M/s. ION EXCHANGE (INDIA) LTD., ANKLESHWAR.environmentclearance.nic.in/.../PFR/...feasibilityReport(PFR)File.pdfGypsum will be sold to Cement ... conforming to customer requirements

M/s. ION EXCHANGE (INDIA) LTD., ANKLESHWAR.

M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 1

INTRODUCTION

M/s. Ion Exchange (India) Ltd. will engage for manufacturing of Cation & Anion Resins at

Plot No. 5811-12-13, GIDC Estate, Ankleshwar, Gujarat.

As per EIA notification 2006 and its amendment, the proposed project is falling under

category 5(f). The unit is having CCA for manufacturing of Cation & Anion Resins. They

have now proposed to go for expansion by increasing in production capacity.

The details of products are given below Table 1.

TABLE 1

LIST OF PRODUCTS

COST OF PROJECT

The expected cost of project is Rs. 25 Crores. The plot has been purchased by M/s. Ion

Exchange (India) Ltd. from GIDC. The total plot area of the unit is 46977 sq.m. The green

belt area will be 8937 sq.m.

FUEL CONSUMPTION

The proposed unit will use Natural gas and LDO as fuel for Boilers and diesel used for DG

Set. The existing Natural Gas consumption is 202.5 Nm3/Hr and Natural gas consumption

due to proposed expansion will be 47.5 Nm3/Hr. Total Natural Gas requirements after

proposed expansion will be 250.0 Nm3/Hr. There will be no changes in proposed expansion

for Diesel consumption for DG set and LDO for Boiler.

1.0 EXECUTIVE SUMMARY

Sr.

No.

Name of

Products

Existing quantity

as per Consent

No. AWH-56490

in (M3/Month)

Proposed quantity for

Expansion in

(M3/Month)

Total quantity

(M3/Month)

1. Resin-Anion 250 750 1000

2. Resin-

Cation

1400 600 2000

By-Product

1. Sulphuric

Acid

(60-70%)

350 250 600



ELECTRICITY CONSUMPTION

The unit have electricity from Daxin Gujarat Vij Company Ltd. The existing electricity

consumption is 900 KVA and electricity consumption due to proposed expansion will be 700

KVA. Total electricity requirement after proposed expansion will be 1600 KVA.

WATER CONSUMPTION

As per Consent

The source of water will be from GIDC water supply scheme.

The water consumption for industrial purpose is 857 KL/day. The unit is use 657 KL/day

fresh water and 200 KL/day recovered water. The water consumption for the domestic

purpose is 8 KL/day fresh water.

Proposed scenario

There will be increase in fresh water 185 KL requirement. The unit has proposed to install RO

system and recover additional 150 KL water. The efficiency of RO plant will be almost 54%

permeate and 46 % reject. Earlier it was only 50% efficiency.

WASTE WATER GENERATION

As per Consent

Total waste water generation is 800 KL/Day. It is sent to RO Plant and Bio stream. 200 KL/

Day RO permeate water is recovered and reuse in process. Rejected from RO 200 KL/ Day,

Recycle stream 200 KL/Day and Bio stream 200 KL/Day is sent to the NCTL for further

treatment.

Proposed scenario

The unit will be segregating its effluent in to high COD (Bio stream) and low COD stream.

The high COD stream will be treated to required norms and discharge in to GIDC drainage

line. The low COD stream along with sewage, cooling tower blow down and boiler blow

down will be treated separately and subjected to RO. The permeate will be recycled back in

process and reject will be discharged.



GASEOUS EMISSION

There will be flue gas emission from Boiler (I to IV & V) having capacity of 850 Kg/Hr each.

Also emissions will come from two D.G. sets having capacity of 200 KVA and 475 KVA

respectively. The D.G. sets will be used in case of emergency only. There will be no change

in Flue gas emission due to Proposed Scenario.

There will be process emission from one vent of the HCl process scrubber, one vent of the

SO2 process scrubber. There will be no additional new process stacks due to proposed

expansion.

HAZARDOUS WASTE MANAGEMENT

As per Consent

As per CCA order no. AWH-56490, the hazardous waste generation are Used Oil (1.2

MT/year), Discarded Barrels (1200 No/Year), discarded Liners (24 MT/Year), Insulation

Waste (0.78 MT/year), Personal Protective Equipment’s (3 MT/Year), Broken Glassware

(0.24 MT/Year). Chemical Gypsum & Bio-Mass from Waste Water Treatment (7860

MT/Year) and Spent Resin/Fines Resin from Ion Exchange Type Material Used For Water

Purification (Non-Toxic & Non-Hazardous) (600 MT/Year), Spent Carbon (120 MT/Year),

Wet Scrubber Residue (0.12 MT/Year) and Spent Acid (H2SO4) (4200 M3/Year).

Used oil is sold to MoEF approved vendors. Discarded Barrels, Discarded Liners, Insulation

Waste, Personal Protective Equipment’s, Broken Glassware are sold to GPCB approved

vendors after decontamination & other items will be disposed to TSDF-BEIL, Ankleshwar.

Gypsum will be sold to Cement Industry, M/s. Gujarat, Ambuja Cement, Kodinar, Gujarat &

M/s. Ultratech Ltd (A Unit Of Gujarat Cement Works), Kovaya, Rajulacity, Amreli & Bio-

Mass will Be Disposed to BEIL, Ankleshwar. Spent Resin/Fines Resin From Ion Exchange

Type Material Used for Water Purification (Non-Toxic & Non-Hazardous) and Spent carbon

are Disposed to BEIL - Ankleshwar. Wet Scrubber Residue is send to ETP for further

treatment. Spent Acid (H2SO4) is sold to actual end users.



Proposed scenario

The hazardous waste generation will be Used Oil (2.4 MT/year), Discarded Barrels (6000

No/Year), Discarded Liners (36 MT/Year), Insulation Waste (1.02 MT/year), Personal

Protective Equipment’s (5.4 MT/Year), Broken Glassware (0.48 MT/Year), Distilled Solvent

(60 MT/Year) and Spent Acid (H2SO4) (7200 M3/Year) as by product. There will be no

change in quantity of Chemical Gypsum & Bio-Mass from Waste Water Treatment, Spent

Resin/Fines Resin from Ion Exchange Type Material Used for Water Purification (Non-Toxic

& Non-Hazardous), Spent Carbon and Wet Scrubber Residue.

Used oil will be sold to MoEF approved vendors. Discarded Barrels, Discarded Liners,

Insulation Waste, Personal Protective Equipment’s, Broken Glassware will be sold to GPCB

approved vendors after decontamination & other items will be disposed to TSDF-BEIL,

Ankleshwar. Gypsum will be sold to Cement Industry, M/s. Gujarat, Ambuja Cement,

Kodinar, Gujarat & M/s. Ultratech Ltd (A Unit of Gujarat Cement Works), Kovaya, Rajula

city, Amreli & Bio-Mass will be Disposed to BEIL, Ankleshwar. Spent Resin/Fines Resin

From Ion Exchange Type Material Used for Water Purification (Non-Toxic & Non-

Hazardous) and Spent carbon will be Disposed to BEIL - Ankleshwar. Wet Scrubber Residue

will be Send to ETP for further treatment. Spent Acid (H2SO4) will be sold to actual end

users. Distilled Solvent will be sold to actual end users.



