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Project: Environmental Impact Assessment Study of Proposed Single Super Phosphate Manufacturing Unit at Village - Kalyangadh, Taluka - Bavla, District - Ahmedabad

Client: Narmada Bio-Chem Pvt. Ltd.

Project No.: EQMS/NBCL/10-11/01

Issue and Revision Issue Date Author Checked Approved Issue Revision

20.12.2010 Naval K.

Chaudhary Dr. Sankalp

Anand S. K. Jain 1.0 -

27.12.2010 Naval K.

Chaudhary Dr. Sankalp

Anand S. K. Jain 1.0 1.0

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EQMS India Pvt. Ltd 304-305, 3rd Floor, Plot No. 16, Rishabh Corporate Tower, Community Centre, Karkardooma, Delhi 110092 Phone: +91 11 3000 3200 Fax: +91 11 2237 4775 Email: [email protected] URL: www.eqmsindia.com

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Rapid Environment Impact Assessment Study for Proposed Single Super Phosphate (Fertilizer) Manufacturing Unit at Village - Kalyangadh,

Taluka - Bavla, District - Ahmedabad by M/s Narmada Bio-Chem Pvt. Ltd.

i

TABLE OF CONTENT Chapters List of Tables ..................................................................................................................iv List of Figures ................................................................................................................. v List of Annexures ............................................................................................................vi Abbreviation ................................................................................................................... vii Executive Summary ......................................................................................................... I 1. Introduction .............................................................................................................. 1

1.1. Project Proponent ............................................................................................ 1 1.2. Project Site ...................................................................................................... 1 1.3. Purpose of the Study ....................................................................................... 3 1.4. Scope and Methodology of the Study .............................................................. 3 1.5. Approved TOR for EIA Study by SEAC, Gujarat .............................................. 5 1.6. Structure of the Report .................................................................................... 8

2. Project Description ................................................................................................. 11 2.1. Prelude .......................................................................................................... 11 2.2. Type of Project .............................................................................................. 11 2.3. Location ......................................................................................................... 11 2.4. Proposed Single Super Phosphate (SSP) Plant ............................................. 12

2.4.1. Product Details .......................................................................................... 12 2.4.2. Manufacturing Process .............................................................................. 13 2.4.3. Mass Balance ............................................................................................ 15

2.5. Resource Requirements ................................................................................ 17 2.5.1. Land Break-up ........................................................................................... 17 2.5.2. Raw Material Requirement ........................................................................ 20 2.5.3. Electricity ................................................................................................... 20 2.5.4. Water ......................................................................................................... 20 2.5.5. Fuel Requirement ...................................................................................... 21 2.5.6. Reactors, Vessels and Equipment Requirement ........................................ 21 2.5.7. Employment ............................................................................................... 23

2.6. Environmental Aspects .................................................................................. 23 2.6.1. Water Pollution .......................................................................................... 23 2.6.2. Air Pollution ............................................................................................... 24 2.6.3. Solid/ Hazardous Waste Generation .......................................................... 25 2.6.4. Noise Pollution ........................................................................................... 25

3. Description of the Environment .............................................................................. 26 3.1. Prelude .......................................................................................................... 26 3.2. Site Description and Its Environs ................................................................... 26 3.3. State of the Environment (Regional) .............................................................. 28

3.3.1. Topography and Geology .......................................................................... 28 3.3.2. Climate and Rainfall ................................................................................... 28 3.3.3. Geomorphology and Soil Types ................................................................. 29 3.3.4. Hydrogeology ............................................................................................ 29 3.3.5. Drainage system ........................................................................................ 30 3.3.6. Seismic Considerations ............................................................................. 31

3.4. State of the Environment (Local) ................................................................... 32 3.4.1. Micro-Meteorology ..................................................................................... 32 3.4.2. Topography ............................................................................................... 34 3.4.3. Land Use ................................................................................................... 34 3.4.4. Soil Characteristics .................................................................................... 36 3.4.5. Water Environment .................................................................................... 39 3.4.6. Air Environment ......................................................................................... 42 3.4.7. Noise Environment .................................................................................... 43 3.4.8. Traffic Density ............................................................................................ 44



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3.4.9. Biological Environment .............................................................................. 45 3.4.10. Socio-Economic Conditions ....................................................................... 49 3.4.11. Industries in the study area ........................................................................ 51 3.4.12. Resettlement and Rehabilitation Plan ........................................................ 51 3.4.13. Public Perception of the Project ................................................................. 51

4. Anticipated Environmental Impacts and Predictions ............................................... 55 4.1. General.......................................................................................................... 55 4.2. Potential Impacts during Project Implementation ........................................... 55

4.2.1. Air Environment ......................................................................................... 56 4.2.2. Land Environment ...................................................................................... 57 4.2.3. Ambient Noise Levels ................................................................................ 57 4.2.4. Water Quality ............................................................................................. 58 4.2.5. Solid Waste Generation (Hazardous/ Non-hazardous) and Disposal ......... 59 4.2.6. Storage of Hazardous Materials/ Dumping Materials ................................. 59 4.2.7. Terrestrial Ecology ..................................................................................... 59 4.2.8. Socio-Economic Environment .................................................................... 59 4.2.9. Site Security and Safety ............................................................................. 60

4.3. Potential Impacts during Project Operation .................................................... 60 4.3.1. Air Environment ......................................................................................... 60 4.3.2. Noise Environment .................................................................................... 67 4.3.3. Water Environment .................................................................................... 67 4.3.4. Land Environment ...................................................................................... 68 4.3.5. Biological Environment .............................................................................. 68 4.3.6. Socio – Economic Environment ................................................................. 68 4.3.7. Impact on Infrastructure ............................................................................. 68

5. Environment Management Plan ............................................................................. 71 5.1. Introduction .................................................................................................... 71 5.2. Objectives of EMP ......................................................................................... 71 5.3. Components of EMP...................................................................................... 71

5.3.1. Central Pollution Control Board {CPCB} Guide Lines for Fertiliser Industry 72 5.3.2. Air Environment ......................................................................................... 73 5.3.3. Noise Environment .................................................................................... 79 5.3.4. Water Environment .................................................................................... 79 5.3.5. Biological Environment .............................................................................. 80 5.3.6. Land Environment ...................................................................................... 81 5.3.7. Resource Conservation/ Waste Minimization ............................................. 81 5.3.8. Corporate Social Responsibility ................................................................. 81 5.3.9. Environment Management Cell .................................................................. 81

5.4. Project Cost and Cost towards Environmental Protection .............................. 81 6. Environmental Monitoring Program ........................................................................ 85

6.1. Prelude .......................................................................................................... 85 7. Risk Assessment ................................................................................................... 86

7.1. Introduction .................................................................................................... 86 7.2. Hazard Identification ...................................................................................... 86

7.2.1. Hazardous Materials to be Stored at the Plant ........................................... 86 7.2.2. Characteristics of Hazardous Materials ...................................................... 87 7.2.3. Associated Hazards ................................................................................... 88 7.2.4. Actions required in case of Exposure ......................................................... 88

7.3. Effect & Consequence Analysis ..................................................................... 89 7.3.1. Scenarios................................................................................................... 89 7.3.2. Risk Assessment of Sulphuric Acid Tank ................................................... 89 7.3.3. Consequence Analysis .............................................................................. 89

7.4. Recommendations ......................................................................................... 90 7.5. Occupational Exposure Mitigation Planning ................................................... 90 7.6. Other Recommended Measures for Safe Operation of the Plant ................... 91



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7.6.1. Personal Protective Equipment .................................................................. 91 7.6.2. Handling of Hazards .................................................................................. 92 7.6.3. General Working Conditions at the Proposed Plant ................................... 92 7.6.4. Safe Operating Procedures ....................................................................... 92 7.6.5. Work Permit System .................................................................................. 92 7.6.6. Fire Protection ........................................................................................... 92 7.6.7. Static Electricity ......................................................................................... 93 7.6.8. Material Handling ....................................................................................... 93 7.6.9. Communication System ............................................................................. 93 7.6.10. Safety Inspections ..................................................................................... 93 7.6.11. Safe Operating Procedures ....................................................................... 93 7.6.12. Predictive and Preventive Maintenance ..................................................... 93 7.6.13. Electrical Safety ......................................................................................... 93 7.6.14. Colour Coding System ............................................................................... 93

8. Summary and Conclusions .................................................................................... 94 8.1. Prelude .......................................................................................................... 94 8.2. Regulatory Compliance ................................................................................. 94 8.3. Baseline Conditions ....................................................................................... 94 8.4. Environmental Impacts and Mitigation Measures ........................................... 95 8.5. Recommendations ......................................................................................... 95

9. Disclosure of Consultants Engaged ....................................................................... 96 9.1. Team Composition ........................................................................................ 96



iv

LIST OF TABLES

Table 1.1 : TOR Compliance Status ...................................................................................... 5 Table 2.1 : Surrounding Area Profile ................................................................................... 11 Table 2.2 : Details of Proposed Products ............................................................................ 12 Table 2.3 : Mass Balance in Powder Single Super Phosphate (400 TPD) ........................... 16 Table 2.4 : Mass Balance in Granular Single Super Phosphate (200 TPD) ......................... 16 Table 2.5 : Specification of Single Super Phosphate (SSP) as per FCO ............................. 16 Table 2.6 : Physical and Chemical Properties of Product, By-Product and Raw Materials .. 17 Table 2.7 : Area Break-up ................................................................................................... 17 Table 2.8 : Raw Material Requirement for Powder Single Super Phosphate (400 TPD) ...... 20 Table 2.9 : Raw Material Requirement for Granular Single Super Phosphate (200 TPD) .... 20 Table 2.10 : Break-up for Fresh Water Requirement ........................................................... 20 Table 2.11 : Details of Reactors, Vessels and Equipments ................................................. 21 Table 2.12 : Break-up of Wastewater Generation ................................................................ 24 Table 2.13 : Details of Flue Gas Stack ................................................................................ 25 Table 2.14 : Details of Process Stack .................................................................................. 25 Table 3.1 : Summary of Micrometeorological Data .............................................................. 32 Table 3.2 : Land Use Distribution ........................................................................................ 34 Table 3.3 : Analysis Results of Soil Sampling ..................................................................... 38 Table 3.4 : Water Quality in the Study Area ........................................................................ 40 Table 3.5 : Land Use Around the Air Sampling Locations ................................................... 42 Table 3.6 : Ambient Air Quality Status in the Study Area ..................................................... 43 Table 3.7 : Ambient Noise Quality Results .......................................................................... 44 Table 3.8 : Hourly Traffic Density – National Highway – 8A................................................. 44 Table 3.9 : Large Trees species found in Study area .......................................................... 45 Table 3.10 : Shrubs found in Study area ............................................................................. 46 Table 3.11 : Herbs found in Study area ............................................................................... 46 Table 3.12 :Agricultural Crops found in Study area ............................................................. 46 Table 3.13 : Amphibian in Study area ................................................................................. 47 Table 3.14 : Reptiles in Study Area ..................................................................................... 47 Table 3.15 : Birds Spices found in Study Area .................................................................... 47 Table 3.16 : Mammals in Study area ................................................................................... 47 Table 3.17 Annelida in Study area ...................................................................................... 47 Table 3.18 : Villages in the Study Area ............................................................................... 49 Table 3.19 : Summary of Demographic Profile .................................................................... 52 Table 3.20 : Summary of Economic Status ......................................................................... 53 Table 3.21 : Summary of Amenities in the Villages in the Study Area ................................. 54 Table 4.1 : Emission Factors of Various Dust Generation Processes .................................. 56 Table 4.2 : Exhaust Emissions for Stationary and Mobile Machinery ................................... 57 Table 4.3 : Typical Noise Sources during Construction Phase ............................................ 58 Table 4.4 : Stack Emission Details ...................................................................................... 62 Table 4.5 : Contribution to GLCs (maximum) due to Proposed SSP Project Stacks ............ 67 Table 4.6 : Pre-mitigation Matrix for Various Project Activities and Associated Potential

Environmental Impacts on Various Environmental Attributes ....................................... 69 Table 5.1 : Action Points as per CREP ................................................................................ 72 Table 5.2 : Scrubbing Efficiency Details .............................................................................. 75 Table 5.3 : Runoff Available for Recharge ........................................................................... 80 Table 5.4 : Recommendation of Recharge Structures based on Hourly Computation of

Runoff - (50 mm/hr) ...................................................................................................... 80 Table 5.5 : Post mitigation Matrix for Various Project Activities and Associated Potential

Environmental Impacts on Various Environmental Attributes ....................................... 83 Table 6.1 : Matrix of Environmental Monitoring Plan ........................................................... 85 Table 9.1 : Team Composition and Expertise Area ............................................................. 96



v

LIST OF FIGURES

Figure 1.1 : Location Map of the Project ................................................................................ 2 Figure 1.2 : Methodology of EIA Study .................................................................................. 4 Figure 2.1 : Project Location in Village Survey Map ............................................................ 12 Figure 2.2 : Process Flow Diagram of Single Super Phosphate (SSP) & Granular Single

Super Phosphate (GSSP) ............................................................................................ 15 Figure 2.3 : Layout Plan of the Project ................................................................................ 19 Figure 2.4 : Water Balance Diagram ................................................................................... 24 Figure 3.1 : Study Area Map of 5 km Radial Zone around the Project Site .......................... 27 Figure 3.2 : Geological Map of Gujarat showing Project Location ....................................... 28 Figure 3.3 : Soil Types in Gujarat ........................................................................................ 29 Figure 3.4 : Ground Water Resources of Gujarat ................................................................ 30 Figure 3.5 : Drainage Map of Gujarat .................................................................................. 31 Figure 3.6 : Seismic Zoning Map of India ............................................................................ 31 Figure 3.7 : Wind Rose (Summer Season) at Project Site ................................................... 33 Figure 3.8 : Wind Class Frequency Distribution ................................................................... 34 Figure 3.9 : Landuse/ Land Cover Map of the Study Area (5 km radial zone) ...................... 35 Figure 3.10 : Sampling Locations in the Study Area ............................................................ 37 Figure 3.11 : Forest Map of Gujarat .................................................................................... 48 Figure 3.12 : National Parks and Sanctuaries in Gujarat ..................................................... 49 Figure 4.1 : Isopleths of PM due to Proposed SSP Project ................................................. 63 Figure 4.2 : Isopleths of SO2 due to Proposed SSP Project ................................................ 64 Figure 4.3 : Isopleths of NOx due to Proposed SSP Project ................................................ 65 Figure 4.4 : Isopleths of HF due to Proposed SSP Project .................................................. 66 Figure 5.1 : Air Pollution Control System in 400 TPD Single Super Phosphate Plant .......... 76 Figure 5.2 : Air Pollution Control System in 200 TPD Granular Single Super Phosphate Plant

.................................................................................................................................... 77 Figure 5.3 : Air Pollution Control System in 12 TPD Grinding Section ................................. 78 Figure 5.4 : Structure of Environment Management Cell ..................................................... 82



vi

LIST OF ANNEXURES

Annexure I - Approved TOR by SEAC, Gujarat Annexure II - Linkage of Rock Phosphate Annexure III - Categorization of the Area by CGWA Annexure IV - CGWA Guidelines for Ground Water Abstraction Permission Annexure V - Form No. 37 of Gujarat Factories Rules.



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ABBREVIATION

AAQ Ambient Air Quality

BDL Below Detection Limit

BRP Beneficial Rock Phosphate

CGWA Central Ground Water Authority

CPCB Central Pollution Control Board

CREP Corporate Responsibility for Environmental Protection

CRP Crystal Rock Phosphate

DG Diesel Generator

EIA Environmental Impact Assessment

EMP Environmental Management Plan

EQMP Environmental Quality Monitoring Programme

GLC Ground Level Concentration

GPCB Gujarat Pollution Control Board

GSSP Granule Single Super Phosphate

GW Ground Water

HAG Hot Air Generator

HF Hydrogen Fluoride

HSE Health Safety and Environment

IDLH Immediately Dangerous to Life or Health

IMD India Meteorological Department

IS Indian Standard

ISCST Industrial Source Complex Short Term

LC Lethal Concentration

MoEF Ministry of Environment and Forests

MSIHC Manufacture, Storage & Import of Hazardous Chemicals

MSL Mean Sea Level

NAAQS National Ambient Air Quality Standard

NBCL Narmada Bio-Chem Pvt. Ltd.

NH National Highway

NOx Oxides of Nitrogen

NPK Nitrogen Phosphorous Potassium

PM Particulate Matter

PPE Personal Protective Equipment

PSSP Powder Single Super Phosphate

SEAC State Level Expert Appraisal Committee

SEIAA State Level Environmental Impact Assessment Authority

SO2 Sulphur Dioxide

SSP Single Super Phosphate

SW Surface Water

TLV Threshold Limit Value

TOR Terms of Reference

UGVCL Uttar Gujarat Vij Corporation Limited

USEPA United States Environmental Protection Agency



I

EXECUTIVE SUMMARY

Project Highlight

Narmada Bio-Chem Pvt. Ltd. (NBCL) (A unit of National Organic Fertilizer Group) is a leading manufacturer and exporter of organic fertilizers with ISO 9001:2008 standard certification. At present, Narmada Bio-Chem Pvt. Ltd. is involved in manufacturing different grades of NPK fertilizers in the Trade Name of "Himalay" in Ahmedabad, Gujarat.

Presently NBCL has three units. Unit I & II are located at Moraiya (Changodar), Ahmedabad & Unit III is located at Malarpura, Kheda in Gujarat. Unit III of NBCL is having NPK mixed fertilizer of 450 MTPD capacity, which is the largest plant of India in NPK mixed fertilizer production. NBCL has successfully stood catering the needs of Indian farmers for more than one decade with the total output of 320,000 MTPA.

NBCL has now proposed to set up its fourth unit for manufacturing of Single Super Phosphate (SSP) fertilizer, with a focus to provide specific fertilizer to farmers for balanced application of nutrients, in District - Ahmedabad, with a total installation capacity of 198,000 MTPA.

Project Categorization

As per the EIA Notification 2006 of Ministry of Environment & Forests (MoEF), Government of India and as amended on December 1, 2009, the proposed SSP manufacturing unit has to required prior environmental clearance for commissioning the plant. The proposed project is covered under Category 'B' as per the Schedule of EIA Notification and hence requires environmental clearance from State Level Environmental Impact Assessment Authority (SEIAA) of Gujarat.

Project Location

NBCL has proposed to set up its new unit (Unit - IV) for manufacturing of Single Super Phosphate at At & PO: Kalyangadh, Survey No. 268, Taluka - Bavla, District - Ahmedabad. Total land area acquired for the proposed project is 32,520 sq. m. The proposed project site for SSP plant is easily approachable and is located along the National Highway No. 8A.

Type of Project

Proposed project is a Greenfield project and has been conceptualized for manufacturing of Single Super Phosphate (SSP) with total installation capacity of 198,000 MTPA, out of which, Powder SSP will be 132,000 MTPA and Granulated SSP will be 66,000 MTPA..

Manufacturing Process

The process of manufacturing of SSP involved chemical reactions between rock phosphate and sulphuric acid. Calcium tri phosphate, which is insoluble in water, is the major part of rock phosphate and calcium fluoride is the major impurity present in the rock.

The manufacturing process of Single Super phosphate is achieved by the reaction between Rock phosphate and Spent Sulphuric Acid/dilute Sulphuric Acid of desired strength.



II

The Single Super phosphate Fertilizer consisting of mono Calcium phosphate Gypsum, Silica and un-reacted Rock Phosphate as a filler material is cured for necessary period on open yard after necessary reshuffling to achieve desired chemical reaction. This process of substantial formation of water soluble P2O5 content in the phosphates is known as curing, and is obtained by leaving the material in the piles for period varying from 5-9 days.

The cured material is reclaimed from piles and is dumped in the Bagging Hopper. The finished product finally packed in to the 50 kg bags or as per any other requirement.

The scrubbed liquor consisting of Water, Hydrofluorosilicic Acid and Silica is taken into a settler to separate the Silica and after necessary washing to the Silica; the same is used as a filler material. The dilute Hydrofluorosilicic Acid is either used for Sulphuric Acid dilution or sold to outside parties as their basic raw material. Then the traces of HF coming from ventury scrubber will be scrubbed with Caustic lye solution in Alkali Scrubber. This Scrubbed liquor will be re-circulated within the scrubber up to pH 9.0 and finally utilized in to the manufacturing process.

The main raw material for manufacture granular SSP is powder SSP. Mix powder SSP with water and make granules in granulator. Pass the hot air from hot air generator in rotary dryer. Moisture will be evaporated from granules. Cool down by passing the air in cooler. Now, granular SSP product will be ready for sale.

Resources Requirement

Land: Total land area under possession of NBCL is 36,220 sq. m., out of that area in National Highway Control Line is about 3,700 sq. m. Hence, remaining plot area available for the plant is 32,500 sq. m. About 9,918 sq. m. area has been kept for green area and greenbelt development, which is more than 30% of the total plot area.

Raw Material: Key raw materials required for the manufacturing of SSP are rock phosphate and spent sulphuric acid. Rock phosphate will be either imported or will be taken from RSMML. Sulphuric acid will be purchased from the nearby areas. All the raw materials will be stored into the designed storage area within the premises. Approximate monthly consumption of rock phosphate and sulphuric acid will be 6,500 MT and 5,000 MT, respectively.

Water: Total fresh water requirement for the manufacturing of proposed SSP products will be approximately 47.0 KLD. Industrial water requirement will be about 40 KLD and domestic and other water requirements will be about 7.0 KLD. The freshwater requirement for the proposed project will be met by ground water abstraction at site. Recycled water from washing and scrubbing will be recycled back in process, which will reduce the fresh water consumption by 20 KLD.

Power: Power requirement for the project is about 1400 KW, which will be sourced from Uttar Gujarat Vij Corporation Limited. A 200 KVA DG set will be provided at site for power backup, which will be used only during grid power failure.

Fuel: Agro waste will be used as a fuel in Hot Air Generator (HAG) at the rate of 285 kg/hr, which will have total capacity of 10.0 lacs Kcal. HSD will be used as fuel for the DG set of capacity 200 KVA. The fuel consumption will be about 40 l/hr. DG set will be used only during grid power failure.



III

Manpower: Manpower requirement during construction phase will be about 30 to 50 personnel and during operation phase will be about 50 personnel.

Environmental Aspects

Air Pollution

The impact on air quality due to the operation of the proposed SSP project will be mainly due to the following sources:

Combustion of agro waste used in HAG

Grinding/ milling of rock phosphate

Emission of hydrogen fluoride and SPM from the mixer & den conveyor

Fugitive emissions

Agro waste will be used as fuel in the HAG, which will generated PM, SO2, and NOx. These pollutants will be emitted into the atmosphere due to combustion. However, the unit will be provided with two stage cyclone separator followed by wet scrubber to achieve the desired norms and scrubbed liquor will be reused in the process.

In the SSP plant dust collector and cyclone separator will be provided for removal of particulate matter generated from grinding of rock phosphate. Dust separated form the cyclone separator as well as from the dust collector will be used in process.

Hydrogen fluoride gas generated from the SSP process will be conveyed in rubber lined ducts to the scrubbers. A settling chamber along with two stage water spray scrubbers and two stage ventury scrubbers followed by alkali scrubber will be provided to obtain the desired level of hydrogen fluoride.

The process gas reacts with the Silica present in the Rock Phosphate, which generates SiF4 and this SiF4 when scrubbed with Water to form liquor Hydroflouro Silicic Acid will be generated and sold as a By product. Then the traces of HF coming from ventury scrubber will be scrubbed with Caustic lye solution in Alkali Scrubber. This Scrubbed liquor will be re-circulated within the scrubber up to pH 7.0 and finally utilized in to the manufacturing process.

