Awarded TOR No.IA-J-11011/266/2018-IA-II(I) Goverment of India … · 2019-06-17 · ix. Traffic...

No.IA-J-11011/266/2018-IA-II(I)

Goverment of India

Minister of Enviroment,Forest and Climate Change

Impact Assessment Division

***

Indira Paryavaran Bhavan,

Vayu Wing,3rd Floor,Aliganj,

Jor Bagh Road,New Delhi-110003

06 Apr 2019

To,

M/s MADURA CARBON INDIA LTD

1, Janki Centre, Off-Veera Desai Road, Andheri west, Mumbai-400053,

Mumbai City-400053

Maharashtra

Tel.No.022-26730890; Email:[email protected]

Sir/Madam,

This has reference to the proposal submitted in the Ministry of Environment, Forest

and Climate Change to prescribe the Terms of Reference (TOR) for undertaking detailed EIA

study for the purpose of obtaining Environmental Clearance in accordance with the provisions of

the EIA Notification, 2006. For this purpose, the proponent had submitted online information in the

prescribed format (Form-1 ) along with a Pre-feasibility Report. The details of the proposal are

given below:

1. Proposal No.: IA/GJ/IND2/76156/2018

2. Name of the Proposal:Proposed project by manufacturing of Carbon

Black

3. Category of the Proposal: Industrial Projects - 2

4. Project/Activity applied for: 5(e) Petrochemical based processing

(processes other than cracking &

5. Date of submission for TOR: 05 Mar 2019

In this regard, under the provisions of the EIA Notification 2006 as amended, the Standard TOR

for the purpose of preparing environment impact assessment report and environment

management plan for obtaining prior environment clearance is prescribed with public consultation

as follows:

Awarded TOR

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

5(e): STANDARD TERMS OF REFERENCE FOR CONDUCTINGENVIRONMENT IMPACT ASSESSMENT STUDY FORPETROCHEMICAL BASED PROCESSING (PROCESSES OTHERTHAN CRACKING & REFORMATION AND NOT COVERED UNDERTHE COMPLEXES)PROJECTS AND INFORMATION TO BEINCLUDED IN EIA/EMP REPORT

A. STANDARD TERMS OF REFERENCE

1) Executive Summary

2) Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3) Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether adequate landis available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water balance diagram,man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow sheet(quantative) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

e. Copy of all the Environmental Clearance(s) including Amendments thereto obtained forthe project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of thelatest Monitoring Report of the Regional Office of the Ministry of Environment and Forestsas per circular dated 30th May, 2012 on the status of compliance of conditions stipulatedin all the existing environmental clearances including Amendments shall be provided. Inaddition, status of compliance of Consent to Operate for the ongoing Iexisting operationof the project from SPCB shall be attached with the EIA-EMP report.

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FORPROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

f. In case the existing project has not obtained environmental clearance, reasons for nottaking EC under the provisions of the EIA Notification 1994 and/or EIA Notification2006 shall be provided. Copies of Consent to Establish/No Objection Certificate andConsent to Operate (in case of units operating prior to EIA Notification 2006, CTE andCTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliancereport to the conditions of consents from the SPCB shall be submitted.

4) Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justificationfor selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scaleon an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plantarea, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layoutof Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, showphotographs of plantation/greenbelt, in particular.

viii. Landuse break-up of total land of the project site (identified and acquired), government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (notrequired for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall beincorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 kmradius of any major river, peak and lean season river discharge as well as flood occurrencefrequency based on peak rainfall data of the past 30 years. Details of Flood Level of theproject site and maximum Flood Level of the river shall also be provided. (mega green fieldprojects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition processand expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5) Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, andrecommendations of the State Forest Department. (if applicable)


ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineatingthe forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along with lateststatus shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves,Migratory Corridors of Wild Animals, the project proponent shall submit the map dulyauthenticated by Chief Wildlife Warden showing these features vis-à-vis the project locationand the recommendations or comments of the Chief Wildlife Warden-thereon

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the StateGovernment for conservation of Schedule I fauna, if any exists in the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to theStanding Committee of the National Board for Wildlife

6) Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and directionand rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and otherparameters relevant to the project shall be collected. The monitoring stations shall be basedCPCB guidelines and take into account the pre-dominant wind direction, population zoneand sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in theNAQQM Notification of Nov. 2009 along with - min., max., average and 98% values foreach of the AAQ parameters from data of all AAQ stations should be provided as an annexureto the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, ifyes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials,additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study areashall be given with special reference to rare, endemic and endangered species. If Schedule-


I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared andfurnished.

xi. Socio-economic status of the study area.

7) Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based onsite-specific meteorological features. In case the project is located on a hilly terrain, theAQIP Modelling shall be done using inputs of the specific terrain characteristics fordetermining the potential impacts of the project on the AAQ. Cumulative impact of all sourcesof emissions (including transportation) on the AAQ of the area shall be assessed. Details ofthe model used and the input data used for modelling shall also be provided. The air qualitycontours shall be plotted on a location map showing the location of project site, habitationnearby, sensitive receptors, if any.

ii. Water Quality modelling - in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding environmentshall be assessed and provided. In this regard, options for transport of raw materials andfinished products and wastes (large quantities) by rail or rail-cum road transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled and reusedfor different purposes shall be included. Complete scheme of effluent treatment. Characteristicsof untreated and treated effluent to meet the prescribed standards of discharge under E(P)Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management. Copiesof MOU regarding utilization of solid and hazardous waste in cement plant shall also beincluded. EMP shall include the concept of waste-minimization, recycle/reuse/recovertechniques, Energy conservation, and natural resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailedplan of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shallbe included. The green belt shall be around the project boundary and a scheme for greeningof the roads used for the project shall also be incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvestrainwater from the roof tops and storm water drains to recharge the ground water and also touse for the various activities at the project site to conserve fresh water and reduce the waterrequirement from other sources.


xi. Total capital cost and recurring cost/annum for environmental pollution control measuresshall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency ManagementPlan including Risk Assessment and damage control. Disaster management plan should belinked with District Disaster Management Plan.

8) Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casualworkers

ii. Details of exposure specific health status evaluation of worker. If the workers' health is beingevaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far& Near vision, colour vision and any other ocular defect) ECG, during pre placement andperiodical examinations give the details of the same. Details regarding last month analyzeddata of above mentioned parameters as per age, sex, duration of exposure and departmentwise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazardsand whether they are within Permissible Exposure level (PEL). If these are not within PEL,what measures the company has adopted to keep them within PEL so that health of the workerscan be preserved,

iv. Annual report of heath status of workers with special reference to Occupational Health andSafety.

9) Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board ofDirectors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures to bringinto focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal with theenvironmental issues and for ensuring compliance with the environmental clearanceconditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of environmentalnorms to the Board of Directors of the company and / or shareholders or stakeholders atlarge? This reporting mechanism shall be detailed in the EIA report

10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to thelabour force during construction as well as to the casual workers including truck drivers duringoperation phase.


11) Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the EnterpriseSocial Commitment based on Public Hearing issues and item-wise details along with timebound action plan shall be included. Socio-economic development activities need to beelaborated upon.

12) Any litigation pending against the project and/or any direction/order passed by any Court of Lawagainst the project, if so, details thereof shall also be included. Has the unit received any noticeunder the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and WaterActs? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13) 'A tabular chart with index for point wise compliance of above TOR.

B. SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FORPETROCHEMICAL BASED PROCESSING (PROCESSES OTHER THANCRACKING & REFORMATION AND NOT COVERED UNDER THECOMPLEXES)

1. Details on requirement of raw material,itssource of supplyandstorageattheplant.

2. Completeprocessflowdiagram for all products with material balance.

3. Details on requirement of auxiliary chemicals, solvents, catalysts, reactors and utilities to supportthe unit processes.

4. Brief description of equipments for various process.

5. Details of proposed source- specific pollution control schemes and equipments to meet the nationalstandards.

6. Detailson VOC emission control system from vents, stacks, fugitive emissions and flare management,etc.

7. Details on proposed LDAR protocol.

8. Ambient air quality should include hydrocarbon (methane and non methane), VOCand VCM (ifapplicable).

9. Risk Assessment & Disaster Management Plan

— Identification of hazards

— Consequence Analysis

— Measures for mitigation of risk.

***

3/5/2019 Report Part 1

http://environmentclearance.nic.in/auth/FORM_A_PDF.aspx?cat_id=IA/GJ/IND2/76156/2018 1/9

APPENDIX I(See Paragraph-6)

FORM 1

Note : If space provided against any parameter is inadequate, Kindly upload supporting document under'Additional Attachments if any' at the last part of the Form1. Please note that all such Annexures mustbe part of single pdf document.

(I) Basic InformationS.No. Item Details

Whether it is a violation case and applicationis being submitted under Notification No.S.O.804(E) dated 14.03.2017 ?

No

1.

Name of the Project/s Proposed project by manufacturing of Carbon BlackBrief summary of project Annexure-Brief summary of projectProposal Number IA/GJ/IND2/76156/2018Project Cost (in lacs) 41500

2.S. No. in the schedule 5(e) Petrochemical based processing (processes other than

cracking & Project Sector Industrial Projects - 2

3.Proposed capacity/area/length/tonnage to behandled/command area/lease area/numberor wells to be drilled

Carbon Black - 230000 TPA & Power Generation - 45 MW ha.

