Environmental Impact Assessment Report Rev. 01

Project No: AESPL/IND-E/ 19-20/EIA/02

Environmental Impact Assessment Report Rev. 01

Proposed Expansion of Synthetic Organic Chemicals Manufacturing Facility

By

Prasol Chemicals Private Limited

(Formerly known as Prasol Chemicals limited)

Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16

pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist:

Raigad, Maharashtra

Ba

seli

ne

Mo

nit

ori

ng

: S

um

me

r 2

01

9

July 2021

Environmental Consultant:

Aditya Environmental Services Pvt. Ltd., Mumbai

QCI- NABET Accredited EIA consultant

www.aespl.co.in

Declaration by Experts contributing to the EIA report “Proposed Expansion of Synthetic organic chemicals manufacturing facility by Prasol Chemicals Private Limited at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra” I, hereby, certify that I was a part of the EIA Team in the following capacity that developed the above EIA.

EIA Coordinator:

Name: Mr. Rajiv V Aundhe

Signature & Date: 1st July 2021 Period of involvement: since January 2019 Contact information: Mob. 09821513367, E-mail: [email protected] Functional Area Experts:

S.N. Functional

Areas Name of the Expert/s

Involvement (Period &

Task**) Signature & Date

1 AP* Rajiv Aundhe (FAA Swapnil Ubale)

January 2019 to till date

2 WP* Shreerang Bhalerao (FAA Swapnil Ubale)

January 2019 to till date

3 SHW* Rajiv Aundhe January 2019 to till date

4 SE* Ms. Anju Chawhan February to December 2019

5 EB* N. K. Shendye February 2019 to till date

6 HG* -- -- -- 7 GEO* -- -- -- 8 SC* -- -- -- 9 AQ* Kavita Takle February 2019 to

till date

10 NV* Rajiv Aundhe January 2019 to till date

11 LU* Bela Pharate February 2019 to till date

12 RH* P K Sarode January 2019 to January 2021

NOTE: (*) Full forms of abbreviations given on Next Page (**) Tasks for each Functional Area Expert given on Next Page

Environmental Baseline monitoring and analysis for this project was carried out by in-house, environmental analytical laboratory, registered by MoEFCC, approved under Environment Protection Act 1986, vide MoEF & CC recognition of Environmental Laboratory vide letter no. Q-

15018/10/2019-CPW dated 20th December 2019 valid upto 8th July 2021.

mailto:[email protected]

Declaration by the Head of the Accredited Consultant Organization

I, Rajiv V. Aundhe, hereby, confirm that the above-mentioned experts prepared the EIA report “Proposed Expansion of synthetic organic chemicals manufacturing facility by Prasol Chemicals Private Limited at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra” I also confirm that Aditya Environmental Service Pvt. Ltd. shall be fully accountable for any mis-leading information mentioned in this statement.

Name: Rajiv V. Aundhe

Designation: Director

Name of the EIA Consultant Organization: Aditya Environmental Service Pvt. Ltd.

NABET Certificate No. & Issue Date: NABET/EIA/1922/SA 0129 dated 17th May 2021.

S.N. Functional Area Code

Complete Name of the Functional Areas

Tasks

1 AP Air Pollution Prevention, Monitoring & Control

Assessing baseline ambient air quality, stack emission, possible impacts and control measures

2 WP Water Pollution Prevention, Control & Prediction of Impacts

Assessing baseline surface/ ground water quality, possible impacts and control measures

3 SHW Solid Waste and Hazardous Waste Management

Assessing solid/hazardous waste generation, treatment and disposal

4 SE Socioeconomics Assessing baseline Socioeconomic, demographic situation, impacts and CSR plan/ measures for upliftment

5 EB Ecology and Biodiversity Assessing baseline biodiversity situation in study area, impacts and Biodiversity management plans

6 HG Hydrology, ground Water & Water Conservation

Assessing baseline hydrogeological situation in study area, impacts and management plans

7 GEO Geology Assessing baseline geological situation in study area, impacts and management plans

8 SC Soil Conservation Assessing baseline soil quality, possible impacts & control measures

9 AQ Meteorology, Air Quality Modeling & Prediction

Assessing nature and scale of impacts on ambient air quality through modeling and management plans

10 NV Noise/ Vibration Assessing baseline ambient noise quality, possible sources, impacts and control measures

11 LU Land Use Assessing baseline Land use Land cover possible impacts and control measures

12 RH Risk Assessment & Hazard Management

Assessing safety measures taken up by company modeling to assess scale of impacts, disaster management and control measures

GSTN: 27AADCA4730B1Z8 CIN: U74999MH2001PTC132091 UAN: MH19E0035348

Head Office: 107/ 110, Hiren Light Industrial Estate,

Mogul Lane, Mahim, Mumbai - 400016

Laboratory: Plot P-1, MIDC Commercial Plots, Mohopada,

P.O. Rasayani, Tal. Khalapur, Dist. Raigad – 410222

022 42127500 / 24456473 [email protected] 02192 252008 / 250352 [email protected]

Contact – Goa: 0832 2652456 Baroda: 0265 2331790 Pune: 9158028585

TO WHOMSOEVER IT MAY CONCERN

This is to confirm that the EIA/ EMP report for the project “Proposed Expansion of

Synthetic organic chemicals manufacturing facility” located at Survey No. 8 pts, 25

pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village

Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra” by Prasol Chemicals

Private Limited has been prepared by me in the capacity of EIA coordinator.

Standard ToR’s prescribed by MoEFCC vide Notification dated 10th April 2015 and as per

MOEF&CC Letter dated 27th June 2019 has been fully complied with in preparing the EIA/

EMP. A point wise compliance to the ToR’s prescribed as above has been presented in

Chapter 1, Section No. 1.6.1.

We also confirm that the EIA prepared is based on factual data and all due diligence has

been followed in preparing the same.

For Aditya Environmental Services Pvt. Ltd.

Rajiv Aundhe EIA coordinator Date: 1st July 2021 Place: Mumbai

Table of Contents 1 INTRODUCTION ........................................................................................................................ 1

1.1 PURPOSE OF ENVIRONMENTAL IMPACT ASSESSMENT (EIA) REPORT ............................................................................ 1 1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT ....................................................................................................... 1

1.2.1 Project ........................................................................................................................................................................... 1 1.2.2 Project Proponent .................................................................................................................................................... 1 1.2.3 Project Proponent & Background of Promoters ......................................................................................... 3

1.3 BRIEF DESCRIPTION OF NATURE, SIZE, LOCATION OF THE PROJECT & ITS IMPORTANCE IN THE COUNTRY, REGION 4

1.3.1 Nature & Size of Project ......................................................................................................................................... 4 1.3.2 Project Location ........................................................................................................................................................ 6 1.3.3 Importance of the Project to the Country, Region ..................................................................................... 9 1.3.4 Export Possibilities ................................................................................................................................................ 10 1.3.5 Employment generation (direct/indirect) due to project ................................................................... 10

1.4 REGULATORY FRAMEWORK .................................................................................................................................................. 10 1.4.1 General clearances and other related permissions ................................................................................. 10 1.4.2 Applicability of EIA Notification 2006 .......................................................................................................... 12

1.5 ENVIRONMENT IMPACT ASSESSMENT ................................................................................................................................ 12 1.5.1 Process of EIA study .............................................................................................................................................. 12 1.5.2 Methodology adopted for EIA study .............................................................................................................. 13 1.5.3 Structure of EIA Report ....................................................................................................................................... 15

1.6 SCOPE OF THE EIA STUDY .................................................................................................................................................... 17 1.6.1 Regulatory Scoping & Its Compliance ........................................................................................................... 18

2 PROJECT DESCRIPTION ........................................................................................................ 29

2.1 TYPE OF PROJECT ................................................................................................................................................................... 29 2.2 NEED OF THE PROJECT .......................................................................................................................................................... 30 2.3 LOCATION OF THE PROJECT .................................................................................................................................................. 30 2.4 SIZE/ MAGNITUDE OF OPERATION ..................................................................................................................................... 31 2.5 SCHEDULE FOR APPROVAL & IMPLEMENTATION ............................................................................................................. 34 2.6 PRODUCTS - TECHNOLOGY & PROCESS DESCRIPTION ..................................................................................................... 34

2.6.1 Phenol and Acetone ............................................................................................................................................... 34 2.6.1.1 Process Chemistry – Phenol and Acetone ............................................................................................... 34 2.6.1.2 Plant Process description – Phenol and Acetone ................................................................................. 34 2.6.1.3 Process block diagram and Material balance – Phenol and Acetone .......................................... 37

2.6.2 Diacetone Alcohol................................................................................................................................................... 38 2.6.2.1 Process Chemistry – Diacetone alcohol ................................................................................................... 38 2.6.2.2 Plant Process description – Diacetone alcohol ..................................................................................... 38 2.6.2.3 Process Block diagram and Material balance – Diacetone alcohol .............................................. 38

2.6.3 Phosphorus Pentasulphide ................................................................................................................................ 39 2.6.3.1 Process Chemistry – Phosphorus Pentasulphide ................................................................................ 39 2.6.3.2 Process block diagram – Phosphorus Pentasulphide ........................................................................ 39 2.6.3.3 Plant Process description – Phosphorus Pentasulphide .................................................................. 40 2.6.3.4 Material balance – Phosphorus Pentasulphide .................................................................................... 40

2.6.4 Phosphorus Acid food grade ............................................................................................................................. 41 2.6.4.1 Process Chemistry – Phosphorus Acid food grade.............................................................................. 41 2.6.4.2 Process block diagram – Phosphorus Acid food grade ..................................................................... 41 2.6.4.3 Plant Process description – Phosphorus Acid food grade ............................................................... 41 2.6.4.4 Material balance – Phosphorus Acid food grade .................................................................................. 41

2.6.5 Dilute Phosphoric acid ......................................................................................................................................... 41 2.6.5.1 Process Chemistry – Dilute Phosphoric acid ......................................................................................... 42 2.6.5.2 Plant Process description – Dilute Phosphoric acid ........................................................................... 42 2.6.5.3 Process block diagram and Material balance – Dilute Phosphoric acid .................................... 42

2.6.6 Isophorone ................................................................................................................................................................ 42 2.6.7 Process Chemistry – Isophorone ..................................................................................................................... 42

2.6.7.1 Plant Process description – Isophorone .................................................................................................. 42 2.6.7.2 Process block diagram and Material balance – Isophorone ........................................................... 43

2.6.8 Phosphorus Pentoxide ......................................................................................................................................... 43 2.6.8.1 Process Chemistry – Phosphorus Pentoxide ......................................................................................... 43 2.6.8.2 Plant Process description – Phosphorus Pentoxide ........................................................................... 43 2.6.8.3 Process block diagram and Material balance – Phosphorus Pentoxide .................................... 44

2.6.9 Zinc Diorgano Dithiophosphate (ZDDP) ...................................................................................................... 44 2.6.9.1 Process Chemistry – Zinc Diorgano Dithiophosphate (ZDDP) ...................................................... 44 2.6.9.2 Process block diagram – Zinc Diorgano Dithiophosphate (ZDDP) .............................................. 45 2.6.9.3 Plant Process description – Zinc Diorgano Dithiophosphate (ZDDP) ........................................ 45 2.6.9.4 Material balance – Zinc Diorgano Dithiophosphate (ZDDP)........................................................... 45

2.6.10 Mesityl Oxide ............................................................................................................................................................ 46 2.6.10.1 Process Chemistry – Mesityl Oxide ............................................................................................................ 46 2.6.10.2 Plant Process description – Mesityl Oxide .............................................................................................. 46 2.6.10.3 Process block diagram and Material balance – Mesityl Oxide ....................................................... 47

2.6.11 Hexylene Glycol. ...................................................................................................................................................... 47 2.6.11.1 Process Chemistry – Hexylene Glycol ....................................................................................................... 47 2.6.11.2 Process block diagram - Hexylene Glycol ................................................................................................ 48 2.6.11.3 Plant Process description - Hexylene Glycol .......................................................................................... 48 2.6.11.4 Material balance - Hexylene Glycol ............................................................................................................ 48

2.6.12 Trimethyl Cyclohexanol ...................................................................................................................................... 49 2.6.12.1 Process Chemistry – Trimethyl Cyclohexanol ....................................................................................... 49 2.6.12.2 Process block diagram - Trimethyl Cyclohexanol ............................................................................... 49 2.6.12.3 Plant Process description - Trimethyl Cyclohexanol ......................................................................... 50 2.6.12.4 Material balance - Trimethyl Cyclohexanol............................................................................................ 50

2.6.13 Trimethyl Cyclohexanone ................................................................................................................................... 50 2.6.13.1 Process Chemistry – Trimethyl Cyclohexanone ................................................................................... 50 2.6.13.2 Process block diagram - Trimethyl Cyclohexanone ........................................................................... 51 2.6.13.3 Plant Process description - Trimethyl Cyclohexanone ..................................................................... 51 2.6.13.4 Material balance - Trimethyl Cyclohexanone ........................................................................................ 51

2.6.14 Methyl Isobutyl Ketone (MIBK) and Disobutyl ketone (DIBK) .......................................................... 51 2.6.14.1 Process Chemistry – MIBK ............................................................................................................................. 52 2.6.14.2 Process block diagram – MIBK and DIBK ................................................................................................ 52 2.6.14.3 Plant Process description – MIBK and DIBK .......................................................................................... 52 2.6.14.4 Material balance – MIBK and DIBK ............................................................................................................ 52

2.6.15 Methyl Isobutyl Carbinol (MIBC) .................................................................................................................... 52 2.6.15.1 Process Chemistry – MIBC ............................................................................................................................. 53 2.6.15.2 Process block diagram – MIBC ..................................................................................................................... 53 2.6.15.3 Plant Process description – MIBC ............................................................................................................... 53 2.6.15.4 Material balance – MIBC ................................................................................................................................. 53

2.6.16 Di Isobutyl Carbinol (DIBC) ............................................................................................................................... 53 2.6.16.1 Process Chemistry – DIBC .............................................................................................................................. 54 2.6.16.2 Process block diagram – DIBC ...................................................................................................................... 54 2.6.16.3 Plant Process description – DIBC ................................................................................................................ 54 2.6.16.4 Material balance - DIBC ................................................................................................................................... 55

2.6.17 3,5 Dimethyl Phenol .............................................................................................................................................. 55 2.6.17.1 Process Chemistry – 3,5 DMP ....................................................................................................................... 55 2.6.17.2 Process block diagram - 3,5 DMP................................................................................................................ 56 2.6.17.3 Plant Process description - 3,5 DMP.......................................................................................................... 56 2.6.17.4 Material balance - 3,5 DMP ............................................................................................................................ 57

2.6.18 Methyl pentadiene ................................................................................................................................................. 57 2.6.18.1 Process Chemistry – methyl pentadiene ................................................................................................. 57 2.6.18.2 Process block diagram - methyl pentadiene .......................................................................................... 57 2.6.18.3 Plant Process description - Methyl pentadiene .................................................................................... 58 2.6.18.4 Material balance - methyl pentadiene ...................................................................................................... 58

2.6.19 Bisphenol S ................................................................................................................................................................ 58 2.6.19.1 Process Chemistry – Bisphenol S ................................................................................................................ 58 2.6.19.2 Process block diagram - Bisphenol S ......................................................................................................... 59 2.6.19.3 Plant Process description - Bisphenol S ................................................................................................... 59 2.6.19.4 Material balance - Bisphenol S ..................................................................................................................... 59

2.6.20 Lubricant additives (Hydraulic / Gear oil packages) ............................................................................. 59

2.6.20.1 Process Chemistry – Lubricant additives ................................................................................................ 60 2.6.20.2 Process block diagram - Lubricant additives ........................................................................................ 60 2.6.20.3 Plant Process description - Lubricant additives .................................................................................. 60 2.6.20.4 Material balance - Lubricant additives ..................................................................................................... 61

2.6.21 Sodium dithiophosphate ..................................................................................................................................... 61 2.6.21.1 Process Chemistry – sodium dithiophosphate ............................................................................................................ 61 2.6.21.2 Process block diagram - sodium dithiophosphate ..................................................................................................... 61 2.6.21.3 Plant Process description - sodium dithiophosphate............................................................................................... 61 2.6.21.4 Material balance - sodium dithiophosphate ................................................................................................................. 62

2.6.22 Sodium dialkyl dithiophosphate ................................................................................................. 62 2.6.22.1 Process Chemistry – sodium dialkyl dithiophosphate ............................................................................................. 62 2.6.22.2 Process block diagram - sodium dialkyl dithiophosphate ..................................................................................... 63 2.6.22.3 Plant Process description - sodium dialkyl dithiophosphate ............................................................................... 63 2.6.22.4 Material balance - sodium dialkyl dithiophosphate .................................................................................................. 63

2.6.23 Benzylidene Acetone ................................................................................................................... 64 2.6.23.1 Process Chemistry – Benzylidene acetone .................................................................................................................... 64 2.6.23.2 Process block diagram - Benzylidene acetone ............................................................................................................. 65 2.6.23.3 Plant Process description - Benzylidene acetone ....................................................................................................... 65 2.6.23.4 Material balance - Benzylidene acetone ......................................................................................................................... 65

2.6.24 Benzyl Acetone ............................................................................................................................ 66 2.6.24.1 Process Chemistry – Benzyl acetone ................................................................................................................................ 66 2.6.24.2 Process block diagram - Benzyl acetone ......................................................................................................................... 66 2.6.24.3 Plant Process description - Benzyl acetone .................................................................................................................. 66 2.6.24.4 Material balance - Benzyl acetone ..................................................................................................................................... 67

2.6.25 PIBSA (Poly Isobutanyl Succinic Anhydride) ............................................................................. 67 2.6.25.1 Process Chemistry – PIBSA ................................................................................................................................................... 67 2.6.25.2 Process block diagram - PIBSA ............................................................................................................................................ 68 2.6.25.3 Plant Process description - PIBSA...................................................................................................................................... 68 2.6.25.4 Material balance - PIBSA ........................................................................................................................................................ 68

2.6.26 PIBSI (Poly Isobutanyl Succinimide) .......................................................................................... 68 2.6.26.1 Process Chemistry – PIBSI ..................................................................................................................................................... 68 2.6.26.2 Process block diagram – PIBSI ............................................................................................................................................ 69 2.6.26.3 Plant Process description – PIBSI ...................................................................................................................................... 69 2.6.26.4 Material balance - PIBSI .......................................................................................................................................................... 69

2.6.27 Phosphate Esters ......................................................................................................................... 69 2.6.27.1 Process Chemistry – Phosphate esters ............................................................................................................................ 69 2.6.27.2 Process block diagram - Phosphate esters .................................................................................................................... 70 2.6.27.3 Plant Process description - Phosphate esters .............................................................................................................. 70 2.6.27.4 Material balance - Phosphate esters ................................................................................................................................. 70

2.6.28 Amine Phosphates ....................................................................................................................... 70 2.6.28.1 Process Chemistry – Amine Phosphate ........................................................................................................................... 70 2.6.28.2 Process block diagram – Amine Phosphate .................................................................................................................. 71 2.6.28.3 Plant Process description – Amine Phosphate ............................................................................................................ 71 2.6.28.4 Material balance – Amine Phosphate ............................................................................................................................... 71

2.6.29 Carbazole Esters ......................................................................................................................... 71 2.6.29.1 Process Chemistry – Carbazole Esters ............................................................................................................................. 71 2.6.29.2 Process block diagram – Carbazole Esters .................................................................................................................... 72 2.6.29.3 Plant Process description – Carbazole Esters .............................................................................................................. 72 2.6.29.4 Material balance – Carbazole Esters ................................................................................................................................. 72

2.6.30 Ashless Lubricant additives ........................................................................................................ 72 2.6.30.1 Process Chemistry – ashless lubricant additives ........................................................................................................ 73 2.6.30.2 Process block diagram – ashless lubricant additives ............................................................................................... 73 2.6.30.3 Plant Process description – ashless lubricant additives ......................................................................................... 73 2.6.30.4 Material balance – ashless lubricant additives ............................................................................................................ 74

2.6.31 Resorcinol .................................................................................................................................... 74 2.6.31.1 Process Chemistry – Resorcinol.......................................................................................................................................... 74 2.6.31.2 Process block diagram – Resorcinol ................................................................................................................................. 75 2.6.31.3 Plant Process description – Resorcinol ........................................................................................................................... 75 2.6.31.4 Material balance – Resorcinol .............................................................................................................................................. 75

2.6.32 Dicumyl Peroxide ........................................................................................................................ 75 2.6.32.1 Process Chemistry – dicumyl peroxide ........................................................................................................................... 76 2.6.32.2 Process block diagram – dicumyl peroxide ................................................................................................................... 76 2.6.32.3 Plant Process description – dicumyl peroxide............................................................................................................. 76 2.6.32.4 Material balance – dicumyl peroxide ............................................................................................................................... 77

2.6.33 Research and Development activities with pilot plant .......................................................................... 77 2.6.34 Hydrogen gas ............................................................................................................................................................ 77

2.6.34.1 Process chemistry - Hydrogen ..................................................................................................................... 77 2.6.34.2 Process block diagram - Hydrogen ............................................................................................................ 77 2.6.34.3 Process Description - Hydrogen .................................................................................................................. 78 2.6.34.4 Stagewise material balance - Hydrogen ................................................................................................... 78

2.6.35 Pollution generation aspects of manufacturing ........................................................................................ 78 2.7 RAW MATERIAL CONSUMPTION AND MODE OF TRANSPORT ........................................................................................... 79 2.8 STORAGES AT SITE.................................................................................................................................................................. 80

2.8.1 Onsite Bulk Storage ............................................................................................................................................... 80 2.9 LIST OF MAJOR EQUIPMENT .................................................................................................................................................. 83 2.10 UTILITIES ................................................................................................................................................................................. 84

2.10.1 Energy Requirements ........................................................................................................................................... 84 2.10.1.1 Electricity............................................................................................................................................................... 84 2.10.1.2 Steam/ process heat requirement .............................................................................................................. 84

2.11 FUGITIVE EMISSIONS AND CONTROL ................................................................................................................................... 85 2.12 SOLVENT RECOVERY AND ITS MANAGEMENT ..................................................................................................................... 86 2.13 WATER REQUIREMENT & WASTEWATER GENERATION ................................................................................................... 87 2.14 MANPOWER REQUIREMENT ................................................................................................................................................. 89 2.15 ENVIRONMENTAL ASPECTS .................................................................................................................................................. 89

2.15.1 Effluent Generation, Treatment and Disposal ........................................................................................... 89 2.15.1.1 Non-Hazardous / Hazardous Waste Management .............................................................................. 89 2.15.1.2 Housekeeping ...................................................................................................................................................... 91 2.15.1.3 Fire Fighting Facilities ..................................................................................................................................... 91 2.15.1.4 Occupational Health .......................................................................................................................................... 92 2.15.1.5 Health, Safety and Environment .................................................................................................................. 92 2.15.1.6 Green Belt development plan ....................................................................................................................... 92

2.15.2 Environmental Monitoring & Management ................................................................................................ 93 2.15.2.1 In-house Monitoring Capabilities ............................................................................................................... 93 2.15.2.2 Management System......................................................................................................................................... 93 2.15.2.3 Risk of Technological Failure ........................................................................................................................ 93

3 DESCRIPTION OF ENVIRONMENT ..................................................................................... 94

3.1 LAND ENVIRONMENT ............................................................................................................................................................ 94 3.1.1 Study area .................................................................................................................................................................. 94 3.1.2 Location and Topography ................................................................................................................................... 96 3.1.3 Scope of work ........................................................................................................................................................... 96 3.1.4 Reconnaissance survey ........................................................................................................................................ 98 3.1.5 Cartographic map layouts ............................................................................................................................... 100 3.1.6 Drainage maps ...................................................................................................................................................... 101 3.1.7 Contour maps ........................................................................................................................................................ 103 3.1.8 Land use and land cover classes ................................................................................................................... 105 3.1.9 Detailed study area ............................................................................................................................................. 110

3.2 SOIL QUALITY SAMPLING .................................................................................................................................................... 114 3.2.1 Methodology of Soil sampling ........................................................................................................................ 114 3.2.2 Soil sampling Locations .................................................................................................................................... 114

3.3 NON- HAZARDOUS & HAZARDOUS WASTE GENERATION, TREATMENT AND DISPOSAL ......................................... 118 3.4 CLIMATE AND METEOROLOGY ........................................................................................................................................... 118

3.4.1 Wind .......................................................................................................................................................................... 118 3.4.2 Temperature profile ........................................................................................................................................... 119 3.4.3 Rainfall profile ...................................................................................................................................................... 120 3.4.4 Inference ................................................................................................................................................................. 121

3.5 AIR ENVIRONMENT .............................................................................................................................................................. 121 3.5.1 Reconnaissance Survey .................................................................................................................................... 121 3.5.2 Methodology for Selection of Monitoring Locations ........................................................................... 121 3.5.3 Baseline Ambient Air Monitoring Studies ................................................................................................ 121 3.5.4 Onsite ambient air and workplace quality monitoring ...................................................................... 125 3.5.5 Stack monitoring ................................................................................................................................................. 126

3.6 NOISE ENVIRONMENT ......................................................................................................................................................... 127

3.6.1 Noise Level Monitoring within study area ............................................................................................... 127 3.6.2 Onsite noise monitoring results.................................................................................................................... 128

3.7 WATER ENVIRONMENT ....................................................................................................................................................... 129 3.7.1 Onsite Water Environment ............................................................................................................................. 129

3.7.1.1 Existing ETP details ........................................................................................................................................ 130 3.7.2 Reconnaissance survey ..................................................................................................................................... 131 3.7.3 Baseline water quality ....................................................................................................................................... 132

3.7.3.1 Ground Water .................................................................................................................................................... 132 3.7.3.2 Surface Water .................................................................................................................................................... 138

3.8 TRAFFIC DETAILS ................................................................................................................................................................. 145 3.9 BIOLOGICAL ENVIRONMENT ............................................................................................................................................... 146

3.9.1 Bio-geographical Setting of Raigad District ............................................................................................. 146 3.9.2 Baseline Studies in Study Area ...................................................................................................................... 150 3.9.3 Baseline Studies at Site ..................................................................................................................................... 182

3.10 SOCIAL ENVIRONMENT........................................................................................................................................................ 189 3.10.1 Baseline status ...................................................................................................................................................... 189 3.10.2 Demographic Structure of Study area ........................................................................................................ 192 3.10.3 Occupational Pattern ......................................................................................................................................... 193 3.10.4 Infrastructure facilities ..................................................................................................................................... 194 3.10.5 Town details .......................................................................................................................................................... 196 3.10.6 Health Status ......................................................................................................................................................... 196 3.10.7 Agriculture Status ............................................................................................................................................... 196 3.10.8 Archaeological sites/ Tourist places ........................................................................................................... 197 3.10.9 Survey observations/ findings ...................................................................................................................... 199

3.10.9.1 Expectation/ Demands from Respondents .......................................................................................... 200 3.10.9.2 Conclusion ........................................................................................................................................................... 203

3.10.10 CSR Activities carried out by Prasol ............................................................................................................ 203

4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES .......... 206

4.1 INTRODUCTION ..................................................................................................................................................................... 206 4.2 IDENTIFICATION OF IMPACTS ............................................................................................................................................. 206 4.3 PREDICTION OF IMPACTS DURING CONSTRUCTION PHASE AND MITIGATION MEASURES ...................................... 207

4.3.1 Land Environment .............................................................................................................................................. 207 4.3.1.1 Anticipated Impacts ........................................................................................................................................ 207 4.3.1.2 Mitigation Measures ....................................................................................................................................... 207

4.3.2 Water Environment ............................................................................................................................................ 208 4.3.2.1 Anticipated Impacts ........................................................................................................................................ 208 4.3.2.2 Mitigation Measures ....................................................................................................................................... 208

4.3.3 Air Environment .................................................................................................................................................. 208 4.3.3.1 Anticipated Impacts ........................................................................................................................................ 208 4.3.3.2 Mitigation Measures ....................................................................................................................................... 208

4.3.4 Ecological & Biological Environment ......................................................................................................... 208 4.3.4.1 Anticipated Impacts ........................................................................................................................................ 208 4.3.4.2 Mitigation Measures ....................................................................................................................................... 209

4.3.5 Noise & Vibration Environment .................................................................................................................... 209 4.3.5.1 Anticipated Impacts ........................................................................................................................................ 209 4.3.5.2 Mitigation Measures ....................................................................................................................................... 209

4.3.6 Occupational Health and Safety .................................................................................................................... 209 4.3.6.1 Anticipated Impacts ........................................................................................................................................ 209 4.3.6.2 Mitigation Measures ....................................................................................................................................... 209

4.3.7 Socio-economic Environment ........................................................................................................................ 209 4.3.7.1 Anticipated Impacts ........................................................................................................................................ 210 4.3.7.2 Mitigation Measures ....................................................................................................................................... 210

4.4 PREDICTION OF IMPACTS DURING COMMISSIONING, OPERATION PHASE AND MITIGATION MEASURES ............... 210 4.4.1 Anticipated Impacts ........................................................................................................................................... 210 4.4.2 Mitigation Measures ........................................................................................................................................... 210 4.4.3 Innovative technological measures proposed to be adopted .......................................................... 211 4.4.4 Land Environment .............................................................................................................................................. 211

4.4.4.1 Anticipated Impacts ........................................................................................................................................ 211

4.4.4.2 Mitigation Measures ....................................................................................................................................... 212 4.4.5 Water Environment ............................................................................................................................................ 213

4.4.5.1 Anticipated Impacts: Additional Water use & Wastewater Generation .................................. 213 4.4.5.2 Mitigation Measures Water Environment ............................................................................................ 213 4.4.5.3 Rain water harvesting .................................................................................................................................... 226

4.4.6 Air Environment .................................................................................................................................................. 226 4.4.6.1 Quantitative Assessment of Impacts due Fuel Burning .................................................................. 227 4.4.6.2 Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed activity 227 4.4.6.3 Modelling Impacts on PM10 ......................................................................................................................... 230 4.4.6.4 Modelling Impacts on PM2.5 ......................................................................................................................... 232 4.4.6.5 Modelling Impacts on SO2 ............................................................................................................................ 233 4.4.6.6 Modelling Impacts on NOx ........................................................................................................................... 234 4.4.6.7 Modelling Impacts on Acid mist ................................................................................................................ 235 4.4.6.8 Modelling Impacts on H2S ............................................................................................................................ 236 4.4.6.9 Modelling Impacts on CO, Hydrocarbon, PM & NOx due to vehicle movement ................... 236 Emission due to vehicular transportation ................................................................................................................ 236 4.4.6.10 Observations from dispersion modeling studies ............................................................................... 238 4.4.6.11 VOC and Fugitive emission control .......................................................................................................... 238 4.4.6.12 Odor control and Plan .................................................................................................................................... 240

4.4.7 Ecological & Biological Environment ......................................................................................................... 240 4.4.7.1 Anticipated Impacts ........................................................................................................................................ 240 4.4.7.2 Mitigation Measures ....................................................................................................................................... 241 4.4.7.3 Wild life conservation plan .......................................................................................................................... 243

4.4.8 Noise & Vibration Environment .................................................................................................................... 244 4.4.8.1 Anticipated Impacts ........................................................................................................................................ 244 4.4.8.2 Mitigation Measures ....................................................................................................................................... 245

4.4.9 Traffic Management ........................................................................................................................................... 246 4.4.9.1 Options for transport of raw materials and finished products ................................................... 247

4.4.10 Solid and Hazardous Waste ............................................................................................................................ 248 4.4.10.1 Anticipated Impacts ........................................................................................................................................ 248 4.4.10.2 Mitigation Measures ....................................................................................................................................... 250

4.4.11 Occupational Health and Safety .................................................................................................................... 250 4.4.11.1 Anticipated Impacts ........................................................................................................................................ 250 4.4.11.2 Mitigation Measures ....................................................................................................................................... 250

4.4.12 Socio-economic Environment ........................................................................................................................ 251 4.4.12.1 Anticipated Impacts ........................................................................................................................................ 251 4.4.12.2 Mitigation Measures ....................................................................................................................................... 252 4.4.12.3 Corporate Environmental Responsibility (CER) ................................................................................ 252

4.5 PREDICTION OF IMPACTS DURING DE COMMISSIONING PHASE AND MITIGATION MEASURES ............................... 253 4.5.1 Anticipated Impacts ........................................................................................................................................... 253 4.5.2 Mitigation Measures ........................................................................................................................................... 254

4.6 ENVIRONMENTAL IMPACT MATRIX ................................................................................................................................... 254 4.7 OBSERVATIONS AND CONCLUSIONS .................................................................................................................................. 260

5 ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE) ........................................... 261

5.1 ANALYSIS OF ALTERNATIVE SITES .................................................................................................................................... 261 5.2 ANALYSIS OF ALTERNATIVE TECHNOLOGIES .................................................................................................................. 261

5.2.1 Wastewater treatment and alternatives ................................................................................................... 262

6 ENVIRONMENTAL MONITORING PROGRAMME ....................................................... 263

6.1 OBJECTIVE OF ENVIRONMENTAL MONITORING PROGRAM ........................................................................................... 263 6.2 ENVIRONMENTAL MONITORING PROGRAM ..................................................................................................................... 263

6.2.1 Measurement Methodologies ........................................................................................................................ 267 6.2.2 Reporting Schedules .......................................................................................................................................... 267

6.3 BUDGETARY PROVISIONS FOR EMP ................................................................................................................................. 268

7 ADDITIONAL STUDIES (RISK ASSESSMENT AND PUBLIC CONSULTATION) ... 270

7.1 OBJECTIVES OF RISK ASSESSMENT .................................................................................................................................... 270 7.2 HAZARD IDENTIFICATION AND RISK ASSESSMENT .......................................................................................................... 271

7.2.1 Approach to the Study ....................................................................................................................................... 271 7.2.2 Hazard Identification ......................................................................................................................................... 271 7.2.3 Identification of Hazardous areas ................................................................................................................ 276 7.2.4 Identification of Failure cases for Hazardous areas ............................................................................. 276 7.2.5 Major Hazardous Areas .................................................................................................................................... 276

7.2.5.1 Hazardous Properties of Chemicals ......................................................................................................... 279 7.3 QUALITATIVE RISK ASSESSMENT ....................................................................................................................................... 283

7.3.1 Ready Reckoner for prioritization of Risk Control ............................................................................... 283 7.4 CHEMICAL HANDLING PROTOCOL AND ITS MANAGEMENT ............................................................................................ 292

7.4.1.1 Storage of Chemicals ...................................................................................................................................... 292 7.4.1.2 Chemical Handling ........................................................................................................................................... 294 7.4.1.3 Labeling ................................................................................................................................................................ 295

7.5 CONSEQUENCE ANALYSIS ................................................................................................................................................... 296 7.5.1 Operating parameters ....................................................................................................................................... 296 7.5.2 Inventory ................................................................................................................................................................. 296 7.5.3 Loss of Containment........................................................................................................................................... 296 7.5.4 Damage Criteria ................................................................................................................................................... 296 7.5.5 Source strength parameters ........................................................................................................................... 297 7.5.6 Consequential Effects ........................................................................................................................................ 297

7.6 QUANTITATIVE RISK ASSESSMENT BASED ON ALOHA .................................................................................................. 297 7.6.1 Individual and Societal Risk ........................................................................................................................... 304

7.6.1.1 Failure frequency data ................................................................................................................................... 304 7.6.1.2 Assumptions for Consequence analysis ................................................................................................. 306 7.6.1.3 Individual risk ................................................................................................................................................... 307 7.6.1.4 Societal risk ........................................................................................................................................................ 309 7.6.1.5 Conclusion ........................................................................................................................................................... 314

7.6.2 Recommendations based on Quantitative Risk Assessment ........................................................... 314 7.7 HAZOP STUDY ..................................................................................................................................................................... 316

7.7.1 Objective .................................................................................................................................................................. 316 7.7.2 Purpose of HAZOP ............................................................................................................................................... 317

7.8 AMMONIA .............................................................................................................................................................................. 317 7.9 HYDROGEN AND HYDROGENATION SAFETY ..................................................................................................................... 317

7.9.1 Hydrogen Cascade System .............................................................................................................................. 317 7.9.2 Hydrogen gas properties.................................................................................................................................. 317

7.9.2.1 Primary Hazards of Hydrogen ................................................................................................................... 318 7.9.3 Effects on Health .................................................................................................................................................. 319 7.9.4 Hydrogen safety management system ....................................................................................................... 321

7.9.4.1 Engineering Practices: ................................................................................................................................... 321 7.9.5 Facility Requirements: ...................................................................................................................................... 321

7.9.5.1 Instrumentation ............................................................................................................................................... 322 7.9.6 Electrical .................................................................................................................................................................. 323 7.9.7 Mechanical .............................................................................................................................................................. 323 7.9.8 Safety Devices / Systems.................................................................................................................................. 324 7.9.9 Protective Measures ........................................................................................................................................... 324

7.10 ON SITE EMERGENCY PLAN ................................................................................................................................................. 325 7.11 PUBLIC CONSULTATION ...................................................................................................................................................... 326

7.11.1 Notice for Public Hearing ................................................................................................................................. 326 7.11.2 Publicity of Public Hearing .............................................................................................................................. 327 7.11.3 Panel for Public Hearing ................................................................................................................................... 327 7.11.4 Proceedings ............................................................................................................................................................ 327

7.12 SOCIAL IMPACT ASSESSMENT, R & R (RELOCATION AND REHABILITATION) ACTION PLAN ................................... 343

8 PROJECT BENEFITS ............................................................................................................. 344

8.1 IMPROVEMENT IN INFRASTRUCTURES .............................................................................................................................. 344 8.2 IMPROVEMENT IN SOCIAL INFRASTRUCTURE .................................................................................................................. 344 8.3 EMPLOYMENT POTENTIAL ................................................................................................................................................. 344 8.4 OTHER TANGIBLE & INTANGIBLE BENEFITS................................................................................................................... 344

9 ENVIRONMENTAL COST BENEFIT ANALYSIS ............................................................. 345

10 ENVIRONMENTAL MANAGEMENT PLAN ..................................................................... 346

10.1 INTRODUCTION ..................................................................................................................................................................... 346 10.1.1 Objective & Scope of EMP ................................................................................................................................ 346 10.1.2 Management Systems ........................................................................................................................................ 347 10.1.3 Environmental Management Cell ................................................................................................................. 348

10.2 EMP FOR WATER ENVIRONMENT MANAGEMENT ........................................................................................................... 350 10.2.1 Water consumption ............................................................................................................................................ 350 10.2.2 Water conservation measures ....................................................................................................................... 350 10.2.3 Waste water generation, treatment and disposal ................................................................................. 351

10.3 EMP FOR IMPACT ON NOISE LEVELS ................................................................................................................................. 352 10.4 EMP FOR IMPACT ON LAND ENVIRONMENT .................................................................................................................. 352

10.4.1 Hazardous/ Non-Hazardous Waste Management ................................................................................ 352 10.5 EMP FOR SAFE ENVIRONMENT ......................................................................................................................................... 352 10.6 EMP FOR SOCIO ECONOMIC ENVIRONMENT .................................................................................................................... 353 10.7 EMP FOR IMPACTS ON ECOLOGICAL ENVIRONMENT ...................................................................................................... 353 10.8 ENVIRONMENT MANAGEMENT THOUGH HOUSEKEEPING .............................................................................................. 353 10.9 OCCUPATIONAL SAFETY AND HAZARD MANAGEMENT ................................................................................................... 354

10.9.1 Occupational Health center (OHC) .............................................................................................................. 354 10.9.2 Onsite Medical treatment ................................................................................................................................ 355 10.9.3 Fund allocation for Occupational Health and Safety measures ...................................................... 357

10.10 ENVIRONMENT BUDGET ALLOCATION ............................................................................................................................. 358 10.10.1 Energy conservation .......................................................................................................................................... 358

10.11 FINANCIAL PROVISIONS FOR EMP IMPLEMENTATION .................................................................................................. 358 10.11.1 Authorities Responsible for EMP Implementation .............................................................................. 358 10.11.2 EMP Implementation Schedule ..................................................................................................................... 358

10.12 REPORTING ........................................................................................................................................................................... 359

11 EXECUTIVE SUMMARY AND CONCLUSION .................................................................. 360

11.1 INTRODUCTION ..................................................................................................................................................................... 360 11.2 MANUFACTURING PROCESS & PROPOSED PRODUCTS .................................................................................................... 360 11.3 FUEL REQUIREMENT ............................................................................................................................................................ 362 11.4 WATER CONSUMPTION & EFFLUENT GENERATION ....................................................................................................... 362 11.5 SOLID WASTE GENERATION & DISPOSAL .......................................................................................................................... 363 11.6 DESCRIPTION OF THE ENVIRONMENT .............................................................................................................................. 363

11.6.1 Land Environment .............................................................................................................................................. 363 11.6.2 Meteorology & Climate ..................................................................................................................................... 363 11.6.3 Air Environment .................................................................................................................................................. 363 11.6.4 Noise Environment ............................................................................................................................................. 364 11.6.5 Water Environment ............................................................................................................................................ 364 11.6.6 Traffic survey ........................................................................................................................................................ 364 11.6.7 Biological Environment .................................................................................................................................... 365 11.6.8 Socio Economic Environment ........................................................................................................................ 365

11.7 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ...................................................................... 366 11.8 ENVIRONMENT MONITORING PROGRAM ......................................................................................................................... 370 11.9 ADDITIONAL STUDIES.......................................................................................................................................................... 370

11.9.1 Safety and risk assessment studies ............................................................................................................. 370 11.9.2 Public consultation ............................................................................................................................................. 370

11.10 PROJECT BENEFITS .............................................................................................................................................................. 370 11.11 ENVIRONMENT MANAGEMENT PLAN ............................................................................................................................... 371 11.12 CONCLUSION ......................................................................................................................................................................... 372

12 DISCLOSURE OF CONSULTANTS ENGAGED................................................................. 373

List of Tables Table 1.1 Existing and Proposed products, By- products and its capacity .................................................................... 5 Table 1.2 Statutory Clearances / Permissions required ..................................................................................................... 10 Table 1.3 Compliance to ToR Prescribed by EAC ................................................................................................................... 18 Table 2.1 Existing and Proposed products, By- products and its capacity ................................................................. 29 Table 2.2 List of industries around project site ...................................................................................................................... 31 Table 2.3 Land break up .................................................................................................................................................................... 31 Table 2.4 List of Major raw materials required, source ...................................................................................................... 79 Table 2.5 Raw material storages ................................................................................................................................................... 80 Table 2.6 Existing storage details ................................................................................................................................................. 80 Table 2.7 Proposed raw material and product bulk storage details ............................................................................. 82 Table 2.8 Warehouse storage details .......................................................................................................................................... 83 Table 2.9 Fuel requirement and APC details ............................................................................................................................ 84 Table 2.10 Sources of Fugitive Chemical vapors .................................................................................................................... 85 Table 2.11 Probable fugitive emiision source/control measure .................................................................................... 86 Table 2.12 Total water requirement (Existing & Proposed) ............................................................................................ 87 Table 2.13 Fresh water requirement .......................................................................................................................................... 88 Table 2.14 Waste water generation and disposal .................................................................................................................. 88 Table 2.15 Expected manpower details ..................................................................................................................................... 89 Table 2.16 Non hazardous waste generation and disposal ............................................................................................... 89 Table 2.17 Hazardous waste generation and disposal ........................................................................................................ 90 Table 3.1 Study area details of Prasol Chemicals Pvt Ltd ................................................................................................... 95 Table 3.2 Land Use Land Cover Classes...................................................................................................................................... 98 Table 3.3 GPS points showing Geographical coordinates .................................................................................................. 99 Table 3.4 Defination of land use and land cover classes ................................................................................................... 105 Table 3.5 Landuse/ Landcover Statistics of the 10 km radius Area ............................................................................ 107 Table 3.6 LULC Statistics of the 500 m angular distance around project site ......................................................... 109 Table 3.7 Soil Analysis report ....................................................................................................................................................... 116 Table 3.8 Standard Soil Classification ....................................................................................................................................... 117 Table 3.9 Hazardous waste generated during 2017-18 and 2018-19 ........................................................................ 118 Table 3.10 Details of Ambient Air Monitoring Stations .................................................................................................... 122 Table 3.11 Summarized AAQM Results - Summer 2019................................................................................................... 124 Table 3.12 National Ambient Air Quality Standards (CPCB, 2009) ............................................................................. 125 Table 3.13 Onsite Ambient Air Quality Monitoring Results ............................................................................................ 125 Table 3.14 Workplace Air Quality Monitoring Results ...................................................................................................... 126 Table 3.15 Stack monitoring results .......................................................................................................................................... 127 Table 3.16 Noise Monitoring Results (Summer 2019) ...................................................................................................... 127 Table 3.17 Onsite noise monitoring results (March 2019) ............................................................................................. 128 Table 3.18 Onsite Noise Monitoring Results (June 2019) ................................................................................................ 129 Table 3.19 Onsite Noise Monitoring Results (June 2019) ................................................................................................ 129 Table 3.20 ETP Outlet Water Analysis ...................................................................................................................................... 131 Table 3.21 Ground Water Analysis Results ............................................................................................................................ 133 Table 3.22 Surface Water Analysis Results............................................................................................................................. 140 Table 3.23 Class of Water as per IS 2296 – 1982 ................................................................................................................. 144 Table 3.24 Existing traffic (8 am to 6 pm) ............................................................................................................................... 146 Table 3.25 Existing traffic: PCU/Hour on Takai Adoshi Road ........................................................................................ 146 Table 3.26 Forest Cover in Raigad District ............................................................................................................................. 147 Table 3.27 Details of reserve forests in study area ............................................................................................................. 154 Table 3.28 Diversity index in dense vegetation .................................................................................................................... 159 Table 3.29 Diversity index in human settlement ................................................................................................................. 163 Table 3.30 Graph showing overall composition in agriculture ..................................................................................... 167 Table 3.31 Diversity index in agriculture ................................................................................................................................ 167 Table 3.32 Graphical representation of diversity index in agriculture ...................................................................... 167 Table 3.33 Diversity index in/ near aquatic habitat ........................................................................................................... 174 Table 3.34 List of Plant Species Observed During Survey within Study Area ......................................................... 176 Table 3.35 List of Fauna Observed During Survey within Study Area ....................................................................... 181 Table 3.36 List of Plant Species Observed within Site ....................................................................................................... 185 Table 3.37 List of faunal Species Observed within Site ..................................................................................................... 186

Table 3.38 Stream adjacent to Prasol compound ................................................................................................................ 187 Table 3.39 Surveyed villages ......................................................................................................................................................... 190 Table 3.40 Administrative details of study area ................................................................................................................... 191 Table 3.41 Population size of villages ....................................................................................................................................... 192 Table 3.42 Population details ....................................................................................................................................................... 192 Table 3.43 Employment pattern .................................................................................................................................................. 193 Table 3.44 Main worker employment pattern ...................................................................................................................... 194 Table 3.45 Educational Institutes Available in Number of Villages ............................................................................. 194 Table 3.46 Medical Facilities Available in Number of Villages ...................................................................................... 195 Table 3.47 Drinking Water Facilities Available in Number of Villages ...................................................................... 195 Table 3.48 Sanitation Facilities Available in Number of Villages ................................................................................. 195 Table 3.49 Communication Facilities Available in Number Of Villages ..................................................................... 195 Table 3.50 Power facilities in number of villages ................................................................................................................ 195 Table 3.51 Town details .................................................................................................................................................................. 196 Table 3.52 Health status data ....................................................................................................................................................... 196 Table 3.53 Archaeological sites/ Tourist places................................................................................................................... 197 Table 3.54 Expectations/ Demands from Villagers ............................................................................................................ 201 Table 4.1 Environmental Aspects and Impacts of the Project ........................................................................................ 206 Table 4.2 Effluent sources, Quantity and Quality of Inorganic and Organic Effluent considered for Design of Inorganic and Organic Effluent ETP ..................................................................................................................................... 216 Table 4.3 Designed stagewise performance of ETP of Inorganic Effluent ................................................................ 217 Table 4.4 Details of major process units for treatment of Inorganic Effluent ......................................................... 217 Table 4.5 Major equipment for the treatment of Inorganic Effluent ........................................................................... 218 Table 4.6 Designed stagewise performance of Organic Effluent................................................................................... 219 Table 4.7 Major process units for treatment of Organic Effluent ................................................................................. 219 Table 4.8 Details of major equipment for the treatment of Organic Effluent .......................................................... 221 Table 4.9 Quality of effluent for MEE / ATFD ........................................................................................................................ 223 Table 4.10: Quality of treated effluent achievable for recycle reuse in Plant .......................................................... 223 Table 4.11 Additional fuel Requirement .................................................................................................................................. 226 Table 4.12 Emission and stack details ...................................................................................................................................... 227 Table 4.13 Prediction of GLC of PM10 ........................................................................................................................................ 231 Table 4.14 Prediction of GLC of PM2.5........................................................................................................................................ 232 Table 4.15 Prediction of GLC of SO2 .......................................................................................................................................... 233 Table 4.16 Prediction of GLC of NOx......................................................................................................................................... 235 Table 4.17 Basis for vehicular emission ................................................................................................................................... 237 Table 4.18 Source strength calculation based on emission factor ............................................................................... 237 Table 4.19 Incremental concentration due to vehicular transportation ................................................................... 237 Table 4.20 Time bound action plan for green belt development .................................................................................. 242 Table 4.21 List of species towards outer periphery ........................................................................................................... 243 Table 4.22 List of species towards inner periphery ........................................................................................................... 243 Table 4.23 Predicted total Noise Level in dB(A) .................................................................................................................. 245 Table 4.24 Additional vehicles movement due to proposed project ........................................................................... 246 Table 4.25 Total traffic expected after expansion ............................................................................................................... 247 Table 4.26 Traffic management plan ......................................................................................................................................... 247 Table 4.27 Non hazardous waste generation & disposal ................................................................................................. 248 Table 4.28 Hazardous waste generation & disposal ........................................................................................................... 249 Table 4.29 Budgetary Allocation for CER ................................................................................................................................ 253 Table 4.30 Environmental Impact Matrix Evaluation without Mitigation Measures .......................................... 256 Table 4.31 Environmental Impact Matrix Evaluation with Mitigation Measures ................................................. 258 Table 6.1 Environment Monitoring Plan ................................................................................................................................. 264 Table 6.2 Reporting Schedule ....................................................................................................................................................... 267 Table 6.3 Budgetary Provisions for EMP ................................................................................................................................. 269 Table 7.1 Hazard Identification & Risk Assessment at Different Project Stages .................................................... 272 Table 7.2 Other Hazards and control......................................................................................................................................... 274 Table 7.3 Storage details (existing) ............................................................................................................................................ 276 Table 7.4 Proposed raw material and product bulk storage details ........................................................................... 278 Table 7.5 Warehouse storage details ........................................................................................................................................ 279 Table 7.6 Hazardous properties of the chemicals................................................................................................................ 280 Table 7.7 Transportation, Unloading, storage and handling of Solvents and chemicals .................................... 285

Table 7.8 Storage and handling of solid Chemicals in warehouse................................................................................ 288 Table 7.9 Storage and handling of Corrosive and toxic Chemicals .............................................................................. 290 Table 7.10 Consequence Analysis studies carried out ....................................................................................................... 298 Table 7.11 Failure Frequency Data ............................................................................................................................................ 298 Table 7.12 Findings of Consequence Analysis Studies ...................................................................................................... 301 Table 7.13 Failure Frequency Data ............................................................................................................................................ 304 Table 7.14 Broadly acceptable risk frequency ...................................................................................................................... 305 Table 7.15 Probit corelations for exposure ............................................................................................................................ 306 Table 7.16 Overall individual risk ............................................................................................................................................... 309 Table 7.17 Societal risk computation ........................................................................................................................................ 312 Table 7.18 Cumulative societal risk ........................................................................................................................................... 312 Table 7.19 Societal risk criteria of some other countries................................................................................................. 313 Table 7.20 Official individual Risk criteria for the public ................................................................................................ 313 Table 7.21 Suggested Individual Risk criteria ....................................................................................................................... 314 Table 7.22 Technical specification of PRV station ............................................................................................................... 320 Table 7.23 Points raised by villagers during Public Hearing (Written and Oral) .................................................. 329 Table 7.24 Reply to points raised by villagers during Public hearing ........................................................................ 331 Table 7.25 Additional points raised by Regional officer, MPCB- Raigad during Public hearing ..................... 341 Table 7.26 Additional points raised by Hon. Add. Dist. Magistrate during Public Hearing .............................. 342 Table 11.1 Existing and Proposed products, By- products and its capacity ............................................................ 361 Table 11.2 Fuel requirement ......................................................................................................................................................... 362 Table 11.3 Total water requirement (Existing & Proposed) .......................................................................................... 362 Table 11.4 Anticipated Impacts & Mitigation measures for different phases of project .................................... 367

List of Figures Figure 1.1 Raigad district map indicating project site ............................................................................................................ 7 Figure 1.2 Google image indicating site boundary co ordinates ........................................................................................ 8 Figure 1.3 Google image of site with 10 km radius .................................................................................................................. 9 Figure 1.4 Google image of site with 1 km radius ..................................................................................................................... 9 Figure 1.5 Flow chart of EIA study- Category A projects .................................................................................................... 13 Figure 2.1 Plant layout ....................................................................................................................................................................... 33 Figure 2.2 Typical solvent recovery scheme ............................................................................................................................ 87 Figure 2.3 Total Water balance Post expansion ..................................................................................................................... 88 Figure 3.1 Geographical Location of Prasol Chemicals Pvt Ltd ....................................................................................... 95 Figure 3.2 Map of Geographical Location of Study Area (10 km around project site) .......................................... 96 Figure 3.3 Map of GPS points in the study area ...................................................................................................................... 99 Figure 3.4 Survey of India Toposheet around Project site............................................................................................... 101 Figure 3.5 Drainage map of 10 km radius area around Project Site............................................................................ 102 Figure 3.6 Drainage map of 500 m angular distance around Project Site ................................................................ 103 Figure 3.7 Contour map of 10 km radius area around Project Site ............................................................................. 104 Figure 3.8 Contour map of 500 m angular distance around Project Site .................................................................. 105 Figure 3.9 Land use/landcover map of 10 km radius area around Project Site..................................................... 107 Figure 3.10 Land use/land cover statistics of 10 km radius area around Project Site ....................................... 108 Figure 3.11 Land use/land cover map of 500 m angular distance around Project Site ...................................... 109 Figure 3.12 Land use/land cover statistics of 500 m radius area around Project Site ....................................... 110 Figure 3.13 Detailed map of 10 km radius study area around Project Site.............................................................. 111 Figure 3.14 Surrounding 10 km study area photographs ................................................................................................ 113 Figure 3.15 Soil sampling locations in 10 km study area ................................................................................................. 115 Figure 3.16 soil sampling photos ................................................................................................................................................ 115 Figure 3.17 Wind Rose during summer 2019 ....................................................................................................................... 119 Figure 3.18 Temperature Profile at Khalapur ....................................................................................................................... 120 Figure 3.19 Rainfall profile ............................................................................................................................................................ 120 Figure 3.20 Photos of AAQM sampling ..................................................................................................................................... 122 Figure 3.21 AAQM locations- closer view ................................................................................................................................ 123 Figure 3.22 AAQM locations- showing in 10 km study area ........................................................................................... 123 Figure 3.23 Ground Water Sampling Location ...................................................................................................................... 132 Figure 3.24 Ground Water Sampling Photos ......................................................................................................................... 132 Figure 3.25 Surface Water Location .......................................................................................................................................... 138 Figure 3.26 Surface Water Sampling Photos .......................................................................................................................... 139 Figure 3.27 Percent total area under forest cover across years.................................................................................... 148 Figure 3.28 Types of vegetation cove across year ............................................................................................................... 149 Figure 3.29 Map Showing villages in Khalapur Taluka of Raigad District & Study Area (Green Circle) ..... 150 Figure 3.30 Extent of Study Area (Red circle) ....................................................................................................................... 151 Figure 3.31 Way Points & Survey Tracks ................................................................................................................................ 152 Figure 3.32 View of Dense Vegetation in Study Area ......................................................................................................... 153 Figure 3.33 Plantation by Forest Department near Sangade ......................................................................................... 154 Figure 3.34 Forest fire near Sangade ........................................................................................................................................ 155 Figure 3.35 Tree cutting near Umbare and Tuksai for ongoing road widening ..................................................... 156 Figure 3.36 Firewood collection .................................................................................................................................................. 156 Figure 3.37 Hill cutting/ blasting and stone crushing unit near Anjrun ................................................................... 157 Figure 3.38 Cattle Grazing .............................................................................................................................................................. 157 Figure 3.39 Industrial units Emitting Continuously ........................................................................................................... 157 Figure 3.40 Graph showing tree species composition in dense vegetation ............................................................. 158 Figure 3.41Graph showing shrub species composition in dense vegetation .......................................................... 158 Figure 3.42 Graph showing herb species composition in dense vegetation ............................................................ 158 Figure 3.43 Graph showing overall composition in dense vegetation ....................................................................... 159 Figure 3.44 Graphical representation of diversity index in dense vegetation ........................................................ 159 Figure 3.45 Typical human habitat in Study Area ............................................................................................................... 160 Figure 3.46 Huge colony of flying fox observed in Khopoli town ................................................................................. 161 Figure 3.47 Typical flora-fauna/ plantation in human settlements ............................................................................ 161 Figure 3.48 Graph showing tree species composition in human settlement .......................................................... 162 Figure 3.49Graph showing shrub species composition in human settlement ........................................................ 162

Figure 3.50 Graph showing herb species composition in human settlement ......................................................... 162 Figure 3.51 Graph showing overall composition in human settlement ..................................................................... 163 Figure 3.52 Graphical representation of diversity index in human settlement ..................................................... 163 Figure 3.53 Agriculture fields ....................................................................................................................................................... 164 Figure 3.54 Standing Rice crop during survey in Kalote Rayti and Gorthan Khurd ............................................. 164 Figure 3.55 Horticulture, and animal husbandry in study area .................................................................................... 165 Figure 3.56 Graph showing tree species composition in agriculture ......................................................................... 166 Figure 3.57 Graph showing shrub species composition in agriculture ...................................................................... 166 Figure 3.58 Graph showing herb species composition in agriculture ........................................................................ 166 Figure 3.59 View of Honad dam and lake in Khopoli ......................................................................................................... 168 Figure 3.60 View of dried rivulet near Chani and rivulet of Patalganag near Khopoli ....................................... 168 Figure 3.61 View of Adoshi dam and dried stream near Madap ................................................................................... 169 Figure 3.62 Vegetation along rivulet ......................................................................................................................................... 169 Figure 3.63 Dumping of domestic waste on bank of Donvat dam ................................................................................ 169 Figure 3.64 Fishing near Palasdari and in Donvat dam .................................................................................................... 170 Figure 3.65 Fish species occur in study area ......................................................................................................................... 171 Figure 3.66 View of Kalote dam and flock of Asian open bill storks hovering over it ......................................... 171 Figure 3.67 Fauna associated with Water Body ................................................................................................................... 172 Figure 3.68 Flora associated with Water Body ..................................................................................................................... 172 Figure 3.69 Graph showing tree species composition in aquatic habitat ................................................................. 173 Figure 3.70 Graph showing shrub species composition in aquatic habitat ............................................................. 173 Figure 3.71 Graph showing herb species composition in aquatic habitat ................................................................ 173 Figure 3.72 Graph showing overall composition in aquatic habitat ........................................................................... 174 Figure 3.73 Graphical representation of diversity index in aquatic habitat ............................................................ 174 Figure 3.74 View of site, tank farm and main plot respectively .................................................................................... 182 Figure 3.75 View of green belt...................................................................................................................................................... 183 Figure 3.76 Site visit with Official of Prasol............................................................................................................................ 184 Figure 3.77 nest of Common crow within site ...................................................................................................................... 184 Figure 3.78 Dead trees within site .............................................................................................................................................. 185 Figure 3.79 View of main gate of Prasol unit ......................................................................................................................... 188 Figure 3.80 Tree cutting in dense vegetation ........................................................................................................................ 188 Figure 3.81 Survey in study area ................................................................................................................................................. 188 Figure 3.82 Primary Socio- economic survey photographs ............................................................................................ 191 Figure 3.83 Population details ..................................................................................................................................................... 193 Figure 3.84 Employment pattern ................................................................................................................................................ 194 Figure 3.85 Archaeological sites/ Tourist places within 10 km study area ............................................................. 197 Figure 4.1 Proposed ETP scheme for Organic & Inorganic effluent ............................................................................ 224 Figure 4.2 Proposed ETP Material Balance ............................................................................................................................ 225 Figure 4.3 Windrose summer ....................................................................................................................................................... 229 Figure 4.4 Isopleths Impacts for PM10....................................................................................................................................... 231 Figure 4.5 Isopleths Impacts for PM2.5 ...................................................................................................................................... 232 Figure 4.6 Isopleths of SO2 ............................................................................................................................................................. 233 Figure 4.7 Isopleths of NOx ............................................................................................................................................................ 234 Figure 4.8 Isopleths of acid mist .................................................................................................................................................. 235 Figure 4.9 Isopleths of H2S ............................................................................................................................................................. 236 Figure 4.10 Ten km radius study area around site ............................................................................................................. 244 Figure 4.11 Combined noise Contour ........................................................................................................................................ 245 Figure 5.1 Product Chain from Cumene ................................................................................................................................... 262 Figure 5.2 Product Chain from Phosphorus and Sulphur ................................................................................................ 262 Figure 7.1 Risk matrix for qualitative risk assessment ..................................................................................................... 283 Figure 7.2 Typical F- N curve ........................................................................................................................................................ 310 Figure 7.3 Iso contour of radiation effect zone ..................................................................................................................... 311 Figure 7.4 F N Curve for the project ........................................................................................................................................... 313 Figure 7.5 Typical P & ID of PRV station .................................................................................................................................. 320 Figure 7.6 Photograph of Public Hearing ................................................................................................................................ 343 Figure 10.1 Integrated Management certificate ................................................................................................................... 347 Figure 10.2 EHS Policy ..................................................................................................................................................................... 348 Figure 10.3 Environment Management Cell ........................................................................................................................... 350

List of Annexures No. Contents

1.1 Existing Consent to Operate

1.1(a) Letter from Turbine supplier

1.2 TOR issued by MOEF&CC as per letter dated 27th June 2019

1.3 CTO compliance status

1.4 Existing granted EC

1.5 RO Nagpur EC compliance letter and Pointwise compliance reply

2.1 Plot Plan layout

2.1(a) Copies of 7/12 extract

2.1(b) Urban Development Notification reg Raigad Regional plan

2.1(c) Agreement for green belt development

2.2 Water permission letter from Irrigation department

3.1 Open Series Map of 10 km study area

3.2 Hazardous waste membership

3.3 Date wise AAQM results

3.4(a) Distance map from project site to ESA area

3.4(b) Wildlife conservation plan for Schedule I species

3.5 Socio economic data

3.6 Corporate Social Responsibility details

4.1 CER Plan submitted to District collector

7.1 Risk assessment compliance letter

7.2 ALOHA study results

7.3 Onsite emergency management plan

7.4 MSDS of Chemicals

7.5 Fire detection and protection measures

7.6 Health status of workers

7.7 Copy of Public Hearing Proceedings

List of Abbreviation Abbreviation Full form

AAQ Ambient Air Quality

ACGIH American Council for Governmental Industrial Hygienists

BDL Below Detectable Limit

BOD Biological Oxygen Demand

CETP Common Effluent Treatment plant

CHWTSDF Common Hazardous Waste Treatment Storage and Disposal Facility

CMD Cubic Meter Per Day

COD Chemical Oxygen Demand

CPCB Central Pollution Control Board

CREP Corporate Responsibility for Environment Protection

CTE

CTO

DISH

Consent to Establish

Consent to Operate

Directorate of Industrial Safety and Health

EAC Expert Appraisal Committee

EC Environment Clearance

EIA Environment Impact Assessment

EMP Environment Management Plan

ERPG Emergency Response Planning Guidelines

ISO International Organization for Standardization

GLC Ground Level Concentration

HW Hazardous Waste

LULC Land Use Land Cover

MIDC Maharashtra Industrial Development Corporation

MOEFCC Ministry of Environment and Forest & Climate Change

MPCB Maharashtra Pollution Control Board

MSDS Material Safety Data Sheet

NAAQS National Ambient Air Quality Standard

NOC No Objection Certificate

OHSAS Occupational Health and Safety Assessment Series

O&M Operation and Maintenance

PM Particulate Matter

PM10 Particulate Matter < 10 µg/cum

PM2.5 Particulate Matter < 2.5 µg/cum

PPE Personal Protective Equipment

PRIA

RWH

Patalganga Rasayani Industrial Association

Rain Water Harvesting

SOCMI Synthetic Organic Chemicals Manufacturing Industry

STEL Short Term Exposure Limit

TPA Ton Per Annum

TLV Threshold Limiting Value

TOR Term of Reference

TPD Ton Per Day

TPH Ton Per Hour

TPM Ton Per Month

TWA Time Weighted Average

Environmental Impact Assessment Prasol Chemicals Private Limited

Chapter 1– Introduction

Environmental Consultant: Aditya Environmental Services Pvt. Ltd. Page 1

1 INTRODUCTION

Prasol Chemicals Private Limited (Prasol) (formerly known as Prasol Chemicals Limited) proposes a brownfield project for expansion of Synthetic organic chemicals manufacturing at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra.

1.1 Purpose of Environmental Impact Assessment (EIA) Report

The purpose of this Environmental Impact Assessment report is to investigate the

principal environmental concerns, assess magnitude of impact and suggest a suitable Environmental Management Plan for the proposed expansion project of Prasol Chemicals Private limited. The existing manufacturing facility of Prasol have valid consent to operate from MPCB. (Refer Annexure 1.1). Terms of Reference (TOR) for proposed expansion project is issued by MOEF&CC as per letter dated 27th June 2019 (Refer Annexure 1.2).

A draft EIA report was prepared based on ToR issued and ‘General Structure of EIA’ given in Appendix III and IIIA of the mentioned EIA Notification and placed for public hearing. This final EIA report incorporates the suggestions for improvement/concerns raised in the public hearing.

1.2 Identification of project & project proponent

1.2.1 Project

The Project is for manufacturing of synthetic organic chemicals. The products fall under activity 5(f) (Synthetic organic chemicals manufacture) listed within the category of the EIA Notification dated 14th September 2006 (amended till date). The project is classified

as Category “A” project.

1.2.2 Project Proponent

The company “Prasol Chemicals Private Limited” (Prasol) is premier manufacture of specialty chemicals (Phosphorus/ acetone/ Cumene derivatives, Lubricant additives,

mining chemicals, pharmaceutical intermediates, aroma chemicals and many more specialty chemicals).

History

Prasol Chemicals Private Limited is one of the leading & fastest growing chemical manufacturing companies in India. Incorporated in 1992, the manufacturing of unsaturated polyester resins was commissioned. In the year 1995, Prasol became a deemed Public limited company and set up a manufacturing unit at Khopoli near Mumbai, India.




Prasol belief in "Customer First, Reputation First" is one which emphasizes the importance of customer satisfaction through both product quality and service. Prasol employs a workforce of over 500+ people who work in beautiful surroundings at its factory in Khopoli. The total occupied area of Prasol is 68,644 sq. m with production plants for Phosphorous based, Cumene based and hydrogenated products.

The products that Prasol manufacturers are prevalent in various sectors such as Paints & Coatings, Thinners, Agrochemicals, Lubricants, Surfactants, Pharmaceuticals, Fragrances, etc. Global reach of Prasol spans 40 countries along with local presence pan India. It also has an in-house Research & Development Center and a Projects team.

Vision "To Become India's Premier Manufacturer / Supplier of Specialty Chemicals & Technical Services." Mission To interact with clients in process up gradation and cost-cutting measures: -

Ensures High Customer Satisfaction Ensures Value Addition to all our Stakeholders

To maintain adequate profitability by growth of Top line, Bottom line and various cost-cutting measures.

Prasol Chemicals Private Limited (Prasol) forms an integral part of the global chemical industry.

Prasol is an ISO 9001:2015, ISO 14001:2015 and OHSAS 18001: 2015 certified company that is well aligned with its vision "To become a premier manufacturer of Specialty Chemicals and to provide Technical Services globally." Prasol is also “A” credit rated by SMERA.

Prasol has its own Research and Development and Manufacturing unit, with production facilities for Phosphorous Based, Acetone Based and Hydrogenated products, situated at Khopoli in Raigad district, Maharashtra state.

Prasol has established aggressive growth plans for its business with a well-defined

pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term.




Company History and milestones

1.2.3 Project Proponent & Background of Promoters

The total occupied area at Khopoli is 68,644 sq. meters with production plants for Phosphorous Pentasulphide, Diacetone Alcohol, Isophorone, Mesityl Oxide, Lubricant Additives, Phenol – Acetone and various Hydrogenated Products.

Prasol has established aggressive growth plans for its business with a well-defined pathway for the next several years. Lead by a strong and enthusiastic team of technocrats, the company is well underway in executing plans for organic growth in the near & medium term.

People at Prasol are dynamic and committed. For them, upholding the company's

reputation is not just a part of their job, but a mission. There is an ongoing quest for excellence, and they are amply supported by the management's emphasis on enhanced communications with clients.

Prasol, strongly believes that, when a team outgrows individual performance and learns team confidence, excellence becomes a reality. Keeping with its belief, the Prasol Family has concocted a perfect blend of wisdom, youth, energy and most importantly passion.

The Company is managed by the promoters and whole time Directors; Mr. Nishith Shah (Chairman), Mr Gaurang Parikh (Managing Director), Mr Dhaval Parikh (Director International business) and Mr Pankil Dharia(Director), assisted by highly skilled technical and commercial professionals.

1995




Background of promoters

Mr. Nishith Shah (Chairman)

B.S (Metallurgical Engineering) California Polytechnic. Past Experience 1985-1992 Quality Control Engineer (Rockwell Intl.) + Heatreaters & Engineers, Mumbai and Heat Fab, Pune. 1992 started Prasol Chemicals Pvt Ltd. Has 40+ years experience in Fabrication, Failure Analysis and Business Development of Organic and Inorganic Chemicals.

Mr. Gaurang Parikh (Managing Director)

M.S. Chemical Engineering at the University of Toledo, USA. B E (Chemical Engineering) from University of Pune. Past Experience 1997-2001 ThyssenKrupp Budd Company in Illinois & Rostone Corporation, USA. 2001 joined Prasol Chemicals as the Director of Sales & Marketing and started division of Distribution of Niche chemicals.

Mr. Dhaval Parikh (Director International Business)

Masters in Plastics Engineering from University of Massachusetts at Lowell & B. Plastics Technology (UDCT Mumbai). Past Experience 1999- 2007 GE Plastics film and sheet division at Mt. Vernon Indiana. 2007 joined Prasol Chemicals as Director of International Business and is responsible for International Marketing and Procurement. Handles local sales of organic manufactured chemicals, along with polymers and chemicals for Distribution.

Mr. Pankil Dharia (Director- Sales & Marketing)

BS (Electrical Engineering) and BS (Molecular & Cellular Biology) from University of Illinois at Urbana Champaign. Past Experience 2006-2010 worked in California at CRDM unit of Medtronic as a Sales Representative for 4 years. 2010 joined Prasol in as a Director of Sales & Marketing. Responsible for the sales and distribution of Value-Added Products and exports of certain niche chemicals. Actively involved in business development and identifying new products that can be made at Prasol to the customer's requirement.

1.3 Brief Description of Nature, Size, Location of the Project & Its Importance in the Country, Region

1.3.1 Nature & Size of Project

The company proposes to expand manufacturing of various synthetic organic chemicals manufacturing at the site as mentioned below:


Chapter 1- Introduction


Table 1.1 Existing and Proposed products, By- products and its capacity

S. No. Products / By Products Existing (*)

Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year) Products

1 Diacetone Alcohol 9,000 23,000 32,000 2 Nonyl Phenol 720 30 750 3 Phosphorous Penta sulphide 6,000 4,000 10,000 4 Phosphorous Acid Food Grade 600 0 600 5 Dil. Phosphoric Acid 500 0 500 6 Phosphorous Pentoxide 624 26 650 7 Isophorone 3,600 8,400 12,000

8 Phenol 20,000 0 20,000

9 Acetone 12,000 3,000 15,000 10 Zinc Diorgano Dithiophosphate 1,500 2,000 3,500 11 Mesityl Oxide 750 2,250 3,000

12 Hexylene Glycol, Trimethyl Cyclohexanol, Trimethyl Cyclohexanone,

1,800 13,200 15,000

13 Methyl Isobutyl Ketone 0 5,000 5,000 14 Methyl Isobutyl Carbinol 0 3,000 3,000 15 Di-isobutyl Ketone 0 1,500 1,500 16 Di-isobutyl Carbinol 0 1,000 1,000 17 Cumene Hydroperoxide 0 5,000 5,000 18 3,5 Dimethyl Phenol 0 3,000 3,000 19 Methyl Pentadiene 0 2,000 2,000 20 Bisphenol-S 0 3,000 3,000

21 Lubricant Additives (Hydraulic Packages/ Gear Oil Packages etc.)

0 500 500

22 Sodium Dithiophosphate 0 500 500 23 Sodium Dialkyl Dithiophosphate 0 500 500 24 Benzylidene Acetone 0 800 800 25 Benzyl Acetone 0 500 500 26 Dialkyl Dithiophosphoric Acid 0 500 500

27 Poly Isobutanyl Succinic Anhydride(PIBSA)

0 1,500 1,500

28 Poly Isobutanyl Succinimide (PIBSI)

0 750 750

29 Phosphate Esters 0 500 500

30 Amine Phosphates 0 300 300 31 Carbazole Esters 0 1,500 1,500 32 Ashless Lubricant Additive 0 300 300 33 Resorcinol 0 3,000 3,000 34 Dicumyl Peroxide 0 500 500

35 Cumyl Alcohol 0 250 250

36 Cogeneration Power @ 4.6 MW 0 4.6 MW





Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year)

37 Steam generation 38 Ton/hr 0 38 Ton/hr

38 Research and Development activities with Pilot Plant

- - -

Sub Total (Products) 57,094 91,306 148,400 By-Products

1 Di-Nonyl Phenol 60 0 60 2 Alpha Methyl Styrene (AMS) 1,500 0 1,500 3 Acetophenone (ACP) 800 0 800

4 Sodium Hydrogen Sulphide (NaHS)/ Flakes

0 2000 2,000

5 Dicarbinol 0 240 240 Sub Total (By Products) 2,360 2,240 4,600

Grand Total (Products + By products)

59,454 93,546 153,000

* As per existing consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.07.2020 valid till 31.10.2021. @ Letter from Turbine Supplier is enclosed as Annexure 1.1(a).

The total plot area of the site is 68,644 sq. m and estimated project cost of expansion is ~ Rs. 50 Crores.

1.3.2 Project Location

The expansion will be carried out at plot situated at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra. List of survey nos. owned by Prasol is given below, Refer Annexure 2.1(a) for Copies of 7/12 extract.