2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

M/s. Ion Exchange (India) Ltd. will engage for manufacturing of Cation & Anion Resins at

plot no. 5811-12-13, GIDC Estate, Ankleshwar, Dist. Bharuch, Gujarat.

The list of products is provided in Table -1.

2.2 Introduction of Project Proponent

M/s. Ion Exchange (India) Ltd. is a steady growing company incorporated in 1994. It is a

registered as Large Scale industrial unit. The project proponents are already in market and

doing manufacturing and trading of these products.

Quality Policy:

The quality policy and environment policy of the company is as under:

“We are committed to manufacture, deliver and Service Ion exchangers and related Products

conforming to customer requirements and to enhance customer satisfaction by

• Implementing and Maintaining ISO 9001: 2008 quality management system and

continual improvement of its performance.

• Training our employees in quality management systems, behavioral and functional

and other areas.

• Providing safe and hazard free work environment.

• Achieving higher levels of quality productivity and safety.

• Improving process for batter efficiency.

• Timely delivers.

Environment Policy

Ion exchange (India) Ltd. has specialized in water and waste water treatment for over three

decades using a wide range of processes and products the company offers total water

management solution for industry homes and communities.

We at Ankleshwar unit are involved in the Manufacture of Ion Exchange Resins.

2.1. Introduction of the Project



We Commit Ourselves To:-

• Conservation of Resources and Continual improvement of our processes and activities

to minimize their Environment Impact.

• Compliance with Legal & other requirements.

• Cultivate more and more activities having positive Environmental Impacts.

• Providing a safe and healthy working Environment and Demonstrating responsibility

towards the environment around us.

• Communicating our environmental policy to all persons working for or on behalf of

the organisation and the public.

• Facilitating employee participation in implementation of system.

• Regular reviews of our environmental performance and practices against Objectives

and Targets.

• Prevention of pollution by minimizing pollution at source.”

The name and address of Directors are given in Table 2.

TABLE 2

CONTACT DETAILS OF THE DIRECTORS

Sr.

No.

Name Address Contact No.

1. Mr. Rajesh

Sharma

32, Vidhani Apartments, Narayan Dabholkar

Marg, Mumbai – 400 006

9324414305

2. Dr. Vijay Narhar

Gupchup

76, Blue Haven, B. Hire Marg, Malabar Hill,

Mumbai – 400 006

022 – 2364 1183

09820020207

3. Mr. Mahabir

Prasad Patni

P-491, CIT Scheme, XL VII Keyatalla Lane,

Kolkata – 700 029.

09830049093

4. Mr. Thekkekkara

Meloth Mohan

Nambiar

172, Jupiter Apartment, Cuffe Parade, Colaba,

Mumbai – 05

022- 2218 2544/4170

09821014261

5. Mr. Parthasarathy

Sampath Kumar

Flat No. 502, EDEN-1,

Hiranandani Estate, Ghodbunder road,

Patahlipada, Thane (w)- 400607

022 – 2218 2960

09821231790

6. Mr. Dinesh

Sharma

Flat No. 64, Vijay Appt, 16, Carmichael Road,

Bh. Jaslok Hospital, Mumbai – 400 026

9324226540

7. Mr. Ankur Patni

P-491 ,CIT, Scheme XLVII, Keyatolla lane ,

Kolkata -700 029

9339871575

8. Mr. Abhiram Seth 18, Anandlok, New Delhi – 110 049 9810182441

9. Mr. Shishir

Tamotia

B98, Surya Vihar, Ph-II, Bhilai, Chattisgarh –

490 020

64848326,

9819889972/

9773301119

10. Mrs. Kishori

Udeshi

15, Sumit Apts., Carmichael Road, Mumbai –

400 026

--



2.3 Nature of project

The unit will manufacture Resin- Cation (600 MT/Month) and Resin- Anion (750

MT/Month) and By-product will Sulphuric acid (250 MT/Month). As per EIA notification

2006 and its amendment, the proposed project is falling under category B-5(f).

2.4 Market Feasibility

In recent years, market demands for chemical products have become increasingly diverse and

specialized, meaning that one must be able to offer customers a diverse range of synthesis

techniques. Keeping in mind this trend, demand for products is increasing.

Ion Exchange (India) Limited pioneered water treatment in India & today they are the

country’s premier company in water & environment management, with a strong global

presence. Among few companies worldwide, with the entire range of technologies, processes,

products & services, they are able to provide solutions for every sector – industrial,

institutional, municipal and household for both urban and rural markets.

They manufacture world class ion exchange resins of all types - gel, macroporous and

isoporous, for water, non-water and speciality applications in industries such as pharma, food

& beverage, nuclear, chemical, bio-diesel, hydrometallurgy, sugar and many more. Located

in Ankleshwar, a well developed industrial and economic zone in Gujarat it is one of the

largest resin producing units and the first ion exchange resin manufacturing plant to receive

ISO 9001:2000 and 14001 certification, in India.

2.5 Employment generation due to the project

Approx 32 persons will get employment from this proposed expansion project. The details

are given below.

Sr.

No.

Category Existing

Manpower

Proposed additional

Manpower

Total Manpower

1 Managerial 28 2 30

2 Technical 79 16 95

3 Administrative 17 2 19

4 Skilled workers 15 2 17

5 Unskilled

workers 68 10 78

Total: 207 32 239



3.0 PROJECT DESCRIPTION

3.1 Type of project

The proposed project will not include any interlinked and interdependent projects. It is

Chemical manufacturing project.

3.2 Project location

The proposed project site is located at plot no 5811-12-13, GIDC Estate, Ankleshwar, Dist.

Bharuch in the state of Gujarat. It is approximately 20 km distance from district head quarter

Bharuch. The approximate geographical positioning of the project site is at Latitude:

21037’59.03”N, Longitude: 73

02’54.75”E. The location of the project site can be identified

from the location map shown in Figure-1 & 2.

The salient features of the location of the project site are presented in give below Table 3.

TABLE 3

SALIENT FEATURES OF THE PROJECT SITE

Particulars Details

Taluka/ Tehsil Ankleshwar

District Bharuch

Approx. Geographical

positioning

Latitude: 21037’59.03”N

Longitude:7302’54.75”E

Nearest City Bharuch about 20 KM

Nearest Town Ankleshwar

Nearest Highway NH No. 8

Nearest State highway Old National Highway No. 8

Nearest Railway line/

Railway station

Ankleshwar Railway Station

Nearest Airport/ Airbase Surat

Protected Areas/

Sanctuaries

--



FIGURE 1

LOCATION OF THE PROJECT SITE

FIGURE -2

SATELLITE IMAGE OF THE PROJECT SITE

Ankleshwar Industrial area

Panoli Industrial area

Jhagadia industrial area

Priaman CETP

Canal

Piraman to Katiyajal Effluent

Pipe

Jhagadia to Piraman CETP

Panoli to Piraman CETP

PROJECT



3.3 Criteria for Site selection

This is expansion project. So the proponent did not consider any other alternative site for

proposed expansion. The existing plot has sufficient area for carrying out expansion.

