollutants obtained as a result of AERMOD modelling at the monitored locations, has been added to the background/existing concentration to obtain the total predicted concentration in ambient air. As shown below in Table 4.9, the resultant concentrations of all the pollutants from the proposed Project expansion in the study area was found to be within the prescribed limits except PM at few monitored locationsw which is due to their background levels. The isopleths of PM, SO2, NOx, H2S, VOC and HCl is provided in Figure 4.4, Figure 4.5, Figure 4.6, Error! Reference source not found., Figure 4.7 and Figure 4.8.


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Table 4.9 Projected Ambient Air Quality Concentrations from the Proposed Project

Receptor Code

Receptor Location

Geographical Co-ordinate Baseline 24 hrly Max. Conc. (µg/m3) Incremental 24 hrly Max. Conc. (µg/m3) Resultant Conc. (µg/m3) (Incremental + Baseline)

X (m E) Y (m N) PM10 SO2 NOx H2S VOC HCl PM10 SO2 NOx H2S VOC HCl PM10 SO2 NOx H2S VOC HCl AAQM – 1 Project Site 73°02’04.0”E 21°37’39.4”N 95.06 20.66 22.92 BDL BDL BDL 0.00 0.29 0.00 0.03 0.30 0.32 95.06 20.95 22.92 BDL BDL BDL AAQM – 2 Dadhal 73°03’41.0”E 21°37’57.8”N 95.91 21.54 32.29 BDL BDL BDL 0.34 0.61 0.21 0.00 0.04 0.04 96.25 22.15 32.51 BDL BDL BDL AAQM – 3 Jitali 73°03’49.0”E 21°37’13.2”N 72.18 20.79 30.43 BDL BDL BDL 0.15 0.27 0.09 0.00 0.03 0.04 72.33 21.06 30.52 BDL BDL BDL AAQM – 4 Sanjali 72°59’42.8”E 21°33’21.1”N 85.83 18.65 36.45 BDL BDL BDL 0.18 0.33 0.12 0.00 0.01 0.01 86.01 18.98 36.57 BDL BDL BDL AAQM – 5 Azad Nagar 73°0'0.0"E 21°36'20.0"N 119.80 25.41 41.58 BDL BDL BDL 0.23 0.41 0.14 0.00 0.01 0.01 120.03 25.82 41.72 BDL BDL BDL AAQM – 6 Ankleshwar 72°59’36.2”E 21°37’22.1”N 121.01 21.40 45.41 BDL BDL BDL 0.10 0.18 0.06 0.00 0.02 0.02 121.11 21.58 45.47 BDL BDL BDL AAQM – 7 Kondh 73°02’16.3”E 21°35’18.0”N 100.40 19.62 37.44 BDL BDL BDL 0.10 0.19 0.07 0.00 0.02 0.02 100.50 19.81 37.51 BDL BDL BDL AAQM – 8 Bhorbhata Bet 73°00’14.4”E 21°40’52.6”N 67.13 16.80 30.20 BDL BDL BDL 0.18 0.32 0.11 0.00 0.02 0.02 67.30 17.12 30.31 BDL BDL BDL AAQM – 9 Mandvabuzarg 73°03’43.3”E 21°40’38.0”N 72.05 17.18 29.38 BDL BDL BDL 0.25 0.45 0.16 0.00 0.02 0.02 72.30 17.63 29.54 BDL BDL BDL National Ambient Air Quality Standards (24 Hourly Average) 100 80 80 - - -


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Figure 4.4 Predicted 24-hourly Maximum PM10 Concentration in Study Area


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Figure 4.5 Predicted 24-hourly Maximum SO2 Concentration in Study Area


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Figure 4.6 Predicted 24-hourly Maximum NO2 Concentration in Study Area


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Figure 4.7 Predicted 24-hourly Maximum VOC Concentration in Study Area


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Figure 4.8 Predicted 24-hourly Maximum HCl Concentration in Study Area


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Embedded Controls A. Flue Gas Emission: Flue gas emissions are monitored regularly to ensure

the flue gas parameters are within the prescribed limit by GPCB. The UPL Unit 2 is facilitated with constant supply of clean fuel – Natural Gas hence source emissionof PM/SO2/NOx are very minimum with respect to other fuels.

B. Process Gas Emission: Process emissions (HCl, Cl2, HC, SO2, H2S, NH3, VOC etc.) are provided with appropriate scrubbing media for compliance. The performance of the scrubbers are also monitored periodically. UPL has provided fume incinerator for thermal destruction of odours generated from Ethyl Mercaptan and other processesThe list of air pollution control measures installed in each process stack is given in Table 2.8 of Section 2.

C. Fugitive & Odour Emissions:

Potential sources of fugitive emissions from the proposed expansion plant will be from solid chemical charging from bags in the production area, bag filling of product power or lumps and HAP chemicals with low volatile pressure and pressurized gases from bulk storage tanks. Following embedded controls will be implemented for fugitive emission controls:

a. UPL will ensure regular fugitive emission monitoring at various

locations in the plant through Quality Assurance (QA) Department of UPL.

b. Volatile Organic Compounds are monitored using in-house VOC monitor.

c. Vent scrubbers have been provided for hazardous chemical storage tanks vents to prevent emissions of chemicals in the ambient air

d. Nitrogen blanketing is used where appropriate on pumps, storage tanks, and other equipment to minimize the release of toxic organics.

Odour can be of some sensitivity in the proposed expansion plant due to nature of industry. Chemical odour can be released from emission of VOCs from bulk storage tanks and from process vents. Following embedded controls will be implemented for odour emission controls:

a. For odour control, fume incinerator has been installed. b. For H2S, a 2 stage scrubber have been installed c. Use of mechanical seals in pumps and agitators d. Liquid raw materials is charged by pumping & closed loops and

dosing will be done by metering system to avoid fugitive emissions. Dedicated measuring tanks is provided for each reactor.

e. Suitable stoichiometric calculations is done and followed to regulate the quantity of reactants to be charged to reaction vessels in order to avoid use of excess chemicals, which in turn will minimize organic load in the effluent.

f. Using a closed loop sampling system to avoid release of chemicals while sampling


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g. Breather valves, PSVs, Rupture discs are installed for process/storage tank vents. Vapor recovery systems are provided at required locations

h. For highly pressurized lines, vent pipes of PRVs to be connected to APCD in case of toxic gases

i. Breather valves, PSVs, Rupture discs j. Vapour recovery system will be installed for process/storage tank

vents k. Periodic inspection of pipes and pipe fittings. l. Covered transfer systems is adopted, workers are provided PPE,

and fume extraction systems are provided, wherever required Mitigations Following mitigation measures are recommended in addition to measures proposed in the project design:

i. All emission sources to be monitored regularly to ensure compliance. ii. Green belts and landscaping should be strengthened to act as an effective

means to control air pollution. iii. Performance evaluation of the pollution control systems will be

undertaken at planned regular intervals; iv. Provision of continuous emissions monitoring systems for the stacks; v. The efficacy of the existing detectors installed will be checked with respect

to the proposed projects activities and or new sensors to detect hydrocarbons will be installed;

vi. LEL detectors and alarms will be installed for odourous compounds; vii. Sensors and breather valves will be provided at hazardous chemicals

storages; viii. LDAR program shall be extended to proposed expansion;

ix. Workplace monitoring shall be extended for the proposed expansion; Impact Significance

Ambient air quality especially particulate emission is a major cause of concern in Bharuch District of Gujarat due to vast spread of industries in the study area. Thus, the baseline particulate matter exceeds the prescribed NAAQS in most of the locations. Hence, sensitivity is termed as medium. The impact significant of upstream project components operation is assessed as following.

Impact Assessment Impact on air quality due to proposed expansion project Nature Negative Positive Neutral Type Direct Indirect Induced Cumulative Extent Local Subregional Regional National / International Duration Temporary Short Term Medium Term Long Term Frequency Remote Occasional Periodic Routine or Continuous Non-Routine Intensity Low Medium High Magnitude Negligible Small Medium Large Resource/Receptor Sensitivity

Low Medium High


Impact assessment based on embedded controls in place showed impact significance as “Minor”, which with mitigation measures in place will also result in impact significance as Minor.

Residual Impacts


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The impact significance with embedded controls and mitigation measures in place is assessed as ‘Minor’. 1) Vehicular Emissions The impacts on air quality will also be from the increase in vehicular traffic from the proposed project due to movement of both men, material, crude oil, natural gas, produced water transportation etc. For the air impact modelling three road networks are considered through which maximum traffic movement takes place. These roads are – Junction near Unit 2 (TR-1), Junction of GIDC Flyover &14th E Road (TR-2), and Junction of SH-64 and 14th E Roads (TR-3). The details of the existing and proposed traffic on these roads is given below in Table 4.10.

Table 4.10 Additional Traffic Due to the Proposed Expansion Project

Category Existing Traffic (veh./hr.)

Proposed Traffic (veh./hr.)

Total (veh./hr.)

Road 1 Road 2 Road 3 Road 1 Road 2 Road 3 Road 1 Road 2 Road 3 2-Wheeler 3,935 5,206 3,205 394 521 321 733 695 454 3-Wheeler 971 3,610 1,730 97 361 173 213 606 305 4-Wheeler 1,768 4,585 2,753 177 459 275 255 483 230 Heavy Vehicles 816 3,816 2,416 82 382 242 297 1576 671

Road Length (km) 11.4 12.5 21.3

The proposed traffic is assumed based on incremental traffic of 10% for two and three wheelers and 15% increase for 4-wheeler and heavy vehicles on Road 1, Road 2 and Road 3 respectively. Based on the above table the likely emissions that has been considered as inputs for the air quality model as given below in Table 4.11

Table 4.11 Emissions from Vehicular Traffic

Roads PM (g/s) NO2 (g/s) CO (g/s) HC (g/s)

Road 1 0.1 2.1 2.3 0.6 Road 2 0.2 8.4 7.2 1.1 Road 3 0.1 3.1 2.6 0.4

Note: The vehicular emission factors (EF) have been taken from Central Pollution Control Board Report entitled - Status of Pollution Generated from Road Transport in Six Mega Cities, March 2015 Modelling Output and Discussion of Vehicular Emissions Results: The isopleths of the model predicted ground level concentrations (GLCs) for PM, SO2, NOx, HC and CO is shown below for Road 1, 2 and 3 in Figure 4.4, Figure 4.5, Figure 4.6 and Error! Reference source not found.. The maximum predicted GLC from the additional transportation is provided below in Table 4.12.

Table 4.12 Maximum Predicted GLC from the Additional Traffic in the Proposed Project

Pollutant 24-hourly GLC (g/m3)

Coordinate X (m, N) Y (m, E)

Particulate Matter 0.42 302431.00 2386254.00 Nitrogen Dioxide 15.8 295431.00 2389454.00 Carbon Monoxide 8-hourly 31.2 295431.00 2389454.00 Hydrocarbons 6.96 295031.00 2389854.00


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The peak 24 hour GLC of particulate matter, nitrogen dioxide and hydrocarbons predicted for proposed expansion was 0.42, 15.8 and 6.96 µg/m3 while the peak 8-hourly GLC for carbon monoxide was 31.2 µg/m3. The peak concentration was near the shoulder of road SH-13 towards the junction TR2. The predicted concentrations of PM, NO2 and CO from the additional traffic due to the proposed Project are within the NAAQS. Embedded Controls Vehicle inspection will be carried out by UPL authorized personnel to

determine fitness of vehicle, as per vehicle inspection checklist. Based on result of the inspection only vehicle that are declared “fit for-purpose will be allowed.


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Figure 4.9 Predicted 24-hourly PM from Additional Traffic


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Figure 4.10 Predicted 24-hourly NO2 from Additional Traffic


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Figure 4.11 Predicted 8-hourly CO from Additional Vehicular Traffic


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Figure 4.12 Predicted 24-hourly HC from Additional Traffic


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Mitigation Measures i. UPL shall ensure periodic preventive maintenance of all of its vehicles

including that of the subcontractors. ii. Driver training to also include aspects related to use of cleaner fuels,

avoid congestions to reduce idling time, switching off engines for long duration waiting etc.

iii. Maintaining optimum vehicle speed. Speed breakers are commonly used to ensure speed limitations.

iv. Regular monitoring of ambient air quality to ensure compliance and corrective actions in case of any exceedances.

v. Attenuation of pollution/protection of receptor through green belts/green cover

Impact Significance The magnitude of air quality impacts from the proposed expansion due to the additional traffic is assessed as

Impact Impacts on air quality due to additional traffic within the Study area Nature Negative Positive Neutral Type Direct Indirect Induced Cumulative Extent Local Subregional Regional National

/International Duration Temporary Short Term Medium Term Long Term Frequency Remote Occasional Periodic Routine or

Continuous Non-Routine

Likelihood Unlikely Possible Likely Intensity Low Medium High Magnitude Negligible Small Medium Large Resource/Receptor Sensitivity

Low Medium High


Impact assessment based on embedded controls in place showed impact significance as “Minor”, which with mitigation measures in place will also result in impact significance as Minor.

Residual Impact The impact significance with mitigation measures in place is assessed to be ‘Minor.

4.5.3 Impacts on Noise Quality due to Proposed Expansion Project

Impact Sources Potential impacts on noise quality from the proposed expansion will be operation of various equipment’s machineries, instruments such as boilers, reactors, scrubbers, pumps, compressors, DG Set etc. Noise is continuously generated from such sources. Impact Assessment Prediction of noise levels post the proposed project was undertaken using SoundPLAN 7.2. The predicted noise propagation in study area is shown in


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Figure 4.13. The predicted noise level at the monitored locations due to the expansion is provided below in Table 4.13.

Figure 4.13 Incremental Noise Level due to the Proposed Project

Table 4.13 Predicted Noise Level from the Proposed Project

S.N. Location Code

Location Name

Baseline Noise Level Incremental Noise Level (dBA)

Resultant Noise Level

Leq Daytime (dBA)

Leq Nighttime (dBA)

Leq Daytime (dBA)

Leq Daytime (dBA)

1 NQ1 Project Site 74.5 68.8 49.8 74.5 68.9 2 NQ2 Dadhal 52.4 42.7 12.0 52.4 42.7 3 NQ3 Jitali 50.7 49.7 10.5 50.7 49.7 4 NQ5 Azad Nagar 66.9 61.5 4.7 66.9 61.5 5 NQ6 Ankleshwar 62.5 57.2 4.6 62.5 57.2

The modelling results indicate that the maximum noise levels within Unit 2 will be ~50 dBA from the proposed sources, which will be within the prescribed limits. The resultant noise levels due to the project operations shall not exceed the prescribed noise standards for daytime and nighttime and will attain background levels within the boundaries. Mitigation Measures Following mitigation measures are recommended in addition to measures proposed in the project design:

i. Efficient engineering control during installation of new equipment and machineries shall be ensured to reduce noise emission levels at source.

ii. Maintaining adequate offset distances from noise generating equipments.


