1 FORM 1 (Application for Environment Clearance Certificate) Sr. No. Item Details 1. Name of the project/s M/s. Safe Enviro Private Limited (Common Hazardous Waste Treatment Storage Disposal Facility) 2. S. No. in the schedule 7(d) Common Hazardous Waste Treatment Storage Disposal Facility 3. Proposed capacity/area/length/tonnage to be handled/command area/lease area/number of wells to be drilled Secured Landfill Cell 15 Million Metric Ton Incinerator 10 Million Kcal/hr Forced Evaporation 3 × 175 KL/day 4. New/Expansion/Modernization New 5. Existing Capacity/Area etc. Not Applicable 6. Category of Project i.e. ‘A’ or ‘B’ Category ‘A’ 7. Does it attract the general condition? If yes, please specify. No 8. Does it attract the specific condition? If yes, please specify. No 9. Location Plot/Survey/Khasra No. Plot no. 697 to 721, 723 to 742, 867 to 874, 893, 938-940, 942 to 957, 966 to 976, 1040, 1045 to 1049 Village Magnad Tehsil Jambusar District Bharuch State Gujarat 10. Nearest railway station/airport along with distance approx 3.16 km (Aankhi)
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1
FORM 1 (Application for Environment Clearance Certificate)
Sr. No. Item Details
1. Name of the project/s M/s. Safe Enviro Private Limited
(Common Hazardous Waste Treatment
Storage Disposal Facility)
2. S. No. in the schedule 7(d) Common Hazardous Waste
Treatment Storage Disposal Facility
3. Proposed capacity/area/length/tonnage to be
handled/command area/lease area/number of wells
to be drilled
Secured Landfill
Cell
15 Million
Metric Ton
Incinerator 10 Million
Kcal/hr
Forced
Evaporation
3 × 175
KL/day
4. New/Expansion/Modernization New
5. Existing Capacity/Area etc. Not Applicable
6. Category of Project i.e. ‘A’ or ‘B’ Category ‘A’
7. Does it attract the general condition? If yes, please
specify.
No
8. Does it attract the specific condition? If yes, please
specify.
No
9. Location
Plot/Survey/Khasra No. Plot no. 697 to 721, 723 to 742, 867
to 874, 893, 938-940, 942 to 957,
966 to 976, 1040, 1045 to 1049
Village Magnad
Tehsil Jambusar
District Bharuch
State Gujarat
10. Nearest railway station/airport along with distance approx 3.16 km (Aankhi)
2
in kms. approx 38 km (Bharuch)
11. Nearest Town, city, District Headquarters along
with distance in kms.
Bharuch (~ 40 km)
12. Village Panchayats, Zilla Parishad, Municipal
Corporation, Local body (complete postal
addresses with telephone nos. to be given)
Magnad Village Panchayat
At Post: Magnad
Taluka: Jambusar
District: Bharuch, Gujarat.
13. Name of the applicant Safe Enviro Private Limited
3.1 Type of project including interlinked and interdependent projects, if any ............ 11
3.2 Location (map showing general location, specific location and project boundary & project site layout) with coordinates ....................................................................... 11
3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted .............. 15
3.4 Size or magnitude of operation .................................................................... 17
3.5 Project description with process details (a schematic diagram/ flow chart showing the project layout, components of the project etc should be given) ............................. 17
3.6 Raw material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finished product ................... 34
3.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined ................................................................................................ 34
3.8 Availability of water its source, energy/ power requirement and source .............. 34
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3.8.1 Water ...................................................................................................... 34
3.8.2 Energy/ Power Requirement ........................................................................ 35
3.9 Quantity of waste to be generated (liquid and solid) and scheme for their management/ disposal ......................................................................................... 35
3.9.1 Waste water ............................................................................................. 35
3.10 Schematic representations of the feasibility drawing which give information of EIA purpose ............................................................................................................. 37
4 Site Analysis ............................................................................................. 38
4.2 Land form, land use and land ownership........................................................ 39
4.3 Topography (along with map) ...................................................................... 39
4.4 Existing land use pattern (agriculture, non agriculture, forest, waterbodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park, wild life, sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of notified industrial area, a copy of Gazette notification should be given ....................................................................... 40
5.1 Planning Concept (type of industries, transportation etc) Town and country planning/ development authority classification ......................................................... 40
5.2 Population projection .................................................................................. 41
5.3 Land use planning (break up along with green belt etc) ................................... 41
5.4 Assessment of infrastructure demand (physical and social) .............................. 41
6.10 Power requirement & Supply/ source ............................................................ 43
7 Rehabilitation and Resettlement (R & R) Plan: Not applicable ........................... 43
7.1 Policy to be adopted (Central/ state) in respect of the project affected persons including home oustees, land oustees and landless laborers ....................................... 43
8 Project schedule and cost estimates ............................................................. 43
8.1 Likely date of start of construction and likely date of completion ....................... 43
8.2 Estimated project cost along with analysis in terms of economic viability of the project ............................................................................................................... 44
9 Analysis of proposal (Final Recommendations) ............................................... 44
9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area: ............................................... 44
LIST OF TABLES
Table 1: District wise break up of hazardous waste generation – Gujarat .......................... 7
Table 2: Examination of Rejection- Knock Out Criteria: ............................................................ 15
Table 3: Quality of HDPE liners ...................................................................................... 19
Table 4: Stack details for incineration system ........................................................................ 25
Table 5: Stack details for force evaporation system ................................................................. 28
Table 6: Specification of Hazardous waste for use as alternative raw material ..................................... 30
Table 7: Specification of HW for use of energy recovery ........................................................... 31
Safe Enviro Private Limited proposes to develop an Integrated Common Hazardous Waste Treatment Storage & Disposal Facility with incineration plant having capacity of 10 Million Kcal/hour and Secured Landfill cell with 15 Million Metric Ton (MMT) capacity. Allied facilities to be developed are 500 KL/day forced evaporation system.
