environmental impact assessment (eia)environmentclearance.nic.in/writereaddata/eia/3010201815... ·...

Environmental Impact Assessment (EIA) Report

for

Expansion of Existing Products and Manufacturing New

Pesticides and Intermediates at E51-1&2, E52, MIDC

Notified Industrial Estate Tarapur, Boisar, District

Palghar (Maharashtra) (ToR F. No.- IA-J-11011/7/2017-IA-II(I))

File No. IA/MH/IND2/61495/2017 dated 10.05.2017

by

UPL Limited, (Unit # 10) E51-1&2, E52, MIDC Notified Industrial Estate,

Tarapur, Boisar, Dist: Palghar

Maharashtra -401506

Consultant Shivalik Solid Waste Management Limited

SCO 20-21, Dhakoli, Zirakpur, Punjab- 140 604

(NABET Accredited Environmental Consultant)

com

Text Box

Undertaking of UPL-10

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra

Shivalik Solid Waste Management Ltd. iii

Declaration by Experts contributing to this EIA - EMP and Risk Assessment Declaration by EIA Co-ordinator/s under NABET scheme for Accreditation of EIA Consultant Organizations

I, hereby, certify that I was a part of the EIA team in the following capacity that developed the

above EIA.

EIA Coordinator: Name: Ashok Kumar Sharma Signature & Date: Period of involvement: from February 2017

Contact information:

Office address: - SCO 20-21, 2nd Floor, Near Hotel Dolphin, Baltana, Zirakpur Punjab- 140604 Phone/Telefax: 01762–509496

Declaration by Experts involved in each Functional Area identified under NABET scheme for

Accreditation of EIA Consultant Organizations

I, hereby, certify that I was a part of the EIA team for the role/s and assignments carried out as

mentioned herewith.

S.

No.

Functional

Areas

Name of the

Expert/s

Involvement

(Period &Task**)

Signature

I. EIA

Coordinator

Mr. Ashok Kumar

Sharma

Feb 2017 –till date

EIA Co-

Coordinator

Mr. Vinod Kumar

Gautam

Oct 2017 to till

II. Functional Area Expert

1. AP*

(Air Pollution

Monitoring,

Ms. Daksha

Gupta

Quantification of Air pollution and Assessment of

Impacts.


Shivalik Solid Waste Management Ltd. iv

S.

No.

Functional

Areas

Name of the

Expert/s

Involvement

(Period &Task**)

Signature

Prevention &

Control)

Period of Involvement: Mar

2017 –till date

2. RH*

(Risk Assessment &

Hazard Management)

Mr. Ashok Kumar

Sharma & Mr.

Vinod Kumar

Gautam

Assisted approved FAE

during study period Coordinating safety studies,

finalization of DMP, contribution to RA/DMP

Documentation and contribution to EIA

documentation.

3. WP*

(Water Pollution Monitoring,

Prevention & Control)

Dr P N

Parameswaran &

Mr Snehal R.

Lokhandwala

Quantification of water

pollution and Assessment of Impacts.


2017 –till date.

4. SHW*

(Solid and Hazardous

Waste

Management)

Ms. Daksha

Gupta &

Mr. Vinod Kumar

Gautam &

Dr. P N

Parameswaran

Quantification of Solid &

Hazardous Waste and Assessment of Impacts.


2017 –till date

5. SE* (Socio-

economics) Sayantani

Chatterjee

Collection and Compilation

of Socio-economic data. scenario and CSR Plan.

Period of Involvement: May 2017 –till date


Shivalik Solid Waste Management Ltd. v

S.

No.

Functional

Areas

Name of the

Expert/s

Involvement

(Period &Task**)

Signature

6. EB* (Ecology &

Biodiversity) Dr. I. S. Dua, Mr

Silbhadra

Brahma &

Shivani Dutt.

Conducted primary survey

work at site, collected

information about flora and fauna from Forest

department and checked.

Period of Involvement: May

2017 –till date.

7. HG* (Hydrology,

Ground Water &

Water Conservation)

Yamesh Sharma Provided guidance on

Hydrology aspects of the

EIA Report.

8. GEO* (Geology)

Subhash

Chander Sharma

Geology and

geomorphologic analysis

based on secondary data.

9. SC* (Soil

Conservation) BS Lole. Interpretation of baseline

data of soil analysis and its

interpretation. Preparation

of draft report considering

impact and mitigation on

Soil as per guidelines.

10 LU and NV* (Land use Noise

& Vibration)

Mr. Vinay Kumar

Kurukula

Quantification of Noise & Vibration and Assessment

of Impacts. Period of Involvement:

March 2017 –till date.

11 AQ*

(Meteorology,

Air Quality Modeling &

Prediction)

Mr. Daksha

Gupta and Mr.

Vinod Gupta

Checking air quality data,

evaluation of results of

Ambient Air Quality Monitoring (AAQM),

supervision of air quality modeling and prediction,

identification of impacts,

suggestion and finalization of mitigation measures.


Shivalik Solid Waste Management Ltd. vi

S.

No.

Functional

Areas

Name of the

Expert/s

Involvement

(Period &Task**)

Signature

Period of Involvement:

March 2017 –till date

Table 12.2: Team Members (TM) and FAA (Functional Area Associate) Associated with the Study

S. No.

Functional Areas

Name of the TM/FAA

Involvement (Period & Task**)

Signature

1. AP* (Air Pollution Monitoring, Prevention & Control)

Vishal Kalhapure Sachin Kumar (TM)

Assisted approved FAE Period of Involvement: during study period. Assisted FAE in Site visit, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM).

2. WP* (Water

Pollution Monitoring, Prevention & Control)

Sachin Kumar (TM)

Assisted approved FAE during study period. Assisted approved FAE, in selection of sampling locations for surface and ground water sampling, evaluation of water pollution control management, identification of impacts, suggestion of mitigation measures, contribution to EIA documentation.

3. SHW* (Solid and Hazardous Waste Management)

Vishal Kalhapure

& Niraj Kumari Parihar

Assisted approved FAE in Identification of solid and Hazardous Wastes generated, designs for temporary storage facilities for hazardous wastes, mitigation measures for management of hazardous waste, contribution to the EIA documentation.

4. SC* (Soil Conservation)

S. Brahma (TM) & Sanjay Sharma (TM)

Assisted approved FAE and site visited and collection of base line data of soil analysis and along with field observation, Preparation of draft report.


Shivalik Solid Waste Management Ltd. vii

S. No.

Functional Areas

Name of the TM/FAA


Signature

5. NV* (Noise & Vibration)

Niraj Kumari Parihar

Assisted approved during study period, analysis of data, identification of impacts and mitigation measures, and contribution to EIA documentation.

6. RH* (Risk Assessment & Hazard Management)

Baseem Zafar Assisted approved FAE during study period Coordinating safety studies, finalization of DMP, contribution to RA/DMP Documentation and contribution to EIA documentation.

7. AQ* (Meteorology, Air Quality Modeling & Prediction)

Baseem Zafar Sachin Kumar (TM)

Assisted approved in checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM), and contribution to EIA documentation& compilation of report.

8. SE* (Socio-economics)

Sunita Dhirta Assisted approved FAE in Collection and Compilation of Socio-economic data.

Declaration by the Head of the Accredited Consultant Organization: I, Ashok Kumar Sharma, hereby, confirm that the above-mentioned experts prepared the EIA / EMP and RA Report for proposed EXPANSION of M/s UPL Ltd. (Unit#10) located at E51/1, E51/2, and E-52, MIDC Notified Industrial Estate Tarapur, Boisar Dist.- Palghar in Maharashtra State, India. I also confirm that I shall be fully accountable for any mis-leading information mentioned in this statement.

Name: Ashok Kumar Sharma Designation: CEO Signature: Name of the EIA Consultant Organization: Shivalik Solid Waste Management Limited. NABET Certificate: Re-accreditation granted for category A Valid till 16th Feb 2019 Listed at sr. no. 133 of list of accredited consultant organizations (alphabetically) – Rev. 63, March 05, 2018.


Shivalik Solid Waste Management Ltd. viii


Shivalik Solid Waste Management Ltd. ix

EXECUTIVE SUMMARY

Sr. No.

Summary Point

1. Project Name and Location

Name: UPL Ltd. (Unit# 10) Address: Plot No. E51/1, E51/2, and E-52, MIDC Notified Industrial Estate, Tarapur, Boisar, District

–Palghar, Maharashtra

2. Products & Capacities. If expansion proposal then existing products with capacities and reference to early EC.

UPL Ltd. Tarapur has existing production capacity 11388 TPA (Pesticide Technical 1620 TPA –

EC Required, pesticide intermediates 1968 TPA - EC Required, Inorganic chemicals 5100 TPA - EC not Required, pesticide Formulation products 2700 TPA – EC not Required), and now

proposing 67632 TPA (Pesticide Technical 25500 TPA - EC Required, pesticide intermediates

16932 TPA - EC Required, Inorganic chemicals 12900 TPA - EC not Required, pesticide Formulation products 12300 TPA - EC not Required), hence total production capacity after

expansion is 79020 TPA. (Pesticide Technical 27120 TPA - EC Required, pesticide intermediates

18900 TPA - EC Required, Inorganic chemicals 18000 TPA – EC not Required, pesticide Formulation products 15000 TPA – EC not Required)

3. Requirement of Land, Water, Power, Fuel with Source of supply (quantitative)

Land Requirement: Expansion of pesticides, pesticide intermediates and pesticide Formulation products manufacturing plant will be developed within existing premises of Tarapur having total plot area 23,454 sqm (2.3454 ha)

Water: Existing fresh water requirement is 166.56 KLD and proposed fresh water requirement will be 538.5 KLD, hence total fresh water requirement after expansion will be 705.06 KLD which will be sourced from MIDC water supply.

Power:

• Total power requirement will be 4332 kW (Existing: 1508 kW + Proposed: 2824 kW) after expansion is/will be sourced from MSEB (Maharashtra State Electricity Board).

• UPL Ltd. has proposed 2 Nos. of D.G. Sets having capacity 750 kVA each.

Fuel: After expansion following fuels will be required they are as follows:

• Total 125 litre/hr (Existing: 125 Lit/hr + Proposed: NIL) FO is/will be sourced from local Supplier

• Total 2985 kg/hr (Existing: 985 kg/hr + Proposed: 2000 kg/hr) imported coal is/will be

sourced from Indonesia • Total 2460 kg/hr (Existing: 2460 kg/hr + Proposed: NIL) Biomass/briquettes/Rice husk

is/will be sourced from local Supplier

• Total 500 Lit/hr (Existing: 500 Lit/hr + Proposed: NIL) LDO is/will be required in case of emergency only which is/will be sourced from local Supplier

• Total 500 Lit/hr HSD (Existing: NIL+ Proposed: 500 Lit/hr) will be required in case of emergency only which will be sourced from local Supplier

4. Process Description in brief, specifically indication the gaseous emission, liquid effluent and solid/hazardous waste

Process Description:


Shivalik Solid Waste Management Ltd. x

UPL Ltd. is not manufacturing any banned pesticide products and they assure that they will

manufacture the pesticide technical, pesticide Intermediate and pesticide formulation products

having valid consents & CIB registration after expansion. Total 12 Nos. of Products will be

manufactured after expansion.

Major Products are Acephate (Technical) 6000 TPA, Clomazone(Technical) 2400 TPA,

Asulam(Technical) 4800 TPA, Di Chlorvos (DDVP) (Technical) 1200 TPA, Glyphosate (Technical)

1200 TPA, Azoxystrobin (Technical) 1800 TPA, Devrinol(Technical) 1200 TPA, Triazinone

(Pesticide Intermediate) 7200 TPA, Tri Phenyl Phosphate (TPPA) (Pesticide Intermediate) 1800

TPA, Ammonium Chloride (inorganic chemical) 3000 TPA, and Asulox Formulation 12000 TPA.

Metribuzin (Technical): Methanol & Sodium Bromide slurry is charged and apply heating start

addition of 98% sulfuric acid to generate Methyl bromide gas in first step. Charge fresh water,

distillate from RVD and Triazinone in reaction kettle with stirring and chilling. Charge bleaching

agent and Defoamer. Then start purging of MeBr from Step 1. After completion of MeBr purging,

the reaction mass is then filtered, dried to obtain final product as Metribuzin.

Acephate (Techical): Dimethyl Phosphorous Amido Thionate (DMPAT) is isomerized to

Methamediphos catalyst. After isomerisation, the mass is reacted with acetic anhydride in the

presence of Dichloro methane as solvent and neutralized with aqueous ammonia. After the layer

separation, the organic layer is taken in another reactor for dichloromethane recovery and Acephate

separation. Isopropyl alcohol and Acephate are taken in an agitate nutche filter. The cake is dried

in rotary vacuum dryer. The dry Acephate is filled in bags as final packing.

Asulam(Technical): Raw materials Dimethyl Carbonate, Sodium Methoxide and Sulfanilamide are

charged in the reaction vessel at room temperature. Reaction mass is heated up to reflux temp of

68°C slowly and is maintained at reflux temperature for some time. After completion of the reaction,

methanol contained in the mass is recovered by steam and vacuum distillation. Balance mass in

the reactor after removal of methanol is transferred to storage tank as product.

Clomazone (Technical): At first step, Charge water and hydroxylamine Sulphate and adjust pH to

7-8 with caustic lye. Add 3-CPC and caustic lye simultaneously to get Propanamide slurry. At

second step, Charge water and step-1 mass and under stirring add caustic lye & adjust pH 8-9,

maintain for 4-5 hrs. Use 4, 4 DMI solutions. And at final step, Charge 4, 4 DMI solution, catalyst,

Na2CO3 and add OCBC and maintain for 5-6 hrs. Cool reaction mass and separate aqueous layer

and organic mass. SOCl2 or HCl is added in organic mass and maintains for 4-5 hrs, add sodium

carbonate and caustic lye and heat mass and add water and maintain temp 70-90 oC for 30 minutes,

separate organic and aqueous layer. Dehydrate organic mass by distillation to get Clomazone Tech.

Triazinone (Pesticide Intermediate): At first step, to prepare pinacolone to Dichloropinacolone by

slowly addition of chlorine in Pinacolone. At second step, preparation of Hydrazine Hydrate to

Thiocarbonohydrazide by addition of CS2 in Hydrazine hydrate. At final stage, prepare

Dichloropinacolone to Kito Acid by Charging water and 48% Caustic Soda Lye under stirring and

heat it to 40°C. Add Dichloropinacolone slowly by maintaining temperature between 30 °C. And

then prepare Keto Acid to Triazinone by Charging water, conc.H2SO4 and TCH solid under stirring.

Heat the reaction mass to 80°C. Start addition of Keto acid solution at temperature 80°C. After

completion of Keto acid addition add conc. H2SO4. Maintain the reaction mass at temperature 70-

75°. Cool the reaction mass to 10°C and filter, Wash with water and dry it.


Shivalik Solid Waste Management Ltd. xi

Process description of other pesticide technical products (Di-chlorvos(DDVP), Glyphosate, Sulfosulfuron (SF10), Pyrazosulfuron Ethyl, Bensulfuron Methyl, Metsulfuron Methyl, Azoxystrobin , Devrinol ), Other Specific Intermediate Chemicals (Tri Phenyl Phosphite (TPPI) , Tri Phenyl Phosphate (TPPA), Phosphorous Trichloride, Phosphorous Oxychloride, Phosphorous Acid Crystals, Phosphorous Acid (60% solution), Di-Potassium Hydrogen Phosphate), Other Inorganic chemicals (Ammonium Sulphate, Ammonium Chloride, Potassium Chloride), other Formulation products (Glyphosate 41% SL Formulation, Metribuzin 70% WDG Formulation) are given in Chapter 2 of EIA Report.

Flue Gas Emission from Proposed Plant:

• PM < 150 mg/NM3, SO2 < 100 ppm and NOx < 50 ppm will be emitted from the proposed

boiler (10 TPH) and 2 Nos. D. G. Set (750 KVA each).

After expansion, total 7 nos of flue gas stacks (Existing: 4 nos. + Additional: 3 nos). Adequate size and No. of Air Pollution Control Measures (APCM) are/will be provided to achieve the statutory

norms. Process Gas Emission from Proposed Plant:

• HCl < 20 mg/Nm3 and Cl2 < 5 (For pesticide products) mg/Nm3 from Asulam Plant.

• HCl < 20 mg/Nm3 from Tri phenyl Phosphate (TPPA) plant

• NH3 < 175 mg/Nm3 and HCl < 20 mg/Nm3 from Ammonium chloride plant.

• HCl < 20 mg/Nm3, H2S < 45 mg/Nm3 from Triazinone Plant.

• NH3 < 30 mg/Nm3 from Acephate plant.

• NH3 < 30 mg/Nm3, HC< 20 Nm3 and HCL< 20 mg/Nm3 from Glyphosate Plant.

• HBr < 5 mg/Nm3 from Metribuzin plant (Common plant scrubber).

• NH3 < 175 mg/Nm3 from Ammonium Sulphate plant.

• HCl < 20 mg/Nm3 from Phosphorous Acid Solid & solution plant

• MeCl < 20 mg/Nm3 from Di-chlorvos (DDVP) Plant.

12 nos of process stacks (Existing: 2 nos+ Additional: 10 nos) will be installed. Adequate size and No. of Air Pollution Control Measures (APCM) are/will be provided to achieve the statutory norms. Liquid Bio-degradable Effluent to ETP:

Total existing waste water generation is 38.1 KLD and additional will be 258.9 KLD. After proposed

expansion, generated effluent of 297 KLD will be treated in proposed Effluent Treatment Plant

(ETP) capacity of @300 KLD. Treated waste water from ETP is/will be sent to CETP of Tarapur for

further treatment and disposal. After expansion, generated sewage will be treated in ETP along

with industrial effluent.

Solid and Hazardous Waste generated after expansion are as follows: After expansion total Landfilling waste generation will be 2584 MTM (Existing: 0.3 MTM + Proposed:

2583.7 MTM). Generated landfilling wastes will be sent to Mumbai Waste Management Limited

(MWML, Taloja) for landfilling. After expansion total Incineration waste generation will be 1663.82


Shivalik Solid Waste Management Ltd. xii

MTM (Existing: 9.75 MTM + Proposed: 1654.07 MTM). Generated incineration waste will be sent

to Mumbai Waste Management Limited (MWML, Taloja) for incineration and also for co-processing

at cement industry on their suitability. Discarded containers / drums / carboys 9636 numbers per

month will be sold to MPCB authorized party. Plastic bags 51562 number per month will be sent to

scrap dealers / CHWTSDF at Taloja for landfilling, after decontamination. Used Oil 500 ltrs per

month will be sold to CPCB registered re-recyclers. Used batteries 5 numbers per month will be

sold to MPCB authorized parties. Spent solvent 10 MT per month will be sold to end-users or

recyclers or will be used for co-processing. Spent Acid 2 MT per year will be given to end-users or

recyclers. Fly Ash (non-hazardous waste) 120 MT per month will be sold to brick manufacturers or

other end-users.

As per Hazardous and Other Waste (Management and trans-boundary movement) Rules-2016, unit is ready to take applicable by product from existing and after expansion in hazardous Waste category. All by products will be sent to end users only.

5. Measures for mitigating the impact on the environment and mode of discharge or disposal

• Total effluent generation after expansion will be 297 KLD & treated in proposed Effluent Treatment Plant (ETP) capacity of @300 KLD. Treated waste water from ETP is/will be sent to CETP of Tarapur for further treatment and disposal. After expansion, generated sewage will be treated in ETP along with industrial effluent.

• High COD and toxic concentrated effluent is being/will be treated in the common incinerator of MWML, Taloja

• High TDS effluent streams will be treated in Multiple Effect Evaporation (MEE) System.

• Solid and hazardous wastes generated at the end of manufacturing process or waste treatment process will be stored on impervious floor having roof and boundary wall. Management of generated wastes will be done as per Hazardous and Other Wastes (Management, and Trans-Boundary Movement) Rules, 2016.

6. Capital Cost of the Project, Estimated time of completion

Capital cost for the expansion of project is Rs. 227.06 crores and it is estimated that approx. 36

months will be required for completion after getting Environmental Clearance.

7. Site selected for the project- Natural of land – Agricultural (Single/double crop), barren, Govt. /Private land, status of is acquisition, nearby (in 2-3 km) water body, population, with in 10 km other industries, forest. Eco-sensitive zones, accessibility.

• Expansion of pesticide, pesticide intermediates and pesticide formulation manufacturing plant is/will be developed in existing premises which is located in MIDC Notified Industrial Area, Tarapur.

• Land is already in possession with UPL Ltd, Total 25 villages are located in the 10-km radius study area. Total population of rural settlements is 48629. The male population is 25558 and female population is 23071.

• Major industries located in the study area are: Tarapur Atomic Power Station, JSW Steel Ltd, Tata steel Global Wires India, D'decor (the world’s 3rdlargest manufacturer of curtain and upholstery), Lupin (the world's largest manufacturer of the anti-TB drug rifampicin), Custom Capsule Pvt. Ltd., Siyaram Silk Mills Ltd, Indian Transformers Company Ltd, The "Common Effluent Treatment Plant" (CETP)

8. Baseline environmental data – Air quality, Surface and Ground water quality, Soil characteristic, Flora and Fauna, Socio-Economic condition of the nearby population.


Shivalik Solid Waste Management Ltd. xiii

• Ambient Air quality monitoring was carried out twice a week at 8 locations for one season from 1st March 2017 to 31st May 2017. As per the baseline study results of study area gaseous parameters (PM2.5: 20.81- 55.87 µg/m3, PM10: 65.94 – 95.94 µg/m3, SOx 11.91-25.84 µg/m3, NOx 20.23 – 45.84 µg/m3, 8-hourly CO 154-435 µg/m3, NH3 BDL – 12.23 µg/m3 etc.) are below the standard norms prescribed by CPCB.

• Surface water parameters such as conductivity, Total Dissolved Solids, Chloride, Sulphate, Nitrate, Sodium at Navapur location were found slightly higher than the desired value as the site is near to sea.

• Ground water monitoring (pH: 7.62-7.9, TDS:447.2-1238 mg/l, Total Hardness: 246-466 mg/l, Total Alkalinity: 236- 400 mg/l etc) for all locations meet the standard IS 10500 – 2012.

• As per soil analysis data (pH: 7.63-8.05, Conductivity: 0.141-1.58 mS/cm, Organic Carbon: 0.6-2.27 %, Organic Matter: 1.04-3.92 %, Available N: 182-285 kg/ha, Available Phosphorous: 47.3-

66.2 kg/ha, Arsenic: BDL-2.1 mg/kg, Nickel: BDL-3.11 mg/kg, Zinc: 1.23-16.2 mg/kg (µg/g) ,

Copper: 9.32-24.4 mg/kg (µg/g), Iron: 12.47-32.72 mg/kg (µg/g), Manganese: 3.45-8.88 mg/kg

(µg/g), Total Boron: 0.42-0.62 mg/kg, Exchangeable Calcium: 6.73-12.9 meq/100g, Exchangeable Magnesium: 1.52-2.26 meq/100g, Exchangeable Sodium: 1.58-2.76 meq/100g, Exchangeable potassium: 0.16-0.48 meq/100g ; while other parameters such as cadmium, Chromium and Lead are Below Detection Limit-BDL) it is concluded that surface soils are neutral to alkaline in nature, but normal from salinity view point.

• No rare, endangered and threatened (RET) species of fauna was reported within 10 Km radius study area. There is no ecological sensitive area like national park, wildlife sanctuary within 10 km radius study area.

• The total household in the study area (both rural and urban areas) are 31823 and the total population is 131187. The male population is 53.08% while female population is 46.91%. Literacy rate is around 77% which is considerably lower than the overall state figure. The SC population is 5% while ST population is 15.64%. Total working population accounts for 41%. Out of total working population, main workers are 34.5% and non-workers are 59%, whereas marginal worker accounts for 6.63% within study area.

9. Identification of hazards in handling processing and storage of hazardous material and safety system provided to mitigate the risk.

After identifying hazards in handling processing and storage of hazardous material both Qualitative and Quantitative risk has been analyzed. Mitigation measures like periodical training on fire drill and using SCBA, conducting emergency response drill on yearly basis, training drivers for transportation of hazardous goods, providing fire extinguishers etc.

10. Likely impact of the project on Air, Water, Land, Flora-fauna nearby population.

• Flue gas and process gas emission will be controlled by dust collector, bag filter, water scrubbers, Alkali scrubber, Two stage (water+ Alkali) scrubber, Venturi scrubber etc. hence impact will be negligible on nearby population.

• No impact on surface water as fresh water will be sourced from MIDC, Waste water will be treated adequately by making separate streams (high COD, High TDS and normal effluent). Final treated effluent from the ETP confirming the CETP norm is being/will be sent to CETP, Tarapur for further treatment.


Shivalik Solid Waste Management Ltd. xiv

• Land cover of area is already changed into factory building as it is an expansion project. No major impact on Land use and land cover.

• Positive impact on flora and fauna due to development of total approx. 1240 sq m of green belt within the factory premises. Unit has also planted 250 trees opposite to the site by adopting a crematorium (approx. land area of 1000 sq. m). It is proposed to create additional green belt of 5865.96 sqm area.

11. Emergency preparedness plan in case of natural or in plant emergencies.

On- Site and Off- Site emergency plan has been prepared by including Safety committee along with their roles and responsibilities, mutual aids arrangements, roles and responsibilities of stake holders including stake holders, etc.

12. Issues raised during public hearing (if applicable) and response given

Not Applicable - Project site is located within the Notified Industrial Area (MIDC), Tarapur

13. Occupational Health Measures

• Personnel protective equipment such as safety shoes, safety goggles, hand gloves, gum boots, safety helmet, and breathing apparatus set kit will be given to all workers and staff. Additional PPEs will be readily available at the workplace.

• Periodic medical check-ups (once in six month) will be carried out of employees.

• Safety awareness programs will be conducted.

14. Post Project Monitoring Plan

• Post project environmental monitoring is/will be done as per MoEF&CC/CPCB/MPCB guidelines by following recommended/standard method approved by MoEF&CC/CPCB.

• Allotted estimated Rs 4.38 Lakhs per annum for Environmental Monitoring. Existing unit has well established laboratory for monitoring.

List of Existing and Proposed Production Capacities after

Expansion

Sr. No

Product Name

Existing Capacity

(TPA)

Proposed Additional Capacity

(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category

As per EC Notification

2006

Products for which environmental clearance is applicable

(A) Pesticide Technical Products-Existing and Proposed capacity

1

Metribuzin Technical (existing and proposed)

1620 4980 6600 21087-

64-9

Fish-96 hr 80 ppm

2000 mg/kg

A-5(b)

Pesticide

(Herbicide)

2 Acephate (Technical) (proposed)

0 6000 6000 30560-

19-1 2050 mg/l

1447 mg/kg

A-5(b) Pesticide

(Insecticide)


Shivalik Solid Waste Management Ltd. xv

Sr. No

Product Name

Existing Capacity

(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006

3

Di Chlorvos (DDVP) (Technical) (proposed)

0 1200 1200 62-73-7 Fish(96 hr) 200 mg/l

Oral- 50 mg/kg

A-5(b)

Pesticide

(Insecticide)

4 Glyphosate (Technical) (proposed)

0 1200 1200 1071-83-6

rat (4 h)

>4.98 mg/l

Rat-oral 5600 mg/kg

A-5(b)

Pesticide

(Herbicide)

5 Clomazone (Technical) (proposed)

0 2400 2400 8177-89-1

96 h- fish- 34

mg/l

2077 mg/kg

A-5(b)

Pesticide

(Herbicide)

6

Sulfosulfuron (SF-10) (Technical) (proposed)

0 120 120 141776-

32-1

Fish (96 h) > 96

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

7

Pyrazosulfuron Ethyl (Technical) (proposed)

0 600 600 93697-74-6.

Fish (96 h) >180 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

8

Bensulfuron Methyl

0 600 600

A-5(b)

(Technical) (proposed)

83055-99-6

Fish (96 h) >150 mg/l

5000 mg/kg

Pesticide

(Herbicide)

9

Metsulfuron Methyl (Technical) (proposed)

0 600 600 74223-

64-6

Rat (4 h) 5 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

10 Asulam (Technical) (proposed)

0 4800 4800 3337-71-1

Fish (96 h) >5000 mg/l

>1200 mg/kg

A-5(b)

Pesticide

(Herbicide)

11 Azoxystrobin (Technical) (proposed)

0 1800 1800 131860-

33-8

Rat- 0.96

mg/kg

5,000 mg/kg

A-5(b)

Pesticide

(Fungicide)

12 Devrinol (Technical) (proposed)

0 1200 1200 15299-

99-7

Rat (4 h) > 5 mg/l

Oral- rats >5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)


Shivalik Solid Waste Management Ltd. xvi

Sr. No

Product Name

Existing Capacity

(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006

Total – A 1620 25500 27120

(B) Pesticide Specific Intermediate Chemicals – Existing and Proposed capacity

13

Tri Phenyl Phosphite (TPPI) (existing and proposed)

240 1560 1800 101-02-

0 Not

listed Rat- 1600

mg/kg A-5(b)

14 Triazinone (proposed)

0 7200 7200 21087-

64-0 Not

listed

Rat-Oral- 2379 mg/kg

A-5(b)

15

Tri Phenyl Phosphate (TPPA) (proposed)

0 1800 1800 115-86-

6 Not

listed


A-5(b)

16

Phosphorous Trichloride (existing and proposed)

900 4200 5100 02-12-7719

50 ppm 18 mg/kg A-5(b)

17

Phosphorous Oxychloride (existing and proposed)

600 600 1200 10025-

87-3 32ppm 380 mg/kg A-5(b)

18

Phosphorous Acid Crystals (existing and proposed)

120 780 900 10294-

56-1 Not

listed Not listed A-5(b)

9

Phosphorous Acid (60% solution) (existing and proposed)

48 252 300 7664-38-2

Not listed

Rat – 2,550 mg/kg

A-5(b)

20

Di-Potassium Hydrogen Phosphate (DPHP) (existing and proposed)

60 540 600 04-11-7758

NA Not listed A-5(b)

Total- B 1968 16932 18900


Shivalik Solid Waste Management Ltd. xvii

Sr. No

Product Name

Existing Capacity

(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006

Total (A+B) 3588 42432 46020

(C) Inorganic chemicals for which Environmental Clearance is not applicable

1

Ammonium Sulphate (existing and proposed)

3600 11400 15000 7783-20-2

NA 2840mg/kg

2 Ammonium Chloride (proposed)

0 3000 3000 12125-

02-9 NA 1650mg/kg

3

Potassium Chloride (existing and to be discontinued)

1500 -1500 0 7447-40-7

NA 2600mg/kg

Total – C 5100 12900 18000

(D) Pesticide formulation products for which environmental clearance is not applicable

4

Glyphosate 41% SL Formulation (existing and to be discontinued)

900 -900 0 -- -- --

5

Metribuzin 70% WDG Formulation (existing and proposed)

1800 1200 3000 -- -- --

6 Asulox Formulation (proposed)

0 12000 12000 -- -- --

Total – D 2700 12300 15000

Total– C+D 7800 25200 33000

Grand Total– A+B+C+D

11388 67632 79020


Shivalik Solid Waste Management Ltd. xviii

Details of By-product Quantity from Existing Manufacturing

Process and After Expansion

Sr No By Product Name

Existing

Quantity (TPA)

Additional

Quantity (TPA)

Total

Quantity (TPA)

Existing By-Products

1 30% HCl 1200 21312 22512

Proposed By- Products

2 30% NaSH 0 9360 9360

3 Methyl Chloride 0 274.2 274.2

4 Ammonium Acetate 0 9400.2 9400.2

5 Methanol 0 1180.8 1180.8

6 Phenol 0 155.4 155.4

7 Ammonium Sulphate 0 3966 3966

8 Ammonium Sulphate Solution (15%) 0 5683.2 5683.2

9 Acetic Acid (30%) 0 8496 8496

10 Acetic Acid (45%) 0 5664 5664

11 Acetic Acid (99%) 0 2574 2574

12 Sodium Acetate (27%) 0 12900 12900

13 Sodium Sulphate 0 998.4 998.4

14 NaBr 0 33000 33000

Total 1200 114964.2 116164.2


xix

TABLE OF CONTENTS

Sr. No Particulars Page No

Undertaking by UPL Ltd I

Declaration by Shivalik Wastes Management Pvt. Ltd. II

Declaration by Experts involved in EIA Studies III-VIII

Executive Summary IX-XVIII

Contents XIX-XXXIII

Abbreviation XXXIV-XXXIX

CHAPTER 1: INTRODUCTION

1.1 Background 1-1

1.2 Identification of Project & Project Proponent 1-2

1.3 Purpose of the EIA Report 1-4

1.4 Brief Description of the Project Nature, Size, Location of the Project

and Its Importance to the Country, Region 1-5

1.4.1 Location of the Project 1-5

1.4.2 Salient Features and Details of Proposed Project 1-5

1.4.3 Importance of the project to the Region & Country 1-12

1.5 Terms of Reference (ToR) for EIA Study 1-12

1.5.1 Compliance of Standard Terms of References (ToR) 1-12

1.5.2 Compliance of Specific TOR vide letter F.NO 11011/7/2017-IA-II (I)

dated 29 April 2017

1-29

1.5.3 Compliance of Amended Specific ToR vide letter F.NO

11011/7/2017-IA-II (I) dated 23rd October 2017

1-31

1.6 Regulatory Framework 1-32

1.6.1 Certified Copies of Previous Environmental Clearance 1-36

1.7 Structure of the EIA Report 1-36

CHAPTER 2: DESCRIPTION OF PROJECT

2.1 Introduction 2-1

2.2 Existing and Proposed Products and By-products Capacity 2-1

2.3 Manufacturing Process, Reaction and Mass Balance for Existing and

Proposed Products 2-6

2.3.1 Phosphorus Tri Chloride (PCl3) 2-6

2.3.2 Phosphorous Oxychloride (POCl3) 2-8

2.3.3 Phosphorus Acid (Crystal) 2-10

2.3.4 Phosphorus Acid (60% Solution) 2-12

2.3.5 Dipotassium Hydrogen Phosphate (DPMP) 2-14

2.3.6 Ammonium Sulphate 2-15

2.3.6.1 Ammonium Sulphate (Purification) 2-17

2.3.7 Ammonium Chloride 2-20

2.3.8 Metribuzin (Alternate Route) 2-22

2.3.8.1 Metribuzin (Existing Route) 2-24

2.3.9 Acephate 2-26


xx

2.3.10 Triazinone 2-30

2.3.11 Glyphosate Acid Technical 2-35

2.3.12 Di Chlorvos (DDVP) 2-40

2.3.13 Asulam (Methyl Sulfanilyl Carbamate) 2-41

2.3.14 Clomazone 2-43

2.3.15 Bensulfuron Methyl 2-45

2.3.16 Sulfosulfuron (SF-10) 2-48

2.3.17 Metasulfuron Methyl 2-51

2.3.18 Pyrazosulfuron Ethyl 2-53

2.3.19 Azoxystrobin 2-58

2.3.20 Asulox (Formulation) 2-63

2.3.21 Metribuzin Formulation 2-63

2.3.22 Devrinol 2-65

2.3.23 Triphenyl Phosphite (TPPI) 2-68

2.3.24 Triphenyl Phosphate (TPPA) 2-70

2.3.25 Potassium Chloride 2-71

2.4 By-Product List (Existing and After Expansion) 2-72

2.5 Raw Materials Requirements and Storage 2-72

2.6 Salt Generation from Evaporation (Before and After Expansion) 2-85

2.7 Solvent Recovery (Before and After Expansion) 2-85

2.8 Utilities Requirements 2-87

2.8.1 Water 2-87

2.8.2 Steam 2-88

2.8.3 Power 2-89

2.8.4 Cooling Tower 2-89

2.8.5 Chilled Water 2-89

2.8.6 Chilled Brine 2-89

2.9 Plant Plot Area and Layout Plan 2-89

2.10 Man-Power Requirement 2-90

2.11 Cost of Proposed Expansion 2-90

2.12 Sources of Pollution and Its Control Strategies 2-91

2.12.1 Effluents Generation, Treatment and Disposal 2-91

2.12.2 Gaseous and Particulate Emissions from Stacks 2-94

2.12.3 Hazardous and Solid Wastes Generations and Its Management 2-94

CHAPTER 3: DESCRIPTION OF THE ENVIRONMENT


3.2 Topography and Physiography 3-1

3.3 Geology 3-1

3.4 Seismology 3-2

3.5 Geohydrology 3-2

3.6 Drainage Pattern of the study area 3-4

3.7 Soil 3-4

3.7.1 Soil Characteristics 3-4


xxi

3.7.2 Soil Sampling 3-6

3.8 Water Resources 3-14

3.8.1 Surface Water Sources 3-14

3.8.2 Ground Water Resources 3-14

3.9 Water Quality 3-15

3.9.1 Ground Water Quality 3-15

3.9.2 Surface Water Quality 3-23

3.9.3 Treated Effluent Analysis 3-26

3.10 Climatology and Meteorology 3-27

3.10.1 Introduction 3-27

3.10.2 Climatology 3-27

3.10.3 Micro Meteorological Data for The Site 3-38

3.11 Ambient Air Quality 3-39

3.11.1 Ambient Air Quality Sampling Period 3-39

3.11.2 Selection of Ambient Air Sampling Locations 3-42

3.11.3 Parameters and Frequency of Ambient Air Quality Monitoring 3-43

3.11.4 Sampling and Analytical Techniques 3-43

3.11.5 Results of Ambient Air Quality Monitoring 3-45

3.12 Stack Emission and Stacks Monitoring 3-54

3.13 Noise Environment 3-54

3.13.1 Noise Monitoring Locations 3-54

3.13.2 Day and Night Time Leq Noise levels 3-57

3.14 Traffic Study in the Study Area 3-59

3.15 Landuse/Landcover 3-61

3.15.1 Methodology adopted for Satellite Imagery Interpretation 3-61

3.15.2 Land Use and Land Cover for the Study Area 3-62

3.16 Biological Environment 3-65

3.16.1 Vegetation Types in the Area 3-65

3.16.2 Floral Species in Buffer Zone 3-68

3.16.3 Faunal Species in the Study Area 3-70

3.16.4 Aquatic Ecology 3-75

3.17 Socio- Economic Environment 3-77

3.17.1 Introduction 3-77

3.17.2 Methodology of Socio-economic Studies 3-78

3.17.3 Demographic Details of Rural Settlements in the Study Area 3-78

3.17.4 Basic Amenities available in the Study area. 3-79

3.17.5 Place of Historical or Archaeological Interest 3-85

3.17.6 Prominent Industries in the Study Area 3-85

CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS


xxii

& MITIGATION MEASURES


4.2 Identification of Activities for Proposed Project 4-1

4.3 Identification of Environmental Components 4-2

4.4 Methodology for Qualitatively Assessment of Environmental

Impacts 4-4

4.5 Anticipated Environmental Impacts Due to the Proposed Expansion 4-10

4.5.1 Topography and Physiographic 4-11

4.5.2 Impact on Soil 4-11

4.5.3 Water Quality 4-15

4.5.4 Meteorology 4-21

4.5.5 Air Environment 4-21

4.5.5.1 Air pollutants dispersion modeling for prediction of impacts on

ambient air quality 4-26

4.5.6 Impact on Noise Levels 4-51

4.5.7 Impact on Land Use& Aesthetics 4-58

4.5.8 Impacts due to Waste Generation 4-59

4.5.9 Impact on Flora and Fauna 4-61

4.5.10 Occupational Health & Safety 4-63

4.5.11 Socio Economic Impacts 4-65

4.5.12 Impacts of the Transport of the Raw Materials and End-Products 4-67

4.6 Impact Evaluation 4-68

CHAPTER 5: ANALYSIS OF ALTERNATIVES


5.2 Project Alternatives 5-1

5.2.1 Without Project Alternative 5-1

5.2.2 With Project Alternative 5-1

5.3 Alternatives for Site 5-2

5.4 Alternatives for Resource Optimization/ Recycling and Reuse 5-2

CHAPTER 6: ENVIRONMENTAL MONITORING PLAN


6.2 Environmental Monitoring Parameters 6-2

6.3 Environmental Monitoring Plan with Cost Estimates 6-4

6.4 Budget for Implementation of Environmental Monitoring Plan 6-4

CHAPTER 7: ADDITIONAL STUDY - RISK ASSESSMENT


7.2 Storage of Hazardous Chemicals at the Plant 7-1

7.3 Hazard Identification 7-6

7.3.1 Hazardous Materials Stored at the Plant 7-6

7.3.2 Bulk Storage of Hazardous Materials 7-6

7.3.3 Hazardous Conditions 7-7


xxiii

7.4 Accidental Release Scenarios for Consequence Analysis 7-7

7.4.1 Methodology for Selection of Accident Scenarios 7-21

7.4.2 Maximum Credible Scenarios for Consequence Analysis 7-21

7.5 Consequence Analysis 7-23

7.5.1 Model Used for Consequence Analysis 7-24

7.5.2 Summary of Consequence Analysis 7-24

7.6 Frequency Analysis 7-32

7.6.1 Equipment Failure Frequency 7-33

7.6.2 Frequency Analysis for the Plant 7-34

7.7 Risk Analysis and Summation 7-34

7.7.1 Qualitative Risk Matrix 7-34

7.7.2 Quantitative Risk Analysis & Summation 7-36

7.7.3 Risk Summation 7-37

7.8 Risk Mitigation Measures 7-42

7.8.1 Safety at the Existing Plant 7-42

7.8.2 System Specific Measures 7-42

7.8.3 Safety Measures at the Plant 7-44

7.8.4 Overall Risk Reduction Measures 7-47

7.9 Disaster Management Plan (DMP) 7-54

7.9.1 Objective of DMP 7-54

7.9.2 On-Site Emergency Plan 7-55

7.9.3 Off-Site Emergency Plan 7-61

CHAPTER 8: PROJECT BENEFITS

8.1 General 8-1

8.2 Employment Opportunities 8-1

8.3 Other Tangible Benefits 8-2

CHAPTER 9: ENVIRONMENTAL COST BENEFIT ANALYSIS

9.1 General 9-1

CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN


10.2 Purpose of Environmental Management Plan (EMP) 10-1

10.3 Health, Safety and Environmental (HSE) Policy 10-2

10.4 Environmental Management Cell 10-3

10.5 Environmental Management Plan for Construction Phase 10-4

10.5.1 EMP for Soil 10-4

10.5.2 EMP for Water Quality 10-6

10.5.3 EMP for Ambient Air Quality 10-6

10.5.4 EMP for Noise Levels 10-7

10.5.5 EMP for Wastes Management 10-7

10.5.6 EMP for Ecological Environment 10-7

10.5.7 Occupational Health & Safety 10-8


xxiv

10.5.8 EMP for Socio-Economic Environment 10-8

10.6 Environmental Management Plan for Operation Phase 10-8

10.6.1 EMP for Water Environment 10-9

10.6.2 EMP for Air Environment 10-9

10.6.3 EMP for Noise Environment 10-10

10.6.4 EMP for Hazardous Wastes (Landfillable & Incinerable Waste) and

Non-Hazardous Wastes

10-10

10.6.5 EMP for Occupational Health & Safety 10-11

10.6.6 EMP for Socio-Economic Environment 10-12

10.6.7 Health, Safety & Environment Management 10-12

10.6.8 Energy Conservation Measures 10-13

10.6.9 Natural Resource Conservation 10-18

10.6.10 “Best Manufacturing practice” and “Safe Practice” for Handling

Storage, Transportation and Unloading of Hazardous Chemicals

10-18

10.6.10.1 Best Manufacturing Practices 10-18

10.6.10.2 Safe Practices 10-19

10.7 Green Belt Development 10-21

10.7.1 Design and Development of Green Belt 10-22

10.7.2 Guidelines & Technique for Green Belt Development 10-22

10.7.3 Species for Plantation of Green Belt Development 10-23

10.8 Occupational Health & Safety after Expansion 10-24

10.8.1 Details of Occupational Health Program 10-24

10.8.2 Occupational Health Surveillance Programme 10-27

10.8.2.1 Liver Function Tests (LFT) during Pre-placement and Periodical

Examination

10-28

10.8.2.2 Pre-employment Medical Examination 10-29

10.9 Rain Water Harvesting 10-30

10.10 Odor Control Action Plan 10-31

10.11 Enterprise Social Commitment (ESC) Programme 10-35

10.12 Compliance to Corporate Responsibility for Environmental

Protection (CREP) Guidelines

10-43

10.12.1 Segregation of Waste Streams and Treatment 10-43

10.12.2 Treatment of High COD Waste Streams 10-43

10.12.3 Improvement in Solvent Recovery 10-43

10.12.4 Air Emission Pollutant Control 10-44

10.12.5 Control of Fugitive Emissions / VOCs 10-44

10.12.6 Bio Assay Test and Toxicity Factor 10-45

10.12.7 Incineration of Hazardous Wastes 10-45

10.12.8 Long Term Strategies for Reduction in Wastes 10-45

10.13 Budgetary Provisions for EMP Implementation 10-46

CHAPTER 11 SUMMARY AND CONCLUSIONS


11.1.1 Terms of Reference for EIA Study 11-2


xxv

11.2 Project Description 11-2

11.2.1 Existing and Proposed Production Capacity 11-2

11.2.2 By Product List (Existing and After Expansion) 11-6

11.2.3 Utilities and Water Requirements 11-6

11.3 Description of the Environment 11-7

11.3.1 Ambient Air Quality 11-7

11.3.2 Stack Emission Monitoring 11-8

11.3.3 Waste Water Generation 11-8

11.3.4 Hazardous Waste Generation and Disposal 11-9

11.3.5 Soil Quality 11-9

11.3.6 Noise Monitoring Details 11-10

11.3.7 Details of Flue Gas and Process Stacks 11-10

11.3.8 Surface Water Monitoring Details 11-10

11.3.9 Ground Water Quality 11-10

11.3.10 Socio Economic Aspects 11-10

11.4 Anticipated Environmental Impacts and Mitigation Measures 11-11

11.4.1 Air quality Modeling and Impact 11-11

11.4.2 Mitigation Measures during Construction Phase 11-11

11.4.3 Mitigation Measuring during Operation Phase 11-11

11.5 Analysis of alternatives (technology and site) 11-12

11.6 Environmental Monitoring Plan 11-12

11.7 Additional Study – Risk Assessment 11-13

11.8 Project Benefits 11-13

11.8.1 ESC Activities 11-14

11.9 Environmental Cost Benefit Analysis 11-14

11.10 Environmental Management Plan 11-14

11.10.1 Green Belt Development 11-15

11.11 Conclusion 11-15

CHAPTER 12: DISCLOSURE OF CONSULTANTS ENGAGED

12.1 The Consultant 12-1

12.2 Profile of Shivalik Solid Waste Management Ltd. 12-1

12.3 EIA Coordinator and Functional Area Experts 12-2

Appendix- Questionnaire

List of Annexure:

Annexure I ToR Approved and Amended by MoEF & CC

Annexure II CC&A (Consent to Operate) by MPCB

Annexure III Certified Copy of Compliance Report of Conditions of Environmental

Clearance from MoEF & CC

Annexure IV Membership of CETP

Annexure V Membership of TSDF

Annexure VI HSE Policy of UPL


xxvi

Annexure VII Photographs of the green belt at the plant

Annexure VIII Annual Health Report

Annexure IX MSDS

Annexure X Acceptance letter for Fly Ash utilization

Annexure XI Baseline data

Annexure XII Undertaking of Not manufacturing of Banned Pesticide


xxvii

LIST OF TABLES

CHAPTER 1: INTRODUCTION

Table 1.1 Salient Features and Details of the Project 1-5

Table 1.2 Regulatory Framework 1-32

CHAPTER 2: PROJECT DESCRIPTION

Table 2.1 Existing and Proposed Products and By-products capacity after

Expansion

2-1

Table 2.2 Details of By-product Generated from Existing Manufacturing

Process and After Expansion

2-5

Table 2.3 Raw Materials Requirements for Existing and after Expansion 2-73

Table 2.4 Monthly Requirement and Maximum Storage of Raw Materials 2-80

Table 2.5 Salt Generation from Evaporation (After Expansion) 2-85

Table 2.6 Solvent Recovery (Before and After Expansion) 2-86

Table 2.7 Water Requirement Details (Existing and after Proposed

Expansion)

2-87

Table 2.8 Break-up of Plant Area 2-90

Table 2.9 Manpower Details for Existing Plant and after expansion 2-90

Table 2.10 Waste Water Generation Details (Existing and after Proposed

Expansion)

2-91

Table 2.11 Discharge Standards for Treated Effluents Prescribed by MPCB 2-92

Table 2.12 Details of Flue Gas Stacks at Existing Plant and after Expansion 2-96

Table 2.13 List of Process Stacks at Existing Plant and after Expansion 2-97

Table 2.14 Hazardous Waste Details (Existing and After Proposed

Expansion)

2-99


Table 3.1 Stratigraphic Sequences of Geological Formation in the Area 2-3

Table 3.2 Soil Sampling Locations 3-6

Table 3.3 Analysis Results of Soil Samples Collected from The Study Area 3-8

Table 3.4 Chemical Classification of Soil Quality 3-10

Table 3.5 Ground Water Sampling Locations 3-15

Table 3.6 Ground Water Analysis Results for Study Area 3-20

Table 3.7 Surface Water Sampling Locations 3-23

Table 3.8 Surface Water Analysis Results for Study Area 3-23

Table 3.9 Designated Best Uses of Water as per CPCB 3-25

Table 3.10 Analysis Results for Treated Effluents from Existing ETP 3-26

Table 3.11 Temperatures and Humidity in the Area 3-28

Table 3.12 Monthly Average Meteorological Data for Past 10 Years (2005-

2015)

3-29

Table 3.13 Rainfall (in mm) 3-30

Table 3.14 Wind Speed (kmph) in the Area 3-31

Table 3.15 Wind Direction & Frequency (From) in the Area 3-32


xxviii

Table 3.16 Special Weather Phenomena in the Area 3-33

Table 3.17 Summary of Micro Meteorological Conditions at the Site 3-38

Table 3.18 Details of Ambient Air Quality Monitoring Locations 3-42

Table 3.19 Techniques Used for Ambient Air Quality Monitoring 3-44

Table 3.20 Ambient Air Quality Results 3-48

Table 3.21 Ambient Air Quality Results for Project-Specific Parameters 3-51

Table 3.22 Existing Stack Emissions Monitoring for Flue Gas and Process

Stacks

3-55

Table 3.23 Noise Monitoring Locations 3-57

Table 3.24 Day and Night Time Leq at Noise Monitoring Locations 3-58

Table 3.25 Traffic Study in the Area on MIDC Road To UPL Plant 3-59

Table 3.26 Traffic Study in the Area on Boisar -Tarapur Road 3-60

Table 3.27 Land Use and Land Cover for the Study Area 3-62

Table 3.28 Floral Species in Core Zone 3-67

Table 3.29 Flora Species within Buffer Zone 3-68

Table 3.30 Avian Fauna within 10 km Radius from Project Site 3-71

Table 3.31 Mammals Species Reported In the Study Area 3-73

Table 3.32 Amphibians Within 10 km Radius from Project Site 3-74

Table 3.33 Fishes, Crustaceans & Molluscs within 10 km radius from Project

Site

3-75

Table 3.34 List of Macro-Benthic Invertebrate Fauna 3-76

Table 3.35 Phytoplankton and Zooplankton found in the Study Area 3-77

Table 3.36 Demographic Details of the Villages of The Study area 3-81

Table 3.37 Demographic Details of the Towns of The Study area 3-82

Table 3.38 Occupational Pattern Details of the Villages of The Study area 3-82

Table 3.39 Occupational Pattern Details of the Towns of The Study area 3-84

CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS

& MITIGATION MEASURES

Table 4.1 Identification of Environmental Components 4-3

Table 4.2 Impact Rating Assessment Matrix 4-5

Table 4.3 Impact Prediction Matrix during Construction Phase 4-8

Table 4.4 Impact prediction Matrix during Operation Phase 4-9

Table 4.5 Impact Assessment Rating Matrix 4-10

Table 4.6 Hazardous Wastes (Landfillable Waste and Incinerable Waste)

Quantity and Category – After Proposed Expansion

4-13

Table 4.7 Total Water Consumption after Expansion after Expansion 4-16

Table 4.8 Total Effluent Generation After Expansion 4-17

Table 4.9 Key Pollutants and Air Pollution Control System 4-24

Table 4.10 Process Stacks, Key Pollutants and Air Pollution Control

System

4-25

Table 4.11 Existing Stack Emissions Characteristics for Flue Gas and Process

Stacks

4-29

Table 4.12 Proposed Stack Emission Characteristics for Flue Gas and Process 4-30


xxix

Stacks After Expansion

Table 4.13 Emission Loads for Flue Gas Stacks After Expansion 4-31

Table 4.14 Emission Loads for Process Stacks After Expansion 4-32

Table 4.15 Highest 24- Hourly and Seasonal Incremental GLC Values for

Particulate Matter and Grid Point Locations

4-34

Table 4.16 24 Hourly GLCs Values for Particulate Matter at Discrete

Locations

4-34

Table 4.17 Highest 24- Hourly and Seasonal Incremental GLC Values for

Sulphur Dioxide and Grid Point Locations

4-36

Table 4.18 24 Hourly GLCs Values for SO2 at Discrete Locations 4-37

Table 4.19 Highest 24- Hourly and Seasonal Incremental GLC values for

Nitrogen Dioxide and Grid Point Locations

4-38

Table 4.20 24 Hourly GLCs Values for Nitrogen Dioxide at Discrete Locations 4-39

Table 4.21 Highest 24- Hourly and Seasonal Incremental GLC Values for HCl

and Grid Point Locations

4-40

Table 4.22 24 Hourly GLCs Values for HCl at Discrete Locations 4-40

Table 4.23 Highest 24- Hourly and Seasonal Incremental GLC values for Cl2


4-41

Table 4.24 24 Hourly GLCs Values for Cl2 at Discrete Locations 4-42

Table 4.25 Highest 24- Hourly and Seasonal Incremental GLC values for NH3


4-42

Table 4.26 24 Hourly GLCs Values for NH3 at Discrete Locations 4-43

Table 4.27 Highest 24- Hourly and Seasonal Incremental GLC Values for H2S


4-44

Table 4.28 24 Hourly GLCs Values for H2S at Discrete Locations 4-44


MeCl and Grid Point Locations

4-45

Table 4.30 24 Hourly GLCs Values for MeCl at Discrete Locations 4-45

Table 4.31 Highest 24- Hourly and Seasonal Incremental GLC values for HBr


4-46

Table 4.32 24 Hourly GLCs Values for HBr at Discrete Locations 4-46


PCl3and Grid Point Locations

4-47

Table 4.34 24 Hourly GLCs Values for PCl3 at Discrete Locations 4-48

Table 4.35 Highest 24- Hourly and Seasonal Incremental GLC

Values for HC and Grid Point Locations

4-48

Table 4.36 24 Hourly GLCs Values for HC at Discrete Locations 4-49

Table 4.37 Typical Noise Levels of Construction Equipment& Works 4-51

Table 4.38 Noise Modelling Results for Construction Phase 4-53

Table 4.39 Impact Prediction of Noise Levels During Construction Phase at

Nearby Settlements

4-54

Table 4.40 Noise Measurements within the Plant Premises 4-55

Table 4.41 Permissible Noise Exposures for Industrial Workers 4-56

Table 4.42 Impact Prediction of Noise Levels During Operation Phase 4-57

Table 4.43 Types of Hazardous Wastes and Mode of Disposal 4-60


xxx

Table 4.44 Mitigation Measures without Weighted Impacts (Matrix Method) 4-70

Table 4.45 Mitigation Measures with Weighted Impacts (Matrix method) 4-71

CHAPTER 6: ENVIRONMENTAL MONITORING PLAN

Table 6.1 Environmental Monitoring Plan during Construction Phase 6-5

Table 6.2 Environmental Monitoring Plan during Operation Phase 6-5


Table 7.1 Details of Storage of Hazardous Chemicals 7-1

Table 7.2 Physical State, Physical and Fire and Toxicity Properties of

Hazardous Materials

7-8

Table 7.3 Hazardous Characteristic, Storage Mode and Type of Hazards (as

per NFPA)

7-13

Table 7.4 Details of Bulk Storage of Hazardous Materials 7-17

Table 7.5 List of Selected Scenarios for Consequence Analysis 7-22

Table 7.6 Summary of Consequence Analysis for Flammable Hazardous

Materials

7-24

Table 7.7 Summary of Consequence Analysis for Toxic Hazardous Materials 7-26

Table 7.8 Qualitative Risk Matrix for the project site 7-36

CHAPTER 10: ENVIRONMENTAL MANAGEMENT PLAN

Table 10.1 Suggested Species for Plantation within Plant Premises 10-24

Table 10.2 Rain Water Harvesting Details 10-30

Table 10.3 Main Odorous compounds, Properties, Exposure, Type of Odour

and Its Health Impact

10-32

Table 10.4 Odor Control Action Plan Implemented at Existing Plant 10-33

Table 10.5 Odour Generating Operations and Activities after Proposed

Expansion of Existing Plant

10-34

Table 10.6 Summary Five-Year Annual Budget 10-36

Table 10.7 Five Year Budget for Enterprise Social Commitment (ESC) 10-41

Table 10.8 Budget for EMP Implementation 10-46

CHAPTER 12: DISCLOSURE OF CONSULTANT ENGAGED

Table 12.1 EIA Coordinator and Functional Area Experts

(FAEs) for the Project

12-2

Table 12.2 Team Members (TM) and FAA (Functional Area Associate)

Associated with the Study

12-4


xxxi

LIST OF FIGURES

CHAPTER 1: INTRUDUCTION

Figure 1.1 Location Index Map of Project site 1-10

Figure 1.2 10 Km Area Around the project site Plan in MIDC 1-11

CHAPTER 2: PROJECT DESCRIPTION

Figure 2.1 Process Flow Diagram for Phosphorus Tri Chloride 2-7

Figure 2.2 Process Flow Diagram for Phosphorous Oxychloride 2-9

Figure 2.3 Process Flow Diagram for Phosphorus Acid (Crystal) 2-11

Figure 2.4 Process Flow Diagram for Phosphorus Acid (60% Solution) 2-13

Figure 2.5 Process Flow Diagram for Di potassium Hydrogen Phosphate 2-15

Figure 2.6 Process Flow Diagram for Ammonium Sulphate 2-17

Figure 2.7 Process Flow Diagram for Ammonium Sulphate (Purification) 2-19

Figure 2.8 Process Flow Diagram for Ammonium Chloride 2-21

Figure 2.9 Process Flow Diagram for Metribuzin (Alternate Route) 2-23

Figure 2.10 Process Flow Diagram for Metribuzin (Existing Route) 2-25

Figure 2.11 Process Flow Diagram for Acephate 2-28

Figure 2.12 Process Flow Diagram for Triazinone (Stage I) 2-32

Figure 2.13 Process Flow Diagram for Triazinone (Stage II) 2-33

Figure 2.14 Process Flow Diagram for Triazinone (Stage III) 2-34

Figure 2.15 Process Flow Diagram for Glyphosate Acid Technical (Stage I)

2-37

Figure 2.16 Process Flow Diagram for Glyphosate Acid Technical Stage II 2-37

Figure 2.17 Process Flow Diagram for Glyphosate Acid Technical Stage III

2-38

Figure 2.18 Process Flow Diagram for Di Chlorvos 2-40

Figure 2.19 Process Flow Diagram for Asulam 2-42

Figure 2.20 Process Flow Diagram for Clomazone 2-44

Figure 2.21 Process Flow Diagram for Bensulfuron Methyl 2-47

Figure 2.22 Process Flow Diagram for Sulfosulfuron (SF-10) 2-50

Figure 2.23 Process Flow Diagram for Metasulfuron Methyl 2-52

Figure 2.24 Process Flow Diagram for Pyrazosulfuron Ethyl 2-56

Figure 2.25 Process Flow Diagram for Pyrazosulfuron Ethyl 2-57

Figure 2.26 Process Flow Diagram for Azoxystrobin Step I 2-60

Figure 2.27 Process Flow Diagram for Azoxystrobin Step II 2-61

Figure 2.28 Process Flow Diagram for Azoxystrobin Step III 2-62

Figure 2.29 Process Flow Diagram for Metribuzin Formulation 2-64

Figure 2.30 Process Flow Diagram for Devrinol 2-67

Figure 2.31 Process Flow Diagram for Triphenyl Phosphite (TPPI) 2-69

Figure 2.32 Process Flow Diagram for Triphenyl Phosphate 2-70

Figure 2.33 Water Balance Diagram for the Plant After Expansion 2-88

Figure 2.34 Site Layout Plan for project site 2-93


Figure 3.1 Seismic Zones for the Region 3-3


xxxii

Figure 3.2 Drainage Map of 5 km Radius Area Around the Plan 3-5

Figure 3.3 Soil Sampling Locations 3-7

Figure 3.4 Ground & Surface Sampling Locations 3-16

Figure 3.5 Maximum & Minimum Temperatures in the Area 3-28

Figure 3.6 Relative Humidity in the Area 3-30

Figure 3.7 Rainfall in the Area 3-30

Figure 3.8 Monthly Wind Speed in the Area 3-31

Figure 3.9 Monthly Wind Rose Diagram for Morning (Jan to June) 3-34

Figure 3.10 Monthly Wind Rose Diagram for Morning (Jul to Dec) 3-35

Figure 3.11 Monthly Wind Rose Diagram for Evening (Jan to June) 3-36

Figure 3.12 Monthly Wind Rose Diagram for Evening (Jul to Dec) 3-37

Figure 3.13 Wind Rose Diagram for Day Time for the Study Period 3-40

Figure 3.14 Wind Rose Diagram for Night Time for the Study Period 3-41

Figure 3.15 Ambient Air Monitoring Locations 3-44

Figure 3.16 PM10 Values During the Study Area 3-51

Figure 3.17 PM2.5 Values During the Study Area 3-52

Figure 3.18 SO2 Values During the Study Area 3-52

Figure 3.19 NO2 Values During the Study Area 3-53

Figure 3.20 CO Values During the Study Area 3-53

Figure 3.21 Noise Monitoring Locations 3-56

Figure 3.22 Graphical Presentation of Day & Night Time Noise Leq 3-59

Figure 3.23 Process Flow Diagram for Satellite Imagery Interpretation 3-63

Figure 3.24 False Colour Composite (FCC) of Satellite 3-64

Figure 3.25 Graphical Presentation of Landuse Classification 3-64

Figure 3.26 Landuse & Land Cover Map of 10 km Radius Study Area 3-65

CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS& MITIGATION MEASURES

Figure 4.1 Hydraulic Flow Diagram for Existing ETP 4-19

Figure 4.2 Schematic Diagram for Proposed ETP 4-20

Figure 4.3 Isopleths for Particulate Matter for 24 Hours GLCs 4-35

Figure 4.4 Isopleths for Sulphur Dioxide for 24 Hours GLCs 4-37

Figure 4.5 Isopleths for Nitrogen Dioxide for 24 Hours GLCs 4-39

Figure 4.6 Attenuation of Noise from Source during Construction 4-53


Figure 7.1 Thermal Radiation Distance for Methanol 5 kl AG Tank 7-27

Figure 7.2 Thermal Radiation Distance for Toluene 140 kl Tank 7-27

Figure 7.3 Overpressure Distance for Toluene 140 kl Tank 7-28

Figure 7.4 Thermal Radiation Distance for Xylene Tank 7-28

Figure 7.5 Thermal Radiation Distance for Hexane Tank 7- 29

Figure 7.6 Thermal Radiation Distance for Carbon Di Sulfide Tank 7- 29

Figure 7.7 Overpressure Distance for Carbon Di Sulfide Tank 7- 30

Figure 7.8 Thermal Radiation Distance for Phenol Tank 7- 30

Figure 7.9 IDLH Concentration for Release from Ammonia Cylinder 7- 31


xxxiii

Figure 7.10 IDLH Concentration for Release from Chlorine Tonner 7- 31

Figure 7.11 IDLH Concentration for Release from Bromine Tank 7- 32

Figure 7.12 IDLH Concentration for Release from Sulphuric Acid Tank 7- 32

Figure 7.13 ALARP Principle 7- 38

Figure 7.14 Iso Risk Contours for UPL 7- 40

Figure 7.15 FN Curve for UPL 7- 41

Figure 7.16 F-N Curve Combined for Day and Night 7- 42

Figure 7.17 Off-Site Emergency Plan 7- 62

CHAPTER 10 ENVIRONMENTAL MANAGEMENT PLAN

Figure 10.1 Organizational Structure of Environmental Management Cell of project site

10-5

Figure 10.2 Green Belt Development Plan 10-26


Shivalik Solid Waste Management Ltd. xxxiv

List of Abbreviations.

