1 SCOPING S. Item Details -...
Transcript of 1 SCOPING S. Item Details -...
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING
LAB PLANT AT NIRMA LTD., ALINDRA FORM - 1
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1 SCOPING
The scoping for the project has been done based on FORM 1, as per EIA Notification, dated September 14, 2006 amended as on date. The scoping details are as follows:
I. Basic Information
S. No.
Item Details
1 Name of the Project EC Amendment for alternate fuel (from FO/NG to FO/NG/Coal) by installing coal
based Thermic fluid Heaters in existing LAB plant
2 S. No. in the Schedule Project or Activity: 5(e): Petrochemical based processing (processes other than
cracking & reformation and not covered under the complexes)
3
Proposed capacity / area / length / tonnage to be
handled/ command area / lease area / no. of wells to
be drilled
There is no change in Production capacity. Existing production capacity is as under:
Sr. No. Product Name Quantity (MT / Month)
1. Liner Alkyl Benzene (LAB) 10,417
2. Detergent Cake 12,500
3. Detergent Powder 12,500
4. Heavy Alkylate (By product) 250
Alternate fuel mix as under:
Sr. No. Fuel Consumption
Existing Proposed Total
1.
Natural Gas
& / or
10.86 KMN3/Hr.
-- 10.86 KMN3/Hr.
Furnace Oil/LSHS
& / or
9.26 MT/Hr. -- 9.26 MT/Hr.
Coal -- 15 MT/hr. 15 MT/hr.
LDO 9.17 MT/Hr. -- 9.17 MT/Hr.
2. HSD 0.15 MT/Hr. -- 0.15 MT/Hr.
3. Naphtha 0.2 MT/Hr. -- 0.2 MT/Hr.
4 New / Expansion /
Modernization
Consumption Proposed Fuel (Coal):
Sr. No.
Unit Capacity
(mnkcal/hr) Fuel Consumption
Indonesian Coal (kg/hr)
1. TFH - 1 12 2,672
2. TFH - 2 12 2,672
3. TFH – 3
(As Stand By) 12 2,672
4. TFH - 4 12 2,672
5. TFH - 5 12 2,672
6. TFH - 6 12 2,672
7. TFH – 7
(As Stand By) 12 2672
TFH: Thermic Fluid Heater
Notes:
a) There is no increase in production quantities.
b) Water Consumption & wastewater generation shall not exceed consented
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S. No.
Item Details
quantity.
c) Only addition of Coal as a Fuel is requested.
d) Seven (7) new Coal Based Thermic Fluid Heaters are proposed to be provided. Out of these, Two (2) would be as a Stand By
e) When the proposed Coal Fired Thermic Fluid Heaters will be in operation, existing FO / NG based Hot Oil Heaters will be in stand-by mode and when existing FO/NG based Hot Oil Heaters will be in operation, proposed Coal based Thermic Fluid Heaters will be in stand-by mode. So, in no case existing FO/NG based Hot Oil Heaters and proposed Coal Fired Thermic Fluid Heaters will be in operation in parallel.
f) GCV of Indonesian coal is 5,307 kcal/kg.
5 Existing Capacity / Area
etc. Mentioned in Table vide Sr. No. 3
6 Category of Project (A or
B) A
7 Does it attract the general conditions? If yes, please
specify. No
8 Does it attract specific
condition? If yes, please specify
No
9
Location Village Alindra
Plot Survey / Khasra No. 167-173,181,183, 185-195, Block no. 3/P, 3/A of Chandranagar, Block no. 90, 132/2,
135/2 of Khokhar
Village Alindra
Tehsil / Taluka / Mandal Savli
District Vadodara
State Gujarat
10 Nearest railway station /
airport / along with distance in km.
Nearest Railway Station
Vadodara: ~24 km towards SW (~Road distance)
~17.8 km towards SW (Aerial distance)
Samlaya: ~18 km towards ENE (~Road distance)
~7.21 km towards ENE (Aerial distance)
Nearest Airport:
Vadodara: ~ 20.7 km towards SSW (~Road distance)
~ 14.61 km towards SSW (Aerial distance)
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING
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S. No.
