PROPOSED CML SMELTING PLANTenvironmentclearance.nic.in/writereaddata/Online/TOR/18...Proposed CML Smelting Plant at HALDIA, West Bengal 1 1 INTRODUCTION 1.1 Preface M/S Chloride Metals

PROPOSED CML

SMELTING PLANT AT HALDIA, WEST BENGAL

WADIA TECHNO ENGINEERING SERVICES LTD. 16, Mahanirban Road, Kolkata 700029

[Pick the date]

Proposed CML Smelting Plant at HALDIA, West Bengal

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CONTENTS

1 INTRODUCTION ................................................................................................. 1

1.1 Preface ........................................................................................................ 1

1.2 Scope of the Report ..................................................................................... 1

1.3 About Haldia ................................................................................................ 2

2 PROJECT APPRECIATION .................................................................................... 5

2.1 Location ....................................................................................................... 5

2.2 Description of the Project Area .................................................................... 7

2.3 Climate & Physiography ............................................................................... 9

2.4 General Topography .................................................................................. 10

2.5 Demography of the Project Influence Area ................................................ 10

2.6 Demography of Haldia Municipal Area at a Glance .................................... 11

2.7 Connectivity ............................................................................................... 12

3 INVENTORY OF INFRASTRUCTURE ................................................................... 14

3.1 Existing Infrastructure in the Region .......................................................... 14

4 SPECIFIC PURPOSE OF THE PROJECT ................................................................ 16

4.1 Introduction............................................................................................... 16

4.2 Purpose ..................................................................................................... 16

5 EMPLOYMENT POTENTIAL ............................................................................... 18

5.1 Employment Requirement ......................................................................... 18

6 TAX REVENUE GENERATION ............................................................................ 19

6.1 Tax Revenue .............................................................................................. 19

7 DEVELOPMENT OF BACKWARD REGIONS ........................................................ 20

7.1 Classification of Backward Region ............................................................. 20

7.2 Improving Grass root Governance ............................................................. 20

7.3 Improvement in Education and Health Indicators ..................................... 21

7.4 Access to Basic Amenities .......................................................................... 21

8 ECONOMIC DEVELOPMENT OF DISADVANTAGED COMMUNITIES ................... 23

8.1 Economic development methods .............................................................. 23

9 POLLUTION LEVEL OF THE PROJECT ................................................................. 24

9.1 Process Flow .............................................................................................. 24


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9.2 Water Supply Environment ........................................................................ 25

9.3 Sewerage and Drainage Environment ........................................................ 30

9.4 Solid Waste Environment .......................................................................... 38

9.5 Rainwater Harvesting System .................................................................... 38

9.6 Treatment of Air Emissions ........................................................................ 40

10 Fire Fighting System ...................................................................................... 43

10.1 Hydrant System ...................................................................................... 43

10.2 Sprinkler System ..................................................................................... 44

10.3 Fire Detection and Alarm System ........................................................... 44

10.4 Hooter .................................................................................................... 45

10.5 Detection Devices ................................................................................... 45

10.6 System –Operation Philosophy ............................................................... 46

11 CLARIFICATION OF LAND REQUIREMENT ...................................................... 47

11.1 Plant Requirements ................................................................................ 47

11.2 Land Area Requirement .......................................................................... 48

PAST RECORD OF M/S EXIDE INDUSTRIES .............................................................. 52

ANNEXURE - I……………………………………………………………………………………………………….52 ANNEXURE - II Process Flow-Chart……………………………………………………………………….54


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LIST OF TABLES

Table 1: Some Salient Features of the Project Area ............................................... 10

Table 2: Decadal Census Population of Haldia ....................................................... 10

Table 3: Demography of Haldia at a Glance ........................................................... 11

Table 4: Working Population of Haldia ................................................................... 11

LIST OF CHARTS

Chart 1: Decadal Population of Haldia ................................................................... 10

Chart 3: Pie-Chart Showing Literacy Rate ............................................................... 11

Chart 2: Bar Chart Showing Literacy Rate: .............................................................. 11

Chart4: Working Population................................................................................... 11

LIST OF PHOTOGRAPHS

Photograph 2: Haldia Petrochemicals ...................................................................... 2

Photograph 3: Haldia Doc ........................................................................................ 2

Photograph 4: Haldia Development Authority ......................................................... 4

Photograph 5: Haldia Municipality ........................................................................... 4

LIST OF MAPS

Map 1: Location map of Haldia ................................................................................ 5

Map 2: Location of the Site ...................................................................................... 6

Map 3: Map Showing BasudevpurMouza and Probable Location of Plot ................. 7

Map 4: Probable Location of Project Site on Land Use Map ..................................... 8

Map 5: Probable Location of Project Site on Satellite Image .................................... 8

Map 6: Connectivity between Haldia and Kolkaa ................................................... 12

Map 7: Proposed Master Plan ................................................................................ 51

LIST OF ANNEXURE

Annexure -1: letter of M/S ENGITEC to M/s CML


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1 INTRODUCTION

1.1 Preface

M/S Chloride Metals Limited, a 100 % subsidiary of Exide Industries Limited, intends to set up a New Smelting Plant on a plot of land of 20 acres towards the north of HPL Link Road at Mouza - Basudevpur, J.L No. -126, on the way to Manjushree More from City Centre, P.S.-Durgachak at Haldia Township, District-Purba Medinipur, West Bengal. The following persons shall be the signing authority on behalf of M/S Chloride Metals Limited for the purpose of obtaining various clearances of statutory bodies;

Name— 1. Mr. U.B. Agrawal, CEO & Whole Time Director 2. Mr Rajib Datta, Works Manager,

Registered Office Address: EXIDE HOUSE, 59E CHOWRINGHEE ROAD, KOLKATA-700020

Accordingly the project was awarded to Wadia Techno Engineering Services Ltd.,

Kolkata vide Work Order No. CML/MAINT/6 dated 10.04.2017as the Consultant for the Design and PMC of the proposed development.

1.2 Scope of the Report

The Consultant has prepared the Report with the intention to cover up the following contents;

- Specific purpose of the Project - Employment Potential - Likely Tax Revenue to be generated from the project - Development of the backward region - Economic development of disadvantaged communities - Pollution level of the Project - Clarification of land development - Past Record of M/s Exide Industries Ltd. as Investor


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1.3 About Haldia

Haldia has made its mark as a major Trade Port and Industrial City. Haldia is located at 22.03°N, 88.06°E at the confluence point of the River Hooghly (Local name- Hooghly, tributaries of the Ganges) and the Haldi River in PurbaMedinipur District of West Bengal. It is about 127 km by road and 140 km by rail from the State Capital City Kolkata. Haldia has an average elevation of 8 meters above MSL. Total area is 761.26 sq. km consisting of 476 mouzas. Haldia is a city and a municipality in Purba-Midnapur District in the Indian state of West Bengal. It is a major river port and industrial belt located on the southwest of Kolkata near the mouth of the Hooghly River. Haldia is being developed as a major trade port for Kolkata, intended mainly for bulk cargoes. The industrial city has several major factories; the following are few of them:

South Asian Petrochemicals Ltd,

Indian Oil Corporation Limited (IOCL),

Exide,

Shaw Wallace,

Tata Chemicals,

Haldia Petrochemicals,

Hindustan Lever Limited

Photograph 2: Haldia Doc

Photograph 1: Haldia Petrochemicals


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In addition to the above major players there exists a large number of various light industries the port has attracted Major International Petrochemicals Companies, like Mitsubishi Chemical Corporation (MCC). Mitsubishi Chemicals has the Second Largest Terephthalic Acid Producing Plant in Haldia. The Haldia Township is bordered by the River Haldi and River Hooghly, an offshoot of the River Ganges. Haldia is also the base of Indian Coast Guard with a hover port to house two of the six hovercrafts belonging to the Indian Coast Guard. It is one of the major ports in India. Haldia has a deep water dock system at dock Complex to facilitate the sea borne trade. It has the most sophisticated port facilities with extensive storage facility for diverse cargo with a modern computerized container terminal.


