ENVIRONMENTAL IMPACT ASSESSMENT REPORT
FOR
“PROPOSED CAPACITY EXPANSION INCLUDING NEW COMPONENT (ZINC DI-THIO PHOSPHATE) MANUFACTURING UNIT AT EXISTING FACILITY”
[Project termed under Category (5F) Synthetic Organic Chemicals industry]
BY
Indian Additives Limited
AT VILLAGE: Manali TALUK: Ambattur DISTRICT: Thiruvallur STATE: Tamil Nadu
Report prepared by HUBERT ENVIRO CARE SYSTEMS PVT. LTD.
JUNE, 2015
EIA for proposed expansion including new component (ZDTP) manufacturing
Hubert Enviro Care Systems Pvt. Ltd.
EIA for proposed expansion including new component (ZDTP) manufacturing
Hubert Enviro Care Systems Pvt. Ltd.
EIA for proposed expansion including new component (ZDTP) manufacturing
TABLE OF CONTENTS EXECUTIVE SUMMARY ...... i 1 INTRODUCTION ...... 2
1.1 PURPOSE OF THE REPORT ...... 2 1.1.1 EIA REQUIREMENT ...... 2 1.2 PROPONENT BACKGROUND ...... 3
1.3 PROMOTERS AND BACKGROUND ...... 4 1.3.1 CHENNAI PETROLEUM CORPORATION LIMITED (CPCL) ...... 4 1.3.2 CHEVRON ORONITE COMPANY LLC ...... 4 1.4 BRIEF DESCRIPTION OF THE PROJECT ...... 5 1.4.1 PROPOSED EXPANSION...... 5 1.4.2 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT ...... 5 1.5 PROJECT SETTING ...... 5
1.6 APPLICABLE REGULATORY FRAMEWORK ...... 6
1.7 METHODOLOGY ADOPTED FOR THE STUDY ...... 12 1.7.1 OBJECTIVES OF THIS EIA REPORT ...... 12 1.7.2 EIA PROCESS ...... 12 2 PROJECT DESCRIPTION ...... 15
2.1 ABOUT THE PROJECT ...... 15 2.1.1 EXISTING FACILITY ...... 15 2.1.2 PROPOSED EXPANSION...... 15 2.1.3 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT ...... 15 2.2 JUSTIFICATION FOR THE PROJECT ...... 16
2.3 PROJECT LOCATION ...... 17
2.4 LAND USE DETAILS ...... 22
2.5 MANPOWER REQUIREMENT ...... 25
2.6 RAW MATERIAL REQUIREMENTS ...... 25 2.6.1 PROPOSED EXPANSION...... 25
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2.6.2 PROPOSED NEW COMPONENT (ZDTP) ...... 27 2.7 UTILITIES AND SERVICES ...... 27
2.8 POWER AND FUELS ...... 28
2.9 WATER REQUIREMENT ...... 29
2.10 PROJECT SCHEDULE ...... 29
2.11 PROJECT COST ...... 30
2.12 MANUFACTURING TECHNOLOGY / PROCESS DESCRIPTION ...... 32 2.12.1 PROPOSED EXPANSION PLANT ...... 32 2.12.2 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING ...... 36 2.13 PLANT LAYOUT ...... 40
2.14 MITIGATION MEASURES - ENVIRONMENT ...... 40 2.14.1 RAW MATERIAL STORAGE, HANDLING AND TRANSPORTATION ...... 40 2.14.2 TREATMENT OF LQUID WASTE ...... 43 2.15 AIR POLLUTION CONTROL MEASURES ...... 44
2.16 SOLID AND HAZARDOUS WASTES ...... 44
2.17 GREENBELT DEVELOPMENT ...... 45 3 DESCRIPTION OF ENVIRONMENT ...... 47
3.1 SCOPE OF STUDY ...... 47
3.2 AIR ENVIRONMENT ...... 47 3.2.1 RECONNAISSANCE ...... 48 3.2.2 MICROMETEOROLOGY ...... 50 3.2.3 BASELINE STATUS ...... 53 3.3 NOISE ENVIRONMENT ...... 55 3.3.1 RECONNAISSANCE SURVEY ...... 55 3.3.2 NOISE LEVELS ...... 58 3.3.3 BASELINE STATUS ...... 58 3.3.4 LIMITS SET BY CPCB ...... 58 3.4 WATER ENVIRONMENT ...... 59
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3.4.1 RECONNAISSANCE ...... 60 3.4.2 BASELINE STATUS ...... 62 3.4.3 Hydrogeology...... 67 3.5 LAND ENVIRONMENT ...... 69 3.5.1 RECONNAISSANCE ...... 69 3.5.2 SOIL ENVIRONMENT ...... 69 3.5.3 LAND USE ...... 73 3.5.4 GEOMORPHOLOGY ...... 75 3.6 TERRESTRIAL ECOLOGY ...... 76 3.6.1 SCRUB ECO-SYSTEM (DRY EVERGREEN VEGETATION) ...... 77 3.6.2 TIDAL ECO-SYSTEM ...... 77 3.6.3 MANGROVE ECO-SYSTEM ...... 77 3.6.4 MARSH ECO-SYSTEM ...... 77 3.6.5 AGRO ECOSYSTEM ...... 77 3.6.6 FLORA ...... 77 3.6.7 FAUNA ...... 78 3.7 AQUATIC ECOLOGY ...... 80 3.7.1 PLANKTONS ...... 80 3.7.2 FISHES ...... 80 3.8 SOCIO ECONOMIC ENVIRONMENT ...... 81 3.8.1 SOCIAL INDICATORS ...... 81 3.8.2 ECONOMY OF THE DISTRICT ...... 88 3.8.3 INDUSTRIES ...... 89 4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ...... 92
4.1 IDENTIFICATION OF SIGNIFICANT IMPACTS ...... 92
4.2 TYPICAL CONSTRUCTION ACTIVITEIS ...... 92 4.2.1 GENERAL ACTIVITIES ...... 92 4.2.2 OTHER ACTIVITIES ...... 93 4.3 CONSTRUCTION PHASE IMPACTS ...... 94
4.4 MITIGATION MEASURES FOR CONSTRUCTION PHASE ...... 95
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4.5 OPERATIONAL PHASE IMPACTS ...... 96 4.5.1 AIR ENVIRONMENT ...... 96 4.5.2 WATER ENVIRONMENT ...... 103 4.5.3 NOISE ENVIRONMENT ...... 106 4.5.4 LAND ENVIRONMENT ...... 107 4.5.5 FLORA AND FAUNA ...... 107 4.5.6 SOCIO ECONOMY ...... 108 4.6 IMPACT ASSESSMENT ...... 108 4.6.1 MATRIX METHOD ...... 108 5 ANALYSIS OF ALTERNATIVES ...... 118
5.1 INTRODUCTION ...... 118
5.2 SITE SELECTION ...... 118
5.3 PROJECT ALTERNATIVES ...... 120 6 ENVIRONMENTAL MONITORING PROGRAM ...... 123
6.1 INTRODUCTION ...... 123
6.2 ENVIRONMENTAL EFFECTS MONITORING IN EIA ...... 123
6.3 POST PROJECT ENVIRONMENT MONITORING PROGRAM ...... 124
6.4 MONITORING METHODOLOGIES ...... 125
6.5 REPORTING & DOCUMENTATION ...... 125
6.6 BUDGET FOR ENVIRONMENTAL MONITORING PLAN ...... 126 7 ADDITIONAL STUDIES ...... 129
7.1 RISK ASSESSMENT ...... 129
7.2 PUBLIC CONSULTATION ...... 129
7.3 SOCIAL IMPACT ASSESSMENT ...... 129 8 ENVIRONMENTAL MANAGEMENT PLAN ...... 131
8.1 INTRODUCTION ...... 131
8.2 OBJECTIVES OF EMP ...... 131
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8.3 EMP STRUCTURE AND ORGANIZATION ...... 132
8.4 ROLES AND RESPONSIBILITIESFOR EMP ...... 132
8.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE ...... 134 8.5.1 AIR QUALITY ...... 135 8.5.2 NOISE ENVIRONMENT ...... 135 8.5.3 WATER QUALITY AND WATER RESOURCES ...... 135 8.5.4 LAND ENVIRONMENT ...... 136 8.5.5 ECOLOGY ...... 136 8.5.6 SOCIO ECONOMIC ...... 136 8.6 ENVIRONMENTAL MANAGEMENT PLAN FOR OPERATION PHASE ...... 137 8.6.1 AIR QUALITY MANAGEMENT ...... 137 8.6.2 WATER QUALITY AND RESOURCES MANAGEMENT ...... 147 8.6.3 NOISE ENVIRONMENT ...... 159 8.6.4 SOLID AND HAZARDOUS WASTE MANAGEMENT ...... 160 8.6.5 LAND ENVIRONMENT ...... 163 8.6.6 GREEN BELT DEVELOPMENT ...... 163 8.6.7 ECOLOGY ...... 164 8.6.8 OCCUPATIONAL HEALTH AND SAFETY ...... 164 8.7 ENVIRONMENTAL MANAGEMENT CELL ...... 172 8.7.1 RESPONSIBILITIES OF ENVIRONMENT MANAGEMENT CELL ...... 173 8.7.2 ENVIRONMENT MONITORING FACILITIES ...... 174 8.8 CORPORATE ENVIRONMENTAL RESPONSIBILITIES...... 174 8.8.1 BUDGETARY PROVISITON FOR ENVIRONMENTAL MANAGEMENT ...... 180 8.9 CORPORATE SOCIAL RESPONSIBILITY ...... 180 9 ENVIRONMENTAL COMPLIANCES ...... 183
9.1 APPLICABILITY OF ENVIRONMENTAL CLEARANCE ...... 183
9.2 CONSENT FOR EXISTING OPERATION ...... 183 9.2.1 CONSENT COMPLIANCE CONDITIONS ...... 184 9.3 HAZARDOUS WASTE AUTHORIZATION FOR EXISTING FACILTIY...... 198 10 PROJECT BENEFITS ...... 207
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11 SUMMARY AND CONCLUSION ...... 209 12 DISCLOSURE OF CONSULTANT ENGAGED ...... 211 COMPLIANCE TO TOR POINTS ...... 213
LIST OF TABLES
Table 1-1 List of industries around10 Km radius of the project site ...... 5 Table 1-2Applicable Acts and Rules for the proposed project ...... 8 Table 2-1 List of products /by-products– existing and proposed with quantity ...... 16 Table 2-2 Salient features of the project ...... 17 Table 2-3 Project site and surrounding features ...... 18 Table 2-4Land use breakup for the project ...... 23 Table 2-5 Manpower requirement for the proposal ...... 25 Table 2-6 List of raw materials - existing and proposed expansion ...... 25 Table 2-7 List of Raw materials for New Component (ZDTP) ...... 27 Table 2-8 Capacity of DG, Boilers and Thermic fluid Heaters ...... 27 Table 2-9 Power and fuel requirement ...... 28 Table 2-10 Water requirement for the project ...... 29 Table 2-11 Project cost for proposed expansion ...... 30 Table 2-12 Project cost for proposed ZDTP Manufacturing ...... 31 Table 2-13 Mode of storage and transportation of raw materials ...... 40 Table 3-1 Ambient Air Quality monitoring locations ...... 48 Table 3-2 Meteorological observations ...... 51 Table 3-3 Test Methods used for the analysis of Ambient Air Quality parameters ...... 53 Table 3-4 Average Ambient Air Quality monitoring data (February to April, 2015) ...... 54 Table 3-5 Noise level monitoring locations ...... 56 Table 3-6 Noise levels in Day and Night Time ...... 59 Table 3-7 Water quality Sampling Locations ...... 60 Table 3-8 Test methods used for the analysis of water quality parameters ...... 62 Table 3-9 Analytical results on water samples collected in the study area ...... 64
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Table -3-10 Soil sampling locations in the study area ...... 70 Table 3-11 Analytical results of soil samples collected at different sampling stations ...... 71 Table 3-12 List of domestic flora in the study area ...... 78 Table 3-13 List of wild fauna ...... 79 Table 3-14 List of amphibians ...... 79 Table 3-15List of rodents ...... 79 Table 3-16List of Zooplankton identified within the study area ...... 80 Table 3-17 Block wise Primary HelathCentres available in the District ...... 86 Table 4-1 Existing and proposed stack details ...... 98 Table 4-2 Stack emission details ...... 99 Table 4-3 Predicted GLC for proposed stack ...... 103 Table 4-4 Effluent and sewage generation, recycling ...... 103 Table 4-5 Overall impact classification ...... 109 Table 4-6 NoProject Scenario ...... 111 Table 4-7 Project Scenario without EMP ...... 113 Table 4-8 Project with EMP ...... 115 Table 5-1Impacts of alternative site location compared with the selected location ...... 119 Table 6-1Post project environmental monitoring plan ...... 124 Table 6-2 Budgetary allocation for Environmental monitoring...... 126 Table 8-1Responsibility for EMP implementation ...... 132 Table 8-2 Stack details for existing and proposed project ...... 138 Table 8-3 Caustic scrubber design specifications ...... 140 Table 8-4 Characteristics of raw and treated effluent ...... 147 Table 8-5 Design specifications of individual components of ETP ...... 149 Table 8-6 Characteristics of raw and treated sewage ...... 156 Table 8-7 Design specifications of individual components of STP ...... 156 Table 8-8 Hazardous wastes generation ...... 160 Table 8-9 Characteristics of Hazardous waste ...... 161 Table 8-10 Non-Hazardous wastes ...... 162 Table 8-11 Capacity of Fire Water pumps ...... 169 Table 8-12 Fire hydrant landing valves, long throw monitors, manual spray system ...... 170
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Table 8-13 Environment improvement initiatives ...... 177 Table 8-14 Budgetary provisions for EMP ...... 180 Table 9-1 Air Act Compliance Conditions ...... 184 Table 9-2 Water Act compliance conditions ...... 192 Table 9-3 Hazardous Waste Authorization compliance conditions ...... 199 Table 12-1Details of the Consultant ...... 211
LIST OF FIGURES Figure 1-1EIA process cycle ...... 13 Figure 2-1 Location of the project site ...... 19 Figure 2-2 Location of project site within Manali Industrial Area ...... 20 Figure 2-3Google image of project site with boundaries (1 Km radius) ...... 21 Figure 2-4Topo sheet showing 5 km radius of project site ...... 22 Figure 2-5Existing Site plan showing facilities ...... 24 Figure 2-6 Project schedule for proposed expansion ...... 29 Figure 2-7 Project schedule for proposed new component manufacturing ...... 30 Figure 2-8 Dispersants process flow diagram ...... 33 Figure 2-9 PIBSA process flow diagram ...... 34 Figure 2-10Phenates process flow diagram ...... 35 Figure 2-11 Blending process flow diagram ...... 36 Figure 2-12 ZDTP process flow diagram ...... 38 Figure 2-13 Material Balance for proposed expansion and new component (ZDTP) manufacturing ...... 39 Figure 3-1Air quality sampling locations within 5Km Radius ...... 49 Figure 3-2 Wind rose for February 2015 ...... 51 Figure 3-3Wind rose for March 2015 ...... 52 Figure 3-4 Wind rose data for April 2015 ...... 52 Figure 3-5 Google earth Image showing noise level monitoring locations within 5Km radius ...... 57 Figure 3-6 Noise monitoring in Edayanchavadi ...... 57 Figure 3-7 Noise monitoring in front of IAL ...... 57 Figure 3-8 Google earth showing water sampling locations in 5Km radius ...... 61 Figure 3-9 Hydro geological map of Thiruvallur district ...... 68
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Figure 3-10 Photographs of the soil sample collection ...... 71 Figure 3-11 Google earth showing soil sampling locations within 5Km radius ...... 71 Figure 3-12 Land use map of the project site around 10Km Radius ...... 74 Figure 3-13 Land cover map of the project site around 10 Km Radius ...... 75 Figure 3-14 Geomorphological map of the project site ...... 76 Figure 3-15 District decadal growth rate ...... 82 Figure 3-16 Statistics of main workers ...... 83 Figure 3-17Bar chart for Operational land holding ...... 84 Figure 3-18 Manali School ...... 85 Figure 3-19 Photograph of Oxford Matriculation School Kodungaiyur ...... 85 Figure 3-20 Map showing the PHCs in Thiruvallur District ...... 86 Figure 3-21 Communicable Diseases Hospital at Tondiyarpet ...... 87 Figure 3-22 Product at net and constant prices ...... 88 Figure 3-23 Percapita income at net and constant prices ...... 89 Figure 4-1 Photograph showing proposed ZDTP unit location...... 94
Figure 4-2 Maximum incremental value for SOX ...... 100
Figure 4-3 Maximum incremental value for NOX ...... 101 Figure 4-4 Maximum incremental value PM ...... 102 Figure 4-5 Water Balance for the proposed expansion and new component manufacturing ...... 105 Figure 4-6 Isopleths of Noise Level ...... 106 Figure 4-7 Noise Modeling within and near plant premises ...... 107 Figure 8-1Caustic scrubber flow diagram ...... 141
Figure 8-2 H2S treatment facility for new Component (ZDTP) ...... 144 Figure 8-3 Photograph of tank farm ...... 146 Figure 8-4Photographs of material handling system ...... 146 Figure 8-5 Photographs of RO and MEE ...... 155 Figure 8-6 ETP and STP Process Flow Diagram...... 158 Figure 8-7Photographs of Effluent and Sewage TreatmentPlant ...... 158 Figure 8-8 Photograph of rainwater harvesting pit ...... 159 Figure 8-9 Photograph of fire fighting layout within the plant premises ...... 169 Figure 8-10 Photograph of First Aid Centre ...... 171
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Figure 8-11 Organogram for Environmental Management ...... 173 Figure 8-12 Quality and Environmental Policy of IAL ...... 175 Figure 8-13 Photographs of CSR activities ...... 181
LIST OF ANNEXURE
Annexure-1 Environmental Clearance copy of existing facility
Annexure-2 Existing Consent from TNPCB
Annnexure-3 10 Km radius map showing the Industries nearby
Annexure-4 TOR from MoEF
Annexure-5 CMDA Land use map
Annexure-6 Land Documents
Annexure-7 Agreement with CMWSSB for water supply
Annexure-8 Site layout plan
Annexure-9 Risk Assessment
Annexure-10 Material Safety Data sheet for the Solvents
Annexure-11 Disaster Management Plan
Annexure-12 STP Adequacy Report
Annexure-13 ETP adequacy report
Annexure-14 Rainwater harvesting system
Annnexure-15 Hazardous Waste Authorization from TNPCB
Annexure-16 Green belt Development Plan
Annexure-17 Environmental protection improvement initiatives
Annexure -18 Post EC compliance report from MoEF Regional Office
Annexure-19 Acknowledgement from TNPCB for submission of Consent renewal application and fee remittance details.
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Annexure-20 Stack Monitoring Reports
Annexure-21 Ambient Air Quality Monitoring Reports
Annexure-22 Noise Monitoring Reports
Annexure-23 Invoice for Spent Caustic
Annexure-24 Effluent Generation details
Annexure-25 Treated effluent Analysis Reports
Annexure 26 Agreement with Tamil Nadu waste Management Limited for Disposal of Hazardous Waste
Annexure 27 Agreement with GEPIL for Disposal of Hazardous Waste
Annexure 28 Details of Hazardous waste
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ABBREVATIONS
AAQM Ambient Air Quality Monitoring ALOHA Aerial Locations of Hazardous Atmospheres BDL Below Detection Level CEC Chief Emergency Coordinator CEPI Comprehensive Environmental Pollution Index CMWSSB Chennai Metropolitan Water Supply and Sewage Board CPA Critically Polluted Area CPCB Central Pollution Control Board CPCL Chennai Petroleum Corporation Limited CREP Corporate Responsibility for Environmental Protection CSR Corporate Social Responsibility EIA Environmental Impact Assessment EMC Environmental Monitoring Consultant EMP Environmental Management Plan EPA Environmental Protection Agency ETP Effluent Treatment Plant FAMCP Fire Alarm Manual Call Point GLC Ground Level Concentration IAL Indian Additives Limited IEMC Independent Environmental Monitoring Consultant LEL Lower Explosive Limit LFT Liver Function Tests MoEF Ministry of Environment and Forests MSDS Material Safety Data Sheets NAAQ National Ambient Air Quality Standards NABET National Accreditation Board For Education & Training NABL National Accreditation Board for Testing and Calibration Laboratories NESHAP National Emissions Standards for Hazardous Air Pollutants NSPS New Source Performance Standards
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OHSAS Occupational Health and Safety Administration Standard PFT Pulmonary Function Tests PIBSA Poly Isobutylene Succinic Anhydride PPE Personal protective equipment PrHA Preliminary Process Hazard Analysis SEIAA State Environment Impact Assessment Authority SMS Safety Management System SPCB State Pollution Control Board STP Sewage Treatment Plant TNPCB Tamil Nadu Pollution Control Board TNWML Tamil Nadu Waste Management Limited TOR Terms of Reference USEPA United States Environmental Protection Agency VOC Volatile Organic Compounds ZDTP Zinc Di-Thio Phosphate
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EIA for proposed expansion including new component (ZDTP) manufacturing Executive Summary
EXECUTIVE SUMMARY
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EIA for proposed expansion including new component (ZDTP) manufacturing Executive Summary
EXECUTIVE SUMMARY
1. INTRODUCTION
Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC. On 24th May 1989, Chevron Oronite Company LLC, USA (then Chevron Chemical Company) and Chennai Petroleum Corporation Limited, Chennai (then Madras Refineries Limited) signed an agreement to form a Company to engage in the development, manufacture and marketing of certain additive intermediates, components and packages for Lubricating Oils. The Company, christened as „Indian Additives Limited‟, was thus born legally on 13th July 1989. The plant is located at Manali Industrial Area, Thiruvottiyur Taluk, Thiruvallur District. The plant has been operational since 1993. IAL was originally incorporated as a Government company to foster domestic manufacture of lubricating oil additives so as to reduce reliance on import of such products and later restructured as Private Joint Venture Company. IAL now proposes to expand its existing lubricating oil additives manufacturing facility and also proposes to manufacture a new component Zinc Di Thio Phosphate (ZDTP) in its existing facility.
1.1. PROJECT DETAILS
IAL proposes to expand its existing facility of manufacturing lubrication oil additive packages and also a new component (ZDTP) manufacturing unit at its existing facility.
S. No Particulars Details 1. Project Expansion of existing lubricating oil additives manufacturing facility Manufacturing of new component Zinc Di- Thio Phosphate (ZDTP), an intermediate for lubricating oil additive manufacturing 2. Geographical Location Village: Manali Taluk: Thiruvottiyur District: Thiruvallur State: Tamil Nadu
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S. No Particulars Details 3. Project Cost Rs. 12 Crores for Expansion Rs.110 Crores for ZDTP Manufacturing 4. Power Requirement Existing-550000 KWH/Month After Expansion- 750000KWH/Month After new Component Manufacturing unit (ZDTP) - 1050000KWH/Month 5. Project land area 23.57 acres (existing) 6. Man power After After Proposed Manpower Existing Proposed new Expansion Component ZDTP Employees 120 140 156 Contractors 200 260 300
7. Land use Special and Hazardous Industrial Use Zone 8. Nearest Railway Station Chennai Central - 9.85 km South Thiruvottiyur-2.01 Km East 9. Nearest Airport Chennai Meenambakkam Airport – 23.10 km south west 10. Nearest habitation Manali-2.6Km 11. Densely populated area Thiruvottiyur-2.1 Km 12. Inland water bodies Surplus canal from Kortalaiyar River - 0.20Km (North) Buckingham canal – 0.63 Km (East) Periyathoppu Lake - 3.04Km (West) Bay of Bengal – 3.15Km (East) Madhavaram Lake-3.65 Km (South West) Kadapakkam Panchayat Lake- 4.26 Km (North West) 13. Source of water supply CMWSSB (Metro water)
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S. No Particulars Details 14. Population in Manali 35248 as per the census data (2011). 15. Highway Manali SH 56 road- Adjacent to site (North) 16. Sea port Chennai port – 7.13 Km South East Ennore Port – 9.57 Km North East 17. Forest/Wildlife Sanctuary Nil within 10Km radius
1.2. TYPE OF PROJECT
Synthetic organic chemical based units located inside the notified industrial area/estate are listed in schedule no. 5(F) under category „B‟ However, due to the applicability of general condition due to project location within 10Km from Critically Polluted Area is treated as category 'A‟ and appraised by Expert Appraisal Committee. The report is in accordance to the Terms of Reference (TORs) given for Environmental Clearance application for expansion and new component manufacturing vide F.No. J-11011/400/2014-IA-II (I) dated 20th February 2015 and amendment TOR dated 8th June, 2015.
2. PROJECT DESCRIPTION
2.1 LOCATION
The project site is located in Industrial town, Manali Village, Thiruvottiyur Taluk, Thiruvallur districtin the state of Tamil Nadu. It is located in north of Chennai City. It is 25 km away from Chennai city. The proposed area falls in the co-ordinates of 13°10'31.27"N, 80°17'1.45"E towards North, 13°10'16.10"N, 80°16'59.89"E towards South, 13°10'24.28"N, 80°16'57.66"E towards West, 13°10'24.25"N, 80°17'3.63"E towards East
2.2 PROPOSED EXPANSION IAL proposes to expand the capacity of its existing manufacturing facility to meet the growing market demand in lubricating oil additives. The proposed expansion activity is planned through debottlenecking with some minor investments, without change in process, raw materials and products. The expansion project scope mainly involves addition of inline blenders, pumps and enhancement of vessels/ storage tanks, with an investment of Rs.12 Crores. The implementation period will be around 10 months.
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2.3 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT
In addition, IAL proposes to set up new component manufacturing unit in the existing facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the intermediate for lubricating oil additive manufacturing. This is a backward integration project involving installation of batch reactors, overhead and filtration systems with other associated supporting facilities, including treatment
facility for H2S off gas generated from the process. The production from this facility will be consumed in-house as intermediate for manufacturing lubricating oil additives and also for exports. The investment for this proposal will be Rs.110 Crores and implementation period will be 20 months.
Table 1 List of products/ by-products – Existing and proposed with Quantity Proposed New After Proposed component Existing S.No Product Expansion Manufacturing unit (ZDTP) MT/annum 1 Automotive, Marine, Industrial, Rail Road and Natural gas engine 25000 60000 - Lubricating Oil additive packages. 2 Succinimides 10000 25000 - 3 Phenates/ Sulfonates 10000 20000 - 4 PIBSAs 8500 20000 - By product (Mix of sodium 5 sulphide, sodium hydrogen 3500 7000 - sulphide & caustic) Zinc Di-Thio Phospate 6 - - 20000 (ZDTP) By product (Sodium 7 - - 5000 Sulphide flakes)
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2.4 JUSTIFICATION OF THE PROJECT
The expansion project will support meeting growing market demand for lubricating oil additives in Indian market, thereby improving country‟s revenue generation. The proposed new component (ZDTP) manufacturing project is of backward integration model will help in improving company‟s revenue apart from mitigating other business risks as the company is currently sourcing this intermediate from external supplier. This project also provides opportunity to export the manufactured component to other lubricating oil additive companies across the world. Hence this will help to boost the economy of the country through additional revenues from exports.
2.5 LAND REQUIREMENTS
Table -2 Land Breakup details Area in acres After proposed After S.No Land allocation details new Existing proposed component Expansion (ZDTP) 1. Roads and drains Area 3.39 3.39 3.39
2. Tank farm and yards 4.94 4.94 5.94
3. Effluent treatment plant 2.78 2.78 2.78
4. Building Area 2.10 2.10 2.90
5. Greenbelt development 8.56 8.56 8.56
6. Vacant land 1.80 1.80 -
Total Area 23.57 23.57 23.57
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2.6 RAW MATERIALS
Table -3 Raw materials for proposed expansion Existing After Proposed Expansion S.No Raw Materials MT/Annum 1. 2 Ethyl Hexanol 43.0 86.0 2. Acetic Acid 6.0 13.0 3. Alkyl Phenol 3157.0 6314.0 4. Boric Acid 52.0 130.0 5. Calcium Chloride 7.0 14.0 6. Carbon -di-Oxide 434.0 869.0 7. Caustic Lye (100%) 708.5 1415.4 8. D.M. Water 1.8 3.6 9. Ethylene Carbonate 729.0 1823.0 10. Filter Aid-Coarse 105.3 210.7 11. Filter Aid-Fine 75.4 173.8 12. Formic Acid 2.4 5.8 13. Heavy Polyamine-HPA/DETA Mix 55.0 138.0 14. Heavy Polyamine-Pure 338.0 845.0 15. HR PIB 1000MW 758.0 1782.0 16. HR PIB 2300MW 4838.0 11384.0 17. Iso Decyl Alcohol 130.0 261.0 18. Maleic Anhydride 452.0 1064.0 19. Molybdenum Tri Oxide 60.2 150.5 20. Mono Ethylene Glycol 484.1 988.2 21. Mono Methyl Amine-MMA 18.1 36.1 22. Para - formaldehyde 25.0 50.0 23. Slaked Lime 1548.6 3098.2 24. Sulfonic Acid 862.0 1726.0 25. Sulfur 491.3 982.9 26. Lube Oil 150N 8562.0 22543.0 27. Imported Additive Components 3000.0 7200.0
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Table-4 Raw materials for new component manufacturing New Component (ZDTP) S. Raw Materials Manufacturing unit No (MT/ Annum) 1 Phosphorous Penta Sulphide (P2S5) 5336
2 Secondary Butyl Alcohol (SBA) 6013
3 Methyl Iso-Butly Carbinol (MIBC) 2702 4 Zinc Oxide 2003 5 Glacial acetic acid 20 6 Lube oil (150N) 6953 7 Caustic lye (100%) 1925 8 Filter aid 342
2.7 WATER REQUIREMENT
The total requirement of raw water for the existing unit is 175 KLD and after proposed expansion / new component (ZDTP) will be 245 KLD/ 308KLD respectively. Entire water requirement will be met from Chennai Metro Water Supply and Sewerage Board (CMWSSB) and there is no bore well source inside the plant premises.
2.8 POWER AND FUELS
Power requirement is being met from TNEB (Tamil Nadu Electricity Board) and third party producer. However, adequate DG sets are available to back-up power requirement during power restrictions by TNEB.
The unit uses furnace oil as the main fuel for its package steam boilers and thermic fluid heaters. Diesel fuel is used for DG generators and consumption quantities will vary based on the utilization.
3. DESCRIPTION OF THE ENVIRONMENT
3.1 AIR AND METEOROLOGICAL ENVIRONMENT
Six ambient air quality stations were proposed within a radius of 5 km from the project site during February to April 2015. Parameters such as VOC, heavy metals, gaseous pollutants and particulate matter were analyzed. PM2.5 ranged between 20.8- 33.6 μg/m3 across the monitoring
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locations, PM10 ranged between 53.7 – 62.3 μg/m3, SO2 varied between 12.8 to 15.2 μg/m3, NO2
varied between 16.7 to 25.8 μg/m3, NH3 ranged from 3.8-7.8 μg/m3, TVOC ranged from 1.7 – 2.8
μg/m3and other NAAQ parameters like O3, Pb, CO were below detectable limits. All the parameters of NAAQ standards were within the prescribed limits.
3.2 NOISE ENVIRONMENT
The prevailing ambient noise levels were monitored at six locations within the study area of 5 Km radius. During the study period, day time noise levels varied between 48 to 68 dB (A) across the sampling stations and night time noise levels varied from 43 to 57 dB (A)and are well within the standards prescribed by CPCB.
3.3 WATER ENVIRONMENT
To assess the quality of water around the project site, three sampling locations of surface water and three locations for ground water were selected within 5km radius of the site for physiochemical and biological parameters. pH: 6.8-7.8; TDS: 1353-59598 mg/l; conductivity: 1990-75440 S/cm; alkalinity : 110-2150 mg/l, total hardness : 496-7407 mg/l; chloride: 416-35137 mg/l; sulphate : 203- 2705 mg/l; sodium : 260-21000 mg/l and potassium: 22-780 mg/l which reflect saline water characteristics due to tidal influence (estuary). Nutrient content in terms of nitrate in all water samples including coastal waters were in the ranges as 1.33 -2.87 mg/l. Dissolved oxygen levels in all surface water including marine water samples are in the range of 6.3- 6.7 mg/l respectively.
3.4 SOIL ENVIRONMENT
Soil characteristics such as color, porosity, soil texture, chromium, copper, sodium, chlorides etc., were analyzed at six sampling locations within 5km radius of the site. The pH of the soil samples ranged from 5.7 to 7.54 across the sampling stations. The electrical conductivity of the soil samples ranged from 126 to 756µohms/cm across the sampling stations. The concentration of organic matter ranged from 0.229 to 0.745 % across the sampling stations. Copper levels ranged from 4.46 to 9.66 mg/kg and bulk density from 1.22 to 1.65 gm/cc.
3.5 ECOLOGY
There are no Wild life sanctuaries/ / National /Parks/ Reserved forest within 10 Km radius of the site and there is no rare/ endangered species within the project study area.
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3.6 SOCIO-ECONOMIC ENVIRONMENT
The proposed site is located in Notified Industrial Area. For the proposed expansion and new component (ZDTP) manufacturing, there is no additional requirement of land. There is no rehabilitation and resettlement is involved. The proposed projects will provide direct and indirect employment opportunities with the project area, there by contributing for socio economic improvement.
4. ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
The emission details for existing stack details are analyzed and modeled by AERMOD software and assessment methods like matrix method.
Based on the baseline monitoring data and incremental concentration, the ground level concentration (GLC)is predicted. It is found that concentration levels arising from the projects are within NAAQ limits. Due to the proposed expansion and new component manufacturing, there will be a no increase in air pollution load.