AAQM : Ambient Air Quality Monitoring

AAS : Atomic Absorption Spectroscopy

ACGIH : American Conference of Governmental Industrial Hygienists

AERMIC : American Meteorological Society/Environmental Protection Agency

Regulatory Model Improvement Committee

AERMOD : AMS/EPA Regulatory Model

AG : Above ground

ALARP : As Low As Reasonably Practicable

ALOHA : Areal Locations of Hazardous Atmospheres

ANP : Ammonium Nitro Phosphate

APCM : Air Pollution Control Measures

APCD : Air Pollution Control Devices

APHA : American Public Health Association

BARC : Bhabha Atomic Research Centre

BIS : Bureau of Indian Standards

BDL : Below detection level

BLEVE : Boiling Liquid Expanding Vapor Explosion

BOD : Biological Oxygen Demand

BSI : British Standards Institution

CAMEO : Computer-Aided Management of Emergency Operations

CAS : Chemical Abstracts Service

CC&A : Consolidated Consent and Authorization

CCTV : Closed Circuit Television

CEC : Cation exchange capacity

CETP : Common Effluent Treatment Plant

CHWTSDF : Common Hazardous Waste Treatment, Storage & Disposal Facility

CIB : Central Insecticides Board

CO : Carbon Monoxide

COD : Chemical Oxygen Demand


Shivalik Solid Waste Management Ltd. xxxv

CLSL : Crop Life Science Limited

CPCB : Central Pollution Control Board

CRO : Control Room Officer

CSR : Corporate Social Responsibility

CT : Census Town

CTO : Consent to Operate

dB : Decibels

DAF : Dissolve air Flotation

DCP : Dry Chemical Powder

DG : Diesel Generator

DM : De-mineralization

DMC : Di Methyl Carbonate

DMP : Disaster Management Plan

EAC : Expert Appraisal Committee

EC : Environmental Clearance

EC : EIA Coordinator

EHS : Environment, Health & Safety

EIA : Environmental Impact Assessment

EMC : Environmental Management Cell

EMP : Environmental Management Plan

EMS : Environmental Management Systems

ENVIS : Environmental Information System

ERPG : Emergency Response Planning Guideline

ESC : Enterprise Social Commitment

ETP : Effluent Treatment Plant

FAA : Functional Area Associate

FAE : Functional Area Expert

FCC : False Colour Composite

FO : Furnace oil

GC : Gas Chromatography


Shivalik Solid Waste Management Ltd. xxxvi

GHGs : Green House Gases

GoI : Government of India

GPS : Global Positioning System

GSI : Geological Survey of India

HAZOP : Hazard and operability study

HBr : Hydrogen Bromide

HCs : Hydro-Carbons

HCl : Hydrochloric Acid

HDPE : High-Density Poly Ethylene

HRT : Hydraulic Retention Time

HSD : High Speed Diesel

HSE : Health and Safety Executive

Hz : Hertz

IC : Incident Controller

ICAR : Indian Council Agriculture Research

IDLH : Immediately Dangerous to Life & Health

IMD : India Meteorological Department

IPP : Import Party Prices

IRC : Indian Roads Congress

IS : Indian Standards

ISO : International Organization for Standardization

IUCN : International Union for Conservation of Nature

JCB : Joseph Cyril Bamford

kPa : Kilo Pascal

kVA : Kilo Volt Amperes

LSIR : Location Specific Individual Risk

LDO : Light diesel oil

LEF : Liver Function Tests

LPH : Litre per hour

MCAS : Maximum Credible Accident Scenario


Shivalik Solid Waste Management Ltd. xxxvii

MCPA : 2-methyl-4-chlorophenoxyacetic acid

MCC : Motor Control Center

MEE : Multiple Effect Evaporator

MPCB : Maharashtra Pollution Control Board

MIDC : Maharashtra Industrial Development Corporation

MLSS : Mixed Liquor Suspended Solids

MTM : Metric Tons Per Month

MTPD : Metric Tons Per Day

MoEF&CC : Ministry of Environment, Forest & Climate Change

MoU : Memorandum of Undertaking

MS : Mild steel

MSDS : Material Safety Data Sheet

MSEB : Maharashtra State Electricity Board

MSTC : Maharashtra State Transport Corporation

MW : Mega Watt

MWC : Main Works Controller

MWML : Mumbai Waste Management Ltd.

NAAQS : National Ambient Air Quality Monitoring Standards

NABET : National Accreditation Board for Education & Training

NABL : National Accreditation Board for Testing and Calibration Laboratories

NFPA : National Fire Protection Association

NH : National Highway

NH3 : Ammonia

NIHL : Noise Induced Hearing Loss

NIOSH : National Institute for Occupational Safety and Health

NOAA : National Oceanic and Atmospheric Administration

NOC : No Objection Certificate

NO2 : Nitrogen Dioxide

NRSA : National Remote Sensing Agency

NTU : Nephelometric Turbidity Unit

https://en.wikipedia.org/wiki/Maharashtra_State_Transport_Corporation


Shivalik Solid Waste Management Ltd. xxxviii

OCP : Operational Control Procedures

OHS : Occupational Health & Safety

OM : Office Memorandum

OSHA : Occupational Safety and Health Administration

OSHAS : Occupation Health and Safety Assessment Series

P&ID : Piping and Instrumentation Diagram

PCM : Pollution Control Measures

PCU : Passenger Car Unit

PEL : Permissible Exposure Level

PFD : Process Flow Diagram

PFT : Pulmonary Function Test

pH : Power of Hydrogen

PHAST : Process Hazard Analysis Software Tool

PM : Particulate Matter

PP : Polypropylene

PPE : Personal Protective Equipment

ppm : Parts per Million

PUCC : Pollution Under Control Certificates

QC : Quality Council

QCI : Quality Council of India

QRA : Quantitative Risk Assessment

GLC : Ground Level Concentration

R & D : Research & Development

RA : Risk Assessment

RDS : Respirable Dust Sampler

RET : Rare, Endangered and Threatened

RO : Reverse Osmosis

SAFETI : Software for the Assessment of Fire, Explosion and Toxic Impacts

SAR : Sodium Absorption Ratio

SCBA : Self-contained breathing apparatus


Shivalik Solid Waste Management Ltd. xxxix

SH : State Highway

SMC : Site Main Controller

SPCB : State Pollution Control Board

SPL : Sound Pressure Level

SO2 : Sulphur Dioxide

SOI : Survey of India

SOP : Standard Operating Procedure

SPM : Suspended Particulate Matter

SS : Suspended Solids

SSWML : Shivalik Solid Waste Management Limited

STEL : Short Time Exposure Limit

TCL : Toxic Concentration Low

TCM : Tri-Chloro Melamine

TDS : Total Dissolved Solids

Tf : Toxicity Factor

TWA : Time-weighted average

TLV : Threshold Limit Value

TOC : Total Organic Carbon

ToR : Terms of Reference

TPH : Ton per hour

TM : Team Members

TREM : Transport Emergency Card

TSDF : Treatment, Storage and Disposal Facility

UG : Under ground

UOM : Unit of Measurement

USEPA : United States Environmental Protection Agency

VOCs : Volatile Organic Compounds

ZLD : Zero Liquid Discharge


Shivalik Solid Waste Management Ltd. 1- 1

Chapter 1

INTRODUCTION

1.1 Background

UPL Limited, Unit#10 is engaged in manufacturing of various technical grade

Pesticides, intermediates chemicals and pesticide formulation products. The

existing unit was established and operated by M/s Punjab Chemicals & Crop

Protection Limited and obtained environmental clearance for expansion from

Ministry of Environment, Forest and Climate Change vide letter no F. No. J-

11011/712/2007-IA II (I) dated 15 April 2008. The existing unit was taken over

by UPL Limited on 14 March 2014.

UPL has planned to expand manufacturing capacities of existing Pesticides

Technical, intermediates, pesticide formulation products and manufacturing of

additional technical and formulation products namely, Acephate (Technical), Di

Chlorvos (DDVP) (Technical), Glyphosate (Technical), Clomazone (Technical),

Sulfosulfuron (SF-10) (Technical), Pyrazosulfuron Ethyl (Technical), Bensulfuron

Ethyl (Technical), Metsulfuron Methyl (Technical), Asulam (Technical),

Azoxystrobin (Technical), Devrinol (Technical) and Asulox (formulation). The Unit

is presently manufacturing one Pesticide Technical @ 1620 TPA, 06 (six) Pesticide

Intermediate @1968 TPA, 02 (Two) inorganic chemicals @ 5100 TPA and 02 (two)

Pesticide Formulation products @2700 TPA. It is proposed to expand Pesticide

Technical capacity from 1620 TPA to 27120 TPA (11 new products and expansion

of existing 1 product, total expansion @ 25500 TPA); Pesticide Specific

Intermediate capacity from 1968 TPA to 18900 TPA ( 2 new products and

expansion of existing 6 product, total expansion @ 16932 TPA); Inorganic chemical

capacity from 5100 TPA to 18000 TPA (1 new product and expansion of existing 1

product, total expansion @ 12900 TPA inclusive of 1 discontinued product i.e.

Potassium Chloride. EC is not applicable for inorganic chemicals), Pesticide

Formulation capacity from 2700 TPA to 15000 TPA (1 new product and expansion

of existing 1 product, total expansion @ 12300 TPA inclusive of 1 discontinued



product i.e. Glyphosate 41 % SL Formulation. EC is not applicable for Formulation

products).

1.2 Identification of Project & Project Proponent

Shri Rajjubhai D. Shroff, an eminent industrialist, is the Chairman of the UPL. It’s

almost 48 years ago, when UPL Ltd (formerly known as United Phosphorus

Ltd.), was started as a small-scale unit to manufacture Red Phosphorus in 1969.

Through backward and forward integrations respectively, today UPL is a leading

global producer of crop protection products, intermediates, specialty chemicals and

other industrial chemicals. Being the largest manufacturer of agrochemicals in

India, the company offers a wide range of products that includes Insecticides,

Fungicides, Herbicides, Fumigants, Plant Grade Regulators (PGR) and

Rodenticides.

UPL Limited is presently an International Company having 25 manufacturing sites

all over the world (11 units in India, 4 units in France, 2 units in Spain, 3 units in

Argentina, 1 unit each in UK, Vietnam, Netherlands, Italy, China) for the

manufacturing of Agrochemical and intermediates chemicals. In India, UPL has

well equipped 11 manufacturing units located at Vapi, Ankleshwar, Jhagadia, Halol,

Tarapur (Maharashtra), Jammu and Haldia (West Bengal) with head office at

Mumbai. UPL ranks amongst the top 3 agrochemical industries in the world. Thus,

UPL has grown rapidly over the years and is a leading Agrochemical manufacturing

company. UPL has marketing network in 25 countries including America, Europe,

Africa, besides in all states of India. The products range of the UPL includes

agrochemicals, industrial chemicals & specialty chemicals. UPL has made a

significant entry in seed business as well.

UPL Ltd is signatory to Responsible Care (RC) initiative of Indian Chemical Council

and ICC has allowed to use RC logo.

UPL Management has taken up various Enterprise Social Commitment (ESC)

activities/programmes and major activities are in the field of education, health

protection and improvement of infrastructure facilities. The important

organizations Sanskardeep Vidyalaya (Ankleshwar), Gyandham School (Vapi),



Nursing College (Vapi) and Shroff S R Rotary Institute of Chemical Technology

(Ankleshwar) are promoted by UPL Limited.

Working in synergy with customers in the marketplace, UPL recognize the

requirement for the highest level of support in product research, development and

registration. Capability in applied R & D is one of major core competences of UPL.

UPL Achievements (AWARDS)

UPL has achieved various honors and awards in past decades as listed below:

➢ 1971: Gold Shield for Red Phosphorus - Board on Awards for Import

Substitution

➢ 1985: Certificate of Merit ALP, PCL3 - Ministry of Commerce

➢ 1990: Top Export Award - CHEMEXCIL



➢ 1992: Innovative Technology Award for TMP - ICMA

➢ 1993: Corporate Excellence Award - Dalal Street Journal

➢ 1993: Consistent Export Award - FGMI Association

➢ 1993: First Export Award – CHEMEXCIL

➢ 1994: The analyst Award - Investor Friendly Company - CFAI

➢ 1994: Outstanding Export Performance Award - Ministry of Commerce


➢ 1995: Accorded the status of TRADING HOUSE


➢ 1996: Outstanding Export Performance Award - ministry of Commerce

➢ 1997: Gujarat Govt.’s Award for Outstanding Export Performance

➢ 1997: Award for “Social Responsibility” - ICMA

➢ 2004: Frost & Sullivan Award in Silver category for Process consistency &

Social Responsible Company.

➢ 2005: National Energy Conservation Award



➢ 2006: Green Tech Safety Award – 2006 from Green Tech Foundation, New

Delhi.

➢ 2007: Greentech Environmental Excellence Award

➢ 2012 & 2013: Green Manufacturing Excellence Award.

➢ 2013: “Awarded by CSR Excellence & Leadership Award 2013 in Global

Summit Competition for Best Waste Water Mgmt. Practices”.

➢ 2016: First position in Agrochemical sector awarded by Dun & Bradstreet

India`s top 500 countries

➢ 2016: “Golden Peacock Occupational Health & Safety Award in Chemical &

Fertilizer Category.

➢ 2017: OSHAI- Special category award for innovation is HSE implementation.

➢ 2017: Silver category for OH&S in EXCEED (EKDKN)

➢ 2017: CII Award for Excellence in Water Management

UPL’s Credentials towards HSE Management

➢ It has a well laid HSE policy approved by its board of directors and mentions

about various process and policies adopted for management of health, safety

and environment.

➢ It has implemented Responsible Care initiative of Indian Chemical Council and

got RC logo.

1.3 Purpose of the EIA Report

The proposed expansion including manufacturing of additional new pesticide

products by UPL falls under Category “A” of EIA Notification dated September 14,

2006 and subsequent amendments issued by MoEF&CC and the proposed

expansion project is listed at 5(b) of the schedule activities for pesticides industry

and pesticide specific intermediates (excluding formulations).

UPL appointed M/s Shivalik Solid Waste Management Ltd. (SSWML), (NABET

Accredited EIA Consultant for Pesticides Sector) as EIA Consultant for ToR

approval and preparation of Environment Impact Assessment (EIA) and



Environment Management Plan (EMP) and for providing technical support for

obtaining environment clearance.

Environmental Impact Assessment (Report) has been prepared as per Standard

ToR, Specific ToR and ToR amendment by MoEF & CC.

1.4 Brief Description of the Project Nature, Size, Location of the Project and

Its Importance to the Country, Region

1.4.1 Location of the Project

The Unit # 10 of UPL is located at Plot No. E51/1, E51/2, and E-52, MIDC Notified

Industrial Estate, Tarapur, Boisar, District –Palghar in Maharashtra state. The

location index map for project site is shown in Figure 1.1. 10 km study area

around the UPL Plant in MIDC is presented in Figure 1.2.

1.4.2 Salient Features and Details of Proposed Project

The salient features and details of the proposed expansion of existing UPL plant

are given in Table 1.1.

Table 1.1: Salient Features and Details of the Project

Sn. Particulars Details

1. Proposed plant capacity The Unit is presently manufacturing one

Pesticide Technical @ 1620 TPA, 06 (six)

Pesticide Intermediate @1968 TPA, 02

(Two) inorganic chemicals @ 5100 TPA and

02 (two) Pesticide Formulation products

@2700 TPA. It is proposed to expand

Pesticide Technical capacity from 1620 TPA

to 27120 TPA (11 new products and

expansion of existing 1 product, total

expansion @ 25500 TPA); Pesticide Specific

Intermediate capacity from 1968 TPA to

18900 TPA ( 2 new products and expansion

of existing 6 product, total expansion @




16932 TPA); Inorganic chemical capacity

from 5100 TPA to 18000 TPA (1 new

product and expansion of existing 1

product, total expansion @ 12900 TPA

inclusive of 1 discontinued product i.e.

Potassium Chloride. EC is not applicable for

inorganic chemicals), Pesticide Formulation

capacity from 2700 TPA to 15000 TPA (1

new product and expansion of existing 1

product, total expansion @ 12300 TPA

inclusive of 1 discontinued product i.e.

Glyphosate 41 % SL Formulation. EC is not

applicable for Formulation products).

2. Total Plot Area 23,454 sqm (2.3454 ha)

3. Location E51/1, E51/2, and E-52, MIDC Notified

Industrial Estate Tarapur, Boisar Dist.-

Palghar in Maharashtra State.

4. Latitude (N) Longitude (E)

Latitude (N) Longitude (E)

19°48'20.24" 72°43'39.71"

19°48'20.34" 72°43'44.70"

19°48'14.91" 72°43'39.94"

19°48'15.09" 72°43'44.84"

5. Water Requirement Total existing water requirement for

industrial & domestic purpose is 166.56 KLD

& additional demand for proposed expansion

is 538.5 KLD. Total water requirement after

expansion will be 705.06 KLD.

6. Source of water The entire water requirement is being met

through MIDC Notified Industrial Estate

Tarapur. For expansion of the plant also,

additional water will be supplied by MIDC.

7. Wastewater Existing (as per CC & A) and proposed

waste water generation:

Sources of

waste water

Existing

in KLD

Additional

KLD

Total

KLD




Domestic 1.8 9.2 11

Industrial 36.3 79.7 116

MEE

Condensate

- 170 170

Total 38.1 258.9 297

Treated effluent will continue to be sent to

CETP, Tarapur for further treatment and

disposal.

8 Man Power For existing plant operation around 150

persons (67 UPL employees + 83

contractual employees) and additional

manpower requirement for proposed

expansion 150 persons (73 UPL employees

+ 77 contractual employees). Total 300

persons (140 UPL employees + 160

contractual employees) will be required

after expansion.

9 Electricity/Power requirement Existing- 1508 kW

Additional required- 2824 kW

Total Power requirement after expansion:

4332 kW.

Source: MSEB (Maharashtra State

Electricity Board)

There are existing 2 nos. of DG sets

(capacity: 500 KVA and 250 KVA)

Additional two DG Sets of 750KVA capacity

each will be installed to meet the power

requirement in the event of grid power

failure.

10 Utilities Existing Boiler @ 10 TPH (coal @ 985 kg /

hr, biomass / briquettes / rice husk @ 2460

kg / hr

Existing Standby Boiler @ 4 TPH (FO @ 125

LPH)




Proposed Boiler @ 10 TPH (Coal @ 2 TPH)

11 Air emissions Process emission after proposed expansion

will be PM, SO2, NO2, HCL, Cl2, PCl3, H2S,

NH3, HBr, MeCL, VOC.

12 Hazardous Waste Hazardous waste / solid waste / municipal

solid waste after proposed expansion is as

below:

Type of Wastes Quantity

Distillation residue 1604.82 MT/M

Discarded

Containers (Drums,

Carboys)

9636 Nos/Month

Plastic Bags 51562 Nos/Month

ETP sludge 40 MT/M

Salt from

Evaporation &

Process

2536 MT/M

Used Oil 500 Ltrs/ Month

Used Batteries 5 Nos/Month

Spent Solvent 10 MT/M

Spent Catalyst 1 MT/M

Aqueous Effluent

from Drum / Tank /

reactor washing

50 MT/M

Date Expired & Off

specific Pesticide 5 MT/M

Used Filter Aids 3 MT/M

Insulation waste

/PPEs 8 TPA

Spent Acid 2 TPA

Ash from Boilers 120 MT/M

13 Alternative site The proposed expansion will be confined

within the existing plant premises only.




14 Land form, Land use and land

ownership

No additional land is required for proposed

expansion. The existing UPL plant is located

in the MIDC Notified Industrial Estate,

Tarapur.

15 Project cost The estimated cost of the proposed project

is Rs.227.06 Crores.

16 Nearest Highway SH-74 is located about 2 km (NE)

NH-8 is located about 19.20 km (E)

17 Nearest Railway Station Boisar Railway Station, 4 km (SE) (Aerial

distance)

18 Nearest Airport Chhatrapati Shivaji Airport, Mumbai is

located at 80 km distance in south direction

(Aerial distance)

19 Nearest Forest Forest patches are located at distance of

about 8 km in East -South East Direction.

However, forest clearance is not required

as project site is located within MIDC

notified Industrial area

20 Nearest Town/ city Boisar/Palghar

21 Seismic zone Zone III



Figure 1.1: Location Index Map of the project site



Figure 1.2: 10 Km Area Around the UPL Plan in MIDC



1.4.3 Importance of the project to the Region & Country

The proposed project of UPL Ltd. (Unit#10, Tarapur) is for expansion of the

existing pesticides manufacturing and to include new products. The proposed

project for manufacturing of various pesticide products is based on the market

surveys and internal estimates to bridge the gaps in demand and supply of

pesticide in region and in the country.

The proposed project is needed to serve increasing demand from domestic and

export market. Benefits of the project are many folds. Indian Pesticides are one

of the rapidly growing markets and has emerged a strong export oriented

business. Out of the present business of 180 Billion, the export accounts 100

billion and is steadily growing at a rate of 6.7%. This is 2.5 times more than

the world market. With the introduction of genetically modified crops in India,

the consumption of insecticides decreased marginally. But the other sectors

such as weedicides & herbicides, fungicides etc. are rapidly growing. UPL’s

focus is on the sectors of fungicides and herbicides especially for the export of

these group molecules. To support the farmers to prevent crop damage, UPL

is supplying various products as per the requirement.

1.5 Terms of Reference (ToR) for EIA Study

The proposal for the proposed project was considered by Expert Appraisal

Committee (EAC) Industry -2 in 18th meeting held on 23 January 2017.

Subsequently, MoEF&CC issued ToR vide letter no. J-11011/7/2017-IA. II (I)

dated 29/04/2017. TOR amendment proposal was considered in the 24th EAC

meeting held on 16th June 2017, and amended ToR with exemption of public

hearing and waiving point of installation of Zero Liquid Discharge (ZLD)

condition was issued by MoEF&CC on 23/10/2017. ToR issued on 29/04/2017

and 23/10/2017 dated are enclosed as Annexure 1.

1.5.1 Compliance of Standard Terms of References (ToR)

The compliance of standard ToR, specific ToR issued by MoEF&CC issued ToR

vide letter no. J-11011/7/2017-IA. II (I) dated 29/04/2017 and amended on

23/10/2017 for the proposed expansion of the existing UPL Plant is given below.



S. No.

ToR Compliance

A. STANDARD TERMS OF REFERENCE

1. Executive Summary Executive Summary of the project is attached along with EIA report.

2. Introduction

i. Details of EIA Consultant including NABET accreditation.

Shivalik Solid Waste Management Limited (SSWML) is the NABET accredited consultant engaged by M/s UPL Limited. SSWML is listed at S. No. is 130, Rev. 61, as per QCI/NABET list of EIA Consultant Organizations as on January 05, 2018. Details are given in Chapter 12 as disclosure of consultant.

ii. Information about the project Proponent.

The proposed project of expansion of existing Unit#10 of UPL Limited, located in MIDC Notified Industrial Area Tarapur). Details of the project proponent are mentioned in Section 1.2. of Chapter 1 of EIA Report.

iii. Importance and Benefits of the Project

The proposed expansion of the project is needed to serve increasing demand from domestic and export market. Importance and benefits of the project have been described in Section 1.4.3 in Chapter 1 of the EIA report.

3 Project Description

i. Cost of Project and time of completion

Total cost of the proposed expansion is Rs. 227.06 Crores. Kindly refer details given in



S. No.

ToR Compliance

Section 2.11 of Chapter-2 of the EIA report.

ii Products with capacities for the proposed project.

Details of existing and proposed products and by product along with capacities are given Table 2.1 of Chapter 2 of the EIA report.

iii If expansion Project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

Details of existing and proposed products and by product along with capacities are given Table 2.1 of Chapter 2 of the EIA report. Land Area: The unit has total 23454 sqm land (Plot no. E51/1, E51/2, and E-52) and adequate land is available for expansion within existing plant. Details of land area are given in Section 2.9 and Table 2.8 of Chapter-2 of the EIA report.

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

Details of raw materials required

and monthly storage capacity (for

existing and proposed expansion)

are given in Table 2.3 and 2.4 in

Chapter-2 of the report. Raw

materials to the plant are

transported by using existing

road.

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

The details of hazardous chemical

storage are provided in Chapter-7

(Table 7.1 of EIA report).

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

Sources of pollution and its Control strategies are given in Section 2.12 of Chapter 2 of the EIA Report. Details of effluents generation, treatment and disposal are given



S. No.

ToR Compliance

in Section 2.12.1 and Table 2.10 in Chapter-2 of the EIA Report. Emissions details with the Air Pollution Control System are given in Section 2.12.2 and Table-2.12 & Table-2.13 in Chapter-2 of the EIA report. Details of hazardous waste generation and its management are given in Section 2.12.3 and Table 2.14 in Chapter 2 of the EIA report.

vii Requirement of water, power, with source of supply, status of approval, water balance diagram, man power requirement (regular and contract)

Total water requirement will be 705.06 kld after expansion and will be met through MIDC. Details of water requirement and water balance are given in Section 2.8.1, Table 2.7 and Figure 2.33 in Chapter-2 of the EIA Report. Total power requirement for UPL’s existing plant is 1508 kW. After expansion power requirement will be increased to 4332 kW, which will be supplied by Maharashtra State Electricity Board (MSEB). Details are given in Section 2.8.3 in Chapter-2 of the EIA report. Total 300 manpower will be required for the project after expansion. Details of manpower for existing and after extension are given in Section 2.10 and Table 2.9 of the Chapter 2 of the EIA report.

viii Process description along with major equipment’s and

Details of manufacturing process, reactions and mass balance for all



S. No.

ToR Compliance

machineries, process flow sheet (quantitative) from raw material to products to be provided

products are given in Section 2.3 of the Chapter 2 of the EIA Report.

ix Hazard identification and details of proposed safety systems.

Hazard identification and details of proposed safety systems are given in Chapter 7 of the EIA Report.

X Expansion/Modernization Proposals:

A Copy of all the environmental clearance(s) including amendments thereto obtain for the project from MOEF/SEIAA shall be attached as annexure. A certified copy of the latest monitoring report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including amendments shall be provided. In addition, status of compliance of consent to operate for the on-going/existing operation of the project from SPCB shall be attached with the EIA-EMP report.

The unit (through M/s Punjab Chemicals & Crop Protection Limited) obtained environmental clearance from Ministry of Environment, Forest and Climate Change vide letter no F. No. J-11011/712/2007-IA II (I) dated 15 April 2008. (Pl refer Annexure- III) Consent to operate for the project from MPCB is attached as Annexure-II.

B In case the existing project has not obtained environmental clearance reasons for not taking EC under the provisions of the EIA Notification 2006 shall be provided. Copies of Consent to Establish/No Objection certificate and consent to operate (in case of units operating prior to EIA Notification 2006. CTE and CTO

UPL has valid Consolidated Consent & Authorization (CC&A) under Water act, Air Act and authorization under Hazardous Waste Rules vide CC&A No.: Format 1.0/BO/AST/UAN No. 0000019382 /R/CC-1708000213 on dated 5.08.2017 and valid up to 28.02.2019



S. No.

ToR Compliance

of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted.

4. Site Details

i. Location of the project site covering village, taluka/tehsil, district and state, justification for selecting the site, whether other sites were considered.

The unit is located in Plot No. E51/1, E51/2, and E-52, MIDC Notified Industrial Estate, Tarapur, Boisar, Dist.- Palghar, Maharashtra. Expansion of the project will be carried out within the existing premises only, therefore no other site was considered. Details of location of the project site are given in Section 1.4 in Chapter 1 of the EIA report.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1: 25,000 scale on an A3/A2 sheet, (including all eco-sensitive areas and environmentally sensitive places).

A topographical map showing 10 km radius area is given in Figure 1.2 in the Chapter 1 of EIA report. There is no eco-sensitive area and environmentally sensitive place within 10 km distance from the site.

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

Alternative analysis has been given in Chapter-5 of EIA report.

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

Latitude and Longitude are given in Table 1.1 in Chapter 1 of EIA report.

v Google map-Earth downloaded of the project site.

Google map-Earth downloaded for the project is given in Figue-1.1 in Chapter-1 of EIA report.

vi Layout maps indicating existing units as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc.

Layout map indicating existing units as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc



S. No.

ToR Compliance

If located within an industrial area/Estate/Complex, layout of the industrial Area indicating location of unit within the industrial area Estate.

is given in Figure-2.34 in Chapter-2 of EIA report.

vii Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation greenbelt in particular.

The photographs of plantation greenbelt at existing plant site are shown in Annexure VII of EIA report.

viii Land use break-up of total land of the project (identified and acquired), government/ private – agricultural, forest, wasteland, water bodies, settlements etc. Shall be included (not required for industrial area)

The break-up of landuse of the plant is given Table 2.8 and Figure 2.34 in Chapter 2 of EIA report.

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

A list of major industries with name and type located within study area are given in Section 3.17.6 in Chapter 3 of the EIA report.

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

Geological features of the study area are described in Section 3.3 and Geo-Hydrological Status of the area is incorporated in Section 3.5 in Chapter 3 of EIA report.

xi Details of drainage of the project upto 5 km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood level of the project site and maximum flood level of the river shall also be provided. (mega green field projects)

Drainage details are given in Section-3.6 and Figure 3.2 in Chapter-3 of EIA report.



S. No.

ToR Compliance

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

The project is expansion of the existing plant within available premises without any land acquisition.

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

As no land acquisition is involved in the project. Therefore, R & R is not applicable.

5 Forests and wildlife related issues (if applicable)

i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department (if applicable)

As no forest land is involved in the project, hence, forestry clearance is not required.

ii Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forestland more than 40 ha)

Not applicable. However, Landuse map based on High Resolution Satellite Imagery for land used study has been incorporated in Figure 3.24 and 3.26 in Chapter 3 of the EIA report.

iii Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted.

As no forest land is involved in the project, hence, Stage I forestry clearance is not required.

iv The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of wild animals, and the project proponent shall submit the map duly authenticated by chief wildlife warden showing these features vis-à-vis the project location and the recommendations or comments

There are no national parks, sanctuaries, biosphere reserves, migratory corridors of wild animals within 10 km radius of the study area. The 10-km study area map is presented as Figure 3.26 in Chapter-3 of EIA report.



S. No.

ToR Compliance

of the chief wildlife warden-thereon.

V Wildlife Conservation Plan duly authenticated by chief wildlife warden of the state government for conservation of schedule I fauna, if any exists in the study area.

There is no Scheduled I fauna within 10 km radius of the project, therefore Wildlife Conservation Plan authenticated by chief wildlife warden is not required/applicable for the project. Details of flora and fauna have been incorporated in Table 3.28 to Table 3.34 in Chapter 3 of EIA report.

vi Copy of application submitted for clearance under wildlife (Protection) Act, 1972 to the standing committee of the National Board Wildlife.

Not applicable, as no forest land is involved in the project.

6 Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Site-specific micro-meteorological data including temp, relative humidity, wind speed, direction & rainfall were collected at the site installing automatic data logger. Details are given in Section 3.10 in Chapter-3 of EIA report.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserve forests.

Based on the CPCB guidelines, Ambient Air Quality monitoring was carried out at 8 locations 1st March 2017 to 31st May 2017 and is incorporated in Section 3.11 and Table 3.18 & Table 3.20 in Chapter 3 of EIA report.

iii. Raw data of all AAQ measurement for 12 weeks of all

Based on the CPCB guidelines, Ambient Air Quality monitoring



S. No.

ToR Compliance

stations as per frequency given in the NAQQM Notification of Nov 2009 along with – min. max. Average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA report.

was carried out at 8 locations 1st March 2017 to 31st May 2017 (12 weeks) as per NAQQM Notification of Nov 2009 and is incorporated in Section 3.11 and Table 3.18 & Table 3.20 in Chapter 3 of EIA report.

iv Surface water quality of nearby River (60m upstream and downstream) and other surface drains at 8 locations as per CPCB/MoEF & CC guidelines.

The surface water quality monitoring from the nearby river & other sources were carried as per the CPCB/MoEF & CC guidelines and presented in Section 3.8.1 & 3.9.2 and Table 3.8 in chapter-3 of the Area.

v Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF & CC guidelines.

No, the site is not falling near polluted stretch of the river identified by the CPCB/MoEF & CC guidelines.

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

Ground water monitoring was carried and detailed given in Section 3.8.2 & 3.9.1 and Table 3.6 in Chapter 3 of the EIA report.

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

Noise levels monitoring was carried at 8 locations and incorporated in Section 3.13 and Table 3.24 in Chapter 3 of EIA report.

viii Soil characteristic as per CPCB guidelines

Characteristics of Soil was done and incorporated in Section 3.7 and Table 3.3 in Chapter-3 of EIA report.

ix Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangements etc.

Traffic study of the area, type of vehicles, frequency of vehicles is given in Section 3.14, Table 3.25 and Table 3.26 in Chapter 3 and Section 4.5.12 of Chapter 4 of EIA report



S. No.

ToR Compliance

x Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a wildlife conservation plan shall be prepared and furnished.

Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area were carried out and incorporated Section 3.16 in Chapter 3 of EIA report.

xi Socio-economic status of the study area.

Socio-economic study for 10 km radius study area was carried out and incorporated in Section 3.17 in Chapter 3 of the EIA report.

7 Impact Assessment and environment Management Plan

I Assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. In case the project is located on a hilly terrain the AQIP modeling shall be done using inputs of the project on the AAQ cumulative impact of all sources of emissions (including transportation on the AAQ of the area shall be well assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby sensitive receptors, if any.

Assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features have been carried out and is given in the Section 4.5.5.1 of Chapter 4 of the EIA Report.

ii Water quality modeling- in case, if the effluent is proposed to be discharged in to the local drain, then water quality modeling

Not applicable and effluent generated will be sent to the adjacent CETP after tertiary treatment given at the Plant.



S. No.

ToR Compliance

study should be conducted for the drain water taking into consideration the upstream and downstream quality of water of the drain.

iii Impacts of the transport of the raw materials and end products on the surrounding environment shall be assessed and provided. In the regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyor-cum-rail transport shall be examined.

Impacts of the transport of the raw materials and end products are given in Section 4.5.12 in Chapter 4 of EIA report.

iv A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment. Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E(P) Rules.

Details of generation of waste water are given in Table 2.10 and Section 2.12 of Chapter 2. Details of treatment of wastewater are given in Section 4.5.3 & Table 4.8 in Chapter 4 of EIA report.

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

Process stacks details along with expected pollutant and air pollution control system are given in Table-4.10 of Section 4.5.5 in Chapter 4 of EIA report.

vi Measures for fugitive emission control

Measures for fugitive emission control are given in Section 10.12.5 in Chapter 10 of EIA report.

vii Details of hazardous waste generation and their storage, utilization and disposal. Copies of MOU regarding utilization of solid and hazardous waste shall

Details of hazardous waste generation & their storage, utilization and disposal. are given in Section 2.12 and in Table 2.14 in in Chapter 2 of EIA report.



S. No.

ToR Compliance

also be included. EMP shall include the concept of waste-minimization, recycle/recover techniques, energy conservation and natural resource conservation.

Membership certificate of Mumbai Waste Management Limited (MWML, Ramky) is enclosed as Annexure V

viii Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan of action shall be provided.

Fly ash (non-hazardous) will be sent to brick manufacturer or other end-users. Details of are given in Section 2.12.3 (II) of Chapter 2 of EIA Report. Pl refer Annexure X

ix Action plan for the green belt development plan in 33% area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated.

Green Belt Development details are given in Section 10.7 and Figure 10.2 of Chapter 10 of EIA Report.

x Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drain and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.

Action plan for rainwater harvesting is given in Section 10.9 and Table 10.2 of Chapter 10.

xi Total capital cost and recurring cost/annum for environmental pollution control measures shall be included.

Budgetary provisions for EMP implementation are given in Section 10.13 and in Table 10.8 of Chapter 10 of EIA report.

xii Action plan for post-project environmental monitoring shall be submitted.

Post-project environmental monitoring plan is given Chapter 6 of EIA Report.



S. No.

ToR Compliance

xiii Onsite and Offsite Disaster (natural and Man-made) preparedness and emergency management plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Onsite and Offsite Disaster (natural and Man-made) preparedness and emergency management plan including Risk Assessment and damage control is incorporated in Chapter 7 in EIA report. Risk Assessment and Disaster Management Plan have been complied as standalone report separately.

8 Occupational Health

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

Occupational Health & Safety Hazards for regular and contract /casual workers have been incorporated in Section 10.8 and allocation of funds are detailed in Table 10.8 of Chapter 10 of the EIA Report. Periodical health check-up of workers will also be carried out.

ii Details of exposure specific health status evaluation of worker. If the workers’ health is being evaluated by pre-designed format, chest x rays, Audiometry, Spirometry, vision testing (far & Near vision, colour vision and any other ocular defect) ECG during pre-placement and periodical examinations give the details of the same. Details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise.

Occupational Health & Safety Surveillance Program for the plant after expansion are given in Section 10.8.2 of the EIA report.

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

Occupational Health & Safety Surveillance Program for the plant after expansion are given in Section 10.8.2 of the EIA report.



S. No.

ToR Compliance

iv Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards and whether they are within Permissible Exposure level (PEL). If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers can be preserved,

Details of Occupational Health & Safety Hazards measures are given in Section 10.8 of the EIA Report.

9 Corporate Environment Policy

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

Environmental Policy for the company is given in Section 10.3 of Chapter 10 and HSE policy is given in Annexure VI.

ii Does the environment Policy prescribe for standard operating process procedures to bring into focus any infringement/ deviation/ violation of the environmental clearance conditions? Details of this system may be given.

Yes HSE Policy of UPL prescribes for standard operating process procedures for environmental regulations compliance. Environment Monitoring cell shall monitor the implementation of the environment policy standards. Details are given Section 10.4 of Chapter 10 of the EIA report.

iii What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given.

Details are given Section 10.4 and Figure 10.1 of Chapter 10 of the EIA report.



S. No.

ToR Compliance

iv Does the company have system of reporting of non-compliances violations of environmental norms to the board of Directors of the company and/or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report.

Environment Monitoring Cell regularly monitor the compliance environment norms and report to Board of Directors appropriately. Details are given Section 10.4 and Figure 10.1 of Chapter 10 of the EIA report.

v Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during constructions as well as to the casual workers including truck drivers during operation phase.

During construction phase required facilities will be provided to construction workers. Necessary facilities including sanitation, food and rest rooms will be provided for workers including drivers during operation phase.

11 Enterprise Social Commitment (ESC)

i Adequate funds (at least 2.5% of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Detail of Enterprise Social Commitment are given in Section-10.11 and budgetary allocation is given in Table 10.6 and Table 10.7 of Chapter 10 of the EIA report.

12 Any litigation pending against the project and/or any direction/order passed by any court of law against the project, if so, details thereof shall also be included. Has the unit received any notice under the section 5 of environment (Protection) Act, 1986 or relevant sections of Air and water Acts? If so, details, thereof and compliance ATR to

No litigation is pending for this project.



S. No.

ToR Compliance

the notice (s) and present status of the case.

13 A tabular chart with index for point wise compliance of above TORs.

Complied and presented in Section 1.5.1 of Chapter 1.

B. SPECIFIC TERMS OF REFERENCE FOR EIA STUDIES FOR PESTICIDES INDUSTRY AND PESTICIDE SPECIFIC INTERMEDIATES (EXCLUDING FORMULATIONS)

1. Commitment that no banned pesticides will be manufactured.

UPL does/will not manufacture any banned pesticide. Undertaking is given in Annexure Annexure-XII

2. Details on solvents to be used, measures for solvent recovery and for emissions control.

Details of solvent recovery system are given in Section 2.7 of Chapter 2 of the EIA report.

3. Details of process emissions from the proposed unit and its arrangement to control.

Process stacks details along with expected pollutant and air pollution control system are given in Table-4.10 of Section 4.5.5 in Chapter 4 of EIA report.

4. Ambient air quality data should include VOC, other process- specific pollutants* like NH3*, chlorine*, HCl*, HBr*, H2S*, HF*, CS2 etc., (*-as applicable)

Based on the CPCB guidelines, Ambient Air Quality monitoring was carried out at 8 locations 1st March 2017 to 31st May 2017 (12 weeks) as per NAQQM Notification of Nov 2009 and is incorporated in Section 3.11 and Table 3.20 in Chapter 3 of EIA report.

5. Work zone monitoring arrangements for hazardous chemicals.

Work zone monitoring arrangements for hazardous chemicals are given in Chapter 6 of EIA Report

6. Detailed effluent treatment scheme including segregation for units adopting 'Zero' liquid discharge.

Effluent generated are sent to the adjacent CETP, Tarapur after tertiary treatment at the Plant. Same will be continued after expansion.



S. No.

ToR Compliance

7. Action plan for odour control to be submitted.

Odour Control Action Plan is given in Section 10.10 of Chapter 10 of EIA Report.

8. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated.

Details of Membership of CETP, Tarapur are given in Annexure IV. Membership of TSDF are given in Annexure V. Fly ash (non-hazardous) will be sent to brick manufacturer or other end-users. Details are given in Section 2.12.3 (II) of Chapter 2 of EIA Report.

9. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste in TSDF, if any.

Details of Membership of CETP are given in Annexure IV. Membership of TSDF are given in Annexure V.

10. Material Safety Data Sheet for all the Chemicals are being used/will be used.

Material Safety Data Sheet for all the Chemicals are being used/will be used, are given Annexure IX.

11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.

Membership of TSDF are given in Annexure V.

12. Details of incinerator if to be installed.

There is no proposal for installation of incinerator at the plant.

13. Risk assessment for storage and handling of hazardous chemicals/solvents. Action plan for handling & safety system to be incorporated.

Risk assessment for storage and handling of hazardous chemicals/solvents and action plan for handling & safety system to be incorporated are described in Chapter 7 of the EIA Report.

14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

Arrangements for ensuring health and safety of workers engaged in handling of toxic materials are given Chapter 7 of the EIA Report.



1.5.2 Compliance of Specific ToR vide letter F.NO 11011/7/2017-IA-II (I)

dated 29 April 2017

Compliance of Specific & General ToR vide letter F.NO 11011/7/2017-IA-II (I) dated 29 April 2017 is given below: Sr No ToR Compliance Status as

A. Specific ToR

I Zero Liquid Discharge System to be installed.

Company has taken up with MoEF&CC and obtain Amended Specific ToR vide letter F.NO 11011/7/2017-IA-II (I) dated 23rd October 2017 for exemption of Zero Liquid Discharge System, attached as Annexure I

II Lay Out plan will be modified making provisions for at least 10 meters wide green belt of perennial indigenous trees around plant periphery.

Revised green belt plan is given Figure 10.2 of Chapter 10.

III Public Hearing to be conducted as per provisions of EIA Notification 2006.

Company has taken up with MoEF&CC and obtain Amended Specific ToR vide letter F.NO 11011/7/2017-IA-II (I) dated 23rd October 2017 for exemption of Public Hearing as Company has located inside Notified Industrial Estate. Annexure I

IV Certified Compliance Report of existing EC to be submitted.

Certified Compliance Report for the Existing Environmental Clearance (EC) is attached as Annexure III.

General ToR

3. These “ToRs” should be considered for the preparation of EIA / EMP for expansion of manufacturing capacity of existing products and manufacturing new pesticides and intermediates at E51-1&2, E52, MIDC Notified Industrial Estate, Tarapur, Boisar, Dist – Palghar, Maharashtra by UPL Limited (Unit # 10) in addition to all the relevant information as per the “General Structure of EIA” given in

Company has considered all standard ToR conditions, Specific ToR conditions & General conditions in EIA report.



Sr No ToR Compliance Status as

Appendix III and IIIA in the EIA Notification 2006.

4. The consultants involved in the preparation of EIA / EMP Report, after accreditation with Quality Council of India / National Accreditation Board of Education and Training (QCI/NABET) would need to include a certificate in this regard in EIA / EMP reports prepared by them and data provided by other Organization(s) / Laboratories including their status of approvals etc.

The consultant M/s Shivalik Solid Waste Management Limited is QCI and NABET approved.

1.5.3 Compliance of Amended Specific ToR vide letter F.NO 11011/7/2017-

IA-II (I) dated 23rd October 2017

After receiving the ToR, UPL requested EAC to exclude Point no 1 and 3. The

EAC after detailed deliberations agreed to exclude these two points and re-

issued the amended ToR vide F. No. J-11011/7/2017-IA. II (I) on dated 23rd

October 2017.

Condition Compliance Status

Sr

No

Description

04 The proposal for amendment in terms of reference

was placed before the EAC (Industry2) in its 24th

meeting held during 14-16 June 2017 in the

Ministry. The project proponent informed EAC

that project is located in Notified Industrial Area

and the effluent from the unit shall be taken to the

common effluent treatment plant (CETP), Tarapur

for treatment as there is no provision of zero liquid

discharge (ZLD) in the Unit. The project proponent

further informed that product details were also not

mentioned in ToR letter. During the meeting, the

project proponent requested for exemption of

Public Consultation, to delete Zero Liquid

Noted.



Condition Compliance Status

Sr

No

Description

Discharge condition and to include product details

in ToR letter. The EAC agreed to the request of the

project proponent and recommended for

amendments as proposed, in the terms of

reference (ToR) dated 29th April 2017.

05 The ToR is hereby amended to the extent as

above. All other terms and conditions in ToR dated

29th April 2017 shall remain the same.

Noted

06 This issues with approval of Competent Authority. Noted.

1.6 Regulatory Framework

UPL (in the name of M/s Punjab Chemicals & Crop Protection Limited) had

obtained the prior Environmental Clearance vide letter no: J-11011/712/2007-

IA-II(I) dated April 15, 2008 for previous expansion. UPL has valid Consolidated

Consent & Authorization (CC&A) under Water act, Air Act and authorization

under Hazardous Waste Rules vide CC&A No.: Format 1.0/BO/AST/UAN No.

0000019382/R/CC-1708000213 on dated 5.08.2017 and valid up to

28.02.2019. The copy of valid CC&A is attached as Annexure-II.

UPL plant is operated under the compliance of applicable environmental acts,

rules & regulations, which have been formulated and amended time to time as

given in Table 1.2

Table 1-2: Regulatory Framework

Sn. Activity Aspects Compliance of Regulations

1. Manufacturing/

operational

• Boiler

Gaseous

emission

Noise



• Process unit

• Cooling

tower

• D.G. Set

Water

Pollution

• Factory License

• The Factories Act, 1948

• The Water (Prevention and

Control of Pollution) Act, 1974

and Rules, 1975, as amended to

date.


Control of Pollution) Cess Act,

1977 and Rules, 1978, as

amended to date.

• The Air (Prevention and Control of

Pollution) Act, 1981 and Rules,

1982, as amended to date.

• Manufacture, Storage and Import

of Hazardous Chemicals Rules,

2000 (as amended).

• Indian Boiler Act, 1923 & Rules

• Bureau of Indian Standards (IS)

• Environment Impact Assessment

Notification, dated 14th

September 2006, as amended on

1st December 2009.

• Environment (Protection) Act

1986

• Hazardous & Other Wastes

(Management & Trans-Boundary

Movement) Rules 2016

• E-Waste (Management)

Rules, 2016

• Plastic Waste Management

Rules, 2016




• Construction and Demolition

Waste Management Rules,

2016

2. Storage of

product and

raw material

Dust

Generation






2000 (as amended).

• The Explosive Act, 1884 and rules,

1983 amended to date

• The Petroleum Act, 1934 & Rules,

2002

• Chemical Accidents (Emergency

Planning, Preparedness and

Response) Rules, 1996.

• Public Liability Insurance Act,

1991 and Rules, 1991 as

amended to date


1992 (as amended).

Gaseous

Emission

Noise

Accidents

3. Transportation

of raw material

and products

Dust

Generation

Gaseous

Emission

Noise




Accidents • Chemical Accidents (Emergency

Planning, preparedness and

response) Rules, 1996



1982, as amended to date

• The Motor Vehicles Act, 1988 &

The Central Motor Vehicle rules,

1989

• The Environment (Protection) Act,


amended to date

• Noise Pollution (Regulation and

Control) Rules, 2006 (as

amended).

4. Treatment

Technology

• ETP

• MEE

• STP

• ESP

• Scrubber

• Sludge

generation

• VOC

Generation


Control of Pollution) Cess Act,


amended to date.






2000 (as amended).

• Hazardous and Other Wastes

(Management and Transboundary

Movement) Rules, as amended in

2016

• Environment Protection Act 1986

& Rules made under.




5. Recruitment /

Labour Welfare

Social • Public Liability Insurance Act,

1991 and Rules, 1991 as

amended to date


1992 (as amended).

• Employment Relations

Amendment Act 2016

• Employees Provident Funds and

Miscellaneous Provisions Act,

1952

• Environment Impact Assessment

Notification, dated 14th

September 2006, as amended on

1st December 2009.

1.6.1 Certified Copies of Previous Environmental Clearance

The certified copy of Environmental Clearance vide letter F. No. J-

11011/712/2007-IA II (I) dated 15 April 2008 obtained from MoEF&CC for

previous expansion is enclosed as Annexure III.

1.7 Structure of the EIA Report

The EIA report for the proposed expansion of UPL plant is based on the

structure of EIA report, as described in the EIA Notification dated 14th

September 2006 and ToR approved and amended by MoEF&CC. The EIA report

is divided into twelve chapters. Details of chapters of EIA are summarized

below:

Chapter 1: Introduction – This chapter gives brief outline of the proposed

project and its proponent, brief description of the nature, size, and location

of the project and its importance, and extent of the EIA study, including the

scope of the study.



Chapter 2: Project Description - This chapter deals with the technical

details of the proposed project including existing production, proposed

production, raw materials requirement and storage, manufacturing

processes, mass balance, utilities requirement, sources of pollution and its

control strategies, etc.

Chapter 3: Description of Environment - This chapter presents existing

environmental conditions within 10km radius study area around the site

including topography, geology, soil, drainage pattern, water environment,

climate & meteorology, ambient air quality, noise levels, flora & fauna, socio-

economic conditions, etc. Both primary and secondary data collected during

the study period are depicted in this chapter.

Chapter 4: Impact Assessment & Mitigation Measures - This chapter

describes the anticipated impacts on the environment and mitigation measures

for project during construction and operation phases. The method of

assessment of impacts including studies carried out, modeling techniques

adopted to assess the impact where pertinent have been elaborated in this

chapter. It gives the details of the impacts on the baseline parameters, both

during the construction and operational phases and suggests the mitigation

measures to be implemented by the UPL. It also describes the overall both-

direct and indirect, reversible and irreversible impacts of the proposed activities

on different environmental parameters on different environmental parameters

during construction and post construction phase and underscores the areas of

concern, which need mitigation measures.

Chapter 5: Analysis of Alternatives - This chapter gives details of various

alternatives both in respect of location of site and technologies to be

deployed. Alternatives have been compared in terms of their potential

environmental impacts, suitability under local conditions, and institutional

training and monitoring requirements.

Chapter 6: Environmental Monitoring Plan - This chapter covers the

Environmental Monitoring Programme for the plant in various phases of the

project implementation. It also includes the technical aspects of monitoring

to ensure the effectiveness of mitigation measures.



Chapter 7: Additional Studies - RISK ASSESSMENT - This chapter covers

the Quantitative Risk Analysis for existing and proposed expansion of the UPL

plant.

Chapter 8: Project Benefits - This chapter highlights the benefits occurring

to the locality, neighborhood, region and nation as a whole. It brings out

details of benefits by way of improvements in the physical infrastructure,

social infrastructure, employment potential and other tangible benefits.

Chapter 9: Environmental Cost Benefit Analysis - Environmental Cost

Benefit Analysis is not recommended in specified ToRs.

Chapter 10: Environmental Management Plan - This chapter

comprehensively presents the Environmental Management Plan (EMP), which

includes the administrative and technical setup to ensure that mitigation

measures are implemented and their effectiveness is monitored, summary of

mitigation measures, the cost involved for implementation of the EMP both

during the construction and operational phases.

Chapter 11: Summary & Conclusions – This chapter deals with the

overall summary of the proposed project giving details of the project i.e.

salient features, baseline monitoring of various attributes of environment their

mitigation measures, project benefits, etc. which have been discussed in the

above chapters

Chapter 12: Disclosure of the Consultant - This chapter presents in brief

about the consultant engaged along with the key experts as per QCI/ NABET

accreditation scheme.


Shivalik Solid Waste Management Ltd. 2-1

Chapter 2

PROJECT DESCRIPTION

2.1 Introduction

The Unit is presently manufacturing one Pesticide Technical @ 1620 TPA, 06

(six) Pesticide Intermediate @1968 TPA, 02 (Two) inorganic chemicals @ 5100

TPA and 02 (two) Pesticide Formulation products @2700 TPA. It is proposed to

expand Pesticide Technical capacity from 1620 TPA to 27120 TPA (11 new

products and expansion of existing 1 product, total expansion @ 25500 TPA);

Pesticide Specific Intermediate capacity from 1968 TPA to 18900 TPA ( 2 new

products and expansion of existing 6 product, total expansion @ 16932 TPA);

Inorganic chemical capacity from 5100 TPA to 18000 TPA (1 new product and

expansion of existing 1 product, total expansion @ 12900 TPA inclusive of 1

discontinued product i.e. Potassium Chloride. EC is not applicable for inorganic

chemicals), Pesticide Formulation capacity from 2700 TPA to 15000 TPA (1 new

product and expansion of existing 1 product, total expansion @ 12300 TPA

inclusive of 1 discontinued product i.e. Glyphosate 41 % SL Formulation. EC is

not applicable for Formulation products).

2.2 Existing and Proposed Production Capacity

The production capacities of existing and proposed pesticide products to be

manufactured after expansion at UPL plant are described in Table 2.1:

Table 2.1: Existing and Proposed Products and By-products capacity after

Expansion

Sr. No

Product Name Existing Capacity

(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006



1


1620 4980 6600 21087-

64-9

Fish-96 hr 80 ppm

2000 mg/kg

A-5(b)

Pesticide

(Herbicide)



Sr. No


(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006


0 6000 6000 30560-

19-1 2050 mg/l

1447 mg/kg

A-5(b) Pesticide

(Insecticide)

3


0 1200 1200 62-73-7

Fish (96 hr) 200 mg/l

Oral- 50 mg/kg

A-5(b)

Pesticide

(Insecticide)


0 1200 1200 1071-83-

6

rat (4 h)

>4.98 mg/l

Rat-oral 5600 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 2400 2400 8177-89-

1

96 h- fish- 34

mg/l 2077 mg/kg

A-5(b)

Pesticide

(Herbicide)

6


0 120 120 141776-

32-1

Fish (96 h) > 96

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

7


0 600 600 93697-74-6.

Fish (96 h) >180 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

8

Bensulfuron Methyl

0 600 600

A-5(b)


83055-99-6

Fish (96 h) >150 mg/l

5000 mg/kg Pesticide

(Herbicide)

9


0 600 600 74223-

64-6

Rat (4 h) 5 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 4800 4800 3337-71-

1

Fish (96 h) >5000 mg/l

>1200 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 1800 1800 131860-

33-8

Rat- 0.96

mg/kg 5,000 mg/kg

A-5(b)

Pesticide

(Fungicide)

12 0 1200 1200 15299-

99-7

A-5(b)

Pesticide



Sr. No


(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006

Devrinol (Technical) (proposed)

Rat (4 h) > 5 mg/l


(Herbicide)

Total – A 1620 25500 27120


13


240 1560 1800 101-02-0 Not

listed Rat- 1600

mg/kg A-5(b)


0 7200 7200 21087-

64-0 Not

listed Rat-Oral-

2379 mg/kg A-5(b)

15


0 1800 1800 115-86-6 Not

listed Rat-Oral-

3500 mg/kg A-5(b)

16


900 4200 5100 02-12-7719

50 ppm

18 mg/kg A-5(b)

17


600 600 1200 10025-

87-3 32ppm 380 mg/kg A-5(b)

18 Phosphorous

Acid Crystals

(existing and

proposed)

120 780 900 10294-

56-1

Not

listed

Not listed A-5(b)

19


48 252 300 7664-38-

2

Rat – 2,550 mg/kg

A-5(b) Not listed

20


60 540 600 04-11-7758


Total- B 1968 16932 18900

Total (A+B) 3588 42432 46020


1


3600 11400 15000 7783-20-2

NA 2840mg/kg



Sr. No


(TPA)


(TPA)

Total Capacity

After Expansion

(TPA)

CAS Number

LC50 LD50

Category


2006


0 3000 3000 12125-

02-9 NA 1650mg/kg

3


1500 -1500 0 7447-40-

7 NA 2600mg/kg

Total – C 5100 12900 18000


4


900 -900 0 -- -- --

5


1800 1200 3000 -- -- --


0 12000 12000 -- -- --

Total – D 2700 12300 15000

Total– C+D 7800 25200 33000


11388 67632 79020

* No Product is banned (as per CIB) from above table.



Table 2.2: Details of By-product Quantity from Existing Manufacturing Process and After Expansion

Sr No By Product Name Existing Quantity (TPA)

Additional Quantity

(TPA)

Total Quantity

(TPA)


1 30% HCl 1200 21312 22512


2 30% NaSH 0 9360 9360



5 Methanol 0 1180.8 1180.8

6 Phenol 0 155.4 155.4


8 Ammonium Sulphate Solution (15%)

0 5683.2 5683.2

9 Acetic Acid (30%) 0 8496 8496

10 Acetic Acid (45%) 0 5664 5664

11 Acetic Acid (99%) 0 2574 2574

12 Sodium Acetate (27%) 0 12900 12900


14 NaBr 0 33000 33000

Total 1200 114964.2 116164.2

Source: UPL Limited Note: Applicable by-products will be considered in hazardous wastes and disposed as per Hazardous & Other Wastes (Management & Trans-Boundary Movement) Rules 2016.



