Annexure No. Name

List of Annexures

Annexure No. Name

Annexure I ToR letter Annexure II MIDC Land transfer letter Annexure III MSDS Annexure IV Wild life sanctuary map Annexure V NBWL application copy Annexure VI QRA and HAZOP study report Correspondence with MOEFCC 1. Public hearing exemption clarification letter submission 2. Addition of product keeping same total production capacity+ project Title change intimation to EAC

No.IA-J-11011/47/2018-IA-II(I) Goverment of India Minister of Enviroment,Forest and Climate Change Impact Assessment Division ***

Indira Paryavaran Bhavan, Vayu Wing,3rd Floor,Aliganj, Jor Bagh Road,New Delhi-110003 22 Mar 2018

To,

M/s FINE ORGANIC INDUSTRIES PVT LTD Fine Organic Industries,Plot no 124, MIDC ,Dombivali (East) Dist. Thane, Pin code 421201, Thane-421201 Maharashtra

Tel.No.22-21025000; Email:[email protected]

Sir/Madam,

This has reference to the proposal submitted in the Ministry of Environment, Forest and Climate Change to prescribe the Terms of Reference (TOR) for undertaking detailed EIA study for the purpose of obtaining Environmental Clearance in accordance with the provisions of the EIA Notification, 2006. For this purpose, the proponent had submitted online information in the prescribed format (Form-1 ) along with a Pre-feasibility Report. The details of the proposal are given below:

1. Proposal No.: IA/MH/IND2/72688/2018

Proposed manufacturing unit for Salts of 2. Name of the Proposal: Propionic acid by M/s. Fine Organic Industries Ltd.

3. Category of the Proposal: Industrial Projects - 2

4. Project/Activity applied for: 5(f) Synthetic organic chemicals industry (dyes & dye intermediates; bulk

5. Date of submission for TOR: 03 Feb 2018

In this regard, 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 as follows: STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

5(f):STANDARD TERMS OF REFERENCE FOR CONDUCTING ENVIRONMENT IMPACT ASSESSMENT STUDY FOR SYNTHETIC ORGANIC CHEMICALS INDUSTRY (DYES & DYE INTERMEDIATES; BULK DRUGS AND INTERMEDIATES EXCLUDING DRUG FORMULATIONS; SYNTHETIC RUBBERS; BASIC ORGANIC CHEMICALS, OTHER SYNTHETIC ORGANIC CHEMICALS AND CHEMICAL INTERMEDIATES) AND INFORMATION TO BE INCLUDED IN EIA/EMP REPORT

A. STANDARD TERMS OF REFERENCE

1) Executive Summary 2) Introduction i. Details of the EIA Consultant including NABET accreditation ii. Information about the project proponent iii. Importance and benefits of the project 3) Project Description i. Cost of project and time of completion. ii. Products with capacities for the proposed project. iii. If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any. iv. List of raw materials required and their source along with mode of transportation. v. Other chemicals and materials required with quantities and storage capacities vi. Details of Emission, effluents, hazardous waste generation and their management. vii. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract) viii. Process description along with major equipments and machineries, process flow sheet (quantative) from raw material to products to be provided ix. Hazard identification and details of proposed safety systems. x. Expansion/modernization proposals: c. Copy of all the Environmental Clearance(s) including Amendments thereto obtained 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 STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

addition, status of compliance of Consent to Operate for the ongoing Iexisting operation of the project from SPCB shall be attached with the EIA-EMP report. d. 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. 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. ii. A toposheet 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) iii. Details w.r.t. option analysis for selection of site iv. Co-ordinates (lat-long) of all four corners of the site. v. Google map-Earth downloaded of the project site. 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. vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular. viii. Landuse 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) ix. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area x. Geological features and Geo-hydrological status of the study area shall be included. xi. Details of Drainage of the project upto 5km 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) 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. xiii. R&R details in respect of land in line with state Government policy. STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

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) ii. Landuse 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) iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted. iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild 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. vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the Standing Committee of the National Board for Wildlife. 6) Environmental Status i. Determination of atmospheric inversion level at the project site and site-specific micro- meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall. 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. iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM 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. 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. v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if yes give details. vi. Ground water monitoring at minimum at 8 locations shall be included. vii. Noise levels monitoring at 8 locations within the study area. viii. Soil Characteristic as per CPCB guidelines. 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. STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

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. xi. Socio-economic status of the study area. 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 Modelling 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 modelling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any. ii. Water Quality modelling - in case of discharge in water body iii. Impact of the transport of the raw materials and end products on the surrounding environment hall 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. 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. v. Details of stack emission and action plan for control of emissions to meet standards. vi. Measures for fugitive emission control 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. viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided. 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 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 STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources. xi. Total capital cost and recurring cost/annum for environmental pollution control measures shall be included. xii. Action plan for post-project environmental monitoring shall be submitted. 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. 8) Occupational health i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers ii. Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour 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. 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 PEL so that health of the workers can be preserved, iv. Annual report of heath status of workers with special reference to Occupational Health and Safety. 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. 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. 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. 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 STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase. 11) Enterprise Social Commitment (ESC) i. 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. 12) Any litigation pending against the project and/or any direction/order passed by any 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 point wise compliance of above TOR.

B. SPECIFIC TERMS OF REFERENCEFOREIASTUDIES FOR SYNTHETIC ORGANIC CHEMICALS INDUSTRY (DYES & DYE INTERMEDIATES; BULK DRUGS AND INTERMEDIATES EXCLUDING DRUG FORMULATIONS; SYNTHETIC RUBBERS; BASIC ORGANIC CHEMICALS, OTHER SYNTHETIC ORGANIC CHEMICALS AND CHEMICAL INTERMEDIATES)

1. Detailsonsolvents to be used,measuresfor solventrecovery and for emissions control. 2. Details of process emissions from the proposed unit and its arrangement to control. 3. Ambient air quality data should include VOC, otherprocess-specificpollutants* like NH3*, chlorine*, HCl*, HBr*, H2S*, HF*,etc.,(*-asapplicable) 4. Work zone monitoring arrangements for hazardous chemicals. 5. Detailed effluent treatment scheme including ssegregation of effluent streams for units adopting 'Zero' liquid discharge. 6. Action plan for odour control to be submitted. 7. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated. 8. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste in TSDF, if any. 9. Action plan for utilization of MEE/dryers salts. 10. Material Safety Data Sheet for all the Chemicals are being used/will be used. 11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF. STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

12. Details of incinerator if to be installed. 13. Risk assessment for storage and handling of hazardous chemicals/solvents. Action plan for handling & safety system to be incorporated. 14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

***

SAFETY DATA SHEET

Issue Date : 26th Apr, 2016 SDS No. : SDS/020/CP Date Revised : 9th Sept, 2016 Revision : (I) According to Regulation (EC) No. 1907/2006.

Calcium Propionate

SECTION 1: Identification of the substance/mixture and of the company/undertaking 1.1 Product identifier Trade name : Calcium Propionate Powder / granule Substance name : Calcium propionate IUPAC name : Calcium dipropanoate EC name : Calcium dipropionate CAS number : 4075-81-4 EC number : 223-795-8

1.2 Relevant identified uses of the substance or mixture and uses advised against Use of the Substance/Mixture : Preservative for breads, cakes and other baked goods.

1.3 Details of the supplier of the safety data sheet Company : Fine Organic Industries Ltd., Fine House, Anandji Street, Off M. G. Road, Ghatkoper (East), Mumbai- 400077 India. Telephone : +91-(22)-2102 5000 to 15 Telefax : +91-(22)-2102 8899 / 2102 6666 E-mail address : [email protected]

1.4 Emergency telephone number: +91 22 2102 5000

SECTION 2: Hazards identification 2.1. Classification of the substance or mixture Classification (Regulation 2012 OSHA Hazard Communication Standard; 29 CFR Part 1910.1200) Not a hazardous substance or mixture according to Regulation 2012 OSHA Hazard Communication Standard; 29 CFR Part 1910.1200.

Classification (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

Classification (67/548/EEC, 1999/45/EC) Not a hazardous substance or mixture according to EC-directives 67/548/EEC or 1999/45/EC.

2.2. Label elements SAFETY DATA SHEET

Labeling (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

2.3. Other hazards No information available.

SECTION 3: Composition/information on ingredients 3.1. Substances Substance name : Calcium Propionate Synonym : Calcium Propionate IUPAC name : Calcium dipropanoate EC name : Calcium dipropionate CAS number : 4075-81-4 EC number : 223-795-8

No dangerous ingredients according to Regulation (EC) No. 1907/2006.

In case of skin contact : Flush skin with plenty of water. Remove contaminated clothing and shoes. Get medical attention if irritation develops and persists. Wash clothing before reuse. Thoroughly clean or destroy contaminated shoes.

In case of eye contact : Immediately flush eyes with plenty of water. If easy to do, contact lenses should be removed during the flushing, by trained personnel. Get medical attention if irritation develops and persists.

If swallowed : Call a physician or a poison control center immediately. Induce vomiting only if directed by medical personnel. The patient should lie on their left side while vomiting to reduce the risk of aspiration. Never give anything by mouth to an unconscious or convulsing person.

4.2. Most important symptoms and effects, both acute and delayed Symptoms: The most important known symptoms and effects are described in the labeling (see section 2) and/or in section 11.

4.3. Indication of any immediate medical attention and special treatment needed

Attending physician should treat exposed patients symptomatically. SAFETY DATA SHEET

SECTION 5: Firefighting measures 5.1. Extinguishing media Suitable extinguishing media : Waterspray, fog or mist, foam, sand, dry chemical

powder, CO2.

Unsuitable extinguishing media : Do not use water jet.

5.2. Special hazards arising from the substance or mixture Specific hazards during : Hazardous decomposition / combustion products firefighting Oxides of Carbon and Calcium.

5.3. Advice for firefighters Special protective equipment : Firefighters must wear fire resistant protective for firefighters equipment. Wear approved respirator and protective gloves.

Further information : Evacuate all non-essential personnel. Cool closed containers with water. Water used to extinguish a fire should not be allowed to enter the municipal drainage system or water courses. After a fire, ventilate thoroughly the area and soak with water, clean the walls and metallic surfaces. Fire and explosion hazard. In case of fire and/or explosion do not breathe fumes.

SECTION 6: Accidental release measures 6.1. Personal precautions, protective equipment and emergency procedures Personal precautions : Do not breathe dust. For personal protection see Section 8. 6.2. Environmental precautions Environmental precautions : Prevent product from entering municipal drains.

6.3. Methods and material for containment and cleaning up Methods for cleaning up : In case of spillage sweep up and shovel into a container for disposal in accordance with local regulations. 6.4. Reference to other sections None.

Advice on protection against : Avoid dust generation. Provide adequate ventilation at fire and explosion places where dust is formed.

SAFETY DATA SHEET

7.2. Conditions for safe storage, including any incompatibilities Requirements for storage : Store in original container. Keep container tightly closed areas and containers in a dry and well-ventilated place.

7.3. Specific end use(s) Preservative for breads, cakes and other baked goods.

SECTION 8: Exposure controls/personal protection 8.1. Control parameters Provide adequate ventilation.

8.2. Exposure controls DNEL and PNEC DNEL- Workers Route of Local Systemic Exposure Acute Chronic Acute Chronic Inhalation No data available No data available No data available No data available Dermal No data available No data available No data available No data available Hazard for the No data available No data available No data available No data available eyes DNEL- General Population Route of Local Systemic Exposure Acute Chronic Acute Chronic Oral No data available No data available No data available No data available Inhalation No data available No data available No data available No data available Dermal No data available No data available No data available No data available Hazard for the No data available No data available No data available No data available eyes PNEC Environmental protection target Fresh water No data available Freshwater sediments No data available Marine water No data available Marine sediments No data available Food (Hazard for predators : Secondary poisoning ) No data available Sewage treatment plant No data available Soil No data available Intermittent releases No data available Air No data available

Other information Emergency-shower and facilities for rinsing eyes must be accessible.

Personal protective equipment Eye protection : Wear safety goggles. Hand protection : Wear suitable protective gloves of neoprene or synthetic rubber. Skin and body protection : Wear suitable protective clothing. Respiratory protection : Wear respiratory protection if ventilation is inadequate. In case of dust formation use dust mask.

SAFETY DATA SHEET

Environmental exposure controls General advice : Prevent product from entering municipal drains.

SECTION 9: Physical and chemical properties 9.1 Information on basic physical and chemical properties Appearance : White powder, Granules Colour : White Odour : Odorless pH : 7.5-9.0 at 1% w/w in water Melting point/range : N.A. Boiling point/boiling range : N. A. Flash Point : N. A. Bulk density : 350-700 kg/m3 (loose) Solubility (Water) : 300kg /m3 at 20o C Partition coefficient : n-octanol / water: No information available. Thermal decomposition : > 250o C Viscosity : N. A. Viscosity, kinematic : N. A. Explosive properties : N. A. Dust Explosion Data : Minimum ignition energy 105-107 mJ Maximum explosion pressure 8.7bar Maximum rate of pressure rise 77bar/s Auto flammability : N. A. Explosiveness : N. A. Oxidizing properties : N. A.

SECTION 10: Stability and reactivity 10.1. Reactivity No data available

10.2. Chemical stability Stable under recommended storage and handling conditions (see section 7). Slightly hygroscopic.

10.3. Possibility of hazardous reactions Hazardous reactions : Polymerization not known to occur. Stable under recommended storage conditions.

10.4. Conditions to avoid Conditions to avoid : None known.

10.5. Incompatible materials Materials to avoid : Keep away from oxidising agents, strong acid and strong alkaline. 10.6. Hazardous decomposition products Hazardous decomposition : Oxides of Carbon and Calcium may be produced. products SAFETY DATA SHEET

SECTION 11: Toxicological information 11.1. Information on toxicological effects Acute Toxicity : Oral: No data available. : Dermal: No data available. : Inhalation: No data available.

Skin corrosion/irritation : No data available.

Serious eye damage/ : No data available. eye irritation

Sensitization : No data available.

Chronic toxicity : Oral: No data available. : Dermal: No data available. : Inhalation: No data available.

Carcinogenicity : No data available.

Reproductive toxicity : No data available.

SECTION 12: Ecological information 12.1. Toxicity Toxicity to fish : No data available.

Toxicity to daphnia and : No data available. other aquatic invertebrates

Toxicity to algae : No data available.

Toxicity to fish (Chronic toxicity) : No data available.

Toxicity to daphnia and other : No data available. invertebrates (Chronic toxicity)

12.2. Persistence and degradability: No data available.

12.3. Bioaccumulative potential Bioaccumulation : No data available.

Partition coefficient : n-octanol / water log Pow = No information available. Or .. 12.4. Mobility in soil Additional advice Environmental fate and : No data available. Pathways SAFETY DATA SHEET

12.5. Results of PBT and vPvB assessment No data available.

12.6. Other adverse effects Additional ecological information: No information available.

12.7. Further information No information available

SECTION 13: Disposal considerations Dispose off in accordance with local regulations.

SECTION 14: Transport information Land transport (ADR/RID) UN number: Not relevant as Not classified Shipping Class: Not relevant as Not classified Classification code: Not relevant as Not classified Packaging group: Not relevant as Not classified Labels: Not relevant as Not classified Special Provisions: None

Inland waterway transport (ADN(R)) UN number: Not relevant as Not classified Shipping Class: Not relevant as Not classified Classification code: Not relevant as Not classified Packaging group: Not relevant as Not classified Labels: Not relevant as Not classified Remarks: None

Marine transport (IMDG) UN number: Not relevant as Not classified Proper shipping name and description: Not relevant as Not classified Chemical name: Not relevant as Not classified Class: Not relevant as Not classified Packaging group: Not relevant as Not classified EmS number: Not relevant as Not classified Labels: Not relevant as Not classified Remarks: None

SAFETY DATA SHEET

Air transport ICAO/IATA UN number: Not relevant as Not classified Proper shipping name and description: Not relevant as Not classified Chemical name: Not relevant as Not classified Class: Not relevant as Not classified Packaging group: Not relevant as Not classified Labels: Not relevant as Not classified Remarks: None Special Provisions: None

Special precautions for user Not classified as dangerous in the meaning of transport regulations.