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iii. The machinery deployed in the plant should be designed with the sufficient noise and vibration controls for minimizing noise at source and purchased through reputed manufacturers and vendors.

iv. DG sets shall be provided with acoustic enclosures conform to the maximum permissible sound pressure level of 75 dB(A) at 1 m from the enclosure surface. The DG sets are also fitted with a proper exhaust muffler to ensure that an insertion loss of minimum 25 dB(A) is achieved to meet the requirements of The Environment (Protection) second Amendment Rules, 2002;

v. Operation of DG sets only in Emergency. vi. Preventive maintenance of equipment and machineries shall be undertaken

regularly. vii. Periodic audiometric tests for employees working close to high noise levels,

such as compressors, DG sets, the loading and unloading sections shall be conducted;

viii. Periodic job rotation shall be provided to the employees, who are working continuously in the high noise areas.

ix. Personal protective equipments (PPE) like ear plugs/muffs shall be provided to workers and staff at the site.

x. Ambient noise levels shall conform to statutory limits; xi. Workplace noise levels for workers shall be as per statutory limits.

Impact Significance

Impact Assessment Noise due to proposed expansion project Nature Negative Positive Neutral Type Direct Indirect Induced Cumulative Extent Local Subregional Regional National / International Duration Temporary Short Term Medium Term Long Term Frequency Remote Occasional Periodic Routine or



Low Medium High


With mitigation measures, impact significance is assessed as Minor.

The impact significance with mitigation measures is assessed as ‘Minor’.

4.5.4 Impacts on Water Quality

Impact Sources Potential impacts on water resource and quality of the operations have been identified from the following sources: 1. Fresh water consumption 2. Storm water runoff 3. Wastewater generation, treatment and disposal


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Impact Assessment 1) Fresh water consumption Total fresh water consumption after proposed Project expansion will be 4,056 m3/day and the total water demand will be 4,751.7 m3/day, out of which ~1,030.5 m3/day is existing and ~3,721.7 m3/day is proposed. The details of the water requirement is provided below in Table 4.14.

Table 4.14 Details of Water Requirement (Existing and after Proposed Expansion)

S.N.

Particulars Existing (m3/day)

Proposed (m3/day)

Total (m3/day)

Recycled Water (m3/day)

Net Fresh Water Demand (m3/day)

1 Processing & Washing 265.5 397.2 662.7 100.0 562.7 2 Boiler & Cooling 704.5 3,309.5 4,014.0 563.0 3,451.0 3 Domestic Purpose 35.0 10.0 45.0 2.4 42.6 4 Gardening 25.0 5.0 30.0 30.0 0.0 Total 1,030.5 3,721.7 4,751.7 695.4 4,056.0

The water requirement for the proposed expansion shall be met from the existing GIDC water supply. No ground water is/shall be used. 2) Storm water runoff There is a potential for contamination from run off from other paved areas and mixing of process and storm water. However, due to the secondary containment (garland drains) and separate drainage of process and storm water, likelihood of mixing of water from process areas into storm water drains will be unlikely. Storm water runoff from other paved areas will be discharged to GIDC drain outside the Plant. The rooftop rainwater is collected and used as cooling tower make-up water. 3) Waste water generation, treatment and disposal The sources of wastewater generation in the project area includes process effluent, boiler blow down, cooling tower blow down, sewage water etc. Discharge of wastewater outside the project area may impact the soil and groundwater. There is also potential contamination of soil due and subsurface aquifers due to potential spills of lubricating oil, crude oil, fuel oil and chemicals. The details of the wastewater generated from the existing plant and post expansion is given below in Table 4.15.

Table 4.15 Details of Wastewater Generation (Existing and after Proposed Expansion)


Proposed(m3/day)

Total (m3/day)

Mode of Treatment

1 Process effluent 207 118 324

In existing ETP of capacity 550 m3/day followed by RO & MEE

2 Boiler and cooling tower blowdown

278 21 299 In RO system for recycling


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Proposed(m3/day)

Total (m3/day)

Mode of Treatment

3 Domestic effluent 28 8 36 In STP having capacity of 40 m3/d 4 MEE condensate 0 170 170 Will be recycled back TOTAL 513 317 829

Source: UPL Embedded Control Measures The wastewater generated from process, boiler, cooling tower etc. is and will continue to be treated in existing effluent treatment plant (ETP) of capacity 550 m3/day having primary, secondary & tertiary treatment as below: UPL proposes to install additional RO Plant of 750 m3/day for wastewater

management. Also additional Multiple Effect Evaporator (MEE) of capacity 450 m3/day will be installed for the expansion Project.

The aqueous waste generated during existing pesticide manufacturing from boiler, distillation residues containing organic impurities is incinerated. The same will be extended for proposed expansion.

High TDS wastewater generated from manufacturing is evaporated in forced evaporation system and the salt generated is being disposed off at BEIL, Ankleshwar which is a common secured landfill site.

High COD wastewater is chemically treated followed by treatment at ETP. The treated wastewater is sent to reverse osmosis (RO) system, The permeate will be recycled back in to the process/cooling tower & reject will be sent to forced evaporation system.

The unit is Zero Liquid Discharge (ZLD) since May-2014 and will continue as ZLD by using RO system followed by evaporation system as shown below in Figure 4.14

Moreover, the Unit has also installed online CCTV camera and magnetic flow meter at ETP outlet line and online CCTV footage is being transmitted to CPCB website.

Figure 4.14 Zero Liquid Discharge (ZLD) Plant at Unit 2

Source: UPL

Front Side Back Side


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The Treated domestic waste water from proposed sewage treatment plant will be recycled/ reused in toilet flushing / green belt and there will not be any discharge from UPL Unit 2 and the Unit will maintain ZLD even after proposed expansion. Other embedded control measures include:

i Use automated filling to minimize spillage ii Use "closed" feed systems for batch reactors iii Use high-pressure hoses for equipment cleaning to reduce wastewater iv Solvent distillation system is designed to achieve more than 96% of

solvent recovery. Mitigations Following mitigation measures are recommended in addition to measures proposed in the project design:

i. Maintaining records of water consumption and wastewater generation ii. Regular monitoring of wastewater inlet and outlet parameters

iii. Ensuring maintenance of wastewater treatment plants and storm water drain

iv. Treatment of storm water runoff from first rainfall of the season in the wastewater treatment plant

v. Develop spill prevention plans in case of hazardous chemical discharges and spills

vi. Ensure secondary containment system for storage of hazardous chemicals and oils.

vii. Wherever possible, use equipment wash down waters and other process waters (such as leakages from pump seals) to be used as makeup solutions for subsequent batches

viii. Storage areas should be secure and covered, preventing exposure to rain and unauthorized access.

Impact Significance Impact Assessment Water resource and quality due to proposed expansion project

Nature Negative Positive Neutral Type Direct Indirect Induced Cumulative Extent Local Subregional Regional National / International Duration Temporary Short Term Medium Term Long Term Frequency Remote Occasional Periodic Routine or



Low Medium High


With embedded controls and mitigation measures, impact significance is assessed as ‘Minor’.

Residual Impacts


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The impact significance on groundwater resources and quality with embedded controls and mitigation measures in place is assessed as Minor.

4.5.5 Impact on Ecology during Operation Phase

Potential impacts as anticipated on ecological environment during the operation phase of proposed expansion Project have been identified as below: 1. Terrestrial habitat loss due to adverse ambient air quality and 2. Habitat disturbance due to noise from the project. Context UPL-2 has proposed to expand within the existing 65,625 m2. land area. Receptors The plant area is situated within the Ankleshwar GIDC (Gujarat Industrial Development Corporation) area. The 2 km surrounding UPL-2 Plant falls in the industrial landscape does not represent the significant habitat for floral and faunal species. One (01) Schedule I species (Black kite (Milvus migrans), of the Indian Wildlife Protection Act, 1972 was observed during baseline assessment beyond 2 km in the study area of 10 km from UPL-2 Plant. Terrestrial habitat loss due to adverse ambient air quality Indirect impacts like fragmented or modified habitats due to air emissions from the stack and fugitive emissions from the proposed project. The process emissions (H2S, NH3, VOC etc.) for the existing and proposed project are provided with appropriate control measures like scrubbing media for minimising their impacts and to be compliant with regulatory norms. The performance of these air pollution control devices are also monitored periodically. Therefore, considering the background air quality levels within the acceptable levels with small impact magnitude but with medium receptor sensitivity, impacts on terrestrial ecology is considered as Minor. Probability of habitat disturbance due to noise from the Project The plant is located within an industrial landscape that extends up to 1.5 km to 2.0km in all directions from the plant. Moreover existing green belt will attenuate produced noise, if any. Further, the existing noise levels at the boundary of the plant was also found to be within the prescribed limits. Therefore, it is less likely that any adverse impact due to noise outside the boundary of plant will be experienced during the operation phase. Therefore, considering the noise levels will be within industrial acceptable levels (~70dB(A)) with small impact magnitude in the immediate surrounding area and low receptor sensitivity in immediate surrounding area, the impact assessment due noise generated from plant operations on terrestrial ecology is considered as Negligible. Embedded Control Measures UPL has developed greenbelt as an integral part of development of its facilities. Till date ~13,911.58 m2 (21.19%) out of total area of 65,625 m2 of Unit


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2 area is developed as green belt and additional greenbelt area of 315 m2 is proposed for the expansion Project. During 2017-18, ~2,250 of native trees have been planted. Mitigation Measures The suggested mitigation measures for habitat improvement are given below: 1. Strengthening of existing greenbelt to the maximum extent possible; 2. Use of native species for greenbelt plantation; 3. Options should be explored to adopt advance technologies for pollution

reduction from process and utilities; 4. Recycled water should conform to the standards before using in the

greenbelt; 5. The offset plantation site at Village Mandwa should be aimed to develop

as forest habitat with gap plantation after maturation of trees planted in first phase;

6. Sufficient water arrangements should be provided for watering the aforesaid plantation;

7. Celebration of Van Mahotsav, Community and road side plantation programs in the GIDC and surrounding areas should be initiated by UPL;

8. Community and schools Awareness programs towards nature conservation and environment protection should be initiated by UPL;

9. Implementation of the Wildlife Conservation plan. Impact Significance Impact significance for habitats is assessed as negligible as it does not cause a substantial change in the habitat. For species also it is assessed as minor as the Schedule I species that is found in the study area is fairly common species in the landscape and project operation activity does not threaten long term viability of population of this species. Impact Assessment Impact on ecology due to proposed expansion project

Nature Negative Positive Neutral Type Direct Indirect Induced Cumulative Extent Local Subregional Regional National / International Duration Temporary Short Term Medium Term Long Term Frequency Remote Occasional Periodic Routine or



Low Medium High


With embedded controls and mitigation measures, impact significance is assessed as Minor.

Residual Impacts The impact significance on ecology and biodiversity is assessed as Minor.


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4.5.6 Impacts of Socioeconomic Environment

Potential impacts – The following are the impacts as anticipated from the proposed Project: 1. Job opportunities 2. Impacts due to CSR Interventions Impact Assessment – 1) Job opportunities – An additional employment of about 253 (permanent and

contractual) is proposed as part of the Project. Preference in employment shall be given to local people indicating positive impacts from the proposed Project.

2) Impacts due to CSR interventions - UPL has reportedly invested 9.7% of company’s total profit in social development activities across its different units. Some of the activities undertaken by the Unit 2 reportedly include – social forestry plantation, organising health camps, providing seeds for agricultural breed improvement, as well as skill based training for Self Help Groups (SHG). As reported, their beneficiaries also include persons from scheduled caste (SC) and scheduled tribes (ST) communities. The details of CSR are given in Section 8 of EIA report. Furthermore, as a result of its work at the community level, UPL is observed to have developed positive perception about itself in the study area. The locals recognise UPL as a company that engages with people in philanthropic means to improve their living conditions – through social forestry plantation and free health camps etc.

Enhancement measures UPL has undertaken a needs assessment study in the study area and identified the major concerns faced by the locals (unemployment, lack of capacity building, lack of adequate clean drinking water, lack of water for irrigation etc.) to further plan suitable interventions to improve the conditions. The detailed expenditures proposed are tabulated below. S. N. Key Focus Area Project Budget (Rs)

1. Agriculture Development UPL KhedutPragati 1,08,82,203 2. Health & Sanitation UPL School Sanitation 73,49,196 3. Environment & Nature

Conservation UPL Social Forestry 3,33,74,787

4. Education & Empowerment School Education & UPL

Udyamita 1,01,13,572 5. Employability &

Entrepreneurship UPL Niyojaniy & Skill development. 1,12,66,519

6. National & Local Area needs UPL GramPragati 42,34,215 Total 7,72,20,492


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Impact Significance Cms

Impact CSR activities in the local area



Duration Temporary Short-term Long-term Permanent

Scale The scale of impact is High

Frequency The quantitative impact in terms of number of beneficiaries is likely to be reooccuring every time a CSR program is implemented. However, the impact on reputation is a continuous process.

Extent Local Regional National /International

Impact Magnitude Positive Negligible Small Medium Large


Low Medium High


Significance of impact is considered Major Positive.

Residual Impact The impact of CSR interventions on company’s reputation in the local area has been assessed as Major positive.

4.6 NON-ROUTINE IMPACTS/RISKS

In conducting its proposed expansion, UPL is committed to prevention and minimization of any kind of pollution mainly water, air, land and socioeconomic related. Risk assessment has been included in Section 7. Risk mitigation measures have been suggested to minimize potential hazards from the expansion Project. Such prevention requires state-of-the-art equipment, properly operated by trained personnel.


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5 ANALYSIS OF ALTERNATIVES

5.1 BACKGROUND

Analysis of alternatives has been carried out considering the technical and operational feasibility. The proposed expansion project involves increase in production capacity of the existing and new pesticides technical and intermediate products and enhancement of processing facilities and utilities to handle the enhanced production. Alternatives have been considered for the project based on technical and economical feasibility of the ongoing assessments by UPL. Implications to physical environment and social conditions were also considered as part of these assessments to the extent possible. The following alternatives to the proposed project were analysed to minimise and prevent any potential environmental and social impacts.

5.1.1 Alternate Source of Land

The proposed project being an expansion project within the existing project site, there were no alternatives considered for the production and or processing facilities. This would also give benefits in utilizing the existing utilities and infrastructure within the project site to have minimal environmental and social footprints. The expansion within the existing site will also maximise the benefits from the available supply chain and will optimize the existing equipment, infrastructure while increasing the operational efficiency.

5.1.2 Additional Wastewater treatment facilities

The existing project facility is operating as zero liquid discharge (ZLD) unit and to continue operating as ZLD unit after expansion, UPL proposes to install additional Multiple Effect Evaporator (MEE) of capacity 450 m3/day. Further to cater to requirement of treating total sewage water generation of ~ 36 m3/day due to proposed project, new activated sludge process based sewage treatment plant (STP) of capacity 40 m3/day will be installed. The treated water from STP will be used within the plant for gardening and utility etc.

5.1.3 Additional Power Sourcing

Additional power required for the proposed expansion will be 9,904 kW which will be obtained from Dakshin Gujarat Vij Company Limited (DGVCL). In case of power failure, power will be generated using an emergency DG set of capacity ~2000 kVA. Use of grid power will avoid the need for any additional source for power generation as well as eliminate the possibility of operation of any diesel generators.


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5.1.4 Addition Manpower sourcing

Additional manpower required for the proposed expansion will be 253 nos. including staff and contract employees. Between local and outsourced manpower, UPL will prefer to utilize locally available man-power for the expansion project. This will contribute in providing employment to local people and contribute positively towards the growth of economy in the region.