The project will be located at Magnad Village, Tal: Jambusar, District: Bharuch Gujarat.
There is no national park or sanctuary in surrounding 10 Km radius. The project doesn’t fall under CRZ boundaries.
Stack with incinerator & Forced evaporation system shall be installed for the proposed project. The water consumption for the proposed project for industrial use is 95 m3/day and the major waste water generation will be from scrubbing reject, washing reject and domestic waste water which will be 50 m3/day approximately. The complete quantity shall be treated in Effluent treatment plant and partly used within plant premises for gardening and dust suppression.
Burnt incinerated ash, salt from spray dryer and scrubber and ETP sludge will be major hazardous waste generated and the same shall be disposed to inhouse landfill cell after pretreatment if required.
Employment shall be generated for local people in surrounding villages. The company is also involved in social activities in the surrounding villages.
The details related to the proposed project are discussed in the upcoming sections.
2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 Identification of project and project proponent
The existing landfill facility serves for around 500 industries sending their hazardous waste for landfilling and incineration. Considering the need of such facility in Bharuch District SEPPL has shortlisted land at village Magnad, Tal: Jambusar District: Bharuch for safe disposal of industrial hazardous waste and support infrastructure growth and ensure ecological and environmental preservation.
Brief Description of nature of project
Company proposes to develop Integrated Common Hazardous Waste Management Facility at Magnad having incineration plant with total capacity of 10 Million Kcal/hour and secured landfill facility of 15 MMT. Allied facilities to be developed along with the incinerator plant are Forced evaporation system, segregation plant, neutralization plant, Defuming plant, Blending unit and Bagging unit.
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2.2 Need of the project and its importance to the country or region
The need for installing this facility is as detailed below:
Central Pollution Control Board (CPCB) has made an assessment of the hazardous incinerable waste generation along with existing incineration & Landfillable capacity available in some of the states in the country. The assessment also includes the proposed capacity addition in the incinerator capacity in these states in future. The inventory of hazardous waste in Gujarat carried out by Gujarat Pollution Control Board brings out the following data.
Total Quantity of Hazardous Wastes generated is 1.792 MMTPA
Break-up: Landfillable 1.106 MMTPA - 61.75%
Recyclable 0.576 MMTPA- 32.19%
Incinerable 0.108 MMTPA- 6.06%
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Table 1: District wise break up of hazardous waste generation – Gujarat
(As on March 2008)
No. of Hazardous Wastes generating Units in Gujarat
Break-up: (a) Red - 11,386
(b) Orange - 4343
(C) Green - 2529
As per CPCB data statistics of availability of Common Hazardous waste Treatment Storage & Disposal facility
Existing TSDF Facilities in Gujarat are as below:
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(1) Secured Landfill Facility - 8 Nos.
(2) Common HW Incinerator - 4 Nos.
(3) Captive HW Incinerator - 38 Nos.
2.3 Demand – Supply gap
As per the National Inventory of Hazardous Wastes Generating Industries & Hazardous Waste Management in India as published by Central Pollution Control Board Hazardous Waste management Division Delhi in February 2009, Gujarat’s percentage contribution towards Land disposable hazardous waste generation is 40.58% and towards Incinerable Hazardous waste generation is 26.12%. Dahej SEZ and PCPIR region is mainly developed to attract different type of petrochemical and chemical industries in this area. More than 1000 such units are expected to start production in next couple of years. The waste generated for these units are yet to be calculated. The industrial growth in Gujarat has been phenomenal between 2008-2012. The waste generated for these newly developed industries is yet not covered in the above table. Looking to the scenario the overall waste generated from Bharuch district will be 50% as compared to overall waste generated in all over Gujarat. Presently there is only one operative site in Ankleshwar which has a balance capacity of 0.77 MMT in SLF cells and incineration to
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address maximum of 20,000 MT of waste annually. The development of this facility will have the overall industrial development and safe disposal of hazardous waste.
Looking into development of different states in country CPCB has prepared “Guidelines for Storage of Incinerable Hazardous Waste by the Operators of Common HW Treatment Storage and Disposable Facilities and Captive HW Incinerators” November 2008, according to that present and proposed capacity of the Incinerators in Gujarat is as below:
(1) Common HW Incinerators 32600 TPA Present Capacity
(2) Captive or Individual HW Incinerators 4000 TPA
(3) Proposed in next 2 to 3 years 165000 TPA to be now created
4.67 Lakh TPA (26%) is the total generation of Hazardous Waste in Bharuch District. There are 750 units generating hazardous waste in the District. The incinerable waste accounts for 48190 TPA. In all these respects Bharuch leads all Districts in the state. There is 1-Common Hazardous Waste Incinerator and 14 Captive HW Incinerators in Bharuch District.
** Note. Hazardous waste inventory as on 31/08/2007 published by Gujarat Pollution Control Board
The Landfillable HW generation in Gujarat is 1.106 MMTPA whereby the current scenario for the TSDF sites is as below:
Existing TSDF Facilities
Approved
Capacity
(in MT)
Utilized
Capacity (in
MT)
Status
Naroda Enviro Projects Private Limited 300000 295000 Operative till
31/03/2013
Green Environment Co-operative
Society Ltd, Vatva
923535 900000 Operative till
30/6/2013
Nandesari Enviro Control Ltd (Baroda) 425000
250000 Working
Bharuch Enviro Infrastructure Ltd 2301404
1275000 Working
Vapi Waste and Effluent Management 900000 880000 Working
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Co Ltd
Gujarat Enviro Protection &
Infrastructure Ltd*
Closed due to
small accident.
