PROPOSED EXPANSION OF SILICA SAND PRODUCTION...
Transcript of PROPOSED EXPANSION OF SILICA SAND PRODUCTION...
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FORM-1
for
PROPOSED EXPANSION OF SILICA SAND
PRODUCTION PLANT (GLASS GRADE) & LPG
STORAGE CAPACITY FOR GLASS
MANUFACTURING UNIT
of
M/s. GUJARAT GUARDIAN LTD.
VILLAGE: KONDH, VALIA ROAD,
TAL: ANKLESHWAR - 393001, DIST: BHARUCH (GUJ.)
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
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APPENDIX I
(See paragraph - 6)
FORM 1
Sr.
No.
Item Details
1. Name of the project/s M/s. Gujarat Guardian Limited
2. S. No. in the schedule 2(b) & 6(b)
3. Proposed capacity/ area/ length/
tonnage to be handled/ command
area/ lease area/ number of wells to
be drilled
Please refer Annexure – I
4. New/Expansion/Modernization Expansion
5. Existing Capacity/Area etc. Existing Capacity:
Float Plant = 2,50,00,000 Sq. meter/Annum
Silica Sand (Glass Grade) = 33,120 MT/Month
LPG Tanks: 4 Nos. (Capacity = 56.25 MT each)
i.e. Total Capacity = 225 MT
Total Proposed Capacity:
Float Plant = 2,50,00,000 Sq. meter/Annum
Silica Sand (Glass Grade) = 86,500 MT/Month
LPG Tanks: 6 Nos. (Capacity = 120 MT each) i.e.
Total Capacity of 720 MT
6. Category of Project i.e. ‘A’ or ‘B’ 'A'
7. Does it attract the general condition?
If yes, please specify.
Yes. Located within 5 km of critically polluted
area (Ankleshwar).
8. Does it attract the specific condition?
If yes, please specify.
No
Location
Plot/Survey/Khasra No. As per the plot detail attached
Village Kondh, Valia Road
Tehsil Ankleshwar
District Bharuch
9.
State Gujarat
10. Nearest railway station/airport along
with distance in kms.
Railway Station: Ankleshwar (15.5 km)
Airport: Surat (75 km)
11. Nearest Town, city, District
Headquarters along with distance in
kms.
Kondh Village (1.5 km),
Bharuch (25 km)
12. Village Panchayats, Zilla Parishad,
Municipal Corporation, local body
(complete postal address with
telephone nos. to be given)
Kondh Village, Taluka: Ankleshwar – 393 001,
Dist: Bharuch (Gujarat)
13. Name of the applicant M/s. Gujarat Guardian Limited
14. Registered Address Village: Kondh, Valia Road,
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Tal: Ankleshwar - 393001, Dist: Bharuch (Guj.)
Address for correspondence:
Name Mr. Shyam Raghuwanshi
Designation (Owner/Partner/CEO) Executive (EHS)
Address M/s. Gujarat Guardian Limited
Village: Kondh, Valia Road,
Tal: Ankleshwar - 393001, Dist: Bharuch (Guj.)
Pin Code 393 001
E-mail [email protected]
Telephone No. Phone: (02643) 275106 to 275115
Mob.: +91 7043058700
15.
Fax No. NA
16. Details of Alternative Sites examined,
if any.
Location of these sites should be
shown on a top of sheet.
NA
17. Interlinked Projects NA
18. Whether separate application of
interlinked project has been
submitted?
NA
19. If yes, date of submission NA
20. If no, reason NA
21. Whether the proposal involves
approval/clearance under: if yes,
details of the same and their status to
be given.
(a) The Forest (Conservation) Act,
1980?
(b) The Wildlife (Protection) Act,
1972?
(c) The C.R.Z. Notification, 1991?
No
22. Whether there is any Government
Order/Policy relevant/relating to the
site?
No
23. Forest land involved (hectares) NA
24. Whether there is any litigation
pending against the project and/or
land in which the project is propose
to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if
any and its relevance with the
proposed project.
NA
• Capacity corresponding to sectoral activity (such as production capacity for
manufacturing, mining lease area and production capacity for mineral production,
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area for mineral exploration, length for linear transport infrastructure, generation
capacity for power generation etc.,)
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr.
No.
Information/Checklist
confirmation
Yes/No Details there of with approximate quantities
frates, wherever possible) with source of
information data
1.1 Permanent or temporary change
in land use, land cover or
topography including increase
intensity of land use (with
respect to local land use plan)
No Proposed Expansion will be carried out
within the existing premises.
Total Cost of the Project is Rs. 624 Crores
(Existing = 584 Crores + Additional = 40
Crores)
Total Plot Area = 6,55,990.4 m2
Green Belt = 80,936.51 m2
1.2 Clearance of existing land,
vegetation and Buildings?
Yes Already available
1.3 Creation of new land uses? No
1.4 Pre-construction investigations
e.g. bore Houses, soil testing?
Yes Soil investigation will be done
1.5 Construction works? Yes Plant Layout attached as Annexure - II
1.6 Demolition works? Yes Demolition of existing sand plant
1.7 Temporary sites used for
construction works or housing of
construction workers?
No
1.8 Above ground buildings,
structures or earthworks
including linear structures, cut
and fill or excavations
No Plant Layout attached as Annexure - II
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Off shore structures? No
1.13 Production and manufacturing
processes?
Yes For detail Please refer Annexure –III
1.14 Facilities for storage of goods or
materials?
Yes Specified storage area shall be provided for
storage of goods, Raw materials & Finished
products.
1.15 Facilities for treatment or
disposal of solid waste or liquid
effluents?
Yes For detail please refer Annexure – IV & V
1.16 Facilities for long term housing of
operational workers?
No
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1.17 New road, rail or sea traffic
during Construction or
operation?
No
1.18 New road, rail, air waterborne or
other transport infrastructure
including new or altered routes
and stations, ports, airports etc?
No
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in Traffic
movements?
No
1.20 New or diverted transmission
lines or Pipelines?
No
1.21 Impoundment, damming,
culverting, realignment or other
changes to the hydrology of
watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water
form ground or surface waters?
No No ground water shall be used. The raw
water shall be supplied by Valia Water
Supply System (Canal Water).
1.24 Changes in water bodies or the
land surface Affecting drainage or
run-off?
No
1.25 Transport of personnel or
materials for construction,
operation or decommissioning?
Yes Transportation of personnel, raw material
and products will be primarily by road only
1.26 Long-term dismantling or
decommissioning or restoration
works?
Yes We will be dismantling the existing Sand
beneficiation plant once the new sand
beneficiation plant would be operational.
1.27 Ongoing activity during
decommissioning which could
have an impact on the
environment?
No
1.28 Influx of people to an area
either temporarily or
permanently?
No M/s. Gujarat Guardian Limited will give direct
employment to local people based on
qualification and requirement. In addition to
direct employment, indirect employment
shall generate ancillary business to some
extent for the local population.
1.29 Introduction of alien species? No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
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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):
Sr.
No.
Information/checklist confirmation Yes/No Details there of (with approximate quantities
frates, wherever possible) with source of
information data
2.1 Land especially undeveloped or
agricultural land (ha)
No Land of 6,55,990.4 m2
2.2 Water (expected source &
competing users) unit: KLD
Yes The entire water requirement will be met
through Valia Water Supply System (Canal
Water). Water available from GIDC. For detail
please refer Annexure – VI
2.3 Minerals (MT) No
2.4 Construction material: stone,
aggregates,
and / soil (expected source – MT)
Yes Construction materials like crushed stones,
sand, rubble, cement, steel, etc. required for
the project shall be procured from the local
market of the region.
2.5 Forests and timber (source – MT) No
2.6 Energy including electricity and
fuels (source, competing users)
Unit: fuel (MT), energy (MW)
Yes For detail please refer Annexure – VI
2.7 Any other natural resources (use
appropriate standard units)
No
3. Use, storage, transport, handling or production of substances or materials,
which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes For detail please refer Annexure –VII.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
3.4 Vulnerable groups of people who
could be affected by the project e.g.
hospital patients, children, the elderly
etc.
No
3.5 Any other causes No
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(II) Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or
commercial wastes)
No
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure – V
4.4 Other industrial process wastes No
4.5 Surplus product No
4.6 Sewage sludge or other sludge from
effluent treatment
Yes
Please refer Annexure – V
4.7 Construction or demolition wastes
Yes
We will be dismantling the existing Sand
beneficiation plant once the new sand
beneficiation plant would be operational
and that will result into generation of metal
scrap and other waste.
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
Please refer Annexure – V
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr.)
Sr.
No.