2.3 Manufacturing Process, Reaction and Mass Balance for Existing and

Proposed Products The manufacturing process, reaction and mass balance for pesticide products

are given in the following sub-sections:

2.3.1 Phosphorus Tri Chloride (PCl3)

The phosphorous and chlorine are charged to a continuous reactor. The product

PCl3 is condensed and collected in tanks continuously. Heat of reaction is used

for distilling the product. The chemical reaction is as follows:

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Phosphorus Tri Chloride are

given below:

2P + 3Cl2

2PCl3

Phosphorous Chlorine Phosphorous Trichloride

MW 62 213 275

Chemical Reaction at Alkali Scrubber:

Cl2

+

2NaOH

NaOCl

+

NaCl

+

H2O

Chlorine Sodium

Hydroxide

Sodium Hypo

Chloride

Sodium Chloride

Water

MW 71 80 74.5 58.5 18



Process Flow Diagram The process flow diagram for manufacturing of Phosphorus Tri Chloride is given

in Figure 2.1:

Figure 2.1: Process Flow Diagram for Phosphorus Tri Chloride

Cl2 (778 kg)

Phosphorous (228 kg)

10 % Caustic Solution (12.18 kg)

Vent

To ETP

(44.99 kg)

Effluent

PCl3 – Product (1000 kg)

Alkali

Scrubber

Reactor

Condenser

Water for scrubber-26.81 KG



Mass Balance for Manufacturing of Phosphorus Tri Chloride Mass balance for manufacturing of Phosphorus Tri Chloride is given below:

INPUT QUANTITY Kgs/MT

PHOSPHORUS TRICHLORIDE

(1000 Kg)

OUTPUT QUANTITY Kgs/MT

Phosphorous 228.00 PRODUCT

Chlorine 778.00 Phosphorous Trichloride

1000.00

32% Caustic Lye 12.1875 RECOVERY

Water 26.8125 Nil --

BY-PRODUCT

Nil --

EFFLUENT GENERATION

To ETP

Stream I: From Scrubber Water (35.98) + NaOCl (3.63) + NaCl (2.84) + Phosphorus (2.55)

44.993

AIR POLLUTION (From Process Vent)

Cl2 0.007

HAZARDOUS WASTE GENERATION

Nil --

TOTAL 1045.00 TOTAL 1045.00

2.3.2 Phosphorous Oxychloride (POCl3) Liquid Phosphorus Trichloride reacts with oxygen to form Phosphorus

Oxychloride. The reaction mixture containing impurities and Phosphorus

Oxychloride is purified in a distillation column. From the top of column

Phosphorus Oxychloride vapors are condensed and collected in a receiver. All

the vents from reactor, receiver and storage tanks are connected with the

scrubber where all the vent gases are scrubbed using 10% caustic solution.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Phosphorous Oxychloride

are given below:



PCl3

+

½ O2

POCl3

Phosphorous Trichloride

Oxygen Phosphorous Oxychloride

MW 137.5 16 153.5

Process Flow Diagram The process flow diagram for manufacturing of Phosphorous Oxychloride is

given in Figure 2.2:

Figure 2.2: Process Flow Diagram for Phosphorous Oxychloride

PCL3 (923 kg)

Oxygen (125 kg)

10 % Caustic Solution (32.53 kg)

Vent

To ETP

(131.08 kg)

Effluent

POCl3 – Product (1000 kg)

Alkali

Scrubber

Reactor

Condenser

Column

Water- 71.57 kg



Mass balance for manufacturing of Phosphorous Oxychloride is given below:

Input Quantity (kg/t)

POCl3 (1000

kg)

Output Quantity (kg/t)

PCl3 923 PRODUCT

Oxygen 125 Phosphorus oxychloride

1000

32% NaOH Solution for Scrubber

32.53 BY PRODUCT

Water for Scrubber 71.57 Nil Nil

RECOVERY

Nil Nil

TO ETP

Scrubbing liquor

131.08

TO AIR (FROM SCRUBBER)

HCl 0.02

Oxygen 21

TO HAZARDOUS WASTE

Nil Nil

TOTAL 1152.1 TOTAL 1152.1

2.3.3 Phosphorus Acid (Crystal)

The process consists of reacting Phosphorus Tri Chloride with controlled

addition of water to produce crude Phosphorus Acid solution. The crude

Phosphorus acid thus formed is then stripped with hot air to remove entrapped

HCl in it. The purified Phosphorus acid is then crystallized and centrifuged.

HCl gas generated is absorbed with water in absorber to get by-product 30%

liquid Hydrochloric Acid. The vent gases from HCl absorber are taken to

scrubber and scrubbed with alkali and taken to ETP

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Phosphorus Acid (Crystal)

are given below:

PCl3 +

3H2O

30% HCl

H3PO3 +

3HCl


Water Phosphorus

Acid Hydrogen Chloride

MW 137.5 54 82 109.5



Chemical reaction of Excess Phosphorous Trichloride

PCl3 +

3H2O

H3PO3 +

3HCl


Water Phosphorus


MW 137.5 54 82 109.5

Chemical reaction at Scrubber

HCl

+

NaOH

NaCl

+

H2O

Hydrochloric

Acid Sodium

Hydroxide Sodium Chloride Water

MW 36.5 40 58.5 18

Process Flow Diagram The process flow diagram for manufacturing of Phosphorus Acid (Crystal) is


Figure 2.3: Process Flow Diagram for Phosphorus Acid (Crystal)



Mass balance for manufacturing of Phosphorus Acid (Crystal) is given below:

Input Quantity

Phosphorous Acid Crystal

1000kg

Output Quantity

Phosphorous Trichloride 1720 Product

Water 4121.588 Phosphorous Acid crystal 1000

32% Caustic Lye 228.66 By Product

30% HCl 4228.64

To ETP

Effluent 841.61

Total 6070.25 Total 6070.25

2.3.4 Phosphorus Acid (60% Solution) Manufacturing Process Phosphorus Acid (60% Solution) process consists of reacting Phosphorus Tri

Chloride with controlled addition of water to produce crude Phosphorus Acid

solution. The crude Phosphorus acid thus formed is then stripped with hot air

to remove entrapped HCl in it. The purified Phosphorus acid is then crystallized

and centrifuged. The mother liquor containing Phosphorus Acid is diluted to get

60 % solution or is recycled back into the process.

HCl gas generated is absorbed with water in absorber to get by-product 30%

liquid Hydrochloric Acid. The vent gases from HCl absorber are taken to

scrubber and scrubbed with alkali and taken to ETP.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Phosphorus Acid (60%

Solution) are given below:

PCl3 +

3H2O

30% HCl

H3PO3 +

3HCl


Water Phosphorus


MW 137.5 54 82 109.5



Chemical reaction of Excess Phosphorous Trichloride

PCl3 +

3H2O

H3PO3 +

3HCl


Water Phosphorus


MW 137.5 54 82 109.5

Chemical reaction at Scrubber

HCl

+

NaOH

NaCl

+

H2O

Hydrochloric

Acid Sodium

Hydroxide Sodium Chloride

Water

MW 36.5 40 58.5 18

Process Flow Diagram The process flow diagram for manufacturing of Phosphorus Acid (60% Solution)

is given in Figure 2.4:

Figure 2.4: Process Flow Diagram for Phosphorus Acid (60% Solution)



Mass balance for manufacturing of Phosphorus Acid (60% solution) is given

below:

Input Quantity

Phosphorous Acid 60%sol

1000kg

Output Quantity


1032 Product

Water 4809.25 Phosphorous Acid (60%)

1000

32% Caustic Lye

229 By Product

30% HCL 4228.64

To ETP

Effluent 841.61

Total 6070.25 Total 6070.25

2.3.5 Dipotassium Hydrogen Phosphate (DPMP) The main process consists of reacting Phosphorus Acid with Potassium

Hydroxide in presence of water. After neutralization is completed, the reaction

mass is diluted with water to get required concentration. There is no effluent

generation from the manufacturing of Dipotassium Hydrogen Phosphate.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Dipotassium Hydrogen

Phosphate (DPMP) are given below:

H3PO3 + 2KOH → K2HPO3 + 2H2O

82 112 158 36

Process Flow Diagram The process flow diagram for manufacturing of Dipotassium Hydrogen

Phosphate (DPMP) is given in Figure 2.5:



Mass balance for manufacturing of Dipotassium Hydrogen Phosphate (DPMP)

is given below:

Input Quantity (kg)

Di Potassium Hydrogen

Phosphate sol

Output Quantity (kg)

Phosphorous Acid

423 Product

Potassium Hydroxide

577 Di Potassium Hydrogen Phosphate (81%)

1000

Total 1000 Total 1000

2.3.6 Ammonium Sulphate Dilute Ammonium Sulphate solution containing about 40% sulfuric acid is

charged into the reactor and start cooling water circulation in the jacket.

Ammonia gas is purged slowly by maintaining temperature to a maximum of

80 °C. The reaction is exothermic and controlled by external cooling. Ammonia

gas addition is continued till the reaction mass pH reaches between 7 – 7.5.

The reactor is connected to a Ventury scrubber to absorb the unreacted

ammonia gas.

Figure 2.5: Process Flow Diagram for Dipotassium

Hydrogen Phosphate



The reaction mass is then allowed to cool up to 30 – 35 oC and then taken for

filtration in the centrifuges. The solid product ammonium Sulphate powder is

packed in 50 kg woven bags. The mother liquor from the centrifuge is recycled

into another reactor for evaporation and 2nd crop recovery. The water is

evaporated under vacuum. The water vapours are condensed and collected

separately into a receiver and then transferred to oxidation & recycling. After

sufficient removal of water through evaporation, the reaction mass is cooled up

to 30 – 35 °C and then sent for filtration in centrifuge. The solid product

Ammonium Sulphate is packed in 50 kg woven bags. The mother liquor is mixed

with the new ML coming from the centrifuge after the 1st crop and sent for

further evaporation as above. The ML is kept on recycling for evaporation.

After about few batches of 2nd crop recovery, 0.2 m of ML / m of AMS is purged

& sent for incineration. Water from the Ventury scrubber & condensed water

from evaporation stage is taken to oxidation treatment for COD reduction with

suitable oxidizing agent & treated water is recycled back into process.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Ammonium Sulphate are

given below:

H2SO4

+

2 NH3

(NH4)2SO4

Sulfuric Acid

Ammonia

Ammonium Sulphate

MW 98 2*17 = 34 132

Process Flow Diagram The process flow diagram for manufacturing of Ammonium Sulphate is given in

Figure 2.6:



Mass balance for manufacturing of Ammonium Sulphate is given below:

2.3.6.1 Ammonium Sulphate (Purification)

The process of purification of Ammonium Sulphate is given below: 1. Charge crude Ammonium Sulphate in to ANF.

Input Quantity (Kgs)

Ammonium Sulphate 1000 kg

Output Quantity (Kgs)

Sulphuric acid (40%)

1670 Ammonium Sulphate 90%

1000

Ammonia Gas 240

Water 200

Distilled Water to Oxidation & recycle

910

Purged ML to common

incineration facility 200


Figure 2.6: Process Flow Diagram for Ammonium Sulphate

NH3 Gas

Water Vap.

Reactor

Centrifuge ML

Evaporator HE

Centrifuge

Receiver

ML

Ammonia Gas (240 kg)

Dilute Ammonium Sulphate soln with

@ 40% Sulphuric acid (1670 kg)

CONDENSATION, OXIDATION &

RECYCLING (910 kg)

Ammonium Sulphate (1000

kg)

Venturi Scrubber

Liquor Ammonia

Purged ML to INC.

(200 kg)

Water- 200kg



2. Charge required quantity of Methanol (fresh + recovered) in to the ANF.

3. Connect the vent of ANF to the heat exchanger with chilling water

circulation.

4. Stirrer the slurry for 30 mins by keeping the ANF drain valve closed.

5. Open the ANF drain valve & remove the ML.

6. Apply nitrogen pressure of 1.5 kg/ sq.cm into the ANF for filtration.

7. Charge required quantity of methanol as 1st wash.

8. Stir the slurry for 15 mins with drain valve closed.


10. Apply nitrogen pressure of 1.5 kg/sq. cm into the ANF for filtration.

11. Charge required quantity of methanol as 2nd wash.

12. Stir the slurry for 15 mins with drain valve closed.


14. Apply nitrogen pressure of 1.5 kg/ sq.cm into the ANF for filtration.

15. Ensure complete drainage of the ML and then start unloading of solids into

bags.

16. Charge wet cake into a RVD connected thru’ a heat exchanger with chilling

water circulation.

17. Maintain a temperature of @ 40oC in RVD using hot water.

18. Ensure complete drying of the solids and then unload the solids & pack it

into 50 kgs woven bags for sales.

19. Collect methanol from the receiver of the ANF & RVD after the HE & all

ML in collection tank to a reactor connected with a receiver thru a HE with

chilling water circulation and flash distill out methanol. Recovered

Methanol to be stored & used in consequent batches.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Ammonium Sulphate

(Purification) are given below:

(NH4)2SO4

+

CH3OH

(NH4)2SO4

+

CH3OH

Crude AMS Methanol Pure AMS

Impure Methanol

MW 132 32 132 32



Process Flow Diagram The process flow diagram for manufacturing of Ammonium Sulphate

(Purification) is given in Figure 2.7.

Mass balance for manufacturing of Ammonium Sulphate (Purification) is given

below:

Input Quantity

(KGS)

Ammonium Sulphate 1000 kg

Output Quantity

(KGS)

Crude AMS 1060 Pure Ammonium

Sulphate 1000

Methanol 2652.52 Recovered MeOH 2632.95

MeOH & Water

Loss 79.57

TOTAL 3712.52 TOTAL 3712.52

CHWR MeOH Vapours

CHWS

ML SOLIDS

MeOH Vapours (79.57 kg) CHWR

CHWS

CHWR ST. CHWS COND.

Methanol (2652.52 kg) Crude Ammonium Sulphate (1060 kg)

ANF

RVD Heat Exchanger

Reactor MeOH Rec

Ammonium Sulphate (1000

kg)

Heat Exchanger

Impure MeOH

Heat Exchanger

Recovered MeOH for Reuse

(2632.95 kg)

Figure 2.7: Process Flow Diagram for Ammonium

Sulphate (Purification)



2.3.7 Ammonium Chloride

The manufacturing process of Ammonium Chloride is given below: Charge spent HCl = 712.5 kg

Charge wet ammonium chloride = 463 kg

Cool to 20 oC

Purge Ammonia Gas till pH become Neutral

Stir for 30 min

Filter the mass

Quantity of wet ammonium chloride: 740 kg

Quantity of ML: 435.5 kg (send it for evaporation)

Dry weight of Ammonium Chloride= 682kg

Purity 90-94%, LOD 1-3%,

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Ammonium Chloride are

given below:

NH3 + HCl NH4Cl

17 36.5 53.5

Process Flow Diagram The process flow diagram for manufacturing of Ammonium Chloride is given

Figure 2.8:



Mass balance for manufacturing of Ammonium Chloride is given below:

Input Quantity (kg)

Ammonium Chloride 1000kg


Product

Spent HCl 1044.72 Ammonium Chloride 1000

Ammonia 39.20 To Crystallization

ML 83.92

Total 1083.92 Total 1083.92

Figure 2.8: Process Flow Diagram for Ammonium Chloride



2.3.8 Metribuzin (Alternate Route)

Triazinone to Metribuzin STEP – 1: Methyl Bromide Generation Methanol & Sodium Bromide slurry is charged and apply heating start addition

of 98% sulfuric acid, purge the generated Methyl bromide gas continuously &

adding 10% C.S Lye to the Na- Triazinone slurry below. After completion of

sulfuric acid addition for generating required MeBr, add CS Lye to neutralize

the mass. Material is then filtered to obtain sodium Sulphate as bye-product,

packed in bags for sales. The mother liquor so obtained is sent for batch

evaporation. After filtration, the solid obtained is packed as sodium Sulphate

for sales & ML is recycled back for evaporation mixed with ML from 1st filtration.

STEP – 2: Metribuzin Reaction Charge fresh water, distillate from RVD and Triazinone in reaction kettle with

stirring and chilling. Charge 32% CS Lye & stir. Charge bleaching agent and

Defoamer. Adjust pH of mass as required by adding 10% CS Lye. Start purging

of MeBr from step – 1 above. After completion of MeBr purging, the reaction

mass is then filtered to obtain wet cake of Metribuzin. The wet cake is then

dried in RVD. Distillate so obtained from RVD is recycled back to Step – 2. ML

containing dilute NaBr obtained from filtration is taken for concentration.

Concentrated NaBr is charged back into Step – 1. Water obtained from the

concentration is sent to ETP for treatment.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Metribuzin (Alternate route) are given below:

CH3OH NaBr 1/2H2SO4 CH3Br 1/2Na2SO4 H2O

Methanol Sodium

Bromide Sulfuric Acid MeBr

Sodium

Sulfate Water

32 103 49 95 71 18

7H12N4OS NaOH CH3Br

C8H14N4OS NaBr H2O

Triazinone C.S lye MeBr Metribuzin Sodium bromide

Water

200 40 95 214 103 18



Process Flow Diagram The process flow diagram for manufacturing of Metribuzin (Alternate route)

is given in Figure 2.9:

Mass Balance for manufacturing of Metribuzin (Alternate Route) is given below:

INPUT Quantity (Kg)

Metribuzin

OUTPUT Quantity (kg)

Sodium Bromide 559 Product

Methanol 210 Metribuzin 1000

Sulfuric Acid 98% 408 Recovery

Water 3500 Methanol 36

Triazinone 1177 Na2SO4 583.4

C. S. Lye 578 To NaBr Concentration &

recycle

SBS 11 NaBr 4044.74

2-Ethyl Hexanol 7 To ETP

Distillate 745

Incineration

Residue 40.86

TOTAL 6450 TOTAL 6450

Figure 2.9: Process Flow Diagram for Metribuzin

(Alternate Route)



2.3.8.1 Metribuzin (Existing Route) Triazinone to Metribuzin Charge water and Triazinone in reaction kettle with stirring and chilling. Charge

32% caustic soda lye & stir. Charge bleaching agent and defoamer. pH of mass

is adjusted as required adding 10% caustic soda lye.

Methyl Bromide Generation: Charge methanol and Sulfur powder & apply

heating start addition of Bromine. Purge the generated Methyl Bromide gas

continuously into the above reaction kettle & add 10% caustic soda lye to adjust

the pH. Complete addition of bromine. Filter the slurry, wash & dry the wet

cake.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Metribuzin (Existing Route)

are given below:

Process Flow Diagram The process flow diagram for manufacturing of Metribuzin (Existing Route) is

given Figure 2.10:

6CH3OH S 3 Br2

6CH3Br H2SO4 2H2O

Methanol Sulfur Br MeBr Sulphuric acid

Water

6*32 32 3*160 6*95 103 2*18

C7H12N4OS NaOH CH3Br

C8H14N4OS NaBr H2O

Triazinone C.S lye MeBr Metribuzin Sodium bromide

Water

200 40 95 214 103 18



Figure 2.10: Process Flow Diagram for Metribuzin (Existing Route)



Mass balance for manufacturing of Metribuzin (Existing route) is given below:

Input Quantity

(Kg)

Metribuzin (1000 kg)

Output Quantity

(kg)

Bromine 162 Product

Methanol 207 Metribuzin 1000

Sulphur 36 By-product

Water 8200 NaBr 5000

Recovery & Recycled

Triazinone 1069 Spent Acid 200

C. S. Lye 485 Wash ML 3774

SBS 15 Methanol 201

2-Ethyl Hexanol 7 HW to CHWTSDF

Chlorine 305 Incineration 200

*Methanol as Raw material 195 Landfill

300

Vent to Air

Methanol 6


UPL will produce Metribuzin either through old route or new route process.

2.3.9 Acephate

Dimethyl Phosphorous Amido Thionate (DMPAT) is isomerized to

Methamediphos catalytic reaction at 30 oC and atmospheric pressure. After

isomerisation, the mass is reacted with acetic anhydride at 40 oC in the

presence of Dichloromethane as solvent. It is neutralized with aqueous

ammonia. The layers are separated and aqueous layer is transferred to effluent

treatment plant. The organic layer is taken in another reactor for

dichloromethane recovery and Acephate separation.

Recovered Dichlormethane is recycled in the next batch and Acephate solution.

It is centrifuged at 50 oC and taken further for purification in another reactor

and dissolved in isopropyl alcohol. Ethyl acetate is recovered from the mother

liquor of crude. Acephate cake and it is recycled. The residue is incinerated.

Isopropyl alcohol and Acephate are taken in an agitate nutche filter. The cake

is dried in rotary vacuum dryer. The solvent isopropyl alcohol is recovered from

the mother liquor and recycled in next batch. The dry Acephate is filled in bags

as final packing.



Preparation of Acetic acid and Ammonium Sulphate from Ammonium

Acetate:

1. Take Ammonium acetate in reactor.

2. Start addition of H2SO4 (98 %) in reactor with Ammonium acetate by

applying cooling in reactor jacket.

3. Maintain temperature of maximum 75 °C during addition.

4. After completion of addition start Acetic acid recovery under vacuum.

5. Recovery to be continued till maximum temperature of 95 °C and

vacuum700mm HG.

6. After recovery cool the mass to 35-45 °C.

7. Recovered Ammonium Sulphate is to be packed in bags.

Preparation of Sodium Acetate from Acetic acid: 1. Take Acetic acid in reactor.

2. Start addition of Sodium hydroxide (48%)in reactor with Acetic acid by

applying cooling in reactor jacket.

3. Maintain temperature of maximum 50°C during addition.

4. After completion of addition cool the mass to room temperature and fill in

tanker.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Acephate are given below:

C2H8O2SPN ISOMERISATION

MDC SOLVENT C2H6O4S

DMS (164)

C2H8O2NPS

DMPAT MMD

141 141

C2H8O2NPS + C4H6O3

Acetylation

C4H10O3SPN + C2 H4O2

MMD Acetic Anhydride

Acephate Acetic

Acid

141 102 183 60



CH3COOH + NH4OH

H2SO4

CH3COONH4 + H2O

Acetic Acid Ammonium Hydroxide

Ammonium Acetate

Water

60 35 77 18

2NH4OH + H2SO4

(NH4)2SO4 + 2H2O

Ammonium Hydroxide

Sulphuric Acid

Ammonium Sulfate

Water

70 98 132 2*18

2NH4CH3CO2 + H2SO4

(NH4)2SO4 + 2CH3COOH

Ammonium Acetate

Sulphuric Acid

Ammonium Sulphate

Acetic Acid

154 98 132 2*60

CH3COOH + NaOH

C2H3NaO2 + H2O

Acetic Acid Sodium Hydroxide

Sodium Acetate

Water

60 40 82 18

Process Flow Diagram The process flow diagram for manufacturing of Acephate is given Figure 2.11.

Figure 2.11: Process Flow Diagram for Acephate



Mass balance for manufacturing of Acephate is given below:

INPUT QUANTITY

Kg/Ton

Acephate

(1000 Kg)

OUTPUT QUANTITY

Kg/Ton

MDC 6500 PRODUCT

DMPAT 921.05 Acephate 1000

DMS 164 RECOVERY

H2SO4(98%) 54 Ethyl Acetate Solvent 1740

Acetic Anhyd 610.84 MDC Solvent 6371

NH3 Solution(17%) 1176 BY-PRODUCT*

Ethyl Acetate 1760 Ammonium Acetate(35%) 1556.7

Water 120 OR

H2SO4* 370 Acetic Acid (30%)OR 1416

Caustic (48%)* 590 Acetic Acid (45%) OR 944

Water* 152 Acetic Acid (99%) 429

AND

Ammonium Sulphate (90%) 519

OR

Ammonium Sulphate (90%) 519

Sodium Acetate (27%) 2150

INCINERATION WASTE GENERATION

Stream:1 Organic waste to

incinerator

(DMS+DMPAT+MDC+Acetic

Anhydrate)

574.79

LOSS

Water Vapour 15

MDC Solvent Traces 28



Ethyl Acetate Solvent Traces 20

SOLID WASTE GENERATION

Nil


2.3.10 Triazinone

Manufacturing Process Step I: Pinacolone to Dichloropinacolone Charge Pinacolone and start apply chilling up to 5 °C. Purge chlorine slowly by

maintaining temperature between 5-10 °C. The reaction is exothermic and

controlled by external cooling. Temperature of reaction mass is raised to 40 °C

and evolved HCl gas to be scrubbed in water and recover 30 % HCl as a by-

product. Vent of water scrubber is connected to common caustic scrubber.

Purge remaining chlorine by maintaining temperature between 65 °C.

Step II: Hydrazine Hydrate to Thiocarbonohydrazide Charge Hydrazine hydrate and catalyst. Apply chilling and cool up to 5 oC then

charge gradually CS2 at 5 oC. Make 25% caustic lye solution for H2S gas to

common caustic scrubber. After charging of CS2 start addition of 48% CS Lye

by maintaining temperature up to 10 oC. During cooking hydrogen sulphide is

liberated which is scrubbed in aqueous alkali. Charge remaining CS2 at 25 oC

and cooking at 60 oC. Cool to 30 oC and filter the solid. Generated H2S gas is

then reacted with caustic lye to produce 30% NaSH solution as a by-product

and water. ML obtained during the filtration is filled in drums & sent to TSDF

for incineration.

Step III: Dichloropinacolone To Triazinone A) Dichloropinacolone to Kito Acid Charge water and 48% Caustic Soda Lye under stirring and heat it to 40°C.

Add Dichloropinacolone slowly by maintaining temperature between 30 °C. Cool



reaction mixture. Add Sodium hypochlorite solution slowly by maintaining

temperature 50°C.

B) Keto Acid to Triazinone Charge water, conc.H2SO4 and TCH solid under stirring. Heat the reaction mass

to 80°C. Start addition of Keto acid solution at temperature 80°C. After

completion of Keto acid addition add conc. H2SO4. Maintain the reaction mass

at temperature 70-75°. Cool the reaction mass to 10°C and filter, Wash with

water and dry it.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Triazinone are given below: STEP I:

C6H12O

+

2 Cl2

C6H10OCl2 +

2 HCl

Pinacolone

Chlorine

Dichloropinacolone HCl gas

MW 100 2*71 169 2*36.5

STEP II:

CS2

+

2 N2H6O

N4H6CS

+

H2S H2O

Carbon

disulphide Hydrazine Hydrate

Thiocarbonohydrazide Hydrogen Sulphide

Water

MW 76 2*50 106 34 2*18

H2S to NaSH Generation:

H2S

+

NaOH

NaSH +

H2O

Hydrogen Sulphide

Caustic

Sodium HydroSulphide Water

MW 34 40 56 18

STEP III:

C6H10OCl2 3*NaOH H2O

C6H11O3Na 2*NaCl 2*H2O

Dichloropinacholone Sodium

hydroxide water

Hydroxy mix

Sodium chloride

Water

169 3*40 18 154 2*58.5 2*18



C6H11O3Na NaOCl

C6H9O3Na NaCl H2O

Hydroxy mix Sodium Hypo

Chloride Keto Acid Sodium chloride Water

154 74.5 152 58.5 18

C6H9O3Na N4H6CS 0.5*

H2SO4

C7H12N4OS 0.5*Na2SO4 2*H2O

Keto Acid Thiocarbonohydrazide Sulfuric

Acid Triazinone

Sodium Sulphate

Water

152 106 0.5*98 200 0.5*142 2*18

Process Flow Diagram The process flow diagram for manufacturing of Triazinone is given in Figure

2.12, Figure 2.13 and Figure 2.14.

STEP I: Pinacolone to Dichloropinacolone STEP II : Hydrazin Hydrate to Thiocarbonohydrazide

Figure 2.12: Process Flow Diagram for Triazinone (Stage I)



Figure 2.13: Process Flow Diagram for Triazinone (Stage II)



Figure 2.14: Process Flow Diagram for Triazinone (Stage III)



Mass balance for manufacturing of Triazinone is given below:

Input Quantity (kg)

Triazinone 1000 kg


Pinacolone 610 Product

Chlorine Gas 870 Triazinone 1000

Hydrazide hydrate 750 By-Product

Catalyst – 1 1 HCL 1859

Catalyst - 2 18 30% NaSH sol 1300

Carbon Di Sulfide 537 Recycled

48 % Caustic Lye 1800 Wash ML 5471

Sodium Hypo Chloride

4500 To CHWTSDF

Sulphuric Acid 758 Landfill 2100

Water 3236 Incineration 1200

To air

Moisture in Drying

150


2.3.11 Glyphosate Acid Technical

STEP: 1 DSIDA PREPARATION Take water, DEA, 32% caustic lye and catalyst in a pressure reactor. Maintain

the reaction temp. 160 OC and pressure at 10 kg/cm2(g). DSIDA formation takes

place with total conversion of 90%. Hydrogen gas is vented to flaring system

during the reaction. Catalyst is filtered at 70 OC and recycled in the next batch

as such.

STEP: 2 DSIDA Conversions to PMIDA Transfer DSIDA from step 1 to another reactor and add PCl3 at 30oC and reflux

at 100 oC. Add formaldehyde at 100-110 oC. After the completion of reaction,

cool the mass to 30 oC and centrifuge the crystals (PMIDA). Mother liquor is

separately taken for the neutralization and evaporation. The cake is washed

with water and washed water taken to ETP. The reactor will be connected to

suitable scrubbing system.



STEP – 3 PMIDA TO GLYPHOSATE Wet PMIDA, is reacted with aqueous Ammonia to form a salt of PMIDA, which

is completely soluble in water. Then add catalyst and in presence of compressed

clean air, Oxidation is carried out. Catalyst is separated in filtration and recycled

in next batch. The filtrate is neutralized with H2SO4 and Glyphosate is

precipitated at low temperature. It is dried with hot air and product is packed.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Glyphosate Acid Technical

are given below



Process Flow Diagram The process flow diagram for manufacturing of Glyphosate Acid Technical is

given in Figure 2.15 to Figure 2.17:

Figure 2.15: Process Flow Diagram for Glyphosate

Acid Technical (Stage I)

Figure 2.16: Process Flow Diagram for

Glyphosate Acid Technical Stage II



Figure 2.17: Process Flow Diagram for Glyphosate

Acid Technical Stage III



Mass balance for manufacturing of Glyphosate Acid Technical is given below:

Input Quantity (kg)

Glyphosate (1000 kg)


DEA 750 PRODUCT

NaOH 1800 Glyphosate 1000

Fresh water 6438 BY-PRODUCT

Catalyst 2910 Ammonium Sulphate Soln. (15 %) OR Solid

4736 / 710

PCl3 1360

HCHO 780 RECOVERY

HCl 560 Catalyst Recycle 2880

NaOH 2600

Excess Air 4600 TO ETP

NH3 Solution 390 water generated 107

Recycle Water 1550

decomposition products of excess PCL3 546

H2SO4 550 Un. DEA 90

Air For Catalytic Converter. 1471 Wash water 1500

Wash water 1250 Water 2830

TO EVAPORATOR

Sodium chloride 692

HCl 216

NaOH 387

30 % HCl 560

Un. DEA 40

Caustic lye 2600

TO AIR

H2 47

Excess air 4146

CO2 781

Un. Oxygen 1105

NH3+HC 0.12

LOSSES

Moisture 966

HAZARDOUS WASTE

To Incinerator 1750

Catalyst Purge 30




2.3.12 Di Chlorvos (DDVP)

Manufacturing Process Raw material Chloral is taken in the reactor and then reaction mass is heated

to 40oC. Then Tri methyl Phosphite (TMP) added by maintaining the

temperature at 40-45oC continuous for 3-4 hours. After completion of addition

of TMP, reaction mass is stirred for half an hour and under vacuum of 750 –

755mm Hg to get DDVP tech. Methyl Chloride generated during the reaction is

compressed and filled in cylinders and stored as by-product and transferred to

our own units as RM or sold as a product in open market.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Di Chlorvos (DDVP) are

given below:

CCl3CHO

+

(CH3O)3 P

C4H7O4Cl2P

+

CH3Cl

Chloral TMP DDVP Methyl Chloride

MW 147.5 124 221 50.5

Process Flow Diagram The process flow diagram for manufacturing of Di Chlorvos (DDVP) is given in

Figure 2.18:

Figure 2.18: Process Flow Diagram for Di Chlorvos



Mass balance for manufacturing of Di Chlorvos (DDVP) is given below:

Input Quantity (Kg/Ton)

DDVP Manufacturing

1000 KG

Output Quantity (Kg/Ton)

Chloral 686.00 Product

TMP 568.00 DDVP 1000.00

Recovery

Nil

By Product

Methyl Chloride 228. 50

Effluent Generation

Nil 0

Air Pollution

Nil Nil

Hazardous Waste (To

Incinerator)

Stream I: To Incinerator

From DDVP Purification Process Waste –TMP (7) + Chloral (18.5)

25.50


2.3.13 Asulam (Methyl Sulfanilyl Carbamate)

Manufacturing Process Raw materials Dimethyl Carbonate, Sodium Methoxide and Sulfanilamide are

charged in the reaction vessel at room temperature. Reaction mass is heated

up to reflux temp of 68°C slowly and is maintained at reflux temperature for

some time. After completion of the reaction, methanol contained in the mass is

recovered by steam and vacuum distillation. Balance mass in the reactor after

removal of methanol is transferred to storage tank as product.

Recovered Methanol along with water is sent for methanol distillation where

ethanol is purified and the waste water is sent for treatment to ETP.



Reaction Chemistry

Process Flow Diagram The process flow diagram for manufacturing of Asulam is given in Figure 2.19:

Mass Balance for Manufacturing of Asulam is given below:

Input Quantity

(Kg)

Asulum 1000 Kg

Output Quantity

(Kg)

Sulfanilamide 704 Product

Sodium methoxide

221 Asulum (Methyl Sulfanilyl Carbamate)

1000

DMC 368 By product

Water 200 Methanol 246

Loss

Methanol 8

To ETP

Effluent 239


C6H8N2SO2 + NaOCH3 + C3H6O3 C8H9N2SO4Na + 2CH3OH 172 54 90 252 64 Sulfanilamide Sodium Dimethyl Asulam Methanol Methoxide Carbonate

Figure 2.19: Process Flow Diagram for Asulam



2.3.14 Clomazone

Manufacturing Process STEP-1: 3-Chloro –N-Hydroxy 2,2-Dimethyl Propanamide Charge water and hydroxylamine Sulphate and adjust pH to 7-8 with caustic

lye. Add 3-CPC and caustic lye simultaneously to get Propanamide slurry and

use in next step.

STEP-2: 4, 4 Dimethyl Isoxazolidinone. Charge water and step-1 mass and under stirring add caustic lye & adjust pH

8-9, maintain for 4-5 hrs. Use 4, 4 DMI solutions for step-3.

STEP-3: Clomazone Charge 4,4 DMI solution, catalyst, Na2CO3 and add OCBC and maintain for 5-6

hrs. Cool reaction mass and separate aqueous layer and organic mass. SOCl2

or HCl is added in organic mass and maintains for 4-5 hrs, add sodium

carbonate and caustic lye and heat mass and add water and maintain temp 70-

90 oC for 30 minutes, separate organic and aqueous layer. Dehydrate organic

mass by distillation to get Clomazone Tech.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Clomazone are given below:

Step - I

Step - II

STEP –2

C5H10ClNO2

+

NaOH

C5H9NO2 Na

+

NaCl

+

H2O

3Chloro-N-Hydroxy 2,2-Dimethylpropanamide

Caustic 4,4-Dimethyl isoxazolidin -3-one

(4,4-DMI) Sodium Chloride Water

MW 151.5 40 115 58.5 18

½ (NH2OH)2.H2S O4

+

NaOH

NH2OH +

½ Na2SO4 +

H2O

Hydroxy-

lamine Sulphate Caustic

Hydroxyl Amine Sodium Chloride Water

MW 82 40 33 71 18

C5H8Cl2O

+

NH2OH

+

NaOH

C5H10ClNO2

+

NaCl

+

H2O

3Chloro-2,2-Dimethylpropanoyl

Chloride Hydroxy- lamine

Caustic 3Chloro-N-Hydroxy 2,2-Dimethyl propanamide

Sodium Chloride Water

MW 155 33 40 151.5 58.5 18



Step – III

Step - IV

OR

Process Flow Diagram The process flow diagram for manufacturing of Clomazone is given in Figure

2.20:

Figure 2.20: Process Flow Diagram for Clomazone

C12H14NO2Cl

+

HCl

+

NaOH

C8H5Cl2NaO3

+

NaCl

+

H2O

Clomazone isomer Hydrochloric Acid Caustic Clomazone Sodium Chloride Water

MW 239.5 36.5 40 239.5 58.5 18

C12H14NO2Cl

+

SOCL2

+

2NaOH

+

H2O

C8H5Cl2NaO

3

+

SO2

+

2NaCl

+

2H2O

Clomazone

isomer Thionyl Chloride Caustic

Water Clomazone

Sulphur Dioxide

Sodium Chloride Water

MW 239.5 119 80

18 239.5

64 117 36

C5H8NO2 Na

+

C7H6Cl2

C12H14NO2Cl

+

NaCl

4,4-Dimethyl isoxazolidin-3-one

(4,4-DM) O-Chloro

Benzylchloride Clomazone isomer Sodium Chloride

MW 137 161 239.5 58.5



Mass Balance for Manufacturing of Clomazone is given below:

Input Quantity

(kg)

Clomazone 1000 kg

Output Quantity

(kg)

Product

Water for process 7427

Hydroxyl amine sulfate 626 Clomazone (94%) 1000

3Chloro-2,2-Dimethylpropanoyl Chloride

911 BY-PRODUCT/Land filling

32% NaOH 3890 Sodium Sulphate 416

Methanol (99%) 1609

98% H2SO4 303 Recovery

Dichloro methane (MDC)

2963 Methanol (50% w/w)

3120

Catalyst CE-227 9 MDC 2880

2-Chloro Benzylchloride (OCBC)

700 To atm after evaporation

11614

Na2CO3 powder 30

Thionyl Chloride (SOCL2)/HCL

49 To land filling

Water for scrubber 2590 Mixed Salt after evaporation

2047

Sodium Hypochloride (NaOCl) 12.5%

10

Distillation residue to incineration

40


2.3.15 Bensulfuron Methyl

Manufacturing Process Brief manufacturing process for Bensulfuron Methyl is given below: 1. Charge xylene and 4,6- Dimethoxy pyrimidine -2-amines.

2. Heat the reaction mass to 60 oC

3. Add solution of Methyl-2- {[Isocyanate sulfamoyl] Methyl} Benzoate in

xylene gradually over a period 2-3 hrs. at 60-65 oC

4. Maintain reaction mass at 60-70 oC for 10 hrs. and check the unreacted 4-6

Dimethoxy pyrimidine -2-amine



5. After completion of reaction, distill out xylene under vacuum 20 mm/Hg at

80 oC.

6. To the residue, add methanol and heat reaction mass to 60 oC for one hrs.

And cool it to room temperature for 2 hrs and filter the solid and wash with

methanol.

7. Dry the solid at 70 oC for 3 hrs Rxn. of Methyl-2- {[Isocyanate Sulfamoyl]

Methyl} Benzoate with 4, 6- Dimethoxy pyrimidine -2- Amine to form

Bensulfuran Methyl Tech.

Process Chemistry: Rxn of Methyl-2-{[Isocyanate Sulfamoyl] Methyl} Benzoate with 4, 6-

Dimethoxy pyrimidine -2- Amine to form Bensulfuran Methyl Tech.

Process Flow Diagram The process flow diagram for manufacturing of Bensulfuron Methyl is given in

Figure 2.21:



Figure 2.21: Process Flow Diagram for Bensulfuron Methyl



Mass Balance for Manufacturing of Bensulfuron Methyl is given below:

INPUT Quantity

Bensulfuron Methyl

1000 kg

OUTPUT Quantity

4, 6- Dimethoxy pyrimidine -2- Amine

418 Product

Methyl-2- {[Isocyanate sulfamoyl] Methyl} Benzoate

620 Bensulfuron Methyl

1000

Xylene 1600 Recovery

Methanol 2000 Xylene 1565

Methanol 1970

Loss

Xylene 30

Methanol 25

To incineration

Residue 48


2.3.16 Sulfosulfuron (SF-10) Manufacturing Process Brief manufacturing process for Sulfosulfuron (SF-10) is given below: STEP 1: ASAM(2-Chloroimidazo[1,2-a] pyridine-3-sulfamide) to ESPA

(2-Ethylthioimidazo[1,2-a] pyridine-3-sulfamide ) Ethyl Mercaptan (EM) is reacted with Sodium Hydride under suitable conditions

to give Na-EM and Hydrogen gas. Na-EA and ASAM are reacted to give

corresponding ESPA (2-Ethylthioimidazo[1,2-a] pyridine-3-sulfamide) and

Sodium Chloride.

STEP 2: ESPA (2-Ethylthioimidazo [1,2-a] pyridine-3-sulfamide) to ESPO (2-EthylSulfonylimidazo[1,2-a] pyridine-3-sulfamide) ESPA reacts with Hydrogen Peroxide in presence of catalyst, solvent & other

reaction conditions to give ESPO.

STEP 3: ADP to ADCP (4,6-Dimethoxy-2- (Phenoxy Carbonyl) amino) Pyrimidine)



ADP and PCF (Phenyl Chloro Format) are reacted in presence of catalyst,

solvent & other reaction conditions to give corresponding ADCP and

Hydrochloric Acid. Wet cake is dried and solvent is recycled.

STEP 4: ESPO ( 2-EthylSulfonylimidazo[1,2-a]pyridine-3-sulfamide) to SF-10 ESPO and ADCP are reacted to form Safener as a product. The product mixture

is the filtered and wet cake is washed with water. The aqueous ML and wash

ML are further treated. The wet cake obtained is dried to get desired product

SF-10.

Process Chemistry STEP 1: ASAM to ESPA

Formula C2H6S

+

NaH

C2H5SNa

+

H2

Name EM Sodium Hydride

EM-Na Hydrogen

Mol. Wt. 62 24 84 2

Formula C7H6ClN3O2S

+

C2H5SNa

C9H11N3O2S2

+

NaCl

Name ASAM EM-Na ESPA Sodium Chloride

Mol. Wt. 231.5 84 257 58.5

STEP 2 : ESPA to ESPO

Formula C9H11N3O2S2

+

H2O2

C9H11N3O4S2

+

H2

Name ESPA Hydrogen Peroxide

ESPO Hydrogen

Mol. Wt. 257 34 289 2

STEP 3 : ADP to ADCP

Formula C6H9N3O2

+

C7H5ClO2

C13H13N3O4

+

HCl

Name ADP PCF ADCP Hydrochloric

Acid

Mol. Wt. 155 156.5 275 36.5

STEP 4 : ESPO to SF-10

Formula C9H11N3O4S2

+

C13H13N3O4 C16H18N6O7S2

+ C6H6O

Name ESPO ADCP SF-10 PH-1

Mol. Wt. 289 275 470 94



Process Flow Diagram The process flow diagram for manufacturing of Sulfosulfuron (SF-10) is given

Figure 2.22:

Figure 2.22: Process Flow Diagram for Sulfosulfuron (SF-10)



Mass balance for manufacturing of Sulfosulfuron (SF-10) is given below

2.3.17 Metasulfuron Methyl Manufacturing Process

Brief manufacturing process for Metasulfuron Methyl is given below: 1. Charge xylene and 4-Methoxy -6-Methyl -2-amine 1, 3, 5-triazine.

2. Add solution of Methyl-2- [Isocyanate sulfamoyl] Benzoate in Xylene at

temperature of 30-35°C within one hr.

3. Mixture is stirred for 16 hrs at 30 oC and check for unreacted 4- Methoxy -6-

Methyl -2-amine 1, 3, 5-trizine.

4. After completion of reaction, distill out xylene under vacuum 20 mm/Hg at

80 oC

5. To the residue add methanol and heat reaction mass to 60 oC for one hr.

Cool to room temperature for 2 hrs and filter the solid and wash with

methanol.

6. Dry the solid at 60 oC for 3 hrs.

INPUT MASS

Sulfosulfuron SF-10

(1000 KG)

OUTPUT MASS

KG KG

DMF 2933 Product

EM 683 SF-10 1000

NaOH (60%) 442 To Evaporation

ASAM 903 ML 74875

Hexane 1725 Wash ML 9610

HCl 1458 Recycled Streams

Water 77546 Hexane Rec. 1674

Cat-700 3058 DMF Rec. 2846

H2SO4 2333 To Incineration

ADP 98% 498 ML 7088

DX-1 1400 WML 720

DX-2 682 Loss

P-1 862 Hexane Loss 51

Sol-1 202 DMF Loss 88

CAN 99% 2850

DBU 99% 377




Process Chemistry Reaction of Methyl-2-[Isocyanate sulfamoyl] Benzoate with 4-Methoxy -6-

Methyl -2-amine 1, 3, 5-triazine to form Metsulfuran methyl Tech.

Process Flow Diagram The process flow diagram for manufacturing of Metasulfuron Methyl is given in

Figure 2.23:

Figure 2.23: Process Flow Diagram for Metasulfuron Methyl



Mass balance for manufacturing of Metasulfuron Methyl is given below:

Input Quantity kg

Metasulfuron Methyl 1000kg


Sulfamoyl Isocynate 620 Product

Xylene 1600 Metasulfuron Methyl

1000

4-Methoxy -6- methyl -2 -amino 1, 3, 5 Triazine

405 Recovery

Methanol 2000 Xylene 1565

Methanol 1970

Loss

Xylene 30

Methanol 25

To Incineration

Residue 35


2.3.18 Pyrazosulfuron Ethyl

Manufacturing Process

Brief manufacturing process for Pyrazosulfuron Ethyl is given below: Stage-1: Reaction of 4, 6-Dimethoxy pyrimidine-2-amine reacts with Phenyl

Chloroformate to form Phenyl (4, 6-dimethoxypyrimidine-2-yl) carbamate.

Brief Procedure: 1. ADMP, 1, 4- Dioxane and N,N-Dimethyl aniline are charged to the reactor

with stirring and cool to 15°C.

2. Add phenyl chloroformate gradually within 1 hr at 20-25°C.

3. Reaction mass stirred for 20hrs at 30-35°C and check ADMP < 0.5%.

4. Distill Dioxane under vacuum 5 torr at 50°C.

5. Reaction mass is quenched in ice water, stir for 2 hrs& solid is filtered &

washed with water.

6. Sodium hydroxide is added to the filtrate to adjust pH 8 and then separate

the layers and aqueous layer further extract with fresh MDC.

7. Aqueous layer sent to effluent treatment plant.

8. Combined organic layer is distilled to recover N, N-Dimethyl aniline and MDC

for recycle in next batch.



9. Wet solid washed with isopropyl alcohol.

10. Solid is dried at R.T. for 5-6 hr.

Stage-2: Reaction of Phenyl (4, 6-dimethoxypyrimidine-2-yl)

carbamate with Ethyl-1- methyl-5-sulfamoyl-1H-pyrazole-4-

carboxylate to form Pyrazosulfuran Ethyl Technical.

Brief procedure is given below: 1. Ethyl-1- methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate, Phenyl (4, 6-

dimethoxypyrimidine-2-yl) carbamate & Acetonitrile are charged and cooled

to 15°C.

2. Add catalyst at 15°C then reaction mass stirred for 5 hr at 25°C. Acetonitrile

is distilled at 50°C under vacuum.

3. Residue is quenched in ice water and precipitated Solid product is filtered &

washed with water.

4. Filtrate is extracted by using MDC two times to recover phenol and combined

organic layer is distilled to recover MDC and phenol for recycle.

5. Aqueous layer sent to effluent treatment plant.

6. Product is purified from methanol & dried at 60-65 °C for 5 hrs.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Pyrazosulfuron Ethyl are

given below:

Stage I



Stage II

Process Flow Diagram The process flow diagrams for Stage I and Stage II manufacturing of

Pyrazosulfuron Ethyl are given in Figure 2.24 and Figure 2.25, respectively:

Stage-1: Reaction of 4, 6-Dimethoxy pyrimidine-2-amine reacts with Phenyl

Chloroformate to form Phenyl (4, 6-dimethoxypyrimidine-2-yl) carbamate.



Figure 2.24: Process Flow Diagram for Pyrazosulfuron Ethyl

(Stage I)



Stage-2: Reaction of Phenyl (4, 6-dimethoxypyrimidine-2-yl) carbamate with Ethyl- 1-

methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate to form Pyrazosulfuran Ethyl

Technical.

Figure 2.25: Process Flow Diagram for Pyrazosulfuron Ethyl

(Stage II)



Mass Balance for manufacturing of Pyrazosulfuron Ethyl is given below:

Input Quantity

(Kg)

Pyrosulfuron Ethyl

1000 kg

Output Quantity

(Kg)

Phenyl Chloromate 760 Product

4-6 Dimethoxy pyrimidine -2 amine

494 Pyrosulfuron Ethyl

1000

N, N Dimethyl aniline 588 Recovery

1,4 Dioxane 1456 1,4 Dioxane 1412

Water 3550 Methylene Dichloride

291

Isopropyl Alcohol (IPA) 1140 N,N Dimethyl Aniline

570

48% Caustic 408 Acetonitrile 1717

Methylene Dichloride 300 Iso Propyl Alcohol (IPA)

1106

Methanol 1067

Ethyl-1- methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate

595

Acetonitrile 1770 To Incineration

Catalyst 2 Residue 38

Methanol 1100 To ETP

Effluent 4703

By Product

Phenol 259


2.3.19 Azoxystrobin Manufacturing Process

Brief manufacturing process for Azoxystrobin is given below: Step-1 (MMBF) Mix the 2-Coumaranone, acetic anhydride & trimethyl orthoformate with stirring

heat the reaction mass with simultaneous distillation of low boilers & high

boilers with stirring. Crystallize the crude product from methanol. Then Recover

methanol from ML & remaining residue sent for Incineration.



Step-2 (MDCPP) 1) Mix the solid MMBF, 4, 6-DCP, trimethyl orthoformate & Catalyst. Then

added of 30% NaOCH3 solution at ambient temp., continue stirring after

reaction is over distilled out trimethyl orthoformate & methanol which is

recycled for next batch.

2) To the Concentrated reaction mass, add water & toluene. Separate organic

layer & again washed with KOH solution & separated. Then add methane

Sulphonic acid & heat & then wash with water & organic layer is concentrate

& residue is crystallized & solvent is recovered & residue sent for

Incineration.

Step-3 (Azoxystrobin) Mix the MDCPP & Cyanophenol, DMF, catalyst & K2CO3 with nitrogen

atmosphere heat reaction mass. After completion of reaction filter the salts

distilled out the solvent the crude product is crystallized from methanol &

residue after recovery of solvent sent for Incineration.

Process Chemistry



Process Flow Diagram The process flow diagrams for Step I, Step II and Step III manufacturing of

Azoxystrobin are given in Figure 2.26 to Figure 2.28, respectively:

Figure 2.26: Process Flow Diagram for Azoxystrobin Step I



Figure 2.27: Process Flow Diagram for Azoxystrobin Step II



Mass balance for manufacturing of Azoxystrobin is given below:

Figure 2.28: Process Flow Diagram for Azoxystrobin Step III



2.3.20 Asulox (Formulation)

Mass Balance for Manufacturing of Asulox is given below

Input Quantity (Kg)

Asulox 1000 kg


Asulam Tech. 919.12 Product

36% HCl 59.74 Asulox 1000

28% NaOH 30.33 To incineration

Solid Waste 9.19

Total 1009.19 Total 1009.19

2.3.21 Metribuzin Formulation

Manufacturing Process There is no chemical reaction or no processing involved, only product

formulation i.e. mixing of solid pesticide Technical product with various

ingredients like Surfactant, Filler material like silica, China Clay etc.

Input Mass

Azoxystrobin

(1000 KG)

Output Mass

KG KG

2 - Coumaranone 600 Product

Trimethyl

Orthoformate 2559.9 Azoxystrobin 1000

Acetic Anhydride 1300 Recycle

Methanol 2800

Mixture of Methyl Formate,

MeOH, Methyl Acetate,

Acetic Acid And Acetic

Anhydride

1018.45

4,6 - DCP 649.82 Methanol (71.7%) 3788

30% NaOCH3 800 Trimethyl Orthoformate 2498

Water 5839.7 Toluene Cut 2133.66

KOH Flakes 45 DMF 1900

Methane Sulfonic Acid 33 Ethyl Acetate 533

Toluene 2199.65 Landfillig

Ethyl Acetate 549.82 Inorganic Salts 630

Incineration

DMF 1959.9 Residue to Incineration 484

K2CO3 546.68 To ETP

2 - Cyno Phenol 351.9 Aqueous Effluent 5989.45

Solvent Loss

Methanol Loss 84

Trimethyl Orthoformate Loss 50.9

Toluene Loss 65.98

DMF Loss 59.9

TOTAL 20235.37 TOTAL 20235.37



Only physical operations are involved like Raw material charging, mixing and

packing of formulated products as per market requirements. The formulated

products will be either wet table powder or in the form of wet table granules.

Since there is no processing and only Physical operation are involved there is

no effluent generation.

Process Flow Diagram The process flow diagram for manufacturing of Metribuzin Formulation is given

in Figure 2.29:

Mass balance for manufacturing of Metribuzin formulation is given below:

Input Quantity

Metribuzin

70% WDG

Output Quantity

Metribuzin Tech.

(95 % to 44) 464.5

Metribuzin

70% WDG

1000

Surfactant – 1 19.9884



Defoamer 9.99

Biocide 0.964

Adjutants (For PH

adjustment) 0.0876

Gel 70.03

Q.S (D.M. Water) 340.93


Figure 2.29: Process Flow Diagram for Metribuzin Formulation



2.3.22Devrinol

Manufacturing Process

Brief manufacturing process for Devrinol is given below: STEP –1 Preparation of CPAM from 2-CPC DEA and Alpha CPA are reacted in Caustic solution to give Alpha CPAM 37 - 40 oC temperature is maintained during reaction. Reaction mixture is washed with

water. Aqueous layer is separated and send to Evaporator. Excess unreacted

EA is stripped off from organic. The recovered DEA is re-cycled to next batch.

For control HCL & CPA emission provided caustic scrubber.

STEP – 2 Preparation of Devrinol from CPAM Alpha CPAM is reacted with Alpha Naphthol and Caustic Lye in presence of

Toluene at 90 oC. The reaction mass is cooked at 103 – 105 oC under continuous

reflux. After completion of reaction, it is washed twice with hot water and

aqueous layer is separated for further treatment.

Toluene, residual water is evaporated in flash vessel and thin film evaporator

at 125 – 130 oC at 250 mm bar pressure. The product from thin film evaporator

is further treated with steam in a steam stripper to remove impurities. The

product is further crystallized in holoflite flakers and crushed in a crusher and

finally packed.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Devrinol are given below:



Process Flow Diagram The process flow diagram for manufacturing of Devrinol Formulation is given in

Figure 2.30:

STEP -1 Preparation of CPAM from 2-CPC

STEP –2 Preparation of Devrinol from CPAM

C3H4Cl2O

+

C4H11N

C7H14ClNO

+

HCl

2-CPC DEA Alpha CPAM Hydrochloric acid

MW 127 73 163.5 36.5

HCl

+

NaOH

NaCl

+

H2O

Hydrochloric acid Sodium Hydroxide Sodium Chloride Water

MW 36.5 40 58.5 18

C7H14ClNO

+

C10H8O

C17H21NO2

+

HCl

Alpha CPAM Naphthol Devrinol Hydrochloric acid

MW 163.5 144 271 36.5

HCl

+

NaOH

NaCl

+

H2O

Hydrochloric acid Sodium Hydroxide Sodium Chloride Water

MW 36.5 40 58.5 18



Mass balance for Manufacturing of Devrinol Formulation is given below:

Input Quantity

(kg)

Devrinol (1000

kg)

Output Quantity

(kg)

Alpha CPC 595 PRODUCT

DEA 391 Devrinol 1000

Toluene 1591 BY-PRODUCT

Caustic (46%) 593 Nil 0

Washwater-(1) 1000 TO RECOVERY

EDTA (50%) 2 Un. DEA 102

Napthol 602 Toluene 2690

Toluene 182 TO ETP

Sodium Bicarbonate 909 Nil 0

Figure 2.30: Process Flow Diagram for Devrinol



Wash water (II) 2000 TO AIR (From

Scrubber)

Toluene 1000 Nil 0

Caustic 1482 FUGITIVE

EMISSIONS

Toluene 43

TO HAZARDOUS WASTE

(Incinerator)

Organic Residue 315

TO HAZARDOUS WASTE (TSDF)

Salt from Eva.-1 348

Salt from Eva.-2 1659

LOSSES

Water (Evaporator) 4190


2.3.23Triphenyl Phosphite (TPPI)

Manufacturing Process Brief manufacturing process for Triphenyl Phosphite (TPPI) is given below: Charge Phenol into the reactor, heat up to 45 oC; add PCl3 slowly and generated

HCL gas is to be absorbed in scrubber. Start Nitrogen purging and heat up to

120 oC and maintain for six hours. Then apply vacuum and distill out the excess

Phenol. Cool up to 40 oC and filter the mass through sparkler filter and fill in

drum.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Triphenyl Phosphite (TPPI)

are given below:

Formula PCl3

+

3 C6H5OH

(C6H5) 3PO3

+

3 HCl

Name Phosphorous Trichloride

Phenol TPPI Hydrochloric

Acid

Mol. Wt. 137.5 282 310 109.5



Process Flow Diagram The process flow diagram for manufacturing of Triphenyl Phosphite (TPPI) is


Mass balance for manufacturing of Triphenyl Phosphite (TPPI) is given below:

Figure 2.31: Process Flow Diagram for Triphenyl Phosphite (TPPI)

INPUT MASS

TPPI

(1000 KG)

OUTPUT MASS

KG KG

PCl3 455 Product

Phenol 1290 TPPI 1000

Hyflow Powder 10 From HCl Scrubber

Water 916 30% HCl Solution 1118.56

32% Caustic Lye 60.5 Recycled Streams

Phenol 341.62

To Incineration

Hyflow with

impurities 11.36

To ETP

From Caustic Scrubber 222.58

Losses

Phenol Loss 37.38

TOTAL 2731.5 TOTAL 2731.5



2.3.24 Triphenyl Phosphate (TPPA)

Manufacturing Process Brief manufacturing process for Triphenyl Phosphate (TPPA) is given below:

Phosphorus oxy-chloride and Phenol charged in a reactor. The material heated

at about 180 oC in the reactor. Then take the crude into distillation column and

from column take two cuts. After this take washing for removing impurities,

then send it to flakers unit.

Stoichiometric Balanced Chemical Reaction The Stoichiometric balanced chemical reactions for Triphenyl phosphate (TPPA)

are given below:

POCl3

+

3(C6H5OH) C18H15

O4P

+

3HCl

Phosphorous Oxychloride

Phenol TPPA Hydrochloric Acid

MW 153.5 282 326 109.5

Process Flow Diagram The process flow diagram for manufacturing of Triphenyl Phosphate (TPPA) is


Figure 2.32: Process Flow Diagram for Triphenyl Phosphate

(TPPA)



Mass balance for manufacturing of Triphenyl phosphate (TPPA) is given below:

INPUT QUANTITY (kg/t)

TPPA (1000 kg)

OUTPUT QUANTITY (kg/t)

Phosphrous oxychloride

481 PRODUCT

Phenol 930 TPPA 1000

Water for HCl Scrubber

792 BY PRODUCT

NaOH Soln for Scrubber

80 30% HCl 1138

Wash water 1500 RECOVERY

Nil Nil

TO ETP

Stream-1:

Scrubbing liquor 80

Stream-2:

Wash water 1500

TO AIR (FROM SCRUBBER)

HCl 0.03

TO HAZARDOUS WASTE

Phenolic residue for Incineration 65

FUGITIVE EMISSIONS

Nil Nil


2.3.25 Potassium Chloride (Powder) (Existing & discontinued after proposed expansion)

Manufacturing process: By evaporation & crystallization converting Potassium Chloride solution in to potassium chloride (KCl) powder.

Chemical Reaction:

KCl solution Δ (heat)

KCl powder

74.55 74.55



Process Flow Diagram :

2.4 By Product List (Existing and After Expansion) The details of by-products quantity from existing manufacturing processes and

after expansion of UPL plant are presented in Table 2.2 & Section 2.2.

2.5 Raw Materials Requirements and Storage

The monthly requirements of raw materials for manufacturing of various

existing and proposed pesticide products after expansion of UPL plant are given

in Table 2.3. Details of maximum storage of raw materials at the plant are

given in Table 2.4. Raw materials to the plant are transported by using existing

road.

Reactor

(Evaporation & crystallization)

KCl solution-

3500 kg

KCl Powder-

1000 kg

Water evaporation- 2500 kg


Shivalik Solid Waste Management Ltd.

