Risk Assessmentenvironmentclearance.nic.in/writereaddata/online/Risk...With this respect the company has appointed M/s SBA Enviro Systems Pvt. Ltd., New Delhi to carry out the Environmental

Risk Assessment

Expansion of Chemical Processing Unit of HPL Additives Ltd.,

Village: Bhagwanpur, Tehsil: Derabassi, Dist.: SAS Nagar, Punjab

DOCUMENT

NO.1003/EIA/2018/RA REVISION: 0 DATE OF ISSUE: 27th

January, 2018

SBA ENVIRO SYSTEMS PVT. LTD.

1 1

Risk Assessment HPL Additives Limited has planned of expansion of its existing chemical processing unit at

Bhagwanpur, Derabassi, Punjab plant. The existing unit of HPL Additives Limited at

Bhagwanpur has only one product, i.e. Hydrazine with a capacity 110 MT per month.

Expansion of the plant is planned mainly to increase its manufacturing strength with some

additional products in relation to external market demand as well as internal demand.

the project attracts EIA requirement for the expansion and requires Environment Clearance

prior to the project under activity 5(f) – “Synthetic organic chemicals industry (dyes & dye

intermediates; bulk drugs and intermediates excluding drug formulations; synthetic rubbers;

basic organic chemicals, other synthetic organic chemicals and chemical intermediates)”.

Additionally, the proposed project location is situated very close to the inter-state boundary of

Punjab & Haryana, thus, the project comes within the ‘A’ category.

With this respect the company has appointed M/s SBA Enviro Systems Pvt. Ltd., New Delhi

to carry out the Environmental Impact Study and to prepare the Environmental Impact

Assessment (EIA) report, and present it to the EAC, MOEFCC to get clearance from the

Ministry for the proposed expansion of chemical processing unit at their Bhagwanpur,

Derabassi unit in Punjab. SBA is a NABET accredited consultant for the sector of 5(f). The

Terms of Reference (TOR) for EIA Study was granted by the EAC, MOEFCC on 26.10.2017.

The Risk Assessment study has been carried out for submission of Fina EIA report as

accorded the TOR issued by EAC, MOEFCC.

The proposed expansion of chemical processing unit of HPL Additives Ltd., at Bhagwanpur

will comprise of 13 new products as well increment of production capacity of Hydrazine

Hydrate also. The detailed Proposed product and raw materials are as follows:

Risk Assessment



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PRODUCTS

Table: Product Details

S. No. Product Production Per Month (MT)

Existing

Capacity

(All Products)

Capacity After

Proposed

Expansion

1 Kinox -30 - 170

2 Kinox-10 - 220

4 HC 301 - 80

5 3,4 DMB - 90

6 Kinox -135L - 15

7 Kinox -57L - 50

8 Kinox -18L - 10

9 Kinox -28 - 25

10 Kinox-DA - 5

11 Hydrazine 110 295

12 HDC - 645

13 ADC 600

14 ADH 48

RAW MATERIALS

For production of 14 products, it is identified that 54 raw materials will be required, in contrast

to three raw materials usage (Caustic Lye, Urea and Chlorine) in existing process to produce

solitary product Hydrazine hydrate. After expansion, there will be requirement of HSD for DG

sets operation and Pet coke for Boiler and Thermic Fluid Heater operation.

The salt will be generated from the process as by-product, which is non-hazardous in nature

and shall be sold out to Detergent manufacturers.

The risk assessment has been carried out with consideration of Materials’ hazardous nature

and storage capacity at a time within the unit. The threshold limit for storage of chemicals has

been assessed by guidelines of MSIHC amendment rule, 2000 and as data comes out,

monthly consumption/ storage capacity of HSD and Chlorine will exceed the threshold

capacity as per MSHIC Rules, 2000, none of the other chemicals would exceed threshold limit

of storage, thus would not requires isolated storage for same. The chemical and hazard profile

of the materials are given below:

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Table: Hazard Profile of the chemicals

Raw Materials

Consumption Per Month

(MT/ KL)

Existing

Products

Expanded

Products Flammability

Threshold

Limit

Schedule 1,

Part II serial

No.

