M/s. Bromchem Laboratories Pvt. Ltd. Environmental Impact & … · Environmental Impact & Risk Assessment Report 12 ABBREVIATIONS µg/m3 Micro gram per meter cube oC Degree centigrade

M/s. Bromchem Laboratories Pvt. Ltd. Environmental Impact & Risk Assessment Report

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INDEX

SR. NO. TITLE PAGE NO.

LIST OF TABLES 8

LIST OF FIGURES 10

COPY OF TOR LETTER 13

TOR COMPLIANCE 19

1 CHAPTER 1: INTRODUCTION

1.1 BACKGROUND 1‐1

1.1.1 PROMOTERS AND THEIR BACK GROUND 1‐1

1.1.2 REGULATORY FRAMEWORK 1‐1

1.2 PROJECT DETAILS 1‐2

1.2.1 TOTAL COST OF THE PROJECT ALONGWITH TOTAL CAPITAL

COST AND RECURRING COST/ANNUM FOR ENVIRONMENTAL

POLLUTION CONTROL MEASURES.

1‐2

1.2.2 LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY 1‐2

1.2.3 JUSTIFICATION OF THE PROJECT 1‐4

1.2.4 INFRASTRUCTRUE FACILITIES 1‐5

1.3 PROJECT LOCATION 1‐6

1.3.1 KEY INFRASTRUCTURAL FEATURES AND SETTLEMENTS 1‐14

1.4 PURPOSE OF EIA 1‐18

1.5 OBJECTIVES OF EIA 1‐18

1.6 METHODOLOGY FOR EIA 1‐18

1.6.1 BASELINE ENVIRONMENTAL CONDITION 1‐18

1.6.2 IDENTIFICATIONS SOURCE OF POLLUTION 1‐20

1.6.3 EVALUATION OF POLLUTION CONTROL & ENVIRONMENTAL

MANAGEMENT SYSTEMS

1‐20

1.6.4 EVALUATION OF IMPACT 1‐20

1.6.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 1‐21

1.7 STRUCTURE OF REPORT 1‐21


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2 CHAPTER 2: PROJECT DESCRIPTION


2.2 SELECTION OF SITE 2‐1

2.3 MAIN PHASE OF THE PROJECT 2‐1

2.3.1 CONSTRUCTION ACTIVITIES 2‐1

2.3.2 MANUFACTURING ACTIVITIES 2‐1

2.4 MANUFACTURING PROCESS, CHEMICAL REACTION & MASS

BALANCE AND RAW MATERIALS

2‐2

2.5 RAW MATERIAL STORAGE AND HANDLING 2‐55

2.6 WATER AND WASTEWATER 2‐57

2.6.1 ETP DETAILS 2‐59

2.7 AIR POLLUTION AND CONTROL SYSTEM 2‐63

2.8 NOISE LEVEL AND CONTROL SYSTEM 2‐64

2.9 HAZARDOUS WASTE GENERATIONS AND DISPOSAL SYSTEM 2‐65

2.10 ELECTRICITY REQUIREMENT & FUEL REQUIREMENT 2‐66

2.11 DETAILS OF GREENBELT 2‐66

2.12 SOLVENT MANAGEMENT PLANT 2‐66

3 CHAPTER 3: DESCRIPTION OF THE ENVIRONMENT

3.1 ESTABLISHMENT OF IMPACT ZONE 3‐1

3.2 METEOROLOGY 3‐2

3.3 MICRO‐METEOROLOGY OF THE AREA 3‐2

3.3.1 TEMPERATURE DETAILS 3‐3

3.3.2 RELATIVE HUMIDITY 3‐4

3.3.3 RAINFALL 3‐5

3.3.4 WIND SPEED 3‐6

3.4 AIR ENVIRONMENT 3‐10

3.4.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY

MONITORING LOCATIONS

3‐10


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3.4.2 RECONNAISSANCE 3‐10

3.4.3 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 3‐11

3.5 NOISE ENVIRONMENT 3‐19


3.5.2 METHODOLOGY FOR NOISE MONITORING 3‐19

3.5.3 NOISE LEVELS AT NEAREST CHOKDI 3‐23

3.6 WATER ENVIRONMENT 3‐23


3.6.2 METHODOLOGY FOR WATER QUALITY MONITORING 3‐23

3.7 LAND ENVIRONMENT 3‐28

3.7.1 METHODOLOGY FOR SOIL MONITORING 3‐28

3.8 LAND USE PATTERN 3‐32

3.8.1 METHOD OF PREPARATION 3‐32

3.8.2 AREA UNDER DIFFERENT LANDUSE 3‐32

3.9 GEOLOGICAL DATA 3‐35


3.9.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA

UNDER DIFFERENT FORMATIONS

3‐35

3.9.3 GEOLOGICAL MAP 3‐35

3.10 ECOLOGICAL INFORMATION 3‐38


3.10.2 FLORA 3‐40

3.10.3 FAUNA 3‐42

3.11 DRAINAGE PATTERN 3‐44

3.12 SOCIO ‐ ECONOMIC ENVIRONMENT 3‐45

3.12.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 3‐45

3.13 LITERACY RATE 3‐49

3.14 OCCUPATIONAL STRUCTURE 3‐51

3.15 AMENITIES 3‐53


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4 CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES

4.1 IDENTIFICATION OF IMPACTS 4‐1

4.2 EVALUATION AND PREDICTION OF IMPACT 4‐1

4.2.1 WATER ENVIRONMENT 4‐4

4.2.2 AIR ENVIRONMENT 4‐4

4.2.3 NOISE ENVIRONMENT 4‐12

4.2.4 LAND USE AND SOIL QUALITY 4‐13

4.2.5 HOUSING 4‐13

4.2.6 INFRASTRUCTURE AND SERVICES 4‐13

4.2.7 ENVIRONMENTAL HAZARDS 4‐14

4.2.8 ECOLOGY 4‐14

4.3 MATRIX REPRESENTATION 4‐18

4.4 CONCLUSION 4‐23

5 CHAPTER‐5: ENVIRONMENTAL MONITORING PLAN

5.1 ENVIRONMENTAL MONITORING PLAN 5‐1

5.2 POST PROJECT MONITORING PLAN 5‐2

5.3 LABORATORY FACILITIES 5‐3

6. CHAPTER‐6: ADDITIONAL STUDIES (RISK ASSESSMENT)


6.2 METHODOLOGY 6‐1

6.3 STORAGE AND HANDLING OF HAZARDOUS CHEMICALS 6‐3

6.4 FACILIES/SYSTEM FOR PROCESS SAFETY, STORAGE,

TRANSPORTATION, FIRE FIGHTING SYSTEM AND

EMERGENCY CAPABILITY

6‐8

6.4.1 PROCESS SAFETY 6‐8

6.4.2 FOR UNDERGROUND AND ABOVE STORAGE TANK FARM 6‐9

6.4.3 FOR DRUM STORAGE AREA 6‐10


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6.4.4 TRANSPORTATION 6‐10

6.4.5 TRANSPORTATION, UNLOADING ANDHANDLING

PROCEDURE FOR SOLVENTS

6‐11

6.4.6 OCCUPTIONAL HEALTH AND SAFETY PROGRAM 6‐12

6.5 HAZARD IDENTIFICATION 6‐15

6.6 DETERMINING SIGNIFICANCE 6‐15

6.7 RISK MANAGEMENT 6‐16

6.8 RISK ACCEPTANCE 6‐16

6.9 QUANTITATIVE RISK ASSESSMENT 6‐18

6.9.1 IDENFICATION OF HAZARDOUS AREA 6‐19

6.9.2 IDENFICATION OF FAILURE CASES FOR HAZARDOUS AREA 6‐19

6.10 CONSEQUENCE ANALYSIS 6‐20

6.10.1 DAMAGE CRITERIA 6‐21

6.10.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS 6‐22

6.10.3 CONSEQUENCE ANALYSIS CALCULATIONS 6‐23

6.10.4 SOFTWARE USED FOR CALCULATINS 6‐24

6.11 SCENARIOS 6‐27

6.11.1 DETAILED SUMMARY OF RESULTS 6‐29

6.12 HAZARDOUS MATERIALS TRANSPORTATION SAFETY

GUIDELINES

6‐41

6.13 RECOMMENDATIONS 6‐47

6.14 DISASTER MANAGEMENT PLAN 6‐49

6.14.1 DEFINING THE NATURE OF EMERGENCY 6‐49

6.14.2 OBSERVER 6‐50

6.14.3 CHIEF EMERGENCY CONTROLLER 6‐51

7 CHAPTER‐7: ENVIRONMENTAL MANAGEMENT PLAN


7.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN 7‐1

7.3 ENVIRONMENTAL MANAGEMENT CELL 7‐2


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7.4 ENVIRONMENT MANAGEMENT PLAN 7‐4

7.4.1 WATER ENVIRONMENT 7‐4

7.4.2 AIR ENVIRONMENT 7‐7

7.4.3 NOISE ENVIRONMENT 7‐12

7.4.4 LAND ENVIRONMENT 7‐13

7.4.5 HEALTH AND SAFETY 7‐15

7.5 TOTAL COST OF THE PROJECT ALONGWITH TOTAL CAPITAL

COST AND RECURRING COST/ANNUM FOR

ENVIRONMENTAL POLLUTION CONTROL MEASURES

7‐17

7.6 RECYCLING, REUSE AND CLEANER PRODUCTION OPTIONS 7‐17

7.7 NATURAL RESOURCES CONSERVATION 7‐18

7.7.1 MEASURES FOR CONSERVATION OF ENERGY 7‐19

7.8 SKILLED AND TRAINED MANPOWER 7‐19

7.9 SOCIO‐ECONOMIC DEVELOPMENTAL ACTIVITIES 7‐19

8 CHAPTER‐8: EXECUTIVE SUMMARY

8.1 INTRODUCTION 8‐1

8.2 TITLE OF THE PROJECT 8‐1

8.3 LAND ACQUIRED 8‐1

8.4 LAND BREAK‐UP 8‐1

8.5 COST OF THE PROJECT & CAPITAL AND RECURRING COST

TOWARDS ENVIRONMENT PROTECTION MEASURES

8‐2

8.6 PROPOSED FACILITIES AND PRODUCTION CAPACITIES IN

TABULAR FORM

8‐2

8.7 LIST OF RAW MATERIALS 8‐4

8.8 SITE SPECIFIC METEOROLOGICAL DATA 8‐5

8.9 AIR ENVIRONMENT 8‐6

8.10 WATER ENVIRONMENT 8‐7

8.11 NOISE ENVIRONMENT 8‐14

8.12 LAND ENVIRONMENT 8‐15


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8.13 STORAGE DETAILS OF HAZARDOUS CHEMICALS 8‐16

8.14 POWER REQUIREMENT 8‐17

8.15 GREEN BELT DEVELOPMENT 8‐17

EXECUTIVE SUMMARY IN GUJARATI

9 CHAPTER‐9: COMPANY PROFILE (EIA CONSULTANT) 9‐1

LIST OF ANNEXURES A‐1


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LIST OF TABLES

TABLE

NO.