SECTION 15: Regulatory information Safety, health and environmental regulations/legislation specific for the substance or mixture Australia: Listed Canada: Listed China: Listed Europe: Listed Japan: Listed Korea: Listed New Zealand: Listed Taiwan: Listed USA: Listed

SECTION 16: Other information SDS Version No.: SDS/020/CP Revision Date: 9th Sept, 2016

DISCLAIMER: The information given herein is in good faith but without guarantee since the conditions of use of this product is not under the control of the manufacturer i.e. Fine Organics or its associates. Determining safe conditions of use of this product is the obligation of the actual user. Nothing is intended as a recommendation for uses, which may infringe valid patents, or as extending license under valid patents. Appropriate warnings and safe handling procedures should be provided to handlers and users.

SAFETY DATA SHEET

Issue Date : 26th Apr, 2016 SDS No. : SDS/021/SP Date Revised : NA Revision : NA According to Regulation (EC) No. 1907/2006. .

Sodium Propionate

SECTION 1: Identification of the substance/mixture and of the company/undertaking 1.1 Product identifier Trade name : Sodium propionate Product code : Registration number : Not Registered Substance name : Sodium propionate IUPAC name : Sodium propanoate EC name : Sodium propionate CAS number : 137-40-6 EC number : 205-290-4

1.2 Relevant identified uses of the substance or mixture and uses advised against Use of the Substance/Mixture : Preservative for breads, cakes and other baked goods.

1.4 Emergency telephone number: +91 22 2102 5000

Classification (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

Classification (67/548/EEC, 1999/45/EC) Not a hazardous substance or mixture according to EC-directives 67/548/EEC or 1999/45/EC. SAFETY DATA SHEET

2.2. Label elements Labeling (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

2.3. Other hazards No data available

SECTION 3: Composition/information on ingredients 3.1. Substances Substance name : Sodium propionate Synonym : Sodium propionate IUPAC name : Sodium propanoate EC name : Sodium propionate CAS number : 137-40-6 EC number : 205-290-4

No dangerous ingredients according to Regulation (EC) No. 1907/2006.

4.2. Most important symptoms and effects, both acute and delayed

4.3. Indication of any immediate medical attention and special treatment needed There are no data available that address medical conditions that are generally recognized as being aggravated by exposure to this material.

SAFETY DATA SHEET

Attending physician should treat exposed patients symptomatically.

SECTION 5: Firefighting measures 5.1. Extinguishing media

Suitable extinguishing media : Water, foam, sand, dry chemical powder, CO2.

Unsuitable extinguishing media : none known.

5.2. Special hazards arising from the substance or mixture Specific hazards during : Hazardous decomposition / combustion products firefighting Oxides of Carbon and Sodium.

5.3. Advice for firefighters Special protective equipment : Firefighters must wear fire resistant protective for firefighters equipment. Wear approved respirator and protective gloves.

Further information : Evacuate all non-essential personnel.. Cool closed containers with water. Water used to extinguish a fire should not be allowed to enter the municipal drainage system or water courses. After a fire, ventilate thoroughly the area and soak with water, clean the walls and metallic surfaces. Fire and explosion hazard. In case of fire and/or explosion do not breathe fumes.

Advice on protection against : Avoid dust generation. Provide adequate ventilation at fire and explosion places where dust is formed. SAFETY DATA SHEET

7.3. Specific end use(s) Preservative for breads, cakes and other baked goods.

SECTION 8: Exposure controls/personal protection 8.1. Control parameters Provide adequate ventilation.

8.2. Exposure controls DNEL and PNEC

DNEL- Workers Route of Local Systemic Exposure Acute Chronic Acute Chronic Inhalation No data available No data available No data available No data available Dermal No data available No data available No data available No data available Hazard for the No data available No data available No data available No data available eyes DNEL- General Population Route of Local Systemic Exposure Acute Chronic Acute Chronic Oral No data available No data available No data available No data available Inhalation No data available No data available No data available No data available Dermal No data available No data available No data available No data available Hazard for the No data available No data available No data available No data available eyes PNEC Environmental protection target Fresh water No data available Freshwater sediments No data available Marine water No data available Marine sediments No data available Food (Hazard for predators : Secondary poisoning ) No data available Sewage treatment plant No data available Soil No data available Intermittent releases No data available Air No data available

Other information Emergency-shower and facilities for rinsing eyes must be accessible.

SAFETY DATA SHEET

Environmental exposure controls General advice : Prevent product from entering municipal drains.

SECTION 9: Physical and chemical properties 9.1 Information on basic physical and chemical properties Appearance : White powder Colour : White Odour : Characteristic slight pH : 8-9.5 Melting point/range : Boiling point/boiling range : N. A. Flash Point : > 200° C Solubility (Water) : Very soluble

SECTION 10: Stability and reactivity 10.1. Reactivity No hazardous reactions are expected if the following technical instructions storage of chemicals.

10.2. Chemical stability Stable under recommended storage and handling conditions (see section 7).

10.3. Possibility of hazardous reactions Hazardous reactions : Polymerization not known to occur. Dust may form explosive mixture in air. Stable under recommended storage conditions. 10.4. Conditions to avoid Conditions to avoid : None known.

SECTION 11: Toxicological information 11.1. Information on toxicological effects Acute Toxicity : Oral: No information available

: Dermal No information available : Inhalation: No information available

Skin corrosion/irritation : No information available Serious eye damage/ : No information available eye irritation

Sensitization : No information available SAFETY DATA SHEET

Chronic toxicity : Oral: No information available

: Dermal: No information available

: Inhalation: No information available

Carcinogenicity : No information available

Reproductive toxicity : No information available

SECTION 12: Ecological information 12.1. Toxicity Toxicity to fish : No information available

Toxicity to daphnia and : No information available other aquatic invertebrates

Toxicity to algae : No information available

Toxicity to fish (Chronic toxicity) : No information available

Toxicity to daphnia and other : No information available invertebrates (Chronic toxicity)

12.2. Persistence and degradability: No information available

12.3. Bioaccumulative potential Bioaccumulation : No information available

Partition coefficient : n-octanol / water: N. A.

12.4. Mobility in soil Additional advice Environmental fate and : No information available Pathways

12.5. Results of PBT and vPvB assessment No information available

12.6. Other adverse effects Additional ecological information: No information available

SECTION 13: Disposal considerations Dispose off in accordance with local regulations.

SAFETY DATA SHEET

SECTION 14: Transport information 14.1. UN number Not regulated as a dangerous good.

14.2. UN proper shipping name Not regulated as a dangerous good.

14.3. Transport hazard class(es) Not regulated as a dangerous good.

14.4. Packing group Not regulated as a dangerous good.

14.5. Environmental hazards Not regulated as a dangerous good.

14.6. Special precautions for user Notified classification and labeling according to CLP criteria: Not classified

14.7. Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code Not applicable for product as supplied.

SECTION 15: Regulatory information Safety, health and environmental regulations/legislation specific for the substance or mixture Australia: Listed Canada: Listed China: Listed Europe: Listed Japan: Listed Korea: New Zealand: Listed Philippines: Taiwan: Listed USA: Listed

SECTION 16: Other information SDS Version No.: SDS/021/SP Revision Date: NA

Issue Date : Issue Date: 12 Oct, 2018 According to Regulation (EC) No. 1907/2006.

Potassium Propionate

SECTION 1: Identification of the substance/mixture and of the company/undertaking 1.1 Product identifier Trade name : Potassium Propionate Substance name : Potassium propionate IUPAC name : Potassium propanoate EC name : Potassium propionate CAS number : 327-62-8 EC number : 206-323-5

1.2 Relevant identified uses of the substance or mixture and uses advised against Use of the Substance/Mixture : Laboratory chemicals, Manufacture of substances

1.3 Details of the supplier of the safety data sheet Company : Fine Organic Industries Ltd., Fine House, Anandji Street, Off M. G. Road, Ghatkopar (East), Mumbai- 400077 India. Telephone : +91-(22)-2102 5000 to 15 Telefax : +91-(22)-2102 8899 / 2102 6666 E-mail address : [email protected]

1.4 Emergency telephone number: +91 22 2102 5000

Classification (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

Classification (67/548/EEC, 1999/45/EC) Not a hazardous substance or mixture according to EC-directives 67/548/EEC or 1999/45/EC.

2.2. Label elements Labeling (Regulation (EC) No. 1272/2008) Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.

1/6

SAFETY DATA SHEET

2.3. Other hazards None known.

SECTION 3: Composition/information on ingredients 3.1. Substances Substance name : Potassium propionate Synonym : Potassium propionate IUPAC name : Potassium propanoate EC name : Potassium propionate CAS number : 327-62-8 EC number : 206-323-5

No dangerous ingredients according to Regulation (EC) No. 1907/2006.

SECTION 4: First aid measures 4.1. Description of first aid measures If inhaled (Dust or vapour): Remove to fresh air. If not breathing, give artificial respiration. Oxygen may additionally be given, by trained personnel, if it is available. Get medical attention if symptoms occur. In case of skin contact: Flush skin with plenty of water and soap. Remove contaminated Clothing and shoes. Get medical attention if irritation develops and persists. Wash clothing before reuse. Thoroughly clean or destroy contaminated shoes. In case of eye contact: Immediately flush eyes with plenty of water. If easy to do, contact lenses should be removed during the flushing, by trained personnel. Get medical attention if irritation develops and persists. If swallowed: Call a physician or a poison control center immediately. Induce vomiting only if directed by medical personnel. The patient should lie on their left side while vomiting to reduce the risk of aspiration. Never give anything by mouth to an unconscious or convulsing person.

4.2. Most important symptoms and effects, both acute and delayed The most important known symptoms and effects are described in the labelling (see section 2.2) and/or in section 11

4.3. Indication of any immediate medical attention and special treatment needed Attending physician should treat exposed patients symptomatically.

SECTION 5: Firefighting measures 5.1. Extinguishing media

Suitable extinguishing media : Water spray, foam, sand, dry chemical powder, CO2. Unsuitable extinguishing media : Do not use water jet.

5.2. Special hazards arising from the substance or mixture

2/6

SAFETY DATA SHEET

Specific hazards during : Hazardous decomposition / combustion products firefighting Oxides of Carbon and Potassium.

5.3. Advice for firefighters Special protective equipment: Firefighters must wear fire resistant protective equipment. for firefighters Wear approved respirator and protective gloves.

Further information: Evacuate all non-essential personnel. Cool closed containers with water. Water used to extinguish a fire should not be allowed to enter the municipal drainage system or water courses. After a fire, ventilate thoroughly the area and soak with water, clean the walls and metallic surfaces. Fire and explosion hazard. In case of fire and/or explosion do not breathe fumes.

SECTION 6: Accidental release measures 6.1. Personal precautions, protective equipment and emergency procedures Personal precautions: Do not breathe dust. For personal protection see Section 8.

6.2. Environmental precautions Environmental precautions: Prevent product from entering municipal drains.

6.3. Methods and material for containment and cleaning up Methods for cleaning up : In case of spillage sweep up and shovel into a container for disposal in accordance with local regulations.

6.4. Reference to other sections None.

SECTION 7: Handling and storage 7.1. Precautions for safe handling Advice on safe handling: When using do not eat, drink or smoke. The usual precautions for handling chemicals should be observed. Avoid Incompatible materials (See Section 10). Advice on protection against: Avoid dust generation. Provide adequate ventilation at places fire and explosion where dust is formed.

7.2. Conditions for safe storage, including any incompatibilities Requirements for storage: Store in original container. Keep container tightly closed in a dry areas and containers and well-ventilated place.

7.3. Specific end use(s) Laboratory chemicals, Manufacture of substances

SECTION 8: Exposure controls/personal protection 8.1. Control parameters Provide adequate ventilation.

3/6

SAFETY DATA SHEET

8.2. Exposure controls DNEL and PNEC No data available

Other information Emergency-shower and facilities for rinsing eyes must be accessible.

Personal protective equipment Eye protection: Wear safety goggles. Hand protection: Wear suitable protective gloves of neoprene or synthetic rubber. Skin and body: Wear suitable protective clothing. protection Respiratory protection: In case of dust formation use dust mask.

Environmental exposure controls General advice: Prevent product from entering municipal drains.

SECTION 9: Physical and chemical properties 9.1 Information on basic physical and chemical properties Appearance : Form: Solid Colour : White Odour : Odourless pH : N. A. Melting point/range : N. A. Boiling point/boiling range : N. A. Flash Point : N. A. Flammability (solid, gas) : N. A. Specific gravity : N. A. Bulk density : N. A. Solubility (water) : N. A. Partition coefficient : n-octanol / water: log Pow = 1.163

SECTION 10: Stability and reactivity 10.1. Reactivity No data available 10.2. Chemical stability Stable under recommended storage and handling conditions (see section 7). 10.3. Possibility of hazardous reactions Hazardous reactions: Polymerization not known to occur. Stable under recommended storage conditions. 10.4. Conditions to avoid Conditions to avoid: None known. 10.5. Incompatible materials Materials to avoid: Keep away from oxidising agents, strong acid and strong alkaline. 10.6. Hazardous decomposition products Hazardous decomposition products: Oxides of Carbon and Potassium may be produced.

4/6

SAFETY DATA SHEET

SECTION 11: Toxicological information 11.1. Information on toxicological effects Acute Toxicity: Oral; Dermal; Inhalation : No data available Skin corrosion/irritation : No data available Serious eye damage/ eye irritation : No data available Sensitization : No data available Chronic toxicity: Oral; Dermal; Inhalation: No data available Carcinogenicity : No data available Reproductive toxicity : No data available.

SECTION 12: Ecological information 12.1. Toxicity Toxicity to fish : No data available Toxicity to daphnia and other aquatic : No data available invertebrates Toxicity to algae : No data available Toxicity to fish (Chronic toxicity) : No data available Toxicity to daphnia and other : No data available invertebrates (Chronic toxicity)

12.2. Persistence and degradability : No information available

12.3. Bioaccumulative potential Bioaccumulation : No information available Partition coefficient : n-octanol / water: log Pow = 1.163

12.4. Mobility in soil Additional advice: Environmental fate and Pathways: No information available

12.5. Results of PBT and vPvB assessment: No data available

12.6. Other adverse effects: Additional ecological information not available.

SECTION 13: Disposal considerations Dispose off in accordance with local regulations.

5/6

SAFETY DATA SHEET

Special precautions for user Not classified as dangerous in the meaning of transport regulations.

SECTION 15: Regulatory information Safety, health and environmental regulations/legislation specific for the substance or mixture Australia: Not listed Canada: Not listed China: Listed Europe: Listed Japan: Listed Korea: Listed New Zealand: Not listed Taiwan: Listed USA: Not listed

SECTION 16: Other information Issue Date : Issue Date: 12 Oct, 2018

6/6

10/26/2018 Wild Life Report

Wild Life Report

Form for seeking recommendation of Standing Committee of NBWL/SBWL.