Location of site within Raigad district is shown below,

Figure 1.1 Raigad district map indicating project site

Details of nearest infrastructural facilities is given below

Sr. No. Particulars Details 1. Group Gram Panchayat Honad, Chinchvali Gohe, Thanenhave 2. Taluka Khalapur 3. District Raigad 4. Latitude 18°46'33.84"N 5. Longitude 73°18'10.37"E

6. Elevation 60 meter above mean sea level 7. Nearest water bodies Patalganga River 8. Nearest Highway Mumbai Pune Expressway 9. Nearest Railway station Khopoli

10. Nearest Airport Mumbai Site coordinates are as follows:

Point Latitude Longitude A 18°46'37.12"N 73°18'12.90"E B 18°46'30.82"N 73°18'12.51"E C 18°46'30.46"N 73°18'8.75"E D 18°46'24.20"N 73°18'6.75"E E 18°46'22.10"N 73°18'10.83"E F 18°46'22.80"N 73°18'14.15"E G 18°46'21.10"N 73°18'14.36"E H 18°46'18.33"N 73°18'11.25"E I 18°46'22.91"N 73°18'3.58"E J 18°46'25.69"N 73°18'3.70"E




Point Latitude Longitude K 18°46'25.70"N 73°18'4.78"E L 18°46'24.01"N 73°18'5.69"E M 18°46'30.57"N 73°18'8.56"E N 18°46'33.29"N 73°18'7.46"E O 18°46'34.85"N 73°18'8.76"E P 18°46'36.27"N 73°18'7.23"E Q 18°46'38.28"N 73°18'7.87"E R 18°46'32.53"N 73°18'3.34"E S 18°46'33.38"N 73°18'1.75"E T 18°46'34.31"N 73°18'1.39"E U 18°46'34.88"N 73°18'3.15"E V 18°46'33.52"N 73°18'3.48"E

Figure 1.2 Google image indicating site boundary co ordinates




Figure 1.3 Google image of site with 10 km radius

Figure 1.4 Google image of site with 1 km radius

1.3.3 Importance of the Project to the Country, Region

All the products above are imported to India on a regular basis. The quantum of imports varies from product to product, but the manufactured goods will be import substitutes.




Amongst the products, hydrogenated products, Phosphorus Pentasulphide and ZDDP are already being manufactured at the project site. The additional products are forward integration of the company’s current products and have a great demand both global and domestic market. The demand is envisaged to increase rapidly in the domestic market.

1.3.4 Export Possibilities

The products can be exported thus leading to Forex revenues for the country.

1.3.5 Employment generation (direct/indirect) due to project

During construction phase around 100 workers and during the operational phase around 110 workers including contractors will be required. Local skilled and semi-skilled workers will be engaged during construction phase. The positives impact includes enhanced direct employment for technical/ administrative works and indirect employment opportunities for transporters of raw materials and finished goods and downstream industries.

1.4 Regulatory framework

1.4.1 General clearances and other related permissions

Prasol shall obtain required statutory permission and clearances from concerned authorities. Details of permits and clearance as applicable to this expansion project are provided in table below.

Table 1.2 Statutory Clearances / Permissions required

No Legal requirement 1.0 Safety Related Laws

1.1 The Explosive Act, 1884 and the Explosives Rules 2008, The Petroleum Rules 2012, The Gas Cylinder Rules 2016 & Static and Mobile Pressure Vessels (unfired) Rules 2016 (as amended till date)

1.2 The Petroleum Act 1934 & the Petroleum Rule 2019 (as amended till date)

1.3 The Factories Act 1948 & The Maharashtra Factories Rules 1963/ 2019 (or as amended till date)

2.0 Planning

2.1 Maharashtra Regional and Town Planning Act 1966/2007 (or as amended till date)

2.2 Maharashtra (Urban Areas) Protection and Preservation of Trees Act 1975/2017 (or as amended till date)

2.3 Forest (Conservation) Act 1980 (1988 ammendment) and Forest Conservation Rules 2003 or as amended till date

2.4 Motor Vehicles Act 1988 & Motor Vehicles Rules 1989 (or as amended till date)

3.0 Environmental Laws

3.1 Water (Prevention and Control of Pollution) Act 1974 & Maharashtra Water (Prevention and Control of Pollution) Rules 1983 (or as amended till date)

3.2 Air (Prevention and Control of Pollution) Act 1981 and & Maharashtra Air (Prevention and Control of Pollution) Rules 1983 (or as amended till date)

3.3 Environment (Protection) Act 1986 & Environment (Protection) Rules 1986 (or as amended till date)




a. The Manufacture, Storage and Import of Hazardous Chemical rules, 1989/2000 (or as amended till date)

b. Public Liability Insurance Act 1991 (or as amended till date) c. Chemical accidents (Emergency Planning, preparedness and response) Rules,

1996/2016 (or as amended till date) d. The Noise Pollution (Regulation and Control) Rules 2000 (or as amended till date) e. Notification on Control of Noise from DG sets 2002 f. Environment Impact Assessment Notification 2006/2020 (or as amended till date) g. Hazardous Waste (Management & Handling) Rules 2016 (or as amended till date) h. Batteries (Management & Handling) Rules 2016 (or as amended till date) i. Solid Waste Management Rules, 2016 (or as amended till date) j. Bio-Medical Waste Management Rules, 2016 (or as amended till date) k. Construction and Demolition Waste Management Rules 2016 (or as amended till

date) l. E-Waste (Management) Rules 2016 (or as amended till date) m. Plastic Waste Management Rules 2016 (or as amended till date)

4.0 Labour Laws (Important)

4.1 Sexual Harassment of Women at Workplace (Prevention, Prohibition and Redressal) Act 2013 (or as amended till date)

4.2 Contract Labour (Regulation and Abolition) Act 1979 (or as amended till date)

4.3 Inter-State Migrant Workmen Act 1979 (or as amended till date)

4.4 Child Labour (Prohibition and Regulation) Act 1986 (or as amended till date)

4.5 Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act 1996 (or as amended till date)

Note: Above list is indicative and not exhaustive. It is recommended that a proper Legal Register be developed and maintained by Prasol Chemicals Pvt. Ltd. to ensure that all legal requirements are identified and tracked for effective compliance. Prasol Chemicals Ltd has its manufacturing unit at Honad since late 1990s. Honad Industrial zone is an approved Industrial zone by Urban Development Department, Government of Maharashtra and Notification under Section 17 of the the Maharashtra Regional and Town Planning Act 1966 was published vide TPS 1490/CR 365/90/UD-12 dt 4th July 1992 as identified by the Raigad Regional Board. Prasol Chemicals was initially a SSI unit and later on with increased capital investments, it has now become a Large Scale Industry. The company has obtained the following clearances/permissions: - Environmental clearance for expansion vide No. J- 11011/260/2012-IA II (I); Dt:

18.09.2014 - Factory Layout approval from DISH vide letter dt 04.10.2019 (including cogeneration

Captive Power Plant) - Consent to Operate from MPCB vide no. Format 1.0/CAC/UAN No. 0000078581/CO-

2007001796 dated 31.07.2020 valid till 31.10.2021. - MSRDC has recently been given Development rights along Mumbai- Pune Expressway

and is now the Planning agency responsible for development of the area around the project – hence Prasol Chemicals has also submitted its layout plans for approval to MSRDC




1.4.2 Applicability of EIA Notification 2006

As a part of Environmental Clearance process, Prasol uploaded and submitted relevant documents, namely Form – 1 (as per the EIA Notification, 2006, as amended), along with a Pre-feasibility Report and Proposed Terms of Reference (ToR) for carrying out Environmental Studies, to the Expert Appraisal Committee (EAC) MoEF&CC on 20th May 2019.

Based on the information contained in the documents submitted, the project has been awarded proposal number IA/MH/IND2/105900/2019.

MOEF&CC issued TOR for carrying out EIA/EMP vide letter No. J-11011/260/2012-IA-II(I) dated 27th June 2019. (Refer Annexure 1.2)

For conducting EIA as per the TORs, project proponent Prasol Chemicals Private Limited has retained the services of M/s. Aditya Environmental Services Private limited, Mumbai, NABET accredited EIA Consultant Organization for synthetic organic chemicals manufacturing sector.

Own Laboratory of Aditya Environmental Services Private limited (Recognized by MOEF&CC as “Environmental Laboratory” letter no. Q-15018/10/2019-CPW dated 20th December 2019 valid upto 8th July 2021) has conducted baseline monitoring during Summer 2019 for EIA report.

1.5 Environment Impact Assessment

Environmental Impact Assessment is a management tool used to identify, frame and prioritize the environmental issues so that the required mitigation measures can be worked out at the project planning phase and the negative impacts can be minimized or avoided during actual operation.

Objectives The objectives of EIA for the expansion of project are listed below:

Characterization and benchmarking of existing environmental status. To identify and quantify significant impact on the environmental parameters during

construction, commissioning and operation phases of the project. To identify and quantify any environmental impacts associated with the project and

recommend appropriate mitigation measures to avoid/minimize pollution, environmental disturbance and nuisance.

Preparation of an environmental management plan to minimize adverse impacts of the project.

Recognize the scope and requirement of the ToR and comply with the same.

1.5.1 Process of EIA study

EIA process passes through the following phases:

Screening, Scoping and consideration of alternatives Study of the project details




Application with environmental pre-feasibility study for approval of ToR. Collection of baseline data for study area Impact identification, prediction and evaluation Assessment of alternatives and delineation of Environment Management Plan Risk Assessment (RA) and Disaster Management Plan (DMP) Review and finalization of EIA report Public consultation Final EIA report and EC Application.

Flow chart of various activities to be carried out for EIA report preparation is depicted in figure below.

Figure 1.5 Flow chart of EIA study- Category A projects

1.5.2 Methodology adopted for EIA study

The methodology adopted for conducting the EIA is mentioned below:




Screening and scoping: Screening is done to see whether a project requires clearance as per the statutory notifications. Scales of investment, type and location of development are the main criteria for screening the project activity. Scoping is carried out in close association with the project proponent and guidance by the Impact Assessment Agency. MoEF&CC has published guidelines for different sectors, which outline the significant issues to be addressed in the EIA studies. Quantifiable impacts are assessed on the basis of magnitude, prevalence, frequency, duration and significance of non-quantifiable impacts is commonly determined through the socio-economic criteria. After the areas where the project can have significant impact are identified, the baseline status of these are to be monitored and then the likely changes in these on account of the construction

and operation of the project are predicted.

Desk top study: Desktop study has been conducted to establish an environmental information database for the EIA. Reference materials such as textbooks, articles, maps, internet, photographs and past EIA reports of similar industries have been used for the preparation of EIA report.

Field study: One season field study for the period of Summer 2019 has been carried out to verify and complement information gathered from desktop study. Baseline data describes the existing environmental status of the identified study area. The study covers all the relevant components of ambient air monitoring; noise, water quality, soil quality, ecological, and socio-economic and health components of the environment. The site-

specific primary data has been collected for the identified parameters and supplemented by secondary data if available.

Air environment

Monitoring of the existing status of ambient air quality and analysis has been carried out as per revised National Ambient Air Quality Standard. Maximum numbers of sampling stations have been selected considering the pre-dominant downward wind direction, population zone and sensitive receptor of the region. Micro-meteorological data like hourly wind speed and direction, temperature, relative humidity, rain fall, etc., have been collected by using wind monitor. Monitoring of flue gas emission was carried out from the existing plant. Air Modeling was done to envisage the likely impact on ambient air quality due to expansion project.

Noise environment

Noise level monitoring has been carried out for day and night times by noise meter to assess the present scenario of the noise environment.

Land Environment

Soil samples have been collected from selected locations within the impact zone and analyzed for relevant parameters. Studies of soil characteristics are carried out. Existing land use and topography, landscape and drainage patterns within the study area is also analyzed.

Water environment




Ground & Surface Water samples have been collected from various locations within 10 km radius from the project. Analysis is carried out for physio-chemical, heavy metal, microbiological as per requirement. Results have been compared to assess the water quality.

Ecology & Socio-Economic Environment

Primary data of flora and fauna have been collected by visiting site & study area survey. Secondary data collected from various literatures published by Forest Department. Data have also been verified by primary data collected. Collection of demographic and related socio-economic data is carried out. Projection of anticipated changes in the socio-economic aspect due to the project related activities, are also studied.

Laboratory Analysis

Samples collected during the field sampling are analyzed in an established recognized laboratory.

Impact Prediction and Evaluation

Impact prediction is a way of ‘mapping’ the environmental consequences of the significant aspects of the project and its alternatives. Evaluation of all associated and potential impacts of the project were carried out using required models. Impact evaluation is carried out using the matrix method.

Mitigation Measures and Environmental Management Plan

Efficient mitigation plan has been drawn up for the selected option and is supplemented with an Environmental Management Plan (EMP) to guide the proponent towards environmental improvements. Depending on nature, location and scale of the project, all significant risks and hazards and their mitigation measures shall be incorporated in the risk report. Risk report contains hazard identification by taking recourse to hazard indices, inventory analysis, natural hazard probability, consequence analysis of failures and accidents resulting in fire, explosion, hazardous releases etc. Assessment of risk on

the basis of the necessary evaluations and preparation of an Onsite /off site Emergency Plan and Disaster Management Plan are also mentioned in the risk report.

EIA Report

Based on the field survey visit primary & secondary data collection, compilation of data

and technical details are done by the project team and reviewed. Draft EIA report is prepared after incorporation of all the technical data, maps, drawings, FAEs comments and inputs. Quality check is conducted by a QA/QC team and their comments are incorporated in the report. After final confirmation from the project proponent draft EIA report is submitted to MPCB for Public consultation. Based on suggestion/ recommendation/ additional compliance from public consultation, Final EIA report is submitted to EAC for appraisal.

1.5.3 Structure of EIA Report

This report comprises of twelve (12) chapters in line with the generic structure of EIA report given in Annexure III of the EIA notification as well as to furnish details required in prescribed TORs as mentioned below,




Chapter

No Description Content

1 Introduction Purpose of the report, Identification of project & project proponent, Brief description of nature, size, location of the project and its importance to the country, region, Scope of the study, EIA methodology and information about assessment agency. Compliance to ToR

2 Project Description

Type of project, need for the project, Location maps showing general location, specific location, project boundary & project site layout), size of project, Technology and process description utilities, Resource consumption etc. Condensed description of those aspects of the project

(based on project feasibility study), likely to cause environmental effects

Schedule for approval and implementation, Description of mitigation measures incorporated into the

project to meet environmental standards, Assessment of New & untested technology, if applicable, for

the risk of technological failure 3 Description of

the Environment

Demarcation and description of Study area, study period, components as identified in the scope & methodology of baseline study, Establishment of baseline for valued environmental components, results of the study and inferences, Base maps of all environmental components, wherever applicable

4 Anticipated Environmental Impact and mitigation measures

Details of Investigated Environmental impacts due to project location, possible accidents, project design, project construction, regular operations.

Measures for minimizing and / or offsetting adverse impacts identified.

Irreversible and Irretrievable commitments of environmental components

Assessment of significance of impacts (Criteria for determining significance, Assigning significance)

Mitigation measures. 5 Analysis of

Alternatives (Site and Technology)

Analysis of alternatives site considered for siting the project.

Analysis of alternatives technologies considered for the project

6 Environmental monitoring program

Technical aspects of environmental monitoring for the effectiveness of mitigation measures (incl. Measurement methodologies, frequency, location data analysis, reporting schedules, emergency procedures, budget procurement schedules)




Chapter No

Description Content

7 Additional studies (Public hearing and Risk assessment)

Hazard Identification Risk Assessment & control/prevention Measures Disaster Management plan Results of public hearing and recommendations

8 Project benefits

Improvements in the physical infrastructure, Improvements in the social infrastructure, Employment potential skilled; semi-skilled and unskilled, Other substantial benefits

9 Environmental cost benefit analysis

Details of the environmental benefits of the project.

10 Environmental management plan

Description of the administrative aspects of ensuring that mitigation measures are implemented, and their effectiveness monitored, after approval of the EIA.

11 Summary and conclusions

Overall justification for the project and explanation of how adverse effects have been mitigated

12 Disclosure of consultant engaged

Details of EIA Consultant engaged, and consultancy rendered.

1.6 Scope of the EIA Study

The proposal falls under activity 5(f), Category A as per EIA notification 2006 and needs prior environmental clearance from Expert Appraisal Committee (EAC).

Accordingly the EIA report is prepared as per Standard TOR prescribed (MOEF&CC document April 2015 for Activity 5(f).

Any development project is likely to impact surrounding environment. The nature and magnitude of impact on different components of the environment will depend on the nature and size of project as well as location aspects of the project site and steps taken for mitigating the environmental impact. The final net impact due to the project on environmental components can be evaluated through Environmental Impact Assessment (EIA) studies within the study area prior to its implementation. The results of EIA Studies form the basis for preparation of a viable Environmental Management Plan (EMP).

The EIA Studies can be broadly divided in to three phases.

1st PHASE: The first phase involves identification of significant environmental components and assessing their baseline (Pre-project) status within the study area.

2nd PHASE: The second phase involves prediction of impacts on various identified significant environmental parameters due to the project. Data regarding the construction activities, design capacity of the individual units, water consumption, solid / hazardous waste, sewage / effluent generation, characteristics of disposal medium and topography of the study area is also taken into consideration to evaluate project related environmental features.




3rd PHASE: The third phase covers the evaluation of final impacts and delineation of an Environmental Management Plan to mitigate adverse impacts on the quality of surrounding environment.

For the purpose of assessing the impacts Study area of 10 km radius around project site was identified for the EIA study as per MOEF&CC guidelines.

The scope of work for the EIA covers the following details:

Assessment of environmental features of project and evaluation of pollution control measures.

Assessment of environmental features of the project.

Establishment of present status of land, air, noise, water, biological and socioeconomic and cultural components of the environment.

Identification and quantification of likely impacts due to implementation of plant on the environmental components during the construction, commissioning, operation and decommissioning phases.

Study of existing activities in the project area.

Evaluation of eco-friendly and pollution control measures.

Assimilation of collected and generated data during the course of EIA studies.

Delineation of an Environmental Management Plan (EMP) outlining measures to

be adopted by the project proponents for mitigation of adverse impacts.

1.6.1 Regulatory Scoping & Its Compliance

Compliance to various TOR items as per MOEF&CC letter dated 27th June 2019 for project activity 5(f) are given in tables below.

Table 1.3 Compliance to ToR Prescribed by EAC

Sr. No.

Particulars Compliance

A STANDARD TERMS OF REFERENCE 1. Executive Summary Executive summary is given in Chapter 11

of EIA report. 2. Introduction i Details of the EIA Consultant including

NABET accreditation Details of the EIA Consultant including NABET accreditation is given in Chapter 12 of EIA report.

ii Information about the project proponent Information about the project proponent is given in Section 1.2, Chapter 1 of EIA report.

iii Importance and benefits of the project Information about the project proponent is given in Section 1.3.3, Chapter 1 & Chapter 8 of EIA report.

3. Project Description i Cost of project and time of completion. Cost of proposed project is ~ Rs. 50 Crores.




Sr. No.


The proposed project will be completed in approx. 5 year from date of receipt of EC.

ii Products with capacities for the proposed project.

Products with capacities for the proposed project is given in Table 1.1, Chapter 1, Table 2.1, Chapter 2 and Table 11.1, Chapter 11 of EIA report.

iii If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Proposed project is expansion of existing manufacturing facility. No additional land required for proposed expansion project.

iv List of raw materials required and their source along with mode of transportation.

List of raw materials required and their source along with mode of transportation is given in Section 2.7, Chapter 2 of EIA report.

v Other chemicals and materials required with quantities and storage capacities

Chemicals and materials required quantities and storage capacities is given in Section 2.8, Chapter 2 of EIA report.

vi Details of Emission, effluents, hazardous waste generation and their management

Details of Emission, effluents, hazardous waste generation and their management is given in Section 2.10 to 2.15, Chapter 2 of EIA report.

vii Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement Section 2.10 to 2.15, Chapter 2 of EIA report.

viii Process description along with major equipment’s and machineries, process flow sheet (quantitative) from raw material to products to be provided

Process description along with major equipment’s, process flow sheet from raw material to products is given in Section 2.6, Chapter 2 of EIA report.

ix Hazard identification and details of proposed safety systems.

Hazard identification and details of proposed safety systems is given in Chapter 7 & it’s annexure of EIA report.

x Expansion/modernization proposals a Copy of all the Environmental Clearance(s)

including amendments there to obtain for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of

Copy of Existing EC letter is attached as Annexure 1.4. Certified copy of the Monitoring Report of the Regional Office of the Ministry of Environment and Forests and its pointwise Compliance reply is attached as Annexure 1.5 of EIA report.




Sr. No.


Consent to Operate for the ongoing existing operation of the project from SPCB shall be attached with the EIA-EMP report.

b In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to Establish/No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance Report to the conditions of consents from the SPCB shall be submitted.

Compliance Report to the conditions of consents is attached as Annexure 1.3 of EIA report.

4 Site Details i Location of the project site covering village,

Taluka/Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

Details of project location & site coordinates are given in Section 1.3.2, Chapter 1 of EIA report. Justification for selecting the site is given in Chapter 5 of EIA report.

ii A topo sheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

Open Series map of 10 km study area is attached as Annexure 3.1 of EIA report.

iii Details w.r.t. option analysis for selection of site

Analysis for site selection is given in Chapter 5 of EIA report.

iv Co-ordinates (lat-long) of all four corners of the site.

Details of site coordinates are given in Section 1.3.2, Chapter 1 of EIA report.

v Google map-Earth downloaded of the project site.

Google map-Earth downloaded images of the project site is given in figure 1.2 to 1.4, Chapter 1 of EIA report.

vi Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. is attached as Annexure 2.1 of EIA report.

vii Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.

Photographs of green belt is given in Section 3.9.3, Chapter 3 of EIA report.




Sr. No.


viii Land use break-up of total land of the project site (identified and acquired), government/ private - agricultural, forest, wasteland, water bodies, settlements, etc. shall be included. (not required for industrial area)

Land use break-up of total land of the project site, government/ private - agricultural, forest, wasteland, water bodies, settlements, etc. is given in Section 3.1, Chapter 3 of EIA report.

ix A list of major industries with name and type within study area (10 km radius) shall be incorporated. Land use details of the study area

List of major industries with name and type within study area is given in Section 2.3, Chapter 2 of EIA report.

x Geological features and Geo-hydrological status of the study area shall be included.

Geological features and Geo-hydrological status of the study area is given in Section 3.1.9, Chapter 3 of EIA report.

xi Details of Drainage of the project up to 5 km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river shall also be provided. (mega green field projects).

Drainage details of the project & 10 km study area is given in Section 3.1.6, Chapter 3 of EIA report.

xii Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.

Not applicable. Land is owned by Prasol & proposed project is within existing manufacturing facility.

xiii R&R details in respect of land in line with state Government policy.

Not applicable. Land is owned by Prasol.

5 Forest and wildlife related issues (if applicable)

i Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department. (if applicable)

Not applicable as land is owned by Prasol. No forest land is involved.

ii Land use map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha)

Not applicable. No forest land involved for proposed project.

iii Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

Not applicable. No forest clearance required for proposed project.

iv The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild

Not applicable.




Sr. No.


Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden-thereon

v Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State Government for conservation of Schedule I fauna, if any exists in the study area.

Wildlife Conservation plan for Schedule I species is prepared & submitted to Chief Wildlife Warden through Regional Division office. Copy of Wildlife Conservation plan submitted is attached as Annexure 3.4 (b).

vi Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife.

Not applicable. No NBWL clearance required for proposed project.

6 Environmental Status i Determination of atmospheric inversion

level at the project site and site-specific micrometeorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Details of meteorology data is given in Section 3.4, Chapter 3 of EIA report.

ii AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, NH3, CO, H2S and nMHC at 8 locations in summer 2019 (March to May).

iii Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAAQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

Raw data of all AAQ measurement for 12 weeks of all stations as per frequency are given in the NAAQM Notification of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters is attached as Annexure 3.3 of EIA report.

iv Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface drains at eight locations as per CPCB/ MoEF&CC guidelines.

Surface water sampling of nearby river is carried out during Summer 2019 & details are given in Section 3.7.3.2, Chapter 3 of EIA report.

v Whether the site falls near to polluted stretch of river identified by the CPCB/ MoEF&CC, if yes give details.

Not applicable. Site does not falls near to polluted stretch of river identified by the CPCB/ MoEF&CC.




Sr. No.


vi Ground water monitoring at minimum at 8 locations shall be included.

Ground water sampling at 8 locations carried out during Summer 2019 & details are given in Section 3.7.3.1, Chapter 3 of EIA report.

vii Noise levels monitoring at 8 locations within the study area.

Noise levels monitoring at 8 locations within the study area is carried out during Summer 2019 & details are given in Section 3.6, Chapter 3 of EIA report.

viii Soil Characteristic as per CPCB guidelines Soil Characteristic as per CPCB guidelines is carried out & details are given in Section 3.2, Chapter 3 of EIA report.

ix Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

Existing traffic details are given in Section 3.8, Chapter 3 of EIA report. Proposed additional traffic details are given in Section 4.4.9, Chapter 4 of EIA report.

x Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule- I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

Detailed description of flora and fauna within study area is given in Section 3.9, Chapter 3 of EIA report. Wildlife Conservation plan for Schedule I species is prepared & submitted to Chief Wildlife Warden through Regional Division office. Copy of Wildlife Conservation plan submitted is attached as Annexure 3.4 (b).

xi Socio-economic status of the study area. Socio-economic status of the study area is given in Section 3.10, Chapter 3 of EIA report.

7 Impact and Environment Management Plan

i Assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modeling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used, and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the

Detailed Air modeling study carried out & given in Section 4.4.6.2, Chapter 4 of EIA report. AAQ modelling for transportation activity was carried out & given in Section 4.4.6.9, Chapter 4 of EIA report. Results shows negligible impacts on surrounding area.




Sr. No.


location of project site, habitation nearby, sensitive receptors, if any.

ii Water Quality modeling - in case of discharge in water body

Not applicable. No effluent discharges to water body. Unit is Zero Liquid discharge facility.

iii Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyor cum- rail transport shall be examined.

Options for transport of raw materials and finished products and wastes by rail or rail-cum road transport or conveyor cum- rail transport examined and concluded that the option is not feasible.

iv A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E(P) Rules.

Detailed ETP scheme is given in Section 4.4.5.2, Chapter 4 of EIA report. Unit is Zero Liquid discharge facility & same will be followed for proposed project.

v Details of stack emission and action plan for control of emissions to meet standards.

Details of stack emission and action plan for control of emissions is given in Section 4.4.6.1, Chapter 4 of EIA report.

vi Measures for fugitive emission control Details of fugitive emission control is given in Section 4.4.6.11, Chapter 4 of EIA report.

vii Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

Details of Non- Hazardous & Hazardous waste generation & disposal is given in Section 2.15.1.1, Chapter 2 & Section 4.4.10, Chapter 4 of EIA report.

viii Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Fly ash will be sale to authorized vendor or brick manufacturer.

ix Action plan for the green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads

Green belt area of 23,004 sq. m (33.5% of plot area) will be developed in post expansion. Budgetary provision of Rs. 20 Lakhs is provided for green belt development. Detailed Green belt development plan is given in Section 4.4.7.2, Chapter 4 of EIA report.




Sr. No.


used for the project shall also be incorporated.

x Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.

Budget of Rs. 10 Lakhs is provided for Rainwater harvesting.

xi Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Total capital cost of Rs. 865 Lakhs and recurring cost of Rs. 337 Lakhs per annum is provided for environmental pollution control measures.

xii Action plan for post-project environmental monitoring shall be submitted.

Action plan for post- project environmental monitoring is given in Section 6.2, Chapter 6 of EIA report.

xiii Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Onsite emergency plan of site is given in Annexure 7.3 of EIA report.

8 Occupational health i Plan and fund allocation to ensure the

occupational health & safety of all contract and casual workers

Capital cost of Rs. 70 Lakhs is allotted for Occupational health & safety. Details given in Table 6.3, Chapter 6 of EIA report.

ii Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by predesigned format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, color vision and any other ocular defect) ECG, during pre-placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above-mentioned parameters as per age, sex, duration of exposure and department wise.

Details of medical examination is given in Section 10.9.2, Chapter 10 of EIA report. Details regarding Health data of worker is given in Annexure 7.6.

iii Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL) If these are not within PEL, what measures the company has adopted to keep them within

Details regarding Health data of worker is given in Annexure 7.6.




Sr. No.


PEL so that health of the workers can be preserved.

iv Annual report of health status of workers with special reference to Occupational Health and Safety

Details regarding Health data of worker is given in Annexure 7.6.

9 Corporate Environment Policy i Does the company have a well laid down

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

Details of Environment policy is given in Section 10.1.2, Chapter 10 of EIA report.

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

Details of Environment management Cell & SOP is given in Section 10.1.3, Chapter 10 of EIA report.

iii What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Yes. Details of hierarchical system is given in Section 10.1.3, Chapter 10 of EIA report.

iv Does the company have system of reporting of non-compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report

Yes. Details given in Section 10.1.3, Chapter 10 of EIA report.

10 Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labor force during construction as well as to the casual workers including truck drivers during operation phase.

Sanitation, fuel, Restroom etc. will be provided to the labors during construction as well as casual workers including truck drivers during operation phase.

11 Enterprise Social Commitment (ESC) Adequate funds (at least 2.5 % of the

project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Prasol is allocating budget of Rs. 50 Lakhs (1% of estimated capital investment) for 5 years for CER. Detailed CER plan is given in Section 4.4.12.3, Chapter 4 of EIA report.

12 Any litigation pending against the project and/or any direction/order passed by any

No. Not applicable




Sr. No.


Court of Law against the project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13 A tabular chart with index for points wise compliance of above TOR.

Tabular chart for points wise compliance of above TOR is given in Section 1.6.1, Chapter 1 of EIA report.

B SPECIFIC TERMS OF REFERENCE FOR EIA STUDIES FOR SYNTHETIC ORGANIC CHEMICALS INDUSTRY

1 Details on solvents to be used, measures for solvent recovery and for emissions control.

Details on solvents to be used, measures for solvent recovery and emissions control is given in Section 2.12, Chapter 2 of EIA report.

2 Details of process emissions from the proposed unit and its arrangement to control.

Details of process emission control is given in Section 4.4.6.11, Chapter 4 of EIA report.

3 Ambient air quality data should include VOC, other process- specific pollutants* like NH3*, chlorine*, HCl*, HBr*, H2S*, HF*, CS2 etc., (*-as applicable)

The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, NH3, CO, H2S and nMHC at 8 locations in summer 2019 (March to May).

4 Work zone monitoring arrangements for hazardous chemicals.

Work zone monitoring details is given in Section 6.2, Chapter 6 of EIA report.

5 Detailed effluent treatment scheme including segregation for units adopting 'Zero' liquid discharge.

Detailed ETP scheme is given in Section 4.4.5.2, Chapter 4 of EIA report. Proposed project will be Zero Liquid discharge facility.

6 Action plan for odor control to be submitted.

Action plan for Odor control is given in Section 4.4.6.12, Chapter 4 of EIA report.

7 A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated.

MoU with brick manufacturer for fly ash disposal is available.

8 Authorization/ Membership for the disposal of liquid effluent in CETP and solid/ hazardous waste in TSDF, if any.

CETP membership is not applicable as proposed project is ZLD facility. Refer Annexure 3.2 for CHWTSDF membership.

9 Action plan for utilization of MEE/ dryers salts.

MEE salts will be disposed off to CHWTSDF.

10 Material Safety Data Sheet for all the Chemicals are being used/ will be used.

Material Safety Data Sheet for all the Chemicals are given in Annexure 7.4 of EIA report.




Sr. No.


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

Refer Annexure 3.2 for CHWTSDF membership.

12 Details of incinerator if to be installed. Not applicable. No incinerator will be installed for proposed project.

13 Risk assessment for storage and handling of hazardous chemicals/ solvents. Action plan for handling & safety system to be incorporated.

Risk assessment for storage and handling of hazardous chemicals/ solvents is given in Section 7.3, Chapter 7 of EIA report.

14 Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

Capital cost of Rs. 70 Lakhs is allotted for Occupational health & safety. Details of medical examination is given in Section 10.9.2, Chapter 10 of EIA report.

General 15 Under the provisions of the EIA

Notification 2006 as amended, the Standard TOR for the purpose of preparing environment impact assessment report and environment management plan for obtaining prior environment clearance is prescribed with public consultation.

Public Hearing for proposed project is carried out on 13th October 2020. The details regarding public hearing is given in Annexure 7.7 of EIA report. Reply to points raised during public hearing is given in Section 7.11, Chapter 7 of EIA report.


Chapter 2- Project Description


2 PROJECT DESCRIPTION

2.1 Type of Project

The proposed project is expansion of existing manufacturing facility. As per EIA Notification dated 14th September 2006, expansion/ establishment in production capacity of synthetic organic chemicals manufacturing Industry falls under activity 5(f) – Category A and needs prior environmental clearance from EAC- Industry II.

The production quantities of the existing products/ by-products and additional at the site will be as below,



Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year) Products


8 Phenol 20,000 0 20,000



1,800 13,200 15,000



0 500 500






Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year)


0 1,500 1,500


0 750 750







- - -




0 2000 2,000



59,454 93,546 153,000

* As per existing consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.07.2020 valid till 31.10.2021. @ Letter from Turbine Supplier is enclosed as Annexure 1.1(a).

2.2 Need of the Project

All the products proposed for manufacture are imported to India on a regular basis. The quantum of imports varies from product to product, but the manufactured goods will be import substitutes. Amongst the products, hydrogenated products, Phosphorus Penta sulphide and ZDDP are already being manufactured at the company’s current facility near Khopoli, Dist: Raigad, Maharashtra. The additional products are forward integration of the company’s current products and have a great demand both global and domestic. The demand is envisaged to increase rapidly in the domestic market.

2.3 Location of the Project

The expansion will be carried out at plot situated at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra.




Following is list of industries around project site. Table 2.2 List of industries around project site

No Name Type of industry 1 Color roof India Limited Engineering 2 AAK Kamani Private Limited Vegetable Oils 3 Ram Ratan Engineering 4 Sanghvi Furniture Furnitures 5 Tribolube Lubricants 6 Frigmaires Engineers Engineering 7 Cradle Runways (I) Pvt. Ltd Engineering 8 Techno forging Engineering 9 Pushpaman forging Engineering

2.4 Size/ Magnitude of Operation

Estimated project cost of expansion is Rs. 50 Crores. Total plot area is 68,644 m2. The land

area utilization shall be as follows:

Table 2.3 Land break up

Area statement Sr. No. Village Survey no. Area in sq. m

1

Chinchvali Gohe

25/5 A 4000 2 25/5 B 3990 3 25/5 D 280 4 25/5 E 570 5 25/5K 100 6 25/6 B 4300 7 25/7 K 1648.5 8 25/10/E 1650.25 9 25/11/G 1739

10 25/12/F 1739 11 25/13/J 1829.5 12 8/1 B 2600 13 8/2 3280 14

Honad

13/1/A 200 15 13/1/B 8000 16 13/5/A 2000 17 13/5/K 2070 18 15/1 100 19 15/2 620 20 15/3 9790 21 15/4 4150 22 15/5 280 23 16/1 2700 24 16/2 100 25 16/3 1000 26 Thanenhave 75/7 3800

Sub total 62536.25 Road Area 6107.75 Total Area 68644




Green belt area break up: Description Existing Proposed@ Total

Area of Green Belt 13374 sq.m 9630 sq.m 23004 sq.m

% of Total Project Area 19.5% 14% 33.5%

No. of Plants* 1845 nos. 1605 nos. 3450 nos. * As per Standard TOR condition 7(ix)- Green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha

@ Additional plot sy. No. 74/3 of Thanenhave will be dedicated for green belt development. Copy of agreement is enclosed as Annexure 2.1(c).

Detailed plant layout showing plants, utilities, storage and other details are as given in figure below (Refer Annexure 2.1 for details)

Refer Annexure 2.1(a) for Copies of 7/12 extract.

Honad Industrial zone is an approved Industrial zone by Urban Development Department, Government of Maharashtra and Notification under Section 17 of the the Maharashtra Regional and Town Planning Act 1966 was published vide TPS 1490/CR 365/90/UD-12 dt 4th July 1992 as identified by the Raigad Regional Board. Copy of Urban Development notification for Raigad Regional plan is enclosed as Annexure 2.1(b).




Figure 2.1 Plant layout




2.5 Schedule for Approval & Implementation

It is expected that the expansion project shall be completed within ~5 years from date of

grant of Environmental clearance.

2.6 Products - Technology & Process Description

All the products will be manufactured on campaign basis.

2.6.1 Phenol and Acetone

There is no proposal to increase capacity of Phenol plant.

2.6.1.1 Process Chemistry – Phenol and Acetone

2.6.1.2 Plant Process description – Phenol and Acetone

Cumene is used on a large scale for the manufacture of Phenol and Acetone. The process involves high efficiency oxidation of cumene with air to produce Cumene Hydroperoxide (CHP). CHP is then concentrated and cleaved in presence of an acid catalyst to produce Phenol and Acetone. The cleavage mixture is then fractionated to produce high purity Phenol and Acetone. Overall Reaction: C6H5CH(CH3)2 + O2 C6H5OH + (CH3)2CO Cumene Oxygen Phenol Acetone

1

2

3

4

5

6

7

8

Phenol – Acetone (Overall reaction):

+ O2 + (CH3)2CO Cumene Oxygen Phenol Acetone Reaction 1:

+ O2 (80–110

oC)

Cumene Oxygen Cumene Hydroperoxide (CHP) Reaction 2:

H2SO4 catalyst + (CH3)2CO (80–85

oC)

CHP Phenol Acetone

120 15232

152 94 58

94 58120 32




A typical Phenol manufacturing plant based on this technology consists of five basic steps as given below.

1. Oxidation 2. Concentration 3. Cleavage 4. Distillation 5. Recovery

Raw Materials required Cumene Air Process Chemicals Required Sulfuric acid Caustic lye Carbonate Process Description: 1. Oxidation Cumene at around 30 oC is preheated to and sparged into to 1st oxidizer where it reacts with oxygen from the air (23% w/w) to form 10-12 % of Cumene Hydroperoxide (CHP). The outlet stream from the first oxidizer is then fed to a second oxidizer placed in series, where further oxidation produces 22-25% CHP. This reaction is exothermic and hence once initiated can sustain itself without providing additional energy to raise temperature. The yield of oxidation reaction is primarily based on temperature. The reaction operates at moderate temperature and pressure. C6H5CH(CH3)2 + O2 C6H5(CH3)2COOH Cumene Oxygen Cumene Hydroperoxide (CHP) Undesirable productrss like Acetophenone (ACP) and Phenyl Dimethyl Carbinol (PDMC) are formed along with CHP. Carbonate is added to the oxidizers to remove any traces of organic acids which can act as retardants to oxidation reaction. 2. Concentration The reaction mass from the oxidation section is pumped to the concentrator pre-flasher operating at high vacuum, where the stream is enriched in CHP. This is then sent to the concentrator also operating at high vacuum, for further removal of cumene and increase in the CHP concentration. The top stream from the pre-flasher and concentrator consists mainly of unreacted cumene which is recycled back to the feed tank. The bottom stream from concentrator containing up to 85% CHP, 4-5% PDMC, 1-2% ACP & 8-10% Cumene is then sent to the reaction section where CHP is then cleaved to form Phenol and Acetone. 3. Cleavage




This cleavage reaction takes place in 2 steps. More than 98%of the cleavage takes place in the 1st stage Cleavage reactor in presence of an acid catalyst like Sulfuric acid at a predetermined temperature and pressure. The reaction is exothermic in nature and hence the temperature needs to be carefully regulated. This is done by addition of external reflux acetone. C6H5(CH3)2COOH C6H5OH + (CH3)2CO CHP Phenol Acetone In the 2nd stage, the cleavage mass reacts further to decompose the remaining CHP. The by-products formed during the cleavage are Alpha-Methyl Styrene (AMS), Bis-Phenol A, OCP/PCP and other heavy boilers. The cleavage product is then cooled before it is sent for neutralization. The cleavage mass being acidic in nature is neutralized with 10% caustic lye at 40oC in a neutralizer drum. This stream is then sent to the distillation section to separate Phenol and Acetone from the mixture. 4. Distillation The distillation system consists of 2 main sections, namely the Acetone distillation section and the Phenol distillation section. Acetone Distillation: The first column is called the Crude Acetone Column. In this column the cleavage mass is separated into two main streams. The one collected at the top, the crude acetone stream, contains acetone, water, cumene and AMS. The other stream, the crude phenol stream, collected at the bottom contains Phenol, ACP, OCP/PCP, Bisphenol-A and other heavy boilers The top stream is fed to the second column called the Acetone Topping Column. In this column, acetone with some water/moisture content is fractionated and collected at the top. Some quantity of this acetone is sent to the 1st stage cleavage reactor as external reflux. The bottom stream contains a mixture of acetone, water, cumene and AMS. The top stream of the ATC is then fed to a third column called the Pure Acetone Column where the remaining acetone is distilled and removed from the top. Phenol Distillation: The bottom stream of the Crude Acetone Column containing the heavier components is fed to a fourth column called the Crude Phenol Column where the mixture is distilled and Phenol with a few impurities is collected at the top. The bottoms of the fourth column containing the heavier components, referred to as tar is sent for cracking. The top product containing mainly phenol and some fractions of ACP and other organics is then fed to a hydro-extraction column where phenol from the top stream is recycled




with addition of water to remove impurities such as traces of ACP, acetone etc. as water forms an azeotropic mixture with phenol and thus can be easily separated. The bottoms of this column are then fed to a sixth column called the pure phenol column. In this column phenol is further purified and is free from any impurities. The top product is recycled, and pure Phenol is drawn from the side. The bottoms are fed back to the crude phenol column.

2.6.1.3 Process block diagram and Material balance – Phenol and Acetone

0.30 157.47

140.00 188.50

694.10

RECYCLE CUMENE optional draw

513.82

180.29 optional draw

5

0.42

184.13 1.58

100.00

60.00 60.00 109.13 100.00

15.00 9.13

8.96

6.04 2.88

6.042 2.88

6.25

ALL NUMBERS IN KGS EXCEPT MENTIONED OTHERWISE

ALKYL PHENOL^

OLEFIN

WATER

TO ETP

CHP PRODUCT

PDMC PRODUCT

AMS PRODUCT ACP PRODUCT

PHENOL PRODUCT

TAR

VENT AIR (INERT)CARBONATE

ALKYL PHENOL

PROCESSING#

CUMENE AIR

AMS RECOVERY ACP RECOVERY

CATALYST

OXIDATION

CHP

CONCENTRATION

CLEAVAGE

ACETONE

DISTILLATION

PHENOL

DISTILLATION

ACETONE PRODUCT

S. No.

Input /Day

of Product

(MT)

1 61.6

2 82.94

3 0.132

4 0.154

5 2.2

147.03

Material / ItemProduct /

Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Phenol 1 - - - 44 Product

2 Acetone 0.6 - - - 26.4 By-Product

3 AMS 0.06 - - - 2.64

4 ACP 0.0289 - - - 1.26984

5 TAR - - - - 2.690 To CHWTSDF

6 Water - 0.057 - - 2.508

7 Vent Gas (Inert Gas) - - 1.5318 - 67.3992

8 Handling Loss / Unaccounted - 0.0028 0 - 0.1232

1.6889 0.0598 1.5318 0.0000

Raw Materials Input/MT of Product (MT)

Cumene 1.4

Air 1.885

Total 0.0611

147.03

RemarksHW

-

-

0.0611

S. No.

Output/MT of ProductOutput/ Day of

Product (MT)

-

-

-

-

-

Carbonate 0.003

Catalyst 0.0035

Water 0.05

Total 3.3415




2.6.2 Diacetone Alcohol

It is proposed to expand capacity of Diacetone alcohol from 9000 TPA to 32000 TPA (increase by 23000 TPA).

2.6.2.1 Process Chemistry – Diacetone alcohol

2.6.2.2 Plant Process description – Diacetone alcohol

Diacetone Alcohol is produced by the Aldol Condensation of Acetone. The reaction is conducted in the reactive distillation mode. Acetone is passed over anionic catalyst to form diacetone alcohol after reaction. The reaction mass containing acetone and Diacetone alcohol is subjected to distillative separation to a) recover and recycle the unreacted acetone and b) recover diacetone alcohol in desired purities. The product will be stored in storage vessel prior to drumming.

2.6.2.3 Process Block diagram and Material balance – Diacetone alcohol

Diacetone Alcohol

(CH3)2CO Alcoholic Caustic Catalyst Acetone Diacetone Alcohol

106.00 0.26

742.18

848.44

0.26 848.18

334.13

514.05

385.54

128.51


3.01

125.50

22.00 25.01

3.50 100.00

2.50

100.00

RECYCLE ACETONE

CATALYST REMOVAL

DAA PRODUCT

OFF-SPEC ACETONE(KG) RECOVERY

ORGANICS

DISTILLATION 3

CAUSTIC + CATALYST R (KG)FEED ACETONE (kg)

REACTION

NEUTRALIZATION

FLASHER

DISTILLATION 1

DISTILLATION 2




2.6.3 Phosphorus Pentasulphide

It is proposed to expand capacity of Phosphorus Pentasulphide from 6000 TPA to 10000 TPA (increase by 4000 TPA).

2.6.3.1 Process Chemistry – Phosphorus Pentasulphide

Reaction involved and process flow diagram is shown below:

4P4 + 5S8 4P4S10

Phosphorus Sulphur Phosphorus Pentasulphide (PPS)

2.6.3.2 Process block diagram – Phosphorus Pentasulphide

S. No.

Input /Day

of Product

(MT)

1 41.64

2 0.08

41.72


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Diacetone Alcohol 1 - - - 40 Product

2 LEs 0.017 - - - 0.68 By-Product

3 HBs - - - - 1 To CHWTSDF

4 Spent Catalyst - - - - - To CHWTSDF

5 Handing Loss / Unaccounted - - 0.00104 - 0.0416

1.017 0 0.00104 0

S. No.

Output/MT of ProductOutput/

Day of

Product

(MT)

Raw MaterialsInput/MT of

Product (MT)

Acetone 1.041

1.0430

0.002Catalyst

-

-

Total 0.025

41.72

RemarksHW

-

-

0.025

Total 1.043




2.6.3.3 Plant Process description – Phosphorus Pentasulphide

In PPS plant, the manufacturing is done in 5 steps:

Feed Preparation;

Reaction;

Distillation;

Flaking;

Grinding & Packaging.

Step 1: Feed Preparation The solid Sulphur is sent to the melting tank for melting. After melting, the Sulphur is sent to the Sulphur Feed Tank for reaction. The Phosphorus is molten and stored under water in the Phosphorus Feed Tank. Step 2: Reaction From feed tanks the liquid Sulphur and phosphorus are fed to the reactor which is operated under Nitrogen blanket. In the reactor a simple addition reaction takes place at high temperatures to form Phosphorus Pentasulphide (PPS) product and then it is drained to the intermediate tank maintained at the desired temperature to be fed to the distillation furnace. The vapors formed (if any, during abnormal conditions) in the reactor and the intermediate tanks are sent to the H2S scrubber attached to the ZDDP plant / DATC Plant. Step 3: Distillation The reaction mass is heated, and the vapors are collected in the distillation pot. The vapors are cooled in the pot and liquid PPS of 99.5% purity is obtained. Periodic maintenance shall be done, during which sludge will be removed. Step 4: Flaking The distillate mass is sent to the flaker. In flaker the distillate mass is solidified over a drum cooled with chilled water to form a thin solid layer which is scraped by a blade arrangement and collected in the form of flakes. Step 5: Grinding & Packaging These flakes are then conveyed through a pin mill arrangement to obtain the product in the required size of granules or powder. This product is then stored in Silos and packed in drums or Tote bins as per the requirement.

2.6.3.4 Material balance – Phosphorus Pentasulphide




2.6.4 Phosphorus Acid food grade

There is no proposal to increase capacity of Phosphorus acid (food grade).

2.6.4.1 Process Chemistry – Phosphorus Acid food grade

2.6.4.2 Process block diagram – Phosphorus Acid food grade

It is mixing operation of polyphosphoric acid with water.

2.6.4.3 Plant Process description – Phosphorus Acid food grade

Phosphoric Acid is prepared by addition of water (dilution) of Polyphosphoric Acid in an Agitated Reactor. On further or excess Dilution, we get a dilute phosphorous Acid product.

2.6.4.4 Material balance – Phosphorus Acid food grade

2.6.5 Dilute Phosphoric acid

It is proposed to expand capacity of Dilute Phosphoric acid from 624 TPA to 650 TPA (increase by 26 TPA).

28.00 73.00

101.00

100.13

0.875

100.13

0.125

100.00

100.00


GRINDING

PPS PRODUCT

RESIDUE

HANDLING LOSSES

Phosphorous SulphurREACTION

FURNACE

FLAKING

85.00 15.00

100.00

100.00

Polyphosphoric AcidMIXING

Water

PHOSPHORIC ACID

PRODUCT




2.6.5.1 Process Chemistry – Dilute Phosphoric acid

It is dilution of phosphoric acid as per strength required by customer.

2.6.5.2 Plant Process description – Dilute Phosphoric acid

The concentration of acid can be varied to suit the customer requirement by changing quantity of water to be added.

2.6.5.3 Process block diagram and Material balance – Dilute Phosphoric acid

2.6.6 Isophorone

It is proposed to expand capacity of Isophorone from 3600 TPA to 12000 TPA (increase by 8400 TPA).

2.6.7 Process Chemistry – Isophorone

2.6.7.1 Plant Process description – Isophorone

Isophorone is produced by Aldol Condensation of Acetone. Acetone with a catalyst mixture is fed in a continuous manner to a reactive distillation column system. The condensation reaction takes place in these reactors forming a mixture of Isophorone, Acetone, water and other organics. The Acetone is recovered and recycled back in the reaction section itself and is further sent for neutralization. The reaction mass, after neutralization, is washed & and then subjected to separation by distillation process to extract Isophorone in desired purities.

Caustic from distillation is recovered as Caustic lye.

85.00 15.00

100.00

100.00

DIL. PHOSPHORIC

ACID PRODUCT

Phosphoric AcidMIXING

Water

Isophorone

3 (CH3)2CO + 2H2O Caustic Catalyst Acetone Isophorone Water




2.6.7.2 Process block diagram and Material balance – Isophorone

2.6.8 Phosphorus Pentoxide

There is no proposal to increase capacity of Phosphorus Pentoxide.

2.6.8.1 Process Chemistry – Phosphorus Pentoxide

P + O2 à P2O5

2.6.8.2 Plant Process description – Phosphorus Pentoxide

Phosphorus is oxidized in furnace and formed product phosphorus pentoxide is pulverized.

0.069

155.88

110

70.16 323.44

195.726 85.726

127.7182

0.069

11.61075

116.1075

100

17.72

1.61252

85.726 16.10748 16.10748


ACETONE +

WATERREACTION

WASHING

RECOVERY

DISTILLATION 2

WATER FOR RECYCLE

DISTILLATION 1

IPH PRODUCT

HEAVIES

CAUSTIC RECOVERY

AQ. DISTILLATION

CAUSTIC

WATER TO ETP

S. No.

Input /Day

of Product

(MT)

1 18.708

2 0.828

3 8.424

27.960

Material / Item

Product /

Byprodu

ct

Liquid

Effluent

Air

EmissionRecovery

1 Isophorone 1 - - - 12 Product

2 HBs - - - - 2.339 To CHWTSDF

3 Spent Catalyst - - - 0.069 0.828 To CHWTSDF

4 Water - 1.063 - - 12.756

5 Handling Loss / Unaccounted - 0.00312 - - 0.03744

1 1.06612 0 0.069


Product (MT)

Acetone 1.559

Catalyst 0.069

Water 0.702

Total 2.33

S. No.


Day of

Product

(MT)

Total 0.1949

27.960

-

RemarksHW

-

0.1949

-

-




2.6.8.3 Process block diagram and Material balance – Phosphorus Pentoxide

2.6.9 Zinc Diorgano Dithiophosphate (ZDDP)

It is proposed to expand capacity of ZDDP from 1500 TPA to 3500 TPA (increase by 2000 TPA).

2.6.9.1 Process Chemistry – Zinc Diorgano Dithiophosphate (ZDDP)

47.00 77.00

124.00

123.50 0.500

23.5

100.00


100.00

PhosphorousREACTION

Air

FURNACERESIDUE

PULVERISINGHANDLING LOSSES

PPO PRODUCT

S. No.

Input /Day

of Product

(MT)

1 0.785

2 1.286

2.071

Material / Item

Product /

Byprodu

ct

Liquid

Effluent

Air

EmissionRecovery

1 Phosphorus Pentoxide 1 - - - 1.67 Product

2 Residue - - - - 0.00835 To CHWTSDF

3 Handling Loss / Excess Air - 0.235 - - 0.3925

1 0.235 0 0


Product (MT)

-

Phosphorus 0.47

Air 0.77

Total 1.24

S. No.


Day of

Product

(MT)

RemarksHW

0.005

-

Total 0.005

2.071

S

1) 4R – OH + P2S5 2 (RO)2 – P = SH + H2S Oxo-Alcohol Phosphorous Reaction Hydrogen

Pentasulphide Intermediate Sulphide

S S S

2) 2 (RO)2 – P = SH + ZnO (RO)2 – P = S – Zn -S= P–(OR)2 + H2O

Reaction Zinc ZDDP Water

Intermediate Oxide

Scrubbing of Hydrogen Sulfide

H2S + NaOH NaHS + H2O

Hydrogen Sulfide Sodium Hydroxide Sodium Hydrosulfide Water




2.6.9.2 Process block diagram – Zinc Diorgano Dithiophosphate (ZDDP)

2.6.9.3 Plant Process description – Zinc Diorgano Dithiophosphate (ZDDP)

ZDDP is manufactured in two major steps. Step 1: Synthesis Step: The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-Alkyl Dithiophosphate Acid with release of Hydrogen Sulphide gas. In this step, the oxo-alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is added to this mass with continuous stirring which results in the evolving of gases which are to be absorbed in the 2-stage caustic scrubber. Hydrogen sulphide gas which is absorbed in caustic solution in a packed bed scrubber system to form sodium hydrogen sulphide as by-product. Step 2: Neutralization Step: The neutralization of the acid is carried out with zinc oxide. Once neutralization is complete, the product mass is dried. Filter aid is added, and the batch is filtered to obtain the product of desired quality. The residue is then removed from the filter in the form of solid cakes. The ZDDP product is then stored, packed and dispatched as required.

2.6.9.4 Material balance – Zinc Diorgano Dithiophosphate (ZDDP)

S. No.


Input /Day of Product

(MT) 1 Phosphorus Pentasulphide 0.275 4.125

2 Alcohols 0.470 7.050

3 Zinc Oxide 0.140 2.100

4 Base Oil 0.150 2.250

5 Caustic 0.072 1.078

6 Water for Scrubbing 0.150 2.252

Total 1.257 18.855




S. No.

Output/MT of Product Output/Day of

Product MT

Remarks Material / Item

Product / Co

product

Liquid Effluen

t

Air Emissio

n

Recovery

HW

1 ZDDP 1 - - - - 15.000 Product

2 NaHS (30%)

0.250 - - - - 3.750 Product

3 H2S - - 0.001 - - 0.013 To

Scrubber

4 Filter

Residue

- - - - 0.006 0.090 To

CHWTSDF

Total 1.250 0.000 0.001

0.000

0.006 18.855

1.257

Specification Sodium Hydrogen Sulphide (NaHS) Appearance Yellow to green translucent liquid

Purity 30% pH 11 to 13

Specific Gravity 1.20 to 1.25

2.6.10 Mesityl Oxide

It is proposed to expand capacity of mesityl oxide from 750 TPA to 3000 TPA (increase by 2250 TPA).

2.6.10.1 Process Chemistry – Mesityl Oxide

Mesityl Oxide

(CH3)2C(OH)(C0)CH3 CH3(CO)CH=C(CH3)2 + H2O Catalyst

Diacetone Alcohol Mesityl Oxide Water

2.6.10.2 Plant Process description – Mesityl Oxide

Mesityl Oxide is manufactured by the dehydration of Di Acetone Alcohol (DAA) in presence of an acid catalyst followed by distillation to obtain the pure product. The raw material DAA is charged into an agitated reactor and the acid catalyst is added. The reaction is maintained at a constant temperature by use of steam for heating. The vapors are then passed through a distillation column to collect Crude MO at the top. The bottoms containing acetone & Di-acetone Alcohol (DAA) are recycled back into the reactor. The top product which is collected in a decanter is the fed to a distillation column where a Pure MO product is extracted from a mixture of MO, water and other lighter hydrocarbons. The pure MO is then stored in a product tank or packed as per requirements.




2.6.10.3 Process block diagram and Material balance – Mesityl Oxide

2.6.11 Hexylene Glycol.

It is proposed to expand combined capacity of Hexylene Glycol, Trimethyl Cyclohexanol, Trimethyl Cyclohexanone from 1800 TPA to 15000 TPA (increase by 13200 TPA).

2.6.11.1 Process Chemistry – Hexylene Glycol

160.25 161.25 1.00

166.88

52.50 210.00 65.625

75.00

35 100.00 26.25

100


MO PRODUCT

DAA ACID

OFF SPEC H2O

TO ETP

REACTION

WASHING

DISTILLATION

S. No.

Input /Day

of Product

(MT)

1 4.455

2 0.033

3 0.86625

5.3543

Material / Item

Product /

Byprodu

ct

Liquid

Effluent

Air

EmissionRecovery

1 Mesityl Oxide 1 - - - 3.3 Product

2 LEs 0.12 - - - 0.396 By-Product

3 HBs - - - - - To CHWTSDF


5 Water - 0.49575 - - 1.63598


1.12 0.5025 0 0

1.6225

S. No.


Day of

Product

(MT)


Product (MT)

DAA 1.35

Water 0.2625

-

Catalyst 0.01

-

-

Total 0

5.3543

RemarksHW

-

-

-

Total

116 2 118

Hexylene Glycol

CH2COCH2C(CH3)2OH + H2 Ni Catalyst DAA Hexylene Glycol (HG)




2.6.11.2 Process block diagram - Hexylene Glycol

2.6.11.3 Plant Process description - Hexylene Glycol

It is hydrogenation of Di acetone alcohol followed by filtration and distillation. Initially the raw material is pumped from the feed tank into the loop reactor which operates at a preset temperature and pressure. The catalyst is fed into the reactor before the batch is initiated. The hydrogen gas in then introduced into the Loop reactor where the hydrogenation reaction takes place. The contents of the loop reactor are thoroughly mixed using a pump circulation system. After the reaction is completed, the reaction mass is emptied into a storage tank and a new batch is charged into the loop reactor. The reaction mass from the tank is then passed through a filter system where the catalyst entrained in the product is removed / recycled. For some of the products a purification system based on distillation and special filtration is used. The product is then pumped into a tank from where the purified product can be packed and shipped. Similar is process description for all other hydrogenation products.

2.6.11.4 Material balance - Hexylene Glycol

0.299 m3

23 m3

103.00

106.03 1.00

1.00

105.03

1.03 100 4

100


VENT GAS

Hydrogenation Plant

REACTION

FILTRATION

DISTILLATION

HEXYLENE GLYCOL

DAA HYDROGEN GAS

CATALYST

CATALYST RECYCLE

OFF SPEC PRODUCTHBs (HW)




2.6.12 Trimethyl Cyclohexanol


2.6.12.1 Process Chemistry – Trimethyl Cyclohexanol

2.6.12.2 Process block diagram - Trimethyl Cyclohexanol

S. No.

Input /Day

of Product

(MT)

1 17.51

2 0.0017

3 0.3502

17.862


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Hexylene Glycol 1 - - - 17 Product

2 LEs 0.0342 - - - 0.5814 By-Product

3 HBs - - - - 0.1751 To CHWTSDF

4 Spent Catalyst - 0.0017 To CHWTSDF

5 Vent Gas 0.003 0.0510

6 Handling Loss / Unaccounted 0.0031 - 0.0527

1.0342 0.0031 0.003 0


Product (MT)

DAA 1.03

Catalyst 0.0001

Total 1.0507

S. No.


Day of

Product

(MT)

0.0001

Total 0.0104

17.862

RemarksHW

-

-

0.0103

Hydrogen 0.0206

138 2 x 2 142

3,3,5 - Trimethyl Cyclohexanol Catalyst

C9H14O + 2 H2 C9H18O IPH Trimethyl Cyclohexanol (TMCHnol)

0.4875 m3

37.5 m3

102.07

107.87 2.50

2.50

105.37

1.07 100 4.3

100


DISTILLATIONOFF SPEC PRODUCT

3,3,5 - TRIMETHYL

CYCLOHEXANOL

Hydrogenation Plant

VENT GAS

IPHREACTION

HYDROGEN GAS

CATALYST

FILTRATIONCATALYST RECYCLE

HBs (HW)




2.6.12.3 Plant Process description - Trimethyl Cyclohexanol

It is hydrogenation of Isophorone followed by filtration and distillation.

2.6.12.4 Material balance - Trimethyl Cyclohexanol

2.6.13 Trimethyl Cyclohexanone


2.6.13.1 Process Chemistry – Trimethyl Cyclohexanone

S. No.

Input /Day

of Product

(MT)

1 17.3502

2 0.00425

3 0.56865

17.9231


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 3,3,5 Trimethylcyclohexanol 1 - - - 17 Product

2 LEs 0.04 - - - 0.68 By-Product

3 HBs - - - - 0.1802 To CHWTSDF


5 Vent Gas 0.0004 0.0060

6 Handling Loss / Unaccounted 0.0031 0.0527

1.04 0.0031 0.0004 0

Raw MaterialsInput/MT of Product

(MT)

IPH 1.0206

Catalyst 0.00025

0.03345

Total 1.0543

S. No.


Product (MT)

0.00025

Total 0.01085

17.9231

RemarksHW

-

-

0.0106

Hydrogen

138 2 140

3,3,5 - Trimethyl Cyclohexanone Catalyst

C9H14O + H2 C9H16O IPH Trimethyl Cyclohexanone (TMCHnone)




2.6.13.2 Process block diagram - Trimethyl Cyclohexanone

2.6.13.3 Plant Process description - Trimethyl Cyclohexanone

It is hydrogenation of Isophorone followed by filtration and distillation.

2.6.13.4 Material balance - Trimethyl Cyclohexanone

2.6.14 Methyl Isobutyl Ketone (MIBK) and Disobutyl ketone (DIBK)

It is proposed to install MIBK capacity of 5000 TPA and DIBK capacity of 1500 TPA.

0.2535 m3

19.5 m3

103.03

107.75 3.00

3.00

104.75

0.75 100 4

100


DISTILLATIONOFF SPEC PRODUCT

3,3,5 - TRIMETHYL

CYCLOHEXANONE

Hydrogenation Plant

IPHREACTION

HYDROGEN GAS

CATALYST


VENT GAS

HBs (HW)

S. No.

Input /Day

of Product

(MT)

1 17.5151

2 0.0051

3 0.2958

17.8160


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 3,3,5 Trimethylcyclohexanone 1 - - - 17 Product

2 LEs 0.04 - - - 0.68 By-Product

3 HBs - - - - 0.0748 To CHWTSDF


5 Vent Gas 0.0002 0.0034


1.04 0.0031 0.0002 0


Product (MT)

IPH 1.0303

Catalyst 0.0003

0.0174

Total 1.048

S. No.


Day of

Product

(MT)

0.0003

Total 0.0047

17.8160

RemarksHW

-

-

0.0044

Hydrogen




2.6.14.1 Process Chemistry – MIBK

2.6.14.2 Process block diagram – MIBK and DIBK

2.6.14.3 Plant Process description – MIBK and DIBK

It is hydrogenation of mesityl oxide followed by filtration and distillation.

2.6.14.4 Material balance – MIBK and DIBK

2.6.15 Methyl Isobutyl Carbinol (MIBC)

It is proposed to install MIBK capacity of 3000 TPA.

98 2 100

MIBK Catalyst

CH3(CO)CH=C(CH3)2 + H2 CH3(CO)CH2CH(CH3)2 Mesityl Oxide Methyl Isobutyl Ketone (MIBK)

0.3445 m3

26.5 m3

114.16

117.50 1.00

1.00

116.5

15

0.2 100 1.3

100


DIBK PRODUCTDISTILLATION

OFF SPEC PRODUCT

MIBK PRODUCT

Hydrogenation Plant

MOREACTION

HYDROGEN GAS

CATALYST


HBs (HW)

VENT GAS

S. No.

Input /Day

of Product

(MT)

1 19.4055

2 0.0017

3 0.4046

19.8118


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 MIBK 1 - - - 17 Product

2 DIBK 0.15 - - - 2.55 Product

3 LEs 0.01 - - - 0.17 By-Product



6 Vent Gas 0.0003 0.0051


1.16 0.003 0.0003 0

-

0.0001

Total 0.0021

19.8118

RemarksHW

-

-

0.002

Hydrogen 0.0238

Total 1.1654

S. No.


Day of

Product

(MT)


Product (MT)

Mesityl Oxide 1.1415

Catalyst 0.0001




2.6.15.1 Process Chemistry – MIBC

2.6.15.2 Process block diagram – MIBC

2.6.15.3 Plant Process description – MIBC

It is hydrogenation of MIBK followed by filtration and distillation.

2.6.15.4 Material balance – MIBC

2.6.16 Di Isobutyl Carbinol (DIBC)

It is proposed to install DIBK capacity of 1000 TPA.

100 2 102

MIBC

Catalyst CH3(CO)CH2CH(CH3)2 + H2 CH3CHOHCH2CH(CH3)2 Methyl Isobutyl Methyl Isobutyl Ketone (MIBK) Carbinol (MIBC)

0.338 m3

26 m3

102.03

105.34 1.00

1.00

104.34

0.34 100 4

100


HBs (HW)DISTILLATION

OFF SPEC PRODUCT

MIBC

Hydrogenation Plant

MIBKREACTION

HYDROGEN GAS

CATALYST


VENT GAS

S. No.

Input /Day

of Product

(MT)

1 17.3451

2 0.0017

3 0.3978

17.7446


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 MIBC 1 - - - 17 Product

2 LEs 0.037 - - - 0.629 By-Product

3 HBs - - - - 0.0578 To CHWTSDF


5 Vent Gas 0.0003 0.0051


1.037 0.003 0.0003 0

0.0001

Total 0.0035

17.7446

RemarksHW

-

-

0.0034

Hydrogen 0.0234

Total 1.0438

S. No.


Day of

Product

(MT)


Product (MT)

MIBK 1.0203

Catalyst 0.0001




2.6.16.1 Process Chemistry – DIBC

2.6.16.2 Process block diagram – DIBC

2.6.16.3 Plant Process description – DIBC

It is hydrogenation of DIBK followed by filtration and distillation.

142 2 144

DIBC

Catalyst (CH3)2CHCH2(CO)CH2CH(CH3)2 + H2 (CH3)2CHCH2CHOHCH2CH(CH3)2 Di Isobutyl Ketone (DIBK) Di Isobutyl Carbinol (DIBC)

0.2405 m3

18.5 m3

102.02

104.65 1.00

1.00

103.65

0.15 100 3.5

100


HBs (HW)DISTILLATION

OFF SPEC PRODUCT

DIBC

Hydrogenation Plant

DIBKREACTION

HYDROGEN GAS

CATALYST


VENT GAS




2.6.16.4 Material balance - DIBC

2.6.17 3,5 Dimethyl Phenol

It is proposed to install 3,5 Dimethyl Phenol capacity of 3000 TPA.

2.6.17.1 Process Chemistry – 3,5 DMP

S. No.

Input /Day

of Product

(MT)

1 17.3434

2 0.0017

3 0.2822

17.6273

Material / Item

Product

/

Byprodu

ct

Liquid

Effluent

Air

Emissio

n

Recover

y

1 DIBC 1 - - - 17 Product

2 LEs 0.032 - - - 0.544 By-Product

3 HBs - - - - 0.0255 To CHWTSDF


5 Vent Gas 0.0003 0.0051

6Handling Loss / Unaccounted 0.003 0.0510

1.032 0.003 0.0003 0

0.0001

Total 0.0016

17.6273

RemarksHW

-

-

0.0015

Hydrogen 0.0166

Total 1.0369

S. No.


Day of

Product

(MT)


Product (MT)

DIBK 1.0202

Catalyst 0.0001




2.6.17.2 Process block diagram - 3,5 DMP

2.6.17.3 Plant Process description - 3,5 DMP

Isophorone is passed over a catalyst bed in a continuous manner in fixed bed reactor at prescribed temperature and pressure conditions to form 3,5 Xylenol with methane gas as a by-product. The reaction takes place forming a mixture of Isophorone, 3,5 Xylenol, other organics impurities along with Methane gas.

The reaction mass is then distilled to remove the low boiling impurities. The bottom mass from the column is then passed through an extraction system. The extraction is carried out by means of a solvent along with caustic.

The extracted mass is then subjected to separation by a final distillation process to extract the final product in desired purities.

The unreacted Isophorone and the extraction solvent is recovered and recycled back to the process.

The product will be stored in storage vessel prior to packing & dispatch.

ISOPHORONE REACTION RECYCLE ISOPHORONE

IMPURITY REMOVAL DISTILLATION 1

EXTRACTION

DISTILLATION 2

DISTILLATION 3

3,5 DMP PRODUCT




2.6.17.4 Material balance - 3,5 DMP

2.6.18 Methyl pentadiene

It is proposed to install methyl pentadiene capacity of 2000 TPA.

2.6.18.1 Process Chemistry – methyl pentadiene

2.6.18.2 Process block diagram - methyl pentadiene

S. No. Raw Materials

Input/M

T of

Product

(MT)

Input /Day

of Product

(MT)

1 1.6 16

2 0.05 0.5

3 0.44 4.4

4 0.35 3.5

2.44 24.4

Output/MT of Product


Byproduct

Liquid

Effluent

Air

EmissionRecovery HW

1 3,5 Dimethyl Phenol 1 10

2 Methane 0.133 1.33

3 LEs 0.27 2.7

4 HBs 0.19 1.9

5 Spent Catalyst 0.687 6.87

6 Water 0.11 1.1


1.403 0.11 0.05 0.687 0.1924.40

Isophorone

Toluene

Catalyst 2

Catalyst 1

Total

S. No.

Output/

Day of

Product

(MT)

Remarks

Total

118 82 36

CH3 CH

CH2

OH

C CH3

CH3

OH

CH

CH3

CH3

CH2

CH

CH

CH

CH2

+ 2H2O

4-methyl1,3-pentadiene2-methylpentane-2,4-diol

MPD Plant

HG REACTION ACID

TO ETP WASHING

OFF SPEC DISTILLATION H2O

MPD PRODUCT




2.6.18.3 Plant Process description - Methyl pentadiene

Methyl Pentadiene is manufactured by the dehydration of Hexylene Glycol (HG) in presence of an acid catalyst followed by distillation to obtain the pure product. The raw material HG is charged into an agitated reactor and the acid catalyst is added. The reaction is maintained at a constant temperature by use of steam for heating. The vapors are then passed through a distillation column to collect Crude MPD at the top. The product which is collected in a decanter is washed and then fed to a distillation column where a Pure MPD product is extracted from a mixture of MPD, water and other impurities. The pure MPD is then stored in a product tank or packed as per requirements.

2.6.18.4 Material balance - methyl pentadiene

2.6.19 Bisphenol S

It is proposed to install Bisphenol S capacity of 3000 TPA.

2.6.19.1 Process Chemistry – Bisphenol S

S. No.

Input /Day

of Product

(MT)

1 6.435

2 0.66

3 1.815

8.9100

Material / Item

Product /

Byprodu

ct

Liquid

Effluent

Air

EmissionRecovery

1 MPD 1 3.3

2 LEs 0.13 0.429

3 HBs 1.089

4 Spent Catalyst -

5 Water 1.238 4.0854


1.13 1.24 0 0

Input/MT of Product

(MT)Raw Materials

RemarksHW

Hexylene Glycol 1.95

Acid Catalyst 0.2

Water 0.55

Total 2.7

S. No.


Output/ Day

of Product

(MT)

0.33

-

Total 0.33

8.9100

OH

+ H2SO

42

S

O

O

OH OH

phenolBisphenol-S




2.6.19.2 Process block diagram - Bisphenol S

2.6.19.3 Plant Process description - Bisphenol S

Bisphenol-S is prepared by the reaction of phenol with Sulphuric Acid. Phenol is reacted with Sulphuric Acid in presence of a catalyst to form Bisphenol-S. The product is then distilled from the crude mass after washing.

2.6.19.4 Material balance - Bisphenol S

2.6.20 Lubricant additives (Hydraulic / Gear oil packages)

It is proposed to install Lubricant additives capacity of 500 TPA.

CATALYST

PHENOL REACTION SULPHURIC ACID

TO ETP WASHING

OFF SPEC DISTILLATION H2O

BISPHENOL-S

S. No.

Input /Day

of Product

(MT)

1 24.65

2 11.543

3 1.7

4 0.493

38.386


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Bisphenol-S 1 17

2 LEs 0.23 3.91

3 HBs 12.41

4 Spent Catalyst 0.476

5 Liquid Effluent 0.27 4.5900


1.23 0.27 0 0

2.2580

0.73

0.028

Total 0.758

S. No.


Day of

Product

(MT)

38.386

RemarksHW

Solvent 0.1

Catalyst 0.029

Total 2.258


Product (MT)

Phenol 1.45

Sulphuric Acid 0.679




2.6.20.1 Process Chemistry – Lubricant additives

2.6.20.2 Process block diagram - Lubricant additives

2.6.20.3 Plant Process description - Lubricant additives

Lubricant Additives used in Hydraulic & Gear Oil Packages are generally prepared by mixing of multiple grades of additives (ZDDP & Ashless additives). It is simply a blending process with addition of base oils and other additives to form packages for Hydraulic Oil & Gear Oil applications.

Optional Draw

NaHS (30%)

NaOH (10%)

PPS

H2S Scrubber

DDP ACID PRODUCT ReactionAlcohol

To Flare

Ethyl Acrylate Synthesis Base Oil

Drying Alcohol (Recovered)

Base Oil

Mixing

Ashless Additive




2.6.20.4 Material balance - Lubricant additives

2.6.21 Sodium dithiophosphate

It is proposed to install sodium dithiophosphate capacity of 500 TPA.

2.6.21.1 Process Chemistry – sodium dithiophosphate

P2S5 + 6 NaOH → 2 Na3PO2S2 + H2S + 2 H2O

2.6.21.2 Process block diagram - sodium dithiophosphate

2.6.21.3 Plant Process description - sodium dithiophosphate

Sodium Dithiophosphate is prepared by base hydrolysis of Phosphorus Pentasulphide.

Step 1: Synthesis Step:

The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-

Alkyl Dithiophosphate Acid with release of Hydrogen Sulphide gas. In this step, the oxo-

alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is

added to this mass with continuous stirring which results in the evolving of gases which

are to be absorbed in the 2-stage caustic scrubber. Hydrogen sulphide gas which is

S. No.

Input /Day

of Product

(MT)

1 0.353

2 0.382

3 0.319

4 0.344

1.398


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Ashless Additive 1 1 Product

2 NaHS 0.1606 0.1606 By-Product

3 Water 0.2272 0.227 To CHWTSDF

4 Vent Gas - - 0.0005 0.0005


1.1606 0.2372 0.0005 0


Product (MT)

Isopropanol 0.353

Phosphorus Pentasulphide 0.382

RemarksHW

NaOH (10%) 0.344

Ethyl Acrylate 0.319

Total 1.398

S. No.


Day of

Product

(MT)

Total 0.0000

1.398

Process block diagram – Sodium Dithiophosphate

Reactor

Purification

Scrubber

NaOH + Water

NaHS solution

H2S Gas

Product

Liquid effluentHz waste

P2S5

Crude mass

NaOH




absorbed in caustic solution in a packed bed scrubber system to form sodium hydrogen

sulphide as by-product.