TITLE PAGE NO.

1.1 LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY (EXISTING

AND PROPOSED)

1‐12

1.2 LAND BREAK UP OF THE PLANT 1‐13

1.3 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM

PROJECT SITE

1‐14

2.1 LIST OF RAW MATERIALS 2‐55

2.2 WATER CONSUMPTION AND WASTEWATER GENERATION 2‐57

2.3 THE DETAILS OF SOURCE OF EMISSION 2‐63

2.4 DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL 2‐65

3.1 TEMPERATURE DETAILS 3‐3

3.2 RELATIVE HUMIDITY (%) DETAILS 3‐4

3.3 RAINFALL DETAILS 3‐5

3.4 WIND SPEED 3‐6

3.5 SITE SPECIFIC METEOROLOGICAL DATA 3‐7

3.6 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 3‐12

3.7 AMBIENT AIR QUALITY STATUS 3‐14

3.8 A DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 3‐20

3.9 B NOISE LEVELS 3‐22

3.9 NOISE LEVELS AT NEAREST CHOKDI 3‐23

3.10 SAMPLING LOCATIONS FOR MONITORING SURFACE AND GROUND

WATER QUALITY

3‐24

3.11 WATER QUALITY 3‐27

3.12 SAMPLING LOCATIONS: SOIL QUALITY 3‐28

3.13 PHYSICO‐CHEMICALS CHARACTERISTICS OF SOIL 3‐30

3.14 AREAS UNDER DIFFERENT LANDUSE 3‐33

3.15 FLORA 3‐40

3.16 FAUNA 3‐42


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3.17 DEMOGRAPHIC DATA 3‐46

3.18 POPULATION DENSITY 3‐47


3.20 OCCUPATIONAL STRUCTURE 3‐52

3.21 DETAILS OF AMMENITIES AVAILABLE IN STUDY AREA (WITHIN 10 KM RADIUS)

3‐55

4.1 DETAILS OF EMISSION FROM STACK (EXISTING & PROPOSED) 4‐6

4.2 SUMMERY OF ISCST3 MODEL OUTPUT FOR PM, SO2, NOx, HCl

(PROPOSED)

4‐11

4.3 PREDICTED AMBIENT AIR QUALITY 4‐12

4.4 OPERATION STAGE POTENTIAL IMPACTS & MITIGATIVE MEASURES 4‐19

4.5 ENVIRONMENTAL IMPACT MATRIX 4‐21

5.1 PROJECT ENVIRONMENT MONITORING PLAN 5‐2

6.1 STORAGE DETAILS Of HAZARDOUS CHEMICALS 6‐4

6.2 PROPERTIES OF CHEMICALS 6‐5

6.3 POSSIBLE ACCIDENT SCENARIOS 6‐27


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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 LOCATION OF PROJECT SITE 1‐7

1.2 PROJECT SITE LOCATION ALONGWITH SITEMAP OF 10 KM AREA

AND SITE DETAILS PROVIDING VARIOUS INDUSTRIES, SURFACE

WATER BODIES, FORESTS ETC.

1‐9

1.3 A MAP INDICATING DISTANCE OF PROJECT SITE FROM CRITICALLY

POLLUTED AREA

1‐11

1.4 LAYOUT OF THE PLANT 1‐12

1.5 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1‐17

3.1 A WIND ROSE DIAGRAM 3‐8

3.1 B STABILITY CLASS DISTRIBUTION 3‐9

3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 3‐13

3.3 LOCATION OF NOISE LEVEL MONITORING STATIONS 3‐21

3.4 LOCATIONS OF WATER SAMPLING STATIONS 3‐25

3.5 LOCATIONS OF SOIL SAMPLING STATIONS 3‐29

3.6 LANDUSE / LANDCOVER 3‐34

3.7 MAJOR GEOLOGICAL FEATURES 3‐36

3.8 DRAINAGE PATTERN 3‐44

3.9 DETAILS OF POPULATION DENSITY AND SEX RATIO 3‐47


4.1 ISOPLETHS 4‐7 TO 4‐10

6.1 QRA METHODLOGY 6‐2

6.2 ALARP PRINCIPLE 6‐3

6.3 SITE PLAN 6‐6

7.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 7‐3


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ABBREVIATIONS

µg/m3 Micro gram per meter cube oC Degree centigrade BG Bank Guarantee BOD Bio‐chemical Oxygen Demand CO Carbon Monoxide COD Chemical Oxygen Demand CPCB Central Pollution Control Board CREP Corporate Responsibility for Environmental Protection DMP Disaster Management Plan ECC Emergency Control Center EIA Environment Impact Assessment EMP Environment Management Plan EPA Environment Protection Act Fe Iron FRP First response Procedure g/kg Gram per Kilogram GDP Gross Domestic Product GI Galvanized Iron Gm/cm3 Gram per centimeter cube GPCB Gujarat Pollution Control Board HC Hydro Carbon Kg/y Kilogram per Year KL Kilo Liter KL/d Kilo liter per day Km Kilometer Km/hr Kilometer per hour KW Kilo Watt l/yr Liter per year m meter m/s Meter per Second mg/L Milli gram per Litre mg/NM3 Milli gram per Normal Meter Cube MoEF Ministry of Environment and Forests Mt Metric Ton Mt/m Metric Ton per Month Mt/y Metric Ton per Year MW Mega Watt NAAQS National Ambient Air Quality Standards NABET National Accreditation Board for Education & Training NABL National Accreditation Board for Testing & Calibration Laboratories NOx Oxides of Nitrogen OH&S Occupational Health and Safety ppm Parts per million QCI Quality Council of India


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REIA Rapid Environment Impact Assessment RSPM Respirable Suspended Particulate Matter (PM10) SEAC State Expert Appraisal Committee SEIAA State Environment Impact Assessment Authority SO2 Sulphur Dioxide SPM Suspended Particulate Matter TDS Total Dissolved Solids TOR Terms of Reference VM Volatile Matter VOC Volatile Organic Compounds


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TOR Letter


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COMPLIANCE OF TERMS OF REFERENCES SR. NO.

TERMS OF REFERENCES COMPLIANCE

1. A separate chapter on status of compliance of Environmental Conditions granted by State/Centre to be provided. As per circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA/EMP report.

• Company would like to inform you that we have no Environmental Clearance for our existing plant of Inorganic Salt. Environmental Clearance is not applicable to inorganic products.

• We have got Consent to Establish & Consent to Operate for our Existing Plant. We have started the production of Calcium Chloride.

2. Executive summary of the project

Please refer Chapter‐8 in EIA Report.

3. Justification of the project.

Justification of the project is referred as Section 1.2.3, Chapter ‐1 (Page No. 1‐4) in EIA Report.

4. Promoters and their back ground.

Promoters and their back ground is referred as Section 1.1.1, Chapter ‐1 (Page No. 1‐1) in EIA Report.

5. Regulatory framework.

Regulatory framework is referred as Section 1.1.2, Chapter‐1 (Page No. 1‐1) in EIA Report.

6. Environment clearance for the existing unit issued by the Ministry (reasons, if not obtained), Consent to Operate and Authorization accorded by the GPCB.

Consent to Operate and Authorization accorded by the GPCB is referred as Annexure ‐6 in EIA Report.

7. Copy of NOC/Consent to Establish for the existing unit.

Copy of NOC/Consent to Establish for the existing unit is referred as Annexure ‐7 in EIA Report.

8. Compliance to the conditions stipulated in the Environmental Clearance / NOC granted by the SPCB.

Compliance to the conditions stipulated in the NOC granted by the SPCB is referred as Annexure ‐8 in EIA Report.

9. 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, compliance to the notice(s).

Company has not received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts till the date.

10. Data for the stack emissions, fugitive emissions; water requirement and water balance chart; wastewater generation, treated effluent quality, re‐utilization and disposal of solid/hazardous waste for the existing unit.

Stack emission from existing plant: Stack attached to furnace. SPM, NOx and SO2 is generated from the stack which is below the NAAQS limit. Water requirement in existing plant: 4 KL/Day. Wastewater generation in existing plant: 1.3 KL/Day. Treatment of Effluent: The existing wastewater 0.3 KL/Day is collected and


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neutralized in neutralization tank and reused in HCl dilution or caustic dilution or sulfuric acid dilution or phosphoric acid dilution or any other manufacturing product at a time Disposal of solid/hazardous waste for the existing unit: ETP Sludge is sent to TSDF site and Discarded containers/drums/bags/liners is disposed to authorized recycler.

11. Project location and plant layout.

Project location is referred as Figure 1.1, Chapter ‐1, EIA Report (Page No. 1‐6) and plant layout is referred as Figure 1.4, Chapter ‐1, EIA Report (Page No. 1‐11) in EIA Report.

12. Infrastructure facilities including power sources.

Infrastructure facilities including power sources is referred as Section 1.2.4, Chapter ‐1 (Page No. 1‐4) in EIA Report.

13. Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures.

Total Project Cost for proposed project activity is Rs. 4.5 Crores. Capital cost of air & water pollution control system and

environmental monitoring equipments will be Rs. 0.4 Crore.

14. Project site location alongwith site map of 10 km area and site details providing various industries, surface water bodies, forests etc.

Project site location alongwith site map of 10 km area and site details providing various industries, surface water bodies, forests etc is referred as Figure 1.2, Chapter‐1 (Page No. 1‐9) in EIA Report.

15. Present land use based on satellite imagery for the study area of 10 km radius. Details of land availability for the project alongwith supporting document.

Present land use based on satellite imagery for the study area of 10 km radius is referred as Section 3.8, Chapter‐3 (Page No. 3‐32 to 3‐34). Total 6981 m2 land is available for proposed project.

16. Location of National Park/Wild life sanctuary/Reserve forest within 10 km radius of the project.

There is no any location of National Park/Wild life sanctuary/Reserve Forest within 10 km radius of the project.

17. Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests.

Not Applicable.

18. Details of the total land and break‐up of the land use for green belt and other uses.

The total land and break‐up of the land use for green belt and other is referred as Table 1.2, Chapter ‐1 (page no. 1‐13) in EIA Report.

