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M/S. NIRMA LTD.
Revised Form 1 : Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat
MAY, 2018
Kadam Environmental Consultants w w w . k a d a m en v i r o . c o m
Env i ro nme nt for Deve lopme nt
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL
SHEET
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 II
M/S. NIRMA LTD.
Revised Form 1 : Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat © Kadam Environmental Consultants (‘Kadam’), May, 2018
This report is released for the use of the M/s. Nirma Ltd., Regulators and relevant stakeholders solely
as part of the subject project’s Environmental Clearance process. Information provided (unless
attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other
purpose without the written consent of Kadam.
PROJECT DETAILS
Name of
Publication Revised Form 1 requiring Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Kalatalav, Near Bhavnagar, Gujarat.
Project
Number 1730141406 Report No. 1 Version 2 Released May, 2018
Prepared &
Managed By
K.K. Antani, Shweta Rajput,
Bhavin Jambucha, & Nirma Ltd.
Representatives
Released By Sangram Kadam
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-6131000
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,
Gurgaon, Haryana, INDIA - 122002.
E: [email protected]; T:0124-4242430 to 436
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.
Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it
is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any
liability resulting from the use or application of the information contained in this report. The information is not
intended to serve as legal advice related to the individual situation.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 III
CONTENTS
1 SCOPING................................................................................................ 1
ANNEXURES
Annexure 1: General and Specific Location Map .............................................................................. 2
Annexure 2: Project Boundary Map ................................................................................................ 3
Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ....................... 4
Annexure 4: Details of Air Emissions ............................................................................................... 5
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 1
1 SCOPING
The scoping for the project has been done based on REVISED FORM 1, as per EIA Notification, dated
September 14, 2006 amended as on date. The scoping details are as follows:
I. Basic Information
S.
No. Item Details
1 Name of the Project
Expansion in Soda Ash (2800 TPD to 4300 TPD) and Caustic Soda (750
TPD to 1000 TPD) and cogeneration Plant (197.18 MW to 350 MW) at
Existing Facility of Nirma Ltd., Kalatalav, Near Bhavnagar, Gujarat.
2 S. No. in the Schedule
Sector
No. Project or activity Category
4 4(e ) Soda Ash Plant A
4(d) Caustic Soda A
1 1(d), Thermal Power Plants A
3
Proposed capacity / area / length / tonnage
to be handled/ command area / lease area /
no. of wells to be drilled
Sr.
No. Project or activity
Capacity (tpd)
Existing Proposed Total
1. Cogeneration Plant
(Area = 69,100m2)
197.18
MW
152.82
MW 350
Soda Ash Plant (Area = 2,61,548.33 m2; )
1. Light Soda Ash Plant 2800 1500 4300
2. Dense Soda Ash * 1800 600 2400
Dense Soda Ash is conversion of Light Soda Ash
Caustic Soda Plant (Area = 2,88,945.55 m2)
1. Caustic Soda (100%) 750 250 1000
2. Hydrochloric Acid
(100%) 280 220 500
Caustic Soda Plant – By Products
1. Chlorine Gas (100%) 665.2 220.8 886
2. Hydrogen (100%) 18.75 6.25 25
3. Sodium Hypo Chlorite
(100%) 12 3 15
4 New / Expansion / Modernization Expansion
5 Existing Capacity / Area etc. Mentioned in Table vide Sr. No. 3
6 Category of Project (A or B) A
7 Does it attract the general conditions? If
yes, please specify. No
8 Does it attract specific condition? If yes,
please specify No
9 Location General Location is provided in Annexure 1. Site Boundary is shown in
Annexure 2. Toposheet is shown in Annexure 3.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 2
S.
No. Item Details
Plot Survey / Khasra No. Survey No. 478/p, 447 - 453, 455 - 457
Village Kalatalav
Tehsil / Taluka / Mandal Bhavnagar
District Bhavnagar
State Gujarat
10 Nearest railway station / airport / along with
distance in km.
Nearest Railway Station
Bhavnagar Railway Station : ~ 10 km
Nearest Airport
Bhavnagar : ~ 10 km
11 Nearest town, city, district headquarters
along with distances in kms
Nearest Town/City/District Headquarter
Bhavnagar (District Headquarter) : ~ 9.0 km
12
Village Panchayat, Zilla Parishad, Municipal
Corporation, Local Body (complete postal
address with telephone nos. to be given)
Panchayat: Sarpanch, Kalatalav
Zilla Parishad: District Development Office,
District Panchayat, Bhavnagar – 364001
Phone No. 0278-2426810
Municipal Corporation: District Collector Office, Opp. Galaxy Cinema,
Kalanala, Bhavnagar – 364001
Phone no.: 0278 - 2428822
13 Name of the applicant Nirma Ltd.,
14 Registered address
Nirma Ltd.
Nirma House, Ashram Road, Nr. Income Tax office, Ahmedabad -
380009
15
Address for correspondence Same as Above
Name Mr. Ashish Desai
Designation Vice President (Project)
Address Nirma Ltd.
Nirma House, Ashram Road, Nr. Income Tax office, Ahmedabad
Pin Code 380009
E-mail [email protected]
Telephone no.
Fax No.
Ph: +91-79-27549319+91-79-27546603 / 05
Mobile No. +91-9825320090
16
Details of alternative sites examined, if any.
Location of these sites should be shown on
the Toposheet.
Not analyzed, since this expansion is on an existing site, with all requisite
facilities and infrastructure available.
17 Interlinked Projects No
18 Whether separate application of interlinked
project has been submitted? No
19 If yes, date of submission No
20 If no, reason NA
21
Whether the proposal involves approval /
clearance under: if yes, details of the same
and their status to be given:
CRZ Notification: Yes, applicable for seawater intake; Effluent disposal
outfall along with return cooling water pipeline and bittern disposal
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 3
S.
No. Item Details
The Forest (Conservation) Act, 1980
The Wildlife (Protection) Act, 1972
The C.R.Z Notification, 1991
22 Whether there is any Government order /
policy, relevant / relating to the site No
23 Forest land involved (ha.) No
24
Whether there is any litigation pending
against the project and / or land in which
the project is proposed to be set up?
Name of the Court Case No.
Order / directions of the Court, if any and
its relevance with the proposed project
No
25 Project Cost (in Lacs) Rs. 132000 lacs
II Activity
1. Construction, operation or decommissioning of the project involving actions,
which will cause physical changes in the locality (topography, land use, changes in
water bodies, etc.)
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with
source of information data
1.1
Permanent or temporary change in
land use, land cover or topography
including increase in intensity of
land use (with respect to local land
use plan)
No No, there is no permanent or temporary change in land. The proposed expansion is within
the existing premises, which will remain same.
1.2 Clearance of existing land,
vegetation and buildings? No
Land is already in use and as this is expansion project. Hence, clearance of existing land,
vegetation and buildings is not required.
1.3 Creation of new land uses? No No additional creation of new land usage as existing plant is already under industrial
usage.
1.4 Pre-construction investigations e.g.
bore houses, soil testing? No Not required.
1.5 Construction works? Yes As part of the Industrial Project, there will be construction of plant machinery, utilities, etc
within the existing facility.
1.6 Demolition works? No Existing facilities for cogeneration thermal power plant; Soda Ash Plant & Caustic soda
plant will be expanded with proposed new facilities.
1.7
Temporary sites used for
construction works or housing of
construction workers?
No
Most of the construction workers will be hired locally as far as possible. Sufficient
accommodation is available at workers colony, hence requirement of additional housing is
not envisaged.
1.8
Above ground buildings, structures
or earthworks including linear
structures, cut and fill or
excavations
Yes
Sr.
No.
Hazardous
Waste Category
Quantity (MTPA) Mode of
Disposal Existing Proposed Total
A. Soda Ash Division
1. Waste Oil /
Lube Oil
5.1 10 kl 5 kl 15 kl Collection,
Storage,
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 4
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with
source of information data
Transportation
&
disposal by
selling to
Registered
Recyclers
2. Spent ion
Exchange
resins
34.2 1830
lt/year
980 lt/year 2810
lt/year
Collection,
Storage,
Transportation,
Disposal by
selling to
authorized
recyclers or sent
to NECL
Nandesari
for Incineration.
3. Discarded
Bags /
drums /
containers
etc…
33.3 3.5 2 5.5 Collection,
Storage,
Transportation,
Disposal by
selling to
authorized
recyclers
B. Caustic Soda Plant
1. Waste Oil /
Lube Oil
5.1 30 kl 10 kl 40 kl Collection,
Storage,
Transportation
&
disposal by
selling to
Registered
Recyclers
2. Spent ion
Exchange
resins
34.2 2.56 1 3.56 Collection,
Storage,
Transportation,
Disposal by
selling to
authorized
recyclers or sent
to NECL
Nandesari for
Incineration.
3. Discarded
Bags /
drums /
containers
etc…
33.3 4.5 1.5 6 Collection,
Storage,
Transportation,
Disposal by
selling to
authorized
recyclers
4. Residue/ 16.2 6526 2175 8701 Collection,
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 5
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with
source of information data
Earthworks will involve cut and fill, excavations. It is likely cut and fill quantities will be
similar. Consequently it is likely that procurement of soil from outside the premises will be
minimal if any.
Sludge &
Filter sludge
Storage,
Transportation,
Disposal at
TSDF
5. ETP sludge 34.3 150 50 200 Collection,
Storage,
Transportation,
Disposal at
TSDF
6. Spent
Sulphuric
Acid (80%)
D2/II 6520 2173 8693 Collection,
Storage,
Transportation,
reuse
as raw material
for Nirma Ltd.
Moraiya and
other end users.
1.9 Underground works including
mining or tunneling? No Not Applicable
1.10 Reclamation works? No Not Applicable
1.11 Dredging? No Not Applicable
1.12 Offshore Structures No Not Applicable
1.13 Production and manufacturing
processes? Yes
Manufacturing process along with PFD and mass balances are provided in Pre-Feasibility
Report, Refer Ch-3, Section 3.5.
1.14 Facilities for storage of goods or
materials? No
Open storage for Harvested Salt, Limestone, Coke, Coal storage under Shed &
Product storage under Shed
1.15 Facilities for treatment or disposal
of solid waste or liquid effluents? Yes
Fly Ash shall be handled, stored and disposed of as per Fly Ash Notification, 2015 as
amended till date. The existing total effluent quantity is 5,86,445.2 m3/day. The effluent
quantity due to expansion activities would be 3,20,189.5 m3/day. Thus, after expansion,
the total effluent quantity would be 9,06,634.7 m3/day. Trade Effluent from expansion
activities will be treated in existing treatment facilities and discharged into Gulf of
Khambhat by outfall, diffuser system for detail please refer Ch-3, Section 3.7.3 of PFR.
NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water
and salt / sea water drawl based projects, such as Nirma Ltd., Kalatalav,
Bhavnagar Dist., cannot work without suitable sea discharge, considering the
huge volumes of sea water involved.
Hazardous Waste Generation details are as per table below:
Sr. No.
Solid Waste Quantity (MTPA)
Mode of Disposal Existing Proposed Total
1. Settling Pond Sludge
880 482 1362 Shall be used in road construction, salt works bund
preparation
2. Lime stone rejects /under size
700 375 1075 Shall be used in boilers for
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 6
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with
source of information data
desulphurization in boilers
3. Brine Sludge 19 10 29 Non-hazardous; Shall be dumped in
identified area
4. Fly ash / Bottom ash
2185 1693 3878 Brick manufacturing,
bund preparation, road making etc.
5. Incineration Ash 15 0 15 Brick manufacturing,
bund preparation, road making etc.
6. Saponification Solid Waste
3 0 3 Non-hazardous; Shall be dumped in
identified area
1.16 Facilities for long term housing of
operational workers? No
Sufficient accommodation available at workers colony, hence requirement of additional
housing is not envisaged.
1.17 New road, rail or sea traffic during
construction or operation? No
Due to proposed project, vehicular movement will be increased only during construction
phase.
1.18
New road, rail, air waterborne or
other transport infrastructure
including new or altered routes and
stations, ports, airports etc?
No No additional transport infrastructure is required due to the proposed expansion.
1.19
Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No It is not required to close or divert existing transport routes and infrastructure.
1.20 New or diverted transmission lines
or pipelines? No No any new or diverted transmission lines are proposed.
1.21
Impoundment, damming,
culverting, realignment or other
changes to the hydrology of
watercourses or aquifers?
No No change in hydrology of water courses/aquifers is envisaged.
1.22 Stream crossings? No Site does not involve any stream crossing.
1.23 Abstraction or transfers of water
from ground or surface waters? Yes
Ground Water
No abstraction of ground water is envisaged.
Surface Water/sea water
The existing total water quantity consumed is 14,06,574.1 m3/day. The water quantity
required due to expansion activities would be 3,60,000 m3/day. Thus, after expansion, the
total water quantity consumed would be 17,66,574.1 m3/day.
1.24
Changes in water bodies or the land
surface affecting drainage or run-
off?
No Not applicable.
1.25
Transport of personnel or materials
for construction, operation or
decommissioning?
Yes
During construction and implementation of the project period, transport of materials and
personnel will be through Coastal State Highway No. 6 (Bhavnagar-Ahmedabad) which is
at a distance of 14.0 km away from the project site in West direction.
1.26 Long-term dismantling or
decommissioning or restoration No
Proposed expansion does not involve any long term dismantling or decommissioning or
restoration works.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 7
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with
source of information data
works?
1.27
Ongoing activity during
decommissioning which could have
an impact on the environment?
No Not envisaged.
1.28 Influx of people to an area either
temporarily or permanently? Yes
During the construction phase around 150 workers and existing manpower is sufficient to
operate proposed expansion units. Local skilled and semi-skilled workers will be engaged
during construction phase.
1.29 Introduction of alien species? No Not applicable
1.30 Loss of native species or genetic
diversity? No No effect on species or generic diversity.
1.31 Any other actions? No Not visualized as required activities will not cause any physical changes in the locality.
2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or
in short supply):
S. No. Information/Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
2.1 Land especially undeveloped or agricultural
land (ha) No
The Plot area of the project duly developed, consists of 555 acre –Kalatalav
Complex. Expansion is proposed within area allotted for these plants within
Kalatalav Complex. The areas of the plants which would undergo proposed
expansion activities would be as under:
Cogeneration plant = 69,100 m2
Soda Ash plant = 2,61,548.33 m2
Caustic Soda plant = 2,88,945.55 m2
2.2 Water (expected source & competing users)
unit: KLD Yes
The source of existing water consumption for Nirma – Kalatalav Complex is Sea
water through RO / desalination plants. The existing water quantity consumed
is 14,06,574.1 m3/day. The water quantity required due to expansion activities
would be 3,60,000 m3/day. Thus, after expansion, the total water quantity
consumed would be 17,66,574.1 m3/day.
2.3 Minerals (MT) Yes During operation phase, coal, coke, pet coke & limestone shall be used based
on availability.
2.4 Construction material stone, aggregates,
sand / soil (expected source, MT) Yes
Construction materials like stones, aggregates, sand, bricks, steel, cement,
rubble, etc. will be procured from the local market.
2.5 Forests and timber (source, MT) No Not Applicable
2.6
Energy including electricity and fuels
(source, competing users) unit: fuel (MT),
energy (MW)
Yes
Electricity:
Power is supplied by captive cogeneration thermal power plant at the facility.
The existing power produced at the site is 197.18 MW. This is to be increased
by 152.82 MW. Thus, the total power consumption after expansion would be
350 MW.
Fuel for Cogeneration Power Plant:
The fuel requirement will be as per table below:
Sr. No. Fuel Type Quantity (tpd)
Existing Proposed Total
1. Coal 7440 5766 13206
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 8
S. No. Information/Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
2. Lignite 7584 5878 13462
3. Pet Coke 1200 3912 5112
4. Limestone 1625 1259 2884
5. Light Diesel Oil
(kl/year) 210 163 373
6. HSD (kl/month) 955 740 1695
2.7 Any other natural resources (use
appropriate standard units) No Not Envisaged.
3. Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about
actual or perceived risks to human health.
S. No. Information / Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
3.1
Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna, and
water supplies)
Yes Hazardous material like FO, HSD, LDO, Chlorine, Caustic will be used.
3.2
Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No Not Applicable.
3.3 Affect the welfare of people e.g. by
changing living conditions? No Not Applicable.
3.4
Vulnerable groups of people who could be
affected by the project e.g. hospital
patients, children, the elderly etc.,
No No vulnerable groups live near project area.
3.5 Any other causes No Not envisaged.
4. Production of solid wastes during construction or operation or decommissioning
(MT/month)
S. No. Information/Checklist confirmation Yes/
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
4.1 Soil, overburden or mine wastes No Not envisaged.
4.2 Municipal waste (domestic and or
commercial wastes) Yes
Municipal Waste
Waste paper from administrative buildings, waste metals, kitchen waste
etc.
Disposal method
Waste paper and metal will be given to recyclers, and kitchen waste will be
converted into manure.
4.3 Hazardous wastes (as per Hazardous Waste
Management Rules) No Hazardous Waste Generation details are as per table in Sr. No. 1.15
4.4 Other industrial process wastes No Not Envisaged.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 9
S. No. Information/Checklist confirmation Yes/
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
4.5 Surplus product No Not Applicable.
4.6 Sewage sludge or other sludge from
effluent treatment Yes Details of the same shall be quantified in EIA report.
4.7 Construction or demolition wastes Yes Minimal quantity of debris, scraps, excavated soil, used cement bags, iron /
steel scrap and cardboards waste could be generated during construction
4.8 Redundant machinery or equipment No Not applicable.
4.9 Contaminated soils or other materials No Not applicable.
4.10 Agricultural wastes No Not envisaged.
4.11 Other solid wastes Yes Solid Waste Generation details are as per table in Sr. No. 1.15
5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)
S. No. Information/Checklist confirmation Yes/
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
5.1 Emissions from combustion of fossil fuels
from stationary or mobile sources Yes
Flue gas emissions like SPM, SO2 & NOx will be from stacks attached to
boilers. For more details refer Table 1-1.
5.2 Emissions from production processes Yes Process emissions from production process are given in Table 1-2
5.3 Emissions from materials handling including
storage or transport Yes
Dust generation is anticipated from coal storage and ash handling.
Arrangements for wetting and water spray / extraction of emission from
transfer points will be provided.
5.4 Emissions from construction activities
including plant and equipment Yes
Emission from diesel operated vehicles, concrete mixers and excavators
are anticipated. However these equipment will be maintained properly to
ensure minimum emissions and vehicles with PUC certificates will be used.
5.5
Dust or odours from handling of materials
including construction materials, sewage
and waste
No Not envisaged.
5.6 Emissions from incineration of waste No Not Applicable
5.7 Emissions from burning of waste in open air
(e.g. slash materials, construction debris) No Not envisaged.
5.8 Emissions from any other sources No None envisaged.
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S. No. Information/Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
6.1 From operation of equipment e.g. engines,
ventilation plant, crushers Yes
Noise will be generated from operation of coal crushers, boilers, turbines,
air blowers, plant machineries, etc. Adequate enclosures and necessary
PPE will be provided to exposed employee.
6.2 From industrial or similar processes Yes Noise shall be generated from boilers, compressors, etc. during operation
phase.
6.3 From construction or demolition Yes During construction phase, noise will be generated due to dumpers,
rollers, truck movement etc.
6.4 From blasting or piling No Not Applicable
6.5 From construction or operational traffic Yes During construction and operational phase noise will be generated due to
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 10
S. No. Information/Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
trucks and other vehicles.
6.6 From lighting or cooling systems Yes Noise will be generation from Cooling tower fans.
6.7 From any other sources No No emissions of light and heat are envisaged.
7. Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea
S. No. Information/Checklist confirmation Yes
/ No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
7.1 From handling, storage, use or spillage of
hazardous materials No
Proper care for handling of hazardous material will be taken as per the
MSIHC rules & HW management Rules. Moreover all of the hazardous
wastes are disposed as per guidance of State Pollution Control
Board. Same will be continued after proposed expansion.
7.2
From discharge of sewage or other effluents to
water or the land (expected mode and place of
discharge)
No
Final discharge will be reduced due to recycle and reuse concept. After
discharge from Kalatalav facility, the treated effluent is discharged into
the Gulf of Khambhat through an outfall comprising of diffuser system.
The Co-Ordinates of the discharge point are:
1. Soda Ash Effluent Discharge - 21050’36.36”N, 72015’27.06”E
2. Bittern Discharge Point - 21049’39”N, 72011’44”E
7.3 By deposition of pollutants emitted to air into
the land or into water Yes
Shall be provided with EIA report after air dispersion modelling using site
specific meteorological data.