Step 2: Neutralization Step:

The neutralization of the acid is carried out with Caustic. Once neutralization is complete,

the product mass is dried. Filter aid is added, and the batch is filtered to obtain the

product of desired quality. The residue is then removed from the filter in the form of solid

cakes. The product is then stored, packed and dispatched as required.

2.6.21.4 Material balance - sodium dithiophosphate

2.6.22 Sodium dialkyl dithiophosphate

It is proposed to install sodium dialkyl dithiophosphate capacity of 500 TPA.

2.6.22.1 Process Chemistry – sodium dialkyl dithiophosphate

S. No. Input /Day of

Product (MT)

1 11.32

2 14.84

3 18

44.16


ByproductLiquid Effluent

1 Na3PO2S2 1 - 20 Product

2 Dil NaHS 1.086 - 21.72 By Product

3 H2O - 0.092 1.84 To ETP

4 HW - 0.6 To CHWTSDF

2.086 0.092

0.03

-

-

Sodium Dithio Phosphate

0.9

2.208 Total

0.0344.160

S. No.


Product (MT)HW

Remarks

NaOH 0.742

H2O

Total 2.208


Product (MT)

P2S5 0.566




2.6.22.2 Process block diagram - sodium dialkyl dithiophosphate

2.6.22.3 Plant Process description - sodium dialkyl dithiophosphate

Sodium Dialkyl DithioPhosphate (SDDP) is manufactured in two major steps.

Step 1: Synthesis Step: The synthesis of Oxo-Alcohols and Phosphorus Pentasulphide takes place to form a Di-Alkyl Dithiophosphoric Acid with release of Hydrogen Sulphide gas. In this step, the oxo-alcohols are charged into the reactor, stirred and heated. Phosphorus Pentasulphide is added to this mass with continuous stirring which results in the evolving of gases which are to be absorbed in the 2-stage caustic scrubber. Hydrogen sulphide gas which is absorbed in caustic solution in a packed bed scrubber system to form sodium hydrogen sulphide as by-product. Step 2: Neutralization Step: The neutralization of the acid is carried out with Caustic Soda. Once neutralization is complete, the product mass is dried. Filter aid is added, and the batch is filtered to obtain the product of desired quality. The residue is then removed from the filter in the form of solid cakes. The SDDP product is then stored, packed and dispatched as required.

2.6.22.4 Material balance - sodium dialkyl dithiophosphate

S. No.

Raw Materials Input/MT of

Product (MT)

Input /Day of Product

(MT) 1 Phosphorus Pentasulphide 0.275 4.125 2 Alcohols 0.470 7.050 3 Caustic 0.140 2.100 4 Base Oil 0.150 2.250 5 Caustic 0.072 1.078 6 Water for Scrubbing 0.150 2.252 Total 1.257 18.855

4.51

23.74

3.87

8.35

Optional Draw

39.85

60.71

0.0387

21.99 16.00

98.70

1.00

97.70

3.00

0.60

101.30

1.30

100.00

100.00SDDP Product


Base Oil

MixingFilter Aid

Filtration Filter Cake


NaOH Neutralization Base Oil

NaHS (30%)

NaOH (10%)

PPS

H2S Scrubber

To Flare




S. No.


Output/Day of Product

MT Remarks

Material / Item

Product / Byproduct

Liquid Effluent

Air Emission

Recovery HW

1 ASDP 1 - - - - 15.000 Product

2 NaHS (30%)

0.250 - - - - 3.750 Product

3 H2S - - 0.001 - - 0.013 To Scrubber

4 Filter

Residue - - - - 0.006 0.090 To CHWTSDF

Total 1.250 0.000 0.001 0.000 0.006

18.855 1.257

Specification Sodium Hydrogen Sulphide (NaHS) Appearance Yellow to green translucent liquid,

Purity 30% pH 11 to 13

Specific Gravity 1.20 to 1.25

2.6.23 Benzylidene Acetone

It is proposed to install Benzylidene acetone capacity of 800 TPA.

2.6.23.1 Process Chemistry – Benzylidene acetone

Benzylidene Acetone CH3C(O)CH3 + C6H5CHO C6H5CH=CHC(O)CH3 + H2O Acetone Benzaldehyde Benzylidene Acetone Water




2.6.23.2 Process block diagram - Benzylidene acetone

2.6.23.3 Plant Process description - Benzylidene acetone

Benzylidene Acetone is manufactured by Aldol condensation of Benzaldehyde & Acetone. Benzaldehyde & Acetone are fed to a reaction system along with a catalyst to form Benzylidene Acetone along with some impurities. The reaction mass is then washed and purified to form Benzylidene Acetone product.

2.6.23.4 Material balance - Benzylidene acetone

1.00

94.00 153.75 58.75

166.88

52.50 202.50 65.625

75.00

27.5 100.00 26.25

100.00


BENZYLIDENE

ACETONE

CATALYST

BENZALDEHYDE REACTION ACETONE

H2O

TO ETP WASHING

OFF SPEC DISTILLATION

S. No.

Input /Day

of Product

(MT)

1 0.141

2 0.088125

3 0.0015

4 0.039375

0.27


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Benzylidene Acetone 1 - - - 0.15 Product

2 LEs 0.275 - - - 0.041 By-Product

3 HBs - - - - - To CHWTSDF


5 Water - 0.525 - - 0.079

1.275 0.525 0 0

-

-

0.2701.800

Catalyst 0.01

-

Remarks

-

-

Total 0

Water 0.2625

Total 1.800

S. No.

Raw Materials


Day of

Product

(MT)

HW

Benzaldehyde 0.94

Acetone

Input/MT of

Product (MT)

0.5875




2.6.24 Benzyl Acetone

It is proposed to install Benzyl acetone capacity of 500 TPA.

2.6.24.1 Process Chemistry – Benzyl acetone

2.6.24.2 Process block diagram - Benzyl acetone

2.6.24.3 Plant Process description - Benzyl acetone

It is hydrogenation of Benzylidene acetone.

146 2 148

Benzyl Acetone C10H10O + H2 C10H12O Benzylidene Acetone Benzyl Acetone

0.2366 m3

18.2 m3

102.40

105.00 1.00

1.00

104

1 100 3

100


BENZYL ACETONE

VENT GAS

Benzylidene AcetoneREACTION

HYDROGEN GAS

CATALYST


DISTILLATIONHBs (HW) OFF SPEC PRODUCT




2.6.24.4 Material balance - Benzyl acetone

2.6.25 PIBSA (Poly Isobutanyl Succinic Anhydride)

It is proposed to install PIBSA capacity of 1500 TPA.

2.6.25.1 Process Chemistry – PIBSA

S. No.

Input /Day

of Product

(MT)

1 15.36

2 0.0015

3 0.243

15.6045


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Benzyl Acetone 1 - - - 15 Product

2 LEs 0.03 - - - 0.45 By-Product



5 Vent Gas 0.0002 0.0030

1.03 0 0.0002 0 Total

0.010115.6045

1.0403

RemarksHW

-

-

0.01

0.0001

Hydrogen 0.0162

Total 1.0403

Output/ Day

of Product

(MT)

S. No.



(MT)

Benzylidene Acetone 1.024

Catalyst 0.0001




2.6.25.2 Process block diagram - PIBSA

2.6.25.3 Plant Process description - PIBSA

PIBSA is manufactured by the reaction of PolyIsobutylene & Maleic Anhydride. Polyisobutylene in presence of catalyst reacts with Maleic Anhydride forms Polyisobutylene Succinic Acid.

2.6.25.4 Material balance - PIBSA

2.6.26 PIBSI (Poly Isobutanyl Succinimide)

It is proposed to install PIBSI capacity of 750 TPA.

2.6.26.1 Process Chemistry – PIBSI

PIB

PIBSA Product

Reaction

Filtration

Maleic Anydride

Filter Residue

S. No.

Input /Day

of Product

(MT)

1 4.613

2 0.578

5.190


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 PIBSA 1 5 Product

2 Filter Residue 0.035 0.175 To CHWTSDF


1.0000 0.038 0 0

Raw Materials

5.190

RemarksHW

Output/MT of Product Output/ Day

of Product

(MT)

Total 0.0000

Total 1.038

S. No.

Input/MT of Product

(MT)

Polyisobutylene 0.9225

Maleic Anhydride 0.1155




2.6.26.2 Process block diagram – PIBSI

2.6.26.3 Plant Process description – PIBSI

It is reaction of PIBSA and Amine in presence of catalyst, followed by filtration.

2.6.26.4 Material balance - PIBSI

2.6.27 Phosphate Esters

It is proposed to install Phosphate esters capacity of 500 TPA.

2.6.27.1 Process Chemistry – Phosphate esters

PIBSA Reaction Amine

Filtration Filter Residue

Catalyst

PIBSI Product

S. No.

Input /Day

of Product

(MT)

1 1.383

2 0.165

3 0.099

1.646


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 PIBSI 1 2.5 Product

2 LEs 0.035 0.088 To CHWTSDF


1.0000 0.038 0 0

0.0395

Catalyst 0.066

Total 0.0000

2.595

RemarksHW

Total 0.659

S. No.


of Product

(MT)


(MT)

PIBSA 0.553

Amine




2.6.27.2 Process block diagram - Phosphate esters

2.6.27.3 Plant Process description - Phosphate esters

Phosphate Esters are produced by a synthesis of Alcohols with Phosphorus Pentoxide. Phosphorus Pentoxide is added to alcohol mixture where reaction takes place at predetermined temperature & pressure conditions to form Phosphate Esters with liberation or water. Different grades of Phosphate Esters can be manufactured by varying the alcohols in the Alcohol mixture of the feed.

2.6.27.4 Material balance - Phosphate esters

2.6.28 Amine Phosphates

It is proposed to install Amine Phosphate capacity of 300 TPA.

2.6.28.1 Process Chemistry – Amine Phosphate

41.46

63.54

106.02

1.02

5 100.00

100.00

H2O to ETP

PPO

Drying Recovered Alcohol

ReactionAlcohol

Phosphate Ester Product

S. No.

Input /Day

of Product

(MT)

1 0.705

2 1.080

1.785


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Phosphate Ester 1 - - - 1.7 Product

2 Water - 0.047 - - 0.0799


1.0000 0.05 0 0

Alcohols 0.6354


(MT)

Phosphorus Pentoxide 0.4146

RemarksHW

-

-

Total 1.0500

S. No.


of Product

(MT)

-

Total 0.0000

1.785




2.6.28.2 Process block diagram – Amine Phosphate

2.6.28.3 Plant Process description – Amine Phosphate

Phosphate Esters when reacted with and alkyl amine form amine phosphates. It is a simple addition reaction taking place at predetermined temperature & Pressure conditions.

2.6.28.4 Material balance – Amine Phosphate

2.6.29 Carbazole Esters

It is proposed to install Carbazole Esters capacity of 1500 TPA.

2.6.29.1 Process Chemistry – Carbazole Esters

78.00 22.00

100.00

100.00

Phosphate Ester Reaction

Amine Phosphate

Product

Amine

S. No.

Input /Day

of Product

(MT)

1 0.705

2 1.080

1.785


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Phosphate Ester 1 - - - 1.7 Product

2 Water - 0.047 - - 0.0799


1.0000 0.05 0 0

Alcohols 0.6354


Phosphorus Pentoxide 0.4146

RemarksHW

-

-

Total 1.0500

S. No.


Product (MT)

-

Total 0.0000

1.785




2.6.29.2 Process block diagram – Carbazole Esters

2.6.29.3 Plant Process description – Carbazole Esters

Carbazole Esters are manufactured by a reaction of Ethyl Acrylate with Carbazole. Ethyl Acrylate and Carbazole at given temperature & pressure conditions in presence of catalyst form Carbzole Esters.

2.6.29.4 Material balance – Carbazole Esters

2.6.30 Ashless Lubricant additives

It is proposed to install ashless lubricant additives capacity of 300 TPA.

68.88 1.00

34.32

104.20

3.2 100.00 1.00

100.00


Carbazole

Reaction

Undesired Impurities Purification

Catalyst

Carbazole Ester

Product

Ethyl Acrylate

Catalyst Recovery

S. No.

Input /Day

of Product

(MT)

1 1.160

2 0.597

3 0.017

1.773


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Carbazole Ester 1 - - - 1.7 Product

2 Impurities - - - - 0.0527

3 Catalyst Recovery - - - - 0.017


1.0000 0.002 0 0


of Product

(MT)

RemarksHW


(MT)

Carbazole 0.6822

Catalyst 0.01


0.01

-

0.031

-

Total 0.0310

1.773

Total 1.0432

S. No.




2.6.30.1 Process Chemistry – ashless lubricant additives

2.6.30.2 Process block diagram – ashless lubricant additives

2.6.30.3 Plant Process description – ashless lubricant additives

Ashless Lubricant additive is manufactured in a manner similar to ZDDP. Alcohol (e.g Ethanol) reacts with Phosphorus Pentasulphide (PPS) to form the corresponding Dithiophosphoric Acid (Dirthyl Thiophosphoric Acid). H2S gas is evolved in the process. The Acid is the reacted with Ethyl Acrylate to form a Dithiophosphate Ester. This Dithiophosphate ester on refinement and addition of base oil act as an Ashless Lubricant Additive.

Optional Draw


Base Oil

Mixing

Ashless Additive


To Flare

Ethyl Acrylate Synthesis Base Oil

NaHS (30%)

NaOH (10%)

PPS

H2S Scrubber




2.6.30.4 Material balance – ashless lubricant additives

2.6.31 Resorcinol

It is proposed to install Resorcinol capacity of 3000 TPA.

2.6.31.1 Process Chemistry – Resorcinol

S. No.

Input /Day

of Product

(MT)

1 0.353

2 0.382

3 0.319

4 0.344

1.398


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Ashless Additive 1 1 Product

2 NaHS 0.1606 0.1606 By-Product

3 Water 0.2272 0.227 To CHWTSDF

4 Vent Gas - - 0.0005 0.0005


1.1606 0.2372 0.0005 0 Total

0.00001.398

RemarksHW

NaOH (10%) 0.344


Total 1.398

S. No.


of Product

(MT)


(MT)

Isopropanol 0.353

Phosphorus Pentasulphide 0.382




2.6.31.2 Process block diagram – Resorcinol

2.6.31.3 Plant Process description – Resorcinol

Resorcinol can be manufactured by various routes. We have selected the manufacture of Resorcinol by Hydroperoxidation of m-Diisopropylbenzene (m-DIPB). M-DIPB is oxidized in a bubble column reactor to form the hydroperoxide mixture containing Dihydroiperoxide (DHP, Ketohydroperxide (KHP) & Hydroxyhydroperoxide (HHP). The mixture undergoes extraction to maximize the DHP concentration. This DHP then undergoes Cleavage to form Resorcinol & Acetone. The reaction mass is then distilled to obtain pure Resorcinol & Acetone in a series of distillation columns.

2.6.31.4 Material balance – Resorcinol

2.6.32 Dicumyl Peroxide

It is proposed to install dicumyl peroxide capacity of 500 TPA.

0.30 66.58

140.00 188.50

1009.54

RECYCLE DIPB

747.32

262.22

5

0.61

266.25 1.58

100.00

60.00 60.00 206.25 100.00

106.25


6.25

AIR

CARBONATE VENT AIR (INERT)

DIPBOXIDATION

PEROXIDE

CONCENTRATION

CATALYSTCLEAVAGE

WATER

TO ETP

ACETONE PRODUCT ACETONE

DISTILLATION

RESORCINOL

DISTILLATION

RESORCINOL PRODUCT

TAR

S. No.

Input /Day

of Product

(MT)

1 61.6

2 82.94

3 0.132

4 0.154

5 2.2

147.03


Byproduct

Liquid

Effluent

Air

EmissionRecovery

1 Phenol 1 - - - 44 Product

2 Acetone 0.6 - - - 26.4 By-Product

3 AMS 0.06 - - - 2.64

4 ACP 0.0289 - - - 1.26984

5 TAR - - - - 2.690 To CHWTSDF

6 Water - 0.057 - - 2.508

7 Vent Gas (Inert Gas) - - 1.5318 - 67.3992

8 Handling Loss / Unaccounted - 0.0028 0 - 0.1232

1.6889 0.0598 1.5318 0.0000

Carbonate 0.003


DIPB 1.4

Air 1.885

Catalyst 0.0035

Water 0.05

Total 3.3415

-

S. No.


Product (MT)Remarks

HW

-

-

-

-

0.0611

-

-

Total 0.0611

147.03




2.6.32.1 Process Chemistry – dicumyl peroxide

2.6.32.2 Process block diagram – dicumyl peroxide

2.6.32.3 Plant Process description – dicumyl peroxide

Dicumyl peroxide is produced by catalytic reaction of CHP and Cumyl alcohol followed by washing and distillation.

+

CHP

Cas no:- 80-15-9

Cumyl alcohol

Cas no:- 617-94-7

Dicumylperoxide

Cas no:- 80-43-3

58.00 114.00 55.00

105.56

43.45 121.80 54.3125

9.5

10.00

2.3 100.00 41.25

100


LEs

HBsDISTILLATION H2O

DICUMYL PEROXIDE

PRODUCT

CHP REACTION Cumyl Alcohol

TO ETP WASHING

Catalyst




2.6.32.4 Material balance – dicumyl peroxide

2.6.33 Research and Development activities with pilot plant

It is proposed to install Research and Development activities with a pilot plant, in order to carry out developmental work as required. The set up will be utilized for multipurpose activities.

2.6.34 Hydrogen gas

It is proposed to install hydrogen generation plant of 5000 Nm3/day at site. Hydrogen gas will be captively consumed.

2.6.34.1 Process chemistry - Hydrogen

2.6.34.2 Process block diagram - Hydrogen

S. No.

Input /Day

of Product

(MT)

1 0.986

2 0.935

3 0.017

4 0.70125

2.6393

Material / Item

Product /

Byprodu

ct

Liquid

Effluent

Air

EmissionRecovery

1 DiCumyl Peroxide 1 - - - 1.7 Product

2 LEs 0.095 - - - 0.1615 By-Product

3 HBs - - - - 0.0391 To CHWTSDF

4 Water - 0.4305 - - 0.73185


1.095 0.4345 0 0


(MT)

Total 0.023

2.6393

-

-

0.023

-

-

RemarksHW

CHP 0.58

Catalyst 0.01

Water 0.4125

Total 1.5525

S. No.


Output/ Day

of Product

(MT)

Cumyl Alcohol 0.55




2.6.34.3 Process Description - Hydrogen

Methanol & DM Water heated to 260-300o C gives Hydrogen gas in presence of catalyst.

2.6.34.4 Stagewise material balance - Hydrogen

2.6.35 Pollution generation aspects of manufacturing

Gaseous emission from fuel (FO) , consist of common pollutants like SO2, NOx, and PM would be discharged into atmosphere through stack of suitable height and appropriate air pollution control devices.

Process emissions SO2/H2S shall be handled in close system. It will be scrubbed with water.

DG set will be used only in case of power outage its stack height shall be provided as per statutory norm.

The operation of centrifuging/ filter will be done in closed equipment to avoid any vapors coming out in the local atmosphere. The vents of centrifuges / filters will be connected to scrubbers.

Wastewater treatment plant shall generate ETP sludge which will be sent to CHWTSDF facility.

Effluent is generated during the process shall be treated at ETP which will be suitably designed. The treated effluent shall be used within the facility as cooling tower make up/ green belt purpose.

Volatile organic solvents are carefully handled in a closed system, and will be vented only after passing through 1 or 2 stage condensers, thereby preventing any discharge of these chemicals into the air.

Odour Control: All the vents of the batch tanks and solvents will be connected to scrubber to absorb any pollutant / odour producing gases and chemicals. Green belt around the plant boundary will absorb the odour to some extent.

Occupational Hazards & Safety Precautions to be taken for various chemicals is given in Chapter 7.

DM Water Generation

5053 Kg DM Water

Water 9958 Kg 4905 Kg Rejected water

Hydrogen Generation

Methanol 6879 Kg 1000 Kg Hydrogen Gas

DM Water 5053 Kg 10932 Kg Loss (CO2)

Catalyst 0.01 Kg

Hydrogem Generation

Water Pirification

Generation




2.7 Raw material consumption and mode of transport

The raw materials comprise of chemicals as liquids, solids as well as compressed gases, its estimated consumption is given below. Mode of transport - The raw materials required for the expansion will be either imported via JNPT port or procured from domestic market and transported conveniently by trucks, trailers and tankers by road.

Table 2.4 List of Major raw materials required, source

S. No.

Name of Raw Material

Consumption (MTPA)

Physical State

Means of Storage

Source

1 Acetone 50,000 L Tanks/Drums Imports /

Local

2 Caustic 1,500 S/L Bags/ Tanks Local

3 Phosphorus 3,500 S Tanks/Drums Imports

4 Sulphur 8,000 S/L Bags/ Tanks Local

5 Cumene 28,000 L Tanks Imports /

Local

6 ZnO 400 S Bags Local

7 Sulphuric Acid 1,500 L Tanks Local

8 Di-isopropyl

Benzene 4,500 L

Tanks/ Drums

Local

9 Benzaldehyde 650 L Tanks Local

10 Hydrogen 300 G Cylinder

Banks Local/In situ generation

11 Polyisobutylene 430 L Tanks Local

12 Maleic Anhydride 120 L Tanks Local

13 Ethyl Acrylate 800 L Tanks Local

14 Phosphorus Pentoxide

500 S Bags Local

15 Methanol 2,000 L Tanks Local

16 Ethanol 2,000 L Tanks Local

17 Isopropanol 2,000 L Tanks Local

18 N-Butanol 2,000 L Tanks Local

19 Isobutanol 2,000 L Tanks Local

20 Pentanol 2,000 L Tanks Local

21 Octanol 2,000 L Tanks Local

22 Oleyl Amine 200 L Tanks Local

23 C12 Alcohol 100 L Tanks Local

24 C14 Alcohol 100 L Tanks Local

25 Methyl Acrylate 100 L Tanks Local

26 Carbazole Powder 100 S Bags Local

NOTE: *RM requirement can be on the basis of the grade of ZDDP manufactured, the figure indicates maximum quantity per annum




2.8 Storages at site

Raw material storages at site will be as follows

Table 2.5 Raw material storages

S. No. Name of Raw Material Physical

State

Bulk Storage Capacity

(MT)

Means of Storage

1 Acetone L 1570.5 Tanks/Drums 2 Caustic S/L 50 Bags/Tanks 3 Phosphorus S/L 100 Tanks/Drums 4 Sulphur S/L 200 Bags/Tanks 5 Cumene L 1000 Tanks 6 Zinc oxide S 10 Bags 7 Sulphuric Acid L 50 Tanks 8 Di-isopropyl Benzene L 100 Tanks/Drums 9 Benzaldehyde L 30 Tanks

10 Hydrogen G 5000 NM3 Cylinder banks 11 Polyisobutylene L 20 Tanks 12 Maleic Anhydride L 10 Tanks 13 Ethyl Acrylate L 30 Tanks 14 Phosphorus Pentoxide S 40 Bags 15 Methanol L 40 Tanks 16 Ethanol L 40 Tanks 17 Isopropanol L 40 Tanks 18 N-Butanol L 40 Tanks 19 Isobutanol L 40 Tanks 20 Pentanol L 40 Tanks 21 Octanol L 40 Tanks 22 Oleyl Amine L 20 Tanks 23 C12 Alcohol L 20 Tanks 24 C14 Alcohol L 20 Tanks 25 Methyl Acrylate L 10 Tanks 26 Carbazole Powder S 5 Bags

2.8.1 Onsite Bulk Storage

Bulk storages at site shall be as follow for raw material and products.

Table 2.6 Existing storage details

No CHEMICAL Physical

state

Storage capacity

(KL/ M3)

Means of

Storage

No of tanks

Diameter, m

Height m

1 Acetone L 407 Tank 2 7.2 10

2 Acetone L 56.5 Tank 1 4 4.5




3 Caustic Lye L 50 Tank 1 3 5

4 Phosphorus L 100 Tank 2 3.5 5.5

5 Sulphur L 200 Tank 3 3 5

6 Cumene L 1000 Tanks 1 10.5 12.5

7 Benzaldehyde L 30 Tanks 1 3 4.5

8 Methanol L 40 Tanks 1 2.7 7.5

9 Ethanol L 40 Tanks 1 2.7 7.5

10 Isopropanol L 40 Tanks 1 2.7 7.5

11 N-Butanol L 40 Tanks 1 2.7 7.5

12 Isobutanol L 40 Tanks 1 2.7 7.5

13 Pentanol L 40 Tanks 1 2.7 7.5

14 Octanol L 40 Tanks 1 2.7 7.5

15 Oleyl Amine L 20 Tanks 1 2.5 4

16 C12 Alcohol L 20 Tanks 1 2.5 4


18 Diacetone

Alcohol L 347 Tank 1 7 9

19 Diacetone


20 Nonyl Phenol L 40 Tank 1 2.7 7.5

21 Phosphorous

Acid Food Grade L 40 Tank 1 2.7 7.5

22 Dil. Phosphorous

Acid L 40 Tank 1 2.7 7.5

23 Isophorone L 300 Tank 1 6.7 9

24 Phenol L 300 Tank 1 6.7 9

25 Mesityl Oxide L 100 Tank 1 4.5 6.5

26 Methyl Isobutyl

Carbinol L 40 Tank 1 2.7 7.5

27 Di-isobutyl

Ketone L 40 Tank 1 2.7 7.5

28 Cumene

Hydroperoxide L 40 Tank 1 2.7 7.5

29 3,5 Dimethyl

Phenol L 50 Tank 1 3 7.5

30

Lubricant Additives

(Hydraulic Packages/ Gear

Oil Packages etc.)

L 40 Tank 1 2.7 7.5

31 Sodium

Dithiophosphate L 20 Tank 1 2.5 4

32 Sodium Dialkyl


33 Benzylidene

Acetone L 20 Tank 1 2.5 4




34 Benzyl Acetone L 20 Tank 1 2.5 4

35 Dialkyl

Dithiophosphoric Acid

L 20 Tank 1 2.5 4

36 Resorcinol L 20 Tank 1 2.5 4

37 Dicumyl Peroxide

L 30 Tank 1 3 4.5

38 Cumyl Alcohol L 10 Tank 1 2 3.5

39 Di-Nonyl Phenol L 10 Tank 1 2 3.5

40 Alpha Methyl

Styreme (AMS) L 40 Tank 1 2.7 7.5

41 Acetophenone

(ACP) L 20 Tank 1 2.5 4

42 Dicarbinol L 10 Tank 1 2 3.5

43 Hydrogen G 5000 Cylinder

Banks - - -

Note: 1. Some tanks are common between RM or Products depending on the manufacturing taken up on Campaign basis.

2. The Tanks indicated as new and existing based on tankage available at site. However, application can be reassigned based on revised capacities.

Table 2.7 Proposed raw material and product bulk storage details


state

Storage capacity

(KL/ M3)

Means of

Storage

No of tanks

Diameter

M

Height m

1 Acetone L 700 Tank 1 9 12

2 Sulphuric Acid L 50 Tanks 1 3.5 5.5

3 Di-isopropyl

Benzene L 100

Tanks/Drums

1 4.5 6.5

4 Polyisobutylene L 20 Tanks 1 2.5 4

5 Maleic

Anhydride L 10 Tanks 1 2 3.3

6 Ethyl Acrylate L 30 Tanks 1 3 4.5

7 Methyl Acrylate L 10 Tanks 1 2 3.5

8 Diacetone


9 Zinc Diorgano

Dithiophosphate L 150 Tank 1 5 8

10

Hexylene Glycol, Trimethyl

Cyclohexanol, Trimethyl

Cyclohexanone,

L 300 Tank 1 6.7 9

11 Methyl Isobutyl

Ketone L 100 Tank 2 3 7.5




12 Di-isobutyl


13 Methyl

Pentadiene L 40 Tank 1 2.7 7.5

14 PIBSA L 40 Tank 1 2.7 7.5

15 PIBSI L 40 Tank 1 2.7 7.5

16 Phosphate

Esters L 40 Tank 1 2.7 7.5

17 Amine

Phosphates L 40 Tank 1 2.7 7.5

18 Carbazole


19 Ashless

Lubricant Additive

L 40 Tank 1 2.7 7.5

20 Resorcinol L 80 Tank 2 2.7 7.5

21 Sodium

Hydrogen Sulphide (NaHS)

L 30 Tank 1 3 4.5

Table 2.8 Warehouse storage details


state Stored in

1 Caustic soda S Bags

2 Acetone L Drums

3 Phosphorus S Drums

4 Sulphur S Bags

5 ZnO S Bags

6 Phosphorus Pentoxide S Bags

7 Phosphorous Pentasulphide S Silo / Tote Bin

8 Bisphenol-S S Bags / Drums

9 Carbazole Powder S Bags

2.9 List of major equipment

As a part of expansion following major equipment’s are to be installed at site. (Tentative list)

Sr. No. Item Capacity 1 Reactors 5 To 20 KL 2 Columns 25 Nos 3 Heat Exchangers 75 Nos 4 Pumps 100 Nos 5 Tanks 70 Nos 6 Filters 10 Nos




2.10 Utilities

2.10.1 Energy Requirements

2.10.1.1 Electricity

Existing power requirement of the site is 2900 KVA. The expansion will need additional 2000 KVA.

Existing Co-Generation Plant (Coal based) of capacity 4.6 MW will be adequate for the power requirement of the expansion.

DG sets

There are two DG sets at site of 250 KVA and 380 KVA capacity. For expansion there is

proposal to add one DG set of 625 KVA capacity.

2.10.1.2 Steam/ process heat requirement

Existing Co-Generation Plant (Coal based) of capacity 4.6 MW will be adequate for the Steam/Heat energy requirement of the expansions. Existing and proposed fuel requirement, APC system and stack details are as follows,

Table 2.9 Fuel requirement and APC details

Sr No

Stack attached to APC System Height in

meter Type of

Fuel Quantity and UoM

Permissible Limit of

pollutant Existing*

1 Boiler – 2 and 3 (3

and 8 TPH)

Mechanical dust collector, bag filter

25 (common)

Imported coal

900 and 2000 kg/hr

384 kg/day SO2

2 Boiler 4 (16 TPH) Mechanical dust collector, bag filter, Cyclone separator

35 Imported

Coal 3200 kg/hr

641 kg/day SO2

3 Boiler 5 (10 TPH) Mechanical dust collector, bag filter,

35 Imported

Coal 2000 kg/hr

384 kg/day SO2

4 Thermic Fluid

Heater - 1 Mechanical dust collector, bag filter,

30 Imported

Coal 400 kg/hr

76.8 kg/day SO2

5 Thermic Fluid

Heater – 2

Mechanical dust collector, bag filter, Cyclone separator

35 Imported

Coal 687 kg/hr 132 kg/day SO2

6 Zinc Di Organo

Dithiophosphate plant

Alkaline scrubber

12 - -

H2S 10 ppm/ SO2 50

ppm/acid mist 35 mg/nm3

7 Phosphorus

Pentasulphide plant

Alkaline scrubber

11 - -

H2S 10 ppm/ SO2 50

ppm/acid mist 35 mg/nm3

8 DG set (250 KVA) Acoustic enclosure 3.6 above

roof HSD

27.5 Lit/hr

13 kg/day SO2

9 DG set (380 KVA) Acoustic enclosure 3.6 above

roof HSD 35 Lit/hr 17 kg/day SO2

10 Boiler (38 TPH for power generation

of 4.6 MW)

ESP 47

Low ash Imported

Coal

5625 kg/hr

1350 kg/day SO2

Proposed




Sr No

Stack attached to APC System Height in

meter Type of

Fuel Quantity and UoM

Permissible Limit of

pollutant

11 Boiler (5 TPH) -- 38

(Common) Furnace Oil

304 Kg/ Hr

655 kg/day SO2

12 Thermic Fluid

Heater 30 Lakh Kcal/hr

-- 40 Furnace Oil 358 kg/hr 770 kg/day SO2

13 625 KVA (DG set) Acoustic enclosure 3.6 above

roof HSD 125 Lit/hr 62 kg/day SO2

* As per existing consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.07.2020 valid till 31.10.2021. Note: (a) 38 TPH boiler is operational and Boilers mentioned in Sr No. 2 and 3 i.e. 16 TPH and 10

TPH are standby. (b) Sr No 1 boiler (3 and 8 TPH- coal fired) operation will be discontinued once Sr No 11

boiler (5 TPH– Oil fired) is installed. (c) Sr No 5 TFH (coal fired) operation will be discontinued once Sr No 12 TFH (Furnace oil

fired) is installed.

2.11 Fugitive emissions and control

Fugitive emissions can be defined as the emissions due to: o the evaporation of organic raw material and solvents, from open vessel, open end

of pipeline/connector, storage tanks, drums and from spills/leaks during improper handling and transfer of chemicals

o escape of gaseous and particulate pollutants from faulty gaskets or pipeline connectors

o Improper equipment maintenance leading to fugitive emissions of reactants/products/solvents.

o Poor housekeeping, These emissions are generally from solvents and solid/powder handling. These fugitive emissions usually spread in the process plant posing a threat to the workmen and sometimes leading to formation of clouds and explosions due to increased concentration of pollutants. Hence, proper collection, treatment and disposal become essential from safety and health point of view.

Table 2.10 Sources of Fugitive Chemical vapors

Area Activity

type Continuous / Intermittent

Type of fugitive

emission

Pollutant added to ambient air

Production. Tank farm

area

Production, storage, handling

Continuous Chemical /

dust

Hazardous air pollutants/ chemicals with low vapor pressures and pressurized

gases Solid

product bagging

area

Powder filling

Continuous Fine

chemical dust

PM10 and PM2.5




Table 2.11 Probable fugitive emiision source/control measure

Probable Source Control measure Vessels and tanks Vents/ Vapor recovery systems shall be provided

at required locations. Chemical vapor from wet cake in filtration and drying area

Covered transfer systems shall be adopted, workers shall be provided PPE, fume extraction systems shall be provided, wherever required

Emissions from Bulk Storage Tanks during storage, loading and unloading

Breather valves, PSVs, Rupture discs Vapor recovery system will be installed for process/storage tank vents

Valves, Flanges, plugs and instrument connections

Welded pipes to be used wherever feasible Suitable gasket material to be used Suitable gland packing to be used in valves Periodic inspection and maintenance of pipes and pipe fittings

Chemical vapor from wet cake in filtration and drying area

Covered transfer systems shall be adopted, workers shall be provided PPE, fume extraction systems shall be provided, wherever required

2.12 Solvent recovery and its management

The purpose of solvent recovery system is to recover solvents from spent solvent streams and reuse the pure solvent in manufacturing process. A solvent is the component of a solution that is present in the greatest amount. It is the substance in which the solute is dissolved. Solvents do not contribute to the effectiveness of the chemical manufactured, with the exception of forming the desired solvate in the process of manufacturing. Solvents play an essential role in chemical processing for controlling the reaction rate, facilitating heat and mass transfer and enabling product separation and purification, which cannot be replaced easily with other alternatives. Toluene is used as solvent in the manufacturing of 3,5 di methyl Phenol (3.5 DMP) at site. Solvent is distilled from process and recovered in same process. Solvents shall be directly pumped into day tanks from the storage tanks and shall be charged into the reactors without involving any manual handling. Measures for achieving maximum solvent recovery and minimize VOC/odour generation:

o The entire manufacturing activities & distillation process will be carried out in a totally closed system.

o All the pumps shall be mechanical seal type to avoid any leakage of solvent. o For solvent handling fireproof electrical motors and components shall be used. o Firefighting systems shall be provided with alarm system.




o All the storage tanks and day tanks shall be connected to a vent system through two-stage chilled water condensers to prevent loss of solvents in the atmosphere.

o All the reactor condenser vents are connected with two-stage chilled water condensers for maximum possible recovery of the solvents and minimum loss.

o Good ventilation will be provided to reduce the workroom concentrations. o Solvents will be stored in a separate space specified with all safety measures. o Entire plant where solvents are used, the equipment’s/pumps/fittings will be of

flame proof. The solvent storage tanks will be provided with nitrogen blanketing system and breather valve to prevent losses.

Figure 2.2 Typical solvent recovery scheme

Solvent recovery is done by distillation assembly provided on reaction vessels. After the reaction the un-reacted solvent is recovered by distillation and reused in next batch. Solvent recovery system shall consist of packed columns and primary condenser having cooling water circulation and secondary condenser having chilled water or chilled brine circulation. Distillation is to be carried out at atmospheric as well as vacuum conditions to obtain minimum 95% recovery.

2.13 Water requirement & wastewater generation

Total water requirement (existing & proposed) of 1518 cmd (Fresh- 1140 & Recycle- 378) is for domestic, process, Boiler and cooling and green belt maintenance purpose.

The fresh water shall be sourced from Patalganga River for which permission has been obtained from Irrigation Department, Raigad. Copy of permission is attached at Annexure 2.2.

Table 2.12 Total water requirement (Existing & Proposed)

No. Purpose Total water Qty after expansion., cmd 1 Domestic 35 2 Industrial cooling/ boiler feed 1024

Reaction/Distillation & Solvent recovery scheme

CW supply/return

CooledProduct Receiver

Reaction/Distillationjacketed vessel

CHW supply/return

Flame arrester

Product cooler

Product cooler

Storage

Vacuum trap/system

CW/CHW supply/return




No. Purpose Total water Qty after expansion., cmd 3 Industrial processing 63 4 Green belt 18 5 Treated recycle water 378 Grand Total 1518

The break up of existing & proposed fresh water requirement is as below,

Table 2.13 Fresh water requirement

No Purpose Existing Additional Total

Quantity in cmd

1 Domestic 27 8 35

2 Industrial cooling/ boiler feed 644 380 1024

3 Industrial processing 39 24 63

4 Green belt 0 18 18 Grand Total 710 430 1140

Existing effluent generation is as below-

Table 2.14 Waste water generation and disposal

No Description Existing Additional Total

Treatment and Disposal Quantity in cmd

1 Domestic 21.6 5.4 27 Domestic and Trade effluent shall be treated at site and treated water will be recycled within site. Proposed project is Zero liquid discharge facility.

2 Trade

effluent 111 253 364

Total 132.6 258.4 391

Figure 2.3 Total Water balance Post expansion




2.14 Manpower requirement

During construction phase, around 100 laborers will be hired. During operation phase, around 110 employees/contract workmen will be hired based on their skills. They may be hired locally. First preference shall be given to skilled, semi-skilled work force of local community. Manpower: Expected manpower requirement for the expansion (during operation phase) shall be as follows:

Table 2.15 Expected manpower details

Description Existing, Nos Additional, Nos Total, Nos Permanent 425 80 505

Contract 75 30 105 Total 500 110 610

2.15 Environmental Aspects

2.15.1 Effluent Generation, Treatment and Disposal

Effluent generation sources will be from o Domestic effluent o Process effluent o DM Plant and Boiler o Cooling tower blow down

High TDS/ COD and low TDS/ COD effluent shall be segregated at source. High TDS/ COD effluent will be chemically oxidized followed by evaporation. Separated salts will be disposed to CHWTSDF. Evaporated condensate and low TDS/ COD effluent shall be treated in conventional aeration system followed by clarification. Clarified treated effluent shall be passed through Pressure sand filter (PSF) and Activated carbon filter (ACF). It will be subsequently treated in RO unit so as to recover condensate for reuse. Existing ETP system is described in chapter 3 under water environment. Details of the proposed treatment scheme is described in chapter 4.

2.15.1.1 Non-Hazardous / Hazardous Waste Management

Details of the waste anticipated for the expansion is presented at tables below. Wastes have been categorized Nonhazardous waste and hazardous waste as per the Hazardous Waste (Management, Handling and Trans boundary Movement) Rules 2016.

Table 2.16 Non hazardous waste generation and disposal

No Waste Type UOM Existing Additional quantity

Total Disposal




Quantity (*)

1 Sand from water

filtration TPA 11 6.5 17.5

Sale to Authorized Vendor/ recycler/ re processor/ landhill

2 Used hand

gloves Cotton/ PVC/ Rubber

Pcs/A 20,000 5000 25,00

0 CHWTSDF/ Sale to Authorized

Vendor

3

Miscellaneous (Rubber & Teflon Gasket/ Packing/

Transmission Belt/ V Belt/ PP

/ FRP etc)

Kg/annum

500 500 1000 CHWTSDF/ Sale to Authorized

Vendor

4 Fly Ash TPD 30 0 30 Sale to Brick manufacturer/

Cement Manufacturer/ Authorized Vendor

* As per existing consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.07.2020 valid till 31.10.2021.

Table 2.17 Hazardous waste generation and disposal

No Waste Type

Category (as per

HW rules 2016)

UOM Existing Quantity

(*)

Additional quantity

Total Disposal

1 Used/ Spent

Oil 5.1 KL/A 12 3 15

Sale to Authorized Vendor/ recycler/ re

processor

2 Filter

residue 6.1 TPA 38 82 120

CHWTSDF/ Sale to Authorized Vendor/

recycler/ reprocessor

3 Tar 1.2 TPA 1500 0 1500 CHWTSDF/ Sale to

Authorized Vendor/ recycler/ reprocessor

4 Distillation

residue 20.3 TPA 613.2 1225 1838.2



5

Used, Empty containers/

barrels/ liners

33.1 Nos/A 7000 18000 25000 Sale to Authorized Vendor/ recycler/

reprocessor

6 ETP sludge from WWT

35.3 TPA 80 320 400 CHWTSDF

7 Evaporation

Residue/ ATFD salts

37.3 TPA 0 1200 1200 CHWTSDF

8 Spent

catalyst 19.2 TPA 5 15 20

CHWTSDF/ Sale to authorized reprocessor

9 Ion

exchange resin

35.2 TPA 1 0.5 1.5 Sale to Authorized

Vendor/ recycler/ re processor





2.15.1.2 Housekeeping

Prasol has a well-developed procedure for maintaining housekeeping in the various sections of the unit with supervisory control from process and safety departments at the site.

The facility is ISO 9001:2015, ISO 14001:2015 & OHSAS 18001: 2015 management systems certified.

Project proponent will extend the management procedure and systems for the expansion as well.

Some of the key points which shall be addressed are as below:

The passages, floors and stairways shall be kept in good condition.

Internal roads and major walkways as well as work areas shall be carpeted either by asphalt or paver blocks to minimize dusting as well as provide ease of transportation and movement.

Walkways shall be kept free from obstructions, as well as marked.

All equipment and auxiliaries, piping shall be labeled appropriately for easy identification

Piping Color code shall be followed.

Wastes shall be collected in separate containers with labels and marking in each department and sent to common waste collection area in the factory for disposal.

Spill Control procedures shall be developed.

Localized extraction and scrubbing facilities for dust and fumes will be installed.

2.15.1.3 Fire Fighting Facilities

With context to operational safety, Prasol has taken suitable safety measures with modern & adequate facilities for accident prevention and hazard control.

As can be anticipated from a unit of such a prestigious group, the factory shall be well-planned with respect to all necessary aspects of layout plan, equipment set-up, utilities and production facilities.

Majority of the production activities shall be automatically operated with PLC /

SCADA for plant automation with least risk factors and in checking hazards and potential risks of emergencies and minimizing chances of hazards due to manual error. These aspects provide inbuilt safety to the plant.

All sections of the factory shall be covered with fire hydrant system. Fire extinguishers will be provided at all necessary locations and of suitable type and capacity.

Flammable areas will be are classified as per applicable rules and protected by spark avoidance and flameproof electric fittings.

Project proponent will develop an on-site emergency plan to handle emergencies and accidents and upgrades it periodically.




In spite of available advance technologies for hazard control and safe operating procedures through automation, the unit will regularly carry out HAZOP and risk assessment studies through in house as well as external agencies to further upgrading the level of safety in the plant.

2.15.1.4 Occupational Health

Project proponent is aware about the issues of Occupational Health and Safety of the employees. All the necessary measures shall be planned for Occupational Health of the employees for the expansion. Routine medical examination of each person shall be carried out as a systematic program on a regular basis. Safe Operating Procedures (SOP) for different works/activities shall be in place. Safety details for different chemicals and activities shall be provided to the workers. Medical surveillance for the workers working in high risk zone shall be carried out regularly and annual report of the health status of workers for the same shall be maintained.

2.15.1.5 Health, Safety and Environment

The company is very much concerned in terms of health, safety and environment protection. The company has a “Health, Safety & Environment Policy” for taking care of the health and safety of its employees.

The following key safety measures are a part of the Health & Safety policy of the company and shall be followed for the expansion.

Safety Training shall be provided to the employees/contract workmen.

LDAR System for solvent shall be provided at appropriate places.

Safety Sirens with Alarm System in case of emergency will be provided.

Fire Hydrant System will be installed.

Fire Extinguishers will be placed as required.

Mock drills will be periodically conducted and factors like response time will be

evaluated.

First Aid Facility and training will be provided.

Personnel protective gears and equipment’s shall be provided to the employees and contract workmen.

Health check-ups will be organized at regular intervals.

Safety/ Health records and MSDS of all chemicals/products will be maintained.

2.15.1.6 Green Belt development plan

Existing green belt at site is proposed to enhance to meet the requirement of 33% prescribed by MoEFCC. Greenbelt development is an efficient mitigation measure for control/ prevention for Air pollution & Noise pollution. Plants play an important role in the absorption of certain pollutants and also act as barrier for noise propagation. The greenbelt landscape plan provides benefits to improve beautification. It also results in the prevention of land degradation due to construction activities; enhancing the canopy cover as a wind breaker wall and restrict the carry away of the PM outside the




premises as well as for noise abatement. After the expansion, regular assessment shall be done to see that greenbelt is growing adequately with all necessary works like dense plantation, rearing, irrigation, manuring, re-plantation (if required), pest control and other allied factors. Regular records of the greenbelt development as suggested in environmental monitoring plan (in subsequent section) shall be maintained.

The greenbelt development plan shall focus on the following objectives:

Reduce air pollution. Attenuate noise generated. Improve the general environment and aesthetics of the area. Provide suitable habitat for fauna. Control soil erosion.

2.15.2 Environmental Monitoring & Management

Prasol Chemicals Private Limited will formulate system for monitoring of stacks & ambient air quality, waste water & treated water through third party laboratory

recognized by MOEF&CC as followed for the site.

2.15.2.1 In-house Monitoring Capabilities

The facility has well established in-house quality control lab for wastewater quality parameter monitoring and other environmental related parameter monitoring.

2.15.2.2 Management System

The expansion will also adopt good manufacturing practices and other management systems such as ISO 9001, ISO 14001 & ISO 18001 as per its existing manufacturing units of the company.

It will identify safety, health and environment aspects and impacts as per the standard.

2.15.2.3 Risk of Technological Failure

Prasol is proposing to expand manufacturing capacity of synthetic organic chemicals.

Prasol has vast experience in manufacturing and developing various technologies and commercializing them successfully in the industrial operation for various types of specialty chemicals.

Hence risk of technological failure is minimal.

No recommendation of assessment of New and Untested Technology was given during appraisal stage; hence it is not carried out.


Chapter 3- Description of Environment


3 DESCRIPTION OF ENVIRONMENT

Every anthropogenic activity has some impact on the environment. More often it is harmful to the environment than individual. Consequently, there is a need to harmonize developmental activities with the environmental concerns. Environmental Impact Assessment (EIA) is one of the tools available with the planners to achieve the above-mentioned goal. It is desirable to ensure that the development options under consideration are sustainable. In doing so, environmental consequences must be characterized early in the project cycle and accounted for in the project design. The baseline data on the pre-installation status of the terrestrial environment covering Land environment, biological environment (flora & fauna) & socio-economic environment in the study area was collected by undertaking primary surveys through field visits, monitoring and laboratory analysis. Secondary data was collected from relevant agencies, such as Raigad town Planning, Forest Department and Directorate of Census Operations. The baseline data collected and generated, together with the relevant project activities will be considered for predicting the likely impacts of the project on the environment. Subsequently, an appropriate environmental management plan (EMP) will be presented to enable the project proponent to run the project within acceptable level of environmental impact and meet the compliance of the regulatory criteria (MOEF & CC’s Guidelines). An Environmental Impact Statement (EIS) will be ultimately made to summarize the post project status of the terrestrial environment, with the project proponent incorporating the suggested EMP measures. For the purpose of assessing the impacts, study area of 10 km radius around project site is identified for the EIA as per MOEF & CC guidelines. Baseline environmental study/monitoring is carried out during Summer 2019 (March-May) within 10 km radius of the project site to understand ambient air quality, water quality, soil quality, noise level, biological study and socio-economic status of study area.

3.1 Land Environment

3.1.1 Study area

Study area includes a buffer zone of 10 km around the central co-ordinate of

18°46'32.09"N and 73°18'9.17"E for M/s Prasol Chemicals Private Limited, Khalapur,

Dist. Raigad.

The area covering 10 km radius falls in the Khalapur, Karjat, Pen and Sudhagad tehsils of

Raigad District and Maval tehsil of Pune District in Maharashtra. Khopoli is the nearest

major town situated approximately 6.3 km towards North east of the project site.

Project site is located approximately 61 km from district headquarter; Alibag whereas 70

km away from the State capital Mumbai by road. Panvel is the nearest major city from

project site located approximately 36 km towards northwest.




Table below represents details of 10 km study area.

Table 3.1 Study area details of Prasol Chemicals Pvt Ltd

Study Area (Sq. km)

Geographical location (center co-ordinate for the study area)

329.81 Latitude Longitude

18°46'32.09"N 73°18'9.17"E

Geographical location of the project is represented in figure below.

Figure 3.1 Geographical Location of Prasol Chemicals Pvt Ltd




Figure 3.2 Map of Geographical Location of Study Area (10 km around project site)

3.1.2 Location and Topography

The project site is approximately 61 km far from District headquarter of Alibag city which is located towards West side. The project site is located approximately 81 km from Chhatrapati Shivaji Maharaj International Airport, Mumbai by road. The project site is reachable from a Mumbai Pune Expressway. It is situated beside Takai Adoshi Road. Khopoli is the nearest railway station located approximately 7.1 km away which is reachable by Pen Khopoli Road and NH 47. The study area consists of highly undulating terrain. One of the Ashtavinayak Ganesh temples located in Mahad, Adlabs Imagica, Lonawala and Khandala are some of the major tourist attraction places within study area.

The area covering 10 km radius is predominantly humid and mostly it exhibits tropical climate. The area shows predominant plantation of mango and coconut. Owing to the tropical climate and high rainfall, rice is the major crop seen within 10km radius.

3.1.3 Scope of work

1:50,000 scale mapping of Land Use/ Land Cover (LULC) with report delineation in the

buffer area of 10 km around the Project site.

Methodology

Software Used

ArcGIS 10.2.1

ERDAS IMAGINE 9.2




QGIS Chugiak (2.4 Desktop Version)

Global Mapper 13.0

Google Earth

Microsoft Office.

Satellite Data used

Satellite Data: RESOURCESAT-2 LISS- IV cloud free data

Satellite Sensor – L4FMX

Resolutions – 5.8 m

Satellite Images:

Path and Row – Path 94, Row 59 Sub scene C

Date of Pass: 15th February 2016

Ancillary Data: GIS and image-processing software are used to classify the image

and for delineating drainage and other features in the study area.

Overview of methodology

The satellite image procured from National Remote Sensing Centre (NRSC), Hyderabad

was in raw format and few pre-processing procedures (georeferencing) were adopted to

bring the image to the real-world coordinate system.

A buffer of 10 km is generated using ArcGIS 10.2.1 software from the center point of the

project site. This image is further used to study the landuse/ landcover of the project

under consideration. Standard image interpretation elements like tone, texture, shape,

size, association, shadow and pattern are useful to identify prominent LULC classes.

However, a reconnaissance survey visit to the project site is carried out to identify the

confusing and doubtful areas. Geographical coordinate of these locations was recorded

using a Global Positioning System (GPS).

To achieve planimetric accuracy, the remote sensing scene was rectified with respect to

SOI maps on 1:50,000 scales. The Ground Control Points (GCP) in the scene such as

railroad intersections, corners of water reservoirs, canals etc. were identified on the

image as well as on the reference map. Third order model was constructed and finally

registration of image was carried out with nearest neighborhood resampling taking map

as reference and one map registration was achieved.

ERDAS IMAGINE 9.2 is used primarily to process geospatial raster data that allows

preparing, displaying and enhancing digital images. It is possible to see features that

would not normally be visible and to locate geo-positions of features that would

otherwise be graphical with the help of ERDAS IMAGINE. This software is of particular

importance in vegetation analysis or linear feature extraction from the image.




Then the subset of image is taken according to the boundary of the study area. The digital

classification technique is used for the extraction of the landuse/ landcover information

from the imagery. Fourteen different landuse/ landcover classes have been identified in

the area under study.

GIS data creation

Satellite data for December month was classified using supervised classification

technique wherein maximum likelihood algorithm classifier is used for the analysis. A

truth table is generated taking 0.95 as the conversion threshold. After aggregation, the

final classified output is converted in raster format. The image is then converted in raster

format.

Raster data creation

The data classification is based on National Natural Resources Information System

(NNRIS) scheme of classification. The classification scheme is given in table below.

Table 3.2 Land Use Land Cover Classes

Level I Level II Level III

Habitation Residential Urban

Village Industrial Area Industrial Area

Agriculture Fallow land Fallow land

Agriculture Agriculture Plantation

Vegetation land

Scrub land Scrub land

Vegetation Degraded vegetation

Dense vegetation Secondary vegetation

Wasteland

Roads National Highways

Minor Roads Railway Rail Track

Mining Area Quarry Open land Open land

Water River

Stream River

Reservoir Ponds/Lakes

Reservoir Heritage Site, if any Heritage Site Heritage Site

3.1.4 Reconnaissance survey

Reconnaissance survey is an important aspect of GIS study that aids in differentiation of various land use classes. Field survey was carried out to understand the land use of the study area. Compared to the vegetation extracted from Satellite image the site showed lower percentage of vegetative cover. A number of land use features were identified and




geographical location was marked using GPS. Altogether 43 different locations were mapped within 10 km radius study area. These locations are shown in Figure below.

Figure 3.3 Map of GPS points in the study area

Table 3.3 GPS points showing Geographical coordinates

SrNo Latitude Longitude Description 1 18°45'30.20"N 73°23'36.94"E Habitation 2 18°45'27.05"N 73°22'38.76"E Scrub on both sides 3 18°45'25.99"N 73°22'18.04"E Khandala Lake 4 18°46'18.11"N 73°21'48.85"E Settlement near Khandala Tunnel 5 18°46'7.85"N 73°21'12.50"E Dense vegetation 6 18°47'8.67"N 73°20'35.84"E Khopoli Town 7 18°47'30.95"N 73°20'16.51"E Scrub on both sides 8 18°47'58.87"N 73°18'24.19"E Pen Khopoli Road, Mahad Phata near Niphan 9 18°48'37.67"N 73°18'3.40"E Varadvinayak Mahad Ganesh temple 10 18°49'15.79"N 73°17'58.09"E Bridge on Patalganga River 11 18°49'46.94"N 73°17'9.19"E Khalapur village 12 18°50'16.17"N 73°17'2.84"E Open land on both sides 13 18°51'18.09"N 73°16'32.17"E Junction at Paudh Kalote Phata 14 18°50'55.54"N 73°15'47.95"E Pond and plantation on left and open on right side in

Nadode Village settlement 15 18°50'34.40"N 73°14'29.07"E Industrial sheds 16 18°50'16.28"N 73°14'36.73"E Bridge above Expressway 17 18°49'22.48"N 73°15'1.95"E Kharsundi Industrial and village settlement 18 18°48'57.57"N 73°16'39.10"E Dhamni village and ponds nearby 19 18°47'44.20"N 73°16'53.19"E Indiabulls gated community on left Open space on right 20 18°46'57.84"N 73°15'26.17"E Donvat Reservoir 21 18°46'40.50"N 73°14'18.67"E Bridge on Balganga River




22 18°46'21.27"N 73°13'8.43"E Paddy fields 23 18°46'11.28"N 73°12'35.64"E Industrial shed and open space 24 18°46'0.68"N 73°15'0.72"E Paddy fields in Gorthan Kh village 25 18°44'54.93"N 73°15'8.77"E Paddy fields near Chilthan Village 26 18°44'40.02"N 73°16'27.90"E Industrial Shed and plantation near Ursoli Village 27 18°44'32.99"N 73°17'17.52"E Khambewadi village 28 18°43'42.66"N 73°17'44.01"E Mixed vegetation 29 18°42'58.57"N 73°17'59.38"E Dense vegetation 30 18°42'0.02"N 73°17'46.88"E Paddy fields in Durshet village 31 73°17'5.01"E 73°17'5.01"E Adlabs Imagica 32 18°46'30.55"N 73°17'14.05"E Parakh Foods industrial settlement 33 18°46'43.80"N 73°17'46.20"E Paddy fields and Brick kilns in Devnhave village 34 18°47'2.53"N 73°18'23.28"E Industrial establishments in Dheku village 35 18°46'32.13"N 73°18'12.54"E Prasol Chemicals Project site 36 18°46'0.36"N 73°19'8.93"E Atkargaon village 37 18°47'48.77"N 73°18'34.53"E Takai Village 38 18°50'3.65"N 73°14'55.55"E Bridge on Patalganga River 39 18°49'34.37"N 73°15'47.48"E Industrial sheds and scrub area 40 18°48'56.04"N 73°16'29.70"E Habitation and scrub area 41 18°47'59.53"N 73°17'10.44"E Khalapur Toll and Tata Steel Industry on left 42 18°46'7.10"N 73°20'26.72"E Mixed vegetation in Ghat section 43 18°46'4.85"N 73°23'23.72"E Lonawala habitation

3.1.5 Cartographic map layouts

A Survey of India (SOI) Toposheet with 1:50,000 scale is used to identify topographic features within 10 km radius around project site (see figure below). Survey of India toposheet numbers 47F1, 47F2, 47F5 and 47F6 cover the study area around proposed project site. Open series map of 10 km study area is enclosed as Annexure 3.1.




Source: Survey of India toposheet no. 47F1, 47F2, 47F5 and 47F6 covering 10km study area around proposed project site.

Figure 3.4 Survey of India Toposheet around Project site

3.1.6 Drainage maps

Drainage layer is generated after scanning the thematic manuscripts which is further

edited for line errors. Two different layers were made separately for line drainage.

Drainage order was given to all the drain lines in the layer. Strahler’s method of ordering

is used for giving order to drainage. Wherein the smallest permanent streams are

designated as the first order and the confluences of two first order streams give rise to

second order stream and so on. The order of trunk stream is not altered by the addition

of lower order. The order of the stream will increase only by the addition of streams of

same order.

The study area covering 10 km radius around project site exhibits majority of fourth

order drainage pattern as shown in figure below. Overall, the study area displays distinct

and dendritic drainage pattern. The study area shows drainage pattern wherein majority

of the streams flow towards south and contribute to Amba River, North and contribute to

Patalganga River whereas few streams are seen to flow towards west and merge into

Balganga River. Some of the minor streams that flow from the hilly terrain merge into

Ulhas River.




Source: Map based on RESOURCESAT-2 LISS- IV imagery from NRSA

Figure 3.5 Drainage map of 10 km radius area around Project Site

A detailed drainage map of the 500 m angular distance around project site is shown in figure above. The proposed project site is topographically positioned in a way that streams are passing away towards north of the project site. Amba River, Patalganga River, Ulhas River and Balganga River are some of the significant rivers within study area. Number of water bodies viz. Donavat Resrvoir, Kalote Rayati Dam, Adoshi Dam, Khandala Lake, Kune Dam, Ghotawade Dam, Bati lake etc. are located within study area. All the water bodies and river with sufficient width were put in a polygon layer and direction of Rivers and streams is shown in figures.





Figure 3.6 Drainage map of 500 m angular distance around Project Site

3.1.7 Contour maps

Thematic manuscript for contour layer was generated from Survey of India toposheet at 1:50,000 scale. After scanning, coverage was generated. Coverage was edited to remove all errors of dangle. Attribute value was given to each contour in the coverage.

A 5 m interval contour map is prepared for the area covering 10 km radius around the project site (see Figure below). As project site is located in the Sahyadri ranges it is observed that majority of the area is highly contoured and hilly. Overall terrain shows undulations and predominant hilly structures are visible throughout the study area. At some places contours are closely spaced and steep slopes are seen in many area. A number of small hills are spread across the study area whereas a dominant hill can be observed on the eastern half of the study area. Highest point within the 10 km radius area

around the project is 855 m above mean sea level whereas lowest point is at 15 m above mean sea level.





Figure 3.7 Contour map of 10 km radius area around Project Site

Detailed map of 1 m interval contour covering 500 m angular distance is shown in Figure below. The map exhibits contoured terrain towards east. Gentle slopes are visible at some locations whereas a number of concentric contours are seen within 500 m angular distance around project site. The contour map depicts presence of hilly structure just outside the project site towards east whereas flat terrain can be seen on north side of project site. Overall slope is of the area is towards the East. Highest point of this map is located in the North side of the project site at 110 m above mean sea level and the lowest point in the 500 m angular distance from project site is at 37 m above mean sea level towards East side. Project site shows variation in contour levels and highest point is

located close to the North Eastern periphery of the project site at 72 m whereas lowest point within the project site is located at 42 m towards west above mean sea level.





Figure 3.8 Contour map of 500 m angular distance around Project Site

3.1.8 Land use and land cover classes

Table 3.4 Defination of land use and land cover classes

No Class Class Definition

1. Dense vegetation It is an area (within the notified forest boundary) bearing an association predominantly of trees and other vegetation types capable of producing timber and other forest produce.

2. Moderate Dense Vegetation

It is described as a forest, which comprises of thick and dense canopy of tall trees, which predominantly remain green throughout the year. It includes both coniferous and tropical broad-leaved evergreen trees. Semi-evergreen forest is a mixture of both deciduous and evergreen trees, but the latter predominate.

3. Secondary Vegetation/Mixed Vegetation

It is described as openings amidst forests without any tree cover. It includes openings of assorted size and shapes as seen on the imagery.

4. Fallow Land

It is described as agricultural land which is taken up for cultivation but is temporarily allowed to rest un-cropped for one or more seasons, but not less than one year. These lands are particularly those which are seen devoid of crops at the time when the imagery is taken of both seasons.




5. Plantation

It is described as an area under agricultural tree crops, planted adopting certain agricultural management techniques. It includes tea, coffee, rubber, coconut, areca nut, citrus, orchards and other horticultural nurseries.

6. Scrub Land Scrub is a stunted tree or bush/shrubs.

7. Open land It is described as land area without any tree cover.

8. Mine/Quarry Mine / quarry areas subject to removal of different earth material (both surface and sub-surface) by manual and mechanized operations.

9. Residential Area (Rural and Urban)

It is defined as an area of human habitation developed due to non-agricultural use and that which has a cover of buildings, transport, communication utilities in association with water vegetation and vacant lands.

10. Industrial Area It is defined as an area of industrial activities.

11. Water body/ River

It is a course of flowing water on the land along definite channels. It includes from a small stream to a big river and its branches. It may be perennial or non-perennial.

12. Reservoir/Ponds It is a natural or man-made enclosed water body with a regulated flow of water. Reservoirs are larger than tanks/lakes and are used for generating electricity, irrigation and for flood control.

Source: http://mospi.nic.in/mospi_new/upload/ax0406.htm

Digital classification technique is used for the extraction of the landuse/landcover

information from the imagery. A landuse land cover map of 10 km radius around the

project site is prepared and the same is shown in figure below. Fourteen different

landuse/landcover classes have been identified in the area under study.

http://mospi.nic.in/mospi_new/upload/ax0406.htm




Source: 10KM lulc Map based on RESOURCESAT-2 LISS- IV imagery from NRSA

Figure 3.9 Land use/landcover map of 10 km radius area around Project Site

The area distributions along with percentage distribution of the different LULC classes

within the study area are shown in table and figure below.

Table 3.5 Landuse/ Landcover Statistics of the 10 km radius Area

No Class_Name Area (Ha) Area (Sq km) Distribution (%)

1 Scrub Land 9646.37 96.46 29.25

2 Open Land 8771 87.71 26.59

3 Mixed Vegetation 7017.88 70.18 21.28

4 Moderate Dense Vegetation 4348.63 43.49 13.19

5 Dense Vegetation 1141.94 11.42 3.46

6 Fallow Land 959.15 9.59 2.91

7 Urban Area 313.00 3.13 0.95

8 Agriculture 298.77 2.99 0.91

9 Industrial Area 137.57 1.38 0.42

10 Reservoir/Dam/Lakes 133.35 1.33 0.40

11 Barren Land 126.75 1.27 0.38

12 Quarry 68.24 0.68 0.21

13 Waterbody 50.52 0.51 0.15

14 Rural Area 18.21 0.18 0.06

Total Area 33031.38 330.32 100.16

Source: 10km LULC Map based on RESOURCESAT-2 LISS- IV imagery




Source: LULC Map based on RESOURCESAT-2 LISS- IV imagery and Land use/ Land cover Statistics for 10km area around site

Figure 3.10 Land use/land cover statistics of 10 km radius area around Project Site

Fourteen different land use land cover classes are extracted from the satellite image. The project site is located in the industrial area close to Mumbai Pune Expressway. As a result, Industrial area (0.42%) is seen amongst the other land use classes found within study area. Quarry area (0.21%) also includes small open quarries which are used to extract stone for construction and filling purposes. East and West side of the project site shows comparatively high altitude and that is the area where dense vegetation (3.46%) is predominantly observed. Moderate dense vegetation is predominantly seen within the study area contributing approximately 13.19% of the land cover and mixed vegetation covers near about 21.28% of the land cover within study area. Scrub land (29.25%) and open land (26.59%) are some of the dominant classes within study area. Kharif crop can be observed during site visit however satellite image shows it as Fallow land. Fallow land comprises of 2.91% of overall land use. At very few locations within the study area 0.91% agricultural area can be seen. Habitation covers rural settlement of 0.06% and there is urban settlement represents 0.40% area within 10km radius. A number of waterbodies located throughout the study area contributes to 0.15% of the land cover. Presence of Amba River, Ulhas River, Patalganga and Balganga River and their tributaries correspond to 0.15% of the land cover within the study area.

3.46%

13.17%

21.25%

29.20%

26.55%

0.38%

0.90% 2.90%

0.06% 0.21% 0.42% 0.95%0.40%0.15%

LULC Area statistics covering 10km angular distance around Prasol Chemicals Pvt. Ltd., at Honad, Taluka Khalapur, Dist. Raigad

Dense Vegetation

Moderate Dense Vegetation

Mixed Vegetation

Scrub Land

Open Land

Barren Land

Agriculture

Fallow Land

Rural Area

Quarry

Industrial Area

Urban Area

Reservoir/Dam/Lakes

Waterbody




Source: 500M LULC Map based on RESOURCESAT-2 LISS- IV imagery from NRSA

Figure 3.11 Land use/land cover map of 500 m angular distance around Project Site

Table 3.6 LULC Statistics of the 500 m angular distance around project site

Source: 10km LULC Map based on RESOURCESAT-2 LISS- IV imagery

Sr. No.

LULC Classes Area (Ha) Area (Sq

km) Distribution

(%) 1 Open Land 53.98 0.54 30.98 2 Scrub Land 31.68 0.32 18.18 3 Mixed Vegetation 29.84 0.30 17.12 4 Industrial Area 18.98 0.19 10.89 5 Moderate Dense Vegetation 19.69 0.20 11.30 6 Fallow Land 13.04 0.13 7.48 7 Agriculture 4.53 0.05 2.60 8 Rural Area 2.53 0.03 1.45 Total Area 174.26 1.74 100.00




Source: LULC Map based on RESOURCESAT-2 LISS- IV imagery dtd. 19th April 2019, Path 94, Row 59 and Land use/ Land cover Statistics for 500m area around site

Figure 3.12 Land use/land cover statistics of 500 m radius area around Project Site

A landuse landcover map covering 500 m angular distance around project site is also

prepared and shown in above figure. The map shows eight different landuse classes. Open land (30.98%) dominates the landuse pattern around 500 m angular distance from the project site. Scrub land is the second most dominant class contributing to 18.18% of the land cover. Mix vegetation (17.12%) and moderate dense vegetation (11.30%) are also predominant classes due to presence of hill towards East of project site. Since the project site is located near the industrial establishments, Industrial area encompasses 10.89% of the LULC pattern. A few village residences are located within 500 m angular distance surrounding project site which contributes to the Rural habitation (1.45%). Whereas patches of fallow land (7.48%) are also visible around the project site.

3.1.9 Detailed study area

A detailed map for the study area is prepared (See Figure 14) that indicates minor roads, State Highways, Village settlements, river and reservoir as well as heritage site. Project site is located in the close proximity of industrial establishments near Yashwantrao Chavan Express Way connecting Mumbai and Pune, MH State Highway 92, MH SH 104, MH SH 88 and National Highway 48. Takai-Adpshi Road, Savroli-Kharpada Road and Dnavat Road are some of the important roads within study area. Central Railway line of Kalyan Khopoli Branch is seen towards Northeast of project site. The site is located in the Khalapur Tehsil and falls under Raigad district. Few reservoirs and small local lakes/ponds are located within study area. Amba River, Patalganga River, Ulhas River and Balganga River are some of the significant rivers within study area. Number of water bodies viz. Donavat Resrvoir, Kalote Rayati Dam, Adoshi Dam, Khandala Lake, Kune Dam, Ghotawade Dam, Bati lake etc. are located within study area. Dukes Nose, Lonawala and khandala tourist destiations are located on the hilly terrain fall within the 10km radius

11.30%

17.12%

18.18%30.98%

2.60%7.48%

1.45%10.89%

LULC Area statistics covering 500 m angular distance around Prasol Chemicals Pvt. Ltd., at Honad, Taluka Khalapur, Dist. Raigad

Moderate Dense Vegetation

Mixed Vegetation

Scrub Land

Open Land

Agriculture

Fallow Land

Rural Area

Industrial Area




around project site. The mountains located in the study area shows dense vegetation whereas patches of Reserved Forest are seen throughout the study area. Varadvinayak Temple at Mahad which is one of the “Ashtavinayaka” and Adlabs Imagica are some of the major tourist attractions along with Lonawala and Khandala.

Source: Map based on RESOURCESAT-2 LISS- IV imagery from NRSA and SOI Toposheets.

Figure 3.13 Detailed map of 10 km radius study area around Project Site




Khandala Lake Hilly terrain around Lonawala

Lake at Mahad Varadvinayak temple

Mumbai Pune Express Way Donvat lake Open scrub within study area




Figure 3.14 Surrounding 10 km study area photographs

Adlabs imagica Rice plantation within study area

Dense vegetation, Dukes nose, Amrutanjan bridge

Expressway & Mixed vegetation

Khopoli town Prasol site




3.2 Soil Quality sampling

Soil quality reflects how well a soil performs the functions of maintaining biodiversity and Productivity, partitioning water and solute flow, filtering and buffering, nutrient cycling, and providing support for plants and other structures. Soil management has a major impact on soil quality. Representative soil samples were collected from the study area to assess the quality of soil. For studying the soil types and the soil characteristics, different sampling locations were selected to assess the existing soil condition representing various land use condition and geological features.

3.2.1 Methodology of Soil sampling

A number of parameters were determined, which are indicative of physical, chemical and

fertility characteristics. Sampling and analysis were conducted as per established standard methods and procedures prescribed in IS 2720 and ASTM.

Soil samples were collected by ramming a hand auger into the soil upto a depth of 90 cm. At each of the sampling location, soil samples were collected from three different depth viz. 30 cm, 60 cm and 90 cm below the surface and homogenized. The homogenized samples were then packed in a polythene plastic bag and sealed, and the sealed samples were sent to the Laboratory for analysis.

The project is located in village Honad by the Takai Adoshi road. Most of the land is back filled & leveled. The sampling locations were chosen based on their land use of study area. The parameters selected give basic information on type of soil, particle size distribution

and water retention.

3.2.2 Soil sampling Locations

Figure below shows the soil sampling locations in the study area map.




Figure 3.15 Soil sampling locations in 10 km study area

Figure 3.16 soil sampling photos




Table 3.7 Soil Analysis report

Sr. No.

Parameter Mahad village

Vadval village

Honad village

Yashwant nagar

Adoshi village

Chinchvali village

Sangadewadi village

Onsite

Soil type Agricultural Industrial 1 pH 6.71 6.81 7.04 7.82 6.89 6.84 6.81 6.43 2 Water content, % 4.52 5.82 3.13 3.4 5.47 4.68 5.82 4.26

3 Particle size, %

Clay 72.1 70.1 70 70.1 70 70.1 72.6 70.5 Silt 17.1 16.2 9 16.2 20 16.2 18.2 12.6

Fine sand 10.8 13.7 21 13.7 10 13.7 9.2 16.9 4 Texture Clay Clay Clay Clay Clay Clay Clay Clay 5 WHC, % 42.83 40.85 38.7 50.8 40.45 38.4 36.4 38.2 6 Organic Carbon, % 0.18 0.19 0.11 0.52 0.51 0.22 0.16 0.14 7 Organic Matter, % 0.306 0.33 0.196 0.896 1.01 0.38 0.27 0.24

8 Available Nitrogen,

Kg/ha 644 1890 250 189 189 189 280 144

9 Sulphate, mg/kg 26.25 37.5 31.7 2.6 55 42.6 40.1 34.8 10 Potassium as K, kg/ha 100 90 180 140 80 140 150 120 11 Chloride, mg/kg 77.99 92.2 85 63.8 35.45 72.6 92.6 71.4 12 Conductivity, µS/cm 270.5 300.2 730.25 486 320.8 312.4 326.4 244.1

13 Available Phosphorus,

kg/ha 68.24 56.3 110.8 79.1 68.24 28.9 52.8 28.6

14 SAR, % 16.73 16.3 5.7 16.3 16.73 16.3 18.2 14.2 15 CEC, Cmol/kg 140 120 100 110 90 120 130 90




Standard soil classification as per Handbook of Agriculture, Indian Council of Agricultural Research is as follows,

Table 3.8 Standard Soil Classification

No Soil Test Classification

1 pH Less than 4.5 : Extremely acidic

4.51 – 5.50 : Very strongly acidic

5.51 – 6.50 : Moderately acidic

6.51 – 7.30 : Neutral

7.31 – 7.80 : Slightly alkaline

7.81 – 8.50 : Moderately alkaline

8.51 – 9.00 : Strongly alkaline

9.01 and above : Very strongly alkaline

2 Salinity Electrical conductivity (µmhos/cm) (1 ppm = 640 µmhos/cm)

Up to 1.00 : Average

1.01 to 2.00 : Harmful to germination

2.01 to 3.00 : Harmful to crops (sensitive to salts)

3 Organic Carbon (%) Up to 0.2 : Very less

0.21 to 0.40 : Less

0.41 to 0.50 : Medium

0.51 to 0.80 : On an average sufficient

0.81 to 1.00 : Sufficient

> 1.0 : More than sufficient

4 Nitrogen (Kg/Ha) Up to 50 : Very less

51 – 100 : Less

101 – 150 : Good

151 – 300 : Better

More than 300 : Sufficient

5 Phosphorous (Kg/Ha) Up to 15 : Very less

16 – 30 : Less

31 – 50 : Medium

51 – 65 : On an average sufficient

66 – 80 : Sufficient

More than 80 : More than sufficient

6 Potash (Kg/ha) 0 – 120 : Very less

121 – 180 : Less

181 - 240 : Medium

241 - 300 : Average

301 – 360 : Better

More than 360 : More than sufficient

Source: Handbook of Agriculture, Indian Council of Agricultural Research

Observation and interpretation from results:

Soil in the area is mainly clay in texture.




pH of soil varies from 6.43 to 7.82 which is “Moderately acidic” to “Moderately

alkaline” in nature. Organic carbon is from 0.11% to 0.52% that is very less to on an average sufficient. Potash content in soil is varies from 80 to 180 kg/Ha i.e. very less to Less. Nitrogen of the soil is varies from 144 to 1890 kg/Ha i.e. good to sufficient. Phosphorus content is varies from 28.6 to 110.8 kg/Ha i.e. less to more than

sufficient.