Table -5 Predicted GLC for existing and proposed stack Estimated NAAQ Baseline Maximum Predicted Downwind standard Plume Parameters data Incremental Maximum distance g/m3 Direction (µg/m3) Concentration GLC (µg/m3) (km) (24hrly) (µg/m3)
SOX 10.65 0.494 11.144 80 SE 0.67
NOX 25.79 2.148 27.938 80 NW 1.06 PM 56.27 0.751 57.02 100 NW 1.09
5. ANALYSIS OF ALTERNATIVES
This project can lead to economic prosperity as there is good market potential for lubricating oil additive packages. In view of growth in demand in recent years for lubricating oil additives; IAL intends to increase its production capacity.
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Since the expansion proposal is through debottlenecking activities involving minimal capital investments the expansion is within the existing facility only.
The proposed new component manufacturing (ZDTP) unit does not have any alternative technology options.
The production of ZDTP in this existing facility will be consumed in-house as intermediate for manufacturing of lubricating oil additives and also for exports.
6. ENVIRONMENTAL MONITORING PLAN
Monitoring of various parameters will be carried out regularly to assess the pollution level inside the plant and nearby area. This will be useful to compile the pollution related data for remedial measures and find out efficiency level of pollution control measures adopted. Monitoring of environmental samples shall be done as per the guidelines provide by MoEF/CPCB/TNPCB. The methods conducted or applied shall be approved or sanctioned by the any recognized body or authority i.e. MoEF/CPCB/TNPCB
7. ADDITIONAL STUDIES
As a part of additional studies Risk Assessment was done for storage of solvents and the existing Disaster Management plan available will be extended for the proposed expansion and new component manufacturing (ZDTP) facility also. Public Consultation has been exempted for the project as per the TOR since the site is located in Notified Industrial area.
7.1 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN
Predicting and evaluating risk to take appropriate preventive measures during the operation phase. The ALOHA software is used to identify the risks such as BLEVE, toxic release, vapor cloud explosion for the hazardous scenario involving chemicals like Hydrogen sulphide, Methylamine,
CO2which are handled in the plant along with the magnitude of its impacts. In most of the cases, the risks are tolerable and existing mitigation measures are found adequate.
Disaster Management plan is already available for the following
Emergency shutdown procedure
Emergency response to H2S alarm
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Failure of utilities
Reporting and responding to emergencies
Role of key persons during emergency.
The same will be extended for proposed expansion and new component manufacturing (ZDTP) facility also 8. ENVIRONMENTAL MANAGEMENT PLAN
The existing and proposed Environmental Management Plan during construction and operation phase to ensure the environmental protection is given below.
H2S gas stream from the existing/ expanded phenate unit is scrubbed completely in 3 stage caustic scrubber before being discharged to the atmosphere. The vent from caustic
scrubber is continuously monitored for H2S through online analyzer. The spent caustic generated from scrubber is stored in closed storage tank and sold to nearby Sodium Sulphide flakes manufacturers
H2S generated from the proposed ZDTP plant will be treated in dedicated Caustic scrubber
system and converted to ~ 13 to 15% Sodium sulphide (Na2S) solution. The Na2S solution is further concentrated in Multiple Effect Evaporators (MEE) system and then flaking is
done in flakers to manufacture Na2S flakes.
H2S sensors are installed in different areas of plant premises to monitor H2S. H2S sensor at the caustic scrubber vents are hooked up to Care Air Center (CAC), TNPCB for continuous monitoring.
The unit has installed Online Ambient Air Quality (AAQ) monitoring station for the following
parameters - PM10, SOX, NOX, CO, NO, NO2& O3and it is connected to Care Air Center (CAC), TNPCB. The unit has also installed online continuous stack monitoring station (for
parameters PM, SOX& NOX) for Thermic Fluid Heater and boiler stacks which are connected to CAC.
The unit has also installed continuous ambient VOC monitors in the plant.
Apart from online monitoring, monitoring is also done through approved Laboratories and monthly reports are submitted to TNPCB
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Existing sewage and effluent treatment plants are sufficient to manage the sewage and effluent generated from the expansion and new component manufacturing facility. Treated effluent is partly recycled for process use after treatment in RO unit and the rest being used for green belt development .Existing zero liquid discharge system will be extended for the proposed projects.
Indian Additives Limited has valid authorization for storage and disposal of Hazardous waste vide Authorization no.1089 dated 19/08/2011. The hazardous wastes are disposed either for incineration or co-incineration or landfill at common hazardous waste management facilities in Tamil Nadu.
8.1 OCCUPATIONAL HEALTH AND SAFETY
IAL has in-house Occupational Health Centre with full time Doctor / Nurses and carry out following activities Pre-Employment Examination Periodic Medical Examinations based on occupations Diet and Nutrition programmes Emergency First aid Treatment IAL has comprehensive Personal Protection Safety practices, which includes
Mandatory PPEs including personal gas monitors for H2S. Risk management activities Safety audits Training programmes Others like fall protection system, mechanized handling system etc.
8.2 FIRE AND EXPLOSION CONTROL
IAL has a structured and an extensive firefighting system that serves all the components of the plant. The main features of the existing firefighting system in IAL are as follows: Fire detector system Manual fire alarm call points Emergency siren Fire protection system
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Manual spray system Central fire hose stations Potable fire extinguishers
8.3 CORPORATE SOCIAL RESPONSIBILITY
Following are the CSR initiatives of the company Rs.20 Lakhs to CPCL Educational Trust Rs.20 lakhs to the Cancer Institute (W.I.A), Rs.40 Lakhs to Indian Institute of Technology (IIT), Madras to part finance their project activities on “sustainable waste management and resource recovery for clean and healthy villages". Rs. 10 Lakhs to M/s. Bhagavatula Charitable Trust (BCT), Visakhapatnam The company has spent Rs.9 lakhs at its Driver Management Centre established at Manali
8.4 BUDGETARY PROVISIONS FOR EMP
The details of capital and recurring (per annum) budget earmarked for pollution control, operation and maintenance of pollution control facilities, for greenbelt development and maintenance are given below. Table-6 Budgetary Provisions for EMP Recurring cost (Lakhs) per Capital Cost (Lakhs) annum Environmental New New S.No protection measures Expansion component Expansion component Project manufacturing Project manufacturing ZDTP Project ZDTP Project 1 Air Pollution Control 15.00 300.00 12.75 3.19 2 Water Pollution Control 15.00 161.02 73.95 18.49 3 Noise Pollution Control 1.00 1.00 0.50 0.13 Occupational Health 4.00 5.00 23.10 5.78 4 and safety
5 Green belt Development 3.00 3.00 2.4 1.0
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Recurring cost (Lakhs) per Capital Cost (Lakhs) annum Environmental New New S.No protection measures Expansion component Expansion component Project manufacturing Project manufacturing ZDTP Project ZDTP Project Storm water 2.00 10.00 1.00 1.00 6 Management 7 Waste Management 3.00 20.00 182.94 331.35
8 Fire Fighting 35.60 100.00 8.62 2.15 Total 78.60 600.02 305.26 363.09
9. ENVIRONMENTAL COMPLIANCES
Indian Additives Limited has obtained Environmental Clearance from MoEF, vide letter No. J11011/451/2009 –IA II (I) dated December 23, 2009. For the proposed expansion, an application was submitted to the Regional Office of MoEF at Chennai on 8/12/2014. Based on the application, the officials monitored the site on 10.01.2015 and the Post EC compliance Report for the existing facility was obtained.
The unit has obtained the consent for the expansion vide order no. 19300 dated04.06.2014 for Water Act and Order No. 15352 dated 04.06.2014 for Air Act. Application has been submitted for consent renewal for 2015-16 with the required fees and the same is in progress.
The unit has not received any notice under Section 5 of the Environmental (Protection) Act 1986 or relevant sections of Air and Water Acts.
The unit has valid authorization for storage and disposal of Hazardous waste vide Autorizationno.1089 dated 19/08/2011.
10. SUMMARY AND CONCLUSION
After studying the impacts and effects of the proposed project, some of the salient features and observations with respect to the proposed project are as follows:
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Since the proposed project is coming up in the existing plant within Notified Industrial area, there will not be any change in land use.
There is no forest land involved for the proposed expansion and new component manufacturing (ZDTP) and hence forest clearance is not applicable for the project.
There are no ecologically sensitive locations within 10 Km radius of the project site.
There will be positive impact on Socio economic conditions in and around the site due to the proposed project.
The increase in pollutant loads due to the proposed project is handled through appropriate pollution control measures without creating any additional impact to the environment.
The proposed expansion and new component manufacturing (ZDTP) is within the existing facility, hence most of the supporting facilities like utilities, effluent and sewage treatment systems will be shared with the existing set up, which are adequate as per the study.
The treated waste water will be partly reused for gardening within the facility and rest will be recycled for process reuse like Cooling Towers and boiler feed water make-up after treatment through RO system. Existing Zero Liquid Discharge system will be extended for the proposed projects.
Hazardous wastes generated from the proposed projects will be disposed through common hazardous waste management facilities similar to the existing facility as per the Authorization.
The facility has a well developed green belt covering 36.3% of the total plot area. There are no changes to the green belt area on account of proposed expansion and new component manufacturing (ZDTP) proposed project.
There are no unmitigated risks as per the Risk Assessment study carried out.
The impact of proposed projects will be fully mitigated by the Environment Management Plans (EMP).
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The unit has obtained Compliance report on the existing Environmental Clearance conditions from MoEF and also complies with all conditions attached to Consent orders. There are no litigation/ directions pertaining to environment against the project / company.
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CHAPTER 1 INTRODUCTION
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1 INTRODUCTION 1.1 PURPOSE OF THE REPORT The Environmental Impact Assessment (EIA) Report is prepared for proposed capacity expansion and new component Zinc Di-Thio Phosphate (ZDTP) manufacturing unit atIndian Additives Limited‟s (IAL) existing facility located at Manali Industrial Area, Thiruvallur District, TamilNadu State. The project scope involves expansion of existing Dispersants, Detergents, Poly Iso Butylene Succinic Anhydride (PIBSA) and Blending units which are used for making a variety of lubricating oil additive packages. The new component manufacturing facility scope involves setting up of unit within the existing facility for Zinc Di-Thio Phosphate (ZDTP) manufacturing, the production from this facility will be consumed in-house as intermediate for manufacturing lubricating oil additives and also for exports.
1.1.1 EIA REQUIREMENT The Government of India, Ministry of Environment Forest and Climate Change (MoEF&CC), New Delhi, vide notification no. S. O. 1533 dated 14th September, 2006, and its amendments, has made it mandatory to obtain „Prior Environmental Clearance‟ for New projects listed in the schedule, expansion and modernization of existing projects listed in the schedule, any change in product mix in the existing manufacturing unit falling within the schedule to that notification from MoEF (for Category A projects) or from SEIAA (for Category B projects).
Since the project involves expansion of existing facility and addition of new component manufacturing unit, the proposal attracts Prior Environmental Clearance as per EIA notification, 2006 and its amendments.
The project falls in synthetic organic chemical based units located inside the notified industrial area/estate are listed in schedule no. 5(F) under category „A‟ due to the applicability of general condition i.e., project location is within 10Km from “Critically Polluted Area (CPA)”.
IAL had already obtained Environmental Clearance from MoEF F.NO-J-11011/451/2009-IA 1(1) dated 23.12.2009 for the existing unit is attached in Annexure-1. The Consent to Operate for existing unit is attached in Annexure-2.
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The application along with the project documents for proposed capacity expansion and new component manufacturing (ZDTP)unit was submitted to MoEF. Based on the information furnished and presentation done before the 30th& 36thExpert Appraisal Committee meetings (Industry-2) held during 23rdDecember, 2014 and 17th March, 2015 respectively and Terms of Reference (TOR) were assigned for the EIA study by MoEF in the letter F.No. J-11011/400/2014-IA-II (I) dated 20th February 2015 and Amendment TOR dated 8th June, 2015, copy of the same is enclosed in Annexure-3. The consolidated compliance against TOR points is enclosed in the report.
With a view to evaluate likely impacts/ risks associated with the proposed projects on various component of the environment and propose appropriate management and monitoring plan, IAL took services of NABET Certified Consultant, Hubert Enviro Care System Pvt. Ltd.
1.2 PROPONENT BACKGROUND Indian Additives Limited (IAL) is a 50:50 joint venture company of Chennai Petroleum Corporation Limited (CPCL) and Chevron Oronite Company LLC. On 24th May 1989, Chevron Oronite Company LLC, USA (then Chevron Chemical Company) and Chennai Petroleum Corporation Limited, Chennai (then Madras Refineries Limited) signed an agreement to form a Company to engage in the development, manufacture and marketing of certain additive intermediates, components and packages for Lubricating Oils. The Company, christened as „Indian Additives Limited‟, was thus born legally on 13th July 1989. The plant has been operational since 1993. IAL was originally incorporated as a government company to foster domestic manufacture of lubricating oil additives so as to reduce reliance on import of such products. IAL‟s operation has, therefore, has a bearing on increasing national foreign exchange savings through import substitution.
IAL, an ISO 14001 certified company, is one of the leading manufacturers of lubricating oil additives for Automotive, Marine, Industrial, Rail Road & Natural gas engines lubricating oils. These lubricating oil additives play a crucial role in engine performance parameters like high specific power outputs, improved fuel-efficiency norms, improved driveability, extended drain Intervals, fuel economy and longer and trouble - free engine life.
IAL primarily caters to sectors of national and public interest as a majority of IAL‟s products are manufactured to meet the requirements of the Indian Railways, and government companies such
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as Indian Oil Corporation, Bharat Petroleum Corporation Limited and Hindustan Petroleum Corporation Limited.
1.3 PROMOTERS AND BACKGROUND 1.3.1 CHENNAI PETROLEUM CORPORATION LIMITED (CPCL) Chennai Petroleum Corporation Limited (CPCL), formerly known as Madras Refineries Limited (MRL) was formed as a joint venture in 1965 between the Government of India (GOI), AMOCOand National Iranian Oil Company (NIOC) having a shareholding in the ratio 74%: 13%: 13% respectively.
CPCL has two refineries with a combined refining capacity of 11.5 Million Tonnes Per Annum (MMTPA). The Manali Refinery has a capacity of 10.5 MMTPA and is one of the most complex refineries in India with Fuel, Lube, Wax and Petrochemical feed stocks production facilities. CPCL's second refinery is located at Cauvery Basin at Nagapattinam. This unit was set up in Nagapattinam with a capacity of 0.5 MMTPA in 1993 and later enhanced to 1.0 MMTPA. As a part of the restructuring steps taken up by the Government of India, Indian Oil Corporation Limited (IOCL) acquired equity from GOI in 2000-01. In July 2003, NIOC transferred their entire shareholding to Naftiran Intertrade Company Limited, an affiliate, in line with the Formation Agreement, as part of their organizational restructuring. Currently IOC holds 51.89% while NICO holds 15.40%.
1.3.2 CHEVRON ORONITE COMPANY LLC Chevron Oronite Company LLC (COCL) is a world-class developer and manufacturer of fuel and lubricant additives and chemicals designed to enhance the performance of all types of transportation and industrial equipment. Chevron‟s global presence allows them to deliver research and innovation, and provide manufacturing and supply chain distribution to meet their customers around the world. Chevron Oronite develops and markets quality additives that improve the performance of fuels and lubricants and it is a subsidiary of Chevron Corporation, Oronite employs more than 2,000 people worldwide in a global organization comprising three regional operations with sales networks that extend to local markets.
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1.4 BRIEF DESCRIPTION OF THE PROJECT 1.4.1 PROPOSED EXPANSION IAL proposes to expand its existing lubricating oil additives manufacturing facility through debottlenecking to meet the growing market demand in lubricating oil additive segment.
1.4.2 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT IAL also proposes to set up new component manufacturing unit in the existing facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the intermediate for lubricating oil additive manufacturing. This is a backward integration project and the production from this facility will be consumed in-house as intermediate for manufacturing lubricating oil additives and also for exports.
Both the above projects provide opportunity for additional revenue generation through both domestic and international markets apart from meeting lubricating oil additives growth requirements in local market. These projects will also create additional employment opportunities both direct and indirect.
1.5 PROJECT SETTING The site is located in Notified Manali Industrial Area. Manali is a Northern Suburb of Chennai city. The Industrial area is mainly allocated for Petroleum Refining and Petrochemical based industries. Major industries located are given below with its distance and direction from the Project site. The satellite imagery for the same is attached as Annexure -4.
Table 1-1 List of industries around10 Km radius of the project site
Distance (Km) & S.No Industry Product Direction from IAL site 1. M/s.MRF Tyres Tyres 8 - SW 2. M/s. Carborundum Universal Ltd. Super Refactories 3 - E 3. M/s. CPCL Petroleum Refinery 1.5 S 4. M/s. Indhumathi refineries Edible Oils 9 – SE 5. M/s. Eveready Industries Batteries 3.5 – SE 6. M/s. IOCL Lube oil Plant 1.2 – W
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Distance (Km) & S.No Industry Product Direction from IAL site 7. M/s. Bharath Petroleum Lube oil Plant 3.64 - W 8. M/s. HPCL Terminal Oil Terminal 7.80 – NE 9. M/s. Madras fertilizers Limited Fertilizers 0.50 – SW 10. M/s. Petro Araldite Epoxy Resins 0.85 – SE 11. M/s. Manali Petrochemicals Limited Petrochemicals 1 – W 12. M/s. Tamilnadu Petroproducts Limited Petrochemicals 0.50 - N 13. M/s.TPL, Heavy Chemicals Division Chlor Alkali 0.50 – SW 14. M/s.TPL Linear Alkyl Benzene Division Petrochemicals 0.50 - N 15. M/s. Indian Oil Corporation Bulk terminal & bottling plant 6.6 - SW 16. M/s. Toshiba JSW Turbine Turbines 3 – NW 17. M/s. Sattva CFS Pvt. Ltd Warehouse 4.94 - NW 18. M/s. Ashok Leyland Automobile 1 6 – NE 19. M/s. North Chennai Thermal Power Station Power Plant 9.26 – NE 20. M/s. Coromandel Fertilizers Fertilizer 5.30 - NE 21. M/s. Hinduja Foundries Foundry 5.30 – NE 22. M/s. Ennore Thermal Power Plant Power Plant 4.40 – NE 23. M/s. Nicholas Piramal Pharmaceutical 4 - NE 24. M/s. Cetex Petrochemicals Limited Petrochemicals 0.48 – SW 25. M/s. Kothari Petrochemicals Limited Petrochemicals 0.52 – SW 26. M/s.SRF Polyesters 2.33 - W
1.6 APPLICABLE REGULATORY FRAMEWORK The following are applicable Acts and Rules related to the proposed project:
1. EIA Notification 2006 and its amendments 2. Manufacture Storage and Import of Hazardous Chemicals Rules,1989and its amendments 3. Water (Prevention and Control of Pollution) Act,1974and its amendments 4. Air (Prevention and Control of Pollution) Act,1981and its amendments
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5. Hazardous Waste (Management, Handling and Transboundary movement)Rules,2008 and its amendments 6. Public Liability InsuranceAct,1991 and its amendments 7. Environmental (Protection)Rules,1986 and its amendments 8. The Noise Pollution (Regulation and control) rules, 2000 9. Tamil Nadu Factories Rules 1950 and its amendments 10. Petroleum Act, 1934 11. Explosive Act,1884 12. Central Motor Vehicle Act, 1988 The details of Acts and Rules with applicability to the proposed project are given in Table 1-2.
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Table 1-2Applicable Acts and Rules for the proposed project
S.No Act and Rules applicable Purpose Objective Applicability 1. EIA Notification 2006 and its New projects, Expansion Protection and Improvement of As the proposal is for expansion amendments. modernization, change of the Environment and new component product mix of the existing manufacturing, Environmental project clearance from Ministry of Environment & Forest is applicable 2. The Manufacture, Storage Handling of Hazardous Regulate the manufacture, Preparation/ update of On-site and Import of Hazardous Chemicals storage and import of Emergency Preparedness Plan Chemicals Rules, 1989 and Hazardous Chemicals and submission to Factory its amendments inspectorate. Preparation/ update of Safety Report and submit to Factory inspectorate. Preparation of Material Safety Data Sheet. 3. The Water (Prevention and New projects, Expansion Prevention, control and Consent to Establish and Consent Control of Pollution) Act, modernization, change of abatement of water pollution to Operate from State Pollution 1974 and its amendments. product mix of the existing Control Board to be obtained for project, expansion and new product Existing plants
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S.No Act and Rules applicable Purpose Objective Applicability 4. The Air (Prevention and New projects, Expansion Prevention, control and Consent to Establish and Consent Control of Pollution) Act, /modernization, change of abatement of air pollution to Operate from State Pollution 1981 and its amendments. product mix of the existing Control Board to be obtained for project, Existing industries expansion and new product 5. The Hazardous waste Management, Handling and Prevention, Control and Hazardous waste Authorization (Management, Handling and Transboundary Movement of abatement of pollution from State Pollution Control Board Transboundary Movement Hazardous waste to be obtained for expansion and Rules) 2008 and its new product amendments. 6. The Environmental New projects, Protection and Improvement of Environmental Standards as (Protection)Rules,1986 and Expansion/modernization the Environment specified are to be complied. its Amendments change of product mix of the Submission of Environment existing project, Existing Statement on yearly basis to industries TNPCB 7. The Noise Pollution New projects, To protect the workers and Noise control measure. (Regulation And Control) Expansion/modernization public from noise related Comply with Noise standards and Rules, 2000 change of product mix of the problems submission of monthly report to existing project, Existing TNPCB industries 8. The Public Liability Insurance Transportation of Hazardous To provide immediate relief to Provision of Liability Insurance Act, 1991 and its Substance. persons affected by accident Policy.
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S.No Act and Rules applicable Purpose Objective Applicability amendments involving hazardous substances and also for Establishing an Environmental Relief fund 9. Tamil Nadu Factories Rules New projects, Control of workplace Factory License from Factory 1950 and its amendments. Expansion/modernization environment, and providing for inspectorate. change of product mix of the good health and safety of existing project, Existing workers industries 10. The Petroleum Act, 1934 New projects, Production, Storage and import License acquired for storage and Expansion/modernization of petroleum and provides the adequate safety measures are in change of product mix of the regulations for the safety and place. existing project, Existing environmental measures industries 11. The Explosive Act, 1884 New projects, Production, Storage and import Safety measures are complied for Expansion/modernization of explosive substance in and the storage of chemicals in the change of product mix of the around the project and plant as per PESO guidelines. existing project, Existing provides the regulations for the industries safety and environmental measures 12. The Central Motor Vehicle New projects, Check the pollution load of Adequate environmental
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S.No Act and Rules applicable Purpose Objective Applicability Act, 1988 Expansion/modernization vehicles inside the plant measures are put in place to change of product mix of the check the vehicular emissions. existing project, Existing industries
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1.7 METHODOLOGY ADOPTED FOR THE STUDY An Environmental Impact Assessment (EIA) is an assessment of the possible impact, whether positive or negative, that a proposed project may have on the environment, together consisting of the natural, social and economic aspects, i.e., aiming at “Sustainable Development” due to the project activities.
1.7.1 OBJECTIVES OF THIS EIA REPORT To ensure environmental considerations are explicitly addressed and incorporated into the development decision-making process. To anticipate and avoid, minimize or offset the adverse significant biophysical, social and other relevant effects of the above project proposal. To protect the productivity and capacity of natural systems and the ecological processes which maintain their respective functions. To promote development that is sustainable and optimizes resource use as well as management opportunities. To fully recognize the scope and requirements of the TOR and comply with the same.
1.7.2 EIA PROCESS The EIA process followed for this EIA report is composed of the following stages:
Study of project information Screening & Scoping Environmental pre-feasibility study & application for approval of ToR Collection of detailed project management plan/report Baseline data collection Impact identification, Prediction & Evaluation Mitigation measures & delineation of EMP Risk assessment and safety & disaster management plan Review & finalization of EIA Report based on the ToR requirements. Submission of EIA report for implementation of mitigation measures & EMP as well as necessary clearances from relevant Authority. The EIA Cycle based on the above stages has been illustrated in Figure 1-1
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Study of Project Details
Screening and Reconnaissance Survey
Feasibility Study and Application Of TOR
Scoping and Application Of TOR
Collection Of Detailed Project Plan/Report Establishment of Baseline Environmental Status
Identification Of Monitoring, Locations For Identification of Secondary Monitoring & Sampling, Analysis Of Samples And Data Sources & Collection of Data Generation Of Primary Data
Compilation of Verification And Validation of data
Identification, Prediction & Evaluation of Impacts Consequence Analysis & Risk Assessment
Citation Of Necessary Mitigation Measures, Delineation of Environment Monitoring And Management Plan Citation Of Necessary Preventive, Control & Precautionary Measure. And Delineation of Safety And Disaster Management Plan
Preparation of Draft EIA Report & Review
Incorporation Of Corrections Or Suggestions By Reviewers
Preparation & Issue Of Final EIA Report
Submission by/Appraisal by Authorities for necessary clearance
Figure 1-1EIA process cycle
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CHAPTER 2 PROJECT DESCRIPTION
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2 PROJECT DESCRIPTION
2.1 ABOUT THE PROJECT 2.1.1 EXISTING FACILITY Indian Additives Limited has a manufacturing facility located at Manali Industrial Area, Thiruvallur District, which consists of intermediates (components) manufacturing and blending units for making variety of lubricating oil additive packages. The intermediates (components) manufacturing involves batch processes to produce Dispersants(Succinimides), Detergents(Phenates/ Sulfonate), Poly Iso Butylene Succinic Anhydride(PIBSAs). Blending is the key operation where the above intermediates (components) made within IAL and other intermediates (components) imported from other Chevron Oronite facilities are blended to make different lubricating oil additive packages based on market requirements.
2.1.2 PROPOSED EXPANSION IAL proposes to expand the capacity of its existing manufacturing facility to meet the growing market demand in lubricating oil additives. The proposed expansion activity is planned through debottlenecking with some minor investments, without change in process, raw materials and products. The expansion project scope mainly involves addition of inline blenders, pumps and enhancement of vessels/ storage tanks, with an investment of Rs.12 Crores. The implementation period will be around 10 months.
2.1.3 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT In addition, IAL proposes to set up new component manufacturing unit in the existing facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the intermediate for lubricating oil additive manufacturing. This is a backward integration project involving installation of batch reactors, overhead and filtration systems with other associated supporting facilities, including treatment
facility for H2S off gas generated from the process. The production from this facility will be consumed in-house as intermediate for manufacturing lubricating oil additives and also for exports. The investment for this proposal will be Rs.110 Crores and implementation period will be 20 months.
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Table 2-1List of products /by-products– existing and proposed with quantity
After Proposed New Existing Proposed component S.No Product Expansion (ZDTP)
MT/annum
1 Automotive, Marine, - Industrial, Rail Road and Natural gas 25000 60000 engine Lubricating Oil additive packages.
2 Succinimides 10000 25000 -
3 Phenates/Sulfonates 10000 20000 -
PIBSAs (Poly Iso- - 4 Butelyne Succinic 8500 20000 Anhydride)
By product (Mix of - sodium sulphide, 5 3500 7000 sodium hydrogen sulphide& caustic)
Zinc Di-Thio 6 - - 20000 Phospates (ZDTP)
By product (Sodium 7 - - 5000 Sulphide flakes)
2.2 JUSTIFICATION FOR THE PROJECT The expansion project will support meeting growing market demand for lubricating oil additives in Indian market, thereby improving country‟s revenue generation.
The proposed new component (ZDTP) manufacturing project is of backward integration model will help in improving company‟s revenue apart from mitigating other business risks as the company is currently sourcing this intermediate from external supplier. This project also provides opportunity to export the manufactured component to other lubricating oil additive companies across the world. Hence this will help to boost the economy of the country through additional revenues from exports.
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The existing Plant has around 120 employees and 200 contract work men supporting all operational activities and there will be an increase in manpower after these proposed projects to a total of 156 employees and 300 contract workmen. Apart from this, there will also be a considerable increase in indirect employment on account of increased material movements
Table 2-2 Salient features of the project
S.No. Particulars Details 1. Project “Proposed Expansion and New Component ZDTP (Zinc Di-Thio Phosphate) Manufacturing Unit at Existing Facility” 2. Project cost Rs. 12 Crores for Expansion Rs.110 Crores for ZDTP Manufacturing 3. Power requirement Existing-550000 KWH/Month After Expansion- 750000KWH/Month After new Component- 1050000KWH/Month 4. Project land area (Existing) 23.57 Acres 5. Manpower After After proposed Manpower Existing proposed new expansion component (ZDTP ) Employees 120 140 156 Contract 200 260 300 Laborers
6. Source of water supply Chennai Metro Water Supply and Sewerage Board (CMWSSB)
2.3 PROJECT LOCATION The project site is located at SF No. 265(P) Manali Village, Thiruvottiyur Taluk, Tiruvallur District,Tamil Nadu. The site is located about 2 km from Thiruvottiyur Town and it is on the express highway connecting Thiruvottiyur and Ponneri. The site is located south of this road. The nearest railway station is Thiruvottiyur .Table 2-3 depicts the project location details. The location of the site is shown in Figure 2-1.
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Table 2-3 Project site and surrounding features
S.No Particulars Details 1. Geographical Location 13°10'31.27"N, 80°17'1.45"E Towards North 13°10'16.10"N, 80°16'59.89"E Towards South 13°10'24.28"N, 80°16'57.66"E Towards West 13°10'24.25"N, 80°17'3.63"E Towards East Village: Manali, Taluk: Thiruvottiyur, District: Thiruvallur State: Tamil Nadu 2. Land Use as per CMDA Special and Hazardous Industrial Zone Vide Map no MP- II/CMA (M) 3/2008 (Enclosed in Annexure -5) 3. Nearest Railway Station Chennai Central - 9.85 km (South) Thiruvottiyur-2.01 Km (East) 4. Nearest Airport Chennai Meenambakkam Airport – 23.10 km (south west) 5. Highway Manali Road - SH 56 road- adjacent to the site 6. Sea port Chennai port – 7.13 Km (South East) Ennore Port – 9.57 Km (North East) 7. Nearest habitation Manali - 2.62 Km (south) 8. Densely populated area Tiruvottiyur -2.30Km (East) 9. Population in Manali 35248 as per the census data (2011). 10. Inland water bodies Surplus canal from Kortalaiyar River - 0.20Km (North) Buckingham canal – 0.63 Km (East) Periyathoppu Lake - 3.04Km (West) Bay of Bengal – 3.15Km (East) Madhavaram Lake-3.65 Km (South West) Kadapakkam Panchayat Lake- 4.26 Km (North West) 11. Forest/Wildlife Sanctuary Nil with in 10 Km radius
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Figure 2-1 Location of the project site
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The layout of Manali Industrial Area is given in Figure 2-2.
Figure 2-2 Location of project site within Manali Industrial Area
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Figure 2-3Google image of project site with boundaries (1 Km radius)
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Figure 2-4 Topo sheet showing 5 km radius of project site
2.4 LAND USE DETAILS The proposed project is planned in the demarked area within the existing facility. There are no major changes in land distribution and the details are as given below in Table 2-4.The land documents are enclosed in Annexure-6. There is no forest land involved for the project hence permission from Forest Department is not applicable.
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Table 2-4 Land use breakup for the project
Area in acres After proposed After S.No Land allocation details new Existing proposed component expansion (ZDTP) 7. Roads and drains Area 3.39 3.39 3.39
8. Tank farm and yards 4.94 4.94 5.94
9. Effluent treatment plant 2.78 2.78 2.78
10. Building Area 2.10 2.10 2.90
11. Greenbelt development 8.56 8.56 8.56
12. Vacant land 1.80 1.80 -
Total Area 23.57 23.57 23.57
The site plan showing various facilities is given in Figure 2-5
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Figure 2-5 Existing Site plan showing facilities
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2.5 MANPOWER REQUIREMENT Table 2-5 Manpower requirement for the proposal
After proposed After proposed new Manpower Existing expansion component (ZDTP) Employees 120 140 156 Contract 200 260 300 Laborers
Total 320 400 456
2.6 RAW MATERIAL REQUIREMENTS 2.6.1 PROPOSED EXPANSION Following list of raw materials are used in the manufacturing of lubricating oil additives and related intermediates. Raw materials are sourced locally as well from global locations based on the requirement.
Table 2-6 List of raw materials - existing and proposed expansion
Existing After Expansion S.No Raw materials MT/Annum
1. 2 Ethyl Hexanol 43.0 86.0
2. Acetic Acid 6.0 13.0
3. Alkyl Phenol 3157.0 6314.0
4. Boric Acid 52.0 130.0
5. Calcium Chloride 7.0 14.0
6. Carbon-di-Oxide 434.0 869.0
7. Caustic Lye (100%) 708.5 1415.4
8. D.M. Water 1.8 3.6
9. Ethylene Carbonate 729.0 1823.0
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Existing After Expansion S.No Raw materials MT/Annum
10. Filter Aid-Coarse 105.3 210.7
11. Filter Aid-Fine 75.4 173.8
12. Formic Acid 2.4 5.8
13. Heavy Polyamine- 55.0 138.0 HPA/DETA Mix
14. Heavy Polyamine-Pure 338.0 845.0
15. HR PIB 1000MW 758.0 1782.0
16. HR PIB 2300MW 4838.0 11384.0
17. Iso Decyl Alcohol 130.0 261.0
18. Maleic Anhydride 452.0 1064.0
19. Molybdenum Tri Oxide 60.2 150.5
20. Mono Ethylene Glycol 484.1 988.2
21. Mono Methyl Amine-MMA 18.1 36.1
22. Para -formaldehyde 25.0 50.0
23. Slaked Lime 1548.6 3098.2
24. Sulfonic Acid 862.0 1726.0
25. Sulfur 491.3 982.9
26. Lube Oil 150N 8562.0 22543.0
27. Imported Additive 3000.0 7200.0 Components
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2.6.2 PROPOSED NEW COMPONENT (ZDTP) Following list of raw materials are used in the manufacturing of the component ZDTP. Raw materials are sourced locally as well from global locations based on the requirement. The raw material requirements are detailed in the Table 2-7.