PART - I & II (To be filled up by User Agency)

A. General Details

A-1. Project Details

(i). Forest Clearance Required?: No

(ii). Proposal No. : FP/MH/IND/2849/2018

(iii). Name of Project: Proposed manufacturing unit for production of food preservatives

(iv). Short narrative of the Project : Fine Organic Industries Ltd., proposes to establish a new manufacturing facility for ‘Food preservatives’ at Additional Patalganga MIDC, Panvel, Raigad, Maharashtra. Prior Environmental Clearance is mandated by Ministry of Environment, Forest and Climate Change as vide EIA Notification SO 1533, date

(v). State : Maharashtra

(vi). Category of the Project : Industry

(vii). Shape of project land : Linear

(viii). Distance of the project from the boundary of the Protected Area (in km.): 2.2

(ix). Estimated cost of the Project(Rupees in lacs) : 0

(x). Total period for which clearance is required (in year): NIL

(xi). Total Project Area(in ha.): 1.2

(xii). Project Area under Protected Area (in ha.): 0

(xiii). Project Area under Non-Protected Area (in ha.): 1.2

(xviii). Project Area inside Wildlife Sanctuaries(in ha.): 0

(xiv). Project Area outside Wildlife Sanctuaries(in ha.): 1.2 http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 1/6 10/26/2018 Wild Life Report

(xv). Project Area inside Conservation Reserve(in ha.): 0

(xvi). Project Area outside Conservation Reserve(in ha.): 0

(xvii). Project Area inside National Park(in ha.): 0

(xviii). Project Area outside National Park(in ha.): 0

(xix). Project Area inside Ecologically Sensitive Zone(in ha.): 0

(xx). Project Area outside Ecologically Sensitive Zone(in ha.): 0

A-2. Details of User Agency

(i). Name : FINE ORGANIC INDUSTRIES PVT LTD

(ii). Address1 : Plot No. G-1, G-1/1, MIDC Kherwai, Badlapur, Dist. Thane

(iii). Address2 : NIL

(iv). State : Maharashtra

(v). District : Thane

(vi). Pin : 421503

(vii). Landmark : NIL

(viii). Email address : [email protected]

(ix). Landline Telephone No. : 21025000

(x). Fax No. : NIL

(xi). Mobile No. : 9820499240

(xii). Website (if any) : NIL

(xiii). Legal status of User Agency : Others

A-3. Details of Person Making Application

http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 2/6 10/26/2018 Wild Life Report

(i). First Name: Amol Kamat

(ii). Middle Name: NIL

(iii). Last Name: Kamat

(iv). Gender: Male

(v). Designation: GM (Manufacturing & Operation)

(vi). Address 1: Fine Organic Industries,Plot no 124, MIDC ,Dombivali (East) Dist. Thane, Pin code 421201

(vii). Address 2: NIL

(viii). State: Maharashtra

(ix). District: Thane

(x). Pin: 421201

(xi). Landmark: NIL

(xii). Email Address: [email protected]

(xiii). Landline Telephone No.: 21025000

(xiv). Fax No.: NIL

(xv). Mobile No.: 9820499240

(xvi). Upload a copy of documents in support of the competence/authority of the person making this application to make application on behalf of the User Agency: Annexure copy of documents in support of the competence

B. Details of Land required for the Project

B-1. Details of Protected Area

B-1.1 No. of Divisions involved in Protected Area

Division wise details of land Project Area Protected Area S.no Division Name under Protected Name Area 1. Thane Karnala Bird Wildlife 0 Sanctuary http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 3/6 10/26/2018 Wild Life Report

B-1.2 Details of Districts involved

District wise breakup Project Area Project Area under Non- S.no District Name under Protected Protected Area(ha.) Area(ha.)

1. Raigad 0 0

B-1.3 Component wise breakup

Component wise breakup Project Area Project Area under Non- S.no Component under Protected Protected Area(ha.) Area(ha.)

1 NA 0 0

C. Maps of protected area

Division 1. : Thane

(i). Project Area under Protected Area (in ha.) : NIL

(ii). Nature of the Project : Linear

(iii). No. of Segments : One

Patch/Segment wise details Protected Area of KML file of protected Segments segment(in ha.) area of segment 1. 0 View File (iv). copy of Survey of India Toposheet indicating boundary of protected area: Annexure Survey of India Toposheet

(v). scanned copy of the Geo-referenced map of the protected area prepared by using DGPS or Total Station: Annexure scanned copy of the Geo-referenced map

D. Justification for locating the Project in protected area and details of alternates examined :

(i). copy of note containing justification for locating the Project in protected area: Annexure Justification

(ii). Whether a copy of map indicating location of alternative examined is required to be provided: No

(a). Reason for not providing such map NA http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 4/6 10/26/2018 Wild Life Report

E. Employment likely to be generated

(i). Whether project is likely to generate employment ?: Yes

(a). Permanent/Regular Employment(Number of persons): 60

(b). Temporary Employment(Number of person-days): 15

F. Displacement of People due to the project, if any

(i). Whether project involve displacement?: No

G. Status of Environmental clearance

(i). Whether the Project requires Clearance under the Environment (Protection) Act 1986 ? : Yes

(a). Status of the Environmental Clearance to the Project : EC under process

(ii).Environmental Clearance File No.: IA-J-11011/47/2018-IA-II(I)

H. Whether proposal is for investigation/survey

(H- Details of the Bio diversity Impact Assessment report in case the proposal involves use of more than 2). 50 ha. NP/WLS.

(a).Copy of the Bio diversity Impact Assessment report: Annexure Copy of Bio diversity Impact Assessment report

(H- Information on the projects undertaken by the proponent agency in the past in Protected Areas 3).

(a).Upload file: Annexure Information on the projects undertaken by the proponent agency in the past in Protected Areas

(H- Details regarding compliance of the conditions on each proposal 4).

(a).Upload file: Annexure Details regarding compliance of the conditions on each proposal (H-5).Whether any matter related to the project is sub judice in any court of law?: No

Documents

S.No Uploaded Additional Info. Files Remarks NIL http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 5/6 10/26/2018 Wild Life Report

Print page

http://forestsclearance.nic.in/Admin/UserAgency_Report_W.aspx?pid=FP/MH/IND/2849/2018 6/6 73°6'0"E 73°7'0"E 73°8'0"E 73°9'0"E 73°10'0"E

!( Project Location 18°54'0"N 18°54'0"N

Ulva

Chauk Karjat 18°53'0"N 18°53'0"N

Chirner 47 F / 1 Karnala 47 F / 5 !( Khalapur Project Location ! Khopoli Vashi Pen

2.5 km Karnala Wild Life Sanctuary Jambhulpada

47 F / 2 47 F / 6

18°52'0"N 18°52'0"N Unhere Nagothane Pali

Toposheet Index . 00.25 0.5 1 Km.

Legend

(!(! Project Location 10 Km Buffer from Project Location

18°51'0"N 18°51'0"N Karnala Wildlife Sanctuary Boundary

73°6'0"E 73°7'0"E 73°8'0"E 73°9'0"E 73°10'0"E

RISK ASSESSMENT

(QRA)

 RISK ASSESSMENT  HAZOP STUDY  ON SITE DISASTER CONTROL PLAN

Proposed manufacturing unit for salts of Propionic acid

FINE ORGANIC INDUSTRIES LIMITED

Plot No E - 73, Additional Patalganga MIDC, Dist. Raigad,Maharashtra.

Prepared By

MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division Behind DIC Office, Agri College Campus, Shivajinagar, Pune – 411 005, Maharashtra.

. 2018

CO NT E N T

PAGE SECTION DESCRIPTION NO. 1 Executive summary 4 2 The Assignment 6 2.1 Scope Of Work 6 2.2 Site Activity 6 2.3 Methodology 7 3 Identification Of Hazards 7 3.1 Classification of dangerous goods 7 3.2 Inventory Analysis 9 3.3 Relative ranking 9 3.4 DOW F&E Index 9 3.5 MOND Index 12 3.6 HAZOP study 12 3.7 Top Ten –Identified Hazards 12 4 Consequence Analysis 13 4.1 Introduction 13 4.2 Result 13 5 Frequency analysis 15 5.1 Event Tree 15 5.2 Initiating event frequency 15 6 Impact assessment 17 6.1 Over Pressure Impact 17 6.2 Jet Fire 19 7 Risk Assessment 22 7.1 Individual risk 22 7.2 Societal Risk 23 8 Risk mitigation measures 25 8.1 Risk mitigation measures suggested 25 8.2 Emergency preparedness plan 25 8.2 On Site Disaster Control Plan 8.2 Off Site Disaster Control Plan

LIST OF ANNSEXURE Sr.No. Description Page No. Annexure 1 Glossary. 27 Annexure 2 Abbreviations. 29 Annexure 3 References. 30 Annexure 4 Dow F & E Index Worksheet 31 Annexure 5 MOND index assessment worksheets 35 Annexure 6 HAZOP Study report 47

2 LIST OF TABLES Table No. Description Page No. Table no. 2.1 Proposed Dangerous Class Wise Inventory 7 Table no. 2.2 Hazardous Waste 7 Table no. 2.3 Product Wise Unit Processes & Operations 7 Table No. 2.4 Inventory Level Tank Farm 7 Table no. 3.1A : FLAMMABILITY HAZARDS ( TOP FIVE) 8 Table no. 3.1B : TOXICITY HAZARDS ( TOP FIVE ) 8 Table no. 3.1C Reactivity Hazard(TOP FIVE) 8 Table no.3.2 Applicability Of MSIHC Rules 1989 8 Table no.3.3 DOW 9 Table no.3.4 MOND INFEX 9 Table no.3.5 Compatability /Reactivity Hazard Matrix 10 Table no.3.6 TRANSFORMATION IF ANY WHICH COULD OCCUR 11 Table no.3.7 NODES OF HAZOP STUDY 12 Table no.4.1A Downwind Affect Distance 13 Table no.4.1B Downwind Affect Distance 13 Table no. 5.1 Event Failure Frequency 16 Table no. 6.1 Effect Of Blast Pressure Wave 20 Table no. 6.2 Fatal Thermal Radiation Exposure Levels 20 Table no. 6.3 Effect Of Thermal Radiation On Unprotected Skin 21 Table no. 7.1 Individual Fatality Criteria 22 Table no. 7.2 Individual Risk Result 22 Table no. 7.3 Societal Risk 24

LIST OF FIGURES Figure No. Description Page No. Figure no. 2.1 Satellite image 6 Figure no. 5.1 Vulnerable Zone Hydrogen Release 15 Figure no. 5.2 Vulnerable Zone Acetone release 16 Figure no. 6.1 Vulnerable Zone Hydrogen Release VCE 17 Figure no. 6.2 Vulnerable Zone Acetone release VCE 17 Figure no. 6.3 Vulnerable Zone Acetone release 18 Figure no.6.4 MARPLOT:VULNERABLE ZONE: Acetic acid 19 pool fire Figure no.6.5 MARPLOT : Vulnarable Zone: Proponic Acid Pool 19 Fire Figure no. 7.1 MARPLOT :Vulnerable Zone 23 Figure no. 7.2 Site Surrounding 23 Figure no. 7.3 Site Surrounding 24 Figure no. 8.1 On Site Disaster Control Plan 26 Figure no. 8.1 Off Site Disaster Control Plan 26

SECTION 1: EXECUTIVE SUMMARY

FINE ORGANIC INDUSTRIES LIMITED , Proposed manufacturing unit for salts of Propionic acid at Plot No E - 73, Additional Patalganga MIDC, Dist. Raigad,Maharashtra.The capacity of the plant will be 25000 MTPA,

This QRA report is prepared for the above mentioned proposal towards compliance to TOR conditions and forms a part of the EIA report required for obtaining Environmental Clearance.

Section 2 describes scope of the work, and gives details of the proposed site activity , the storage arrangement and infrastructural facilities provided at site

Section 3 is devoted for identification of hazards the materials handled and processes used . MSDS of the substances taken for study.

Applicability of Manufacture Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989”.formed under Environment protection Act 1986, these were amended in 1994and 2000 checked for inventory. The inventory of does not exceeds the criteria of threshold quantity as per schedule 2 parts I and Part II of these rules hence the site is not classified as MAH (Major accident hazard installation.

Relative ranking by DOW F & E index , Fire index as per MOND analysis are applied for storage of flammable substances area , decompositions products , reactivity and compatibility hazards are assessed .

HAZOP study carried out considering storages , major unit processes and ETP as separate node. As a outcome of these identification of hazards exercise worst possible events are listed and used for selection of events for carrying out consequence analysis.

Section 4 Consequence analyses is carried out modeling Propionic acid evaporating pool, dispersion down wind, and pool fire is considered as worst possible scenarios having potential for serious off site consequence are considered for further quantities risk estimation . Consequence analyses of furnace oil and Diesel storage tanks pool fire are also carried out .

Section 5 Estimation of the event frequency of event is carried by developing Event tree for spill of Acetic acid , Propionic acid & Fuels at storage tank installation .

Section 6 the vulnerable zones as obtained during consequence analysis are superimposed on the satellite image of site plan termed as MARPLOT to assess the impact on the site activities and surroundings.

Section 7 the individual risk considering 80 employees engaged in site operations is estimated. The site is located in MIDC industrial Area hence assuming the same population density as that of the site societal risk of fatality is estimated data collected for constructing F-N curve. It should be noted that the risk estimation is for unmitigated risk.

A series of risk mitigation measures are suggested in section 8 of the report. These measures are of two types 1) to reduce the probability of undesired event and 2) reducing the severity of the consequences.

As a part of risk mitigation measures in order to address the residual risk after providing risk mitigation measures following disaster control plans are prepared .Emergency Preparedness Plan, On Site Disaster Control Plan and Off Site Disaster Control Plan. In essence these plans are relevant to emergency level 1, 2 and 3 respectively. The offsite disaster control plan gives fact sheet and other dove tailing data for further use.

The study reveals that the risk posed by the proposed site activities are at reasonably acceptable level however it should be noted it depends heavily upon the maintenance of the hardware and of the management procedures; neglect of either will lead to loss of protection and the rating will rise to the higher level .

SECTION 2 THE ASSIGNMENT 2.1 SCOPE OF WORK The scope of the report covers the proposed site activities of manufacturing. The battery limits of this study are restricted to the installations indicated over the proposed site plan.

FIGURE NO:2.1:SATELLITE IMAGE

18°52'30.22"N Latitude and 73° 9'48.79"E Longitude, elevation 10 meter above MSL.

Plot area 12,000 sq. m.;Presently there is an existing warehouse on the site admeasuring around 2250 sq.mt of area from that of the plot area.  Savroli – Kharpada road adjacent  Mumbai –Pune express way 5 km  Railway station: Rasyani at 2.4 km,  Apta at 1.72 km,Panvel Railway station 13.46 km  Chhatrapati Shivaji international airport 39.5 lm  Nearest town/city Rasyani at 2 km, Panvel at 13.51 km

2.2 METHODOLOGY Risk assessment Methodology is as per the Technical EIA Guidance Manual for Synthetic Organic Chemicals, prepared for the Ministry of Environment and Forests Government of India .The major steps in risk assessment are as outlined below;  Hazard Identification.  Failure Frequency Analysis.  Consequence Analysis.  Impact Assessment.  Protective System & Hazard Analysis.  Risk Mitigation Measures.  DMP.