7.4 From any other sources No None identified.
7.5
Is there a risk of long term build-up of
pollutants in the environment from these
sources?
No
Adequate mitigation measures, monitoring and periodic maintenance of
equipment’s will ensure no risk of long term buildup of pollutants in the
environment.
8. Risk of accidents during construction or operation of the Project, which could
affect human health or the environment
S. No. Information/Checklist confirmation Yes /
No
Details thereof (with approximate quantities / rates, wherever
possible) with source of information data
8.1
From explosions, spillages, fires etc. from
storage, handling, use or production of
hazardous substances
Yes The associated hazard from the plant is fire in coal storage yard as well
as fuel storages.
8.2 From any other causes Yes
Common risks in factories such as Electric Shock, Hit by Objects, Fall /
Slips, Hot Work such as Welding and Cutting & during maintenance
activities.
8.3
Could the project be affected by natural
disasters causing environmental damage e.g.
floods, earthquakes, landslides, cloudburst
etc)?
Yes
Site falls under the seismic intensity Zone III, which is classified as
Moderate Damage Risk Zone. Thus, suitable seismic coefficients
accordingly shall be adopted while designing the structures to make it
earthquake resistant.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 11
9. Factors which should be considered (such as consequential development) which
could lead to environmental effects or the potential for cumulative impacts with
other existing or planned activities in the locality
S. No. Information/Checklist confirmation Yes / No Details thereof (with approximate quantities/ rates, wherever
possible) with source of information data
9.1
Lead to development of supporting Facilities,
ancillary development or development
stimulated by the project which could have
impact on the environment e.g.: supporting
infrastructure (roads, power supply, waste
or waste water treatment, etc.) housing
development extractive industries supply
industries, (other)
Yes The proposed expansion project will encourage industrial growth,
employment and result in additional revenue for government.
9.2 Lead to after-use of the site, which could
have an impact on the environment No Not Applicable
9.3 Set a precedent for later developments No Not Applicable
9.4
Have cumulative effects due to proximity to
other existing or planned projects with
similar effects
No Very negligible cumulative effect, as adequate mitigation measures will
be provided.
III Environmental Sensitivity
S. No. Areas Name / Identity Aerial Distance (within 15 km) of the proposed project
location boundary
10.1
Areas protected under international
conventions, national or local legislation for
their ecological, landscape, cultural or other
related value
No No such areas exist within 15 Km radius of the proposed
project site.
10.2
Areas which are important or sensitive for
ecological reasons - Wetlands, watercourses
or other water bodies, coastal zone,
biospheres, mountains, forests
Coastal Zone
Reserved Forest
Project boundary is well beyond minimum distance of 500 m
from CRZ boundary.
Madhia Reserved Forest-8.2 km (West)
10.3
Areas used by protected, important or
sensitive species of flora or fauna for
breeding, nesting, foraging, resting, over
wintering, migration
No -
10.4 Inland, coastal, marine or underground
waters
Gundala Creek,
Malcolm Channel
& Bhavnagar
Creek (Gulf of
Khambhat)
Gundala Creek : About 6.5 km (North)
Malcolm Channel : 6.0 km (East),
Bhavnagar Creek: 3.0 km (South).
10.5 State, National boundaries No -
10.6
Routes or facilities used by the public for
access to recreation or other tourist, pilgrim
areas
Coastal State
Highway
Coastal State Highway No.6 (Bhavnagar-Ahmedabad) is
passing 14 km away from the project site in West direction.
10.7 Defense installations No None Identified
10.8 Densely populated or built-up area Yes Bhavnagar city is located approx. 10 km (aerial) away from the
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR FORM - 1
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 12
S. No. Areas Name / Identity Aerial Distance (within 15 km) of the proposed project
location boundary
Kalatalav site of Nirma Ltd. in the South direction
10.9
Areas occupied by sensitive man-made land
uses (hospitals, schools, places of worship,
community facilities)
Yes Located within Bhavnagar city
10.10
Areas containing important, high quality or
scarce resources (ground water resources,
surface resources, forestry, agriculture,
fisheries, tourism, minerals)
No None Identified
10.11
Areas already subjected to pollution or
environmental damage. (Those where
existing legal environmental standards are
exceeded)
No None Identified
10.12
Areas susceptible to natural hazard which
could cause the project to present
environmental problems (earthquakes,
subsidence, landslides, erosion, flooding or
extreme or adverse climatic conditions)
No
Earthquake: The site falls in Seismic zone III (Moderate Risk)
as per Seismic Zone Map of India.
Cyclone: It is 6.0 km from Malcolm Channel (Gulf of Khambhat)
thus susceptible to natural hazards like cyclone/storm etc.
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 1
ANNEXURES OF REVISED FORM 1
Annexure 1: General and Specific Location Map .............................................................................. 2
Annexure 2: Project Boundary Map ................................................................................................ 3
Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ....................... 4
Annexure 4: Details of Air Emissions ............................................................................................... 5
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 2
Annexure 1: General and Specific Location Map
NIRMA LTD. REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION
POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 3
Annexure 2: Project Boundary Map
NIRMA LTD. REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION
POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 4
Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 5
Annexure 4: Details of Air Emissions
Air emissions from stationary sources are provided below:
Table 1-1 Details of Stacks APCM attached to Flue Gas Stacks
S. No. Stack Attached to Stack Height
(m)
Stack Top
Dia. (m) APCM
Expected
Pollutants*
Existing
Soda Ash Division
1 Boiler - A, B, C & D (100 TPH Each) 100 (Common
Stack) 5.04 ESP to Each Boiler PM, SO2 & NOx
2. DG Set (1000 KVA) 2 nos. 24 each 0.2 -- PM, SO2 & NOx
Caustic Soda & CPP Division
2 Boiler - E (200 TPH) 121 (Common
Stack) 4.5
ESP PM, SO2 & NOx
3 As per EC 2014 Boiler - F (200 TPH)
– Not Installed Yet ESP PM, SO2 & NOx
4
As per EC 2017 Boiler - G & H (350
TPH each ) – Installed One boiler
having capacity 410 TPH
121 (Common
Stack) 4.5 ESP PM, SO2 & NOx
5 DG Set (1000 kVA) 30 0.32 - PM, SO2 & NOx
6 DG Set (1500 kVA) 30
0.32
-
PM, SO2 & NOx
7 DG Set (1500 kVA)
Toilet Soap plant
8 Thermic Fluid Heater (3 nos.) 45 0.4 PM, SO2 & NOx
Proposed
Soda Ash Division
1. DG Set (2000 kVA) 30 0.32 -- PM, SO2 & NOx
Caustic Soda & CPP Division
1 Boiler - I & J (410 TPH + 130 TPH) * 121 (Common
Stack) 13.4# ESP PM, SO2 & NOx
2 DG Set (1850 kVA) 30 0.32 -- PM, SO2 & NOx
* Capacity of proposed boilers may vary however total proposed capacity of steam generation will
remain same as 540 TPH.
# Considering better dispersion, Engineering design has calculated the stack dia. as 13.4m
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 6
Table 1-2: Details of Process Emissions
Sr.
No. Vent Attached to Stack Height (m)
Stack
Dia. (m)
Air Pollution Control
System Pollutant
1
Soda Ash Plant – Existing & Proposed
Lime Kilns (A to H) – 8 nos. 68 (Common Stack) 0.8 4 scrubbers and 3 ESP in
Series PM, SO2, NOx
Ammonia Recovery System (A to E) - 5
nos. 56 (Common Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia
Lime Grinding System (A to E) - 5 nos. 60 (each) 0.65 Bag Filter PM
Calcinations Vessel (A to D) - 4 nos. 29 (each) 0.7 Water Scrubber PM
Densification 1 40 1.37 Water Scrubber PM
Densification 2 51 1.37 Water Scrubber PM
Densification 3 51 1.37 Water Scrubber PM
Lime Kilns (I to L) – 4 nos.
(Proposed) 68 (Common Stack) 0.8
Two scrubbers and two
ESP in Series PM, SO2, NOx
Ammonia Recovery System (F & G) 2
nos. (Proposed) 56 (Common Stack) 0.75 Brine Scrubbers (2 nos.) Ammonia
Lime Grinding System (F) - 1 no.
(Proposed) 60 0.65 Bag Filter PM
Calcinations Vessel (E & F) - 2 nos.
(Proposed) 29 (Common vent) 0.7 Water Scrubber PM
Densification 4 (Proposed) 51 1.37 Water Scrubber PM
2
Caustic Soda and CPP - Existing & Proposed
HCl Synthesis Unit – 1 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit - 2 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit – 3 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit - 4 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit – 5 (Proposed) 30 0.1 Water Scrubbers HCl & Cl2
Waste Gas Dechlorination
System - 1 30 0.3 18% NaOH Scrubber Cl2
Waste Gas Dechlorination System - 2 30 0.3 18% NaOH Scrubber Cl2
Waste Gas Dechlorination System – 3 30 0.3 18% NaOH Scrubber Cl2
Hydrogen unit with Flame arrestor and steam snuffing – 1
30 -- -- --
Hydrogen unit with Flame arrestor and
steam snuffing – 2 30 -- -- --
Hydrogen unit with Flame arrestor and
steam snuffing – 3 30 -- -- --
3. Bromine Plant
De-bromination System 30 0.3 Alkali Scrubber Bromine
4.
Chlorine & Hydrogen Derivatives
Solvent Recovery 30 0.3 Ceramic + Activated
Carbon Filter Aromatic Solvent
Hydrogenation Plant (purge gas) 30 0.3 Ceramic + Activated
Carbon Filter H2 + Aromatic Solvent
NIRMA LTD.
REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 7
Sr.
No. Vent Attached to Stack Height (m)
Stack
Dia. (m)
Air Pollution Control
System Pollutant
Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,
HCl, TOC
HCl Synthesis Unit 30 0.1 Water Scrubbers HCl
Chlorination Plant 30 0.3 Acidic/Water Scrubber (3
nos.) SO2, HCl, Cl2
Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2
Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2
Hydrogenation Plant (purge gas) 30 0.3 ---- H2
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-6131000
Delhi / NCR
Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,
Gurgaon, Haryana, INDIA - 122002.
E: [email protected]; T:0124-4242430 to 436
Kadam Environmental Consultants w w w . k a d a m e n v i r o . c om
Env i ro nme nt fo r Dev e lopment
M/S. NIRMA LIMITED
Revised Pre-Feasibility Report for Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat.