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Photograph 3: Haldia Development Authority

Photograph 4: Haldia Municipality

1.3.1 Haldia Development Authority (HDA)

Haldia Development Authority (HDA) is an autonomous body constituted under the West Bengal Town & Country Planning Act in 1980. The Authority is guided by the Board of Haldia Development Authority. HDA discharges its function through the CEO, HDA and implements the decision of Board in accordance with the established

Government rules and procedures and manages the finance as per the financial norms of the Government. 1.3.2 Haldia Municipality

The Department of Municipal Affairs dissolved Haldia Notified Area Authority on 01/10/1996 and an Administrator was appointed till election is held to form a popular Board and accordingly the first Board took oath on 9th June 1997 . Haldia Municipality has done a commendable work in the field of extending

various Municipal Services to the citizens. The Municipal nature of services are mainly - Domestic Water supply, Roads, Housing, Peripheral drainage. Electrification, Solid waste management. Conservancy, Transport., Education, Sports & Cultural activities etc. to both the Industrial area and Residential aras.


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2 PROJECT APPRECIATION

2.1 Location

The proposed site is located in the City of Haldia at 22.03°N 88.06°E with an average elevation of 8 meters to 10 meters above MSL covering an area of 333.67 acres.

Haldia is an industrial town located in the PurbaMedinipur District of West Bengal. The Haldia Industrial area along the Western coastal region of River Hooghly is surrounded by rivers Haldi, Hooghly and Rupnarayan. The region has been developed with the Haldia port as the focal point in the District.

Map 1: Location map of Haldia

The project area is lying on the north-east side of the city of Haldia. Bounded by two major roads and having the privilege of excellent connectivity in all directions by means of Road, Rail, Portland, Air. On the south-east side HPL Link Road is running in the east-west direction close to the southern boundary of the Industrial Park connecting the City Center with the industrial park and with other parts of

http://tools.wmflabs.org/geohack/geohack.php?pagename=Haldia&params=22.03_N_88.06_E_


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West Bengal, NH 41 running to Haldia City connecting City Center with the State Capital Kolkata via NH 6. On the east HPL Link Road is running through the Park eventually acting as the main ingress/ egress to the proposed industrial park; and is connected with SH – 4. The location of the project area has been shown in the Location Map. Haldia is well connected with Kolkata through rail also; daily trains are available from Haldia to Howrah via. Panskura. Haldia Port is well connected with the Railways and huge bulk & container cargo is exported and imported through Indian Railways.

The port has been primarily designed to reduce the pressure on Calcutta port. Harbor of the dock complex is wide enough to accommodate an extensive fleet of ocean going vessels. Thus Haldia being a satellite port of Kolkata has found opportunities for developing most of the port based industries which were found

declining in the Hooghly industrial belt due to the deterioration of Calcutta port because of loss of navigability of the Hooghly River. The Haldia port contributes much for the growth of industries through importing industrial machineries as well as raw materials from foreign countries.

Moreover the market for products of the Haldia industrial Complex has been extended beyond national boundaries through export trade. Haldia is connected to Kolkata by both bus and train. The Kolkata Airport 138 km. from Haldia connects the port city to the rest of the India and world by air.

Map 2: Location of the Site


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2.2 Description of the Project Area

The project site is bounded by Village on the Northern & Residential settlements on the Eastern Side; and by Industrial plot of Dhanseri Petro Chemicals on the Southern Side. On the Western side there is a temporary access road which is proposed to be developed. The site is approximately 700m from HPL Link Road on the South.

Map 3: Map Showing Basudevpur Mouza and Probable Location of Plot

The proposed Site is within the Mouza-Basudevpur, J.L. No. 126, P.S.-Durgachak, District- PurbaMedinipur, West Bengal. The proposed site is approximately 6.19 Kms. from the City Center and 2.80 Kms. from Manjushree More.

The general Contour of the site shows undulations and is a low lying area. A Land use Mouza Map and a Location Map is shown to explain the same.

It is observed that the site is lower from the adjacent access Road and requires filling for land development. The total land area available for Development is yet to be decided.


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There is no existence of Power transmission overhead line/ pylon/ telephone post/ electric post etc. which requires relocation.

Map 4: Probable Location of Project Site on Land Use Map

Map 5: Probable Location of Project Site on Satellite Image


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1 : 22°4’55.21”N 88°7’15.52”E

2 : 22°5’18.23”N 88°7’21.39”E

3 : 22°5’14.20”N 88°7’41.53”E

4 : 22°5’2.19”N 88°7’46.45”E

5 : 22°5’1.00”N 88°7’49.23”E

2.3 Climate & Physiography

The climate of Haldia is a typical moderate one with winter temperatures ranging from a low of around 9.6 degrees Celsius to a high of 29.3 degrees Celsius. Summers on the other hand can be very hot and humid. Usual summer temperatures in May range from a low of 24 degrees to highs around 42 degrees. Rainfall is heavy during monsoons, and the rainy months are between May and September.

Map 6: Latitude & Longitude References


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Table 1: Some Salient Features of the Project Area

Location Haldia

Topography 5.8 mtrs. - 10 mtrs. above MSL

Wind Mean speed – 5.5 to 9.9 km per hour

Rainfall Average – 1580 mm

Temperature Summer – 41.7 c to 24.0 c

Winter – 29.3 c to 9.6 c

Humidity 68 to 80%

Soil Alluvial, black, ragger and red terrogineous

Geology Khodalites, chamockites, quartzites and quartz veins

2.4 General Topography

There is a general gradual slope towards Southern side i.e. towards the 45 meter Service Corridor (Nananjuli), running parallel to the HPL Link Road, on the way to City Centre from Durgachak at Haldia Township area. The most prevalent soil in the region is black cotton soil. However, sandy, light grey, reddish and brown soil also occurs in the area. Major portion of the area is black and red sandy loam soil. The excessive salt content in the area has led the area into poor yield and not suitable for irrigation. Geological formations are of Khodalites, Chamockites, Quartzite and quartz veins origin occurring in elongated bands.

2.5 Demography of the Project Influence Area

In the 2011 census, Haldia had a population of 200,827, out of which 104,841 were males and 95,986 were females. The 0–6 year’s population was 21,945. Effective literacy rate was 79%. As of 2001 India census, Haldia had a population of 170,673. Males constitute 53% of the population and females 47%. In Haldia, 13% of the population is under 6 years of age.

Table 2: Decadal Census Population of Haldia

year population Decadal growth

1991 100,347

2001 170,673 7% 2011 200,827 2%

Chart 1: Decadal Population of Haldia


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2.6 Demography of Haldia Municipal Area at a Glance

Table 3: Demography of Haldia at a Glance

Population Persons Males Females

Total No. of Household 44065

Total Population 200827 104841 95986

Sex Ratio 916

In the age group 0-6 years 21945 11194 10751

Child Sex Ratio 960

Literates 158380 87334 71046

79% 55% 45%

Illiterate 42447 17507 24940

21% 41% 59%

Table 4: Working Population of Haldia

Total Worker 61216 54477 6739

30% 89% 11%

Main Worker 50,792 46,004 4,788

25% 91% 9%

Marginal Worker 10424 8473 1951

5% 81% 19%

Non Worker 139611 50364 89247

70% 36% 64%

Chart4: Working Population

Chart 2: Pie-Chart Showing Literacy Rate

Chart 3: Bar Chart Showing Literacy Rate:


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2.7 Connectivity

The port of Haldia acts as the guiding factor to trade and commerce of vast hinterland comprising the entire Eastern India including Bihar and Eastern Uttar Pradesh and the two land locked Himalayan Kingdoms of Nepal and Bhutan. Thus it has been rightly called as the “Gateway to Eastern India”. Beside Haldia is connected to Kolkata by both bus and train.

