gpcb.gujarat.gov.in...From: [email protected] Date: 25 December 2017 at 3:05:47 PM IST To:...

From: [email protected]

Date: 25 December 2017 at 3:05:47 PM IST

To: [email protected]

Cc: [email protected]

Subject: Acceptance Letter for TOR Application

Acceptance Letter for TOR application

F.No.- IA-J-11011/560/2017-IA-II(I)

Ministry of Environment, Forests and Climate Change

Government of India

Indira Paryavaran Bhawan

Jor Bagh Road, Jor Bagh

New Delhi-110003

Dated: 25 Dec 2017

To,

Mr. Ashish Desai

Ahmedabad, Bhavnagar

Gujarat , 380009

Subject : Expansion in Soda Ash (2,800 TPD to 4,300 TPD), Caustic Soda (750 TPD to 1,000

TPD) and Captive Power Plant (197.18 MW to 350 MW) at Existing Facility of Nirma Ltd.,

Kalatalav, Near Bhavnagar, Gujarat

Sir,

This has reference to your proposal No. IA/GJ/IND2/71426/2017 dated 06 Dec 2017

regarding grant of TORs for the above mentioned proposal.

2.0 This is to acknowledge that the proposal has been received in the Ministry along with Form

1 and pre-feasibility report. You are requested to submit a hard copy (signed) of the documents

in the Ministry(at the address given below) within a week, along with email alert genereated by

the system(through speed post).

Address:

Section Officer, 3rd floor, Vayu wing, Indira Paryawaran Bhawan, Jor Bagh Road, Jor Bagh,

New Delhi-110003

3.0 The proposal shall be included in the agenda for its consideration by the EAC for grant of

TORs after receipt of the hard copy along with email alert. The hard copy of the same can also

mailto:[email protected]



be submitted by hand in the Ministry in between 3PM to 4PM on each working day. You are

requested to visit website of the Ministry at http://environmentclearance.nic.in to check its

inclusion in the agenda. Once the proposal is included in agenda for a meeting, you may

circulate hard copies of documents to the Chairman and Members of EAC within a week of

uploading of agenda on Ministry’s portal.

Yours Sincerely

Member Secretary

Note: ***This is an automatically generated email, please do not reply***

http://environmentclearance.nic.in/

NIRMA LIMITED PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE

POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR BRIEF SUMMARY

Kadam Environmental Consultants | November, 2017 1

1 BRIEF SUMMARY

Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the

production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl

Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt and consumer salt to facilitate

quality production of their consumer products.

It is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District Bhavnagar, Gujarat.

Nirma Limited, Bhavnagar now proposes for modernization with expansion of their existing production plant

capacity.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category

including Project / Activity: 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant, 1(d) - Captive Power Plant and

categorized under “A”.

1.1 Plant Features and Production Capacity

Existing cost of project is INR 3,110 crores. The expected cost of the proposed expansion project will be around

INR 1,320 crores. Details of existing and proposed products are listed in Table 1-1.

Table 1-1: Products Capacity (Existing & Proposed)

Sr.

No. Products/By-Products Units

Existing

Capacity Proposed

Total Capacity after

Expansion

1 Soda Ash Plant

A Light Soda Ash TPD 2,800 1,500 4,300

B Dense Soda Ash TPD 1,800 600 2,400

C Refined Sodium Bicarbonate (RBC)

(NOC) TPD 400 0 400

D Pure Water Plant M3/D 6,720 0 6,720

E Vacuum Salt TPD 2,400 0 2,400

2 Caustic Soda Plant

A Product

Caustic Soda (100%) TPD 750 250 1,000

Hydrochloric Acid (100%) TPD 280 220 500

B By-Products

Chlorine Gas (100%) TPD 665.2 220.8 886

Hydrogen (100%) TPD 18.75 6.25 25

Sodium Hypo Chlorite (100%) TPD 12 3 15

3 Captive Power Plant

Power MW 197.18 152.82 350

4 Chlorine & Hydrogen Derivatives

A Hydrogen Peroxide (100%) TPD 84 0 84

B Epichlorohydrin (ECH) TPD 150 0 150

C Glycerin TPD 160 0 160

D Mono Chloro Acetic Acid (MCAA) TPD 120 0 120

By-Products





Sr.


Existing

Capacity Proposed


Expansion

Mother Liquor of MCAA TPD 30 0 30


Product

E Tricolor Acetyl Chloride (TCAC) TPD 10 0 10

By-Product



Sodium Bisulfite Solution (100%) TPD 3 0 3

F Calcium Chloride (100%) (NOC) TPD 152 0 152

Calcium Chloride Granules TPD 160 0 160

By-Product

CO2 Gas TPD 60 0 60

Solid CO2 (Dry Ice) & / or Liquid CO2 TPD 60 0 60

G Phosphoric Acid (61.5% P2O5) (NOC) TPD 100 0 100

5 Toilet Soap Plant

Toilet Soap TPD 200 0 200

Detergent Powder TPD 414.66 0 414.66

Detergent Cake TPD 414.66 0 414.66

Fatty Acid TPD 150 0 150

Glycerin TPD 167 0 167

6 Bromine Plant

Bromine TPD 20 0 20

1.2 Infrastructure

The proposed expansion would be implemented in Nirma Ltd.’s existing manufacturing facility at Kalatalav, near

Bhavnagar, Gujarat.

Main components of the existing project which includes Captive Power Plant, Soda Ash Plant, Caustic Soda Plant,

Chlorine and Hydrogen derivatives plant, , Toilet soap plant and Bromine Plant and their associated utilities /

components like Boiler House of CFBC Boilers, Steam Turbine, Generator, Utility Area consisting of cooling tower,

ESP section Fly ash storage area. Water & wastewater infrastructure like Effluent Treatment Plant (ETP), Air

compressors & Hazardous storage facility area are being used.

1.3 Utility

Power: The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH ,

total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.

* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as

540 TPH.

Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.

Fuel: Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr

for existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.




Raw Water: Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater

intake – 14 x 105 m3/day. Additional seawater intake - 3.6 x 105 m3/day.

Manpower: Existing manpower at the operational site is 1,630 nos. Manpower during Construction phase would

be 150 nos. The manpower for operation phase of Expansion plants would be 100 nos. Thus, the total manpower

during full operation phase of Nirma-Kalatalav complex will be approximately 1,730 nos.

1.4 Environment

Environmental issues associated with proposed units are:

Air Emissions: These would be due to presence of various Flue Gas stacks and process vents.

Wastewater: The wastewater generated from the proposed activities would be treated in Effluent treatment

plant. The treated effluent would be discharged into the Gulf of Khambhat through existing outfall equipped

with diffuser system.

Solid & Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per

the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016.

1.5 Sensitivity

Project boundary is well beyond minimum distance of 500 m from CRZ boundary. About 6.5 km in North (Gundala

Creek), 6.0 km East side (Malcolm Channel), and 3.0 km in the South direction (Bhavnagar Creek). Project site falls

in Zone-III of Seismicity. Civil and Structures shall be designed according to applicable code. It is 6.0 km from

Malcolm Channel (Gulf of Khambhat) thus susceptible to natural hazards like cyclone/storm etc.

1.6 Conclusion

There is no adverse impact on the water environment due to the operation of the project. The air environment has

negligible effect due to the activities related to the operation of the project.

After implementation of pollution control measures there will be no emission from the plant beyond the norms

specified by Gujarat Pollution Control Board (GPCB). The project is not contributing to any adverse impact on the

surrounding soil, as the pollutants emitted are of the negligible amount.

Project intends to generate employment for local people and unskilled / semiskilled workers during construction

phase. If this project comes up, it will have social, financial benefits and will be environmentally sustainable.

Pre-feasibility study confirms viability of the project.

12/26/2017 Report Part 1

http://environmentclearance.nic.in/auth/FORM_A_PDF.aspx?cat_id=IA/GJ/IND2/71426/2017 1/10

APPENDIX I(See Paragraph-6)

FORM 1

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

(I) Basic InformationS.No. Item Details

Whether it is a violation case andapplication is being submitted underNotification No. S.O.804(E) dated14.03.2017 ?

No

1.

Name of the Project/s

Expansion in Soda Ash (2,800 TPD to 4,300 TPD), CausticSoda (750 TPD to 1,000 TPD) and Captive Power Plant(197.18 MW to 350 MW) at Existing Facility of Nirma Ltd.,Kalatalav, Near Bhavnagar, Gujarat

Brief summary of project Annexure-Brief summary of projectProposal Number IA/GJ/IND2/71426/2017Project Cost (in lacs) 132000

2.S. No. in the schedule 4(d) Chlor-alkali industry

4(e) Soda ash Industry Project Sector Industrial Projects - 2

3.Proposed capacity/area/length/tonnage tobe handled/command area/leasearea/number or wells to be drilled

vide Annexure-4 attached ha.

4. New/Expansion/Modernization ExpansionProposal Number IA/GJ/IND2/71425/2014MoEFCC file number(Previous EC) j-11011/Uploaded EC letter Annexure-Uploaded EC letter

5. Existing Capacity/Area etc. 2249458 ha.

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

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

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

9.Location of the project General Location is provided in Annexure 1. Site Boundary is

shown in Annexure 2. Toposheet is shown in Annexure 3Shape of the project land Block (Polygon)

Uploaded GPS file Annexure-GPS file Uploaded copy of survey of IndiaToposheet Annexure-Survey of india toposheet

Plot/Survey/Khasra No. Survey No. 478/p, 447 - 453, 455 - 457Town / Village KalatalavState of the project Gujarat

Details of State of the project

S.no State Name District Name Tehsil Name

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Dec_2017_16515732728R4RPHOBriefSummary.pdf

http://environmentclearance.nic.in/writereaddata/Form-1A/EC/05_Dec_2017_165157310F4VR513HPrivious_EC.PDF

http://environmentclearance.nic.in/auth/Testmap1.aspx?type=ca&fname=05_Dec_2017_165543927S9FZEKQPNIRMALTDkml.kml&proposalno=IA/GJ/IND2/71426/2017

http://environmentclearance.nic.in/download.aspx?files=writereaddata/Online/TOR/05_Dec_2017_165543927S9FZEKQPNIRMALTDkml.kml

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Dec_2017_165157323F4VR513HToposheet.pdf



(1.) Gujarat Bhavnagar Bhavnagar

10.Nearest railway station along with distancein kms Bhavnagar Railway Station, 10 km

Nearest airport along with distance in kms Bhavnagar, 10 km

11. Nearest Town/City/District Headquartersalong with distance in kms Bhavnagar (District Headquarter) , 9.0 km

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

Panchayat: Sarpanch, Kalatalav Zilla Parishad: DistrictDevelopment Office, District Panchayat, Bhavnagar –364001 Phone No. 0278-2426810 Municipal Corporation:District Collector Office, Opp. Galaxy Cinema, Kalanala,Bhavnagar – 364001 Phone n

13. Name of the Applicant Mr. Ashish Desai

14. Registered Address Nirma Ltd. Nirma House, Ashram Road, Nr. Income Taxoffice, Ahmedabad

15.

Address for correspondance:Name of the Company Mr. Ashish DesaiName of the Applicant Mr. Ashish DesaiDesignation (Owner/ Partner/ CEO) Vice President (Project)Pin code 380009E-mail [email protected] No. 079-27546565Fax No. 079-27546603Copy of documents in support of thecompetence/authority of the personmaking this application to make applicationon behalf of the User Agency .

