For Proposed Expansion of Organic Chemical Manufacturing Plant

Transcription

1 For Proposed Expansion of Organic Chemical Manufacturing Plant Prepared For Dujodwala Products Ltd. Village, Maharashtra Prepared By MITCON Consultancy & Engineering Services Ltd., Pune Environment Management and Engineering Division Shivajinagar Pune, Pune Phone: /407/500, Fax: MITCON Consultancy and Engineering Services Ltd., Pune 1 EME/CS/EIA- DPL-IND/ /111 R01 Date.:

2 Contents TOR COMPLIANCE... 8 CHAPTER 1 INTRODUCTION Preamble Purpose of the Identification of Project & Project Proponent Nature and Size of the Project Project Location Environmental Policies and Legal Provision For Environment Scope of the Study Scope of Environment Impact Assessment (EIA) EIA Methodology Organization of CHAPTER 2 PROJECT DESCRIPTION Introduction Type of Project Need for the Project Project Location Plant Layout Raw Material Requirement and Transport Process Details Basic Requirement Of The Project Utilities Existing Environmental Compliance CHAPTER 3 DESCRIPTION OF THE ENVIRONMENT Study Area Methodology of Conducting Baseline Study Physical Environment Air Environment Micro Meteorology MITCON Consultancy and Engineering Services Ltd., Pune 2

3 3.6 Ambient Air Quality (AAQ) Noise Environment Water Environment Land Environment Ecology & Biodiversity Socio-Economic Environment CHAPTER 4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Identification of Impacts Air Pollution Impact on Soil Environment Impact on Water Use Impact on Water Quality Rainwater Harvesting Impact on Noise Environment Impact on Socio-Economic Environment CHAPTER 5 ANALYSIS OF ALTERNATIVES Introduction Analysis of Site Alternative CHAPTER 6 ENVIRONMENTAL MONITORING PROGRAM Introduction Sampling Schedule and Locations Laboratory Facilities CHAPTER 7 ADDITIONAL STUDIES Risk Assessment Risk Mitigation Measures Disaster Management Plan Off-Site Emergency Plan Public Hearing CHAPTER 8 PROJECT BENEFITS Introduction Improvement in the Physical Infrastructure MITCON Consultancy and Engineering Services Ltd., Pune 3

4 8.3 Improvement in Social Infrastructure Other Tangible Benefits Employment Potential Skilled, Semi-Skilled and Unskilled CHAPTER 9 ENVIRONMENT MANAGEMENT PLAN Introduction Objectives of Environmental Management Plan Checklist of Statutory Obligations Environmental Management Cell (EMC) Construction Phase Environment Management Operational Phase Air Environment Management Operational Phase Noise Environment Management Ash Evacuation System Biological Environment Land Environment Green Belt Occupational Safety & Health Socio-Economic Welfare Activities Environmental Monitoring Schedule Environmental Budget CHAPTER 10 SUMMARY AND CONCLUSION Introduction Project Description Description of the Environment Environmental Impact Assessments Environmental Management Plan Environmental Monitoring Project Benefits CHAPTER 11 DISCLOSURE OF CONSULTANT ENGANGED Background of the Organization About EME Division and Consultancy Services Offered Consultants Engaged in Preparation of EIA EMP MITCON Consultancy and Engineering Services Ltd., Pune 4

5 TABLES Table No. 1.1 Product Profile of Dujodwala Table No. 1.2 List of following products against the existing products Table No. 1.3 Summary of Environmental Legislation applicable for Proposed Project. 19 Table No. 2.1 Detailed project cost break up Table No. 2.2: Salient Features of the Project Site Table No. 2.3 List of Raw Material & Quantities Table No. 2.4 Imported Raw Materials Table No. 2.5 Water Balance for Existing Chemical Unit Table No. 2.6 Water Balance for proposed Chemical Unit Table No. 2.7 Current Effluent Generation Table No. 2.8 Proposed Effluent Generation Table No. 2.9 Solid Wastes Generated Quantity and Mode of Disposal Table No. 3.1 Baseline Environmental Parameters Table No. 3.2 Location Features of the Site Table No. 3.3 Meteorological Parameters Monitored At Site Table No. 3.4 Wind direction from October to December Table No. 3.4 (A) Wind speed from October to December Table No. 3.4 (B) Temperature data for the months of October to December Table No. 3.4 (C) Relative humidity for the months of October to December Table No.3.4 (D) Temperature recorded at the site Table No. 3.4 (E) Relative Humidity recorded at the site Table No. 3.5 Description of Ambient Air Quality Monitoring Stations Table No. 3.6 Techniques Used for the Analysis of Ambient Air Quality Parameters Table No. 3.7 Observations of Air Monitoring Table No. 3.8 Ambient Noise Levels in Study Area Table No. 3.9 Water sampling locations Table No Water Quality Results (Sortout parameters) Table No Soil Quality Monitored within Buffer Zone of project Table No Ecology Survey Sampling Locations Table No List of plant species observed in 10km radius of the project area Table No Mammal species in the study area Table No Amphibian and reptile in the study area Table No Avifauna of the study area Table No Common fish species found in the river (Patalganga) Table No Demographic details of the study area Table No (A) Population by Sex and Sex Ratio Table No (B) SC and ST population in the study area Table No Population and sex ratio among SC s and ST s Table No Population in the study area (0-6 years) age group MITCON Consultancy and Engineering Services Ltd., Pune 5

6 Table No Number of Household Population and Household Size Table No Literacy & Illiteracy rate of the Study Area Table No Educational Facility in the Study Area Table No Occupational Structure of Worker Falls in the Study Area Table No Amenities Facility (Water) Table No Medical Facility in the Study Area Table No Land use Pattern In The Study Area (in Ha) Table No. 4.1Component Wise Emission Table No. 5.1 Salient Features of Site Table No. 6.1 Post project Monitoring Schedule Table No. 9.1 Solid Waste Generation Details of Proposed and Existing Plant Table No. 9.2 Projected Treated Effluent Characteristics Table No. 9.3 Budgetary allocation for environmental protection measures FIGURES Figure No. 1.1 Map Showing Chemical Industries in Maharashtra, India Figure No. 2.1 Index Map showing the location of the Project Figure No. 2.2 Plot Boundary Marked on Google Earth Image Figure No. 2.3 Figure showing10 Km Radial Study Area Figure No. 2.4 Diagram of Solvent Recovery Process Figure No. 2.5 Products of α - pinene conversion Figure No. 2.6 Process Flow Chart for Camphor Manufacturing Figure No. 3.1 Hydrogeology of the Pune District Figure No 3.2 Depth to water level (May 2007) Figure No. 3.3 Depth to water level (November 2007) Figure No. 3.4 Pre-monsoon (L) and Post-mansoon (R) Water Level trend (May & Nov Figure No. 3.5 Talukawise Ground Water Resources in Raigad Figure No. 3.6 (A) Wind rose for the month of October Figure No. 3.6 (B) Wind rose for the month of November Figure No. 3.6 (C) Wind rose for the month of December Figure No. 3.6 (D) Seasonal Wind rose for the month of October December Figure No. 3.7 Ambient Air Monitoring Locations Figure No. 3.8 Ambient Noise Monitoring Locations Figure No. 3.9 Water Sampling Locations Figure No Soil Sampling Locations Figure No Map showing Cultivation (L) & Uncultivated Land (R) of Raigad District Figure No Seismic Map showing the project site Figure No Ecological Sampling Locations MITCON Consultancy and Engineering Services Ltd., Pune 6

7 Figure No Photographs of the Study Area Figure No Land use of study area Figure No.7.1. Schematic Flow Chart for On-Site Emergency Plan Figure No.7.2. Schematic Flow Chart for Off-Site Emergency Plan Figure No. 7.3 Glimpses of the Public Hearing Figure No. 9.1 Environment Management Cell Figure No. 9.2 Schematic diagram of proposed ETP Figure No. 9.3 Schematic diagram of existing ETP ANNEXURE Annexure No. 1 Master Layout Plan Annexure No. 2 Additional Water Requirement Permission Letter Annexure No. 3 Power Permission by Maharashtra State Electricity Distribution Co. Ltd Annexure No. 4 Three Months Ambient Air Quality Results Annexure No. 5 Noise Monitoring Results Annexure No. 6 Water Quality Results Annexure No. 7 Soil Quality Results Annexure No. 8 Satellite imagery for the study area of 10 km radius Annexure No. 10 Minutes of Public Hearing _English Annexure No. 11 Consent to Establish Annexure No. 12 Consent to Operate Annexure No. 13 Environmental Audit Statement MITCON Consultancy and Engineering Services Ltd., Pune 7

8 TOR COMPLIANCE Ltd. Vide letter No, J-11011/154/2012-IA II (i) dated 11th January, No. Terms of References Compliance 1 Executive summary of the project Refer chapter 10 of EIA/EMP report 2 Justification of the project Justification of the project is discussed under Section 1.2 and 1.3 of Chapter 1 and 2.3 of chapter 2 of EIA/EMP report. 3 Project location and plant layout Project location is discussed under Section 1.5 of chapter 1 of EIA/EMP report and for plant layout refer Annexure 1 4 Promoters and their back ground Refer Section 1.3, Chapter 1 of EIA/EMP report 5 Regulatory framework Refer Section 1.6, Chapter 1 of EIA/EMP report 6 A separate chapter on status of compliance of Environmental Condition granted by State/Central to be provided. As per circular dated 30 th may, 2012 issued by MoEF, a certified report by RO, MoEF on status of compliance of condition on existing unit to be provided in EIA/EMP report 7 Environmental clearance for the existing unit issued by the ministry (reasons, if not obtained), Consent to Operate and Authorization accorded by the MPCB 8 Data for the stack emission, fugitive emission; water requirement and water balance chart; wastewater generation, treated effluent quality, re-utilization and disposal of solid/hazardous waste for existing unit 9 A map indicating location of the project and distance from severely polluted area Refer Section 2.10, Chapter 2, Existing Environmental Compliance is elaborated in the text with copy of consents annexed. The existing factory became functional in 1990s and was not covered under EIA notification Consent to Operate for existing unit and Consent to Establish for proposed expansion is available. Same is enclosed as Annexure No. 11 & 12 For water requirement and water balance chart refer Section & 2.8.3, chapter 2 of EIA/EMP report For wastewater generation treated effluent quality, re-utilization and disposal of solid/hazardous waste for existing unit refer Section & 2.9.2, chapter 2 of EIA/EMP report Refer fig. 2.1 and 2.3 for 10 km radius map. No severely polluted area is in 10 km radius of project site. 10 Infrastructure facilities including power sources Refer Section 2.8, chapter 2 of EIA/EMP report MITCON Consultancy and Engineering Services Ltd., Pune 8

9 No. Terms of References Compliance 11 Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures Total cost of the project Rs. 31 Crore Capital cost :- Rs. 50 lakhs Recurring cost per annum: - Rs 24 lakhs 12 Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests etc. 13 Present land use based on satellite imagery for the study area of 10 km radius 14 Location of National Park/Wild Life Sanctuary/Reserve Forest within 10 km radius 15 Details of the total land and break-up of the land use for green belt and other uses. 16 List of the products along with the production capacities. 17 Detailed list of raw material required and source, mode of storage and transportation. 18 Manufacturing process details along with the chemical reaction and process flow chart. 19 Site-specific micro-metrological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary. 20 Ambient air quality monitoring at 6 locations within the study area of 5 km., aerial coverage from project site as per NAAQES notified on 16 th September, Location of one AAQMS in downwind direction. 21 One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, SO2, NOx including HC and VOCs should be collected. The monitoring station should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring should also be included. 22 Air pollution control measures proposed for the effective control of gaseous emission within permissible limits. Refer figure 2.3 showing 10 km map of the study area, chapter 2 of EIA/EMP report Refer Annexure 8 Satellite imagery of 10 km radius There is no National Park/Wild Life Sanctuary/Reserve Forest within the study area Total Area 20 Acres Expansion of the project 5 Acres Green Belt 7 ha. Refer Section 2.1, chapter 2 of EIA/EMP report Refer Section 2.6, chapter 2 of EIA/EMP report For manufacturing process details refer Section 2.7, chapter 2 of EIA/EMP report Refer Section 3.5, chapter 3 of EIA/EMP report Refer Section 3.6 Ambient Air Quality table 3.5, chapter 3 of EIA/EMP report Refer Section 3.5, 3.6, chapter 3 of EIA/EMP report. Refer section 3.7 and 3.8 for noise and water quality respectively. Dust collector with wet scrubber. State-ofthe-art scrubbers will be installed for 10TPH boiler to limit the air pollution. MITCON Consultancy and Engineering Services Ltd., Pune 9

10 No. Terms of References Compliance Unloading areas will be provided with water sprinklers to prevent the fugitive dust. 23 Name of all the solvents to be used in the process and details of solvent recovery systems. Refer Section 2.6.4, chapter 2 of EIA/EMP report 24 Design details of ETP, incinerator, boiler, scrubbers/bag filters etc. Refer Section 9.8, fig, 9.2 and 9.3 chapter 9 of EIA/EMP report 25 Details of water and air pollution and its mitigation measures plan. 26 Action plan to control ambient air quality as per NAAQES standards notified by the Ministry on 16 th September, An action plan to control and monitor secondary fugitive emissions from all the sources. 28 Determination of atmospheric inversion level at 29 the Permission project site from and concerned assessment Authority of ground for the level drawl of 182m3/day water from River Patalganga. Water balance chart including quantity of effluent generated recycled and reused and discharged. 30 Action plan for Zero discharge of effluent should be included. 31 Ground water quality monitoring minimum at 6 locations should be carried out. Geological features and geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic). 32 The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste. 33 Action plan for management of fly ash generated from boiler should be included. Tie-up or agreement with brick manufacturers to be provided. 34 Precautions to be taken during storage and transportation of hazardous chemicals should be clearly mentioned and incorporated. 35 A copy of the Memorandum of understanding signed with cement manufacturing indicating clearly that they will utilized all the organic solid Refer Section 4.2 for Air Pollution and its Mitigation Measures and Section 4.4 For Water Pollution and its Mitigation Measures, chapter 4 of EIA/EMP report Refer Section 9.6, chapter 9 of EIA/EMP report Refer Section 9.6 and 9.8, chapter 9 of EIA/EMP report Refer Section 4.2, chapter 4 of EIA/EMP report Refer Annexure 2 for water withdrawal permission and for water balance refer Table 2.5, 2.6, chapter 2 of EIA/EMP report The generated waste water will be used for water sprinkling and greenbelt development. Refer Section 3.8.2, Chapter 3 of EIA/EMP report for ground water quality Section Geomorphology & Soil Types, Geology and Section 3.10 Biological Environment of EIA /EMP report. Refer Section 9.8.3, chapter 9 of EIA/EMP report Fly ash will be stored in a silo. Fly ash will be given to Cement /brick manufacturers. The details refer Section 9.8, Chapter 9 of EIA/EMP report. Refer Section 7.1. & 7.2, chapter 7 of EIA/EMP report Will made available MITCON Consultancy and Engineering Services Ltd., Pune 10

11 No. Terms of References Compliance waste generated. 36 A copy of Memorandum of Understanding (MoU) Will made available signed with coal supplier for imported coal and brick manufactures for management of fly ash. 37 Authorization/Membership for the disposal of Will made available liquid effluent in CETP and solid/hazardous waste in TSDF, if any. 38 Risk assessment for storage for chemicals/solvents. Refer Section 7.2 chapter 7 of EIA/EMP report 39 Material safety data sheet of chemicals to be Refer Annexure 9 submitted. 40 An action plan to develop green belt in 33% area. Refer Section 9.11, chapter 9 of EIA/EMP report 41 Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water. Refer Section 4.6, chapter 4 of EIA/EMP report 42 Details of occupational health programme. To which chemicals, workers are exposed directly or indirectly. I. Whether these chemicals are within threshold Limit values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation. II. What measures company has taken to keep these chemicals within PEL/TLV. III. 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 disaster. V. Liver function tests (LFT) during preplacement and periodical examination. VI. Details of occupational health surveillance programme. 43 Socio-economic development activities should be in place. 44 Note on compliance to the recommendations mentioned in the CREP guidelines. 45 Detailed Environment Management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, Refer Section 9.12 Occupational Safety & Health chapter 9 of EIA/EMP report Section On-Site Emergency Plan & Section 7.4 Off Site Emergency Plan of Chapter 7 Refer Section 9.13, chapter 9 of EIA/EMP report Not Applicable Refer chapter 9 environmental Management Plan MITCON Consultancy and Engineering Services Ltd., Pune 11

12 No. Terms of References Compliance monitoring frequency, responsibility and time bound implementation plan for mitigation measures should be provided. 46 EMP should include the concept of wasterminimization, recycle/reuse/recover techniques, Energy conservation and natural resource conservation. 47 Corporate Environmental Responsibility (a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. (b) Does the Environmental Policy prescribe for standard operating process/procedures to bring into focus any infringement/ deviation/violation of the environmental or forest norms/conditions? If so, it may be detailed in the EIA report. 48 What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions. Details of this system may be given. 49 Does the company have a system of reporting of noncompliance / violations of environmental norms to the Board of Directors of the company and /or shareholders or stakeholders at large? The reporting mechanism should be detailed in the EIA report. 50 Any litigation pending against the project and/or any direction/order passed by any court of Law against the project, if so, details thereof. 51 Public hearing to be conducted and issues raised and commitments made by the project proponent on the same should be included in EIA/EMP report in the form of tabular chart with financial budget for complying with the commitments made. Refer Chapter 9 Environmental Management Plan Refer Section 9.13 Socio-Economic Welfare Activities Refer Section 9.4 Environment Management Cell, Chapter 9 Refer Section 9.4 Environment Management Cell, Chapter 9 No litigation pending against the project and/or any direction/order passed by any court of Law against the project, if so, details thereof Public Hearing was conducted on 11 th September Refer Section 7.5 Public Hearing, Chapter 10, and Annexure No. 10 & Figure No MITCON Consultancy and Engineering Services Ltd., Pune 12

13 CHAPTER 1 INTRODUCTION 1.1. Preamble The Indian chemical industry is among the traditional sectors of the country that play an integral role in the country s economic development. This sector forms a part of the basic goods industry and is a critical input for industrial and agricultural development. The Indian chemical industry is one of the oldest industries in India and has made immense contribution to the industrial and agricultural development of India. It encompasses both large and small-scale units. The fiscal incentives granted to the smallscale units in the mid-1980s provided the thrust to the growth of Micro, Small and Medium Enterprises (MSMEs) in the sector. The chemical industry serves the needs of sectors such as textiles, pharma, petrochemicals, dyes, leather, plastics, paper, printing inks and food stuffs, among others. It is the one of the most diversified industrial sectors and includes basic chemicals and its products, petrochemicals, fertilizers, paints, gases, pharmaceuticals, dyes, etc. The sector covers over 70,000 commercial products, and provides the feedstock to many downstream industries such as finished drugs, dyestuffs, paper, synthetic rubber, plastics, polyester, paints, pesticides, fertilizers and detergents. Over the years, the industry has been evolving with a shift towards product innovation, brand building and environmental friendliness. Besides, customer focus is gaining significance in the industry Development of Chemical Industrial Sector in Maharashtra The Indian chemical industry is well-established in Maharashtra. During year , the production of major chemicals in the state was 565,481 MT. In the same year, chemical production capacity of 17,928 MT was added that took and the total installed capacity increased to 5, 83,409 MT Under the National Industrial Classification, the chemical industry includes basic chemicals and its products petrochemicals, fertilizers, paints, varnishes, gases, soaps, MITCON Consultancy and Engineering Services Ltd., Pune 13

14 perfumes, toiletries and pharmaceuticals. For the purpose of the cluster and industry study, the chemical industry is classified into five major segments and these are as follows: alkali, inorganic chemicals, organic chemicals, pesticides, and dyes and dyestuff. Accordingly, any reference made to the Indian chemical industry hereon will include the information on these five major segments exclusively. Figure No. 1.1 Map Showing Chemical Industries in Maharashtra, India 1.2. Purpose of the M/s Dujodwala Products Ltd. (DPL) located near Khalapur, Dist. Raigad, Maharashtra, is manufacturing Organic chemicals. Now, it plans to expand its plant capacity. As per EIA notification 2006, and amendments their on such projects are considered in category 5(f) of schedule and requires prior environmental clearance. Environmental Impact MITCON Consultancy and Engineering Services Ltd., Pune 14

15 Assessment is prepared as a procedure for obtaining prior Environmental Clearance for the proposed expansion. This environment impact assessment (EIA) is prepared, based on studies carried out during the post monsoon (October) & winter (November, December) of Year The environmental attributes like ambient air, water, soil, noise selected for study are those, which are likely to be affected by the project. The study area is defined as an area within 10.0 kms radius around site located at Kumbhivali Village. (As per the Terms of Reference approved by MoEF, New Delhi Vide their letter No, J-11011/154/2012-IA.II (i) dated 11th January, Terms of Reference The Environment Impact Assessment (EIA) study based on: Dujodwala Product Ltd. has submitted Form-1 along with proposed ToR and prefeasibility report for EIA study to the MoEF. Presentation to finalize ToR was held on 30th October 2012 at MoEF, New Delhi. Terms of Reference (ToR) provided by Expert Appraisal Committee (Industrial Project) of MoEF to Dujodwala Product Ltd. Vide letter No, J-11011/154/2012- IA II (i) dated 11th January, Environmental Impact Assessment studies are carried out. The objective of the Environmental Impact Assessment (EIA) study is to understand the prevailing physical and biological environment. The purpose of any EIA exercise is to identify and assess the adverse impacts of a project in the planning stage itself, so that necessary mitigation measures to prevent or minimize these adverse impacts can be planned early and cost-effectively. In view of this, the specific objectives of this EIA are. To have an in-depth know-how of the project and to identify the probable sources of pollution that may arise from each stage of the process. MITCON Consultancy and Engineering Services Ltd., Pune 15

16 To review the current environmental status of the area within 10Km radius of the proposed project site - collection of baseline data on the environmental attributes including air, noise, water, land, ecological, hydro-geological climate and socio-economic environments. To assess likely or potential environmental impacts of the proposed activity To estimate the impacts of the proposed project on the surrounding environment. To prepare a comprehensive Environmental Management Plan to ensure that the Environmental quality of the area would be preserved Identification of Project & Project Proponent Dijodwala's entered in the field of naval stores industry in 1947 and since then have been engaged in manufacturing / supplying the products of naval stores industry which consists of Gum Rosin, Oil of Turpentine and their derivatives. The plant at Kumbhivali village became functional in 1990s and is operational till today. The product profile of the Dujodwala Products Ltd is given in Table No.1.1. Table No. 1.1 Product Profile of Dujodwala Sr. No. Name of Chemical Sr. No. Name of Chemical 1 Camphor 12 Rosin 2 Camphene 13 Rosin Emulsion Size 3 Isoborneol Acetate 14 Rosin Esters 4 Isoborneol Powder 15 Ester Gums 5 Camphor Oil 16 Maleic Resins 6 Sodium Acetate 17 Phenolic Resins 7 Dipentene 18 Rosinets 8 Turpentine 19 Terpene Phenolics 9 Alpha Pinene 20 Foundry Resins 10 Beta Pinene 21 Ketonic Resins 11 Longifolene 22 Polyamide Resins 23 Polyester Resins MITCON Consultancy and Engineering Services Ltd., Pune 16

17 1.4. Nature and Size of the Project DPL has planned to enhance the production of the following products against the existing products given in Table No Table No. 1.2 List of following products against the existing products Sr. Existing capacity Proposed capacity Name of the chemical No (MT/Month) (MT /Month) 1. Alphapinene (95%) Polyester Resin Phenolic Resin Alkyd Resin Coating Rosin Easter Maleic Modified Resin Phenolic Modified Resin PVC chemicals Camphene Dipentene Ketonic Resin Polyamide Resin The proposed expansion is backed by high demand of products in growing resin industry. Currently, large quantity of material is being imported. The proposed expansion will reduce the import of the material. Camphene, which is mainly imported, is one of the major intermediate for camphor manufacturing. The proposed expansion includes production of camphene at site Project Location The existing organic manufacturing plant site is located at village Kumbhavali, Taluka Khalapur, Dist. Raigad, Maharashtra and is near Pune Mumbai Expressway. The nearest railway station is Khopoli located at 9.80 kms (aerial distance) from the project site. The nearest airport is Chhatrapati Shivaji Airport at 52 kms from the project site. The approximate co-ordinates of the existing site are 18 o 49' 34.76" N and 73 o 15' 34.46" E. The location of the site is shown in the index map attached. MITCON Consultancy and Engineering Services Ltd., Pune 17

18 1.5.1 Approach to the Site Khopoli railway station is at a distance of 9.80 kms (aerial distance) from the project site and Khalapur town is about 2.6 kms (aerial distance) away from the site. One can also approach to the site by through the Pen connector located on the right side of Khalapur Toll Plaza (while coming from Pune to Mumbai) which bifurcates into two roads further one road leading to Pen and the other road leading to a series of industries out of which one is Dujodwala Products Ltd. The nearest operating Airport is at, Mumbai (Chhatrapati Shivaji Airport) which is about 52 kms (aerial distance) away Environmental Policies and Legal Provision For Environment Several environment policy statements have been formulated in the last few decades as a part of the Governments approach to integrate environmental and developmental aspects of planning. The policies reflect a gradual shift in emphasis from pollution abatement and control to proactive and voluntary approaches for pollution prevention in keeping with global paradigm shifts and trends in environment management. Following are some of the key policies that have been laid down by the Central Government: National Forest Policy, 1988; National Conservation Strategy and Policy Statement on Environment and Development, 1992; Policy Statement on Abatement of Pollution, Despite these policy documents, a need for a comprehensive policy statement had been evident for some time in order to infuse a common approach to the various sectoral and cross-sectoral, approaches to environmental management. As a result, a National Environment Policy (NEP, 2006) has been drawn up as a response to our national commitment to a clean environment, mandated in the Constitution in Articles 48 A and 51 A (g), strengthened by judicial interpretation of Article 21. MITCON Consultancy and Engineering Services Ltd., Pune 18

19 The principal environmental regulatory agency in India is the Ministry of Environment and Forests (MoEF), New Delhi. MoEF formulates environmental policies and accords environmental clearance for the projects. It is important to note that the Central Government framed umbrella legislation, called the Environment (Protection) Act, 1986 to broadly encompass and regulate an array of environmental issues. The overall purpose of EPA is to establish an overall coherent policy and provide a basis for the coordinated work of various government agencies with operational responsibility for the environment and natural resources. This legislation also invests authorities with regulatory powers to address specific issues affecting the environment. The Act does not allow any person to establish an industry, operation or process that discharge or emit any environmental pollutant in excess of standards prescribed under specific rules and notifications. The Acts, Rules and Notifications applicable to environmental aspects of the construction and operational phases of proposed project is summarized in following Table No Table No. 1.3 Summary of Environmental Legislation applicable for Proposed Project Legislation Environment (Protection) Act, 1991 (as amended) with Rules. Air (Prevention and Control of Pollution) Act, 1987 (as amended) with Rules. Water (Prevention and Control of Pollution) Act, 1974 with Rules. Water Cess Act, 2003 (as amended) Noise Pollution (Regulation and Control) Rules, 2006 (as amended) The Public Liability Insurance Act,1992 (as amended) Areas / Activities Covered Overall Environment Protection Compliance to environmental (Air, Water, Noise) Standards issued under EPR Protection of Air Quality Consent to Establish (NOC) for establishing and Consent to Operate (CTE) for activities causing air pollution from DG sets from SPCB, Compliance to National Ambient Air Quality Standard Protection of Water Quality, Discharge of sewage from proposed project, Obtaining Consent to Establish (NOC) for establishing and Consent to Operate (CTE) for activities causing water pollution from SPCB Paying Water Cess to Local Body for sourcing of domestic water Compliance with Ambient Noise Standards in accordance to land use of the area An Act to provide public liability- insurance for the purpose of providing immediate relief to the persons affected by accident while handling any hazardous MITCON Consultancy and Engineering Services Ltd., Pune 19

20 Legislation Manufacture, Storage and Import of Hazardous Chemicals Rules, 2000 (as amended) State Groundwater Regulation Siting Guidance National Policy on Resettlement and Rehabilitation Ancient Monuments and Archaeological Sites and Remains Act, 1958 Areas / Activities Covered substance and for matters connected therewith or incidental thereto Notifying regulatory authority (in this case, the State Factories Inspectorate) of storage of hazardous substances like Waste Oil, etc Follow guidance on such storage, maintain updated MSDS, submit annual Safety to authority Prepare Onsite Emergency Plan Conform to restriction for drawing of groundwater Arrange for recharge through Rainwater Harvesting Schemes (as applicable) Follow Siting Guidance as far as practicable Avoid sites which are environmentally sensitive Avoid sites which are environmentally sensitive Resettlement and Rehabilitation issues of project affected people No development activity (including building, mining, excavating, blasting) is permitted within radii of 100m (protected area), and 300m (controlled area) without prior permission of the Archaeological Survey of India (ASI) or State Department of Archaeology Scope of the Study In order to obtain, prior Environmental Clearance, as required as per EIA notification 2006 from the Ministry of Environmental & Forest (MoEF) & Expert Appraisal Committee, Ministry of Environment & Forest, New Delhi it is required to carry out Environment Impact Assessment (EIA) study for the proposed expansion of organic chemical manufacturing plant, deliberating the positive and negative impacts on the environment. A befitting environment management and monitoring plan (EM&MP) will be prepared to mitigate or minimize the negative impact vis-à-vis retaining the positive impacts of the project. Keeping in line with TOR, having a high degree of concern, for the environment and in order to assess the likely impacts arising out of the proposed project, Dujodwala Products Ltd., has retained services of MITCON Consultancy and Engineering Services Ltd., Shivajinagar, Pune to carry out the Environmental Impact Assessment (EIA). MITCON Consultancy and Engineering Services Ltd., Pune 20

21 1.8. Scope of Environment Impact Assessment (EIA) The study envisages characterization of the existing status of physical environment such as air, water, soil, land use, meteorology, socio-economic and heritage etc. as well as biological environment such as flora and fauna of the study area of 10 km radius and quantifying impacts on the environmental parameters. Based on the baseline data, EIA evaluates the proposed control measures by the project and prepares an environment management plan, outlining additional proposed activities and delineates the requirements of environmental monitoring program. EIA study shall cover the following aspects Evaluation of present environmental factors through analysis of generated and collected baseline data for one complete non-monsoon season (3 months). Assess the probable impact on the environmental factors due to implementation of the project with respect to existing scenario. Analyze the predicted impact with respect to the regulatory environmental standards. Assess the probable risk at the proposed plant. Develop an Environmental Management Plan and on site Disaster Management Plan for the proposed project to mitigate the negative significant impacts that would arise from the proposed project. The baseline data has been collected for the following environmental components, during Post Monsoon & Winter 2012 Air Quality Meteorology Noise Environment Water Use & Quality Soil Quality Land Use, Crop Pattern, Agricultural Practices Demographic aspects Ecology & Biodiversity MITCON Consultancy and Engineering Services Ltd., Pune 21