Item Details
11 Nearest town, city, district headquarters along with
distances in kms
Nearest Town/City
Savli: ~16.1 km towards NNW (~Road distance)
~11.19 km towards NNW (Aerial distance)
District Headquarters
Vadodara: ~24.6 km towards SSW (~Road distance)
~18.12 km towards SSW (Aerial distance)
12
Village Panchayat, Zilla Parishad, Municipal
Corporation, Local Body (complete postal address with telephone nos. to be
given)
Taluka Panchayat
Seva Sadan Savli, Muval Road, Tal: Savli, Dist. Vadodara.
13 Name of the applicant NIRMA LTD.
14 Registered address
NIRMA LTD.
Nirma House, Ashram Road, Nr. Income Tax office,
Ahmedabad - 380009
15
Address for correspondence
Same as Above
Name Mr. Ashish Desai
Designation Project Coordinator
Address
Nirma Ltd.
Nirma House, Ashram Road, Nr. Income Tax office,
Ahmedabad
Pin Code 380009
E-mail [email protected]
Telephone No. Ph: +91-79-27549319+91-79-27546603 / 05
Fax No. -
Mobile No. +91-9825320090
16
Details of alternative sites examined, if any. Location of these sites should be
shown on the Toposheet.
Alternative sites are not identified since the existing facility possesses sufficient Infrastructure for the proposed establishment of New Thermic Fluid Heaters
17 Interlinked Projects No Interlinked Projects
18
Whether separate application of interlinked
project has been submitted?
Not Applicable
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S. No.
Item Details
19 If yes, date of submission Not Applicable
20 If no, reason Not Applicable
21
Whether the proposal involves approval /
clearance under: if yes, details of the same and their status to be given:
The Forest (Conservation) Act, 1980
The Wildlife (Protection) Act, 1972
The C.R.Z Notification, 1991
No
22
Whether there is any Government order / policy, relevant / relating to the
site
No
23 Forest land involved (ha.) Not Applicable
24
Whether there is any litigation pending against
the project and / or land in which the project is
proposed to be set up?
Name of the Court Case No. Order / directions of the Court, if any and its
relevance with the proposed project
No
25 Project Cost (in Lacs) INR 8000 lakhs
II Activity 1. Construction, operation or decommissioning of the project involving actions, which will cause
physical changes in the locality (topography, land use, changes in water bodies, etc.)
S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
1.1
Permanent or temporary change in land use, land
cover or topography including increase in
intensity of land use (with respect to local land use
plan)
No The proposed Coal based Thermic fluid heaters would be constructed in
vacant land available within existing premises of Nirma – LAB plant at Savli
1.2 Clearance of existing land, vegetation and buildings?
No Land clearance is not involved. The land is already available and earmarked
for the proposed activity within existing plant.
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S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
1.3 Creation of new land uses? No The proposed Coal based Thermic fluid heaters will be constructed on vacant land available in existing LAB plant, hence no new land use will be created.
1.4 Pre-construction
investigations e.g. bore houses, soil testing?
Yes Prior to commencement of construction activities, essential studies such as
soil testing will be conducted to ensure a safe structural design.
1.5 Construction works? Yes Additional construction work will be carried out as per the plant requirements.
1.6 Demolition works? No No demolition work would be undertaken because land is plain and proposed
expansion is to be carried out within the existing factory premises.
1.7
Temporary sites used for construction works or
housing of construction workers?
No
The proposed site has sufficient availability of land for development of construction activities whenever required. Local workers will be hired during construction phase. Hence, no temporary housing facilities will be created for
construction workers.
1.8
Above ground buildings, structures or earthworks
including linear structures, cut and fill or excavations
Yes Above ground buildings includes, structures for Coal fired Thermic fluid
heaters, Coal storage yard etc. cut, fill or excavation activities are part of the project.
1.9 Underground works including mining or
tunnelling? No Not Applicable
1.10 Reclamation works? No Not Applicable
1.11 Dredging? No Not Applicable
1.12 Offshore Structures No Not Applicable
1.13 Production and
manufacturing processes? Yes
Proposed Coal based Thermic Fluid heaters (07 nos. including 02 no. on standby) would be installed. Please refer Annexure 7, Pg. 23 for process
description of Thermic Fluid Heaters – FO / NG (existing) & Coad fired (Proposed)
1.14 Facilities for storage of
goods or materials? Yes
Additional storage facility in the form of New Coal Storage yard is proposed. Covered coal storage area would be ~3,500 m2 (13,000 MT)
1.15 Facilities for treatment or disposal of solid waste or
liquid effluents? Yes
Solid waste:
Fly ash & Bottom Ash would be generated due to combustion of coal in proposed Thermic Fluid heaters (as and when these are in operation). The
expected quantities of these generated would be:
Fly Ash = 16 MT/Day
Bottom Ash = 72 MT/Day
Scrubber Solid=4 MT/Day
Storage method: The ash (bottom & fly) would be stored in Silos.