3.4 Neighboring Industries

The industry is located in an area, which is already industrialized. The industries in the

vicinity of the proposed project are given in the table 4:

TABLE 4

NEARBY INDUSTRIES IN THE VICINITY

Name of

Industry

Direction with respect to

project site Address

Open plot of

GIDC

East side of company Open GIDC Plot

Open plot of

GIDC

North side of company Ankleshwar to Jhagadia Railway Line

Heubach

Colour Pvt.

Ltd.

South side of company Plot No. 9113/2, GIDC Estate,

Ankleshwar

Sajjan India

Ltd

West side of company Plot No. 6117-19 GIDC Estate,

Ankleshwar

3.5 Size of Project

The expected cost of proposed project is Rs. 25 Crores.

New Plant and machinery installations will also have to be acquired and installed.

Environment Protection and safety systems have also been considered in planning the Cost

Projection. Green belt development, provision of fire extinguishers etc. are also calculated.

The following table shows the break-up of the proposed project cost.



TABLE 5

CAPITAL COST OF PROJECTION

Sr. No. Purpose Proposed

1. Land --

2. Building

Rs. 20.00 Crores

3. Plant and Machinery

4. Q.A. Lab set up

5. Environment Protection & Safety

a) Effluent treatment Plant Rs. 4.98 Crores

b) Safety Equipment (PPE, fire

extinguishers, Ventilation, etc.)

Rs. 0.02 Crores

c) Green belt development --

d) Fire --

Total Rs. 25.00/- Crores

3.6 Process Technology

The details are covered in Annexure-IV of Form-I.

3.7 Raw-Materials

The proposed products are Cation & Anion Resins and the required raw materials will be

purchased from the local/ Indian market. Details of raw-material consumption are attached as

Annexure-III of Form-I.

3.8 Resource optimization/recycling and reuse

3.8.1 Solvent Recovery

Methanol and EDC solvents are used for manufacture, Distilled solvent will be sent to end

users.

3.9 Resource Requirements

3.9.1 Land

The plot has been purchased by M/s. Ion Exchange (India) Ltd. The total plot area of the unit

is 46977 sq. m.

3.9.2 Building

The new building will be constructed. The approximate requirement or construction materials

are given below table. Details are provided in plant lay out.



TABLE 6

APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS

Sr.

No.

Construction material Proposed Quantity

1. Stone 78.44 m2

2. Sand 62.84 m3

3. Aggregate 76.73 m3

4. Soil 209.56 m3

3.9.3 Power and Fuel

The unit’s power and fuel requirement is provided in Table 7. There will not be any increase

in fuel consumption. The unit is using natural gas as fuel in normal circumstances. Whenever,

any issue of availability of natural gas is there, unit use LDO as fuel.

TABLE 7

POWER AND FUEL REQUIREMENT

Sr.

No

Name Existing

Quantity As

per Consent

Proposed

Quantity

Total Quantity Source

1. Natural

Gas for

Boilers

202.5 M3/Hr. 47.5 M

3/Hr. 250.0 M

3/Hr. GGCL

2. LDO as

Alternate

Fuel to

Boilers

0.025

Kl/Hr.(Only

When Natural

Gas not

Available)

00 0.025

Kl/Hr.(Only

When Natural

Gas not

Available)

LOCAL

MARKET

3. Diesel For

DG Sets

0.135 Kl/Hr. 00 0.135 Kl/Hr. LOCAL

MARKET

4. Energy-

Electricity

900 KVA 700 KVA 1600 KVA DGVCL



The category wise bifurcation of the water requirement is given in Table 8. The source of

water will be from GIDC water supply scheme. There will be increase in fresh water

requirement. The unit has proposed to install RO system and recover additional 150 KL

water. The efficiency of RO plant will be almost 54% permeate and 46 % reject. Earlier it

was only 50% efficiency. The detail of water consumption is given in Table 8.

TABLE 8

DETAILS OF WATER CONSUMPTION

Particulars Existing Quantity

(KL/Day)

Proposed

Quantity

(KL /Day)

Total Quantity

(Proposed Scenario)

(KL/Day)

i) Domestic 8 +4 12

ii) Industrial

Process

527 (Fresh) +

200 (Reused RO

Permeate)

+90 (Fresh)+ 150

(Reused RO

Permeate)

617 (Fresh)+ 350

(Reused RO

Permeate)

Boiler +

Cooling 90 +70 160

Washing 26 +5 31

Gardening 14 +16 30

Total

665 (Fresh) + 200

(Reused RO

Permeate

185 (Fresh) + 150

(Reused RO

Permeate)

850 (Fresh) + 350

(Reused RO

Permeate)

3.9.5 Manpower

The manpower required for the project as well as during the construction/ commissioning

activities will be employed from the local area. The details are provided in Table 9.

TABLE 9

DETAILS OF MAN POWER REQUIREMENT

Sr.

No.

Category Existing

Manpower

Proposed additional

Manpower

Total Manpower

1. Managerial 28 2 30

2. Technical 79 16 95

3. Administrative 17 2 19

4. Skilled workers 15 2 17

5. Unskilled

workers

68 10 78

Total: 207 32 239

3.9.4 Water



3.10 Mitigation Measures & EMP

Based on overall manufacturing & operation activities, the mitigation measures have been

proposed by the company for the control of the anticipated pollution load.

3.10.1 Wastewater Management

3.10.1.1 Wastewater Generation

The category-wise bifurcation of the anticipated wastewater generation details is given in the

below Table.10. The unit will be segregating its effluent in to high COD (Bio stream) and

low COD stream. The high COD stream will be treated to required norms and discharge in to

GIDC drainage line. The low COD stream along with sewage, cooling tower blow down and

boiler blow down will be treated separately and subjected to RO. The permeate will be

recycled back in process and reject will be discharged. Total Waste water generation will be

1100 KL/Day. It will be sent to RO Plant and Bio stream. 350 KL/ Day permeate water will

be recovered and reuse in process. Rejected from RO 300 KL/ Day, Recycle Stream 100

KL/Day and Bio stream 350 KL/Day will be sent to the NCTL after treatment for final

disposal. When we have received permission of NCTL for wastewater generation, the

quantity of wastewater generation is 750 KL/day otherwise we will be send wastewater

generation quantity (600 KL/day) to NCTL. In future we will plan to 70-80 % efficiency of

RO plant.

The detailed water balance diagram is provided in Figure 3A and 3 B.