19. List of products along with the production capacities. List of products along with the production capacities is referred as Table 1.1, Chapter ‐1 (Page No.1‐2) in EIA Report.

20. Detailed list of raw material required and source, List of raw material required and source,


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mode of storage.

mode of storage is referred as Section 2.5, Chapter‐2 (Page No. 2‐55) in EIA Report.

21. Manufacturing process details along with the chemical reactions and process flow chart.

Manufacturing process details along with the chemical reactions and process flow chart is referred as Section 2.4, Chapter‐2 (Page No. 2‐2 to 2‐45) in EIA Report.

22. Action plan for the transportation of raw material and products.

Action plan for the transportation of raw material is referred as Section 6.4.5, Chapter‐6 (Page No. 6‐11 to 6‐12) in EIA report.

23. Site‐specific micro‐meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary.

Site‐specific micro‐meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is referred as Section 3.3.1, Table No. (Temp. Details), Table No. 3.2 (Relative Humidity), Table No: 3.3 (Rainfall) and Table No. 3.4 (Wind Speed), Chapter‐3 (Page No. 3‐3 to 3‐6) in EIA Report.

24. Ambient air quality monitoring at 6 locations within the study area of 5 km., aerial coverage from project site as per NAAQES notified on 16th September, 2009. Location of one AAQMS in downwind direction.

Ambient air quality monitoring at 6 locations within the study area of 5 km., aerial coverage from project site as per NAAQES notified on 16th September, 2009 is referred as Table 3.7, Chapter‐3 (Page No. 3‐ 14 to 3‐15) in EIA Report. There is no any location in downwind direction.

25. One season site‐specific micro‐meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM2.5, PM10, SO2, NOx, CO including VOCs shall be collected. The monitoring stations shall take into account the pre‐dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring shall also be included.

Please refer Chapter ‐3 for One season site‐specific micro‐meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, SO2, NOx including HC and VOCs, data for water and noise also.

26. Air pollution control measures proposed for the effective control of gaseous/process emissions within permissible limits.

Air pollution control measures proposed for the effective control of gaseous/process emissions is referred Section 7.4.2, Chapter ‐7 (Page No. 7‐8 to 7‐11) in EIA Report.

27. Name of all the solvents to be used in the process and details of solvent recovery system.

Solvent recovery system is referred as Section 2.12, Chapter‐2 (Page No. 2‐67) in EIA Report.

28. Design details of ETP along with RO plant need to installed if TDS in ground water is more than 3000 mg/l, incinerator, if any along with boiler, scrubbers/bag filters etc.

A detail of ETP is referred as Section 2.6.1, Chapter‐2 (Page No. 2‐59 to 2‐62) in EIA Report. TDS in ground water at project site and


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surrounding area is below the 2100 mg/L, So there will not require the RO plant.

29. Details of water and air pollution and its mitigation plan.

Water and air pollution and its mitigation plan is referred as Table No.4.4, Section 4.3, Chapter ‐4 (Page No.4‐19) in EIA Report.

30. Action plan to control ambient air quality as per NAAQS Standards notified by the Ministry on 16th September, 2009.

Action plan to control ambient air quality as per NAAQS Standards notified by the Ministry on 16th September, 2009 is referred Section 7.4.2, Chapter ‐7 (Page No. 7‐8 ) in EIA Report.

31. An action plan prepared by SPCB to control and monitor secondary fugitive emissions from all the sources.

Not Applicable

32. Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site specific meteorological features. Air quality modeling for proposed plant.

Atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site specific meteorological features and Air quality modeling for proposed plant is referred as Section 4.2.2.2, Chapter‐4 (Page No. 4‐4 to 4‐10) in EIA Report.

33. Source and Permission from competent Authority for the drawl of water. Water balance chart for existing and expansion project including quantity of effluent generated recycled and reused and effluent discharge.

There is no required to take the permission from competent Authority for the drawl of water because of water consumption will be less than 50 KLD. Water balance chart for existing and expansion project including quantity of effluent generated recycled and reused and effluent discharge is referred as Section 2.6, Chapter ‐2 (Page No. 2‐58) in EIA Report.

34. Attempt to be made for reduction for usage of water.

Treated effluent will reuse to dilute HCL (30%) in scrubber system, so uses of fresh in scrubber system will reduce.

35. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the standard.

A detail of ETP is referred as Section 2.6.1, Chapter‐2 (Page No. 2‐59 to 2‐62) in EIA Report.

36. Zero discharge effluent concepts to be adopted. Company will explore the possibility of zero discharge effluent concept through recycle/reuse of treated effluent will be use to dilute HCL (30%) in scrubber system.

37. Ground water quality monitoring minimum at 6 locations shall be carried out. Geological features and Geo‐hydrological status of the study area and ecological status (Terrestrial and Aquatic).

Ground water quality monitoring minimum at 6 locations is referred as Section 3.6, Chapter‐3 (Page No. 3‐23 to 3‐27) in EIA Report.

38. The details of solid and hazardous wastes generation, The details of solid and hazardous


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storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler shall be included.

wastes generation, storage, utilization and disposal are referred as Section 2.9, Chapter‐2 (Page No. 2‐65) in EIA Report.

39. Precautions to be taken during storage and transportation of hazardous chemicals shall be clearly mentioned and incorporated.

Precautions to be taken during storage and transportation of hazardous chemicals are referred as Section 6.4.5, Chapter‐6 (Page No. 6‐11 to 6‐12) in EIA report.

40. Material Safety Data Sheet for all the Chemicals are being used/will be used. CAS No./RTECS No./DOT/UN etc to be mentioned against each chemicals.

Material Safety Data Sheet for all the Chemicals is referred as Annexure ‐9.

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

Authorization/Membership for the disposal of solid/hazardous waste in TSDF is referred as Annexure ‐10.

42. Risk assessment for storage for chemicals/solvents. Action plan for handling & safety system.

Please refer Chapter‐6.

43. Action plan for development of green belt over 33 % of the total project area within plant premises with at least 10 meter wide green belt on all sides along the periphery of the project area, in downward direction, and along road sides etc.

The main objective of the green belt is to provide a barrier between the plant and surroundings areas. M/s. Bromchem Laboratories Pvt. Ltd. has developed green belt within factory premises. About 6981 sq. meter of the total land area is available Company is proposing 2303 sq. meter (32%) for green belt.

44. Action plan for rainwater harvesting measures at plant site shall be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.

Action plan for rainwater harvesting is referred as Section 7.4.1.4, Chapter‐7 (Page No.7‐6) in EIA Report.

45. Details of occupational health programme.

i) To which chemicals, workers are exposed directly or indirectly.

ii) Whether these chemicals are within Threshold Limit Values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation.

iii) What measures company has taken to keep these chemicals within PEL/TLV.

iv) How the workers are evaluated concerning their exposure to chemicals during pre‐placement and periodical medical monitoring.

v) What are onsite and offsite emergency plan during chemical disaster.

vi) Liver function tests (LFT) during pre‐placement and periodical examination.

vii) Details of occupational health surveillance programme.

Occupational health programme is referred as Section 6.4.6, Chapter‐6 (Page No. 6‐12 to 6‐14 )

46. Socio‐economic development activities shall be in Socio‐economic development activities


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place. are referred as Section 7.9, Chapter‐7 (Page No. 7‐19) in EIA Repot.

47. Note on compliance to the recommendations mentioned in the CREP guidelines.

Please refer Annexure 11.

48. Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure shall be provided.

Please refer Chapter‐7.

49. EMP shall include the concept of waste‐minimization, recycle / reuse / recover techniques, Energy conservation, and natural resource conservation.

The concept of waste‐minimization, recycle / reuse / recover techniques is referred as Section 7.6, Chapter‐7 (Page No. 7‐17 to 7‐18) in EIA Report. Energy Conservation is referred as Section 7.7.1, Chapter‐7 (Page No.7‐19) in EIA Report. Natural resource conservation is referred as Section 7.7, Chapter‐7 (Page No. 7‐18) in EIA Report.

50. Total capital cost and recurring cost/annum for environmental pollution control measures.

Total Project Cost for proposed project activity is Rs. 4.5 Crores. Costs for Environmental Pollution Control Measures will Rs. 70 lakhs. Recurring cost/annum for environmental pollution control measures will Rs. 4 lakhs.

51. Corporate Environmental Responsibility (a) Does the company have a well laid down

Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report.


(b) Does the Environmental Policy prescribe for standard operating process/procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA report.


(c ) What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given.

Administrative order of the company is referred as Section 7.3, Chapter‐7 (Page No. 7‐3) in EIA Report.

(d) Does the company have a system of reporting of non compliance / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report.

Administrative order of the company is referred as Section 7.3, Chapter‐7 (Page No. 7‐3) in EIA Report.

52. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof.

There is no any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof.


26

53. Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart.

‐

54. A tabular chart with index for point wise compliance of above TORs.

Complied

General Points 1. All documents should be properly indexed, page

numbered All the chapters and annexure of EIA/EMP report has properly numbered and indexed. Being complied.

2. Period/date of data collection should be clearly indicated.

Ambient Air Quality Monitoring and Analysis Period – January to March, 2014. Noise level Monitoring date ‐ February 10, 2014 to February 14, 2014 Ground and Surface water samples date ‐ February 11 to 13, 2014. Soil Samples Collection date ‐ February 11 to 13, 2014. Please Refer Chapter‐3.

3. Authenticated English translation of all material provided in Regional languages.

EIA/EMP Report summary and Project Report summary (Hard copy and Soft Copy in CD) has provided separately in Regional Language (Gujarati).

4. The letter/application for EC should quote the MoEF file No. and also attach a copy of the letter.

MoEF File No. J‐11011/260/2013‐ IA II (I) and TOR letter is attached as Annexure‐13.

5. The copy of the letter received from the Ministry should be also attached as an annexure to the final EIA‐EMP report.

Please refer TORs letter in Index (Page No.13)

6. The final EIA‐EMP report submitted to the Ministry must incorporate the issues in this letter. Then index of the final EIA‐EMP report must indicate the specific chapter and page no. of the EIA‐EMP Report.

We have incorporated all the issues as per MoEF Letter in EIA/EMP report and also given compliance of all the points. We have provided index indicated specific chapter and page no of EIA‐EMP Report. Being Complied.

7. ‘Certificate of Accreditation’ issued by the QCI to the environmental consultant should be included.

Consultant has stay order against the accreditation with Quality Council of lndia (QCl) / National Accreditation Board of Education and Training (NABET). Please refer Stay Order as Annexure‐14.


