Tamil Nadu Petroproducts Ltd (Epichlorohydrin [Ech] Plant) “Proposed Change in Product Mix from Ech to Propylene Oxide (Po)”

ENVIRONMENTAL IMPACT ASSESSMENT REPORT

FOR

TAMIL NADU PETROPRODUCTS LTD (EPICHLOROHYDRIN [ECH] PLANT) “PROPOSED CHANGE IN PRODUCT MIX FROM ECH TO PROPYLENE OXIDE (PO)”

VILLAGE: MANALI

DIST: THIRUVALLUR

STATE: TAMIL NADU [PROJECT TERMED UNDER CATEGORY 5 (E) PETROCHEMICAL BASED PROCESSING]

REPORT PREPARED BY

HUBERT ENVIRO CARE SYSTEMS PVT LTD.,

CHENNAI

AUGUST 2014

TPL- EIA for Change of Product Mix

ACKNOWLEDGEMENT The following people are gracefully acknowledged for their fullest support in rendering needful information regarding the project and kind cooperation in fulfilling the report Tamilnadu Petroproducts Limited Mr.M.PazhaniandyPillai - Whole Time Director (Operations) Mr.B.PramodPillai- General Manager (Operations) Mr.K.Pattabi- General Manager (Site) Mr.A.Rajakumar – Deputy Manager (Safety) Mr.N.SuriyaKumar – Sr. Engineer (Technical Services)

Hubert Enviro Care Systems Pvt. Ltd.

Dr.J.R.Moses Dr.Rajkumar Samuel Dr.V.Sundararaj Mr.A.Manoharan Dr.T.P.Natesan Mr.V.Dhivakar Ms.RamaaPrakash Ms.A.Ragatharani Mr.V.Venkateswaran Mr.K.G.Gowthaman

Envision Enviro Engineers Pvt. Ltd.

Ms. Smitha Rajesh Mr.Jignesh Patel

Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

Table of Contents EXECUTIVE SUMMARY ...... i 1 INTRODUCTION ...... 1

1.1 COMPANY BACKGROUND ...... 1

1.2 PROMOTERS AND BACKGROUND ...... 1

1.3 MANUFACTURING FACILITY&CURRENT STATUS ...... 1

1.4 CHANGE OF PRODUCT MIX ...... 2

1.5 JUSTIFICATION FOR THE PROJECT ...... 2

1.6 MARKET POTENTIAL ...... 2 1.6.1 Propylene Glycol...... 2 1.6.2 Polyols ...... 3

1.7 PROJECT SETTING ...... 4

1.8 PROJECT LOCATION ...... 6

1.9 EIA REQUIREMENT ...... 7

1.10 ENVIRONMENTAL AND RELATED ACTS AND RULES APPLICABLE ...... 7

1.11 METHODOLOGY ADOPTED FOR THE STUDY ...... 12 1.11.1 Objectives of this EIA report ...... 12 1.11.2 EIA Process ...... 12 2 PROJECT DESCRIPTION ...... 14

2.1 ABOUT THE PROJECT ...... 14

2.2 PROJECT LOCATION ...... 14

2.3 LAND REQUIREMENTS ...... 19 2.4 MANPOWER ...... 20

2.5 PLANT LAYOUT ...... 20

2.6 RAW MATERIAL REQUIREMENTS ...... 20 2.6.1 Source of raw materials ...... 20

2.7 MANUFACTURING PROCESS ...... 22 2.7.1 Existing Epichlorohydrin Plant ...... 22 2.7.2 Manufacturing Process of Propylene Oxide ...... 27

2.8 UTILITIES AND SERVICES ...... 30 2.8.1 Water System ...... 30 2.8.2 Water Supply ...... 34 2.8.3 Sewage Treatment Plant ...... 36 2.8.4 Effluent Treatment Plant ...... 38 Hubert Enviro Care Systems Pvt. Ltd.

TPL- EIA for Change of Product Mix

a) Design of Outfall Pipeline ...... 42

2.9 STEAM SYSTEM ...... 43

2.10 COMPRESSED AIR SYSTEM ...... 43

2.11 INERT GAS SYSTEM ...... 44

2.12 STORAGE FACILITIES ...... 44

2.13 POWER SUPPLY ...... 44

2.14 STACK DETAILS ...... 44 3 BASELINE ENVIRONMENTAL STATUS ...... 46 3.1 INTRODUCTION ...... 46

3.2 AIR AND METEOROLOGICAL ENVIRONMENT ...... 46 3.2.1 Reconnaissance ...... 46 3.2.2 Micro metrology ...... 48 3.2.3 Base line air quality status ...... 50

3.3 NOISE ENVIRONMENT ...... 53 3.3.1 Reconnaissance ...... 53 3.3.2 Community noise levels ...... 54 3.3.3 Baseline Noise status ...... 54

3.4 WATER ENVIRONMENT ...... 55 3.4.1 Hydrogeology ...... 55 3.4.2 Reconnaissance ...... 57 3.4.3 Baseline Water quality Status ...... 58 3.4.4 Surface water Quality ...... 61 3.4.5 Ground water quality ...... 63

3.5 SOIL ENVIRONMENT ...... 64

3.6 LAND USE ...... 67 3.6.1 Geomorphology ...... 69

3.7 TERRESTRIAL ECOLOGY ...... 70 3.7.1 Scrub Eco-system (Dry Evergreen Vegetation) ...... 70 3.7.2 Tidal Eco-system ...... 70 3.7.3 Mangrove Eco-system ...... 70 3.7.4 Marsh Eco-system ...... 71 3.7.5 Agro Ecosystem ...... 71 3.7.6 Flora...... 71

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3.7.7 Fauna ...... 72

3.8 AQUATIC ECOLOGY ...... 73 3.8.1 Planktons ...... 73 3.8.2 Fishes ...... 73

3.9 SOCIO ECONOMIC ENVIRONMENT ...... 74 3.9.1 Social Indicators ...... 75 3.9.2 Economy of the District...... 78 3.9.3 Land use and Resource availability ...... 79 3.9.4 Industries ...... 80 3.9.5 Discussion with local people...... 81 4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ...... 83

4.1 IMPACT IDENTIFICATION ...... 83

4.2 CONSTRUCTION AND COMMISSIONING PHASE ...... 83

4.3 COMMISSIONING OF PLANT ...... 83

4.4 OPERATION PHASE ...... 83 4.4.1 Air Environment ...... 84 4.4.2 Water Environment ...... 91 4.4.3 Noise Environment ...... 91 4.4.4 Land Environment ...... 92 4.4.5 Flora And Fauna ...... 94

4.5 IMPACT ASSESSMENT ...... 94 4.5.1 Matrix method ...... 95 5 ANALYSIS OF ALTERNATIVES ...... 100 5.1 INTRODUCTION ...... 100

5.2 SITE SELECTION ...... 100

5.3 PROJECT ALTERNATIVES ...... 102 5.3.1 Site alternatives ...... 102 5.3.2 Fuel alternatives ...... 103 5.3.3 Water supply alternatives...... 103 5.3.4 Alternative Technologies...... 103 5.3.5 Justification for the Selected Technology ...... 104 6 ENVIRONMENTAL MONITORING PROGRAM...... 106 6.1 INTRODUCTION ...... 106

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6.2 MONITORING METHODOLOGIES ...... 108

6.3 REPORTING & DOCUMENTATION ...... 108 7 ENVIRONMENTAL MANAGEMENT PLAN ...... 110 7.1 INTRODUCTION ...... 110

7.2 OBJECTIVES OF EMP ...... 110

7.3 EMP STRUCTURE AND ORGANIZATION IN TPL ...... 111

7.4 EMP ROLES AND RESPONSIBILITIES ...... 111

7.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE ...... 113 7.5.1 Air Quality...... 114 7.5.2 Noise Environment ...... 114 7.5.3 Water Quality and Water Resources ...... 115 7.5.4 Solid Waste ...... 115 7.5.5 Land Environment ...... 115 7.5.6 Ecology...... 115 7.5.7 Socio Economic ...... 115

7.6 ENVIRONMENTAL MANAGEMENT PLAN FOR OPERATION PHASE ...... 116 7.6.1 Air Quality...... 116 7.6.2 Noise Environment ...... 119 7.6.3 Water Quality and Water Resources ...... 119 7.6.4 Effluent Treatment Plant ...... 122 7.6.5 Solid & Hazardous Wastes ...... 122 7.6.6 Land Environment ...... 123 7.6.7 Ecology...... 124 7.6.8 Green Belt Development Plan...... 124 7.6.9 Socio – Economic Environment ...... 126 7.6.10 Occupational Health and Safety Program ...... 130 7.6.11 Environmental Policy of TPL ...... 131 7.6.12 Fire & Explosion Controls ...... 132 7.6.13 On line Leak detections ...... 135 7.6.14 Chemicals Management System ...... 136

7.7 OCCUPATIONAL HEALTH / INDUSTRIAL HYGIENE PROGRAM...... 137 7.7.1 Occupational Health Monitoring ...... 137 7.7.2 Emergency Management ...... 138

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7.7.3 Materials Handling Storage and Transportation ...... 138 7.7.4 H&S Audits & Inspections program ...... 139 7.7.5 Industrial Hygiene Monitoring ...... 140

7.8 ENVIRONMENTAL MANAGEMENT CELL ...... 142 7.8.1 Responsibilities of Environment Management Cell ...... 143 7.8.2 Monitoring of Environment ...... 144 7.8.3 Laboratory Facilities ...... 146 7.8.4 Corporate Responsibility for Environmental Protection (CREP) ...... 146 7.8.5 Budgetary Provisions for EMP ...... 150 8 CONSENT- COMPLIANCE STATUS ...... 151

8.1 APPLICABILITY OF ENVIRONMENTAL CLEARANCE ...... 151

8.2 CONSENT FOR EXISTING OPERATION ...... 151

8.3 COMPLIANCE CONDITIONS ...... 151 9 PROJECT BENEFITS ...... 160 9.1.1 Polyols ...... 160 9.1.2 Miscellaneous applications ...... 161 10 SUMMARY & CONCLUSION ...... 162 11 DISCLOSURE OF CONSULTANTS ENGAGED ...... 164

LIST OF FIGURES

Figure 1-1 Location of the Project Site ...... 6 Figure 1-2 EIA Process Cycle ...... 13 Figure 2-1 Location of the Project Site ...... 15 Figure 2-2 10 Km Radius Google Map of the Site and Surroundings ...... 17 Figure 2-3 Google Image of Project Site...... 18 Figure 2-4 Topo map showing 5 km around the site ...... 18 Figure 2-5 Process overview of Allyl Chloride Section...... 24 Figure 2-6 Process overview of Epichlorohydrin Section...... 25 Figure 2-7 ECH Material balance - ALC unit ...... 26 Figure 2-8 Mass Balance for Epichlorohydrin Production ...... 26 Figure 2-9Flow diagram of propylene Oxide plant ...... 28 Figure 2-10 Mass Balance for Propylene Oxide ...... 30

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TPL- EIA for Change of Product Mix

Figure 2-11 Emergency Eye washer ...... 33 Figure 2-12 Safety Showers ...... 33 Figure 2-13 Water balance for existing ECH plant ...... 35 Figure 2-14 Water Balance for Proposed PO Manufacturing ...... 36 Figure 2-15 Sewage treatment Plant Process Flow ...... 37 Figure 2-16Effluent Treatment Plant in the site ...... 40 Figure 2-17Proposed Effluent Treatment Plant...... 41 Figure 3-1Google earth Image Showing the Location of Air quality Sampling Stations ...... 48 Figure 3-2 Wind rose Data for Manali ...... 50 Figure 3-3 Hydro geological map of Thiruvallur district ...... 57 Figure 3-4Google Earth Image Showing the Location of Sampling Stations ...... 60 Figure 3-5 Water sampling at different locations ...... 60 Figure 3-6Google Earth Image showing Location of Soil sampling...... 65 Figure 3-7 Soil Sampling Location ...... 66 Figure 3-8 Land use / Land cover Map of the Study area ...... 68 Figure 3-9 Land Use classification chart ...... 69 Figure 3-10 Geomorphologic map of the project site ...... 70 Figure 3-11 District Decadal Growth Rate ...... 75 Figure 3-12 Statistics of Main workers ...... 76 Figure 3-13 Bar chart for Operational land holding ...... 77 Figure 3-14 School in Manali ...... 77 Figure 3-15 Product at net and constant prices ...... 78 Figure 3-16 Per Capita Income at Net and Constant Prices ...... 79 Figure 3-17 Discussion with the local fisherman ...... 82 Figure 3-18 Discussion with a worker in the study area ...... 82 Figure 4-1 Ground Level Concentration (GLC) of SOX at 10 Km radius(without DG set) ...... 87

Figure 4-2 Zoomed image - (GLC) of SOX at 10 Km radius (without DG set) ...... 87 Figure 4-3 Ground Level Concentration (GLC) of SOX at 10 Km radius (With DG set) ...... 88 Figure 4-4 Zoomed Image of GLC of SOX at 10 Km radius (With DG set) ...... 88

Figure 4-5 Ground Level Concentration (GLC) of NOX at 10 Km radius ...... 89

Figure 4-6 Zoomed Image - (GLC) of NOX at 10 Km radius ...... 89 Figure 4-7 Ground Level Concentration (GLC) of PM at 10 Km radius ...... 90 Figure 4-8 Zoomed Image - (GLC) of PM at 10 Km radius ...... 90

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Figure 4-9 Noise level Contour- Isoline view ...... 92 Figure 4-10 Land use in the year 2005 ...... 93 Figure 4-11 Land use in the year 2008 ...... 93 Figure 4-12 Land use in the year 2014 ...... 94 Figure 7-1 Chlorine Sensor in Chlorine scrubber stack ...... 117 Figure 7-2 Online Chlorine sensor connected to TNPCB ...... 117 Figure 7-3 Continuous Ambient Air Quality Station at the site ...... 118 Figure 7-4 Rain water harvesting system – Roof top rain water collection system ...... 122 Figure 7-5 Rain Water Percolation Pit ...... 122 Figure 7-6 Photos of existing Green belt...... 125 Figure 7-7 Fire Alarm point ...... 133 Figure 7-8 Water Monitor ...... 134 Figure 7-9 Sprinkler System in Storage Tanks ...... 135 Figure 7-10 Propylene Detector ...... 136 Figure 7-11 Chlorine detector ...... 136 Figure 7-12 Organizational set up for Environmental Management plan ...... 143

LIST OF TABLES

Table 1-1Change in Products and Production Capacity 2 Table 1-2 List of Industries Within 10 Km radius of the Project Site 4 Table 1-3Applicable Acts and Rules for the Proposed Project 9 Table 2-1 Change in Products and Production Capacity 14 Table 2-2 Salient Features of Project and Surrounding features 16 Table 2-3 Land use breakup details 19 Table 2-4 Source and Transportation of Raw materials and products 21 Table 2-5 Raw materials used in existing and proposed facility 21 Table 2-6 Epichlorohydrin characteristics 27 Table 2-7 Water Consumption for Existing and Proposed plant 34 Table 2-8 Dimensions of Outfall pipeline 42 Table 2-9 Output Design Details 43 Table 2-10Existing Stack Details 44 Table 2-11Existing stack details utilized for proposed facility 45 Table 3-1Locations of the Ambient Air Quality Stations 47

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TPL- EIA for Change of Product Mix

Table 3-2 Meteorological observations 49 Table 3-3 Test Methods used for the Analysis of ambient air quality parameters 51 Table 3-4 Summary of findings of ambient air quality monitoring (Average) 52 Table 3-5Table Summary of findings of Noise monitoring in the study area (Average) 54 Table 3-6 Summary of test methods used for the analysis of water quality parameters 58 Table 3-7 Locations of the water quality stations 59 Table 3-8 Summary of analytical results on Surface water samples collected in the study area 61 Table 3-9 Results of Ground water samples collected in the study area 63 Table -3-10Summary of findings of soil sampling studies in the study area (Average) 65 Table 3-11 Summary of analytical results of soil samples collected at different sampling stations 66 Table 3-12Landuse Classification and Area 68 Table 3-13 List of Domestic Flora in the Study Area 71 Table 3-14 List of Wild Fauna in the Study Area 72 Table 3-15 Amphibian 72 Table 3-16 Rodents 73 Table 3-17 List of Zooplankton identified within the Study Area 73 Table 3-18 Land Use data - Thiruvallur 79 Table 4-1Stack details in the existing ECH facility 84 Table 4-2Source of Process Emissions after Proposed change in Product Mix 85 Table 4-3 Reduction in emission load due to proposed change in product mix 85 Table 4-4 Stack Emission Details 86 Table 4-5 Predicted GLC for Proposed Stack 91 Table 4-6 Overall Impact Classification 96 Table 4-7 No-Project Scenario 96 Table 4-8 Project Scenario without EMP 97 Table 4-9 Project with EMP 98 Table 5-1 Impacts of alternative site location compared with the selected location 101 Table 6-1Post Project Environmental Monitoring Plan 107 Table 7-1 Responsibilities for EMP Implementation 111 Table 7-2 Quantity of Non hazardous waste 123 Table 7-3 Quantity of hazardous waste expected to be generated in the proposed facility 123 Table 7-4 Fire Fighting Equipments Available in the Plant 133 Table 7-5 Fire Alarm points and its components inside the plant 133

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TPL- EIA for Change of Product Mix

Table 7-6 Fire Water Storage Capacity 134 Table 7-7Pumps Available with Capacity 134 Table 7-8 Sprinklers Installed in the Plant 135 Table 7-9 Environmental Monitoring Plan 144 Table 7-10 CREP Points and Compliance status 146 Table 7-11CEPI (Comprehensive Environment Pollution Index) Action Plan Status 149 Table 7-12Cost for Environmental Protection Measures in (Rs.) 150 Table 8-1 Consented quantity vide order No 17966 dated 21.04.1999 151 Table 8-2Consent order under water Act No. 17966 dated 21.04.1999 151 Table 8-3 Renewal consent order under Air Act No. 28635dated 21.04.1999 152 Table 8-4 Consent order under Air Act- no. 14090 dated 03.11.2010 154 Table 8-5 Consent order under Water act- No.17966 dated 03.11.2010 156 Table 11-1Details of the Consultant 164

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TPL- EIA for Change of Product Mix

List of Annexure

Annexure-1Location of Industries within 10 Km radius of the site

Annexure-2 TOR from MoEF dated 31/3/2014 for Proposed Change of Product Mix

Annexure-3 Topo sheet showing the Project site

Annexure-4 Land Documents

Annexure-5 CMA land Use Map

Annexure-6 Existing ECH Layout

Annexure-7 Proposed PO Layout

Annexure-8 Transportation Route for proposed PO unit

Annexure-9 CMWSSB receipt for water supply

Annexure-10 Treated effluent Disposal Pipeline to sea

Annexure-11 Monitoring Reports

Annexure-12 Rain water Harvesting pits Layout at site

Annexure-13 Layout showing the existing and proposed green belt development area

Annexure-14 Fire hydrant Layout

Annexure-15 MSDS of Raw materials and finished products

Annexure-16 Licence for storage of Propylene and Chlorine

Annexure-17 Consent To Establish for ECH plant obtained in 1993

Annexure-18 Consent To Operate Renewal for ECH Plant obtained in 1999

Annexure-19 Consent To Operate Renewal for ECH Plant obtained in 2010

Annexure-20 Consent To Operate Renewal application for ECH Plant in 2014

Annexure-21 Hazardous Waste Authorization from TNPCB for ECH Plant

Annexure-22 Consolidated Reports of Treated Effluent

Annexure-23 Lime Sludge disposal for brick Manufacturers

Annexure- 24 Consolidated Reports of Stack Monitoring

Annexure-25 Consolidated Reports of Ambient Air Quality Monitoring

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Annexure-26 LDAR Report

Annexure-27 Report of Ground Water Quality Monitoring at site

Annexure-28 Industrial Waste Management Membership

Annexure-29 Agreement with Ramky for disposal of Hazardous waste

Annexure-30 Risk Assessment and Disaster Management Plan

Annexure-31 Letter Regarding Exemption for Public Hearing

Annexure-32 NABETCertificate

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ABBREVATIONS

TPL Tamilnadu Petroproducts Limited TIDCO Tamil Nadu Industrial Development Corporation Limited SPIC Southern Petrochemical Industries Corporation Ltd CMWSSB Chennai Metropolitan Water Supply and Sewage Board TOR Terms of Reference ECH Epichlorohydrin LAB Linear Alkyl Benzene PO Propylene Oxide NAAQ National Ambient Air Quality Standards CPCB Central Pollution Control Board SEIAA State Environment Impact Assessment Authority MoEF Ministry of Environment and Forests CPA Critically Polluted Area EIA Environmental Impact Assessment HCl Hydrochloric acid ALC Allyl Chloride WTP Water Treatment Plant RWR Raw Water Reservoir FWR Fire Water Reservoir ACF Activated Carbon Filters DM Demineralization Plant ETP Effluent Treatment Plant STP Sewage Treatment Plant FWPH Fire Water Pump House MCR Main Control Room MLSS Mixed Liquor Suspended Solids TNPCB Tamil Nadu Pollution Control Board HDPE High-density polyethylene AAQM Ambient Air Quality Monitoring APHA American Public Health Association VOC Volatile Organic Compounds

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USEPA United States Environmental Protection Agency BDL Below Detection Level MMDA Madras Metropolitan Development Authority SIDCO Small Industries Development Corporation EMC Environmental Monitoring Consultant GLC Ground Level Concentration OHSAS Occupational Health and Safety Administration Standard EMP Environmental Management Plan IEMC Independent Environmental Monitoring Consultant MACT Maximum Achievable Control Technology LDAR Leak Detection and Repair NESHAP National Emissions Standards for Hazardous Air Pollutants NSPS New Source Performance Standards PPE Personal protective equipment SPCB State Pollution Control Board TNWML Tamil Nadu Waste Management Limited CSR Corporate Social Responsibility PHA Process Hazard Analysis SCBA Self Contained Breathing Apparatus MSDS Material Safety Data Sheets SABA Supplied Air Breathing Apparatus PFT Pulmonary Function Tests LFT Liver Function Tests CFL Compact Fluorescent Lamp CREP Corporate Responsibility for Environmental Protection BLEVE Boiling Liquid Expanding Vapor Explosion ALARP As Low As Reasonably Practicable level HAZOP Hazard and Operability PrHA Preliminary Process Hazard Analysis ALOHA Aerial Locations of Hazardous Atmospheres EPA Environmental Protection Agency IARC International Agency for Research on Cancer

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LEL Lower Explosive Limit AEGL Acute Exposure Guideline Level HCD Heavy Chemical Division SMS Safety Management System TAC Tariff Advisory Committee TNEB Tamil Nadu Electricity Board CEC Chief Emergency Coordinator CPCL Chennai Petroleum Corporation Limited PAPL Petro Araldite Private Limited MPL Manali Petrochemicals Limited MFL Madras Fertilizers Limited NABL National Accreditation Board for Testing and Calibration Laboratories FAMCP Fire Alarm Manual Call Point NABET National Accreditation Board For Education & Training

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Executive Summary TPL- EIA for Change of Product Mix

EXECUTIVE SUMMARY

1. Introduction Tamilnadu Petroproducts Limited (TPL) was established in 1984 at Manali, Thiruvallur district in Tamil Nadu State as a joint venture between TIDCO and SPIC manufactures Industrial Intermediary Chemicals.Tamilnadu Petroproducts Limited (TPL) has established facilities to manufacture 10908 MTPA of Epichlorohydrin since 1995 which is a key raw material in the manufacture of epoxy resins, pesticides and in pharmaceutical formulations. The manufacturing product is proposed to change from Epichlorohydrin to Propylene Oxide which uses same raw material like propylene, lime, chorine with minor modification in the existing facility. 1.1. Project Details TPL proposes to change the product mix from Epichlorohydrin to Propylene Oxide using same raw materials S.No Particulars Details 1. Project Product mix change- Epichlorohydrin to Propylene Oxide 2. Geographical Location Village: Manali Taluk: Thiruvottiyur District: Thiruvallur State: Tamil Nadu 3. Project Cost 12.96 Crores 4. Power Requirement 1.6MW Standby DG-3.2MW 5. Project land area 38.72 acres 6. No of Employees 95 Contract based 180 7. Land use Special and Hazardous Industrial Use Zone 8. Nearest Railway Station Chennai Central - 10 Km Thiruvottiyur -2.1Km East 9. Nearest Airport Chennai Meenambakkam Airport - 38 km in south west direction 10. Nearest habitation Manali-2.6Km

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11. Densely populated area Thiruvottiyur-2.1 Km East 12. Inland water bodies Buckingham canal – 0.5 Km (East)

Surplus canal – 0.02 Km (North)

Satthankadu Lake–2.17 Km (South)

Madhavaram Lake–3.35Km (South West)

Kadapakkam Panchayat Lake- 3.65 Km (North West)

Retteri – 7.64 Km (South West) 13. Source of water supply CMWSSB 14. Population in Manali 58,174 as per the census data (2014) 15. Highway Manali SH 56 road- Adjacent to site 16. Sea port Chennai port – 5 Km South East

Ennore Port – 10.9 Km North East

17. Forest/Wildlife Sanctuary Nil within 10Km radius 18. Industries around TPL MPL, CPCL, Indian Additives Limited

1.2. Type of Project Petrochemical based processing units located inside the notified industrial Area/estate are listed at S.N. 5(e) 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 product change on 31st March 2014. 2. Project Description 2.1 Location The project site is located in Industrial town, Manali Village, ThiruvottiyurTaluk, Thiruvallur districtin thestate ofTamil Nadu. It is located in north ofChennaiCity. It is 25 kms away from Chennai city. The proposed area falls in the co-ordinates of 13°10'50.94"N, 80°16'47.91"E towards North, 13°10'35.51"N, 80°16'45.12"E towards West, 13°10'32.29"N, 80°17'8.98"E towards East.