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

16. Details of Alternative Sites examined, ifany. Location of these sites should beshown on a toposheet

No

17. Whether part of Interlinked projects? No

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

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

20. If No, Reason N/A

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

No

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

No

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

Yes

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

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

http://environmentclearance.nic.in/writereaddata/Online/TOR/05_Dec_2017_165939117SQLZQDI8Undertaking.pdf



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

No

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

(II) Activity

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

S.NoInformation/Checklist confirmation Yes/No

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

source of information data

1.1

Permanent or temporary change in landuse, land cover or topography includingincrease in intensity of land use (withrespect to local land use plan)

NoNo, there is no permanent or temporary change inland. The proposed expansion is within the existingpremises, which will remain same

1.2 Clearance of existing land, vegetation andbuildings? No

Land is already in use and as this is expansion project.Hence, clearance of existing land, vegetation andbuildings is not required.

1.3 Creation of new land uses? No No additional creation of new land usage as existingplant is already under industrial usage.

1.4 Pre-construction investigations e.g. borehouses, soil testing? No Not required.

1.5 Construction works? YesAs part of the Industrial Project, there will beconstruction of plant machinery, utilities, etc within theexisting facility.

1.6 Demolition works? No Not envisaged

1.7 Temporary sites used for constructionworks or housing of construction workers? No

Most of the construction workers will be hired locallyas far as possible. Sufficient accommodation isavailable at workers colony, hence requirement ofadditional housing is not envisaged.

1.8

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

Yes

Earthworks will involve cut and fill, excavations. It islikely cut and fill quantities will be similar.Consequently it is likely that procurement of soil fromoutside the premises will be minimal if any.

1.9 Underground works including mining ortunneling? 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? YesManufacturing process along with PFD and massbalances are provided in Pre-Feasibility Report, ReferCh-3, Section 3.5

1.14 Facilities for storage of goods or materials? NoOpen storage for Harvested Salt, Limestone, Coke,Coal storage under Shed & Product storage underShed

1.15 Facilities for treatment or disposal of solid Yes The existing total effluent quantity is 5,86,445.2



waste or liquid effluents? m3/day. The effluent quantity due to expansionactivities would be 3,20,189.5 m3/day. Thus, afterexpansion, the total effluent quantity would be9,06,634.7 m3/day. Trade Effluent from expansionactivities will be treated in existing treatment facilitiesand discharged into Gulf of Khambhat by outfall,diffuser system for detail please refer Ch-3, Section3.7.3 of PFR Hazardous waste details and solid wastedetails are attached in Annexure-5

1.16 Facilities for long term housing ofoperational workers? No

Sufficient accommodation available at workers colony,hence requirement of additional housing is notenvisaged

1.17 New road, rail or sea traffic duringconstruction or operation? No Due to proposed project, vehicular movement will be

increased only during construction phase

1.18

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

No No additional transport infrastructure is required dueto the proposed expansion.

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

No It is not required to close or divert existing transportroutes and infrastructure.

1.20 New or diverted transmission lines orpipelines? No No any new or diverted transmission lines are

proposed.

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

No No change in hydrology of water courses/aquifers isenvisaged.

1.22 Stream crossings? No Site does not involve any stream crossing.

1.23 Abstraction or transfers of water fromground or surface waters? Yes

Ground Water No abstraction of ground water isenvisaged. Surface Water/sea water The existing totalwater quantity consumed is 14,06,574.1 m3/day. Thewater quantity required due to expansion activitieswould be 3,60,000 m3/day. Thus, after expansion, thetotal water quantity consumed would be 17,66,574.1m3/day.

1.24 Changes in water bodies or the landsurface affecting drainage or run-off? No Not applicable.

1.25Transport of personnel or materials forconstruction, operation ordecommissioning?

Yes

During construction and implementation of the projectperiod, transport of materials and personnel will bethrough Coastal State Highway No. 6 (Bhavnagar-Ahmedabad) which is at a distance of 14.0 km awayfrom the project site in West direction.

1.26 Long-term dismantling or decommissioningor restoration works? No Proposed expansion does not involve any long term

dismantling or decommissioning or restoration works.

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

No Not envisaged.

1.28 Influx of people to an area in eithertemporarily or permanently? Yes

During the construction phase around 150 workersand existing manpower is sufficient to operateproposed expansion units. Local skilled and semi-skilled workers will be engaged during constructionphase.

1.29 Introduction of alien species? No Not applicable

1.30 Loss of native species or genetic diversity? No No effect on species or generic diversity.

1.31 Any other actions? No Not visualized as required activities will not cause anyphysical changes in the locality.

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):


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


2.1 Land especially undeveloped or agriculturalland (ha) No

The Plot area of the project duly developed, consists of555 acre –Kalatalav Complex. Expansion is proposedwithin area allotted for these plants within KalatalavComplex. The areas of the plants which would undergoproposed expansion activities would be as under:Power plant = 69,100 m2 Soda Ash plant =2,61,548.33 m2 Caustic Soda plant = 2,88,945.55 m2

2.2 Water (expected source & competingusers) unit: KLD Yes

The source of existing water consumption for Nirma –Kalatalav Complex is Sea water through RO /desalination plants. The existing water quantityconsumed is 14,06,574.1 m3/day. The water quantityrequired due to expansion activities would be 3,60,000m3/day. Thus, after expansion, the total waterquantity consumed would be 17,66,574.1 m3/day

2.3 Minerals (MT) Yes During operation phase, coal, coke, pet coke &limestone shall be used based on availability.

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

Construction materials like stones, aggregates, sand,bricks, steel, cement, rubble, etc. will be procuredfrom the local market

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

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

Yes

Electricity: Power is supplied by captive thermal powerplant at the facility. The existing power produced atthe site is 197.18 MW. This is to be increased by152.82 MW. Thus, the total power consumption afterexpansion would be 350 MW. Fuel for Captive PowerPlant: The fuel requirement is attached as Annexure-6.

2.7 Any other natural resources (useappropriate standard units) No Not Envisaged.

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




3.1

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

Yes Hazardous material like FO, HSD, LDO, Chlorine, andCaustic will be used.

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

No Not Applicable.

3.3 Affect the welfare of people e.g. bychanging living conditions? No Not Applicable.

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

No No vulnerable groups live near project 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) withsource of information data

4.1 Spoil, overburden or mine wastes No Not envisaged.

4.2 Municipal waste (domestic and orcommercial wastes) Yes

Municipal Waste Waste paper from administrativebuildings, waste metals, kitchen waste etc. Disposalmethod Waste paper and metal will be given torecyclers, and kitchen waste will be converted intomanure.

4.3 Hazardous wastes (as per Hazardous WasteManagement Rules) Yes Hazardous Waste Generation details are as per table in

Annexure-5.

4.4 Other industrial process wastes No Not Envisaged.

4.5 Surplus product No Not Applicable.

4.6 Sewage sludge or other sludge fromeffluent treatment Yes Details of the same shall be quantified in EIA report.

4.7 Construction or demolition wastes YesMinimal quantity of debris, scraps, excavated soil,used cement bags, iron / steel scrap and cardboardswaste could be generated during construction

4.8 Redundant machinery or equipment No Not applicable.

4.9 Contaminated soils or other materials No Not applicable.

4.10 Agricultural wastes No Not envisaged.

4.11 Other solid wastes Yes Solid Waste Generation details are as per table inAnnexure-5.

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




5.1 Emissions from combustion of fossil fuelsfrom stationary or mobile sources Yes

Flue gas emissions like SPM, SO2 & NOx will be fromstacks attached to boilers. For more details referAnnexure-7.

5.2 Emissions from production processes Yes Process emissions from production process is given inAnnexure 7.

5.3 Emissions from materials handling includingstorage or transport Yes

Dust generation is anticipated from coal storage andash handling. Arrangements for wetting and waterspray / extraction of emission from transfer points willbe provided.

5.4 Emissions from construction activitiesincluding plant and equipment Yes

Emission from diesel operated vehicles, concretemixers and excavators are anticipated. However these

equipment will be maintained properly to ensureminimum emissions and vehicles with PUC certificates

will be used.

5.5Dust or odours from handling of materialsincluding construction materials, sewageand waste

No Not envisaged.

5.6 Emissions from incineration of waste No Not Applicable

5.7Emissions from burning of waste in openair (e.g. slash materials, constructiondebris)

No Not envisaged.



5.8 Emissions from any other sources No None envisaged.

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




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

Noise will be generated from operation of coalcrushers, boilers, turbines, air blowers, plantmachineries, etc. Adequate enclosures and necessaryPPE will be provided to exposed employee

6.2 From industrial or similar processes Yes Noise shall be generated from boilers, compressors,etc. during operation phase.

6.3 From construction or demolition Yes During construction phase, noise will be generated dueto 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 willbe generated due to trucks and other vehicles.

6.6 From lighting or cooling systems Yes Noise will be generation from Cooling tower fans.

6.7 From any other sources No No emissions of light and heat are envisaged.

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




7.1 From handling, storage, use or spillage ofhazardous materials No

Proper care for handling of hazardous material will betaken as per the MSIHC rules & HW managementRules. Moreover all of the hazardous wastes aredisposed as per guidance of State Pollution ControlBoard. Same will be continued after proposedexpansion.

7.2From discharge of sewage or othereffluents to water or the land (expectedmode and place of discharge)

No

Final discharge will be reduced due to recycle andreuse concept. After discharge from Kalatalav facility,the treated effluent is discharged into the Gulf ofKhambhat through an outfall comprising of diffusersystem. The Co-Ordinates of the discharge point are:1. Soda Ash Effluent Discharge - 21050’36.36”N72015’27.06”E 2. Bittern Discharge Point - 21049’39”N72011’44”E

7.3 By deposition of pollutants emitted to airinto the land or into water No Shall be provided with EIA report after air dispersion

modelling using site specific meteorological data.

7.4 From any other sources No None identified.

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

No

Adequate mitigation measures, monitoring andperiodic maintenance of equipment’s will ensure norisk of long term build-up of pollutants in theenvironment.

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



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


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

Yes The associated hazard from the plant is fire in coalstorage yard as well as fuel storages.

8.2 From any other causes YesCommon risks in factories such as Electric Shock, Hitby Objects, Fall / Slips, Hot Work such as Welding andCutting & during maintenance activities.

8.3

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

Yes

Site falls under the seismic intensity Zone III, which isclassified as Moderate Damage Risk Zone. Thus,suitable seismic coefficients accordingly shall beadopted while designing the structures to make itearthquake resistant.

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

S.No Information/Checklist confirmation Yes/NoDetails thereof (with approximate

quantities/rates, wherever possible) withsource of information data

9.1

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

Supporting infrastructure (roads,power supply,waste or waste watertreatment, etc.)housing developmentextractive industriessupply industriesOther

YesThe proposed expansion project will encourageindustrial growth, employment and result in additionalrevenue for government

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

9.3 Set a precedent for later developments No Not Applicable

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

No Very negligible cumulative effect, as adequatemitigation measures will be provided.

(III) Environmental Sensitivity

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

1

Areas protected under internationalconventions, national or local legislationfor their ecological, landscape, cultural orother related value

No No such areas exist within 15 Km radius of theproposed project site.