1-1

CHAPTER – 1

INTRODUCTION

1.1 BACKGROUND

M/s. Bromchem Laboratories Pvt. Ltd. has proposed for expansion of Chemicals manufacturing

unit at survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat.

Proposed project will be carried out within the existing unit having land area of 6981 m2.

Total project cost is Rs. 4.5 Crores.

1.1.1 PROMOTERS AND THEIR BACK GROUND

The detail of project proponent is as below:

• Mr. Raman A. Patel: He is B.Sc. (Chemistry). He has experience of 30 years as analytical chemist & Production Support.

• Mr. Mayaben R. Patel

1.1.2 REGULATORY FRAMEWORK

As per the Schedule of the EIA Notification, 2006 amended from time to time, the proposed

project is covered under Project or Activity, 5(f), namely Specialty Chemical Plant in existing

premises, requires prior Environmental Clearance (EC). They are categorized as Category ‘A’

(Outside any Industrial Estate), requiring EC from the Ministry of Environment and Forest, New

Delhi.

For proposed expansion; following assumption has been considered:

a. Capacity of Plant: 2536 MT/Month

b. Total project cost is Rs. 4.5 Crores.

c. Total working days in a year 330

d. Raw material storage facility for two months

e. Finished product storage facility for one month


1-2

1.2 PROJECT DETAILS


unit at survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat.

1.2.1 Total cost of the project alongwith total capital cost and recurring cost/annum for

environmental pollution control measures.

Total Project Cost for proposed project activity is Rs. 4.5 Crores. Capital cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 0.4 Crore.

1.2.2 List of products along with production capacity is given Table 1.1

TABLE 1.1

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY (EXISTING AND PROPOSED)

Sr. No.

Product Existing Capacity (MT/Month)

After Proposed Expansion Capacity (MT/Month)

1. Potassium chloride

2. Calcium chloride

3. Barium chloride

4. Zinc chloride

400 Max. 1 product

400 Max. 1 product

5. Potassium bromate

6. Sodium bromate

100 Max. 1 product

100 Max. 1 product

7. Potassium bromide

8. Sodium bromide

9. Calcium bromide

10. Ammonium bromide

70 Max. 1 product

70 Max. 1 product

11. Sodium carbonate

12. Potassium carbonate

100 Max. 1 product

100 Max. 1 product

13. Sodium phosphate

14. Potassium phosphate

15. Dicalcium phosphate

16. Tricalcium phosphate

300 Max. 1 product

300 Max. 1 product

17. Sodium sulphate

18. Potassium sulphate

19. Copper sulphate

20. Zinc sulphate

200 Max. 1 product

200 Max. 1 product


1-3

21. Chloroacetyl chloride ‐‐ 80

22. Benzoyl chloride ‐‐ 310

23. Pivaloyl chloride ‐‐ 40

24. Propionyl chloride ‐‐ 80

25. 2‐chloropropionyl chloride ‐‐ 40

26. Butyryl chloride ‐‐ 40

27. Isobutyryl chloride ‐‐ 40

28. 4‐Chlorobenzoyl chloride ‐‐ 40

29. 2‐chlorobenzoyl chloride ‐‐ 40

30. Velaryl chloride ‐‐ 40

31. 3‐chloropropionyl chloride ‐‐ 40

32. 4‐chlorobutyryl chloride ‐‐ 40

33. 4‐methoxybenzoyl chloride ‐‐ 25

34. 3‐methoxybenzoyl chloride ‐‐ 25

35. 3‐chlorobenzoyl chloride ‐‐ 25

36. 2,3‐Dichlorobenzoyl chloride ‐‐ 25




40. 4‐methylbenzoyl chloride ‐‐ 25

41. 2‐methylbenzoyl chloride ‐‐ 25

42. Isophthaloyl chloride ‐‐ 20

43. N‐butyl chloride ‐‐ 20

44. Isobutyl chloride ‐‐ 20

45. N‐Hexyl chloride ‐‐ 20

46. Propiophenone ‐‐ 20

47. 3‐chloropropiophenone ‐‐ 20

48. Benzophenone ‐‐ 20

49. 4‐chlorobenzophenone ‐‐ 20

50. 2,4‐dichloroacetophenone ‐‐ 20

51. Valarophenone ‐‐ 20

52. Trityl chloride ‐‐ 50

53. Acetanilide ‐‐ 20

54. Triethylamine hydrochloride ‐‐ 21

55. 2,4,6‐Trichloropyrimidine ‐‐ 20

Total 1170 2536


1-4

By‐Products

1.2.3 JUSTIFICATION OF THE PROJECT

Based on their informal survey of the market with their current customers and various traders,

they have found that there is a big potential for the range of the products they are planning.

Strong end use industry demand is expected to boost demand of the chemical products. The

focus of govt. is going to be on ensuring that this demand be met through domestic production.

Strong outlook for chemical demand is likely to result in significant investment in capacity

additions and hence import substitution. However, increasing local production requires global

competitiveness to withstand imports as well as for exports of surplus. Key success factors

needed are feedstock cost & availability, value chain access, technology, capital investment,

presence of strong local players as well as access to a rapidly growing large domestic market.

Sr. No.

Product Existing Capacity (MT/Month)

Proposed Capacity (MT/Month)

1. HCl (30 % ) ‐‐ 872 2. Sodium Bisulfite ‐‐ 1772 3. Aluminium Chloride ‐‐ 396


1-5

1.2.4 Infrastructure facility

Sr. No.

Salient Features Details

1

Location of project

Co‐ordinates of Project Site

Survey No. 295, Village: Lunej, Taluka: Khambhat, Dist: Anand (Guj.)

72º 35’ 13.90” E and 22º 20’ 49.73” N 2 Land requirement Existing plot 6981 sq. meters, no additional

LAND REQUIRED 3 Status of Land acquisition The proposed unit shall also be done in the

same plot with no acquisition of additional land.

4 Break‐Up of Land‐Use of project site The plot area is 6981 m2 .

5 Fuel to be used Existing: Coal/Agro waste: 3 MT/Month After Proposed Expansion: Wood/Agro waste:

5 MT/Day or coal: 4 MT/Day & Diesel ‐ 150 Liter/Day (Emergency)

6 Source of Water & Consumption Water requirement for the project will be met through Ground Water

Water Consumption (Existing): 4 KL/Day Water Consumption (Total After expansion): 45

KL/Day 7 Quantity of industrial effluent

generation and domestic Wastewater generation.

Existing: Domestic: 1.0 KL/day Industrial: 0.3 KL/day

After expansion: Domestic: 2.5 KL/day Industrial: 6.3 KL/day

8 Power requirement & source 150 KVA from mgvcl

9 Nearest highway nh no. 8 ‐50 km

10 nearest town Khambhat‐6 Km

11 nearest railway station Khambhat‐6 Km


1-6

1.3 PROJECT LOCATION


unit at Survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat is located at 22º 20’

49.73” North latitude and 72º 35’ 13.90” East longitude. The location of the plant in Gujarat is

shown in figure 1.1, Project site location along with site map of 10 km area and site details

providing various industries, surface water bodies, forests, etc. is shown in figure ‐1.2, A map

indicating distance of project site from critically polluted area along with coordinates is shown

in figure ‐1.3 and detailed layout map of the plant are shown in figure 1.4 respectively.

Important places around Project Site are: Khambhat ‐To the South East

Project site, where M/s. Bromchem Laboratories Pvt. Ltd. is located near Khambhat, Dist:

Anand, GUJARAT.


1-7

FIGURE ‐ 1.1

LOCATION OF THE PROJECT SITE


1-8

FIGURE ‐ 1.1 (CONTD.)

LOCATION OF THE PROJECT SITE (GOOGLE MAP)


1-9

FIGURE ‐ 1.2

Project site location along with site map of 10 km area and site details providing various

industries, surface water bodies, forests, etc.

Nearest various Industries


1-10

NEAREST SURFACE WATER BODY


1-11

FIGURE ‐ 1.3

A map indicating distance of project site from critically polluted area alongwith coordinates

88 km


1-12

FIGURE ‐ 1.4 LAYOUT OF THE PLANT


1-13

Table 1.2

Land Break‐up of the Plant

1 Parking 5 x 6 30

2 Office 10 x8 80

3 D.G. Set 5 x 5 25

4 Cooling Tower 10 x 10 100

5 Tank Farm Area 10 x 12 120

6 Raw Materials & Products Storage Area 18 x 12 216

7 Boiler 5 x 5 25

8 Coal/Agro Waste Storage Area 5 x 5 25

9 Existing Manufacturing Unit 18 x 9 162

10 Proposed Manufacturing Unit‐1 29 x 15 435

11 Proposed Manufacturing Unit‐2 40 x 30 1200

12 Green Belt 45 x 51.17 2303

13 ETP 10 x 10 100

14 Road & Open Area 2160

Total 6981


1-14

1.3.1 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1.3.1.1 METHOD OF DATA PREPARATION

Key infrastructure features have been extracted from Survey of India (SoI) topographical maps of 1:50,000 scale. The features have been updated using satellite data and have been verified with ancillary information derived from TTK maps and guide maps. The locations of the settlement have been extracted from Census of India (CoI) maps and have been verified by using SoI topographical maps and satellite data. 1.3.1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

The distance of railways and National and State highways are presented in Table 1.3 below:

TABLE 1.3

DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE Sr.

No. Nearest Infrastructure Feature Distance from Project Site

1. Nearest Settlement, Lunej village 2.66 km North West

2. State Highway SH 16 3.30 km East

3. Railway Line – Khambhat Railway Station 5.02 km South East

5. Khambhat Town 5.0 km South East

6. Anand City 43.0 Km North East

7. Sea (Gulf of Khambhat) 3.5 km South West

8. Vadodara Airport 62 Km East

9. Protected Area None within 15 Km


1-15

TABLE 1.3 (CONTD.)

DISTANCE OF NEAREST INDUSTRIES FROM PROJECT SITE

Sr.

No. Nearest Industries Distance from Project Site

1. Gujarat Halogen Petroleum

Corporation

0.25 Km

2. Tulsi Intermediates 0.4 Km

3. Pacific Organic Pvt. Ltd. 0.5 Km

5. Cambay Organics Pvt. Ltd. 0.55 Km

6. Gujarat Industrial Chemical Co. Pvt.

Ltd.

0.7 Km

7. Shreeji Chemicals 0.8 Km

8. Stermone Chemicals 1.68 Km

9. Shivam Chemicals 1.0 Km

TABLE 1.3 (CONTD.)

DISTANCE OF NEAREST SURFACE WATER BODY FROM PROJECT SITE Sr.