22 Baseline data on parameters of the above-mentioned aspects over a season provides means for identifying possible impact-positive as well as adverse. An environmental impact assessment and environment management plan comprising an overall assessment of the impact due to project activity over baseline condition of the existing environment and a mitigating action plan to counter the adverse impact as defined. An environmental monitoring program is also prepared to provide scientific support to future actions of environmental protection EIA Methodology Environmental Impact Assessment study has been conducted within an area of 10 km radius around the proposed project area. The various steps involved in the study for a particular project are divided into three following phases. Identification of significant environmental parameters and assessing the status within the impact zone Prediction of Impacts envisaged due to proposed scheme on various environmental parameters Evaluation of impacts after superimposing the predicted scenario over the baseline scenario to prepare Environmental Management Plan Accordingly, field studies were carried out during post monsoon and winter 2012 to establish the existing conditions. To determine the magnitude of significant potential impacts and to ensure that the environmental considerations are given adequate weightage, subsequently, a preliminary environmental screening was carried out. The environmental screening was based on the available secondary data supplemented by regular field visits. During screening, significant environmental issues were examined for all the alternatives. Primary and secondary data were collected to describe the existing environmental setup. MITCON Consultancy and Engineering Services Ltd., Pune 22

23 Keeping in view the activities envisaged and size of the project activities, the work carried out is briefly reported below and has been described in detail in the subsequent sections. Environment Focus Areas A) Air Environment: The prevailing ambient air quality status of the study region was assessed through a network of ambient air-monitoring stations during post monsoon & winter Different pollution parameters viz. PM10, PM2.5, Sulphur-di-oxide (SO2), and Oxides of nitrogen (NOX) were identified for representing the baseline status of ambient air quality within the study region. Micro-meteorological parameters like wind speed & direction were continuously recorded using an automatic weather station during study period. The recorded data were used to determine predominant meteorological conditions, which are useful in characterizing the baseline air quality status and in prediction of impacts on air environment. B) Noise Environment: Noise is generated by many activities associated with the plant activities. Noise monitoring has been carried in the study area to assess the baseline status of noise in the area. C) Water Environment: Primary and secondary information on water resources (ground/surface) was collected. The parameters of prime importance selected under physico-chemical characteristics were estimated to describe the baseline environmental status of the water resources during the study period D) Land Environment: Soil samples were collected from different locations within the project study area during the study period and were analyzed for various physico - chemical parameters. E) Socio-Economic Environment: Socio-economic information such as, demographic pattern, population density, literacy levels, gender ratio, educational facilities, agriculture, income, medical facilities, etc., was collected through basic surveys and MITCON Consultancy and Engineering Services Ltd., Pune 23

24 from few reliable secondary sources. The same has been analyzed and presented in the subsequent chapters Organization of The report has been divided into following eleven chapters: Chapter-1 Introduction: This chapter provides background information of the project, brief description and objectives of the project, description of the area, scope and organization of the study. Chapter-2 - Project Description: This chapter deals with the process and specifications of the project. This also deals with the sources of pollution for the proposed project and proposed control measures. Chapter-3 Description of the Environment: This chapter presents the methodology and findings of field studies undertaken with reference to meteorology, ambient air, water, soils, noise, and ecology to define the existing environmental status in the area. Details on land use, socio-economics, geo-hydrology and industries are presented from published secondary data. Chapter-4 Anticipated Environmental Impacts & Mitigation Measures: This chapter highlights the inferences drawn from the environmental impact assessment. It describes the overall impact of the proposed expansion project and underscores the areas where applicable environmental standards are expected to be violated. The impact is assessed after considering both pre-expansion and post-expansion scenario. Chapter- 5 - Analysis of Alternatives: This chapter presents the analysis of alternatives (site) studied and final alternative selected based on account of various reasons Chapter- 6 - Environmental Monitoring Program: The Environmental monitoring requirements for determining the efficiency of the environmental protection and mitigation measures are delineated in this Chapter along with required institutional arrangements for ensuring their implementation. MITCON Consultancy and Engineering Services Ltd., Pune 24

25 Chapter- 7- Additional Studies: This chapter describes studies carried out as per the ToR, MoEF, New Delhi of the EIA, if any. This includes a Risk Assessment for the proposed unit along with Social-Economic study, review of the Safety and Disaster Management Plan proposed for the proposed expansion project. Chapter- 8- Project Benefits: This Chapter highlights the expected benefits of the proposed activity to the socio-economic scenario in the study area and to the country as a whole. Chapter -9 - Environmental Management Plan: This Chapter consolidates the proposed and recommended environmental protection and mitigation measures and the required institutional structure that ensures its proper implementation during the construction as well as operational phase of the project. The assessment will cover the baseline data generation, predictions and evaluation of impact on various environmental components and preparation of adequate Environmental Management Plan. Chapter-10- Summary and Conclusion: This chapter summarizes the findings presented in the EIA report. Chapter 11 Disclosure of consultants engaged: This chapter presents the profile of consultants engaged for preparation of the EIA report. MITCON Consultancy and Engineering Services Ltd., Pune 25

26 CHAPTER 2 PROJECT DESCRIPTION 2.1. Introduction Dujodwala Products Ltd. has planned to enhance the production of the following products against the existing products as given in following table. Sr. No Name of the chemical Existing capacity (MT/Month) 1. Alphapinene (95%) N.A Polyester Resin Phenolic Resin Alkyd Resin Coating NIL Rosin Easter Maleic Modified Resin Phenolic Modified Resin PVC chemicals NIL Camphene Dipentene Ketonic Resin Polyamide Resin Type of Project Proposed capacity (MT /month) The project is neither an interlinked project nor an interdependent project. It is the expansion project of existing organic chemicals manufacturing unit. Sr. No Item DESCRIPTION 1. Title of the project Proposed expansion of Organic Chemical Plant at Khalapur Dist. Raigad, Maharashtra by Dujodwala Products Ltd. 2. Land acquired The total existing plot area is 20 acres and out of these 5 acres of land will be used for proposed expansion. 3. Cost of the project Rs 31 Crore 4. Proposed facilities a) Raw material storage area which will be around 7 x 60 m in dimension and will house the tanks for the following chemicals Formaldehyde Phenol MITCON Consultancy and Engineering Services Ltd., Pune 26

27 Sr. No Item 5. Production capacities 6. Air pollution control measures proposed 7 Power Requirement & Source 8 Coal Requirement & Source DESCRIPTION Crude Sulphate of Terpentine Local Turpentine Dipentene fraction of local turpentine Dipentene fraction of imported turpentine b) Finished material storage which will be around 7 x 60 m in dimension and will house the tanks for the following finished materials :-- Camphene DRT 5004 (Resin) DRT 4001 (Resin) Pure fraction of Turpentine c) The plant equipment housing area will be around 30 m x 46 m which will house the equipment s from Ground Floor to the Third (10th floor) Sr. No Name of the chemical Existing capacity (MT/Month) Proposed capacity (MT /Month) 1. Alphapinene (95%) N.A Polyester Resin Phenolic Resin Alkyd Resin Coating NIL Rosin Easter Maleic Modified Resin 8. Phenolic Modified Resin 9. PVC chemicals NIL Camphene Dipentene Ketonic Resin Polyamide Resin Dust collector with wet scrubber. State-of-the-art scrubbers will be installed for 10TPH boiler to limit the air pollution. Unloading areas will be provided with water sprinklers to prevent the fugitive dust. Fly ash will be stored in a silo. Fly ash will be given to Cement /brick manufacturers. New Connected Load 1645 KW New Maximum demand 180 KVA MSED 30 MT/Day Indonesian coal will be procured from the local vendor 10 Waste water The existing ETP consists of the following units :-- MITCON Consultancy and Engineering Services Ltd., Pune 27

28 Sr. No Item treatment 11. Solid hazardous waste / Hazardous waste DESCRIPTION Equalization tank. Flash mixer Primary clarifier Secondary clarifier Oil and Grease Trap Aeration tank Outlet tanks Sand filter Carbon filter The existing ETP will be revamped based on the aforesaid unit operations to cater to an effluent of 100 m3/day Kindly refer Annexure -1 for details. The final treated effluent will be sent to Patalaganga CETP. Name of the hazardous waste /solid waste Quantity (MT) / year Disposal Resin Residue 0.5 CHWTSDF of Trans Thane Creek Waste Management Association ETP Sludge 2.05 CHWTSDF Trans Thane Creek Waste Management Association. *Fly ash from the use of coal for 10TPH Boiler * Bottom ash from the use of coal for 10 TPH Boiler Copper based catalyst Titanium based catalyst 285 Will be sent to cement manufacturers 51 Will be sent to cement manufacturers 3 CHWTSDF of Trans Thane Creek Waste Management Association. 1 CHWTSDF of Trans Thane Creek Waste Management Association. Indion catalyst 0.5 CHWTSDF of Trans Thane Creek Waste Management Association. Contaminated filter cloth 0.25 CHWTSDF of Trans Thane Creek Waste Management Association. Discarded containers 500 nos Cleaned / washed & reused. 12. Green Belt Around 7.5 acres of green belt already exists out of existing 20.5 acres plot area. 13. Capital cost and recurring cost per Capital cost :-- Rs. 50 lakhs Recurring cost per annum: -- Rs 24 lakhs. MITCON Consultancy and Engineering Services Ltd., Pune 28

29 Sr. No Item annum for environmental protection measures DESCRIPTION Table No. 2.1 Detailed project cost break up Sr. No. Item Cost (in Rs lakhs) 1. Procurement of land around 5 acres around the existing plant in phases 2. One no. 15 KL Isomerisation reactor with energy efficient agitator 50, limpet coil, condenser, column, instruments etc 3. One no. 15 KL Esterification reactor with energy efficient agitator, 40 limpet coil, condenser, column, instruments etc 4. Eight nos. 15 KL S.S Resin reactors with energy efficient agitator, 400 limpet coil condenser instrument etc. 5. Two nos 25 KL S.S resin reactors with energy efficient agaitator, 150 limpet coil, condenser, instruments 6. Six nos. 50KL MS tanks for Resin & Dipentene Six nos. 100 KL MS tanks for resin raw materials One nos. 40 KL. M.S. tank for local turpentine 4 9. Two nos 30 KL. S.S tank with internal coil for Camphene Six nos. 25 KL. MS intermediate tanks Civil works including site development, road development C-301 S.S column with condensers, re-boiler C-401 S.S column with condensers, re-boiler DCS expansion Pelletiser (2 Nos.) Process cooling Tower with pumps Chilling plant (400 TR) Chilled water pumps, cooling towers and cooling water pumps for 10 new chilling plant 19. One no 10 TPH coal fired boiler Expansion of coal storage area Eight nos 2 KL SS Day tank for resin reactors Electrical control panel along with cable works Structural works Pipe line jobs, hook up of new system with existing system Pilot plant SS Air compressor (Atlas Copco GA 37+) N2 compressor (Atlas Copco GA 37+) Expansion of ETP Relocation of laboratory 25 MITCON Consultancy and Engineering Services Ltd., Pune 29

30 30. Miscellaneous works Centrifuge (48, S-316) for sodium Phenoxyacetate One no 15 KL S.S Resin Reactors with energy efficient agitator, 50 limpet coil, condenser, instruments, etc. for sodium Phenoxyacetate 33. One no. fluidized Bed Dryer for SPA reactor Need for the Project As far as camphene is considered it is one of the stage for manufacturing camphor due to growing demand of camphene for exports to Germany, Japan & USA hence the expansion is being planned Project Location The existing organic manufacturing plant site is located near to Pune Mumbai Expressway. The approximate coordinates of the existing site are 18o 49' 34.76" N and 73o 15' 34.46" E. Salient features of the project presented in Table No. 2.2 and the location of the site is shown in the index map given in Figure No. 2.1, project boundary marked on Google Earth Image is attached in Figure No. 2.2and 10 km study area map is shown in Figure No Table No. 2.2: Salient Features of the Project Site Location Dujodwala Products Ltd, Kumbhivali Village, Khalapur Tehsil, Raigad Dist. Maharashtra Area Total Area: 20.0 acres (Proposed expansion of the existing organic chemicals manufacturing facility is 5 acres.) Geographical Location Latitude: N Longitude: E Nearest Railway Station Khopoli 9.8 Kms Nearest Airport Chhatrapati Shivaji 52 Kms Road Access Mumbai Pune Expressway - can be accessed using district road of around 9 km. Nearest Town Khalapur 2.60 km from project site Religious / Historical Place None Archeological monuments None Reserved Forest None MITCON Consultancy and Engineering Services Ltd., Pune 30

31 Figure No. 2.1 Index Map showing the location of the Project MITCON Consultancy and Engineering Services Ltd., Pune 31

32 Figure No. 2.2 Plot Boundary Marked on Google Earth Image 2.5. Plant Layout The layout for proposed expansion of the organic chemicals manufacturing unit shall be developed to accommodate the proposed expansion. The layout of the proposed expansion shall be compact. Master layout plan of Dujodwala Products Ltd., attached as an Annexure No Raw Material Requirement and Transport The following raw materials are required is as given in Table No. 2.3 with the quantities MITCON Consultancy and Engineering Services Ltd., Pune 32

33 Figure No. 2.3 Figure showing10 Km Radial Study Area MITCON Consultancy and Engineering Services Ltd., Pune 33

34 Table No. 2.3 List of Raw Material & Quantities Sr. No. Raw materials Quantity (MT) 1. Alpha Pinene Phenol Formaldehyde Dipentene / Carene TEG /PEG 100 The following raw materials will be imported yearly given in Table No Table No. 2.4 Imported Raw Materials Sr. No. Raw material Quantity (MT) Country(s) 1. Alpha pinene 5000 China, Indonesia, Brazil, Chile 2. Dipentene 300 China, New Zealand 3. Gum Turpentine Oil 3000 China, Indonesia, Brazil, Chile, Vietnam 4. Gum Rosin 600 China, Indonesia, Vietnam 5. PTBP 600 Russia, China 6. Hexamine 500 Saudi Arabia Mode of Storage of Raw Materials Raw material storage area which will be around 7 x 60 m in dimension and will house the tanks for the following chemicals:- Formaldehyde Phenol Crude Sulphate of Terpentine Local Turpentine Dipentene fraction of local turpentine Dipentene fraction of imported turpentine b) Finished material storage which will be around 7 x 60 m in dimension and will house the tanks for the following finished materials:- Camphene DRT 5004 (Resin) DRT 4001 (Resin) Pure fraction of Turpentine MITCON Consultancy and Engineering Services Ltd., Pune 34

35 c) The plant equipment housing area will be around 30 m x 46 m which will house the equipment s from Ground Floor to the Third (3 rd floor) Source of raw material(s) and mode of transport The raw materials which will be various chemicals will be transported by trucks from source to the factory site. The auxiliary fuel like High Speed Diesel (HSD) and Heavy Fuel Oil (HFO) will be transported to the factory site by tankers. The Indonesian coal will be purchased from the local vendor and brought to the factory site by covered trucks Mode of transport of product The products will be transported through trucks from the factory premises to the destination Detail of Proposed Solvent Recovery System Process Details: The solvents will be recover and reuse for the process. The fixed volume of Spent solvent shall be charge into the reactor for recovery and heated, to distil out collected in receiver. The residue left in the reactor shall be drained. The small quantity of solid waste material (Tar Type material) may be float on top surface and which will be taken out and collected in drums /containers. The washing effluent shall be drain to E.T.P. for further treatment & the solid wastes are shall be dispose through CHWTSDF. Figure No. 2.4 Diagram of Solvent Recovery Process MITCON Consultancy and Engineering Services Ltd., Pune 35

36 2.7. Process Details The following products will be manufactured along with the capacities as tabulated below Sr. No. Name of the Chemical Proposed capacity (MT /month) 1. Alphapinene (95%) Polyester Resin Phenolic Resin Alkyd Resin Coating Rosin Easter Maleic Modified Resin Phenolic Modified Resin PVC chemicals Camphene Dipentene Ketonic Resin Polyamide Resin Brief Process Description of Manufacture of Camphor The process of manufacture of Camphor involves the following steps: Turpentine Oil distillation Isomerisation Esterification Saponification Dehydrogenation Turpentine Oil distillation: Turpentine oil is subjected to distillation for continuous separation of Alpha-Pinene from the rest of its constituents. Alpha Pinene is obtained as distillate which is stored in storage tanks. Bottom product from this column is distilled in another column for recovery of Carene as distillate and bottoms are collected as Dipentene Residue that is stored in a storage tank. Isomerisation : Distilled Alpha Pinene is subjected to isomerization in reactor which gets converted in the presence of TiO2 as catalyst into different isomers namely Tricyclene and Camphene along with Terpene intermediates under controlled temperature conditions. The crude Tricyclene and camphene (T + C) formed is stored in storage tanks. Crude T + C are then distilled to get purified T + C. The bottoms from the MITCON Consultancy and Engineering Services Ltd., Pune 36

37 distillation column are further distilled in a different column to recover Dipentene which is sent to storage as byproduct. Bottoms from this Dipentene recovery column are collected as Dipentene which is sent to storage. Figure No. 2.5 Products of α - pinene conversion Esterification: Tricyclene + Camphene (T+C) are subjected to Esterification in reactor. Slow addition is carried out in Esterification reactor, which is reacted with Acetic acid in the presence of Resin catalyst to form crude Iso Bornyl Acetate. Acetic acid is recovered from crude Iso-Bornyl Acetate in a distillate column and collected in a storage tank. Crude Iso-Bornyl Acetate containing T +C is then recovered in a separate column to produce pure Iso- Bornyl Acetate (IBA), which is sent to storage. Recovered T+C are sent to storage. Saponification: Pure Iso - Bornyl Acetate is then subjected to hydrolysis by reacting with caustic soda in reactor to form Iso-Borneol and Sodium Acetate Lye. Sodium acetate lye is separated from organics which is used for producing Sodium Acetate Trihydrate in a separate plant, IsoBorneol (IBO) is transferred to dehydrogenation reactor. Dehydrogenation: IBO is then subjected to dehydrogenation in reactor in the presence of CuO catalyst in which reaction hydrogen is liberated forming crude camphor. Xylene MITCON Consultancy and Engineering Services Ltd., Pune 37

38 is added as a solvent. Xylene is recovered from crude camphor in a distillation column. A low boiler along with T+ C present in camphor oil is then separated in another column. Crude camphor is then distilled in another column to get pure camphor which is flaked in a flaker and packed in bags. Residue collected from the bottom of this column is subjected to reclamation for recovering camphor. Manufacture of Sodium Acetate Tri Hydrate Sodium acetate lye received from camphor plant is collected in a reactor and neutralized. Neutralized lye is subjected to carbon treatment. After carbon treatment lye is heated in an evaporator to evaporate water and subsequently to obtain a requisite specific gravity. The resultant lye is charged into crystallizer for crystallization. In crystallizer Sodium Acetate lye is cooled slowly to obtain crystals. The wet crystals are further centrifuged to remove mother liquor. The resultant crystals obtained is Sodium Acetate Trihydrate which is packed in bags. P.F Resin Powder Procedure: Hydrated liquid phenol, formaldehyde (37%) and oxalic acid charged into the reactor and stirred well to mix. ph of the mixture is Slow heating is applied just to reach temperature upto C and then the heating is stopped. The reflux temperature is allowed to reach 100 to 1050C by itself. As the reaction is exothermic in nature, cooling is applied to control the vigorous reaction to proceed smoothly under reflux. The reaction is continued under reflux for about 4 hours till F.F.C is below 1%. Again the heating is started and distillation of water is continued till the temperature of resin reaches upto 1600C. The vacuum is applied to remove the unreacted phenol from the reaction mixture and get the required properties as per customer. Then the resin is discharged into the shallow trays, allowed to cool naturally, removed from trays ; mixed with the required quantity of hexamine, fed into the ACM mill for fine grinding. The resin is then transferred to ribbon blender; blended well and packed into bags. Alkyl Phenolic Resin Procedure: PTBP formaldehyde (37%), Toluene and caustic lye charged into the reactor. It is stirred well to mix. The ph of the mixture is Slow heating is applied just to reach temperature up to C and then the heating is MITCON Consultancy and Engineering Services Ltd., Pune 38

39 stopped. The reflux temperature is allowed to reach up to C by itself. As the reaction is exothermic in nature, cooling is applied to control the vigorous reaction to smoothen under reflux. The vaccum cooling is applied up to 700C and then acid and toluene is added. The temperature is adjusted to C; mixed for 30 minutes and the agitator is stopped. The reaction water is removed from bottom valve of the reactor. About 1000 kg of water is added temperature adjusted to C. The mixture is mixed for 30 minutes and then the agitator is stopped. The ph is checked whether it is in the range of The first wash water is removed from bottom valve of the reactor and the ph is checked whether it is in the range of The distillation is started by applying heat up to 1200C. The vacuum is applied to remove the un-reacted phenol from the reaction mixture and the desired properties are obtained as per the customer. The resin is then discharged into the shallow trays, allowed to cool naturally and removed from the tray and packed in the bags with net weight of 25 kgs and sealed Alkyl Phenolic Resins Process Flow Chart PTBP/POP, Formaldhyde (37 %) O.5 N Caustic Solution Keep under reflux for reaction for 1 Hrs Add 0.5 N Sulphuric Acid Solution for Neutralisation Add Toulene for Dissolution Decant out water from bottom layer Heating up to 1200C Add oxalic acid and start distillation Alkyl Phenolic resins and Toulene (Recycle) Drain Resins in tray, cool and crack and packed in bags MITCON Consultancy and Engineering Services Ltd., Pune 39

40 P.F. Resin Liquid Procedure: Hydrated Liquid phenol, formaldehyde (37%) and oxalic acid are charged into the reactor; stirred well to mix and the ph is maintained to 1-2.The slow heating is applied just to reach the temperature up to C. Then the heating is stopped. The reflux temperature is allowed to reach up to C by itself. As the reaction is exothermic in nature, cooling is applied to control the vigorous reaction to smoothen under reflux. The reaction is continued under reflux for about 4hours till F.F.C is below 1%. The heating is started again and distillation of water continued till temperature of the resin reaches upto 1600C. The vacuum is applied to remove the un-reacted phenol from the reaction mixture and required properties are obtained as per the customer. The solvent addition is started to get the required viscosity and solid content along with cooling. The final product is then cooled to room temperature and filled in the M.S drum with 200 kg net weight with proper labeling. Terpene Phenolic Resin Procedure: Hydrated phenol and toluene are charged and heating started to remove the water. The cooling is done up to 250C. Then BF3 acetate is added. The isotherm is checked externally by addition of dipentene is lab. The addition of Dipentene is started under chilling to avoid the raising of temperature above 400C. The reaction is continued for C. The washing is started to get the required acid value less than 1. The distillation is started and steaming is applied with vacuum till required softening point is obtained. The required resin is discharged into the shallow trays, allowed to cool naturally, removed from the tray. Then the resin is filled into bags with net weight of 25 kg with proper labeling and sealed. Resin Derivative Procedure (Easter gum) : The rosin is charged into the reactor and melted to 1700C in presence of nitrogen gas. The agitator is started and glycerol / penta, catalyst (anthraquinone and antioxidant) added. The temperature is gradually raised to 2650C in 3-4 hours and held there till required properties (Acid value and softening point) attained. The BHT is added when temperature reached to 2500C. The TPP is 2600C and maintained for 1 hour. The live steam sparged into the mass for 2 hours keeping heating off. The resins is then discharged into the shallow trays and allowed to cool naturally, removed from the tray. The resin is filled into the bag with net weight 25 kg with proper labeling and sealed. MITCON Consultancy and Engineering Services Ltd., Pune 40

41 Rosin derivative procedure (Maleic resins) : The rosin charged into the reactor and melted to 1700C in presence of nitrogen gas. The agitator is started and cooled to 1500C. The maleic is added in 1 hour s duration. The temperature is gradually raised to 2000C and maintained for one hour for completion of adducts. The glycerol / pentais added in 1-2 hours duration. The temperature is gradually raised to 2700C (maintained at C) till the required properties are attained. The temperature is cooled to 2500C and discharged into the shallow trays to cool naturally and then removed from the tray and then filled into the bags with net weight 25 kg with proper labeling and seal. Rosin Derivative Procedure (Phenolic resins) : The rosin is charged into the reactor and melted to 1700C in presence of nitrogen gas. The agitator is started and cooled to 1500C and then Bisphenol is added in 30 minutes duration and allowed to mix well for 60 minutes and magnesium oxide is added. The para-formaldehyde is added at 1350C in about 2 hours and allow to mix for one hour. The temperature is gradually raised to 1700C and maintained for 2 hours for completion of reaction. The temperature is gradually raised to 2000C and add glycerol / penta is added in one hour. The temperature is raised to 2700C in 4 hours and TPP is added when temperature reaches to 2500C. The reaction is continued at 2700C till the required properties are attained. The resin is cooled to 2500C and discharged into the shallow trays, allowed to cool naturally and removed from the tray. The resin is then filled in bags of net weight 25 kg and labeled and sealed properly. Rosin Derivative Procedure (Zinc Calcium rosinate) : The rosin is melted to 2000C in presence of Nitrogen gas and agitator started. The temperature is raised to C. Zinc oxide and calcium hydroxide is added slowly and temperature is maintained to C in about 3-4 hours. After that the temperature is raised to C and maintained till properties attained. The resin is allowed to cool to C and discharged in tray. The resin is cracked and filled into bag with net weight 25 kg with proper labeling & seal. P.F Resin Liquid Procedure : Hydrated liquid phenol, formaldehyde (37%), Cardinol, CNSL, and oxalic acid and charged into reactor. It is stirred well to ensure proper MITCON Consultancy and Engineering Services Ltd., Pune 41

42 mixing. The ph of the mixture is maintained at The slow heating is applied till the temperature is just reaches to C, then the heating is stopped. The reflux temperature is allowed to reach C by itself. As the reaction is exothermic in nature, the cooling is applied to control the vigorous reaction to smoothen under reflux. The reaction is continued under reflux for about 4 hours till F.F.C is below 1%. The heating is started again and the distillation of water continued till temperature of the resin reached up to 1600C. The vacuum is applied to remove the unreacted phenol from the reaction mixture and the required properties are obtained as per the customer. The solvent is added to get the required viscosity and solid content along with cooling. The resin is then cooled to room temperature, filled in MS drum with 200 kg net weight with proper labeling. Polyamide Resin : The Dimer acid and SOFA are charged into the reactor and EDA is added and stirred. The temperature is raised slowly to 1300C and held for minutes. The mixture is further is heated to C and BHT is added and held for 30 minutes. The temperature is raised to C and held till the required properties are obtained. The resin is discharged into shallow trays, allowed to cool naturally and removed from tray. The resin is cracked and filled into the bag with net weight 25 kg with proper labeling and sealed. Polyamide Resin Process Flow Chart Dimer Acid, SOFA and EDA and Start Agitator Held Till To Get Required Properties Polymide Resins Drain Resins In Tray,Cool And Crack And Packed In Bags MITCON Consultancy and Engineering Services Ltd., Pune 42

43 Ketonic Resin: Cyclo-hexanone, formaldehyde, para- formaldehyde and BHT are charged and the agitator is started. The caustic soda is added slowly in 3-4 hours duration and the temperature maintained to C by applying cooling as and when required. The temperature is raised to C and maintained to 2 hours for completion of reaction. The reaction mass is allowed to settle for minutes and aqueous layer sucked off from the top. The washing continued with fresh water till ph of about attained. The final distillation is started in presence of inert gas till the temperature reaches to C. The vacuum is applied and temperature is raised to C for hours. When the required properties are attained the material is discharged in shallow trays. Ketonic Resins Process Flow Chart CycloHexanone and Formaldhyde C Add slowly Caustic Soda Soln Continue reaction for 45 min and maintain temp by applying Distillation up to C Ketoniuc resins and low boiling oil (recycle) Drain resins in tray, cool and crack and packed in bags Paper sizing chemicals: The rosin is melted to C and the agitator is started and nitrogen purged. Maleic anhydride is added and temperature raised to C and maintained for 2 hours for completion reaction. The reaction mass is cooled to C and caustic soda solution (25%) added gradually in hours. The dilution with water is done in 2 hours. Add STPP, salt, urea and stabilizers. The properties like viscosity and solid content adjusted and discharged through filter to storage tank. MITCON Consultancy and Engineering Services Ltd., Pune 43

44 Paper Sizing Agent Process Flow Chart Gum Rosin And Maleic up to C Rosin maleic adduct Add 25% caustic soda solution Sodium salt of maleiopemric acid Add dilution water Paper seizing agent solution Add S.T.P.P Salt and urea adjust solid content, viscosity and add 50% aq. Solution of paper size agent packed in drum Polyester Resin: Glycol, DEG, MEG Pthalic anhydride and maleic anhydride are charged into reactor. The nitrogen gas is added and agitator started. The heating is started to reach C and held for some time or distillation to start. The gradual heating is started to reach C. The reaction temperature is maintained till a required property (acid value) is attained. The vacuum is applied till the final properties are attained. The reaction mixture is cooled to C, add Hydroquinone (catalyst) and discharged into the blender where mixture is mixed with Styrene. The viscosity and acid value etc is adjusted and then the resin is stored in storage tank. Polyster Resin Process Flow Chart Glycol,M/A,P/A added Heat up to C Held till to get required propertied Resin diluted with styrene Unsaturated Polyster resin (GP) MITCON Consultancy and Engineering Services Ltd., Pune 44

45 Alkyed Resin: The vegetable oil is charged with nitrogen gas and the agitator started. The Glycerine and Penta is added. The temperature is raised to C, the catalyst is added and maintained for about 2 hours to get alcohol tolerance 1:3. The reaction mass is cooled to C and balance glycerine / penta and phtalic is added. The temperature is raised to C and maintained till required properties achieved. Then the reaction mass is cooled to C and mixed with MTO for making solution (50-55%). The final product is cooled to room temperature and stored in storage tank. Manufacturing of PVC compounds: PVC Resin is used as main basic Raw Materials. It gives desired properties i.e. (Flexibility, Resistance to Thermal degradation, Flame retardancy by compounding the base PVC Resin with a variety of Additives Plasticizers, Heat Stabilizers and Flame retardants at an elevated temperature. Although each individual PVC Compounder uses its own property mix of additives, they all employ a similar PVC compounding process. PVC compounds are prepared in a batch process using blenders that allow precise temperature control the compounding process involves high intensity blending of PVC Resin and additives to form a dry blend powder which is then compounded using compounding equipment such as Farrell continuous Mixer, a buss kneader or twin screw and other machines. The compounded Mixture is then pelletized. The pellets are Spherical or Cylindrical with diameters averaging 1 to 5 mm. MITCON Consultancy and Engineering Services Ltd., Pune 45

46 Camphor flakes Dujodwala Products Ltd. X-Pinene Pure Figure No. 2.6 Process Flow Chart for Camphor Manufacturing Acetic Acid Resin Pure IBA Caustic lye T.O.Distillatio n Isomerisation Reactor Esterification Reactor Methan Saponificatio n Reactor Xylen Acetic acid Water vapour Distillation column Cr.Camphene Distillation Acetic acid Column Saponification Reactor Longifonene to stordipentene to Camphene &DipenteneSeperation Column Sod Acetate IsoBorneol+Xylene Xylene to be recycled IBA Flash Column Cmprreclaimation Dehydrogenat ion Reactor Cr. Xylene Recovery Camphor oil Camphor Oil Column Campho Column MITCON Consultancy and Engineering Services Ltd., Pune 46 Flaker camphor

47 2.8. Basic Requirement Of The Project Land The total land requirement of the proposed expansion of the existing organic chemical manufacturing facility is 5 acres. The total existing plot area is 20 acres. The proposed expansion of the organic chemical manufacturing facility is within the existing premises, which is already in possession of Dujodwala Products Ltd and this area does not come under CRZ Water Requirement Water required for existing organic chemicals manufacturing facility is 146m3/day and for proposed water requirement is 66 m3/day Water Balance The water balance for Existing and proposed unit is given in Table 2.5 and Table No. 2.6 Table No. 2.5 Water Balance for Existing Chemical Unit Sr. No Water usage Water requirement Losses /evaporation Effluent generation 1. Domestic Industrial use Cooling Boiler Total Note: - All figures in m 3 /day Table No. 2.6 Water Balance for proposed Chemical Unit Sr. No. All figures in m 3 /day Water usage Water requirement Losses /evaporation Effluent generation 1. Domestic Industrial use Cooling Boiler Total MITCON Consultancy and Engineering Services Ltd., Pune 47