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6 ENVIRONMENTAL MONITORING PROGRAM

6.1 APPROACH

Environemental performance assessment through environmental monitoring of industrial operations is governed through applicable environmental regulations, conditions of environmental permits and UPL’s corporate requirements. The objective of environmental monitoring is to assess the pollution load generated from sources of emissions and discharges and also track changes in the ambient environmental condition, on a regular basis. This will, in turn, enable suitable mitigation measures to be taken to safeguard the environment. A comprehensive environmental monitoring framework helps in timely determination of anomalies and corrective measures. The approach adopted by UPL for carrying out environmental monitoring of the proposed expansions will include in-house monitoring as well monitoring through external agencies approved by NABL and the regulatory authorities such as the Ministry of Environment and Forests & Climate Change and Gujarat Pollution Control Board.

6.2 SCOPE

The scope of monitoring activities shall include monitoring and analysis of the following: Air emissions from point sources through their stacks/chimneys to estimate

concentration of pollutants emitted; Ambient air quality monitoring at upwind, downwind and cross wind

directions covering potential human receptors, if any, in the vicinity; Ambient noise levels at fence-line of the facility; Workplace noise levels near high noise generating equipment/

machineries in the facility; Quality of treated wastewater discharged; Fugitive emissions from point sources in the project area; VOC and other pollutants emission at point source in the project area; Drinking water used in the project area

6.2.1 Monitoring parameters and frequency

UPL Unit 2 is an ISO 14001: 2015, ISO 9001:2008, OHSAS 18001: 2007, ISO 50001: 2011 Certified Company with latest environmental monitoring laboratory supported by scientific officers and environmental monitoring staff. The monitoring parameters and frequency defined in this section are those prescribed by regulatory agencies and UPL’s corporate requirements to measure environmental performance of the proposed augmented project. There may however be need for including additional parameters if warranted considering future developments, change in regulations or operational


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requirements. The frequency of monitoring may also be changed depending upon future requirements. The various parameters to be monitored along with their frequency have been described in Table 6.1.

Table 6.1 Environmental Monitoring Plan for Construction and Operation Phase

Monitoring Locations Frequency Parameters Annual Cost Estimates (INR)

Construction Phase Ambient Air Quality (AAQ) monitoring

Minimum 2 locations

Monthly

PM10, PM2.5, SO2 & NO2 and CO

1,20,000

Ambient noise level monitoring

At construction site within Plant and Plant gate

Quarterly Leq (night), Leq (day), Leq (24 hourly)

40,000

Monitoring Cost for Construction Phase 1,60,000 Operation Phase

Ambient Air Quality (AAQ) monitoring

Minimum 3 locations in the project area

Twice a week

PM10, PM2.5, SO2, NO2, NH3, HCl, CS2, H2S, VOC and Cl2.

3,40,000

Ambient noise level monitoring

Minimum 14 locations in the project area

Monthly Leq (night), Leq (day), Leq (24 hourly)

50,000

Stack Monitoring

Stacks attached to process vents, DG Sets and Boilers

Monthly PM, SO2, NOx, NH3, H2S, HCl, Cl2, VOC,

2,25,000

Sewage monitoring

Treated water from STP

Monthly pH, TSS, BOD and Residual Chlorine

48,000

Treated Waste Water from ETP

Effluent discharge water to RO System

Daily pH, COD, BOD, TDS, Toxicity factor/Bio Assay once in 15 days.

40,000

Fugitive emission monitoring

Monitoring at point sources of fugitive emissions

Once in a quarter

Cl2/EM/H2S/NH3/ Ethyl Acetate, Toluene, Total Mercaptan, EDC

65,000

Maintenance cost of ZLD Plant, expenses incurred towards hazardous waste disposal, greenbelt maintenance and Environmental Management Cell

33,93,00,000

Monitoring Cost for Operation Phase 34,00,68,000

6.2.2 Guidelines for External Agency

The selected third party environmental monitoring agency will be instructed to carry out monitoring and reporting as per the following guidelines.


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Monitoring locations: The monitoring locations will be identified and finalised by the UPL’s site environmental engineer in consultation with the monitoring agency. The monitoring locations would include stacks/ vents, effluent inlets/ outlets, waste storage areas, access roads and peripheral areas of the plant. Monitoring facilities: All monitoring equipment and consumables will be arranged by the monitoring agency. Access to monitoring points i.e. ladders, monitoring platforms, port holes, necessary HSE permits etc. will be arranged by UPL. Monitoring schedule: A detailed monitoring schedule will be prepared by the monitoring agency and approved by UPL’s site environment manager. Monitoring requirement at the facilities will be informed to the monitoring agency from time to time based on which the monitoring schedule will be amended.

6.2.3 In-house Laboratory at UPL

An in-house laboratory is very useful for monitoring on a regular and unhindered basis attributes that are not covered by the monitoring agency as well as for taking immediate decisions on treatment and disposal of solid wastes and effluent discharges. The UPL Unit 2 is ISO 14001 – 2016 certified unit with latest environmental monitoring laboratory supported by scientific officers and environmental monitoring staff. The in-house laboratory developed within UPL has capability of monitoring parameters related to water/wastewater quality, emissions, ambient air quality, Solid waste, VOCs Fugitive emissions and noise. The laboratory is under the technical guidance of the Environmental Manager and is manned by trained personnel.

6.2.4 Odour Monitoring

All venting of equipment are connected to condensers/ process Scrubbers to scrub excess vapour. LDAR (Leak Detection And Repairs) system is being followed to reduce VOC / HC emission. We also monitor LEL through LEL meter. In addition, sensors are provided for hazardous chemicals like EM, H2S, NH3 and VOC. All odorous streams (Gaseous form) generated from the phorate plant are sent to captive fume incinerator for thermal destruction. Usage of seal less/mechanical seal pumps for toxic chemicals. Mechanical seals for certain reactors. Regular inspections are carried out with reference to plant operations like pumps, valves, pipes etc., as per maintenance software (SAP).

6.2.5 Leak Detection Monitoring

Following tagging system is being used for LDAR: Leakage /Spillage tags are round shape having 3 inch dia.

Three color code are used


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(1) Red color round tags for leakage point which is having Tag number, Tagging date ; Name & Employee Code.

(2) Blue color round tag for temporarily attended leakage point for example steam leakage attended by On-line system.

(3) Yellow color round tag for leakage point that is attended but kept on observation This tag is to be removed after one week observation if no leakage occurs.

Shop floor person is identified the leakage and put red color circular tag and note down the tag number and location in a Leakage spillage register. The sample format of register is as follows:

Sr. No.

Tag No

Location Type of Leakage Freq. of occurrence

Correction RC CA Leakage attended date

Remarks

Chemical water Air Steam Oil Sweating One time / Reoccurrence

The identified leakage has to be arrested at the earliest opportunity.

If leakage occurs, the root cause analysis is to be done such as is it due to tension in line OR flange surface damaged OR is there any issue of gasket compatibility OR is line not supported adequately OR is there any workmanship issue etc . This is then to be addressed.

Monthly reports / Graphs are to be displayed on Leakages.

Spillages are also to be addressed by doing root cause analysis and ensure spilled material is collected & disposed off properly as per Safety & Environment guidelines.

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7 ADDITIONAL STUDIES – RISK ASSESSMENT AND EMERGENCY RESPONSE PLAN

7.1 PUBLIC CONSULTATION

UPL Unit 2), Plot No # 3405/3406/3460 A is located within Notified GIDC Ankleshwar Industrial Estatein the revenue survey nos.# 122/5/P, 124/3/P, 125/P, 126/P & 182/P of village Gadkhol and revenue survey nos. 161/P, 162/P, 182/P of village Sarangpur within the village limits Sarangpur and Gadkhol Taluka, Ankleshwar, District, Bharuch having area of 6.56 ha (65,625 m2). The land was allotted to UPL by GIDC Ankleshwar in 1992 i.e., prior to 14th September 2006 i.e., before the EIA Notification 2006 coming into force. The said plot is a part of GIDC Notification dated 1st February 1978 allotted to UPL in 1992. Therefore, in view of Office Memorandum (OM) vide J-11013/36/2014-IA.II (I) dated 4th April, 2016, para 3, and OM vide J-11011/321/2016-IA.II (I) dated 27th April, 2018, sub para (iii), Public Consultation is not applicable for the proposed Project. Refer to ToR compliance in the beginning of this report (i.e. before Section 1) for details.

7.2 RISK ASSESSMENT

This section on Risk Assessment (RA) aims to provide a systematic analysis of the major risks that may arise from the expansion of UPL’s proposal on expansion for manufacturing of technical pesticides and intermediate products within UPL’s Unit 2 at Plot no 3405/3406/3460A, Notified GIDC Industrial Estate, Ankleshwar-393002, Bharuch District, Gujarat, India. The RA process outlines rational evaluations of the identified risks based on their significance and provides the outline for appropriate preventive and risk mitigation measures. The output of the RA will contribute towards strengthening of the Emergency Response Plan (ERP) in order to prevent damage to personnel, infrastructure and receptors in the immediate vicinity of the plant. Additionally, the results of the RA can also provide valuable inputs for keeping risk at As Low As Reasonably Practicable (ALARP) and arriving at decisions for mitigation of high risk events. The following section describes the objectives, methodology of the risk assessment study and assessment for each of the potential risk separately. This includes identification of major hazards, hazard screening and ranking, frequency and consequence analysis for major hazards. The hazards have been quantitatively evaluated through a criteria base risk evaluation matrix. Risk mitigation measures to reduce significant risks to acceptable levels have also been recommended as a part of the risk assessment study.


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7.3 RA STUDY OBJECTIVE

The overall objective of this RA with respect to the proposed project involves identification and evaluation of major risks, prioritizing risks identified based on their hazard consequences and using the outcome to guide and strengthen both onsite and offsite ERP. Hence in order to ensure effective management of any emergency situations that may arise from failure of isolated storages of flammable and toxic chemical storages with respect to the proposed expansion operations, the following specific objectives need to be achieved. Identify potential risk scenarios that may arise from storage and handling

of hazardous chemicals; Review existing information and historical databases to arrive at possible

likelihood of such risk scenarios; Predict the consequences of such potential risk scenarios and if

consequences are observed to be high, establish the same through application of quantitative simulations; and

Recommend feasible preventive and risk mitigation measures as well as provide inputs for strengthening of the Project’s onsite Emergency Response Plan (ERP) and Disaster Management Plan (DMP).

7.4 RA METHODOLOGY

The risk assessment process is primarily based on likelihood of occurrence of the risks identified and their possible hazard consequences particularly being evaluated through hypothetical accident scenarios. With respect to the proposed project, major risks viz. leaks and rupture of storage tanks and containers evaluated through a risk matrix generated to combine the risk severity and likelihood factor. Risk associated with the chemical storages have been determined semi-quantitatively as the product of likelihood/probability and severity/consequence by using order of magnitude data (risk ranking = severity/consequence factor X likelihood/probability factor). Significance of such project related risks was then established through their classification as high, medium, low, very low depending upon risk ranking. The risk matrix is widely accepted as standardized method of risk assessment and is preferred over purely quantitative methods, given that it’s inherent limitations to define a risk event is certain. Application of this tool has resulted in the prioritization of the potential risks events for the existing operations and proposed expansion thus providing the basis for drawing up risk mitigation measures and leading to formulation of plans for risk and emergency management. The overall approach is summarized below in Figure 7.1.


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Figure 7.1 Risk Assessment Methodology

7.5 PROJECT – FLAMMABLE AND TOXIC MATERIAL STORAGE DETAILS

The list of chemicals stored or likely to be stored in the UPL Unit 2 facility as part of the proposed expansion Project has been provided below in Table 7.1.

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Table 7.1 Flammable and Toxic Chemical Storage Details –Existing and Proposed

S.N. Chemical Name Tank Type Diameter (m) Height (m) Existing Storage (KL)

Proposed Storage (KL)

Pressure (kg/cm2g) Temperature (°C)

1 Thionyl Chloride Drums: MS/GL – 0.237KL

0.58 0.9 15 50 Ambient pressure Ambient temperature

2 Methanol Tank: CS Underground-ST5007

3.6 ID 5 50 70 Ambient pressure Ambient temperature

3 Sulphuric Acid (98%) CS Tank 2.4 OD 3.5 15 180 Ambient pressure Ambient temperature

4 Bromine Glass line tank 0.65 1.5 Nil 5 Ambient pressure Ambient temperature

5 Triethyl Amine (TEA) MS Drums 0.576 0.9 Nil 1 Ambient pressure Ambient temperature

6 Hydrogen Peroxide Tank 4.25 3.5 Nil 30 Ambient pressure Ambient temperature

7 Ammonia (30%) CS Dishedend tanks i) 3.4 ii)4.6 i) 4.5 ii)6 i)40 260 Ambient pressure Ambient temperature

8 Acetic Anhydride SS316 Flat bottom tank 4.5 6.7 100 370 Ambient pressure Ambient temperature

9 Ethyl Acetate CS flat bottom tank 3.4 4.5 20 40 Ambient pressure Ambient temperature

10 Chlorine Tonner 0.8 2.0 Nil 5 Ambient pressure Ambient temperature

11 Phosphorous Oxy chloride (POCl3)

Tank 3.0 1.5 Nil 10 Ambient pressure Ambient temperature

12 Acetone Drums 0.576 0.9 0 2 Ambient pressure Ambient temperature

13 Acetone Cyanohydrin Carbuoys 1.0 1.0 0 1 Ambient pressure Ambient temperature

14 Ethanol Tank: CS Underground- ST5008

3.6 ID 5 50 200 Ambient pressure Ambient temperature

15 O-Cresol Drums 0.576 0.9 0 10 Ambient pressure Ambient temperature

16 Phosphorus Trichloride MS Tank 2.1 2.55 8 110 Connected scrubber with negative draft

Connected scrubber with negative draft

17 Methyl Chloride Tonner 0.8 2.0 Nil 24 Tonner Pressurised Ambient temperature

18 Monocrotophos Drums 0.576 0.9 10 40 Ambient pressure Ambient temperature

19 Furnace oil Tank 3.66 4.0 40 20 Ambient pressure Ambient temperature

20 Formaldehyde Tank 3.66 4.0 40 10 Ambient pressure Ambient temperature

21 Caustic (48%)-Devrinol Tank 2.5 OD 4 50 250 Ambient pressure Ambient temperature

22 Caustic (32%)-Clomazone Tank 3.2 OD 4.92 40 50 Ambient pressure Ambient temperature

23 Sodium Cyanide Drums 0.576 0.9 0 4 Ambient pressure Ambient temperature

Source: UPL

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Figure 7.2 Map showing Existing and Proposed Tanks in UPL Plant

Source: UPL


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7.6 HAZARD IDENTIFICATION

The first stage in any risk assessment is to identify the potential incidents that could lead to the release of a hazardous material from its normal containment and result in a major accident. This is achieved by a systematic review of the facilities to determine where a release of a hazardous material could occur from various parts of the installation. The major hazards are generally one of three types: flammable, reactive and/or toxic. For the present project, flammable and toxic releases have been identified as the predominant scenarios resulting from chemical storage and transfer pipeline failure in the form of leaks, ruptures etc. Based on the result of this exercise, potential hazards that may arise due to proposed project were identified and a qualitative understanding of their probability and significance were obtained. Taking into account the applicability of different risk aspects the following hazard has been identified with respect to the proposed Project, which has been dealt in detail in the subsequent sections. Release of flammable liquids and gases from failure of loading/unloading

line or hose and from storage tank/container leaks that may lead to jet fire (from immediate ignition), pool fire and VCE (from delayed ignition); and

Toxic vapour cloud formation from leakage of toxic chemical storage containers, pumps, valves and flanges.

