LIST OF ANNEXURES SR. NO. NAME OF ANNEXUREenvironmentclearance.nic.in/writereaddata/FormB/TOR/... ·  · 2017-10-26II Layout Map of the Plant ... IV Water, Fuel & Energy Requirements

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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 Water, Fuel & Energy Requirements

V Details of Stacks and Vents

VI Details of Hazardous Waste Generation and Disposal

VII Storage Details of Hazardous Chemical

VIII Noise level at Different source within the premises

IX Socio-economic Impacts

X Proposed Terms of Reference for EIA studies

XI Coal Analysis Certificate

XII Water Supply Certificate

XIII Copy of Plot Allotment Letter

XIV Copy of CC&A

XV Copy of NOC Amendment

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ANNEXURE-I

_______________________________________________________________________

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

SR.

NO.

PRODUCT EXISTING TOTAL PROPOSED

1. Captive Power plant 2x11 MW + 1x4.2 MW +

1x12.5 MW (stand by)

= 38.7 MW

2x11 MW + 1x12.5 MW +

1x4.2 MW (stand by)

= 38.7 MW

2. Soda Ash 11,00,000 TPA 11,00,000 TPA

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ANNEXURE-II

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LAYOUT MAP OF THE PLANT

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ANNEXURE-III

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BRIEF MANUFACTURING PROCESS DESCRIPTION

SODA ASH

PROCESS DESCRIPTION:

Soda ash (Na2CO3) is manufactured from limestone, which is mainly composed of CaCO3

(88-90%) and MgCO3 (2-6%). The major impurities present in the mineral are silica (4-6%),

and Al2O3 + Fe2O3 (2%). Deposits of limestone occur in commercially exploitable quantities

at several sites in the Junagadh and Kachchh Districts. Other major raw materials used in the

process are common salt and coke. Common salt, which is produced from seawater in salt

pans through solar evaporation, contains NaCl (94%) and traces of other major metals in

seawater such as Ca (0.2%) and Mg (0.1%). Insoluble impurities namely sediment and sand

particles may constitute upto 0.4%. Coke and lignite used in the process have calorific value

6000 & 3000 Kcal/ Kg respectively while the nonvolatile residue in the fuel is mainly ash

(14%). Details of raw materials required to manufacture 1 t of soda ash are summarised

below:

Material Quantity

Salt 1.7 to1.8 t

Limestone 1.5 to 1.6 t

Coal + lignite 0.5 to 0.6 t

Freshwater 5 to 6 m3

Cooling seawater 140 to 150 m3

Ammonia 3 – 4 kg

At GHCL, soda ash is produced by a continuous process as illustrated in simplified flow

diagram. The limestone and coke which are used as raw material and fuel respectively are

mixed in a definite proportion and charged to a vertical lime kiln where the mixture is burnt

using combustion air at 1000oC. Here, the limestone is decomposed to lime (CaO) and carbon

dioxide gas. Crude lime thus produced, is grounded and pulverized to an effective size of

0.15 mm. The kiln gas is fed to the compressors for carbonation.

The salt is fed at the rate of 100 - 130 t/h. The oversize salt is transported to the lump

crusher. The salt is then dissolved in raw water to produce the brine solution. Residual

impurities of calcium and magnesium compounds are removed from the brine by treating it

with milk of lime and soda ash. The purified brine is passed through packed towers along

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with ammonia that is supplied from the distillation plant to obtain the ammoniated brine. The

ammoniated brine is carbonated by passing through carbonating tower along with

compressed CO2 as well as CO2 recovered from the soda Ash calciner.

Temperature of the tower is controlled by the circulating sea water and chilled water. The

reaction taking place in the carbonating tower is as follows:

NH3 + CO2 + NaCl → NaHCO3 + NH4Cl + Energy

The major product Sodium Bicarbonate (NaHCO3) which is sparingly soluble in water

precipitates while NH4 Cl and other salts remain in mother liquor in the dissolved state. The

bicarbonate Slurry cold as magma is filtered in rotary. Vacuum filters and the bicarbonate

separated is washed with fresh water to remove trace impurities. The crude Bicarbonate thus

obtained is decomposed in a rotary tube steam heated calciner in to Soda Ash (Na2CO3) and

CO2 which is scrubbed, cooled and recycled to the CO2 Compressor. Apart from this the

product is sent to densification and the balance is cooled to ambient temperature and sent for

packing.