No. Nearest Surface Water Body Distance from Project Site

1. Nareshwar Lake 4.0 km South East

2. Sea (Gulf of Khambhat) 3.50 km South West

3. Malasoni Pond 4.24 km North

5. Neja Pond 2.36 km East

6. Lunej Pond 2.66 km West‐North

7. Canal (Virpara) 1.70 km West‐South


1-16

1.3.1.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS:‐

A map depicting administrative boundaries up to Taluka level, showing locations of towns and

villages along with National and State highways, major and medium roads and railways is

presented as Figure 1.3. The map also shows the water bodies and forest boundaries for better

understanding of project area. The map marks the area within 10 km with the project site as

the center.


1-17

FIGURE‐1.5

KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS


1-18

1.4 PURPOSE OF EIA The purpose of the EIA study is to critically analyze the manufacturing process of different

products existing at present and proposed to be manufactured with reference to types and

quantity of different raw material consumption, possible source of wastewater, air emission

and hazardous waste generation, control measures to reduce the pollution and to delineate a

comprehensive environment management plan along with recommendations and suggestions

in existing environment management system.

1.5 OBJECTIVES OF EIA

The main objectives of the study are 1) To assess the background environmental status.

2) To identify potential sources of pollution.

3) To predict and evaluate the impact on environment along with pollution control

measures taken.

4) To prepare a comprehensive Environment and Disaster Management Plan.

1.6 METHODOLOGIES FOR EIA

Taking into consideration proposed project activities and guidelines, an area of 5 km radius

from the center of the project has been selected and is designated as the study area for the

purpose of EIA study.

1.6.1 Base Line Environmental Condition

The samples of ambient air, ground and surface water and soil are collected and analyzed as

per the standard methods for establishing the baseline data and to determine the impact of

proposed activity on the same.


1-19

16.1.1 Ambient Air Environment

The air environment around the plant was studied by setting up seven locations within the

study area of 5 km radius from the project site and collection and monitoring the site specific

meteorological data viz. wind speed, wind direction, humidity, rainfall and ambient

temperature was carried out. Design of network for ambient air quality monitoring locations is

based on guidelines provided by CPCB. The ambient air samples were collected and analyzed

for SPM, PM10, PM2.5, SO2, NOX, O3, Pb, HC, CO, NH3, C6H6, Benzo (a) Pyrene (BaP), Arsenic (As),

Nickel (Ni) & VOCs for identification, prediction, evaluation and assessment of potential impact

on ambient air environment.

1.6.1.2 Ground And Surface Water Environment

The water required for domestic and industrial uses is being made available from ground water

only. Hence, to assess the Physico‐chemical quality of the water, a number of water samples

were collected and analyzed for pollution parameters viz., pH, TDS, Turbidity, BOD3, COD,

Fluorides, Chlorides, Sulphates, Ammonical Nitrogen, Hardness, Alkalinity, Iron and some trace

heavy metals, in order to find out the contamination, if any.

1.6.1.3 Noise Environment

Noise pollution survey was conducted in the study zone for evaluating existing status. The anticipated noise sources were automobile activities, which are likely to be increased due to proposed activity. Noise levels were also recorded at the noise generating places and in the surrounding villages for evaluating general scenario of the study area. Hourly equivalent sound levels (Leq) were also recorded for calculating Day and Night noise levels in the surrounding villages.

1.6.1.4 Soil Environment

Soil sampling and analysis was carried out to assess physico‐chemical characteristics of the soils

and delineate existing cropping pattern, existing land use and topography, within the study

area. Identification of potential utilities of effluent in land application and subsequent impacts

are assessed.


1-20

1.6.1.5 Biological Environment

Keeping in view, the importance of biological component of total environment due to the proposed project, biological characterization of terrestrial and aquatic environments, changes in species diversity of flora and fauna in terrestrial as well as aquatic systems were studied for impact analysis due to proposed project activity. 1.6.1.6 Socio‐economic Environment

Demographic and related socio‐economic data was collected from census handbook. Assessment of impact on significant historical, cultural, and archeological sites/places in the area and economic and employment benefit arisen out from the project is given special attention.

1.6.2 Identification of Source of Pollution

Detailed studies of manufacturing process for existing production scenario and proposed expansion scenario are carried out along with input and output of materials, water, and wastewater as well as infrastructure facilities available.

1.6.3 Evaluation of Pollution Control and Environmental Management System

The qualitative and quantitative analysis of various pollution sources as well as evaluation of pollution control system is carried out.

1.6.4 Evaluation of Impact

A comprehensive evaluation of environmental impact with reference to proposed activities is carried out.

1.6.5 Preparation of Environmental Management Plan

A comprehensive Environmental Management Plan has been prepared covering all the aspects of pollution prevention measures, Air and Water Pollution Control measures, Hazardous Waste Management, Environmental Surveillance and Environmental Management Plan.

The present report is a EIA conducted during January, 2014 to March, 2014. The baseline

environmental conditions have been established through field monitoring and literature survey.


1-21

1.7 STRUCTURE OF REPORT

The objectives of the EIA study is preparation of Environment Impact Assessment (EIA) report based on the guidelines of the Ministry of Environment and Forests (MoEF), CPCB and GPCB, Incorporating:

• Chapter‐1 is an Introduction of Industry, their premises and surrounding areas. It is also

expressing the basic objectives and methodologies for EIA studies and work to be

covered under each Environment component.

• Chapter‐2 is Project Description and Infrastructure facilities delineating all industrial and

environmental aspect of M/s. Bromchem Laboratories Pvt. Ltd. during pre‐construction,

construction and operation phase activities as well as manufacturing process details of

existing and proposed products. This chapter gives information about raw material

storage and handling, water and wastewater quantitative details, air pollution and

control system, sludge storage facility, utilities, greenbelt and safety measures for

existing and proposed. It also provides information about existing Environmental

Management facilities available at the project site.

• Chapter‐3 is Base Line Environmental Status delineating meteorological details and

identification of base line status of Environmental components (primary data) of

surrounding area and land use pattern, Biological Environment & Socio‐Economic

Environment (secondary data) giving details about District Anand, Taluka Khambhat and

study area in terms of land use pattern, biological environment, and socio‐economic

environment.

• Chapter‐4 is Identification and Prediction of Impact, which provides quantification of

significant impacts of the proposed activities of plant of various environmental

components. Evaluation of the existing and proposed pollution control facilities is also

carried out in this chapter.

• Chapter ‐5 is Environmental Monitoring Plan


1-22

• Chapter‐6 is Risk Analysis and Disaster Management Plan; it provides basis for what

should be type and capacity of its on‐site and off‐site emergency plan also what types of

safety measures are required. Risk and consequence analysis is carried out considering

storage and handling of various hazardous raw materials, intermediates and product as

well as manufacturing process.

• Chapter ‐7 is Environment Management plan delineating preparation of Environment

Management Plan (EMP) to be adopted for mitigation of anticipated adverse impacts if

any, and to ensure acceptable impacts.

• Chapter‐8 is Executive Summary.

• Chapter‐9 is Company Profile of EIA Consultant.


2‐1

CHAPTER ‐ 2

PROJECT DESCRIPTION 2.1 BACKGROUND

M/s. Bromchem Laboratories Pvt. Ltd. has proposed for expansion of Chemicals

manufacturing unit at survey no. 295, Village: Lunej, Tal: Khambhat, Dist: Anand, Gujarat.

Proposed project will be carried within the existing unit having land area of 6981 m2.

Total project cost is Rs. 4.5 Crores.

2.2 SELECTION OF SITE

Major factors involved in the selection of site are listed below:

• Expansion is within the existing unit so there is no need to construct any approach road.

• Site is very well connected by road or site access.

• Availability of power supply

• All infrastructure facility is available at site

• Proximity to Raw Material suppliers

• Transportation cost is cheap

2.3 MAIN PHASES OF THE PROJECT

2.3.1 CONSTRUCTION ACTIVITIES

Existing building/premises will be utilized and additional construction will be done to meet

requirement. Erection of various machineries shall start simultaneously. Construction

materials like steel, cement, crushed stones, sand etc. shall be required for the project, shall

be procured from the local market of the region.

2.3.2 MANUFACTURING ACTIVITIES

Manufacturing activities proposed in the project include various processes as a part of

manufacturing specialty chemicals. The activities shall also include operation of various

utilities. The manufacturing process is described in details in following sections.


2‐2

2.4 MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE

EXISTING 1. POTASSIUM CHLORIDE BRIEF PROCESS In brick lined reaction vessel 56 kg potassium hydroxide is taken and then 122 kg 30% hydrochloric acid will be added slowly, reaction was started automatically. After the completion of reaction potassium chloride solution will be dried to produce solid 74 kg potassium chloride. Chemical Reaction: KOH + HCL → KCl + H2O Potassium hydroxide Hydrochloric acid Potassium chloride Water 56 kg 36 kg 74 kg 18 kg REACTION FLOWCHART


2‐3

2. CALCIUM CHLORIDE

BRIEF PROCESS In brick lined reaction vessel 56 kg calcium oxide is taken and then 122 kg 30% hydrochloric acid will be added slowly, reaction was started automatically. After the completion of reaction calcium chloride solution will be dried to produce solid 111 kg calcium chloride. Chemical Reaction: CaO + 2 HCL → CaCl2 + 2 H2O Calcium oxide Hydrochloric acid Calcium chloride Water 56 kg 36 kg 111 kg 18 kg REACTION FLOWCHART


2‐4

3. BARIUM CHLORIDE

BRIEF PROCESS In brick lined reaction vessel 153 kg barium oxide is taken and then 244 kg 30% hydrochloric acid will be added slowly. Reaction was started automatically. After the completion of reaction barium chloride solution will be dried to produce solid 208 kg barium chloride. Chemical Reaction: BaO + 2 HCL → BaCl2 + H2O Barium Oxide Hydrochloric acid Barium Chloride Water 153 Kg 73 Kg 208 Kg 18 gm REACTION FLOWCHART


2‐5

4. ZINC CHLORIDE

BRIEF PROCESS In brick lined reaction vessel 79 kg zinc oxide is taken and then 244 kg 30% hydrochloric acid will be added slowly. Reaction was started automatically. After the completion of reaction zinc chloride solution will be dried to produce solid 134 kg zinc chloride. Chemical Reaction: ZnO + 2 HCL → ZnCl2 + 2 H2O Zinc oxide Hydrochloric acid Zinc chloride Water 79 kg 73 kg 134 kg 18 kg REACTION FLOWCHART


