Expansion of Pesticide, Pesticide Intermediates and Fine...

Expansion of Pesticide, Pesticide Intermediates

and Fine Chemicals manufacturing at PI

Industries Ltd. Plot No.237, GIDC Estate Panoli,

Ankleshwar, Gujarat

Environmental Consultant

EQMS INDIA PVT. LTD. INDIA

304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower,

Community Centre, Karkardooma, Delhi – 11009

Nabet certi: QCI/NABET/ENV/ACO/18/0701

Website: www.eqmsindia.com

E-mail – [email protected]

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CONTENTS 1. EXECUTIVE SUMMARY .................................................................................................................................. 4

2. INTRODUCTION ............................................................................................................................................. 5

2.1 Identification of Project and Project Proponent ............................................................ 5

2.2 Brief Description of the Project ...................................................................................... 6

2.3 Need for the Project and Its Importance to the Country and / or Region .................. 6

2.4 Demand Supply Gap ....................................................................................................... 6

2.5 Import vs. Indigenous Production .................................................................................. 7

2.6 Export Possibility ............................................................................................................ 7

2.7 Domestic / Export Markets.............................................................................................. 7

2.8 Employment Generation (Direct and Indirect) due to the project ................................ 7

3. PROJECT DESCRIPTION .................................................................................................................................. 8

3.1 Type of Project Including Interlinked and Interdependent Projects ............................ 8

3.2 Location (Map Showing General Location, Specific Location and Project Boundary and Project Plant Layout) with co-ordinates ....................................................................... 8

3.3 Details of alternate sites considered and the basis of selecting the proposed site ... 9

3.4 Size or Magnitude of Operation .....................................................................................10

3.5 Technology and Process Description ...........................................................................11

3.6 Raw material required along with estimated quantity & Storage details. ...................15

3.7 Resource optimization / recycling and reuse envisaged in the project, if any. .........15

3.8 Availability of water its source, energy/power requirement and their source. ..........15

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management /disposal ..................................................................................................16

4. SITE ANALYSIS.............................................................................................................................................. 22

4.1 Connectivity ....................................................................................................................22

4.2 Land Form, Land Use and Land Ownership .................................................................22

4.3 Topography (along with map) .......................................................................................22

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from the HFL of the river), CRZ. .............................................................23

4.5 Existing Infrastructure ...................................................................................................26

4.6 Soil classification ...........................................................................................................26

5. PLANNING BRIEF ......................................................................................................................................... 28

5.2 Population Projection ....................................................................................................28

5.3 Land use Planning .........................................................................................................28

5.4 Assessment of Infrastructure Demand .........................................................................28

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5.5 Amenities / Facilities ......................................................................................................28

6. PROPOSED INFRASTRUCTURE .................................................................................................................... 29

6.1 Industrial Area (processing area) ..................................................................................29

6.2 Residential Area (non-processing area) .......................................................................29

6.3 Green belt .......................................................................................................................29

6.4 Social Infrastructure .......................................................................................................29

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.) ................29

6.6 Drinking water management (source and supply of water) .........................................29

6.7 Sewage system ...............................................................................................................29

6.8 Industrial waste water management .............................................................................29

7. REHABILITATION AND RESETTLEMENTS (R AND R) PLAN .......................................................................... 31

8. PROJECT SCHEDULE AND COST ESTIMATE ................................................................................................. 32

8.1 Likely date of start of construction and likely data of completion (time schedule for the project to be given) ........................................................................................................32

8.2 Estimated project cost along with analysis in terms of economic viability of the project. ..................................................................................................................................32

9. ANALYSIS OF PROPOSAL ............................................................................................................................. 33

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area .......................................................33

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Annexure

Annexure I Site layout map

Annexure II Product wise manufacturing Process

Annexure III Raw materials details

Annexure IV Water balance

Annexure V STP details

Annexure VI ETP Details

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1. EXECUTIVE SUMMARY PI Industries Ltd (PI) is undertaking an expansion project of manufacturing facility at its existing

site located at Plot No. 237, GIDC-Panoli, Bharuch, Gujarat.

The Proposed Expansion Project falls under S.N. 5 (b) & 5(f) “Category “A”. Pesticide & pesticide

intermediates 5(b) and synthetic Organic Chemicals 5(f).

1. Name of the Industry PI Industries Ltd (PI)

2. Products to be manufactured Pesticides Technical & pesticides

intermediates and Synthetic Organic

Chemicals at 83250 MTPA capacity &

By Products 1,08,000 MTPA

3. Total Plot Area 56868 Sq.mt

4. Water Requirement Total Fresh Water requirement = 1200 KLD Industrial = 1020 KLD Domestic = 60 KLD Gardening = 120 KLD Source of Water- GIDC

5. Power Requirement Current requirement 40,800 KVA,

Proposed 61,200 KVA

6. Manpower Requirement Existing: 700

Proposed: 850

7. Total Project cost Rs 95 crores

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2. INTRODUCTION

2.1 Identification of Project and Project Proponent

2.1.1 Project Proponent – PI Industries

PI Industries Ltd (PI) was incorporated in 1947 (as Mewar Oil & General Mills Ltd.) with its

registered office in Udaipur, Rajasthan. The company has three manufacturing facilities in Gujarat

and a Research & Development Centre at Udaipur. The manufacturing facilities include 4 multi-

purpose plants at Panoli and 5 multi-purpose plants at Jambusar.

