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Risk Assessment 7.1.1 Introduction As Indicated in the Earlier Chapter The Environmental Impact Assessment Report For Expansion of M/s Shogun Organics Ltd. Located At Kurkumbh MIDC, Taluka Daund, District Pune, Maharashtra. SEEPL/EIA/F/IND/SOL/001/2017-18/00 Chapter 7: Additional Studies Risk Assessment 7.1.1 Introduction As indicated in the earlier chapter the expansion project facilitates to manufacture pesticide, pesticide intermediates and related formulations various types of hazards due to storage, handling & transportation of various chemicals, which are indicated in Chapter no. 2. In order to study the risks envisaged by the activities, the following methodology was adopted. 7.1.1.1 The factory would be manufacturing various products with production quantity Pesticide Technical – 44.5 MT/M, Intermediates – 12.25 MT/M, By-products – 13.8 MT/M and heater machines – 25,000 nos./month. The products would be manufactured on batch basis; a maximum of five products will be manufactured at any given point of time. However hazop studies have been carried out for some hazardous operations and process. 7.1.1.2 A detailed scrutiny of various chemicals which would be stored on the site was done. All the raw materials will be stored either in bags/drums/boxes or carbuoy. Details of the raw materials in storage area is tabulated in Table no – 7.1. 7.1.1.3 Plot layouts showing locations of tanks, fire hydrant tanks & other safety features are depicted in the plot layout discussed in the onsite emergency plan. 7.1.1.4 M.S.D.S.s: Brief M.S.D.S.s of all the above chemicals and other raw materials which would be used in the manufacturing processes of products are used as reference for preparation of Quantitative Risk Assessment & Hazop study.The copies of MSDS is attached as Annexure – 7.5. Table No. 7.1: Raw Material List Quantity Drum No. of Qty at Qty at Area occupied Sr. Raw Material per Cap. Drums any given any pint by drum No. Description Month ( Kg ) time of time (Sq. Ft.) ( MT ) (Tonnes) 1. Allethlone Alcohol 3.744 50 75 28 1.4 24 2. Chrysanthemic Acid 10.894 50 218 83 4.15 71 Chloride Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 1 Environmental Impact Assessment Report For Expansion of M/s Shogun Organics Ltd. Located At Kurkumbh MIDC, Taluka Daund, District Pune, Maharashtra. SEEPL/EIA/F/IND/SOL/001/2017-18/00 Chapter 7: Additional Studies 3. Sodium Hydroxide 2.912 50 58 22 1.1 19 4. Pyridine 6.474 225 29 11 2.475 44 5. Hydrochloric Acid 10.608 50 212 81 4.05 70 6. Toluene 21.931 220 100 38 8.36 152 7. Prallethlone Alcohol 3.614 50 72 28 1.4 24 8. Potassium 1.586 50 32 12 0.6 10 Carbonate 9. Activated Clay 1.56 50 31 12 0.6 10 10. 2,3,5,6-Tetra Fluoro 3.094 50 62 23 1.15 19 Benzyl Alcohol 11. R-Cypermethric 4.056 200 20 8 1.6 32 Acid Chloride 12. Activated Charcoal 0.312 50 6 2 0.100 2 13. m-Phenoxy 3.328 200 17 7 1.4 28 Benzaldehyde 14. Becisthemic Acid 1.742 200 9 3 0.6 12 Chloride 15. Sodium 1.092 50 22 8 0.4 7 Hypochloride 16. Sodium Cynaide 0.962 50 19 7 0.35 6 17. 2-chloro-5-chloro 3.796 200 19 7 1.4 28 methyl pyridine 18. NitroiminoImidazoli 3.354 200 17 7 1.4 28 dine 19. Dimethyl 21.32 200 106 41 8.2 164 Formamide 20. 2-Methyl-3- 1.456 200 7 2 0.4 8 Biphenyl Methanol 21. Cyhalothric Acid 0.936 200 5 2 0.4 8 Chloride 22. n-Hexane 2.575 210 12 4 0.84 16 23. Sodium Bicarbonate 0.312 50 6 2 0.100 2 24. Thiopyrazol 2.47 200 12 4 0.800 16 Alcohol 25. Trichloro Acetic 6.162 200 31 12 2.4 48 Acid 26. Monochloro 2.626 200 13 5 1.0 20 Benzene 27. Hydrogen Peroxide 0.468 50 9 3 0.15 2 28. Boric Acid 0.026 25 1 1 25 2 29. Cypermethric Acid 5.746 225 25 10 2.25 40 Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 2 Environmental Impact Assessment Report For Expansion of M/s Shogun Organics Ltd. Located At Kurkumbh MIDC, Taluka Daund, District Pune, Maharashtra. SEEPL/EIA/F/IND/SOL/001/2017-18/00 Chapter 7: Additional Studies Chloride 30. 