Ject report

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Ject report

  1. 1. List of AnnexuresAnnex. No. Annex. Description1 Permission letter from Ministry of Commerce & Industry, New Delhi2 Site Plan of the land3 Layout Plan of the project site4 (1) Flow Chart for manufacture of SSP / GSSP4(2) Flow Chart for manufacture of Sulphuric Acid4(3) Flow Chart for Captive Power Plant5 List of Plant & Machinery6 Material Balance7 Water Balance8 Fluorine Balance9 MSDS for Hazardous chemicals in use10 Details of proposed pollution control measures11 Treatment of domestic waste12 Reuse of liquid effluent13 Risk analysis14 Environment Management Plan
  2. 2. ANNEXURE 1PERMISSION LETTER FROM MINISTRY OF COMMERCE & INDUSTRY, NEW DELHI
  3. 3. ANNEXURE 2SITE PLAN OF THE LAND
  4. 4. ANNEXURE 3LAYOUT PLAN OF THE PROJECT SITE
  5. 5. ANNEXURE 4 (1)MANUFACTURING PROCESSES FOR SSP, GSSP AND SULPHURIC ACIDFLOW CHART FOR SSP/GSSP PRODUCTION PROCESS
  6. 6. ANNEXURE 4 (2)FLOW CHART FOR SULPHURIC ACID PRODUCTION PROCESSCausticScrubberStack ToAtmosphereSoft WaterMistCandleIPAT Economiser1stConverter3rdBedHHE (T) Converter2ndBedAP Tank 98.4% Conc.Sulphuric AcidCHE (S)2 ndCHE (S)1stHHE (S) ConverterIV BedCHE(T) 2NDSSP for CaptiveConsumptionFAT CandleFilterSulphuric AcidStorage Tanks (NF)Sulphuric AcidStorage Tanks (F)SALEFATSulphur Sulphur(NF) (F)Molten MoltenSulphur Sulphur(NF) (F)Saturated SteamCondensate toBoiler Feed WaterSulphurBurnerBoiler I Super Heater Hot Gas Filter Converter 1stBed Boiler IISuper Heated Steam Captive Power PlantSteam Turbine CaptivePower Generation &Supply to SAP.DryingTowerAir BlowerEconomizerIIndCHE(T)1STOleumTowerOleumProcess TankOleumStorageTankSaleNF = Non FertilizerF = Fertilizer
  7. 7. ANNEXURE 4 (3)FLOW CHART FOR CAPTIVE POWER PLANTThe captive power plant is based on the steam generated in Sulphuric Acid as a bye product. The fully condensing Steam Turbo generating set is proposed. No furaw materials are used and hence there is no emissions / effluent from this captive power plant. The blow down of Cooling Tower is recycled to SSP lagoon fusing in SSP process.Cool HotWater WaterSuperheated steamfrom SulphuricAcid Plant.Fully CondensingSteam TurboGenerating set5MW..PowerGeneration.Condenser Condensate toBoiler feed waterTank.Cooling Tower Blow down waterto SSP Process.
  8. 8. ANNEXURE 5List of Plant and Machinery(A) SSP Fertilizer PlantS. No. Equipment Quantity1 EOT Crane 7.5 MT capacity 2 Nos.2 Rock Feed Hopper 1 No3 Feed Bell Conveyor 1 No4 Ball Mill for Rock grinding 1 No5 Hot air Generator 1 No6 Grit Seperator / cyclones 1 set7 D.C. Bags 1 set8 Ground Rock hopper 1 No9 Screw conveyer 1 No10 Ground Rock Bucket Elevater 1 No11 Mass flow hopper 1 No12 Belt weigher 1 No13 Screw conveyer 1 No14 Mixer 1 No15 Den 1 No16 Scrubber 1 No17 scrubbing fan 1 No18 scrubbing pumps 6 Nos19 Sulphuric Acid pump 1No20 Raw Water Pump 1No21 Sulphuric Acid Storage Tanks 2Nos22 Raw Water Storage Tank 1 No23 Fo Storage Tank 1No
  9. 9. 24 Lagoon 1No25 powder packing RM hopper 1 No26 Feed Belt 1 No27 Bucket Elevator 1 No28 Vibrating Screen 1 No29 Crusher 1 No30 Powder hopper 1 No31 Stiching m/c 1 No32 Slat Conveyor 1 No33 Weighing Machinery 1 No34 Portable Tank Loader 1 No35 Stack 30 Meter high 1No(B) Granulated SSP Fertilizer Plant1 Feed Hopper 1No2 Feed Belt 1No3 Recycle Belt 1No4 Bucket Elevator 1No5 Granulator Drum 1No6 Dryer Drum 1No7 Hot Air Generator 1No8 Dryer to cooler belt 1No9 Cooler Drum 1No10 Raw Material Pump 1No11 FO Storage Tank 1No12 Cooler to Bucket Elevator Belt 1No13 Cyclones Dryer / Cooler 1No14 Multiclones Dryer / Cooler 1No
  10. 10. 15 Stack 30 Meter high 1No16 Bucket Elevator 1No17 Vibrating Screens oversize & under size 1 Set18 Chain Mill 2 Nos19 Product belt 1No20 Product Hopper 1No21 Weighing m/c 1No22 Slat Conveyor 1No23 Stitching M/c 1No( C ) Sulphuric Acid1 Sulphur Melter Agitator 1No2 Molten Sulphur Pumps 2Nos3 Air Blower 1No4 Air Drying Tower 1No5 Sulphur Burner 1No6 Waste Heat Boiler with BFW Pumps 1 Set7 Hot Gas Filter 1 No8 Converter 1No9 Hot Heat Exchanger 1No10 Cold Heat Exchanger 2 Nos.11 Economizer 1No12 Super Heater 1No13 Inter Pass Absorption Tower 1No14 Acid Process Tank Pumps 2Nos15 Acid Coolers DT / IPAT / FAT 1Set Each16 Final Absorption Tower 1No17 Mist Eliminators IPAT / FAT 1Set Each
  11. 11. 18 DT Mist Pad 1Set19 Alkali Scrubbing Tower 1No20 Acid Process Tank 1No21 Acid Transfer / Dispatch pumps 2 Nos.22 Acid Storage Tanks 5 Nos.23 Cooling tower with pumps 1 Set24 Raw Water Pumps 2 Nos.25 D/M. Water plant 1 Set26 Soft Water Plant 1 Set27 stack 50 m high 1 No(D) Captive Power Plant1 Steam Turbine Fully Condensing type 1 Set2 Condenser 1 No3 Condensate Pumps 2 Nos.4 Oil Tank, Oil Pumps, Oil Filters 1 Set5 Cooling Tower 1 Set6 Vacuum Pumps 2 Nos.