PI has two business activities namely Agri Inputs and Custom Synthesis & Manufacturing. Agri

Inputs offers plant protection products, and specialty plant nutrient products and solutions. PI has a

strong rural reach and brand equity with millions of Indian farmers duly backed by a robust pipeline

of products, for sustained growth in the sector.

List of Chairman and Board of Directors:

Mr. Salil Singhal Chairman Emeritus

Mr. Narayan K. Seshadri Non-Executive Chairman

Mr. Mayank Singhal Managing Director and CEO

Mr. Rajnish Sarna Executive Director

Mr. Arvind Singhal Non-Executive Director

Mr. Ravi Narain Independent Director

Mrs. Ramni Nirula Independent Director

Mr. Pravin K. Laheri Independent Director

Dr. T.S. Balganesh Independent Director

https://www.piindustries.com/about-us/about-PI/PI-leadership









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2.2 Brief Description of the Project

The proposed expansion project is located within the GIDC wherein M/s PI Industries Limited

operates a plant at Plot No 237 GIDC-Panoli, Bharuch, Gujarat. M/s. PI Industries ltd. proposes to

manufacture Pesticide technical and pesticide intermediates [Category 5 (b)] and synthetic organic

chemicals [Category 5 (f)].

2.3 Need for the Project and Its Importance to the Country and / or Region

Agrochemicals are used to improve crop performance, yield or control pests. As per Indian Journal

of Ecology report, major crop losses due to non-usage of pesticides were about 17.5% of the yield

valued at ~INR 90,000 Cr per annum (FY12 estimated). It is estimated that the present food grain

production can increase from 3 Trillion Ton to 4 Trillion Ton by using appropriate crop protection.

Therefore, right usage of crop protection chemicals is essential in increasing agricultural

production by preventing crop losses before and after harvesting.

Crop losses in the country due to various pests range from 10 to 30 percent each year depending

upon the severity of pest attack. Pesticides play an important role in sustaining agricultural

production of the country by protecting crops from pest attacks and by keeping the pest population

under control. Availability of safe and efficacious pesticides and their judicious use by the farming

community is critical to a sustained increase in agricultural production and productivity. Pesticides

are also useful in health programs for controlling vectors responsible for diseases like malaria.

Pesticides proposed to be manufactured by the project proponent are widely used all over the

world including India. At present, there are only few industries in India manufacturing these

particular products, which have good market potential and will help farmers for better crop yield. By

using appropriate pesticides, up to 90% crop loss can be avoided in various crops. Benefit in terms

of saving of crop output is multifold compared to expenses for buying Agrochemicals.

It is thus, very much justified to manufacture these Pesticides not only to increase the market

availability but also to reduce import burdens of the country.

2.4 Demand Supply Gap

This would thus appear from the above that there is an unabridged major gap between the

demand and supply of pesticides for both public health and agriculture. The investments involved

in setting up of basic manufacturing plants as compared to formulation units are fairly high. It has

been possible for small scale entrepreneurs to go in for formulation business but financially not

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possible to invest in basic manufacturing facilities. In the country basic manufacturing are mostly

with large scale multi-national companies and, in some cases, may be wholly owned by them. In

view of the fact that the present companies of these subsidiaries have sizeable capacities for the

manufacture of basic chemical in their own countries, they are reluctant to invest money for basic

manufacture in India. Also, these companies are reluctant to transfer technology and losing

monopoly sales especially when these products are proprietary.

2.5 Import vs. Indigenous Production

The Indian crop protection industry was estimated to be USD 4.25 billion in FY14 and is expected

to grow at a CAGR of 12% to reach USD 7.5 billion by FY19. Globally, India is fourth largest

producer of crop protection chemicals, after United States, Japan and China. The crop protection

companies in India can be categorized into three types –Multi-National, Indian including public

sector companies

2.6 Export Possibility

Global generic market of pesticides was $45 billion. Export opportunities for Indian companies are

immense with Key markets being USA, France, Netherlands, South Africa, and Bangladesh. All the

products have very high possibilities of Export.

2.7 Domestic / Export Markets

The Indian pesticides industry grew at a rate of 8-9% over the past five years (fy07-fy11). Industry

size is estimated to be $3.8 billion in FY11 with exports accounting for~50% of the market. Over

the XIIth plan period, the segment is expected to grow at 12-13%per annum with domestic demand

growing at 8-9% per annum and export demand growing at 15-16% per annum. Based on the

Export Potential and Potential for increased penetration in the domestic market, the Indian

agrochemical industry target a size of US $7.7 billion by FY17. 6 The technical grade pesticides

will be sold to many formulators all over the country. At the same time export will be done to Middle

East, Latin America and south Asian countries.