TABLE 10

DETAILS OF WASTEWATER GENERATION

Particulars Existing

Quantity

(KL/Day)

Proposed

Quantity

(KL /Day)

Total Quantity

(Proposed

scenario)

(KL /Day)

i) Domestic

a) Domestic 8 +4 12

ii) Industrial

a) Process (Including Recycle

water) 723 +234 957

b) Boiler + Cooling Tower 45 +58 103

c) Washing 24 +4 28

d) Gardening 0 0 0

Total 800 +300 1100

Recovered by RO plant 200 +150 350

Actual Discharge 600 +150 750



FIGURE -3A

WATER BALANCE DIAGRAM (EXISTING)

Gardening

(14 KL)

Process:

(Fresh: 527 KL + RO Permeate:

200.0* KL)

Boiler + Cooling Tower

(Fresh: 90 KL)

Domestic

(8 KL)

General Washing

(26 KL)

Low COD effluent

to recycle stream

(523 KL)

Blow down

(45 KL)

Sewage-

soak pit

(8 KL)

From

Washing

(24 KL)

Effluent Treatment Plant (800 KL/D)

(Bio Stream: 200 KL/D +

Recycle Stream: 600 KL/D)

High COD

Effluent to

Biostream

(200 KL)

Evaporation

Loss

(20 KL)

RO Plant (400KL)

RO Reject

(200 KL)

Waste Water Tank

(200 +200+ 200) = 600 KL

Final Discharge to NCTL

(600 KL/D)

GIDC Water Consumption (665.0 KL/D)

Bio Stream

(200 KL)

RO Permeate

(200.0* KL)

Reuse in

Process

Evaporation

Loss

(2 KL)

Evaporation

Loss

(4 KL)

Steam Water (25)*

(Recycle)

Recycle Stream (600 KL

From Bio

Stream

(200 KL)

From

Recycle

Stream

(200 KL)



FIGURE -3B

WATER BALANCE DIAGRAM (PROPOSED)

Process:

(Fresh: 617 KL + RO Permeate:

350.0* KL)

Boiler + Cooling Tower

(Fresh: 160 KL)

Domestic

(12 KL)

General Washing

(31 KL)

Gardening

(30 KL)

Low COD/TDS

effluent to recycle

stream (607 KL)

Blow down

(103 KL)

Sewage-

soak pit

(12 KL)

From

Washing

(28 KL)

Effluent Treatment Plant (1100 KL/D)

(Bio Stream: 350 KL/D +

Recycle Stream: 750 KL/D)

High COD/TDS

Effluent to

Biostream

(350 KL)

Evaporation

Loss

(30 KL)

RO Plant (650 KL)

RO Reject

(300 KL)

Waste Water Tank

(350 + 100 + 300) = 750 KL

Final Discharge to NCTL

(750 KL/D)

GIDC Water Consumption (Existing: 665.0 KL/D

+ Proposed: 185 KL/D)

Bio Stream (350

KL)

RO Permeate

(350.0* KL)

Reuse in Process

Evaporation

Loss

(3 KL)

Evaporation

Loss

(10 KL)

Steam Water (27)*

(Recycle)

Recycle Stream (750 KL)

From Bio

Stream

(350 KL)

From

Recycle

Stream

(100 KL)



3.10.1.2 Wastewater Characteristics

Industrial wastewater will be generated from process, cooling tower and boiler. The expected

characteristics of industrial wastewater are provided in Table 11.

TABLE 11

CHARACTERISTICS OF WASTEWATER

Sr.

No.

Parameter Unit Recycle

Stream

Bio Stream Final Treated

Effluent

1 pH -- 3.20 – 12.04 3.00 – 13.13 6.88 – 7.88

2 COD Ppm 818 10049 98

3 Total Dissolved Solids Ppm 7174 16126 1978

4 Suspended Solids Ppm 121 308 69

5 Ammonical Nitrogen Ppm 9.20 134.31 8.2

3.10.1.3 Wastewater Treatment & Disposal

BRIEF DESCRIPTION OF THE EFFLUENT TREATMENT PLANT

• MODE OF COLLECTION Mainly two types of effluent streams are generated in this scheme. One of recycle stream for

recycle through biological, UF and RO system and another Biostream are for treatment through

anaerobic & biological system.

Recycle stream contain low COD generated within the manufacturing plant will be conveyed to

the effluent treatment plant after due neutralization and collection in the separate equalization

tank, equalization tank is designed for 1400 m3 / day.

Bio stream contain high COD generated within the manufacturing plant will be conveyed to the

effluent treatment plant after due neutralization and collection in the separate equalization tank,

equalization tank is designed for 450 m3 / day.

A. Effluent Collection Tank (200 m3):

The Recycle stream effluent from the production units comes to the tank through by gravity and

domestic sewage comes to the tank through pump. It follows the treatment mentioned below.

B. Neutralisation Tank: Pump the effluent from the common collection sump to neutralization tank. Effluent is mixed up

with 5% caustic lye solution to make pH 7-8. For this operation we are having dedicated one

caustic lye dosing tank.

C. Equalization Tank (1400 m3):

We are having one Equalization tank of having total capacity of 1400 m3. Equalisation tank is

equipped with perforated pipe grid to supply air to mix the contents of equalization. Then transfer

to mixing tank.



D. Mixing Tank (20 m3):

The effluent coming from the Equalization is mixed up with 2% of lime solution to adjust pH.

Here, ferric chloride is added for floc generation. For this operation we are having dedicated one

lime dosing tank and one ferric chloride dosing tank.

E. High Rated Solid Contact Clarifier (HRSCC) (100 m3):

Neutral effluent with suspended particles comes here by gravity from mixing tank. Here,

polyelectrolyte is added approximately 2-4 ppm in concentration. Hence, suspended particles are

settled down. The clean supernatant effluent is transferred to aeration Tank and settled sludge is

transferred to sludge pit for further treatment.

F. Aeration Tank (850 m3):

The neutral effluent is comes to the aeration tank for bio degradation, which is, equipped with

imported silicone membranes for diffused aeration. The capacity of tank is 850 m3. One air

blower is operating on continuously and another one for standby.

G. Lamella Clarifier : The mixed liquor from aeration tank comes to this system by gravity. Here, biodegradable

polyelectrolyte is added, so the active sludge is settled down and recycled to aeration tank. The

supernatant effluent is transferred to clarifier water tank for further treatment in UF and RO plant.

Here, sodium hypo chlorite is added in supernatant for antibacterial treatment.

H. Clarifier Water Tank (40 m3):

The supernatant from secondary clarifier comes to clarifier water tank by gravity for further

treatment. Then water transfer through multi grade filter (MGF) and activated carbon filter to

Ultra filtration (UF) plant by pump.

I. Ultra Filtration (UF) (34 m3/Hrs):

After passing through ACF, effluent feed into UF via cartridge filter for ultra filtration which is

set in auto system. UF permeate water taken in UF permeate tank for treatment of RO plant.

J. Reverse Osmosis Plant (807 m3/Day) :

After treatment of UF plant, UF permeate water feeding in RO plant. RO Permeate water taken in

RO permeate tank through degasser tower. Permeate water reusing for Process/Boiler/Cooling

Tower. RO Reject water transfer to final collection sump.