2

Areas which are important or sensitive forecological reasons - Wetlands,watercourses or other water bodies, coastalzone, biospheres, mountains, forests

Yes Coastal Zone : Project boundary is well beyondminimum distance of 500 m from CRZ boundary.

3 Areas used by protected, important or No --



sensitive species of flora or fauna forbreeding, nesting, foraging, resting, overwintering, migration

4 Inland, coastal, marine or undergroundwaters Yes

Costal/Marine Waters: Gundala Creek : About6.5 km (North) Malcolm Channel : 6.0 km (East),Bhavnagar Creek (Gulf of Khambhat): 3.0 km(South).

5 State, National boundaries No ---

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

YesCoastal State Highway No.6 (Bhavnagar-Ahmedabad) is passing 14 km away from theproject site in West direction.

7 Defence installations No None Identified

8 Densely populated or built-up area YesBhavnagar city is located approx. 10 km (aerial)away from the Kalatalav site of Nirma Ltd. in theSouth direction

9Areas occupied by sensitive man-madeland uses (hospitals, schools, places ofworship, community facilities)

Yes Located within Bhavnagar city

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

No None Identified

11

Areas already subjected to pollution orenvironmental damage.(those whereexisting legal environmental standards areexceeded)

No None Identified

12

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

No

Earthquake: The site falls in Seismic zone III(Moderate Risk) as per Seismic Zone Map ofIndia. Cyclone: It is 6.0 km from MalcolmChannel (Gulf of Khambhat) thus susceptible tonatural hazards like cyclone/storm etc.

(IV) Proposed Terms of Reference for EIA studies

1 Uploaded Proposed TOR File Annexure-TOR file

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

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

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

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

V.(i)

Name of Applicant Mr. Ashish DesaiDesignation Vice President (Project)Name of Company (Applicant Nameshould not be given here) Mr. Ashish Desai

Address Nirma Ltd. Nirma House, Ashram Road, Nr. Income Taxoffice, Ahmedabad

http://environmentclearance.nic.in/writereaddata/Online/TOR/06_Dec_2017_121615250TX618UQ0ProposedToR.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/06_Dec_2017_121615257TX618UQ0CoverLetter.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/06_Dec_2017_121615267G5DUFJNHPFR.pdf

http://environmentclearance.nic.in/writereaddata/Online/TOR/06_Dec_2017_1216152909D73YU0QAnnexures-Form1.pdf



Print

NIRMA LTD. FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND

CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES

ANNEXURES OF FORM 1

Annexure 1: General and Specific Location Map ....................................................................................................... 2

Annexure 2: Project Boundary Map ......................................................................................................................... 3

Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ................................................ 4

Annexure 4: Proposed Product List (Existing & Proposed) ......................................................................................... 5

Annexure 5: Details of Hazardous Waste Generation ................................................................................................ 7

Annexure 6 : Fuel Consumption Details ................................................................................................................... 9

Annexure 7 : Details of Air Emissions .....................................................................................................................10



Annexure 1: General and Specific Location Map

NIRMA LTD. FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT IN

EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 3

Annexure 2: Project Boundary Map

NIRMA LTD. FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT

IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles




Annexure 4: Proposed Product List (Existing & Proposed)

Sr.


Existing

Capacity Proposed


Expansion

1 Soda Ash Plant




(NOC) TPD 400 0 400




A Product

Caustic Soda (100%) TPD 750 250 1,000


B By-Products

Chlorine Gas (100%) TPD 665.2 220.8 886

Hydrogen (100%) TPD 18.75 6.25 25



Power MW 197.18 152.82 350






By-Products




Product


By-Product






By-Product

CO2 Gas TPD 60 0 60



5 Toilet Soap Plant





Sr.


Existing

Capacity Proposed


Expansion





6 Bromine Plant

Bromine TPD 20 0 20




Annexure 5: Details of Hazardous Waste Generation

Sr.

No.

Hazardous

Waste

Category Quantity (MTPA) Mode of Disposal

Existing Proposed Total

A. Soda Ash Division

1. Waste Oil /

Lube Oil

5.1 10 kl 5 kl 15 kl Collection, Storage, Transportation &

disposal by selling to Registered Recyclers

2. Spent ion

exchange

resins

34.2 1,830

lt/year

980

lt/year

2,810

lt/year

Collection, Storage, Transportation,

Disposal by selling to authorized recyclers or sent to NECL

Nandesari

for Incineration.

3. Discarded

Bags /

drums /

containers

etc…

33.3 3.5 2 5.5 Collection, Storage, Transportation, Disposal by selling to

authorized recyclers

B. Caustic Soda Plant

1. Waste Oil /

Lube Oil

5.1 30 kl 10 kl 40 kl Collection, Storage, Transportation &

disposal by selling to Registered Recyclers

2. Spent ion

exchange

resins

34.2 2.56 1 3.56 Collection, Storage, Transportation,

Disposal by selling to authorized recyclers or sent to NECL

Nandesari for Incineration.

3. Discarded

Bags /

drums /

containers

etc…

33.3 4.5 1.5 6 Collection, Storage, Transportation, Disposal by selling to

authorized recyclers

4. Residue/

Sludge

& Filter

sludge

16.2 6,526 2,175 8,701 Collection, Storage, Transportation,

Disposal at TSDF

5. ETP sludge 34.3 150 50 200 Collection, Storage, Transportation,

Disposal at TSDF

6. Spent

Sulphuric

Acid (80%)

D2/II 6,520 2,173 8,693 Collection, Storage, Transportation, reuse

as raw material for Nirma Ltd. Moraiya and

other end users.

Solid Waste Generation Details:-

Sr.

No.

Solid Waste Quantity (MTPA) Mode of Disposal


1. Settling Pond

Sludge

880 482 1,362 Shall be used in road construction, salt works bund preparation

2. Lime stone rejects

/under size

700 375 1,075 Shall be used in boilers for desulphurization in boilers

3. Brine Sludge 19 10 29 Non-hazardous; Shall be dumped in identified area

4. Fly ash / Bottom 2,185 1,693 3,878 Brick manufacturing, bund preparation, road making etc.




ash

5. Incineration Ash 15 0 15 Brick manufacturing, bund preparation, road making etc.

6. Saponification

Solid Waste

3 0 3 Non-hazardous; Shall be dumped in identified area




Annexure 6 : Fuel Consumption Details

Sr.

No.

Fuel Type Quantity (tpd)


1. Coal 7,440 5,766 13,206

2. Lignite 7,584 5,878 13,462

3. Pet Coke 1,200 1680+2232 5,112

4. Limestone 1,625 1,259 2,884

5. Light Diesel Oil (kl/year) 210 163 373

6. HSD (kl/month) 955 740 1,695




Annexure 7 : Details of Air Emissions

Air emissions from stationary sources are provided below:

Table Error! No text of specified style in document.-1 Details of Stacks APCM attached to Flue Gas Stacks

S. No. Stack Attached to Stack Height

(m)

Stack Top

Dia. (m) APCM

Expected

Pollutants*

Existing

Soda Ash Division

1 Boiler - A, B, C & D (100 TPH Each) 100 (Common

Stack) 5.04

ESP to Each

Boiler PM, SO2 & NOx

2 DG Set (1000 KVA)

2 No. 24 each 0.2 -- PM, SO2 & NOx

Caustic Soda & CPP Division

2 Boiler - E (200 TPH) 121 (Common

Stack) 4.5

ESP PM, SO2 & NOx

3 As per EC 2014 Boiler - F (200 TPH) –

Not Installed Yet ESP PM, SO2 & NOx

4

As per EC 2017 Boiler - G & H (350 TPH each

) – Installed One boiler having capacity 410

TPH

121 (Common

Stack) 4.5 ESP PM, SO2 & NOx

5 DG Set (1000 KVA) 30 0.32 - PM, SO2 & NOx

6 DG Set (1500 KVA) 30

0.32

-

PM, SO2 & NOx

7 DG Set (1500 KVA)

Toilet Soap plant

8 Thermic Fluid Heater

(3 No.) 45 0.4 PM, SO2 & NOx

Proposed

Soda Ash Division

1. DG Set (2000 KVA) 30 0.32 -- PM, SO2 & NOx


1 Boiler - I & J (410 TPH + 130 TPH) * 121 (Common


2 DG Set (1850 KVA) 30 0.32 -- PM, SO2 & NOx

* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as 540

TPH.

Table Error! No text of specified style in document.-2: Details of Process Emissions

Sr.

No. Vent Attached to

Stack Height

(m)

Stack Dia.

(m)

Air Pollution Control

System Pollutant

1

Soda Ash Plant – Existing & Proposed

Lime Kilns (A to H) – 8 nos. 68 (Common

Stack) 0.8

4 scrubbers and 3 ESP in

Series PM, SO2, NOx

Ammonia Recovery System (A

to E) 5 No.

56 (Common

Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia

Lime Grinding System A to E (5

nos.) 60 (each) 0.65 Bag Filter PM




Sr.


Stack Height

(m)

Stack Dia.

(m)


System Pollutant

Calcinations Vessel (A to D 4

nos) 29 (each) 0.7 Water Scrubber PM

Densification 1 40 1.37 Water Scrubber PM



Lime Kilns (I to L) – 4 nos.

(Proposed)

68 (Common

Stack) 0.8

Two scrubbers and two

ESP in Series PM, SO2, NOx

Ammonia Recovery System (F

& G) 2 nos. (Proposed)

56 (Common


Lime Grinding System (F 1

nos.) (Proposed) 60 0.65 Bag Filter PM

Calcinations Vessel (E & F 2

nos) (Proposed)

29 (Common

vent) 0.7 Water Scrubber PM

Densification 4 (Proposed) 51 1.37 Water Scrubber PM

2

Caustic Soda and CPP - Existing & Proposed

HCl Synthesis Unit – 1 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit - 2 30 0.1 Water Scrubbers HCl & Cl2



HCl Synthesis Unit – 5

(Proposed) 30 0.1 Water Scrubbers HCl & Cl2

Waste Gas Dechlorination

System - 1 30 0.3 18% NaOH Scrubber Cl2




System – 3 30 0.3 18% NaOH Scrubber Cl2

Hydrogen unit with Flame arrestor and steam snuffing –

1 30 -- -- --

Hydrogen unit with Flame

arrestor and steam snuffing –

2

30 -- -- --



3

30 -- -- --

3. Bromine Plant

De-bromination System 30 0.3 Alkali Scrubber Bromine

4.

Chlorine & Hydrogen Derivatives

Solvent Recovery 30 0.3 Ceramic + Activated

Carbon Filter Aromatic Solvent

Hydrogenation Plant (purge

gas) 30 0.3

Ceramic + Activated

Carbon Filter

H2 + Aromatic

Solvent

Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,

HCl, TOC




Sr.


Stack Height

(m)

Stack Dia.

(m)


System Pollutant

HCl Synthesis Unit 30 0.1 Water Scrubbers HCl

Chlorination Plant 30 0.3 Acidic/Water Scrubber (3

nos.) SO2, HCl, Cl2

Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2

Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2


gas) 30 0.3 ---- H2

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-6131000

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T:0124-4242430 to 436

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

M/S. NIRMA LIMITED

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat.