Disposal method: These would be utilised in Brick and Cement manufacturing as well as for Road construction. Scrubber Solid is used as a filler material in detergent plant.
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S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
Liquid effluents:
3 KL/day would be generated in the form of Scrubber effluent. This would be treated in existing ETP location within the LAB plant premises. Please refer
Annexure 4, Pg. 18 for details of existing ETP
1.16 Facilities for long term housing of operational
workers? No
Most of the workers are locally employed who reside in nearby villages / town. A colony for labourers is also constructed beside Nirma-LAB plant premises on
land belonging to Nirma Ltd.
1.17 New road, rail or sea traffic
during construction or operation?
Yes Some traffic is likely to be generated due to additional road trips during
construction and operation but the same will not be significant.
1.18
New road, rail, air waterborne or other
transport infrastructure including new or altered
routes and stations, ports, airports etc?
No As the site is well connected with access road and state highways, no
additional transportation infrastructure will be required.
1.19
Closure or diversion of existing transport routes or
infrastructure leading to changes in traffic
movements?
No As there is no major increase in traffic due to construction and then operation
activity, closure or existing routes in traffic movement is not foreseen.
1.20 New or diverted
transmission lines or pipelines?
No No transmission lines / pipelines pass inside the plant premises
1.21
Impoundment, damming, culverting, realignment or
other changes to the hydrology of watercourses
or aquifers?
No These activities will not be carried out.
1.22 Stream crossings? No There is no stream crossing through the project site.
1.23 Abstraction or transfers of
water from ground or surface waters?
No
Surface water:
There is no incremental consumption above the consented quantities. The total water consumption quantity as per GPCB Consent is 1706.5 KLD.
Nirma Ltd. has permission from State Government to draw water from River Mahi, through the intake facility near village Bhadarwa and as per agreement, Nirma Ltd. is allowed to draw 0.5 MGD (2250 KLD) of water from Mahi river.
Letter is attached as Annexure 9.
Ground Water:
No abstraction or transfer of water from ground due to proposed activity is envisaged.
1.24 Changes in water bodies or the land surface affecting
drainage or run-off? No
There would be no changes in Water bodies or land surface in the facility. The Run-off water will continue to flow in the existing pattern after the proposed
project is commissioned.
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S. No. Information/Checklist
Confirmation
Yes/
No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
1.25
Transport of personnel or materials for construction,
operation or decommissioning?
Yes During the construction and implementation of the project period, transport of
materials and personnel would take place through existing roads.
1.26 Long-term dismantling or
decommissioning or restoration works?
No Not Applicable
1.27
Ongoing activity during decommissioning which could have an impact on
the environment?
No No decommissioning work is envisaged, hence no impact on the environment.
1.28 Influx of people to an area
either temporarily or permanently?
No There would be movement of labourers during construction phase but will not
cause any permanent influx of people.
1.29 Introduction of alien
species? No Not Applicable
1.30 Loss of native species or
genetic diversity? No Not Applicable
1.31 Any other actions? No Not Applicable
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials
or energy, especially any resources which are non-renewable or in short supply):
S. No.
Information/Checklist confirmation
Yes / No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
2.1 Land especially
undeveloped or agricultural land (ha)
No Not required since the proposed Coal based Thermic Fluid heaters would be established on land within the existing premises of Nirma – LAB plant.
2.2 Water (expected source & competing users) unit: KLD
Yes
Source: Existing intake facility from River Mahi. There is no incremental consumption above the consented quantities. The total
water consumption quantity as per GPCB Consent is 1706.5 KLD. Additional fresh water requirement in scrubber will be 4 KLD. Water requirement in KLD is as per
table below:
Existing (KLD) Proposed (KLD)
Total (KLD)
1702.5 4 1706.5
Note:
Sprinkling water on coal stockpile will be source from the existing ETP treated water. Nirma Ltd. has permission from State Government to draw water from River
Mahi, through the intake facility near village Bhadarwa and as per agreement, Nirma Ltd. is allowed to draw 0.5 MGD (2250 KLD) of water from Mahi river.