K. Final Collection Sump (50 m3):

The effluent coming from the RO plant, after blending with MBR permeate water and then

discharge to the GIDC drainage system for further treatment to NCTL through final outlet tank.

L. Effluent Collection Tank (450 m3):

The Bio stream effluents from the production units comes to the tank through pumps and

Decantor washing effluent comes to the tank through pump. Equalisation tank is equipped with

perforated pipe grid to supply air to mix the contents of equalization. Then transfer to mixing

tank. It follows the treatment mentioned below.

M. Mixing Tank (10 m3):

The effluent coming from the Equalization is mixed up with 2% of lime solution to adjust pH.

Here, poly alluminium chloride is added for floc generation. For this operation we are having

dedicated one lime dosing tank and one poly alluminium chloride dosing tank.



N. High Rated Solid Contact Clarifier (HRSCC) (45 m3):

Neutral effluent with suspended particles comes here by gravity from mixing tank. Here,

polyelectrolyte is added approximately 8-10 ppm in concentration. Hence, suspended particles are

settled down. The clean supernatant effluent is transferred to recirculation tank and settled sludge

is transferred to sludge pit for further treatment.

O. Recirculation Tank (30 m3) :

The supernatant from HRSCC comes to recirculation tank by gravity for further treatment. Here,

nutrients are added for bacteria growth and sodium carbonate is added for maintain alkalinity. The

effluent is transferred to UASB reactor.

P. Up flow Anaerobic Sludge Blanket Reactor (UASB) (1100 m3) :

Effluent from the recirculation tank is pumped to the two numbers of division boxes placed at the

platform above the UASB reactor. Effluent is then further distributed to the ten numbers of inlet

boxes from where by gravity effluent is fed to the UASB reactor with the help of 20 Nos HDPE

pipes connected on each inlet box. Treated effluent is collected through two FRP launders and

falls in to the common RCC launder. From this launder, one part of the UASB treated effluent is

recycled back to the UASB through the UASB buffer tank, while other part is clarified in a

lamella clarifier. Flow equal to the HRSCC outlet shall be sent to the lamella clarifier the other

part has to be recycled back to UASB tank. The settled sludge, in normal operation is disposed off

through centrifuge after Mixing with other sludge. Biogas is flared off through a biogas flare

system installed at site and excess biomass has to be disposed above a certain level of MLSS in

the reactor.

Q. Lamella Clarifier:

The treated effluent from UASB comes to lamella clarifier by gravity for further treatment. The

clean supernatant effluent is transferred to pre aeration tank and settled sludge is transferred to

sludge pit for further treatment.

R. Pre Aeration Tank (30 m3) :

Clarified effluent from lamella clarifier is collected by gravity in to the Pre-aeration tank

from where it is pumped to the aeration tank for its further treatment.

S. First Aeration Tank (366 m3):

The neutral effluent is comes from pre aeration to the aeration tank for bio degradation, which is,

equipped with imported silicone membranes for diffused aeration. The capacity of tank is 366 m3.

One air blower is operating on continuously and another one for standby.

T. Second Aeration Tank (315 m3):

The effluent is comes from first bio aeration to the second aeration tank for bio degradation,

which is, equipped with imported silicone membranes for diffused aeration. The capacity of tank

is 366 m3. One air blower is operating on continuously and another one for standby.

U. Membrane Bio Reactor (117 m3):

The mixed liquor from aeration tank comes to this system by gravity. Always keep the flow at

higher than the permeate flow so that the effluent is always in a circulation mode. MBR tank

blower will always be in continuously operation. One air blower is operating on continuously and

another one for standby. MBR permeate water taken in MBR permeate tank for further treatment.

The effluent coming from the MBR permeate water, after blending with RO plant effluent and

then discharge to the GIDC drainage system



Highly Acidic effluent of the plant is neutralized with 10% of lime solution in separate

neutralizer reactor. After neutralization of effluent, drain to decanter feed tank. Here,

other tanks drain sludge is mixed with these neutral effluents.

V. Decanter:

The slurry of decanter feed tank is pumped into the decanter for dewatering. Here,

polyelectrolyte is added approximately 8-10 ppm in concentration. The clean supernatant effluent

is transferred to bio effluent collection tank for further treatment and separated sludge is

transferred to sludge storage area and finally sent to cement industries for recycle purpose.

Decanter will always be in continuously operation. One decanter is operating on continuously and

another one for standby.

DIMENTIONAL DETAILS OF ETP UNITS

Sr.

No.

Tank Name Unit Bio Stream Recycle

Stream

1 Effluent Collection Tank 01 NA 200 m3

2 Equalization Tank 02 450 m3 1400 m

3

3 Mixing tank 02 10 m3 20 m

3

4 HRSCC Tank 02 45 m3 100 m

3

5 Aeration Tank

03

First - 315 m3

Second – 366 m3

850 m3

6 Clarifier water tank 01 NA 40 m3

7 Recirculation tank (PCO) 01 30 m3 NA

8 UASB 01 1100 m3 NA

9 Pre Aeration Tank 01 30 m3 NA

10 MBR 01 10 m3/hr NA

11 MBR Permeate Tank 01 87 m3 NA

12 MGF 02 NA 34 m3/hr

(02 nos.)

13 ACF 01 NA 34 m3/hr

14 UF Plant 01 NA 34 m3/hr

15 UF Permeate tank 01 NA 100 m3

16 RO Plant 01 NA 807 m3/Day

17 RO Permeate Tank 01 NA 100 m3

18 Final Collection Sump 02 50 m3 50 m

3

19 Sludge Pit for HRSCC 01 10 m3 Common

20 Final Outlet Tank 01 Common 50 m3

21 MBR (117 m3) 01 20 m

3/hr NA

22 Lime preparation Reactor 02 10 m3 10 m

3

23 Neutralizer Reactor 02 10 m3 10 m

3



FLOW DIAGRAM OF ETP FACILITY

FLOW DIAGRAM OF ETP ANIONIC - ACIDIC STREAM

POLYELECTROLYTE

LIME ADD

SLUDGE

FROM MBR & BOTH HRSCC’s& Secondary clarifier

SLUDGE

EFFLUENT TREATMENT VIA

ANIONIC (BIO STREAM)

ACID

NEUTRALIZATI

ON

DECANTO

R FEED

TANK

ANIONIC

EFFLUENT

(ACIDIC

STREAM)

DECENTOR

CENTRIFUGE

SLUDGE

COLLECTION

TANK LIME SLURRY TANK

PRIMARY

TREATMENT

SLUDGE STORAGE

AREA

EQUALIZATION

TANK (450KL)



FLOW DIAGRAM OF ETP CATIONIC - RECYCLE STREAM

FeCL3, LIME poly electrolyte

POLYELECTROLYTE, HYPO

RO PERMEATE

RO ROJECT

CATIONIC

EFFLUENT

(RECYCLE

STREAM)

EQUALI

ZATION

TANK

(1400KL)

MIXING

TANK

HRSCC

MULTI

GRADE

FILTER

LAMELLA

CLARIFIER AERATION TANK

(850 KL)