  12. 12. ANNEXURE - 6Material Balance – Single Super Phosphate FertilizerFor 1 MT SSP Fertilizer PowderRock Phosphate having + 31.5% Total P2O5 0.565 MTSulphuric Acid 0.370 MT(98.4% Concentration Technical Grade)Moisture 0.110 MT(-) CO2 Gaseous losses (-) 0.027 MT(-) Water Vapour Losses (-) 0.018 MTTOTAL 1.000 MT• Specific Furnace Oil or Equivalent Wood / Biomass ConsumptionSSP 2.0 Ltrs / MT SSP or equivalent wood / biomassGSSP 10 Ltrs / MT GSSP or equivalent wood / biomassThe additional furnace oil or equivalent wood/biomass requirement will be 14.4 Kl /dayday for the proposed 2x600 MTPD SSP & 3x400 MTPD GSSP Plants.
  13. 13. • Specific Raw Water ConsumptionSSP 0.30 MT / MT SSPGSSP 0.06 MT / MTGSSPSA 1.75 MT / MT SACaptive Power Plant 6 Kgs / KWHDomestic 25 KL / dayThe Raw Water requirement will be 2052 Kl / day for the proposed 2x600 MTPD SSP3x400 MTPD GSSP, 500 MTPD Sulphuric Acid & 5 MW Captive power plants. KCFLis paying water cess as per the prevailing rates to the CG. Govt. for drawing ground waterfrom the tube wells.• Specific Sulphur ConsumptionSulphur 0.335 MT / MT Sulphuric Acid
  14. 14. ANNEXURE - 7Water BalanceBreak Up Of Water Uses and Water Balance for proposed 4.00 Lac MT/Yr SSP Fertilizer,3.96 Lac MT/Yr Granulated SSP Fertilizers, 500 MTPD Sulphuric Acid, 5 MW Captive Power PlantRaw water from Bore wells2052 KL / DaySSP Fertilizer Plant1200 MTPD @ 0.30KL/MT SSP360 KLDGSSP Fertilizer Plant1200 MTPD @ 0.06KL/MT GSSP72 KLD72 KL/DayDomestic use25KL/DaySewage SepticTankHorticultureUse within thePremisesScrubber LiquorMicrobiologicalvermiculturetreatmentSulphuric Acid Plant500 MTPD @ 1.75 MT/MT Acid875 KLDCaptive PowerPlant 5 MW @ 6kgs/ KWH720 KLD720 KL / DayBlow DownBoiler, CT,DM/SoftnerBack washBlow down CTMixer
  15. 15. ANNEXURE - 8Fluorine and H2SiF6 Balance(A) H2SiF6 LiquorThe 100% H2SiF6 Liquor is recycled into the SSP Mixer for acidulation of Rock Phosphate.(B) FluorineTotal Fluorine25 mg / Nm³„F‟0.0131 0.00003H2SiF6 0.0166(CaSiF6 as insoluble)„F’ 0.01307MT/SSPMTSulphuric Acid H2SiF6 LiquorRock PhosphateCa3(PO4)2.CaF2Mixer / Den Scrubber StackInput Fluorine 0.565 x 0.03= 0.01695 MT / SSP MTHF/ SIF4 Curing Shed Silica‘F’ 0.007 MT / SSP MTSSP Fertilizer‘F’ 0.01622 MT / MT SSP‘F’ 0.00003MT /MT SSP
  16. 16. ANNEXURE 9MATERIAL SAFETY DATA SHEET FOR HAZARDOUS MATERIALS1. SULPHURIC ACIDCommonsynonymsSulphuric acid, vitriol, oil of vitriolFormula H2SO4CAS /EINECS No.7664-93-9PhysicalpropertiesForm: Colourless oily liquid when concentrated; colourless liquid when dilutedStability: Stable, but hygroscopicMelting point: -2 °CWater solubility: Miscible in all proportions (dissolution is very exothermic)Specific gravity: 1.84 (concentrated), close to 1 (dilute)PrincipalhazardsContact with the eyes or skin can cause serious permanent damageConcentrated solutions of acid are extremely corrosiveDissolution of sulfuric acid in water is very exothermic; enough heat may be releasedto make the water boilHazardCodesNFPAFlammability (Red) = 0, Reactivity (Yellow) = 2, Health (Blue) = 3 Sulfuric acid iswater-reactive if concentrated.Safe Always wear safety glasses. Do not allow the acid or a solution of it to come into
  17. 17. handling contact with your skin. Concentrated sulfuric acid acid should not be diluted byinexperienced users. When diluting acid always wear eye protection, and ALWAYSadd acid to water (not the reverse) slowly and with great care. Use constant stiring(sulfuric acid is much denser than water, and if you do not stir when adding acid towater, a layer of concentrated acid may form at the bottom of the beaker, creating asubstantial temperature gradient where acid and water meet).Note that freshly-prepared solutions will be warm or hot, and will as a consequence bemore corrosive than a cool solution.EmergencyEye contact: Immediately flush the eye with plenty of water. Continue for at least tenminutes and call for immediate medical help.Skin contact: Wash off with plenty of water. Remove any contaminated clothing. Ifthe skin reddens or appears damaged, call for medical aid.If swallowed: Drink plenty of water and call for immediate medical helpDisposalSmall amounts of dilute sulfuric acid can be flushed down a sink with a large quantityof water, unless local rules prohibit this.Larger amounts should be neutralised before disposal. Concentrated acid should not beflushed down a sink.ProtectiveequipmentALWAYS wear safety glasses when handling sulfuric acid or its solutions.If you need gloves, use neoprene, butyl rubber, natural rubber, polyethylene or PVCfor handling solutions at concentrations of up to 70%. Use butyl rubber orpolyethylene for concentrated sulfuric acid.2. FURNACE OILCommonsynonymsDiesel fuel; Fuel Oil; Gas Oil; or Product use Fuel Heating OilCAS No.PhysicalpropertiesForm Clear, slightly viscous, oily liquid