In addition to the above, there will be some air emission due to the movement of trucks, which will be used for receipt of raw material from Kandla Port/ RSMML mines and for dispatch of final product for export as well as to the local market as per the requirement. Based on the monthly raw material requirement for the project, it has been estimated that about 30 - 35 Trucks per day will enter in the plant with raw material from mines/ port and about 30 Trucks per day will take out final product (PSSP and GSSP) from the plant. Hence, about 3 to 4 trucks/ hour will be at the project site at any point of time.

Water Pollution

There will not be any wastewater generation due to industrial process. Wastewater generated from washing and scrubbing will be recycled back in the process. Hence, no industrial wastewater is anticipated from the project. From domestic application about 1.5 KLD of wastewater will be generated, which will be sent to septic tank followed by soak pit. Hence, due to no wastewater discharge, the unit will be "Zero Discharge Unit".



IV

Noise Pollution

The plant will have various rotating machines including blowers, vacuum pumps, process pumps, etc. along with DG sets, which will generate noise. These machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.

Waste Generation

There will be no major source of hazardous waste generation due to the proposed project. Only hazardous waste generation will be in the form of used oil, which is categorized as 5.1 in the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008. Annual generation of hazardous waste will be approximately 150 litres. In addition to that, scrap generated will be sold to the recyclers and other non-hazardous waste/ garbage will land filled within the factory premises.

Environmental Status of Plant Site and Study Area

Site Characteristics

The site identified and acquired for setting up the proposed single super phosphate manufacturing plant is located at Survey No. 268 of Village Kalyangadh in Bavla Taluka of Ahmedabad District. The project site is bounded by NH-8A (Ahmedabad - Rajkot) on the South and agricultural/ barren land of Kalyangadh village on other three sides. The site is situated at Latitude 22°42'54.38"N and Longitude 72°15'24.76"E. Nearest village is Kalyangadh, which is about 1.5 km from the project site. The study area for the EIA study constitutes of 5 km radial zone around the project site, which is mainly having rural environment.

Topography: The topography of the area is almost flat covered by brown sandy and clayey soil and has gentle westerly and south westerly slope. The elevation of the land surface varies from 12.5 m to 13.0 above MSL. There are no hills, hillocks or undulating land in the region.

Geology: The geology is underlain by recently placed alluvial sands and few sporadic outcrops of Deccan Trap and Limestone towards southern part of the region, The rock formations ranging in age from Archaean to recent include gneises, schishts, phyllites, intrusive medium to coarse grain sandstone, basalts and recents alluvium.

Climate: The region has a tropical type of climate with extreme summers and winters. The Arabian Sea and Gulf of Khambhat reduce the temperature and render the climate more pleasant and healthy. The average annual temperature varies from 36ºC in summer to 8ºC in winter. The relative humidity varies from maximum of 90% to a minimum of 10%. The area receives an average annual rainfall of 732 mm.

Seismicity: According to the seismic-zoning map of India, the project area falls in Zone III - Moderate Seismic Intensity.

Micro-meteorology: The meteorological data recorded during the study period is used for interpretation of the baseline information as well as input for air quality simulation models. Meteorological data was collected for Post-monsoon season (September to November 2010). Average daily temperature varies between 28.0 to 30.0°C, whereas average relative humidity varies between 50 to 66%. The analysis of the average wind pattern shows predominant winds from W followed by N with wind frequencies of 16.5% & 10.1%, respectively. The calm wind (wind speed < 0.5



V

m/s) conditions prevailed for 11.2% of the total time. Average wind speed was observed as 2.66 m/s.

Soil: The soil samples collected from the study area reveal sandy characteristics. The soil is slightly alkaline in nature. Levels of nitrogen and phosphate were observed to be low.

Landuse: The land use in the study area can be broadly classified into 5 major categories viz., agricultural land, fallow land, sparse vegetation, barren land & rural settlements. The landuse break-up within 5 km radial zone from the project site with respect to agricultural land, fallow land, sparse vegetation, barren land & rural settlements is 39.5%, 30.3%, 16.7%, 4.8% & 4.7%, respectively.

Water: The water quality in the region (ground and surface water) has been compared with respect to the Drinking Water Quality Standards as per IS: 10500:1991. The drinking water available at Village Kalyangadh coming from River Narmada is absolutely fit for drinking and confirm fully to the drinking water standards. Ground water samples as well as other surface water samples were showing TDS level higher than the desirable limit of 500 mg/l, but below the permissible limits. The high TDS values can be easily traced to the high levels of Magnesium and Calcium Hardness (mg/l) and high Chloride concentration in these samples. The high concentrations of these ions may be attributed to the geological nature of the area. Rest of the parameters physico-chemical parameters and heavy metals were well within the desirable limits of the IS:10500:1991 drinking water standards.

Air Quality: Ambient air quality was monitored for PM10, PM2.5, SO2, NOx and HF at 6 locations within the study area. All the criteria pollutants concentrations were observed well within National Ambient Air Quality Standards for industrial, residential and rural areas. HF was not detected in any of the ambient air quality sample.

Noise: The noise levels at the villages of Kalyangadh and Bhamsara was found to be slightly more than the ambient noise standards for Residential and Rural Areas during day as well as night time for which the standards are 55 dB(A) and 45 dB(A) during daytime & night time, respectively. This is due to the heavy traffic density in the NH-8A passing through these areas. The Noise level at the Project site though was more than the standard level for Residential area but was within the standard for Industrial area.

Flora & Fauna: There are no national parks, wild life sanctuaries, tiger reserve, bird sanctuaries or elephant reserves within the study area. Also, no endangered plant and/or faunal species were found within the study area.

Demography: The 5 km radial zone study area constitutes of 9 villages. Total population of the study area is 19,176, out of which total male and female population is 10,039 and 9,137, respectively. Sex ratio in the study area is 910. The schedule cast and schedule tribe population in the study area is 10.23% and 0.34%, respectively. As per Census 2001, total number of households in the study area is 3,808 and average household size is 5.1. Literacy rate of the study area is 46.73%. Total working population in the study area is 41.5%, out of which main working population is 26.4%.



VI

Environmental Impact Assessment

Topography and Soils

The activities involved in site preparation will be site clearance of the project site, cutting and uprooting of shrubs, earthwork excavation etc. The development of site will also involve the removal of top soil, removal of shrubs, soils, etc. As the topography of the land is almost flat, there will be very minimum cutting and filling required for setting up of the plant and no filling material from outside is required. Hence, there will be very limited impact on the land environment due to the proposed project.

Soil around construction sites, haulage roads, and workshop areas, will get compacted due to transportation of man, machine and materials. Soil may also get contaminated around construction site, machine maintenance area, fuelling station, construction camp, road construction material storage and preparation site, and haulage road.

Air Quality

The major air pollutants expected to be emitted from proposed SSP project are SPM, NOx, SO2, and some quantity of HF, from combustion of agro waste used in HAG, grinding/ milling of rock phosphate, emission of hydrogen fluoride and SPM from the mixer and den conveyor. The point sources of emission will be stack attached with HAG, DG set stack and scrubber vent.

For the proposed project, computations of 24-hour average ground level concentrations were carried out using ISC-AERMOD View model, which is a recommended model by CPCB for prediction of air quality from point, area and line sources.

S. No.

Stack Stack Height

(m)

Stack Diameter

(m)

Exit Velocity

(m/s)

Exit Temp

(K)

Emission Rate (g/s)

PM SO2 NOx HF

1 Process 50 0.9 11 323 0.55 0.9 0.33 0.1

2 HAG 30 0.6 20 323 0.46 0.8 0.3 -

The contribution to GLC due to the point sources of proposed SSP plant is as below:

Description Maximum Ground Level Concentration (μg/m3)

PM SO2 NOx HF

Process Stack HAG Stack

3.93 6.72 2.50 0.24

Distance of Occurrence (km) 1.0 1.0 1.0 0.8

Direction of Occurrence ESE ESE ESE S

It is evident from the modeling results that the incremental GLC due to the proposed project is not significant.

Noise

The sources of noise during the operational phase of the SSP plant are mainly granulator, dryers and coolers, crushers, bucket elevators, screw conveyors, pumps etc. The other sources of noise are the movement of vehicles along the road all



VII

around the plant. The proposed SSP project will be a smaller project with advanced technology and improved equipments both in terms of energy efficiency and less noisy. However the material handling equipments especially crushers, bucket elevators and pay-loaders are noisy but the noise level is limited. These machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.

The existing ambient noise levels near the project site are in the range of 50 to 60 dB(A). Therefore, the future noise impacts on the environment are not expected to be significant. Due to the masking effect, the ambient noise level in the nearby areas will not increase during the operation of the plant. Also, the greenbelt with taller trees is proposed in the plant periphery. Hence, there would not be any adverse impact due to the operation of the plant on the residents of the nearby areas. Employees working near crushers, bucket elevators and pay-loaders are exposed to slightly high decibels noise (+ 80 dBA). Employees working in these areas will be provided with adequate PPEs.

Water Resources and Water Quality

There will not be any wastewater generation due to industrial process. Wastewater generated from washing and scrubbing will be recycled back in the process. Hence, no industrial wastewater is anticipated from the project. From domestic application about 1.5 KLD of wastewater will be generated, which will be sent to septic tank followed by soak pit. Due to no wastewater discharge outside the plant premises, the unit will be "Zero Discharge Unit". In addition to that, for rainwater harvesting within the plant premises, a total of 9 no. of percolating wells will be provided. These wells will help in recharging the groundwater aquifer. Hence, it can be envisaged that the proposed project will not have any significant impact on water environment.

Land Use

No significant impact on land environment has been envisaged during the operation phase as the project is not going to generate huge quantities of hazardous/ solid waste. Also, about 30% of the land will be utilized for greenbelt development, which will help in enhancing the aesthetic environment of the area.

Biological Environment

During the operation phase of the project, a total of 516 tall trees will be planted along the periphery of the project and about 9918 sq. m. area will be developed as green area. These activities will help in reducing the air and noise pollution as well as will enhance the biological and aesthetic environment in and around the project site. The development of green belt provides habitat, food and breeding areas to birds, small animals and insects. No rare or endangered species of fauna are reported to exist in the area. Thus, no impacts on rare / endangered species are envisaged due to normal operations. Indigenous tree plantation will be preferred in greenbelt development. Hence, no negative impact on biological environment is envisaged.

Demographic and Socio-economic

Proposed project will generate direct employment for about 50 persons. In addition to that, indirect employment opportunities will be generated in raw material and final products transportation, contractual manpower for non-critical activities at the plant (canteen, gardening, housekeeping etc.). The industrial growth of the region will help in infrastructure development in the area. It will also generate income for government through taxes. Overall the project will have positive impacts on socio-economic environment.



VIII

Infrastructure

The raw material (rock phosphate & sulphuric acid) will be transported from RSMML mines/ Kandla Port or from nearby areas. Approximately 30-35 trucks/ day will come to the plant. The final product will be dispatched from plant to Kandla Port for export and to various part of the country via existing road network. Approximately 25 to 30 trucks/ day will be used for the same. Based on the estimation, approximately 4 to 5 trucks per hour will remain at the project site. Hence, due to the project activity the increase in trucks traffic density in the study area will be about 55 to 65 trucks/ day. This will have some impact on the existing road network within the study area. However, adequate parking for trucks at the project site along with rest room and canteen facilities within the premises of the factory for drivers will be provided. The national highway adjacent to the project site is already having 4-lanes and is planned to widen further. Hence, additional increase of traffic due to the proposed project does not have any significant impact on the road infrastructure.

Environmental Management Plan

Air Environment

In order to mitigate the adverse environmental impact due to the construction and operation of the proposed SSP project following measures are recommended:

Construction Phase:

To keep the damage to topsoil minimum, excavators shall be used for construction. The excavated material such as topsoil and stones shall be stacked at safe places for reuse at a later stage of construction.

To prevent soil erosion during construction phase, temporary seeding, sedimentation basins, contour trenching, mulching etc. can be done based on the net imperviousness of the site and it should not exceed the imperviousness factor as prescribed by the National Building Code, 2005.

Preserving existing vegetation or re-vegetating disturbed soils is one of the most effective ways to control soil erosion.

During dry weather, control of the dust nuisance created by excavation, and transportation activities shall be carried out by water sprinkling.

Spill prevention and control plans shall be made, clearly stating measures to stop the source of the spill, to contain the spill, to dispose the contaminated material including paints, cleaners, and petroleum products.

Operation Phase:

All trucks will be transported after covering from the top.

Dust collectors will be in line with unloading hoppers.

HAG will be provided with two stage cyclone separator followed by wet scrubber.

Dust collector and cyclone separator will be provided for removal of particulate matter generated from grinding of rock phosphate.

Dust separated form the cyclone separator as well as from the dust collector will be used in process.

Hydrogen fluoride gas generated from the SSP process will be conveyed in rubber lined ducts to the scrubbers. A settling chamber along with two stage water spray scrubbers and two stage ventury scrubbers followed by alkali scrubber will be provided to obtain the desired level of hydrogen fluoride.

DG set shall be provided with 3 m stack height above roof top of DG room for better dispersion of pollutants.



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Greenbelt and green area will be developed with tall trees with wide leaves in the periphery of the plant for control of air pollution.

Noise Environment

All the equipments in the plant would be designed to have a total noise level not exceeding 85- 90 dB(A) as per the requirement of OSHA (Occupational Safety and Health Administration) standards.

Manufacturers/Suppliers of major noise generating machines/ equipments like compressors, feed pumps, vacuum pumps, diesel engines, generators etc. should ensure the State-of-the-Art low noise equipments to comply with international standards.

Noise traps/ mufflers silencers shall be provided for noise reduction wherever possible. Acoustic design with sound proof glass panelling should be provided for in-house operators/ control rooms to mitigate any occupational exposure.

Use of personal protective devices such as ear-muffs, ear-plugs etc. should be strictly enforced for the workers engaged in high noise areas.

Provision of acoustic dampeners in foundations and insulators in the interiors.

The insulation provided for prevention of loss of heat and personnel safety will also act as noise reducers.

Water Environment

NBCL has taken ample precautions to reduce water consumptions and tackle effluents problem. All the industrial effluent generated from the proposed project will be recycled back in the process itself and there will not be any disposal of industrial effluent. Only effluent generation will be in the form of domestic effluent, which will be sent to septic tank followed by soak pit. No impact on ground or surface water is envisaged due to the project and hence, no mitigation measures are required. However, rainwater harvesting and recycle & reuse of all the industrial effluent have been adopted in the project to conserve the water resources.

Green Belt

NBCL has proposed to develop more than 30% of the total area as greenbelt. Thick greenbelt will be developed in the periphery of the project with two rows of taller trees. Some locally available species of trees will be preferred for plantation to promote the greenbelt in the study area. It is proposed to plant about 516 trees in the first three years of the project.

Corporate Social Responsibility

NBCL will be partner in the development of local people with a long term vision. The study area of 5 km is having very scattered settlements with nearest village at 1.5 km from the proposed project site. At the initial stage, NBCL has taken a provision of Rs. 50,000/- fund allocation for the socio-economic activities near the plant area, which will include: books & notebooks distribution, medical check-up of villagers, drinking water tank, and bus-pickup stand etc.

Occupational Exposure Mitigation Planning

To control any occupational health and safety impact a detailed planning for mitigation measures has been done in the design stage of the project. Apart from the occupational exposure mitigation plans for various activities and work areas of hazards, following administrative control measures will be followed:

All the employees will be trained for EHS policies.



X

Health check-up for OSA – Yearly once

Health check up for Employees- 2 years once

All the OSA peoples have been trained for Basic life support, first aid, Basic fire safety and emergency preparedness.

Ambient air quality monitoring in every month at 3 locations

Monthly monitoring of environmental parameters.

Safety display boards provided throughout the plant.

Monthly fire extinguisher audit.

Work permit system

PPE adherence

Waste management and hazardous waste handling

Safe lifting operation

Industrial hygiene

Environment Monitoring Plan

A detailed environmental monitoring plan for the proposed project during construction and operation phases of the project has been outlined. The same will be adhered during the project execution. In addition to that all the conditions being imposed in the consent to establish/ operate and environmental clearance shall be adhered.

General Safety Measures

All the personnel at the plant will be made aware about the hazardous substance stored at the plant and risk associated with them.

Personnel engaged in handling of hazardous chemicals will be trained to respond in an unlikely event of emergencies.

Safe work practices will be developed to provide for the control of hazards during operation and maintenance.

The workers will be made aware about the hazards associated with manual handling of chemicals.

Adequate fire fighting facilities will be provided at the plant, including, dry chemical powder type, water CO2 type, mechanical foam type, CO2 type of Fire Extinguishers and sand buckets. Personnel will be trained to combat the fire in various hazardous chemicals.

The fire fighting system and equipment will be tested and maintained as per relevant standards.

Safety measures in the form of DO and Don‟t Do will be displayed at strategic locations especially in local language.

Good house keeping will be maintained in the plant.

The required PPEs for each area/operation should be identified and the necessary PPEs, like, helmets, goggles, hand gloves, mask, PVC suit, Self Containing Breathing Apparatus, safety belts, ear muff and plug, etc. will be provided to the personnel.

The plant will check and ensure that all instruments provided in the plant are in good condition and documented.

Adequate ventilation will be provided. Local exhaust ventilation will be effective in controlling the dust and fumes in the work environment.

All equipment and storage tanks/containers of flammable chemicals should be bounded and earthed.

First aid box will be provided within the plant.



XI

List of important telephone numbers will be displayed at each and every location in the plant.

All the accidents and incidents will be recorded, investigated and analysed in the proposed plant.

Safety awareness programme and training of the worker will be carried out to motivate the workers to increase the safety level at personal level.

Occupational Health Aspect: As per govt. standard all facilities will be provided.

Safety Precautions for Storage & Handling of Acids: The unit will provide special precautions for storage & handling of Sulphuric Acid

& Hydro Fluoro Silicic Acid within the premises.

Acids storage tanks will be placed in to the separate storage area within the premises.

The proper collection system will be provided for the leakage & spillage collection of both the acids by preparing dyke wall and Acid Proof RRC Flooring with spillage collection tank and will be transferred to the emergency storage tank.

Proper vent will also be provided to each storage tank. Moreover, Weather shed and water sprinkling system will be provided.

Project Cost & Cost towards Environmental Protection

The total project cost of the proposed SSP project is Rs. 12 crores. The cost of air pollution and water pollution control measures is about Rs. 55 Lacs and Rs. 20 Lacs, respectively. The recurring cost for pollution control will be about 2 Lacs/ annum.



1

1. INTRODUCTION

1.1. Project Proponent

1. Narmada Bio-Chem Pvt. Ltd. (NBCL) (A unit of National Organic Fertilizer Group) is a leading manufacturer and exporter of organic fertilizers with ISO 9001:2008 standard certification. At present, Narmada Bio-Chem Pvt. Ltd. is involved in manufacturing different grades of NPK fertilizers in the Trade Name of "Himalay" in Ahmedabad, Gujarat.

2. Presently NBCL has three units. Unit I & II are located at Moraiya (Changodar), Ahmedabad & Unit III is located at Malarpura, Kheda in Gujarat. Unit III of NBCL is having NPK mixed fertilizer of 450 MTPD capacity, which is the largest plant of India in NPK mixed fertilizer production. NBCL has successfully stood catering the needs of Indian farmers for more than one decade with the total output of 320,000 MTPA.

3. NBCL has now proposed to set up its fourth unit for manufacturing of Single Super Phosphate (SSP) fertilizer, with a focus to provide specific fertilizer to farmers for balanced application of nutrients, in District - Ahmedabad, with a total installation capacity of 198,000 MTPA.

4. This EIA study report is for Narmada Bio-Chem Pvt. Ltd.'s “Single Super Phosphate (SSP)” plant. The proposed SSP project will require an investment of about Rs. 12 crores.

1.2. Project Site

5. M/s Narmada Bio-Chem Pvt. Ltd. has proposed to set up its new unit (Unit - IV) for manufacturing of Single Super Phosphate at At & PO: Kalyangadh, Survey No. 268, Taluka - Bavla, District - Ahmedabad. Total land area acquired for the proposed project is 32,520 sq. m. The proposed project site for SSP plant is easily approachable and is located along the National Highway No. 8A. The project location has been shown in Figure 1.1.

This chapter provides background information of the project, need of the project, need of the EIA study, scope and EIA methodology adopted and structure of the report.



2

Figure 1.1 : Location Map of the Project



3

1.3. Purpose of the Study

6. As per the EIA Notification 2006 of Ministry of Environment & Forests (MoEF), Government of India and as amended on December 1, 2009, the proposed SSP manufacturing unit has to required prior environmental clearance for commissioning the plant. The proposed project is covered under Category 'B' as per the Schedule of EIA Notification and hence requires environmental clearance from State Level Environmental Impact Assessment Authority (SEIAA) of Gujarat.

7. The environmental impact assessment (EIA) study undertaken is aimed at identifying existing environmental conditions, predicting environmental impacts associated with the various activities during the construction and operation phases of the proposed SSP manufacturing plant and suggesting mitigation measures to mitigate the adverse environmental impacts. This study is also focused on analysis of various activities that are likely to take place and proposed pollution prevention options have been analyzed to assess the adequacy. Further, mitigation measures have been also proposed where considered necessary. The study also aims at reflecting the acceptability of the project to different stakeholders and at incorporating the concerns raised by them into impact assessment and of the subsequent Environmental Management Plan (EMP).

1.4. Scope and Methodology of the Study

8. The scope of the study would include a detailed characteristic of environment in the study area associated with the proposed SSP project for various environmental components. The project is currently in the design preparation stage. For the purpose of the environmental assessment, areas within 5 km radius of the project have been studied and the following methodology have been adopted:

Generation and collection of baseline data for valued environmental components as per the MoEF guidelines.

Identification and quantification of significant environmental impacts due to the project and associated activities.

Evaluation of impacts due to proposed activities and preparation of an environmental impact statement.

Preparation of appropriate Environmental Management Plan (EMP) encompassing strategies for minimizing identified adverse impacts along with budgetary provisions to be made by the project authorities for implementation of mitigation measures.

Delineation of post Environmental Quality Monitoring Programme (EQMP) along with organizational setup required for monitoring the effectiveness of mitigation measures.

9. The flow diagram showing methodology adopted for the EIA study has been presented in Figure 1.2.



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Figure 1.2 : Methodology of EIA Study



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1.5. Approved TOR for EIA Study by SEAC, Gujarat

10. The application for the scoping of the said project has been submitted to the State Level Expert Appraisal Committee (SEAC), Gujarat. Presentation to SEAC for the scoping of the project (Terms of Reference (TOR) approval for EIA study) was held on October 29, 2010. The SEAC has issued the TOR for the EIA study on December 16, 2010 vides its letter no. EIA-10-2010-739-E. Copy of the same has been annexed as Annexure – I.

11. The EIA study has been conducted in-line with the approved TOR by SEAC and taking into consideration the structure of the report given in the EIA Notification 20061. The compliance to the approved TOR has been presented in Table 1.1:

Table 1.1 : TOR Compliance Status

S. No.

Term of Reference (TOR) Status

1. Project site specific details such as distance of the project site from the nearest (i) Village, (ii) Water Body: Creek/ Nallah/ Lake/ Pond/ Reservoir/ Canal, (iii) National Highway, (iv) State Highway, (v) Railway Line, (vi) Heritage Site, (vii) National Park/ Wild Life Sanctuary shall be included in the rapid EIA report to be prepared covering one season (other than monsoon) data

Table 2.1. The EIA report has been prepared covering post-monsoon season

2. Present land use pattern of the study area based on satellite imagery

Section 3.4.3

3 Factory layout plan. Provision of separate entry, exit and adequate margin all round the periphery for easy unobstructed movement of fire tender without reversing. Mark the same in the layout.