The mother liquor rich in NH4Cl and NH4OH is pumped to the Ammonia still where free

Ammonia is removed using gas heat exchangers; the remaining is treated with lime in

prelimer to liberate Ammonia via reaction.

CaO + 2NH4 Cl → CaCl2 + 2NH3 + H2O

The liberated Ammonia is recycled back to process and CaCl2 along with unreacted part of

NaCl, CaCO3 is the final waste.

List of unit operation along with chemical reaction & residence time is given as under.

List of Unit Operation

1. Dissolution of Salt in Water

2. Absorption of Brine

3. Distillation of Ammonia

4. Filtration of Draw Liquor

5. Drying of Monohydrate

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CAPTIVE POWER PLANT

PROCESS DESCRIPTION:

Hot gases produced during carbonization of coal inside the ovens are being trapped and

canalized through hot gases ducts and brought to the steam boilers. This hot gas is allowed to

pass through the series of hot gas tubes, which are submerged in water inside the boiler

chamber. Water is continually circulated into the boiler and high pressure steam at very high

temperature is allowed to inject on the turbine blades. This results in rotation of turbine which

in turn rotate generator rotor as both are mechanically coupled. This rotation of generator

rotor produces electricity due to interaction of magnetic field of rotor and stator. Electricity

generated is coupled to substation through transformer and through protective switchgears.

Finally supply is given to the load though the substation or alternatively coupled to state

electricity grid.

FLOW DIAGRAM:

GHCL have total five nos. of boilers out of that 4 nos. are working and one boiler is stand by

flue gas of all the boilers are going to one chimney.

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Details of the boilers are as follows:

1) LB-74, LB-75, LB-76

Type AFBC Boilers

Make M/s Cethar Vessels Limited

Capacity 90 TPH

Pressure 105 Kg/cm2

Temperature 505 ° C

2) LB-77

Type AFBC Boilers

Make Thermax Babcock & Wilcox Ltd

Capacity 90 TPH

Pressure 105 Kg/cm2

Temperature 505 ° C

3) LB-78

Type CFBC Boilers

Make Thermax Babcock & Wilcox Ltd

Capacity 125 TPH

Pressure 105 Kg/cm2

Temperature 505 ° C

4) Turbines

Make BHEL

Capacity 2x11 MW 1x4.2 MW 1x12.5 MW

(Stand by)

Power

Generation

6.6 KV 6.6. KV

Type Single extraction

back pressure

Double extraction

back pressure

Condensing

turbine

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ANNEXURE-IV

_______________________________________________________________________

WATER, FUEL & ENERGY REQUIREMENT

(EXISTING & TOTAL PROPOSED)

WATER CONSUMPTION AND WASTE WATER GENERATION

SR.

NO.

DESCRIPTION WATER

CONSUMPTION

m3/day

WASTE WATER

GENERATION

m3/day

1. Domestic 2100 1400

2. Processing 22500 19800

3. Cooling 384000 362808

TOTAL 408600 384008

Note: After modernization of CPP the quantity of water consumption & wastewater

generation remain unchanged.

FINAL EFFLUENT DISPOSAL SYSTEM

DIFFUSER SYSTEM

Liquid waste from distiller and salt purification section is conveyed through pipeline and pre

diluted with once through cooling seawater in a mixing pond. It is discharged through a

combination of open channel of approximate 810 meters length and a submarine pipeline

inside the Arabian Sea with special designated diffuser system for spontaneous dilution inside

the sea as recommended by M/s NIO.

TOTAL FUEL REQUIREMENT

Sr.

No.

Fuel Quantity

1 Existing - Coal/Lignite 1500 MT/Day

2 Total Proposed – Coal/Lignite 1500 MT/Day

Note: After modernization of CPP the quantity of fuel will remain unchanged.