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2.2 Change of Product Mix Considering the demand for propylene Oxide in the country, TPL is proposing to change the product mix to produce Propylene Oxide instead of Epichlorohydrin using existing facility. The change in products and production capacity details are given in Table ES-1

ES-1 Change in Products and Production Capacity

S. No. Description Existing (MTD) Proposed (MTD)

1 Epichlorohydrin 30.3 NIL 2 Hydrochloric Acid 17.3 NIL 3 Chlorinated Organics 13.3 6.75 4 Propylene Oxide NIL 45

2.3 Justification of The Project To meet the existing shortfall of Propylene Oxide in Indian Market, the existing facility of ECH will be used to manufacture Propylene Oxide with the same raw materials(like propylene, lime and chlorine). Propylene Oxide will be supplied to Manali Petrochemicals Limited and other users. 2.4 Land Requirements ES-2Land Breakup details S. No. Description Area (Sq.m) 1. Total Plot Area 156694.29 /38.72 Acres 2. Factory coverage area 17900 3. Administration building 848 4. Green belt Existing - 16187.43 (10.3%) Proposed - 32374.85 (20.7%) Total – 48562.28 (31%) 5. Roads and Pavement 25786 6. Storage Area 20372 7. Parking Area 1177 8. Utilities 25440 9. Vacant area 16609.41 (vacant area is considered after development of additional green belt).

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2.5 Raw materials

ES-3 Raw materials used in existing and proposed facility S. No. List of Raw Materials Existing Proposed (MTPD) (MTPD) 1 Propylene (Grade - 95%) 20.8 40.5

2 Chlorine 64.6 67.5 3 Water (KLD) 2150 (Fresh water 1650, 2150 (Fresh water 1650, Treated effluent- 500) Treated effluent- 500 ) 4 Furnace Oil 37.3 35.5 (Boiler -15.0, (Boiler -15.0, DG – 20.5 DG – 20.5) Propylene Heater- 1.8) 5 Lime 31 65

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 March to May 2014. Parameters such as VOC, heavy metals, gaseous pollutants and particulate matter were analyzed. PM2.5 ranged between 21-32 μg/m3 across the monitoring locations, PM10 3 3 3 ranged between 51-60 μg/m , SO2 varied between 11-15μg/m , NO2 varied between 14-25 μg/m , 3 3 NH3 ranged from 5-8.6 μg/m , TVOC ranged from 1.5 – 3.1 μg/m and 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 at study area were monitored at five locations within 10km radius. The field observations during the study period indicate that the ambient noise levels during day and night in the study area ranged between 50-72 dB(A) and 40-60 dB(A) respectively and are well within the prescribed standards at all the different noise zones prescribed by CPCB. 3.3 Water Environment To assess the quality of water around the project site seven sampling locations of surface water and three locations for ground water were selected within 10km radius of the site for Physiochemical parameters, heavy metals, and biological parameters. The pH of the surface water ranged from 6.08 to 8.18 across the sampling stations. The Electrical conductivity of the sample

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ranged from 1602 to 30300µs/cm across the sampling stations. The E.C value was the highest at Thiruvottiyur shore. The concentration of Total Dissolved solids (TDS) ranged between 1650 to 20260.0 mg/l across the sampling stations. The highest TDS is observed in Thiruvottiyur shore. The total hardness varied from 120- 8500 mg/l. Total hardness is exceeding the limits at sampling locations at Thiruvottiyur Shore and Opp. MFL bus stop. Total alkalinity exceeds the limits in Opp. MFL bus stop. The concentration of chlorides varied from 183 to 19052.96 mg/l Chlorides and total dissolved solids exceed limits in Thiruvottiyur Shore. Rest of the parameters in the sampling stations were well within the prescribed limits. The concentration of other parameters like Aluminum (mg/l), Chromium (mg/l), Lead (mg/l) and Chromium (mg/l) were below the detection limits. 3.4 Soil Environment Soil characteristics such as color, porosity, soil texture, chromium, copper, sodium, chlorides etc., were analyzed at four sampling locations within 10km radius of the site. Organic matter of the soil ranged between 0.04 to 0.43%, organic carbon ranged between 0.04 to 0.38%.Sandy soil ranged between 67.25 to 92.94%, silt varies between 1.08 to 4.68% and clay content ranged between 5.83 to 28.07%. 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. 3.6 Socio-Economic Environment The proposed site is located in Industrial Area. For the proposed change of product mix, there is no additional requirement of land and the existing land is within Industrial area. Hence there is no specific impact on Socio economics and no rehabilitation and resettlement is involved. 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 AERMOD software the Maximum Ground level concentration is estimated and based on the baseline monitoring data and Ground level concentration predicted. It is found that concentration levels arising are within NAAQ limits.

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ES-4Predicted GLC for Proposed Stack Parameters Baseline data Estimated Predicted Direction Downwind (µg/m3) Maximum Maximum distance Incremental GLC (µg/m3) (km) Concentration (µg/m3)

SOX 13 9.2 22.2 W 1 13 22.3 35.3 W 1 SOX*

NOX 25 4.14 29.14 W 1 PM 60 0.414 60.414 W 1

*Emission load predicted when DG is in continuous operation (Worst case scenario), however DG will be used only as a backup in case of power failure.

ES-5 Reduction in emission load due to change of product mix S.No Contents Existing (MTPD) Proposed (MTPD) 1. Particulate Matter 0.052 0.0507

2. SO x 2.984 2.84

3. NO x 0.505 0.5 4. HCl 0.00006 Nil 5. Chlorine 0.00001 0.00001 Total 3.5410 3.3907

Due to the proposed change in the product mix, there will be a decrease in air pollution. 5. Environmental Management Plan The Environmental Management Plan during construction and operation phase is discussed to ensure the environmental protection around the project area. . Additional20.7% green belt area is proposed along with the existing green belt area. . STP and ETP outlet should contain following requirements as per TNPCB/CPCB are Flow meter, pH, BOD, COD, TSS for proposed product change. . Air quality mitigation measures available in the existing plant will be used in proposed project are:

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Caustic scrubber with an Intallox saddle packing is used in the proposed PO plant to take care of Chlorine emissions. On line chlorine Monitoring system in the scrubber stack, will be used and connected to Care Center TNPCB. Dust scrubber is proposed for Milk of lime Plant. Continuous Ambient Air Quality monitoring station is available to monitor the ambient air quality. LDAR program will be implemented to reduce fugitive emissions. 6. Occupational Health and safety TPL medical surveillance program include following major elements:

Developing a OH-IH Medical Surveillance Program Pre-Employment Examination and Periodic Medical Examinations Determination of Fitness for Duty Communications Emergency Medical Treatment Medical Records 7. Fire and Explosion Control TPL 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 TPL is as follows: The fire station inside the plant consists of the following components:

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A fully equipped fire station with trained firemen is available to serve the plan whenever the emergency arise. Two central multipurpose fire tenders are available that serves all the plants inside TPL. Fire alarm annunciation panel. Communication facilities such as Wireless, Hotline (LAB, PO, CPCL), direct line telephone and intercom facilities are accessible from all the locations of the plant. Emergency PPEs are available (Leather gloves, dust mask, ear muff, goggles, PVC coat, PVC pant, PVC hood, PVC gloves, helmet with face shield, asbestos lug guard, asbestos apron, half mask, full mask, gum boot) and are provided to the employees with sufficient training as to how and when to use them. Fire fighting equipments like Fire suits, Chemical protection suit, Elkhart nozzle, triple purpose nozzles, short branches are available to serve the employees in the time of emergency. Fire station is constructed with concrete wall and provided with fire protection doors. 8. 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 ES-6 Budgetary Provisions for EMP

Recurring cost Environmental Capital Cost S.No Proposed per Annum protection measures (Lakhs) (Lakhs) 1. Air Pollution Control 50 25 5 Water Pollution 2. 300 35 50 Control Noise Pollution 3. 5 1 2 Control Occupational Health 4. 50 - 10 and safety Green belt 5. 2 5 2 Development Storm water 6. 20 7 3 Management 7. Waste Management 20 5 3

8. Fire Fighting 120 15 10 Total 567 93 85

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9. Risk Assessment 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 vapour explosion for the chemicals such as Propylene oxide, propylene and chlorine that are stored in the plant along with the magnitude of its impacts. Also, additional safety measures are recommended for the same. Emergency management plan, policies and principles for safety aspects of the employees is given which are to be strictly followed by management and employees. 10. Applicability of Environmental Clearance for Existing Facility Since the Epichlorohydrin plant commenced its operation in the year 1995, Environmental Clearance was not applicable. Valid Consent to Establish has been obtained from TNPCB vide Letter dated 22/9/1993 and Consent to Operate Renewal was obtained vide letter dated 21/4/1999. The unit is not operational since 1st April, 2013 owing to unviable business opportunities for the product. 11. Conclusion The Environmental Impact Assessment report studied the proposed project and assessed its predicted impacts on land, water, air, soil and biological environment of the region. 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: Due to elimination of propylene heater and HCl scrubbing unit, the emissions from respective stack will be reduced in the proposed production unit, thereby reduction in the overall air pollution load. Project study area is not falling within 10 km radius of National Park, Wildlife Sanctuary, etc. As the proposed project falls within the existing site, there is no need for rehabilitation and resettlement. No extraction of ground water is proposed. There will be no additional water requirement and no additional water discharge for the proposed project. Hence there is no change in waste water discharge and water pollution load with respect to quantity and quality. Lime sludge will be disposed to brick manufacturers. TPL has adequate safety measures and does not anticipate any adverse effect on health of workers.

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For handling and storage of raw materials and finished products proper measures has been considered. On line chlorine Monitoring system in the existing scrubber stack, is available and connected to Care Center TNPCB. LDAR program is available and the same will be followed to reduce fugitive emissions. Dust scrubber is proposed for Milk of lime Plant. Additional 20.7% area of Green belt is proposed with existing Green belt area. STP and ETP outlet will have online monitoring system for Flow meter, pH, BOD, COD, TSS for proposed product change.

Other than the above, proposed project will be bringing in various economical, social and environmental benefits to the Manali town, Tamil Nadu.

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1 INTRODUCTION

1.1 COMPANY BACKGROUND

Tamilnadu Petroproducts Limited (TPL) was established in 1984,at Manali, Thiruvallur district in the State ofTamil Nadu.

TPL commenced commercial production in the year 1985 with manufacturing facilities for Linear Alkyl Benzene (LAB), finding application in manufacture of detergents and cleaning agents.

TPL established a plant to manufacture 10908 MTPA of Epichlorohydrin (ECH) in the year 1995 which is a key raw material in the manufacture of epoxy resins, pesticides and certain pharmaceutical formulations.

TPL also acquired the Heavy Chemicals Division from SPIC in the year 2000 which manufactures Caustic Soda and Chlorine which are the most commonly used industrial chemicals in Textile, Pulp & Paper, Soaps & Detergents and Aluminium industries in India.

1.2 PROMOTERS AND BACKGROUND

TPL is a joint venture between Tamil Nadu Industrial Development Corporation Limited(TIDCO)wholly owned by the Government of Tamilnadu and Southern Petrochemical Industries Corporation Ltd. (SPIC) with more than 80,000 shareholders.

TPL is a listed company on Bombay Stock Exchange and National Stock Exchange.

M/s. SPIC Limited, has diverse interest in fertilizers, other services.

TIDCO is a public financial institution engaged in promoting industries in the State of Tamil Nadu.

1.3 MANUFACTURING FACILITY&CURRENT STATUS

TPL has established the facility to manufacture Epichlorohydrin (ECH) of 10,908 MTPA in the year 1995 realizing the vitality of ECH in epoxy resin polymers. The technology for manufacture of ECH was obtained from M/s. Conser S.p.A Italy.

ECH is a key input used in Epoxy Resins for anti-corrosive surface coating in Chemical Plants, Infrastructure, Telecommunication, Construction, Electronics etc., The existing ECH facility is located at, Manali Industrial Area, Thiruvottiyur Taluk, Thiruvallur District. The unit is not operational since 1stApril, 2013 owing to unviable business opportunities for the product.

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1.4 CHANGE OF PRODUCT MIX

Considering the demand for propylene Oxide in the country, TPL is proposing to change the product from Epichlorohydrin to Propylene Oxide using the existing facility with the same raw material. The change in products and production capacity details are given in Table 1-1.

Table 1-1Change in Products and Production Capacity

S. No. Description Existing (MTD) Proposed (MTD)

1 Epichlorohydrin 30.3 NIL 2 Hydrochloric Acid 17.3 NIL 3 Chlorinated Organics 13.3 6.75 4 Propylene Oxide NIL 45

1.5 JUSTIFICATION FOR THE PROJECT

To meet the existing shortfall of Propylene Oxide in Indian Market the existing facility of ECH will be used to manufacture Propylene Oxide with the same raw materials (like propylene, lime and chlorine).

Propylene Oxide will be supplied to Manali Petrochemicals Limited and other users.

1.6 MARKET POTENTIAL

Current imports of Propylene oxide is about 20000 MTA. Considering the domestic production, the total demand for Propylene oxide is around 60000 MTA.

Current Propylene glycol imports is about 50000 MTA and polyol imports is more than 1 lakh tone per annum.

The 15000 MTA Propylene oxide produced can be sold as such or used for making Polyols.

1.6.1 Propylene Glycol Propylene glycol is used for various applications in industries viz

Pharmaceuticals

Food flavors and essences

Polyester resins

Perfumery compounds

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Cosmetics

Cigarettes

Tooth paste

Pesticides

Of this, Pharmaceuticals, food flavors and polyester resins manufacturing sectors account for a major share in the present consumption of Propylene Glycol in the country.

1.6.2 Polyols The polyols are broadly classified based on application as given below

Flexible Polyurethane foams

Rigid Polyurethane foams

Semi-rigid Polyurethane foams

Miscellaneous applications

a) Flexible Polyurethane foams–These are largely used for various household applications such as furniture cushions, beds, mattresses etc. Also in automobiles, seat cushions, arm rests coverings etc are made using flexible foams. In certain cases these are used as packaging material for high value items. Some of the miscellaneous applications include foam laminations, toys, and novelties.

b) Rigid Polyurethane foams -The specific thermal insulation characteristics of rigid PU foams are far superior to that of all other polymeric foams. The obvious advantage of polyurethane rigid foam is the lesser thickness required to achieve the same thermal efficiency as other materials.

These are used as insulating materials in

Air conditioning and refrigeration industry (insulation of domestic refrigerators, Air conditioner, refrigerated vans etc.,)

Process industry (insulation of process equipments, pipelines, storage tanks etc)

Transportation industry (insulation of rail coaches, bus coaches, air craft, ships etc)

c) Semi-rigid Polyurethane foams–They are used in the manufacture of steering wheels, scooters/motorcycles/bicycles/car seats, arm rests, shoe soles etc.

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d) Miscellaneous applications -Polyols are also used in the manufacture of polyurethane elastomer, coatings, paintings, adhesives/sealants, binders etc.

1.7 PROJECT SETTING

The site is located in Manali Industrial Area. Manali is a Northern Suburb of Chennai city. The Industrial area caters to mostly Petrochemical based industries. Major industries located are given below with its distance and direction from the site. The satellite imagery for the same around a radius of 10 Km is attached as Annexure 1.

Table 1-2 List of Industries Within 10 Km radius of the Project Site S.No Industry Product Distance &Direction 1. M/s.MRF Tyres Tyres 2.85 Km, E 2. M/s.Carborundum Universal Ltd Super Refractories 2.9 Km, E 3. M/s.CPCL Petroleum Refinery 1.1 Km, S 4. M/s.Indhumathi refineries Edible Oils 3.58Km, SE 5. M/s.Eveready industries Batteries 3.76Km, SE 6. M/s.IOCL Lube oil Plant 3.5Km, SE 7. M/s.Bharath Petroleum Lube oil Plant 5.2 Km, S 8. M/s.HPCL Terminal Oil Terminal 5.6 Km, S 9. M/s.Madras fertilizers Limited Fertilizers 1.4 Km, W 10. M/s.PetroAraldite Epoxy Resins 50 M, Adjacent 11. M/s.Manali Petrochemicals Limited Petrochemicals 65 M, SW 12. M/s.Indian Additives Limited Additives Adjacent opposite to the site 13. M/s.TPL, Heavy Chemicals Division Chlor Alkali 20m, opposite to the site 14. M/s.TPL Linear Alkyl Benzene Division Petrochemicals Opposite to the site 15. M/s.IOC Bulk terminal & bottling 1.65 Km, W plant 16. M/s.Toshiba JSW Turbine Turbines 1.86Km, NW 17. M/s.Sattva CFS Pvt. Ltd Warehouse 1.05 Km, NW 18. M/s.Tivary CFS Pvt. Ltd Ware house 4.3Km, N 19. M/s.NDR Ware housing Ware house 4.6Km, N 20. M/s.East coast organics Organic Chemicals 5.45 Km, N

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S.No Industry Product Distance &Direction 21. M/s.AshokLeyland Automobile 1 5.87Km, N 22. M/s.Vallur Thermal Power Plant Power Plant 6.81 Km, NE 23. M/s.India Cements Cement 6.9 Km, NE 24. M/s.North Chennai Thermal Power Station Power Plant 9.7 Km, NE 25. M/s.Coromandel Fertilizers Fertilizer 6.18 Km, NE 26. M/s.Hinduja Foundries Foundry 5.59 Km, NE 27. M/s.AshokLeyland Automobile 2 5.20Km, NE 28. M/s.Ennore Thermal Power Plant Power Plant 3.2Km, NE 29. M/s.NicholasPiramal Pharmaceutical 3.83Km, NE 30. M/s.Cetex Petrochemicals 0.6 Km, S 31. M/s.Kothari Petrochemicals 0.7 Km, S 32. M/s.SRF Polyesters 1 Km, SE

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1.8 PROJECT LOCATION

The project site is located at R.S.No.254/3 (part),259/2, 260/2, 261/2, 262/2, 263/2A, 265/1A1, 265/1A2, 266/1A.1A1B (part), 266/1A1B/2B1A2 (part),Manali Industrial Area, Manali Village, Thiruvottiyur Taluk, Thiruvallur District in the state of Tamil Nadu. The proposed site falls in the co-ordinates of 13°10'50.94"N, 80°16'47.91"E towards North, 13°10'35.51"N, 80°16'45.12"E towards West, 13°10'32.29"N, 80°17'8.98"E towards East.The project site is situated on the State Highway 56 which is called Manali High Road. The location of the project site is given in Figure 1-1.

TPL Site

Figure 1-1 Location of the Project Site

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1.9 EIA REQUIREMENT

The Government of India, Ministry of Environment and Forests (MoEF), New Delhi, vide notification no. S. O. 1533 dated 14thSeptember, 2006, (subsequently amended by S. O. 3067(E) dated 1st December 2009), has made it mandatory to obtain „Prior Environmental Clearance‟ for change in the product mix of existing projects or activities entailing capacity addition with change in process falling within the schedule to that notification from MoEF (for Category A projects) or from SEIAA (for Category B projects).

The proposed project is about product change from Epichlorohydrin to propylene Oxide which falls in Petrochemical based processing units located inside the notified industrial area/estate are listed in schedule no. 5(e) under category „B‟. However, applicability of general condition due to project location within 10Km from Critically Polluted Area (CPA) proposal is treated as category „A‟ and will be appraised by expert Appraisal committee.

The application along with the project documents for the product mix change was submitted by TPL on 5.09.2013 (Letter no: TPL/ENV/2013/5542).Based on the information furnished and presentation done before the Expert Appraisal Committee (EAC) and after giving due consideration to various aspects of the project, scoping of the project was done on the14thReconstituted Expert Appraisal Committee (Industry) meeting held during 19th and 20th December, 2013 vide Agenda No. 14.5.15 and Terms of Reference (TOR) were assigned for the EIA study by MoEF in the letter F.No. J-11011/280/2013-IA-II (I) dated 31st March 2014. The TORs along with its point-wise compliance are given at the end of the report and is attached as Annexure 2. Thus, TPL was required to prepare an Environmental Impact Assessment (EIA) Study Report for the final appraisal by EAC. With a view to evaluate likely impacts on various components of the environment because of the proposed project, TPL took services of Hubert Enviro Care System Pvt. Ltd for preparation of Environmental Impact Assessment Report.

1.10 Environmental and Related Acts and Rules Applicable

The following are some of the acts and rules related to environment which are applicable for 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

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4. Air(Prevention and Control of Pollution) Act,1981and its amendments

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

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The details of applicable Acts and Rules and the applicability to the project is given in Table 1-3.

Table 1-3Applicable 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 Environmental clearance from Ministry of amendments. modernization, change of the Environment Environment & Forest. product mix of the existing project 2. Manufacture, Storage and Handling of Hazardous Regulate the manufacture, Preparation/ update of On-site Emergency Import of Hazardous Chemicals storage and import of Preparedness Plan and submission to Chemicals Rules, 1989 and Hazardous Chemicals Factory inspectorate. its amendments Preparation/ update of Safety Report and submit to Factory inspectorate. Preparation of Material Safety Data Sheet. 3. Water (Prevention and New projects, Expansion Prevention, control and Consent to establish and Consent to Control of Pollution) Act, modernization, change of abatement of water pollution Operate from State Pollution Control 1974 and its amendments. product mix of the Board existing project, Existing plants 4. Air (Prevention and Control New projects, Expansion Prevention, control and Consent to Establish and Consent to of Pollution) Act, 1981 and /modernization, change abatement of air pollution Operate from State Pollution Control its amendments. of product mix of the Board.

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existing project, Existing industries 5. Hazardous waste Management, Handling Prevention, Control and Hazardous waste Authorization from State (Management, Handling and and Transboundary abatement of pollution Pollution Control Board. Transboundary Movement Movement of Hazardous Rules) 2008 and its waste amendments. 6. The Environmental New projects, Protection and Improvement of Environmental Standards as specified are (Protection)Rules,1986 and Expansion/modernization the Environment to be complied. its Amendments change of product mix of Submission of Environment Statement. the existing project, Existing industries 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. Rules, 2000 change of product mix of problems the existing project, Existing industries 8. Public Liability Insurance Transportation of To provide immediate relief to Provision of Liability Insurance Policy. Act, 1991 and its Hazardous Substance. persons affected by accident amendments involving hazardous substances and also for Establishing an Environmental Relief fund

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9. Tamil Nadu Factories Rules New projects, Control of workplace Factory License from Factory inspectorate. 1950 and its amendments. Expansion/modernization environment, and providing for change of product mix of good health and safety of the existing project, workers Existing industries 10. Petroleum Act, 1934 New projects, Production, Storage and import License acquired for storage and adequate Expansion/modernization of petroleum and provides the safety measures are in place. change of product mix of regulations for the safety and the existing project, environmental measures Existing industries 11. Explosive Act, 1884 New projects, Production, Storage and import Safety measures are complied for the Expansion/modernization of explosive substance in and storage of chemicals in the plant as per change of product mix of around the project and provides PESO guidelines. the existing project, the regulations for the safety Existing industries and environmental measures 12. Central Motor Vehicle Act, New projects, Check the pollution load of Adequate environmental measures are put 1988 Expansion/modernization vehicles inside the plant in place to check the vehicular emissions. change of product mix of the existing project, Existing industries

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1.11 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.

1.11.1 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.

1.11.2 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

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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 presented as illustration in subsequent Figure. 1-2

Figure 1-2 EIA Process Cycle

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2 PROJECT DESCRIPTION

2.1 ABOUT THE PROJECT

Tamilnadu Petroproducts limited (TPL) has established facilities to make Epichlorohydrin (ECH) since 1995 which is used in manufacture of epoxy resins, pesticides and in pharmaceutical formulations, which is not operating since April 2013 as

cheaper imports of epoxy resins reduced the market process for ECH,

increase in raw material cost

The manufacturing product is proposed change from Epichlorohydrin to propylene oxide which uses the same raw materials like propylene, lime, chorine with minor modification in the existing facility. The change in products and production capacity are given below in Table 2-1

Table 2-1Change in Products and Production Capacity Existing Proposed S. No. Description (MTPD) (MTPD) 1. Epichlorohydrin 30.3 NIL

2. Hydrochloric Acid 17.3 NIL

3. Chlorinated Organics 13.3 6.75 4. Propylene Oxide NIL 45

2.2 PROJECT LOCATION

The project site is located in Industrial town and Municipality inThiruvallur districtin theIndianstate ofTamil Nadu. It is located in north ofChennaiCity. It is 25 kms away from the Chennai city. The Google image of 10 km radius is given in Figure 2-2.The topographic map of the site is attached as Annexure 3

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Figure 2-1 Location of the Project Site

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Table 2-2 Salient Features of Project and Surrounding features

S.No Particulars Details

1. Project Product mix change- Epichlorohydrin to Propylene oxide

2. Geographical Location 13°10'50.94"N, 80°16'47.91"E Towards North

13°10'35.51"N, 80°16'45.12"E Towards West

13°10'32.29"N, 80°17'8.98"E Towards East

Village: Manali

Taluk: Thiruvottiyur

District: Thiruvallur

State: Tamil Nadu

3. Project Cost 12.96 crores

4. Power Requirement 1.6MW

Stand by DG-3.2MW

5. Project land area 38.72 Acres

6. Land Use asper CMDA Special and Hazardous Industrial Zone Vide Map no MP- II/CMA (M) 3/2008

7. Topo sheet No. D4408 (66C8)

8. No. of employees 95

Contract based man power 180

9. Land use Special and Hazardous Industrial Use Zone Vide Map No. MP-II/CMA(M) 3/2008

10. Nearest Railway Station Chennai Central-10 km

Thiruvottiyur-2.1 Km East

11. Nearest Airport Chennai Meenambakkam Airport - 38 km in south west direction

12. Nearest habitation Manali - 2.6 Km

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13. Densely populated area Tiruvottiyur -2.1 Km

14. Inland water bodies Buckingham canal – 0.5 Km(East)

Surplus Canal – 0.02 Km (North)

Satthankadu Lake -2.17 Km (South)

Madhavaram Lake-3.35Km (South West)

Kadapakkam Panchayat Lake- 3.65 Km (North West)

Retteri – 7.64 Km (South West)

15. Source of water supply CMWSSB

16. Population in Manali 58,174 as per the census data (2014).

17. Highway Manali Road - SH 56 road- adjacent to the site

18. Sea port Chennai port – 5 Km South East

Ennore Port – 10.9 Km North East

19. Forest/Wildlife Sanctuary Nil with in 10 Km radius

Figure 2-2 10 Km Radius Google Map of the Site and Surroundings

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Project Site

Figure 2-3 Google Image of Project Site

Figure 2-4 Topo map showing 5 km around the site

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2.3 LAND REQUIREMENTS

The land use breakup of the existing plant is given below in Table 2-3.