2.7.1 RoadConnectivity

A well connected road network with good condition of the roads is extremely important for an industrial region to prosper. This has motivated HDA to engage in construction of new roads along with widening of existing

roads. The port city is traversed by a good network of roads and highways connecting different parts of the industrial area. Haldia Development Authority ensures that every industrial, residential and commercial plot has an access through a road. At present all the roads in Haldia are in good conditions. The National Highway 41 connects the port city with National Highway 6 (part of Golden Quadrilateral) at Kolaghat. From Kolaghat NH-6 connects Orissa, Jharkhand, Kharagpur, Bankura and Purulia and also Durgapur, through NH-34 to North Bengal, Bangladesh via Petrapole and Bhojadanga.

Map 7: Connectivity between Haldia and Kolkata


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A State Highway also connects Haldia with Kolaghat via Tamluk town which is the district headquarters as an alternate connectivity. Besides the major Highways the Haldia Township has an extensive network of roads that

serve the different parts of the city and the industrial area. A 4-Lane Expressway linking Haldia to Kolkata up-to Airport (via Raichak-Kukrahati) is already become visible on the horizon. The Land acquisition for the road is nearing completion. There is a proposal to build up a 4 lane bridge connecting Raichak with Kukrahati which will improve connectivity with Kolkata and reduce the travel time between Kolkata and Haldia.

2.7.2 Rail Connectivity

Haldia port is connected with the broad-gauge line of the South-Eastern Railways. Panskura-Haldia electrified rail route is highly suitable for the

daily commuters. Also a circular railway connecting the core industrial areas to provide additional facilities to the industries are among the plans for the future. The rail route from Mecheda to Haldia has already been made double and remaining portion is being converted to double line. 2.7.3 Air Connectivity

The Netaji Subhash Chandra Bose International Airport, Kolkata, connects the port city to the rest of the India and world by air. Available road

transport from the airport to the port city provides an easy means of communication in spite of the distance. Currently a helipad has started operating in the port city for the VIPs to travel to and fro. Haldia Development Authority has identified a location for medium size airport. 2.7.4 Water Connectivity

The location of the city gives it a major advantage over many other industrial towns in the country. A well-knit system of navigation canals and

rivers serves the region. The Allahabad-Haldia stretch of the Ganga-Hooghly River serves as national waterways No 1. With Haldia Dock Complex, the country's 5th largest port with all modern facilities for industrial growth close to its doorstep, the city has its gates open to the Far East and the other ports along the Indian coast line. Bulk cargo-handling facilities, full-fledged container facilities, an oil jetty to handle tankers with liquid cargo are a few of the facilities that the Haldia Dock provides. Along with these the city is also equipped with river ferry services between Kukrahati-Raichak and Kukrahati - Diamond Harbor.


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3 INVENTORY OF INFRASTRUCTURE

3.1 Existing Infrastructure in the Region

The details on the existing core infrastructure facilities are dealt in the above paragraph some additional important aspects are dealt below:

3.1.1 Water

Haldia is served by rivers like Rupnarayan, Haldi and Hooghly that ensure abundant water supply for irrigation of the agricultural farms. The

Authority has made requisite arrangements to ensure treated industrial and domestic water supply round-the-clock. Due to current water demand of industries, HDA augmented 25 MGD Water Treatment Plant beside its existing 25 MGD Water Treatment Plant at Geonkhali. For fulfillment of future demand to a tune of 25 MGD the treatment plant has been started operating recently on BOT basis.

3.1.2 Power

West Bengal State Electricity Distribution Corporation Ltd. (WBSEDCL) is primarily responsible for a stable and quality power supply to the Haldia Planning Area. Nevertheless HDA has come forward to participate in many

of their projects both functionally and financially in the larger interests to promote more industrial development together with water supply etc. and thereby guaranteeing power supply also. Recently HDA has installed, through WBSEDCL, a dedicated power supply network to Chaitanyapur Water Works from HFC supply. The Authority is also planning to take up a number of projects involving renovation of electrical network in certain areas, illumination of roads and electrification of the underdeveloped areas. Moreover development of Kolaghat thermal power station has ensured power supply to the industrial region. Those willing to set up their captive power plants are also encouraged. CESC is setting up a new 200 MW power plant for to support PCPIR (Petroleum, Chemical & Petrochemical Investment Region) at Haldia, production has been started and thereby producing power. There are substations at Chiranjibpur, and another on NH-41. A new 132/33kv substation is set up just by the side of the proposed Industrial Park.

3.1.3 Telecommunication

For instantaneous communication to any part of the globe, Haldia port city is well equipped with the latest telecom facilities provided by BSNL,


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Reliance, Airtel, Vodafone etc. and postal services. The conventional cable networks have already replaced by the optical fibres. Other modern means of communication such as Internet and mobile telecommunication have turned into reality. Haldia Development Authority assists the entrepreneurs in obtaining telecom, telex and fax connections on a priority basis. HDA facilitates the telecom players in setting and strengthening telecommunication infrastructure in Haldia by providing well located land for their Base Terminal stations etc.

3.1.4 Land

With passage of time the statutory body of HDA has been given more teeth to acquire and distribute land. Land distribution norms have been eased to facilitate easy disbursement. About one thousand six hundred hectares of

land has been vested with HDA, and land is no problem for big or small-scale industry. With increasing land possession and hassle free procedure has made it even easier for the investors to set up various industries along the industrial belt. Similarly for the proposed development of Industrial Park at the designated location it was understood during the site visit and meeting with the Authority that out of 337.67Acres of land 314.17Acres of land parcel is under the procession of WBIDC for such development works. 3.1.5 Drainage

The Irrigation and Waterways Department of West Bengal plays a significant role in the planning and execution of the comprehensive drainage scheme for Haldia. To supplement, this scheme HDA has

undertaken a number of projects like construction of drainage culverts and RCC Box type culverts over Manasatala Canal. Also some secondary drainage schemes for Storm Water Drainage have been taken. To avoid any piece meal drainage scheme, HDA has entrusted IIT, Kharagpur for preparation of comprehensive Storm Water Drainage Master Plan for Haldia Area where intensive development has taken place & likely to be developed in the near future. The rough cost of the plan has been estimated to be Rs.64 crores (approx).


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4 SPECIFIC PURPOSE OF THE PROJECT

4.1 Introduction

4.1.1 M/S Exide Industries Ltd. is having two subsidiary Lead Acid Battery Recycling Units in Pune and on the outskirts of Bangaluru city in the name of M/s Chloride Metals Limited. Another New Recycled unit have been thought to be set up in Haldia Township, between City center and Manjushree More on HPL Link Road in the district of Purba Medinipur, West Bengal in the name of M/s Chloride Metals Limited.

4.2 Purpose

The basic purpose of the Project is to set up an industry which would be unique of its kind, with the best available Technology in Secondary Lead Smelting Industry. The technology would be in collaboration with the renowned similar Group in Europe, U.S. The technology would be shared from M/S ENGITEC TECHNOLOGIES SPA of Novate Milanese (MI)-Italy. The very purpose of the project is to establish an Industry where ‘State of Art’ in Lead Recycling shall be carried out with full compliance of Environmental Regulations worldwide. The Engitec process is mentioned as an example of best Technology available for the Recycling of Batteries which is mentioned in the document issued by the Secretariat of Basel Convention “ Technical Guidelines For The Environmentally Sound Management of Waste Lead Acid Batteries”. A letter of M/S ENGITEC to M/s CML is enclosed as Annexure-1 at the end of the report along with the past record of the company for ready reference. Following are the elaborated purposes of the project;

- Re-Cycling and Re-use of Lead acid Batteries which are already used in different sectors. The wasted batteries storage in the market is hazardous for the immediate Environment. Re-use of such batteries not only helps in keeping the Environment non hazardous, but also develops a Sustainable Industrial growth of the Region.

- This Industry helps in the Re-use of available materials


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- M/S Exide Industries Ltd. already have an obligation to collect the scrap Batteries which are there in the market, whether in use or not in use.


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5 EMPLOYMENT POTENTIAL

5.1 Employment Requirement

The Proposed Industry would run in three shifts, that is, it would run for 24 hours.