2.3 Minerals (MT) No Imported Coal would be used in the proposed Coal Based Thermic Fluid Heaters.
2.4 Construction material
stone, aggregates, sand / soil (expected source, MT)
Yes Construction materials like stones, aggregates, sand, brick, steel, cement, rubble, etc. would be procured from the local market of the region, which are available
locally.
2.5 Forests and timber (source, No Not Applicable
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING
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S. No.
Information/Checklist confirmation
Yes / No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
MT)
2.6
Energy including electricity and fuels (source,
competing users) unit: fuel (MT), energy (MW)
Yes
Electricity Source: MGVCL
Existing consumption = 170000 KWH/Day Proposed Consumption = 120000 KWH/Day
2.7
Any other natural resources (use appropriate standard
units)
None No other natural resources would be used
3. Use, storage, transport, handling or production of substances or materials, which could be harmful
to human health or the environment or raise concerns about actual or perceived risks to human health.
S. No. Information / Checklist confirmation Yes /
No Details thereof (with approximate quantities / rates, wherever possible) with source of information data
3.1
Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna,
and water supplies)
Yes
As per MSICHR, Sodium Hydroxide (NaOH) is the only hazardous chemical used in proposed project as scrubbing
media.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne
diseases)
No
Suitable OH & EMS, proper drainage and waste management measures will be adopted in construction and operation phase,
which will restrict the growth and reproduction of disease vectors.
3.3 Affect the welfare of people e.g. by
changing living conditions? No -
3.4 Vulnerable groups of people who could be
affected by the project e.g. hospital patients, children, the elderly etc.,
No No Vulnerable groups reported in the study area
3.5 Any other causes No Not envisaged
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
S. No. Information/Checklist
confirmation Yes/ No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
4.1 Soil, overburden or mine wastes No Not Applicable
4.2 Municipal waste (domestic and or
commercial wastes) Yes
Municipal waste:
Waste paper from administration building, waste metals, kitchen waste etc.
Disposal method:
Waste paper and metal will be given to recyclers and kitchen waste will be converted into manure.
4.3 Hazardous wastes (as per
Hazardous Waste Management Rules)
Yes Hazardous wastes generated from existing & proposed operations are as
per Annexure 10,Pg. 31
4.4 Other industrial process wastes
Yes Fly Ash & Bottom ash will be generated during operation of proposed Coal based thermic fluid heaters, the quantities of which are as Annexure 10,
Pg. 31
4.5 Surplus product No No Surplus product
4.6 Sewage sludge or other sludge
from effluent treatment No
Sewage is treated in existing Sewage treatment plant (STP) at the site. The sewage from toilet blocks of proposed coal based thermic fluid
heater plant would be conveyed to this STP for treatment
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING
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S. No. Information/Checklist
confirmation Yes/ No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
4.7 Construction or demolition wastes Yes
Minimal quantity of debris, scrap, excavated soil, used cement bags, iron / steel scrap and cardboard waste could be generated during
construction.
Demolition activity is not applicable.
4.8 Redundant machinery or
equipment No
None
4.9 Contaminated soils or other
materials No
Not Applicable
4.10 Agricultural wastes No Not Applicable
4.11 Other solid wastes No Fly ash and Bottom Ash would be generated as per details in Sr. No. 4.4
above.
5. Release of pollutants or any hazardous, toxic or noxious substances to air(kg/hr)
S. No. Information/Checklist
confirmation Yes/ No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
5.1
Emissions from combustion of fossil fuels from stationary or
mobile sources
Yes Due to combustion of Coal in proposed Coal based Thermic Fluid heaters
(as and when these are operational)
5.2 Emissions from production
processes
No Emissions from Existing and Proposed sources are vide Annexure 5, Pg. 20. Emission Estimate and Pollution Load table is given in Annexure 6.
5.3 Emissions from materials handling
including storage or transport
Yes Minor emissions from Truck movement & coal handling.
5.4 Emissions from construction activities including plant and
equipment
Yes Emission from diesel operated concrete mixers and excavators. However these equipment will be maintained properly to ensure minimum
emissions and vehicles with PUC certificate will be used. Dust emission due to earth moving machinery.