48 The additional water required will be made available from Patalganga River. Irrigation Department, Govt. of Maharashtra has already obtained permission for the same. The permission has been attached in Annexure No Power Requirements The permission of H.T power supply for additional load has already been sanctioned by Maharashtra State Electricity Distribution Co. Ltd as per the following details :- a) New connected load : KW & b) New maximum demand: KVA. The same permission has been attached as Annexure No Man Power Proposed staff requirement is about 20 nos, proposed worker is 10 and proposed staff is 10 nos Utilities Effluent Generation: The current effluent generation is about 62 m 3 /day and for the proposed expansion will be 24.6 m 3 /day. The current effluent generation and effluent resulting from the proposed expansion is given in Table No. 2.7 &Table No. 2.8 respectively. Table No. 2.7 Current Effluent Generation Sr. No Item Quantity (m 3 /day) 1. Domestic Industrial 49 Total 62 Table No. 2.8 Proposed Effluent Generation Sr. No Item Quantity (m 3 /day) 1. Domestic Industrial 23 Total 24.6 MITCON Consultancy and Engineering Services Ltd., Pune 48

49 2.9.2 Solid Waste Generation and Mode of Disposal The existing and proposed solid wastes generated quantity and disposal is given in Table No Table No. 2.9 Solid Wastes Generated Quantity and Mode of Disposal Name of the hazardous waste Quantity (MT) / year Disposal Resin Residue 0.5 CHWTSDF ETP Sludge 2.05 CHWTSDF *Fly ash from the use of coal for 10TPH Boiler 285 Will be sent to cement * Bottom ash from the use of coal for 10 TPH Boiler 51 manufacturers Copper based catalyst 3 CHWTSDF Titanium based catalyst 1 CHWTSDF Indion catalyst 0.5 CHWTSDF Contaminated filter cloth 0.25 CHWTSDF Discarded containers 500 nos Cleaned / washed & reused. * Proposed solid waste Fly ash from the use of coal for 10TPH Boiler shall be given to the cement manufacturers. The hazardous waste would be sent to CHWTSDF of Trans Thane Creek Waste Management Association Existing Environmental Compliance Existing unit became operational in 1990s; and hence was not covered under EIA notification The plant is operational based on Consent to Operate is granted by MPCB and is valid up to Consent Number: No,Bo/RO- RD/P]I- / /R/CC-88 Date For details refer Annexure No. 12 The environmental monitoring is regularly carried out and annual environmental statement is duly submitted to MPCB as compliance. (ref. Annex. 13) The proposed expansion, (which has now attracted obligations of EIA notification 2006) have been granted consent to establish in December Consent Number: MPCBHQ/AS (T)/Raigad/Establish (expansion)/cc 74 Date:13/12/2011. For details refer Annexure 11. Also it is to be noted that existing plant is operational smoothly without any complaint/notices related to environmental concerns from various stakeholders/mpcb. MITCON Consultancy and Engineering Services Ltd., Pune 49

50 CHAPTER 3 DESCRIPTION OF THE ENVIRONMENT Any developmental activity may cause some environmental impacts on the surrounding environment. In order to know the cumulative impacts due to the proposed site on the surrounding environment, it is very important to know the baseline environmental status in the study area. This section provides the background information about the study area with an overall description of environmental baseline of the area where the proposed site would take place. Various baseline environmental parameters, with each respective inference, as per the Table No. 3.1 were monitored as primary data and the secondary data was collected for the analysis. 3.1 Study Area The project site lies at Village - Kumbhivali in Taluk -Khalapur, and State Maharashtra. The total land requirement of the proposed expansion of the existing organic chemicals manufacturing facility is 5 acres and total existing plot area is 20 acres. Table No. 3.1 Baseline Environmental Parameters Parameter Inference Micro-meteorological To assess the air pollution impacts on the neighboring environment. studies Air quality data To assess the baseline air quality status prior to the commencement of the project. Predicted concentrations will be superimposed on the baseline values to know the overall baseline scenario during the operational phase. Water quality and Even though the proposed site does not generate any wastewater from soil quality in the study area the process, it is proposed to identify the baseline water quality for future reference. Ecological environment Baseline ecological data was collected to identify any presence of endangered species and the impact due to proposed site. Land use and land To identify land cover and land use pattern in the study area. This forms MITCON Consultancy and Engineering Services Ltd., Pune 50

51 Parameter cover data Socio economic and demographic data Inference the actual baseline data in the study area. The same was compared with Survey of India Toposheet 47F/1, 47 F/2, 47 F/5, 47 F/6. Relevant secondary data has been collected from various sources to know the baseline socioeconomic status in the study area. The baseline environmental status is important to understand region's existing physical, biological, cultural and social environmental characteristics. Information and data presented in this section is based on primary surveys and environmental quality monitoring, secondary data collected from various departments and prior studies undertaken by MITCON on the subject. The information on the baseline environmental conditions forms the basis to analyze the probable impacts of the proposed activities. 3.2 Methodology of Conducting Baseline Study The guiding factors for the present baseline study are the MoEF s requirements for the Environmental Impact Assessment notification and local regulations and directives. The primary study area for the proposed development is within a radius of 5 km from the center of the development site since most of the potential impacts are most likely to occur within this area. Further, a buffer area extending to 10 km radii from the site has also been studied, though with a lesser degree of detail. The baseline study and primary data were collected based on observation and measurements made during the field survey carried out in the post monsoon (Oct) and winter season (Nov, Dec) Studies were conducted by considering the following: The various environmental attributes were divided into primary and secondary studies. Primary attributes such as air environment, water, soil, biological environment were assessed by conducting field studies, on-site monitoring; MITCON Consultancy and Engineering Services Ltd., Pune 51

52 Secondary attributes such as land use studies, geology, physiological characteristics, and socio-economic environment have been assessed by literature review of previous studies conducted by various government publications. The scoping and the extent of data generation were formulated with interdisciplinary team discussions, criteria questions and professional judgment. The baseline studies started with site visits and reconnaissance survey in the study area for fixing the monitoring locations for the primary data. As a secondary data source, various government agencies were approached for getting information and relevant data. 3.3 Physical Environment Site Surrounding and Geography Proposed expansion of organic manufacturing plant of Dujodwala Product ltd. Located at Khalapur, Raigad, which lies at 18 o 49' 34.76" N latitude and 73 o 15' 34.46" Elongitude. The existing organic manufacturing plant site is located adjacent to Pune Mumbai Expressway. The nearest railway station is Khopoli located at 9.80 kms (aerial distance) from the project site. The nearest airport is Chhatrapati Shivaji Airport at 52 kms from the project site. The proposed site is nearby from Patalganga River (2.75 km). The surrounding of Project site is as follows Geomorphology and Soil Types Soil types and Geomorphology within Raigad district: Soil Types and Geomorphology within the Raigad district given below The district has three physiographic divisions i.e. MITCON Consultancy and Engineering Services Ltd., Pune 52

53 Coastal zone in west covers about 20% percent of the district Central zone covers about 1/3rd of the district, consisting of fertile land in low lying area Hilly zone in the eastern part highly uneven in altitude and covered with forest This hill range is characterized by ruggedness and uneven topography, with crestline of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three main rivers in northern part. Kundalika River is the main river in central part whereas in the southern part Savitri River is the main river. The soils in the district are formed from the Deccan Trap which is predominating rock formation with small out crops of Laterite at a few places in the Poladpur taluka and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or Saline, Coastal Alluvium and Laterite as per the location and topographical situation. A) Ground Water Scenario Figure No. 3.1 Hydrogeology of the Pune District Hydrogeology Formation and intruded by a number of dykes. The western part of the district consisting Basalt flows are altered to Laterite. Recent deposits comprising Beach Sand and Alluvium occur along the coast and in the river mouth; however they do not form potential aquifer. A map depicting the hydro-geological features is shown as Figure No MITCON Consultancy and Engineering Services Ltd., Pune 53

54 Soft Rock (Alluvium) The Alluvial deposits are found along the coastal areas in few isolated patches having limited areal extent as Beach Sand and along the course of major rivers. In the alluvial deposits, primary porosity is due to the inter-granular pores paces making sands and gravels good water bearing formations. The groundwater occurs under phreatic /unconfined aquifer at relatively shallow depths of 3-5m and their yield ranges from about 18 to 43 m3/hr. B) Water Level Scenario Central Ground Water Board periodically monitors 28 National Hydrograph Network Stations (NHNS) in Raigarh district, four times a year i.e. January, May, August and November. Depth to Water Level Pre monsoon (May 2007) The depth to water levels in the district during May 2007 ranges between 0.55 m bgl (Nagothan) and 8.60 m bgl (Chinchwad). Depth to water levels during pre-monsoon (May 2007) has been depicted in Figure No. 3.2 Shallow water levels i.e., less than 2 m bgl are seen in the central part of the district. The water levels 5 to 10 m bgl are seen in the southern part of the district i.e. around Poladpur and Mahad and also as scattered patches across the district. In the major part of the district water level ranges from 2 to 5 m bgl. Depth of water level May 2007 is shown in Figure No MITCON Consultancy and Engineering Services Ltd., Pune 54

55 Figure No 3.2 Depth to water level (May 2007) Depth to Water Level Post monsoon (Nov. 2007) The depth to water levels during post monsoon (Nov. 2007) ranges between0.30 m bgl (Kargaon) to 3.28 m bgl (Khalapur). Spatial variation in post monsoon depth to water levels is shown in Figure 4. Shallow water levels of less than 2.0m bgl are seen in major part of the district whereas water levels of 2 to 5 m bgl are seen as patches in north western part and along the eastern periphery of the district around Khalapur, Karjat and Poladpur in southern part of the district. The water levels of 5 to 10 m bgl are restricted around south eastern part of the district. Depth to water level (November 2007) is shown in Figure No MITCON Consultancy and Engineering Services Ltd., Pune 55

56 Figure No. 3.3 Depth to water level (November 2007) Seasonal Water Level Fluctuation (May to Nov. 2007) The fluctuation between May and Nov, 2007 water levels in the district range from 0.25 (Indapur) to 7.98 m (Chinchwad). In the major part of the district the fluctuation range is less than 2.0 m. The higher fluctuation of more than 2 mis observed in southern part i.e. around Mahad, Poladpur and as scattered patches around. Karjat, Chinchwad, Khutal and Chandora. The negative fluctuation i.e., fall in post monsoon period has been observed in the range of 0.12 (Jite and Pali) to 0.18 m (Khalapur) in central part of the probably due to supplement well irrigation to paddy crop. Water Level Trend ( ) Trend of water levels for pre monsoon and post monsoon periods for last ten year ( ) have been computed for 28 NHNS. Analysis of trend indicated that during premonsoon period, rise in water level has been recorded at 12 stations and it ranges between MITCON Consultancy and Engineering Services Ltd., Pune 56

57 negligible (Phugaon) and 0.35 m/year (Veshwi). Fall in water levels has been observed at 16 stations and it ranges between negligible (Neral) and 0.48 m/year (Dapoli). During post monsoon period, rise in water levels is observed at only 6 stations and it ranges from negligible (Saigaon Govalwadi) to 0.12 m/year (Neral), whereas the fall is observed at 22stations and it ranges from negligible (Nagothan) to 0.14 m/year (Indapur). Thus in major parts of the district decline in water levels both during pre-monsoon and post monsoon was observed. The spatial distribution of pre monsoon and post monsoon water level trends is presented in Figure No.5. The perusal of Figure No. 5 shows that during both the periods major part of the district shows declining water level trend in the range of0 to 0.20 m/year. During pre-monsoon rising water level trend is observed in patches in north central part in parts of Uran, Khalapur and Pen talukas; in central part in major part of Murud taluka; and in southern part of the district in parts of Mhasala and Shrivardhan and almost entire Poladpur and Mahad talukas, whereas in post monsoon period rising trend is further reduced/restricted to central part around Pen taluka and in northern part around Karjat talukas. Pre monsoon (L) and Post-monsoon (R) Water Level trend (May & Nov ) is shown in figure no. 3.4 Figure No. 3.4 Pre-monsoon (L) and Post-mansoon (R) Water Level trend (May & Nov MITCON Consultancy and Engineering Services Ltd., Pune 57

58 C) Yields of Dug wells and Bore wells The yields of the wells are the functions of the permeability and transmisivity of aquifer encountered. This varies with location, diameter and depth of wells. There are mainly two types of ground water structures in the district i.e., dug wells and bore wells. Yield of dug wells in Basalt varies according to the nature of formations tapped. The yield of dug wells in phreatic aquifer ranges from 45 to 60 m3/day and pumping rarely exceeds 2 to 3 hours. As per the exploration data of CGWB, the discharge of the exploratory wells was found in the range of traces to lps. Bore wells drilled by GSDA down to the depth of90 m tapping weathered and vesicular basalt are found to yield 0.5 to > 20 m3/hr, however most of the bore wells yield up to 5 m3/hr. In the Alluvial area of coastal tract dug wells are capable of yielding 18 to 43 m3/hr for 2 to 5 m drawdown for two to four hours/day. D) Ground Water Resources Central Ground Water Board and Ground Water Survey and Development Agency (GSDA) have jointly estimated the ground water resources of Raigad district based on GEC 97 methodology. Taluka wise ground water resources are shown in Figure No Ground water assessment is done for an area of 3747 sq. km of which sq. km area is under command and sq. km area is under non command. As per the estimation the total annual ground water recharge is MCM with the natural discharge of 8.16 MCM, thus the net annual Figure No. 3.5 Talukawise Ground Water Resources in Raigad MITCON Consultancy and Engineering Services Ltd., Pune 58

59 groundwater availability comes to be MCM. The gross draft for all uses is estimated of MCM with irrigation sector being the major consumer having a draft of MCM, whereas the domestic and industrial draft is to the tune of16.13 MCM. The net ground water availability for future irrigation is estimated to be MCM, whereas the allocation for domestic and industrial supply up to next 25 years is MCM. Stage of ground water development varies from26.25% (Mangaon) to 76.79% (Mhasala). The overall stage of ground water development for the district is 46.16%. All the 14 talukas and 17 watersheds of the district fall in Safe category. E) Status of Ground Water Development Ground water development depends on many factors viz., availability, crop water requirement, socio-economic fabric and on the yield of the aquifers existing in that area. Ground water in the district is predominantly used for irrigation as it is the major ground water utilizing sector. The ground water development in the district is mostly through dug wells. The minor irrigation census data of indicates that the area irrigated by ground water is about 18 sq.km., whereas surface water accounts for about 87 sq. km. of the area and the net irrigated are a stand at 105 sq. km. Thus it is clear that surface water is the major source of irrigation as it accounts for 83% of the net irrigated area. There are about 4598dugwells in use in the district which create an irrigation potential of 18 sq. km. out of which almost entire irrigation potential of sq. km. is utilized, whereas 475borewells create irrigation potential of about 4 sq. km. and entire irrigation potential is utilized. 3.4 Air Environment Air quality is represented generally in terms of concentration of Particulate Matter (PM10 & PM2.5), Sulphur Dioxide and Oxides of Nitrogen. A wide variety of sources contribute particulate matter in ambient air. Some of them are construction activities, vehicular emissions, industrial process emissions, dust storms etc. MITCON Consultancy and Engineering Services Ltd., Pune 59

60 The baseline studies for air environment covers reconnaissance, identification of specific air pollutants due to proposed project and assessing their existing levels in ambient air within study area. Micrometeorology data at and around project site during study period is also an essential requirement for proper interpretation of baseline environmental status. The baseline status within the study area of 10 Km radial distance from the site of proposed project has been studied. Details of the location features are given in Table No Table No. 3.2 Location Features of the Site No. Particulars Details 1 Site Address Dujodwala Products Ltd. At kumbhivali, Khalapur, Dist: Raigad 2 Site Coordinates Latitude: N Longitude: E No. of Villages in 10Km Study Area 28 4 Nearest IMD Station No (Nearest IMD is Bhira Km away from the project Site) 5 Nearest town Khalapur km 6 Nearest Railway Line Khopoli 9.80 Km 7 Access by Sea No 8 Access by Air No 9 Approach to site by Road Mumbai Pune expressway km 10 Religious Place/ Historical Place Mahad temple 4.77 Km 11 Archeological monuments No 12 Reserved Forest / Ecological Sensitive area No 3.5 Micro Meteorology Data from Secondary Source The methodology adopted for monitoring surface observations is as per the standard norms laid down by Bureau of Indian Standards (IS: 8829) and Indian Meteorological Department (IMD). On-site monitoring was undertaken for various meteorological parameters generate the site specific data. The generated data is then compared with the meteorological data available with IMD Bhira. MITCON Consultancy and Engineering Services Ltd., Pune 60

61 The Central Meteorological Station (CMS) equipped with continuous monitoring equipment was set up at the plant site to collect the primary data such as wind speed, direction, relative humidity and temperature. Cloud cover is recorded by visual observations. Rainfall was monitored by rain gauge. Hourly average, maximum, and minimum values of wind speed, direction, relative humidity, and temperature were recorded continuously at the site. The station was in operation for three months from 1 st October 2012 to 31 st December Table No. 3.3 Meteorological Parameters Monitored At Site Sr. No Parameters Instruments Frequency 1. Wind speed Counter Cup Anemometer Hourly /Continuous 2. Wind direction Wind vane Hourly /Continuous 3. Temperature Thermo sensor Hourly /Continuous 4. Relative humidity Thermo hydro sensor Hourly /Continuous Climatological Data IMD Bhira : The meteorological data has been taken from the Climatological tables of IMD The wind direction of October to December is given below in Table No Table No. 3.4 Wind direction from October to December Sr. Wind direction (Percentage frequency) Month Time No. N NE E SE S SW W NW Calm 1. October 8.30 am pm Novembe 8.30 am r pm December 8.30 am pm The Table 3.4 reflects that the predominant wind direction is South East to North West. The wind speed from the month of October to November is given below in Table 3.4 (A) on next page. MITCON Consultancy and Engineering Services Ltd., Pune 61

62 Table No. 3.4 (A) Wind speed from October to December Sr. No of days with wind speed Month Time No. 62 or more (kmph) kmph 1-19 kmph 0 kmph 1. October 8.30 am pm November 8.30 am pm December 8.30 am pm The most predominant wind speed category is 1-19 kmph. The mean wind speed for the months of October November and December is 11 kmph, 11.5 kmph and 12.5 kmph respectively. The temperature data for the month of October, November and December is given below Table No. 3.4 (B) Temperature data for the months of October to December Sr. Daily Daily min. Highest in the Lowest in Month No. max. ( 0 C) ( 0 C) month ( 0 C) the month ( 0 C) 1. October November December The Table 3.4 (B) reflects the following, The daily maximum temperature ranged from C to C The daily minimum temperature ranged from C to C The highest temperature in the month ranged from C to C The lowest temperature in the month ranged from C to C The relative humidity for the month of October, November and December is given below in Table No. 3.4 (C) on the next page:- Table No. 3.4 (C) Relative humidity for the months of October to December Sr. No. Month Time Relative humidity MITCON Consultancy and Engineering Services Ltd., Pune 62

63 1. October am pm November am pm December am pm 54 (%) The Table 3.4 (C) reflects that the minimum relative humidity was in the month of December i.e54% and maximum relative humidity was in the month of October i.e.81%. Rainfall: No rain has been recorded during the study period. Usually the major rainy days are during the months of June to September. Annual rainfall of Raigad region is 2055 mm Climatological Data - Project Site Temperature: The temperature recorded at the project site is tabulated in Table 3.4 (D) for the month of October, November and December Table No.3.4 (D) Temperature recorded at the site Sr. Month Minimum temp. Average Temp. Maximum No ( 0 C) ( 0 C) ( 0 C) 1. Oct Nov Dec temp. The Table No. 3.4 (D) reflects the following:- The minimum temperature varied from C to C. The average temperature varied from C to C. The maximum temperature varied from C to C. Humidity: The humidity recorded for the month of October to December 2012.is tabulated in Table No. 3.4 (E). MITCON Consultancy and Engineering Services Ltd., Pune 63

64 Table No. 3.4 (E) Relative Humidity recorded at the site Sr. No Month Min. humidity (%) Average humidity (%) Max. Humidity (%) 1. Oct Nov Dec The Table 3.4 (E) reflects that the following, The minimum relative humidity varied from 20% to 27%. The average relative humidity varied from 37% to 43.7%. The maximum relative humidity varied from 60% to 59%. Wind Pattern: A wind rose is a graphic tool used by meteorologist to give a succinct view of how wind speed and direction are typically distributed at a particular location. The meteorology was monitored by installing a automatic weather station of Bhira for the period of October to November The site specific wind roses are depicted from Figure 3.6 (A) to Figure 3.6 (D). The interpretation of the site specific wind roses is given below... October 2012:- The wind rose diagram depicts that predominant wind direction is from South East. The 0.3 m/sec 1.4 m/sec fraction and 1.4 m/sec -3.1 m /sec fraction was found to be 30% and 25% respectively. The average wind speed was found to be 0.68 m/sec and calms prevailed for 8.20 % of the entire month. November 2012:- The wind rose diagram depicts that predominant wind direction is from South East. The 0.3 m/sec 1.4 m/sec fraction and 1.4 m/sec -3.1 m /sec fraction was found to be 20 % and 15 % respectively. 1.57m/sec and calms prevailed for 6.25 % of the entire month. The average wind speed was found to be December 2012:- The wind rose diagram depicts that predominant wind direction is from South East. The 1.4 m/sec 3.1 m/sec fraction and 3.1 m/sec -5.2 m /sec fraction was MITCON Consultancy and Engineering Services Ltd., Pune 64

65 found to be 55 % and 60 % respectively. The average wind speed was found to be 1.85m/sec and calms prevailed for 4.03 % of the entire month. Seasonal wind rose (October 2012 to December 2012):- The seasonal wind rose diagram depicts that predominant wind direction is from South East. The 2.1 m/sec 3.6 m/sec fraction and 3.6 m/sec -5.7 m /sec fraction was found to be 45 % and 50 % respectively. The average wind speed was found to be 1.36/sec and calms prevailed for % of the entire season. Figure No. 3.6 (A) Wind rose for the month of October 2012 Chart 1: Wind Class Frequency Distribution for October 2012 MITCON Consultancy and Engineering Services Ltd., Pune 65

66 Figure No. 3.6 (B) Wind rose for the month of November 2012 Chart 2: Wind Class Frequency Distribution for November 2012 MITCON Consultancy and Engineering Services Ltd., Pune 66

67 Figure No. 3.6 (C) Wind rose for the month of December 2012 Chart 3: Wind Class Frequency Distribution for December 2012 MITCON Consultancy and Engineering Services Ltd., Pune 67

68 Figure No. 3.6 (D) Seasonal Wind rose for the month of October December 2012 Chart 4: Wind Class Frequency Distribution for October December 2012 MITCON Consultancy and Engineering Services Ltd., Pune 68

69 3.6 Ambient Air Quality (AAQ) Sampling Locations Ambient air quality of the study area has been assessed during winter period of 1 st October 2012 to 31 st December 2012, through a network of five ambient air quality stations within an area of 10 km region around the project site. Based on the established selection criteria the locations of ambient air quality monitoring (AAQM) stations have been identified. The concentrations of PM10, PM2.5, SO2 and NOX samples were collected as 24 hourly average by drawing air at the rate of m 3 /min through glass fibre filter paper and analyzing by the gravimetric method. Whereas, the concentrations of SO2 and NOX were analyzed by absorption & colorimetric method. Three months ambient air quality results enclosed as Annexure No.4. The air monitoring locations are shown in Figure No.3.7 and Table No.3.5 Table No. 3.5 Description of Ambient Air Quality Monitoring Stations station Code Station Name Distance From Project Site (km) Direction AAQ-1 Project Site - - Upwind/ Downwind AAQ-2 Dhamani 1.6 E Upwind AAQ-3 Kharsundi 1.4 W Downwind Nimode Downwind AAQ NW katarwadi AAQ-5 Ambivali 4.8 NW Downwind AAQ-6 Khalapur 1.4 E Crosswind MITCON Consultancy and Engineering Services Ltd., Pune 69

70 Figure No. 3.7 Ambient Air Monitoring Locations MITCON Consultancy and Engineering Services Ltd., Pune 70

71 Pre-calibrated fine particulate samplers were used for monitoring of PM10& PM2.5. Analysis techniques used for different air quality parameters are presented in Table 3.6. Table No. 3.6 Techniques Used for the Analysis of Ambient Air Quality Parameters Sr. No Parameter Technique Technical Protocol Minimum Detectable Limit 1 PM 10& PM2.5 Gravimetric method IS (Part-4) 1.0 g/m 3 2 Sulphur Dioxide Modified West and Gaeke IS-5182 (Part-2) 4.0 g/m 3 3 Nitrogen Oxide Jacob & Hochheiser IS-5182 (Part-6) 4.0 g/m 3 4 Carbon Monoxide CO analyzer / monitor IS-5182 (Part-10) 1.0 ppm Observations sought out during baseline study period October December 2012 presented in Table No Table No. 3.7 Observations of Air Monitoring PM 2.5 (μg/m 3 ) PM 10 (μg/m 3 ) SO 2 (μg/m 3 ) NO x (μg/m 3 ) Hydrocarbon (μg/m 3 ) O 3 (μg/m 3 ) VOC AAQ-1 Project Site Minimum Maximum Average percentile AAQ-2 Dhamani Minimum Maximum Average percentile AAQ-3 Kharsundi Minimum Maximum Average percentile AAQ-4 Nimode Katarwadi BDL BDL BDL BDL BDL BDL BDL BDL BDL MITCON Consultancy and Engineering Services Ltd., Pune 71

72 PM 2.5 (μg/m 3 ) PM 10 (μg/m 3 ) SO 2 (μg/m 3 ) NO x (μg/m 3 ) Hydrocarbon (μg/m 3 ) O 3 (μg/m 3 ) VOC Minimum Maximum Average BDL BDL BDL 98 percentile AAQ-5 Ambivali Minimum Maximum Average BDL BDL BDL 98 percentile AAQ-6 Khalapur Minimum Maximum Average BDL BDL BDL 98 percentile Industrial, Residential and Rural Areas 100 µg/m3 CPCB Standards (November 2009) 24 hourly 60 µg/m3 Note: Below Detection Limit (BDL) 80 µg/m3 80 µg/m3 The concentrations of PM10 PM2.5, SO2 and NOx (Table 3.7) were found within the National Ambient Air Quality Standards (NAAQ). Total hydrocarbon (HC) & volatile organic compound (VOC) were found to be below detectible limit. 3.7 Noise Environment Ambient noise standards are prescribed for residential, commercial and industrial areas and silence zone vide The Noise Pollution (Regulation and control) Rules, 2000, notified by the MoEF on February 14, The ambient noise standards have been stipulated during day time (6 am to 10 pm) and night time (10 pm to 6 am) keeping in the view the different MITCON Consultancy and Engineering Services Ltd., Pune 72

73 sensitive and the resultant impacts at community level during these periods. The ambient noise levels were monitored at selected villages within the study area during day and night time covering residential, commercial/industrial and silence zones. Background noise levels were measured at the project site and surrounding villages by a standard- noise- level- meter for 24 hours. Equivalent noise levels during day ( hrs) Ld, night ( hrs) Ln and the equivalent noise levels for day & night, the Ldn values were calculated. The Noise quality monitoring Station& results are shown in Figure 3.8 &Table 3.8. Table No. 3.8 Ambient Noise Levels in Study Area Units: db (A) N1 N2 N3 N4 N5 N6 Min Max Ld Ln L Min Minimum Noise Level Recorded Ld Day Equivalents L Max Maximum Noise Level Recorded Ln Night Equivalents Analysis of Ambient Noise Levels: CPCB Standards For Noise Levels Day Time Night Time Industrial 75 db(a) 70 db(a) Commercial 65 db(a) 45 db(a) Residential 55dB(A) 45 db(a) Silence Zone 50 db(a) 40 db(a) The above results are within the CPCB Standards. Noise monitoring results enclosed as Annexure No. 5.The minimum noise level 30.8 db (A) and the maximum noise level 52.6 db (A) were observed. The relative high values of noise recorded in factory premises and suburban areas were primarily due to vehicular traffic and other activities. MITCON Consultancy and Engineering Services Ltd., Pune 73

74 Figure No. 3.8 Ambient Noise Monitoring Locations MITCON Consultancy and Engineering Services Ltd., Pune 74

75 3.8 Water Environment Reconnaissance Survey Assessment of baseline data on water environment includes Identification of surface water sources Identification of ground water sources Collection of water samples Analyzing water samples for physic o-chemical and biological parameters Assessment of water quality in the study area includes the water quality testing and assessment per the Indian standard IS (drinking water standard). Water samples from various locations in and around the project site within 10 km radius were collected for assessment of the physico-chemical and bacteriological quality. Methodologies adopted for sampling and analysis were according to the IS methods. Field parameters such as ph, Temperature and Dissolved Oxygen were tested at site. The parameters thus analyzed were compared with IS Baseline Status Surface Water Natural drain in the study area includes Patalganga 2.75 km away from the project site. The map depicting water Quality locations are shown in Figure No Ground Water The water sampling locations are given in Table No Water samples from various locations in and around the plant site within 10 km radius were collected for assessment of the physico-chemical and bacteriological quality. Field parameters such as ph, Temperature and Dissolved Oxygen were monitored at site. The parameters thus analyzed MITCON Consultancy and Engineering Services Ltd., Pune 75

76 Sr. No Parameter Unit Project Site Abbh-ivali Madap Khara-sindi Savaroli Dhamani Patalganga Up-stream Patalganga Downstream Dujodwala Products Ltd. were compared with IS Details of surface and ground water quality are presented in Table Table No. 3.9 Water sampling locations S No. Location Code Location Name Sample Source Surface Water 1 SWQ1 Patalganga River Up-stream 2 SWQ2 Patalganga River Down-stream Ground Water 1 GWQ1 Project Site Open Well 2 GWQ2 Abbhivali Open Well 3 GWQ3 Madap Open Well 4 GWQ4 Kharasindi Open Well 5 GWQ5 Savaroli Open Well 6 GWQ6 Dhamani Open Well Table No Water Quality Results (Sortout parameters) 1 ph Conductivity mho/cm Turbidity N.T.U TDS mg/l Alkalinity mg/l Total Hardness mg/l (as CaCO 3) 7 Calcium mg/l (as Ca) 8 DO mg/l (Refer Annexure-6 for Water Quality Results) MITCON Consultancy and Engineering Services Ltd., Pune 76

77 Assessment of Water Quality The ground water quality parameters were assessed as per the Indian Standard IS (Drinking Water Standard). The observations are given below: It is observed that the ph of the ground water and surface water samples are in the range of 6.50 to 7.38 Total dissolved solids (TDS) of the ground water & surface water samples were in the range 58 to 444 mg/l Total hardness of the ground water & surface water samples was found to vary between 36.0 to 268 mg/l MITCON Consultancy and Engineering Services Ltd., Pune 77