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TOTAL POWER REQUIREMENT

Note: Two DG Sets (1000 KVA & 500 KVA) are kept for emergency power back up.

Sr.

No.

Description Requirement

( MW)

Source

1 Existing:

2x11 MW + 1x4.2 MW +

1x12.5 MW (stand by) = 38.7

MW

26.2 MW Captive power plant

2 Total Proposed :

2x11 MW + 1x12.5 MW +

1x4.2 MW (stand by) = 38.7

MW

34.5 MW Condensing turbine

in operation

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ANNEXURE-V

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DETAILS OF STACKS & VENTS (TOTAL)

The flue gas emission through stack attached to boiler shall conform to the following

standards:

Common Stack

Attached to

Stack Height in

Meter

Air Pollution

Control System Parameters

Permissible

Limit

Boiler

(1 to 5 nos.)

1-Stand by

145 ESP with each

boiler

PM

SO2

NOx

150 mg/Nm3

100 ppm

50 ppm

The process emission through various stacks/vent of process shall confirm to the

following standards:

Stack

No.

Stack Attached

to

Stack Height in

Meter

Air Pollution

Control System Parameters

Permissible

Limit

1 Filter Gas

scrubber 30 Scrubber NH3

175 mg/Nm3

2 Tower gas

scrubber 35.1 Scrubber NH3

175 mg/Nm3

3 Lime mill A 59.6 Bag filter PM

150 mg/Nm3

4 Lime mill B 59.6 Bag filter PM

150 mg/Nm3

5 Lime mill C 59.6 Bag filter PM

150 mg/Nm3

6 Dense ash

scrubber (old) 34 Bag filter PM

150 mg/Nm3

7 Dense ash

scrubber (New) 34 Bag filter PM

150 mg/Nm3

8 Lignite Tippler 15 Bag filter and

Dry Fog system PM

150 mg/Nm3

9 Lignite screen

House 15

Bag filter and

Dry Fog system PM

150 mg/Nm3

10 Boiler Bunker

Top 15

Bag filter and

Dry Fog system PM

150 mg/Nm3

11 Lime stone

Tippler 15 Bag filter PM

150 mg/Nm3

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12 Limestone

screen house 15 Bag filter PM

150 mg/Nm3

13 Lignite feed

Building 15

Bag filter/

Dry Fog system PM

150 mg/Nm3

14 Belt 213 / lime

kiln DSL 15 Bag filter PM

150 mg/Nm3

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ANNEXURE-VI

_______________________________________________________________________

DETAILS OF HAZARDOUS WASTE GENERATION AND DISPOSAL

Non-hazardous Waste

SR.

NO.

NAME OF

WASTE

WASTE

CATEGORY

QUANTITY

MODE OF DISPOSAL

1 Used Oil 5.1 40.5 MT/Year Collection, Storage, Transportation

and selling to registered re-refiners

units

2 Used Battery 17 8 MT/Year Collection, Storage, Transportation

and selling to registered re-refiners

units

1 Fly Ash -- 88560 MT/Yea

Bricks manufacturing plant within

factory premises & sell to National

Highway Authority of India (NHAI)

for road construction.

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ANNEXURE-VII

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STORAGE & HANDLING DETAILS OF HAZARDOUS CHEMICALS

GHCL is handling Ammonia and it is used in process in small quantity Two storage tank for

storing Liquid Ammonia with licensed capacity of 75 MT of each has been provided. The

Inspector of Explosives, Government of Gujarat, approves the tank construction and layout.

• Out of Two tanks one tank is kept always empty. In case of any emergency, the liquid

Ammonia can be transferred from one tank to another.

• The tank is designed for the pressure higher than operating pressure and has been

fabricated by the explosive Department, approved manufacturer. The controller of the

Explosives is inspecting this and they are providing Approvals.

• All the Nozzles are provided with two isolation valves.

• Each tank is provided with two safety release valves.

• Specially designed excess flow prevention valves have been provided on both inlet and

outlet Nozzles of each tank.