The Man power that would be required per shift would be approximately 40, that

is a total of 120 numbers of labours would be required per day. Besides this, there

is a requirement of 15 % of Administrative staff. The Tentative staff list would be

as follows:

5.2 Plant Staff Requirement per shift

--. Foreman per shift

-- Operators for the rotary operation

--- Operators for Refinery and Casting section

--- Skilled operators

--- Labours for material receiving, and material handling

--- Drivers for general material handling

--- Operations Manager

--- Quality control Manager

---Plant Engineer

---Staff for Shipping/Receiving

-- Labours for maintenance, logistics

The above mentioned Plant staff is the statutory requirement. Besides this, there

would be requirement of labours in Security staff in three shifts. There would also

be requirement in the Transport division for logistics, Tyre washing, outsourced

repairs , reclamation and engineering workshop etc. The above man power shall

be required after completion of the entire project.

Hence, setting up of this new Industry shall generate Employment potentiality

for the Region.


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6 TAX REVENUE GENERATION

6.1 Tax Revenue

TOTAL PRODUCTION QUANTITY PER MONTH================15000 MT (FINAL PRODUCT—LEAD & LEAD ALLOY AVERAGE MONTHLY PRODUCTION) TOTAL PRODUCTION PER YEAR========================= 180000 MT TOTAL SALES REALISATION REVENUE========= RS. 1.75 LAKH PER TONNE HENCE, TOTAL SALES VALUE PER YEAR======= RS. 3150 CRORES TAX GENERATION PER YEAR (in Crores) ON TOTAL SALES REALISATION Add : Taxes on above

GST @ 18 % 567

567.00

Total Turnover

3,717.00

Expected minimum of 2% income on the gross turnover 74.34

Income Tax @ 34%

25.28


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7 DEVELOPMENT OF BACKWARD REGIONS

7.1 Classification of Backward Region

Based on the National Committee on the Development of Backward areas ( N.C.D.B.A.) formed in the Year 1978, it is understood that the following are under the backward regions;

- Chronically drought—prone areas - Desert Areas - Tribal Areas - Hill Areas - Flood affected Areas - Coastal areas affected by Salinity

However, Haldia have only Schedule caste and Tribes distributed in village areas of Purba Medinipur. Following Programme shall be initiated to the development of backward class of the district;

- Initiating in the construction of Pucca roads and sanitation

- Promotion of healthcare programme

- Promotion of Child welfare Programme

- Raising funds of Primary level Education Programme

- Create awareness through training programme to develop community assets which can be used in the industry like seasonal crops

7.2 Improving Grass root Governance

7.2.1 One of the important objectives of the Backward class development is to improve grassroots governance by promoting transparent, accountable and efficient Public relation. There is a special fund for capacity building and a provision for the utilization of 5 per cent of the development grants for the strengthening of functionaries of the local institutions. The overall utilization


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of the capacity building grants was erratic and irregular, and lacked any clear purpose.

7.2.2 Three types of activities were undertaken through the capacity building grants:

(a) Construction of resource and training centres;

(b) Purchase of equipments, comprising mostly computers and furnishing, for the training centre; and

(c) Incurring of expenditure on the training.

However, even the incidence of low use of resources was not very helpful. In a few states, the state governments distributed the capacity building grants between the districts. The receipt of district-wise information about the use of the capacity building grants shows the tendency of the districts to spend them on the construction of resource and training centres, purchase of computers and equipments, and imparting of trainings.

7.3 Improvement in Education and Health Indicators

Literacy Rate

As mentioned earlier, the changes in the literacy rate levels between the years

2001 and 2011 can be attributed mainly to the SSA and the mid-day-meal scheme.

However, the interventions under the BRGF, which were mostly in the form of

addition of class rooms, provision of a mid-day-meal kitchen, construction of

hostels and playgrounds, and offering of some other facilities, were also helpful in

improving the overall literacy rate in the surveyed districts.

7.4 Access to Basic Amenities

Safe Drinking Water

Drainage and Toilet Facilities

Electricity

Under the RSVY, in a number of districts, investment was made in electricity

generation. The investments were related to the production and distribution of


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electricity, as also in terms of increasing the coverage of the households with

access to electricity. On the other hand, no significant investments were observed

in the production and distribution of electricity under the government grant.

However, investments in solar and other non-conventional sources of energy were

made in a number of districts, though these investments did not constitute a very

significant proportion of the total investments.


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8 ECONOMIC DEVELOPMENT OF DISADVANTAGED

COMMUNITIES

8.1 Economic development methods

Economic Development of Disadvantaged Communities issue could be taken up by providing direct or indirect assistance to the identified communities within the nearby villages. There could be training of such community people to take participation in the Material Transport sector of the Plant. They could be given training and financial assistances or given support to obtain financial loans to develop community assets, which could be utilized for the proposed plant.

This sector of community could be trained for possible utilisation in the

Catering supply, security system, Tyre washing, and other Non skilled labour involvement of the proposed plant including Workshop requirements.


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9 POLLUTION LEVEL OF THE PROJECT

9.1 Process Flow

9.1.1 In order to elaborate the pollution level of the project, we would like to give a brief introduction of the Process flow diagram of the proposed Industry. The detail process flowchart and write-up is attached in Annexure – II at the end of the report.

Process Flow Chart

Metallic Lead

Lead Paste Separator PP Acid

ETP By Product Selling to Authorized Recycles

Gypsum Water recycled to Gardening

Purpose and Process

Water Washing

Smelting Unit

Lead Bullion Slag (To be dispatched off by authorized agencies)

Refinery

Pure Lead and Lead Alloys

DISPATCH Dispatched off by Govt. Authorized Vendors per Day Basis

Receive of Used batteries (ULAB)

Battery Breaking


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The concerned areas of pollution according to Environmental guidelines and manual are as follows;

- Land Environment - Water Environment - Effect on Vegetation, Fauna - Air Environment - Garbage Disposal

Following are precautions and mandate that shall be followed in the proposed project 9.1.2 LAND ENVIRONMENT

Land area that would be required to set up this industry would be 20 acres. The built up areas along with all the necessary Utilities, Roads, & Infrastructural facilities shall be 45% of the land area, that is 9.00 Acres. Compulsory Green Belt around the industry to be kept as per MoEF guidelines, which is 35% of Land Area, that is 7.00 Acres. Balance 20 % of land area shall be open spaces, that is 4.00 Acres. The Proposed Land has already been defined as a classified Industrial zone by Haldia Development Authority. Hence, there is no change in the character of the land to be used for the Industry. The land would be approached by a road, which have already been shown in the Master land use plan and is existing as a Kutcha road. This would be developed further for the industry. The proposed land is a low land and needs to be raised at least to the level of the HPL Link Road for natural drainage to the nayanjulli running parallel to the HPL Link road.

9.2 Water Supply Environment

The water requirements for operation of the plant will be of two major categories viz.-

Domestic: To meet up the domestic needs of the plant operators and management personnel potable water of quality as per BIS 10500 will be required


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in appropriate quantity as per NBC norms. The domestic demand has been assessed as 40 KLD.

Industrial: Process water for Plant operation as well as for Pollution abatement measures will be needed as per the specific requirements of each unit of operation. The process water demand has been assessed as 40000 Liters per day. In order to run an HVAC system for the plant additional water requirement will be 10000 liters/day

Over and above, a bulk quantity of water will be needed for cleaning and washing of Transport trucks.

Total Industrial demand = 50000 Liters /day =50 Cu. M./day

9.2.1 Sources

The existing sources for availability of water at site has been analyzed in details along with the feasibility of other sources.

It is presumed that the Municipal Authority will be able to supply the potable water of quantity 22.0 cu.m /day to the plant. To meet up the Industrial needs the Plant will have to depend upon own sources i.e. by extraction of ground water by means of Bore wells.