78 Figure No. 3.9 Water Sampling Locations MITCON Consultancy and Engineering Services Ltd., Pune 78

79 3.9 Land Environment There are four chief varieties of soil: ailuvial and alluvia, powdered laterite and trap, clayey mould resting on trap, and soil containing marine deposits with, much sand and other matter in concretion. Of these the first, which is composed of various disintegrated rocks of the overlying trap formation, with a varying proportion of calcareous substances, is at once the richest and the most widespread. It is red, yellow or black in colour, crumbly, and, from the drainage of hill streams, free from salt of the three colours. All are equally productive, but the black is most suited for growing-rice. Its richness is due chiefly to its lime nodules or kankar, and to the vegetable matter in valleys and near river banks. The second soil, powdered laterite and clay, which cover the sides and slopes of hills, is next in point of excent. Though filted for the growth of such hill crops as nachni, vari, harik, udid, and til, this soil, owing to its shallowness, soon becomes exhausted, and, after bearing for three years, has to be allowed a three years fallow. The third soil, clayey mould resting on trap, is found near the banks of the Nagothna, Roha, and Mandad creeks, and in the strip of land that stretches from Dasgaon ten miles west along the sides of the Savitri River. In the strip of land that runs by the side of the Nagothna creek, about eighteen miles long and from half a mile to three miles broad, the soil is mixed with chalky tubes locally called ladh. Some detached flats of this soil along the Roha and Mandad creeks arc cultivated with inferior rice. Where the supply of fresh water is scanty the yield is small, but, where the supply of fresh water is plentiful, the yield equals that of uthlapat or sweet rice land. The third sort is mostly very dark brown, and, when dry, is extremely hard. In places where it is or was liable to be flooded from creeks and backwaters it is called kharepat or salt land. Below this soil is a stratum of mud, in many places half liquid. The fourth soil, containing marine deposits and sand, lies along the sea-coast and is favourable to garden crops, which are helped by the abundant supply of water contained in a belt of concrete and lime. MITCON Consultancy and Engineering Services Ltd., Pune 79

80 Sr. No. Parameters of Analysis Unit Project Site Ambin-ali Madap Dhamani Sava-roli Kharasundi Dujodwala Products Ltd Geology The rock of the district is trap. In the plains it is found in tabular masses a few feet below the soil and sometimes standing out from the surface. In the hills it is tabular and is also found in irregular masses and shapeless boulders varying from a few inches to several feet in diameter. In many places the surface of the trap has a rusty hue showing the presence of iron. Baseline Status Soil samples were collected within the radius of 10 Km in the study area. The detailed analysis is given in table 3.11.The map depicting soil sample locations are depicted in Figure Table No Soil Quality Monitored within Buffer Zone of project Soil Sample Identity 1. ph of 20 % suspension ph Organic matter % Bulk density gm/c m Free Ammonical % Nil Nil Nil Nil Nil Nil Nitrogen 7. Potassium as K % Phosphorous as P % Particle size distribution Sand Slit Clay % % % (Refer Annexure-7 for Soil Quality Results) MITCON Consultancy and Engineering Services Ltd., Pune 80

81 Figure No Soil Sampling Locations MITCON Consultancy and Engineering Services Ltd., Pune 81

82 Soil quality of study area shows the following observation: All the samples having ph in range of All the samples having average concentration of Electrical Conductivity and Organic Carbon. Concentration of Nitrogen, Phosphorus and Potassium are under better, medium and very less category as per standard soil classification Overall it is observed that the soils of the region are suitable for agriculture Land Use & Crop Pattern The analysis of general land use denotes the status of land surface in an area. The general land use of the district is classified into forest land, net sown area, land not available for cultivation, cultivable waste and fallow land. The above classification is used for present study. In this paper an attempt has been made to study the change in general land use in Raigad District of Maharashtra. Raigad District is located in North Konkan of Maharashtra and covers 7148 sq. km. area. The entire study is based on secondary data. The period of 20 years i.e. from to is selected for spatio-temporal changes of land use. The tahsil is a basic unit of investigation. Cartographic techniques are employed to strengthen the analysis of study. The study reveals that during the last two decades drastic changes have taken place in general land use pattern. Raigad district has high proportion of non-agriculture land due to rapid growth of urbanization. Figure 3.11 is showing cultivation and uncultivated land, Figure 3.12 is showing Uncultivated and Fallow land and figure 3.9 is showing forest land of Raigad region. MITCON Consultancy and Engineering Services Ltd., Pune 82

83 Figure No Map showing Cultivation (L) & Uncultivated Land (R) of Raigad District Figure No Map Showing Uncultivated Land (L), Fallow Land (M) & Forest Land (R) of Raigad MITCON Consultancy and Engineering Services Ltd., Pune 83

84 Crop Pattern of Raigad In , of 476,693 acres, the total area of tilled land, 171,858 or per cent were fallow or under grass. Of the remaining 304,835 acres, 4636 were twice cropped. Of the 309,47.1 acres under tillage, grain crops occupied 285,490 acres or per cent, 141,144 of them under rice, bhat, Oryza sativa; 63,579 under ragi or nachni, Eleusine coracana; 49,097 under vari, Panicum miliare; 31,669 under kodra, Paspalum scrobiculatum, and one under wheat, gaku, Triticum aestivum. Pulses occupied 15,031 acres or 4.35 per cent, 5899 of them under udid, Phaseolus mungo; 1796 under gram, harbhara, Gicer arietinum; 1686 under tur, Cajanus indicns; 1488 under mug, Phaseolus radiatus; one under kulith, Dolichos biflorus; and 4161 under other pulses. Oilseed occupied 4609 acres or 1.48 per cent, 4413 of them under gingelly seed, til, Sesamum indicum; and 196 under other oilseeds. Fibres occupied 1522 acres or 0.49 per cent, of which 1497 acres were under Bombay hemp, tag, Crotolaria juncea; and 25 under cotton, kapus, Gossypium herbaceum. Miscellaneous crops occupied 2819 acres or 091 per cent, 65 of them under sugarcane, us, Saccharum officinarum; and the remaining 2754 under various vegetables and fruits. Rice: The following are the chief details of the more important crops: Rice, bhat, Oryza sativa, holds the first place, with, in , 141,144 acres or per cent of the whole tillage area. The twenty-four chief sorts of rice belong to two main groups, red rice and white rice. Red rice is inferior and is grown only in salt low lying lands near creeks which are liable to be flooded by spring tides. White rice grows only in lands beyond the reach of salt water. Of the sixteen sorts of white or sweet soil rice, seven, known as early or halve, ripen about the middle of October, and nine, known as late or garvi, about a month later. Of the sweet rice lands, some, chiefly in the southern sub-divisions near the villages of Mahad, Ghodegaon, Birvadi, Latvan, Nateh, and Poladpur, grow cold weather crops of tur, gram, and other pulse. But over the greater part of the district the rice lands lie bare during the cold weather. During the cold weather months patches in the fields are covered with a MITCON Consultancy and Engineering Services Ltd., Pune 84

85 thin layer of cow dung on which a second layer of brushwood and tree-lopping is laid, and, above this, grass is spread to the depth of a foot. Earth is scattered on the grass, and the whole is set on fire early on some morning towards the end of the hot season. In June, just before the rains, the ground is strewn with seed, and then ploughed along with the wood and dung ashes. After a few heavy showers, the plants begin to shoot, and are allowed to grow for three weeks or a month. When the soil is thoroughly softened they are pulled up in little bunches of from six to eight seedlings, and planted, from eight to ten inches apart, in soil previously ploughed and cleared of weeds. The rice is weeded by hand about a month after planting. It is reaped in the end of October or the beginning of November. After drying for some days in the field, the rice is tied in sheaves, and, about a month later, is threshed by beating the sheaves against a well-cleaned threshing floor, and the whole is afterwards winnowed. In salt rice land neither ploughing nor manure is required. When the ground is well soaked with rain, the seed is either thrown into the mud, or, when the land is low, it is wetted and placed in a heap until it sprouts, when it is thrown into the mud or on the surface of the water. After the plants have grown a little, crowded patches are thinned and bare spaces planted. The chief labour and expense in growing salt rice is the making and mending of the banks. Every field is surrounded by a bank from two to four feet high according to its distance from a creek. This bank has to be renewed every year and kept in repair during the time the crop is on the ground. During spring tides it must be carefully watched day and night. If by any oversight the field is flooded by salt water, years pass before it again yields a good crop. The reaping and threshing of salt rice is the same as of sweet rice. Pulse: Of 15,031 acres under pulse, 5899 were under black gram, udid, Phaseolas mungo. It is grown chiefly in Mangaon, Roha, and, Mahad after the rice crop has been reaped. For the udid crop the soil is ploughed three times, and the clods of earth are broken by the hand. No manure is used and the seed is sown broadcast. The crop ripens about March. Udid flour is used as food in a variety of ways, and the stalks of the plant are a good fodder for cattle of MITCON Consultancy and Engineering Services Ltd., Pune 85

86 other pulses tur and mug are grown in Roha, Mangaon, and Mahad, and gram in Mangaon only. Sesamum: Sesamum, til, Sesamum indicum, occupying, in , 4413 acres, is raised mostly in Mangaon and Mahad, and grows best on fairly flat land. The soil does not require to have brushwood burnt on it and is only ploughed twice after rain has fallen. No manure is used and the seed is sown broadcast from the middle to the end of June. The crop does not require to be weeded and ripens about the beginning of November. Betel Leaf: Betel-leaf, pan, is grown to a considerable extent in the plantations between Alibag and Chaul. The soil is well ploughed and dug, ridges are made, and the betel-vine cuttings planted on the ridges, Tur sticks are set in the ground for the vines to grow up. They are shaded with palm leaves and manured with fish, if well watered the creeper yields after the first year. During the rains the leaves are largely sent to Bombay. Betel Palm: The Betel-palm, sopari, is grown in large numbers, from 50,000 to 60,000, in cocoa-palm plantations along the Alibag coast. After the nuts have dried and fallen to the ground they are buried about two inches deep in loosened and leveled soil. When the seedlings are a year old, they are planted out in July and buried about two feet deep. The soil is then enriched by a mixture of salt and nachni, sometimes with the addition of cow dung. During the first four months the plant does not require watering. After four months, it is watered either daily or at an interval of one or two days. A well-watered betel-palm begins to yield nuts in its fifth or sixth year. But if water is stinted the tree does not begin to bear till it is eight, nine or ten years old. The tree yields twice and sometimes thrice in a year, about 250 nuts being considered an average yearly yield. The price in the local market is about 700 or 800 nuts for 2s. (Re.1). The nuts are not inferior to Thana nuts and are sent to Bombay where they are sold at from 6s.to 8s.(Rs. 3-Rs. 4) a man. Mango: The Mango, amba, Mangifera indica, grows wild throughout the district; but grafted mangoes are little grown except in Alibag, Chaul, and Revdanda, The common mangoes are sent green to Bombay for pickling. MITCON Consultancy and Engineering Services Ltd., Pune 86

87 3.9.3 Seismo-Tectonic Appraisal of the Area Bureau of Indian Standards (BIS) has prepared a seismic zoning map of India based on tectonic features and records of past earthquakes. The site is located in Zone-III as per the seismic map given in Figure Zone III is defined as having a maximum intensity expected of around VII on MM scale. Zone Max. MSK Intensity 2 VI 3 VII 4 VIII 5 IX or higher Figure No Seismic Map showing the project site MITCON Consultancy and Engineering Services Ltd., Pune 87

88 3.10 Ecology & Biodiversity Study of Biological Environment is one of the most important aspects for Environmental Impact Assessment Studies in view of the need for conservation of environmental quality and biodiversity. Ecological systems show complex inter-relationships between biotic and abiotic components including dependence, competition and mutualism. Biotic components comprise both plant and animal communities, which interact not only within and between themselves but also with the abiotic components viz. physical & chemical components of the environment. The data in the study area is collected on types and status of flora and fauna, for assessing the potential impacts on flora and fauna due to construction and operation of the project with associated facilities Ecology Ecological impact assessment is used to predict and evaluate the impacts of development on ecosystems and their components, thereby providing the information needed to ensure that ecological issues are given full and proper consideration in development planning. Ecological assessment has a major part to play as a component of EIA but also has other potential applications in environmental planning and management. The vegetation and wild life describes the environment setting in terms of type of communities, community uniqueness, and types of species forming each community, dominant species, rare and endangered species, and their habitat vulnerability to various disturbances. Ecological cycle also is an important representation of biological environmental setting Reconnaissance Survey An exhaustive survey was carried out within project site and 10 km radial area to get an idea of major vegetative patterns, plant, animal communities, dominant species, correlation MITCON Consultancy and Engineering Services Ltd., Pune 88

89 between plant, animal communities in order to establish existing scenario of flora and fauna. Reconnaissance survey was carried out to have an overview of the terrestrial ecosystem of the core and buffer area. These surveys revealed that the study area mainly consists of residential area with few patches of a degraded scrub Land and agricultural land. Some random representative locations are selected for studying the ecological status. These locations were selected to cover the core and buffer area of the project site Survey Methodology In order to assess the prevailing status of flora and fauna in the project region, particularly on the endemic, rare and endangered species; and migratory path/ route of animals and birds and their breeding and nesting places in different terrestrial and aquatic locations of project area; baseline ecological surveys were conducted during the study period. The baseline ecological status in the project area has been established through the following methods: 1. Collection of secondary information on ecological conditions pertaining to flora and fauna and its review. 2. Reconnaissance surveys of the entire project area, in order to have a broad understanding on the prevailing situation on flora and fauna in the project area for stratifying different areas into different representative classes in order to select most appropriate sampling locations for conducting detailed ecological surveys; 3. Detailed primary ecological field surveys for establishing the first-hand information on prevailing ecological status in the project area, covering different representative physiognomic and habitat conditions; and establishing the present status of plant species and their importance MITCON Consultancy and Engineering Services Ltd., Pune 89

90 The survey was carried out by random sampling methodology in the project area and 10 Km radius including the forest patches. The sampling locations are shown in Figure 3.14 and Table Table No Ecology Survey Sampling Locations Sr. No. Location Direction w.r.t. Distance w.r.t Project Site Project Site (km) 1. Project site Kharsundi Village w Sajgaon Takai SE Thakur Wadi Kumbhivali S Dhamani E Khalapur-Vanve N Ecological status of the Study Area Survey was carried out in study area for vegetative patterns, plant, animal communities, dominant species, correlation between plant, animal communities in order to establish existing scenario of flora and fauna. The key species in the study area of 10 kms radius were found from the different localities including the forest patches like Mangifera indica (Amba), Acacia nilotica (Babul), Albizia lebbeck (Shirus), Azadirachta indica (Neem), Bauhinia racemosa (Apta), Butea monosperma (Palas), Eucalyptus globules (Nilgiri), Ficus benghalensis (Wad), Ficus religiosa (Pipal) etc. Polyalthia longifolia (Ashoka), Tamarindus indica (Chinch), Tectona grandis (Sagwan), Ziziphus jujube (Bor). Photograph of the study area is given in Figure MITCON Consultancy and Engineering Services Ltd., Pune 90

91 Figure No Ecological Sampling Locations MITCON Consultancy and Engineering Services Ltd., Pune 91

92 Figure No Photographs of the Study Area Nearby Forest Area Vegetation nearby Thakurwadi village Vegetation near Khalapur-Vanve village Common vegetation surrounding houses Observations and Results The study area represents as arid or semi-arid region. Nearby reserved forest patches in close vicinity of the proposed Project site are also surveyed. The vegetation was very sparse consisting mainly stunted and thorny shrubs, trees and herbs capable of drought resistance. Trees were very few and scattered. The proposed area has represented mostly open land and hilly terrain means low diversity in the study area. The list of plant species is given in Table MITCON Consultancy and Engineering Services Ltd., Pune 92

93 Table No List of plant species observed in 10km radius of the project area Sr. No. Common Name Botanical Name 1. Rui Calotropis gigantea 2. Mango Mangifera indica 3. Shevri bombax ceiba 4. Sag Tectona grandis 5. Apta Bauhinia racemosa 6. Umber Ficus glomerata 7. Tad Borassus flabellifer 8. Cactus Cactus Sps. 9. Babul Acacia arabica 10. Neem Azadirachta indica 11. Mahua Madhuca longifolia 12. Drumstick Moringa oleifera 13. Papaya Carica Papaya 14. Jamun Syzygium cumini 15. Kaju Anacardium occidentale 16. Palash Butea monosperma 17. Jackfruit Artocarpus heterophyllus 18. Subabul Leucaena leucocephala 19. Tamarind Tamarindus indica 20. Ain Terminalia tomentosa 21. Guava Psidium guajava 22. Vilayati chinch Pithecellobium dulce 23. Bor Zizyphus mauritiana 24. Gulmohar Delonix regia 25. Ashok Saraca indica 26. Badam Terminalia catappa 27. Bambu Bambuseae arundinella 28. Bogenvillia Bougainvillea sps 29. Coconut Cocos nucifera 30. Chandani Tabernaemontana coronaria 31. Raintree Samanea saman 32. Vad Ficus bengalensis 33. Peepal Ficus religiosa 34. Lotus Nelumbo nucifera 35. Champak Plumaria alba 36. Silver Oak Grevillea robusta 37. Hibiscus Hibiscus Rosa Sinensis 38. Croton Codiaeum variegatum 39. Gokarna Clitoria ternatea vine MITCON Consultancy and Engineering Services Ltd., Pune 93

94 Sr. No. Common Name Botanical Name 40. Banana Musa acuminata Terrestrial Fauna: The project area is surrounded by the urban habitat and therefore showing the common type of terrestrial fauna. The same is given in Table Table No Mammal species in the study area Common Name Zoological Name Local Name Schedule Five Striped palm squirrel Funambulus pennati Khar IV Common / Indian Mongoose Herpestes edwerdsi Mungoose IV Common Indian Hare Lepus nigricollis Sasa IV Bonnet monkey Macaca radiata Bandar II Indian Field Mouse Mus booduga Undir V House mouse Mus musculus Undir V Common House rat Rattus rattus Undir V House Shrew Suncus murinus Chichundri V Jackal Glossogobius giuris Kolha Wild Boar Sus indicus Dukkar Table No Amphibian and reptile in the study area Sr. No. Common Name Scientific Name A) Amphibian 1. Common frog Rana tigrina 2. Toad Bufo melanostictus B) Reptiles 1. Garden lizard Calotes versicolor 2. Wall lizard Hemidactylus brooki 3. Cobra Naja naja 4. Krait Bungarus coeruleus MITCON Consultancy and Engineering Services Ltd., Pune 94

95 Common Birds of Project site The fauna is also common type the study area. The birds found in the study area are enlisted in Table Table No Avifauna of the study area Aquatic Fauna Sr. No. Common Name Scientific Name 1. Red Vented Bulbul Pycnonotus cafer 2. Myna Acridotheres tristis 3. Owl Tyto alba 4. Magpie-Robin Copsychus saularis 5. Common Egret Casmerodius albus 6. Sunbird Cinnyris asiaticus 7. Crow Corvus splendens 8. Drongo Dicrurus macrocercus 9. Horn Bill Spotted Dove Spilopelia chinensis 11. Jungle Babbler Turdoides striata 12. Green Bee eater Merops orientalis 13. Shama Copsychus malabaricus 14. Asian Koel Eudynamys scolopaceus The Patalganga River is 2.75 km away from the project site in the NE direction. As the common fish species found in the river are as given in Table Table No Common fish species found in the river (Patalganga) Sr. No. Common Name Scientific Name 1. Catla Catla catla 2. Rohu Lebio rohita 3. Maral Channa punctata 4. Dokh Channa gachua 5. Mangur Clarius batracus 6. Dandvan Garra malya 7. Malya Orereochrimis mosambicus 8. Darai Puntius sarana 9. Khavli Puntius sophore MITCON Consultancy and Engineering Services Ltd., Pune 95

96 10. Dara Rasbora daniconius 11. Chikli Indoreonectes evezardi 12. Chikani Lepidocephalichthys thermalis 13. Sona tengra Arius sona 14. Sona tengra Hexanematichthys sagor 15. Gappi Gambusia affinis 16. Guppy Poecilia reticulata 17. Chavari tamb Lutjanus johni 18. Ravas Elutheronema tetradactylum 19. Chilna Leptomelanosoma indicum 20. Koth Otolithoides biauritus 21. Kaski Scatophagus argus 22. Mangan Mugil cephalus 23. Kharbi Glossogobius giuris 3.11 Socio-Economic Environment Baseline Status Baseline information is collected to define the socio-economic profile of the study area. Baseline data generated includes: 1. Demographic structure 2. Infrastructure Resources base in the study area 3. Economic attributes 4. Health status 5. Awareness and opinion of the people about the project The data is generated using secondary sources viz Census Records, District Statistical Abstract, Primary Health Centres etc Demographic Structure The data on the demographic structure of the study area were collected from censes records of Raigad District. There are 28 villages in the study area. The demographic profile of the study area including no. household, total population, population structure viz MITCON Consultancy and Engineering Services Ltd., Pune 96

97 scheduled Caste population and number of literates & illiterates, are discussed below. The salient features arising out of demographic details such as number of persons (i.e. Male & Female), sex ratio, is presented in Table 3.18.The demographic details have been abstracted from Primary Census Abstract of Maharashtra. The salient features of the study area are as follows: Study area includes 28 villages from Khalapur Tahsil Total population of villages under the study area is Sex ratio (No. of females per 1000 males) is which indicates that females are less in number than their male counterpart in the study are. The overall literacy rate in the study area is 58 %, which is quite satisfactory. Scheduled caste population is 3% while scheduled tribe population in the study area is 13.49%. Infrastructure Resource Base : The infrastructure resources base of the villages coming within the study area with reference to education, medical facility, water supply, post and telegraph, transportation and communication facility and power supply etc. Educational Facility: Villages in the study area are mostly having educational facilities in the form of primary, middle, secondary schools and colleges. Higher education is available at Raigad District level. Medical facility: Medical institutions in rural parts of the region are inadequate, as per the data recorded in the statistical handbook. At Raigad primary health Centres/Government hospitals are available to provide primary health services to the people. Drinking Water Facility: All the villages in the region are having drinking water facility in the form of hand pumps dug, wells and tube wells and water tanks. Communication Facility: Most of the villages in the study area having communication facilities in the form of post office, post, telegraph and telephone connections. MITCON Consultancy and Engineering Services Ltd., Pune 97

98 Transportation Facility: The facility is available in the form of bus and railway network in the region. Transportation facility in the region is good; people have to travel at long distance to access railway facility. Roads : The plant site is located adjacent to Pune Mumbai Expressway. The nearest railway station is Khopoli located at 9.80 kms (aerial distance) from the project site. Economic Activity: The occupation of population and work force of the study area are presented in Table 3.19 People in the rural area are mostly engaged in agricultural activities. Unemployment level is high in the region as non-worker population share higher percentage in the region. Average monthly income of the people in the study area is about Rs Health Status: Health of the people is not only a desirable goal, but it is also an essential investment in human resources. As per the National Health Policy (1983), primary Health Care has been accepted as main instrument for achieving this goal of development and strengthening rural health infrastructure through a three-tier system, viz., Primary Health Centre (PHCs), Subentries and Community Health Centre, which has to be established. During the study health problems were observed which could be attributed to improper sanitation, lack of health awareness among the people and lack of health related infrastructure facilities. People are not having sense of hygiene and sanitation and are not responsible for cleanliness near the drinking water source. MITCON Consultancy and Engineering Services Ltd., Pune 98

99 Demography of the study area The demography of the 10km study area is depicted through Table 3.18 Table No Demographic details of the study area Sr. No. Description Numbers 1 Total District 1 2 Total Villages 28 3 Total no. of House Hold Total Population Total Male Population Total Female Population Total SC Population Total ST Population Total Literate Population Total Illiterates Population Total Workers Population Total Male workers Total Female Workers Main Workers Marginal Workers Non-Workers Main Cultivator Population Marginal Cultivator Population 870 Table No (A) Population by Sex and Sex Ratio Sr. No. Village Total Persons Males Females Sex ratio 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe MITCON Consultancy and Engineering Services Ltd., Pune 99

100 The Table 3.18 (A) reflects that the number of males and females in the study area are and respectively. In terms of percentage - males and females constitute 52 % and 48 % of the total population respectively. The sex ratio of the study area was found to be Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL The SC and ST population in the study area is depicted in Table 3.17(B). Table No (B) SC and ST population in the study area Sr. Total SC population ST population Village No. population Population Percentage Population Percentage 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi MITCON Consultancy and Engineering Services Ltd., Pune 100

101 11 Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL The total population of SC s is 815 in total population of i.e, 3% of the total population while there are 3645 ie 13.5% STs in the study area as reflected by the Table 3.18 (B). The population and sex ratio among SCs and STs is given in Table Table No Population and sex ratio among SC s and ST s Population Sex ratio Sr. Village SC s ST s No. SC s ST s Male Female Male Female 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon MITCON Consultancy and Engineering Services Ltd., Pune 101

102 12 Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL The Table 3.19 reflects that the highest sex ratio among SCs in the study area is in village Vanivli 2000 while highest sex ratio among STs is in the village Parkhande 1142.The population in the study area in the age group 0-6 years along with sex ratio is given in Table Table No Population in the study area (0-6 years) age group Sr. No. Village Children Total Male Total Female Sex Ratio 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe Nadode MITCON Consultancy and Engineering Services Ltd., Pune 102

103 Sr. No. Village Children Total Male Total Female Sex Ratio 14 Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL The Table 3.20 reflects that the total males and females under 0-6 age group are 2081 and 1928 respectively. The females and males constitute 49% and 51 % of the total persons (0-6 age group) 4009 respectively and sex ratio was found to be 926. The number of household population and household size is given in Table 3.21 Table No Number of Household Population and Household Size Sr. No. Village No. of Population Size households 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe MITCON Consultancy and Engineering Services Ltd., Pune 103

104 13 Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL The Table 3.20 reflects that of total population lives in 4954 households. The average household size is 5.5 Population Distribution: The percentile distribution of population is given below in Chart 5. Total population consists of 52 % male and 48 % female, In ST population there is 51% male and 49% female and in SC population there is 52 % male and 48 % female. Chart 5: Percentile Distribution of Male-Female Population MITCON Consultancy and Engineering Services Ltd., Pune 104

105 Literacy Rate Educational status of population of the study area is poor as illiterate population is greater than the literate population. Detailed literacy pattern and educational Facilities of the study area is included in Table 3.22 below: Table No Literacy & Illiteracy rate of the Study Area Sl. No Name of Village Population literate Male Literate Female literate Population Illiterate Male Illiterate Female Illiterate 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL PERCENTAGE MITCON Consultancy and Engineering Services Ltd., Pune 105

106 Chart 6: Literacy & Illiteracy rate Based on census data and field survey following observations have been drawn: All villages having medical facilities Primary Health Sub Centre is available in almost every village. Drinking water from dug well and hand pump are available in all villages. The study region is well facilitated with road and rail network. Table No Educational Facility in the Study Area Sr. Name of the Education Primary Secondary No. village Facility Facility SCH College 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi MITCON Consultancy and Engineering Services Ltd., Pune 106

107 11 Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL Occupational structure of Workers Chart 7 depicts Occupational Structure of the study area. Details of the same have been given in Table Table No Occupational Structure of Worker Falls in the Study Area Worker's Classification Main Marginal Non Total Name of Workers Workers Workers Workers Village Mal Femal Mal Femal Mal Femal Mal e e e e e e e 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Sr. No. Femal e MITCON Consultancy and Engineering Services Ltd., Pune 107

108 10 Kalote Mokashi Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali TOTAL Chart 7: Operational Structure of Study Area MITCON Consultancy and Engineering Services Ltd., Pune 108

109 Table No Amenities Facility (Water) Sl. No. Name of Village P & T WATER FACILITIES FACILITIES PT DWF TP WL TK TW HP RV CA LK SP OT PO TO BS COMM. FACILITY RL CB 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote MITCON Consultancy and Engineering Services Ltd., Pune 109

110 Tap Well tank Tube well Hand pump River Cnal Lake Power Supply Post Office Telegraph Office Post & Tele. Office Tele. Conn Bus Railway Spring Others Dujodwala Products Ltd. 22 Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali O = Not Available TP WL TK TW HP RV CV LK PS PO TO PT TC BS RL SP OT Table No Medical Facility in the Study Area No. Village Name MEDI FAC MCWC MH CWC HC PHC PHSC FWC TBC NH RMP SMP CHW OTH CNTR 1 Vasheni Ajivali Lodhivali Morbe Pali Kh MITCON Consultancy and Engineering Services Ltd., Pune 110

111 No. Village Name MEDI FAC MCWC MH CWC HC PHC PHSC FWC TBC NH RMP SMP CHW OTH CNTR 6 Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali MITCON Consultancy and Engineering Services Ltd., Pune 111

112 Land Use Pattern The land use pattern as per the Census of India is presented in Table 3.25 and the land use pattern is presented in the form of pie chart in Figure Present land use based on satellite imagery for the study area of 10 km radius in given in Annexure 8. Figure No Land use of study area The land use diagram in the form of pie chart is shown in Chart 3.6. The pie chart depicts that the predominant land use is un-irrigated land (16%), followed by Forest land (12%), total Culturable Waste is (10%), land under area not under cultivation (11%) and Irrigated area is (1%). Sr. Percentage of total area Land use No (approximate) in % 1 Forest Area 12 2 Irrigated Area 1 3 Un-irrigated Area 16 4 Culturable waste 10 5 Area Not Available for cultivation 11 MITCON Consultancy and Engineering Services Ltd., Pune 112

113 Table No Land use Pattern In The Study Area (in Ha) Sr. No Name of the Village Total Area Forest Area Irrigated Area Unirrigated area Culturab le Waste Area Not Available for Cultivation 1 Vasheni Ajivali Lodhivali Morbe Pali Kh Sarang Vayal Kambe Vanivali Kalote Mokashi Vinegaon Isambe Nadode Nimbode Anjrun Kumbhivali Sajgaon Parkhande Donvat Padale Ghote Koproli Vanwali Savroli Ambivali Dhamani Chinchavali Vadavali Total Percentage MITCON Consultancy and Engineering Services Ltd., Pune 113

114 CHAPTER 4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 4.1 Identification of Impacts This chapter deals with the prediction and evaluation of impacts resulting from the proposed project activity. Any activity making a significant effect is not permissible. This significant effect is required to be neutralized to a level of insignificance. This can be brought about by various tools like: in plant measures, segregation, environment friendly process and collectively termed as pollution control say by providing Effluent Treatment Plant (ETP) and Emission Control Equipment s (ECE) etc. Predictions are superimposed over baseline environmental status to derive ultimate environmental scenario. The impact of the existing as well as proposed unit has been considered and discussed in this chapter. Environmental Impact refers to the alteration of environmental conditions or creation of a new set of environmental conditions, adverse or beneficial, caused or induced by the action or set of actions under consideration. Both the beneficial (positive) and adverse (negative) impacts on various components of environment due to proposed expansion & modernization are identified, based on the nature of the various activities associated with the proposed project operations. Environment impact analysis gives an indication of ways to consider modeling the project to mitigate adverse impacts through best practicable environmental option or alternate processes. Based on the present environmental scenario and baseline data, an exercise has been done to identify and evaluate the impact on the environment of the study area due to the proposed project. The proposed project may influence the environment of the area in two phases: MITCON Consultancy and Engineering Services Ltd., Pune 114

115 Construction Phase: During the Construction period, the impact may be temporary or short term Operational Phase: During the Operation Phase which may have long term effects Phase I All the construction impacts on the environment can be considered short term as compared to the operational impacts. During construction stage, excavation, material storage and movement, vehicular movement, mixing operation etc. will generate fugitive dust pollution and vehicular emissions at the project site. However, by taking appropriate measures as described in EMP, such impacts will be minimized. The following activities among others are likely to contribute towards impacts on the surroundings during construction phase: Land Development Plant Construction The impacts are likely to primarily affect land use, demography and socio economics, soil and onsite noise. It could also lead to minor impacts on air and water quality and ecology. The detailed impacts & mitigation measures have been discussed in the following sections Phase II Operational phase activities may have impacts minor or major, positive or negative on environmental discipline such as soils, surface and ground water hydrology, micro meteorology, land use, water use, water and air quality, ecology, socio economics and noise environment. The component wise emissions and its impact are listed below in Table No. 4.1 MITCON Consultancy and Engineering Services Ltd., Pune 115