ULTRA

FILTRATION

PLANT

REVERSE

OSMOSIS

PLANT

ACTIVETED

CARBON FILTER

EFFLUENT

COLLECTIO

N TANK

FINAL

COLLECTION

SUMP

OXIDATION

SUMP

CARBON

FILTER

TREATED

EFFLUENT

OUTLET

TANK

GIDC

DRAIN

PERMEATE FOR

REUSE



FLOW DIAGRAM OF ETP ANIONIC - BIO STREAM

POLYELECTROLYTE

PAC, LIME

HRSCC TANK

DAP, Na2CO3

CULTURE ADDED

RECIRCULATION

TANK

PRE-AERATION TANK

DAP, CULTURE

DAP, CULTURE

GIDC DRAIN

ANIONIC

EFFLUENT

(BIO STREAM)

UASB TANK

MEMBRANE

BIO REACTOR

FINAL

COLLE

CTION

SUMP

LAMELLA CLARIFIER

OXIDATION

TANK

COLLECTION /

EQUALIZATIO

TANK (450 KL)

Second

AERATION

TANK

TREATED

EFFLUENT

OUTLET TANK

FOR

DISCHARGE

MIXING

TANK (BIO

STREAM)

First

AERATION

TANK



3.10.2 Gaseous emissions & control

There will be flue gas emission from five boilers and Two DG sets. Natural gas is regular fuel

and LDO as alternate fuel will be used as in boilers and diesel will be used as fuel in DG set.

The air pollution control measures are covered in below table 13.

TABLE 13

DETAILS OF FLUE GAS EMISSIONS

Sr.

No.

Stack

Attach

to

Stack

Height in

Meter

Diameter

in meter

Parameter Permissible Limit

As per Consent No. AWH· 56490

1. Boiler

(I to IV)

30 0.45 Particulate Matter

SO2

NOx

150 Mg/Nm3

100 ppm

50 ppm 2. Boiler

(V)

30 0.45

3. D.G Set

(2 Nos.)

09 (Each)

0.1 Particulate Matter

SO2

NOx

150 Mg/Nm3

100 ppm

50 ppm

As per proposed expansion

1 There will be no change in Flue gas emission due to Proposed Scenario.

The process emissions from the proposed manufacturing activities are given in Table 14.

TABLE 14

DETAILS OF PROCESS EMISSION

Sr.

No.

Stack

Attached

to

Stack

Height

in meter

Stack

Diameter in

meter

APCM Parameter Permissible

Limit

As per Consent No. AWH· 56490

1. HCl

Process

Scrubber

27 0.1 Water

Scrubber

followed by

Alkali

scrubber

HCl

Cl2

20 Mg/Nm3

09 Mg/Nm3

2. SO2

Process

Scrubber

20 0.1 Caustic

Scrubber

SO2 40 Mg/Nm3

As per proposed expansion

There will be no additional new process stacks due to proposed expansion.

3.10.2.1 Flue gas emissions

3.10.2.2 Process emissions



3.10.3 Hazardous/ Non-hazardous waste management

The following type of hazardous waste will be generated from the operational activities. All

the waste will be stored separately in a designated storage area.

TABLE 15

DETAILS OF HAZARDOUS WASTE

Sr.

No.

Name of

waste

Cat.

No.

Quantity Method of

disposal As per

consent No.

AWH·

56490

As per

proposed

expansion

Total

1. Used Oil 5.1 100

Lit/Month

200

Lit/Month

300

Lit/Month

Collection,

Storage, Sold to

MoEF Approved

Vendors.

2. Discarded

Barrels

33.3 100

Nos./Month

500

Nos./Month

600

Nos./Month

Collection,

Storage, Sold to

GPCB approved

vendors after

decontamination

& other items will

be disposed to

TSDF-BEIL,

Ankleshwar.

Liners 2000

Kg/Month

3000

Kg/Month

5000

Kg/Month

Insulation

Waste

65

Kg/Month

85

Kg/Month

150

Kg/Month

Personal

Protective

Equipment’s

250

Kg/Month

450

Kg/Month

700

Kg/Month

Broken

Glassware

20

Kg/Month

40

Kg/Month

60

Kg/Month



3. Chemical

Gypsum &

Bio-Mass

from Waste

Water

Treatment

34.3 655

MT/Month

0 655

MT/Month

Gypsum Will Be

Sold to Cement

Industry, M/s.

Gujarat, Ambuja

Cement,

Kodinar, Gujarat

& M/s. Ultratech

Ltd (A Unit Of

Gujarat Cement

Works), Kovaya,

Rajulacity, Amreli

& Bio-Mass Will

Be Disposed to

BEIL,

Ankleshwar.

4. Spent

Resin/Fines

Resin From

Ion

Exchange

Type

Material

Used For

Water

Purification

(Non-Toxic

& Non-

Hazardous)

34.2 50

MT/Month

0 50

MT/Month

Disposed to BEIL

- Ankleshwar.

5. Spent

Carbon 35.3 10

MT/Month

0 10

MT/Month

Disposed to BEIL-

Ankleshwar.

6. Wet

Scrubber

Residue

36.1 10

Kg/Month

0 10

Kg/Month

Send to ETP for

further treatment.

7. Spent Acid

(H2SO4) D2 350

M3/Month

250

M3/Month

600

M3/Month

Sold to actual end

users.

8. Distilled

Solvent 36.1 --- 5 MT/Month 5 MT/Month Sold to actual end

users.



3.10.4 Noise Control & Odour

Ear plugs will be provided to the operating personnel in boiler room. Low noise generating

equipments will be selected. Adequate engineering controls will be implemented to avoid

noise pollution.

The following steps will be taken for odour control.

• Raw-material feeding will be carried out by pumps and in close loop system.

• All reactions will be taken in closed reactor system.

• Roof top ventilation will be provided in the entire plant area.

• Regular monitoring will be done of piping and fittings for checking of any leakages.

3.10.5 Storage, Handling and Transport of Hazardous Chemicals

The storage and mode of transport of chemicals will be done as per detailed MSDS and

chemical hazards guide (NIOSH) for the hazardous chemicals.

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per

the Schedule-1 of the MSIHC Rules, as amended in 2000.

3.10.6 Health and Safety measures

Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per

the Schedule-1 of the MSIHC Rules, as amended in 2000.

Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of

large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of

MSIHC Rules.

Below mentioned is the summary proposed safety measures to be taken at site for control of

anticipated hazards.

Storage Hazards & Control Measures:

Main products are Anion and Cation resins. They are in granules form and packed in bags of

25 kg and higher size. They are stored in fully ventilated store age locations. Spillage of the

product may lead to slippery hazard and dusty atmosphere. People in the storage location

may get exposed to dust hazards. Leakage of these granules has no effect on health. Fire in

such go down can generate toxic fumes of the chemicals. Products flow along with firewater

and flowing outside the go down and spreading in surrounding can also cause toxic effect. In

case of fire, effluent generated from fire fighting operation is required to be collected, treated



and disposed off in environmental friendly manner. Therefore, precautions regarding

prevention of fire and leakage of such chemicals are most necessary. Fire detectors in product

go down will be useful in this regard. Similarly, for raw material go down, Hazardous RM is

being stored. These chemicals are hazardous, toxic and having fire hazards. Necessary

precautions signage should be displayed. Material handling signage should be displayed.