3-methyl Benzoic 1.222 200 6 2 0.4 8 Acid 31. D-ethyl Amine 0.754 50 15 6 0.3 5 32. Orthophosphric 0.104 25 4 1 0.025 2 Acid 33. W-52 Alcohol 4.134 50 83 32 1.6 27 34. Chrysanthemic Acid 2.028 200 10 4 0.8 16 35. n-Heptane 1.534 210 7 3 0.630 12 36. Thionyl Chloride 7.436 275 27 10 2.75 40 37. Cypermethric Acid 17.134 220 78 30 6.6 120 38. Ephedrine 8.944 200 45 17 3.4 68 39. Caustic Flakes 2.236 50 45 17 0.85 15 40. EDC 26.39 200 132 50 10 200 41. MDC 10.868 200 54 20 4 80 Total : 1751 665 1505 7.1.2 DOW Index The Dow index has been performed for raw materials which are flammable. As it is a manufacturing industry the use of the solvents are limited. The solvents requirement are less in quantity, therefore the storage of the solvents are mostly in drums. The DOW summary sheet is displayed below in table no. 7.4 which states that the degrees of hazard for all the raw materials are light. The DOW index worksheet is attached as Annexure 7.1. Table No. 7.2: DOW Index Summary Sheet Chemical EDC Toluene n-Hexane Monochloro Benzene Storage Considered Drums Drums Drums Drums N h 2 2 1 3 N f 3 3 3 1 N r 0 0 0 1 Material Factor, MF 16 16 16 14 Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 3 Environmental Impact Assessment Report For Expansion of M/s Shogun Organics Ltd. Located At Kurkumbh MIDC, Taluka Daund, District Pune, Maharashtra. SEEPL/EIA/F/IND/SOL/001/2017-18/00 Chapter 7: Additional Studies F1 (General Process Hazard) 2.55 2.55 2.55 2.55 F2 (Special Process Hazard) 1.6 1.7 1.4 1.6 F3 (Hazard Factor) 4.08 4.335 3.57 4.08 Fire & Explosion Index 65.28 69.36 57.12 65.28 Degree of Hazard Moderate Moderate Light Moderate Interpretation DOW index was performed for four different materials. The degrees of hazard for all the materials were understand to be moderate, except for n-Hexane where it was found to be light. Fire & explosive Index for Toluene was higher than the other materials i.e. 69.3. Therefore the radius and area of exposure was calculated for methanol drum storage. The radius of exposure for toluene is determined to be 18.4 m & area of exposure is around 1072.34 sq. m. The impact would be confined within the factory boundaries. It will lead to an onsite emergency situation which could be handled through appropriate mitigation measures listed below- Recommendation/Suggestions 1. The raw materials are stored according to their compatibility with other raw materials. 2. Company has adequate written operating instruction and fully documented operating discipline for emergency shutdown, normal operating conditions, routine shutdown etc. which are important for maintaining satisfactory control of a unit. 3. The raw materials are stored in a dedicated area with minimum interference. 4. Appropriate drainage with the slope of 2 % is provided to remove small and large spillage of the chemicals. 5. The provision of fire water supply is provided through the hydrant line passing from the raw material storage area. 6. Provision of hand Extinguishers are provided and found to be adequate with reference to the storage quantity of raw materials. Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 4 Environmental Impact Assessment Report For Expansion of M/s Shogun Organics Ltd. Located At Kurkumbh MIDC, Taluka Daund, District Pune, Maharashtra. SEEPL/EIA/F/IND/SOL/001/2017-18/00 Chapter 7: Additional Studies 7. Provision of spill kit is provided to deal with the minor spillage scenario. The existing safety features provided are satisfactory to tackle the emergency situation raised in the site. 7.1.3 Mond's Index The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index is a series of papers by lewis (1979). The main development made to the DOW Index in the Mond Index are: 1. It covers a wider range of process and storage installation 2. It covers the processing of chemicals with explosive properties 3. A calculation procedure is included to allow for the off-setting effects of good design and control and safety instrumentation 4. The procedure has been extended to cover plant layout 5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial explosion. Most of the raw materials stored in the site are toxic, corrosive in nature. Hence appropriate standard operating procedure are established by the company for ensuring the safety of the workers handling the raw materials on daily basis. Some selected toxic raw materials are used for calculating the toxicity index using Mond's index. The Mond's index worksheet is attached as Annexure 7.1 Table 7.3: Mond's Index Summary Sheet Trichloro Thionyl Chemicals NaOH HCl Acetic acid Chloride Storage Bags Drums Drums Bags N (NFPA Index h 3 3 3 3 Number) Sadekar Enviro Engineers Pvt.
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