4. New/Expansion/Modernization New

5. Existing Capacity/Area etc. 0 ha.

6. Category of project i.e. 'A' or 'B' A

7. Does it attract the general condition? If yes,please specify No

8. Does it attract the specific condition? If yes,please specify No

9.Location of the project Survey no. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318,

Village:Karanj, Taluka: Umbergaon, Dist. ValsadShape of the project land Block (Polygon)

Uploaded GPS file Annexure-GPS file Uploaded copy of survey of India Toposheet Annexure-Survey of india toposheetPlot/Survey/Khasra No. Survey no. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318Town / Village KaranjState of the project Gujarat

Details of State of the project

S.no State Name District Name Tehsil Name

(1.) Gujarat Valsad Umbergaon

10. Nearest railway station along with distance Bhilad, 5.85 km

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_182210270BV5AVTS3Annexure-BriefSummaryofProject.pdf

http://environmentclearance.nic.in/auth/Testmap1.aspx?type=ca&fname=05_Mar_2019_201551137XFGA10QGkml.kml&proposalno=IA/GJ/IND2/76156/2018

http://environmentclearance.nic.in/download.aspx?files=writereaddata/Online/TOR/05_Mar_2019_201551137XFGA10QGkml.kml

http://environmentclearance.nic.in/writereaddata/Online/TOR/10_Aug_2018_164853980D2IYQ1FBAnnexure-SurveyofIndiaToposheet.pdf



in kmsNearest airport along with distance in kms Daman, 14.5 km

11. Nearest Town/City/District Headquartersalong with distance in kms Sarigam , 2.59 km

12.Village Panchayats, Zila Parishad, MuncipalCorporation, Local body (Complete postaladdress with telephone nos. to be given)

Village Panchayat, Karanj

13. Name of the Applicant Vipan

14. Registered Address Survey No. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318,Village- Karanj, Taluka- Umbergaon, Dist.- Valsad, Gujarat

15.

Address for correspondance:Name of the Company MADURA CARBON INDIA LTDName of the Applicant VipanDesignation (Owner/ Partner/ CEO) CMDPin code 400053E-mail [email protected] No. 022-26730890Fax No. 022-Copy of documents in support of thecompetence/authority of the person makingthis application to make application on behalfof the User Agency .

Annexure-Uploaded Copy of documents in support of thecompetence/authority

16. Details of Alternative Sites examined, if any.Location of these sites should be shown on atoposheet

Yes

Uploaded details Annexure-Uploaded details

17. Whether part of Interlinked projects? No

18. Whether separate application of Interlinkedproject has been submitted? N/A

19. If Yes, MoEF file number N/ADate of submission N/A

20. If No, Reason N/A

21. Whether the proposal involves Approval/ Clearance under: if yes, details of the same and theirstatus to be given(i) Whether the proposal involvesapproval/clearance under the Forest(Conservation) Act,1980?

No

(ii) Whether the proposal involvesapproval/clearance under the wildlife(Protection) Act,1972?

No

(iii) Whether the proposal involvesapproval/clearance under the C.R.Znotification, 2011?

No

22. Whether there is any GovernmentOrder/Policy relevant/relating to the site? No

23. Whether any Forest Land Involved? NoArea of Forest land Involved (hectares) N/A

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_201551157XFGA10QGAnnexure-Copyofdocumentsinsupportofcompetentauthority.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/10_Aug_2018_171814670RYZN7P2IAnnexure-SiteAlternatives.pdf



24. Whether there is any litigation pendingagainst the project and/or land in which theproject is proposed to be set up?

No

(a) Name of the Court N/A(b) Name of the Sub court N/A(c) Case No. N/A(d) Orders/directions of the court, if any andrelevance with the proposed project N/A

(II) Activity

1 Construction, operation or decommissioning of the Project involving actions, which will causephysical changes in the locality (topography, land use, changes in water bodies, etc.)

S.NoInformation/Checklist confirmation Yes/No

Details there of (with approximatequantities/rates, wherever possible) with

source of information data

1.1

Permanent or temporary change in land use,land cover or topography including increasein intensity of land use (with respect to localland use plan)

No The proposed land in NA land.

1.2 Clearance of existing land, vegetation andbuildings? No Proposed project will be established in the vacant land.

1.3 Creation of new land uses? No The proposed land in NA land.

1.4 Pre-construction investigations e.g. borehouses, soil testing? No --

1.5 Construction works? Yes New plant will be constructed for proposed expansionproject.

1.6 Demolition works? No Not applicable

1.7 Temporary sites used for construction worksor housing of construction workers? Yes Temporary housing will be provided to construction

workers.

1.8Above ground buildings, structures orearthworks including linear structures, cutand fill or excavations and fill or excavations

Yes

The construction work will include required buildings formanufacturing facilities, utilities including additional ETP,admin building and internal roads for proper movement.A thick greenbelt will be developed around the peripheryof the plant area.

1.9 Underground works including mining ortunnelling? No Not applicable

1.10 Reclamation works? No Not applicable

1.11 Dredging? No Not applicable

1.12 Offshore structures? No Not applicable

1.13 Production and manufacturing processes? Yes Please refer Project Pre-Feasibility report. Chapter-3,Section 3.4, pg no. 6-9.

1.14 Facilities for storage of goods or materials? Yes Storage facilities will be provided for proposed rawmaterials & products

1.15 Facilities for treatment or disposal of solidwaste or liquid effluents?

Yes • Please refer Project Pre-Feasibility report. Chapter-3,Section 3.8, pg no. 13-15 for disposal of liquid effluent.



• Please refer Project Pre-Feasibility report. Chapter-3,Section 3.10, pg no. 15 for disposal of solid waste.

1.16 Facilities for long term housing ofoperational workers? No Local persons/ contractors will be employed.

1.17 New road, rail or sea traffic duringconstruction or operation? No Not applicable

1.18

New road, rail, air water borne or othertransport infrastructure including new oraltered routes and stations, ports, airportsetc?

No Not applicable

1.19Closure or diversion of existing transportroutes or infrastructure leading to changesin traffic movements?

No Not applicable

1.20 New or diverted transmission lines orpipelines? No Not applicable

1.21Impoundment, damming, culverting,realignment or other changes to thehydrology of watercourses or aquifers?

No Not applicable

1.22 Stream crossings? No Not applicable

1.23 Abstraction or transfers of water fromground or surface waters? Yes Water requirement will be met from Damanganga Canal

Distri.

1.24 Changes in water bodies or the land surfaceaffecting drainage or run-off? No Not applicable

1.25 Transport of personnel or materials forconstruction, operation or decommissioning? Yes

We shall hire personnel from local / nearby area. Thesources of raw materials and machinery for operationwill vary based on market driven forces which will betransported via road.

1.26 Long-term dismantling or decommissioningor restoration works? No Not applicable

1.27Ongoing activity during decommissioningwhich could have an impact on theenvironment?

No Not applicable

1.28 Influx of people to an area in eithertemporarily or permanently? No Not applicable

1.29 Introduction of alien species? No Not applicable

1.30 Loss of native species or genetic diversity? No Not applicable

1.31 Any other actions? No Not applicable

2 Use of Natural resources for construction or operation of the Project (such as land, water, materialsor energy, especially any resources which are non-renewable or in short supply):


Details thereof (with approximatequantities/rates, wherever possible) with


2.1 Land especially undeveloped or agriculturalland (ha) No N.A. Land

2.2 Water (expected source & competing users) Yes Usage: 3220 kL/day (Fresh – 2890 + Recycle - 330)



unit: KLD Source: Damanganga Canal Distributory. Please referProject Pre-Feasibility Report– Chapter No. 3, Sectionno. 3.7.5, Page No. 11-12.

2.3 Minerals (MT) No Not Applicable.

2.4 Construction material – stone, aggregates,sand / soil (expected source – MT) Yes Construction materials such as stone, aggregates, and

sand will be sourced from Govt. approved vendors.

2.5 Forests and timber (source – MT) No Not Applicable.

2.6Energy including electricity and fuels(source, competing users) Unit: fuel(MT),energy (MW)

YesTotal power requirement will be 13 MW. Please referProject Pre-Feasibility Report– Chapter No. 3, Sectionno. 3.7.4, Page No. 12 for fuel details.

2.7 Any other natural resources (use appropriatestandard units) No Not Applicable.

3Use, storage, transport, handling or production of substances or materials, which could be harmfulto human health or the environment or raise concerns about actual or perceived risks to humanhealth




3.1

Use of substances or materials, which arehazardous (as per MSIHC rules) to humanhealth or the environment (flora, fauna, andwater supplies

No Please refer Project Pre-Feasibility Report– Chapter No.3, Section no. 3.6, Page No. 11 for raw material details.

3.2Changes in occurrence of disease or affectdisease vectors (e.g. insect or water bornediseases)

No Not Applicable.

3.3 Affect the welfare of people e.g. by changingliving conditions? Yes The project will create direct & indirect employment

3.4Vulnerable groups of people who could beaffected by the project e.g. hospital patients,children, the elderly etc.

No --

3.5 Any other causes No --

4 Production of solid wastes during construction or operation or decommissioning (MT/month)




4.1 Spoil, overburden or mine wastes No Not applicable

4.2 Municipal waste (domestic and orcommercial wastes) Yes

The commercial waste generated from administrationbuilding would be disposed through sale to scrapvendors.

4.3 Hazardous wastes (as per Hazardous WasteManagement Rules) Yes Please refer Project Prefeasibility Report. Chapter-3,

Table no. 3.10, pg no. 16.

4.4 Other industrial process wastes Yes Same as above



4.5 Surplus product No Not applicable

4.6 Sewage sludge or other sludge from effluenttreatment Yes

Domestic waste water will be generated and it will betreated in STP. ETP sludge will be generated from ETP &it will be disposed to TSDF.

4.7 Construction or demolition wastes Yes Construction waste will be minimized to the extentpossible or will be disposed as per C&D rules, 2016.

4.8 Redundant machinery or equipment No Not applicable

4.9 Contaminated soils or other materials Yes Precautionary measures will be taken to avoid anycontamination of the soil

4.10 Agricultural wastes No Not applicable

4.11 Other solid wastes No Not applicable

5 Release of pollutants or any hazardous, toxic or noxious substances to air(Kg/hr)




5.1 Emissions from combustion of fossil fuelsfrom stationary or mobile sources Yes Please refer Project Prefeasibility Report. Chapter-3,

Section no. 3.9.2, pg no. 15-16.

5.2 Emissions from production processes Yes Please refer Project Prefeasibility Report. Chapter-3,Section no. 3.9.1, pg no. 15.

5.3 Emissions from materials handling includingstorage or transport Yes

Possibility of fugitive emissions has been considered andappropriate mitigation methods have been considered asdeemed necessary. Please refer Project PrefeasibilityReport. Chapter-3, Section No. – 3.9.3, pg no. 15.