3.3 Non- hazardous & Hazardous Waste Generation, Treatment and Disposal

Hazardous waste from existing manufacturing facility is disposed of as per valid existing consent to operate. Prasol is a member of Mumbai waste management limited facility (CHWTSDF).

Copy of CHWTSDF membership is attached as Annexure 3.2.

Table 3.9 Hazardous waste generated during 2017-18 and 2018-19

No Description Category UOM As per CTO*

Year 2017-18

Year 2018-19

Method of Disposal

1 Used/Spent Oil 5.1 KL/A

12 - - Sale to authorized reprocessor

2 Filter residue 6.1 TPA 38 43.19 59.69 CHWTSDF/ Sale to authorized reprocessor

3 Tar 1.2 TPA 1500 - 73.89 4 Distillation

residue 36.1 TPA 613.2 9.66 11.27

5 Used barrels 33.1 Nos/A

7000 - 4058 Sale to authorized reprocessor

6 ETP sludge 35.3 TPA 80 - 0.27 CHWTSDF 7 Spent catalyst 19.2 TPA 5 1.0 1.473 CHWTSDF/ Sale

to authorized reprocessor


3.4 Climate and Meteorology

3.4.1 Wind

Meteorology of the site and nearby areas is affected primarily by the presence of coastline about 47 km to the west of site and presence of hillocks in immediate vicinity. The prevailing micrometeorology at project site plays a vital role in transport and dispersion of air pollutants released into atmosphere. The persistence of the predominant wind direction and wind speed class during a particular time period at the project site will decide the direction and extent of the worst impact zone at that time. The prominent wind direction at project site during the study period (summer 2019) is from north east and north east east direction.




Wind rose diagram for project site is presented in Figure below, (which shows

predominant wind direction at site).

Figure 3.17 Wind Rose during summer 2019

3.4.2 Temperature profile

Temperature – Honad village falls near Khalapur in Raigad district which has warm & humid weather throughout the year. Temperature data of Khalapur is presented in Figure below.




Figure 3.18 Temperature Profile at Khalapur

Reference- https://www.meteoblue.com

3.4.3 Rainfall profile

The area receives rainfall for more than four months of the year, which provides main climatic variations. Out of total rainfall 90% is experienced during Monsoon season of

months June to September. The details of monthly precipitation observed at Khalapur is graphically represented in Figure below.

Figure 3.19 Rainfall profile

Reference- https://www.meteoblue.com




3.4.4 Inference

Climate being hot and humid, temperature inversion formation is less likely to happen. In monsoon season due to heavy rains huge surface water runoff is observed which goes mainly in the river Patalganga and Amba. Even though the region experiences heavy rains no flood like situations are observed, surrounding terrain is hilly and undulating and drains towards the Arabian Sea to the West. Wind speeds are also in range of low to moderate (monsoon season) hence storms are seldom phenomena.

3.5 Air Environment

3.5.1 Reconnaissance Survey

The prime objective of this AAQ study is to establish the existing regional background levels within study zone of project. Major sources of air pollution were identified as medium and small-scale units spread over surrounding 10 km area & traffic on Akai Adoshi and Mumbai Pune expressway, Mumbai- Pune NH04 and other roads near site.

Other miscellaneous sources were identified as burning of minor fuels and dust from

movement of traffic along rural roads. Minor sources are identified as low-quality fuels burnt in rural area and dust emanated from unpaved roads, brick kilns.

3.5.2 Methodology for Selection of Monitoring Locations

Ambient air quality status within the study area forms the baseline information over which the predicted impacts due to the project activities are to be superimposed.

Ambient air quality is assessed through a scientifically designed ambient air quality monitoring network based on the following considerations:

Meteorological conditions on synoptic scale.

Topography of the study area.

Representations of regional background levels.

Representations of plant site.

Representations of predominant and cross-sectional distribution in the downward direction.

Influence of the existing sources if any.

Inclusion of population zone and sensitive receptors including Ecological Sensitive areas, reserve forests to collect baseline.

Ambient Air Quality Monitoring (AAQM) stations were set up at 8 locations with due consideration of above-mentioned points. Table below and Figure overleaf give details of AAQM stations selected.

3.5.3 Baseline Ambient Air Monitoring Studies

The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, NH3, CO, H2S and nMHC at 8 locations in summer 2019 (March to May). PM10 & PM2.5 was monitored

on 24 hourly bases, gaseous parameters were monitored for 1/ 8/ 24 hourly (as per std)




bases using respirable High-Volume Sampler and standard methods prescribed by

APHA/IS. CO was monitored using handheld electronic meter (electro-chemical sensor). Table and Figure below give locations of air monitoring stations and bearing with respect to the sites.

Table 3.10 Details of Ambient Air Monitoring Stations

Location Aerial

Distance & Direction

Latitude Longitude Remarks

Onsite -- 18°46'32.09"N 73°18'9.17"E -- Mahad village 3.7 km to N 18°48'35.90"N 73°18'7.28"E Upwind

Yashwant nagar 2.5 km to NE 18°47'19.35"N 73°19'17.77"E Upwind Adoshi village 3.5 km to SE 18°45'34.53"N 73°19'50.40"E Crosswind Honad village 1.4 km to S 18°45'54.46"N 73°18'32.82"E Crosswind Sangadewadi

village 1.8 km to SW 18°46'1.95"N 73°17'17.73"E Downwind

Vadval village 3.2 km to W 18°46'39.86"N 73°16'24.80"E Downwind Chinchvali village 2 km to NW 18°47'11.22"N 73°17'11.38"E Crosswind

The statistical data for each location is given in Table below. Date wise results of AAQ data are presented in Annexure 3.3.

Figure 3.20 Photos of AAQM sampling




Figure 3.21 AAQM locations- closer view

Figure 3.22 AAQM locations- showing in 10 km study area


Chapter 3 – Description of the Environment


Table 3.11 Summarized AAQM Results - Summer 2019

Sr. No

Location PM10 PM2.5 SO2 NOX NH3 CO H2S nMHC µg/m3 µg/m3 µg/m3 µg/m3 µg/m3 mg/m3 µg/m3 ppm

1 On site

Min 59.8 25.7 11.7 19.1 14.0 0.20 <1.0 0.16 Max 73.0 31.4 15.1 24.6 21.5 0.45 <1.0 0.31

Average 66.1 28.4 13.4 21.7 17.6 0.32 <1.0 0.23 98th 72.6 31.2 15.0 24.5 21.0 0.44 <1.0 0.31

2 Mahad village

Min 60.9 25.6 11.9 19.2 13.7 0.18 <1.0 0.16 Max 75.2 31.1 15.5 25 20.6 0.44 <1.0 0.32

Average 66.5 27.9 13.9 22.4 17.7 0.31 <1.0 0.22 98th 74.9 31.0 15.3 24.7 20.6 0.43 <1.0 0.31

3 Yashwant

nagar

Min 57.2 24.0 11.5 18.6 13.5 0.20 <1.0 0.15 Max 68.2 28.8 14.2 22.7 19.4 0.40 <1.0 0.26

Average 62.3 26.2 12.9 20.8 16.9 0.27 <1.0 0.2 98th 67.7 28.5 14.2 22.7 19.3 0.38 <1.0 0.25

4

Adoshi village (ESA

village)

Min 57.3 24.1 11.4 18.2 13.7 0.18 <1.0 0.15 Max 67.8 28.5 14.3 22.8 19.8 0.33 <1.0 0.25

Average 63.0 26.3 12.8 20.6 16.2 0.25 <1.0 0.2 98th 67.2 28.3 14.2 22.7 19.7 0.33 <1.0 0.25

5 Honad village

Min 55.3 23.4 11.9 19.2 14.3 0.17 <1.0 0.15 Max 69.0 29.0 14.7 23.8 22.1 0.40 <1.0 0.31

Average 61.7 26.0 13.5 21.8 18.2 0.27 <1.0 0.2 98th 68.3 28.7 14.6 23.6 21.8 0.38 <1.0 0.29

6 Sangadewadi village

Min 55.2 23.2 11.6 18.7 14.3 0.18 <1.0 0.16 Max 68.2 28.7 14.9 24 22.1 0.37 <1.0 0.3

Average 62.3 26.2 13.3 21.3 17.8 0.27 <1.0 0.21 98th 67.8 28.4 14.9 23.8 21.6 0.36 <1.0 0.29

7 Vadval village

Min 54.1 22.2 10.8 17.1 11.5 0.17 <1.0 0.16 Max 69.6 28.5 14.3 22.7 14.3 0.36 <1.0 0.3

Average 62.6 25.7 12.8 20.2 12.9 0.25 <1.0 0.22 98th 69.3 28.4 14.3 22.7 14.3 0.36 <1.0 0.29

8 Chinchvali

village

Min 53.7 22.2 11.1 17.7 15.1 0.18 <1.0 0.15 Max 69.1 29 14.4 23.1 22.3 0.36 <1.0 0.27

Average 61.9 25.9 13.0 20.7 18.6 0.28 <1.0 0.2

98th 68.6 28.8 14.4 23.0 22.0 0.36 <1.0 0.26 NAAQ norms 100 60 80 80 400 4 - -

- Concentration of PM10 is varying from 53.7 μg/m3 to 75.2 μg/m3.

- Concentration of PM2.5 is varying from 22.2 μg/m3 to 31.4 μg/m3.

- Concentration of SO2 is varying from 10.8 μg/m3 to 15.5 μg/m3.

- Concentration of NOx is varying from 17.1 μg/m3 to 25.0 μg/m3.

- Concentration of Ammonia is varying from 11.5 μg/m3 to 22.3 μg/m3.

- Concentration of CO is varying from 0.17 mg/m3 to 0.45 mg/m3.

- Concentration of H2S is below detectable limit (DL– 1 μg/m3).




- nMHC values varying from 0.15 to 0.32 ppm.

Results are compared with National Ambient Air Quality Standards (NAAQ) in respect of monitored parameters as shown in Table below. As can be seen the results, ambient air is well within the NAAQS standards for Industrial and Residential areas.

Table 3.12 National Ambient Air Quality Standards (CPCB, 2009)

3.5.4 Onsite ambient air and workplace quality monitoring

Prasol carry out onsite ambient air quality and workplace monitoring once in a quarter at site for compliance assessment. Its results are tabulated below.

Table 3.13 Onsite Ambient Air Quality Monitoring Results

Location Main gate New land gate Main gate Gate no 4 Limits

# Unit

Sampling date

05.03.2019 05.03.2019 24.06.2019 24.06.2019

Parameter SO2 12.8 11.7 14.2 13.9 80 * µg/m3 NOX 16.6 15.9 18.5 18.1 80 * µg/m3

Pollutant Time

weighted Average

Concentration in ambient air Method of

measurement Industrial,

Residential, Rural and other

area

Ecologically sensitive Area

(Notified by Central Government

Particulate Matter <10mm or PM10, µg/m3

Annual *

24 hours**

60

100

60

100

Gravimetric TEOM Beta attenuation

Particulate Matter <2.5mm or PM2.5, µg/m3

Annual *

24 hours**

40

60

40

60

Gravimetric TEOM Beta attenuation

Sulphur Di oxide (SO2), µg/m3

Annual *

24 hours**

50

80

20

80

Improved West and Gaeke Method

UV - fluorescence

Nitrogen di oxide (NO2),

µg/m3

Annual *

24 hours**

40

80

30

80

Jacob & Hochheiser modified Method

Chemiluminescenc Carbon

Monoxide (CO) (mg/m3)

8 hours **

1 hour**

02

04

02

04

Non-dispersive infrared spectroscopy

Ammonia (NH3), µg/m3

Annual *

24 hours**

100

400

100

400

Chemiluminescence

Indophenol method




Location Main gate New land gate Main gate Gate no 4 Limits

# Unit

Sampling date

05.03.2019 05.03.2019 24.06.2019 24.06.2019

Parameter PM10 62.9 62.3 64.0 62.7 100 * µg/m3 PM2.5 20.7 20.1 21.6 20.9 60 * µg/m3

CO 0.22 0.21 BDL BDL 04 ** mg/m3 Ozone [O3] BDL BDL BDL BDL 180 ** µg/m3 Lead [Pb] BDL BDL 0.24 0.21 1.0 * µg/m3 Benzene

[C6H6] BDL BDL BDL BDL 05 *** µg/m3

Benzopyrene BDL BDL BDL BDL 01 *** ng/m3 Arsenic [As] BDL BDL BDL BDL 06 *** ng/m3 Nickel [Ni] BDL BDL BDL BDL 20 *** ng/m3

NH3 BDL BDL BDL BDL 400 * µg/m3

Reference

AESPL/LAB/A-19/03/13,

Date: 12/03/2019


Date: 12/03/2019


Date: 02/07/2019


Date: 02/07/2019

[#] Specified under National Ambient Air Quality Standards by CPCB [*] 24 hourly monitoring values; [**] 1 hourly monitoring values; [***] annually monitoring values; BDL-Below detection limit

Table 3.14 Workplace Air Quality Monitoring Results

Location Monitoring

date Parameter

Result (DL is in ppm)

Limit as per ACGIH (TLV)

Reference

IPH Plant 05.03.2019 Acetone BDL (DL 0.04) 750 ppm

AESPL/LAB/WP-19/03/01 to 05,

Date: 11/03/2019

DAA Plant 05.03.2019 Acetone BDL (DL 0.04) 750 ppm Chiller Plant

05.03.2019 Ammonia BDL (DL 0.05) 35 ppm 15 minutes

PPS Plant 05.03.2019 H2S BDL (DL – 6 µg/m3) 10 ppm ZDDP Plant

05.03.2019 H2S BDL (DL – 6 µg/m3) 10 ppm

DM Plant 24.06.2019 Acid mist BDL (DL 0.01) 1 mg/m3 (OSHA)


Date: 02/07/2019

DDA Plant 24.06.2019 Acetone BDL (DL 0.04) 750 ppm Chiller Plant


PPS Plant 24.06.2019 H2S BDL (DL – 6 µg/m3) 10 ppm ZDDP Plant

25.06.2019 H2S BDL (DL – 6 µg/m3) 10 ppm

DM Plant 28.09.2019 Acid mist BDL (DL 0.01) 1 mg/m3 (OSHA)


Date: 05/10/2019

DDA Plant 28.09.2019 Acetone BDL (DL 0.04) 750 ppm Chiller Plant


PPS Plant 28.09.2019 H2S 2.6 ppm 10 ppm ZDDP Plant

28.09.2019 H2S 2.2 ppm 10 ppm

All monitored results are within specified norm.

3.5.5 Stack monitoring

Prasol carry out stack monitoring once in a quarter at site for compliance assessment

purpose. Its results are tabulated below.




Table 3.15 Stack monitoring results

Location/Reference Parameter Unit Result Limit

16 TPH Boiler stack (Coal fired) sampling date 27.09.2019 (Ref No: AESPL/LAB/ST-19/09/68)

TPM mg/nm3 86.4 150 SO2 Kg/day 428 641 NOx ppm 40 50

Thermic fluid II heater stack sampling date 27.09.2019 (Ref No: AESPL/LAB/ST-19/09/69)

TPM mg/nm3 92.3 150 NOx ppm 42 50

Scrubber PPS Plant stack sampling date 28.09.2019 (Ref No: AESPL/LAB/ST-19/09/70)

H2S ppm 3.2 10

Scrubber ZDDP stack sampling date 28.09.2019 (Ref No: AESPL/LAB/ST-19/09/71)

H2S ppm 3.6 10

Thermic fluid II heater stack sampling date 24.06.2019 (Ref No: AESPL/LAB/ST-19/06/96)

TPM mg/nm3 82.4 150 NOx ppm 42 50

16 TPH Boiler stack (Coal fired) sampling date 24.06.2019 (Ref No: AESPL/LAB/ST-19/06/97)

TPM mg/nm3 72.8 150 NOx ppm 36 50

Scrubber PPS Plant stack sampling date 24.06.2019 (Ref No: AESPL/LAB/ST-19/06/98)

H2S ppm 3.6 10

DG set 250 KVA stack sampling date 24.06.2019 (Ref No: AESPL/LAB/ST-19/06/99)

TPM (mg/Nm3) 42.6 150 SO2 (kg/d) 4.73 13 NOx ppm 36 50

NMHC ppm 2 -


TPM (mg/Nm3) 58.4 150 SO2 (kg/d) 0.13 17 NOx ppm 38 50

mMHC ppm 4 -


TPM (mg/Nm3) 52.8 150 SO2 (kg/d) 0.12 -- NOx ppm 32 50

mMHC ppm 3 -

Diesel driven fire pump 1 stack sampling date 25.06.2019 (Ref No: AESPL/LAB/ST-19/06/102)

TPM (mg/Nm3) 38.2 150 SO2 (kg/d) 0. 24 -- NOx ppm 28 50

mMHC ppm ND -

3.6 Noise Environment

3.6.1 Noise Level Monitoring within study area

Noise levels were monitored at 8 locations i.e. onsite & nearby villages / on access routes during summer 2019 to judge impact of industrialization and transportation on ambient noise levels. The reports are as below:

Table 3.16 Noise Monitoring Results (Summer 2019)

No. Location/ Date of Survey Noise Level Leq dB(A)

Day Time

Norms* Night-time Norms*

Land Use: Industrial 1 Onsite 63.0 75 60.3 70

Land Use: Residential 2 Adoshi 55.0 55 49.0 45




3 Chinchvali 53.3 46.4 4 Honad 54.3 42.1 5 Mahad 64.8 46.7 6 Sangade 51.7 43.0 7 Vadval 53.6 47.9 8 Yashvantnagar 55.3 39.4

(*) Standard as prescribed in Schedule II of the Environment Protection Act, 1986.

Note: Day Time: 06.00 am to 10.00 pm, Nighttime: 10.00 pm to 06.00 am

Noise monitoring Observation in Industrial area

Data monitored in Industrial area (at site) is within specified limits during Day &

Nighttime.

Noise monitoring Observation in Residential area

Noise levels were found to be exceeding the standard at Mahad village and marginally at Yashwantnagar during daytime & Adoshi, Chinchvali, Mahad and Vadval village during nighttime. Exceedance of noise level is mainly due to nearby localized disturbances/ traffic.

3.6.2 Onsite noise monitoring results

Prasol carry out noise monitoring once in a quarter at site for compliance assessment purposes. Its results are tabulated below.

Table 3.17 Onsite noise monitoring results (March 2019)

Sr. No.

Location Noise Level Day Time

dB(A) Leq Noise Level Nighttime

dB(A) Leq 1. Main gate 57.2 53.8 2. PA Project 67.8 66.3 3. Scrap area 63.1 58.2 4. Workshop 64.5 63.1 5. Storeroom 62.9 61.7 6. Boiler house 69.4 68.8 7. Offside area 59.5 55.3 8. Gate no 2 59.3 55.1 9. Nitrogen area 71.0 68.9

10. Sulpher area 67.2 67.1 11. HG Plant 68.4 68.2 12. Warehouse 61.1 59.4 13. DAA Plant 71.5 69.4 14. Packing section 67.2 65.6 15. IPH Plant 69.6 69.3 16. Near compressor 71.8 69.5

Limit as per EP Act 75 70 Ref: AESPL/LAB/N-19/03/10, monitoring date 06.03.2019




Table 3.18 Onsite Noise Monitoring Results (June 2019)

Sr. No.

Location Noise Level Day Time

dB(A) Leq Noise Level Night

time dB(A) Leq

1. Main gate No – 1 73.1 69.4 2. PA Project Admin

building 71.5 69.7

3. Scrap area 70.1 65.9 4. Workshop 71.5 65.4 5. Storeroom 68.1 61.9 6. Boiler house 73.1 68.0 7. Offside area 60.5 57.5 8. Gate no 2 58.6 55.7 9. Nitrogen area 56.9 54.1

10. Sulpher area 58.5 54.5 11. HG Plant 63.7 59.8 12. Warehouse 65.9 61.6 13. DAA Plant 65.4 58.9 14. Packing section 64.7 59.2 15. IPH Plant 66.9 61.4 16. Near compressor 73.1 67.9

Limit as per EP Act 75 70 Ref: AESPL/LAB/N-19/06/105, Monitoring date 24.06.2019

Table 3.19 Onsite Noise Monitoring Results (June 2019)

All monitored results are within specified norm.

3.7 Water Environment

3.7.1 Onsite Water Environment

Existing fresh water requirement is 710 cmd. The freshwater requirement for existing facility is met from River Patalganga. The effluent generation from the facility is 132.6 cmd. (Domestic sewage is 21.6 cmd and trade effluent is 111 cmd.) Waste water is treated at combined effluent treatment plant and used within site.

Details of DG Sound Pressure Level dB(A)

Locations East West South North

DG-1 (250 KVA) 73.7 74.4 73.1 74.5

DG-2 (380 KVA) 72.8 73.8 72.4 73.2

DG-3 (625 KVA) 73.4 74.5 71.8 73.1

DG-4 (Diesel driven fire pump 1) 70.9 73.9 72.6 72.7

Ref: AESPL/LAB/N-19/06/108-111, Monitoring date 24.06.2019




3.7.1.1 Existing ETP details

a. Organic Treatment:

The treatment plant comprises of neutralization, primary settling, Biodegradation, secondary settling and tertiary treatment.

The details of the systems are mentioned below:

Primary treatment:

- Effluent from the manufacturing facility sent to equalization tank in Organic pit. pH is maintained between 8.0 to 8.5.

- Acid and alkali added as required for neutralization and Collected effluent pumped collection tank & the mixing is done by diffusing air from air blowers.

- The neutralized effluent is pumped through flocculation tank in which Alum and Poly electrolyte are added respectively for better coagulation and flocculation.

- Overflow of flocculation tank is taken into Settling tank where the sludge is settled down and clear overflow sent to Multigrade sand filter (MGSF).

- Settled sludge removed periodically from bottom of tank by pump and sent to filter press.

- Effluent from MSF pumped through Ozonator unit to reduce COD of effluent by Ozonation and collected in tank.

Secondary Treatment:

- Effluent from Ozonator sent to Aeration tank where mixing and oxygen transfer is

provided by fine bubble diffused aeration system by Air blower along with uniform mixing.

- Effluent from aeration tank sent to clarifier & the settled biomass from clarifier is recycled back to the aeration tank for maintaining MLSS concentration. Excess biomass is sent to sludge dewatering unit. The clear supernatant of the settling tank/ clarifier is overflow to intermediate collection tank for further treatment

Tertiary Treatment:

- Treated effluent from intermediate collection tank passed through PSF & ACF for removal of refractory COD.

- Treated effluent is collected in final treated tank to check parameter of effluent and transferred to Utility collection tank for combined treatment.

b. Inorganic Treatment:

- Effluent generated from Boiler blow down and cooling tower blow down is collected in Inorganic pit by gravity. Oil and grease is removed manually.

- Collected effluent pumped to Utility collection tank. The mixing is done by diffusing air from air blowers.

- Acid and Alkali is added as required for neutralization. - The neutralized effluent is pumped through flash mixer tank (FMT) in which Alum,

Polyelectrolyte, soda ash and lime are added respectively for better coagulation and flocculation.

- Overflow of flash mixing tank is taken in settling tank provided with plate settlers

to increase the rate of settling where the sludge is settled down and clear




supernatant of the settling tank is overflow to intermediate collection tank for

further treatment. - Settled sludge removed periodically from bottom of primary settling tank and sent

to filter press. - The sludge cake obtained from filter press is sent for disposal to MWML and

filtrate is sent back for further treatment to ETP. - Supernatant collected effluent is pumped & passed through MGSF and pumped to

ultra filtration (UF) system through 5 micron Cartridge filter. - Collected effluent pumped by feed pump to RO system by high pressure pump

through 5 micron Cartridge Filter with continuous dosing of Antiscalent (for removing hardness), SMBS (for removing free chlorine) and HCl (for pH adjustment).

- RO Permeate collected and pumped to softener plant which is used for Fire storage tank and process plants.

- RO reject water collected in tank and pumped to MEE for further process. MEE condensate recycled back within plant & and bottom residue disposed off to MWML.

Prasol routinely carry out treated water analysis (ETP outlet) for compliance assessment purposes. Its results are tabulated below.

Table 3.20 ETP Outlet Water Analysis

Sr. No.

Parameter Sample date 24.06.2019

Sample date 27.09.2019

Consent Limits

1 pH 7.42 6.78 5.5-8.5 2 SS, mg/l 32 12 < 100 3 COD, mg/l 100 10 < 250 4 BOD, mg/l 26 04 < 30 5 Oil & Grease, mg/l BDL(DL-0.8) BDL(DL-0.8) < 10 6 TDS, mg/l 80 90 < 2100 7 Chloride, mg/l 19 28 < 600 8 Sulphate, mg/l 8 12 < 1000

9 Phenolic compounds,

mg/l BDL (DL-0.05) BDL (DL-0.05) < 1

10 Bioassay, % 90%

survival 90%

survival

90% survival of fish after 96hr in 100 % effluent

Reference AESPL/LAB/W-

19/06/236, Date: 01/07/2019

AESPL/LAB/W-19/09/123, Date:

07/10/2019 --

Treated effluent results are well within consent limits.

3.7.2 Reconnaissance survey

The fresh water for domestic and industrial is sourced from Irrigation department (pumping from Patalganga river).

Majority of the study area (10 km around site) has an agriculture land use. Agriculture in the area is rain fed. Majority of villages in the study area get fresh water from dug/bore

wells.




3.7.3 Baseline water quality

Selected physico-chemical characteristic along with biological indicators of pollution are used to describe the baseline status of water environment and assessing impacts due to project activities.

3.7.3.1 Ground Water

Baseline Ground water sampling (summer 2019) collected at 8 locations for borewell & open/ dug well water.

Baseline Ground water results and sampling locations are presented below,

Figure 3.23 Ground Water Sampling Location

Figure 3.24 Ground Water Sampling Photos




Table 3.21 Ground Water Analysis Results

Sr. No

Parameter

Locations Limits as per IS 10500:2012

Prasol Borewell Well water Accepta

ble Permissibl

e Onsite Chinchvali Yashwant

nagar Vadval

Borewell Adoshi

Honad Sangde

wadi Mahad

1 Colour, Hazen

5 5 5 5 5 BDL(DL-5.0) 5 5 5 Max 15 Max

2 Odour Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeabl

e Agreeable

Agreeable

Agreeable

3 pH 6.62 7.69 7.07 7.16 8.36 7.11 7.51 7.94 6.5 – 8.5 No

Relaxation

4 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeabl

e Agreeable

Agreeable

Agreeable

5 Turbidity,

NTU 2 2 2 2 2 BDL(DL-2.0) 2 2 1 Max 5 Max

6 TDS, mg/l 424 278 448 250 308 445 355 280 500 Max 2000 Max

7 Aluminum, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01) BDL(DL-

0.01) BDL(DL-

0.01) 0.03 Max 0.2 Max

8 NH3(as

N), mg/l BDL(DL-0.5) BDL(DL-0.5) 0.5 0.5

BDL(DL-0.5)

BDL(DL-0.5) BDL(DL-

0.5) BDL(DL-0.5) 0.5 Max

No Relaxation

9 Detergent

s, mg/l BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1)

BDL(DL-0.1)

BDL(DL-0.1) BDL(DL-

0.1) BDL(DL-0.1) 0.2 Max 1.0 Max

10 Barium,

mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.7 Max No

Relaxation

11 Boron, mg/l

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)


0.05) BDL(DL-

0.05) 0.5 Max 2.4 Max

12 Calcium

as Ca, mg/l

12 19.2 35.2 37.6 37.6 12 73.6 46 75 Max 200 Max

13 Chloramines, mg/l

BDL(DL-2.0) BDL(DL-2.0) BDL(DL-2.0) BDL(DL-2.0) BDL(DL-

2.0) BDL(DL-2.0)

BDL(DL-2.0)

BDL(DL-2.0) 4.0 Max No

Relaxation

14 Chlorides,

mg/l 85 48 78 48 50 80 55 58 250 Max 1000 Max




Sr. No

Parameter



ble Permissibl


nagar Vadval

Borewell Adoshi

Honad Sangde

wadi Mahad

15 Copper,

mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.05 Max 1.5 Max

16 Fluoride,

mg/l 0.32 0.4 BDL(DL-0.2) 0.27 0.32 0.34

BDL(DL-0.2)

BDL(DL-0.2) 1.0 Max 1.5 Max

17 Free

ResCl2, mg/l


0.5) BDL(DL-0.5)

BDL(DL-0.5)

BDL(DL-0.5) 0.2 Min 1.0 Min

18 Iron, mg/l 0.08 0.2 0.02 0.19 0.09 0.11 0.08 0.03 1.0 Max No

Relaxation

19 Magnesium as Mg,

mg/l 65.2 32.6 49.9 19.7 21.1 63.8 7.2 19.2 30 Max 100 Max

20 Manganes

e, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.1 Max 0.3 Max

21 Mineral oil, mg/l


0.5) BDL(DL-0.5)

BDL(DL-0.5)


Relaxation

22 Nitrate,

mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5)

BDL(DL-0.5)

BDL(DL-0.5) BDL(DL-

0.5) BDL(DL-0.5) 45 Max

No Relaxation

23 Phenolic

comp, mg/l

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)


0.05) BDL(DL-

0.05) 0.001 Max

0.002 Max

24 Selenium,

mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.01 Max No

Relaxation

25 Silver, mg/l


0.1) BDL(DL-0.1)

BDL(DL-0.1)


Relaxation

26 Sulphate,

mg/l 54 42 58 38 56 52 50 34 200 Max 400 Max

27 Sulphide,

mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5)

BDL(DL-0.5)

BDL(DL-0.5) BDL(DL-

0.5) BDL(DL-0.5) 0.05 Max

No Relaxation




Sr. No

Parameter



ble Permissibl


nagar Vadval

Borewell Adoshi

Honad Sangde

wadi Mahad

28 Alkalinity, as CaCO3

mg/l 290 186 290 184 184 310 218 200 200 Max 600 Max

29 Hardness,

mg/l 302 184 296 176 182 314 214 196 200 Max 600 Max

30 Zinc, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

5 Max 15 Max

31 Cadmium,

mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.003 Max

No Relaxation

32 Cyanide,

mg/l BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-0.05)

BDL(DL-0.05)

BDL(DL-0.05)

0.05 Max No

Relaxation

33 Lead, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)


0.01) BDL(DL-

0.01) 0.01 Max

No Relaxation

34 Mercury,

mg/l BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) 0.001 Max

No Relaxation

35 Molybdenum, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)


0.01) BDL(DL-

0.01) 0.07 Max

No Relaxation

36 Nickel, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)


0.01) BDL(DL-

0.01) 0.02 Max

No Relaxation

37 PCB, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.0005Max

No Relaxation

38 PAH, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)


0.01) BDL(DL-

0.01) 0.0001M

ax No

Relaxation

39 Arsenic,

mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

0.01 Max 0.05 Max

40 Chromium, mg/l

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)

BDL(DL-0.01)


0.01) BDL(DL-

0.01) 0.05 Max

No Relaxation

41 Alachlor,

µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0)

BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 20 Max

No Relaxation




Sr. No

Parameter



ble Permissibl


nagar Vadval

Borewell Adoshi

Honad Sangde

wadi Mahad

42 Atrazine,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 2 Max

No Relaxation

43 Aldrin,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 0.03 Max

No Relaxation

44 Alpha

HCH, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0)

BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 0.01 Max

No Relaxation

45 Beta HCH,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 0.04 Max

No Relaxation

46 Butachlor

, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0)

BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 125 Max

No Relaxation

47 Chlorpyriphos, µg/l


1.0) BDL(DL-1.0)

BDL(DL-1.0)

BDL(DL-1.0) 30 Max No

Relaxation

48 Delta

HCH, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0)

BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 0.04 Max

No Relaxation

49 2,4DCPAA


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 30 Max

No Relaxation

50 DDT, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0)

BDL(DL-1.0)


Relaxation

51 Endosulphan, µg/l


1.0) BDL(DL-1.0)

BDL(DL-1.0)


Relaxation

52 Ethion,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 3 Max

No Relaxation

53 Lindane,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 2 Max

No Relaxation

54 Isoproturon, µg/l


1.0) BDL(DL-1.0)

BDL(DL-1.0)


Relaxation

55 Malathion


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 190 Max

No Relaxation




Sr. No

Parameter



ble Permissibl


nagar Vadval

Borewell Adoshi

Honad Sangde

wadi Mahad

56 Methyl

parathion, µg/l


1.0) BDL(DL-1.0)

BDL(DL-1.0)


Relaxation

57 Monocrot

ophos, µg/l


1.0) BDL(DL-1.0)

BDL(DL-1.0)


Relaxation

58 Phorate,


BDL(DL-1.0)

BDL(DL-1.0) BDL(DL-

1.0) BDL(DL-1.0) 2 Max

No Relaxation

59 Coliforms Absent Absent Absent Absent Absent Present Present Present Absent No

Relaxation

60 E-coli Absent Absent Absent Absent Absent Absent Absent Absent Absent No

Relaxation

61 Sodium as

Na mg/l 10 10 12 11 11 11 12 11 NS NS

62 Potassium as K mg/l

5 3 5 4 5 4 4 3 NS NS

63

Electrical Conductance at 25 °C, μS/cm

650 415 685 375 470 665 550 425 NS NS

Note: All parameters in mg/L except where specifically indicated (pH has no units) (NS: Not specified, BDL: Below Detection limit)




Observation:

Ground water quality is mostly within specified standards except presence of coliform at Well water Honad, Sangdewadi and Mahad probably due to sewage contamination.

3.7.3.2 Surface Water

Surface water samples were collected from 6 different locations of Patalganga river, 1 location from Amba river & 3 locations from Dam within 10 km study area. The location wise analysis results given in Table below,

o Patalganga river near Khalapur o Patalganga river near Niphan o Patalganga river near Khopoli Bus stand o Patalganga river near Dahivati Tarf o Patalganga river near Thanenhave o Patalganga river near Atkargaon o Amba river near Chavni o Dam water near Sangade village o Dam water near Atkargaon o Dam water near Usaroli

Figure 3.25 Surface Water Location




Figure 3.26 Surface Water Sampling Photos




Table 3.22 Surface Water Analysis Results

Sr. No. Parameter

Patalganga River Near

Khalapur village

Near Niphan village

Near Khopoli

Bus stand

Near Dahivati

tarf village

Near Thane nhave

Near Atkargaon

1 pH 6.97 6.94 7.02 7.22 7.12 7.08 2 Dissolved Oxygen, mg/l 6.4 6 6.2 5.9 6.6 6.5 3 BOD @25°C 3days, mg/l 4 12 10 12 6 8 4 Colour, Hazen units 5 BDL(DL-5.0) BDL(DL-5.0) BDL(DL-5.0) BDL(DL-5.0) BDL(DL-5.0) 5 Odour Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 6 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 7 TDS, mg/l 230 260 240 305 230 240 8 Hardness as CaCO3, mg/l 134 150 140 168 120 120 9 Ca as Ca, mg/l 30.4 35.2 34.4 40 32 21

10 Mg as Mg, mg/l 14 14.9 12.9 16.3 9.6 16.3

11 Copper as Cu, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

12 Iron as Fe, mg/l 0.02 0.02 0.02 0.06 1 0.02

13 Manganese as Mn, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

14 Chlorides as Cl-, mg/l 38 47 38 46 44 52 15 Sulphate as SO42-, mg/l 40 40 52 48 38 38 16 Nitrates as NO3-, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) 17 Fluorides as F-, mg/l BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2)

18 Phenolic compound, mg/l BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-0.05) BDL(DL-0.05)

19 Mercury (as Hg), mg/l BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-

0.001) BDL(DL-0.001) BDL(DL-0.001)

20 Cadmium as Cd, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)




Sr. No. Parameter


Khalapur village

Near Niphan village

Near Khopoli

Bus stand

Near Dahivati

tarf village

Near Thane nhave

Near Atkargaon

21 Selenium as Se, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

22 Arsenic as As, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

23 Cyanides as CN-, mg/l BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-0.05) BDL(DL-0.05)

24 Lead as Pb, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

25 Zinc as Zn, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

26 Hexavalent Cr, mg/l BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) 27 Anionic detergents, mg/l BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4)

28 PAH, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

29 Mineral oil, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5)

30 Barium as Ba, mg/l BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-

0.01) BDL(DL-0.01) BDL(DL-0.01)

31 Silver as Ag, mg/l BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) 32 Pesticides, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) 33 Insecticides, mg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) 34 Oil & Grease, mg/l BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) 35 Free Ammonia as N, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5)

36 Electrical Conductance at

25 °C, μS/cm 343 396 370 455 348 352

37 Sodium Adsorption Ratio,

% 12.3 32.9 16.1 70.3 11.8 8.2




Sr. No. Parameter


Khalapur village

Near Niphan village

Near Khopoli

Bus stand

Near Dahivati

tarf village

Near Thane nhave

Near Atkargaon

38 Boron (as B), mg/l BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-

0.05) BDL(DL-0.05) BDL(DL-0.05)

39 Sodium Percentage, % 0.0017 0.0006 0.0003 0.0045 0.0011 0.001 40 Coliforms >1600 > 1600 > 1600 >1600 70 > 1600 41 Sodium as Na (mg/l) 12 13 13 13 13 14 42 Potassium as K ( mg/l) 4 5 9 6 9 9 43 Alkalinity as CaCO3 (mg/l) 140 164 156 178 130 112

Cont…

Sr. No. Parameter Amba River Dam water

Chavni village Usaroli village Atkargaon village Sangade village 1 pH 7.4 7.45 7.49 7.84 2 Dissolved Oxygen, mg/l 6.4 6.3 6.4 6.5 3 BOD @25°C 3days, mg/l 30 8 10 18 4 Colour, Hazen units 5 BDL(DL-5.0) BDL(DL-5.0) BDL(DL-5.0) 5 Odour Agreeable Agreeable Agreeable Agreeable 6 Taste Agreeable Agreeable Agreeable Agreeable 7 TDS, mg/l 245 110 220 250 8 Hardness as CaCO3, mg/l 120 40 100 120 9 Ca as Ca, mg/l 21 8.8 30.4 32

10 Mg as Mg, mg/l 16.3 3.84 5.76 9.6 11 Copper as Cu, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 12 Iron as Fe, mg/l 0.07 0.06 0.08 0.07 13 Manganese as Mn, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 14 Chlorides as Cl-, mg/l 19 18 28 16 15 Sulphate as SO42-, mg/l 21 20 44 10 16 Nitrates as NO3-, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5)




Sr. No. Parameter Amba River Dam water

Chavni village Usaroli village Atkargaon village Sangade village 17 Fluorides as F-, mg/l BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) 18 Phenolic compound, mg/l BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) 19 Mercury (as Hg), mg/l BDL(DL-0.001) BDL(DL-0.001) BDL(DL-0.001) BDL(DL-0.001) 20 Cadmium as Cd, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 21 Selenium as Se, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 22 Arsenic as As, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 23 Cyanides as CN-, mg/l BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) 24 Lead as Pb, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 25 Zinc as Zn, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 26 Hexavalent Cr, mg/l BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) BDL(DL-0.2) 27 Anionic detergents, mg/l BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4) BDL(DL-0.4) 28 PAH, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 29 Mineral oil, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) 30 Barium as Ba, mg/l BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) BDL(DL-0.01) 31 Silver as Ag, mg/l BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) BDL(DL-0.1) 32 Pesticides, µg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) 33 Insecticides, mg/l BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) BDL(DL-1.0) 34 Oil & Grease, mg/l BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) BDL(DL-0.8) 35 Free Ammonia as N, mg/l BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) BDL(DL-0.5) 36 Electrical Conductance at 25 °C, μS/cm 378 164 328 390 37 Sodium Adsorption Ratio, % 15.2 18.2 15.2 11.2 38 Boron (as B), mg/l BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) BDL(DL-0.05) 39 Sodium Percentage, % 0.0036 0.0037 0.0036 0.0017 40 Coliforms >1600 540 920 350 41 Sodium as Na (mg/l) 14 12 14 10 42 Potassium as K ( mg/l) 6 8 9 8 43 Alkalinity as CaCO3 (mg/l) 225 52 120 245

Note: BDL- Below Detection Limit




Table 3.23 Class of Water as per IS 2296 – 1982

Parameter Classification for inland surface water

A B C D E pH 6.5 to 8.5 6.5 to 8.5 6.5 to 8.5 6.5 to 8.5 6.5 to 8.5

Dissolved Oxygen, mg/l, 6 5 4 4 NS BOD @20°C 5days 2 3 3 NS NS

Colour, Hazen units 10 300 300 NS NS

Odour Unobjectio

nable NS NS NS NS

Taste Agreeable NS NS NS NS TDS, mg/l 500 NS 1500 NS 2100

Electrical Conductance at 25 °C, μS

NS NS NS 1000 2250

Hardness as CaCO3 mg/l 300 NS NS NS NS Ca as CaCO3, mg/l 200 NS NS NS NS Mg as CaCO3, mg/l 100 NS NS NS NS Copper as Cu, mg/l 1.5 NS 1.5 NS NS

Iron as Fe, mg/l, 0.3 NS 50 NS NS Manganese as Mn, mg/l 0.5 NS NS NS NS

Chlorides as Cl, mg/l 250 NS 600 NS 600 Sulphate as SO4, mg/l 400 NS 400 NS 1000 Nitrates as NO3, mg/1 20 NS 50 NS NS Fluorides as F, mg/l 1.5 1.5 1.5 NS NS Phenolic comp, mg/l 0.002 0.05 0.005 NS NS

Mercury (as Hg), mg/l 0.001 NS NS NS NS Cadmium as Cd, mg/ 0.01 NS 0.01 NS NS Selenium as Se, mg/l 0.01 NS NS NS NS Arsenic as As, mg/l 0.05 0.2 0.2 NS NS

Cyanides as CN,mg/l 0.05 0.05 0.05 NS NS Lead as Pb, mg/l 0.1 NS 0.1 NS NS Zinc as Zn, mg/l, 15 NS 15 NS NS

Hexavalent Chromium, mg/l 0.05 1 0.05 NS NS Anionic detergents, mg/l 0.2 1 1 NS NS

PAH, mg/l 0.2 NS NS NS NS Mineral oil, mg/l 0.01 NS NS NS NS

Barium as Ba, mg/l 1 NS NS NS NS Silver as Ag, mg/l 0.05 NS NS NS NS

Pesticides Absent NS NS NS NS Selenium (as Se), mg/l NS NS 0.05 NS NS

Insecticide NS NS Absent NS NS Oil and Grease mg/l NS NS 0.1 0.1 NS

Free Ammonia (as N), mg/l NS NS NS 1.2 NS Sodium Adsorption Ratio,% NS NS NS NS 26

Boron (as B), mg/l NS NS NS NS 2 Sodium Percentage NS NS NS NS 60

Coliforms 50 500 5000 NS NS Sodium as Na (mg/l) NS NS NS NS NS




Parameter Classification for inland surface water

A B C D E Potassium as K ( mg/l) NS NS NS NS NS

Alkalinity as CaCO3 (mg/l) NS NS NS NS NS

Classification TYPE OF USE

CLASS A Drinking water source without conventional treatment but after disinfection.

CLASS B Outdoor bathing.

CLASS C Drinking water source with conventional treatment followed by disinfection

CLASS D Fish culture and wildlife propagation. CLASS E Irrigation, industrial cooling or controlled waste disposal.

Based on analysis, surface water analysis mainly falls under classification E.

3.8 Traffic details

Traffic study, type of vehicles plying, frequency of vehicles is an important parameter to

know the present traffic pattern of the study area and help to determine the carrying capacity of existing road due to the additional traffic due to the proposed project.

Transportation of raw materials and end products do affect surrounding environment.

Vehicles are of two types, passenger and commercial/goods vehicles. Passenger vehicles includes Buses, Taxies, Jeeps, Autorickshaws, two wheelers etc. and commercial/goods

vehicles includes Tempos, tankers, trucks and containers.

Road identification

Prasol site is located on Takai Adoshi Road.

Traffic survey is important study helps to find existing traffic density on the road and with reference to existing traffic so that estimation of future increment based on project in the

vehicle numbers as well as pollution levels due to the project.

Main approach road to the project site is Takai Adoshi Road. This road is connected to main Mumbai Pune expressway.

The road considered for traffic study was main approach road to site i.e. Takai Adoshi

road which is 2-way road.

Traffic survey was carried out on this road at Prasol site.

Methodology

Traffic survey was carried out on both sides (up & down) on the road. Vehicles were classified into two types i.e. mechanized (car/ trucks/ buses/ jeeps/ tractors/ tankers/ containers/ two wheelers/ autorickshaws) and non-mechanized vehicles (Cycle/carts).




Table 3.24 Existing traffic (8 am to 6 pm)

Road name

Traffic flow

mechanized vehicles non-

mechanized vehicles

Total 2 W 3 W 4 W 2 W 4 W

Bike/ Scoote

r Auto Car Bus

Truck/ tanker/

Container/ trailer

Tractor /

tempo Bicycle Cart

Takai Adoshi road

Up 380 195 340 60 127 38 167 62 1369 Down 414 210 375 65 135 46 175 70 1490 Total 794 405 715 125 262 84 342 132 2859

Up– Towards Adoshi, Down– Towards Takai

Table 3.25 Existing traffic: PCU/Hour on Takai Adoshi Road

Sampling point At Prasol site Road Takai Adoshi Road

Vehicle type No of

vehicles Equivalent

factor* PCU PCU/Hr

Two Wheelers MotorCycle or scooter

794 0.75 596 60

Auto-rickshaw 405 2.0 810 81 Passenger car, pick-up

van 715 1.0 715 72

Bus 125 3.7 463 46 Truck / tanker/

container/ trailer 262 5.0 1310 131

Tractor/Tempo 84 5.0 420 42 Bicycle 342 0.5 171 17

Cart 132 2.0 264 26 Total 2859 - 4749 475

Equivalent Factor* - based on percentage composition of vehicle type in traffic stream (10% and above as per IRC: 106-1990 & IRC 64:1990)

3.9 Biological Environment

3.9.1 Bio-geographical Setting of Raigad District

District Raigad is one of the costal districts of Konkan region of Maharashtra, spread over an area of 7152 km2. It shows variation in topography from high altitudinal Sahyadri hill ranges to coastal plains. The soils of the district are formed from the predominating rock formation i.e. Deccan Trap. According to the topographical situation and location, soils in Raigad district are grouped as Forest, Varkas, Rice, Khar or Salt, Coastal Alluvial and Laterite soils. District receives average 3029 mm annual rainfall mostly contributed by southwesterly monsoon. These climatic and edaphic conditions support different types of forests. As per Champion and Seth’s classification, following forest types are generally found in the district.




Moist Mixed Deciduous Forests: These are found on the hill slopes and valleys,

dominant species in this type are Pterocarpus marsupium (Bija), Salmalia malabaricum (Semal), Terminalaia bellarica (Behada), Dalbergia latifolia (Shishum), Syzigium cumini (Jambul), Terminalia tomentosa (Ain), Lagerstremia parviflora (Bondara) etc.

Southern Tropical Semi-Evergreen Forests: Forests of this type occur mostly on upper hill slope from 450 meters to 1050 meters above the MSL. In Western Ghats dominant species are Terminalia paniculata (Kinjal), Memocylon umbellatum (Anjani), Terminalia chebula (Hirda), Syzigium cumini (Jambul), Olea diocea (Parjamun), Mangifera indica (Mango), Actinodaphne hookeri (Pisa), etc.

Littoral and Swamp Forests: These are found along the creeks and estuaries. Vegetation here is adapted for saline environment. Although comparatively area under cover is

marginal, these forests are important for protection of seacoast and marine life. Prominent species are Avicennia sp., Rhizophora mucronata and Sonneratia sp. Some associated species are also found.

According to ‘India State of Forest Report, 2019’, Forest Survey of India; forest cover in Raigad district is about 41% of geographical area. Area (km2) distribution of forest cover is presented below:

Table 3.26 Forest Cover in Raigad District

Geographical Area

Very Dense Forest

Moderately Dense Forest

Open Forest

Total Scrub

7,152 13 1,250 1,676 2,939 78

Forest cover in terms of canopy density is classified in very dense, moderately dense, open and scrub forest. Defining criteria of each class is given below.

Very Dense Forest: - All lands with tree canopy density of 70% and above

Moderately Dense Forest: - All lands with tree canopy density of 40% or more but less than 70%

Open Forest: - All lands with tree canopy density of 10% or more but less than 40%

Scrub Forest: - Degraded forest lands with canopy density less than 10%

District level forest cover data extracted from 9 reports spanning from year 2001 to 2019

reveals following:




Figure 3.27 Percent total area under forest cover across years




Figure 3.28 Types of vegetation cove across year

it is noticed from above, ‘Very Dense’ cover decrease sharply leading to increase in ‘Open’ area which, gets stabilizes due to plantation efforts made by forest department. This is supported by the fact that, ‘Moderately Dense’ area increased and stabilized afterwards. Thus, overall forest cover is increased after 2013.

Besides this, some areas are designated as ‘Protected Area’ under Wildlife Protection Act 1972; such as Karnala Bird Sanctuary, Phansad Wildlife Sanctuary and Sudhagad Wildlife Sanctuary.

Village map of Khalapur Taluka and extent of study area is shown below.




Figure 3.29 Map Showing villages in Khalapur Taluka of Raigad District & Study Area (Green Circle)

3.9.2 Baseline Studies in Study Area

Study area is area within radial distance of 10 Km from proposed site. It encompasses part of Khalapur, small parts of Sudhagad and Pen, talukas of Raigad district and part of Maval Taluka of Pune District. According to bio-geographic zone classification of India, entire study area falls under ‘Western Ghats’. Villages like Adoshi, Tuksai, Tondali, Chavani, Karambeli, Khambewadi, Talashi, Parkhande, Kalote Rayti, Kalote Mokashi, Ghodivali, Gohe, Jambrung and Ubervira, Kune are listed as Eco-Sensitive Areas (ESA) in Order under section 5 of EP Act 1986 dated 13th November 2013, draft Notification dated 10th March 2014, 4th September 2015, 27th February 2017 and 03rd October 2018 issued by Ministry of Environment, Forest & Climate Change (MoEFCC). Nearest ESA, Adoshi

village is about 2.2 km towards SE. Distance map is enclosed in Annexure 3.4(a).




Figure 3.30 Extent of Study Area (Red circle)

Ecology & Biodiversity study pertaining to Environmental Impact Assessment report for expansion of synthetic organic chemical manufacturing unit of Prasol Chemical Pvt. Ltd. was carried out in Summer 2019.

Survey Methodology: The study was carried out by visiting locations at dusk, day and dawn, taking care that representative locations of all habitats were covered. Geographical coordinates were marked at important locations and geo-tagged photographic evidences were collected using Global Positioning System. Villages falling within eco-sensitive area

were also visited to understand the biodiversity. Listing of species was done based on actual sighting, interviewing locals, indirect evidences, Literature survey, data collected from forest officials and internet references. To ensure maximum coverage of faunal species, observations were made 1.5 to 2 Km beyond study area.

During survey, total 16 locations (4 in each habitat) were visited for phyto-sociological studies. 10m X 10m quadrant for trees, 5m X 5m for shrubs & 1m X 1m for herbs were established. Data collected is used to determine Species Richness, Species Composition and Shannon-Weiner Diversity Index by standard methods. Survey tracks and waypoints are marked on Goggle Earth and presented below.




Figure 3.31 Way Points & Survey Tracks

Field visits reveal that, study area has undulating terrain as commonly seen in Konkan region. Besides dense vegetation on hills /Reserved Forest, study area contains habitats like, water bodies, agricultural fields and human settlements. These habitats possess different characteristic which supports typical composition of flora and fauna within them. Occurrences of species in respective habitats are presented in table below.

A) Dense Vegetation: Natural vegetation along hill slopes was noticed within study area. Most of these hills have either tapering crown or open plateau with hardly any trees.

Often it was observed that, vertical continuity of vegetation disturbs as slope becomes steeper intermittently and appears as barren patches along slope. Except some human settlements, most of the forest areas are inaccessible to human and remained untouched due to dense vegetation and topography. This supports good vegetation cover. Tectona, Bombax, species of Terminalia, Firmiana colorata, Holarrhena antidysenterica, Meyna laxiflora, Mangifera indicca were found dominant similarly, faunal species generally noted are Bulbuls, Kingfisher, Drongo, Jungle babblers, evidences of black napped hare in ‘Dense Vegetation’. According to species composition, it can be classified as Moist Mixed Deciduous forest. Trees were observed to be infested by pests at some places however, at places where human interference is less, presence of lianas indicates stable and healthy forest ecosystem.




Figure 3.32 View of Dense Vegetation in Study Area

At few places like, near Sangade, Forest Department (Alibag Division, Khalapur Range)

has done plantation of number of plants of Embilica officinalis and Eucalyptus sp.




Figure 3.33 Plantation by Forest Department near Sangade

The forest department has put-up display boards at some places in study area, appealing public to conserve natural wealth and importance of wildlife for awareness. Additionally, some trust also undertaken plantation drive at many places.

Vegetated hills at many places are notified as Reserve Forests. Details of reserve forests

in vicinity are obtained from Khalapur Range Forest Office, department of forest and revenue, government of Maharashtra, same are reproduced below:

Table 3.27 Details of reserve forests in study area

Sr. No.

Round Beat Place Type of Forest Area (ha.)

1 Khalapur Khalapur Ghodivali, Navandhe

Reserve Forest Comp. No.511 272.81.83

2 Khalapur Bid Khurd Bid Chichavali Terfe Atgaon

Reserve Forest Comp. No.512 168.01.51

3 Khalapur Jamrung Jamrung Reserve Forest Comp. No.514 250.87.43

4 Khalapur Kharsundi Dhamani,

Kumbhivali Reserve Forest Comp. No.516 155.18.65

5 Khalapur Madap Madap Reserve Forest Comp. No.518,

519 303.76.67

6 Umbra Umbra Umbra Reserve Forest Comp.

No.468,469 565.00.00

7 Umbra Tuksai Doorshet Reserve Forest Comp.

No.470 142.85.38

8 Umbra Tuksai Tuksai Reserve Forest Comp. no. 466 200.00.00 9 Umbra Chavani N. Chavani N. Reserve Forest Comp. 460 289.00.00

10 Umbra Chavani N. Chavani N. Reserve Forest Comp. 463 188.00.00 11 Umbra Chavani N. Chavani N. Reserve Forest Comp. 464,465 523.00.00

12 Shirvali Horale Horale, Apti,

Parkhade Reserve Forest Comp.498 370.91.00

13 Shirvali Horale Tambati Reserve Forest Comp. 499 156.98.81 14 Chilthan Sangade Sangade Reserve Forest Comp. 467 235.68.85 15 Chilthan Khanav Khanav Reserve Forest Comp. 472 225.85.47 16 Chilthan Khanav Tondali Reserve Forest Comp.473 199.01.38 17 Chilthan Khanav Tondali Reserve Forest Comp. 474 94.04.62 18 Chilthan Chilthan Chilthan Acquired Forest Sr No.133 147.41.30. 19 Chilthan Chilthan Ujloli Acquired Forest Sr No. 13/1 133.43.10




Sr. No.

Round Beat Place Type of Forest Area (ha.)

20 Chilthan Chiltan Narangi Acquired Forest Sr No. 12.46.20 21 Chilthan Chiltan Gohe Acquired Forest Sr No. 1.52.00 22 Chilthan Khanav Khanav Acquired Forest Sr. No. 4.63.70

In addition to Dense Vegetation, open plateaus, small hillocks, scrub lands were also studied.

Human interfering activities such as quarrying, chopping trees for firewood, manmade forest fires and tree cutting, operating water park, sporadic unorganized industrial units emitting gaseous pollutants closed to reserve forest were observed during survey. These activities exert pressure or adversely affect reserve forests nearby. Cutting/ blasting of

hill and stone crushing unit close to dense vegetation (for widening of roads) near village Anjrun (about 2.5Km towards W of ESA village, Jambrung), Kalote Mokashi (about 1.3Km towards NW of ESA village, Kalote Mokashi) and other few places in study area causing threat to wildlife in surrounding along with heavy dust load on leaves. Widening of Khopoli-Pali road also taken a toll on avenue trees, mass tree cutting was observed near Umbare and Tuksai closed to reserve forest (about 1.3Km towards NE of ESA village,

Khambewadi). Road widening activities has also increased dust load on surrounding flora. Firewood collection and cattle grazing are common practices in villages but, this may call for man-animal conflict especially abating reserve forests. Setting selected forest patch on fire also noticed near Sangade and few other places. Such fires destroy ground flora, herbaceous vegetation, soil microflora and fauna and even trees up to some extent. This directly pose threat to wildlife, vegetation and overall ecosystem of reserve forest.

Figure 3.34 Forest fire near Sangade




Figure 3.35 Tree cutting near Umbare and Tuksai for ongoing road widening

Figure 3.36 Firewood collection




Figure 3.37 Hill cutting/ blasting and stone crushing unit near Anjrun

Figure 3.38 Cattle Grazing

Figure 3.39 Industrial units Emitting Continuously

Phyto-sociological study reveals herbs species dominated followed by trees and then shrubs. Diversity index is moderate. Species composition of trees, shrubs, herbs and climbers at each location are presented below.




Figure 3.40 Graph showing tree species composition in dense vegetation

Figure 3.41Graph showing shrub species composition in dense vegetation

Figure 3.42 Graph showing herb species composition in dense vegetation




Figure 3.43 Graph showing overall composition in dense vegetation

Shannon-Weiner diversity index is presented below:

Table 3.28 Diversity index in dense vegetation

Trees 1 2 3 4

Species Richness 4.00 8.00 8.00 11.00

Diversity Index 1.21 2.03 1.91 2.27

Shrubs 1 2 3 4



Herbs 1 2 3 4



Figure 3.44 Graphical representation of diversity index in dense vegetation

B) Human Settlements: Human habitation in study area is rural in nature. Villages in

study area are found situated at base of hills and along major roads. Small part of village/




hamlet often, called “Wadi/ Pada” may situated middle/plateau of hill. Typical plant

species are grown in and around habituated areas. These species are intentionally planted for the purpose of beautification, shade, protection from stray/grazing animals and for food value. Similarly, faunal species of interest such as cattle, domestic animals/ birds were inhabited. Besides these, gardens developed in housing colonies and green belt in industries shows artificial plantation of species. These exhibit different kinds of species composition. Open spaces/ waste areas, plants exist naturally, both supports respective fauna and constitutes part of biodiversity. For the purpose of listing the species; such open/waste area adjacent to human settlement, roadside plantation etc. are also considered in this habitat.

Figure 3.45 Typical human habitat in Study Area




Figure 3.46 Huge colony of flying fox observed in Khopoli town

Figure 3.47 Typical flora-fauna/ plantation in human settlements

Phyto-sociological study reveals trees, shrubs and herbs contribute flora almost equally.

This may be because of intentionally planted species. Diversity index is moderate. Species

composition of trees, shrubs, herbs and climbers at each location are presented below.




Figure 3.48 Graph showing tree species composition in human settlement

Figure 3.49Graph showing shrub species composition in human settlement

Figure 3.50 Graph showing herb species composition in human settlement




Figure 3.51 Graph showing overall composition in human settlement


Table 3.29 Diversity index in human settlement

Trees 1 2 3 4

Species Richness 8 7 12 5


Shrubs 1 2 3 4



Herbs 1 2 3 4



Figure 3.52 Graphical representation of diversity index in human settlement

C) Agricultural Fields: Agricultural fields in study area are seen towards foothills and in between open area. Total agricultural land in study area contributes about 0.91%. Major crop in the region is Rice, however secondary crops like Wari, Nagali etc are grown. In




addition to agriculture crops, vegetable and horticultural crops growing and animal

husbandry are also practiced in study area.

Agriculture is rainfed in major part of study area. But, at some places, like Kalote Rayti, Gorthan Khurd double cropping was observed. Although, second crop is Rice, water requirement is met through natural stream which get water from overflow of Kalote reservoir and Donvat dam respectively.

Figure 3.53 Agriculture fields

Figure 3.54 Standing Rice crop during survey in Kalote Rayti and Gorthan Khurd




Figure 3.55 Horticulture, and animal husbandry in study area

Introduction of new/ non-native, non-routine species for commercial plantation/ agriculture has also bearing on biodiversity as it has potential to replace set of associated fauna and floral members from the region. In hostile conditions, replaced species may even reach up-to verge of locally extinct.

Agriculture flora supports corresponding members of fauna in study area. For the purpose of listing of species; areas adjacent to fields, orchards and vegetation on fallow/

open lands are also included.

Phyto-sociological study reveals herbs contribute flora majorly, followed by shrubs. This may be due to paddy crop and cultivation/vegetable farms where, crop is herbaceous in nature in majority cases. Diversity index is moderate to poor. Species composition of

trees, shrubs, herbs and climbers at each location are presented below.




Figure 3.56 Graph showing tree species composition in agriculture

Figure 3.57 Graph showing shrub species composition in agriculture

Figure 3.58 Graph showing herb species composition in agriculture




Table 3.30 Graph showing overall composition in agriculture


Table 3.31 Diversity index in agriculture

Trees 1 2 3 4 Species Richness 4.00 4.00 6.00 4.00 Diversity Index 1.21 1.33 1.64 1.24

Shrubs 1 2 3 4 Species Richness 3.00 2.00 2.00 2.00 Diversity Index 0.72 0.41 0.66 0.30

Herbs 1 2 3 4 Species Richness 5.00 3.00 3.00 6.00 Diversity Index 1.40 1.03 0.85 1.58

Table 3.32 Graphical representation of diversity index in agriculture

D) Water Bodies: Drainage in the area is mainly through Patalganga and Amba River. Due to undulating terrain, number of stream/ nallah and other small rivers flow downhill




and joins the river. River Patalganga and Amba are major sources of water in study area.

During its course it bifurcates and rejoins the mainstream at few places, forming islands. These islands possess herbaceous to tree vegetation depending upon soil cover. Species like Polygonum glabrum, Ipomoea carnea, Pongamia pinnata etc. were dominant along riverbanks and on islands. Three major reservoirs/ dams viz. Donvat, Kalote and Honad are sources of drinking water. Flocks of birds like Cormorant, Egrets etc. were observed perching on trees/rock outcrops here during survey. Open bill storks were found in large number at Kalote reservoir. Evergreen vegetation cover, availability of food and water and comparatively undisturbed nature of this place makes it suitable habitat for these birds.

Figure 3.59 View of Honad dam and lake in Khopoli

Figure 3.60 View of dried rivulet near Chani and rivulet of Patalganag near

Khopoli




Figure 3.61 View of Adoshi dam and dried stream near Madap

Figure 3.62 Vegetation along rivulet

Human interference like brick kilns on riverbank, washing vehicles, dumping garbage and setting it on fire, establishing elite resorts right on bank of water bodies are degrading water quality resulting in disturbing aquatic ecology.

Figure 3.63 Dumping of domestic waste on bank of Donvat dam

Small scale/ own consumption fishing is observed (in Donvat dam) during survey. Fishing

is done by hooks & by deploying small floating net depending upon location. Trawling is




not possible because of lack of navigable channel owing to shallow depth and rock

outcrops.

Figure 3.64 Fishing near Palasdari and in Donvat dam




Figure 3.65 Fish species occur in study area

Figure 3.66 View of Kalote dam and flock of Asian open bill storks hovering over it




Figure 3.67 Fauna associated with Water Body

Figure 3.68 Flora associated with Water Body

Phyto-sociological study reveals herbs contribute flora majorly, followed by shrubs. This may be due to weeds and floating /aquatic plants. Diversity index is poor. Species composition of trees, shrubs, herbs and climbers at each location are presented below.




Figure 3.69 Graph showing tree species composition in aquatic habitat

Figure 3.70 Graph showing shrub species composition in aquatic habitat

Figure 3.71 Graph showing herb species composition in aquatic habitat




Figure 3.72 Graph showing overall composition in aquatic habitat


Table 3.33 Diversity index in/ near aquatic habitat

Trees 1 2 3 4 Species Richness 1.00 3.00 3.00 2.00 Diversity Index 0.00 1.04 1.05 0.64

Shrubs 1 2 3 4 Species Richness 2.00 1.00 1.00 1.00 Diversity Index 0.69 0.00 0.00 0.00

Herbs 1 2 3 4 Species Richness 6.00 4.00 5.00 3.00 Diversity Index 1.67 1.17 1.54 0.83

Figure 3.73 Graphical representation of diversity index in aquatic habitat




For the purpose of study and enlisting the species, areas adjacent to riverbanks,

freshwater lakes/ reservoirs has also been visited and studied.

Though, each above identified habitat experiences similar climatic conditions, they differ in edaphic conditions, location, use/interference of human and shows variation in floral composition. These members of flora support different kinds of fauna associated with it. Some species are present in more than one habitat. List of flora observed/reported within study area is presented in Table 3.34, with respect to different habitats described earlier. Similarly, list of fauna is presented in Table 3.35.




Table 3.34 List of Plant Species Observed During Survey within Study Area

Sr. No. Scientific Name Common/ Local Name Family Dense

Vegetation Human

Settlements Agricultural

Fields Water Bodies

Trees 1. Acacia auriculiformis Earleaf Acacia Mimosaceae

2. Acacia catechu Cutch Tree, Khair Mimosaceae

3. Adenanthera pavonina Ratan Gunj Fabaceae

4. Aegle marmelos Bel Rubiaceae

5. Ailanthus excelsa Maharukh Simarubaceae

6. Albizia lebbeck Shirish Mimosaceae

7. Alstonia scholaris Saptparni Apocynaceae

8. Anacardium occidentalae Kaju Anacariaceae

9. Artocarpus heterophyllus Fanas Moraceae

10. Azadirachta indica Neem Meliaceae

11. Bombax malbaricum Silk Cotton Tree, Shalmali Bombacaceae

12. Butea monosperma Flame of the Forest, Palash Fabaceae

13. Careya arborea Kumbhi Lecythidaceae

14. Carica papaya Papaya Caricaceae

15. Cassia fistula Amaltas Caesalpiniaceae

16. Cassia siamea Son-mohar Caesalpiniaceae

17. Casuarina equisetifolia Suru Casuarinaceae

18. Cocos nucifera Coconut/ Naral Palmae

19. Cordia myxa Bhokar Boraginaceae

20. Couroupita guianensis Kailash chafa Lecythidaceae

21. Delonix regia Gulmohar Caesalpiniaceae

22. Emblica officinalis Aawla Euphorbiaceae

23. Erythrina indica Indian Coral Tree, Pangara Fabaceae

24. Eucalyptus sp. Nilgiri Myrtaceae

25. Ficus bengalensis Banyan tree, Vat Moraceae

26. Ficus exasperata -- Moraceace

27. Ficus glomerata Umbar Urticaceae

28. Ficus religiosa Scared fig/Pimpal Moraceace

29. Gliricidia sepium Mother of cocoa Fabaceae

30. Grewia tiliifolia Dhaman Tilliaceae

31. Kigelia pinnata -- Bignoniaceae





Vegetation Human


Fields Water Bodies

32. Lagerstroemia speciosa Pride of India, Taman Lythraceae

33. Lanea coromandelica Indian Ash Tree, Mohin Anacardiaceae

34. Lucena lucocephalla Subabhul Mimosaceae

35. Macaranga peltata Chandvada Euphorbiaceae

36. Madhuca indica Moh Sapotaceae

37. Mangifera indica Mango, aam Anacardiaceae

38. Meyna laxiflora Alu Rubiaceae

39. Millingtonia hortensis Indian Corck Tree Milingtoniaceae

40. Mitragyna parviflora Kalam Rubiaceae

41. Moringa oliefera Drumstick tree Moringaceae

42. Morinda tinctoria Noni Rubiaceae

43. Neolamarckia cadamba Kadam, Kadamb Rubiaceae

44. Oroxylum indicum Broken Bones Tree, Tayitu Bignoniaceae

45. Peltophorum pterocapum Sonmohar Caesalpinaceae

46. Pithecellobium dulcii Vilayti chinch Mimosaceae

47. Plumeria alba Chafa Apocynaceae

48. Pongamia pinnata Pongam Tree, Karanj Fabaceae

49. Polyalthia longifolia Ashok Annonaceae

50. Roystonea sp. Royal palm Plamae

51. Samanea saman Rain Tree Mimosaceae

52. Sterculia urens Ghost tree Sterculiaceae

53. Syzygium cumini Jamun Myrtaceae

54. Tamarindus indicus Chinch Caesalpiniaceae

55. Tectona grandis Sag (Teak) Verbenaceae

56. Terminalia catappa Deshi Badam Combretaceae

57. Terminalia paniculata Kinjal Combretaceae

58. Thespesia populnea Indian tulip tree Malvaceae

59. Trema orientalis Indian Charcoal Tree Ulmaceae

60. Ziziphus jujuba Bor Rhamnaceae

Shrubs 1. Adhatoda vasica Vasaka Acanthaceae 2. Bauhinia racemosa Apta Caesalpiniaceae 3. Bougainvillea spectabilis Bougainvellia Nyctaginaceae 4. Calotropis gigentea Crown Flower, Safed aak Asclepiadaceae





Vegetation Human


Fields Water Bodies

5. Caesalpinia haematocephala -- Caesalpiniaceae

6. Calycopteris floribunda Paper flower climber, Ukshi Combretaceae

7. Carissa carandus Karawandi Apocynaceae

8. Codieum variegatum Croton Euphorbiaceae

9. Euphorbia quadrangularis -- Euphorbiaceae

10. Gardenia jasminoides Anant Rubiaceae

11. Hibiscus rosa-sinensis Jaswand Malvaceae

12. Holarrhena antidysenterica Kala Kuda Apocynaceae

13. Holoptelea integrifolia Papda Ulmaceae

14. Homonoia riparia Ran kaner Euphorbiaceae

15. Ixora coccinia Ixora Rubiaceae

16. Ipomoea carnea Besharmi Convolveulaceae

17. Lantana camara wild sage/Ghaneri Verbenaceae

18. Lawsonia inermis Henna, Mehendi Lythraceae

19. Musa paradisiaca Banana Musaceae

20. Nerium indicum Kanher Apocynaceae

21. Ricinus communis Erund/ Castor Euphorbiaceae

22. Rosa indica Guab Rosaceae

23. Tabernamontena coronaria Tagar Apocynaceae

24. Thevetia neriifolia Bitty Apocynaceae

25. Thuja orientalis Morpanlhi Cupressaceae

26. Vitex negundo Nirgundi Verbenaceae

27. Wrightia tinctoria Indrajav/ Indigo Apocynaceae

28. Ziziphus microphylla Jangli bor Rhamnaceae

Herbs

1. Aeschynomene indica -- Fabaceae

2. Ameranthus spinosus Math Ameranthaceae

3. Agave americana ghaypat Furcariaceae

4. Alternanthera sessilis -- Amaranthaceae

5. Argemone mexicana Satyanashi Papaveraceae

6. Canna indica Kradal Cannaceae

7. Cassia tora Takala Caesalpinaceae

8. Chromolaena odorata -- Asteraceae





Vegetation Human


Fields Water Bodies

9. Colocasia esculenta Alu Araceae

10. Crotalaria juncea khulkhula Fabaceae

11. Cyperus sp. Cyperus Cyperaceae

12. Eichhornia crassipes Water hyacinth Pontederiaceae

13. Euphorbia hirta -- Euphorbiaceae

14. Hamelia patens -- Rubiaceae

15. Heliotropium indicum -- Boraginaceae

16. Hydrilla sp. Water thyme Hydrochaitaceae

17. Hyptis suaveolens -- Bilabiatae

18. Jatropha curcus Moghuli erund Euphorbiaceae

19. Jasminum sp. Jasmin Oleaceae

20. Lemna minor Duck weed Lemnaceae

21. Leea macrophylla Gajparn Leaceae

22. Marsilea sp. Water Clover Marsileaceae

23. Nymphaea alba Red Water lily Nymphaeaceae

24. Occimum sanctum Tulas Bilabiatae

25. Pancratium caribium Lily Amerylidaceae

26. Phyllanthus asperulitus Bhui aavali Euphorbiaceae

27. Polygonum glabrum Knotweed Polygonaceae

28. Scoparia dulcis -- Scrophulariaceae

29. Solanum xanthocarpum Bhui ringani Solanaceae

30. Tephrosia purpuria -- Fabaceae

31. Tridax procumbens Dagadi Asteraceae

32. Typha anguistifolia Ram ban Typhaceae

33. Urena sinuata -- Malvaceae

34. Vinca rosea Sadafuli Apocynaceae

35. Wedelia sp. -- Compositae

36. Xanthium strumarium Chor Solanaceae

Climbers 1. Clitoria ternatea Gokarn Fabaceae 2. Hemidesmus indicus Anantamul Asclepiadaceae

3. Mucuna pluriens Khaj kuhiri Fabaceae 4. Tinospora cordifolia Gulvel Menispermeceae 5. Quisqualis indica Madhumalti Combrataceae





Vegetation Human


Fields Water Bodies

Epiphytes 1. Cuscuta reflexa Amar vel Convolvulaceae

2. Dendrophthoe falcata Bandgul Loranthaceae 3. Epidendrum tessellatum Orchid Orchidaceae

Grass 1. Bambussa bamboo Bamboo Graminae 2. Chloris barbata -- Poaceae 3. Coix lacryma jobi -- Poaceae 4. Cynodon dactylon Durva Poaceae 5. Dendrocalamus strictus Velu Graminae 6. Oryza sativa Rice Poaceae

{ Indicates presence of species in respective habitat


Chapter 3 – Description of Environment


Table 3.35 List of Fauna Observed During Survey within Study Area Sr. No. Scientific Name Common/ Local Name Family Schedule

Mammals

1. Bubalus bubalis Buffalo Bovidae

2. Felis catus Cat Felidae

3. Bos indicus Cow Bovidae

4. Canis lupus familiaris Dog Canidae

5. Capra hircus Goat Bovidae

6. Pteropus giganteus Indian flying fox Pteropodidae IV 7. Equus sp. Horse Equidae 8. Funambulus palmarum Squirrel Sciuridae

Reptiles

1. Calotes versicolor Common Garden Lizard Agamidae

2. Xenochrophis piscator Divad, Water Snake Natricidae

Amphibians 1. Euphlyctis cyanophlyctis Indian Skipping Frog Dicroglossidae

Birds

1. Dicrurus leucophaeus Ashy Drongo Dicruridae IV 2. Anastomus oscitans Asian openbill stork Ciconiidae IV 3. Ploceus philippinus Baya Ploceidae IV 4. Dicrurus macrocercus Black Drongo Dicruridae IV 5. Milvus migrans Black Kite Accipitridae

6. Pseudibis papillosa Black ibis Threskiornithidae IV 7. Elanus axillaris Black shouldered kite Accipitridae

8. Columba livia Blue rock pigeon Columbidae

9. Megalaima zeylanica Brown headed barbet Megalaimidae IV 10. Bubulcus ibis Cattle Egret Ardeidae IV 11. Aegithina tiphia Common Iora Aegithinidae 12. Alcedo atthis Common Kingfisher Alcedinidae IV 13. Acridotheres tristis Common Myna Sturnidae IV 14. Apus apus Common swift Apodidae

15. Oriolus oriolus Golden Oriole Oriolidae IV 16. Merops orientalis Green bee-eater Meropidae IV 17. Ocyceros birostris Grey Hornbill Bucerotidae IV 18. Corvus splendens House Crow Corvidae IV 19. Saxicoloides fulicata Indian Robin Muscicapidae IV 20. Coracias benghalensis Indian Roller Coraciidae IV 21. Turdoides striata Jungle babbler Leiothrichidae IV 22. Eudynamys scolopacea Koel Cuculidae IV 23. Microcarbo niger Little Cormorant Phalacrocoracidae IV 24. Egretta garzetta Little Egret Ardeidae IV 25. Copsychus saularis Magpie Robin Muscicapidae

26. Anthus rufulus Paddy field Pipit Motacillidae IV 27. Ardeola grayii Pond heron Ardeidae IV 28. Pycnonotus cafer Red Vented Bulbul Pycnonotidae IV 29. Pycnonotus jocosus Red whiskered bulbul Pycnonotidae IV 30. Vanellus indicus Red-wattled lapwing Charadriidae IV 31. Merops orientalis Small Green Bee eater Meropidae IV 32. Pericrocotus cinnamomeus Small Minivet Campephagidae IV 33. Streptopelia chinensis Spotted Dove Columbidae IV 34. Butorides striata Striated heron Ardeidae IV 35. Pycnonotus luteolus White browed bulbul Pycnonotidae IV 36. Motacilla maderaspatensis White browed Wagtail Motacillidae IV 37. Halcyon smyrnensis White-throated Kingfisher Alcedinidae IV

Insects

1. Apis sp. Honeybee Apidae




Sr. No. Scientific Name Common/ Local Name Family Schedule 2. Hemiptera sp. Cicada Cicadidae 3. Delias eucharis Common Jezebel Pieridae

4. Vespula vulgaris Common Wasp Vespidae 5. Parantica aglea Glassy Tiger Nymphalidae

6. Danaus chrysippus Plain tiger Nymphalidae

Summary:

Overall, study area has good biodiversity but owing to ongoing adversely impacting activities, health of ecosystem is moderate to poor.