5.5
Dust or odours from handling of materials including construction materials, sewage and waste
Yes
Dust:
Coal Handling: Covered coal storage area, closed conveyor belt as well as water sprinkling system will be provided to control dust emission.
Truck Movement: Coal will be transported in truck covered by tarpaulin and water will be sprinkled on truck movement road.
Dust will be generated during handling of construction materials, this will be controlled by sprinkling of water.
Sewage:
Sewage will be disposed STP for further treatment
5.6 Emissions from incineration of
waste
No Not Applicable
5.7 Emissions from burning of waste in
open air (e.g. slash materials, construction debris)
No Not Applicable
5.8 Emissions from any other sources No None envisaged
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S. No. Information/Checklist
confirmation Yes /
No Details thereof (with approximate quantities / rates, wherever possible) with source of information data
6.1 From operation of equipment e.g. engines, ventilation plant, crushers
Yes
Noise:
Noise will be generated from operation of coal crushers, boilers, TFH, air blowers, plant machineries, etc. Adequate enclosures and
necessary PPE will be provided to exposed employees
6.2 From industrial or similar processes Yes Noise shall be generated from crushers, fans, etc. during operation
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING
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S. No. Information/Checklist
confirmation Yes /
No Details thereof (with approximate quantities / rates, wherever possible) with source of information data
phase.
6.3 From construction or demolition Yes During construction phase, noise will be generated due to dumpers,
rollers, truck movement etc.
6.4 From blasting or piling No Not Applicable
6.5 From construction or operational
traffic Yes
During construction and operational phase noise will be generated due to trucks and other vehicles.
6.6 From lighting or cooling systems No No emissions of light or cooling system is envisaged.
6.7 From any other sources No Not Applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers,
surface waters, groundwater, coastal waters or the sea
S. No. Information/Checklist
confirmation
Yes
/ No
Details thereof (with approximate quantities / rates, wherever possible) with source of information data
7.1 From handling, storage, use or spillage of hazardous materials
No
Proper care for handling of hazardous material will be taken as per the MSIHC rules & HW management Rules. Moreover all of the
hazardous wastes are disposed as per guidance of State Pollution Control Board. Same will be continued after installation of proposed
Coal based Thermic Fluid Heaters.
7.2
From discharge of sewage or other effluents to water or the land (expected mode and place of
discharge)
No Sewage generated from toilet blocks of proposed Coal based
Thermic fluid heater will be conveyed to existing STP for treatment & further disposal.
7.3 By deposition of pollutants emitted to
air into the land or into water No
As pollutants would be released less than the permitted levels as well as Fly ash would be stored in silos & bottom ash will be
collected in pit having HDPE lining.
7.4 From any other sources No None identified.
7.5
Is there a risk of long term build-up of pollutants in the environment from
these sources? No
Adequate mitigation measures, monitoring and periodic maintenance of equipment’s will ensure no risk of long term build-
up of pollutants in the environment.
8. Risk of accidents during construction or operation of the Project, which could affect human health or
the environment
S. No. Information/Checklist
confirmation Yes /
No Details thereof (with approximate quantities / rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc.
from storage, handling, use or production of hazardous substances
Yes The associated hazard from the plant is fire in coal storage yard.
8.2 From any other causes Yes
Common risks in factories such as Electric Shock, Hit by Objects, Fall / Slips, Hot Work such as Welding and Cutting & during
maintenance activities.
8.3
Could the project be affected by natural disasters causing
environmental damage e.g. floods, earthquakes, landslides, cloudburst
etc)?
Yes
Site falls under the seismic intensity Zone III, which is classified as Moderate Damage Risk Zone. Thus, suitable seismic coefficients
accordingly shall be adopted while designing the structures to make it earthquake resistant.
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9. Factors which should be considered (such as consequential development) which could lead to
environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
S. No. Information/Checklist
confirmation Yes /
No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
9.1
Lead to development of supporting Facilities, ancillary development or
development stimulated by the project which could have impact on the environment e.g.: supporting
infrastructure (roads, power supply, waste or waste water treatment,
etc.) housing development extractive industries supply industries, (other)
Yes
The installation of proposed coal based thermic fluid heater would result in economic plant operations, better / rationalised use of
natural resources
9.2
Lead to after-use of the site, which could have an impact on the
environment No Not Applicable
9.3 Set a precedent for later
developments No
Not Applicable
9.4
Have cumulative effects due to proximity to other existing or planned
projects with similar effects No
Very negligible cumulative effect, as adequate mitigation measures will be provided.