2.8 Employment Generation (Direct and Indirect) due to the project

PI Industries Ltd, Gujarat generates the employment on various levels time to time and gives the

priority to local persons. After expansion additional 150 vacancies will be created. The total

employment at the site post expansion will be 850.

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3. PROJECT DESCRIPTION 3.1 Type of Project Including Interlinked and Interdependent Projects

3.1.1 Type of Project

The proposed project is for manufacturing pesticide technical, pesticide intermediate and synthetic

organic chemicals that is covered under S.N. 5 (b) & 5(f) respectively “Category A” projects of

MoEF&CC as per the new EIA notification vide gazette no. S.O. 1533 dated 14th September,

2006.

3.1.2 Interlinked and Interdependent Project

There is no interlinked project.

3.2 Location (Map Showing General Location, Specific Location and Project Boundary and

Project Plant Layout) with co-ordinates

The proposed facility is located at GIDC-Panoli. The total plot area of the unit is 56868 Sq.mt.

Coordinates of the proposed project is 21°34’ 52.74” N and 72°59’42.61” E Google map showing

coordinates of the site is given as Figure 3.1. Location map of proposed site is given as Figure

3.2. Site layout map of proposed site is given as Figure 3.3

Figure 3.1 Site Location Map

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Table 3-1: Co-ordinates of GIDC Area

Points Latitude Longitude

A 21.583056 72.994208

B 21.583101 72.995232

C 21.579519 72.996627

D 21.579215 72.994540

Figure 3.2 Location Map in Google Image

Site Layout Map is given as Annexure-I

3.3 Details of alternate sites considered and the basis of selecting the proposed site

No alternate sites were evaluated as the proposed site is operating at GIDC with all infrastructure

including land, water, power supply, common treatment facility and other infrastructure is readily

available.

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3.4 Size or Magnitude of Operation

PI plans to produce Pesticides and its intermediates, Fine Chemicals, Formulation, R&D products

& Synthetic Organic Chemicals at 83250 MTPA capacity & By-products of 108000 MTPA capacity

at its plant, located at plot No. 237, GIDC Estate, Panoli, District Bharuch.

Table 3.2 Product list of Pi Industries site-I

S.No. Groups Quantity

(TPA)

EC

Category

1 Insecticides and Intermediates 10000 5 (b)

2 Herbicides and Intermediates 8000

3 Fungicides and Intermediates 8000

4 Acaricide & Intermediates 2000

5 Synthetic Organic Chemicals 10000 5 (f)

6 Pharma intermediates 1000

7 R&D Products for pilot scale 250

8 Formulation 44000

Total 83250

Table 3.3 List of By-Products

S.No. By Products Revised (MT)

1 SMM 8000

2 NaSH/Na2s 5000

3 NaBr/Hbr/MgBr 50000

4 Distilled Solvent 15000

5 HCl 12000

6 Ammonia Solution 1500

7 H2SO4 5000

8 Sodium Propionate 3000

9 Acetic Acid 1500

10 Ortho Cresol 1000

11 Propionic Acid 1500

12 Sodium hypochloride 2000

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S.No. By Products Revised (MT)

13 Ammonium Chloride 2500

Total 108000

3.5 Technology and Process Description

Attached below is the general process flow diagram and description for the manufacturing process.

Depending on the type of product produced suitable operation will be employed.

Figure 3-4: Typical Flow Diagram for PI Products

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Description of Manufacturing Process

Raw Material Preparation: Various types of organic and inorganic chemicals are used in the

manufacturing process. In the raw material preparatory stage, the desired raw materials are

weighed and mixed together in proportion. The type of raw materials depends on the product being

manufactured. For e.g. in the manufacturing of product Orysastrobin raw materials like MIPD-

Ketal, Methoxy Amine Hydrochloride, Sodium Methylate etc. is utilized in various proportions.

Reaction in Reactor System:

The next step in manufacturing process involves various types of chemical reactions that take

place in reactors. The MOC of the reactors are either SS-316 or MS Glass Lined reactor. The

major chemical reactions involved in production are: alkylation, carboxylation, acetylation,

condensation, cyclization, dehydration, halogenation, oxidation, sulphonation, nitration and

amination.

Fractionation:

Fractionation is a separation process in which a certain quantity of a mixture (gas, solid, liquid,

enzymes, suspension, or isotope) is divided during a phase transition, into a number of smaller

quantities (fractions) in which the composition varies according to a gradient. Fractions are

collected based on differences in a specific property of the individual components.

Crystallization:

Crystallization is the (natural or artificial) process by which a solid forms, where the atoms or

molecules are highly organized into a structure known as a crystal. The crystallization process

consists of two major events, nucleation and crystal growth which are driven by thermodynamic

properties as well as chemical properties. In Crystallization, nucleation is the step where the solute

molecules or atoms dispersed in the solvent start to gather into clusters, on the microscopic scale

(elevating solute concentration in a small region), that become stable under the operating

conditions. These stable clusters constitute the nuclei. Therefore, the clusters need to reach a

critical size in order to become stable nuclei. Such critical size is dictated by many different factors

(temperature, supersaturation, etc.). It is at the stage of nucleation that the atoms or molecules

arrange in a defined and periodic manner that defines the crystal structure — note that "crystal

structure" is a special term that refers to the relative arrangement of the atoms or molecules, not

the macroscopic properties of the crystal (size and shape), although those are a result of the

internal crystal structure.