NOVEMBER, 2017



NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND

CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL SHEET

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 II

M/S. NIRMA LIMITED

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat. © Kadam Environmental Consultants (‘Kadam’), November, 2017

This report is released for the use of the M/s. NIRMA LIMITED., Regulators and relevant stakeholders solely as part

of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced

third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of

Kadam.

PROJECT DETAILS

Name of

Publication

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex

at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat

Project Number 1730141406 Report No. 1 Version 1 Released November,

2017

Prepared &

Managed By

Tanu Prasad & Bhavin Jambucha, K.K

Antani Released By Sangram Kadam

CONTACT DETAILS



E: [email protected]; T:+91-265-6131000

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana,

INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also

believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss

absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or

application of the information contained in this report. The information is not intended to serve as legal advice related to the

individual situation.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 III

CONTENTS

1 EXECUTIVE SUMMARY ................................................................................................ 1

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 1

1.2 INFRASTRUCTURE ....................................................................................................... 2

1.3 UTILITY ................................................................................................................. 2

1.4 ENVIRONMENT ........................................................................................................... 3

1.5 SENSITIVITY ............................................................................................................. 3

1.6 CONCLUSION ............................................................................................................ 3

2 INTRODUCTION ......................................................................................................... 4

2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT ................................................................. 4

2.1.1 Project Proponent ............................................................................................... 4

2.1.2 Proposed Project ................................................................................................ 4

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................... 4

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION .......................................... 4

2.4 DEMAND & SUPPLY GAP ................................................................................................. 5

2.5 EXPORT POSSIBILITY .................................................................................................... 5

2.5.1 Domestic / Export Market ..................................................................................... 5

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............................................. 5

3 PROJECT DESCRIPTION .............................................................................................. 6

3.1 TYPE OF PROJECT ....................................................................................................... 6

3.2 LOCATION OF THE PROJECT ............................................................................................. 6

3.3 DETAILS OF ALTERNATE SITES CONSIDERED ............................................................................ 8

3.4 SIZE OR MAGNITUDE OF OPERATION.................................................................................... 8

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ....................................................................... 9

3.5.1 Soda Ash (Existing + Expansion) ............................................................................. 9

3.5.2 Caustic Soda (Existing + Expansion) ....................................................................... 10

3.5.3 Captive Power Plant (Existing + Expansion) ............................................................... 12

3.6 UTILITIES .............................................................................................................. 13

3.6.1 Power Requirement ............................................................................................ 13

3.6.2 Fuel Requirement .............................................................................................. 13

3.6.3 Water Requirement ............................................................................................ 13

3.6.4 Storage Details ................................................................................................. 13

3.7 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 13

3.7.1 Air Emissions & Control ....................................................................................... 13

3.7.2 Noise Generation ............................................................................................... 16

3.7.3 Waste Water Generation ...................................................................................... 16

3.7.4 Hazardous Waste & Other Solid Waste ..................................................................... 17

4 SITE ANALYSIS ........................................................................................................ 20

4.1 CONNECTIVITY ......................................................................................................... 20

4.1.1 By Road .......................................................................................................... 20

4.1.2 By Rail ........................................................................................................... 20

4.1.3 By Air ............................................................................................................ 20

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 20


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 IV

4.3 TOPOGRAPHY ........................................................................................................... 20

4.4 EXISTING INFRASTRUCTURE ............................................................................................ 20

4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 20

4.5.1 Soil Classification ............................................................................................... 20

4.5.2 Geology .......................................................................................................... 20

4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 21

4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 21

5 PLANNING BRIEF ..................................................................................................... 22

5.1 PLANNING CONCEPT .................................................................................................... 22

5.2 LANDUSE PLANNING .................................................................................................... 22

5.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 22

5.4 AMENITIES/FACILITIES ................................................................................................. 22

6 PROPOSED INFRASTRUCTURE ................................................................................... 23

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 23

6.2 NON- PROCESSING AREA ............................................................................................... 23

6.3 GREENBELT ............................................................................................................. 23

6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 23

6.5 CONNECTIVITY ......................................................................................................... 23

6.6 DRINKING WATER MANAGEMENT ...................................................................................... 23

6.7 SEWAGE SYSTEM ....................................................................................................... 23

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 23

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 24

7 REHABILITATION AND RESETTLEMENT (R&R) PLAN ..................................................... 25

8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................... 26

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 26

8.2 ESTIMATED PROJECT COST ............................................................................................ 26

8.2.1 Profitability ...................................................................................................... 26

9 ANALYSIS OF PROPOSAL .......................................................................................... 27

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 27


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR LIST OF ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 V

ANNEXURES

Annexure 1: Preliminary Site Layout Map ......................................................................................................... 29

Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ......................................... 30

Annexure 3: Long Term Meteorological Data for Bhavnagar City ........................................................................ 31


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR LIST OF TABLES

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER, 2017 VI

LIST OF TABLES

Table 1-1: Products Capacity (Existing & Proposed) ............................................................................................1

Table 2-1: Products Capacity .............................................................................................................................4

Table 3-1: Co-ordinates of Site Boundary ...........................................................................................................8

Table 3-2: Area Statement* ..............................................................................................................................8

Table 3-3: Details of Stack Emissions ............................................................................................................... 14

Table 3-4: Details of Process Emissions ............................................................................................................ 14

Table 3-5: Wastewater Generation Details ........................................................................................................ 16

Table 3-6: Solid Waste Generation & Disposal................................................................................................... 17

Table 3-7: Hazardous Waste Generation and Disposal ....................................................................................... 18

Table 6-1: Identification of Other Wastes ......................................................................................................... 24

Table 8-1: Tentative Project Time Schedule ...................................................................................................... 26

Table 8-2: Breakup of Project Cost .................................................................................................................. 26

LIST OF FIGURES

Figure 3-1: General Location of Proposed Project Site .........................................................................................6

Figure 3-2: Specific Map Showing Project Boundary ............................................................................................7

Figure 3-3: Process Flow Diagram - Soda Ash Manufacturing Process ................................................................. 10

Figure 3-4: Process Flow Diagram - Caustic Soda Manufacturing Process ............................................................ 12


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY



Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt and consumer salt to facilitate

quality production of their consumer products.

It is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District Bhavnagar, Gujarat.

Nirma Limited, Bhavnagar now proposes for modernization with expansion of their existing production plant

capacity.




1.1 Plant Features and Production Capacity

Existing cost of project is INR 3,110 crores. The expected cost of the proposed expansion project will be around

INR 1,320 crores. Details of existing and proposed products are listed in Table 1-1.

Table 1-1: Products Capacity (Existing & Proposed)

Sr.


Existing

Capacity Proposed


Expansion

1 Soda Ash Plant




(NOC) TPD 400 0 400




A Product

Caustic Soda (100%) TPD 750 250 1,000


B By-Products

Chlorine Gas (100%) TPD 665.2 220.8 886

Hydrogen (100%) TPD 18.75 6.25 25



Power MW 197.18 152.82 350






By-Products






Sr.


Existing

Capacity Proposed


Expansion


Product


By-Product






By-Product

CO2 Gas TPD 60 0 60



5 Toilet Soap Plant






6 Bromine Plant

Bromine TPD 20 0 20

1.2 Infrastructure

The proposed expansion would be implemented in Nirma Ltd.’s existing manufacturing facility at Kalatalav, near

Bhavnagar, Gujarat.

Main components of the existing project which includes Captive Power Plant, Soda Ash Plant, Caustic Soda Plant,

Chlorine and Hydrogen derivatives plant, , Toilet soap plant and Bromine Plant and their associated utilities /

components like Boiler House of CFBC Boilers, Steam Turbine, Generator, Utility Area consisting of cooling tower,

ESP section Fly ash storage area. Water & wastewater infrastructure like Effluent Treatment Plant (ETP), Air

compressors & Hazardous storage facility area are being used.

1.3 Utility

Power: The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH ,



540 TPH.


Fuel: Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr

for existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

Raw Water: Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater

intake – 14 x 105 m3/day. Additional seawater intake - 3.6 x 105 m3/day.




Manpower: Existing manpower at the operational site is 1,630 nos. Manpower during Construction phase would

be 150 nos. The manpower for operation phase of Expansion plants would be 100 nos. Thus, the total manpower

during full operation phase of Nirma-Kalatalav complex will be approximately 1,730 nos.

1.4 Environment

Environmental issues associated with proposed units are:

Air Emissions: These would be due to presence of various Flue Gas stacks and process vents.

Wastewater: The wastewater generated from the proposed activities would be treated in Effluent treatment

plant. The treated effluent would be discharged into the Gulf of Khambhat through existing outfall equipped

with diffuser system.

Solid & Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per

the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016.

1.5 Sensitivity

Project boundary is well beyond minimum distance of 500 m from CRZ boundary. About 6.5 km in North (Gundala

Creek), 6.0 km East side (Malcolm Channel), and 3.0 km in the South direction (Bhavnagar Creek). Project site falls

in Zone-III of Seismicity. Civil and Structures shall be designed according to applicable code. It is 6.0 km from

Malcolm Channel (Gulf of Khambhat) thus susceptible to natural hazards like cyclone/storm etc.

1.6 Conclusion

There is no adverse impact on the water environment due to the operation of the project. The air environment has

negligible effect due to the activities related to the operation of the project.

After implementation of pollution control measures there will be no emission from the plant beyond the norms

specified by Gujarat Pollution Control Board (GPCB). The project is not contributing to any adverse impact on the

surrounding soil, as the pollutants emitted are of the negligible amount.

Project intends to generate employment for local people and unskilled / semiskilled workers during construction

phase. If this project comes up, it will have social, financial benefits and will be environmentally sustainable.

Pre-feasibility study confirms viability of the project.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project Proponent & Project

2.1.1 Project Proponent

Nirma is one of the few names - which is instantly recognized as a true Indian brand, which took on mighty

multinationals and rewrote the marketing rules to win the heart of princess, i.e. the consumer.

Nirma, the proverbial ‘Rags to Riches’ saga of Dr. Karsanbhai Patel, is a classic example of the success of Indian

entrepreneurship in the face of stiff competition. Starting as a one-man operation in 1969, today, it has about

15,000+ employee-base and annual turnover is more than 10,000 Crores INR.



Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt, Cement and consumer salt to

facilitate quality production of their consumer products.

2.1.2 Proposed Project

Proposed project is for expansion in Existing Production Capacity.

2.2 Brief Description of nature of the Project

Details of existing and proposed products for which expansion is proposed are listed in Table 2-1.

Table 2-1: Products Capacity

Sr.

No. Project or activity

Capacity (TPD)


Soda Ash Plant (Area = 2,61,548.33 m2)

1. Light Soda Ash Plant 2,800 1,500 4,300

2. Dense Soda Ash* 1,800 600 2,400

Ash * Dense Soda is conversion of Light Soda Ash

Caustic Soda Plant (Area = 2,88,945.55 m2)

1. Caustic Soda (100%) 750 250 1,000

2. Hydrochloric Acid (100%) 280 220 500

Caustic Soda Plant – By Products

1. Chlorine Gas (100%) 665.2 220.8 886

2. Hydrogen (100%) 18.75 6.25 25

3. Sodium Hypo Chlorite (100%) 12 3 15

Captive Thermal Power Plant (Area = 69,100 m2)

1. Captive thermal Power Plant 197.18 MW 152.82 MW 350 MW

2.3 Need for the Project and its Importance to the Country & Region

There is regular use of these products and has demand in local market as well as in export. This will meet the local

demand and generate employment.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2.4 Demand & Supply Gap

Limestone requirement is approximate 5,050 TPD for existing Soda Ash Plant.