5.4 Emissions from construction activitiesincluding plant and equipment Yes

Dust/fugitive emission which are predominant will bemitigated by use of water sprays to keep it under

control. All construction equipment will be maintained toensure lowest possible emissions.

5.5Dust or odours from handling of materialsincluding construction materials, sewage andwaste

YesFor construction materials, de-dusting measures likespraying of water, encasement of dumpers, barriersaround the construction area will be done.

5.6 Emissions from incineration of waste No Not Applicable.

5.7 Emissions from burning of waste in open air(e.g. slash materials, construction debris) No Not Applicable.

5.8 Emissions from any other sources No Not Applicable.

6 Generation of Noise and Vibration, and Emissions of Light and Heat:




6.1 From operation of equipment e.g. engines,ventilation plant, crushers

Yes Please refer Project Prefeasibility Report. Chapter-3,Section No. 3.11, pg no. 16-17.



6.2 From industrial or similar processes Yes PPE’s will be provided to reduce noise exposure toworkers wherever required.

6.3 From construction or demolition Yes Appropriate noise mitigation measures will beimplemented and PPE’s will be provided.

6.4 From blasting or piling No Not Applicable.

6.5 From construction or operational traffic Yes Slight increase in noise levels due to the vehicularmovement is expected during material transportation.

6.6 From lighting or cooling systems No Not Applicable.

6.7 From any other sources No Not Applicable.

7 Risks of contamination of land or water from releases of pollutants into the ground or into sewers,surface waters, groundwater, coastal waters or the sea:




7.1 From handling, storage, use or spillage ofhazardous materials Yes Materials will be stored in designated area and all proper

steps will be followed to prevent accidents.

7.2From discharge of sewage or other effluentsto water or the land (expected mode andplace of discharge)

NoPlease refer Project Prefeasibility Report. Chapter-3,Section No. 3.8, pg no. 13-15 for discharge of domesticeffluent & industrial effluent.

7.3 By deposition of pollutants emitted to air intothe land or into water Yes Emissions of PM, SO2 and NOx from use of fuels.

7.4 From any other sources No Not Applicable.

7.5Is there a risk of long term build up ofpollutants in the environment from thesesources?

No Not anticipated

8 Risk of accidents during construction or operation of the Project, which could affect human healthor the environment




8.1From explosions, spillages, fires etc fromstorage, handling, use or production ofhazardous substances

Yes Materials will be stored safely and all precautions will betaken to prevent accidents.

8.2 From any other causes No Not Applicable.

8.3

Could the project be affected by naturaldisasters causing environmental damage(e.g. floods, earthquakes, landslides,cloudburst etc)?

YesHowever, the project is located in Seismic zone III,which is a moderate zone. No occurrences of floods,landslides, cloudburst etc.

9Factors which should be considered (such as consequential development) which could lead toenvironmental effects or the potential for cumulative impacts with other existing or plannedactivities in the locality



S.No Information/Checklist confirmation Yes/No Details thereof (with approximatequantities/rates, wherever possible) with


9.1

Lead to development of supporting utilities,ancillary development or developmentstimulated by the project which could haveimpact on the environment e.g.:

Supporting infrastructure (roads, powersupply,waste or waste water treatment,etc.)housing developmentextractive industriessupply industriesOther

NoSupporting infrastructure like roads, power grids alreadyexist. Individual Effluent treatment plant alreadyinstalled. Local labour will be utilized.

9.2 Lead to after-use of the site, which couldhave an impact on the environment No Not Applicable.

9.3 Set a precedent for later developments No Not Applicable.

9.4Have cumulative effects due to proximity toother existing or planned projectswith similar effects

No --

(III) Environmental Sensitivity

S.No Areas Name/Identity Aerial distance (within 15km.) Proposedproject location boundary

1

Areas protected under internationalconventions, national or local legislation for their ecological, landscape, cultural or otherrelated value

No Not applicable

2

Areas which are important or sensitive forecological reasons - Wetlands, watercoursesor other water bodies, coastal zone,biospheres, mountains, forests

Yes River Damanganga ˜ 6.66 km. (NE) River Darotha˜ 5.00 km (E)

3

Areas used by protected, important orsensitive species of flora or fauna forbreeding, nesting, foraging, resting, overwintering, migration

No Not applicable

4 Inland, coastal, marine or undergroundwaters Yes River Damanganga ˜ 6.66 km. (NE) River Darotha

˜ 5.00 km (E)

5 State, National boundaries No UT of Daman & Diu ˜ 7.65 km (NE)

6Routes or facilities used by the public foraccess to recreation or other tourist, pilgrimareas

No Not applicable

7 Defence installations No Not applicable

8 Densely populated or built-up area Yes Village Sarigam ˜ 2.59 km (SE)

9Areas occupied by sensitive man-made landuses (hospitals, schools, places of worship,community facilities)

Yes Primary schools , hospitals & colleges in 5 to 10km area



10 Areas containing important, high quality or scarceresources.(ground water resources,surfaceresources,forestry,agriculture,fisheries,tourism,minerals)

Yes River Damanganga ˜ 6.66 km. (NE) RiverDarotha ˜ 5.00 km (E) Reserved forest ˜Within 10 km radial periphery

11Areas already subjected to pollution orenvironmental damage.(those where existinglegal environmental standards are exceeded)

No Not applicable

12

Areas susceptible to natural hazard whichcould cause the project to presentenvironmental problems (earthquakes,subsidence, landslides, erosion, flooding orextreme or adverse climatic conditions)similar effects

Yes Seismic Zone-III (Moderate)

(IV) Proposed Terms of Reference for EIA studies

1 Uploaded Proposed TOR File Annexure-TOR file

2 Uploaded scanned copy of coveringletter Annexure-scanned copy of covering letter

3 Uploaded Pre-Feasibility report(PFR) Annexure-PFR

4 Uploaded additional attachments(onlysingle pdf file) Annexure-Additional attachments

(V) UndertakingI hereby give undertaking that the data and information given in the application and enclosures aretrue to be best of my knowledge and belief and I am aware that if any part of the data andinformation found to be false or misleading at any stage, the project will be rejected and clearancegiven, if any to the project will be revoked at our risk and cost.

V.(i)

Name of Applicant VipanDesignation CMDName of Company (Applicant Nameshould not be given here) MADURA CARBON INDIA LTD

Address Survey No. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318,Village- Karanj, Taluka- Umbergaon, Dist.- Valsad, Gujarat

Print

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_204106937O9MOUJR6Annexure-ProposedTOR.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_2041069430QPVIHSCCoveringletter.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_2102271501A5AJXPLAnnexure-PrefeasibilityReport.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Mar_2019_2041069907UAI7B9RAnnexure-AdditionalAttachment.pdf

BRIEF SUMMARY OF PROJECT

PARTICULARS DETAILS Name of the unit M/s. Madura Carbon India Ltd.

Occupier Mr. Vipan Kalra (CMD)

Products S. No. Name of the Product Quantity

1. Carbon Black 230000 TPA

2. Thermal Power plant 45 MW

Location Survey no. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318, Village: Karanj, Taluka: Umbergaon, Dist.: Valsad, Gujarat

Nature of project

Proposed project by manufacturing of Carbon Black (2,30,000 TPA) & Power Generation (45 MW)

RESOURCES

Resource type Requirement Source

Land 94499 m2 NA land

Water Total: 3220 kL/day (Fresh – 2890 kL/day + Recycle – 330 kL/day)

Domestic: 110 kL/day

Gardening: 175 kL/day

Industrial: 2935 kL/day

Damanganga Canal Distry.

Power 13 MW TPP & DGVCL

Fuel CBFS (Carbon black feed stock)/ LDO/

Imported Local market

POLLUTION POTENTIAL & MITIGATION MEASURES

Parameter Potential Mitigation

Wastewater Total: 347 kL/day



The total domestic wastewater generated will be 100 kL/day which will be treated in STP. Treated water from STP will be used for gardening.

Wastewater generated from industrial activities will be 247 kL/day, from which 30 kL/day will be treated in ETP and the treated wastewater will be recyled for plant washing. Remaining water like boiler blowdown, CT blowdown & DM plant reject will be directed to RO. Permeate from RO will be recycled for plant uses.

Reject from RO-1 & RO-2 @84 kL/day will be evaporated in MEE. MEE condensate will be collected in plant water tank, from where it will be recycled for plant uses. Hence, there will be no discharge of treated effluent outside premises.

Air Emissions

Emission from utility stack

Boiler – 92 TPH x 2 nos.

Dryer – one no.

DG set – 1000 kVA x one no.

The utility emissions are likely to occur from boiler, DG set & dryer due to proposed project.

Mixed Gas/ Tail Gas from Carbon Black Unit will be used as fuel in boiler & dryer. LDO/ HSD will be used as fuel in DG Set.

PARTICULARS DETAILS

Adequate chimney height will be provided.

Bag filter will be used as APCM

Good housekeeping will be maintained in the plant.

Hazardous & solid waste

Sr. No

Type of Waste

Category Quantity (T/Annum)

1 ETP Sludge + MEE Salt

35.3 200

2 Oily Cotton Waste

28.1 2

3 Spent used Oil

5.1 100

4 Discarded Bags

33.1 5

The Hazardous wastes will be handled, stored & transported as per CPCB/ MoEF Guidelines

ETP sludge will be disposed to TSDF site

Oily cotton waste will be incinerated at CHWIF.

Spent used oil & Discarded bags will be sold to registered re-processor..

Noise Proposed operations

Inside the plant: <85 dB(A) The major sources of noise generation

in plant area will be equipment, boilers and pumps

DG sets will be provided with accoustic enclosure

Regular maintenance will be carried out.

Ear plugs and Ear muffs will be provided to the workers in Utility Section

Turbine will be equipped with sound proof chamber.