Gujarat Maritime Board, Alang 61000 40000 Working, only
for GMB
Saurashtra Enviro Projects Pvt Ltd
(Kutch)
1200000
105000 Working
Need of the project in Bharuch:
Bharuch is ranked as the highest Hazardous waste generating unit in India with the district producing HW of more than 40000 MTA. Its hazardous waste generation per annum is shown in Table above
There are different types of industries in Bharuch. Apart from the existing units many new units are proposed in Dahej SEZ as well as GIDC and also in many industrial estates such as Jambusar, Valia, Palej, Jhagadia etc. The waste generated in the existing units is mainly transported to far by for its final disposal. Due to large number of industrial units in Dahej, the waste generation is very high. The waste generation is either dumped into the landfill site or sent for incineration and then further dumped in the landfill site
Apart from the exiting industries many new industrial development are in line at GIDC estate of Dahej and Special Economic Zone. The PCPIR (Petroleum, Chemical and Petrochemical Investment Region) Dahej Area and DMIC (Delhi Mumbai Industrial Corridor) are the upcoming developments in the region which will attract many new industrial projects in the area
2.4 Import vs Indigenous production
Not applicable
2.5 Export possibility
Not applicable
2.6 Domestic/ export market
Disposal of the hazardous/ solid waste generated from the different industry located in Gujarat State.
2.7 Employment generation (Direct and indirect) due to the project
The total employment generated due to proposed project is as below:
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Type of employees Employment generation Skilled workers : Direct Labour 30
Indirect Labour 45 Unskilled labours : Direct Labour 70
Indirect Labour 105 Total : 250 person
3 PROJECT DESCRIPTION
The proposed project i.e incineration plant with capacity of 10 MKcal/hour and Secured landfill cell with 15 MMT capacity, falls under schedule ‘A’, Sr. no 7 (d) of EIA notification September 2006 and amendment thereoff.
Apart from incineration & Landfill the company proposes to install supporting facilities at the site which includes forced evaporation system, neutralization plant, Defuming plant, Blending unit and Bagging unit.
3.1 Type of project including interlinked and interdependent projects, if any
No interlinked and interdependent projects
3.2 Location (map showing general location, specific location and project
boundary & project site layout) with coordinates
Latitude Longitude 22° 2'42.96"N
72°51'27.82"E
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Figure 1: Base map of 10 Km radius
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Figure 2: Satellite Map of Surrounding area
Nearest village: 1.54 Km
River: 0.7 Km
Connecting Road:~ 1.5 Km
Nearest Town: Jambusar
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Figure 3: Survey Map
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3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the
environmental considerations gone into should be highlighted
Following 8 sites were identified for examination for knock-out criteria and then verified through detail site selection criteria at the following villages and were visited and investigated for their suitability as per the above criteria. Site-1 at Singhla (Ankleshwar) Site-2 at Kanthraw Site-3 at Chor Bhuj(Karjan. Vadodara) Site-4 at Amod (Amod, Bharuch) Site-5 at Shah Village (Jakharda) Site-6 at Azam Nagar (Amod, Bharuch) Site-7 at Masar (Padra, Vadodara) Site 8 at Magnad (Jambusar, Bharuch)
Table 2: Examination of Rejection- Knock Out Criteria:
Sr. No.
Identification/ Location of Site Village/City
Singhla Kanthran Chor Bhuj
Amod Shah Village
Azam Nagar
Masar Magnad
Criteria
1 Existing or planned drinking water protection and catchment areas
Y N N N N N N N
2 High flood prone areas N N N N N N N N
3 Areas with unstable ground N N N N N N N N
4 Closer than 200 meters to populated areas
N N N Y N Y N N
5 Closer than 200 meters to river boundaries
N N Y N N N N N
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6 Close to National Parks, monuments, Forests with large no. of flora and fauna, historical, religious and other important cultural places
N N N N N N N N
7 Existing use of site (Agricultural/Forest/Old dump site)
Y N Y N Y Y Y N
8 REMARKS Agricultural Land, pond nearby fills up with monsoon rains, Village at 0.25 Kms, religious place next to the site
Highway passes through the site boundary.
Current LandUse: Agricultural Land. River stream at 0.19 km
Populated area
Populated area, surrounding land use is agricultural Land
Agricultural Land
Agricultural Land, Vadodara Jambusar Highway passing through the site.
Non-agricultural Fallow Land
Site is suitable for detailed study (Y/N)
N N N N N N N Y
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The salient features of site are as follows:
i. The site i.e. Plot no. 697 to 721, 723 to 742, 867 to 874, 893, 938-940, 942 to
957, 966 to 976, 1040, 1045 to 1049 With an area of 291 acres is located near
Magnad Village, District: Bharuch, Gujarat.
ii. Road infrastructure is well developed for the transportation of waste to site
iii. There is no existence of Natural Park / wild life sanctuary within 10 km radius.
iv. There are no sensitive places of archaeological, historical, cultural and religious
or tourist importance within 10 km of site
v. There are no defense installations within 10 km of site
vi. The project site being a non-agricultural fallow land, is best suitable for the
proposed activity.
vii. The site does not fall within the approach funnel of airport runway.
viii. Site is meeting the knock out criteria as specified by CPCB.
3.4 Size or magnitude of operation
Secured landfill cell with 15 MMT capacity shall be developed in different phase manner over a period of 20 years and Incinerator with 10 Million Kcal/ hour (2 incinerators of 5 Million Kcal/ hour capacity each) shall be installed.
Allied facilities to be developed along with the incinerator plant are forced evaporation system (3*175 KL/day), neutralization plant, Defuming plant, Blending unit and Bagging unit.
3.5 Project description with process details (a schematic diagram/ flow chart
showing the project layout, components of the project etc should be given)
3.5.1 Secured Landfill Disposal Facility (TSDF)
The wastes are either disposed off directly into the landfill and/or after the treatment like
solidification & stabilization, segregation, pyrolysis process etc. The decision on whether to treat
or directly dispose off will be taken as per the finger print analysis and criteria mentioned in the
CPCB guideline “Criteria for Hazardous Waste Landfills”
The secured landfill cell comprises of the following components.