  18. 18. Specific gravity 0.881 max @ 15°C (59°F)Colour Clear to goldenOdour Petroleum odourVapour pressure Typically 2.1 to 2.6 mm Hg @ 21°C (70°F)Boiling point Typically 130-400°C (266-752°F)Hazard CodesNFPA - Health: 0; Flammability: 2; Reactivity: 0Combustible Liquid Class B, Division 3; Classification: Very ToxicFire & ExplosionHazardsConditions May be ignited by heat or flames.Flash point 43°C (109°F)Auto ignition temperature 241°C (466°F)Lower flammable limit 0.6 to 1.3%Upper flammable limit 6 to 7.5%Explosion data: Sensitivity to: Mechanical impact Not expected to be sensitiveStatic discharge Vapor: YesHazardouscombustionproductsCarbon monoxide (CO). Nitrogen oxides. PAHs and other aromatic hydrocarbons.ReactivityInformationStability: StableConditions to avoid: Sources of ignition. Static discharges. High temperatures.Incompatible substances: Oxidizers such as peroxides, nitric acid, and perchlorates.Extinguishing offireMeans of extinction In general, do not extinguish fire unless flow can be stopped.Use carbon dioxide, dry chemical, or foam. Cool containers with flooding
  19. 19. quantities of water until well after the fire is out.Special precautions Vapor may spread along the ground and collect in low orconfined areas (sewers, basements). May also travel to a source of ignition andflash back. Containers may explode when heated.Principal healthhazardsRoute of Entry Inhalation Hazardous Contact Eye, Ingestion Skin, SkinabsorptionAcute exposure: Headache and giddiness following inhalation. Aspiration intothe lungs can cause severe pneumonitis (serious lung irritation), with coughing,gagging, shortness of breath, chest pain, and/or pulmonary edema (fluidaccumulation in the lungs). Ingestion may produce nausea, vomiting, andcramping. Kidney effects have been reported.Chronic exposure Kidney, liver, lung, blood, and skin disorders.Irritation to Skin and respiratory tract.Sensitization Skin, in some animal studies.ProtectiveequipmentUse of gloves recommended.Eye Chemical safety goggles or face shield, as a good general safety practice.Respiratory NIOSH-approved SCBA or air line respirator with escape cylinder forconfined spaces. If an air purifying respirator is appropriate, use a “P series” filter& organic vapor cartridges. A qualified occupational health and safetyprofessional should advise on respirator selection.Personal protective equipment Clothing & footwear.Coveralls to prevent skin contact with product. If clothing or footwear becomescontaminated with product, completely decontaminate it before re-use, or discardit.Engineering controls.Enclose processes. Use local exhaust ventilation to remove vapour at its site ofgeneration. Handle laboratory samples in a fume hood. Use mechanicalventilation in confined spaces.
  20. 20. First – AidInhalation Move victim to fresh air. Give artificial respiration if breathing hasstopped and if a qualified AR administrator is available. Apply CPR if both pulseand breathing have stopped. Get medical help immediately.Ingestion Never give anything by mouth if the person is unconscious, rapidlylosing consciousness, or convulsing. If the person is conscious, have them drink 8to 10 ounces of water or milk to dilute the material in the stomach. Do not inducevomiting. If vomiting occurs spontaneously, have the person lean forward toavoid aspiration. Get medical help immediately.Eye If irritation occurs, flush eye with lukewarm, gently flowing fresh water for atleast 10 minutes. Get medical help.Skin Quickly and gently blot away excess product. Gently remove contaminatedclothing and shoes under running water.Wash gently and thoroughly with water and non-abrasive soap. Get medical help.Handlingprocedure &equipmentAvoid heating open containers of product so as to minimize vapour productionand accumulation. Use non-sparking equipment, explosion-proof ventilation, andintrinsically safe electrical equipment. Ground handling equipment. Have cleaneyewash and shower near the work area. Never siphon product by mouth. Leaks& spills Keep unauthorized persons away. Eliminate all sources of ignition.Ventilate area. Stop leak if it can be done safely. Prevent entry into sewers,waterways, or confined spaces. Absorb or cover with dry earth, sand or other non-combustible material and use clean, non-sparking tools to transfer to container.Storage May be stored at ambient temperatures. Containers should be vented andequipped with a flame arrester.3. SULPHURCommonsynonymsSulphur, brimstone, flowers of sulfur, precipitated sulfur, sublimed sulfur,bensulfoid, flowers of sulphur, precipitated sulphurCAS No. 7704-34-9
  21. 21. Physical propertiesAppearance: Bright yellow powderMelting point: ca. 116 °C (depending upon form)Boiling point: 445 °CVapour density: 8.8 (air = 1)Density (g cm-3): 2.01Flash point: 188 °CWater solubility: negligibleHazard CodeNFPA Hazard codeHealth – 2, Fire -1 , Reactive- 0.Fire & ExplosionHazardsExplosive Limits: LEL 35 gm/m3; UEL - 1400 gm/m3Dust suspended in air is readily ignited by flame, static electricity or frictionspark. Every reasonable step must be taken to minimize dust formation. Dusttight casings should be equipped with explosion relief vents. Sparkless electricalequipment is recommended.Handling equipment must be grounded or bonded to avoid static electricity. Keepaway from sources of flame or sparks.HazardouscombustionproductsMixtures with chlorates, nitrates or other oxidizing agents may be explosive.Sulphur will react with alkalis or alkaline earths.ReactivityInformationStability: Stable.Dust may form a flammable or explosive mixture with air. Incompatible withstrong oxidizing agents, most common metals, hydrogen, chlorine, fluorine.Extinguishing offire1. A fine water spray or fog is recommended.