2.3 SITE ACTIVITY TABLE NO .2.1:List of Products for Environmental Clearance CAS Batch Size Capacity Total SR. Name Of Products Mt Capacity NO. MTPA MTPA 1 Spray Drying method 10,000 1.1 4075-81-4 Calcium Propionate and /or 2.950 1.2 137-40-6 Sodium Propionate and /or 4.500 10,000 1.3 Calcium acetate 3.160 2 Mixing method 15,000 2.1 4075-81-4 Calcium Propionate 4.080 15,000 TOTAL - - 25000 By product : nil ABLE NO. 2.2: HAZARDOUS WASTE

Category Type Of Waste Quantity No Method of disposal 1 Sludge 20-25 kg/m CHWTSDF 2 filter material from the process 45-50kg/m CHWTSDF

TABLE NO. 2.3 : INVENTORY

No. Name Mode of of storage Maximum Remark Quantity Stored at any point of time 1 CalciumPropionate 2 Sodium Propionate Bags 400 MT Finished Good 3 Calcium Acetate 4 Propionic acid 250 kl Tank- 5 nos. 1250 KL Raw Material 5 Hydrated Lime Silos 2 nos / bags 9900 MT Raw Material 6 Sodium hydroxide Bags 450 MT Raw Material 7 Acetic acid 150 Kl tank 1 no. 100 KL Raw Material 8 Furnace oil 100 kl (AG )Tank 100 KL Fuel 9 Diesel 20 kl (UG) Tank 20 KL Fuel 10 Sludge Non- Hazardous 11 filter material from Bags 84 MT Waste , suitable for the process Landfill

TABLE NO. 2.4: INVENTORY LEVEL Tank farm

No. Name Maximum Quantity Max Inventory level Stored at any point Consumption Number of of time level TPM Qty. days storage 1 Propionic acid 1250 MT 1563 24 2 Acetic acid 100 Kl 625 5 3 Hydrated Lime 300 kl 764 12 4 Furnace oil 100 kl 250 12 *Imported ,Transport to site is by road truck/tankers. 7

SECTION 3: IDENTIFICATION OF HAZARDS

3.1 HAZARDOUS CHEMICALS

TABLE NO. 3.1 A: FLAMMABILITY HAZARDS ( TOP FIVE ) Sr. Name LEL UEL Flash Boiling NFPA No. Point Point Flammability Hazard Index % % 0c 0c Nf 1 Acetic acid 5.4 16 39 118 2 2 Diesel 0.6 7.5 32 -62 >150 2 3 Propionic acid 2.9 12.1 52.2 141 2 4 Furnace Oil 0.7 5 >65 175-325 2 5 Sodium Propionate - - >200 NA

NFPA 704 M Hazard Index, Scale 1 to 4.

TABLE NO. 3.1 B: TOXICITY HAZARDS ( TOP FIVE )

Sr. Name Oral Dermal LD50 Inhalation NFPA No. LD50 LC50 Health Index mg/kg. ml/kg. mg/m3 N h 1 Propionic acid Toxic * NA NA 3 2 Sodium hydroxide Toxic * NA NA 3 3 Acetic acid Toxic * Toxic * Toxic * 2 4 Hydrated Lime NA NA NA 2 5 Lime NA NA NA 2

NFPA 704 M Hazard Index, Scale 1 to 4. , NA data not available Toxic *-Indicative Criteria used as per “MSIHC Rules 1989, schedule I , Part I ( a ) ”. TABLE NO. 3.1 C: REACTIVITY HAZARDS ( TOP FIVE ) Sr.No. Name CAS No. NFPA Hazard Index Material Factor N f Nr MF 1 Hydrated Lime 1305-62-0 0 2 24 2 Propionic acid 79-09-4 2 1 14 3 Sodium hydroxide 1310-73-2 0 1 14 4 Lime 1305-78-8 0 1 14 5 Acetic acid 64-19-7 2 0 10

NFPA 704 M Hazard Index, Scale 1 to 4. , Material factor scale 1 to 40 .

TABLE NO 3.2: APPLICABILITY OF MSIHC RULES 1989 Max. Threshold Group Material Storage Qty. Mt. Capacity * 5.5 Highly Flammable Chemicals having 2500 Liquids 230 C < flash point ≤ 600 C 150 kl Acetic Acid 1250 mt Propionic acid Diesel 20 kl 5.6 Flammable Liquids Chemicals having 5000 600 C < flash point < 900 C Furnace oil 100 kl 8

*Criteria used: “Manufacture Storage and Import of Hazardous Chemicals Rules, 1989”.formed under Environment protection Act 1986, these were amended in 1994and 2000. Threshold quantity as per schedule 2 part I And Part II of these rules .

Inventory analysis revels that the inventory of hazardous chemicals of any group does not exceeds the threshold specified quantity specified in Schedule II Column 3 of "The the MSIHC Rules, 1989”. Thus the site is not classified as Major Accident Hazards (MAH) Installation .

3.2 RELATIVE RANKING

3.3 DOW F&E INDEX

Identification of hazardous units and segments of plants and storage units based on “Relative Ranking Technique,” such as DOW Fire and Explosion Index is used.

As per DOW F & E index assessment propionic acid storage installation is having the highest radius of exposure of 10.5 m with damage factor 0.31.

As per DOW Toxicity hazard index assessment Methanol storage installation category as I. TABLE NO 3.3: DOW F & E INDEX Sr. Installation DOW The Degree Radius Of Damage Toxicity Toxicity No. F&E Of Hazard Exposure Factor Index Category Index (m) 1 Propionic 43.7 Light 11.2 0.32 8.50 II Acid 2 Acetic acid 38.6 Light 9.9 0.30 5.87 I 3 Furnace oil 20.7 Light 5.3 0.12 - - 4 Diesel 19.8 Light 5 0.10 - -

3.4 MOND INDEX

TABLE NO 3.4: MOND Index Sr. Installation Fire Internal Aerial Over All No. Index Explosion Explosion Hazard Index Index Rating 1 Propionic Acid High Moderate Low High Group II 2 Furnace oil Low Moderate Low Moderate 3 Diesel Light Moderate Light Moderate 4 Acetic acid Moderate Moderate Low High Group II

The MOND Index is a rapid hazard assessment method for use on chemical plant or in plant design. The use of this technique puts the hazard of a plant on a numerical scale, where the comparative pictures of all subdivisions of the plant form emerge. The assessment is carried out as per MOND INDEX Manual 1993.

As per Mond index assessment for the hazardous chemical storages are Moderate or less than that “as over all hazard rating. It is reasonable to assume that a unit assessed at this level can be operated in a satisfactory manner by providing adequate off setting measures, giving full regard to the hazards indicated by the assessment It should be noted that the assessment depends heavily upon the maintenance of the hardware and of the management procedures; neglect of either will lead to loss of protection and the rating will rise.

TABLE NO. 3.5: COMPATABILITY /REACTIVITY HAZARD MATRIX

Chemicals Mixing With →

acid Acetic Compressed Air, CarbonateCalclim HydroxideCalclum Propionic Acid Sodium Hydroxide Solid Water Acetic acid Air, Compressed C Calclum Carbonate C Y Calclum Hydroxide C Y Y Propionic Acid Y C C C Sodium Hydroxide N C Y Y N Water Y Y C C Y C

CHART LEGEND Y Compatible - No hazardous reactivity issues expected

N Incompatible - Hazardous reactivity issues expected

C Caution - May be hazardous under certain conditions

SR Self reactive - Potentially self reactive e.g. polymerizable

(incompatibility implies as the equimolar mixing of two materials under ambient temperature and pressures that will produce heat (10Kcal per mole), gases, or other real and immediate hazards)

Risk Mitigation

Storage of chemicals considering the compatibility and reactivity hazards. smoke detector at warehouses.

Transformation products Hazards due to gases released decpmposition , transformation during fire condition.

TABLE NO. 3.6: TRANSFORMATION IF ANY WHICH COULD OCCUR

Sr.No. Name Decomposition Products In Case Of Fire Sodium oxide. Decomposition by reaction with certain 1 Sodium hydroxide metals releases flammable and explosive hydrogen gas. Calcium hydrate; Caustic fumes of calcium oxide form when heated to 2 slaked lime. decomposition (580C; 1076F). Furnace oil Carbon dioxide and carbon monoxide may form when 3 heated to decomposition. Diesel Carbon dioxide and carbon monoxide may form when 4 heated to decomposition. 5 Propionic acid Poisonous gases are produced in fire. Calcium Acetate Decomposes above 160) C producing Acetone vepors and 6 Calcium carbonate . Lime Reactivity with water – heat may cause ignition of 7 combustibles , material swells during reaction .

Separate chemicals storage in bulk considering the compatibility and reactivity hazards at open storage area and warehouse.

PRELIMINARY HAZARD ANALYSIS

Pre Construction phase Construction phase Operation phase

Post Operation /De commissioning /demolition

Natural calamities Physical hazards Biohazards Electrical hazard Hazardous substances and wastes Mechanical hazards Frequent causes of accidents during construction Activity Ergonomics & psychosocial hazard General Hazards

3.5 HAZOP STUDY

Identification of hazards by HAZOP Study under following nodes:

TABLE NO.3.7:NODES OF HAZOP STUDY Node 1 Propionic acid storage tank Node 2 Furnace oil storage tank Node 3 Diesel storage tank Node 4 Caustic soda storage tank Node 5 Acetic acid storage tank Node 6 Spray Drying method Operations Node 7 Mixing method Operations Node 8 ETP

3.6 IDENTIFIED HAZARDS

Top ten identified hazards/events / accident scenarios having risk rating (evaluating the indentified hazardous event on severity(S) and Probability(P) of the event on the scale 1 to 5 resulting in risk rating ( R) on the scale 1 to 25 during HAZOP study) in 16 to 25 range are as follows:

TOP TEN –IDENTIFIED HAZARDS Sr.no. Identified hazard S P R 1 Spill of Propoinic acid , Fire / explosion hazard on propionic acid 5 4 20 release as above 54°C explosive vapour/air mixtures may be formed also it Attacks many metals forming flammable/explosive gas (hydrogen ) 2 Spill of Furnace oil followed by pool fire 4 4 16 3 Spill of Diesel followed by pool fire 4 4 16 4 Organic contaminated water generated during fire fighting operations 4 4 16 entering storm drain. 5 Static charge accumulation to dangerous level in handling of 5 4 20 materials , fire hazard ., Dust explosion at spray dryer operations 6 Reactivity and compatibility hazards due to accidental spill and mix 4 4 16 up at tank farm / ware house 7 Health hazard due to minor leaks / vapors emissions,and vent of the 4 4 14 spray dryer odor issues at work place. ( Propionic acid is a colorless liquid with a pungent odor. The odor threshold is 0.16 ppm) 8 Handling alkaline materials at high temperature for long years of 5 4 20 service may result in “Caustic imbrittlement” for MS equipments and weaken the equipment leading to rupture at these week points especially welding joints. 9 Accumulation Impurity in product due to recycle streams 4 4 16 10 Emergency in the neighborhood industrial installations. 4 4 16

SECTION 4: CONSEQUENCE ANALYSIS

4.1 INTRODUCTION

The accident scenarios as identified during HAZOP study are divided in two categories considering the consequence seriousness and occurrence frequency.

 MAXIMUM CREDIBLE LOSS SCENARIO (MCLS).  WORST POSSIBLE SCENARIO.

MAXIMUM CREDIBLE LOSS SCENARIO (MCLS)

Maximum Credible Loss Scenario (MCLS) is one of the methodologies evolved to access the events in realistic and practical way. An MCLS can be described as the worst “credible” accident or as an accident with a maximum damage distance, which is still believed to be probable. Minor Leaks from hose/ piping failure are quite probable events. Such accidental release is considered as MCLS.

WORST POSSIBLE SCENARIO

Worst Case Scenario/ MCA (Maximum Credible Accident) Accident Scenario accidental release of Actic acid release followed by dispersion down wind and fire/explosion is considered as Worst Case Scenario/ MCA (Maximum Credible Accident).

4.2 RESULTS TABLE NO. 4.1 A: DOWN WIND AFFECT DISTANCE

Sr. Accident Scenario Downwind Affect Distance (m) No. Toxic Vapor Cloud Flammable Vapor Cloud LEL PAC 3 PAC 2 PAC 1 IDLH 60 % 10 % 1 Propionic Acid 75 347 508 - 11 22 2 Furnace oil - - - - <10 <10 3 Diesel - - - - <10 <10 4 Acetic acid 117 399 1200 327 <10 23

TABLE NO. 4.1 B : DOWN WIND AFFECT DISTANCE

Sr. Accident Scenario Downwind Affect Distance (M) No. Blast Over Pressure Psi Thermal Radiation (KW/M2)

8 3.5 1.0 10 5 2 1 Propionic Acid - - - 20 30 40 2 Furnace oil - - - 9 13 18 3 Diesel - - - 11 12 13.5 4 Acetic acid - - - 10 13 21

Note 1 The potential consequences from the hazardous scenarios identified is determined and the impact zones modeled using ALOHA and PHAST software tools. The primary consequence types are pressure wave, thermal radiations and toxic gas release. The stable atmospheric stability conditions , ambient temperature of 30 oC, wind speed was 1.5 m/s. and humidity (50%) , No inversion used for Consequence Analysis.

Note 2 Apart from the maximum credible releases, the conservative approach appears in adoption of atmospheric conditions, used in the dispersion calculation. In general, the assumptions/ conditions will result in the largest damage distances. Hence, it must be remembered that this analysis will be pessimistic & conservative in approach & is only a planning tool. Its use should not be extended without understanding its limitations.

Note 3. DISCLAIMER: Information contained in this report is believed to be reliable but no representation; guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them. It is up to the manufacturer to ensure that the information contained in the report is relevant to the product manufactured/ handled or sold by him as the case may be. We make no warranties expressed or implied in respect of the adequacy of this document for any particular purpose.

SECTION 5: FREQUENCY ANALYSIS

5.1 EVENT TREE

Event trees begin with an initiating event and work toward a final result. This approach is inductive. The method provides information on how a failure can occur and the probability of occurrence. Frequency of the incident is estimated by Event Tree.

FIGURE NO:5.1:EVENT TREE

EVENT FREQUENCY: 1 X 10-4 per Year

5.2 INITIATING EVENT FREQUENCY

Initiating event frequency/yr range (all causes included) is 1 x 10-2 to 1x 10-3

Typical frequency values assigned to initiating events  Regular failure 1x10 -1  Gas kept/ packing blow out 1x10-2 yr  Piping leak (10% sections), 100m 1x10-3/yr  Piping residual failure ,100m ,full breach 1x10-5 /yr  Safety value opens spuriously 1x10-2 /yr  Operator failure (to execute routines procedure, well trained, unstressed, not fatigued) range 1 x 10-1 to 1 x 10-3/ opportunity

Raf: Table 11.3, Chemical process safety fundamentals with apptications; Dainel A Crowl / Joseph L.Second edition,

TABLE 5.1: EVENT FAILURE FREQUENCY S.N. Event Event Frequency/ Yr 1 Acetic acid pool fire 1.0 × 10-4 2 Propionic Acid pool fire 1.0 × 10-4 3 Furnace oil pool fire 1.0 × 10-4 4 Diesel pool fire 1.0 × 10-4

It is reasonable to assume this change however it should be noted it depends heavily upon the maintenance of the hardware and of the management procedures; neglect of either will lead to loss of protection and the rating will rise to the original estimate (a ) indicated above .

SECTION 6: IMPACT ASSESSMENT

6.1 TOXICITY IMPACT ALOHA modeling of the vulnerable zones is superimposed on satellite site maps Called MARPLOT for Bromine release is as follows:

Figure No.6.1 MARPLOT:VULNERABLE ZONE: Acetic ACID REALESE

Figure No.6.2 MARPLOT:VULNERABLE ZONE: Acetic acid REALESE

Short Term Exposure: Can cause severe irritation, burns, and permanent eye damage. Skin contact can cause severe irritation and burns. Breathing can cause irritation of the mouth, nose, and throat; coughing; and shortness of breath. Higher exposures can cause bronchopneumonia and pulmonary edema, a medical emergency. Medical observation recommended for 24_48 h following inhalation overexposure, as pulmonary edema may be delayed.

Figure No.6.3 MARPLOT:VULNERABLE ZONE: PROPIONIC ACID REALESE

Short Term Exposure: Corrosive to the eyes, skin, and respiratory tract. Contact can cause severe eye burns, leading to permanent damage. Skin contact causes skin burns.Inhalation can cause irritation of the respiratory tract with mild cough; asthmatic response was found in medical reports of acute exposure of workers.

IMPACT a) Acetic acid and Propionic acid release - ERPG 3 concentration prevails up to 117 and 75 m down wind respectively and immediate evacuation of the area is required . b) It is reasonable to assume that well trained employees within the vulnerable zone are likely to move out of this zone in less than 10 minutes hence avoiding fatality. c) It should be noted that depending the prevailing atmospheric conditions at the time of the event the impact will undergo change. d) The event if not controlled immediately have potential of serious off site consequences affecting surrounding population . e) Acetic acid can react with water and/or water vapour. This can affect the downwind dispersion estimate .