PROJECT PRE FEASIBILITY REPORT

On

Proposed Project

For

Manufacturing of Carbon Black

At

Survey No. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318,

Village: Karanj, Taluka: Umbergaon

Dist.: Valsad, Gujarat

Project proponent

Madura Carbon India Ltd.

i

CONTENTS

Chapters

S. No. Particulars Page No.

1 EXECUTIVE SUMMARY 1-2

2 INTRODUCTION OF THE PROJECT 3-4

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 3

2.1.1 IDENTIFICATION OF THE PROJECT 3

2.1.2 PROJECT PROPONENT 3

2.1.3 NATURE OF THE PROJECT 3

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP 4

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION 4

2.1.6 EXPORT POSSIBILITY 4

2.1.7 DOMESTIC / EXPORT MARKETS 4

2.1.8 EMPLOYMENT GENERATION DUE TO PROPOSED PROJECT 4

3 PROJECT DISCRIPTION 5-17

3.1 TYPE & LOCATION OF PROJECT 5

3.1.1 TYPE 5

3.1.2 LOCATION 5

3.2 DETAILS OF ALTERNATIVE SITE 6

3.3 SIZE & MAGNITUDE OF OPERATION 6

3.4 PROJECT DISCRIPTION WITH PROCESS DETAILS 6

3.4.1 CARBON BLACK 6

3.4.1.1 PROCESS DESCRIPTION 6

3.4.1.2 PROCESS FLOW DIAGRAM 8

3.4.1.3 MATERIAL BALANCE 9

3.4.2 THERMAL POWER PLANT 9

3.4.2.1 PROCESS FLOW DIAGRAM 9

3.4.2.2 PROCESS DESCRIPTION 9

3.5 RAW MATERIAL FOR FINISHED PRODUCTS 10

3.6 STORAGE & TRANSPORT OF RAW MATERIAL 10

3.7 RESOURCE OPTIMIZATION & AVAILABILITY 10

3.7.1 LAND & BUILDING REQUIREMENT 10

3.7.2 EQUIPMENT 12

3.7.3 POWER REQUIREMENT 12

3.7.4 FUEL REQUIREMENT 12

3.7.5 WATER REQUIREMENT 12

3.7.6 MAN-POWER REQUIREMENT 13

3.8 QUANTITY OF WASTE TO BE GENERATED 13

3.8.1 WASTE WATER GENERATION & MANAGEMENT 13

3.8.1.1 WASTE WATER TREATMENT AND DISPOSAL 15

3.9 AIR EMISSIONS & CONTROL 15

3.9.1 PROCESS EMISSION 15

3.9.2 UTILITY EMISSION 15

3.9.3 FUGITIVE EMISSION 16

3.10 HAZARDOUS/NON-HAZARDOUS WASTES MANAGEMENT 16

3.11 NOISE CONTROL 16

3.12 HEALTH AND SAFETY MEASURES 17

3.13 ENVIRONMENTAL HEALTH & SAFETY CELL 17

4 SITE ANALYSIS 18-20

4.1 CONNECTIVITY 18

4.2 LAND FORM, LAND USE & LAND OWNERSHIP 18

ii

S. No. Particulars Page No.

4.3 TOPOGRAPHY 18

4.4 SALIENT FEATURES 18

4.5 EXISTING INFRASTRUCTURE 18

4.6 SOIL CLASSIFICATION 18

4.7 CLIMATE & METEROLOGY 18

4.7.1 TEMPERATURE 19

4.7.2 HUMIDITY 19

4.7.3 RAINFALL 19

4.7.4 WIND PATTERN 19

4.8 SOCIAL INFRASTRUCTURE 20

4.8.1 EDUCATIONAL FACILITIES 20

4.8.2 MEDICAL FACILITIES 20

5 PLANNING BRIEF 21-22

5.1 PLANNING CONCEPT 21

5.2 DEMOGRAPHIC DETAILS 21

5.3 AREA STATEMENT 21

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) 21

5.5 AMENITIES/FACILITIES 21

5.5.1 DRINKING WATER FACILITIES 21

5.5.2 POWER SUPPLY FACILITIES 21

5.5.3 COMMUNICATION & BANKING FACILITIES 22

5.5.4 TRANSPORT FACILITIES 22

6 PROPOSED INFRASTRUCTURE 23-23

6.1 INDUSTRIAL AREA 23

6.2 RESIDENTIAL AREA 23

6.3 GREENBELT AREA 23

6.4 SOCIAL INFRASTRUCTURE 23

6.5 CONNECTIVITY 23

6.6 DRINKING WATER MANAGEMENT 23

6.7 SEWERAGE SYSTEM 23

6.8 INDUSTRIAL WASTE MANAGEMENT 23

6.9 SOLID WASTE MANAGEMENT 23

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY 23

7 REHABILITATION & RESETTLEMENT ( R& R) PLAN 24-24

7.1 POLICY TO BE ADOPTED 24

8 PROJECT SCHEDULE & COST ESTIMATES 25-25

8.1 TIME SCHEDULE OF THE PROJECT 25

8.2 ESTIMATED PROJECT COST 25

9 ANALYSIS OF PROPOSAL 26-26

9.1 FINANCIAL & SOCIAL BENEFITS 26

iii

List of Tables

Table No. Topic Page No.

1.1 PROJECT SUMMARY 1

2.1 LIST OF PRODUCTS 3

2.2 LIST OF DIRECTORES 3

3.1 MATERIAL BALANCE FOR CARBON BLACK 9

3.2 LIST OF RAW MATERIALS 10

3.3 DETAILS OF STORAGE OF MATERIALS 10

3.4 AREA STATEMENT 10

3.5 LIST OF PROPOSED EQUIPMENT 12

3.6 TOTAL WATER CONSUMPTION (KL/DAY) 13

3.7 MAN-POWER REQUIREMENT 13

3.8 CATEGORY-WISE WASTEWATER GENERATION 13

3.9 ETP UNIT 15

3.10 DETAILS OF PROCESS VENTS 15

3.11 DETAILS OF UTILITY EMISSIONS 16

3.12 HAZARDOUS AND SOLID WASTE GENERATION, MANAGEMENT AND DISPOSAL

16

4.1 SALIENT FEATURES OF THE PROJECT SITE 18

4.2 SUMMARY METEOROLOGICAL DATA AT NEAREST IMD STATION- DAHANU

18

5.1 DISTRIBUTION OF POPULATION 21

5.2 AREA STATTEMENT CHART 22

8.1 TOTAL CAPITAL COST PROJECTION 25

8.2 RECURRING COST PROVISION FOR EHS 25

List of Figures

Sr. No. Description Page No.

3.1 SATELLITE IMAGE OF THE PROJECT SITE 5

3.2 LAYOUT OF PROJECT SITE 11

3.3 WATER BALANCE DIAGRAM (KL/DAY) 14

3.4 ORGANOGRAM OF PROPOSED EHS CELL 17

Project Pre-feasibility report

Project: Proposed project for manufacturing of Carbon Black 1 | P a g e

CHAPTER – 1

EXECUTIVE SUMMARY

The project is summarized in the below table:

Table 1.1: Project Summary

PARTICULARS DETAILS Name of the unit M/s. Madura Carbon India Ltd.

Occupier Mr. Vipan Kalra (CMD)

Products S. No. Name of the Product Quantity


2. Thermal Power plant 45 MW

Location Survey no. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318, Village: Karanj, Taluka: Umbergaon, Dist.: Valsad, Gujarat

Nature of project

Proposed project by manufacturing of Carbon Black (2,30,000 TPA) & Power Generation (45 MW)

RESOURCES

Resource type Requirement Source

Land 94499 m2 NA land

Water Total: 3220 kL/day (Fresh – 2890 kL/day + Recycle – 330 kL/day)


Gardening: 175 kL/day


Damanganga Canal Distry.

Power 13 MW TPP & DGVCL

Fuel CBFS (Carbon black feed stock)/ LDO/

Imported Local market

POLLUTION POTENTIAL & MITIGATION MEASURES

Parameter Potential Mitigation

Wastewater Total: 347 kL/day




Wastewater generated from industrial activities will be 247 kL/day, from which 30 kL/day will be treated in ETP and the treated wastewater will be recyled for plant washing. Remaining water like boiler blowdown, CT blowdown & DM plant reject will be directed to RO. Permeate from RO will be recycled for plant uses.

Reject from RO-1 & RO-2 @84 kL/day will be evaporated in MEE. MEE condensate will be collected in plant water tank, from where it will be recycled for plant uses. Hence, there will be no discharge of treated effluent outside premises.

Air Emissions

Emission from utility stack

Boiler – 92 TPH x 2 nos.

Dryer – one no.

DG set – 1000 kVA x one no.

The utility emissions are likely to occur from boiler, DG set & dryer due to proposed project.

Mixed Gas/ Tail Gas from Carbon



PARTICULARS DETAILS

Black Unit will be used as fuel in boiler & dryer. LDO/ HSD will be used as fuel in DG Set.

Adequate chimney height will be provided.

Bag filter will be used as APCM

Good housekeeping will be maintained in the plant.

Hazardous & solid waste

Sr. No

Type of Waste

Category Quantity (T/Annum)

1 ETP Sludge + MEE Salt

35.3 200

2 Oily Cotton Waste

28.1 2

3 Spent used Oil

5.1 100

4 Discarded Bags

33.1 5

The Hazardous wastes will be handled, stored & transported as per CPCB/ MoEF Guidelines

ETP sludge will be disposed to TSDF site

Oily cotton waste will be incinerated at CHWIF.

Spent used oil & Discarded bags will be sold to registered re-processor..

Noise Proposed operations

Inside the plant: <85 dB(A) The major sources of noise

generation in plant area will be equipment, boilers and pumps

DG sets will be provided with accoustic enclosure

Regular maintenance will be carried out.

Ear plugs and Ear muffs will be provided to the workers in Utility Section

Turbine will be equipped with sound proof chamber.



CHAPTER – 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT

Madura Carbon India Limited, is to be located at survey no. 3705, 3708, 3719, 3725, 3738, 4108,

4110, 4318,, Village: Karanj, Taluka: Umbergaon, Dist. Valsad.

The list of products is provided in table 2.1.