• Bottom Liner System
• Side Liner System
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• Top liner system (placed at the time of closure)
• Leachate Sump for Collection and removal of Leachate
• Monitoring wells
Liner System
1) Bottom Liner
Figure 4:Typical Bottom Liner System
Layer 1:- 450 mm Blended Clay Layer with permeability k less than or equal to 10-7 cm/sec.
Layer 2 :- 1.5 mm Thick HDPE Geo Membrane
Layer 3 :- 150 mm Thick Drainage layer i.e. detection layer consist of graded invert sand layer.
Layer 4 :- Geo Textile layer to protect drainage layer.
Layer 5 :- 350 mm Blended Clay Layer with permeability k less than or equal to 10-7 cm/sec.
Layer 6 :- 1.5 mm Thick HDPE Geo Membrane.
Layer 7 :- 150 mm Thick Drainage layer.
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Table 3: Quality of HDPE liners
The wastes are placed as per the SLF operation and maintenance plan on the bottom liner
system.
The daily, weekly and monthly cover systems with compacted soil of desired thickness will be
regularly provided over the waste layers.
2) Side Liner
Side liner will be single composite liner system suggested in CPCB guidelines will be adopted.
The same is given in figure below.
Figure 5: Typical Side Liner System
Layer 1:- 300 mm Blended Clay Layer with permeability k less than or equal to 10-7cm/sec.
Layer 2 :- 1.5 mm Thick HDPE Geo Membrane
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Figure 6: Top Liner
Layer 1:- 300 mm Compacted Hard Murrum.
Layer 2 :- 600 mm Blended Clay Layer with permeability k less than or equal to 10-7 cm/sec.
Layer 3 :- 1.5 mm Thick HDPE Geo Membrane
Layer 4 :- 150 mm Thick Drainage layer.
Layer 5 :- 750 mm Yellow Soil Layer.
Layer 6 :- Vegetation.
**Actual design will be done and approved by GPCB
Leachate Sump
The leachate sumps of 5 KL holding capacity is proposed with cell. The leachate from the sump
will be pumped to ETP for treatment.
Piezometers:
Six number of piezometers per cell i.e. 3 in the upstream and 3 in the downstream of ground
water flow direction covering 3 ground water strata will be provided. The ground water quality
will be monitored in 3 ground water strata once in 3 months, as per the CPCB guidelines.
Additionally, company proposed to install Ground water suction sampler to insure immediate
detection of leakages in worst scenario such as earthquake.
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3.5.2 Incineration Plant
The system consists of following components
1. Feed section
a. Feed tanks
b. Feed pumps
c. Heaters
2. Incineration system
a. Primary chamber (Rotary kiln)
b. Secondary chamber
c. Mixing chamber/ Quench chamber
d. Waste heat recovery system
e. Force evaporation (Liquid quenching)
3. Flue gas treatment section
a. Cyclone,
b. Multicyclone
c. ID Fan (Booster)
d. 1st stage scrubbing - Water
e. 2nd stage scrubbing – Alkaline
f. 3rd stage scrubbing – Sodium hypochloride
g. Mist eliminator,
h. ID Fan, Chimney
Process Description for Incineration system
Primary and secondary chamber
Incinerator system shall consists of primary chamber and secondary combustion chambers in series, followed by quenching section. Both the combustion chambers shall have refractory lined self supported structure. Primary chamber burner and secondary chamber burner shall fire the liquid fuel, when required. Primary and secondary chambers are wall mounted burners. Air blowers, supply combustion air to these burners and liquid waste atomizers. Fuel oil flow will be regulated to maintain the temperature inside the furnaces, with help of modulation control panel.
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Combustion air flow will be regulated by manually operated air flow dampers. Temperature in primary chamber will be maintained at about 800 – 900 deg C.
Burners will be provided with flame detector, which controls flame and burner for safe and automatic operation. Liquid waste shall be injected using pumps through nozzle into primary chamber. Atomizing air will be supplied to it which will helps in proper combustion of the waste. The nozzles shall be supplied with air to avoid any damage, which also helps for efficient combustion. Primary combustion chamber, which is a rotary kiln, also has a solid waste charging system with double door automatic feeding system to ensure safety of a person and equipment as well.
The flue gases from the primary chamber travel to the secondary chamber which will be further heated beyond 1150 deg C with help of burner and air supply for complete combustion. The secondary chamber will be designed in such a way that the residence time of flue gas coming from primary chamber will be more than 2 sec.
Ash generated in the incinerator shall fall at the rear end of primary chamber (Rotary Kiln) in ash collection pit and at the bottom of secondary combustion chamber, which shall be removed periodically by opening ash removal door at side for its further disposal to a secure land fill site.
All the operating parameters will be controlled and monitored by PLC based SCADA system.
Sight glass near burner assembly and minimum two no. of peep holes will be provided in primary chamber and secondary chamber as well. With help of which, the flame and chamber can be seen from both the chambers.
Both the chambers will be provided with refractory bricks which can withstand approx 1500 deg C.
Explosion window with vent pipe will be provided in both the chambers for safety of the equipment and personnel, to release the flue gases to safe location and avoid backfire in case of any eventuality of pressure rise.
Quench chamber
Quenching chamber is provided to quench the flue gas to desirable temperature by adding fresh air. The air is being fed with quench air blower and flow rate is controlled by controlling the blower speed with help of VFD
Quenching system will be placed at the first stage of an APCS to reduce temperature of flue gas after secondary chambers immediately from 1200 deg C to 500 deg C. Gas quench system includes use of a cooling blower. Apart from this due to quenching formation of furans and dioxins will be eliminated.