2‐6

5. POTASSIUM BROMIDE & POTASSIUM BROMATE

BRIEF PROCESS In brick lined reaction vessel 112 kg potassium hydroxide was dissolved in 18 kg of water, then 160 kg of bromine was added with continuous purging of 32 kg of oxygen gas (Air). After the completion of reaction precipitated 167 kg potassium bromate was separated by centrifuge, remaining aqueous potassium bromide solution will be dried to produce solid 119 kg potassium bromide. Chemical Reaction: Br2 + 2 KOH + H2O + O2 (Air) → KBr + KBrO3 + 2 H2O Bromine Potassium Water Oxygen Potassium Potassium Water 160 Kg hydroxide 18 kg 32 kg bromide bromate 36 Kg 112 kg 119 Kg 167 Kg REACTION FLOWCHART


2‐7

6. SODIUM BROMIDE & SODIUM BROMATE BRIEF PROCESS In brick lined reaction vessel 80 kg Sodium hydroxide was dissolved in 18 kg of water, then 160 kg of bromine was added with continuous purging of 32 kg of oxygen gas (Air). After the completion of reaction precipitated 151 kg Sodium bromate was separated by centrifuge, remaining aqueous Sodium bromide solution will be dried to produce solid 103 kg Sodium bromide. Chemical Reaction:

Br2 + 2 NaOH + H2O + O2 (Air) → NaBr + NaBrO3 + 2 H2O Bromine Sodium Water Oxygen Sodium Sodium Water 160 Kg hydroxide 18 kg 32 kg bromide bromate 36 Kg 80 kg 103 Kg 151 Kg REACTION FLOWCHART


2‐8

7. CALCIUM BROMIDE

BRIEF PROCESS In brick lined reaction vessel 56 kg calcium oxide is taken and then 320 kg 50% hydrobromic acid will be added slowly. Reaction was started automatically. After the completion of reaction calcium bromide solution will be dried to produce solid 200 kg calcium bromide. Chemical Reaction: CaO + 2 HBr → CaBr2 + 2 H2O Calcium oxide Hydrobromic acid Calcium bromide Water 56 kg 160 kg 200 kg 18 kg REACTION FLOWCHART


2‐9

8. AMMONIUM BROMIDE

BRIEF PROCESS In brick lined reaction vessel 69 kg ammonium carbonate is taken and then 320 kg 50% hydrobromic acid will be added slowly. Reaction was started automatically with evolution of carbon dioxide gas. After the completion of reaction ammonium bromide solution will be dried to produce solid 196 kg ammonium bromide.

Chemical Reaction: (NH4)2CO3 + 2 HBr → 2 NH4Br + H2O + CO2 Ammonium Hydrobromic acid Ammonium bromide Water Carbon carbonate dioxide 69 kg 160 kg 196 kg 18 kg 44 Kg REACTION FLOWCHART


2‐10

9. SODIUM CARBONATE BRIEF PROCESS In brick lined reaction vessel 80 kg Sodium hydroxide was dissolved in 18 kg of water, then 44 kg of carbon dioxide gas was passed to this solution. After the completion of reaction sodium carbonate solution was dried to give 106 kg of solid sodium carbonate. Chemical Reaction:

NaOH + CO2 + H2O → Na2CO3 + 2 H2O Sodium Carbon dioxide Water Sodium carbonate Water hydroxide 44 Kg 18 Kg 106 Kg 36 Kg 80 Kg REACTION FLOWCHART


2‐11

10. POTASSIUM CARBONATE BRIEF PROCESS In brick lined reaction vessel 80 kg Potassium hydroxide was dissolved in 18 kg of water, then 44 kg of carbon dioxide gas was passed to this solution. After the completion of reaction Potassium carbonate solution was dried to give 138 Kg of solid Potassium carbonate. Chemical Reaction: 2 KOH + CO2 + H2O → K2CO3 + 2 H2O Potassium Carbon dioxide Water Potassium carbonate Water hydroxide 44 Kg 18 Kg 138 Kg 36 Kg 112 Kg REACTION FLOWCHART


2‐12

11. SODIUM PHOSPHATE

BRIEF PROCESS In brick lined reaction vessel 120 kg Sodium hydroxide is taken and then 330 kg 30% Phosphoric acid will be added slowly, reaction was started automatically. After the completion of reaction sodium phosphate solution will be dried to produce solid 164 kg sodium phosphate. Chemical Reaction: 3 NaOH + H3PO4 → Na3PO4 + 3 H2O Sodium hydroxide Phosphoric acid Sodium phosphate Water 120 Kg 98 Kg 164 Kg 54 Kg REACTION FLOWCHART


2‐13

12. POTASSIUM PHOSPHATE BRIEF PROCESS In brick lined reaction vessel 168 kg Potassium hydroxide is taken and then 330 kg 30% Phosphoric acid will be added slowly, reaction was started automatically. After the completion of reaction Potassium phosphate solution will be dried to produce solid 212 kg Potassium phosphate. Chemical Reaction: 3 KOH + H3PO4 → K3PO4 + 3 H2O Potassium hydroxide Phosphoric acid Potassium phosphate Water 168Kg 98 Kg 212 Kg 54 Kg REACTION FLOWCHART


2‐14

13. DICALCIUM PHOSPHATE

BRIEF PROCESS In brick lined reaction vessel 330 kg 30% Phosphoric acid is taken and then 74 kg calcium hydroxide will be added slowly, reaction was started automatically. After the completion of reaction dicalcium phosphate solution will be dried to produce solid 136 kg dicalcium phosphate. Chemical Reaction: H3PO4 + Ca(OH)2 → CaHPO4 + 2 H2O

Phosphoric acid Calcium hydroxide DCP Water 98 Kg 74 Kg 136 Kg 36 Kg REACTION FLOW CHART


2‐15

14. TRICALCIUM PHOSPHATE BRIEF PROCESS In brick lined reaction vessel 98 kg 30% Phosphoric acid is taken and then 225 kg calcium hydroxide will be added slowly, reaction was started automatically. After the completion of reaction Tricalcium phosphate solution will be dried to produce solid 215 kg Tricalcium phosphate.

Chemical Reaction: H3PO4 + 3 Ca(OH)2 → Ca3PO4 + 6 H2O

Phosphoric acid Calcium hydroxide TCP Water 98 Kg 225 Kg 215 Kg 108 Kg REACTION FLOW CHART


2‐16

15. SODIUM SULPHATE

BRIEF PROCESS In brick lined reaction vessel 80 kg Sodium hydroxide is taken and then 196 kg 50% Sulfuric acid will be added slowly, reaction was started automatically. After the completion of reaction sodium sulphate solution will be dried to produce solid 142 kg sodium sulphate. Chemical Reaction: 2 NaOH + H2SO4 → Na2SO4 + 2 H2O Sodium hydroxide Sulfuric acid Sodium sulphate Water 80 Kg 98 Kg 142 Kg 36 Kg REACTION FLOWCHART


2‐17

16. POTASSIUM SULPHATE BRIEF PROCESS In brick lined reaction vessel 112 kg Potassium hydroxide is taken and then 196 kg 50% Sulfuric acid will be added slowly, reaction was started automatically. After the completion of reaction Potassium sulphate solution will be dried to produce solid 174 kg Potassium sulphate. Chemical Reaction: 2 KOH + H2SO4 → K2SO4 + 2 H2O Potassium hydroxide Sulfuric acid Potassium sulphate Water 112Kg 98 Kg 174 Kg 54 Kg REACTION FLOWCHART


2‐18

17. COPPER SULPHATE

BRIEF PROCESS In brick lined reaction vessel 79 kg copper oxide is taken and then 196 kg 50% sulfuric acid will be added slowly. Reaction proceeds automatically. After the completion of reaction copper sulfate solution will be dried to produce solid 159 kg copper sulfate. Chemical Reaction: CuO + H2SO4 → CuSO4 + H2O Copper Sulfuric acid Copper sulphate Water 79 Kg 98 Kg 159 Kg 18 Kg REACTION FLOWCHART


2‐19

18. ZINC SULPHATE

BRIEF PROCESS In brick lined reaction vessel 83 kg zinc oxide metal is taken and then 196 kg 50% sulfuric acid will be added slowly. Reaction proceeds automatically. After the completion of reaction zinc sulfate solution will be dried to produce solid 161 kg zinc sulfate. Chemical Reaction: ZnO + H2SO4 → ZnSO4 + H2O Zinc oxide Sulfuric acid Zinc sulphate Water 83 Kg 98 Kg 161 Kg 18 Kg REACTION FLOWCHART


2‐20

Proposed: 1. CHLOROACETYL CHLORIDE – (New Product) Brief process: In SS‐316 reactor benzotrichloride and chloroacetic acid was mixed and heated slowly to 800C. Generated hydrochloric acid gas was scrubbed by water then after completion of reaction chloroacetyl chloride was distilled at simple distillation and benzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart with Material Balance:


2‐21

2. (A) PIVALOYL CHLORIDE – (New Product) Brief process: In mild steel glass lined vessel Pivalic Acid will be reacted with Thionyl Chloride by slowly addition. During this reaction hydrochloric acid and sulphur dioxide gas formation will take place, both exhaust gases will be connected with absorber like sodium hydroxide and will also be connected to scrubbing tower to scrubs the gas and neutralized it. After completion of reaction pure product will be taken for distillation. Reaction formula: Flow Chart With Material Balance:


2‐22

3. (B) PIVALOYL CHLORIDE – (New Product) Brief process: In SS‐316 reactor benzotrichloride and pivalic acid was mixed and heated slowly to 1000C. Generated hydrochloric acid gas was scrubbed by water then after completion of reaction pivaloyl chloride was distilled at simple distillation and benzoyl chloride was distilled by vacuum distillation. Reaction formula:

Flow Chart With Material Balance:

2


2‐23

4. (A)PROPIONYL CHLORIDE – (New Product) Brief process: In mild steel glass lined vessel Pripionic Acid will be reacted with Thionyl Chloride by slowly addition. During this reaction hydrochloric acid and sulpher dioxide gas formation will take place, both exhaust gases will be connected with absorber like sodium hydroxide and will also be connected to scrubbing tower to scrubs the gas and neutralized it. After completion of reaction propionyl chloride will be collected by distillation. Reaction formula: Flow Chart With Material Balance:

62 Kg


2‐24

5. (B) PROPIONYL CHLORIDE – (New Product) Brief process: In SS‐316 reactor benzotrichloride and propionic acid was mixed and heated slowly to 600C. Generated hydrochloric acid gas was scrubbed by water then after completion of reaction propionyl chloride was distilled at simple distillation and benzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

2


2‐25

6. 2‐CHLOROPROPIONYL CHLORIDE – (New Product) Brief process: In SS‐316 reactor benzotrichloride and 2‐chloropropionic acid was mixed and heated slowly to 800C. Generated hydrochloric acid gas was scrubbed by water then after completion of reaction 2‐chloropropionyl chloride was distilled at simple distillation and benzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