2-73

Table 2.3: Raw Materials Requirements for Existing Plant and after Expansion

Sr No

Product name Existing Capacity

MTM

Total Capacity After

Expansion MTM

Raw Material Name Consumption

(kg/MT of product)

Existing Consumption

MTM

Total consumption

after Expansion

MTM

1 Phosphorous Trichloride

75 425

White Phosphorous 228.00 17.1 96.90

Chlorine 778.00 58.4 330.65

32% Caustic for Scrubbing

12.19 0.9 5.18

2 Phosphorous Oxychloride

50 100

Phosphorous Tri Chloride 923.00 46.2 92.30

Oxygen 125.00 6.3 12.50

32% Caustic lye 32.53 1.6 3.25

3 Phosphorous Acid Crystal

10 75 Phosphorous Trichloride 1720.00 17.2 129.00

32% Caustic Lye 229.00 2.3 17.18

4 Phosphorous Acid sol (60%)

4 25 Phosphorous Trichloride 1032.00 4.1 25.80

32% Caustic lye 229.00 0.9 5.73

5 Di Potassium Hydrogen Phosphate (DPHP)

5 50 Phosphorous Acid 423.00 2.1 21.15

Potassium hydroxide 577.00 2.9 28.85

6 Tri Phenyl Phosphate (TPPA)

0 150

Phosphorous Oxychloride

481.00 0.0 72.15

Phenol 930.00 0.0 139.50

32% Caustic Lye 80.00 0.0 12.00

7.1 Ammonium sulphate

300 450 Spent Sulphuric Acid 1670.00 501.0 751.50

Ammonia 240.00 72.0 108.00

7.2 Ammonium Sulphate Purification Process

0 800

Methanol 19.57 0.0 15.66

Crude Ammonium Sulphate

1060 0.0 901.00



2-74

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

8 Ammonium Chloride

0 250 Spent HCL 1044.72 0.0 261.18

Ammonia 39.20 0.0 9.80

9 Triazinone 0 600

Pinacolone 610.00 0.0 366.00

Chlorine Gas 870.00 0.0 522.00

Hydrazide hydrate 750.00 0.0 450.00

Catalyst-1 1.00 0.0 0.60

Catalyst-2 18.00 0.0 10.80

Carbon Di Sulfide 537.00 0.0 322.20

48% Caustic Lye 1800.00 0.0 1080.00

Sodium Hypo Chloride 4500.00 0.0 2700.00

Sulphuric Acid 758.00 0.0 454.80

10 Metribuzin 135 550

Sodium bromide solid 162.00 21.9 89.10

Methanol 201.00 27.1 110.55

Sulphur 36.00 4.9 19.80

Triazinone 1069.00 144.3 587.95

Caustic soda Lye (32%) 485.00 65.5 266.75

Sodium Bisulphate 15.00 2.0 8.25

2-Ethyl hexanol 7.00 0.9 3.85

Chlorine 305.00 41.2 167.75

11 Acephate 0 500

Methylene Di Chloride 129.00 0.0 64.50

DMPAT 921.05 0.0 460.53

DMS 164.00 0.0 82.00

Acetic Anhydrous 610.84 0.0 305.42


Liquor Ammonia 1176.00 0.0 588.00



2-75

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

Methanol for Amm. Sulphate Purification

19.57 0.0 6.46

Caustic (48%)* 590.00 0.0 295.00

Crude AMS 1060.00 0.0 530.00

Ethyl Acetate 20.00 0.0 10.00

12 Di-chlorvos 0 100 Chloral 686.00 0.0 68.60

Tri Methyl Phosphite 568.00 0.0 56.80

13 Glyphosate 0 100

Di Ethyl Amine (DEA) 750.00 0.0 75.00

NaOH 4400.00 0.0 440.00

Catalyst 2910.00 0.0 291.00

Phosphorous Trichloride (PCl3)

1360.00 0.0 136.00

Formaldehyde (HCHO) 780.00 0.0 78.00

Hydrochloric Acid 560.00 0.0 56.00

Excess Air 4600.00 0.0 460.00

Liquor Ammonia 390.00 0.0 39.00


Air for Catalytic convertor

1471.00 0.0 147.10

14 Asulam 0 400

Sulfanilamide 704.00 0.0 281.60

Sodium methoxide 221.00 0.0 88.40

DMC 368.00 0.0 147.20

15 Clomazone 0 200 Caustic Flakes 3890.00 0.0 778.00



2-76

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

3Chloro-2,2-Dimethylpropanoyl Chloride

911.00 0.0 182.20

Hydroxylamine Sulphate 626.00 0.0 125.20

Catalyst 9.00 0.0 1.80

H2SO4 (98%) 303.00 0.0 60.60

Thionyl Chloride (SOCL2)/HCL

49.00 0.0 9.80

2-Chloro Benzylchloride (OCBC)

700.00 0.0 140.00

Na2CO3 powder 30.00 0.0 6.00

Sodium Hypo Chloride 10.00 0.0 2.00

Methanol 49.00 0.0 9.80

MDC 83.00 0.0 16.60

16 Sulfosulfuron 0 10

DMF (Dimethyl Formamide)

87.00 0.0 0.87

EM (Ethyl Mercaptan) 683.00 0.0 6.83

NaH (Sodium Hydride) 442.00 0.0 4.42

ASAM (2-chloroimidazo [1,2-a] pyridine-3-sulfonamide)

903.00 0.0 9.03

Hexane 51.00 0.0 0.51

Hydrochloric Acid 1458.00 0.0 14.58

Cat-700 3058.00 0.0 30.58




2-77

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

CAN 2850.00 0.0 28.50

DBU 377.00 0.0 3.77

ADP 498.00 0.0 4.98

DX-1 1400.00 0.0 14.00

DX-2 682.00 0.0 6.82

P-1 862.00 0.0 8.62

SOL-I 202.00 0.0 2.02

17 Pyrazosulfuron Ethyl

0 50

4-6 Dimethoxy pyrimidine -2 amine

494.00 0.0 24.70

N, N Dimethyl aniline 18.00 0.0 0.90

1,4 Dioxane 44.00 0.0 2.20

Isopropyl Alcohol (IPA) 34.00 0.0 1.70

48% Caustic 408.00 0.0 20.40

Methylene Dichloride 9.00 0.0 0.45

Ethyl-1- methyl-5-sulfamoyl-1H-pyrazole-4-carboxylate

595.00 0.0 29.75

Acetonitrile 53.00 0.0 2.65

Catalyst 2.00 0.0 0.10

Phenyl Chloromate 760.00 0.0 38.00

Methanol 33.00 0.0 1.65

18 Bensulfuron Methyl 0 50 4, 6- Dimethoxy pyrimidine -2- Amine

418.00 0.0 20.90



2-78

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

Methyl-2-{[Isocyanate sulfamoyl] Methyl} Benzoate

620.00 0.0 31.00

Xylene 35.00 0.0 1.75

Methanol 30.00 0.0 1.50

19 Metasulfuron Methyl

0 50

Sulfamoyl Isocynate 620.00 0.0 31.00

Xylene 35.00 0.0 1.75

4-Methoxy -6- methyl -2 -amino 1, 3, 5 Triazine

405.00 0.0 20.25

Methanol 30.00 0.0 1.50

20 Glyphosate 41% SL

75 0.00

Glyphosate Technical 384.00 -28.8 0.00

Mono Iso Propyl Amine 189.00 -14.2 0.00

slepentent 99.00 -7.4 0.00

21 Metribuzin 70% WDG

150 250

Metribuzin Tech. ( 95 % to 44)

464.50 69.7 116.13

Surfactant – 1 19.98 3.0 5.00

Surfactant – 2 78.53 11.8 19.63

Surfactant – 3 14.98 2.2 3.75

Defoamer 9.99 1.5 2.50

Biocide 0.96 0.1 0.24

Adjutants (For PH adjustment)

0.09 0.0 0.02

Gel 70.03 10.5 17.51

22 Asulox 0 1000 Asulam Tech. 919.12 0.0 919.12

36% HCl 59.74 0.0 59.74



2-79

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

28% NaOH 30.33 0.0 30.33

23 Azoxystrobin 0 150

2 - Coumaranone 600.00 0.0 90.00

Trimethyl Orthoformate 61.90 0.0 9.29

Acetic Anhydride 1300.00 0.0 195.00

Methanol 84.00 0.0 12.60

4,6 - DCP 649.82 0.0 97.47

30% NaOCH3 800.00 0.0 120.00

KOH Flakes 45.00 0.0 6.75

Methane Sulfonic Acid 33.00 0.0 4.95

Toluene 65.99 0.0 9.90

Ethyl Acetate 16.82 0.0 2.52

DMF 59.90 0.0 8.99

K2CO3 546.68 0.0 82.00

2 - Cyno Phenol 351.90 0.0 52.79

24 Devrinol 0 100

Alpha CPC 595.00 0.0 59.50

DEA 289.00 0.0 28.90

Toluene 83.00 0.0 8.30

Caustic (46%) 2075.00 0.0 207.50

EDTA (50%) 2.00 0.0 0.20

Napthol 602.00 0.0 60.20

Sodium Bicarbonate 909.00 0.0 90.90

25 Tri Phenyl Phosphite (TPPI)

20 150

PCl3 455.00 9.1 68.25

Phenol 946.00 18.9 141.90

Hyflow Powder 10.00 0.2 1.50

32% Caustic Lye 60.50 1.2 9.08



2-80

Sr No


MTM


Expansion MTM


(kg/MT of product)


MTM

Total consumption

after Expansion

MTM

26 Potassium Chloride 125 0.00 KCl solution 3500 437.5

NIL (as discontinued

after proposed

expansion) Source : UPL Limited

Table 2.4: Monthly Requirement and Maximum Storage of Raw Materials

Sr

No

Chemical Name

Physical

State

Storage mode Monthly

Requirement Maximum Storage

Capacity

Tank /Drum /Bag MTM MT OR KL

1 1,4 Dioxane Liquid 250 kg HDPE/MS Drum 73 8

2 2-Coumaranone Solid 250 kg HDPE/MS Drum 90 10

3 2-Cyno Phenol Solid 250 kg HDPE/MS Drum 53 7

4 2-ethyl Hexanol Liquid 120 kg Drum 7 0.84

5 3 Chloro 2,2 Dimethyl propanoyl

Chloride Liquid 250 kg HDPE/MS Drum 92 10

6 4,6 Dimethoxy pyrimidine 2 Amine Liquid 25 kg Drum 24.7 2.65

7 4,6 DCP Liquid 250 kg HDPE/MS Drum 97.47 12

8 4 methoxy 6 Methyl 2 Amino 1,3,5

triazine Liquid 25 kg Fiber drum 21 2.25

9 Acetic Anhydrous Solid 500 kg HDPE jumbo bag 420 45



2-81

Sr

No

Chemical Name

Physical

State



Capacity


10 Acetic Anhydride Solid 250 kg HDPE/MS Drum 195 22

11 Acetonitrile Liquid 250 kg HDPE/MS Drum 89 10

12 Ammonia Gas 900 kg Tonner 118 13.5

13 Asulam Technical Solid 500 kg HDPE jumbo bag 919.12 100

14 ASAM Solid 50 Kg bag 9.03 3

15 Bromine Liquid Glassline Tank 89.1 6.3

16 Carbon di sulphide Liquid ISO Tank 322.2 35

17 Caustic flakes Solid 25 kg Poly liner Bag 451.6 48.4

18 Caustic Soda lye Liquid 35 KL Tank 300 35

19 Chloral Liquid 250 kg HDPE/MS Drum 69 7.5

20 Chlorine Gas 900 kg Tonner 1020.4 109.8

21 Di Ethyl Amine Liquid 250 kg HDPE/MS Drum 75 8.25

22 Di Methyl Carbonate (DMC) Liquid 250 kg HDPE/MS Drum 147.2 16

23 Dimethyl Formamide Liquid 250 kg HDPE/MS Drum 22 3

24 Di Methyl Phosphorous Amido

thioate (DMPAT) Liquid 80 KL Tank 674 80

25 Di Methyl Sulphate Liquid 250 kg HDPE/MS Drum 82 9

26 Ethyl Mercaptan Liquid 250 kg HDPE/MS Drum 6.83 3

27 Ethyl Acetate Liquid 250 kg HDPE/MS Drum 109 11.75

28 Ethyl 1 methyl 5 sulfamoyl 1 , 1 H-

pyrozole -4 carboxylate Liquid 250 kg HDPE/MS Drum 30 5

29 Formaldehyde Liquid 250 kg HDPE/MS Drum 78 8.5



2-82

Sr

No

Chemical Name

Physical

State



Capacity


30 Glyphosate technical Solid 25 kg HDPE Bag 57.6 6.17

31 Hydrochloric Acid Liquid Tanker 129 14

32 hydrochloric Acid 36% Liquid 250 kg HDPE/MS Drum 60 6.5

33 Hexane Liquid 250 kg HDPE/MS Drum 5 0.75

34 Hydrazide hydrate Solid 25 kg HDPE Bag 450 48.22

35 hydroxylamine hydrochloride Solid 25 kg HDPE Bag 10 1.07

36 Hyflow powder Solid 25 kg HDPE Bag 1.5 0.17

37 Iso Propyl Alcohol Liquid 250 kg HDPE/MS Drum 34 4

38 Liquor Ammonia Liquid 60 KLTank 489 60

39 Methanol Liquid 40 KLTank 227 30

40 methyl-2-{Isocyanate sulfamoyl}

methyl } Benzoate Liquid 250 kg HDPE/MS Drum 31 3.35

41 Methylene Di chloride Liquid 250 kg HDPE/MS Drum 95.45 12

42 Methane Sulfuric Acid Solid 25 kg HDPE Bag 5 1

43 Metribuzin Technical Solid 500 kg HDPE jumbo bag 464.5 50

44 Mono Iso Propyl Amine Liquid 250 kg HDPE/MS Drum 29 3.25

45 N,N Dimethyl Aniline Liquid 250 kg HDPE/MS Drum 30 3.25

46 O- chloro Benzylchloride Liquid 250 kg HDPE/MS Drum 35 3.75

47 Oxygen Gas 50 kg Tonner 12.5 0.5

48 Phenol Liquid 250 kg HDPE/MS Drum 194 21

49 Phosphorous Solid 250 kg MS Drum 97 13

50 Phosphorous Acid Liquid 250 kg HDPE/MS Drum 21.15 2.5



2-83

Sr

No

Chemical Name

Physical

State



Capacity


51 Potassium Hydroxide Solid 50 kg HDPE jumbo bag 34.85 9

52 Phosphorous Trichloride Liquid 50 KL Tank 452 50

53 Pinacolone Liquid 40 KL Tank 366 40

54 Sodium Bisulphate Solid 25 kg HDPE Bag 9 1

55 Sodium Bromide solid Solid 500 kg HDPE jumbo bag 89.1 10

56 Sodium Carbonate Solid 25 kg HDPE Bag 10 1.07

57 Sodium Hydride Solid 25 kg HDPE Bag 4.42 0.475

58 Sodium Hypochloride Liquid 300 KL Tank 2700 300

59 Sodium Methoxide Solid 25 kg HDPE Bag 88.4 10

60 Spent HCL Liquid 30 KL Tank 262 30

61 Spent Sulphuric Acid Liquid 90 KL Tank 752 90

62 Sulfamoyl Isocyanate Solid 25 kg HDPE Bag 31 5

63 Sulfanilamid Liquid 250 kg HDPE/MS Drum 282 30.25

64 Sulphur Solid 50 kg bag 19.8 15

65 Sulphuric Acid Liquid 65 KL Tank 560.13 65

66 Tri Methyl Phosphite Liquid 250 kg MS Drum 57 6.25

67 Triazinone Solid 500 kg HDPE jumbo bag 588 63

68 White Phosphorous Solid 250 kg MS Drum 97 10.5

69 Bromine Liquid Tanker 89 18

70 Sulphur Solid Bag-25 kg 20 5

71 Ethyl Hexanol Liquid 250 kg MS Drum 4 2



2-84

Sr

No

Chemical Name

Physical

State



Capacity


72 3Chloro-2,2-Dimethylpropanoyl

Chloride Liquid 250 kg HDPE Drum 182 20

73 Hydroxylamine Sulphate Solid Bag-25 kg 125.2 6

74 Thionyl Chloride (SOCL2)/HCL Liquid Tanker 9.8 6.3

75 2-Chloro Benzylchloride (OCBC) Liquid 250 kg HDPE Drum 140 10

76 Alpha CPC Solid Bag-50 kg 59.6 30

77 DEA Liquid tanker 39.1 20

78 Toluene Liquid Tanker 277.3 140

79 EDTA (50%) Solid Bag 0.2 0.2

80 Naphthol Solid Bag 60.2 30

81 Sodium Bicarbonate Solid Bag 90.9 45

82 PCl3 Liquid Tank 68.25 35

83 Hyflow Powder Solid Bag 1.5 0.75

84 4, 6- Dimethoxy pyrimidine -2-

Amine Liquid Tank 20.9 10

85 Xylene Liquid Tank 1.75 1

86 Methyl-2-{[Isocyanate sulfamoyl]

Methyl} Benzoate Liquid Tank 31 15

Source : UPL Limited



2.6 Salt Generation from Evaporation (Before and After Expansion)

UPL will evaporate residues to produce salt from various pesticide

manufacturing processes after expansion. Total 2435.206 Tonnes salt will be

generated per month after expansion. The products wise salt generation from

evaporation (after expansion) are given in Table 2.5.

Table 2.5: Salt Generation from Evaporation (After Expansion)

Products

Total

Capacity

After

Expansion

Evaporation

Norms

Total evaporation

Quantity after

Expansion

Salt

Generation

MTM Lit/MT Lit/Month KL/Day MTM

Metribuzin 550 1500 825000 29.46 165

Ammonium

Chloride 250 83.92 20980 0.749285714 4.196

Triazinone 600 10500 6300000 225 1260

Glyphosate 100 4495 449500 16.05357143 89.9

Clomazone 200 13661 2732200 97.57857143 546.44

Sulfosulfuron 10 84485 844850 30.17321429 168.97

Devrinol 100 10035 1003500 35.83928571 200.7

Total 6585 12176030 434.85 2435.206

Source : UPL Limited Salt generated from evaporation will be hazardous wastes and will be sent to

Common Hazardous Waste Treatment Storage and Disposal facility (CHWTSDF)

for land filling.

2.7 Solvent Recovery (Before and After Expansion)

For manufacturing of pesticide products at existing plant and after expansion,

solvents will be used in the various processes, which are recovered through

efficient solvent recovery system. Details of solvent consumption and recovery

after expansion are given in Table 2.6.



Table 2.6: Solvent Recovery (Before and After Expansion)

Sr.

No Product Solvent Consumption Recovery Difference % Recovery

Kg/MT Kg/MT Kg/MT %

1 Metribuzin Methanol 207 201 6 97.10

2 Acephate MDC 6500 6371 129 98.02

Ethyl Acetate 1760 1740 20 98.86

Methanol

(Amm. Sulphate

Purification

Process)

2652.52 2632.95 19.57 99.26

3 Chlomazone Methanol 1609 1560 49 97.00

MDC 2963 2880 83 97.20

4 Sulfosulfuron Hexane 1725 1674 51 97.04

DMF 2933 2846 87 97.03

5

Pyrasulfuron

Ethyl 1,4 Dioxane 1456 1412 44 97.00

Methylene

Dichloride 300 291 9 97.00

N,N Dimethyl

Aniline 588 570 18 97.00

Acetonitrile 1770 1717 53 97.01

Iso Propyl

Alcohol (IPA) 1140 1106 34 97.02

Methanol 1100 1067 33 97.00

6

Bensulfuron

Methyl Xylene 1600 1565 35 97.81

Methanol 2000 1970 30 98.50

7

Metasulfuron

Methyl Xylene 1600 1565 35 97.81

Methanol 2000 1970 30 98.50

8

Azoxystrobin

Methanol 2800 2715.996 84.004 97.00

Trimethyl

Orthoformate 2559.9 2498 61.9 97.58

Toluene 2199.65 2133.66 65.99 97.00

DMF 1959.9 1900 59.9 97.00

Ethyl Acetate 549.82 533 16.82 97.00



Sr.

No Product Solvent Consumption Recovery Difference % Recovery

9 Devrinol Toluene 2773 2690 83 97.01

Source : UPL Limited 2.8 Utilities Requirements

2.8.1 Water

Total existing water consumption at the UPL plant is 166.56 KLD. After

proposed expansion, additional water requirement will be 538.5 KLD. Total

water consumption after expansion is estimated 705.06 KLD. Total water

requirement after expansion will be met through water supply by MIDC Notified

Industrial Estate Tarapur. Water requirement details for existing and after

expansion plant operation are given in Table 2.7. Water balance diagram for

the UPL plant after expansion is given in Figure 2.33.

Table 2.7: Water Requirement Details

(Existing and After Proposed Expansion)

S. No.

Particulars Existing Water

Consumption (KLD)

Additional Water

Consumption for

Expansion (KLD)

Total Water Consumption

after Expansion

(KLD)

1. Boiler & Cooling 110.9 110.1 221

2. Domestic Purpose 3 11 14

3. Processing &Washing

42.66 407.40 450.06

4. Gardening 10 10 20

Total 166.56 538.5 705.06 Source : UPL Limited



2.8.2 Steam

Total steam (Existing + Proposed) requirement at full production of UPL Plant

is about 20 tph, which is meet through 10 tph capacity Coal or

Biomass/Briquettes/rice husk fired boiler. Fuel consumption in this boiler is 985

kg/hr coal or 2460 kg/hr biomass/briquettes/rice husk. One standby 4 tph

capacity furnace oil fired boiler is also available, which consumes 125 litres

furnace oil per hour. After expansion additional steam requirement will be 14

tph. To meet the steam requirement after expansion of the plant, additional 10

tph capacity boiler will be installed, which will consume 2 tph coal at full load

operation.

Figure 2.33: Water Balance Diagram for the Plant after Expansion



2.8.3 Power

Total power requirement of existing plant is 1508 kW. After expansion power

requirement will be increased to 4332 kW, which will be supplied by

Maharashtra State Electricity Board (MSEB). To meet the power requirement in

the event of grid power failure, UPL has two DG sets of 500 KVA and 250 KVA

capacities presently. After expansion two DG Sets of 750 KVA capacity each will

be installed to meet the power requirement of the plant during grid power

failure. Additional HSD consumption as 500 Liter/hr is estimated for operation

of existing DG sets of 250 kVA, 500 kVA capacity and two additional DG sets of

2x750 kVA.

2.8.4 Cooling Tower

UPL have existing cooling towers with 700 TR and after proposed expansion

additional @2300 TR at temperature drop of nearly 5.5oC. After proposed

expansion total cooing tower @3000 TR.

2.8.5 Chilled Water

UPL have existing chilling plants with 150 TR and after proposed expansion

additional @300 TR at temperature drop of nearly 7oC. After proposed

expansion total chilling plant @450 TR.

2.8.6 Chilled Brine As on UPL have no any existing chilling plants and after proposed expansion

additional @250 TR at temperature drop of nearly -15oC. After proposed

expansion total chilling plant @250 TR.

2.9 Plant Plot Area and Layout Plan

The UPL plant is located on the land allocated in notified Chemical Zone

Industrial area by the “Maharashtra Industrial Development Corporation

(MIDC)” at Tarapur, Boisar, District Palghar. The total area of Unit#10 of UPL

is 23454 sqm. The break-up of plant area is given in Table 2.8. The layout

plan for the existing and proposed UPL plant is given in Figure 2.34.



Table 2.8: Break-up of Plant Area

S. No Particulars Existing m2

1 Total Open Space Area 12820.06

2 Existing Plant Area 8128.94

3 Total Green Belt Area 5865.96

4 Total Plot Area 23454.00

Source : UPL Ltd.

2.10 Man-Power Requirement

The man power requirement for existing UPL plant is 150 persons including 67

staff and 83 workers. For plant operation after expansion, additional 73 staffs

and 77 workers will be required. Total manpower requirement after proposed

expansion will be 140 staff and 160 workers. Details for manpower requirement

for the existing plant and after expansion are given in Table 2.9.

Table 2.9: Manpower Details for Existing Plant and after expansion

S.

No.

Manpower

particulars Existing Plant Additional After expansion

1. Staff 67 73 140

2. Workmen 83 77 160

Total 150 150 300

Source : UPL Ltd.

2.11 Cost of Proposed Expansion

Total cost of the proposed expansion of UPL plant is estimated as Rs. 227.06

Crores. The project cost details are given below:

Project cost details

Type of costs Rs in Lacs

Equipment Cost 6538.44

Piping 2581.32

Electrical 1420.60

Instrumentation 1228.10

Civil and Structure 3047.30

Insulation 564.59

Painting 286.45

Safety equipment 275.81

Consultancy 428.94



Project cost details

Type of costs Rs in Lacs

Services Costs 0.9

Contingency 808.44

HAZOP Cost 859.04

Services Cost 944.95

Out of pocket expenses 515.42

Utility cost 2147.61

Total 21647.97

EMS cost including ETP, MEE, Green Belt,

Waste Handling, STP

1058.12

Grand Total 22706.09

2.12 Sources of Pollution and Its Control Strategies

2.12.1Effluents Generation, Treatment and Disposal

Details of effluent generation from existing and after proposed expansion of

the plant are given in Table 2.10.

Table 2.10: Waste Water Generation Details

(Existing and after Proposed Expansion)

S. No.

Particulars Existing Permitted

Quantity of Discharge

(KLD)

Additional Effluent

Discharge due to Expansion

(KLD)

Total Effluent Generation

After Expansion

(KLD)

1. Trade effluent 33.3 42.7 76

2. Boiler & Cooling 3 37 40

3. Domestic effluent

1.8 9.2 11

4. MEE Condensate

0 170* 170*

Total 38.1 258.9 297 *Multi Effect Evaporator (MEE) condensate @ 170 KLD and we will check for recycling possibility once the characteristics of condensate water is being analysed.

Source : UPL Ltd.

Note: 38.1 kld waste water/effluents are generated from the existing UPL

plant, which includes 33.3 kld trade effluents, 3 kld boiler blow down and 1.8

kld domestic waste water. At the existing plant, domestic waste water is treated

in septic tank followed by soak pit. There is no discharge of treated domestic



waste water on land and outside the plant premises. Trade effluents are

treated in existing ETP of 50 kl/day capacity comprising primary, secondary and

tertiary treatment facilities. Treated waste water is sent to Common Effluent

Treatment Plant (CETP of Tarapur). UPL is member of Tarapur Environment

Protection Society located in MIDC Tarapur, which is operator of CETP. UPL’s

Membership details of Tarapur Environment Protection Society for CETP are

enclosed in Annexure IV.

After expansion, total effluent generation will be 297 kld. The UPL will expand

the capacity of ETP to 300 kld. Treated effluent generated from various

processes after expansion will be sent to CETP of Tarapur for further treatment

and disposal after expansion also. UPL meets the following discharge standards

as given in Table 2.11 for treated effluents as prescribed by MPCB in CC&A.

Table 2.11: Discharge Standards for Treated Effluents Prescribed by MPCB

Sr.

No.

Parameters Standards Prescribed By

MPCB

1. pH 5.5 to 9.0

2. BOD (3 days) 100

3. COD 250

4. Suspended Solids 100

5. Oil & Grease 10

6. Total Dissolved Solids 2100

7. Phenol & Phenolic Compounds as

C6H5OH

1

8. Phosphate 5

9. Sulphur 30

10. Bioassay Test 90 % Survival of Fish after 96

hours in 100 % effluents



Figure 2.34: Site Layout Plan for UPL Plant



2.12.2 Gaseous and Particulate Emissions from Stacks

The emissions from stacks at the existing plant and after expansion of UPL

plant are distributed into two categories and described below:

I. Existing and Proposed Flue Gas Stack Emissions Existing Stack Emission Sources

• Stack emissions from coal or biomass/briquettes/rice husk fired 10 tph

boiler

• Stack emissions from furnace oil fired 4 tph boiler

• Stack emissions from 250 kVA and 500 kVA capacity DG Sets

Proposed Stack Emission Sources

• Stack emissions from Coal fired 10 tph boiler

• Stack emissions from two 750 kVA capacity each DG Sets

Details of existing flue gas stacks and after expansion of the plant are presented

in Table 2.12.

Process Emissions

Details of existing process stacks and after expansion of the plant are presented

in Table 2.13.

2.12.3Hazardous and Solid Wastes Generations and Its Management

Details of hazardous (landfillable wastes and incinerable wastes) and non-

hazardous wastes generations and its management at the existing UPL plant

and after expansion are discussed below:

I. Hazardous Wastes (Landfillable Wastes and Incinerable Wastes)

Generations and Its Management

UPL plant generates, various types of hazardous wastes. Details of hazardous

wastes generation, category, quantities, mode of disposal for existing plant and

after proposed expansion are described in Table 2.14. UPL is member of

Mumbai Waste Management Limited (Ramky), Taloja for disposal of hazardous

wastes as per condition of CC&A by MPCB. Details of membership of UPL for



Mumbai Waste Management Limited (Ramky), Taloja are enclosed as

Annexure V.

Distillation residue, spent catalyst, aqueous effluent from drum/tank/reactor

washing, date expired & off specific pesticide and used filter aids generated

from the plant are/will be sent to Common Hazardous Waste Treatment Storage

and Disposal facility (CHWTSDF) for incineration.

Used Oil generated from the maintenance of DG sets is handed over to CPCB

authorized used oil recyclers. Discarded containers (drums, carboys)

contaminated with hazardous chemicals are sent for decontamination to

CHWTSDF. Sludge generated from the ETP are also sent to CHWTSDF for

landfilling.

Salt proposed to be generated from evaporation of process residue after

expansion will be sent to CHWTSDF for landfilling.

II. Non-hazardous Wastes Generations and Its Management At the existing plant, approx. 60 tones ash per month is generated from coal

or biomass/briquettes fired boilers, which is sold to bricks manufacturers / other

end-users. After expansion of the existing plant, additional 60 tones ash per

month will be generated from boilers. Same will also be sold to bricks

manufacturers / other end-users. Acceptance letter for Fly Ash utilization is

annexed in Annexure X



Table 2.12: Details of Flue Gas Stacks at Existing Plant and after Expansion

Particulars Capacity Stack Height (m)

Type of Fuel Fuel Consumption Air Pollution Control System

Permissible Limit

I. Existing Flue Gas Stacks

Boiler-I 10 TPH 40 Coal or

Biomass/Briquettes/ rice husk

Coal (985 kg/hr) or Biomass/briquettes/Rice husk

(2460 kg/Hr)

Dust Collector and bag filter, CEMS

PM- 150 mg/Nm3

SO2- 100 ppm NOx- 50 ppm.

Boiler-II (Stand By)*

4 TPH 30 Furnace oil 125 litre/hr NA

D.G Sets

1x 500 KVA 3.1

(above roof) LDO 500 Litre/hr

NA

1x 250 KVA 3.1

(above roof) NA

Note: Oil Fired boiler shall be kept standby and operated only in case when the other boiler is not in operation

II. Proposed- Additional Flue Gas Stacks after Expansion

Particulars Capacity Stack

Height (m) Type of Fuel Fuel consumption

Air Pollution Control system

Permissible Limit

Boiler –III 10 TPH 40 Coal 2 TPH Dust Collector and bag filter, CEMS PM- 150

mg/Nm3 SO2- 100 ppm NOx- 50 ppm

D. G. Sets 2x750 KVA 18 HSD 500 Litres/ hr NA

Source : UPL Ltd.



Table 2.13: List of Process Stacks at Existing Plant and after Expansion

Sr. No.

Stack attached to Stack Height (m)

Expected Pollutant

Permissible Limit

(mg/nm3)

Air Pollution Control System

I. Existing Process Stacks

1. PCl3 –I 30 m from

ground floor

HCl 20 Two stage (water and Alkali)

scrubber Cl2 9

PCl3 9

2. PCl3- II (Phosphorus Oxychloride) Phosphorous plant HCl scrubber & Tri Phenyl Phosphite (TPPI)

30 m above ground

HCl 20 Two stage (water and Alkali)

scrubber Cl2 9

PCl3 9

II. Proposed Process Stacks

1. Asulam 30 m above

ground

HCl 20 Alkali scrubber

Cl2 5

2. Tri Phenyl Phosphate (TPPA) 30 m above

ground HCl 20 Water + Caustic Scrubber

3. Ammonium Chloride 30 m above

ground

NH3 175 Water scrubber

HCl 20

4. Triazinone 30 m from

ground floor

HCl 20 Caustic Scrubber

H2S 45

5. Acephate 30 m from

ground floor NH3 30 water Scrubber

6. Glyphosate NH3 30 water and Alkali Scrubber



Sr. No.

Stack attached to Stack Height (m)

Expected Pollutant

Permissible Limit

(mg/nm3)


30 m from ground floor

HC 20

HCl 20

7. Metribuzin (common plant scrubber)

30 m from ground floor

HBr 5 Caustic Scrubber

8. Ammonium Sulphate 30 m above

ground NH3 175 Water Venturi scrubber

9. Phosphorus Acid Solid & Solution 30 m above

ground HCl 20 Water & Caustic Scrubber

10. Di-Chlorvos (DDVP) 30 m above

ground MeCl 20 Caustic Scrubber

Source : UPL Ltd.



Table 2.14 Hazardous Waste (Landfillable and Incinerable) Details (Existing and After Proposed Expansion)

Sr No

Type of Waste Category Existing Quantity

Additional Quantity

Total Quantity

after Expansion

UOM Mode of Disposal

I. Hazardous Wastes (Landfillable Wastes and Incinerable Wastes)

1 Distillation residue 29.1 9.75 1595.07 1604.82 MTM CHWTSDF(Incineration)

2 Discarded Containers (Drums, Carboys )

33.1 34 9602 9636 Nos/Month Sale to MPCB Authorized

Party

3 Plastic Bags 33.1 NIL 51562 51562 Nos/Month Decontamination and give

to Scrap Dealer / CHWTSDF (landfill)

4 ETP sludge 35.3 0.3 39.7 40 MTM CHWTSDF(landfill)

4 Salt from Evaporation & Process

35.3 0 2536 2536 MTM CHWTSDF(landfill)

6 Used Oil 5.1 0 500 500 Ltrs/

Month Sale to CPCB registered

recycler

7 Used Batteries B1(B1020) 0 5 5 Nos/Month Sale to MPCB Authorized

Party

8 Spent Solvent 29.4 0 10 10 MTM To end users OR recyclers

OR Co-Processing

9 Spent Catalyst 29.5 0 1 1 MTM CHWTSDF(Incineration)

10 Aqueous Effluent from Drum/Tank/reactor washing

29.1 0 50 50 MTM CHWTSDF(Incineration)

11 Date Expired & Off specific Pesticide

29.3 0 5 5 MTM CHWTSDF(Incineration)

12 Used Filter Aids 36.2 0 3 3 MTM CHWTSDF(Incineration)



Sr No

Type of Waste Category Existing Quantity

Additional Quantity

Total Quantity

after Expansion

UOM Mode of Disposal

13 Insulation waste /PPEs 33.2 0 8 8 MT/Year CHWTSDF(landfill)

14 Spent Acid 29.6 0 2 2 MT/Year To end users OR recyclers

II. Non Hazardous Wastes

15 Fly Ash from Boilers Non

hazardous 60 60 120 MTM

Sale to Brick Manufacturer OR other end-users

Source : UPL Ltd.


Shivalik Solid Waste Management Ltd. 3 - 1

Chapter 3

DESCRIPTION OF THE ENVIRONMENT

3.1 Introduction This chapter describes the status of the baseline environmental conditions in

the study area with reference to the various environmental attributes. The

study area covers the 10-km radius distance around the site for proposed

expansion.

Baseline study is conducted in order to identify the likely changes in natural,

biological and socioeconomic environments and to have a thorough

understanding of baseline environmental conditions prior to commencement of

the proposed expansion of the existing UPL plant. The description of

environmental conditions of the study area have been described in this chapter

in respect of topography & physiography, geology, soil, hydrogeology, water

resource and quality, climatology and meteorology, ambient air quality, stack

emissions from the plant, ambient noise levels, land use/cover, biological

environment and socio-economic environment.

The baseline information on soil analysis, water quality, micro-meteorological

data, ambient air quality, stack monitoring and noise level monitoring were

carried out during pre-monsoon season from 1st March to 31st May 2017 by M/s

Shivalik Solid Waste Management Ltd.’s NABL accredited and Ministry of

Environment, Forest & Climate Change (MoEF&CC) recognized environmental

laboratory.

3.2 Topography and Physiography

The area around the UPL plant is almost plain having elevation of 25 meters

above mean sea level (amsl). General slope in the study area is east to west

direction. As the plant is located in MIDC notified industrial area, the existing

plant is surrounded by industrial units. Arabian sea coastal line is about 5 km

in west direction.

3.3 Geology

The area is covered by Deccan trapes which was formed by flow of basalt lava,

which is generally known as Deccan trap. The volcanic activities were confined



mainly to Upper Cretaceous to Lower Eocene age. Besides Deccan traps, the

formation like local alluvium, beach sand, coastal alluvium, laterites, trachytes

& rhyolite cover very small area of the study area.

Stratigraphic sequences of the geological formation of the area are given in

Table 3.1.

Table 3.1: Stratigraphic Sequences of Geological Formation in the Area

Formation Age Lithology

Alluvium Recent clay, silt and sand

Beach sand Recent sand and silt

Laterite Pleistocene Laterite

Dykes Basic intrusion

Deccan traps basalt Eocene to upper cretaceous

Amygdular basalt

Rhyolite Eocene to upper cretaceous

Rhyolite

Trachyte Eocene to upper cretaceous

Trachyte

3.4 Seismology

The state of Maharashtra falls in a region of moderate to high seismic hazard.

As per the Bureau of Indian Standards (BIS) map, Maharashtra falls in Zones

II, III & IV. Historically, parts of this state have experienced seismic activity in

the M6.0-6.5 range. Approximate locations of selected towns and basic political

state boundaries are displayed in the Figure 3.1. The project site is located in

Seismic Zone III.

3.5 Geohydrology Deccan trap Basalt of Upper Cretaceous to Lower Eocene age is the major rock

type covering about 80% of the area, coastal alluvium is other formation

occurring only in western end of the area.

Deccan Trap Basalt

Ground water in Deccan traps mostly occurs in the weathered and fractured

parts down to 10-15m depth. At places potential zones are encountered at

deeper levels in the form of fractures and inter-flow zones which are generally



confined down to 60-80m in the district. The weathered portions of both

vesicular and massive units have better porosity and permeability.

Intensity of weathering is less in hilly region as seen in the eastern part of the

area while it is higher in plain area. The yield of dug wells tapping phreatic

aquifer ranges between 18 to 152 cum/day, which have 5-12m depth range.

The bore wells are generally drilled down to 40 to 60m tapping weathered and

fracture/vesicular zones, these wells have a discharge of 2 to 4lps. It is noticed

and reported that the yields of the wells drastically get reduced in summer

months beginning form March up June end.

Alluvium

Alluvium are developed in the western part of the area along the coast and

river courses and are lacustrine in nature. Along the coast, alluvium consists of

clayey and mud deposits. The quality of water is slightly brackish and pumping

from this formation has to be restricted to prevent ingression of seawater. The

alluvium constitutes the potential aquifer in the area. The yield of dug wells

ranges between 122 to 252 cum/day, which have 8-16m depth range. The bore

wells are generally drilled down to 20 to 30m tapping weathered and

fracture/vesicular zones, these wells have a discharge of 4 to 6 lps.

Figure 3.1: Seismic Zones for the Region



3.6 Drainage Pattern of the study area

The drainage pattern of the study area has been determined by using remote

sensing technique. Satellite imagery has been processed to obtain drainage

pattern map of the 5-km radius area around the plant.

The study area is a mix of flat and undulating terrain characterized by presence

of hillocks near the Gundale, Padghe & Devkhop villages. Presence of these

hills & hillocks in the study area has affected in large number of lineaments &

fractures thus resulting in dendritic type of drainage pattern, also the westerly

meandering Banganga & Jununa Rivers form the prominent features of the

surface drain in the study area. Arabian sea is located at distance of about 5

km in the west direction. The drainage pattern map of 5 km area is shown in

Figure 3.2.

3.7 Soil

The soil of the area has been derived from Deccan trap, which is locally known

as the "regur” or “black cotton soil”. The black soil contains high alumina and

carbonates of calcium and magnesium with variable amount of potash and

phosphorus. The soil is generally porous and swells considerably on addition of

water and dries up with cracks on loosing moisture. Alluvial soils are also

observed near rivers and along the coast.

3.7.1 Soil Characteristics

Soil characteristics is the capacity of a specific kind of soil to function, within

natural or managed ecosystem boundaries to sustain plant and vegetation. Soil

characteristics reflect that how well a soil performs the functions of maintaining

biodiversity and productivity, partitioning water and solute flow, filtering and

buffering, nutrient cycling and providing support for plants and other

structures. Soil characteristics play vital role in any particular geographical

phenomenon of ecology as well as physico-chemical environment. It is clearly

visible that soil contamination may result in eventuality in form of contamination

of water, ecological destruction, and loss of agricultural productivity, etc. The

major sources of soil contamination are solid & hazardous wastes and untreated

effluents from industries as well as overuse of fertilizers & pesticides in

agricultural practices. Thus, it is essential to determine the baseline soil

characteristics for environmental impact assessment studies.


Shivalik Solid Waste Management Ltd . 3 - 5

Figure 3.2: Drainage Map of 5 km Radius Area Around the Plan



3.7.2 Soil Sampling

To understand the soil characteristics, 8 locations in the study area were

selected for soil sampling. For selection of soil sampling locations, the following

criterion were considered:

• Soil from agricultural land, park open land, and

• Soil from industrial area, where there is possibility of contamination.

The details of soil sampling locations are given in Table 3.2. The soil sampling

locations are shown in Figure 3.2. Composite sampling of soil upto root depth

(10 - 15 cm) was carried out at each location.

Analysis results of physical and chemical parameters of soil samples are given

in Table 3.3. Chemical classification of soil quality as per Indian Council

Agriculture Research (ICAR) is given in Table 3.4.

Table 3.2: Soil Sampling Locations

Code Soil Sampling Locations

Distance (km)

Direction from Site

Latitude & Longitude

Selection Criteria like

Agriculture/Non-Agriculture land

S1 Plant Site 0 -- 19° 48’ 25”N 72° 43’ 52”E

Non-Agriculture

S2 Kudan 4.83 NNW 19° 48’ 19.2”N 72° 44 57.9”E

Agriculture land

S3 Parnali 2.49 North 19°49'37.37"N 72°43'48.53"E

Agriculture land

S4 Pasthal 0.89 NW 19°48'58.03"N 72°43'34.59"E

Agriculture land

S5 Salvad 0.38 WSW 19° 48’ 33.7”N 72° 43’ 19.7”E

Agriculture land

S6 Pam 2.61 SW 19°47’ 28.8”N 72° 42’ 24.8”E

Agriculture land

S7 Saravali 5.69 SE 19° 46’ 41.5”N 72° 45’ 13.7”E

Agriculture land

S8 Betegaon 5.40 SE 19°46'48.27"N 72°46'13.01"E

Agriculture land



From the tabulated values, the following inferences can be made about the

physical and chemical characteristics of the soil samples collected from the

study area:

Texture: Texture indicates relative proportion of sand, silt and clay particles

present in the soil. Based on quantities of sand, silt and clay present in the soil

samples textural classification is carried out. Soil samples from all eight

locations are silt loam, sandy loam, clay silty and sandy clay in texture.

Bulk Density: Soil texture, soil structure and organic matter content are the

factors influencing the bulk density of a soil. Bulk density of soil in the study

area is found to be in the range from 1.41 to 1.58 g/cc.

Figure 3.3: Soil Sampling Locations



Table 3.3: Analysis Results of Soil Samples Collected from The Study Area

Parameters Units S1 S2 S3 S4 S5 S6 S7 S8

Project Site

Kundan Parnali Pasthal Salvad Pam Saravali Betegaon

Soil Texture

Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

Clay silty Sandy Loam

Sandy Clay

Sand % 78.6 75.5 82.5 78.4 74.8 18.4 79.4 72.5

Clay % 9.1 8.8 12.5 17.7 12.7 55.8 9.5 21.4

Silt % 12.3 15.7 5 3.9 12.5 25.8 11.1 6.1

Bulk Density g/cc 1.41 1.45 1.44 1.46 1.52 1.47 1.58 1.48

Porosity % 37 32 45 48 47 32 38 44

Permeability cm/hour 1.4 1.5 1.8 1.4 1.7 2.2 1.4 1.9

Ph

7.81 7.72 8.05 7.71 7.67 7.63 7.86 8.04

Conductivity mS/cm 0.64 0.511 1.15 0.23 0.597 1.58 0.162 0.141

Organic Carbon % 0.77 0.60 1.73 0.92 2.27 0.77 1.06 1.72

Organic Matter % 1.33 1.04 2.98 1.58 3.92 1.33 1.83 2.97

CEC meq/100g 19.14 17.36 22.22 24.56 21.48 15.22 22.82 12.60

Available N Kg/Ha 192 182 285 244 272 187 248 228

Available Phosphorus

Kg/Ha 51.7 63.5 47.9 51.2 66.2 53.8 47.3 52.6

Arsenic as As mg/Kg BDL (DL=0.2)

2.1 1.8 1.1 0.15 BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

Cadmium as Cd mg/Kg BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

Chromium as Cr mg/Kg BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

Lead as Pb mg/Kg BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)



Parameters Units S1 S2 S3 S4 S5 S6 S7 S8

Project Site

Kundan Parnali Pasthal Salvad Pam Saravali Betegaon

Nickel as Ni mg/Kg BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

BDL (DL=0.2)

0.98 1.22 3.11

Zinc as Zn mg/kg (µg/g)

2.62 3.22 3.12 2.22 1.23 10.2 16.2 12.5

Copper as Cu mg/kg (µg/g)

9.32 13.4 10.6 12.2 24.4 13.8 12.5 13.5

Iron as Fe mg/kg (µg/g)

21.21 23.45 24.48 14.54 12.47 32.24 32.72 25.48

Manganese as Mn

mg/kg (µg/g)

4.65 8.22 3.45 4.56 8.88 5.96 6.51 5.44

Total Boron mg/kg 0.47 0.42 0.48 0.62 0.51 0.55 0.58 0.48

Exchangeable Calcium

meq/100g 8.7 8.4 11.7 12.9 10.7 8.81 11.42 6.73

Exchangeable Magnesium

meq/100g 1.85 1.76 2.14 2.26 1.95 1.91 2.17 1.52

Exchangeable Sodium

meq/100g 2.28 1.97 2.41 2.76 2.19 2.07 2.56 1.58

Exchangeable Potassium

meq/100g 0.22 0.19 0.36 0.48 0.32 0.27 0.39 0.16

Date of Soil Sampling: 14 April 2017



Table 3.4: Chemical Classification of Soil Quality Sr. No.

Soil Analysis Parameters Classification

1

pH 4.5 Extremely acidic 4.51- 5.50 Very strongly acidic 5.51-6.00 moderately acidic 6.01-6.50 slightly acidic 6.51-7.30 Neutral 7.31-7.80 slightly alkaline 7.81-8.50 moderately alkaline 8.51-9.0 strongly alkaline 9.01 very strongly alkaline

2

Salinity Electrical Conductivity (mmhos/cm) (1ppm = 640 mmho/cm)

Upto 1.00 Average 1.01-2.00 harmful to germination 2.01-3.00 harmful to crops (sensitive to salts)

3 Organic Carbon (%) Upto 0.2: very less 0.21-0.4: less 0.41-0.5 medium, 0.51-0.8: on an average sufficient 0.81-1.00: sufficient >1.0 more than sufficient

4 Nitrogen (Kg/ha) Upto 50 very less 51-100 less 101-150 good 151-300 Better >300 sufficient

5 Phosphorus (Kg/ha) Upto 15 very less 16-30 less 31-50 medium 51-65 on an average sufficient 66-80 sufficient >80 more than sufficient

6 Potash (Kg/ha) 0 -120 very less 120-180 less 181-240 medium 241-300 average 301-360 better >360 more than sufficient

Source: Hand Book of Agriculture, ICAR, New Delhi

Porosity: The pore space of a soil is the space occupied by air and water and

is expressed as percent pore space. The amount of pore space is determined

by structural conditions, that is by inter-related influence of texture,

compactness and aggregation. Porosity is also related to aeration and retention

and movement of water in the soil. The porosity of soil samples collected from

the study area ranges between 32 to 48 %.



Permeability: Permeability is the entry of fluid from one medium to another.

In soil - water relationship, it means entry of water from air in to soil.

permeability rate is defined as maximum rate at which a soil in a given condition

can absorb rain or irrigation water as it comes at soil surface. Permeability rate

is the rate of water entry in to the soil when flow is non-divergent. Permeability

of soil samples collected from the study area ranges between 1.4 to 2.2 cm/hr

are correlating with physical characters and classified as moderate for

agriculture and conservation, indicating moderate availability of moisture to

cops after rain or irrigation.

pH: pH was determined by taking 1:5 ratio of soil and distilled water. pH of soil

in the study area is found to be slightly alkaline in the range of 7.63 to 8.05.

Electrical Conductivity: Electrical conductivity of the soil samples collected

from the study area is found to be in the range of 0.141 to 1.58 mS/cm.

Organic Carbon: Organic carbon of the soil in the study area is found to be

in the range from 0.6 to 2.27% which is average sufficient to more than

sufficient for crops.

Organic Matter: Organic matter of the soil in the study area is found to be in

the range from 1.04 to 3.92 %.

Cation Exchange capacity (CEC): The total amount of exchangeable cations

that a soil can retain is designated as cation exchange capacity (CEC) and

usually expressed as me/100gm of soil. Determination of amount of cations

present in soil is useful, because CEC influences the availability of adsorbed

cations to both higher plants and soil microorganisms. Thus, CEC is directly

related to fertility of soils. The CEC of the eight samples ranges between 12.60

to 24.56 meq / 100gm soil. A soil with low CEC indicates low fertility and soils

with high CEC indicates high fertility.

Available Nitrogen: Nitrogen is a part of all living cells and is a necessary

part of all proteins, enzymes and metabolic processes involved in the synthesis

and transfer of energy. Nitrogen is a part of chlorophyll, the green pigment of

the plant that is responsible for photosynthesis. It helps plants with rapid

growth, increasing seed and fruit production and improving the quality of leaf



and forage crops. Available Nitrogen content of the soil samples in the study

area ranges from 182 to 285 kg/ha, which is classified as better for crop growth.

Available Phosphorus (P): Like Nitrogen, Phosphorus (P) is an essential part

of the process of photosynthesis, which helps with the transformation of solar

energy into chemical energy; proper plant maturation; withstanding stress. It

effects rapid growth, encourages blooming and root growth. The phosphorus

content of soil of 8 samples ranges between and falls under very low and low

category, for crop growth. Available Phosphorus content of the soil samples in

the study area ranges from 47.3 to 66.2 kg/ha.

Arsenic (As): Arsenate can adsorb or co-precipitates with metal sulfides and

has a high affinity for other sulfur compounds. Elemental arsenic and arsine,

AsH3, may be present under extreme reducing conditions. In the soil samples

collected from the study area, arsenic values range between BDL (DL 0.2 mg

/kg) to 2.1 mg/kg.

Cadmium (Cd): In the soil samples collected from the study area, Cadmium

values are Below detection limit.

Chromium (Cr): Chromium mobility depends on sorption characteristics of

the soil, including clay content, iron oxide content, and the amount of organic

matter present. Chromium can be transported by surface runoff to surface

waters in its soluble or precipitated form. Soluble and un-adsorbed chromium

complexes can leach from soil into groundwater. In the soil samples collected

from the study area, Chromium values are below detection limit.

Lead (Pb): In the soil samples collected from the study area, Lead content are

below detection limit.

Nickel (Ni): In the soil samples collected from the study area, Nickel values

are below the detectible limit (DL= 0.2 mg/kg) to 3.11 mg/kg.

Zinc (Zn): Zn deficiency most often is present in sandy soils with neutral or

alkaline pH, or with low organic matter. Total zinc may be high but the

availability depends on other factors. In the soil samples collected from the

study area, Zinc value ranges between 1.23 to16.2 mg/kg.



Copper (Cu): Copper is an essential element for plant growth. Most plants

contain about 8 to 20 ppm. Without adequate copper, plants will fail to grow

properly. Therefore, maintaining fair amounts of copper in the soil is important.

In the soil samples collected from the study area, Copper value in soil ranges

between 9.32 to 24.4 mg/kg.

Iron (Fe): Iron is essential for crop and other plants for chlorophyll formation.

Iron deficiency likely occurs in soils with high pH, poor aeration, excessive

phosphorus, or low organic matter. It may be produced also by an imbalance

of Mo, Cu, and Mn. In plants, the deficiency shows up as a pale green leaf color

(chlorosis) with sharp distinction between green veins and yellow inter-venial

tissues. In the soil samples collected from the study area, Iron value ranges

between 12.47 to 32.72 mg/kg.

Manganese (Mn): Manganese is used in plants as major contribution to

various biological systems, including photo synthesis, respiration and nitrogen

assimilation. Manganese content in the soil samples collected from the study

area ranges between 3.45 to 8.88 mg/kg.

Total Boron: In the soil samples collected from the study area, Total Boron

value ranges between 0.42 to 0.62 mg/kg.

Exchangeable Calcium (Ca++): Calcium, an essential part of plant cell wall

structure, provides for normal transport and retention of other elements as well

as strength in the plant. It is also thought to counteract the effect of alkali salts

and organic acids within a plant and soil acidity. The exchangeable calcium

content of 8 soil samples ranges between 6.73 to 12.9 meq/100g soil, and

having normal base saturation percentage.

Exchangeable Magnesium (Mg++): Magnesium is part of the chlorophyll in

all green plants and essential for photosynthesis. It also helps activate many

plant enzymes needed for growth. The magnesium content of the 8 soil samples

ranges between 1.52 to 2.26 meq /100 g soil, which is further adding to base

saturation.

Exchangeable Sodium (Na+): Though sodium is not an essential plant

nutrient, but it has some role in potassium nutrition. Sodium also has a role in

affecting the pH of soils; Sodium present above a certain limit makes soil



alkaline which affect soil physical condition, and fixing of available phosphorus.

Out of the 8 samples sodium ranges between 1.58 to 2.76 meq/100g soil.

Exchangeable Potassium (K+): Potassium is absorbed by plants in larger

amounts than any other mineral element except nitrogen and, in some cases,

potassium helps in the building of protein, photosynthesis, fruit quality and

reduction of diseases. The Potassium content of 8 soil samples ranges between

0.16 to 0.48 meq /100 g and is sufficient for crop growth.

3.8 Water Resources

3.8.1 Surface Water Sources Arabian sea is located on the western side of the plant as the major surface

water body and is observed to ingress into the study area in the form of few

creeklets, creek and back water rivers. Main creeks in the study area are Satpati

Creek and Dandi Creek. Apart from the salt water body, Surya River flows in

eastern direction of the study area. Banganga and Jamuna River is also flowing

in the study area. The study area has presence of canal which carries water

from the Surya River (just outside of 10 km study area) and in from North East

to South West Direction. The canal remains dry during the summer season.

Apart from this the study area also has presence of few artificial lakes and

ponds. The study area has several stagnant water bodies near coastal area,

which are used as salt pans. The sampling locations for the water bodies were

finalized after reconnaissance survey and consultation with the functional area

expert.

3.8.2 Ground Water Resources

In the area, basaltic terrain has aquifers in the form of jointed and fractured

traps. The occurrence of ground water in Deccan trap is governed by its degree

of weathering, concentration of joints & fractures planes, porosity &

permeability of geological units. The movement & storage of ground water are

mainly controlled by physical & geological set up of the terrain. The basaltic

terrain has very less primary porosity, therefore cracks develop after

weathering, allow ground water to store. However due to adverse

morphological conditions, the availability of ground water is mainly restricted

to plains & valley fill. The irrigation based on ground water is seen only in the

parts of Dahanu, Talasari, Vasai & Palghar Tahsils. The coastal sandy aquifers

are sufficiently good yielding, but even a marginal over exploitation causes



intrusion of saline water. Although, fresh water is supplied by the pipelines in

the areas of Tarapur and Boisar city, ground water is used as an alternate

source in surrounding villages for drinking and domestic purposes. Therefore,

it is important to assess the existing baseline status of the ground water quality.

3.9 Water Quality

3.9.1 Ground Water Quality To evaluate the physico-chemical characteristics of the ground water resources

in the study area, ground water samples were collected during the study period.

Ground Water Sampling Locations

Reconnaissance survey was carried out for identification of ground water

samples. For selection of ground water samples, the following criterion were

considered.

• Drainage Pattern,

• Areas which may be affected due to the proposed activity,

• Ground water sources which are being used for local population for domestic

purpose.

Ground water sampling and analysis were carried out at six sampling locations

as given in Table 3.5. The ground water sampling locations are shown in

Figure 3.4.

Table 3.5: Ground Water Sampling Locations

Code Location of Ground

Water

Distance (Km)

Latitude & Longitude

Direction from

Project Site

Handpump/ Well/

Tube well

GW1 Shivaji Nagar

0.67 19°48'3.22"N

72°43'19.02"E

SW Handpump

GW2 Salvad 0.37 19 ͦ 48’ 33.7’ N

72 ͦ 43’ 19.7” E

WSW Handpump

GW3 Pasthal 0.89 19°48'51.57"N

72°43'30.21"E

NW Handpump

GW4 Saravali 5.69 19 ͦ 46’ 41.5” N

72 ͦ 45’ 13.7” E

SE Handpump



GW5 Kumbhavali 3.90 19 ͦ 46’ 18” N

72 ͦ 42’ 58” E

SSW Handpump

GW6 Boisar 4.65 19 ͦ47’56” N

72 ͦ 45’ 52” E

ESE Handpump

Note: At the plant site, there is no ground water source.

Methodology During study area, grab samples were collected from ground water sources.

The ground water samples were filled into a sampling bottles. The ground water

samples were collected and analyzed as per the procedures specified in

'Standard Methods for the Examination of Water and Wastewater' published by

American Public Health Association (APHA) and relevant Indian Standards

codes.

The samples collected during the period, were brought to M/s Shivalik Solid

Wastes Management Ltd. laboratory, which is NABL and MoEF & CC recognized

environmental laboratory. At the time of collection of samples proper

preservatives were added in ground water samples. During the transportation

samples were stored in deep freezer.

The collected water samples were analyzed for organoleptic & physical and

chemical parameters as parameters described in IS: 10500:2012.

Figure 3.4: Ground & Surface Sampling Locations



The analysis results of ground water samples collected during the study period

are given in Table 3.6. From the tabulated data the following inferences can

be made:

Temperature: The temperature of ground water samples was found between

27.7 to 29.8 oC.

Colour: The colour of ground water samples was found 1 to <5 Hazen unit

and meets the acceptable limit of drinking water standards.

Odour: The odour in ground water samples was agreeable and meets the

acceptable limit for drinking water standards.

Taste: The taste of ground water samples was agreeable and meets the

acceptable limit for drinking water standards.

Turbidity: The turbidity of water samples was found <1 NTU (Nephelometric

Turbidity Unit) and meets acceptable limit for drinking water standards.

pH: The pH value of ground water samples ranges from 7.62 to 7.9 and meets

the acceptable drinking water standards.

Total Dissolved Solids (TDS): The TDS in ground water samples range from

447.2 to 1238 mg/l and meet permissible limit of 2000 mg/l in the ground water

samples.

Total Alkalinity: Total alkalinity in ground water samples ranges from 236

mg/l to 400 mg/l. Total alkalinity values of the ground water samples exceeding

acceptable limit of 200 mg/l, however meeting permissible limit of 600 mg/l in

all the ground water samples.

Total Hardness: The total hardness of ground water samples ranges between

246 mg/l to 467 mg/l. Total hardness values of the ground water samples

exceeding acceptable limit of 200 mg/l, however meeting permissible limit of

600 mg/l in all the ground water samples.

Iron: The iron content in all ground water sample ranges from 0.11 to 0.24

mg/l and meets acceptable limits of 0.3 mg/l for the ground water samples.



Calcium: The Calcium content in ground water samples ranges from 48.34 to

99 mg/l. Calcium content of most of the ground water samples exceeding

acceptable limit of 75 mg/l, however meeting permissible limit of 200 mg/l in

all the ground water samples.

Magnesium: The magnesium content in ground water samples ranges from

28.08 mg/l to 54 mg/l and meeting permissible limit of 100 mg/l in all the

ground water samples.

Chloride: The Chloride content in ground water samples ranges from 55.08

mg/l to 337.34 mg/l and meeting permissible limit of 1000 mg/l in all the ground

water samples.

Sulphate: Sulphate content in ground water samples ranges from 31.34 to

127.26 mg/l and meets the acceptable limit of 200 mg/l at all the ground water

sampling locations.

Nitrate: Nitrate content in ground water samples ranges from 0.65 mg/l to

2.72 mg/l and meet the acceptable limit of 45 mg/l at all the ground water

sampling locations.

Fluoride: Fluoride content in ground water samples ranges from below

detection level (BDL) to 0.34 mg/l and meets acceptable limit of 1 mg/l at all

the ground water sampling locations.

Total Ammonia-N: Total Ammonia-N content in ground water samples ranges

from 0.09 to 0.18 mg/l and meets acceptable limit of 0.5 mg/l at all the ground

water sampling locations.

Total Phosphorus: Total Phosphorus content in ground water samples ranges

from 0.12 mg/l to 0.47 mg/l.

Total Nitrogen: Total Nitrogen content in ground water samples were found

below detection levels.

Sodium: Sodium content in ground water samples ranges from 28.7 mg/l to

171.3 mg/l.



Potassium: Potassium content in ground water samples ranges from 3.3 mg/l

to 46.7 mg/l.

Bacteriological Quality of Drinking Water: Total Coliform <1.8.

Escherichia coli (E. coli) was not be detectable in any ground water sample.

Other Parameters: Cyanide (CN), Phenolic Compounds (C6H5OH), Boron (B),

Total Arsenic (as As), Copper (as Cu), Total Chromium (as Cr), Cadmium (as

Cd), Lead (as Pb), Manganese (as Mn), Mercury (as Hg), Nickel (as Ni), Zinc

(as Zn) contents were found below detection limit (BDL) in all the ground water

samples.

The results of ground water samples were compared to Indian Standard

Specification of drinking water IS: 10500:2012. Some of analyzed parameters

in ground water samples meet acceptable limit however all the analyzed

parameters are meeting permissible limit in the absence of alternate source as

per Indian Standard Specification of drinking water IS: 10500:2012. The ground

water resources in the study area were found fit for drinking purpose.



Table 3.6: Ground Water Analysis Results for Study Area Sr.

No.

Parameters Unit Limits

(IS: 10500:2012)

Shivaji

Nagar Salvad Pasthal Saravali

Kumbhav

ali Boisar

Acceptable

Permissible Limit in the

Absence of Alternate

Source

GW1 GW2 GW3 GW4 GW5 GW6

1. Temperature oC -- -- 28.3 27.7 29.1 28.7 28.6 29.8

2. Colour Hazen 5 15 1 1 <5 1 1 1

3. Odour -- Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

4. Turbidity NTU 1 5 <1 <1 <1 <1 <1 <1

5. pH -- 6.5-8.5 No Relaxation 7.69 7.76 7.87 7.62 7.84 7.9

6. Conductivity µS/cm - - 1313 1053 2063 1770 852 721

7. Total Dissolve Solids mg/l 500 2000 788 632 1238 1062 528 447

8. Alkalinity as CaCO3 mg/l 200 600 400 344 400 316 236 248

9. Total Hardness as CaCo3

mg/l 200 600

467 312 462 362 251 246

10. Iron (as Fe) mg/l 0.3 No Relaxation 0.19 0.14 0.24 0.21 0.17 0.11

11. Calcium (as Ca) mg/l 75 200 99 77 97 82.57 48.34 52.36

12. Magnesium (as Mg) mg/l 30 100 54 29 54 37.8 31.74 28.08

13. Chloride (as Cl) mg/l 250 1000 120.48 80.89 337.34 298 111.87 55.08

14. Sulphate (as SO4) mg/l 200 400 53.29 48.19 126.32 127.26 42.23 31.34

15. Nitrate (as NO3) mg/l 45 No Relaxation 0.83 0.65 2.72 1.23 1.44 0.81

16. Fluoride (as F) mg/l mg/l 1 1.5 BDL BDL 0.34 BDL BDL BDL

17. NH3 (Total Ammonia-N)

mg/l 0.5 No Relaxation 0.12 0.14 0.18 0.11 0.13 0.09

18. Cyanide (CN) mg/l 0.05 No Relaxation

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

19. Phenolic Compounds (C6H5OH)

mg/l 0.001 0.002

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

20. Boron (B) mg/l 0.5 1.0

BDL

(DL-0.2)

BDL

(DL-0.2)

BDL

(DL-0.2)

BDL

(DL-0.2)

BDL

(DL-0.2)

BDL

(DL-0.2)



Sr. No.