III Environmental Sensitivity
S. No. Areas Name / Identity
Aerial Distance (within 15 km) of the proposed project location boundary
10.1
Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other
related value
None No such areas reported
10.2
Areas which are important or sensitive for ecological reasons - Wetlands, watercourses
or other water bodies, coastal zone, biospheres, mountains, forests
None No such areas reported
10.3
Areas used by protected, important or sensitive species of flora or fauna for
breeding, nesting, foraging, resting, over wintering, migration
None No such areas reported
10.4 Inland, coastal, marine or underground waters None No such areas reported
10.5 State, National boundaries None No such areas reported
10.6 Routes or facilities used by the public for
access to recreation or other tourist, pilgrim areas
None No such areas reported
10.7 Defence installations None No such areas reported
10.8 Densely populated or built-up area None No such areas reported
10.9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship,
community facilities) None
Primary health centres, primary schools, hospitals, worship places etc. are located within
15 km
10.10
Areas containing important, high quality or scarce resources (ground water resources,
surface resources, forestry, agriculture, fisheries, tourism, minerals)
None No such areas reported
10.11 Areas already subjected to pollution or
environmental damage. (Those where existing legal environmental standards are exceeded)
None No such areas reported
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S. No. Areas Name / Identity
Aerial Distance (within 15 km) of the proposed project location boundary
10.12
Areas susceptible to natural hazard which could cause the project to present
environmental problems (earthquakes, subsidence, landslides, erosion, flooding or
extreme or adverse climatic conditions)
None No such areas reported
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Annexure 1: General and Specific Location Map
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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Annexure 2: Project Boundary Map on Google Earth
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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Co-ordinates of Site Boundary
POINT LATITUDE LONGITUDE
A 22°27'29.47"N 73°14'5.87"E
B 22°27'32.89"N 73°13'57.77"E
C 22°27'34.42"N 73°13'55.93"E
D 22°27'54.39"N 73°13'54.53"E
E 22°27'59.80"N 73°14'29.29"E
F 22°28'5.45"N 73°14'46.11"E
G 22°27'55.02"N 73°14'47.51"E
H 22°27'47.22"N 73°14'47.81"E
I 22°27'36.33"N 73°14'49.00"E
J 22°27'33.67"N 73°14'36.13"E
K 22°27'33.17"N 73°14'17.37"E
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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Annexure 3: Plant Layout map
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
17
Layout map of Thermic Fluid Heater
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
18
Annexure 4: Existing Effluent Treatment Plant (ETP) Details
Brief Description of the Effluent Treatment Plant: - Wastewater coming from the plant including proposed coal fired thermic fluid heater is collected in equalization tank where it is equalized and is transferred to the CPI oil separator tank. This separated oil is collected in oil collection tank and the effluent flows by gravity to the DAF unit. In this DAF unit polyelectrolyte is dosed. The effluent from this unit is taken by gravity to the aeration tank where diffused aeration system is provided. The effluent from aeration tank goes into the secondary clarifier where settling time is given for settling of the sludge. The sludge from the clarifier is taken to the sludge drying bed. The clarified effluent is taken to the polishing sump where DM water regeneration and cooling water blow down is mixed. Here either acid or alkali is dosed. This polished effluent is transferred to guard pond from where this treated effluent is used for gardening and plantation. Details of Effluent Treatment Plant units Name and size of all units:-
Sr. No. Name of unit Size of unit in meters
[(L x B ) / Dia. x SWD x TD]
1. Equalization / Panic Pond 15.1 sq. x 15.1 x 3.65
2. CPI Oil Separator Tank 5.0 x 2.50 x 2.6
3. Oil Collection Tank 0.8 Dia. x 1.4 h
4. DAF Unit 2.0 Dia. x 1.5h
5. Aeration Tank 7.0 sq. x 7.0 x 2.8
6. Secondary Tank 4.0 Dia. x 2.7h
7. Polishing Sump 2.6 sq. x 2.6 x 1.8
8. Guard Pond (2 Nos.) 24.8 x 10.5 x 2.8
9. Sludge Drying Bed (4 Nos.) 4.0 x 2.5 x 1.1
NOTE: L – Length TD – Total Depth Dia. – Diameter B – Breadth SWD – Side Water Depth
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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ETP FLOW DIAGRAM:
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
20
Annexure 5: Air Emission details (Existing and Proposed)
Air emissions from stationary sources are provided below: Table 1-1 Details of Stacks APCM attached to Flue Gas Stacks
Sr.