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The crystal growth is the subsequent size increase of the nuclei that succeed in achieving the

critical cluster size. Crystal growth is a dynamic process occurring in equilibrium where solute

molecules or atoms precipitate out of solution, and dissolve back into solution. Supersaturation is

one of the driving forces of crystallization, as the solubility of a species is an equilibrium process

quantified by Ksp. Depending upon the conditions, either nucleation or growth may be predominant

over the other, dictating crystal size.

Filtration:

Filtration is any of various mechanical, physical or biological operations that separate solids from

fluids (liquids or gases) by adding a medium through which only the fluid can pass. The fluid that

passes through is called the filtrate. For filtration Agitated Nutsche Filter (ANF) is utilized. Agitated

Nutsche filters are fabricated in materials like Hastelloy & stainless steel. A typical unit consists of

a dished vessel with a perforated plate. The entire vessel is kept at the desired temperature by

using a limpet jacket, jacketed bottom dish and stirrer (blade and shaft) through which heat transfer

media flows. The vessel is made completely leak-proof for vacuum or pressure service. In Filtration

the following five steps are followed:

1. Filling/Charging

The first step involves the transferring of the product to be filtered, usually an aqueous or solvent

based solid/liquid slurry, from the reactor to the filter. The filter is sized appropriately to handle the

solids volume that is being charged

2. Filtering

The second step involves the use of pressure and/or vacuum to force liquid through the solid bed

and filter media. The process is stopped when solids are visible, or can be continued until all the

liquid is pushed out. There are various types of filter media available in nutsche filters – cloth,

single layer metal screen, or multi-layer sintered metal. The media is determined based on the

characteristics of the slurry including particle size and shape, cake porosity, and, will determine

filtration rate).

3. Displacement Washing

Here, fresh wash liquid is sprayed on top of the solid cake taking care not to disturb the surface of

the cake. The liquid is forced through with pressure or vacuum. Displacement washing serves

several purposes – it removes the liquid and its impurities while keeping the cake intact and it

https://en.wikipedia.org/wiki/Hastelloy

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replaces the previous liquid with fresh liquid. There is also the opportunity prior to this step to try

and close cracks if the cake has any via smoothing.

4. Reslurry Washing

As an additional washing option, a re-slurry washing is sometimes performed if additional

extraction or dissolving of impurities is necessary. This is executed by the addition of fresh wash

liquid that is mixed with the solids. The agitator is stopped and raised before filtering the wash

liquid. The re-slurry process is also used when a long contact time is needed between the wash

fluid and the solids or the displacement wash does not provide the required wash quality.

5. Smoothing

This next step is used after any filtration or wash, especially after the final wash, when gas is blown

through the cake. The agitator is used to close cracks and compress the cake to reduce residual

moisture level. This function helps to achieve uniform flow of liquid or gas through the filter cake,

while helping to eliminate liquid and gas channelling that reduces the efficiency of displacement

washing and gas blow through.

Drying:

Drying is carried out with the aid of Rotary Vaccum Dryer (RVD) or Pan Dryer.

Rotary Vacuum Dryers (RVD) also known as Vanuleuth Dryer is a cylindrical jacketed vessel with

a central agitator having specially designed blades. The drying in a rotary vacuum dryer is a batch

operation under vacuum. It is done to dry heat sensitive materials at well below boiling points of

water and solvents. Drying time depends on material being dried, amount of solvent or water to be

removed, desired final moisture content, permissible jacket temperature etc. The volume of wet

material loaded into the dryer is usually restricted to 50% of gross volume.

The blades of this Rotary Vacuum Paddle Dryer (RVPD) are so designed that they sweep the

entire internal surface and at the same time turn the material so that all the particles come in

contact with the heated surface. The central agitator shaft is supported on the two end bearings

housed in bearing housing in such a way that the alignment remains always intact. This central

agitator is driven by means of a Motor & Gear box through the bull Gear. Cooling is provided by

cold water / brine refrigerant through the jacket. The horizontal shell is jacketed to heat the shell

with steam/hot water. Limpet coil is provided instead of jacket if the heating media is thermic fluid.

A Vacuum Pump of adequate capacity is provided & fitted to the receiver of rotary vacuum dryers

to create the vacuum in the dryer shell through the Receiver, Condenser and Dust Catcher.

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Rotary Vacuum Dryer gives drying, mixing and breaking effects simultaneously. Wet cake or slurry

is fed through charging door, while the agitator is rotating in clockwise direction, vacuum is applied

in the dryer and heating media is circulated in the jacket. Evaporation of moisture takes place

under vacuum and vapours passes through the dust catcher into the condenser, where it is

condensed and collected in the receiver. Dried material is discharged through discharge valve. The

lump breaker rods are provided to achieve good drying effect.