Table 2-3 Land use breakup details S. No. Description Area 1. Total Plot Area 156694.29 (Sq.m) /38.72 Acres 2. Factory coverage area 17900 (Sq.m). 3. Administration building 848 Sq.m 4. Green belt Existing - 16187.43 (10.3%)

Proposed - 32374.85 (20.7%)

Total – 48562.28 (31%) 5. Roads and Pavement 25786 Sq.m 6. Storage Area 20372 Sq.m 7. Parking Area 1177 Sq.m 8. Utilities 25440 Sq.m 9. Vacant area 16609.41 Sq.m(vacant area is considered after development of additional green belt).

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The land documents are enclosed in Annexure-4.The land use of the site as per CMDA Land Use map is enclosed in Annexure-5.

2.4 MANPOWER

The existing manpower at ECH facility can be used for operating the PO plant. The total manpower for the proposed PO plant will be 95 employees and 180 contract manpower.

2.5 PLANT LAYOUT

The existing layout plan of ECH Plant is enclosed in Annexure-6 and the proposed layout plan of Propylene Oxide is enclosed in Annexure-7.

2.6 RAW MATERIAL REQUIREMENTS

2.6.1 Source of raw materials The raw materials used in the proposed site are acquired from different sources and different modes of transport. The movement of the raw materials across the site is attached as Annexure-8 . The details for the source and transportation of raw materials are as follows:

There is no change in the raw materials used for proposed modification. The details of raw materials used for existing facility and proposed modification is given in Table 2-4

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Table 2-4 Source and Transportation of Raw materials and products S.No Raw materials Storage Quantity of Source Means of Transport details storage (MT) 1. Propylene 2 Tanks 346 CPCL and 3Tankers each of 16 (2*346m3) other KL per day companies 2. Chlorine NA (Pipe line) - HCD plant of Pipelines TPL 3. Lime Godown 300 Imported 3Trucks of each of 22 through Tonnes per day from Chennai Port the Chennai port trust to the plant 4. Furnace Oil (1X400 M3) 394.4 From LAB Pipeline inside the Plant through site Pipeline/ tankers from other sources 5. Propylene Oxide 2 Bullets * 145 232 - 3Tankers each of 16 KL per day

6. Chlorinated 2 Tanks * 100 220 - 1 Tanker of 16 KL Organics once in two days

Table 2-5 Raw materials used in existing and proposed facility S. No. List of Raw Materials Existing(MTPD) Proposed(MTPD) Propylene 1 20.8 40.5 (Grade - 95 %) 2 Chlorine 64.6 67.5 2150 (Fresh water 1650 2150 (Fresh water 1650, 3 Water (KLD) Treated effluent- 500) Treated effluent- 500) 37.3 (Boiler -15.0, DG – 20.5, 4 Furnace Oil 35.5 (Boiler -15.0, DG – 20.5) Propylene Heater-1.8) 5 Lime 31 65

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2.7 MANUFACTURING PROCESS

2.7.1 Existing Epichlorohydrin Plant The manufacturing of Epichlorohydrin consists of two steps. 1) Manufacturing of allyl chloride which is intermediate product and 2) Manufacture of Epichlorohydrin from allyl chloride.

In allyl chloride reaction system, the dry gaseous propylene feed is first preheated to 80°C by condensate in the super heater and then at 300°C in the furnace. This hot Propylene is fed to the reactor where it mixes well with dry Chlorine gas exothermically. The reaction gases leaving the chlorination reactor are quenched in the quench tower where in dichloropropane is used as quenching medium which on vaporization cools the reaction gases and condenses the heavy fractions at the bottom.

The over head vapours from the quench tower after partial condensation is then subjected to chilling and partial condensation in three consecutive exchangers by means of depropanizer over head vapors, cold vapour propylene and by vaporizing propylene respectively. The heavy ends of the quench tower are striped in stripper and the residual bottom contents are disposed to the chlorinated organic disposal system after cooling.

The condensed liquid or vapor mixture is fed to the depropanizer feed separator which separates the vapor and liquid is than passed into depropanizer column at middle and lower feed trays respectively. The depropanizer column separates the gaseous mixture of propylene and hydrogen chloride at the top free of chlorinated organic and chlorinated organics at the bottom. The over head gas steam from depropanizer column is then passed on to the hydrogen chloride separation and recovery section and the bottom crude allyl chloride steam is sent to purification system.

The crude allyl chloride is passed to the lights column where the light ends are removed overhead. The bottom product stream of allyl chloride plus heavy ends is continuously removed and is fed to the heavies column. In the heavies column, the overhead vapors containing allyl chloride product is condensed and product cut is sent to storage vessel. The bottom of the heavies column is partially used in quench tower and partially sent to chlorinated by-products disposal system.

The hydrogen chloride and propylene gas is fed to the HCl absorber column where the acid vapours are absorbed in DM water. The residual HCl vapors from the absorber is washed with water and then preheated and fed to stripping column to remove the traces of light organics.

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Then, from the stripping column, the final HCl vapors are condensed and cooled subsequently transferred to acid storage facility.

The gaseous propylene leaving the HCl recovery section is passed through caustic water scrubber to remove traces of HCl. The scrubbed propylene vapours sent to compressor then compressed in two stages, then condensed, cooled and liquefied. The liquid propylene is then cooled by vaporizing propylene and the vaporized refrigerant propylene is sent to coalescer which removes most of free water. The recycled liquid propylene stream and the fresh propylene stream are together fed into drying system and after vaporization are fed to the reactors.

The reaction for producing Epichlorohydrin is carried out by contacting allyl chloride and chlorine previously diluted in aqueous solution. The liquid allyl chloride and gaseous chlorine is metered into parallel mixers and fed to the reaction unit. The reaction is carried out at 40 to 50oC. The resultant chlorohydrins solution from the reactor is fed to the chlorohydrins solution from the reactor is fed to the chlorohydration tank. The organic byproduct phase trichloropropane is allowed to separate from the liquid in reaction circulation loop and the dichlorohydrins is being fed to the Dehydrochlorination towers.

In the Dehydrochlorination system the premixing of dichlorohydrins stream and alkali takes place followed by the conversion of dichlorohydrins into Epichlorohydrin takes place in the steam stripped column by means of reaction with milk of lime. In further the overhead stripper vapours are condensed and cooled and then phase separated.

In the dehydration still system, the removal of water contained in the raw Epichlorohydrin takes place combined removing the low boiling organic impurities to produce a good purity raw Epichlorohydrin.

The raw Epichlorohydrin is further effectively distilled in high efficiency structured packing column to obtain 99% min. purity Epichlorohydrin which is free from high boiling impurities. The heavy ends of the dehydration still column are fed to the extraction tower to recover valuable Epichlorohydrin and dichlorohydrins. The residue of the extraction tower is sent to disposal.

The overview of the process is given in Figure 2-5andFigure 2-6.

Mass balance for the existing ALC and ECH unit is given in Figure 2-7 and Figure 2.8 respectively.

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HCL CHLORI HCL STORAGE NE SEP. SYSTEM SYSTE M

REACT PROPYL PROPYLE OR ENE NE PROPYL SYSTE SEPARA COMPRES ENE M TION SOR SYSTEM SYSTEM

CRUDE PURIFICA CHLORIN ALC TION ATED STORAG SYSTEM ORGANIC E S SYSTEM STORAGE SYSTEM

PURE ALC

Figure 2-5 Process overview of Allyl Chloride Section

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PURE ALC

DEHYDRO DEHYDRO CHLORI REACTI CHLORINAT CHLORINAT NE ON ION ION SYSTEM SYSTEM SYSTEM

ECH LIGHTS AND PURIFICAT HEAVIES ION TO SYSTEM CHLORINATED ORGANICS STORAGE

PRODUCT ECH STORAGE SYSTEM

Figure 2-6Process overview of Epichlorohydrin Section

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Figure 2-7 ECH Material balance - ALC unit

Figure 2-8 Mass Balance for Epichlorohydrin Production

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Table 2-6 Epichlorohydrin characteristics

Sl. No. Characteristics Specification 1. Density gm/ml @ 200C 1.179-1.182 2. Color (Hazen Scale ) 15 Alpha Max 3. Refractive index (250C) 1.434 - 1.436 4. Purity WT% 99.5 Min 5. Moisture WT% 0.1 Max 6. Iron (ppm) 0.2 Max

2.7.2 Manufacturing Process of Propylene Oxide The major raw material used in this process is propylene, which is received through tankers and stored in two bullets. Propylene from the storage bullets is drawn to the propylene oxide plant. Then it is vaporized and sent to the PO reactor. It reacts with chlorine and water to form propylene chlorohydrin according to the following reaction.

Cl2 +H2O HCL +ClOH

ClOH + C3H6ClC3H6OH

The solution is then saponified with milk of lime to generate propylene oxide.

2ClC3H6OH+ Ca (OH)22C3H6O + CaCl2 + 2H2O

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Figure 2-9Flow diagram of propylene Oxide plant

The vapour of Propylene Oxide is stripper with steam and distilled to get final product. The final product is sent to Propylene Oxide storage. The propylene oxide product is used for the manufacture of propylene glycol and Polyether Polyols.

The basic process is based on reaction of vapour phase propylene with a mixture of chlorine and water in liquid phase under controlled conditions followed by saponification of the chlorohydrins formed with lime.

The different sections of the plant are

Propylene Vapourisation Section Cholohydrination section Saponification section Purification section

2.7.2.1 Propylene Vapouriser

Propylene in the form of liquid obtained from the bullet would be vaporized on the shell side of the vaporizer circulating the water on the tube side. The cold will be recovered in the water and the chilled water will be used in different section of the plant. The Propylene so vaporized would be piped through a control valve to the chlorohydrin reactor made of Titanium.

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2.7.2.2 Chlorohydrination section

Propylene, Chlorine and water are continuously introduced into the bottom of the Chlorohydrins reactor where Chlorohydrination takes place as the bubbles of propylene and chlorine pass up in the reactor. The reactions that are taking place in the reactor are exothermic in nature and temperature will settle down without external heating or cooling due to enormous quantity of water that is under circulation in the reactor. The Chlorohydrin solution thus obtained is overflowed from the reactor and sent to the Saponification section.

2.7.2.3 Saponification section

A slightly excess calcium Hydroxide in an aqueous slurry form is used to saponify the Propylene Chlorohydrin .The Chlorohydrin solution leaving the reactor is mixed with the lime solution in a static mixer and is fed into the Saponifier where the Propylene Chlorohydrin is saponified and converted into propylene oxide. The propylene oxide is then stripped with live low pressure steam and is removed rapidly from the reaction zone and taken to a distillation section for the further purification. The waste lime solution from the bottom of the saponifier along with calcium chloride formed in the reaction is sent through a hydrocyclone to remove the solid particles and clear solution is sent through plate heat exchangers to recover the heat before discharging to the effluent treatment section.

2.7.2.4 Purification section:

Distillate from the saponifier consists of propylene oxide and water with some chlorinated byproducts. It is fed into the propylene oxide column where the crude propylene oxide is further purified and the pure propylene oxide is condensed in the overhead condenser and sent to storage tanks. The Propylene oxide column bottom consisting of chlorinated Organics and water is fed to a decanter where water is separated and recycled back to the reactor ,pure Chlorinated Organics is sent to storage and sold as a by-product.

2.7.2.5 Uses of Propylene Oxide:

About 60 and 70% of all Propylene Oxide is converted to polyether polyolsfor the production of polyurethaneplastics. About 20% of propylene oxide is hydrolyzed intopropylene glycol.

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Figure 2-10 Mass Balance for Propylene Oxide

2.8 UTILITIES AND SERVICES

The existing utilities and offsite of ECH will meet the requirements of the proposed PO facility.

2.8.1 Water System Water received from CMWSSB is stored in reservoirs and treated at the Water Treatment Plant (WTP).Depending on the applications, various treatments are done. We can divide the Storage and WTP into various systems, viz.,

Raw water system

Service water system

Process water system

DM water system

Fire water system.

I. Raw Water System -Water is always received in fire water reservoir from where it overflows to raw water reservoir. Inter compartment transfer and transfer from fire water reservoir to raw water reservoir is possible. Water can be received directly into any of these compartments. The storage capacity of the raw water reservoir (RWR) is generally based on 3 to 4 days requirement. Storage capacity of the Firewater Reservoir (FWR) is based on the Tariff Advisory Committee‟s Assessment of our plant. Raw

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water is pumped to Raw Water Treatment Plant using transfer pumps. The RW Reservoir has a Chlorination system. II. Service Water System -Raw water is pumped to a unit where suspended particles are removed. Filtered water is drawn off from this unit outlet and sent to the drinking water storage tank. A centrifugal pump with emergency power supply discharges water from this tank to all the safety showers and eye wash fountains in the plant as shown in the Figures 2-11, 2-12 respectively. Maintaining level is very critical in this tank. III. Process Water System- A second stream from suspended solids removal unit outlet flows through Activated Carbon Filters (ACF) operating in parallel. ACF outlet water free of organics and residual chlorine is drawn off as process water. One main stream flows to DM plant and another to process water system from ACF outlet. Process water (PW) flows to various parts of the plant in the following ascending order of distance. Cooling tower make up Main plant In general, PW also flows to utility points. For the operation ease, all the valves of PW system are kept in ground level and in one location. From this location water is branched and sent to the various user points. IV. DM Water System -After drawing Service water (SW) and Process Water (PW), chlorine free water with charged ions flows to DM plant. DM water is mainly used for the operation of boiler.The DM plant can be arranged in different forms according to the requirement. One such form which consists of a strong acid cation exchanger, followed by weak base anion exchanger, degasser and strong base anion exchanger with regeneration facility and acid / alkali proof tiled trench for effluent flow is described below. A DM water storage tank, and transfer pumps are provided. DM plant is operated manually. DM plant is designed to be in line continuously with say, for example 16 hours of operation. Balance time is available for regeneration. DM plant capacity is 60 m3/hr and regeneration is done after say, 480 m3 of DMW production. This is called one service cycle. DM Water pump discharges to Boiler, Main plant and also to DM plant for SBA regeneration. Effluents flow to Effluent Treatment Plant (ETP) by

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gravity. Regeneration chemicals, 33% HCl and 20% NaOH are stored in two separate tanks. V. Fire Water System -The Tariff Advisory Committee of the State Government gives the design requirements of Fire Fighting System. Fire hydrants (pipelines) are provided underground with anti corrosive tape wounded on it over molten bitumen throughout the plant. Water outlets with valves are provided from these hydrants which have sluice valves at various locations. These sluice valves enable us to attend underground leak in hydrant after isolation. Water from the individual outlets can be used for fighting fire. Outlets are provided in various forms – viz., Single hydrant. Double hydrant. Monitors. Deluge valve cum automatic sprinkler system for storage tanks. Main hydrant pumps motor driven as well as diesel engine driven take suction from the firewater reservoir with spill back and connect to underground fire water hydrant network. The network is continuously charged with jockey pumps (motor driven). These pumps also take suction from Fire Water Reservoir (FWR) and connect to the network. An underground room called the Firewater Pump House (FWPH) houses the pumps and enables flooded suction for the pumps. A Dewatering Pump is provided for the pump house. Pumps running indication are provided in DCS of Main Control Room (MCR), in repeater panel in MCR and in SafetyBuilding panel.

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Figure 2-11 Emergency Eye washer

Figure 2-12 Safety Showers

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2.8.2 Water Supply Water supply for both existing and proposed facility of TPL is obtained from CMWSSB. The receipt form CMWSSB for watersupply is enclosed in Annexure- 9.Water requirement for existing manufacturing facility - plant purpose, cooling, for process and steam makeup etc., is 2150m3/day. The proposed water consumption is 2150m3/day as existing requirements. There is no change in the water requirements.

Table 2-7Water Consumption for Existing and Proposed plant S.No. Sources of water requirement Existing (m3/day) Proposed (m3/day)

1. Cooling tower 230 220

2. Domestic 50 50

3. Process 1575 (1075 Fresh water + 1645 (1145 Fresh water + 500 500 Treated effluent) Treated effluent) 4. DM plant regeneration 75 55

5. DM Water Make up to Boiler 220 180

Total 2150 2150

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Figure 2-13Water balance for existing ECH plant

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Figure 2-14Water Balance for Proposed PO Manufacturing

2.8.3 Sewage Treatment Plant A combined Sewage treatment Plant for all TPL units is located at ECH plant for the Toilet and canteen waste water.

Design

Capacity : 160 cu.m / day

BOD : 400 mg / l

Flow : Complete mix

MLSS mg/l : 3000 - 8000

Hydraulic Retention Time : 18 – 36 Hrs

BOD Removal : 90 – 98 %

2.8.3.1 Description

The sewage water generated from above source is pumped to Raw Effluent collection tank. From Raw Effluent collection tank it is pumped to Aeration Tank through the Screen Chamber. The solid particles retained in the Screen Chamber are periodically removed for disposal. The screened effluent enters the Aeration tank. One number of 10 HP Aerator is

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provided to supply the necessary oxygen for biodegradation. Air diffusion is provided in the aeration tank through air blower and diffuser arrangement.

The overflow from aeration tank is then sent to the Clarifier tank for settling. The bioflocs formed in the aeration tank will be settled at the bottom of the Clarifier tank through clarifier rake mechanism placed inside the clarifier tank. The settled sludge will be re- circulated to the aeration tank in order to maintain MLSS concentration and the settled sludge will be pumped to the sludge holding tank through the return sludge pump. A part of the sludge is routed to the sludge draining bed (4 Nos). The clarified overflow will be collected in the clarified water tank from where it is pumped to the Pressure sand filter through filter feed pump in order to remove the suspended solids, organic matter & odour. Sodium hypo chlorite dosing is given manually in the filtered water tank with the help of dosing system for disinfection purpose.

The filtered water from Pressure sand filter will be collected in the filtered water tankand used for gardening.

2.8.3.2 Disposal of Treated Sewage Effluent

Thetreated sewage collected is fully utilized for green belt development.

The same treatment system will be used for the proposed facility also.

Figure 2-15 Sewage treatment Plant Process Flow

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2.8.4 Effluent Treatment Plant The wastewater is generated at ECH plant from the following sources:

Process waste stream from column bottom,

Cooling tower blow down,

Water treatment plant effluent,

Boiler blow down.

2.8.4.1 Treatment method for TPL

The treatment scheme envisages the following stages:

Primary Clarification -The effluent from ECH plant dehydrochlorination stream column bottom enters the primary clarifier. A flocculent of Magnofloc is added to the effluent. Sludge settles at the bottom and sent to rotary vacuum filter for separation. The clear effluent from clarifier overflow is sent for further treatment.

Cooling -The clear effluent from Primary Clarifier enters at the top of the induced draft cooling tower to reduce the temperature of the effluent. The cooled effluent collected at the bottom and pumped to Equalization Tank.

Flow Equalization -Effluent from the cooling tower, other process effluents like cooling tower blow down, water treatment plant effluents are collected in the Equalization Tank. The treatment system incorporate flow equalization in order to have a more consistent blend of organics to the downstream biological treatment process.

The Equalization Tank is provided with an agitator to keep the contents in suspension and for thorough mixing of all effluents stream.The capacity of the Equalization Tank is 790 m3 which is about a hydraulic retention time of 7 hrs.

pH control system -The combined effluent from Equalization Tank enters pH Correction Tank. Here pH of the combined effluent is neutralized if necessary, using hydrochloric acid/Sodium hydroxide. pH Correction tank is provided with Agitator to mix the contents.

The acid dosing system consists of 1 no. of Acid holding Tank, 2 nos Acid dosing pumps. The Acid addition is controlled by the control of dosing pumps. Also provision is given for 48 % sodium hydroxide dosing pumps. These pumps get supply

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fromSodium Hydroxide Tank. The effluent after pH Correction overflows from pH Correction Tank to Bio-reactor.

Nutrients required for the Bio- reactors are also added in the pH Correction tank .

Biological treatment -The Bio-reactors, Ten in Nos are the heart of this treatment process. The Bio-reactors are inoculated with specific culture developed to degrade the pollutants present in the combined effluent. Bio-reactors are provided with Floating type Surface Aerators to ensure an optimum Dissolved Oxygen (DO) level of 2 ppm and to suit the BOD reduction profile in the Bioreactors. The required quantity of micro- organism (MLSS) is to be maintained in the Bio-reactor by recycling sludge from the secondary clarifier downstream of the Bio-reactor.

Nutrients required for the microbial growth (Urea and Di-Ammonium Phosphate DAP) are added in required quantities in Bio – reactors.The overflows from Bio-reactors are collected in Bio-reactors overflow Tank. The treated effluent from Bio-reactors overflow tank is pumped by Flocculation Tank feed pump. Dissolved oxygen measurement systems are installed in Bio-reactors, to control the running of Surface Aerators so as to maintain an optimum DO level of 2 ppm.

Sludge Clarification -The effluents from Bio-reactors overflow tank containing around 4000 ppm MLSS enter the flocculation tank, by means of Flocculation feed pumps. In the flocculation Tank, Flocculants are added in required quantities and are mixed well by Agitator, where in poly-electrolyte is added in required quantity to enable the settling of Secondary Sludge to be effected in secondary Clarifier.

After the flocculation Tank, the effluent enters secondary clarifier,which is provided with a clarifying mechanism for settling the secondary solids. After settling the sludge collected at the bottom of the secondary clarifier the solid concentration has reached to 9000 ppm from 4000 ppm, this is taken to the secondary thickener while the overflow from the secondary clarifier flows by gravity to the treated effluent tanks.

The under flow from secondary clarifier with a concentration of about 9000 ppm MLSS are fed into Bio-reactor as sludge recycling. Bleeding fed into secondary thickener to get thickened sludge having a concentration of around 2.5%, while the overflow from Secondary Thickener flows to the Bio-reactor. The under flow is taken to a filter press for de-watering.

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Thickening- Filter press feed pumps takes the 2.5 % thickener sludge to a filter press system. In the filter press the sludge is further de-watered from 2.5 % to solid cakes containing around 70 % moisture. The filtrate is recycled back to bio-reactor, while the solid cakes are disposed to a secured landfill facility (M/s. Tamilnadu Waste Management Limited, Gummidipoondi)

Treated Effluent Tank - The over flow from the secondary clarifier flows to Treated effluent tanks. This is further pumped to sea after meeting the requirements of TNPCB norms for disposal by the existing treated effluent pumps.

Figure 2-16Effluent Treatment Plant in the site

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Figure 2-17Proposed Effluent Treatment Plant

2.8.4.2 Disposal of Treated Trade Effluent

The treated effluent collected in treated water tank is pumped to sea after meeting the norms of TNPCB.

The effluent is pumped through HDPE pipeline in to the sea with diffuser arrangements at the end. HDPE pipeline of 400 mm Outer Diameter, is provided for the out fall pipe line. The length of the pipe line between the Land Fall Point and the diffuser in the sea is 700m. Minimum clear velocity will be maintained continuously to avoid deposition and siltation in the pipe line.

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a) Design of Outfall Pipeline

Input Design: Table 2-8Dimensions of Outfall pipeline Parameters Value Outer dia in m 0.400 Deepwater wave height in m 0.75 Wave period in s 8.0 Wave crest angle with respect to the pipeline(deg) 10.0 Design depth in m 9.4 Current speed in m/s 0.2 Slop of sea bed in deg 2.3 Tk. Of conc.block in m 0.34 Outer dia.of conc. Blockin m 1.0 Dia of hole in m 0.41 Specific gravity of HDPE 0.955 Specific gravity of effluent 1.005 Specific gravity of sea water 1.025 Sea water temperature (⁰C) 25 M.O. C of pipe HDPE PE100, PN10 Soil type (1=clay,2=sand,3=gravel) 2 Buoyancy(50% air filled) 50

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Output Design Table 2-9Output Design Details Parameters Units Value

Buoyant force (100%) Kg 120

Buoyant Force (120%) Kg 144

Buoyant Force (200%) Kg 240

Volume of concrete m3 0.154 Weight of concrete in air kg 370

Weight f concrete in water kg 216

Spacing between blocks (for 120% buoyancy) m 1.8 c/c(selected- 1.5c/c)

Spacing between blocks (for 200% buoyancy) m 0.9 c/c (selected - 1.0 c/c)

The pipeline in intertidal zone of first 50m is buried 2m below the sea bed till the top of pipeline. For next 100m, the pipeline is buried 1.0m below the seabed till the top of the pipeline. The remaining portion of the pipeline will be laid on the seafloor which will be left for natural burial.The Layout of effluent disposal line is enclosed in Annexure-10.