Secondary data obtained from forest department was compared with observations made during survey. It revealed similar species composition except in human settlement

habitat.

Flora: During survey, 60 tree, 28 shrub, 36 herb and some other species were observed. None of the observed species is listed in ‘Red Data Book Plants of India (Nayar & Sastry 1987-88)’.

Fauna: During survey, 8 mammal, 2 reptile, 37 bird, 7 insects’ species were observed. Conservation status as per Indian Wildlife Protection Act 1972 of respective species is mentioned against it in table. Some species are not classified in any of the schedule. None of faunal species observed during survey is classified as schedule I as per Wildlife Protection Act 1972.

3.9.3 Baseline Studies at Site

Prasol Chemical Pvt. Ltd. is functional Synthetic Organic Manufacturing Industry. The facility is spread over total area of 68,644 m2. It has existing green belt in the form of trees planted in single row along boundary except at some places. Proposed green belt area is approximately 23,004 m2 (33.5% of plot area).

The plot area mentioned in this section is inclusive of main plot and tank farm area which are two different land parcels, non-contiguous, separated by a public road but connected by overhead pipe racks and utility bus.

Figure 3.74 View of site, tank farm and main plot respectively




Present proposal is to increase in production quantity, capacity of synthetic organic

chemicals manufacturing facility, installation of utilities & associated equipment’s & machineries.

Figure 3.75 View of green belt




Figure 3.76 Site visit with Official of Prasol

During visit, 3 nests of common crow were observed. Maintenance of green belt looks to be mediocre. Two dead trees were observed one each in main plot and tank farm area. About ~1845 trees in total are planted as green belt.

Figure 3.77 nest of Common crow within site




Figure 3.78 Dead trees within site

Prasol has planted few trees along roadside just outside main plot.

List of floral species observed within site during survey is given below:

Table 3.36 List of Plant Species Observed within Site

Sr

No Scientific Name

Common/

Local Name Family

Main

plot

Tank

farm

1. Acacia mangium -- Mimosaceae --

2. Aeschynomene indica -- Fabaceae --

3. Alstonia scholaris Saptparni Apocynaceae

4. Alternanthera sessilis -- Amaranthaceae --

5. Ameranthus spinosus Math Ameranthaceae --

6. Azadirachta indica Neem Meliaceae --

7. Bauhinia veriegata -- Caesalpiniaceae

8. Bambussa bamboo Bamboo Graminae --

9. Bougainvillea spectabilis Bougainvillea Nyctaginaceae --

10. Cassia siamea Son-mohar Caesalpiniaceae --

11. Calotropis gigentea Rui Asclepiadaceae --

12. Caesalpinia haematocephala -- Caesalpiniaceae --

13. Cassia tora Takala Caesalpinaceae --

14. Canna indica Kradal Cannaceae --

15. Chloris barbata -- Poaceae --

16. Clitoria ternatea Gokarn Fabaceae --

17. Cynodon dactylon Durva Poaceae

18. Delonix regia Gulmohar Caesalpiniaceae --

19. Dendrocalamus strictus Velu Graminae

20. Eucalyptus sp. Nilgiri Myrtaceae --

21. Euphorbia hirta -- Euphorbiaceae --




Sr

No Scientific Name

Common/

Local Name Family

Main

plot

Tank

farm

22. Ficus bennjamina -- Moraceace --

23. Ficus benghalensis Vad Moraceae --

24. Ficus glomerata Umbar Urticaceae --

25. Gardenia jasminoides Anant Rubiaceae --

26. Grewia tiliifolia Dhaman Tilliaceae --

27. Hamelia patens -- Rubiaceae --

28. Jasminum sp. Jasmin Oleaceae --

29. Kigelia pinnata -- Bignoniaceae --

30. Ixora coccinia Ixora Rubiaceae --

31. Lucena lucocephala Subabhul Mimosaceae --

32. Mangifera indica Amba Anacardiaceae

33. Neolamarckia cadamba Kadamb Rubiaceae --

34. Nolina sp. -- Palmae --

35. Occimum sanctum Tulas Bilabiatae --

36. Pancratium caribium Lily Amerylidaceae --

37. Peltophorum pterocapum Sonmohar Caesalpinaceae

38. Pithecellobium dulcii Vilayti chinch Mimosaceae --

39. Phyllanthus asperulitus Bhui aavali Euphorbiaceae --

40. Philodendron sp. -- Euphorbiaceae --

41. Polyalthia longifolia Ashok Annonaceae --

42. Portulaca sp. Office time Portulacaceae

43. Pulmeria alba Champa Apocynaceae --

44. Roystonea sp. Royal palm Plamae --

45. Scoparia dulcis -- Scrophulariacea

e --

46. Syzygium cumini Jamun Myrtaceae --

47. Tabernamontena coronaria Tagar Apocynaceae --

48. Tectona grandis Sag (Teak) Verbenaceae --

49. Terminalia catappa Deshi Badam Combretaceae

50. Thevetia nerifolia Bitty Apocynaceae --

51. Thuja orientalis Morpanlhi Cupressaceae --

52. Urena sinuata -- Malvaceae --

53. Vinca rosea Sadafuli Apocynaceae --

54. Quisqualis indica Madhumalti Combrataceae --

{ Indicates presence of species in respective plot

List of faunal species observed within site during survey is given below:

Table 3.37 List of faunal Species Observed within Site

Sr. No. Scientific Name Common name Family 1. Cannis domesticus Dog Cannidae




2. Columba livia Blue Rock Pigeon Columbidae 3. Corvus splendens Crow Corvidae

A stream flowing adjacent to tank farm plot is observed having greenish, stagnant/ very slow flowing water with vegetation along and within it. Some water pumps were installed drawing water was observed. Apparently, water quality seems to be low.

Table 3.38 Stream adjacent to Prasol compound

None of faunal species observed within site during survey is schedule I as per Wildlife Protection Act 1972 similarly, none of floral species is listed in ‘Red Data Book Plants of India (Nayar & Sastry 1987-88)’.

Though, no schedule I species is observed during survey, species Pavo cristatus is reported in secondary data collected from forest department. Wildlife Conservation plan for Schedule I species is prepared & submitted to Chief Wildlife Warden through Regional Division office. Copy of Wildlife Conservation plan submitted is attached as Annexure 3.4 (b).

Photo-documentation




Figure 3.79 View of main gate of Prasol unit

Figure 3.80 Tree cutting in dense vegetation

Figure 3.81 Survey in study area




Species and description of habitats mentioned in this report correspond to location, time and season during which study was carried out. These habitats may harbour/ support other set of species which may be found during different seasons of the year. Thus, species list given is not comprehensive.

3.10 Social Environment

3.10.1 Baseline status

The baseline study of socio economic aspect was carried out for proposed expansion project of Prasol located at tehsil Khalapur, dist. Raigad.

The information on Socio-economic aspects of the study area (10 km radius) has been

compiled from various secondary sources along with primary survey carried out along in the project area.

Objective of the study To prepare baseline data based on primary and secondary sources.

To know the existing socio-economic condition of villages in the study area through

primary data collection

To know basic requirements/ needs in the study area.

Methodology of study

Desktop study- Preparation of 10 km study area map & selection of villages for primary survey, use of google earth & toposheet for preparation of report

Primary data collection within 10 km study area- Communication through focus group discussion within selected villages, Visit to Gram panchayat within selected villages, visit to respective Medical practitioner of PHC or sub- center, Discussion with farmers, Visit to archaeological site/ Heritage place/ tourist place

Secondary data collection- Census 2011, District census handbook 2011 & Town directory has been taken from Census of India website. For Health data AESPL team visited 2 primary health centers namely Khalapur & Vavoshi. Various websites also referred to know the study area in detail.

Methodology for Primary data collection

For the primary data collection, structured questionnaires are used by survey team.

Two types of formats have been used for survey- Focus group discussion format and Village leader format.

All these formats include village Information like demographic details, infrastructure details, employment status, health status etc. For focus group discussion male, female groups were interviewed in community hall, school ground, temple, panchayat hall etc. For Village leader format Sarpanch/ members/ Gram sevak were interviewed.

For the selection of respondents random sampling was conducted. Direct observation during transit walk in villages, telephonic calls to peruse information is also consider as primary data collection.




For survey purpose, villages within 10 km study area selected. Proportionate and

purposive sampling methods were used for selecting villages. 10 km study area is distributed in 4 zone mainly 0-3 km, 3-5 km, 5-7 km and 7-10 km.

In the 10 km study area, there are total 72 villages and 1 town from Raigad district and 2 villages from Pune district. From Raigad district 2 taluka namely Khalapur and Sudhagad and from Pune district Mawal taluka are falling in the study area.

Total 17 villages & 1 town were selected and surveyed from the study area which is 24% of total villages in the study area.

Table 3.39 Surveyed villages

No Village name Zone Aerial Distance, in km

and Direction

1 Thanenhave & Sangade

0-3 km

1.18 (S) 2 Devnhave 1.66 (S)

3 Dheku 1.15 (NE) 4 Chinchvali & Gohe 0.72 (S)

5 Sarsan 1.98 (N)

6 Honad 1.25 (SE) 7 Tambati

3-5 km

4.55 (NW)

8 Mahad 3.80 (N) 9 Khopoli Town - Ward No. 9 4.50 (E)

10 Adoshi 3.40 (SE)

11 Khanavi 4.98 (SW)

12 Khalapur

5-7 km

6.20 (NW)

13 Mankivali 5.64 (NE) 14 Chavani 6.65 (SE)

15 Narangi 5.53 (W) 16 Durshet

7-10 km

8.26 (S)

17 Parkhande 8.30 (NW) 18 Navandhe 7.88 (NE)




Figure 3.82 Primary Socio- economic survey photographs

Administrative details: In the 10 km study area, there are total 72 villages and 1 town from Raigad district and 2 villages from Pune district. From Raigad district 2 taluka namely Khalapur and Sudhagad and from Pune district Mawal taluka villages are falling in the study area.

Table 3.40 Administrative details of study area

Chavani village Discussion with Sarpanch at Thanenhave village

Discussion with traders at Mahad village

Visit to Devnhave village grampanchayat

Discussion with local traders at Khalapur village Visit to PHC at Khalapur village




Sr. No District Tehsil No of villages No of Town 1 Raigad Khalapur 72 1 Sudhagad 1 0

2 Pune Mawal 2 0 Total 2 3 75 1

Source: Primary census abstract 2011, district Raigad & Pune, Maharashtra

3.10.2 Demographic Structure of Study area

Demographic structure of the study area was studied in terms of selected parameters such as Households, population, sex ratio, scheduled cast, literacy etc. Summarized information of study area is given below

Population size: Population size of the villages is given in table below. Below table indicates that 33% village population size was under 501-1000.

Table 3.41 Population size of villages

Population size

1-100 101-250 251-500 501-1000 1000-3000 3000 Above

No. of villages 0 7 17 25 23 4 Source: Primary census abstract 2011, district Raigad & Pune, Maharashtra

Population details: In the 10 km radial study area, total population is 141626. Total male population is 74786 and total female population is 66840. Average family size is 4 persons. Total 0-6 child population is 16808 which was (11.87%) of total population.

Total SC population is 11109 (7.84%) and ST population is 103818(13.41%). Total literate population is 18986 (73.30%). Average sex ratio is 893 females per 1000 males, 0-6 child sex ratio is 917.

Population details are presented in table below and Annexure 3.5.

Table 3.42 Population details

House holds

Population Male

Population

Female Population

Child Population

Scheduled Castes

Scheduled Tribes

Literates

31,674 1,41,626 74,786 66,840 16,808 11,109 18,986 1,03,818 Source: Primary census abstract 2011, district Raigad & Pune, Maharashtra




Figure 3.83 Population details

Population Density: Population density is number of persons to per sq. km. According to DCHB, total area of 75 villages is 256.2208 sq.km. Population density is 275 person per sq. km.

3.10.3 Occupational Pattern

Summarized information on Occupational pattern is given below

Employment pattern: Total worker population is 54810 which is (39%) of total population. Total male workers are 43292 (79%) and female workers are 11518 (21%). Total main workers are 46242 (33%) and marginal workers are 8568 (6%). Total non-workers are 86816 (61%). Employment pattern is given in table below

Table 3.43 Employment pattern

Total Workers Total Male workers

Total Female workers

Total Main Workers

Total Marginal Workers

Total Non -Workers

54,810 43,292 11,518 46,242 8,568 86,816 Source: Primary census abstract 2011, district Raigad & Pune, Maharashtra

7.84

13.4

78.76

Total SC Total ST Population Other




Figure 3.84 Employment pattern

Main worker employment pattern:

In the study area there are total 3831 (8%) population is engaged in cultivation.

Total 3584 (8%) are engaged in agriculture works

Household industry workers are 1026(2%)

Other working population are 37801(82%)

Table 3.44 Main worker employment pattern

Total Cultivators

Total Agricultural workers

Total household Industry Workers

Total Other Workers

3,831 3,584 1,026 37,801 Source: Primary census abstract 2011, district Raigad & Pune, Maharashtra

3.10.4 Infrastructure facilities

Infrastructure facilities plays a vital role in the village development. In district census handbook 2011 there are different types infrastructure facilities given eg. Education,

medical, water, communication, power, transportation facilities, road etc. Infrastructural facilities in the study area is given in tables below.

Primary survey findings are presented in Annexure 3.5

Education: Out of total 75 villages, 71 villages have primary school, 34 villages have middle schools, 8 villages have secondary school facility. Only 2 villages have senior secondary school facility in the study area.

Table 3.45 Educational Institutes Available in Number of Villages

Govt Primary School

Govt middle School

Govt Secondary School

Govt Senior Secondary School

71 34 8 2

33

6

61

MAINWORK_P MARGWORK_P NON_WORK_P




Source: District Census Handbook 2011, Raigad & Pune, Maharashtra

Medical Facilities: Out of total 75 villages, in 20 villages primary health sub centres are presented. Other medical facilities are MCW, dispensary, veterinary hospital, FCWC, medical shops etc.

Table 3.46 Medical Facilities Available in Number of Villages

Primary Health

Sub Centre

Maternity & Child Welfare Centre

Dispensary

Veterinary Hospital

Family Welfare Centre

Non-Government

Medical Facilities

Traditional Practitioner

Medical facilities Medicine

Shop

Medical facilities Others

20 1 3 2 1 2 4 9 3 Source: District Census Handbook 2011, district Raigad & Pune, Maharashtra

Drinking Water: More than 93% village population is depending on tap water source. Various water sources are available in the study area for the drinking water purpose (Tap water, tube wells, River, Canal, Lakes etc). From the below given table, it indicates only 17% villagers are availed treated tap water facility for drinking purpose.

Table 3.47 Drinking Water Facilities Available in Number of Villages

Tap Water-

Treated

Tap Water

Untreated

Covered Well

Un-covered

Well

Hand Pump

Tube Wells/

Borehole

Spring River/ Canal

Tank/ Pond/ Lake

13 58 16 70 55 53 5 30 20 Source: District Census Handbook 2011, district Raigad & Pune, Maharashtra

Sanitation: In most of the villages open drainage are availed for wastewater discharge. This data indicates sanitation facility is not satisfactory in the study area.

Table 3.48 Sanitation Facilities Available in Number of Villages

Closed Drainage

Open Drainage

No Drainage

Open Pucca Drainage

Covered with Tiles Slabs

Open Pucca Drainage

Uncovered

Open Kuccha

Drainage

0 38 37 3 22 13 Source: District Census Handbook 2011, district Raigad & Pune, Maharashtra

Communication: Out of total 75 villages, 3 villages availed post office facility. Mobile phone coverage is available in 70 villages and landlines presented in 40 villages. Only in 3 villages internet facility available through internet cafes.

Table 3.49 Communication Facilities Available in Number Of Villages

Post Office Sub Post Office Telephone

3 5 40 Source: District Census Handbook 2011, district Raigad & Pune, Maharashtra

Power: All villages are availed power supply for domestic and agriculture uses.

Table 3.50 Power facilities in number of villages

Power Supply




for Domestic Use for Agriculture Use for Commercial Use for All Users 75 75 40 40

Source: District census handbook 2011, district Raigad & Pune, Maharashtra

3.10.5 Town details

Khopoli MCI town details has been taken from Town directory 2011.The city comes under class II category. Population density of the city is 2358.

Table 3.51 Town details

Town

Name Cla

ss

Civ

ic S

tatu

s o

f T

ow

n

Are

a (

sq. k

m.)

To

wn

Po

pu

lati

on

(Ce

nsu

s 2

01

1)

Gro

wth

Ra

te T

ow

n

(Ce

nsu

s 2

01

1)

De

nsi

ty (

Ce

nsu

s

20

11

)

Se

x R

ati

o (

Ce

nsu

s

20

11

)

Ma

nu

fact

ure

d

Co

mm

od

ity

(F

irst

)

Ma

nu

fact

ure

d

Co

mm

od

ity

(S

eco

nd

)

Ma

nu

fact

ure

d

Co

mm

od

ity

(T

hir

d)

Khopol

i (M Cl) II M Cl 30.17 71141 21.3 2358 907

Electricit

y

Steel

Products Honey

Source: Town directory 2011, Maharashtra

3.10.6 Health Status

Data regarding health status has been collected from Deputy Director of health Services from Khalapur & Vavoshi PHC located under Khalapur Taluka, Raigad District. Primary Health Center wise information regarding the registered number of birth, death, infant mortality and morbidity pattern data of the study area is given in Annexure 3.5.

Summarized table of health status data for both PHCs is given below

Table 3.52 Health status data

Year Birth rate Death rate Infant mortality Khalapur Vavoshi Khalapur Vavoshi Khalapur Vavoshi

2015-16 17.06 13.60 4.00 3.24 0.22 0.28 2016-17 14.78 13.46 3.36 3.42 0.11 0.24 2017-18 13.51 14.86 3.06 3.32 0.10 0.09

Morbidity pattern data reveals that the general prevailing diseases are Malaria, Diarrhoea, Dysentry and Breathe. Health problems are reported which could be attributed due to lack of health related infrastructure facilities and untreated water & improper sanitation facilities in the study area.

3.10.7 Agriculture Status

In the study area agriculture is secondary occupation. Main crop pattern is Paddy, vegetables, lentils etc. Farmers informed that they are facing poor yield of crops, water problem, air pollution etc.




Due to lack of irrigation facility agricultural workers depend on labor work in industries. During group discussion, farmers expressed their interest in initiatives from industrial units for quality improvement of crop production. Farmers primary need/ demands are agricultural market, irrigation facility, soil testing facility, new technical method of farming.

3.10.8 Archaeological sites/ Tourist places

Details of Archaeological sites/ Tourist places within 10 km study area is as below Table 3.53 Archaeological sites/ Tourist places

Sr. No.

Archaeological sites/ Tourist places

Aerial Distance & Direction from site

Remark/ Status

1 Songiri Fort 9.7 km to North- East Historical site 2 Ashtavinayak temple 3.8 km to North Religious place 3 Theme park 2.32 km to South West Tourist place 4 Khandala ghat 5.7 km to East Tourist place

Figure 3.85 Archaeological sites/ Tourist places within 10 km study area




Songiri Fort: Songiri Fort is located near Kajrat in Raigad District. This fort is situated around 9.7 km to North- East from project site. The fort shares a close approx. aerial distance from Karjat Railway Station giving an easy accessibility route. The fort offers a beautiful view of Morbe Dam, Prabalgad, Irshalgad, Rajmachi, Songiri forts and Matheran mountain range. The fort was used as watch tower in the past.

Ashtavinayak temple, Mahad: Varad Vinayak Ganpati or Mahad Ganpati Temple is one of the Ashtavinayak temples of the Hindu deity Lord Ganesha. It is located in Mahad town situated in Khalapur taluka near Khopoli of Raigad District. It is situated around 3.8 km to North from project site. The Varadvinayak Mahad Ganpati Temple is the Seventh Ganesha temple among Ashtavinayak to be visited during the Ashtavinayak Darshan yatra/ tour. Theme park: Adlabs Imagica, opened in April 2013, is one of the most popular entertainment theme park. It is located on Mumbai-Pune Expressway near Khopoli. Imagica theme Park is around 2.32 km to South West from project site. Khandala ghat:




Khandala is a hill station in the Western Ghats in the state of Maharashtra. Khandala ghat is favorite destination to enjoy the nature's trail, in any season, especially in monsoon. It is around 5.7 km to East away from project site.

3.10.9 Survey observations/ findings

Survey observation of the study area is given below.

Education- Various types of education institutes were seen in the study area. Almost all villages which are surveyed availed the Anganwadi facilities. Primary school and middle school are available at villages or in the distance of 2-3 km. For higher studies majority of the students preferred Khopali town.

Medical facilities- 33% of the villagers availing medical facilities in the form of PHS, Pvt. clinics, drug shops etc. Rural hospital is in Khalapur tehsil. District hospital and

other private hospitals are located at Raigad district. In villages where medical facilities are not available, need to travel in the range of 3-20 km for treatments.

Fuel -Main cooking fuel in the villages is LPG. 90% households had connections of LPG. Other fuel sources are wood chip, coal, cow dung cake etc.

Employment- Main employment pattern is Pvt jobs, labour work & agriculture. Daily wage of the labours are in between Rs. 120 to 450 based on the type of work. During

discussion with villagers, they informed that youth group migrating in nearby cities like Pune, Mumbai for employment purpose.

Drinking water- Tap water through Grampanchayat is main source of drinking water in most of the villages. Other sources are hand pump, river, well etc.

Road & transportation- Village roads are in pucca form and fairly connected with Khalapur town, Khopoli and Raigad district. Internal village roads are not satisfactory. For transportation purpose various types of facilities are available in the form of Govt & Pvt buses, auto and personal vehicles etc. Railway facility availed at Dolavali village.

Sanitation- More than 80% population are using personal toilets. Other population are depending on common toilets or open defection. Drainage pattern is not satisfactory. Open drainage is not properly discharge in some villages. Due to open drainage most of the villagers are facing mosquito, fly problem. For solid waste disposal almost 50% villagers have Ghantagadi facility on daily basis.

Imagica Theme Park Khandala ghat




Market- Study area is totally rural dominant. Weekly market facility is available at

some villages. Khalapur & Khopoli town is main center for marketing.

Language- Local language in the study area is Marathi, other language often spoken in the study area is Hindi.

Govt. Welfare Scheme/ Activity- Majority of the villages are benefitted by govt welfare scheme like Gharkul yojna, Sanjay Gandhi niradhar yojna, water conservation scheme etc.

Power- Power facility is available in all villages and villagers are satisfied with the power supply. Majority of the villagers using power facility for domestic purpose.

3.10.9.1 Expectation/ Demands from Respondents

All respondents are aware about the industrial area and its activities. Villagers expressed their positive response for expansion project as it will lead to increase employment opportunity for locals. Villagers also shows concern regarding air pollution & expecting authorities and industrialists well-planned precautionary measures for pollution problem.




Table 3.54 Expectations/ Demands from Villagers

Sr. No.

Villages Expectations

1 Thanenhae

1] Drainage Line 2] Cleaning facility 3] Sub Centre Facility 4] Regular Doctor Visit 5] Water Tank Repairing 6] Playing Ground 7] SHG-Empowerment 8] Damping Ground 9] Road Construction [Road Repair]

2 Devnhave 1] Permanent water Sources 2] Drainage line [ Underground] 3] Sub Centre Facilities 4] Doctor Visit 5] Tree Planation 6] Cleaning facility 7] Health Medical facility

3 Dheku 1] Medical facility 2] Self Help Group training 3] Drinking Water Filter Plant 4] Agriculture facility 5] Vocational training 6] Lake Dredging

4 Chinchvali Gohe

1] Medical facility 2] Filter Plant for Drinking Water 3] Gym 4] Strength of Self-Help Group

5 Sarsan 1] Drinking Water Filter Plant 2] Common Hall 3] Gym 4] Medical facility & Ambulance Facility 5] Provide the Sports Instrument to children’s of anganwadi

6 Honad 1] Drinking water filter plant 2] Local Employment 3] Common Toilets in Industries area 4] School Building Repairing [ Primary School] 5] Gym 6] Ghantagadi-Garbage Collection

7 Tambati 1] Vocational Training 2] Self Help Group training & Guidance 3] Company should use CSR Funds for betterment

8 Mahad 1] Drainage line 2] Street Light 3] Shop Shed 4] Road expansion 5] Toilet facility 6] Ban to fishpond business [ Production of fish should be stop by Govt. because of bad smell]

9 Khopoli 1] Vocational training 2] Self Help Group training 3] Common Toilets 10 Adoshi 1] Health facility 2] Drinking water filter plant 3] Main Road 4] Samaj Mandir 5] Agriculture tolls

11 Khanavi 1] Drinking water filter plant 2] Self Help Group training 3] Drainage line 4] Medical facility 5] Tree Planation 5] Local Employment

12 Khalapur 1] Higher Education facility 2] Water Supply Scheme 3] Bus stand 4] ITI [ Technical Education] 5] Market Facilities [ Infrastructure]

13 Mankivali 1] Solid Waste management 2] Community Hall 3] Gym 4] Library 5] Bus stop shed 6] Tree planation 7] Benches 8] Lake repairing 9] Water restoration

14 Chavani 1] Water supply by tata power 2] Common Toilets 3] Road construction 4] Bus Service 5] Training & Financially Support for SHG Group also available market facility 6] Higher Education 7] Local Empowerment.

15 Narangi 1] Medical Facility 2] Playground 3] Internal Road 4] Drainage line 5] Lake Dredging & Beautification 6] Library 7] Drinking water filter plant 7] Training for Self Help Group




16 Durshet 1] Permanent water sources 2] Need for good quality education facility 3] Road 4] Regular Doctor visit 5] Houses of ST family 6Park (Recreation) 7] Drainage line

17 Parkhande 1] Local Employment 2] Drainage line 3] Gym 4] Medical facility 5] Garbage collection 6] Solar Light Facility in Tribal Area 7] Samaj Mandir 8] Drinking water filter plant.

18 Navandhe 1] Park/Garden Provision 2] Gym 3] Water filter plant 4] Bench facility 5] Lake facility 6] Street Light 7] Basics infrastructure in school [ like-Computer] 8] community Hall.




3.10.9.2 Conclusion

On the basis of primary and secondary data collection following conclusion has come:

- According to 2011, only 16% workforce is engaged in cultivation & agricultural. Non worker population is 61%. This data indicates unemployment is major issue in the study area.

- During FGDs respondents also informed that crop production is not satisfactory. Due to single crop pattern farmer/ labour have only 4-5 months to work. Migration of workforce for employment in nearby areas also informed by respondents.

- Proposed expansion of the project will lead to additional employment opportunities which will be beneficial for local workforce.

- The proposed expansion project is within existing facility & no additional land will be utilized/ acquired for expansion.

- The expansion project has a strong positive prospect of industrialization in its surrounding vicinity.

- Due to proposed project, additional infrastructure facilities will be carried out through CER & CSR.

The expansion project is likely to bring about positive changes in life style and quality of life for people located in the surrounding vicinity.

3.10.10 CSR Activities carried out by Prasol

The Company’s corporate social responsibility policy integrates economic progress and social commitment. It aspires to always fuse its business values, cultural pillars and operating principles to exceed the expectations of its customers, employees, partners, investors, communities and the wider society. The Company’s core values form an integral part of the corporate social responsibility programmes and aim towards responsibility improving the quality of life. It is focused on engaging in directly or through contributions to entities engaged in the field of eradicating hunger and poverty, empowering women, setting up old age homes for aged etc. It may be noted that the CSR policy is aligned under the guidelines of the requirements of Clause 135 and Schedule VII of the Companies Act 2013 and the corresponding Rules. Details of CSR is given in Annexure 3.6 of EIA report & some of the activities are mentioned below- Year 2015-16 Sr. No.

CSR Project or activity identified

Sector in which project is covered

Project or Program

Amount spent

Implementing agency

1 Donation to Education Trust

Promotion of Education

Sindhudurg – Maharashtra

Rs. 10 lakhs

Sindhudurg Shikshan Prasarak Mandal

2 Imparting Computer Training to Local People

Promotion of Education

Khopoli – Maharashtra

Rs.1.50 lakh

Direct Agency: S. S. Enterprises




3 Promotion, education including special education and employment enhancement vocation skills

Promotion of education and employment enhancing skills


Rs.7.18 Lakhs

Spent directly

4 Ensuring environmental sustainability

Tree plantation to ensure environmental sustainability


Rs.0.82 Lakhs

Spent directly

5 Making availability of safe drinking water

Supplying water to local people


Rs.3 Lakhs Spent directly

6 Donation to charitable trust

Promotion of education by donating to schools


Rs.0.50 Lakhs

Donation to various schools

Total - - Rs. 23 Lakhs

-

Year 2016-17 Sr. No.



Project or Program

Amount spent

Implementing agency

1 Employment to Local people

Providing employment enhancing Skills


Rs.9.52 lakhs

Amount spent directly

2 Tree Plantation Ensuring Environment Sustainability


Rs.1.40 lakh


Total - - Rs. 10.73 Lakhs

-




Project or Program

Amount spent

Implementing agency

1 Promoting education including special education and employment enhancing vocation skills, Tree Plantation

Promotion of education and employment by enhancing skills


Rs. 10.28 lakhs


2 Promoting education Promoting education to local people


Rs. 13.13 lakhs


Total - - Rs. 23.41 Lakhs

-







Project or Program

Amount spent

Implementing agency

1 Promoting education including special education, employment enhancing vocation skills, Infrastructure development

Promotion of education and employment by enhancing skills, Infrastructure

Nearby areas Rs. 32.12 lakhs


Total - - Rs. 32.12 lakhs

-




Project or Program

Amount spent

Implementing agency

1 Promoting education including special education, employment enhancing vocation skills, Infrastructure development

Promotion of education and employment by enhancing skills, Infrastructure

Nearby areas Rs. 34.57 lakhs


Total - - Rs. 34.57 lakhs

-

CSR activity photo documentation:

14 nos. of street light poles installed at Hirewadi village,

Amount spent: ~ 5 Lakhs

Beautification of school, Chinchvali gohe village


Chapter 4– Anticipated Environmental Impacts & Mitigation measures


4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 Introduction

Any Chemical manufacturing has various impacts during construction commissioning, operation phase and at end of project life on environmental parameters like land environment, water, air quality of surrounding area and due to generation of solid and hazardous wastes.

4.2 Identification of Impacts

Environmental impact identification is based on stage of project and the type, scale and

location of proposed project activity. Environmental components that may be affected

negatively and positively due to proposed activity are identified for construction and

operation phase and presented below:

Table 4.1 Environmental Aspects and Impacts of the Project

Sr. No.

Step/Activity Environmental Aspect

Impact Type Severity

1.0 Construction of buildings and Erection of Plant

Emission to air (dust) Air Pollution Temporary Use of water, energy and materials

Natural resources, conservation

Temporary

Use of manpower Employment Temporary Hazardous and nonhazardous Waste Disposal on land

Land pollution Permanent

Cutting of Trees Biodiversity loss Temporary 2.0 Commissioning Use of water, energy

and materials Air Pollution Temporary

Use & storage of hazardous chemicals

Safety, Occupational Hazards

Temporary

Wastewater discharge

Water Pollution Temporary

Hazardous and nonhazardous Waste Disposal on land

Land Pollution Temporary

3.0 Operation Use of Water Natural resources/ conservation

Permanent

Wastewater discharge

Water Pollution Permanent




Sr. No.


Impact Type Severity

Hazardous and non-hazardous waste for disposal

Land Pollution Permanent

Use of manpower Employment Permanent Use of material, energy and resources

Air Pollution Permanent

Use & storage of materials

Safety, Occupational Hazards

Permanent

Production of goods Revenue Generation

Permanent

Operation of Plant and machinery

Noise Pollution Permanent

4.0 Closure and Decommissioning

Stoppage of New product

Revenue & employment loss

Permanent

Decommissioning Land pollution Permanent

4.3 Prediction of Impacts during Construction Phase and Mitigation Measures

4.3.1 Land Environment

4.3.1.1 Anticipated Impacts

Plant erection involves land levelling and excavation, Transportation and handling of construction material and plant machineries and equipment.

Contamination of land due to construction debris- Solid waste generated will include demolition rubble, substratum removed during foundation, broken concrete, glass, bricks and scrap iron pieces, insulation, packaging materials, plastic drums etc.

Disposal of sewage & contamination- due to construction works, from labour camp/ site office

Hazardous waste- generated includes paint drums, glass wool insulation, asbestos pieces etc. Improper waste disposal can lead to unhygienic conditions and hazards to nearby

populace.

Construction material (concrete, iron sheets, plant and machinery) transport will lead to increase in number of vehicles plying on roads by about 4 – 5 no’s/ day. However existing road is tarred and hence no traffic congestion is expected.

4.3.1.2 Mitigation Measures

Water sprinkling on unpaved area, construction area to reduce dust generation

Separate area will be earmarked for storage of solid wastes generated while hazardous wastes will be stored in existing covered area earmarked for the purpose.




Substratum removed during foundation, broken pieces of concrete, bricks shall be

stored in stockpiles and covered with plastic/ tarpaulin sheets. Excavated material will be used for leveling within plot/ nearby plots.

Wastes like broken glass, plastic drum/bags/iron scrap will be sold to scrap dealers for recycle.

Waste paint cans, brushes and filters, glass wool material and asbestos packing will be stored separately and disposed of to CHWTSDF facility.

Separate space shall be earmarked for parking of construction trucks so that they do not clog road. Heavy material will be brought in during nighttime only at site.

Storm water drain extensions, greenbelt development should be the activities of

priority in the construction phase

4.3.2 Water Environment


Water (15 - 20 cmd) required will be supplied from existing plant facility. About 100 - 150 workers from nearby villages will be employed during construction. Additional Sewage generation will be treated in ETP provided at site.


Temporary arrangement of clean drinking water will be provided for workers.

Toilets will be provided and connected to septic tanks discharging to soak pit/

combined ETP at site.

4.3.3 Air Environment


Impact on air environment will be due to dust generation and expected to be localized and confined to plant boundaries. Also, there are no major human settlement up to 1 km from site, hence impact will be localized and temporary in nature. Particulate emissions may cause occupational health like respiratory problems i.e. allergic asthma and watering of eyes.


Provision of PPE (dust masks, goggles) for onsite workers.

Screening of construction area at boundary with tin sheets

Periodic water sprinkling in the construction area.

4.3.4 Ecological & Biological Environment


There is no wildlife sanctuary/ national park located within study area. There is considerable agricultural fallow land in study area.

As mentioned earlier, study area has existing permanent adverse impacts such as,

quarrying, dumping plastic, domestic waste, emitting gaseous pollutant, forest fires, tree




cutting. In addition to these, proposed expansion project will have some adverse impacts

at different phases of project like Construction and Operation phase.

Construction phase of expansion unit involves leveling, removal of herbaceous vegetation within plot, assembling of different components of plant. As this is existing operational unit, impacts in this phase are insignificant.

Species of existing herbs within plot that need to be cleared are found commonly in the region and does not have conservation concern. Clearing herbs does not pose significant impact on flora.

Particulate emissions during construction will have some impact on trees located near construction site. However, since the particulate are non-toxic in nature and emission is temporary thus no serious impacts are considered.


Provide barriers around site with water sprinkling to reduce particulate dust generation

Tree plantation around boundary and on roadsides adjoining plot.

4.3.5 Noise & Vibration Environment


Noise and vibrations will be generated in construction phase. The project site is part of

industrial area and there is no major human settlement in 1 km vicinity of the site, thus

the noise generated will not have any major impact in the study area. As the phase of

construction and plant erection will be of temporary nature, noise pollution will be

confined to plant boundaries only.


Adequate PPE (earmuffs, ear plugs) for construction workers.

Adequate barrier will be provided to prevent noise propagation.

Use construction machinery meeting in EP Act norms for noise

4.3.6 Occupational Health and Safety


Health of workers may be affected due to dust and noise and possibility of accidents.


Adequate provision of PPE (helmets, safety shoes, harness, ear plugs, muffs, dust masks) for construction workers.

Insurance for construction workers and extending existing medical facilities to them.

4.3.7 Socio-economic Environment

Impacts on socio-economic environment due to proposed project during construction phase are envisaged due to direct and indirect employment which will be beneficial.





There will be temporary employment for ~ 100 – 150 persons over about 8 - 12 months. It will create business opportunities to suppliers of construction material, fabricators, manpower suppliers, civil contractors, Local labors will be employed during construction phase.


Engage local contractors for non-specialized work.

Provide adequate water supply and sanitation for onsite workers.

Employ local labors and youth for construction work.

4.4 Prediction of Impacts during commissioning, operation phase and Mitigation Measures

4.4.1 Anticipated Impacts

Impacts during commissioning phase will be due to:

Use of water: Additional water requirement for plant operation will be ~ 430 cmd and will be sourced from existing water supply arrangement i.e. from Patalganga river.

Similarly, electricity required will be sourced from captive power plant / MSEDCL.

During commissioning stage, the water and energy demands will be fluctuating as plants / equipment are commissioned sequentially.

Use of materials: Industry will be using hazardous chemicals such as Acetone, cumene, Sulphur, sulphuric acid, methanol ethanol, Phosphorus, caustic lye, n butanol, Isobutanol, Pentanol, Octanol and many more chemicals, some for the first time at the site. Incorrect procedures followed during initial stages can lead to accidental exposure to employees, leakage of chemicals thereby polluting land and water bodies.

Wastewater generation during plant operation will result in estimated ~ 258 cmd additional effluent. During commissioning phase risks of water pollution are enhanced since in plant pollution control facility such as effluent treatment plant, MEE and RO will also be under commissioning and there might be shock load to the effluent treatment systems.

Waste generation: As the plant operation shall not be stabilized immediately, there is possibility of failed batches which will need to be stored and recycled and disposed safely so as not to cause land pollution.

4.4.2 Mitigation Measures

PP has the technical competence to handle the chemicals and has extensive experience.

Proper training to employees in handling chemicals mentioned by hiring trained personnel well versed in handling such chemicals.

Personal supervision by Senior executive staff and HSE staff to ensure that there is

no shock load to effluent treatment plant. Active support from R & D team and




Quality control staff to ensure that the plant process is stabilized as soon as possible

to ensure that loads to ETP remain at the predicted levels.

Have a documented procedure to ensure waste generated during commissioning is collected separately, segregated and sent to CHWTSDF site.

4.4.3 Innovative technological measures proposed to be adopted

PLC / DCS controlled Automated closed-circuit process control will be provided.

Due to advanced control system, with multiple check points where hazards are

involved, and additional backup system to make the system fail safe, and the latest

system adoption ensures better control over process and mitigate any hazards.

Double Mechanical seals will be provided to all pressure reactors involving

hazardous operation. All safety precaution will be taken to ensure safe operations.

The use of Double mechanical seal helps in environment, plant, and personal

safety, so that in case, one mechanical seal fails, there is no exposure of any

hazardous gas to atmosphere, as the other seal takes over. The reactors are

provided with safety valve and rupture disk, for safety purpose, and the vent of

which will be collected in suitably sized enclosed vessel.

Interlocks will be provided at appropriate place for safety purpose. This interlock

help in ensuring plant, environment, human, and process safety.

Close loop process from unloading of Raw material to packing, no exposure to

atmospheric condition, and to avoid any hazards.

Multi-Tier communication includes Walkie Talkie, Mobile phone, paging systems,

and intercoms. Due to effective communication, action can be taken immediately

when needed.

Smoke detectors, Gas detectors, safety showers, will be provided at appropriate

locations.

Assembly point, safety evacuation, Mock drill, breathing apparatus to be provided

at various locations for environmental safety and human safety.



Major concern in land environment during operation phase is contamination of land by:

Improper disposal of ETP sludge from ETP plant

Spill and leak during transport, handling, storage activity of chemicals.

Spill of oil and greases during maintenance of equipment, machineries and vehicles.

Improper storage/dumping of hazardous wastes, resulting in leachate contaminating the soil.

Contaminated runoff from site and contaminated drain from storage areas of hazardous wastes and chemical storages, tanker loading/unloading areas

draining to land.




Transportation in tanker or drums through highway, which may have

considerable impacts on environment of the area falling in the route of the transportation. During the incidence of major accident, the hazardous materials being transported can have serious impacts on land where on it spilled or leaked.

Trucks, tankers and other transportation vehicles may cause disruption in traffic flow in the surrounding areas may increase to vehicular emission


ETP sludge shall be disposed to CHWTSDF facility.

Production, maintenance area and warehouses for storage of raw materials, finished products and hazardous wastes will be provided with impervious

flooring.

All bulk storage tanks will be provided with adequate dyke walls to prevent spreading of spill or leaked chemicals causing contamination of soil.

Necessary cleanup procedures (SOPs) for the specific area will be designed and implemented.

Used oil from machineries/equipment etc. will be collected in drums & stored in designated storage area.

ETP facilities for management of effluents will be provided as planned during erection and commissioning phase and untreated effluents will not be disposed of on land.

The chemicals used will be transferred through closed pipelines by PLC/DCS control system to avoid/prevent spill/leak of the materials.

Hazardous waste management will be done as per statutory guidelines & requirements. ETP sludge generated will be dried in mechanical dewatering system and stored on sludge drying beds or kept in sacks in covered godown, with impervious flooring sloping so that any leachate will be collected and taken back for treatment.

Empty Chemical drums will be decontaminated and reused/recycled or sent back to supplier or sold to MPCB authorized party.

All transportation of hazardous wastes will be done in closed truck/tanker by MPCB approved agencies.

HAZMAT guidelines will be followed for transport of all hazardous materials. All required safety & emergency equipment & materials will be provided on the transport vehicles.

Proponent will maintain a good spill or leak control action plan to cope up with such incidents.

Monitoring of soil samples in areas near hazardous waste storage will be done as per Environmental monitoring plan.

No waste will be stored on open barren land under any condition.





4.4.5.1 Anticipated Impacts: Additional Water use & Wastewater Generation


The Effluent Treatment facility will also have to be fail safe since there is no discharge permitted and the treated effluent has to be recycled within the site.

Impacts on water resources may also occur as secondary impacts of soil contamination as well as runoff of contaminated water from premises resulted due to the spill/ leak of hazardous chemicals or from leachates from hazardous waste storage areas.

4.4.5.2 Mitigation Measures Water Environment

Prasol is proposing to expand existing ETP facility with tertiary treatment facility for treatment of effluents followed by RO & MEE.

ETP facility being upgraded comprises primary-secondary-tertiary treatment followed by RO & MEE Unit, brief description as given below.

The manufacturing activity will generate process effluent, Utilities effluent as well as Domestic sewage which will require treatment to achieve quality of treated effluent for recycle and reuse in the process plant and ensure Zero Liquid Discharge outside the facility premises.

Effluent Treatment Plant Scheme

Effluent will get generated from different sources during the manufacturing of different chemicals as well as from Utilities and Domestic activity on the premises.

The sources of effluent will be from:

Process plants (Di Acetone Alcohol Plant, Zinc Di-organo Dithio Phosphate Plant, Hydrogenation Plant, Mesityl Oxide Plant, 3,5 Xylenol Plant, Cumene Hydro Peroxide Plant)

Plant equipment / Floor washings,

Cooling Tower Blowdown (CT BD),

Boiler Blowdown (BD),

Condensates,

De Mineralised (DM) water treatment plant regeneration and

Domestic use

Other sources from where effluent will get generated are:

ETP Reverse Osmosis (RO) Rejects,

Multiple Effect Evaporator (MEE) Condensate.




Proposed Effluent management scheme is described below

Mostly all the manufacturing processes are closed operation processes however there will be generation of organic effluent from manufacturing processes as well as Low COD Low TDS inorganic effluent mainly from utility activities and Plant washings.

The organic and inorganic effluent will be segregated at source and will be imparted separate treatment in the Effluent Treatment Plant with a provision of a Reverse Osmosis (RO) facility to ensure the quality of treated effluent for recycle back in the process. High COD High TDS effluent will also get generated from ETP RO Reject.

Low COD & Low TDS inorganic effluent will get generated from Cooling Tower Blow Down, Boiler Blow Down, DM plant regeneration, MEE condensate and Domestic use.

High COD High TDS effluent generated during RO operation will be treated in a well-designed Multiple Effect Evaporator (MEE) and an Agitated Thin Film Drier (ATFD).

Low COD Low TDS inorganic effluent generated from CT BD, Boiler BD will be collected in a Collection cum Equalization tank and then pumped to Neutralization tank where neutralization will be effected by Hydrated Lime or HCl depending upon the pH of incoming effluent. The neutralized effluent will flow by gravity to a coagulation tank for coagulation of solids with Alum and then Flash Mixed with a Polyelectrolyte for further Flocculation in a Flocculator. The flocculated solids will be separated in a Primary Clarifier from where the separated and settled solids will be transferred to a Sludge Collection Tank for compaction before further dewatering through a suitable mechanical dewatering device. The dewatered solids will be sent to CHWTSDF at Taloja. The primary

clarified effluent will be transferred to Pressure Sand Filter Feed Tank for further treatment along with treated organic effluent.

Organic effluent from manufacturing plants will be collected in an Equalization tank from where it will be pumped to a Neutralization Tank for neutralization with Hydrated Lime Solution or HCl depending upon the pH of incoming effluent. The neutralized effluent will flow by gravity to a coagulation tank to coagulate with Ferrous Sulphate and then Flash mixed with a Polyelectrolyte in a Flash Mixer to flocculate the suspended solids which will be flocculated in a Flocculator. Flocculated solids will be separated in a Primary Clarifier of organic effluent treatment and clarified effluent will be treated in a secondary treatment system. The separated and settled solids from the Primary Clarifier will be transferred to a Sludge Collection Tank for compaction before further dewatering

through a suitable mechanical dewatering device. The dewatered solids will be sent to CHWTSDF at Taloja.

The overflow from clarifier will flow by gravity to Trickling Filter Feed Tank and will be pumped and spread over the packings of the trickling filter through self rotating arm. The treated effluent from the Trickling Filter will be collected in a settling tank to separate the sludge to recycle back to Trickling Filter and to Clarify the treated effluent. The Treated effluent will then be fed to an Aeration tank of adequate capacity for extended aeration aerobic biodegradation by suspended growth aerobic activated sludge process. Oxygen required for biodegradation will be supplied in the form of air through tubular membranes by a well designed diffused aeration system.




The aerobically biodegraded effluent will flow by gravity to a Secondary Clarifier to

separate the biomass and transfer back to aeration tank to maintain the process parameters. Excess biomass will be withdrawn from the system and will be transferred to Sludge Collection Tank for compaction and further dewatering through a suitable mechanical dewatering device. The dewatered solids will be sent to CHWTSDF at Taloja. The overflow from the clarifier will be collected in a disinfection tank and imparted oxidation with hypochlorite solution to destroy escaping bacteria. The disinfected effluent will be filtered through a Pressure Sand Filter (PSF) to trap the suspended solids and then will be passed through an Activated Carbon Adsorber/Filter (ACF) to adsorb trace organics, colour and odour. The treated effluent will be collected in a treated effluent collection tank from where part of the effluent will be used for backwash of PSF and ACF. The backwash will be to the inlet of secondary clarifier.

Entire treated effluent after conventional treatment will be further purified through an UF and RO system to achieve treated effluent quality for recycle and reuse within the plant premises for various suitable use.

Reject from UF will be transferred to the PSF Feed tank and Reject from RO will be transferred to MEE Feed tank for feeding to the Evaporator followed by ATFD. The separated solids from ATFD will be sent to CHWTSDF at Taloja. The condensate from the evaporator will be transferred to the equalization tank of organic effluent ETP for further conventional treatment or will be recycled for suitable use.

Domestic Effluent generated on the premises will treated in a separate Sewage Treatment Plant (STP) and the treated Domestic effluent will be recycled for gardening on the

premises. The excess sludge from the STP will be transferred to Aeration tank for supply of active biomass and nutrients.

Tables / Figure below shows –

o Different effluent sources, Quantity and Quality of Inorganic and Organic Effluent

considered for Design of Inorganic and Organic Effluent ETPs.

o Proposed Treatment for Inorganic and Organic Effluent.

o Designed stagewise performance of ETP of Inorganic Effluent.

o Details of major process units for treatment of Inorganic Effluent.

o Details of major equipment for the treatment of Inorganic Effluent.

o Designed stagewise performance of Organic Effluent.

o Details of major process units for treatment of Organic Effluent.

o Details of major equipment for the treatment of Organic Effluent.

o Quality of effluent for MEE / ATFD.

o Quality of treated effluent achievable for recycle reuse in Plant.

o Water Effluent Material Balance




Table 4.2 Effluent sources, Quantity and Quality of Inorganic and Organic Effluent considered for Design of Inorganic and Organic Effluent ETP

Inorganic Effluent Flow pH COD BOD TSS TDS Cl SO4-2 PO4-3 Theoretical, Experience, Prasol values mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d Softener Regeneration 20 m3/d 0.83 m3/h 7.00 0 0.0 0 0.0 0 0.0 1000 20.0 500 10.0 0 0.0 0.0 DM Plant Regeneration 16 m3/d 0.67 m3/h 0 0.0 0 0.0 0 0.0 6000 96.0 0.0 0.0 0.0 CT Blow Down 58 m3/d 2.42 m3/h 7.00 100 5.8 25 1.5 100 5.8 1500 87.0 0.0 0.0 0.0 Condensate 24 m3/d 1.00 m3/h 7.00 50 1.2 20 0.5 500 12.0 1000 24.0 500 12.0 0 0.0 0.0 PPS 2 m3/d 0.08 m3/h 0 0.0 0 0.0 0 0.0 200 0.4 0.0 0.0 0.0 Total 120 m3/d 5.00 m3/h 58 7.0 16 1.9 148 17.8 1895 227.4 183 22.0 0 0.0 0 0.0 CoGen Boiler Blow Down 25 m3/d 1.04 m3/h 7.00 50 1.3 20 0.5 100 2.5 3500 87.5 20 0.5 30 0.8 CT Blow Down 20 m3/d 0.83 m3/h 7.00 100 2.0 25 0.5 100 2.0 1500 30.0 0.0 0.0 DM Plant 10 m3/d 0.42 m3/h 50 0.5 20 0.2 500 5.0 200 2.0 0.0 0.0 Condensate etc, 9 m3/d 0.38 m3/h 7.00 50 0.5 20 0.2 500 5.0 1000 20.0 500 10.0 0 0.0 RO 96 m3/d 4.00 m3/h Total 160 m3/d 6.67 m3/h 111 17.8 32 5.1 282 45.1 3589 574.3 278 44.5 5 0.8 50 8 Inorganic Effluent Total 280 m3/d 11.67 m3/h 7.00 88 24.8 25 7.0 225 62.9 2863 801.7 238 66.5 3 0.8 29 8.0

Organic Effluent Flow pH COD BOD TSS TDS Cl SO4-2 PO4-3 ASEPL Analysed/Prasol values mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d DAA 1900MT/M 30 m3/d 0.96 m3/h 2.36 3000 90.0 990 29.7 12 0.4 1280 38.4 1130 33.9 81.2 2.4 0 0.0 ZDDP 200MT/M 2 m3/d 0.08 m3/h 11.94 3000 6.0 700 1.4 1740 3.5 500 1.0 200 0.4 284.1 0.6 0 0.0 HG 500MT/M 2 m3/d 0.08 m3/h 9.25 5000 10.0 3347 6.7 60 0.1 660 1.3 43 0.1 91 0.2 0 0.0 MO 100MT/M 7 m3/d 0.29 m3/h 1500 10.5 600 4.2 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 3,5 Xylenol 150MT/M 35 m3/d 1.46 m3/h 3000 105.0 900 31.5 0 0.0 5000 80.0 0 0.0 0 0.0 0 0.0 CHP 100MT/M 1 m3/d 0.04 m3/h 3000 3.0 1200 2.4 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 Washings 3 m3/d 0.13 m3/h 10000 30.0 3000 105.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 Total Organic Effluent from Source 80 m3/d 3.33 m3/h 3181 254.5 2261 180.9 50 4.0 1509 120.7 430 34.4 40 3.2 0 0.0 Organic Effluent Total @+20% 96 m3/d 4.00 m3/h 3181 305 2261 217 50 5 1509 145 430 41 40 4 0 0

4000 384 2843 273

Domestic Effluent Flow pH COD BOD TSS TDS Cl SO4-2 PO4-3 mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d Domestic Effluent 27 m3/d 1.11 m3/h 8.00 400 11 200 5 200 5 600 16 400 11 200 5 0 0




Table 4.3 Designed stagewise performance of ETP of Inorganic Effluent

S. N. Description Flow/Quantity pH COD BOD TSS TDS Cl SO4-2 PO4-3 mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d

1 Inorganic Effluent for Design 280 m3/d 11.7 m3/h 7.00 88 25 25 7 225 64 2863 806 238 67 3 1 29 8 2 Lime @50ppm, 5% 0.3 m3/d 14 kg/d 3 HCl, 10% 0.1 m3/d 14 kg/d 4 Alum @50ppm, 5% 0.3 m3/d 14 kg/d 5 PE @5ppm, 0.05% 2.8 m3/d 1.4 kg/d 6 Combined Effluent through Primary 285 m3/d 11.9 m3/h 87 25 25 7 327 93 2879 820 284 81 3 1 28 8 7 Primary Sludge generation 4.2 m3/d 85 kg/d 8 Primary Sludge for disposal 0.1 m3/d 85 kg/d 9 After Primary Clarifier 282 m3/d 11.7 m3/h 7.00 70 19.9 20 5.6 30 8.5 2908 820 287 81 0.3 0.1 1 0.4

Table 4.4 Details of major process units for treatment of Inorganic Effluent

Sr. No.

Description

Required Total

Liquid Capacity

Nos. of

Units

Required Unit

Liquid Volume

Inside Length

Inside Breadth

Liquid Height / SWD

Inside Diamet

er

Free Board

Total Tank

Height

Inside Area

Unit Liquid

Volume

Total Designed

Liquid Volume

Desired HRT

Designed HRT

Desired Overflow

Rate

Overflow Rate

Provided

m3 nos. m3 m m m m m m2 m3 m3 h h m3/m2.d m3/m2.d

1 Inorganic Effluent Collection Tank

140 2 70 5.00 5.00 3.00 0.5 3.50 25 75 150 12 13

2 Neutralisation Tank 5.8 1 5.8 2.00 2.00 1.50 0.5 2.00 4.0 6.0 6.0 0.5 0.5 3 Coagulation Tank 1.9 1 1.9 1.25 1.25 1.25 0.5 1.75 1.6 2.0 2.0 0.2 0.2 4 Flash Mixer 0.4 1 0.4 0.75 0.75 0.75 0.5 1.25 0.6 0.42 0.42 0.03 0.04 5 Flocculator 6.9 1 6.9 2.00 2.25 0.5 2.50 4.0 8.0 8.0 0.6 0.7 6 Primary Clarifier 35 1 35.4 3.00 4 0.3 3.30 12.6 37.7 37.7 3 3.2 29 23

13 HCl Solution Preparation cum Dosing Tank

2

14 Lime Solution Preparation cum Dosing Tank

2

15 Alum Solution Preparation cum Dosing Tank

2

16 Polyelectrolyte Solution Preparation cum Dosing Tank

4




Table 4.5 Major equipment for the treatment of Inorganic Effluent

S.N. Description Total Nos.

Unit Capacity

Power Motor Pump Head

Reduction Remarks

nos. m3/hr kW/ unit Total kW

rpm/ unit

Final rpm

mmWC

1 Inorganic Effluent Collection Tank Discharge Pumps

2 14.6 1.49 2.98 1440 15000 Centrifugal Pump, MOC PP, Impeller SS304, Double Seal/Mechanical Seal

2 Air Blower for Collection Tank 2 68 2.25 4.50 1440 3000 Coarse Bubble Diffuser System in SS304 3 Neutralisation Tank Agitator 1 0.37 0.37 1440 100 14:1 Turbine Stirrer in SS304 4 Coagulation Tank Agitator 1 0.37 0.37 1440 100 14:1 Turbine Stirrer in SS304 5 Flash Mixer Agitator 1 0.37 0.373 1440 100 14:1 Turbine Stirrer in SS304 6 Flocculator Agitaor 1 0.37 0.37 1440 24 60:1 Paddle Stirrer in SS 304 7 Primary Clarifier Mechanism 1 0.37 0.37 1440 0.07 360:1 Centrally driven Rake Mechanism with bottom Scrapper 8 Primary Clarifier Sludge Pumps 1 1.4 0.37 0.37 1440 0.07 5000 360:1 Open Impeller Centrifugal Pump SS304

14 HCl Solution Preparation cum Dosing Tank Discharge Pump

2 0 to 50 LPM Non Contact Pneumatic Pump

15 Lime Solution Preparation cum Dosing Tank Agitator

2 0.37 0.75 1440 100 14:1 Paddle Stirrer in SS304

16 Alum Solution Preparation cum Dosing Tank Agitator

2 0.37 0.75 1440 100 14:1 Turbine Stirrer in SS304

17 Polyelectrolyte Solution Preparation cum Dosing Tank Agitator

4 0.37 1.49 1440 100 14:1 Turbine Stirrer in SS304

18 Lime Solution Preparation cum Dosing Tank Dosing Pump

2 0.0175 0.37 0.7 1440 1440 10000 Closed Impeller Centrifugal Pump SS304

19 Alum Solution Preparation cum Dosing Tank Dosing Pump

2 0.0175 0.37 0.7 1440 1440 10000 Closed Impeller Centrifugal Pump SS304

20 Polyelectrolyte Solution Preparation cum Dosing Tank Dosing Pump

4 0.175 0.37 1.5 1440 1440 10000 PP Dosing/Metering Pump




Table 4.6 Designed stagewise performance of Organic Effluent

S. N.

Description Flow/Quantity pH COD BOD TSS TDS Cl SO4-2 PO4-3 TAN NO3- O&G mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d mg/L kg/d

1 Total Organic Effluent for Design 96 m3/d 4.0 m3/h 2 - 12 3181 384 2261 273 50 5 1509 145 430 41 40 4 0 0 0 0 0 0 0 0 2 Organic Effluent for Primary 80 m3/d 3.3 m3/h 2 - 12 4800 384 3412 273 59 5 1811 145 516 41 49 4 0 0.0 0 0.0 0 0.0 0 0.0 3 Lime @200ppm, 5% 0.3 m3/d 16 kg/d 4 HCl, 10% 0.2 m3/d 20 kg/d 5 Ferrous Sulphate @100ppm, 5% 0.2 m3/d 8 kg/d 6 PE @5ppm, 0.05% 0.8 m3/d 0.4 kg/d 7 Organic Effluent through Primary 81 m3/d 3.4 m3/h 7 4724 384 3358 273 359 29 2028 165 754 61 48 4 0 0.0 0 0.0 0 0.0 0 0.0 8 Primary Sludge generation 1.3 m3/d 26 kg/d 9 Primary Sludge for disposal 0.03 m3/d 26 kg/d

10 After Primary Clarifier 80 m3/d 3.3 m3/h 7 3842 307 2730 218 36 3 2062 165 766 61 5 0.4 0 0 0 0 0 0 0 0 11 To Secondary (addition of

~0.005cmd domestic sludge) 80 m3/d 3.3 m3/h 7 3841 307 2730 218 36 3 2061 165 766 61 5 0.4 0 0.0 0 0.0 0 0.0 0 0.0

12 After Secondry (after Trickling Filter) 80 m3/d 3.3 m3/h 7 2497 200 1638 131 1000 80 2061 165 766 61 5 0.4 0 0.0 0 0 0 0 0 0 13 After Secondry (after Extended

Aeration) 76 m3/d 3.3 m3/h 7 494 38 209 16 105 8 2061 165 766 61 5 0.4 0 0 0 0 0 0 0 0

14 Secondary Sludge 5.5 m3/d 55 kg/d 15 Secondary Sludge for disposal 0.07 m3/d 55 kg/d 16 UF Reject of Combined Treated

Effluent to PSF Feed 39 m3/d 1.6 m3/h 7 315 12 108 4 42 2 9308 367 782 31 3 0.1 2.0 0.1 0 0.0 0 0.0 0 0.0

17 Hypochlorite @0.1 ppm, 1% 0.08 m3/d 0.008 kg/d 18 After Disinfection to PSF 398 m3/d 16.6 m3/h 7.5 131 52 48 19 45 18 2558 1018 185 74 1 0.5 0 0 0 0 0 0 0 0 19 Treated effluent after PSF & ACF 396 m3/d 16.5 m3/h 7.5 112 44 41 16 5 2 2570 1018 186 73.5 1 0.5 0 0 0 0 0 0 0 0 20 PSF ACF backwash 2.0 m3/d 0.08 m3/h 7.5 3937 7.79 1455 2.88 8229 16.29 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 0 0.00 21 Treated Organic effluent to UF 394 m3/d 16.4 m3/h 7.5 112 44.2 41 16.3 5 1.8 2583 1017.6 187 73.5 1 0.5 0 0.0 0 0.0 0 0.0 0 0.0

Table 4.7 Major process units for treatment of Organic Effluent

S.N. Description

Required Total Liquid

Capacity

Nos. of

Units

Required Unit Liquid

Volume

Inside Length

Inside Breadth

Liquid Height /

SWD

Inside Diameter

Free Board

Total Tank

Height

Inside Area

Hopper Volume

Unit Liquid

Volume

Total Designed

Liquid Volume

Desired HRT

Designed HRT

m3 nos. m3 m M m m m m m2 m3 m3 m3 h h 1 Oil/Solvent Separator New 16.0 1 16.0 5.00 0.75 3.00 0.5 3.50 2 11 11 4 3 2 Organic Effluent Collection Tank 96.0 2 48.0 4.50 2.50 3.00 0.5 3.50 11 34 68 24 17

3 Existing Utility Effluent Holding Tank T1

1 6.00 4.00 2.50 0.3 2.80 60

4 Existing RO Product Water Tank T2

1 5.00 4.00 2.50 0.3 2.80 50

5 Neutralisation Tank New 2.0 1 2.0 1.25 1.25 1.00 0.5 1.50 1.6 1.6 1.6 0.5 0.4




S.N. Description


Capacity

Nos. of

Units


Volume

Inside Length

Inside Breadth

Liquid Height /

SWD

Inside Diameter

Free Board

Total Tank

Height

Inside Area

Hopper Volume

Unit Liquid

Volume

Total Designed

Liquid Volume

Desired HRT

Designed HRT

m3 nos. m3 m M m m m m m2 m3 m3 m3 h h 6 Coagulation Tank New 0.7 1 0.7 0.80 0.80 0.75 0.5 1.25 0.6 0.5 0.5 0.2 0.1 7 Flash Mixer New 0.1 1 0.1 0.50 0.50 0.50 0.5 1.00 0.3 0.13 0.13 0.03 0.03 8 Flocculator New 1.7 1 1.7 1.00 1.25 0.5 1.50 1.2 1.2 1.2 0.4 0.3

9 Primary Clarifier, 45 Hopper Bottom New

12.2 1 12.2 2.00 2.00 2.00 0.5 2.50 4.0 2.0 10.0 10.0 3 2.5

10 UF Feed Tank 34.3 1 34.3 7.00 2.00 3.00 0.5 3.50 14.0 42 42 2 2

11 Existing Organic Effluent Holding Tank T5

4.00 4.00 2.50 0.3 2.80 40

12 Existing Ozone Reaction Tank I T6

2.00 4.00 2.50 0.3 2.80 20

13 Existing Ozone Reaction Tank II T7

2.00 4.00 2.50 0.3 2.80 20

14 Trickling Filter Feed Tank New 33 1 32.5 4.00 4.00 2.00 0.3 2.30 32 32 4 3.9 15 Trickling Filter New 127 1 127.0 6.00 5.2 1.0 7.00 20.9 125 125 16 Trickling Filter Settling Tank 33 1 32.5 4.00 4.00 2.50 0.3 2.80 40 40 4.0 4.9 17 Aeration Feed Tank New 65 1 65.0 5.70 5.70 2.00 0.3 2.30 65 65 8.0 8.0 18 Aeration Tank New 195.1 1 195.1 9.00 5.00 4.50 1.0 5.50 45.0 203 203 48 50 19 Secondary Clarifier New 12.2 1 12.2 2.50 2.5 0.5 3.00 4.9 12.3 12.3 3 3.0 20 Combined Sludge Collection Tank 5.6 1 5.6 2.70 1.8 0.5 3.20 2.5 5.6 5.6 12 12.0

21 Existing RO Reject Water Tank T3

1 2.00 4.00 2.50 0.3 2.80 20

22 Sludge Thickener New 2.8 1 2.8 2.01 1.50 0.5 2.51 1.8 2.7 2.7 12 2.9 23 Filter Press, 2 x 2 New 1 5.00 3.00 0.00

24 Disinfection Tank / PSF Feed Tank

34.3 1 34.3 8.00 1.50 3.00 1.0 4.00 12.0 36.0 36.0 2 2.1

25 Existing Clarified Effluent Holding Tank T9

1.50 4.00 2.50 0.3 2.80 15

26 Pressure Sand Filter (Sand height 1.5m) New

2 2.50 1.0 1.0 3.50 0.8 2.0 3.9

27 Activated Carbon Filter (Carbon Height 2m) New

2 3.00 1.5 1.0 4.00 1.8 5.3 10.6

28 Combined Treated Effluent Collection Tank / UF Feed Tank

137.9 2 69.0 5.00 5.00 3.00 0.5 3.50 25.0 75 150 8 9

29 Existing Organic Treated Effluent Tank T4

4.00 4.00 2.50 0.30 2.80 40




S.N. Description


Capacity

Nos. of

Units


Volume

Inside Length

Inside Breadth

Liquid Height /

SWD

Inside Diameter

Free Board

Total Tank

Height

Inside Area

Hopper Volume

Unit Liquid

Volume

Total Designed

Liquid Volume

Desired HRT

Designed HRT

m3 nos. m3 m M m m m m m2 m3 m3 m3 h h

30 Existing BioReactor Aeration Tank T8

4.00 4.00 2.50 0.30 2.80 40

31 RO Reject Collection / MEE Feed Tank

37.1 1 37.1 3.75 3.75 2.50 0.5 3.00 14.1 35 35 12 11.4

32 Existing Underground Drain Sump T10

4.00 2.00 2.00 0.20 2.20 16

33 RO Permeate Collection Tank New 296.5 2 148.2 7.00 7.00 3.00 1.0 4.00 49.0 147 294 24 23.8

34 HCl Solution Preparation cum Dosing Tank New

2 0.00

35 Lime Solution Preparation cum Dosing Tank New

2 0.00

36 Alum Solution Preparation cum Dosing Tank New

2 0.00

37 Polyelectrolyte Solution Preparation cum Dosing Tank New

4 0.00

Table 4.8 Details of major equipment for the treatment of Organic Effluent

S.N. Description Unit

Capacity, m3/hr

Total Nos.

kW/unit Total kW

Motor rpm

Final rpm

Head, mmWC

Reduction Remarks

1 Oil/Solvent Separator New 1 1.5m/hr Oil Separator Package 2 Organic Effluent Collection Tank Discharge

Pumps 5.0 1 0.75 0.75 1440 100 10000 Centrifugal Pump, MOC PP, Impeller SS304, Double

Seal/Mechanical Seal Existing Utility Effluent Holding Tank T1

Existing RO Product Water Tank T2

3 Agitator of Neutralisation Tank New 1 0.37 0.37 1440 24 60:1 Turbine Stirrer in SS304 4 Agitator of Coagulation Tank New 1 0.37 0.37 1440 100 14:1 Turbine Stirrer in SS304 5 Agitator of Flash Mixer New 1 0.19 0.19 1440 100 14:1 Turbine Stirrer in SS304 6 Agitator of Flocculator New 1 0.37 0.37 1440 35 40:1 Paddle Stirrer in SS 304 7 Primary Clarifier Bottom Sludge Discharge Pump 0.51 2 0.37 0.75 1440 15000 Open Impeller Centrifugal Pump SS304 8 Air Blower for Buffer Tank 38 2 1.12 2.24 1440 2500 Coarse Bubble Diffuser System in SS304 Existing Organic Effluent Holding Tank T5 Existing Ozone Reaction Tank I T6




Existing Ozone Reaction Tank II T7 Trickling Filter Distribution system 9 Air Blower for Aeration Tank 243 2 3.73 7.5 1440 1440 5000 90mm, 2m length; Retrievable Type Fine Bubble

Silicon Membrane Diffuser Complete system 10 Mechanism for Secondary Clarifier New 1 1.49 1.5 1440 24 60:1 Centrally driven Rake Mechanism with bottom

Scrapper 11 Agitator for Sludge Collection Tank 1 0.37 0.37 1440 24 60:1 Paddle Stirrer in SS 304 Sludge Collection Tank Discharge Pump 2 0.37 0.75 1440 10000 Open Impeller Centrifugal Pump SS304 Existing RO Reject Water Tank T3

12 Agitator for Sludge Thickener New 1 0.37 0.37 1440 24 60:1 Paddle Stirrer in SS 304 Sludge Thickener New Discharge Pumps 2 1.49 2.98 1440 20000 Part of Filter Press Package

13 Filter Press, 2 x 2 New 1 Part of Filter Press Package 14 PSF Feed Pump 2 Part of PSF ACF Package Existing Clarified Effluent Holding Tank T9

17 Treated Effluent Collection Tank / UF Feed Tank Discharge Pumps

7.9 2 0.75 1.49 1440 15000 Centrifugal Pump, MOC PP, Impeller SS304, Double Seal/Mechanical Seal

Existing Organic Treated Effluent Tank T4 Existing BioReactor Aeration Tank T8

18 UF RO Reject Collection Tank / MEE Feed Tank Discharge Pumps

4.4 2 Part of MEE Package

Existing Underground Drain Sump T10 19 RO Permeate Collection Tank Discharge Pumps 17.6 2 2.24 4.5 1440 1440 30000 Closed Impeller Centrifugal Pump SS304 20 HCl Solution Preparation cum Dosing Tank New 21 Lime Solution Preparation cum Dosing Tank

New

22 Alum Solution Preparation cum Dosing Tank New

23 Polyelectrolyte Solution Preparation cum Dosing Tank New




Table 4.9 Quality of effluent for MEE / ATFD


1 MEE Feed from Combined Effluent RO 70.9 m3/d 3.0 m3/h 559 39.7 193 13.7 2 0.1 20167 1430 1390 98.6 5 0.3 4 0.3 2 MEE Condensate for Recycle Reuse 67.4 m3/d 2.8 m3/h 7 29 2.0 10 0.7 0 0.0 1061 72 73 4.9 0 0.0 0 0.0 3 ATFD Feed 3.5 m3/d 0.1 m3/h 10625 37.7 3660 13.0 40 0.1 383177 1359 26412 93.6 94 0.3 68 0.2

Table 4.10: Quality of treated effluent achievable for recycle reuse in Plant


1 Treated Inorganic effluent to UF 280.5 m3/d 11.7 m3/h 7 63 17.8 18 5.0 0.2 0.04 2908 815.7 287 80.5 0 0.1 1 0.4 2 Treated Organic effluent to UF 393.9 m3/d 16.4 m3/h 8 112 44.2 41 16.3 5 1.8 2583 #### 187 73.5 1 0.5 0 0.0 3 Total Combined Treated effluent to UF 393.9 m3/d 28 m3/h 7 157 62.0 54 21.3 5 1.9 4654 1833 474 154.0 1 0.5 1 0.4 4 UF Reject to Organic Effluent ETP 39.4 m3/d 1.6 m3/h 7 315 12.4 108 4.3 42 1.7 9308 367 782 30.8 3 0.1 2 0.1 5 After UF to RO 354.5 m3/d 14.8 m3/h 7 140 49.6 48 17.1 0.5 0.2 4137 1467 348 123.2 1 0.4 1 0.3 6 RO Permeate 283.6 m3/d 11.8 m3/h 7 35 9.9 12 3.4 0 0.0 129 37 87 24.6 0 0.1 0 0.1 7 RO Reject to MEE 70.9 m3/d 3.0 m3/h 7 559 39.7 193 13.7 2 0.1 20167 1430 1390 98.6 5 0.3 4 0.3




Figure 4.1 Proposed ETP scheme for Organic & Inorganic effluent

Secondary

Sludge

Evaporated Dry Solids

Disinfection

Sand Filtration

UF Reject to PSF Feed

RO RejectEvaporationATFD

UF

RORO Permeate

for Recycle

Reuse

Condensate to Organic Effluent

Equalisation after Primary

treatment or suitable reuse

Neutralisation

Inorganic Effluent

CollectionSewage

Treatment Plant

Excess Sludge

Wastage

Treated Domestic

Effluent for

Domestic Effluent

Organic Effluent

Collection

Neutralisation

Backwash to Secondary

Clarifier Inlet

Treated Effluent

Activated

Carbon

Secondary

Clarification

Dewatered Sludge

Disposal to

CHWTSDF

Biodegradation by Trickling

Filter followed by Extended

Aeration

FiltrateClarified Inorganic Effluent

Sludge Recycle

Excess Sludge

Coagulation

Flash Mixing

Primary Sludge

EqualisationSludge

Dewatering

Coagulation

Flash Mixing

Flocculation

Primary

Clarification

Flocculation

Primary

Clarification

To Secondary Treatment of

Organic Effluent




Figure 4.2 Proposed ETP Material Balance




Following mitigation measures will be adopted to reduce impacts on water environment:

Implementation of scheme of in plant pollution control system for process effluents generated (as described in chapter 2) comprising

o segregation of process effluents

Implementation of measures for management of hazardous chemicals/wastes as given under land environment

Regular monitoring of effluents for statutory purpose and to gauge the functioning of ETP and in plant effluent treatment system to be carried out as given in Chapter 6

Proper preventive and breakdown maintenance of ETP units from civil,

mechanical, electrical and instrumental angle will be undertaken.