Information/Checklist
confirmation
Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data
5.1 Emissions from combustion of
fossil fuels from stationary or
mobile sources
Yes For details Please refer Annexure – VIII
5.2 Emissions from production
processes
Yes For details Please refer Annexure – VIII
5.3 Emissions from materials
handling storage or transport
Yes All liquid raw materials, chemicals are procured
in tankers and are transferred through a closed
pipe lines.
Solid raw materials (Batch) are feed into furnace
through close pipeline/chute/conveyors and the
dust collection hoppers are connected to a bag
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filter and ID fan.
Also, all hazardous chemicals (flammable) storage
tanks are provided with safety, Excess flow valve &
remote operating valve for safety wherever
applicable.
5.4 Emissions from construction
activities including plant and
equipment
Yes During construction work, only dust
contamination will be there & water sprinklers
shall be utilized whenever necessary.
5.5 Dust or odours from handling
of materials including
construction materials,
sewage and waste
Yes All the waste shall be stored in designated place
and shall be transported to TSDF site in approved
closed vehicles owned by the TSDF authority.
Dust from drying will be collected in to dust
collector through cyclone separator & recovered
powder will be recycled back to process. Air
Handling Unit will be provided where ever
applicable.
5.6 Emissions from incineration of
waste No
5.7 Emissions from burning of
waste in open air e.g. slash
materials, construction debris)
No
5.8 Emissions from any other
sources No
(III) Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data with source of
information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes All machinery / equipment shall be well
maintained, shall have proper foundation with
anti vibrating pads wherever applicable.
Expected Noise level at different locations in
the plant is enclosed as Annexure – IX
6.2 From industrial or similar processes Yes Please refer Annexure – IX
6.3 From construction or demolition Yes
6.4 From blasting or piling No
6.5 From construction or operational
traffic
Yes
6.6 From lighting or cooling systems Yes Please refer Annexure – IX
6.7 From any other sources No
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7. Risks of contamination of land or water from releases of pollutants into the
ground or into sewers, surface waters, groundwater, coastal waters or the sea:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or
spillage of hazardous materials
Yes Hazardous material shall be stored in
designated storage area with bund walls for
tanks. Other material will be stored in
bags/drums on pallets with concrete flooring
and no spillage is likely to occur. All liquid raw
materials shall be transported through pumps
and closed pipelines and no manual handling
shall be involved. Spill Container will be kept at
appropriate places to collect spillage. SOP for
collection, decontamination & disposal of
spilled material will be displaced at necessary
locations. For details please refer Annexure –
VII
7.2 From discharge of sewage or
other effluents to water or the
land (expected mode and place of
discharge)
Yes The wastewater generated from Cooling,
Chilling & Washing will be reused in Sand Plant
for Sand Washing through recirculation. The
Domestic wastewater will be treated in Sewage
Treatment Plant and will be reused for Land
Irrigation/Gardening. Hence it will be a Zero
Liquid Discharge Plant.
7.3 By deposition of pollutants
emitted to air into the and or into
water
No
7.4 From any other sources No
7.5 Is there a risk of long term build
up of pollutants in the
environment from these sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
Sr.
No.
Information/Checklist
confirmation
Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
8.1 From explosions, spillages, fires
etc from storage, handling, use
or production of hazardous
substances
Yes For detail please refer Annexure – VII
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8.2 From any other causes No
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g.
floods, earthquakes, landslides,
cloudburst etc)?
No
9. Factors which should be considered (such as consequential development)
which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
(IV) Environmental Sensitivity
Sr. No. Areas Name/
Identity
Aerial distance (within 5 km.) Proposed
project location boundary
1 Areas protected under international
conventions, national or local
legislation for their ecological,
landscape, cultural or other related
value
No Proposed expansion is within the existing
premises.
Sr.
No.
Information/Checklist confirmation
Yes/
No
Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
9.1 Lead to development of supporting.
utilities, ancillary development or
development stimulated by the project
which could have impact on the
environment e.g.
• Supporting infrastructure (roads, power
supply, waste or waste water treatment,
etc.)
• housing development
• extractive industry
• supply industry
• other
Yes For detail please refer Annexure – X
9.2 Lead to after-use of the site, which could
have an impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity
to other existing or planned projects with
similar effects
No
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2 Areas which important for are or
sensitive Ecol logical reasons –
Wetlands, watercourses or other
water bodies, coastal zone,
biospheres, mountains, forests
No
3 Area used by protected, important
or sensitive Species of flora or fauna
for breeding, nesting, foraging,
resting, over wintering, migration
No
4 Inland, coastal, marine or
underground waters
No No inland, costal or marine within 5 km
from the proposed project
5 State, National boundaries No 6 Routes or facilities used by the
public for access to recreation or
other tourist, pilgrim areas
No
7 Defense installations No
8 Densely populated or built-up area Ankleshwar Ankleshwar is around 4 km from the
proposed expansion project site.
9 Area occupied by sensitive man-
made land uses Hospitals, schools,
places of worship, community
facilities)
No
10 Areas containing important, high
quality or scarce resources (ground
water resources, surface resources,
forestry, agriculture, fisheries,
No
11 Areas already subjected to pollution
environmental damage. (those
where existing legal environmental
standards are exceeded)or
No
12 Areas susceptible to natural hazard
which could cause the project to
present environmental problems
(earthquakes, subsidence,
landslides, flooding, erosion, or
extreme or adverse climatic
conditions)
No
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure–
XI
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LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products with their Production Capacity
II Layout Map of the Plant
III Brief Manufacturing Process Description
IV Description of Effluent Treatment Plant with flow diagram
V Details of Hazardous Waste
VI Water, Fuel & Energy Requirements
VII Details of Hazardous Chemicals Storage & Handling
VIII Details of Stacks and Vents
IX Expected Noise level at Different source within the premises
X Socio-economic Impacts
XI Proposed Terms of Reference for EIA studies
XII Water Supply Letter
XIII TSDF & CHWIF Membership Letter
XIV Lease Deed Documents
XV Toposheet
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ANNEXURE-I
LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY
Float Plant Details:
Quantity in Square Meter/Annum S. No. Product
Permitted Additional Total
1 Float Glass
2 Mirror
3 Lacquered Glass
4 Coater Glass
2,50,00,000
- 2,50,00,000
Proposed Expansion Details:
SR.
NO.
PRODUCT NAME EXISTING CAPACITY
(MT/MONTH)
PROPOSED CAPACITY
(MT/MONTH)
1 Silica Sand (Glass Grade) 13,500 56,225
2 By-Products (Coarse, Fines and rejects) 19,620 30,275
3 Total 33,120 86,500
LPG Storage Tank Details
Existing Capacity:
LPG Tanks = 4 Nos. (Capacity = 56.25 MT each)
SR.
NO.
Storage Material No. of Tanks Capacity Total Capacity Tank Dimensions
1 LPG 4 56.25 MT (each) 225 MT Length = 16.2 m
Diameter = 3200 mm
Total Proposed Capacity:
LPG Tanks = 6 Nos. (Capacity = 120 MT each)
Proposed combine capacity: 720 MT
SR.
NO.
Storage
Material
No. of Tanks Capacity Total Capacity Tank Dimensions
1 LPG 6 120 MT
(each)
720 MT Design Pressure: 21 Kg/cm2
Overall Length = 24000 mm,
Tank ID 4010 mm,
Tank Shell = 28 mm thick
Dished End 18 mm Thick.
Note: M/s. Gujarat Guardian Limited is exploring the option to merge the existing and
proposed LPG storage yard for future so that the new LPG yard would be (existing + proposed)
capacity which is 720 MT. By proposing this we are also proposing that existing yard be
demolished and merged with new LPG storage yard in case above is the decision.