Table 2-7 List of Raw materials for New Component (ZDTP)
Quantity S. No Raw Materials (MT/Per Annum)
1 Phosporous Penta Sulphide (P2S5) 5336
2 Secondary Butyl Alcohol (SBA) 6013
3 Methyl Iso-Butly Carbinol (MIBC) 2702 4 Zinc Oxide 2003 5 Glacial acetic acid 20 6 Lube oil (150N) 6953 7 Caustic lye (100%) 1925 8 Filter aid 342
2.7 UTILITIES AND SERVICES The utility requirements for the proposed project will be met from existing facility with appropriate augmentations. Details of the utilities are listed in Table 2-8
Table 2-8 Capacity of DG, Boilers and Thermic fluid Heaters Capacity Details After proposed After proposed new Fuel Existing Expansion component (ZDTP) Boilers 1x 5.0 TPH 1x 5.0 TPH 1x 5.0 TPH Furnace Oil 1x 6.5 TPH 1 x 10 TPH 1x 10 TPH 1x 15 TPH (stand-by) Thermic 2x 0.6MMKCal/hr 2x 0.6 MMKCal/hr 2x 2.0 MMKCal/hr Furnace Oil Fluid (standby) (will be decommissioned) (1 unit as stand-by) Heaters 1 X 2.0 2x 2.0 MMKCal/hr
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Capacity Details After proposed After proposed new Fuel Existing Expansion component (ZDTP) MMKCal/hr (1 unit as stand-by) DG 2x 550 kVA 1x 550 kVA 1x 550 kVA HSD Sets 1x 1010 kVA 1x 1010 kVA 1x 1010 kVA 1x 1500 kVA 1x 1500 kVA 1x 1500 kVA
2.8 POWER AND FUELS Power requirement is being met from TNEB (Tamil Nadu Electricity Board) and third party producer. However, adequate DG sets are available to back-up power requirement during power restrictions by TNEB.
The unit uses furnace oil as the main fuel for its package steam boilers and thermic fluid heaters. Diesel fuel is used for DG generators and consumption quantities will vary based on the utilization. Details of the power and fuel requirements are listed in Table 2-7
Table 2-9 Power and fuel requirement
Capacity Details After proposed After proposed new Source Existing Expansion component (ZDTP) Power 550000 750000 1050000 TNEB/ Third party Requirement KWH/Month KWH/Month KWH/Month producer Fuel oil for Diesel 60* KL/month 80* KL/month 110* KL/month PSU Oil companies generators (HSD) Fuel oil for Boilers 240 KL/month 400 KL/month 625 KL/month PSU Oil companies & Thermic Fluid heaters (Furnace Oil) * Consumption based on current power restrictions and may vary based on changes in restrictions from TNEB.
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2.9 WATER REQUIREMENT The total requirement of raw water for the Existing unit is 175 KLD, after proposed Expansion will be 245 KLD and after proposed new component (ZDTP) will be 308KLD. Entire water requirement will be met from Chennai Metro Water Supply and Sewerage Board (CMWSSB) and there is no bore well source inside the Plant premises. Details of water requirement for the proposed project is given in Table 2-10.The agreement for water supply is enclosed in Annexure-7
Table 2-10 Water requirement for the project
After proposed After proposed S. No Description Existing (KLD) new component expansion (KLD) (ZDTP) (KLD) 1 DM plant 47 66 75 2 Cooling tower 83 104 141 3 Caustic scrubber 15 30 42 4 Potable water 30 45 50 Total raw water 175 245 308 consumption
2.10 PROJECT SCHEDULE Proposed Expansion Project will be implemented in a period of around 10 months as the scope is mainly through debottlenecking activities.
MONTH S.No. TASK 1 2 3 4 5 6 7 8 9 10 1 ENGINEERING 2 PROCUREMENT 3 CONSTRUCTION i. CIVIL ii. MECHANICAL iii. ELECTRICAL iv. INSTRUMENTATION 4 COMMISSIONING Figure 2-6 Project schedule for proposed expansion
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Proposed ZDTP manufacturing unit will be implemented in a period of 20 months and this will be independent of the expansion project. (Gantt chart)
MONTH
S.NO. TASK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DETAILED 1 ENGINEERING 2 PROCUREMENT 3 CONSTRUCTION i. CIVIL ii. MECHANICAL iii. ELECTRICAL iv. INSTRUMENTATION PRE 4 COMMISSIONING 5 COMMISSIONING Figure 2-7 Project schedule for proposed new component manufacturing
2.11 PROJECT COST The Project Cost for proposed expansion is Rs.12 Crores. Details are as below in Table 2-11
Table 2-11 Project cost for proposed expansion
S.No Details Cost in Lakh Project Management & Detail Engineering 150 1 Service 2 Material cost
Equipment & Packages 465 Bulk Materials 197 Sub Total 663 3 Construction & Commissioning Cost Civil works 56 Equipment Installation work 29 Structural steel Erection cost 8 Piping works 31 Electrical works 36 Instrumentation works 60
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S.No Details Cost in Lakh Sub Total 221 4 Contingency 109 5 Commissioning & Testing Cost 12 6 Environmental Related Cost 46 Total Project Cost 1200
The project Cost for proposed ZDTP manufacturing is 110 Crores. Details are given below in Table 2-12 Table 2-12 Project cost for proposed ZDTP Manufacturing
S.No Details Cost in Lakh 1 Project Management &Detail Engineering 1,379 Service 2 Material cost
Equipment & Packages 3,752 Bulk Materials 1,807 Sub Total 5,560 3 Construction & Commissioning Cost
Civil works 1,027 Equipment Installation work 267 Structural steel Erection cost 77 Piping works 281 Electrical works 332 Instrumentation works 551 Sub Total 2,535 4 Contingency 996 5 Commissioning & Testing Cost 113 6 Environmental Related Cost 418 Sub Total 1,526 Total Project Cost 11,000
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2.12 MANUFACTURING TECHNOLOGY / PROCESS DESCRIPTION 2.12.1 PROPOSED EXPANSION PLANT The process units built for Additives manufacturing are as under:
Dispersant ( Succinimides) plant
Detergent (Phenate / Sulfonate) plant.
PIBSA Plant (Raw material for Dispersant plant)
Blending plant
A brief process description is given below:
2.12.1.1 SUCCINMINDE UNIT The Succinimide unit consists of a batch agitated reactors and overhead collection systems. Succinimides are produced by reacting Poly Iso Butyl Succinic anhydride (PIBSA) and Heavy polyamine (HPA) mixture in typical proportions. PIBSA and HPA are reacted in the reactor at typical process conditions. The reactor overhead systems collects water formed during the reaction, along with the nitrogen used in the reactor to help sweep water vapour. A vent stream consisting of nitrogen is produced from the overhead system which is discharged through a high point vent system. The product from the reactor is stored in storage tanks and used in blending plant for making finished lubricating oil additive packages. Different types of succinimides are manufactured in this unit by based on the requirement in blending plant.
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Figure 2-8 Dispersants process flow diagram
2.12.1.2 PIBSA (POLY ISO BUTYLENE SUCCINIC ANHYDRIDE) UNIT PIBSA is an intermediate chemical that is used as key raw material for the production of succinimides. PIBSA is formed by reacting poly iso-butene with maleic anhydride. The operation is done in batches.
The PIBSA plant includes a hot oil coiled reactor, a reactor overhead system with steam ejectors and a filtration section. Polybutene is charged with excess maleic anhydride to the reactor. After the reaction, excess Maleic anhydride is stripped and reused back in next batches. A condensate stream containing trace quantities of Maleic acid and a vent stream consisting mostly of air leaks into vacuum system are discharged to the overhead system which is been scrubbed with water being discharged through vent. From the reactor, crude PIBSA is transferred to intermediate tank and then filtered. The filtrate is transferred to the intermediate storage tanks. The remnants left in the filter are filter cake which was collected in barrels and disposed as hazardous wastes as per authorization approval from PCB. Different grades of PIBSA are manufactured in this plant.
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Figure 2-9 PIBSA process flow diagram 2.12.1.3 PHENATES / SULFONATES UNIT Phenates are classified functionally as detergents. This is produced by reacting alkyl phenol with lime, sulfur and carbon dioxide in the presence of promoters such as ethylene glycol, Do Decyl alcohol, and sulfonic acid / Sulfonate. The Phenate plant consists of hot oil coiled reactors, reactor overhead system with steam jet ejectors a recovery section to recycle the promoters, and a filtration section.
The Phenate manufacturing operation is a batch process. The promoters and diluents oil are premixed with alkyl phenol before charging to the reactor. The remaining ingredients are charged in subsequent steps to form the active Phenate.
Hydrogen sulfide and water are formed during part of this reaction sequence. They are stripped
through the overhead system. Waste Gas containing Hydrogen Sulfide (H2S) is scrubbed in
Caustic scrubber unit, where H2S is fully absorbed in Caustic Lye and a byproduct Spent Caustic is produced. Glycol, water, alcohol and oil are recovered from the reactor overhead system and are separated in a water-glycol-oil separator. The alcohol- oil stream is sent to an alcohol-oil
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recycle tank. The wet glycol is sent to a glycol tank for recovery. The recovered alcohol and glycol are being reused in the process. From the reactor the crude Phenate product is sent to the filtration section for filtration. The final product is stored in intermediate storage tanks and being used in blending plant for making lubricating oil additives. The remnants left in the filter are filter cake which was collected in barrels and disposed as hazardous wastes as per authorization approval from TNPCB. Different types of detergents are manufactured in this plant using similar raw materials.
In the same unit, Sulfonate is manufactured by reacting Sulfonic acid with Lime, 2 Ethyl Hexanol, Calcium Chloride, Acetic acid and Formic acid in a similar process. From the reactor, the crude Sulfonate is sent to the filtration section for filtration. The final product is stored in intermediate storage tanks and being used in blending plant for making lubricating oil additives. The remnants left in the filter are filter cake which was collected in barrels and disposed as hazardous wastes as per authorization approval from TNPCB.
Figure 2-10 Phenates process flow diagram
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2.12.1.4 BLENDING UNIT Various components both manufactured within the plant premises and imported from other Chevron Oronite facilities are blended in batch and continuous inline blenders to make different lubricating oil additive packages. The product is pumped in to finished storage tanks, or directly loaded in road tankers or packed in MS barrels for dispatch to customers.
Manufactured &DMPlantManufactured
Succinimides Detergents
Imported additive components
Finished lube oil additive package
Figure 2-11 Blending process flow diagram
2.12.2 PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING ZDTP is produced by reacting mixed alcohol (Secondary Butyl Alcohol and methyl ISo-Butyl
carbinol) with Phosporous Penta Sulfide (P2S5) and Zinc oxide (ZnO) in the presence of promoter acetic acid.
The ZDTP plant consists of a steam coiled reactor, a reactor overhead system with steam vacuum pump, a neutralizer reactor, wiped film evaporator and a filtration section.
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The ZDTP manufacturing operation is a batch process. The mixed alcohol and P2S5 are mixed with lube oilin the reactor. This forms acid which will be neutralized with zinc oxide to form crude component. Hydrogen sulfide and water are formed as part of this reaction. The overhead stream containing Hydrogen Sulfide (H2S) is treated with Caustic in scrubber and spent caustic containing Sodium Sulphide is then converted to Sodium Sulphide flakes (by-product) through evaporation and flaking processes.
Synthesis of the Di- thio phosphoric acid (DTPA) by the reaction of Phosphorus penta sulphide (P2S5) and a hydroxylated compound (secondary alcohol).
Secondary alcohol used is Secondary butyl alcohol(SBA) + Methyl iso butyl carbinol(MIBC) mixture.
Reaction of Di –thio phosphoric acid(DTPA) on Zinc oxide (ZnO) to manufacture Zinc Di Thio Phosphate (ZDTP).
From the neutralizer, the crude ZDTP product is sent to the wiped film evaporation section to strip out the unreacted solvents in the crude. The spent solvent will be disposed to third party as per PCB authorization. From the evaporator, the crude ZDTP product is sent to the filtration section for filtration. The final product is stored in component storage tanks. The remnant left in the filter is filter cake which will be collected in barrels and disposed to third party as per PCB authorization.
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Figure 2-12 ZDTP process flow diagram
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Figure 2-13 Material Balance for proposed expansion and new component (ZDTP) manufacturing
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2.13 PLANT LAYOUT There may not be any change in Plant layout for the proposed expansion project. The proposed new component manufacturing unit (ZDTP) plant layout incorporating project components is attached as Annexure-8.
2.14 MITIGATION MEASURES - ENVIRONMENT 2.14.1 RAW MATERIAL STORAGE, HANDLING AND TRANSPORTATION All the raw materials input to the process are been metered through mass flow meters/ weigh vessels with appropriate automations to avoid excess charges. All key raw materials are charged to the reactors through closed pipeline systems including pneumatic systems for solid handling. Raw materials/ intermediates/ products are stored in closed tanks/drums provided with breather arrangements to avoid fugitive emissions. All material transfers are done through pumps in closed pipeline systems, however, containment dykes with appropriate segregations from storm water gutters are provided in all pumping areas to contain spillages in case of leaks. Table below shows the source and mode of transportation of raw materials. All the imported raw materials will be transported by road through Ennore Port.
Table 2-13 Mode of storage and transportation of raw materials
Mode of Material Material Mode of Transport Storage S.No Source Transport - Name Type - Primary Facility Secondary Ethylene Sea - Ship - Bulk 1 Liquid Imported Road - Trailers Tank Carbonate Containers Sea -Ship - Box Filter Aid- 2 Solid Imported Containers - FCL - Road - Trailers Warehouse Coarse Bags Sea -Ship - Box 3 Filter Aid-Fine Solid Imported Containers - FCL - Road - Trailers Warehouse Bags
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Mode of Material Material Mode of Transport Storage S.No Source Transport - Name Type - Primary Facility Secondary Sea - Ship - Bulk 4 HPA-DETA Liquid Imported Road - Trailers Tank Containers Sea - Ship - Bulk 5 HPA-Pure Liquid Imported Road - Trailers Tank Containers IsoDecyl Sea - Ship - Bulk 6 Liquid Imported Road - Trailers Tank Alcohol Containers Maleic Sea - Ship - Bulk 7 Liquid Imported Road - Trailers Tank Anhydride Containers Sea - Ship - Bulk 8 MIBC Liquid Imported Road - Trailers Tank Containers Sea -Ship - Box Molybdenum 9 Solid Imported Containers - LCL - Road - Trailers Warehouse Tri Oxide Bags Sea - Ship - Bulk 10 PIB 1000 MW Liquid Imported Road - Trailers Tank Containers Sea - Ship - Bulk 11 PIB 2300 MW Liquid Imported Road - Trailers Tank Containers Sea -Ship - Box Slaked Lime- 12 Solid Imported Containers - FCL - Road - Trailers Warehouse Malaysia Bags Sea -Ship - Box Slaked Lime- 13 Solid Imported Containers - FCL - Road - Trailers Warehouse Lhoist Bags Sulfonic Acid- Sea - Ship - Bulk 14 Liquid Imported Road - Trailers Tank AS 305D Containers OLOA Sea - Ship - Bulk 15 Liquid Imported Road - Trailers Tank Components Containers
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Mode of Material Material Mode of Transport Storage S.No Source Transport - Name Type - Primary Facility Secondary Sea - Ship - Bulk 2 Ethyl 16 Liquid Local Containers / Road - Road - Trailers Tank Hexanol Tanker Trucks Road - Trucks - 17 Acetic Acid Solid Local - Warehouse Carboys Road - Tanker 18 Alkyl Phenol Liquid Local - Tank Trucks Road - Trucks - 19 Boric Acid Solid Local - Warehouse Bags Calcium Road - Trucks - 20 Solid Local - Warehouse Chloride Carboys Carbon-di- 21 Liquid Local Road -Tanker Bullet - Bullet Oxide Caustic Lye Road - Tanker 22 Liquid Local - Tank (100%) Trucks Defoamer 350 Road - Trucks - 23 Solid Local - Warehouse CST Carboys Road - Trucks - 24 Formic Acid Solid Local - Warehouse Carboys Road - Tanker 25 Lube Oil 150N Liquid Local - Tank Trucks Mono Sea - Ship - Bulk 26 Ethylene Liquid Local Containers / Road - Road - Trailers Tank Glycol Tanker Trucks Mono Methyl 27 Liquid Local Road -Tanker Bullet - Bullet Amine 28 Para Solid Local Road - Trucks - - Warehouse
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Mode of Material Material Mode of Transport Storage S.No Source Transport - Name Type - Primary Facility Secondary Formaldehyde Bags
29 P2S5 Solid Local Road -Totes - Warehouse SBA- Road - Tanker 30 Secondary Liquid Local - Tank Trucks Butyl Alcohol Road - Trucks - 31 Sulfur Solid Local - Warehouse Bags Road - Trucks - 32 Zinc Oxide Solid Local - Warehouse Bags Road - Tanker 33 OLOA 262 Liquid Local - Tank Trucks Tank & OLOA Liquid & Sea - Ship - Bulk & 34 IAL Road - Trucks Ware Products Solid Box Containers House
2.14.2 TREATMENT OF LQUID WASTE Based on the adequacy review, the existing ETP and STP facilities are capable enough to handle increased effluents from the proposed ZDTP project. RO plant capacity will be augmented to handle the additional recycle requirements.
2.14.2.1 FOR PROPOSED EXPANSION Trade effluent streams of total quantity 196 KLD generated from process are treated in ETP of 300 KLD capacity. Sewage stream of quantity 40 KLD is treated in STP of 60 KLD capacity. Treated water is partially used for green belt development and the remaining water is sent to RO plant for further treatment and recycled to Cooling Tower and DM plant.
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2.14.2.2 FOR PROPOSED NEW COMPONENT (ZDTP) Trade effluent streams of total quantity 265 KLD generated from process will be treated in existing Effluent Treatment Plant (ETP), which is capable of handling300 KLD of effluent. There are no major changes to the effluent characteristics. Sewage stream of quantity 45 KLD will be treated in existing Sewerage Treatment Plant (STP), which is capable of handling 60 KLD effluents. Treated water from both the treatment plants is partially used for green belt development while the rest is being treated in Reverse Osmosis (RO) plant for recycle to Cooling Tower (CT) and Demineralization (DM) plant. The details of effluent management are given in Environmental Management Plan under Chapter- 7.
2.15 AIR POLLUTION CONTROL MEASURES The existing/ proposed package boilers, thermic fluid heaters and DG sets are of highly efficient in terms of combustion control and featured with in-built pollution control design. Hence the pollutant load from theseunits will be minimal which finally has been vented through chimneys of appropriate height.
The unit has also installed online stack monitoring station (CEMS) for thermic fluid heaters and
boiler stack and connected with Care Air Center (TNPCB). PM, SOX& NOX are being analyzed.
H2S sensors are installed at different areas of plant premises to monitor H2S. H2S sensor at the caustic scrubber ventsare hooked to CAC, TNPCB.
The unit has installed Online Ambient Air Quality (AAQ) monitoring station and it is connected with
Care Air Center (CAC), TNPCB. PM10, SOX, NOX, CO, NO, NO2& 03 are the parameters which are being analyzed. The unit has also installed continuous VOC monitors in the plant.
2.16 SOLID AND HAZARDOUS WASTES The hazardous wastes generated from this unit are collected, stored and disposed through authorized disposal cum recycle facilities as per the authorization from PCB and the unit has agreements with all waste disposal facilities for the same. There is no internal disposal facility availability within the site. The Authorization Letter from TNPCB is enclosed in Annexure-15.
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2.17 GREENBELT DEVELOPMENT Greenbelt is already developed inside the factory premises covering a total area of about 8.56 acres which is 36.3% of the total area. The species and plantation norms are followed as per the CPCB/ PCB directions.
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CHAPTER 3 DESCRIPTION OF ENVIRONMENT
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3 DESCRIPTION OF ENVIRONMENT
3.1 SCOPE OF STUDY The objective of the study is to assess environmental impacts due to proposed expansion and new component manufacturing (ZDTP) Unit. The area covering 5Km radial distance around the Project site has been delineated as study area.
The pre-project status of environmental quality is assessed through field surveys corresponding to different components of environment, viz. air, noise, water, land, biology/ecology and socio- economics. The current environmental quality status around the project site becomes the baseline status for proposed Project but at the same time it includes the environmental impacts from the already existing industrial area, commercial, infrastructure activities as well as residential zones in the study area. In this EIA study, the baseline status of all environmental components has been monitored during February to April 2015.
3.2 AIR ENVIRONMENT Assessment of baseline ambient air quality status in the vicinity of industrial site is an indispensable part of environmental impact assessment studies. The pre-project air quality status serves as the baseline upon which the predicted air pollution impacts from the proposed projects could be superimposed to derive the final (post-project) status of air environment in the project region. The tropical climatic conditions, especially monsoon winds prevailing over India mainly control the transport and dispersion of air pollutants during different seasons. According to the climatological conditions in India, the seasons considered for all practical purposes in air pollution studies are winter, summer and post-monsoon seasons. Significant changes, in predominant winds and weather conditions are observed in these seasons apart from the local topographic influences.
The baseline studies for air environment covers identification of specific air pollutants expected to have significant impacts from the proposed project along with the conventional/criteria air pollutants and assessing their prevailing levels in ambient air at optimum representative locations within the impact zone. The environmental impact assessment study requires monitoring of baseline status during one season (preferably non-monsoon season). The baseline status of air environment in the study area is assessed through a systematic air quality surveillance programme.
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Micro-meteorological data at project site is an essential requirement during study period for proper interpretation of baseline air quality status. The same data would also be useful in prediction of impacts through mathematical models. The baseline status within the impact zone around project site has been studied through reconnaissance followed by ambient air quality survey, and continuous record of meteorological data during field survey.
3.2.1 RECONNAISSANCE Reconnaissance survey was conducted around5 km radius from the project site which is located in Northern coast of Tamil Nadu in Thiruvallur District. The project site is situated in a flat terrain with ground elevation varying from about 3-8 meters Above Mean Sea Level (AMSL). In general, the study area experiences predominant wind from ENE, ESE, SE, E directions during the season of February to April, 2015. To establish the baseline monitoring status of air environment in the study area during the period of Feb - April, 2015, 6 AAQM locations within the radius of 5 kms were selected using network design criteria and monitored as per CPCB guidelines (Twice a week sampling and 24 hr continuous sampling). The selected sampling locations are reported in Table 3- 1 and Figure 3-1. The pollutants were analyzed during ambient air quality monitoring as listed in latest MoEF notification.
The background ambient air quality has been monitored for all the 12 parameters as per NAAQS notified on 16th September, 2009.
Table 3-1 Ambient Air Quality monitoring locations
Aerial Sampling Geographical distance from Direction with S.No Sampling station code coordinates the site in respect to site (km) 1. IAL – Near main AAQ1 13°10'28.90"N & 0 -- Gate 80°17'2.56"E 2. Ponniamman Nagar AAQ2 13°12'40.00"N 4.29 NW &80°16'17.50"E 3. Jai-Hind Nagar AAQ3 13°11'0.14"N & 2.17 NE 80°18'7.58"E
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Aerial Sampling Geographical distance from Direction with S.No Sampling station code coordinates the site in respect to site (km) 4. Tiruvottiyur AAQ4 13° 9'37.24"N & 2.36 SE 80°18'0.38"E 5. Krishna Nagar AAQ5 13° 9'15.58"N & 4.51 SW 80°14'52.71"E 6. Shastri Nagar AAQ6 13° 8'19.02"N & 3.94 S 80°16'50.37"E
Figure 3-1 Air quality sampling locations within 5Km Radius
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3.2.2 MICROMETEOROLOGY The micro-meteorological conditions in study area during air quality study period are of importance to understand the variations in ambient air quality status in study region. The prevailing micrometeorology at project site plays a crucial role in transport and dispersion of air pollutants released from the plant. The principal variables are horizontal transport and dispersion (average wind speed and directions), convective transport and vertical mixing (atmospheric stability) and also topography of the area as local influences.
For determining the prevailing micro-meteorological conditions during the study period, an automatic continuous digital weather station was installed at project site. The location is chosen such that there is no obstruction to the flow of wind and sunlight. The hourly meteorological data of humidity, wind speed, wind direction, temperature and solar radiation were recorded at the project site. These frequencies were computed on 8 hourly as well as 24 hourly basis and the corresponding results are used to draw wind rose for 00-08hrs, 08-16 hrs, 16-24 hrs and 00-24hrs corresponding to study period as shown in subsequent sections. The wind rose for the months of February, March, and April 2015 shows the predominant wind directions. The wind directions during the study period are ENE, ESE, SE, E. Accordingly, the impact zone will be spread in WSW, WNW, NW, W and NW directions. The average wind speed observed during the study period is 3 m/sec with the considerable frequency of a wind range of calm to about 22 km/hour.
Due to its proximity with the Bay of Bengal, the ambient temperature at project site ranged between 22-33.9°C while the relative humidity range from 47-87% at project site. The meteorological data collected during monitoring were used for interpretation of baseline status and to simulate the meteorological conditions for prediction of impacts in modeling studies. The Meteorological observations are summarized in Table 3-2 and the wind rose pattern for February, March and April 2015 are given in Figures 3-2 to 3-4 respectively.
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Table 3-2Meteorological observations
S.No Parameter Observation
1 Wind Direction ENE, ESE, SE, E 2 Wind Speed Range 0.5 to 13.75Km/ Hr 3 Annual Average Rainfall 950 mm to 1150 mm (2007 CGWB Report) 4 Average Wind Speed 3 Km/Hr 5 Temperature Range Max. Temp: 33.9°C Min. Temp: 22°C 6 Average Temperature 29°C 7 Humidity Range (24hr) 47 to 87% 8 Cloud cover clear
Figure 3-2 Wind rose for February 2015
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Figure 3-3 Wind rose for March 2015
Figure 3-4 Wind rose data for April 2015
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3.2.3 BASELINE STATUS
The three months (February to April, 2015) mean value of Particulate Matter (PM2.5), Particulate
Matter (PM10), Sulphur Dioxide (SO2), Nitrogen Dioxide (NO2), CO μg/m3, Pb μg/m3, O3, NH3, Benzene, Benzo (a) pyrene, As and Ni at various monitoring locations were within NAAQ
Standards during the monitoring period. The concentration of SO2 ranged from12.8 to
15.2μg/m3,NO2levels from 16.7 to25.8μg/m3, PM 2.5 Levels from 20.8 – 33.6 μg/m3, PM 10 levels from 53.7 – 62.3 μg/m3.
Table 3-3 Test Methods used for the analysis of Ambient Air Quality parameters
S.No Parameters Analytical method NAAQ Standards: 2009 1. Sulphur Dioxide IS:5182(Part-2):2001 50 (Annual) 80(24 Hours) (SO2), μg/m3 (Reaff:2006) 2. Nitrogen Dioxide IS: 5182 (Part - 6): 2006 40 (Annual) 80(24 Hours) (NO2), μg/m3 3. Particulate Matter IS: 5182 (Part - 23): 2006 40 (Annual) 60(24 hours) (PM2.5), μg/m3 4. Particulate Matter IS:5182 (Part– 23): 2006 60 (Annual) 100(24 hours) (PM10), μg/m3 5. CO μg/m3 IS:5182(Part–10):1999 2 (8 hours) 4 (1hour) (Reaff:2006) 6. Pb μg/m3 IS:5182(Part–22):2004 0.5(Annual) 1(24 hours) (Reaff:2006)
7. O3, μg/m3 IS: 5182 (Part – 9): 1974 100(8hours) 180 (1hour)
8. NH3, μg/m3 APHA(air) 2nd edition 100(Annual) 400(24 hours) (Indophenol-blue method) 9. Benzene, μg/m3 IS:5182(Part–11):1999 5 (Annual) 5 (Annual) (RA:2009) 10. Benzo (a) pyrene, IS:5182(Part– 1 (Annual) 1 (Annual) ng/m3 12):2004(RA:2009) 11. Arsenic, ng/ m3 APHA (air) 2nd edition 6 (Annual) 6 (Annual) 12. Nickel ng/ m3 APHA (air) 2nd edition 20 (Annual) 20 (Annual)
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Table 3-4 Average Ambient Air Quality monitoring data (February to April, 2015)
S.No Sampling stations Parameters
SO2 NO2 PM2.5 PM10 CO Pb O3 μg/m3 NH3 μg/m3 Benz-ene Benzo (a) As Ni ng/m3 TVOC μg/m3 pyreneng/m3 μg/m3 μg/m3 μg/m3 μg/m3 μg/m3 μg/m3 ng/m3 (μg/m3)
1. AAQ1 –IAL Site BDL BDL BDL BDL BDL BDL BDL 13.8 25.7 33.6 61.7 7.8 1.7 (DL 0.005) (DL 0.05) (DL10) (DL1) (DL1) (DL1) (DL5)
2. AAQ2 – Ponniamman BDL BDL BDL BDL BDL BDL BDL Nagar 12.7 22.2 20.8 53.7 8.3 2.8 (DL 0.005) (DL 0.05) (DL10) (DL1) (DL1) (DL1) (DL5)
3. AAQ3-Jaihind Nagar BDL BDL BDL BDL BDL BDL BDL 14.7 25.8 33.2 58.5 5.4 2.5 (DL0 .005) (DL 0.05) (DL10) (DL1) (DL1) (DL1) (DL5)
4. AAQ4 - Thiruvottiyur BDL BDL BDL BDL BDL BDL BDL 15.2 23.7 25.6 57.2 6.4 2.2 (DL0.005) (DL 0.05) (DL10) (DL1) (DL1) (DL1) (DL5)
5. AAQ5- Krishna Nagar BDL BDL BDL BDL BDL BDL BDL 13.5 20.3 27.3 62.3 3.8 1.8 (DL0 .005) (DL 0.05) (D10) (DL1) (DL1) (DL1) (DL5)
6. AAQ 6 – Shastrinagar BDL BDL BDL BDL BDL BDL BDL 12.8 16.7 32.4 58.8 4.8 2.3 (DL0 .005) (DL 0.05) (DL10) (DL1) (DL1) (DL1) (DL5)
NAAQS 80 80 60 100 4 1 180 400 5 1 6 20 - (24 Hours) (24 Hours) (24 hours) (24 hours) (1hour) (24 hours) (1hour) (24 hours) (Annual) (Annual) (Annual) (Annual)
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3.3 NOISE ENVIRONMENT The noise generated due to operation of individual process units at an industrial project site cause significant impacts on the surrounding environment including nearby human habitats. Such operations fall in the category of continuous point sources of noise generation. There are also some secondary noise sources associated with almost all types of large scale industrial projects, which are mainly vehicles used for transportation of materials as well as employees and material handling equipment at the project site. However, such sources could be categorized as intermittent/continuous noise sources depending on frequency/intensity.
The prevailing ambient noise level at a particular location is nothing but the resultant (total) of all kinds of noise sources existing at various distances around that location. The ambient noise level at a location varies continuously depending on the type of surrounding activities. The ambient noise levels generally does not reflect any seasonal variation, however, the weather conditions of wind direction, rain, snow, fog etc., physical conditions like barrier or any other natural ground variations (topography) as well as direction of source play significant role in regulating the noise propagation and ultimately the intensity of its impact.
The current status of noise environment within 5 km radius of the project site was assessed through identification of major noise sources, monitoring of baseline noise levels in the study area and measurement of resultant noise levels due to existing vehicular movement on major roads, according to existing land use pattern.
3.3.1 RECONNAISSANCE SURVEY A reconnaissance survey was conducted with a view to establish the baseline status of the environment with respect to noise levels in the study area. The Project site is adjacent to SH 56at Manali, Thiruvallur district, Tamil Nadu. There are number of large scale industries existing around the IAL site. The vehicular traffic on existing national highways in study area also contributes to the ambient noise levels in project area. The prime objective of noise monitoring is to establish the existing ambient noise levels during the day as well as night time in residential, industrial, commercial and silence zones in the study area around proposed project site. The prevailing ambient noise levels were monitored in and around 5Km radius at 6 locations during February to April, 2015 as represented in below Table 3-5 and Figure 3-3 using precision noise level meter.
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Table 3-5 Noise level monitoring locations
Aerial distance Sampling Sampling Geographical Direction with S.No from the site in station code coordinates respect to site (km)
1. IAL – Site NL1 13°10'30.17"N & -- 0 Entrance 80°17'1.52"E
2. Edayanchavadi NL2 13°12'13.97"N & NW 4.29 80°16'13.19"E
3. Jai-Hind Nagar NL3 13°11'0.14"N & NE 2.17 80°18'7.58"E
4. Tiruvottiyur NL4 13° 9'34.18"N & SE 2.36 80°18'3.37"E
5. Krishna Nagar NL5 13° 9'15.58"N & SW 4.51 80°14'52.71"E
6. Shastri Nagar NL6 13° 8'19.02"N & S 3.94 80°16'50.37"E
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Figure 3-5 Google earth Image showing noise level monitoring locations within 5Km radius
Figure 3-6 Noise monitoring in Edayanchavadi Figure 3-7 Noise monitoring in front of IAL
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3.3.2 NOISE LEVELS Noise is determined by recording the noise levels at day time and night time. Day time noise levels were recorded from 0600 to 2200 hrs and night time noise levels were recorded from 2200 to 0600 hrs.
3.3.3 BASELINE STATUS Noise levels in the villages and along Highways within the study area were measured using a precision microprocessor based digital noise level meter. Taking into consideration the quieter hour, the minimum equivalent noise level at a particular place is called the background noise level.
During the study period, day time noise levels varied between 48to 68 dB (A) across the sampling stations and night time noise levels varied from 43 to 57 dB (A) across the sampling stations. The field observations during the study period indicate that the ambient noise levels in the study area were well within the prescribed standards at all the different noise zones prescribed by CPCB.