Parameters Unit Limits (IS: 10500:2012)

Shivaji Nagar

Salvad Pasthal Saravali Kumbhav

ali Boisar

Acceptable

Permissible

Limit in the Absence of

Alternate Source


21. Total Arsenic (as As) mg/l 0.02 0.05

BDL

(DL=0.009)

BDL

(DL=0.009)

BDL

(DL=0.009)

BDL

(DL=0.009)

BDL

(DL=0.009)

BDL

(DL=0.009)

22. Copper (as Cu) mg/l 0.05 1.5

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

BDL

(DL=0.02)

23. Total Chromium (as

Cr)

mg/L 0.05 No Relaxation

BDL

(DL=0.04)

BDL

(DL=0.04)

BDL

(DL=0.04)

BDL

(DL=0.04)

BDL

(DL=0.04)

BDL

(DL=0.04)

24. Cadmium (as Cd) mg/l 0.003 No Relaxation

BDL (DL=0.003)

BDL (DL=0.003)

BDL (DL=0.003)

BDL (DL=0.003)

BDL (DL=0.003)

BDL (DL=0.003)

25. Lead (as Pb) mg/L 0.01 No Relaxation

BDL (DL=0.008)

BDL (DL=0.008)

BDL (DL=0.008)

BDL (DL=0.008)

BDL (DL=0.008)

BDL (DL=0.008)

26. Manganese (as Mn) mg/l 0.1 0.3

BDL

(DL=0.09)

BDL

(DL=0.09)

BDL

(DL=0.09)

BDL

(DL=0.09)

BDL

(DL=0.09)

BDL

(DL=0.09)

27. Mercury (as Hg) mg/l 0.001 No Relaxation

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

28. Nickel (as Ni) mg/l 0.02 No Relaxation

BDL (DL=0.01)

BDL (DL=0.01)

BDL (DL=0.01)

BDL (DL=0.01)

BDL (DL=0.01)

BDL (DL=0.01)

29. Zinc (as Zn) mg/L 5 15

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

30. Total Phosphorous mg/l -- -- 0.27 0.39 0.47 0.12 0.39 0.21

31. Total Nitrogen mg/l -- -- BDL BDL BDL BDL BDL BDL

32. Dissolved Oxygen mg/l -- -- 6.2 5.7 6.1 5.8 6.4 6.3

33. Oil & Grease mg/l -- -- BDL BDL BDL BDL BDL BDL

34. Sodium mg/l -- -- 58.2 48.3 171.3 162.6 53.32 28.7

35. Potassium mg/l -- -- 5.1 5.7 46.7 34.2 3.3 3.4



Sr. No.

Parameters Unit Limits (IS: 10500:2012)

Shivaji Nagar

Salvad Pasthal Saravali Kumbhav

ali Boisar

Acceptable

Permissible

Limit in the Absence of

Alternate Source


36. Total Coliform MPN

/100 ml 10 --

<1.8 <1.8 <1.8 <1.8 <1.8 <1.8

37. E Coli --- Shall not be

detectable

in any 100ml

sample

--

Absent Absent Absent Absent Absent Absent

Note: BDL – Below Detection Limit

Date of Soil Sampling: 12 April 2017



3.9.2 Surface Water Quality

During the study period, surface water samples were collected and analysed

from surface water bodies in the study area. sampling locations are given in

Table 3.7 and shown in Figure 3.4. Grab samples were collected from surface

water sources. The surface water samples were filled into a sampling bottles

and necessary preservative were added in the collected samples. The surface

water samples collected were brought to M/s Shivalik Solid Waste Management

Ltd. Laboratory, which is NABL and MoEF&CC recognized environmental

laboratory. During the transportation, samples were stored in deep freezer. The

surface water samples were collected and analyzed as per the procedures

specified in 'Standard Methods for the Examination of Water and Wastewater'

published by American Public Health Association (APHA) and relevant Indian

Standards codes.

Table 3.7: Surface Water Sampling Locations

Code Surface Water

Sampling

Locations

Distance

(Km)

Latitude &

Longitude

Direction from

the Site

SW1 Banganga River 2.50 19°48'38.05"N

72°43'27.86"E WNW

SW2 Nandgaon Lake 6.2 19°45'40.58"N

72°41'27.60"E SW

SW3 Bandhara Talav 5.73 19°45'36.25"N 72°42'6.29"E

SSW

SW4 Navapur Sea water 4.85 19°46'58.35"N

72°40'46.12"E WSW

SW5 Surya River 10.65 19°48'19.41"N 72°50'14.52"E

NE

The analysis results for surface water bodies are given in Table 3.8.

Table 3.8: Surface Water Analysis Results for Study Area

Sr.No

Parameters Units SW1 SW2 SW3 SW4 SW5

Banganga River

Nandgaon lake

Bandhara Talav

Navapur Sea water

Surya River

1. Temperature oC 28.3 27.4 27.9 28.3 27.8

2. Odour - Agreeable Agreeable Agreeable Agreeable Agreeable

3. Color Hazen 2 2 2 2 2

4. Turbidity NTU 3.6 4.2 3.9 3.3 3.8

5. pH -- 7.77 7.62 7.56 7.96 7.81

6. Conductivity 402 328 426 56234 431

7. Total Suspended solids (TSS)

mg/l 45 36 56 62 42



Sr.No


Banganga River

Nandgaon lake

Bandhara Talav

Navapur Sea water

Surya River

8. Total Dissolved Solids (TDS)

mg/l 268 221 271 36743 282

9. DO mg/l 6.2 5.7 5.5 6.7 6.2

10. COD mg/l 3.8 7.6 3.8 7.6 3.8

11. BOD mg/l 2.1 2.53 <2 <2 <2

12. Oil & Grease mg/l BDL BDL BDL BDL BDL

13. Calcium mg/l 36 30 34 435 32

14. Magnesium mg/l 15 10 18 1330 9

15. Chloride mg/l 41.31 30.98 32.7 19825.32 43.03

16. Sulphate (SO4) mg/l 16.74 11.64 21.61 2845.32 14.56

17. Nitrate (NO3) mg/l 1.93 0.84 1.77 26.00 0.59

18 Nitrite, mg/l BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

19. Fluoride (as F) mg/l BDL BDL BDL 0.07 BDL

20. Cyanide (as CN) mg/l BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

21. Phenolic Compounds (as C6H5OH)

mg/l BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

BDL (DL=0.001)

22. Boron (as B) mg/l BDL (DL-0.2)

BDL (DL-0.2)

BDL (DL-0.2)

BDL (DL-0.2)

BDL (DL-0.2)

23. Total Arsenic (as As)

mg/l BDL (DL=0.009)

BDL (DL=0.009)

BDL (DL=0.009)

0.006

BDL (DL=0.009)

24. Copper (as Cu) mg/l BDL (DL=0.03)

BDL (DL=0.02)

BDL (DL=0.02)

0.02 (DL=0.02)

BDL (DL=0.02)

25. Total Chromium (as Cr)

mg/l BDL (DL=0.04)

BDL (DL=0.04)

BDL (DL=0.04)

BDL (DL=0.04)

BDL (DL=0.04)

26. Cadmium (as Cd) mg/l BDL (DL=0.003)

BDL (DL=0.003)

BDL (DL=0.003)

0.004 BDL (DL=0.003)

27. Iron (as Fe) mg/l BDL (DL=0.02)

0.14 BDL (DL=0.02)

1.8 BDL (DL=0.02)

28. Lead (as Pb) mg/l BDL (DL=0.008)

BDL (DL=0.008)

BDL (DL=0.008)

BDL BDL (DL=0.008)

29. Manganese (as Mn)

mg/l BDL (DL=0.09)

BDL (DL=0.09)

BDL (DL=0.09)

0.02 BDL (DL=0.09)

30. Mercury (as Hg) mg/l BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

BDL

(DL=0.001)

31. Nickel (Ni) mg/l BDL (DL=0.01)

BDL (DL=0.01)

BDL (DL=0.01)

0.01 BDL (DL=0.01)

32. Zinc (as Zn) mg/l BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

2.3 BDL (DL=0.02)

33. Sodium mg/l 18.53 15.31 19.24 11554.32 23.36

34 Potassium Mg/l 2.1 1.9 2.8 463.23 3.7

35 Total Nitrogen mg/l BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

BDL (DL=0.02)

36 Total Phosphorus 0.9 1.1 1.6 1.3 1.4 1.2



Sr.No


Banganga River

Nandgaon lake

Bandhara Talav

Navapur Sea water

Surya River

37. Total Coliform MPN/ 100 ml

1532 1754 1154 265 956

38. Fecal Coliform MPN/ 100 ml

342 527 212 98 187

Note: BDL – Below Detection Limit Date of Soil Sampling: 11 April 2017

From the tabulated data given in Table 3.8 the following inferences can be

made:

River Water (SW-1 & SW-5) As per classification of Inland Surface Water Standards, analysis results for all

surface water of all river could be considered under Class “B”.

Lake and Pond Water (SW-2 & SW-3) Based on the tabulated results, it can be stated that the surface water from the

above lake and pond can be classified as “B” category and be used for bathing

and cattle use.

Quality of Sea Water (SW-4) The analysis result for sea water indicates that the analyzed parameters are reasonable.

Table 3.9: Designated Best Uses of Water as per CPCB

Designated-Best-Use Class of water

Criteria

Drinking water source without

conventional treatment but

after disinfection

A Total Coliforms Organism

MPN/100ml shall be 50 or less;

pH between 6.5 and 8.5;

Dissolved Oxygen 6mg/l or more

Outdoor bathing (Organized) B Total Coliforms Organism


pH between 6.5 and 8.5;


Drinking water source after

conventional treatment and

disinfection

C Total Coliform Organism


pH between 6 to 9;



Designated-Best-Use Class of water

Criteria


Propagation of Wild life and

Fisheries

D pH between 6.5 to 8.5;

Dissolved Oxygen 4mg/l or more;

Free Ammonia (as N) 1.2 mg/l or

less

Irrigation, Industrial Cooling,

Controlled Waste disposal

E pH between 6.0 to 8.5;

Electrical Conductivity at 25°C

micromhos/cm Max.2250;

Sodium absorption ratio max. 26;

Boron Max. 2mg/l

Below-E

Not Meeting A, B, C, D & E

Criteria

3.9.3 Treated Effluent Analysis

Trade effluents generated from various processes at UPL Plant are treated in

existing ETP comprising primary, secondary and tertiary treatment facilities.

Treated effluents from UPL Plant are sent to common effluent treatment plant

(CETP) located within MIDC Tarapur Notified industrial area. During the study

period sample of treated waste water/effluents after tertiary treatment was

collected and analyzed. Analysis results for treated waste water at the disposal

point from ETP at UPL’s existing plant to CETP are given in Table 3.10. Treated

effluent are meeting discharge limit prescribed by MPCB in CC&A.

Table 3.10: Analysis Results for Treated Effluents from Existing ETP

Sr.

No.

Parameters Analysis Results

for Treated

Effluents

Standards

Prescribed by

MPCB in CC&A

1. pH 7.51 5.5 to 9.0

2. BOD (3 days) 14.7 100

3. COD 137.5 250

4. Suspended Solids 11.6 100

5. Oil & Grease 0.53 10

6. Total Dissolved Solids 1341 2100

7. Phenol & Phenolic

Compounds as C6H5OH

BDL 1

8. Phosphate 0.12 5



Sr.

No.

Parameters Analysis Results

for Treated

Effluents

Standards

Prescribed by

MPCB in CC&A

9. Sulphur 0.31 30

Date of Sampling: 10 April 2017

3.10 Climatology and Meteorology 3.10.1Introduction

The meteorological parameters play a vital role in transport and diffusion of

pollutants in the atmosphere. The collection and analysis of meteorological

data, therefore, is an essential component of environmental impact assessment

studies. The long term and short-term impact assessment could be made

through utilization and interpretation of meteorological data collected over long

and short periods, respectively. Since the meteorological parameters exhibit

significant variations in time and space, meaningful interpretation can only be

drawn through a careful analysis of reliable data collected at the site.

3.10.2 Climatology Climatological (long-term) data is obtained from the closest Indian Meteorology

Department (IMD) station, which has been collecting meteorological data for

more than ten years. Climatological data for the project site was obtained and

the same is discussed in following subsections. For environmental impact

assessment study for proposed expansion of UPL, climatological data was

obtained from Dahanu IMD station, which is located about 28 km in north

direction from the existing UPL plant at Tarapur.

A. Temperature The climate in the area is hot and humid. The diurnal range of temperature

does not exceed 17°C. The climate is pleasant during winter (November to

February), when the humidity is low. During summer the climate is very warm

particularly in the eastern parts, which is away from the coastal region. Highest

and lowest temperatures in the area are given Table 3.11. The highest and

lowest temperatures are shown in Figure 3.5.



Table 3.11: Temperatures and Humidity in the Area

Month Highest Temperature

(oC)

Lowest Temperature

(oC)

Relative Humidity (%)

08.30 17.30

January 32.7 13.4 65 66

February 33.4 14.2 63 64

March 35.7 17.4 64 62

April 35.8 21.3 71 65

May 36.1 24.4 72 67

June 35.7 23.8 81 75

July 33.0 23.8 88 83

August 32.0 23.8 88 82

September 33.0 22.8 86 77

October 35.6 20.9 75 69

November 35.0 17.5 64 67

December 33.6 14.9 63 67

Annual 37.4 12.8 73 70

Source: IMD Station, Dahanu

Figure 3.5: Maximum & Minimum Temperatures in the Area



Monthly average meteorological data for past 10 years (2005-2015) is given

in Table 3.12.

Table 3.12: Monthly Average Meteorological Data for Past 10 Years

(2005-2015)

Month Highest Temperature

(oC)

Lowest Temperature

(oC)

Relative Humidity (%)

08.30 17.30

January 34.5 12.9 68 49

February 35.9 13.9 65 47

March 38.0 17.0 66 51

April 37.4 21.3 70 60

May 36.1 24.0 69 65

June 34.8 23.0 80 75

July 31.9 23.3 86 82

August 31.2 23.4 86 81

September 33.2 22.8 85 77

October 36.1 20.6 75 65

November 35.6 17.5 62 55

December 34.5 14.6 62 52

Annual 38.9 12.5 73 63 Source: IMD Station, Dahanu

B. Humidity Table 3.10 also gives the relative humidity (RH) data at IMD station Dahanu.

The air is very humid during monsoon when relative humidity is 81 to 88 %.

When the monsoon is over, the relative humidity decrees progressively upto

63% and weather become pleasant. In the hot season the humidity increases

reached to 72 %. Humidity generally in the afternoons goes down except in

January month. The monthly relative humidity is shown in Figure 3.6.



C. Rainfall The south-west monsoon normally enters into the area in the first week of June

and prevails till last week of September. Rainfall data for Dahanu IMD station

is given Table 3.13. Monthly rainfall given in Table 3.13 is in millimeter (mm)

while values given parenthesis are rainy days.

Table 3.13: Rainfall (in mm)

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual 0.3 0.1 0.1 0.5 3.9 391.4 628.3 430.6 265.6 47.1 16.5 0.5 1784.5

(0.1) (0.0) (0.0) (0.1) (0.7) (11.3) (20.0) (18.2) (10.8) (2.6) (0.9) (0.2) (64.8)


Average rainfall received annually in the area is 1784.5 mm. Rainy months are

June to September and 96.2% rainfall is received during these months. There

are about 64.8 rainy days in a year. Graphical representation of rainfall in the

area is shown in Figure 3.7.

Figure 3.7: Rainfall in the Area

Figure 3.6: Relative Humidity in the Area



D. Wind Speed Mean wind speed at Dahanu IMD station is given Table 3.14 and shown in

Figure 3.11. Annual average wind speed at Dahanu IMD station is 10.7 kmph.

Highest average monthly wind speed is observed in July (18.1 kmph) while

lowest mean wind speed (6.5 kmph) is observed in November month.

Table 3.14: Wind Speed (kmph) in the Area

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Annual

7.5 8.5 9.2 10.4 12.4 14.4 18.1 17.7 10.7 7.1 6.5 6.6 10.7


E. Wind Direction In the area, winds blow predominantly from the west to south-west direction

from April to September months. From October to March months predominant

winds during morning time are from East while evening winds blow from North

West direction. In April month predominant winds during morning time are from

East-South direction while evening from South West-West direction. In the area

calm period varies from 0 to 30 % of the total time.

Wind direction and wind speed for Dahanu IMD station at 8:30 hours and 17:30

hours are also given in Table 3.15. Monthly windrose diagrams for morning

and evening time are given in Figure 3.9 to Figure 3.12, respectively.

Figure 3.8: Monthly Wind Speed in the Area



Table 3.15: Wind Direction & Frequency (From) in the Area

Sn Months N NE E SE S SW W NW Calm

1. January 15 9 41 11 0 0 0 1 23

30 1 1 0 0 2 6 50 10

2. February 13 11 38 10 0 0 1 3 24

21 1 0 0 0 3 14 57 4

3. March 12 8 39 15 0 0 0 3 23

15 0 0 0 0 7 25 51 2

4. April 5 4 19 25 3 5 5 4 30

5 0 0 0 0 21 47 26 1

5. May 1 1 5 13 6 32 20 5 17

1 0 0 0 1 44 47 7 0

6. June 0 1 5 16 6 43 17 2 10

0 0 1 3 5 62 24 2 3

7. July 0 0 2 9 3 57 19 2 8

0 0 0 1 3 66 25 1 4

8. August 0 0 2 7 2 48 27 3 11

0 0 0 1 1 59 33 2 4

9. September 2 2 20 21 2 15 12 5 21

3 0 1 3 2 30 35 18 8

10. October 3 5 48 22 0 0 1 1 20

13 2 1 1 1 7 21 42 12

11. November 3 6 49 19 0 0 0 1 22

26 2 1 1 0 2 8 44 16

12. December 7 9 43 18 0 0 0 0 23

32 2 0 0 0 1 5 41 19

Annual 5 5 26 15 2 17 8 3 19

12 1 0 1 1 25 24 29 7 Source: IMD Station, Dahanu Special Weather Phenomenon

The precipitation 0.3 mm or more is observed 92 days in year. Maximum

thunder is observed in June, September & October (6.9 d). Fog is observed in

December & February (0.2 d). Hail, Dust Storm, Squall are rare in the area.

Special Weather Phenomena for the area is given in Table 3.16.



Table 3.16: Special Weather Phenomena in the Area

Months PPT 0.3 mm or more

Hail Thunder Fog Dust Storm

Squall

January 0.3 0.0 0.1 0.0 0.0 0.0

February 0.1 0.0 0.1 0.1 0.0 0.0

March 0.1 0.0 0.1 0.0 0.0 0.0

April 0.1 0.0 0.0 0.0 0.0 0.0

May 1.1 0.0 0.4 0.0 0.0 0.0

June 15.4 0.0 2.8 0.0 0.0 0.0

July 27.2 0.0 0.9 0.0 0.0 0.0

August 26.3 0.0 0.3 0.0 0.0 0.0

September 15.6 0.0 2.7 0.0 0.0 0.0

October 3.8 0.0 1.4 0.0 0.0 0.0

November 1.5 0.0 0.5 0.0 0.0 0.0

December 0.3 0.0 0.0 0.1 0.0 0.0

Annual 92 0.0 9.3 0.2 0.0 0.0




Winds From

Figure 3.9: Monthly Wind Rose Diagram for Morning (Jan to June)



Winds From

Figure 3.10: Monthly Wind Rose Diagram for Morning (Jul to Dec)



Figure 3.11: Monthly Wind Rose Diagram for Evening (Jan to June)

Winds



Figure 3.12: Monthly Wind Rose Diagram for Evening (Jul to Dec)

Winds From



3.10.3 Micro Meteorological Data for the Site

Micrometeorology data changes after a few kilometers due to changes in local

topography. Furthermore, IMD data records only at 8:30 AM and 5:30 PM for

only eight wind directions with wind speeds over widely spaced ranges, which

is not of much use in air pollution dispersion modeling.

Because of these limitations, micrometeorological data was collected near site

round the clock and an automatic weather monitoring instrument was installed

at the plant site free from any obstruction. The hourly meteorological data,

such as, wind speed and direction, ambient temperature, and relative humidity

was collected at the site and is presented in Table 3.17 for study period.

Table 3.17: Summary of Micro Meteorological Conditions at the Site

Temperature

(°C)

Relative Humidity

(%)

Wind Speed

(kmph)

Wind Direction

(Towards)

March, 2017

Maximum 35.9 67 11.4 W (Day) SE (Night)

Minimum 18.3 58 Calm

Average 25.4 62 9.1

April, 2017

Maximum 36.1 72 14.7 NW (Day) E (Night)


Average 29.5 69 10.9

May, 2017

Maximum 36.8 76 16.3 NE (Day) E (Night)


Average 30.3 71 11.6

March-May 2017

Maximum 36.8 76 16.3 W (Day) E (Night)


Average 31.8 73 12.3

A. Temperature The maximum ambient temperature recorded at the plant site during the study

period was 36.8 ˚C, while minimum temperature was recorded as 18.3 ˚C.



B. Relative Humidity During the study period, maximum relative humidity recorded at the plant site

was 76 % while minimum humidity was recorded as 58 %.

C. Wind Speed During the study period, maximum wind speed recorded at the site was 16.3

kmph while minimum wind speed was recorded as less than 1.8 kmph (calm

period). Mean wind speed during the study period was recorded as 12.3 kmph.

D. Wind Pattern During the study period, predominant wind direction was recorded from E

Sector towards W Sector. Wind rose diagram for Day time and Night Time for

study period are shown in Figure 3.13 and 3.14, respectively.

3.11 Ambient Air Quality

The prime objective of the ambient air quality monitoring is to evaluate the

baseline air quality of the area, which is essential to predict impact of existing

plant and operation of plant after expansion. During the study period, ambient

air quality monitoring was carried out in the study area. This section describes

the selection of sampling locations for air quality monitoring, methodology

adopted for sampling, analytical techniques and frequency of sampling.

3.11.1 Ambient Air Quality Sampling Period

The ambient air quality monitoring was carried out during from 1st March 2017

to 31st May 2017.



Figure 3.13: Wind Rose Diagram for Day Time for the Study Period



Figure 3.14: Wind Rose Diagram for Night Time for the Study Period



3.11.2 Selection of Ambient Air Sampling Locations

The ambient air quality monitoring locations were established in the study area.

For selection of ambient air quality monitoring locations, the following factors

were considered:

✓ Meteorological conditions in the area;

✓ Topography of the study area;

✓ Representativeness of the habitation for establishing baseline status;

✓ Likely impact areas.

The ambient air quality monitoring locations in the study area are described in

Table 3.18 and shown on Figure 3.15.

Table 3.18: Details of Ambient Air Quality Monitoring Locations

Code Locations of

Ambient Air

Monitoring

Locations

Latitude &

Longitude

Distance

(km)

Direction Angle

from

North

A1 Project Site 19°48'19.60"N

72°43'41.53"E

0 - 0

A2 Salvad 19 ͦ 48’ 33.7’ N

72 ͦ 43’ 19.7” E

0.37 WSW 265

A3 Pasthal 19°48'51.57"N

72°43'30.21"E

0.93 NW 340

A4 Saravali 19 ͦ 46’ 41.5” N

72 ͦ 45’ 13.7” E

5.78 SSE 150

A5 Kumbhavali 19 ͦ 46’ 18” N

72 ͦ 42’ 58” E

3.90 SSW 200

A6 Boisar 19 ͦ 47’56” N

72 ͦ 45’ 52” E

4.80 ESE 90

A7 Kudan 19 ͦ 48’ 19.2” N

72 ͦ 44’ 57.9” E

4.83 NNW 335

A8 Pam 19 ͦ 47’ 28.8” N

72 ͦ 45’ 13.7” E

1.84 SSW 210



3.11.3 Parameters and Frequency of Ambient Air Quality Monitoring Envirotech APM 460 BL Respirable Dust Sampler (RDS) and (Envirotech APM

550)/Ecotech (AAS 127) fine particulate matter Sampler were deployed for

ambient air quality monitoring.

The baseline ambient air quality was monitored for the following parameters as

per National Ambient Air Quality Standards:

• Particulate Matter (PM2.5);

• Particulate Matter (PM10);

• Sulphur dioxide (SO2);

• Nitrogen Dioxide (NO2);

• Ozone (O3);

• Lead (Pb);

• Carbon Monoxide (CO);

• Ammonia (NH3);

• Benzene (C6H6);

• Benzo (a) Pyrene (BaP);

• Arsenic (As); and

• Nickel (Ni).

Ambient Air quality monitoring was carried out twice a week at each location

for one season from 1st March 2017 to 31st May 2017.

During the study period, ambient air quality monitoring was also carried for

project specific parameters namely, Hydrogen Chloride gas (HCl), Chlorine

(Cl2), Phosphorus trichloride (PCl3), Hydrogen Sulfide (H2S), Methylene Chloride

(MeCl), Hydrogen Bromide (HBr) and Hydrocarbon (HC).

3.11.4 Sampling and Analytical Techniques PM2.5 and PM10 have been estimated by gravimetric method. Modified West and

Gaeke method (IS-5182 part-II, 1969) have been adopted for estimation of

SO2. Jacobs-Hochheiser method (IS-5182 part-IV, 1975) has been adopted for

the estimation of NO2.



Samples for carbon monoxide were analyzed using NDIR techniques. The

techniques adopted for sampling and analysis are given in Table 3.19 along

with the minimum detection limits for each parameter.

Table 3.19: Techniques Used for Ambient Air Quality Monitoring

S.

No.

Parameter Technique Detectable

Limit

(µg/m3)

1. Particulate Matter

(PM10)

Gravimetric [EPA -40 (CFR Part

50)]

2.0

2. Particulate Matter

(PM2.5)

Gravimetric [EPA -40 (CFR Part

50)]

2.0

3. Sulphur Dioxide

(SO2)

Improved West and Gaeke 5.0

4. Nitrogen Dioxide

(NO2)

Modified Jacob & Hochheiser 5.0

5. Carbon Monoxide

(CO)

NDIR [IS 13270 : 1992] 0.1

6. Ammonia (NH3) Nesslers Method (APHA) 20

Figure 3.15: Ambient Air Monitoring Locations



S.

No.

Parameter Technique Detectable

Limit

(µg/m3)

7. Ozone (O3) KI Absorption Method 5.0

8. Lead (Pb) AAS Method [IS 5182 (Part 22):

2004]

0.1

9. Arsenic (As) AAS Method [IS 5182 (Part 22):

2004]

0.001

10. Nickel (Ni) AAS Method [IS 5182 (Part 22) :

2004]

0.001

11. Benzene (C6H6) Adsorption & Desorption followed

by GC [IS 5182 (Part 11): 2006]

0.01

12. Benzo (a) pyrene

(BaP)

Solvent Extraction followed by

GC Analysis [IS 5282 (Part 12):

1991]

0.001

3.11.5 Results of Ambient Air Quality Monitoring

The summary of results of ambient air quality monitoring of PM2.5, PM10, SO2,

NO2, NH3, O3, C6H6, BaP, Pb, As, Ni and CO are presented in Table 3.20. The

summary of monitoring results for Hydrogen Chloride gas (HCl), Chlorine (Cl2),

Phosphorus trichloride (PCl3), Hydrogen Sulfide (H2S), Methylene Chloride

(MeCl), Hydrogen Bromide (HBr) and Hydrocarbon (HC) are presented in Table

3.21. Detailed monitoring results are given in Appendix 1. The graphical

representation of ambient air quality in the study area is given in Figure 3.16

to Figure 3.20.

On the basis of tabulated data in Table 3.20, the following observations can be made: Particulate Matter (PM10) The maximum and minimum concentrations for PM10 were recorded as 95.94

µg/m3 and 65.94 µg/m3, respectively. The maximum concentration of PM10 was

recorded at the Project site and minimum concentration was observed at village

Kumbhavali. The mean concentrations range between 74.69 and 89.03 µg/m3.

98th percentile values for PM10 during study period range between 79.74 to

95.64 µg/m3.



Fine Particulate Matter (PM2.5) The maximum and minimum concentrations for PM2.5 were recorded as 55.87

µg/m3 and 20.81 µg/m3, respectively. The maximum concentration was

recorded at Project site and the minimum concentration was recorded at village

Pam. The mean concentrations range between 26.72 and 48.66 µg/m3. 98th

percentile values for PM2.5 during study period range between 30.42 to 55.77

µg/m3.

Sulphur Dioxide (SO2) The maximum and minimum SO2 concentrations were recorded as 25.84 µg/m3

and 11.91 µg/m3. The maximum concentration was recorded at village Salvad

and the minimum concentration was recorded at village Kumbhavali. The mean

values were observed from 13.96 µg/m3 to 22.43 µg/m3. 98th percentile values

for SO2 during study period range between 15.63 to 25.77 µg/m3.

Nitrogen Oxide (NO2) The maximum and minimum NO2 concentrations were recorded as 45.84 µg/m3


and the minimum concentration was recorded at Kumbhavali. The mean values

for NO2 were observed in the range between 23.31 and 3764 µg/m3. 98th

percentile values for NO2 during study period range between 28.19 to 44.6

µg/m3.

Carbon Monoxide (CO) The 8-hourly CO concentrations during study period were found below

detection limit during the study period in the study area.

Ammonia (NH3)

The NH3 concentrations were found BDL to 12.23 g/m3 during the study

period. The mean values for NH4 were observed in the range between 2.96 to 6.90 µg/m3. 98th percentile values for NH4 during study period range between 3.76 to 12.20



Ozone (O3) The Ozone concentrations were found below detection limit during the study

period in the study area.

Benzene (C6H6) The Benzene concentrations were found below detection limit during the study


Benzo (a) Pyrene (BaP) The BaP concentrations were found below detection limit during the study


Lead (Pb) The Lead concentrations were found below detection limit during the study


Arsenic (As) The Arsenic concentrations were found below detection limit during the study


Nickel (Ni) The Nickel concentrations were found below detection limit during the study


Monitoring of the Plant Specific parameters During the study period, ambient air quality monitoring was also carried out for

Hydrogen Chloride gas (HCl), Chlorine (Cl2), Phosphorus trichloride (PCl3),

Hydrogen Sulfide (H2S), Methylene Chloride (MeCl), Hydrogen Bromide (HBr)

and Hydrocarbon (HC). The concentrations of these parameters during study

period were found below detection limit.



Ambient Air Quality Status

National ambient air quality standards for industrial, residential, rural & other

areas are met for all monitored parameters at all AAQM locations during the

study period.

Table 3.20: Ambient Air Quality Results

Air Quality Parameters

Location Min. Max. Avg. 98%tile NAAQS Limit

PM10(µg/m3)

Project Site 82.18 95.94 89.03 95.64

100(µg/m3)

Salvad 80.45 93.85 85.2 93.26

Pasthal 81.47 92.02 86.02 91.71

Saravali 80.36 92.42 85.57 92.42

Kumbhavali 65.94 80.94 74.69 80.73

Boisar 75.11 85.17 80.76 84.86

Kudan 75.94 88.98 81.28 87.92

Pam 70.27 80.47 75.07 79.74

PM2.5(µg/m3)

Project Site 41.41 55.87 48.66 55.77

60(µg/m3)

Salvad 35.13 48.09 41.01 48.08

Pasthal 31.33 40.77 36.27 40.55

Saravali 30.37 39.76 35.22 39.75

Kumbhavali 23.77 30.87 27.88 30.62

Boisar 31.08 40.54 34.29 39.88

Kudan 40.25 49.04 43.89 49.02

Pam 20.81 31.04 26.72 30.42

SO2(µg/m3)

Project Site 15.63 20.35 17.99 20.15

80(µg/m3)

Salvad 15.89 25.84 22.43 25.77

Pasthal 15.06 20.34 17.97 20.32

Saravali 16.07 25.21 21.88 25.06

Kumbhavali 11.91 15.71 13.96 15.63

Boisar 12.37 18.74 16.2 18.64

Kudan 14.33 20.86 18.37 20.79

Pam 14.83 20.21 17.17 20.21

NO2(µg/m3)

Project Site 24.65 38.52 30.24 38.17

80(µg/m3) Salvad 30.82 45.84 35.07 44.6

Pasthal 25.18 35.51 27.25 34.03

Saravali 25.19 32.38 27.21 32.12





Kumbhavali 20.23 28.61 23.31 28.19

Boisar 25.4 31.86 28.82 31.79

Kudan 33.32 42.47 37.64 41.80

Pam 20.29 30.45 23.82 30.16

Ammonia (NH3) (µg/m3)

Project Site 3.49 12.23 6.90 12.20 400(µg/m3)

Salvad 1.21 3.83 2.96 3.76

Pasthal BDL BDL BDL BDL

Saravali BDL BDL BDL BDL

Kumbhavali BDL BDL BDL BDL

Boisar BDL BDL BDL BDL

Kudan BDL BDL BDL BDL

Pam BDL BDL BDL BDL

Ozone(O3) (µg/m3)

Project Site BDL BDL BDL BDL 100(µg/m3)

Salvad BDL BDL BDL BDL






Pam BDL BDL BDL BDL

CO(µg/m3)

Project Site BDL BDL BDL BDL

2000 (ug/m3)







Pam BDL BDL BDL BDL

Lead (Pb) (µg/m3)


1 µg/m3











Pam BDL BDL BDL BDL

Benzene

(µg/m3)


5 µg/m3







Pam BDL BDL BDL BDL

Benzo (a) pyrene

(BaP) (ng/m3)

Project Site BDL BDL BDL BDL 1 ng/m3







Pam BDL BDL BDL BDL

Arsenic (As)

(ng/m3)








Pam BDL BDL BDL BDL

Nickel (Ni)

(ng/m3)








Pam BDL BDL BDL BDL



Table 3.21: Ambient Air Quality Results for Project-Specific

Parameters

Sr. No.

Location HCl (µg/m3)

Cl2

(µg/m3) PCl3

(µg/m3) H2S

(µg/m3) MeCl

(µg/m3) HBr

(µg/m3) HC

(µg/m3)

1 Project Site BDL BDL BDL BDL BDL BDL BDL

2 Salvad BDL BDL BDL BDL BDL BDL BDL

3 Pasthal BDL BDL BDL BDL BDL BDL BDL

4 Saravali BDL BDL BDL BDL BDL BDL BDL

5 Kumbhavali BDL BDL BDL BDL BDL BDL BDL

6 Boisar BDL BDL BDL BDL BDL BDL BDL

7 Kudan BDL BDL BDL BDL BDL BDL BDL

8 Pam BDL BDL BDL BDL BDL BDL BDL

Figure 3.16: PM10 Values During the Study Area



Figure 3.17: PM2.5 Values During the Study Area

Figure 3.18: SO2 Values During the Study Area



Figure 3.19: NO2 Values During the Study Area

Figure 3.20: CO Values During the Study Area



3.12 Stack Emission and Stacks Monitoring At the existing plant of UPL, coal, husk and furnace fired boilers, DG sets and

process vents/stacks are the source of continuous and intermittent sources of

emissions. During the study period stack emission monitoring was carried out

for all the stacks at the existing plant. Stack monitoring results are given in

Table 3.22. Stack monitoring parameters are within the permissible emission

standards as stipulated in CC&A by MPCB for the existing UPL Plant.

3.13 Noise Environment

Noise after a certain level can have a very disturbing effect on the people and

animals exposed to it. Hence, it is important to assess the present noise quality

of the area in order to predict the potential impact of future noise levels due to

the proposed expansion project. To understand the noise environment in the

study area, noise survey was conducted using Sound Level Meter 2031

manufactured by Cygnet Systems. Noise levels were measured as per IS:

9989:1981 R-2002. Noise measurements were carried out at the same location

where ambient air quality was monitored. The 24-hourly sound levels were

measured at each location once during the study period.

3.13.1 Noise Monitoring Locations

For noise monitoring, eleven monitoring locations were selected in the study

area. Noise monitoring locations are given in Table 3.23 and shown on the 10

km study area map in Figure 3.21.



Table 3.22: Existing Stack Emissions Monitoring for Flue Gas and Process Stacks Sn Parameters DG Set

250 kVA DG Set

500 kVA 10 TPH

Coal/Biomass/ Husk Fired

Boiler

4 TPH FO Fired Boiler

Metribuzin Plant

1. Stack Height, m 3.1 m (above

roof) 5.1 m (above

roof) 40 30 30

2. Stack Dia, m 0.2 0.3 1.0 1.0 0.35

3. Temp. oC 165 160 124 132 36

4. Stack Gas Velocity (m/s)

12.3 11.1 7.7 2.7 3.0

5. Volumetric Flowrate Nm3/hr

1380 2810 21750 7540 1002

6. Concentration of Pollutants

SPM (mg/Nm3) 56.1 53.2 78.3 61.2 --

SO2 (mg/Nm3) 54.1 59.2 154.4 185.9 --

NO2(mg/Nm3) 28.1 24.2 24.0 25.2 --

HCl (mg/Nm3) -- -- -- -- --

Cl2 (mg/Nm3) -- -- -- -- --

PCl3 (mg/Nm3) -- -- -- -- --

H2S (mg/Nm3) -- -- -- -- --

NH3 (mg/Nm3) -- -- -- -- --

MeCl (mg/Nm3) -- -- -- -- --

HBr (mg/Nm3) -- -- -- -- *BDL

HC (mg/Nm3) -- -- -- -- --

Date of Stack Monitoring: 05 April 2017



Figure 3.21: Noise Monitoring Locations



Table 3.23: Noise Monitoring Locations

Code Location of Noise

Sampling Stations

Latitude &

Longitude

Distance

(Km)

Direction

N1 Project Site

Near Main Gate

19°48'19.60"N

72°43'41.53"E

0 -

N2 Salvad 19 ͦ 48’ 33.7’ N

72 ͦ 43’ 19.7” E

0.58 WSW

N3 Pasthal 19°48'51.57"N

72°43'30.21"E

0.93 NW

N4 Saravali 19 ͦ 46’ 41.5” N

72 ͦ 45’ 13.7” E

5.78 SSE

N5 Shivaji Nagar 19°48'3.22"N

72°43'19.02"E

0.78 SW

N6 Kudan 19 ͦ 48’ 19.2” N

72 ͦ 44’ 57.9” E

5.5 NW

N7 Parnali 19°49'32.97"N

72°43'47.56"E

2.58 NE

N8 Betegaon 19°47'5.75"N

72°46'12.29"E

4.78 SE

N9 Navapur 19°47'22.21"N

72°41'24.39"E

4.37 SW

N10 Pam 19 ͦ 47’ 28.8” N

72 ͦ 45’ 13.7” E

1.84 SSW

N11 Boisar 19°47'51.97"N

72°45'39.71"E

4.80 ESE

3.13.2 Day and Night Time Leq Noise levels

Day and night time Leq noise levels were computed from the hourly Leq noise

levels. Day and night time Leq (Lday and Lnight) for ambient noise levels for the

study area are given in Table 3.24. It is observed from the day and night time

noise level equivalent (Lday and Lnight) were well within limit specified for

residential areas i.e. 55 dB (A) during day time, 45dB (A) during in night time,

commercial area limits i.e. 65dB (A) during day time & 55dB(A) during Night

time and industrial limits i.e. 75dB during in day time, 70dB during night time.

Graphical presentation of Day & Night Time noise Leq is shown in Figure 3.22.



Table 3.24: Day and Night Time Leq at Noise Monitoring Locations

Sr. No

Location Category Unit Results Standard Limits

LDay LNight Day Time

Night Time

1. Project Site Industrial dB(A) 64.80 55.93 75 70

2. Salvad Residential dB(A) 52.11 42.25 55 45

3. Pasthal Commercial dB(A) 61.18 52.14 65 55

4. Saravali Residential dB(A) 52.05 42.42 55 45

5. Shivaji Nagar Commercial dB(A) 62.18 51.43 65 55

6. Kudan Residential dB(A) 49.69 42.21 55 45

7. Parnali Residential dB(A) 51.99 41.04 55 45

8. Betegaon Residential dB(A) 49.89 41.43 55 45

9. Navapur Residential dB(A) 49.66 40.70 55 45

10. Pam Residential dB(A) 52.63 39.81 55 45

11. Boisar Commercial dB(A) 61.28 51.18 65 55

Figure 3.22: Graphical Presentation of Day & Night Time Noise Leq



3.14 Traffic Study in the Study Area

For transportation of raw materials and products from existing UPL plant,

MIDC’s two lane road and Boisar-Tarapur road (SH-74) are used. Every day

tank lorries/trucks for transportation raw materials and products are

approached to UPL existing plant. Therefore, traffic study was carried on

MIDC’s two lane road and Boisar-Tarapur road (SH-74) and presented in Table

3.25 and Table 3.26, respectively:

Table 3.25: Traffic Study in the Area on MIDC Road to UPL Plant

Time Bus Truck Cars Two Wheelers

Total Vehicles

6.00 to 7.00 2 3 12 22 39

7.00 to 8.00 4 6 15 24 49

8.00 to 9.00 16 5 58 276 355

9.00 to 10.00 6 7 23 128 164

10.00 to 11.00 1 12 7 18 38

11.00 to 12.00 0 16 12 14 42

12.00 to 13.00 0 12 17 23 52

13.00 to 14.00 3 9 8 21 41

14.00 to 15.00 4 6 5 117 132

15.00 to 16.00 5 15 8 68 96

16.00 to 17.00 12 8 7 81 108

17.00 to 18.00 18 12 43 253 326

18.00 to 19.00 8 16 37 161 222

19.00 to 20.00 2 6 21 21 50

20.00 to 21.00 0 2 17 19 38

21.00 to 22.00 6 8 21 34 69

22.00 to 23.00 5 5 18 13 41

23.00 to 24.00 0 8 7 3 18

24.00 to 1.00 0 0 6 5 11

1.00 to 2.00 0 0 0 0 0

2.00 to 3.00 0 0 0 0 0

3.00 to 4.00 0 0 0 0 0

4.00 to 5.00 0 3 0 0 3

5.00 to 6.00 0 6 3 0 9

Total 92 165 345 1301 1903



Table 3.26: Traffic Study in the Area on Boisar -Tarapur Road

Time Bus Truck Cars Two Wheelers

Total Vehicles

6.00 to 7.00 6 9 23 43 81

7.00 to 8.00 12 45 35 65 157

8.00 to 9.00 27 37 144 112 320

9.00 to 10.00 14 21 112 243 390

10.00 to 11.00 6 34 76 167 283

11.00 to 12.00 5 63 42 56 166

12.00 to 13.00 6 71 37 43 157

13.00 to 14.00 3 82 23 32 140

14.00 to 15.00 5 59 44 41 149

15.00 to 16.00 8 69 32 52 161

16.00 to 17.00 12 52 37 67 168

17.00 to 18.00 19 48 76 156 299

18.00 to 19.00 23 51 91 212 377

19.00 to 20.00 11 48 54 156 269

20.00 to 21.00 5 99 43 78 225

21.00 to 22.00 3 111 32 107 253

22.00 to 23.00 2 128 28 43 201

23.00 to 24.00 1 153 22 32 208

24.00 to 1.00 2 98 18 27 145

1.00 to 2.00 0 67 13 4 84

2.00 to 3.00 0 44 0 6 50

3.00 to 4.00 0 23 0 0 23

4.00 to 5.00 0 29 0 0 29

5.00 to 6.00 3 43 4 32 82

Total 173 1484 986 1774 4417

As per IRC guideline, diffident types of vehicles plying on the roads have been

converted to Passenger Car Unit (PCU). On the on MIDC Road to UPL Plant

total PCUs are 1638 per day while on the Boisar -Tarapur Road total PCU plying

per day are 6015.

3.15 Landuse/Landcover

The term land use involves the management and modification of natural

environment or wilderness into built environment such as settlements and semi-

natural habitats. To study land use and land cover of the study area, satellite

imagery by IRS–Resourcesat-2 dated 11 January 2017 was procured from

NRSC, Hyderabad



3.15.1 Methodology adopted for Satellite Imagery Interpretation

The methodology adopted for satellite imagery interpretation is discussed

below:

• Satellite data of IRS Resourcesat-2 sensor is geometrically corrected and

enhanced using principal component method and nearest Neighborhood re-

sampling technique.

• Preparation of basic themes like layout map, transport & settlement map

and from the satellite image by visual interpretation.

• Essential maps (related to natural resources) like Land use/Land cover map

are prepared by visual interpretation of the satellite imagery. Visual

interpretation is carried out based on the image characteristics like tone,

size, shape, pattern, texture, location, association, background etc. in

conjunction with existing maps/ literature.

• Preliminary quality check and necessary corrections are carried out for all

the maps prepared.

• Maps prepared are converted into soft copy by digitization of contours and

drainages. In that process editing, labeling, mosaicing, quality checking,

data integration etc., are done, finally land use areas are measured in

square Kilometers.

The process flow diagram for satellite imagery interpretation for land use and

land cover study is given in Figure 3.23.



3.15.2 Land Use and Land Cover for the Study Area

False Colour Composite (FCC) of satellite imagery dated IRS–Resourcesat-2

dated 11 January 2017 is shown in Figure 3.24. The supervised classification

of the satellite image for land use and land cover is given in Table 3.27.

Graphical Presentation of Landuse Classification is given in Figure 3.25. The

land use and land cover for the study area by the satellite imagery

interpretation is given in Figure 3.26.

Table 3.27: Land Use and Land Cover for the Study Area

Sr. No. Landuse Classes Area in ha Percentage (%)

1. Built-up Area 6944.66 22.11

2. Agricultural Land 4763.98 15.16

3. Water Bodies 6744.12 21.47

4. Hill Area 1044.04 3.32

5. Marshy/Scrub Land 7012.7 22.32

6. Open Scrub/Barren Land 4906 15.62

Total 31415.5 100.00

Figure 3.23: Process Flow Diagram for Satellite Imagery

Interpretation



Graphical presentation of Landuse classification within 10 km radius distance of

the project site is given in Figure 3.25.

Figure 3.24: False Colour Composite (FCC) of Satellite

Imagery

Figure 3.25: Graphical Presentation of Landuse Classification



Figure 3.26: Landuse& Land Cover Map of 10 km Radius Study Area



3.16 Biological Environment

Biological diversity comprises the variability of species, genus and ecosystems

and is very crucial for maintaining the basic processes on which the life

depends. Broadly it can be divided in to two types i.e. the floral diversity and

faunal diversity. Conservation of the biodiversity is essential for the sustainable

development as it not only provides the food, fodder and medicine but also

contribute in improvement of essential environmental attributes like air, water,

soil, etc. For carrying out environmental impact assessment study, it is

necessary to identify the baseline of relevant environmental parameters, which

are likely to be affected as a result of operation of the proposed project. A

similar approach has been adopted for conducting the study on Biological

Environment for this Project. Both terrestrial and aquatic ecosystems have been

studied to understand the biological environment.

3.16.1 Vegetation Types in the Area

The forest/vegetation in the area is of tropical moist deciduous types and

Terminalia paniculata, T. bellerica, Grewia tilliaefolia, Dalbergia latifolia,

Lagerstroemia, Adina cordifolia, etc., are common species observed. Some

other common associates species are Terminalia tomentosa, Dellenia species,

Eugenia species, Boswellia species, Mallotus philippensis, etc. The

vegetation/forests in the area can be grouped under the following types as per

the "Revised Classification of Indian Forest types, by Champion & Sethi (1968).

These are described below:

• Southern Moist Mixed Deciduous Forest (3B/C2): The proportion of

teak is relatively low than the teak-bearing forests. This type is usually found

in damp valleys and wet conditions. The main species are Pterocarpus

marsupium, Salmalia malbarica, Terminalia bellerica, Anogeissus latifolia

Lannea coromandelica.

• Western Sub Tropical Hill Forest (8A/C2): This type of found in the

northern parts of Western Ghats in the South eastern hilly part of the buffer

zone of the proposed project area. Species observed include Syzygium

cumini, Memecylon umbellatum, Randia dumetorum, Terminalia chebula,

Flacourtia latifolia etc.

• Man-made vegetation



Ecological Study in the Study Area The objective of the present study was undertaken with a view to understand

the present ecosystem on the following lines:

• To assess the distribution of vegetation in the area;

• To assess the distribution of faunal life in the areas; and

• To assess the biodiversity resource potential.

Methodology Adopted for the Biological Survey Detailed study of the area was undertaken within 10-km radius study area from

the UPL Plant. The different methods adopted for biological study were as

follows:

• Collection and compilation of secondary data with respect to the study area

from published literature and Government agencies;

• Generation of primary data by undertaking site visits and systematic

ecological studies in the area; and

• Interviews with local people so as to elicit information for local plants,

animals and their uses.

Biological studies in the study area were conducted during March to May 2017. Primary / Field Data Collection The study area comprises of Arabian Sea in the west and the Western Ghats in

the south east of the project site. The core area does not encompass natural

vegetation and mainly consists of human influenced ecosystem, which does not

require systematic sampling / quantification. Therefore, only inventory of floral

and faunal components was carried out by visiting buffer zone habitats from

Chinchni Beach to Nandgaon in the west. Floral components also recorded

along the agricultural land in the east, Banganga River in North & Surya River

in east. Also, local people were interviewed to know presence of faunal species

in the study area. Samples of aquatic microflora was collected from estuaries

and lakes present in the buffer zone.



Baseline Status of Biodiversity in Core Zone The core zone encompasses landscape plantation of trees, herbs, shrubs and

grass species, while, buffer zone comprises mainly of agriculture fields and part

of Arabian sea and scrub vegetation.

Floral Species in Core Zone About 20 numbers of floral species were identified in the core zone and listed

in Table 3.28.

Table 3.28: Floral Species in Core Zone

Sr. No

Species Name Common Name Habitat

1. Calotropis procera Aakdo Shrub

2. Prosopis juliflora Gando Baval Shrub

3. Nerium indicum Lalkaren Shrub

4. Hygrophila auriculata Kanatashelio,Akaro Herb

5. Parthenium hysterophorus Gajar Ghas Herb

6. Cressa cretica Palio, Rudanti Herb

7. Typha angustata Elephant Grass Herb

8. Cynodon dactylon Doobgrass Grass

9. Phragmites karka Tall reed, Nal Grass

10. Ficus elastic Rabar Vad Tree

11. Prosopis cineraria Khejdo Tree

12. Azadirachta indica Neem, Limdo Tree

13. Pithecellobium dulce Goras Aamli Tree

14. Salvadora oleoides Mithi Jal Tree

15. Acacia nilotica Babul Tree

16. Leucaena leucocephala Subabul Tree

17. Eucalyptus hybrida Nilgiri Tree

18. Verbascum chinense Kutki Herb

19. Oldenlandia corymbosa Pitpapda Herb

20. Eichhornia crassipes Water hyacinth Herb (Aquatic)



3.16.2 Floral Species in Buffer Zone

In the buffer zone tree species Prosopis cineraria (Khejri) is found very common

on agriculture hedges and in open area. Floral species reported from buffer

zone are enlisted in Table 3.29.

Table 3.29: Flora Species within Buffer Zone

Sr. No.

Botanical Name Vernacular Name

Family Habitats

1 Mangifera indica Amba Anacardiaceae Tree

2 Tamarindus indicum

Amali Caesalpiniaceae Tree

3 Carica papaya Papaya Caricaceae Tree

4 Casuarina equisetifolia

Sharu Casuarinaceae Tree

5 Terminalia catappa Badam Combretaceae Tree

6 Azadirachta indica Limbado Meliaceae Tree

7 Acacia nilotica Baval Mimosaceae Tree

8 Pithecellobium dulce

Gorasmli Mimosaceae Tree

9 Prosopis cineraria Khyigdo Mimosaceae Tree

10 Ficus benghalensis Vad Moraceae Tree

11 Ficus religiosa Piplo Moraceae Tree

12 Moringa oleifera Sargawo Moringaceae Tree

13 Eucalyptus sp. Nilgari Myrtaceae Tree

14 Syzygium cumini Jambu Myrtaceae Tree

15 Salvadora oleoides Piludi Salvadoraceae Tree

16 Manilkara hexandra Rayan Sapotaceae Tree

17 Manilkara zapota Chikoo Sapotaceae Tree

18 Nerium indicum Lalkaren Apocynaceae Shrub

19 Thevetia peruviana Pili karan Apocynaceae Shrub

20 Calotropis gigantea Akado Asclepiadaceae Shrub

21 Calotropis procera Akado Asclepiadaceae Shrub

22 Capparis decidua Kerdo Capparaceae Shrub

23 Ipomoea fistulosa Nasarmo Convolvulaceae Shrub

24 Euphorbia neriifolia Thor Euphorbiaceae Shrub

25 Ricinus communis Devalo Euphorbiaceae Shrub

26 Lawsonia inermis Mendhi Lythraceae Shrub

27 Abelomoschus manihot

Jagali bhindi Malvaceae Shrub

28 Abutilon indicum Khapat Malvaceae Shrub

29 Musa paradisiaca Kela Musaceae Shrub

30 Prosopis juliflora Gando baval Mimosaceae Shrub



Sr. No.


Family Habitats

31 Sesbania sesban Shevari Papilionaceae Shrub

32 Zizyphus nummularia

Chanibor Rhamnaceae Shrub

33 Datura metel Daturo Solanaceae Shrub

34 Solanum incanum Ubhi ringan Solanaceae Shrub

35 Solanum nigrum Laghukavali Solanaceae Shrub

36 Lantana camara Ganthai Verbenaceae Shrub

37 Hygrophila auriculata

Kanatashelio, Akaro

Acanthaceae Herb

38 Limnophyton obtusifolium

-- Alismataceae Herb

39 Blumea eriantha Kalhar Asteraceae Herb

40 Echinops echinatus Shulio Asteraceae Herb

41 Tridax procumbens Pardesi Bhangro Asteraceae Herb

42 Parthenium hysterophorus

-- Asteraceae Herb

43 Cressa cretica Palio, Rudanti Convolvulaceae Herb

44 Ipomoea aquatic Nalini bhaji Convolvulaceae Herb

45 Fimbristylis dichotoma

-- Cyperaceae Herb

46 Euphorbia hirta -- Euphorbiaceae Herb

47 Hydrilla verticillata -- Hydrocharitaceae Herb

48 Aloe barbadensis Kunvarpato Liliaceae Herb

49 Abutilon indicum Khapat, Dabaliar Malvaceae Herb

50 Alhagi maurorum Fabaceae Herb

51 Boerhavia diffusa Satodi Nyctaginaceae Herb

52 Argemone mexicana

Darudi Papaveraceae Herb

53 Cynodon dactylon -- Poaceae Herb

54 Phragmites kara -- Poaceae Herb

55 Eichhornia crassipes

Kanphutti Pontederiaceae Herb

56 Solanum indicum Ringni Solanaceae Herb

57 Solanum nigrum Piludi Solanaceae Herb

58 Solanum surattense Bhoringni Solanaceae Herb

59 Typha angustata Ramban Typhaceae Herb

60 Corchorus depressus

-- Tiliaceae Herb

61 Triumfeta rotundifolia

-- Tiliaceae Herb

62 Tribulus terrestris Mithu Gokhru Zygophyllaceae Herb

63 Coccinia grandis Ghiloda Cucurbitaceae Climber

64 Luffa cylindrica Galku Cucurbitaceae Climber



Sr. No.


Family Habitats

65 L. acutangular Jungli turia Cucurbitaceae Climber

66 Cuscuta reflexa Amarvel Cuscutaceae Climber

67 Tinospora cordifolia Galo Menispermaceae Climber

68 Mucuna prurita Kavach, Koyli Papilionaceae Climber

69 Abrus precatorius Chanothi Papilionaceae Climber

70 Salvinia molesta Kariba weed Salviniaceae Weed

71 Azolla pinnata Water velvet Salviniaceae Weed

72 Sagittaria trifolia Three leaf arrow head

Alismataceae Herb

Source: Field Studies by SSWML Status of Threatened Floral Species No rare, endangered and threatened (RET) species of flora was reported in the

core zone as well as buffer zone of the study area.

3.16.3 Faunal Species in the Study Area

Faunal survey was conducted during the study period. The fish from river Surya

were noted by observing the fish catch from local fisherman. The reptiles and

amphibians were studied by direct sighting and indirect signs like mounts as

well as road kills in the survey area.

The birds in the area were studied by direct sighting, listening to the calls as

well as by locating nest on the trees. The survey was conducted during dawn

to midmorning, since most avian species are active during that time. For

observation of birds’ optic binocular (16 x 50) Zenith Hi-Lux was used. All field

observations were verified by using field guide “The Book of Indian Birds” by

Dr. Salim Ali.

Avifauna comprised of local as well as migrant species. Waders include, Asian

openbill (Anastomus oscitans), Common teal (Anas crecca), Little grebe

(UTachybaptus ruficollis), Western cattle egret (Bubulcus ibis), Indian pond

heron (Ardeola grayii), Chestnut bittern (Ixobrychus cinnamomeus), Glossy ibis

(Plegadis falcinellus), White breasted water hen (Amaurornis phoenicurus),

Little ringed plover (Charadrius dubius), Marsh sandpiper (Tringa stagnatilis),

Common sandpiper (Actitis hypoleucos), Little stint (Calidris minuta), Little tern

(Sternula albifrons), etc. were observed near the Chinchni beach area. Avian

Fauna within 10 km radius from project site are given in Table 3.30.



Table 3.30: Avian Fauna within 10 km Radius from Project Site

Sr. No.

Scientific Name Common Name WPA-1972

IUCN Red List

1. Accipiter badius Shikra IV LC

2. Acridotheres tristis Common Myna IV LC

3. Aegithina tiphia Common iora LC

4. Aethopyga siparaja Crimson sunbird IV LC

5. Alcedo atthis Small Blue Kingfisher IV LC

6. Anthus rufulus Paddy field pipit IV LC

7. Anthus similis Long billed pipit IV LC

8. Apus apus Common Swift LC

9. Ardeola grayii Indian Pond Heron IV LC

10. Athene brama Spotted owlet IV LC

11. Butastur teesa Buzzard IV LC

12. Caprimulgus asiaticus Indian little nightjar LC

13. Cattle Egret Bubulcus ibis IV LC

14. Centropus sinensis Crow pheasant IV LC

15. Chalcophaps indica Indian emerald dove IV LC

16. Cinnyris asiaticus Purple sunbird IV LC

17. Columba livia Blue Rock Pigeon IV LC

18. Copsychus saularis Oriental magpie robin IV LC

19. Coracina melanoptera Black headed cuckoo IV LC

20. Corvus macrorhynchos Indian jungle crow IV LC

21. Corvus splendens House crow IV LC

22. Coturnix coturnix Common quail IV LC

23. Cypsiurus balasiensis Asian palm swift LC

24. Dendrocitta

vagabunda

Rufous treepie IV LC

25. Dicaeum concolor Nilgiri flowerpecker IV LC

26. Dicrurus macrocercus Black Drongo IV LC

27. Dicrurus paradiseus Racket tailed drongo IV LC

28. Egretta garzetta Little Egret IV LC

29. Eudynamys

scolopaceus

Asian koel IV LC

30. Francolinus

pondicerianus

Grey Francolin IV LC

31. Galerida malabarica Malabar lark IV LC



Sr. No.


IUCN Red List

32. Gallus sonneratii Grey jungle fowl IV LC

33. Halcyon smyrnensis White - throated

Kingfisher

IV LC

34. Hierococcyx varius Common hawk cuckoo IV LC

35. Hirundo smithii Wire tailed swallow LC

36. Lanius schach Shrike LC

37. Lanius vittatus Bay backed shrike LC

38. Larvivora brunnea Indian blue robin IV LC

39. Leptocoma minima Small sunbird IV LC

40. Lonchura punctulata Scaly breasted munia LC

41. Lonchura striata White rumped munia LC

42. Merops orientalis Little green bee eater LC

43. Milvus migrans Black Kite IV LC

44. Motacilla

maderaspatensis

White browed wagtail IV LC

45. Nycticorax nycticorax Black- crowned Night-

Heron

IV LC

46. Ocyceros birostris grey hornbill LC

47. Oriolus kundoo Indian golden oriole IV LC

48. Orthotomus sutorius Common tailorbird LC

49. Passer domesticus House sparrow LC

50. Phalacrocorax niger Little Cormorant IV LC

51. Ploceus philippinus Baya weaver bird IV LC

52. Psilopogon

haemacephalus

Coppersmith barbet LC

53. Psittacula krameri Rose-ringed Parakeet IV LC

54. Pycnonotus cafer Red- vented Bulbul IV LC

55. Pycnonotus jocosus Red Whiskered Bulbul IV LC

56. Rhipidura albicollis Fantail flycatcher LC

57. Saxicola caprata Pied bush chat IV LC

58. Saxicola torquatus Common stone chat IV LC

59. Saxicoloides fulicata Indian Robin IV LC

60. Spilopelia chinensis Spotted dove IV LC

61. Spilopelia senegalensis Little brown dove IV LC

62. Streptopelia chinensis Spotted Dove IV LC



Sr. No.


IUCN Red List

63. Terpsiphone paradisi Asian paradise

flycatcher

IV LC

64. Turdoides caudatus Common Babbler IV LC

65. Turdoides striata Jungle babbler LC

66. Turdus merula Common blackbird LC

67. Turdus saxatilis rock thrush LC

68. Upupa epops Common hoopoe LC

69. Vanellus indicus Red-wattled Lapwing IV LC

Source: Field Studies by SSWML Mammals The mammals in the area were enlisted by information’s local people along the

survey area. Mammals recorded during the study were, jungle rat, fruit bat,

Small Indian mongoose, Bandicoot, Indian Hare, Five striped palm squirrel and

rhesus monkey and Hanuman langur. Mammals found in the study area are

listed in Table 3.31.

Table 3.31: Mammals Species Reported in the Study Area

Sr. No.