It is proposed to sink Bore-well with design yield of 20 m3/hr. the depth of Aquifer

with potential capacity will be decided as per electro logging analysis carried out

during sinking of the Tube well. The primary structure of the Bore Well is proposed

as under:

9.2.2 Bore well structure:

Size: 250 x 150 mm Housing Pipe; Dia: 250 MM- LENGTH: 30 – 36 M Pipe: PVC Strainer: Slotted PVC 24-30 m length Aquifer Position: 350 m.bgl (app) Depth of Well: 380 - 390 m. Bottom blank pipe: 6.0 m Discharge: 15 - 20 M3/Hr. Pump: Submersible Type placed at 30 m depth below GL. Design Flow Rate: 20M3/Hr. Discharge Head: 50 M


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Capacity: 7.5 HP Normal Hours of operation: 5 Hrs.

The bore well will be able to meet up the domestic need as well in case of

exigencies.

9.2.3 Water Treatment Plant (WTP)

The water abstracted from Bore-wells will have to be treated for making it suitable for process needs as well as for domestic purposes.

The proposed WTP structure is as per following:

Oxidation chamber: For oxidizing soluble ferrous compounds to insoluble ferric compounds

Filter feed Tank: For storage of water prior to Filtration unit

Coagulant Dosing system: Addition of coagulant aids directly on line through

metering plant

Multi-grade Sand Filter: For filtration of coagulated colloidal matters by means of

sand filter beds

Activated Carbon Filter: For removal of odors and gases by means of adsorption

through activated carbon bed

RO unit: For removal of salinity

Softening Plant: For removal of Calcium and Magnesium compounds causing

Hardness

Demineralization Plant: For removal of undesirable chemicals and minerals as per

individual process requirement

Disinfection unit: For disinfection of water before domestic consumption by means

of Hypochlorite solution.

The WTP has been proposed to be in operation for 8 Hours per day in two shifts

and accordingly the capacity of WTP will become 10Cum/Hr. to meet up the

present demand.


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Outlet parameter of water ( As per IS 10500 )

Parameters quantity

Colour - <1 0

Odour – Agreeable Agreeable

Taste - Agreeable

Calcium ( Ca) 75 mg/l

Chloride ( Cl) 250 mg/l

Iron ( Fe) 0.01mg/l

Total alkalinity as Calcium carbonate 200 mg/l

Total Hardness CaCO3 200 mg/l

Total Dissolved Solids

500 mg/l

9.2.4 Underground Reservoir

The capacities of all the reservoirs have been analyzed and adequacy verified with respect to the actual demand.

Capacity of Reservoir

As per NBC Considering one day storage: Underground - 66.66% and

Over Head storage -33.33% I) UNDER GROUND TANK SCHEDULE

Location Application Required capacity QTY Proposed

Pump House Fire Tank 200 Cu.M 1 200 Cum

Pump House Raw Water Tank 1 72 Cum

Domestic Water Tank

1 40 Cu. M

Process Water Tank

1 50 Cu.M

9.2.5 Water Supply Distribution

The entire pipe network will be designed as per CPHEEO and NBC guidelines using Computer software.

Proposed Drinking Water Arrangements : Cold and normal Drinking water points have been provided at convenient places .The water supply points are provided with appropriate chilling process. 4 nos taps have been provided in each unit of chiller.


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Pumping Station: Total no of Pumps required for firefighting and domestic purposes have been worked out and the locations are proposed within the existing pump house for operation under positive suction head.

Clear water pump :

2 nos. Hydro- pneumatic Pumps (1w+1s) of capacity 6.0 Cu.m./hr with 50 m head for domestic water supply.

2 nos. Centrifugal Pumps (1w+1s) of capacity 9.0 Cu.m./hr with 50 m head for process water supply.

Sump Pump: 2 nos Hydro- pneumatic pumps of capacity 1.0 HP

The capacity, flow rate and working head of all the pumps have been studied and their effectiveness against their specific performance needs are analyzed.

The pumping system has been proposed as a centralized one located at the existing Pump House. The system has been designed for direct supply of water to all the consumer points by means of hydro-pneumatic system. In addition, overhead tanks are proposed as well for each unit located on the top of buildings , wherefrom water will be distributed to each consumer point by gravity ,maintaining the supply chain in case of necessity/maintenance and break down situations.,. The pumps are proposed to be operating on positive suction head all the time.

The Pumping system is proposed to be with stand-by arrangements. which will operate automatically through VFD control and Pressure device along with level switch control arrangements at the Ground level as well as the OH Tanks . Distribution to various points will be controlled and managed by means of Solenoid Valves to ensure effective pumping operations without any wastage of water and power with minimum operating manpower needs.

Metering System: Electro-Magnetic Meters are proposed at all source points including existing ones and at the take off points for all OH Reservoirs for proper water audit and effective water management.


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9.3 Sewerage and Drainage Environment

Plumbing and sanitary fittings and fixtures are proposed as per NBC guide line and ease of availability with effective O & M proximity. .

The storm-water drainage system has been proposed as underground Pipe drainage using HDPE pipe to ensure smooth flow of both storm and spent water. The drainage system of the site has been designed as a separate system of surface run off and sullage water from the individual Building, Toilets and Public facilities.

The system has been proposed with proper slope and pipe sizes to maintain non silting and non scouring velocity of flow through them. Street inlets, catch basins, Gully Pits as required for collection and inlet to the pipelines have been provided.

The final disposal of the storm-water from the site will lead to the nearest outfall channel. The surface run off will be ascertained from the past Rainfall records, considering a Time of concentration around 23 mins, the rainfall intensity has been considered as 35mm/hr from the I-T graph.

The entire rainwater from Roof tops will be collected separately and conveyed through CI Pipes to the respective rain water harvesting tanks which will ultimately flow for ground water recharging following the SPCB norms.

One storm water outfall pump will be provided for discharge of water from the Plant site to the outside drainage canal running around the site for ultimate discharge.

Total quantity of Surface Run-Off 448 Cum/Hr

0.12 Cum/Sec


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Figure 1: Rainfall intensity vs Duration Curve The sewerage system for the proposed Smelting plant comprises of two aspects:

Spent water from domestic activities

Spent water from Industrial activities

Collection and treatment of both types of waste will be done separately:

Sanitary sewerage system for collection of domestic waste and effluent sewer for collection of Industrial waste.

The collection of the black water from WCs and Urinals (30% of the consumed water) out of the activities in the individual building blocks will be done through sanitary fixtures at the designated places and will be transmitted to the ground level Inspection pits. Sewage will flow from the pits to the underground Sewer lines. For computation of sewage flow, 90 % of the supplied water has been considered as spent water through the sewerage system. The spent water comprises of;

Grey water (70%) as washing effluent from Wash basins, Showers, Ablution taps and Sinks etc.as applicable.

Black water (30 %) from soil appliances as WCs and Urinals.

The underground sewer lines compose of Branch lines and Main lines. The branch lines are proposed as 100 mm dia HDPE & main line of 150/200/250/300 mm dia


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HDPE pipes as per requirements for transmission of Sewage from the source to the STP

The collection of Industrial effluent will be done from each process outlet by means of DWC pipes. Which will contribute their flows to the underground effluent sewers by means of gravity.

The entire sewerage system has been designed with a minimum sewage velocity of 0.6m/s following Manning’s Formula for flow through closed conduits.

The Smelting plant will have in house facility for On-site treatment and safe disposal of both types of waste observing the MOEF and WBPCB norms and Standards.

ETP for treatment of Industrial effluent

STP for treatment of Domestic sewage.

9.3.1 Sewage Treatment Plant.

Capacity calculation of Sewerage treatment Plant

Total water demand cum / Day = 40 (Considering 90% of total water

demand) Total Sewage generation cum / Day = 36

Proposed STP capacity 40 KLD Treatment Process proposed

Moving Bed Bio-Reactor (MBBR) along with Tube Settler Raw Sewer characteristics (Indicative):-

a. Flow (max.) : 40 KLD b. pH : 6.5 – 8.5 c. TSS : < 200 - 400 mg/l d. Oil & Grease : < 50mg/l. (max.) e. BOD5 (20 0C) : < 350 mg/l. f. COD (20 0C) : < 700 mg/l.