7.6.1 Hazards from Flammable Chemical Storages

With respect to flammable chemicals, this study is concerned with ‘major hazards’ which may result from the storage and handling of chemicals viz. methanol, triethyl amine, acetic anhydride, acetone, acetone cyanohydrin, ethanol, o-cresol, methyl chloride and furnace oil. These are as follows: Jet fires; Pool fires and Vapour cloud explosions (VCE); Each of these hazards has been described below. Jet Fire Jet fires result from ignited releases of pressurized flammable gas or superheated/pressurized liquid. The momentum of the release carries the material forward in a long plume entraining air to give a flammable mixture. Jet fires only occur flammable gas is being handled under pressure or when handled in gas phase and the release are unobstructed. Pool Fires One of the type of chemical fire of interest in this study is a pool fire. If a liquid release has time to form a pool and is then ignited before the pool evaporates or drains away, then a pool fire results. Because they are less well aerated, pool


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fires tend to have lower flame temperatures and produce lower levels of thermal radiation than some other types of fire (such as jet fires); however, this means that they will produce more smoke. Although a pool fire can still lead to structural failure of items within the flame, this will take several times longer than in a jet fire. A burning liquid pool can spread along a horizontal surface or run down a vertical surface to give a running fire. Due to the presence of kerbs, slopes, drains and other obstacles; pool fire areas and directions can be unpredictable. Vapour Cloud Explosion When a flammable chemical is released into the atmosphere, it forms a vapor cloud that will disperse as it travels downwind. If the cloud encounters an ignition source, the parts of the cloud where the concentration is within the flammable range will burn. In some situations, the cloud will burn so fast that it creates an explosive force (blast wave). The effects of an explosion, defined by blast overpressure, can be significant.As such, if the vapour cloud is ignited in a confined or congested space, an explosion could also occur.

7.6.1 Hazards from Toxic Chemical Storages

For the toxic chemicals presently and likely to be stored and handled for the proposed project, the following hazards have been identified and presented in Table 7.2 along with their existing control measures. For the hazard rating of the toxic chemicals to be used for the proposed project, the National Fire Protection Agency (NFPA) 704 rating system has been used. Chemical substances are rated for degree of HEALTH RISK, FLAMMABILITY and REACTIVITY, on a scale of 0 to 4 as described below. Health Risk Level 4 – Can affect health or cause serious injury, during periods of very

short exposure, even though prompt medical treatment is given. Level 3 – Can affect health or cause serious injury, during periods of short

exposure, even though prompt medical treatment is given. Level 2 – Can cause incapacitation or residual injury, during intense or

continued exposure, unless prompt medical treatment is provided. Level 1 – Cause irritation upon exposure, but only minor injury is sustained

even if no medical treatment is provided. Level 0 – Offer no unusual hazards upon exposure to fire conditions. Flammability Level 4 – Completely vaporize at normal pressure and temperature and

burn readily. Level 3 – Liquids and solids that can be ignited under the most ambient

conditions. Level 2 – Must be moderately heated before ignition can occur. Level 1 – Must be strongly heated before ignition will occur. Level 0 – Will not burn. Reactivity


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Level 4 – Capable of explosive decomposition at normal temperatures and pressure.

Level 3 – Easily capable of explosive decomposition, but require an ignition source or will react explosively with water.

Level 2 – Easily undergo a violent reaction, but do not explosively decompose.

Level 1 – Normally stable, but become explosive at elevated temperatures and pressure.

Level 0 – Stable even under exposure to fire. The fire and health hazards of the chemicals being and/or likely to be used for the proposed expansion project is presented in Table 7.2.

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Table 7.2 Hazard Summary of Toxic Chemicals

S.No Chemical Name NFPA Hazard Rating

Toxicity Control Measure Health Flammability Reactivity

1 Thionyl Chloride 4 0 2 Identified as a corrosive and toxic chemical with life threatening health effects likely to be experienced at a concentration of 14ppm and above for an hour of exposure (AEGL-3).

Level trans meter with interlocks on LL and DCS operation, vent to scrubber, sand pit for leakage spillage. MSDS

2 Sulphuric Acid (98%)

3 0 2 Identified as a corrosive chemical with life threatening health effects likely to be experienced at a concentration of 160 mg/m3 and above for an hour of exposure (AEGL-3).

Flange guard, dyke wall, trained Operator, DCS operation, safety shower.

3 Bromine 3 0 0 Identified as a toxic chemical with life threatening health effects likely to be experienced at a concentration of 8.5ppm and above for an hour of exposure (AEGL-3).

Preventing and controlling exposure by o Engineering controls

Such as chlorine enclosure, ventilation with automatic or remote shut-down device

o Administrative controls with alarm systems, multi-gas instruments, detector tubes

Personal protective equipment - Eye protection, skin protection, respiratory protection

First AID: First aid kit and knowledge on first aid to all workers working in hazardous chemicals handling /storage area.

4 Hydrogen Peroxide

3 0 3 Life threatening health effects likely to be experienced at a concentration of 100ppm and above (EPRG-3).

-

5 Ammonia 3 1 0 Identified as a toxic chemical with TOXIC; with inhalation, ingestion or skin contact may cause severe injury or death. Life threatening health effects

Preventing and controlling exposure by


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S.No Chemical Name NFPA Hazard Rating

Toxicity Control Measure Health Flammability Reactivity

likely to be experienced at a concentration of 1100ppm and above for an hour of exposure (AEGL-3).

o Engineering controls such as chlorine enclosure, ventilation with automatic or remote shut-down device

o Administrative controls with alarm systems, multi-gas instruments, detector tubes

Personal protective equipment - Eye protection, skin protection, respiratory protection

First AID: First aid kit and knowledge on first aid to all workers working in hazardous chemicals handling /storage area.

6 Chlorine 4 0 0 High toxic chemical with life threatening health effects likely to be experienced at a concentration of 20ppm and above for an hour of exposure (AEGL-3).

Written safe work procedures A Workplace Hazardous Materials Information System (WHMIS) program

7 Phosphorous Oxychloride

4 0 2 The chemical is highly toxic by inhalation and ingestion and is strongly irritating to skin and tissues. Life threatening health effects likely to be experienced at a concentration of 0.85ppm and above for an hour of exposure (AEGL-3).

Exposure control plan Respiratory protection program (personal protective equipment) Written emergency procedures

8 Phosphorus Trichloride

4 0 2 This material is highly toxic; it may cause death or permanent injury. Life threatening health effects likely to be experienced at a concentration of 5.6ppm and above for an hour of exposure (AEGL-3).

Vent to scrubber system, Sprinkler for cooling. All flanges covered flange guard, Dyke wall safety shower.

Source: https://cameochemicals.noaa.gov/ and https://www.epa.gov/aegl/access-acute-exposure-guideline-levels-aegls-values#chemicals; file:///C:/Users/20007398/Downloads/chlorine-pdf-en.pdf


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7.7 FREQUENCY ANALYSIS

The frequency analysis of the hazards identified with respect to the proposed project was undertaken to estimate the likelihood of their occurrences during the project life cycle. Hazard frequencies in relation to the proposed project were estimated based on the analysis of historical accident frequency data and professional judgment. Based on the range of probabilities arrived at for different potential hazards that may be encountered with respect to the storage and handling of flammable and toxic chemicals including fuel with respect to the expansion project, the following frequency categories and criteria have been defined (ReferTable 7.3).

Table 7.3 Frequency Categories and Criteria

Likelihood Ranking Criteria Ranking (cases/year) Frequency Class 5 Likely to occur often in the life of the project, with

a probability greater than 10-1

Frequent

4 Will occur several times in the life of project, with a probability of occurrence less than 10-1, but greater than 10-2

Probable

3 Likely to occur sometime in the life of a project, with a probability of occurrence less than 10-2, but greater than 10-3

Occasional/Rare

2 Unlikely but possible to occur in the life of a project, with a probability of occurrence less than 10-3, but greater than 10-6

Remote

1 So unlikely it can be assumed that occurrence may not be experienced, with a probability of occurrence less than 10-6

Improbable

Source: Guidelines for Developing Quantitative Safety Risk Criteria – Centre for Chemical Process and Safety

7.7.1 Frequency Analysis – Flammable Fuel & Chemical Storage Tankages

The most credible scenario of a flammable and toxic liquid tankages will be pool fire, VCE and toxic vapour cloud. In order to determine the probability of a toxic vapour cloud/VCE/pool fire occurring, the failure rate needs to be modified by the probability of the material finding an ignition source. The probability of any of the aforesaid incident occurring in the event of a release is therefore equal to the product of the failure rate and the probability of ignition. The frequency of the possible release scenarios has been presented in Table 7.4 below. The ignition probability is dependent on a number of factors including the type of site, the release rate and the type of material released.

Table 7.4 Tank Failure Frequency – Flammable and Toxic Chemicals

S.N Type of Release Failure Rate (per vessel per year) Frequency

A Ambient Temperature & Pressure Vessels

1 Catastrophic tanks failure 5.0 x 10-6 Remote

2 Major failure 1.0 x 10-4 Remote

3 Minor failure 2.5 x 10-3 Occasional/Rare

4 Roof top release 2.0 x 10-3 Occasional/Rare

Source: Failure Rate and Event Data for use within Risk Assessments (28/06/2012) - UK HSE


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Based on the chemical inventory made available, majority of flammable chemicals viz. methanol, acetone, o-cresol, tri-ethyl amine etc. are being or to be stored under ambient conditions. In all such cases, the catastrophic failure frequency rate is found to be ~5.0 X 10-6 per vessel per year. Roof failures being considered for atmospheric tanks include all failures of the roof and do not include liquid pooling on the ground. For vessels that are storing flammable liquids, this could lead to a flammable atmosphere being formed and possible ignition and escalation. Event Tree Analysis Event tree analysis (ETA) is used to model the evolution of an event from the initial release through to the final outcome such as jet fire, fireball, flash fire etc. This may depend on factors such as whether immediate or delayed ignition occurs, or whether there is sufficient congestion to cause a vapour cloud explosion. Ignition Probability Immediate ignition for gas storage vessels is assigned a probability of 0.3 for large releases following Cox, Lees and Ang (Lees, 1996). For massive liquid releases the ignition probability is found to be comparatively lower i.e. 0.08 given higher flash points (see Table 7.5).

Table 7.5 Ignition Probabilities from Cox, Lees and Ang

Sl. No

Leak Rate Probability of Ignition

Gas Release Liquid Release

1 Minor (< 1kg/s) 0.01 0.01

2 Major (1-50 kg/s) 0.07 0.03

3 Massive (>50 kg/s) 0.3 0.08

Delayed ignition is assigned a probability of 0.5 (ENSR, 2008). Delayed ignition of flammable gas cloud may produce a flash fire or vapour cloud explosion (VCE). Given the fairly open nature of the surroundings, an explosion probability of 0.2 has been assumed.

7.8 CONSEQUENCE ANALYSIS

In parallel with the frequency analysis, hazard prediction / consequence analysis exercises were undertaken to assess the likely impact of project related risks on onsite personnel, infrastructure and environment. In relation to the proposed project as well as the existing activities have been considered, the estimation of the consequences for each possible event has been based either on accident frequency, consequence modeling or professional judgment, as appropriate. Overall, the consequence analysis takes into account the following aspects:


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Nature of impact on environment and community; Occupational health and safety; Asset and property damage; Corporate image; and Timeline for restoration of property damage. The following criteria for consequence rankings (Refer Table 7.6) have been drawn up in context of the possible consequences of the risk events that may occur during the proposed project operations:

Table 7.6 Severity Categories and Criteria

Consequence Ranking Criteria Definition Catastrophic 5 Multiple fatalities/permanent total disability to more than 50

persons. Net negative financial impact of >10 crores International media coverage Loss of corporate image and reputation

Major 4 Single fatality/permanent total disability to one or more persons

Net negative financial impact of 5 -10 crores National stakeholder concern and media coverage.

Moderate 3 Short term hospitalization & rehabilitation leading to recovery

Net negative financial impact of 1-5 crores State wide media coverage

Minor 2 Medical treatment injuries Net negative financial impact of 0.5 – 1 crore Local stakeholder concern and public attention

Insignificant 1 First Aid treatment Net negative financial impact of <0.5 crores. No media coverage

Risk Evaluation Based on ranking of likelihood and frequencies, each identified hazard has been evaluated based on the likelihood of occurrence and the magnitude of consequences. The significance of the risk is expressed as the product of likelihood and the consequence of the risk event, expressed as follows: Significance = Likelihood X Consequence The Table 7.7 below illustrates all possible product results for the five likelihood and consequence categories while the Table 7.8 assigns risk significance criteria in three regions that identify the limit of risk acceptability. Depending on the position of the intersection of a column with a row in the risk matrix, hazard prone activities have been classified as low, medium and high thereby qualifying for a set of risk reduction / mitigation strategies.


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Table 7.7 Risk Matrix

Likelihood →

Frequent Probable Unlikely Remote Improbable

5 4 3 2 1

Con

sequ

ence

→

Catastrophic 5 25 20 15 10 5

Major 4 20 16 12 8 4

Moderate 3 15 12 9 6 3

Minor 2 10 8 6 4 2

Insignificant 1 5 4 3 2 1

Table 7.8 Risk Criteria and Action Requirements

S.N. Risk Significance Criteria Definition & Action Requirements

1 High (16 - 25)

“Risk requires attention” – Project HSE Management need to ensure that necessary mitigation are adopted to ensure that possible risk remains within acceptable limits

2

Medium (10 – 15)

“Risk is tolerable” – Project HSE Management needs to adopt necessary measures to prevent any change/modification of existing risk controls and ensure implementation of all practicable controls.

3 Low (5 – 9)

“Risk is acceptable” – Project related risks are managed by well-established controls and routine processes/procedures. Implementation of additional controls can be considered.

4 Very Low (1 – 4)

“Risk is acceptable” – All risks are managed by well-established controls and routine processes/procedures. Additional risk controls need not to be considered

7.8.1 Consequence Analysis – Tankages

The main hazards associated with the storage and handlings of chemicals with respect to the proposed project are toxic vapour cloud including pool fire, jet fire and VCEs resulting from the ignition of released material. The hazards may be realised following tank overfilling and leaks/failures in the storage tank and ancillary equipment such as transfer pumps, metering equipment, etc. all of which can release significant quantities of flammable material on failure. The Section 7.5.1 had previously provided an explanation of the events, which may occur as a result of release of flammable material, followed by ignition. Risk Modelling Scenarios In addition to overfill, the scenarios considered for chemical/fuels storage tanks and containers were leaks and catastrophic failures. Factors that have been identified as having an effect on the integrity of tanks are related to design,


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inspection, maintenance, and corrosion1. The following representative scenarios for the tanks were considered (Refer Table 7.9).