Zoological Name Common Name WPA 1972

IUCN Red list

1. Bandicota bengalensis Jungle rat V LC

2. Pteropus giganteus Fruit Bat V LC

3. Herpestes javanicus Small Indian

mongoose

II LC

4. Bandicota bengalensis Bandicoot IV LC

5. Lepus nigricollis Indian Hare IV LC

6. Funambulus pennantii Five striped palm

squirrels

IV LC

7. Macaca mulatta Rhesus monkey IV LC

8. Simia entellus Hanuman langur IV LC

9. Canis aureus Jackal II LC

10. Cervus unicolor Sambar III LC

11. Mantiacus muntjak Barking deer III LC

12. Boselaphus

tragocamelus

Nilgai III LC

13. Axis axis Chital III LC

Source: Field Studies by SSWML



Amphibians reported within the study area are listed in Table 3.32.

Table 3.32: Amphibians Within 10 km Radius from Project Site

Sr. No.

Common Name Zoological Name WPA 1972

IUCN Red List

1. Indian bull frog Hoplobatrachus tigerinus

IV LC

2. Fungoid frog Hylarana malabarica IV LC

3. tree frogs Polypedates leucomystax

IV LC

4. Russell's viper Daboia russelii II LC

5. Saw scaled viper Echis carinatus II NA

6. Boa Eryx conicus II NA

7. Cobra Naja naja II DD

8. Common Krait Bungarus caeruleus II NA

9. Blind snake Typhlops spp. -- NA

10. Jerdon's Many-tooth Snake or Dumeril's black-headed snake

Sibynophis subpunctatus

-- NA

11. Bronze backed Tree snake

Dendrelaphis tristis -- NA

12. Buff striped keelback Amphiesma stolatum -- NA

13. Rat snake Ptyas Mucosa II NA

14. Common lizards Zootoca vivipara -- LC

16. Common Garden lizard Calotes versicolor -- NA

17. Roux's Forest lizard Calotes rouxii -- LC

18. Kollegal Ground Gecko Geckoella collegalensis

-- LC

19. Fan throated lizard Sitana ponticeriana -- LC

20. Indian chameleon Chamaeleo zeylanicus

II LC

21. Common skink Mabuya carinata -- LC *LC: Least concern, VU: Vulnerable, NA: Not Assessed, DD: Data Deficient Source: Field Studies by SSWML



Status of Threatened Floral Species No rare, endangered and threatened (RET) species of fauna was reported from

the core zone as well as buffer zone of the study area.

Ecological Sensitive Area: There is no ecological sensitive area like national

park, wildlife sanctuary within 10 km radius study area.

3.16.4 Aquatic Ecology

Fishes, crustaceans & mollusks reported during the study within 10 km radius

study area are listed Table 3.33.

Table 3.33: Fishes, Crustaceans & Mollusks within 10 km radius

from Project Site

Sr. No.

Zoological Mame Common Name Family

Fishes

1. Sardinella longiceps Tarli Clupeidae

2. Rastrelliger kanagurta Mackerel Scombridae

3. Stolephorus indicus Indian anchovy, Mandeli

Engraulidae

4. Harpadon nehereus Bombil Synodontidae

5. Trichiurus lepturus Ribbon fish Trichiuridae

6. Otolithes ruber Tigertooth croaker Sciaenidae

7. Parastromateus niger Pomfret Stromateidae

8. Pampus chinensis Stromateidae

9. Mugil cephalus Common grey mullet Mugilidae

10. Pampus argenteus silver or white pomfret

Stromateidae

11. Sillago sihama Silver whiting Sillaginidae

12. Coilia dussumieri Ray-finned fish Engraulidae

13. Bregmaceros mcllelandi Unicorn Cod Bregmacerotidae

14. Megalaspis cordyla Horse Mackerel Carangidae

15. Alepes djedaba shrimp scad Carangidae

16. Caranx heberi Carangidae

17. Otolithoides biauritus Bronze croaker

18. Pellona ditchella Indian pellona Pristigasteridae

19. Coilia dussumieri Golden Anchovy Engraulidae

20. Tenulosa toli Toli shad Clupeidae

21. Catla catla Catla Cyprinidae

22. Labeo rohita Rohu Cyprinidae



Sr. No.

Zoological Mame Common Name Family

Crustaceans

23. Penaeus merguiensis Banana shrimp Penaeidae

24. Metapenaeus affinis Jhinga shrimp Penaeidae

25. Melicertus latisulcatus Western king shrimp Penaeidae

26. Nematopalaemon tenuipes Spider shrimp Palaemonidae

27. Acetes indicus Paste shrimp Sergestidae

28. Parapenaeopsis sculptilis Rainbow shrimp Penaeidae

29. Solenocera crassicornis Coastal mud shrimp Solenoceridae

30. Exhippolyasmata ensirostris Hunter shrimp

31. Charybdis callianasa Crab Portunidae

32. Exopalaemon styliferus Shrimp Palaemonidae

Molluscans

33. Loliolus investigatoris Inshore squid Loliginidae

34. Sepia aculeata Needle Cuttlefish Sepiidae Source: Field Studies by SSWML

Macro-benthic Invertebrate Fauna

During the study period, species of Crustacea, Gastropoda and Bivalvia found,

are listed in Table 3.34.

Table 3.34: List of Macro-Benthic Invertebrate Fauna

Sr. No. Zoological Name

I. Crustacea 1 Metopograpsus messor 2 Metopograpsus maculates 3 Uca dussumieri 4 Uca annulipes 5 Leptodius exaratus 6 Scylla serrata 7 Charybdis annulata 8 Thalamita crenata 9 Epixanthus fronthalis

II. Gastropoda 1 Littorina scabra 2 Littorina undulata 3 Telescopium Telescopium 4 Bursa granularis 5 Thais blanfordi 6 Thais carinifera 7 Nassarius pictus



Sr. No. Zoological Name

8 Nassarius mucronatus 9 Pyrene artrata

III Bivalvia 1 Modiolus emarginatus 2 Meretrix meretrix 3 Katelysia marmorata 4 Saccostrea cucullata

Source: Field Studies by SSWML Phytoplankton and Zooplankton Found in the Study Area -

Phytoplankton and Zooplankton species found in the study area are as listed in

Table 3.35.

Table 3.35: Phytoplankton and Zooplankton found in the Study Area

I. Phytoplankton

1. Myxophyceae Anabaena, Microcystis, Merismopedia

2. Chlorophyceae Periastrum, Closteridium, Microspora

3. Bacillariophyceac Fragilaria, Navicula. Nitzschia

II. Zooplankton

1. Rotifera Brachionus sp, Filinia lngiseta, Keratella tropica

2. Cladocera Ceriodaphnia cornuta, Moina

3. Copepoda Cyclops, Mesocyclops, & Nauplius

4. Ostracoda Stenocypris spp.

Source: Field Studies by SSWML

3.17 Socio- Economic Environment

3.17.1 Introduction Baseline scenario for socio-economic environment for the study area with

respect to demographic and socio-economic conditions has been obtained from

primary and secondary sources. The existing UPL plant is located in Palghar

District, which came into the existence on 1 August 2014.

The socio- economic study was carried out through a socio-economic survey and secondary data analysis.



Industrial Estate -Tarapur Tarapur houses two huge industrial estates Maharashtra Industrial

Development Corporation, Tarapur Industrial Estate and Additional Tarapur

Industrial Estate), which include bulk drug manufacturing units, specialty

chemical manufacturing units, steel plants, a few textile plants, etc.

Tarapur is a census town in Palghar district (earlier Palghar was taluka) in the

Maharashtra state. It is an industrial town located some 45 km north of Virar,

on the western railway line of Mumbai Suburban Division (Mumbai Suburban

Railway). Chinchani, Nawapur, Palghar, Umbergaon are the nearby cities to

Tarapur. Tarapur village have facilities of many schools, colleges, petrol pumps,

hospitals, temples, hotels, cinema theaters, etc.

3.17.2 Methodology of Socio-economic Studies

The socio-economics profile of the study area has been studied through random

sample primary surveys and secondary data from publish sources. Villages and

urban settlements located within the study area were identified through survey

of India Toposheet. Demographic and occupational pattern data for settlements

located in the study area were obtained from Primary Census Abstract 2011.

On the basis of a preliminary reconnaissance survey, a questionnaire was

developed to make it suitable to fulfill the objectives of the socio-economic

study. The data collected during the socio-economic survey was analyzed to

evaluate the prevailing socio-economic profile of the area.

3.17.3 Demographic Details of Rural Settlements in the Study Area

Demographic details of the rural settlements of the study area are given in

Table 3.36. Total 25 villages are located in the 10 km radius study area. Total

population of rural settlements is 48629. The male population is 25558 and

female population is 23071. The sex ratios of villages in the study area is 902.

Literacy in the rural settlement is 73.3 %. Schedule cast and schedule tribes

population in the study area are 4.1% and 28.5%, respectively.

https://en.wikipedia.org/wiki/Specialty_chemical

https://en.wikipedia.org/wiki/Specialty_chemical



Baseline Data of Urban settlement

Demographic details of the urban settlements of the study area are given in

Table 3.37. Total 5 towns are located in the 10-km radius study area. Total

population of urban settlements is 82558. The male population is 44077 and

female population is 38481. The sex ratio of urban area in the study area is

873. Literacy in the urban settlements is 79.1 %. Schedule cast and schedule

tribe population in the study area are 5.4% and 8.1% of the total population,

respectively.

The total household in the study area (both rural and urban areas) are 31823

and the total population is 131187. The male population is 53.08% while female

population is 46.91%. Literacy rate is around 77% which is considerably lower

than the overall state figure. The SC population is 5% while ST population is

15.64%.

Occupational details of the rural and urban settlements of the study area are

given in Table 3.38 and Table 3.39, respectively. Total working population

accounts for 41%. Out of total working population, main workers are 34.5%

and non-workers are 59%, whereas marginal worker accounts for 6.63% within

study area.

Road, Rail and Air Connectivity to Study Area Tarapur village is connected with road and railway. The nearest railway station

is Boisar Railway Station which is 4 km (SE). The nearest airport is Chhatrapati

Shivaji Terminal, (Mumbai), which is about 80 km from the site. The nearest

Highway is State Highway -74 located about 2 km in (North-East direction).

National Highway-8 is about 19.20 km (East).

3.17.4 Basic Amenities available in the Study area.

• Educational

Villages in the study area have one or more primary schools. In urban area

like Tarapur good educational facilities area available.



• Medical

Good medical facilities like nursing home, charitable hospital, civil hospital, private clinics are located in urban area of the study area.

• Electricity Electricity for domestic and irrigation purpose is available in all the villages of the study area.

• Housing and Drinking water The most of houses in the study area are pucca houses. All villages/towns

in the study area have water supply for domestic purposes. The sources of

water supply in most of the villages are through pipe line, however people

have preference for ground water. The water source in these areas is

through the municipal water connections and private bore wells.



Table 3.36: Demographic Details of the Villages of The Study area

Sr No

Name of Villages House Hold

Total Population Schedule Case

Schedule Tribe

Literacy

Person Male Female

1 Ghivali 539 2396 1195 1201 65 157 1987

2 Tarapur 514 2020 1024 996 214 704 1497

3 Akkarpatti 123 478 230 248 0 5 401

4 Kurgaon 857 3513 1944 1569 254 958 2755

5 Nawapur 1194 4773 2414 2359 64 378 3785

6 Pam 1246 4150 2547 1603 342 126 3174

7 Kumbhavali 677 2361 1402 959 36 49 1832

8 Nandgaon T. Tarapur 605 2553 1258 1295 10 155 2186

9 Umroli 977 4011 2025 1986 360 319 3382

10 Dapoli 186 628 315 313 223 2 525

11 Shigaon 998 4642 2322 2320 0 4207 1916

12 Mahagaon 237 1091 552 539 5 960 609

13 Betegaon 696 2832 1616 1216 47 1036 2064

14 Padghe 498 2663 1390 1273 1 2374 1529

15 Ambadi 125 561 267 294 0 499 354

16 Khatali 22 92 39 53 0 0 80

17 Dahisar T. Mahim 76 272 118 154 9 135 175

18 Nagavepada 155 642 330 312 0 41 505

19 Saravali 163 673 366 307 0 187 587

20 Umbhrai 280 1314 640 674 249 12 961

21 Khutal 99 549 273 276 2 511 276

22 Kudan 582 2334 1218 1116 54 214 2007

23 Parnali 235 986 508 478 25 304 760

24 Kharekuran 562 2377 1210 1167 4 229 1743

25 Morekuran 186 718 355 363 3 296 552



11832 48629 25558 23071 1967 13858 35642 Source: Primary Census Abstract 2011

Table 3.37: Demographic Details of the Towns of The Study area

Sr No

Name of Town House Hold

Total Population Schedule Case

Schedule Tribe

Literacy

Person Male Female

1 Umbar Pada Nandade (CT)

1789 7605 3868 3737 284 1432 5552

2 Tarapur (CT) 1558 6962 3462 3500 644 809 5747

3 Pasthal (CT) 4804 18194 9635 8559 1641 965 15216

4 Boisar (CT) 8711 36151 20319 15832 1741 636 27658

5 Chinchani (CT) 3129 13646 6793 6853 117 2820 11166

Total 19991 82558 44077 38481 4427 6662 65339

Note: CT- Census Town. Source: Primary Census Abstract 2011

Table 3.38: Occupational Pattern Details of the Villages of The Study area

Sr No

Name of Villages Total Workers Main Workers Marginal Workers

Non- Workers

1 Ghivali 894 712 182 1502

2 Tarapur 894 744 150 1126

3 Akkarpatti 165 149 16 313

4 Kurgaon 1601 1334 267 1912

5 Nawapur 2305 1791 514 2468

6 Pam 2074 1984 90 2076

7 Kumbhavali 1103 1016 87 1258

8 Nandgaon T. Tarapur

1030 678 352 1523

9 Umroli 1504 1094 410 2507



Sr No

Name of Villages Total Workers Main Workers Marginal Workers

Non- Workers

10 Dapoli 205 144 61 423

11 Shigaon 1857 1195 662 2785

12 Mahagaon 536 244 292 555

13 Betegaon 1344 1025 319 1488

14 Padghe 1091 571 520 1572

15 Ambadi 299 298 1 262

16 Khatali 27 27 0 65

17 Dahisar T. Mahim 173 17 156 99

18 Nagavepada 327 313 14 315

19 Saravali 341 232 109 332

20 Umbhrai 504 412 92 810

21 Khutal 305 301 4 244

22 Kudan 1039 768 271 1295

23 Parnali 349 329 20 637

24 Kharekuran 939 634 305 1438

25 Morekuran 278 261 17 440

Total 21184 16273 4911 27445 Source: Primary Census Abstract 2011



Table 3.39: Occupational Pattern Details of the Towns of The Study area

Sr No

Name of Towns Total Workers Main Workers Marginal Workers

Non- Workers

1 Umbar Pada Nandade (CT)

2972 2513 459 4633

2 Tarapur (CT) 2673 2191 482 4289

3 Pasthal (CT) 7165 6789 376 11029

4 Boisar (CT) 14372 12837 1535 21779

5 Chinchani (CT) 5604 4661 943 8042

Total 32786 28991 3795 49772

Note: CT- Census Town. Source: Primary Census Abstract 2011



• Transport

The general mode of transportation in the study area is by road. Private

vehicles like rented cars, taxis, auto rickshaws and private buses services share

a major responsibility of the transport in the study area. Private and State Govt.

owned Maharashtra State Transport Corporation (MSTC) buses are operating

on roads to provide transport facilities to public.

• Post and Telegraph

The post office facility, telegraph office and telephone office and telephone,

FAX, STD, ISD etc.is located in the villages and towns. The study area is

connected through mobile network. The Palghar city with all modern facility is

at distance of 13 Km.

3.17.5 Place of Historical or Archaeological Interest

No place of historical or archaeological importance exists within the study area.

Tarapur fort is situated from project site at a distance of around 8 km. Tarapur is

mentioned as one of the towns conquered from the Naiks by Bhim the legendary

ruler of Mahim in Bombay island. In 1533 it was burnt by the Portuguese. Now,

Tarapur is one of the biggest industrial hub near Mumbai.

3.17.6 Prominent Industries in the Study Area

The following major industries are located in the study area:

• Tarapur Atomic Power Station is located in Tarapur, Maharashtra; India. It is

the largest nuclear power station in India.

• JSW Steel Ltd.is a leading Exporter, Manufacturer & Supplier of MS Steel, coils,

gp coils from Tarapur, Maharashtra, India. Some of the industrial units are Zeus

International Karamtara Engineering.

• Tata steel Global Wires India - Taar Company (India's largest wire

manufacturers).

• D'decor (the world’s 3rdlargest manufacturer of curtain and upholstery).

• Lupin (the world's largest manufacturer of the anti-TB drug rifampicin).

https://en.wikipedia.org/wiki/Maharashtra_State_Transport_Corporation



• Custom Capsule Pvt. Ltd. (Manufacturing of Different sizes of capsules, world

leader in veterinary capsules & manual Capsule filling machines).

• Siyaram Silk Mills Ltd, one of the best fabric manufacturing unit as well as

Balkrishna Synthetics Asia largest processing unit.

• Indian Transformers Company Ltd, largest manufacturer of high voltage

instrument transformers.

• The "Common Effluent Treatment Plant" (CETP) in Maharashtra came up at

Tarapur.

• These are the famous industries in Tarapur in Maharashtra.

• The Bhabha Atomic Research Centre (BARC) is India's premier nuclear research

facility.



Chapter 4

ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES

4.1 Introduction

The main objective of environmental impact assessment is to identify the nature

and significance of anticipated adverse and beneficial environmental impacts

due to UPL plant after expansion. This chapter assesses nature, type and

magnitude of the potential environmental impacts likely on the various relevant

physical, biological, social and cultural components due to proposed expansion

of UPL’s existing plant, Unit #10 at Tarapur. The physical, biological and social

impacts likely from the plant after expansion can be direct as well as indirect.

For identification and assessment anticipated environmental impacts of various

activities during construction and operation phases of existing plant and after

expansion on environmental parameters scientific techniques and

methodologies based on mathematical modeling and cause & effect methods

are available and used for the EIA study.

The next step is prediction of impacts which is an important component in

environmental impact assessment process. The proposed expansion of UPL

plant may cause adverse environmental impacts on surrounding environment

unless proper mitigation measures and environmental management plan are

adopted during construction and operation phases. Implementation of

mitigation measures in terms technologies, machineries and operations can

minimize the major possible adverse environmental impacts due to the

proposed expansion of UPL plant.

4.2 Identification of Activities for Proposed Project

For identification and assessment of environmental impacts from the existing

UPL plant and from proposed expansion of project, identification of activities

during construction, erection & commissioning and operation phases are

essential. As UPL plant is already an existing plant, therefore, extent of

construction, erection & commissioning and operation related activities will be

limited. Various activities during construction, erection & commissioning and

operation phases are described below:



I. Activities During Construction and Erection & Commissioning

• Site clearing for new construction.

• Excavation of foundations by construction equipment.

• Operation of construction equipment and vehicles

• Transportation of construction materials like sand, aggregate, steel, brick,

cement, etc.

• Civil construction activities including foundations

• Concreting, mixing and RCC works

• Generation of construction debris

• Domestic wastes and sewage generation from labour engaged in

construction works

• Transportation of equipment, pumps, motors, structures, plants

components machineries, etc.

• Installation of equipment, pumps, motors, structures, plants components

• Commissioning of plants and machineries

II. Activities During Operation Phase

• Transportation, storage and handling of raw materials, fuels and finished

products

• Storage and handling of hazardous chemicals

• Transfer and charging of raw materials

• Operation of various plants and machineries including reactors, distillation

units, mixers, driers, pumps, motors, etc.

• Operation of boilers, blowers, DG sets, cooling towers, etc.

• Water consumption for process, boilers, cooling, domestic purposes, etc.

• Storage, handling and packing of the products

• Operation of effluent treatment plant

• Operation of Multi Effect Evaporators

• Operation of Air Pollution Control Equipment

• Hazardous waste storage, handling and disposal

• Manpower involvement

4.3 Identification of Environmental Components

Based on identification of activities of the proposed expansion of the UPL plant,

relevant environmental components have been identified, which are likely to be



effected adversely or beneficially during construction, erection & commissioning

and operation phases of the proposed project. The following environmental

components have been identified and presented in Table 4.1, which are likely

to be affected due to proposed expansion of the UPL plant:

Table 4.1: Identification of Environmental Components

Sr.

No.

Environmental

Components

Cause for Impacts on Environmental

Components

1. Topography &

Physiography

• Construction of new building and plants

2. Soil • Effluents generation

• Hazardous wastes generation

• Solid wastes and ash generation from

boilers.

• Spillage of hazardous materials and

fuels, while handling

3. Water Resources • Water consumption for processes,

boilers, domestic purposes

4. Surface Water Quality • Contaminated runoff from the plant, if

solid and hazardous wastes are not

stored and handled properly.

5. Ground Water Quality • Percolation of hazardous chemicals and

fuels to ground water aquifers, if not

stored and handled properly.

6. Micro-meteorology • Hot stack gas emissions, DG sets and

boilers

7. Ambient Air quality • Emissions from process stacks, DG sets

operation during grid power failure and

Boilers stacks without air pollution

control measures

• Emissions from vehicles approaching to

the plants.

• Fugitive emissions from hazardous

material storage, handing, charging,

leakage from gland, flange, storage

tanks vents, etc.



Sr.

No.

Environmental

Components

Cause for Impacts on Environmental

Components

8. Noise Levels • Operation of plants, reactors, mixtures,

driers, pumps, motors, blowers, boilers,

DG sets

• Vehicular movement to the plant for

transportation of man & materials

9. Occupational Health &

Safety

• Handling of toxic and flammable

hazardous chemicals

• Possibility of unsafe acts and conditions

• Fugitive emissions and noise generation

• Exposures to hazardous chemicals

10. Terrestrial Flora and

Fauna

• Existing green belt at the plant

• Enhancement of green belt at the plant

11. Socio-Economic

Environment

• Deployment of construction workers

• Increase in manpower requirement after

expansion

• Direct and indirect employment

generation

• Flow of economy and revenue

• Improvement in agriculture health and

more crop production in the country

4.4 Methodology for Qualitatively Assessment of Environmental Impacts

The key procedural steps of anticipated environmental impact assessment for

the proposed project are described below:

A. Identification of Environmental Impacts

Environmental impact identification involves, major project activities during

various stages of the proposed expansion namely, construction and operation

phases, environmental attributes, impacts of the activities on the environmental

attributes and formulation of ‘activity-impact’ matrix. The environmental impact

rating assessment matrix is given in Table 4.2.



Table 4.2: Impact Rating Assessment Matrix

Impact Criteria

Nature of Impact Beneficial Positive

Adverse Negative

Duration of Impact Short term Impacts shall be confined to a stipulated time

Long term Impacts shall be continued till the end of life cycle of the plant

Impacted Area Localized Impacts shall be confined within the plant boundary

Regional Impacts shall be continued beyond plant boundary

The impact of proposed expansion of UPL plant activities on each environmental

attribute is assessed. The construction and operation phases are considered to

identify the likely impacts due to the proposed expansion of the existing plant.

The matrix method has been selected to list the potential impacts of the

proposed expansion of the plant. The activities have been arranged in columns

and the environmental attributes in the row of the matrix. The beneficial and

adverse impacts have been analyzed in the following section for prediction and

evaluation of impacts.

The proposed expansion of the existing plant activities has been divided into

two phases for assessment and prediction of anticipated environmental

impacts:

i. Construction Phase (including erection & commissioning new plants)

ii. Operation Phase

Construction Phase The construction phase of the proposed expansion of the UPL plant will involve

the activities starting with site clearing and ending with mechanical and

electrical erection of equipment/machineries and commissioning. This phase

will include site clearing for new construction, excavation of foundations by

construction equipment; operation of construction equipment and vehicles;

transportation of construction materials like sand, aggregate, steel, brick,

cement, etc; civil construction activities including foundations; concreting

mixing and RCC works; generation of construction debris; domestic wastes and



sewage generation from labour engaged in construction works; transportation

of equipment, pumps, motors, structures, plants components machineries, etc.;

installation of equipment, pumps, motors, structures, plants components;

commissioning of plants and machineries; etc.

The construction phase of the proposed expansion of the plant will be for

shorter duration for about 12 months only and mainly involves generation of

dust & noise due to excavation, civil works, erection and commissioning, and

demand for water during construction, debris and sewage generation, increase

of turbidity of runoff from excavated area, etc. Socio-economic factors are also

identified for construction phase. However, impact on these during construction

will be marginal and for short duration as mostly, local workers will be deployed

during construction phase.

Operation Phase The operation phase is important from the environmental impact assessment

point of view as potential to create long-term adverse and beneficial impacts

both. Operation related activities like transportation, storage and handling of

raw materials, fuels and finished products; storage and handling of hazardous

chemicals; transfer and charging of raw materials; operation of various plants

and machineries including reactors, distillation units, mixers, driers, pumps,

motors, etc.; operation of boilers, blowers, DG sets, cooling towers, etc.; water

consumption for process, boilers, cooling, domestic purposes, etc.; storage,

handling and packing of the products; operation of effluent treatment plant;

hazardous waste storage, handling and disposal may have potential adverse

impact on water resources, water quality, soil, micrometeorology, ambient air

quality, noise level, etc.

B. Prediction of Environmental Impacts Prediction of environmental impacts involves nature, magnitude and

significance of the anticipated environmental impacts. It also includes analysis

of the likelihoods and/or probabilities of occurrences of the environmental

impacts. The impact prediction matrix establishes ‘Cause-effect’ relationship

between the project activities and the environmental attributes likely to be

affected by them as shown in Table 4.3 and Table 4.4 with respect to

activities during construction and operation phases, respectively.



C. Evaluation of Environmental Impacts

All the potentially significant environmental impacts due to proposed project is

evaluated and a qualitative assessment is made. An environmental impact level

is rated as “low”, “medium” or “high”.

The impact rating is based on two parameters i.e. the “severity of impact” and

the “likelihood of occurrence of impact”.

• Severity of Impact: The severity of an impact is a function of a range of

considerations including impact magnitude, impact duration, impact extent,

compliance of prescribed legal framework and the characteristics of the

receptors/ resources; and

• Likelihood of Occurrence: How likely is the impact (this is particularly

important consideration in the evaluation of unplanned/ accidental events)

The significance of each environmental impact is determined by assessing the

impact’s severity against the likelihood of the environmental impact occurring,

as summarized in the environmental impact significance assessment matrix

provided in Table 4.5.



4 - 8

Table 4.3 Impact Prediction Matrix during Construction Phase

Environmental Attributes

Project Activities During Construction of Proposed Expansion of UPL Plant Site

Cleaning

Excavation Construction

of Civil Works

Transportation

of Materials &

Machinery

Deployment

of Manpower

Installation of

Equipment &

Equipment

Commissioning

of Plants &

Machinery

Topography & Physiography

Dust and Gaseous Pollution

Vehicular Emissions

Turbidity of runoff

Water Quality

Soil Quality

Land Cover

Ambient Air Quality

Traffic

Ambient noise levels

Terrestrial flora and fauna

Social Impacts

Employment Generation

Businesses and Economy



4 - 9

Table 4.4 Impact prediction Matrix during Operation Phase

Environmental Attributes

Project Activities During Construction of Proposed Expansion of UPL Plant Storage

and

handling of raw

materials, fuels and

finished

products

Charging

of raw

materials

Operation of various

plants & machinerie

s

Operation of boilers,

blowers, DG sets,

Hazardous Waste

Generation

Fuel Consump

tion

Water consumpti

on

Operation

of effluent

treatment

plants

Manpower

Deployment

Green

Belt

Dust and Gaseous

Pollution

Fugitive Emissions

Vehicular Emissions

Water Resources

Water Quality

Soil Quality

Ambient Air Quality

Ambient noise levels

Traffic

Flora & fauna

Social Impacts

Employment

Generation



4 - 10

Table 4.5: Impact Assessment Rating Matrix

Impact

Severity

Impact Likelihood

Unlikely (e.g.

not expected

to occur

during the

project

lifetime)

Low Likelihood

(e.g. may

occur once or

twice during

the project

lifetime)

Medium

Likelihood

(e.g. may

occur every

few years)

High Likelihood

(e.g. routine,

happens

several times a

year)

Slight Negligible

Impact

Negligible

Impact

Negligible

Impact

Negligible Impact

Low Negligible

Impact

Negligible

Impact

Negligible to

Minor Impact

Minor Impact

Medium Negligible

Impact

Minor Impact Minor–

Moderate

Impact

Moderate Impact

High Minor Impact Moderate Impact Major Impact Major Impact

Notes:

Negligible Impact : Defined as magnitude of change comparable to natural variation

Minor Impact : Defined as detectable but not significant

Moderate Impact : Defined as insignificant; amenable to mitigation; should be

mitigated where practicable

Major Impact : Defined as significant; amenable to mitigation; must be

mitigated

4.5 Anticipated Environmental Impacts Due to the Proposed Expansion

The environmental impacts are anticipated due construction activities as well

as that of generation, handling, treatment and disposal of gaseous emissions,

liquid effluents, solid and hazardous wastes during operation of UPL plant after

expansion on various environmental parameters.

The proposed expansion of UPL plant may have impact on soil, water resources

and water quality, ambient air quality, noise, terrestrial flora & fauna and socio-

economic environment in surrounding area. Therefore, these impacts have

been discussed in detail in the following sections for construction and operation

phases of the proposed expansion of the UPL plant.



4 - 11

4.5.1 Topography and Physiographic A. Construction Phase

The construction activities for the proposed expansion, such as, excavation,

construction of buildings, erection & commissioning will be limited within the

land available at the existing UPL plant located in notified industrial area.

Therefore, topography and physiography of the area will not be affected during

the construction of the proposed expansion project. Hence, no significant

impact is anticipated on the topography and physiography due to construction

of the proposed expansion project.

B. Operational Phase During operation phase of the proposed expansion of existing plant, no impact

is anticipated on the topography and physiography of the area as plant

operation after expansion will be within the existing premises of the plant.

Hence, the impact on the topography and physiography of the study area

around the UPL plant is as given below:

Impact Rating Topography & Physiography

Significance and Nature of impact Insignificant

Duration of impact Long term

Impacted Area Localized

Likelihood of occurrence Low

Severity of impact Slight

4.5.2 Impact on Soil

A. Construction Phase During the construction phase, soil would be excavated at the plant site for

foundations of buildings, plants and machineries, etc. Prior to excavation on

fresh land with ground flora, top soil will be segregated and stockpiled. Top soil

will be used for the greenbelt development and landscaping at the plant. At the

time of construction, some amount of debris, cuttings of construction materials,

etc., may be generated. However, the quantity of these waste materials would

be very small and limited up to the construction site only. These wastes may

contaminate soil of the plant site if not disposed properly. However, the extent



4 - 12

of the contamination would be negligible. Solid wastes and debris generated at

the construction site will be collected time to time and disposed-off suitably to

avoid such contamination. The inert debris generated during construction will

be used for land filling at the site only.

During construction phase of the proposed UPL plant, approx. 5 kg/day solid

wastes may be generated by construction workers. The type of wastes

expected to be generated by workers will be segregated into the following

possible categories:

• Waste from food, etc.,

• Paper, packing, plastic bottles and polythene waste, etc.,

This will be segregated and disposed-off using established disposal techniques.

Therefore, soil at the plant site and area will not be affected by the solid waste

generated at the project site during construction phase.

There may be generation of small amount of wastes, such as, spillage of fuel

oil, grease, metal cuttings, debris, etc. from construction of proposed expansion

of the UPL plant that may contaminate soil at the site. However, extent of

contamination will not be significant.

Mitigation Measures

• Prior to excavation, top soil from fresh land with ground flora will be

segregated and stockpiled. Top soil will be used during the greenbelt

development and landscaping at the plant site.

• Wastes and debris generated at the site will be collected time to time and

disposed suitably to avoid any contamination. The inert debris generated

during construction will be used for land filling at the site only.

• Fuel oil for construction equipment will be stored on the cemented floor.

• Excavation of foundations will be carried out during dry season to eliminate

possibility of erosion by runoff.

Hence, the impact on the soil during construction phase of the proposed

expansion of the UPL plant is as given below:



4 - 13

B. Operation Phase During operation phase of the proposed expansion, hazardous wastes

generated at the UPL plant are given in Table 4.6.

Table 4.6: Hazardous Wastes (Landfillable Waste and Incinerable

Waste) Quantity and Category – After Proposed Expansion

Sr. No.

Hazardous Waste with Category Quantity

1 Distillation residue (29.1) 1604.82 (MTM)

2 Discarded Containers (Drums, Carboys) (33.1) 9636 (Nos/Month)

3 Plastic Bags (33.1) 51562 (Nos/Month)

4 ETP sludge (35.3) 40 (MTM)

5 Salt from Evaporation & Process (35.3) 2536 (MTM)

6 Used Oil (5.1) 500 Ltrs/ Month

7 Used Batteries (B1(B1020)) 5 Nos/Month

8 Spent Solvent (29.4) 10 MTM

9 Spent Catalyst (29.5) 1 MTM

10 Aqueous Effluent from Drum/Tank/reactor

washing (29.1)

50 MTM

11 Date Expired & Off specific Pesticide (29.3) 5 MTM

12 Used Filter Aids (36.2) 3 MTM

13 Insulation waste /PPEs (33.2) 8 MT/Year

14 Spent Acid (29.6) 2 MT/Year

Hazardous wastes generated from the plant after expansion will have potential

to contaminate soil of the plant and nearby area, if not disposed properly.

Therefore, UPL has already prepared elaborated strategy for collection, storage

and disposal of hazardous wastes to Common Hazardous Waste Treatment

Impact Rating Soil

Significance and Nature of impact Negligible and Adverse







4 - 14

Storage and Disposal facility (CHWTSDF at Taloja) and recyclable hazardous

wastes are sold to authorized cyclers.

After expansion of the proposed UPL plant, approx. 120 tones ash will be

generated from coal/husk fired boilers, (which will be non-hazardous). Ash

generated from the plant can affect characteristics of soil, if these are not

disposed properly. Please refer Annexure X for utilization of Fly ash

During operation phase, approx. 297 kld (Existing & proposed) effluents will be

generated from the proposed expansion of UPL plant and will be treated in ETP

comprising primary, secondary and tertiary treatment facilities. Treated waste

water will be sent to Common Effluent Treatment Plant (CETP Tarapur).

Hence, the impact on the soil during operation phase of the proposed expansion

of the UPL plant is as given below:

Mitigation Measures To avoid impact on the soil of the plant and area, the following mitigation

measures, which are already implemented at existing UPL plant, will be

followed after expansion of the plant:

• Process (Bio-degradable) effluents will be treated in ETP comprising

primary, secondary and tertiary treatment facilities. Treated waste water

will be sent to Common Effluent Treatment Plant (CETP).

• Hazardous wastes (incinerable wastes) generated in the form of distillation

residue, spent catalyst, aqueous effluent from drum/tank/reactor washing,

date expired & off specific pesticide and used filter aids will be sent to

Common Hazardous Waste Treatment Storage and Disposal facility

(CHWTSDF) for incineration.

• Used Oil generated from the maintenance of DG sets will handed over to

CPCB authorized used oil recyclers.

Impact Rating Soil

Significance and Nature of impact Significant and Adverse



Likelihood of occurrence High

Severity of impact Moderate



4 - 15

• Discarded containers (drums, carboys) contaminated with hazardous

chemicals will be sent for decontamination to CHWTSDF or sold to approved

scrap processors after decontamination.

• Sludge generated from the ETP will also be sent to CHWTSDF for landfilling.

• Salt proposed to be generated from evaporation of process residues will

also be sent to CHWTSDF for landfilling.

4.5.3 Water Quality

A. Construction Phase

The construction phase of the proposed expansion of the UPL plant will be

located on the land available within existing UPL plant. No water from surface

water body will be withdrawn for construction purpose. Water requirement

during construction phase will be met through water supplied by MIDC. During

construction phase, proper drainage will be provided for runoff movement

during rains, hence, no changes in the natural drainage pattern of the site and

area is envisaged, the impact of construction phase of the proposed expansion

of the UPL plant on surface water resources is likely to be insignificant.

During the construction phase, loose soil from excavated area may be washed

out from the site with runoff during rainfall and may increase the turbidity of

runoff ultimately meeting to surface water resource. However, this impact may

last as first rain is over and loose soil will be stabilized after first rainfall.

Therefore, the impact on soil during construction phase will be marginal and

reversible in nature.

Mitigation Measures

• Excavation of foundations will be carried out during dry season and site will

be restored before rains.

• Silt chambers at discharge point of storm water from construction area.

• Compaction and level of construction area after completion of foundation

and construction activities.

• Before unexpected rains, cover loose construction materials by tarpaulin

sheets



4 - 16

Hence, the impact on water quality during construction phase of the proposed


Impact Rating Water Quality

Significance and Nature of impact Insignificant

Duration of impact Short term




B. Operation Phase

At the existing UPL plant, total existing water consumption is 166.56 kld. After

proposed expansion, additional water requirement is estimated as 538.5 kld.

Therefore, total water consumption after expansion is estimated 705.06 kld as

given in Table 4.7, which will be met through water supply by MIDC Notified

Industrial Estate. For the existing plant and proposed expansion, no water will

be taken from ground water or surface water resources.

Table 4.7: Total Water Consumption after Expansion after Expansion

Sr. No.

Particulars Total Water Consumption after Expansion (kld)

1. Boiler & Cooling 221

2. Domestic Purpose 14

3. Processing & Washing 450.06

4. Gardening 20

Total 705.06

297 kld waste water/effluents will be generated from the UPL plant from the

existing plant after expansion as per details given in Table 4.8. Effluents will

be treated in ETP comprising primary, secondary and tertiary treatment

facilities and will be sent to Common Effluent Treatment Plant (CETP Tarapur).

At the existing plant, domestic waste water is treated in septic tank followed

by soak pit. There is no discharge of treated domestic waste water or treated

effluents on land and outside the plant premises.



4 - 17

Table 4.8: Total Effluent Generation After Expansion

Sr. No.

Particulars Total Effluent Generation After Expansion (kld)

1. Trade effluents 76

2. Boiler & Cooling 40

3. Domestic waste water 11

4. MEE Condensate 170*

Total 297 *Multi Effect Evaporator (MEE) condensate @ 170 kld and we will check for recycling possibility once the characteristics of condensate water is being analysed.

Hazardous wastes generated from the existing plant and after expansion have

potential to contaminate ground water quality and surface water quality of

nearby area, if not disposed properly. Therefore, hazardous wastes generated

at the plant are collected and disposed to Common Hazardous Waste Treatment

Storage and Disposal facility (CHWTSDF) for landfilling and incineration, and

recyclable hazardous wastes are sold to authorized cyclers.

Hence, the impact on water quality during operation phase of the proposed


Impact Rating Water Quality

Significance and Nature of Impact Significant and Adverse

Duration of Impact Long term


Likelihood of Occurrence High

Severity of Impact Moderate

Mitigation Measures

• Generated Bio-degradable effluents @297 KLD will be treated in ETP

comprising primary, secondary and tertiary treatment facilities. Treated

waste water will be sent to Common Effluent Treatment Plant (CETP).

• Hazardous wastes (incinerable wastes) generated in the form of distillation

residue, spent catalyst, aqueous effluent from drum/tank/reactor washing,

date expired & off specific pesticide and used filter aids will be sent to

Common Hazardous Waste Treatment Storage and Disposal facility

(CHWTSDF) for incineration at Ramky, Taloja.

• Hazardous wastes (Landfilling wastes) like ETP sludge, salts from

evaporation systems & process, insulation wastes/PPEs and plastic bags will



4 - 18

be sent to Common Hazardous Waste Treatment Storage and Disposal

facility (CHWTSDF) for landfilling at Ramky, Taloja.

• Used Oil generated from the maintenance of DG sets will be handed over

to CPCB authorized used oil recyclers.

• Generated spent solvents will be sent to CPCB authorized end users having

permission of Rule 9 or for co-processing at cement industries.

• Generated spent acids will be sent to CPCB authorized end users having

permission of Rule 9.

• Used batteries will be sale to MPCB authorized party.

• Generated fly ash from boilers will be sale to brick manufacturers or other

end-users.

I. Details of Existing ETP Details of existing effluent treatment plant are given below: Existing ETP Capacity: 50 kld

This ETP is designed to achieve stipulated standards: Hydraulic flow diagram

for existing ETP is shown in Figure 4.1:

The ETP consists of the following components:

• Grit removal: this being aimed to achieve for the removal of the physical

particles which has carried from the floor of factory /drainage system

• Oil & Grease trap: this being aimed to achieve for removal of the oily

particles in side from effluent which has carried from the various operation

& spillage inside the factory or system

• Equalization: this being design to achieve for maximum uniformity for

input of the effluent plant by collecting & storing effluent from various

effluent stream

• Neutralization: this is to achieve Neutralization of the effluent by the

virtue of suitable agent of the further effluent process safe- grading.

• Flash Mixture: It is tank where dusing off flocculate/clarifier agent takes

place in precession & adequate manner. This helps to accelerate the

sedimentation along with desirable property of the treatment

• Flocculation Tank: It is tank allows dosed chemicals to react with effluent

& get accelerated the sedimentation & other desirable property of the

treatment scheme.



4 - 19

• Practical Separation by DAF (Dissolve air Flotation) is the process where

the sludge formation & removal (Mechanically) takes place by exposing the

water dissolved air in the effluent. This also helps to reduce COD from the

effluent.

• Primary clarifier: this is meant for removal of micro sedimentations which

are carried over with the effluent. It is gravity separation method.

• Bio Tank: The effluent is being treated with microbes to reduce the COD

& BOD

• Lamella Separator : this is meant for removal of micro sedimentations

which are carried over with effluent from the bio tank by gravity separation.

• Carbon & Sand filter: This is used for polishing the effluent.

Further, treated effluents are being sent to the Common Effluent Treatment

Plant (CETP) through MIDC drainage line for final treatment & disposals.

Natural Sun Drying: For solid/ sludge generated from various activity during

effluent treatment process is dried in natural sunlight, which is further sent for

Mumbai Waste Management Ltd. (MWML) Taloja for landfill.

II. Proposed ETP Details The proposed ETP with design capacity 300 m3/day will be installed for the

treatment of biodegradable effluent generated from process, boiler blow down,

cooling tower blow down and domestic waste water. Schematic diagram for the

proposed ETP is shown in Figure 4.2.

Figure 4.1: Hydraulic Flow Diagram for Existing ETP



4 - 20

The proposed ETP will cover the full-fledged primary, secondary and tertiary

treatment systems, as described below:

In the primary treatment, the equalized raw effluent neutralized with lime and

flocculent is added. The clear overflow from the primary clarifier is taken to the

secondary treatment. The sludge from clarifier bottom is taken to filter press

for sludge dewatering. Generated Sludge will be sent for landfilling to common

TSDF.

In the secondary treatment, two aeration tanks will be provided in series. The

treated effluent coming out of the tertiary treatment will be collected in the

sump and passed through activated carbon filter. Treated effluent will be

collected in a tank and transferred to CETP for further treatment. Unit has

provided online monitoring systems for pH, COD, BOD, Flow, TSS and data

transmitted to CPCB/MPCB website. It shall be continued after proposed

expansion.

Figure 4.2: Schematic Diagram for Proposed ETP



4 - 21

4.5.4 Meteorology A. Construction Phase The construction of the proposed expansion of the UPL plant will have no impact

on meteorology of the study area as no hot gas emissions are likely to emit

during construction phase. Therefore, no mitigation measure is required.

A. Operation Phase At the existing plant and after proposed expansion, 2x10 tph boilers, 1x4 TPH

Boiler, 2x750 kVA, 1x500 kVA and 1x250 kVA DG sets will be sources of stack

emissions and hot flue gases will be vented into the atmosphere. UPL has

installed heat recovery unit to utilize waste heat of flue gases. Therefore, hot

gases are not vented out into atmosphere and there is no possibility for rising

temperature at the plant and in the vicinity. The process emissions are/will be

discharged into atmosphere only after passing through the scrubbers at the

about ambient temperature. Hence, no impact is anticipated on the micro-

meteorology due to operation of existing plant and after operation.

4.5.5 Air Environment


During the construction phase of the proposed expansion of the plant, small

amount of particulate matter, some gaseous pollutants and some noise will be

generated at the site due to movement and operation of construction machines.

Furthermore, this impact will be of temporary nature and will disappear after

the completion of construction activities.

The potential sources of air emissions during construction phase of the

proposed expansion of the plant will be as follows:

• Dust from earth works during clearing excavation;

• Emissions from the operation of construction equipment and machines;

• Fugitive emissions from vehicles transporting construction materials;

• Fugitive emissions during the unloading of cement bags;

• Fugitive emissions during mixing of cement with other building materials;

• Fumes and gases due to cutting, welding & grinding of steel structures.

• Dust emission from scrap and waste construction materials, etc.



4 - 22

Impact of construction activity on air quality is a cause for concern mainly in

the dry months due to settling of dust particles. The main sources of dust

emissions during the construction period will be the movement of equipment at

site and dust emitted during, grading, earthworks, foundation works and other

construction related activities. The dust emitted during construction will depend

upon the type of soil being excavated and the moisture content. The suspended

particulate matter/dust in ambient air as a result of construction activities like

excavation may be relatively coarse and these will settle within a short distance

from the site. The impact of particulate matter, gaseous pollutants and noise is

expected to be restricted within the close vicinity of the construction activities.

The composition of dust will be inorganic and non-toxic in nature and these are

not expected to travel long distance before settling.

Exhaust emissions from vehicles and equipment deployed during the

construction phase will also result in marginal increase in the levels of SO2, NO2,

PM2.5, CO and un-burnt hydrocarbons. It is estimated that on an average 2

trucks will approach to site every day and one construction machinery will be

deployed only for few weeks. Therefore, impact will be reversible, marginal,

and temporary in nature.

The impact of construction activities would be temporary and restricted to the

construction phase. The impact will be confined within the project boundary

and is expected to be negligible outside the plant boundaries. Proper upkeep

and maintenance of vehicles, sprinkling of water at the construction site,

providing sufficient vegetation are some of the proposed measures that would

greatly reduce the impact on the air quality during the construction phase of

the proposed expansion of the plant. During the excavation, unloading of

cement bags and mixing of cement with other building materials, fugitive dust

emissions may be emitted at the construction site. It may be noted that these

emissions would be in the form of coarse particulate matter and will be settled

down ultimately in the closed vicinity of construction site.

Mitigation Measures

• To suppress dust, sprinkling of water on the loose soil area after excavation

• Sprinklers of water on unpaved construction areas at the site.

• Covering of loose construction materials

• Maintenance of construction equipment and machineries to reduce exhaust

emission



4 - 23

• Ensure pollution under control certificate for vehicles transporting materials

• Unloading of cement bags and close chamber

• 3.5 m high curtain wall around the construction zone by garden net or tin

sheets.

Hence, the impact on ambient air quality during construction phase of the

proposed expansion of the UPL plant is as given below:

Impact Rating Ambient Air Quality

Significance and Nature of impact Significant

Duration of impact Short term



Severity of impact Minor

B. Operation Phase

During operation phase, at the existing plant and proposed expansion, boilers,

DG sets, process vents, scrubber stacks will be sources of emissions.

At the existing UPL plant, 10 tph capacity coal or biomass/briquettes/rice husk

fired boiler is available, which consumes 985 kg/hr coal or 2460 kg/hr

biomass/briquettes/ rice husk. One standby 4 tph capacity furnace oil fired

boiler is also available, which consumes 125 Litres furnace oil per hour. After

expansion additional 10 tph capacity boiler will be installed, which will consume

2 tph coal at full load operation. Presently, UPL has two DG sets of 500 KVA

and 250 KVA capacities. After expansion two additional DG Sets of 750 KVA

capacity each will be installed to meet the power requirement of the plant

during grid power failure. LDO and HSD consumption as 500 Liter/hr is

estimated for operation of existing and proposed DG sets.

From the boilers and DG Sets, SO2, NO2 and Particulate Matters (PM) are

considered as key pollutants. Boilers are continuous sources of emissions while

DG sets are intermittent sources of emissions. From flue gas stacks, key

pollutants and air pollution control system for the UPL plant after expansion are

given in Table 4.9.

Table 4.9: Key Pollutants and Air Pollution Control System



4 - 24

Sr. No.

Stack attached to Key Pollutants

Nature of Emissions


I. Existing Flue Gas Stacks

1. 10 tph Coal or

Biomass/Briquettes/Rice

Husk Fired Boiler

SPM, SO2

and NO2

Continuous Dust collector,

Bag filter and

stack height

based on

Sulphur

emission load

as per CPCB

Guidelines

2. 4 tph Furnace Oil Fired

Boiler

SPM, SO2

and NO2

Intermittent

(during grid

power failure)

Stack height

based on

Sulphur

emission load

as per CPCB

Guidelines

3. DG Set 250 kVA PM, SO2

and NO2

Intermittent

(during grid

power

failure)

Stack height as

per CPCB

Guidelines

4. DG Set 500 kVA PM, SO2

and NO2

Intermittent

(during grid

power

failure)

Stack height as

per CPCB

Guidelines

I. Proposed Flue Gas Stacks

1. 10 tph Coal Fired Boiler SPM, SO2

and NO2

Continuous Dust Collector,

bag filter and

stack height will

be based on

Sulphur

emission load

as per CPCB

guidelines

2. DG Set 750 kVA (2 nos) PM, SO2

and NO2

Intermittent

(during grid

power

failure)

Stack height

will be as per

CPCB

guidelines



4 - 25

From the existing plant, PCl3 - I and PCl3 - II (Phosphorus Oxychloride)

Phosphorous plant HCl scrubber & Tri Phenyl Phosphite (TPPI) stacks are

source of process emissions and HCl, Cl2 and PCl3 are key pollutants from these

process stacks. To control emissions from these two stacks water and alkali

scrubbers have been provided.

After expansion of existing plant, process emissions will be vented out through

separate stacks for manufacturing processes for Asulam, Tri Phenyl Phosphate

(TPPA), Ammonium Chloride, Triazinone, Acephate, Glyphosate, Metribuzin

(Common Plant Scrubber), Ammonium Sulphate, Phosphorus Acid Solid &

Solution, Di-Chlorvos (DDVP). Water and caustic/alkali scrubbers will be

provided as required to control emissions of HCl, Cl2, HBr, MeCl, H2S, NH3 and

HC well within the stipulated emission standards.

From the process stacks, key pollutants and air pollution control system for

existing plant, key pollutants and air pollution control system are given in Table

4.10.

Table 4.10: Process Stacks, Key Pollutants and Air Pollution Control

System

Sr. No.



I. Existing Process Stacks

1. PCl3 –I

HCl Two stage water and Alkali

scrubber Cl2

PCl3

2. PCl3- II (Phosphorus

Oxychloride)

Phosphorous plant HCl

scrubber & Tri Phenyl

Phosphite (TPPI)

HCl

Two stage water and Alkali

scrubber

Cl2

PCl3

II. Proposed Process Stacks

1. Asulam HCl Alkali scrubber

Cl2

2. Tri Phenyl Phosphate (TPPA)

HCl Water + Caustic Scrubber

3. Ammonium Chloride NH3 Water Scrubber

HCl

4. Triazinone HCl



4 - 26

Sr. No.



H2S Caustic Scrubber

5. Acephate NH3 water Scrubber

6. Glyphosate

NH3

Water and Alkali Scrubber HC

HCl

7. Metribuzin (common plant scrubber)

HBr Caustic Scrubber

8. Ammonium Sulphate NH3 Water Venturi scrubber

9. Phosphorus Acid Solid & Solution

HCl Water & Caustic Scrubber

10. Di-Chlorvos (DDVP) MeCl Caustic Scrubber Source: UPL Ltd.

During the operation of existing plant after expansion, continuous and

intermittent sources of stack emissions from boilers, DG sets and process stacks

may impact ambient air quality of the study area. For assessment of impacts of

stack emissions from the UPL plant after expansion, air pollution dispersion

mathematical modelling has been carried out for short term incremental ground

level concentrations (GLCs) prediction.

When air pollutants are emitted into the atmosphere, they are immediately

diffused into surrounding atmosphere, transported and diluted due to winds.

The air pollution dispersion models are designed to simulate these processes

mathematically and to relate emissions of primary pollutants to the resulting

downwind air quality. The inputs include emission load, stack parameters,

micro-meteorology and surrounding topographic details to predict the impacts

of pollutants on the ambient air quality and discrete receptors in the area.

4.5.5.1 Air Pollutants Dispersion Modeling for Prediction of impacts on

Ambient Air Quality The objective of dispersion modeling is to predict the ground level concentration

during the operation of UPL plant after expansion and its impact on ambient air

quality of the area. The ground level concentrations of pollutants have been

computed using computer simulation model AERMOD (as recommended in

Technical EIA Guidance Manual for Pesticide Industry and Pesticide Specific

Intermediates by Ministry of Environment, Forest and Climate Change,

Government of India) and considering guidelines stipulated by CPCB for air

pollution dispersion modeling.



4 - 27

The key emissions from the UPL plant after proposed expansion will be

Particulate Matter (PM), Sulphur Dioxide (SO2) and Nitrogen Oxide (NO2) from

boilers and DG sets stacks, while Hydrogen Chloride gas (HCl), Chlorine (Cl2),

PCl3, Hydrogen Sulfide (H2S), Ammonia (NH3), Methylene Chloride (MeCl),

Hydrogen Bromide (HBr) and Hydrocarbon (HC) are emissions from the process

stacks.

Mathematical Model used for Prediction Modelling Prediction of GLC values are made by using AERMOD computer software model.

This model uses a steady state, sector-averaged Gaussian plume equation for

application in complex terrain (i.e. terrain stack or release height) and is run

using stability classes developed by Pasquill and Gifford.

The following are the assumptions made while using the model:

• The plume rise is estimated by Briggs formulae, but the final rise is always

limited to that of the mixing layer;

• Stack tip down-wash is not considered;

• Buoyancy Induced Dispersion is used to describe the increase in plume

dispersion during the ascension phase;

• Calms processing routine is used by default;

• Complex terrain is used for computations;

• It is assumed that the pollutants do not undergo any physico-chemical

transformation and that there is no pollutant removal by dry deposition;

• Washout by rain is not considered;

• Cartesian co-ordinate system has been used for computations;

• No dry and wet depletion of pollutants;

• Receptors are on flat terrain with no flag pole.

Source Characteristics and Emissions Load

The emissions sources characteristics at existing UPL plant after expansion are

as given in Table 4.11 and Table 4.12, respectively:

Pollution Loads – Based on emissions sources characteristics given for

existing UPL plant and after expansion, pollution loads have been computed for

plant operation after expansion for flue gas stacks and process stacks as given

in Table 4.13 and Table 4.14, respectively.

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,

Dist. Palghar, Maharashtra


4-28

Table 4.11: Existing Stack Emissions Characteristics for Flue Gas and Process Stacks Sn Parameters DG

Set

250 Kva

DG

Set

500 kVA

10 TPH

Coal/Biomass/

Husk Fired Boiler

4

TPH

FO Fired

Boiler

PCl3 -I

Scrubber

Stack

PCl3 -II

Scrubber

Stack

Metribuzin

Plant

Ammonium

Sulphate

Plant

1. Stack Height, m

3.1 m

(above

roof)

5.1 m

(above

roof)

40 30

Not

manufactured

till the date

Not

manufactured

till the date

30

Not

manufactured

till the date

2. Stack Dia, m 0.2 0.3 1.0 1.0 -- -- 0.35 --

3. Temp. oC 165 160 124 132 -- -- 36 --

4. Stack Gas Velocity m/s

12.3 11.1 7.7 2.7 -- -- 3.0 --

5.

Volumetric

Flowrate Nm3/hr

1380 2810 21750 7540 -- -- 1002 --

6. Concentration

of Pollutants -- -- --

SPM (mg/Nm3) 56.1 53.2 78.3 61.2 -- -- -- --

SO2 (mg/Nm3) 54.1 59.2 154.4 185.9 -- -- -- --

NO2(mg/Nm3) 28.1 24.2 24.0 25.2 -- -- -- --

HCl (mg/Nm3) -- -- -- -- -- -- -- --

Cl2 (mg/Nm3) -- -- -- -- -- -- -- --

PCl3 (mg/Nm3) -- -- -- -- -- -- -- --

H2S (mg/Nm3) -- -- -- -- -- -- -- --

NH3 (mg/Nm3) -- -- -- -- -- -- -- --

MeCl (mg/Nm3) -- -- -- -- -- -- -- --

HBr (mg/Nm3) -- -- -- -- -- -- *BDL --

HC (mg/Nm3) -- -- -- -- -- -- -- --




4-29

Table 4.12: Proposed Stack Emission Characteristics for Flue Gas and Process Stacks After Expansion Sn Parameters DG

Sets 750 kVA

10 TPH Coal fired

Boiler

Asulam Stack

Tri Phenyl Phosphate

Stack

Ammo nium

Chloride Stack

Triazi none Stack Stack

Acephate Stack

Glyph osate Stack

Metribuzin (common

plant scrubber)

Stack

Phosphorus Acid Stack

Ammonium Sulphate

Stack

Di-Chlorvs Stack

PCl3 -I Scrubber

Stack

PCl3 -II Scrubber

Stack

1. Stack Height, m

18 40 30 30 30 30 30 30 30 30 30 30 30 30

2. Stack Dia, m 0.3 1.0 0.3 0.3 0.3 0.3 0.3 0.3 0.35 0.3 0.3 0.3 0.3 0.3

3. Temp. oC 165 130 34 33 36 32 35 35 36 36 33 33 35 35

4. Stack Gas Velocity m/s

16.7 6.9 3.2 3.0 3.1 2.9 3.0 3.1 3.0 3.2 3.1 3.2 3.0 3.0

5. Volumetric Flowrate Nm3/hr

4262 18840 1021 999 1017 1004 1027 985 1026 1018 1003 1016 989 989

6. Concentration of Pollutants

SPM (mg/Nm3)

50 67 -- -- -- -- -- -- -- -- -- -- -- --

SO2 (mg/Nm3) 64.4 111.5

-- -- -- -- -- -- -- -- -- -- -- --

NO2

(mg/Nm3) 25.0 29.5 -- -- -- -- -- -- -- -- -- -- --

HCl (mg/Nm3)

-- -- 4 3.4 2.8 6.7 -- 8.8 -- -- 7.6 -- 6.6 5.3

Cl2 (mg/Nm3) -- -- 1.1 -- -- -- -- -- -- -- -- -- 2.1 1.4

PCl3

(mg/Nm3) -- -- -- -- -- -- -- -- -- -- -- -- 2.2 1.9

H2S (mg/Nm3)

-- -- -- -- -- 3 -- -- -- -- -- -- -- --

NH3

(mg/Nm3) -- -- -- -- 9.1 -- 11 7.8 -- 12.2 -- -- -- --




4-30

Sn Parameters DG Sets 750 kVA

10 TPH Coal fired

Boiler

Asulam Stack

Tri Phenyl Phosphate

Stack

Ammo nium

Chloride Stack

Triazi none Stack Stack

Acephate Stack

Glyph osate Stack

Metribuzin (common

plant scrubber)

Stack

Phosphorus Acid Stack

Ammonium Sulphate

Stack

Di-Chlorvs Stack

PCl3 -I Scrubber

Stack

PCl3 -II Scrubber

Stack

MeCl (mg/Nm3)

-- -- -- -- -- -- -- -- -- -- -- 3.5 -- --

HBr (mg/Nm3)

-- -- -- -- -- -- -- -- <1 -- -- -- -- --

HC (mg/Nm3)

-- -- -- -- -- -- -- 2.4 -- -- -- -- -- --




4-31

Table 4.13: Emission Loads for Flue Gas Stacks After Expansion

Flue Gas Emission Sources SO2 (g/s) NO2 (g/s) SPM (g/s)

Existing

DG Set of 250 kVA 0.02 0.01 0.02

DG Set of 500 kVA 0.05 0.02 0.04

10 TPH Coal/Husk Fired Boiler 0.93 0.15 0.47

4 TPH FO Fired Boiler 0.39 0.05 0.13

Proposed

DG Set of 750 kVA 0.08 0.03 0.06

DG Set of 750 kVA 0.08 0.03 0.06

10 TPH Coal Fired Boiler 0.61 0.16 0.37




4-32

Table 4.14: Emission Loads for Process Stacks After Expansion

Process Emissions Sources HCl

(g/s)

Cl2

(g/s)

PCl3

(g/s)

H2S

(g/s)

NH3

(g/s)

MeCl

(g/s)

HBr

(g/s)

HC

(g/s)

Asulam 0.0011 0.0003 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Tri Phenyl Phosphate (TPPA) Stack 0.0009 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Ammonium Chloride Stack 0.0008 0.0000 0.0000 0.0000 0.0026 0.0000 0.0000 0.0000

Triazinone Stack 0.0019 0.0000 0.0000 0.0008 0.0000 0.0000 0.0000 0.0000

Acephate Stack 0.0000 0.0000 0.0000 0.0000 0.0031 0.0000 0.0000 0.0000

Glyphosate Stack 0.0024 0.0000 0.0000 0.0000 0.0021 0.0000 0.0000 0.0007

Metribuzin Stack 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0003 0.0000

Phosphorus Acid Stack 0.0000 0.0000 0.0000 0.0000 0.0034 0.0000 0.0000 0.0000

Ammonium Sulphate 0.0021 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Di-Chlorvos Stack 0.0000 0.0000 0.0000 0.0000 0.0000 0.0010 0.0000 0.0000

PCl3 -I Scrubber Stack 0.0018 0.0006 0.0006 0.0000 0.0000 0.0000 0.0000 0.0000

PCl3 -II Scrubber Stack 0.0015 0.0004 0.0005 0.0000 0.0000 0.0000 0.0000 0.0000

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial

Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra


4-33

Atmospheric Stability The persistence of atmospheric stability classes has been estimated using hourly

monitored wind velocity data along with compiled data for sunrise, sunset, solar

isolation for day-time and cloud cover for night-time for the site.