Forced evaporation system will be installed for disposal of high TDS, low organic impurity liquid waste having gross calorific value < 500 kcal/kg through forced evaporation system as a pretreatment. Forced evaporation system will be operated by waste heat generated from the incineration plant
Figure 7: Process Flow diagram for common Incineration system
Flue gas treatment Section
The flue gases after getting cooled in quenching chamber and waste heat recovery section, will be passed through series of cyclones and scrubbed in three stages
• Cyclone,
• Multicyclone
• ID Fan (Booster)
• 1st stage scrubbing - Water
• 2nd stage scrubbing – Alkaline
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• 3rd stage scrubbing – Sodium Hypochlorite
• Mist eliminator,
• ID Fan, Chimney
Cyclone Separator / Multicyclone Separator:
Flue gas from forced evaporation system will be passed through cyclone separator and Multicyclone separator, which shall be connected in series to remove solid particles up to ~100 micron from flue gas.
Venturi scrubber/ Water scrubber
In venturi scrubber the flue gases will come in close contact of alkaline water which will help in scrubbing of any tiny suspended particles, and acid in the gas will react with alkali in the circulating water. It also helps in cooling of the gas to major extent.
Wet Scrubber/ Alkaline scrubber
Wet scrubber will be used to clean acid gas and remove toxic or fine particles. An alkaline solution is injected into the Wet Scrubber or sprayed to scrub all the acidity of gas and smaller particulate matter.
The scrubber solution needs to be removed and replaced frequently, as it becomes contaminated with the particulates and salts from reaction with the acid. The purged stream from scrubber may have to be treated before disposal.
Mist eliminator
After treating in venturi scrubber & wet scrubber, the flue gases are again treated in polishing scrubber – also having packed bed, where it will be treated with Hypochlorite solution to remove odor, if any / and also remaining neutralization of acid, if any. The flue gases leaving the polishing scrubber will be passed through mist eliminator to remove the liquid droplets and solid particles if any.
ID fan
The ID fan shall be handling all the flue gases coming out of polishing scrubber. It also maintains required /little vacuum (draught) in primary and secondary chambers. It shall discharging the gases to chimney.
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Chimney /stack
The stack is cylindrical, vertical, self supporting unit designed to discharge flue gases coming from polishing scrubber. Salient features include:
• Base size
• Overall height
• Type of CS with SS cladding construction
• Flange inlet connection
• Sampling connection for local sampling and online analyser as well
• Online monitoring system for HC, CO, HCl, SOx, NOx, PM
Table 4: Stack details for incineration system
Stack attached to Incinerator Boiler
No. of stacks 2 1
Proposed Stack Height 40 m 40 m
Online Monitoring System: It is proposed to install online monitoring system to measure major pollutant parameter. Online monitoring system will be installed for major following parameters i.e HC, CO, HCl, Sox, NOx and PM.
Compliance to CPCB Guidelines for Common Hazardous Waste Management Facility for Operational Parameters of Combustion Chamber
Safety View Glass View glass 50 mm in both the chambers
Will be provided
ID fan Centrifugal type with suitable power motor for effective control of emission from chimney
Centrifugal type ID fan with suitable power motor which is controlled by VFD shall be provided
Chimney Height Min 30 m 32 m
Sampling points As per CPCB guidelines Shall be Provided as per CPCB/MoEF guidelines
Oil service tank Oil service tank of 1000 Lit capacity made of 5 mm thick MS plate with support structure, control
Will be provided
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Description Requirement as per CPCB guidelines
Design parameters
valve, fuel indicator gauge, fuel lifting pump.
Paint for Whole system Painted with 2 coats of Heat resistance aluminum paint
Will be provided
3.5.3 Force Evaporation
Pharmaceutical, pesticide, dyes – dyes and intermediate industry and certain other industries generate very high TDS and very low organic wastewater which is practically difficult to treat in ETP or CETP and achieve norms prescribed by the State Pollution Control Board. Treatment of this liquid waste has always been a major threat and challenge to Industries, but with the CETP, this wastewater was conveyed to CETP illegally thereby disturbing the overall performance of CETP and outlet characteristics of wastewater. To control this situation the industries were forced to treat their stream of wastewater through Multi Effect Evaporator and reduce the COD of wastewater which comes through condensate. About 30 % of waste of this waste liquid comes out as reject which has residual COD and High TDS of whole stream. Natural Evaporation is the best methodology for treatment of this wastewater but due to land constraint and in a rain prone area; this has become a major bottle neck.
To address the safe disposal of this waste water, we propose to install a forced Evaporation System which will work on stand alone basis using hot gas generated from Hot Air generator. Fuel for the Hot air generator will be coal. High TDS High COD wastewater will be sprayed on the top of evaporator column through specially designed atomizers and hot air above 450 oC is forced from the bottom of chamber maintaining counter current effect. Fine droplets of liquid waste will be converted in to vapour and the salt generated shall be settled at the bottom by gravity. Flue gas and vapour from the liquid is than passed through scrubbing and exhausted to atmosphere through stack of 30 meter height. Salt collected at the bottom of the unit will be evacuated regularly using rotary Air Lock valve and the same is disposed off in Secured landfill cell. Waste scrubbing bleed having traces of organic waste will be send for incineration.
Objective: Disposal of high TDS, low CV waste
STAND ALONE:
Fuel: Waste heat recovery
Fuel: Coal
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Technical Specifications
Cyclone + Scrubber
Hot Air generator/ Waste heat generated from incinerator
Evaporation Column
Pumping rate : 8 Kl/hr per unit
Operating Hour : 20 Hr
Salt generated : 50 T/day
Table 5: Stack details for force evaporation system
Stack attached to Forced evaporation system
No. of stack 1
Proposed Stack Height 30 m
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Figure 8: Flow diagram of Forced Evaporation
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3.5.4 Utility
Blending Unit (Mixing Of Hazardous Waste)
To make the waste compatible for co processing (use as alternative raw material or use of energy recovery) it is proposed to install the blending unit.