Table 7.9 Flammable & Toxic Chemical Storages– Risk Modelling Scenarios

Sl. No

Chemical Name Total Storage including expansion (KL)

Event Scenario

1 Thionyl Chloride 50 Toxic Gas Release 5mm leak

Toxic Gas Release 10mm leak

Toxic Gas Release MCLS

2 Methanol 70 Pool Fire 50mm leak

Pool Fire 100mm leak

VCE MCLS 3 Bromine 5 Toxic Gas Release 2.5mm leak



4 Triethyl Amine(TEA)

1 Pool Fire 50mm leak


VCE MCLS

5 Ammonia (30%) 260 Toxic Gas Release 2m dia puddle

Toxic Gas Release 4m dia puddle

Toxic Gas Release 8m dia puddle

6 Acetic Anhydride 370 Pool Fire 50mm leak


VCE MCLS

7 Ethyl Acetate 40 Pool Fire 50mm leak


VCE MCLS

8 Chlorine Tonners 5 Toxic Gas Release 2.5mm leak



9 Phosphorous Oxy chloride (POCl3) 10

Toxic Gas Release 2.5mm leak


Toxic Gas Release MCLS 10 Acetone 2 Pool Fire 50mm leak

Pool fire 100mm leak

VCE MCLS

11 Acetone Cyanohydrin

1 Pool Fire 50mm leak


VCE MCLS

12 Ethanol 200 Pool Fire 50mm leak


VCE MCLS

13 O-Cresol 10 Pool Fire 50mm leak


VCE MCLS


110 Toxic Gas Release 2.5mm leak



1 AEA Technology, HSE Guidance Document


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Sl. No

Chemical Name Total Storage including expansion (KL)

Event Scenario

15 Methyl Chloride 24 Tonners Jet Fire 50mm leak

Jet fire 100mm leak

VCE MCLS

16 Furnace Oil 60 Pool Fire 50mm leak

VCE MCLS

NOTE: Monocrotophos, Formaldehyde, Sodium Cyanide, Caustic (48%)-Devrinol and Caustic (32%)-Clomazone are not considered for risk assessment as they are not likely to pose any immediate threat (like toxic exposure, pool fire etc.) from their accidental release unless subjected to any physical contact The chemical storage tank and container failure scenarios have been modeled using ALOHA and interpreted in terms of Thermal Radiation and Toxic Level of Concern (LOC) encompassing the following threshold values (measured in kilowatts per square meter) and ppm or mg/m3 respectively to create the default threat zone. Toxic Level of Concern Toxic Level of Concern has been interpreted in the form of Acute Exposure Level Guidelines (AEGLs) and Emergency Response Planning Guidelines (ERPGs) calculated for– 60 minutes. AEGL “levels” are dictated by the severity of the toxic effects caused by the exposure, with Level 1 being the least and Level 3 being the most severe. All levels are expressed as parts per million or milligrams per cubic meter (ppm or mg/m3) of a substance above which it is predicted that the general population could experience, including susceptible individuals:

AEGL-1 (Yellow): Notable discomfort, irritation, or certain asymptomatic non-sensory effects. However, the effects are not disabling and are transient and reversible upon cessation of exposure;

AEGL-2 (Orange): Irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape; and

AEGL-3 (Red): Life-threatening health effects or death.

ERPGs estimate the concentrations at which most people will begin to experience health effects if they are exposed to a hazardous airborne chemical for 1 hour. The three ERPG tiers are defined as follows:

ERPG-3 (Red): This is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.

ERPG-2 (Orange) This is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action.

ERPG-1 (Yellow): This is the maximum airborne concentration below which nearly all individuals could be exposed for up to 1 hour without experiencing more


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than mild, transient adverse health effects or without perceiving a clearly defined objectionable odour.

Thermal Radiation Level of Concern

Red: 10 kW/ (sq. m) -- potentially lethal within 60 sec;

Orange: 5 kW/ (sq. m) -- second-degree burns within 60 sec; and

Yellow: 2 kW/ (sq. m) -- pain within 60 sec

For vapour cloud explosion, the following threshold level of concern has been interpreted in terms of blast overpressure as specified below: Red: 8.0 psi – destruction of buildings; Orange: 3.5 psi – serious injury likely; and

Yellow: 1.0 psi – shatters glass

The MSDS of the Products and Raw materials is included as Annex F. The risk contours for Maximum Credible Loss Scenario (MCLS) for flammable and toxic chemical storages have been have been included in Annex F. The risk significance as established based on risk scenarios modelled and failure frequencies considered presented in Table 7.10.


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Table 7.10 Hazardous Chemical Storages – Risk Modelling Results

S. N Chemical Name Event Scenario LOC 1 (in m) LOC 2 (in m) LOC 3 (in m)

Likelihood Consequence Significance AEGL-3 /EPRG-3 8 psia 10

kW/m2 AEGL-2 /EPRG-2 3.5 psia 5

kW/m2 AEGL-1 /EPRG-1 1 psia 2

kW/m2 1 Thionyl Chloride Toxic Gas

Release 5mm leak

51 125 - 3 3 9

Toxic Gas Release

10mm leak 97 237 - 3 4 12

Toxic Gas Release

MCLS 154 379 - 2 4 12

2 Methanol Pool Fire 50mm leak 12 14 18 3 2 6

Pool Fire 100mm leak 22 26 35 3 2 6

VCE MCLS - - 268 2 3 6

3 Bromine Toxic Gas Release

MCLS 104 645 1900 3 3 9

4 Triethyl Amine(TEA)



VCE MCLS - 42 70 2 3 6

5 Ammonia (30%) Toxic Gas Release

2m dia puddle

19 52 121 3 3 9

Toxic Gas Release

4m dia puddle

38 101 237 3 3 9

Toxic Gas Release

8m dia puddle

73 198 467 2 5 10

6 Acetic Anhydride Pool Fire 50mm leak 12 14 19 3 3 9


7 Ethyl Acetate Pool Fire 50mm leak 13 16 22 3 2 6


8 Chlorine Toxic Gas Release

2.5mm leak 67 220 454 3 5 15

Toxic Gas Release

5mm leak 137 452 912 3 5 15

Toxic Gas Release

MCLS 233 769 1500 2 5 10

9 Phosphorous Oxy chloride (POCl3)

Toxic Gas Release

2.5mm leak 83 3 3 9

Toxic Gas Release

5mm leak 155 - - 3 4 12

Toxic Gas Release

MCLS 180 - - 2 5 10

10 Acetone Pool Fire 50mm leak 13 17 23 3 3 9

Pool fire 100mm leak 24 30 42 3 3 9

VCE MCLS - 53 82 2 3 6

11 Acetone Cyanohydrin

Pool Fire 50mm leak <10 <10 <10 3 1 3

Pool fire 100mm leak <10 <10 <10 3 1 3

12 Ethanol Pool Fire 50mm leak 13 16 21 3 2 6


VCE MCLS - - 676 2 3 6


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S. N Chemical Name Event Scenario LOC 1 (in m) LOC 2 (in m) LOC 3 (in m)

Likelihood Consequence Significance AEGL-3 /EPRG-3 8 psia 10

kW/m2 AEGL-2 /EPRG-2 3.5 psia 5

kW/m2 AEGL-1 /EPRG-1 1 psia 2

kW/m2 13 O-Cresol Pool Fire 50mm leak 12 14 19 3 2 6



Toxic Gas Release

2.5mm leak 38 64 156 3 2 6

Toxic Gas Release

5mm leak 76 128 315 3 4 12

Toxic Gas Release

MCLS 152 257 641 2 5 10

15 Methyl Chloride Jet Fire 50mm leak 10 24 45 3 2 6

Jet fire 100mm leak 12 25 44 3 2 6

VCE MCLS 27 27 2 3 6

16 Furnace Oil (FO) Pool Fire 50mm leak 15 19 28 3 2 6



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7.9 RA OUTCOME

The RA results for storage tanks indicates that in most of the scenarios involving leakages leading to Pool/Jet Fire, the risk significance is assessed as “Low”. For scenarios with low risk significance, the effective distance for damage in terms of radiation intensity is likely to remain up to 53m. For medium risk significance, catastrophic failures of highly flammable chemical and fuel storage tanks were found to result in VCEs. For VCEs, the maximum blast overpressure of 8.0 psi, which may cause destruction of building, did not exceed the LOC in all cases except for triethyl amine (TEA) which will be up to ~19m within the Plant premises. While the blast overpressure of 3.5 psi (which may cause serious injury) is expected to remain up to a radial distance of 53m. Hence, damaging effects from thermal radiation and VCE are expected to remain limited within the plant premises to nearby process equipment and machineries. The damaging effects may result in occupation injuries/fatalities to site personnel and workers operating in the immediate vicinity, requiring adequate risk mitigation measures be in place together with strict use of adequate PPEs by personnel working in nearby areas. The potential threat from toxic releases were found to be particularly significant with respect to chlorine tonners wherein the life threatening health effects are likely to be experienced up to a distance of 233 m from source. The release scenario leading to irreversible or other serious, long lasting adverse health effects are expected up to 769 m due to catastrophic rupture of a chlorine tonner (i.e. maximum credible leak scenario). The RA results show requirement of implementation of appropriate engineering and administrative controls together with strict risk mitigation measures to minimize potential exposure risks. The above RA outcome shows requirement of implementation of appropriate engineering and administrative controls together with strict risk mitigation measures to minimize potential exposure risks. Following risk mitigation measures need to be included: Preventing and controlling exposure by

o Engineering controls such as chlorine enclosure, ventilation with automatic or remote shut-down device;

o Provision of neutralizing systems for toxic gases and liquid chemicals; o Administrative controls with alarm systems, multi-gas instruments,

detection sensors; o Chemicals, which upon fire give rise to toxic fumes, requiring special

fire control measures. In addition, runoff fire-water from toxic chemicals is to be dyked for its neutralization and treatment prior to disposal.

Written safe work procedures A Workplace Hazardous Materials Information System (WHMIS) program.


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Exposure control plan Respiratory protection program (personal protective equipment) Written emergency procedures Written preventive maintenance procedures Checking on a worker working alone Training, instruction, and supervision In addition, adequate fire protection system is required to be in place and supplemented by implementation of focussed training and awareness sessions and organizing periodic Onsite and occasional Offsite Emergency Preparedness drills to check effectiveness of existing risk management system. UPL’s emergency preparedness and response plan will comply with requirement of the Gujarat Factories Rules 1963 & MSIHC Rules, 1989 as amended. UPL is to conduct a detailed process hazard analysis and HAZOP at two stages i.e. as part of the Front End Engineering and Design (FEED) study and prior to commissioning of each process of the proposed expansion to assess associated risks and implement recommendation for safe operations.


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7.10 EMERGENCY PREPAREDNESS AND RESPONSE PLAN

UPL handles various hazardous chemicals and employ processes involving high pressure and temperature. In spite of precautions and safety measures one take, an incidence of potential damage may arise by system failure or unavoidable circumstances. An emergency preparedness and response plan for proposed expansion project will lay down guidelines to handle such emergencies. UPL’s Emergency preparedness and response plan will comply with requirement of schedule 8-A of sub rule 68-J-(12) (1) of Gujarat Factory Rule 1963 & Schedule-11 of Rule 13(1) of MSIHC Rule 1989.

7.10.1 Classification of Emergency

Emergencies at UPL have been classified in three categories: Level – 11: The incident or emergency which are confinable, controllable within the plant premises, which under normal circumstances does not affect area outside the said plant battery limit and controlling does not involve / require external help. This situation is called emergency stand by and affected unit / plant have to handle emergency Level – 2: When the incident or emergency level-1 is not controlled within 10 to 15 minutes or does not come under control within 10 to 15 minutes, incident controller, site main controller reviews the situation and decides. If situation is Worsening. Level – 3: After surveying off-site implications of level – 2 emergency if there is a likelihood of chlorine gas cloud formation and spreading of cloud in down wind direction affecting neighbouring population of industry and villagers and /or in case of following incident IC (Incident Controller) and SMC (Site Main Controller) are of the opinion that there will be off-site implications. The emergencies have been identified and categorized in three modes: Man-made: Heavy Toxic Leakage/Spillage, Fire, Explosion, Failure of Critical Control system, Design deficiency, unsafe acts, In-adequate maintenance Natural Calamities: Flood, Earthquake, Cyclone, Outbreak of Disease, Tsunami, Lightning Extraneous: Riots/Civil Disorder/Mob Attack, Terrorism, Sabotage, Bomb Threat, War/Hit by missiles, Abduction, Food Poisoning/Water Poisoning The On-site emergency plan deals with, measures to prevent and control emergencies within the factory and not affecting outside public or Environment. The Off-site emergency plan deals with, measures to prevent and control emergencies affecting public and the environment outside the premises. 1 Level-I and Level- II shall normally be grouped as onsite emergency and Level-III as off- site emergency


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The organizational structure and communication management for Emergency response is given below in Figure 7.3.

Figure 7.3 IRT Organizational Support Matrix

7.10.2 Emergency Response Personnel

First responder: Any person who notices the abnormal incident of hazardous nature, must act as a first responder. Alarm Riser: After getting instruction from Respective Incident Controller, the Alarm riser will raise the siren. In case of failure of power supply, a manual bell will be rung loudly. Site Main Controller: Site Main Controller is the head authority of the Emergency Organization. He/she is having overall responsibility for directing operation and calling for outside help from Emergency Control Centre. In absence of Unit Head, Incident site Group Head will Act as a Deputy Site Main Controller and during Silent hours, NDO/ DDO will be holding responsibility of Dy. Site Main Controller.


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Incident Controller: If the incident occurs in the plant area, Respective Shift In-charge of the Plant (Site) & Head of the Department holds the responsibility of the Incident Controller. On being informed of the emergency and its location, incident controller will rush to the site and will do the specific set of assessment and actions. Deputy Incident Controller: In the absence of Shift In-charge (Incident Controller), Deputy Incident Controller of respective Plant will hold the responsibility of the Incident Controller. Key Personnel: On being informed of the emergency he will rush to the incident site and will report to incident controller or Site Main Controller at ECC. The key personnel identified in UPL’s ERP are: A. Production Manager B. Safety Manager C. Security officer D. Factory Medical Officer E. P& A &IR F. Adjacent Plant in-charge G. Telephone Operator Essential Personnel Team: As soon as the essential personnel hear the emergency siren or any emergency brought to the knowledge, they first report to incident controller (After hand over their charge to other plant supervisor) with fully equipped themselves. (For proper information all team member have to contact immediately on telephone Number). The team of the essential personnel is trained in firefighting, first aid and engineering controls and they are available in factory in all shifts.

7.10.3 Emergency Control Centre

The emergency control centre (or room) is the place from which the operations to handle the emergency are directed and coordinated. The site main controller, key personnel and senior officers of the fire, police, factory inspectorate, district authorities and emergency services will attend it. The centre should be equipped to receive and transmit information and directions from and to the incident controller and areas of the works as well as outside. It should also have equipment for logging the development of the incident to assist the controllers to determine any necessary action. In addition to the means of communication, the centre should be equipped with relevant data and equipment which will assist those manning the centre to be conversant with the developing situation and enable them to plan accordingly. It should be sited in an area of minimum risk and close to a road to allow for ready access by a radio-equipped vehicle for use if other systems fail or extra communication facilities are needed. The centre should be equipped with adequate number of supplies required to handle emergency situation such as


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plant layout and surrounding areas map, sirens, safety equipment, fire extinguishers and emergency vehicles.

7.10.4 Other companies/ external organizations to be involved in on-site emergency

Site main controller is responsible to inform below authorized organizations in case of on/off site emergencies: 1. UPL Limited Unit 1 – GIDC, Ankleshwar 2. UPL Limited Unit -3 – GIDC. Ankleshwar 3. UPL Limited Unit-5 – GIDC, Jaghadia 4. DPMC – GIDC, Ankleshwar (full scale fire brigade services with rescue

team) Site main controller (SMC) and deputy SMC are responsible for liaising with government authority, nearby organization, journalist, population, employees and nest of kin of the employees. Further mutual aid arrangements with neighbouring industries and nearby hospitals will be made to respond to level-II emergencies.