Existing LPG storage yard: 225 MT
Additional Proposed LPG storage: 495 MT
Total Storage of LPG onsite: 720 MT
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LIST OF RAW MATERIAL (EXISTING & PROPOSED)
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
Float Glass
1 Sand MT 14,000 0 14,000
2 Soda Ash MT 4,500 0 4,500
3 Dolomite MT 3,800 0 3,800
4 Limestone MT 1,400 0 1,400
5 Feldspar MT 850 0 850
6 Salt Cake MT 215 0 215
7 Carbon MT 21 0 21
8 Cullet MT 6,000 0 6,000
Wet Coater
1 Raw Glass Sq. Meter 5,83,000 0 5,83,000
2 Washing & Polishing Chemicals Kg 2,062 0 2,062
3 Tin Sensitizer Litre 119 0 119
4 Palladium Sensitizer Litre 45 0 45
5 Silver Solution
Silver Nitrate
Litre
Kg
2,600
1,088 0
2,600
1,088
6 Reducer/
Silver less solution
Litre
Litre
4,830
2,920 0
4,830
2,920
7 GMPA & GMPB Litre 1,190 0 1,190
8 Paint MT 68 0 68
9 Ortho-Xylene Litre 9,971 0 9,971
10 HCL-32% Litre 11,393 0 11,393
11 Caustic-32% Litre 13,508 0 13,508
12 Ferric Sulfate kg 256 0 256
Lacquered Glass
1 Raw Glass Sq. Meter 1,50,000 0 1,50,000
2 Washing and polishing chemical Kg 200 0 200
3 Adhesion Promoter Litre 50 0 50
4 Paint MT 10 0 10
A GLASSOLUX NG 9003 PURE WHITE Kg 2,500 0 2,500
B GLASSOLUX NG 2105 Sapphire Kg 2,500 0 2,500
C GLASSOLUX NG 3004 Burgundy Kg 2,500 0 2,500
D GLASSOLUX NG 6113 Fluo green Kg 2,500 0 2,500
E GLASSOLUX NG 9005 Black Kg 2,500 0 2,500
F Ivory Kg 2,500 0 2,500
G Red Kg 2,500 0 2,500
5 Ortho-Xylene Litre 1,000 0 1,000
Sand Beneficiation Plant
1 Raw Silica Sand MT 33,120 53,380 86,500
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ANNEXURE-II
LAYOUT MAP OF THE PLANT
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LPG STORAGE LAYOUT (EXISTING)
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LPG STORAGE LAYOUT (PROPOSED)
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ANNEXURE-III
BRIEF PROCESS DESCRIPTION
EXISTING
Below is the manufacturing process for following products;
1. Float Glass
2. Mirror Glass
3. Deco crystal Glass
1. Sand Beneficiation Process
The basic beneficiation process comprises of chemical and mechanical treatment of
raw sand to remove embedded heavy minerals, clay and over and under size grain.
This involves washing sand with water and then applying mechanical media to scrub
the impurities and there after treating with chemicals to froth out the heavy
minerals and other impurities.
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2. Glass Manufacturing
a) Float Glass
The basic float glass manufacturing process was invented in the mid- 1950’s due to
inherent efficiency over the then existing sheet and plate production methods, the
float glass industry worldwide has subsequently been essentially converted to the
float process. The most significant advantages of the float process lie in its highly
automated production process and the consistency of product quality. For example,
the float process compared to the sheet glass process requires less manual handling,
it is more cost efficient to produce and eliminates significant distortion in the glass.
Over the last thirty years, there have been several technological advances towards
design and manufacture of refractories and equipment applicable to the float glass
manufacturing.
The float glass manufacturing process would consist of receiving raw materials (Silica
sand, Soda Ash, Limestone, Dolomite, Salt Cake, and minor ingredient materials
including Rouge and Charcoal) in bulk quantities by rail and road from various
locations. Raw materials would be unloaded and stored in batch house, then
weighed into batches, mixed and then layered with broken glass (“Cullet”) returned
from the end of the process line. The mixed batch would be conveyed to the furnace
where the raw materials would be melted using either natural gas or fuel oil.
Molten glass from the furnace would flow by gravity and displaced into a tin bath
where a continuous ribbon would be formed by controlling glass temperature with
time. The ribbon would be pulled, or drawn, through the bath on a layer of molten
tin, the temperature of which would be controlled electrically. Upon existing the
bath, the ribbon of glass would enter the electrically heated annealing lehr where in
it would be cooled preparatory to cutting into sheets.
A computer controlled automatic cutting system would cut the ribbon into
predetermined sizes as dictated by customer orders. Pieces would than either be
placed racks, boxes, or on dollies for storage or direct shipment. Any waste or
damaged glass would be broken and recycled to the batch house as cullet. Additional
information about each stage of the manufacturing process is contained in the
following sections.
Raw Materials:
Raw materials needed for the manufacture of float glass include Silica sand, Soda
Ash, Limestone, Dolomite, Salt Cake and minor amounts of Rouges and Charcoal.
Silica sand would comprise about 60% of the total raw material input with Soda Ash,
Dolomite together making up about 35% of the total by weight. The remainder
would be distributed among Limestone, Salt cake, Charcoal and Rouge.
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Batch House:
Raw material would be received at the plant site in trucks and/or rail cars. Materials
would be dumped into a hopper in a unloading area by a belt conveyer to a bucket
elevator where they would be discharged into the proper bins with the help of a
rotary spout. The concrete storage bins would be designed in such a way that
material segregation would be reduced to a minimum, an important quality
consideration in glass manufacturing. Each material would be weighed individually
on high accuracy industrial scales, and then checked on a totalizer scale prior to the
bin discharged into the mixer. The dry ingredients would be thoroughly mixed, and
then measured amount of water would be added to the mixer for wet mixing. After
mixing a precise amount of cullet would be layered on the mixed batch prior to
conveying to a melting furnace. The batch would be stored in large hopper over the
furnace feeder. In the event of mechanical or electrical failure of any batch, system
component, this hopper would provide mixed batch for about six hours of continues
feeding in to the furnace. Dust control equipment in the unloading area and batch
house would operate continuously to maintain a safe, healthy and working
environment for the employees, as well as to minimize dust and particulate
emissions.
Melting Furnace:
The melting furnace would be capable of melting clear glass at a desired rate. The
batch materials would be fed into the glass-melting furnace from the blanket. The
operation of the feeder would control by a precise glass level controller.
The melting furnace would be a large refractory structure enclosed in structure and
binding steel. Many different types of refractory materials are used in furnace
construction. Each one is carefully selected to use in certain areas where it will
perform with a long life and not contribute to product defects. The furnace
refractory, if misapplied, can very often be a major source of glass defects. The batch
material would be pushed away from the furnace back wall by the blanket feeder.
Floating on top of the molten glass, the batch would pass under the fuel flames,
pouring out of the ports above the furnace side wall. Temperature exceeding 2900
degree F would melt the batch ingredients. Combustion products would be
discharged through a stack.
After the batch material melts into solution, the molten glass would be gradually
cooled in the refiner section of the furnace. By the time the glass would reach the
end of the melting furnace, it should be completely free of un-melted batch particles
and uniform in composition. This homogeneous blend of molten glass would now be
delivered to the float bath in a constant pouring action through the channel.
Float Bath:
The float bath would consist of an electrically heated forming oven. The glass would
flow on to the surface of a pool of molten tin at approximately 2900 degree F. A
continuous ribbon would be drawn from this pool and transported and cooled along
the length of the float bath. The temperature of glass at the bath exist would be
approximately 1100 degree F, still a plastic material but solid enough to the removed
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22
from the surface of the tin with mechanical rolls. A flow of SO2 gas mixed with
nitrogen is applied on these rolls to prevent any damage to the bottom of glass
ribbon by these or the subsequent rolls. The bath chamber would be carefully sealed
and maintained under positive pressure by a nitrogen atmosphere made slightly
reducing by the addition of small amount of Hydrogen. This is necessary to maintain
a clean pristine surface for the tin, which would rapidly oxidize in air.
The molten glass, when flowing on the surface of the molten tin, forms a ribbon of
perfectly flat parallel surface 6 mm thick. Additional process manipulation of the
glass can produce thickness ranging from 2 mm to 12 mm and above. The ribbon
emerges from the tin bath at different speeds to provide the desired thickness.
Annealing Lehr:
The Annealing lehr must cool the glass ribbon from 1100 degree F to approximately
200 degree F, in a precise uniform manner to prevent residual stresses that make
cutting difficult and also to prevent temporary stresses that causes ribbon fractures.
The lehr would use small amounts of electric heat to keep the edge of the sheet
from cooling faster than the center. There are special rollers and drive systems
required for the lehr as well as a sophisticated temperature control system to
accomplish the controlled cooling.
Cutting Line:
The glass would emerge from the annealing lehr in continuous ribbon at a
temperature slightly above room temperature. The glass would pass under a
darkened booth where, under special lighting conditions, inspector would scan every
square foot for defects. An automated inspection system would detect defects in the
glass ribbon and help command the defect marking system to spray ink on the
defect. The glass sheets containing defect would be broken crushed and returned to
the batch house to be recycled with the raw materials.
The inspected ribbon would be cut to exact dimensions with precise, high-speed
cutters. The edge trim would be eliminated, crushed and returned to the batch
house. The glass sheets, free of defects, would now be boxed or put on metal racks
and warehoused for shipment. Special vacuum units are required to unload large
glass sheets. Due to the fragile nature of glass, most of the float glass leaving the
plant would be shipped by truck.