2


2‐26

7. BUTYRYL CHLORIDE – (New Product) Brief process: In mild steel glass lined vessel Isobutyric Acid will be reacted with Thionyl Chloride by slowly addition. During this reaction hydrochloric acid and sulpher dioxide gas formation will take place, both exhaust gases will be connected with absorber like sodium hydroxide and will also be connected to scrubbing tower to scrubs the gas and neutralized it. After completion of reaction Isobutyryl chloride will be collected by distillation. Reaction formula: Flow Chart With Material Balance:


2‐27

8. ISOBUTYRYL CHLORIDE – (New Product) Brief process: In mild steel glass lined vessel Isobutyric Acid will be reacted with Thionyl Chloride by slowly addition. During this reaction hydrochloric acid and sulpher dioxide gas formation will take place, both exhaust gases will be connected with absorber like sodium hydroxide and will also be connected to scrubbing tower to scrubs the gas and neutralized it. After completion of reaction Isobutyryl chloride will be collected by distillation. Reaction formula: Flow Chart With Material Balance:


2‐28

9. 4‐CHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 4‐chlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 4‐chlorobenzoyl chloride was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐29

10. 2‐CHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 2‐chlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 2‐chlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐30

11. VALARYL CHLORIDE – (New Product) Brief process: In SS‐316 reactor benzotrichloride and valeric acid was mixed and heated slowly to 800C. Generated hydrochloric acid gas was scrubbed by water then after completion of reaction valeryl chloride was distilled at simple distillation and benzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐31

12. 3‐CHLOROPROPIONYL CHLORIDE – (New Product) Brief process: In glass lined reactor hydrochloric acid was passed in to acrylic acid at room temperature with continuous stirring then thionyl chloride was added slowly to the reaction mixture. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 3‐chloropropionyl chloride was distilled by vacume distillation. Reaction formula:

Flow Chart With Material balance:

63 Kg


2‐32

13. 4‐CHLOROBUTYRYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a gamma‐butyrolactone, thionyl chloride was added slowly at room temperature. Generated sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 4‐chlorobutyryl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐33

14. 4‐METHOXYBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 4‐methoxybenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 4‐methoxybenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐34

15. 3‐METHOXYBENZOYL CHLORIDE – (New Product) Name Quantity (MT/Annum) Product 3‐METHOXYBENZOYL CHLORIDE 25 Brief process: In glass lined reactor to a 3‐methoxybenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 3‐methoxybenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐35

16. 3‐CHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 3‐chlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 3‐chlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:

63 Kg


2‐36

17. 2,3‐DICHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 2,3‐dichlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 2,3‐chlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart with Material Balance:


2‐37

18. 2,4‐DICHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 2,4‐dichlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 2,4‐chlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐38

19. 3,4‐DICHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 3,4‐dichlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 3,4‐chlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐39

20. 3,5‐DICHLOROBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 3,5‐dichlorobenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 3,5‐dichlorobenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐40

21. 4‐METHYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 4‐methylbenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 4‐methylbenzoyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐41

22. 2‐METHYLBENZOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a 2‐methylbenzoic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 2‐methylbenzoyl chloride was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐42

23. ISOPHTHALOYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a Isophthalic acid, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction isophthaloyl chloride was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐43

24. n‐BUTYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a n‐butanol, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction n‐butyl chloride was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐44

25. ISOBUTYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a isobutanol, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction isobutyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐45

26. n‐HEXYL CHLORIDE – (New Product) Brief process: In glass lined reactor to a n‐hexanol, thionyl chloride was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction n‐hexyl chloride was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐46

27. TRITYL CHLORIDE – (New Product) Brief process: In glass lined reactor benzene and aluminium chloride was mixed and then benzotrichloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by distillation to get solid trityl chloride as a final product. Reaction formula: Flow Chart With Material Balance:


2‐47

28. PROPIOPHENONE – (New Product) Brief process: In glass lined reactor benzene and aluminum chloride was mixed and then propionyl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and propiophenone was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐48

29. 3‐CHLOROPROPIOPHENONE – (New Product) Brief process: In glass lined reactor benzene and aluminum chloride was mixed and then 3‐chloropropionyl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and 3‐chloropropiophenone was distilled by vacuum distillation. Reaction formula: Flow Chart With Material Balance:


2‐49

30. BENZOPHENONE – (New Product) Brief process: In glass lined reactor benzene and aluminium chloride was mixed and then benzoyl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and benzophenone was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐50

31. 4‐CHLOROBENZOPHENONE – (New Product) Brief process: In glass lined reactor chlorobenzene and aluminium chloride was mixed and then benzoyl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and 4‐chloro benzophenone was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐51

32. 2,4‐DICHLOROACETOPHENONE – (New Product) Brief process: In glass lined reactor2,3‐dichloro benzene and aluminium chloride was mixed and then acetyl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and 2,4‐dichloroacetophenone was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐52

33. VALAROPHENONE – (New Product) Brief process: In glass lined reactor benzene and aluminium chloride was mixed and then valaryl chloride was added to it at 15‐200C. Whole mixture was refluxed overnight. Generated hydrochloric acid gas was scrubbed by water. After completion of reaction whole mixture was dumped in to water then organic layer was separated and excess benzene was removed by simple distillation and valerophenone was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐53

34. ACETANILIDE – (New Product) Brief process: In glass lined reactor aniline and triethylamine was mixed in ethyl acetate and cooled to 100C. Then acetyl chloride was added to it very slowly to it. After completion of reaction whole mixture was dumped in water and extracted by ethyl acetate. Organic layer was separated and excess of ethyl acetate was distilled by simple distillation to get solid acetanilide as a final product. Reaction formula: Flow Chart With Material Balance:


2‐54

35. 2,4,6‐TRICHLOROPYRIMIDINE – (New Product) Brief process: In glass lined reactor thionyl chloride was palced and barbituric acid was added slowly at room temperature. Generated hydrochloric acid gas was scrubbed by water and sulphur dioxide was scrubbed by caustic solution to form sodium bisulphite solution. After completion of reaction 2,4,6‐Trichloropyrimidine was distilled by vacume distillation. Reaction formula: Flow Chart With Material Balance:


2‐55

2.5 RAW MATERIAL STORAGE AND HANDLING The raw materials are received in M.S. tank, HDPE, Bags as well as through tankers. All the storage

tanks of hazardous substances are located within premises in separate storage area. Large area is

covered by well‐designed warehouse, which is containing store office, raw material store, finished

product store, etc. The personnel protective equipments like hand gloves, gumboot, goggles,

helmet, clothing etc. are provided to those handling hazardous chemicals as per requirement.

TABLE 2.1

LIST OF RAW MATERIALS

Sr. No.

Raw Material Required

Existing Consumption (MT/Month)

Proposed consumption (MT/Month)

1. Potassium hydroxide 818 818 2. 30% Hydrochloric acid 1570 1570 3. Calcium oxide 222 222 4. Calcium hydroxide 743 743 5. Barium oxide 294 294 6. Zinc oxide 339 339 7. Bromine 202 202 8. Sodium hydroxide 460 460 9. 50% Hydrobromic acid 226 226 10. Ammonium carbonate 25 25 11. 30% Phosphoric acid 2262 2262 12. 50% sulfuric acid 990 990 13. Copper oxide 100 100 14. Monochloroacetic acid (MCA) ‐‐ 84 15. Benzotrichloride ‐‐ 509 16. Pivalic acid ‐‐ 34 17. Thionyl chloride ‐‐ 640 18. Sodium hydroxide ‐‐ 1434 (15%) 19. Propionic acid ‐‐ 64 20. 2‐Chloropropionic acid ‐‐ 34 21. Butyric acid ‐‐ 33 22. Isobutyric acid ‐‐ 33 23. 4‐Chlorobenzoic acid ‐‐ 36 24. 2‐Chlorobenzoic acid ‐‐ 36 25. Valeric acid ‐‐ 34 26. Acrylic acid ‐‐ 23 27. Gamma‐butyrolactone ‐‐ 25 28. 4‐Methoxybenzoic acid ‐‐ 22 29. 2‐Methoxybenzoic acid ‐‐ 22 30. 3‐Chlorobenzoic acid ‐‐ 22 31. 2,3‐Dichlorobenzoic acid ‐‐ 23


2‐56

32. 2,4‐Dichlorobenzoic acid ‐‐ 23 33. 3,4‐Dichlorobenzoic acid ‐‐ 23 34. 3,5‐Dichlorobenzoic acid ‐‐ 23 35. 4‐Methylbenzoic acid ‐‐ 18 36. 2‐Methylbenzoic acid ‐‐ 18 37. Isophthalic acid ‐‐ 16 38. N‐Butanol ‐‐ 16 39. Isobutanol ‐‐ 16 40. N‐Hexanol ‐‐ 17 41 Aluminium chloride ‐‐ 104 42. Benzene ‐‐ 65 43. Propionyl chloride ‐‐ 14 44. 3‐Chloropropionyl chloride ‐‐ 15 45. Benzoyl chloride ‐‐ 28 46. 1,3‐Dichlorobenzene ‐‐ 16 47. Acetyl chloride ‐‐ 21 48. Valeryl chloride ‐‐ 15 49. Aniline ‐‐ 14 50. Triethylamine ‐‐ 15 51. Barbituric acid ‐‐ 14


2‐57

2.6 WATER AND WASTEWATER

Daily water consumption of M/s. Bromchem Laboratories Pvt. Ltd. is 4 m3/day for existing scenario.

Water consumption is primarily for processing, washing, boiler, cooling and domestic purposes. In

existing scenario source of water is ground water. Daily 1.3 m3/day of wastewater is generated. After

Proposed expansion water consumption will be 45 m3/day and wastewater generation will be 8.8

m3/day. Water source will be same after proposed expansion. Details of water consumption and

wastewater generation for existing and proposed scenario are given in Table 2.2.

TABLE ‐ 2.2

WATER CONSUMPTION AND WASTEWATER GENERATION

Existing

Existing Scenario (m3/day) Sr.

No.

Category

Water Consumption Waste Water Generation

1. Industrial

Process 1.7 ‐‐

Boiler ‐‐ ‐‐

Cooling ‐‐ ‐‐

Washing 0.3 0.3

2. Gardening 1 ‐‐

3. Domestic 1.0 1.0

Total (Industrial) 3.0 0.3

Total 4.0 1.3


2‐58

Proposed (Total)

WATER BALANCE DIAGRAM

Proposed (Total)

Proposed Scenario (m3/day) Sr.