MAY, 2018
Kadam Environmental Consultants w w w . k a d a m en v i r o . c o m
Envi ronment for Deve lopment
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL SHEET
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 II
M/S. NIRMA LIMITED
Revised Pre-Feasibility Report for Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat. © Kadam Environmental Consultants (‘Kadam’), May, 2018
This report is released for the use of the M/s. NIRMA LIMITED., Regulators and relevant stakeholders solely as part
of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced
third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of
Kadam.
PROJECT DETAILS
Name of
Publication
Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at
Village – Kalatalav, Taluka & District Bhavnagar, Gujarat
Project Number 1730141406 Report No. 1 Version 2 Released May, 2018
Prepared &
Managed By
Tanu Prasad & Bhavin Jambucha, K.K
Antani Released By Sangram Kadam
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: [email protected]; T:+91-265-6131000
Delhi / NCR
Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana,
INDIA - 122002.
E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also
believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss
absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or
application of the information contained in this report. The information is not intended to serve as legal advice related to the
individual situation.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 III
CONTENTS
1 EXECUTIVE SUMMARY ................................................................................................ 1
1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 1
1.2 INFRASTRUCTURE ....................................................................................................... 1
1.3 UTILITY ................................................................................................................. 2
1.4 ENVIRONMENT ........................................................................................................... 2
1.5 SENSITIVITY ............................................................................................................. 2
1.6 CONCLUSION ............................................................................................................ 2
2 INTRODUCTION ......................................................................................................... 4
2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT ................................................................. 4
2.1.1 Project Proponent ............................................................................................... 4
2.1.2 Proposed Project ................................................................................................ 4
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................... 4
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION .......................................... 5
2.4 DEMAND & SUPPLY GAP ................................................................................................. 5
2.5 EXPORT POSSIBILITY .................................................................................................... 5
2.5.1 Domestic / Export Market ..................................................................................... 5
2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............................................. 5
3 PROJECT DESCRIPTION .............................................................................................. 6
3.1 TYPE OF PROJECT ....................................................................................................... 6
3.2 LOCATION OF THE PROJECT ............................................................................................. 6
3.3 DETAILS OF ALTERNATE SITES CONSIDERED ............................................................................ 8
3.4 SIZE OR MAGNITUDE OF OPERATION.................................................................................... 8
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ....................................................................... 9
3.5.1 Soda Ash (Existing + Expansion) ............................................................................. 9
3.5.2 Cogeneration Plant (Existing + Expansion) ................................................................ 14
3.6 UTILITIES .............................................................................................................. 15
3.6.1 Power Requirement ............................................................................................ 15
3.6.2 Fuel Requirement .............................................................................................. 15
3.6.3 Water Requirement ............................................................................................ 15
3.6.4 Storage Details ................................................................................................. 15
3.7 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 15
3.7.1 Air Emissions & Control ....................................................................................... 15
3.7.2 Noise Generation ............................................................................................... 18
3.7.3 Waste Water Generation ...................................................................................... 18
3.7.4 Hazardous Waste & Other Solid Waste ..................................................................... 19
4 SITE ANALYSIS ........................................................................................................ 22
4.1 CONNECTIVITY ......................................................................................................... 22
4.1.1 By Road .......................................................................................................... 22
4.1.2 By Rail ........................................................................................................... 22
4.1.3 By Air ............................................................................................................ 22
4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 22
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 IV
4.3 TOPOGRAPHY ........................................................................................................... 22
4.4 EXISTING INFRASTRUCTURE ............................................................................................ 22
4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 22
4.5.1 Soil Classification ............................................................................................... 22
4.5.2 Geology .......................................................................................................... 22
4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 23
4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 23
5 PLANNING BRIEF ..................................................................................................... 24
5.1 PLANNING CONCEPT .................................................................................................... 24
5.2 LANDUSE PLANNING .................................................................................................... 24
5.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 24
5.4 AMENITIES/FACILITIES ................................................................................................. 24
6 PROPOSED INFRASTRUCTURE ................................................................................... 25
6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 25
6.2 NON- PROCESSING AREA ............................................................................................... 25
6.3 GREENBELT ............................................................................................................. 25
6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 25
6.5 CONNECTIVITY ......................................................................................................... 25
6.6 DRINKING WATER MANAGEMENT ...................................................................................... 25
6.7 SEWAGE SYSTEM ....................................................................................................... 25
6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 25
6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 26
7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .................................................... 27
8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................... 28
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 28
8.2 ESTIMATED PROJECT COST ............................................................................................ 28
8.2.1 Profitability ...................................................................................................... 28
9 ANALYSIS OF PROPOSAL .......................................................................................... 29
9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 29
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR LIST OF ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 V
ANNEXURES
Annexure 1: Preliminary Site Layout Map 31
Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles 32
Annexure 3: Long Term Meteorological Data for Bhavnagar City 33
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR LIST OF TABLES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 VI
LIST OF TABLES
Table 1-1: Products Capacity (Existing & Proposed) ............................................................................................1
Table 2-1: Products Capacity (Existing & Proposed) ............................................................................................4
Table 3-1: Co-ordinates of Site Boundary ...........................................................................................................8
Table 3-2: Area Statement* ..............................................................................................................................8
Table 3-3: Details of Stack Emissions ............................................................................................................... 16
Table 3-4: Details of Process Emissions ............................................................................................................ 17
Table 3-5: Wastewater Generation Details ........................................................................................................ 18
Table 3-6: Solid Waste Generation & Disposal................................................................................................... 19
Table 3-7: Hazardous Waste Generation and Disposal ....................................................................................... 20
Table 6-1: Identification of Other Wastes ......................................................................................................... 26
Table 8-1: Tentative Project Time Schedule ...................................................................................................... 28
Table 8-2: Breakup of Project Cost .................................................................................................................. 28
LIST OF FIGURES
Figure 3-1: General Location of Proposed Project Site .........................................................................................6
Figure 3-2: Specific Map Showing Project Boundary ............................................................................................7
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 1
1 EXECUTIVE SUMMARY
Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the
production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl
Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt and consumer salt to facilitate
quality production of their consumer products.
It is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District Bhavnagar, Gujarat.
Nirma Limited, Bhavnagar now proposes for modernization with expansion of their existing production plant
capacity.
As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category
including Project / Activity: 1(d) Thermal Power Plant, 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant and
categorized under “A”.
1.1 Plant Features and Production Capacity
Existing cost of project is Rs. 3110 crores. The expected cost of the proposed expansion project will be around Rs.
1320 crores.
Details of existing and proposed products are listed in Table 1-1.
Table 1-1: Products Capacity (Existing & Proposed)
Sr.
No. Project or activity
Capacity (tpd)
Existing Proposed Total
1. Cogeneration Plant (Area = 69,100m2) 197.18 MW 152.82 MW 350
Soda Ash Plant (Area = 2,61,548.33 m2; )
1. Light Soda Ash Plant 2800 1500 4300
2. Dense Soda Ash * 1800 600 2400
Dense Soda Ash is conversion of Light Soda Ash
Caustic Soda Plant (Area = 2,88,945.55 m2)
1. Caustic Soda (100%) 750 250 1000
2. Hydrochloric Acid (100%) 280 220 500
Caustic Soda Plant – By Products
1. Chlorine Gas (100%) 665.2 220.8 886
2. Hydrogen (100%) 18.75 6.25 25
3. Sodium Hypo Chlorite (100%) 12 3 15
1.2 Infrastructure
The proposed expansion would be implemented in Nirma Ltd.’s existing manufacturing facility at Kalatalav, near
Bhavnagar, Gujarat.
Main components of the existing project which includes Cogeneration Plant, Soda Ash Plant, Caustic Soda Plant,
Chlorine and Hydrogen derivatives plant, , Toilet soap plant and Bromine Plant and their associated utilities /
components like Boiler House of CFBC Boilers, Steam Turbine, Generator, Utility Area consisting of cooling tower,
ESP section Fly ash storage area. Water & wastewater infrastructure like Effluent Treatment Plant (ETP), Air
compressors & Hazardous storage facility area are being used.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 2
1.3 Utility
Power: The total additional power demand for the expansion has been estimated about 152.82 MW. The power
requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH ,
total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.
* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as
540 TPH.
Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.
Fuel: Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr
for existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.
Raw Water: Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater
intake – 14 x 105 m3/day. Additional seawater intake - 3.6 x 105 m3/day.
Manpower: Existing manpower at the operational site is 1630 nos. Manpower during Construction phase would be
150 nos. The manpower for operation phase of Expansion plants would be 100 nos. Thus, the total manpower
during full operation phase of Nirma-Kalatalav complex will be approximately 1730 nos.
1.4 Environment
Environmental issues associated with proposed units are:
Air Emissions: These would be due to presence of various Flue Gas stacks and process vents
Wastewater: The wastewater generated from the proposed activities would be treated in Effluent treatment
plant. The treated effluent would be discharged into the Gulf of Khambhat through existing outfall equipped
with diffuser system.
NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water and salt / sea water
drawl based projects, such as Nirma Ltd., Kalatalav, Bhavnagar Dist., cannot work without suitable
sea discharge, considering the huge volumes of sea water involved.
Solid & Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per
the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016
1.5 Sensitivity
Project boundary is well beyond minimum distance of 500 m from CRZ boundary. About 6.5 km in North (Gundala
Creek), 6.0 km East side (Malcolm Channel), and 3.0 km in the South direction (Bhavnagar Creek). Project site falls
in Zone-III of Seismicity. Civil and Structures shall be designed according to applicable code. It is 6.0 km from
Malcolm Channel (Gulf of Khambhat) thus susceptible to natural hazards like cyclone/storm etc.
1.6 Conclusion
There is no adverse impact on the water environment due to the operation of the project. The air environment has
negligible effect due to the activities related to the operation of the project.
After implementation of pollution control measures there will be no emission from the plant beyond the norms
specified by Gujarat Pollution Control Board (GPCB). The project is not contributing to any adverse impact on the
surrounding soil, as the pollutants emitted are of the negligible amount.
Project intends to generate employment for local people and unskilled / semiskilled workers during construction
phase. If this project comes up, it will have social, financial benefits and will be environmentally sustainable.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 3
Pre-feasibility study confirms viability of the project.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR INTRODUCTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 4
2 INTRODUCTION
2.1 Identification of Project Proponent & Project
2.1.1 Project Proponent
Nirma is one of the few names - which is instantly recognized as a true Indian brand, which took on mighty
multinationals and rewrote the marketing rules to win the heart of princess, i.e. the consumer.