Table 2.1: List of Product

S. No. Name of the Product Quantity


2. Thermal Power Plant (TPP) 45 MW

2.1.2 PROJECT PROPONENT

The list of directors for Madura Industrial Textiles Ltd. is given below –

Table 2.2: List of Directors

S. No. Name of Directors Residential Address

1. Mr. Vipan Ramnath Kalra 21 A/ 21B, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

2. Mr. Anil Radheshyam Kalra 12 A/ 12B, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

3. Mr. Sanil Radheshyam Kalra 11 A/ 11B, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

4. Mrs. Promilla Raman Kalra 51, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

5. Mr. Gautam Kalra 21 A/ 21B, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

6. Mr. Rishi Kalra 51, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

7. Mr. Varun Kalra 12 A/ 12B, Royal Accord III, Lokhandwala Complex, Andheri (W), Mumbai – 400 053

2.1.3 NATURE OF THE PROJECT

The proposed project falls under item no. 5(e) i.e. “Petroleum products and petrochemical based

processing such as production of carbon black and electrode grade graphite (processes other

than cracking and reformation and not covered under the complexes)”and under the category

A as it is not located in GIDC, as per the EIA notification, 14 September 2006 (& amendments).

Moreover, the project of power generation of 45 MW falls under item no. 1(d) i.e. Thermal Power

Plants and under the category B (<50 MW and 5 MW (all other fuels except biomass and municipal

solid non-hazardous waste) as per the EIA notification, 14 September 2006 (& amendments).



2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP

Carbon black is reinforcing material & filler in rubber products. There is severe crisis, due to lack of

availability of Carbon Black. Currently, the carbon black demand, including that of tyre manufacturers,

is at 12.85 lakh tonnes while the country’s manufacturing capacity is at 9.5 lakh tonnes.

Apparently the Carbon Black manufacturers were not aware that imposition of Anti-Dumping on

Chinese Tyres would create a huge spike in demand for Carbon Black. Further, global supply

constraints were causing increase in prices of Carbon Black.

Due to acute shortage and spiraling prices of Carbon Black in last months, all Rubber goods

manufacturers are struggling to maintain their production and supply.

The industry are in a dilemma, that there is a serious shortfall leading to non-availability of Carbon

Black, along with spiraling prices, and many of the small & medium industries are on the verge of

closing down. Hence, this project will bridge for demand & gap.

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION

At present the carbon black from international market is not available at competitive prices. Increase

in production can fill the gap.

2.1.6 EXPORT POSSIBILITY

The domestic production in the current scenario will have a competitive edge over the international

prices which will help in bridging the gap of demand and supply for export.

2.1.7 DOMESTIC / EXPORT MARKETS

The rubber industry is growing domestically fast. There has been no increase in capacity of carbon

black in last few years. The gap between demand and supply is increasing consistently.

2.1.8 EMPLOYMENT GENERATION DUE TO PROJECT

The proposed project will provide direct employment opportunity to 385 persons. The man-power

required for the proposed project will be employed locally from the nearby areas.



CHAPTER – 3

PROJECT DESCRIPTION

3.1 TYPE & LOCATION OF THE PROJECT

3.1.1 TYPE

The proposed project is the new project for manufacturing of Carbon Black @230000TPA along with

power generation @45 MW for utilization of the off-gas generated from the process.

3.1.2 LOCATION

The project is to be located at survey no. 3705, 3708, 3719, 3725, 3738, 4108, 4110, 4318, Village:

Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest town to the project site is Sarigam.

Sarigam GIDC is a cluster of profuse large-scale, medium scale and small-scale industries, engaged

in manufacturing of various products, bulk drugs, organic pigments, Organic and Inorganic Chemicals,

The site is approximately 10-15 km from Vapi - a well-known industrial town. It is situated on the

banks of Damanganga River in southern Gujarat, India. The satellite image of the project site is

provided in figure 3.1 and the site layout plan of the project site in figure 3.2.

Figure 3.1: Satellite image of the project site

(Source: Google Earth)



3.2 DETAILS OF THE ALTERNATIVE SITE

Many sites was opted for plant but due to non-availability of such large area in GIDC Sarigam and

due to vicinity of MCIL’s sister concern unit, the particular site is selected.

Sister concern unit of Madura Carbon India Ltd. is close to the GIDC Sarigam.

Due to Sarigam industrial area, required skilled man power will be available easily.

Location of site is approximately 6 km from NH8, which is very suitable for transportation of

raw materials & finished products from proposed site.

Based on the above reasons, this location is most suitable for the proposed project.

3.3 SIZE & MAGNITUDE OF OPERATION

The proponent plans to establish a new project for manufacturing of carbon black 230000 T/annum

along with a Thermal Power Plant of 45 MW for utilization of the off-gas generated from the process.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

3.4.1 CARBON BLACK

3.4.1.1 PROCESS DESCRIPTION

In this project, oil furnace black process will be used for producing carbon black.

Heavy aromatic oils of petroleum oil refinery or coal tar distillation units are used as main feedstock.

The furnace is basically a specially designed refractory lined horizontal steel vessel having different

segments like combustion zone, venture zone, reaction zone, quench zone & evaporation cum

conveying sections.

Combustion zone or hot flue gas generating section: Secondary feed stock e.g., natural gas or

fuel oil or sometimes the main feed stock in proper ratio with preheated air is introduced in this section

to produce hot gas. Adiabatic flame Temperature is maintained nearly 1900oC-20000C.

Venture section: Preheated main feed stock (aromatic oil) is introduced in atomized form under

controlled conditions on the hot gas where liquid oil vaporizes. Velocity of gas stream maintained ~

2000 FPM.

Reaction section: Pyrolysis of oil takes place in the vapour phase to form microscopic carbon

particles. The basic reaction is dehydrogenation.

Hydrocarbon + Oxygen + Energy Carbon Black + Carbon Monoxide + Hydrogen +Carbon

Dioxide + Water etc.

Quench zone: the reaction rate is controlled by using water sprays.

Evaporation cum conveying sections: Water vaporizes in this zone. After all, carbon particles along

with combustion gas convey to the next downstream equipment.

Furnace black process consists of several downstream sections after reactor e.g., Heat recovery

sections, filtration sections, conveying section, beading & drying sections and finished product

transportation & storage, ware housing, pulling & dispatch section. The process which is selected for

this project is illustrated bellow.

Heat recovery sections: Hot reactor combustion gas along with carbon black particles are cooled

down by air. Preheated air is used in combustion section of reactor. Relatively cooled combustion gas

along with carbon black again passes through oil preheater to preheat main feed stock. After passing



through oil preheater, the combustion gas has sufficient sensible heat. In most of the energy efficient

carbon black plants have in line sensible heat recovery (waste heat recovery) boilers. Saturated

Steam is generated from waste heat recovery boilers which are used for steam tracing, & other

equipment heating purposes.

Main Filtration section: High filtration efficiency pulsejet bag filter modules (main filter) will be used

for filtering carbon black from carbon black laden gas (process gas). A specially designed

agglomerator unit will be installed before bag house to agglomerate carbon black particles. This

agglomerator unit will not only enhance filtration efficiency, it will also enhance life of the filter cloth.

Agglomerated carbon black particles will be deposited on the outer surface of the cloth and

compressed air pulse will release carbon black particles from bags. A sequential timer will be used in

pulsing system. Gas will pass through bags and finally it will be passed through a common header

which is connected to other downstream unit e.g., dryer combustor etc. Carbon black dislodge from

the bags will be collected in hopper. Accumulated carbon black powder will be transported to the

conveying system via rotary air locks.

Conveying system: It consists of drop box of rotary air locks, suction conveying ducts, conveying

fans, conveying fan discharge ducts, conveying bag filter, conveying bag filter vent scrubber & a

surge tank at the bottom of conveying bag house. All the rotary air locks placed at the bottom of main

bag filter modules will be discharging carbon black particles to a common duct which is connected

with a pneumatic conveying fan. In this process, air will be used for conveying carbon black. All

carbon black particles from the rotary air locks discharge will be picked up by air and conveyed to

another bag filter called conveying bag filter by conveying fans. Air from the bag filter can be vented to

atmosphere after passing through venture scrubber. Carbon black collected from bag filter will be

stored in surge tank to remove adsorbed air from carbon black.

Beading & drying system: The beading & drying system consists of pelletizer, polisher, rotary dryer

with insulated jacket and combustor as hot gas generator and purge gas filter. Fluffy carbon black,

water and molasses solution (used as binder) mixed in pelletizer to form beads. Polishers are also

used for making uniform diameter beads or pallets. This polisher also helps to reduce fines in carbon

black. After polishing the pallets, the wet pallets pass through indirect heating rotary dryer to remove

water from pallets. Hot gas required for drying is generated in refractory lined combustor. Process

combustion gas from main bag filter is used as fuel in combustor. Vapour generated inside dryer

along with fines is sucked by purge gas fan and filter through purge gas filter. Carbon black from

purge gas filter is connected in main conveying line and vapour is vented to atmosphere after passing

through venture scrubber.

Product transportation & storage: This section consists of elevator, screw conveyors magnetic

separator, rotary screen, storage silos, off spec silo & de dusting bag house. Dried carbon black is

transported to final storage silos by above mentioned material handling equipment.

Warehouse, pulling & dispatch section: Depending on customer requirement, the granular carbon

black is packed in 25 kg paper bag or in 1 m PP jumbo bulk bags.

Capacity & Conversion: The capacity of the reactor is mainly dependent on air rate and oil BMCI.

The reactor is designed for an air rate of 13500 nm3/hr. An output of 78 T/day/reactor for N-330 grade

will be produced based on 130 BMCI oil. The yield for N-330 grade will be 56% on total oil. The

production capacity & yield will be different for other grades.

Energy efficiency: The system will be designed to extract heat up to 80%. Approximately 7.5 T

steam/ton of carbon black will be generated. The major part of steam will be used for sale to other

process industry and some will be used for power generation at a later stage in co-generation system.

The power consumption for the process would be 350 KwH/T of carbon black.