  22. 22. 2. CO2 or dry chemical.3. Small fires may be smothered with sand or solid sulphur.Because burning sulphur evolves sulphur dioxide, breathing apparatus or gasmasks approved for use in acid-gas atmosphere should be used. Fumes fromunprotected sulphur fires shall be avoided, if possible, by approaching for theupwind side.Principal healthhazardsInhalation: Sulphur dust may irritate the mucous membranes of the respiratorypassages.Ingestion: Solid sulphur is virtually non-toxic. It can be taken internally in fairlylarge doses without injury.Skin: In some individuals, sulphur dust has an irritant action, which may beaggravated by perspiration or moisture.Eyes: Sulphur dust is capable of irritating the inner surfaces of the eyelids.ProtectiveequipmentRespiratory Protection: Dust-type respirators shall be provided for dustyconditions. Breathing apparatus must be available for emergency use in case offire.Eyes and Face: Dust-tight goggles with plastic or rubber frames may be helpfulin dusty conditions.Hands, Arms and Body: Workers whose skin may be sensitive to sulphur dustshould button collars, roll sleeves down, and gather trousers at the ankle. Glovesmay be helpful.Other Clothing and Equipment: Hard hat and safety shoes. Fire-retardant fabric isrecommended. Sulphur impregnated clothing should not be worn.First – AidSkin: Wash with mild soap and water.Eyes: Irrigate thoroughly with copious quantities of plain water. Inadequateirrigation may increase the irritation. Do not use Boric Acid.Handlingprocedure &equipmentVentilation: Local exhaust if dusty conditions prevail.Normal Handling: Avoid breathing dust and keep clothing as free from dust as
  23. 23. possible.Storage: Solid becomes corrosive to metals when stored wet. Sulphur/bentonitefertilizer will physically break down when exposed to moisture or water.Spill or Leak: Shovel into disposal containers or cover with tarp. For landfilldisposal, mix with limestone 3 times the weight of sulphur.
  24. 24. ANNEXURE - 10Details of facility for controlling air pollution from manufacturing process and processplantA. AirS.No. Name of Equipment Attached to Efficiency %ReductionFinal Concentration ofpollutant being emittedA. SSP Plant1.DC bagsBall Mill for RockGrindingPM – 150 PPM2. Venturi Scrubber I Den and Mixer forSSP Manufacturing3. Separator Scrubber I Venturi Scrubber I4. Venturi Scrubber II Seperator Scrubber I4. Separator Scrubber II Ventury Scrubber II5. Scrubber Fan Separator Scrubber II6. MSRL Stack 40 meters high Scrubber Fan PM - 150 PPMTotal Fluoride 25 mg / Nm³B. GSSP Plant1. Multi-clones Dryer and CoolerDrums2. Cyclones Multi Clones3. Fans Cyclones4. Stack 30 meters high Fans PM - 150 PPMC. Sulphuric Acid Plant1. MIST Eliminator for DT2. MIST Eliminator for IPAT
  25. 25. 3. MIST Eliminators FAT4. Tail End Gas Scrubber5. 50 m high stack SO2 4 kgs / MT SA, Acid MIST50 mg / N m³6. DCDA TechnologyTwo stacks of 40 meters height for each SSP plant & one stack of 30 meters height for each GSSP plant are proposed. Fromeach stack air flow rate shall be 36000 m3/hr. One stack of 50 m high for SAP with air flow of 50000 m³ / hr. is proposed.These stacks are for:a. Rock Phosphate Grinding and Dryingb. Scrubber for Acidulationc. Granulated SSPd. Sulphuric Acid PlantFO / Agro waste shall be used as fuel.B. WaterINDUSTRIAL :PLANT POLLUTANTS POLLUTION CONTROL MEASURESSULPHURIC ACID PLANTS DM/SOFTNER/RO PLANT EQUALISED WITH RAW WATER AND USED FOR
  26. 26. REGENERATED WATERAND THE BACK WASH OFWATER TREATMENT PLANTUNITS.SCRUBBING THE OFF GASES OF SSP PLANTS.SINGLE SUPER PHOSPHATE PLANTS SCRUBBER LIQUOR i.e.FLUOROSILICIC ACID1) USED ALONG WITH CONCENTRATEDSULPHURIC ACID FOR ACIDULATION OFROCK PHOSPHATE TO MANUFACTURESINGLE SUPER PHOSPHATE FERTILIZER, THISALSO REDUCES SULPHURIC ACID SPECIFICCONSUMPTION BY 4.3 KGS PER MT SSP.2) RCC FRP LINED LAGOON FORSCRUBBER LIQUOR.C. DOMESTIC (25 M³ / DAY):UTILITIES POLLUTANTS POLLUTION CONTROL MEASURESADMINISTRATIVE OFFICE & COLONY DOMESTIC SEWAGEWATER1) SEWAGE TREATMENT PLANT TO TREAT25 M³ / DAY WASTE WATER IS PROPOSEDON VERMI-CULTURE TECHNOLOGYINSTALLED AFTER SEPTIC TANK. THETREATED WATER IS FREE FROM ODOURAND IS BEING USED FOR HORTICULTURE.D. HAZARDOUS WASTES:PLANTS WASTES MANAGEMENT OF DISPOSALSULPHURIC ACID PLANTS 1) VANADIUMPENTOXIDE CATALYSTWASTE (CAT 17.20) 3.5MT/ANNUMSENT FOR SAFE AND SECURE DISPOSAL TO UTTERPRADESH WASTE MANAGEMENT PROJECT ATKANPUR (U.P.). WHICH IS AN AUTHORISED AGENCYBY UPPCB LUCKNOW.