Nirma, the proverbial ‘Rags to Riches’ saga of Dr. Karsanbhai Patel, is a classic example of the success of Indian
entrepreneurship in the face of stiff competition. Starting as a one-man operation in 1969, today, it has about
15,000+ employee-base and annual turnover is more than 10,000 Crores INR.
Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the
production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl
Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt, Cement and consumer salt to
facilitate quality production of their consumer products.
2.1.2 Proposed Project
Proposed project is for expansion in Existing Production Capacity.
2.2 Brief Description of nature of the Project
Details of existing and proposed products are listed in Table 2-1.
Table 2-1: Products Capacity (Existing & Proposed)
Sr. No. Project or activity Capacity (tpd)
Existing Proposed Total
Soda Ash Plant (Area = 2,61,548.33 m2)
1. Light Soda Ash Plant 2800 1500 4300
2. Dense Soda Ash* 1800 600 2400
* Dense Soda Ash is conversion of Light Soda Ash
Caustic Soda Plant (Area = 2,88,945.55 m2)
1. Caustic Soda (100%) 750 250 1000
2. Hydrochloric Acid (100%) 280 220 500
Caustic Soda Plant – By Products
1. Chlorine Gas (100%) 665.2 220.8 886
2. Hydrogen (100%) 18.75 6.25 25
3. Sodium Hypo Chlorite
(100%) 12 3 15
1. Cogeneration Plant (Area =
69,100m2) 197.18 MW 152.82 MW 350
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR INTRODUCTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 5
2.3 Need for the Project and its Importance to the Country & Region
There is regular use of these products and has demand in local market as well as in export. This will meet the local
demand and generate employment.
2.4 Demand & Supply Gap
Limestone requirement is approximate 5050 TPD for existing Soda Ash Plant.
Additional approximate 3964 TPD (2705 TPD for SA + 1259 TPD for CPP) is required for proposed Soda Ash
Expansion and desulphurization in Cogeneration Plant. Limestone requirement will be met from the limestone mines
located in Junagadh & Porbandar districts as well as imports.
2.5 Export Possibility
2.5.1 Domestic / Export Market
There is regular use of these products and has demand in local market as well as in export. This will meet the local demand, generate employment and generate revenue for government.
2.6 Employment Generation (Direct & Indirect) due to the project
During the construction phase around 150 workers and existing manpower is sufficient to operate proposed
expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 6
3 PROJECT DESCRIPTION
3.1 Type of Project
As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category
including Project / Activity: 1(d) Thermal Power Plant, 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant and
categorized under “A”.
3.2 Location of the Project
Proposed project is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District
Bhavnagar, Gujarat.
Location map showing general location of proposed project is given in Figure 3-1. Specific Map showing project
boundary is given in Figure 3-2. The co-ordinates of the project site are given in Table 3-1.
Figure 3-1: General Location of Proposed Project Site
NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE COGENERATION POWER
PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 7
Figure 3-2: Specific Map Showing Project Boundary
Red highlighted boundary shows boundary of Plant. No extra land is required.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 8
Table 3-1: Co-ordinates of Site Boundary
POINT LATITUDE LONGITUDE
A 21°51'56.83"N 72° 9'30.48"E
B 21°51'46.15"N 72°10'17.76"E
C 21°51'42.81"N 72° 9'23.53"E
D 21°51'39.12"N 72° 9'28.14"E
E 21°51'33.87"N 72° 9'27.12"E
F 21°51'32.87"N 72° 9'25.35"E
G 21°51'31.17"N 72° 9'25.11"E
H 21°51'30.23"N 72° 9'20.84"E
I 21°51'24.09"N 72° 9'20.45"E
J 21°51'23.82"N 72° 9'25.64"E
K 21°51'13.96"N 72° 9'26.98"E
L 21°51'12.59"N 72° 9'17.77"E
M 21°51'7.73"N 72° 9'13.03"E
N 21°50'51.17"N 72° 9'8.71"E
O 21°50'52.41"N 72°10'8.26"E
P 21°51'16.70"N 72°10'10.47"E
Q 21°51'23.75"N 72°10'15.83"E
3.3 Details of Alternate Sites Considered
The expansion and set-up of new project is within the existing chemical complex. Hence no alternative sites were
explored.
3.4 Size or Magnitude of Operation
Total plot area is 2249458 m2. The details of area calculations are given in Table 3-2. Site layout is provided as
Annexure 1.
Table 3-2: Area Statement*
S. No. Particular Area (Acre) Area (m2)
1 Plant facilities 84.0 339825
2 Storage (Raw Material & Finished Products) 23.0 92930
3 Storage (Fuel) 107.2 433940
4 Storage (Water) 7.5 30400
5 Storage (Others) 22.3 90286
6 Utilities 16.9 68250
7 Laboratory 0.9 3600
8 Approach Road(s) 3.2 13000
9 Green Belt 183.4 742321
10 ETP 3.1 12500
11 Office + Parking + Security 3.6 14500
12 Open area 100.8 407906
Total 555.8 2249458
* Area given are tentative and are subjected to changes, which will be clearly demarcated in the EIA study report.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 9
3.5 Project Description with Process Details
3.5.1 Soda Ash (Existing + Expansion)
The global theoretical equation for the production of soda ash, involving sodium chloride and calcium carbonate is
as follows;
2 NaCl + CaCO3 Na2CO3 + CaCl2
In practice the reaction is not possible and needs the participation of other substances and many different process
steps to get the final product. The first reaction involves absorption of ammonia in salt solution, followed by
reaction of ammoniated brine with carbon dioxide to obtain ammonium carbonate followed by ammonium
carbonate. The continuous introduction of carbon dioxide injection and cooling the solution, precipitation of sodium
bicarbonate is achieved and ammonium chloride is formed. The chemical reactions of the process are given below:
NaCl + H2O + NH3 NaCl + NH4OH
2 NH4OH + CO2 (NH4)2 CO3 + H2O
(NH4)2CO3 + CO2 + H2O 2 NH4HCO3
2 NH4HCO3 + 2 NaCl 2 NaHCO3 + 2 NH4Cl
Sodium Bicarbonate crystals are separated from the mother liquor by filtration, followed by thermal decomposition
to obtain sodium carbonate, water and carbon dioxide. Sodium carbonate, thus formed is called “light soda ash”
because its bulk density is approximately 0.5 t/m3.
2 NaHCO3 Na2CO3 + H2O + CO2
CO2 is recovered in the carbonation step. The mother liquor is treated to recover ammonia, by reacting with dry lime
followed by steam stripping to recover free gaseous ammonia, which is recycled to absorption step.
2 NH4Cl + H2O+CaO CaCl2 + 2 NH3 + 2 H2O
Carbon dioxide and Calcium oxide originate from limestone calcinations CaCO3 CaO + CO2. Calcium and
magnesium which are impurities in the brine are removed by reacting with alkali and carbon dioxide to produce
insoluble salts. Brine purification reactions are described in the following equations:
Ca2+ + CO32- CaCO3
Mg2+ + 2 OH- Mg (OH)2
The difference between Light and Dense Soda ash is bulk density & the size of particles. Dense Soda ash is produced
via the monohydrate process. The hot light soda ash discharge from Calciner is transported via chain conveyors and
bucket elevator to Hydrator. In hydrator Light Soda ash is mixed with water to form monohydrate according to the
exothermic reaction:
Na2CO3 + H2O Na2CO3.H2O
The next step is dehydration and drying of the monohydrate in Fluid Bed Dryer according to endothermic reaction:
Na2CO3.H2O Na2CO3 + H2O
The Dense Soda Ash is cooled and transported to storage to packing plant. The block diagram of the Soda Ash
Manufacturing unit is given in the Figure shown below:
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 10
Coke 0.102 MT
Waste water 6.5 m3
Soda ash 1 MT
CaCl2 1.05 MT
CO2 gas
0.415 MT NH3 gas 0.32 MT
Reuse in next operation
Lime Stone 1.75 MT
Ammonia 0.003 MT
Water 6 m3
Sodium Sulphide
0.005 MT
Process
Salt- 2 MT
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 11
Mass Balance
Caustic Soda (Existing + Expansion)
The Caustic soda manufacturing technology being used i.e. membrane technology is completely environment
friendly. The by products are hydrogen, chlorine & sodium hypo chlorite. Hydrochloric acid is manufactured using
H2 and Cl2 (produced from cell house).
Manufacturing process of Caustic Soda involves the following key steps:
Brine Saturation: Desirable circulating rate of brine in saturator is attained by dissolving salt from solar salt works
and depleted brine from the process. The water loss by membrane is compensated by supply of demineralized
water.
Chemical Preparation: In precipitation tanks saturated brine is treated to remove Ca, Mg & Sulphates by adding
Na2CO3, NaOH and Barium Chloride.
Clarification: Flocculants are added to enhance the settling. Impurities are removed in clarifier. Main impurities
are solids which are pumped to sludge filtration unit. Filtrate is recycled to clarifier.
Filtration: Anthracite filters are used to remove suspended solids.
Secondary Brine Purification: Polishing candle filters and ion exchange system is used for this process. The
objective of producing ultra-pure brine required for membrane cell operation is achieved. Polished brine after
heating through brine heater is passed through two ion exchange columns connected in series. The columns have
cation exchange resin, which provides active sites for adsorption of residual calcium and magnesium salts still
present in brine. Brine is passed through heat exchanger for achieving the temperature required at cell inlet.
Electrolysis: Brine flows into the anode chamber. Cl2 is liberated at the anode surface with depleted brine left
behind. Cl2 and depleted brine overflows from the anode chambers into the anolyte header. Weak caustic flows into
SALT
BRINE PREPARATION
RO / RAIN WATER LIME STONECOKE
LIME KILNS
ABSORPTION
CARBONATION
CALCINATION
DENSIFICATION
STORAGE
WASTE TREATMENT
DISTILLATION
COMPRESSION
GAS CONDENSATION
PACKING
FILTERATION
FINAL PRODUCTS
CLEAR LIQ. TO SALT WORKS
AIR
STEAM38-40% CO2
80-90% CO2
PURIFIED BRINECaCl2 Waste
CRUDE BICARBONATE
STEAM
LSA
DSA
LSA
LSA & DSA
MOTHER LIQUOR
NH4Cl
AMMONIA GAS
AMMONIA MAKE UP
LIME
CO2 + H2O
STEAM
ZERO
DISCHARGE
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 12
the cathode chamber. H2 is generated at the cathode surface and OH ions combine with the Na+ ions diffusing
through the membrane. A two-phase mixture of 32% NaOH and hydrogen overflows into the catholyte header.