The bulk storage areas are separated from main plant and transfer is thro pipe line which is a

safe handling. The storage tanks have dyke wall to take care in case of emergency. Looking

to the flammable and toxic property of certain raw material like methanol, Di-Methyl Amino

Ethanol, Iso-Butyl Alcohol, MYL (Di Methoxy Methane), Methacrylic Acid, Methacrylate

and many such chemicals, it is flame proof electrical fitting uniformly in the entire storage

sheds and provided proper ventilation to prevent accumulation of flammable vapors.

Installation of continuous LEL detector with hooter / alarm is also very much advisable.

The above ground storage tanks area and underground tank area pose high fire hazards. The

area need to be ensured cordoned off as per the drawing approved by PESO- Nagpur.

Necessary fire protection measures need to be ensured for the area viz keeping the fire

hydrant posts approachable, avoiding waste accumulation in the area. Heat / fire detectors

will help to detect fire and control it in time.

Process, hazards and controls:

Manufacturing process includes use of raw materials like styrene, DVB , H2SO4, Oleum,

EDC, Dilute H2SO4, DMA, TMA, DMEA, HCl, MYL, CSA, MF, Methanol, many other

flammable, toxic as well as reactive chemicals. Their reactions with other chemicals generate

toxic fumes and gases. These are toxic hazards. Necessary controls are provided on reaction

vessels viz suction of fumes with blower and scrubbing the fumes. Reaction controls are from

DCS. Most of the reactions are carried out at atmospheric pressure and required temperature.

Addition / transfer of solvent / chemicals in the Process vessel is run by trained people and

use of special PPEs. SOP’s is available and updated from time to time. Many operations

generate dust hazards where we provide dust control measures as necessary. Dilution

ventilation or Local exhaust ventilation are provided.



Other Hazards:

Loading and unloading of materials, use of acids and alkalis, methanol handling and use of

flammable chemicals, working with hazardous processes, working near D.G. Sets, pumps and

motors, transmission machinery etc. and use of utilities contribute variety of hazards like

toxic effect, fire, dust exposures, high noise, hot surfaces, rotating part of the machines etc.

Necessary control measures depending on the type of hazards are provided. Their proper

maintenance and safe working methods are provided. The area is kept neat and clean and

housekeeping is maintained, unobstructed, No damaged floor and covered plant channels to

avoid primary hazards.

4.0 SITE ANALYSIS

4.1 Connectivity

The site is located at Plot no. 5811-12-13, GIDC Estate, Ankleshwar, Gujarat. The land and

Infrastructure is already available and the raw materials are easily available through the easy

transport via road connectivity.

Ankleshwar Industrial Estate was set up by Gujarat Industrial Development Corporation in

early 70s. This industrial estate is spread over an area of 1600 hectares in close proximity to

National Highway No.8 and Delhi-Mumbai Railway Line. Being an ideal location for

industrialization, as on date, more than 1500 industries, consisting of chemicals, pesticides,

pharmaceuticals, bulk drugs, petroleum products, engineering, textiles, plastics, rubber and

packaging etc. are located in this industrial estate.

The town is known for its industrial township called GIDC (Gujarat Industrial Development

Corporation). Ankleshwar has an office of the ONGC (Oil and Natural Gas Corporation

Limited). GIDC is organizing Trade fare and Industrial expo occasionally to attract large

number of industries all over from India. It also helps to get customer on large basis.

Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by

the Western Railway Division of Indian Railways. The railway division also runs the broad

gauge train services to Rajpipla. The 133 year-old Golden Bridge connects Ankleshwar to

Bharuch across the Narmada on the station front while a new bridge connects the highway,

the other bridge on the highway is now ready to use.

Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western

section).



Development project of Ankleshwar Airport & City Bus are in pipe line in last stage.

Ankleshwar is an educated city. It has an average literacy rate of 79%, higher than the

national average of 59.5%; with 56% of the males and 44% of females literate.

Ankleshwar JN Rail Way Station, Sanjali Railway Station are the very nearby railway station

to Ankleshwar GIDC. However Surat Railway Station is major railway station 56 KM near to

Ankleshwar GIDC.

Healthcare

Hospitals include are the

• Jayaben Modi Hospital,

• Sarvajanik Hospital,

• Sanjivani Hospital

• Sardar Patel Hospital.

• And now ESIC's (Employee State Insurance Corporation) New Hospital is under

Construction.

• In April 2014, the "New Life" private hospital was constructed in Jasaat Plaza

(Station Road). It is conveniently served by Ankleshwar's main bus & railway

stations.

Shopping and Recreation:

• There is a lake in GIDC & City area. Situated in front of GIDC Lake, Lakeview Plaza

Mall is city's first truly integrated mall for restaurants, entertainment and hotel stay.

• Nav Graha Jain Mandir (G.I.D.C), Manav Mandir, Sai & Swaminarayan Temple are

big temples in Ankleshwar. Ankleshwar City is also having big Mosques Halimsha

Datar Bhandari, Garib nawaz, etc.

• Centers of Brahma Kumaris World Spiritual University is located in both GIDC and

City area which helps you to Know your true self with the help of Free Rajyoga

Meditation Classes.

• There are parks such as The Millennium Park and old parks in Ankleshwar city, the

GIDC Water Reservoir, and sports center.

• There are swimming pools, Joggers park, children's park, Rotary library and other

recreation centers in the GIDC area.



• There is an Open Air Theater in GIDC Area. Chauta Bazar is the biggest shopping

area in Ankleshwar.

4.2 Land use and land ownership

The proposed project site is located at plot no 5811-12-13, GIDC Estate, Ankleshwar,

Gujarat. The total plot area of the unit is 46977 Sq. M. The project is located at private land.

Land ownership is with project proponents. They have valid consent from Gujarat Pollution

Control Board, Gandhinagar. And the consent no. is AWH: 56490 and it is attached as an

Annexure-X.

4.3 Existing Land use

The proposed project site is located at plot no 5811-12-13, GIDC Estate, Ankleshwar, The

plot is notified by GIDC for industrial purpose.

4.4 Existing Infrastructure

The project is located in a well-developed zone, which have all essential facilities such as

well-connected road network with ease of transportation, arrangement for supply of water

and power to industries, effluent disposal facilities etc.

4.5 Soil Classification

The soils of the district are derived from the Deccan trap which is main rock formation of the

district. The soil of the district can be classified as light, medium and heavy according to

depth, texture and location. There is sandy loam to loamy in texture, brownish black in color.

4.6 Climate data

Vadodara is the nearest meteorological observatory station to the project site. The various

meteorological details of Vadodara station for the year of March, 2015 to May, 2015 are

given in below Table 16.