• Ammonia can be easily absorbed in the water. Specially designed Fire Hydrant System

as per the Guideline of Tariff Advisory Committee is provided. This has got special jets

water to the height of 75 meters.

• All the electrical Lighting and fittings are of flameproff construction to avoid any

sparking.

• The operating staff is well trained to face any eventualities. Gas mark with breathing air

sets is readily available.

• Special task force has been formed to tackle any hazard.

• Regularly third party Safety Audits.

• GHCL has adopted fire hydrant system. It consists of network of 3.5 KM of hydrant

System and is governed by various codes and guidelines from Tariff Advisory

Committee.

SR.

NO.

NAME OF CHEMICAL TYPE OF

HAZARD

MODE OF

STORAGE

STORED

QUANTITY

1 Ammonia Toxic MS Tank

75 MT – Licensed

capacity

(2 Nos.)

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• Emergency organization has been formed to handle any possible hazards. The duties of

each personnel have been properly written.

• Assembly points are fixed. Provisions of both side roads have been made.

• Training and rehearsals are regular features.

• A booklet on the Ammonia has been prepared and distributed to the all-surrounding

areas to overcome any eventuality.

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ANNEXURE-VIII

_______________________________________________________________________

NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES

Various Location Noise Level are monitored and its results are given below.

Sr.

No.

Location

Noise Levels in dB (A)

1st

Monitoring 2nd

Monitoring

3rd

Monitoring

Day Night Day Night Day Night

1 Main Gate 73 62 78 68 80 65

2 HR building 68 58 72 59 67 58

3 Canteen 75 62 77 63 73 60

4 STP Plant

Colony-1

70 61 74 65 72 62

5 Boiler Area 71 68 76 66 79 71

6 Turbine area 82 80 81 83 85 84

7 Colony-2 67 62 71 62 70 64

8 Coal Storage

area

68 64 72 63 77 66

9 Pump Station 77 70 77 67 79 72

Following are the various remedial measured applied to reduce Noise Pollution.

Sr.

No.

Source of Pollution Remedial Measures

1 CO2 Compressors Noise Hood in the form of closed

enclosures

2 Kiln Blowers VFD & enclosures has been provided

3 Vacuum Pumps Enclosures has been provided

be attached to exiting coke oven batteries.

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ANNEXURE-IX

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

During operation phase, skilled and unskilled manpower will be needed. This will

temporarily increase the employment opportunity. Secondary jobs are also bound to be

generated to provide day-to-day needs and services to the work force. This will also

temporarily increase the demand for essential daily utilities in the local market. The

manpower requirement for the proposed modernization is expected to generate some

permanent jobs and secondary jobs for the operation and maintenance of plant. This will

increase direct / indirect employment opportunities and ancillary business development to

some extent for the local population. This phase is expected to create a beneficial impact on

the local socio-economic environment.

2) INDUSTRIES

During operation of the project, the required skilled and unskilled laborers will be utilized

maximum from the local area. The increasing industrial activity will boost the commercial

and economical status of the locality, to some extent.

3) PUBLIC HEALTH

During operation period, workers will be provided with basic amenities like safe water

supply, low cost sanitation facilities, first aid, required personal protective equipment, etc.

Otherwise, there could be an increase in diseases related to personal hygiene. The company

will regularly examine, inspects and tests its emission from sources to make sure that the

emission is below the permissible limit. Hence, there will not be any significant change in the

status of sanitation and the community health of the area, as sufficient measures have been

taken and proposed under the EMP.

4) TRANSPORTATION AND COMMUNICATION

Since the proposed factory is having proper linkage for the transport and communication, the

development of this project will not cause any additional impact. In brief, as a result of the

modernization there will be no adverse impact on sanitation, communication and community

health, as sufficient measures have been proposed to be taken under the EMP. The proposed

modernization is not expected to make any significant change in the existing status of the

socio - economic environment of this region.

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ANNEXURE-X

_______________________________________________________________________

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES

The Environmental Impact Assessment of the project shall examine the project’s potential

negative and positive environmental impacts and shall recommend any measure needed to

prevent, minimize, mitigate or compensate for adverse impacts and improve environmental

performance of the schemes. It should prevent future liabilities or expensive alternatives in

the project. Impact assessment requires as a sound knowledge and understanding of the

baseline situation and of the autonomous development situation.