Additional approximate 3,964 TPD (2,705 TPD for SA + 1,259 TPD for CPP) is required for proposed Soda Ash

Expansion and desulphurization in Captive Power Plant. Limestone requirement will be met from the limestone

mines located in Junagadh & Porbandar districts as well as imports.

2.5 Export Possibility

2.5.1 Domestic / Export Market

There is regular use of these products and has demand in local market as well as in export. This will meet the local demand, generate employment and generate revenue for government.

2.6 Employment Generation (Direct & Indirect) due to the project

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project




3.2 Location of the Project

Proposed project is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District

Bhavnagar, Gujarat.

Location map showing general location of proposed project is given in Figure 3-1. Specific Map showing project

boundary is given in Figure 3-2. The co-ordinates of the project site are given in Table 3-1.

Figure 3-1: General Location of Proposed Project Site

NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY

AT KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION


Figure 3-2: Specific Map Showing Project Boundary

Red highlighted boundary shows boundary of Plant. No extra land is required.




Table 3-1: Co-ordinates of Site Boundary

POINT LATITUDE LONGITUDE

A 21°51'56.83"N 72° 9'30.48"E

B 21°51'46.15"N 72°10'17.76"E

C 21°51'42.81"N 72° 9'23.53"E

D 21°51'39.12"N 72° 9'28.14"E

E 21°51'33.87"N 72° 9'27.12"E

F 21°51'32.87"N 72° 9'25.35"E

G 21°51'31.17"N 72° 9'25.11"E

H 21°51'30.23"N 72° 9'20.84"E

I 21°51'24.09"N 72° 9'20.45"E

J 21°51'23.82"N 72° 9'25.64"E

K 21°51'13.96"N 72° 9'26.98"E

L 21°51'12.59"N 72° 9'17.77"E

M 21°51'7.73"N 72° 9'13.03"E

N 21°50'51.17"N 72° 9'8.71"E

O 21°50'52.41"N 72°10'8.26"E

P 21°51'16.70"N 72°10'10.47"E

Q 21°51'23.75"N 72°10'15.83"E

3.3 Details of Alternate Sites Considered

The expansion and set-up of new project is within the existing chemical complex. Hence no alternative sites were

explored.

3.4 Size or Magnitude of Operation

Total plot area is 22,49,458 m2. The details of area calculations are given in Table 3-2. Site layout is provided as

Annexure 1.

Table 3-2: Area Statement*

S. No. Particular Area (Acre) Area (m2)

1 Plant facilities 84.0 3,39,825

2 Storage (Raw Material & Finished Products) 23.0 92,930

3 Storage (Fuel) 107.2 4,33,940

4 Storage (Water) 7.5 30,400

5 Storage (Others) 22.3 90,286

6 Utilities 16.9 68,250

7 Laboratory 0.9 3,600

8 Approach Road(s) 3.2 13,000

9 Green Belt 183.4 7,42,321

10 ETP 3.1 12,500

11 Office + Parking + Security 3.6 14,500

12 Open area 100.8 4,07,906

Total 555.8 22,49,458

* Area given are tentative and are subjected to changes, which will be clearly demarcated in the EIA study report.




3.5 Project Description with Process Details

3.5.1 Soda Ash (Existing + Expansion)

The global theoretical equation for the production of soda ash, involving sodium chloride and calcium carbonate is

as follows;

2 NaCl + CaCO3 Na2CO3 + CaCl2

In practice the reaction is not possible and needs the participation of other substances and many different process

steps to get the final product. The first reaction involves absorption of ammonia in salt solution, followed by

reaction of ammoniated brine with carbon dioxide to obtain ammonium carbonate followed by ammonium

carbonate. The continuous introduction of carbon dioxide injection and cooling the solution, precipitation of sodium

bicarbonate is achieved and ammonium chloride is formed. The chemical reactions of the process are given below:

NaCl + H2O + NH3 NaCl + NH4OH

2 NH4OH + CO2 (NH4)2 CO3 + H2O

(NH4)2CO3 + CO2 + H2O 2 NH4HCO3

2 NH4HCO3 + 2 NaCl 2 NaHCO3 + 2 NH4Cl

Sodium Bicarbonate crystals are separated from the mother liquor by filtration, followed by thermal decomposition

to obtain sodium carbonate, water and carbon dioxide. Sodium carbonate, thus formed is called “light soda ash”

because its bulk density is approximately 0.5 t/m3.

2 NaHCO3 Na2CO3 + H2O + CO2

CO2 is recovered in the carbonation step. The mother liquor is treated to recover ammonia, by reacting with dry lime

followed by steam stripping to recover free gaseous ammonia, which is recycled to absorption step.

2 NH4Cl + H2O+CaO CaCl2 + 2 NH3 + 2 H2O

Carbon dioxide and Calcium oxide originate from limestone calcinations CaCO3 CaO + CO2. Calcium and

magnesium which are impurities in the brine are removed by reacting with alkali and carbon dioxide to produce

insoluble salts. Brine purification reactions are described in the following equations:

Ca2+ + CO32- CaCO3

Mg2+ + 2 OH- Mg (OH)2

The difference between Light and Dense Soda ash is bulk density & the size of particles. Dense Soda ash is produced

via the monohydrate process. The hot light soda ash discharge from Calciner is transported via chain conveyors and

bucket elevator to Hydrator. In hydrator Light Soda ash is mixed with water to form monohydrate according to the

exothermic reaction:

Na2CO3 + H2O Na2CO3.H2O

The next step is dehydration and drying of the monohydrate in Fluid Bed Dryer according to endothermic reaction:

Na2CO3.H2O Na2CO3 + H2O

The Dense Soda Ash is cooled and transported to storage to packing plant. The block diagram of the Soda Ash

Manufacturing unit is given in Figure 3-3.




Figure 3-3: Process Flow Diagram - Soda Ash Manufacturing Process

3.5.2 Caustic Soda (Existing + Expansion)

The Caustic soda manufacturing technology being used i.e. membrane technology is completely environment

friendly. The by products are hydrogen, chlorine & sodium hypo chlorite. Hydrochloric acid is manufactured using

H2 and Cl2 (produced from cell house).

Manufacturing process of Caustic Soda involves the following key steps:

Brine Saturation: Desirable circulating rate of brine in saturator is attained by dissolving salt from solar salt works

and depleted brine from the process. The water loss by membrane is compensated by supply of demineralized

water.

Chemical Preparation: In precipitation tanks saturated brine is treated to remove Ca, Mg & Sulphates by adding

Na2CO3, NaOH and Barium Chloride.

Clarification: Flocculants are added to enhance the settling. Impurities are removed in clarifier. Main impurities

are solids which are pumped to sludge filtration unit. Filtrate is recycled to clarifier.

Filtration: Anthracite filters are used to remove suspended solids.

Secondary Brine Purification: Polishing candle filters and ion exchange system is used for this process. The

objective of producing ultra-pure brine required for membrane cell operation is achieved. Polished brine after

heating through brine heater is passed through two ion exchange columns connected in series. The columns have

cation exchange resin, which provides active sites for adsorption of residual calcium and magnesium salts still

present in brine. Brine is passed through heat exchanger for achieving the temperature required at cell inlet.

Electrolysis: Brine flows into the anode chamber. Cl2 is liberated at the anode surface with depleted brine left

behind. Cl2 and depleted brine overflows from the anode chambers into the anolyte header. Weak caustic flows

SALT

BRINE PREPARATION

RO / RAIN WATER LIME STONE COKE

LIME KILNS

ABSORPTION

CARBONATION

CALCINATION

DENSIFICATION

STORAGE

WASTE TREATMENT

DISTILLATION

COMPRESSION

GAS CONDENSATION

PACKING

FILTERATION

FINAL PRODUCTS

CLEAR LIQ. TO SALT WORKS

AIR

STEAM 38-40% CO2

80-90% CO2

PURIFIED BRINE CaCl2 Waste

CRUDE BICARBONATE

STEAM

LSA

DSA

LSA

LSA & DSA

MOTHER LIQUOR

NH4Cl

AMMONIA GAS

AMMONIA MAKE UP

LIME

CO2 + H2O

STEAM

ZERO

DISCHARGE




into the cathode chamber. H2 is generated at the cathode surface and OH ions combine with the Na+ ions diffusing

through the membrane. A two-phase mixture of 32% NaOH and hydrogen overflows into the catholyte header.

Anode Reaction: 2NaCl 2Na+ + Cl2 + 2 e –

Cathode Reaction: 2H2O + 2 e – 2OH– +H2

Overall Reaction: 2NaCl + 2H2O 2NaOH + Cl2 + H2

Catholyte System: In the catholyte header the two-phase mixture of NaOH and Hydrogen gets separated. This

catholyte stream is tapped as “Product” and fed to the caustic evaporation unit. Whole stream is not tapped and

some part is sent for internal consumption.

Anolyte Dechlorination: Depleted brine containing dissolved chlorine (called anolyte) is dechlorinated in two

stages: Vacuum dechlorination and chemical dechlorination. A part stream of chemically dechlorinated brine is be

purged out of the system to keep the sulphate within the desired levels.

Caustic Evaporation Unit: Here the incoming 32% Caustic is concentrated to 50%. The 50% caustic coming

from this unit can be stored in 50% storage tank.

Chlorine Treatment: The water vapor is removed, from the saturated chlorine, using series of coolers. The gas is

then passed through the moist chlorine filter to remove the entrained brine aerosol. In drying towers 98% H2SO4 is

used to dry moist chlorine.

The dried chlorine gas is compressed to the required pressure and then liquefied. Liquid chlorine from the liquefiers

is sent to liquid chlorine storage tanks. Sniff gas from the liquefier containing inlets and chlorine gas is sent to the

HCl synthesis unit. Excess sniff gas, is diverted to the waste air system.

Hydrogen Treatment: Hydrogen gas leaving the cells saturated with water vapor is cooled. The cooled gas is

passed through filters to remove the NaOH aerosols. Some amount of hydrogen is required for HCl synthesis and a

part of the gas is sent to caustic flaking unit to be used as fuel and a part is sent to hydrogen bottling through

hydrogen compressors as per requirement and the balance hydrogen is vented through with flame arrestor.

HCl Synthesis Unit

Hydrogen is burnt in Chlorine atmosphere and the combustion gases are absorbed in water to yield a 32% HCl

solution. HCl produced is pumped to HCl head tank from HCl receiver for internal consumption within plant. The

Block diagram showing the Caustic Soda Manufacturing Process is shown in Figure 3-4.




Figure 3-4: Process Flow Diagram - Caustic Soda Manufacturing Process

3.5.3 Captive Power Plant (Existing + Expansion)

In the case of lignite/coal-fired boilers, steam generation with any of following firing technology is technically

feasible:

Circulating fluidized bed combustion (CFBC)

Pressurized Fluidized Bed Combustion (PFBC)

Integrated Gasification Combined Cycle (IGCC)

Pulverized Fuel Firing (PF)

Circulating fluidized bed combustion (CFBC) technology is adopted for the proposed captive power plant. A 100 MW

captive power plant turbo-alternator and 350 TPH + 350 TPH (standby) lignite / coal / petcoke based CFBC Boilers,

along with captive power plant machineries will be installed in order to meet internal steam and power requirement

for the proposed expansion.