2.9 STEAM SYSTEM

The requirement of steam for the propylene oxide plant is about 5T/hr. steam of medium pressure and low pressure is required.

The existing boiler produces 12.5T/hr steam at 17ksc(g).

2.10 COMPRESSED AIR SYSTEM

For the existing facility the compressed air is draw from TPL LAB plant through pipeline. For the proposed facility also the same system will be followed. In case of necessity, the existing instrument air compressor of 800 Nm3/hr capacity will supply the air to the proposed PO plant.

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2.11 INERT GAS SYSTEM

Inert gas is required for blanketing the tanks and vessels, flushing of instruments, process lines etc. the total quantity of nitrogen required will be about 50-60 m3/hr. It is proposed to draw this nitrogen from TPL LAB plant or by sourcing liquid nitrogen.

2.12 STORAGE FACILITIES

Storage for the following raw materials are available

Propylene – Bullets

Chlorine- Pipeline

Quick lime – 300MT (Godown)

It is proposed to modify the existing bullet to store propylene oxide.

2.13 POWER SUPPLY

Power supply for the existing ECH plant was 2.2 MW and the proposed Propylene Oxide will need a power requirement of 1.6 MW. Apart from the main power supply, the proposed plant also has a backup facilities in the form of a Generator run by Furnace oil with a capacity of 3.2 MW.

2.14 STACK DETAILS

Table 2-10Existing Stack Details

Stack Stack Stack Dia. Stack Gas Discharge Qty. Source Temp. Velocity (m) Height (m) (m3/hr) (oC) (m/sec.) Boiler 0.65 47.4 162 12.7 11450 Propylene heater 0.25 23.2 172 12.1 1050 DG 3.2 MW(Furnace oil) 1.0 31.5 241 13.5 30952 HCl Production unit stack 0.17 30 30 11.8 5000 Chlorine scrubber 0.17 30 32 11.7 800

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Table 2-11Existing stack details utilized for proposed facility

Stack Stack Stack Stack Gas Discharge Qty. Source Dia. Temp. Velocity Height (m) (m3/hr) (m) (oC) (m/sec) Boiler 0.65 47.4 162 12.7 11450 DG 3.2 MW 1.0 31.5 241 13.5 30952 (Furnace oil) Chlorine scrubber 0.17 30 32 11.7 800

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3 BASELINE ENVIRONMENTAL STATUS

3.1 INTRODUCTION

Environment is a dynamic system which differs from place to place and changes over a period of time. This change can be natural or anthropogenic. Natural changes occurring in the environment is due to many factors and it is out of bounds to control by mankind. Anthropogenic changes or impacts on the environment can be identified and suitable remedial measures can be implemented to attenuate the impacts. To assess the impact of a project or activity it is necessary to generate baseline environment information in the proposed project site. Base line environmental information helps the decision makers to evaluate the present scenario and to predict the impact the project might pose to the environment. Data on the prevailing environmental components such as air, meteorology, water, noise, soil, ecology, and socio-economics are collected and analyzed. The monitoring reports of the components are attached as Annexure-11.

3.2 Air and Meteorological Environment

The objective for collecting data on baseline ambient air quality is to predict the incremental pollutant concentration that might occur during the construction and operation phase of the project. If adverse impacts are anticipated suitable mitigation measures are proposed at the design stage of the project itself. This survey gives information on type of air pollutant which will have significant impact near the vicinity of the project location. To achieve this objective, 6 ambient air quality stations are selected within a radius of 10 km from the project site. The air quality stations are selected based on the predominant wind direction, wind speed and atmospheric stability category in the region which governs the plume rise and dispersion of air pollutants. Selection of the stations are also based on locations of existing sources of air pollution and sensitive receptors such as hospitals, schools, thickly populated residential localities, elderly homes etc.

3.2.1 Reconnaissance Reconnaissance survey was conducted upto 10 km radius from the project site which is located in Northerncoast of Tamil Nadu in Thiruvallur District. The project site is situated in a flat terrain with ground elevation varying from about 3-6 meters above mean sea level. The surrounding impact zone of 5 km radial distance consisting of the rural, urban and industrial areas is marked. In general the study area experiences predominant wind from SW-W-WWS and SE. direction during the season March to May, The baseline status of air environment

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includes identification of specific air pollution parameters expected to have significant impacts and assessing their existing levels in ambient air within the impact zone. The baseline status of air environment with respect to the identified air pollutants can be assessed through air quality monitoring programme using methodically designed air monitoring network.

To establish the baseline monitoring status of air environment in the study area during the period of April, 2014, 6 AAQM locations within the radius of 5 kms (with one station outside the radius) were selected using network design criteria and monitored as per CPCB guidelines (Twice a week sampling and 24 hr continuous sampling each day). The selected sampling locations reported in Table 3-1and Figure 3-1 below. 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 16th September 2009, NAAQ standards

Table 3-1Locations of the Ambient Air Quality Stations S.No Sampling station Geographical Aerial distance from Direction with coordinates the site in (km) respect to site 1. AAQ1 - Site 13°10'37.64"N SITE NA 80°16'58.00"E 2. AAQ2-Sekkadu 13°10'23.73"N 3.2 West Village 80°15'0.28"E 3. AAQ3 - 13°10'1.49"N 1.7 South East Thiruvottiyur 80°17'40.42"E 4. AAQ4 - Manali New 13°12'22.12"N 3.2 North Town 80°16'30.71"E 5. AAQ5- Madhavaram 13° 9'15.58"N 4.5 South West 80°14'52.71"E 6. AAQ 6 - Korrukupet 13° 7'27.56"N 5.9 South 80°16'30.15"E

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Figure 3-1Google earth Image Showing the Location of Air quality Sampling Stations 3.2.2 Micro metrology The study of micro-meteorological conditions of a particular region is of utmost importance to understand the variations in ambient air quality status. The prevailing micrometeorology at project site plays a crucial role in transport and dispersion of air pollutants released from the plant. The persistence of the predominant wind direction and wind speed at the project site will decide the direction and extent of the air pollution impact zone. The principal variables which affect the air pollution dispersion and resultant air quality status micrometeorology are horizontal transport and dispersion (average wind speed and directions), convective transport and vertical mixing (atmospheric stability) and also topography of the area towards 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 wind speed, wind direction, temperature and solar radiation were

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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 terrain is flat and elevation varied from 3-6 m above mean sea level when one travels from coast and landward. The wind rose for the months of March, April and May2014 shows the predominant winds from direction. The wind directions during the study period are SW-W- WSW and SE. Accordingly, the impact zone will be spread in NE-E-ENE 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 25-40°C while the relative humidity range from 49-79% at project site. The meteorological data collected during monitoring is used for interpretation of baseline status and to simulate the meteorological conditions for prediction of impacts in modeling studies.

Table 3-2 Meteorological observations

S.No Parameter Observation 1 Wind Direction SW-SE-W-WSW 2 Wind Speed Range 2 to 8.8 m/sec 3 Annual Average Rainfall 1211 mm 4 Average Wind Speed 3 m/sec 5 Temperature Range Max. Temp: 40°C Min. Temp: 25°C 6 Average Temperature 32°C 7 Humidity Range (24hr) 49 to 79 % 8 Cloud cover Partly cloudy

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Figure 3-2 Wind rose Data for Manali 3.2.3 Base line air quality status The, mean value of Particulate Matter (PM2.5), Particulate Matter (PM10), Sulphur Dioxide 3 3 (SO2), Nitrogen Dioxide (NO2), CO μg/m ,Pb μg/m ,O3,NH3, Benzene, Benzo (a) pyrene, As and Ni at various monitoring locations during the AAQ monitoring period. The concentration 3 of SO2 ranged from 11-15 μg/m across the sampling stations. The highest concentration of 3 3 SO214.3 μg/m was observed at AAQ3. The concentration of NO2 ranged from14-25μg/m 3 across the sampling stations. The highest concentration of NO2was 25 μg/m was observed

atAAQ1 and AAQ3. The concentration of SO2and NO2 is well below the permissible level of 80 and 80 μg/m3.The concentration of PM2.5ranged between 21-32 μg/m3 andPM10ranged between 51-60 μg/m3. The concentrations of PM10 and PM2.5was found to be below the permissible limit of100 and 60 μg/m3respectivelyat all the sampling stations. The

concentrations CO, Pb, Benzene, Benzo (a) pyrene,O3, As and Ni were BDL at all the sampling stations.

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Table 3-3Test Methods used for the Analysis of ambient air quality parameters S.No Parameters Analytical method NAAQ standards: 2009

1. Sulphur Dioxide (SO2), IS: 5182 (Part - 2):2001 50 (Annual) 80 (24 μg/m3 (Reaff:2006) Hours)

2. Nitrogen Dioxide (NO2), IS: 5182 (Part - 6): 2006 40 (Annual) 80 μg/m3 (24 Hours) 3. Particulate Matter IS: 5182 (Part - 23): 2006 40 (Annual) 60 (PM2.5), μg/m3 (24 hours) 4. Particulate Matter IS:5182 (Part– 23): 2006 60 (Annual) 100 (PM10), μg/m3 (24 hours) 5. COμg/m3 IS: 5182 (Part – 10): 1999 2 (8 hours) 4 (1hour) (Reaff:2006) 6. Pbμg/m3 IS: 5182 (Part – 22): 2004 0.5(Annual) 1 (24 hours) (Reaff:2006) 3 7. O3, μg/m IS: 5182 (Part – 9): 1974 100(8hours) 180 (1hour) 3 8. NH3, μg/m APHA (air) 2nd edition 100(Annual) 400 (24 (Indophenol-blue method) hours) 9. Benzene, μg/m3 IS: 5182 (Part – 11): 1999 (R 5 (Annual) 5 (Annual) A:2009) 10. Benzo (a) pyrene, ng/m3 IS: 5182 (Part – 12): 2004 (R 1 (Annual) 1 (Annual) A: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) 13. Total VOC μg/m3 USEPA TO17 - -

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Table 3-4 Summary of findings of ambient air quality monitoring (Average) S.No Sampling stations Parameters 3 SO2 NO2 PM2.5 PM10 CO Pb O3 μg/m NH3 Benz- Benzo (a) As Ni TVOC μg/m3 μg/m3 μg/m3 μg/m3 μg/m3 μg/m3 μg/m3 ene pyrene ng/m3 ng/m3 (μg/m3) μg/m3 ng/m3 1. AAQ1 - Site 13 25 32 60 BDL BDL BDL 7.2 BDL BDL BDL BDL 1.5 (DL 0.005) (DL (DL10) (DL1) (DL1) (DL1) (DL5) 0.05) 2. AAQ2-Sekkadu 13.2 23 30 56 BDL BDL BDL 6.3 BDL BDL BDL BDL 3.1 Village (DL0 .005) (DL (DL10) (DL1) (DL1) (DL1) (DL5) 0.05) 3. AAQ3 - 14.3 25 24 54 BDL BDL BDL 7.1 BDL BDL BDL BDL 2.3 Thiruvottiyur (DL0.005) (DL (DL10) (DL1) (DL1) (DL1) (DL5) 0.05) 4. AAQ4 - Manali 13.8 20 21 51 BDL BDL BDL(DL 8.6 BDL BDL BDL BDL 2.6 New Town (DL 0.005) (DL 10) (DL1) (DL1) (DL1) (DL5) 0.05) 5. AAQ5- 12.9 19 25 60 BDL BDL BDL(D1 4.3 BDL BDL BDL BDL 2.1 Madhavaram (DL0 .005) (DL 0) (DL1) (DL1) (DL1) (DL5) 0.05) 6. AAQ 6 - 11.2 14 30 60 BDL BDL(DL BDL(DL 5.2 BDL BDL BDL BDL 2.6 Korrukupet (DL0 .005) 0.05) 10) (DL1) (DL1) (DL1) (DL5)

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3.3 NOISE ENVIRONMENT

The study area consists of 10 km radiusfrom the site which consists of urban, rural and industrial area. The noise generated due to operation of individual process units at an industrial site cause significant impacts on the surrounding environment including nearby residential areas. Such operations fall in the category of continuous primary sources. 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 noise sources.

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 level generally does not reflect any seasonal variation, however, the wind direction, rain, snow, fog or any other barrier as well as direction of source play significant role in regulating the noise propagation and ultimately the intensity of impact.

The current status of noise environment around the existing TPL industries is assessed through identification of major noise sources, characterization of such noise sources, measurement of prevailing ambient noise levels in the study area and measurement of noise levels due to vehicular movements, according to existing land use pattern. The prevailing noise levels in the neighboring industrial areas shall represent the baseline status for assessment of noise impacts from proposed developments. The baseline study for noise environment has been carried out through reconnaissance in the impact zone, identification of representative sampling locations and monitoring of prevailing noise levels during study period.

3.3.1 Reconnaissance Reconnaissance survey was conducted to locate the existing noise generating sources and identify suitable locations to evaluate background noise levels. The project site is located in northcoast of Tamil Nadu in Thiruvallur district. The surrounding impact zone of 10 km radial distance consisting of the rural, urban and industrial areas is marked. State highways number SH 56 passes by the site.

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Table 3-5Table Summary of findings of Noise monitoring in the study area (Average) S.No Date Location Geographical coordinates Noise level in dB(A) Leq

Day Night

1. 19.05.2014 Retteri 13°09'02.0"N and 080°12'56.7"E. 69 55

2. 19.05.2014 Tiruvottiyur 13°11'02.5"N and 080°19'00.5"E 72 60 sea shore

3. 19.05.2014 Jai-hind Nagar 13°11'04.2"N and 080°18'10.7"E. 59 49

4. 19.05.2014 Mathur 13°09'45.1"Nand 080°14'59.6"E. 50 40

5. 19.05.2014 ChinnaSekkadu 13°09'48.3"N and 080°15'30.5"E. 57 47

Since the project site is located in industrial zone there are many small scale and few large scale industries which contribute to baseline noise levels. The heavy vehicular traffic on state highway SH 56contributes significantly to the noise levels in study area. The commercial activities in the individual villages also influence the background noise levels. The noise levels in surrounding selected villages, industrial complexes and junction of the state highways were monitored using a precision noise level meter.

3.3.2 Community noise levels The community noise is determined by recording the day-night noise level (Ldn). Ldn is defined as the 24 hours equivalent sound level derived with a penalty of 10 dB (A) is added to the measured instantaneous noise level measured during night time. i.e. from 2200 hrs to 0600 hrs. This is because the same level of noise during night time is more annoying than day time. Ldn for a given location is calculated from hourly equivalent sound levels (Leq) using the following equation:

Ldn = 10 log [1/24{16(10(Ld/10)) + 8(10(Ln+10)/10))}]

Where, Ld – equivalent noise level during day time (0600 to 2200 hrs)

Ln – equivalent noise level during night time (2200 to 0600 hrs)

3.3.3 Baseline Noise status The prevailing ambient noise levels along, the sites were monitored at 5 locations. During the study period day time noise levels varied between50 to 72dB (A)across the sampling stations

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and night time noise levels varied from40 to 60 dB (A) across the sampling stations. The details of the monitoring stations are presented in Table 3-5. 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.

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)

3.4 WATER ENVIRONMENT

The study area has medium sized water courses namely Periyathoppu Lake, Madhavaram Lake, Korttalaiyar River etc. The project site is located 3.3 Km west of the Bay of Bengal. The project site is located in Manali, where Petro Chemical industries are concentrated.

3.4.1 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

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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 yield of large diameter wells tapping the weathered mantle of crystalline rocks ranges from 100 to 500 lpm and are able to sustain pumping for 2 to 6 hours per day. The yield of bore wells drilled down to a depth of 50 to 60 m ranges from 20 to 400 lpm. The yield of successful bore wells drilled down to a depth of 150 m bgl during the ground water exploration programme of Central Ground Water Board ranged from 1.2 to 7.6 lpm.

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Figure 3-3 Hydro geological map of Thiruvallur district

3.4.2 Reconnaissance Reconnaissance survey was undertaken to ascertain the location of water bodies viz streams, rivers, lakes etc. 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 about 1211 mm per year. The South west monsoon season is from July – Septemberand North east monsoon is from October to December. Groundwater is the principal source for domestic and drinking purposes in almost all villages near the study area. The water samples were collected and analyzed by standard test methods which are given in table: The prevailing status of water quality has been assessed during March - May.Three sampling stations forground water and sevensampling stations for surface water were selected for the study the details are given in Table: 3-7and the findings of the water quality monitoring study is summarized in Table 3-8

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Table 3-6 Summary of 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 asAl IS:3025 (Part - 55) 2003 (Reaff 2009) 10. Chromium asCr IS:3025 (Part - 52) 2003 (Reaff 2009) 11. LeadasPb 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 IS:3025 (Part-58)-2006 as O2 16. Dissolved Oxygen (mg/l) IS:3025 (Part - 38)1989 (Reaff 2009) 17. Salinity - 18. Copper as Cu IS:3025 (Part - 42)1992 (Reaff: 2009) 0 nd 19. BOD,5 days @20 C as O2 5210B APHA22 Edn 2012 20. Total coliform bacteria IS:1622 1981 (Reaff: 2009) (MPN/100ml) 21. F-Coli IS:1622, 1981 (Reaff: 2009)

3.4.3 Baseline Water quality Status Physico-chemical parameters along with biological indicators of pollution have been identified for assessing the baseline status of water environment and identification of impacts due to proposed developmental activities. In order to assess the water quality, standard methods (IS Standards) were followed for sample collection, preservation and analysis in the laboratory. The water quality was assessed by various Physiochemical parameters such as pH, Electrical conductivity(µohms/cm), Color(Hazen Unit), Total Hardness

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(mg/l),Aluminium(mg/l), Zinc (mg/l), Total Alkalinity (mg/l), Chloride (mg/l),Cadmium (mg/l), Total Dissolved Solids (mg/l), Sodium (mg/l), Lead(mg/l), Chromium (mg/l), copper (mg/l) and chemical Oxygen Demand (mg/l).

Table 3-7Locations of the water quality stations S.No Location Geographical coordinates Aerial distance from the site in (km) 1. Nala Near Site 13°10'41.85"N 0.02 80°16'56.29"E 2. B.canal backside of 13° 9'35.29"N 1.8 CPCL 80°17'13.00"E 3. Thiruvottiyur Shore 13°11'02.5"N 4.7 080°19'00.5"E 4. Retteri 13°09'02.0"N 7.4 080°12'56.7"E 5. MadhavaramEri 13°09'45.1"N 3.7 080°14'59.6"E 6. Opp MFL bus stop 13° 10.632'N 1.18 80° 16.244'E 7. Near Deccan Bitumen 13°10'42.18"N 2.9 80°15'8.26"E 8. Chinnasekkadu 13°09'48.3"N 4.6 080°15'30.5"E 9. Near Thiruvottiyur 13° 9'28.93"N 2.5 Railway station 80°17'42.80"E 10. Jai-hind Nagar 13°11'04.2"N 2.7 080°18'10.7"E

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Figure 3-4Google Earth Image Showing the Location of Sampling Stations

Figure 3-5 Water sampling at different locations

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3.4.4 Surface water Quality The water quality status in the study area revealed heavy pollution of surface water at all the surface water quality monitoring stations. The pH of the surface water ranged from 6.10 to 8.18 across the sampling stations. The Electrical conductivity of the sample ranged from 2770 to 30300µohms/cm across the sampling stations. The E.C value was the highest at Thiruvottiyurshore. The concentration of Total Dissolved solids (TDS) rangedbetween 1650 to 20260mg/l across the sampling stations. The highest TDS value of 20260 mg/l was observed at Thiruvottiyurshore. The total hardness varied from 380- 8500 mg/l. The concentration of chlorides varied from 504 to 19052.96 mg/l across the sampling stations. High concentration of chlorides was observed at Thiruvottiyur shore.Other parameters like aluminium, cadmium, Chromium Lead were well below the surface water quality standards.

Table 3-8Summary of analytical results on Surface water samples collected in the study area S.N Parameters Sampling stations Drinking water IS o 10500 : 2012 Nala B.Canal Thiruv Retteri Madha Opp.M Near Desira Permissibl Near at back ottiyur varam FL Decca ble e Site side of shore Eri n CPCL Bitum in 1. pH (at 25°C) 6.76 6.46 6.10 6.70 7.59 8.18 7.03 6.5-8.5 No relaxation 2. Electrical 3240 3170 30300 2770 4130 8040 2930 -- -- conductivity( µohms/cm) 3. Color 2.0 3.0 BDL 3.0 3.0 1.0 3.0 5 15 (Hazen Unit) (DL 1) (max) 4. Total 560 540 8500 380 540 2000 380 200 600 (max) Hardness as (max) CaCO3 (mg/l) 5. Aluminium BDL BDL BDL BDL BDL BDL BDL 0.03 0.2 (max) (mg/l) (DL 0.02) (DL 0.02) (DL 0.02) (DL 0.02) (DL (DL 0.02) (DL (max) 0.02) 0.02) 6. Zinc (mg/l) 0.25 0.91 0.08 0.04 0.05 0.13 0.07 5 15 (max) (max) 7. Total 640 600 140 320 560 1380 280 200 600 (max) Alkalinity as (max)

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S.N Parameters Sampling stations Drinking water IS o 10500 : 2012 Nala B.Canal Thiruv Retteri Madha Opp.M Near Desira Permissibl Near at back ottiyur varam FL Decca ble e Site side of shore Eri n CPCL Bitum in CaCO3 (mg/l) 8. Chloride 633.45 593.86 19052.9 504.78 772 700 673 250 1000 (mg/l) (max) (max) 9. Copper (mg/l) 0.03 0.03 0.14 0.03 0.04 0.19 0.04 0.05 1.5 (max) (max) 10. Total 1880 1810 20260 1690 2480 1950 1650 500 2000 Dissolved (max) (max) Solids (mg/l) 11. Cadmium BDL BDL BDL BDL BDL BDL BDL 0.003 No (mg/l) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL (max) Relaxation 0.01) 12. Sodium 350 330 11410 290 456 280 380 - - (mg/l) 13. Total BDL BDL BDL BDL BDL BDL BDL 0.05 0.05 (max) Chromium (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL (max) (mg/l) 0.01) 14. Lead (mg/l) BDL BDL BDL BDL BDL BDL BDL 0.01 No (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL 0.01) (DL (max) Relaxation 0.01) 15. Chemical 60 88 256 40 52 280 40 - - oxygen

demand as O2 (mg/l) 16. Temperature 29.5 29.8 29.8 29.3 29.5 29.7 29.7 - - (oC) 17. Dissolved BDL BDL 5.80 8.10 7.80 8.30 5.20 - - Oxygen (DL 0.1) (DL 0.1) (mg/l) 18. Salinity (ppt) 1.15 1.07 34.40 0.91 1.39 69.7 1.21 - - 19. BOD, %days 2.0 2.0 3.0 2.0 2.0 3.0 1.0 - - o @20 C as O2 (mg/l)

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S.N Parameters Sampling stations Drinking water IS o 10500 : 2012 Nala B.Canal Thiruv Retteri Madha Opp.M Near Desira Permissibl Near at back ottiyur varam FL Decca ble e Site side of shore Eri n CPCL Bitum in 20. Total ------140 130 500 <2 <2 6.5 8.5 coliform Bacteria (MPN/100ml ) 21. Fecal ------70 50 300 Absent Absent - - coliform (MPN/100ml )

3.4.5 Ground water quality The pH of the ground water was alkaline and ranged from 6.08 to 6.35 across the sampling stations. The Electrical conductivity of the sample ranged from 1602 to 2610µohms/cmacross the sampling stations. The E.C value was the highest atJai-hind Nagar. The concentration of Total dissolved solids (TDS) ranged between 910.0 to 1620 mg/l across the sampling stations. The highest TDS value of 1620 mg/l was observed at Jai-hind Nagar. The total hardness varied from 120-760 mg/l. The concentration of chlorides varied from 183-475mg/l across the sampling stations. High concentration of chlorides was observed at Jai-hind Nagar. The concentration of other parameters like Aluminium (mg/l), Chromium (mg/l), Lead (mg/l) and Chromium (mg/l) were below the detection limit.