Pan Drier: The atmospheric pan drier has a jacketed round pan in which a stirrer revolves slowly,

driven from below. The slow moving stirrer exposes fresh surfaces and thereby raises the rate of

evaporation and, hence, of drying. The pan drier is a batch machine and is limited to small

batches.

Packing:

The final stage of the manufacturing process is packaging of the finished product. The packaging

of the finished product is carried out in a closed room. Packaging is done using 400 Kg Jumbo

Bags or 50/100 Kg cardboard drum. The packed product is appropriately labelled and stored in the

finished good godown for shipment to various parts of the country and abroad.

Product wise manufacturing process is given in Annexure- II

3.6 Raw material required along with estimated quantity & Storage details.

List of raw material given in Annexure-III

3.7 Resource optimization / recycling and reuse envisaged in the project, if any.

The solvent distillation system shall be designed so as to achieve minimum 92% - 95% recovery of

solvent. Energy efficient equipment will be installed at all locations. The company has full-fledged

effluent treatment plant in its premises with primary, secondary and tertiary treatment systems. The

treated waste water is transferred to guard pond where its final analysis is done. From here the

treated waste water is discharged to Panoli pumping station. From Panoli pumping station treated

waste water is discharged into FETP through pipeline and ultimately discharges into deep sea

through NCT pipeline.

3.8 Availability of water its source, energy/power requirement and their source.

3.8.1 Water consumption

Total Fresh Water requirement = 1200 KLD

Industrial = 1020 KLD

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Domestic = 60 KLD

Gardening = 120 KLD

Source of Water- GIDC Supply

Water balance is given as Annexure- IV

3.8.2 Power Requirement

Current requirement 40,800 KVA, proposed 61,200 KVA. The power requirement is met via captive

power plants (CPP-1 & CPP-2) & the power sourced from DGVCL. In addition, the plant is

proposing an additional captive power plant to meet the energy demands arising out of the

proposed expansion. Also the company plans to install a 66 KVA substation at the site. As an

emergency back-up the plant has proposed 1 DG set of 1250 KVA capacity and 4 D.G. Sets of

1500 KVA capacity with common stack.

3.8.4. Fuel Requirement

Table 3-4: Fuel Consumption

S.No. Equipment Present

Equipment

status

Fuel Existing

Quantity

Proposed

1

Boiler + Gas

Turbine +

Thermic

Fluid Heater

Existing Natural

Gas

40000 SM3/day 100000

SM3/day

LDO 250 Lit/Day 1000 Lit/day

FO 731 Lit/hr 2500 Lit/hr

2 D.G. Sets (5

Nos.)

Proposed HSD - 45000 Lit/Day

3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management

/disposal

The generation of pollutants associated with the proposed expansion will be in the form of gaseous

emissions, liquid effluent, solid waste, and hazardous waste.

3.9.1 Process Stack Emission

The PI plant will have following sources of emission namely,

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Table 3.5 Process Stack Emission and Control Measures

Sr. No.

Stack attached to

Stack Height (Mtr.)

Current Status

Probable Pollutants

Air Pollution Control Measures

Permissible Limit

1 Process Stack MPP-1

26.5 Existing HBr Hypo scrubber followed by alkali scrubber

30 mg/Nm3

Br 02 mg/Nm3

SO2 40 mg/Nm3

H2S 45 mg/Nm3

Pesticide compound in the form of Particulate matter

20 mg/Nm3


26.5 Existing HCl Alkali Scrubber

20 mg/Nm3

Cl2 9 mg/Nm3

HC 15 mg/Nm3


26.5 Existing HCl Alkali scrubber

20 mg/Nm3

Cl2 05 mg/Nm3

NH3 30 mg/m3

Mercaptan 0.5 PPM


26.5 Existing HCl Alkali scrubber

20 mg/Nm3

5 Process stack– 4 A

26.5 Proposed NH3 Acid scrubber

30 mg/Nm3

6 Process Stack

MPP-4B

26.5 Proposed HCl Alkali scrubber

20 mg/Nm3

Cl2 9 mg/Nm3

NH3 30 mg/Nm3

SO2 40 mg/Nm3

Pesticide compound in the form of particulate matter

20 mg/Nm3

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3.9.2 Flue Gas Emission

3.9.3 Waste Water Treatment and Disposal

Sr. No.

Stack attached to

Stack Height (Mtr.)

Current Status

Probable Pollutants

Air Pollution Control Measures

Permissible Limit

7 Process Stack

MPP-4C

26.5 Proposed HCl Alkali scrubber

20 mg/Nm3

Cl2 9 mg/Nm3

SO2 40 mg/Nm3

NH3 30 mg/Nm3

Pesticide compound in the form of particulate matter

20 mg/Nm3

8 Fume Incinerator

40 (Common Stack for

fume incinerator & Rotary

Kiln incinerator)

Existing

PM Quencher & Caustic Scrubber

50 mg/Nm3

SO2 200 mg/Nm3

9 Rotary Kiln

incinerator

PM Caustic Scrubber, Multi-cyclone, Ventury followed by packed bed scrubber & demister

50 mg/Nm3

HCl 50 mg/Nm3

SO2 200 mg/Nm3

CO 100 mg/Nm3 (30 mins)

TOC 20 mg/Nm3

Total dioxin and furan 0.1 ng TEQ/Nm3

Sb+As+Pb+ Cr+CO+Cu+Mn+Ni+V+their compound

0.5 mg/Nm3

Sr. No.