Regular logbook of ETP and in plant effluent treatment system will be maintained to indicate chemical consumption and operational status of equipment.

Regular records of energy consumption for ETP units will be maintained

Close monitoring of effluents will be undertaken to ensure proper functioning of ETP to meet MPCB norms.

The treated effluent shall be reused on site as CT make up/ used for green belt on site.

Online monitoring of effluents will be undertaken including flow measurement.

4.4.5.3 Rain water harvesting

Rain water harvesting scheme is already implemented in existing facility.

The rainwater during monsoon season from the roof top of warehouse is collected in raw water tank of 100 m3 capacity. Harvested rain water is stored in tank and reused for utilities. Excess rain water is drained to storm water drain. Due to this, during rainy season water requirement is get reduced.


Impact on air environment is anticipated due to addition of boiler and Thermic fluid heaters (TFH) and process plants at site.

Fuel Requirement- Proposed

Fuel requirement for proposed Boiler and Thermic Fluid heater shall be as follows:

Table 4.11 Additional fuel Requirement

No Capacity Nos Fuel type Fuel requirement 1 Boiler (5 TPH steam) 1 Furnace oil 304 kg/hr i.e. 7.3 TPD 2 TFH (30 Lakh Kcal/hr) 1 Furnace oil 358 kg/hr i.e. 8.6 TPD Total - Furnace oil 662 kg/hr i.e. 15.9 TPD




4.4.6.1 Quantitative Assessment of Impacts due Fuel Burning

Impact on air environment is anticipated due to emissions from fuel burning (furnace oil) leading to emission of PM, SO2 & NOx, and also from process plants in terms of H2S and acid mist.

Prasol is proposing to provide suitable stack height to Boiler and TFH for effective dispersion of pollutants in atmosphere.

These emissions may cause occupational health impact on site and study area like respiratory problems i.e. allergic asthma and watering of eyes, damage of respiratory organs, necrosis of plant tissues, if no proper control measures are taken.

Details of proposed boiler and TFH stacks and emission details are given in table below:

Table 4.12 Emission and stack details

Stack number(s) Unit 1 2 3 4

Attached to Boiler TFH

Process stack ZDDP Plant

Process stack PP

Capacity - 5 TPH 30 lakh Kcal/hr - - Fuel type - Furnace oil Furnace oil - -

Sulphur content (maximum considered)

% 4.5 4.5 - -

Fuel quantity kg/hr 304 358 - - Fuel quantity TPD 7.3 8.6 - -

Sulphur kg/hr 13.7 16.1 - - SO2 generation kg/hr 27.3 32.1 - -

Material of construction - CS CS - - Shape (round/rectangular) - Round Round - -

Min Height, m (above ground level)

meter 38 40 12 11

Diameter/size, in meters at top meter 0.4 0.5 0.15 0.15 Cross section area of stack at top m2 0.13 0.20 0.02 0.02

Flue Gas quantity Nm3/hr 3396 4262 40 15 Flue Gas quantity m3/hr 5138 6448 45 17

Flue Gas temperature at stack Deg C 140 140 35 35 Flue gas exit velocity meter/sec 11.35 9.12 0.71 0.27

Particulate Matter (PM10) grams/sec 0.142 0.178 0.002 0.001

Particulate Matter (PM2.5)* grams/sec 0.074 0.092 - -

SO2 grams/sec 6.4 8.0 0.002 0.001

NOx grams/sec 0.095 0.120 0.002 0.001

Acid mist/HCl grams/sec - - 0.0003889 0.0001458

Hydrogen sulphide (H2S) grams/sec - - 0.0001667 0.0000625

APC Stack Stack Scrubber Scrubber

*Estimate based on US EP 42.

4.4.6.2 Modeling Studies to Predict Magnitude of Impact on Air Quality from proposed activity

In order to compute air quality impacts due to proposed additional sources, dispersion modeling studies were carried out using AEROMOD model assumptions of which are as

given below:




Steady state conditions & uniform emission rates

No removal/ transformation of pollutants

Pollutant material

Averaging time 24 hours

Data mentioned in above table is used for air modeling

The AERMOD is steady state advanced Gaussian plume model that simulates air quality

and deposition fields up to 50 km radius. The model is applicable to rural and urban areas,

flat and complex terrain, surface and elevated releases and multiple sources including

point, area, flare, line and volume sources. AERMOD is approved by USEPA and is widely

used software for air dispersion modelling studies. For prediction of maximum Ground

Level Concentrations (GLC’s), the air dispersion modelling software, AERMOD have been

used.

Model overview

The AERMOD model features include:

The ability to model dispersion of primary pollutants, toxic and hazardous waste

pollutants;

The ability to handle multiple sources in an industrial complex (point, area,

volume and pit types) with no buildings or single or multiple buildings with

building downwash;

Constant or time-varying emissions;

Gas and particle depositions;

Concentration estimates for all terrain locations, except in lee areas;

Predictions at distances up to 50 km from the source;

Specification of receptors locations as gridded and/or discrete receptors in

Cartesian or polar coordinates; and

Use of real-time meteorological data to account for the atmospheric conditions

that affect the dispersion of air pollutants.

Dispersion modelling using AERMOD requires hourly site-specific meteorological data

which include wind direction, wind speed, temperature etc. AERMET is integral software

of AERMOD. AERMET provides a general-purpose meteorological pre-processor for

organizing available meteorological data into a format suitable for use by the AERMOD

air quality dispersion model. Site specific data is used for executing current modelling

studies. The site-specific meteorological data is processed using AERMET processor and

resultant output (pfl file) is used for air pollutant modelling study.

Model Set up




The model set-up details are presented in Table below.

No Parameter Details

1 Model Name AERMOD

2 Model Type Steady state Gaussian Plume Air Dispersion model

3 Topography Elevated

4 Averaging Time 24 hours

5 Source Type Point Source

6 Boundary Limits 10 km X 10 km

7 Co-ordinate System Uniform Polar Grid

8 Receptor Height 2 m

9 Surface meteorological data Pre-processed from Site Data

10 Upper air Data Pre-processed from Site Data

11 Anemometer Height 10 m

Site specific meteorological data for a period of three months (March, April, May 2019) has been processed using AERMET. Site specific wind rose generated is shown in Figure below. As per the wind rose, it can be observed that the predominant wind direction is from north east.

Figure 4.3 Windrose summer

Emission rates considered for modeling are given in table above.

Modelling Results

The model simulations have been carried out to evaluate the pollutant emissions from the project that are likely to contribute to the ambient air environment. For the short-term simulations, the concentrations were estimated and evaluated to obtain an optimum description of variations in concentrations over the site within 10 km radius covering all




the directions. The predicted results for pollutants are presented in table below and

isopleths showing the incremental concentrations are presented in Figures below.

Based on the modeling results, expected highest incremental increase in concentration of Pollutants are summarized in the table below.

Highest Values

X Coordinate meter

Y Coordinate meter

Concentration in µg/m3

PM10 PM2.5 SO2 NOx H2S Acid mist

1 320284 2076849 0.19 0.09 8.54 0.22 0.01 0.02 2 320384 2076849 0.19 0.09 8.54 0.22 0.01 0.02 3 320184 2076849 0.18 0.08 8.21 0.21 0.01 0.02 4 320484 2076849 0.18 0.08 7.90 0.21 0.01 0.02 5 320084 2076849 0.17 0.08 7.73 0.21 0.01 0.02 6 319984 2076849 0.16 0.07 7.20 0.21 0.01 0.02 7 319884 2076849 0.15 0.07 6.67 0.21 0.01 0.02 8 320296 2076710 0.14 0.06 6.43 0.20 0.01 0.02 9 320394 2076727 0.13 0.06 6.41 0.20 0.01 0.02 10 320197 2076693 0.13 0.06 6.18 0.20 0.01 0.02

Similarly, incremental increase is also predicted at various locations where ambient air quality was monitored.

4.4.6.3 Modelling Impacts on PM10

Based on the modeling results, isopleths for incremental increase in concentrations for PM10 were drawn and are shown below:




Figure 4.4 Isopleths Impacts for PM10

Based on the modeling results, the highest incremental increase in concentration of PM10 occurs at coordinates in the West direction at aerial distance of 700 m and the incremental increase is 0.19 µg/m3.

Predicted incremental concentration of component is added to the baseline concentration at monitored locations in the study area to indicate the ground level concentrations.

Table 4.13 Prediction of GLC of PM10

AAQM location Background

value (µg/cum)

Predicted GLC (µg/cum) at

location

Net Impact (µg/cum)

Norms* (µg/cum)

Project site 66.1 0.00 66.10 100 Mahad 66.5 0.01 66.51 100

Yashwant nagar 62.3 0.02 62.32 100 Adoshi 63.0 0.00 63.00 100 Honad 61.7 0.01 61.71 100

Sangadewadi 62.3 0.06 62.36 100 Vadval 62.6 0.02 62.62 100

Chinchwali 61.6 0.04 61.64 100




(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazette Notification

dated 16th November 2009.

4.4.6.4 Modelling Impacts on PM2.5

Based on the modeling results, isopleths for incremental increase in concentrations for PM2.5 were drawn and are shown below:

Figure 4.5 Isopleths Impacts for PM2.5

Based on the modeling results, the highest incremental increase in concentration of PM2.5 occurs at coordinates in the West direction at aerial distance of 800 m and the incremental increase is 0.09 µg/m3.


Table 4.14 Prediction of GLC of PM2.5

AAQM location Background value

(µg/cum) Predicted GLC

(µg/cum) at location Net Impact (µg/cum)

Norms* (µg/cum)






AAQM location Background value

(µg/cum) Predicted GLC

(µg/cum) at location Net Impact (µg/cum)

Norms* (µg/cum)


Chinchwali 25.9 0.00 25.9 60



4.4.6.5 Modelling Impacts on SO2

Based on the modeling results, isopleths for incremental increase in concentrations for SO2 were drawn using aerial view of the site using google earth which is shown below:

Figure 4.6 Isopleths of SO2

Based on the modeling results, the highest incremental increase in concentration of SO2

occurs at coordinates in the West direction at aerial distance of 800 m and the incremental increase is 8.54 µg/m3.


Table 4.15 Prediction of GLC of SO2


value (µg/cum) Predicted GLC (µg/cum)

at location Net Impact (µg/cum)

Norms* (µg/cum)


Yashwant nagar 12.9 0.02 12.92 80







Norms* (µg/cum)

Adoshi 12.8 0.01 12.81 80 Honad 13.5 0.01 13.51 80


Chinchwali 13.0 0.06 13.06 80

(*) Norms specified by Central Pollution Control Board, New Delhi vide Gazette Notification dated 16th November 2009.

4.4.6.6 Modelling Impacts on NOx

Based on the modeling results, isopleths for NOx were drawn and were superimposed on

an aerial view of the site using maps from Google Earth which is shown in the figure below:

Figure 4.7 Isopleths of NOx

Based on the modeling results, the highest incremental increase in concentration of NOx occurs at coordinates in the West direction at aerial distance of 701 m and the incremental increase is 0.22 µg/m3.

Predicted incremental concentration of component is added to the baseline concentration at monitored locations in the study area to indicate the ground level

concentrations.




Table 4.16 Prediction of GLC of NOx




Norms* (µg/cum)




Chinchwali 20.7 0.07 20.77 80



4.4.6.7 Modelling Impacts on Acid mist

Based on the modeling results, isopleths for acid mist were drawn and were superimposed on an aerial view of the site using maps from Google Earth which is shown in the figure below:

Figure 4.8 Isopleths of acid mist

Based on the modeling results, the highest incremental increase in concentration of acid mist occurs at coordinates in the West direction at aerial distance of 800 m and the incremental increase is 0.02 µg/m3.




Its predicted increase in GLC is nil at monitored locations.

4.4.6.8 Modelling Impacts on H2S

Based on the modeling results, isopleths for H2S were drawn and were superimposed on an aerial view of the site using maps from Google Earth which is shown in the figure below:

Figure 4.9 Isopleths of H2S

Based on the modeling results, the highest incremental increase in concentration of H2S

occurs at coordinates in the West direction at aerial distance of 800 m and the incremental increase is 0.01 µg/m3.

Its predicted increase in GLC is nil at monitored locations.

4.4.6.9 Modelling Impacts on CO, Hydrocarbon, PM & NOx due to vehicle movement

Emission due to vehicular transportation

One of the sources likely to be affecting the pollutant concentrations in project area would be vehicular emission due to transportation. The road can be a continuous, infinite line source. It is estimated that ~ 50 number of trucks/tankers will be required per day for raw material and product transportation. Thus it is assumed that 50 number of trucks will be arriving / leaving the site daily.




Table 4.17 Basis for vehicular emission

No Parameter Quantity Unit 1 No of Vehicles per day 50 - 2 Average speed of Vehicle 60 km / hr 3 Surface wind speed* 4 m/sec 4 Emission source height 0.5 m

Note: *Wind speed is considered on the basis of moderate to slightly unstable meteorological conditions based on Pasquill-Stability classes (stability ‘C’ is there for this case at 4 m/s). To obtain a source strength q with units of g/s-m, the number of vehicles/m of highway must be calculated and multiplied by the emission per vehicle as follows Vehicles per meter= Vehicles per day / (24 x Vehicle speed km/hr x 1000) Vehicles per meter= 50/ (24 x 60 x 1000) Vehicle per meter factor= 3.472E-05

Table 4.18 Source strength calculation based on emission factor

Parameter

Emission factor

(g/km)

Emission (g/hr)

Emission (g/sec)

Line Source strength (g/s-m)

a b = a x vehicle speed (km/hr)

c = b/3600 c x vehicle per meter

CO 6 360 0.1 3.47222E-06 HC 0.37 22.2 0.006166667 2.1412E-07

NOx 9.3 558 0.155 5.38194E-06 PM 1.24 74.4 0.020666667 7.17593E-07

Note: (1) Emission factors (source: Automotive association of India data) (2)Emission is calculated by formula (g/hr)= Emission Factor x Average speed of Vehicle) (3) Line Source strength (g/s-m)= Vehicle/meter x Emission of gas

Based on above table, incremental concentration of different parameters is calculated and are as below:

Table 4.19 Incremental concentration due to vehicular transportation

Distance in

meter

Sigma z from Pasquill Gifford

curve (rural area)

Concentration of CO in µg/m3

Concentration of HC in µg/m3

Concentration of NOx in

µg/m3

Concentration of PM in µg/m3

100 20 0.034412 0.002122 0.053339 0.007112

200 40 0.017260 0.001064 0.026753 0.003567

500 100 0.006917 0.000427 0.010721 0.001430

1000 200 0.003461 0.000213 0.005364 0.000715

2000 400 0.001731 0.000107 0.002683 0.000358

3000 600 0.001154 0.000071 0.001789 0.000238

4000 800 0.000866 0.000053 0.001342 0.000179




5000 1000 0.000692 0.000043 0.001073 0.000143

6000 1020 0.000679 0.000042 0.001052 0.000140

7000 1050 0.000660 0.000041 0.001022 0.000136

8000 1070 0.000647 0.000040 0.001003 0.000134

9000 1090 0.000635 0.000039 0.000985 0.000131

10000 2000 0.000346 0.000021 0.000537 0.000072

Note: 1) X (m) - Downwind Distance from center line of source 2) 6z (m) – Vertical Dispersion Parameter which is calculated based on Pasquill-Gifford curves 3) Concentration of pollutant (g/m3) - 2q*[exp{-1/2(H2/6z)}]/[√2ᴫ(6z*u)] 4) H (m) – Height of source 5)(Reference: Environmental Health and Hazard Risk Assessment: Principles and Calculations By Louis Theodoure, R. Ryan Dupont) Results interpretation It can be observed that the maximum incremental concentration due to traffic load will be 0.034 μg/m3 for CO, 0.002 μg/m3 for HC, 0.053 μg/m3 for NOx and 0.007 μg/m3 for PM at 100-meter downwind distance from centre line source (As shown in above table) and concentration gets decreasing further up to 10 km distance from centre line source. Based on NAAQ standards it is assessed that the impact on the present ambient air quality is negligible due to traffic load in 10 km study area.

4.4.6.10 Observations from dispersion modeling studies

From the dispersion modeling studies conducted, it is observed that the maximum ground level concentration occurs in the West direction.

The incremental increase will have negligible impact on the air environment.

4.4.6.11 VOC and Fugitive emission control

1. VOC Emissions from Process

Fugitive dust as chemical PM and fugitive vapors of low volatile chemicals are the sources of fugitive emission in the unit.

The chemicals being proposed for manufacture are organic chemicals and will lead to increased emissions of volatile organic chemicals during handling, storage and from process and emergency vents.

VOCs are harmful to human health and cause secondary air pollutants on emission into atmosphere. This will lead to increased odor nuisance for neighboring populace and industrial environment.

Scrubber Process for H2S emissions

- The H2S generated during process will be absorbed in a two stage caustic scrubber system.




- Both the stages of the scrubber system will have a SS 304 column above packed with

SS 304 packings.

- Initially 20% caustic solution will be prepared and fed to both the stages

- H2S gas coming released from the reaction will be fed into the 1st stage for scrubbing and then subsequently pass through the second stage.

- Circulation in both the stages is to be kept ON and discharge of pump should enter at the top of the vessel. The scrubbers are to be periodically checked for NaHS concentration.

- Once NaHS concentration in the 1st stage reaches, the NaHS solution is to be sent for drumming. The content from the second stage is to be transferred to the second

stage and fresh 20% caustic solution is to be fed to the second stage.

Hydrogen sulfide gas readily dissolves in caustic solutions due to its solubility at high pH or “caustic pH” conditions, typically above pH 10-12. It can be released from solution as a gas easily when the solution is disturbed or the pH is lowered. Thus, close control and watch over the concentration of caustic and immediate replenishment with fresh caustic is necessary to prevent episodal emissions. Also, considering toxicity of the gas, utmost care in designing systems with reduced redundancies is essential.

The by product from wet scrubber which is sodium hydrogen sulfide will be sold. Any change in the disposal strategy may affect the nearby environment and hence should not be resorted to without due introspection. Regular monitoring, preventive and operational maintenance of air pollution control systems is necessary to ensure that

emission levels are within norms laid down by MPCB.

Mitigation Measures

Following mitigation measures are planned and suggested in view of air environment during operation phase:

Controlling fugitive / VOC emissions

o During transfer of materials, spillages shall be avoided by use of proper equipment and SOPs.

o Safety interlocking systems and automatic shutdown systems shall be provided on critical equipment

o Transportation must be carried out in closed approved vehicles only and HAZMET guidelines and statutory requirements.

o All safety & control measures shall be provided to prevent spill, leak and accident during transportation.

o Environmental Monitoring Plan shall be developed for regular monitoring of flue gas emissions, work place environment and ambient air quality of all plant facilities.

o Periodic maintenance plan for all pipelines, fittings, instrumentation and control devices.

o Leak detection and rectification (LDAR) program shall be formulated to detect leaks and repair them with scheduled monitoring




o It is essential that best practicable control measures and practices are introduced

to control VOC emissions from plant. This shall include:

o Providing vent condensers to control VOC emissions

- Ensure that cooling water/chilled water supply to the condensers is always maintained by providing standby pumps and DG power.

- Having a preventive maintenance program.

- Providing mechanical seals on agitators, pumps.

4.4.6.12 Odor control and Plan

Volatile organic compounds and odorous substances handled at site are primarily responsible for odour. In addition, to measures indicated above, under VOC and fugitive emission control following measures are proposed to control odor at site.

o All solvent handling reactor vents to be connected to condensers to minimize escaping of VOC emissions.

o All solvent handling agitators and pumps to be provided with mechanical seal to eliminate leakages.

o Storage facilities to be provided with adequate measures to avoid losses by exposure to ambient condition.

o Utility line sizes for condensers to be properly designed & adequate supply of utility (flow & temperature) to be provided to all condensers.

o Temperature indicators to be provided for condensers to avoid solvent losses. o Solvent traps to be provided in vent lines of reactors. o The charging of odorous raw materials to be done through closed systems like

Duct hoods, isolated cabins etc. o Vents connected to common condensers/scrubbers.

o Water circulation pumps of condensers/scrubbers shall be provided with dedicated DG power supply in addition to normal power supply.

General

Provide green belt all around the factory to ensure that site is screened from

surroundings and air impacts are reduced.

Adequate open area and ventilation.

4.4.7 Ecological & Biological Environment

The impacts during operation phase of expansion are mentioned below:


Operation phase of synthetic organic chemical manufacturing unit and Co-generation plant involves transportation of raw material and work force. This leads to increase in noise levels at site; however existing surrounding activities have other noise sources, which overall establishes background noise level for the area. Thus, propose project activity envisage insignificant adverse impact on fauna due to noise generation.




Gaseous and particulate matter emission from stacks and other process related sources are predicted to increase levels of particulate matters, SO2 & NOx. Threshold limit of SO2 for sensitive plant species is 1820 µg/m3 for 1-hour exposure. Visible injury caused in the form of development of interveinal necrotic blotches. Similarly, threshold limit of NOx for sensitive plant species is 38000 µg/m3 for 1-hour exposure. Visible injury is seen same as in case of SO2. Considering baseline environmental conditions and pollution load calculation indicates, concentrations of gaseous pollutants together with existing baseline concentrations are lower than threshold limit specified in CPCB publication, March 2000 for Green belt Development. Operations at Prasol manufacturing unit envisage insignificant adverse impact on flora and fauna, provided efficient working of suitable pollution control equipment and development and maintenance of suitable green belt.


Impacts of Co-generation plant and expansion of synthetic organic chemicals manufacturing facility are discussed earlier; these impacts can be minimized by adopting following mitigation measures. For particulate and noise abatement, two rows of trees will be planted all around the boundary of site. Green belt will be developed in two levels i.e. tall, native and evergreen broad-leaved species towards outer periphery whereas dwarf and native species towards inner side of it. This arrangement provides better screening effect.

Saplings of recommended species will be brought from the nearby private nursery or nursery under forest department (social forestry division). It will be ensured that these saplings have undergone hardening before planted at pre-decided locations.

Hardening off seedlings is the process where in, seedling exposes to open-air environment progressively. This process makes the seedling strong enough to withstand in climatic changes where they get planted. Generally, hardening is done for 10 to 15 days before it is taken out for planting.

The process involves gradually increase in light duration keeping them in shade and progressively cutting down the water supply up to 80% to 75%.

Saplings will be protected from grazing, wilting/ infected or pest attacks. This increases survival rate of sapling. Considering 80% survival rate, 570 number of saplings needs to be replaced next year. This translates to increase in operation and maintenance cost by Rs. 1.6 lakhs/ year.

Objectives and principles of green belt development are listed below. In practice, green belt will be developed in consultation with horticulture expert, as per available species nearby. Indicative species list for green belt is given in Tables below.

Objectives of Green belt development




1. Partial check on air pollution 2. Partial check on noise level 3. Increase in esthetic value of surrounding 4. Indirect partial help to maintain biodiversity

Principles of Green belt development

1. Green belt will be composed of native species. 2. Species will be suitable for agro-climatic zone, i.e. Western Ghats. 3. Species will be selected according to soil type, climate, rain fall etc. 4. Taller plants will be planted towards outer periphery. 5. Shorter plants will be planted towards inner periphery. 6. Evergreen species will be selected as far as possible to have least litter fall. 7. Plant will be tolerant to air pollution. 8. Green belt will have indicator species with respect to air pollution 9. Species may have quick growing ability

Total area proposed under green belt is 23,004 m2 (33.5% of total plot area). Green belt area break up:

Description Existing Proposed@ Total

Area of Green Belt 13374 sq.m 9630 sq.m 23004 sq.m

% of Total Project Area 19.5% 14% 33.5%

No. of Plants* 1845 nos. 1605 nos. 3450 nos. * As per Standard TOR condition 7(ix)- Green belt development plan in 33 % area i.e. land with not less than 1,500 trees per ha

@ Additional plot sy. No. 74/3 of Thanenhave will be dedicated for green belt development. Copy of agreement for green belt development is enclosed as Annexure 2.1(c). Green belt layout is presented in Annexure 2.1. There will be separate budgetary provision of Rs. 20 lakhs made for green belt development. Plantation must be started prior to commencement of site development. In operation phase, yearly monitoring will be conducted to assess any sort of impact due to project activity on flora and fauna, for first three years. Frequency of monitoring may be reduced to once in three years from forth year. Reports prepared based on monitoring, primary surveys will be conserved as record and made available on demand. Monitoring will be conducted in consultation with ecology/ biodiversity expert or department of Botany/ Zoology, of reputed college/ University or officials of forest department. There will be separate monitory provision of Rs. 10 lakhs per year made for maintenance of green belt. A gardener and supervisor will be appointed for the same. Maintenance will include watering and manuring plants at appropriate time, weeding out unwanted plants, cleaning, replacing wilted/ died plants.

Table 4.20 Time bound action plan for green belt development

Timeline for green belt development Nos. of saplings Rs. in lakhs Phase-1 (during monsoon 2021) 1000 15

Phase-2 (within 3 months from Phase-1) 605 5 Total no. of saplings 1605 20




Table 4.21 List of species towards outer periphery

Sr. No.

Scientific name Common

name Height

(m) Growth rate

Evergreen/ Deciduous

Crown Shape

1. Garcinia indica Kokam 12 Slow

Growing Evergreen Oblong

2. Anacardium occidentale

Cashew, Kaju 10 Fast Growing Evergreen Round

3. Artocarpus

heterophyllus Jack fruit tree 10

Slow Growing

Evergreen Oblong

4. Anona squamosa Custard apple 10 Fast Growing Evergreen Round 5. Mammea suriga Suringi 18 Fast Growing Evergreen Spreading 6. Mimusops elengi Bakuli 10 Fast Growing Evergreen Oblong/ Round

7. Lagerstroemia

speciosa Queen Crape

Myrtle 10 Fast Growing Evergreen Oblong

8. Polyalthia longifolia

Ashok 10 Fast Growing Evergreen Conical/Round

ed 9. Careya arborea Kumbhi 8 Fast Growing Evergreen Spreading 10. Ficus glomerata Umbar 15 Fast Growing Evergreen Spreading 11. Meyna laxiflora Alu 10 Fast Growing Evergreen Spreading 12. Terminalia arjuna Arjun 15 Fast Growing Deciduous Oblong/ Round

13. Terminalia

bellerica Behda 15 Fast Growing Deciduous Oblong/ Round

14. Syzygium cumini Jamun 20 Fast Growing Evergreen Oblong /

Spreading

Table 4.22 List of species towards inner periphery

Sr. No.

Scientific name Common

name Height

(m) Growth rate

Evergreen/ Deciduous

Crown Shape

1. Bauhinia purpurea Butterfly Tree 7 Fast Growing Deciduous Oblong

2. Bauhinia racemosa

Astha 5 Fast Growing Deciduous Oblong

3. Gardenia

jasminoides Anant 5 Fast Growing Evergreen oblong

4. Hibiscus rosa-

sinensis Chinese Hibiscus

3 Fast Growing Evergreen Round/ oblong

5. Nyctanthus arbor-

tristis Parijatak 5 Fast Growing Deciduous Oblong/ Round

6. Saraca asoka True Ashok 5 Fast Growing Evergreen Spreading 7. Psidium guava Guava tree 5 Fast Growing Evergreen Oblong

4.4.7.3 Wild life conservation plan

Though, no schedule I species is observed during survey, species Pavo cristatus is reported in secondary data collected from forest department. Wildlife Conservation plan for Schedule I species is prepared & submitted to Chief Wildlife Warden through Regional Division office. Copy of Wildlife Conservation plan submitted is attached as Annexure 3.4(b).




4.4.8 Noise & Vibration Environment


Noise & vibrations generated from the equipment & machineries including pumps, motors, blowers will add to occupational noise level, exposing on site workers to high noise level

The project is located away from human settlement.

Cumulative noise impact has been considered for expansion project. Following sources of noise generation during the operation phase are considered for impact prediction.

Noise Generating Sources

S. No. Source Noise Levels dB(A) 1. Compressor 85 2. Pump 85 3. Cooling Tower 80 4. Chiller 80 5. Blower 85 6. Vehicular movement 80

Map showing site layout within a 10 km radius is provided in figure below.

Figure 4.10 Ten km radius study area around site

Noise modeling methodology and results




In order to predict the noise propagation within indicated area above, Dhwani-Pro model Based on CPCB algorithm and standards is used to predict changes in noise due to the project activity i.e. transport and manufacturing activities. The combined noise contour is provided in figure below,

Figure 4.11 Combined noise Contour

Results of the predicted noise level at project and other monitored location is given in table below.

Table 4.23 Predicted total Noise Level in dB(A)

S.No Location

Existing Noise Level, dB(A)

Expected incremental Level dB(A)

Resultant dB(A)

Day Time

Night Time

Day Time

Night Time

1 Project site 63.0 60.3 47.9 63.1 60.5 2 Adoshi 55.0 49.0 20.6 55.0 49.0 3 Chinchavali 53.3 46.4 25.0 53.3 46.4 4 Honad 54.3 42.1 28.8 54.3 42.1 5 Mahad 64.8 46.7 19.8 64.8 46.7 6 Sangade wadi 51.7 43.0 26.4 51.7 43.0 7 Vadval 53.6 47.9 21.6 53.6 47.9 8 Yashvantnagar 55.3 39.4 23.6 55.3 39.4


There will be no/ negligible increase in noise levels beyond the allowable limit predicted. Noise environment also includes the people who are working within the project site, and who may face hearing issues, in case they face the noise beyond the allowable level.




Therefore, it is important to implement the following mitigations:

o Acoustic Enclosures on all major equipment in the plant will have to be provided for noise attenuation.

o Proper mounting of equipment & machinery on strong non-vibrating foundation & fitted by proper shunting & rubber padding to avoid vibration and thereby noise.

o Workers will also be provided with suitable personal protective equipment (PPE) such as earmuffs and earplugs.

o Rotation of workers in the high noise area o High noise generating areas will be identified and tags marked.

o Dense Greenbelt development around the noise source area and along the boundary of premises shall be carried out.

o Vehicle trips to be minimized to the extent possible. o Equipment to be maintained in good working order. o Implement good working practices (equipment selection) to minimize noise and

reduce its impacts on human health. o Noise levels be monitored within site as per plan.

o Undertake in plant audit to identify high noise level generating equipment.

o All equipment operated within specified design window. Conclusion The noise level will not exceed the permissible limit for noise level for the project site and surrounding. No adverse impact is envisaged on social and ecological environment outside the project site.

4.4.9 Traffic Management

After proposed expansion, increase in vehicles plying are envisaged on Therefore, basis for transportation of raw material and finished product. Expected traffic increase due to project is anticipated as below

Table 4.24 Additional vehicles movement due to proposed project

Vehicle type No of

vehicles Equivalent

factor* PCU PCU/ Hr

Truck/ tanker/ container/ trailer

50 5 250 25

Auto-rickshaw 20 2 40 4 Passenger car, pick-up van 20 1 20 2

Bus 3 3.7 11 1 Total 93 - 321 32




Table 4.25 Total traffic expected after expansion

Vehicle type No of

vehicles Vehicles per hour

PCU PCU/ Hr

Existing 2859 286 4749 475 Proposed additional 93 9 321 32

Total 2952 295 5070 507

As per the IRC: 106-1990, type of carriageway is 2-Lane (Two-Way) and design service volume for this road is considered under category Arterial and PCU per hour 1500.

The calculated PCUs per hour is 507, which is well within recommended design service volume (PCU/Hour) by IRC.

Anticipated impact Impacts due to Road Transportation

o Increase in transportation will lead to increase in road traffic; o Generation of dust due to vehicular movement. o Emission of pollutants like HC, SO2, NOx and PM; o Noise generation from vehicular movement; o Spillage or leak of raw materials during transportation. o Chances of accidents.

Mitigation Measures as mentioned shall be taken whilst transporting Raw material/ products

o Trucks to be covered with tarpaulins before traveling on public roads. o No overloading / overspending to be done. o Traffic management to be ensured. o Adequate parking arrangement at site. (3092 sq meter onsite).

The engines and exhaust systems of all vehicles and equipment used will be maintained as such, that exhaust emissions are low and do not breach statutory limits set for the concerned vehicle/equipment type.

4.4.9.1 Options for transport of raw materials and finished products

Options for transport of raw materials and finished products and wastes by rail or rail-cum road transport or conveyor cum- rail transport examined and concluded that the option is not practical and feasible.

As, discussed earlier, Prasol will develop good network of internal peripheral roads in the plots for the safety and access requirements to various buildings/ warehouse/ plants/ emergency services.

The access roads to the plant premises are developed and maintained throughout the year.

As a part of EIA study, the EMP for traffic management is presented in the following table,

Table 4.26 Traffic management plan




Objective To ensure that there is smooth traffic within and outside the facility for the duration of the construction phase and operation phase

Concern Trucks, tankers and other vehicles may cause traffic jam outside and within the premises / accident.

Impacting activity

Mitigation measure

Location and timing

Responsibility Monitoring

Vehicular movement

Controlled vehicular movement (preferably with clearly demarcated entry/exit) with adequate supervision

Within and immediately outside the site - Construction & operation Phase

Contractor/ Project Manager during construction phase. Security and concerned departments during operation phase.

Security-in charge and security team

Vehicular movement

Demarcation of separate vehicular lanes and pedestrian routes

Within the site - Construction & operation Phase Security and concerned departments during operation phase.

Contractor/ Project Manager during construction phase.

Security team

Vehicular movement

Vehicle entry and exit scheduling so that traffic congestion is not created on the external road leading to the site

Within and immediately outside the side - Construction & operation phase

Contractor/ Project Manager during construction phase. Security and concerned head of department during operation phase.

Security-in charge and security team

4.4.10 Solid and Hazardous Waste


During operation phase, following nonhazardous and hazardous waste generation is expected. Waste if not stored properly may cause short term, temporary impact on the environment, particularly during monsoon season due leachate formation.

Waste generation quantities from existing and proposed operation are as follows:

Table 4.27 Non hazardous waste generation & disposal




No Waste Type UOM Existing Quantity

Additional quantity

Total Disposal

1 Sand from water

filtration TPA 11 6.5 17.5

Sale to Authorized Vendor/ recycler/ re processor/ landhill

2 Used hand

gloves Cotton/ PVC/ Rubber

Pcs/A 20,000 5000 25,000 CHWTSDF/ Sale to Authorized

Vendor

3

Miscellaneous (Rubber & Teflon Gasket/ Packing/

Transmission Belt/ V Belt/ PP /

FRP etc)

Kg/annum

500 500 1000 CHWTSDF/ Sale to Authorized

Vendor

4 Fly Ash TPD 30 0 30 Sale to Brick manufacturer/

Cement Manufacturer/ Authorized Vendor

Table 4.28 Hazardous waste generation & disposal

No Waste Type

Category (as per

HW rules 2016)

UOM Existing Quantity

(*)

Additional quantity

Total Disposal

1 Used/ Spent

Oil 5.1 KL/A 12 3 15

Sale to Authorized Vendor/ recycler/ re

processor

2 Filter

residue 6.1 TPA 38 82 120



3 Tar 1.2 TPA 1500 0 1500 CHWTSDF/ Sale to

Authorized Vendor/ recycler/ reprocessor

4 Distillation

residue 20.3 TPA 613.2 1225 1838.2



5

Used, Empty containers/

barrels/ liners

33.1 Nos/A 7000 18000 25000 Sale to Authorized Vendor/ recycler/

reprocessor

6 ETP sludge from WWT

35.3 TPA 80 320 400 CHWTSDF

7 Evaporation

Residue/ ATFD salts

37.3 TPA 0 1200 1200 CHWTSDF

8 Spent

catalyst 19.2 TPA 5 15 20

CHWTSDF/ Sale to authorized reprocessor

9 Ion

exchange resin

35.2 TPA 1 0.5 1.5 Sale to Authorized

Vendor/ recycler/ re processor

Hazardous Wastes will be stored in impervious lining/flooring in covered shed. The dewatered sludge will be stored in bags and in shed and then disposed of to CHWTSDF periodically through trucks owned by MPCB authorized contractors or sold to MPCB

authorized recyclers.




No impacts are envisaged on the 10 km surrounding study area in case above disposal

methodologies are adhered to. However, close monitoring and control over waste disposal contractors/transporters by use of manifest system is essential to ensure that the waste reaches the designated waste disposal site and is not dumped in undesignated areas impacting agricultural areas, soil and ground water adversely.


Adequate use of PPE for onsite workers.

Disposal through authorized recycler/ re-processor or to designated CHWTSDF site.

Follow of Manifest system scrupulously to ensure waste reaches designated site.

Disposal through MPCB authorized transport contractor.

Waste storage in designated covered area having impervious flooring and epoxy lining wherever necessary.

Maintenance of records as required under HW Rules 2016.

4.4.11 Occupational Health and Safety


The expansion project involves use of hazardous raw materials which are listed in Schedule I of MSIHC Rules, 2000 having fire and toxic hazards. Methanol, Ethanol, Cumene, Acetone, Isopropyl alcohol, Octanol, Isophorone, Diacetone alcohol, Benzaldehyde, MIBK, Mesityl oxide, Isobutanol etc are of major concern for impacts on

occupational health. Continuous exposure of employee to the chemical beyond permissible limit (TWA/TLV) may result in acute or chronic toxic or lethal effects. A detailed Quantitative Risk Assessment (QRA) for the proposed project is conducted and it is noticed that the hazardous condition causing serious effects on occupational health may occur only during the catastrophic incident as described in Chapter 7 additional studies. However, minor continuous exposure to toxic chemicals may lead to health issue in long term. Hence, it is necessary to monitor the health status of all employees on regular basis.

Further, impacts on occupational health may also occur due to works like manual lifting of heavy good, continuous working in single position, working in improper ergonomic

conditions etc. Such condition or operations may lead to health problems like back ache etc. Considering these, Prasol plans for closed automated transfer system for major raw materials as well as forklift & trolley for other handlings.


Prasol will extend good engineering practices and management system for the expansion project.

Provision of facilities like safe drinking water & dining rooms etc. and good sanitation including proper waste disposal.

Isolation of drinking water & refreshment area including canteen etc. from the area of hazardous materials storage & handling.




Chemical Safety Booklet/Documents for hazardous chemicals will be prepared and

made available well before commissioning to all employees handling the chemicals.

Strict Prohibition of edibles & potables in the area of hazardous materials storage & handling.

Strict Prohibition of match box, lighters, and clothes having potential of static charges as well as smoking in plant & storage area.

Prasol will ensure implementation of emergency action plan including on-site & off-site emergency management plan.

Prasol undertakes to do regular safety audit and necessary improvement suggested by auditor will be done on regular basis as required.

Necessary emergency facilities including firefighting equipment, medical facilities, evacuation facilities will be provided within premises.

Properly designed & designated storage area and provision of good handling equipment and procedures will be ensured before commissioning.

Proper shift planning of workers exposed to hazard prone areas to manage the total exposure level as per stipulated standards & / or statutory norms.

Company will train a group of employees for comprehensive first aid and basic fire-fighting training and ensure trained staff availability in all three shifts.

Mechanical handling system will be provided wherever feasible to reduce the stress

of pulling -pushing and lifting.

Ergonomic design of all facilities wherever possible (e.g. chairs, tables, working platforms, self and position & height of display screens & panel).

Management will provide all necessary PPEs, safety tools, equipment/tackles to ensure healthy & safe work conditions.

Workplace monitoring will be carried out on regular basis and corrective actions initiated as needed.

Necessary training programs & audit will be done on regular basis to improve workplace condition & provide safe work system.

PFT & LFT test will be carried out during pre-placement and periodical examination

considering the toxic effects of various chemicals handled.

Company follows all statutory guidelines related with occupational health & safety which will be extended to the proposed expansion also.

Safety committee will be to ensure worker participation

4.4.12 Socio-economic Environment


Employment Opportunities




The proposed project will have positive effect on socio – economic environment as there

will be growth in employment i.e. about 110 for direct workers. During employment, local populace will be given preference considering their skills & suitability.

Other Impacts

Pollution level is likely to increase in the study area in the form of air, water and soil pollution. Prasol is committed to implement adequate precautionary measures from design stage itself to mitigate/control the environmental pollution from project to comply all emissions/discharges as well as plans of waste management standards/norms prescribed by MoEF&CC/CPCB/MPCB with the objective of environment protection.

There is likely to be growth in the revenue generation and economy at local, regional and state levels. There will certainly be improvement in standard of living due to required

facilities provided or upgraded by management under CSR.


Maintaining health status by organizing health check-up camps.

Assistance to local authority i.e. gram Panchayat for provision of toilets, drinking water, safe disposal of wastes.

Distribution of educational aids & stationary, library books for local schools.

Donate seeds & sapling of shrubs / small trees or sponsor social forestry programs.

All mitigation measures shall be implemented for control of air pollution, water

pollution, land pollution and noise pollution.

Priority will be given to local people for the employment.

Hazards shall be managed/control by implementation of safe work procedures, risk/hazard control /prevention measures and provision of PPEs for all employees as followed at the existing plants.

There will be generally positive and beneficial impacts by way of economic improvements, transportation, aesthetic environment and business generation.

4.4.12.3 Corporate Environmental Responsibility (CER)

In order to mitigate adverse impact likely to arise in social, cultural and economic aspects in the surrounding region the project is expected to contribute towards upliftment of

local people quality of life.

Corporate Environment Responsibility Plan

As per OM F. No. 22-65/2017-IA. III issued by MoEF & CC on 1st May 2018 on Corporate Environment Responsibility (CER), some of the activities which can be carried out under CER, are infrastructure creation for drinking water supply, sanitation, health, education, skill development, roads, cross drains, electrification including solar power, solid waste management facilities, scientific support and awareness to local farmers to increase yield of crop and fodder, rain water harvesting, soil moisture conservation works, avenue plantation, plantation in community areas, etc.




Fund allocation for the CER is based on criteria such as % of capital investment for green

field/brown field projects.

For brown field project, Fund allocation is 1.0% of project capital investment (for Investment less than Rs. 100 crores).

As the expansion project is brown field, Prasol is allocating Rs. 50 Lakhs i.e. 1% of estimated project investment of Rs. 50 crores for CER.

CER Plan proposal for improvement in nearby vicinity will include creation of infrastructural facilities which are lacking with special emphasis on water, and sanitation, health, education, skill development and tree plantation.

Table 4.29 Budgetary Allocation for CER

Proposed Activity

Year wise allocation of Fund (INR In Lakh)

1st Year 2nd

Year 3rd

Year 4th Year 5th Year

Total (April – March)

Water supply, Sanitation, health

- - - 5 6 11

Education & Skill development

- 5 2 5 5 17

Solid waste disposal and associated activities

5 - 5 - - 10

Avenue tree Plantation - 4 4 1 1 10

Solar lights for community 2 - - - - 2 Total 7 9 11 11 12 50

Note: The above budgetary allocation and activities are tentative, subject to change.

Copy of plan submitted to District collector is attached at Annexure 4.1.

4.5 Prediction of Impacts during De Commissioning Phase and Mitigation Measures

This section examines impacts during decommissioning of project, should the need arise.

4.5.1 Anticipated Impacts

Impacts during de commissioning phase will be due to:

Stoppage of production facility: Stoppage of production facilities will lead to having a stockpile of chemicals at the site, which will need to be safely disposed of. Decommissioning, if not undertaken in a safe way, may lead to catastrophic incidents which may have effects within/outside the factory. In addition, decommissioning will cause revenue loss to company and loss of employment to workers.

Waste generation there is possibility that failed batches will need to be stored and disposed safely so as not to cause land pollution.




4.5.2 Mitigation Measures

Proper procedure for safe decommissioning shall be established as part of project development with training to employees.

Wastes generated will have to be identified and disposed of safely and site will not be considered shut down unless all wastes are safely disposed

Have a designated procedure to ensure that workers do not suffer in this eventuality.

4.6 Environmental Impact matrix

The possible impacts of various constructional and operational activities as identified above have been denoted in a matrix form. A quantitative matrix rating has been devised

to give severity of impacts in the following manner:

Highly Negative Overall Impacts: Total Score= above -353

Moderately Negative Overall Impacts: Total Score= -176 to - 352

Slightly Negative Overall Impacts: Total Score= -1 to -176

Neutral overall Impacts: Total Score = 0

Slightly Positive Overall Impacts: Total Score= 1 to 176

Moderately Positive Overall Impacts: Total Score= 176 to 352

Highly Positive Overall Impacts: Total Score = above 353

The matrix system assumes the environmental indices into the following:

Physical Parameters: Surface water quality

Ground water quality

Air quality & Climate

Soil Quality

Land use pattern & Topography

Ecological Parameters:

Forests/ Parks/ Sanctuary

Flora & Fauna

Aquatic ecosystem

Social Parameters: Aesthetics

Local Housing structure

Services

Health & Safety

Economic Parameters: Agriculture

Fisheries




Industries

Employment

The assessment of the impact of the general impacting activities on the above parameters

of environmental indices can be done by establishing a co-relation by “Cause and effect

relationship” with the help of impact matrices. The matrices for construction as well as

operation phase are presented below for two conditions:

Without mitigation/control measures.

With proposed mitigation measures for adverse / beneficial effects.

The criteria for evaluation of qualitative matrix are presented herewith:

1. No Impact (0): This indicates that the project activity is unlikely to have any impact on an environmental attribute.

2. Negligible Adverse Impact (-1) / Negligible Beneficial Impact (+1): It signifies that the actions have minor effect, adverse or beneficial, on the environmental parameters concerned.

3. Significant Adverse Impact (-2) / Significant Beneficial Impact (+2): The activities and their environmental Impacts are judged to be significant if they create or have the potential to create concern in the public or professional community.

4. High Adverse Impact (-3) / High Beneficial Impact (+3): The action that can

create or have a potential to create controversy in the public or professional community due to its long-term effect. They may be at times irreversible.

The environmental Impact matrix without mitigation / control measures during the construction phase and operation phase is given below, which shows the slightly negative impact of the project is (-) 140 i.e. no significant impact. The matrix with proposed mitigation measures during the operation phase is given below, which shows the overall

impact with environmental controls is reduced to (-) 75 i.e. slightly negative.

Environmental Impact Assessment Prasol Chemicals Private Limite



Table 4.30 Environmental Impact Matrix Evaluation without Mitigation Measures

Impact Source

Parameters

Construction Phase Operation Phase

Pla

nt

con

stru

ctio

n

Wa

ter

req

uir

em

en

t, w

ast

e

wa

ter

ge

ne

rati

on

& d

isp

osa

l

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

e

mis

sio

ns

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h &

co

nst

ruct

ion

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

roje

ct s

ite

To

tal

Pla

nt

op

era

tio

n &

pro

cess

Wa

ter

req

uir

em

en

t, w

ast

e

wa

ter

ge

ne

rati

on

& d

isp

osa

l

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h

che

mic

als

& o

pe

rati

on

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

rod

uct

To

tal

Physico-chemical parameters:

Surface water quality

0 -1 0 0 -1 -2 -2 0 0 -6 -3 -3 -3 0 -2 -2 -2 -2 0 -17


0 0 0 0 -1 -2 0 0 0 -3 0 -3 0 0 -3 -2 -3 0 0 -11

Air quality & climate

-1 0 -1 0 0 -1 -1 0 0 -4 -3 0 -3 0 0 -2 -2 -3 -2 -15

Soil quality 0 -1 0 0 -2 0 -1 0 0 -4 -2 -3 0 0 -3 -2 -2 -2 0 -14 Land use pattern

-1 0 0 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0 0 0

Ecological parameters: Forest/ park/

sanctuary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Flora & fauna 0 -1 -1 0 -1 0 0 0 -1 -4 -2 -2 -3 -1 -2 -1 -2 -2 -2 -17 Aquatic

ecosystem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -3 0 -3

Social parameters: Aesthetics -2 0 -2 0 -3 -1 -2 -1 0 -11 -2 -2 -2 0 -3 -3 -3 -2 +1 -16

Local housing structure

0 -1 0 0 -1 -1 0 0 0 -3 0 -2 -2 0 -1 -2 -1 0 0 -8

Service 0 -1 -1 0 0 -1 -1 -1 0 -5 0 -1 -1 0 0 -1 -2 -2 0 -7




Impact Source

Parameters


Pla

nt

con

stru

ctio

n

Wa

ter

req

uir

em

en

t, w

ast

e

wa

ter

ge

ne

rati

on

& d

isp

osa

l

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

e

mis

sio

ns

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h &

co

nst

ruct

ion

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

roje

ct s

ite

To

tal

Pla

nt

op

era

tio

n &

pro

cess

Wa

ter

req

uir

em

en

t, w

ast

e

wa

ter

ge

ne

rati

on

& d

isp

osa

l

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h

che

mic

als

& o

pe

rati

on

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

rod

uct

To

tal

Health & safety -2 -1 -1 -1 -1 -2 -2 -1 0 -11 -2 -2 -3 -2 -3 -2 -3 -2 +2 -17 Economic parameters:

Agriculture 0 -1 0 0 -1 -1 0 0 0 -3 -2 -3 -3 0 -2 -1 -2 -1 -2 -16 Fisheries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -3 0 -3

Industries 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0 0 0 0 0 +1 +1 Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 +2 0 0 -1 +3

Total -5 -7 -6 -1 -11 -11 -9 -3 +2 -51 -14 -21 -20 -3 -19 -16 -22 -22 -3 -140




Table 4.31 Environmental Impact Matrix Evaluation with Mitigation Measures

Impact Source

Parameters


Pla

nt

con

stru

ctio

n

Wa

ter

req

uir

em

en

t,

wa

ste

wa

ter

ge

ne

rati

on

&

dis

po

sal

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h &

co

nst

ruct

ion

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

roje

ct s

ite

To

tal

Pla

nt

op

era

tio

n &

pro

cess

Wa

ter

req

uir

em

en

t,

wa

ste

wa

ter

ge

ne

rati

on

&

dis

po

sal

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

&

dis

po

sal

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h

che

mic

als

& o

pe

rati

on

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

rod

uct

To

tal

Physico-chemical parameters:

Surface water quality

0 0 0 0 0 -1 -1 0 0 -2 -2 -2 -2 0 -1 -1 -1 -1 0 -10


0 0 0 0 0 -1 0 0 0 -1 0 -2 0 0 -2 -1 -2 0 0 -7

Air quality & climate

0 0 0 0 0 0 0 0 0 0 -2 0 -2 0 0 -1 -1 -2 -1 -9

Soil quality 0 0 0 0 -1 0 0 0 0 -1 -1 -2 0 0 -2 -1 -1 -1 0 -8 Land use pattern

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Ecological parameters: Forest/ park/

sanctuary 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Flora & fauna 0 -1 -1 0 -1 0 0 0 -1 -4 -1 -1 -2 0 -1 0 -1 -1 -1 -8 Aquatic

ecosystem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -3 0 -3

Social parameters: Aesthetics -1 0 -1 0 -2 -1 -1 0 0 -6 -1 -1 -1 0 -2 -2 -2 -1 +1 -9

Local housing structure

0 0 0 0 0 0 0 0 0 0 0 -1 -1 0 0 -1 0 0 0 -3

Service 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 -1 0 -2 Health & safety -1 0 -1 -1 -1 -1 -1 -1 0 -7 -1 -1 -1 -1 -2 -2 -2 -1 +2 -9

Economic parameters:




Impact Source

Parameters


Pla

nt

con

stru

ctio

n

Wa

ter

req

uir

em

en

t,

wa

ste

wa

ter

ge

ne

rati

on

&

dis

po

sal

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

& d

isp

osa

l

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h &

co

nst

ruct

ion

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

roje

ct s

ite

To

tal

Pla

nt

op

era

tio

n &

pro

cess

Wa

ter

req

uir

em

en

t,

wa

ste

wa

ter

ge

ne

rati

on

&

dis

po

sal

Sta

tio

na

ry, p

roce

ss &

fu

git

ive

em

issi

on

s

No

ise

Wa

ste

ge

ne

rati

on

&

dis

po

sal

Ma

teri

al

tra

nsp

ort

ati

on

, st

ora

ge

& h

an

dli

ng

Ha

zard

s a

sso

cia

ted

wit

h

che

mic

als

& o

pe

rati

on

of

pla

nt

Bre

ak

do

wn

of

con

tro

l e

qu

ipm

en

t

En

d u

se o

f p

rod

uct

To

tal

Agriculture 0 -1 0 0 -1 -1 0 0 0 -3 -2 -2 -2 0 -1 0 -1 0 -1 -9 Fisheries 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 0 -1

Industries 0 0 0 0 0 0 0 0 +1 +1 0 0 0 0 0 0 0 0 +1 +1 Employment +1 0 0 0 0 0 0 0 +2 +3 +2 0 0 0 0 +2 0 0 0 +4

Total -1 -2 -3 -1 -6 -5 -3 -1 +2 -20 -8 -12 -13 -1 -11 -7 -12 -12 +1 -75




4.7 Observations and Conclusions

The study for the expansion project of Prasol has revealed that the upcoming activities of manufacturing will have negligible impacts which would mainly occur only upon Improper discharge of effluent/release of untreated gaseous pollutant to air/Improper disposal of solid waste/accidental spill/leak of volatile/gaseous chemicals/materials. Risk assessment study has been conducted for the proposed project and the suggestions made in the report shall be implemented strictly to prevent any chances of environmental contamination and employee health & safety. By the efficient implementation of Hazard/Risk control/Prevention measures the negative impacts would be avoided.

Besides, the hazardous waste generated from the production process & utility operation

will be managed as per MoEF&CC/CPCB/MPCB Guidelines. Hence issues of air & land contamination are not envisaged. The water requirement will be met by irrigation department & through recycle of treated effluent hence no impact on ground water availability envisaged. As mentioned, the project will operate as zero liquid discharge.

Prasol will plant varieties of trees & shrubs in the premises. Greenbelt will be maintained in excellent condition giving visual of dense vegetation. Greenbelt will be managed with all possible care & attention to improve environmental condition. Thus, the beneficial impacts due to the dense greenbelt are envisaged.

It is also found that the high noise generation sources are not part of proposed project. Hence noise levels are not expected to go up. The noise level out of the premises is

envisaged to be <65-70 dB(A) in day and 55-60 dB(A) in night as maximum. Thus, looking to the source, potential noise level generation & planned mitigation measures; impacts due to noise are not envisaged.

Company intends to conduct the CSR activities for social welfare & upliftment. Necessary documents & records of all activities shall be maintained.

All aspects of safety will be adequately managed and required safety material, equipment and facilities will be provided to all employees, contractor & visitors. Thus, issue of impacts due to probable hazards/ risk/ disaster would be minimal.

Thus, looking all the management procedures/ actions, environmental management activities and other allied functions of management system, it is concluded that there will

not be any major considerable impacts on environment.


Chapter 5- Analysis of Alternatives


5 ANALYSIS OF ALTERNAT IVES (TECHNOLOGY & SITE)

5.1 Analysis of Alternative Sites

Proposed expansion will be within existing facility which comprises of total 68,644 sq. m of area. Following aspects are considered for expansion

Existing operating plant.

Availability of adequate land, utilities and infrastructure.

Availability of major raw material from nearby industries.

Synergy with Prasol’s existing operation and other manufacturing site.

Availability of technically skilled and unskilled workers in the area.

Proximity to end users.

Doesn’t involve R&R issues.

JNPT port and Mumbai international airports are nearby.

Availability of medical, educational facility, transportation and other

infrastructure.

5.2 Analysis of Alternative Technologies

Products for which this expansion is planned are manufactured with the best available technology as on date and process technology is also proven.

All plant sections will be equipped with adequate process control and instrumentation to provide inbuilt safety and process efficiency. There is an excellent R&D team working on advancement of processes and optimization of raw materials and resources. Latest design and instrumentations shall be used in process equipment fabrication. DCS and PLC shall be provided wherever feasible.

Although the product list of the company appears quite large, the chemicals proposed to be produced are downstream products based on Cumene, Sulphur and Phosphorous. Most of the expansion products proposed to be produced are based on hydrogenation of acetone for which technologies are readily available and well developed. Product chain based on Cumene, Sulphur and Phosphorous are shown in Figures below


Chapter 5- Analysis of Alternatives


Figure 5.1 Product Chain from Cumene

Figure 5.2 Product Chain from Phosphorus and Sulphur

5.2.1 Wastewater treatment and alternatives

Since the proposed project shall be ZLD, different alternative treatments like RO, MEE, ETP scheme will be adopted for different types of effluent streams with different characteristics based on the feasibility to achieve the limits for recycle/reuse of the treated effluent. Different alternatives for reduce, reuse & recycle will be adopted in the plant. There will be overall integrated approach for the effluent treatment.


Chapter 6- Environmental Monitoring Programme


6 ENVIRONMENTAL MONITO RING PROGRAMME

Based on the predicted & assessed impacts as well as the baseline environmental status of the project area, an environmental monitoring program is suggested for implementation during various stages of the project cycle.

6.1 Objective of Environmental Monitoring Program

For tracking of the effectiveness of mitigation measures & EMP at specific interval,

regular monitoring of the necessary environmental parameters is required. With this vision, an environment monitoring program is prepared with due consideration of the baseline status of the expansion project area, various components of project & environmental attributes likely to be affected.

Major objectives of the Environmental Monitoring Program are as under:

To comply with the statutory requirements of monitoring for compliance with conditions of EC, Consent to operate and provisions under Factory Act & Environmental Protection Act provisions.

Assessment of the changes in environmental conditions, if any, during the project operation/activities.

Monitoring & tracking the effectiveness of Environment Management Plan & implementation of mitigation measures planned.

Identification of any significant adverse transformation in environmental condition to plan additional mitigation measures; if & as required.

Prasol shall implement the environment monitoring programs in line with the planned schedule. The company shall ensure that the necessary requisite facilities are made available and budgetary provision is made as & when required to ensure regular efficient environmental monitoring activities.

6.2 Environmental Monitoring Program

Environmental monitoring parameters and frequencies of monitoring are given in below table. In case of accidental spill & leak of hazardous chemicals, monitoring of the environment for detection of the spilled/leaked chemical shall be done in the affected area. In such case, soil & groundwater sample of the affected area shall be collected and analyzed for detection of the spilled / leaked chemicals at regular interval for the period as required to ensure safe level of contamination.




Table 6.1 Environment Monitoring Plan

Sr. No.

Project Phase Environmental Component

Parameters Frequency Locations Conducted by

1 Construction Air Environment Ambient air PM10/PM2.5/SO2/ NOx/CO Once/3

Month Adjacent to new construction site

MoEF&CC approved Laboratory Ambient Noise

Level Leq day and nighttime or over one work shift

Once/3 Month

At new construction site

Water Quality Drinking Water Quality

Microbiological parameters as per IS 10500: 2012

Once/3 month

Construction site -each drinking water locations.

MoEF&CC approved Laboratory

2 Commissioning Stage

Air Environment Ambient air PM10/PM2.5/SO2/NOx/CO/

nMHC/Ammonia/ benzene/As/Ni/Pb/Ozone

Once/3 Month

Project site MOEF&CC approved lab

Work place Acetone/ammonia/H2S/acid mist

Ambient Noise Level

Leq day and nighttime or over one work shift

Water Quality Drinking Water Quality

Microbiological (as per IS 10500: 2012)

Once/3 month

at each drinking water location.

MOEF&CC approved lab

In plant ETP pH, TSS, TDS, COD, BOD and Oil and Grease, MEE solids

Once/ shift ETP at intermediate stages and MEE

In house lab and periodically through MOEF approved lab

Waste Generated ETP sludge from waste water

As per Schedule II of HW Rules, 2008 and

Once ETP / MEE / Plant CHWTSDF or MOEF&CC




Sr. No.



treatment, MEE salts, distillation residue,

parameters for identifying disposal pathway as per CPCB

approved lab for identifying disposal pathway

3 Operation Phase

Air Environment Stacks – TFH / Boilers / DG sets

TPM/ SO2/ NOx Once/ 3 months

Respective stacks MoEF&CC approved Laboratory + Online continuous Monitoring

Ambient Air PM10/PM2.5/SO2/NOx/CO/nMHC/Ammonia/ benzene/As/Ni/Pb/Ozone

Designated locations


Workroom environment

Acetone/ammonia/H2S/acid mist

Plant / Storage/ handling Area

Water Environment ETP Operational parameters

like pH, TSS, COD, MLSS, DO, SVI.

Daily Equalization, after primary clarifier, after secondary treatment.

Own QC lab

Parameters as per MPCB Consent.

Once/3 month

At inlet and outlet of ETP

MoEF&CC recognized laboratory + Online continuous Monitoring

Drinking water Microbiological parameters as per IS 10500: 2012

Once/ 3 month

at each drinking water locations.

MoEF&CC recognized laboratory

Noise Environment




Sr. No.



Ambient Noise Leq (day & night) Once/ 3 month

at fence level and at nearest habitats.


Workroom noise Leq (8 hours) Once/ 3 month

near noise producing sources like DG set, Boiler house. TFH etc.

Biological Environment Ecological survey Study growth of trees at

site as per plan and identify new species for plantation

Once every 3 years

At site QCI NABET approved Biological expert

Land Contamination

Soil /Ground water Quality

For specific contaminants of spilled chemicals

Regularly until no traces noticed

At/near site of spillage

MOEF&CC approved laboratory

4 Decommissioning Stage

Ambient air PM10 / PM2.5/ SO2/ NOx/CO/NMHC

Once/ Month

Adjacent to project site

Ambient Noise Level

Leq day and nighttime or over one work shift

Once/ Month

Adjacent to project site

Soil /Ground water Quality

For specific contaminants of spilled chemicals

Regularly until no traces noticed

At/near site of spillage

ETP pH, TSS, TDS, COD, BOD, Oil and Grease

Daily until effluent stops completely

At various stages of in plant effluent treatment system as in 2 above




6.2.1 Measurement Methodologies

Monitoring of environmental samples shall be carried out through a laboratory recognized under section 5 of Environmental Protection Act 1986 and/or National Accreditation Board for Laboratories (NABL) under ISO: IEC 17025:2017. The methodologies for environmental monitoring shall be as per the methods/guidelines provided by MoEF&CC/ Central Pollution Control Board /or relevant Indian Standards or methods as specified by Standard Methods for Water and Wastewater Treatment by American Public Health Association (APHA). Methodology of monitoring (sampling & analysis) shall be documented as SOP (standard Operating Procedure) for parameters analyzed through in-house laboratory and shall be subjected to Internal audit and review

under the QMS system of Prasol.

For monitoring of workplace area, methods suggested / published by National Institute of Occupational Safety and Health (NIOSH), USA or as specified in Standard Methods for Air Analysis published by APHA shall be adopted.

6.2.2 Reporting Schedules

The records of the monitoring program viz water, wastewater, solid waste, air, emission, soil shall be prepared and preserved properly. The records showing results/outcome of the monitoring programs will be submitted as per the schedule below.

Monitoring reports will be reviewed regularly by Factory Management along with Environmental Consultant for necessary improvement of the monitoring plan/mitigation

measures/environmental technologies as well as for necessary actions of environmental management cell.

Table 6.2 Reporting Schedule

Sr. No.

Monitoring During

Reporting Schedule

Applicable Statute

Compliance Reporting To

1 Construction

Phase 1st June and 1st December of each year till end of construction

EIA Notification Clause 10

a) MPCB – Regional Office (Raigad)

b) CPCB, Regional Office (Pune)

c) MOEFCC- Western Zone office (Nagpur) and Monitoring Cell

2 Commissioning Phase

1st June and 1st December of each year till end of construction





3 Operation Phase

1st June and 1st December of each year








Baseline environmental monitoring - Before 10th of next Month in respect of stack/ vents, AAQ, ETP inlet/outlet, Noise levels

Combined Consent & Authorization (CC & A)

MPCB – Regional Office (Raigad)

4 Decommissioning Phase

1st June and 1st December of each year





Prasol will also file returns under HW Rules (30th June every year) and annual Environmental statements (30th September every year) &/or performance report/compliance report/audit report as per conditions of EC and CC&A and submit to MPCB within the stipulated timeframe (monthly or quarterly). CC&A and other statutory permission/consents must be obtained & renewed timely as per legal provision &

guidelines. Similarly, all necessary report & forms will be prepared and submitted to the concerned authority as per the statutory requirement of Environmental Acts/rules, Factory Act & MSIHC rules. Reporting of accident & other requirements will be made in prescribed format well within stipulated time frame as per statutory requirements & guidelines.

6.3 Budgetary Provisions for EMP

Environment management cell shall inspect the necessity & availability of the materials, technologies, services & maintenance works, on regular basis. The cell shall make appropriate budget for the purpose. Regular record review for change in financial requirement of environment management shall be done and appropriate budgetary

provisions shall be made. Budget for environmental management shall be prepared and revised regularly. The budget shall include provisions for:

Environmental Monitoring Program

Operation & Maintenance of environmental Technologies/Equipment

Laboratory works for Environmental management activities

Emergency Purchase of necessary material, equipment, tools, services

Greenbelt development

Social & Environmental Welfare & Awareness programs/training

Annual Environmental Audit.




The company has made budgetary provision for the proposed expansion as a part of their

initial planning. The same is presented below.

Table 6.3 Budgetary Provisions for EMP

Environmental Controlling Measure

Capital Investment (Rs. In Lakhs)

O&M Cost/Annum (Rs. In Lakhs)

Air Pollution Control 50 25 Environment Monitoring 50 25 Water Pollution Control 600 200 Hazardous waste & Solid waste management

50 50

Noise pollution control 10 2 Green Belt Development 20 10 Occupational Health & Safety 70 20 Other Green Initiatives

- Rainwater Harvesting 10 5 - Energy Conservation (LED) 5 0

Total 865 337


Chapter 7- Additional Studies (Risk Assessment & Public Consultation)


7 ADDITIONAL STUDIES ( RISK ASSESSMENT AND PUBLIC

CONSULTATION)

7.1 Objectives of Risk Assessment

Risk Assessment is a management tool for determining the hazards and risk associated with the various activities of a project and computes the damage potential of these hazards to life and property. Risk Assessment provides basis for determining the safety measures required to eliminate, minimize and control the risks as detailed in Disaster Management Plan (DMP) to handle onsite and offsite emergencies. Risk Assessment is carried out for the various hazards involved in storage and handling of hazardous raw materials, intermediates and finished products as well as for the manufacturing processes used by the unit.

Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of risks the neighboring populations are exposed to as a result of hazards present at project site. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. (Much of this information is difficult to get or generate. Consequently, the risk analysis is often confined to maximum credible accident studies).

It provides basis for

The type and nature of its On-Site and Off-Site Emergency Plan and,

The types of safety measures required.

Preventive and control measures needed for reducing risk involved.

Risk assessment is carried out for following objectives

To identify hazard and risk resulting from the hazards

To study and foresee the effects of such risks on the workers, public, property and

Environment and to find out necessary control measures to prevent or minimize risk.

To comply the legal requirement by various safety and environment laws of the country like…

o The Factories Act, 1948

o The Environment Protection Act and Rules, 1986

o Hazardous waste (Management & Handling) Rules, 2016

o Public Liability Insurance Act & Rules,1991

o Chemical Accident, (Emergency, planning, preparedness and response) Rules,1996

To get the necessary information for Emergency planning and evacuation.




7.2 Hazard identification and risk assessment

Hazard analysis involves the identification and quantification of the various hazards (unsafe conditions) associated with expansion project.

Risk analysis deals with the quantification of risk to the plant equipment, personnel and neighboring population, due to accidents resulting from hazards present in the plant.

Prasol handles various chemicals, most of which are hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of them. Fire, explosion, toxic release or combinations of them are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of safety engineering, such as, Hazard Analysis and Qualitative/Quantitative Risk Assessment have been developed to

improve upon the integrity, reliability and safety of industrial plants, the same has been discussed in detail under their respective headings.

Hazards identified during different stages of the project cycle are given in table below identifying cases where quantification of hazards might be necessary. This requires an assessment of failure probability, credible accident scenario, vulnerability of population.

7.2.1 Approach to the Study

Risk involves the occurrence or potential occurrence of some accidents consisting of an event or sequence of events. The risk assessment study covers the following:

o Identification of potential hazard area; o Identification of representative failure cases; o Visualization of the resulting scenarios in terms of fire and explosion; o Assess the overall damage potential of the identified hazardous events and the

impact zones form the accidental scenarios; o Furnish the recommendations on the minimization of the worst accident

possibilities o Preparation of Disaster Management Plan; o Emergency Plan, which includes Occupational and Health Safety Plan;

7.2.2 Hazard Identification

Identification of hazards in the proposed project activity is of primary significance of the analysis, and quantification. Hazard states the characteristics of system/plant/process that presents potential for an accident. All the components of a system/plant/process need to be thoroughly examined to assess their potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an accident.




Table 7.1 Hazard Identification & Risk Assessment at Different Project Stages

Sr. No.

Step/Activity Hazard identification

Typical Areas /activities

Possible causes Safety Measures Required

Risks

1.0 Construction of buildings and Erection of Plant

Physical Hazards

- Fall from height

- Working at ht > 2m - Formwork - Ramps - Unprotected sides

and edges - Roofing - Overhead brick

laying

- Untrained workers

- Wearing loose clothes

- No safety gear

Fall protection - guardrail - safety net/PPEs - harness - warning lines - appropriate clothes - supervision to

identify hazards

Accidental injury (personal)

- Motor vehicle crash

Ramps, excavation sites, roads

- Untrained reckless drivers

Vehicles with - service, emergency

and parking brake - hooter system - windows, wipers,

lights, rear window mirrors, reflectors


- Excavation accidents

foundation - Unidentified cables & utilities

Notify prior to starting excavation Check oxygen levels Design safe access


- Electrocution

Entire site - Temporary connections

- Cables running across site

Supervision to identify hazards


- Struck by falling objects

Entire site walking below loading or

Supervision Warning ribbons and signs





Sr. No.




Risks

working equipment

- Dust Generation Entire site excavation Dust mask Injury personal Noise exposure

Entire plant Construction &

erection activities

Ear Muffs/plugs oiling and greasing Vibration dampening

Personal injury (noise induced hearing loss)

2.0 Commissioning Electrocution Use of Energy Temporary connections

Tagging & Lock out Warning signs

Electrocution (personal injury)

Chemical exposure Use & storage of chemicals

Improper handling

Safety Gear/PPEs Training

Personal injury (Chemical burn, organ damage)

Instrumental failure

Complying HAZOP recommendations

On/offsite Accident injuries

Noise exposure

Entire plant Commissioning activities

Ear Muffs/plugs Oiling and greasing Vibration dampening


3.0 Operation Electrocution Use of Energy Temporary connections

Tagging & Lock out Warning signs

Electrocution (personal injury)

Chemical exposure Use & storage of chemicals & hazardous wastes

Improper handling

Safety Gear/PPE’s Training


Instrumental failure

Regular HAZOP & audits & complying recommendations

On/offsite Accident injuries

Noise generation Entire plant Improper maintenance

Ear Muffs/plugs Preventive maintenance, oiling and greasing





Sr. No.




Risks

4.0 Closure and Decommissioning

Chemical exposure Use & storage of chemicals & hazardous wastes

Improper handling

Safety Gear/PPE’s Training


Table 7.2 Other Hazards and control

No Possible hazard / Emergency

Its source and possible reason

Effect on person, property and environment

Place of its effect

Control measures suggested.

1 Natural calamity Nature Injury / Death to persons, damage to property

Within & outside the unit

Emergency preparedness, Alarm, Evacuation rescue & shelter/ Welfare

2 Toxic release from outside the premises

Outside the factory Injury/Death Within & outside the unit

Emergency preparedness, Alarm, Evacuation rescue & shelter/ Welfare

3 Structural failure Inside the factory (Corrosion)

Injury/Death to persons, damage to property

Within the factory

Inspection and Maintenance practices/ Automatic operation Periodic Testing of safety valves / systems

4 Pipeline leakages / Spillages. (1) Corrosion (2) Toxic gas release

Leaking of pipeline due to corrosion, Loose contact

Physical / Chemical Thermal Burn Injury (Major / Minor)

Plant area Proper maintenance, Proper Selection of Material for pipelines, Immediate attention, Earthing, flame proof fitting, No Smoking display Boards.

5 Electricity (burning, fire, shock)

Loose Contacts, Weak earthling Short Circuit Improper Insulation

Burning, Shock, Death

Surrounding the accident area

Proper Earthing, Periodical Checking of joints, proper insulations of Equipment’s, etc. Flame proof fitting in solvent storage area,




bounding and jumpers to all solvent barrier lines to be provided.

6 Boiler (burning, physical injury, explosion)

Over pressure in the boiler if safety valve not working. Water level indicator not working. Low water level indicator fails. High temp. System fails.

Minor/Major Injury Loss of human life Loss of property (Loss of Main/ Machine Material)

Boiler House and surrounding places

Lower & Upper Level Indication System provision. Safety valves for pressure control fixed temp. & pressure indicator provided. Blow down & blowing system provided for cleaning tube and shell. Soft water used. Interlocking provided on pumps, FD fan, ID fan. Periodical checking & inspection maintenance done. Yearly inspection done by Boiler Inspector

7 Housekeeping (physical, Fire, burning, exposure to chemicals)

Bad House keeping Physical / Chemical Thermal Burn Injury (Major / Minor)

In all surrounding areas i.e. Storage, Plants

Proper Handling, regular cleaning, Proper placement of material (RIGHT THING AT THE RIGHT PLACE)




7.2.3 Identification of Hazardous areas

The procedure for QRA starts with identification of major risk areas in the proposed installation. At Prasol Chemicals limited, major risk areas are as follows:

o Bulk storage area for raw materials at ambient temperature and

pressure(methanol, ethanol, octanol, Isobutanol, isopropanol, acetone, MIBK, Isophorone, cumene, benzaldehyde, mesityl oxide, diacetone alcohol etc.)

o Bulk storage area for raw materials at ambient temperature and higher pressure (hydrogen, ammonia)

o Process Plant involving pumping, transportation, reactors, distillation, heating, cooling, etc.

o Bulk loading and unloading from road tankers to storage and vice versa. o Hydrogenation reaction, exothermic reactions.

7.2.4 Identification of Failure cases for Hazardous areas

o Release due to catastrophic failure of storage tanks or process vessels. o Rupture of connected pipe with storage tank or process vessels. o Continuous release at significant rates for long durations transfer pipelines caused

by sudden, major break of the pipeline. o Continuous release at low rate through small holes or cracks in piping and vessels,

flange leaks, and leakage from pump glands and similar seals. It is to be noted that for Quantitative Risk Assessment, worst case scenarios have to be considered, though their frequency of occurrence is much lower than the cases of small leaks.