The steam generator units proposed for the plant will be compact, semi-outdoor, natural/assisted circulation,

balanced draft, single drum, water tube type provided with Circulating Fluidized Bed Combustion system using pan-

leg furnace configuration. In a typical Circulating Fluidized Bed furnace, the lignite fed on a bed of suitable inert

material with addition of a sorbent material (such as lime stone) is burnt in suspension through the action of

primary air distributed below the combustor floor. In addition, secondary air is introduced at suitable points in the

combustion zone to ensure controlled and complete combustion of the fuel. Suitable lignite feeding and limestone

feeding arrangements are provided in the typical Circulating Fluidized Bed Combustion systems and is commonly

used as bed material for initial start-up of the boiler. The steam generators will be designed for satisfactory

continuous operation with the range of lignite/coal expected for this plant without any need for auxiliary fuel oil for

fire stabilization etc. Lignite and Coal are used as fuel after mixing in appropriate ratio.

VENT

CAUSTIC TO STORAGE AND

FILLINGSALT SATURATION

BRINE PRECIPITATION

CHLORATE DESTRUCTION

CATHOLYTE SYSTEM

DM WATER/CONDENSATE

CHEMICALS Na2CO3,NaOH SALT

FLOCCULANT

NaHSO3, NaOH 32% SOLUTION

DM WATER

FLAKES STORAGEAND BAGGING

HYDROGEN BOTTLING

FLAKING UNIT

CAUSTIC EVAPORATION

CHLORINE LIQUEFICATION

HYDROGEN TREATMENT

LIQUID CHLORINE STORAGE

CHLORINE FILLING

48.5 / 50%NaOH SOLUTION

BRINE PURIFICATION

(ION EXCHANGE)

BRINE FILTRATION

SLUDGE FILTRATION

BRINE CLARIFICATION

ANOLYTE DECHLORINATION

SLUDGE

CHLORINE COOLING &

DRYING

98% H2SO4

CHLORINE COMPRESSION

ANODE CATHODE+ -

78% H2SO4

H2 TO STACK

HCL FILLING

HCL STORAGE

HCL SYNTHESIS UNIT

HYPO FILLING

HYPOCHLORITE STORAGE

WASTE GAS DECHLORINATION

VENT

SALT SATURATION

BRINE PRECIPITATION

CATHOLYTE SYSTEM




Steam generating unit would be provided with electrostatic precipitator in the flue gas path. The overall efficiency

of ESP will be around 99.70% with one field remaining as operational standby. The ESP would have adequate

number of ash hoppers provided with electric heaters. The design of ESP will be such that the dust burden at the

outlet of chimney with one field out of service doesn’t exceed 50 mg/Nm3 at 100 % BMCR with worst fuel.

Common chimney for boiler G and H will be constructed. The NOx emission from the steam generator is least in

case of CFBC steam generator design in view of low combustion temperature maintained in the furnace. The steam

generator and auxiliaries will perform continuously within noise limits as per relevant standard specification but not

more than 85 dB (A) at 1.0 meter from any equipment or sub equipment. The steam from the boiler will go to back

pressure turbo generators. The extracted back pressure steam will be used in process.

3.6 Utilities

The estimated list of utilities required for the new project is as given below:

3.6.1 Power Requirement

The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH,



540 TPH.


3.6.2 Fuel Requirement

Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr for

existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

3.6.3 Water Requirement

Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater intake – 14 x 105

m3/day. Additional seawater intake - 3.6 x 105 m3/day.

3.6.4 Storage Details

Unit will create additional storage facilities for products, raw materials as per the MSIHC rules.

3.7 Pollution Load on Environment due to project

Environmental issues include:

Air emissions;

Wastewater;

Solid Wastes.

3.7.1 Air Emissions & Control

Point Source

Likely air pollutants from proposed project shall be PM, SOx & NOx from flue gas stack, HCl, Cl2 & NH3 from process

stacks/vents as point source.




Volume Source

PM emission from coal storage yard is envisaged as volume source emissions.

Fugitive Emissions

Line Source Emissions

The ambient air quality & stack emissions will be maintained as per GPCB/CPCB norms. Details of proposed stacks

with fuel consumption and attached Air Pollution Control Equipment details are tabulated in Table 3-3 & Table

3-4.

Table 3-3: Details of Stack Emissions

S. No. Stack Attached to Stack Height

(m)

Stack Top

Dia. (m) APCM

Expected

Pollutants*

Existing

Soda Ash Division

1 Boiler - A, B, C & D (100 TPH Each) 100 (Common

Stack) 5.04

ESP to Each

Boiler PM, SO2 & NOx

2 DG Set (1000 KVA)

2 No. 24 each 0.2 -- PM, SO2 & NOx


2 Boiler - E (200 TPH) 121 (Common

Stack) 4.5

ESP PM, SO2 & NOx

3 As per EC 2014 Boiler - F (200 TPH) –

Not Installed Yet ESP PM, SO2 & NOx

4

As per EC 2017 Boiler - G & H (350 TPH

each ) – Installed One boiler having

capacity 410 TPH

121 (Common


5 DG Set (1000 KVA) 30 0.32 - PM, SO2 & NOx

6 DG Set (1500 KVA) 30

0.32

-

PM, SO2 & NOx

7 DG Set (1500 KVA)

Toilet Soap plant

8 Thermic Fluid Heater

(3 No.) 45 0.4 PM, SO2 & NOx

Proposed

Soda Ash Division

1. DG Set (2000 KVA) 30 0.32 -- PM, SO2 & NOx


1 Boiler - I & J (410 TPH + 130 TPH) * 121 (Common


2 DG Set (1850 KVA) 30 0.32 -- PM, SO2 & NOx


540 TPH.

Table 3-4: Details of Process Emissions

Sr.


Stack

Height (m)

Stack Dia.

(m)


System Pollutant

1

Soda Ash Plant – Existing & Proposed

Lime Kilns (A to H) – 8 nos. 68 (Common

Stack) 0.8

4 scrubbers and 3 ESP in

Series PM, SO2, NOx

Ammonia Recovery System (A

to E) 5 No.

56 (Common





Sr.


Stack

Height (m)

Stack Dia.

(m)


System Pollutant

Lime Grinding System A to E

(5 nos.)

60

(each) 0.65 Bag Filter PM

Calcinations Vessel (A to D 4

nos) 29 (each) 0.7 Water Scrubber PM




Lime Kilns (I to L) – 4 nos.

(Proposed)

68 (Common

Stack) 0.8

Two scrubbers and two

ESP in Series PM, SO2, NOx

Ammonia Recovery System (F

& G) 2 nos. (Proposed)

56 (Common


Lime Grinding System (F 1

nos.) (Proposed) 60 0.65 Bag Filter PM

Calcinations Vessel (E & F 2

nos) (Proposed)

29 (Common

vent) 0.7 Water Scrubber PM

Densification 4 (Proposed) 51 1.37 Water Scrubber PM

2

Caustic Soda and CPP - Existing & Proposed





HCl Synthesis Unit – 5

(Proposed) 30 0.1 Water Scrubbers HCl & Cl2






System – 3 30 0.3 18% NaOH Scrubber Cl2

Hydrogen unit with Flame arrestor and steam snuffing –

1 30 -- -- --



2

30 -- -- --



3

30 -- -- --

3. Bromine Plant

De-bromination System 30 0.3 Alkali Scrubber Bromine

4.


Solvent Recovery 30 0.3 Ceramic + Activated

Carbon Filter Aromatic Solvent


gas) 30 0.3

Ceramic + Activated

Carbon Filter

H2 + Aromatic

Solvent

Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,

HCl, TOC

HCl Synthesis Unit 30 0.1 Water Scrubbers HCl




Sr.


Stack

Height (m)

Stack Dia.

(m)


System Pollutant

Chlorination Plant 30 0.3 Acidic/Water Scrubber (3

nos.) SO2, HCl, Cl2

Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2

Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2


gas) 30 0.3 ---- H2

3.7.2 Noise Generation

From the proposed project, noise shall be generated from the various activities. Source of noise generation are:

The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during construction

phase;

Operation of plant machinery and diesel generator set;

Vehicle movement for transportation of raw material.

3.7.3 Waste Water Generation

The main source of the industrial wastewater generation will be from domestic, process, utilities, washing and

others. The total quantity of effluent will be increased from 5,86,445.2 KLD to 9,06,634.7 KLD. Entire quantity of

wastewater will be treated in existing treatment facilities. In existing scenario Treated effluent is partly reused /

recirculated in salt works and around 12000 m3/day of Soda Ash effluent and 6000 m3/day of Bittern is being

disposed off in to the sea at a discharge point suggested by National Institute of Oceanography (NIO).

In proposed expansion, Additional soda ash effluent, additional bittern & cooling water will be disposed in sea along

with existing effluent and bittern at point suggested by NIO. Return cooling water of 3,00,000 m3/day will be

disposed into deep sea at a discharge Point suggested by NIO on permanent basis and during emergency purpose /

monsoon 8,60,000 m3/day will be disposed into sea.

Details of Waste water generation is given in

Table 3-5: Wastewater Generation Details

Sr. No. Source Wastewater Generation (m3/day)


Soda Ash plant

1. Domestic 184 99 283

2. Process 32,547 17,436 49,983

3. Boiler 216 0 216

4. Cooling 4,73,571 2,86,840 7,60,411

5. Others 0 0 0

Total (I) 5,06,518 3,04,375 8,10,893

Toilet Soap plant

1. Domestic 48 0 48

2. Process 0 0 0

3. Washing 25 0 25

4. Cooling 275 0 275

Total (II) 348 0 348

Caustic Soda Plant & CPP

1. Domestic 11 3.5 14.5

2. Process 750 250 1,000




Sr. No. Source Wastewater Generation (m3/day)


3. Boiler 1,340 447 1,787

4. Cooling 4,03,842 14,614 58,456

Total (III) 45,943 15,314.5 61,257.5

Salt works

1. Salt works 11,000 500 11,500

Total (IV) 11,000 500 11,500

Bromine plant

1. Cooling tower 1,000 0 1,000

2. Process 12,500 0 12,500

Total (V) 13,500 0 13,500


1. Domestic 6.6 0 6.6

2. Process + DM 1,595 0 1,595

3. Cooling + Chilling 2,977 0 2,977

4. Boiler 0 0 0

5. Washing/Others 41 0 41

Total (VI) 4,619.6 0 4,619.6

RBC Plant, Calcium Chloride plant & Phosphoric acid plant

1 Domestic 8.6 0 8.6

2 Process 4,250 0 4,250

3 Cooling 258 0 0

Total (VII) 4,516.6 0 4,516.6

Grand Total (I to VI) 5,86,445.2 3,20,189.5 9,06,634.7

3.7.4 Hazardous Waste & Other Solid Waste

The main source of hazardous waste generation will increase after proposed expansion. ETP sludge will be dispose

to TSDF site. Used oil will be sold to authorized recycler and discarded containers & plastic liners will be sold to

registered recyclers.

The details of Solid & hazardous waste are given in Table 3-6 & Table 3-7.

Table 3-6: Solid Waste Generation & Disposal

Sr.