Anode Reaction: 2NaCl 2Na+ + Cl2 + 2 e –
Cathode Reaction: 2H2O + 2 e – 2OH– +H2
Overall Reaction: 2NaCl + 2H2O 2NaOH + Cl2 + H2
Catholyte System: In the catholyte header the two-phase mixture of NaOH and Hydrogen gets separated. This
catholyte stream is tapped as “Product” and fed to the caustic evaporation unit. Whole stream is not tapped and
some part is sent for internal consumption.
Anolyte Dechlorination: Depleted brine containing dissolved chlorine (called anolyte) is dechlorinated in two
stages: Vacuum dechlorination and chemical dechlorination. A part stream of chemically dechlorinated brine is be
purged out of the system to keep the sulphate within the desired levels.
Caustic Evaporation Unit: Here the incoming 32% Caustic is concentrated to 50%. The 50% caustic coming
from this unit can be stored in 50% storage tank.
Chlorine Treatment: The water vapor is removed, from the saturated chlorine, using series of coolers. The gas is
then passed through the moist chlorine filter to remove the entrained brine aerosol. In drying towers 98% H2SO4 is
used to dry moist chlorine.
The dried chlorine gas is compressed to the required pressure and then liquefied. Liquid chlorine from the liquefiers
is sent to liquid chlorine storage tanks. Sniff gas from the liquefier containing inlets and chlorine gas is sent to the
HCl synthesis unit. Excess sniff gas, is diverted to the waste air system.
Hydrogen Treatment: Hydrogen gas leaving the cells saturated with water vapor is cooled. The cooled gas is
passed through filters to remove the NaOH aerosols. Some amount of hydrogen is required for HCl synthesis and a
part of the gas is sent to caustic flaking unit to be used as fuel and a part is sent to hydrogen bottling through
hydrogen compressors as per requirement and the balance hydrogen is vented through with flame arrestor.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 13
HCl Synthesis Unit
Hydrogen is burnt in Chlorine atmosphere and the combustion gases are absorbed in water to yield a 32% HCl
solution. HCl produced is pumped to HCl head tank from HCl receiver for internal consumption within plant. The
Block diagram showing the Caustic Soda Manufacturing Process is shown in below figure:
Cl2 Gas
0.887 MT
H2 Gas
0.025 MT
Drift loss
0.12 MT
Evp. Loss
1.36 MT
Salt
1.564 MT Salt
Na2CO3 – 0.017 MT
2.81 MT- Na2CO3
H2SO4-98%
0.02 MT- H2SO4
α.cellulose
0.10 MT
Flocculent
0.01 MT
NaHSO3 – 1.268
MT
Process water
2560.66 MT
Sludge 0.012 MT
Water - 0.0035 MT
Liq. Effluent
1 MT
CT Blow Down
0.562 MT Purge Brine
1.32 MT
NaOH-1MT
Water - 284.0 MT
HCL-32% - 0.37MT
Water - 0.25 MT
Hypo – 0.016 MT
Water-MT – 0.014 MT
H2SO4-78% - 0.025 MT
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 14
Schematic Diagram of Caustic Soda Manufacturing Process
3.5.2 Cogeneration Plant (Existing + Expansion)
In the case of lignite/coal-fired boilers, steam generation with any of following firing technology is technically
feasible:
Circulating fluidized bed combustion (CFBC)
Pressurized Fluidized Bed Combustion (PFBC)
Integrated Gasification Combined Cycle (IGCC)
Pulverized Fuel Firing (PF)
Circulating fluidized bed combustion (CFBC) technology is adopted for the proposed cogeneration plant. A 100 MW
cogeneration plant turbo-alternator and 350 TPH + 350 TPH (standby) lignite / coal / petcoke based CFBC Boilers,
along with cogeneration plant machineries will be installed in order to meet internal steam and power requirement
for the proposed expansion.
The steam generator units proposed for the plant will be compact, semi-outdoor, natural/assisted circulation,
balanced draft, single drum, water tube type provided with Circulating Fluidized Bed Combustion system using pan-
leg furnace configuration. In a typical Circulating Fluidized Bed furnace, the lignite fed on a bed of suitable inert
material with addition of a sorbent material (such as lime stone) is burnt in suspension through the action of
primary air distributed below the combustor floor. In addition, secondary air is introduced at suitable points in the
combustion zone to ensure controlled and complete combustion of the fuel. Suitable lignite feeding and limestone
feeding arrangements are provided in the typical Circulating Fluidized Bed Combustion systems and is commonly
used as bed material for initial start-up of the boiler. The steam generators will be designed for satisfactory
continuous operation with the range of lignite/coal expected for this plant without any need for auxiliary fuel oil for
fire stabilization etc. Lignite and Coal are used as fuel after mixing in appropriate ratio.
VENT
CAUSTIC TO STORAGE AND
FILLINGSALT SATURATION
BRINE PRECIPITATION
CHLORATE DESTRUCTION
CATHOLYTE SYSTEM
DM WATER/CONDENSATE
CHEMICALS Na2CO3,NaOH SALT
FLOCCULANT
NaHSO3, NaOH 32% SOLUTION
DM WATER
FLAKES STORAGEAND BAGGING
HYDROGEN BOTTLING
FLAKING UNIT
CAUSTIC EVAPORATION
CHLORINE LIQUEFICATION
HYDROGEN TREATMENT
LIQUID CHLORINE STORAGE
CHLORINE FILLING
48.5 / 50%NaOH SOLUTION
BRINE PURIFICATION
(ION EXCHANGE)
BRINE FILTRATION
SLUDGE FILTRATION
BRINE CLARIFICATION
ANOLYTE DECHLORINATION
SLUDGE
CHLORINE COOLING &
DRYING
98% H2SO4
CHLORINE COMPRESSION
ANODE CATHODE+ -
78% H2SO4
H2 TO STACK
HCL FILLING
HCL STORAGE
HCL SYNTHESIS UNIT
HYPO FILLING
HYPOCHLORITE STORAGE
WASTE GAS DECHLORINATION
VENT
SALT SATURATION
BRINE PRECIPITATION
CATHOLYTE SYSTEM
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Steam generating unit would be provided with electrostatic precipitator in the flue gas path. The overall efficiency
of ESP will be around 99.70% with one field remaining as operational standby. The ESP would have adequate
number of ash hoppers provided with electric heaters. The design of ESP will be such that the dust burden at the
outlet of chimney with one field out of service doesn’t exceed 50 mg/Nm3 at 100 % BMCR with worst fuel.
Common chimney for boiler G and H will be constructed. The NOx emission from the steam generator is least in
case of CFBC steam generator design in view of low combustion temperature maintained in the furnace. The steam
generator and auxiliaries will perform continuously within noise limits as per relevant standard specification but not
more than 85 dB (A) at 1.0 meter from any equipment or sub equipment. The steam from the boiler will go to back
pressure turbo generators. The extracted back pressure steam will be used in process.
3.6 Utilities
The estimated list of utilities required for the new project is as given below:
3.6.1 Power Requirement
The total additional power demand for the expansion has been estimated about 152.82 MW. The power
requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH,
total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.
* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as
540 TPH.
Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.
3.6.2 Fuel Requirement
Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr for
existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.
3.6.3 Water Requirement
Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater intake – 14 x 105
m3/day. Additional seawater intake - 3.6 x 105 m3/day.
3.6.4 Storage Details
Unit will create additional storage facilities for products, raw materials as per the MSIHC rules.
3.7 Pollution Load on Environment due to project
Environmental issues include:
Air emissions;
Wastewater;
Solid Wastes.
3.7.1 Air Emissions & Control
Point Source
Likely air pollutants from proposed project shall be PM, SOx & NOx from flue gas stack, as point source.
NIRMA LIMITED
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 16
Volume Source
PM emission from coal storage yard is envisaged as volume source emissions.
Fugitive Emissions
Line Source Emissions
The ambient air quality & stack emissions will be maintained as per GPCB/CPCB norms.
Details of proposed stacks with fuel consumption and attached Air Pollution Control Equipment details are tabulated
in Table 3-3 & Table 3-4.
Table 3-3: Details of Stack Emissions
S. No. Stack Attached to Stack Height
(m)
Stack Top
Dia. (m) APCM
Expected
Pollutants*
Existing
Soda Ash Division
1 Boiler - A, B, C & D (100 TPH
Each)
100 (Common
Stack) 5.04 ESP to Each Boiler PM, SO2 & NOx
2. DG Set (1000 KVA)
2 No. 24 each 0.2 -- PM, SO2 & NOx
Caustic Soda & CPP Division
2 Boiler - E (200 TPH) 121 (Common
Stack) 4.5
ESP PM, SO2 & NOx
3 As per EC 2014 Boiler - F (200
TPH) – Not Installed Yet ESP PM, SO2 & NOx
4
As per EC 2017 Boiler - G & H
(350 TPH each ) – Installed
One boiler having capacity 410
TPH
121 (Common
Stack) 4.5 ESP PM, SO2 & NOx
5 DG Set (1000 KVA) 30 0.32 - PM, SO2 & NOx
6 DG Set (1500 KVA) 30
0.32
-
PM, SO2 & NOx
7 DG Set (1500 KVA)
Toilet Soap plant
8 Thermic Fluid Heater (3 No.) 45 0.4 PM, SO2 & NOx
Proposed
Soda Ash Division
1. DG Set (2000 KVA) 30 0.32 -- PM, SO2 & NOx
Caustic Soda & CPP Division
1 Boiler - I & J (410 TPH + 130
TPH) *
121 (Common
Stack) 13.4# ESP PM, SO2 & NOx
2 DG Set (1850 KVA) 30 0.32 -- PM, SO2 & NOx
* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as
540 TPH.
# Considering better dispersion, Engineering design has calculated the stack dia. as 13.4m
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 17
Table 3-4: Details of Process Emissions
Sr. No. Vent Attached to Stack Height
(m)
Stack Dia.
(m)
Air Pollution Control
System Pollutant
1
Soda Ash Plant – Existing & Proposed
Lime Kilns (A to H) – 8 nos. 68 (Common
Stack) 0.8
4 scrubbers and 3 ESP in
Series PM, SO2, NOx
Ammonia Recovery System (A to
E) - 5 nos.