No. Stack Attached to
Stack Height
(m)
Stack Diameter
(m)
Exit Velocity (m/sec)
Pollutants Air Pollution
Control measures
Flue Gas Stacks (Existing)
1. Boilers (2 nos.) 75 1.85 6.28
Particulate Matter, SOX, NOX
--
2. Pacol Charge Heater & Hot
Oil Heaters 89 5.23 10 --
3. Hot Oil Heaters 76 2.86 9.2 Ultra Low NOX
burners
4. Union Finning Charge
Heaters 35 1.00 8.50 --
5. Reformer Furnace 32 0.65 5.0 --
6. D.G. Set (stand by) 17 0.50 15.0 --
Flue Gas Stacks (Proposed)
1 Thermic Fluid Heater - 1
63.5 1.8 9
PM, SO2, NOX
ESP with minimum three Fields for PM;
Tower type wet scrubber for SO2 &
NOX
2 Thermic Fluid Heater - 2
3 Thermic Fluid Heater – 3
(stand-by)
4 Thermic Fluid Heater - 4
70 2.0 10
5 Thermic Fluid Heater - 5
6 Thermic Fluid Heater - 6
7 Thermic Fluid Heater –
7(Stand-by)
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
21
Annexure 6: Pollution Load Statement
In our proposal, there is no increase in production capacity as well as in pollution load in comparison to existing permissible limits. Our proposal is to use coal as alternate fuel along with
FO/NG. As form of fuel is solid, we need to install the solid base Thermic Fluid Heaters (TFH). Details of Thermic Fluid Heaters are given in Annexure-5 of Form-1.
When these proposed coal fired thermic fluid heaters will be in operation, our existing Hot Oil Heaters which are mentioned in Annexure-5 of form-1 will be in standby mode and when our
existing FO/NG based Hot Oil Heaters will be in operation, our proposed Coal based Thermic Fluid Heaters will be in standby mode. So, in no case existing FO/NG based Hot Oil Heaters and
proposed Coal Fired Thermic Fluid Heaters will be in operation in parallel.
Pollution Load - Actual (as per fuel specifications)
S. NO.
Parameter Unit
Fuel (Either FO/LSHS or NG or Coal will be used)
FO/LSHS NG Coal
1 SO2 kg/day 1919 9.9 752
2 PM kg/day 50.1 1.0 235.5
3 NOx kg/day 1670 1670 330
Total kg/day 3639 1681 1318
Total (As per EC dated 03.08.2007) kg/day 4239.11
Pollution Load - As per GPCB Norms
S. NO.
Parameter Unit
Fuel (Either FO/LSHS or NG or Coal will be used)
FO/LSHS NG Coal
1 SO2 kg/day 4712 4712 932
2 PM kg/day 2700 2700 534
3 NOx kg/day 1694 1694 335
Total kg/day 9105 9105 1800
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
22
Seismic Map of Gujarat
Break up of Seismic Zones: Zone II: Least Active Seismic Zone Zone III: Moderate Seismic Zone Zone IV: High Seismic Zone Zone V: Highest Seismic Zone
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
23
Annexure 7: Precess description of Thermic Fluid Heaters
Coal fired Thermic Fluid Heaters (Proposed)
In order to fulfil the heat requirement of the process, there are two hot oil heaters, two process heaters, one reformer and two boilers. One of the process heater viz. Pacol Charge Heater is
connected to hot oil heater, resulting into a common stack.
It is intended to add Coal Fired Thermic Fluid Heaters (CFTFH) as a substitute for Hot Oil Heaters
(HOH). Coal fired thermic fluid heaters are available in smaller sizes i.e. 10, 11, 12, & 15 mmKcal/Hr capacity and are used in multiples as per the need. HOH (new) shall require three
units of 12 mmKCal /Hr capacity whereas the other HOH shall require four units of 12 mmKCal/Hr capacity. A total of 7 nos. of coal fired heaters would be required. There will be two stacks taking
care of the flue gases generated.