3.3.4 LIMITS SET BY CPCB Industrial Area : Day Time - 75 dB (A); Night Time - 70 dB (A)
Commercial : Day Time - 65 dB (A); Night Time - 55 dB (A)
Residential Area : Day Time - 55 dB (A); Night Time - 45 dB (A)
Silence Zone : Day Time - 50 dB (A); Night Time - 40 dB (A)
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Table 3-6 Noise levels in Day and Night Time
Noise level in dB(A) Leq Limits dB(A) S.No Sampling location Area Day Night Day Night IAL – Site Entrance Industrial 1 65.7 48.9 75 70 (NL1) Area Edayanchavadi Residential 2 58.3 47.6 55 40 (NL2) Area Jai-Hind Nagar Residential 3 57.3 48.7 55 40 (NL3) Area Tiruvottiyur (NL4) Commercial 4 68 57 65 55 area Krishna Nagar (NL5) Residential 5 52.8 44.6 55 40 Area Shastri Nagar (NL6) Commercial 6 48.7 43.2 65 55 area
3.4 WATER ENVIRONMENT The impacts on water environment are inherent part of any major developmental projects in two ways: one is stress on water resources (continuous withdrawal of large quantities of water) and the other is pollution impacts through discharge of effluents. These impacts may be on either or both surface and groundwater resources in the project area depending on the specific situation. To address these issues it is necessary to take a stock of available water resources in project area with respect to their existing quality as well as their supportive capacity to represent the baseline status of water environment.
The existing water resources, both surface and ground water with the corresponding significance are identified within the study area around proposed Project of IAL. The representative sampling locations for surface water and groundwater are selected through reconnaissance of project area to assess the existing (pre-project) status of water quality in the study area. Physico-chemical, nutrient, Oxygen demand, bacteriological and biological parameters having relevance to public health and
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aesthetic significance are selected to assess the water quality status with special attention to raw water resources and the receiving body of the treated effluent discharge from proposed project. The standard methods prescribed for surface, groundwater and coastal marine water sampling as well as the analytical procedures for individual parameters is followed in this study.
3.4.1 RECONNAISSANCE The study area consists of Korttalaiyar River, Periyathoppu Lake, Madhavaram Eri and Sea coast- Bay of Bengal at about 3.12 Km distance on the Eastern side of project site. The sampling stations were chosen based on the existing pollution sources near these water bodies and threat of pollution in the future. The flow in the rivers passing through the study region are seasonal, high flows occur during monsoon season and low flow occurs during summer season. The region receives rainfall predominantly during monsoon season with an average annual rainfall of 950mm to 1150mmper year. The South west monsoon season is from July – September and North east monsoon is from October - December. Groundwater and water supply from CMWSSB (Metro water) are the principal sources for domestic and drinking purposes in almost all the villages near the study area. The water samples were collected around 5km radial distance from the site and analyzed by standard test methods which are given in table: The prevailing status of water quality has been assessed during February – April, 2015. Three sampling stations each for ground and surface water were selected for the study and the details are given in Table: 3-7, the findings of the water quality monitoring study is summarized in Table 3-8, 3.9 respectively. Table 3-7 Water quality Sampling Locations
Direction Aerial distance Sampling Geographical with S.No Sampling locations from the site in code coordinates respect to (km) site 1. IAL – test borewell GW1 13°10'26.48"N & -- -- 80°17'0.98"E 2. Netaji Nagar GW2 13°11'32.45"N & NE 3.50 80°18'34.64"E 3. Thiruvottiyur GW3 13° 9'50.89"N & SE 2.25 80°18'11.06"E
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Direction Aerial distance Sampling Geographical with S.No Sampling locations from the site in code coordinates respect to (km) site 4. Madhavaram Eri SW 13°9'47.09"N & SW 3.71 80°15'1.08"E 5. Korttaliayar River SW2 13°10'36.29"N & N 0.18 80°17'5.34"E 6. Marine water SW3 13°11'2.00"N & E 3.73 80°19'1.00"E
Figure 3-8 Google earth showing water sampling locations in 5Km radius
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Table 3-8 Test methods used for the analysis of water quality parameters
S.No Parameter Measured Test Method 1. pH (at 25°C) IS:3025 (Part - 11): 1983 (Reaff: 2006) 2. Electrical Conductivity IS:3025 (Part - 14): 1983 (Reaff: 2006) 3. Color IS:3025 (Part- 4) 1983 (Reaff 2006) 4. Total Hardness as CaCO3 IS:3025 (Part - 21) 1983 (Reaff 2006)
5. Total Alkalinity as CaCO3 IS:3025,1 (Part - 23) 1986 (Reaff 2009) 6. Cadmium IS:3025 (Part 41) 1991 7. Chloride as Cl IS:3025 (Part - 32) 1988(Reaff 2009) 8. Total Dissolved Solids IS:3025:1(Part - 16) 1984 (Reaff 2006) 9. Aluminium as Al IS:3025 (Part - 55) 2003 (Reaff 2009) 10. Chromium as Cr IS:3025 (Part - 52) 2003 (Reaff 2009) 11. Lead as Pb IS:3025 (Part - 47) 1994 (Reaff 2009) 12. Zinc as Zn IS:3025 (Part - 49) 1994 (Reaff 2009) 13. Sodium as Na IS:3025,5(Part - 45) 1993 (Reaff 2006) 14. Temperature IS:3025 (Part - 9) 1983 (Reaff 2006)
15. Chemical oxygen demand as O2 IS:3025 (Part-58)-2006 16. Dissolved Oxygen (mg/l) IS:3025 (Part - 38)1989 (Reaff 2009) 17. Salinity By calculation using Electrical Conductivity 18. Copper as Cu IS:3025 (Part - 42)1992 (Reaff: 2009)
19. BOD,5 days @200C as O2 5210B APHA22ndEdn 2012 20. Total coliform bacteria IS:1622 1981 (Reaff: 2009) (MPN/100ml) 21. F-Coli IS:1622, 1981 (Reaff: 2009)
3.4.2 BASELINE STATUS The prevailing status of water quality has been assessed through identification of water resources and appropriate sampling locations for both surface and groundwater quality in study area depending on topography, surface runoff as well as natural drainage systems during Post- monsoon season.
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Total 6 sampling locations were identified among that 3 ground water and 3 surface water samples collected at around 5Km distance. The depth of bore wells varied between 20 feet to 45 feet.
3.4.2.1 PHYSICO-CHEMICAL CHARACTERISTICS The results obtained for physico-chemical characteristics of surface water collected during Post- monsoon season are presented in Table3-9. The observed concentrations of various physico- chemical parameters in all surface water samples excluding marine water samples stretch falling in study area were pH : 6.8-8.2; TDS: 1353-39666 mg/l; conductivity: 1990-50200 S/cm; alkalinity : 110-270 mg/l, total hardness : 496-7407 mg/l; chloride: 416-19795 mg/l; sulphate : 203-2705 mg/l; sodium : 260-10800 mg/l and potassium: 22-780 mg/l Nutrient content in terms of nitrate in all water samples including coastal waters were in the ranges as 1.33 -2.87 mg/l. Dissolved oxygen levels in all surface water including marine water samples were in the range of 6.3- 6.7 mg/l respectively.
The heavy metals like nickel, cadmium, chromium, copper, lead and mercury were not detected in all surface water samples including marine water.
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Table 3-9 Analytical results on water samples collected in the study area
Korattalaiyar Madhavaram Netajinagar Thiruvottiyur River IAL Test S. No. Parameters Unit Eri (surface Sea water ground Ground (surface borewell water) water water water)
1 Colour Hazen Colourless Colourless Colourless Colourless Colourless Colourless
2 Turbidity NTU BDL (DL 1) 4 2 BDL (DL 1) BDL (DL 1) BDL (DL 1) 3 pH -- 7.81 8.03 8.22 6.93 7.57 6.89 4 Conductivity µS/cm 1990 50200 75440 12500 4860 4410 5 Total Dissolve Solids mg/l 1353 39666 59598 9250 3207 2999
6 Alkalinity as CaCO3 mg/l 185 130 2150 270 110 240
7 Total Hardness as CaCo3 mg/l 496 7407 1512 1650 1298 1075 8 Calcium as Ca mg/l 56 405 65 281 281 244 9 Magnesium as Mg mg/l 87 1554 328 230 145 113 10 Sodium mg/l 260 10800 21000 2345 452 516 11 Potassium mg/l 22 780 22 56.2 28.5 24.6 12 Chloride as Cl mg/l 416 19795 35137 3450 713 891
13 Sulphate as SO4 mg/l 203 2705 2078 1653 1617 853 14 Carbonate mg/l NIL NIL NIL NIL NIL NIL 15 Bi carbonate mg/l 226 159 2623 329 134 293
16 Nitrate as NO3 mg/l 2.56 2.89 1.33 1.42 2.87 2.65
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Korattalaiyar Madhavaram Netajinagar Thiruvottiyur River IAL Test S. No. Parameters Unit Eri (surface Sea water ground Ground (surface borewell water) water water water) 17 Fluorides as F mg/l 0.065 0.047 0.056 0.234 0.145 0.177 18 Cyanide mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01)
19 Arsenic mg/l BDL BDL BDL BDL BDL BDL (DL 0.005) (DL 0.005) (DL 0.005) (DL 0.005) (DL 0.005) (DL 0.005)
20 Cadmium mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01)
21 Chromium, Total mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01)
22 Copper mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) 23 Iron mg/l 0.218 0.339 0.26 0.436 0.276 0.339
24 Lead mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) 25 Zinc mg/l 0.154 0.567 0.346 0.452 0.986 0.578
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Korattalaiyar Madhavaram Netajinagar Thiruvottiyur River IAL Test S. No. Parameters Unit Eri (surface Sea water ground Ground (surface borewell water) water water water) 26 Manganese mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01)
27 Nickel mg/l BDL BDL BDL BDL BDL (DL 0.01) BDL (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01)
28 Selenium mg/l BDL (DL BDL BDL BDL BDL BDL 0.005) (DL 0.005) (DL 0.005) (DL 0.005) (DL 0.005) (DL 0.005)
29 Mercury mg/l BDL (DL BDL BDL BDL BDL BDL 0.001) (DL 0.001) (DL 0.001) (DL 0.001) (DL 0.001) (DL 0.001) 30 Dissolved Oxygen mg/l 6.4 6.7 6.3 NA NA NA 31 COD mg/l 6.3 4 5.9 BDL (DL 2.0) BDL (DL 2.0) BDL (DL 2.0) 32 BOD mg/l 2.9 2.6 2.2 BDL (DL 1.0) BDL (DL 1.0) BDL (DL 1.0) NA - Not Applicable
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3.4.3 HYDROGEOLOGY
The project study area is underlain by both porous and fissured formations. The important aquifer systems in the district are constituted by
I. unconsolidated & semi-consolidated formations II. Weathered, fissured and fractured crystalline rocks. The porous formations in the area include sandstones and clays of Jurassic age (Upper Gondwana), marine sediments of Cretaceous age, Sandstones of Tertiary age and recent alluvial formations. As the Gondwana formations are well-compacted and poorly jointed, the movement of ground water in these formations is mostly restricted to shallow levels. Ground water occurs under phreatic to semi-confined conditions in the inter-granular pore spaces in sands and sandstones and the bedding planes and thin fractures in shales. In the area underlain by Cretaceous sediments, ground water development is rather poor due to the rugged nature of the terrain and the poor quality of the formation water. Quaternary formations comprising mainly sands, clays and gravels are confined to major drainage courses in the district. The maximum thickness of alluvium is 30.0 m. whereas the average thickness is about 15.0 m. Ground water occurs under phreatic to semi-confined conditions in these formations and is being developed by means of dug wells and filter points. Alluvium, which forms a good aquifer system along the Araniyar and Korattalaiyar river bed which is one of the major sources of water supply to urban areas of Chennai city and also to the industrial units.
Ground water generally occurs under phreatic conditions in the weathered mantle and under semi- confined conditions in the fissured and fractured zones at deeper levels. The thickness of weathered zone in the district is in the range of 2 to 12 m. The depth of the wells ranged from 8.00 to 15.00 m BGL.
The depth to water level in the district varied between 2.38 – 7.36 m BGL during pre-monsoon (May 2006) and 0.79 – 5.30 m BGL during post monsoon(Jan 2007). The seasonal fluctuation shows a rise between 0.28 and 4.80 m BGL. The piezometric head varied between 2.20 to 10.30 m BGL (May 2006) during premonsoon and 2.72 to 8.55 m BGL during post monsoon. The Hydrogeology Map of the district is given in Figure 3-9.
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Figure 3-9 Hydro geological map of Thiruvallur district
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3.5 LAND ENVIRONMENT In general any major developmental projects related to industrial sector are expected to cause direct and indirect impacts on land environment, which could be attributed to mainly change in land use pattern (direct and indirect) as well as pollution impacts due to disposal of solid/hazardous wastes on the land and discharge of wastewater either on to land (direct impacts) or in to surface water resources. Moreover, impacts on agriculture land/vegetation are also expected due to fallout of air pollutants in case of excessive emissions beyond certain limit (indirect impacts). Accordingly, for impact assessment on land component, it is pertinent to study the existing landuse pattern in project area, soil characteristics and details of estimated waste generation from proposed Expansion, new component activities including the impacts on soil with respect to land application/disposal of solid/hazardous wastes and the consequential impacts on the surrounding terrestrial and aquatic environment.
3.5.1 RECONNAISSANCE The proposed project is located at Manali Industrial area, Manali, Thiruvallur, Tamil Nadu. The site is located adjacent to Manali Express highway.
Location : Latitude 13°10'31.27"N, and Longitude 80°17'1.45"E Site elevation within 5 Km radius : Ground elevations varying from about 3 m MSL to about 8 m MSL Highway Connectivity : SH-56along the project site Nearest Railway Station/distance : Thiruvottiyur -2.01Km Nearest Port/ distance : Chennai Port- 7.13Km Ennore Port – 9.57Km
3.5.2 SOIL ENVIRONMENT The predominant soil type is brown soil followed by alluvial and sandy soils in the coastal areas. The pH of the soil samples ranged from 5.7 to 7.54 across the sampling stations. The electrical conductivity of the soil samples ranged from 126to 756µohms/cm across the sampling stations. The concentration of organic matter ranged from 0.229 to 0.745 % across the sampling stations.
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Copper levels ranged from 4.46 to 9.66 mg/kg and bulk density from 1.22 to 1.65 gm/cc. The soil sampling locations and results are given in Table 3-10 and Table 3-11 respectively. The Google earth image showing soil sampling locations are given in Figure 3-11.
Table 3-10 Soil sampling locations in the study area
Sampling Geographical S.No Aerial distance (Km) Direction W.R. T site location coordinates
1. Mathur (S1) 13°10'26.96"N & W 2.88 80°15'21.25"E
2. Ernavur (S2) 13°11'14.77"N & NE 2.80 80°18'22.26"E
3. IAL Entrance 13°10'31.97"N & -- 0 (S3) 80°16'58.48"E
4. Tiruvottiyur 13° 9'38.63"N & SE 2.14 (S4) 80°18'3.75"E
5. Manali New 13°11'49.48"N & N 2.40 town (S5) 80°16'13.94"E
6. Thilakar 13° 9'4.01"N & SE 2.72 Nagar (S6) 80°17'55.36"E
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Figure 3-10 Photographs of the soil sample collection
Figure 3-11 Google earth showing soil sampling locations within 5Km radius
Table 3-11 Analytical results of soil samples collected at different sampling stations
Sampling stations Manali S.No Parameters with units Thilakar Mathur Ernavur IAL site Tiruvottiyur New Nagar Town 1. pH at 25°C (1:10) 7.51 5.72 7.3 7.35 7.54 7.48
2. Electrical Conductivity (1:10) 126 172 175 331 756 280
3. Color Light Dark Dark Dark Brown Dark Brown Brown Brown Brown Brown
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Sampling stations Manali S.No Parameters with units Thilakar Mathur Ernavur IAL site Tiruvottiyur New Nagar Town 4. Bulk density (gm/cc) 1.24 1.15 1.65 1.48 1.36 1.22 5. Potash (%) 0.16 0.28 0.06 0.18 0.20 0.16 6. Organic matter (%) 0.516 0.229 0.409 0.738 0.745 0.459 7. Zinc (mg/kg) 19.5 14.5 14.5 10.4 23.8 12.3 8. Lead (mg/kg) 1.35 0.345 1.94 2.17 1.56 0.45 9. Cadmium (mg/kg) 0.78 0.48 0.78 0.79 0.79 0.67 10. Copper (mg/kg) 4.46 6.34 9.66 8.57 9.23 5.40 11. Nitrogen (%) 0.047 0.098 0.027 0.052 0.062 0.036 12. Magnesium (%) 0.63 0.58 0.66 0.73 0.58 0.42 13. Organic carbon (%) 0.299 0.713 0.237 0.428 0.432 0.373 14. Cation Exchange Capacity 16.2 16.5 10.8 32.2 19.86 12.56 (meq/100g) 15. Calcium (%) 0.62 0.57 0.52 0.39 0.28 0.32 16. Iron (mg/kg) 298 244 294 476 467 346 17. Chromium (mg/kg) 1.15 1.78 1.22 2.97 2.12 1.43 18. Moisture Content (%) 1.14 0.655 0.45 16.35 19.43 4.75 19. phosphorus (%) 0.02 0.04 0.01 0.02 0.03 0.02 20. Manganese (mg/kg) 16.4 21.5 12.7 9.46 12.5 7.89 21. Infiltration Rate (Cm/hr) 1.46 1.25 1.28 1.36 1.11 1.3 22. Texture Sandy Sandy Sandy Clay Clay Clay Loam Loam Loam Loam silt Loam Soil texture (%) Sand 26 19 28 15 13 18 Silt 26 28 22 28 24 23 Clay 48 53 50 57 63 59
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3.5.3 LAND USE The land use/land cover in the study area of 10 km radius from the proposed expansion and new component manufacturing unit at Indian Additives Limited is evaluated by using recent land use/land cover estimates from Resourcesat-1 LISS III (2009) image and data about spatial distribution of land use/cover types obtained from database.
The study found that (Agricultural land) crop land at 45.47%, followed by agricultural fallow land- 19.31%, (water bodies) reservoirs/ Lakes/ ponds and River/Stream/ canal covering 9.8%, Towns / cities (urban) class covering about 5.43% coastal wetland covering 3.52% and Forest Land (deciduous, scrub, plantation etc) covers about 3.6%. The Land use Map is given in Figure 3-12 and the land cover pattern in Figure 3-13.There are no sensitive locations like Reserve Forests, National Parks etc within the study area.
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Figure 3-12 Land use map of the project site around 10Km Radius
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Figure 3-13 Land cover map of the project site around 10 Km Radius 3.5.4 GEOMORPHOLOGY The prominent geomorphic units identified in the district through interpretation of Satellite imagery are Alluvial Plain, Old River Courses, Coastal plains, Shallow & deep buried Pediments, Pediments and Structural Hills.
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The major part of the area is characterized by an undulating topography with innumerable depressions which are used as irrigation tanks.
The coastal tract is marked by three beach terraces with broad inter-terrace depressions. The coastal plains display a fairly lower level or gently rolling surface and only slightly elevated above the local water surfaces or rivers. The straight trend of the coastal tract is resultant of development of vast alluvial plains. There are a number of dunes in the coastal tract. Figure 3-14 shows the geomorphologic map of the project site taken from the Multi-temporal satellite data from Resourcesat-1 LISS III.
Figure 3-14 Geomorphological map of the project site 3.6 TERRESTRIAL ECOLOGY There is no National park/ Wild life Sanctuary/ Reserved forests within 10 Km radius of the study area. There is no rare/endangered species within study area
The study of terrestrial ecology within the study area of 5 km radius has been carried out through field investigation and satellite imagery data as discussed earlier. The area can be classified into the following ecological zone.
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3.6.1 SCRUB ECO-SYSTEM (DRY EVERGREEN VEGETATION) This type of ecosystem is dominated by Phoenix sylvestris species. Apart from typical scrub jungle species, a few salt tolerant species were also recorded, probably because of the proximity to the sea and the estuary.
3.6.2 TIDAL ECO-SYSTEM The plant growing in this area are salt tolerant as they are covered by the saline water during high tides. The species like Arthrocnemum indicum, Suaeda maritima are dominating species in this ecosystem.
3.6.3 MANGROVE ECO-SYSTEM This type of ecosystem existsnear Ennore creek. This is dominated by Avicinnia marina. Sesuviumportul acastrum & Suaeda maritima. These plants are periodically washed by the tides and as result in some areas quick sands are noticed.
3.6.4 MARSH ECO-SYSTEM The marshes are essentially fresh water supporting variety of plant. Acacia nilotica and Azadirachata indica are the common species of the study area.
3.6.5 AGRO ECOSYSTEM Rice and banana species are the main species of this ecosystem.
3.6.6 FLORA The field investigation and satellite imagery data show, that the study area is a mixture of agricultural, wasteland and get irrigated by the tanks and tube wells. The dry tropical vegetation is observed within the study area. The experimental finding of the pre monsoon season shows the dominance of Parthenium hysterophorus, Croton sparsiflorus and trees like Acacia nilotica, Azadirachta indica, Annona squamosa, Delonix regia, Ficus bengalensis within the study area. The list of flora available in study area is given in Table 3-12
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Table 3-12 List of domestic flora in the study area
Vernacular Name SI. No Botanical Name Family Name (Tamil) 1. Annona squamosa Annonaceae Sitapazha Maram 2. Alstoni ascholaris Apocynaceae Elilaipilai 3. Anthocephaluschinensis Rubiaceae Vellai Katambu 4. Acacia nilotica Fabaceae Karuvela maram 5. Bambus abambos Gramineae Mullu mungil 6. Bauhinia variegata Fabaceae/Leguminosae Mandarai 7. Citrus aurantifolia Rutaceae Yelumichai Maram 8. Delonix regia Caesalpiniaceae Mayirkonrai 9. Ficus religiosa Moraceae Arasu Maram 10. Ficus benghalensis Moraceae Ala maram 11. Mangifera indica Anacardiaceae Maangai Maram 12. Psidium guajava Myrtaceae Koyya Maram 13. Phoenix sylvestris Arecaceae Echha maram 14. Tamarindus indica Fabaceae Puliya maram 15. Ziziphus mauritiana Rhamnaceae Elenthai Maram
3.6.7 FAUNA I. Domestic - The domestic animals are mainly mammals like cow, goat, cat, dog etc.
II. Wild Animals - Wild animals are rarely seen due to absence of natural dense forest and land occupied by human being. Other than these, some reptiles and amphibians can also be seen with a number of bird species.
A list of birds, reptiles, amphibians and rodents based on information gathered from local inquiries is presented in Tables 3-13 to 3-15.
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Table 3-13 List of wild fauna
SI.No Zoological Name Common Name 1 Ahaetullanasuta Green tree snake 2 Athenebrama Spotted owlet 3 Canisaureus Jackal 4 Eudynamysscolopacea Koel 5 Francolinuspondicerianus Gray Frankolin 6 Harpestesedwardsi Indian gray mongoose 7 Haliasturindus Brahminy kite 8 Lepusnigricollis Indian Hare 9 Milvusmigrans Black kite 10 Najanaja Cobra 11 Ptyas mucosa Common rat snake
Table 3-14 List of amphibians
SI.No Zoological Name Common Name 1 Bufomelanostictus Toad 2 Ranacyanophlyctis Indian Skipper Frog 3 Ranatigrina Indian bull Frog 4 Rhacophorusbimaculatus Asiatic Tree frog
Table 3-15List of rodents
SI.No Zoological Name Common Name 1 Bandicotaindica Badicoot 2 Musmusculus Common Mouse 3 Rattusrattus Rat 4 Funambuluspalmarum Squirrel
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3.7 AQUATIC ECOLOGY The specific biological species (Fishes, Phytoplankton, Zooplankton etc.) for particular environmental conditions are the best indicators of environmental conditions. Information on the environmental stress due to the impacts of any industrial activities on the community structure serves as inexpensive and efficient early warning and control system to check the effectiveness of the measures to prevent damage to a particular ecosystem.
3.7.1 PLANKTONS Phytoplankton and Zooplankton are indicators of environmental stress. The quality and quality of such biological species in a particular environmental largely depends on various physicochemical characteristics of water such as pH, Conductivity, nutrients, BOD, alkalinity etc.
3.7.2 FISHES The fishes/ aquatic fauna of the study area is reported based on the inputs by the local people and secondary data provided by Thiruvallur district office. The fishes like, Lesser Sardines, Anchoviella, Flying Fish, Mackerel, Seer, Crabs were found in good number in the study area.
Table 3-16List of Zooplankton identified within the study area
S.No Zooplankton 1. Acartiadanae 2. Acartiaerythraea 3. Acartiaclausi 4. Calannsfinmarchicns 5. Paracalanusparvus
6. Microsetellanorvegica
7. Microsetellarosea
8. Corycaeusdanae
9. Oithonarigida
10. Oncaeavenusta
11. Gastropod veliger
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S.No Zooplankton 12. Brachionusurceolaris
13. Brachionucalyciflorus
14. Monostyla bulla
15. Paracalanusparvus
16. Labidoceraacuta
17. Euterpinaacutifrons
18. Macrosetellagracilis
19. Metis jousseaumei
20. Copiliavitrea
21. Oithonabrevicornis
22. Bivalve veliger
23. Copepod nauplius
. 3.8 SOCIO ECONOMIC ENVIRONMENT Manali is an Industrial town and Municipality in Thiruvallur district in the state of Tamil Nadu. It is located in north of Chennai City. As of 2011, the town had a population of 35,248. It borders Tiruvottiyur to the east, Mathur MMDA to the west, Kodungaiyur to the south, SH 56 to the North. The main through fares in the area is Kamarajar Salai, Chinna Mathur Road, Parthasarathy Street. Manali area is the home to petroleum refinery and allied petrochemical industries.
3.8.1 SOCIAL INDICATORS 3.8.1.1 DEMOGRAPHY The population of the district is 37,28,104 as per 2011 Census. The male population is 18,76,062 (50.32%) and the female population is 18,52,042(49.67%). The Schedule Caste population is 22% of the total population. The area of the district is 3,42,243Ha. The district‟s share of the state is 2.63%. Over 65% of population of district lives in the urbanized part of the district. The Sex Ratio in the district is at 987 per 1000 male as per census 2011 compared to 971 during the 2001
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census. It shows the awareness of importance of girl child. The average national sex ratio is 940 as per Census 2011.
3.8.1.2 POPULATION DENSITY The population density of the district is 1098 as per 2011 census, but it was 776 as per 2001 census.
3.8.1.3 DECADAL GROWTH The decadal growth of the district is 35.25 during 2001-11 but it was 23.06 during 1991-01. It shows the dynamic migration and the vibrant economic activities of the district. The State decadal growth for 2001-2011 is 15.60.
District Decadal Growth (%) 40 35.25 35 30 25 23.06 20 15 10 5 0 1991-01 2001-11
Figure 3-15 District decadal growth rate 3.8.1.4 OCCUPATION The majority of working population is belonging to the main workers category (81%) and marginal workers category is 19%. It shows the vibrancy of economy of the area. In main workers category, “Others” consists of workers in services sectors, industries Govt. dept. etc.The predominant workers are mostly working in Industries.
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District -Main Workers (%) 90 77.94 80 70 60 50 40 30 20 13.88 10 4.84 3.34 0 Cultivators Agri.Labor Household Others
Figure 3-16 Statistics of main workers
3.8.1.5 AGRICULTURE Agriculture is one of the main occupations in the district .The net area sown is 31% of the total area. Paddy is the principal crop in the district. As per the dept. of Economics and Statistics, GoT, there are 83,912 acres are under paddy cultivation. Ground nut cultivation is in 10,348 Ha.
There are 1895 tanks in the district for irrigation purpose and there are 1929 dug wells and 9307 open wells in the district. There are 189 km canals serving irrigation in the district.
The majority of farmers are marginal landholders (below 1 Ha). Of the total farmers, 82.63% of them are marginal farmers. As the marginal farmers cannot depend on the agricultural activities, they work as agriculture labors and non agriculture labors. Cattle rearing is one of the income generating activities, mostly women-folks are involved in it. As per Livestock Census 2004, there are 6,83,535 live stocks in the district.
The majority of farmers are marginal landholders (below 1 Ha). Of the total farmers, 82.63% of them are marginal farmers. As the marginal farmers cannot depend on the agricultural activities, they work as agriculture labors and non agriculture labors. Cattle rearing is one of the income generating activities, for marginal farmers and mostly women-folks are involved in it. As per Livestock Census 2004, there are 6,83,535 live stocks in the district.
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Operational Land Holding 250000 195116 200000
150000
100000
50000 24549 10426 3079 2955 0 Marginal Small Semi-medium Medium Large
Figure 3-17Bar chart for Operational land holding
source- Agriculture census 2005
3.8.1.6 EDUCATION Average literacy rate of Thiruvallur as per 2011 census is 84.03 compared to 76.94 of 2001. The male and female literacy as per 2011 census data is 89.69 and 78.32 respectively. The literacy rate of male and female was at 85.26 and 68.39 according to 2001 census. There are 1417 primary schools in the district. The dropout rate is 1.36 which is higher when compare to the State dropout rate (1.0).
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Figure 3-18 Manali School
Figure 3-19 Photograph of Oxford Matriculation School Kodungaiyur 3.8.1.7 HEALTH There are 44 Primary health centers in the district. Medical facilities are available in the district as Chennai City is nearby and also the district is more urbanized. The details of Public Health Centres and Sub Centres are given in Table 3-17 and Figure 3-21.
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Figure 3-20 Map showing the PHCs in Thiruvallur District Source: RGI, SOI
Table 3-17 Block wise Primary Helath centres available in the District
Name of the Block No.of Primary Health No.of Sub- S.No /Municipality Centres Centres 1 Thiruvallur 3 18 2 Kadambathur 4 20 3 Poondi 3 19 4 Ellapuram 3 26 5 Poonamallee 3 23 6 Thiruthani 3 18 7 Thiruvalangadu 3 19
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Name of the Block No.of Primary Health No.of Sub- S.No /Municipality Centres Centres 8 Pallipet 2 18 9 R.K.Pet 3 16 10 Gummidipoondi 3 30 11 Minjur 5 35 12 Sholavaram 4 21 13 Puzhal 2 16 14 Villivakkam 3 24 Total 44 303 Source: Joint Director of Health Services, Thiruvallur, 2011-12
Figure 3-21 Communicable Diseases Hospital at Tondiyarpet
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3.8.2 ECONOMY OF THE DISTRICT The economy of the district depends on the agriculture and its allied activities besides industrial growth. The district has an advantage of being near to Chennai city. So the opportunities of evolving new industrial area are high.
The Gross Domestic Product (at Current Prices) of the district is increased exponentially from 657775 lakhs during 1999-00 to 1414211 lakhs during 2006-07.
District Gross Domestic Product at Current and Constant Prices (1999-2000 New series) 1600000 1400000 1200000 1000000 800000 Ar Current Prices Rs.Lakh 600000 At Constant prices 400000 200000 0
Figure 3-22 Product at net and constant prices
Source: Department of Economics and Statistics, GoTN
The per capita income of the district has increased from Rs.21167/- at 1999-00 to Rs.38388/- at 2006-07.
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Per Capita Income at Current and Constant Prices 1999- 2000 New Series 45000 40000 35000 30000 25000 20000
Rupees At Current Prices 15000 At Constant Prices 10000 5000 0
Figure 3-23 Percapita income at net and constant prices
Source: Department of Economics and statistics, GoTN
3.8.3 INDUSTRIES Thiruvallur district is one of the fastest developing districts in Tamil Nadu in terms of Industrial Development. The district has many leading industries like Chennai Petroleum Corporation Limited, Madras Fertilizers, Manali Petro Chemicals, MRF, Ashok Leyland, TI Cycles, Britannia India Ltd etc.. It also has the Ennore Thermal Power Station and the Avadi Tank Factory. The District has 16 Industrial Estates, all in operation: 11 developed by the Government and 5 by Private Organisation.
3.8.3.1 INDUSTRIAL ESTATES PROMOTED BY GOVERNMENT . Ambattur Industrial Estate, Ambattur. . Electrical Industrial Estate, Kakalur. . SIDCO Industrial Estate, Chennai - 98. . Industrial Estate, Madhavaram.
. SIDCO Industrial Estate, Kakalur . Petrochemical Industrial Estate, Vichoor . SIDCO Industrial Estate, R.K. Pet
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. SIDCO Industrial Estate, Gummidipoondi . Industrial Estate, Mugappair
3.8.3.2 INDUSTRIAL ESTATES PROMOTED BY PRIVATE ORGANISATION . G.K. Industrial Estate, Porur . M.M.Industrial Estate, Alapakkam . Moccaram Industries, VelappanChavadi . Nagappa Industrial Estate, Puzhal . EkambaraNaicker Industrial Estate, Alapakkam This district has 16940 Small Scale Industries, notable among them being food, wood, textile, chemical, engineering, non-metallic and leather industries.
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CHAPTER 4 ANTICIPATED IMPACTS AND MITIGATION MEASURES
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4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
4.1 IDENTIFICATION OF SIGNIFICANT IMPACTS One of the important components in the process of environmental impact assessment is identification of significant impacts as it leads to other elements such as quantification and evaluation of impacts. Identification of significant impacts from the proposed expansion and proposed new component (ZDTP) manufacturing unit is an imminent step for evaluation of impacts.
For identifying and assessing impacts the entire project has been divided into two phases:
Construction Phase Operational Phase 4.2 TYPICAL CONSTRUCTION ACTIVITEIS The following generic construction activities have been identified as being required during the project construction phase.