6.2 THERMAL RADIATION IMPACT

Release of Flammable material leading to Pool fire at tank farm will result in thermal radiations and likely to have direct impact on the personnel in vulnerable zone with burn injuries and even fatality as given in table no. 6.1 and table 6.2.

Figure No.6.4 MARPLOT:VULNERABLE ZONE: Acetic acid pool fire

Figure No.6.5 MARPLOT : VULNARABLE ZONE: Proponic Acid Pool Fire

TABLE NO. 6.1: FATAL THERMAL RADIATION EXPOSURE LEVELS

Radiation Level Seconds Exposure For A % Fatality Levels Kw/M2 1 % 50 % 99 % 1.6 500 1300 3200 4.0 150 370 930 12.5 30 80 200 37.5 8 20 50

TABLE NO. 6.2: EFFECTS OF THERMAL RADIATION ON UNPROTECTED SKIN. Radiation Level Duration Period Seconds Before (Kw/M2) Pain Is Felt Blistering Starts 22 02.0 03.0 18 02.5 04.3 11 05.0 08.5 08 08.0 13.5 05 16.0 25.0 2.5 40.0 65.0 Below 2.5 Prolonged exposure can. Be tolerated.

IMPACT

a) Acetic acid and Propionic acid release followed by pool fire is estimated to be resulting 30 % and 31 % damage within 9.9 and 10.5 m radius zone respectively. b) Thermal radiations of 10 Kw/m2 from Acetic acid and Propionic acid are likely within 10 and 20 m radius zone respectively , which is mainly tank farm . c) It is reasonable to assume that well trained employees within the vulnerable zone are likely to move out of this zone within 90 seconds hence avoiding fatality. d) Continued exposure to heat flux of 4.0 KW/m2 level of heat flux or greater is considered sufficient to cause injury. Hence, injury risk is likely up to 10 m around the pool fire e) It may be noted that thermal effect of a pool fire is usually limited to a distance of 2 to 3 times the pool diameter. f) Acetic acid and Propionic acid pool fire impact at Assembly point will not be significant .

6.3 OVER PRESSURE IMPACT

ALOHA modeling of the vulnerable zones are superimposed on satellite site maps called MARPLOT for estimation of impact

Flammable vapors cloud in flammable range finding source of ignition resulting into vapor cloud explosion is considered as Worst case scenario and following Table indicates the over pressure impact.

TABLE NO.6.3: EFFECT OF BLAST PRESSURE WAVE.

OVER PRESSURE (bar) EFFECTS 0.01 Shattering of glass windows. Failure of panels. 0.03 Shattering of asbestos siding. 0.1 Collapse of steel framing panels. 0.3 Shearing of brick walls (8-12 inches).

Any of the events studied Explosion is not likely as flammable cloud is not formed .

SECTION 7: RISK ESTIMATION

7.1 INDIVIDUAL RISK

INDIVIDUAL RISK (IR) = (1 /N) ∑ Ii x f Where N = number of persons i = Incident identification number I, = impact of Incident i Fi = frequency of the i incident

Manpower Approx. 80 (65 + 15) skilled and unskilled .The proposed activity required 30-50 workers during construction and during operation 80,

THREAT AT ASSEMBLY POINT : Thermal Radiation Estimates at the AP : Max Thermal Radiation: 0.114 kW/(sq m) Max Concentration: Outdoor: 387 ppm and Indoor: 135 ppm

Average individual risk estimated at assembly point is less than 1.25 x 10 -6

TABLE 7.1: INDIVIDUAL FATALITY CRITERIA

Individual Fatality (IR) Individual Fatality Criteria 1 × 10-4 per year This contour remains on-site. 1 × 10-5 per year This contour extends into industrial developments only. 1 × 10-6 per year This contour extends into commercial and industrial developments only.

TABLE 7.2: INDIVIDUAL RISK RESULTS*

Downwind Contour Individual Fatality Affect Remarks No. (IR) Distance (M) 1. 4.3 × 10-4 per year. <10 This contour remains within the site 2. 4.4 × 10-5 per year. <10 This contour remains within the site 3. 4.4 × 10-6 per year. 12 This contour remains within the industrial area

7.2 SOCIETAL RISK

Figure No.7.1 MARPLOT:VULNERABLE ZONE: Acetic acid Pool fire

FIGURE NO. 7.2:SITE SRROUNDING

FIGURE NO. 7.3:SITE SRROUNDING

TABLE 7.3: SOCIETAL RISK

Sr. No. Of Cumulative Release event No. fatality frequency 1. Acetic acid pool fire 0 1.0 × 10-4 2 Propionic Acid pool fire 0 2.0. × 10-4 3 Furnace oil pool fire 0 3.0 × 10-4 -4 4 Diesel pool fire 0 4.0 × 10

SECTION 8: RISK MITIGATION MEASURES

To address the residual risk issues risk mitigation measures are suggested which includes preventive as well as protective measures to achieve reasonable acceptable risk level.

1. Accidental spill control

1.1 Provide dyke for accidental spill containment for above ground storage tanks with mobile pump arrangement to transfer the accidental spill contained in dyke to emergency spare tank.

1.2 Provide overflow line of the day tank back to the storage tank of the origin in order to avoid any spill hazard .

1.3 Provide arrangement to avoid any organic contaminated water generated during fire fighting operation going to storm drain without proper treatment 1.4 Provide acid / alkali proof tile lining flooring at corrosive chemicals handling area . 2 FIRE PROTECTION

2.1 Provide Fire hydrant system, Portable fire Extinguishers, Personnel Protective Equipment (PPE) especially SCBA sets , Safety Shower & Eye Wash Fountain and safety training .

2.2 Avoid any sources of ignition and fire hydrant at Parking area for road tankers of Acetic acid , Propionic acid and fuels.

3. DUST HANDLING

3.1 Carry out powder safety tests .

3.2 Ensure absence of any flammable organic vapors at fine powder handling equipments such as desintigrator , sifter and packing in this section to eliminate the possibility of formation of Hybrid powder mixture .

3.3 Provide explosion vent at the spray dryer and locate the vent to safe place to avoid any secondary dust explosion .

3.4 Provide electricals to suit the IP class of the powders handled in the area .

4. General

4.1 Store chemicals considering the compatibility and reactivity hazards at tank farm .

4.2 Provide effective measures for prevention of static charge accumulation to dangerous level . . 4.3 Fugitive emissions over reactors, dusting etc., are to be collected through hoods & ducts by induced draft, and controlled by scrubber/dust collector.

4.3 Adopt standard engineering practices , System of leak detection and repair (LDAR) programme especially for solvents Should be developed 4.4 Monitor concentration of air born chemicals within the prescribed limits. 4.5 Handling alkaline materials at high temperature for long years of service may result in Caustic imbrittlement and weaken the MS equipment leading to rupture at week points .especially welding joints .Hence Avoid MS for such service . 4.6 Transport of hazardous materials / waste -Display of class labels , Valid registration to carry the said goods , PPE, First aid box, tool box, safety equipments, antidotes as may be necessary to contain an accident , TREM card , MSDS , Training to drivers and Specified predetermined routes. 5 Disaster management plan A practical working document on site disaster control plan to address the residual risk issues is drawn as per the format specified under "The the MSIHC Rules, 1989" is prepared and enclosed as annexure 6

FIGURE NO:8.1 DESASTER MANAGEMENT PLAN

ANNEXURE 1: GLOSSARY

Acceptance : Defines the level of risk to which an individual is exposed, as either tolerable Criteria (Risk). (negligible risk), intolerable or within the ALARP region.

Consequence : This is the severity associated with an event in terms of toxic doses, fire or explosion etc., i.e. the potential effects of a hazardous event.

ERPG : The Emergency Response Planning Guidelines. ERPG 1: 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: 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: 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.

Frequency : This is the number of occurrences of an event expressed per unit time. It is usually expressed as the likelihood of an event occurring within one year.

Hazard : A physical situation with the potential for human injury, damage to property, damage to the environment or some combination of these.

Hazardous : The identified isolatable sections and/or those which have been broken down into Scenario scenarios for specific items of equipment.

IDLH : Immediately Dangerous To Life And Health. The maximum concentration would not cause any escape imparting symptoms or irreversible health effects to a person exposed for 30 minutes.

Individual Risk : The frequency at which an individual may be expected to sustain a given level of harm from the realization of specified hazards.

Individual Risk : As IR (Individual Risk) is calculated at a point, calculating the IR at many points Contours. allows the plotting of IR contours, these being lines that indicate constant levels of risk. Most commonly used are the 1 chance per million-year contour and the 10 chances per million-year contour.

Individual Risk : Individual risk with “harm” measured in terms of fatality. It is calculated at a particular Of Fatality. point for a stationary, unprotected person for 24 hours per day, 365 days per year. Normally measured in chances of fatality per million years.

Individual Risk : Similar to individual risk of fatality, however with “harm” measured in terms of injury. Of Injury.

Isolatable Section. : A system of pipes or vessels containing the hazardous materials that are bounded by specific isolation points.

Isolation Point. : A point in the process, which can be used to isolate one part of the process from the rest of the system.

LEL. : Lower Flammability Limit. Expressed as % by volume of flammable gas in air. This is the minimum concentration of gas in air mixture which can ignite. Gas air mixtures below this concentration do not ignite.

Probability. : The expression for the likelihood of an occurrence of an event or an event sequence or the likelihood of the success or failure of an event on test or demand. By definition, probability must be expressed as a number between 0 and 1.

Quantitative : A risk assessment undertaken by combining quantitative evaluations of event Risk Assessment. frequency and consequence.

Risk. : The combination of frequency and consequences, the chance of an event happening that can cause specific consequences.

Risk Reduction. : The process of risk assessment coupled to a systematic consideration of potential control measures and a judgment on whether they are reasonably practicable to implement.

TEEL : Temporary Emergency Exposure Limits. TEEL-1: Maximum concentration in air below which it is believed nearly all individuals could be exposed without experiencing other than mild transient health effects or perceiving a clearly defined objectionable odor.

TEEL-2: Maximum concentration in air below which it is believed nearly all individuals could be exposed without experiencing or developing irreversible or other serious health effects or symptoms that could impair their abilities to take protective action.

TEEL-3: Maximum concentration in air below which it is believed nearly all individuals could be exposed without experiencing or developing life-threatening health effects.

UFL : Upper Flammability Limit. Expressed as % by volume of flammable gas in air. This is the maximum concentration of gas in air mixture which can ignite. Gas air mixtures above this concentration do not ignite.

Vapor Cloud : An accidental release of flammable liquid or gas, there is possibility that it may form a Explosion cloud which can spread along the wind direction. Delayed ignition of the cloud away from the source of release results in Vapor cloud explosion (flash back) and associated blast/ over pressure effects.

ANNEXURE 2: ABBREVIATIONS AIChE. American Institute Of Chemical Engineers. ALARP. As Low As Reasonably Practicable. BTU. British Thermal Unit. CCPS. Centre For Chemical Process Safety. DMP. Disaster Management Plan ECC. Emergency Control Centre. EIA. Environmental Impact Assessment. EMP. Environment Management Plan. F & E I. Fire And Explosion Index. HAZOP. Hazard Operability. HSD. High Speed Diesel. IDLH. Immediately Dangerous To Life And Health. IPL. Independent Protection Layer. KCal. Kilocalories. lb. Pound. LOC. Level Of Concentration. Lopa. Layers Of Protection Analysis. MCA. Maximum Credible Accident. MF. Material Factor. MIDC. Maharashtra Industrial Development Corporation. MoEF. Ministry Of Environment And Forests. MSDS. Material Safety Data Sheet. MT. Metric Ton. NFPA. National Fire Protection Association. PFD. Probability Of Failure On Demand. PHA. Preliminary Hazard Analysis. QRA. Quantative Risk Assessment. RH. Risk Assessment And Hazard Management. SIF. Safety Integrated Function. TEEL. Temporary Emergency Exposure Limits. UK. United Kingdom.

29 ANNEXURE 3: REFERENCES

1. Technical EIA Guidance Manual for Synthetic Organic Chemicals, prepared for the Ministry of Environment and Forests Government of India.

2. MOND INDEX Manual 1993.

3. “TNO Yellow Book”. Method for calculation of the Physical Effects of the escape of Dangerous Material (Liquid & Gases) Published by the Directorate General of Labour, Ministry of Social affair, Netherlands (1979).

4. Frank P. Lees – Loss Prevention in the Process Industries – Volume I.

5. Risk Assessment for Process Industries, Loss Prevention News April - June 2001.

6. Techniques for assessing Industrial Hazards (World Bank Technical Paper, ISSN 0253; No. 55).

7. Ref. Table 3.8 – Vapor Pressure of Organic Compounds, R. H. Perry, C.C., Chemical Engineers Handbook, 5th Edition (1969) McGrow – Hill Book co. (New York, London).

8. Guideline for Quantitative Risk Assessment “Purple Book”.

ANNEXURE 4: DOW FIRE & EXPLOSION INDEX WORKSHEET. PLANT: Tank farm MATERIALS AND PROCESS: Propionic acid MATERIAL FACTOR: 14

PENALTY FACTOR PENALTY FACTOR USED RANGE 1. GENERAL PROCESS HAZARDS. Base Factor. 1.0 1.0 A. Exothermic Chemical Reactions. 0.30 to 1.25 00 B. Endothermic Process. 0.20 to 0.40 00 C. Material Handling & Transfer. 0.25 to 1.05 0.20 D. Enclosed or Indoor Process Unit. 0.25 to 0.90 00 E. Access. 0.20 to 0.35 00 F. Drainage and Spill Control. 0.25 to 0.50 0.0

General Process Hazards Factor (F1). – 1.2

2. SPECIAL PROCESS HAZARDS. Base Factor. 1.0 1.0

A. Toxic Materials. 0.20 to 0.80 0.6 B. Sub – Atmospheric Pressure. 0.50 00 C. Operation in or Near Flammable Range Inerted. – – 1. Tank Farm Storage Flammable Liquids. 0.0 – 2. Process Upset or Purge Failure. 0.3 – 3. Always in Flammable Range. – – D. Dust Explosion. 0.25 to 2.0 00 E. Pressure Operating atmospheric; Relief Setting. 00 F. Low Temperature. 0.20 to 0.50 00

G. Quantity of Flammable/UnstableQuantity 250 KL, Hc 8.883 – –  103 BTU/Lb. 1. Liquid or Gases in Process. – – 2. Liquid or gases in Storage. – 0.8 3. Combustible Solids in Storage. – – H. Corrosion and Erosion. 0.10 to 0.75 0.1 I. Leakage – Joint and packing. 0.10 to 1.50 0.1 J. Use of fired heaters. – 00 K. Hot Oil Heat Exchange system > 210 ft. 0.15 to 1.15 00 L. Rotating Equipment. 0.5 00

Special Process Hazards Factor (F2) – 2.6

Unit Hazards Factor (F1  F2 = F3). 3.12

Fire and Explosion Index (F3  MF) (F & IE). 43.68 THE DEGREE OF HAZARD. LIGHT RADIUS OF EXPOSURE. 11.2 meter DAMAGE FACTOR. 0.32 T = {250 +125×(1 + 1.2 + 2.6 )}/100 = 8.50 T Category II.