Blending unit also utilize for mixing the hazardous waste to feed into rotary kiln for the optimizing design capacity
Blending will be done in liquid – liquid waste, liquid – solid waste, solid – solid waste. Blending will be done such that after the blending material will meet specifications mentioned in below table and also maintain the physical form of waste which is accepted to cement kiln
Regular permission for categories of hazardous waste has been granted by CPCB for co processing in cement plant. For any other waste prior to supply the waste for co processing protocol for trial run for co processing of hazardous waste shall be followed. After getting the model permission for co processing same shall be supplied to cement industry
Acceptance criteria for use as alternative raw material is mentioned below
Table 6: Specification of Hazardous waste for use as alternative raw material
Parameter Limit
Volatile organic hydrocarbon < 5000 ppm
Total organic carbon (T0C) < 1000 ppm
CaO+SiO2+Al2O3+Fe2O3+SO3 (in ash) >80 %
Chloride < 1.5 %
Sulphur < 1.5 %
PCB/PCT (ppm) < 5.0
Heavy metals (ppm)
Hg
Cd+ Tl + Hg
As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V
<10
<100
<10000
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Table 7: Specification of HW for use of energy recovery
Parameter Limit
Calorific value as received basis > 2500 Kcal/kg
Ash
Liquid
Solid
< 5%
< 20 %
Chloride < 1.5 %
Halogens (F+Br+I) <1.0 %
Sulphur <1.5 %
PCB/PCT (ppm) < 50
Heavy metals (ppm)
Hg
Cd+ Tl + Hg
As+Co+Ni+Se+Te+Sb+Cr+Sn+Pb+V
< 10
<100
<2500
pH 4 to 12
Viscosity (cSt) for liquid < 100
Flash point (deg centigrade) (for liquid) > 60
Neutralization Plant
The waste having alkaline or acidic nature will be neutralized here by adding of effective neutralizing agents. The waste with highly alkaline or acidic pH will be brought to neutral pH.
Bagging Unit
Compatible waste will be transferred to bagging unit and shall be packed in bag of 50 -100 kg and finally transferred to cement plant/ end user
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Defuming Plant
Company proposes to install defuming unit at different storage facility to arrest the fume generated from different storage shed and tank. Collective fume shall be destructed into the incineration system
Laboratory facility
Generators sending hazardous waste to the incineration facility are required to provide necessary test report of hazardous waste to the operator along with the information on the process(s) of its generation.
The laboratory is required to be well equipped, suitable for the purpose for which the operating agency is working. It is proposed to develop the laboratory facility at site doing the finger print analysis. Major equipment required for finger analysis is as below:
• Fume Hoods
• Precision balances
• UV-VIS double beam Spectrophotometer
• Voltage Regulator (Servo)
• Glove Box
• Refrigerator
• Muffle Furnace
• Hot Air Oven
• Freezer
• pH Meter
• Vaccum Pump
• Micropipettes
• Centrifuge
• Heating Mantles
• Magnetic stirrer with hot plates
• Stop Watch
• Water Bath
• Automatic Burrettes
• Flash point tester
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• Corrosivity test - Fabricated
• Bomb colorimeter
• Volatile organic sampling
• Lab Furniture (working tables, cupboards, chemical racks etc.)
• Infrastructure like D. G. set, electrical fittings, air conditioning of cold room etc.
Photocopy Machine
• Computer
• Fax/Telex
Laboratory will be developed as per MoEF guidelines. NABL approved procedures shall be followed for testing and analysis.
Fire fighting system
Fire fighting system comprises of single loop pressurized water line which will be through separate water storage tank of 2 lakh capacity.
Water hydrant will be provided on this loop at appropriate location. The line will be pressurized through jockey pump and diesel pump will also be provided in the line to operated the system in absence of power. The storage area shall be provided with water sprinkler at periphery of gate to develop water gutters.
Different type and size of fire extinguisher shall be provided in godown, incineration shed, office area, security cabin and at assembly point.
Weigh bridge
Weigh bridge with 60 MT capacity shall be provided at entrance of unit
DG Set
Two D.G Sets of 500 KVA each shall be installed as a standby power in the proposed facility
ETP Details
The effluent will be mainly generated from scrubber bleed, washing & leachate from landfill. The same shall be treated through ETP but as an additional precaution the company proposes to install Effluent Treatment Plant. The Effluent treatment plant shall consist of primary, secondary and tertiary treatment plant. The treated effluent shall be utilized for gardening purpose.
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3.6 Raw material required along with estimated quantity, likely source,
marketing area of final product/s, mode of transport of raw material and
finished product
Raw material will be in form of incineration waste which will be burned in the incineration chamber. Fuel in form of Furnace oil will be added in the rotary kiln and secondary chamber. Coal shall be used in hot air generators for the operation of spray dryers. Cement shall be used for solidification and stabilization purpose.
Quantity of waste to be charged along with fuel in form of furnace oil is as mentioned below along with the source and mode of transportation.
Table 8: Fuel details
Fuel Calorific value Quantity Source Transportation
Furnace oil 10500 kcal/kg 952.3 kg/hr From local vendor
By tankers
Coal 3600 – 4000 kcal/kg
120 T/day From local vendor
By truck/ dumpers
Cement -- Depending on material received
From local vendor
By truck/ dumpers
3.7 Resource optimization/ recycling and reuse envisaged in the project, if any,
should be briefly outlined
Generated hot gas will be utilized for the different application to reduce fuel consumption as discussed in previous sections
3.8 Availability of water its source, energy/ power requirement and source
3.8.1 Water
Source of water
As Magnad Village Tal. Jambusar falls in the safe zone groundwater shall be utilized.
Water Consumption
The total water consumption for the proposed project is 95 m3/day as mentioned below
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Table 9: Water consumption for industrial purpose
Purpose Quantity (KL/day)
Scrubbing/ Sprinkling 80
Washing 10
Domestic 5
Total 95
Addition to the above we have proposed to develop the green belt area (30% of the total land acquired) hence water requirement for gardening and plantation is 200 KL/day
3.8.2 Energy/ Power Requirement
Source of Power: GEB
Power Consumption: 1.5 KVA
In case of power failure, stand by DG set will be installed at the site with capacity of 2 units of 750 KVA
3.9 Quantity of waste to be generated (liquid and solid) and scheme for their
management/ disposal
3.9.1 Waste water
Waste water will be mainly generated from scrubbing unit, leachate and washing area. The same shall be treated in the effluent treatment plant. The quantity of waste water generated is as mentioned below.