  27. 27. 2) SULPHUR SLUDGE(CAT 17.10) 230MT/ANNUMREUSED WITH ROCK PHOSPHATE FOR ENRICHMENTOF ELEMENTAL SULPHUR IN SSP FERTILIZER,WHICH IS RECOGNISED AS FOURTH ESSENTIALNUTRIENT FOR AGRICULTURE CROPS IN FCO 1985REVISION JUNE-03.SINGLE SUPER PHOSPHATE PLANTS 1. FLUOROSILICIC ACID(CAT 36.10) 2700MT/ANNUM (100%)2. USED LUBRICATINGOIL3. SPENT RESIN FROMDM PLANTUSED FOR ACIDULATION OF ROCK PHOSPHATEWITH SULPHURIC ACID TO MANUFACTURE SSPFERTILIZER.TURBINE OIL IS CENTRIFUSED AND REUSED. DG SET(400 KVA) AND OTHEREQUIPMENTS USINGLUBRICATING OIL IS OPEN DRIVE CHAINS ON DEN,BUCKET ELEVETORS MIXTURE DRUM ETC.WITHOUT AFFECTING SOIL CONDITIONS. USED OILSHALL BE DISPOSED OFF TO AUTHORISEDRECYCLERES / VENDORS AS APPROVED BY UPPCB,LUCKNOW.SHALL BE DISPOSED OFF TO UTTAR PRADESHWASTE MANAGEMENT PROJECT, KANPUR (U.P.) ASAND WHEN REPLACEMENT OF RESIN IS DONE.ACHIEVED ZERO LIQUID DISCHARGE FROM JHANSI WORKSLIQUID EFFLUENTS ARE TOTALLY RECYCLED BACK INTO PROCESS WITHOUT AFFECTING GROUND WATER QUALITY.RECYCLE OF SOLID HARZADOUS WASTES IS DONE WITHOUT AFFECTING SOIL CONDITION.E. SOLID WASTES:
  28. 28. SULPHURIC ACID PLANTS AND SINGLESUPER PHOSPHATE PLANTS1) MS SCRAP2) POLYETHYLENE/ PLASTIC3) USED BATTERIES1) SALE FOR RECYCLE ANDREUSE.2) SALE FOR RECYCLE AND REUSEAFTER WASHING IN THE ETPLAGOON.3) SELL TO AUTHORISED VENDORONLY.SOLID HARZADOUS WASTES DISPOSED TO AUTHORISED VENDOR ONLY WITHOUT AFFECTING SOIL CONDITION.-
  29. 29. ANNEXURE 11DOMESTIC EFFLUENT TREATMENT FACILITYFilter FeedPumpSumpHorticultureSolid collectedduring cleaningPSFACFVermiculture Technologybased treatment plantStage I Stage IIPump SumpSeptic tankDomestic waste
  30. 30. ANNEXURE 12REUSE OF LIQUID EFFLUENTDrained off liquor100% RecyclingH2SiF6 liquorOverflowSiO2 Solids to SSP GodownScrubberUnitLagoonFRP LinedRCC PitMixer SSPProcessFeed Tank toMixerRaw WaterH2SiF6 liquorGases from Den/mixer
  31. 31. ANNEXURE 13HAZARD AND RISK ANALYSIS OF ACTIVITIES RELATED TO MANUFACTURING PROCESS, STORAGE, HANDLING ANDUSE OF CHEMICALS AND RAW MATERIALS FOR SSP, GSSP, SULPHURIC ACID PRODUCTIONSl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendations1. Operation ofconveyor beltsAccidentalstartup ofconveyorbelta. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofgreen SSP orrockphosphatea. Improperloadingb. Procedureviolationc. Operator errora. Exposure tomaterialhence skinirritationImmediateworkers/personsLow Low Engineeringa. SOPb. Shower to be providedAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryContact withmoving partsa. Safety guardnot providedb. Not using PPEa. ContactwithmovingpartsImmediateworkers/personsLow Low Engineeringa. SOPb. Guard will be providedAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatory2. Operation ofpumpsAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedured. violationa. Body injury Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be available
  32. 32. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency RecommendationsSpillage ofsulphuricacida. Operator errorb. Incorrectprocedurec. Procedured. violatione. Equipmentfailurea. Body Burn Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsc. Proper inspection for pump, pipe lines,flanges, union and valvesd. ShowerAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availabled. MSDS will be available at the sitewhich shall be explained to allSpillage ofHydrofluorosilic acid,a. Operator errorb. Incorrectprocedurec. Procedured. violatione. Equipmentfailurea. SkinirritationImmediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsc. Proper inspection for pump, pipe lines,flanges, union and valvesd. ShowerAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availabled. MSDS will be available at the sitewhich shall be explained to allSpillage ofWatera. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defectivetightness orincompleteclosing ofvalves andconnectionsa. Slip and fallb. Exposure tocontaminated waterc. Skincontactwithcontaminated waterImmediateworkers/personsLow Low Engineeringa. Proper slopeb. Proper drainage lines to Lagoonc. Proper inspection for pump, pipe lines,flanges, union and valvesAdministrativea. Proper trainingb. Showerc. SOPd. PPE will be provided and their use willbe made mandatory
  33. 33. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationse. Not followingSOPf. Equipmentfailure3. Operation of aircompressorAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedured. violationa. Body injury Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableBodycontact withhot partsa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body burn Immediateworkers/personsLow Low Engineeringa. SOPAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availabled. Signage indicating hot partsNoisegenerationa. Incorrectprocedurea. HearinglossImmediateworkersLow Low Engineeringa. Acoustic enclosure providedb. Regular inspectionAdministrativea. Proper trainingb. Ear muff will be provided and their usewill be made mandatoryc. Signage indicating high noise area willbe displayedSpillage ofWatera. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defectivetightness orincompleteclosing ofa. Slip and fallb. Exposure tocontaminated waterc. Skincontactwithcontaminated waterImmediateworkers/personsLow Low Engineeringa. Proper slopeb. Proper drainage lines to Lagoonc. Proper inspection for pump, pipe lines,flanges, union and valvesAdministrativea. Proper trainingb. Showerc. SOP
  34. 34. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsvalves andconnectionse. Not followingSOPf. Equipmentfailured. PPE will be provided and their use willbe made mandatory4. Operation andmaintenance ofdust collectionbag filtersDustemissiona. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. LungdiseaseImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory5. Operation ofball millAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofRockPhosphatea. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. LungdiseaseImmediateworkers /personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory6. Operation ofcraneAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedurea. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnections
  35. 35. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsviolation Administrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableFalling ofobject fromheighta. Failure of craneb. Operator errorc. More load oncraned. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsc. Crane with sirenAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be available7. Operation ofbucket elevatorAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableFalling ofobject fromheighta. Failure of craneb. Operator errorc. More load oncraned. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsc. Crane with sirenAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableContact withmoving partsa. Safety guardnot providedb. Not using PPEa. Contactwith movingpartsImmediateworkers /personsLow Low Engineeringa. SOPb. Guard will be providedc. Regular inspectionAdministrative
  36. 36. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsa. Proper trainingb. PPE will be provided and their use willbe made mandatory8. Operation of milfanAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableFalling ofobject fromheighta. Failure of fanb. Operator errorc. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableDustemissiona. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. LungdiseaseImmediateworkers /personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory9. Operation ofmixing unit:Transfer ofsulphuric acid,spent acid,hydrofluorosilicacid, silicaliquor to pits,Spillage ofacid /materiala. Operator errorb. Incorrectprocedurec. Procedureviolationd. Equipmentfailuree. Handling isa. Inhalationof chemicalsb. Skincontact withchemicalshence burninjuryImmediateworkers /personsModerate Low Engineeringa. Exhaust will be providedb. Proper equipment designsc. Regular maintenance and inspection oftransfer pumps, pipelines, valves andother fittingsAdministrativea. MSDS will be available at the point of