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23
Process Block Diagram:
Product Sand
(Used as Raw Material for
Manufacturing of Float
Glass)
Chemical
Dosing &
Iron
Removal
Batching Melting Furnace
Forming
(Float Bath) Inspection Annealing Lehr
Cutting Line and
Storage
Final Product Float Glass
(Used as Raw Material for Mirror
Glass Manufacturing)
Sand Mining
Screening Washing Sizing Sand Yard
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Mirror from Float Glass
Silvered mirror is manufactured by deposition of silver by reduction process. Layer of
silver deposited on clear glass acts as reflective surface in which images can be seen
clearly.
Raw floated glass is loaded flat on the atmospheric side on the loading table with the
help of robotic arm. This raw glass is rinsed with Ultra filtered water to get rid of
separator powder, dirt, dust and any other water soluble contamination. After
rinsing, Glass is cleaned and polished with the help of oscillating cylindrical brushes
and applying a polishing agent. This process smoothens the surface of glass and
exposes a fresh layer of glass.
On the cleaned glass surface, first layer of sensitizer, which is basically a tin chloride
solution, is applied. After first layer of sensitizer, second layer of super sensitizer i.e.
Palladium chloride solution is sprayed. After sensitization, glass surface is rinsed off
with D.M water and silver nitrate solution along with the reducer is sprayed. Silver
nitrate is reduced to silver ion on the glass surface and deposited in multiple layers,
forming a reflective surface. This reflective surface of silver is protected by spraying
tin solution, and a reducer, which deposits a layer of tin over the layer of silver. This
helps prolong the life of silver layer as it is not exposed directly to corroding
atmosphere.
After application of passivator, two coats of paint are applied with the help of curtain
coater. First coat of paint provides chemical and corrosion resistance protection to
the reflective surface. Second layer of paint provides mechanical resistance such as
abrasion, dirt, dust etc. Both the paint are dried and cured in ovens which use MW IR
heaters as source of heat. After application of paints, glass passes through ovens at a
fixed speed for specified time duration and temperature. Mirror is then cooled,
washed, branded and packed.
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Flowchart for Mirror:
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26
1. Lacquered Glass from Float Glass
Lacquered glass is a back painted flat glass, used for decorative purposes.
Raw floated glass is loaded flat on the atmospheric side on the loading table with the
help of robotic arm. This raw glass is rinsed with Ultra filtered water to get rid of
separator powder, dirt, dust and any other water soluble contamination. After
rinsing, Glass is cleaned and polished with the help of oscillating cylindrical brushes
and applying a polishing agent. This process smoothen the surface of glass and
exposes a fresh layer of glass.
On the cleaned glass surface, a layer of neutral silicone adhesive along with DI water
is sprayed, allowed to settle and then excess is rinsed. After application of adhesive,
a coat of paint is applied with the help of curtain coater. Paint is baked in electrically
heated ovens for a fixed duration at certain temperature, which is dependent on
thickness of glass and color of paint.
Lacquered glass is cooled, washed, branded and packed.
Flowchart for Lacquered Glass:
Raw Glass
UF WaterWashing with UF
waterdrained
Cerium
Oxide
slurry
Cleaning with
Cerium Powderdrained
UF WaterFinal cleaning with
cylindrical brushesDrained
GMP A &
GMP B SolnAdhesive spray drained Packing
Dryer & Preheat Branding
Base Coat paint
CurtainFace wash
Base Coat Oven Top Coat Oven
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2. Coater Glass from Float Glass
Float glass is used as the primary raw material for the coating operation. The glass is washed
using ultra-pure water. A de-ionization and/or reverse osmosis (DI/RO) water treatment
system is used to obtain the water purity necessary for washing the glass. A small amount of
a detergent is added to the wash water. A scrubbing media, typically Aluminum Oxide, may
be also be used to clean the glass. After the glass has been washed, it is air dried and then
conveyed to the coater.
The coater is a high-tech process in which a molecular-level deposit of metals and other
compounds are bonded to the glass. This molecular-level thickness of coating compounds
provides the glass with various reflective and refractive properties. The coater consists of a
series of vacuum chambers in which the washed glass in conveyed into. Once the glass is in
the vacuum chamber, short strong pulses of electricity are sent through both the glass and a
‘target’. The target is a pre-manufactured source of the coating. Examples of coating target
materials include: Silver, Nickel, Chromium, Titanium, Aluminum, Tin, Zinc, and Silicone.
None of the target materials used is emitted/released to atmosphere, because of a vacuum
pressure within the coater.
The target material is atomized by bombarding it with positively charged Argon ions from
plasma. These are created by feeding gas into the plasma at the cathode (or target). A
magnetic field determines the density of the plasma. The metal atoms emitted from the
cathode target will adhere to the glass substrate. So that the gas discharge process can be
initiated and maintained, the related electrostatic field intensity is necessary. These are
created by a sputter power/current supply.
After the glass receives the appropriate layers of coating, it is conveyed out of the coater,
rinsed with water, cut into specific sizes, packed to reduce breakage, stored, and ultimately
shipped to customers.
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PROCESS FLOW DIAGRAM
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27
SAND PLANT (PROPOSED – CAPACITY ENHANCEMENT)
Process Description
It is to be noted that the process description below is based upon preliminary information
and design only at this stage. Further test work particularly in regards to the settling velocity
of the slimes and efficiency of the dewatering/filter equipment will have ramifications on
the design of the final process.
FEED PREPARATION
Feed will be received in a dump hopper with a 150mm grizzly screen. Feed will be metered
into the circuit via belt feeder governed by a belt weigher on an inclined conveyor. The feed
will be conveyed into a drum scrubber where it will have water added. The drum scrubber is
intended to liberate the agglomerated material and free some of the clay material in the
feed. The discharged product will pass through a coarse screen attached to the drum to
remove any material >6mm.
DESLIMING AND SIZING STAGE
The scrubbed material will transfer via gravity to a desliming sump to be pumped to a
cyclone for removal of clay particles. The overflow of the cyclone containing the fine clay
particles will report to the thickener for processing. The underflow will report to a sizing
screen. All particles less than 600 micron will be pumped to the attritioner feed cyclone.
Oversize material will launder to the ball mill for comminution. Milled material will launder
back to the desliming sump for re-processing in the desliming cyclone.
ATTRITIONING STAGE
Material that passes through the sizing screen will be pumped to a cyclone above the
attritioner. The cyclone will dewater the feed to the attritioner to a high density prior to
laundering to the attritioner. The attritioner scrubs the high density slurry using a series of
rotating paddles to remove any contamination from the surface of the sand particles. The
overflow from the cyclone will launder via gravity to the thickener.
UP CURRENT CLASSIFICATION STAGE
After processing in the attritioner the slurry will be pumped to an up current classifier (UCC)
for classification by size using a current of rising water in a vessel. Larger, higher density
particles pass down through the current while smaller, lighter particles are lifted over a
weir. The flow rate of the up current water can be varied to adjust the cut size of the
particles reporting to the overflow. The UCC overflow consisting of particles
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28
launder to a process sump feeding the product dewatering cyclone and screen. The product
will be dewatered and transferred to a conveyor system for stockpiling. The overflow
fraction of the cyclone will be laundered directly to the drum scrubber for re-use. The
middlings fraction will either be sent to the rejects process sump or returned to the spiral
feed sump in response to operational conditions and feed characteristics.
PROCESS WATER AND THICKENER
A process water tank will be the source of all water distribution through the circuit. Through
the use of dewatering equipment on all output streams MT has endeavored to minimize the
net water loss therefore reducing water make-up demand into the circuit. Clean water is
recirculated within the system, where possible, to reduce both thickener size and flocculent
consumption. Water removed from the circuit in high slimes stages will be treated in the
thickener using a flocculent such that clean water will flow over the weir. This water will
then report via a coarse static screen to the process water tank. Thickened slimes will flow
via the underflow to a process pump for transfer to the belt filter press. The filter press will
dewater the slimes as much as possible prior to stockpiling. A requirement for further
flocculent dosage prior to filtering will be determined in detailed test work.
Chemical Usage
The only chemical addition to the plant process will be a flocculant. Detailed test work will
determine the best type of flocculant for these slimes, what type of dosing system would be
most appropriate and at what rate flocculant will need to be added to the system to remove
the slimes and clarify the water. Assuming a dry granular type flocculant is to be used then
consumption has been assumed to be between approx. 0.5 to 1.5 metric tonne/month.
Product Mass Balance
Given the variability and range of feed sources the mass balance can vary markedly. Below is
an estimate based upon information provided by Gujarat Guardian.
Estimated Output Quantities as % per Month
Note: Values are based upon feed characteristics provided by GG.