7.10.5 List of Emergencies

UPL’s emergency response plan has identified emergency situations which are categorized as man-made emergencies, natural calamities and extraneous emergencies. The list of emergencies is provided below in Table 7.11 which can be rehearsed and updated on regular basis.

Table 7.11 List of Emergencies identified at UPL

Man made Natural Calamities Extraneous Toxic gas release Flood Riot/Civil disorder

Mob attack Fire Earthquake Terrorism Explosion Cyclone Sabotage Failure of critical control system

Outbreak of disease Bomb threat

Spillage of strong acid and alakalis

Tsunami, Lightning War/hit by missiles Abduction Food poisoning/ water poisoning

7.10.6 Identification and Assessment of Hazards

This is the most crucial stage to both on-site and off-site emergency planning, as the hazard would range from small events which can be dealt by works personnel without outside help, to the large accidents, for which it is vital to have a plan systematically designed to combat the disaster. UPL is to conduct a detailed process hazard analysis and HAZOP at two stages i.e. as part of the Front End Engineering and Design (FEED) study and prior to commissioning of each process of the proposed expansion to assess associated risks and implement recommendation for safe operations.


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7.10.7 Emergency due to Natural Calamities

UPL has identified possibility of occurrence of following natural calamities at the project site and has developed a response plan to each of these calamities as part of ERP: 1. Earthquake 2. Lighting and Thunderstorm 3. Heavy rain

7.10.8 Communication Arrangements for On-site and Off-site Emergencies

For the purpose of on-site and off-site emergency plan, UPL has quick and effective communication system to make the emergency known: a. Inside the factory; b. To key personnel outside normal working hours; c. To outside emergency services and authorities; and d. To neighbouring factories and public in vicinity. Arrangement of off-site emergency plan and communication is explained below in Figure 7.4. The details of Onsite Emergency Response Plan (ERP) is included as Annex H.


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Figure 7.4 Arrangement for off-site emergency plan and communication

7.11 OCCUPATIONAL HEALTH AND SAFETY

7.11.1 In-Plant Safety Precautions Employed

M/s. UPL is having a full-fledged safety department headed by safety manager. The safety department undertakes various safety-related activities to improve awareness among the employees. Continuous training is imparted to all concerned employees at all the levels.

For chemical transportation and unloading of tankers, all unloading points are identified and are equipped with grounding / earthling facilities.


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All vehicles going inside the process premises are fitted with mufflers at security gate itself to avoid any probable fire risk.

The Hazardous Chemical - Ethanol which is having low flash point, is stored underground

For highly flammable reactants, the storage tanks are fitted with sprinkler type cooling arrangements and flame arrestors in their vent.

All solvent transfer lines are provided with the earthing strips to avoid the accumulation of any static charges during its transfer operations.

All plants are well equipped with self-contained breathing apparatus and compressed air to take care of any accidental leakage/spillage/gas release.

Provision of portable gas detectors/handy samplers to know the concentration of the gases in ambient air, which would help decide the evacuation of the surrounding people in case of gaseous cloud formation, thereby reducing the environmental hazards.

For safe handling of solids, a flameproof type caged hoist fitted with necessary interlock system is provided.

All warehouses are equipped with exhaust ventilation and portable type fire extinguishers to take care of any fire.

The provision has also been made for sufficient storage of water for firefighting requirement, extinguisher at all critical locations and sufficient manpower to combat fire hazards.

Canister / cartridge type gas masks are provided to the employees for their day-to-day working.

7.11.2 Approach for Safety Management

The approach to safety management may divide into the following categories:

Provision of personal protective devices like chemical resistant suits, gloves, glass, shoes etc.

Provision of plant safety measures - this includes the provision of proper colour coding and labelling of pipelines, identification of safety assembly points, placing of caution boards at several locations within the plant, emergency showers.

Protective measures for safe storage and transportation of hazardous chemicals/wastes are as follows:

All necessary precautions for the safe storage and transportation of all raw materials and other recyclable chemicals. Utmost care has been taken for the siting of storage locations of the above chemicals keeping in mind the proper spacing, ventilation and compatibility of the chemicals to be stored.

While transporting the above hazardous chemicals/wastes, all the provisions mentioned in Central Motor Vehicles Rules, 1989 are complied with. The tankers carrying the chemicals are labelled properly and carry all the instructions like technical name of the chemical transported, urgent actions to be taken in case of leakage / fire, contact telephone numbers for


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emergencies etc. Compliance with the provisions of on-site and off-site emergency plans.

Provision of medical assistance including the First-Aid provisions.

Yearly safety audit through expert agencies like – Tata AIG Risk Management Services Ltd – is being carried out.

7.11.3 Occupational health programs

At UPL, health of employees is given great importance. The company is having medical doctor and Occupational Health Center (OHC) and an ambulance. Pre-employment and routine medical examinations are being carried out. We are also doing full body medical check-up by external expert agency every year for physical examination, haemoglobin, complete blood count, ESR, complete urine examination, lever function, kidney function, creatinine, blood sugar, Electro Cardiogram, X Ray for chest and Sonography etc. regular blood cholinesterase activity (BCA) test for employees is also being carried out All medical records are being maintained. During July-Dec 2017, medical check-up done for total 289 employees including contract employee. Experienced part time doctor for each unit who visits the site 3 times a week

Occupational health centre for with availability of male nurse in general shift

Detailed Health check-up of each employee every 2 years (this check -up includes X ray, ECG, physical check-up, lung function test, eye check-up etc.)

For employees working in pesticide environment, check up by company doctor every 3 months

Check-up of all contract workers by FMO during / after their entry to company

Blood and urine test of each employee working in Pesticide environment once in 6 months

Individual health file is maintained for each employee working at site.

Regular blood Choline Esterase tests for all contract workers coming to the site and ensuring that minimum 75 % BCA number is maintained as prerequisite for job. At Unit 2, frequency is 15 days.

Regular BCA tests for employees working in Pesticide environment at frequency of 30 days.

Beyond the programs mentioned above, FMO (Factory Medical Officer) conduct HOD sessions for bringing the health awareness. The Medical Examination Record and Annual Medical Check-up records is included as Annex I.


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8 PROJECT BENEFITS

8.1 DEMAND SUPPLY GAP

The Indian pesticides industry is characterized by low capacity utilization. The present total installed capacity is 146,000 tonnes and has a low capacity utilization of less than 60%1. With strong global demand for pesticides and India being the low cost producer, exports of pesticides from the country are expected to remain buoyant. As per FICCI report in 2016, Indian agrochemical industry, which is estimated at $ 4.4 billion in FY15, is expected to grow at 7.5% annually to reach $ 6.3 billion by FY20, with domestic demand growing at 6.5% per annum and export demand at 9% per annum. Further, pesticides worth $ 4.1 billion are expected to go off-patent by 2020. This provides significant export opportunities for Indian players who majorly produces generic products. On a broader scale, crop protection chemicals will help in increasing crop productivity and ensuring food and nutritional security for the country. The expansion project will also be beneficial due to the following: The availability of most of the existing plant’s infrastructure which will

help in minimising both the economical and environmental impacts; Availability of supply chain logistics which can be extended to the

proposed expansion and will help in economical and environmental impacts;

Re-engineering capabilities and relatively low cost of production; It will provide a boost to the local economy by providing employment

generation to the local man power; Continuous growth of exports and increase in the Indian market demand

off set the local competitions; The export opportunities will help in generating foreign currency; The proposed expansion project is based on the market surveys and in

house captive consumption; Indirectly help exporters to tap the organic export market, given India’s

low fertiliser and pesticide use per acre compared to world standards.

8.2 SOCIAL BENEFITS

The company has allocated some budget for CSR activities, which can lead to improved social infrastructure. UPL Management have identified six thematic focus areas based on their CSR policy and deep need analysis study to understand the society’s need. Six key focus areas of UPL’s CSR are: 1) Agriculture Development 2) Health & Sanitation

1 Indian Chemical Industry, XIIth Five Year Plan – 2012-2017


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3) Environment & Nature Conservation 4) Education & Empowerment 5) Employability & Entrepreneurship 6) National & Local Area needs

1. UPL KhedutPragati (Agriculture Development) UPL KhedutPragati Program is an Agriculture Development initiative implemented by the CSR department of UPL limited. This programme is mainly focused on agriculture development because agriculture is the backbone of rural India. More than 70% of the total population is dependent directly or indirectly on agriculture for its subsistence. Considering the situation surrounding Ankleshwar villages, multiple agriculture projects will be carried out under the umbrella of “UPL KhedutPragati” Goal “To enhance food security and improve the socio-economic conditions of small holders and marginal farmers by providing sustainable agricultural solutions in a period of 5 years” Objectives: To increase the knowledge of farmers by training and awareness campaign To improve the agriculture productivity by introducing best package of

practices in agriculture To enhance the water use efficiency by providing innovative irrigation

practices (Drip/Sprinkler/lift irrigation etc) Strategy: UPL KhedutPragati will work on making the agriculture more sustainable and profitable venture for the farmers through increasing the yield of agriculture produce, reducing the cost of cultivation and better management of natural resources. The strategy which will be adopted to execute is detailed below:

Box 8.1 UPL KhedutPragati Strategy


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Source: UPL 2. Health and Sanitation

UPL School Sanitation programme will construct toilet blocks in surrounding schools. Along with building toilets in school, which they consider an easiest task and only a beginning, their sanitation programme also works on 5 major issues:

a. A toilet has no meaning without availability of water – Even though it would add first to the overall initial investment. UPL will ensure water facility is connected to school toilet complex.

b. The second important issue is changing hygiene habits of kids going to school. Merely providing a toilet in school might not work when the kid is used to answering nature's call in the open fields. Even teachers have that habit. UPL will work on behavioural aspect.

c. The third issue is maintaining the toilets, keeping the soak pits clean for instance so that it doesn’t becomes breeding ground for germs and diseases. This can be done by having a token fee of Rs. 1 per month, which goes in funding the maintenance. This is important because after the initial thrust School toilet has to be self-sustaining and not supported only through external financial aid.

d. The fourth issue with school toilets is about ownership. How to make the students responsible for the process? The idea is to make teacher and student owner of school toilet. UPL will have something like a cabinet, with say one of the students appointed as health minister who would be responsible with his school mates to run the show.

e. The fifth and final is designing the toilets of the future. For instance, having a biogas unit (technologies to convert sludge-to-energy, having horticulture to use water, working in new toilet technologies like new pit latrines, septic tank emptying technologies etc.

Box 8.2 Building toilets in schools as part of school sanitation programme

Source: UPL

3. UPL Vasudha (Environment & Nature Conservation)


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Vasudha in Sanskrit means the Mother Earth, the giver of wealth. The UPL Vasudha will be aiming for integrated nature conservation project involving all stakeholders. The concept of UPL Vasudha programme is further explained in Figure 8.1.

Figure 8.1 UPL Vasudha Programme

Source: UPL

UPL Social Forestry - To enhance the biodiversity by increasing the forest cover which will give sustainable livelihood opportunity to local community”. Eco Club - This is an initiative to make the young generation aware about the importance of protecting nature and maintaining ecological balance. These clubs are formed in schools and students participate in environment related activities through these clubs.

Box 8.3 Mangrove plantation carried out by UPL

Source: UPL


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4. Education & Empowerment UPL will go for School Development Programme and will have provision for infrastructure support to government school to enhance the access and to provide enabling condition for quality education. Infrastructure support in the area of upgradation of school can be: Providing class rooms with furniture, library, Integrated Laboratory,

Computer room, Head Art and Craft room, Toilet Blocks, Drinking water etc.

Strengthening of existing schools through construction of additional classrooms, Laboratories, Library, computer room, separate toilets for girls and boys, resource room for Science, etc.

Vocational Education related workshops Major repair for school building This will be a need based initiative and as per availability of funds.

5. UPL Niyojaniy (Skill Development) “Niyojaniy” is a Hindi word meaning employable. The UPL Niyojaniy is a skill training centre that aims to make youth employable, hence the name. UPL will establish one centre in area under the S R Shroff Aajivika Trust to equip the school dropout youth with the skills needed to become financially independent. Objective for UPL Niyojaniy is to provide comprehensive skills training on industry specific skills like welding, fitting, electrical, Chemical Plant Operator and Instrument Operator Chemical Plant and prepare the youths for job opportunities in the surrounding industries. Before every intake, UPL will conduct mobilization drives in the villages to make the youth aware about the training and its prospects.

Figure 8.2 Skill development of youths of nearby community

Source: UPL


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6. UPL GramPragati (Local area Need)

Being a responsible corporate citizen, UPL is committed to respond to address the local area need by undertaking development initiative to help community grow by taking need based activity for community around their factory sites UPL’s focus area include: Response to Natural Disaster Suraksha Abhiyan (Road safety, Girl Safety. Home safety and Industrial

Safety) Support of Non-Financial Aid Any other Development Activity

Box 8.4 Need based Analysis conducted with community

Source: UPL

The details of the CSR initiatives carried out in sourrounding villages is provided below in Table 8.1

8.3 EMPLOYMENT GENERATION

As per Indian Chemicals Industry’s five year plan (2012-2017) report, pesticides manufacturing sector provides direct and indirect employment to approximately 60,000 people, nearly 10,000 of these working in pesticides manufacturing units. The industry envisaged employment increase to the extent of 7% as per XII five year plan. Currently, UPL employs 493 people in permanent staff and contractual role. In addition to this 746 people will be employed as staff and contractual role as part of the proposed Project. UPL is committed towards giving preference to locally available man-power during the course of construction and operation phase.


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Table 8.1 CSR Initiatives by UPL in Sourrounding Villages of Unit 2

S.N. VILLAGE NAME

CSR INITIATIVES FOR SURROUNDING 14 VILLAGES

UPL Niyojaniy Kendra (Skill Development)

UPL KhedutPragati Programme (Agriculture & Animal Husbandry Development)

UPL GramPragati

UPL School Sanitation Programme (Toilet Blocks & Awareness programme in School)

School Development Programme

UPL Vasudha Programme (Nature Conservation)

UPL Social Forestry Project (Tree Plantation)

UPL School Eco club & School plantation

1 Motali √ √ √ √ √ √ √ 2 Amratpura √ √ √ √ √ √ √

3 Nava Kanshiya √ √ √ √ √ √ √

4 Juna Kanshiya √ √ √ √ √ √ √

5 Mandava Bujarg √ √ √ √ √ √ √

6 Juna Diva √ √ √ √ √ √ √ 7 Naugama √ √ √ √ √ √ √ 8 Samor √ √ √ √ √ √ √ 9 Andala √ √ √ √ √ √ √ 10 Borbhatha bet √ √ √ √ √ √ √ 11 Bhadkodara √ - - √ √ √ √ 12 Kosamdi √ - - - - √ √ 13 Kapodara √ - - - - √ - 14 Gadkhol √ - - √ - √ - 15 Sapar √ - - - - √ -

Source: UPL The details of allocated budget for CSR for next five years are provided in Table 10.1 (Chapter 10).