7.2.5 Major Hazardous Areas

The major Hazardous chemicals stored, transported, handled and utilized within the plant are summarized in the table below.

Table 7.3 Storage details (existing)


state

Storage capacity (KL/M3)

Means of

Storage

No of tanks

Diameter, m

Height m

1 Acetone L 407 Tank 2 7.2 10

2 Acetone L 56.5 Tank 1 4 4.5

3 Caustic Lye L 50 Tank 1 3 5

4 Phosphorus S/L 100 Tank 2 3.5 5.5

5 Sulphur L 200 Tank 3 3 5

6 Cumene L 1000 Tanks 1 10.5 12.5

7 Benzaldehyde L 30 Tanks 1 3 4.5

8 Methanol L 40 Tanks 1 2.7 7.5

9 Ethanol L 40 Tanks 1 2.7 7.5

10 Isopropanol L 40 Tanks 1 2.7 7.5

11 N-Butanol L 40 Tanks 1 2.7 7.5

12 Isobutanol L 40 Tanks 1 2.7 7.5




13 Pentanol L 40 Tanks 1 2.7 7.5

14 Octanol L 40 Tanks 1 2.7 7.5

15 Oleyl Amine L 20 Tanks 1 2.5 4



18 Diacetone


19 Diacetone


20 Nonyl Phenol L 40 Tank 1 2.7 7.5

21 Phosphorous

Acid Food Grade L 40 Tank 1 2.7 7.5

22 Dil. Phosphorous

Acid L 40 Tank 1 2.7 7.5

23 Isophorone L 300 Tank 1 6.7 9

24 Phenol L 300 Tank 1 6.7 9

25 Mesityl Oxide L 100 Tank 1 4.5 6.5

26 Methyl Isobutyl


27 Di-isobutyl

Ketone L 40 Tank 1 2.7 7.5

28 Cumene

Hydroperoxide L 40 Tank 1 2.7 7.5

29 3,5 Dimethyl

Phenol L 50 Tank 1 3 7.5

30

Lubricant Additives

(Hydraulic Packages/ Gear

Oil Packages etc.)

L 40 Tank 1 2.7 7.5

31 Sodium


32 Sodium Dialkyl


33 Benzylidene

Acetone L 20 Tank 1 2.5 4

34 Benzyl Acetone L 20 Tank 1 2.5 4

35 Dialkyl

Dithiophosphoric Acid

L 20 Tank 1 2.5 4

36 Resorcinol L 20 Tank 1 2.5 4

37 Dicumyl Peroxide

L 30 Tank 1 3 4.5

38 Cumyl Alcohol L 10 Tank 1 2 3.5

39 Di-Nonyl Phenol L 10 Tank 1 2 3.5

40 Alpha Methyl

Styreme (AMS) L 40 Tank 1 2.7 7.5




41 Acetophenone

(ACP) L 20 Tank 1 2.5 4

42 Dicarbinol L 10 Tank 1 2 3.5

43 Hydrogen G 5000 NM3

Cylinder Banks

- - -

Table 7.4 Proposed raw material and product bulk storage details

No

CHEMICAL Physical state

Storage capacity (KL/M3)

Means of

Storage

No of tanks

Diameter M Height

m

1 Acetone L 700 Tank 1 9 12

2 Sulphuric Acid L 50 Tanks 1 3.5 5.5

3 Di-isopropyl

Benzene L 100

Tanks/Drums

1 4.5 6.5

4 Polyisobutylen

e L 20 Tanks 1 2.5 4

5 Maleic

Anhydride L 10 Tanks 1 2 3.3

6 Ethyl Acrylate L 30 Tanks 1 3 4.5

7 Methyl

Acrylate L 10 Tanks 1 2 3.5

8 Diacetone


9 Zinc Diorgano Dithiophospha

te L 150 Tank 1 5 8

10

Hexylene Glycol,

Trimethyl Cyclohexanol,

Trimethyl Cyclohexanone

,

L 300 Tank 1 6.7 9

11 Methyl

Isobutyl Ketone

L 100 Tank 2 3 7.5

12 Di-isobutyl


13 Methyl

Pentadiene L 40 Tank 1 2.7 7.5

14 PIBSA L 40 Tank 1 2.7 7.5

15 PIBSI L 40 Tank 1 2.7 7.5

16 Phosphate


17 Amine

Phosphates L 40 Tank 1 2.7 7.5




18 Carbazole


19 Ashless

Lubricant Additive

L 40 Tank 1 2.7 7.5

20 Resorcinol L 80 Tank 2 2.7 7.5

21

Sodium Hydrogen Sulphide (NaHS)

L 30 Tank 1 3 4.5

*The dimensions are indicative and preliminary. It will be finalized during detail engineering stage. Dyke dimension shall be maintained as per good engineering practice / norms/standards.

Table 7.5 Warehouse storage details


state Stored in

1 Caustic soda S Bags 2 Acetone L Drums 3 Phosphorus S Drums 4 Sulphur S Bags 5 ZnO S Bags 6 Phosphorus Pentoxide S Bags 7 Phosphorous Pentasulphide S Silo / Tote Bin 8 Bisphenol-S S Bags / Drums 9 Carbazole Powder S Bags

7.2.5.1 Hazardous Properties of Chemicals

The characterictics of chemicals stored/used/handled were studied and the hazard exhibited

by each have been identified and is presented below




Table 7.6 Hazardous properties of the chemicals

No Chemical (CAS No) State color Odor Sp Gr at 20 deg C

Melting point Deg C

Boiling point, Deg C

Flash point, Deg C

Explosive limit TLV

ppm

Water solubil

ity

NFPA code

Hazard %

LEL %

UEL H F R

1 Methanol (67-56-1) Liquid Colorless Alcohol like. Pungent

when crude 0.7915 -97.8 64.5 12 6 36.5 250 Soluble 1 3 0 T & F

2 Ethanol (64-17-5) Liquid Colorless Mild to strong, rather

pleasant. 0.789 -114.1 78.5 12.8 3.3 19 1000 Soluble 2 3 0 T & F

3 Octanol (111-87-5) Liquid Colorless Not available 0.827 -16.5 194.5 81.1 1.1 7.4 Not

available Soluble 1 2 0 T & F

4 Isopropanol (67-63-0) Liquid Colorless Pleasant 0.785 -88.5 82.5 11.7 2 12.7 400 Soluble 1 3 0 T & F

5 N Butanol (71-36-3) Liquid Colorless Vinous. (Slight.) 0.81 -89.5 117.7 28.9 1.4 11.2 152

mg/m3 Soluble 1 3 0 T & F

6 Caustic lye (1310-73-2) Liquid Colorless Alkaline. Bitter.

(Strong.) 1.53 12 140 NA NA NA NA Soluble 3 0 1 T, C

7 Nitrogen Gas (7727-37-9) Gas colorless Odorless 0.97 NA -195.8 NA NA NA NA Not

soluble 0 0 0

Asphyxiant

8 Hydrogen (1333-74-0) Gas colorless Odorless 0.07 -259 -253 NA 4 76 NA Not

soluble 0 4 0 F

9 Isophorone (78-59-1) Liquid Pale

yellow peppermint odor-

camphor 0.92 -8 213 84 NA NA 5 Partial 2 2 0 T, F

10 Zinc Diorgano Dithiophosphate

(ZDDP) Liquid

Colorless to pale brown

Mild petroleum odor 1.135 < 10 > 120 93 NA NA NA Insolu

ble - - - T

11 Alkyl Sodium Dithiophosphate Liquid Amber to

dark brown

Slightly Sulphur odor 1.12 NA 100 >93.4 NA NA NA Fully

soluble 3 1 0 T, F

12 Sodium Dithiophosphate Liquid Amber to

dark brown

Slightly Sulphur odor 1.07 NA NA >93 NA NA NA Slightl

y soluble

3 1 0 T, F

13 3,3,5 Trimethyl Cyclohexanol Liquid NA NA 0.878 30 - 32 198 88 NA NA NA NA - - - T

14 Sodium Hydrogen Sulphide

(NaHS) (16721-80-05) Liquid

Yellow, green, to

brown liquid

H2S like, rotten eggs 1.15 NA 100 NA NA NA NA Soluble 3 2 1 T, C

15 Hydrochloric Acid (HCl) Liquid Colorless

to light yellow

Pungent, irritating 1.16 -46.2 83 NA NA NA 5 Soluble 3 0 1 T, C





Melting point Deg C


Flash point, Deg C

Explosive limit TLV

ppm

Water solubil

ity

NFPA code

Hazard %

LEL %

UEL H F R

16 Phosphorus (7723-14-0) solid waxy

Colorless to yellow

Odorless 1.83 44 NA

Spontaneousl

y flamm

able

- - 0.1

mg/m3 3 ppm 4 4 2 F, T, R

17 Sulphur (7704-34-9) solid yellow Odorless 1.96 235 445 207 35

g/m3 1400 g/m3

- Insolu

ble 1 1 0 F, T

18 Cumene (98-82-8) Liquid Colorless - 0.862 -96 152 31 - - 50 - - - - T,F

19 ZnO (1314-13-2) Solid white

powder Odorless 5.61 - - - - - - - - - - T

20 Sulphuric acid (7664-93-9) Liquid Colorless Odorless, choking

odor when hot. 1.84 -35 270 NA - - 1 Soluble 3 0 2 T,C

21 Di-isopropyl Benzene (100-18-

5) Liquid Colorless Aromatic 0.85 -17 220 73 0.64 5.3 -

Negligible

2 2 0 T, F

22 Benzaldehyde (100-52-7) Liquid Colorless Aromatic 1.05 - - - - - - Negligi

ble - - - T, F

23 Polyisobutylene(9003-27-4) Liquid Colorless Faint 0.89 - - > 210 - - - Not

soluble 0 1 0 F

24 Maleic Anhydride (108-31-6) Solid,

crystalline

Colorless Irritant 0.83 53 200 103 1.4 7.1 0.4

mg/m3 400 g/lit

- - - T, F

25 Ethyl Acrylate (140-88-5) Liquid Colorless Sharp, biting - 72 100 8 1.8 12 5 ppm 15 g/l 2 3 2 T,F,R

26 Phosphorus Pentoxide) (1314-

80-3) Solid yellow stench 2.08 286 514 > 100 - -

1 mg/m3

Insoluble

2 3 2 T,F,R

27 Isobutanol (78-83-1) Liquid Colorless sweet 0.8 -108 108 29 - - 50 Moder

ate 3 3 0 T,F

28 Pentanol (71-41-0) Liquid Colorless stench 0.811 -78 137 49 1.3 10.5 - 22 g/l 2 2 1 T,F,R 29 Oleyl Amine (112-90-3) Paste beige - 0.813 18 348 154 - - - - 3 1 0 T,F 30 Methyl Acrylate (96-33-3) Liquid Colorless Pungent - -75 80 -2.7 2.1 14.5 2 52 g/l 2 3 2 T,F,R

31 Carbazole Powder (86-74-8) powder beige - 1.1 243 355 220 - - - sparin

gly - - - T,F

32 Diacetone Alcohol (123-42-2) Liquid light

yellow - 0.938 - 158 58 1.8 6.9 - - - - - T,F

33 Nonyl Phenol Liquid colorless phenol like - -8 290 155 - - - sparin

gly 3 1 0 T,F

34 Phosphorous Penta sulphide

(1314-80-3) Solid yellow stench 2.08 286 514 > 100 - - 3

Insoluble

2 3 2 T,F, R





Melting point Deg C


Flash point, Deg C

Explosive limit TLV

ppm

Water solubil

ity

NFPA code

Hazard %

LEL %

UEL H F R

35 Phosphoric acid (7664-38-2) Liquid Syrupy liquid

odorless 1.68 21 158 NA NA NA 3

mg/m3 soluble 3 0 0 T

36 Phenol (108-95-2) Solid at room T

white Sweet and acrid 1.05 42 182 79 1.7 8.6 5 soluble 3 2 0 T,F

37 Acetone (67-64-1) Liquid Colorless Ether like 0.79 -95 56 -20 2.6 12.8 750 Soluble 1 3 0 T,F 38 Mesityl Oxide (141-79-7) Liquid - - 0.854 -53 129 28 - - 25 28 g/l 3 3 1 T,F R 39 Hexylene Glycol (107-41-5) Liquid Colorless Olorless 0.93 -50 198 98 1.2 8.1 25 - 2 2 0 T,F

40 Trimethyl Cyclohexanol (116-

02-9)

Solid, crystalli

ne white - 0.878 93 388 165 - -

10 mg/m3

Insoluble

3 2 0 T,F

41 Trimethyl Cyclohexanone (873-

94-9) Liquid Colorless aromatic 0.89 -10 188 64 1.1 - - 30 g/l - - T,F

42 Methyl Isobutyl Ketone (108-

10-1) Liquid Colorless sweet 0.8 -84 117.4 14 1.2 8 20 Soluble 2 3 0 T,F

43 Methyl Isobutyl Carbinol (108-

11-2) Liquid Colorless mild 0.82 -90 132 41 - - 25

Moderate

2 2 0 T,F

44 Di-isobutyl Ketone (108-83-8) Liquid Colorless mild 0.81 - 163 49 - - 25 sparin

gly 1 2 1 T,F,R

45 Di-isobutyl Carbinol (108-82-7) Liquid Colorless sweet 0.81 -65 178 62 - - 25 Insolu

ble - - - T,F

46 3,5 Dimethyl Phenol (108-68-9) Solid white phenolic 0.986 63 219.5 109 - - - 4.8 g/l - - - T,F

47 Methyl Pentadiene (26472-00-

4) Liquid

light yellow

Odorless 0.94 -51 200 26 1 10 - - 0 3 0 F

48 Bisphenol-S (80-09-1) Solid

powder white - 1.366 245 - - - - -

Insoluble

- - - T

49 Benzylidene Acetone (122-57-

6) Solid Yellow strong - 38.5 261 116 - - Soluble 2 1 0 T,F

50 Benzyl Acetone (2550-26-7) Liquid Clear - 0.988 - 235 105 - - - 2 1 0 T,F

51 Resorcinol (108-46-3) Solid,

crystals white pleasant 109 276 127 - - 20 Soluble 2 1 0 T,F

52 Dicumyl Peroxide (80-43-3) Solid white mint like 1.02 38 110 110 - - - Insolu

ble 2 1 1 T,F,R

53 Cumyl Alcohol (617-94-7) Solid Colorless - 0.973 28 88 87 - - - - 2 0 0 T E = EXPLOSIVE, R = REACTIVE, BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT, UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY, H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS, R = REACTIVE HAZARD, TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-USA, C = CORROSIVE, T=TOXIC, NA – Data not available




7.3 Qualitative risk assessment

At times Risk involved in various processes / process equipment’s cannot be addressed completely by Consequence Analysis. As a conservative approach, these risks have been considered separately herein. The approach is to identify hazards associated in operation of equipment’s as well as in processes, assessing its impacts, ranking the risk posed by it and finally to propose remedial actions/ mitigation measures such that the risk is minimized to tolerable level. The Risk Matrix presented below will be referred in evaluating the risk during project/operation phase of the expansion. In Qualitative Risk Assessment, risk has been analysed using methodology called HIRA-Hazards Identification & Risk Assessment. In HIRA, major manual activities carried out by plant personnel as well as contract labours have been considered. Qualitative Risk Assessment has been carried out for the following areas: 1) Storage and Handling of Toxic Liquid Chemicals. 2) Storage and Handling of Flammable Chemicals. 3) Storage & Handling of Solid Chemicals.

Probability X Severity = Risk rating & Priority & Time Frame

Figure 7.1 Risk matrix for qualitative risk assessment

7.3.1 Ready Reckoner for prioritization of Risk Control

Risk rating number from table

Risk Level Priority and time frame for controls to be assigned to the hazard.

20 Intolerable Stop or prohibit the activity immediately until the risk has been reduced. Isolate the Hazard immediately.

Emergency response procedure provision & up gradation (for offsite emergencies)

15 – 16 Significant Do not start the activity until the risk has been reduced. If activity is in progress, take urgent action.

SEVERITY

Catastrophic [5]

Critical [4]

M A J O R [ 3 ]

Minor [2]

Negligible [1]

PR

OB

AB

ILIT

Y

Very Likely [4]

20 Intolerable

16 Significant

12 Moderate

8 Moderate

4 Tolerable

Likely [3]

15 Significant

12 Moderate

9 Moderate

6 Tolerable

3 Tolerable

Unlikely [2]

10 Moderate

8 Moderate

6 Tolerable

4 Tolerable

2 Trivial

Highly Unlikely

[1]

5 Tolerable

4 Tolerable

3 Tolerable

2 Trivial

1 Trivial




Review existing control measures to determine effectiveness.

An action plan must be developed to show how to risk will be reduced.

8 – 12 Moderate Implement risk reduction measures within a defined period.

More detailed risk assessment of serious consequences to determine more precisely the probability of occurrence. Review existing control measures to determine effectiveness.

An action plan must be developed to show how to risk will be reduced.

3 – 6 Tolerable Monitoring may be required to verify on going effectiveness of controls. Hazard to be controlled within 4 months (Consider risk reduction measures)

1 – 2 Trivial Adequately controlled. No additional controls are required. No actions required but keep assessment under review or when work environment, work task or plant or process changes.




Table 7.7 Transportation, Unloading, storage and handling of Solvents and chemicals

(Bulk Chemicals such as Methanol, ethanol, octanol, IPA, Isobutanol, benzaldehyde, cumene, MIBK etc)

No Activity / Process

Hazard associated

Safety and health impact risk

Initial risk Existing control measures

Residual risk Additional recommendations

Se

ve

rity

Lik

eli

ho

od

d

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

1 Unloading from Tanker.

Spillage/ Leakage. Generation of static Charge. Fire Explosion

Burn injury. Fatality. Damage to Equipment’s and facilities.

4 2

Mo

der

ate

Spill containment kit is available to contain the leakage. Earthing mechanism is provided for tankers. Appropriate PPEs like Safety Goggles, Butyl or Nitrile rubber gloves, gumboot, plastic apron etc. are used. Only trained operators are allowed to work in this area.

3 2

To

lera

ble

SOPs to be prepared and followed. Foam type fire extinguisher to be provided in nearby Location. Fire monitor with provision of connection of foam To be provided. AFFF foam trolley to be made available. Proper fencing to be provided for underground solvent tanks.





Hazard associated




Se

ve

rity

Lik

eli

ho

od

d

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

2 Transferring of solvent from storage area to process plant.

Spillage/ Leakage. Generation of static charge. Fire Explosion

Burn injury. Fatality. Damage to equipment and facilities.

4 2

Mo

der

ate

Earthing is done for transfer pump, transfer lines etc. Flange-to-flange bonding is done for transfer lines. Storage Area is marked as “No Smoking”, Hazardous Area”, “Hot work Restricted” etc. Only trained operators are allowed to work in this area. Operators are trained for the chemical hazards, preventive/mitigative measures for chemicals, handling emergency situation Inspection (for pumps, flange joints etc) is carried out on regular

3 2

To

lera

ble

As above





Hazard associated




Se

ve

rity

Lik

eli

ho

od

d

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

basis. Spill containment kit is available. Firefighting facilities is available as mentioned above. PPEs are used.

3 Storage Area Leakage Fire Explosion

Burn injury. Fatality. Damage to equipments and facilities.

4 2

Mo

der

ate

Storage area has provision of natural/forced ventilation. Routine inspection of the area is carried out by field operator. Storage Area is marked as “No Smoking”, “Hazardous Area”, “Hot work Restricted” etc. Other relevant measures are same as above.

3 2

To

lera

ble

As above Flame detectors, Temperature actuated heat detectors with alarms and automatic sprinkler systems to be installed in storage area, if possible, or required.




Table 7.8 Storage and handling of solid Chemicals in warehouse

(such as phosphorus, sulphur zinc oxide, bisphenol S, carbazole powder, caustic soda etc)


Hazard associated


Initial risk Existing control measures Residual risk

Additional recommendations

Se

ve

rity

Lik

eli

ho

od

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

1 Handling Chemical bags

Exposure to the chemical

Skin / Eye Irritation.

4 2

Mo

der

ate Chemicals are stored in

isolated storage rooms/warehouse having provision for natural & forced ventilation. Certified Dust respirator is used. Suitable protective clothing and other PPEs are used.

3 2

To

lera

ble

Operators/Workers to be trained for Safe Work Practices. Chemical handling bags to be labelled properly. Chemicals compatibility to be studied while storing solid and liquid in warehouse





Hazard associated


Initial risk Existing control measures Residual risk


Se

ve

rity

Lik

eli

ho

od

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

2 Cleaning of Chemical Spillage.

Fumes Inhalation. Dust Exposure.

Severe irritation to eyes, skin. Inhalation.

4 3

Mo

der

ate -Certified Dust

Respirator is used. Suitable protective clothing, gloves, safety shoes are used. - Spillage is cleaned or Neutralized with suitable media. Chemicals are stored in isolated storage rooms having provision for natural & forced ventilation

3 2

To

lera

ble

Operators/Workers to be trained for Safe Work Practices. Chemical handling bags to be labelled properly. Chemicals compatibility to be studied while storing solid and liquid in warehouse




Table 7.9 Storage and handling of Corrosive and toxic Chemicals

(e.g. Caustic lye, HCl, Sulphuric acid etc)


Hazard associated



Residual risk


Se

ve

rity

Lik

eli

ho

od

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

1 Tanker unloading

Toxic chemical release

- Toxic Vapour Inhalation -Skin/Eye Irritation/burn

4 3

Mo

der

ate PPEs are used.

Storage tank area is and will be in open space.

3 2

To

lera

ble

SOPs to be prepared and followed. Spill containment kit to be made available Flange/Ferrule joints etc. to be checked Periodically.

2 Transferring of chemical from storage area to Process plant.

Spillage / Leakage.

Inhalation of Toxic Vapours.

4 3

Mo

der

ate Storage tank area is

in open space. Spill containment kit is available. Dyke Wall is available. PPEs are used. Only trained operators are allowed to work in this area. Inspection (for pumps, flange

3 2

To

lera

ble

As above





Hazard associated



Residual risk


Se

ve

rity

Lik

eli

ho

od

Ris

k

Se

ve

rity

Lik

eli

ho

od

Ris

k

joints etc.) is carried out on Regular basis.




7.4 Chemical handling protocol and its management

Storage and handling of chemicals shall be done in a planned and systematic manner at the plant site to minimize the chances of chemical exposure to personnel, risk of spill and the consequent impact on the environment and safety of personnel on site and off site. In order to ensure safe handling and storage of the various chemicals, following guidelines should be considered.

7.4.1.1 Storage of Chemicals

General Guidelines

Chemical storage areas shall be designed based on the hazardous properties of the chemical, applicable regulatory requirements, codes and standards and operating procedures for the storage and handling based on good engineering practice.

o All storage areas shall be provided with appropriate spill containment measures together with facilities for mitigation and clean up commensurate with the materials being stored.

o All storage areas will be provided with proper access to enable normal operation and maintenance, spill cleanup, emergency action such as firefighting etc.

o All storage areas will be designed based on fire load to minimize effects of thermal radiation due an accidental fire on personnel in the area and neighboring storage/operation.

o All storage areas will be provided with adequate ventilation facilities to avoid buildup of chemical vapors in the work environment leading to problems of personnel exposure and possible explosive concentration being reached.

o All material in the storage area should be suitably labelled in accordance with labelling requirement of the site.

o Chemical storage will be segregated based on the properties of the chemical. Incompatible, reactive, corrosive and sensitive chemicals will not be stored in a manner where they can affect other material in the storage area.

o The storage areas have an electrical classification commensurate with the properties of the material being stored.

Storage in Smalls

Non-bulk storage in small containers (plastic carboys, fiber drums, 200-liter drums etc.) shall constitute smalls.

o All chemicals in smalls shall be stored in a secure store well protected from

elements of nature. o The nature of the container used for storing the chemical should be based on the

characteristics of the chemical. o Material handling in the storage area shall be done with due regard to damage to

drums through dropping and collision. Use of forklift truck, pallet truck together with suitable drum grabbers can provide an elegant solution for handling 200-liter drums.




o Material in smalls shall, as far as possible, be stored on pallets with facility for spill containment provided below. The following guideline for containment trays may be adopted for chemicals stored in stacks:

In case of non-corrosive chemical, the volume of the spill tray shall be

adequate to hold the contents of two of the largest capacity drums of the stack, subject to a minimum height of the lip of the tray of 100 mm.

In case of corrosive chemical stacks, the volume should be increased to the number of layers of stacking of drums multiplied by two with the same stipulation of minimum lip height.

The tray footprint shall extend beyond the stack footprint 200 mm on each side.

The material of construction of the containment trays shall be compatible with the chemical being contained.

Liquid material should, as far as possible, be stored at floor level to avoid splashing in the event of a leak.

o The floor in the liquid storage area should be provided with gentle gradient to lead

spills, if any, away to a safe spot for collection and recovery. o Stacking of material shall be done in a manner that ensures stability of the stack.

Stacking height for each type of container should be carefully determined and prominently marked in the storage area to avoid accidents due to slipping of the material container.

o Access and aisle space should be provided around stacks of containers for purposes of inspection, stock taking and emergency action. These aisles should always be kept unobstructed.

Storage in Bulk

Bulk storage of chemicals will be in a dyked area.

o The dyke shall have a volume not less than 110 % of the volume of the largest tank in the dyked area provided that, the nature of the liquid being stored in bulk is not corrosive to the other tanks located in the dyked area through external contact with the liquid. In such an event, the dyke volume shall be 110% of the total volume of liquid being stored inside the dyked area.

o Operating equipment such as pumps, motors etc. shall not be located within the dyked area. Only piping and fittings associated with the filling and emptying of the tanks shall be permitted. Location of such operating equipment shall take into account the access to the area during a leak from the tank.

o Electrical fittings used in/near the dyked area shall conform to the requirements of the electrical area classification for the material being stored.

o In case of flammable liquids, the tanks shall be earthed. Further, suitable steps shall be taken to avoid generation of static electricity in the system through measures such as prevention of splashing of liquid inside the tank, limiting pumping velocity, avoidance of contamination etc.

o The material of construction of the tanks located within the dyked area shall be suitable for the liquid being stored – both internally and externally.




o The dyked area walls and flooring shall be suitable for containing the contents of the tank without any reaction, corrosion or attack. The integrity of the dyke shall be examined to ensure this from time to time.

o The dyked area shall be provided with a drain valve that shall normally be kept close to contain the leaked material. Only during the monsoon months, the drain valve shall be kept open. The drain from the dyked area shall be led to a hold tank from where it shall be discharged to storm water drainage system after ensuring that there is no contamination.

o Provision will be made in the dyked area to recover any leaked material in a safe manner without delay.

o Access and aisle space should be provided around tanks/dyked areas for purposes of inspection and emergency action. These aisles should be kept unobstructed at all times.

o Emergency equipment for firefighting and spill management should be kept in the vicinity of the dyked area and shall be accessible at all times. Their integrity and adequacy shall, further, be ensured through regular checks.

o As far as possible, provision of a spare tank should be available to receive the contents of a leaky tank located in a dyked area through transfer. This will minimize the magnitude of the problem.

o All equipment relating to the transfer of material to/from the tanks shall be properly tagged showing direction of flow. This is important to avoid operational errors during emergencies.

o All tanks shall be painted with their number, contents and their storage capacities.

7.4.1.2 Chemical Handling

The handling of chemicals on site shall be carried out according to the following guidelines, that should be incorporated in the procedures. Access Routes/Parking o Once allowed to enter the site, the movement of all chemical transport vehicles

within the site shall be based on pre-determined routes and site operating procedures.

o Parking of chemical transport vehicles will only be permitted at areas authorized for the purpose. This shall be shown on the site layout plan and suitable boards placed near factory entrance and the parking areas.

o Vehicles in-waiting for unloading their cargo shall be placed far away from the manufacturing plant and at designated safe locations.

o The safety precautions to be observed by the driver of the vehicle shall be provided to the driver for compliance in the form of a “safety instruction card”.

Material Handling The following procedure shall apply to loading and unloading operations relating to chemicals at site.

o Vehicles will be immobilized prior to any unloading operation. This shall normally be done using the brakes. In case of chemical tankers connected for unloading




through a system of hose/pipeline, chocks shall be used under all four wheels to positively ensure immobilization.

o The vehicle driver shall be near the vehicle (within 5 m) and in a position from where he can observe the loading/unloading operations. He shall always be available for any emergency action.

o The availability of equipment required for material handling, firefighting, spill management and personal protection, together with personnel trained in their use, shall be ensured. Likewise, all precautions as stipulated in the material handling procedures will be taken prior to starting the handling operations. It will be the responsibility of the supervisor in-charge of the area to ensure that the above facilities are in good conditions and safe for the operation in question

o Procedure for handling material will be documented and key elements thereof shall be displayed in the area for immediate attention of the persons carrying out the operation. The above operations shall be ensured through a checklist.

7.4.1.3 Labeling

All chemicals received, stored, handled, used, manufactured at and dispatched from the site shall have appropriate labels to identify the material and indicate their properties. India being a signatory to the U.N. System of Transport of Dangerous Goods (TDG), the class labels used in the Indian Regulations are those conforming to the TDG. The purpose of a label is to provide ready information on the nature, quantity, properties, associated hazards, precautions to be taken and the supplier details. Prasol will adopt the following labeling convention for all its incoming and outgoing material, unless otherwise specifically agreed between the sender and the receiver. o Labels shall be printed on paper or other durable material and shall be resistant to

normal handling/weathering that the package shall be subject to. o The color and size of the labels shall be so chosen as to provide a prominent display

of the label information. Typically, 200-liter drum labels are of 200 mm x 300 mm in size. Prasol shall determine and notify the label size and other label to be adopted based on site requirements.

o Labels shall contain the following information relating to the chemicals. − Chemical Name − CAS No. and U.N. No − U.N Hazard Class Label (Primary and subsidiary) − Quantity contained in the package (kg/l) − Quality Information (Purity/Strength/Other Details) − Relevant Hazard Warnings − Target Organ Information − Manufacturers Name/Address and Contact Details

o In case of formulations, it is important to provide information on the key hazardous

constituent in the formulation to enable any emergency responder to determine the containment/mitigation measures.

o Labels shall be affixed on the container in a prominent manner to be visible easily. o In case of re-use of containers, the old label shall be removed or completely masked

or defaced and new label affixed in its place. No container shall have two labels affixed on it.




7.5 Consequence Analysis

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or vapor clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits.

7.5.1 Operating parameters

Potential vapor release for the same material depends significantly on the operating conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential. If we take up an example of ammonia, if it is stored at ambient temperature, say 30 Deg C, and then the vapor release potential of the inventory is much higher as compared to the case if it is stored at 0 Deg C.

7.5.2 Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short listing of release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a vessel or a system, larger the quantity of potential release. The potential vapor release (source strength) depends upon the quantity of liquid release, the properties of the materials and the operating conditions (pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source strength estimated for each release case, a ranking should become a credible exercise.

7.5.3 Loss of Containment

Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all significant release cases and then to short list release scenarios for a detailed examination. Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden appearance of such a major crack that practically all of the contents above the crack shall be released in a very short time. The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is depending on the size of the hole as well as on the pressure, which was present, in front of the hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The vaporization of released liquid depends on the vapor pressure and weather conditions. Such consideration and others have been kept in mind both during the initial listing as well as during the short-listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the largest potential hazard inventories have been considered for consequence estimation.

7.5.4 Damage Criteria

In consequence analysis, use is made of a number of calculation models to estimate the physical effects of an accident (spill of hazardous material) and to predict the damage (lethality, injury, material destruction) of the effects. The calculations can roughly be divided in three major groups:

Determination of the source strength parameters;




Determination of the consequential effects; Determination of the damage or damage distances.

The basic physical effect models consist of the following.

7.5.5 Source strength parameters

Calculation of the outflow of liquid, vapor or gas out of a vessel or a pipe, in case of rupture. Also, two-phase outflow can be calculated.

Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of the dimensions of the remaining liquid pool.

Calculation of the evaporation rate, as a function of volatility of the material, pool dimensions and wind velocity.

Source strength equals pump capacities, etc. in some cases.

7.5.6 Consequential Effects

o Dispersion of gaseous material in the atmosphere as a function of source strength, relative density of the gas, weather conditions and topographical situation of the surrounding area.

o Intensity of heat radiation [in kW/ m2] due to a fire or a BLEVE, as a function of the distance to the source.

o Energy of vapor cloud explosions [in N/m2], as a function of the distance to the distance of the exploding cloud.

o Concentration of gaseous material in the atmosphere, due to the dispersion of evaporated chemical. The latter can be either explosive or toxic.

It may be obvious, that the types of models that must be used in a specific risk study strongly depend upon the type of material involved:

Gas, vapor, liquid, solid. Inflammable, explosive, toxic, toxic combustion products. Stored at high/low temperatures or pressure. Controlled outflow (pump capacity) or catastrophic failure.

7.6 Quantitative risk assessment based on ALOHA

ALOHA (Arial Locations of Hazards Atmosphere) is an atmospheric dispersion model

used for evaluating releases of hazardous chemical vapors. ALOHA is a part of software called CAMEO (Computer Aided Management of Emergency Operation). CAMEO is one of the tools developed by EPA’s Chemical Emergency Preparedness and Prevention Office (CEPPO) and the National Oceanic and Atmospheric Administration Office of Response and Restoration (NOAA), to assist front-line chemical emergency planners and responders.

CAMEO consists of three parts viz. CAMEO (which is basically a data base), ALOHA and MARPLOT (Mapping Applications for Response, Planning, and Local Operational Tasks).

ALOHA allows the user to estimate the downwind dispersion of a chemical cloud based on the toxicological/physical characteristics of the released chemical, atmospheric

conditions, and specific circumstances of the release. Graphical outputs include a "cloud




footprint" that can be plotted on maps with MARPLOT to display the location of other

facilities storing hazardous materials and vulnerable locations, such as hospitals and schools. Specific information about these locations can be extracted from CAMEO information modules to help make decisions about the degree of hazard posed.

Systematic study based on ALOHA has been carried out for critical tanks (methanol, ethanol, octanol, Isobutanol, isopropanol, acetone, MIBK, Isophorone, cumene, benzaldehyde, mesityl oxide, di acetone alcohol and hydrogen gas leakage scenarios. The details of consequence analysis studies carried out are presented at Annexure 7.2 for various accident and consequence scenarios like:

Table 7.10 Consequence Analysis studies carried out

Failure Scenarios Accident Scenario Effects Catastrophic failure of tank

vapor cloud formation and dispersion

Toxic area of vapor cloud

Flammable area of vapor cloud Explosion of vapor cloud Overpressure effects of VCE Vapor cloud catching fire Radiation Effects from pool fire Radiation effect from fireball Leakage from pump discharge valve

vapor cloud formation and dispersion

Toxic area of vapor cloud

Flammable area of vapor cloud Explosion of vapor cloud Overpressure effects of VCE

Failure frequency data as given in Loss Prevention in Process Industries by Frank P Lees is presented below for information.

Table 7.11 Failure Frequency Data

SR. NO.

ITEM FAILURE FREQUENCY (No. per 106 years)

1 Shell 1.0

2 Process / Pressure Vessel 1.0 3 Atmospheric Pressure Storage 0.1 4 Full Bore Vessel Connection 25 30.0 40 10.0 50 7.5 100 4.0 150 3.0 5 Full Bore Process Pipeline (Diameter in mm) Less Than 50 0.30* >50, <150 0.09* More than 150 0.03* (*Failure frequency expressed in No. per met length per 106 years)

The Maximum Credible Loss Scenario (MCLS) likely identified is tank on fire i.e. BLEEVE tank explodes and chemical burns in fireball. (MCLS is defined as the worst “credible”




accident or as an accident with a maximum damage distance, which is still believed to be

possible).

The damage distances worked out for this scenario indicates that for most of the effects the damage will not be confined to the plant boundary.

The above table indicates that probability of occurrence of this scenario is very low (<0.5 X 106 years), which is within the acceptable limits. However, various preventive and protective measures are required to ensure that the above accident scenarios do not occur.

WHAT IS ERPG?

Adverse health effects due to toxic products which could be released from the facility will depend on the LOC (level of concern) determined by The Emergency Response Planning Guidelines (ERPGs) developed by the ERPG committee of the American Industrial Hygiene Association.

The ERPGs were developed as planning guidelines, to anticipate human adverse health effects caused by exposure to toxic chemicals. The ERPGs are three-tiered guidelines with one common denominator: a 1-hour contact duration. Each guideline identifies the substance, its chemical and structural properties, animal toxicology data, human experience, existing exposure guidelines, the rationale behind the selected value, and a list of references. ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or perceiving a clearly defined, objectionable odor. ERPG 2: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action. ERPG 3: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects. AEGL - Acute exposure guideline levels (AEGLs) describe the human health effects from once-in-a-lifetime, or rare, exposure to airborne chemicals. Used by emergency responders when dealing with chemical spills or other catastrophic exposures, AEGLs are set through a collaborative effort of the public and private sectors worldwide. PAC - Protective Area Criteria for Chemicals - he PACs dataset is a hierarchy-based system of the three common public exposure guideline systems: AEGLs, ERPGs, and TEELs. A particular hazardous substance may have values in any—or all—of these systems.

https://response.restoration.noaa.gov/oil-and-chemical-spills/chemical-spills/resources/public-exposure-guidelines.html

https://response.restoration.noaa.gov/oil-and-chemical-spills/chemical-spills/resources/acute-exposure-guideline-levels-aegls.html

https://response.restoration.noaa.gov/oil-and-chemical-spills/chemical-spills/resources/emergency-response-planning-guidelines-erpgs.html

https://response.restoration.noaa.gov/oil-and-chemical-spills/chemical-spills/resources/temporary-emergency-exposure-limits-teels.html




WHAT ARE RADIATION EFFECTS?

A Thermal Radiation Level of Concern (LOC) is a threshold level of thermal radiation, usually the level above which a hazard may exist. 10 kW/(sq m) -- potentially lethal within 60 sec; 5 kW/(sq m) -- second-degree burns within 60 sec; and 2 kW/(sq m) -- pain within 60 sec. The thermal radiation effects that people experience depend upon the length of time they are exposed to a specific thermal radiation level. Longer exposure durations, even at a lower thermal radiation level, can produce serious physiological effects. Below are some effects at specific thermal radiation levels and durations (on bare skin): 10 kW/(sq m) -- people will feel pain after 5 seconds and receive second-degree burns after 14 seconds 5 kW/(sq m) -- people will feel pain after 13 seconds and receive second-degree burns after 40 seconds; and 2 kW/(sq m) -- people will feel pain after 45 seconds and receive second-degree burns after 3 minutes

WHAT ARE OVERPRESSURE EFFECTS?

Overpressure. A major hazard associated with any explosion is overpressure. Overpressure, also called a blast wave, refers to the sudden onset of a pressure wave after an explosion. This pressure wave is caused by the energy released in the initial explosion—the bigger the initial explosion, the more damaging the pressure wave. Pressure waves are nearly instantaneous, traveling at the speed of sound. Although a pressure wave may sound less dangerous than a fire or hazardous fragments, it can be just as damaging and just as deadly. The pressure wave radiates outward like a giant burst of air, crashing into anything in its path (generating hazardous fragments). If the pressure wave has enough power behind it, it can lift people off the ground and throw them up against nearby buildings or trees. Additionally, blast waves can damage buildings or even knock them flat—often injuring or killing the people inside them. The sudden change in pressure can also affect pressure-sensitive organs like the ears and lungs. The damaging effects of the overpressure will be greatest near the source of the explosion and lessen as you move farther from the source. Overpressure Levels of Concern. An Overpressure Level of Concern (LOC) is a threshold level of pressure from a blast wave, usually the pressure above which a hazard may exist. When you run a vapor cloud explosion scenario, ALOHA will suggest three default LOC values. ALOHA uses three threshold values to create the default threat zones: • Red: 8.0 psi (destruction of buildings); • Orange: 3.5 psi (serious injury likely); and • Yellow: 1.0 psi (shatters glass).




Table 7.12 Findings of Consequence Analysis Studies

Chemical

Downward affected distance, meters

Tank Failure Radiation effect from pool

fire Radiation effect from Fire

ball Toxicity Effect Flammable area of vapor

cloud Overpressure

Effects AEGL 3 / PAC 3/

EPFG 3

AEGL 2 / PAC 2 /

EPRG 2

AEGL 1 / PAC 1 /

EPRG 1

60 % LEL

10 % LEL 8.5 psi

3.5 psi

1 psi 10

kw/m2 5

kw/m2 2

kw/m2

10 kw/m

2

5 kw/m

2

2 kw/m2

Methanol 13 29 65 < 10 13 - - - < 10 <10 <10 198 286 452

Ethanol < 10 15 22 < 10 15 - - - < 10 < 10 <10 230 329 517

Octanol < 10 < 10 22 < 10 < 10 -- - - < 10 < 10 < 10 278 394 615

Isobutanol - 10 41 - < 10 - - - < 10 < 10 < 10 260 370 578

Isopropanol < 10 18 44 < 10 18 - < 10 < 10 < 10 < 10 < 10 249 355 556

Acetone 17 22 102 11 23 - <10 19 < 10 < 10 < 10 546 780 1200

MIBK < 10 23 74 < 10 14 - - - < 10 < 10 < 10 280 398 622

Isophorone < 10 15 33 < 10 < 10 - - - < 10 < 10 < 10 529 750 1200

Cumene 11 17 82 < 10 14 - - - < 10 < 10 < 10 823 1200 1800

Benzaldehyde 23 103 175 < 10 < 10 - - - < 10 < 10 < 10 247 352 550

Mesityl oxide - 11 115 - < 10 - - - < 10 < 10 < 10 357 507 793

Diacetone alcohol

< 10 < 10 14 < 10 < 10 - - - < 10 < 10 < 10 484 691 1100




Chemical

Downward affected distance, meters

Failure of pump 100 % of rated flow

Toxicity Effect Flammable area of vapor cloud Overpressure Effects

AEGL 3 / PAC 3/ EPFG 3

AEGL 2 / PAC 2 / EPRG 2

AEGL 1 / PAC 1 / EPRG 1

60 % LEL 10 % LEL 8.5 psi 3.5 psi 1 psi

Methanol 148 304 665 46 148 - - 37

Ethanol 85 192 262 73 192 - - 61

Octanol 505 1200 2100 105 237 - 83 124

Isobutanol 102 247 664 91 217 - 72 106

Isopropanol 88 218 475 88 218 - 67 100

Acetone 132 177 663 78 195 - 60 92

MIBK 145 333 758 96 223 - 74 113

Isophorone 457 955 1400 112 250 - 89 129

Cumene 268 397 841 109 246 - 85 129

Benzaldehyde 907 1900 2700 102 235 - 81 122

Mesityl oxide 120 276 1200 97 225 - 75 115

Diacetone alcohol 176 394 565 83 189 - 65 104




PAC- Protective Area Criteria for Chemicals

AEGL - Acute exposure guideline level

EPRG- Emergency Response planning guidelines

PAC 3

(400,000

ppm)

PAC 2

(230,000

ppm)

PAC 1

(65000

ppm)

100 %

LEL

60 % LEL 10 % LEL 8.5 psi 3.5 psi 1 psi 10 kw/m2

5 kw/m2

2 kw/m2

1 Leak of gas from the valve – flammable gas not burning Toxic area of vapour cloud < 10 < 10 < 102 Leak of gas from the valve – flammable gas not burning Flammable area of vapour cloud 10 13 313 Leak of gas from the valve – flammable gas not burning Blast area of vapour cloud explosion < 10 11 194 Leak of gas from the valve – flammable gas burning Thermal radiation from jet fire < 10 < 10 <105 Gas escaping from pipeline after pressure reduction

station – flammable gas not burningToxic area of vapor cloud

< 10 < 10 14

6 Gas escaping from pipeline after pressure reduction

station – flammable gas not burningFlammable area of vapour cloud

25 32 79


station – flammable gas not burningBlast area of vapour cloud explosion

20 26 49


station – flammable gas burning Thermal radiation from jet fire

< 10 < 10 <10

9 Bursting of cylinder – flammable gas not burning Toxic area of gas cloud < 10 < 10 < 1010 Bursting of cylinder – flammable gas not burning Flammable area of gas cloud <10 12 2811 Bursting of cylinder – flammable gas not burning Overpressure area of gas cloud

Scenerio for Hydrogen

Toxicity Effect Flammable area of vapor cloud Overpressure Effects

Radiation effect from jet fire

Downward affected distance, metersNo

Tank Failure




Comments / Recommendations based on Consequence analysis

Toxic release scenarios

o Out of the toxic chemical’s dispersion considered above, affected distance goes beyond plant boundaries in case of containment failure.

Radiation effect from pool fire

o Radiation effect from pool fire affected distance mostly is within plant boundaries.

Radiation effect from the fireball

o Radiation effect from fireball affected distance goes beyond plant boundaries.

7.6.1 Individual and Societal Risk

7.6.1.1 Failure frequency data

Failure frequency data as given in UK HSE Publication PCAG chp_6K Version 14 – 06/11/17

is presented below for information.

Table 7.13 Failure Frequency Data

Failure rates (Small and medium atmospheric tanks)

Type of release Non-Flammable Contents (per

vessel year) Flammable Contents (per

vessel year) Catastrophic 8 x 10-6 1.6 x 10-5

Large 5 x 10-5 1 x 10-4 Small 5 x 10-4 1 x 10-3

Failure rates (Pressure vessels)

Type of release Failure rate (per vessel year)

Catastrophic 6 x 10-6 50 mm diameter hole 5 x 10-6 25 mm diameter hole 5 x 10-6 13 mm diameter hole 1 x 10-5 6 mm diameter hole 4 x 10-5

Failure rates (Pumps)

Type of event Failure rate (per year per pump)

Casing failure 3 x 10-5

Failure rates (Hoses and couplings)

Facility Probability of failure per transfer x 10-6

Guillotine failure

15 mm diameter hole 5 mm diameter hole

Basic facilities 40 1 13 Average facilities 4 0.4 6

Multi safety system facilities 0.2 0.4 6




Failure rates (Flanges and gaskets)

Type of event

Failure rate (per year per

joint) Notes

Failure of one segment of a gasket.

5 x 10-6 The hole size is calculated as the distance

between two bolts and the gasket thickness. Failure of Spiral Wound

Gasket 1 x 10-7

Hole size calculated as gasket thickness multiplied by pipe circumference.

Failure rates (Pipe work)

Failure rates (per m per y) for pipework diameter (mm)

Hole size 0 - 49 50 - 149 150 - 299 300 - 499 500 - 1000

3 mm diameter 1 x 10-5 2 x 10-6 - - -

4 mm diameter - - 1 x 10-6 8 x 10-7 7 x 10-7

25 mm diameter 5 x 10-6 1 x 10-6 7 x 10-7 5 x 10-7 4 x 10-7

1/3 pipework diameter - - 4 x 10-7 2 x 10-7 1 x 10-7

Guillotine 1 x 10-6 5 x 10-7 2 x 10-7 7 x 10-8 4 x 10-8

Failure rate (Road tanker)

Failure category Failure rate (per km) Serious accident rate 2.2 x 10-7

Pasquill stability meterological conditions

Surface wind speed (at 10 m height)(m/s)

Day time insolation (sunlight intensity)

Night time cloud cover

Strong Moderate Slight < 50 % < 50

% < 2 A A - B B F F

2 - 3 A - B B C E F 3 - 4 B B – C C D E 4 - 6 C C – D D D D >6 C D D D D

A – Extremely unstable condition, B – Moderately stable condition, C- Slightly unstable condition, D- Neutral condition, E- Slightly stable condition, F – very stable condition.

Incoming solar radiation is based on the following: strong (> 700 W m−2), moderate (350-700 W m−2),

slight (< 350 W m−2).

Table 7.14 Broadly acceptable risk frequency

Annual fatality risk level per year

Description

1 x 10-3 Intolerable risk and unacceptable (Immediate action shall be taken to reduce the hazard and risk)

1 x 10-4 Maximum tolerable risk for public (Management should invest / take measures to control hazards, e.g. Fire detection and control system, traffic signages)




1 x 10-5 Tolerable risk (People still recognize. Safety slogans have precautionary rings. Such as never swim alone, never point a gun, avoid air travels

1 x 10-6 Negligible risk (acceptable risk) (Not of major concern i.e. e risk refers to the level of human and property loss that can be tolerated by an individual, group, organization, community, e.g. risk of flooding can be accepted once every 500 years but it is not unacceptable in every ten years).

7.6.1.2 Assumptions for Consequence analysis

WheAther data considered for consequence analysis

Wind speed ( m/sec) Pasquill stability class 1.02 (as per data) F

Atmospheric Conditions: No Inversion

o Ambient Temperature: 31°C has been considered as MCA approach. o Relative Humidity: RH of 50% has been considered.

Damage criteria In Consequence Analysis studies, in principle three types of exposure to hazardous effects are distinguished. 1. Heat radiation, from a pool fire, a flash fire or a BLEVE. 2. Explosion 3. Toxic effects, from toxic materials or toxic combustion products. The damage criteria are as explained as per Guidelines for QRA – ALOHA Software Purple Book for QRA and Guidelines for Chemical Process Quantitative Risk Analysis 2nd edition, Centre for Chemical Process Safety (CCPS).

Accident effects

There are many methods to arrive at response dose curve for human exposure to accident effects. Here the dose refers to the intensity of accident outcome (air borne concentration of a toxic material, overpressure due to an explosion and radiation intensity due to fire), while response implies the human/property damage caused by the accident.

For single exposure probit (probit = probability unit) method is particularly suitable.

Probit (Y) = k1 + k2 ln (V)

Causative factor represent the dose V.

Probit variable Y is computed from following equations.

Table 7.15 Probit corelations for exposure

Type of Injury or damage Causative variable V

Probit parameter k1 k2

Fire Burns death from fire

teIe 4/3/104

-14.9

2.56




te = effective tine of exposure (seconds) Ie = effective radiation intensity received by target (w/m2) Explosion Death from lung hamorrhage Eardrum ruptures Structural damage Glass breakage Po = peak overpressure (N/m2)

Po

Po

Po

Po

-77.1 -15.6 -23.8 -18.1

6.91 1.93 2.92 2.79

Toxic release for Acetone C = concentration (ppm), T= time interval in minutes n = exponent factor (K1,K2 and n for Acetone not published)

CnT -- --

Estimation of Risk

The risk is defined in “Chemical process quantitative risk assessment {as a function of probability or frequency and consequence of a particular accident scenario Risk = Function(s,c,f) where s = hypothetical scenario c = estimated consequence f = estimated frequency

This ‘‘function” can be extremely complex and there can be many numerically different risk measures (using different risk functions) calculated from a given set of s,c,f.

In simple term for the EIA study purpose,

Risk – Frequency x Consequence Where, R = risk (loss or injury per year) F = frequency (event per year) C = consequence (loss or injury per event)

The input details are discussed below:

7.6.1.3 Individual risk

Individual risk is defined (by AIChE/CCPS) as risk to a person in the vicinity of a hazard. This includes the nature of the injury to the individual, the likelihood of the injury occurring and the time period over which the injury might occur. Individual risk can be

estimated for the most exposed individual, for groups of individuals at places or for an average individual in an effect zone. For a given incident or set of incidents, these individual risk measures have different values.

Individual risk to a person at a specific point in the direction of the wind/plume or heat radiation will be dependent on many factors. Important ones are listed below. - Wind direction at the time of release/spillage - Individual person may be inside or outside of building/location. - In the case of the wind direction, the plume width may be represented by the sector

of a circle having an included angle of 15°. In such case, on the basis that wind direction arise, it is possible to approximate that an individual present in a single location for one year may be exposed for only 15/360th of that year, or 4.16 x 10-2




- In actual practice, it is unlikely that a person would be present at any one location in the open air for 100% of the year. Allowing for periods at work or indoors, a risk reduction factor of 3 is reasonably conservative.(three shift operation assumed.)

- Also, the fatality % due to radiation is assumed at 50%, which assumption is based on the response time and the duration of fire.

- The overall consequence of the mitigation due to wind direction and indoor/outdoor location would be the product of these factors, namely 1.38 x 10-2.

- Ref: Guidelines for Chemical Process quantitative risk assessment (CCPS) book page no 596-597)

The overall chance of an individual being affected at a specific location by exposure due to accident (due to toxicity, flammability, and radiation) is indicated in following table.

Estimation of Individual risk

Total individual risk at any geographic location x , y in and around the industrial area is the sum of individual risk at that point, due to various incident outcome cases associated with the various industries in the industrial area.

Individual Risk at a geographical location x, y is given by (AIChE/CCPS) as

where IR x, y is the total individual risk of fatality at geographic location x , y, .IRx.y is the individual risk of fatality at geographical location x,y from the incident outcome case i, n is the total number of individual outcome cases from the industrial area. IRx,y,i, can be estimated using the equation,

where fi is the frequency of incident outcome case i, from the frequency analysis and p f , I is the probability that that incident outcome case i will result in a fatality at location x,y, from the consequence and effect models. Frequency fi of incident outcome case is estimated.

Where fi is the frequency of incident I which has incident outcome case i as one of its incident outcome case (per year) ), pO, i is the probability that incident outcome, having i as one of its incident outcome cases, occurs, given that incident I has occurred and OC, i p probability that incident outcome case i occurs given the occurs of the precursor incident I and the incident outcome corresponding the outcome case i. Based on information, data collected, individual risk has been computed as tabulated below.




Table 7.16 Overall individual risk

7.6.1.4 Societal risk

Societal risk is a measure of risk to a group of people. It is most often expressed in terms of the frequency distribution of multiple casualty events (FN curve.) However, societal risk can also be expressed in terms like individual risk. For example, the likelihood of 100 fatalities at a specific location x,y is a type of societal risk measure. The calculation of

societal risk requires the same frequency and consequence information as individual risk.

Additionally, societal risk estimates require a definition of the population at risk around the facility. This definition can include the population type, the likelihood of people being present, or mitigation factors. Individual and societal risk is the different presentation of the same underlying combinations of incident frequency and consequences. Both measures may be of importance in assessing the benefits of risk reduction measures or

in judging the acceptability of a facility in absolute terms.

No Chemical Incident Consequence

Effect

Frequency

of

occurance

per year

No of

Probable

Sources

(Tanks)

Frequency

Of

Occurance

per year

Consequenc

e Mitigation

factor

Frequency of

Occurance per

year (Individual

Risk)

Cummulative

Individual

Risk

(Areawise)

1 Methanol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 2.21E-07

Pump discharge leak 4.00E-05 1 4.00E-05 1.38E-02 5.52E-07 7.73E-07

2 Ethanol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 9.94E-07


3 Octanol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 1.77E-06


4 Isobutanol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 2.54E-06


5 Isopropanol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 3.31E-06


6 Acetone Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 4.08E-06


7 MIBK Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 4.86E-06


8 Isophorone Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 5.63E-06


9 Cumene Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 6.40E-06


10 Benzaldehyde Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 7.18E-06


11 Mesityl oxide Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 7.95E-06


12 Diacetone alcohol Tank failure 1.60E-05 1 1.60E-05 1.38E-02 2.21E-07 8.72E-06


13 Hydrogen Cylinder / piping failure 6.00E-06 1 6.00E-06 1.38E-02 8.28E-08 9.36E-06

Toxic release,

fire, explosion




Figure 7.2 Typical F- N curve

The calculation of societal risk requires the same frequency and consequence information as individual risk.

Additionally, societal risk estimation requires a definition of the population at risk around the facility. This definition can include the population type (e.g., residential, industrial, school), the likelihood of people being present, or mitigation factors.

Individual and societal risks are different presentations of the same underlying combinations of incident frequency and consequences.

In order to calculate societal risk, following information is needed,

- Information on population type (e.g., residential, office, factory, school, hospital) for evaluating mitigation factor.

- Information about time-of-day effects (e.g. for schools) - Information about day-of-week effects (e.g., for industrial, educational, or

recreational facilities) - Information about percentage of time population is indoors for evaluating mitigation

factors.

Estimation of social risk

Number of people affected by all incident outcome cases can be estimated using the following equation

where Ni is the number of fatalities resulting from incident outcome case I, Px,y is the number people at locations x , y and pfi is the probability that that incident outcome case i will result in a fatality at location x , y.




Consequence analysis

Estimation of the impact of each incident requires two steps. First a model estimates a physical concentration of material or energy at each location surrounding the facility for example,

- Radiant heat from the fire, - Overpressure from the explosion, and - Concentration of toxic material in the atmosphere.

A second set of models estimates the impact that this physical concentration of material or energy has on people, the environment or property for example toxic material dose response relationships. Various models are used for consequence analysis such as fire, explosion and dispersion modelling of flammable and toxic substances.

Based on modelling analysis,

a) Toxicity effect mostly remain within plant boundary. b) Explosion overpressure remains within plant boundary. c) Radiation effect from pool fire remains within plant boundary. d) Average radiation effect from fireball is found beyond plant boundary at around

distance of ~ 800 m. Iso contours are drawn around site as shown below,

Figure 7.3 Iso contour of radiation effect zone

Discussion

- There is no residential zone within innermost contour drawn. - Based on wind pattern, during the winter season wind blow is mainly from east,

north east, and some from south west. - Assumption - 70 % from east and 20 % from south direction and 5 % each from west

and north direction. - 80 % wind blowing during day and 20 % wind blowing during night (assumption).

- Expected manpower of the unit is 610 Nos.




- It is assumed that there will be ~ 400 nos of persons during day and 210 persons

during night-time around area considered equally in each of four quadrants. - If the loss of containment that leads to these outcomes is 6 chances in a million per

year (6 x 10-6) then the following table shows the calculation of the frequencies of the individual outcomes and the expectation value for each outcome.

Table 7.17 Societal risk computation

Direction Base

frequency (per year)

Direction Day

/Night

Outcome frequency (per year)

Outcome fatalities (based on 5 %

fatality (radiation exposure)

Expected value (fatalities per year) Societal

risk East - day 6.00E-06 0.7 0.8 3.36E-06 20 6.72E-05

East - night 6.00E-06 0.7 0.2 8.40E-07 11 8.82E-06 North - day 6.00E-06 0.2 0.8 9.60E-07 20 1.92E-05

North - night 6.00E-06 0.2 0.2 2.40E-07 11 2.52E-06 South - Day 6.00E-06 0.05 0.8 2.40E-07 20 4.80E-06

South - Night 6.00E-06 0.05 0.2 6.00E-08 11 6.30E-07 West - day 6.00E-06 0.05 0.8 2.40E-07 20 4.80E-06

West - night 6.00E-06 0.05 0.2 6.00E-08 11 6.30E-07 6.00E-06 1.09E-04

The expectation value of 1.09E-04 is often used for valuing safety improvements in monetary terms.

In order to produce a FN curve, the table of outcomes is then sorted into decreasing number of fatalities and an additional column added for the cumulative frequency.

Table 7.18 Cumulative societal risk

Direction

Base frequency

(per year)

Direction Day/ Night

Outcome frequency (per year)

Outcome fatalities (based on 5 %

fatality (radiation exposure)

Cumulative Frequency

(Societal risk)

East - day 6.00E-06 0.7 0.8 3.36E-06 20 3.36E-06 North - day 6.00E-06 0.2 0.8 9.60E-07 20 4.32E-06 South - day 6.00E-06 0.05 0.8 2.40E-07 20 4.56E-06 West - day 6.00E-06 0.05 0.8 2.40E-07 20 4.80E-06 East - night 6.00E-06 0.7 0.2 8.40E-07 11 5.64E-06

North - night 6.00E-06 0.2 0.2 2.40E-07 11 5.88E-06 South - night 6.00E-06 0.05 0.2 6.00E-08 11 5.94E-06 West - night 6.00E-06 0.05 0.2 6.00E-08 11 6.00E-06




The resulting values of fatalities (N) are then plotted against cumulative frequency (F) conventionally on a log/log plot as shown below.

Figure 7.4 F N Curve for the project

Table 7.19 Societal risk criteria of some other countries

Authority F/N curve slope

Maximum tolerable intercept with N = 1

Negligible tolerable intercept with N = 1

Limit on N

VROM, The Netherlands, (New Plants) -2 10 -3 10 -5 - Hong Kong Government, (New Plants) -1 10 -3 10 -5 1000 Health and safety commission, UK -1 10 -3 10 -5 -

Risk Criteria

Risk criteria are the acceptable levels of risk which can be tolerated under a situation.

In many countries the acceptable risk criteria has been defined for industrial installations and are shown in below table.

Table 7.20 Official individual Risk criteria for the public

Authority and application

Maximum tolerable risk (per

year)

Negligible risk (per

year)

VROM, The Netherlands (New Plants) 10 -6 10 -8




VROM, The Netherlands (Existing or combined new plants)

10 -5 10 -6

Health and safety executive UK (Existing hazardous industries)

10 -4 10 -6

Health and safety executive UK (New nuclear plants) 10 -5 10 -6 Health and safety executive UK (existing dangerous substances transport)

3 x 10 -4 3 x 10 -6

Health and safety executive UK (New housing near existing plants)

10 -6 10 -7

Hong Kong government ( New plants) 10 -5 Not used Department of planning, New south wales (New plants and housing)

10 -6 Not used

Environment protection authority (Western Australia (New plants)

10 -6 Not used

Santa Barbara county, California, USA 10 -5 10 -7

These criteria are yet to be defined in the Indian context, but values employed in other countries can be used for comparison purpose.

Table 7.21 Suggested Individual Risk criteria

Authority and application Maximum tolerable risk (per year) Maximum tolerable risk for the worker 10 -3 Maximum tolerable risk for the public 10 -4

Negligible risk 10 -6

7.6.1.5 Conclusion

Individual Risk Assessment:

The risk to the member of the public from the raw material storage system at Prasol is well within ‘Acceptable’ region.

Societal Risk Assessment:

As per Health and safety commission (Existing Hazardous Industry) it is Acceptable.

7.6.2 Recommendations based on Quantitative Risk Assessment

Tank storage area

o The major fire scenario is pool fire. If pool fire arises due to failure of any of the tank inside common dyke of explosive tank-farm, it is important to prevent failure of other tanks in the dyke. This can be achieved by keeping the other tanks cool with water spray.

o It is recommended to have water spray for all the tanks inside tank farm. The actuation of the water spray can be automatic or manual.

o The fire fighting distance should be from at distance of minimum 15 m from tank dyke with fire resistant clothing.

o Fire water network providing hydrants and monitors should be around tank farm, reactor building/ process area. Also, provision of hydrants on elevated structures and buildings to be ensured.




o The foam fire extinguishing system should be used for pool firefighting. This can be semi fixed system with connections to all tanks and dykes and portable foam cans can be used along with fire water monitors around tank farm.

o Fireproofing requirement of structure and equipment supports needs to be analysed and fireproofing to be provided accordingly.

o No pumps to be installed inside the dyke. o All transfer pumps should have double mechanical seals to avoid leakage o The tanks shall have proper designed breather valve and emergency vent. o The tanks shall be provided with breather valve and flammable material tanks

breather valves shall be provided with flame arrester. o Evacuation routes shall be planned such that alternate route is available from any

corner in more than one direction. o Extra precautions to be taken in unloading of flammable solvents. The details of

precautions during storage handling and transportation of solvents has been mentioned separately.

o Elaborate Firefighting arrangements shall be provided as per the statutory guidelines.

o Storage tanks: Statutory guidelines and good engineering practices shall be followed in design, installation and maintenance of storage tanks.

Drum storages

o Chemicals compatibility matrix will be prepared and followed while demarking

area in the warehouse. o In drum storage area in warehouse, toxic and flammable materials shall be stored

separately. o The area shall be provided with small bund wall (100mm) to contain any spill. o The warehouse shall be well ventilated. o Fire water network providing hydrants and monitors should be around

warehouse. o Safety shower & eye washer to be placed near warehouse.

General

o Spiral wound gaskets are recommended for hydrocarbon lines. Screwed fittings

should not be used except for stainless steel instrumentation. o The construction and fabrication should be as per standard codes and practices

(ASME/ANSI/IS) as the failure frequencies will be valid for such construction. If there is some deviation, then the frequencies may increase.

o Fireproofing requirement of structure and equipment supports needs to be analyzed and fireproofing to be provided accordingly.

o The plant handles flammable materials like Methanol, Ethanol, Acetone, cumene, diacetone alcohol and many more. Handling of these materials requires control of spark, ignition source, and open flame. This will be ensured by selecting equipment as per Hazardous area classification analysis. Ensure that all electrical installations and instruments are as per hazardous area classification (ref IS 5571 & 5572).

o The atmospheric storage tanks breather valves are very important safety device to prevent tank from failure.




o Hence it is much more important to keep this valve always in line without any obstacle. They are susceptible for choking due to plastic sheets, leaves, bird activities. These breather valves should be monitored and visually inspected at regular frequency preferably once in a month.

o Proper arrangement to be provided to drain rainwater accumulated inside the dyke.

o Critical switches and alarms shall always be kept online especially in reactor area. o Provide training for employees in the procedures established for their operating

and maintenance functions. Also, a refresher training program at specific intervals is to be prepared to keep operators updated.

o Shut off and isolation valves shall be easily approachable in emergencies. o Some of the chemicals handled in the plant have both toxic and flammable effects.

The fire fighters crew who is responding to emergency involving such chemicals should be aware of toxic effects of those chemicals and should use the advised PPEs for those chemicals.

o A wind direction pointer shall also be installed at site so that in an emergency the wind direction can be directly seen, and downwind population cautioned.

o Smoking shall be prohibited in designated locations. Work likely to involve flame or sparks, such as, welding or burning, shall be performed only after the area is checked for no presence of flammable material and other safety arrangement as required.

o A proper training shall be given to the staff to handle any emergency situation and use of PPE during the work and emergency.

o Self-Contained Breathing apparatus (SCBA) shall be well maintained for emergency handling.

o Personal protective equipment to be provided to all the employees related to the type of work and hazard associated

o Mutual aid from neighboring industries to be made available whenever need arises.

o To check preparedness of workers for emergency control, mock drills on regular basis and disaster drills as per factory inspectorate guidelines to be conducted.

Prasol is committed to comply risk assessment mitigation measures. (Refer Annexure 7.1) Proposed fire detection and protection measures are given in Annexure 7.5.

7.7 HAZOP Study

7.7.1 Objective

For identifying cause and the consequences of perceived mal operations of equipment and associated operator interfaces in the context of the complete system. It accommodates the status of recognized design standards and codes of practice but rightly questions the relevance of these in specific circumstances where hazards may remain undetected.




7.7.2 Purpose of HAZOP

It emphasizes upon the operating integrity of a system, thereby leading methodically to most potential and detectable deviations which could conceivably arise in the course of normal operating routine

- including "start-up” and "shut-down" procedures - as well as steady-state operations.

It is important to remember at all times that HAZOP is an identifying technique and not intended as a means of solving problems nor is the method intended to be used solely as an undisciplined means of searching for hazardous scenarios.

Prasol will carry out HAZOP study of all proposed plants and processes once P & ID’s are frozen during engineering stage and will draw action plan for implementation.

7.8 Ammonia

Ammonia is used at site for refrigeration purpose and not for direct process use. Ammonia handling and its safety aspects are described in IS 4544:2000 which will be followed at site.

7.9 Hydrogen and Hydrogenation safety

Prasol will be using hydrogen for Hydrogenation reaction in the production of various chemicals such as Hexylene glycol, trimethyl cyclohexanol, trimethyl cyclohexanone, MIBK, MIBC, DIBK, DIBC etc.

7.9.1 Hydrogen Cascade System

Hydrogen required for reaction will be partially met through in situ generation and balance will be supplied through cascade of Cylinders. A total of 128 cylinders (each with water capacity of 80 liters) are planned to be stored. Prasol will apply for storage of cylinders under gas cylinder rules to PESO (Petroleum and Explosives Safety Organization).

Safety Management System with regards to the receipt/handling and storage of hydrogen cylinder cascades is described below.

7.9.2 Hydrogen gas properties

Appearance – Colorless, odorless extremely flammable gas; slightly soluble in water. UN Number – 1049 UN Class – 2.1 Physical state – Compressed Gas Auto-ignition temperature (°C) – 571 Melting point / freezing point (°C) – 259.14 Initial boiling point and boiling range (°C) – 252.8 Molecular weight (g/mol) – 2.016 (H2) Flash point (°C) – Not Available Upper Explosive Limit (% v/v) – 75.0




Lower Explosive Limit (% v/v) – 4.1 Vapor pressure (kPa) – 16900 cyl @ 15°C

Gas group – IIC

Vapor density (Air = 1) – 0.09 @ 0C/1 atm, g/L

Note - When liquefied Hydrogen converts to gaseous Hydrogen at standard condition, it expands 850 times. It diffuses through various sizes of the opening 2 to 3.8 times faster than air. Minimum ignition energy required is 0.017mj as compared to 0.28 mj for Methane. It gets ignited by static electricity generated from high velocity leak. The stoichiometric hydrogen – air mixture burns as a velocity roughly nine times faster than methane – air mixture, which makes explosion venting of hydrogen explosion more difficult and increases likely hood for hydrogen deflagration in pipes or long enclosure will escalate to detonation. Due to high velocity, it is difficult to arrest hydrogen flame. Pressure more than 7 MPa can embrittle and significantly affect structural steel & other metal.

7.9.2.1 Primary Hazards of Hydrogen

The primary physical hazards associated with hydrogen gas are its flammability and explosivity. This is because hydrogen can form a flammable mixture with air over a wide range of concentrations (4% to 75%), and very low energy is needed to ignite hydrogen-air mixtures. Once hydrogen is ignited, the reaction can proceed either by deflagration (subsonic propagation) or detonation (supersonic propagation). Deflagration in a closed volume can cause a pressure increase of almost eight times the initial pressure. Detonation from a low-energy ignition source is possible in hydrogen-air mixtures of 18% - 60% volume that are well mixed and confined.

Hydrogen gas is highly explosive, prone to leakage and permeation, difficult to detect, so special care must be taken during process engineering design of equipment and systems that handle or contain hydrogen. The reactions involving hydrogen tend to be exothermic and in many cases are conducted under high pressures and temperatures.

Hydrogenation and other hydrogen-handling processes involve a considerable amount of process equipment, instrumentation and piping components, such as reactors, catalyst feed vessels, spent catalyst filters, pumps, valves, pressure relief devices, pressure regulators and check valves. Many such systems, particularly those for hydrogenation of organic chemicals, are located inside a building. Such facilities must be designed with four levels of safeguards, namely:

o A high degree of automation, with remote operations, interlocks and alarms to monitor process and environment conditions

o Certified relief devices for process equipment and piping. The relief devices vent discharges must be directed to safe locations

o Adequate, dependable space ventilation to prevent accumulation of hydrogen gas pockets for systems located inside buildings

o Damage-limiting building construction to protect personnel and property.




Although hydrogen air mixtures have the same calorific value per pound as TNT, the rate of energy release is much slower for hydrogen-air mixtures. Hydrogen detonations, although rare, are characterized by pressure increases so rapid that pressure-relief devices are usually ineffective. When using hydrogen in enclosed areas, consult National Fire Protection Association documents 68 and 69.

7.9.3 Effects on Health

Hydrogen is nontoxic and has even been used as a filler for oxygen sources for underwater diving. The primary health effect associated with hydrogen is the possibility that it could displace air in a poorly ventilated or confined space, resulting in asphyxiation. However, because it is flammable at only 4% in air, the most significant concern should be the physical hazard of flammability and the possibility of burns resulting from fires and explosions. When working with liquid hydrogen, there is an additional health hazard of cryogenic burns. The following is an overview of the primary hazards to be avoided when handling, storage and usage of hydrogen gas in cylinders. Asphyxiation: As hydrogen gas is colourless and odourless, it can escape into the atmosphere undetected and quickly reduce the concentration of oxygen below the level necessary to support life. The use of oxygen monitoring equipment is strongly recommended for enclosed areas where it is being used. Except for oxygen, any gas can cause asphyxiation. In most scenarios, hydrogen’s buoyancy and diffusivity make hydrogen unlikely to be confined where asphyxiation might occur. Fire and Explosion: Fire and explosion are the primary hazards associated with hydrogen. It can be ignited by static electricity or by a heat source, such as a flame or a hot object. Oxygen and other oxidizing gases do not burn but will support combustion of flammable materials. Increasing the concentration of an oxidizer accelerates the rate of combustion. High Pressure: Hydrogen is stored at very high pressure stored inside the cylinder (about 150 kgf/cm2g). A sudden release of pressure can cause injuries by propelling a cylinder or whipping a line. Improper Handling of Cylinders: Compressed gas cylinders are heavy and awkward to handle. Improper handling of cylinders could result in sprains, strains, falls, bruises, and broken bones. Other hazards such as fire, explosion, chemical burns, poisoning, and cold burns could occur if gases accidentally escape from the cylinder due to mishandling. Hydrogen is non-toxic and has no color or smell. It is highly flammable, with flammability range of 4% to 75% in air by volume. Hydrogen is much lighter than air (therefore will collect in roof spaces). Hydrogen flames from leaks can be almost invisible and thus difficult to detect. In dark color of flame will be pale blue. Hydrogen is typically stored and transported in cylinders for industrial use having

pressure more than 150 kg/cm2g, which is used in hydrogenation process at lower

pressure depending upon process requirement.




Following arrangement show typical P&ID of PRV station for hydrogen pressure

reduction which will be installed at Prasol for hydrogen pressure reduction.

Figure 7.5 Typical P & ID of PRV station

Table 7.22 Technical specification of PRV station




7.9.4 Hydrogen safety management system

Risk Control Mechanism:

7.9.4.1 Engineering Practices:

o All tools which need to be used should be spark proof.

o Only trained engineer should be deputed on Hydrogenator.

o There should not be short or long bolting.

o All components should be of appropriate pressure rating.

o SRV and Pressure Vessel should be tested through the Competent Person as per

the Goa state laws dealing with Pressure Vessels and plants.

o All devices including gauges, gas detectors, O2 sensor on the hydrogenation system

or part thereof should be considered as critical and frequency of checks /

calibration should be in adherence / in-line with the same.

o At no case substandard / low rating pressure components to be used for

hydrogenator.

o H2 supply line should be considered as pressure line and should be tested at the

specific intervals specified in relevant Standard Operating procedure.

o On N2 supply line double NRV needs to be installed. There should be Pressure

gauge in between two NRVs. One NRV should be installed very near to the reactor

and another should be near to the N2 supply line automated valve.

o No Lines / Cables / electrical fittings excluding Fire Detectors should be mounted

/ installed / passed on ceiling above hydrogenator.

o Any window should have Fireproof / shatter proof glass.

7.9.5 Facility Requirements:

Civil: Layout & Building Design

Hydrogen cylinder shall be kept in an open area, near manufacturing block. MOC will be

Brick masonry. Should have fragile roof preferably fin roof. Front door with full mesh and

with locking arrangement.

Hydrogenation area should be at least 9 m away from any plant building or installation

or separate by RCC fire retardant wall of 2 hours fire rating.

The floors and walls shall have 2 hours of fire rating. Room walls shall be continuous from

floor to ceiling and shall be securely anchored.

There shall be no opening in the walls common to the other building. If opening is a must,

seal the opening with 2 hours fire retardant material. Walls should be 6” RCC or Brick

wall of 18 inch.




The building shall be naturally ventilated.

Provision of ventilation also should be made at top of the block ceiling so as to avoid

Hydrogen gas logging.

The facility shall be provided with 2 staircases opening outside.