  37. 37. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationssolid silicasludge asdiluents,operation ofventuri fluorinegas scrubberdone withoutreference tocontents andMSDSf. Not using PPEuse and explained to the operatorb. Showerc. SOPd. Mask and other PPE will be providedtheir use will be made mandatory10. Operation andmaintenance offurnace unitFalling fromheighta. Operator errorb. Not using PPEa. Body injury Immediateworkers /personsModerate Low Engineeringa. Hand rail and support structure will beprovidedAdministrativea. PPE will be provided their use will bemade mandatorySpillage ofFOa. Operator errorb. Cleaning andmopping not donec. Procedureviolationd. Leakages intransfer linesa. Slip andfallImmediateworkers /personsModerate Low Engineeringa. Immediate cleaning and moppingb. Regular inspection and maintenance oftransfer pump and linesBodycontact withhot partsa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body burn Immediateworkers /personsLow Low Engineeringa. SOPAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availabled. Signage indicating hot parts will bedisplayed
  38. 38. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency RecommendationsFire a. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body burn Immediateworkers /personsHigh Low Engineeringa. SOPAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableEmission offumesa. Fans notworkingb. Impropermaintenancec. Operator errord. Procedureviolationa. Inhalationof fumesImmediateworkers /personsLow Low Engineeringa. SOPb. ID and FD fans will be providedc. Stack will be providedd. Exhaust will be providede. Regular maintenance and inspectionAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatory11. Operation ofscrubber fanAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers /personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofsilica liquora. Operator errorb. Incorrectprocedurec. Procedureviolationd. Equipmenta. Inhalationof chemicalsb. Skincontact withchemicalshenceImmediateworkers/personsLow Low Engineeringa. Exhaust will be providedb. Proper equipment designsc. Regular maintenance and inspection oftransfer pumps, pipelines, valves andother fittings
  39. 39. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsfailure irritationc. Slip andfallAdministrativea. Showerb. SOPc. Mask and safety shoes will be providedtheir use will be made mandatory12. Cleaning ofscrubber towerand tanksFalling fromheighta. Operator errorb. Not using PPEa. Body injury Immediateworkers/personsModerate Low Engineeringa. Hand rail and support structure will beprovidedAdministrativea. PPE will be provided their use will bemade mandatorySpillage ofsilica liquora. Personnel‟serrorb. Incorrectprocedurec. Procedureviolationd. Not using PPEa. Inhalationof chemicalsb. Skincontact withchemicalshenceirritationc. Slip andfallImmediateworkers/personsLow Low Engineeringa. Exhaust will be providedb. Proper equipment designsc. Regular maintenance and inspection oftransfer pumps, pipelines, valves andother fittingsAdministrativea. Showerb. SOPc. PPE and safety shoes will be providedtheir use will be made mandatory13. Operation ofscrew conveyorsAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedureviolationa. Body injury Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofdusta. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsa. LungdiseaseImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory
  40. 40. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsf. EquipmentfailureSlippageduringhandlinga. Operator errorb. Incorrectprocedurec. Procedureviolationa. Slip andfall hencebody injuryImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. PPE and safety shoes will be providedtheir use will be made mandatory14. Operation ofrotary valvesSpillage ofground rocksa. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. LungdiseaseImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory15. Operation of den Spillage ofSSP slurrya. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. BreathingproblemImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatoryGenerationof fumesa. Operator errorb. Incorrectprocedurec. Procedured. violatione. Defective toolsf. Defectiveequipmentsg. Equipmentfailurea. LungdiseaseImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and other PPE will be providedtheir use will be made mandatory17. Operation of Accidental a. Operator error a. Body injury Immediate Low Low Engineering
  41. 41. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationsvibrating screen startup b. Incorrectprocedurec. Procedured. violationworkers/personsa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofmateriala.Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. Lungdiseaseb.Body injurydue to slipand fallImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and safety shoes will beprovided their use will be mademandatory18. Operation ofcrushersAccidentalstartupa. Operator errorb. Incorrectprocedurec. Procedured. violationa. Body injury Immediateworkers/personsLow Low Engineeringa. SOPb. Regular inspection for electricalconnectionsAdministrativea. Proper trainingb. PPE will be provided and their use willbe made mandatoryc. First-aid box will be availableSpillage ofmateriala. Operator errorb. Incorrectprocedurec. Procedureviolationd. Defective toolse. Defectiveequipmentsf. Equipmentfailurea. Lungdiseaseb.Body injurydue to slipand fallImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. Mask and safety shoes will beprovided their use will be mademandatory19. Operation anduse of electricalExposure tolive wirea. Missing earthb. Operator errorc. Electricalshock mayImmediateWorker / personHigh Low Engineeringa. Regular inspection and maintenance
  42. 42. Sl.No.Activity Hazards Cause Risk Receptor Consequences Frequency Recommendationscontrol paneland appliancesc. Not using PPE be fatal b. Earthing will be checked regularly forcontinuityAdministrativea. Proper trainingb. Use of gloves will be made mandatory20. Use andhandling ofchemicalsSpillage,leakage and /or exposureto material/ potentchemicalsa. Operator errorb. Incorrectprocedurec. Procedureviolationd. Equipmentfailurea. Cutsb.Inhalationor skincontact ofchemicalsc. Burn injuryImmediateworkers/personsModerate Low Engineeringa. Proper design of equipments and toolsb. Regular inspection of chemical transferpumps, lines, valves, etc.Administrativea. Proper Trainingb. Showerc. SOPCleaning thespills andleakagesLand andwaterpollutionPremises High Low Engineeringa. Drainage line to ETPb. Operational ETP21. Cleaning oftanks, pipeline,storage vessels,Slippageduringhandlinga. Operator errorb. Incorrectprocedurec. Procedured. violationa. Slip andfall hencebody injuryImmediateworkers/personsNormal Low Engineeringa. Regular inspection and maintenanceAdministrativea. Proper trainingb. PPE and safety shoes will be providedtheir use will be made mandatoryDrainingcontaminated waterEnvironmentalLand andwaterpollutionPremises High High a. Drainage line to ETPb. Operational ETP
  43. 43. ANNEXURE - 14ENVIRONMENTAL MANAGEMENT PLANEnvironmental Management Plan (EMP) of the organization will ensure that the residual environmental impacts areminimized by adopting best possible economically viable techniques. The EMP has also to ascertain compliance with allstatutory conditions.A comprehensive plan has been worked out keeping in view these requirements.The environmental management plan shall be directed to the following:a. Insuring the operations of various process units as per specified operating guidelines/operating manuals.b. Strict adherence to maintain schedule for various machinery/equipments/road repair and maintenance.c. Good house keeping practices.d. Periodic and planned environmental monitoring.