Triethyl amine 3.19 Y - 652

Acetic acid 57.90 Y - 2

2,6 DTBP 371.5 may be in high

temp. - NA

Methyl Acrylate 82.20 Y - NA

Methanol 584.00 Y - 377

Xylene 245.00 Y - 442

Phosphorous Trichloride 9.58 N - 506

Pentaerythritol 33.60 may be in high

temp.

- NA

Caustic Soda Flakes 3.50 N - 571

Potassium Hydroxide 1.50 N - 522

Dibutyl amine 0.40 Y - NA

Hydrazine Hydrate (100%) 324.00 Combustible -

Thioglycolate 12.60 NA - NA

Para-formaldehyde 131.60 Y - NA

Soda Ash 0.23 N - NA

Diethyl amine 5.00 Y - 196

Methylene Di Chloride 383.20 may be in high

temp.

- 400

Mesitylene 30.70 Y - 362

Toluene 64.00 Y - 628

Sulphuric Acid 205.0 N - 591

HCl (30%) 1044.00 N - NA

Ammonia soln. (20%) 45.29 N 60/600 T 31

D-Sorbitol 44.21 may be in high

temp.

- NA

PTSA 19.89 may be in high

temp.

- NA

Hexane 145.84 Y - 306

PEG 600 18.69 N - NA

DMBC 150.40 NA - NA

Hexamine 296.00 Y - NA

Tec-07 0.36 - NA

K-68 0.19 - NA

Risk Assessment



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Iso octyl alcohol 9.50 Y - NA

DBTA 0.01 NA - NA

Activated Carbon 0.33 NA - NA

Diphenyl amine 28.85 may be in high

temp.

- NA

Anh. Aluminium chloride 5.20 NA - 22

Di-isobutylene 26.55 Y - NA

Cyclohexane 11.00 Y - 161

Bleaching Clay 10.55 N - NA

Isotridecyl Alcohol 4.60 N - NA

Thioglycolic acid (80%) 2.82 NA - NA

Formaldehyde soln. (37-38%) 3.27 Y - 295

2,4 DCP 21.56 NA - 182

TBAB 0.43 NA - NA

Diphenyl salicylate 3.00 may be in high

temp.

- NA

3,4 ATRZ 0.52 -

Phenol 10.54 may be in high

temp.

- 481

Caustic Lye (47.5%) 1858.00 4986.00 N - 571

Urea(%w/w) 317.00 1718.00 may be in high

temp.

- NA

Chlorine 358.00 960.00

MAY CAUSE OR INTENSIFY FIRE;

OXIDIZER 10/25 T 119

Sodium Bicarbonate 0.48 N - NA

Hydrobromic Acid (48%) 437.00 N - NA

Hydrogen Peroxide(50%) 1478.00 N - 318

Dimethyl Adipate 49.73 Non-hazardous - NA

EDTA 0.13 may be in high

temp.

- NA

Risk Assessment has been carried out in the Software – ALOHA, developed by USEPA, to

predict the future risk related to the project and to identify the response requirement. The

detailed Risk Assessment is given below:

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• Ammonia 20% Solution

Monthly requirement/ storage capacity: 45.29 KL

Slightly or non-flammable solution, stable in nature.

Storage: in Evaporating Puddle. Isolated Storage required: No. But unit will have isolated

storage area for Ammonia solution near to its usage area.

Risk Data

Risk Assessment



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Threat Zone Diagram

Risk Assessment



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• Chlorine

Monthly requirement/ storage capacity: 960 MT

Stable in under normal condition, Toxic fume, oxidizer.