Stack attached To

Current status

Fuel Stack Height (Mtr.)

Parameters

1 Boiler 1 & Boiler 2. (Common Stack)

Existing NG/FO 54 PM 150 mg/Nm3 SO2 100 PPM NOx 50 PPM 2 Thermic Fluid Heater Existing NG/FO 20

3 Power Plant -1 (2.4 MW) Existing NG 30

4 Power Plant -2 (2.4 MW) Existing NG 30

5 Power Plant-3 (2.5 MW) Proposed NG 30

6 D.G. (4 Nos. of 1500 KVA + 1 No. of 1250 KVA

capacity) Common stack

Proposed HSD 30

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Current waste water generation 208 KLD and proposed generation will be 650 KLD. The current

treated effluent disposal from the site is 143.575 KLD and the proposed quantity is 250 KLD. The

treated effluent conforming to the statutory standards shall be discharged into final pumping station

at Panoli and conveyed to FETP of NCT for ultimate disposal in deep sea. Toxic effluent of 35 KLD

shall be incinerated in house or in approved common incineration facility or sent for co-processing.

High TDS waste of 205 KLD shall be treated in MEE in in-house facility or any other approved

common facility.

Sewage System

Domestic wastewater treated in sewage treatment plant will be treated and used in gardening and

for any other appropriate use deemed fit. Detail of Sewage Treatment Plant is given as Annexure-

V

Effluent Treatment Plant

Industrial effluent is treated in the state of the art effluent treatment plant which comprises of

primary and secondary treatment units. The treated waste water is transferred to guard pond

before disposal to FETP of NCT. Before the discharge of treated waste water online TOC meter is

available which is connected to CPCB server. Detail of Effluent Treatment Plant is given as

Annexure-VI

3.9.4 Solid / Hazardous Waste

PI being an environmentally conscious Organization has always emphasized on pollution

prevention rather than pollution Control. To strengthen the waste management system, different

types of wastes are identified along with proper disposal / recycling / reuse mechanisms.

Basically the following types of solid wastes are generated at PI:

Table 3.6 Hazardous Waste Generation and disposal Details

Sr.No.

Type of Hazardous Waste

Unit Category Total Quantity

Method of Disposal

1a Sludge ( ETP)

MT/Annum

34.3 24000 Collection, storage, transportation and disposal in approved common TSDF

1b Sludge (MEE)

MT/Annum


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Sr.No.



Method of Disposal

2 Incinerator Ash

MT/Annum


3 Process solid wastes /residues

MT/Annum

29.1 22000 Collection, storage, & Incineration in house or in approved common incineration facility or co-processing

4 Spent oil/other spent lube oil/ system

KL/Annum 5.1 18000 Collection, storage, & Incineration in house or in approved common incineration facility or Sale to Authorized recyclers

5 Packing waste

MT/Annum

33.3 3600 Tons or 6,00,000 Nos./Annum

Recycled or sold to authorized end users or disposal in approved common TSDF

6 Spent Solvent

MT/Annum

20.2 18000 Collection, storage, & Incineration in house or in approved common incineration facility or Co-processing or reuse by in-house solvent distillation or Sale to GPCB Authorized recyclers/ distillators/re-processor for recovery

7 Solvent Distillation Residue

MT/Annum

20.3 6000 Collection, storage, & Incineration in house or in approved common incineration facility or co-Processing

8 Spent catalyst

MT/Annum

35.2 500 Collection, storage, & Incineration in house or in approved common incineration facility or Send to Authorized recyclers/ re-processors for recovery

9 Spent Carbon

MT/Annum

35.3 500 Collection, storage, & Incineration in house or in approved common incineration facility or Send to Authorized recyclers/ re-processors for recovery or co-processing

10 Spent Resin

MT/Annum


11 Filter & Filter cake

MT/Annum

35.1 100 Collection, storage, & Incineration in house or in approved common incineration facility/Co-processing

12 Date Expired off specification products

MT/Annum

29.3 1000 Collection, storage, & Incineration in house or in approved common incineration facility/co-processing

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Sr.No.



Method of Disposal

13 Contaminated cotton rags or other cleaning materials

MT/Annum

33.2 500 Collection, storage, & Incineration in house or in approved common incineration facility/co-processing

PI External

4. SITE ANALYSIS

4.1 Connectivity

The plant site is well connected by road to the major national and state highway network.

The approach road to the site is suitable for movement of heavy loads involved including the

construction materials.