  44. 44. 1. Overview of the Project SiteThe project site is in the village Farhad Somni, Distt. & Teh.: Rajnandgaon (CG.) Attached maps shows land use within a 1and 10 km radius of the site under consideration. Nearest airport is Raipur and the nearest railway station is Rajnandgaon(CG.).The estate does not have any environmentally sensitive areas. It has adequate infrastructure, such as roads, water supply,and electricity supply. The Project will require no new infrastructure.ClimateThis region of C.G. has four distinct seasons: winter (December–March), summer (April–June), rainy season (July–September), and monsoon season (October–November). Air temperatures range from an average daily maximum around45 C, normally recorded in April and May, to an average daily minimum around 13 C in the winter. Relative humidity isquite high, exceeding 70% during rainy season. The sky is mostly cloudy during the rainy season and less cloudy in thepost–monsoon months, with clear sky during the other months of the year. Wind speeds are generally low, though theyaccelerate during the latter part of summer and early southwest monsoons. Wind speeds range from calm to more than24 km per hour.(a) Impact on Land Use and SoilThe project is coming up in the existing premises of KCFL. The area has been marked for the industrial activities. Thus theland use will not change due to the proposed industrial activity. The area will not undergo any topographical changes.
  45. 45. During Construction PhaseTo avoid erosion of the top soil the development is planned in the shortest possible time and land-clearing activity shall bekept to the absolute minimum by working at the specific sites one by one where construction is to take place so as toincrease detention and infiltration.The activities that result in soil being laid bare shall be scheduled in such a way that some type of vegetative coverappropriate to the site shall be established.Natural waterways/drainage pattern shall be maintained by providing culverts where needed.The solid waste generated from the construction activities shall be effectively recycled within the project.The requirements of sand and aggregates for the construction works will be met from in and around area, where, theseare taken out from seasonal rivulets that get replenished annually.For the development works the use of wood shall not be allowed (Timber Free Construction) and shall be replaced by MildSteel, Aluminium, Glass and Plastic.During Operational PhaseManagement has planned to develop thick green belt in the area and hence there is low level of weathering and soilerosion. M/s Khaitan Chemical & Fertilizers Limited will take appropriate action for plantation inside and outside the
  46. 46. premises. Due to the proposed programme and project, the topographic features shall remain unaffected and unaltered.The more and thick plantation in the area shall create a positive impact to the landscape and shall help in the reduction ofbarren land. This will not only reduce soil erosion but shall also act as air purifier and control the air pollution further.The various solid wastes will be collected at the point of origin and will be disposed off through the registered vendor.Thus there is little or no chance for land pollution due to solid wastes. For on-site storage of solid waste, management hasalready planned a proper arrangement.The manufacturing of Single Super Phosphate & Granulated Single Super Phosphate do not generate any solid orhazardous waste. Entire dust, slurry, etc from pollution control equipments will be reused in the process. Solid wastegenerated from domestic waste water treatment facility shall be used as bio-manure in the factory premises.(b) Impact on Surface WaterThe impact can be discussed under following three sub-heads:(i) Physical characteristics,(ii) Chemical Nature and(iii) Biological Nature.
  47. 47. During Construction PhaseThe run-off during development shall be controlled by removing construction related solid waste as malba, loose soil etc.quickly. Further land clearing activity shall be kept to the absolute minimum by working at the specific sites one by onewhere construction is to take place.During Operational PhaseNo surface water course exist in the area therefore there will be no effect of mining on the water regime. The groundwater structures fall under tube well.Soil permeability studies shall be made prior to discharge of scrubber liquid containing 10 – 12% hydroflorosilicic acid intothe holding tanks or lagoons and steps will be taken to prevent percolation and ground water contamination. Organisationhas planned RCC structure with FRP lining for lagoon.A septic tank shall be provided with Toilet facilities. Entire domestic waste will be treated through the septic tank.Overflow of septic tank shall be taken into the sewage treatment plant based on vermiculture bio-technology followed bytertiary treatment to meet the requirement of CPCB and CGPCB. Entire treated domestic effluent will be used forgardening and plantation purpose within the factory premises.There is no generation of liquid effluent from the process. Scrubber liquid and slurry from air pollution control equipmentswill be reused in the manufacturing process through a closed loop system. Thus the organization will work on zerodischarge concept.Both roof top rainwater harvesting and storm water run off shall be tapped for recharging the aquifers and storage.
  48. 48. The analysis of water samples for physical, chemical and biological parameters of the ground water shall be done on half-yearly basis.c. Impact on Air EnvironmentDuring Construction PhaseProvision shall be made for sprinkling of water on loose soil to avoid dust generation. The debris and unutilizedconstruction material and earth from the construction site shall be removed immediately to recycle within the project sothat no nuisance dust is generated due to wind.The vehicles used during construction activity shall be checked for vehicular emissions.The steps shall be taken to reduce the impact of noise by taking to plantations from the very beginning. ConstructionActivities shall not be allowed at Night.The mitigation measures shall include regular maintenance of machinery and provision of personnel protectiveequipments to workers where needed.During Operational PhaseThe proposed unit shall have a number of stacks as point source for discharge. These stacks shall be associated withvarious equipments. These plants and therefore stacks emit fluorides fumes and dust particles. Efficient pollution controlequipments having wet scrubbers, cyclones, dust collection bag filters will be installed to arrest fine dust particles and forconverting fluorides fumes into hydroflorosilicic acid. Thus the industry will maintain the clean air emission. The emissionlevels of pollutants from the various stacks would be well within the permissible limits as per CPCB or CGPCB norms.