Mixing Height The knowledge of the site-specific mixing height (convective stable boundary layer

and inversion height or nocturnal boundary layer) is crucial in a realistic adoption

of appropriate plume rise and vertical dispersion parameters. In the absence of

site specific mixing heights, “Hourly Mixing Height and Assimilative Capacity of

Atmosphere in India” published by Environmental Monitoring and Research Centre,

India Meteorological Department, New Delhi, 2008, has been referred for hourly

mixing heights.

Maximum 24-Hourly and Seasonal Incremental GLC Isopleths

Using mathematical model as described above, the maximum 24-hourly and

seasonal incremental ground level concentration (GLCs) values calculated at

different grid points using 24-hourly and seasonal averaging period are used for

obtaining the maximum 24-hourly and seasonal incremental ground level

concentrations (GLCs) isopleths for the study period and considering that X, Y

coordinates of the stack center (0.0).

The following conclusions can be made from the air pollution dispersion modeling:

(i) GLCs Values for Particulate Matter (PM)

The highest 24-hourly and seasonal incremental GLCs values for Particulate Matter

due to stack emissions are given in Table 4.15 along with co-ordinates of their

location. Isopleth of maximum 24-hourly incremental GLCs values of Particulate

Matter (PM) are given in Figure 4.3.

Highest 24 hourly GLCs value 3.71 µg/m3 for Particulate Matter (PM) is obtained

at (+) 000 m, (-) 500 m at distance of 0.500 km and 180o angle from North




4-34

(clockwise), while highest seasonal GLCs value 0.96 µg/m3 for Particulate Matter

is obtained at (+) 500 m, (-) 500 m at distance of 0.707 km and 135o angle from

North (clockwise).

Table 4.15: Highest 24- Hourly and Seasonal Incremental GLC Values

for Particulate Matter and Grid Point Locations

Pollutant Concentration &

Location

24 Hourly GLCs Seasonal GLCs

GLCs for Particulate Matter 3.71 µg/m3 0.96 µg/m3

Location of Highest GLCs

Grid Point (m) (+) 000,

(-) 500

(+) 500,

(-) 500

Distance (km) 0.500 0.707

Angle from North (Clockwise) 180o 135o

24 Hourly GLCs Values for particulate matter at discrete locations at settlements

in the area, where ambient air quality monitoring was carried are given Table

4.16.

Table 4.16: 24 Hourly GLCs Values for Particulate Matter at Discrete

Locations

Code Locations 24 Hourly

GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0.06998 93.85 93.92

A3 Pasthal 0 92.02 92.02

A4 Saravali 0.00887 92.42 92.43

A5 Kumbhavali 0.00268 80.94 80.94

A6 Boisar 0.67135 85.17 85.84

A7 Kudan 0 88.98 88.98

A8 Pam 0.00567 80.47 80.48




4-35

Figure 4.3: Isopleths for Particulate Matter for 24 Hours GLCs




4-36

(ii) GLCs Values for Sulphur Dioxide (SO2)

The highest 24-hourly and seasonal incremental GLCs values for Sulphur Dioxide


location. Isopleth of maximum 24-hourly incremental GLCs values of Sulphur

Dioxide (SO2) are given in Figure 4.4.

Highest 24 hourly GLCs value 5.54 µg/m3 for Sulphur Dioxide (SO2) is obtained at

(+) 000 m, (-) 500 m at distance of 0.500 km and 180o angle from North

(clockwise), while highest seasonal GLCs value 1.28 µg/m3 for Sulphur Dioxide is

obtained at (+) 500 m, (-) 500 m at distance of 0.707 km and 135o angle from

North (clockwise).

Table 4.17: Highest 24- Hourly and Seasonal Incremental GLC

Values for Sulphur Dioxide and Grid Point Locations


Location

24 Hourly

GLCs

Seasonal GLCs

GLCs for Sulphur Dioxide 5.54 µg/m3 1.28 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for Sulphur Dioxide at discrete locations at settlements in

the area, where ambient air quality monitoring was carried are given Table

4.18.




4-37

Table 4.18: 24 Hourly GLCs Values for SO2 at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0.11356 25.84 25.95

A3 Pasthal 0 20.34 20.34

A4 Saravali 0.0149 25.21 25.22

A5 Kumbhavali 0.00453 15.71 15.71

A6 Boisar 1.00681 18.74 19.75

A7 Kudan 0 20.86 20.86

A8 Pam 0.00707 20.21 20.22

Figure 4.4: Isopleths for Sulphur Dioxide for 24 Hours

GLCs




4-38

(iii) GLCs Values for Nitrogen Dioxide (NO2)

The highest 24-hourly and seasonal incremental GLCs values for Nitrogen Dioxide


location. Isopleth of maximum 24-hourly incremental GLCs values of Nitrogen

Dioxide are given in Figure 4.5.

Highest 24 hourly GLCs value 2.11 µg/m3 for Nitrogen Dioxide is obtained at (+)

000 m, (-) 500 m at distance of 0.500 km and 180o angle from North (clockwise),

while highest seasonal GLCs value 0.53 µg/m3 for Nitrogen Dioxide is obtained at

(+) 500 m, (-) 500 m at distance of 0.707 km and 135o angle from North

(clockwise).


Values for Nitrogen Dioxide and Grid Point Locations


Location


GLCs for Nitrogen Dioxide 2.11 µg/m3 0.53 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for Nitrogen Dioxide at discrete locations at settlements in

the area, where ambient air quality monitoring was carried are given Table

4.20.




4-39

Table 4.20: 24 Hourly GLCs Values for Nitrogen Dioxide at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0.03824 38.52 38.56

A3 Pasthal 0 45.84 45.84

A4 Saravali 0.00489 35.51 35.51

A5 Kumbhavali 0.00147 32.38 32.38

A6 Boisar 0.38209 28.61 28.99

A7 Kudan 0 31.86 31.86

A8 Pam 0.00355 30.45 30.45

Figure 4.5: Isopleths for Nitrogen Dioxide for 24 Hours GLCs




4-40

(iv) GLCs Values for HCl

The highest 24-hourly and seasonal incremental GLCs values for HCl due to stack

emissions are given in Table 4.21 along with co-ordinates of their locations.

Highest 24 hourly GLCs value 0.17 µg/m3 for HCl is obtained at (+) 000 m, (-) 500

m at distance of 0.500 km and 180o angle from North (clockwise), while highest

seasonal GLCs value 0.04 µg/m3 for HCl is obtained at (+) 500 m, (-) 500 m at

distance of 0.707 km and 135o angle from North (clockwise).


Values for HCl and Grid Point Locations


Location


GLCs for HCl 0.17 µg/m3 0.04 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for HCl at discrete locations at settlements in the area,

where ambient air quality monitoring was carried are given Table 4.22.

Table 4.22: 24 Hourly GLCs Values for HCl at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0.0001 BDL BDL

A3 Pasthal 0 BDL BDL

A4 Saravali 0.0001 BDL BDL

A5 Kumbhavali 0.00004 BDL BDL

A6 Boisar 0.0196 BDL BDL

A7 Kudan 0 BDL BDL




4-41


GLCs (µg/m3)

Max Background

Monitored Values

(µg/m3)

Resultant

Value

(µg/m3)

A8 Pam 0.0002 BDL BDL

Note: Detection Limit for HCl is 1 µg/m3

(v) GLCs Values for Cl2

The highest 24-hourly and seasonal incremental GLCs values for Cl2 due to stack

emissions are given in Table 4.23 along with co-ordinates of their location.

Highest 24 hourly GLCs value 0.018 µg/m3 for Cl2 is obtained at (+) 000 m, (-)

500 m at distance of 0.500 km and 180o angle from North (clockwise), while

highest seasonal GLCs value 0.004 µg/m3 for Cl2 is obtained at (+) 500 m, (-) 500

m at distance of 0.707 km and 135o angle from North (clockwise).


Values for Cl2 and Grid Point Locations


Location


GLCs for Cl2 0.018 µg/m3 0.004 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for Cl2 at discrete locations at settlement in the area,





4-42

Table 4.24: 24 Hourly GLCs Values for Cl2 at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)




A5 Kumbhavali 0 BDL BDL


A7 Kudan 0 BDL BDL


Note: Detection Limit for Cl2 is 1 µg/m3

(vi) GLCs Values for NH3

The highest 24-hourly and seasonal incremental GLCs values for NH3 due to stack


Highest 24 hourly GLCs value 0.16 µg/m3 for NH3 is obtained at (+) 000 m, (-) 500

m at distance of 0.500 km and 180o angle from North (clockwise), while highest

seasonal GLCs value 0.035 µg/m3 for NH3 is obtained at (+) 500 m, (-) 500 m at

distance of 0.707 km and 135o angle from North (clockwise).


Values for NH3 and Grid Point Locations


Location


GLCs for NH3 0.16 µg/m3 0.035 µg/m3



(-) 500

(+) 500,

(-) 500






4-43

24 Hourly GLCs Values for NH3 at discrete locations at settlements in the area,


Table 4.26: 24 Hourly GLCs Values for NH3 at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0.00016 3.83 3.83



A5 Kumbhavali 0.00004 BDL BDL


A7 Kudan 0 BDL BDL


Note: Detection Limit for NH3 is 1 µg/m3

(vii) GLCs Values for H2S

The highest 24-hourly and seasonal incremental GLCs values for H2S due to stack


Highest 24 hourly GLCs value 0.011 µg/m3 for H2S is obtained at (+) 000 m, (-)


highest seasonal GLCs value 0.003 µg/m3 for H2S is obtained at (+) 500 m, (-) 500

m at distance of 0.707 km and 135o angle from North (clockwise).




4-44

Table 4.27: Highest 24- Hourly and Seasonal Incremental GLC Values

for H2S and Grid Point Locations


Location


GLCs for H2S 0.011 µg/m3 0.003 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for H2S at discrete locations at settlements in the area,

where ambient air quality monitoring was carried, are given Table 4.28.

Table 4.28: 24 Hourly GLCs Values for H2S at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)






A7 Kudan 0 BDL BDL


Note: Detection Limit for H2S is 70 µg/m3

(viii) GLCs Values for MeCl

The highest 24-hourly and seasonal incremental GLCs values for MeCl due to stack





4-45

Highest 24 hourly GLCs value 0.014 µg/m3 for MeCl is obtained at (+) 000 m, (-)


highest seasonal GLCs value 0.003 µg/m3 for MeCl is obtained at (+) 500 m, (-)

500 m at distance of 0.707 km and 135o angle from North (clockwise).


Values for MeCl and Grid Point Locations


Location


GLCs for MeCl 0.014 µg/m3 0.003 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for MeCl at discrete locations at settlements in the area,


Table 4.30: 24 Hourly GLCs Values for MeCl at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)






A7 Kudan 0 BDL BDL


Note: Detection Limit for MeCl is 70 µg/m3




4-46

(ix) GLCs Values for HBr

The highest 24-hourly and seasonal incremental GLCs values for HBr due to stack


Highest 24 hourly GLCs value 0.004 µg/m3 for HBr is obtained at (+) 000 m, (-)


highest seasonal GLCs value 0.0009 µg/m3 for HBr is obtained at (+) 500 m, (-)



Values for HBr and Grid Point Locations


Location


GLCs for HBr 0.004 µg/m3 0.0009 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for HBr at discrete locations at settlements in the area,


Table 4.32: 24 Hourly GLCs Values for HBr at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)

A2 Salvad 0 BDL BDL


A4 Saravali 0 BDL BDL





4-47


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)


A7 Kudan 0 BDL BDL


Note: Detection Limit for HBr is 1 µg/m3

(x) GLCs Value for PCl3

The highest 24-hourly and seasonal incremental GLCs values for PCl3 due to stack


Highest 24 hourly GLCs value 0.015 µg/m3 for PCl3 is obtained at (+) 000 m, (-)


highest seasonal GLCs value 0.003 µg/m3 for PCl3 is obtained at (+) 500 m, (-)



Values for PCl3and Grid Point Locations


Location


GLCs for PCl3 0.015 µg/m3 0.003 µg/m3



(-) 500

(+) 500,

(-) 500



24 Hourly GLCs Values for PCl3 at discrete locations at settlement in the area,





4-48

Table 4.34: 24 Hourly GLCs Values for PCl3 at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)






A7 Kudan 0 BDL BDL


Note: Detection Limit for PCl3 is 100 µg/m3

(xi) GLCs Value for HC

The highest 24-hourly and seasonal incremental GLCs values for HC due to stack


Highest 24 hourly GLCs value 0.0096 µg/m3 for HC is obtained at (+) 000 m, (-)


highest seasonal GLCs value 0.0022 µg/m3 for HC is obtained at (+) 500 m, (-)



Values for HC and Grid Point Locations


Location


GLCs for HC 0.0096 µg/m3 0.0022 µg/m3



(-) 500

(+) 500,

(-) 500






4-49

24 Hourly GLCs Values for HC at discrete locations at settlement in the area,


Table 4.36: 24 Hourly GLCs Values for HC at Discrete Locations


GLCs (µg/m3)

Max Background

Monitored

Values

(µg/m3)

Resultant

Value

(µg/m3)






A7 Kudan 0 BDL BDL


Note: Detection Limit for HC is 0.16 ppm

Since the 24-hourly predicted incremental glc values from UPL Plant after

expansion when added together with 24-hourly baseline values of Particulate

Matter, SO2 and NO2 remain below the 24-hourly ambient air quality standards of

80 µg/m3 for SO2 & NO2 and 100 µg/m3 for PM10 in industrial, residential, rural and

other area. 24 Hourly GLC values for HCl, Cl2, NH3, H2S, MeCl, HBr, PCl3, and HC

are also extremely low and negligible. It is important to mention that impact of

existing plant operation in terms of GLCs values has already included in baseline

air quality values monitored in the area. Therefore, operation of the plant after

expansion will not cause any appreciable adverse impact on ambient air quality of

the study area.

Since the Seasonal incremental glc values from UPL plant after expansion are

extremely low in comparison to monitored baseline values of Particulate Matter,

SO2 and NO2. Seasonal GLC values for HCl, Cl2, NH3, H2S, MeCl, HBr, PCl3, and HC

are also extremely low and below detection limits. Therefore, the operation of the

UPL plant after expansion will not cause any adverse impact on ambient air quality

of the area due to process stacks.




4-50

Hence, the impact on the ambient air quality of during operation phase is as given

below:







Mitigation Measures

During the operation phase of expansion of the UPL plant, the following mitigation

measures will be taken as a part EMP for air quality:

• Performance of dust collectors provided at coal /husk fired boiler will be

ensured time to time.

• Proposed 10 tph coal fired boiler will be provided well designed and efficient

dust collectors & Bag filter.

• At proposed process stacks two stage water, water/caustic /alkali scrubbers

will be provided.

• Stack height for DG sets will be ensured as per CPCB guidelines.

• Regular monitoring of stacks/process vents will be carried out to ensure that

concentrations of pollutants are well within the permissible limit described in

CC&A.

• Predictive and preventive maintenance for valves, pumps, flanges, etc. will be

ensured to avoid possibility of leakage and fugitive emissions.

• Preventive and predictive maintenance for valves, pumps, flanges, to avoid

possibility of leakage and fugitive emissions.

• Transport vehicles will be properly maintained to reduce vehicular emissions

and pollution under control certificate (PUC) will be obtained as per regulation.

• Regular maintenance of DG sets in order to control emissions.

• A good housekeeping will be practiced in the plant after proposed expansion.




4-51

4.5.6 Impact on Noise Levels


During the construction phase of the proposed expansion of the plant, noise will

be generated from various sources, such as, due to use of machineries and vehicles

for transporting construction materials, hammering, metal cutting, welding, etc.

Some major sources of noise generation at the construction of the plant site are

listed below:

Generation of noise during movement of vehicles carrying materials, loading &

unloading activities,

Generation of noise from excavation machines, concrete mixer and other

construction machines,

Generation of noise during hammering, metal cutting, welding, etc.,

Noise from the mechanical operations, like, drilling, fitting, etc. at the site.

All the above-mentioned noise sources at the proposed construction site will be

intermittent and would be experienced occasionally. It may also be noted that,

most of the construction activities will be carried out only during the daytime.

The expected noise levels from these activities are given hereunder in Table 4.37:

Table 4.37: Typical Noise Levels of Construction Equipment& Works

Particulars Noise Levels dB(A)

Earth Movers

Front End Loaders 72-84

Tractors 76-86

Scrapers, Graders 80-93

Trucks 75-82

Material Handlers

Concrete mixers 75-88

Concrete pumps 81-88




4-52

Particulars Noise Levels dB(A)

Steel Works

Metal Cutting 78-92

Hammering 85-97

Grinding 82-91

Welding 74-81

Heavy Fabrication Work 78-95

Resultant Noise Level

The combined effect of above sources can be determined as per the following

equation:

Lp(total) = 10 log(10(Lp1/10) + 10(Lp2/10) + 10(Lp3/10) + …….)

Where: Lp1, Lp2 and Lp3 are noise pressure level at a point due to different sources

in dB(A).

For an approximate estimation of dispersion of noise in the ambient air from the

source point, a standard mathematical model for sound wave propagation is used.

The sound pressure level generated by noise sources decreases with increasing

distance from the source due to wave divergence. An additional decrease in sound

pressure level from the source is expected due to atmospheric effect or its

interaction with objects in the transmission path. The noise level generated from

a source would decrease with increase in distance from the source because of the

wave divergence.

For hemispherical sound wave propagation through homogenous loss of free

medium, noise levels at various locations can be calculated due to different sources

using model based on the first principles as per the following equation:

Lp2 = Lp1 – 20 log(r2)-8 …………(1) Where: Lp2 and Lp1 - Sound Pressure Level (SPLs) at points located at source and

at distances of r2 from the source respectively in dB (A)




4-53

The resultant maximum noise level for the above sources as calculated using

combined effect equation is 85 dB(A). Assuming no environmental attenuation

factors, noise modelling has been done, which shows noise level will mingle with

the baseline noise level within short distance. Noise modelling results for

construction phase have been given in Table 4.38 and shown in Figure 4.6:

Table 4.38: Noise Modelling Results for Construction Phase Area Permissible Limits

(Day Time) Distance from Source

Silence Zone 50 dB (A) 141.3 m

Residential 55 dB (A) 79.4 m

Commercial 65 dB (A) 25.1 m

Industrial 75 dB (A) 7.9 m

The noise produced during construction phase will have temporary impacts on the

existing ambient noise levels at the project site but restricted to small distance

(maximum upto 79.4 m for 55 dB(A)) and only during daytime.

The impact prediction of noise levels generated during construction phase have

been carried out at nearby settlements and presented in Table 4.39:

Figure 4.6: Attenuation of Noise from Source during Construction

0

10

20

30

40

50

60

70

80

90

100

0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0

Distance from Source (m)

No

ise

Le

ve

ls d

B(A

)

Resultant Noise Level Background Noise Level




4-54

Table 4.39: Impact Prediction of Noise Levels During Construction Phase

at Nearby Settlements

Sr.

No.

Location Distance

from

Plant

(m)

Predicted

Noise

Levels

dB(A)

Monitored

Noise

Levels

(day)

dB(A)

Resultant

Noise Levels

dB(A)

1. Salvad, Near

village

580 29.9 64.80 64.80

2. Pasthal, Near

market

930 25.7 52.11 52.12

3. Saravali 5780 9.8 61.18 61.18

4. Shivaji Nagar,

Near Market

780 27.2 52.05 52.06

5. Kudan, Near

village

5500 10.2 62.18 62.18

6. Parnali 2580 16.8 49.69 49.69

7. Betegaon 5360 10.4 51.99 51.99

8. Navapur, Near

village

4370 12.2 49.89 49.89

9. Pam 1840 19.7 49.66 49.66

10. Boisar, Near

Market

4800 11.4 52.63 52.63

11. Bhim Nagar,

Near Apartment

2340 17.6 61.28 61.28

Impact prediction given in Table 4.39 indicates that impact of noise levels during

construction phase on surrounding area will be negligible. Mitigation measures to

be implemented for noise control during construction and green belt at the UPL

plant will further attenuate noise levels generated from the construction activities.

Hence, the impact on the noise levels during construction phase is as given below:




4-55

Impact Rating Noise Levels

Significance and Nature of Impact Negligible and Adverse




Severity of Impact Slight

Mitigation Measures

• Provision of rubber padding/ noise isolators construction machines

• Preventive maintenance of the machine/ equipment will be carried out;

• Provision of silencers to modulate the noise generated by machines;

• Provision of protective devices like ear muff/ plugs to the workers; and

• Monitoring of ambient noise levels will be carried out as per details given in

Chapter 6 or as stipulated by the CPCB/ MPCB.

B. Operation phase

During operation of the plant after expansion, boilers, coal crushers, DG sets,

cooling tower, multi effect evaporator, etc. may generate high noise levels.

During the EIA studies noise measurements were carried out with the plant

premises as per details given in Table 4.40:

Table 4.40: Noise Measurements within the Plant Premises

Sr.

No.

Noise Sources Noise Level at 1-

Meter Distance

Noise Abatement Measure

I. Existing Plant

1. 10 tph Boiler 81 Housing


3. 500 kVA DG Set 84 Enclosure

4. 250 kVA DG Set 82 Enclosure

6. Coal Grinder 79 Enclosure

7. Product Dispatch 71 Housing




4-56

Sr.

No.

Noise Sources Noise Level at 1-

Meter Distance

Noise Abatement Measure

II. Proposed Expansion


2. 750 kVA DG Set x 2

nos 84

Enclosure

3. Coal Grinder 79 Enclosure

The permissible noise exposure for the workers working at the noise sources is

listed in the following Table 4.41.

Table 4.41: Permissible Noise Exposures for Industrial Workers

Exposure Time

(in hr/day)

Limit in dB

(A)

8 90

4 93

2 96

1 99

½ 102

¼ 105

1/8 108

1/16 111

1/32 114

Noise levels generated from various sources at the UPL plant, are attenuated by

the noise barriers available at the plant like building walls, enclosures and green

belt available the UPL plant. Further, DG sets are operated only during grid power

failure.

The resultant maximum noise level for the above sources as calculated using

combined effect equation is 90.6 dB(A). Assuming no environmental attenuation

factors, noise modelling has been carried out to evaluate impacts of noise

generation from UPL plant after expansion.




4-57

The impact prediction of noise levels generated during operation phase after

expansion of the UPL plant have been carried out at nearby settlements and

presented in Table 4.42:

Table 4.42: Impact Prediction of Noise Levels During Operation Phase

Sr.

No.

Location Distance

from

Plant

(m)

Predicted

Noise

Levels

dB(A)

Monitored

Noise

Levels

(day)

dB(A)

Resultant

Noise Levels

dB(A)

1. Salvad, Near

village

580 35.5 64.80 64.81

2. Pasthal, Near

market

930 31.3 52.11 52.15

3. Saravali 5780 15.4 61.18 61.18

4. Shivaji Nagar,

Near Market

780 32.8 52.05 52.10

5. Kudan, Near

village

5500 15.8 62.18 62.18

6. Parnali 2580 22.4 49.69 49.70

7. Betegaon 5360 16.0 51.99 51.99

8. Navapur, Near

village

4370 17.8 49.89 49.89

9. Pam 1840 25.3 49.66 49.68

10. Boisar, Near

Market

4800 17.0 52.63 52.63

11. Bhim Nagar,

Near

Apartment

2340 23.2 61.28 61.28

Above prediction of impact on noise levels due to operation of plant after

expansion on the nearby settlements is without considering environmental

attenuation, like walls, green belt, etc. which are available at the plant. Therefore,

resultant noise levels dB(A) will be much below the predicted above. Overall impact

of noise levels during operation phase after expansion will be negligible.




4-58

Hence, the impact on the noise levels during operation phase is as given below:

Impact Rating Noise Levels






Mitigation Measures Mitigation measures to control noise levels during operation phase of UPL Plant

after expansion are as given below:

• DG set room will be provided acoustic treatment to control the noise.

• Ear muff and plugs will be provided to workers working relatively high noise

areas.

• Green belt will be enhanced for the attenuation of noise pollution and to

maintain ambient noise quality within the statutory limit.

• All the equipment will be designed/ operated in such a way that the noise level

shall not exceed 85 dB(A) as per the requirement of OSHA (Occupational Safety

and Health Administration).

• Proper maintenance of pump, machinery, blower etc. will be ensured to control

noise levels.

4.5.7 Impact on Land Use & Aesthetics A. Construction Phase The construction of proposed expansion of the plant will be within the existing

plant. Therefore, no impact on land use & aesthetics of the study area is

anticipated and no mitigation measure is required.




4-59

B. Operation Phase The operation of the plant after proposed expansion will have no impact on the

land use pattern, as no change in land use pattern of the study area is anticipated.

At the plant 5865.96 sqm green belt have been developed by planting indigenous

trees species. This will improve aesthetics and have positive impact.

Hence, the impact on aesthetics during operation phase of the proposed expansion

of the UPL plant is as given below:


Significance and Nature of Impact Negligible & Positive




Severity of Impact Low

4.5.8 Impacts due to Waste Generation

A. Construction Phase During the construction phase of the proposed expansion of the plant, construction

wastes, debris, metal cuttings and solid wastes from labour will be generated.

These wastes may contaminate soil of the site, if not collected and disposed

properly.

Mitigation Measures

• Waste generated from the construction site will be collected daily and disposed

properly.

• Waste bins will be placed at the construction site to disposal paper, plastic and

food wastes.

• Inert debris will be disposed for filling at the site.

• Metal cuttings and packing materials will be sent for recycling.

Hence, the impact of waste disposal during the construction phase of the proposed





4-60

Impact Rating Waste Disposal

Significance and Nature of Impact Significant

Duration of Impact Short term



Severity of Impact Minor

B. Operation Phase

During operation various type of hazardous wastes will be generated from the

plant after expansion. Safe and scientific arrangement for handling, storage and

disposal of all hazardous wastes is ensured by the UPL. Details of hazardous wastes

generation, category, quantities, mode of disposal for existing plant and after

proposed expansion of the plant are described in Table 2.14 of Chapter 2. The

summary of types of hazardous wastes generation and mode of disposal from the

plant after expansion are given in Table 4.43:

Table 4.43: Types of Hazardous Wastes and Non-hazardous Wastes;

and Mode of Disposal

Sr. No

Types of Hazardous Wastes Mode of Disposal

I. Hazardous Wastes (Landfillable Waste and Incinerable Waste)

1 Distillation residue CHWTSDF(Incineration)

2 Discarded Containers (Drums,

Carboys) Sale to MPCB Authorized Party

3 Plastic Bags Decontamination to Scrap

Dealer/CHWTSDF(landfill)

4 ETP sludge CHWTSDF(landfill)

4 Salt from Evaporation & Process CHWTSDF(landfill)

6 Used Oil Sale to CPCB registered recycler

7 Used Batteries Sale to MPCB Authorized Party

8 Spent Solvent To end users OR recyclers OR

Co-Processing

9 Spent Catalyst CHWTSDF(Incineration)




4-61

Sr. No

Types of Hazardous Wastes Mode of Disposal

10 Aqueous Effluent from

Drum/Tank/reactor washing CHWTSDF(Incineration)

11 Date Expired & Off specific

Pesticide CHWTSDF(Incineration)

12 Used Filter Aids CHWTSDF(Incineration)

13 Insulation waste /PPEs CHWTSDF(landfill)

14 Spent Acid To end users OR recyclers

II. Non- Hazardous Wastes

15 Ash from Boilers Sale to Brick Manufacturing or

other end-users

Hazardous wastes (incinerable wastes) generated in the form of distillation

residue, spent catalyst, aqueous effluent from drum/tank/reactor washing, date

expired & off specific pesticide and used filter aids will be sent to Common

Hazardous Waste Treatment Storage and Disposal facility (CHWTSDF) for

incineration. Used Oil generated from the maintenance of DG sets will handed over

to CPCB authorized used oil recyclers. Discarded containers (drums, carboys)

contaminated with hazardous chemicals will sent for decontamination to

CHWTSDF. Sludge generated from the ETP will also be sent to CHWTSDF for

landfilling. Salt proposed to be generated from evaporation of process residue will

be sent to CHWTSDF for landfilling.

After expansion of the existing plant of UPL, approx. 120 tones ash per month will

generated from coal or biomass/briquettes fired boilers, which is sold to bricks

manufacturers or other end-users.

4.5.9 Impact on Flora and Fauna A. Construction Phase There is no wildlife sanctuary or any other sensitive area located in within 10 km

distance from the UPL plant site. The land for proposed expansion within the

existing plant, is free from trees and shrubs. The site required for expansion will

be cleared from all kind of vegetation in the form of grasses and ground flora.




4-62

However, no tree needs to be cut for proposed plant construction. Therefore, some

loss of vegetation in the form of ground flora is anticipated during construction

phase. Construction activities may cause deposition of dust leaves of green belt

already grown at the plant. However, this impact will be for short duration. The

construction of proposed expansion will not have any significant adverse impacts

on the flora and fauna.

The green belt plantation is already done at the existing UPL plant. This has

positive and beneficial impact on the project in terms of flora at the site.

Mitigation Measures

• Green belt at the plant site will be enhanced by planting saplings during

construction phase.

• Spraying of water on the leaves of green belt growing the plant to remove dust

deposition.

Hence, the impact on flora and fauna during the construction phase of the


Impact Rating Flora & Fauna

Significance and Nature of Impact Insignificant



Likelihood of Occurrence Low


B. Operation Phase

During of operation of the existing UPL plant after expansion, there will be no

adverse impact on the terrestrial ecology. Greenbelt/ plantations being developed

at the existing plant premises covering 5865.96 sqm area. Green belt will have

positive impacts on flora and fauna (Avi fauna) of the area as green belt provides

shelter to the faunal species and therefore, positive impact on the fauna is

anticipated.




4-63

Hence, the impact on the flora and fauna during the operation phase of the


Impact Rating Flora & Fauna

Significance and Nature of Impact Minor and Positive



Likelihood of Occurrence Low

Severity of Impact Slight

4.5.10 Occupational Health & Safety

A. Construction Phase During construction phase, occupational health and safety may be affected by the

following reasons:

• Exposure to dust during excavation

• Hazardous fumes during arc welding

• Electrical hazards by loose electrical wiring

• Exposure to high noise levels

• Working at height – falling danger

• Injuries to the workers during construction operation

Mitigation Measures To enhance the occupational health and safety during contraction phase, the

following measures will be taken:

• Water sprinkling to avoid dust emission

• Use of suitable PPEs like mask during arc welding operation

• Electrical safety to be maintained as per regulations

• Use of ear muff and plug in high noise area

• Use of safety belt while working at height

• Induction training to worker to enhance safety of worker

• First aid facilities will be provided.




4-64

Hence, the impact on occupational health and safety during the construction phase

of the proposed expansion of the UPL plant is as given below:

Impact Rating Occupational Health and Safety

Significance and Nature of Impact Significant





B. Operation Phase

During operation phase, workers may be directly or indirectly exposed by

hazardous chemicals during charging, process or hazardous materials handling.

The exposure of hazardous chemicals and work floor hazards may affect

occupational health and safety of the workers. There may be unsafe conditions,

which may cause threat to occupational health and safety of the workers.

Hence, the impact on the occupational health and safety during operation phase will be as given below:

Impact Rating Occupational Health and Safety

Significance and Nature of impact Significant and Adverse




Severity of impact High

Mitigation Measures

During the operation phase, necessary mitigation measures and health checkup

will be carried to ensure occupational health and safety of plant personnel.

• Process will be carried out in closed system following Standard operating

procedures (SOP).




4-65

• Dilution ventilation/local exhaust ventilation system will be provided.

• Hazardous materials will handled by trained persons.

• MSDS of hazardous substance will be maintained and displayed.

• Quantity of substance will be kept to absolute minimize

• Suitable personal protective equipment (PPE) will be provided to all workers in

hazardous area.

• “Do’s and Don’ts” will be displayed at strategic locations in English and Marathi

Language.

• Relevant safety sign boards will be displayed at strategic locations.

• Firefighting facilities, sprinkling system and emergency exit will be ensured.

• Routine health check-up will be carried out for workers engaged in hazardous

operations.

• Regular training for workers working in hazardous area will be given time to

time.

4.5.11 Socio Economic Impacts


During construction phase about 40 to 50 construction workers will be deployed

for about 12 months. This will be direct beneficial impacts due to the engagement

of workers in construction activities.

The indirect beneficial impact is anticipated due to employment opportunity for

skilled/unskilled workforce in associated activities. Contractor will employ local

workers for construction. Hence, no other issues like, social conflict etc. envisaged,

economic benefits to the local contractors. As no habitation on land and hence, no

displacement is required.

The relatively short-lived economic impacts are likely to be experienced in local

area for the duration of construction phase as workers will make everyday

purchases from local traders in nearby areas. This is likely to give a short-lived

stimulus to the traders that will disappear as soon as the construction is over.

Noticeable, flow-on economic impacts will be experienced in other sectors of

economy as a result of purchase of construction materials and the payment of

wages and salaries to the personnel engaged in the plant activities.




4-66

Hence, the impact on socio economic environment during the construction phase

of the proposed expansion of the UPL plant is as given below:

Impact Rating Socio economic Environment

Significance and Nature of Impact Significant Beneficial




Severity of Impact Moderate

B. Operation Phase The operation of plant after expansion will create direct and indirect employment

opportunities during plant operation, transportation of raw materials and

transportation products as well as secondary services. The direct man power

requirement for existing UPL plant is 150 persons including 67 staff and 83

workers. For plant operation after expansion, additional 73 staffs and 77 workers

will be required. Total manpower requirement after proposed expansion will be

140 staff and 160 workers. As an estimate plant will provide indirect employment

to about 2000 persons. Therefore, operation of the plant would have positive

impacts on the status of job opportunities in the study area.

Hence, the impact on socio economic impacts during the operation phase of the


Impact Rating Socio Economic Impacts

Significance and Nature of Impact Significant and Beneficial


Impacted Area Regional


Severity of Impact High




4-67

4.5.12 Impacts of the Transport of the Raw Materials and End-Products

For transportation of raw materials and products from existing UPL plant, MIDC’s

two lane road and Boisar -Tarapur road (SH-74) are used. Every day tank

lorries/trucks for transportation raw materials and products are approached to UPL

existing plant. Details of traffic due to existing UPL plant and after expansion are

given below:

Traffic Due to UPL’s Existing Unit # 10 and After Proposed Expansion

Sr.No. Vehicles Movement Traffic Par Day

(Average)

I. Existing Plant

1. Truck Transporting Raw Materials 3 Trucks

2. Truck Transporting End Products 3 Trucks

3. Passenger Car 18 Cars

4. Passenger Bus 3 Buses

II. After Expansion

1. Truck Transporting Raw Materials 20 Trucks

2. Truck Transporting End Products 18 Trucks

3. Passenger Car 30 Cars

4. Passenger Bus 7 Buses

The road from Boisar -Tarapur road (SH 74) to UPL plant in Notified Industrial area

of MIDC is two lanes with shoulders, which is capable for 15000 Passenger Car

Unit (PCU) per day traffic as per IRC Guidelines. Current traffic on the MIDC road

from UPL plant to SH -74 is about 1638 PCU per day. Average traffic is 6015 PCU

per day on the Boisar -Tarapur road (SH 74). Therefore, existing MIDC road and

Boisar -Tarapur road (SH 74) are well sufficient to bear additional traffic from UPL

plant after proposed expansion. For parking of trucks, cars and buses, necessary

parking arrangement will be carried at the plant after expansion. Hence, no

significant impact is anticipated on the traffic and surrounding environment due to

transportation of raw materials and end products from the plant after expansion.




4-68

4.6 Impact Evaluation The evaluation of the impacts on the environment of the proposed activities for

expansion of UPL plant, both in terms of quality & quantity have been carried. For

quantification of impacts, matrix system as modified to some extent has been used

as given below:

Criteria adopted for rating the impacts are the following:

The magnitude of each impact has been rated on the scale of 1 to 5

❖ Very High Impact = 5

❖ High Impact = 4

❖ Moderate Impact = 3

❖ Less Impact = 2

❖ Very Less Impact = 1

For importance of each impact, area has been rated on the scale of 1 to 3

❖ Very Important = 3

❖ Moderately Important = 2

❖ Less important = 1

Ranking Criteria

Keeping in view, six major activities having an impact on the environment and

considering seven major impact areas (as shown in Tables below) the criteria for

overall ranking is developed as follows:

Total Score, if

❖ Above 600 the proposed project is having Very High Adverse Impact

❖ 300 - 600 the proposed project is having Moderate Adverse Impact

❖ 100 – 300 the proposed project is having Less Adverse Impact

❖ Below 100 the proposed project is having Very Less Adverse Impact




4-69

Based on the criteria for rating the impacts, the weighted impacts are given below

in Table 4.44 and Table 4.45. In this weighted impact table, the entries are

presented in the form x(y), where x denotes the magnitude of the impact and y

denotes the importance of the impact while T denotes the impact rating.

The weighted impact without mitigation measures due to the proposed expansion

of UPL plant are quantified as 268 and, the weighted impact with mitigation

measures due to the proposed expansion of UPL plant are quantified as 167. After

implementation of all the mitigation measures proposed expansion of UPL plant

can be considered as Less Adverse Impact on the basis of rating criteria.




Table 4.44: Mitigation Measures without Weighted Impacts (Matrix Method)

Sr.No.

Potential Impact Area

Construction Phase Operation Phase Total

Excavation, Movement of equipment, Civil Works, Workers, Mobilization

Vehicular movement for transportation, materials and equipment.

Heavy fabrication work, erection and Commissioning

Operation of equipment for production of pesticides

Operation of Reactors and raw materials handling, storage and charging

Condensation, Distillation, Filtration, Washings, Drying, etc.

Storage and Dispatch of Products

Utilities like Boilers, DG Sets, Cooling Tower, Compressor, Pumps, Blowers etc.

X Y T X Y T X Y T X Y T X Y T X Y T X Y T X Y T

1. Air 3 2 6 4 2 8 3 2 6 4 2 8 2 2 4 4 2 8 3 2 6 2 2 4

2. Water 2 2 4 2 2 4 1 1 1 4 3 12 3 2 6 4 3 12 4 2 8 2 2 4

3. Land 4 2 8 2 2 4 3 2 6 3 2 6 2 2 4 2 2 4 2 2 4 2 2 4

4. Noise 3 3 9 3 2 6 3 3 9 3 3 9 4 2 8 3 2 6 2 1 2 2 1 2

5. Vegetation 3 2 6 2 2 4 1 2 2 2 1 2 2 1 2 1 1 1 3 2 6 3 2 6

6. Socio-

Economic

1 1 1 1 1 1 1 2 2 2 2 4 1 1 1 1 1 1 2 2 4 1 2 2

7. Aesthetic

Value

3 2 6 2 1 2 3 2 6 2 2 4 2 1 2 3 1 3 2 2 4 2 2 4

Total 40 29 32 45 27 35 34 26 268




Table 4.45: Mitigation Measures with Weighted Impacts (Matrix method) Sr.No.

Potential Impact Area

Construction Phase Operation Phase Total

Excavation, Movement of equipment, Civil Works, Workers, Mobilization

Vehicular movement for transportation, materials and equipment.

Heavy fabrication work, erection and Commissioning

Operation of equipment for production of pesticide

Operation of Reactors and raw materials handling, storage and charging

Condensation, Distillation, Filtration, Washings, Drying, etc.

Utilities like Boilers, DG Sets, Cooling Tower, Compressor, Pumps, Blowers etc.

Storage and Dispatch of Products

X Y T X Y T X Y T X Y T X Y T X Y T X Y T X Y T

1 Air 2 2 4 3 2 6 3 1 3 3 2 6 2 1 2 2 2 4 2 1 2 2 2 4

2 Water 2 1 2 2 2 4 1 1 1 3 3 9 2 2 4 4 2 8 2 2 4 2 2 4

3 Land 3 1 3 2 1 2 2 1 2 2 2 4 3 1 3 2 2 4 2 2 4 2 1 2

4 Noise 2 2 4 2 2 4 2 2 4 2 2 4 3 2 6 2 2 4 2 1 2 2 1 2

5 Vegetation 2 2 4 2 2 4 1 1 1 2 1 2 2 1 2 1 1 1 2 1 2 2 1 2

6 Socio-

Economic

1 1 1 1 1 1 1 2 2 2 1 2 1 1 1 1 1 1 2 1 2 2 1 2

7 Aesthetic

Value

3 1 3 2 1 2 2 1 2 3 1 3 1 1 1 2 1 2 1 1 1 2 1 2

Total 21 23 15 30 19 24 17 18 167



5-1

Chapter 5

ANALYSIS OF ALTERNATIVES

5.1 Introduction

UPL Limited, Unit#10 is engaged in manufacturing of various Technical grade Pesticides,

intermediates chemicals and pesticide formulation products. The existing unit was

established and operated by M/s Punjab Chemicals & Crop Protection Limited and obtained

environmental clearance for expansion from Ministry of Environment, Forest and Climate

Change vide letter no F. No. J-11011/712/2007-IA II (I) dated 15 April 2008. The existing

unit was taken over by UPL Limited on 14 March 2014. The proposed expansion will be

based on advanced process technologies. The plant after expansion will also be

equipped with the most efficient auxiliary sub systems, material handling facilities

and pollution control equipment.

UPL is having its own R&D Division and technologies for manufacture of different

pesticides and intermediates.

5.2 Project Alternatives

5.2.1 Without Project Alternative

Without project alternative scenario is considered to be less advantageous in view

of increasing demand of pesticide products and need of employment opportunities

in the area and region.

5.2.2 With Project Alternative

With project scenario is more advantageous and beneficial as it will not only

contribute to fill the gap in the demand and supply of pesticide products but also

create direct and indirect employment opportunities in the area and region. With

the project option, some adverse environmental impacts are anticipated, which will

be mitigated through the implementation of required mitigation measures and

environmental management plan (EMP).



5-2

5.3 Alternatives for Site

The proposed expansion of the UPL plant will be located on the land available

within the existing plant in MIDC Industrial Notified Area at Tarapur. As necessary

infrastructure, skill and land are available for proposed expansion of the existing

plant, alternative site is not required to consider.

5.4 Alternatives for Resource Optimization/ Recycling and Reuse

After expansion of UPL Plant, the following resource optimization, recycling and

reuse cleaner production measures will be adopted, which will have considerable

environment benefits in terms of:

▪ Energy Conservation – Reduced power requirement

▪ Heat recovery units for boiler flues gases.

• Used Oil generated from the maintenance of DG sets will handed over to CPCB

authorized used oil recyclers.

▪ High TDS Mother liquor will be evaporated in multi effect evaporators (MEE)

and salt proposed to be generated from evaporation will be sent to CHWTSDF

for landfilling

▪ At proposed process stacks two stage water, water/caustic /alkali scrubbers

will be provided.

▪ Solvents are recovered above 95 % and will continue after expansion.



6 - 1

Chapter 6

ENVIRONMENTAL MONITORING PLAN

6.1 Introduction

Environmental monitoring plan will ascertain efficacy of implemented mitigation

measures to mitigate adverse environmental impacts of the proposed expansion

of existing UPL plant. To ensure effective implementation of the mitigation

measures and environmental management plan during the construction and

operation phases of the proposed expansion, it is essential that an effective

environmental monitoring plan must be designed and followed.

The objective of carrying out environmental monitoring for the proposed expansion

of existing UPL plant is given below:

• To provide a database against which any short or long term environmental

impacts of the proposed expansion can be determined.

• To provide an early indication that any of the environmental control measures

fail to achieve the acceptable standards.

• To monitor the performance of the proposed expansion and effectiveness of

implemented mitigation measures.

• To verify the effectiveness of environmental management measures during the

EIA study.

• To determine project compliance with regulatory requirement, standards and

government policies.

• To submit six monthly Environmental Clearance conditions compliance reports

to Regional Office of MoEF&CC.

Environmental monitoring plan for various environmental parameters for the

proposed expansion is described below:



6 - 2

6.2 Environmental Monitoring Parameters

Environmental Management Cell (EMC) has been created at the UPL plant to

ensure proper implementation of mitigation measures/EMP at the existing plant.

After expansion of the plant, infrastructure of Environmental Management Cell will

be enhanced. Environmental Management Cell will ensure monitoring of the

following environmental parameters:

A. Ambient Air Quality (AAQ) Monitoring

Ambient air quality will be monitored monthly at the plant for Particulate Matter

(PM), Sulphur Dioxide (SO2), Nitrogen Oxide (NO2), Hydrogen Chloride gas (HCl),

Chlorine (Cl2), PCl3, Hydrogen Sulfide (H2S), Ammonia (NH3), Methylene Chloride

(MeCl), Hydrogen Bromide (HBr), Hydrocarbon (HC) and VOC. A MoEF&CC or

NABL accredited laboratory will be engaged to monitor ambient air quality at the

plant.

B. Stack Emissions Monitoring

Coal, Husk and Furnace oil fired Boilers and DG sets will be major sources of

particulate matter, SO2 and NO2 while from process vents/stacks Hydrogen

Chloride gas (HCl), Chlorine (Cl2), PCl3, Hydrogen Sulfide (H2S), Ammonia (NH3),

Methylene Chloride (MeCl), Hydrogen Bromide (HBr) and Hydrocarbon (HC) will

be emitted in fraction. Monthly stack monitoring of particulate matter, SO2, NO2,

Hydrogen Chloride gas (HCl), Chlorine (Cl2), PCl3, Hydrogen Sulfide (H2S),

Ammonia (NH3), Methylene Chloride (MeCl), Hydrogen Bromide (HBr),

Hydrocarbon (HC) and VOC concentrations in emissions of the flue gas stacks and

process vents will be carried out as applicable rules by engaging NABL approved

laboratory.



6 - 3

C. Water Quality Monitoring

The sampling and analysis of ground water / MIDC supplied-water quality will be

carried out six monthly at the plant in accordance with the Indian Standard

Drinking Water Specification - IS 10500:2012 by engaging NABL approved

laboratory.

D. Waste Water Quality Monitoring

During operation of plant after expansion, treated waste water will be analyzed

monthly by engaging NABL approved laboratory and daily by internal laboratory.

The parameters analyzed in treated waste water are pH, Total Suspended Solid,

Total Dissolved Solids, BOD (3 days), COD, Oil & Grease, Phenol & Phenolic

Compounds as C6H5OH, Phosphate, Sulphur and Toxicity Factor (TF) as per CC&A

condition for the existing plant.

E. Noise Levels Monitoring

The measurement of noise levels will be carried out at the boundaries of the plant

after expansion in accordance to the ambient noise standards formulated by

Ministry of Environment, Forest and Climate Change (MoEF&CC). Noise levels

would be monitored on hourly basis for twenty-four hours once in six months.

Occupational noise levels will also be monitored at 1 m from DG sets, boilers,

blowers, dispatch area, shop floor areas, etc.

F. Soil Quality

During operation phases of the expansion of the existing plant, soil may be

contaminated if suitable mitigation measures are not taken for disposal of solid &

hazardous wastes, sewage and waste water generated from the plant. Therefore,

composite samples of soil will be collected and analyzed six monthly by engaging

NABL approved laboratory during operation phase of the plant. Parameters for soil

analysis will be particle size distribution, texture, pH, electrical conductivity,



6 - 4

nitrogen, phosphorous, sulphur, caution exchange capacity, alkali metals, Sodium

Absorption Ratio (SAR), permeability and porosity.

G. Occupational Health Check-up

Occupational health checkup, especially for diseases of eye, ear, lung, BCA Test

and chest for the workers and staff who work in the hazardous area at the plant

area will be carried out annually. If any abnormalities found after occupational

health checkup, person will be provided extended treatment at nearby hospital

depending upon on the type and severity of the health effect.

6.3 Environmental Monitoring Plan with Cost Estimates

For construction and operation phases of the proposed expansion of UPL plant,

monitoring plan is given in Table 6.1 and Table 6.2 with frequency of monitoring

and cost estimates.

6.4 Budget for Implementation of Environmental Monitoring Plan

The cost of monitoring plan for construction phase (12 months) of the proposed

expansion is estimated as Rs. 2,16,000/- while for operation phase cost of

monitoring plan is estimated as Rs. 9,64,000/-. During operation phase

environmental monitoring will be carried out every year. Fresh budget will be

allocated every year for environmental monitoring.



Table 6.1: Environmental Monitoring Plan during Construction Phase

Attribute Location Parameter Frequency Cost Estimates in

Indian Rupees

Ambient Air At construction site

within the plant, Salvad,

Pasthal and Pam

PM10, PM2.5, SO2, NO2 and

CO

Monthly,

externally

192000

Ambient

Noise

At construction site

within the plant, Salvad,

Pasthal and Pam

Equivalent noise level

dB(A).

Six Monthly 24000

Monitoring Cost for Construction Phase 216000

Table 6.2: Environmental Monitoring Plan during Operation Phase


Indian Rupees

(for One year)

Ambient Air At plant site Particulate matter, SO2, NO2,

Hydrogen Chloride gas (HCl),

Chlorine (Cl2), PCl3, Hydrogen

Sulfide (H2S), Ammonia (NH3),

Methylene Chloride (MeCl),

Hydrogen Bromide (HBr),

Hydrocarbon (HC) and VOC

Monthly 84000

Stack

Emissions

Flue gas stacks of

Boilers and DG sets

particulate matter, SO2 and

NO2

Monthly 70000

Process

Emissions

Process vents/stacks

after scrubbers

Hydrogen Chloride gas (HCl),

Chlorine (Cl2), PCl3, Hydrogen

Monthly 160000




Indian Rupees

(for One year)

Sulfide (H2S), Ammonia (NH3),

Methylene Chloride (MeCl),

Hydrogen Bromide (HBr),

Hydrocarbon (HC) and VOC

Ambient

Noise

At the plant Equivalent noise level dB(A). Six Monthly 24000

Ground Water

Quality /

MIDC

supplied-

water

At the plant As parameters mentioned in IS

10500:2012

Six Monthly 40000

Treated

Waste Water

Out let of ETP pH, TSS, TDS, BOD (3 days),

COD, Oil & Grease, Phenol &

Phenolic Compounds as

C6H5OH, Phosphate, Sulphur

and Toxicity Factor (TF)

Daily by

internal

laboratory and

monthly by

external

laboratory

36000

Soil Composite Sample at

the Plant

Soil particle size distribution,

texture, pH, Electrical

Conductivity, Nitrogen,

Phosphorous, Sulphur, Caution

exchange capacity, Alkali

metals, Sodium Absorption

Six Monthly 20000




Indian Rupees

(for One year)

Ratio (SAR), Permeability and

Porosity

Occupational

Noise

At DG sets, Boilers,

blowers, dispatch

area, shop floor areas,

etc.

Noise Level dB(A) Six Monthly 30000

Occupational

Health

Health Check-up As prescribed by Occupational

Health Officer/ Medical

Practitioner/ As per the

prescribed norms

Annually 500000

Monitoring Cost for Operation Phase 964000

Note: Monitoring parameters and frequency may be changed as per Environmental Clearance conditions

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,

Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra


Chapter 7

ADDITIONAL STUDY

(RISK ASSESSMENT)

7.1 Introduction

UPL Limited, Unit#10 is engaged in manufacturing of various Technical

Grade Pesticides, intermediates chemicals and pesticide formulation

products. The existing unit was established and operated by M/s Punjab

Chemicals & Crop Protection Limited and obtained environmental clearance

for expansion from Ministry of Environment, Forest and Climate Change

vide letter no F. No. J-11011/712/2007-IA II (I) dated 15 April 2008. The

existing unit was taken over by UPL Limited on 14 March 2014

7.2 Storage of Hazardous Chemicals at the Plant

UPL will store and handle numbers of hazardous chemicals at the existing

plant and after expansion. Details of hazardous chemical name, physical

state, storage made, requirement and maximum storage are given in Table

7.1. The UPL has taken necessary safety measures at the plant as per

Manufacture, Storage and Import of Hazardous Chemical (Amendment)

Rules, 2000.

Table 7.1: Details of Storage of Hazardous Chemicals

Sr No

Hazardous

Chemical Name

Physical State

Storage mode Requirement

Maximum

Storage

Capacity

Tank /Drum /Bag MTM MT or KL

1 1,4 Dioxane Liquid 250 kg HDPE/MS

Drum

73 8

2 2-Coumaranone Solid 250 kg HDPE/MS

Drum

90 10

3 2-Cyno Phenol Solid 250 kg HDPE/MS

Drum

53 7

4 2-ethyl Hexanol Liquid 120 kg Drum 7 0.84

5 3 Chloro 2,2 Dimethyl

propanoyl Chloride

Liquid 250 kg HDPE/

MS Drum

182.20 10




Sr No

Hazardous

Chemical Name

Physical

State Storage mode Requir

ement Maximum

Storage

Capacity


6. 4,6 Dimethoxy

pyrimidine 2 Amine

Liquid 25 kg Drum 24.7 2.65

7. 4,6 DCP Liquid 250 kg HDPE/MS

Drum

97.47 12

8. 4 methoxy 6 Methyl 2

Amino 1,3,5 triazine

Liquid 25 kg Fiber drum 21 2.25

9 Acetic Anhydrous Solid 500 kg HDPE jumbo

bag

420 45

10 Acetic Anhydride Solid 250 kg HDPE/MS

Drum

195 22

11 Acetonitrile Liquid 250 kg HDPE/MS

Drum

89 10

12 Ammonia Gas 900 kg Tonner 118 13.5

13 Asulam Technical Solid 500 kg HDPE jumbo

bag

919.12 100

14 ASAM Solid 50 Kg bag 9.03 3

15 Bromine Liquid Glassline Tank 89.1 6.3

16 Carbon di sulphide Liquid ISO Tank 322.2 35

17 Caustic flakes Solid 25 kg Poly liner Bag 451.6 48.4

18 Caustic Soda lye Liquid 35 KL Tank 300 35

19 Chloral Liquid 250 kg HDPE/MS

Drum

69 7.5

20 Chlorine Gas 900 kg Tonner 1020.4 109.8

21 Di Ethyl Amine Liquid 250 kg HDPE/MS

Drum

75 8.25

22 Di Methyl carbonate

(DMC)

Liquid 250 kg HDPE/MS

Drum

147.2 16

23 Dimethyl Formamide Liquid 250 kg HDPE/MS

Drum

22 3

24 Di Methyl

Phosphorous Amido

thioate (DMPAT)

Liquid 80 KL Tank 674 80

25 Di Methyl Sulphate Liquid 250 kg HDPE/MS

Drum

82 9

26 Ethyl Mercaptan Liquid 250 kg HDPE/MS

Drum

6.83 3




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


27 Ethyl Acetate Liquid 250 kg HDPE/MS

Drum

109 11.75

28 Ethyl 1 methyl 5

sulfamoyl 1, 1 H-

pyrozole -4

carboxylate


Drum

30 5

29 Formaldehyde Liquid 250 kg HDPE/MS

Drum

78 8.5

30 Glyphosate technical Solid 25 kg HDPE Bag 57.6 6.17

31 Hydrochloric Acid Liquid Tank 129 14

32 Hydrochloric Acid

36%


Drum

60 6.5

33 Hexane Liquid 250 kg HDPE/MS

Drum

5 0.75

34 Hydrazide hydrate Solid 25 kg HDPE Bag 450 48.22

35 Hydroxylamine

Hydrochloride

Solid 25 kg HDPE Bag 10 1.07

36 Hyflow powder Solid 25 kg HDPE Bag 1.5 0.17

37 Iso Propyl Alcohol Liquid 250 kg HDPE/MS

Drum

34 4

38 Liquor Ammonia Liquid 60 KLTank 489 60

39 Methanol Liquid 40 KLTank 227 30 (5 KL

above

ground &

25 KL

undergroun

d)

40 Methyl-2-{Isocyanate

sulfamoyl} Methyl }

Benzoate


Drum

31 3.35

41 Methylene Di chloride Liquid 250 kg HDPE/MS

Drum

95.45 12

42 Methane Sulfuric Acid Solid 25 kg HDPE Bag 5 1

43 Metribuzine Technical Solid 500 kg HDPE jumbo

bag

464.5 50

44 Mono Iso Propyl

Amine


Drum

29 3.25




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


45 N,N Dimethyl Aniline Liquid 250 kg HDPE/MS

Drum

30 3.25

46 O- chloro

Benzylchloride


Drum

35 3.75

47 Oxygen Gas 50 kg Tonner 12.5 0.5

48 Phenol Liquid 250 kg HDPE/MS

Drum

194 21

49 Phosphorous Solid 250 kg MS Drum 97 13

50 Phosphorous Acid Liquid 250 kg HDPE/MS

Drum

21.15 2.5

51 Potassium Hydroxide Solid 50 kg HDPE jumbo bag 34.85 9

52 Phosphorous

Trichloride

Liquid 50 KL Tank 452 50

53 Pinacolone Liquid 40 KL Tank 366 40

54 Sodium Bisulphate Solid 25 kg HDPE Bag 9 1

55 Sodium Bromide solid Solid 500 kg HDPE jumbo

bag

89.1 10

56 Sodium Carbonate Solid 25 kg HDPE Bag 10 1.07

57 Sodium Hydride Solid 25 kg HDPE Bag 4.42 0.475

58 Sodium Hypochloride Liquid 300 KL Tank 2700 300

59 Sodium Methoxide Solid 25 kg HDPE Bag 88.4 10

60 Spent HCL Liquid 30 KL Tank 262 30

61 spent Sulphuric Acid Liquid 90 KL Tank 752 90

62 Sulfamoyl Isocyanate Solid 25 kg HDPE Bag 31 5

63 Sulfanilamid Liquid 250 kg HDPE/MS

Drum

282 30.25

64 Sulphur Solid 50 kg bag 19.8 15

65 Sulphuric Acid Liquid 65 KL Tank 560.13 65

66 Tri Methyl Phosphite Liquid 250 kg MS Drum 57 6.25

67 Triazinone Solid 500 kg HDPE jumbo

bag

588 63

68 White Phosphorous Solid 250 kg MS Drum 97 10.5

69 Bromine Liquid Tank 89 18

70 Sulphur Solid Bag-25 kg 20 5

71 Ethyl Hexanol Liquid 250 kg MS Drum 4 2




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


72 3Chloro-2,2-

Dimethylpropanoyl

Chloride

Liquid 250 kg HDPE Drum 182 20

73 Hydroxylamine

Sulphate

Solid Bag-25 kg 125.2 6

74 Thionyl Chloride

(SOCL2)/HCL

Liquid Tanker 9.8 6.3

75 2-Chloro

Benzylchloride

(OCBC)

Liquid 250 kg HDPE Drum 140 10

76 Alpha CPC Solid Bag-50 kg 59.6 30

77 DEA Liquid Tank 39.1 20

78 Toluene Liquid Tank 277.3 140

79 EDTA (50%) Solid Bag 0.2 0.2

80 Naphthol Solid Bag 60.2 30

81 Sodium Bicarbonate Solid Bag 90.9 45

82 PCl3 Liquid Tank 68.25 35

83 Hyflow Powder Solid Bag 1.5 0.75

84 4, 6- Dimethoxy

pyrimidine -2- Amine

Liquid Tank 20.9 10

85 Xylene Liquid Tank 1.75 1

86 Methyl-2-

{[Isocyanate

sulfamoyl] Methyl}

Benzoate

Liquid Tank 31 15




7.3 Hazard Identification

Hazard is defined as a chemical or physical condition that has the potential

for causing damage to people, property and/or the environment. Hazard

identification is the first step in the quantitative risk analysis and entails the

process of collecting information on:

• The types and quantities of hazardous substances stored, handled and

disposed in the location;

• The location of storage tanks & other facilities.

• Potential hazards associated with the spillage and release of hazardous

chemicals.

The starting point of the quantitative risk analysis study is the identification

of hazards and selection of scenarios that are then addressed for further

analysis.

7.3.1 Hazardous Materials Stored at the Plant

The plant is engaged in handling and storage of various flammable and

toxic hazardous materials. Details of hazardous materials, physical state,

physical and fire and toxicity properties of hazardous materials are given in

Table 7.2. Hazardous characteristic, storage mode and type of hazards

(as per NFPA) of the hazardous materials at the plant are given in Table

7.3.

7.3.2 Bulk Storage of Hazardous Materials

At the existing plant, some hazardous materials are stored in bulk quantity

in tanks and tonners while other hazardous materials are stored in HDPE/MS

tank, fibber drum and bags. Storage tank nos., type of storage (above or

underground storage), diameter and height of tanks, storage conditions,

dyke around tank farm and safety measures are described in Table 7.4.




7.3.3 Hazardous Conditions An accidental release of hazardous materials from barrels, cylinders,

tonners or tanks or piping would result in formation of fixed or spreading

pool. In case of immediate ignition of flammable hazardous materials, a

pool fire will result, while delayed ignition may result in explosion or flash

fire, if quantity of explosive mass is sufficient and some confinement is

present.

7.4 Accidental Release Scenarios for Consequence Analysis

The existing pesticides plant is dealing with many hazardous chemicals as

described above. Most of hazardous chemicals are flammable in nature and

may create threat to life and property in the event of spillage. Dykes have

been provided around the tanks for full containment. Subsequently, their

consequence will be confined within short distances in the form of thermal

radiation. In the event of release of toxic gases consequence may be off

site as toxic cloud will be moved towards wind direction. Accidental release

scenarios have been selected for consequence analysis. For selection of

maximum credible accident scenarios following methodology have been

adopted:




Table 7.2: Physical State, Physical and Fire and Toxicity Properties of Hazardous Materials

Sn. Hazardous

Materials

CAS

Numbers

Physical

State

Physical and Fire Hazard

Properties

Toxicity Sp

gr.

V.D.

B.P.

(˚C)

F.P.

(oC)

LEL

%

UEL

%

Auto.

Temp.