Section 2.5.1

4 Copy of permission obtained from Central Ground Water Authority for withdrawal of ground water. Detailed study of hydrology of the area. Quality of ground water at site and impacts of ground water withdrawal on hydrology and ground water quality.

Section 2.5.4 Annexure III Annexure IV

5 Details of all the proposed products & by-products to be manufactured with break-up of individual quantities, raw material consumption for each product.

Section 2.4.1 Section 2.4.3

6 Detailed manufacturing process along with chemical reactions and mass balance for each product.


7 Explore the possibility of reuse/ recycle and other cleaner production options for reduction of wastes.

Section 5.3.7

8 Detailed water balance (including reuse-recycle, evaporation, if any). Specific measures proposed to conserve water and plans for the future in this regard.

Section 2.5.4 Figure 2.4 Section 5.3.4

9 Quantitative and qualitative assessment of effluent to be generated from washing, spillage, leakage etc., plan for its collection and reuse/ recycle in process so as to achieve zero industrial effluent discharge.

Section 2.5.4 Figure 2.4 Section 5.3.4

1 Appendix III (Generic Structure of Environmental Impact Assessment Document) of EIA Notification, 2006

(http://envfor.nic.in/divisions/iass/notif/notif.htm) – S.O. 1533, dated 14th September 2006, as published in the

Gazette of India, Extraordinary, Part II, and Section 3, Sub-section (ii), Ministry of Environment and Forests.

http://envfor.nic.in/divisions/iass/notif/notif.htm



6

S. No.


10 Technical details of sewage treatment plant (STP), along with size of each unit, its location on the plan and its adequacy. Availability of open land area within the premises for utilization of treated sewage for plantation/ gardening.

Section 4.3.3 The domestic effluent generation is limited to 1.5 KLD and hence only septic tank followed by soak pit is proposed for domestic effluent.

11 One season site-specific meteorological data including temperature, relative humidity, hourly wind speed and direction and rainfall shall be provided.

Section 3.4.1

12 One complete season AAQ data (except monsoon) to be given along with the dates of monitoring. The parameters to be covered shall include PM10, PM2.5, SO2, NOx and Fluoride. The location of the monitoring stations should be so decided so as to take into consideration the pre-dominant downwind direction, population zone and sensitive receptors. There should be at least one monitoring station in the upwind direction and one monitoring station in the pre-dominant downwind direction at a location where maximum ground level concentration is likely to occur.

Section 3.4.6

13 Impact of the project on the AAQ of the area. Details of the model used and the input parameters used for modelling should be provided. The air quality contours may be plotted on a location map showing the location of project site, habitation, and sensitive receptors, if any. The wind rose should also be shown on this map.

Section 4.3.1

14 Specific details of (i) Process emission from each unit process with its quantification, (ii) Air pollution control measures proposed for control of process emission, (iii) Adequacy of the air pollution control measures to achieve the GPCB norms, (iv) Details of the utilities required, (v) Type, quantity and source of fuel to be used, (vi) Flue gas emission rate, emission from the utilities along with stack height, (vii) Air pollution control measures proposed to the utilities along with its adequacy, (viii) Sources of fugitive emission from the unit along with its quantification and proposed measures to control it.

Section 2.6.2 Section 4.3.1 Section 5.3.2

15 Details of measures proposed for the online monitoring of the pollutants from the process stack and its monitoring plan.

Table 6.1

16 Source of rock phosphate and copy of agreement/ linkage with respective mine.

Section 2.5.2 Annexure II

17 Impact of the project on local infrastructure of the area such as on road network especially due to handling and transportation of rock phosphate and finished products. Measures proposed for preventing fugitive emission due to transportation of raw materials and finished products.

Section 4.3.7

18 Details of flora and fauna in the study area and conservation plan in case of any scheduled flora/

Section 3.4.9



7

S. No.


fauna.

19 Details of management of the hazardous wastes to be generated from the project stating details of storage area for each type of waste, its handling, its utilization and disposal etc. How the manual handling of the hazardous wastes will be minimized.


20 Name and address of end consumers to whom hydro fluoro silicic acid will be sold. Copies of agreement/ MoU/ acceptance letter from them, showing their willingness to purchase hydro fluoro silicic acid from the proposed project.

Section 2.4.1

21 Methodology of de-contamination and disposal of discarded containers and its record keeping.

Section 5.3.6

22 Details of measures proposed for the noise pollution abatement and its monitoring.

Section 4.2.3 Section 4.3.2 Section 5.3.3

23 Detailed five year greenbelt development program including annual budget, types & number of trees to be planted, area under green belt development (with map), budgetary outlay; along with commitment of the management to carry out the tree plantation activities outside the premises at appropriate places in the nearby areas and elsewhere.

Section 4.3.5 Section 5.3.5 Section 5.4

24 A detailed EMP including the protection and mitigation measures for impact on human health and environment as well as detailed monitoring plan and environmental management cell proposed fro implementation and monitoring of EMP. The EMP should also include the concept of waste-minimization, recycle/ reuse/ recover techniques, energy conservation, and natural resource conservation. Total capital cost and recurring cost/ annum earmarked for environment pollution control measures.

Chapter 5 Section 5.3.7 Section 5.3.9 Section 5.4

25 An action plan showing list of socio-economic upliftment activities based on socio-economic profile of the surrounding villages and need base field assessment along with the fund allocation for the five years, shall be incorporated in the EMP

Section 5.3.8

26 Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health impacts. This shall include the details of antidotes also.


27 Details of number, capacity and material of construction of storage tanks for each hazardous chemical to be stored as well as threshold storage quantity as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules. Storage of hazardous chemicals should be in multiple small capacity tanks/ containers instead of one single large capacity tank for safety purpose. How manual handling of the hazardous chemicals will be minimized.

Section 7.2.1



8

S. No.


28 Occupational health impacts on the workers and mitigation measures proposed to avoid the human health hazards. Details about provision of personal protective equipments and first aid for the workers. Plan for periodic medical check up of the workers exposed.

Section 7.5

29 Measures proposed to be taken for the work zone ambient air quality monitoring as per Gujarat Factories Rules. Details of equipments/ instruments to be deployed to measure record and analyze workplace exposure.

Annexure V Table 6.1

30 Detailed risk assessment report including prediction of the worst-case scenario and maximum credible accident scenario along with damage distances and preparedness plan to combat such situation and risk mitigation measures.

Section 7.3

31 Submit checklist in the form of Do's and Don'ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures.

Section 7.4 Section 7.6

32 Details of scheme for surface as well as roof top rain water harvesting and groundwater recharge revealing that quantity of ground water extraction would be compensated by equivalent or more quantity of rainwater recharged, with proper scientific calculations considering rainfall in the region, catchments area, land/ soil characteristics, ground water recharge rate, duration of rain water harvesting etc. details of provisions of pre-treatment of the rainwater in the case of surface run off is to be harvested. Location of recharge percolation wells on the layout plan.

Section 5.3.4 Figure 2.3

33 Plan for compliance of the CREP guidelines for the proposed plant.

Section 5.3.1

34 A tabular charge for the issues raised and addressed during public hearing/ consultation and commitment of the project proponent on the same should be provided. An action plan to address the issues raised during public hearing and the necessary allocation of funds for the same should be provided.

This will be included after public hearing.

These additional TORs should be considered for the preparation of the draft EIA report in addition to all the relevant information as per the generic structure of EIA given in Appendix III in the EIA Notification, 2006. The draft EIA report shall be submitted to the Gujarat Pollution Control Board for conducting the public consultation process as per the provisions of the EIA Notification, 2006. The project shall be appraised on receipt of the final EIA report.

1.6. Structure of the Report

12. This EIA report has been prepared on the basis of available on-site primary data (survey/ monitoring) and secondary/literature data. The EIA report contains project features, baseline environmental setup,



9

assessment of environmental impacts, and formulation of mitigation measures, environmental management and monitoring plan with risk & disaster management plan.

13. The report includes 9 Chapters excluding Executive Summary, which is included in the beginning of the report. The structure of the EIA Report with necessary tables, drawings and annexure is as follows:

14. Chapter 1: Introduction - This chapter provides background information on need of project, need of EIA study and brief of the project. The scope and EIA methodology adopted in preparation of EIA report have also been described in this Chapter. It also covers the identification of project & project proponent, brief description of nature, size, and location of the project.

15. Chapter 2: Project Description - This chapter deals with the project details of the proposed SSP plant, with type of project, need for the project, location, size & magnitude of operation including associated activities required by and for the project, proposed schedule for approval and implementation, including technical details of raw material, quality and quantity etc.

16. Chapter 3: Description of the Environment - This chapter presents the existing environmental status of the study area around the proposed project including topography, drainage pattern, water environment, geological, climate, transport system, land use, flora & fauna, socio-economic aspects, basic amenities etc. Environmental assessment of the proposed project site in regard to its capability to receive the proposed new development is also discussed in this Chapter.

17. Chapter 4: Anticipated Environmental Impacts and their Predictions - This chapter describes the overall impacts of the proposed project activities and underscores the areas of concern, which need mitigation measures. It predicts the overall impact of the proposed project on different components of the environment viz. Air, Water, Land, Noise, Biological, and Socio-Economic.

18. Chapter 5: Environmental Management Plan - This chapter details the inferences drawn from the environmental impact assessment exercise. It describes the overall impacts of the proposed activities during construction and operation phases and underscores the areas of concern, which need mitigation measures. It also provides mitigation and control measures for environmental management plan (EMP) for minimizing the negative environmental impacts and to strengthening the positive environmental impacts of the proposed project.

19. Chapter 6: Environmental Monitoring Program - Technical aspects of monitoring the effectiveness of mitigation measures have been given in this Chapter.

20. Chapter 7: Risk Assessment – This chapter details the risks associated with the project activities and storage of hazardous chemicals.

21. Chapter 8: Summary & Conclusion - This chapter provides the summary and conclusions of the EIA study of the proposed project



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with overall justification fro implementation of the project and also explanation of how, adverse effects will be mitigated.

22. Chapter 9: Disclosure of Consultants Engaged - This chapter provides the disclosure of consultants engaged to carryout the EIA study along with other additional studies.



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2. PROJECT DESCRIPTION

2.1. Prelude

23. The details of the proposed SSP manufacturing project location, facilities, infrastructure details, chemical properties of products, by-products and raw materials, manufacturing process, water & wastewater details, air pollution and pollution prevention measures, solid and hazardous waste management have been presented in the following sections.

2.2. Type of Project

24. Proposed project has been conceptualized for manufacturing of Single Super Phosphate (SSP) with total installation capacity of 198,000 MTPA, out of which, Powder SSP will be 132,000 MTPA and Granulated SSP will be 66,000 MTPA. Proposed project is a Greenfield project.

2.3. Location

25. M/s Narmada Bio-Chem Pvt. Ltd. has acquired a plot entitled as Unit-IV at Village - Kalyangadh, Survey No. 268, NH-8A, Taluka - Bavla, District - Ahmedabad (Gujarat). Site co-ordinates and surrounding area profile has Latitude and longitude of the project site are as follows:

Table 2.1 : Surrounding Area Profile

S. No. Particular Details Remarks

1 Latitude 22°42'54.38"N

2 Longitude 72°15'24.76"E

3 Nearest Village Kalyangadh 1.2 km (East)

4 Nearest Town Bavla 16 km (NE)

5 District Headquarters Ahmedabad 45 km (NE)

6 Water Bodies

Canal Narmada Canal 0.5 km (North)

River Sabarmati River 27 km (East)

Nallah Bhogavo 13 km (WSW)

Lake Nal Sarovar 16 km (WNW)

Pond Kalyangadh 1.0 km (E)

7 National Highway NH-8A Adjacent (South)

8 State Highway SH-16 5 km (South)

9 Railway Line 10.2 km (SE)

10 Railway Station Bavla 17 km (NE)

11 Heritage Site None within 25 km

12 National Park/ Wildlife Sanctuary

Nal Sarovar Bird Sanctuary

16 km (WNW)

This chapter deals with the project details of the proposed Single Super Phosphate manufacturing plant, with need for the project, location, size & magnitude of operation including associated activities required by and for the project, proposed schedule for approval and implementation, including technical details of raw material, quality and quantity, etc.



12

26. Location of the project in village survey map has been presented in Figure 2.1. The project site is directly accessible from NH-8A connecting Ahmedabad to Rajkot. The project site is regular in shape. The terrain of the land is generally flat and levelled.

Figure 2.1 : Project Location in Village Survey Map

2.4. Proposed Single Super Phosphate (SSP) Plant

27. NBCL has now proposed to set up 'Single Super Phosphate' plant of capacity 198,000 MTPA along with associated utilities and off-site facilities.

2.4.1. Product Details

28. The proposed project will have two kinds of products, namely Powder Single Super Phosphate (PSSP) and Granular Single Super Phosphate (GSSP). Details of products and by-products in the proposed manufacturing plant will be as follows:

Table 2.2 : Details of Proposed Products

S. No. Product Production

(MTPA)

1. Powder Single Super Phosphate 132,000

2. Granular Single Super Phosphate 66,000

3. By Product: Hydro Fluorosilicic Acid (100% basis)

660

29. The by-product (hydro fluoro silicic acid) will be either used in the process itself after scrubbing system or will be sold to the interested parties. Following



13

users have shown their willingness to purchase Hydro Fluoro Silicic Acid from the proposed plant of NBCL:

Vidisa India A-82, M.I.A. Madri Udaipur - 313 003 Rajasthan

Nilkanth Refines Plot No. C1/5508, GIDC Estate Ankaleshwar - 393 002 Gujarat

A. K. Enterprises Main Road, M.I.A. Madri Udaipur - 313 003 Rajasthan

Maruti Chemicals Company C-2, Parul Flats, B/H Umiya Vijay Society Satellite Road, Ahmedabad - 380 015 Gujarat

2.4.2. Manufacturing Process

2.4.2.1 Powder Single Super Phosphate (PSSP)

30. The main raw materials for manufacturing of SSP are rock phosphate and sulphuric acid. Rock phosphate is easily available in two forms

Crystal Rock Phosphate (CRP) : Total P2O5 (31 to 33%)

Beneficial Rock Phosphate (BRP) : Total P2O5 (32 to 34%)

31. The process of manufacturing of SSP involved chemical reactions between rock phosphate and sulphuric acid. Calcium tri phosphate, which is insoluble in water, is the major part of rock phosphate and calcium fluoride is the major impurity present in the rock.

32. An EOT grab crane is used for the major material handling. the crane dump rock phosphate to a hopper, from where it is pass through by a pin-gate and transferred by a belt conveyor to the mill feed hopper. The belt conveyor equipped with suspended electromagnet to remove all magnetic materials.

33. The grinding mill is a complete unit comprising of grinding mill, mill fan, grit separator, flapper valve, cyclone separator, dust collection unit, hot air generator and required air ducting etc.

34. The Cyclone is mounted on the top of the Ground Rock Hopper, from where ground Rock Phosphate is transferred to the Acidulation section of the Plant comprising of Rotary Van Feeder, Screw Conveyor, Bucket Elevator and feed and Return Screw conveyor. The Feed of Rock Phosphate to the Acidulation is regulated by the volumetric variable speed Screw feeder.

35. The manufacturing process of Single Super phosphate is achieved by the reaction between Rock phosphate and Spent Sulphuric Acid/dilute Sulphuric Acid of desired strength.

36. The chemical reaction that takes place for obtaining the Mono Calcium phosphate known as Single Super Phosphate is as below:

Ca3(PO4)2 + 2H2SO4 Ca(H2PO4)2 + 2CaSO4

310 196 234 272

CaF2 + H2SO4 CaSO4 + 2HF

78 98 136 40

37. The Single Super phosphate Fertilizer consisting of mono Calcium phosphate Gypsum, Silica and un-reacted Rock Phosphate as a filler material is cured for necessary period on open yard after necessary reshuffling to achieve desired chemical reaction. This process of substantial formation of water soluble P2O5 content in the phosphates is known as curing, and is obtained by leaving the material in the piles for period varying from 5-9 days.



14

38. The cured material is reclaimed from piles by EOT Crane, and is dumped in the Bagging Hopper. The finished product finally packed in to the 50 kg bags or as per any other requirement. This material will be ready to sale. SSP will be as per the F.C.O. norms.

39. The scrubbed liquor consisting of Water, Hydrofluorosilicic Acid and Silica is taken into a settler to separate the Silica and after necessary washing to the Silica; the same is used as a filler material. The dilute Hydrofluorosilicic Acid is either used for Sulphuric Acid dilution or sold to outside parties as their basic raw material. Then the traces of HF coming from ventury scrubber will be scrubbed with Caustic lye solution in Alkali Scrubber. This Scrubbed liquor will be re-circulated within the scrubber up to pH 9.0 and finally utilized in to the manufacturing process.

2.4.2.2 Granular Single Super Phosphate (GSSP)

40. The main raw material for manufacture granular SSP is powder SSP. Mix powder SSP with water and make granules in granulator. Pass the hot air from hot air generator in rotary dryer. Moisture will be evaporated from granules. Cool down by passing the air in cooler. Now, granular SSP product will be ready for sale.

41. There will not be any wastewater discharge from the proposed manufacturing process; hence the unit will be "Zero Discharge Unit". Process flow diagram of manufacturing of Powder SSP and Granular SSP has been presented in Figure 2.2.



15

Mixer

442

Den

Conveyer

Hips of Raw (Green) SSP

Curing

Finished Product to Sale

(SSP Powder)

400

Granulator

200OR

SSP Powder to Sale

200

Rotary

Dryer

Cooler

Screening

Finished Product

(Granular SSP)

200

Water Evaporation

(12)

Water

12

APCM

Stack

Water Evaporation

(12)

Water

12

Air : 27,200 m3/hr

Rock Phosphate : 234

Spent Sulphuric Acid : 180

Water : 12

Note:

All units are expressed in MT/day.

Manufacturing process is continuous process.

Figure 2.2 : Process Flow Diagram of Single Super Phosphate (SSP) & Granular Single Super Phosphate (GSSP)

2.4.3. Mass Balance

42. The main raw materials for the manufacturing of SSP are rock phosphate and sulphuric acid. The requirement of rock phosphate is 0.585 MT per MT of SSP. Therefore, total requirement of rock phosphate for 400 TPD will be 234



16

TPD and spent sulphuric acid will be 180 TPD. The mass balances in powder single super phosphate and granular single super phosphate have been presented in Table 2.3 and Table 2.4.

Table 2.3 : Mass Balance in Powder Single Super Phosphate (400 TPD)

Raw Materials Consumption

Kg/Kg of Product

MT/Day

Input

Rock Phosphate 0.585 234

Spent Sulphuric Acid (80%) 0.450 180

Water 0.07 28

Total 1.105 442

Out put

Single Super Phosphate 1.0 400

Hydro Fluoro silicic Acid 0.050 20

Water evaporation & trapped in Scrubber

0.055 22

Total 1.105 442

Table 2.4 : Mass Balance in Granular Single Super Phosphate (200 TPD)


Kg/Kg of Product

MT/Day

Input

Powder Single Super Phosphate 1.00 200

Water 0.06 12

Total 1.06 212

Out put

Granular Single Super Phosphate 1.0 200

Water Evaporation 0.06 12

Total 1.06 212

Table 2.5 : Specification of Single Super Phosphate (SSP) as per FCO

S. No. Contents of SSP % contents of SSP

1. Water Soluble P2O5 16.0%

2. Free Acid 4.0% max

3. Sulphur 11.0% min.

4. Moisture 12.0% max



17

Table 2.6 : Physical and Chemical Properties of Product, By-Product and Raw Materials

Physical & Chemical Properties

Product By Product Raw Materials

Single Super Phosphate

Hydroflouro silicic Acid

Rock Phosphate Sulphuric

Acid

Physical State Solid Liquid Solid Liquid

Color Grey or Brown colorless Yellow colorless

Odor Odorless Acrid Odorless Odorless

Bulk Density 1.12 g/cc -- 1.36 g/cc --

Specific Gravity -- 1.15-1.18 -- 1.844

Solubility in water Soluble Infinitely Soluble Insoluble soluble

pH < 4 Highly Acidic Neutral 0.3 (1N)

Boiling Point 203 0C 108 0C -- 327 0C

Melting Point 109 0C < -36 0C -- -2 0C

Vapor Density -- 1.97 -- 3.4

Molecular Weight (G/Mol)

234.05 144 310 98.07

Molecular Formula CaH4P2O8 H2SiF6 Ca3(PO4)2 H2SO4

2.5. Resource Requirements

2.5.1. Land Break-up

43. Total land area acquired for the setting up the proposed SSP manufacturing plant is 36,220 sq. m. Out of that area in national highway control line is 3,700 sq. m. Hence, remaining plot area available for the plant is 32,500 sq. m. The break-up of the land has been presented in Table 2.7 and layout plan of the project has been presented in Figure 2.3.

Table 2.7 : Area Break-up

S. No. Particular Area (sq. m.)

1. Total Plot Area 36,220

2. Area under NH Control Line 3,700

3. Remaining Plot Area 32,520

4. Proposed Built-up on Ground Floor 7,517

5. Internal Road Area 3749

6. Parking Area 3456

7. Green Area 9918

8. Open Area 7880

44. In the proposed plant layout adequate provisions internal roads and parking facility has been provided. For entry and exit two separate gates have been



18

provided, which are further connected with 18.0 m wide internal approach road. All the other internal roads of the plant are of 9.0 m width. Provision of a separate emergency exit has also been made in the plant layout. The adequate width of all the internal roads will provide unobstructed movement of fire tender in case of any emergency.



19

Figure 2.3 : Layout Plan of the Project



20

2.5.2. Raw Material Requirement

45. Raw materials required for the manufacturing of proposed SSP will be procured from RSMML / nearby areas of the project site. Rock phosphate will be either imported or will be taken from RSMML. M/s Zimex India has shown its willingness to supply rock phosphate from Egypt. Copy of the same is attached as Annexure - II. All the raw material will be stored into the designed storage area within the premises. The detailed product wise raw material requirement is given in Table 2.8 and Table 2.9:

Table 2.8 : Raw Material Requirement for Powder Single Super Phosphate (400 TPD)


Kg/Kg of Product

MT/Day

Rock Phosphate 0.585 234

Spent Sulphuric Acid (80%) 0.450 180

Water 0.07 28

Total 1.105 442

Table 2.9 : Raw Material Requirement for Granular Single Super Phosphate (200 TPD)


Kg/Kg of Product

MT/Day

Powder Single Super Phosphate 1.00 200

Water 0.06 12

Total 1.06 212

2.5.3. Electricity

46. Total power requirement for the project will be approximately 1400 KW. The power will be taken from Uttar Gujarat Vij Corporation Limited (UGVCL).

2.5.4. Water

47. Total fresh water requirement for the manufacturing of proposed SSP products will be approximately 47.0 KLD. Industrial water requirement will be about 40 KLD and domestic and other water requirements will be about 7.0 KLD. Break-up of fresh water requirement has been presented in Table 2.10.

Table 2.10 : Break-up for Fresh Water Requirement

S. No. Purpose Water Consumption (KLD)

1. Industrial 40.0

Process 20.0

Washing 2.0

Others Use (Scrubbing) 18.0

2. Domestic 2.0

3. Gardening 5.0

Total (Sum 1+2+3) 47.0



21

48. Recycled water from washing and scrubbing will be recycled back in process, which will reduce the fresh water consumption by 20 KLD. In addition to that, rainwater harvesting will be adopted to conserve the ground water resources.