Table 3-9Results of Ground water samples collected in the study area S.No Parameters Sampling Stations Drinking water IS 10500 : 2012

Chinnasekkadu Near Thiruvottiyur Jai-hind Desirable Permissible Railway station Nagar 1. pH (at 25°C) 6.25 6.35 6.08 6.5-8.5 No relaxation 2. Electrical conductivity 2580 1602 2610 -- -- (µohms/cm) 3. Color (Hazen Unit) BDL 2.0 5.0 5 (max) 15 (max) (DL 1)

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4. Total Hardness as 760 290 120 200 (max) 600 (max) CaCO3 (mg/l) 5. Aluminium (mg/l) BDL BDL BDL 0.03 (max) 0.2 (max) (DL 0.02) (DL 0.02) (DL 0.02) 6. Zinc (mg/l) 0.12 0.04 0.12 5 (max) 15 (max) 7. Total Alkalinity as 320 230 400 200 (max) 600 (max) CaCO3 (mg/l) 8. Chloride (mg/l) 297 183 475 250 (max) 1000 (max) 9. Copper (mg/l) BDL 0.02 0.02 0.05 (max) 1.5 (max) (DL 0.01) 10. Total Dissolved Solids 1560 910 1620 500 (max) 2000 (max) (mg/l) 11. Cadmium (mg/l) BDL BDL BDL 0.003 No (DL 0.01) (DL 0.01) (DL 0.01) (max) Relaxation 12. Sodium (mg/l) 160 96.0 270 - - 13. Total Chromium as Cr BDL BDL BDL 0.05 (max) 0.05 (max) (mg/l) (DL 0.01) (DL 0.01) (DL 0.01) 14. Lead (mg/l) BDL BDL BDL 0.01 (max) No (DL 0.01) (DL 0.01) (DL 0.01) Relaxation 15. Chemical oxygen 12 16.0 20 - -

demand as O2 (mg/l) 16. Temperature (oC) 29.7 29.6 29.6 - - 17. Dissolved Oxygen 6.20 5.70 6.30 - - (mg/l) 18. Salinity (ppt) 0.53 0.33 0.85 - - 19. BOD, %days @20oC as 1.0 1.0 1.0 - - O2 (mg/l) 20. Total coliform Bacteria 17 <2 110 6.5 8.5 (MPN/100ml) 21. Fecal coliform 8 Absent 80 - - (MPN/100 ml)

3.5 SOIL ENVIRONMENT

Assessment of soil characteristics is of paramount importance since the vegetation growth, agricultural practices and production is directly related to the soil fertility and quality. 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 7.22 to 8.26 across the sampling stations. The Electrical conductivity of the soil samples ranged from155 to 211µohms/cm across the sampling stations. The

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E.C value was the highest at S3 sampling stations. The concentration of chlorides varied from 197.95mg/kg to 346.42mg/kg across the sampling stations. A high concentration of chlorides was observed at S4 sampling station. The texture of sandy soil varied from 67.25 to 92.94%. Thehighest percentage of sandy soil 92.94% was recorded at Mathur. The concentration of total phosphorus ranged from 11.07-70.6 mg/kg and organic matter ranged from 10 to 30 % across the sampling stations. Other parameters like cadmium (mg/l), Chromium (mg/l), were below the detection limit.

Table -3-10Summary of findings of soil sampling studies in the study area (Average) S.No Aerial Location Geographical coordinates distance

1 3.80Km Mathur (S1) 13°9'822.0"N and 80°14.941"E 2 1.2Km Opp MFL bus stop (S2) 13°10.664"N and 80°16.226"E 3 2.69Km Chinnasekkadu (S3) 13°9.917"N and 80°15.601"E 4 2.80Km KCP limited (S4) 13°9.598"N and 80°18.005"E

Figure 3-6Google Earth Image showing Location of Soil sampling

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Figure 3-7 Soil Sampling Location Table 3-11Summary of analytical results of soil samples collected at different sampling stations S.No Parameters with units Sampling stations S1 S2 S3 S4 1. pH at 25°C (1:10) 7.22 7.85 8.26 7.31 2. Electrical Conductivity (1:10) 155.0 184 211.0 202.0

3. Color Light grey Brown Grey Light brown 4. Chlorides (mg/kg) 270 198 297 346 5. Bulk density (gm/cc) 1.50 1.28 1.20 1.49 6. Sodium (mg/kg) 180.0 13.0 100.0 210.0 7. Potassium (mg/kg) 20.0 10.0 10.0 30.0 8. Organic matter (%) 0.43 0.24 0.10 0.04 9. Zinc (mg/kg) 18.15 37.29 26.27 8.20 10. Lead (mg/kg) 6.50 6.95 3.50 1.0 11. Cadmium (mg/kg) BDL (DL-0.1) 0.89 BDL BDL 12. Copper (mg/kg) 82.84 13.41 12.94 4.89 13. Porosity (%) 0.41 0.47 0.45 0.36 14. Total KjeldahlNitrogen (%) 0.053 0.046 0.05 0.049 15. Organic carbon (%) 0.38 0.21 0.08 0.04 16. Cation Exchange Capacity (meq/Kg) 8.2 4.7 1.3 1.4 17. Chromium (mg/kg) BDL BDL BDL BDL (DL 0.1) (DL 0.1) (DL 0.1) (DL 0.1)

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S.No Parameters with units Sampling stations S1 S2 S3 S4 18. Total phosphorus (mg/kg) 11.07 70.6 39.7 61.41 19. Soil texture (%) Sand 92.94 67.25 72.47 92.18 Silt 1.23 4.68 3.18 1.08 Clay 5.83 28.07 24.35 6.74

3.6 LAND USE

The land use/land cover in the study area of 10 km radius from the proposed change of product mixfor Tamilnadu Petroproducts 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 Towns/ cities (urban)was the most dominant class covering 40% followed by (Agricultural land) crop land and Fallow land at 22.15 % and 14.08 % coastal wetland covers 5.66 %, (water bodies)reservoirs/ Lakes/ ponds and River/Stream/ canal covers 4.24 % and 3.08 %. The Land use Map is given in Figure 3-6. There is no sensitive locations like Reserve Forests, National Parks etc within the study area.

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Figure 3-8 Land use / Land cover Map of the Study area Table 3-12Landuse Classification and Area Land use Land cover Class Area (Sq. Km.) Coastal Wetland 15.54 Cropland 60.83 Fallow land 38.67 Inland Wetland 0.22 Plantation 12.27 Reservoirs/ Lakes/ Ponds 11.63 River/ Stream/ Canals 8.47 Rural 7.89 Salt affected land 0.72 SandyArea 0.51 Scrub land 7.32 Urban 110.52

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Figure 3-9 Land Use classification chart

3.6.1 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.

The elevation of the area ranges from 183 m above mean sea level (amsl) in the west to sea level in the east. Four cycles of erosion has given rise to a complex assemblage of fluvial, estuarine and marine deposits. 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. The below geomorphologic map is taken from the Multi-temporal satellite data from Resourcesat- 1 LISS III

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Project Site

Figure 3-10 Geomorphologic map of the project site

3.7 TERRESTRIAL ECOLOGY

The study of terrestrial ecology within the study area of 10 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.

3.7.1 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.

3.7.2 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.

3.7.3 Mangrove Eco-system This type of ecosystem existed in western bank of the river Korattailar. This is dominated by Avicinnia marina. Sesuvium portulacastrum&Suaeda maritima. These plants are periodically washed by the tides and as result in some areas quick sands are noticed.

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3.7.4 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.

3.7.5 Agro Ecosystem Rice and banana species of plant are the main species of this ecosystem.

3.7.6 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 grasses like Cyanodon dactylon followed by Parthenium hysterophorus, Croton sparsiflorusand trees like Acacia nilotica, Azadirachta indica, Annona squamosa, Delonix regia, Ficus benghalensis within the study area.

Table 3-13List of Domestic Flora in the Study Area SI. No Botanical Name Family Name Vernacular Name (Tamil) 1 Annona squamosa Annonaceae Atta 2 Alstonia scholaris Apocynaceae Elilappalai 3 Anthocephalus chinensis Rubiaceae Vellai 4 Acacia nilotica Fabaceae Karuvelamaram 5 Bambusa arundinacea Gramineae Mullumungil 6 Bauhinia variegata Fabaceae/Leguminosae Shemmandarai 7 Citrus aurantifolia Rutaceae Yelumicham 8 Delonix regia Caesalpiniaceae Mayaram 9 Ficus religiosa Moraceae Arasu 10 Ficus benghalensis Moraceae Mayarum 11 Mangifera indica Anacardiaceae Maangai 12 Psidium guajava Myrtaceae Koyya 13 Phoenix sylvestris Arecaceae Lcham 14 Tamarindus indica Fabaceae Amilampul 15 Ziziphus mauritiana Rhamnaceae Elentha

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3.7.7 Fauna i. Domestic - The domestic animals are mainly mammals like cow, goat, cat, dog etc.

ii. Wild Animals -Since the natural forests constitute negligible of the forest area and since they are in isolated pockets, the wild life does not offer a wide spectrum of species. 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.

Table 3-14List of Wild Fauna in the Study Area SI.No Zoological Name Common Name 1 Ahaetulla nasuta Green whip snake 2 Athene brama Spotted owlet 3 Canis aureus Jackal 4 Eudynamys scolopacea Koel 5 Felis chaus Jungle cat 6 Funambulus pennantii and F palmarum Palm squirrels 7 Francolinus pondicerianus Patridge 8 Harpestes edwardsi Comman mongoose 9 Haliastur indus Brahminy kite 10 Lepus nigricollis Hare 11 Manis crassicaudata Pangolin 12 Milvus migrans govinda Pariyakite 13 Naja naja Cobra 14 Ptyas mucosa Comman rat snake 15 Suscus sp Shrew

Table 3-15Amphibian 1 Bufo melanostictus Toad 2 Rana cyanophlyctis Frog 3 Rana tigrina Frog 4 Rhacophorus bimaculatus Tree frog 5 Hyla arborea Tree frog

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Table 3-16 Rodents 1 Bandicota indica Badicoot 2 Mus musculus Mouse 3 Rattus rattus Rat 4 Ratufa indica Squirrel

3.8 AQUATIC ECOLOGY

The specific biological species (Fishes, Phytoplankton, Zooplankton etc.) for a particular environmental conditions are the best indicators of environmental conditions are the best indicators of environmental quality. 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.

3.8.1 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.

3.8.2 Fishes The fishes/ aquatic fauna of the study area is reported based on the field sampling and confirmed by the local people and secondary data provided by Thiruvallur district office is listed. The fishes like Chirocentrus dorab, Lesser Sardines, Anchoviella, Flying Fish, Sciaenids, Caranx, Mackerel, Seer, Crabs found in good number in the study area.

Table 3-17List of Zooplankton identified within the Study Area S.No Zooplankton 1. Favela species 2. Tintinnopsis species 3. Globigerina species 4. Acartia danae 5. Acartia erythraea 6. Acartia clausi 7. Calanns finmarchicns

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8. Paracalanus parvus

9. Microsetella norvegica

10. Microsetella rosea

11. Corycaeus danae

12. Oithona rigida

13. Oncaea venusta

14. Gastropod veliger

15. Brachionus urceolaris

16. Brachionu calyciflorus

17. Monostyla bulla

18. Paracalanus parvus

19. Labidocera acuta

20. Euterpina acutifrons

21. Macrosetella gracilis

22. Metis jousseaumei

23. Copilia vitrea

24. Oithona brevicornis

25. Bivalve veliger

26. Copepod nauplius

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.

3.9 SOCIO ECONOMIC ENVIRONMENT

Manali is an Industrial town and Municipality in Thiruvallur district in the Indian state of Tamil Nadu. It is located in north of Chennai City. As of 2011, the town had a population of 35,248. Manali is a Northern Suburb of Chennai city. It borders Tiruvottiyur to the east, MathurMMDA to the west, Kodungaiyur to the south, 100 ft road to the North. The main throughfares in the area is KamarajarSalai,Chinna Mathur Road,Parthasarathy street. Main street in Manali isKamarajarSalai,

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school Street. Manali area is the home to petroleum refinery (Chennai Petrochemical Corporation Limited or CPCL) and allied petrochemical industries.

3.9.1 Social Indicators 3.9.1.1 Demography:The population of the district is 3728104 as per 2011 Census. The male population is 1876062 (50.32%) and the female population is 1852042(49.67%). The Schedule Caste population is 22% of the total population. The area of the district is 342243Ha. 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 census. It shows the awareness of importance of girl child. The average national sex ratio is 940 as per Census 2011.

3.9.1.2 Population Density: The population density of the district is 1098 as per 2011 census, but it was 776 as per 2001 census.

3.9.1.3 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 3-11 District Decadal Growth Rate

3.9.1.4 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.

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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 3-12 Statistics of Main workers

3.9.1.1 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 83912 acres are under paddy cultivation. The ground nut cultivation is in 10348 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 683535 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 683535 live stocks in the district.

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Operational Land Holding 250000

195116 200000

150000

100000

50000 24549 10426 3079 2955 0

Source- Agriculture Census 2005

Figure 3-13Bar chart for Operational land holding

3.9.1.1 Education:Average literacy rate of Thiruvallur as per 2011 census is 84.03 compared to 76.94 of 2001. The male and female literacy were 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).

Figure 3-14 School in Manali

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3.9.1.2 Health: There are 45 Primary health centers in the district. The medical facilities are available in the district as Chennai City is nearby and also the district is more urbanized.

3.9.2 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

Source: Department of Economics and Statistics, GoTN Figure 3-15Product at net and constant prices 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

Source: Department of Economics and statistics, GoTN

Figure 3-16 Per Capita Income at Net and Constant Prices 3.9.3 Land use and Resource availability The types of soil predominantly found are red non-calcareous and coastal alluvial. The soil found in the coastal region is of the erinaceous type (sandy), suitable for casuarina plants. The predominant soil types are sand and sandy loam. Saline and alkaline soils also noticed in some patches of Ambathur, Ponneri and Thiruvallur Division. The Land use data of Thiruvallur district is given below in Table 3-17

Table 3-18Land Use data - Thiruvallur Land Geographical Forest Land under Permanent Cultivable Land Barren Current Others Use area area non- pastures wasteland under Fallows Pattern agricultural Misc use tree crops

Ares 342.2 19.7 107.9 8.1 8.0 7.7 13.6 26.3 39.3 („000 ha) Source : ICAR 2011 3.9.3.1 Crops Cultivated (Thiruvallur) i. Paddy: Paddy is the principal crop extensively cultivated during three season & Sornavari (April to July), Samba (August to November) and Navarai (December to

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March). Normal area under paddy is 82869 ha and Normal productivity of rice per ha. is 3359 Kgs. ii. Millets:The normal area under millets is 1578 ha. Among millets, cumbu is major millet crop generally sown under rainfed condition in a normal area of 1220 ha. The normal productivity under millet is 2049 Kgs / ha. iii. Pulses: The normal area under pulses is 8611 ha under Kharif and Rabi seasons and larger area of pulses is cultivated during Rabi season. The normal productivity of pulses is 549 Kgs. / ha. The predominant pulses crop cultivated are Greengram, Blackgram and Redgram. iv. Oilseeds: Groundnut is the major oilseed crop cultivated in a normal area of 17401 ha under Kharif and Rabi seasons. More area is cultivated during Rabi Season. The Normal productivity is 4274 Kgs. / ha. v. Sugarcane:Sugarcane is cultivated in a total area of 5848 ha. With normal cane productivity of 117 MT / ha.

3.9.4 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, Parry India Ltd and Hindustan Motors. 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. 3.9.4.1 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 . SIDCO Industrial Estate, Gummidipoondi . Industrial Estate, Mugappair

3.9.4.2 Private . G.K. Industrial Estate, Porur

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. 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.

3.9.5 Discussion with local people The discussion with local people centered on the ecology of the area and also people and natural resources. Out of the discussions, the following points emerged i. The water quality of the areas has really gone down ii. Drinking water availability is a real problem. iii. To some extent, agriculture is affected due to the impact of industrialization. iv. The employment opportunities in the area are generally less v. Workers for agriculture in the interior areas, are not available, vi. The practice of agriculture is not yielding meaningful returns to satisfy the expectations of the farmers. vii. In general transport, education facilitates and support for health is not up to the mark. viii. If the developmental programme is taken up involving the people with financial assistance, youngsters remarked that they will be able to decide and lead a better way of life based on training and entrepreneurship.

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Figure 3-17 Discussion with the local fisherman

Figure 3-18 Discussion with a worker in the study area

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4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 IMPACT IDENTIFICATION

To identify and assess the impact of the proposed product mix change, the entire project has been divided into two phases:

Pre - operational Phase (Expansion erection/Construction)

Operational Phase

4.2 CONSTRUCTION AND COMMISSIONING PHASE

As TPL has complete infrastructure suitable for manufacturing of proposed products, no major construction activity will be carried-out. Only minor civil work like foundation of new vessels etc. will be carried-out. The broad activities during this period will be as follows:

Foundation work only for new machinery.

Erection of only new mechanical equipments

Synchronization of various equipments / processes

4.3 COMMISSIONING OF PLANT

Construction cum commissioning phase of the projectwill be for a shorter duration as compared to operational phase. Construction cum commissioning phase will mainly involve noise pollution (erection of mechanical machineries etc.) and demand for water (for domestic requirement of construction and commissioning work force). Though Aesthetics and Socio-economic factors are also identified, the impacts related to the same will be marginal.Local man power will be used during this phase. Similarly, there will be no displacement and rehabilitation of people due to the proposed product mix change.

4.4 OPERATION PHASE

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 and solid waste will have the potential to adversely affect air, water and land / soil in the vicinity of the project site.

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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

4.4.1 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 (NAAQ) for Industrial Area, Residential, Rural & Other area. Emission of PM, SOx& NOx from stacks attached to Boiler, DGs and Chlorine from scrubber are the only source of air pollution.

Table 4-1Stack details in the existing ECH facility

Stack Stack Stack Stack Dia. Gas Discharge Qty. Source Height Temp. Velocity (m) (m3/hr) (m) (oC) (m/sec.) Boiler 0.65 47.4 162 12.7 11450 Propylene heater 0.25 23.2 172 12.1 1050 DG 3.2 MW (Furnace oil) 1.0 31.5 241 13.5 30952 HCl Production unit stack 0.17 30 30 11.8 5000 Chlorine scrubber 0.17 30 32 11.7 800

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Table 4-2Source of Process Emissions after Proposed change in Product Mix S.No. Description and Source of APC measures provided Point of Discharge height (m) Generation 1 Emission from Boiler Common Stack 47.4 2 Emissions from DG Stack Common Stack 31.5

3 Chlorine from production unit Scrubber and Stack 30

Table 4-3Reduction in emission load due to proposed change in product mix S.No Contents Existing (MTPD) Proposed (MTPD) 1. Particulate Matter 0.052 0.0507

2. SOx 2.984 2.84

3. NOx 0.505 0.5 4. HCl 0.00006 Nil 5. Chlorine 0.00001 0.00001 Total 3.5410 3.3907

As it is observed from the above table, the proposed project would result in a reduction in the emission load as the existing stacks for propylene heater, HCl Production unit will not be used in the proposed facility and the proposed facility will have a stack attached to the 12 TPH fuel oil fired boiler, one to the DG, 3.2 MW and one stack attached to the chlorine scrubber. In order to assess the air quality impact of the proposed change in product mix air quality modelling was done using AERMOD software. Based on the Emission Details, Air Dispersion Modelling was conducted and the estimated GLC‟s is shown in the Figure 4-1. AERMOD Software Version 7.5.0 was used for dispersion modelling, site specific meteorological data for three months (March, April and May 2014) were obtained from on site metrological monitoring station. Data included in the data set were hourly wind speed, wind direction, temperature, relative humidity, air pressure, precipitation etc The emission from existing stackhas been taken as basis for modeling are shown below:

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Table 4-4 Stack Emission Details

S.No Source Fuel Height Diameter Exit Exit SO2 NO2 Suspended (m) (m) Velocity Temperature Emission Emission Particular (m/s) (0C) Rate Rate Matter (g/sec) (g/sec) (g/sec) 1 Boiler FO 47.4 0.65 12.7 162 15 0.636 0.159 DG, 3.2 2 FO 31.5 1 13.5 241 20 5.15 0.42 MW Chlorine 3 - 30 0.17 11.7 32 0 0.002 0.001 scrubber

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Figure 4-1 Ground Level Concentration (GLC) of SOX at 10 Km radius(without DG set)

Figure 4-2 Zoomed image - (GLC) of SOX at 10 Km radius (without DG set)

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Figure 4-3Ground Level Concentration (GLC) of SOX at 10 Km radius (With DG set)

Figure 4-4 Zoomed Image of GLC of SOX at 10 Km radius (With DG set)

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Figure 4-5Ground Level Concentration (GLC) of NOX at 10 Km radius

Figure 4-6 Zoomed Image - (GLC) of NOX at 10 Km radius

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Figure 4-7Ground Level Concentration (GLC) of PM at 10 Km radius

Figure 4-8Zoomed Image - (GLC) of PM at 10 Km radius

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Table 4-5 Predicted GLC for Proposed Stack Parameters Baseline data Estimated Predicted Direction Downwind (µg/m3) MaximumIncremental MaximumGLC distance Concentration (µg/m3) (µg/m3) (km)

SOX 13 9.2 22.2 W 1 13 22.3 35.3 W 1 SOX*

NOX 25 4.14 29.14 W 1 PM 60 0.414 60.414 W 1

*Emission load predictedwhen DG is in continuous operation (Worst case scenario), however DG will be used only as a backup in case of power failure.

Due to the proposed change in the product mix, existing Propylene heater & HCL production unit will not be operated and therefore there will be a marginal decrease in air pollution load. As seen from the above table the concentration levels arising from the proposed change in product mix are within the NAAQ limits.

4.4.2 Water Environment The proposed project facility will generate 4.76 KLD wastewater from domestic purposes and 1805 KLD wastewater from industrial processes. The sewage generated will be treated in STP & the treated water will be used for gardening. The effluent generated from the process will be treated in ETP & disposed to sea. The Existing ETP is capable of handling the flow of 2702 KLD in the primary & secondary treatment and there will be no additional effluent load. The proposed change in product mix involves no additional water requirement and no additional discharge from the site. Moreover, there will be no change in pollution load with respect to quantity and quality.

4.4.3 Noise Environment The impacts of the proposed product mix change on the noise levels of the surrounding areas were modeled using CUSTIC software. All equipments in the plant is 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 isopleths of the noise modeling is given as the Figure 4-9. From the below

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model it can be inferred that the noise level at the surrounding vicinity of the site is anticipated to be within the prescribed standards.

Scale-X-axis 2900m; Y-axis 1900m

Figure 4-9 Noise level Contour- Isoline view 4.4.4 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 project is product mix change under the same TPL site, no land use change is foreseen, as the current land use is that of industries. A land use change of the project site from 2003 to 2014 is shown in the figure.

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Figure 4-10Land use in the year 2005

Figure 4-11Land use in the year 2008

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Figure 4-12Land use in the year 2014

As seen from the above slides, the land use remains Industrial since 2005, but gradual increase in Human settlements can be seen from 2008.

4.4.5 Flora And Fauna 4.4.5.1 Forest Area -No forest area exists within10 km radius from the project site and hence no impact. is envisaged. 4.4.5.2 Wild Life -No wild life crossing is found along the project corridor. 4.4.5.3 Cattle Grazing -No cattle grazing grounds have been found along the corridor of Impact. 4.4.5.4 Aquatic life –Korttalaiyar River is located adjacent to the site boundary. Sewage & Effluent generated from the industry will be treated in STP & ETP. The treated sewage will be used for gardening. The effluent generated from the site is treated and disposed in sea. The same method will be followed for product change also. The treated effluent will meet the standards prescribed by the Pollution Control Board and there is no significant impact on aquatic life.

4.5 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

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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.

4.5.1 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 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:

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Total 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 4-6Overall 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

4.5.1.1 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 change in product mix. The existing activities in the plant and the consequent secondary growth were also considered in evaluating the impact in this “no project” scenario.

Table 4-7No-Project Scenario Environmental Components Activities likely to affect Environmental Components likely to be affected

Construction Process Solid/Hazardous Impacts on Activities waste components Air Quality Magnitude 0 -1 -1 -6 Importance 3 3 3

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Noise and Magnitude 0 -1 -1 -5 Vibration Importance 3 3 2 Surface water Magnitude 0 0 0 0 quality Importance 4 4 4 Ground water Magnitude 0 0 0 0 quality Importance 4 4 4 Water Resources Magnitude 0 -2 0 -8 Importance 4 4 4 Soil Quality Magnitude 0 0 -1 -3 Importance 3 3 3 Flora and Fauna Magnitude 0 0 0 0 Importance 2 2 2 Land use Pattern Magnitude 0 0 0 0 Importance 4 4 4 Employment Magnitude 0 0 0 0 Importance 4 4 4 Total impact of activity -22

Total impact of activity on a scale of 100 -5

The total project impact for this scenario was found to be –5, which is extremely low adverse impact

b) Scenario 2 - Project without EMP

Proposed change in product mix takes place without any Environmental Management measures.

Table 4-8Project Scenario without EMP Environmental Components Activities likely to affect Environmental Components likely to be affected

Construction Process Solid/Hazardous Impacts on Activities waste Components Air Quality Magnitude -2 -4 -3 -27 Importance 3 3 3

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Noise and Magnitude 1 2 1 12 Vibration Importance 3 3 3 Surface water Magnitude -1 -3 -1 -20 quality Importance 4 4 4 Ground water Magnitude -2 -3 -4 -36 quality Importance 4 4 4 Water Resources Magnitude 0 -2 0 -8 Importance 4 4 4 Soil Quality Magnitude -2 -2 -3 -21 Importance 3 3 3 Flora and Fauna Magnitude -1 0 0 -2 Importance 2 2 2 Land use Pattern Magnitude 0 0 0 0 Importance 4 4 4 Employment Magnitude 2 1 1 16 Importance 4 4 4 Total impact of activity -86 Total impact of activity on a scale of 100 -20.0

The total project impact for this scenario was found to be –20, which is minimally adverse impact

c) Scenario 3 - Project with EMP

Proposed change in product mix takes place with proper Environmental Management measures.