Excavation Formwork & concreting Material handling and Transportation Use of Tools and Potable power tools Scaffolding Crane and Rigging Equipment Mechanical Equipments Working in Confined space
4.2.1 GENERAL ACTIVITIES Demolition and dismantling works in Utility Area (Nitrogen vessel, Air compressor and etc.) and erection of new Utility Packages. Installation of Raw Material and Component Storage Tanks Erection of Component Loading Bay (Loading arm)
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Piling works and New Pipe rack erection. Tie-in works Cabling works in the existing/new pipe rack
4.2.1.1 NITROGEN SYSTEM 1 No. of Nitrogen package shall be dismantled from the utility area. 1 No. of New higher capacity Nitrogen package to be erected in the same area. Provision for entry of any crane to the utility shed is minimal. Provision for entry of any gantry crane is minimal. The dismantling of existing facilities and erection of new facilities can be carried out using chain block pulley methods.
4.2.1.2 AIR COMPRESSOR 1 Nos. of Compressor shall be dismantled from the utility area. 1 No. of New higher capacity reciprocating compressor to be erected in the space of demolished Boilers with 2 Nos. of tie in connection with the existing discharge header. 1 No. Air Dryer Package to be erected in the demolished area of existing Compressor. Provision for entry of any crane to the utility shed is minimal. Provision for entry of any gantry crane is minimal. The dismantling of existing facilities and erection of new facilities can be carried out using chain block pulley methods.
4.2.2 OTHER ACTIVITIES ZDTP building
Equipments (P2S5, odour gas, WFE and etc.,) and associated works within the ZDTP building. Caustic Scrubber. DM/RO plant Dry Material Warehouse.
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Figure 4-1 Photograph showing proposed ZDTP unit location 4.3 CONSTRUCTION PHASE IMPACTS As the main impacts of the construction phase are envisaged in terms of air pollution only, this natural mitigation would be significantly helpful in elimination of predicted impacts of the phase. However the following principal major impacts to the environment are considered for further planning of mitigation measures:
Release of construction materials and dust into the environment from the construction site/materials can spoil the surrounding air quality Improper disposal of construction wastes can damage air, water and land quality. The use of automobiles and machinery during construction can deteriorate the air quality and generate temporary emission. The use of automobiles and machinery generates Noise pollution from construction activities. The irregular working hours, & traffic, night-working, flood-lighting and transportation damage the socioeconomic balance of surrounding region. Effects may occur due to the accumulation of the contaminant in water resources &
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soil due to uptake of construction material. Short term heavy construction might cause increase in noise level Effects on work place condition & human health due to the accidents during the construction works. Effects on the socio-economic activity due to direct impacts or indirect impacts on socio-economic activities.
4.4 MITIGATION MEASURES FOR CONSTRUCTION PHASE The entire construction activities will be confined with the designated area inside the existing premises. The small amount of unused construction material shall be stored in proper area to utilise further in construction activities and surplus excavated material shall be disposed of in suitable pre-identified areas. It is suggested that the construction waste containing sand, brick, gravel, cement etc. shall be used for filling or PCC for construction of internal road or project structures. Construction material shall stored at adequate distance from the water storage in order to prevent any chances of accidental leakage or spillage which could pollute the water storage Wherever required impervious lining shall be provided to storage premises to avoid accidental mixing or mixing due to fugitive losses. To reduce the dust generation on site wherever & whenever required water shall be sprinkled on ground or stock pile of excavated soil. Equipments / machineries shall be used efficiently and shall be kept shut in order to reduce air emission, noise pollution and consumption of energy resource Emission from the equipments/machineries shall be monitored on regular basis and possible implementation shall be provided on site Transport vehicles shall be monitored & maintain regularly to control the emission quality and fuel consumption Provision of necessary PPEs like face mask & eye-glasses to employees /labours engaged in construction activities. The machineries/equipment used on site shall be of highly maintained so they do work
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with optimum efficiency generating less noise pollution Operation of machineries/equipment causing high noise level shall be stopped during the night time and all such operations shall be planned for day time only. Transportation activities shall not be conducted during the night to avoid high noise level in nearby villages/locality. Only in case of emergency the transportation activities shall be allowed in night time. 4.5 OPERATIONAL PHASE IMPACTS Because of its potential to create long-term impacts, this phase is very important from the environmental impact point of view. The basic impacts like gaseous emissions, water consumption/ pollution and solid waste will have the potential to adversely affect air, water and land / soil in the vicinity of the project site.
This phase will broadly include the following direct and indirect activities / actions:
Storage and transportation of raw materials and finished products. Gaseous emissions Effluent Generation, treatment and disposal Noise Generation Solid waste generation
4.5.1 AIR ENVIRONMENT
Base line data reveals that ambient air quality in the study area for the Parameters PM2.5, PM10,
SO2, NO2, are well within the permissible Limits as prescribed by the National Ambient Air Quality Standards (NAAQS) for Industrial Area, Residential, Rural & Other area. Stack Emission of PM,
SOx & NOx are attached to Boiler, DGs and thermic fluid heaters are the source of air pollution. Process vents are scrubbed before being discharged to the atmosphere.
4.5.1.1 METEROLOGICAL DATA The site specific meteorological data for three months from February 2015 to April 2015 were obtained from onsite metrological station. Other data included for AERMET were daily wind speed, wind direction, temperature, relative humidity, air pressure, precipitation, and solar radiation recorded during the period. AERMET reformats meteorological data so that it can be used as input for AERMOD model.
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4.5.1.2 AERMET PROCESS For the 3 phase AERMET processing of the meteorological data, specifications of the land use in the area are required to determine the terrain roughness for modelling. The land use was characterized for in and around the site. The surface characteristics for the site and surroundings were selected and used to calculate the albedo, Bowen ratio, and surface roughness parameter. The meteorological data were processed in the AERMET software to generate wind flow pattern & to generate surface meteorological data and profile meteorological data in a prescribed format that can be fed to AERMOD for modeling.
4.5.1.3 AERMOD PROCESS AERMOD Software Version 7.5.0 was used for air dispersion modelling and is applicable to a wide range of buoyant or neutrally buoyant emissions up to a range of 50km. In addition to more straight forward cases, AERMOD is also suitable for complex terrain and urban dispersion scenarios.
AERMOD is a steady-state plume model. In the stable boundary layer (SBL), it assumes the concentration distribution to be Gaussian in both the vertical and horizontal. In the convective boundary layer (CBL), the horizontal distribution is also assumed to be Gaussian, but the vertical distribution is described with a bi-Gaussian probability density function (pdf). This behaviour of the concentration distributions in the CBL was demonstrated by Willis and Deardorff (1981) and Briggs (1993). Additionally, in the CBL, AERMOD treats “plume lofting,” whereby a portion of plume mass, released from a buoyant source, rises to and remains near the top of the boundary layer before becoming mixed into the CBL. AERMOD also tracks any plume mass that penetrates into the elevated stable layer, and then allows it to re-enter the boundary layer when and if appropriate. For sources in both the CBL and the SBL AERMOD treats the enhancement of lateral dispersion resulting from plume meander. The emissions from existing and proposed stacks have been taken as basis for modeling and are shown below
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Table 4-1 Existing and proposed stack details
1 2 (Connected 7 (Connected Stack/Vent (Connected 8 to CAC, 3 4 5 6 to CAC, Details to CAC, (Proposed) TNPCB) TNPCB) TNPCB) Material of Carbon Steel Carbon Steel Carbon Carbon Carbon Steel Carbon Steel Carbon Steel Carbon Steel Construction Steel Steel Stack/vent Common Common Stack Exhaust Common High Point High point Vent from Proposed vent attached to: Stack to 3 to 2 Nos. of Oil pipe to Exhaust discharge via discharge to Phenate from Caustic Nos. of oil fired Thermic D.G set Stack to DG water Succinimides reactor scrubber fired Boilers fluid heater 550 KVA sets - 1010/ scrubber for Reactor through attached to 1500 KVA PIBSA Caustic ZDTP reactor reactor vent scrubber Stack/vent 47 m 30 m 16 m 16 m 22 m 17 m 27 m 30 m Height Stack/ vent 0.80 m 0.3 m 0.2 m 0.4 m 0.15 m 0.1 m 0.1 m 0.2 m Dia at top Gas Exit 447 477 444 458 341 325 335 313 Temp (K) Gas Exit velocity 15.2 15.8 16.3 14.8 4.4 1.0 0.35 0.35 (m/sec)
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Table 4-2 Stack emission details
Emission Rate (g/sec) Exit gas flow rate S.No. Stack SOX NOX PM (m3/s) 1. Common Stack of Boilers 0.5003 0.2373 0.34012 7.65 Common Stack to Thermic 2. 0.0295 0.0952 0.0544 1.12 fluid heater Exhaust pipe to D.G set 3. 0.0053 0.0975 0.0261 0.51 550 KVA Exhaust Stack to DG sets - 4. 0.01882 0.3981 0.0941 1.8 1010/ 1500 KVA 5. PIBSA reactor vent BDL BDL 0.0019 0.078 6. Succinimides Reactor BDL BDL 0.0009 0.008 7. Vent from Phenate reactor BDL BDL 0.00120 0.003 Proposed scrubber for ZDTP 8. BDL BDL 0.00120 0.011 reactor
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Figure 4-2 Maximum incremental value for SOX
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Figure 4-3 Maximum incremental value for NOX
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Figure 4-4 Maximum incremental value PM
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Table 4-3 Predicted GLC for existing and proposed stack
Parameters Baseline Estimated Predicted NAAQ Direction Downwind data Maximum Maximum standard distance (µg/m3) Incremental GLC g/m3 (km) Concentration (µg/m3) (24hrly) (µg/m3)
SOX 10.65 0.494 11.144 80 SE 0.67
NOX 25.79 2.148 27.938 80 NW 1.06 PM 56.27 0.751 57.021 100 NW 1.09
As seen from the above table the concentration levels arising from the proposed project are well within the NAAQ Standards.
4.5.2 WATER ENVIRONMENT Existing sewage treatment and Effluent Treatment Plants are adequate for handling effluent from proposed expansion and new component manufacturing facility. Existing Zero Liquid Discharge system will be extended for proposed expansion and new component manufacturing (ZDTP) unit.
The details of effluent and sewage generation with the recycling details are given in Table 4-4. Water Balance is given in Figure 4-4.
Table 4-4 Effluent and sewage generation, recycling
Total -After Total – [After expansion S. Description Existing (KLD) proposed +After proposed new No Expansion (KLD) component (ZDTP)] in KLD A Effluent/ sewage generation details 1 Effluent from Process 2 Cooling tower blow down 3 DM plant washings 140 196 265 4 Process condensate 5 Boiler blow down
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Total -After Total – [After expansion S. Description Existing (KLD) proposed +After proposed new No Expansion (KLD) component (ZDTP)] in KLD 6 Sewage 27 40 45 Total effluent generation 167 236 310 B Treated effluent usage details 1 Recycle to DM plant 63 89 100 2 Recycle to CT plant 16 23 86 3 Gardening 88 124 124 Total Recycling 167 236 310
4.5.2.1 FOR PROPOSED EXPANSION Trade effluent streams of total quantity 196 KLD generated from process are treated in ETP of 300 KLD capacity. Sewage stream of quantity 40 KLD is treated in STP of 60 KLD capacity. Treated water is partially used for green belt development and the remaining water is sent to RO plant for further treatment and recycled to Cooling Tower and DM plant
4.5.2.2 FOR PROPOSED NEW COMPONENT (ZDTP) Trade effluent streams of total quantity 265 KLD generated from process will be treated in existing Effluent Treatment Plant (ETP), which is capable of handling300 KLD of effluent. There are no major changes to the effluent characteristics. Sewage stream of quantity 45 KLD will be treated in existing Sewerage Treatment Plant (STP), which is capable of handling 60 KLD effluents. Treated water from both the treatment plants is partially used for green belt development while the rest is being treated in Reverse Osmosis (RO) plant for recycle to Cooling Tower (CT) and Demineralization (DM) plant.
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Figure 4-5 Water Balance for the proposed expansion and new component manufacturing
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4.5.3 NOISE ENVIRONMENT The impacts of the proposed expansion and proposed new component (ZDTP) manufacturing on the noise levels of the surrounding areas were modelled using CUSTIC software. All equipments in the plant produce 13 to 15dB(A) after control measures and equipments are designed/operated to have a noise level not exceeding 85 to 90 dB(A) as per the requirement of Occupational Health and Safety Administration Standard (OHSAS). In addition, since most of the noise generating equipment would be in closed structures, the noise transmitted outside would be still lower. The sources of noise levels and the isopleths of the noise modelling are given in Figure 4-6. Based on the noise modelling shown in Figure 4-7, the noise levels emitted from the plant (with all attenuation facilities) will be 15.27 dB(A). From the below model it can be inferred that the noise level at the surrounding vicinity of the site is anticipated to be within the prescribed standards.
Figure 4-6 Isopleths of Noise Level
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Figure 4-7 Noise Modeling within and near plant premises
4.5.4 LAND ENVIRONMENT One of the factor that is usually considered as a major impact from any project is the land use change. But since the proposed expansion and new component manufacturing are to be established within the existing IAL site, no land use change is foreseen, as the current land use is that of industries.
4.5.5 FLORA AND FAUNA Forest Area -No forest / ecologically sensitive area exists within10 km radius from the project site. Hence there is no permission required form the Forest Department for the proposed expansion and new component manufacturing.
Wild Life -No wild life crossing is found along the project corridor. There is no Rare / Endangered species found within 10 Km radius of the project site.
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Cattle Grazing -No cattle grazing grounds have been found along the corridor of Impact.
4.5.6 SOCIO ECONOMY The proposed site is located in Notified Industrial Area. For the proposed expansion and new component (ZDTP) manufacturing, there is no additional requirement of land. There is no rehabilitation and resettlement is involved. The proposed projects will provide direct and indirect employment opportunities with the project area, there by contributing for socio economic improvement.
4.6 IMPACT ASSESSMENT A number of techniques are available for the assessment of impacts. Each of these techniques has their own advantages and disadvantages. The selection of any of these techniques for any particular project depends largely upon the choice of judgment of the analysis. The technique chosen should be comprehensive, easy to understand, systematic and flexible. Considering these criteria, for this project, the matrix method was used, with an impact scale of -4 to +4.
4.6.1 MATRIX METHOD Impact identification and assessment of the site can be assessed by the matrix method, popularly known as Leopold matrix method, which is a universal tool for the EIA studies. The matrix used for the EIA consists of project activities on the x-axis and the environmental components likely to be affected by these activities on the y-axis. Each cell of the matrix represents a subjective evaluation of the impact of the particular components, in terms of magnitude importance. A blank cell indicates no impact of the activity on the component. The magnitude (m) is represented by a number from 1-4 where,
1= Minimal
2= Appreciable
3= Significant
4= Severe
A positive sign indicates a beneficial impact and the negative sign indicates an adverse impact. The importance (w) of the impact is given on a scale of 1-4 in each cell. This number indicates the relative importance of the impact of the activity on the concerned component for this project. The
magnitude and importance are multiplied to give a score for each cell (mijwij). The scores of
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individual cells in each row are added to determine the total impact of all project activities on each component. Similarly, the scores in individual cells in each row are added to determine the total impact of each activity on all the environmental components likely to be affected. The grand total of all cells indicate the total project impact. This can be represented by the following equation:
Total project impact= mijwij
Where mij = (positive or negative) magnitude of the jth activity on the ith environmental component and wij = importance of the jth activity on the ith environmental component
Since both m and n vary from 1-4 the total score in each cell can theoretically vary between -16 and +16, therefore the total project impact can vary between (-16*total number of cells in the matrix) and (16*total number of cells in the matrix), to compare scores from the matrices containing different number of cells, the total project score can be normalized to a scale of 100 as follows:
Project impact
Total project impact = ------* 100
16 * Total number of cells in matrix
On the scale, the overall impact can be classified as follows:
Table 4-5 Overall impact classification
Total project impact (Scale of 100) Magnitude -100 to –75 Severely adverse -75 to –50 Significantly adverse -50 to -25 Appreciably adverse -25 to -16 Minimally adverse -15 to -6 Low Adverse Impact -5 to 0 Extremely low adverse impact 0 to 25 Minimally beneficial 25 to 50 Appreciably beneficial 50to 75 Significantly beneficial 75 to 100 Highly beneficial
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4.6.1.1 ALTERNATIVE SCENARIOS Impact score for the project was calculated for three scenarios using the matrix method described above. Matrices were prepared to represent each of these scenarios:
a) Scenario 1 - No Project - This scenario considers that there is no expansion and no new component manufacturing (ZDTP). The existing activities in the plant and the consequent secondary growth were also considered in evaluating the impact in this “no project” scenario.
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Table 4-6 NoProject Scenario
Environmental Components Construction Operation and Maintenance
likely to be affected
uring uring
t
on on
Transportation construction of Civil works material UsageWater of DG of Running Disposal of construction Raw Material wastes & transport sewerage Manufac process Usagewater of Usagepower of Storage of chemicals Waste Disposal (solidand liquid) activities CSR Impact components Air Quality Magnitude 0 0 -- 0 0 1 -1 -- -- 2 1 -- 9 Importance 3 4 -- 3 3 2 4 -- -- 4 3 -- Noise and Magnitude 0 0 -- 0 -- 3 -1 ------3 Vibration Importance 3 3 -- 4 -- 2 3 ------Surface water Magnitude -- 0 0 -- 3 -- -2 2 -- 2 2 -- 17 quality Importance -- 3 3 -- 3 -- 4 3 -- 3 2 -- Ground water Magnitude ------0 quality Importance ------water resource Magnitude -- 0 0 ------3 -3 ------0 Importance -- 4 3 ------3 3 ------
Soil Quality Magnitude 0 0 ------2 -- -- 8 Importance 2 2 ------4 -- -- Flora and Magnitude ------0
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Environmental Components Construction Operation and Maintenance likely to be affected
uring uring
t
on on
Transportation construction of Civil works material UsageWater of DG of Running Disposal of construction Raw Material wastes & transport sewerage Manufac process Usagewater of Usagepower of Storage of chemicals Waste Disposal (solidand liquid) activities CSR Impact components Fauna Importance ------Land use Magnitude -- 0 ------0 ------0 Pattern Importance -- 4 ------3 ------Employment Magnitude 0 0 -- -- 0 1 1 -- 0 0 0 0 6 Importance 3 3 -- -- 3 3 3 -- 3 3 3 3 Total impact of activity ------43
Total impact of activity on a scale of 100 2.45
The total project impact for this scenario was found to be 2.45, which is minimally beneficial impact
b) Scenario 2 - Project without EMP -Proposed expansion proposed new product takes place without any Environmental Management measures.
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Table 4-7 Project Scenario without EMP
Construction Operation and Maintenance
Environmental Components likely
to be affected
uring process uring
t
liquid)
Equipment
CSR activities CSR
Running of DG of Running
Usage of water of Usage
Usage of Water of Usage
Usage of power of Usage
Transportation of of Transportation
wastes & sewerage wastes&
Storage of chemicals of Storage
construction material construction
Raw Material transport transport Material Raw
Impact on components on Impact
Manufac
Civil works with Heavy withHeavy works Civil
Disposal of construction construction of Disposal Waste Disposal (solid and and (solid Disposal Waste
Magnitude -2 -2 -- -2 -- -2 -2 -- -- -2 -3 -- Air Quality -44 Importance 2 3 -- 3 -- 3 4 -- -- 4 2 -- Magnitude -3 -4 -- -3 -- -4 -3 ------Noise and Vibration -58 Importance 4 4 -- 3 -- 3 3 ------Magnitude -- -- -3 -- -2 -- -- 3 -- -2 1 -- Surface water quality -11 Importance -- -- 4 -- 3 -- -- 3 -- 2 2 -- Magnitude ------Ground water quality 0 Importance ------Magnitude -- 1 -1 ------1 -2 -- -- -2 -- water resource -6 Importance -- 2 3 ------1 1 -- -- 2 -- Magnitude -2 -2 -- -- -1 -1 -3 -- -- -2 -2 -- Soil Quality -31 Importance 2 3 -- -- 1 2 4 -- -- 1 2 -- Flora and Fauna Magnitude -- -1 ------2 -- -4
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Construction Operation and Maintenance
Environmental Components likely
to be affected
uring process uring
t
liquid)
Equipment
CSR activities CSR
Running of DG of Running
Usage of water of Usage
Usage of Water of Usage
Usage of power of Usage
Transportation of of Transportation
wastes & sewerage wastes&
Storage of chemicals of Storage
construction material construction
Raw Material transport transport Material Raw
Impact on components on Impact
Manufac
Civil works with Heavy withHeavy works Civil
Disposal of construction construction of Disposal Waste Disposal (solid and and (solid Disposal Waste
Importance -- 2 ------1 -- Magnitude -- 3 ------Land use Pattern 12 Importance -- 4 ------Magnitude 1 1 ------1 1 -- 1 1 0 0 Socio Economics 12 Importance 2 2 ------2 2 -- 2 2 2 2 Total impact of activity -130
Total impact of activity on a scale of 100 -8.47
The total project impact for this scenario was found to be –8.45, which is minimally adverse impact.
c) Scenario 3 - Project with EMP - Considered the Proposed expansion proposed new product takes place with proper Environmental Management measures.
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Table 4-8 Project with EMP
Construction Operation and Maintenance
Environmental Components
likely to be affected uring
t
works with works
wastes
material process
transport transport
chemicals
Storage of of Storage
Impacts on on Impacts
Disposal of of Disposal
components
construction construction construction
Raw Material Material Raw
CSR activities CSR
Manufac
Running of DG of Running
Usage of water of Usage
Usage of Water of Usage
Waste Disposal Disposal Waste
Usage of power of Usage
Civil Civil
(solid and liquid) and (solid
Transportation of of Transportation Heavy Equipment Heavy
Magnitude -1 -2 2 2 1 2 -1 - Air Quality 11 Importance 3 3 3 2 4 4 2 -
Noise and Magnitude -1 -2 -1 1 1 1 1 - -4 Vibration Importance 4 4 3 3 3 3 2 -
Surface water Magnitude 2 2 2 1 1 24 quality Importance 4 3 3 2 2
Ground water Magnitude 0 quality Importance
Magnitude 1 -1 2 -2 -2 water resource -3 Importance 2 3 3 2 2
Magnitude -1 1 -1 -1 3 2 1 Soil Quality 18 Importance 2 3 1 2 4 3 2
Magnitude -1 2 1 Flora and Fauna 5 Importance 2 3 1
Land use Pattern Magnitude 3 9
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Construction Operation and Maintenance
Environmental Components
likely to be affected uring
t
works with works
wastes
material process
transport transport
chemicals
Storage of of Storage
Impacts on on Impacts
Disposal of of Disposal
components
construction construction construction
Raw Material Material Raw
CSR activities CSR
Manufac
Running of DG of Running
Usage of water of Usage
Usage of Water of Usage
Waste Disposal Disposal Waste
Usage of power of Usage
Civil Civil
(solid and liquid) and (solid
Transportation of of Transportation Heavy Equipment Heavy Importance 3
Magnitude 1 1 0 1 1 0 1 1 1 Socio Economics 14 Importance 2 2 2 2 2 2 2 2 2
Total impact of activity 74
Total impact of activity on a scale of 100 5.32
There is minimally beneficial impact on Air, water, soil & noise quality due to the proposed project with proper EMP and is found to be 5.32, which is minimal beneficial impact. The main objective of the proposed project is to bring the economically viable production of proposed expansion and new component (ZDTP) manufacturing and use it beneficially.
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CHAPTER 5 ANALYSIS OF ALTERNATIVES
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5 ANALYSIS OF ALTERNATIVES
5.1 INTRODUCTION This chapter presents a comparative analysis of various alternatives considered to avoid or minimize impacts that would be inevitable in technically advanced processes. Several alternatives are analyzed for avoiding localized environmental impacts & arriving at the proposed processes. Screening procedure for the alternatives considered are presented in the following sections. The consideration of alternatives to a proposal is a requirement of the EIA report. Range of alternatives selected for analysis includes - Site alternatives, Fuel alternatives, Water supply alternatives, Technology alternatives. The relative impact of each alternative is compared against the baseline environment to select a preferred alternative.
Finalization of various options such as fuel type and construction materials, keeping in view of the obligatory points and environmental safety aspects etc., The Project alternatives without mitigation measures and with mitigation measures are analyzed before choosing the proposed alternatives. The objective of this chapter is to highlight some of the salient issues considered for exercising the alternative options.
5.2 SITE SELECTION The proposed expansion and new component manufacturing is within the existing unit of Indian Additives Limited located in Manali Industrial Area, Thiruvallur district.
The criterion for site selection included the below mentioned points:
The proposed project site is suitable from operation point of view since it is situated in the already existing manufacturing unit within Notified Industrial Area. As it is located inside the existing plant, there is no habitation present inside the project area. The project site shall not require displacement of habitation and away from the habitation area. The project does not involve any displacement of local residents as it is located inside the existing premises. The plot allotted for the plant is flat and stable to increase its resistance against any natural disturbances like earthquake.
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The project site is above the flood level and thus will avoid any accident in case of flooding from the nearby canal. The project site is free from any environmental restrictions like forest, natural parks; wild life sanctuaries. In addition to the above mentioned issues various environmental issues are also considered while choosing the current location which is given in Table 5-1
Table 5-1Impacts of alternative site location compared with the selected location
Options Environmental Centrally located S.No If located outside the Issues within the existing Comments existing plant plant Water flows Larger project footprint Project footprint Ability to minimize and quality creates potential for minimized, reducing project footprint is 1 increased disturbance and potential for impacts on a major factor in pollution water to a minimum mitigating Air quality Extended footprint increases Project footprint environmental potential for dust emissions; minimized, reducing impacts potential for greater potential for dust exposure of adjacent generation to a communities to programmed minimum; buffer 2 emissions, depending on mitigates against location exposure of adjacent communities to emission of gases and fumes Noise and Increased potential for Decreased potential for vibration greater exposure of noise exposure of noise levels 3 levels to adjacent to adjacent communities communities
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Options Environmental Centrally located S.No If located outside the Issues within the existing Comments existing plant plant Soil Larger footprint increases Optimized footprint 4 land and direct impact on minimizes land take and soils direct impact on soils Biodiversity Larger footprint increases Optimized footprint land acquisition and direct Nil land acquisition and 5 impact on flora and fauna no direct impact on flora and fauna Landscape Larger footprint increases Optimized footprint land acquisition and visual No land acquisition and 6 impact visual impact
Socio-economic No discrimination in regard to socio-economic factors Potential impacts issues of proximity of 7 industries with nearby settlements is decreased Transportation No significant discrimination in regard to transportation As the project is issues issues, unless a processing site was selected remote established within from the existing facilities, in which case, there would be the existing facility, 8 potential for major impacts related to transportation there are no transportation issues. 5.3 PROJECT ALTERNATIVES In view of growth in demand in recent years for lubricating oil additives; IAL intends to increase its production capacity. This project can lead to economic prosperity as there is growing market potential for lubricating oil additive packages.
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Since the expansion proposal is through debottlenecking activities of existing facilities involving minimal capital investments, the alternative of establishing new stand alone facility is economically inviable and may have other associated impacts. The proposed new component manufacturing (ZDTP) unit technology is proven and tested at other geographic locations and no other equivalent technology is available
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CHAPTER 6 ENVIRONMENTAL MONITORING PROGRAM
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6 ENVIRONMENTAL MONITORING PROGRAM
6.1 INTRODUCTION The Environmental Monitoring Program is laid out based on the following definition of environmental monitoring:
“Environmental effects monitoring is the repetitive and systematic measurement of the characteristics of environmental components to test specific hypotheses of the effects of human activity on the environment. Environmental monitoring is undertaken primarily to determine the environmental effects of human activities, and secondarily to increase understanding of cause- effect relationships between human activity and environmental change.”
6.2 ENVIRONMENTAL EFFECTS MONITORING IN EIA
Environmental effects monitoring programs provide the necessary information to:
Verify the accuracy of EIA predictions; Determine the effectiveness of measures to mitigate adverse effects of projects on the environment. Environmental monitoring program is a vital process of any management plan of the development project. This helps in signalling the potential problems resulting from the proposed project and will allow for prompt implementation of effective corrective measures. The environmental monitoring will be required for the construction and operational phases. The main objectives of environmental monitoring program are:
i. To assess the changes in environmental conditions, ii. To monitor the effective implementation of mitigation measures, iii. Warn significant deteriorations in environmental quality for further prevention action. iv. In order to meet the above objectives, the following parameters need to be monitored: a. Rehabilitation and Resettlement Program, b. Afforestation, c. Water Quality and Public Health,
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d. Air and Noise quality, e. Soil Conservation, and f. Sanitation and Waste Disposal 6.3 POST PROJECT ENVIRONMENT MONITORING PROGRAM The summarized plan of post monitoring details is presented in the following Table 6.1.
Table 6-1Post project environmental monitoring plan
S. No Particulars Frequency of monitoring Parameters for monitoring 1. Air pollution monitoring
Scrubber monitoring Continuous monitoring H2S
Once in a month H2S
Boiler emissions Continuous PM, SOX, and NOx
Boiler and DG Stack Once in a month PM, SOX, CO, CO2 and NOx emissions
Ambient air quality within the Continuous PM10, SOx, NOX, NO, NO2, CO, O3 premises Ambient air quality at 1 Once in a month All 12 parameters as given in location in Prevalent Down NAAQS Wind Direction Ambient air quality at 1 Once in a month All 12 parameters as given in location in Up Wind Direction NAAQS 2. Noise monitoring At four locations within the Once in a month Noise levels in dB(A) premises 3. Ground water quality monitoring At four locations within the Once in a month Physicochemical properties, heavy Premises through test bore metals wells. 4. Soil Quality monitoring One location near Hazardous Once in a month Physicochemical properties,
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S. No Particulars Frequency of monitoring Parameters for monitoring waste storage area at site Nutrients, heavy metals 5. Effluent Quality Monitoring Inlet and outlet of ETP Once a month pH, Temp, TDS, TSS, Chloride, Sulphide, Sulphate, fluoride, ammoniacal Nitrogen, Sodium, Copper, Zinc, Phenolic compounds, Oil and Grease, Boron, BOD, COD, Total Residual Chlorine, Arsenic, Cadmium, Total Chromium, Hexavalent Chromium, Lead, Selenium, Mercury, Pesticides, Alpha emitters, Free Ammonia, Dissolved Phosphates, Total Kjeldhal nitrogen, Cyanide, Nickel, Residual Sodium Carbonate. Inlet and out let of STP Once a month pH, Temp, TDS, TSS, BOD, COD, Oil and grease 6. Work place monitoring Quarterly Noise, VOC, Lux levels
6.4 MONITORING METHODOLOGIES Monitoring of environmental samples shall be done as per the guidelines provide by MoEF/CPCB/TNPCB. The methods conducted or applied shall be approved or sanctioned by the any recognized body or authority i.e. MoEF/CPCB/TNPCB.
6.5 REPORTING & DOCUMENTATION All the necessary reports and documents shall be prepared complying to the statutory rules & regulations. Proper and due care shall be taken to adhere to the laid down rules and regulation by the Government. Regular and periodic record shall be kept in order to ensure easier, comparable and brisk review and projection of past, present and future performances. Also, the management
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shall ensure to prepare separate records for water, wastewater, solid waste, air, emission& soil regularly and periodically in order to provide better and smooth vigilance.
The management shall look into the fact that as soon as the preparation of reports gets over it shall be forwarded to the concerned authority with due care for the purpose of reviewing. Adhering to the rules and regulations, the management shall ensure that the outcome of the reports and the conclusions been drawn shall be prepared as per the laid down regulations and procedures. No breach of any convention shall be availed.
These reports/documents shall be regularly and periodically reviewed and any changes/discrepancies found in mitigation measures/operation/management/technology shall be brought into notice instantaneously and all possible corrective actions shall be taken to match the discrepancies been witnessed.
6.6 BUDGET FOR ENVIRONMENTAL MONITORING PLAN The yearly budget allocation for Environmental monitoring is given in Table 6-2.
Table 6-2 Budgetary allocation for Environmental monitoring
Budget per Year S. No Particulars Frequency of monitoring (Rs.) 1. Air pollution monitoring Scrubber monitoring Once in a month 6,000/- Boiler and DG Stack emissions Once in a month 6,000/- At 1 location in Prevalent Down Once in a month 60,000/- Wind Direction At 1 location in Up Wind Direction Once in a month 60,000/- 2. Noise monitoring At four locations within the Once in a month 1,500/- premises 3. Ground water quality monitoring At four locations within the Once in a month 1,20,000/- Premises through test bore wells.
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Budget per Year S. No Particulars Frequency of monitoring (Rs.) 4. Soil quality monitoring One location near Hazardous waste Once in a month 20,000/- storage area at site 5. Effluent quality monitoring Inlet and outlet of ETP Once in a month 1,44,000/- Inlet and out let of STP Once in a month 12,000/- 6. Work place monitoring Quarterly 35,000/- Total budget for Environmental monitoring 4,64,500/-
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CHAPTER 7 ADDITIONAL STUDIES
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7 ADDITIONAL STUDIES
7.1 RISK ASSESSMENT As per the Terms of Reference give vide Letter No. J-11011/ 400 /2014 -IA II (I), following additional studies are required to be performed.
Risk Assessment for handling of chemicals.
Risk Assessment is performed and the necessary risk management plan is incorporated as a separate Annexure–9.
Material Safety Data Sheet is enclosed in Annnexure-10 and the Disaster Management Plan is enclosed in Annnexure-11.
7.2 PUBLIC CONSULTATION As the project site is located within Manali Industrial Area, Public Consultation is exempted for the proposed expansion and new component manufacturing as vide Letter No. J-11011/ 400 /2014 -IA II (I),
7.3 SOCIAL IMPACT ASSESSMENT The project site is located within Manali Industrial Area and for the proposed expansion and new component manufacturing; there is no additional land requirement or change in land use. Hence there is no requirement for Social Impact Assessment or Rehabilitation and Resettlement action plans required for the proposal.