49. The proposed project site is located in Bavla Taluka of Ahmedabad District, which is categorized as "Semi-Critical Area for Ground Water Abstraction" as per the Public Notice No. 26-1/CGWA/D1/09 dated 8 October 2009 from Central Ground Water Authority (Refer Annexure - III)

50. Also, as per the guidelines issued by Central Ground Water Authority for taking permission for ground water abstraction vide letter no. 21-4/Guidelines/CGWA/2009-832 dated 14/10/2009, ground water abstraction permission from CGWA is required only in case of more than 100 KLD ground water abstraction in semi-critical areas. The industry desirous of extracting ground water up to the below specified limit is exempted from obtaining 'No Objection Certificate (NOC)' from CGWA. (Refer Annexure - IV)

51. Since the water requirement and subsequent groundwater abstraction for the proposed project is only 47 KLD, and hence it does not require any permission for groundwater abstraction from CGWA/CGWB.

2.5.5. Fuel Requirement

52. Agro waste will be used as a fuel in Hot Air Generator (HAG) at the rate of 285 kg/hr, which will have total capacity of 10.0 lacs Kcal. HSD will be used as fuel for the DG set of capacity 200 KVA. The fuel consumption will be about 40 l/hr. DG set will be used only during grid power failure.

2.5.6. Reactors, Vessels and Equipment Requirement

53. The list of reactors, vessels and equipments required for the proposed SSP plant has been presented in Table 2.11.

Table 2.11 : Details of Reactors, Vessels and Equipments

S. No.

Equipments Quantity Capacity Motor

Capacity

1. EOT Grabbing crane 1 7.5 MT lifting 170

2. Coarse Rock Feed Hopper 1 40 MT -

3. Pin Gate 1 - -

4. Rotary Table Feeder 1 15 MT/ hr 5

5. Belt Conveyor 1 20 MT/ hr 5

6. Flapper Valve 1 - 2

7. Grinding Mill 2 12 MT/ hr 300

8. Grit Separator 2 - -

9. Cyclone Separator 1 - -

10. I.D. Fan 1 - 150

11. Dust collector 2 - -

12. Hot Air Generator 1 10 lacs KCAL 20

13. Ground Rock Hopper 1 40 MT -

14. Rotary Vane Feeder 1 15 MT/ hr 5

15. Screw Conveyor 1 15 MT/ hr 7.5

16. Ground Rock Bucket Elevator 1 15 MT/ hr 7.5

17. Return Screw Conveyor 1 15 MT/ hr 7.5



22

S. No.

Equipments Quantity Capacity Motor

Capacity

18. Feed Screw Conveyor 1 15 MT/ hr 7.5

19. Acid & Liquor Feeder 1 each 10 MT/ hr 10

20. Weigh Belt Feeder with Drive 1 15 MT/ hr 5

21. Paddle Mixer 1 20 MT/ hr 40

22. Reciprocating Den 1 20 MT/ hr 35

23. Venturi Scrubber 1 - -

24. Scrubbing Fan 1 27,200 Cum/

hr 100

25. Water pumps 2 - 6

26. Recycle Tanks 1 50 cu.m. -

27. Liquor Recirculation Pump 5 different 72.5

28. Sulphuric Acid Storage Tank 2 500 MT each -

29. Sulphuric Acid Day Tank 1 50 MT -

30. Scrubbing tank 5 50 MT each -

31. S. Acid Pump 2 10 MT/hr 15

BAGGING SECTION

32. SSP Feed Hoppe 1 40 MT -

33. SSP Feed Belt Conveyor 1 25 MT /hr 5

34. Vibratory Screen 1 25 MT/hr 7.5

35. Hammer mill 2 12 MT/hr 20

36. Hopper Twin 1 25 MT -

37. Bag Filling & Weighing machine

1 - 1

38. Stitching Machine with Slat Conveyor

1 - 5

39. Platform / Chutes As

required - -

GRANULATED SSP PLANT

40. RM Hopper 1 40M.T. -

41. RM Feed Belt Conveyor 1 - 5

42. RM Screen 1 - 7.5

43. Hammer Mill 1 - 20

44. RM Elevator 1 12 M.T./hr. 10

45. Granulator Drum 1 - 20

46. Hot Air Furnace 1 - -

47. Furnace Blower 2 - 25

48. Dryer Fan 1 - 40

49. Dryer Drum 1 - 40

50. Dryer Cyclone 2 - -

51. Dryer-cooler Belt 1 - 3

52. Cooler Fan 1 - 40

53. Cooler cyclone 2 - -

54. Cooler Drum 1 - 40

55. CM Elevator 1 15 M.T./hr. 10

56. Over size Screen 1 - 10

57. Under size Screen 1 - 10

58. Chain Mill 4 - 60

59. Product Belt 1 - 5

60. Recycle Belt 1 - 5

61. Stitching Machine 2 - 2

62. Weighing Machine 2 100 Kg. -



23

2.5.7. Employment

54. The proposed unit will generate full time employment to approximately 50 persons. The manpower requirement for the proposed project will be fulfilled from the nearby areas. In addition to that indirect employment will also be generated due to the project.

2.6. Environmental Aspects

55. The SSP Plant generates several liquid and gaseous effluent containing phosphate and fluorine during reaction for SSP manufacture.

56. Unique features of the process scheme developed for the proposed project include incorporation of innovations in the manufacturing process, which will result in minimizing the emission and discharge of effluent from the Plant. A very high emphasis is placed on reliability of individual equipments to ensure that discharge of any pollutant from the plant is completely avoided.

57. These will reduce loads on the pollution control systems. The pollution control systems, which will be installed for the proposed SSP plant designed for the specific requirement for the plants in accordance with the standards adopted by Gujarat Pollution Control Board.

58. While designing the SSP Plant Pollution Control System, main objective was „zero liquid discharge‟. There should be no discharge of any liquid stream or effluent from the SSP Plant as whole. As such all liquid streams and effluents should be appropriately recycled to the various processing units, there by achieving „zero liquid discharge‟ from manufacturing of SSP.

59. The environmental aspects of the proposed SSP project will be linked with the following environmental attributes:

Water Pollution

Air Pollution

Solid/ Hazardous Waste Generation

Noise Pollution

2.6.1. Water Pollution

60. In the proposed SSP project, water will be required for industrial use as well as for domestic & gardening purposes. There will not be any wastewater generation due to industrial process. Wastewater generated from washing and scrubbing will be recycled back in the process. Hence, no industrial wastewater is anticipated from the project. From domestic application about 1.5 KLD of wastewater will be generated, which will be sent to septic tank followed by soak pit Break-up of wastewater generation due to the proposed project has been presented in Table 2.12. The water balance diagram has been presented in Figure 2.4. Hence, due to no wastewater discharge, the unit will be "Zero Discharge Unit".



24

Table 2.12 : Break-up of Wastewater Generation

Sr. No.

Purpose Waste Water

Generation (KLD) Remarks

1. Industrial

i) Process -- No w/w generation

ii) Washing 2.0 Recycle in Process

iii) Others use (Scrubbing) 18.0

By-product (Recycle to process)

2. Domestic 1.5 Septic Tank/Soak Pit

Total 1.5 --

Fresh Water

47 KLD

Gardening

5 KLD

Domestic

2 KLD

Industrial

Purpose

40 KLD

Scrubber

18 KLD

Washing

2 KLD

Process

40 KLD

20 KLD

No Wastewater

18 KLD

2 KLD

Septic Tank/

Soak Pit

1.5 KLD

Figure 2.4 : Water Balance Diagram

2.6.2. Air Pollution

61. During reaction on mixing of Rock Phosphate with dilute Sulphuric Acid, SiF4 liberates in gas form due to Fluorine contained in the Rock Phosphate. It has to be treated for Fluorine removal, to the levels as per environmental standards. Mixer and Den, where these reactions take place are kept under suction to avoid pollution of working area. Gases sucked from these equipments will be taken through two numbers of Spray Scrubbers, Two numbers Ventury Scrubbers and Alkali Scrubbers connected in series. The Scrubbers operate at different concentration and are progressively fortified in a counter current flow arrangement. This arrangement of flow ensures that high concentration of liquid solution confined to sump no. I and last sump has very low concentration or almost ZERO. The gases from the Scrubbers are vented to the Atmosphere through Alkali Scrubber by a 50 m tall stack via a Scrubbing Exhaust Blower with facility of Port Platform and Ladder.

62. The impact on air quality due to the operation of the proposed SSP project will be mainly due to the following sources:

Combustion of agro waste used in HAG



25

Grinding/ milling of rock phosphate

Emission of hydrogen fluoride and SPM from the mixer & den conveyor

Fugitive emissions

63. The gaseous air emissions will be mainly due to flue gas stack and process stack. Details of flue gas stacks and process stacks have been presented in Table 2.13 and Table 2.14, respectively.

Table 2.13 : Details of Flue Gas Stack

S. No.

Stack attached

to

Stack Height (m)

Stack Internal

Diameter (m)

Type of

Fuel

Fuel Quantity

(per Hour)

Concentration of Pollutants

1 Hot Air Generator (10 Lac Kcal)

30 0.6 Agro Waste

285 kg PM < 150 mg/Nm3 SOx < 100 ppm NOx < 50 ppm 2 DG Set

(200 KVA) 11 0.15 HSD 40 L

Table 2.14 : Details of Process Stack

S. No.

Stack attached to

Stack Height (m) Stack Internal Diameter (m)

Concentration of Pollutants

1 Vent (Attached to Alkali Scrubber)

50 0.9 PM < 150 mg/Nm3 SOx < 100 ppm NOx < 50 ppm

2 Mill/ Grinder PM < 150 mg/Nm3

2.6.3. Solid/ Hazardous Waste Generation

64. There will be no major source of hazardous waste generation due to the proposed project. Only hazardous waste generation will be in the form of used oil, which is categorized as 5.1 in the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008. Annual generation of hazardous waste will be approximately 150 litres.

65. In addition to the above, scrap generated will be sold to the recyclers and other non-hazardous waste/ garbage will land filled within the factory premises.

2.6.4. Noise Pollution

66. The plant will have various rotating machines including blowers, vacuum pumps, process pumps, etc. along with DG sets, which will generate noise. These machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.



26

3. DESCRIPTION OF THE ENVIRONMENT

3.1. Prelude

67. It is necessary for the environmental assessment studies to establish baseline status for valued environmental components, which are likely to be affected because of the developmental activities/ modernization or expansion. Hence, it is imperative to study the existing environmental conditions not only to establish the pre-project physical, biological, and socio-economic conditions, but also to predict environmental impacts caused during the construction and operation phases of the project.

68. The environmental status around the proposed project site is determined by studying in detail the major environmental attributes viz., Air, Water, Land, Noise, and Socio-economic in a 5 km radial zone. For collecting the baseline information, primary data were generated wherever possible and the other information was gathered from secondary data sources. The study was carried out during the months of September to November 2010. The ambient air quality, water quality, and soil quality status within the area forms the baseline information over which the predicted impacts due to the proposed project can be super imposed in order to obtain the net impact of the proposed project on the environment.

3.2. Site Description and Its Environs

69. The site identified and acquired for setting up the proposed single super phosphate manufacturing plant is located at Survey No. 268 of Village Kalyangadh in Bavla Taluka of Ahmedabad District. The project site is bounded by NH-8A (Ahmedabad - Rajkot) on the South and agricultural/ barren land of Kalyangadh village on other three sides with Survey Nos. 274, 269, and 267 (Refer Figure 2.1). Nearest village is Kalyangadh, which is about 1.5 km from the project site. The study area for the EIA study constitutes of 5 km radial zone around the project site, which is mainly having rural environment. The study area is shown in Figure 3.1 with main features and villages of the study area.

This Chapter describes the baseline environmental conditions around the project site for various environmental attributes, viz., physical, biological and socio-economic, within the 5 km radial zone, which is termed as the study area. Topography, soil, water, meteorology, air, noise, and land constitute the physical environment, whereas flora and fauna constitute the biological environment. Demographic details and occupational pattern in the study area constitute socio-economic environment. Baseline environmental conditions are based on the field studies carried out during Post-monsoon Season at and around the proposed site and through secondary data collected from published sources.



27

Figure 3.1 : Study Area Map of 5 km Radial Zone around the Project Site



28

3.3. State of the Environment (Regional)

3.3.1. Topography and Geology

70. The geology is underlain by recently placed alluvial sands and few sporadic outcrops of Deccan Trap and Limestone towards southern part of the region, The rock formations ranging in age from Archaean to recent include gneises, schishts, phyllites, intrusive medium to coarse grain sandstone, basalts and recent alluvium. The Geological Map of Gujarat state is enclosed as Figure 3.2 with marked project location.

71. The topography of the area is almost flat covered by brown sandy and clayey soil and has gentle westerly and south westerly slope. The elevation of the land surface varies from 12.5 m to 13.0 above MSL. There are no hills, hillocks or undulating land in the region.

Figure 3.2 : Geological Map of Gujarat showing Project Location

3.3.2. Climate and Rainfall

72. The region has a tropical type of climate with extreme summers and winters. The Arabian Sea and Gulf of Khambhat reduce the temperature and render the climate more pleasant and healthy. The average annual temperature varies from 36ºC in summer to 8ºC in winter. The relative humidity varies from maximum of 90% to a minimum of 10%. The area

Project Site



29

receives an average annual rainfall of 732 mm. The study area is characterized by hot summers and the four different seasons are as follows:

Winter Season : December to February

Summer Season : March to May

Monsoon Season : June to September,

Post-monsoon Season : September to November.

3.3.3. Geomorphology and Soil Types

73. The district of Ahmedabad is located partly if in the mainland area of Gujarat and partly in the Saurashtra peninsula. Mainland Gujarat, consists of the eastern rocky highlands [alt. 300 to 1000 meters], the extensions of the mountains of western India, and the western alluvial plains including the coastal plains [alt. 25 to 75 meters]. The Saurashtra region is a rocky tableland [alt.300-600meters] fringed by coastal plains, with a central part made up of an undulating plain broken by hills and considerably dissected by various rivers that flow in all directions. The eastern fringe of Saurashtra is a low-lying ground marking the site of the former sea connection between the Gulfs of Kachchh and Khambhat. The western alluvial plains cover the major part of the district of Ahmedabad.

74. The main type of soil observed in the region is namely grey black deltaic coastal alluvium. The soil type map of Gujarat is enclosed as Figure 3.3.

Figure 3.3 : Soil Types in Gujarat

3.3.4. Hydrogeology

75. On the mainland area of Gujarat, the groundwater accumulates only in the secondary porosity zone i.e. zone of weathering, joint planes, cracks and fissures. Water table in these rocky areas varies from 4 to 10 meter below the ground level and is mostly unconfined. The alluvial plains provide better conditions for the storage of groundwater. The junction between the eastern hill areas and the well-demarcated alluvial plains is the principal

Project Site



30

site for recharge of groundwater. In Saurashtra the areas of sandstone and alluvial cover yield moderate quantities of water while the basalt areas hold good amount of water. Here, the Zones of weathering between successive lava flows also act as aquifers.

3.3.4.1 Ground Water Scenario

76. Ahmedabad district has vast low lying alluvial tracts which are underlain by saline ground water (EC 3.46 ds/cm). Figure 3.4 shows the district wise ground water resource map of Gujarat state. The litho logy of Ahmedabad district has coastal alluvium and low level alluvium sediments transported from the Aravalli region by the Sabarmati and Mahi River.

Figure 3.4 : Ground Water Resources of Gujarat

3.3.5. Drainage system

77. The rivers Banas, Sabarmati, Mahi, Narmada and Tapi are the important drainage lines of the Gujarat plain draining into the Gulf of Khambatt while the rivers Bhadar, Ojat and Shetrunji are those of the Kathiawar peninsula draining into the Arabian sea. There are few seasonal and small rivers draining into the Gulf of Kachchh. Figure 3.5 shows the drainage pattern of the state of Gujarat.

Project Site



31

Figure 3.5 : Drainage Map of Gujarat

3.3.6. Seismic Considerations

78. According to the Seismic-zoning Map of India [IS 1893 (Part I):2002], the study region falls in Zone III – Moderate Seismic Intensity. The Seismic Zoning Map is shown in Figure 3.6.

Figure 3.6 : Seismic Zoning Map of India

Project Site



32

3.4. State of the Environment (Local)

79. The environmental status of the local vicinity at 5 km radial zone around the project site has been studied during the (September to November 2010) and the details are given in the following sub-sections:

3.4.1. Micro-Meteorology

80. Meteorological study exerts a critical influence on air quality as it is an important factor in governing the ambient air quality. The meteorological data recorded during the study period is used for interpretation of the baseline information as well as input for air quality simulation models. Meteorological data was collected for the months of September to November 2010. A meteorological station was installed in the project area at about 10 m above the ground level. All care was taken to see that the station was free from obstructions to free flow of winds. Wind speed, wind direction, temperature and relative humidity data was collected daily on hourly basis during the study period. The maximum, minimum and average temperatures as well as relative humidity of the study period are presented in Table 3.1.

Table 3.1 : Summary of Micrometeorological Data

Month Temperature(ºC) Humidity (%)

Max Min Mean Max Min Mean

September 2010 37 24 30 94 5 66

October 2010 39 17 28 94 7 51

November 2010 37 14 24 94 18 50

(Source: Field Monitoring)

81. The windrose diagram for the study area is shown in Figure 3.7 and the wind class frequency distribution is shown in Figure 3.8. The analysis of the average wind pattern shows predominant winds from W followed by N with wind frequencies of 16.5% & 10.1%, respectively. The calm wind (wind speed < 0.5 m/s) conditions prevailed for 11.2% of the total time.



33

WRPLOT View - Lakes Environmental Software

PROJECT NO.:

EQMS/NBC/10-11/01

DATE:

12/5/2010

MODELER:

NKC

COMPANY NAME:

EQMS India Pvt. Ltd.

COMMENTS:WIND ROSE PLOT:

Wind Rose DiagramNarmada Bio-Chem Pvt. Ltd., Kalyangadh, Bavla, Ahmedabad

Resultant Vector

334 deg - 38%

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%DATA PERIOD:

2010 Sep 1 - Nov 3000:00 - 23:00

WIND SPEED

(m/s)

>= 5.5

4.5 - 5.5

3.5 - 4.5

2.5 - 3.5

1.5 - 2.5

0.5 - 1.5

Calms: 11.17%

AVG. WIND SPEED:

2.66 m/s

CALM WINDS:

11.17%

TOTAL COUNT:

2184 hrs.

DISPLAY:

Wind SpeedDirection (blowing from)

Figure 3.7 : Wind Rose (Summer Season) at Project Site



34

11.2

3.8

29.4 29.3

18.7

5.8

1.8

5

10

15

20

25

30

35

%

Wind Class Frequency Distribution

Wind Class (m/s)

Calms 0.5 - 1.5 1.5 - 2.5 2.5 - 3.5 3.5 - 4.5 4.5 - 5.5 >= 5.5

Figure 3.8 : Wind Class Frequency Distribution

3.4.2. Topography

82. In the study area, the terrain is almost flat with a few low lying areas. Study area elevation varies from 10 to 20 m and is having slope in west and south west direction. There are no hills and hillocks in the area.

3.4.3. Land Use

83. The land use in the study area can be broadly classified into 5 major categories viz., agricultural land, fallow land, sparse vegetation, barren land & rural settlements. The land use distribution in the 5 km study area is shown in Table 3.2 and Figure 3.9.

Table 3.2 : Land Use Distribution

Category Area (Within 5 km Study Area)

Sq. Km. In Percentage

Agricultural Land 31.19 39.5

Fallow Land 23.96 30.3

Sparse Vegetation 13.17 16.7

Barren Land 3.83 4.8

Settlement 3.75 4.7

Road 2.94 3.7

Water Bodies 0.21 0.3

Total 79.03 100



35

Figure 3.9 : Landuse/ Land Cover Map of the Study Area (5 km radial zone)



36

3.4.4. Soil Characteristics

84. Soil samples were collected in the study area to assess its physico-chemical characteristics. Samples were collected from (i) Project Site, (ii) Gangad Village (Barren land), (iii) Kalyangadh Village (Barren Land), (iv) Bhamsara Village (Barren Land) (v) Kanotar Village (Barren Land) and (vi) Kesardi Village (Barren Land). The sampling locations are shown in Figure 3.10 and the analysis results are given in Table 3.3.

85. The soil samples collected from the study area reveal sandy characteristics. The soil is slightly alkaline in nature. Levels of nitrogen and phosphate were observed to below.



37

Figure 3.10 : Sampling Locations in the Study Area



38

Table 3.3 : Analysis Results of Soil Sampling

S. No. Parameter Unit Project Site Gangad Kalyangadh Bhamsara Kanotar Kesardi

1 pH 8.3 7.9 8.7 8.4 8.2 7.7

2 Water Holding Capacity % 25 32 37 46 21 34

3 Bulk Density gm/cm3 1.48 1.60 1.36 1.44 1.5 1.37

4 Electrical Conductivity µS 230 290 740 360 510 380

5 Chloride (as Cl) g./Kg. 0.17 0.20 0.15 0.25 0.29 0.22

6 Moisture Content % 11.86 10.34 9.80 12.39 11.50 13.25

7 Total Organic Content % 2.45 2.31 3.18 1.77 2.63 2.28

8 Phosphate (as P) % 0.0013 0.022 0.042 0.015 0.027 0.011

9 NH4 % 0.0004 0.0008 NIL 0.0002 NIL 0.0007

10 Sodium (as Na) % 0.12 0.13 0.16 0.18 0.12 0.15

11 Potassium (as K) % 0.10 0.10 0.18 0.17 0.11 0.13

12 Nitrogen (as N) % 0.069 0.078 0.11 0.043 0.055 0.061

13 Iron % 0.20 0.23 0.14 0.15 0.11 0.16 (Source: Soil analysis during study period)



39

3.4.5. Water Environment

86. The water resources, both surface and groundwater plays an important role in the development of an area. Likewise, the water resources of the area have been studied to establish the current status of water availability and quality in the area.

3.4.5.1 Surface Water

87. The study area has a river Bhogavo which lies at a distance of 21 km from the site. Few shallow streams also intersect the area passing near the boundary of the project. From Kalyangadh side two shallow streams are flowing, one towards the village Gangad and another is flowing towards the National Highway. These streams ultimately get discharged into the river Bhogavo near Dhingada. Also there are two lakes present in the villages of Bhamsara and Kalyangadh. The drinking water requirement of the villagers is met by the water supply from River Narmada.

3.4.5.2 Ground Water

88. Ground water is pressed for domestic and agriculture activities in the study area. Generally, every village has hand pumps to draw water for domestic uses. In addition to that, there are rain water storage ponds at each village of the study area, which are used by the villagers for irrigation, domestic applications other than drinking and also for cattle.

3.4.5.3 Water Quality Assessment

89. Water samples were collected from ground and surface waters covering 5 km radial zone. A total of 8 samples were taken from different sampling locations including surface and ground water bodies. The samples were analysed for physico-chemcial parameters, the sampling and analysis of water were carried out as described in standard methods of water and waste water analysis (APHA). The results of water analysis were compared with IS 10500:1993 drinking water standard to study their suitability for drinking purpose. Samples were taken on the following dates from the locations mentioned below:

Sl. No:

Sampling Locations

SW1 Kalyangadh-Drinkable water supply from Narmada

SW2 Surface water from Kalyangadh Lake

SW3 Surface water from Bhamsara Lake

GW1 Ground water from Gangad Village

GW2 Ground water from Bhamsara Village

GW3 Ground water from Kalyangadh Village

GW4 Ground water from Kesardi Village

GW5 Ground water from Project Site

90. Sampling locations for water samples are shown in Figure 3.10 and the analytical results of the water samples are shown in Table 3.4.