Table 4-9Project with EMP Environmental Components Activities likely to affect Environmental Components likely to be affected

Construction Process Solid/Hazardous Impacts on Activities waste Management components

Air Quality Magnitude -1 -2 -1 -12 Importance 3 3 3 Noise and Magnitude -1 -1 0 -6

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Vibration Importance 3 3 3 Surface water Magnitude 0 0 0 0 quality Importance 4 4 4 Ground water Magnitude 0 0 0 0 quality Importance 4 4 4 Water Resources Magnitude -1 -3 0 -16 Importance 4 4 4 Soil Quality Magnitude -1 0 -1 -6 Importance 3 3 3 Flora and Fauna Magnitude 0 0 0 0 Importance 2 2 2 Landscape Magnitude 0 0 0 0 Importance 4 4 4 Employment Magnitude 3 4 3 40 &socio Importance 4 4 4 economics Total impact of activity 0 Total impact of activity on a scale of 100 0

There is minimally adverse impact on Air, water, soil & noise quality. However due to the employment activities proposed by the proponent the cumulative impact for this scenario is found to be 0, which is neither beneficial nor adverse to the Environment, The main objective of the proposed project is to bring the economically viable production of Propylene Oxide and use it beneficially.

For the proposed product mix, the emission load from stack is reduced. Hence the impact should be positive.

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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 existing project with product mix change, Propylene Oxide manufacturing, is proposed inside the existing TamilnaduPetroproducts Limited situated in Manali, 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. The project site shall not require displacement of habitation and away from the habitation area. As it is located inside the existing plant, there is no habitation present inside the project area. The plot allotted for the plant is flat and stable to increase its resistance against any natural disturbances like earthquake. The project site is above the flood level and thus will avoid any accident in case of flooding from the nearby canal.

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The project site is free from any environmental restrictions like forest, natural parks; wild life sanctuaries. The project does not involve any displacement of local residents as it is located inside the existing premises. 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 Environmental Options Issues If located outside the Centrally located Comments existing plant within the existing plant Water flows Larger project Project footprint Ability to minimize andquality footprintcreates minimized,reducing projectfootprint is a potential forincreased potential forimpacts on major factor in disturbance andpollution water to aminimum mitigating Air quality Extended Project footprint environmental impacts footprintincreases minimized,reducing potential fordust potential for emissions;potential for dustgeneration to a greaterexposure of minimum;buffer adjacentcommunities mitigates toprogrammed againstexposure of emissions,depending on adjacentcommunities to location emission ofgases and fumes Noise andvibration Increased potential for Decreased potential for greater exposure of exposure of noise levels noise levels to to adjacent communities adjacentcommunities Soil Larger footprint Optimized increasesland and footprintminimizes land directimpact on soils take anddirect impact on soils

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Biodiversity Larger footprint Optimized footprint increasesland Nil land acquisition and acquisition and nodirect impact on flora directimpact on flora and fauna and fauna

Landscape Larger footprint Optimized footprint increases No land acquisition land acquisition and andvisual impact visual impact Socio- No significant discrimination in regard to socio- Potential impacts of economicissues economicfactors proximity of industries with nearby settlements is decreased

Transportationissues No significant discrimination in regard to Ability to minimize transportationissues, unless a processing site was Projectfootprint is a selected remotefrom the existing facilities, in which major factor case, there would be potential for major impacts inmitigating related to transportation againstenvironmental impacts

5.3 PROJECT ALTERNATIVES

This project can lead to economic prosperity as there is good market potential for Propylene Oxide and its derivatives Propylene Glycol and Polyether Glycol. The purpose of PO manufacturing unit is to meet the growing demand of Propylene Glycol and Polyol.

5.3.1 Site alternatives Since this is a product mix change project, there is only a minor change in the existing Epichlorohydrin plant, the area earmarked for future development inside the already existing site will best fit in terms of ease in operation. Therefore this project is located inside the existing TPL plant. The process equipment, supporting infrastructure and pollution control equipment will be installed inside the existing premises.

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5.3.2 Fuel alternatives Fuels like Coal, Bio Briquette and Natural Gas werethe alternatives considered as fuel source. The safety aspects and pollution aspects of each fuels during transport, storage, usage, availability and end products of combustion is considered and discussed. The existing premise doesnot have the required space for storage of coal, and combustion of coal generates large

amounts of SPM and gaseous emissions like SO2 and NOX. The generation of fly ash during the coal combustion will add to the burden of EMP team in disposing them to cement industries or brick kilns. The storage of Natural gas in the existing premises will be unsafe due to space constraints and close proximity of many industries nearby. After analyzing the safety and economic alternatives, it was decided to have fuel oil as the source of fuel inside the plant.

5.3.3 Water supply alternatives The selection procedure and evolution of the preferred option for process water has involvedmany water supply studies and consideration of options, including those addressed duringearlier feasibility and other scoping studies. Fundamental options for water supply in the initial screening included: Groundwater

Existing surface storage facilities

Use of municipal water supply.

Since the site is located within the Industrial Estate and CMWSSB is already providing water supply, the same will be utilized for process modification.

5.3.4 Alternative Technologies Propylene Oxide (PO) can be manufactured by different process technologies, that varies according to the raw material requirements, process conditions, economic feasibility and so on. Some of the process technology alternatives for the production of PO are given below and compared with the existing process for the proposed site. 5.3.4.1 POSM Technology -POSM (Propylene Oxide/Styrene Monomer) technology is used for about a third of the world's production of propylene oxide and involves the reaction of propylene and ethylbenzene to produce propylene oxide and styrene. 5.3.4.2 POMTBE Technology–TBA a coproduct of propylene oxide (PO), is produced by PO manufacturers.Although it can be used directly as an oxygenate, it can also be used as a rawmaterial in the production of MTBE.An alternative epoxidation route uses isobutane

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which makes a tertiary-butyl alcohol (TBA) co-product that can be converted to methyl tertiary butyl ether (MTBE). 5.3.4.3 Direct oxidation-The direct gas-phase oxidation of propylene by molecular oxygen has long been the most desirable as well as challenging goal of production of PO. However, despite considerable effort, no economically viable catalyst has yet been found. 5.3.4.4 Hydrogen Peroxide -Hydrogen Peroxide method is also called as Organic Peroxide Method. In this method, there is a method using Ethyl benzene and a method using isobutane, and in each of them PO is synthesized by indirect epoxidation of propylene using ethyl benzenehydro peroxide or tert-butyl hydroperoxide as the organic peroxide. A styrene monomer (SM) or tert-butanol (TBA) is produced as the co-product. 5.3.4.5 Chlorohydrin Technology- In the chlorohydrin process, propylene reacts with the mixture of Chlorine and water forming propylene chlorohydrin (PC), followed by the reaction of PC with lime (Ca(OH)2) to form PO and CaCl2 as a co-product. Nearly 50% of world PO production is currently based on this method.

5.3.5 Justification for the Selected Technology Some of the reasons for TPL to implement the Chlorohydrin technology for the production of PO in the proposed facility are as follows: Same raw materials as that of ECH

Catalyst is not required

No storage constraints as Chlorine is readily transported via pipelines from the unit‟s HCD Plant.

Most of the equipments used in the production of ECH can be used readily in this technology.

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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.”

Environmental monitoring programs provide the necessary information to:

i. Verify the accuracy of EIA predictions;

ii. Determine the effectiveness of measures to mitigate adverse effects of projects on the environment.

Feedback from environmental monitoring programs will be used to:

i. Determine whether more or less stringent mitigation measures are needed; and

ii. To improve the predictive capabilities of EIA‟s.

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 constructionand operational phases.

The main objectives of environmental monitoring are:

To assess the changes in environmental conditions,

To monitor the effective implementation of mitigation measures,

Warn significant deteriorations in environmental quality for further prevention action,

In order to meet the above objectives the following parameters need to be monitored,

Rehabilitation and Resettlement Program,

Afforestation,

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Water Quality and Public Health,

Air and Noise quality

Soil Conservation, and

Sanitation and Waste Disposal

Post Project Environment Monitoring Program

The summarized form of post monitoring details is presented in the following Table 6.1.

Table 6-1Post Project Environmental Monitoring Plan S. Area of Frequency of Sampling Parameters to be Analyzed No Monitoring 1 Ambient Air Monthly once 24 hourly All the 12 parameters given in NAAQS Quality VOC – online

2. Noise Every six months by in Ambient Equivalent continuous Sound (Workplace) house staff and yearly by Pressure Levels (Leq) near compressors, external agencies motors, reactors, DG sets at day and night- time.

3. Stack Emission Continuous -online PM, CO, SOx and NOx monitoring 4. Effluent (inlet Monthly pH, Temp, TSS, TDS, Chloride, sulphide, and outlet) 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 Kjeldahl nitrogen, Cyanide, Nickel, Residual Sodium Carbonate. . 5. Sewage (inlet Monthly pH, Temperature, Oil and grease, TDS, TSS, ad outlet) BOD. 6 Process Water Quarterly pH, Temp, TSS, TDS, Conductivity, Hardness, Quality Chlorides, Sulphates, Silica, Total Residual

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S. Area of Frequency of Sampling Parameters to be Analyzed No Monitoring Chlorine, Iron.

6. Drinking Water Quarterly Color, Odour, pH, Turbidity, Taste, TDS, Quality Total Hardness, Calcium, Magnesium, Chlorides, Iron, Sulfate, Manganese, Copper, Nitrate, Fluorides, Lead, Zinc, Total Chromium, Residual Chlorine, Total Alkalinity, Aluminium, Mercury, Cadmium, Arsenic 7. Soil Monthly once Physicochemical properties, Nutrients, Heavy metals 8. Noise Once in a month Noise level in dB (A) monitoring (Ambient) 9. Workplace Quarterly VOC & Lux Level monitoring

6.2 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.

6.3 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 review and projection of past, present and future performances. Also, the management shall ensure to prepare separate records for water, wastewater, solid waste, air, emissions and 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

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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.

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7 ENVIRONMENTAL MANAGEMENT PLAN

7.1 INTRODUCTION

This Environmental Management Plan (EMP) for the Tamilnadu Petroproducts Ltd (TPL) identifies the principles, procedures and methods that will be used to control and minimize the environmental impacts of the proposed minor construction and operational activities associated with the product mix change project. It is intended to ensure that commitments made by the TPL to minimize project related environmental and social impacts are upheld throughout all project phases.

As part of our ongoing commitment to excellence in environmental and social performance we 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, 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 an Adaptive management approach to continuous improvement and to meet the future regulations.

7.2 Objectives of EMP

Propose practical measures to avoid, reduce, restore, and compensate for identified adverse impacts. Conserve highly significant aspects of the biophysical, cultural and social environments. Protect human health and safety. Inform an environmentally sound and sustainable engineering design process. Propose a plan to monitor and manage project implementation, such that the project is environmentally sustainable and it optimizes the resource use. Preparation of Afforestation or Greenbelt Development scheme. Preparation of rain water harvesting scheme and energy conservation actions

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To prepare a capital cost estimate and annual recurring cost for Environmental Management Plan.

7.3 EMP Structure and Organization in TPL

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 phase of the project. The EMP contains guiding environmental principles and procedures for communication, reporting, training, monitoring and plan review to which all TPL staff, contractors and subcontractors are required to comply with throughout the preconstruction, construction and operation phases of the proposed product change mix of Propylene Oxide manufacturing facility. The EMP should also be considered as an overall framework document that establishes the terms of reference for all project environmental and social sub-plans that will completed including the following: Environmental Supervision Plan (construction); Environmental Monitoring Plan (Operation); and Social and Health Management Plan (Operation).

7.4 EMP Roles and Responsibilities

This section describes the organizational structure and responsibilities for implementation of the EMP as shown in Table 7-1

Table 7-1Responsibilities for EMP Implementation S.No Organization Responsibility 1. M/S TPL Overall responsibility for environmental performance of TPL. Decision-maker on applicable policies to the TPL. Overall supervisory role during the construction phase Overall responsibility for EMP implementation during the operating phase 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 of the TPL. 2. M/S TPL Develop an environmental unit, headed by the Project Environmental Officer to implement EMP responsibilities.

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S.No Organization Responsibility Oversight, implementation, monitoring and compliance of the EMP and any approval conditions, including construction supervision and performance of all TPL 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. Supervising Implementation of the Environmental Monitoring Plan during construction Engineer and operation. 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. 4. Construction Preparation and implementation of the Construction Management Plan Contractor Prepare and maintain records and all required reporting data as stipulated by the EMP, for submission to the Supervising Engineer. 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

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S.No Organization Responsibility 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)

7.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE

Environmental monitoring will be done during construction and operation. 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: 1. Air quality 2. Noise 3. Water quality and water resources 4. Solid waste 5. Land environment 6. Ecology 7. Socio Economic

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7.5.1 Air Quality Since Tamilnadu Petroproducts Ltd has complete infrastructure, no major construction activity will be carried-out. Only minor civil work like foundation for new vessels, boiler house and supporting infrastructure for the new machineries will be carried out. During construction activities, dust resuspension and emissions from the movement of vehicles and construction activity is 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 shall 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 equipments / machineries will be properly maintained to reduce air emissions. Idle running of vehicles will be minimized during material loading / unloading operations. All construction workers will be provided appropriate PPEs like dust mask, ear plug, helmet, safety belt etc. and it will be mandatory for them to wear while entering the site itself. Increase signage and speed limit postings. 7.5.2 Noise Environment Following measures are proposed during construction period to mitigate adverse impacts of noise Construction activities should 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 by these equipments will be emphasized by TPL. All construction workers working in high noise areas will be provided appropriate PPEs like ear muffs and made to wear them during working hours.

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7.5.3 Water Quality and Water Resources Maximum water requirement for construction purpose including domestic water requirement of construction workers is estimated to be approximately 3 KLD. 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 & STP. 7.5.4 Solid Waste Main solid waste generation during construction phase will be construction debris like rubble, brick bats, debris, steel scrap, wooden scrap, 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, steel scrap will be given to authorized scrap dealers. On completion of civil work, all debris etc. will be completely removed from site to avoid any incompatibility with future use. All the wastes will be stored at a designated site within the premises to prevent scattered discharge on land. 7.5.5 Land Environment Top soil layers shall be stored for reclamation and re-vegetation and reforestation at approved locations. Re-contour slopes Ensure proper drainage is maintained Re-vegetate, wherever feasible to contain runoff. 7.5.6 Ecology Project site is an existing unit with a number of shrubs and trees. There is no cutting of trees for the product mix change project and no major impact on ecology is anticipated.

7.5.7 Socio Economic

As there will be no temporary housing colony for construction workers, no socio economic impact due to the same 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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7.6 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 Noise environment Water quality and water resources Solid and hazardous waste Land environment Ecology Socio Economic 7.6.1 Air Quality Following measures are proposed to mitigate negative impact during the operation phase of the project on the surrounding air environment. Existing caustic scrubber with an Intallox saddle packing is used in the proposed PO plant to take care of Chlorine emissions. Height of scrubber (5.5 m) and the packing bed height (3.5 m) are as per statutory requirements. On line chlorine Monitoring system in the existing scrubber stack is available and connected to Care Air Centre of TNPCB. Adequate spares of critical components of scrubber system are kept to ensure trouble-free operations and continuous compliance to emission norms. Transport vehicles will be properly maintained to reduce air emissions. Vehicles will be periodically checked for pollutant emissions against stipulated norms. Idle running of vehicles will be minimized during material loading / unloading operations. Dust scrubber is proposed for Milk of lime Plant

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Figure 7-1 Chlorine Sensor in Chlorine scrubber stack

Figure 7-2 Online Chlorine sensor connected to TNPCB

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Figure 7-3 Continuous Ambient Air Quality Station at the site

7.6.1.1 Air Emissions The major source of emission is from Boiler stack, DG stack, scrubber stack connected to reactors. The details of proposed source of air pollution & corresponding Air Pollution control equipment are already given in Chapter 4 Environmental Impacts and mitigation measures.

7.6.1.2 Fugitive Emission Control a) Leak Detection and Repair -Leak Detection and Repair (LDAR) is a program implemented to comply with environmental regulations for reducing the fugitive emissions of targeted chemicals into the environment. Several standards such as Maximum Achievable Control Technology (MACT) standards, New Source Performance Standards (NSPS), National Emissions Standards for Hazardous Air Pollutants (NESHAP) and Central Pollution Control Board (CPCB) require the monitoring and reporting of these fugitive emissions from process equipment. The environmental regulation prescribes LDAR programs as a means of reducing emissions with specified standards and applies to monitoring and repairing process components. As a part of industrial hygiene as well as environmental monitoring, TPL carried out the leak detection and repair study as per CPCB guideline through an MoEF

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approved lab. Leak Detection and Repair (LDAR) is a program implemented to comply with environmental regulations for reducing the fugitive emissions of targeted chemicals into the environment. 7.6.2 Noise Environment Following measures are proposed to mitigate negative impact of operation phase of the project on the surrounding noise environment All the noise generating equipments 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 generated by them. Wherever feasible, acoustic enclosures will be provided for compressors. Walls and ceilings of buildings will be lined with sound absorbing materials, wherever required. Compliance with noise control norms will be given due importance at the time of purchase of various equipments and it will be mentioned while placing the purchase orders and guarantee for noise standards will be sought from suppliers. Moreover, all the personnel working in other high noise generating areas too will be provided with sufficient ear protecting devices. Green belt will act as a noise barrier. Training will be imparted to personnel to generate awareness about effects of noise and importance of using PPEs. 7.6.3 Water Quality and Water Resources Following measures are proposed to mitigate negative impact of operation phase of the project on the water quality and water resources. Total water requirement for operation phase of the proposed project is estimated at 2150KLD and is proposed to be met through municipal water supply(CMWSSB).The proposed project will generate45KLD wastewater from domestic purposes and1805 KLD wastewater from industrial processes. There will be no additional water discharge in the proposed project and no change in pollution load with respect to quantity and quality. The sewage arising from domestic purposes will be treated separately and reused for irrigating greenbelt.

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7.6.3.1 Domestic waste water

The Sewage Generated from Canteen, toilet & wash area are treated separately in STP. The treated water from STP will be used for Green Belt maintenance. The process flow and details are given in Chapter 2, Project Description. STP outlet will have the following requirements as per TNPCB//CPCB - continuous monitoring for Flow pH, BOD, COD,TSS.

7.6.3.2 Rain water harvesting system

Rain water harvesting system is installed and all rain water will be collected, filtered and stored for reuse within our plant process. This system is been implemented for conservation of water. The roof top water is collected through pipe system which is treated and used.

The rainwater harvesting pits will be provided near major built up areas, so that the roof water can be directly sent to nearest Rainwater harvesting pit. The excess water if any from the rainwater harvesting pits is diverted to storm water drains.

7.6.3.3 Rain Water Harvesting Details and Calculations

1. The rain water harvesting is proposed to augment the ground water table and also to meet some of the water requirement of the project during rainy season.

2. Rooftop water from the terrace is proposed to be collected in rain water harvesting sump which will be used for domestic purposes after appropriate treatment.

3. Storm water run-off road / paved / landscaped areas will be directed to shallow recharge pits constructed along storm water drains for recharging the ground water.

4. The location of Rain water harvesting pits inside the proposed plant layout is attached as Annexure-12 Design Parameters Intensity of Rain fall Considered = 50 mm/hr or 0.050 m/hr Coefficient for run off considered Roof Top & Terrace - 0.90 Paved area - 0.70 Other building area - 0.60 Landscaped area - 0.20

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Area Details Total road Area & Paved area - 26963 Sq.m Total Roof Area - 1100 Sq.m Other building area - 17648 Sq.m Total Landscape Area - 65171.29 Sq.m (Green belt + Vacant area) Hence, the Total Quantity of Rainfall Will Be: Q= A x P x R Q= Quantity of rainwater run - off in cu.m / hr. A= Area of catchments drained in sq.m P = Permeability factor R = Rainfall intensity in mm / hr. Road Area : 26963 Sq.m x 0.70 x 0.050 m =943Cu.m/hr. (A) Landscape Area : 65171.29 Sq.m x 0.20 x 0.050 m =651.71Cu.m/hr. (B) Roof Area : 1100 Sq.m x 0.90 x 0.050 m =50 Cu.m/hr. (C) Other building area : 17648 Sq.m x0.60 x0.050m = 530 Cu.m /hr (D) Hence, total volume of rainwater run - off will be: (A) + (B) + (C) + (D) = 2174.71 Cu.m/hr. Rainwater Management Measures Run-off from Terraces: The run-off from the Terraces shall be separately piped to fire water tank, after duly filtering the same. This water is proposed to be used for fire fighting. Run-off from Roads, Paved area & Landscape areas: The calculated run-off from roads/pavements, landscaped area and other building area are 2174.71 m³ /hr in total This run-off is proposed to be channelized through storm drains to individual recharge pits and the rain water will be re-charged into underground aquifers. Excess run off will be discharged into to external storm water drain. Total Run-off: Podium Area/Hardscape & Driveway & Landscape Data assumed: Considering 15 min of rainfall Volume of rainwater available for recharging =527m³ Size of Rainwater Percolation Pit – 2 m Dia X 3 m, Depth Volume of pit = (3.14x r2 X Depth)= 3.14 X (1.41)2 X 3=18.7Cu.m/pit Total No of storage pit required =527/18.7= 29 Infiltration rate = 10cms/hr =0.1m/hr

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Total number of Percolation pits required = 29 Nos No. of Pits provided= 15 Nos.

Figure 7-4 Rain water harvesting system – Roof top rain water collection system

Figure 7-5 Rain Water Percolation Pit 7.6.4 Effluent Treatment Plant

The Effluent generated from the plant is treated in the Effluent Treatment Plant and disposed in Sea. The specification and process details are given in Chapter -2 Project Description. ETP Outlet will have the following requirements as per TNPCB//CPCB - continuous monitoring for Flow pH, BOD, COD,TSS.

7.6.5 Solid & Hazardous Wastes

The following measures are proposed to mitigate negative impact of solid waste generation during the operation phase of the project. The Solid waste generation can be broadly categorized in to Non- Hazardous & Hazardous. Non-hazardous wastes in the form of MOL rejects amounts to 2200 MT/annum and Rotary Vaccum Drum Filter(Lime) sludge amounts to

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950 MT/annum. The details of waste generation in existing & proposed project are listed below. Non Hazardous wastes like Packing material will be disposed through authorized vendors, Food waste from canteen, Garden waste will be composted and used as a manure for the green belt. The quantity of hazardous waste expected to be generated in the proposed facility is given in Table 7-3

Table 7-2 Quantity of Non hazardous waste S.No Type of waste Quantity Storage 1. Packaging material 1 MTPA Sold to recyclers

2. Garden waste 5 MTPA Composting and used as manure 3. STP sludge 5 MTPA 4. Lime Sludge 3150 MTPA Sold to brick manufactures (Annexure-23)

Table 7-3Quantity of hazardous waste expected to be generated in the proposed facility S.No Type of Hazardous Quantity Storage waste 1. Used oil 2.0 MT/year Stored in barrels and sold to SPCB authorized vendor 2. Waste oil 140 MT/year Stored in barrels and disposed to authorized vendors 3. ETP Sludge 300 MT/year Stored and disposed to M/s. TNWML, Gummidipoondi

TPL has obtained Hazardous waste Authorization for the existing ECH facility and the same is enclosed in Annexure-21. The quantity of Hazardous waste generated for proposed modification will be same as that of existing facility.

7.6.6 Land Environment Following measures are proposed to mitigate negative impact of operation phase of the project on the land environment. Air emissions are effectively controlled by use of scrubbers and therefore deposition of air pollutants in and around the premises and surrounding area is not envisaged.

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Disposal of solid waste is carried out through authorized vendor.

As the treated effluents are disposed off the sea, impact on the land environment is not envisaged.

All the hazardous wastes to be generated from the project will be properly stored and disposed as per the hazardous waste authorization issued by SPCB.

Hazardous materials are prohibited to be drained or dumped in the premises. Accidental spills shall be cleaned, reported and monitored.

Thus, no impact on land is envisaged due to discharge of gaseous emission, solid waste or liquid effluent from the proposed product mix change.

7.6.7 Ecology Since the proposed project is equipped with the treatment system, and the treated effluent will be disposed to sea. Solid wastes generated during the operation phase are disposed off through authorized vendor and hence no impact is anticipated due to solid waste in and around the site. The air pollution control devices expected to be installed at the proposed modification facility will control release of air pollutants to a greater extent, however a two tiered thick green belt consisting of shrubs and trees around the periphery of the site has been planned to intercept and arrest air pollutants released at various heights and to attenuate the increased quantity of air pollutants released into the environment. It is expected that the ecology of the region is preserved by these mitigation measures.

7.6.8 Green Belt Development Plan TPL has already developed a greenbelt of 4 acres of the total plot area in consultation with horticulture experts as per Ministry of Environment and Forests/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 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. A well designed green-belt helps in intercepting particulate matter and gaseous pollutants and helps in purifying the air. Trees acts as effective barrier and absorber of noise. The green belt

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around an industry acts as a buffer in the event of emission control equipment failure and acts as an indicator in the event of toxic release by visible morphological changes in the leaves, stem etc. To accrue the benefits of greenbelt and to maximize its potential in environmental management around an industry, choice of the green belt tree and shrub species plays a vital role. In the proposed project, additional 8 acres of green area is proposed. Hence the total green area will be 12 Acres (33 % of plot area).The layout showing existing and proposed green belt development in the project site is attached as Annexure-13.This green belt development will be done in phased manner in 3-5 years.

7.6.8.1 Plantation Along Road Sides As part of the initiative to improve the green cover near the roadways of the site. Trees and shrubs will be planted along the roadsides. Since automobiles are the source of pollution of gaseous and particulate pollutants the choice of plants for road side includes shrubs of height 1 to 1.5 meter, medium sized trees of 3-5 meter height and tall trees of 10-20 m height. Medium sized trees, alternating with shrubs are ideal for sorption of particulates and gases.