PLANT: Tank Farm MATERIALS AND PROCESS: ACETIC ACID. MATERIAL FACTOR: 14

General Process Hazards Factor (F1). – 1.20

2. SPECIAL PROCESS HAZARDS. Base Factor. 1.0 1.0 A. Toxic Materials. 0.20 to 0.80 0.6 B. Sub – Atmospheric Pressure. 0.50 00 C. Operation in or Near Flammable Range Inerted. – – 1. Tank Farm Storage Flammable Liquids. 0.0 – 2. Process Upset or Purge Failure. 0.3 – 3. Always in Flammable Range. – – D. Dust Explosion. 0.25 to 2.0 00 E. Pressure Operating atmospheric; Relief Setting. 00 F. Low Temperature. 0.20 to 0.50 00 G. Quantity of Flammable/ Unstable Material Quantity – – 3 150 kl ., Hc 5.6  10 BTU/Lb. 1. Liquid or Gases in Process. – – 2. Liquid or gases in Storage. – 0.5 3. Combustible Solids in Storage. – – H. Corrosion and Erosion. 0.10 to 0.75 0.1 I. Leakage – Joint and packing. 0.10 to 1.50 0.1 J. Use of fired heaters. – 00 K. Hot Oil Heat Exchange system > 210 ft. 0.15 to 1.15 00 L. Rotating Equipment. 0.5 00

Special Process Hazards Factor (F2) – 2.3

Unit Hazards Factor (F1  F2 = F3). 2.76

Fire and Explosion Index (F3  MF) (F & IE). 38.6 THE DEGREE OF HAZARD. LIGHT RADIUS OF EXPOSURE. 9.9 meter DAMAGE FACTOR. 0.30 T = {250 + 75 × (1 + 1.2 + 2.3 )}/100 = 5.87 T Category I.

PLANT: TANK FARM. MATERIALS AND PROCESS: FURNACE OIL. MATERIAL FACTOR: 10.

PENALTY FACTOR PENALTY FACTOR USED RANGE 1. GENERAL PROCESS HAZARDS Base Factor. 1.0 1.0 A. Exothermic Chemical Reactions. 0.30 to 1.25 0.0 B. Endothermic Process. 0.20 to 0.40 0.0 C. Material Handling & Transfer. 0.25 to 1.05 0.2 D. Enclosed or Indoor Process Unit. 0.25 to 0.90 0.0 E. Access. 0.20 to 0.35 0.0 F. Drainage and Spill Control. 0.25 to 0.50 0.0

General Process Hazards Factor (F1). 1.2

2. SPECIAL PROCESS HAZARDS Base Factor. 1.0 1.0 A. Toxic Materials. 0.20 to 0.80 0.2 B. Sub – Atmospheric Pressure. 0.50 0.0 C. Operation in or Near Flammable Range Inerted. – – 1. Tank Farm Storage Flammable Liquids. 0.0 – 2. Process Upset or Purge Failure. 0.3 – 3. Always in Flammable Range. – 0.0 D. Dust Explosion. 0.25 to 2.0 0.0 E. Pressure Operating atmospheric; – 0.0 F. Low Temperature. 0.20 to 0.50 0.0 G. Quantity of Flammable/ Unstable Material Quantity – – 3 100 kl , Hc 18.7  10 BTU/Lb. 1. Liquid or Gases in Process. – – 2. Liquid or gases in Storage. – 0.33 3. Combustible Solids in Storage. – – H. Corrosion and Erosion. 0.10 to 0.75 0.1 I. Leakage – Joint and packing. 0.10 to 1.50 0.1 J. Use of fired heaters. – 0.0 K. Hot Oil Heat Exchange system > 210 ft. 0.15 to 1.15 0.0 L. Rotating Equipment. 0.5 0.0

Special Process Hazards Factor (F2) 1.73

Unit Hazards Factor (F1  F2 = F3). 2.07

Fire and Explosion Index (F3  MF) (F & IE). 20.7 THE DEGREE OF HAZARD LIGHT RADIUS OF EXPOSURE 5.3 meter. DAMAGE FACTOR 0.12

PLANT: DIESEL OIL DRUMS MATERIALS AND PROCESS: DIESEL OIL. MATERIAL FACTOR: 10.

General Process Hazards Factor (F1). 1.2

2. SPECIAL PROCESS HAZARDS Base Factor. 1.0 1.0 A. Toxic Materials. 0.20 to 0.80 0.2 B. Sub – Atmospheric Pressure. 0.50 0.0 C. Operation in or Near Flammable Range Inerted. – – 1. Tank Farm Storage Flammable Liquids. 0.0 – 2. Process Upset or Purge Failure. 0.3 – 3. Always in Flammable Range. – 0.0 D. Dust Explosion. 0.25 to 2.0 0.0 E. Pressure Operating atmospheric; – 0.00 F. Low Temperature. 0.20 to 0.50 0.0 G. Quantity of Flammable/ Unstable Material Quantity – – 3 20 kl , Hc 18.7  10 BTU/Lb. 1. Liquid or Gases in Process. – – 2. Liquid or gases in Storage. – 0.25 3. Combustible Solids in Storage. – – H. Corrosion and Erosion. 0.10 to 0.75 0.1 I. Leakage – Joint and packing. 0.10 to 1.50 0.1 J. Use of fired heaters. – 0.0 K. Hot Oil Heat Exchange system > 210 ft. 0.15 to 1.15 0.0 L. Rotating Equipment. 0.5 0.0

Special Process Hazards Factor (F2) 1.65

Unit Hazards Factor (F1  F2 = F3). 1.98

Fire and Explosion Index (F3  MF) (F & IE). 19.8 THE DEGREE OF HAZARD LIGHT. RADIUS OF EXPOSURE 5 meter. DAMAGE FACTOR 0.1

ANNEXURE 5: MOND INDEX WORKSHEET.

Annexure 6

HAZOP STUDY

FINE ORGANIC INDUSTRIES LIMITED

Plot No E - 73, Additional Patalganga MIDC, Dist. Raigad,Maharashtra.

2018

CONTENTS

Sr.No. Description Page No.

6.1 Methodology 48

6.2 Process , flow chart , reactions, by products 49

6.3 Material balance 51

6.4 Compatibility and reactivity hazards 51

6.5 Preliminary hazard analysis 56

6.6 HAZOP work sheets 58

6.1 Methodology

The methodology used as per Hazard Identification and Hazard Analysis Techniques of Hazard Identification and Risk Analysis – Code of Practice IS 15656: 2006.

Identification of hazards by HAZOP study is carried out for 9 nodes, The thrust area being the environmental issues in the proposed activities.

. Hazard are identified and risk evaluated for each identified hazard on the scale 1 to 25 using the hazard rating matrix given in table 2.12

HAZARD RATING MATRIX.

SEVERITY Very High. Moderate Slight Nil. High (4) (3) (2) (1) (5) Very Likely. (5) 25 20 15 10 05 Likely. (4) 20 16 12 08 04 Quite Possible (3) 15 12 09 06 03 Possible. (2) 10 08 06 04 02

PROBABILITY Not Likely. (1) 05 04 03 02 01

6.2 Process description flow chart and reactions

Brief Process Description:

Process I - Spray Drying method

It is a Neutralization process where Propionic acid is neutralized with mixture of Hydrated Lime + water in case of Calcium Propionate. Whereas in case of Sodium Propionate Propionic acid is neutralized with Sodium hydroxide (Caustic soda) + water, with suitable process parameters. All the starting raw materials are mixed till they get completely neutralized. After this the neutralized mixture is passed through a Filter press to obtain the semi-finished product in liquid phase. This is then spray dried to obtain the Calcium Propionate / Sodium Propionate powder as finished product. The steam formed due to drying process will be scrubbed + condensed out to obtain all the traces of product, if any, and it will be again recycled at the stage of neutralization of next batch of product.

Water used in the scrubber will get saturated over a period of cycles & once it reaches the saturation level then it will be charged to the mfg process at the stage of neutralization of next batch of product. Process block diagram of Process I: Spray Drying method

Figure 3: Salts of Propionic acid by Spray Drying method

Process II - Mixing method

It is an also a Neutralization process where alkaline salts are mixed with Propionic acid in a blender. Due to chemical reaction steam is generated which is passed through a condenser and the condensate is collected separately. This condensate can be used in Process I at the stage of neutralization for a fresh batch of Calcium Propionate.

After blender the semi-finished product is send to Disintegrator to get the final product in desired size. After this product is send to sifter so as to obtain the granular grade of Calcium Propionate & Fine grade of Calcium Propionate.

Process block diagram of Process II: CALCIUM PROPIONATE MANUFACTURINGPROCESS

BY MIXING PROCESS

Figure 4: Calcium Propionate Manufacturing Process

6.3 Material Balance Material balances are detailed in the EIA report. Product wise raw material consumption and waste generation kg/kg Sr.no. Product Sodium Calcium Calcium Propionate Propionate Acetate powder Granules /Powder Batch size kg 4,500 4,080 3,160 Raw materials / waste generated kg / kg of finished product 1 Propionic acid 0.740 0.765 2 Sodium Hydroxide 0.455 3 Lime / Quick Lime 0.367 4 Lime 0.506 5 Acetic acid 0.759 6 Water 1.025 1.898 7 Water of condensation generated 1.222 0.132 8 Filterate 3.043 9 Sludge 0.122

6.4 Compatibility/ reactivity hazard worksheet

(Of chemicals unintended mix up predicted hazards report ACETIC ACID, GLACIAL AIR, COMPRESSED CALCIUM CARBONATE CALCIUM HYDROXIDE PROPIONIC ACID SODIUM HYDROXIDE, SOLID WATER ------

ACETIC ACID, GLACIAL mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

AIR, COMPRESSED mixed with ACETIC ACID, GLACIAL - PREDICTED HAZARDS: May be hazardous but unknown POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

AIR, COMPRESSED mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

CALCIUM CARBONATE mixed with ACETIC ACID, GLACIAL -

PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) Reaction liberates gaseous products and may cause pressurization POTENTIAL GASES: Carbon Dioxide --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

CALCIUM CARBONATE mixed with AIR, COMPRESSED - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

CALCIUM CARBONATE mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

CALCIUM HYDROXIDE mixed with ACETIC ACID, GLACIAL - PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) Reaction liberates gaseous products and may cause pressurization POTENTIAL GASES: Carbon Dioxide --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

CALCIUM HYDROXIDE mixed with AIR, COMPRESSED - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

CALCIUM HYDROXIDE mixed with CALCIUM CARBONATE - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

CALCIUM HYDROXIDE mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

PROPIONIC ACID mixed with ACETIC ACID, GLACIAL - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES:

No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

PROPIONIC ACID mixed with AIR, COMPRESSED - PREDICTED HAZARDS: May be hazardous but unknown POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

PROPIONIC ACID mixed with CALCIUM CARBONATE - PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) Reaction liberates gaseous products and may cause pressurization POTENTIAL GASES: Carbon Dioxide --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

PROPIONIC ACID mixed with CALCIUM HYDROXIDE - PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) Reaction liberates gaseous products and may cause pressurization POTENTIAL GASES: Carbon Dioxide --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

PROPIONIC ACID mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

SODIUM HYDROXIDE, SOLID mixed with ACETIC ACID, GLACIAL - PREDICTED HAZARDS: Reaction liberates gaseous products and may cause pressurization Reaction may be particularly intense, violent, or explosive Reaction products may be corrosive Reaction products may be flammable Reaction products may be toxic POTENTIAL GASES: Acid Fumes Base Fumes --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

SODIUM HYDROXIDE, SOLID mixed with AIR, COMPRESSED - PREDICTED HAZARDS: May be hazardous but unknown POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

SODIUM HYDROXIDE, SOLID mixed with CALCIUM CARBONATE -

PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

SODIUM HYDROXIDE, SOLID mixed with CALCIUM HYDROXIDE - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

SODIUM HYDROXIDE, SOLID mixed with PROPIONIC ACID - PREDICTED HAZARDS: Reaction liberates gaseous products and may cause pressurization Reaction may be particularly intense, violent, or explosive Reaction products may be corrosive Reaction products may be flammable Reaction products may be toxic POTENTIAL GASES: Acid Fumes Base Fumes --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

SODIUM HYDROXIDE, SOLID mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

WATER mixed with ACETIC ACID, GLACIAL - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with AIR, COMPRESSED - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with CALCIUM CARBONATE - PREDICTED HAZARDS: Reaction liberates gaseous products and may cause pressurization POTENTIAL GASES: Carbon Dioxide --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with CALCIUM HYDROXIDE - PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with PROPIONIC ACID - PREDICTED HAZARDS: No known hazardous reaction POTENTIAL GASES: No gases predicted. --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with SODIUM HYDROXIDE, SOLID - PREDICTED HAZARDS: Exothermic reaction at ambient temperatures (releases heat) Reaction liberates gaseous products and may cause pressurization Reaction products may be corrosive Reaction products may be toxic POTENTIAL GASES: Base Fumes --- END OF HAZARDS FOR THIS MIXTURE PAIR ---

WATER mixed with itself - INTRINSIC REACTIVE HAZARDS: No reaction expected. --- END OF HAZARDS FOR THIS ITEM ---

6.5: Preliminary hazard analysis The site is existing operating plant . Sr.No. Hazard during operating stage of the plant Status Natural Cyclone √ Causes Earth quake √ Land slide √ Flooding - heavy rain , √ Physical Noise √ hazards Radiation (UV , radioactive materials ) X Extreme temperatures √ Vibration √ Material handling operations. √ Steam pressure piping failure/ boiler drum failure. √ Boiler explosion. √ Biohazards Epidemics /Communicable diseases by pests ,insects ,rodents √ Animal / snake bites √ Occupational health hazards at industry √ Electrical Transformer oil fire /explosion √ hazard Lightening strike √ fires due to Short circuit √ Power outage √ Hazardous AC , Refrigerators , Air conditioners Units fire/ explosion √ substances and Diesel fire at DG set √ wastes Foul odor at dumping sites √ Hazardous waste uncontrolled disposal √ Hazardous waste uncontrolled disposal - e –waste batteries √ Welding cutting flammable gas cylinders fire /explosion √ LPG / fuel cylinder at canteen failure fire /explosion √ Release of toxic gas at (such as Chlorine) at Cooling tower √

Site decontamination X Smoke in fire , acrid gases in fire , dumping yard √ Vehicles fuel fire √ Mechanical Failure of machinery and equipment √ Lack of safety guards in machines √ Poor maintenance of machinery and equipment √ power driven tools , saws , grinders ,d abrasive cutting wheels √ scaffolding –fixed and portable failure √ structural failure √ Truck and transport vehicles √

Sr.No. Hazard during operating stage of the plant Status Storages & Spill Toluene at tank farm leading to fire /explosion √ process Uncontrolled Reaction exotherm pressurization / explosion √ operations Static charge as source of ignition leading to fire/explosion √ Hydrogen chloride gas release at vent √ Dust explosion √ Hazardous waste spill hazard √ Compatability and reactivity hazard at chemical store √ Frequent causes Being struck by falling object √ of accidents Caught in or compressed √ during Cranes , winches , hoisting and hauling equipments failure √ construction Dusting √ Activity Electricity ( electrocution ) √ Fall from height, √ uncontrolled explosion during demolition / land development

Hit by sharp objects

Injuries during Handling heavy objects

Lack of PPE , housekeeping practices , safety signs √ Oxygen deficiency in confined spaces √ Paint/ thinner cleaners, pesticides , waste oil , flammable √ combustible materials fire at store Poor illumination √ Slipping on wet surfaces

Snapping cables , ropes , chains , slings , hooks , chains √ Struck by moving objects √ Welding fumes and Radiations

Ergonomics & Repetitive ,monotonous ,excessive workload , strain injuries √ psychosocial Mental stress , human relations ( aggressive behavior , alcohol √ hazards and drug abuse , violance ) Poverty , low wages , lack of education √ Long working hours , shift work , temporary employment √ Security threats

Escalating the designed event during MOCK drill √ Ot her s Power outage to emergency equipments / cable failure √

Stampede during evacuation /at assembly point √

Spreading Rumors √

Organic contaminated water generated during fire fighting √ operations, sprinkler operation, spill / floor washing may enter storm drain.