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CHAPTER 8 ENVIRONMENTAL MANAGEMENT PLAN
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8 ENVIRONMENTAL MANAGEMENT PLAN
8.1 INTRODUCTION The Environmental Management Plan (EMP) identifies the principles, procedures and methods that will be used to control and minimize the environmental impacts of the proposed construction and operational activities associated with the expansion and new component manufacturing projects. It is intended to ensure that commitments made by Indian Additives Limited will minimize project related environmental and social impacts are upheld throughout all project phases.
As part of ongoing commitment to excellence in environmental and social performance, IAL will ensure the following:
Fulfill all environmental conditions associated with project approvals. Develop, promote and foster a shared sense of responsibility for environmental and performance of the project. Promote environmental awareness and understanding among employees and contractors through training, identification of roles and responsibilities towards Environmental management and linking project performance to overall Environmental performance. Monitor environmental performance throughout the project and implement a proactive management approach towards continuous improvement and to meet the future regulations. 8.2 OBJECTIVES OF EMP To suggest the formation of a core group (Environment Management Cell) responsible for implementation of environmental control & protective measures as well as monitoring of such implementation. To ensure project components are compliant with all laws and approval conditions Continue baseline monitoring Facilitate a continual review of post construction and operation activities. To suggest preventive and mitigation measures to minimize adverse impact and to maximize beneficial impacts like: Preparation of afforestation or Greenbelt Development scheme.
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Preparation of rain water harvesting scheme and energy conservation actions To prepare a capital cost estimate and annual recurring cost for Environmental Management Plan. To prepare a detailed action plan for implementation of mitigation measures. Measure the effectiveness and success of proposed mitigation measures
8.3 EMP STRUCTURE AND ORGANIZATION This EMP is designed as an overriding document in a hierarchy of control plans, and sets out the overarching framework of environmental management principles that will be applied to the project during preconstruction, construction and operation phases of the project.
The EMP contains guiding environmental principles and procedures for communication, reporting, training, monitoring and plan review to which all staff, contractors and subcontractors are required to comply with throughout the preconstruction, construction and operation phases of the proposed expansion and new component manufacturing facility.
The EMP should also be considered as an overall framework document that establishes theterms of reference for all project environmental and social sub-plans including the following:
Environmental supervision plan (construction); Environmental monitoring plan (construction and operation); and Social and health management plan (construction and operation). 8.4 ROLES AND RESPONSIBILITIESFOR EMP This section describes the organizational structure and responsibilities for implementation of the EMP as shown below in Table: 8-1
Table 8-1Responsibility for EMP implementation
S.No Organization Responsibility 1 IAL Leadership Overall responsibility for environmental performance team Decision-maker on applicable policies. Overall supervisory role during the construction phase Overall responsibility for EMP implementation during the operating phase
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S.No Organization Responsibility Review reports of the Environmental Monitoring Consultant(EMC) Responsible for changes to the EMP as part of an adaptive approach to environmental and social management 2 IAL Project/ Develop an environmental unit, headed by the Project Environmental Technical Officer to implement EMP responsibilities. Manager Oversight, implementation, monitoring and compliance of the EMP and any approval conditions, including construction supervision and performance of all staff, contractors and all subcontractors Review of EMP performance and implementation of correction action, or stop work procedures, in the event of breaches of EMP conditions, that may lead to serious impacts on local communities, or affect the reputation of the project Ensuring effective communication and dissemination of the content and requirements of the EMP to contractors and subcontractors Assisting the contractor with implementation of EMP sub-plans Ensuring compliance to all project social commitments, including implementation of corporate social responsibility. Report environmental performance of the project directly to MoEF Report on environmental performance also to other government regulators as required. 3 IAL Implementation of the Environmental Monitoring Plan during construction Environmental and operation. Officer Supervision of contractor performance of implementation of the Construction. Reporting any incidents or non-compliance with the EMP to the TNPCB. Ensuring adequate training and education of all staff involved in environmental supervision. Making recommendations to the MoEF regarding EMP performance as part of an overall commitment to continuous improvement.
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S.No Organization Responsibility 4 Construction Preparation and implementation of the Construction Management Plan Supervisor Prepare and maintain records and all required reporting data as stipulated by the EMP, for submission to the Environmental Officer. Ensure that all construction personnel and subcontractors are informed of the intent of the EMP and are made aware of the required measures for environmental and social compliance and performance During construction, maintain traffic safety along access roads, with special emphasis on high trafficked areas 5 Independent Report to MOEF on project compliance with environmental and social Environmental commitments in the EMP, EIA and other applicable standards. Monitoring Consultant (IEMC)
8.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE The focus of monitoring during the construction phase will be to implement systematic observations to periodically measure the success of proposed mitigation measures and continue baseline data collection. The majority of construction monitoring shall be done visually and verified by the Construction Supervisor. An Independent Environmental Monitoring Consultant (IEMC) will be responsible for carrying out environmental sampling and monitoring on all environmentally related issues regarding the construction contractor‟s activities. Specific aspects to be addressed during construction include:
Air quality Noise Water quality and water resources Solid waste Land environment Ecology
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Socio Economic
8.5.1 AIR QUALITY There are only limited construction activities for the project like foundation for new vessels, tanks, pumps, boiler house and supporting infrastructure for the new machineries. During construction activities, dust emission and emissions from the movement of vehicles are expected. However, following measures will be taken to reduce / contain such emissions.
Water will be sprinkled on inner roads to prevent re-suspension of dust into ambient air due to movement of heavy vehicles etc. Roads will be kept free from mud, debris and other obstacles. Separate civil construction material storage yard will be created within the site and it will be enclosed. Cement bags will be separately stored under cover in bales. Sand will be stacked under tarpaulin cover. Transport vehicles and construction equipment / machineries will be properly maintained to reduce air emissions. All construction workers will be provided appropriate PPEs like dust mask. Signage and speed limit postings will be provided.
8.5.2 NOISE ENVIRONMENT Following measures are proposed during construction period to mitigate adverse impacts of noise
Construction activities will be confined to daylight hours. All machineries to be used for construction purpose will be of highest standard of reputed make and compliance of noise pollution control norms. All construction workers working in high noise areas will be provided appropriate PPEs like ear muffs and made to wear them during working hours.
8.5.3 WATER QUALITY AND WATER RESOURCES Maximum water requirement for construction purpose including domestic water requirement of construction workers is estimated to be approximately 7 KLD.
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Since the construction workers are hired from nearby villages, there will be no housing facility at the site for construction workers and hence lesser water requirement. Proper and sufficient sanitary facility already exists at the site in the form of toilets &existing STP will be used for treatment of sewage generated.
8.5.4 LAND ENVIRONMENT Top soil layers will be stored for reclamation and re-vegetation and reforestation at approved locations. Existing storm water drainage facility will be used for disposal of storm water. Since there is minor construction activity proposed, there will not be significant disturbance of land.
8.5.4.1 SOLID WASTE Main solid waste generation during construction phase will be construction debris like rubble, brick bats, debris, sand, gravel etc. However, these materials are inert in nature and will not result into leaching of any substance or its constituent. These materials will be carefully sorted and will be used within premises for filling of low lying areas. Wooden scrap and steel scrap generated during construction phase will be disposed through authorized scrap dealers. All the wastes will be stored at a designated site within the premises.
8.5.5 ECOLOGY Project site is an existing unit with established greenbelt. There is no cutting of trees for the proposed expansion or new component manufacturing project and hence no major impact on ecology is anticipated.
8.5.6 SOCIO ECONOMIC As there will be no temporary housing colony for construction workers, no socio economic impact due to the rehabilitation is envisaged. Overall socioeconomic effect of construction phase will be positive due to direct and indirect employment opportunity for the local population.
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8.6 ENVIRONMENTAL MANAGEMENT PLAN FOR OPERATION PHASE Monitoring during the operation phase shall reflect those environmental and socio-economic issues that may persist upon completion of construction activities. Monitoring shall focus on evaluating the effectiveness of project mitigation measures and continue baseline monitoring and sampling. The mitigation measures to prevent adverse impact during the operation phase of the project shall focus on the following:
Air quality Water quality and water resources Noise environment Solid and hazardous waste Land environment Ecology Socio Economic
8.6.1 AIR QUALITY MANAGEMENT As the proposed expansion and new component manufacturing facility is planned within the existing unit, there are no significant changes/ additions to the stacks or vents as shown in the Table 8-2. However, following air pollution mitigating measures will be ensured during the operation phase:
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Table 8-2 Stack details for existing and proposed project
1 2 (Connected 7 (Connected Stack/Vent (Connected 8 to CAC, 3 4 5 6 to CAC, Details to CAC, (Proposed) TNPCB) TNPCB) TNPCB) Material of Carbon Steel Carbon Steel Carbon Carbon Carbon Steel Carbon Steel Carbon Steel Carbon Steel Construction Steel Steel Stack/vent Common Common Stack Exhaust Common High Point High point Vent from Proposed vent attached to: Stack to 3 to 2 Nos. of Oil pipe to Exhaust discharge via discharge to Phenate from Caustic Nos. of oil fired Thermic D.G set Stack to DG water Succinimides reactor scrubber fired Boilers fluid heater 550 KVA sets - 1010/ scrubber for Reactor through attached to 1500 KVA PIBSA Caustic ZDTP reactor reactor vent scrubber Stack/vent 47 m 30 m 16 m 16 m 22 m 17 m 27 m 30 m Height Stack/ vent 0.80 m 0.3 m 0.2 m 0.4 m 0.15 m 0.1 m 0.1 m 0.2 m Dia at top Gas Exit 447 477 444 458 341 325 335 313 Temp (K) Gas Exit velocity 15.2 15.8 16.3 14.8 4.4 1 0.35 0.35 (m/sec)
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H2S gas stream from the existing phenate plant is scrubbed completely in 3 stage caustic scrubber before being discharged to the atmosphere. The vent from caustic scrubber is
continuously monitored for H2S through online analyzer.
The spent caustic generated from scrubber is stored in closed storage tank and sold to nearby Sodium Sulphide flakes manufacturers
H2S generated from the proposed ZDTP plant will be treated in dedicated Caustic scrubber
system and converted to ~ 13 to 15% Sodium sulphide (Na2S) solution. The Na2S solution is further concentrated in Multiple Effect Evaporators (MEE) system and then flaking is
done in flakers to manufacture Na2S flakes.
12 Nos of H2S sensor installed in different areas of plant premises to monitor H2S. H2S sensor at the caustic scrubbers vents are hooked up to CAC, TNPCB.
The unit has installed Online Ambient Air Quality (AAQ) monitoring station and it is
connected to Care Air Center (CAC), TNPCB for the following parameters - PM10, SOX,
NOX, CO, NO, NO2&O3.
The unit has installed online stack monitoring station (CEMS) for hot oil stack and boiler
stack and connected with CAC (TNPCB). PM, SOX& NOX are being analyzed.
Apart from online monitoring system, Ambient Air Quality, stack and effluent monitoring are done through approved Laboratories and monthly reports are submitted to TNPCB
The unit has also installed continuous ambient VOC monitors in the plant.
Since there are no solid fuel fired boilers, there is no ash disposal system proposed.
8.6.1.1 CAUSTIC SCRUBBING SYSTEM FOR H2S TREATEMENT FROM EXISTING PLANT
H2S gas stream from the existing Phenate plant is scrubbed completely in 3 stage caustic scrubber before being discharged to the atmosphere. The vent from caustic scrubber is
continuously monitored for H2S through online analyzer. The spent caustic generated from scrubber is stored in closed storage tank and sold to nearby Sodium Sulphide flakes manufacturers.
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i. Design Basis - The design highlighted in Table 8-2is for continuous scrubbing of H2S by three stage system, an educator, baffle tray scrubbing tower and a packed scrubber. The peak
hourly rate of H2S off-gas has been measured to be approximately equal to 90% of the
excepted H2S evolution for the batch per hour. The caustic scrubber disposal facilities are
sized to handle peak H2S and air leakage rate of 600 Kg/Hr and this is expected to occur over 2 to 3 hour period.
Table 8-3 Caustic scrubber design specifications
S.No Description Unit Specifications A Process Data Bottom Top
1 Fluid Name H2S gas/Caustic 2 Vapour flow rate Kg/h 600 50 3 Vapour Density Kg/m3 1.25 1.05 4 Liquid Flow rate Kg / h 16175 15625 5 Liquid density Kg/ m3 1043 1043 6 Liquid Viscosity Cp 1.6 1.6 7 Liquid Surface Tension dyn/cm 61.6 61.6 Minimum Rate as % of Design VTA VTA 8 Rate 9 Maximum Flood Factor 0.95 0.95 Allowable Pressure Drop 0.012 10 (Total) Kg/cm2 11 Operating Temperature deg C 12 Operating Pressure Kg/cm2 G ATM B Geometrical Data 1 Column inside diameter mm 450/2300 2 No of packed column 1 3 Packed dia mm 457.2 4 Packed height mm 3000 5 Packed Volume M3 0.5 6 Packing type Pall ring Packing Nominal size X 25.4 7 Thickness mm 8 Packing Material CS 9 No of Tray column 10 10 Tray type mm Fixed plate 11 Tray dia mm 450 12 Tray height mm 6390
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S.No Description Unit Specifications 13 Tray spacing mm 6.1 14 Reservoir dia mm 2300 15 Reservoir height mm 4800 16 Reservior volume M3 19.93
ii. Process Chemistry -The following reactions take place in the scrubber
H2S + 2 NaOH------> Na2S + 2 H2S + Heat
H2S + Na2S ------> NaHS + Heat
iii. Process Description - The Process flow scheme and process control for the caustic scrubber are shown in Figure 8-1.
Figure 8-1 Caustic scrubber flow diagram
Process off-gas (H2S) is scrubbed total of 3 times before being exhausted to the atmosphere
K-930 caustic educator is used to pull H2S rich gases into the scrubber. Aqueous caustic from column C-930 reservoir is used to feed the educator.
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Column C-930 has a lower 10 tray side to side baffle scrubber used to remove most of
the remaining H2S. Aqueous caustic is recycled from the column reservoir to the top of the 10 tray section.
Column C-930 has an upper packed bed scrubber section to remove trace H2S and act as a backup for the other two scrubbing systems. Aqueous caustic supply for the packed scrubber is provided from tank T-930, separate from the caustic supply for the other two systems
Column C-930 reservoir has sufficient capacity to treat 6 batches of OLOA 219C before scrubber caustic is 25% spent. Spent caustic is discharged to tank T-932 and further it is being dispatched as by-product, while 2000 liters is retained by an internal baffle section of the column reservoir. The retained volume will allow for continuous educator and baffle tray scrubber section operation while the reservoir is being refilled. 14.8 M³ of caustic from the packed section scrubber supply tank T-930 is used to refill column C-930 reservoir leaving a heel of 5 M³ in T-930 to allow the packed column section to operate continuously. Fresh 50% caustic is mixed with fresh water to bring down the caustic concentration to 22% in tank T-930.
iv. Process Control
Liquid level is maintained in the reservoir of C-930 at all times. A low level alarm and a high level alarm are used to notify operating personnel of potential problems
Spillback to educator K-930 is controlled by a PIC which operates during periods when the batch has low off gases flow
Diesel driven pump is installed to ensure the continuous flow to the Caustic scrubber
AOD Pump is second back up for the continuous flow to the caustic scrubber system
All key parameters of caustic scrubber operations have been hooked up to state of the art centralized computerized control system (DCS) and are continuously monitored. All process control and emergency logics are provided in the DCS.
H2S sensors are located at different areas covering all the H2S generation & treatment systems
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All the sensors monitor the H2S levels continuously. All are connected to DCS and their
online values are captured in DCS. In case of H2S levels above 5ppm, these sensors will raise alarms both in field and in DCS control room.
IAL has a well-developed onsite emergency plan in case of emergencies related to H2S and necessary training on emergency response has been provided to all employees working inside the plant.
All employees include contract work men are provided with H2S badges.
8.6.1.2 H2S OFF GAS TREATMENT FACILITYFOR PROPOSED NEW COMPONENT (ZDTP) MANUFACTURING UNIT H2S generated from the proposed new component unit will be treated in dedicated caustic scrubber system is designed similar to existing scrubber and converted to ~ 13 to 15% Sodium sulphide
(Na2S) solution. The Na2S solution may either be sold as by-product to local flake manufacturing units or be flaked in-house after concentrating in Multiple Effect Evaporators (MEE) system, flakes will be sold as by-product in the market, as shown in the Figure 8-2.The process condensate from the MEE system is recycled back to Caustic scrubber system for caustic dilution and the balance is sent to ETP for
treatment. The Na2S flakes from flakers are bagged and sold as by product in the market to textile, paper and leather industries.
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Figure 8-2 H2S treatment facility for new Component (ZDTP)
8.6.1.3 PROCESS VAPOR RECOVERY SYSTEMS a) Recovery of Iso Decyl Alcohol and Mono Ethylene Glycolfrom Phenate process–Iso Decyl Alcohol along with Mono ethylene glycol and & water vapors which come from the reactor gets condensed in the overhead condensers. This mixture of condensed liquid is collected in the receivers and this liquid mixture is allowed to settle in the gravity separators. After sufficient time of settling, MEG & water mixture settles down in the bottom the separators. Iso Decyl Alcohol which settles at the top of the separators is pumped to another separator where traces of water present in the Iso Decyl Alcohol are also removed. This Iso Decyl Alcohol is reused in the process. MEG & water are easily miscible and it is not possible to separate them through gravity settling. This liquid mixture is distilled in the distillation column to separate them. The overhead water vapor is condensed, cooled and sent to ETP for treatment.
b) Recovery of 2 Ethyl Hexanol from Sulfonate process - 2 Ethyl Hexanol along with water vapors collected from the process plant. This vapor mixer is condensed in the overhead condensers and the liquid from the overhead condensers is allowed to settle in the gravity
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separator. After sufficient time of settling, water settled in the bottom of the separator drained and pumped to the chemical sump of ETP. 2 Ethyl Hexanol is pumped back to the storage tank and reused in the process.
c) Recovery of Maleic Anhydride (MA) from PIBSA process - MA vapors from the reactor is condensed in the overhead condenser and the recovered MA from the overhead condenser is pumped back to the storage tank and reused in the process.
d) Recovery of Secondary Butyl Alcohol (SBA) & Methyl Iso Butyl Carbinol (MIBC) from new component (ZDTP) process - SBA & MIBC vapors from the ZDTP reactor gets condensed in the overhead condenser and collected in the collection tanks. This spent solvent will be filled in closed PVC drums and disposed for recycling through authorized agency.
8.6.1.4 FUGITIVE EMISSION CONTROL SYSTEM Raw materials/ intermediates/ products are stored in closed tanks/drums provided with breather arrangements to avoid fugitive emissions. However, VOC analyzers are installed and hooked up to TNPCB Care Air Centre for continuous monitoring.
a) Material Handling Storage and Transportation
Hazardous chemicals are stored in closed tanks and drums with appropriate blanketing systems. All material transfers are done through pumps in closed pipeline systems, however, containment dykes with appropriate segregations from storm water gutters are provided in all pumping areas to contain spillages in case of leaks. The loading of finished products to trucks and drums is done through automated filling systems with overflow protections All key raw materials are charged to the reactors through closed pipeline systems.
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Figure 8-3 Photograph of tank farm
Mass flow meter Closed piping system
Figure 8-4 Photographs of material handling system
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8.6.2 WATER QUALITY AND RESOURCES MANAGEMENT 8.6.2.1 EFFLUENT TREATMENT SYSTEM The unit has well established ETP Plant designed for handling 300KLD of combined effluent from process and utility systems through Activated Sludge aerobic process as detailed below. Sewage effluent is treated separately in exclusive sewage treatment plant. The treated effluent meeting PCB norms is then treated partly in multi stage Reverse Osmosis Plant for recycle into process while the rejects are concentrated to salts in multiple effect evaporators for disposal. Part of treated effluent meeting PCB discharge norms is used for green belt developments.
There are two effluent streams generated in the plant as below.
i. Stream A-Basically consist of process waste water, wash/storm water from curbed process area, process wash downs, and streams from lab, pump leakage, storm water from truck loading and tank farm areas. This stream contains traces of oil and other chemicals used in the process.
ii. Stream B- Consist of cooling tower blow down, boiler blow down and DM plant regeneration wastes.
The effluent treatment plant basically consists of three sections:
Oil/water separation and oil recovery. Treatment of separator water and its disposal. Sludge digestion, thickening and dewatering Table 8-4 Characteristics of raw and treated effluent
S.No Parameters Raw Effluent Treated effluent
1 pH 6.0 – 9.0 5.5 – 9.0
2 Temperature ambient ambient
3 COD (mg/l) 1500 - 2500 100 - 150
4 BOD (mg/l) 450 - 850 15 - 20
5 Oils & Grease (mg/l) 5 - 8 5 - 8
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S.No Parameters Raw Effluent Treated effluent
6 TSS (mg/l) 20 – 50 20 - 50
7 TDS (mg/l) 1600 - 2000 < 2100
Note: * Combined effluent characteristics of stream A & Stream
The free-floating oil in the process effluents from various unit processes is removed by skimmers and corrugated float separator units. The emulsified oil in the effluent stream is removed by dissolved floatation techniques. These various steps of oil removal enable a reduction in the Bio- chemical Oxygen demand contributed by the oil.
In the oil –water mixture, the free oil due to its relative lower specific gravity, floats on the surface which is removed by mechanical skimming. The collected process effluent is pumped to cross flow separator (CFS) where further free oil is removed. The effluent from CFS bearing certain amount of emulsified oil and free oil is sent to Dissolved Air floatation unit (DAF) through a Surge Pond. The DAF unit acts as secondary treatment in the removal of oil.
The out let of the DAF unit is sent to Equalization basin where the utility stream is mixed. The combined effluent is subjected to biological treatment based on activated sludge system.(Aerobic Process) An activated sludge unit consisting of an aeration basin and a clarifier removes dissolved organic contaminants. The waste biological sludge is sent to a sludge digester where it is further degraded the water from the digester is sent back for treatment and the digested sludge is sent to dewatering facility. The dewatered sludge is sent to solar ponds for drying. The treated water is pumped to surge pond (west) The treated water is used for firefighting, gardening. The treated water is partially sent to RO plant for further processing &recycle to plant for usage in DM plant and Cooling Tower and the remaining water is used for gardening/green belt activities.
Online monitoring of parameters (pH & TDS) for treated effluent from ETP done and it is also connected with CAC, TNPCB. The design details of individual components of ETP are given in Table 8-5
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Table 8-5 Design specifications of individual components of ETP
S.No. Tag No. Component L X B X H + FB
1. - Chemical House 16750 x 8250
2. X-801 Screen Chamber 2500 x 150 x 150
3. T-802 Chemical sump 6400 x 6400 x 1250
4. T-811 Utility sump 5250 x 5250 x 1350
5. T-812 Sanitary sump 5250 x 950 x 1300
6. T-803 Cross flow separator 2000 x 1000 x 2500 + 250
7. T-823 Oily sump 2000 x 1000 x 2500 + 250
8. T- 824 Oil collection tank 1500 (Dia) x 1500 LD
9. T-827 Primary sludge sump 2000 x 1000 x 2500 + 250 T-804 21250 x 21250 x 2500 x + 250 ( 2 10. Surge pond A/B compartments ) 11. - Surge pond outlet sump 3500 x 3500 x 2400 + 350
12. - Fire hydrant sump 2000 x 2000 x 2400 + 350
13. T-805 DAF unit 3500 x 2000 x 2500 + 250
14. T-809 Float Separator 500 x 250 x 1500 + 250
15. T-810 Slop oil sump 1000 x 1000 x 1500 + 250
16. T-813 Equalization basin 6400 x 6400 x 2500 +300
17. T-814 Aeration Tank 8000 x 8000 x 2750 + 500
18. T- 817 Intermediate settlingtank 8000 x 1500 x 2000 + 600
19. T-818 Intermediate sludge sump 750 x 750 x 2000 + 600
20. T- 820 Final clarifier 51200 (Dia) x 2250 + 250
21. T-821 Final effluent sump 2100 x 2100 x 1500 + 450
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S.No. Tag No. Component L X B X H + FB
22. T- 819 Oxidation Ditch 18000 x 8000 x 1350 + 500
23. - Hypo chlorite preparation area 2000 x 2000
24. T- 825 A/B Recovered oil tanks 4800 (Dia) x 3000 LD
25. T-828 Aerobic Digester 5600 x 5600 x 2750 LD + 500
26. T- 829 Thickener 2000 (Dia) x 2250 + 250
27. T-830 Thickened sludge sump 1000 x 750 x 2250 +250
28. T-831 Centrifuge shed 4000 x 3000
29. - Sludge drying bed (3 Nos.) 2000 x 2000 x 1250 + 250
a) Screen chamber - Stream A containing oil in free and emulsified form flows into the `Screen Chamber' by gravity. Here the coarse solid particles are removed by the screens. The screened liquid flows to the chemical sump.
b) Chemical sump - In chemical sump, free oil floating on water is removed by the oil skimmer and pumped to the oil collecting tank. The effluent water with the unseparated oil is pumped by the vertical centrifugal, submerged pump P - 802 A/B to the cross flow separator. During upset conditions the water can be pumped fully/partially to the surge pond by passing the cross flow separator.
c) Cross Flow Separator - In the cross flow separator (CFS) the incoming effluent is distributed over a large surface area. Parallel corrugated sheets inclined at 60 Deg. are installed as flow distribution baffles for optimizing the vertical distance travel under stable laminar flow. Oil is separated by the principle of gravity separation. Due to the density difference between oil and water oil flows to the surface and water flows downwards. The top oil layer is removed by the adjustable slotted skimmer and flows to oily sump. The bottom sludge flows by gravity to the primary sludge sump. The overflow water flows to the surge pond by gravity.
d) Surge pond - Surge Pond is used to hold up large quantities of effluent in case of sudden inflow due to process upset. The sludge collected at the bottom of the surge pond is transferred to the primary sludge sump by gravity. The overflow water collected in the surge pond outlet sump is pumped by P-804 A/B to the flocculation unit. The water in surge pond is also used for fire fighting.
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e) Flocculator - The effluent water from the surge pond outlet sump is pumped by P - 804 A/B and flows through the flocculator. Prepared polyelectrolyte and alum are dozed at a constant rate to the flocculator.
f) Dissolved Air Floatation unit - From the flocculator the effluent flows to the Dissolved air flotation unit (DAF) T-805. Here the impurities from the effluent are separated by the introduction of fine air bubbles in to the waste water. The air bubbles attach themselves to the solid and liquid pollutants. The combined density of the air and impurities is lower than that of the liquid phase causing them to rise to the surface from where they will be removed easily. Plate packs in the DAF increase the surface area for the separation of impurities.
The floating oil layer is separated by skimmer and flows by gravity to the float separator T-809 and then to stop oil sump T - 810 by gravity. From slop oil sump, collected oil is pumped by P-805 A/B to the oil collection tank. The bottom sludge flows to the in let of thickener. The overflow effluent water free from oil flows to the equalisation basin (T-813). A portion of the effluent water is pumped by P-805 A/B to a pressure tank T-806. Compressed air is pumped into this to achieve a very fine dispersion of air bubbles in it. These mix with the effluent water at the outlet of the flocculation unit.
g) Oil recovery units - Oil collected in the oily sump (T-823) transferred by pumps P-823 A/B to the oil collection tank T-824. Here it combines with other oils collected from chemical sump and D.A.F. unit. Periodically the accumulated oil with small fractions of water is transferred to the Recovered oil tank T-823 A. T-823 A is provided with a steam heating coils. The tank contents are kept warm to aid oil/water separation. Clear floating oil from T-823 A tank overflows to the Recovered oil tank T-823 B. The accumulated water stream at the bottom is pumped back by the pump P-825 A/B to the CFS. .
h) Equalisation tank - Stream B, effluent water from the centrifuge, overflow from the thickener and overflow from the D.A.F. flows to the equalisation basin. Air is blown through the effluent to increase the dissolved O2 content in it. Two blowers (T-833 A/B) blow air into the bank of tubes layed at the bottom of the Equalisation Basin. Holes are provided at equal intervals in the tubes for the uniform distribution of air in the equalisation basin through the effluent. From here, the effluent is pumped by P-813 A/B to the Aeration tank.
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i) Aeration tank - In Aeration tank, the activated sludge in the effluent water undergoes biological
degradation by the micro organisms. The O2 required by the micro organism is supplied by a surface aerator. In order to maintain sufficient food for the micro organism, some amount of solid sludge from the Intermediate Sludge Sump is recycled. For this the suspended solids in mixed liquid should not be less than 4,000 mg/l. The micro organisms will die if the level of food in the
tank is less than a minimum (4000 mg/l). The dissolved O2 content is maintained at 1.5 - 2 mg/l.
j) Intermediate settling tank - The bio mass in the effluent from the aeration tank is settled in the intermediate settling tank. Water over flowing from top is collected in a pit and flows to Oxidation Ditch by gravity. Sludge, settled in the bottom of the tank is collected in the intermediate sludge sump T-818 and is pumped to the Aerobic digestor by the pump-818 A/B. A part of the sludge is recycled back to the Aeration tank.
k) Oxidation Ditch - Oxidation ditch is designed as an extended aeration system. To maintain the food for the system a portion of the activated sludge from final clarifier is pumped back to the
Oxidation Ditch. O2 required for the oxidation is provided by two nos of cage rotors. The oxidation capacity can be varied by changing the depth of immersion of rotors by adjusting the weirs. From here the effluent flows by gravity to the final clarifier.
l) Final Clarifier - The developed Bio-mass enters through the centre of the clarifier and radially moves outwards; sludge gets settled in the clarifier. Slow moving radial rakes driven from a central shaft helps the sludge to collect in the bottom cone.
The settled sludge is pumped by P-820 A/B to the thickener. A portion of it is fed back to the oxidation ditch for maintaining the food for the biomass in it. The clear effluent water overflows from the clarifier to the final effluent sump T-821. Here the effluent is chlorinated before discharge. Chlorination is done through chlorinating towers and the chlorine enters the tower through diffusers.
m) Primary Sludge Sump - Sludge from the CFS and surge pond collected in the primary sludge sump is pumped by P-827 A/B to the thickener periodically.
n) Aerobic Digester - Sludge from the primary sludge sump is pumped by P-827 A/B to the Aerobic digester. Air to the micro organism is provided by surface aerators. The sludge after the aerobic digestion becomes biologically stable and easily dewater able. The treated sludge flows by gravity to the thickener.
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o) Thickener- Sludge from Aerobic Digester sent by gravity to the thickener. Sludge from primary sludge sump and the D.A.F bottom are fed to the thickener. Here the solid contents of the sludge are increased by gravity settling. Any floating oil is skimmed and flows by gravity to slop oil sump. The overflowing effluent water flows to the equalisation basin by gravity. The concentrated sludge from bottom cone is transferred to the thickened sludge sump. From here P-830 A/B pumps the collected sludge at a uniform rate to the centrifuge.
8.6.2.2 REVERSE OSMOSISAND MULTI PLE EFFECT EVAPORATOR SYSTEM The system mainly consists of four stages as below:
i. Filtration System - The reservoir water is collected to the raw surge storage Tank; T 851.This stored water will be pumped to the Multi grade Filter MGF 851 to reduce the Suspended solids and dissolved silt. The Outlet of the MGF was feed to the Activated carbon Filter ACF-851 to inhere water colour & unwanted smell will be reduced.
ii. Ultra-Filtration System - The filtered water will be passed through a downstream basket strainer to trap any carry over suspended solids and turbidity. The filtered feed then Passes through an Ultra filtration system for the removal of fine & colloidal Particles and makes the water suitable for RO feed and the filtrate will be stored in the UF filtrate storage tank T-852, Suitable chemicals will be dosed While backwashing at present intervals to enhance proper backwashing. The Back wash water from the UF and the filters will be led to the collection sump for further treatment.
iii. Reverse Osmosis system -The filtered water from the tank is pumped using RO feed pump into RO System. The filtered water is dosed with an acid, anti-oxidant and anti scalant for de-chlorination and preventing scale forming salts from precipitating over membranes surface in the feed water. The conditioned feed is then filtered through a 5 – micron cartridge filter. High pressure pump pressurizes the feed to the RO system. The reverse osmosis unit separates the feed into two streams; the permeate stream with low total dissolved solids and reject stream with high TDS.
iv. Multiple Effect Evaporation system - To treat the effluent from RO reject, the Triple effect, forced circulation type evaporation system is used. The system is designed to handle total effluent load 800kg/hr based on 24 hours operating in a day.
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Each stage of forced circulation Evaporation has a combination of Calendria as a Heat Exchanger with a Separator & preheater. There are three Calendria (CL-851, CL-852 & CL-853) each is equipped with one vapors separator (SP-851, SP-852 & SP-853) & preheater (PH-851, PH-852, & PH-853).
The effluent is first received in a feed balance tank (T-858). Then pumped through preheaters (PH-853, PH-852, PH-851) to Calendria (CL-851), using the feed pump (P- 856).Then from Calendria (Cl-851) by using recirculation Pump (P-857) effluent is circulated continuously. Dry saturated steam is supplied to the Thermo compressor (TVR- 851), attached to Calendria (CL-851) at 7-bar (g) min. The thermo compressor sucks a part of vapour from separator (SP-851) & the Mixture of vapour& steam is added to the Calendria (CL-851) steam chest as heating medium. Vapour from the first effect separator (SP-851) is added to the chest of Calendria (CL-852). The part effluent from Calendria (Cl- 851) is added to suction of pump (P-858) to circulate effluent through Calendria (CL-852). The part of effluent from Calendria (Cl-852) is added to suction of pump (P-859) to circulate effluent through Calendria (CL-853) & then from Of Calendria (CL-853). The effluent is recirculated continuously. After required concentration reached the Concentrated product is then transferred to Basket centrifuge (BSK 851 & 852) through product pump (P-860). The filtrate from centrifuge is added to filtrate tank (T-861) & from the tank it is sent to third effect separator (SP-853) through filtrate pump (P-861).