56 (Common
Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia
Lime Grinding System (A to E) - 5
nos. 60 (each) 0.65 Bag Filter PM
Calcinations Vessel (A to D) - 4
nos. 29 (each) 0.7 Water Scrubber PM
Densification 1 40 1.37 Water Scrubber PM
Densification 2 51 1.37 Water Scrubber PM
Densification 3 51 1.37 Water Scrubber PM
Lime Kilns (I to L) – 4 nos.
(Proposed)
68 (Common
Stack) 0.8
Two scrubbers and two
ESP in Series PM, SO2, NOx
Ammonia Recovery System (F &
G) - 2 nos. (Proposed)
56 (Common
Stack) 0.75 Brine Scrubbers (2 nos.) Ammonia
Lime Grinding System (F- 1 no.)
(Proposed) 60 0.65 Bag Filter PM
Calcinations Vessel (E & F - 2
nos.) (Proposed)
29 (Common
vent) 0.7 Water Scrubber PM
Densification 4 (Proposed) 51 1.37 Water Scrubber PM
2
Caustic Soda and CPP - Existing & Proposed
HCl Synthesis Unit – 1 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit - 2 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit – 3 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit - 4 30 0.1 Water Scrubbers HCl & Cl2
HCl Synthesis Unit – 5
(Proposed) 30 0.1 Water Scrubbers HCl & Cl2
Waste Gas Dechlorination
System - 1 30 0.3 18% NaOH Scrubber Cl2
Waste Gas Dechlorination
System - 2 30 0.3 18% NaOH Scrubber Cl2
Waste Gas Dechlorination
System – 3 30 0.3 18% NaOH Scrubber Cl2
Hydrogen unit with Flame
arrestor and steam snuffing – 1 30 -- -- --
Hydrogen unit with Flame
arrestor and steam snuffing – 2 30 -- -- --
Hydrogen unit with Flame
arrestor and steam snuffing – 3 30 -- -- --
3. Bromine Plant
De-bromination System 30 0.3 Alkali Scrubber Bromine
4.
Chlorine & Hydrogen Derivatives
Solvent Recovery 30 0.3 Ceramic + Activated
Carbon Filter Aromatic Solvent
Hydrogenation Plant (purge gas) 30 0.3 Ceramic + Activated H2 + Aromatic Solvent
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Sr. No. Vent Attached to Stack Height
(m)
Stack Dia.
(m)
Air Pollution Control
System Pollutant
Carbon Filter
Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,
HCl, TOC
HCl Synthesis Unit 30 0.1 Water Scrubbers HCl
Chlorination Plant 30 0.3 Acidic/Water Scrubber (3
nos.) SO2, HCl, Cl2
Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2
Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2
Hydrogenation Plant (purge gas) 30 0.3 ---- H2
3.7.2 Noise Generation
From the proposed project, noise shall be generated from the various activities. Source of noise generation are:
The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during construction
phase;
Operation of plant machinery and diesel generator set;
Vehicle movement for transportation of raw material.
3.7.3 Waste Water Generation
The main source of the industrial wastewater generation will be from domestic, process, utilities, washing and
others. The total quantity of effluent will be increased from 5,86,445.2 KLD to 9,06,634.7 KLD. Entire quantity of
wastewater will be treated in existing treatment facilities. In existing scenario Treated effluent is partly reused /
recirculated in salt works and around 12000 m3/day of Soda Ash effluent and 6000 m3/day of Bittern is being
disposed off in to the sea at a discharge point suggested by National Institute of Oceanography (NIO).
In proposed expansion, Additional soda ash effluent, additional bittern & cooling water will be disposed in sea along
with existing effluent and bittern at point suggested by NIO. Return cooling water of 3,00,000 m3/day will be
disposed into deep sea at a discharge Point suggested by NIO on permanent basis and during emergency purpose /
monsoon 8,60,000 m3/day will be disposed into sea.
NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water and salt / sea water drawl based
projects, such as Nirma Ltd., Kalatalav, Bhavnagar Dist., cannot work without suitable sea discharge, considering
the huge volumes of sea water involved.
Details of Waste water generation are given in Table 3-5.
Table 3-5: Wastewater Generation Details
Sr. No. Source Wastewater Generation (m3/day)
Existing Proposed Total
Soda Ash plant
1. Domestic 184 99 283
2. Process 32547 17436 49983
3. Boiler 216 0 216
4. Cooling 473571 286840 760411
5. Others 0 0 0
Total (I) 506518 304375 810893
Toilet Soap plant
1. Domestic 48 0 48
2. Process 0 0 0
3. Washing 25 0 25
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Sr. No. Source Wastewater Generation (m3/day)
Existing Proposed Total
4. Cooling 275 0 275
Total (II) 348 0 348
Caustic Soda Plant & CPP
1. Domestic 11 3.5 14.5
2. Process 750 250 1000
3. Boiler 1340 447 1787
4. Cooling 43842 14614 58456
Total (III) 45943 15314.5 61257.5
Salt works
1. Salt works 11000 500 11500
Total (IV) 11000 500 11500
Bromine plant
1. Cooling tower 1000 0 1000
2. Process 12500 0 12500
Total (V) 13500 0 13500
Chlorine & Hydrogen Derivatives
1. Domestic 6.6 0 6.6
2. Process + DM 1595 0 1595
3. Cooling + Chilling 2977 0 2977
4. Boiler 0 0 0
5. Washing/Others 41 0 41
Total (VI) 4619.6 0 4619.6
RBC Plant, Calcium Chloride plant & Phosphoric acid plant
1 Domestic 8.6 0 8.6
2 Process 4250 0 4250
3 Cooling 258 0 0
Total (VII) 4516.6 0 4516.6
Grand Total (I to VI) 586445.2 320189.5 906634.7
3.7.4 Hazardous Waste & Other Solid Waste
The main source of hazardous waste generation will increase after proposed expansion. ETP sludge will be dispose
to TSDF site. Used oil will be sold to authorized recycler and discarded containers & plastic liners will be sold to
registered recyclers.
The details of Solid & hazardous waste are given in Table 3-6 & Table 3-7.
Table 3-6: Solid Waste Generation & Disposal
Sr. No. Solid Waste
Quantity (TPD)
Mode of Disposal Existing Proposed
After
Expansion
1 Settling Pond Sludge 880 482 1362 Shall be used in road construction,
salt works bund preparation
2 Lime stone rejects /
under size 700 375 1075
Shall be used in boilers for
desulphurization in boilers
3 Brine Sludge 19 10 29 Non-hazardous; Shall be used
dumped in identified area
4 Fly ash/ Bottom ash 2185 1693 3878 Brick manufacturing, bund
preparation, road making etc…
5 Incineration Ash --- 15 15 Brick manufacturing, bund
preparation, road making etc…
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Sr. No. Solid Waste
Quantity (TPD)
Mode of Disposal Existing Proposed
After
Expansion
6 Saponification
Solid Waste 3 0 3
Non-hazardous; Shall be
dumped in identified area
Table 3-7: Hazardous Waste Generation and Disposal
Sr. No. Hazardous Waste Category
Quantity (MTPA)
Mode of Disposal Existing Proposed
Total After
Expansion
1
Soda Ash Plant
Waste Oil / Lub. Oil from 5.1 10 5 15
Collection, Storage,
Transportation & disposal
by selling to Registered
Recyclers
Spent ion exchange resins 34.2 1830 lt/year 980 lt/year 2810 lt/year
Collection, Storage,
Transportation, Disposal
by selling to authorized
recyclers or sent to NECL
Nandesari for
Incineration.
Discarded
bags/drums/containers etc… 33.3 3.5 2 5.5
Collection, Storage,
Transportation, Disposal
by selling to authorized
recyclers
2
Caustic Soda Plant
Waste Oil/ Lub. Oil from 5.1
30 kl 10 kl 40 kl Collection, Storage,
Transportation & disposal
by selling to Registered
Recyclers
Spent ion exchange resins 34.2
2.56 1 3.56 Collection, Storage,
Transportation, Disposal
by selling to authorized
recyclers or sent to NECL
Nandesari for
Incineration.
Discarded
Bags / drums / containers
etc…
33.3 4.5 1.5 6
Collection, Storage,
Transportation, Disposal
by selling to authorized
recyclers
Residue/ Sludge & Filter
sludge 16.2 6526 2175 8701
Collection, Storage,
Transportation, Disposal
at TSDF
ETP sludge 34.3 150 50 200
Collection, Storage,
Transportation, Disposal
at TSDF
Spent Sulphuric Acid (80%) D2 6520 2173 8693
Collection, Storage,
Transportation, reuse as
raw material for Nirma
Ltd. Moraiya and other
end users.
3 Toilet Soap Plant
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 21
Sr. No. Hazardous Waste Category
Quantity (MTPA)
Mode of Disposal Existing Proposed
Total After
Expansion
Waste Oil/ Lub. Oil from 5.1 0.45 0 0.45
Collection, Storage,
Transportation & disposal
by selling to Registered
Recyclers
ETP sludge 34.3 48 0 48
Collection, Storage,
Transportation, Disposal
at TSDF
Glycerin foot D6-II 72 0 72
Collection, Storage,
Transportation & disposal
by selling to M/s.
Ultratech Cement for Co-
incineration in cement kiln
/ NECL for Incineration.
Spent Sulphuric Acid (80%) D2 24000 0 24000
Collection, Storage,
Transportation, reuse as
raw material for Nirma
Ltd. Moraiya and other
end users.
4
Chlorine & Hydrogen Derivatives
Waste Oil/ Lub. Oil 5.1 10 0 10
Collection, Storage,
Transportation & disposal
by selling to Registered
Recyclers
Discarded containers/
Barrels/empty drums/empty
bags
33.3 10 0 10
Collection, Storage and
disposal by selling to
authorized recyclers.
ETP sludge 34.3 120 0 120
Collection, Storage,
Transportation, Disposal
at TSDF
Glycerin foot D6-II 5356 0 5356
Collection, Storage &
incineration in plant
incinerator.
Catalyst from regeneration 35.2 1.2 0 1.2
Collection, Storage,
Transportation, Disposal
at Common Haz. Waste
incineration facility
Spent Carbon from solvent
recovery 35.3 3 0 3
Collection, Storage,
Transportation, Disposal
at Common Haz. Waste
incineration facility
Spent Carbon from ETP 34.3 3 0 3
Collection, Storage,
Transportation, Disposal
at TSDF
Distillation Residue 36.4 550 0 550
Collection, Storage,
Transportation, Disposal
at Common Haz. Waste
incineration facility.