  49. 49. The 10 – 12% hydroflorosilicic acid generated from wet scrubber will be recycled back to mixer along with concentratedSulphuric acid by incorporating a Distributed Control System (DCS) / PLC for computerized control of the total process..In-plant control measures should be taken to contain the fugitive emissions. A Sewage Treatment Plant with tertiary levelof treatment is being provided to avoid any odor pollution from the sewage generated. Extensive plantation is planned tomitigate the impact of noise and to improve the ambient air in general.Infrastructural facilities will be provided for monitoring the stack emissions and measuring the ambient air quality.Monitoring of ambient air and stack emission shall be done on monthly basis for various parameters.d. Noise EnvironmentDuring Construction PhaseEntire construction shall be restricted during day time only.During Operation PhaseAdequate measures will be taken for control of noise and vibrations in the industry. Equipments and machinery shall beinspected regularly. Regular and routine maintenance will be done. Wherever feasible, acoustic enclosure will be providedto machines creating high noise.Signage will be displayed indicating high noise area. Ear muff and plug will be provided to users.Road side plantations shall be a part of the regular activity to control the noise level.f. Socio-Economic Environment
  50. 50. With the establishment of industries in this area, the local inhabitants have adopted a western culture. They have nowmodern electrical and electronic gadgets. The villagers now enjoy good food and they have better choice. The villagers andlocal inhabitants have better choice for employment.They have all modern communication and transportation facility. These observations and the study indicate positiveimpact of industries on the socio-economic aspect of the area.g. Green belt developmenth.The main objective of the green belt is to provide a barrier between the source of pollution and the surrounding areas.The green belt helps to capture the fugitive emission and to attenuate the noise generated apart from improving theaesthetics. Development of green belt and other forms of greenery shall also prevent soil erosion and washing away oftopsoil besides helping in stabilizing the functional ecosystem and further to make the climate more conducive and torestore water balance. While making choice of plant species for cultivation in green belts, weight age has to be givenpriority to the natural factor of bio-climate. It is also presumed that the selected plants will be grown as per normalhorticultural (or forestry) practice and authorities responsible for plantation will also make sure that adequate provisionfor watering and protection of the saplings exists at site.For effective removal of pollutants, it is necessary that: Plants grow under conditions of adequate nutritional supply (for health and vigor of growth), Absence of water stress (to maintain openness of stomata apertures and form of epidermal structures),
  51. 51.  Plants are well exposed to atmospheric conditions of light and breeze (i.e. away form engineering structureshindering free flow of air) to maintain free interaction with gases.Selection of plants will also take into consideration: For absorption of gases: For removal of suspended particulate matterThe landscaping and green belt will be designed and trees will be planted in open areas, around factory boundary alongfootpaths and dividers. Treated domestic effluent will be used for watering of plants and trees.h. Transport SystemsProper parking places will be provided for the trucks and other vehicles by the industries to avoid any congestion orblocking of roads.Spillage of chemicals/substances or furnace oil on roads inside the plant will be cleaned immediately. Proper road safetysigns both inside and outside the plant will be displayed for avoiding road accidents.Vehicles having PUC certificate will be allowed to move inside the factory premises.
  52. 52. i. Disaster Management PlanningProper disaster planning will be done to meet any emergency situation arising due to fire or explosion, or sudden leakageof gas etc. Fire fighting equipment and other safety appliances will be provided as per the requirement. Regular mockdrilling will be done.To avoid any hazards and accidents due to chemical process and storage of chemicals industry has taken followingadministrative and design controls.(i) Administrative Control1. Work Instruction2. Operational Control Procedures i.e., Standard Operating Procedure (SOP)3. Training to all employees on safety and storage of chemicals4. Emphasis on segregation of different chemicals and fuels based on flammability, toxicity, hazard nature, oxidizationproperty etc.5. On-site Emergency Management Plan will be established6. Calibration and testing of vessels, gauges, etc shall be done regularly7. Monitoring of tank during filling and transfer of chemicals and fuels shall be done8. Acceptable working conditions for operators9. Emergency services will be provided10.Emergency escape routes to on-site emergency personnel11.Control access of unauthorised personnel at the Main Gate12. Proper warehousing management system13. Proper labelling of chemical / fuel storage containers
  53. 53. 14.Proper recording of inventories of on-site chemcials15.Marking of emergency escape routes to on-site emergency personnel16.Chemical inventory system are sufficient to address and categorise hazardous materials into compatible groups17.Classification and segregation of compatible, hazardous materials to avoid overlap of these areas.18.Instructions are given that oxidising agents and flammable substances areas will not overlap, strong acidscompound areas will not overlap, peroxides will not be stored near any metallic compounds that could causedecomposition and the liberation of oxygen.19.Prior approval will be required from Technical Director / Manager – Production / Manager Ware Housing / Manager- QC before carrying out any process.(ii) Design Control1. Personnel Protective Equipments will be provided2. Emergency shower will be provided at all critical points3. Dyke and confinement for bulk storage of flammable and hazardous chemicals and fuels4. Proper drain to lagoon and STP5. Concrete structure with sufficient slope for storage of chemicals and fuels6. No nearby heat source7. Fire fighting systems with alarm8. Wet scrubbers, cyclones, dust collection bag filters to control emissions from various manufacturing operations9. Lighting protection10.Earthing pits11.Operations to start if scrubber is working
  54. 54. The areas containing flammable and toxic chemicals will be sufficiently ventilatedj. Environment Management CellTo implement the Environment Management Programme, a structured Environment Management Cell (EMC) interwovenwith the management system will be created.EMC will undertake regular monitoring of the environment and conduct yearly audit of the environmental performanceduring the operational phase. It will also check that the stipulated measures are being satisfactorily implemented andoperated. It shall also co-ordinate with local authorities to see that all environmental measures are well coordinated.k. Monitoring FrequencyA comprehensive environmental monitoring program that has been prepared for the purpose of implementation in theproposed project by the EMC is described below:The frequency of monitoring for air, effluent, water and hazardous waste is as follow: Ambient air quality shall be monitored on monthly basis for SPM, RSPM, SO2, NOx, and CO. Ambient noise level shall be monitored on monthly basis at different locations. Quality of under ground water shall be monitored on half-yearly basis as per IS-10500 standard.
  55. 55.  Stack monitoring will be done on monthly basis.

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