91. The water quality in the region (ground and surface water) has been compared with respect to the Drinking Water Quality Standards as per IS: 10500:1991. The SW1 sample i.e. drinking water from Village Kalyangadh coming from River Narmada is absolutely fit for drinking and confirm fully to the drinking water standards.



40

Table 3.4 : Water Quality in the Study Area

S. No.

Parameter

Standard Limit as per IS:10500-1993

SW1 SW2 SW3 GW1 GW2 GW3 GW4 GW5 Desirable

Limit Permissible

Limit

1 pH 6.5-8.5 No Relaxation 7.9 8.1 7.7 7.6 8.3 7.9 7.8 8.1

2 Color (pt. Co. Scale) 5 25 Colorless 3.6 2.2 Colorless Colorless Colorless Colorless Colorless

3 Turbidity (NTU) 5 10 0.12 0.69 0.78 0.18 0.25 0.33 0.19 1.2

4 Suspended Solids (mg/lit.) BDL 284 128 BDL BDL BDL 6 9

5 Total Dissolved Solids (mg/lit.) 500 2000 182 954 1093 1134 1012 1000 700 692

6 B.O.D. (3 DAYS 27 C) (mg/lit.) BDL BDL BDL BDL BDL BDL BDL BDL

7 Chemical Oxygen Demand (mg/lit.) BDL 20 38 BDL BDL BDL BDL BDL

8 Oil & Grease (mg/lit.) BDL BDL BDL BDL BDL BDL BDL BDL

9 Chlorides (mg/lit.) 250 1000 125 500 610 575 325 428 270 198

10 Sulphate (mg/lit.) 200 400 47 118 163 69 52 60 39 55

11 Dissolved Oxygen (mg/lit.) 4.7 4.9 6.1 3.5 4.0 - - -

12 Calcium Hardness (mg/lit.) 75 200 56 180 320 203 169 210 200 190

13 Magnesium Hardness (mg/lit.) 30 100 8 45 54 61 35 49 40 60

14 Conductivity (µS) 241 1103 1138 1260 1030 1100 1000 1030

15 P-Alkalinity (as CaCO3) (mg/lit.) NIL NIL NIL NIL NIL NIL NIL NIL

16 M-Alkalinity (as CaCO3) (mg/lit.) 265 485 512 350 315 290 200 310

17 Nitrate (NO3) (mg/lit.) 45 100 NIL NIL NIL NIL NIL NIL NIL NIL

18 Flouride (as F) (mg/lit.) 1 1.5 0.40 0.90 0.50 0.65 0.32 0.49 0.22 0.30

19 Sodium (as Na) (mg/lit.) 45 59 60 88 75 61 59 68

20 Potassium (as K) (mg/lit.) 0.31 0.93 0.99 0.68 0.80 .85 .70 .88



41

S. No.

Parameter

Standard Limit as per IS:10500-1993

SW1 SW2 SW3 GW1 GW2 GW3 GW4 GW5 Desirable

Limit Permissible

Limit

21 Phenolic Compound (mg/lit.) 0.001 0.002 BDL BDL BDL BDL BDL BDL BDL BDL

22 Total Carbonate (mg/lit.) 2.63 5.3 12.7 3.68 4.2 6.2 5.0 4.9

23 Lead (as Pb) (mg/lit.) 0.05 No Relaxation BDL 0.1 BDL BDL BDL BDL BDL BDL

24 Cadmium (as Cd) (mg/lit.) 0.01 No Relaxation BDL BDL BDL BDL BDL BDL BDL BDL

25 Zinc (as Zn) (mg/lit.) 5 15 BDL BDL BDL BDL BDL BDL BDL BDL

26 Copper (as Cu) (mg/lit.) 0.05 1.5 BDL 0.25 BDL BDL BDL BDL BDL BDL

27 Cromium (as Cr) (mg/lit.) 0.05 No Relaxation BDL BDL BDL BDL BDL BDL BDL BDL

28 Arsenic (as As) (mg/lit.) 0.05 No Relaxation BDL BDL BDL BDL BDL BDL BDL BDL

29 Mercury (as Hg) (mg/lit.) 0.001 No Relaxation NIL BDL BDL BDL BDL BDL BDL BDL

30 Iron (as Fe) 0.03 1 NIL BDL BDL BDL BDL BDL BDL BDL BDL- Below Detectable Limit (Source: Monitoring and Analysis carried out during study period)



42

92. However, rest of the water samples both surface and ground water have high levels of TDS, which is below the permissible limits but higher than the desirable limit of 500 mg/l. The high TDS values can be easily traced to the high levels of Magnesium and Calcium Hardness (mg/l) and high Chloride concentration in these samples. (Total dissolved solids (TDS) comprise of inorganic salts principally calcium, magnesium, potassium, sodium, bicarbonates, chlorides and sulphates and some small amounts of organic matter that are dissolved in water). The high concentrations of these ions may be attributed to the geological nature of the area. The TDS concentration is a secondary drinking water standard and therefore is regulated because it is more of an aesthetic rather than a health hazard. The elevated TDS and ion concentrations show the water quality of the area has temporary hardness and may cause the water to be corrosive, salty or brackish taste and result in scale formation if not given pretreatment before use.

93. Rest of the parameters physico-chemical parameters and heavy metals were well within the desirable limits of the IS:10500:1991 drinking water standards.

3.4.6. Air Environment

94. Preliminary air sampling and monitoring was carried out in the months of September to November, 2010 to establish the air quality of the study area. The main sources of air pollution in the study area are vehicular emission, re-suspended dust from the paved and unpaved tracks, fuel burning for domestic requirements and wind blown dust from the open agricultural land. Sampling locations were selected based upon:

Sensitivity of site, where the construction activity and traffic due to the proposed project will take place.

Presence of sensitive receptors such as settlements.

Representative locations of regional air quality

95. Based on the above, 6 sampling locations were selected, namely, Project Site, Gangad, Bhamsara, Kalyangadh, Kanotar and Kesardi villages. The salient features (land use) of the sampling locations are given in Table 3.5 and sampling locations are marked in Figure 3.10. Bhamsara location was selected for upwind direction air monitoring.

Table 3.5 : Land Use Around the Air Sampling Locations

S. No.

Sampling Location

Land Use

w. r. t. NAAQS Description

1. Project Site Industrial Open area

2. Gangad Residential & Rural Domestic and vehicular emissions

3. Kalyangadh Residential & Rural Domestic and vehicular emissions

4. Bhamsara Residential & Rural Domestic and Vehicular Emissions

5. Kanotar Residential & Rural Domestic and Vehicular Emissions with some industrial activities nearby

6. Kesardi Residential & Rural Domestic and Vehicular Emissions

96. Ambient air quality was monitored for PM10, PM2.5, Sulphur Dioxide (SO2) and Oxides of Nitrogen (NOx). Samples of Carbon Monoxide (CO) & Hydrogen Fluoride (HF) were taken with the help of Vacuum Pumps. Samples were collected and analyzed for PM10, PM2.5, SO2, NOx, CO



43

and HF. Monitoring was done twice a week for at each location during the study period.

97. The average of the analytical results of air quality monitoring in the above mentioned locations are compared against the National Ambient Air Quality Standards (NAAQS). The maximum, minimum and average concentrations of the air pollutants are given in Table 3.6.

Table 3.6 : Ambient Air Quality Status in the Study Area

Pollutant Particular

Location

Project Site

Gangad Kalyangadh Bhamsara Kanotar Kesardi

PM10 (µg/m3)

Max. 81 65 70 75 65 61

Min. 59 45 50 45 41 36

Mean 70 51 60 55 50 43

PM2.5 (µg/m3)

Max. 42 35 33 39 35 34

Min. 27 14 17 21 22 17

Mean 32 21 28 31 29 24

SO2 (µg/m3)

Max. 15 10 13 14 14 13

Min. 7 5 6 7 5 7

Mean 12 7 9 10 9 10

NOx (µg/m3)

Max. 37 21 29 31 30 19

Min. 12 10 12 10 10 13

Mean 24 17 20 23 17 16

CO (µg/m3)

Mean 360 230 300 320 290 310

HF (µg/m3)

Mean BDL BDL BDL BDL BDL BDL

98. Hence, it can be concluded that the air quality of the monitored locations in the study area are well within the permissible standards for Industrial, Residential & Rural & areas. The values for all parameters are slightly higher at the project site than compared to rest of the locations because of its nearness to the National Highway and open areas with limited vegetation in the surroundings but are within the permissible standards.

3.4.7. Noise Environment

99. Noise after a certain level can have a very disturbing effect on the people and animals exposed to it. Hence, it is important to assess the present noise quality of the area in order to predict the potential impact of future noise levels due to the proposed project.

100. Noise monitoring was carried out at six locations, namely, Project Site, Gangad, Kalyangadh, Bhamsara, Kanotar and Kesardi villages. The sampling locations have been marked in the sampling location map Figure 3.9. Noise measurements were done using Envirotech Sound Level Meter SLM 100. Monitoring was carried out both in the day and night time and accordingly Leq day and night were derived from the monitored data including the peak values.

101. The results of the monitoring are provided in Table 3.7. Monitored levels were compared against Ambient Noise Standards prescribed under Gazette Notification 643 of Ministry of Environment and Forests, Government of India.



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Table 3.7 : Ambient Noise Quality Results

Location Location

Classification

Noise Quality Standard (dB(A))

Results (Leq) (dB(A))

Daytime Nighttime Daytime Nighttime

Gangad Residential 55 45 52 43

Kalyangadh Residential 55 45 56 47

Bhamsara Residential 55 45 63 52

Kesardi Residential 55 45 55 42

Kanotar Residential 55 45 49 41

Project Site Industrial 75 70 69 54

102. The noise levels at the villages of Kalyangadh and Bhamsara was found to be slightly more than the ambient noise standards for Residential and Rural Areas during day as well as night time for which the standards are 55 dB(A) and 45 dB(A) during daytime & night time, respectively. This is due to the heavy traffic density in the NH-8A passing through these areas. The Noise level at the Project site though was more than the standard level for Residential area but was within the standard for Industrial area.

3.4.8. Traffic Density

103. To access the existing traffic density on the National Highway (NH-8A), 24 hourly monitoring was conducted on the road. The details of the hourly traffic density in NH-8A (Kilometerage - 42/600, station –Vhayla) are presented in Table 3.8.

Table 3.8 : Hourly Traffic Density – National Highway – 8A

Hour of Count

2-Wheelers

4-Wheelers,

3-Wheelers

LCV (Light Commercial

Vehicles) Bus

Two Axile

Truck/ Tanker

Multi Axile Truck /

TruckTrailer Tanker

Agricultural Tractor

with Trailer Total

00-01 34 133 91 94 151 130 0 633

01-02 8 167 105 64 143 154 0 641

02-03 21 154 122 52 120 160 5 634

03-04 41 162 133 80 138 196 4 754

04-05 17 192 135 74 105 182 7 712

05-06 41 214 153 84 151 216 11 870

06-07 59 239 131 105 157 229 33 953

07-08 102 263 164 108 152 172 46 1007

08-09 99 184 129 67 160 114 34 787

09-10 109 208 156 81 157 116 43 870

10-11 118 234 159 83 173 118 21 906

11-12 84 219 157 83 183 124 18 868

12-13 115 237 138 85 140 107 18 840

13-14 155 264 132 90 177 95 31 944

14-15 119 207 107 68 133 130 35 799

15-16 149 284 132 88 177 144 16 990

16-17 144 224 144 78 158 134 18 900

17-18 149 255 153 107 193 149 37 1043

18-19 164 245 173 111 183 128 22 1026

19-20 126 216 126 59 119 142 19 807

20-21 61 205 103 67 144 176 12 768

21-22 69 248 82 89 145 170 17 820

22-23 47 188 83 55 143 156 14 686



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Hour of Count

2-Wheelers

4-Wheelers,

3-Wheelers

LCV (Light Commercial

Vehicles) Bus

Two Axile

Truck/ Tanker

Multi Axile Truck /

TruckTrailer Tanker

Agricultural Tractor

with Trailer Total

23-24 18 178 100 56 139 165 5 661

Total 2049 5120 3108 1928 3641 3607 466 19919

(Source: Field Monitoring)

3.4.9. Biological Environment

104. The biological environment is an important component of the environment of any area. It covers flora & fauna in the region, details of forests and wildlife sanctuaries in the region, with list of endangered species. These components are addressed in details in the following sections:

3.4.9.1 Flora & Fauna

105. Flora and fauna are vital components of the environment. They are organized into natural communities with natural dependencies among their members and show various responses and sensitivities to anthropogenic activities. Flora and fauna describes information on various species of trees, plants, shrubs, crops and natural vegetation, animal, birds etc. and endangered species.

106. Topography of the region is plain, dry and sandy. There are no woods or forests nearby.

107. A list of flora recorded during the field survey are given in Table 3.9 - Table 3.12. The list of large trees, shrubs, herbs and cultivated species in the study area are given in Table 3.9, Table 3.10, Table 3.11 and Table 3.12 respectively.

Table 3.9 : Large Trees species found in Study area

S. No.

Scientific Name Family Vernacular Name

1. Acacia auriculiformis Mimosaceae Australian Baval

2. Acacia caiechu Mimosaceae Khair

3. Acacia nilotica Subsp. Indica

Mimosaceae Baval

4. Albizzia indica Mimosaceae Siris

5. Azadirachta indica Meliaceae Limdo

6. Eucalyptus globules Myrtaceae Nilgiri

7. Ficus virens Moraceae Pipli

8. Leucena leucocephala Mimosaceae Pardesi Baval

9. Parkinsonia aculeate Caesalpiniaceae Ram Baval

10. Peltophorum pterocarpum Caesalpiniaceae Tamarafali

11. Pongamia pinnata Fabaceae Karanj

12. Prosopis juliflora Mimosaceae Gando Baval

13. Prosopis spicigera Mimosaceae Khijado

14. Roystonea regia Arecaceae Royal Palm

15. Salvadora aleoides Salvadoraceae Pilvo

16. Salvadora persica Salvadoraceae Pilvo

17. Samanea saman Mimosaceae Rato Sarasdo



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Table 3.10 : Shrubs found in Study area

S. No.


1. Cadaba indica Capparidaceae Telio hemkand

2. Calotropis gigantean Asclepiadaceae Akado

3. Calotropis procera Asclepiadaceae Akado

4. Capparis sepiaria Capparidaceae Kerdo

5. Capparis sepiaria Capparidaceae Kanthar

6. Euphorbia nerifolia Euphorbiaceae Thor

7. Ipomoea fistulosa Convolvulaceae Nafatio

8. Nerium indicum Apocynaceae Lal Karen

9. Zizyphus rotundifolia Rhamnaceae Chani Bor

Table 3.11 : Herbs found in Study area

S. No.


1. Abutilon indicum Malvaceae Khapat

2. Amaranthus viridis Amarathaceae -

3. Cassis pumila Caesalpiniaceae Nani Chimed

4. Cenchrus setigerus Poaceae Dhaman Ghas

5. Chenopodium album Chenopodiaceae Chil

6. Chloris barbata Poaceae Mindadin

7. Clitoria tematea Fabaceae Gokern

8. Cynodon cretica Convolvulaceae Rudanti

9. Cynodon doctylon Poaceae Darbh

10. Cyperus compressus Cyperaceae -

11. Daemia extensa Asclepiadaceae Chamar Dudheli

12. Echinops echinatus Asteraceae Shulio

13. Heliotropium Supinum

Borginaceae Ghedio Okharad

14. Heteropogon contortus Poaceae Dabhsuliu

15. Ipomoea aquatica Convolvulaceae Nali Ni Bhaji

16. Nymphaea stelata Nymphaeaceae Poyana

17. Triumfeitta Rotundifolia

Tiliaceae Gol Zipti

18. Typha angustata Typhaceae Ramban

19. Xanthium strumarium Asteraceae Gokhuru

Table 3.12 :Agricultural Crops found in Study area

S. No.


1. Triticum aestivum Poaceae Gehu

2. Oryza sativa Poaceae Chokha

3. Sorghum vulgare Poaceae Bajra

4. Gossypium herbaceum Malvaceae Kapas

5. Cuminum cyminum Apiaceae Jiru

108. The list of amphibians, reptiles, birds and mammals species in the study area are given in Table 3.13, Table 3.14, Table 3.15, Table 3.16 and Table 3.17 respectively.



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Table 3.13 : Amphibian in Study area

S. No. Common Name Scientific Name

1. Skipper frog Euphlyctis cyanophlytis

2. Common Indian Toad Bufo melanostictus

Table 3.14 : Reptiles in Study Area


1. Calotes Calotes versicolor

2. Skink Mabuya caninata

3. Wall Lizard Hemidoctylus flaviviridis

4. Rat Snake Ptyas mucous

5. Cobra Naja naja

Table 3.15 : Birds Spices found in Study Area


1. Pond Heron Ardeola grayli

2. Cattle Egret Bulbulcus ibis

3. Pariah Kite Milvus migrans

4. Red Wattled Lapwing Vanellus indicus

5. Blackwinged Stilt Himantopus himantopus

6. Common Sandpiper Tringa hypoleucos

7. Spotted Dove Streptopelia chinensis

8. Red Turtle Dove Streptoplia tranquebarica

9. Blue Rock Pigeon Columbia livia

10. Common Kingfisher Alcedo athis

11. White Breasted Kingfisher

Halcyon smyrensis

12. Small Green Bee-Eater Merops orientalis

13. Indian Roller Corecius benghalensis

14. House Crow Corvus splendens

15. Common Myna Acredotheres tristis

16. Red Vented Bulbul Pycnonotus cafer

17. Jungle Babbler Turdoides striatus

18. Indian Robin Saxicoloids fulicata

19. House Sparrow Passar domesticus

Table 3.16 : Mammals in Study area


1. Palm Squirrel Funambulus pennati

2. Mongoose Herpestes edwardsii

3. Common Langur Presbytis entellus

Table 3.17 Annelida in Study area


1. House Cricket Acheta domesticus

2. Cockroach Blatta germanica

3. House Fly Musca domestica

4. Mosquito Anopheles sp.

5. Striped Tiger Danaus genutia genutia

6. Mosquito Culex Sp.



48

7. Common Grass Yellow Eurema hecabe simulata

8. Common Crow Euploea core core

9. Black Ant Pheidole sp.

10. Red Ant Oecophylla smar

11. Wasp Vespa sp.

12. Bumble Bee Bombus sp.

13. Social Spider Stegodyphus sarasinorum

14. Jumping Spider Phidippus punjabensis

15. Lynx Spider Oxyopes shweta

16. Funnel web spider Hippasa sp.

17. Wolf Spider Pardosa mukundi

18. Wolf Spider Lycosa sp.

19. Garden Spider Argiope anasuja

3.4.9.2 Forests & Wildlife

109. There is no forest land in the 5 km radial zone around the project site. There are 21 Wildlife Sanctuaries and 4 National Parks in Gujarat, however, none of them are falling in the study area. Infact District Ahmedabad does not have any National Parks and Wildlife Sanctuaries. The Forest Area Map of Gujarat is shown in Figure 3.11. The map showing National Parks and Wildlife Sanctuaries in Gujarat is presented in Figure 3.12.

Figure 3.11 : Forest Map of Gujarat

Project Site



49

Figure 3.12 : National Parks and Sanctuaries in Gujarat

3.4.9.3 Protected Areas

110. There are no protected areas in the vicinity of the project area.

3.4.9.4 Historical Importance

111. There are no monuments of historical and archaeological importance within the study area.

3.4.10. Socio-Economic Conditions

112. The study of socio-economic components of environment incorporates various features viz., demographic structure, availability of basic amenities such as housing, education, medical facilities, drinking water facilities, post, telegraph and telephone facilities, communication facilities, recreational and cultural facilities, approach to villages etc. The study of these parameters helps in identifying, predicting and evaluating the likely impacts due to the proposed project activity in that region.

113. The area within 5 km radius from the periphery of the project site has been designated as study area, which falls in Bavla Taluka of Ahmedabad District. A total of 9 villages fall within the study area. The list of villages in the study area is given in Table 3.18 as follows:

Table 3.18 : Villages in the Study Area

Villages

Gangad Kanotar

Bhamsara Dahegamda

Kalyangadh Bhayla

Project Site



50

Villages

Kesrandi Kochariya

Lagdana

114. The data on baseline status of the study area has been collected from the Census 2001 of Government of India and basic information about the socio-economic profile has also been collected during the site visit. Baseline information was collected to define the socio-economic profile of the study area. The database, thus generated in the process includes:

Demographic structure

Infrastructure base in the study area

Economic attributes

Health status

Socio-economic status with reference to Quality of Life

Awareness and opinion of the people about the project

3.4.10.2 Demography

115. The demographic structure of the study area covering 5 km area radial zone around the periphery of the project area has been abstracted from Primary Census Abstract – 2001 compact disk of Gujarat State obtained from the Office of Registrar General India, New Delhi.

116. Total Population in the study area is 19,176 which include 10,039 male and 9,137 females. The total number of household present in the study area is 3,726. The summary of the Demography within the region has been given in the following Table 3.19.

3.4.10.3 Economic Status

117. The occupational structure within 5 km radius of the project site constitutes of 26.42% as main workers and marginal workers contribute 36.34%.

118. Total working population in the study area is about 41.5% of the total population in which distribution of male and female workforce is 68% and 32% respectively.

119. Table 3.20 gives the details about the economic status of the villages of the study area.

3.4.10.4 Education Facility,

120. The education facility for Primary and Secondary standard is good within the Study area. All villages in the study area (9 villages) have education facility of primary level. A total of 9 Primary Schools are existing in the study area. In addition to that there are 2 Secondary Schools in the study area. However, there is no college for higher studies in the area. Summary is given in Table 3.21 .

3.4.10.5 Health Care Facilities

121. Medical Facilities are available in 7 villages in the study area. Primary health centres and Primary Health Sub Centres are available in 1 and 6 villages respectively. Also private registered practitioners are available in the 5 villages and Community Health Works are also there in few villages. Summary is given in Table 3.21 .



51

3.4.10.6 Drinking Water Facility

122. Drinking water facility is available in all the 9 villages of the study area. Tap water, well water and hand pumps are present in all the villages as sources of drinking water. Summary is given in Table 3.21 .

3.4.10.7 Post, Telegraph & Telephone Facilities

123. 6 villages out of 9 villages in the study area have connectivity in the form of either Post Office, or telephone or telegraphic facilities. Summary is given in Table 3.21.

3.4.10.8 Communication Facilities

124. All the 9 villages in the study area are connected with communication facilities. Bus service and water ways Navigation is available in all these villages. All the villages have paved roads as approach means to these villages. Summary is given in Table 3.21

3.4.10.9 Power Supply

125. All the villages are connected with power supply. Electricity is available for domestic application, agricultural purposes, and all the other purposes in all 9 villages of the study area.

3.4.11. Industries in the study area

126. Most of the lands in the study area belong to the villages of the area and are either agricultural land or barren land. New industries are coming up in the study area due to the favourable industrial policy of Gujarat Government.

3.4.12. Resettlement and Rehabilitation Plan

127. About 32,520 sq. m. land has been acquired by the Narmada Bio-Chem Pvt. Ltd (Unit IV) for the proposed project. The entire land belongs to Kalyangadh village. The proposed site is not inhabited, hence does not involve resettlement and rehabilitation of people. It has also been noticed during the reconnaissance survey that there will be no loss of agricultural land. The baseline status studied through survey and substantiated with secondary data reveals that the proposed project will have positive impact on the socio-economic status of the study area.