Table 10: Waste water generation
Activity Quantity (KL/day)
Scrubbing 25
Washing 5
Domestic 5
Leachate generation from Secured Landfill
Cell
Upto 10 KL/day
Total 50 KL/day
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Company proposes to install Effluent treatment plant with capacity of 50 m3/day. The waste
water generated shall be treated in the same and later reused for gardening.
The details of Effluent treatment plant are as mentioned below
Figure 9: ETP flow diagram
The waste water generated from the scrubber operation and drum washing will be treated in effluent treatment plant of 50 m3/ day capacity. The treatment scheme of the effluent treatment plan is as given below:
• The raw wastewater shall enter in to the equalization tank which is provided with air
purging system to keep the particulate matter in suspension.
• Effluent Transfer Pump shall transfer the effluent from Equalization Tank to flash
mixture. The effluent shall be further transferred to the flocculation chamber where
gradual dosing of polyelectrolyte shall be done. This mixture is then transferred to
Primary Settling Tank.
• Supernatant from primary settling tank shall be transferred to first stage Aeration tank for
further removal of organic load followed with the first stage secondary settling tank.
• Supernatant from the first stage settling tank shall be transferred to secondary stage
aeration tank followed with the Secondary stage settling tank.
• Sludge from the first stage and second stage secondary settling tank shall be transferred
to Sludge drying bed.
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• From the 2nd stage secondary Settling Tank Supernatant transferred to the intermediate
collection tank and further treated through Pressure Sand Filter and Activated Carbon
Filter.
• Thereafter treated water to be stored in Treated Water Storage Tank and used in
gardening, sprinkling
• The sludge from Primary Settling Tank, further dewatered through filter press bed and
after that sludge shall be disposed off to secured land fill site.
• Leachate from the filter Beds shall be collected and directed to equalization tank for
further treatment. 3.10 Schematic representations of the feasibility drawing which give information
of EIA purpose
The proposed activities of the industry; fall under category A Sr. no. 7 (d) in the Government of India Notification no. 1533 dated 14th September, 2006; which require prior Environmental Clearance before starting construction, production or any other allied activities related to the project. For getting the Environmental Clearance; it is required to carry out the Environmental Impact Assessment (EIA) study report.
Definition of EIA
Environmental Impact Assessment (EIA) is a formal process used to predict how industrial development or construction project will affect natural resources such as water, air, land, socioeconomic and bio ecological environment.
An EIA usually involves a sequence of steps:
(1) Screening to decide if a project requires assessment and to what level of detail.
(2) Preliminary assessment to identify key impacts, their magnitude, significance, and importance.
(3) Scoping to ensure the EIA focuses on key issues and to determine, where more detailed information is needed.
(4) Implementing the main EIA study, which involves detailed investigations to predict impacts, assess their consequences, or both.
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Methodology
Environmental Impact Assessment (EIA) studies include identification, assessment, quantitative evaluation and prediction of possible impacts. To minimize the impact of the project on various environmental attributes, mitigation measures are suggested for implementation along with the project.
The methodology of this study can be schematized as detailed below:
To gather information on present environmental conditions and relevant national
environmental guidelines and EIA procedures.
Scoping of impacts.
Assessment of significant impacts.
Description of residual impacts.
Development of monitoring plans.
To inform all relevant and involved authorities regarding the impact of the project on the environment and the proposed mitigation measures.
4 Site Analysis
4.1 Connectivity
The proposed Integrated Common Hazardous Waste Management facility is located at Plot no. 697 to 721, 723 to 742, 867 to 874, 893, 938-940, 942 to 957, 966 to 976, 1040, 1045 to 1049.
The Site is well located with major district road and Bharuch – Jambusar Highway.
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Area generating Hazardous Waste Connectivity
Bharuch Bharuch – Jambusar Highway – Amod - Site
Ankleshwar Golden bridge or NH-8/ SH 140 –Bharuch
Jambusar Highway- site
Panoli SH-140 or NH-8- Ankleshwar- Bharuch-
Bharuch Jambusar Highway- site
Surat Surat kamrej highway- SH-140- Ankleshwar-
Bharuch- Bharuch Jambusar Highway- site
Valsad SH-140 or NH-8- Surat kamrej highway- SH-
140- Ankleshwar- Bharuch- Bharuch
Jambusar Highway- site
Dahej Dahej Chokdi- Amod- Bharuch Jambusar
Highway- site
Vapi SH-140 or NH-8- pardi- valsad- Surat
kamrej highway- SH-140- Ankleshwar-
Bharuch- Bharuch Jambusar Highway- site
Vadodara Padara Road- Vadodara Jambusar Highway-
Jambusar chokdi- Bharuch Jamusar
Highway- Site
Ahmedabad Vadodara Ahmedabas Express Highway-
Vodadara- Padara Road- Vadodara Jambusar
Highway-Jambusar chokdi- Bharuch Jamusar
Highway- Site
4.2 Land form, land use and land ownership
Land form: Agricultural Fallow Land. No agricultural activity has been carried out
4.3 Topography (along with map)
The topography is plain
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4.4 Existing land use pattern (agriculture, non agriculture, forest, waterbodies
(including area under CRZ), shortest distances from the periphery of the
project to periphery of the forests, national park, wild life, sanctuary, eco
sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of
notified industrial area, a copy of Gazette notification should be given
The proposed land is a Agricultural fallow Land. There is no national park, wild life sanctuary, eco sensitive areas in surrounding 10 Km of the plant boundary. CRZ is not applicable to the project.
4.5 Existing infrastructure
Not applicable. The proposed project is green field project. No infrastructure is developed within the premises on site.