Vapours from separators (SP-851& SP-852) are reused for heating in Calendria (CL-852 & CL-853) respectively. Vapour from separator (SP-853) is condensed in barometric Condenser (BC-851). Steam condensate are collected in Condensate tank (T-860) through chest side of Calendria (CL-851, CL-852, CL-853) respectively. Condensate is then pumped through Condensate pump (P-862) for multiple uses in factory.
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Figure 8-5 Photographs of RO and MEE
8.6.2.3 SEWAGE TREATMENT SYSTEM The design capacity of STP is 60 KLD with a plant flow rate of 3 M3/hr.
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Table 8-6 Characteristics of raw and treated sewage
Treated S.No Parameter Units Raw sewage Standards sewage 1 PH - 6.0 – 8.5 5.5 – 9.0 5.5 – 9 2 TSS mg/l 200 – 300 < 30 < 30 3 BOD mg/l 250 – 350 < 20 < 20 The raw sewage from various sources will get collected in the collection tank where it is pumped to the bar screen chamber through raw sewage transfer pump in order to remove the floating particles & then collected in the equalization tank.
The screened sewage is then pumped to the aeration tank through raw sewage transfer pump. Air diffusion is provided in the aeration tank through air blower & diffuser arrangement. Biological treatment takes place through special type of floating media called “MBBR Media”. MBBR media will expedite the treatment with minimum sludge.
The aerated sewage is then led to the clari-settler tank provided with clari-settler internals where the sludge settles at the bottom of the tank. The clarified water is then sent to the Chlorine contact tank.
The settled sludge from clari-settler tank will be pumped to sludge drying beds through sludge transfer pump for drying purpose and the filtrate is taken back to the collection tank.
The clarified water is then pumped to pressure sand filter & Activated carbon filter using filter feed pump in order to remove the suspended particles, colour and odour. Sodium hypo chlorite dosing is done online for disinfection purpose. The filtered water is used for gardening.
The STP and ETP adequacy reports for proposed expansion and new component manufacturing projects are enclosed in Annexure-12 and Annexure-13 respectively. The design details of individual components of STP are given in Table 8-7
Table 8-7 Design specifications of individual components of STP
S.No. Component L X B X H + FB
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S.No. Component L X B X H + FB
1. Bar screen chamber 1 m x0.6m x 1m
2. Equalization tank 2 m x 2.5 m x 2.5 m
3. Aeration tank 5.5 m x 2.5 m x 2.5 m
4. Clarisettler tank 1.8 m x 2.5 m x2.5 m
5. Clarified water tank 1.2 m x 2.5 m x 2.5 m
6. UV sterilizer 3 m3/ hr, 39 W
7. Pressure sand filter 650 mm dia x 1250mm HOS
8. Activated carbon filter 650 mm dia x 1250mm HOS
The Process flow Diagram of ETP and STP are given in Figure 8-6 and the photographs in Figure 8-7.
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Process plant (N-Pit, Hot well) Alum Dosing Poly electrolyte Dosing
Surge pond Chemical sump Cross flow separator Dissolved air (East) (T- (T-802) (T-803) floatation (T- 804) 805) )
Boiler Blow down
Urea & DAP
Utility sump (T-811) Equalization basin (T- 813) Aeration Tank(T-814 aeration tank)
Sanitary waste from plant & Non VAZ Solution dosing Intermediate Sludge plant areaBlending Plant Sump T-818 Over flow Surge Pond (West) (Treated sump water) Sanitary sump (T-812)
Oxidation Ditch (T- 9Treated Final Clarifier (T-820) 819)
RO Plant
Sewage Treatment Gardening Plant Sludge for drying Recycle to plant
Figure 8-6 ETP and STP Process Flow Diagram
EFFLUENT TREATMENT PLANT SEWAGE TREATMENT PLANT
Figure 8-7Photographs of Effluent and Sewage Treatment Plant
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8.6.2.4 RAINWATER HARVESTING SYSTEM All buildings are provided with rain water harvesting systems. Recharge pits are provided near the administrative building and blending unit. Around 9 nos. of recharge pits are provided. The site plan showing rainwater harvesting system is enclosed in Annexure-14.The photograph of rainwater harvesting pit is given in Figure 8-8.
Figure 8-8 Photograph of rainwater harvesting pit
8.6.2.5 WATER REQUIREMENT There is no ground water tapping for the existing and the proposed facilities. Complete requirement is met through purchase from CMWSSB and recycling of treated effluent.
8.6.3 NOISE ENVIRONMENT Following measures are proposed to mitigate impact during operation phase of the project on the surrounding noise environment
All the noise generating equipment will be designed / operated to ensure that noise level does not exceed 75 dB (A) during day and 70 dB (A) during night at plant boundary as per the requirement of Central / State Pollution Control Board. Noise generating sources will be maintained properly to minimize noise levels and wherever applicable, acoustic enclosures will be provided.
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Compliance with noise control norms will be given due importance at the time of purchase of various equipment and it will be mentioned while placing the purchase orders and guarantee for noise standards will be sought from suppliers. Adequate Green Belt development is ensured to mitigate noise. Moreover, all the personnel working in high noise generating areas will be provided with sufficient ear protecting devices.
8.6.4 SOLID AND HAZARDOUS WASTE MANAGEMENT Hazardous wastes from the existing to proposed are increasing, the details of Hazardous wastes generated are given in Table 8-8. The hazardous wastes generated from this unit are collected, stored and disposed through authorized disposal cum recycle facilities as per the authorization from PCB and the unit has agreements with all waste disposal facilities for the same. There is no internal disposal facility availability within the site. There is no solid fuel used in the Boiler and hence there is no fly ash generation.
The Authorization Letter from TNPCB is enclosed as Annexure-15.
Table 8-8 Hazardous wastes generation
Quantity (MT/ year) Cat. After After proposed Details of waste Method of disposal No. Existing proposed new component Expansion (ZDTP) Collection, Storage and Disposal for incineration at Distillation residue 20.3 800 1250 2300 common TSDF facilities & co- (from process) incineration at cement industries. Collection, Storage and 5.1 Used/ Spent oil 100 150 150 Disposal to Authorized Recycling Agencies.
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Quantity (MT/ year) Cat. After After proposed Details of waste Method of disposal No. Existing proposed new component Expansion (ZDTP) Collection, Storage and Wastes/ residues 5.2 7 10.5 15 Disposal to Authorized containing oil Recycling Agencies. Chemical sludge Collection, Storage and 34.3 from waste water 10 15 20 Disposal for land fill at treatment authorized TSDF facilities. Toxic metal containing 34.2 0.5 1 2 Residue from water purification 20.2 Spent Solvents ** ** 1500 Collection, Storage and Discarded Disposal to Authorized 33.3 2500 Nos 3500 Nos 4000 Nos Containers Recycling Agencies. ** Not applicable
The characteristics of Hazardous waste is given in Table 8-9 below
Table 8-9 Characteristics of Hazardous waste
Chemical sludge from Distillation Wastes/residue S.No. Properties Used spent oil waste water residue containing oil treatment
1 Sp. Gravity 0.9 --- 0.5 (Bulk density) ---
50 – 70% in a Percentage 100% solid. Residues of 2 0.5 % 18 % semi solid pasty solids oil in the saw dust form
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Chemical sludge from Distillation Wastes/residue S.No. Properties Used spent oil waste water residue containing oil treatment Filter cake contains 50 – Oil sticking to the saw Chemical Oil and oil Sludge from 70% of filter aid dust is mostly the oil 3 composition emulsions. ETP * and remaining spillages of PIBSA/ actives and lube Phenate/ Succinimides oil
4 Flash point > 150 deg C --- > 170 deg C ---
5 Reactivity Non reactive Non reactive Non reactive Non reactive
6 Toxicity Nil Nil Nil Nil
7 Explosivity Non explosive Non explosive Non explosive Non explosive
8 Calorific Value 3500 – 4000 --- 3500 – 4000 ---
9 Biodegradability --- Biodegradable ------
Table 8-10 Non-Hazardous wastes
Quantity (MT/ year)
After proposed Details of waste After proposed Method of disposal Existing new component Expansion (ZDTP)
Sold as scrap to authorized Used paper waste 0.32 0.48 0.55 buyers
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Quantity (MT/ year)
After proposed Details of waste After proposed Method of disposal Existing new component Expansion (ZDTP)
Taken back by outsourced Food waste 1.08 1.44 1.65 catering service provider for appropriate disposal
8.6.5 LAND ENVIRONMENT Following measures are proposed to mitigate impact during operation phase of the project on the land environment.
Air emissions are effectively controlled by appropriate air pollution control systems and therefore deposition of air pollutants in and around the premises and surrounding area is not envisaged. Disposal of solid wastes is disposed through authorized disposal cum recycle facilities as per the authorization from PCB and there is no internal disposal facility availability within the site. All the hazardous wastes to be generated from the project will be properly stored and disposed as per the hazardous waste authorization issued by TNPCB. Hence there may not be any impact to the land environment. As the treated effluent is reused, impact on the land environment is not envisaged. Hazardous chemicals are stored in closed tanks and drums with appropriate blanketing systems. Thus, no impact on land is envisaged due to discharge of gaseous emission, solid waste or liquid effluent from the proposed project..
8.6.6 GREEN BELT DEVELOPMENT IAL has already developed a greenbelt of 8.56 acres of the total plot area 23.57 acres in consultation with horticulture experts as per Ministry of Environment, Forests and Climate Change/Central Pollution Control Board guidelines. Adequate numbers of saplings are planted all along the periphery of the plant, roadways and available open spaces. The major aim of greenbelt
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development plan is to attenuate air pollutants released into the environment but it can also help in overall improvement in the environmental conditions of the project site. The plan will address the following issues such as attenuation of air pollution, noise reduction, improving the biodiversity of the region, adding aesthetics and combating soil erosion and prevention of land degradation. The plot plan indicating Green Belt development is enclosed in Annexure-16.
8.6.7 ECOLOGY The project site is located within designated Industrial area and there is no eco-sensitive region within 10 Km of the project site. Solid wastes generated during the operation phase are disposed through authorized disposal cum recycle facilities as per the authorization from PCB and hence no impact is anticipated due to solid waste in and around the site. The scrubbers and stack provided control the release of air pollutants to a greater extent. In addition, thick green belt also attenuates the air pollutants released into the environment. It is expected that the ecology of the region is preserved by these mitigation measures.
8.6.8 OCCUPATIONAL HEALTH AND SAFETY Industrial Hygiene is one of the fast emerging fields and is a critical requirement for the wellbeing of employees, for which IAL has developed a comprehensive Occupational Health Program.
The Occupational Health Management system / the industrial hygiene and medical system protects and enhances health, productivity, and wellness by anticipating, recognizing, evaluating, controlling, and managing workplace health hazards (e.g. chemical, physical, biological, ergonomic, psychological, etc). These systems also mitigate illnesses and injuries by promptly recognizing, treating, investigating, and taking corrective actions.
IAL‟s Occupational Health & Wellness Program covers the policies, work practices and procedures to provide a safe and healthy environment and protect the shop floor employees, laboratory employees and researchers from health hazards associated with the use of hazardous chemicals
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8.6.8.1 INDUSTRIAL/ OCCUPATIONAL HEALTH MONITORING Some of the existing measures in the IAL plant are listed below and the same will be followed as a part of the Industrial/ occupational health program
Regular inspection and maintenance of pollution control systems. The workers exposed to noisy sources are provided with ear muffs/plugs. Adequate facilities for drinking water and toilets are provided to the employees. The health of the workers will be regularly checked by a qualified Doctor and proper records will be kept for each worker. Isolated storage for all hazardous chemicals with adequate safety measures, sign board outside storage etc., Good air circulation will be ensured within the plant area. Showers and hand – wash are provided in vicinity of work area with ample quantity of water available. Medical Surveillance Program: Medical surveillance program is essential to assess and monitor employees' health and fitness both prior to employment and during the course of work; to determine fitness for duty and to provide emergency and other treatment as needed. Effectiveness of a medical program depends on active involvement of employees. IALs medical surveillance program include following major elements: Pre-Employment Examination Periodic Medical Examinations based on occupations Diet and Nutrition programmes Emergency First aid Treatment Moreover, based on past occupational health record of its existing unit, IAL has already put in place adequate measures and does not anticipate any adverse effect on health of workers.
8.6.8.2 PERSONAL PROTECTIVE MEASURES Chemical Handling Area: Non-respiratory protection such as Helmet, Safety goggles, Nitrile /Neoprene/PVC gloves, Safety shoes and respiratory protection such as Full/half face respirator with organic /inorganic cartridge. Material loading/unloading operations, Supplied Air Breathing Apparatus (SABA) are being used.
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Welding operation: Welding face shield, leather apron, leather gloves and safety shoes are being used by welders. Helper use UV resistant goggles, leather apron, leather-gloves and safety shoes.
Gas Cutting operation: IR resistant goggles, leather gloves, safety shoes are being used by both cutter and helper.
Boiler operation: Cotton type retardant suit, IR resistant goggles, helmet, safety shoes and cotton gloves.
Concentrated Acid and Base handling (i.e. Sulphuric acid/HCL/Caustic Lye): Full body PVC suit, Gum boot and PVC gloves.
Electrical Work area (MCC and PCC): 410 V to 22KV electrical resistance gloves, Electrical safety shoes (without metal toe guard) and helmet and electrical gloves
Working at Height: Personal fall protection (i.e. Full body harness), helmet and Safety- shoes.
Other safety features available during emergency situation in the site
Breathing air stations are provided through out the plant area with full face mask and air is supplied from a dedicated compressor and the air is fed to the system after purification.
Emergency shower and eye washers are located in all plant area and water supply is assured from a dedicated sources.
Self contained breathing sets are available and people have been trained of it‟s use.
Proximity suits are available for use in fire emergency.
Chemical protective suits to deal with most offensive chemicals are available.
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8.6.8.3 EMERGENCY MANAGEMENT IAL is committed to constructively report and investigate all EHS incidents (e.g. near misses, illnesses, injuries, process safety, environmental, fire, distribution accidents, etc) to establish the facts and hence take prompt steps to prevent a recurrence.
A detailed Incident Investigation and Reporting (IIR) guideline is in place to assure an effective and efficient incident reporting and investigation process, and implementing appropriate corrective or preventive measures to prevent recurrence of such incidents.
The essential aspects of Emergency Management system is given below:
Identification of potential emergency scenarios and schedule Revision of Emergency response plan based on Consequence Analysis Emergency Response Team Training Periodic evacuation mock drills and observations of gaps - Table top exercises Onsite Emergency Preparedness and Response Plan
a) FIRE (SMOKE) DETECTOR SYSTEM
Smoke detectors are provided in administration and control room buildings. They are installed above and below false ceiling to cover all the areas of the building and are divided into several zones and are numbered.. Detectors will sense the smoke and radiation due to fire and will send impulse to fire alarm indication panels located in Administration and Control Room buildings. Panel on receiving impulse, will sound the hooter and visually indicate the particular zone at which fire has occurred. The fire alarm panel located in Reception Hall of Administration building is linked to fire alarm indication panel at Control Room. This link is to provide parallel indication to Control Room in case of smoke / fire at Administration / Laboratory building.
b) MANUAL FIRE ALARM CALL POINTS
Manual fire alarm call points are provided at various locations of the factory and are numbered.
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If the glass of the fire alarm call point is broken / opened, the push button electrical contact gets closed and signal reaches the fire alarm indication panel at Administration and Control Room. Panel on receiving impulse, will sound the hooter and visually indicate the particular zone at which fire has occurred. All the fire alarm call points are connected with uninterrupted power supply, so that they are available even in case of power failure.
c) EMERGENCY SIREN
Emergency siren is located above main Control room. Operating switch is located inside UPS room at Control room (Near fire alarm panel). Based on the emergency needs, DCS operator in concurrence with Shift Superintendent is authorized to operate the siren. The modalities of operating siren: a) Fire Warning – High pitched continuous wailing siren [Should be given for 30 Seconds] b) Toxic release - Long siren followed by short siren [Should be given for 30 Seconds] c) All clear - Long continuous blow [ Should be given for 30 Seconds]
d) FIRE PROTECTION SYSTEM
i. FIRE HYDRANT SYSTEM
Fire hydrant system comprises of the following:
Fire water reservoir -Fire water is stored in an above ground concrete storage tank having a capacity of 564 M3. In addition, there are two above ground concrete raw water storage tanks each having capacity of 1000 M3from where raw water can be pumped into Fire water compartment in case of additional requirement.
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Figure 8-9 Photograph of fire fighting layout within the plant premises
Fire water pumps-Operation philosophy of the fire hydrant pumps is given in Table 8-11 below
Table 8-11 Capacity of Fire Water pumps
Pump Capacity Mode Pressure setting @Kg/Cm2
Jockey-1 27.3M3/Hr. Run Manually NA Jockey-2 27.3 M3/Hr. Run in Auto Start: 6.0 Kg/Cm2 Stop : 7.0 Kg/Cm2 Electrical 273 M3/Hr. Run Manually Start: 4.5 Kg/Cm2 Stop : Manually Diesel 273 M3/Hr. Run in Auto Start: 4.0 Kg/Cm2 Stop : Manually
Fire water distribution network -The system is a "Ring main system" to supply water to all sections of the factory. The entire fire water header is 8 inches (200 mm) and reduces to 4 inches to feed water to single and double headed hydrants, and water monitors. This network also supplies water for Manual Spray System.
Emergency support team is responsible for isolation of sluice valve.
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Table 8-12 Fire hydrant landing valves, long throw monitors, manual spray system
S.No Description Available Qty 1 Single headed hydrant landing valves 22 Nos 2 Double headed hydrant landing valves 22 Nos 3 Fire water monitors 14 Nos
Fire escape hydrants (Hydrant provided at various floors in Blending, 4 11 Nos Imidation and Phase II ) 5 Sluice valves for isolation of ring main 26Nos
e) MANUAL SPRAY SYSTEM Manual Spray System has been provided to PIBSA and Phenate Schenk Filter Cake outlets. The system can be operated by opening the individual gate valves attached to this system. An automatic water spray system has been provided for Mono Methyl Amine storage tank.
f) CENTRAL FIRE HOSE STATIONS There are 8 fire hose stations at strategic locations which house emergency firefighting equipment. The list of Equipment available in each hose station is displayed in all hose stations.
g) PORTABLE FIRE-EXTINGUISHERS Portable fire extinguishers are provided at various locations of the factory as per Tariff Advisory Committee (TAC) norms.
h) INSPECTION AND MAINTENANCE OF FIRE /SAFETY EQUIPMENT / SYSTEM Scheduled inspection is carried out on Fire Hydrant System, Fire Extinguishers, Fire Hose Stations, SCBA and Safety Showers. The inspection records are available with HSE department.
i) EMERGENCY HELP Formal mutual aid agreement with Tamilnadu Petroproducts Limited [TPL], Manali and Chennai Petroleum Corporation [CPCL], Manali are available. However, emergency help can be obtained from the other nearby industries in case of necessity. The contact telephone numbers of key persons and nearby industries are displayed in the control room and main gate security.
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j) FIRST-AID FACILITIES A well-equipped first-aid centre is functioning in our factory premises. It is managed by a qualified full-time medical practitioner and manned round the clock by qualified staff nurses. First-aid centre is located in non-plant area. The First Aid centre is well equipped.
An ambulance with driver is available round the clock inside the factory premises to mobilize the accident victims, in case of emergency. An emergency vehicle is available during after office hours. First-aid centre has a formal tie-up with an established hospital in the nearby surrounding, for rendering suitable medical care for accident victims.
Figure 8-10 Photograph of First Aid Centre
8.6.8.4 HEALTH AND SAFETY AUDITS & INSPECTIONS PROGRAM IAL has established and implemented a comprehensive audit and inspection program to be carried out and managed by competent resources.
External Safety Audit Internal Safety Audit Special Fire safety audits /Fire Risk Assessments Critical equipment safety inspection
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Emergency and life-saving equipment inspection IMS (Integrated Management System) Internal and External audits Daily Safety Inspection Monthly Environmental inspection Workplace exposure monitoring using VOC meters - PID Vessels and storages are tested for their integrity at regular frequency. Preventive maintenance carried out. Sensors and alarms are provided to alert on fugitive emissions. Work place monitoring by personal sampler is carried out. Measurement of noise level and illumination. 8.7 ENVIRONMENTAL MANAGEMENT CELL In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to for the effective implementation of environmental management plan. Environmental Management Cell increases the strength of the environmental management team to deal with EMP effectively and efficiently. Hence a team has been formed consisting of officers from various departments to co-ordinate the activities concerned with management and implementation of the environmental control measures. This team will undertake the activity of monitoring the stack emissions, ambient air quality, noise level, and water quality etc. either departmentally or by appointing external agencies wherever necessary. Regular monitoring of environmental parameters will be carried out to find out any deterioration in environmental quality and also to take corrective steps, if required, through respective internal departments. The Environmental Management Cell will also collect data about health of workers, green belt development etc. Organogram of the Environmental Management Cell is presented in Figure 8-11
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Figure 8-11 Organogram for Environmental Management 8.7.1 RESPONSIBILITIES OF ENVIRONMENT MANAGEMENT CELL The cell will also be responsible for monitoring of the plant Environment and Occupational Health related systems which include
A regular monitoring of environmental parameters like air, water, industrial effluent, noise and soil as well as performance of pollution control facilities Keeping the management updated on regular basis about the conclusions / results of monitoring activities and proposes measures to improve environment preservation and protection. Submitting environmental monitoring report to TNCPB. Data monitored by the cell will be submitted to the Board regularly. The cell will also take mitigation or corrective measures as required or suggested by the board. Environment Management Cell will handle monitoring of air and water pollutants as well as the solid wastes generation as per the requirements of Tamil Nadu Pollution Control Board and Central Pollution Control Board. Monitoring of various parameters will be carried out regularly to assess the pollution level inside the plant and in nearby area.
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8.7.2 ENVIRONMENT MONITORING FACILITIES Full-fledged laboratory is available at IAL to analyze and monitor the quality of ambient air, water and noise within the plant. IAL analyses the sewage and effluent quality parameters on daily basis and AAQ on fortnightly basis.
H2S sensors are installed in different areas of plant premises to monitor H2S. H2S sensor at the caustic scrubber vents are hooked to TNPCB Care Air Centre. The unit has installed Online Ambient Air Quality (AAQ) monitoring station for the following
parameters - PM10, SOX, NOX, CO, NO, NO2 & O3and it is connected to Care Air Center (CAC), TNPCB. The unit has installed online stack monitoring station (CEMS) for hot oil stack and boiler
stack and connected with CAC (TNPCB). PM, SOX & NOX are being analyzed. The unit has also installed continuous ambient VOC monitors in the plant. Online monitoring of parameters (pH & TDS) for treated effluent from ETP done and it is also connected with CAC, TNPCB
Apart from online monitoring systems, monitoring are done through approved laboratories and monthly reports are submitted to TNPCB
8.8 CORPORATE ENVIRONMENTAL RESPONSIBILITIES Evidence of top management commitment to development and implementation of the Environmental management system is provided through the following manner:
Environmental policy is established The importance of meeting regulatory & legal requirements is communicated to employees of the organisation Environmental objectives are established Management review meetings are regularly conducted Availability of adequate resources is ensured. The Environmental policy of the company is given in Figure 8-12
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Figure 8-12 Quality and Environmental Policy of IAL Environmental objectives are established in consistent with the environmental policy as below.
Minimize waste generation Minimize the significant impacts Optimize plant efficiency and yield Prevent land and air contamination
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Reduce oil spillage and leaks Conserve the resources to the possible extent
The company has well laid down procedures for addressing any non compliance with respect to environmental norms and the same is being brought to the Board of Directors during Board Meetings and also discussed in Management Review meetings.
IAL management has implemented many environmental improvement initiatives as highlighted in Table 8-13.The details of the same is enclosed in Annexure- 17.
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Table 8-13 Environment improvement initiatives
Sl. Present status of project / Action Point Present practice Proposed practice Benefits No Budget provision 1 Implementing dry cleaning Presently IAL is washing Oil is cleaned by Dry cleaning method Reduction of oil and methods in plant area for the floor and transfer the absorbent cloth or introduced in plant area to grease by 65 kg/day. minimizing oil & grease levels effluent to the effluent saw dust minimize oil & grease load in effluent treatment plant in ETP.
2 Installation and running of Steam ejectors were used Ejectors will be Vacuum pump installed in Reduction of COD by vacuum pump instead of to create vacuum in the replaced by place of ejectors for 1300 Kg/day. ejectors for minimizing high process vacuum pump optimizing effluent load. COD effluent generation from process. 3 Installation of additional oil One oil skimmer is used to One more oil One more oil skimmer Reduction of oil and skimmer in effluent treatment skim oil in the input stream skimmer to be installed in ETP to remove grease by 130 Kg/day. plant for minimizing the oil installed to reduce oil & grease in the input content in effluent oil content in the stream to ETP. incoming effluent 4 Installation of additional Presently two aspirators Additional Additional aspirators Reduction of BOD by aspirator in ETP for improving are used in ETP. aspirators to be installed to keep the BOD at 390 Kg/day. outlet water BOD installed in ETP minimum levels.
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Sl. Present status of project / Action Point Present practice Proposed practice Benefits No Budget provision 5 Provide online connectivity of Presently H2S and VOC Online connectivity All stack and ambient To ascertain H2S and H2S sensor and ambient VOC being monitored by IAL of H2S and ambient analyzers connectivity ambient VOC values are analyzer to TNPCB from DCS VOC to TNPCB provided to TNPCB server. well within the stipulated limits 6 Install continuous ambient air Presently IAL is monitoring Installation and Continuous ambient air Effective monitoring and quality monitoring station ambient air quality (AAQ) online connectivity quality monitoring station control of ambient air through external accredited of AAQ to TNPCB installed and hooked up to quality levels as per new laboratory. TNPCB server. standards 7 Provide analyzers for Presently IAL is monitoring Installation and Continuous Stack To ascertain SO2 and
continuous monitoring of SO2 SO2 and NOx in stack online connectivity Monitoring System installed NOx values are well &Nox in thermic fluid heater through external accredited of SO2 and NOx and hooked up to TNPCB within the stipulated and boiler stacks and connect laboratory analyzers in stack server limits it online to TNPCB to TNPCB 8 Installation of ground water Ground water monitoring Installation of 4 Nos of monitoring bore To ascertain the quality monitoring piezometers at system not available. ground water wells installed and of ground water. specified depth within the monitoring monitoring done factory area piezometers at periodically. specified depth within the factory area.
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Sl. Present status of project / Action Point Present practice Proposed practice Benefits No Budget provision 9 Increase covered hazardous Additional storage to be Additional storage Additional storage shed Hazardous waste wastes storage space area constructed to be constructed constructed storage facility area within factory increased. 10 Installation of RO cum IAL is using the treated To install RO cum RO plant with evaporator is Zero discharge plant. evaporation system for water for gardening inside evaporation system being used for recycling 100% reuse of treated treating effluent water and the facility. for treating effluent treated effluent for process water. reusing it for process and reuse it for reuse. process. 11 Additional greenery Presently IAL has Additional saplings 450 saplings planted in the Environmental development in and around developed greenery in and to be planted in the plant. improvement initiative. factory area around factory area. plant.
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8.8.1 BUDGETARY PROVISITON FOR ENVIRONMENTAL MANAGEMENT The details of capital and recurring (per annum) budget earmarked for Environmental Management is given separately for proposed expansion and new component manufacturing (ZDTP) project in Table 8-14
Table 8-14 Budgetary provisions for EMP
Recurring cost (Lakh) per Capital Cost (Lakh) annum Environmental New New S.No protection measures Expansion component Expansion component Project manufacturing Project manufacturing ZDTP Project ZDTP Project 1 Air Pollution Control 15.00 300.00 12.75 3.19 2 Water Pollution Control 15.00 161.02 73.95 18.49 3 Noise Pollution Control 1.00 1.00 0.50 0.13 Occupational Health 4.00 5.00 23.10 5.78 4 and safety
5 Green belt Development 3.00 3.00 2.4 1.0 Storm water 2.00 10.00 1.00 1.00 6 Management 7 Waste Management 3.00 20.00 182.94 331.35 8 Fire Fighting 35.60 100.00 8.62 2.15 Total 78.60 600.02 305.26 363.09
8.9 CORPORATE SOCIAL RESPONSIBILITY The company has initiated CSR activities as highlighted below.
Rs.20 Lakhs to CPCL Educational Trust which runs CPCL Polytechnic College at Manali towards “Promotion of Education”.
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Rs.20 lakhs to the Cancer Institute (W.I.A), situated in Adyar, Chennai ,a public charitable voluntary institution registered under the Societies registration Act 1860, towards „preventive health care‟. Rs.40 Lakhs to Indian Institute of Technology (IIT), Madras to part finance their project activities on “sustainable waste management and resource recovery for clean and healthy villages". Rs. 10 Lakhs to M/s. Bhagavatula Charitable Trust (BCT), Visakhapatnam, to build a "Center for Holistic Interventions and Learning for the Challenged [CHILD] primarily to support and contribute to their special education and employment enhancing vocational skills in the rural areas of its operations. In addition to the above, the company has spent Rs.9 lakhs at its Driver Management Centre established at Manali to ensure road safety policy compliances in terms of vehicle, driver and journey. Recent photos of CSR activities are enclosed in Figure 8-13
Figure 8-13 Photographs of CSR activities
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CHAPTER 9 ENVIRONMENTAL COMPLIANCES
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9 ENVIRONMENTAL COMPLIANCES
9.1 APPLICABILITY OF ENVIRONMENTAL CLEARANCE
Indian Additives Limited has obtained Environmental Clearance from MoEF, vide letter No. J11011/451/2009 –IA II (I) dated December 23, 2009. For the proposed expansion, an application was submitted to the Regional Office of MoEF at Chennai on 8/12/2014. Based on the application, the officials monitored the site on 10.01.2015 and the Post EC compliance Report for the existing facility is enclosed in Annexure- 18. 9.2 CONSENT FOR EXISTING OPERATION
Indian Additives Limited has obtained the consent for the existing operation vide order no. 19300 dated 04.06.2014 for Water Act and Order No. 15352 dated 04.06.2014 for Air Act. The copies are enclosed in Annexure – 3. The company has already filed application for renewal of the consent for the year 2015 -2016. The acknowledgement from TNPCB and fee remittance details is enclosed in Annnexure-19.
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9.2.1 CONSENT COMPLIANCE CONDITIONS Table 9-1 Air Act Compliance Conditions
S. Condition Action taken No Specific Conditions 1 Production qty of Finished Lubricating Oil Additive for Automotive, Marine, Production quantities are maintained within the authorized Industrial, Rail, Road, Natural gas engine within authorized limits. limits.
2 Emission is permitted through the following chimneys/stacks and shall not Emissions are only from permitted Chimneys/Stacks. Online exceed the prescribed standards. emissions monitoring for Boiler & Hot oil unit stacks. Quarterly emissions analysis through third party and yearly emission analysis through TNPCB Lab being done to monitor & ensure compliance of the prescribed standards. Recent Results of analysis(ROA) attached in Annexure-20 3 (a) The emission shall not contain constituents in excess of the tolerance Emissions from stacks are meeting TNPCB norms. limits and The unit shall adhere to the emissions standards prescribed by the Board from time to time
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S. Condition Action taken No 3 (b) The Ambient Air in the industrial plant area shall not contain constituents Ambient air quality (AAQ) parameters are within the limits in excess of the tolerance limits prescribed in AAQ standards prescribed by the TNPCB. Online AAQ monitoring, quarterly analysis through third party and yearly analysis through TNPCB Lab being done to monitor & ensure compliance of the prescribed standards. Results of analysis(ROA) attached in Annexure-21 3 (b) The Ambient Noise Level in the industrial plant area shall not exceed the Noise levels are within the norms prescribed by TNPCB. Noise limits prescribed standards survey report being submitted to TNPCB on monthly basis. Results of analysis(ROA) attached in Annexure-22. 4 Additional Conditions i The unit shall comply with the conditions stipulated in the environmental Environmental Clearance compliance Report from MoEF, clearance accorded by the Ministry of Environment and Forest, Regional Office is enclosed in Annexure-18. Government of India vide F.No.J-11011/451/2009-1 All(l) dt.23.12.2009. ii The unit shall ensure that the expansion activity through process No additional equipment/new constructions installed as part of improvements without any addition of equipment/new construction as expansion activity. Expansion done only through process reported. improvements. iii The unit shall comply with the conditions stipulated in the authorization Compliance report of the conditions stipulated in the Hazardous issued under HW (MHRM) Rules 2008. waste authorization issued under HW(MHRM) Rules 2008 attached in Section 9.3
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S. Condition Action taken No iv The unit shall operate and maintain the air pollution control measures Air pollution control equipments are operated continuously to provided in the phenate reactor, PIBSA reactor and Succinimide reactor ensure emissions meet the standards prescribed by the Board. and ensure that the emission let out shall satisfy the Ambient Air Quality / Online AAQ monitoring, quarterly emissions analysis through emission standards prescribed by the Board. third party and yearly emission analysis through TNPCB Lab being done to ensure compliance of the prescribed standards. v The unit shall ensure that emission let out from the stacks attached to Online emissions monitoring for Boiler & Hot oil unit stacks, boilers, HOUs and D G sets satisfy the emission standards prescribed by quarterly emissions analysis through third party and yearly the Board. emission analysis through TNPCB Lab being done to ensure compliance of the prescribed standards. vi The unit shall maintain the online stack monitors provided to monitor SPM, Online stack monitors provided to monitor SPM, SOx and NOx
SOx and NOx to monitor the emission from boiler and HOU and ensure in the emissions from boiler and HOU and hooked to Care Air that data is continuously transferred to CAC of Tamil Nadu Pollution Centre (CAC), TNPCB. Control Board vii The unit shall main the online VOC sensors -2 nos installed at tank farm VOC online analyzers (2 Nos) at tank farm area and phenate area and phenate and ensure that data is continuously transferred to CAC plant installed and data continuously transferred to CAC, of Tamil Nadu Pollution Control Board. TNPCB. viii The unit shall monitor the levels of H2S through H2S gas sensors installed H2S online analyzer data transferred to CAC, TNPCB and also at strategic locations as reported continuously monitored.