Product Name
Minimum
Throughput
MT/month)
Maximum
Throughput
(MT/month)
Remarks
X Feed 100% Based upon nominal feed rate of 120 t/h at 80%
plant availability
A Finished Sand for Float
Glass 70% 90% Based upon range of values provided by GG
B Fines Rejection of (-) 150
micron 5% 25% 5% to 25% of head feed
C
Pebbles and Coarser
Particle (+) 6 mm to (-) 50
mm
0% 5% Allowance only
D Boulders (+) 50 mm 0% 0% Allowance only
E Rejected Clay 5% 25% This assumes 5-25% slimes however actual rejected
clay depends upon sale of clay product
F Any other (HMC) 2% 10%
This assumes 2-10% HMC within the head feed.
Actual reject depends upon saleability of HMC
product.
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Proposed Sand Beneficiation Process Diagram
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LPG SYSTEM START-UP TO FURNACE
This procedure will describe the entire startup process of the LPG system from the tanks to
the peak shaving station.
Under normal operating conditions the LPG system should have 80-90 Degree C water
running through the vaporizers.
1. Recirculation System:
a. Start circulating water:
i. Verify all valves are open to circulate water through the boiler and
vaporizer
ii. Ensure the water system has a pressure of 1-1.5 bar
iii. Start the recirculation pump for the desired vaporizer and hot water
generator (Note: valves have been provided to allow either hot water
generator to feed either vaporizer)
iv. Pump inlet pressure should be 1 – 1.5 bar and outlet should be 3.0 – 4.0 bar
depending on water temperature
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i. Verify the vapor pressure before the second stage regulator is 2.5 bar.
ii. Open safety shut-off valve on second stage regulator by opening the
bypass valve while at the same time, pull down on the bottom handle.
iii. Verify the pressure after the second stage regulator is 300 mbar
iv. Check that the final regulated pressure is 50-60 mbar when burner is
working.
c. Hot Water Generator Startup
i. Verify control voltage to the boiler control panel from the 220V panel next to the
AES control panel is on.
ii. On the boiler control panel, Turn “Burner Control” switch to “on” and turn
“Circulation” switch to “on”.
iii. Check the Burner start-up sequence (ref. figure 3)
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Note: If there is a burner fault (light F) reset by pressing button 2, if the fault reappears,
contact Engineering.
2. LPG Supply (ref. figure 4):
a. Verify that the tank valves are open. (They are normally all open)
b. Verify that the System pressure is above 4.8 bar at the liquid transfer pumps.
c. Verify that inlet and outlet valves of the pump(s) are open.
d. If system pressure is below 4.8 bar you will need to start one of the pumps.
e. The Liquid Return line going from the transfer pump to the tank(s) where LPG is
being consumed from should be open while the transfer pump is running
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3. Vaporizers (ref. Figure 5.):
a. Confirm that the vaporizer that will be used is hot. The water inlet temperature
should be above 65oC. (Note: if water inlet temp is cold, the LPG liquid level will rise
in the vaporizer. If the LPG liquid level reaches the liquid carry over sensor or if the
vapor out temp is below 10oC, the solenoid valve allowing liquid LPG into the
vaporizer will close)
b. Power on the vaporizer from the vaporizer control panel.
c. The LPG liquid inlet valve should be closed
d. Open the vaporizer vapor discharge valve.
e. Open the LPG inlet pneumatic valve by pressing “inlet valve open/close” on the
Vaporizer control panel.
f. Open LPG liquid inlet ball valve slowly allowing LPG to the vaporizer.
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4. Mixer/Blender (ref. figure 6.):
a. Ensure that the manual valves at the discharge of the mixer are closed
b. Open the inlet ball valves on the LP vapor and compressed air lines
c. Turn on the power at the control panel.
d. Open the inlet ball valves by pressing “Inlet valve open/close”.
e. Check the inlet pressure gauges. They should read around 6.2 bar on the
compressed air and 5.0 bar or greater on the LPG vapor.
f. If the pressure difference in less than 1.4 bar, then open the regulators by pressing
“POM start/stop”. [If not, check plant compressed air and/or start the liquid transfer
pumps (tank to vaporizer) if needed.]
g. Start the flare unit (this will allow the system to stabilize). The flare can be shut
down once LPG is flowing to the furnace.
h. Verify that the outlet pressure at the mixer is as follows:
i. When flowing LPG: 3.5 bar
ii. When outlet valves are closed: 4.0 bar
iii. Alarm pressure: 4.3 bar
Note: At this point, the PLC will energize the loading solenoid valve for a period of time,
overriding any alarm conditions. If all alarm conditions clear during this time, the mixer will
continue to operate. If any alarm conditions remain, the mixer will shut down. These alarm
conditions must be cleared before the mixer will start and remain in operation.
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PROPANE GAS TO THE FURNACE (ref. figure 8):
1. After completing steps 1 – 5, communicate with the furnace to ensure the supply
pressure at the furnace is 3.5 bar and the incoming LPG valve is closed.
2. SLOWLY open the outlet valve to the furnace at the mixer.
3. Verify the peak shaving valve is closed and then open the isolation valve after the peak
shaving valve.
4. Using the peak shaving valve, slowly open the flow to the furnace and confirm that the
blended LPG vapor is flowing.
5. Once flow is confirmed, slowly close the natural gas valve feeding the furnace
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NATURAL GAS TO THE FURNACE:
1. SLOWLY close the peak shaving valve on the LPG supply line as you slowly open the
natural gas supply valve.
2. You should now be able to hear the natural gas flowing to the furnace.
3. Leave the outlet valve at the mixer to the furnace open, and start the flare to bleed the
excess pressure from the supply line to the furnace.
LPG SYSTEM SHUTDOWN:
1. Vaporizers:
a. Shut off the liquid transfer pump (if running), this can either be done locally or from the
AES panel.
b. Close the vaporizer inlet valve, allowing the propane gas in the system to evacuate and
burn off using the flare
2. Mixer/Blender
a. Close mixer air and propane valves.
b. Close the solenoid supply to the regulators.
c. Close the flare valve at the outlet of the mixers.
3. LPG Storage Tanks:
a. Verify transfer pumps are off.
b. Close pump outlet valve only, leave the inlet valve open.
4. Flare stack:
a. Close the flare stack pilot valve and main line valve.
b. Swing the rain cap over the top of the flaring stack for weather protection.
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EMERGENCY SHUT-DOWN SWITCHES (ESD) AND REMOTE OPERATED VALVES (ROV’s)
There are six (6) emergency shut-down pushbuttons located within the LPG area as follows:
a. Unloading shed #1
b. Unloading shed #2
c. Transfer pump shed
d. Hot Water Generator and Vaporizer shed (near overhead door)
e. Hot Water Generator and Vaporizer shed (west end)
f. Blender room
These buttons maintain a constant air supply to the ROV’s at the LPG supply tanks to keep
them open. During an emergency, any of these buttons can be pressed to stop ALL flow out
of the LPG tanks.
When any of these six buttons are pressed, it will trigger a relay in the main control panel.
The relay will release the compressed air out of the remote operated valves on the tanks.
There is also a manual 3 way valve on the compressed air supply in the hot water generator
and vaporizer shed that will stop the incoming supply of compressed air and dump the air
out of the line supplying the ROV’s. This will also cause the valves on the bottom of the
tanks to close.
Pull out the ESD pushbutton to reset the alarm and apply pressure back to the excess flow
valves.
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ROV CONTROL PANEL (Figure 11)
Outside the South gate of the LPG yard there is a panel that allows you to control each ROV
Independently. This can be used if you want to utilize LPG from a specific tank. It also
receives signals from the high level sensors on the tanks (set at 85%). If one of the sensors is
tripped an alarm will be triggered at this station.
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LPG UNLOADING PROCEDURE
This procedure will describe the unloading procedure using the new Alternate Energy
Systems (AES) equipment.
1. Pre-Unloading Checklist:
a. Prior to unloading the technician responsible should check the level of the tanks
by using the Roto-Gauge on the front (see figure 1)
b. Verify that there is enough room in the LPG tanks to unload the LPG (an LPG truck
in India will have around 18 tons of LPG). Note: Each tank has a 60 ton LPG capacity,
but they should not be filled up beyond the 85% mark (51 tons), if a tank is filled
beyond this point the high level alarms will trip.
c. For maximum unloading efficiency the LPG should be unloaded into two or more
tanks simultaneously (this is because the LPG liquid in lines at the top of the tanks is
2” and the liquid line feeding them from the unloading stations is 3”)
d. Once the tanks have been determined the liquid inlet and vapor inlet valves at the
top of these tanks should be opened (see figure 2).
e. Prior to connecting the liquid and vapor hoses to the tanker all valves in the
unloading shed should be closed.