9.3.2 Operation units in sequence

1. Manual Screening for removal of floating materials 2. Oil & Grease Trap for removal of oily substances 3. Grit chamber for removal of inorganic settable matters 4. Bio-reactor unit for removal of Bio-chemical and Chemical loads using attached

growth reaction system on moving beds. 5. Tube Settler used for settling of Sludge generated from the process


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6. Filtration through Multi grade filter unit for removal of suspended solids 7. Activated Carbon adsorption process for removal of dissolved gases from the

Effluent from Filtration process 8. Ultrafiltration Process for final BOD removal 9. Sludge holding Tank for holding settled sludge. 10. Filter Press Unit for formation of sludge cakes by receiving the settled Sludge

from the SHT,

9.3.3 Treated effluent characteristics:-

a. pH : 6.5 – 8.5 b. TSS : <10 mg/l c. Oil & Grease : <10mg/l. / or Nil d. BOD (20 0C) : <10mg/l. e. COD (20 0C) : <100mg/l.

9.3.4 Management of STP Effluent and Sludge

The treated effluent from STP is proposed to be reused for the following non domestic purposes:

landscaping, gardening , cleaning and washing watersheds Automobile and Truck cleaning.

The STP effluent will be stored in a reservoir, wherefrom it will be supplied to the user points all around the campus by means of pumps as per necessity. Excess water will be laid to the drainage system.

Sludge can be used as a soil conditioner for gardening and landscaping in the surrounding area and excess may be disposed-off periodically.


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9.3.5 Effluent Treatment Plant

The effluent Treatment Plant will be designed according to the composition, characteristics and pH value of the waste. Efforts will be there for maximum recovery of valuable materials and chemical compounds from the effluent. The Plant discharge after the treatment process will be according to the following safe parameters as per MOEF guidelines.

The input to the ETP has been considered as 80% of the process water requirements. The wash water from the Pollution Abatement units like Venturi-Scrubber and Truck washings will also have to be treated in the ETP alongwith process effluents. Accordingly the plant capacity has been derived as 40KLD


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37


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9.4 Solid Waste Environment

The solid waste generated from the different activities in the Plant complex is also of two distinct natures: Industrial and General.

The Industrial waste will possess some pollution parameters and Calcium Sulfate will be its major composition, which can be put into other downstream uses. This category of waste will be treated further in a Common treatment Plant operated and managed by RAMKY in Haldia. Hence, this entire quantum will be handed over as per negotiated terms and conditions to them.

The general waste will also compose of inorganic, organic, plastics and hazardous materials.

The entire waste volume is proposed to be segregated and the inorganic, plastics and hazardous ones will be stored in protected chambers. The storage vat will be properly secured, ventilated and enclosed with a capacity of 10 days storage for ultimate transfer to the Collection vehicles of Waste Managers.

The organic part of domestic waste will however be treated on site through Bio-compost plant operated mechanically. The available compost will be utilized for the landscaping and gardening purposes within the Plant premises.

The average quantification of waste has been assessed as under:

Industrial: 50MT/day

Domestic: 160Kg/day

9.5 Rainwater Harvesting System

9.5.1 Main Principles :

• To store the rooftop rainwater run-off and collection of surface run off from open areas in an RW Tank (i.e., RHT).

• Natural recharge through the top soil by limiting the area of impervious surface in the open spaces to the bare minimum.

• To reuse 40% of the stored water during the period of shortage/crisis and 60% for recharging the underground aquifer

SYSTEM OF MANAGEMENT OF RAIN WATER AT THE PROJECT Total Plot Area of the Project Site 40850 Sq,m. Covered Area of Building 17425 Sq,m.


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Blocks

Road Surface & Paved Areas 10212.

5 Sq,m. Car Parking 5400 Sq,m. Open ground area 7812.5 Sq,m. 40850 Sq,m. Annual Rainfall of Kolkata 1640 mm Run-off co-efficient

Roof Top & Paved surfaces 0.9

Open ground surfaces 0.75 Evaporation losses 10% Rainfall Duration per Annum 120 days Available Rain water

Roof Top 21861 Cu.M. per Annum

182 Cu.M. per Day

Open ground surfaces 8168 Cu.M. per Annum

68 Cu.M. per Day

Paved surfaces 19587 Cu.M. per Annum

163 Cu.M. per Day Total 413 Cu.M. per Day Rainfall Intensity Peak 25 mm/15min Average 35 mm/hr Peak Run off quantity for 15 mins Roof Top 333 Cu.M Open ground surfaces 125 Cu.M Paved surfaces 299 Cu.M Total 756 Cu.M

Recharge Volume @100% 0f Roof Top Run off 182 Cu.M

To provide Recharge chamber 4 nos. 50 Cu.M

Recarge shafts 2 nos.

150mm PVC pipe at 150m depth with 30 m strainer at each chamber

Surface Run Off 448 Cum/Hr 0.12 Cum/Sec


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Precipitation on open ground surfaces will get recharged naturally (40-50%) by means of seepage to the ground water environment. Remaining surface run off along with the run off from paved areas will flow through the campus drainage system for ultimate disposal to the external outfall.

9.6 Treatment of Air Emissions

Metallurgical processing in the smelting operation generates three major types of air emissions: sulfur dioxide, particulates, and constituents such as fluorides.

Though it is well known that Sulphur Di-Oxide gas is the primary pollutant generated by the smelting of Copper, Lead and Zinc ore concentrates, Proposed Smelter is Secondary Smelting Unit. The Raw Material is Used Lead Acid batteries instead of Ore. Sulphur Di Oxide emission in this case will be very less compared to Primary Smelting Unit which directly deals with Sulphide Ore.

Another common type of air emission from the processing of nonferrous metals consists of micron sized particulates.

Finally, smelters generate small concentrations of volatile constituents such as arsenic, lead, zinc and fluorides

9.6.1 Control Measures

Emission of SO2 being less in quantity can well be neutralized through Wet scrubber by spray of water with Alkali dossing.

Control of the fine particles requires efficient collection equipment such as bag houses, electrostatic precipitators and high pressure drop scrubbers.

9.6.2 Ensured Level of Emission


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9.6.3 Pollution abatement measures initiated:

The flue gas coming out from the furnace will be taken into the settling chamber where velocity of the gas gets reduced by expanding inside higher volume chamber. Coarse particles with higher weight will get settled inside the chamber. The next step will be to take the gas to the Bag filter system. Solid particles of size greater than 5 micron will get separated here. In next step Gas with finer particles will be treated to Wet scrubber by sonic water spray with Alkali dossing. This will separate fine particles, volatile constituents from the gas as well as will dissolve SO2 gas into alkaline water. The clean gas will go to the atmosphere through a chimney of height 30 Mtr.

9.6.4 Power and DG Backup

The total power requirement is 2800 KVA. Provisions of 3 nos. 1010 KVA DG Set shall be used for the proposed Industry which shall be synchronized.

DG Sets will be used for 100% back-up. So, during power failure DG Set will be the main source of air and noise pollution. Gaseous pollutants like NO2, SO2, and PM shall be generated from activities like burning of fuel through DG Sets. HSD diesel will be used with low Sulphur. During operation, vehicular movement and operation of DG Sets are the major sources of noise pollution. But both these activities – DG Sets and vehicular movement will not have any significant impact on the people residing in the area. Since DG sets will not be operational continuously and moreover it will be placed enclosed with suitable enclosure, hence no or minimal impact will be anticipated. It is envisaged that the movement of the motor vehicles will be restricted to the designated carriageway only.

9.6.4.1 Impacts on air quality

Impacts on ambient air quality during operation due to emissions from the stacks attached to standby DG Sets will be very less. However suitable mitigation measures will be adopted.

9.6.4.2 Mitigation measures for Impacts of DG sets on Ambient Air Quality

DG Sets will comply with the applicable emission norms.