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S. Condition Action taken No ix The unit shall maintain the continuous AAQM station to monitor PM10, AAQ online monitoring station provided to monitor PM10, SOx, SOx, NOx, CO, NO, NO2, H2S and 03 and ensure that data is NOx, CO, NO, NO2, H2S and 03 and the data is continuously continuously transferred to CAC of TNPCB. transferred to CAC, TNPCB. x The unit shall maintain the MSDS in prescribed format as per Schedule 9 MSDS are maintained in GHS formats, but incorporating all of MSIHC rules 1989 for handling the chemicals data as per Schedule 9Letter submitted to TNPCB seeking clarifications regarding maintaining MSDS in global format. xi The unit shall carry out safety audit through competent agency and the Safety audit has been done and report has been submitted as follow the recommendations and submit report on the same within three specified by the Board. months. xii The unit shall dispose the byproduct -mix of sodium, sodium hydrogen Spent caustic disposed only to authorized vendors and all sulphide and caustic to the recycling units having valid consent of the disposals are maintained in centralized log for reference. The Board and maintain the log book for the same invoice copy is enclosed in Annexure-23 xiii All the analog flow meters shall be made digital and hooked to DCS Analog flow meters are installed and hooked up to DCS
5 All units of the air pollution control equipment required to achieve the No new installation of air pollution control equipment. All quality of the emissions to the tolerance limits prescribed above shall be existing air pollution control instruments are being operated completed along with the commissioning of production continuously to ensure that the quality of emissions is within the prescribed tolerance limits.
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S. Condition Action taken No 6 The applicant shall provide port holes for sampling the emission and Sampling port holes for sampling the emissions are available. access -platform for carrying out stack sampling and provide electrical Permanent access platforms are provided for sampling. outlet points and other arrangements for Chimneys/stacks and other sources of emissions so as to collect samples of emission by the Board or the applicant at any time in accordance with the provisions of the Act or Rules made therein. 7 The applicant shall at his own cost get the samples of emission collected Samples are tested through TNPCB Lab once in a year and and analyzed by the TNPC Board Laboratory every month for the once in a month through third party. parameters indicated in condition No.3(a) and shall furnish in triplicate the report thereof to the Board by the 10th of succeeding month 8 This Consent is given by the Board in consideration of the particulars For Information given in the application. Any change or alteration or deviation made in actual practice from the particulars furnished, in the application will also be ground for review/variation/revocation of the Consent Order under Section 21 of the Act to make such deviation as deemed fit for the purpose of the Act.
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S. Condition Action taken No 9 The applicant shall not change or alter either the quality or quantity or rate Letter submitted with TNPCB requesting amendment of of emission or install, replace or alter the air pollution control equipment or consent order for replacement of old boiler and chimney. change the raw material or manufacturing process resulting in any change in quality and/or quantity of emissions, without the previous written permission of the Board. 10 The applicant shall provide and maintain at his own cost one ambient air Monthly extract of the data is furnished to TNPCB quality monitoring stations for monitoring Suspended Particulate Matter, Sulphur Dioxide, Oxides of Nitrogen, Hydro -Carbon, Carbon -monoxide and monitor the same all in a day, once in a month. The data collected shall be maintained in a register and a monthly extract furnished to the Board 11 The applicant shall provide and maintain at his own cost a meteorological Meteorological station installed and monthly extract of the data station to collect the data on wind velocity, direction, temperature, being submitted to TNPCB. humidity, rainfall, etc.,. and the daily readings shall be recorded and the extract sent to the Board once in a month
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S. Condition Action taken No 12 The applicant shall forward the following information to the Member Details being furnished to TNPCB every month. Secretary/DEE/AEE, Tamil Nadu Pollution Control Board, Chennai/Concerned District Office regularly before 10th of every month. a. Progress on the installation of Air Pollution Control equipments. b. Progress on the procurement and installation of equipments for monitoring ambient air quality, stacks, chimneys and meteorological data c. Monthly extract of daily discharge of emission through each chimney/stack. d. Report of Analysis of stack monitoring, ambient air quality monitoring, meteorological data as required under conditions. e. Progress on planting of trees and plants as referred to under General Conditions No.8. 13 Any upset conditions if any of the plant/plants of the factory which is likely For Information to result in increased emissions and/or result in violation of the standards mentioned above shall be reported to the Head Quarters and District Environmental Engineer's Office/Regional Joint Chief Environmental Engineer's Office of the Board telegraphically
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S. Condition Action taken No 14 The applicant shall furnish to the Visiting Officer of the Board any For Information information regarding the stack monitoring system/or operation of the plant or any other particulars as may be pertinent in preventing and controlling of pollution of Air 15 The applicant shall submit process flow sheet and particulars of proposed No new installation of air pollution control equipment. control equipment, monitoring equipment and time schedule for completing the installation of the same so as to reach the Board within 30 days from the date of receipt of this Order.
16 The conditions imposed as above shall continue in force until revoked For Information under Section 21 of the Act.
17 The unit shall install display board for stack emissions parameters at the Digital display board for display of stack emission parameters & entrance of the unit AAQ parameters available at the entrance of the unit.
18 The unit shall develop green belt considering 33% of its total area as Green belt development covering 33% of total plot area has green belt area with 2m tall trees in and around the premises been completed
19 The unit shall provide online SPM monitor to the stack with computer Online stack monitors provided to monitor SPM in the recording facility and shall connect it to the Care Air Centre for monitoring emissions from boiler and HOU and hooked upto Care Air as committed. Centre (CAC), TNPCB.
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S. Condition Action taken No 20 The unit shall operate and maintain Air Pollution control measures All existing air pollution control instruments are being operated attached to the Boiler and the DG sets and ensure that the emission shall continuously to ensure that the quality of emissions satisfy the Ambient Air Quality / emission standards prescribed by the Board 21 The unit shall continue to develop adequate width of green belt inside the Green belt development covering 33% of total plot area has premises been completed
22 The unit shall adhere to the Ambient noise level standards prescribed by Ambient noise levels are within the limits prescribed by the the Board Board. Noise survey report being submitted to TNPCB on monthly basis.
Table 9-2 Water Act compliance conditions
S. No Condition Action taken Specific conditions
1 Production qty of Finished Lubricating Oil Additive for Automotive, Marine, Production quantities are maintained within the authorized Industrial, Rail, Road, Natural gas engine within authorized limits. limits.
2 Discharge of effluent is permitted from the prescribed outlets. The quantity Total effluent discharge per day is within the prescribed of effluent discharged shall not exceed the prescribed standard limits. Effluent generation report attached in Annexure-24
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S. No Condition Action taken 3 The effluent discharge shall not contain constituents in excess of the Treated effluent is meeting the TNPCB norms. Online tolerance Limits as laid down by TNPCB monitoring of treated effluent parameters (pH & TDS only), monthly analysis of treated effluent constituents by TNPCB lab & third party lab are being done to monitor and ensure compliance of the prescribed standards. The report copy is enclosed in Annexure-25. 4 All units of the sewage / trade effluent treatment plant to achieve the quality The treated effluent quality is meeting the specifications of the effluent according to the tolerance limits prescribed by Board. prescribed by the Board. Online monitoring of treated effluent parameters (pH & TDS only), monthly analysis of treated effluent constituents by TNPCB lab & third party lab are being done to monitor and ensure compliance of the prescribed standards. 5 Meters must be affixed at the entrance of the water supply connection so Water meter available at the entrance of the raw water that such meters are easily accessible for inspection and maintenance and supply. for other purposes of the Act, provided that the place where it is affixed shall in no case be at a point before which water has been tapped by the consumer for utilization for any purposes whatsoever.
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S. No Condition Action taken 6 Separate Meters with necessary pipe -line for assessing the quantity of Separate water meters available for assessing the quantity water used for each of the purposes mentioned below: of water used for different purposes. a. Industrial Cooling, Spraying in mine pits or boiler feed. b. Domestic purpose. c. Process 7 The applicant shall take immediate action to install mechanical composting Mechanical composting sampling equipment is installed for sampling equipment and continuous flow measuring/recording devices on ETP sampling. the effluent drains of trade as well as sewage effluent within three months from the date of this Consent Order. A record of daily effluent discharge shall be maintained. 8 This Consent is given by the Board in consideration of the particulars given For information in the application. Any change or alteration or deviation made in actual practice from the particulars furnished in the application will also be ground for review/variation/revocation of the Consent Order under Section 27 of the Act and to make such variation as deemed fit for the purpose of the Act 9 The Applicant shall not change or alter either the quality or quantity the rate For information of the discharge or temperature or the route of discharge without the previous written permission of the Board
10 The applicant shall comply with the carryout directions/orders issued by the For information Board in this Consent Order and at all subsequent times without any negligence on his/her/their part. The applicant shall be liable for such legal
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S. No Condition Action taken action as per provisions of the Law/Act in case of non/compliance of any order/directions issued at any time and or violation of the terms and conditions of this Consent Order 11 The following information shall be forwarded to the Member Details being furnished to TNPCB every month. Secretary/DEE/AEE regularly on or before 10th of every month: a. Progress on the installation of effluent treatment plant. b. Progress on the installation of Mechanical Compost sampling equipment and continuous flow recording/measuring devices. c. Monthly statement of daily discharge of sewage as well as trade effluent. 12 Any upset condition in any of the plant/plants of the factory which is, likely to For information result in increased effluent discharge and or result in violation of the standards mentioned above shall be reported to the Head Quarters and District Environmental Engineer's Office/Regional Joint Chief Environmental Engineer's Office of the Board telegraphically. 13 The applicant shall furnish to the visiting officer of the Board any information For information regarding the construction installation or operation of the plant or effluent treatment plant and any other particulars as may be pertinent to preventing and controlling pollution of Water.
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S. No Condition Action taken 14 Not withstanding anything contained in this conditional letter of Consent. the For information Board hereby reserves to it the right and power under Section 27(2) of the Water (Prevention and Control of Pollution) Act, 1974 (as amended) to review any and/or all the conditions imposed herein above and to make such variation as deemed fit for the purpose of the Act by the Board. 15 The conditions imposed as above shall continue in force until revoked under For information Section 27(2) of the Act 16 The industry has to ensure that minimum three varieties of trees Tree plantation done as per the guidelines. (Eucalyptus, Subabul and any other suitable variety) are planted at the density of not less than 1,000 trees per acre of land. The trees may be planted along the boundaries of the industry or industrial premises. This plantation is stipulated over and above the bulk plantation of trees in that area and maintains them. 17 Additional Conditions i The unit shall comply with the conditions stipulated in the environmental The Compliance report of the conditions stipulated in the clearance accorded by the MoEF, GOI vide F.No.J-11011/451/2009-1 IA ll environmental clearance accorded by MoEF attached in (l) dt.23.12.2009. Annexure-19 ii The unit shall ensure that the expansion activity through process No additional equipment/new constructions installed as part improvements without any addition of equipments/new construction as of expansion activity. Expansion done only through process reported. improvements.
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S. No Condition Action taken iii The unit shall operate and maintain the ETP efficiently and continuously to ETP operated efficiently and the treated effluent achieve the standards prescribed by the Board. parameters are meeting the specifications prescribed by the Board. iv iv. The unit shall utilise part of treated trade effluent for green belt/gardening The treated effluent parameters are meeting the within the premises after satisfying the standards prescribed by the Board. specifications prescribed by the Board. Part of the treated effluent is being used for green belt/gardening. v The unit shall utilise part of the treated effluent for cooling water make up Part of the treated effluent after processing through the RO and DM plant after treatment through R.O. system provided by the unit. system in the unit is being used for Cooling tower make up and DM plant. vi The unit shall evaporate the RO rejects through multiple effect evaporators MEE concentrates are centrifuged and disposed into SEP. and MEE concentrate shall be centrifuged and disposed into SEP of adequate area. vii The unit shall ensure that there shall not be discharge of treated/untreated No discharge of treated/untreated trade effluent outside the trade effluent outside the premises under any circumstances and remove premises done. the pump if any provided. viii The unit shall provide Sewage Treatment Plant for the treatment of sewage Sewage treatment plant has been installed and made within a period of 4 months, thus ensuring sewage and trade effluent are operational. treated separately. ix The unit shall comply with the conditions stipulated in the authorization Compliance report of the conditions stipulated in the issued under HW (MHRM) Rules 2008. Hazardous waste authorization issued under HW(MHRM) Rules 2008 attached in Section 9.3
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S. No Condition Action taken x The unit shall maintain the MSDS in prescribed format as per Schedule 9 of MSDS are maintained in GHS formats, but incorporating all MSIHC rules 1989 for handling the chemicals. data as per Schedule 9. xi The unit shall carry out safety audit through competent agency and the Safety audit has been done and report has been submitted follow the recommendations and submit report on the same within three as specified by the Board. months. xii The unit shall dispose the by product -mix of sodium, sodium hydrogen Spent caustic disposed only to authorized vendors and all sulphide and caustic to the recycling units having valid consent of the Board disposals are maintained in centralized log for reference. and maintain the log book for the same. xiii All the analog flow meters shall be made digital and hooked to DCS Analog flow meters are installed and hooked up to DCS
9.3 HAZARDOUS WASTE AUTHORIZATION FOR EXISTING FACILTIY
Indian Additives Limited has valid authorization for storage and disposal of Hazardous waste vide Autorizationno.1089 dated 19/08/2011. The same is enclosed in Annexure- 13. The Agreement with Tamil Nadu Waste Management Limited is enclosed in Annexure-27 and the agreement with Gujarat Enviro Protection and Infrastructure Limited, Ranipet is enclosed in Annexure-28.
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Table 9-3 Hazardous Waste Authorization compliance conditions
Schedule -A [See rule 5(4).] S.NO Conditions Status
1 The industry shall comply with the provisions of the Environment (Protection) Act, All the provisions of the Environment (Protection) 1986, and the Rules hereunder Act,1986 complied with. 2 The Authorization or its renewal shall be produced for inspection at the request of any Consent renewal authorization has been officer authorized by the State Pollution Control Board provided during inspection by TNPCB official.
3 Any authorization change in personnel, equipment and working conditions as There is no change of conditions against mentioned in the application by the person authorized shall constitute a breach of this authorization. authorization. 4 An application for the renewal for the authorization shall be made in Form I, as per Authorization.No.1089 dated 19.08.2011(Valid Rule 5 (7) before the date of expiry of authorization for 5 years). Application renewal will be done as per Rule 5(7) before the date of expiry. 5 Tamil Nadu Pollution Control Board shall renew the authorization after examining the For informatin each case on merit, subject to the following: (i) On submission of annual return by the occupier or operator of a facility in Form-4. Form 4 has been submitted for the year 2014-15 on April 2015. (ii) On evidence of reduction in the waste generation or recycled or reused and
(iii) On fulfillment of conditions prescribed in the authorization regarding management of waste in an environmentally sound manner
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
6 All the hazardous wastes should be stored in a secured way so that they do not All hazardous wastes are stored under cause leachate problem or are carried away with runoff water during rains. appropriate weather shelter without any leachate issue. 7 The occupier shall demarcate the secured storage area with a sign board including All hazardous wastes are stored in demarcated the name of hazardous waste area with appropriate signages.
8 First aid box, Masks, Fire control equipment and other safety devices shall be All relevant safety devices are provided to meet provided to meet emergency situations. emergency situations 9 The occupier shall educate the workers and nearby public of possible accidents and All people handling hazardous wastes are remedial measures. provided necessary training. 10 For any accident or spillage of hazardous wastes causing damage to the Appropriate systems put in place to avoid Environment, The occupier or the transporter as the case shall be held responsible. spillage/accident during hazardous wastes handling.
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
11 In case of closure of industry, the un-used not consumed raw materials falling under For information the category of Hazardous Chemicals under Manufacture, Storage and Import Hazardous Chemicals Rules,1989 and Amendment Rules,2000 shall be removed and sold to other units within 90days from the date of closure to prevent any possibility of occurrence of an accident, In case the above hazardous chemicals have lost their properties originally required, then they shall be treated as Hazardous Waste and they should be disposed off only to the authorized agencies of Tamil Nadu Pollution Control Board as in a safe manner. 12 The occupier shall prepare/update an emergency preparedness plan for safe Detailed onsite emergency plan including safe handling or hazardous waste from time to time and submit the same to Tamil Nadu handling of hazardous wastes is available and Pollution Control Board. Emergency preparedness plan must be implemented same has been submitted to TNPCB. immediately whenever there is fire, explosion or release of hazardous waste or hazardous waste constituents, which could endanger to human health or environment. 13 The occupier shall maintain inventory of hazardous wastes, in Form-3 of the Inventory of hazardous being maintained in Hazardous Waste Management Rules, 1989 & amendments thereof. Form -3. 14 The occupier shall submit annual return to Tamil Nadu Pollution Control Board in Form 4 has been submitted for the year 2014-15 Form-4 of the Hazardous Waste Management Rules, 1989 & Amendments thereof on April 2015.
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
15 The occupier shall submit information on any accidents that have occurred in handling For information of hazardous waste to Tamil Nadu Pollution Control Board in Form-14 of the Hazardous Waste management Rules, 1989 & amendments thereof. 16 The occupier or operator of facility shall ensure that the Hazardous Wastes are Hazardous wastes are packed based on the packed based on the composition in a manner suitable for handling, storage and composition and labeled accordingly. transport and labeled accordingly. The labeling and packing shall be clearly visible and be able to with stand physical conditions and climatic factors 17 Packaging, labeling and transport of Hazardous Wastes shall be in accordance with All the regulations related to packaging, labeling the provisions of the rules issued by the Central Govt., under the Motor Vehicles Act, and transport of hazardous wastes are followed 1988 and other guidelines issued from time to time. The packaging and labeling shall with. be based on the composition and hazardous constituent of the waste, however all Hazardous Waste containers should be provided with a general label. 18 A driver who transports Hazardous Waste should be well acquainted about the Training given to drivers on Do's &Don‟t's and to procedure to be followed in case of emergency during transit. The transporter shall follow TREM card during any accidental spillage. carry a Transport Emergency (TREM) card (as given in the guidelines for management and handling of hazardous wastes) duly filled by the Hazardous Waste generator.
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
19 Any environment damage due to indiscriminate disposal of Hazardous Waste shall be For information assessed by the appropriate authority. The cleanup costs shall be recovered from the generator/Operator/Occupier/Transporter of the said Hazardous Wastes 20 The industry shall maintain the 'Six Copy Manifest System' for the movement of Six copy manifest system is being followed and wastes. 'The manifest copies should be furnished to the Tamil Nadu Pollution Control manifest copies are furnished to TNPCB office. Board, Guindy, Chennai - 32 under intimation to the concerned District Office. 21 Safe/Secure storage facility should be provided to all recyclable soilds /liquids till they Closed storage shed provided for storing are processed recyclable solids & liquids 22 Industry should maintain good housekeeping with respect to all solid wastes, liquid Good housekeeping ensured in hazardous wastes and effluents wastes storage area. 23 No Hazardous waste shall be mixed with any other waste or shall be discharged to a Each category of wastes are stored separately common, other internal, external sewerage or other drainage system without prior so that there are no commingling. approval of Tamil Nadu Pollution Control Board 24 If HDPE bags are used for storing Hazardous Wastes, it should be ensured that they All hazardous wastes are stored in sealed are perfectly sealed mechanically or double hot sealed containers and not in HDPE bags 25 If MS/HDPE bags are used for storing Hazardous Wastes, it should be ensured that All hazardous wastes are stored in sealed they are perfectly sealed mechanically or double hot sealed. containers and not in HDPE bags
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
26 The Hazardous Wastes packed in HDPE bags or MS/Plastic drums should be stored All hazardous wastes containers are stored in in a covered shed on a raised platform with leachate management system covered shed with raised platform & leachate management system 27 The industry shall follow the Guidelines for setting up of operating facility for Not applicable Hazardous Waste Management published by Central Pollution Control Board (Documents series Hazwams /II/98-99). 28 Tamil Nadu Pollution Control Board reserves the right to review, impose additional For information condition or conditions, revoke, change or alter the terms and conditions of this authorization. Also the Board reserves the right to withdraw the authorization without any prejudice/Notice on receiving any complaints by the Board regarding Environmental Pollution problems caused by the industry. 29 The person authorized shall not rent, lead, sell transfer their industrial premises For information without obtaining prior permission of State Pollution Control Board. 30 The authorized person shall take prior permission of the state Pollution Control Board For information to close down their Hazardous Waste facility 31 The industry shall dispose/sell recyclable wastes such as waste/used oil, used lead All the hazardous wastes are disposed or sold to acid batteries and non ferrous metal scrap to only agencies/industries which are recylable waste agencies having valid having valid Authorization of Tamil Nadu Pollution Control Board and valid registration authorisation from TNPCB and valid registration of Central Pollution Control Board, Government of India. of CPCB.
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Schedule -A [See rule 5(4).]
S.NO Conditions Status
32 The industry shall comply with the provisions of Batteries (Management and Complied with. Handling) Rules, 2001. SCHEDULE - B [ see rule 5(4)] S.NO Form for grant of authorization for occupier or operator handling hazardous Status wastes 1 Industry shall give top priority to waste minimization and cleaner production practices. All measures towards waste minimization Industry shall submit action plan for minimization of hazardous wastes within three implemented and details submitted to TNPCB months from the date of issue of the authorization 2 Industry shall dispose the hazardous waste (mentioned in Form-2) to only the Hazardous wastes are disposed only to TNPCB recycling industries, which have registered with Ministry of Environment and Forests, authorized agencies. Government of India as "Actual user with ESM". If the waste is disposed to industries which are not having valid authorization of Tamil Nadu Pollution Control Board and not registered with Central Pollution Control Board, Government of India then, industry is liable for legal action under Environmental (Protection) Act 3 Industry shall maintain good housekeeping & maintain proper records for Hazardous Good housekeeping and documentation related Wastes stated in Authorization (Form-2). to hazardous wastes management is being done.
4 The industry shall submit the condition wise compliance report of the conditions Complied with stipulated in Schedule A and Schedule B of this Authorization Half-yearly basis to Board Office, Chennai and concerned District Office.
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CHAPTER 10 PROJECT BENEFITS
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10 PROJECT BENEFITS
IAL proposes to expand the capacity of its existing manufacturing facility to meet the growing market demand in lubricating oil additives. The proposed project which is of de-bottlenecking model will help in improving company‟s revenue. This project also provides opportunity to export lubricating oil additives across the world.
IAL also proposes to set up new component manufacturing unit in the existing facility to manufacture Zinc Di-Thio Phosphate (ZDTP), one of the intermediate for lubricating oil additive manufacturing. This is a backward integration project and the production from this facility will be consumed in-house as intermediate for manufacturing lubricating oil additives and also for exports. Hence this will help to boost the economy of the country through additional revenues from exports.
The existing Plant has around 120 employees and 200 contract workmen supporting all operational activities and there will be an increase in manpower after these proposed projects to a total of 156 employees and 300 contract workmen. Apart from this, there will also be a considerable increase in indirect employment on account of increased material movements.
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EIA for proposed expansion including new component (ZDTP) manufacturing Summary and Conclusion
CHAPTER 11 SUMMARY AND CONCLUSION
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11 SUMMARY AND CONCLUSION
After studying the impacts and effects of the proposed project, some of the salient features and observations with respect to the proposed project are as follows:
Since the proposed project is coming up in the existing plant within the Industrial area, there will not be any change in total land use.
There is no forest land involved for the proposed expansion and new component manufacturing (ZDTP) and hence forest clearance is not applicable for the project.
There are no ecologically sensitive locations within 10 Km radius of the project site.
The proposed expansion and new component manufacturing (ZDTP) is within the existing facility, hence most of the supporting facilities like utilities, effluent and sewage treatment systems will be shared with the existing set up.
The increase in pollutant loads due to the proposed project is appropriately handled through pollution control measures.
The treated waste water will be partly reused for gardening within the facility and rest will be recycled for process reuse like Cooling Towers and boiler feed water make-up after treatment through RO system. Zero liquid discharge system is proposed.
The facility has a well developed green belt covering more than 33% of the total plot area. There are no changes to the green belt area on account of proposed expansion and new component manufacturing (ZDTP) proposed project.
The impact of proposed project within the existing facility will be fully mitigated by the Environment Management Plans (EMP).
There will be positive impact on Socio economic conditions in and around the site due to the proposed project
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EIA for proposed expansion including new component (ZDTP) manufacturing Disclosure of Consultant
CHAPTER 12 DISCLOSURE OF CONSULTANT
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EIA for proposed expansion including new component (ZDTP) manufacturing Disclosure of Consultant
12 DISCLOSURE OF CONSULTANT ENGAGED
Details of the consultant engaged are as follows:
Table 12-1Details of the Consultant
Consultant Hubert Enviro Care Systems Pvt. Ltd., Chennai NABET Sr.No 77 EIA Coordinator Dr.J.R. Moses
Following are the Accreditations of the consultant
National Accreditation Board for Testing and Calibration Laboratories (NABL) accreditation for Laboratory services for ISO17025 MoEF Recognized Laboratory ISO 9001:2008 qualified and certification by URS Environmental Management System complying AS/NZS ISO 14001:2004 Occupational Health & Safety Management System OHSAS 18001:2007 Approved by Karnataka PCB and Kerala PCB. Achilles joint qualification system. Achilles Id.15148 Kiwa Quality Management System
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Mass Flow Meter COMPLIANCE TO TOR POINTS
Solid Handling System Closed Piping system
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COMPLIANCE TO TOR POINTS
S.NO TOR Points Page no. 1 Executive Summary i to xvi 2 Justification of project 16 3 Promoters and their background 4 4 Regulatory Framework 6 5 Environmental clearance for the existing unit issued by the ministry (reasons, if not Environmental Clearance for existing obtained),consent to operate and authorization accorded by the SPCB facility – Annexure-1, Existing Consent copy – Annexure-2, Hazardous Waste Authorization copy – Annexure-15 6 Copy of NOC/ consent to establish for the existing unit. Annexure-2 7 Compliance to the conditions stipulated in the NOC granted by the SPCB. 184 8 Has the unit received any notice under the section 5 of environment (protection) act, 1986 or Not received given in Page xiv of relevant sections of air and water acts. If so, compliance to the notice executive summary
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S.NO TOR Points Page no. 9 Data for the stack emissions, fugitive emissions, water requirement and water balance chart, Stack emission data – 99 waste water generation, treated effluent quality, re-utilization and disposal of solid/hazardous Fugitive emission control – 145, waste for the existing unit Water requirement and waste water generation data – 29, effluent quality – 147, disposal of solid and hazardous waste- 160, 162 10 A map indicating Location of the project and distance from severely polluted area. 22 11 Project Location and plant layout Project location – 17, Plant layout - 24 12 Infrastructure facilities including power sources 25 to 30 13 Total cost of the project along with total capital cost and recurring cost/annum for 30 environmental pollution control measures 14 Project site location along with site map of 10km area and site details providing various Project site map showing 10 Km – industries, surface water bodies, forest etc., Annexure-3, Project site details showing industries – 5, other sensitive areas -18
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S.NO TOR Points Page no. 15 Present land use based on satellite imagery for the study area of 10km radius. Details of land Land of site based on satellite image – availability for the project along with supporting document 73, Land availability for project -22, Land deed – Annexure- 6 16 Location of national park/wild life sanctuary/reserve forest within 10km radius of the project Not available given in page 76 17 Permission from the state forest department regarding the impact of the proposed plant on the Not required mentioned in page -22 surrounding reserve forests. 18 Details of the total land and break-up of the land use for green belt and other uses. 23 19 Detailed list of the raw materials required and source, mode of storage. 40 20 Manufacturing process details along with the chemical reactions and process flow chart 32-39 21 Action plan for the transportation of raw material and products. 40 22 Site-specific micro-meteorological data using temp, relative humidity, hourly wind speed and 50, direction, and rainfall is necessary. 23 Ambient air quality monitoring at 6 locations within the study are of 5 km aerial coverage from Locations of monitoring – 48 project site as per NAAQS notified on 16th September 2009. location of one AAQMS in Results- 54 downwind direction 24 One season site-specific micro-meteorological data using temperature, relative humidity, Micro – Meteorology data -50, hourly wind speed and direction and rainfall and AAQ data (except monsoon)for PM2.5, Ambient Air Quality data – 54, PM10,SO2,NOX, CO,NH3 including VOC's shall be collected. The monitoring stations shall Water Quality results – 64, take into account the pre-dominant wind direction, population zone and sensitive receptors Noise Monitoring results- 58 including reserved forests. Data for water and noise monitoring shall also be included.
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S.NO TOR Points Page no. 25 Details of water and air pollution and its mitigation plan Water Pollution and mitigation – 147, Air pollution and mitigation - 137 26 Air pollution control measures proposed for the effective control of gaseous/process 137 emissions within permissible limits. 27 An action plan prepared by SPCB to control and monitor secondary fugitive emissions within 145 permissible limits. 28 Determination of atmospheric inversion level at the project site and assessment of GLC of 96 pollutants from the stack emission based on-site specific meteorological features. Air quality modeling for proposed plant. 29 Name of all the solvents to be used in the process and details of solvent recovery system. 144 30 List of products along with the production capacities 16 31 Design details of ETP, Incinerator, if any along with boiler, scrubber/bag filters etc., Design details of ETP – 147, Scrubber- 139 32 Action plan to control ambient air quality as per NAAQs Standards notified by the ministry on 137 16th September 2009. 33 Source and permission from competent authority for the drawl of water. Water balance chart Water Source – 29 including quantity of effluent generated recycled and reused and effluent discharge Agreement with CMWSSB for water supply – Annexure-7 34 Complete scheme of ETP. characteristics of untreated and treated effluent to meet the ETP scheme - 147 standard 35 Zero discharge effluent concepts to be adopted 147
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S.NO TOR Points Page no. 36 Ground water quality monitoring minimum at 6 locations shall be carried out. Geological; Ground water results -64 features and geo-hydrological status of the study area and ecological status (terrestrial and Geomorphology- 75, aquatic) Terrestrial Ecology – 76, Aquatic Ecology - 80 37 The details of solid and Hazardous waste generation, storage, utilization and disposal Hazardous waste management- 160, particularly related to the hazardous waste calorific value of hazardous waste and detailed Characteristics - 161 characteristics of the hazardous waste. Action plan for the disposal of flyash generated from boiler shall be included 38 Material safety data sheet for all the chemicals are being used/will be used. Annexure-15 39 Authorization/ membership for the disposal of solid/ hazardous waste in TSDF. Annexure-15, Agreement with TNWML Annexure- 26, 40 Risk assessment for storage of chemicals/solvents. Action plan for handling & safety system. Risk Assessment Annexure-9, Disaster Management Plan – Annexure - 11 41 An action plan to develop greenbelt in 33% area. Layout plan for green belt shall be provided. Annexure-16 42 Action plan for rain water harvesting measures at plant site shall be included to harvest Rainwater Harvesting details- 159, rainwater from the roof tops and storm water drains to recharge the ground water Plan showing the Pits - Annexure-14 43 Details of occupational health programme 164 44 Socio-economic development 81
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S.NO TOR Points Page no. 45 At least 5% of the total cost of the project should be earmarked towards the enterprise social 180 commitment based on public hearing issues and item-wise details along with time bound action plan should be prepared and incorporated 46 Note on compliance to the recommendations mentioned in the CREP guidelines. Environmental Improvement initiatives- 177, Annexure-17 47 Detailed EMP with specific reference to details of air pollution control system, water & waste Air Pollution and control – 137, water management, monitoring frequency, responsibility and time bound implementation plan Water and waste water management- for mitigation measure shall be provided. 147, Monitoring – 124, 48 EMP shall include the concept of waste-minimization, recycle/ reuse/ recover techniques, Waste minimization – 137, energy conservation and natural resource conversation Recycle/ reuse/ recover- 147, 49 Total capital cost and recurring cost/annum for Environmental pollution control measures. 180 50 Corporate Environmental Responsibilities a Does the company have a well laid down Environment Policy approved by its Board of 174 Directors? lf so, it may be detailed in the EIA report b Does the Environmental Policy prescribe for standard operating process/procedures to bring 174 into focus any infringement / deviation / violation of the environmental or forest norms / conditions? lf so it may be detailed in the EIA Report c What is the hierarchical system or Administrative Order of the Company to deal with the 173 environmental issues and for ensuring compliance with the EC Conditions. Details of this system may be given.
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S.NO TOR Points Page no. d Does the company have a system of reporting of non-compliance/ violations of environmental 174 norms to the Board of Directors of the company and / or shareholders or stakeholders at large? The reporting mechanism should be detailed in the EIA report 51 Any litigation pending against the project and/or any direction/order passed by any Court of xiv Law against the project, if so details thereof. Additional TOR 1 Separated chapter on status of Compliance of environmental conditions granted by 183 , state/centre to be provided. As per circular dated 30th may 2012 issued by MoEF, a certified EC compliance certificate from MoEF report by RO, MoEF on status of compliance of conditions on existing unit to be provided in Annexure-18 EIA-EMP Report. 2 Public hearing is exempted for preparation of EIA/EMP Report as unit is located in notified 122 industrial area established prior to 2006. 3 Recommendation of TNPCB for proposed expansion -
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