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2. Unloading LPG
a. It takes approximately 4 hours to fully unload an LPG tanker, ensure that the
proper personnel will be available to witness the entire unloading.
b. The first tanker should always pull up to the South unloading station, this will
allow the second tanker to pull in behind the first and unload at the North unloading
station (if required)
c. When the truck is in position the grounding lead on the unloading shed should be
connected to the frame of the truck
d. Connect the liquid and vapor unloading hoses to the truck.
e. Verify all the valves in the unloading shed are closed and SLOWLY open the valves
on the tanker. Check for leaks.
f. Once no leaks have been observed, slowly open the vent line on the liquid line to
purge the air from the line. Liquid will begin to flow through the check valve on the
unloading skid. When the liquid fills 50% of the check valve (this can be witnessed
through the sight glass) close the vent line.
g. Open the inlet and outlet valves on the liquid transfer pump (figure 3)
h. SLOWLY open the globe valve on the unloading skid. As it is opened LPG will begin
flowing from the truck to the tanks based on the pressure differential.
Typically the tanks will be around 6 bar and the truck will be around 7 bar when
unloading begins.
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i. When the pressure in the truck lowers and gets closer to the pressure in the tanks
the flow will slow down. At this point the liquid transfer pump can be turned on.
j. Eventually the pump will begin to vibrate because the pressure in the truck is not
high enough. At this time the transfer pump should be shut off, and the compressor
should be turned utilized.
k. BEFORE TURNING ON THE COMPRESSOR slowly open the ALL the valves on the
vapor line in the unloading shed and the skid (including the compressor bypass
valve). The pressure between the tanker and the tanks having LPG unloaded to them
will equalize. The 4-way valve should be pointing to the LEFT in order to pressurize
the tanker by pulling vapor from the LPG tanks.
l. Verify all the valves are open, if a valve is closed on the discharge side of the
compressor the pressure will quickly rise, causing a very unsafe condition.
m. Turn on the compressor, the pressure gauges for the suction and return lines on
the compressor should be equal because the bypass valve is open. Very SLOWLY
close the bypass valve while monitoring the discharge pressure. The pressure should
rise slightly and LPG liquid will once again begin flowing to the tanks. Note: the
discharge pipe going from the compressor to the tanker will heat up due to the
compressed gases; this is normal and can be used as a verification the flow is in the
correct direction.
n. Monitor the pressure on the tanker, it should not go above 8 bar, if it does shut off
the compressor until it drops below 7.5 bar and start again. If time is a concern the
transfer pump can also be turned on again to maximize the flow to the tanks (if the
transfer pump begins to vibrate again turn off the pump and continue unloading
with the compressor)
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43
o. If there is too much flow coming from the truck tanker, the excess flow valve on
the truck will trip and flow will be reduced or cut off completely. If this happens, shut
the valve on the truck (you will hear the excess flow valve reset when flow is
stopped) and slowly open it again.
p. Throughout the process the LPG level on the truck and the tanks being unloaded
to should be checked and recorded.
q. When the Roto-Gauge on the truck shows less than 3% only the unloading
compressor should be used (while making sure the truck tanker does not exceed 8
bar pressure.
r. As the last amounts of liquid leave the truck the check valve will begin to shut and
LPG will cease to flow. When this happens the compressor should be turned off and
all the valves on the liquid line should be shut and the remaining LPG in the
unloading hose should be SLOWLY vented until all pressure is gone. At this point the
hose can be removed from the truck.
3. Depressurizing the truck
a. SLOWLY open the vapor bypass line around the compressor. This will cause the
pressure in the truck to equalize with the LPG tanks in the yard.
b. When the pressure difference drops to the point where vapor is no longer flowing
on its own the 4-way valve on the compressor should be rotated so that the handle
is pointed UP. In this configuration the compressor will pull vapor from the truck and
load it back into the tanks.
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44
c. BEFORE TURNING ON THE COMPRESSOR verify ALL the valves on the vapor line in
the unloading shed and the skid are open (including the compressor bypass valve).
d. Turn on the compressor and verify the pressure on the suction and discharge are
correct.
e. Continue to run the compressor until the pressure on the tanker is around 2.5 bar.
f. Turn the compressor OFF
g. Close all the valves on the vapor line and the outlet of the truck.
h. Depressurize the hose using the vent on the skid by SLOWLY opening the valves.
i. The vapor hose can now be removed from the truck.
j. Close the valves on top of the LPG tanks
k. Close the gates to the LPG yard
l. Unloading Complete
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ANNEXURE-IV
TREATMENT PROCESS
DETAILS OF STP
Process Description of Sewage Treatment Plant
The Domestic waste water (Sewage) from the service/amenity blocks of plant flows through
gravity towards a dedicated Sewage Treatment Plant provided within the GGL Ankleshwar
Premise.
As per the original design, sewage/domestic waste water through gravity flows into the 1st
Unit of STP provided viz. the equalization tank through hand racked bar screens. The sewage
in the Equalization tanks is kept well mixed with the help of air supply through 2 blowers (1
working 1 standby) The Equalized sewage is pumped to the Aeration Tank by means of 1
Nos. submersible pump.
The Aeration Tank is designed for Extended Aeration for considerable reduction of organic
matter. To maintain the MLSS in Aeration Tank and for continuous oxygen supply to
maintain the DO levels, surface Aerator provided in the Aeration Tank is kept in continuous
operation also we have provided back up air supply line from blowers which are used for
supply air in equalisation tank. The overflow from the Aeration tank is taken to the Clarifier.
In the Clarifier, the particulate as well as colloids and suspended solids are allowed to settle
down by gravity. For better settlement, we have provided flocculent dosing in secondary
clarification process. The supernatant thus formed is taken to filter feed tank by gravity,
where we have provided filtration process by passing the water through Pressure sand filter
and Activated charcoal filter an finally collected into treated water tank cum chlorine
contact tank.
To kill the pathogenic bacteria we are using sodium Hypochloride chemical, doing is through
the automated dosing pump which dose the quantity based on the PPM level of water in
treated water tank to maintain the minimum 0.5 PPM all the time before pump it to reuse
for gardening by means of a piping network. The partial sludge from the Clarifier is recycled
back to Aeration Tank, which accelerates the aerobic digestion of sewage. As and when
required, part of sludge is wasted to sludge drying beds. The filtrate from the Sludge Drying
Beds is returned back to the bar screen chamber by gravity and the solar dried sludge is
used as manure for gardening purpose.
Adequacy Statement of Existing STP Units is suitable to 90 KLD Hydraulic Load and
Characterization
Sr. No. Parameters GPCB Limit for Sewage Outlet water
1 BOD < 20
2 SS < 30
3 Residual Chlorine � 0.5
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DISPOSAL MODE OF SEWAGE
The domestic waste water after treatment in STP is used for irrigating the green belt area
within the plant Premise. Consolidated Consent and Authorization Order No. AWH-62530 of
GPCB valid up to 27-01-2019, stating the parameters for disposal of treated domestic waste
water for gardening.
Details of Existing Sewage Treatment Plant
Description of Units and sizing of Existing Sewage Treatment Plant are enlisted in Table
Sr. No. Name of the Unit Size Capacity/Volume No. of Units
1 Screen Chamber 3.3 x 2.5 x 3.5 m SWD 28.9 m3 1
2 Equalization Tank 4.0 x 3.5 x 3.5 m SWD 49 m3 1
3 Aeration Tank 6.0 x 5.0 x 3.0 m SWD 90 m3 1
4 Secondary Clarifier 4.0 m Diameter x 1.5
m SWD 19 m3 1
4 Chlorine Contact
Tank 4.0 x 2.0 x 5.0 m SWD 40 m3 1
5 Sludge Drying Beds
3.0 x 2.0 m with 1.5 m
Sludge Application
Depth
Area = 6 m2 x 6
Nos. = 36 m2 6 Nos.
6 MCC Panel/Return
Sludge Pump House ---- ---- 1
7 Flocculation dosing
tank Capacity 500 litres Capacity 500 litres 1
8 PSF 5 m3/Hr capacity 5 m3/Hr capacity 1
9 ACF 5 m3/Hr capacity 5 m3/Hr capacity 1
Description of Existing Sewage Treatment Plant Units with Suggestive Modifications
1. Inlet Collection Sump and Screen Chamber: (1 No.)
The prime purpose of providing the Inlet Collection sump cum Screen Chamber is that the
sewage through gravity from the entire plant Premise is conveyed to this unit. MSEP Fine
Screens of 50 mm spacing are provided to arrest any large floating matter, settle-able solids,
rags, plastics etc. Fine bar screens shall be manually cleaned periodically.
Dimensions of Existing Inlet Collection Sump cum Screen Chamber are 3.3 x 2.5 x 3.5 m SWD
(Side Water Depth) with a retention time of 12.8 hours at an existing flow of 54 KLD.
2. Equalization Tank: (1 No.)
The main objective of providing an Equalization Tank is to store and homogenize the sewage
waste water in this unit so as to have constant load onto the further treatment units.