The conduct of the assessment will be governed and content of the report will be specified by

following legislation and other relevant regulation, if applicable.

• Environmental Protection Act – 1986

• Water (Prevention and Control) of Pollution Act – 1974

• Air (Prevention and Control) of Pollution Act – 1981

• Hazardous Waste (Management & Handling) Amended Rules - 2003

• Environmental Impact Assessment Notification – 2006

METHODOLOGIES FOR EIA

Taking into consideration proposed project activities and guidelines, an area of 10 km radius

from the center of the project has been selected and is designated as the study area for the

purpose of rapid EIA studies.

BASE LINE CONDITION

The samples of ambient air, ground and surface water and soil are collected and analyzed as

per the standard methods for establishing the baseline data and to determine the impact of

proposed activity on the same.

AMBIENT AIR ENVIRONMENT

The air environment around the plant was studied by setting up eleven locations within the

study area of 10 Km radius from the project site and collection and monitoring the site

specific meteorological data, viz. wind speed, wind direction, humidity, rainfall and ambient

temperature was carried out. Design of network for ambient air quality monitoring locations

is based on guidelines provided by CPCB. The ambient air samples were collected and

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analyzed for SPM, RSPM, SO2, Nox, HCl and Cl for identification, prediction, evaluation

and assessment of potential impact on ambient air environment.

GROUND AND SURFACE WATER ENVIRONMENT

The water required for domestic and industrial use is being made available from surface

water. Hence, to assess the physico-chemical quality of the water, a number of water samples

were collected and analyzed for pollution parameters viz., pH, TDS, Turbidity, BOD3, COD,

Fluorides, Chlorides, Sulphates, Nitrates, Ammonical Nitrogen, Hardness, Alkalinity, Oil &

Grease and some heavy metals in order to find out the contamination, if any.

NOISE ENVIRONMENT

Noise pollution survey was conducted in the study zone. The anticipated noise sources were

industrial activities, which are likely to be increased due to proposed activity. Noise levels

were also recorded in surrounding villages for evaluating general scenario of the study area.

Hourly equivalent sound levels (Leq) were also recorded for calculating Day and Night noise

levels in the surrounding villages.

SOIL ENVIRONMENT

Soil sampling and analysis was carried out to assess physico-chemical characteristics of the

soils and delineate existing cropping pattern, existing land use and topography, within the

study area.

BIOLOGICAL ENVIRONMENT

Keeping in view, the importance of biological component of total environment due to the

proposed project, biological characterization of terrestrial and aquatic environments, changes

in species diversity of flora and fauna in terrestrial as well as aquatic systems were studied for

impact analysis due to proposed project activity, if any.

SOCIO-ECONOMIC ENVIRONMENT

Demographic and related socio-economic data was collected from census handbook to assess

socio-economic status of the study area. Assessment of impact on significant historical,

cultural, and archeological sites/places in the area and economic and employment benefit

arisen out from the project is given special attention.

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IDENTIFICATION OF POLLUTION SOURCE

Detailed study of manufacturing process for existing production scenario and post

modernization scenario is carried out along with input and output of materials, water, and

wastewater as well as infrastructure facilities available.

EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL

MANAGEMENT SYSTEM

The qualitative and quantitative analysis of various pollution sources as well as evaluation of

pollution control system is carried out.

EVALUATION OF IMPACT

A comprehensive evaluation of environmental impact with reference to proposed

modernization activities is carried out.

PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN

A comprehensive Environmental Management Plan has been prepared covering all the

aspects of pollution prevention measures, Air and Water Pollution Control measures,

Hazardous Waste Management, Environmental Surveillance and Environmental Management

Plan.

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ANNEXURE-XI

_______________________________________________________________________

COAL ANALYSIS CERTIFICATE

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ANNEXURE-XII

_______________________________________________________________________

WATER SUPPLY CERTIFICATE