Emission: The system would be designed to control particulate matter well within the GPCB & CPCB

norms, around 50-60 mg/Nm3. The stacks for gas emission would be designed for height and velocity



to comply with the GPCB & CPCB laid norms to ensure minimum impact from NOx and SOx

emissions. The pollution control system will be designed to ensure zero discharge from the plant.

3.4.1.2 PROCESS FLOW DIAGRAM



3.4.1.3 MATERIAL BALANCE

Table 3.1: Material balance for carbon black

S. No.

Quantity(T/T) Remarks

Raw material Input/T of Product

Output/T of Product

1 Carbon Black Feed Stock as raw material

1.71 Carbon black 1 --

2 CBFS / LDO as secondary fuel

0.15 Off gas 3.2647 Off gas will be used for dryer combustor and boiler for power plant

3 Molasses 0.0045 -- -- --

4 Potassium Nitrate 0.0002 -- -- --

5 Water 2.4 -- -- --

Total 4.2647 -- 4.2647 --

3.4.2 THERMAL POWER PLANT

3.4.2.1 PROCESS FLOW DIAGRAM

3.4.2.2 PROCESS DESCRIPTION

Low Btu off gases generated in the manufacturing process of CB in the reactor section and separated

from accompanying CB particles in PBC section are collected in the off gas header. In spite of their

low calorific value, these gases can be utilized to recover their calorific value in a specially designed

boiler system to generate high pressure steam and in a specially designed dryer combustor furnace to

supply the heat energy requirements in the pelletizing and drying section.

The quantum of high pressure steam which can be generated through burning of these off gases

meets the plant requirement of steam and power.

So the benefit of above scheme is being fully taken care of by installing the following system:

1. High pressure boiler system

2. Turbo Generators

3. Power Export

High pressure boiler which can be run on a combination of off gases generates high pressure

superheated steam at 88atm& 525OC. This high-pressure steam is used to generate sufficient power

required for plant consumption through turbo generator system.



3.5 RAW MATERIAL FOR FINISHED PRODUCTS

The raw materials for the proposed range of products will be indigenously available and will be also

imported. The product-wise raw-material consumption is given in Table 3.1.

Table 3.2: List of Raw Materials

Name of product Raw material Requirement

(T/T of product)

Carbon Black Carbon Black Feed Stock as raw material 1.71

CBFS / secondary fuel 0.15

Molasses 0.0045

Potassium Nitrate 0.0002

3.6 STORAGE & TRANSPORT OF RAW MATERIAL

The details of storage and transportation of raw materials & products are given in Table 3.2 below:

Table 3.3: Details of storage of materials

Name

Source Means of transportation

Means of storage (No. of containers & size)

Storage Location

Max. Qty. to be stored at any given time i.e. storage capacity

Product

Carbon Black -- Trucks Bulk Bag & Paper Bag

Ware House

3000 T

Raw Materials

Carbon Black Feed

Stock as raw material

Import & Indian Market

Tankers 6 x 5000 kL (Tanks) 6 x 1250 kL (Tanks)

Tank Farm 20000 kL

Molasses Local Tankers 60 kL (1 Tank)

Tank 60 kL

Potassium Nitrate Local Truck 50 kg Bags In Store 3 T

3.7 RESOURCE OPTIMIZATION & AVAILABILITY

The major resources for the proposed project will be plant & machinery, raw-materials, power, fuel,

water, man-power, etc.

3.7.1 Land & Building Requirement

Total plot area for proposed project will be 94499 m2. The 63AA permission for proposed land is

obtained.

Table 3.4: Area Statement

Sr. No. Description Area (m2)

1. Built-up Area 30307

2. Open Area (Roads, Drains, Space) 40755

3. Greenbelt Area 23437

Total 94499



Figure 3.2: Layout of Project Site



3.7.2 Equipment

Based on process necessity, list of the proposed equipment’s and machinery is given in table 3.5.

Table 3.5: List of Proposed Equipment

Sr. No. Equipment Capacity x Size

1 Oil Tank Storage and Unloading / Charging System (Day Tanks)

6 Nos X 5000 kL + 6Nos X 1250 kL

2 Process Air Blowers 8 Nos.

3 Air Compressors (Normal & HP) 5 X 2 Nos.

4 KNO3 Dosing System 2 X 2 Nos.

5 Reactors 8 Nos.

6 Air Preheater 8 Nos.

7 Oil Preheater 8 Nos.

8 In-line Boiler 6 Nos. X 3 TPH 2 Nos. X 3.5 TPH

9 Quench Tower 4 Nos.

10 Agglomerator 4 Nos.

11 Process Bag Collectors 13 X 2 Modules

12 Pneumatic Conveying System 2 X 2 Nos.

13 Dense Tank Bag Collectors 4 X 2 Nos.

14 Dense (Surge) Tank 3 X 2 Nos.

15 Pelletizing System 4 Nos.

16 Dryer System along with Vapor Bag Collectors 2 Nos. X 240 TPD

17 Dryer System along with Vapor Bag Collectors 2 Nos. X 180 TPD

18 Fugitive Dedusting bag filter Systems Lot

19 Elevator 4 Nos.

20 Screw Conveyors & Product Distribution System Bulk

21 Product Silos 2 X 14 Nos. X 150 T

22 Packing Machines with Rerun System including Palletizer Lot

23 Water pumps & Storage Tanks Lot

24 Electrical Distribution System Lot

25 Instrumentation System Lot

26 Civil, Structure, Warehouse, Non-Plant Building & Roads Lot

27 Piping System Lot

28 Fire Fighting System Lot

29 Cooling tower 2400 m3/day

30 Power Plant with Tail Gas Boiler & Air Cooled Condensers 2 X 16 MW + 2 X 6.5 MW Boiler (2 Nos. X 92 TPH)

31 Reject silos 2 X 2 Nos.

3.7.3 Power Requirement

For proposed project 13 MW power will be required. The total requirement will be fulfilled by in-house

TPP & Dakshin Gujarat Vij Co. Ltd. (DGVCL).

3.7.4 Fuel Requirement

LDO /FO/CBFS will be used as auxiliary fuel for startup in boilers & dryer. HSD will be used as fuel in D.G. Set. CBFS will be Imported & sourced from Indian Market also. LDO, HSD & FO sources from local market. Tail gas will be generated during carbon black manufacturing process.

3.7.5 Water Requirement

Necessary water requirement for the proposed project will be fulfilled from Damanganga Canal Distry. Total water requirement for proposed project will be 3220 kL/day. From which 2890 kL/day will be fresh water & remaining 330 kL/day will be recycled water



The category wise bifurcation of the water requirement is given in the Water Balance Data in Table 3.6.

Table 3.6: Total Water Consumption (kL/day)

S. No. Particulars Requirement (kL/day)

Fresh Recycle Total

1. Domestic 0 110 110

2. Gardening 0 175 175

3. Industrial

4. Process 1500 0 1500

5. Cooling Tower (Make-up) 84 16 100

6. Boiler (Make-up) 220 0 220

7. DM plant Regeneration 16 0 16

8. Plant Washing 1 29 30

9. Dryer 1040 0 1040

10. RO Reject 29 0 29

Sub-Total: Industrial 2890 45 2935

Grand Total 2890 330 3220

3.7.6 Man-Power Requirement

The man-power required for the project will be employed locally from the nearby areas. Skilled as well as unskilled labor will be employed for the project. Due to proposed project, 385 persons will be employed. The man-power requirement for the proposed expansion project is provided in table 3.7.

Table 3.7: Man-power requirement

S. No. Types of Employee Numbers of Manpower

1 Managerial 15

2 Supervisory 60

3 Skilled 100

4 Unskilled 160

5 Others 50

Total 385

3.8 QUANTITY OF WASTE TO BE GENERATED

3.8.1 WASTE WATER GENERATION & MANAGEMENT

The category wise bifurcation of the wastewater generation is given in table 3.8.

Table 3.8: Category-wise Wastewater Generation

Particulars Wastewater Generation (in kl/day)

Domestic 100

Industrial

Process 0

Cooling tower blow down 60

Plant Washing 30

Boiler blow down 107

DM plant Regeneration 16

RO Reject 34

Sub – Total: Industrial 247

Grand Total 347



Figure 3.3: Water Balance Diagram (kL/day)



3.8.1.1 WASTE WATER TREATMENT AND DISPOSAL


Industrial waste water is Categorized in two section as following:

1. Effluent from Plant wash: It is further sub categorized in two section which are:

i) Effluent containing free floating oil particles from tank farm & reactor section of plant passes through Oil Skimmer to reduce the oil content and then passes through Pressure sand bed filter before being recycled back either for plant wash.

ii) Effluent containing Suspended carbon black particle from Bag filter, Silo & Packing area passes through Pressure sand bed filter before being recycled back for plant wash.

2. Effluent from DM Unit, boiler & CT blowdown: Boiler blowdown, CT blowdown & DM plant reject will be directed to Neutralization cum collection pit before being sent to RO. Permeate from RO will be recycled back for plant uses

3. Reject from RO-1 & RO-2: Reject from RO-1 & RO-2 will be directed to MEE for evaporation. Recovered condensate will be recycled back for plant uses.

Table 3.8: ETP units

Sr. No. Unit Quantity (Nos.)

Capacity

1 Oil & Grease Trap 1 30 kL/day

2 Collection cum Neutralization Tank 1 100 kL/day

3 Multi Effect Evaporator 1 100 kL/day

3.9 AIR EMISSION AND CONTROL

3.9.1 PROCESS EMISSIONS

The details of process vents are provided in table 3.9.

Table 3.9: Details of process vents

3.9.2 UTILITY EMISSIONS

The details of utility stacks are provided in table 3.10.