6.4 TABLE NO. 3.1: SAFETY PROPERTIES

Sr. Name CAS LEL UEL Flash Boiling NFPA Hazard TLV STEL IDLH oral der LD50 inhal

No. Point Point Index LD50 LC50

% % 0c 0c Nh Nf Nr ppm ppm ppm mg/kg. ml/kg. mg/m3 1 Acetic acid # 64-19-7 5.4 16 39 118 2 2 0 10 15 50 5620 3310 5620 2 Calcium Propionate 4075-81-4 ------3 Calcium Acetate 62-54-4 - - - >160 * ------4 Diesel 68476-34-6 0.6 7.5 32 -62 >150 0 2 0 5 10-15 - 7.5 - - 5 Furnace Oil HC Mixture 0.7 5 >65 175-325 1 2 0 200 - - >500 - - 6 Hydrated Lime 1305-62-0 - - - - 5-15 2 0 2 5 mg/m3 - - - g/kg 7 Lime 1305-78-8 - - - - 25 3 0 1 2 mg/m3 - - - - mg/m3 8 Propionic acid 79-09-4 2.1 12 54 141 3 2 1 10 15 - 2600 - - 9 Sodium hydroxide 1310-73-2 - - - - 3 0 1 - - - 500 - - 10 Sodium Propionate 137-40-6 - - >200 ------

0 # Solidifies below 16.6 c , *Decomposes , ** OSHA PEL – TWA 5 mg/m3,total dust , 5 gm/m3 respirable fraction Toxicity indicative criteria - MSIHC rules 1989 , Schedule I part I (a) Sr. Toxicity Oral Toxicity Dermal toxicity Inhalation toxicity No LD 50 (mg/kg) LD50 (mg/kg) LC50 (mg /I) 1 Extremely Toxic <5 <40 <0.5 2 Highly toxic >5-50 >40-200 >0.5-2.0 3 Toxic >50-200 >200-1000 >2-10

6.5 HAZOP worksheets NODE 1 O50 F 7 : Propionic acid storage tanks DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 250 kl capacity 5 tanks of Propionic acid Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures None. Flow. No flow of Propionic No material in the Delayed operation. LG. 2 3 6 Log book record. acid during road road tanker or tanker unloading to storage tank. storage tank or Delayed operation. Preventive 3 3 9 transfer to day tank Valve failure/ maintenance. from storage tank. blockage. Spill hazard during SOP for blockage blockage removal PPE. removal operation. Line blockage. operation. Training. 3 3 9 Delayed operation. Transfer pump Preventive failure (loss of Delayed operation. maintenance. 3 3 9 power, impeller came off or corroded etc.). Human error. Supervision.

More. Flow. More flow of Valve Delayed operation. LI at storage tank. 3 3 9 Preventive maintenance. Propionic acid during malfunctioning. transfer to day tank Improved from storage tank. Human error. supervision.

Less. Flow. Less flow of Valve Delayed operation. LI at storage tank. 3 3 9 Preventive maintenance. Propionic acid during malfunctioning. transfer to feed tank Improved from storage tank. Human error. supervision.

Reverse. Flow. Reverse flow of line Power failure during Delayed operation. NRV in discharge 3 2 6 Preventive maintenance. hold up . transfer to plant line. As Well As. Flow. As well as. Rust, dirt etc. Disturbed operation. Strainer in supply 2 3 6 Preventive maintenance. line.

Fire/ explosion hazard at Propionic acid tank farm

Other. Flow. Release of liquid/ Pump land leak. Spill release of Propionic Open area. 4 3 12 Monitor the work place vapors. acidvapors. air born concentration of Gasket failure. Formation of flammable chemicals within mixture with air. prescribed limit. Sampling. Fire/ explosion hazard if finds source of ignition. Provide leak detection Vent release. Health hazard due to system. minor leaks / vapors emissions at work place.

Other. Flow. Large spill of Failure of the vessel, Spill of flammable Supervision. 5 4 20 Revise “On Site Propionic acid at tanker etc. Due to Propionic acid at tank Emergency Plan” based tank farm. impact/ mechanical farm ,Pool fire UG tank. on MCLS Study. failure. Fire/explosion hazard at Curb wall for tank farm if the containment. Consider periodic Leak due to external flammable vapors finds checking of soil corrosion of tank source of ignition. condition at the tank.

NODE 1 OF 7 : Propionic acid storage tanks DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 250 kl capacity 5 tanks of Propionic acid Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures Other. Flow. Large spill of Propionic acid is a Soil pollution Corrosion resistant 5 4 20 Avoid Organic Propionic acid at colorless liquid with a Health hazard due to painting to external contaminated water tank farm. pungent odor. The odor minor leaks / vapors surface of buried generated during fire threshold is 0.16 ppm emissions , odor tank fighting operations issues at work place. Fire fighting system. entering storm drain . Other than Flow Material other Accidental mix up. Depends on the mix Dedicated piping, 3 3 9 than intended in up components. hence, not likely. tank. Human error. Reactivity and compatibility hazards Supervision. due to accidental spill and mix up at Process control tank farm / drain check. More. Temperature. More temperature Temperature indicator Release of vapors at Supervision. 2 3 6 Regular calibration of at Propionic acid malfunctioning. vent.Fire / explosion instrumentation. storage tank. hazard on propionic acid release as above 54°C explosive vapour/air mixtures may be formed also it Attacks many metals forming flammable/explosive gas (hydrogen ). Less. Temperature. Less Winter season. Freezing not 3 3 9 – Temperature. anticipated. More. Pressure. More Pressure. More rate of pumping in Pressurization. Vent inspection. 4 3 12 Preventive maintenance. and vent blockage.Vent blanked off./Plastic bag over vent. /Vent choked/Flame arrestor choked/Vent connected to water seal/ too small/ modified/Flexible tubing connected to vent.

NODE 1 OF 7 : Propionic acid storage tanks DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 250 kl capacity 5 tanks of Propionic acid Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures Less. Pressure. Less Pressure. More rate of Implosion hazard. Vent inspection. 4 3 12 Preventive maintenance. pumping out and vent blockage.

More Phase. Increase in phases. Moisture/ water in Disturbed operation/ Rain cap at vent. 2 2 4 feed rain. quality issue. As Well As. Composition Impurities. Contamination in Disturbed operation. Dedicated piping. 3 2 6 tanker. Process control Supply source. checks.

More. Level. More Level. More feed in error to Spill hazard. High level interlock 5 3 15 SOP. day tank in feed line. Less. Level. Less Level. Less material in the Starving of pump Low level interlock 3 3 9 tank. suction. in feed line.

Other. Hazardous Cleaning of the Inspection, repair, Residual vapors in SOP. 3 3 9 Work permit. chemicals piping/ tank/ maintenance work. the equipment/ Handling. equipments. External corrosion. piping fire hazard. Supervision.

Health hazard.

Other. Hazardous Transportation road Transportation of Fire /explosion Spark arrestor. 4 4 16 Training to drivers. chemicals mishap Flammable , toxic Health hazard on Display of class Specified predetermined materials transport exposure labels. Valid routes. on road outside and registration to carry Antidotes as may be at site the said goods. necessary to contain an PPE, First aid box, accident. tool box, safety equipments, TREM card. MSDS

NODE 2 OF 7 : TANK FARM. Sub node 1.1 Acetic acid tank DESIGN INTENT : Receipt, storage & transfer to plant of Acetic acid at tank farm. Guide Parameter Deviation Cause Consequence Protection Measures S P R Recommendations Word None. Flow. No flow of No material in the road Delayed operation. LG. 2 3 6 Log book record. Acetic Acid tanker or storage tank. during road tanker Valve failure/ blockage. Delayed operation. Preventive 3 3 9 unloading to maintenance. storage tank or Line blockage. SOP for blockage removal transfer to day Transfer Pump failure PPE. operation. tank from (loss of power, impeller Spill hazard during Training. 3 3 9 storage tank. came off or corroded blockage removal etc.). operation. Preventive Human error. maintenance. 3 3 9 Delayed operation.

Delayed operation. Supervision. More. Flow. More flow of Valve malfunctioning. Delayed operation. LI at storage tank. 3 3 9 Preventive maintenance. Acetic Acid during transfer Human error. Improved supervision. to day tank from storage tank. Less. Flow. Less flow of Valve malfunctioning. Delayed operation. LI at storage tank. 3 3 9 Preventive maintenance. Acetic Acid during transfer Human error. Improved supervision. to feed tank from storage tank. Reverse. Flow. Reverse flow. Dip pipe in the tank. Spill hazard. NRV in supply line. 3 2 6 Preventive maintenance. Siphon in case of line failure. As Well Flow. As well as. Rust, dirt etc. Disturbed operation. Strainer in supply line. 2 3 6 Preventive maintenance. As. Other Flow. Other than. Impurity / accidental Depends on the mix Dedicated piping. 3 3 9 Than. mix up. up components. Hence, not likely. Supervision. Human error. Process control check.

NODE 2 OF 7 : TANK FARM. Sub node 1.1 Acetic acid tank DESIGN INTENT : Receipt, storage & transfer to plant of Acetic acid at tank farm. Guide Parameter Deviation Cause Consequence Protection Measures S P R Recommendations Word Other. Flow. Static Static sensitive material Static discharge as Supervision. 5 4 20 Ground all containers during discharge. Acetic Acid transfer by source of ignition in transfer or take precautionary pump. case of any spill and Dip pipe provided in measures against electrostatic vapors coming in feed lines loading. Free fall of Acetic Acid flammable range in the vessel. with air. Fire/ explosion hazard. Other. Flow. Release of Pump land leak. Spill Release of Open area. 4 3 12 Monitor the work place air born liquid/ vapors. Acetic Acid vapors. concentration of chemicals Gasket failure. Formation of within prescribed limit. flammable mixture Sampling. with air. Provide leak detection system. Vent release. Fire/ Explosion hazard if finds source of ignition. Other. Flow. Large spill. Failure of the vessel, Spill hazard. Supervision. 5 3 15 Revise “On Site Emergency tank etc. Due to Dyke fire. Dyke. Plan” based on MCLS Study. impact/ mechanical If the flammable failure. vapors finds source Fire fighting system. Mock Drill to test the of ignition, fire effectiveness of the plan. hazard. Other. Handling. Cleaning of the Inspection, repair, Residual vapors in SOP. 3 3 9 Work permit. piping/ tank/ maintenance work. the equipment/ equipments. piping fire hazard. Supervision. Health hazard. More. Temperature More Temperature indicator Release of vapors at Supervision. 2 3 6 Regular calibration of . temperature at malfunctioning. vent of FB – 1209. instrumentation. Acetic Acid storage tank. Less. Temperature Less Winter season. Freezing likely. 3 3 9 . Temperature. Failure of piping if material is trapped between the valves.

NODE 2 OF 7 : TANK FARM. Sub node 1.1 Acetic acid tank DESIGN INTENT : Receipt, storage & transfer to plant of Acetic acid at tank farm. Guide Parameter Deviation Cause Consequence Protection Measures S P R Recommendations Word More. Pressure. More Pressure. More rate of pumping Pressurization. Vent inspection. 4 3 12 Preventive maintenance. in and vent blockage. Vent blanked off. Plastic bag over vent. Vent choked. Flame trap choked. Vent connected to water seal. Vent too small. Vent modified. Flexible tubing connected to vent. In let of hot recycle liquid. Less. Pressure. Less Pressure. More rate of pumping Implosion hazard. Vent inspection. 4 3 12 Preventive maintenance. out and vent blockage. More Phase. Increase in Moisture/ water in feed Disturbed operation. Rain cap at vent. phases. rain.

As Well Composition Impurities. Contamination in Disturbed operation. Dedicated piping. 3 2 6 As. tanker. Process control checks. Supply source. NRV in inert gas Back flow in inert gas supply line. supply.

More. Level. More Level. More feed in error, Spill hazard. High level interlock in 5 3 15 SOP. excessive recycle feed line. Acetic Acid feed. Less. Level. Less Level. Less material in the Starving of outlet Low level interlock in 3 3 9 tank. pump suction. feed line. Other. Handling. Emergency. Lightening. Tank fire. Lightening arrestor. 4 1 4

NODE 3 OF 7 : FURNACE OIL STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 100 kl capacity of Furnace oil Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures None. Flow. No flow of No material in the Delayed operation. SOP. 2 2 4 Safe Operating Procedures (SOP’s). Furnace Oil road tanker. Log record. from road Spill hazard during Preventive 3 3 9 tanker to Valve/ line choke. blockage removal maintenance. storage tank. Transfer pump operation. (electrical/ Delayed operation. mechanical) problem. Human error. Delayed operation. Supervision. 2 2 4

Less. Flow. Less flow of Blocked flow (e.g., Spill hazard during SOP. 3 3 9 Furnace Oil. plugged line). blockage removal operation. Blockage of piping. More. Flow. More flow of Flow control valve. Disturbed operation. Supervision. 2 3 6 Furnace Oil. Transfers or fails. Open.

Reverse. Reverse Reverse flow Power failure. Reverse flow from NRV. 3 3 9 Flow. of Furnace piping. Oil. Not significant.

Other. Leak. Minor spill of . Pump gland leak. Spill release of Open area. 2 4 8 Furnace Oil. . Drain points. vapors. . Hose Formation of Curb wall at connections. flammable mixture installation. . Sampling. with air. Fire/ explosion hazard if finds source of ignition.

NODE 4 OF 7 : FURNACE OIL STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 100 kl capacity of Furnace oil Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures Other. Leak. Major spill of The large leakages Loss of containment. Open area. 5 4 20 Provide routing for accidental spill Furnace Oil. can also occur from collection containment to safe pump glands and Fire/ explosion Dyke / Curb wall at location at road tanker hard stand. seals & hose failures. hazard if evaporating installation. liquid pool finds Avoid organic contaminated water Catastrophic failure source of ignition. Pool fire generated during fire fighting of the transfer hose/ Fire hydrant system operations entering storm drain . road tanker overflow at vent day tank.

Other. Static Charge. Static charge Higher flow rates of Static charge as Flameproof 5 3 15 as source of during transfer. source of ignition. electricals are ignition. Use of non provided. conductive/ plastic hose. Fire/ explosion Free fall of material hazard. Equipments are in tank. earthed. ‘V’ belt drive. More. Temperature. More No credible causes – – – temperature identified. of tank. Less. Temperature. Less Low ambient Freezing not – – – temperature temperature. anticipated. of tank. More . Pressure. More More rate of pumping Pressurization Regular inspection 4 4 16 Pressure. in and vent blockage Less. Pressure. Less Pumping out liquid or Implosion hazard. Local pressure 4 5 20 Pressure. emptying liquid too gauge at discharge fast. Tank damage of upstream pump. resulting from collapse of the tank Vent. under vacuum.

NODE 2 OF 7 : FURNACE OIL STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 100 kl capacity of Furnace oil Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures Other. Maintenance. Cleaning of . Corrosion/ Residual gas in the Work permit. 3 3 9 tank for erosion. tank. inspection / . Material defect. maintenance. . Sample station. Health hazard. . Valve leaking. . Vent or drain. Fire hazard. . Valve leaking.

More. Level. More level. Inventory control. Overflow at vent, Supervision. 4 5 20 SOP for Furnace oil transfer spill hazard. Log book. procedures with checklist that includes Error – Tank full and checking field reading of tank level more receipt in error. Fire/ explosion Emergency response before receipt. hazard if evaporating procedures. liquid pool finds source of ignition.

Less. Level. Low level No material or Dry run of pumps. Supervision. 3 3 9 during excessive dispensing. dispensing. As Well Composition. Impurities. From feed, mix up No safety 2 3 6 As. during port. consequences — quality issues. As Well Composition. Ingress of Water not completely Disturbed operation. 2 3 6 As. water. drained.

Following a cleaning operation.