116 Table No. 4.1Component Wise Emission Environmental Component Air emissions Water Pollution Noise emissions Solid Waste Impact Impact on flora and fauna, Impact on soil Impact on surrounding community Impact on soil due to land discharge of effluent. The impact on surface and ground water bodies due to leachetes te and drain from plant Impact on community Impact on fauna Impact on ground water quality Impact on community hygiene Impact on flora & fauna 4.2 Air Pollution There are three stacks in the existing factory and no new staks are envisaged in proposed expansion. So there is no increase in Incremental values. Air quality modeling, since the same has been covered under baseline environmental monitoring. Suspended Particulate Matter would be the predominant pollutant affecting the air quality during the construction period. Dust will be generated mainly during excavation, back filling and hauling operation along with transportation activities. However, wind-blown dust is not expected to have tangible effects on the air quality of the area. The vehicular exhausts and other related activities will result in insignificant rise of pollutants in the air. 4.3 Impact on Soil Environment Any major construction activity could tend to create changes in the soils of the area. Excavation work tends to denude the soil and make it loose. Destruction of the soil and removal of vegetative cover enhances the possibility of soil erosion. However, in this case the land is in possession of factory and is without any significant vegetation. The excavated soil and construction materials, such as sand etc. could tend to infiltrate and clog the inter-granular spaces, leading to decreased permeability, such construction MITCON Consultancy and Engineering Services Ltd., Pune 116

117 impacts would, however, be confined principally to the plant site and thus would be of localized nature. Mitigation Measures during Construction Phase During the construction stage, the following steps will be taken to check the adverse effect: All earth work will be completed in such a way so that the soil erosion and carryover of the materials in other areas are protected. The packaging materials which may consist of wooden boxes and jute wrappers will be stored at suitable place and disposed off suitably. Proper drainage system will be constructed for the waste water generated during construction period which will be discharged into low land areas and accumulation of water will be avoided. Mitigation Measures during Operational Phase During operation phase the soil will not be affected due to any operation. However, any percolation of any contaminates into ground water will be prevented by constructing suitable storage facilities. 4.4 Impact on Water Use Dujodwala s has permission to withdraw 146 m 3 /day of water from Patalgnga River. Mitigation Measures during Construction Phase All the units of the proposed project will be made from MS, Steel structures. Hence, water will be used only for cooling & domestic use only. Compared to the total availability of ground water, the impact will be intangible even during dry season. MITCON Consultancy and Engineering Services Ltd., Pune 117

118 Mitigation Measures during Operation Phase Water will be drawn from Patalganga River perennial source of water at a distance of 2.78 km from the site. The permission is already obtained for water drawl. 4.5 Impact on Water Quality Impacts & Mitigation Measures during Construction Phase Nominal quantity of water will be used during construction period. Stagnant pools of water would promote breeding of mosquitoes and generally create unsanitary conditions. However, adequate arrangements would be made to ensure proper drainage of wastewater from the construction sites, so that such waters do not form stagnant pools nor aggravate soil erosion. The waste water during construction will contain only suspended impurities. The waste water will be drained into spared own land which will dry up within a month or so. In no case, this waste water will be allowed to flow outside the premises. Impacts on Surface Water & Mitigation Measures during Operation Phase No major impact on surface water quality is envisaged, as all the wastewater generated from the proposed unit will be treated in the ETP and reused for ash management, dust suppression and green belt development. Proposed unit will be run on zero discharge concepts. 4.6 Rainwater Harvesting The raw water & surface water will be collected through open storm water drain network. The discharge will then be connected to recharging pit. The collected water will be allowed to percolate into the ground or recycled. For recycling, the recharging pit will be connected to sump through filter channel for re-circulation. The necessary pumps & pipes of the suitable size shall be provided for recycling of retrieved water for gardening. MITCON Consultancy and Engineering Services Ltd., Pune 118

119 4.7 Impact on Noise Environment Noise would be an inevitable by-product of the operation. DPL will take all mitigation measures to control noise pollution. Some methods of noise pollution control are given below Noise level can be reduced by stopping leakages from various steam lines, compressed air lines and other high pressure equipment By providing padding at various locations to avoid rattling due to vibration By adopting new technologies for control of noise in various units Encasement of noise generating equipment where otherwise noise cannot be controlled Providing noise proof cabins to operators where remote control for operating noise generating equipment is feasible. High noise generating sources will be insulated adequately by providing suitable enclosures; Design and layout of building to minimize transmission of noise, segregation of particular items of plant and to avoid reverberant areas; Use of lagging with attenuation properties on plant components / installation of sound attenuation panels around the equipment Other than the regular maintenance of the various equipment, ear plugs/muffs are recommended for the personnel working close to the noise generating units; All the openings like covers, partitions will be designed properly Inlet and outlet mufflers will be provided which are easy to design and construct. All rotating items will be well lubricated and provided with enclosures as far as possible to reduce noise transmission. Extensive vibration monitoring system will be provided to check and reduce vibrations. Vibration isolators will be provided to reduce vibration and noise wherever possible; MITCON Consultancy and Engineering Services Ltd., Pune 119

120 4.8 Impact on Socio-Economic Environment The proposed project is expected to have several positive impacts on demography and socio-economic condition which are listed below: Increase in employment opportunities so as people will not migrate outside for employment. Increase in literacy rate. Growth in service sectors Improvement in prices of indigenous produce and services benefiting local people such as increase in land value, house rent rates and labour wages. Improvement in socio-cultural environment of the area. Improvement in transport, communication, health and educational services. Increase in employment due to increased business, trade, and commerce and service sector. Thus the overall impact on the socio economic environment of the region is expected to be beneficial for the local population. Impact on Human Settlements Due to the requirement of support services to the guest community in the proposed plant, the host community will be benefited by way of generation of employment opportunities, increased demand for the local produce and services. Hence, there will be rise in the income level of the host community. Impact on Health As discussed adequate air, water and noise pollution control measures conforming to the regulatory standards will be provided in the proposed project. The EMP and the Emergency Preparedness Plans will also be in place to ensure that the probability of undesired events and consequences are greatly reduced the overall impact on human health will be insignificant during operation phase. MITCON Consultancy and Engineering Services Ltd., Pune 120

121 CHAPTER 5 ANALYSIS OF ALTERNATIVES 5.1 Introduction It is the best practice that the EIA should consider project alternatives and their relative potential impact on the environment. Alternatives must, however, be both practical and reasonable, within the overall constraints of the proposed project development. A project of any nature consists of various activities, which involve men, money and material. These activities may consume natural resources and discharge wastes, which are likely to have serious consequence to the environment. A number of alternative options may be available to carry out many of these activities. An option with least or nil adverse environment impacts is to be selected. Critical analysis is therefore required for selection of the right alternative. Alternative Analysis (AA) has been done for critical aspects of the project. Dujodwala Products Ltd. has proposed to expand the organic chemical manufacturing unit within the existing premises which is already in possession of Dujodwala Products Ltd. While selecting this site Dujodwala s has considered following factors on the basis of which the site was finalized. While setting -up the proposed expansion project following parameters were kept in consideration. 5.2 Analysis of Site Alternative A number of factors related to economical operations, land availability, power availability and environmental aspects are involved in site selection. The important factors which influence the project site selection are given below: 1) Techno-economic considerations 2) Available infrastructure 3) Environmental considerations MITCON Consultancy and Engineering Services Ltd., Pune 121

122 5.2.1 Techno-Economic Considerations The techno-economic considerations in the selection of a site are as detailed below: Availability of suitable land for proposed project. Availability of facility for receipt of raw materials such as sugarcane, bagasse etc. Availability of adequate water for process within reasonable distance. Suitability of land from topography and geological aspects No displacement of people. Availability of construction water and power Available Infrastructure Available Infrastructure considerations in the selection of a site are as detailed below: Availability of infrastructure facilities such as State Highway road access to the proposed project site for ease of transportation of workforce, consumables, plant equipment s and fuel etc., Facility for interconnection with transmission and distribution systems for evacuation of power, transportation of sugarcane & sugar also. Availability of facilities like medical, education, civic amenities and railway station within a reasonable distance from the site Environmental Consideration Environmental considerations critical to the selection of a site are listed below: a. Avoiding the use of forest land b. Minimum use of cultivable land c. Away from thickly populated town d. Minimum requirement of cutting of trees MITCON Consultancy and Engineering Services Ltd., Pune 122

123 e. No displacement of people f. Away from critically polluted area g. Away from national park and wildlife sanctuaries h. Away from tiger reserve/elephant reserve/turtle nestling grounds. i. Away from core zone of biosphere reserve. j. Away from Archeological sites. k. Away from defense installations. As per above site selection criteria the proposed site is most suitable for set-up the plant. The salient features of proposed site presented in Table No. 5.1 Table No. 5.1 Salient Features of Site Project Configuration Proposed expansion of Organic Chemical Manufacturing Plant of Dujodwala Products Ltd at Khalapur, Dist: Raigad Source of Raw material Raw material imported from China, Indonesia, Brazil, Rusia, Vietnam and coal will be purchased from the local vendor. Availability of water Dujodwala s has permission to withdraw 146 m 3 /day of water from Patalgnga River. Water permission letter from competent authority attached as an Annexure-2 Plant Location Nearby towns Seismic Zone Access to site by Road Access to site by Rail Access by Air Religious/ Historical Place Archeological within 10Km monuments Reserved Forest within 10Km Village: Taluka: Khalapur Dist : Raigad Latitude: N Longitude: E Khalapur 2.60 km III District road Khopoli 9.8Kms Chhatrapati Shivaji airport, Mumbai 52Kms None None None MITCON Consultancy and Engineering Services Ltd., Pune 123

124 CHAPTER 6 ENVIRONMENTAL MONITORING PROGRAM This chapter contains technical aspects of monitoring the effectiveness of mitigation measures and the environmental management plan. It ensures the smooth execution of EMP and also monitors the changes in the ambient environmental quality due to the proposed project. It includes laboratory and other facilities monitoring facilities, environmental parameters to be monitored, data to be analyzed and sampling location and schedule. A chemical or process industry in general produces solid, liquid and gaseous wastes, which are discharged to the environment. The waste product may contain pollutants which may harm environment. It is the responsibility of the industries to prevent or minimize the discharges of waste products by adopting suitable control measures in the factory. The effectiveness of such measures is ascertained by systematic monitoring of discharges at factory level and at receiving level. Monitoring of various environmental parameters will be carried out on regular basis to ascertain the following, i. Pollution status within the plant and in its vicinity. ii. Generate data for predictive or corrective purpose in respect of pollution. iii. Effectiveness of pollution control measures and control facilities. iv. To assess environmental impacts. v. To follow the trend of parameters which have been identified as critical. 6.1 Introduction Regular monitoring of important and crucial environmental parameters is of immense importance to assess the status of environment during plant operation. The knowledge of baseline status and monitored data is an indicator to ascertain for any deterioration MITCON Consultancy and Engineering Services Ltd., Pune 124

125 in environmental conditions due to operation of the plant. Based on these data, suitable mitigation steps could be taken in time to safeguard the environment. Monitoring is as important as that of pollution control since the efficiency of control measures can only be determined by monitoring. The routine monitoring program as indicated below will be implemented in the industry. A comprehensive monitoring program is suggested. Meteorology Meteorological parameters such as wind, atmospheric pressure, temperature, humidity and rain fall shall be monitored. Gaseous Emissions and Ambient Air Quality Both ambient air quality and stack emissions shall be monitored for pollutants such as PM10, PM2.5, NOx and SO2. Monitoring will be done as per CPCB guidelines. Water and Waste Water Quality All the effluents emanating from the plant should be monitored for their physicochemical characteristics and heavy metals. In addition, ground water samples at downstream and up stream of the compost yard shall be monitored on regular basis. 6.2 Sampling Schedule and Locations Post Project Monitoring Plan for monitoring waste water and flue gases discharged from the industry and the environmental parameters including meteorology, quality of ambient air, ground water and soil is given in Table No.6.1 Table No. 6.1 Post project Monitoring Schedule Sr. No. 1. Ambient Air quality for PM10,PM2.5,SO2 and NOx Particulars Location Frequency a. 2 samples downwind direction at 500 m and 1000m respectively. b. 1 sample upwind direction at 500m. 24 hour sample half yearly MITCON Consultancy and Engineering Services Ltd., Pune 125

126 2. Flue gas from chimney for Sampling port of chimney. Monthly flow rate PM,SO2 and NOx 3. Wind velocity and direction At site Hourly 4. Temperature (max. & min.) Humidity (max. & Min.) Rainfall At site At site At site 5. Ground water Within 1 km radius from spent wash tank and compost yard. 2 locations downward 1 location upward additional three locations within 10 km radius from the site. 6. River water Drinking water standards 7. Soil Organic and Inorganic matter One each at upstream and downstream At lands utilizing compost manure and treated effluent, 3 locations Daily Daily Daily Half yearly Quarterly Pre monsoon & Post monsoon. 8. Waste water At site Daily 9. Bio-manure At site Weekly 6.3 Laboratory Facilities Laboratory is provided with man power and facilities for self-monitoring of pollutants generated in the industry and also its effects on the receiving soil, water, body and atmosphere. The list of laboratory facilities to be provided in the industry is given below For water component ph, temp, BOD, C.O.D, T.D.S, CL, SO2, PO3 4, N, Na, K, D.O. etc. For gases Velocity, Temp, SPM, SO2, NOX CO and CO2 from the stack. SPM, SO2, NOx, RSPM, from ambient air Meteorology Wind speed and direction, atmospheric pressure, temperature, relative humidity and rainfall. MITCON Consultancy and Engineering Services Ltd., Pune 126

127 Air Quality High volume sampler, Meteorological station (continuous), Spectrophotometer (Visible range), Sound level meter Water and Soil Quality - Chemical Analysis ph meter, Conductivity Meter, Turbidity Meter, Dissolved oxygen apparatus, Flame photometer, Kjeldhal Assembly, Microscope, Muffle Furnace, Soxhlet apparatus, BOD incubator, COD reflux set, Spectrophotometer, Bacteriological Analysis Autoclave, Bacteriological Incubator General Distilled water plant, Balances, Magnetic Stirrer, Refrigerator, Drying Oven, Balances, Centrifuge, A set of chemicals, glass ware and apparatus MITCON Consultancy and Engineering Services Ltd., Pune 127

128 CHAPTER 7 ADDITIONAL STUDIES 7.1 Risk Assessment It is imperative to conduct risk analysis for all the projects which involves construction activity, erection of plant and raw material as well as finished product are handled and transported. The risk assessment is carried out here as the proposed project will involve construction, digging of land, erection of unit, electrification, transportation and handling of raw material and finished products. The following have been addressed as part of the risk analysis. The section deals with the objective and methodology of carrying out the risk analysis. Hazard Identification and Risk Analysis discusses about the various types of hazards associated with the operation of the Plant due to process, storage & handling, human errors, electric failures and natural calamities. It also presents the calculated frequencies of occurrence of different accident scenarios for the identified potential hazard occurrence in the plant and the details of consequence modelling / analysis for the identified potential accidents/disaster scenarios in the plant Objective The principal objective of the study is to identify the potential hazards from the proposed facility and estimate the effects of the hazards to people and property within the vicinity of the plant premises. The consequences resulting due to accidental release of toxic & flammable gases and leakage of fuels will provide data for developing strategies to prevent accidents right from design to operational phase. This will also generate information for formulating a meaningful Disaster Management Plan (DMP). A risk analysis is defined as an assessment of the likelihood of a release of HAZMAT (hazardous materials) and the consequences that may result, based on information gathered during the hazard identification and vulnerability analyses. Risk analysis MITCON Consultancy and Engineering Services Ltd., Pune 128

129 requires evaluation of existing base and local community plans, response capabilities, and previous incidents. In order to determine the risk factor at each facility on the base, the following information was evaluated: Procedures for storing, handling, shipping, and transferring of HAZMAT; Facility information including: physical features and location of storm and sanitary sewer systems; Site measures for managing and controlling HAZMAT releases; and, Base emergency response and preparedness programs Methodology The Risk Analysis Study carried out under the following task heads: System Study: The system description covers the plant description, storage & handling of fuels / chemicals, etc. Hazard Identification: The hazards associated with the proposed organic chemical Plant have been discussed in terms of material & process hazards. Frequency of Hazard Occurrence: Based on the available international statistics and in-house risk database, the frequencies of occurrence for the different accident scenarios were determined. The frequencies derived from the historical database have been checked with the possible hazard scenario identified during hazard identification. Consequence Analysis: : Based on the identified hazards, accident scenarios and the frequency of occurrence, consequence modelling was carried out for calculating the spreading distances (zone of influence) or risk distance for Pool fires and Explosions etc. Risk Reducing Measures: Necessary risk reducing measures have been suggested based on the consequence scenarios. The three main goals of risk assessment are MITCON Consultancy and Engineering Services Ltd., Pune 129

130 Identify risks, Quantify the impact of the potential threats and Provide an economic balance between the impact of risk and the cost of the safeguard Identification of Risks For identification of risk due to proposed project, following parameters will be studied. Raw material and finished product Process Risk Operations Maintenance Safety Fire protection Effluent disposal A) Risk: Raw Material and Finished Product There are various chemicals (toxic and flammable), which will be used as raw material for proposed manufacturing plant. Separate storage area will be provided for these chemicals and will be handled with at most care following the safety norms for handling of hazardous chemicals. Material Safety Data Sheets attached as an Annexure 9. Raw material storage area which will be around 7 x 60 m in dimension and will house the tanks for the following chemicals Formaldehyde Phenol Crude Sulphate of Terpentine Local Turpentine MITCON Consultancy and Engineering Services Ltd., Pune 130

131 Dipentene fraction of local turpentine Dipentene fraction of imported turpentine Finished material storage which will be around 7 x 60 m in dimension and will house the tanks for the following finished materials:-- Camphene DRT 5004 (Resin) DRT 4001 (Resin) Pure fraction of Turpentine The plant equipment housing area will be around 30 m x 46 m which will house the equipments from Ground Floor to the Third (3 rd floor) B). Risk: Process Mechanical hazards: Mechanical operations such as welding, maintenance, falling objects etc. - basically those NOT connected to hazardous materials. Electrical hazards: Electrocution, high voltage levels, short circuit, etc. C). Risk: Fire incident Storage area and fuel handling area follow up of standard operating procedures and regular training on fire fighting. Mock drills of fire fighting, Installation of fire alarm & proper fire extinguisher. Ensure suitability and adaptability of electrical equipment with respect to classified hazardous areas and protection against lightening protection and static charges. Adopting preventive maintenance practices as per testing and inspection. D). Risk: Solid/ Liquid waste disposal Particular: Ash generated from plant, solid waste and effluent generated from chemical unit Standard operating procedures for disposal of ash for bio composting, brick & cement manufacturing. Effluent will be treated as per regulatory norms and treated MITCON Consultancy and Engineering Services Ltd., Pune 131

132 water will be reused. Regular monitoring will be carried out as per schedule to avoid any kind of pollution E). Risk: Health Risk Hazards waste: The hazardous waste would be sent to CHWTSDF of Trans Thane Creek Waste Management Association. F). Risk: Safety risk Ensure Worker Safety: Periodical SHE training of staff and contractor. Ensuring special training to develop competent persons to manage specific issues such as safety from the system, risk assessment, scaffolding, and fire protection, Training will include the proper use of all equipment operated, safe lifting practices, the location and handling of fire extinguishers, and the use of personal protective equipment. Ensure good housekeeping practices (e.g., keeping all walkways clear of debris, cleaning up oil spots and excess water as soon as they are noticed, and regular inspection and maintenance of all machinery). Daily collection and separate storage of hazardous and non-hazardous waste. 7.2 Risk Mitigation Measures The materials handled at the proposed installation are inflammable and reactive substances and based on the consequence analysis; the following measures are suggested as risk mitigation measures. It should be ensured that combustible materials such as oiled rags, wooden supports, oil buckets etc. are not kept in the storage and process areas as well as road tankers loading/unloading sites where there is maximum possibility of presence of flammable hydrocarbons in large quantities, to reduce the probability of secondary fires. Smoke and fire detectors should be suitably located and linked to fire fighting system to reduce the response time and ensure safe dispersal of vapours before ignition can occur. MITCON Consultancy and Engineering Services Ltd., Pune 132

133 Training in fire fighting, escape action, operation of emergency switches etc. is vital. Emergency procedures should be well rehearsed to achieve state of readiness. Possibilities, Nature and Effects of Emergency Leaving aside earthquake, cyclone, flood, arson and sabotage, the possible emergencies that can arise in the chemical plant due to operations and storages and handling of the fuels and gases are: Subsequent fire in the fuel handling area Accidental release of fly ash Accidental fire due to some other reasons such as electrical short circuit. 7.3 Disaster Management Plan Disaster Management Plan (DMP) will consider all the factors responsible for management of any small or big disaster. Emergency prevention through good design, operation, maintenance and inspection are essential to reduce the probability of occurrence. However, certain operation & practices may lead to unwarranted situation wherein disaster scenario can emerge. The DMP, therefore, addresses to mitigate the effects of such situation with a view to bring restoration of normality at the earliest. The overall objective of a disaster management plan is to make use of the combined resources at the site and outside services to achieve the following: To localize the emergency and if possible eliminate it. To minimize the effects of the accident on people and property. Effect the rescue and medical treatment of casualties; Safeguard other people, outside the project boundary; Evacuated people to safe areas; Inform and collaborate with statutory local and state authorities; MITCON Consultancy and Engineering Services Ltd., Pune 133

134 Initially contain and ultimately bring the incident under control; Preserve relevant records and equipment for the subsequent enquiry into the cause and circumstances of the emergency; Investigate and take steps to prevent recurrences of similar incidents Disaster Control Philosophy The principal strategy of DMP is "Prevention" of identified major hazards. The "Identification" of the hazards will employ one or more of the techniques [e.g. Hazard and Operability Study (HAZOP), accident consequence analysis etc.]. Since these hazards can occur only in the event of loss of containment, one of the key objectives of technology selection, project engineering, construction, commissioning and operation is "Total and Consistent Quality Assurance". The Project Authority will be committed to this strategy right from the conceptual stage of the plant so that the objective of prevention can have ample opportunities to mature and be realized in practice. The DMP or Emergency Preparedness Plan (EPP) will consist of: On-site Emergency Plan Off-site Emergency Plan Disaster Management Plan preparation under the headlines of On-site Emergency Plan and Off-site Emergency Plan is in consonance with the guidelines laid by the Ministry of Environment and Forests (MoEF) which states that the "Occupier" of the facility is responsible for the development of the On-site Emergency Plan. The Off-site Emergency Plan should be developed by the Government (District Authorities) On-Site Emergency Plan Objectives The objective of the On-site Emergency Plan should be to make maximum use of the combined resources of the plant and the outside services to Effect the rescue and treatment of casualties; MITCON Consultancy and Engineering Services Ltd., Pune 134

135 Safeguard other personnel in the premises; Minimise damage to property and environment; Initially contain and ultimately bring the incident under control; Identify any dead; Provide for the needs of relatives; Provide authoritative information to the news media; Secure the safe rehabilitation of affected areas; Preserve relevant records and equipment for the subsequent enquiry into the cause and circumstances of emergency Action Plans The Action Plan should consist of Identification of Key Personnel; Defining Responsibilities of Key Personnel; Designating Emergency Control Centres and Assembly Points; Declaration of Emergency; Sending All Clear Signal; Defining actions to be taken by non-key personnel during emergency Key Personnel The actions necessary in an emergency will clearly depend upon the prevailing circumstances. Nevertheless, it is imperative that the required actions are initiated and directed by nominated people, each having specified responsibilities as part of coordinated plan. Such nominated personnel are known as Key Personnel. The detailed on-site emergency plan presented in Figure No The Key Personnel are: Site Controller (SC) MITCON Consultancy and Engineering Services Ltd., Pune 135

136 Incidental Controller (IC) Liaison and Communication Officer (LCO) Fire and Security Officer (FSO) Team Leaders (TL) Site Controller (SC) In the emergency situation, decisions have to be taken which may affect the whole or a substantial part of the plant and even places outside. Many of these decisions will be taken in collaboration with the other officers at the plant and the staff. It is essential that the authority to make decision be invested in one individual. In this plan, he is referred to as the 'Site Controller'. The Plant Manager (however called) or his nominated deputy will assume responsibility as SC. Responsibilities of SC On getting information about emergency, proceed to Main Control Centre; Call in outside emergency services; Take control of areas outside the plant, which are affected; Maintain continuous communication, review situation and assess possible course of events; Direct evacuation of nearby settlements, if necessary; Ensure that casualties are getting enough help; Arrange for additional medical help and inform relatives; Incident Controller (IC) In the emergency situation, someone has to direct the operations in the plant area and co-ordinate the actions of outside emergency services at the scene of incident. The one who will shoulder this responsibility is known as 'Incident Controller' in this plan. MITCON Consultancy and Engineering Services Ltd., Pune 136

137 A Senior Operations Officer or an officer of similar rank of the unit may be nominated to act as the IC. Responsibilities of IC Activate emergency procedure such as calling in various teams Direct all operations within plant with following priorities: a) Control and contain emergency b) Secure safety of personnel c) Minimize damage to plant, property and the environment d) Minimize loss of material Direct rescue and repair activities Guide fire-fighting teams Arrange to search affected area and rescue trapped persons Arrange to evacuate non-essential personnel to safe area/assembly point Set up communications network and establish communication with SC Arrange for additional help/equipment to key personnel of various teams Consider need for preserving all records, information for subsequent enquiries Liaison and Communication Officer (LCO) Operations Officer or any other officer of deputy rank will work as LCO and will be stationed at the main entrance during emergency to handle Police, Press and other enquiries. He will maintain communication with the IC Responsibilities of LCO To ensure that casualties receive adequate attention, arrange additional help if required and inform relatives. MITCON Consultancy and Engineering Services Ltd., Pune 137

138 To control traffic movements into the plant and ensure that alternative transport is available when need arises. When emergency is prolonged, arrange for the relief of personnel and organize refreshments/catering facility. Advise the Site Controller of the situation, recommending (if necessary) evacuation of staff from assembly points. Recruit suitable staff to act as runners between the Incident Controller and himself if the telephone and other system of communication fail. Maintain contact with congregation points In case of a prolonged emergency involving risk to outside areas by windblown materials contact local meteorological office to receive early notification of changes in weather conditions Fire and Safety officer (FSO) The Fire and Safety Officer will be responsible for firefighting. On hearing the fire alarm he shall contact the fire station immediately and advise the security staff in the plant and cancel the alarm. He will also announce on PAS (public Address System) or convey through telephones or messengers to the SC, IC and LCO about the incident zone. He will open the gates nearest to the incident and stand by to direct the emergency services. He will also be responsible for isolation of equipment from the affected zone. Responsibilities of FSO Announce over the PAS in which zone the incident has occurred and on the advice of the Shift Officer informs the staff to evacuate the assembly Inform the Shift Officer In-charge, if there is any large escape of products Call out in the following order: 1) Incident Controller or his nominated deputy 2) Maintenance Officer 3) Personnel and Administrative Officer MITCON Consultancy and Engineering Services Ltd., Pune 138

139 4) Departmental Head in whose area the incident occurred 5) Team Leaders (TL) Team Leaders (TL) A number of special activities may have to be carried out by specified personnel to control as well as minimize the damage and loss. For this purpose designated teams would be available. Each team will be headed by a Team Leader (TL). Following teams are suggested Repair Team Fire Fighting Team Communication Team Security Team Safety Team Medical Team Emergency Control Centre The Emergency Control Centre will be the focal point, in case of an emergency from where the operations to handle the emergency are directed and coordinated. It will control site activities. Emergency management measures in this case have been proposed to be carried from single control Centre designated as Main Control Centre (MCC) MCC is the place from which messages to outside agencies will be sent and mutual aids and other helps for the management of emergency will be arranged. It will be located in the safe area. It will be equipped with every facility for external and internal communication, with relevant data, personal protective equipment s to assist those manning the centre to enable them to co-ordinate emergency control activities. MCC will be attended by SC. MITCON Consultancy and Engineering Services Ltd., Pune 139

140 Following facilities would be available in the MCC: P&T phones, mobile phones, intercoms, and wireless Fax Emergency manuals Blown up area maps Internal telephone directories District telephone directories Emergency lights Wind direction and speed indicator Requisite sets of personal protective equipment such as gloves, gumboots and aprons MCC will be furnished with call out list of key persons, fire, safety, first aid, medical, security, police and district administrative authorities. MCC will also contain safety data pertaining to all hazardous materials likely to cause emergency and well-defined procedures of firefighting, rescue operations, first aid etc. Assembly Point In an emergency, it will certainly be necessary to evacuate personnel from affected areas and as a precautionary measure, to further evacuate non-essential workers, in the first instance, from areas likely to be affected, should the emergency escalate. The evacuation will be effected on getting necessary message from i.e. On evacuation, employees would be directed to a predetermined safe place called Assembly Point. Proposed Location: Area opposite to service building will be the Assembly Point where all non-key personnel would assemble on getting direction over Public-Address System. Outdoor assembly points, predetermined and premarked, will also be provided to accommodate evacuees from affected plant area(s). Roll call of personnel collected at these assembly points, indoor and outdoor will be carried out by roll call crew of safety MITCON Consultancy and Engineering Services Ltd., Pune 140

141 team to account for any missing person(s) and to initiate search and rescue operations if necessary. Declaration of Emergency An emergency may arise in the terminal due to the outbreak of fire/explosion. In case of major leak or major outbreak of fire the state of emergency has to be declared by the concerned by sounding Emergency Siren. Upon manual or sensor detection of a major loss of containment of volatile hazardous substance, the DMP is activated by raising an audible and visual alarm through a network of geographically dispersed gas/vapour and heat detectors and also "break glass" type fire alarm call points with telephone handsets to inform the Central Control Room. A separate siren audible to a distance of 5 km range will be available for this purpose. The alarm is coded such that the nature of emergency can be distinguished as a leakage or major fire. The Control Centre and Assembly point will be located at an area of the minimum risk or vulnerability in the premises concerned, taking into account the wind direction, areas which might be affected by fire/explosion, leakage etc. After cessation of emergency, FSO will communicate to IC. After verification of status, IC will communicate with SC and then announce the "All Clear" by instructing the Time Office to sound the "All Clear Signal". Alarms would be followed by an announcement over Public Address System (PAS).In case of failure of alarm system, communication would be' by telephone operator who will make announcement in the complex through PAS. Walkie-talkie system is very useful for communication during emergency with predetermined codes of communication. If everything fails, a messenger could be used for sending the information. MITCON Consultancy and Engineering Services Ltd., Pune 141

142 Two 5 km, range variable pitch electric sirens (one in service and the other standby)will generate the main alarm for the entire site as well as for the district fire brigade. The alarm is coded such that the nature of emergency can be distinguished as a leakage or major fire. Fire and Gas alarm matrices are provided at the Central Control room, security gate, on-site fire station and main administrative office corridor to indicate location of the site of emergency and its nature. Mutual Aid Procedure: All factories may not be equipped with an exhaustive stock of equipment/materials required during an emergency. Further, there may be a need to augment supplies if an emergency is prolonged. It would be ideal to pool all resources available in and nearby outside agencies especially factories during an emergency, for which a formal Mutual Aid scheme should be made among industries in the region. Essential Elements Essential elements of this scheme are given below: Mutual aid must be a written document, signed by Location In-charge of all the industries concerned It should specify available quantity of materials/ equipment that can be spared (not that which are in stock) Mode of requisition during an emergency. It should authorize the shift-in-charge to quickly deploy available material/equipment without waiting for formalities like gate pass etc. It should spell out mode of payment/replacement of material given during an emergency It should specify key personnel who are authorized to requisition materials from other industries or who can send materials to other industries MITCON Consultancy and Engineering Services Ltd., Pune 142