No. Solid Waste

Quantity (TPD) Mode of Disposal

Existing Proposed After Expansion

1 Settling Pond Sludge 880 482 1,362 Shall be used in road construction,

salt works bund preparation

2 Lime stone rejects /under

size 700 375 1,075

Shall be used in boilers for

desulphurization in boilers

3 Brine Sludge 19 10 29 Non-hazardous; Shall be used

dumped in identified area

4 Fly ash/ Bottom ash 2,185 1,693 3,878 Brick manufacturing, bund

preparation, road making etc…

5 Incineration Ash --- 15 15 Brick manufacturing, bund

preparation, road making etc…

6 Saponification

Solid Waste 3 0 3

Non-hazardous; Shall be

dumped in identified area




Table 3-7: Hazardous Waste Generation and Disposal

S No Hazardous Waste Category

Quantity (MTPA)

Mode of Disposal Existing Proposed

Total After

Expansion

1

Soda Ash Plant

Waste Oil/ Lub. Oil

from 5.1 10 5 15

Collection, Storage, Transportation &

disposal by selling to Registered

Recyclers

Spent ion exchange

resins 34.2

1,830

lt/year

980

lt/year 2,810 lt/year


Disposal by selling to authorized

recyclers or sent to NECL Nandesari

for Incineration.

Discarded

bags/drums/containers

etc…

33.3 3.5 2 5.5



recyclers

2

Caustic Soda Plant

Waste Oil/ Lub. Oil

from 5.1 30 kl 10 kl 40 kl



Recyclers

Spent ion exchange

resins 34.2 2.56 1 3.56



recyclers or sent to NECL Nandesari

for Incineration.

Discarded

Bags / drums /

containers etc…

33.3 4.5 1.5 6



recyclers

Residue/ Sludge &

Filter sludge 16.2 6,526 2,175 8,701


Disposal at TSDF

ETP sludge 34.3 150 50 200 Collection, Storage, Transportation,

Disposal at TSDF

Spent Sulphuric Acid

(80%) D2 6,520 2,173 8,693


reuse as raw material for Nirma Ltd.

Moraiya and other end users.

3

Toilet Soap Plant

Waste Oil/ Lub. Oil

from 5.1 0.45 0 0.45



Recyclers


Disposal at TSDF

Glycerin foot D6-II 72 0 72


disposal by selling to M/s. Ultratech

Cement for Co- incineration in cement

kiln/NECL for Incineration.

Spent Sulphuric Acid

(80%) D2 24,000 0 24,000


reuse as raw material for Nirma Ltd.

Moraiya and other end users.




S No Hazardous Waste Category

Quantity (MTPA)

Mode of Disposal Existing Proposed

Total After

Expansion

4


Waste Oil/ Lub. Oil 5.1 10 0 10



Recyclers

Discarded containers/

Barrels/empty

drums/empty bags

33.3 10 0 10 Collection, Storage and disposal by

selling to authorized recyclers.


Disposal at TSDF

Glycerin foot D6-II 5,356 0 5,356 Collection, Storage & incineration in

plant incinerator.

Catalyst from

regeneration 35.2 1.2 0 1.2


Disposal at Common Haz. Waste

incineration facility

Spent Carbon from

solvent recovery 35.3 3 0 3



incineration facility

Spent Carbon from

ETP 34.3 3 0 3


Disposal at TSDF

Distillation Residue 36.4 550 0 550



incineration facility.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS


4 SITE ANALYSIS

4.1 Connectivity

4.1.1 By Road

The nearest highway (Bhavnagar-Ahmedabad SH-6 Coastal highway) is about 14.0 kms away from the plant in the

West direction.

4.1.2 By Rail

Major railway station for public transportation is Bhavnagar Railway Station located at an aerial distance of ~10 Km

from the project site in the South-South West Direction.

4.1.3 By Air

Bhavnagar has its own airport, Bhavnagar Airport, which is at ~10 Km from project site.

4.2 Land Form, Land use & Land Ownership

There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma

Limited. Land Cover will be as per the Site Layout Map as shown in Annexure 1.

4.3 Topography

Project site is shown on Toposheet in Annexure 2.

4.4 Existing Infrastructure

Existing infrastructure like roads, power supply, water supply line, etc. are readily available at the site.

4.5 Soil Classification, Geology & Drainage

4.5.1 Soil Classification

Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. The soil type is a mixture

of sand & gravel with intermediate golden colour laterites with clay as binder. The subsoil strata of the study area

consist of a mixture of sandy gravel with clay as binder in the top 10 m. Thereafter the strata of about 50 m is a

thick layer of Grayish-blue clay having very hard to stiff consistency tending to rock like formation. The topsoil

around Kalatalav is made up of coarse saline soil poor in nutrients.

Most of the 10 km radial zone around Kalatalav has alluvial deposits and consists of sandy soil, tidal mudflats,

raised beaches and freshwater alluvium. Clay (size < 0.002mm) amount in the soil samples ranges from 17% to

22%; Silt (size 0.002 to 0.075 mm) in the soil samples is 14% to 18% Sand (size 0.075 to 0.475mm) in the soil

samples is 50% to 58% and gravel (size > 4.75 mm) in soil samples is 10% to 14%.

4.5.2 Geology

The Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. It falls in the seismic

zone-III as per IS 1893 (part -1) 2003. Peninsula is bounded by sea on all sides except northeast side where it is

flanked by alluvium plains of main land.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS


Bhavnagar district shows diverse features like uneven, rocky (basaltic) land surface traversed by mountain

ranges/ridges and trappean dykes. Most of the district is composed of Weathered to Hard & massive Deccan Trap

formation, which is impervious with low yield. Rocks with cracks, fractures and fissures provide some discharge and

potable water quality.

4.6 Climatic data from secondary sources

Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term

Climatological Tables, 1981-2010, Bhavnagar (A). These tables give useful information about a region’s weather,

since they are collected over a 29-year period. Copy of the same is attached as Annexure 3.

Mean daily maximum temperature is recorded in the month of May at 40.0°C. From October to December, both day

and night temperatures begin to decrease rapidly. January is generally the coldest month, having minimum

morning temperature at 13.9°C. During the post-monsoon months of October, November, December day

temperatures remain between 17.8ºC - 26.7ºC. In winters, i.e. December, January and February, average day

temperatures remain between 16.2 – 18.8ºC.

The total rainfall in year is observed to be 655.9 mm. Distribution of rainfall by season is 2.4 mm in winter

(December, January, February), 5.2 mm in summer (March, April, May), 612.4 mm in monsoons (June, July,

August, September) and 35.9 mm in post-monsoons (October, November, December). Annual total heaviest rainfall

recorded in 24 hrs is observed to be 434.4 mm on 20th July, 1996.

An online weather logger was set up at Plant site. The co-ordinates for the same are 21051’14.1”N; 72010’32.8”E.

4.7 Social Infrastructure Available

Educational Facilities

As per 2001 census in all 5 villages, there are 4 primary schools & other educational facilities are in 10 km radius of

the study area.

Medical Facilities

Out of 4 villages in the study area, one has Primary Health Sub-Centers & other medical facilities are within 10 km

of the study area. Almost all medical facilities are available there.

Drinking Water Supply

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility.

Communication & Transport

The main mode of public transport available in the study area is by bus service. All villages are near Bhavnagar, so

almost all villages have approach to railway station as western railway meter gauge line is passing through nearby.

Post & Telegraph

There are 5 villages in study area, 2 villages have post office facility at doorstep & almost all have phone facility.

Power Supply

All the villages are getting power supply for domestic purposes.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept

Site falls under the seismic Zone III, which is classified as Low Risk zone (Area liable to shaking Intensity VI (and

lower). Thus, suitable seismic coefficients accordingly shall be adopted while designing the structures to make it

earthquake resistant.

Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc. are already

developed in the project site.

5.2 Landuse Planning

There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma Ltd.

5.3 Assessment of Infrastructure Demand (Physical & Social)

No additional infrastructure demand is required.

5.4 Amenities/Facilities

Within the study area (i.e. 10 kms) basic amenities/ facilities like there are 4 primary schools & other educational

facilities, is available in all the nearby villages. Out of 4 villages in the study area, one has Primary Health Sub-

Centres & other medical facilities are within 10 km of the study area. Bhavnagar is nearest city to the study area,

which is around 10 km away from project site. Almost all medical facilities are available there.

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility. The main mode of public

transport available in the study area is by bus service. All villages are near Bhavnagar, so almost all villages have

approach to railway station as western railway meter gauge line is passing through nearby. Majority of villages in

the study area is connected with pucca road. Out of 5 villages in study area, 2 villages have post office facility at

doorstep & almost all have phone facility. All the villages are getting power supply for domestic purposes.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing unit comprises of following sections:

Boiler House consisting of CFBC Boilers – 2 Nos., Steam Turbine, Alternator / Generator;

Fuel storage area;

Utility Area consisting of cooling tower, compressors, ESP section, ETP area;

Fly Ash & Hazardous waste storage area.

Adequate storage space for fuel storage, hazardous and other solid waste is already available. Additional storage

space will be provided as per the requirement.

6.2 Non- Processing Area

Existing non processing area includes Weighbridge, Administrative Building, Laboratory, Security cabins, Workers

restroom, Vehicle Shed, Water reservoirs for raw water and fire hydrant system, Temporary storage sites, Works

block etc.

6.3 Greenbelt

Nirma has done extensive plantation in around 110 acres and spared total 183.4 acres for greenbelt development.

Unit is also taking interest to develop greenbelt peripheral outside of the factory premises

6.4 Social Infrastructure

Refer Chapter 4, Section 4.7.

6.5 Connectivity

Refer Chapter 4, Section 4.1.

6.6 Drinking Water Management

Drinking water source for the existing Nirma plant at Kalatalav is from RO plant.

6.7 Sewage System

Sewage would be generated from the various units within the manufacturing facility. The existing sewage quantity

generated is 258.2 m3/day. The sewage expected to be generated for proposed expansion would be 102.5 m3/day.

Thus, the total sewage generation would be 360.7 m3/day. The sewage would be disposed off in soak pits of

individual plants and the same is being used in greenbelt development.

6.8 Industrial Waste & Solid Waste Management

Solid and hazardous waste as mentioned in Chapter 3, Section 3.7.4 shall be collected, stored, disposed to

authorized vendors and sold to local suppliers as per it’s characterization and based on the prescribed Fly Ash


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


Notification, 2015 & Hazardous Waste Rules, 2016 amended till date. Other wastes to be generated from the

project are tabulated in Table 6-1. Details will be provided in EIA report.

Table 6-1: Identification of Other Wastes

S. No. Type of Waste Constituents

1 Municipal Solid Waste Kitchen waste, cardboard, paper and garden wastes

2 Inorganic Waste Scraps, paper bags, cardboards and glassware’s etc.

3 Plastic Waste Plastic bags, plastic scraps etc.

4 E-waste CD’s, LAN Cables, Fuses, Data cables, circuit boards, etc.

5 Biomedical Waste Syringe, Bandages, used cotton, medicine etc.

6 Construction & Demolition waste Debris

6.9 Power Requirement & Supply / Source

Refer Chapter 3, Section 3.6.1.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR R&R PLAN


7 REHABILITATION AND RESETTLEMENT (R&R) PLAN

Since no additional land is acquired for the proposed expansion project, and all the proposed units will be inside the

existing plant premises, R & R issues are not envisaged.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROJECT SCHEDULE & COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely date of completion

The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized

committee. Tentative schedule for the project to be completed is given in Table 8-1.