NODE 5 OF 7 : Diesel STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 20 kl capacity of Diesel Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures None. Flow. No flow of No material in the Delayed operation. SOP. 2 2 4 Safe Operating Procedures (SOP’s). Diesel from road tanker. Log record. road tanker to Spill hazard during Preventive 3 3 9 storage tank. Valve/ line choke. blockage removal maintenance. Transfer pump operation. (electrical/ Delayed operation. mechanical) problem. Human error. Delayed operation. Supervision. 2 2 4 Less. Flow. Less flow of Blocked flow (e.g., Spill hazard during SOP. 3 3 9 Diesel . plugged line). blockage removal operation. Blockage of piping. More. Flow. More flow of Flow control valve. Disturbed operation. Supervision. 2 3 6 Diesel Transfers or fails. Open. Reverse. Reverse Reverse flow Power failure. Reverse flow from NRV. 3 3 9 Flow. of Diesel piping. Not significant. Other. Leak. Minor spill of . Pump gland leak. Spill release of Open area. 2 4 8 Diesel . Drain points. vapors. . Hose Formation of Curb wall at connections. flammable mixture installation. . Sampling. with air.Fire/ explosion hazard if finds source of ignition. Other. Leak. Major spill of The large leakages Loss of containment. Open area. 5 4 20 Provide routing for accidental spill Diesel can also occur from collection containment to safe location pump glands and Fire/ explosion Curb wall at at road tanker hard stand. seals & hose failures. hazard if evaporating installation. Catastrophic failure liquid pool finds of the transfer hose/ source of ignition. road tanker overflow at vent day tank.

NODE 3 OF 7 : Diesel STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 20 kl capacity of Diesel Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures Other. Static Charge. Static charge Higher flow rates of Static charge as Flameproof 5 3 15 as source of during transfer. source of ignition. electricals are ignition. Use of non provided. conductive/ plastic hose. Fire/ explosion Free fall of material hazard. Equipments are in tank. earthed. ‘V’ belt drive. More. Temperature. More No credible causes – – – temperature identified. of tank. Less. Temperature. Less Low ambient Freezing not – – – temperature temperature. anticipated. of tank. More. Pressure. More Pumping in liquid too Pressurization. Tank vented to 4 5 20 Standard procedures and checklist for pressure at fast and vent atmosphere. checking vent of tank. tank. blockage. Other. Maintenance. Cleaning of . Corrosion/ Residual gas in the Work permit. 3 3 9 tank for erosion. tank. inspection / . Material defect. maintenance. . Sample station. Health hazard. . Valve leaking. . Vent or drain. Fire hazard. . Valve leaking. More. Level. More level. Inventory control. Overflow at vent, Supervision. 4 5 20 SOP for Diesel transfer procedures spill hazard. Log book. with checklist that includes checking Error – Tank full and field reading of tank level before more receipt in error. Fire/ explosion Emergency response receipt. hazard if evaporating procedures. liquid pool finds source of ignition.

NODE 3 OF 7 : Diesel STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 20 kl capacity of Diesel Guide Protection Parameter Deviation Cause Consequence S P R Action Word Measures Less. Level. Low level No material or Dry run of pumps. Supervision. 3 3 9 during excessive dispensing. dispensing. As Well Composition. Impurities. From feed, mix up No safety 2 3 6 As. during port. consequences — quality issues. As Well Composition. Ingress of Water not completely Disturbed operation. 2 3 6 As. water. drained.

Following a cleaning operation.

More . Pressure. More More rate of pumping Pressurization Regular inspection 4 4 16 Pressure. in and vent blockage.Vent blanked off./Plastic bag over vent. /Vent choked/Flame arrestor choked /Vent connected to water seal/ too small / Flexible tubing connected to vent. Less. Pressure. Less Pumping out liquid or Implosion hazard. Local pressure 4 5 20 Pressure. emptying liquid too gauge at discharge fast. Tank damage of upstream pump. resulting from collapse of the tank Vent. under vacuum.

NODE 4 OF 7 : Caustic soda STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 150 kl capacity of caustic soda Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures None. Flow. No flow of Caustic No material in the road Delayed operation. LG. 2 3 6 Log book record. Soda during road tanker or storage tank. tanker unloading to storage tank or Valve failure/ Delayed operation. Preventive 3 3 9 transfer to day tank blockage. maintenance. from storage tank. Spill hazard during SOP for blockage Line blockage. blockage removal PPE. removal operation. operation. Training. 3 3 9 Transfer pump failure Delayed operation. (loss of power, Preventive impeller came off or Delayed operation. maintenance. 3 3 9 corroded etc.). Human error. Supervision. More. Flow. More flow of Caustic Valve malfunctioning. Delayed operation. LI at storage tank. 3 3 9 Preventive Soda during maintenance. transfer to day tank Human error. Improved from storage tank. supervision. Less. Flow. Less flow of Caustic Valve malfunctioning. Delayed operation. LI at storage tank. 3 3 9 Preventive Soda during transfer maintenance. to feed tank from Human error. Improved storage tank. supervision. Reverse. Flow. Reverse flow of line Power failure during Delayed operation. NRV in discharge 3 2 6 Preventive hold up . transfer to plant line. maintenance. As Well As. Flow. Minor leaks , spill Pump gland leak Fugitive emissions Supervision 4 4 16 Monitor the work Vent releases Preventive place air born Minor spill maintenance. concentration of Transfer Hose residual Safety shower and chemicals within material eye wash fountain prescribed limit. Other. Flow. Static discharge. Not significant - - -

Other than Flow Undesired flow , mix Mix up Health hazard Dyke 3 3 9 up flow Corrosion Dedicated piping closed handling

NODE 4 OF 7 : Caustic soda STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 150 kl capacity of caustic soda Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures More temperature at Summer season Not significant Supervision. 2 3 6 More. Temperature. storage tank. Less Temperature. Winter season. Freezing not 3 3 9 Less. Temperature. anticipated. Pressure. More Pressure. More rate of pumping Pressurization. Vent inspection. 4 3 12 Preventive in and vent blockage. maintenance. Vent blanked off/Plastic bag over vent/ choked/Flame More. arrestor choked/Vent connected to water seal/Vent too small/ Vent/modified/Flexible tubing connected to vent. Pressure. Less Pressure. More rate of pumping Implosion hazard. Vent inspection. 4 3 12 Preventive Less. out and vent blockage. maintenance.

Phase Increase in number Rust, dirt. Disturbed operarion Preventive 2 2 4 More of phases. maintenance Transformation Reaction with carbon As Well As. Composition Not significant 3 3 9 products di oxide from air Level More Level. at day More feed in error to Spill hazard. High level interlock 4 4 16 Connect Overflow line tank while receipt day tank in feed line. of day tank to from storage tank SOP corresponding storage More. tank

Level Less level at Tank empty. Transfer pump LI provided at 3 3 9 Concentrated storage suction dry. Concentrated Nitric Less. tank Acid storage tank Disturbed operation.

NODE 4 OF 7 : Caustic soda STORAGE TANK DESIGN INTENT : Receipt by road tanker , storage in above ground tank of 150 kl capacity of caustic soda Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures Other. Hazardous Corrosive chemicals. Caustic lye handling. Splash on gasket PPE. 4 3 12 Provide splash guards chemicals leak. Safety shower and on flange joints of the Handling. eye wash fountain corrosive chemicals Spill hazard. Alkali proof tile transfer piping. flooring Avoid any flange joint in pipeline over rack crossing walk way.

NODE 5 OF 7 : Spray Drying method DESIGN INTENT : Process operations of Spray Drying method Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures None. Flow. No flow of inlet air. Human error in Disturbed operation. Valve is provided 5 5 10 Training. operation of with a limit switch Inlet air damper is for the quantity of air provided in the inlet which is actuated if air duct for the damper is fully controlling the closed machine will quantity of inlet air. not run. More. Flow. More flow of inlet Human error Disturbed operation. Supervision 3 3 9 Regular calibration of air. Instrumentation instrumentation. Less. Flow. Less flow of inlet Human error Disturbed operation. Supervision 3 3 9 Regular calibration of air. Instrumentation instrumentation. Reverse. Flow. Reverse.flow Power failure Slurry Disturbed operation. Supervision 3 3 9 Regular calibration of entering in air line Instrumentation instrumentation. As Well As. Flow. Static charge: charge Gases cannot, on Smoldering/ fire at Supervision. 2 4 7 Provide effective development on their own, carry bag house. Equipments are measures for suspensions. significant Fire / explosion earthed Flameproof prevention of concentrations of Ignition occurs when electricals accumulation of static electrostatic charge. the charge on the charge to a dangerous Hazardous charge suspended material extent. concentrations may, generates an however, be carried Incendive discharge. Carry out dust safety on solid particles or The Incendive tests liquid droplets discharge may be a suspended in a gas brush discharge to an (i.e. on dusts, sprays earthed object or mists). protruding.

Dust safety properties of Calcium Propionate

MIE = 10 % - 10 7 mJ Maxium explosion pressur =8.7 bar Maxium rate of pressure rise = 77 bars / sec.

Dust explosions can occur when the following conditions are satisfied simultaneously; 1. The dust must be flammable. 2. The particle size distribution must be capable of propagating flame. 3. The dust concentration must fall within the Flammable Range. 4. The air must contain sufficient Oxygen to support combustion. 5. The dust suspension must be in contact with an ignition source of sufficient energy. DUST EXPLOSION DUST EXPLOSION PENTAGON

CONTROL OF DUST EXPLOSION Therefore, control of dust explosion is accomplished by at least any one of these five factors

HYBRID MIXTURES

 Dust suspensions in air containing a proportion of flammable gas or Vapour are frequently termed “hybrid mixtures”.

 The occurrence of hybrid mixtures in industrial plant is an increased danger even when the concentration of flammable gases or Vapours in itself is below the LFL.

 Handling non-flammable dusts or granules can also present an electrostatic hazard if a flammable gas or Vapour is present.  Dust mixtures and gas mixtures in non-flammable concentrations can form explosible hybrid mixtures when combined.  A flammable dust mixed with a flammable gas and air will explode more violently than in air alone even if the gas concentration is below the LFL.  A dispersion of flammable dust that is too coarse to be explosible may be rendered explosible by admixture of a small quantity of flammable gas or Vapour.

Low energy electrostatic discharges that would not be capable of igniting a flammable dust dispersion may ignite a hybrid mixture of that dust even when the concentration of the gas or Vapour component is below its LFL.

NODE 5 OF 7 : Spray Drying method DESIGN INTENT : Process operations of Spray Drying method Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures Other than Flow Undesired flow Accidental mix up , Unsafe condition Dedicated piping 3 3 9 human error Wrong valve operation More. Temperature. More temperature of Malfunction of heating Disturbed operation High temperature 4 4 16 Regular calibration of inlet air. unit interlock instrumentation Human error.

Less. Temperature. Less Temperature. Human error delayed operation Supervision 3 3 9 More. Pressure. More pressure. Dust explosion Pressurization. SOP. 4 4 16

Explosion hazard.

Less. Pressure. Less pressure. Vacuum in the system. Implosion. Equipments are 3 3 9 Regular inspection of hazard designed for vent. vacuum. More Phase. More phases. Drying Process not significant SOP. 3 3 9

Supervision. As Well As. Composition Impurities. Impurities,intermediates, Quality issues Process control and 3 3 9 Obtain MSDS of side reaction products and Supervision. impurities, decomposition products/ intermediates, side by products. reaction products and decomposition products (if any), in absence of the information the chemicals should be treated as if hazardous chemicals. More. Level. More level. Less. Level. Less level. Others. Emergency Emergency. Pressurization, local fire Disturbed operation. An emergency off 5 5 10 Training. etc. switch is provided to

Unsafe condition. put off the entire system in case of emergency. Other. Flow Leak. Gasket failure. Dust/ vapours Supervision. 3 5 9 Carry out work area release. monitoring for Container failure. maintaining air born Health hazard. PPE. concentration of chemicals within prescribed limit as prescribed in “The Second Schedule of Factory Act 1948”. Other. Handling Alkaline materials Handling alkaline Failure of the Preventive 5 4 20 Handling alkaline materials at high containment maintenance materials at high temperature for long years temperature for long of service may result in years of service may Caustic imbrittlement and result in Caustic weaken the equipment imbrittlement and leading to rupture at these weaken the equipment week points .especially leading to rupture at welding joints . these week points .especially welding joints .

NODE 6 OF 7 : Mixing method DESIGN INTENT : Process operations of Mixing method Protection Guide Word Parameter Deviation Cause Consequence S P R Action Suggested Measures

Other. Handling Alkaline materials Handling alkaline Failure of the Preventive 5 4 20 Handling alkaline materials at high containment maintenance materials at high temperature for long temperature for long years of service may years of service may result in Caustic result in Caustic imbrittlement and imbrittlement and weaken the weaken the equipment equipment leading to leading to rupture at rupture at these week these week points points .especially .especially welding welding joints . joints .

79 NODE 7OF 7 : ETP DESIGN INTENT : ET Guide Word Parameter Deviation Cause Consequence Protection Measures S P R Action Suggested None. Flow. No Flow of The Transfer Pump’ (TP) Delayed operation. Supervision. 3 3 9 Provide Log book/ thoroughly mixed failure / SG records. SOP and effluent to the malfunctioning / check list for transfer. ‘Settling Tank’ power failure 3 3 9 Valve failure More. Flow. More qty flow to Large spill in plant Over flow , spill Supervision 3 3 9 ETP Fire fighting water hazard Human error Filter blockage Less. Flow. Less qty flow to Leak over piping, Spill hazard. Supervision. 3 3 9 ETP value gasket failure etc. Reverse Flow Reverse flow Not anticipated - - - As well as Flow Spill Piping Leak Health hazard Safety shower and 3 3 9 corrosive chemicals eye wash fountain Other Flow Static charge Not anticipated as Equipments are 2 1 2 hazard aqueous earthed. solution Other than Flow Undesired flow Accidental mix up , Unsafe condition Dedicated piping 3 3 9 human error Wrong valve operation More. Temperature. High temperature Not anticipated - - -

Less. Temperature. Less temperature Not significant. – – – More. Pressure. More Pressure. Not anticipated Systems Open to 2 2 4 atmosphere Less. Pressure. Less Pressure. Not anticipated Systems Open to 2 2 4 atmosphere

NODE 7OF 7 : ETP DESIGN INTENT : ET Guide Word Parameter Deviation Cause Consequence Protection Measures S P R Action Suggested More Phase. Solid waste The settled heavy Waste accumulation Sludge will be 3 3 9 . sludge is collected at site disposed by third through the discharge party (Authorized valve into a Solid waste Centrifuge or Filter management Press’ company). More Composition Incompatibles The effluent outflow Potential for serious Supervision. 4 4 16 Route the spill/ floor mix up at plant , from the various consequences washing through drain system or ETP process tank washing depending up on mix collection pit for and floor washing is up controlled transfer to collected in these ETP for treatment . tanks, through common header.

More Composition More TDS content of High TDS effluent Pollution issues Segregation of High 4 4 16 Provide effluent stream generated TDS and Low TDS Multiple Effect during the process Effluent streams Evaporator and Agitated Thin Film Dryer for High TDS effluent stream treatment

More. Level. Higher level at The effluent outflow Overflow Equalization tank/ 3 3 9 Holding Cum from the various Neutralization Tank Equalizing Tank process tank washing and floor washing is Supervision collected in these tanks, through common header. Overfilling due to operator error. Less. Level. Less level. Less batch charging. Thermowell may not SOP. 3 3 9 Human error. dip. Unsafe condition. Supervision.

NODE 7OF 7 : ETP DESIGN INTENT : ET Guide Word Parameter Deviation Cause Consequence Protection Measures S P R Action Suggested Other Handling Handling of corrosive Acid and bases are Injury in case of PPE 3 3 9 chemicals used splash Safety shower and eye wash fountain Other Maintenance Repair over Inspection/ Fire/ explosion. PPE. 4 3 12 installation. maintenance. Residual gas in the Health hazard. Work permit. system need to be removed.