143 It should state clearly mode of receipt of materials at the affected unit without waiting for quantity/quality verification etc. Revision number and validity of agreement should be mentioned This may be updated from time to time based on experience gained Emergency Management Training: The Key Personnel would undergo special courses on disaster management. This may preferably be in-plant training. The Managers, Senior Officers and Staff would undergo a course on the use of personal protective equipment. The Key Personnel belonging to various Teams would undergo special courses as per their expected nature of work at the time of emergency. The plant management should conduct special courses to outside agencies like district fire services to make them familiar with the plant layout and other aspects, which will be helpful to them during an emergency. Mock Drills: It is imperative that the procedures laid in this Plan are put to the test by conducting Mock Drills. To avoid any lethality, the emergency response time would be clocked below 2 minutes during the mock drill. 1st Step: Test the effectiveness of communication system 2nd Step: Test the speed of mobilization of the plant emergency teams 3rd Step: Test the effectiveness of search, rescue and treatment of casualties 4th Step: Test emergency isolation and shut down and remedial measures taken on the system 5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency The Disaster Management Plan would be periodically revised based on experiences gained from the mock drills. MITCON Consultancy and Engineering Services Ltd., Pune 143

144 Proposed Communication System: The instrument and control system will take care of the following operating philosophy of the plant: The project will be provided with a control system located in a central control room. The shift engineer will operate the plant from his console panel. All operations will be represented in a graphic panel on the console and every operation will be depicted as operating sequences. All operating parameters will be displayed in digital format. Alarms will be provided for all parameters, when they exceed set values. High-High/Low-Low alarms and trip functions will be provided to trip Pumps/compressors to bring the entire system to a safe shutdown. Proposed Fire Fighting System Elaborate firefighting system will be available for fighting fires in any corner of the plant. A comprehensive fire detection and protection system is envisaged for the complete power station. Fire water storage tanks of adequate capacity. Fire water pump house containing combination of diesel and electrically driven pumps. Hydrant system complete with suitable size piping, valves, instrumentation, hoses, nozzles, hose boxes/stations, monitors etc. Automatic high velocity water spray system consisting of detectors, deluge valves projectors, valves, piping and instrumentation. Automatic medium velocity water spray system consisting of QB Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves, isolation valves, nozzles, piping, instrumentation etc. MITCON Consultancy and Engineering Services Ltd., Pune 144

145 Portable and mobile extinguishers, such as pressurized water type, carbon dioxide type, foam type, dry chemical powder (DCP) type located at strategic locations throughout the plant. Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep etc. provided in the fire station. Complete instrumentation and control system for the entire fire detection and protection system for safe operation of the complete system. Other safety Measures: Considering that fire and explosion is the most likely hazard in such installations, the plant is being provided with systems to guard against such hazards. Salient among these are: A proper layout to prevent and minimize the effects of any hazardous situation Design of storage vessels and all components to codes and standards to withstand the rigorous duty Provision of operating systems to conduct the process through well-established safe operating procedures A control system, which monitors all, plant parameters and give alarms Control system, which has trip provisions to prevent hazard conditions escalating A gas detection system which will provide early warning of any leaks Provision of a fire protection system to control fire Provision of flame-proof lighting system in the fire prone areas Proposed First Aid and Medical Facilities: The First Aid Medical Centre has been proposed. It will be fully equipped with emergency facilities. It will be open round the clock. A Medical Officer with Compounder will always be available in the centre. Emergency cars will be available in all the shifts. Adequate number of first aid boxes will be kept at strategic locations. Required stock of first aid medicines will be maintained. Trained first aiders will be available in all departments. MITCON Consultancy and Engineering Services Ltd., Pune 145

146 Facilities to be kept in the Medical Room along with others will include: Oxygen Cylinders, Injection Corarnine, Glucose Saline, LV. Sets, Syringes, Injection Needles, Stretchers and medicines. Proposed Emergency Power Supply: Strategic areas will be provided with emergency lights fed through stationed battery system. Portable emergency lamps will be also available at required points. A Diesel Driven Generator of adequate capacity will be available to keep the operations running in case of power failure. Diesel Engine operated fire pumps will be available. MITCON Consultancy and Engineering Services Ltd., Pune 146

147 Figure No.7.1. Schematic Flow Chart for On-Site Emergency Plan SAFETY OFFICER SITE CONTROLLE INCIDENT CONTROLLER RAIL/ROAD SHIFT INCHARGE OPERATOR EMERGENCY CONTROL INCIDENT CONTROLLER FOR OPERATIONS SHIFT INCHARGE OPERATOR EMERGENCY COORDINATOR (RESCUE,FIRE SECURITY PERSONNEL EMERGENCY COORDINATOR (Medical Mutual Aid, FIRST AID TRANSPORT,DRIVER TELEPHONE Emergency coordinator (essential services) SHIFT INCHARGE ELECTRICIAN PUMP OPERATOR 7.4 Off-Site Emergency Plan Objective If the effects of the accident or disaster inside the plant are felt outside its premises, it calls for an off-site emergency plan, which should be prepared and documented in advance in consultation with the District Authorities. The detail of off-site emergency plan presented in Figure No.7.2. MITCON Consultancy and Engineering Services Ltd., Pune 147

148 Key Personnel The ultimate responsibility for the management of the off-site emergencies rests on the Collector / District Magistrate / Deputy Commissioner. He will be assisted by representatives from all concerned organisations, departments and services at the District level. This core group of officers would be called the District Crisis Management Group (CMG). The members of the group will include: 1) Collector/District Magistrate Deputy Commissioner 2) Commissioner of Police 3) Municipal Commissioner, if municipalities are involved 4) Deputy Director, Health 5) Pollution Control Board Representative An Operation Response Group (ORG) will then be constituted to implement the directives of the CMG. The various government departments, some or all of which will be concerned, depending on the nature of the emergency, could include Police, Health & Family Welfare, Medical, Revenue, Fire Service, Transport, Electricity, Animal Husbandry, Agriculture, Civil Defense, PWD, Civil Supplies, Panchayats. The SC and IC, of the on-site emergency team, will also be responsible for communications with the CMG during the off-site emergency. Education to Public People living within the influence zone should be educated how to tackle emergency plan. This can be achieved only through the Local and District Authorities. However, the Project Authority can extend necessary information to the Authorities. Figure No.7.2. Schematic Flow Chart for Off-Site Emergency Plan MITCON Consultancy and Engineering Services Ltd., Pune 148

149 7.5 Public Hearing Public Hearing was conducted on 11th September 2014 at Vishvaniketan, Institute of Management Entrepreneurship & Technology, Savroli Kharpada Road, Raigad. Mr. Satish Bagal (Additional District Magistrate, Raigad ) was chairman of the committee. The public hearing was conducted successfully. Various questions asked by participants were answered satisfactorily. Representatives from local villages mentioned that they have benefited from operation of the plant and welcome the proposed expansion. The minutes of the meeting are given in Annexure No. 10 The glimpses of the same are shown in Figure No MITCON Consultancy and Engineering Services Ltd., Pune 149

150 Figure No. 7.3 Glimpses of the Public Hearing MITCON Consultancy and Engineering Services Ltd., Pune 150

151 List of Attendees for the Public Hearing MITCON Consultancy and Engineering Services Ltd., Pune 151

152 MITCON Consultancy and Engineering Services Ltd., Pune 152

153 CHAPTER 8 PROJECT BENEFITS 8.1 Introduction Project benefit focused on those points which become beneficial to the surrounding area or community in terms of infrastructural development, Social development, boosting employment and other tangible benefits due to upcoming or proposed activities in form side benefits. The proposed project expansion has a potential for employment of skilled, semi-skilled and unskilled employees during construction phase as well as operational phase. Followings are benefits that surrounding area will get due to the proposed project. 8.2 Improvement in the Physical Infrastructure The proposed expansion project is expected to yield a positive impact on the socioeconomic environment. It helps in sustainable development of this area including further development of physical Infrastructural facilities. The following physical infrastructure facilities will improve due to proposed project. Road Transport facilities Educational facilities Water supply and sanitation 8.3 Improvement in Social Infrastructure This Project will improve the social infrastructure of this area. The proposed expansion project will lead to indirect employment opportunity. Employment is expected during civil construction period, in trade, garbage lifting, sanitation, afforestation works and other ancillary services. Employment in these sectors will be primarily temporary or contractual and involvement of unskilled labour will be more. A major part of this labour force will be mainly from local villagers who MITCON Consultancy and Engineering Services Ltd., Pune 153

154 are expected to engage themselves both in agriculture and project activities. This will enhance their income and lead to overall economic growth of the area. The project will have a strong positive employment and income effect, both direct as well as indirect because of better indirect employment opportunities due to this project. The project is going to have positive impact on consumption behaviour by way of raising average consumption and income through multiplier effect. The following changes in socio-economic status are expected to take place with this project. People perceive that the project will help in the development of social infrastructures/such as. Education facilities Banking facilities Post offices and Communication facilities Medical facilities Recreation facilities Business establishments 8.4 Other Tangible Benefits The proposed project is likely to have other tangible benefits as given below. Indirect employment opportunities to local people in contractual works like housing construction, transportations, sanitation, for supply of goods and services to the project and other community services Additional housing demand for rental accommodation will increase Market and business establishment facilities will also increase Cultural, recreation and aesthetic facilities will also improve Improvement in communication, transport, education, community development and medical facilities The project will contribute additional revenue to the State and Central exchequer in the form different kind of taxes MITCON Consultancy and Engineering Services Ltd., Pune 154

155 Surrounding villages and area will get unique identity in the map due to the development of the project as the outside people come here will focus to surrounding village to reach there 8.5 Employment Potential Skilled, Semi-Skilled and Unskilled The industry and its supporting activity need many types of people right from manual to managerial strength, in a pyramid. The raw material growing may need unskilled workers with people on tractors and tractor repairers as skilled ones. So in manufacturing activity all three types i.e. skilled, semi-skilled and unskilled people are required. The overall potential including loading-unloading actions, eateries, and small shop owners is substantial. The local people can get a good share out of this. In the factory, science and technology prevails and there some outsiders will have to be engaged at least for the time being. If the second generation local people acquire that skill, they too will be able to fill the gap and accrue benefit of higher jobs. MITCON Consultancy and Engineering Services Ltd., Pune 155

156 CHAPTER 9 ENVIRONMENT MANAGEMENT PLAN 9.1 Introduction In view of the global concept of sustainable development, Environment Management is a crucial segment of Industrial Management. Apart from the social obligation, the industries are required to meet a series of statutory norms laid by Government bodies. Better environment management means less waste generation, better resources management leading to cost savings. Further, it gives a better public image. Therefore, preparation of Environmental Management Plan is a must to fulfill bifocal aspect of the statutory compliance as well as that of social concern. The objective of Environment Management Plan (EMP) is to conserve resources, minimize waste generation, treatment of wastes and protect natural properties. Environmental Management Plan (EMP) has been prepared on the basis of existing environmental status of the project location and the expected impacts of the project activities on environment The management of the Dujodwala s will take all the necessary steps to control and mitigate the environmental pollution in the designing stage of the project. While implementing the project Dujodwala s will follow guidelines specified by CPCB under the Corporate Responsibility for Environmental Protection (CREP) for organic chemical plants. The EMP task will likely be administered by the Health, Safety and Environment (HSE) Department, who will have the authority where necessary to stop the job if an environmentally detrimental activity is being conducted. The EMP operation/implementation will be the responsibility of the HSE Officer, who will be coordinating, arranging the collection and reporting of the results of all emissions, ambient air quality, noise and water quality monitoring. Water needs of proposed expansion plant may be reasonably low, but generally this resource is declining. Thus, on one hand one should use it less and on the other the source should not be left polluted for others. Air environment needs to be continuously MITCON Consultancy and Engineering Services Ltd., Pune 156

157 managed, because man needs inhalation every moment, so also is Flora and Fauna dependent on it. The biological aspects, soil and ground water are all interdependent. Thus, there is a need of proper environmental management and a conscious plan for it. It is mandatory for the industry to submit Environmental Statement to State Pollution Control Board as per Environment (Protection), Amendment Rule, 1993 for the previous financial year ending 31 st March on or before 30 th September every. To draw a rigid EMP is especially important because, Due to the increase in demand of camphor at present a large quantity of this material is being imported hence the expansion is being planned to meet the requirement. Fly ash and bottom ash will be sent to cement manufacturers Effluent remaining is further used for green belt development & agricultural purposes. 9.2 Objectives of Environmental Management Plan To define the components of environmental management. To prepare an environmental hierarchy. To prepare a checklist for statutory compliance. To prepare environmental organization. To prepare a schedule for monitoring and compliance. 9.3 Checklist of Statutory Obligations There are a number of environmental statutes required to be attained by the industries. Dujodwala s shall obey the provisions of all relevant Acts, Rules, Notifications and Orders. The checklist of these obligations, which facilitates the obedience of the laws of land are given below : Water (Prevention and Control of Pollution) Act, 1974; MITCON Consultancy and Engineering Services Ltd., Pune 157

158 Water (Prevention and Control of Pollution) Cess Act, 1977; Air (Prevention and Control of Pollution) Act, 1981; Environment (Protection) Act, 1986; Environment (Protection) Rules, 1986; Hazardous Waste (Management and Handling) Rules 2003; EIA Notification Environmental Management Cell (EMC) An Environment Management Cell shall be developed by an effective mixing of a group of technical experts from various departments of the project to look after the all obligatory requirements and shall be responsible for the effective implementation of all environmental pollution control measures. The cell shall be headed by the Plant In charge as shown in Figure No. 9.1 There should be one SHE manager, who will report to plant in charge and will be assisted by chemist environment and environment & safety officer. Figure No. 9.1 Environment Management Cell Plant In charge SHE Manager Chemist- Environment Environment & Safety Officer Plant Manager MITCON Consultancy and Engineering Services Ltd., Pune 158

159 9.5 Construction Phase Environment Management Site Preparation The development of site for erections of plant structure, office building & other allied activities shall require careful management planning as the construction activities shall be located in plain barren land owned by the project proponent. Therefore, construction site development process should incorporate certain precautions. It is necessary to control the dust nuisance that would be created by excavation, leveling and transportation activities so that impacts on the various components of environment would be minimized Noise Though level of construction activities shall not be very high, still some specific sources of noise like welding, transportation, movement of earth movers, tractors, concrete or asphalt mixing etc. should be carried out in a controlled manner. Neither the plant nor the construction workers should be exposed to excessive noise levels Construction Equipment and Waste Transport vehicles as well as transport routes should be properly maintained during whole construction phase to minimize smoke / dust emission from vehicle exhausts and unpaved roads. Composite solid wastes including metal scrape, earthwork, other wastes, getting generated in construction process should be disposed off in safe manner. Certain hazardous waste materials, though the requirement of such materials shall be small, should be stored safely and be disposed off properly Site Security Construction site has a potential hazardous environment. To ensure that the local inhabitants and stray cattle are not exposed to these hazards, the site shall be secured by fencing and manned entry points. It will be fully illuminated during nighttime. MITCON Consultancy and Engineering Services Ltd., Pune 159

160 9.6 Operational Phase Air Environment Management The monitored ambient air quality has been found to be very much within the norms established by the regulating agency such as Central Pollution Control Board. However, to maintain the existing status and minimize the impact due to the proposed project operations the following steps would be initiated for a better air environment: The emission characteristics should also be monitored regularly. At plant periphery as well as in-between spaces, recommended plant species should be grown in a manner that such small green patches act as a part of green belt to trap dust being emitted from fuel combustion and /or fugitive sources and also attenuate the other gaseous pollutants. The control of fugitive emission such as hydrocarbons from DG sets, process units/storage, the following measures are recommended: o Proper maintenance and clearing of the roads inside the plant to avoid excess fugitive dust generation o Raw materials and ash disposal trucks should be covered to stop dust emission o Monitor the consented parameters at ambient station. o Monitor the work zone at various stations to satisfy the corporate requirements for health and environment. 9.7 Operational Phase Noise Environment Management The design features provided to ensure low noise levels are as given below: All rotating items will be well lubricated and provided with enclosures as far as possible to reduce noise transmission. Vibration isolators will be provided to reduce vibration and noise wherever possible Manufacturers and suppliers of machine/equipment like cane handling equipment s i.e. crusher, kicker, roller, Truck Tippler, Belt Conveyor, Vacuum Pans, turbines and generators will be manufactured as per OSHA/MoEF guidelines. MITCON Consultancy and Engineering Services Ltd., Pune 160

161 The insulation will be provided to reduce noise. The personnel safety such as ear muffs, ear plugs and industrial helmets will also act as a noise reducers Layouts of equipment foundations and structures will be designed keeping in view the requirement of noise abatement; Central control room(s) provided for operation and supervision of plant and equipment will be air-conditioned, glass fiber insulated frames which will help in reducing noise levels. Necessary enclosures will also be provided on the working platforms/areas to reduce the noise levels ; The workers working in the high noise areas like compressor houses, crushers, blowers, generators, steam generation plant and turbo generator area will be provided with ear muffs/ear plugs Acoustic laggings and silencers will be provided in equipment wherever necessary. The compressed air station will be provided with suction side silencers. Ventilation fans will be installed in enclosed premises Supply ducts and grills on the ventilation and air conditioning system will be suitably sized for minimum noise level The silencers and mufflers of the individual machines will be regularly checked The noise level will not exceed the permissible limit 75 db (A) during the day time 70 db (A) night time within the plant premises. Green belt around the plant area will reduce the noise level further. Occupational Safety and Health Administration (OSHA) System for evaluation of exposure of noise pollution on the associated staff and comparing it with permissible exposure and subsequently taking corrective actions will be developed. The adoption of the above measures, it is anticipated that noise levels will be maintained in db (A) range at the boundary of the plant premises. Earth mounds and plantations on the periphery of the plant would further attenuate noise level. MITCON Consultancy and Engineering Services Ltd., Pune 161

162 9.8 Ash Evacuation System The ash generated from the boiler shall be collected separately and taken to a common ash silo system for disposal Fly Ash Handling System The 10TPH boiler will utilize Indonesian coal with average ash content of about 5% to 10%. The control equipment preceding the stack shall be dust collector with wet scrubber type. The emissions control system provided will be of air pre-heater heat recovery unit Ash Utilization/Management System As per the MoEF notification dated on 3rd April 2007 S.O.513 (E) on fly ash utilization, as per the item (2) under the responsibility of organic chemical plant fly ash shall not at any time store more than three months in their storage/ ash pond. Fly ash generated from the organic chemical plant will be commercially utilized, to the extent possible, in one or more of the following industries: (i) cement, (ii) brick, (iii) fly ash, (iv) road making and paving, (v) agriculture (soil conditioner), (vi) back filling and (vii) any other industry that is technically feasible. Apart from these uses, fly ash can be used for the construction of ash- pond dyke, reclamation of low-lying areas. Basic technology, as well as initial expert advice for using fly ash in making bricks and cement blocks, will be provided to local brick and cement block makers free of charge. The state government will be requested to provide certain financial incentives to brick and cement block makers, and to ensure the use of fly ash building materials in public works projects to the fullest possible extent. The state government can be requested to provide valuable assistance by creating ash depots under its auspices Solid /Hazardous Waste Management Solid Waste: Solid by-products such as resin residue, fly ashare generated as process waste products (byproducts) from the industry. Fly ash from the use of coal for Boiler MITCON Consultancy and Engineering Services Ltd., Pune 162

163 shall be given to the cement manufacturers. The hazardous waste would be sent to CHWTSDF of Trans Thane Creek Waste Management Association. Details of solid waste generation and management presented Table 9.1 Table No. 9.1 Solid Waste Generation Details of Proposed and Existing Plant Name of the hazardous waste Quantity (MT) / year Disposal Resin Residue 0.5 CHWTSDF ETP Sludge 2.05 CHWTSDF *Fly ash from the use of coal for 10TPH Boiler 285 Will be sent to cement manufacturers * Bottom ash from the use of coal for 10 TPH Boiler 51 Will be sent to cement manufacturers Copper based catalyst 3 CHWTSDF Titanium based catalyst 1 CHWTSDF Indian catalyst 0.5 CHWTSDF Contaminated filter cloth 0.25 CHWTSDF Discarded containers 500 nos Cleaned / washed & reused Water and Wastewater Management An effluent management plan will be implemented with collection, treatment, recirculation and disposal of effluents. The various plans proposed are given below. Recirculation of treated effluent in firewater storage tanks Recirculation of effluents from coal dust extraction and suppression systems (after setting in settling tanks) and service water system (after treatment in plate separator / tube settlers). Rain water will be collected from roof tops and will be recharged through a rainwater recharge tank. Storm rain water drainage will be routed through a silting tank, for arresting of silt. Storm water will be used during the rains for the purpose of the plant water requirement. The sewage from plant will be directed to STP. The capacity of STP will be adequate and the treated effluent would be utilized in greenbelt development. The project would also MITCON Consultancy and Engineering Services Ltd., Pune 163

164 not lead to water pollution since the effluents generated shall be treated in suitably upgraded existing Effluent Treatment Plant (ETP) based on Krofta process and the water from ETP shall transported onwards to Patalganga CETP by tankers. Currently also similar practice is adopted. The schematic diagram of proposed and existing ETP is shown in figure 9.2 and 9.3 respectively. The expected quality of the treated effluent will meet the Inland surface and land disposal water quality standards and is presented in Table 9.2. Table No. 9.2 Projected Treated Effluent Characteristics Sr. No Particulars Unit Values 1. COD mg/l BOD mg/l 2 3. TSS mg/l Phenols mg/l Oil & Grease mg/l Total Iron mg/l Total dissolved solids mg/l 6632 MITCON Consultancy and Engineering Services Ltd., Pune 164

165 Figure No. 9.2 Schematic diagram of proposed ETP FLOW=100M 3 /DAY COD=28000mg/l BOD=2 mg/l TSS= 150 mg/l PHENOL=200mg/l OILLAND GRAESE=50mg/l TDS=6635 mg/l Total iron=6.77 MG/L POLYELELECTROL BLOWER POLYELELECTROL DOSING POLYELELECTROLpolyelectr BAR SCREEN COLLECTION PRIM CLARIFI ER AERATION TANK V- 1458M 3 SECONDRY LAMELLA CLARIFIER AERATION TANK V-288M 3 THIRD LAMELLA CLARIFIER INTERMEDIATE CLARIFIED WATER TANK SLUDGE SUMP SLUDGE SUMP SLUDGE SUMP PRESSUR E SAND FILTER SLUDGE DRYING BED FLOW=100M 3 /DAY COD=28000mg/l BOD=2 mg/l TSS= 150 mg/l PHENOL=200mg/l OILLAND GRAESE=50mg/l ACTIVATE D CARBON FILTER MITCON Consultancy and Engineering Services Ltd., Pune 165 RO UF FINAL TREATED WATER TANK

166 Bottom sludge towards sludge Bed Dujodwala Products Ltd. Bottom Sludge towards Sludge Bed Figure No. 9.3 Schematic diagram of existing ETP Secondary clarifier Aeration Tank Flash Mixer Primary Clarifier Sand filter Carbon filter Equalization Tank Equalization Tank Outlet MITCON Consultancy and Engineering Services Ltd., Pune 166 Oil and grease trap (inlet)

167 9.9 Biological Environment Special attention is required to maintain green belt in and around the factory premises. Adequate provisions are to be made to facilitate daily watering of all plants and lawns. Special attention provided during summer to ensure that the green belt does not suffer from water shortage. Development & maintenance of green belt to be considered as a priority issue. No outside soil/rubble will be brought for site development Land Environment The impacts on the land environment in this case is again associated with the land applications of ETP effluent for crop irrigation and green belt development & maintenance, which has been discussed earlier under water environment component. However, the construction of green belts, parks, would largely offset the change to the existing landscape and would provide visual comfort. The improved economy of the area is expected to cause increased outputs to agriculture, trade and commerce. As DPL will implement zero wastewater discharge methodology, there would be no impact due to any wastewater disposal on land Green Belt Already 7 Hectares of green belt already exists within the extant premises of DPL. Around 10,000 nos of trees are planned to be planted in factory premises and 10,000 outside the premises. Features of Green belt Suitable tree species will be planted in the green belt. This will act as a noise barrier and would also reduce the air pollution Plantation will also Improve the aesthetic backdrop of the site MITCON Consultancy and Engineering Services Ltd., Pune 167

168 As far as possible, the species should be indigenous and locally available Species would be planted. List of species for Plantation The Project proponents have proposed a landscape development plan, which includes planting of flowering and shady trees, shrubs and lawn within the plot. The open spaces inside the plot will be suitably landscaped and covered with vegetation of indigenous variety. The list of trees to be planted is as follows- List of Native Trees suitable for roadside & Garden plantation: Sr. No. Tree Common Name Scientific Name 1 Shirish Albizia lebbeck 2 Neem Azadiracta indica 3 Maharukh Ailanthus excelsa 4 Nandruk Ficus retusa 5 Satwin Alstonia scholaris 6 Karanj Pongamia pinnata 7 Katesavar Bombax ceiba 8 Kadamb Anthocephallus cadamba 9 Bahava Cassia fistula 10 Bakul Mimusops elengi 11 Parijatak Nyctanthes arbortristis 12 Tamhan Lagerstroemia flosregineae 13 Kunti Murraya paniculata 14 Sita Ashok Saraca asoka 15 Shivan Gmelina arborea 16 Apta, Bauhinia racemosa 17 Pangara Erythrina indica 18 Palas / Flame of the forest Butea monosperma 19 Son chafa Michelia champaca 20 Putranjiva Putranjiva roxburghii 21 Curry leaf / kadipatta Murraya koengii 22 Lemon Citrus Sr. No. Shrub / Climber Scientific name 1. Nirgudi Vitex negundo 2. Adulasa Adhatod avasica 3. White plumbago, Plumbago zeylanica 4. Ber Ziziphus mauritiana 5. Stachytarpheta Stachytarphetasp 6. Takala Cassia tora MITCON Consultancy and Engineering Services Ltd., Pune 168

169 7. Tarwad Cassia auriculata 8. Kusar / ran-jai (Climber) - 9. Sagargota Krushnakamal Passiflora edulis 9.12 Occupational Safety & Health All precautionary methods will be adopted by the company to reduce the risk of exposure of employees to occupational safety and health hazards. Pre & post medical check-ups will be done of all the employees. Employees will be regularly examined and the medical records will be maintained for each employee. Pulmonary function test and periodical medical checkup shall be done once in every year. The following tests shall be conducted for each worker: Lung Function Test Radiology X-ray Pulmonary Function Test Audiometric Test General clinical examination with emphasis on respiratory system Pre-employment examinations Periodical medical examinations at the time of employment and after completion of employment. For the safety of workers, personnel protective appliances like hand gloves, goggles, aprons, ear mufflers, nose mask etc. will be provided. Nose mask will be provided at places, where there is possibility of dust generation. In high noise generation areas ear mufflers will be provided for the workmen. Proper ventilation system will be provided in the process area Socio-Economic Welfare Activities The operators and workers are to be trained in various aspects of ESH (Environment, Safety and Health). The managers and officers involved in Environment Management Cell shall undergo refresher workshop and up-gradation of information on various environmental issues. MITCON Consultancy and Engineering Services Ltd., Pune 169

170 The management of DPL shall help in promoting the activities related to environmental awareness in nearby villages. The proponent shall help in promoting local people for livelihood commensurate with their will, skill and abilities. Many other welfare measures will be taken from time to time Environmental Monitoring Schedule Monitoring of the post project environment is of utmost importance and has legal requirements. Regular monitoring of the environment helps in assessing the benefits of implementation of environment management plan. DPL shall adopt an effective monitoring plan with proper schedule as a step forward to ensure better environment management practices. Details about Environmental Monitoring Schedule given in the Chapter Environmental Budget Before the commission of the plant the Environment Management Cell will be formed to take care of environmental issues including plantation. The details are given in Table no Table No. 9.3 Budgetary allocation for environmental protection measures Sr. No. Name of Activity Capital Cost (Rs.Lakhs) 1 Air Pollution Control System Water Pollution Control Systems (E.T.P.) Noise pollution control Green Belt Development/ Maintenances Recurring Cost (Rs. Lakhs) 6 Environmental Monitoring / Environmental Management 7 Solid waste / Hazardous Waste Management Occupational Health & Safety TOTAL MITCON Consultancy and Engineering Services Ltd., Pune 170

171 CHAPTER 10 SUMMARY AND CONCLUSION 10.1 Introduction The Indian chemical industry is among the traditional sectors of the country that play an integral role in the country s economic development. This sector forms a part of the basic goods industry and is a critical input for industrial and agricultural development. The Indian chemical industry is one of the oldest industries in India and has made immense contribution to the industrial and agricultural development of India. It encompasses both large and small-scale units. The fiscal incentives granted to the small-scale units in the mid-1980s provided the thrust to the growth of Micro, Small and Medium Enterprises (MSMEs) in the sector. The chemical industry serves the needs of sectors such as textiles, pharma, petrochemicals, dyes, leather, plastics, paper, printing inks and food stuffs, among others. M/s Dujodwala Products Ltd.(DPL) located near Khalapur, dist. Raigad, Maharashtra, is manufacturing Organic chemicals. Now, it plans to expand its plant capacity. As per EIA notification 2006, and amendments their on such project are considered in category 5(f) of schedule and requires prior environmental clearance. Environmental Impact Assessment is prepared as a procedure for obtaining prior Environmental Clearance for the proposed expansion. The environmental Study was undertaken during Post monsoon and winter season (Oct - Dec 2012) as per EIA guidelines of Ministry of Environment & Forests (MoEF), New Delhi. The Details of the study carried out is presented in draft EIA report Project Description Sr. No Item DESCRIPTION 1. Title of the project Proposed expansion of Organic Chemical Plant at Khalapur Dist. Raigad, Maharashtra by Dujodwala Products Ltd. 2. Land acquired The total existing plot area is 20 acres and out of these 5 3. Cost of the project acres of land required for proposed expansion. Rs 31 Crore MITCON Consultancy and Engineering Services Ltd., Pune 171

172 4. Proposed facilities 5. Production capacities 6. Air Pollution Control Measures Proposed 7 Power Requirement & Source Raw material storage area which will be around 7 x 60 m in dimension & will house the tanks for the following chemicals Formaldehyde Phenol Crude Sulphate of Terpentine Local Turpentine Dipentene fraction of local turpentine Dipentene fraction of imported turpentine b) Finished material storage which will be around 7 x 60 m in dimension and will house the tanks for the following finished materials :-- Camphene DRT 5004 (Resin) DRT 4001 (Resin) Pure fraction of Turpentine c) The plant equipment housing area will be around 30 m x 46 m which will house the equipment s from Ground Floor to the Third (10 th floor) Sr. No. 8 Coal 30 MT/Day Name of the chemical Existing capacity (MT/Month) Proposed capacity (MT /month) 1. Alphapinene (95%) N.A Polyester Resin Phenolic Resin Alkyd Resin Coating NIL Rosin Easter Maleic Modified Resin 8. Phenolic Modified Resin 9. PVC chemicals NIL Camphene Dipentene Ketonic Resin Polyamide Resin Dust collector with wet scrubber. State-of-the-art scrubbers will be installed for 10TPH boiler to limit the air pollution. Unloading areas will be provided with water sprinklers to prevent the fugitive dust. Fly ash will be stored in a silo. Fly ash will be given to Cement /brick manufacturers. New Connected Load 1645 KW New Maximum demand 180 KVA MSED MITCON Consultancy and Engineering Services Ltd., Pune 172