Figure 7-6 Photos of existing Green belt

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7.6.8.2 Selection of Trees For development of greenbelt it is advisable to select tree species high are tolerant to air

pollutants, since certain species of trees has the ability to uptake large quantities of SO2 than other species and grow at a faster rate by utilizing the available nutrients in the soil etc.

In general, following factors have to be considered for the selection of tree species.

Native tree species should be preferred over non native trees. The trees must be tolerant to all the pollutants present in the area. The trees which are evergreen and forms large round canopy with broad leaves. The morphological feature of leaves like rough surfaced and large number of stomatal aperture. The trees should be able to grow faster and should help in stabilization of the soil. The trees should maintain ecological, land and hydrological balance of the region. 7.6.9 Socio – Economic Environment TPL is committed to the socio – economic up-lift of the people in region and has actively involved in formulating and implementing proactive measures as part of the corporate social responsibility. The following activities are carried on by TPL as a part of Corporate Social Responsibility (CSR).

7.6.9.1 Toilets for Panchayat Middle school - Sadayankuppam Village, Manali Tamilnadu Petroproducts Limited Manali has constructed toilets in one of the school unit in Sadayankuppam, Manali town, Chennai. This is a village inhabited by the economically weaker sections. They still perform open defecation in school. This causes a lot of difficulties and health problems to children in school.

TPL has involved many people in several discussions concerning this project and it is with their consent and based on their felt-need, this project is being implemented. TPL has constructed total 4 toilets in school.

Cost-1.5 Lakhs

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7.6.9.2 Stationery items and Notebooks to Students at Panchayat Middle School Sadayankuppam, Manali, Chennai The children‟s studying in the Panchayat middle school are extremely poor and hence they do not have the opportunity to have admission in a proper school. They usually study in Govt. run schools where the standard of education is very low. The Govt. run schools are always free and so the poor children can afford to go the same. However the lack of stationary facilities can prove to be an obstacle for their progress in education.

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TPL has provided stationery items and notebooks to the students who are studying in school that will be useful in their education.

Cost –Rs.25000/-

7.6.9.3 Painting of interior & exterior walls, benches, provision of Tables, Chairs and Blackboards to Panchayat Middle School, Sadayankuppam, Manali, Chennai. Basic needs are to be given to the students in school where they can study with no difficulties.

The basic requirements like chairs tables and blackboards are sponsored to the school by TPL and also exterior and interior school buildings are painted.

Cost – Rs.1.25 Lakhs

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7.6.9.4 Tree plantation at Panchayat Middle School, Sadayankuppam, Manali, Chennai TPL with a responsibility towards the society and environment has planted the trees in a school in Sadayankuppam, which reduces the environmental pollution and provides shade to the children. The environmental awareness has been given to the students to save environment for a clean and green surrounding.

Cost-Rs.10000/-

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7.6.10 Occupational Health and Safety Program TPL is committed to protecting the safety, health and well-being of its employees, the community in which they operate a wider environment.

TPL review and improve its processes, services and products to reduce industrial risk and impacts. TPL educate, train and motivate employees to conduct their activities in a safe, healthy and environmentally responsible manner.

The Health and Safety management system provides the framework towards organized efforts and procedures for identifying workplace hazards and reducing exposure to harmful situations and substances and thereby reducing accidents. It also includes training of personnel in accident prevention, accident response, emergency preparedness and use of protective clothing and equipment. Systems are put in place to ensure the safe handling, movement, storage, recycling, reuse, or management of waste, air emissions and wastewater discharges.

The organization implements a series of checks and balances in administrative procedures and authorizations such that all process safety related matters receive proper review and approval prior to initiating changes or modifications.

The Factories Act specifies the permissible exposure levels (PEL) and Threshold Limit Values (TLV),which has to be strictly adhered for a better occupational health and safety in the site. Several measures are taken by TPL to keep the values below TLV.

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7.6.10.1 Process Safety Process safety is treated as a priority and Process safety reviews are conducted on a periodic basis and findings addressed prior to the start-up of new or modified processes. Process Hazard Analysis (PHA) necessitates the site for identifying, evaluating, controlling, and documenting hazards at various times and stages in the life cycle of a processes and operations. PHA is conducted for the following: New processes, products, materials and facilities prior to startup Cyclical/Periodic PHAs of existing facilities Dismantling of a process facility Management of change (e.g. process design basis, hazards of materials, equipment design basis, personnel, etc) PHAs include the activities of identification of significant hazards, consequence analysis, human factors evaluation and facility siting evaluation, inherently safer process evaluation, risk analysis, and development of recommendations.

7.6.10.2 Operational control measures Vapor / Fumes control: The process involved corrosive chemicals operation equipments are connected to wet scrubber with suitable scrubbing media. Storage tank operational control measures to be provided Secondary cooling system is enabled.

7.6.11 Environmental Policy of TPL TPL has a structured environmental policy, that is committed to environmental protection through:

Conservation of natural resources and

Waste minimization

Some of the salient features of the environmental policy of TPL are:

Improve the environmental performance through innovative techniques, best work practices and technology upgradation.

Carry out all the activities complying with applicable environmental laws and regulations and strive to go beyond.

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Conserve water, fuel oil, electrical energy and hydrocarbon feed stocks through promotion of recovery, recycle and waste minimization techniques.

Ensure safe storage and transportation of raw materials and finished products.

Continually improve the Environmental Management System.

Enhanceenvironmental awareness amongst employees and contractors through education and training.

7.6.12 Fire & Explosion Controls

Fire fighting system is one of the important areas that is vital for the safety in a chemical plant. TPL has a structured and an extensive fire fighting system that serves all the components of the plant. The main features of the fire fighting system in TPL is as follows: The fire station inside the plant consists of the following components: A fully equipped fire station with trained firemen is available to serve the plan whenever the emergency arise. Two centralmultipurpose fire tenders are available that serves all the plants inside TPL. Fire alarm annunciation panel Communication facilities such as Wireless, Hotline (LAB, PO, CPCL), direct line telephone and intercom facilities are accessible from all the locations of the plant. Emergency PPEs are available (Leather gloves, dust mask, ear muff, goggles, PVC coat, PVC pant, PVC hood, PVC gloves, helmet with face shield, asbestos lug guard, asbestos apron, half mask, full mask, gum boot) and are provided to the employees with sufficient training as to how and when to use them. Fire fighting equipments like Fire suits, Chemical protection suit, Elkhart nozzle, triple purpose nozzles, short branches are available to serve the employees in the time of emergency. Fire station is constructed with concrete wall and provided with fire protection doors. Fire hydrant system inside the existing ECH plant will be used for the proposed PO plant and the same is attached as Annexure-14. The list of fire fighting equipments used in the plant are as follows:

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Table 7-4Fire Fighting Equipments Available in the Plant S.No Equipments Nos. 1 Single Hydrant 1 2 Double Hydrant 59 3 Fire Escape hydrant 19 4 Water Monitors 11 5 DCP Extinguisher – 70 Kg 10 6 DCP Extinguisher – 10 Kg 69 8 CO2 Extinguisher – 4.5 kg 31 9 CO2 Extinguisher – 22.5 kg 5 10 Fire Buckets 24 11 SCBA 7 12 Online air breathing apparatus 5

The list of Fire Alarm points and its components inside the plantis given below

Table 7-5Fire Alarm points and its components inside the plant S.No Equipments Nos. 1 Fire Alarm Call Point 33 + 1 in Culvert 2 Smoke detector 95 + 1 in culvert 3 Siren 5 + 1 Hand operated manual siren at the north entrance of Main Control Room 4 Windsock 5

Figure 7-7Fire Alarm point

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The capacity of Fire water storage is given below:

Table 7-6Fire Water Storage Capacity S.No Storage type Capacity 1 Fire water Storage capacity 2 x 1193 = 2386 m3 2 Fresh water Reservoir 5605 + 5332 = 10937 m3 3 Total water storage capacity 12130m3

The capacity and types of pumps present in the Fire pump room are as follows

Table 7-7Pumps Availablewith Capacity Plant Pump Name Capacity 40 m3/hr Jockey Pump – 2 Nos 40 m3/hr PO Electrical Driven pump – 1 Nos 610 m3/hr 410 m3/hr Diesel Driven Pump – 2 Nos 410 m3/hr

Figure 7-8 Water Monitor

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The number of sprinklers installed in the plant are as follows

Table 7-8Sprinklers Installed in the Plant Plant Total No. of Sprinkler mode Remarks Sprinkler Auto Manual ECH Plant 11 --- 11 Sprinklers are tested periodically. Culvert at Manali Express Water curtains have been provided at both the ends highway

Figure 7-9 Sprinkler System in Storage Tanks 7.6.13 On line Leak detections TPL has provided on-line leak detectors for the control of emissions as well as any leaks during emergencies. The detectors previously installed in the ECH plant is used for the proposed plant. Some of the important detectors installed in the plant are given below.

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Figure 7-10 Propylene Detector

Figure 7-11 Chlorine detector 7.6.14 Chemicals Management System TPL‟s policy of protecting employee health and safety and the environment requires safe management of chemicals throughout the life cycle. Since the nature of TPL‟s activities are such that highly hazardous and carcinogenic chemicals are employed and the inventories of chemicals are large, a well conceived system of chemicals management is put in place to enable the facility to conform to the EHS policy as well as meet the requirements of the regulations applicable to the operations.

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The Chemicals Management system provides with a framework for managing the various aspects associated with handling chemicals in a safe and environmentally sound manner with the below salient features. Detailed guideline New Chemical Approval MSDS/Chemical Hazard Review Hazardous chemical classification and hazardous substances based on MSIHC rules, 1989. Bulk Chemical storage safety inspections Chemical transport safety checklists

7.7 OCCUPATIONAL HEALTH / INDUSTRIAL HYGIENE PROGRAM

Industrial Hygiene is one of the fast emerging fields and is a critical requirement for the well being of employees, for which TPL 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. TPL‟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. 7.7.1 Occupational Health Monitoring 7.7.1.1 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.TPL medical surveillance program include following major elements: Developing a OH-IH Medical Surveillance Program Pre-Employment Examination and Periodic Medical Examinations Determination of Fitness for Duty Communications Emergency Medical Treatment

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Medical Records 7.7.1.2 Pre-Employment Screening / Examinations- All employees shall be subject to pre- placement medical examinations to determine their fitness for the nature of jobs on site. Potential exposures to the work environment shall be considered before placing an employee on the job. 7.7.1.3 Periodic Medical Examinations- Periodic medical examination is the same as the pre- employment screening and may be modified according to current conditions, such as changes in the employee's symptoms, site hazards, or exposures. Comparison of sequential medical reports with baseline data is essential to determine biologic trends that may mark early signs of adverse health effects, and thereby facilitate appropriate protective measures. The frequency and content of examinations are normally one year.Apart from this for workers working in Hazardous area, medical examination is conducted by Doctor authorised by Factory Inspectorate. 7.7.2 Emergency Management TPL 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 7.7.3 Materials Handling Storage and Transportation Considered the properties of the materials involved in order to establish efficient material handling procedure. Operators are physically qualified and trained in the operation of the equipment and the safe practice followed. General consideration concerning the storage of the materials is piled, cradled, cross tied, packed and blocked so that they will not fall or slide.

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Safe rules for the manual handling of the materials and operation of the vehicles is practiced. 7.7.4 H&S Audits & Inspections program TPL 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 Self and Inter/ Cross unit audits Critical equipment safety inspection Emergency and life saving equipment inspection IMS (Integrated Management System) Internal and External audits Daily Safety Inspection Monthly Environmental inspection Daily Workplace exposure monitoring using VOC meters - PID Vessels and storages are tested for their integrity at regular frequency. Preventive / opportunity maintenance carried out. Condition monitoring techniques are followed. Sensors and alarms are provided to alert on fugitive emissions. Area monitoring by personal sampler is carried out. Measurement of noise level and illumination is carried out. Personal protection equipments and 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. 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.

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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 Tested date and due date are marked legibly. 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 areas 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. 7.7.5 Industrial Hygiene Monitoring TPL has carried out Health hazards monitoring for the existing plant through the following activities and the same will be implemented for the proposed product mix change project. Exposure to airborne chemical substances in the workplace were monitored by through area and personnel monitoring depending of the nature of the processes, sources of chemical exposure and toxicity of the chemicals by the following sampling methods. 7.7.5.1 Area Monitoring- sampling pumps or passive monitoring badges are placed at static/fixed locations to collect airborne chemicals in the areas. Time weighted average (TWA) concentration of the chemicals present in the air was calculated. 7.7.5.2 Personnel Monitoring- This is a method using personal passive monitoring badges or sampling pumps attached to the individuals, subject to chemical exposure. TWA then computed from the analytical results and determined the exposure level to the individuals. 7.7.5.3 Noise Monitoring - Measurement of individual noise sources (e.g. compressors, motors, reactors, DG etc.) were monitored by in-house program in every six month as periodical base in addition to the yearly monitoring by external agencies. 7.7.5.4 Industrial health monitoring - Some of the existing measures in the ECH plant and the proposed measures that has to be implemented to improve industrial health and safety for

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the proposed product mix change project are listed below and the same will be followed as a part of the Industrial health and safety program for PO plant: Regular inspection and maintenance of pollution control systems. All measures related to safety such as safety appliances, training, safety awards, posters, slogans are undertaken. 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 fire and safety equipments are properly utilized and maintained regularly. The health of the workers will be regularly checked by a well 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., Fire – proof electric fittings are used. Good air circulation will be ensured within the plant area. Training has been given to deal with emergency situation, to operate fire extinguishers, to provide first – aid to affected persons by arranging safety work- shop once in six months. Showers and hand – wash are provided in vicinity of work area with ample quantity of water available. Fire and Smoke detectors are installed at suitable place in the premises to get alert warning and avoid major accident. Automatic water sprinklers areinstalled throughoutthe building to retard spread of fire. On site emergency plan is prepared and implemented to safe guard human life and property. Occupational health tests such as Liver Function Tests (LFT) and Pulmonary Function Tests (PFT) are conducted frequently to monitor the health of the workers and are well documented. Moreover, based on past occupational health record of its existing unit, TPL has already put in place adequate safety measures and does not anticipate any adverse effect on health of workers. 7.7.5.5 General considerations For good housekeeping of the project, following measures will be planned:

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Maintaining cleanliness of roads to prevent accumulation of dust and waste material. Inculcating positive attitude among employees for good house – keeping. Maintaining hygienic conditions near drinking water source and toilets. Waste - minimization, Recycle / Reuse / Recover Techniques &Energy conservation Unit will take following steps in this regard: High efficiency pumps with auto level cut off is installed. Liquid chemicals dosing is through metering pumps. CFLs with high frequency ballast shall be used. Energy efficient fluorescent tube lights/CFL are used for office areas. Self starters and variable drives are installed for motors. All tanks are installed with level controllers and cut off for pumps. Process improvement by R & D to reduce waste water generation.

7.8 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 increase the strength of the environmental management team to deal with EMP effectively and efficiently. Hence will create a team 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 Figurebelow:

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Whole Time Director (Operations)

Deputy manager (ENV) Deputy Manager (safety)

Field Staff (ENV) Firemen

Figure 7-12Organizational set up for Environmental Management plan 7.8.1 Responsibilities of Environment Management Cell The cell will also be responsible for monitoring of the plant safety and safety related systems which include : Checking of safety related operating conditions. Visual inspection of safety equipment‟s. Preparation of a maintenance plan and documentation of maintenance work specifying different maintenance intervals and the type of work to be performed. Other responsibilities of the cell will include : Submit annual Environmental statement (in Form – V). This Form –V will be submitted every year before 30th September. Timely renewal ofConsents & Authorization will also be taken care of. Submitting environmental monitoring report toTNCPB. 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. Keeping the management updated on regular basis about the conclusions / results of monitoring activities and propose measures to improve environment preservation and protection. Conducting regular safety drills and training programs to educate employees on safety practices.

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A qualified and experienced safety officer will be responsible for the identification of the hazardous conditions and unsafe acts of workers and advise on corrective actions, organise training programs and provide professional expert advice on various issues related to occupational safety and health. Conducting safety and health audits to ensure that recommended safety and health measures are followed. 7.8.2 Monitoring of Environment A regular monitoring of environmental parameters like air, water, industrial effluent, noise and soil as well as performance of pollution control facilities and safety measures in the plant are important for proper environmental management of any project. Therefore, the environment and safety 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. Useful to compile pollution related data for remedial measures and find out efficiency level of pollution control measures adopted.

Table 7-9Environmental Monitoring Plan S. Particulars Frequency of Parameters for Monitoring No monitoring 1. Air pollution monitoring Scrubber monitoring Once in a month Chlorine

Boiler and DG Stack Once in a month PM, SOX, CO and NOx emissions Ambient air quality within Once in a month All 12 parameters as given in NAAQS the premises of the proposed unit At 1 location in Prevalent Once in a month Down Wind Direction At 1 location in Up Wind Once in a month Direction 2. Noise monitoring At various locations within Once in amonth Noise Levels in dB(A)

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the premises 3. Water quality monitoring (Surface and Process) One location Once in amonth pH, Color, Turbidity, TSS, TDS, COD,BOD, Chlorides, Sulphates, Total Alk. Ca & Mg, Hardness, Fluoride etc. 4 Soil Quality monitoring

One location near Once a month Physicochemical properties, Nutrients, Heavy Hazardous waste storage metals area at site and one location outside site 5 Ground water quality monitoring

One location near Once a month Physicochemical properties, Heavy metals Hazardous waste storage area at site and one location outside site 6 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, Disssolved Phosphates, Total Kjeldhal nitrogen,Cyanide, Nickel, Residual Sodium Carbonate. 7 Sewage Quality Monitoring

STP inlet and outlet Once a month pH, temperature, TDS,TSS, BOD

8 Work place Monitoring Quarterly Noise, VOC, Lux levels

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7.8.3 Laboratory Facilities Full fledged laboratory is available at TPL to analyze and monitor the quality of air, water and noise in the plant surroundings. 7.8.4 Corporate Responsibility for Environmental Protection (CREP)

Table 7-10 CREP Points and Compliance status S.No Action points Compliance Status 1 Adoption of state-art technology State of art technology is adopted for process technology and engineering to control the emission at the design stage itself. 2 Management of storm water Storm water generated from process area and tank farm area during initial hours of rain is pumped to effluent treatment plant for treatment. 3 Effective detoxification and waste Full fledged activated sludge process based effluent water scheme treatment plant is available. Adequate numbers of suspended aerators and diffuser are provided for better aeration and reduction of COD. Neutralization pit is available for uniform mixing of effluents to avoid the shock load of high COD (Max of 1200- 1500 ppm) to the treatment system. 4 Control of emission from As a pollution abatement and fuel conservation measure, combustion DG set is provided with waste heat recovery boiler to produce steam from the flue gas waste heat &this had reduced the fuel consumption in boilers.

Also DG is fitted with low NOx components. 5 Proper functioning of point All scrubbers (chlorine vent gas scrubber, HCI absorber) source emission control systems in our unit are in continuous operation. Control equipment has got 100% standby and starts automatically if one fails. Backup power supply is also available through emergency DG sets, which starts automatically. Continuous online sensor is available in the stacks for monitoring of chlorine & HCI vapour and monitoring data has been connected to CAC TNPCB server.

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S.No Action points Compliance Status Stack emission is being monitored by our laboratory and TNPCB laboratory. 6 LDAR programme Continuous Online detectors, for Propylene, Chlorine and Allyl chloride are available at critical locations. Also, Leak Detection and Repair programme is being followed at scheduled frequency and recorded and reviewed. Continuous online VOC sensor is provided for monitoring in ambient air and monitoring data has been connected to CAC, TNPCB server. 7 Handling of halogenated organics Chlorinated organics (halogenated Organic) is a byproduct in the process and stored in storage tanks. Since the CO is in liquid form and having high boiling point (>1000C), there is no possibility for CO vapour to escape to flare. It is sold as a product and also burnt to produce Hydrochloric Acid. Scrubber is provided to take care of Chlorine vapour emissions if any. Continuous online sensor is available in the stack for monitoring of chlorine & HCL vapour and monitoring data has been connected to CAC, TNPCB server. 8 Control of fugitive emissions of Online detectors are provided to check the fugitive carcinogenic components emissions and health checks of the workers are being carried out once in three months and monitored and recorded. 9 Management of solid waste Facility is available for proper storage of hazardous waste at the site. ETP waste will be disposed to a secured landfill facility. Used oil is sold to CPCB/SPCB authorized vendor. Waste oil is used as fuel in heaters. Manifest system is being followed during transportation

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S.No Action points Compliance Status of hazardous wastes. 10 Proper operation of incinerator Not applicable 11 Optimizing the inventory of In a highly competitive market, inventory management hazardous chemicals already calls for minimum storage only. TPL follows the same. Continuous efforts are taken to optimize the inventory of all chemicals. The maximum storage of most of the hazardous chemicals at any time is not more than 10 days requirement and is based on the transportation time from the source of suppliers.

12 Self-regulation by industry Air emission and liquid effluents are being monitored in through regular monitoring and the laboratory at the TPL at regular intervals. environmental auditing Also it is being monitored by TNPCB. Environmental issues are reviewed on a daily basis in the plant meetings and in the environment management meeting. 13 Organizational restructuring and This is taken care during recent organizational accreditation of environmental restructuring. manager of industry Also, in line with this, head of the business unit, who has wide and in depth knowledge of the plant., is made as the chairman of the Environment Management Committee. Other members of the committee are mostly chemical engineers, with adequate knowledge and experience in process industries to assist the chairman.

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Table 7-11CEPI (Comprehensive Environment Pollution Index) Action Plan Status S.No Condition Status

1 Online sensor for monitoring chlorine Completed.

will be provided and monitoring data will Chlorine online sensor is provided in be uploaded to TNPCB server by July Ambient Air and in stack and monitoring 2010. data has been uploaded to Care Air centre,

TNPCB server on 15.07.2010

2 To conduct AAQ survey as per the Ambient Air quality Survey is being was NAAQS, 2009 conducted regularly through external laboratory as per the new standards.

3 Environmental monitoring will be carried Environmental monitoring is being carried out through accredited laboratory also. out through external accredited laboratory from October 2010.

4 The marine impact study will be Marine impact study for the treated conducted either jointly with M/s. MPL effluent discharge into the sea was or stand-alone. conducted through accredited EIA consultant and the report is sent to the pollution control board dated

5 Replacing of Ferric chloride with Ferric chloride is replaced with environment friendly coagulant in ETP to environment friendly coagulant in the improve colour. flocculation tank of ETP.

Results are encouraging in color and quality improvement in the treated effluent.

6 Replacing of Ferric Chloride with Ferric chloride is replaced with an environment friendly coagulant in ETP to environment friendly coagulant (Flocool – reduce ETP sludge (hazardous waste) 120 and Flocool-1020) in the flocculation generation. tank of ETP.

Results are encouraging in color and quality reduction of sludge generation.

ETP sludge generation:

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S.No Condition Status

Period – Apr 09 - March10 – 150MT

Period –Apr 10 - March 2011- 124MT

Period – Apr 11 – March 2012 – 115MT

7 Green belt development 150 nos of trees were planted during Dec 2012.

7.8.5 Budgetary Provisions for EMP Adequate budgetary provisions have been made by TPL for execution of environmental management plan. 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 will be as given in Table 7-12.

Table 7-12Cost for Environmental Protection Measures in (Rs.)

Recurring cost Environmental protection Capital Cost S.No Proposed per Annum measures (Lakhs) (Lakhs) 1. Air Pollution Control 50 25 5 2. Water Pollution Control 300 35 50 3. Noise Pollution Control 5 1 2 Occupational Health and 4. 50 - 10 safety 5. Green belt Development 2 5 2 6. Storm water Management 20 7 3

7. Waste Management 20 5 3

8. Fire Fighting 120 15 10 Total 567 93 85

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8 CONSENT- COMPLIANCE STATUS

8.1 Applicability of Environmental Clearance

Since the Epichlorohydrin plant commenced its operation in the year 1995, Environmental Clearance was not applicablevide Section III (b) of EIA notification dated 27/1/1994

8.2 Consent For Existing Operation

TPL has established facilities to make Epichlorohydrin (ECH) in the year 1995, the company is in possession of valid consent order form TNPCB Vide order No 14090 dated 03.11.2010. The unit is not operational since 1stApril, 2013 owing to unviable business opportunities for the product. The Consent to Establish vide Letter dated 22/9/1993 is enclosed in Annexure-17. The Renewal for Consent to Operate vide letter dated 21/4/1999, 3/11/2010 and application for renewal dated 28/3/2014 are enclosed in Annesure-18, Annexure-19 and Annexure-20respectively. Hazardous waste Authorization for existing facility is enclosed in Annexure-21.

Table 8-1 Consented quantity vide order No 17966 dated 21.04.1999 S.No Products Quantity 1 Epichlorohydrin 909 T/month 2 Hydrochloric Acid 518 T/day 3 Chlorinated Organics 400 T/day

8.3 Compliance Conditions

Table 8-2Consent order under water Act No. 17966 dated 21.04.1999 S.No. Condition Status 1 The unit shall operate and maintain the Effluent Treatment Plant has been operated and effluent treatment plant to treat the trade being maintained efficiently and effectively to effluent so as to achieve the standards treat the trade effluent. prescribed by the Board During the time of operation treated effluent was periodically analyzed through TNPCB Laboratory, in-house and NABL/ MoEF approved external Laboratory. The consolidated Report of Treated Effluent is enclosed in Annexure-22.