S. No Location Distance in KM

1 Nearest Railway Station Ankleshwar Junction (4.9 Km, N)

2 Nearest Air Port Surat International Airport (57.34 Km, SSW)

3 Nearest Highway NH 8

4.2 Land Form, Land Use and Land Ownership

Land Form: GIDC Land

Land Use: Industrial

Land ownership: It will be incorporated in EIA Studies.

4.3 Topography (along with map)

Bharuch district is located in the Sourthern part of Gujarat, near the Gulf of Khambhat in Arabian

Sea. In 1997, Bharuch district is bifurcated into two parts (1) Narmada District and (2) Bharuch

District. The newly formed Bharuch District has 5253.30 Sq.km. area and situated between 21.30’

to 22.00’ North Latitude and 72.45’ to 73.15’ East Longitude Bharuch District comes under Seismic

Zone- III. Bharuch District is bounded by Baroda and Anand District on the North, Narmada District

on the East, Surat District is on the South and on its west lies the Gulf of Cambay. The Eastern

strip of the district is a hilly and forest area. Main rivers in Bharuch District are Narmada, Dhadhar

and Kaveri. The rivers flow throughout the year.

PI External

Figure 4-2: Location Map in Topo Map)

(SOURCE India and Pakistan series U.S Army Map series 1955)

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life sanctuary, etc sensitive areas, water bodies (distance from

the HFL of the river), CRZ.

● Existing Land use pattern: Industrial

1 Areas protected under

international

conventions, national or

local legislation for their

ecological, landscape,

cultural or other related

value

No

There are no Areas protected under international

conventions, national or local legislation for their

ecological, landscape, cultural or other related value

PI External

2 Areas which are

important or sensitive for

ecological reasons -

Wetlands, watercourses

or other water bodies,

coastal zone,

biospheres, mountains,

forests

Yes There is Amlakhadi Creek at a distance of 1.70km(E)

3 Areas used by protected,

important or sensitive

species of flora or fauna

for breeding, nesting,

foraging, resting, over

wintering, migration

No

There are no Areas used by protected, important or

sensitive species of flora or fauna for breeding, nesting,

foraging, resting, over wintering, migration

4 Inland, coastal, marine or

underground waters

Yes There is Amlakhadi Creek at a distance of 1.70km(E)

5 State, National

boundaries No There are no state or National boundaries

6 Routes or facilities used

by the public for access

to recreation or other

tourist, pilgrim areas

Yes NH-8,0.38km(E)

7 Defense installations No There are no Defense installations

8 Densely populated or

built-up area Yes Sanjali,3.27km(S)

9 Areas occupied by

sensitive man-made land

uses (hospitals, schools,

places of worship,

community facilities)

Yes

Shree Gattu Vidhalaya(3.85km,NE)

Shree Rang Childerns Hospital(4.34km,NE)

10 Areas containing

important, high quality or

scarce resources

No

PI External

(ground water resources,

surface resources,

forestry, agriculture,

fisheries, tourism,

minerals)

11 Areas already subjected

to pollution or

environmental damage.

(Those where existing

legal environmental

standards are exceeded)

No -

12 Areas susceptible to

natural hazard which

could cause the project

to present environmental

problems (earthquakes,

subsidence, landslides,

erosion, flooding or

extreme or adverse

climatic conditions)

Project area falls in the seismic zone-III (Moderate Risk Zone)

PI External

Figure 4.6 Environment Sensitivity Map of Pi Industries Site I

4.5 Existing Infrastructure

This is a proposed expansion project within existing site, hence there is already infrastructure

available at the site. The Project proponent has available infrastructure like water, electricity,

roads, transportation, storage sheds, parking, availability of raw material and drainage system.

4.6 Soil classification

The soil in the study area is deep black clayey soil.

4.7 Climatic data from secondary sources

The climate of region is moderate with greater humidity on its coastal side. The weather of

Bharuch district is hot and dry-starting from mid-march till mid-June, mid during summer season

weather remains hot and dry. While from mid-June till end of September weather remains humid

and can be considered pleasant. From October-November weather is bit hot. From December to

PI External

February climate remains cool. The Climatological data of nearest India Meteorological

Department (IMD) station - Bharuch is given below:

Month Temp. Humidity Wind

speed

Solar

Radiation

Rainfall

Max. (C) Min. (C) (%) kmph (MJ/m2 /d) mm

Jan 31.3 11.9 51.5 5.9 17.3 1.2

Feb 33.8 14.4 45.0 6.2 19.6 1.2

Mar 37.6 19.0 44.0 7.0 22.7 0.8

Apr 40.0 23.3 45.0 8.8 25.2 1.0

May 39.6 26.2 55.5 12.4 26.2 12.5

Jun 35.6 26.5 69.5 14.7 21.3 121.0

Jul 32.0 25.5 81.0 13.2 16.5 307.6

Aug 31.2 25.0 83.5 11.5 15.9 243.1

Sep 32.6 24.4 76.0 8.6 18.1 197.6

Oct 35.9 22.0 59.5 5.7 18.5 35.2

Nov 34.8 16.9 52.5 4.7 16.5 3.7

Dec 32.2 13.2 53.5 5.2 16.5 0.1

Average 34.7 20.7 59.7 8.7 19.5 Total 924.8

Source: Groundwater Brochure, Bharuch Dist., Central Ground Water Board (CGWB), Ahmedabad, March

2014

4.8 Social infrastructure available

Educational facilities in project area are quite good because all nearby villages/town have

primary schools.