Sr. No Stack attached to

No of Stack

Height (m)

Emissions Air Pollution Control Measures Attached

1 Process Bag Collector

4 35 Normally closed Stack (Normally closed)

2 Dense Bag collector

4 35 PM Bag Filter/Adequate stack Height

3 Vapor Bag collector

4 35 PM, SO2, NOx (as NO2)

Bag Filter /Adequate stack Height



Table 3.10: Details of utility emissions

Sr. No

Locations Fuel Stack Height

Emissions

1 Boiler – 2 nos. Capacity: 92 TPH

Mixed Gas/ Tail Gas from CB Unit/ Fuel Oil

100 m PM, SO2, NOx

2 DG Set - stand by – one no. Capacity: 1000 kVA

LDO /HSD 35 m PM, SO2, NOx

3 Dryer – 4 nos. Mixed Gas/ Tail Gas from CB Unit / Fuel Oil

Common stack -2 nos. 60 m (each)

PM, SO2, NOx

3.9.3 FUGITIVE EMISSIONS

The fugitive emissions are likely to occur from following sources:

Equipment leaks like pumps, pipelines, reactors etc.

Process venting

Evaporation losses

Accident and equipment failures

Following measures will be adopted to control fugitive emissions:

All vessels used in the manufacturing areas shall be closed and the transfer of material within

the plant shall be through pipelines.

A Leak detection and repair (LDAR) will be prepared and implement.

Pumps will have double mechanical seal to prevent any chance of emission.

Detectors will be installed near all potential sources of leakage to detect and provide alarm in

case of any leakage.

3.10 HAZARDOUS AND NON-HAZARDOUS WASTE MANAGEMENT

The detail of the hazardous waste and its management is given below in table 3.11.

Table 3.11: Hazardous and Solid waste generation, management and disposal

Sr. No Type of Waste Category Quantity (T/Annum)

Disposal

1 ETP Sludge+ MEE Salt 35.3 200 Disposal at TDSF

2 Oily Cotton Waste 28.1 2 Incineration at CHWIF

3 Spent used Oil 5.1 100 Sale to reprocessor

4 Discarded Bags 33.1 5 Sale to reprocessor

3.11 NOISE CONTROL

Noise are likely to generate in the process area mainly from operation of heavy duty motors, blowers

and compressors in various sections of the manufacturing plant area. The compressors and blowers’

operation in utility area also result in high noise generation viz. above 85 dB (A). Due to power plant

operations, noise pollution is arising from turbine, compressor, generator room, etc. Also there will no

generation of noise from soot blowing. The control measures to be taken for reduction in noise levels

are as below:

The plant and equipment will be specified and designed with a view to minimize noise

pollution.

The major noise producing equipment such as turbine will be provided with acoustic

enclosure.

Sturdy foundation & pads to all the noise generating equipment will be provided.

Ear Plugs and Ear muffs will be provided to the workers in Utility Section.



Regular maintenance of equipment’s will be carried out to minimize the noise generated by

the equipment’s.

Regular monitoring of noise levels at all areas will be carried out.

Greenbelt will be maintained.

3.12 HEALTH AND SAFETY MEASURES

In proposed operations, following safety measures to be implemented:

Fire hydrant system will be provided.

Automatic hydrant sprinkler system will be provided.

Fire extinguishers of proper type & size will be placed in complete plant as per rules & regulations.

All other area of the plant will be fully ventilated for human comfort.

First Aid facility will be provided at all the necessary locations.

Personal protective gears and equipment’s will be provided to the employees.

Health check-ups will be organized at regular intervals.

Safety Training will be provided to the employees timely.

Manual call bells in case of emergency will be provided.

Emergency Control Room with emergency sirens will be established.

3.13 ENVIRONMENTAL HEALTH & SAFETY CELL

The environment cell will also be responsible to plan, implement and monitor the environmental

performance of the proposed project.

Figure 3.4: Organogram of proposed EHS Cell



CHAPTER – 4

SITE ANALYSIS

4.1 CONNECTIVITY

The proposed project is located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest town to the project site is Sarigam which is situated at about 2.59 kms from project site. The site is approximately 6.1 km from National Highway. The land and infrastructure is already available and the raw material is easily available through the easy transport via road connectivity. The nearest Railway station is Bhilad railway station which is approximately 5.85 km from the project site.

4.2 LANDFORM, LAND USE & LAND OWNERSHIP

The land is currently vacant land purchased from private owners. The total land area is 235239 m2.

4.3 TOPOGRAPHY

The topography of land is flat.

4.4 SALIENT FEATURES

Table 4.1: Salient Features of the Project Site

S. No. Particulars Details

1 Village Karanj

2 Taluka/ Tehsil Umbergaon

3 District Valsad

4 Nearest Town Sarigam ≈ 2.59 km (SE)

5 Approx. Geographical positioning Lat.: 20°18'7.41"N, Long: 72°50'20.66"E

6 Nearest Water body River Damanganga ≈ 6.66 km. (NE) River Darotha ≈ 5.00 km (E)

7 Nearest Highway N.H. 8 ≈ 6.1 km (E)

8 Nearest Railway line/ Railway station Bhilad≈ 5.85 km (SE)

9 Nearest Airport/ Airbase Airport - Daman ≈ 14.5 km (N)

10 Reserved Forests Patches of RF within 10 km radial periphery of project site.

11 Protected Areas/ Sanctuaries No

12 State/ International boundary UT of Daman & Diu ≈ 7.65 km (NE)

13 Defense installations No

14 CRZ applicability No

15 Seismicity Seismic Zone-III (Moderate)

Note: All the above mentioned distances are the aerial distance from the project site

4.5 EXISTING INFRASTRUCTURE

Well-developed infrastructure is available around the site.

4.6 SOIL CLASSIFICATION

About 60% of the Umbergaon taluka is covered by Ustropepts, of which Calcarious Typic Ustropepts

soil is predominant. Typic Chromusterts with small amount of Vertic Ustropepts are the other soil

types found in Umbergaon taluka along.

4.7 CLIMATE& METEROLOGY

The year can be divided into four seasons. Climate is warm and dry from mid-March to June, during

season of summer, climate remains warm and dry, while during rainy season, from mid-June to end of



September, climate is humid and pleasant. From October to November mild warm climate prevails,

and from December to February climate is cold.

The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of IMD,

Dahanu published by IMD.

Table 4.2: Summary Meteorological Data at nearest IMD Station –Dahanu

Location: In the compound of Old Girdhardhas Dispensary, DAHANU, Maharashtra ( Lat: N 19o 58’, Long: E 72o 43’) Aerial Dist from Project Site: Approx.40.48 km (SSW) Height of installation: 11m above MSL,

Month Temperature (oC)

Relative Humidity

(%)

Cloud Cover

(Oktas)

Mean Wind

Speed (m/s)

Pre-dominant

Wind Direction

Rainfall (mm)

Max. Min. Mor. Eve. Max. Min.

January 27.7 16.5 67 69 1.3 1.1 11.3 N 0.2

February 28.3 17.4 66 69 1.1 0.8 11.7 N 0.2

March 30.3 20.7 68 67 1.4 1.1 12.9 N 0.1

April 32.2 24.0 74 69 2.1 1.4 13.7 W 0.1

May 33.1 26.8 77 73 3.8 2.3 15.5 W 5.2

June 32.2 26.3 85 80 6.1 5.6 17.7 SW 522.1

July 30.1 25.0 89 84 7.1 6.8 22.6 SW 771.7

August 29.5 24.7 88 83 6.9 6.7 22.6 W 502.3

September 30.0 24.0 87 79 5.4 4.9 14.6 W 319.1

October 32.1 23.1 77 72 2.8 2.4 10.0 E 44.4

November 32.1 20.5 67 71 1.9 1.9 9.4 N 17.1

December 29.8 18.0 67 71 1.6 1.5 10.0 N 0.3 (Source: Book “Climatological tables of Observatories in India (1951 - 1980)” published by IMD)

4.7.1 TEMPERATURE

The summer season from March to May is a one of continuous increase in temperatures which

decreases during monsoons, increases slightly during the post-monsoon season and again

decreases during the winter.May is generally the hottest month with the mean daily maximum

temperature recorded at 33.1 oC and mean daily minimum temperature recorded at 26.8oC. January is

the coldest month with the mean daily maximum temperature as 27.7 oC and mean daily minimum

temperature observed as 16.5 oC.

4.7.2 HUMIDITY

The climate of the region is characterized by a humid summer because of the closeness to coastline.

Humidity is usually high during the monsoon months, with average relative humidity generally

exceeding 80%. Humidity decreases gradually during the post-monsoon months and for rest of the

year i.e. the period of December to April, the average relative humidity ranges around 50-70%.

4.7.3 RAINFALL

About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to

September, July being the month with highest rainfall. The total annual rainfall observed from the

historical data of year 1951-1980 is 2182 mm.

4.7.4 WIND PATTERN

The annual resultant vector for wind direction shows winds blowing from WSW. During summers and

monsoon, the winds blow mostly from the sea i.e. the SW or WSW direction. The post-monsoon &

winter seasons experience a change in direction, with the winds blowing from NE, ENE or NNE. The



wind speed is high during monsoon and post monsoon seasons, slightly moderate during summer

and winter seasons.

4.8 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well-being of the region. There

are about 43 villages and 7 Towns in the Umbergaoun Taluka.

4.8.1 EDUCATIONAL FACILITIES

As per census of India, 113 Primary school, 0 Middle School, 13 Secondary School, 6 senior

secondary school and 0 Training institute were found in 43 villages. The female literacy rate is 59%.

4.8.2 MEDICAL FACILITIES

Out of the 43 villages, There is no hospital in villages, There is no Dispensary in villages, Primary

health centers in 6 villages and Primary health sub center in 39 villages.



CHAPTER – 5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The project is to be located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest

town to the project site is Sarigam which is situated at about 2.59 kms from project site. The region is

well planned with all the basic infrastructural facilities like internal roads, water supply, arrangements

for power, streetlights, solid waste disposal sites etc.

5.2 DEMOGRAPHIC DETAILS

The average household size is around 4 to 5.

Table 5.1: Distribution of population

Sr. No.