Dimensions of Equalization tank are 4.0 x 3.5 x 3.5 m SWD (Side Water Depth) with a
retention time of 21.7 hours at an existing flow of 54 KLD.
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47
After equalization, sewage will be pumped into the Aeration Tank through pumps manually.
This is important to prevent back flow of sewage into the Screen Chamber cum Inlet
Collection sump.
3. Aeration tank: (1 No.)
Extended Aeration is adopted as the biological treatment wherein micro organisms are
introduced in waste water which has the capacity to stabilize the organic matter present in
sewage and in turn results in reduction of BOD load. Aeration is provided so that the waste
water is brought in contact with oxygen which serves as energy for the micro organisms for
aerobic decomposition. Aeration tank is provided with surface aerator for providing
required amount of dissolved oxygen for microbial activity. MLSS (Mixed Liquor Suspended
Solids) shall be maintained in the Existing Aeration tank at retention time of 24 hours has
been provided. Treated sewage from aeration tank will be discharged under gravity into the
Secondary Clarifier. Dimensions of Existing Aeration tank are 6.0 x 5.0 x 3.0 m SWD (Side
Water Depth) with a retention time of 40 hours at an existing flow of 54 KLD.
4. Secondary Clarifier: (1 No.)
The biological sludge generated in Aeration tank will be allowed to settle in Secondary
Clarifier. Secondary Settling for circulation of clarified biomass is essential to maintain
required MLSS concentrations in Aeration Tank. The return sludge from the bottom of the
Secondary Clarifier will be withdrawn and re-circulated back to Aeration tank for
maintaining required MLSS concentration by means of sludge recirculation pumps and
partly wasted to Sludge Drying Beds. Effluent from Aeration tank is received into central
well of secondary clarifier from where it is allowed to move down and subsequently moved
up with very slow velocity. In the process of downward and upward movement MLSS is
settled down and clear supernatant effluent is obtained at the outlet of the clarifier; the
basic purpose of the secondary clarifier is to separate solids from liquids by the process of
gravity sedimentation. The clarifier is of conventional type having central shaft for
scrapping, from where the clarified effluent is transferred to Chlorine Contact Tank.
Dimensions of Existing Secondary Clarifier are 4.0 m Diameter x 1.5 m SWD (Side Water
Depth) with a retention time of 8.37 hours at an existing flow of 54 KLD.
5. Flocculent Chemical dosing tank: (1No)
The Flocculent Chemical dosing attached to secondary clarifier is used to help better
settlement of solids and to prevent any solids into the pressure sand filter and activated
charcoal filter system for better operation, less maintenance and better efficiency with
better treated waste water quality parameters complying with CCA conditions.
6. Sodium Hypochlorite mixing and treated water tank: (1 No.)
The clarified sewage from Secondary Clarifier shall be pumped to the Chlorine Contact Tank
cum final treated water storage tank. The clarified sewage will be dossed with sodium
Hypochloride solution for disinfection and killing of pathogenic bacteria and viruses.
Chlorine dosing is controlled such that the resulting treated waste water has residual
chlorine of 0.5 mg / lit. The treated waste water is being further pumped and re-used for
irrigating the green-belt area with GGL Ankleshwar Plant Premise.
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48
Dimensions of Existing Chlorine Contact Tank are 4.0 x 2.0 x 5.0 m SWD (Side Water Depth)
with a retention time of 17.7 hours at an existing flow of 54 KLD.
The treated waste water from the outlet of Chlorine contact tank is stored in a Final
Collection sump within the plant Premise.
7. Sludge Drying Beds: (6 Nos.)
The biological sludge formed in the Secondary Settling tank shall be discharged directly to
sludge drying beds. The resulting sludge shall be solar dried in the sludge drying beds. Six
Nos. of sludge drying beds are provided of dimensions 3.0 x 2.0 m and sludge application
depth of 0.3 m. The sludge drying bed will be divided into compartments to facilitate in easy
sludge drying handling and disposal. The dried sludge is being currently used as a fertilizer or
manure within the existing green belt area at GGL Plant Premise.
Contingency plan for incidents possibly encountered in sewage treatment plant
� CONTENTS
1) Introduction
2) Objective
3) Activation of contingency plan
4) Emergency action
5) Deactivation of contingency plan.
� Introduction
The contingency plan is to provide guidelines for all employee of plant in dealing with
different incidents, which have potential of environmental nuisance
� Objectives
The contingency plan has following objectives.
1) To avoid and, if not possible, to minimize environmental impact to the surroundings.
2) To seek assistance from relevant work agents for emergency handling.
3) To minimize damages to affected plant.
4) To ensure emergency procedure required is organized & implemented in an orderly
manner.
� Activation Of contingency plan
Types of incidents, which is considered to vulnerable to giving rise to possible
environmental nuisance, are given below.
a) Power failure
Mains failure leading to total blackout in a part or whole of STP plant area; interruption
of power supply due to failure of switchgear & operator malpractice.
b) Fire breakout
Setting furniture & equipment on fire through negligence, overheating of equipment &
improper handling of inflammable materials.
c) Abnormal effluent
Abnormal swage to plant, which directly affect normal operation of process.
d) Swage overflow
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49
Excessive flow particularly in rainy season burst of pipes, treatment failure due to
inadequate standby equipment
e) Non-compliance with discharge standard.
Plant overloaded in terms of quantity or quality. Illegal discharge of toxic waste.
� Emergency action
Action to be taken, where appropriate, are shown below
o To detect sign of abnormality
o To investigate & assess environmental impact
o Wherever required arrange emergency equipment
o To consider various actions to implement measures to mitigate
environmental impact & restore plant to normal operation.
o To plan corrective action & preventive action to improve plant reliability
� Deactivation of contingency plan
Contingency plan will be deactivated when the concerned plant is brought back to
normal working condition & potential of generating environmental nuisance is
eliminated.
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50
FLOW DIAGRAM
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51
EXPECTED CHARACTERISTIC OF EFFLUENT
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52
ANNEXURE-V
HAZARDOUS WASTE GENERATION AND DISPOSAL
S. No. Items Category Existing Additional Total Treatment and Disposal
Method
1 Used Oil 5.1 25
KL/Year
- 25
KL/Year
Collection, Storage,
Transportation & Sending to
Registered Refiners for recycle
/ reuse
2 Chemical Sludge
from Wastewater
Treatment
35.3 5
MT/Year
- 5
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
3 Waste residue
containing oil
5.2 20
MT/Year
- 20
MT/Year
Collection, Storage,
Transportation & Sent to GPCB
registered TSDF for land Filling
or Incineration
4 Process wastes,
residues & debris
from production
and/or industrial use
of paints, pigments,
lacquers, varnishes,
plastics and inks
21.1 20
MT/Year
- 20
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company
Recycle as a fuel or
Incineration
5 Spent solvents from
the production
and/or industrial use
of solvents
20.2 5
MT/Year
- 5
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company
Recycle as a fuel or
Incineration
7 Discarded Containers
& barrels
contaminated with
hazardous
wastes/chemicals
33.3
240
MT/Year
- 240
MT/Year
Collection, Storage,
Transportation & Disposal by
selling to Registered Vendors
8 Furnace/reactor
residue and debris
from pyrolytic
operations
D1 60
MT/Year
- 60
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
9 Inorganic Tin
compounds
B 7 1
MT/Year
- 1
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company for
Recycling
10 Spent catalyst and
molecular sieves
1.7 4
MT/Year
- 4
MT/Year
Collection, Storage,
Transportation & Sent to
licensed disposal company for
Recycling
11 Spent ion exchange
resin containing toxic
metal
34.2 15
MT/Year
- 15
MT/Year
Collection, Storage,
Transportation & Disposal by
landfill at authorized TSDF
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53
Solid (Non-Hazardous) Wastes:
S.No Waste Type Permitted Additional Total Disposal Method
1. Mirror Cullet 100
MT/Month
0 100
MT/Month
Collection, Storage,
Transportation & Sold as non-
hazardous waste for recycling
/ reuse
2. Bad Batch, Gcore, other NH
organic chemicals
100
MT/Month
0 100
MT/Month
Collection, Storage,
Transportation &
Recycling/Reuse/Landfill
3. G-Core 100
Kg/Month
0 100
Kg/Month
Collection, Storage,
Transportation & Reuse in-
house for water
neutralization
4. Waste sand 9200
MT/Month
5800
MT/Month 15000
MT/Month
Collection, Storage,
Transportation & Recycling in
house / Landfill & Recycled in
house
5. Cullet 2500
MT/Month
0 2500
MT/Month
Collection, Storage,
Transportation & Recycling
in house / Landfill
6. Sludge Generation from STP 1
MT/Month
0 1
MT/Month
Collection, Storage, Transportation &
Using as manure in-house
7. Furnace refractory waste,
Kwool, Mud, Cement etc.