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 22
4 SITE ANALYSIS
4.1 Connectivity
4.1.1 By Road
The nearest highway (Bhavnagar-Ahmedabad SH-6 Coastal highway) is about 14.0 kms away from the plant in the
West direction.
4.1.2 By Rail
Major railway station for public transportation is Bhavnagar Railway Station located at an aerial distance of ~10 Km
from the project site in the South-South West Direction.
4.1.3 By Air
Bhavnagar has its own airport, Bhavnagar Airport, which is at ~10 Km from project site.
4.2 Land Form, Land use & Land Ownership
There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma
Limited. Land Cover will be as per the Site Layout Map as shown in Annexure 1.
4.3 Topography
Project site is shown on Toposheet in Annexure 2.
4.4 Existing Infrastructure
Existing infrastructure like roads, power supply, water supply line, etc. are readily available at the site.
4.5 Soil Classification, Geology & Drainage
4.5.1 Soil Classification
Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. The soil type is a mixture
of sand & gravel with intermediate golden colour laterites with clay as binder. The subsoil strata of the study area
consist of a mixture of sandy gravel with clay as binder in the top 10 m. Thereafter the strata of about 50 m is a
thick layer of Grayish-blue clay having very hard to stiff consistency tending to rock like formation. The topsoil
around Kalatalav is made up of coarse saline soil poor in nutrients.
Most of the 10 km radial zone around Kalatalav has alluvial deposits and consists of sandy soil, tidal mudflats,
raised beaches and freshwater alluvium. Clay (size < 0.002mm) amount in the soil samples ranges from 17% to
22%; Silt (size 0.002 to 0.075 mm) in the soil samples is 14% to 18% Sand (size 0.075 to 0.475mm) in the soil
samples is 50% to 58% and gravel (size > 4.75 mm) in soil samples is 10% to 14%.
4.5.2 Geology
The Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. It falls in the seismic
zone-III as per IS 1893 (part -1) 2003. Peninsula is bounded by sea on all sides except northeast side where it is
flanked by alluvium plains of main land.
NIRMA LIMITED
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PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 23
Bhavnagar district shows diverse features like uneven, rocky (basaltic) land surface traversed by mountain
ranges/ridges and trappean dykes. Most of the district is composed of Weathered to Hard & massive Deccan Trap
formation, which is impervious with low yield. Rocks with cracks, fractures and fissures provide some discharge and
potable water quality.
4.6 Climatic data from secondary sources
Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term
Climatological Tables, 1981-2010, Bhavnagar (A). These tables give useful information about a region’s weather,
since they are collected over a 29-year period. Copy of the same is attached as Annexure 3.
Mean daily maximum temperature is recorded in the month of May at 40.0°C. From October to December, both day
and night temperatures begin to decrease rapidly. January is generally the coldest month, having minimum
morning temperature at 13.9°C. During the post-monsoon months of October, November, December day
temperatures remain between 17.8ºC - 26.7ºC. In winters, i.e. December, January and February, average day
temperatures remain between 16.2 – 18.8ºC.
The total rainfall in year is observed to be 655.9 mm. Distribution of rainfall by season is 2.4 mm in winter
(December, January, February), 5.2 mm in summer (March, April, May), 612.4 mm in monsoons (June, July,
August, September) and 35.9 mm in post-monsoons (October, November, December). Annual total heaviest rainfall
recorded in 24 hrs is observed to be 434.4 mm on 20th July, 1996.
An online weather logger was set up at Plant site. The co-ordinates for the same are 21051’14.1”N; 72010’32.8”E.
4.7 Social Infrastructure Available
Educational Facilities
As per 2001 census in all 5 villages, there are 4 primary schools & other educational facilities are in 10 km radius of
the study area.
Medical Facilities
Out of 4 villages in the study area, one has Primary Health Sub-Centers & other medical facilities are within 10 km
of the study area. Almost all medical facilities are available there.
Drinking Water Supply
All the villages in the study area have two or more sources of drinking water. All villages in study area have tap
water supply (almost all) with tank water supply. One village has well water facility.
Communication & Transport
The main mode of public transport available in the study area is by bus service. All villages are near Bhavnagar, so
almost all villages have approach to railway station as western railway meter gauge line is passing through nearby.
Post & Telegraph
There are 5 villages in study area, 2 villages have post office facility at doorstep & almost all have phone facility.
Power Supply
All the villages are getting power supply for domestic purposes.
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KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 24
5 PLANNING BRIEF
5.1 Planning Concept
Site falls under the seismic Zone III, which is classified as Low Risk zone (Area liable to shaking Intensity VI (and
lower). Thus, suitable seismic coefficients accordingly shall be adopted while designing the structures to make it
earthquake resistant.
Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc. are already
developed in the project site.
5.2 Landuse Planning
There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma Ltd.
5.3 Assessment of Infrastructure Demand (Physical & Social)
No additional infrastructure demand is required.
5.4 Amenities/Facilities
Within the study area (i.e. 10 kms) basic amenities/ facilities like there are 4 primary schools & other educational
facilities, is available in all the nearby villages. Out of 4 villages in the study area, one has Primary Health Sub-
Centres & other medical facilities are within 10 km of the study area. Bhavnagar is nearest city to the study area,
which is around 10 km away from project site. Almost all medical facilities are available there.
All the villages in the study area have two or more sources of drinking water. All villages in study area have tap
water supply (almost all) with tank water supply. One village has well water facility. The main mode of public
transport available in the study area is by bus service. All villages are near Bhavnagar, so almost all villages have
approach to railway station as western railway meter gauge line is passing through nearby. Majority of villages in
the study area is connected with pucca road. Out of 5 villages in study area, 2 villages have post office facility at
doorstep & almost all have phone facility. All the villages are getting power supply for domestic purposes.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 25
6 PROPOSED INFRASTRUCTURE
6.1 Industrial Area (Processing Area)
The existing unit comprises of following sections:
Boiler House consisting of CFBC Boilers – 2 Nos., Steam Turbine, Alternator / Generator;
Fuel storage area;
Utility Area consisting of cooling tower, compressors, ESP section, ETP area;
Fly Ash & Hazardous waste storage area.
Adequate storage space for fuel storage, hazardous and other solid waste is already available. Additional storage
space will be provided as per the requirement.
6.2 Non- Processing Area
Existing non processing area includes Weighbridge, Administrative Building, Laboratory, Security cabins, Workers
restroom, Vehicle Shed, Water reservoirs for raw water and fire hydrant system, Temporary storage sites, Works
block etc.
6.3 Greenbelt
Nirma has done extensive plantation in around 110 acres and spared total 183.4 acres for greenbelt development. Unit is also taking interest to develop greenbelt peripheral outside of the factory premises
6.4 Social Infrastructure
Refer Chapter 4, Section 4.7.
6.5 Connectivity
Refer Chapter 4, Section 4.1.
6.6 Drinking Water Management
Drinking water source for the existing Nirma plant at Kalatalav is from RO plant.
6.7 Sewage System
Sewage would be generated from the various units within the manufacturing facility. The existing sewage quantity
generated is 258.2 m3/day. The sewage expected to be generated for proposed expansion would be 102.5 m3/day.
Thus, the total sewage generation would be 360.7 m3/day. The sewage would be disposed off in soak pits of
individual plants and the same is being used in greenbelt development.
6.8 Industrial Waste & Solid Waste Management
Solid and hazardous waste as mentioned in Chapter 3, Section 3.7.4 shall be collected, stored, disposed to
authorized vendors and sold to local suppliers as per it’s characterization and based on the prescribed Fly Ash
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT
KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 26
Notification, 2015 & Hazardous Waste Rules, 2016 amended till date. Other wastes to be generated from the
project are tabulated in Table 6-1. Details will be provided in EIA report.
Table 6-1: Identification of Other Wastes
S. No. Type of Waste Constituents
1 Municipal Solid Waste Kitchen waste, cardboard, paper and garden wastes
2 Inorganic Waste Scraps, paper bags, cardboards and glassware’s etc.
3 Plastic Waste Plastic bags, plastic scraps etc.
4 E-waste CD’s, LAN Cables, Fuses, Data cables, circuit boards, etc.
5 Biomedical Waste Syringe, Bandages, used cotton, medicine etc.
6 Construction & Demolition waste Debris
6.9 Power Requirement & Supply / Source
Refer Chapter 3, Section 3.6.1.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR REHABILITATION AND
RESETTLEMENTS
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 27
7 REHABILITATION AND RESETTLEMENT (R& R) PLAN
Since no additional land is acquired for the proposed expansion project, and all the proposed units will be inside the
existing plant premises, R & R issues are not envisaged.
NIRMA LIMITED
REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA
PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY
AT KALATALAV, NEAR BHAVNAGAR PROJECT SCHEDULE & COST
ESTIMATE
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 28
8 PROJECT SCHEDULE AND COST ESTIMATE
8.1 Likely date of start of construction and likely date of completion
The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized
committee. Tentative schedule for the project to be completed is given in Table 8-1.
Table 8-1: Tentative Project Time Schedule
S. No. Activities Start Finish
1 EC Approval August, 2018 December, 2018
2 Detailed Engineering April, 2019 July, 2019
3 Procurement and Delivery August, 2019 Delivery start from
December, 2019
4 Construction at Site (Buildings, Mech., Piping, Elec., Inst etc.) August 2019 December, 2020
5 Pre Commissioning January, 2021 June, 2021
6 CTO Approval July, 2021 January, 2022
7 Process Startup and Stabilization September, 2021 March, 2022
8.2 Estimated Project Cost
The project cost is estimated to be INR 1320 crores. The breakup of project cost is given in Table 8-2.
Table 8-2: Breakup of Project Cost
S. No. Particulars Amount (INR in Crores)
1 Soda Ash Plant 570
2 Caustic Soda and CPP 750
Total Project Cost 1320
8.2.1 Profitability
The project has been conceived upgrading old inefficient sets with new efficient sets, hence increasing profitability.
Further capacity enhancement leads to a reasonable ROI, based on consuming plant expansion.
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PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANALYSIS OF PROPOSAL
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9 ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits
During the construction phase around 150 workers and existing manpower is sufficient to operate proposed
expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.
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ANNEXURES
NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
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Annexure 1: Preliminary Site Layout Map
NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN
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Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles
NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN
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Annexure 3: Long Term Meteorological Data for Bhavnagar City
NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN
EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES
KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 34