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9 ENVIRONMENTAL COST BENEFIT ANALYSIS

The Environmental Cost Benefit Analysis was not recommended during scoping stage and in standard ToR granted for proposed expansion of UPL Unit 2 by Expert Appraisal Committee (EAC) of Ministry of Environment, Forest & Climate Change (MoEF & CC). Hence, this study was not carried out as part of the current EIA study.


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10 ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

This section presents environmental management plan, which highlights actions which are being taken by UPL along with any additional actions that also need to be considered. Some of the key components of EMP are as discussed in the following subsections. The key objectives of the EMP are to: Provide a framework for compliance with UPL’s Health, Safety and

Environmental (HS&E) policy, HS&E Management System (HSEMS), and relevant Indian environmental legal requirements;

Summarise the potential impacts associated with the Project and clearly set out the corresponding control/ mitigating measures that need to be implemented; and

Set out the environmental monitoring programme for key environmental parameters to monitor environmental performance.

The EMP will be a “live” document. It will be reviewed by the Project team prior to any change in equipment or modification in the process scheme in consultation with UPL’s HSE Department, on a periodic basis during the Project Phase. The EMP will be updated as needed to provide effective management of environmental issues associated with the Project. Implementation of the EMP will not only involve UPL staff but will also be adhered to by its contractors and its service providers. This will involve the incorporation of the commitments contained in the EMP, including relevant mitigation and control measures, working practices and overall management procedures as appropriate.

10.2 ELEMENTS OF EMP

EMP includes four major elements: Commitment and Policy: UPL will strive to implement the Environmental

Management Plan; Planning: This includes identification of environmental impacts, legal

requirements and setting environmental objectives. Implementation: This comprises of resources available for the project,

accountability of contractors and or service providers, documentation of measures to be taken;

Measurement & Evaluation: This includes monitoring, corrective actions and record keeping.

Management Review: Actions are taken to continually improve the HSE performance.

10.2.1 Commitment & Policy

UPL’s HSE and Corporate Social Responsibility policies are given below in Figure 10.1 and Figure 10.2.


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Figure 10.1 UPL’s HSE Policy

Source: UPL


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Figure 10.2 UPL’s Corporate Social Responsibility Policy

Source: UPL

10.2.2 Planning

Various components of planning for the Proposed Project will include as per the following sub sections. Organization, Roles and Responsibilities

UPL’s Environmental cell has the overall responsibility for implementation of the proposed environmental management plan along with the mitigation measures and monitoring the progress of the proposed management plans and actions to be implemented for the project.


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In general, the Environmental cell performs the following activities: Development and implementation of Environmental Management System

(EMS); Identifying legal requirement and preparation of required documents on

environmental management; Ensuring availability of resources and appropriate institutional

arrangements for implementation of EMP; Selection of appropriate NABL and MoEF&CC approved monitoring

agency for carrying out monitoring and analysis; Compliance of regulatory requirements; Reviewing and updating the EMP as and when required for its effective

implementation. A safety department also exists comprising of a Safety committee as per section 41 G & 41 H of Factories Act and 68 F & 68 J as per Factories Act with defined role and responsibilities and defined framework covering all aspects of plant and personnel safety. Qualified Safety Officer, Supervisors and Factory Medical Officer are also employed. UPL unit-2 being a group division, follows the group HSE policies drafted for all manufacturing units of the group around the world.


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Figure 10.3 UPL’s HSE Organization Chart

Source: UPL


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HSE Organization and Personnel UPL has formulated an Environment Management Department having officers from various disciplines to co-ordinate the activities concerned with management and implementation of environmental and safety measures. The organizational set up for HSE management is shown above in Figure 10.3 At an operational level, the respective functional managers are responsible for identifying and assessing risks within their area of responsibility; implementing agreed actions to treat such risks; and for reporting any event or circumstance that may result in new risks, or changes in existing risk profile. Environmental Impacts & Mitigation Measures UPL will understand the requirement of environmental impacts and mitigation measures as worked out in this EIA (Section 4) and as summarised in Table 10.2. Prior to starting the Project. The proposed expansion project will be executed after obtaining all the necessary approvals. The tentative plan to start the project will be from the Financial Year 2019 – 2020. Prior to starting the Project, UPL will further understand regulatory/permit requirements, environmental impacts and required mitigations. The EMP will be a “live” document. It will be reviewed by the Project team prior to start of activities related to expansion project. UPL will review the required mitigation measures and ensure pollution control equipment or addition of capacity or modifications required are ensured by the contractors in consultation with UPL’s Environment Management Team. UPL will ensure that where practical, equipment’s are adequate to achieve the levels of environmental performance outlined in this EIA. The EMP will be updated as needed to provide effective management of environmental issues associated with the Project.

10.2.3 Implementation

The implementation mainly comprises of resources available for the Project, accountability of contractors and documentation of measures to be taken. The management plan is aimed at control, reduction and management of emissions, discharges and wastes to prevent impacts on environmental components. Implementation of the EMP will involve UPL staff and its contractors, subcontractors and its service providers. This will involve the incorporation of the commitments contained in the EMP, including relevant mitigation and control measures, working practices and overall management procedures as appropriate. Inspection, Monitoring and Audit Inspection and monitoring of the environmental impacts of the Project activities increases the effectiveness of EMP. Through the process of inspection and


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auditing, UPL ensures that the conditions stipulated in Environmental Clearance, Consent to Operate, storage of chemicals and petroleum products are complied with. The entire process of inspections and audits are documented and inspection and audit findings are implemented by UPL through contractor and consultants engaged. Monitoring, Reporting and Documentation UPL has developed and implemented a programme of reporting through all stages of the project life cycle. Delegated personnel have been deputed to comply with the reporting programme in terms of both timely submissions of reports as per acceptable level of detail. External Monitoring, Reporting and Communication UPL has hired an external agency(ies) to conduct monitoring for ambient air, noise, stacks / vents, effluent outlets, waste storage areas, access roads, nearby villages and other receptor locations. Compliance statements and annual environmental reports (Environmental Statement’ as per Form V of EPA Rules, 1986 and Hazardous Waste Returns HW Rules 2016) are being submitted to the regulatory agencies. Global VP Environment & GM - Environment will be responsible for ensuring that communication with regulatory agencies is maintained as per the requirement. All complaints and enquiries shall be appropriately dealt with and records be maintained in a Complaint/Enquiry Register by the delegated staff of environment department. Internal Monitoring, Reporting and Communication Internal monitoring focuses on measuring and reporting progress of implementing EMP activities. Head-Laboratory is responsible for internal monitoring. Inspection and audits finding along with their improvement program are regularly reported to the senior management for their consideration. Documentation UPL has established a documentation and record keeping system to ensure recording and updating of documents as per the requirements specified in EMP. EMP Review & Amendments The EMP shall be reviewed periodically to update it addressing any changes in the organisation, process or regulatory requirements.

10.2.4 Checking

Environmental monitoring and audits will be undertaken during both construction and operation phase to ensure that the environmental


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management measures are being satisfactorily implemented and that they are delivering the appropriate level of environmental performance. Inspections & Auditing The audit programme will include pre-commissioning audits of the facilities focusing on the compliance of equipment and procedures to deliver the specified level of performance to ensure that all environmental requirements are met. Regular audits will check: The integrity and function of physical systems; Compliance with operating procedures; Testing and review of emergency procedures; Compliance with maintenance procedures and records; and Competence and training of operatives and terminal and field management

staff. Audit results will be reported to management and field staff responsible for the process or equipment in question. Where audits reveal non-compliance with requirements, corrective actions will be implemented. These will be prioritised according to the significance of the environmental risks arising. Monitoring The inspections and audit process will be further supported by monitoring i.e. ensuring practical achievement of implementation of required actions. Sampling and analysis as per the identified monitoring plan will be implemented to check level of compliance of discharges, emissions and required environmental conditions. Inspections and monitoring by regulators i.e. GPCB, MoEF&CC, CPCB and District Administration and other agencies will also help ensuring effective checking process of the implementation of the required actions. Records of all of the monitoring activities will be maintained and will be available for review as required by the management representative. Environmental and pollution monitoring related requirement have been separately specified in Section 6.

10.2.5 Management Review

UPL management will review the performance against the required actions during construction and operation phase of the proposed expansion project. UPL will ensure the following: 1. UPL will review all the conditions of environmental clearance, consent to

establish, consent to operate and other permits and ensure their compliance is fully achieved;

2. Any specific environmental training needs will be identified for key personnel and training executed either directly by UPL or through expert agency/contractor;


324

3. Prior to commencing operations all personnel will be briefed on the environmental sensitivities relevant to the operations and measures in place for the proposed Project;

4. All personnel will be encouraged to take an active part in meeting the environmental performance criteria;

5. UPL’s representative (Global VP- Environment & Sustanability) will be in all key activities associated with ensuring compliance with agreed procedures to protect the environment;

6. Environmental performance will be discussed during regular meetings between UPL representative and the contractor representative. Senior management will regularly review performance assessments or progress of implementation of the EMP;

7. A review of the performance of the contractor will be undertaken on completion of Project components; and

8. In the event of non-compliance, UPL will ensure that the deficiencies are rectified with a defined corrective action plan in a time bound manner.

10.3 MANAGEMENT ACTION

Table 10.2 sets out specific actions and monitoring requirements for the issues identified in Section 4. UPL has also developed action plans to be available and communicated to all concerned during implementation of the proposed Project components. These include: Air pollution control measures (refer to Section 2.4.1) Solid Waste Management (refer to Section 2.4.2) Wastewater Management (refer to Section 2.4.3) Hazardous Chemicals Management (refer to Section 2.4.4) Water Conservation Measures (refer to Section 2.4.5) Solvent Management Plan (refer to Section 2.4.6) Emergency Response Plan (refer to Section 7.10 for relevant excerpts from ERP); Occupational Health & Hygiene Procedure (refer to Section 7.11) Prior to start of Project components, UPL will also ensure that the Safety Management Systems (SMSs) are in place as per the requirement of Factories Act, 1947 and MSIHC Rules to cover the following elements: 1) Control of Exposure levels of hazardous chemicals, 2) Occupational Health centre (OHC) 3) Onsite Medical treatment 4) Contractor Safety, 5) Competency of Personnel, 6) Management of Change procedures, 7) Emergency Response Plan, 8) Maintenance Practices, 9) Operating Procedures on safety and other requirements, 10) Incident Reporting, 11) Performance Monitoring, 12) Regulatory Requirements, and 13) HSE Organisation and Risk identification


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All the above mentioned documents will be updated from time to time prior to start of the Project activities.

10.4 BUDGET ALLOCATION FOR THE ENVIRONMENTAL MANAGEMENT PLAN

The EMP implementation and environment related indicative budget has been described below: For mitigations of ongoing operations and contingency cost related to

proposed expansion Project (namely, APCM, waste management, wastewater treatment, STP etc.) is budgeted as INR 26.02 crores. The safety equipment cost will be around INR 2.3 crores. The expenses on the environmental protection measures for the existing plant for the year 2017-18 was around INR 36.88 crores.

UPL has a separate budget for CSR activities, which is spent mostly in alignment with the local administration on annual basis for CSR development in operational areas. The tentative budget commitment of UPL for CSR activities is 7.7 Crores INR over 5 years period. The key CSR initiatives to be considered for implementation during this plan period will focus on identified key areas that include agricultural development, health and sanitation, environment and nature conservation, education and empowerment, employability and entrepreneurship, and national and local area needs. Key projects under these focus areas are UPL khedutPragati, UPL School sanitation, UPL social forestry, School education and UPL Udyamita, UPL Niyojaniy and skill development, and UPL GramPragati. The break-up of tentative five year CSR budget is given below in Table 10.1.

Table 10.1 Break-up of Five- year CSR budget

Sr. No.

Key Focus Area Project Budget (Rs)

1 Agriculture Development UPL KhedutPragati 1,08,82,203 2 Health & Sanitation UPL School Sanitation 73,49,196 3 Environment & Nature Conservation UPL Social Forestry 3,33,74,787 4 Education & Empowerment School Education & UPL Udyamita 1,01,13,572 5 Employability & Entrepreneurship UPL Niyojaniy & Skill development 1,12,66,519 6 National & Local Area needs UPL GramPragati 42,34,215 Total 7,72,20,492


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Table 10.2 Environmental Management Plan for the Project

S.N.

Activity Ref. Aspect Interaction with environmental component

Impact Mitigation measures Monitoring Timing/ frequency

A. Construction Phase A.2. Site

development A.2.1 Stripping of

top soil; Operation of

vehicles and machineries outside the proposed expansion site;

Disposal of construction waste/ MSW in non-designated area;

Spillage of chemical, hazardous waste, etc.;

Surface runoff from material & waste storage areas and oil spillage area

Soil quality Loss of top soil

Soil contamination

Stripping of top soil, effective storage including the maintenance till final usage;

Construction waste would be stored in dedicated storage area and disposed as per handling of construction demolition waste management rules, 2016;

Restricted project and related activities during monsoon season;

Hazardous material and waste will be stored in designated storage area and disposed as per hazardous and other wastes (management and transboundary movement) rules, 2016;

Storm water drainage system at site shall be maintained and ensured free from any contamination carryover before monsoon.

Drip trays and paved surface with secondary containment shall be provided for all possible oil/chemical spill from the equipment and / or process;

Adequate provision shall be made for segregation of solid waste, storage of solid waste and for easy access to the dustbins.

Site inspection; Periodic soil quality monitoring

Site construction phase


327

S.N.



All paints, solvents, oils and wastes must be stored in a dedicated area which shall be weather proof and imperviously floor area with bund wall.

All spills to be reported and & contained to prevent entry of spilled chemicals/fuels to land or any surface water body or drainage channel.

Periodic monitoring of soil quality monitoring shall be conducted in accordance with the environment monitoring program.

A3 Operation of construction machineries, equipment etc operated on electricity

A.3.1 Fugitive emission from site development & construction of site;

Gaseous emission from vehicles and construction machinery;

Fugitive emission from transportation, storage, handling of construction

Air quality Fugitive emission and emission of gasses with potential to degrade the ambient air quality; impacts are expected to be localised and over a short period.

Enclosures and dust curtains to be provided at all construction sites;

Minimise movement of construction vehicles and enforce a speed limit around the construction site;

Regularly maintain all diesel-powered equipment and reduce idling time to avoid emissions of NOx, PM10 and SO2;

All material storages areas/warehouses to be adequately covered and contained so that they are not exposed to situations where winds on site could lead to dust / particulate emissions;

Ensure periodic preventive maintenance of vehicles and equipment;

Site inspection; Periodic air quality monitoring



328

S.N.



material, disposal of construction waste;

Carry out regular water sprinkling at the site especially during summer season to prevent dust emission from the stockpiled, loose sand materials and road.

The trucks used for transport of fill material during the site preparation and debris transport during the decommissioning shall be provided with tarpaulin cover;

Use of low sulphur diesel oil. Periodic monitoring of air quality

monitoring will be conducted in accordance with the environment monitoring program.

A3.2 Emission of noise from machineries equipment,

Noise quality Increase in ambient noise levels

All vehicle and equipment involved in site development and drilling activity shall be provided with noise control measures;

The maximum noise levels near the construction site will be aimed to limit to 75 dB(A) Leq day and 70 dB(A) night outside the battery limit;

The construction sites will be protected by providing fencing to control entry of outsiders;

Vehicular speed limit of 10 kmph will be maintained for HMVs and 20 kmph of LMVs thus to minimize any disturbance due to noise to any nearby industry;

Night-time activities shall be restricted to essential activities only;

Site inspection; Periodic noise quality monitoring



329

S.N.