10 MT/
Year
0 10 MT/
Year
Collection, Storage, Transportation &
Sent for Construction earth-
filling
8. Cullet Dust 40
MT/Month
0 40
MT/Month
Collection, Storage, Transportation &
Sold To GPCB approved
recycler
9. E-waste 250
Kg / Month
0 250
Kg /
Month
Collection, Storage, Transportation &
Sold to scrap vendor
10. Trash and Packaging
material waste
20
MT/Month
0 20
MT/Month
Collection, Storage, Transportation &
Sold to scrap vendor
11. Metal Scrap 10
MT/Month
15
MT/Month 25
MT/Month
Collection, Storage, Transportation &
Sold as non-hazardous waste
for recycling / reuse (increase
in scrape would be because
of demolish of existing sand
beneficiation plant)
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54
ANNEXURE-VI
_______________________________________________________________________
WATER, FUEL & ENERGY REQUIREMENT
WATER CONSUMPTION AND WASTEWATER GENERATION: NO CHANGE
Water Consumption Waste Water Generation Sr.
No.
Section
(KL/day)
Existing Proposed Existing Proposed
1. Domestic 350 350 205* 205*
2. Process 25 25 0 0
3. Boiler NA NA NA NA
4. Cooling & Chilling 400 400 150** 150**
5. Washing 775 775 566** 566**
6. Gardening 100 100 0 0
Total 1650 1650 921 921
* 205 m3/day of domestic wastewater is treated in STP and then reused for land
irrigation/gardening.
** 716 (i.e. 150 + 566) m3/day is recycled back to Sand Plant for Sand Washing.
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55
WATER BALANCE DIAGRAM (TOTAL PROPOSED)
Domestic
350
Washing
775
Water Consumption
1650
Domestic
205
Cooling &
Chilling
400
Wastewater
716
Washing
566
Cooling
150
716
Reused back in Sand Plant for
Sand Washing and irrigation –
Process
25
Gardening
100
All Figures in KL/Day
STP and Septic Tank
205
Reused for Land
Irrigation/Gardening
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56
TOTAL POWER REQUIREMENT & SOURCE OF POWER
Power requirement is 6.5 MW which is taken from GEB in addition 4 Nos. of (155 KVA each)
& 3 Nos. of (2.5 MW, 2.5 MW & 500 KVA) DG Sets will be kept for emergency power back
up. We also have 34 wind mills installed at Dwarka (Gujarat).
FUEL REQUIREMENT
Quantity S.No Fuel
Existing Additional Total Proposed
1 Natural Gas 6600 m3/hr - 6600 m
3/hr
2 LPG 4 MT/hr* - 4 MT/hr*
3 Diesel 1515 Ltrs /Hr 60 Ltrs/Hr 1575 Ltrs /Hr
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57
ANNEXURE-VII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
Existing:
Sr.
No.
Name of the
Material
Type of
Hazard
Kind of
Storage
Max.
quantity to
be stored
(MT)
Storage
condition
i.e. temp.
pressure
Tank Dimensions Dyke
Dimensions
1 Ammonia Corrosive,
Toxic
Bullets 20 4 to 7.5 Kg/cm2 Length: 6.546 m
Dia: 2 m
32' x 32' x 1'
2 LPG Storage Flammable Bullets 56.25 x 4 =
225
5 to 8.5 Kg/Cm2 Dia: 3200 mm
Length: 16.126 m
MOC: SA-515/SA
35 x 11.2 m
3 H2SO4
Storage
Corrosive Tank 4 KL Atmospheric
Pressure
Dia: 1.15 m
Length: 2.85 m
7 x 4.5 x 0.2 m
4 Diesel
Storage
Flammable Tanks 145 KL 0.344 Kg/cm2 @
200C
Ht: 4.2 m
Dia: 5.6 m
16.7 x 10.1 x 1 m
5 MTO &
Xylene
Flammable Barrels 30 KL Atmospheric
Pressure
Room Size:
7.7 x 9 x 7 m
7.7 x 9 x 0.5 m
Proposed:
Sr.
No.
Name of the
Material
Type of
Hazard
Kind of
Storage
Max.
quantity to
be stored
(MT)
Storage
condition
i.e. temp.
pressure
Tank Dimensions Dyke
Dimensions
1 Ammonia Corrosive,
Toxic
Bullets 20 4 to 7.5 Kg/cm2 Length: 6.546 m
Dia: 2 m
32' x 32' x 1'
2 LPG Storage Flammable Bullets 120 x 6 =
720
21 Kg/Cm2 Dia: 4010 mm
Length: 24 m
35 x 11.2 m
3 H2SO4
Storage
Corrosive Tank 4 KL Atmospheric
Pressure
Dia: 1.15 m
Length: 2.85 m
7 x 4.5 x 0.2 m
4 Diesel
Storage
Flammable Tanks 145 KL 0.344 Kg/cm2 @
200C
Ht: 4.2 m
Dia: 5.6 m
16.7 x 10.1 x 1 m
5 MTO &
Xylene
Flammable Barrels 30 KL Atmospheric
Pressure
Room Size:
7.7 x 9 x 7 m
7.7 x 9 x 0.5 m
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58
ANNEXURE-VIII
_______________________________________________________________________
DETAILS OF STACKS & VENTS
There is no addition or changes in the Flue Gas Stacks & Process Vents
Flue Gas Stacks
Sr.
No.
Stack Attached
To
No. of
Stacks
Height From
Ground (m)
Fuel Used Air Pollution
Control System
Expected
Pollutants
1. Melting Furnace 1 91 Natural Gas,
LPG
Low NOx Burner,
Stack height
PM,TF
2. DG Set
(2.5 MW)
1 30 Diesel - PM, NOx,
NMHC, CO
3. DG Set
(2.5 MW)
1 30 Diesel - PM, NOx,
NMHC, CO
4. DG Set
(500 KVA)
1 14 Diesel - PM, NOx,
NMHC, CO
5. LPG Hot water
generator
exhaust
1 12 LPG - PM, SO2, NOx
6. Diesel Engine 1
(155 KVA)
1 12 Diesel - PM, NOx, CO
7. Diesel engine 2
(155 KVA)
1 12 Diesel - PM, NOx, CO
8. Diesel engine 3
(155 KVA)
1 11 Diesel - PM, NOx, CO
9. Diesel engine 4
(155 KVA)
1 11 Diesel - PM, NOx, CO
10. Glass Edge
Burner
1 16 Natural Gas,
LPG
- PM, SO2, NOx
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59
Process Vents
S.
No.
Stack attached to No. of
Stacks
Stack
height (m)
Pollutant
Emitted
Air Pollution Control
Measures Attached
1. Main Melting Furnace 1 91 PM, TF Stack
2. Ammonia Cracking Plant 1 21 PM,
Ammonia
Stack, Nitrogen
Purging
3. Mirror Line Plant 7 12 VOC,
Ammonia
Stack
4. SO2 Vent 2 17 SO2 Stack
5. Batch House Raw
Materials DCF Vents
9 36.5 PM Dust Collector
6. Batch House Raw
Materials DCF Vents at
Basement
2 5.5 PM Dust Collector
7. Batch House Unloading
DCF Vent
1 6 PM Dust Collector
8. Cullet Return System DCF
Vent
1 3 PM Dust Collector
9. Hot Air Exhaust 5 16 PM Not Required
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60
ANNEXURE-IX
_______________________________________________________________________
EXPECTED NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES
Various sources of noise in industry have been identified as under,
• Pumps
• Blowers
• Rod Mill
The typical noise levels of equipments, as indicated by the equipments manufacturers are
given below:
Sr. No. Name of Machinery / Units Noise level, dB(A)
1 Pumps 60 – 65
2 Blowers 80 – 85
3 Rod Mill 85 – 95
EXPECTED NOISE LEVELS:
SR.
NO.
SOURCE OF NOISE PERMISSIBLE LIMIT
(DAY/NIGHT)
dB (A)
EXPECTED NOISE
LEVEL dB (A)
1. Near Security Gate 75/70 60
2. Near Administration Building 75/70 60
3. Near Cooling tower & Utility Block 75/70 65
4. Near DM Plant 75/70 65
5. Near Process Plant 75/70 65
6. Near Canteen 75/70 50
• Ear muffs & ear plugs are provided to operators where ever noise level is higher than
85 dB(A) inside the plant.
• Regular preventive maintenance of equipments is carried out.
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61
ANNEXURE-X
_______________________________________________________________________
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
During construction phase, skilled and unskilled manpower will be needed. This will
tempo