173 Requirement & Source 9. Waste Water Treatment 10. Solid Hazardous Waste / Hazardous Waste Indonesian coal will be procured from the local vendor The existing ETP consists of the following units :-- Equalization tank. Flash mixer Primary clarifier Secondary clarifier Oil and Grease Trap Aeration tank Outlet tanks Sand filter Carbon filter The existing ETP will be revamped based on the aforesaid unit operations to cater to an effluent of 100 m3/day Kindly refer Annexure -1 for details. The final treated effluent will be sent to Patalaganga CETP. Name of the hazardous waste /solid waste Quantity (MT) / year Disposal Resin Residue 0.5 CHWTSDF of Trans Thane Creek Waste Management Association. ETP Sludge 2.05 CHWTSDF Trans Thane Creek Waste Management Association. *Fly ash from the use of coal for 10TPH Boiler * Bottom ash from the use of coal for 10 TPH Boiler 285 Will be sent to cement manufacturers 51 Will be sent to cement manufacturers Copper based catalyst 3 CHWTSDF of Trans Thane Creek Waste Management Association. Titanium based catalyst 1 CHWTSDF of Trans Thane Creek Waste Management Association. Indion catalyst 0.5 CHWTSDF of Trans Thane Creek Waste Management Association. Contaminated filter 0.25 CHWTSDF of Trans MITCON Consultancy and Engineering Services Ltd., Pune 173

174 cloth Thane Creek Waste Management Association. Discarded containers 500 nos Cleaned / washed & reused. 11. Green Belt Around 7.5 acres of green belt already exists out of existing 12.. Capital Cost & Recurring Cost per annum for Environmental Protection Measures 10.3 Description of the Environment 20.5 acres plot area. Capital cost :-- Rs. 50 lakhs Recurring cost per annum: -- Rs 24 lakhs. Environmental Baseline Data Collection is carried out during Winter & Post monsoon Season i.e. from Oct to Dec The study area comprises of 10 km radial distance around the proposed Project. The predominant wind direction during the study period is South East to North West Meteorology: Micrometeorological data within the project area was monitored at site during Winter & Post monsoon Sl. No. Parameters Data 1 Maximum temperature ( 0 C) Minimum temperature ( 0 C) Maximum Relative Humidity (%) 81 4 Minimum Relative Humidity (%) 54 5 Predominant Wind Direction South East Ambient Air Quality: Ambient Air Quality is monitored at 6 locations near project site. The ambient air quality results obtained are well within the prescribed limits of National Ambient Air Quality Standards. Station Code Station Name Distance From Project Site (km) Direction Upwind/ Downwind AAQ-1 Project Site - - AAQ-2 Dhamani 1.6 E Upwind AAQ-3 Kharsundi 1.4 W Downwind AAQ-4 Nimodekatarwadi 1.7 NW Downwind AAQ-5 Ambivali 4.8 NW Downwind AAQ-6 Khalapur 1.4 E Crosswind MITCON Consultancy and Engineering Services Ltd., Pune 174

175 Summary of Air quality Data are given below: Units: µg/ m 3 Station Name PM2.5 PM10 SO2 NOX Project site Dhamani Kharsundi Nimodekatarwadi Ambivali khalapur Ambient Noise Levels Ambient Noise Levels were monitored at 6 locations near project area. The ambient noise levels obtained were well within the prescribed limits of National Ambient Air Quality Standards with respect to noise. Summary of Noise Data are given below: Units: db (A) N1 N2 N3 N4 N5 N6 Min Max Ld Ln L Min Minimum Noise Level Recorded Ld Day Equivalents L Max Maximum Noise Level Recorded Ln Night Equivalents Water Quality About 4 ground water samples and 2 surface water samples have been collected to assess the water quality in the study area. The physico-chemical characteristics of water samples are in compliance with the prescribed drinking water standards of IS S No. Location Code Location Name Sample Source Surface Water SWQ1 Patalganga River Up-stream SWQ2 Patalganga River Down-stream Ground Water GWQ1 Project Site Open Well GWQ2 Abbhivali Open Well GWQ3 Madap Open Well MITCON Consultancy and Engineering Services Ltd., Pune 175

176 GWQ4 Kharasindi Open Well GWQ5 Savaroli Open Well GWQ6 Dhamani Open Well The Quality of ground and surface water samples collected during winter season is given below: It is observed that the ph of the ground water samples are in the range of Total dissolved solids (TDS) in the samples are in the range mg/l Total hardness of the ground water samples was found to varies between mg/l The Heavy metal concentration are within the prescribed limits Soil Quality Six soil samples were collected and analysed. Station Code S1 S2 S3 S4 S5 S6 Station Name Project Site Ambivali Madap Dhamani Savaroli Kharsundi Results show the ph ranges from of and the Nutrients like N, P and K are in moderate concentration Ecological Status Flora- The prominent plant in the study area is Mango, which is found commonly near the road side. Babul was a common tree near the villages and on the hedge of agricultural field. The commonly found trees are Jamun, Bor, Tamrind, Eucalyptus, Neem, Peepal, Vad, Teak, Sheesham, Mango, Palas, etc. MITCON Consultancy and Engineering Services Ltd., Pune 176

177 Fauna- The Mammals found in the study area are Five Striped palm squirrel, Common / Indian Mongoose, Common Indian Hare, Indian Field Mouse, House mouse, House Shrew. Some reptiles like water snakes, monitor lizards and common lizards were also observed near village boundary. The dominant birds in the study area are House crow, Owl, Asian koel, Common Myna Socio-Economics The data on the demographic structure of the study area were collected from censes records of Raigad District. There are 28 villages in the study area. The demographic profile of the study area including no. household, total population, population structure viz scheduled Caste population and number of literates & illiterates, are summarized below. Total population of villages under the study area is Sex ratio (930 nos. females per 1000 males) is which indicates that females are less in number than their male counterpart in the study are The overall literacy rate in the study area is 58 %, which is quite satisfactory. Scheduled caste population is 3% while scheduled tribe population in the study area is 13.49% Environmental Impact Assessments The Environmental Impact due to the project is tabulated below: Environmental Impact Assessment Parameter Construction Phase Operational phase Air Environment Short term negative impact. Long term negative impact. Noise Environment Short term negative impact Long term negative impact Water Environment short term negative impact No negative impact Land Environment No negative impact Long term positive impact. Soil Short term negative No impact Construction Waste Short term negative No impact Ecological Environment No Negative impact Long term positive impact. Employment Generation Short term positive impact Long term positive impact MITCON Consultancy and Engineering Services Ltd., Pune 177

178 Parameter Construction Phase Operational phase Improvement in Health Care No impact Long term positive impact Facilities Economic Condition of the Short term positive impact Long term positive impact study area Aesthetics Environment Short term negative Long term positive impact Resettlement and No negative impact No impact rehabilitation issues Impact on Infrastructure No negative impact Long term positive impact Facilities Historical, Archaeological and Architectural Sites No impact Long term positive impact 10.5 Environmental Management Plan Construction Phase Environment Management a) Site Preparation The development of site for erections of plant structure, office building and other allied activities shall require careful management planning as the construction activities will be located in plain land owned by the project proponent and within existing factory premises. Care will be taken to control the dust nuisance that would be created by excavation, leveling and transportation activities so that impacts on the various components of environment would be minimized. b) Noise Though level of construction activities shall not be very high, still some specific sources of noise like welding, transportation, movement of earth movers, tractors, will be carried out in a controlled manner. Neither the plant nor the construction workers should be exposed to excessive noise levels. c) Construction Equipment and Waste Transport vehicles as well as transport routes will be properly maintained during whole construction phase to minimize smoke / dust emission from vehicle exhausts and unpaved roads. Composite solid wastes including metal scrape, earthwork, other wastes, getting generated in construction process will be disposed off in safe manner. Certain hazardous waste MITCON Consultancy and Engineering Services Ltd., Pune 178

179 materials, though the requirement of such materials shall be small, will be stored safely and be disposed off properly Operational Phase Environment Management a) Water Environment & Management The Surface water shall be used for the plant operation and generation of waste water & discharge should be maintained as per the MoEF current guidelines. The followings are to be strictly followed to meet the requirement: Recirculation of treated effluent in firewater storage tanks Recirculation of effluents from coal dust extraction and suppression systems (after setting in settling tanks) and service water system (after treatment in plate separator / tube settlers). Rain water will be collected from roof tops and will be recharged through a rainwater recharge tank. Storm rain water drainage will be routed through a silting tank, for arresting of silt. Storm water will be used during the rains for the purpose of the plant water requirement. The sewage from plant will be directed to STP. The capacity of STP will be adequate and the treated effluent would be utilized in greenbelt development. b) Air Environment Management To minimize the impact due to the proposed project operations the following steps would be initiated: The emission characteristics should also be monitored regularly. Green belt to trap dust being emitted from fuel combustion and /or fugitive sources and also attenuate the other gaseous pollutants. The control of fugitive emission such as hydrocarbons from DG sets, process units/storage, the following measures are recommended: MITCON Consultancy and Engineering Services Ltd., Pune 179

180 o Proper maintenance and clearing of the roads inside the plant o Raw materials trucks should be covered to stop dust emission o Monitor the consented parameters at ambient air quality monitoring station. o Monitor the work zone at various stations to satisfy the corporate requirements c) Noise Environment for health and environment. The following precautionary measures are to be adopted in the proposed project Insulate/enclose all the noise sources to avoid occupational exposure to the workers and to minimize the generation of excess noise level. Monitor the ambient and work zone noise level to conform the stipulated norms. Noise attenuation devices such as ear mufflers must be provided to the workers in the high noise exposure areas. d) Biological Environment Already 7 Hectares of green belt exists within the extant premises of DPL. Tree plantation within premises and outside factory premises is also envisaged. Features of Green belt Suitable tree species will be planted in the green belt. This will act as a noise barrier and would also reduce the air pollution Plantation will also Improve the aesthetic backdrop of the site e) Land Environment The impacts on the land environment in this case is again associated with the land applications of ETP effluent for crop irrigation and green belt development & maintenance, which has been discussed earlier under water environment component. MITCON Consultancy and Engineering Services Ltd., Pune 180

181 However, the construction of green belts would largely offset the change to the existing landscape and would provide visual comfort. The improved economy of the area is expected to cause increased outputs to agriculture, trade and commerce. As DPL will implement zero wastewater discharge methodology, there would be no impact due to any wastewater disposal on land. f) Occupational Safety & Health All precautionary methods will be adopted by the company to reduce the risk of exposure of employees to occupational safety and health hazards. Pre & post medical check-ups will be done of all the employees. Employees will be regularly examined and the medical records will be maintained for each employee. Pulmonary function test and periodical medical checkup shall be done once in every year. The following tests shall be conducted for each worker: Lung Function Test Radiology X-ray Pulmonary Function Test Audiometric Test General clinical examination with emphasis on respiratory system Pre-employment examinations Periodical medical examinations at the time of employment g) Socio-Economic Welfare Activities The operators and workers are to be trained in various aspects of ESH (Environment, Safety and Health). The managers and officers involved in Environment Management Cell shall undergo refresher workshop and up-gradation of information on various environmental issues. The management of DPL shall help in promoting the activities related to environmental awareness in nearby villages. The proponent shall help in promoting local people for livelihood commensurate with their will, skill and abilities. Many other welfare measures will be taken from time to time. MITCON Consultancy and Engineering Services Ltd., Pune 181

182 Environmental Protection Cost The DPL has proposed to incur the following one time and recurring cost for the EMP measures. Budgetary allocation for environmental protection measures Sr. No. Name of Activity Capital Cost (Rs. Lakhs) Recurring Cost (Rs. Lakhs) 1 o Air pollution Control System Water pollution control systems (ETP) Noise pollution control Green Belt Development Environmental Monitoring / Environmental Management 7 Solid waste / Hazardous waste management 8 Occupational health & safety Environmental Monitoring TOTAL Environmental Monitoring is a tool to check the implementation of the Environmental Management Plan. It involves formation of a committee involving experts in various fields as well as Govt. officials for checking the implementation of the environmental management plan. The following monitoring plan is suggested for the project. The regular Environmental monitoring will be carried out to check the impact of the project on air, water, soil noise quality. Effluent from the distillery will also be monitored Project Benefits Project benefit focused on those points which become beneficial to the surrounding area or community in terms of infrastructural development, Social development, boosting employment and other tangible benefits due to upcoming or proposed activities in form side benefits. The proposed project expansion has a potential for employment of skilled, semi-skilled and unskilled employees during construction phase as well as operational phase. MITCON Consultancy and Engineering Services Ltd., Pune 182

183 CHAPTER 11 DISCLOSURE OF CONSULTANT ENGANGED 11.1 Background of the Organization MITCON Consultancy and Engineering Services Ltd., (MITCON) is a rapidly growing, an ISO certified Consultancy Company, promoted by ICICI, IDBI, IFCI, and State Corporations of Maharashtra and Public Commercial Banks. It was founded in 1982; with Head Office at Pune and with supporting offices spread over entire country including Mumbai, Delhi, Bangalore, Hyderabad, Chennai, Chandigarh and Ahmadabad etc. With experience, expertise and track record developed over last almost three decades, MITCON provides diverse range of macro and micro consultancy services in the areas of -- Environment Management and Engineering (EME). Energy Efficiency. Biomass and Co-gen power. Agricultural Business and Bio-technology. Infrastructure. Market Research. Banking Finance and Securitisation. Micro Enterprise Development. IT Training and Education. The attached broacher also showcases the snapshot of the each of these divisions and wide portfolio of services we offer. The company, being working only in consultancy and training sector, is having a turnover of more than 20 Crs. per annum for last three years MITCON Consultancy and Engineering Services Ltd., Pune 183

184 11.2 About EME Division and Consultancy Services Offered Environmental Management and Engineering Division (EME) is one of the key division of MITCON and provide expert consultancy and laboratory services for various matrix of services in the field of environmental management. Thus, EME division partners with an organization in their efforts of achieving sustainable business model. Some of our Credentials of EME division is State-of-the-art Environment Laboratory with experienced and trained manpower. Recognition by Ministry of Environment and Forest (MoEF), Government of India and OHSAS 18001/2007. Accredited by QCI-NABET as an EIA consultant. We are recommended as Technical Consultant by Directorate of Municipal Administration, Govt. of Maharashtra, Mumbai, for preparation of Detailed Project s (DPR) on Municipal Solid Waste Management for the Municipal Councils in Maharashtra. Services Offered: A. Consultancy Services 1. Environmental Impact Assessment Field study, primary and secondary data collection. Preparation of rapid environmental impact assessment report. Securing clearance from competent authorities. 2. Environmental Audit / Status. Filed study. Preparation of report. 3. Consent Preparation and submission of application for consent to establish / consent to operate. Follow-up with the state pollution control board and securing consent to establish / consent to operate. MITCON Consultancy and Engineering Services Ltd., Pune 184

185 4. Municipal Solid Waste Management (MSW)/ Hazardous Waste (HZ) Management & Technical Services Survey. Preparation of techno-commercial feasibility report on WTE/ integrated MSW project. MSW due-diligence report. Preparation of detailed project report [DPR]. MSW tender evaluation and preparation. MSW & Hz. Landfill engineering design costing. Project management consultancy services for MSW projects. 5. Water Supply and Sanitation Water treatment and distribution system survey, design sewerage system survey and treatment plant design. Preparation of detailed project report (DPR), bankable documents. 6. Small Turnkey Projects Biogas design and installation. Sewage treatment plant. Effluent treatment plant. 7. Technical Appraisal Solid waste management projects. Zero discharge effluent projects for distillery. 8. GIS and Remote Sensing Preparation of various maps. Land use/ land cover. Preparation of various layers. GIS based analysis. Modeling B. Laboratory Services (Environmental Laboratory is recognized by Ministry of Environment and Forests, Govt. of India, New Delhi, under Environment Protection Act,1986) MITCON Consultancy and Engineering Services Ltd., Pune 185

186 1. Analytical Services Water Quality Water Analysis Water Audit Waste Water/Effluent Characterization & Analysis Ground Water Monitoring & Analysis Storm Water Characterization & Analysis Waste Water Reduction Rain Water Harvesting Feasibility & Treatability Studies of Various Effluent & Sewage Pesticide & Various Organic Pollutant Analysis Soil Quality Agriculture Soil Analysis Physico-Chemical and Biological Analysis Bacteriological Analysis Wastes (Solid & Semisolid) Municipal Solid Waste Analysis Hazardous Waste Survey Wastes Audit Detailed Investigation Preparation of Detailed Project Design, Engineering of Treatment Plant Design, Engineering of Landfill Site Zero Discharge / Waste Studies Industrial Hygiene Audit Specialized Services Health & Hygiene Survey Stress Survey Ergonomics Survey Strom Water Analysis & Management Sludge/Lechate Analysis Rain Water Harvesting & Recharging MITCON Consultancy and Engineering Services Ltd., Pune 186

187 Flow & Load Analysis Ground Water Survey & Analysis Bore Well/Tube wells- Yield Assessment Water Audit Flow & Load Survey ETP & STP-Risk Assessment 2. Monitoring Services Ambient air quality, work-zone air quality monitoring Source emission, fugitive emission monitoring Efficiency assessment of air pollution control equipment Noise level monitoring Illumination and ventilation survey Vibration survey 3. Operation&Maintenance Services Water Treatment and Distribution System Survey, Design Sewerage System Survey & Treatment Plant Design ETP, CETP and STP DM Plant RO Plant Sewage Treatment Plant Effluent Treatment Plant 4. Miscellaneous PAH, Pesticides, VOC, Dioxins & Furans, etc. analysis Oil testing Chemical Testing Lighting/Illumination Survey Ventilation Survey Noise Survey Hazardous Substances Survey Lead & Asbestos Containing Material (ACM) Survey Environmental Audit Environmental Site Assessment (Level I, II, III) MITCON Consultancy and Engineering Services Ltd., Pune 187

188 EME division of MITCON serves to various sectors like GIS & RS, solid waste, infrastructure, power, sugar, engineering, chemical, real estate etc Consultants Engaged in Preparation of EIA EMP Sr. No. Name of the Personnel 1. Mr. Sanjay Shevkar 2. Dr. Chaitanya Sathe 3. Mr. Nilesh Deshmukh Degree Designation Role M.Sc. Environmental Sciences Ph.D in Inorganic Chemistry M.Tech. Environmental Engineering Executive Vice President Assistant Vice President Assistant Vice President EIA Co-ordinator. Inputs related to air pollution management Coordination and suggestions in report related to Solid waste Management & WP aspects Inputs related to Water pollution management Signature 4. Mr. Ashvin Badge B.E. Chemical Engineering. Environmental Engineer Baseline data collection of study area., 5. Ms. Kavita Zog M.Sc. Environmental Science 6. Mr. Shrikant Kakade 7. Dr. (Mrs.) Suvarna Sachin Tikle 8. Mr. Sharad Bade M.Sc. Environmental Science Ph. D in Environmental Science B.Sc Chemistry Zoology and Physics Senior Consultant Principal Consultant Principle Consultant Senior Executive (Environment) Baseline, ecology aspects, preparation of EMP. Baseline EB study, EIA EMP report preparation. Map preparation, Baseline data collection surveys MITCON Consultancy and Engineering Services Ltd., Pune 188

189 Sr. No. Name of the Personnel 9. Mrs. Prajakta Chitnis Degree Designation Role B.Sc. {chemistry} & Post Graduation Diploma in industrial & Analytical Chemistry Senior Chemist Co-ordinating testing of samples, water and soil Signature 10. Mr. Ganesh Dhansing Khamgal 11. Mrs. Seema Nazarkar MSW (Urban & Rural Community Development) B.Sc. Microbiology Divisional Manager Chemist socioeconomic aspects in EIA report Assistance in analysis of samples 12. Mrs. Renuka Ingale 13. Mrs. Seema Nazarkar M.Sc. Botany B.Sc. Microbiology Project Consultant Chemist Assistance in analysis of Soil samples & Assisted in identification of floral species Analysis of Environmental Samples. MITCON Consultancy and Engineering Services Ltd., Pune 189

190 ANNEXURE 1 to 13 MITCON Consultancy and Engineering Services Ltd., Pune 190

191 Annexure No. 1 Master Layout Plan MITCON Consultancy and Engineering Services Ltd., Pune 191

192 Annexure No. 2 Additional Water Requirement Permission Letter MITCON Consultancy and Engineering Services Ltd., Pune 192

193 MITCON Consultancy and Engineering Services Ltd., Pune 193

194 MITCON Consultancy and Engineering Services Ltd., Pune 194

195 MITCON Consultancy and Engineering Services Ltd., Pune 195

196 MITCON Consultancy and Engineering Services Ltd., Pune 196

197 MITCON Consultancy and Engineering Services Ltd., Pune 197

198 MITCON Consultancy and Engineering Services Ltd., Pune 198

199 MITCON Consultancy and Engineering Services Ltd., Pune 199

200 MITCON Consultancy and Engineering Services Ltd., Pune 200

201 MITCON Consultancy and Engineering Services Ltd., Pune 201

202 MITCON Consultancy and Engineering Services Ltd., Pune 202

203 MITCON Consultancy and Engineering Services Ltd., Pune 203

204 Annexure No. 3 Power Permission by Maharashtra State Electricity Distribution Co. Ltd MITCON Consultancy and Engineering Services Ltd., Pune 204

205 MITCON Consultancy and Engineering Services Ltd., Pune 205

206 MITCON Consultancy and Engineering Services Ltd., Pune 206

207 MITCON Consultancy and Engineering Services Ltd., Pune 207

208 Annexure No. 4 Three Months Ambient Air Quality Results Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m 3 µg/m 3 µg/m 3 µg/m 3 AAQ1 PLANT SITE (Dujodwala Factory ) 1 2/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th MITCON Consultancy and Engineering Services Ltd., Pune 208

209 Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m 3 µg/m 3 µg/m 3 µg/m 3 AAQ2 Dhamani (Upwind) 1 2/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th MITCON Consultancy and Engineering Services Ltd., Pune 209

210 Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m 3 µg/m 3 µg/m 3 µg/m 3 AAQ3 Kharsundi (Downwind) 1 2/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th MITCON Consultancy and Engineering Services Ltd., Pune 210

211 Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m 3 µg/m 3 µg/m 3 µg/m 3 AAQ4 Nimode Katarwadi (Downwind) 1 5/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th MITCON Consultancy and Engineering Services Ltd., Pune 211

212 Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m 3 µg/m 3 µg/m 3 µg/m 3 AAQ5 Ambivali (Downwind) 1 5/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th MITCON Consultancy and Engineering Services Ltd., Pune 212

213 Sr.No Monitoring PM2.5 PM10 SO2 NOX Units Date µg/m3 µg/m3 µg/m3 µg/m3 AAQ6 Khalapur 1 5/10/ /10/ /10/ /10/ /10/ /10/ /10/ /10/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ /12/ Min Max Avg th Note:, Total hydrocarbon (HC), Ozone & volatile organic compound (VOC) were found to be below detectible limit in all the samples. MITCON Consultancy and Engineering Services Ltd., Pune 213

214 Annexure No. 5 Noise Monitoring Results Noise Levels db(a) Time N1 N2 N3 N4 N5 N6 Location Working Dhamani Kharsundi Nimode Ambivali Khalapur Name Area Katarwadi Min Max Ld Ln MITCON Consultancy and Engineering Services Ltd., Pune 214

215 Annexure No. 6 Water Quality Results MITCON Consultancy and Engineering Services Ltd., Pune 215

216 MITCON Consultancy and Engineering Services Ltd., Pune 216

217 MITCON Consultancy and Engineering Services Ltd., Pune 217

218 MITCON Consultancy and Engineering Services Ltd., Pune 218

219 MITCON Consultancy and Engineering Services Ltd., Pune 219

220 MITCON Consultancy and Engineering Services Ltd., Pune 220

221 MITCON Consultancy and Engineering Services Ltd., Pune 221

222 MITCON Consultancy and Engineering Services Ltd., Pune 222

223 MITCON Consultancy and Engineering Services Ltd., Pune 223

224 MITCON Consultancy and Engineering Services Ltd., Pune 224

225 MITCON Consultancy and Engineering Services Ltd., Pune 225

226 MITCON Consultancy and Engineering Services Ltd., Pune 226

227 MITCON Consultancy and Engineering Services Ltd., Pune 227

228 MITCON Consultancy and Engineering Services Ltd., Pune 228

229 MITCON Consultancy and Engineering Services Ltd., Pune 229

230 MITCON Consultancy and Engineering Services Ltd., Pune 230

231 Annexure No. 7 Soil Quality Results MITCON Consultancy and Engineering Services Ltd., Pune 231

232 MITCON Consultancy and Engineering Services Ltd., Pune 232

233 MITCON Consultancy and Engineering Services Ltd., Pune 233

234 MITCON Consultancy and Engineering Services Ltd., Pune 234

235 MITCON Consultancy and Engineering Services Ltd., Pune 235

236 MITCON Consultancy and Engineering Services Ltd., Pune 236

237 Annexure No. 8 Satellite imagery for the study area of 10 km radius MITCON Consultancy and Engineering Services Ltd., Pune 237

238 Annexure No. 9 Material Safety Data Sheets Material Safety Data Sheet: Alpha-Pinene Section 1: Chemical Product and Company Identification Product Name: Alpha-Pinene Chemical Formula: C10H16 Section 2: Composition and Information on Ingredients Composition: Name CAS # % by Weight {Alpha-}Pinene Toxicological Data on Ingredients: Alpha-Pinene: ORAL (LD50): Acute: 3700 mg/kg [Rat]. Potential Acute Health Effects: Section 3: Hazards Identification Hazardous in case of eye contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (irritant). Potential Chronic Health Effects: Hazardous in case of eye contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (irritant). CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS: Not available. TERATOGENIC EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Not available Section 4: First Aid Measures Eye Contact: Check for and remove any contact lenses. Do not use an eye ointment. Seek medical attention Skin Contact: After contact with skin, wash immediately with plenty of water. Gently and thoroughly wash the contaminated skin with running water and non-abrasive soap. Be particularly careful to clean folds, crevices, creases and groin. Cover the irritated skin with an emollient. If irritation persists, seek medical attention. Wash contaminated clothing before reusing. Serious Skin Contact: Not available Inhalation: Allow the victim to rest in a well-ventilated area. Seek immediate MITCON Consultancy and Engineering Services Ltd., Pune 238

239 medical attention. Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. Seek medical attention. Ingestion: Do not induce vomiting. Loosen tight clothing such as a collar, tie, belt or waistband. If the victim is not breathing, perform mouth-to-mouth resuscitation. Seek immediate medical attention. Section 5: Fire and Explosion Data Flammability of the Product: Flammable. Auto-Ignition Temperature: 255 C (491 F) Flash Points: CLOSED CUP: 33 C (91.4 F). Flammable Limits: Not available. Products of Combustion: These products are carbon oxides (CO, CO2). Fire Hazards in Presence of Various Substances: Highly flammable in presence of open flames and sparks. Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of mechanical impact: Not available. Risks of explosion of the product in presence of static discharge: Not available. Fire Fighting Media and Instructions: Flammable liquid, insoluble in water. SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray or fog. Cool containing vessels with water jet in order to prevent pressure build-up, auto ignition or explosion. Special Remarks on Fire Hazards: Explosive in the form of vapor when exposed to heat or flame. Special Remarks on Explosion Hazards: Not available. Section 6: Accidental Release Measures Small Spill: Absorb with an inert material and put the spilled material in an appropriate waste disposal. Large Spill: Flammable liquid, insoluble in water. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not get water inside container. Do not touch spilled material. Prevent entry into sewers, basements or confined areas; dike if needed. Eliminate all ignition sources. Call for assistance on disposal. MITCON Consultancy and Engineering Services Ltd., Pune 239

240 Section 7: Handling and Storage Precautions: Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapour/spray. Avoid contact with eyes Wear suitable protective clothing In case of insufficient ventilation, wear suitable respiratory equipment If ingested, seek medical advice immediately and show the container or the label. Storage: Flammable materials should be stored in a separate safety storage cabinet or room. Keep away from heat. Keep away from sources of ignition. Keep container tightly closed. Keep in a cool, well-ventilated place. Ground all equipment containing material. A refrigerated room would be preferable for materials with a flash point lower than 37.8 C (100 F). Section 8: Exposure Controls/Personal Protection Engineering Controls: Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value. Ensure that eyewash stations and safety showers are proximal to the workstation location. Personal Protection: Splash goggles. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self-contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product. Exposure Limits: Not available. Section 9: Physical and Chemical Properties Physical state and appearance: Liquid. Odor: Strong. Taste: Not available. Molecular Weight: g/mole Color: Colorless. ph (1% soln/water): Not applicable. Boiling Point: 156 C (312.8 F) Melting Point: -55 C (-67 F) Critical Temperature: Not available. MITCON Consultancy and Engineering Services Ltd., Pune 240

241 Specific Gravity: (Water = 1) Vapor Pressure: Not available. Vapor Density: 4.7 (Air = 1) Volatility: Not available. Odor Threshold: Not available. Water/Oil Dist. Coeff.: Not available. Ionicity (in Water): Not available. Dispersion Properties: See solubility in water, methanol, diethyl ether. Solubility: Soluble in methanol, diethyl ether. Insoluble in cold water Stability: The product is stable. Instability Temperature: Not available. Conditions of Instability: Not available. Section 10: Stability and Reactivity Data Incompatibility with various substances: Not available. Corrosivity: Non-corrosive in presence of glass Special Remarks on Reactivity: Not available. Special Remarks on Corrosivity: Not available. Polymerization: No. Section 11: Toxicological Information Routes of Entry: Eye contact. Inhalation. Ingestion. Toxicity to Animals: Acute oral toxicity (LD50): 3700 mg/kg [Rat]. Chronic Effects on Humans: Not available. Other Toxic Effects on Humans: Hazardous in case of ingestion, of inhalation. Slightly hazardous in case of skin contact (irritant). Special Remarks on Toxicity to Animals: Not available. Special Remarks on Chronic Effects on Humans: Not available. Special Remarks on other Toxic Effects on Humans: Not available. Ecotoxicity: Not available. Section 12: Ecological Information MITCON Consultancy and Engineering Services Ltd., Pune 241

242 BOD5 and COD: Not available. Products of Biodegradation: Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise. Toxicity of the Products of Biodegradation: The products of degradation are more toxic. Special Remarks on the Products of Biodegradation: Not available Waste Disposal: Section 13: Disposal Considerations Section 14: Transport Information DOT Classification: Class 3: Flammable liquid. Identification: : alpha-pinene : UN2368 PG: III Special Provisions for Transport: Not available. Federal and State Regulations: Section 15: Other Regulatory Information Pennsylvania RTK: Alpha-Pinene Massachusetts RTK: Alpha-Pinene TSCA 8(b) inventory: Alpha-Pinene Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR ). Other Classifications: WHMIS (Canada): CLASS B-2: Flammable liquid with a flash point lower than 37.8 C (100 F). DSCL (EEC): R10- Flammable. R36- Irritating to eyes. HMIS (U.S.A.): Health Hazard: 1 Fire Hazard: 3 Reactivity: 0 National Fire Protection Association (U.S.A.): Health: 1 Flammability: 3 Reactivity: 0 Protective Equipment: Not applicable. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator when ventilation is inadequate. Splash goggles MITCON Consultancy and Engineering Services Ltd., Pune 242