PROCESS:
Coal fired thermic fluid heaters are used to heat the thermic fluid to the desired temperature. This heated thermic fluid is used as heating medium in various exchangers.
Coal fired thermic fluid heaters unit consist of the following:
1. Coal handling:
i. Crushers ii. Conveyer
iii. Bucket elevator
iv. Vibrating screen 2. Furnace
i. Fuel bunkers ii. Firing & combustion chamber
iii. Radiation & convection section iv. Air pre heater
v. Pollution control equipment vi. ID & FD fan
vii. Stack
3. Ash handling i. Dense phase Pneumatic fly ash handling system.
ii. Ash storage silo
1. Coal handling:
Coal is collected and its size is reduced in crushers & particles are sieved in vibrating
screens and from there it is conveyed to fuel bunkers through bucket conveyors.
2. Furnace: It consists of the following loops,
2.1 Combustion air & flue gas.
2.2 Thermic fluid. 2.3 Fuel firing.
2.1 Combustion air & flue gas. Air is drawn from atmosphere through FD fan and it is preheated in APH and fed to
furnace for fuel fluidization and combustion. Flue gas which is coming from furnace convection section exchange the heat with
cold air in APH and passed through pollution control equipment (Electrostatic precipitator or bag house, etc.,). It is transported from pollution control equipment to
stack through ID fan.
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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2.2 Thermic fluid Thermic fluid from thermic fluid circulation pump is passed through furnace (tubes)
and it is heated in furnace to desired temperature and sent to plant. From the plant it returns to thermic fluid surge drum and from thermic fluid surge drum it is pumped to
furnace through thermic fluid pumps.
2.3 Fuel firing Coal is conveyed to fuel bunkers from here it is fed to fluidized bed of furnace and
where combustion takes places. Heat delivered by combustion is absorbed by thermic
fluid flowing through tubes. Further, flue gases travels to convection section and heat is transferred to thermic
fluid flowing through tubes in convection section.
3. Ash Handling:
Dense phase ash is collected by pneumatic dense ash collection system from APH, & ESP. From there it is collected in ash silos.
Bed ash is also collected from fluidized bed.
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
25
Figure 1-1: Block Diagram of Pacol Enhancement Process
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
26
Annexure 8: Analysis of Alternative Sites
Alternative sites are not identified since there is sufficient land available in existing facility of Nirma Ltd. – LAB plant. Further, the proposed Coal based heaters are part of the utilities for the existing LAB plant.
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
27
Annexure 9: Water Supply Agreement Letter from Irrigation Department
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
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NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
29
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
30
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
31
Annexure 10: Hazardous Waste & Solid Waste Details
Hazardous waste Details:
NIRMA LTD. - ALINDRA EC AMENDMENT FOR FUEL CHANGE IN THERMIC FLUID HEATERS IN
EXISTING LAB PLANT AT NIRMA LTD., ALINDRA ANNEXURES
32
Sr. No Waste# Category Quantities (MT/Year)
Disposal Existing Proposed Total
1. Adsorbent 1.6 79 0 79
Disposal by selling to registered/ Ms. Nandesari Environment Control Ltd.
(NECL)-TSDF
2. Spent Catalyst 1.6 46.53 0 46.53 Disposal by selling to authorised recyclers
3. Used Spent Oil 5.1 6.8 2.5 9.3 Disposal by selling to authorized recyclers
4. Discarded Container
33.3 5 0 5 Decontamination within
factory premises.
5. ETP Sludge I-34.3 17.04 0 17.04
Disposal to Ms. Nandesari Environment Control Ltd.
(NECL)-TSDF
6. Spent Clay 35.1 10 0 10 Disposal to Ms. Nandesari Environment Control Ltd.
(NECL)-TSDF
7. Inorganic Acid II-B15 12,000 0 12,000 Disposal at M/s. Nirma
Limited, Moraiya, Ta: Sanand
#: As per the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016. Solid Waste Details
Waste Name Quantities Generated (MTPD) Disposal
Fly Ash 16 Will be sold to Brick manufacturing unit/ Block manufacturing unit. Bottom Ash 72
Scrubber Sludge 4 used as a filler material in detergent plant