Adequate stack height for DG Sets will be provided as per CPCB norms. 9.6.5 Environment Pollution Abatement:

The Present smelting plant at Haldia has been proposed to be set up with the objective of minimizing the pollution potentiality of Secondary Lead Smelting Industries in the environment. The broken or used batteries will be recycled in this


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plant for recovery of Lead and Sulphuric acid in the form of Calcium Sulphate by means of State of the Art technology with minimum adverse impact on the nature. The used batteries used to create mass pollution in the environment when dealt in the unorganized sector for recovery of valuable elements through crude and unscientific processes by local vendors.

The control measures initiated are:

Air Pollution:

The stack height has been considered as 30m for release of the spent gas in the environment.

Employment of Venture Scrubber (wet) and Fabric filter units to arrest maximum particulate matters as well as SO2 gas from escaping into the atmosphere.

Water pollution:

ETP will be installed to treat all the industrial effluent and STP will be installed to treat the entire domestic waste. The effluents from both the plants will be reused and recycled in the Process as well as for non-domestic purposes like cleaning, washing and landscaping. Such system of reuse of water will substantially reduce the demand on ground water extraction that will help in preserving the underground lithological structure.

Rain water Harvesting is another measure initiated here in the proper form to replenish the aquifer for balancing the groundwater extracted from it.

Land pollution

Pollution of ground surfaces by solid and Industrial waste generated from the plant activities have also been abated totally by secured storage and handing over to the licensed waste managers for proper treatment and disposal as per MOEF norms and standards. The 3R principles have been adopted in house for reduction in the volume of waste generated. Recycling of waste has been proposed for conversion of organic waste into valuable compost manures by setting up indoor mechanical bio-compost plant.

9.6.6 Conclusion :

The basic objective of the smelting plant is to salvage lead and Sulphur from the waste batteries. This will substantially reduce the demand on mining operations of both the elements in the battery industry that will directly have a positive effect on the reduction of Carbon Footprint of such Industries which will consequently help on reduction of Global Warming. This Project is therefore basically a Green Field Project.


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10 FIRE FIGHTING SYSTEM

The proposed Plant appears in the category of Industrial Building as per norms stipulated in the NBC. The schedule of services proposed for this category and the height of building in the NBC are as per following:

Fire Extinguisher: Required

Hose Reel: Required

Wet Riser: Required

Down Comer: Required

Yard Hydrant: Required

Automatic Sprinkler system: Required

Manually operated Electric Fire alarm: Required

Automatic Detection and Alarm System: Required

Underground Static water storage: 200000 LITRES

Terrace Tank : Required

Fire Pumps:

Hydrant Pump Electrical-1 no of capacity 2280 l/min with minimum pressure of 3.5 kg/cm2 at terrace level

Sprinkler Pump Electrical-1 no of capacity 2280 l/min with minimum pressure of 3.5 kg/cm2 at terrace level

Jockey Pump Electrical-1 no of capacity 180 l/min with minimum pressure of 3.5 kg/cm2 at terrace level

Diesel Engine operated Pump -1 no of capacity 2280 l/min with minimum pressure of 3.5 kg/cm2 at terrace level

10.1 Hydrant System

The Hydrant System is comprised of one Main Pump (Motor driven), one Jockey Pump (Motor driven), one Diesel Engine driven Pump, which will be


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connected with the Wet Riser, as per the requirements of N.B.C .An under-ground Hydrant Ring Main will run throughout the campus for installation of yard hydrants at ground level

The entire Plant is to be covered by the hydrant system including the provision of required nos. of Yard Hydrants along the external periphery and required nos. Hydrant Valves at Stair Landings of each floor:-

10.2 Sprinkler System

The Sprinkler System will comprise of one Sprinkler Pump (motor driven) connected with a Sprinkler Main and a Sprinkler Wet Riser through the Staircase Block, which will feed the floor wise sprinkler system through separate Branch Mains.

The Sprinkler Main should be of MS black ‘heavy’ grade pipes (as per IS – 1239) and MS black, heavy type butt weldable pipe fittings, specials (viz. Valves, Strainers and other accessories etc. and slip-on flanges of approved make / or brand and necessary flow switches, Pressure switch, Pressure gauge, “UL”-listed (as per NFPA 13 & 25 standard) or (as per IS-9972) - approved sprinklers with quartzoid bulbs of 740C rated, HMHDPE film based fibre glass reinforced wrapping coating as per IS – 10221) for underground Main.

The System is designed as follows-

Design Discharge Density (required as per IS-9972) : 5.0 mm / min.

Since a circular covering Influence zone on Floor should not leave any void or unwetted part, and as par NFPA-13 standard the Minimum Distance between Pendent & Upright (above False ceiling) Sprinklers is 14 feet (4.0m)

So Spacing between two Sprinklers : 4.0 M X 4.0 M.

Max. Location from any wall 0.5x4.0m allowable : 2.0 M – Maximum

10.3 Fire Detection and Alarm System

The fire alarm system shall be wired as 2 core signal loops. Alarm sounders may preferably be wired from the control unit.

The system shall incorporate a P A. System at the main control panel with selectors switch and Hooter/Speaker.

The fire alarm system shall conform to BS 5139 in respect of design and installation and shall give audio/Visual Alarm signals when the temperature in case


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of Heat Detector or smoke density in case of ionization detector exceeds the pre-set limits. The system shall give zone wise location of fire with warning system zone wise, two tones for alert and voice communication for commands and instruction if required.

All audible alarm either for fire or fault conditions shall have push button/ cancellation arrangements with reset feature, to ensure that no alarm is inadvertently switched off. The fire or fault lamp shall however continue to glow until the fault condition has been corrected or the fire extinguished. Test push buttons on Main Control Panel shall be provided to test the electronic circuits in each zone.

10.4 Hooter

Dual tone hooter shall be of electronic type and shall give discontinuous/ intermittent audible alarm automatically when ever smoke detector or heat detector operates. Hooter shall be complete with magnetic coil (sound coil) and accessories, ready for mounting (fixing). The hooter shall also have facilities for speaker announcement along with the capability for adjustment of the sound output.

10.5 Detection Devices

Smoke Detector

Smoke detectors shall be working on ionization principle and shall be of dual caliber and dual source type. These shall be completely solid state with LED indication at the base ionization smoke detectors shall be analogue addressable, suitable for detection of visible and invisible products of combustion, and will be of the dual chamber single source type. The detector shall be capable to sense incipient fire by detecting the pressure of visible and invisible products of combustion. The detector shall be suitable for low voltage (24 V DC) two wire supply.

i) Temperature (Heat) Detectors

Temperature detectors shall be analogue addressable, suitable for detection of rate-of rise of ambient temperature and fixed temperature threshold. Detection shall be by means of a thermostat.

ii) Manual Call Points (MCP)

Each MCP installed on the loop shall have a unique address, set at the commissioning stage by means of a seven-segment DIL switch.


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10.6 System –Operation Philosophy

Operation of hydrant & sprinkler system shall be semi - automatic. The entire piping net work for Hydrant & sprinkler system is pressurized by Jockey pump at 11.0 kg/ cm2.

Due to minor leakage in the line, the pressure will reduce gradually in the piping network and when pressure reduces to 9 kg/cm², the jockey starts automatically through pressure switch when Pressure developed in the line at 11 kg /cm2 the Jockey pump stops automatically through pressure switch (PS-1).

In case of Fire, the Hydrant valve to be opened, Hose pipe along with Branch pipe to be connected with Hydrant valve. The water from header will come out, Due to huge loss of pressure in the piping network, which cannot be maintained by Jockey Pump, the main Fire Pump will start automatically by the actuation of pressure switch at 7 kg /cm². As soon as the main pump starts the Jockey Pump will be tripped automatically by inter locking arrangement.

In case of Fire, the Sprinkler (QBD) will burst automatically, Control Valve will open simultaneously and the water from sprinkler header will come out, Due to huge loss of pressure in the piping network, which cannot be maintained by Jockey Pump, the main sprinkler Pump starts automatically by the actuation of pressure switch (PS-3) at 7 kg/cm². As soon as the main pump starts the Jockey Pump will be tripped automatically by inter locking arrangement.