3.4.13. Public Perception of the Project

128. During the baseline data collection, informal discussions were held with the villagers of the nearby areas. The villagers were positive towards the proposed project. In fact they extended wide acceptance of the project considering that it will contribute in improving economic conditions of the area.



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Table 3.19 : Summary of Demographic Profile

Villages HH

Population SC Population ST Population Literate Population

T M F T M F T M F T M F

Gangad 1012 4840 2535 2305 401 202 199 0 0 0 2347 1486 861

Bhamsara 300 1592 829 763 21 11 10 3 2 1 569 408 161

Kalyangadh 203 1088 582 506 97 51 46 0 0 0 547 365 182

Kesrandi 596 3094 1619 1475 268 148 120 0 0 0 1388 1009 379

Lagdana 184 843 452 391 75 44 31 5 2 3 367 268 99

Kanotar 301 1657 868 789 0 0 0 0 0 0 463 350 113

Dahegamda 344 1784 914 870 133 64 69 0 0 0 772 584 188

Bhayla 437 2365 1251 1114 322 167 155 50 22 28 1411 930 481

Kochariya 431 2171 1136 1035 288 153 135 6 3 3 964 664 300



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Table 3.20 : Summary of Economic Status

Villages

Working Population Main Workers Marginal Workers

T M F T M F T M F

Gangad 1961 1385 576 711 698 13 1250 687 563

Bhamsara 800 508 292 583 459 124 217 49 168

Kalyangadh 426 332 94 419 331 88 7 1 6

Kesrandi 1165 825 340 723 675 48 442 150 292

Lagdana 321 209 112 134 104 30 187 105 82

Kanotar 862 482 380 451 439 12 411 43 368

Dahegamda 791 493 298 558 416 142 233 77 156

Bhayla 934 675 259 916 669 247 18 6 12

Kochariya 699 503 196 572 457 115 127 46 81

Total 7959 5412 2547 5067 4248 819 2892 1164 1728

T- Total, M-Male, F-Female



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Table 3.21 : Summary of Amenities in the Villages in the Study Area

Sr. No.

Villages Education Medical Drinking

Water Post &

Telegraph Communication

Approach to Village

Nearest Town

Power Supply

1 Gangad PS, SS PHSC,PHC,HC TW, WW, HP

PO,PTTF,TC Bus,NWW, PR Bavla EAP

2 Bhamsara PS TW, WW, HP

PO,PTTF,TC Bus,NWW PR Bavla EAP

3 Kalyangadh PS CHW, PRP,PHSC

TW, WW, HP

PO,PTTF,TC Bus,NWW,

PR Bavla EAP Railway

4 Kesrandi PS PHSC TW, WW, HP


5 Lagdana PS CHW TW, WW, HP

Bus,NWW PR Bavla EAP

6 Kanotar PS TW, WW, HP


7 Dahegamda PS CHW,PHSC TW, WW, HP


8 Bhayla PS CHW, PRP,PHSC

TW, WW, HP

PTTF,TC Bus,NWW PR Bavla EAP

9 Kochariya PS, SS PHSC TW, WW, HP


Note: PS- Primary School SS- Senior School PHSC- Public Health Sub Centre PHC- Public Health Centre PRP- Private Registered Practiptioner CHW- Community Health Works TW- Tab Water WW- Well Water HP- Hand Pump PO- Post Office PTTF- Postal, Telegraph & telephone Facilities TC - Telephone Connection NWW - Navigated Water Ways PR- Paved Road EAP- Electricity for All Purposes



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4. ANTICIPATED ENVIRONMENTAL IMPACTS AND PREDICTIONS

4.1. General

129. The possible impact on various components of environment due to the proposed single super phosphate project of Narmada Bio-Chem Pvt. Ltd. (Unit IV) can be assessed in terms of:

Physical and Biological Environment and

Demographic and Socio-economic Environment.

130. For proper assessment of significance and magnitude of environmental changes due to construction and operational phases of the plant, the impacts are analyzed on the 5 km radius study area around the proposed plant site for each environmental parameter. Prediction of impacts is an important component in environmental impact assessment process. Several techniques and methodologies are in vogue for predicting the impacts due to existing and proposed industrial development on physico-ecological and socio-economic components of environment. Such predictions delineate contribution in existing baseline data for the operational project and superimpose over the baseline (pre-project) status of environmental quality to derive the ultimate (post-project) scenario of the environmental conditions due to the proposed project. The quantitative prediction of impacts lead to delineation of suitable environmental management plan needed for implementation during the construction, commissioning and operational phases of the proposed project in order to mitigate the adverse impacts on environmental quality.

131. The following sections identify the potential impacts on the environment from the proposed project based on the nature and extent of the various activities associated with the project implementation and operation, as well as the current status of the environmental quality at the project site. Both beneficial (positive) and adverse (negative) impacts are considered.

4.2. Potential Impacts during Project Implementation

132. Construction activities normally spread over pre-construction, preparatory construction, machinery installation and commissioning stages and end with the induction of manpower and start-up.

133. Pre-construction phase basically involves completion of all legal formalities with respect to the No Objection Certificates from the various statutory bodies, surveys/ studies required, acquisition of land, settlement of all issues related to compensation, if any, finalization of contract for procurement of machinery/ equipments, recruitment and hiring of requisite skilled, semi-skilled manpower and labour, provision of space and other facilities like water supply, disposal of wastewater and solid waste etc. on temporary basis for the contracted labour to be employed and provision for storage of machinery and materials to be used for construction.

This chapter details the inferences drawn from the environmental impact assessment of the proposed project. It describes the overall impacts of the project activities and underscores the areas of concern, which need mitigation measures. Predictions have been done based on the various quantitative and qualitative methods suggested by Ministry of Environment & Forests, New Delhi.



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134. Preparatory construction phase in the project mainly consist of transportation of machinery, equipments and materials to the site for construction, clearing and levelling of land, site grading, fencing, road design, surface drainage, sewerage system, common effluent treatment plant, integrated solid waste management system, power supply and electrification, street lighting, rainwater harvesting, fire protection services, telecommunications along with common facilities & administrative complex buildings, etc.


135. The sources of air emission during construction phase will include site levelling, vehicles movement, materials storages and handling and operation of construction equipments and machinery. Emissions from them are expected to result in temporary degradation of air quality, primarily in the working environment affecting construction employees. However, Suspended Particulate Matter (SPM) rise in the ambient air will be of coarse nature and will settle within a short distance close to the construction activity sites. Hence, dust and other gaseous emissions are unlikely to spread sufficiently to affect the surrounding villages of the project site.

136. Traffic to the site during construction will increase slightly. However, as the project site is situated on the National Highway – 8A, therefore, this will not cause any problem. The main access to the project site will be through this four lane NH-8A. The south boundary of the project site is covered by 280 m stretch of NH-8A.

137. The present road conditions are reasonably good for the proposed additional movement of vehicular traffic. However, construction of the internal roads in the project site will require attention to reduce the fugitive dust emissions due to various construction activities and transportation of materials. The impacts on the ambient air quality during construction phase will be temporarily for short duration and reversible in nature and restricted to small area. It is also to be noted that there is no habitation in the close vicinity of the project site. The nearest habitation is at Kalyangadh, which is about 1.5 km away from the project site in east direction.

138. The emission of particulate matter during the construction phase will be generated from the activities like receipt, transfer and screening of aggregate, crushing activity, road dust emissions. The likely emission levels from these sources are indicated at Table 4.1. In addition to that emissions from various construction machinery fueled by diesel and from mobile source will be in the form of PM10, VOC, CO, NOx and SO2. The emissions from stationary and mobile diesel engines with respect to their working/ movement are presented in Table 4.2:

Table 4.1 : Emission Factors of Various Dust Generation Processes

Source Unit Emission

Factor

Receipt of new aggregate at Hot Mix Plant g/ton 1.86

Transfer of aggregate from storage to conveyor belt or between conveyor belts in Hot Mix Plant

g/ton 0.021

Screening of aggregate in Hot Mix Plant g/ton 0.38

RAP crushing g/ton 0.27

Paved road dust emissions g/VMT 7.26

Unpaved road dust emissions g/VMT 925.3

(Note: VMT: Vehicle Mile Traveled)



57

(Source: AP 42, Fifth Edition, Volume I, Chapter 13: Miscellaneous Sources of United State Environmental Protection Agency (USEPA) http://www.epa.gov/ttn/chief/ap42/ch13/index.html )

Table 4.2 : Exhaust Emissions for Stationary and Mobile Machinery

Source PM10 VOC CO NOx SO2

Diesel exhaust emissions (idle)

0.043 g/min

0.208 g/min

1.57 g/min

0.917 g/min

18.8 S g/l

Diesel exhaust emissions (moving)

0.4 g/mile

3.18 g/mile

18.82 g/mile

8.5 g/mile

18.8 S g/l

(Source: AP 42, Fifth Edition, Volume I, Chapter 13: Miscellaneous Sources of United State Environmental Protection Agency (USEPA) http://www.epa.gov/ttn/chief/ap42/ch13/index.html )

4.2.2. Land Environment

139. The project site is bounded by part of NH-8A on the south and village land on rest of the sides. These lands are completely barren lands with few shrubs and hence, there is no conflict of existing as well as future landuse pattern. The project site is free from any type of vegetation and hence, no land clearing is required. However, development of greenbelt and lawns after completion of the construction phase will enhance the beauty of the site as well as act as a pollution barrier during the operation stage of the project.

140. The excavation of earth and earthwork may change the terrestrial ecology as well as natural drainage of the site. However it is proposed in the plan that the storm water drainage network will be laid taking the advantage of the natural topography.

141. The existing topography of the project site has flat terrain. The elevation of ground surface varies between 12.5 to 13.0 m above mean sea level and hence, no site levelling is required in the project.

4.2.3. Ambient Noise Levels

142. The general noise levels during construction phase such as due to working of heavy earth moving equipment and machinery installation may sometimes go up to 90 dB(A) at the work sites during day time. The workers in general will be likely to be exposed to an equivalent noise level of 70 - 80 dB(A) in 8 hours shift for which all statutory precautions will be implemented. Use of proper personal protective equipment will further mitigate any adverse impact of noise to the workers.

143. The noise generation will be considerable during such type of medium scale construction activities. Typical noise sources during construction phases are mentioned in Table 4.3. Different phases of construction activities at project site are scheduled to take place for about 4 - 6 months. The impacts during construction phase are temporary and will be marginal. Necessary mitigative measures are required to be implemented during construction period. The noise impact will be relatively more on construction workers during their duty hours, which will be mitigated though compliance to occupational exposure standards. Use of personal protective devices like ear muffs/plugs etc. will further minimize the noise impacts. Increase in the ambient noise levels will be temporary for a short duration and is reversible in nature.

http://www.epa.gov/ttn/chief/ap42/ch13/index.html

http://www.epa.gov/ttn/chief/ap42/ch13/index.html



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Table 4.3 : Typical Noise Sources during Construction Phase

Description Noise Level dB(A)

Earth Movers

Dozers 95-100

Front Loaders 72-84

Backhoes 72-93

Tractors 76-96

Tippers/Trucks 82-94

Material Handlers

Concrete mixers 75-83

Concrete pumps 81-83

Cranes (movable) 75-86

Vehicular Traffic (Construction material & plant machinery)

85-98

Stationary Equipments

DG Sets 90-95

Pumps 69-71

Compressors 74-86

Impact Based Equipments

Pneumatic Wrenches 83-88

Jack hammer and rock drills 81-98

Pile drivers (peak) 95-105

144. Noise levels can affect local residents‟ amenities both during transportation and construction. However, it is to be noted that the nearest village Kalyangadh is about 1.5 km from the project site boundary and noise generated from the project activities will be attenuated significantly due to atmospheric attenuation. Also, by using standard practice of operation, these impacts can be minimized and made insignificant.

4.2.4. Water Quality

145. The likely impacts on water quality during the construction phase may arise from inappropriate disposal of construction waste, mismanagement of domestic effluent from the construction camps, and wastewater generated from the construction sites.

146. Wastewater generated from the site during the construction contains suspended materials, spillage and washings from the various areas, which can be hazardous and should not be mixed with the domestic effluent or allowed to percolate into the ground.

147. During the construction phase of the project, total water requirement will be about 5 - 10 KLD, which will be required mainly for construction activities, growing plants and developing lawns as well as for domestic water requirement for the construction work force. Raw water will be taken from ground water. The daily water requirement will vary based on the project activities.

148. It is estimated that the total workforce required for the project will be about 40 - 50, which will mostly come from the nearby villages. No construction camp is proposed in the project. Domestic wastewater generation will be about 0.5 to 1 KLD. All the domestic wastewater generated from the construction site will be sent to septic tank followed by soak pit, so that it shall not contaminate the ground water or surface water in the nearby areas.



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4.2.5. Solid Waste Generation (Hazardous/ Non-hazardous) and Disposal

149. Construction activities lead to generation of sand, gravel, concrete, stone, bricks, wood, metal, glass, polythene sheets, plastic, paper etc. as waste. Various operations during the construction activities lead to the varied compositions in the total solid waste stream and affect the site. Excavated topsoil shall be used for backfilling/ greenbelt development & plantation. As soon as the construction will be over, all wastes from the site will be cleared with due care, meeting regulatory requirement, if any. Also, hydraulic oil, fuels and lubricating oils will be used. There is potential for accidental spills while re-fuelling or servicing vehicles and through the breakage due to wear and tear. Procedures for maintenance of equipment will ensure that this risk is minimized and cleanup response is rapid if any spill occurs. During construction phase, waste oil will be generated as and when lubricating oil is changed. Waste oil will be collected through the drain ports and stored in leak proof steel drums. The waste oil drums will be properly identified with label of what is contained both in local language (Gujarati) and English. It will be mainly disposed off by selling to appropriate vendors as per Hazardous Waste (Management, Handling and Transboundary Movement) Rules 2008 & amendments thereafter.

150. Municipal waste will be minimal as most of construction workforce will belong to local area and no construction camp is proposed. The waste generated will be collected and segregated and will be disposed off suitably. Hence impacts will be insignificant, reversible and for short duration only. These impacts will be confined to the construction site only and no adverse impact on the surroundings is anticipated.

4.2.6. Storage of Hazardous Materials/ Dumping Materials

151. Limited quantity of petrol, diesel, lubricating oil etc. will be required to be stored at site. These materials shall be stored as per stipulated safety standards/ guidelines. Also, some construction waste material will be generated for disposal during construction activity. These, if disposed off haphazardly can pollute the nearby water bodies adversely. They would increase the accident incidences also.

4.2.7. Terrestrial Ecology

152. As per the field investigation, the project site is barren area and does not have any vegetation. Hence, no impact on terrestrial ecology is envisaged due to the construction activity at site. Also, the study zone does not have any ecologically sensitive location and hence, the proposed activities are not expected to have any major impact on the Flora and Fauna.

4.2.8. Socio-Economic Environment

153. All the activities to be carried out during the planning, and construction phases will require skilled, semi-skilled and un-skilled labours, hence creating temporary as well as permanent employment for the local people. The workforce required during the construction phase will be about 40 - 50 persons, which will be depending upon construction activities, since most of the construction activities like fencing, road construction, common facilities construction are labour intensive. Most of the unskilled and semi-skilled labor will be by and large available from the nearby villages and from Bavla Taluka. Thus, impact on the physical and aesthetic resources will be minimal. Further, local skilled, semi skilled and unskilled labourers will get direct and indirect employment during the construction phase. Hence, short-term positive



60

impacts on socio-economic conditions of the area are anticipated during the construction phase.

4.2.9. Site Security and Safety

154. A construction site forms a potentially hazardous environment due to the various construction activities, involvement of heavy construction machinery, vehicular movement, storage of hazardous chemicals, etc. Any accident happens in the project site can affect the construction workers.

4.3. Potential Impacts during Project Operation

155. The potential impacts during the Operation Phase have been identified within the project site as well as the study area of 5 km radial zone around the project site. The basic environmental attributes likely to be affected due to the proposed project are as follows:

Air Environment

Water Environment

Noise Environment

Land Environment

Socio-economic Environment

156. The impact on each of the above components of environment are identified through cause condition network using appropriate mathematical model and evaluated through environmental evaluation system. The summary of project activities and impacts are represented in matrix form in Table 4.6.


157. Prediction of impacts of the proposed SSP plant on air environment i.e. ambient air quality was carried out using computer based air quality simulation model known as „Industrial Source Complex Short Term‟ (ISCST3).

158. In the present study, the mathematical model that has been used for predictions on air quality includes steady state Gaussian Plume Dispersion model designed for multiple point sources.

159. The impacts on air quality from any project depend on various factors like design capacity, configuration, process technology, raw material, fuel to be used, air pollution control measures, operation and maintenance.

160. The major air pollutants expected to be emitted from proposed SSP project are SPM, NOx, SO2, and some quantity of HF, from combustion of agro waste used in HAG, grinding/ milling of rock phosphate, emission of hydrogen fluoride and SPM from the mixer and den conveyor. The point sources of emission wll be stack attached with HAG, DG set stack and scrubber vent. The details of flue gas stack and process stack have been presented in Table 2.13 and Table 2.14.

4.3.1.1 Micro-Meteorology

161. The hourly wind speed, solar insulation and total cloudiness during day time and wind speed and total cloudiness during night time were used to determine the hourly atmospheric stability classes (defined by Pasquill and Gifford as A to F, A being most unstable and F being most stable). The hourly stability classes were determined based on the technique suggested by Turner.

162. Turner‟s system used for determining the stability classes is as follows:



61

For day or night: If total cloud cover (TC) = 10/10 and ceiling <7000 ft (2134 m), NR=0

For night-time (defined as period from one hour before sunset to one hour after sunrise):

If TC<4/10, use NR = -2

If TC>4/10, use NR = -1

For daytime: Determine insolation class number (IN)

If TC<5/10, use NR=IN

If TC>5/10, modify IN by the sum of the following applicable criteria

If ceiling<7000 ft (2134m), modification = -2

If ceiling>7000 ft but <16000 ft (4877 m), modification = -1

If TC=10/10 and ceiling>7000 ft, modification = -1, and let modified value of IN=NR, except for day-time NR cannot be <+1

163. During the study period stability calculated based on above mentioned Turner method gives average stability as F class during night, C & D class during morning and evening and A & B class during noon.

4.3.1.2 Air Quality Modeling and Predictions using the ISCST - 3 Model

164. The impact on air quality due to emissions from single source or group of sources is evaluated by use of mathematical models. When air pollutants are emitted into the atmosphere, they are immediately diffused into surrounding atmosphere, transported and diluted due to winds. The air quality models are designed to simulate these processes mathematically and to relate emissions of primary pollutants to the resulting downwind air quality. The inputs include emissions, meteorology and surrounding topographic details to predict the impacts of conservative pollutants.

165. The impacts of air pollutants were predicted using Industrial Source Complex – Short Term (ISCST Version 3) air quality model, which is selected on the basis of existence of multiple point sources within the industrial complex as well as the plain terrain at the project site.

166. The Industrial Source Complex – Short Term Version 3 (ISCST-3) model has been developed to simulate the effect of emissions from point sources on air quality. The ISCST-3 model was adopted from the USEPA guideline models and routinely used as a regulatory model to simulate plume dispersion and transport from up to 100 point sources and 10000 receptors. ISCST–3 is the state of the art model with USEPA and extensively used for predicting the Ground Level Concentrations (GLCs) of conservative pollutants from point, area and volume sources. The impacts of primary air pollutants are predicted using this air quality model keeping in view the plain terrain at the project site. The micrometeorological data monitored at project site during study period have been used in this model.

167. The ISCST-3 model provides estimates of pollutant concentrations at various receptor locations. It is, an hour-by-hour steady state Gaussian model which takes into account the following:

Terrain adjustments

Stack-tip downwash

Gradual plume rise

Buoyancy-induced dispersion, and



62

Complex terrain treatment and consideration of partial reflection

Plume reflection off elevated terrain

Building down wash

Partial penetration of elevated inversions is accounted for

168. Hourly source emission rates, exits velocity, and stack gas temperature In the present case, prediction of impacts has been carried out for the winter season on 24-hourly basis in the entire study area of 5 km radius using the mentioned ISCST–3 model.

4.3.1.3 Predicted GLC due to SSP Project

169. The contribution to GLCs for the pollutants i.e. NOx, SOx, SPM, and HF were predicted over the study area due to proposed SSP project have been considered in the worst scenario. The emission loads from proposed SSP project are given in Table 4.4. The prediction (maximum) is based on the expected total emission rate from each stack and the isopleths of PM, SO2, NOx and HF has been presented in Figure 4.1, Figure 4.2, Figure 4.3 and Figure 4.4, respectively. The maximum contribution to GLC due to the proposed SSP project is presented in Table 4.5.

Table 4.4 : Stack Emission Details

S. No.

Stack Stack Height

(m)

Stack Diameter

(m)

Exit Velocity

(m/s)

Exit Temp

(K)

Emission Rate (g/s)

PM SO2 NOx HF

1 Process 50 0.9 11 323 0.55 0.9 0.33 0.1

2 HAG 30 0.6 20 323 0.46 0.8 0.3 -



63

Figure 4.1 : Isopleths of PM due to Proposed SSP Project



64

Figure 4.2 : Isopleths of SO2 due to Proposed SSP Project



65

Figure 4.3 : Isopleths of NOx due to Proposed SSP Project



66

Figure 4.4 : Isopleths of HF due to Proposed SSP Project



67

Table 4.5 : Contribution to GLCs (maximum) due to Proposed SSP Project Stacks

Description Maximum Ground Level Concentration (μg/m3)

PM SO2 NOx HF

Process Stack HAG Stack

3.93 6.72 2.50 0.24

Distance of Occurrence (km)

1.0 1.0 1.0 0.8

Direction of Occurrence ESE ESE ESE S

170. Based on the above prediction, it is clear that there will be marginal increase in the ambient air pollutants concentrations due to the proposed SSP project and the maximum ground level concentrations of pollutants will be confined to within 1 km from the project site. It shall also be noted that there is no habitation within 1.5 km from the project site and hence, the impact can be termed as insignificant.


171. The sources of noise during the operational phase of the SSP plant are mainly granulator, dryers and coolers, crushers, bucket elevators, screw conveyors, pumps etc. The other sources of noise are the movement of vehicles along the road all around the plant. The proposed SSP project will be a smaller project with advanced technology and improved equipments both in terms of energy efficiency and less noisy. However the material handling equipments especially crushers, bucket elevators and pay loaders are noisy but the noise level is limited. These machines will be provided with appropriate acoustic enclosures to maintain the noise levels within limits.


172. Total water demand for the proposed SSP project is about 47 KLD, out of which industrial water requirement is about 40 KLD and remaining will be utilized for domestic purposes and greenbelt development. The freshwater requirement will be met by on-site bore well.

173. There will not be any wastewater generation due to industrial process. Wastewater generated from washing and scrubbing will be recycled back in the process. Hence, no industrial wastewater is anticipated from the project. From domestic application about 1.5 KLD of wastewater will be generated, which will be sent to septic tank followed by soak pit. Characteristics of the domestic effluent (sewage) will be as follows:

pH : 6.5 - 8.5

Suspended Solids : 400 - 500 mg/L

BOD : 200 - 300 mg/L

174. Due to no wastewater discharge outside the plant premises, the unit will be "Zero Discharge Unit".

175. In addition to that, for rainwater harvesting within the plant premises, a total of 9 no. of percolating wells will be provided. These wells will help in recharging the groundwater aquifer. Hence, it can be envisaged that the proposed project will not have any significant impact on water environment.