The town has private dispensaries and hospitals in all major branches of medicines and

surgery.

All small villages have postal and telephone connection facilities.

Electricity for all purpose (industrial and residential) is available.

PI External

5. PLANNING BRIEF

5.1 Planning Concept

The entire area is a well-developed industrial area with numerous industrial units.

5.2 Population Projection

During the Construction and Execution phase of the Project, it is estimated that about 100 workers will be involved for a period of about 12 months.

Thereafter during the operation phase at the new plant around 150 person’s positions will be created and employed.

5.3 Land use Planning

S.N. Area Description Area Sq.M

1 Production plants including ware house, utilities 15057

2 Administration, QC, R&D, HSE, Security and

welfare facilities

3444

3 Open Areas, Roads, Pathway & Auxiliary 18186

4 ETP, Laboratory, APCM 2731

5 Green belt/Plantation 14220

6 Other Miscellaneous Facility 3230

Grand Total 56868

5.4 Assessment of Infrastructure Demand

PI Industry 1 is an existing unit located inside Notified GIDC Industrial estate. Well-developed

Infrastructure is already existed as project site is located inside Notified Industrial estate GIDC.

5.5 Amenities / Facilities

Following facilities will be made available at site:

● First Aid Facility/ OHC (occupational health center)

● Hygienic Drinking Water Facility

● Green Area

● Regular Worker Medical Checkup Facility

● Change Room for Workers

● Canteen facilities

PI External

6. PROPOSED INFRASTRUCTURE 6.1 Industrial Area (processing area)

Site located in Notified industrial area developed by GIDC, Ankleshwar.

6.2 Residential Area (non-processing area)

No residential facility will be provided.

6.3 Green belt

The Proposed Project Plant will have 14220 Sq.M Green Belt

6.4 Social Infrastructure

Canteen, Rest shelter / room, Recreation Room is provided and it will be augmented.

6.5 Connectivity (Traffic and transportation road/ rail/metro/water ways etc.)

The expansion project will be at existing site only which is located inside Notified GIDC industrial

estate of Ankleshwar. The existing connectivity is convenient for future also.

6.6 Drinking water management (source and supply of water)

Existing unit & the source of drinking water is from GIDC water supply & same will be continue for

proposed expansion.

6.7 Sewage system

Sewage generated will be sent to STP operated by the PI Industries Ltd.

6.8 Industrial waste water management

The company has full-fledged effluent treatment plant in its premises with primary, secondary and

tertiary treatment systems. The treated waste water is transferred to guard pond where its final

analysis is done. From here the treated waste water is discharged to Panoli pumping station. From

Panoli pumping station treated waste water discharge into FETP through pipeline and ultimately

discharges into deep sea through NCTL pipeline.

Domestic wastewater treated in sewage treatment plant will be used in gardening or any other

suitable purpose within the unit.

6.9 Solid waste management

PI External

Hazardous wastes generated will be maintained as per Hazardous Waste (Management, Handling

and Transboundary Movement) Rules, 2016 and will be disposed of as per the details given in

Table 3-6.

6.10 Power requirement and supply/ source

Current requirement 40, 800 KVA, proposed 61,200 KVA. The power requirement is met via

captive power plants (CPP-1 & CPP-2) & the power sourced from DGVCL. The unit has proposed

additional power plant (CPP-3) to meet its energy demands owing to proposed expansion. Also the

Unit will install a 66 KVA substation at the site for power transmission.

PI External

7. REHABILITATION AND RESETTLEMENTS (R AND R) PLAN

Not applicable as rehabilitation and resettlement will not be required, since the project lies in an

Industrial Area, with land acquisition procedures completed by the GIDC.

PI External

8. PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely data of completion (time schedule for the

project to be given)

The proposed expansion project will start immediately after getting Environmental clearance from

Ministry of Environment, Forest and Climate Change (MoEF&CC) & Consent to Established (CTE)

from State Pollution Control Board (SPCB).

8.2 Estimated project cost along with analysis in terms of economic viability of the project.

The estimated project cost is 95 Crores. The expansion is in terms of capacity enhancement in the

existing multipurpose Plants and setting up of two additional multipurpose plants.

PI External

9. ANALYSIS OF PROPOSAL 9.1 Financial and social benefits with special emphasis on the benefit to the local people

including tribal population, if any, in the area

The proposed activities will be carried out in the existing unit itself. Hence, no additional land is to

be purchased. The project will improve the socio-economic status of the society in the region by

generating direct and indirect employment opportunities and lead to ensure continued employment

to existing workforce without affecting work conditions and hence supporting their families. The

project will contribute additional revenue to the State & Central exchequers in the form of taxes,

cess, etc.

Expansion of Pesticide, Pesticide Intermediates and Fine...

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