Table 8-1: Tentative Project Time Schedule

S. No. Activities Start Finish

1 EC Approval November, 2017 August, 2018

2 Detailed Engineering January, 2019 April, 2019

3 Procurement and Delivery June, 2019 Delivery start from

December, 2019

4 Construction at Site (Buildings, Mech., Piping, Elec., Inst etc.) June, 2019 December, 2020

5 Pre Commissioning January, 2021 June, 2021

6 CTO Approval July, 2021 January, 2022

7 Process Startup and Stabilization September, 2021 March, 2022

8.2 Estimated Project Cost

The proposed project cost is estimated to be INR 1,320 crores. The breakup of project cost is given in Table 8-2.

Table 8-2: Breakup of Project Cost

S. No. Particulars Amount (INR in Crores)

1 Soda Ash Plant 570

2 Caustic Soda and CPP 750

Total Project Cost 1,320

8.2.1 Profitability

The project has been conceived upgrading old inefficient sets with new efficient sets, hence increasing profitability.

Further capacity enhancement leads to a reasonable ROI, based on consuming plant expansion.


CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.




ANNEXURES

NIRMA LIMITED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 1: Preliminary Site Layout Map


AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles




Annexure 3: Long Term Meteorological Data for Bhavnagar City

CONTACT DETAILS



E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon,

Haryana, INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433



M/S. NIRMA LTD PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE POWER

PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROPOSED TERMS OF

REFERENCE


2 PROPOSED TERMS OF REFERENCE

Proposed Terms of Reference (TOR) are prepared based on Chapter 4, 4(d), 4(e), Chapter 1, Section 1(d) of “Standard

Terms of Reference for EIA/EMP Report for projects / activities requiring Environment Clearance under EIA Notification,

2006” as published by Ministry of Environment, Forest & Climate Change, April, 2015.

Summarized Terms of Reference for this project is as tabulated below:

Table 1: Proposed Terms of Reference

S. No. Proposed Terms of Reference

1. Executive Summary

2. Introduction

3. Details of the EIA Consultant including NABET accreditation

4. Information about the project proponent

5. Importance and benefits of the project

6. Project Description

7. Cost of project and time of completion

8. Products with capacities for the proposed project.

9. If expansion project, details of existing products with capacities and whether adequate land is available for

expansion, reference of earlier EC if any.

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

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

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

13. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power

requirement (regular and contract).

14. Process description along with major equipment and machineries, process flow sheet (quantitative) from raw

material to products to be provided.

15. Hazard identification and details of proposed safety systems.

Expansion/modernization proposals

16.

Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from

MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional

Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of

compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be

provided. In addition, status of compliance of Consent to Operate for the ongoing Existing operation of the

project from SPCB shall be attached with the EIA-EMP report

17.

In case the existing project has not obtained environmental clearance, reasons for not taking EC under the

provisions of the EIA Notification 1994 and/or EIA Notification 2006 shall be provided. Copies of Consent to

Establish/No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification

2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to

the conditions of consents from the SPCB shall be submitted

Site Details

18. Location of the project site covering village, Taluka/Tehsil, District and State, Justification for selecting the site,



REFERENCE



whether other sites were considered.

19. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet.

(including all eco-sensitive areas and environmentally sensitive places)

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

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

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

23.

Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area,

utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of

unit within the Industrial area/Estate.

24. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of

plantation/greenbelt, in particular.

25. Landuse break-up of total land of the project site (identified and acquired), government/ private - agricultural,

forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area).

26. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use

details of the study area.

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

28.

Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km radius of any major

river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of

the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river shall also be

provided. (mega green field projects).

29. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of

complete possession of the land.

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

Environmental Status

31. Determination of atmospheric inversion level at the project site and site-specific micro-meteorological data using

temperature, relative humidity, hourly wind speed and direction and rainfall.

32.

AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the

project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-

dominant wind direction, population zone and sensitive receptors including reserved forests,

33.

Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification

of Nov. 2009 along with - min., max., average and 98% values for each of the AAQ parameters from data of all

AAQ stations should be provided as an annexure to the EIA Report.

34. Surface water quality of nearby River (100m upstream and downstream of discharge point) and other surface

drains at eight locations as per CPCB/MoEF&CC guidelines.

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

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

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

38. Soil Characteristic as per CPCB guidelines.

39. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic

due to proposed project, parking arrangement etc.



REFERENCE



40.

Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with

special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area,

a Wildlife Conservation Plan shall be prepared and furnished.

41. Socio-economic status of the study area

Impact and Environment Management Plan

42.

Assessment of ground level concentration of pollutants from the stack emission based on site-specific

meteorological features. In case the project is located on a hilly terrain, the AQIP Modelling shall be done using

inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ.

Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed.

Details of the model used and the input data used for modelling shall also be provided. The air quality contours

shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if

any.

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

44.

Impact of the transport of the raw materials and end products on the surrounding environment shall be assessed

and provided. In this regard, options for transport of raw materials and finished products and wastes (large

quantities) by rail or rail-cum road transport or conveyor-cum-rail transport shall be examined.

45.

A note on treatment of wastewater from different plant operations, extent recycled and reused for different

purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated

effluent to meet the prescribed standards of discharge under E(P) Rules.

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

47. Measures for fugitive emission control

48. Budget allocation of resources and responsibilities for plan implementation.

49. Details of the emergency preparedness plan for Hazardous material storage, handling and transportation and on-

site and off-site disaster management plan.

50.

Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management Plan including

Risk Assessment and damage control. Disaster management plan should be linked with District Disaster

Management Plan.

Occupational health

51. Plan and fund allocation to ensure the occupational health & safety of all contract and casual workers

52.

Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by pre

designed format, chest x rays, Audiometry, Spirometer, Vision testing (Far & Near vision, color vision and any

other ocular defect) ECG, during pre-placement and periodical examinations give the details of the same. Details

regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and

department wise.

53.

Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are

within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to

keep them within PEL so that health of the workers can be preserved,

54. Annual report of health status of workers with special reference to Occupational Health and Safety

Corporate Environment Policy

55. Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be

detailed in the EIA report

56.

Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any

infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in

the EIA.



REFERENCE



57. What is the hierarchical system or Administrative order of the company to deal with the environmental issues and

for ensuring compliance with the environmental clearance conditions? Details of this system may be given

58.

Does the company have system of reporting of non-compliances / violations of environmental norms to the Board

of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be

detailed in the EIA report

59. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labor force

during construction as well as to the casual workers including truck drivers during operation phase

Enterprise Social Commitment (ESC)

60.

Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment

based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-

economic development activities need to be elaborated upon.

61.

Any litigation pending against the project and/or any direction/order passed by any Court of Law against the

project, if so, details thereof shall also be included. Has the unit received any notice under the Section 5 of

Environment (Protection) Act, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and

compliance/ATR to the notice(s) and present status of the case.

62. A tabular chart with index for point wise compliance of above TOR

SPECIFIC TERMS OF REFERENCE FOR CHLOR ALKALI INDUSTRIES AND SODA ASH

63. Details on demand of the product- chlorine and its associated products

64. Details on raw materials (sodium chloride, potassium chloride, sea water, lime stone, coke, ammonia, additives

etc.), its storage and handling

65. Details of proposed source - specific pollution control schemes (salt washing, filtration, cell ventilating as, chlorine

handling and safety, etc.) and equipment to meet the national standards

66. Details on products to rage and handling-chlorine, caustic soda, etc

67. Details on tail gas treatment

68. Details on requirement of energy and water along with its source and authorization from the concerned

department

69.

Details on ground water quality and surface water quality of nearby water sources and other surfaced rains. The

parameters of water quality may include Residual chlorine*, TDS*, alkalinity*, pH* & Mercury* (in water &

sediment), etc. (*- As applicable)

70.

Details on existing ambient air quality and expected, emissions for PM10, PM2.5, SO2, NOx, NH3, CO, Chlorine, acid

mist etc., and evaluation of the adequacy of the proposed pollution control devices to meet standards for point

sources and to meet AAQ standards.

71. Specific program to monitor safety and health protection of workers

72. Risk assessment should also include leakages and location near to caustic soda plant & proposed measures for

risk reduction

73. Details of the emergency preparedness plan for chlorine/ Hydrogen storage, handling and transportation and on-

site and offsite disaster management plan

74. Details of handling ammonia and risk assessment.

75. Details on water balance including water use, quantity of effluent generated, recycled and reused and its impact

of discharge to receiving water body.

76. Detail so effluent treatment plant, inlet and treated water quality with specific efficiency of each treatment unit in

reduction in respect of all concerned/ regulated environmental parameters.



REFERENCE



77. Details of CO2 emissions including its quantum per ton of soda ash

78. Management plan for solid waste generation (fines of lime stone, grits, brine sludge etc.), storage, utilization and

disposal modes

79. In case of coast at plants details on extraction of seawater and effluent disposal, development of solar salt works

based on sea water evaporation, etc

80.

Details on ground water quality and surface water quality of nearby waters ounces and other surfaced rains. The

parameters of water quality may include Cl-*,Ca2+*, Na+*, SO42-*, NH4+, Suspended solids* etc. (*- As

applicable)

SPECIFIC TERMS OF REFERENCE FOR THERMAL POWER PLANT

81. Harnessing solar power within the premises of the plant particularly at available roof tops and other available

areas shall be formulated and for expansion projects, status of implementation shall also be submitted

82.

Details of fly ash utilization plan as per the latest fly ash Utilization Notification of GOI along with firm agreements

/ MoU with contracting parties including other usages etc. shall be submitted. The plan shall also include disposal

method / mechanism of bottom ash.

83.

The water requirement shall be optimized (by adopting measures such as dry fly ash and dry bottom ash disposal

system, air cooled condenser, concept of zero discharge) and in any case not more than that stipulated by CEA

from time to time, to be submitted along with details of source of water and water balance diagram. Details of

water balance calculated shall take into account reuse and re-circulation of effluents.

84.

It shall also be ensured that a minimum of 500 m distance of plant boundary is kept from the HFL of river system

/ streams etc. and the boundary of site should also be located 500 m away from railway track and National

Highways.

85. Detailed plan for rainwater harvesting and its proposed utilization in the plant shall be furnished.

86. Feasibility of near zero discharge concept shall be critically examined and its details submitted.

87. Optimization of Cycles of Concentration (COC) along with other water conservation measures in the project shall

be specified.

88. Plan for recirculation of ash pond water and its implementation shall be submitted

89. Radio activity and heavy metal contents of coal to be sourced shall be examined and submitted along with

laboratory reports.

90. Fuel analysis shall be provided. Details of auxiliary fuel, if any, including its quantity, quality, storage etc should

also be furnished.

91.

Quantity of fuel required, its source and characteristics and documentary evidence to substantiate confirmed fuel

linkage shall be furnished. The Ministry's Notification dated 02.01.2014 regarding ash content in coal shall be

complied. For the expansion projects, the compliance of the existing units to the said Notification shall also be

submitted

92. For proposals based on imported coal, inland transportation and port handling and rail movement shall be

examined and details furnished. The approval of the Port and Rail Authorities shall be submitted.

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