If the Electric Driven Main Pumps are unable to restore the pressure or fails to start for any Fault the standby Diesel Engine Main Pump (FP-3) comes into operation automatically by the actuation of the pressure switch (PS-4) ,when pressure drop in line becomes 5kg /cm².

The operation of all pumps is controlled by Local Control Panel which is installed near the Fire Pump House. This panel is equipped with necessary push button, switches, indicating lamp & annunciations. In each case above, if any of the above pumps is not started even after the signal from pressure switch is through, "pump fails to start" alarm shall be annunciating in the local control panel.

These Fire water main pumps will Start automatically as stated above But CLOSING of all Pumps (except Jockey pump) is done manually only when Fighting or Demand of water is over.

All isolation valves in Pump house, yard Hydrant & Sprinkler, Risers to be kept in: NORMALLY OPEN “POSITION when All Hydrant valves/ Landing valves to be kept in “NORMALLY CLOSE POSITION “.


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11 CLARIFICATION OF LAND REQUIREMENT

11.1 Plant Requirements

The Proposed New Smelting Plant shall be grouped in the following heads;

- MAIN PLANT - AUXILIARY REQUIREMENTS OF THE PLANT - UTILITIES & INFRASRUCTURE - AMENITIES & STAFF FACILITIES

MAIN PLANT This have been classified in the following departments

1. Battery Breaking Plant 2. Charge Preparation Area 3. Smelting Plant 4. Refining Plant 5. Ingot Casting Plant 6. Dispatch Area

AUXILLIARY FACILITIES OF THE PLANT

1. Desulphurization and Crystallizer section 2. Bag House 3. Laboratories 4. Slag Demolition Area 5. Separators 6. Dispatch department 7. Raw material unloading Yard 8. Finished goods Loading Yard 9. Engineering store 10. Workshop 11. Oxygen Generator Plant 12. Compressor room 13. Manager & Supervisor Staff room 14. Workers locker room & Wash rooms


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UTILITIES & INFRASTRUCTURE

1. Electrical substation 2. ETP AND STP 3. D.G.SETS 4. Diesel Oil Storage Area 5. Furnace Oil storage area 6. Scrap Yard 7. Vehicle Tyre Washing area 8. U.G. Tank & O.H. Tank 9. Water Treatment plant 10. Ro Plant 11. Organic Waste Converter 12. Rain Water Harvest Tanks 13. Truck Parking Bays and Plant Road network 14. Weigh Bridge

AMENITIES & STAFF FACILITIES

1. Administrative Building 2. Canteen 3. Car & Scooter Parking 4. Cycle Parking 5. Gate Office 6. Guard room

11.2 Land Area Requirement

Clarification of the Land requirement have been worked out on the basis of the Plant area required and the incidental peripheral facilities of the Plant, along with the necessary Utilities Infrastructure facilities, Road net work, Parking bays for Truck parking, car & scooter parking, cycle parking, and the compulsory Green belt to be kept in the Periphery as per MoEF guidelines, Area Requirement

1. Plant Area with adjacent

Area for material dispatch

Slag demolition, Bag house,

Paste desulphurization etc. and

Expansion of rotary, furnace : 6175 Sqm

: 6120 Sqm 12295 Sqm


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2. Admin. Building for 18 Staff : 215 Sqm

3. Security & Medical Unit : 70 Sqm

4. Guard Room : 30 Sqm

5. Engineering Store : 400 Sqm

6. Raw Material Store Yard : 1800 Sqm

7. Finished Goods Storage : 750 Sqm

8. Laboratory Building : 180 Sqm

9. Canteen for 60 Staff/ Worker : 215 Sqm

10. Staff Lockers & Wash Room : 400 Sqm

11. Scrap Yard : 1500 Sqm

12. Mechanical Workshop : 200 Sqm

13. Truck Parking Area (50 Nos.) : 5400 Sqm

23455 Sqm Utility Area

1. O2 Generation Plant : 70 Rqm

2. Substation : 550 Sqm

3. Computer Room : 140 Sqm

4. R O Plant : 90 Sqm

5. UG Tank : 205 Sqm

6. ETP : 300 Sqm

7. STP : 80 Sqm

8. HSD Area : 300 Sqm

9. Furnace Oil Storage : 700 Sqm

10. DG (1000 KvA)- 2 nos : 80 Sqm

11. OHT : 50 Sqm

12. Rain Water Harvesting Tank- 4 nos : 300 Sqm

13. Weigh Bridge : 70 Sqm

2935 Sqm Total Ground area footprint required = (23455 + 2935) sqm

= 26390 sqm


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Add for Roads, car parking etc = 9000 sqm Total coverage required = 35390 sqm SAY =========== 36000 SQM Hence, the total land area that would be required for the project if we consider 36000sqm as 45% of the total land area, with 30 % as building and utilities footprint, and 15% as roads, then the required land area would be as follow: 36000x100 = 80000 sqm 45 That is = 20 Acres A tentative Master Plan of the proposed Plant is enclosed in the MAP-7

Final Land use Area Pattern for the Project;

Plant area including roads, utilities, parking etc.= 45% of land area= 9.00 acres

Compulsory Green belt===================== 35 % of land area= 7.00 acres

Other incidental pen spaces================ 20% of land area= 4.00 acres


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Master Plan of Proposed Smelting Plant at Haldia Map 8: Proposed Master Plan


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PAST RECORD OF M/S EXIDE INDUSTRIES

The Investment Pattern of Exide Industries Limited for the last three Financial

years as well as proposed for this Financial year is mentioned below along with the

Brief History of the company.

Financial Year Exide Haldia

Unit

Exide

Shyamnager

Unit

Other Five

units outside

West Bengal

Total

Investment

for the FY

2017 – 2018 (Proposed) 260 46 290 596

2016 – 2017 150 43 317 510

2015 – 2016 40 26 169 235

2014 – 2015 430 36 180 646

Total Investment 880 151 956 1987

All figures are in Crore INR

This company was incorporated as Associated Battery Makers (Eastern) Ltd., on 31 January

1947 under the Companies Act, 1913 to purchase all or any of the assets of the business of

manufacturers, buyers and sellers of and dealers in and repairers of electrical and chemical

appliances and goods carried on by the Chloride Electric Storage Company (India) Ltd., in India,

since 1916 with a view thereto to enter into and carry into effect (either with or without modification)

an agreement which had already been prepared and was expressed to be made between the

Chloride Electric Storage Co. (India) Ltd. on the one part and the company of the other part. The

name of the company was changed to Chloride India Ltd. on 2 August 1972. The name of the

company was again changed to Chloride Industries Ltd. vide fresh Certificate of Incorporation dated

12 October 1988. The company was further changed to Exide Industries Ltd. on 25 August 1995.

The company manufactures the widest range of storage batteries in the world from 2.5 Ah to 20,600

Ah capacity, covering the broadest spectrum of applications. The company has seven factories

located across the country – two in Maharashtra, two in West Bengal - Shamnagar (Mother plant) &

Haldia, one in Tamil Nadu, Hosur, one in Haryana and two in Uttarakhand. The company’s

predecessor carried on their operations as import house from 1916 under the name Chloride

Electrical Storage Company. Thereafter, the company started manufacturing storage batteries in the

country and have grown to become one of the largest manufacturer and exporter of batteries in the

sub-continent today. Exide separated from its UK-based parent, Chloride Group Plc., in 1989,

after the latter divested its ownership in favour of a group of Indian shareholders.

Exide is only company which provide Submarine Batteries to Indian Navy.

https://en.wikipedia.org/wiki/Maharashtra

https://en.wikipedia.org/wiki/West_Bengal

https://en.wikipedia.org/wiki/Tamil_Nadu

https://en.wikipedia.org/wiki/Haryana


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ANNEXURE - I


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Documents

PROPOSED CML SMELTING PLANTenvironmentclearance.nic.in/writereaddata/Online/TOR/18...Proposed CML Smelting Plant at HALDIA, West Bengal 1 1 INTRODUCTION 1.1 Preface M/S Chloride Metals