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S.No. Condition Status 2 The unit shall maintain proper temperature Proper temperature is being maintained to and atmosphere to obtain the correct product obtain the correct product during fractional during fractional distillation distillation. 3 The unit shall not discharge any trade effluent Treated effluent is discharged only to sea into the nearby nulla, which carries the through M/s. Manali Petrochemicals Limited‟s surplus from Red Hills treated effluent disposal pipeline, after satisfying the standards prescribed by the Board 4 The unit shall discharge the effluent through Treated effluent is discharged only to sea M/s. Manali Petrochemicals Limited‟s through M/s. Manali Petrochemicals Limited‟s pipeline into the Bay of Bengal after treated effluent disposal pipeline. satisfying the standards prescribed by the Board 5 The unit shall provide the Fire extinguishers Fire fighting facilities are provided to prevent to avoid any explosion of fire any explosions. The photographs of fire fighting systems are given in Section 7.6.11 of this Report (Chapter -7) 6 The unit shall dispose the solid waste as The agreement executed for disposal of reported Hazardous waste with quantity is enclosed in Annexure-29 Lime sludge generated is sent to Brick manufacturers. The receipt of the same is enclosed in Annexure-23 7 The unit shall store the Epichlorohydrin in a Epichlorohydrin is stored in tanks with cool dry place to avoid fire hazard adequate fire fighting facilities.

Table 8-3Renewal consent order under Air Act No. 28635dated 21.04.1999 S.No. Condition Status

1 The unit shall operate and maintain the Air Air Pollution control measures are operated and Pollution control measures so as to achieve maintained efficiently to achieve the ambient the ambient air standards prescribed by the air quality standards. The APC measures

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S.No. Condition Status

Board provided are enclosed in Section

Ambient Air quality is monitored through TNPCB laboratory, In-house laboratory and NABL/ MoEF approved external laboratory. The reports of Stack Monitoring is enclosed in Annexure-24 and Ambient Air Quality Monitoring is enclosed in Annexure-25

2 The unit shall provide a proper diversion for Complied the flare towards a wind direction

3 The chlorine gas shall be vented into Counter current scrubber with dilute caustic lye atmosphere after allowing it to pass through a solution is provided to absorb chlorine scrubber. emission from process Reactor area.

Chlorine online continuous sensor is provided in the stack and connected to TNPCB (Care Air Centre) for real time monitoring from 15.07.2010.

4 The toxic liquids are to be incinerated and the i. There is no toxic liquid generated from resulting process emission to be tested the ECH plant. However byproduct - periodically. To avoid any discharge of toxic Dichloro Propane (chlorinated Organics) gas and to avoid suffocation. is sold in the market.

ii. Upon requirement, Dichloro propane is burnt to produce HCL and emission from HCL production unit is Counter current scrubbed with water to remove chlorine and HCL vapours.

iii. Continuous online sensor is available in the stack to monitor HCL emission and monitoring data has been connected to TNPCB Care Air Centre) for real time monitoring from 15.07.2010.

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S.No. Condition Status

iv. Stack monitoring and Ambient Air quality survey were carried out by an MoEF approved laboratory on and the report of analysis is enclosed as Annexure- 24.

5 The unit shall continue to develop green belt Green belt has been developed inside and around the premises of the unit. outside the factory premises covering about 4.0acres and the photographs enclosed

Tree saplings are regular planted during world Environment Day celebrations.

We have proposed to develop additional green belt around the premises.

6 The unit shall maintain emission standards of Stack monitoring was conducted by TNPCB on 150 g/m3 for the particulate matter. 1.12.2011 and the report of analysis is enclosed as Annexure -24

Table 8-4Consent order under Air Act- no. 14090 dated 03.11.2010 S.No. Condition Status

1 The unit has to comply the directions as Online continuous monitors are provided issued in proceeding dated 31.12.09 in for monitoring chlorine and VOC in respect of installation of online air quality ambient air and connected to TNPCB (Care monitoring and data uploading Air Centre) for real time monitoring from 15.07.2010.

Online continuous monitors are provided for monitoring chlorine in scrubber stack and HCL vapour in Hydrochloric acid production unit stack. Monitoring data has been uploaded to CAC, TNPCB from 15.07.2010

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S.No. Condition Status

2 The unit shall operate and maintain the air Ambient air quality was conducted through pollution control measures continuously and an NABL/MoEF approved laboratory and efficiently to satisfy the ambient air quality the results attached as Annexure-25 standards prescribed in ministry of Environment and Forests notification dated 16.11.2009 and the emission standards prescribed by the board.

3 For protection, improving the quality of Fully fledged laboratory facilities are environment, the unit shall have self available for monitoring of air, water waste monitoring system for stack emission, water, and ground water samples.

fugitive emission ambient air quality, Continuous online sensors are provided for untreated/ treated trade effluent/ sewage monitoring chlorine, Hydrochloric acid effluent / ground water/ soil quality and vapour and VOC and the monitoring data surface water monitoring, hazardous/ non has been connected to CAC for continuous hazardous solid waste generation, reduction monitoring at TNPCB. recycling and scientific disposal options so as Online detectors for monitoring chlorine to ascertain the compliance status of and propylene are installed at appropriate standards prescribed by Tamil Nadu pollution location for continuous fugitive emission control board, ministry of environment and monitoring. forests, EP Acts 1986 Treated trade effluent and sewage effluents are analyzed regularly by TPL laboratory, external accredited laboratory and by TNPCB laboratory. The reports are enclosed in Annexure- 22

4 The unit shall carry out detailed environment Environment Audit study on water, air, land Audit study on water, air, land environment environment was conducted through and prepare detailed action plan for reduction external consultants M/s. of pollution at source so as to minimize the HubertEnviroCare system(P) Ltd. and generation of pollution load before July 2010. submitted to TNPCB vide letter dated TPL/ENV/24/2012 dated 21.03.2012

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S.No. Condition Status

5 The unit shall ensure that the units activities Effluent treatment plant has been operated shall not create any environmental impact to efficiently and effectively to ensure to the nature eco system and shall have remedial protect environment by maintaining the action plan by ascertaining the existing TNPCB standards.

status. Hazardous wastes generated at ECH plant are handled as per the authorization obtained from TNPCB.

Ambient air quality is being continuously monitored and monitoring data has been connected to CAC, TNPCB ascertain that our adherence towards environmental standards prescribed by TNPCB/ MoEF.

Treated sewage is utilized for gardening and green belt development.

6 The unit shall furnish the proposal with action Action plan will be submitted during start- plan for compliance of proposed revised up of the proposed change of product mix. standards for petrochemical plants.

7 The unit shall have a leak detection program Leak detection program is available. The and shall furnish the quarterly report. analysis report is enclosed in Annexure -26

Table 8-5Consent order under Water act- No.17966 dated 03.11.2010 S.No. Condition Status

1 The unit shall furnish the compliance status of Furnished Regularly to the Board conditions stipulated in the authorization issued under hazardous waste (M,H, and TM) Rules 2008.

2 For protection, improving the quality of environment, Full-fledgedin house laboratory the unit shall have self monitoring system for stack facilities are available for emission, fugitive emission ambient air quality, monitoring of air, water, waste untreated/ treated trade effluent/ sewage effluent/ water, ground water samples.

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S.No. Condition Status

ground water/ soil quality and surface water Continuous online sensors are monitoring, hazardous/ non hazardous solid waste provided for monitoring chlorine, generation, reduction recycling and scientific disposal Hydrochloric acid vapour and options so as to ascertain the compliance status of VOC and the monitoring data has standards prescribed by Tamil Nadu Pollution control been connected to CAC for board, ministry of environment and forests, EP Acts continuous monitoring at TNPCB.

1986. Online detectors for monitoring chlorine and propylene are installed at appropriate location for continuous fugitive emission monitoring.

Effluent treatment plant has been operated efficiently and effectively to ensure to protect environment by maintaining the TNPCB standards.

3 The unit shall carry out detailed environment audit Environment Audit study on study on water, air, land environment and prepare water, air, land environment was detailed action plan for reduction of pollution at source conducted through external so as to minimize the generation of pollution load consultants M/s. before July 2010. HubertEnviroCare system(P) Ltd. and submitted to TNPCB vide letter dated TPL/ENV/24/2012 dated 21.03.2012.

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S.No. Condition Status

4 The unit shall ensure that the unit‟s activity shall not Effluent treatment plant has been create any environment impact to the nature eco operated efficiently and effectively system and shall have remedial action plan by to ensure to protect environment ascertaining the existing status. by maintaining the TNPCB standards.

Hazardous wastes generated at ECH plant are handled as per the authorization obtained from TNPCB.

Ambient air quality is being continuously monitored and monitoring data has been connected to CAC, TNPCB ascertain that our adherence towards environmental; standards prescribed by TNPCB/MoEF.

5 The unit shall not discharge any waste water into Treated effluent is discharges to nearby water courses directly/indirectly. sea thro M/S Manali petrochemicals Limited‟s pipeline after satisfying the standards prescribed by the board.

Treated sewage is used for gardening.

6 The unit shall furnish the proposal with action plan for Action plan will be submitted compliance of proposed revised standards for during start-up of the proposed petrochemical plants. change of product mix.

7 The unit shall monitor the ground water in and around Ground water (test bore well the sludge area by providing piezometers. water) is analyzed regularly by external laboratory and by TNPCB laboratory. The reports are

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S.No. Condition Status

attached in Annexure -27

8 The unit has to dispose the accumulated hazardous Hazardous wastes generated at wastes obtaining authorization from the board. ECH plant are handled/ disposed as per the authorization obtained from TNPCB. Authorization No. 3563 dated 17.12.2009. The Industrial Waste Management Membership is enclosed in Annexure-28 and agreement with Ramky for Disposal of Hazardous Waste is enclosed in Annexure-29

9 The unit shall conduct the marine impact study where TPL has conducted Marine impact the treated effluents discharge into the sea. study for the treated effluent discharge into sea through accredited EIA consultant M/s. HubertEnviroCare system, Chennai .and submitted to TNPCB.

10 The unit has to monitor the effluent quantity and Monitoring is being done by quality at the outlet at sea. TNPCB.

11 The unit has to revamp the effluent treatment plant by Ferric chloride is replaced with an using alternative coagulation/ flocculants. environment friendly coagulant (Flocool-120 and flocool- 1020) in the flocculation tank of ETP.

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9 PROJECT BENEFITS

9.1 MARKET POTENTIAL

MPL is the only domestic manufacturer of Propylene Oxide. The Propylene Oxide is mostly consumed in-house to manufacture Propylene glycol and Polyol. There is good market potential for Propylene oxide and its derivatives Propylene glycol and Polyol. Current imports of Propylene oxide is about 20000 MTPA. Considering the domestic production, the total demand for Propylene oxide is around 60000 MTPA. Current Propylene glycol imports is about 50000 MTPA and polyol imports is more than 1 lakh tone per annum. The 15000 MTPA Propylene oxide produced can be sold as such or used for making Propylene Glycol and Polyols. Propylene glycol is used for various applications in industries viz Pharmaceuticals

Food flavors and essences

Polyester resins

Perfumery compounds

Cosmetics

Cigarettes

Tooth Paste

Pesticides

Of this, Pharmaceuticals, food flavors and polyester resins manufacturing sectors account for a major share in the present consumption of Propylene Glycol in the country. 9.1.1 Polyols The polyols are broadly classified based on application as given below

Flexible Polyurethane foams

Rigid Polyurethane foams

Semi-rigid Polyurethane foams

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9.1.1.1 Flexible Polyurethane Foams Flexible foams are largely used for various household applications such as furniture cushions, beds, mattresses etc. Also in automobiles, seat cushions, arm rests coverings etc are made using flexible foams. In certain cases these are used as packaging material for high value items. Some of the miscellaneous applications include foam laminations, toys, and novelties

9.1.1.2 Rigid Polyurethane foams The specific thermal insulation characteristics of rigid PU foams are far superior to that of all other polymeric foams. The obvious advantage of polyurethane rigid foam is the lesser thickness required to achieve the same thermal efficiency as other materials.

These are used as insulating materials in

Air conditioning and refrigeration industry (insulation of domestic refrigerators, Air conditioner, refrigerated vans etc.,)

Process industry (insulation of process equipments, pipelines, storage tanks etc)

Transportation industry ( insulation of rail coaches, bus coaches, air craft, ships etc)

9.1.1.3 Semi-rigid Polyurethane foams Semi-rigid PU foams are used in the manufacture of steering wheels, scooters/motorcycles/bicycles/car seats, arm rests, shoe soles etc.

9.1.2 Miscellaneous applications Polyols are also used in the manufacture of polyurethane elastomer, coatings, paintings, adhesives/sealants, binders etc.

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10 SUMMARY & CONCLUSION

10.1 SUMMARY

The Environmental Impact Assessment report studied the proposed project and assessed its predicted impacts on land, water, air, soil and biological environment of the region. The proposed project was found to be complying with all the environmental, health and safety standards, and is planning to use efficient equipments and advanced technologies to reduce its air emission, water and waste generation. It is also taking proper care in its hazardous chemicals and waste handling. It has also laid down solid plans to monitor and combat any disaster or emergency situation in the project. Other than the above, proposed project will be bringing in various economical, social and environmental benefits to the Manali town, Tamil Nadu and to the county. The Social, Economical and Environmental benefits of the project includes the ones mentioned in the earlier chapter. 10.2 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: Due to elimination of propylene heater and HCl scrubbing unit, the emissions from respective stack will be reduced in the proposed production unit, thereby reduction in the overall air pollution load. Project study area is not falling within 10km radius of National Park, Wildlife Sanctuary, etc., As the proposed project falls within the existing site, there is no need for rehabilitation and resettlement. No extraction of ground water is proposed. There will be no additional water requirement and no additionalwater discharge for the proposed project. No change in waste water discharge and water pollution load with respect to quantity and quality. Lime wastes are disposed to brick manufacturers. Hazardous wastes are disposed as per hazardous waste rules.

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TPL has adequate safety measures and does not anticipate any adverse effect on health of workers. For handling and storage of raw materials and finished products proper measures has been considered. .On line chlorine Monitoring system available in the existing scrubber stack, will be used and connected to Care Center TNPCB. LDAR program is available and same will be followed to reduce fugitive emissions Dust scrubber and it is proposed for Milk of lime Plant. STP and ETP outlet will have flow measurement, pH, BOD, COD, TSS for online monitoring. Additional 20.7% area of Green belt is proposed apart from the existing Green belt area.

10.3 RECOMMENDATIONS

With the above benefits, environmental, societal commitment and readiness of the project, the environmental impact assessment report strongly affirms and recommends the proposed project of product change mix. Some of the recommendations given by the consultant with respect to the project are as follows: Suggestions of qualitative risk analysis study will be followed to minimize accidents and for safe operations. Environmental Management Plan will be strictly adhered to minimize the environmental impacts of proposed project. Green belt development will be well maintained to improve the aesthetics and biodiversity of the area.

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Disclosure of Consultants TPL-EIA for Change of Product Mix

11 DISCLOSURE OF CONSULTANTS ENGAGED Details of the consultancy and consultant engaged are as follows:

Table 11-1Details of the Consultant Consultant Hubert Enviro Care Systems Pvt Ltd, Chennai NABET Certificate No NABET/ EIA/ 1013/ 041 EIA Coordinator Dr.JRMoses

1. National Accreditation Board for Testing and Calibration Laboratories (NABL) accreditation for Laboratory services for ISO17025 2. MoEF Recognized Laboratory 3. ISO 9001:2008 qualified and certification by URS 4. Environmental Management System complying AS/NZS ISO 14001:2004 5. Occupational Health & Safety Management System OHSAS 18001:2007 6. Approved byKarnataka PCB and Kerala PCB. 7. Achilles joint qualification system. Achilles Id.15148 8. Kiwa Quality Management System

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TERMS OF REFERENCE

S. No TOR Points Compliance Status provided in the report

1. A separate chapter on status of compliance of Environmental Chapter 8, Pg 149 Conditions granted by State/Centre to be provided. As per circular dated 30th May, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of conditions on existing unit to be provided in EIA/EMP report.

2. Executive summary of the project Pg i

3. Justification of the project. Chapter 1, Pg 2

4. Promoters and their background. Chapter 1, Pg 1

5. Regulatory frame work. Chapter 1, Pg 7

6. Environment clearance for the existing unit issued by the Annexure-17,18,19,20 Ministry (reasons, if not obtained), Consent to Operate and and 21 Authorization accorded by the SPCB.

7. Data for the stack emissions, fugitive emissions; water Chapter 2,

requirement and water balance chart; waste water generation, Stack emission – Pg 43 treated effluent quality, re-utilization and disposal of Water balance- pg.14 solid/hazardous waste for the existing unit. ETP – Pg 37

Solid and hazardous waste – Pg 121

8. Project location and plant layout. Chapter 2, Pg 14

Annexure – 6 & 7

9. Infrastructure facilities including power sources. Chapter 2,Pg 29

10. Total cost of the project along with total capital cost and Project cost - Table 2.2 Pg recurring cost / annum for environmental pollution control -16

measures. Cost for Pollution Control

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-Table7.12 pg 148

11. Project site location along with site map of 10 km area and site Chapter 2, Fig 2.2 Pg 17

details providing various industries, surface water bodies, Annexure-1 forests etc.

12. Present land use based on satellite imagery for the study area Land for the project of10 km radius. Details of land availability for the project along Chapter 2.

with supporting document. Table 2.-3, Pg 19

Annexure-4

Land use of study area

Chapter -3

Fig. 3-8, pg- 67

13. Location of National Park / Wildlife sanctuary / Reserve forest Not applicable with in10 km radius of the project.

14. Permission from the State Forest Department regarding the Not applicable impact of the proposed plant on the surrounding reserve forests.

15. Details of the total land and break-up of the land use for green Chapter 2, Table 2-3 Pg18 belt and other uses.

16. List of products along with the production capacities. Chapter 2, Table-2.1, Pg 14

17. Detailed list of raw material required and source, mode of Chapter 2, Table 2.4, 2-5 storage. Pg 21

18. Manufacturing process details along with the chemical reactions Chapter 2, Pg 22 -28 and process flowchart.

19. Action plan for the transportation and storage of raw materials Chapter -2

and products. Table 2-4 pg 21,

Annexure-8

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20. Sources and quantity of fuel (coal etc.) for the boiler. Measures Not applicable as coal is

to take care of SO2emission. A copy of Memorandum of not used. Furnace oil Understanding (MoU) signed with the coal suppliers should be requirements Chapter 2, submitted, incase coal is used. Table 2-4, Pg 21

21. Site-specific micro-meteorological data using temperature, Chapter 3, Table 3.2, Pg relative humidity, hourly wind speed and direction and rainfall 48

is necessary. Annexure-11

22. Ambient air quality monitoring at 6 locations within the study Chapter 3, Table 3.1, Pg area of 5km, aerial coverage from project site as per NAAQES 46 notified on 16th September, 2009. Location of one AAQMS in downwind direction.

23. One season site – specific micro-meteorological data using Chapter 3, Table 3.4, Pg temperature, relative humidity, hourly wind speed and direction 51

and rain fall and AAQ data (except monsoon) for PM2.5, PM10, Table 3-5, pg 53 SO2, NOx, CO, HC including VOCs shall be collected. The Table 3-8, pg 60 monitoring stations shall take into account the pre-dominant wind direction, population zone and sensitive receptors Annexure-11 including reserved forests. Data for water and noise monitoring shall also be included.

24. Air pollution control measures proposed for the effective control Chapter 7, Pg 108 of gaseous/ process emissions with in permissible limits. Emphasis should be on effective control of VOC and odour.

25. Name of all the solvents to be used in the process and details of Not applicable solvent recovery system.

26. Design details of ETP, incinerator, if any along with boiler, Chapter 2, 2.8.4, Pg 29 scrubbers/bag filters etc.

27. Details of water and air pollution and its mitigation plan. Chapter 7 Pg 108

28. Action plan to control ambient air quality as per NAAQS Chapter 7, Pg 114 Standards notified by the Ministry on16th September, 2009.

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29. An action plan prepared by SPCB to control and monitor Chapter7,7.6.1, Pg 114 secondary fugitive emissions from all the sources.

30. Determination of atmospheric inversion level at the project site Chapter 4, Pg 82 and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modeling for proposed plant.

31. Permission from competent Authority for the drawal of water. Chapter 2, Pg 34, 35 Fig- Water balance chart for existing and product mix change project 2-13,2-14

including quantity of effluent generated recycled and reused and Annexure- 9 CMWSSB effluent discharge. Receipt

32. Complete scheme of effluent treatment. Characteristics of Chapter 2,

untreated and treated effluent to meet the standard. Treated 2.8.4 Pg 37 -41 waste water to meet the norms of CETP/ marine discharge.

33. Zero discharge effluent concepts to be adopted. Not applicable

34. Ground water quality monitoring minimum at 6 locations shall Chapter 3, , Table-3-9

be carried out. Geological features and Geo-hydrological status Pg 62 of the study area and ecological status (Terrestrial and Aquatic).

35. The details of solid and hazardous wastes generation, storage, Chapter 7, Pg 121 utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste.

36. Material Safety Data Sheet for all the Chemicals are being used/ Annexure-15 will be used.CAS No./ RTECS No./DOT/UNetc to be mentioned against each chemicals.

37. Details of chlorine handling and storage facilities. Measures to Annexure-30

be taken in case of leakage along with alarm system. Risk Assessment

38. Authorization/ Membership for the disposal of solid /hazardous Annexure-21, 28, 29 waste in TSDF.

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39. Risk assessment for storage for chemicals/ solvents. Action plan Annexure 30-Risk for handling &safety system. Assessment

40. Action plan for development of green belt over 33% of the total Chapter 7, Pg122

project area within plant premises with atleast 10 meter wide Annexure- 13 green belt on all sides along the periphery of the project area, in downward direction, and along roadsides etc.

41. Action plan for rain water harvesting measures at plant site shall Chapter 7, Pg 117

be included to harvest rain water from the roof tops and storm Annexure-12 water drain store charge the ground water.

42. Details of occupational health programme. Chapter 7, , Pg 135- 139

i. To which chemicals, workers are exposed directly or indirectly. -do-

ii. Whether these chemicals are within Threshold Limit Values -do- (TLV)/ Permissible Exposure Levels as per ACGIH recommendation.

iii. What measures company have taken to keep these chemicals -do- within PEL/TLV? How the workers are evaluated concerning their exposure to chemicals during pre-placement and periodical medical monitoring.

iv. What are onsite and offsite emergency plan during chemical Annexure-30 Emergency disaster. Preparedness Plan

v. Liver function tests(LFT) during pre-placement and periodical Chapter 7, Pg-138 examination.

43. Details of occupational health surveillance programme. Chapter 7, Pg 138

44. Socio-economic development activities shall be in place. Chapter 3, 7 Pg-73

45. Note on compliance to the recommendations mentioned in the Chapter 7, 7.8.4, Pg 144 CREP guidelines.

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46. Detailed Environment management Plan (EMP) with specific Chapter 7, Pg 108 reference to details of air pollution control system, water & waste water management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure shall be provided.

47. EMP shall include the concept to waste-minimization, recycle / Chapter 7, Pg-114 reuse / recover techniques, Energy conservation, and natural resource conservation.

48. Total capital cost and recurring cost / annum for environmental Chapter7,Table7-12

pollution control measures Pg-148

49. Corporate Environmental Responsibility Chapter 7, Pg140

i. Does the company have a well laid down Environment Policy Chapter 7, Pg 141 approved by its Board of Directors? If so, it may be detailed in the EIA report.

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

iii. What is the hierarchical system or Administrative order of the Chapter 7, Pg 141 company to deal with the environmental issues and for ensuring compliance with the EC conditions? Details of this system may be given.

iv. Does the company have a system of reporting of noncompliance Not applicable / violations of environmental norms to the Board of Directors of the company and / or shareholders or stake holders at large? This reporting mechanism should be detailed in the EIA report.

50. Any litigation pending against the project and / or any direction / Not applicable order passed by any Court of Law against the project, if so, details thereof.

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51. A tabular chart with index for point wise compliance of above Pg-163-168 TORs.

The following general points shall be noted:

i. All documents shall be properly indexed, page numbered. ii. Provided Period / date of data collection shall be clearly indicated.

ii. Authenticated English translation of all material provided in - Regional languages.

iii. The letter /application for EC shall quote the MOEF file No. and Annexure-2 also attach a copy of the letter.

iv. The copy of the letter received from the Ministry shall be also Annexure-2 attached as an annexure to the final EIA-EMP Report.

v. The final EIA-EMP report submitted to the Ministry must - incorporate the issues in this letter. The index of the final EIA- EMP report must indicate the specific chapter and page no. of the EIA-EMP Report.

vi. Certificate of Accreditation issued by the QCI to the Annexure -32 environmental consultant shall be included. vii. It was decided that TOR s prescribed by the Expert Appraisal - Committee (Industry) shall be considered for preparation of detailed report for the above mentioned project in addition to all the relevant information as per the Generic Structure of EIA given in Appendix III and III Ain the EIA Notification, 2006. After detailed deliberations, the Committee exempted the public hearing as per Section7(i), III Stage(3), Para(i)(b)of EIA Notification 2006, subject to submission of authentic document from the State Govt. indicating that the project is located in the notified industrial area. The final EIA/EMP report shall be submitted to the Ministry for obtaining environmental clearance.

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