Particulars Observed values in Umbergaoun Taluka

1 Total Population 522408

2 No. of Households 109628

3 Avg. household size (persons) 5

4 Male population 270118

5 Male population (in %) 51.7%

6 Female population 252290

7 Female population (in %) 48.3

8 Sex ratio 934 (Source: Primary Census Abstract – Census of India, 2011)

5.3 AREA STATEMENT

The proposed project will be established in an area of approx. 94499 m2. The establishment will

include required buildings for manufacturing facilities, utilities including additional ETP, admin building

and internal roads for proper movement. A thick greenbelt will be developed around the periphery of

the plant area.

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

In this proposed project the company will acquire plant and machinery so there will be some demand

of change in physical infrastructure and social infrastructure. As manpower requirement for the

proposed project shall be fulfilled locally, employment generation will lead to additional benefits to

social infrastructure.

5.5 AMENITIES/ FACILITIES

5.5.1 DRINKING WATER FACILITIES Tap water is available in 34 villages as per the Census 2011. 8 had Wells, 16 villages had tanks and all vilages had hand pumps. 31 Villages had River passing. Power supply was also available in all the villages.

5.5.2 POWER SUPPLY FACILITIES

As per census 2011, all the villages have power supply facilities in the study region.



5.5.3 COMMUNICATION & BANKING FACILITIES

Communication facilities like Post and telegraph, telephones exist in almost all the villages as per the

2011 census.

5.5.4 TRANSPORT FACILITIES

Bus service is available in the study region. The villages are well connected with the State Highways.

National Highway-8 also passes from Bhilad. The Western railway line between Bombay to

Ahmedabad passes from the study region and Bhilad Town has a railway station on the same.



CHAPTER – 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA

The total area of the land will be 235239 m2.

6.2 RESIDENTIAL AREA

In the said proposal, temporary residence will be provided to no proposed construction workers.

6.3 GREENBELT AREA

Maximum open land will be allotted for green belt development. If required, experts will also be consulted for selection of species for the development of the greenbelt.

6.4 SOCIAL INFRASTRUCTURE

6.5 CONNECTIVITY

The proposed project is located in Village: Karanj, Taluka: Umbergaon, Dist.:Valsad, Gujarat. The nearest town to the project site is Sarigam which is situated at about 2.59 kms from project site. The site is approximately 6.1 km from National Highway. The land and infrastructure is already available and the raw material is easily available through the easy transport via road connectivity. The nearest Railway station is Bhilad railway station which is approximately 5.85 km from the project site.

6.6 DRINKING WATER MANAGEMENT

The fresh water to be sourced from Damanganga Canal Distributory. Adequate treatment will be provided to source water before use.

6.7 SEWARAGE SYSTEM

From proposed operation, the domestic waste water generated @100 kl/day will be treated in STP.

6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained in Chapter 03, Section 3.8.1.

6.9 SOLID WASTE MANAGEMENT

Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant, Used oil from gear boxes of the machineries, Used Containers/ Bags/ Carboys from storage of raw materials. Adequate storage area for proper storage of wastes will be provided. Details of solid waste generation are given in table 3.11.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY

The power requirement for the proposed project will be 13 MW which will be sourced from Captive Power Plant / Dakshin Gujarat Electricity Board.



CHAPTER – 7

REHABILITATION & RESETTLEMENT (R&R) PLAN

7.1 POLICY TO BE ADOPTED

The proposed project is to be established in NA land. Hence, no displacement of any population is required for the proposed project. Therefore, detailed Social Impact Assessment studies or R&R action study has not been proposed.



CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE OF THE PROJECT

The installation/ construction will be started after getting approval for Environmental Clearance and NOC from authorities.

8.2 ESTIMATED PROJECT COST

The approx. capital cost for proposed project will be 415 Cr. (in INR). The bifurcation is as below

Table 8.1: Total Capital Cost Projection

Sr. No. Purpose Capital Cost in Crore

(INR)

1. Land 20

2. Building 35

3. Plant & Machinery 325

4 Electrification and Administrative set-up 25

5. Safety instruments 5

6. Chartered services/ Government fees 5

TOTAL 415

Table 8.2: Recurring cost provision for EHS

Sr. No.

Purpose Recurring Cost (Lakhs per annum)

1. ETP operations (chemicals/electricity/manpower) 50

2. Air pollution control device 4

3. Fees for Common disposal facilities 20

4. Env. Monitoring expenses 20

5. Safety instruments maintenance 20

6. Environment & safety training 10

7. Chartered services/ Government fees 10

8. Green belt maintenance 10

9. Corporate Environment Responsibility (@1.5% of capital cost) 622.5

10. Medical surveillance 10

TOTAL 776.5



CHAPTER – 9

ANALYSIS OF PROPOSAL

9.1 FINANCIAL & SOCIAL BENEFITS

The project benefits from proposed project are as below -

Large demand of carbon black due to serious shortfall in domestic market & increased prices, many small & medium scale rubber industries are closing down. The new project will bridge the gap between demand & supply.

There will be reduction in the total load on the electricity department due to power generation from waste gas.

Considerable employment & trade opportunities in India.

Considerable benefit to public infrastructure of this region.

The company will carry out the social development activities in surrounding area.

Proposed Draft Terms of Reference

pg. 1

Proposed Draft Terms of Reference Environmental Baseline Study for one season is being conducted within the study area, in line with the Standard TERMS OF REFERENCE (TOR) for industrial projects. We request you to consider these data in the EIA study for our proposed project. We propose the following terms of reference for the EIA report. Project Description:

Project location map and Project Layout map will be submitted.

Products and their quantity will be delineated.

Process Details like Process Description, Flow charts, Reactions, Material

Balance etc. will be provided.

Resource requirements (Raw-materials, Water, Power and Fuel etc.) will be

specified.

Anticipated pollution potential (wastewater, air emissions, waste generation etc.)

from the project will be specified.

Proposed mitigation measures including details of effluent treatment and

disposal, air pollution control, waste storage and disposal will be provided.

Baseline Environment Setting:

Study Area: The Study Area of 10 km radius is considered for establishing the

Baseline Environmental Setting:

Core Zone – Project site area,

Buffer zone – 10 km radial periphery from the project site

Following data is generated by primary monitoring and data collection from secondary

sources is reported:

Environmental Attribute

Methodology/ Source

Topography Digital Terrain map from 10 km radial periphery is prepared using

SRTM3 data. (Shuttle Radar Topography Mission) (~90m resolution).

Water quality Surface water: Grab sampling from surrounding water bodies. Analysis

for Physico-chemical characteristics & Heavy metals as per APHA.

Ground water: Grab sampling from bore wells in surrounding villages.

Analysis for Physico-chemical characteristics & Heavy metals as per

APHA.

http://www2.jpl.nasa.gov/srtm/


pg. 2

Environmental Attribute

Methodology/ Source

Climate & meteorology

Secondary data from already published literature of National Data

Centre of Indian Meteorological Department - to establish the general

meteorological pattern.

MM5 processed meteorological data for one calendar year/ data

monitored at nearby location to be used for Air Dispersion Modeling.

Air quality studies

AAQM at 8 locations, including project site in study area of 10 km.

24 nos. of (24 hourly) samples (twice in a week for 12 weeks at each sampling location) to be collected for PM10, PM2.5, SO2, NOx, HC & CO once in a season at each location.

Sampling location is selected such that at least one location is in the

down wind direction and one in the upwind direction – based on the

historical pattern; rest of the locations are in the cross-wind directions.

Sampling and analysis for PM10, PM2.5, SO2 and NOx as per relevant

sections of IS 5182 and CPCB guidelines.

Noise levels Measurement of Day and Night noise levels with hand held Noise level

meter at 8 locations within the study area.

Land-use pattern Land use map for the study area to be prepared by using satellite

image from Google Earth.

Socio-economic layout

Demographic studies and details of available amenities using

secondary data available in public domain.

Secondary data from Census 2001 (since 2011 data is provisional) will

be used for establishing the demographic pattern for the study area and

details of available amenities will be delineated.

Ecological layout Secondary data for list of local Flora & Fauna obtained from various

published sources will be included.

Primary reconnaissance survey will be carried out for establishing the

ecological layout of the region.

Identification & Anticipation of Impacts:

Identification of impacting activities.

Anticipation of the significance of the impacts from the proposed project during construction and operational phase.

Environment Management Plan: Proposed plan for implementation of mitigation measures including details of

effluent treatment and disposal, air pollution control, waste storage and disposal.

Details of Greenbelt development.

Proposed Post-project monitoring plan.

Details of Budgetary provisions for Environment & Safety.


pg. 3

Additional Studies: 1. Risk Assessment studies shall include:

• Maximum Credible Accident (MCA) analysis to identify potential hazardous scenarios.

• Consequence analysis of failures and accidents resulting in fire, explosion, toxic releases, etc.

2. Onsite Emergency Plan shall be developed.

3. Since, the project is proposed in existing operational site as well as it is located in

notified industrial area, hence, no displacement is required, No R&R studies are proposed.

Reporting: 1. Reporting will be as per the Generic Structure of the EIA report given in Appendix

III and IIIA of the EIA notification-2006.

2. All documents will be properly indexed, page numbered.

3. Period/date of data collection will be clearly indicated.

4. The copy of the letter received from the Ministry for the Final Awarded TORs will be attached as an annexure to the final EIA-EMP Report.

5. The final EIA-EMP report submitted to the Ministry will incorporate the issues in

the letter in form of a tabular chart with index for point wise compliance of the Awarded TORs. .

The Consultant Organization to carry out the EIA study: The EIA study will be carried by Precitech Laboratories Pvt. Ltd. - QCI-NABET Accredited EIA Consultant Organization.

DETAILS OF ALTERNATIVE SITES EXAMINED

Many sites was opted for plant but due to non-availability of such large area in GIDC Sarigam and due to vicinity of MCIL’s sister concern unit, the particular site close to GIDC Sarigam is selected. For site details please refer figure 3.2 ‘Site Layout Plan’ at page no 11 of project Pre-feasibility report.

Awarded TOR No.IA-J-11011/266/2018-IA-II(I) Goverment of India … · 2019-06-17 · ix. Traffic...

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Transcript of Awarded TOR No.IA-J-11011/266/2018-IA-II(I) Goverment of India … · 2019-06-17 · ix. Traffic...