Storage: in standard tonner. Isolated Storage required: YES. Unit will have isolated storage

area for Chlorine tonner and storage will be controlled by minimum requirement only. Storage

and operation area will have proper fume control and PPE facility

Risk Data

Risk Assessment



DOCUMENT


January, 2018


8 8

Threat Zone Diagram

Risk Assessment



DOCUMENT


January, 2018


9 9

• Hydrogen Peroxide (H2O2) 50%

Monthly requirement/ storage capacity: 1478 KL

Non-flammable, stable, pungent, corrosive liquid.

Storage: in vertical cylindrical tank. Isolated Storage required: No. Chemical will be stored in

isolated tank or container at liquid Chemical Storage area only with proper spillage control

facility.

Risk Data

Risk Assessment



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January, 2018


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• Hydrobromic Acid (HBr) 48%


Non-flammable Mutagenic liquid; Boiling point 108 degree centigrade. Stable in nature.

Storage: in vertical cylindrical tank. Isolated Storage required: No. Chemical will be stored in

isolated tank or container at liquid Chemical Storage area only with proper spillage control

facility.

Risk Data

Risk Assessment



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January, 2018


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Threat Zone Diagram

Risk Assessment



DOCUMENT


January, 2018


12 12

• Hydrochloric Acid (HCl) 30% Solution


Non-flammable, non-combustible, corrosive liquid, lowest known boiling point 89.5 degree

centigrade.

Storage: in evaporating puddle having diameter of 16 metre. Storage and operation area will

have proper fume control and PPE facility. Isolated Storage: No.

Risk Data

Risk Assessment



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January, 2018


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Threat Zone Diagram

Risk Assessment



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14 14

• Methanol


Flammable liquid. Flash point is 12-degree centigrade in Closed cup condition.

Storage: in vertical cylindrical tank with a maximum diameter of 12 meter. Storage and

operation area should be equipped with DCP type extinguisher and alcohol foam or fog facility

in extreme fire. Isolated Storage: No.

Risk Data

Risk Assessment



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January, 2018


15 15

• Xylene




operation area should be equipped with DCP type extinguisher. Isolated Storage: No.

Risk Data

Risk Assessment



DOCUMENT


January, 2018


16 16

• Para-formaldehyde

Monthly requirement/ storage capacity: 131.60 KL



operation area should be equipped with DCP type extinguisher. Isolated Storage: No.

Risk Data

Risk Assessment



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January, 2018


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Threat Zone Diagram

Risk Assessment



DOCUMENT


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• HSD

Monthly requirement/ storage capacity: 50-55 KL/ storage 20 KL underground tank

Highly Flammable liquid. Flash point is 32-degree centigrade.

Storage: in underground isolated storage area. Storage area should be equipped with Jet

Extinguisher nozzle having Foam and water facility, operation area should be equipped with

DCP/ CO2 type extinguisher. Isolated Storage: Yes.

• Pet Coke

Monthly requirement/ storage capacity: 1225 MT

Combustible dust.

Storage: in open shed area with RCC basement near Boiler. Storage area should be equipped

with DCP/ CO2 type extinguisher and proper Dust control facility with provision of Personal

Goggles and Nose musk usage. Isolated Storage: No.

By assessing the above Risk Assessment study, it can be concluded that highly operation

control and safety measures required for the proposed expansion project. On-site Emergency

plan should be maintained and updated with regular interval. The unit should maintain Fire

Hydrant system and all type of Fire extinguisher, Self-contained Breathing Apparatus (SCBA),

Safety Shower, First-aid facility and all requisite PPE’s. Regular Safety training, Mock-Drill,

Awareness programme is suggested. Use of signage is mandate. Incident/ Accident record

should be maintained stringently. Isolated storage for Chlorine and HSD is identified. The Risk

Assessment findings is considered in EIA Report and Safety audit conducted by unit

management, Mitigation and control measures has been discussed in chapter 6 of EIA report

and in DMP prepared by HPL Additives Ltd.

Documents

Risk Assessmentenvironmentclearance.nic.in/writereaddata/online/Risk...With this respect the company has appointed M/s SBA Enviro Systems Pvt. Ltd., New Delhi to carry out the Environmental