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176. No significant impact on land environment has been envisaged during the operation phase as the project is not going to generate huge quantities of hazardous/ solid waste. Also, about 30% of the land will be utilized for greenbelt development, which will help in enhancing the aesthetic environment of the area.


177. During the operation phase of the project, a total of 516 tall trees will be planted along the periphery of the project and about 9918 sq. m. area will be developed as green area. These activities will help in reducing the air and noise pollution as well as will enhance the biological and aesthetic environment in and around the project site. The development of green belt provides habitat, food and breeding areas to birds, small animals and insects. No rare or endangered species of fauna are reported to exist in the area. Thus, no impacts on rare / endangered species are envisaged due to normal operations. Indigenous tree plantation will be preferred in greenbelt development. Hence, no negative impact on biological environment is envisaged.

4.3.6. Socio – Economic Environment

178. Proposed project will generate direct employment for about 50 persons. In addition to that, indirect employment opportunities will be generated in raw material and final products transportation, contractual manpower for non-critical activities at the plant (canteen, gardening, housekeeping etc.). The industrial growth of the region will help in infrastructure development in the area. It will also generate income for government through taxes. Overall the project will have positive impacts on socio-economic environment.

4.3.7. Impact on Infrastructure

179. The raw material (rock phosphate) will be transported from mines located in Rajasthan or will be imported from Egypt, Israel through Kandla Port. Spent sulphuric acid will be transported from nearby areas. Approximately 20 to 25 trucks/ day will com to the plant. The final product (PSSP and/or GSSP) will be dispatched from plant to various parts of the country and/or will be exported through Kandla Port. Approximately 20 - 25 trucks will be used for the same. Based on the estimation, approximately 2 to 3 trucks per hour will remain at the project site. Hence, due to the project activities the increase in the vehicular traffic density in the study area will be about 40 to 50 trucks per day. However, adequate parking for trucks at the project site along with rest room and canteen facilities within the premises of the factory for drivers will be provided. The National Highway (NH-8A), which is adjacent to the project site is having 4-lanes and is going to be converted into 6-lanes. Hence, this marginal increase in the traffic, will not affect the road infrastructure of the study area.



69

Table 4.6 : Pre-mitigation Matrix for Various Project Activities and Associated Potential Environmental Impacts on Various Environmental Attributes

Air

Lan

d

Am

bie

nt

No

ise

Wa

ter

Qu

ality

So

lid

Wa

ste

Flo

ra

Fau

na

So

cio

-

eco

no

mic

En

vir

on

me

nt

Construction Phase

Earthwork and Excavation ST- ST- ST-

Disposal of Excavated Earth ST- ST- ST- ST-

Disposal of Construction Waste ST- ST- ST- ST-

Operation of Construction Machinery ST- ST-

Transportation of Construction Material ST- ST-

Material Handling ST- ST- ST-

Use of DG Sets ST- ST-

O & M of Construction Machinery ST- ST-

Disposal of Domestic Waste & Effluents ST- ST- ST-

No Greenbelt Development ST- ST- ST- ST- ST- ST-

Disposal of Hazardous Waste ST- ST- ST-

Influx of Workers ST- ST- ST- ST-

Sewage Discharge ST-

Income Generation ST+

Employment Generation ST+

Operation Phase

Operation of Industry LT- LT- ST+

Effluent Generation & Discharge ST-

Solid Waste Generation & Disposal ST- LT-

Hazardous Waste Generation & Disposal LT- LT- LT- LT- LT-

Increase in Vehicular Movement LT- LT- LT-

Transportation of Raw Material and Final Products LT- LT- LT-



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Air

Lan

d

Am

bie

nt

No

ise

Wa

ter

Qu

ality

So

lid

Wa

ste

Flo

ra

Fau

na

So

cio

-

eco

no

mic

En

vir

on

me

nt

Storage of Hazardous Chemicals LT- LT-

No Greenbelt Development LT- LT- LT- LT- LT- LT- LT-

Influx of Workers LT- ST- LT- LT-

Employment Generation ST+ Notations:

ST+ : Short Term Positive

ST- : Short Term Negative

LT+ : Long Term Positive

LT- : Long Term Negative



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5. ENVIRONMENT MANAGEMENT PLAN

5.1. Introduction

180. Prediction of the potential adverse environmental and social impacts arising from development interventions is at the technical heart of EIA process. An equally essential element of this process is to develop measures to eliminate, offset, or reduce impacts to acceptable levels during implementation and operation of projects. The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental Management Plan (EMP).

181. Normally, potential impacts are identified early during the initiation of project, and measures to avoid or minimize impacts are incorporated into the alternatives being considered. In this respect, some of the most important measures to protect the environment and local communities become integral to the project design, and may not be reflected in a formal EMP.

182. NBCL by way of EIA study propose to identify all the likely potential impacts, collect data information and incorporate all the measures necessary to avoid or minimize impacts on surrounding environment. Many of the mitigation measures are already taken up in the engineering design itself.

5.2. Objectives of EMP

183. Overall objective of EMP:

Prevention: Measures aimed at impeding the occurrence of negative environmental impacts and/or preventing such an occurrence having harmful environmental impacts.

Preservation: Preventing any future actions that might adversely affect an environmental resource or attribute.

Minimization: Limiting or reducing the degree, extent, magnitude, or duration of adverse impacts.

5.3. Components of EMP

184. EMP for NBCL to set up SSP plant considers the following aspects:

Description of mitigation measures

Description of monitoring program

Institutional arrangements

Implementation schedule and reporting procedures

This chapter provides mitigation and control measures to attenuate or eliminate environmental impacts, which are likely to be caused by the proposed project. An Environmental Management Plant (EMP) has been developed to mitigate the potential adverse impacts and to strengthen the beneficial environmental impacts during the construction and operation phases. In addition to that during the operation phase, the industry will have an additional responsibility to comply with the statutory requirements as per the guidelines of Central/ State Government.



72

Institutional framework includes the responsibilities for environmental management as well as responsibilities for implementing environmental measures.

5.3.1. Central Pollution Control Board {CPCB} Guide Lines for Fertiliser Industry

185. CPCB in its publication “Probe/97/2002 - 03”- „Environmental Management in Selected Industrial Sectors Status / Needs‟, which also includes fertilizer sector has brought out suggestions / recommendations and norms for fertilizer units. The suggestions / recommendations and norms as applicable to proposed SSP project and their compliance status is detailed below:

Table 5.1 : Action Points as per CREP

Action Points Status

Purge gas recovery unit (PGRU) should be installed by all ammonia plants for recovery of gases.

Not applicable

All the plants should recover ammonia as well as bottom water from condensate arising from ammonia plant by installing steam-stripping system.

Not applicable

All the operating urea plants should install deep hydrolyser – stripper as a facility for treatment of condensate arising from urea plant and to recycle ammonia and use bottom water.

Not applicable

As far as possible, the treatment units should be provided at the end of the processing plant for specific pollutants such as oil removal system at the place of oil handling, phosphate and fluoride removal system after phosphate and fluoride bearing effluents, ammonia removal system for ammonia bearing effluents, chromium removal system for CW blow down where chromate based chemicals are used.

Proposed plant is a "Zero Effluent" plant. All the wastewater generated will be recycled back into the process.

Residual pollutants can be removed in a centralized biological treatment plant, where necessary by providing nitrification and de -nitrification system. It must be ensured that performance of de -nitrification process is complete.

Not applicable

The industries should install holding ponds for storing occasional, accidental and unforeseen effluents, which can disturb the performance of effluent treatment system. Such holding ponds should have an arrangement to pump the effluents to ETP at regulated rate.

For SSP plant all the water from scrubbers will be recycled in the system. SSP plant will be „Zero‟ effluent plant.

Water Conservation: Industry should consider and attempt dry floor cleaning so as to minimize use of water for floor washing. No process water is to be used for floor washing.

Rainwater harvesting is proposed for conservation of water resources. Washing effluent will also be recycled back to the process.



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Action Points Status

The leakages, overflows and spillages taking place in distribution system should be checked and controlled to avoid wastage of water.

This will be adhered.

For development of green belt treated wastewater may be used instead of fresh water.

All the effluent generated will be recycled back in the process. Hence, due to unavailability of treated effluent, fresh water will be utilized for green belt development.

Spillage urea around prilling tower should be recovered by dissolving in urea dissolving tank followed by recycle in the process. At the bagging plant also spilled urea and the de-dusting scrubber liquor are to be collected and recycled in the process plant through urea dissolving unit.

In SSP plant all dust (including fugitive) generated in the system will be captured either in Scrubbers or Cyclone separators and will be recycled in the system.

Hazardous chemicals are to be adequately stored and marked.

This will be adhered

Solid Waste Management: Catalysts are charged or made up based on loss of activity after use for some time. The waste catalysts are to be disposed. Disposal should be done with appropriate and organised manner – secured land fill, returning to the supplier with special contract at the time of purchasing, selling for metal recovery.

This will be adhered

Monitoring: AAQ monitoring at appropriate locations.

Ambient Air Quality Monitoring at three stations will be carried out as per the standard procedures on monthly basis.

Ground water monitoring around the storage facilities and also beyond the factory premises are to be carried out .at the regular interval – particularly for the parameters nitrate, fluoride, pH etc. The records of sampling, Depth and locations are to be maintained are to be maintained. The locations of sampling stations should be indicted in a map showing the contours of the area.

Monitoring of ground water will be carried out by a pizometric well within the plant premises.

Environment Management Cell headed by an experienced technologist and provided with facilities like laboratory, library and sufficient manpower.

An environment management cell headed by the Managing Director will be constituted for the proposed project to monitor the performance of the EMP.


5.3.2.1 Air Pollution Control Measures during the Construction Phase

All the safety measures prescribed in code for building and construction will be followed.



74

Personal Protective Equipments (PPEs) will be provided to all the workers.

Regular monitoring of Construction activity and PPEs provided to the workers by the contractor will be done.

Sprinkling of water in open area of factory premises will be done.

Speed of vehicles inside the factory premises will be controlled.

5.3.2.2 Control Measures for Fugitive Emissions

Special care will be taken for the handling & transportation of the raw material within the premises.

Sprinkling of water in an open ground area of the factory premises

Speed of vehicles inside the factory premises will be controlled.

Greenbelt will be developed to attenuate the air pollution.

Closed loop system will be adopted to reduce the workers exposure to hazardous chemicals during manufacturing process.

Proper personal protective equipments will be provided to the workers.

All trucks will be transported after covering from the top.

Raw material unloading will be done by mechanized truck unloading system.

Dust collectors will be in line with unloading hoppers.

Material handling in the plant will be done in closed conveyors.

All the trucks being used for transportation of raw material and final product shall be checked for "Pollution Under Control" certificate prior to their entry to the plant premises.

5.3.2.3 Air Pollution Control Measures during Operation Phase

186. Agro waste will be used as fuel in the HAG, which will generated PM, SO2, and NOx. These pollutants will be emitted into the atmosphere due to combustion. However, the unit will be provided with two stage cyclone separator followed by wet scrubber to achieve the desired norms and scrubbed liquor will be reused in the process.

187. In the SSP plant dust collector and cyclone separator will be provided for removal of particulate matter generated from grinding of rock phosphate. Dust separated form the cyclone separator as well as from the dust collector will be used in process.

188. Hydrogen fluoride gas generated from the SSP process, will be conveyed in rubber lined ducts to the scrubbers. A settling chamber along with two stage water spray scrubbers and two stage ventury scrubbers followed by alkali scrubber will be provided to obtain the desired level of hydrogen fluoride.

189. The process gas reacts with the Silica present in the Rock Phosphate, which generates SiF4 and this SiF4 when scrubbed with Water to form liquor Hydroflouro Silicic Acid will be generated and sold as a By product. Then the traces of HF coming from ventury scrubber will be scrubbed with Caustic lye solution in Alkali Scrubber. This Scrubbed liquor will be re-circulated within the scrubber up to pH 7.0 and finally utilized in to the manufacturing process.

190. Reaction during the scrubbing system:

CaF2 + H2SO4 CaSO4 + 2HF 4HF + SiO2 SiF4 + 2H2O 3SiF4 + 2H2O SiO2 + 2H2SiF6



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191. The gases from the Scrubbers will be vented to the atmosphere by a 50 m tall Stack via a Scrubbing Exhaust Fan with facility of porthole platform and ladder, hence the concentration of HF will be well within the norms specified by the GPCB.

192. The details of scrubbers efficiency has been presented in Table 5.2 and schematic diagram of air pollution control systems in 400 TPD SSP plant, 200 TPD Granular SSP plant and 12 TPD Grinding Section has been presented in Figure 5.1, Figure 5.2 and Figure 5.3, respectively.

Table 5.2 : Scrubbing Efficiency Details

Scrubbing Section

Efficiency Inlet

Loading Scrubbed Outlet

Pump Capacity

Tank Size

Wet Scrubber

25% 2938 mg/Nm3

734.5 mg/Nm3

2203.5 mg/Nm3

4 m (dia) x 3.5 m (height)

First Scrubber

45% 2203.5 mg/Nm3

991.57 mg/Nm3

1211.93 mg/Nm3

40 m3/hr 4 m (dia) x 3.5 m (height)

First Ventury Scrubber

90% 1211.93 mg/Nm3

1090.73 mg/Nm3

121.2 mg/Nm3


Second Ventury Scrubber

90% 121.2 mg/Nm3

109.08 mg/Nm3

12.12 mg/Nm3


First & Second Ventury Ejector

As per design maximum height will be 5 m and Ejector size will be 600 mm diameter

Final Scrubber (Alkali)

25% 12.12 mg/Nm3

3.03 mg/Nm3

9.09 mg/Nm3


193. The monitoring at working environment shall be carried out and shall be recorded in the Form No. 37 (prescribed under Rule 12B) of Gujarat Factories Act. Format of the same is attached as Annexure - V. All necessary equipments/ instruments will be deployed to measure, record and analyze the work place exposure. If the equipments/ instruments will not be available, then the same will be conducted with the help of GPCB approved environmental monitoring agency.



76

F-9.09 mg/nm3 & SPM- 50 mg/nm3 Water

1.6 TPH Feed through crane

Spent Sulphuric acid

9.0 TPH

10.6 TPH

GR Rock

sampling SPM Mixer

point Lessthan 50mg/nm3 PRODUCT

Dust collector Packed in 50kg.

20 TPH Green super phosphate HDPE Bag

Rock phosphate Den for curing

11.7 TPH

Grinding mill

Raw water

chimney Alkli Scr.

scrubber-II Scrubber-I Wet Scrubber

scrubbing fan Ventury -II Ventury -I

27000 M3/Hrs.

H2SiF6 Sale

Note: Based on 20 hours working per day.

400 TPD SINGLE SUPER PHOSPHATE PLANT

Figure 5.1 : Air Pollution Control System in 400 TPD Single Super Phosphate Plant



77

200 TPD G.S.S.P.PLANT POLLUTION UNIT

SPM:-Lessthan 80 mg/nm3

Chimney 20 mg/nm3 200 mg/nm3

20 mg/nm3 50 mg/nm3 250 mg/nm3

WetScrubber Dryer Blower TwineCyclone Cooler Blower TwineCyclone

10000 M3/Hrs. 12000 M3/Hrs.

Dryer Drum Outlet Cooler Drum Outlet

1000 mg/nm3 1000 mg/nm3

EFFICIENCY DETAILS

1 Dryer Drum Twine Cyclone 80-90%

2 Cooler Drum Twine Cyclone 75-80%

3 Wet Scrubber 40%

Figure 5.2 : Air Pollution Control System in 200 TPD Granular Single Super Phosphate Plant



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12 TPD GRINDING SECTION AIR POLLUTION CONTROL UNIT

Main Stack

1000 mg/nm3 1000 mg/nm3

From Grinding Unit No. II SPM From Grinding Unit No. I

50 mg/nm3

Material recycle to process

Dust Collector details

No.of D.C. Bags 120

Inlet Dust loading designe 2000mg/nm3

Dust Collector efficiency 98%

Dust Collector out let 50 mg/nm3

MOC of Bags P.P.

Figure 5.3 : Air Pollution Control System in 12 TPD Grinding Section



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194. The statutory national standards for noise levels at the plant boundary and at residential areas near the plant will be met. The following mitigation measures are proposed to meet the objectives:

195. The selection of any new plant equipment is to be made with specification of low noise levels. Noise suppression measures such as acoustic enclosures / cabins, buffers and / or protective measures are be provided (wherever noise level is around +80 dB (A) and exposure limits to workers is more than 8 hours a day) to limit noise levels within occupational exposure limits. Areas with high noise levels are to be identified and segregated where possible and will include prominently displayed caution boards.

196. However, in areas where noise levels are high and exposure time is less, employees will be provided with ear protection measures like earplugs or earmuffs. Earplug should be provided to all workers where exposure level is > 85 dB (A). The exposure of employees working in the noisy area should be monitored regularly to ensure compliance with the regulatory requirements.

197. The existing practice of regularly monitoring of noise levels is essential to assess the efficacy of maintenance schedules undertaken to reduce noise levels and noise protection measures.

198. The green belt around the plant will attenuate the noise level but instead of block plantation there should be variability in tree height and shape, as this would disperse the sound waves more efficiently. Plant that attenuate should be planted at the noise zone.


199. NBCL has taken ample precautions to reduce water consumptions and tackle effluents problem. All the industrial effluent generated from the proposed project will be recycled back in the process itself and there will not be any disposal of industrial effluent. Only effluent generation will be in the form of domestic effluent, which will be sent to septic tank followed by soak pit. No impact on ground or surface water is envisaged due to the project and hence, no mitigation measures are required. However, rainwater harvesting and recycle & reuse of all the industrial effluent have been adopted in the project to conserve the water resources.

200. Roof top rainwater harvesting, which involves the collection of rainwater from the roof of the buildings and its storage in surface tanks or recharge to sub-surface acquifer, can play an important role in conservation of water. It is proposed to implement rain water harvesting structures by diverting the runoff that is generated from the roof sheds, paved areas, roads and greenbelt areas for recharging into the ground water syste. Implementation of recharge mechanism shall ensure the balance between the discharge vis-à-vis recharge relationships of the acquifer system and improve in the ground water quality. The normal annual rainfall for the said area has been taken as 732 mm, as per the data of IMD.



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Table 5.3 : Runoff Available for Recharge

S. No.

Land Use Area (m2) Co-efficient of Runoff

Rainfall (m) Quantity of Rainwater

(m3)

1. Roof Area 7516.65 0.8 0.732 4402

2. Road & Paved Area 7204.31 0.6 0.732 3164

3. Green & Open Area 17799 0.15 0.732 1954

Total 32520 9520

Table 5.4 : Recommendation of Recharge Structures based on Hourly Computation of Runoff - (50 mm/hr)

S. No.

Land Use Area (m2) Co-

efficient of Runoff

Intensity of Rainfall

(m)

Quantity of Rainwater

(m3)

Structures Required

1. Roof Area 7516.65 0.8 0.05 301 2

2. Road & Paved Area

7204.31 0.6 0.05 216 4

3. Green & Open Area

17799 0.15 0.05 133 2

Total 32520 650 8

201. It has been worked out that in order to tap effectively the rainfall runoff and subsequently recharging to the aquifer system, about 8 recharge structures are required. However, NBCL has already taken provision of 9 nos. of percolating wells within the plant premises to capture all the runoff during the rainy days. Oil & grease separators and desiltation arrangements will be provided in all the rainwater harvesting structures to avoid any contamination of ground water aquifer. The locations of the recharge percolation wells on the layout plan have been presented in Figure 2.3.


202. It is proposed to develop a green area of about 9708 sq. m. within the plant premises of the proposed project site. The green area development and tree plantation will be done by using indigenous species as well as ornamental plants. Approximately 3 trees per 200 sq. m. area will be planted. Based on that a total of 516 trees will be planted in the periphery of the project site as well as along the internal roads. In the plant periphery the tree plantation will be done in two rows. Separate budget will be provided for greenbelt development within the premises. It is a continual process and NBCL is committed to develop healthy green belt, which will help in absorbing the pollutants as well as providing aesthetic environment within and around the plant. Sludge generated from the septic tank/ soak pit will be used as manure in the greenbelt. The plant layout showing greenbelt development area is presented in Figure 2.3. NBCL is also committed to carry out the tree plantation activities outside the premises at appropriate places in the nearby areas as well as villages. The same will be done after taking concurrence from the local administration as well as villagers.

203. Few guidelines for greenbelt development are as follows:

Strict surveillance shall be made to increase the survival rate of the trees

Plants with higher height, medium and low height shall be planted to ensure thick belt for attenuation of fugitive emission.



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Avenue trees should not block the view of road or building. This is necessary from safety and security point of view.

The road curbs should not have trees rather shrubs.

Expert advice and guidance shall be taken for greenbelt development planning and implementation.


204. The proposed SSP project will generate very limited quantity of solid and hazardous waste, which needs to be disposed off suitably to avoid any contamination of land environment. Disposal of waste shall be ensured as per the GPCB guidelines.

205. Discarded containers will be kept at a designated place with paved surface. These containers will be decontaminated (washed/ cleaned) and after that will be stored in the designated area in scrap yard. Later on these will be sold to the actual users/ recyclers as per the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008. The record of discarded containers stored in scrap yard shall be maintained and also inventory of their selling to the registered recyclers shall be maintained. The same shall be reviewed by the environment management cell of the proposed project.

5.3.7. Resource Conservation/ Waste Minimization

206. NBCL has proposed to take adequate resource conservation measures in the proposed plant. Key steps, which are proposed in the project are as follows:

Recycle and reuse of industrial wastewater in process itself to reduce the fresh water consumption

Effluent generated from the scrubbing and washing will be sent back to the process

Reuse of by-product in the process

Adequate provision of rainwater harvesting has been taken in the design stage itself for recharging of the ground water aquifer.

5.3.8. Corporate Social Responsibility

207. NBCL will be partner in the development of local people with a long term vision. The study area of 5 km is having very scattered settlements with nearest village at 1.5 km from the proposed project site. At the initial stage, NBCL has taken a provision of Rs. 50,000/- fund allocation for the socio-economic activities near the plant area, which will include: books & notebooks distribution, medical check-up of villagers, drinking water tank, and bus-pickup stand etc. NBCL is also committed to carry out the tree plantation activities outside the premises at appropriate places in the nearby areas as well as villages. The same will be done after taking concurrence from the local administration as well as villagers.

5.3.9. Environment Management Cell

208. The proposed unit will provide an adequate Environmental Management Cell to assure the regular and efficient working /operation of the environmental management plan. The structure of the EMC has been presented in Figure 5.4.

5.4. Project Cost and Cost towards Environmental Protection

209. The total project cost of the proposed SSP plant is Rs. 12.0 crores. The total capital cost of air pollution and water pollution control measures is Rs. 55



82

Lacs and Rs. 20 Lacs, respectively. The recurring cost for pollution control will be about 2 Lacs/ annum. In addition to that separate budget will be provided for greenbelt development within the premises.