243 Material Safety Data Sheet (MSDS): Formaldehyde Section 1 : Product Identification Product Name Material Uses Formaldehyde For Laboratory Use only Section 2: Hazardous Ingredients Name CAS# % TLV 1. Formaldehyde 2. Methanol 3. Water Section 3: Physical Data Physical state ph Odour threshold Percent volatile Freezing point Balance Exposure limits: 0.3 ppm (0.37mg/m3) Exposure limits: 200 ppm (262mg/m3) N/A Clear, colourless liquid with strong formaldehyde odour (25 degrees Celsius) (37% solution) 0.8 1ppm 100%(V/V) Boiling point Insoluble polymer gradually forms. Specific gravity 1.08 to (Water = 1) Vapour pressure ~40 mm of Hg (@ 39 C) Vapour density 0.62 to 1.04 (Air = 1) Evaporation rate Solubility 2.1(n-Butyl acetate = 1) (Methanol). Miscible in water. Section 4: Fire and Explosion Data Flash point degrees Celsius Flammability Lower: 7%; Upper: 73% Fire extinguishing procedures Section 5: Reactivity Data Stability Incompatibility Section 6: Toxicological Properties Routes of entry Effects of acute exposure Use DRY chemical, carbon dioxide, alcohol-resistant foam or water spray. Cool containing vessels with flooding quantities of water until well after fire is out. Stable. Conditions to avoid: heat, sparks and flame, temperatures below 20 C. May react violently with: acids, alkalis, anhydrides, isocyanates, urea, phenol, oxidizing agents, oxides, organic oxides, reducing agents, ammonia, aniline, magnesium carbonate, performic acid, alkali metals, amines, hydrogen peroxide, nitromethane, nitrogen dioxide, perchloric acid, perchloric acidaniline mixtures, bases, monomers, water reactive materials, magnesium carbonate hydroxide. Inhalation, ingestion, absorption through skin and eyes. Death if inhaled or absorbed; severe eye irritation and burns; allergic dermatitis, skin burns; bronchitis, pulmonary oedema; headache, dizziness, MITCON Consultancy and Engineering Services Ltd., Pune 243

244 Effects of chronic exposure Section 7: Preventative Measures Protective clothing and PPE Handling procedures Spill containment Section 8: First Aid Measures Eye contact Skin contact Inhalation Ingestion nausea, vomiting; abdominal pain; blindness. Nasal cancer, respiratory tract irritation; reproductive disorders, asthma, dermatitis; multiple organ damage. Wear self-contained breathing apparatus, rubber boots and heavy rubber gloves, and an acid suit. Store in a cool place away from heated areas, sparks, and flame. Store in a well-ventilated area. Store away from incompatible materials. Do not add any other material to the container. Do not wash down the drain. Do not breathe gas/fumes/vapor/spray. In case of insufficient ventilation, wear suitable respiratory equipment. Keep container tightly closed. Manipulate under an adequate fume hood. Take precautionary measures against electrostatic discharges. Ground the container while dispensing. Ground all equipment containing material. Use only explosion proof equipment. Use non-sparking tools. Watch for accumulation in low confined areas. Do not use pressure to dispense. Storage temperature depends on methanol content and should be controlled to avoid precipitation or vaporization. Handle and open container with care. Take off immediately all contaminated clothing. This product must be manipulated by qualified personnel. Do not get in eyes, on skin, or on clothing. Wash well after use. In accordance with good storage and handling practices. Do not allow smoking and food consumption while handling. Evacuate and ventilate the area. Stay upwind: Keep out of low areas. Eliminate all sources of ignition. Dyke the area with sand or a natural barrier. Absorb on sand or vermiculite and place in a closed container for disposal. Use nonsparking tools. Transport outdoors. Wash spill site after material pick up is complete. DO NOT empty into drains. DO NOT touch damaged container or spilled material. Runoff to sewer may create fire or explosion hazard. Immediate first aid is needed to prevent eye damage. IMMEDIATELY flush eyes with copious quantities of water for at least 20 minutes holding lids apart to ensure flushing of the entire surface. Seek immediate medical attention. DO NOT use an eye ointment. Immediate first aid is needed to prevent skin damage. Immediately flush skin with plenty of water for at least 20 minutes while removing contaminated clothing and shoes. Seek immediate medical attention. Wash contaminated clothing before reusing. Remove patient to fresh air. Administer approved oxygen supply if breathing is difficult. Administer artificial respiration or CPR if breathing has ceased. Seek immediate medical attention. If conscious, wash out mouth with water. DO NOT induce vomiting. Seek immediate medical attention. MITCON Consultancy and Engineering Services Ltd., Pune 244

245 Product Name: Phenol Material Safety Data Sheet (MSDS): Phenol Chemical Formula: C6H5OH Composition: Section 1: Chemical Identification Section 2: Composition and Information on Ingredients Name CAS # % by Weight Phenol Toxicological Data on Ingredients: Phenol: ORAL (LD50): Acute: 317 mg/kg [Rat]. 270 mg/kg [Mouse]. DERMAL (LD50): Acute: 630 mg/kg [Rabbit]. 669 mg/kg [Rat]. Section 3: Hazards Identification Potential Acute Health Effects: Very hazardous in case of skin contact (corrosive, irritant), of eye contact (irritant), of ingestion, of inhalation. Hazardous in case of skin contact (sensitizer, permeator). The amount of tissue damage depends on length of contact. Eye contact can result in corneal damage or blindness. Skin contact can produce inflammation and blistering. Inhalation of dust will produce irritation to gastro-intestinal or respiratory tract, characterized by burning, sneezing and coughing. Severe over-exposure can produce lung damage, choking, unconsciousness or death. Inflammation of the eye is characterized by redness, watering, and itching. Skin inflammation is characterized by itching, scaling, reddening, or, occasionally, blistering. Potential Chronic Health Effects: CARCINOGENIC EFFECTS: A4 (Not classifiable for human or animal.) by ACGIH, 3 (Not classifiable for human.) by IARC. MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. Mutagenic for bacteria and/or yeast. TERATOGENIC EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Not available. The substance may be toxic to kidneys, liver, central nervous system (CNS). Repeated or prolonged exposure to the substance can produce target organs damage. Repeated exposure of the eyes to a low level of dust can produce eye irritation. Repeated skin exposure can produce local skin destruction, or dermatitis. Repeated inhalation of dust can produce varying degree of respiratory irritation or lung damage. Repeated exposure to a highly toxic material may produce general deterioration of health by an accumulation in one or many human organs. MITCON Consultancy and Engineering Services Ltd., Pune 245

246 Section 4: First Aid Measures Eye Contact: Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Cold water may be used. Get medical attention immediately. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold water may be used. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention immediately Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek immediate medical attention. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention immediately. Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar, tie, belt or waistband. If breathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-mouth resuscitation. WARNING: It may be hazardous to the person providing aid to give mouth-to-mouth resuscitation when the inhaled material is toxic, infectious or corrosive. Seek immediate medical attention. Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar, tie, belt or waistband. Serious Ingestion: Not available. Section 5: Fire and Explosion Data Flammability of the Product: May be combustible at high temperature. Auto-Ignition Temperature: 715 C (1319 F) Flash Points: CLOSED CUP: 79 C (174.2 F). OPEN CUP: 85 C (185 F). Flammable Limits: LOWER: 1.7% UPPER: 8.6% Products of Combustion: These products are carbon oxides (CO, CO2). Fire Hazards in Presence of Various Substances: Flammable in presence of open flames and sparks, of heat. Non-flammable in presence of shocks. Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of mechanical impact: Not available. Risks of explosion of the MITCON Consultancy and Engineering Services Ltd., Pune 246

247 product in presence of static discharge: Not available. Fire Fighting Media and Instructions: SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do not use water jet. Special Remarks on Fire Hazards: Phenol + nitrides results in heat and flammable gas generation. Phenol + mineral oxdizing acids results in fire. Phenol + calcium hypochlorite is an exothermic reaction producing toxic fumes which may ignite Special Remarks on Explosion Hazards: Phenol + sodium nitrite causes explosion on heating. Peroxydisulfuric acid + phenol causes explosion. Section 6: Accidental Release Measures Small Spill: Use appropriate tools to put the spilled solid in a convenient waste disposal container Large Spill: Corrosive solid. Stop leak if without risk. Do not get water inside container. Do not touch spilled material. Use water spray to reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Eliminate all ignition sources. Call for assistance on disposal. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities. Section 7: Handling and Storage Precautions: Keep locked up.. Keep container dry. Keep away from heat. Keep away from sources of ignition. Empty containers pose a fire risk, evaporate the residue under a fume hood. Ground all equipment containing material. Do not ingest. Do not breathe dust. Never add water to this product. In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and show the container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, acids. Storage: Air Sensitive. Sensitive to light. Store in light-resistant containers. Moisture sensitive. Keep container tightly closed. Keep container in a cool, well-ventilated area. Section 8: Exposure Controls/Personal Protection Engineering Controls: Use process enclosures, local exhaust ventilation, or other engineering controls to keep airborne levels below recommended exposure limits. If user operations generate dust, fume or mist, use ventilation to keep exposure to airborne contaminants below the exposure limit. Personal Protection: Splash goggles. Synthetic apron. Vapor and dust respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. MITCON Consultancy and Engineering Services Ltd., Pune 247

248 Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor and dust respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product. Exposure Limits: TWA: 5 (ppm) from ACGIH (TLV) [United States] SKIN TWA: 19 (mg/m3) from ACGIH (TLV) [United States] SKIN TWA: 5 from NIOSH [United States] TWA: 19 (mg/m3) from NIOSH [United States] TWA: 5 (ppm) from OSHA (PEL) [United States] TWA: 19 (mg/m3) from OSHA (PEL) [United States] TWA: 5 (ppm) [Canada] TWA: 19 (mg/m3) [Canada]Consult local authorities for acceptable exposure limits Physical state and appearance: Solid Section 9: Physical and Chemical Properties Odor: Distinct, aromatic, somewhat sickening sweet and acrid Taste: Burning Molecular Weight: g/mole Color:Colorless to light pink ph (1% soln/water): Not available. Boiling Point: 182 C (359.6 F) Melting Point: 42 C (107.6 F) Critical Temperature: ( F) Specific Gravity: (Water = 1) Vapor Pressure: Not applicable. Vapor Density: 3.24 (Air = 1) Volatility: Not available. Odor Threshold: ppm Water/Oil Dist. Coeff.: The product is more soluble in oil; log(oil/water) = 1.5 Ionicity (in Water): Not available. Dispersion Properties: See solubility in water, methanol, diethyl ether, acetone Solubility: Easily soluble in methanol, diethyl ether. Soluble in cold water, acetone. Solubility in water: 1g/15 ml water. Soluble in benzene. Very soluble in alcohol, chloroform, glycerol, petroleum, carbon disulfide, volatile and fixed oils, aqueous alkali hydroxides, carbon tetrachloride, acetic acid, liquid sulfur dioxide. Almost insoluble in petroleum ether. Miscible in acetone. Sparingly soluble in mineral oil. MITCON Consultancy and Engineering Services Ltd., Pune 248

249 Section 10: Stability and Reactivity Data Stability: The product is stable. Instability Temperature: Not available. Conditions of Instability: Heat, ignition sources (flames, sparks), light, incompatible materials Incompatibility with various substances: Reactive with oxidizing agents, metals, acids, alkalis. Corrosivity: Extremely corrosive in presence of copper. Slightly corrosive in presence of stainless steel(304), of stainless steel(316). Non-corrosive in presence of glass, of aluminum. Special Remarks on Reactivity: Air and light sensitive. Prone to redden on exposure to light and air. Incompatible with aluminum chloride, peroxydisulfuirc acid, acetaldehyde, sodium nitrite, boron trifluoride diethyl ether + 1,3 - butadiene, isocyanates, nitrides, mineral oxidizing acids, calcium hypochlorite, halogens, formaldehyde, metals and alloys, lead, zinc, magnesium and their alloys, plastics, rubber, coatings, sodium nitrate + trifluoroacetic acid. Phenol + isocyanates results in heat generation, and violent polymerization. Phenol + 1,3-butadiene and boron trifluoride diethyl ether complex results in intense exothermic reaction. Phenol + acetaldehyde resultes in violent condensation. Special Remarks on Corrosivity: Minor corrosive effect on bronze. Severe corrosive effect on brass. Polymerization: Will not occur Section 11: Toxicological Information Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion. Toxicity to Animals: Acute oral toxicity (LD50): 270 mg/kg [Mouse]. Acute dermal toxicity (LD50): 630 mg/kg [Rabbit]. Chronic Effects on Humans: CARCINOGENIC EFFECTS: A4 (Not classifiable for human or animal.) by ACGIH, 3 (Not classifiable for human.) by IARC. MUTAGENIC EFFECTS: Mutagenic for mammalian somatic cells. Mutagenic for bacteria and/or yeast. May cause damage to the following organs: kidneys, liver, central nervous system (CNS). Other Toxic Effects on Humans: Very hazardous in case of skin contact (corrosive, irritant), of ingestion,. Hazardous in case of skin contact (sensitizer, permeator), of MITCON Consultancy and Engineering Services Ltd., Pune 249

250 eye contact (corrosive), of inhalation (lung corrosive). Special Remarks on Toxicity to Animals: Lowest Published Lethal Dose: LDL [Human] - Route: Oral; Dose: 140 mg/kg LDL [Infant] - Route: Oral; Dose: 10,000 mg/kg Special Remarks on Chronic Effects on Humans: Animal: passes through the placental barrier. May cause adverse reproductive effects and birth defects (teratogenic) Embryotoxic and/or foetotoxic in animal. May affect genetic material (mutagenic). Special Remarks on other Toxic Effects on Humans: Section 12: Ecological Information Ecotoxicity: Ecotoxicity in water (LC50): 125 mg/l 24 hours [Fish (Goldfish)]. >50 mg/l 1 hours [Fish (Fathead minnow)]. >50 mg/l 24 hours [Fish (Fathead minnow)]. >33 mg/l 72 hours [Fish (Fathead minnow)]. >33 ppm 96 hours [Fish (Fathead minnow)]. BOD5 and COD: Not available Products of Biodegradation: Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise. Toxicity of the Products of Biodegradation: The products of degradation are less toxic than the product itself. Special Remarks on the Products of Biodegradation: Not available. Section 13: Disposal Considerations Waste Disposal: Waste must be disposed of in accordance with federal, state and local environmental control regulations. Section 14: Transport Information DOT Classification: CLASS 6.1: Poisonous material Identification: Phenol, solid UNNA: 1671 PG: II Special Provisions for Transport: Not available Section 15: Other Regulatory Information Federal and State Regulations: Connecticut hazardous material survey.: Phenol Illinois toxic substances disclosure to employee act: Phenol Illinois chemical safety act: Phenol New York release reporting list: Phenol Rhode Island RTK hazardous MITCON Consultancy and Engineering Services Ltd., Pune 250

251 substances: Phenol Pennsylvania RTK: Phenol Minnesota: Phenol Massachusetts RTK: Phenol Massachusetts spill list: Phenol New Jersey: Phenol New Jersey spill list: Phenol Louisiana RTK reporting list: Phenol Louisiana spill reporting: Phenol TSCA 8(b) inventory: Phenol TSCA 4(a) proposed test rules: Phenol TSCA 8(a) IUR: Phenol TSCA 8(d) H and S data reporting: Phenol: effective: 6/1/87; sunset: 6/01/97 SARA 302/304/311/312 extremely hazardous substances: Phenol SARA 313 toxic chemical notification and release reporting: Phenol CERCLA: Hazardous substances.: Phenol: 1000 lbs. (453.6 kg) Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR ). EINECS: This product is on the European Inventory of Existing Commercial Chemical Substances. Other Classifications: WHMIS (Canada): CLASS D-1A: Material causing immediate and serious toxic effects (VERY TOXIC). CLASS D-2A: Material causing other toxic effects (VERY TOXIC). CLASS E: Corrosive solid. DSCL (EEC): R24/25- Toxic in contact with skin and if swallowed. R34- Causes burns. R40- Possible risks of irreversible effects. R43- May cause sensitization by skin contact. R52- Harmful to aquatic organisms. S1/2- Keep locked up and out of the reach of children. S24- Avoid contact with skin. S26- In case of contact with eyes, rinse immediately with plenty of water and seek medical advice. S28- After contact with skin, wash immediately with plenty of water S37/39- Wear suitable gloves and eye/face protection. S45- In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible). S46- If swallowed, seek medical advice immediately and show this container or label. S56- Dispose of this material and its container at hazardous or special waste collection point. HMIS (U.S.A.): Health Hazard: 3 Fire Hazard: 2 Reactivity: 0 National Fire Protection Association (U.S.A.): Personal Protection: j Health: 4 Flammability: 2 Reactivity: 0 Specific hazard: Protective Equipment: Gloves. Synthetic apron. Vapor and dust respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator when ventilation is inadequate. Splash goggles MITCON Consultancy and Engineering Services Ltd., Pune 251

252 Material Safety Data Sheet (MSDS): Polyethylene Glycol 400 Product Name: Polyethylene Glycol Chemical Formula: H (OCH2CH2)nOH Composition: Section 1: Chemical Identification Section 2: Composition and Information on Ingredients Name CAS # % by Weight Polyethylene glycol Toxicological Data on Ingredients: Polyethylene glycol 400: ORAL (LD50): Acute: mg/kg [Rat] mg/kg [Mouse] mg/kg [Rabbit]. DERMAL (LD50): Acute: >20000 mg/kg [Rabbit]. VAPOR (LC50): Acute: >13 ppm 8 hours [Rat]. Section 3: Hazards Identification Potential Acute Health Effects: Slightly hazardous in case of skin contact (irritant, permeator), of eye contact (irritant), of ingestion, of inhalation. Potential Chronic Health Effects: CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS: Not available. TERATOGENIC EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Not available. Repeated or prolonged exposure is not known to aggravate medical condition Section 4: First Aid Measures Eye Contact: Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Cold water may be used. Get medical attention if irritation occurs. Skin Contact: Wash with soap and water. Cover the irritated skin with an emollient. Get medical attention if irritation develops. Cold water may be used. Serious Skin Contact: Not available Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention. Serious Inhalation: Not available. Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to an unconscious person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a MITCON Consultancy and Engineering Services Ltd., Pune 252

253 collar, tie, belt or waistband. Serious Ingestion: Not available. Section 5: Fire and Explosion Data Flammability of the Product: May be combustible at high temperature. Auto-Ignition Temperature: Not available. Flash Points: CLOSED CUP: C (440 F). OPEN CUP: C (448 F). Flammable Limits: Not available. Products of Combustion: These products are carbon oxides (CO, CO2). Fire Hazards in Presence of Various Substances: Slightly flammable to flammable in presence of heat. Non-flammable in presence of shocks Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of mechanical impact: Not available. Slightly explosive in presence of open flames and sparks: Not available. Fire Fighting Media and Instructions: SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do not use water jet. Special Remarks on Fire Hazards: Not available. Special Remarks on Explosion Hazards: Not available. Section 6: Accidental Release Measures Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste disposal container. Finish cleaning by spreading water on the contaminated surface and dispose of according to local and regional authority requirements Large Spill: Absorb with an inert material and put the spilled material in an appropriate waste disposal. Finish cleaning by spreading water on the contaminated surface and allow to evacuate through the sanitary system. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities. Section 7: Handling and Storage Precautions: Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing. If ingested, seek medical advice MITCON Consultancy and Engineering Services Ltd., Pune 253

254 immediately and show the container or the label. Keep away from incompatibles such as oxidizing agents, acids, alkalis. Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area. Section 8: Exposure Controls/Personal Protection Engineering Controls: Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value. Ensure that eyewash stations and safety showers are proximal to the workstation location. Personal Protection: Safety glasses. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self-contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product. Exposure Limits: TWA: 10 (mg/m3) from AIHA Consult local authorities for acceptable exposure limits. Section 9: Physical and Chemical Properties Physical state and appearance: Liquid. (Viscous) Odor: Odorless Taste: Not available Molecular Weight: 400 ( )g/mole Color: Clear ph (1% soln/water): Not applicable. Boiling Point: Not available. Melting Point: 4 C (39.2 F) - 6 C. Critical Temperature: Not available. Specific Gravity: (Water = 1) Vapor Pressure: Not available. Vapor Density: Not available. Volatility: Not available. Odor Threshold: Not available. Water/Oil Dist. Coeff.: Not available. Ionicity (in Water): Not available. Dispersion Properties: See solubility in water. MITCON Consultancy and Engineering Services Ltd., Pune 254

255 Solubility: Soluble in cold water, hot water. Readily soluble in aromatic hydrocarbons. Slightly soluble in aliphatic hydrocarbons Stability: The product is stable. Instability Temperature: Not available. Section 10: Stability and Reactivity Data Conditions of Instability: Incompatible materials (strong oxiders), excess heat. Incompatibility with various substances: Reactive with oxidizing agents, acids, alkalis. Corrosivity: Non-corrosive in presence of glass. Special Remarks on Reactivity: Slightly Hygroscopic Special Remarks on Corrosivity: Not available. Polymerization: Will not occur Section 11: Toxicological Information Routes of Entry: Absorbed through skin. Eye contact. Toxicity to Animals: Acute oral toxicity (LD50): mg/kg [Rabbit]. Acute dermal toxicity (LD50): >20000 mg/kg [Rabbit]. Acute toxicity of the vapor (LC50): >13 8 hours [Rat]. Chronic Effects on Humans: Not available. Other Toxic Effects on Humans: Slightly hazardous in case of skin contact (irritant, permeator), of ingestion, of inhalation. Special Remarks on Toxicity to Animals: Not available. Special Remarks on Chronic Effects on Humans: Not available. Special Remarks on other Toxic Effects on Humans: Acute Potential Health Effects: Skin: It may cause mild skin irritation. It may be absorbed through the skin, but absorption of harmful amounts is unlikely. Eyes: It may cause mild eye irritation. Inhalation: At room temperature, exposure to vapor is minimal due to low volatility. A single exposure is not likely to be hazardous. Ingestion: Low toxicity. Harmful effects not anticipated from swallowing small amounts. Ingestion of larger amounts may cause nausea, vomiting, cardiac arrhythmias, hypotension. It may also affect the urinary system. Prolonged or repeated ingestion may affect metabolism (weight loss). Section 12: Ecological Information MITCON Consultancy and Engineering Services Ltd., Pune 255

256 Ecotoxicity: Ecotoxicity in water (LC50): >5000 mg/l 24 hours [Goldfish]. BOD5 and COD: Not available Products of Biodegradation: Possibly hazardous short term degradation products are not likely. However, long term degradation products may arise. Toxicity of the Products of Biodegradation: The products of degradation are less toxic than the product itself. Special Remarks on the Products of Biodegradation: Not available. Section 13: Disposal Considerations Waste Disposal: Waste must be disposed of in accordance with federal, state and local environmental control regulations. Section 14: Transport Information DOT Classification: Not a DOT controlled material (United States). Identification: Not applicable. Special Provisions for Transport: Not applicable. Section 15: Other Regulatory Information Federal and State Regulations: Minnesota: Polyethylene glycol 400 TSCA 8(b) inventory: Polyethylene glycol 400 Other Regulations: Not Available Other Classifications: WHMIS (Canada): Not controlled under WHMIS (Canada). DSCL (EEC): Not Available S24/25- Avoid contact with skin and eyes. HMIS (U.S.A.): Health Hazard: 1 Fire Hazard: 1 Reactivity: 0 Personal Protection: g National Fire Protection Association (U.S.A.): Health: 0 Flammability: 1 Reactivity: 0 Specific hazard: Protective Equipment: Gloves. Lab coat. Dust respirator. Be sure to use an approved/certified respirator or equivalent. Safety glasses MITCON Consultancy and Engineering Services Ltd., Pune 256

257 Material Safety Data Sheet (MSDS): Rosin (Gum) Product Name: Rosin (Gum) Composition: Section 1: Chemical Identification Section 2: Composition and Information on Ingredients Name CAS # % by Weight Rosin (Gum) Toxicological Data on Ingredients: Rosin (Gum) LD50: Not available. LC50: Not available. Section 3: Hazards Identification Potential Acute Health Effects: Hazardous in case of ingestion. Slightly hazardous in case of skin contact (irritant), of eye contact (irritant), of inhalation. Potential Chronic Health Effects: Slightly hazardous in case of skin contact (sensitizer). CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS: Not available. TERATOGENIC EFFECTS: Not available. DEVELOPMENTAL TOXICITY: Not available. The substance may be toxic to lungs, skin. Repeated or prolonged exposure to the substance can produce target organs damage. Section 4: First Aid Measures Eye Contact: Check for and remove any contact lenses. In case of contact, immediately flush eyes with plenty of water for at least 15 minutes. Get medical attention if irritation occurs. Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical attention. Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Seek medical attention. Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Get medical attention. Serious Inhalation: Not available. Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. MITCON Consultancy and Engineering Services Ltd., Pune 257

258 Never give anything by mouth to an unconscious person. If large quantities of this material are swallowed, call a physician immediately. Loosen tight clothing such as a collar, tie, belt or waistband. Serious Ingestion: Not available. Section 5: Fire and Explosion Data Flammability of the Product: May be combustible at high temperature. Auto-Ignition Temperature: Not available. Flash Points: CLOSED CUP: 187 C (368.6 F). OPEN CUP: 205 C (401 F). Flammable Limits: Not available. Products of Combustion: Not available. Fire Hazards in Presence of Various Substances: Slightly flammable to flammable in presence of heat. Non-flammable in presence of shocks Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of mechanical impact: Not available. Slightly explosive in presence of open flames and sparks. Fire Fighting Media and Instructions: SMALL FIRE: Use DRY chemical powder. LARGE FIRE: Use water spray, fog or foam. Do not use water jet. Special Remarks on Fire Hazards: Thermal decomposition products include formaldehyde, acetone, methanol, aldehydes, carbon dioxide, carbon monoxide, methane, ethane, and acids. Special Remarks on Explosion Hazards: Fine dust dispersed in air in sufficient concentrations, and in the presence of an ignition source is a potential dust explosion hazard. Section 6: Accidental Release Measures Small Spill: Use appropriate tools to put the spilled solid in a convenient waste disposal container. Finish cleaning by spreading water on the contaminated surface and dispose of according to local and regional authority requirements Large Spill: Use a shovel to put the material into a convenient waste disposal container. Finish cleaning by spreading water on the contaminated surface and allow to evacuate through the sanitary system. Be careful that the product is not present at a concentration level above TLV. Check TLV on the MSDS and with local authorities. MITCON Consultancy and Engineering Services Ltd., Pune 258

259 Section 7: Handling and Storage Precautions: Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material. Do not breathe dust. Keep away from incompatibles such as oxidizing agents. Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area. Section 8: Exposure Controls/Personal Protection Engineering Controls: Use process enclosures, local exhaust ventilation, or other engineering controls to keep airborne levels below recommended exposure limits. If user operations generate dust, fume or mist, use ventilation to keep exposure to airborne contaminants below the exposure limit. Personal Protection: Safety glasses. Lab coat. Dust respirator. Be sure to use an approved/certified respirator or equivalent. Gloves. Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Dust respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the product. Suggested protective clothing might not be sufficient; consult a specialist BEFORE handling this product. Exposure Limits: Rosin Core Solder Pyroloysis Products: TWA: 0.1 (mg/m3) (as formaldehyde) from ACGIH (TLV) [United States] Gum Rosin (solid): TWA: 10 (mg/m3) Consult local authorities for acceptable exposure limits. Section 9: Physical and Chemical Properties Physical state and appearance: Solid. Odor: Not available. Taste: Not available. Molecular Weight: Not available. Color: Yellow. (Light.) ph (1% soln/water): Not applicable. Specific Gravity: 25 deg. C (Water = 1) Dispersion Properties: See solubility in water, diethyl ether. Stability: Stable Section 10: Stability and Reactivity Data MITCON Consultancy and Engineering Services Ltd., Pune 259

260 Incompatibility with various substances: Reactive with oxidizing agents. Corrosivity : Non-corrosive in presence of glass. Special Remarks on Reactivity: Not available. Special Remarks on Corrosivity: Not available. Polymerization: Will not occur. Routes of Entry: Inhalation. Ingestion. Section 11: Toxicological Information Toxicity to Animals: LD50: Not available. LC50: Not available. Chronic Effects on Humans: May cause damage to the following organs: lungs, skin. Other Toxic Effects on Humans: Hazardous in case of ingestion. Slightly hazardous in case of skin contact (irritant), of inhalation Special Remarks on Toxicity to Animals: Not available. Special Remarks on Chronic Effects on Humans: Not available. Special Remarks on other Toxic Effects on Humans: Acute Potential Health Effects: Rosin has two types of hazards - from the rosin itself, and from the thermal decomposition products. The thermal decomposition products (aka Rosin Core Solder Pyrolysis Products) include formaldehyde, acetone, methanol, aldehydes, carbon dioxide, carbon monoxide, methane, ethane, and acids. The handling of the rosin in the solid state is expected to be a low hazard. It may cause skin, eyes, and respiratory tract irritation. Ingestion may cause digestion tract irritation. The thermal decomposition products of Rosin (Rosin core solder pyrolysis products) can be irritating to the eyes, nose, throat in acute exposure. Chronic Potential Health Effects: Skin: Repeated or prolonged skin contact with the rosin itself can cause contact dermatitis, an allergic reaction. It can also cause eczema. Inhalation: Repeated or prolonged inhalation of the rosin dust or smoke can cause asthma, an allergic reaction. Rosin core solder pyrolysis products can be sensitizing, and exposures should be reduced to as low as possible Ecotoxicity: NA BOD5 and COD: NA Section 12: Ecological Information Toxicity of the Products of Biodegradation: Not available. Special Remarks on the Products of Biodegradation: Not available. MITCON Consultancy and Engineering Services Ltd., Pune 260

261 Section 13: Disposal Considerations Waste Disposal: Waste must be disposed of in accordance with federal, state and local environmental control regulations. Section 14: Transport Information DOT Classification: Not a DOT controlled material (United States). Identification: Not applicable. Special Provisions for Transport: Not applicable. Section 15: Other Regulatory Information Federal and State Regulations: Minnesota: Rosin (Gum) TSCA 8(b) inventory: Rosin (Gum) Other Regulations: OSHA: Hazardous by definition of Hazard Communication Standard (29 CFR ). EINECS: This product is on the European Inventory of Existing Commercial Chemical Substances. Other Classifications: WHMIS (Canada): CLASS D-2A: Material causing other toxic effects (VERY TOXIC). DSCL (EEC): R43- May cause sensitization by skin contact. S24- Avoid contact with skin. S37- Wear suitable gloves HMIS (U.S.A.): Health Hazard: 2 Fire Hazard: 1 Reactivity: 1 Personal Protection: E National Fire Protection Association (U.S.A.): Health: 2 Flammability: 1 Reactivity: 0 Equipment: Gloves. Lab coat. Dust respirator. Be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator when ventilation is inadequate. Safety glasses MITCON Consultancy and Engineering Services Ltd., Pune 261

262 Annexure No. 10 Minutes of Public Hearing _English MITCON Consultancy and Engineering Services Ltd., Pune 262

263 MITCON Consultancy and Engineering Services Ltd., Pune 263

264 MITCON Consultancy and Engineering Services Ltd., Pune 264

265 MITCON Consultancy and Engineering Services Ltd., Pune 265

266 MITCON Consultancy and Engineering Services Ltd., Pune 266

267 MITCON Consultancy and Engineering Services Ltd., Pune 267

268 Annexure No. 11 Consent to Establish MITCON Consultancy and Engineering Services Ltd., Pune 268

269 MITCON Consultancy and Engineering Services Ltd., Pune 269

270 MITCON Consultancy and Engineering Services Ltd., Pune 270

271 MITCON Consultancy and Engineering Services Ltd., Pune 271

272 Annexure No. 12 Consent to Operate MITCON Consultancy and Engineering Services Ltd., Pune 272

273 MITCON Consultancy and Engineering Services Ltd., Pune 273

274 MITCON Consultancy and Engineering Services Ltd., Pune 274

275 Annexure No. 13 Environmental Audit Statement MITCON Consultancy and Engineering Services Ltd., Pune 275

276 MITCON Consultancy and Engineering Services Ltd., Pune 276