All the Hydrogenator rooms shall be provided with metallic doors with 2 hours of fire

rating.

Hydrogenator area should be provided with weak roof. The design shall be such that in

case of explosion the roof sheet will break, however the hydrogenator parts if broken will

not go out of the room. Accordingly, concrete grid shall be provided with a metal roof /

fin roof sheet. PRV Station should be separated from cylinder cage and facility by brick

masonry partition.

7.9.5.1 Instrumentation

Hydrogenation should be entirely supervised and controlled from the operator station

and PLC in the control room. Critical parameters like pressure & temperature shall be

displayed in control room and on Hydrogenator.

PLC/DCS should also have emergency shutdown button enclosed in a glass cabinet with

break glass if possible.

The hydrogenation reaction takes place under pressure and is exothermic. It must be

considered as a potentially hazardous reaction. For these reasons the production

conditions are continuously monitored, and the unit needs to be protected by a

sophisticated interlocks and safety system.

In order to avoid the possibility of human error and to always maintain the plant under

safe conditions, the production follows an established program, which can be sub divided

into smaller single sequences in the form of standard operating procedures.

The production is started from the operator station. Once started, the different sequences

are conducted automatically through PLC.

In order to ensure the quality of the product, the program pauses at some predefined key

points of production process. The operator must check that the present conditions are

correct and that the operations were completed, before start-up of following step.

The system should protect the plant and automatically stops the reaction in case the

conditions in the reactor (Temperature, Pressure) go beyond normal, or if the reaction

cannot be safely controlled. (e.g. Loss of cooling media).




In case of the problem, the operator should stop production at any time by pressing the

“Hold” key. The reaction or the other dynamic operation will stop, but the conditions in

the reactor are maintained. After proper checking, the operation can be restarted by

pressing “RUN” key.

The emergency push button should be provided in the field and one in the control room

for each hydrogenator, allowing the operator to immediately stop the reaction in case of

abnormal situation.

7.9.6 Electrical

All the electrical systems within Hydrogenation area, Gas Cylinder cage, PRV Station

should be designed FLP as per gas group IIC of IS 2148, and temperature classification T5

/ T4, Class F which include motors, electrical light fittings, sockets, instruments etc.

All the electrical systems outside hydrogenation should be designed FLP as per gas group

II A/B classification of IS 2148.

The complete building should fall under flame proof zone as per IS 5572 and all the

electrical appliances shall be considered under FLP suitable for gas group II A/B.

All electrical cables should be armoured cables.

Hydrogenator, PRV Station, Vent outlet and all electrical gazettes should be earthed.

Static earthing grid and electrical earthing grid down comers should be separate.

Fire alarm / gas detection system inside hydrogenation area should be flame proof /

intrinsically safe. In case of intrinsically safe system / components, Zener barrier should

be kept outside the hazardous area.

7.9.7 Mechanical

All the open vents (after knocking out pot & manifold safety valves) shall be provided

with Nitrogen at the open end. Hydrogen and Nitrogen Venting ratio should be 1:4 E. All

the isolation valves on the hydrogenator and the Hydrogen line shall be designed for the

design pressure & temperature of the Hydrogenator reactor. Accordingly, pound rating

of valves and pipes shall be selected. All the valves in the system shall be fire safe ball

valves as per API 607.

Special Procedures: · Ensure that, reactor is depressurised and under Nitrogen

blanketing while Sampling must be done.

Hydrogenation initiation should be done only in General shift

Before any Hydrogenation, Pressure and Vacuum testing at appropriate pressure with

use of Nitrogen is must.

Follow Nitrogen purging cycles before charging / purging Hydrogen.




Nitrogen cylinder should be provided on H2 Cylinder manifold. Before starting and after

stopping H2 cylinder N2 should be flushed through said cylinder.

7.9.8 Safety Devices / Systems

Provide 68 0 C rated automatic sprinklers designed to discharge a 10 LPM/m2 over and

above hose stream demand for the hydrogen cylinder storage and reaction area.

Provision of Smoke Detector and Gas detectors in line with the requirements of electrical

area classification.

Provision of Fire Extinguishers inside and nearby area as per the norms.

Provision of Steam fog at H2 vent.

Provision of Temperature Sensor at outlet of Vent.

At least one Safety Shower near the Hydrogenation block within distance of 10 meters is

required.

7.9.9 Protective Measures

o There should be no open flames or smoking in areas where hydrogen is used. o Work in an area with plenty of ventilation. o Ground all equipment and piping used with hydrogen, and make sure that you are

properly grounded before working with hydrogen. Rubber soled shoes prevent you from being grounded, so you should touch a grounded object to discharge built up static electricity before beginning work.

o Wear appropriate safety gear for the work being performed: safety glasses/ goggles, coat, gloves and preferably a face shield.

o Remove electrical equipment or electronic devices from the vicinity of hydrogen gas unless the device is certified "intrinsically safe". Even invisible small sparks from electronic devices could ignite hydrogen.

o Use metal piping with hydrogen. Do not use non-conductive or plastic tubing. Be sure to dissipate static charge when flowing hydrogen gas by electrically bonding and grounding the cylinder, metal piping and apparatus being used.

o Hydrogen cylinders must be stored with valve’s protective cap in place. If the cap has been removed, the cylinder must be stored upright and secured with non-combustible straps or chains.

o Hydrogen cylinders must be stored more than 20 feet away from cylinders of oxygen or other oxidizers, e.g., bromine, chlorine be separated by a noncombustible wall extending not less than 18” above and to the sides of the stored material.

o Never open the cylinder valve before making sure all your connections are secure as the static discharge from flowing gas may cause hydrogen to be ignited.

o NEVER USE ADAPTERS. o Be aware of leaks! Hydrogen has a low viscosity which makes it to have a high

leakage rate. A leak as small as 4 micrograms/second can support combustion. o Due to hydrogen’s low molecular weight, this gas will diffuse rapidly in a room and

will collect near the ceiling. It is important to only use hydrogen in well ventilated locations.

o There must be no more than 1000 cubic feet of flammable gases per fire control area unless there are adequate engineering controls. Contact EH&S for an evaluation if there will be more than one large cylinder used in a room and one in




storage. A standard large cylinder contains about 260 cubic feet of hydrogen. If there are inadequate engineering controls the management may restrict the volume of H2, request that they be stored in an exhausted location and require hydrogen monitoring and alarms, or other safety controls. There should be fire sprinklers wherever hydrogen is used.

o All electronic equipment used near hydrogen gas must be grounded. o Check that the pressurized system does not leak hydrogen with leak detection

solution or pressure sensing. o Close the cylinder valve when not in use. Do not leave the piping pressurized if not

is use. o Hydrogen is incompatible with many materials and situations (check your MSDS

for list of incompatibles): o It ignites easily with oxygen, could explode when heated. o It reacts violently or explosively or forms heat- and/or-shock sensitive explosive

mixtures with oxidizers, halogens, halogen compounds, acetylene, bromine pentafluoride, chlorine oxides, fluorine perchloride, oxides of nitrogen (check MSDS for list of incompatibles).

o Mixtures with chlorine may explode on exposure to light. o Mixtures with oxygen may explode in presence of platinum catalyst. o It forms hydrides when heated with alkalis, alkaline earth, and some other

elements. o Prepare standard operating procedures (SOP) well in advance, train and validate

all concerned involved in hydrogen handling and hydrogenation system.

7.10 On site emergency plan

Prasol Chemicals limited has developed emergency management system to tackle any emergency situation for the site. The disaster management plan (DMP) provides for a framework of actions to handle various emergency situations at the site. It also provides for on-site resources and appropriate outside assistance in case of any incident at the facility. The ERP will be in place before the commencement of operations at site, and all personnel will have undergone a comprehensive training in emergency response. The primary objective of the plan is

Minimization of the risks to lives and safety of proposed plant personnel and of the neighboring community.

Containing and minimizing environmental damage, to surroundings, and to site property, and equipment, this could occur from emergency or accidental situations beyond the normal operations of the plant.

Coordinating appropriate and effective actions with outside regulatory agencies during and after their involvement in on-site emergencies.

Maintaining effective trained personnel capable of performing the established emergency response procedures when it is required.




Prasol has developed elaborate onsite emergency management plan (Refer Annexure 7.3). It will be further augmented for the expansion project, during project execution.

7.11 Public Consultation

“Public Consultation” refers to the process by which the concerns of local affected persons and others who have plausible stake in the environmental impacts of the project or activity are ascertained with a view to considering all the material concerns in the project or activity design as appropriate.

Since this is an expansion project of synthetic organic chemicals manufacturing facility (under Category 5 (f)) and falls outside notified industrial area, it is categorized as category A and public consultation is required to be carried out. (Refer MoEF&CC OM No. J-11011/321/2016-IA.II (I) dated 27th April 2018) (http://moef.gov.in/wp-content/uploads/2018/05/estates.pdf). The Standard Auto TOR granted to the project vide ref No J-11011/260/2012-IA-II(I) dt. 27th June 2019 also specified that a public consultation be conducted. An application requesting to conduct public hearing was made to Maharashtra pollution Control Board (MPCB), Sub- Regional office, Raigad-I, MPCB, Navi Mumbai on 25.02.20 along with following documents:

Draft EIA/ EMP report Executive Summary in English & Marathi (Local language) Soft copies in CD containing Draft EIA & Executive summary

However, due to nCOVID Lockdown enforced from 22nd March 2020, and the pandemic situation which ensued, the Public hearing could not be conducted. After the lockdown restrictions were partially lifted, Raigad District Collector gave date for public hearing as 13th October 2020 and an advertisement placed in 3 Newspapers. In the meanwhile, MoEFCC issued Office Memorandum No. 22-25/2020-IA.III dt 14th September 2020, requiring a physical public hearing with restriction for 100 attendees at a time and a virtual Public hearing be conducted. Considering above situation District Collector Raigad and MPCB decided to hold both a physical public hearing and a virtual Public hearing.

7.11.1 Notice for Public Hearing

MPCB and district administration fixed the date of physical public hearing as 13th October 2020 at 12.00 noon and venue as Samuel Hall, 4th Floor, Old Mumbai Pune Highway (NH4), Khopoli, Dist. Raigad- 410710. MPCB placed an advertisement for conduct of public hearing, in English daily newspaper “Indian Express” and Marathi daily newspaper “Loksatta” & “Krushival” on 13/09/2020. In addition, MPCB placed an advertisement in same newspapers as above on 26/09/2020 giving instructions on how to access the on line Public hearing to be conducted through CISCO WEBEX app simultaneously due to COVID-19 pandemic situation, in view of MoEFCC O.M dt 14th September 2020.

Draft Environmental Impact Assessment report and the Executive Summary in both English

http://moef.gov.in/wp-content/uploads/2018/05/estates.pdf

http://moef.gov.in/wp-content/uploads/2018/05/estates.pdf




and local language (Marathi) were sent to the following authorities and made available to public for inspection by MPCB: 1. Ministry of Environment, Forest and Climate Change, Zonal Office, West Central Zone,

New Secretariat Building, Ground Floor, East wing, Civil Lines, Nagpur- 440 001 2. District Magistrate Office, Raigad 3. Additional District Magistrate Office, Raigad 4. Zilla Parishad Office, Dist. Raigad 5. District Industries Center office, Dist. Raigad 6. Tahsildar Office- Khalapur, Dist. Raigad 7. Grampanchayat Offices- at Group Grampanchayat Honad, Chinchvali, Tebewadi, Dheku,

Thane-Nhave, Aatakargaon, Tal. Khalapur, Dist. Raigad 8. Sub Regional Office, Raigad- I, MPCB 9. Regional Office, Raigad, MPCB 10. Head Office of Maharashtra Pollution Control Board, Mumbai 11. Environment Department, Govt. of Maharashtra, Mantralaya, Mumbai

In addition to above, the Draft EIA report and the executive summary in English and Local language Marathi were made available electronically at the website of MPCB (http://mpcb.gov.in/).

7.11.2 Publicity of Public Hearing

To ensure maximum participation from the nearby local people, wide publicity of the public hearing was done by keeping the Draft Environmental Impact Assessment report and the Executive Summary in both English and local language (Marathi) with CD soft copy at above mentioned locations . Also, Executive summary was hosted on MPCB web site.

7.11.3 Panel for Public Hearing

Chairperson- Dr. (Ms) Padamshri Shriram Bainade (Addl. District Magistrate, Raigad), Member and Convener- Shri. J. S. Salunkhe (Regional Officer, MPCB, Raigad) supervised and presided over the entire public hearing proceedings. For the virtual Public hearing, Y. P. Vaishyampayan from District Collector Raigad office and Shri. Abhijeet Lohia from MPCB were present all the time while Dr. (Ms) Bainade attended from the venue.

7.11.4 Proceedings

Physical public hearing was carried out in two batches with minimum 100 persons in

each batch. Virtual Public hearing was also conducted simultaneously.

The proceedings of public hearing is attached as Annexure 7.7. Summary of points raised during Public hearing and Company’s replies are given below.

Total 20 points were raised during public hearing, out of which 13 were raised for positive comments, suggestions and remaining 7 were raised for queries/ objections.

http://mpcb.gov.in/




The key objections received, suggestions and comments raised (written and oral) during public hearing have been summarized as presented below,




Table 7.23 Points raised by villagers during Public Hearing (Written and Oral)

Name of person

Points raised

Po

llu

tio

n

Ca

nce

lla

tio

n o

f P

H

Ex

isti

ng

EC

co

mp

lia

nce

Od

ou

r p

rob

lem

Sa

fety

asp

ect

s

Eff

lue

nt

dis

cha

rge

Du

st &

sm

ok

e

ge

ne

rati

on

No

ise

po

llu

tio

n

Lo

cal

em

plo

ym

en

t

Gre

en

be

lt

Co

rpo

rate

E

nv

iro

nm

en

t R

esp

on

sib

ilit

y

Co

rpo

rate

So

cia

l R

esp

on

sib

ilit

y

La

nd

re

late

d &

O

pe

n s

pa

ce

Sp

ace

co

nst

rain

ts

Av

ail

ab

ilit

y o

f A

mb

ula

nce

Su

pp

ort

fo

r e

xp

an

sio

n

Narendra Gaikwad, Aatakargaon village

Shashikant Sudam Deshmukh, Honad

village

Prakash Patil, Chinchwali village

Sandip Deshmukh, Adoshi village

Viju Hange, Khopoli town

Manish Khavale, Dheku village

Ramchandra Deshmukh, Khalapur

village

Nitesh Patil, Aatakargaon village

Naresh Patil, Raigad zilla prishad member

Ulhas Deshmukh Sandip Ravindra

Borle, Thane nhave village




Name of person

Points raised

Po

llu

tio

n

Ca

nce

lla

tio

n o

f P

H

Ex

isti

ng

EC

co

mp

lia

nce

Od

ou

r p

rob

lem

Sa

fety

asp

ect

s

Eff

lue

nt

dis

cha

rge

Du

st &

sm

ok

e

ge

ne

rati

on

No

ise

po

llu

tio

n

Lo

cal

em

plo

ym

en

t

Gre

en

be

lt

Co

rpo

rate

E

nv

iro

nm

en

t R

esp

on

sib

ilit

y

Co

rpo

rate

So

cia

l R

esp

on

sib

ilit

y

La

nd

re

late

d &

O

pe

n s

pa

ce

Sp

ace

co

nst

rain

ts

Av

ail

ab

ilit

y o

f A

mb

ula

nce

Su

pp

ort

fo

r e

xp

an

sio

n

Uchharppa Warchale, Phata village

Rahul Patil, Chinchwali village

Mahadev Thombar, Honad village

Vilas Deshmukh, Honad Village

Abhijit Deshmukh, Honad Village

Digambar Patil, Chinchwali village

Devendra Patil, Chinchwali village

Rina Patil, Takai village

Mohan Patil, Chinchwali village




Table 7.24 Reply to points raised by villagers during Public hearing

Sr. No. Issue

concerning

Various Points raised by public during PH

Reply to points from project proponent Time Bound Action Plan Proposed

Budgetary Provision

1.0 ISSUES RECEIVED AGAINST THE PROJECT 1.1 Water

Pollution- (4 at venue

and 1 written)

MPCB does not specify the strict guidelines of water pollution. Pollution control measures promised in earlier EC are not fully installed.

Existing facility has installed latest pollution control measures in compliance with Consent to Operate granted by MPCB & Environmental clearance granted by MoEF & CC. Effluent from existing facility is treated in Effluent treatment plant and completely recycled within facility. Unit is maintaining Zero Liquid discharge facility and same will be followed for proposed project. Treated effluent quality is regularly monitored by Inhouse ETP laboratory, Third party MoEF & CC recognized laboratory and JVS analysis by MPCB. Camera & energy meters are installed on both organic effluent treatment plant and inorganic ETP. EC compliance received from Regional office (WCZ), MoEF&CC, Nagpur is attached as Annexure 1.5, of EIA report, wherein no lapse of pollution control equipment are brought out. Details of pollution control measures in existing facility and its performance is given in Chapter 2 & 3 of EIA report. Details of mitigation measures for proposed project is given in Chapter 4 of EIA report. Any issues raised by neighbours are and will be taken up immediately. No complaints have been received from the nearby school.

Ongoing & further upgradation

before commissioning

phase

Rs. 600 lakhs proposed for

Water pollution control




Sr. No. Issue

concerning



Budgetary Provision

1.2 Air Pollution- (4 at venue

and 1 written)

Pollution from unit is affecting 10 km radius and surroundings areas of four Grampanchayats. The livelihood of the area is disturbed. MPCB does not specify the strict guidelines of air pollution. School is located at 60-70 m away from the project site. Students are facing the pollution problems. Smoke and dust is released from the project and at this moment also it is released. Boilers were to be repaired as part of earlier EC, but one boiler is not repaired and people are suffering due to its smoke. And has installed the boiler near the road. Hence, if the street passer suffers any injury, then whether the company will take any responsibility? Pollution control measures promised in earlier EC are not fully installed.

Existing facility has installed latest pollution control measures in compliance with Consent to Operate granted by MPCB & Environmental clearance granted by MoEF & CC. For fuel burning sources, coal fired CPP- ESP is provided while for other stacks (Boilers & Thermic fluid heaters- mechanical dust collector followed by Bag Filter is provided). Adequate stack height is also provided. Regular monitoring of stack & ambient air quality is carried out by Third party MoEF&CC recognized laboratory. Pollutant emissions from stacks are well within permissible limits of consent granted by MPCB. CEMS has been installed on CPP stack to ensure emissions are within norms laid down by MPCB. Regular preventive and operational maintenance of air pollution control systems is done to ensure their functioning. Thus, there is no danger to street passerby as alleged. Process emissions (H2S from existing facility) is scrubbed by 2 stage Alkaline scrubber followed by flare. Details of Stack & APC’s provided to fuel burning sources is given in Table 2.9, Chapter 2 of EIA report. Details of scrubber system for proposed facility is given in Section 4.4.6.11, Chapter 4 of EIA report. Dispersion



phase

Rs. 50 Lakhs proposed for Air pollution

control




Sr. No. Issue

concerning



Budgetary Provision

modelling study has been carried out for proposed emission sources and it is observed that incremental increase will have negligible impact on the air environment. Details of Dispersion modelling study is given in Section 4.4.6, Chapter 4 of EIA report. EC compliance received from Regional office (WCZ), MoEF&CC, Nagpur is attached as Annexure 1.5, of EIA report, wherein no lapse of pollution control equipment are brought out. Any issues raised by neighbours are and will be taken up immediately. No complaints have been received from the nearby school.

1.3 Noise pollution

There is huge noise in the process. Nearby people do suffer due to pollution.

During commissioning of CPP, temporary Steam venting resulted in noise – now that it is regular operation, this noise is stopped. Regular ambient noise monitoring has been carried out by Third party MoEF & CC recognized laboratory. Ambient noise levels are maintained as per Environment Protection Act, 1986. Noise modeling study for proposed project is carried out & presented in Section 4.4.8, Chapter 4 of EIA report.

Ongoing Rs. 10 Lakhs proposed for

Noise pollution control

1.4 Odour problem

The people staying in the vicinity of project suffer due to smell nuisance.

Company has taken various measures to reduce fugitive organic emissions and reduce odours as below: - Provided mechanical seal for pumps, agitators,

compressors etc - Provided closed loop sampling

Ongoing Rs. 50 Lakhs proposed for Air pollution

control




Sr. No. Issue

concerning



Budgetary Provision

- All process openings/reactor vents are discharged through condensors with chilled water supply to reduce emissions by 90-95%

- All vents, charging point, discharge points in P2S5 plant are covered with hood and -ve suction provided and this vents to a caustic scrubber to reduce emissions to atmosphere

- H2S emissions are taken through two stage caustic scrubber followed by Online monitoring system. In case concentration of H2S exceeds set value, the hooter alarm is sounded. The exhaust vent from scrubber is directed to flare

Odor control plan for proposed plants is given in Section 4.4.6.12, Chapter 4 of EIA report & will be implemented strictly.

1.5 Safety aspects The project officials have totally violated the strict Safety guidelines. While entering in the company/ project, there should be open space. It is not there. Clarification regarding safety measures in the project. Project Proponent to carry out detailed inspection/ survey report in respect of Accident & safety aspect through Directorate of Industrial Safety & Health, Maharashtra State

Site has implemented all safety precautions in compliance with Factories Act and Maharashtra Factories Rules. Factory layout is approved by DISH. Site is certified OHSAS 18001: 2015 by BVQI. Site is inspected by DISH Inspector once every six months and Inspection Book maintained – all observations are complied and closed. Form VII is submitted every year to DISH office. Onsite emergency plan is developed for existing facility & same is followed. Mock drills are conducted. Copy of Onsite emergency plan is attached as Annexure 7.3, Chapter 7 of EIA report. Site has received Fire NOC from Khopoli Municipal Council vide letter no. KMC/Fire/655 dated 01/10/2020.



phase

Rs. 70 Lakhs proposed for

Health & safety




Sr. No. Issue

concerning



Budgetary Provision

(DISH) in view of closeness to populace

Same practice will be followed & implemented for proposed project. Occupational Health Centre is operational on 24 x 7 basis equipped with necessary equipment and arrangements for first-aid treatments in compliance with the requirements of Factories Act and Maharashtra Factories Rules. Trained First aiders, Safety officers are available at site on 24 x 7 basis. Pre-employment medical examination & Periodic medical examination has been carried out as per Factories Act and Maharashtra Factories Rules. Details of Occupational safety and hazard management is given in Section 10.9, Chapter 10 of EIA report. Details of Risk related mitigations measures, safety aspects given in Chapter 7 and its associated annexures. Prasol has undertaken to comply with all recommendations of the risk assessment studies. Copy of undertaking is given in Annexure 7.1, Chapter 7 of EIA report. In existing project, 13,374 sq. m is reserved as Open space (green belt within premises).

1.6 Effluent discharge

(2 complaints)

Despite promises of not discharging the treated effluent in the river, it has been released in the past and resulted in fish kill, heavy losses to the local farmers and rendering water supply unfit for drinking. Hence,

We reiterate that unit is maintaining Zero Liquid discharge facility and same will be followed for proposed project. Treated effluent quality is regularly monitored by Inhouse ETP laboratory, Third party monitoring is conducted through MoEF&CC recognized laboratory and MPCB does regular JVS analysis. Details of existing & proposed effluent treatment scheme, units, equipment and stagewise ETP



phase

Rs. 600 lakhs proposed for

Water pollution control




Sr. No. Issue

concerning



Budgetary Provision

local poor farmers sat at Tahsil Office for Fast-unto-Death. PP is not following any rule and playing with life of poor villagers. MPCB is also not taking any action against the industry. The company does dispose off its effluent into the river in rainy season.

load & performance is given in Section 4.4.5.2, Chapter 4 of EIA report. The incident referred is of an accidental discharge into the nearby drains and was carried to the nearby nalla. As directed by MPCB, we have now provided garland drains all around our storage tanks and other areas where chemicals are handled and spillage collected is conveyed to ETP.

1.7 Land related & Open space

Company has given survey nos 8, 13, 15, 16, 25, 75 – exact location should be given? Distance from the road is not maintained by the company. Where the expansion project will be implemented? Layout plan should show open spaces, green belt and parking plan. Company has violated all the rules while construction. Safe distance are not maintained while constructing the project. The vehicles of the company stand on the road and obstructs daily traffic. If the local people are taken into confidence, then only the

The factory plot is owned by Prasol Chemicals Pvt. Ltd for which earlier EC was obtained by MoEF &CC vide letter no. J-11011/260/2012-IA II (I) dated 18th September 2014. Proposed expansion project will be developed within existing facility. No additional land will be developed for project. Copies of 7/12 extracts given in Annexure 2.1(a). Existing layout plan is approved by by Joint Director Industrial Safety & Health (DISH), Raigad vide dated 04.10.19 In existing project, 13,374 sq. m is reserved as Open space (green belt within premises). Additional area of 9630 sq. m will be developed as green belt in plot 74/3 of Thanenhave village. Area of 3092 sq. m is reserved for parking. Parking area, green belt is marked on Layout plan. Copy of layout plan given in Annexure 2.1.

-- --




Sr. No. Issue

concerning



Budgetary Provision

project expansion will be supported.

The enhancement in production proposed is to produce more downstream value added products and thus there will be no major traffic load on nearby roads.

1.8 Green belt During earlier EC, PP was to plant 850 nos. of trees on project site. Now seven years have passed, whether 850 nos. trees exist? Whether sufficient land is available for green belt development at site? Area available seems too low PP to clarify if all guidelines as stipulated by MoEFCC are implemented & vigilance has been carried out by the agency. Oxygen generating trees such as Vad, Pimpal and Umbar should be planted.

In existing facility, 13,374 sq. m of area is developed as green belt with plantation of ~1845 nos. of trees/ saplings. List of tree species planted is given in Table 3.36, Section 3.9.3, Chapter 3 of EIA report. Green belt as per CPCB guidelines will be developed for expansion project in an area of 23,004 sq. m. to meet 33% Green belt requirements. Detailed action plan for green belt development is given in Section 4.4.7.2, Chapter 4 of EIA report. Suggested species for green belt is given in Table 4.20 & 4.21, Chapter 4 of EIA report which includes all local indigenous species. Measures to improve survival of species planted are incorporated in the revised EMP and will be adhered to.

Plantation within 1 year from grant

of EC

Rs. 20 Lakhs

1.9 Cancellation of PH-

(2 at venue and 1 written)

This Public hearing should be cancelled or held after nCOVID pandemic since– People affected by the project

in jurisdiction of four Grampanchayat should be given a say

Restriction of 100 persons is inappropriate

The draft EIA report was submitted to MPCB on 22.02.20 and due to nCOVID lockdown the Public hearing could not be held for long time. MPCB and district administration fixed the date of physical public hearing as 13th October 2020 at 12.00 noon and venue as Samuel Hall, 4th Floor, Old Mumbai Pune Highway (NH4), Khopoli, Dist. Raigad- 410710. MPCB placed an advertisement for conduct of public hearing, in English daily newspaper

-- --




Sr. No. Issue

concerning



Budgetary Provision

2013 public hearing was conducted in jurisdiction of Grampanchayat area

Local people are not familiar with online systems and there is net problem in rural areas.

“Indian Express” and Marathi daily newspaper “Loksatta” & “Krushival” on 13/09/2020. Due to current COVID-19 pandemic situation, gathering of persons was restricted. However, MoEFCC issued OM F. No. 22-25/2020-IA.III dated 14th September 2020, Public Hearing may be carried out in accordance with order no. 40-3/2020-DM-I(A) dated 29th August 2020 issued by Ministry of Home Affairs, Government of India- The permitted activities include, social/ academic/ sports/ entertainment/ cultural/ religious/ political functions and other congregations with a ceiling of 100 persons. To conform to above MOEFCC directives, MPCB placed an advertisement in same newspapers as above on 26/09/2020 giving instructions on how to access the on line Public hearing to be conducted through CISCO WEBEX app simultaneously to physical public hearing. Thus, the public hearing has been carried out as below : Physical public hearing in two batches with 100 persons in each batch at Samuel Hall, Khopoli, Dist. Raigad to enable to maintain social distancing and to regulate entry which would have been otherwise difficult in rural area In addition, online public hearing was conducted through CISCO WEBEX app simultaneously. Advertisement for conducting Public hearing was issued by MPCB and published in English daily newspaper “Indian




Sr. No. Issue

concerning



Budgetary Provision

Express” and Marathi daily newspaper “Loksatta” & “Krushival” on 13/09/2020 (for physical public hearing) and 26/09/2020 (giving instructions for on line public hearing)

1.10 Commitments during earlier PH about CSR

aspects

Commitments during earlier PH given by project proponent for village development are not kept. After expansion, whether the commitments will be fulfilled?

PP has spent Rs. 123.83 Lakhs in nearby areas from year 2015-16 to 2019-20 as CSR/social upliftment fund. Details of projects undertaken is given in Section 3.10.10, Chapter 3 of EIA report. As per OM F. No. 22-65/2017-IA. III issued by MoEF & CC on 1st May 2018, Rs. 50 Lakhs is allocated under Corporate Environment Responsibility (CER). CER plan is submitted to District collector for approval and copy of same is attached as Annexure 4.1, Chapter 4 of EIA report. PP undertakes to spend the money as directed by District Collector.

Ongoing CSR activities. CER

implementation- within 5 years from project

implementation

CER budget- Rs. 50 Lakhs

1.11 Local employment

Job opportunities are not given to youths from nearby villages. Moreover, outside people are appointed.

In existing facility, there are total 500 employees, of which 390 persons working are local people from nearby villages and Taluka. Thus, about 80% employment is local. In proposed project, there will be additional 110 persons employed and preference will be given to locals considering their skills & suitability. Skill development and training program will be provided to local people to enhance their skills to complete jobs with efficiency. Budget of Rs. 17 lakhs is allocated for Skill development program.

Before project implementation

Rs. 17 lakhs for Skill

development program

2.0 SUPPORTING THE PROJECT WITH SUGGESTIONS FOR IMPROVEMENT




Sr. No. Issue

concerning



Budgetary Provision

2.1 Corporate Social

Responsibility & Corporate Environment

Responsibility

PP should implement various social welfare schemes, health schemes

Govt should ensure this Grampanchayat should get the

revenue.

CSR amount of Rs. 123.83 Lakhs has been spent in nearby areas from year 2015-16 to 2019-20. Details of CSR is given in Section 3.10.10, Chapter 3 of EIA report. As per OM F. No. 22-65/2017-IA. III issued by MoEF & CC on 1st May 2018, Rs. 50 Lakhs is allocated under Corporate Environment Responsibility (CER). CER plan is submitted to District collector for approval and copy of same is attached as Annexure 4.1, Chapter 4 of EIA report. Local populace will be given preference considering their skills & suitability. We will comply all conditions stipulated by MoEF&CC/ CPCB/ MPCB as applicable for our project.

Ongoing CSR activities. CER

implementation- within 5 years from project

implementation

CER budget- Rs. 50 Lakhs

2.2 Pollution Health issues of the local people should be given priority. PP should implement pollution control systems as directed and follow strict guidelines of Environment.

We consider this suggestion positively and assure that we will co-operate local people. Any issues raised by neighbours with respect to pollution will be taken up immediately. We will comply all conditions stipulated by MoEF&CC/ CPCB/ MPCB as applicable for our project.

-- --

2.3 Local Issues Local issues should be given priority and it should be solved mutually.

We consider this suggestion positively and assures that we will co-operate local people. Any issues raised by neighbours are and will be taken up immediately. Local populace will be given preference considering their skills & suitability.

-- --

2.4 Green belt Oxygen generation trees such as Vad, Pimpal and Umbar should be planted.

Green belt as per CPCB guidelines will be developed for expansion project in an area of 23,004 sq. m. (over 33% area). Detailed action plan for green belt development is given in Section 4.4.7.2, Chapter 4 of EIA report. Suggested

Plantation within 1 year from grant

of EC

Rs. 20 Lakhs




Sr. No. Issue

concerning



Budgetary Provision

species for green belt is given in Table 4.20 & 4.21, Chapter 4 of EIA report.

2.5 Local employment

Local unemployed youths and young ladies should get job opportunities.

Local contractors should get jobs

PP should initiate Skill Development Program so that 100% local people will be appointed.

We consider this suggestion positively and assure that we will co-operate local people. Local populace will be given preference considering their skills & suitability. In existing plant out of 80 contractors, 56 are local. Skill development and training program will be provided to local people to enhance their skills to complete jobs with efficiency. Budget of Rs. 17 lakhs is allocated for Skill development program.



development program

2.6 Ambulance purchase for

village

It is requested that under CSR Fund, an ambulance be purchased for our village.

We consider this suggestion positively provided some NGO come forward and take full responsibility for upkeep of the same. During extreme emergency (nCOVID lockdown period) Prasol has extended the facility to locals.

-- --

Table 7.25 Additional points raised by Regional officer, MPCB- Raigad during Public hearing

Sr. No. Points raised Reply to points from project proponent Time Bound Action Plan Proposed

Budgetary Provision

1 Project Proponent to carry out detailed inspection/ survey report in respect of Accident & safety aspect through Directorate of Industrial

Detailed site inspection has been carried out by Deputy Director, DISH- Raigad on 23rd April 2019. Existing facility have already installed all safety measures as per Factories Act and Maharashtra Factories Rules. Site is certified for OHSAS 18001: 2015. Onsite emergency plan is developed for existing facility & same is followed. Copy of Onsite emergency plan is attached as Annexure 7.3, Chapter 7 of EIA report.



phase

Rs. 70 Lakhs proposed

for Health & safety





Budgetary Provision

Safety & Health, Maharashtra State (DISH) in view of closeness to populace

Site has received Fire NOC from Khopoli Municipal Council vide letter no. KMC/Fire/655 dated 01/10/2020. Prasol has undertaken to comply with all risk assessment studies recommendations. Copy of undertaking is given in Annexure 7.1, Chapter 7 of EIA report.

Table 7.26 Additional points raised by Hon. Add. Dist. Magistrate during Public Hearing


Budgetary Provision

1 100% job opportunities be given to local people. The skill which is required in the project should be given by training. Project officials to give training programmes to the locals.

We consider this suggestion positively and assure that we will co-operate local people. Local populace will be given preference considering their skills & suitability. Skill development and training program will be provided to local people to enhance their skills to complete jobs with efficiency. Budget of Rs. 17 lakhs is allocated for Skill development program.



development program




Figure 7.6 Photograph of Public Hearing

7.12 Social Impact Assessment, R & R (Relocation and rehabilitation) action plan

Not Applicable. The project is within plot of the company and hence no relocation and rehabilitation are involved.


Chapter 8- Project Benefits


8 PROJECT BENEFITS

8.1 Improvement in Infrastructures

Project is to be located at existing site of Prasol and does not require any additional infrastructure as the site is well connected by road so no major benefits in terms of direct improvement in infrastructure is anticipated.

8.2 Improvement in Social Infrastructure

Local youth will be employed during construction stage. During operation phase, locals

will be given preference based on qualification and skill. Prasol’s CSR/ CER activities also will benefit the society.

8.3 Employment Potential

Recruitments will be done from local area which will be the considerable benefit to the local area considering the demography of the region/project area (5 Km). Further, the indirect employment via increased transportation, ancillary units, downstream industries & local economic activities will also add in the employment potential due to the project. During construction stage approx. 100 - 150 persons will be hired. The project will create employment at site to ~ 110 persons (80 permanent & 30 contract

workmen) once the project comes to the operational phase.

8.4 Other Tangible & Intangible Benefits

Due to implementation of the project people of nearby areas / villages will be benefited by way of generation of direct as well as indirect employment opportunities.

With the development of this plant there will be a lot of scope for more ancillary development, which in turn will benefit the local people and society.

This will uplift financial and social condition of local people leading to overall improvement in the income level of the people.


Chapter 9- Environmental Cost Benefit Analysis


9 ENVIRONMENTAL COST B ENEFIT ANALYSIS

This analysis is not carried out in this study as it is not recommended at scoping stage and not specified in terms of reference. Also, it is not considered as necessary as all the environmental costs of the project are committed by the Project Proponent for implementation since they are necessary measures for the environmental management of the project.


Chapter 10- Environmental Management Plan


10 ENVIRONMENTAL MANAGE MENT PLAN

10.1 Introduction

Description of the administrative aspects of ensuring the mitigative measures is implemented and their effectiveness monitored, after approval of EIA are presented in this chapter.

10.1.1 Objective & Scope of EMP

The Environmental Management Plan is prepared with the main objective of enlisting all

the requirements to ensure effective mitigation of adverse impacts for all the components of the proposed project. The objectives considered in preparation of EMP are summarized here as follows:

a) The prevention, control and abatement of pollution, i.e. air pollution, water pollution, hazardous/ non-hazardous wastes and noise pollution,

b) To comply with the stipulated enviro-legal requirements and standards,

c) To direct the steps to be followed, for effective maintenance and regulation of environmental management system.

d) To ensure the better and safe work environment through pre-meditated planning of prevention and control of hazards,

e) To direct the investments towards sustainable development by considering the cost of effluent treatment, emission control, waste disposal, social development, green belt development and health & safety in the planning stage only,

f) To account for recycling and reusing measures, proposed or required to be adopted for minimization of consumption of resources and generation of pollutants.

As the proposed project is an expansion, the present EMP has been prepared to meet the requirements of pollution control from the project as an integrated environment management plan. The EMP does not cover scope of management of hazardous substance as it forms the key part of RA study (Additional Studies).

EMP focuses on potential impact and risks that have been identified as part of the Impact Assessment process (Refer Chapter 4).

Site specific Environmental Management Plan has been formulated to mitigate potential adverse environmental impacts both for construction and operation phases of the proposed project.




10.1.2 Management Systems

Prasol is committed for ensuring environmentally sustainable and responsible operations

to achieve the highest standards of excellence. Prasol’s manufacturing facilities at Honad

Dist Raigad has not only instituted internationally accepted Environmental Management

System based on ISO-14001, but the site has also integrated the same with Quality

Management and Occupational Health & Safety Management Systems.

The same shall be extended to the expansion project activity also.

Prasol’s integrated management system certificate is given below,

Figure 10.1 Integrated Management certificate

Safety and Environment policy of the company is approved by Board of Directors and signed by the Managing Director of the Company is as below,




Figure 10.2 EHS Policy

10.1.3 Environmental Management Cell

Prasol has environment management cell at site with vision to operate the EMP requirements as suggested in the chapter; Environmental Management Cell has been

formulated for efficient & easy operation of environment management system & operations. Site environmental management cell organogram is presented in figure below.




All the project activities will be monitored to ensure appropriate implementation of all Environmental mitigation activities and to identify areas where environmental management plan compliance is not satisfied. For effective implementation of the monitoring program, it is also necessary to have a permanent organizational set-up. The unit will assign responsibility to officer from various disciplines and cadres to perform and co-ordinate the activities concerned with management and implementation of Environmental control measures for the proposed project. In compliance with the requirement of EP Act and Factories Act, EHS cell will keep a close watch on the performance of the pollution control equipment, emissions from the sources and the quality of surrounding environment in accordance with the monitoring program. The cell includes the safety cell for observing, inspecting and regulating the safety measures inside the plant campus. EHS cell will directly to Unit head and Unit head in turn reports to Executive Director and the board of directors are appraised through emails and other communication means. Responsibilities of EHS cell are:

o Collect information from regular monitoring and create database. o Analyze the data and decide thrust area. o Carry out “project” in each thrust area to arrive at practical solutions to

environmental problems. o Discuss the reports of study on environment and disseminate the information. o Work out action plan for implementation of the recommendations made in the

report. o Prepare Management Information System (MIS) reports and budget for

Environment management program. o To deal with the environmental issues and for ensuring compliance with the

Conditions prescribed by State pollution control board. o Effluent Treatment plant operation, APCD’s, hazardous waste management, green

belt development, housekeeping, ambient air management, work area monitoring, safety department and OHC / facilities etc. The activities will be managed by systematic assignment of responsibilities to each member.

o Monitor Health, Safety and Environment standards and practices. o Maintaining records of all the data, documents and information in line with the

statutory requirements and regularly furnish the same to the State regulatory authorities.

o General prevention and maintenance of pollution control system as proposed to be done by the maintenance department, to achieve optimum efficiency of the control equipment and to maintain the quality of the environment.




Figure 10.3 Environment Management Cell

EHS cell shall also act as safety department in compliance with the requirements of section 41 G & 41 H of Factories Act and 68 F & 68 J as per Factories Act with defined role and responsibilities and defined framework covering all aspects of plant and personnel safety.

10.2 EMP for water environment management

10.2.1 Water consumption

Additional water requirement for expansion project is anticipated to be ~ 430 CMD. It will be supplied from existing arrangement (i.e. from Patalganga river) and partly by recycle water). There will be no ground water extraction.

10.2.2 Water conservation measures

The process water consumption shall be optimized by Prasol Team by applying reuse and recycling techniques, wherever possible.

Entire treated water will be recycled. Proposed project is Zero Liquid discharge facility.

Following measures are suggested to reduce fresh water consumption,

Water meters should be provided at main areas of consumption to maintain records and to conduct water audit from time to time.

Drip irrigation for watering of green belt within plant premises. Dry sweeping of passages and building floors in place of washing with water. Water saving faucets in toilets and washrooms.




10.2.3 Waste water generation, treatment and disposal

Adequate waste water treatment provided with primary, secondary and tertiary treatment for treatment and recycle.

There shall be sufficient holding capacity for storage of treated and untreated effluent (At least for 24 hrs).

Proper housekeeping practices shall be followed in the unit to maintain clean and clear environment and prevent contamination of surface runoffs and storm water.

Plants shall be provided with well-structured storm water drainage network for preventing surface run-offs from mixing into sewers during monsoon.

During monsoon, periodic monitoring of storm water shall be carried out to ensure that it is not contaminated.

Prasol is committed for the following: To install online pH meters, flow and conductivity meters at strategic locations in

the treatment scheme in order to monitor performance of the effluent treatment system.

For performance monitoring of treatment systems, proponent shall provide and maintain separate electric meter, operational logbook for effluent treatment systems.

In house analytical laboratory for analysis of basic parameters of raw effluents as well as effluent quality at various treatment stages is already developed. Third party sampling and analysis shall also be carried out.

To take utmost care to prevent leakages from pipe fittings, valves etc., drains shall be provided at all plants and tank farms to route such occasional effluents to effluent treatment plant.

Spill control procedure shall be practiced. Further to above following measures are suggested,

Consider EMP for unforeseen waste stream generation due to equipment breakdown or emergency control

Causes or source of generation of wastewater stream can be –

- Spillage from drums, bags etc. - Leakage from drums, bags, reactors, tanks, vessels, pipelines, valves, etc. - Vessel washing, container washing. For such effluent generation, following measures should be taken, Plant buildings handling chemicals shall be provided with drains which shall be connected to separate collection tank for storage of such unexpected effluents. This effluent shall be analyzed in laboratory for giving suitable treatment in controlled manner in the ETP. Monsoon preparedness shall be implemented for following compliances - Gate valves with shall be installed at all storm water outlets. - Maintenance of adequate freeboard in all open tanks / containers to prevent overflow

during monsoon.




- General Housekeeping in chemical storage areas to ensure that there is no spillage on the ground which can mix with rain water and flow out of the industry.

10.3 EMP for impact on noise levels

For noise abatement, following measures shall be taken – Use of acoustic enclosures for boiler/ TFH and DG installations. For minimizing and controlling noise levels, following measures are proposed.

- Ear muffs and ear plugs to operating personnel / contract workmen. - Maintenance of pumps and machinery and all rotating equipment. - Maintaining the greenbelt since it also helps in reducing noise. - Routine audit and corrective action for high noise area.

10.4 EMP For Impact on Land Environment

Storm water shall be collected and adequately drained. Pre-monsoon maintenance schedule for clearing storm water drain shall be carried

out. Appropriate precautionary measures to prevent contaminated run-offs from mixing

in storm water by regular analysis and necessary cordoning of process, ETP and storage areas.

All such areas which pose contamination of storm water should be provided with drains going to ETP.

Fugitive emissions and fugitive dusts shall be controlled.

10.4.1 Hazardous/ Non-Hazardous Waste Management

Storage Prasol is committed to provide adequate facilities for collection, storage and disposal of Hazardous and solid wastes in line with the requirements of Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016 and authorization granted by MPCB. Wastes shall be segregated and stored in separate areas having covered roof and

concrete flooring. Appropriate leachate collection system shall also be provided. Leachate shall be sent

to ETP for treatment and recycle. It is also planned to explore possibilities for reducing manual handling of hazardous

wastes wherever possible – by packing the waste at place of generation, minimum transport distances, transport in closed containers, minimum inventory of wastes.

Prasol shall keep a vigilant check on the characteristics of each waste and review storage and disposal methods periodically.

10.5 EMP for Safe Environment

The plant sections shall be built with proper safety features and safety equipment and devices at all required locations as per good engineering practice and code.

Fire hydrant system shall be provided to cover all plant facilities. Fire extinguishers shall be placed at all required locations of plant facilities.




Safety and health of workers and all contract workmen shall be ensured through proper SOPs, safety devices, fail-safe instrumentation, interlocks, sound equipment, emergency control systems and procedures.

Automation shall be used wherever possible, feasible and practical. Noise shall be controlled by –

- Placing of noise barriers along noise emitting area. - Ear muffs and ear plugs to workers.

Transporters shall be instructed to follow road safety and use well maintained trucks and tankers.

Restrooms/area shall be provided for truck drivers and assistants. Night time maintenance activities shall be avoided as far as possible.

10.6 EMP for socio economic environment

Proposed Man power: 100 – 150 nos. of workers on contract basis during construction activities and for material movement etc. For operation activities ~ 110 nos. of additional technical & skilled manpower will be required.

Prasol is committed to give employment to locals according to skill and academic qualification.

Project specific training shall be imparted to enhance skills and increase employment of local people.

It shall also provide opportunities for trade and commerce and development of ancillary businesses for the local people during construction phase and operational phase, such as

mechanical supplies, machinery services and repair work spare parts and accessories supplies canteen services and supplies, housekeeping, security, green belt maintenance, Contractual labor for packaging and other activities.

10.7 EMP for impacts on ecological environment

The management of air, water and land environment as proposed in the previous sections shall ensure that there is no adverse impact on the terrestrial and aquatic ecology of the area. EIL proposes to develop adequate green belt as required within plot. Green belt will be developed in scientific manner to give screening effect to surrounding environment from proposed facility.

10.8 Environment management though housekeeping

Following are suggested good housekeeping practices,

Prepare a checklist for maintaining good housekeeping in the plant premises. To regularly inspect the housekeeping in various sections of the plant. The passages, floors and stairways should be kept in good condition.




Internal roads and major walkways as well as work areas should be carpeted either by asphalt or paver blocks to minimize dusting as well as provide ease of transportation and movement.

Walkways should be free from obstructions, as well as marked. All equipment and auxiliaries, piping should be labeled appropriately. Piping color code to be followed. Wastes to be collected in separate containers with labels and marking in each

department and sent to common waste collection area in the factory for disposal. Spill control procedures to be developed and given to shift in charge and all

concerned. Sweeping to be done in all departments on daily basis. Electrical wirings should be properly housed/ dressed. Localized extraction and scrubbing facilities for dust and fumes should be

provided wherever required.

10.9 Occupational safety and hazard management

The chemicals involved in manufacturing processes are of toxic and flammable nature. The major hazardous materials, their inventories and their hazardous properties are tabulated in Chapter 2 and 7. The unit is an MAH installation in accordance to the schedule 3 of MSIHC rules, 2000. The probable hazards related to the various operations and processes have been assessed and suitable control measures have been proposed. Details are provided in chapter 7 of this report. Preventive Measures Chilled water circulation, Flame proof fittings, Tank level indication/ control on DCS. PESO License premises, Earthing and Bonding, Tank insulated with suitable insulation, SOP for tanker unloading, Flame arrester on tank top, Lightning arrester near the tank, Gas Leak Detector. Control Measures Provided: Fire hydrant system, Portable Fire Extinguishers, Foam Trolley, Water Hydrant and Monitor, Self-Contained Breathing Apparatus, Flame proof electricals, Dyke wall for containment, Shower & Eye Washer near Tank Farm Area. Following sections discuss on measures which shall be taken for fulfilling the requirements of applicable statutory rules and regulations related to health aspects. First aid boxes In all plants / depts., First aid boxes (min. one no. in each plant or building) shall be installed and all the necessary items shall be maintained by OHC. They shall be inspected on regular interval of one month.

10.9.1 Occupational Health center (OHC)

Occupational Health Centre is near the plant main gate and is operational on 24 x 7 basis equipped with Bed, Stretcher, Emergency medicine cabinet, Oxygen cylinder with assembly (1 number is operational one is standby), Doctor table & inspection tools.




The emergency cabinet consists of necessary medicine & equipment mainly,

o Ambu bag o Titans’ injections o Saline bottles o Pulse Meter o Sugar monitoring kit o OHC general medicines o Ambulance o Stethoscope o BP monitor o Thermometer o BA Cyanide Kit o Doctor’s inspection room with necessary equipment

Following are the contents of First aid

o Absorbent cotton wool o Antiseptic liquid o Adhesive Plaster o Neosulf o Burnol o iodine Ointment o Paracetamol tablets o Bandage cloth roller o Bandage cloth FII triangle shape o Band aid

In addition to above, there is snake bite & dog Bite venoms (4 Nos each) in Quality control fridge. Prasol has tied up with with Anvesha Health Clinic in Takai village & Jakhotia Hospital in Khopoli town for outdoor medical treatment if required. The part time factory medical officer visit to OHC as per periodicity.

OHC have necessary equipment and arrangements for first-aid treatments in compliance with the requirements of Factories Act and Maharashtra Factories Rules.

List of trained first aider which is trained by approved organization is kept at ECC as well as in OHC and safety notice board to get help in organizing for medical help major problem.

Antidotes for major chemicals handled by the unit are identified and listed and list is maintained at OHC.

10.9.2 Onsite Medical treatment

Visiting doctor is appointed as Factory Medical Officer (FMO) who visits the unit to attend routine medical illness of workers and employees. Factory Medical Officer (FMO) is responsible for;

1. Responding to medical emergencies.




2. Carrying health surveillance which includes pre-employment, routine examination, periodic examination, fitness for Confined space entry and working at height.

3. Conducting training and wellness programs. 4. Ensuring fitness of workers reporting after sickness and recuperation.

Medical examination & Health surveillance practiced are Pre-employment medical check-up and periodic medical examination of all

employees and contract laborer’s are carried out by FMO and records are maintained in health register.

Annual medical examination for all employees. Certificate of fitness issued to workers as per rule. Canteen Workers’ Medical Examination. Examination of persons exposed to high noise. Fitness to wear Respiratory Protective Equipment. Fitness to drive. Skin Surveillance. Pre- medical examinations

Type of employment

Test to be conducted By (examining agency)

For company employees as as well as contract workmen

o Physical Examination. o Present complaints / illnesses o Family History o Past History o Hematology Profile - Complete Blood Count with

Differential Count, E S R & Blood Group & Rh factor. o Urine Analysis o Liver Profile - S G P T, SGOT, Sr. Bilirubin o Kidney Profile - Blood Urea, Uric Acid & Sr. Creatinine. o Lipid Profile - Cholesterol, Triglycerides, HDL -

Cholesterol – VLDL Cholesterol, LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio (Risk Factor).

o X - Ray Chest - P A View o E C G Signed by Cardiologist o Blood Sugar o Audiometry o Pulmonary Function Test

OHC + External Agency

Periodic Medical examinations

Type of employment

Test to be conducted By (examining agency)

For company employees as as well as contract workmen

o Physical Examination. o Present complaints / illnesses o Family History o Past History o Hematology Profile - Complete Blood Count with

Differential Count, E S R & Blood Group & Rh factor. o Urine Analysis

OHC + External Agency




o Liver Profile - S G P T, SGOT, Sr. Bilirubin o Kidney Profile - Blood Urea, Uric Acid & Sr. Creatinine. o Lipid Profile - Cholesterol, Trigycerides, HDL -

Cholesterol – VLDL Cholesterol, LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio (Risk Factor).

o X - Ray Chest - P A View o Pulmonary Function Test o E C G Signed by Cardiologist o Blood Sugar o USG – for chemicals which are toxic on liver (once in a

year frequency)

10.9.3 Fund allocation for Occupational Health and Safety measures

Appropriate fund allocation is carried out for implementing Occupational Health and Safety measures as per standard procedures and directions. Towards management of occupational health and safety in the unit, provisions to be made for maintaining an efficient system are described hereunder:

o Safe and ergonomic design and layout of plant, machinery, tools and control equipment keeping in view the safety and pollution prevention in mind.

o In-house training programs as well as programs with help of outside agencies on Health hazards and safety for the workers and staff. Trainings shall cover topics on firefighting, awareness training for hazards, first aid.

o Proper handling of all spillages by introducing spill control procedures for various chemicals.

o Sufficient lighting, ventilation, drinking water facility, sanitary blocks, firefighting and first aid arrangements.

o SOPs for all operations and critical equipment. o Work permit system for specific task. o PPE as per operations shall be provided and it shall be ensured that workers make

proper use of PPE. o Regular workplace monitoring as per Maharashtra Factories rule to be carried out

and records maintained in prescribed form. o Material safety data sheet for all the concerned materials to be available at the site. o Adequate firefighting equipment’s provided at relevant areas. o Fire alarms and LEL detectors to be installed in process plants and storage areas. o Emergency telephone numbers displayed at required places. o Planned schedule for inspections of safety devices shall be followed and records

shall be maintained. o On-site emergency plan is practiced and upgraded periodically. o Regular emergency mock drills to be carried out.

Following suggestions shall be considered by Prasol, All aspects of Industrial hygiene and occupational health such as

o Noise minimization. o Proper illumination at all floors. o Minimum exposure to fugitive emission while charging.




o Proper plant layout and equipment design to provide correct working postures and body postures.

o Suitable platforms and ladders to minimize accidents due to movements. Following shall be considered at the time of detail engineering of the project.

o Since there are more than one main raw material for many of the products, it is suggested to implement stringent three level permit system for raw material issue from warehouse and tank farms before indenting in process plants so as to minimize mis operation and batch failures due to miscommunication or operator flaws and errors. A good record keeping practice should be maintained. Store activities need to be given due importance and handled by qualified personnel.

o Ensure that the transporters of hazardous chemicals are provided with PPE and carry TREM cards during transportation

10.10 Environment Budget Allocation

Prasol has allotted Rs. 865 Lakhs towards investment in environmental management and monitoring. (Refer Chapter 6).

10.10.1 Energy conservation

Prasol proposes to use LED lamps for illumination in order to conserve electricity.

10.11 Financial Provisions for EMP Implementation

Costs for pollution control, monitoring and management will be included in the account under separate head in CAPEX as well as OPEX provisions.

10.11.1 Authorities Responsible for EMP Implementation

Structural measures (such as installation of RO/MEE, Air pollution control equipment, Green belt development, occupational health and safety preventive and protective equipment): Directors, Project manager, accounting head/ manager, Site Officer & engineers, Contractors.

Non-Structural measures (SOP’s, studies, implementing systems etc): Directors,

Production manager, accounting head/manager, Plant in-charge, safety & environment Officer & engineers, Contractors & operators.

10.11.2 EMP Implementation Schedule

Structural measures identified will be provided in construction phase prior to commissioning of plant operation.

Maintenance will be done throughout the extent of operation phase.

Proper installation of pumps, motors will be done well before commissioning to prevent wastage & efficient use of water

The non-structural actions will be initiated with inception of commissioning stage

and will be implemented & practiced as routine throughout the project life.




Prasol proposes activities under CER (Corporate Environment Responsibility) of Rs 50

Lakhs which are described in Chapter 4 under social environment.

10.12 Reporting

Project proponent shall prepare & submit quarterly/ half yearly reports regarding implementation of the environmental management program as described in conditions of various licenses/ certificate of clearance like EC, CTO, CC etc. which will be submitted to concerned authorities is as listed below:

Board of Director through MD & General/Production manager.

Maharashtra Pollution Control Boards & other authority as required by regulatory

provisions.

Other organizations/firms as directed timely by Board of Directors or General/production Manager or Govt. authority like MoEF&CC, MPCB, CPCB.


Chapter 11- Executive Summary & Conclusion


11 EXECUTIVE SUMMARY AN D CONCLUSION

11.1 Introduction

Prasol Chemicals Private Limited (Prasol) is one of the leading & fastest growing chemical manufacturing companies in India. Prasol is an ISO 9001:2015, ISO 14001:2015 and OHSAS 18001: 2015 certified company. It has an in-house R & D, with production plants for Phosphorous and acetone based and hydrogenated products with their own warehouse for storage and distribution of specialty chemicals.

The proposed project of Prasol is expansion of synthetic organic chemicals manufacturing facility located at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra. As per EIA Notification S.O. No 1533 dated 14th Sep 2006 the project falls under activity 5 (f) (Synthetic organic chemicals manufacturing), Category “A” and requires prior environmental clearance from EAC-II, Ministry of Environment, Forest and Climate Change for which Terms of Reference (ToR) granted as per MOEF&CC letter No. J-11011/260/2012-IA-II(I) dated 27th June 2019.

The total plot area is 68,644 sq. m. The expansion will be affected by addition of new machineries, utilities, increased automation and addition of new products. The total estimated cost of proposed project Rs. 50 Crores.

Unit is having valid Consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.07.2020 valid till 31.10.2021 for manufacturing of existing Products.

The project is located at latitude 18°46'33.84"N and longitude 73°18'10.37"E (central co-ordinate) with an elevation of 60 meter above sea level MSL.

The site is well connected by rail and road. It is situated beside Takai Adoshi Road. Khopoli is the nearest railway station located approximately 7.1 km away which is reachable by Pen Khopoli Road and NH 47.

11.2 Manufacturing process & Proposed products

Manufacturing activities in the expansion project include various processes. The activities shall also include operation of various utilities. The manufacturing process is described in chapter 2.

All unit processes and unit operations shall be carried out under stringent controls and monitoring through local indicators and manual monitoring. Safety system – PLC, Auto shutdown, inertization and interlock system shall be provided wherever necessary.






Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year) Products


8 Phenol 20,000 0 20,000



1,800 13,200 15,000



0 500 500



0 1,500 1,500


0 750 750









Capacity (MT/Year)

Additional Capacity

(MT/Year)

Total Capacity

(MT/Year)



- - -




0 2000 2,000



59,454 93,546 153,000

* As per existing consent to operate order no. Format 1.0/CAC/UAN No. 0000078581/CO-2007001796 dated 31.10.2021 valid till 30.06.2021. (@) Capacity as certified by Turbine manufacturer

11.3 Fuel requirement

5 TPH Boiler & 30 Lakh Kcal/hr Thermic Fluid Heater are proposed to be installed to fulfill heating requirement of the proposed project.

Table 11.2 Fuel requirement

11.4 Water Consumption & Effluent generation


Fresh water will be fulfilled through Irrigation Dept, Raigad.

Table 11.3 Total water requirement (Existing & Proposed)

No. Purpose Total water Qty after expansion., cmd 1 Domestic 35 2 Industrial cooling/ boiler feed 1024 3 Industrial processing 63 4 Green belt 18 5 Treated recycle water 378 Grand Total 1518

5 TPH Boiler 30 Lakh Kcal/hr Thermic Fluid Heater

Fuel used & Quantities

Furnace oil: 7.3 TPD Furnace oil: 8.6 TPD




Effluent generation

Post expansion project, 391 cmd of effluent will be generated. Domestic and Trade effluent shall be treated at site and treated water will be recycled within site. Proposed project is Zero liquid discharge facility.

11.5 Solid waste generation & disposal

Wastes have been categorized as Non Hazardous waste and Hazardous waste as per the Hazardous Waste (Management, Handling and Trans boundary Movement) Rules 2016. Details of waste generation & its disposal is given in Chapter 2 & 4.

11.6 Description of the Environment

Considering the local and regional setting of the area surrounding the plant facility, surrounding area of 10 km of the plant site is considered as study area for setting up environmental baseline to study/ predict the impacts in surroundings due to the proposed project, as per MoEFCC guidelines. Environmental data monitoring was done during Summer 2019 for meteorology, air quality, water quality, noise levels and soil characteristics, by setting up monitoring stations as prescribed. Further, existing ecological and socio-economic features were also studied.


The soil samples were collected at 8 locations having different land use. Soil texture in the area is mainly clay in texture.

pH of soil varies from “Moderately acidic” to “Moderately alkaline” in nature. For most agronomic crops the suitable soil pH should be between 6.9- 7.0. Hence pH is not much of a concern. Conductivity of soil is observed in range of ‘Average’. Potassium content is less in soil. Organic carbon is in range of very less to average sufficient. Phosphorous content in the soil is varies from less to more than sufficient. From above observation, it is observed that the soil is having low content of macro nutrient & fertilizers shall be required suitably.

11.6.2 Meteorology & Climate

The temperature data recorded in study area is ranging from 170C to 370C. From the wind

rose graph it was observed that average wind speed is 1 m/s. Out of total data 68.5% contributing as calm. The winds flow predominantly from directions north east and north

east east during the summer season.


The baseline air quality was established by monitoring PM10, PM2.5, SO2, NOx, NH3, CO, H2S and nMHC at 8 locations (including onsite) in study area for 24 hours during period of

Summer 2019. The air quality was observed to be within the NAAQS norms for residential and rural area.

• Concentration of PM10 ranged from 53.7 μg/m3 to 75.2 μg/m3. It is noted that the PM10 results are within permissible limit of 100 μg/m3 for 24 Hrs.




• Concentration of PM2.5 ranged from 22.2 μg/m3 to 31.4 μg/m3. It is noted that the

PM2.5 results are within permissible limit of 60 μg/m3 for 24 Hrs.

• Concentration of SO2 ranged from 10.8 μg/m3 to 15.5 μg/m3. It is noted that the SO2 results are within permissible limit of 80 μg/m3 for 24 Hrs.

• Concentration of NOx ranged from 17.1 μg/m3 to 25.0 μg/m3. It is noted that the NOx results are also within permissible limit of 80 μg/m3 for 24 Hrs.

• Concentration of CO ranged from 0.17 mg/m3 to 0.45 mg/m3. It is noted that the CO results are also within permissible limit of 4 mg/m3 for 1 Hr.

• Concentration of NH3 ranged from 11.5 μg/m3 to 22.3 μg/m3. It is noted that the NH3 results are also within permissible limit of 400 μg/m3 for 24 Hrs.

• Concentration of nMHC is found in range of 0.15 to 0.32 ppm.

• Concentration of H2S is below detectable limit (DL– 1 μg/m3).

With Comparison of NAAQ standards, Ambient Air monitoring results are below the specified norms.

Thus, it can be concluded that ambient air quality in the area is not polluted.

11.6.4 Noise Environment

The onsite data was observed well within standard for Day & Night time.

Day time: Noise levels were found to be exceeding the standard at Mahad village and marginally at Yashwantnagar during daytime due to local disturbances/ nearby traffic.

Night time: Noise levels were found to be exceeding the standard at Adoshi, Chinchvali, Mahad and Vadval village during nighttime due to local disturbances/ nearby traffic.


Ground water sampling includes collection of Borewell water at 4 locations, well water at 3 locations, tap water from site.

Ground water quality is mostly within specified standards except presence of coliform at Well water Honad, Sangdewadi and Mahad probably due to sewage contamination.

Surface water samples were collected from 6 different locations of Patalganga river, 1 location from Amba river & 3 locations from Dam within 10 km km study area. Based on analysis, surface water analysis mainly falls under classification E.

11.6.6 Traffic survey

Traffic survey was carried out on Takai Adoshi Road which is main approach road to the project site.

As per the IRC: 106-1990, type of carriageway is 2-Lane (Two-Way) and design service volume for this road is considered under category Arterial and PCU per hour 1500.

The calculated PCUs per hour is 507, which is well within recommended design service volume (PCU/Hour) by IRC. Existing roads are adequate.




11.6.7 Biological Environment

According to ‘India State of Forest Report, 2019’, Forest Survey of India; forest cover in Raigad district is about 41% of geographical area.

According to bio-geographic zone classification of India, entire study area falls under ‘Western Ghats’.

Field visits reveal that, study area has undulating terrain as commonly seen in Konkan region. Besides dense vegetation on hills /Reserved Forest, study area contains habitats like, water bodies, agricultural fields and human settlements. These habitats possess different characteristic which supports typical composition of flora and fauna within them.

Field observations at the site shows green belt in the form of trees planted in single row

along boundary except at some places. Green belt is already developed at site.

11.6.8 Socio Economic Environment

In the 10 km study area, there are total 72 villages and 1 town from Raigad district and 2 villages from Pune district. From Raigad district 2 taluka namely Khalapur and Sudhagad and from Pune district Mawal taluka are falling in the study area.

Total 17 villages & 1 town were selected and surveyed from the study area which is 24% of total villages in the study area.

As per 2011 census record:

- In the study area, total population is 141626. Total male population is 74786

(53%) and total female population is 66840 (47%).

- Average family size is 4 persons.

- Average sex ratio is 893 females per 1000 males, 0-6 child sex ratio is 917.

- Total worker population is 54810 which is (39%) of total population.

Observations from site survey:

Villagers expressed their positive response to proposed project as it will lead to increase employment opportunity for locals. Villagers expressed that the industrial activity should be beneficial in terms of local employment so that the standard of living of nearby population enhance & will develop the area suitably.

Villagers also shows concern regarding air pollution. Main concern of villages is that

pollution problem should be sorted out by authorities and industrialists by well-planned precautionary measures for pollution.

Along with local recruitment villagers also expecting the development of infrastructural facilities in the form of village roads, health facilities, higher educational facilities, youth training centre etc.




11.7 Anticipated Environmental Impacts & Mitigation Measures

Environmental impact identification & Mitigation measures are based on the type, scale and location of proposed project activity. Environmental components that may be affected negatively and positively due to proposed activity are identified.

Environment parameters are selected for impact assessment due to proposed activity during various phases. The maximum impacts during Construction & Operation phase were listed below:




Table 11.4 Anticipated Impacts & Mitigation measures for different phases of project

Sr. No.


Anticipated Impact Suggested Mitigation Measures

1.0 Construction Phase

Land Environment

Generation of Solid waste/ Improper disposal method

Segregation of Solid waste & Hazardous waste/ Separate storage for solid waste/ Disposal of solid waste as per MPCB norms

Air Environment

Dust generation/ emission of SO2, NOx, CO from construction activities

Dust suppression & Water sprinkling system for Dust generating area/ Proper maintenance of equipment's & vehicles

Noise Environment

From loading, unloading of material/ Equipment handling/ Noise generating equipment

Use of damping material/ Regular maintenance of equipment/ Isolation of noise generating equipment/

Water Environment

Consumption of fresh water 15- 20 cmd / Improper disposal of sewage

Fresh water requirement will be fulfilled from existing facility. Sewage of ~10 cmd will be reused for green belt.

Biological Environment

Generation of dust/ Improper disposal of sewage/

Existing green belt will be developed suitably. Sewage will be disposed off properly & reused for green belt.

Socio Economic Environment

Employment generation/ Health of workers

Approx. 100 – 150 no. of persons will be employed from nearby area for construction phase. Adequate provision of PPE/ Suitable infrastructure facilities for workers.

2.0 Operation Phase

Land Environment

Generation of Solid & Hazardous waste requiring disposal

Non-Hazardous & Hazardous waste will be segregated & stored in designated storage area. Hazardous waste will be disposed off as per CPCB/ MPCB norms.

Air Environment

Emission of TPM & flue gases from Boiler, TFH / Fugitive emission/ Increase in conc. of PM10: 0.19 µg/m3

Boiler & Thermic Fluid heater will be provided with adequate Stack height. Process vents will be provided with adequate scrubber. Regular monitoring of stacks will be carried out as per MPCB/ CPCB norms. From the air modelling




Sr. No.



Increase in conc. of PM2.5: 0.09 µg/m3 Increase in conc. of SO2: 8.54 µg/m3

Increase in conc. of NOx: 0.22 µg/m3

study, it is observed that flue gas emission is within permissible standard.

VOCs Increase in VOC levels due to increased handling/ processing of organic chemicals and storages

Adequate size condensors will be installed to condense VOC emissions generated from the process. Company will have strict VOC control through use of: All solvent handling reactor agitators and pumps will be provided with mechanical seal. All storage tanks shall be provided with breather valves to prevent loss of solvents.

Noise Environment

From loading, unloading of material/ Operation of pumps & machineries

Isolation of vibrating units & equipment/ Regular maintenance of equipment's/ Use of vibration dampening/ Adequate PPE for workers

Water Environment

Additional fresh water consumption, Effluent generation, treatment & disposal

Fresh water will be sourced from Irrigation department for which NOC has been received. Water conservation measures: Effluent will be segregated, treated & recycled in order to have ZERO liquid discharge facility. ETP at site is comprising of Primary, Secondary & Tertiary treatment.

Biological Environment

Emission of pollutant/ Solid & Hazardous waste generation/ Effluent generation & disposal

23,004 sq. m of area will be developed as Green belt. Green belt will be suitably developed to provide screening effect.

Socio Economic Environment

Employment generation/ Health of workers

Approx. 110 nos. of persons will be employed during operation phase. Preferences shall be given to local employment.




Sr. No.



CER budget of Rs. 50 Lakhs for 5 years. Proposed project will result in Increased taxes to local Gram panchayat




11.8 Environment Monitoring Program

For tracking of the effectiveness of mitigation measures & EMP at specific interval, regular monitoring of the necessary environmental parameters is required.

Regular monitoring through MoEFCC recognized laboratory for compliance with conditions of EC, Consent to operate and provisions under Factory Act & Environmental Protection Act

Monitoring of environmental samples shall be done as per the methods/ guidelines provided by MoEFCC/ CPCB and /or relevant Indian Standards or methods as specified by Standard Methods

Assessment of the changes in environmental conditions, if any, during the project

operation/ activities.

Identification of any significant adverse transformation in environmental condition to plan additional mitigation measures; if & as required.

11.9 Additional Studies

11.9.1 Safety and risk assessment studies

Safety and risk assessment studies have been conducted for principal storage tanks and chemicals proposed to be handled onsite (OSBL tanks).

Systematic study based on ALOHA has been carried out for methanol, ethanol, octanol,

Isobutanol, isopropanol, acetone, MIBK, Isophorone, cumene, benzaldehyde, mesityl oxide, di acetone alcohol and hydrogen gas.

The details of consequence analysis studies have been presented in the EIA chapter 7. The precautions to be taken and recommendation for safe operations are mentioned at site.

Company has committed to comply with suggested recommendation.

11.9.2 Public consultation

Public Hearing for proposed project is carried out on 13th October 2020. The details regarding public hearing is given in Annexure 7.7 of EIA report. Reply to points raised

during public hearing is given in Section 7.11, Chapter 7 of EIA report.

11.10 Project Benefits

Project will result in benefit to the country in form of foreign exchange revenues, duties etc.

Enhanced production will also result in increased taxes to local gram panchayat and State Exchequer.

Manpower requirement during Construction phase will be approximately 100- 150 no. of persons from nearby local area




Manpower requirement during Operation phase will be approximately 110 no. of

Persons from nearby local area

Further, the indirect employment via increased transportation, ancillary units & local economic activities with enhances spending power will also add in the employment potential.

Indirect improvement in public infrastructure through CER activities carried by Prasol with enhances spending power will help to improve the overall quality of life in study area.

11.11 Environment Management Plan

The plan incorporates environment management measures during construction and operation phases. The capital outlay for environmental control & management measures estimated to be Rs. 865 lakhs.

Environmental Controlling Measure Capital Investment (Rs. In Lakhs)

O&M Cost/Annum (Rs. In Lakhs)

Air Pollution Control 50 25 Environment Monitoring 50 25 Water Pollution Control 600 200 Hazardous waste & Solid waste management

50 50

Noise pollution control 10 2 Green Belt Development 20 10 Occupational Health & Safety 70 20 Other Green Initiatives

- Rainwater Harvesting 10 5 - Energy Conservation (LED) 5 0

Total 865 337

Corporate Environment Responsibility (CER) Budget of Rs. 50 Lakhs (1 % of estimated capital investment) has been kept for 5 years. CER Budget breakup is as below:

Proposed Activity

Year wise allocation of Fund (INR In Lakh)

1st Year 2nd

Year 3rd

Year 4th Year 5th Year

Total (April – March)

Water supply, Sanitation, health

- - - 5 6 11

Education & Skill development

- 5 2 5 5 17

Solid waste disposal and associated activities

5 - 5 - - 10

Avenue tree Plantation - 4 4 1 1 10 Solar lights for community 2 - - - - 2

Total 7 9 11 11 12 50




11.12 Conclusion

The study for the proposed project of Prasol Chemicals Private Limited at Survey No. 8 pts, 25 pts (village Chinchvali Gohe), 13 pts, 15 pts, 16 pts (village Honad), 75 pt (village Thanenhave), Tal: Khalapur, Dist: Raigad, Maharashtra has revealed that the upcoming activities of synthetic organic chemicals will have some minimal impacts during operation phase. All other impacts of the project will remain far below acceptable limits after necessary mitigation as described & suggested in EIA report. The major impacts will also be brought under acceptable limits by implementing the required hazard prevention & control measures as suggested in the EIA report. Thus, it has been concluded that there would not be any major impacts on environment due to the proposed project.


Chapter 12- Disclosure of Consultants Engaged


12 DISCLOSURE OF CONSULTANTS ENGAGED

Name : ADITYA ENVIRONMENTAL SERVICES PVT. LTD.

Reg. Office : 107, Hiren Light Indl. Estate, Mogul Lane, Mahim, Mumbai – 400016

Phone No. : 022 42127500 Email id : [email protected]

Central Lab : P-1, MIDC Mohopada, P.O. Rasayani, Dist. Raigad Pin 410207

Phone No. : 02192 252008 Email id : [email protected]

Branches :

Goa : 08322652456 Ahmedabad : 079 40063271

Pune : 915802585 Delhi : 011 64595949

Baroda : 02652331790

Accreditation Obtained

: 1. ‘A’ Category EIA Consultancy Organization by QCI-NABET Certificate No. NABET/EIA/1922/SA 0129 dated 17th May 2021

2. Recognized by MoEFCC as “Environmental Laboratory” vide letter no. Q-15018/10/2019-CPW dated 20th December 2019 valid upto 8th July 2021

3. ISO 9001:2015 Certified 4. OHSAS 18001:2007 Certified

Services Offered by AESPL

: Environmental planning studies

Policy planning studies for CPCB, MPCB and other agencies like World Bank.

Environmental Impact Assessment (EIA) & Environment Management Plan (EMP)

Risk Analysis Studies & On Site/Off Site Emergency Management Plan.

Environment Health & Safety audits & Due Diligence audits

Effluent Characterization & Treatability Studies

Project Management Consultancy for Effluent Treatment Plants

Ventilation, work room air quality surveys

Air pollution control system design

Analytical Services covering entire spectrum of environmental analysis

Ambient air monitoring

Ambient noise level monitoring

Ground & Surface water analysis

Soil analysis

Marine water & sediment analysis

Ecological & Biodiversity surveys

Socio-economic surveys

Hydro-geological surveys

Coastal engineering & coastal process studies & management plans

Website : www.aespl.co.in

http://www.aespl.co.in/


Chapter 12- Disclosure of Consultants Engaged


Environmental Impact Assessment Report Rev. 01

Documents

Transcript of Environmental Impact Assessment Report Rev. 01