Regular maintenance of equipment including lubricating moving parts, tightening loose parts and replacing worn out components should be conducted;

Low noise equipment should be used as far as practicable;

Ear muffs / plugs shall be provided for the people working in and around noisy equipment’s / activities.

No use of DG supplied power for construction.

A3.3 Exposure to dust & gaseous emission and high noise-onsite working population

Occupational health & safety

Discomfort due to dust and noise; Pulmonary disease related problems; Hearing loss

Appropriate PPEs (e.g. Masks, earplugs) shall be provided for the workers while working near dust generating area and high noise generating equipment. Periodic health check-up will be conducted;

Site inspection; Periodic health check-up


A3.4 Incident and accident during operation of construction machineries and equipment.


Injuries, mortality

The contractor will prepare and implement a health and safety plan prior to commencing work. This plan will include method statements for working methods, plant utilisation, construction sequence and safety arrangements;

Measures will be implemented to reduce the likelihood and consequence of the following hazards:

- Falling from height;

Site inspection; Incident/ accident reporting



330

S.N.



- Entanglement with machinery; - Tripping over permanent

obstacles or temporary obstructions;

- Slipping on greasy oily walkways;

- Falling objects; - Contact with dangerous

substances; - Electric shock; - Lifting excessive weights; - A permit to enter system will be

established to ensure that only authorised persons gain entry to the site;

All persons working on site will be provided information about risks on site and arrangements will be made for workers to discuss health and safety with the contractor;

All workers will be properly informed, consulted and trained on health and safety issues;

Personal protective equipment (PPE) shall be worn at all times on the site.

Before starting work all the appropriate safety equipment and the first-aid kit will be assembled and checked as being in working order;

All lifting equipment and cranes will be tested and inspected


331

S.N.



regularly. All hoist ways will be guarded;

Safety hoops or cages will be provided for ladders with a height in excess of two metres;

The contractor shall provide appropriate safety barriers with hazard warning signs attached around all exposed openings and excavations when the work is in progress.

A.3.6 Removal of vegetation and cutting of trees;

Terrestrial floral habitat & flora

Loss of floral habitat & plant species distribution

Restrict the construction within the site;

Adequate plantation with local plant species within plant area;

The records shall be maintained towards green belt development and trees trim.

Site inspection


A.4 Souring of construction water

A.4.1 Sourcing of construction water from GIDC

Fresh water resource

Depletion of fresh water resources and impact on competitive users.

As far as possible, the water should be reused/recycled;

Opportunity should be explored to use treated water from ETP of ongoing operation, for construction activities of proposed expansion project;

UPL will implement the rainwater harvesting scheme within its facilities and communities;

Water conservation measures shall be initiated across project and operational excellence.

Maintaining water consumption records by source



332

S.N.



A.5 Generation of waste water and discharge

A.5.1 Generation of waste water and discharge;

Surface runoff from construction site,

Surface water quality

Increased sediment content of surface water;

Contamination of surface water

Construction activities will be avoided during monsoon season;

Proper contour shall be maintained at the construction site for effective storm water run off;

Proper treatment of all waste water generated at the site and reusing treated wastewater in the system;

All chemical and fuel storage areas, process areas shall have proper bunds so that contaminated run-off cannot escape into the storm-water drainage system;

An oil-water separator shall be provided at the storm water drainage outlet, to prevent discharge of contaminated run-off;

Spill kits to be used for removal of any oil or chemical spillage on site;

Treated STP water to be used in green belt development;

Periodic monitoring of surface water quality

Site inspection; Periodic surface water quality monitoring


A.5.2 Discharge of waste water to nearby land

Soil quality Change of soil characteristics and contamination of soil

Site inspection; Periodic soil quality monitoring


A.5.3 Spillage of hazardous waste on open soil/ discharge of waste water on open soil

Ground water quality

Contamination of groundwater

Prevent & mitigate spill of paint/fuel within the construction site;

Conduct all the fuel transfer operations in paved areas;

Regular monitoring of ground water quality in the vicinity of the Plant

Site inspection; Periodic ground water quality monitoring



333

S.N.



A.6 Transportation of construction materials and manpower

A.6.1

Road accident Community health & safety

Injury/ fatal incidence of nearby community

Avoid the traffic movement during school hours and market times;

Road movement shall be carried out only with approved journey management plan

All the regular routes shall be surveyed for traffic study and only authorized routes by UPL road transport safety officer shall be followed.

Site inspection;


B. Operation Phase B.1 Air emission B.1.1 Emission of air

pollutants from : Flue gas

stacks; Process gas

stacks; Fugitive

emission of VOC from chemical storage

Air quality Degradation ambient air quality

All point sources of emissions will continue to be monitored on a regular basis to ensure compliance with emissions standards. Emissions from individual stacks, fugitive emissions, VOCs will comply with the emission standards stipulated by CPCB and GPCB;

Periodically conduct HSE audit of to minimize air pollutants emission as part of continual improvement of environmental management;

Monitoring and measurement of scrubber efficiency & periodic review of scrubber performances.

Regular shutdown of Air Pollution Control Devices with plant shutdown for maintenance.

Upgradation of Air pollution control devices with latest technologies & achive minimum emissions beyond compliance.

Periodical monitoring of ambient air quality and stack emission

Throughout the operation phase


334

S.N.



Installation of Online Sensors / Meters for Leak detection and Alaram sent to CCR.

Green belts and landscaping should be strengthened to act as an effective means to control air pollution;

B.1.2 Exposure of emission: workers in the Plant


Health impact All point sources of emissions will continue to be monitored on a monthly basis to ensure compliance with emissions standards. Emissions from individual stacks will comply with the emission standards stipulated by CPCB and GPCB;



Provide appropriate PPE to the workers;

Periodical health check-up

Periodical health check-up


B.1.3 Exposure of emission: nearby community

Community health & safety

Health impact All point sources of emissions will continue to be monitored on a monthly basis to ensure compliance with emissions standards. Emissions from individual stacks will comply with the emission standards stipulated by CPCB and GPCB;

Grievance redressal system

Throughout the operational period of terminal


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Grievance redressal system for community health & safety issues.

B.2 Noise emission from plant operation

B.2.1 Noise emission from various equipment’s machineries, instruments- Steam turbines, boilers, generators, compressors, transfer pumps, boiler feed pump, booster compressors, fans etc.

Noise quality Increase of ambient noise level in the project impacted area

Efficient engineering control during installation of equipment and machineries shall be ensured to reduce noise emission levels at source;

The machinery deployed in the plant should be designed with the sufficient noise and vibration controls for minimizing noise at source and purchased through reputed manufacturers and vendors

Regular maintenance of equipment including lubricating moving parts, tightening loose parts and replacing worn out components should be conducted;

Low noise equipment should be used as far as practicable;

Periodic monitoring of ambient noise quality;

Peripheral plantation shall be carried out to attenuate noise.

Periodic monitoring of ambient noise quality



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B.2.2 Exposure of high noise level: workers of the plant


Discomfort due to noise related problems; Hearing loss

Appropriate PPEs (e.g. earplugs) will be used for by workers while working near high noise generating equipment.

Periodic health check-up / audiometric tests for employees working close to high noise levels, such as compressors, DG sets, the loading and unloading sections shall be conducted;

Maintaining adequate offset distances from noise generating equipments;

If required, job rotation shall be carried out for the people working in noisy areas.

Site inspection; Periodic health check-up


B.2.3 Exposure to noise pollution

Changes to/existing environmental conditions;

Community health & safety

Discomfort due to noise emission to nearby community

Appropriate PPEs (e.g. earplugs) will be used for by workers while working near high noise generating equipment.

Periodic health check-up will be conducted;

If required, job rotation shall be carried out for the people working in noisy areas.

Site inspection; Community grievance redrassal system


B.3 Consumption of fresh water resources

B.3.1 Supply of fresh water from GIDC

Fresh water resources

Depletion of usable fresh water resources;

The wastewater shall be treated in Effluent Treatment Plant (ETP) and treated water shall be reused in the system.

There shall not be any discharge of treated waste water from Plant, since expansion is proposed with

Regular treated water monitoring



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continuation of Zero Liquid Discharge (ZLD) Since May 2014.

The domestic sewage water shall be treated in Sewage Treatment Plant (STP) and treated sewage water shall be used for gardening purpose in the plant area.

Rain water collection systems shall be developed to collect runoff from paved areas in Plant. Thus collected water shall be reused appropriately.

Regular monitoring of treated water from ETP and STP shall be conducted

B.4 Spillage of oil, lubricant, chemical, hazardous waste

B.4.1 Spillage of oil, lubricant, chemical, hazardous waste on open soil;

Surface runoff from spilled area into open soil

water quality, Soil quality

Impact on water quality

Impact on soil quality

All chemical and oil storage facilities shall be provided with adequate containment system to prevent contamination of soil and subsurface aquifer due to potential spills of lubricating oil, fuel oil and chemicals;

UPL is to ensure that regular training is imparted to its staff on avoiding spillages and take necessary actions if any spill happens.

UPL shall take public liability insurance policy covering chemical management system. Thus ensuring the risks related to chemicals handling, storage and transportation in its premises

Soil and Ground water quality monitoring



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Periodical monitoring of soil and ground water quality.

B.5 Waste water generation and disposal

B.5.1 Generation of wastewater; treatment and use in the plant

Sewage generation, treatment and use in greenbelt development

Water quality Potential to contaminate the soil and ground water quality

The wastewater shall be treated in Effluent Treatment Plant (ETP) and treated water shall be reused in the system.

The domestic sewage water shall be treated in Sewage Treatment Plant (STP) and treated sewage water shall be used for gardening purpose in the plant area.

The Unit is ZLD since May 2014 and expansion is proposed with ZLD only. No effluent shall be discharged from Unit.

Ground water quality monitoring

Throughout the operational period of Unit

B.6 Hazardous waste generation & disposal

B.6.1 Spillage of hazardous waste

Soil quality & ground water quality

Contamination of soil & water

The used oil and waste oil (oily sludge) generated from the activities are disposed of through CPCB/GPCB approved recycler.

Landfilling / incinerable wastes to be disposed to BEIL common hazardous waste incineration and landfill site

UPL shall continue to maintain the inventory of all hazardous and non-hazardous wastes including the biomedical wastes generated at site including that from the proposed expansion project;

All wastes shall be segregated at the source of generation and disposed in the legally acceptable manner;

Soil & ground water quality monitoring



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All hazardous wastes will be stored in covered sheds provided with impervious surface.

Liquid wastes from laboratories shall be treated and disposed.

B.7 Hazardous chemical storages

B.7.1 Leakages and rupture from hazardous chemical storages

Community health and safety

Toxic and flammable risks from hazardous chemical storages

UPL is to conduct a detailed process hazard analysis and HAZOP at two stages i.e. as part of the FEED study and prior to commissioning of each process of the proposed expansion to assess associated risks and implement recommendation for safe operations.

Site inspection



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11 SUMMARY AND CONCLUSION

This EIA study report prepared for the proposed expansion project has assessed environmental impacts and risks likely to arise during construction and operation phase of the proposed increase in existing production capacity of technical grade pesticides and pesticide intermediate products and addition of new products. Mitigation measures already in place have been reviewed and specified for the likely adverse environmental impacts arising out of existing operation phases of the project to bring it to acceptable levels. The significant aspects of the proposed expansion project is listed as following: Existing site is located inside Notified industrial estate, GIDC Ankleshwar.

The proposed expansion project will not require any additional land as it is planned within the existing site premises;

The proposed expansion will use most of existing plant’s infrastructures such as roads, security, water and power supply;

Additional power required for the proposed project is about 9,904 kW which will be be supplied from Dakshin Gujarat Vij Company Limited (DGVCL);

Additional water requirement for the proposed project is ~3,722 m3/day. It shall be met through GIDC water supply. No ground water is/shall be used.

The unit is Zero Liquid Discharge (ZLD) since May-2014 and will continue as ZLD for the proposed expansion

Out of 65,625 m2 of existing plant area, ~13,911.58 m2 is developed as green belt and additional greenbelt area of 315 m2 is proposed for the expansion Project.

The impact assessment for the existing operations together with the proposed increase production shows the following: Impact of Project related air emissions will result in incremental

concentrations which together with baseline will remain within the ambient air quality norms;

Impact of noise emissions have been found to be within the prescribed limits;

Water quality of the study has been monitored. It was observed to be acceptable;

For the wastewater management, the existing ETP of capacity 550 m3/day is adequate for treatment of effluent from the proposed plant. A new sewage treatment plant (STP) of capacity 40 m3/day will be installed for the treatment of sewage water generated during expansion project;

Hazardous and non-hazardous industrial wastes are segregated at source of generation and disposed in legally acceptable manner. Recyclable hazardous waste shall be sent to authorized recyclers and UPL shall ensure valid membership of common hazardous waste landfill site at all times during the construction and operation phase of the plant.


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Impact on ecology is minimized as no forest or vegetation will be affected. A greenbelt in the plant area will result in positive impact on ecology;

UPL has developed and implemented several initiatives under its CSR activities such as skill development, education, sanitation, health, provision of drinking water, cleanliness drive etc. which will result in socio-economic improvements in the area. UPL has allocated dedicated budget for implementation of environment management plans, CSR initiatives and other social measures as part of the plan.

The exports of finished product will also contribute to the economy of the country.

UPL has put in place measures to help prevent contamination of air quality, soil and water.

Environmental Management Plan describes implementation mechanism for the identified mitigation measures and related monitoring plans for operation phase of the Project.

Risk scenarios have been identified for pool fire, jet fire and vapour cloud explosion (unconfined) and toxic release. UPL will have adequate enginnering and administrative controls for hazardous chemicals storage and handling. Fire protection system will be in place supplemented by implementation of focussed training and awareness sessions and organizing periodic Onsite and occasional Offsite Emergency Preparedness drills to check effectiveness of existing risk management system. UPL is to conduct a detailed process hazard analysis and HAZOP at two stages i.e. as part of the Front End Engineering and Design (FEED) study and prior to commissioning of each process of the proposed expansion to assess associated risks and implement recommendation for safe operations.

Compliance to all legal requirements and adherence to the prescribed mitigation measures and plans will enable UPL in minimizing its impact on environmental and social parameters. The overall assessment of impacts and effective implementation of mitigation measures, as included in the EMP, shows that the impact significance due to the existing and proposed expansion project would remain within acceptable levels and will conform to the prescribed environmental standards.


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12 DISCLOSURE OF CONSULTANT

Environmental Resources Management (ERM) is one of the world’s largest providers of environmental management and technical consulting services. ERM has more than 25 years of experience working with clients in both the private and public sectors to help them address environmental concerns and challenges within their organization. ERM India Private Limited (ERM India) was formally established in 1995 with its headquarters in Delhi and regional offices in Mumbai (Maharashtra), Bangalore (Karnataka), Ahmedabad (Gujarat) and Kolkata (West Bengal) The contact address of ERM India is as following: ERM India Private Limited Building No. 10 Tower A, 4th Floor DLF Cyber City, Gurgaon 122002, India Tel: +91-124-4170300; Fax: +91-124-4170301


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13 TERMS OF REFERENCE FOR EIA STUDY


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Documents

Final EIA Report - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/EIA/300120198N... · 2019. 1. 30. · EIA Coordinator I, hereby, certify that I was a part of the