TABLE 16

DETAILS OF MICRO METEOROLOGICAL DATA

Month Temperature(oC) Humidity (%) Rain fall (mm)

Maximum Minimum Maximum Minimum Maximum Minimum

March-15 41 17 57 32 012.1 00

April-15 41.4 22.4 67 30 006.9 00

May-15 42.7 27.0 75 29 0.0 00

(Data from Indian Meteorological Department, Baroda)

Based on the above metrological data, wind rose has been prepared for the summer season

period from March 2015 to May 2015. As per the metrological data, it shows that the

average wind speed in March, April, and May 2015 is 2.76 m/s with wind direction blowing

to NE.



The wind rose prepared from same data is shown at Figure 8.

FIGURE 8

WIND ROSE DIAGARM FOR PERIOD (MARCH TO MAY, 2015)

4.7 Social Infra structure

Population density and sex ratio of Bharuch District was reported 238 persons/sq.km. and

920 females per 1000 males respectively in 2011 census report. Total literacy of Bharuch

District was found 81.51 %.The basic amenities like primary and secondary education

schools, community health workers, primary health sub centre, private practitioners, primary

health centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre,

hospital, drinking water, transportation facilities, electricity , telephone etc. are available.

5.0 PLANNING BRIEF

5.1 Planning concept

Ankleshwar is largely an industrial area dominated by large scale industries, especially

chemical plants.

Now the unit has proposed to manufacture Anion resins and Cation resins.



Ankleshwar in Gujarat has an industrial area with common effluent treatment plant, common

incinerator and land fill site. Govt. agencies provide many basic facilities like uninterrupted

water supply, power and road network.

5.2 Population projection

As per provisional reports of Census India, Population of Bharuch District in 2011 is

1,551,019. Population of male and female are 805,707 and 713,676 respectively. The sex

ratio of Bharuch city is 920 females per 1000 males.

In education section, total literates in Vadodara District are 2,893,080 of which 1,614,087 are

males while 1,278,993 are females. Average literacy rate of Vadodara district is 78.92%.

5.3 Land use planning

The proposed project is on a GIDC land.

5.4 Assessment of Infrastructure Demand

The M/s. Ion Exchange (India) Ltd. shall get water from GIDC water supply scheme. So

there will be no additional stress on ground water resources and there will be no adverse

effect on the ground water resources available in the nearby area.

The unit has proposed 700 KVA connected load form DGVCL. The transportation facilities

will also expect to improve due to increase in the movement of workers and raw material and

finished products.

5.5 Amenities/Facilities

The available basic amenities are as under:

(A) Education Facilities:

All the villages have a minimum of one primary school.

(B) Medical Facilities:

All the surrounding villages have medical facilities.

(C) Drinking water Facilities & Power Supply:

All the villages have potable water supply and in 100% area the drinking water is

supplied through taps, wells and tube wells. All the villages have power supply

facilities in the study region.



(D) Post, Telegraph & Telephone facilities

The information collected clearly indicates that the infrastructural facilities are

provided by respective government agencies for the development of this area. For

communication purpose, post office and phones are available in most of the villages.

(E) Transport Facilities:

Bus services are available in all the villages of the study region within 5 km area and

are the most preferable mode of transport in the region. Auto-rickshaw is also used as

transport facility. Villages are connected with paved roads. All the surrounding area is

covered with 108 emergency facilities.

6.0 PROPOSED INFRASTRUCTURE

6.1 Processing Area

The process area will cover plant area, raw material storage area, hazardous waste storage

area, ETP and utilities. The process area covered by the unit at ground level will be 21009

sq.m.

6.2 Non Processing Area

The non process area will cover Admin Building, and security cabin. The non process area

covered by unit at ground level will be 3744 sq. m.

6.3 Green Belt Area

The existing green belt area is 8937 sq. m. and the proposed green belt area is 8937 sq. m.

6.4 Social Infrastructure

The availability of basic amenities is covered as under:

(A) Training & Education: All the employees will be trained and educated periodically

about the hazardous nature of chemicals used in the process. Also, training for

firefighting, work permit system, first aid, safe handling of hazardous chemicals and

integrating safety, in all activities.

(B) Medical facility: Pre-employment medical checkup at the time of employment. In order

to safe guard the health of the employees, all the employees undergo periodic health

checkup.

(C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to

provide purified water for drinking purpose.



(D) Transportation: The unit will provide basic transportation facility for workers.

(E) Telegraph & Post: There will be provision of telephone, fax & internet facility.

(F) Power supply: There will be total connected load of 1600 KVA from DGVCL.

6.5 Connectivity

Ankleshwar estate is well connected by rail and road to rest of country.

6.6 Drinking water Management

Average daily water consumption of unit will be 8 KL/Day for domestic purpose. The entire

water requirement will be meeting through GIDC water supply system.

6.7 Sewage system

The sewage will be treated in soak pit.

6.8 Industrial waste management

The hazardous waste like Used Oil, Discarded Barrels, Liners, Insulation Waste and

Chemical Gypsum & Bio-Mass from Waste Water Treatment, Spent Resin/Fines Resin,

Spent Carbon, Wet Scrubber Residue and Spent Acid (H2SO4) will be generated from the

proposed activity. The hazardous waste management and disposal is shown in Annexure-IX.

6.9 Solid waste management

The record of hazardous and non Hazardous waste solid waste like Personal Protective

Equipments and Broken Glassware etc. will be mentioned.

6.10 Power requirement & supply

The unit will use total 1600 KVA electricity connected load from DGVCL. And 684 HP D.G.

sets will be provided.

7.0 Rehabilitation and Resettlement(R &R) Plan

The proposed project is located in Plot No: 5811·12·13, GIDC Estate, Ankleshwar, Dist-

Bharuch, Gujarat-393002. There will be no any human settlement affected by proposed

project.

8.0 Project Schedule & cost estimates

8.1 Project implementation Schedule



TABLE: 17

PROJECT IMPLEMENTATION SCHEDULE

Project implementation schedule after getting NOC from GPCB

Sr.

No.

Activity Required Period

1. Civil work Immediately after getting NOC

2. Procurement of

machinery

1 month after getting NOC

3. Eraction & installation

of machinery

Immediately after competition of activity no.2

4. Trial of machinery &

equipment

Within 1 months after competition of activity no.3

5. Commercial activity 1 months after competition of activity no.4

8.2 Estimated project cost

Total project cost is Rs. 25 Crores for this proposed project.

9.0 Analysis of proposal

All the manpower is utilized from local region around Ankleshwar. Company shall also try to

provide indirect employment opportunities by availing local contract services during

transportation during operational phase.

The company intends to donate Rupees 47, 83,379 of the profit to agencies like NGOs or

social welfare societies for projects carried out in nearby village for their welfare and

upliftment.

Documents

M/s. ION EXCHANGE (INDIA) LTD., ANKLESHWAR.environmentclearance.nic.in/.../PFR/...feasibilityReport(PFR)File.pdfGypsum will be sold to Cement ... conforming to customer requirements