No.

Category

Water Consumption Waste Water Generation

2. Industrial

Process 21.7 ‐‐

Boiler 6.0 1.5

Cooling 8.0 2.0

Washing 2.8 2.8

2. Gardening 3.0 ‐

3. Domestic 3.5 2.5

Total (Industrial) 38.5 6.3

Total 45 8.8

Reused to dilute the HCL (30%), this will be used to produce the calcium chloride (Own Consumption) – Option ‐1

Raw Water: 45 KL/Day

Domestic:3.5 KL/Day

Process: 21.7 KL/Day

Boiler: 6 KL/Day

Cooling Tower: 8 KL/Day

Gardening: 3.0 KL/Day

Septic Tank & Soak Pit: 2.5 KL/Day

1.5 KL/Day 2.0 KL/Day

ETP: 6.3KL/Day

Washing: 2.8 KL/Day

2.8 KL/Day

CETP: 6.3 KL/Day for further Treatment in future (Option ‐2)


2‐59

2.6.1 ETP Details

M/s. Bromchem Laboratories Pvt. Ltd. shall have an Effluent Treatment Plant consisting of primary

and tertiary treatment unit. The effluent confirming the GPCB standards shall be reused into plant

premises or send to CETP. The details of ETP are as follows.

EXISTING:

The existing wastewater 0.3 KL/Day is collected and neutralized in neutralization tank and reused in

HCl dilution or caustic dilution or sulfuric acid dilution or phosphoric acid dilution or any other

manufacturing product at a time.

PROPOSED

PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)

The treatment scheme will be divided in two different stages:

Stage 1‐ Primary Treatment

Stage No ‐2 Tertiary Treatment

1) Primary Treatment:

The waste water from unit will be brought to the treatment plant via a series of underground

pipelines or trenches. The waste water will pass through oil & grease separator and will be collected

in the equalization tank. Two numbers of tanks are proposed. One will in filling mode for

equalization of waste water while the other will be in pumping mode. The equalized wastewater is

pumped to the flash mixer for addition of chemicals like lime. From the flash mixer the waste water

flows into the flocculator where chemical flocs are formed by coagulation and flocculation by

addition of Alum/Ferrous sulphate and polyelectrolyte. These flocs are removed in the primary

settling tank. The underflow (sludge) from the primary settling tank is taken to sludge dewatering

unit (Sludge Drying Bed).

2) Tertiary Treatment:

The treated waste water will further under go polishing in Tertiary Treatment Unit, which will

comprise of pressure sand filter and activated carbon filter. The tertiary treated water will be

collected in final collection tank.

Option‐ 1 for disposal of Treated effluent

Treated effluent will be reused to dilute HCL (30%). This will be used to produce the calcium chloride

(Own Consumption).


2‐60

Note:

Option‐ 2 for disposal of Treated effluent

The treated effluent will be sent to CETP for further treatment (Option ‐2) as per CETP norms in

futue.

The Domestic wastewater is disposed of through septic tank & soak pit.

Effluent Treatment Plant (Dimension):

Sr. No. Name of the Unit Dimension Volume (m3) MOC

1. Oil & Grease Trap 3.0(m) x 2.0(m)x 1.0(m)

6.0 m3 RCC (Acid/Alkali Proof Lining)

2. Collection Tank (2 Nos.) 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

3. Dosing Tank (1 Nos.) 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

4. Flash Mixer 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

5. Flocculator 1.0(m) x 1.0(m )x 1.0(m)

1.0 m3 RCC

6. Neutralization Tank 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

7. Primary Settling Tank 2.5(m) x 2.5(m)x 2.0(m)

12.0 m3 RCC

8. Sand Filter ‐‐ 0.5 m3/hr MSEP 9. Activated Carbon Filter ‐‐ 0.5 m3/hr

10. Final Collection Tank 4.0(m) x 4.0(m)x 3.0(m)

48.0 m3 RCC

11. Sludge Dewatering Unit ‐ Sludge Drying Beds

6.0(m) x 3.0(m) x 2.0(m)

‐‐ Brick


2‐61

Flow Diagram:

Raw Effluent Oil & Grease Trap Collection Tank Neutralization Tank

Primary Settling Tank

Sand Filter Activated Carbon Filter

Final Collection Tank

CETP for further Treatment in future (Option‐2)

DST FMT Floc.

Reused to dilute the HCL (30%), this will be used to produce the calcium chloride (Own Consumption) – Option ‐1


2‐62

EXPECTED CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATMENT (if CETP)

Characteristics (mg/L) CETP Inlet Norms

(mg/L)

Sr.

No.

Parameter

Untreated Treated

1. pH 6.5 ‐ 8.5 7‐8 5‐9

2. SS 600 100 600

3. Phenolic Compound 0.8 0.2 5

4. COD 4680 250 2000

5. BOD3 1960 80 500

6. Ammonical Nitrogen 10 6 50

7. Oil & Grease 32 5 20


2‐63

2.7 AIR POLLUTION AND CONTROL SYSTEM

There are sources of air pollution at M/s. Bromchem Laboratories Pvt. Ltd., flue gas through boiler &

Thermopack stack, vent attached to process reactor. The details of the stack and vent along with

pollution control system for existing and proposed scenario are given in Table 2.3.

TABLE – 2.3

DETAILS OF SOURCE OF EMISSION (EXISTING & PROPOSED)

Existing: 1. Details of Flue Gas Stack; Stack Attached To Furnace

SOURCES OF GASESOUS EMISSION STACK

Fuel Used Agro Waste/Coal

Type of Emissions SO2 NOx SPM

Permissible Limits 262 mg/Nm3 94 mg/Nm3 150 mg/Nm3

Stack Height 10 meters

Proposed Flue Gas Emission 2. Details of Flue Gas Stack; Stack Attached To Thermopack Boiler

SOURCES OF GASESOUS EMISSION STACK

Capacity 6 Lack KCal /Hr





Stack Diameter at the Top 600 mm Control Measures Cyclone Separator with dust collector

3. Details of Flue Gas Stack; Stack Attached To Steam Boiler SOURCES OF GASESOUS EMISSION STACK

Capacity 1 TPH





Stack Diameter at the Top 600 mm

Control Measures Cyclone Separator with dust collector


2‐64

4. Details of Process Vent ; Vent Attached To Process Sr. No. Stack attached to Stack Height Air Pollution

Control System Parameter Permissible Limit

Proposed 1 Process Vent

(Chlorination Plant) 11 m HCl

SO2 20 mg/Nm3 40 mg/Nm3

2 Process Vent

11 m

Two StageScrubber

HCl

20 mg/Nm3

2.8 NOISE LEVEL AND CONTROL SYSTEM

Extensive oiling and lubrication and preventive maintenance is carried out to reduce noise

generation at source to the permissible limit. However, at place where noise levels can

exceed the permissible limit, Earplugs and Earmuffs shall be provided to those working in

such area.


2‐65

2.9 HAZARDOUS WASTE GENERATIONS AND DISPOSAL SYSTEM

The hazardous waste generation and disposal are given in table given below.

TABLE: 2.4

DETAILS OF HAZARDOUS WASTE GENERATION & DISPOSAL Type of

Waste

Schedule Category Source Quantity Disposal Method

ETP wASTE

34.3

ETP 17 MT/ MONTH COLLECTION, STORAGE, TRANSPORTATION & DISPOSAL TO TSDF sITE

USED OIL

5.1 Plant & Machinery

5 LITERS/ MONTH

COLLECTION, STORAGE, TRANSPORTATION & sALE TO GPCB aUTHORIZED rECYCLER

DISCARDED CONTAINERS/ BAGS/ CARBOYS

33.3 Process 500 Nos. DECONTAMINATION, STORAGE & gIVEN TO GPCB rEGISTERED vENDOR.

DISTILLATION RESIDUE

20.3 Process 12 MT/ MONTH COLLECTION, sTORAGE, tRANSPORTATION, dISPOSAL BY iNCINERATION AT CHWI OF NECL OR co‐pROCESSING IN cEMENT iNDUSTRIES.

FLY ASH ‐‐ Boiler 17 MT/ MONTH WILL BE SOLD TO BRICK MANUFACTURERS

HCl (30 %) ‐‐ Process 872 MT/Month Captive Consumption

SODIUM BISULFITE

‐‐ Process 1772 MT/Month Will be sold to end user.

ALUMINUM CHLORIDE SOLUTION

‐‐ Process 396 MT/Month Will be sold to end user.


2‐66

2.10 ELECTRICITY REQUIREMENT & FUEL REEQUIREMENT

S. No. PARTICULARS REQUIREMENT

POWER

1 POWER REQUIREMENT 150 KVA

2 SOURCE OF sUPPLY MGVCL

FUEL

1 FUEL & IT'S CONSUMPTION WOOD/AGRO WASTE ‐ 5 MT/DAY or COAL ‐ 4 MT/DAY

DIESEL ‐ 150 LITER/DAY (EMERGENCY)

2 SOURCE OF sUPPLY NEAREST SUPPLIER

2.11 DETAILS OF GREENBELT

The main objective of the green belt is to provide a barrier between the plant and surroundings areas. M/s. Bromchem Laboratories Pvt. Ltd. has developed green belt within factory premises. Company is proposing 2303 sq. meter (32 %) for green belt out of 6981 sq. meter of the total land area. 2.12 SOLVENT RECOVERY SYSTEM

• Wherever required, the solvents shall be directly pumped into day tanks from the storage

tanks and shall be charged into the reactors without involving any manual handling.

• All the pumps shall be mechanical seal type to avoid any leakage of solvent.

• All necessary fire fighting systems shall be provided with alarm system. Flame proof wiring

and flame proof electrical accessories shall be provided to avoid any mishap.

• All the storage tank and day tank shall be connected to a vent system through chilled water

condensers to prevent loss of solvents in the atmosphere.

• All the distillation column vents are also connected to chilled water condensers for maximum

possible recovery of the solvents.


2‐67

Name of

Solvent

Total Input

(kg)

Qty. of

Recovered

Solvent (kg)

Qty. of Losses

(kg)

%

Recovery

%

Losses

N‐BUTANOL 170 165 5 97.05 2.95

ISOBUTANOL 53 50.5 2.5 95.28 4.72

BENZENE 69 66.3 2.7 96.08 3.92

TEA 18 17 1 94.45 5.55

Documents

M/s. Bromchem Laboratories Pvt. Ltd. Environmental Impact & … · Environmental Impact & Risk Assessment Report 12 ABBREVIATIONS µg/m3 Micro gram per meter cube oC Degree centigrade