4.6 Soil classification
Detail soil testing report of the project location shall be given in the EIA Report
4.7 Climatic data from secondary sources
The climatic data for month of March 2012- May 2012 in the study are as below
Average Wind speed 2.54 m/s
Temperature 17 0C- 43 0C
Average Relative humidity 12 % to 91 %
4.8 Social infrastructure available
The project site is located approximately 1.54 km from the human settlement. Basic amenities of life are easily available in the area. Primary health centre, school, drinking water, electricity, communication, road network, transportation facility is available in the vicinity.
5 Planning Brief
5.1 Planning Concept (type of industries, transportation etc) Town and country
planning/ development authority classification
Bharuch has emerged out to be a rapid growing industrial area. With a detailed planning of Dahej GIDC, SEZ, Industrial estates in different Talukas like Jambusar, Valia, Palej, Jhagadia etc. it has turned up to be fastest growing Industrial Estate.
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5.2 Population projection
Total 250 people will get the direct and indirect employment. Maximum local people will be employed. Hence there is negligible influx of people due to proposed project.
5.3 Land use planning (break up along with green belt etc)
The land area is divided for incineration activity, Landfill cell and other allied projects. The total land allocated for green belt will be 30% of total land acquired.
Table 11: Land area break up
Green area 19 acres
Road 16 acres
Parking 2 acres
Cell area 224 acres
Other & open space 30 acres
Total area 291 acres
5.4 Assessment of infrastructure demand (physical and social)
There are roads, street light, and water available in the area.
5.5 Amenities/ Facilities
Major basic facilities are available for the proposed project. Road, electricity, water, transportation facility etc are well developed in the surrounding area.
6 Proposed infrastructure
6.1 Industrial area (Processing area)
The total industrial area under acquisition by the company is 291 acres.
6.2 Residential area (Non processing area)
No labour colony is envisaged in the proposed project. Only administrative building is the residential area in the project
6.3 Green belt
The green belt area of the project location is given below
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Proposed green belt area: 30% of the land area acquired
The green belt for the proposed project will consist of following green belt species
Gulmohar, Ashoka and other trees
6.4 Social infrastructure
Basic amenities of life are easily available in the area. Primary health centre, school, drinking water, electricity, communication, road network, transportation facility is available in the vicinity.
6.5 Connectivity (Traffic and transportation road/ rail/ metro/ water ways etc)
The connectivity to the project site is given in table.
Table 12: Connectivity
Description Distance
Transportation
Nearest Road : 1.5 Km Magnad road
Approx 3.5 Km (Vadodara Jambusar Highway)
Rail : approx 3.16 km (Aankhi)
: approx 38 km (Bharuch)
Nearest Town/City Bharuch: approx 38 km
Nearest Village Magnad: ~1.54 km
6.6 Drinking water management (Source & supply of water)
Groundwater shall be procured.
6.7 Sewerage system
Domestic waste water generated shall be treated in the septic tank and later shall be partly reused for gardening purpose.
6.8 Industrial waste management
The industrial waste generated mainly will be in form of hazardous waste and solid waste.
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The major hazardous waste generated due to proposed incineration project is as mentioned below
Table 13: Details of Hazardous Wastes generation and Disposal
Type of Waste Quantity Storage/ Disposal Facilities
Ash 10 Tonnes per day Shall be disposed in captive landfill cell
Scubber bleed 10 KL/day ETP, Forced evaporation or incineration
ETP Sludge 50 kg/day Shall be disposed in captive landfill cell
Salt generation from
forced evaporation
system
50 T/ day Shall be disposed in captive landfill cell
6.9 Solid waste management
Solid waste generated is categorized as hazardous in nature and same has been listed above in hazardous waste section
6.10 Power requirement & Supply/ source
Source of Power: GEB
Power Consumption: 750 KVA
In case of power failure, stand by DG set (2 No.s) will be installed at the site with capacity of 750 KVA each.
7 Rehabilitation and Resettlement (R & R) Plan: Not applicable
7.1 Policy to be adopted (Central/ state) in respect of the project affected
persons including home oustees, land oustees and landless laborers
Not applicable
8 Project schedule and cost estimates
8.1 Likely date of start of construction and likely date of completion
Likely date of start of construction: With in two months after obtaining EC
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Likely date of completion of construction: June 2016
8.2 Estimated project cost along with analysis in terms of economic viability of
the project
Total project cost: Rs. 125 crores
9 Analysis of proposal (Final Recommendations)
9.1 Financial and social benefits with special emphasis on the benefit to the local
people including tribal population, if any, in the area:
Budgetary allocation shall be discussed in detail in EIA Report
UNIQUE ENGINEERING TESTING AND ADVISORY SERVICES216, Road No. 6-F, New Estate, Udhyognagar, Udhna, Surat-394210, Gujarat
Project :Project No.
Ns Rock Natural Density Spe- Shri- Free Shear PropertiesI. S. Additional/Samples Properties LimitsAnalysis(in gms/cc)No. of Moist. cific nkge swell C ØTestVisual Soil Descriptionin Classi- Tests orSPT UDS Blows per C.R.
:
Bore Hole No. : Bore Hole Started on : Completed on : Depth of :
Diameter of Bore Hole : R. L. of Ground Level :Method of Drilling : Location of Bore Hole :
Field Test Particle Size Atterberg
RQDContent Gra- Gr. Sn Silt+ LL PL PI Lim. Indx (Kg/ inTypemetres fication Bulk Dry Remarks% vityVST DS 300 mm % % % % Clay % % % % % cm²) Deg.
qu in Kg/cm²
Cv - Coeff. of ConsolidationStandard Penetration Test DS - Disturbed Sample Gr - Gravel LL - Liquid Limit PI - Plasticity Index C.R. - Core RecoverySPT -UDS - Undisturbed Sample Mv - Coeff. of Volume ChangeVST - Vane Shear Test Sn - Sand PL - Plastic Limit C, Ø - Shear Parameters RQD - Rock Quality Designation