Figure 5.4 : Structure of Environment Management Cell

Managing Director

General Manager

Chemist

Helpers

Operator



83

Table 5.5 : Post mitigation Matrix for Various Project Activities and Associated Potential Environmental Impacts on Various Environmental Attributes

Air

Lan

d

Am

bie

nt

No

ise

Wa

ter

Qu

ality

So

lid

Wa

ste

Flo

ra

Fau

na

So

cio

-

eco

no

mic

En

vir

on

me

nt

Construction Phase

Earthwork and Excavation ST- ST- ST-

Disposal of Excavated Earth ST- ST- ST- ST-

Disposal of Construction Waste ST- ST- ST- ST-

Operation of Construction Machinery ST- ST-

Transportation of Construction Material ST- ST-

Material Handling ST- ST- ST-

Use of DG Sets ST- ST-

O & M of Construction Machinery ST- ST-

Disposal of Domestic Waste & Effluents ST- ST- ST-

Development of Green Belt LT+ LT+ LT+ ST+ LT+ LT+ LT+

Disposal of Hazardous Waste ST- ST- ST-

Influx of Workers ST- ST- ST- ST+

Sewage Discharge ST- ST+ ST+

Income Generation ST+

Employment Generation ST+

Operation Phase

Operation of Industry LT- ST- LT- LT- LT- ST- ST+

Effluent Generation & Discharge

Solid Waste Generation & Disposal ST-

Hazardous Waste Generation & Disposal

Increase in Vehicular Movement ST- ST- ST-

Transportation of Raw Material and Final Products ST- ST- ST-



84

Air

Lan

d

Am

bie

nt

No

ise

Wa

ter

Qu

ality

So

lid

Wa

ste

Flo

ra

Fau

na

So

cio

-

eco

no

mic

En

vir

on

me

nt

Storage of Hazardous Chemicals ST- ST- ST-

Greenbelt Development LT+ LT+ LT+ LT+ LT+ LT+ LT+

Employment Generation ST- ST- ST- LT+ Notations:

ST+ : Short Term Positive

ST- : Short Term Negative

LT+ : Long Term Positive

LT- : Long Term Negative



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6. ENVIRONMENTAL MONITORING PROGRAM

6.1. Prelude

210. Based on the findings of the Environmental Impact Assessment study, various mitigation measures have been proposed, which have been detailed out in Environmental Management Plan (EMP). In order to monitor the impacts and efficacy of these plans monitoring of various environmental attributes have been proposed during and after the completion of the management plans. A well defined environmental monitoring programme would be employed with trained and qualified staff of Environmental Management Cell of the proposed project, to monitor the environmental attributes of the area with respect to EMP as well as the guidelines of the GPCB/CPCB. Environmental monitoring schedule proposed to be adopted by the project authorities is given in Table 6.1.

Table 6.1 : Matrix of Environmental Monitoring Plan

Discipline Location Parameter Frequency

Ambient Air Quality

Three AAQ stations

SOx, NOx, PM10, PM2.5 & HF

Monthly

Work Zone Ambient Air Quality

Within Plant Premises

As per Gujarat Factories Rules

Monthly (Shall be reported as per Form 37 of Gujarat Factories Rules)

Stack Emission All continuous stacks2

PM, NOx, SOx, HF (as applicable) in process and HAG stack.

Monthly

Ground Water Quality

Borewell Parameters as per IS 10500 Monthly

Ground Water Level

At Plant Premises

Water Table Monthly

Noise Plant area & Boundary

Day & Night time noise level Monthly

Health Check Up

All Plant Personnel

Disease of eyes, ears and chest

General - Yearly & specific parameters for Critical area – Six monthly

2 The process vent will be attached with water and alkali scrubber. As per the GPCB guidelines online monitoring of the

pollutants from the process stack of SSP plant is not required. Hence, no provision of online monitoring is made in the proposed project. However, monthly in-house stack analysis will be conducted by NBCL as well as by the third party environmental monitoring agency approved by GPCB and the reports of stack analysis will be submitted to GPCB as per the guidelines.

This chapter provides the proposed environmental monitoring programme for the proposed project to access the environmental attributes after the commissioning of the project.



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7. RISK ASSESSMENT

7.1. Introduction

211. NBCL is proposed to handle and storage of hazardous materials at the proposed plant at Kalyangadh, which can pose risk to life and properties in an unlikely event of release emergencies. Therefore, the risk assessment study has been conducted for identification of hazards, to calculate consequence distances, to evaluate safety at the plant and to spell out risk mitigation measures to enhance safety at the plant.

7.2. Hazard Identification

212. Hazard is defined as a chemical or physical conditions those have the potential for causing damage to people, property or the environment. This chapter describes hazards associated with the proposed SSP project.

213. Hazard identification is the first step in the risk analysis and entails the process of collecting information on:

the types and quantities of hazardous substances stored and handled at the plant,

the location of storage tanks & other facilities, and

potential hazards associated with the spillage and release of hazardous chemicals.

7.2.1. Hazardous Materials to be Stored at the Plant

214. Only major hazardous chemical to be stored at the project site is spent sulphuric acid, which will be used in two forms:

Sulphuric Acid 98% with specific gravity 1.84, and

Sulphuric Acid 80% with specific gravity 1.78.

215. The acid will be stored in two separate tanks, with total capacity of 504.78 MT each. The specification of each tank will be as follows:

MOC M.S.

Diameter 8.5 m.

Height 5.0 m

Capacity 283.58 m3

504.78 MT

216. In addition to that there will be two service tanks for regular use of sulphuric acid in the process. The details of the service tanks has been presented below:

Particular Service Tank - I Service Tank - II

MOC M.S. M.S.

Diameter 3.5 m 3.5 m

Height 1.75 m 2.5 m

Capacity 16.8 m3 (30 MT) 24.04 m3 (42.79 MT)

This chapter details risks associated with the project activities and storage of hazardous chemicals.



87

217. Total acid storage capacity in two acid tanks and two service tanks will be 1082.35 MT. These will be stored in the spent acid storage tank yard, which will have length, width and height as 22 m, 12 m and 1.2 m, respectively.

7.2.2. Characteristics of Hazardous Materials

218. Important characteristics of the hazardous material (i.e. sulphuric acid) has been presented below:

CAS number 7664-93-9

ChemSpider 1086

UNII O40UQP6WCF

EC number 231-639-5

UN number 1830

RTECS number WS5600000

Properties

Molecular formula H2SO4

Molar mass 98.086 g/mol

Appearance Clear, colorless, odorless liquid

Density 1.84 g/cm3, liquid

Melting point 10 °C, 283 K, 50 °F

Boiling point 337 °C, 610 K, 639 °F

Solubility in water miscible

Acidity (pKa) −3

Viscosity 26.7 cP (20 °C)

Hazards

MSDS External MSDS

EU Index 016-020-00-8

EU classification

Toxic (T) Corrosive (C) Dangerous for the environment (N)

R-phrases R35

S-phrases (S1/2) S26 S30 S45

NFPA 704

0 3 2 W

Flash point Non-flammable

Related compounds

Related strong acids Selenic acid Hydrochloric acid Nitric acid

Related compounds Sulfurous acid Peroxymonosulfuric acid

http://en.wikipedia.org/wiki/CAS_registry_number

http://www.commonchemistry.org/ChemicalDetail.aspx?ref=7664-93-9

http://en.wikipedia.org/wiki/ChemSpider

http://www.chemspider.com/1086

http://en.wikipedia.org/wiki/Unique_Ingredient_Identifier

http://fdasis.nlm.nih.gov/srs/srsdirect.jsp?regno=O40UQP6WCF

http://en.wikipedia.org/wiki/EC_number_(chemistry)

http://ecb.jrc.ec.europa.eu/esis/index.php?GENRE=ECNO&ENTREE=231-639-5

http://en.wikipedia.org/wiki/UN_number

http://en.wikipedia.org/wiki/RTECS

http://en.wikipedia.org/wiki/Chemical_formula

http://en.wikipedia.org/wiki/Molar_mass

http://en.wikipedia.org/wiki/Density

http://en.wikipedia.org/wiki/Melting_point

http://en.wikipedia.org/wiki/Boiling_point

http://en.wikipedia.org/wiki/Solubility

http://en.wikipedia.org/wiki/Water

http://en.wikipedia.org/wiki/Acid_dissociation_constant

http://en.wikipedia.org/wiki/Viscosity

http://en.wikipedia.org/wiki/Poise

http://en.wikipedia.org/wiki/Material_safety_data_sheet

http://en.wikipedia.org/wiki/Sulfuric_acid_(data_page)#Material_Safety_Data_Sheet

http://en.wikipedia.org/wiki/Directive_67/548/EEC

http://en.wikipedia.org/wiki/List_of_R-phrases

http://en.wikipedia.org/wiki/R35:_Causes_severe_burns

http://en.wikipedia.org/wiki/List_of_S-phrases

http://en.wikipedia.org/wiki/(S1/2):_Keep_locked_up_and_out_of_the_reach_of_children

http://en.wikipedia.org/wiki/S26:_In_case_of_contact_with_eyes,_rinse_immediately_with_plenty_of_water_and_seek_medical_advice

http://en.wikipedia.org/wiki/S30:_Never_add_water_to_this_product

http://en.wikipedia.org/wiki/S45:_In_case_of_accident_or_if_you_feel_unwell_seek_medical_advice_immediately_(show_the_label_where_possible)

http://en.wikipedia.org/wiki/NFPA_704

http://en.wikipedia.org/wiki/Flash_point

http://en.wikipedia.org/wiki/Strong_acid

http://en.wikipedia.org/wiki/Selenic_acid

http://en.wikipedia.org/wiki/Hydrochloric_acid

http://en.wikipedia.org/wiki/Nitric_acid

http://en.wikipedia.org/wiki/Sulfurous_acid

http://en.wikipedia.org/wiki/Peroxymonosulfuric_acid



88

Sulfur trioxide Oleum

7.2.3. Associated Hazards

219. Hazards associated with the use and storage of sulphuric acid has been presented in the following table:

Types of Hazard / Exposure

Acute Hazards / Symptoms

Prevention First Aid/ Fire Fighting

Fire Not combustible. Many reactions may cause fire or explosion. Gives off irritating or toxic fumes (or gases) in a fire.

NO contact with flammable substances. NO contact with combustibles.

NO water. In case of fire in the surroundings: powder, foam, carbon dioxide

Explosion Risk of fire and explosion on contact with base(s), combustible substances, oxidants, reducing agents or water.

In case of fire: keep drums, etc., cool by spraying with water but NO direct contact with water.

7.2.4. Actions required in case of Exposure

Exposure Effect Prevent generation of mists! Avoid all

contact!

In all cases consult a doctor!

Inhalation Corrosive. Burning sensation. Sore throat. Cough. Laboured breathing. Shortness of breath. Symptoms may be delayed (see Notes).

Ventilation, local exhaust, or breathing protection.

Fresh air, rest. Half-upright position. Artificial respiration may be needed. Refer for medical attention.

Skin Corrosive. Redness. Pain. Blisters. Serious skin burns.

Protective gloves. Protective clothing.

Remove contaminated clothes. Rinse skin with plenty of water or shower. Refer for medical attention.

Eyes Corrosive. Redness. Pain. Severe deep burns.

Face shield or eye protection in combination with breathing protection.

First rinse with plenty of water for several minutes (remove contact lenses if easily possible), then take to a doctor.

Ingestion Corrosive. Abdominal pain. Burning sensation. Shock or collapse.

Do not eat, drink, or smoke during work.

Rinse mouth. Do NOT induce vomiting. Refer for medical attention.

http://en.wikipedia.org/wiki/Sulfur_trioxide

http://en.wikipedia.org/wiki/Oleum



89

7.3. Effect & Consequence Analysis

220. As a part of risk assessment study, maximum credible accident analysis (MCA) is carried out to determine the maximum loss scenario from this analysis. It is an eventuality, which is possible and will have maximum consequential distances for the particular hazardous chemicals under evaluation.

221. The selection of the accident scenarios is based on the engineering and professional judgment, accident descriptions of the past in similar type of plants & the expertise in risk analysis studies.

7.3.1. Scenarios

Skin irritation and corrosive effects after spillage

Spill pool evaporation through 500 MT sulphuric acid storage tank catastrophic failure

Catastrophic failure giving rise to spill pool evaporation dispersion upto LC50, IDLH and TLV level

7.3.2. Risk Assessment of Sulphuric Acid Tank

222. The risk factors of sulphuric acid tank can be calculated as follows:

223. In the present scenario for sulphuric acid tank of 500 MT, following factors has been considered:

Nh - NFPA Health Rating : 1

Nf - NFPA Fire Rating : 3

Nr - NFPA Reactive Rating : 0

GPH - General Process Hazard : 2.05

SPH - Special Process Hazard : 1.5

MF - Material Factor : 1

FEI - Fire and Explosion Index : 5.3

Hazard : Light

7.3.3. Consequence Analysis

224. Spill pool evaporation through 500 MT sulphuric acid storage tank catastrophic failures. Catastrophic failure will give rise to spill pool evaporation dispersion up to LC50, IDLH and TLV level. The results of consequence analysis has been presented below:



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Type of Failure Considered

Spill Quantity Consideration

Max. Credible Loss

Scenario in MT

Evaporation Rage (g/s)

LC50 Distance in meter

IDLH Distance in meter

TLV Distance in meter

Catastrophic rupture of 500 MT Tank of Sulphuric Acid

500 MT 1000 59 587 1349

7.4. Recommendations

225. Based on the outcome of the risk assessment, following recommendation has been made to avoid any risk associated with the storage and use of sulphuric acid in the plant:

Double drain valve will be provided to sulphuric acid storage tank.

Full body protection will be provided to operator.

Caution note and emergency first aid will be displayed

All employees will be trained for use of emergency first aid.

Safety shower and eye wash will be provided in storage tank area and plant area.

Total close process will be adopted for Sulphuric acid handling.

Dyke wall will be provided to storage tank

Tanker unloading procedure will be prepared.

SOP will be prepared for sulphuric acid handling.

Training programme will be conducted for safe handling and emergency handling of Sulphuric Acid

In Storage Tank Area, reaction with water generating fumes should be displayed and avoided

Suitable extinguishing media-Extinguish with dry powder / sand. DO NOT USE WATER.

Fire and explosion hazards-Not flammable. May evolve toxic fumes in fire (sulphur oxides).

Personal protective equipment-Fire fighter must use fresh-air helmet and chemical protection suit

Personal protection: complete protective clothing including self-contained breathing apparatus. Do NOT let this chemical enter the environment.

Evacuate danger area! Do NOT absorb in saw-dust or other combustible absorbents.

7.5. Occupational Exposure Mitigation Planning

226. To control any occupational health and safety impact a detailed planning for mitigation measures has been done in the design stage of the project. Apart from the occupational exposure mitigation plans for various activities and work areas of hazards, following administrative control measures will be followed:

All the employees will be trained for EHS policies.

Health checkup for OSA – Yearly once

Health checkup for Employees- 2 years once



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All the OSA peoples have been trained for Basic life support, first aid, Basic fire safety and emergency preparedness.

Ambient air quality monitoring in every month at 3 locations

Monthly monitoring of environmental parameters.

Safety display boards provided throughout the plant.

Monthly fire extinguisher audit.

Work permit system

PPE adherence

Waste management and hazardous waste handling

Safe lifting operation

Industrial hygiene

7.6. Other Recommended Measures for Safe Operation of the Plant

227. In addition to the specific recommendations made in the above section for storage and handling of sulphuric acid within the plant premises, for safe operation of the plant and risk reduction, following suggestions and recommendations are made:

Personnel especially contractor workers at the plant should be made aware about the hazardous substance stored at the plant and risk associated with them.

A written process safety information document may be compiled for general use.

The document compilation should include an assessment of the hazards presented including (i) toxicity information (ii) permissible exposure limits. (iii) physical data (iv) thermal and chemical stability data (v) reactivity data (vi) corrosivity data (vii) information on process and mechanical design.

The process design information in the process safety information compilation must include P&IDs/PFDs; process chemistry; maximum intended inventory; acceptable upper and lower limits, pressures, flows and compositions and process design and energy balances.

The adequate numbers of heat, smoke, detectors may be provided at strategic locations in the plant and indication of detectors/sensors should be provided in main control room.

Predictive and preventive maintenance schedule should be prepared for equipment, piping, pumps, etc. and thickness survey should be done periodically as per standard practices.

Safe work practices should be developed to provide for the control of hazards during operation and maintenance.

Personnel engaged in handling of hazardous chemicals should be trained to respond in an unlikely event of emergencies.

The plant should check and ensure that all instruments provided in the plant are in good condition and documented.

Safety measures in the form of DO and Don‟t Do should be displayed at strategic locations especially in Gujarati and English language.

7.6.1. Personal Protective Equipment

228. Personal protective equipments (PPEs) are devices that are fitted and issued to each worker personally for his or her exclusive use. They are intended for temporary use and emergency response action only. If a worker must enter a contaminated area, he must wear adequate protective equipment. Employees



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should be taught when and how to use respiratory apparatus (SCBA) provided, and how to recognize defects in the equipment. Without SCBA entry into the contaminated area should not be attempted.

Keep personal protective equipment where it can be accessed quickly, outside the hazardous material storage area and away from areas of likely contamination.

Each employee should maintain his personal protective equipment in clean, working condition at all times.

All equipment should be used and maintained in accordance with the manufacturer‟s instructions.

Equipment installed for body and eye wash should be checked properly for round the clock operation.

7.6.2. Handling of Hazards

Personal protective equipment used by the workers during handling of hazardous chemicals, should be replaced after certain time.

If any spillage of hazardous chemicals, it should be cleaned and disposed as per standard practiced.

Empty drums of hazardous chemicals should neutralize immediate.

Workers engaged in handling of hazardous chemicals should be made aware of properties of hazardous chemicals.

7.6.3. General Working Conditions at the Proposed Plant

7.6.3.1 House Keeping

All the passages, floors and stairways should be maintained in good conditions.

The system should be available to deal with any spillage of dry or liquid chemical at the plant.

Walkways should be always kept free from obstructions.

In the plant, precaution and instructions should be displayed at strategic locations in Gujarati and English Languages.

All pits, sumps should be properly covered or securely fenced.

7.6.3.2 Ventilation

Adequate ventilation should be provided in the work floor environment.

The work environment should be assessed and monitored regularly as local ventilation is most effective method for controlling dust and gaseous emissions at work floor.

7.6.4. Safe Operating Procedures

Safe operating procedures will be available for mostly all materials, operations and equipment.

The workers will be informed of consequences of failure to observe the safe operating procedures.

7.6.5. Work Permit System

229. Work permit system will be followed at the plant during maintenance.

7.6.6. Fire Protection

The fire fighting system and equipment will be tested and maintained as per relevant standards.



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Smoke detectors will be provided at the plant and shall be calibrated and maintained properly.

7.6.7. Static Electricity

All equipment and storage tanks/containers of flammable chemicals shall be bounded and earthed properly.

Electrical pits shall be maintained clean and covered.

Electrical continuity for earthing circuits shall be maintained.

Periodic inspections shall be done for earth pits and record shall be maintained.

7.6.8. Material Handling

The workers shall be made aware about the hazards associated with manual material handling.

The workers shall be made aware and trained about the use of personal protective equipment (PPE) while handling hazardous chemicals.

7.6.9. Communication System

230. Communication facilities shall be checked periodically for its proper functioning.

7.6.10. Safety Inspections

231. The system shall be initiated for checklist based routine safety inspection and internal audit of the plant. Safety inspection team shall be formed from various disciplines and departments.

7.6.11. Safe Operating Procedures

Safe operating procedures should be formulated and updated, specific to process & equipment and distributed to concerned plant personnel.

7.6.12. Predictive and Preventive Maintenance

232. Predictive and preventive maintenance schedule shall be followed in religious manner.

7.6.13. Electrical Safety

Insulation pad at HT panels shall be replaced at regular interval.

House keeping in MCC room shall be kept proper for safe working conditions.

7.6.14. Colour Coding System

233. Colour coding for piping and utility lines shall be followed in accordance with IS: 2379:1990.



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8. SUMMARY AND CONCLUSIONS

8.1. Prelude

234. The present study was aimed at identifying the potential environmental impacts due to the various project activities, assessment of impact with and without project, public concerns addressed under mitigation measures, and at developing an environmental management and monitoring plans for proper mitigation of any adverse environmental impact. In this study, the various activities likely to take place during the construction and operation phases of the project have been analyzed in relation to the baseline condition of different environmental components. The mitigation measures proposed for the project proponent have also been discussed. The key points considered in this study are described in the following sections:

8.2. Regulatory Compliance

235. The project is yet at its technical investigation stage. Prior to its implementation, it will be necessary to acquire all the necessary clearance from the Government of India, as per the applicable national regulations. Key clearances include obtaining the Consent to establish from the Gujarat Pollution Control Board (GPCB) under The Water (Prevention and Control of Pollution) Act, 1974 and Rules, 1975; The Air (Prevention and Control of Pollution) Act, 1981 and Rules, 1982; and Environmental Clearance from the State Level Environmental Impact Assessment Authority (SEIAA)-Gujarat, under the EIA Notification, 2006, The Environment (Protection) Act, 1986 and Rules, 1986. In addition to that Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989 and amendments thereafter, Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008 and amendments thereafter, will also be applicable to the proposed single super phosphate project of Narmada Bio-Chem Pvt. Ltd. at Kalyangarh.

8.3. Baseline Conditions

236. The monitoring of the existing environmental conditions of the proposed project site and of its close vicinity have been established with respect to physical, biological and human environment. The air quality of the area meets the prescribed National Ambient Air Quality Standards applicable for the Industrial, Residential & Rural Areas. The background noise levels were also found well within the standards as at present most of the area is not developed.

237. The water quality also meets all standards for use in domestic and industrial applications. No forest land is falling in the study area. In addition to that there is no sensitive ecosystem in the vicinity. No rehabilitation and resettlement issue is emerging with the selected project site due to the proposed development.

This chapter concludes on the findings that emerged from the environmental assessment study and summarizes the key points to be addressed to ensure the environmental sustainability of the project during the construction and operation phases.



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8.4. Environmental Impacts and Mitigation Measures

238. The project entails various impacts on the study area, some negative and some positive. The impacts will be caused by the construction activities as well as by the other industrial activities during the construction and operation phases, respectively. Various impacts identified during the study have been provided mitigation measures for a better environmental management. In addition to that the roles and responsibilities of the developers have also been given in the Environmental Monitoring Programme to monitor the implementation of the environmental management plan to ensure the mitigations of adverse impacts.

8.5. Recommendations

239. Based on the environmental impact assessment conducted, the following recommendations are made:

Since regulations are fast changing in India, the project proponent must keep themselves updated with respect to applicable laws and take appropriate actions in case the provisions in some regulations undergo change.

Most of the impacts envisaged are due to construction activities. Systems of periodic auditing and reporting shall be adopted during the construction period to ensure that the contractors adhere to the Environmental Management Plan.

The project proponent and its team of consultants and contractors are urged to develop a strategy for effective communication with local people. The construction team/ developer should effectively follow the suggestions made in the EMP and/ or any other environmental measures so as not to damage the environment of the project area.



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9. DISCLOSURE OF CONSULTANTS ENGAGED

9.1. Team Composition

The team composition and their respective responsibilities are listed in Table 9.1.

Table 9.1 : Team Composition and Expertise Area

Name Organization Position and Responsibility

Mr. S. K. Jain EQMS Environmental Expert & Overall Project Coordinator

Mr. Naval K. Chaudhary EQMS Environmental Assessment & Mathematical Modelling Expert

Dr. Koel Kumar EQMS Waste Management and Pollution Control

Dr. Sankalp Anand EQMS Specialist (Air Quality Assessment)

Mr. Sameer Deshpande EQMS Ecology Expert

Mr. Debanshu Sinha EQMS Field Data Collection & Monitoring Specialist

Mr. Omkar Singh EQMS Primary and Secondary Data Collection

Project: Environmental Impact Assessment - gpcb.gov.in · Rapid Environment Impact Assessment Study...

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