˚C

LC-50

(Inhl)

mg/l

LD-50

(O)

mg/kg

LD-50

(D)

mg/kg

1 1,4 Dioxane 123-91-1 Liquid 101.1 18.3 2 22 180 37000 NA 2000 1.0337 3.3

2 2-Coumaranone 553-86-6 Solid 249 112 NA NA NA NA NA NA NA NA

3 2-Cyno Phenol 611-20-1 Solid 149 NA NA NA NA NA NA NA NA NA

4 2-ethyl Hexanol 104-76-7 Liquid 186 75 0.88 9.7 288 234 1180 NA 1.83 4.49

5 3 Chloro 2,2 Dimethyl

Propanoyl Chloride

4300-97-4 Liquid 86 63 NA NA NA NA NA NA 1.19 5.35

6 4,6 Dimethoxy

Pyrimidine 2 Amine

36315-01-2 Solid 276 NA NA NA NA NA NA NA 1.43 NA

7 4,6 DCP 120-83-2 Solid 210 114 NA NA NA NA NA NA 1.40 5.62

8 4 methoxy 6 Methyl 2

Amino 1,3,5 triazine

1668-54-8 Liquid 329 153 NA NA NA NA NA NA 1.322 NA

9 Acetic Anhydride 64-19-7 Liquid 140 49 2.7 10.3 332 1000 1780 4 1.08 3.52

10 Acetonitrile 75-05-8 Liquid 81.6 2 4.4 16 524 5.1 2460 1250 0.79 1.4

11 Ammonia 7664-41-7 Gas -2.2 NA 16 25 651 NA 350 NA 0.9 0.59

12 Asulam Technical 2302-17-2 Solid 104 NA NA NA NA NA NA NA 1.18 NA

13 ASAM 112566-17-3 Solid NA NA NA NA NA NA NA NA NA NA

14 Bromine 7726-95-6 Liquid 58.8 NA NA NA NA NA 3100 NA 3.11 7.1

15 Carbon Di Sulphide 75-15-0 Liquid 46.3 -32 1.3 50 90 NA 3188 NA 1.263 2.63

16 Caustic flakes 1310-73-2 Solid 1388 NA NA NA NA NA NA NA 2.13 NA

17 Caustic Soda lye 1310-73-2 Liquid 145 NA NA NA NA NA NA NA 1.53 NA

https://www.chemicalbook.com/CASEN_36315-01-2.htm

https://www.chemicalbook.com/CASEN_120-83-2.htm

https://www.sigmaaldrich.com/catalog/search?term=1668-54-8&interface=CAS%20No.&N=0&mode=partialmax&lang=en&region=IN&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


Properties

Toxicity Sp

gr.

V.D.

B.P.

(˚C)

F.P.

(oC)

LEL

%

UEL

%

Auto.

Temp.

˚C

LC-50

(Inhl)

mg/l

LD-50

(O)

mg/kg

LD-50

(D)

mg/kg

18 Chloral 7681-52-9 Liquid 96 57 NA NA NA NA 479 3030 1.9081 NA

19 Chlorine 7782-50-5 Gas NA NA NA NA NA 293 NA NA 1.47 2.49

20 Di Ethyl Amine 111-42-2 Liquid 55.5 -18 1.8 10.1 312 NA 540 820 0.71 2.5

21 Di Methyl Carbonate

(DMC) 616-38-6

Liquid 90 22 4.22 12.87 NA NA 6000 5000 1.0636 3.1

22 Dimethyl Formamide 68-12-2 Liquid 153 58 2.2 15.2 445 NA 2800 4720 0.949 2.7

23 Di Methyl Phosphorous

Amido thioate 10265-92-6

Liquid 162 52 NA NA NA NA 410 4360 1.283 NA

24 Di Methyl Sulphate 77-78-1 Liquid 188 83.3 NA NA 495 NA 140 NA 1.33 4.35

25 Ethyl Mercaptan 75-08-1 Liquid 35 4.83 2.8 18.2 299 NA 1034 NA 0.84 2.14

26 Ethyl Acetate 141-78-6 Liquid 77 7.2 2.2 7 427 NA 5620 NA 0.902 3.04

27 Ethyl Hexanol 104-76-7 Liquid 184 73.3 NA NA NA NA 3,290

mg/kg

LC50

(Rat):

1.2mg/l

0.08 NA

28 Ethyl 1 methyl 5

Sulfamoyl 1, 1 H-

pyrazole -4

carboxylate

88398-81-6 Solid NA NA NA NA NA NA NA NA NA NA

29 Formaldehyde 50-00-0 Liquid 96 60 7 73 300 0.203 100 NA 1.08 1.04

30 Glyphosate technical 1071-83-6 Solid NA NA NA NA NA 1500 5000 2000 1.705 NA

31 Hydrochloric Acid 7647-01-0 Liquid 108 NA NA NA NA 3124 900 NA 1.19 1.267

https://www.sigmaaldrich.com/catalog/search?term=1071-83-6&interface=CAS%20No.&lang=en&region=US&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


Properties

Toxicity Sp

gr.

V.D.

B.P.

(˚C)

F.P.

(oC)

LEL

%

UEL

%

Auto.

Temp.

˚C

LC-50

(Inhl)

mg/l

LD-50

(O)

mg/kg

LD-50

(D)

mg/kg

32 Hydrochloric Acid 36% 7647-01-0 Liquid 108 NA NA NA NA NA NA NA 1.1 NA

33 Hexane 110-54-3 Liquid 68 -23 1.2 7.7 224 NA 28710 NA 0.66 3.0

34 Hydrazide Hydrate 7803-57-8 Solid 113.5 72 NA NA NA NA NA NA 1.1 NA

35 Hydroxylamine

Hydrochloride 5470-11-1

Solid NA 152 NA NA NA NA 141 NA 1.67 NA

36 Hyflow Powder 61790-53-2 Solid 2230 NA NA NA NA NA 500 NA 2.35 NA

37 Iso Propyl Alcohol 67-63-0 Liquid 82 12 1.2 12.7 399 16000 5045 12800 0.79 2.1

38 Liquor Ammonia 1336-21-6 Liquid -2.2 NA 16 25 651 NA 350 NA 0.9 0.59

39 Methanol 67-56-1 Liquid 64.5 12 6 36 464 64000 5628 NA 0.8 1.1

40 Methyl-2-{Isocyanate

Sulfamoyl} methyl}

Benzoate

93-58-3 Liquid 199 82 NA NA NA NA 1177 NA 1.04 4.7

41 Methylene Di chloride 75-09-2 Liquid 39.8 NA 12 19 556 NA 1600 NA 1.33 2.39

42 Methane Sulfonic Acid 75-75-2 Liquid 100 NA NA NA NA NA 1429 NA 1.2 3.31

43 Metribuzin Technical 21087-64-9 Solid NA NA NA NA NA 0.65 700 20000 1.29 NA

44 Mono Iso Propyl Amine 75-31-0 Liquid 33.5 -15 2 10.4 402 NA 111 380 0.694 2.04

45 N,N Dimethyl Aniline 121-69-7 Liquid 55.5 -18 1.8 10.1 312 NA 540 820 0.71 2.03

46 O- chloro

Benzylchloride 611-19-8

Liquid 416 180 NA NA NA NA 1140

NA 1.274 5.5

47 Oxygen 7782-44-7 Gas 100 NA NA NA NA NA NA 2500 1.13 0.62

48 Phenol 108-95-2 Liquid 182 79 1.7 8.6 715 630 317 669 1.057 3.25

http://www.molbase.com/en/cas-611-19-8.html




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


Properties

Toxicity Sp

gr.

V.D.

B.P.

(˚C)

F.P.

(oC)

LEL

%

UEL

%

Auto.

Temp.

˚C

LC-50

(Inhl)

mg/l

LD-50

(O)

mg/kg

LD-50

(D)

mg/kg

49 Phosphorous 7323-14-0 Solid NA NA NA NA 260 NA NA NA 2.36 NA

50 Phosphorous Acid 13598-36-2 Liquid 158 NA NA NA NA NA 1530 2740 1.685 3.4

51 Potassium Hydroxide 1310-58-3 Solid 1320 NA NA NA NA NA 273 NA 2.04 NA

52 Phosphorous

Trichloride 7719-12-2

Liquid 76 NA NA NA NA NA 18 NA 1.574 4.75

53 Pinacolone 75-97-8 Liquid 106.2 23 NA NA NA NA 610 NA 0.725 NA

54 Sodium Bisulphate 7681-38-1 Solid NA NA NA NA NA NA 2800 NA 2.435 NA

55 Sodium Bromide Solid 7647-15-6 Solid 1390 NA NA NA NA NA 3500 NA 3.21 NA

56 Sodium Carbonate 497-19-8 Solid NA NA NA NA NA NA 4090 NA 2.53 NA

57 Sodium Hydride 7646-69-7 Solid 360 NA NA NA 229 NA NA NA 0.89 NA

58 Sodium Hypochlorite 7681-52-9 Liquid 40 NA NA NA 230 NA 5800 NA 1.07 0.62

59 Sodium Methoxide 124-41-4 Solid 126 33 7.3 36 88 NA 2037 NA 1.1 1.1

60 Spent HCL 7647-01-0 Liquid 108 NA NA NA NA NA NA NA 1.1 NA

61 Spent Sulphuric Acid 7664-93-9 Liquid 270 NA NA NA NA NA 2140 NA 1.84 3.4

62 Sulfamoyl Isocyanate 15804-29-2 Solid NA NA NA NA NA NA NA NA NA NA

63 Sulfanilamide 15804-29-2 Liquid NA NA NA NA NA NA 3900 NA 1.08 NA

64 Sulphur 63-74-1 Solid 445 188 NA NA 248 NA 5050 2020 2.07 8.8

65 Sulphuric Acid 7704-34-9 Liquid 290 NA NA NA NA NA 2140 NA 1.84 3.4

66 Tri Methyl Phosphite 7664-93-9 Liquid 112 27 5.2 61.2 250 32700 4280 2600 1.052 NA

67 Triazinone 121-45-9 Solid NA NA NA NA NA NA 1724 5000 NA NA

https://www.sigmaaldrich.com/catalog/search?term=7646-69-7&interface=CAS%20No.&N=0&mode=partialmax&lang=en&region=IN&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


Properties

Toxicity Sp

gr.

V.D.

B.P.

(˚C)

F.P.

(oC)

LEL

%

UEL

%

Auto.

Temp.

˚C

LC-50

(Inhl)

mg/l

LD-50

(O)

mg/kg

LD-50

(D)

mg/kg

68 White Phosphorous 21087-64-9 Solid NA NA NA NA 30 3.03 4.3 100 1.83 4.66

69 Hydroxylamine

Sulphate 10039-54-0

Solid NA NA NA NA NA NA NA NA 1.67 NA

70 Thionyl Chloride

(SOCl2)/HCL 7719-09-7

Liquid 76 NA NA NA NA NA NA NA 1.64 4.1

71 2-Chloro

Benzylchloride (OCBC) 611-19-8

Liquid 214 82 NA NA NA NA NA NA 1.274 5.5

72 Alpha CPC 147-14-8 Solid NA NA NA NA NA NA NA NA 1.5 NA

73 Toluene 108-88-3 Liquid 111 7 3.3 19 422 49 636 16.3 0.86 3.14

74 EDTA (50%) 60-00-4 Solid NA NA NA NA NA NA 30 NA 0.72 NA

75 Naphthol 90-15-3

Solid 288 161 NA NA NA NA 1870 880

1.095

4 NA

76 Sodium Bicarbonate 144-55-8 Solid NA NA NA NA NA NA 3360 NA 2.159 NA

77 Xylene 1330-20-7 Liquid 138 24 1 7 464 NA 4300 1700 0.864 3.7

Note: B.P. : Boiling Point, F.P. Flash Point, LEL: Lower Explosive Limit, UEL: Upper Explosive Limit, Auto Temp: Auto Ignition Temperature, Sp.Gr:

Specific Gravity, V.D.: Vapour Density






Table 7.3: Hazardous Characteristic, Storage Mode and Type of Hazards (as per NFPA)

Sn. Hazardous Materials Storage Mode Hazardous Characteristic Type of Hazards [National Fire

Protection Association (U.S.A.)]

1 1,4 Dioxane HDPE/MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 1

2 2-Coumaranone HDPE/MS Drum May be combustible at High

Temperature

Health: 2; Flammability: 1; Instability: 0

3 2-Cyno Phenol HDPE/MS Drum Non-flammable Health: 2; Flammability: 0; Reactivity: 0

4 2-ethyl Hexanol Drum Flammable Health: 2 Flammability: 2 Reactivity: 0

5 3 Chloro 2,2 Dimethyl Propanoyl

Chloride

HDPE/MS Drum Non-flammable Health: 2; Flammability: 0; Reactivity: 0

6 4,6 Dimethoxy Pyrimidine 2 Amine Drum Non-flammable Health: 1 Flammability: 0 Reactivity: 0

7 4 methoxy 6 Methyl 2 Amino 1,3,5

triazine

Fibber drum Non-flammable Health: 1 Flammability: 0 Reactivity: 0

8 Acetic Anhydride HDPE/MS Drum Flammable Health: 3 Flammability: 2 Reactivity: 1

9 Acetonitrile HDPE/MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 0

10 Ammonia Tonner Toxic Health: 3 Flammability: 1 Reactivity: 0

11 Asulam Technical HDPE jumbo bag Non-flammable Health: 2; Flammability: 0; Reactivity: 0

12 Bromine Glassline Tank Non-flammable Health: 3 Flammability: 0 Reactivity: 0

13 Carbon Di Sulphide ISO Tank Flammable Health: 3 Flammability: 4 Reactivity: 0

14 Caustic flakes Polyliner Bag Non-flammable Health: 3; Flammability: 0, Reactivity 1

15 Caustic Soda lye Tank Non-flammable Health: 3; Flammability: 0, Reactivity 1

16 Chloral HDPE/MS Drum May be combustible at High

Temperature

Health: 2 Flammability: 1 Reactivity: 0

17 Chlorine Tonner Toxic Health: 0 Flammability: 0 Reactivity: 0

18 Di Ethyl Amine HDPE/MS Drum Flammable Health: 3 Flammability: 3 Reactivity: 0

19 Di Methyl Carbonate (DMC) HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0






20 Dimethyl Formamide HDPE/MS Drum Flammable Health: 1 Flammability: 2 Reactivity: 0

21 Di Methyl Phosphorous Amido thioate

(DMPAT)

Tank Corrosive Health: 1 Flammability: 0 Reactivity: 0

22 Di Methyl Sulphate HDPE/MS Drum Combustible Health: 4 Flammability: 2 Reactivity: 0

23 Ethyl Mercaptan HDPE/MS Drum Flammable Health: 2 Flammability: 4 Reactivity: 0

24 Ethyl Acetate HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0

25 Formaldehyde HDPE/MS Drum Flammable Health: 3 Flammability: 2 Reactivity: 0

26 Glyphosate technical HDPE Bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0

27 Hydrochloric Acid Tanker Corrosive Health: 3 Flammability: 0 Reactivity: 1

28 Hydrochloric Acid 36% HDPE/MS Drum Corrosive Health: 2 Flammability: 0 Reactivity: 2

29 Hexane HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0

30 Hydrazide Hydrate HDPE Bag Combustible Health: 1 Flammability: 1 Reactivity: 0

31 Hydroxylamine Hydrochloride HDPE Bag May be combustible at High

Temperature


32 Hyflow Powder HDPE Bag Non-flammable Health: 2 Flammability: 0 Reactivity: 0

33 Iso Propyl Alcohol HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0

34 Liquor Ammonia Tank Toxic Health: 3 Flammability: 0 Reactivity: 0

35 Methanol Tank Flammable Health: 1 Flammability: 3 Reactivity: 0

36 Methylene Di chloride HDPE/MS Drum May be combustible at High

Temperature


37 Methane Sulfonic Acid HDPE/MS Drum Non-flammable Health: 3 Flammability: 0 Reactivity: 0

38 Metribuzin Technical HDPE jumbo bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0

39 Mono Iso Propyl Amine HDPE/MS Drum Flammable Health: 3 Flammability: 4 Reactivity: 3

40 N,N Dimethyl Aniline HDPE/MS Drum Flammable Health: 3 Flammability: 4 Reactivity: 3

41 O- chloro Benzylchloride HDPE/MS Drum Toxic/Corrosive Health: 3 Flammability: 2 Reactivity: 0






42 Oxygen Tonner Non-flammable Health: 2 Flammability: 0 Reactivity: 0

43 Phenol HDPE/MS Drum Flammable Health: 4 Flammability: 2 Reactivity: 0

44 Phosphorous MS Drum Flammable Health: 1 Flammability: 1 Reactivity: 1

45 Phosphorous Acid HDPE/MS Drum Highly corrosive Health: 3 Flammability: 0 Reactivity: 0

46 Potassium Hydroxide HDPE jumbo bag Non-flammable Health: 3 Flammability: 0 Reactivity: 1

47 Phosphorous Trichloride (PCl3) Tank Non-flammable Health: 4 Flammability: 0 Reactivity: 2

48 Pinacolone Tank Flammable Health: 2 Flammability: 3 Reactivity: 0

49 Sodium Bisulphate HDPE Bag Non-flammable Health: 3 Flammability: 0 Reactivity: 0

50 Sodium Bromide Solid HDPE jumbo bag Non-flammable Health: 2 Flammability: 0 Reactivity: 0

51 Sodium Carbonate HDPE Bag Non-flammable Health: 2 Flammability: 0 Reactivity: 1

52 Sodium Hydride HDPE Bag Flammable Health: 0 Flammability: 1 Reactivity: 0

53 Sodium Hypochlorite Tank Non-flammable Health: 1 Flammability: 0 Reactivity: 0

54 Sodium Methoxide HDPE Bag Flammable Health: 3 Flammability: 2 Reactivity: 2

55 Spent HCL Tank Corrosive Health: 2 Flammability: 0 Reactivity: 2

56 Spent Sulphuric Acid Tank Corrosive Health: 3 Flammability: 0 Reactivity: 2

57 Sulfanilamide HDPE/MS Drum May be combustible at High

Temperature


58 Sulphur Bag Flammable Health: 1 Flammability: 1 Reactivity: 0

59 Sulphuric Acid Tank Corrosive Health: 3 Flammability: 0 Reactivity: 2

60 Tri Methyl Phosphite MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 1

61 Triazinone HDPE jumbo bag Non-flammable Health: 0 Flammability: 3 Reactivity: 0

62 White Phosphorous MS Drum Spontaneously Flammable Health: 4 Flammability: 4 Reactivity: 2

63 Hydroxylamine Sulphate Bag May be combustible at High

Temperature

Health: 3 Flammability:1 Reactivity: 0

64 Thionyl Chloride (SOCl2)/HCL Tanker Non-flammable Health: 4 Flammability: 0 Reactivity: 2






65 2-Chloro Benzylchloride (OCBC) HDPE Drum Toxic/Corrosive Health: 2 Flammability: 0 Reactivity: 0

66 Alpha CPC Bag May be combustible at High

Temperature


67 Toluene Tanker Flammable Health: 2 Flammability: 3 Reactivity: 0

68 EDTA (50%) Bag May be combustible at High

Temperature


69 Naphthol Bag May be combustible at High

Temperature


70 Sodium Bicarbonate Bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0

71 Xylene Tank Flammable Health: 2 Flammability: 3 Reactivity: 0




Table 7.4: Details of Bulk Storage of Hazardous Materials

S

No.

Name of

Hazardous

Chemicals

Tank/Bulle

ts with Nos

Tank/Bullet

s/ Tonner

Types

(UG/AG)

Dia &

Height of

Tank

Storage

Conditions

(Pressure &

Temperature)

Dyke around

Tanks Farm

Safety Measure

already providing

1. Bromine

(Liquid)

ST-202(6.3

kl)

DT-202 A

(1 kl)

DT-202 B

(1 kl)

DT-202 C

(1 kl)

Tank (AG) S.T-202, D-

1763 mm

Horizontal

Height -

3205 mm

D.T-202,

A/B/C

D-1173 mm

Horizontal

Height -

1560 mm

Atmospheric

Pressure and

temperature

ST-202(6.3)-

9250Lx3920Wx250

H (mm)

1. PRS valve provided. 2. Safety signage. 3. SOP available. 4. Gas detector 5. SCBA set 6. Sodium thiosulphate

sprinkler system provided.

7. Scrubber system provided

2. Chlorine N.A Tonner

(Net weight:

900 kg)

N.A 8 to 10 kgs /

cm2,

atmospheric

temperature

1. Safety signage. 2. On site emergency

plan. 3. SOP available. 4. Gas detector. 5. Scrubber system

provided




S

No.

Name of

Hazardous

Chemicals

Tank/Bulle

ts with Nos

Tank/Bullet

s/ Tonner

Types

(UG/AG)

Dia &

Height of

Tank

Storage

Conditions

(Pressure &

Temperature)

Dyke around

Tanks Farm

Safety Measure

already providing

3. 2-Ethyl

Hexanol

N.A Drum (Net

weight =170

kg)

N.A Atmospheric

Pressure and

temperature

Isolated storage area.

4. Methanol UGST-1(25

kl)

D.T-201(5

kl)

Tank(UG)

Tank(AG)

UGST – D-

2250 mm

Horizontal

Height

/Length-

6890 mm

DT-201 – D

–2005 mm

Height-

1950 mm

Atmospheric

Pressure and

temperature

UGST-

8700Lx4170W

(mm)

1. Isolated solvent yard. 2. Safety signage. 3. On site emergency

plan. 4. SOP available. 5. Fire hydrant system 6. Fire extinguisher

provided at nearest position.

7. Fire Bucket provided at nearest position

8. Cathodic protection & earthing to UGST-1

9. Double bonding provided for Earthing.

10. Earthing bonding provided to transferring line.

11. FLP system




S

No.

Name of

Hazardous

Chemicals

Tank/Bulle

ts with Nos

Tank/Bullet

s/ Tonner

Types

(UG/AG)

Dia &

Height of

Tank

Storage

Conditions

(Pressure &

Temperature)

Dyke around

Tanks Farm

Safety Measure

already providing

5.

Spent Acid

(Sulphuric

Acid 50%)

Black Spiral

tank (90 kl) Tank (AG)

D- 2400 mm

Height-

4500 mm

Atmospheric

Pressure and

temperature

4880Lx3920Wx103

0H (mm)

Isolated storage area

with acid resistance dyke.

6. Caustic Soda

Lye (32%)

ST-203

(18.5 kl)

ST-204 (15

kl)

DT-203(3

kl)

Tank (AG)

ST-203-D-

2214 mm

HT.-4120

mm

ST-204.D-

2230 mm

Height-

5000 mm

DT.203 – D-

1513 mm

HT.-1870

mm

Atmospheric

Pressure and

temperature

11220Lx4970Wx98

0H (mm)

Isolated storage area

dyke.

7. Sulphur

(Powder) N.A 50 kg Bags N.A

Atmospheric

Pressure and

temperature

-`

Isolated Storage area

with fire hydrant & water

sprinkler.

8. Sodium

Bisulphite N.A 50 kg Bags N.A

Atmospheric

Pressure and

temperature

- Isolated Storage Area.




S

No.

Name of

Hazardous

Chemicals

Tank/Bulle

ts with Nos

Tank/Bullet

s/ Tonner

Types

(UG/AG)

Dia &

Height of

Tank

Storage

Conditions

(Pressure &

Temperature)

Dyke around

Tanks Farm

Safety Measure

already providing

9. Sodium

Thiosulfate N.A 50 kg Bags N.A

Atmospheric

Pressure and

temperature

- Isolated Storage area.

10. Triazinone N.A 25 kg bags N.A

Atmospheric

Pressure and

temperature

- Isolated storage area.

11 Toluene Two Tanks

D- 5700 mm

HT.-6100

mm

Atmospheric

Pressure and

temperature

10.1Lx9.5Wx1.5H

Isolated Storage area

with fire hydrant with

dyke

12

Di Methyl

Phosphorous

Amido

thioate

DMPAT

One Tank

D- 2800 mm

HT.-4400

mm

Atmospheric

Pressure and

temperature

8.1Lx7.2wx1.5H Isolated Storage area

with dyke

13 Sodium

Hypochlorite One Tank

D- 6900 mm

HT.-9100

mm

Atmospheric

Pressure and

temperature

15.3Lx13.8wx1.5H Isolated storage area.

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified

Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra


7.4.1 Methodology for Selection of Accident Scenarios

The following steps have been followed for scenario selection for consequence

analysis:

• The hazardous materials handled at the plant and the associated hazards

were identified and assessed though materials safety data sheet.

• Operating and storage quantity, conditions of handling and storage of

hazardous materials were studied.

• An assessment was made of what inventories can get released accidentally.

7.4.2 Maximum Credible Scenarios for Consequence Analysis

At the plant, hazardous materials may be released due to loss of containment.

A leak can range in size from a pinhole leak to a catastrophic failure. In general,

smaller leaks have higher accident likelihood but lower consequence distances.

On the other hand, larger releases have lower accident likelihood but longer

consequence distance.

Criteria for Selection of Scenarios for Consequence Analysis: For

selection of maximum credible scenarios for consequence analysis for

quantitative risk assessment, the following criterion were considered:

• Hazardous chemicals which are highly flammable and flammable have been

selected for consequence calculations.

• Hazardous chemicals which are toxic gas and have potential to disperse as

toxic cloud have been used for consequence calculations.

Remaining hazardous chemicals, which are only combustible, non-flammable,

corrosive and do not have potential to create serious emergency situation, have

been studied qualitatively and risk mitigation measures have been provided

accordingly.

The selected scenarios for consequence calculations are given in Table 7.5.




Table 7.5: List of Selected Scenarios for Consequence Analysis

Sl. Type of Release Outcome Cases Considered

1. Catastrophic rupture of 5 Kl AG

Methanol tank

Fixed Pool Fire in Dyke Area

Flash Fire/Explosion

2. Catastrophic rupture of 140 kl

Toluene Tank

Fixed Pool Fire in Dyke Area


3. Catastrophic Rupture of 1 kl Xylene

tank

Fixed Pool Fire


4. Release of Ammonia from Cylinder Dispersion of Toxic Vapour Cloud

5. Release of Chlorine from Tonner Dispersion of Toxic Vapour Cloud

6. Release of Bromine from 6.3 kl

Bromine tank

Dispersion of Toxic Vapour Cloud

7. Release of Sulphuric Acid from 65

kl Tank

Dispersion of Toxic/Corrosive

Vapour Cloud

8. Release Carbon Di Sulphide (35 kl

tank)

Fire, Flash Fire/Explosion

9. Diethylamine (DEA) (20 kl tank) Fire, Flash Fire/Explosion in Dyke

10 1,4 Dioxane (8 kl) Fire and Explosion

11. 2-ethyl Hexanol (0.84 Kl) Fire and Explosion

12. Acetonitrile (10 Kl) Fire and Explosion

13. Di Methyl Carbonate (DMC) (16 Kl) Fire and Explosion

14. Dimethyl Formamide (3 kl) Fire and Explosion

15. Ethyl Mercaptan (3 kl) Fire and Explosion

16. Ethyl Acetate (11.75 kl) Fire and Explosion

17. Formaldehyde (8.5 kl) Fire and Explosion

18. Hexane (0.75 kl) Fire and Explosion

19. Iso Propyl Alcohol (4 kl) Fire and Explosion

20. Mono Iso Propyl Amine (3.25 kl) Fire and Explosion

21. N,N Dimethyl Aniline (3.25 kl) Fire and Explosion

22. Phenol (21 kl) Fire and Explosion

23. Tri Methyl Phosphite (6.25 kl) Fire and Explosion

24. Ethyl Hexanol (2 Kl) Fire and Explosion

Note: Vapour Cloud Explosion (Confined) and Flash Fire (Non-confined)




7.5 Consequence Analysis

Subsequent to the accidental release of hazardous materials, the consequence

of an accidental release depends on various factors e.g. type and quantity of

release, presence and location of an ignition source, meteorological conditions,

etc. Any loss of containment at the plant will lead to a release of hazardous

materials. The released quantity will depend on failure size and the duration of

release. All the tanks at the plant have been provided with bund (dyke). On

release of containment from tanks, a fixed pool may be formed, which may or

may not ignite. If immediate or delayed ignition takes place a pool fire will result.

Delayed ignition may also lead to vapour cloud explosion / flash fire, if release

quantities/surface areas are significant. In the event of release from transfer

piping and/or pipeline, spreading pool will be formed followed by spreading pool

fire on getting source of ignition.

The following effects are distinguished for consequence analyses for flammable

materials, immediate ignition followed by pool fire, or evaporation and delayed

ignition of a vapour cloud resulting in a fire and/or explosion. Representative

consequences distance up to where 1% fatality-occurs among those exposed,

has been calculated.

The following damage distances for thermal radiation have been used:

37.5 kW/m2 Damage to process equipment. 100%

lethality in 1min. 1% lethality in 10sec.

12.5 kW/m2 First degree burn for 10 sec exposure

4 kW/m2 First degree burn for 30 sec exposure

The 0.1 bar overpressure due to explosion at 1 % fatality has been considered

for computations.

Release of toxic hazardous materials like chlorine, ammonia, bromine and

sulphuric acid will result in dispersion of toxic vapour cloud toward wind

direction. Immediately Dangerous to Life or Health (IDLH) limit values for toxic

hazardous materials have been considered for computation of vulnerable

distances. IDLH Values for considered for toxic hazardous materials are given

below:




Sn Toxic Hazardous Materials IDLH Values

1. Chlorine 10 ppm

2. Ammonia 300 ppm

3. Bromine 3 ppm

4. Sulphuric acid 20 ppm

7.5.1 Model Used for Consequence Analysis

The consequence analysis studies involve a large number of calculations for

which established computing aids are essential. PHAST/SAFETI software of

DNV has been used to perform the consequence calculations. PHAST/SAFETI is

a consequence and risk assessment software for calculation of physical effects

(fire, explosion, atmospheric dispersion) of the escape of hazardous materials.

PHAST/SAFETI (v6.7) software allows detailed modelling and quantitative

assessment of release of pure and mixtures of liquid and gaseous chemicals.

For computation of consequence distances for Hazardous chemicals which are

not available in PHAST data base, ALOHA software developed by EPA and the

NOAA (USA) was also used. ALOHA® is the hazard modelling program for the

CAMEO® software suite, which is used widely to plan for and respond to

chemical emergencies.

7.5.2 Summary of Consequence Analysis

The summary of maximum consequence distance for flammable hazardous

materials at UPL Plant is given in Table 7.6. The consequence distance are

marked on google image layout plan and presented in Figure 7.1 to Figure

7.12.

Table 7.6: Summary of Consequence Analysis for Flammable Hazardous

Materials

Sr.

No.

Release Scenarios Thermal

Radiation

Distance (m)

4 kW/m2

Flash Fire

Envelope

(m)

Explosion

Effects (Delayed

Ignition) (m)

0.1 Bar

1. Rupture of Methanol

Tank followed by

Immediate/ Delayed

Ignition

Pool Fire: 5.1 m 1.9 m No Explosion

effect




Sr.

No.


Radiation

Distance (m)

4 kW/m2

Flash Fire

Envelope

(m)

Explosion

Effects (Delayed

Ignition) (m)

0.1 Bar

2. Rupture of Toluene

Tank followed by

Immediate/ Delayed

Ignition

Pool Fire:35.3m 39.4 m 16.4 m

3. Rupture of Xylene

Tank followed by

Immediate/ Delayed

Ignition

Pool Fire:11.3 m 1.2 m No Explosion

effect

4. Rupture of Hexane

Tank


effect

5. Rupture of Carbon Di

Sulphide Tank

Pool Fire: 22.5 m 72.4 m 44.4 m

6. Rupture of Phenol

Tank


effect

7. Diethylamine (DEA) 16.7 5.7 No Explosion

effect

8. 1,4 Dioxane 18.5 m 6.8 m No Explosion

effect

9. 2-ethyl Hexanol 7.8 m 3.1 m No Explosion

effect

10 Acetonitrile 19.5 m 4.6 m No Explosion

effect

11. Di Methyl Carbonate

(DMC)

22.7 m 5.7 m No Explosion

effects

12. Dimethyl Formamide 13.1 m 3.1 m No Explosion

effect

13. Ethyl Mercaptan 14.7 m 2.9 m No Explosion

effect

14. Ethyl Acetate 18.9 m 4.7 m No Explosion

effect

15. Formaldehyde 14.1 m 3.2 m No Explosion

effect

16. Iso Propyl Alcohol 15.2 m 4.1 m No Explosion

effect

17. Mono Iso Propyl

Amine

9.6 m 2.7 m No Explosion

effect




Sr.

No.


Radiation

Distance (m)

4 kW/m2

Flash Fire

Envelope

(m)

Explosion

Effects (Delayed

Ignition) (m)

0.1 Bar

18. N,N Dimethyl Aniline 8.7 m 1.8 m No Explosion

effect

19. Tri Methyl Phosphite 10.3 m 1.4 m No Explosion

effect

20. Ethyl Hexanol 6.6 m 2.2 m No Explosion

effect

The summary of consequence distances for toxic hazardous materials like

Ammonia, Chlorine, Bromine and Sulphuric acid toxic vapors at UPL Plant is

given in Table 7.7.

Table 7.7: Summary of Consequence Analysis for Toxic Hazardous

Materials

Sr.

No.

Release Scenarios IDLH

Concentrations

Distances (max.)

1. Release of Ammonia from Cylinder followed

by Toxic Vapour Cloud Dispersion

377.62 m

2. Release of Chlorine from Tonner followed by

Toxic Vapour Cloud Dispersion

513.8 m

3. Release of Bromine followed by Toxic Vapour

Cloud Dispersion

255.74 m

4. Release of Sulphuric Acid from Tank followed

Toxic Vapour Cloud Dispersion

241.77 m

The consequence of accidental release of toxic hazardous materials will be off

site beyond the boundary of the plant. The consequence distances of IDLH

concentration for toxic hazardous chemicals are marked on google image layout

plan and presented in Figure 7.9 to Figure 7.12.




Figure 7.1: Thermal Radiation Distance for Methanol 5 kl AG Tank

Figure 7.2: Thermal Radiation Distance for Toluene 140 kl Tank




Figure 7.3: Overpressure Distance for Toluene 140 kl Tank

Figure 7.4: Thermal Radiation Distance for Xylene Tank




Figure 7.5: Thermal Radiation Distance for Hexane Tank

Figure 7.6: Thermal Radiation Distance for Carbon Di Sulfide Tank




Figure 7.7: Overpressure Distance for Carbon Di Sulfide Tank

Figure 7.8: Thermal Radiation Distance for Phenol Tank




Figure 7.9: IDLH Concentration for Release from Ammonia Cylinder

Figure 7.10: IDLH Concentration for Release from Chlorine Tonner




7.6 Frequency Analysis

Figure 7.11: IDLH Concentration for Release from Bromine Tank

Figure 7.12: IDLH Concentration for Release From Sulphuric Acid Tank

Tank




The estimation of probability of an accident scenario is an essential step in

Chemical Process Quantitative Risk Analysis (CPQRA). The objective of Failure

Frequencies & Data Sources is to compile a database of existing leak frequency

data and ignition probabilities for use in quantitative risk analysis. Experience

data from operating companies in the petroleum and petrochemicals have been

used in this database. Apart from developing leak frequencies per equipment

item, generation of a hole size distribution i.e. information about the size of

releases, has been given priority. The holes size distributions are often based

on engineering judgment, as very little detailed information is available in this

area. The data taken from this database and used for this QRA are listed below:

Sn Equipment/Event Probability

1. Gas Sensor Failure 3.00×10-4

2. Controller Failure 3.00×10-2

3. Suction Pump Failure 1.08×10-2

4. Storage Tank Physical Defect 8.83×10-5

5. Storage Tank Bad Welding 1.88×10-4

6. Erosion of Storage Tank 1.00×10-3

7. Connecting Flange Damage 1.88×10-4

8. Leak Detector Failure 3.00×10-4

9. Pipe Erosion 1.00×10-3

10. Chlorine Alarm System Failure 3.30×10-4

11. Personnel did not detect the leak in five

minutes

9.50×10-2

12. Failure to reopen the valve after Replacement 5.01×10-5

13. Malfunction of Safety Valve 1.18×10-3

14. Chlorinator pressure-regulating valve fail 1.12×10-3

7.6.1 Equipment Failure Frequency

The data sources referred for failure frequencies are E & P Forum Frequency

database from TNO and Failure frequency data from the Rijnmond Report

(COVO Study). The failure frequencies have been distributed for three different

failure sizes, rupture, hole (50 mm equivalent hole size) and leak (13 mm

equivalent hole size).




Equipment Rupture Hole Leak

Process

piping

4.0 x 10 -6 /m

yr

6.0 x 10 -6 /m yr 1.6 x 10 -5 /m yr

Storage Tank 1 x 10 –6 /yr 1 x 10 -5 /yr. 1 x 10 -4 /yr.

Pumps 1 x 10 –4 /yr 1 x 10 -3 /yr. 1 x 10 -2 /yr.

Valves 9.2 x 10 -6 /yr 1.8 x 10 -5 /yr. 5.3 x 10 -5/yr.

Flanges - 3.52 x 10 -6 / flange

yr

8.5x 10 -5/flange

yr

Tapping - - 1 x 10 -4 /yr.

7.6.2 Frequency Analysis for the Plant

The following methodology/ assumptions have been adopted:

• The release frequency is obtained by adding the failure frequencies of all the

valves, flanges, pumps, pipeline etc.

• The immediate ignition probability for pool fire has been taken as 0.065 and

delayed ignition probability has been taken as 0.035.

For the plant, accident frequencies for scenarios for various storage tanks

facilities are given below:

The release frequency for storage tanks at the plant is given below:

Storage Tank Catastrophic Failure Frequency 1E-6 tank -1 yr. -1

Accident likelihood for hose failure is given below:

Base flexible hose failure frequency 4.0E-6/hr

7.7 Risk Analysis and Summation

7.7.1 Qualitative Risk Matrix

Qualitative Risk Assessments are often shown in the form of a simple risk matrix

where one axis of the matrix represents the probability and the other axis

represents consequences. The risk then is identified by the intersection of the

chosen assessment level. Severity, Likelihood/ Probability ranking and Risk

Acceptability Criteria used for preparation of risk matrix for the plant are given

below:

I. Severity Ranking




Severity Ranking

Catastrophic (Death/System Loss) 1

Major/ Critical (Serious injury) 2

Moderate (Less Serious Injury) 3

Minor/ Marginal (Minor Injury) 4

Insignificant/ Negligible (No injury) 5

II. Likelihood/ Probability Ranking

Likelihood/ Probability Ranking

Almost Certain E

Likely D

Possible C

Unlikely B

Impossible A

III. Risk Acceptability Criteria Ranking

Risk Ranking

Risk Acceptability Criteria Remark

H Unacceptable/High Management’s Decision/Action Plan Required. Potential off-site Impact.

M Medium Generally Minor Impact. Acceptable with Management’s Review. Specific monitoring or SOP to be followed.

L Low Acceptable without Review. Manage through Routine Procedure.

Risk matrix for the UPL plant. with implemented and proposed risk mitigation

measures is shown in Table 7.8.




Table 7.8: Qualitative Risk Matrix for the project site

Likelihood/ Probability

Catastrophic (Death/Syste

m Loss)

Major/ Critical

(Serious injury)

Moderate (Less

Serious Injury)

Minor/ Marginal (Minor Injury)

Insignificant/

Negligible (No

injury)

1 2 3 4 5

Almost Certain E Low Low Moderate Moderate High

Likely D Moderate Moderate Moderate High High

Possible C Moderate Moderate Moderate High High

Unlikely B Moderate Moderate High High High

Impossible A High High High High High

7.7.2 Quantitative Risk Analysis & Summation

Risk is defined as the unwanted consequence of a particular activity in relation

to the likelihood that this may occur. Risk thus comprises of two variables-

magnitude of consequences & the probability of occurrence. The risk analysis

and summation are most often presented in terms of individual and group or

societal risk. Individual Risk is the probability of death occurring as a result of

accidents at a plant, expressed as a function of the distance from such an

activity. Such a risk actually exists only when a person is permanently at that

spot (out of doors). The individual risk is well illustrated with the aid of risk -

curves or Iso-risk contours. Societal risk is the probability of a certain number

of victims per year. In calculating the group risk demographic data relating to

the presence of humans is necessary. The societal risk is represented as an F-

N curve, which depicts the frequency of occurrence per year F of a certain

number of fatalities, N. The individual and societal risks from a existing and

after expansion of existing pesticide plant are the result of the cumulating of

risks connected with all possible scenarios. From the standpoint of what

constitutes acceptable risk levels from a complex, both the Individual as well as

Societal risk should be within the acceptance criteria.

The DNV Software model SAFETI (PHAST RISK) has been used for plotting

the iso-risk contour of individual risk and F-N curves of Societal Risk. The ‘PHAST

RISK’ (v6.7) program package is a very powerful tool to combine the

probabilities and consequences of all release scenarios considered into risk and

then sum them. Data input to SAFETI (PHAST RISK) comprises of results of

effects-consequence and frequency analyses for the scenarios included for risk

summation, along with population and meteorological data for the locality in

question.




7.7.3 Risk Summation

Risk Acceptance Criteria

The risk analysis provides a measure of the risk resulting from plant. The

methodology for calculating risk levels has been well defined and consistent

results can therefore be expected. However, the assessment of the acceptability

or otherwise of that risk is left to the judgement and experience of the people

undertaking and/or using the risk assessment study. The normal approach

adopted is to relate the risk measures obtained to risk acceptance criteria.

Criteria Adopted for Individual Risk

As per Health and Safety Executive (HSE) UK, Individual Risk of death to the

members of the public outside the plant boundaries has been adopted as:

• 10-5 per year for intolerable risk

• Lower than 10-6 per year for negligible risk.

ALARP - Tolerability and Acceptability of Risk

Risk from a hazardous activity is judged against the benefits from the activity,

since no activity can claim to be totally risk-free. Risk criteria are recognised

below:

• There is a level of risk that is so high that it is considered unacceptable or

intolerable regardless of the benefits derived from an activity.

• There is also a level of risk that is low enough as to be considered negligible.

• Levels of risk in between are to be considered tolerable subject to their being

reduced As Low As is Reasonably Practicable (ALARP). In other words risks

are only tolerable provided that it can be demonstrated that all reasonably

practicable measures have been implemented to reduce risks. A reasonably

practicable risk reduction measure is one where the costs of implementation

are not grossly disproportionate to the risk reduction benefits achieved.

The above is the formulation of the, well-established, three tier structure of risk

criteria and risk control shown in Figure 7.13. The two horizontal straight lines

in divide risk space in to three regions. That above the upper line is the region




of unacceptable risk, while that below the lower line is the region of acceptable

risk. The region in between is the so-called ALARP region where risk is

acceptable subject to its being As Low as Reasonably Practicable (the ALARP

principle). All the various levels proposed within each tier are judgmental. Actual

decisions on what should then be done in the ALARP region to reduce risk

depend on choice of specific remedial measures.

Risk in intolerable region implies that reduction is called for irrespective of any

other considerations. Such limits have been set out by various countries both

for Individual as well as Societal risk. In between the upper and lower bands

the risks should be reduced ‘As Low As Reasonably Practicable’ using a cost

benefit approach. In cost benefit analysis the reduction in risks associated with

a particular remedial measure are compared against the costs of implementing

the measure. Where the benefits exceed the costs, the measures can be said

to be cost justified.

The risk criteria simply attempt to establish whether is risk is “tolerable”. Below

is a list of words generally in use and their meaning.

ACCEPTABLE RISKS: Since risks in general are unwelcome no risk should be

called “acceptable”. It might be better to say that the activity may be acceptable

generally, but the risks can only ever be tolerable.

Figure 7.13: ALARP Principle




TOLERABLE RISKS are risks the exposed people are expected to bear without

undue concern. A subtle difference is made out here between Acceptable Risks

and Tolerable Risks though these terms are sometimes used interchangeably.

NEGLIGIBLE RISKS are risks so small that there is no cause for concern and

there is no reason to reduce them.

Criteria Adopted for Societal Risk Criteria

In the assessment of the societal risk, demographic data on the offsite of the

plant have been used. Only the employees working in the plant are not included

in the 'society'. With regard to the risk of people employed in nearby industries

with similar risk, it is debatable to consider them as population.

FN Curve Slope

Intolerable Intercept With N=1

Negligible Intercept With N=1

Limit on N

Existing and New Plants

-1 10-3 10-6 -

Individual Risk Due to Existing Facilities

Iso risk contour for hazardous materials storage and handling at Unit # 10 of

UPL Ltd. are presented in Figure 7.14. From the figure, it is observed that risk

level contour 1.0E-5 is within the boundary of Plant. The risk level 1.0E-6 per

year individual risk contour also crosses the plant boundary, which is negligible.

It is thus clear that individual risk as computed 3.62898E-5/avg. yr higher than

1.0E-5/yr is within the UPL Ltd boundary and does not cover any populated

areas and is hence acceptable. The individual risk contours up-to risk level 1.0E-

6/avg. yr crosses boundary of the plant as toxic gas like chlorine from tonners

and ammonia gas may move outside the boundary. Day time individual risk as

2.33430E-5/avg yr, while night time individual risk as 5.57101E-5/ avg yr

remains within the boundary and considered as acceptable.

Societal Risk

The individual risk values for each location when combined with population at

that location gives the societal risk at same location i.e. the probability of a

certain number of victims per year. The total Societal Risk can be obtained by

adding the values for all the locations. The Societal risk is represented as F-N




curve, frequency of number of fatalities (F) from all the accidents versus No. of

fatalities (N).

For Unit #10 of UPL Ltd., F-N curves have been drawn for combined (Day and

night) time and separately for day and Night time. These F-N curves are shown

in Figures 7.15 and 7.16, respectively. F-N curves show two straight lines

(with negative slope) which indicate the Societal Risk Acceptance criteria

adopted for this study. That above the upper line is the region of unacceptable

risk, while that below the lower line is the region of acceptable risk. The region

in between is the so-called ALARP Zone where risk is acceptable subject to its

being As Low As Reasonably Practicable (the ALARP principle). Major risk

contributors have been identified using the Analysis Tools feature of PHAST

RISK.

From Figures 7.15 and 7.16, it is observed that the F-N curve of societal risk

lies in the ALARP Zone in acceptable zone for risk 3.62038E-005 /avg yr.

Findings of Risk Analysis

Based on risk analysis and summation, following conclusions can be made:

1. Individual risk from existing and after proposed expansion of Unit #10 of

UPL Ltd., is tolerable, as it is below the tolerance criterion of individual risk

not to exceed 1.0E-5 per year outside the boundary,

2. Individual risk contour for 1.0E-5 per year is also within the boundary limit

of the plant,

Figure 7.14: Iso Risk Contours for UPL




3. Individual risk contours for 1.0E-5 and 1.0E-6 per year are observed for

failure of Chlorine Tonner and ammonia cylinder, However, contour (1.0E-5

per avg. year) is within the boundary limit of plant.

4. Day time individual risk as 2.33430E-5/avg yr, while night time individual

risk as 5.57101E-5/ avg. yr remains within the boundary and considered as

acceptable.

F-N curve of societal risk as 3.62038E-005 /avg yr lies in the ALARP Zone and

in acceptable zone.

Figure 7.15: FN Curve for UPL




7.8 Risk Mitigation Measures

7.8.1 Safety at the Existing Plant

Based on hazard identification, consequence analysis, risk analysis and

observations recorded during the plant visit, the following risk mitigation

measures to enhance safety at the UPL plant are emerged:

7.8.2 System Specific Measures

The plant has already adopted various safety measures for handling and storage

of hazardous materials. Safety initiatives adopted at the existing plant are

described below:

i. Occupational Health, Environment and Safety Policy The plant has prepared Occupational Health, Environment and Safety Policy.

The Occupational Health, Environment and Safety Policy has been displayed at

locations prominently within the plant and is circulated to all employees.

Figure 7.16: F-N Curve Combined for Day and Night Time




ii. Environment, Health & Safety Organization a) Environment, Health & Safety Department The HSE department is managed by qualified, experienced and competent

personnel and strict safety controls are enforced for each hazardous activity.

iii. Accident Reporting, Investigation and Analysis Records for near-miss, incidents and accidents are maintained and analyzed to

take precautionary measures. All near-miss incidents and accidents are reported

and investigated to take corrective measures. The accident statistics and data

are maintained by Environment, Health & Safety Department. Accident statistics

and data are reviewed regularly by the senior management to take corrective

measures.

iv. Safety Inspections and Internal Audit Safety inspections are carried out regularly at the plant. Internal safety audits

are also conducted frequently.

v. Safety Education and Training (a) Safety Training There are provisions at the plant for induction training for new workers. The

assessment of the trainee is done to ensure the effectiveness of training.

(b) Periodic Training / Reporting The workers are trained as per need of training. (c) Safety Communication / Motivation / Promotion

• The system for safety suggestion schemes are implemented at the plant.

• There is provision at the plant for the safety contests for motivation of safety

at the plant.

vi. First Aid

• First aid boxes are available within various departments in existing plant.




• First aid facilities will be provided through well-equipped first aid box &

Occupational Health Centre. Trained first aid persons will be available in each

shift. Pre- employment & periodic medical examination will be carried and

records will be maintained.

vii. Occupational Health

• The pre- employment and periodical medical check-up are carried out at

regular interval for all employees.

• Emergency vehicle/ambulance for the event of an emergency are available

round the clock at the plant in each shift.

7.8.3 Safety Measures at the Plant

i. Hazard Control Measures

• Procedures and actions are well defined and known to all operating

personnel for safe shut down of plant in case of failure of any power,

instrumentation, etc.

• All the tanks have been provided with temperature indicator, pressure gauge

and safety valves depending upon the process and operating parameters.

• HAZOP studies will be carried out using P&IDs for identification of hazards

during operation considering deviation of operational parameters, their

possible cause and consequence and safe guards.

• All the motors and other rotating equipment machines have been provided

with suitable safety guards.

• Fire extinguishers have also been installed in the plant area.

• Flame arrestors will be provided at all vent lines at solvent tanks.

• Suitable fire extinguishers, such as, DCP, CO2 & foam type have been kept

in every plant area at easily approachable spots and in sufficient numbers.

• Fire hydrant points with sufficient length of hose reel have been provided at

major emergency spots.

• Bound walls, bonded wire fencing, detached storage areas are kept away

from probable ignition sources;

• Safety showers and eye washers are installed at crucial places.

• Sufficient space has been provided for free movement in the plant area.

• Certificate of structure stability are taken from competent person.

• All elevated structures will be provided with lightening arrestors.

• All exposed parts of moving machineries will be provided with suitable

guards for personnel safety.




• All piping and equipment will be provided with earthing connection and it

will be tested regularly.

• Safety valves & rupture disc will be provided to prevent over pressurization

of vessels and reactors.

• SOP will be available of safe shut-down of plant during any emergency

situation.

ii. Operational Safety

• All operators & maintenance personnel concerned with the plant will be

given material safety data sheets for hazardous chemicals and to be trained

to combat any leakage spillage, etc.

• Detections and sensors for smoke, heat, ammonia, chlorine, etc. will be

provided with alarm at strategic locations at the plant.

• Non-destructive thickness measurements will be carried out regularly

corrosion through competent person to prevent sudden bursting by thinning

out of metal by erosion or.

• Safety appliances like PVC suit, hand gloves, safety goggles, helmets etc.

will be used during material handling. Also, SCBA/emergency air masks will

be kept available all the time.

• Internal and external inspection of tanks, piping, thickness measurement of

piping, inspection and testing of lifting tackles, etc, will be carried out as per

schedule.

iii. Toxic Releases: Controls Small quantities - say leakage from piping, valves, pin holes etc. will be easily

controlled by isolating the equipment/piping etc. & using personal protective

equipment’s like helmet, shoes, hand gloves, airline respirator, breathing

apparatus (SCBA), apron, etc.

iv. Spillages, Leakages: Controls Depending on the leaking rate/source the following actions will be taken.

• Isolation/cutting of supply at leaking point, transfer to some other

vessel/equipment, and using protective appliances like hand gloves,

helmets, PVC suits etc.

• Efforts will be made, to prevent spread of spillage by neutralization/ earth

barriers.




v. Hazards in Transportation: Controls Highly inflammable chemicals are transported by road. Therefore, adequate

safety precautions for transportation are followed.

The following safety precautions are suggested during transportation of toxic,

inflammable and corrosive chemicals in tankers, while loading and unloading,

transportation and response to emergencies arising out of leakages and

spillages of hazardous materials:

• Ensure TREM card with Tanker and tonner/cylinder transporting trucks.

• Park the vehicle at designated place.

• Stop the engine while unloading and loading of hazardous materials.

• Check-up spark arrester.

• Provide earthing to tanker securely.

• Ensure that fireman is available near the place with proper equipment’s.

• Connect the piping properly

• Before start unloading, check that, there will not be any leakage.

• In case of leakage, immediately attend the leakages & rectify it.

• After unloading is over, close the lid properly.

• Vehicle to be started only after removal of all pipelines connected with

tanker.

vi. Safety Instructions for Transportation of Hazardous Materials

• The name of the chemical along with pictorial sign denoting the dangerous

goods will be marked on the vehicle and the packing material.

• The name of the transporter, his address and telephone number will be

clearly written on the road tanker and on the vehicle.

• The important safety precautions will be mentioned on the tanker as a

warning label.

• The tanker or vehicle will not be used to transport any material other than

what is written on it.

• Only trained drivers and cleaners will transport hazardous chemicals.

• The transporter and the manufacturer must ensure the safe transportation

of the material.




vii. Tankers

• The tanker will be checked for its fitness and safe condition before loading.

• During loading and unloading, the tanker will be breached and isolated

against any movement, while loading/unloading, use safety appliances.

• The tanker will not be overloaded by hazardous materials beyond the weight

permitted by the concerned authority.

• Check for leakages from the line connections before starting and stopping

the filling operations.

• Drive the vehicles carefully, especially in crowded localities and on bumpy

roads.

• Do not apply sudden break.

• The tanker will not be parked for long time on the way and especially in

crowded places. Park the vehicle away from residential areas.

viii. Maintenance Hazards

• Safety permit system like hot work, cold work, confined space entry will be

followed,

• Adequate inventory of spare parts will be maintained.

• Scaffoldings/Ladders will be used for maintenance.

• Personal Protective Equipment (PPEs) will be utilized for protection against fall,

hand injury, head injury etc.

• Maintenance procedures will be developed and followed.

• All physical hazards will be eliminated.

• Lifting tackles will be maintained and examined periodically as per rules &

regulation.

• Hand tools/power tools will be used with approved types and of good quality.

7.8.4 Overall Risk Reduction Measures

For risk mitigation/reduction, attempts will be made to either reduce inventories

that could get released in the event of loss of containment or failure likelihood’s

or both as feasible. Risk analysis identifies the major risk contributors, which

enables prioritization of the plant that deserve special attention in terms of

inspection and maintenance in particular and over all safety management as a

whole. Based on hazard identification, consequence analysis the following

suggestions to enhance safety at the plant are emerged.




Risk Mitigation/Reduction Measures for Process Operations For the risk reduction at the process operations after expansion, the following

mitigation measures are given:

• A written process safety information document may be compiled for general

use.

• Personnel especially contractor workers at the plant will be made aware

about the hazardous substance stored at the plant and risk associated with

them.

• The process design information in the process safety information compilation

must include P&IDs/PFDs; process chemistry; maximum intended inventory;

acceptable upper and lower limits, pressures, flows and compositions and

process design and energy balances.

• The document compilation will include an assessment of the hazards

presented including (i) toxicity information (ii) permissible exposure limits.

(iii) physical data (iv) thermal and chemical stability data (v) reactivity data

(vi) corrosivity data (vii) information on process and mechanical design.

• Heat, smoke, ammonia, chlorine detectors may be provided at strategic

locations in the plant and indication of detectors/sensors will be provided in

main control room.

• Thickness survey for tanks and piping will be carried out periodically as per

standard practices.

• Safety measures in the form of do's and don'ts will be displayed at strategic

locations especially in Marathi and English language.

• Personnel engaged in handling of hazardous chemicals will be trained to

respond in an unlikely event of emergencies.

• The plant will check and ensure that all instruments provided in the plant

are in good condition and documented.




Personal Protective Equipment If a worker enters a hazardous area, he must wear suitable personal protective

equipment (PPE). Workers will be taught when and how to use mask or

respiratory apparatus (SCBA) provided. Without SCBA entry into the confined

space or toxic gas area will not be attempted.

• Keep personal protective equipment where it can be accessed quickly,

outside the hazardous material storage area and away from areas of likely

affected.

• Each employee will maintain his personal protective equipment in clean,

working condition at all times.

• All equipment will be used and maintained in accordance with the

manufacturer’s instructions.

• Equipment installed for body and eye wash will be checked properly for

uninterrupted operation.

Risk Mitigation Measures for Proposed Expansion

• Hazardous chemicals will be stored in separate storage along with necessary

safety measures.

• Hazardous process operations will be carried out by trained operators &

under supervision Process Safety Engineer.

• Hazardous chemicals will be handled in close circuit.

• Enclosures will be provided with vent connected to scrubber for Bromine etc.

• Safety fittings like safety valve, pressure reducing valve, vent, flame

arrestor, pressure / temperature indicators, level indicators, rupture discs

etc. will be provided to the concern equipment.

• Calibration of all instruments in the plant will be carried out periodically.

• Loading/unloading will be ensured with earthing & bonding for flammable

chemicals.

• Flameproof fitting, earthing & bonding of equipment’s & pipelines will be

provided for flammable chemicals.

• Work permit system will be followed strictly.

• Periodic onsite emergency mock drills will be arranged.

• Work area monitoring will be done periodically.

• Safety training’s will be given to the workers for handling of hazardous

chemicals.




• Monthly Cholinesterase enzyme (Blood) test will be carried for those who

will work in manufacturing process.

• Protective clothing will be provided to all workers & casual workers and these

will be regularly washed properly.

• Necessary PPE’s will be readily available. Jobs will be accomplished using

relevant PPEs

• Necessary cautionary and safety awareness placards will be displayed at

conspicuous places in company.

• Eating & chewing will be prohibited in manufacturing area.

Bulk Storage of Finished Product

• Stacking of manufactured products in warehouse will be restricted to certain

fixed height. Drums/plastic carboys/jars & other finished goods packing shall

not be stacked at very high levels. This may cause accidents.

• Some space must be left while storing the product to easily identify lot

numbers.

• It will be marked with Lot No. for easy stacking and removal.

• It will be insured that plant personnel are wearing safety protective

equipment while entering in the warehouse or handling products.

Handling of Hazardous Materials

• Personal protective equipment used by the workers during handling of

hazardous chemicals, will be replaced after certain time.

• If any spillage of hazardous chemicals, it will be cleaned and disposed as per

standard practiced.

• Empty drums of hazardous chemicals will neutralize immediately.

• Workers engaged in handling of hazardous chemicals will be made aware of

properties of hazardous chemicals.

• Material Safety Data Sheets (MSDS) will be displayed in storage area.

• Do's and don'ts will be displayed at strategic locations especially in Marathi

and English languages.




General Working Conditions at the Plant after Expansion (a) House Keeping

• All the passages, floors and stairways will be maintained in good condition.

• The system will be available to deal with any spillage of dry or liquid chemical

at the plant.

• Walkways will be always kept free from obstructions.

• In the plant, precaution, instructions and Do's and don'ts will be displayed

at strategic locations in Marathi and English Languages.

• All pits, sumps will be properly covered or securely fenced.

(b) Ventilation

• Adequate ventilation will be provided in the work floor environment,

hazardous material storage and warehouse for products.

• The work environment will be assessed and monitored regularly as local

ventilation is most effective method for controlling dust and gaseous

emissions at work floor.

Safe Operating Procedures

• Safe operating procedures will be available for hazardous materials handling,

operations and equipment.

• The workers will be informed of consequences of failure to observe the safe

operating procedures.

• Safe operating procedures will be formulated and updated, specific to

process & equipment and distributed to concerned plant personnel.

• Safety procedure near anhydrous Ammonia and Chlorine tonners will be

prepared and displayed meticulously in Marathi and English languages.

Work Permit System Work permit system will be followed at the plant during maintenance. Fire Protection

• Well-designed pressured hydrant system comprising with jockey pump,

electrical & diesel pumps, hydrant, monitor, etc maintained at the plant.




• The firefighting system and equipment will be tested and maintained as per

relevant standards.

• Heat and smoke detectors will be provided at the plant and shall be

calibrated and maintained properly.

Static Electricity

• All equipment and storage tanks/containers of flammable hazardous

materials will be bounded and earthed properly.

• Electrical pits shall be maintained clean and covered.

• Electrical continuity for earthing circuits of earth pits will be maintained.

• Periodic inspections will be carried for earth pits and record will be

maintained.

Communication System Communication facilities will be checked periodically for its proper functioning. Safety Inspections The system will be initiated for checklist based routine safety inspection and

internal safety audit of the plant after expansion. Safety inspection team shall

be formed from various disciplines and departments.

Predictive and Preventive Maintenance

Predictive and preventive maintenance schedule will be prepared for equipment,

piping, pumps, etc., after expansion of the plant.

Electrical Safety

• Insulation pad at HT panels shall be replaced at regular interval.

• Housekeeping in MCC room shall be kept proper for safe working conditions.

• All the three-phase motor and equipment will be double earthed.

• Danger signage showing bone and skull will be displayed at all three phase

motors.

• Insulation mat will be provided to the three phase electrical control panels.

Colour Coding System Colour coding for piping and utility lines shall be followed in accordance with IS:

2379:1990.




Control of Odour The efforts will be made to control odour from the plant. Odour Threshold

Concentrations for Hazardous Chemicals is as give below:

Sn. Hazardous Chemicals Odor Threshold Concentration

1. Methanol 200 ppm (MSDS)

2. Isopropyl Alcohol 400 ppm (MSDS)

3. Toluene 200 ppm (MSDS)

4. Ammonia Gas 5 ppm (MSDS)

5. Bromine 0.1 ppm (MSDS)

6. Chlorine 0.5 ppm (USEPA)

7 Tri Methyl Phosphite 0.0001 ppm (ACGIH)

8 Di Methyl Sulphate Not Established as per USEPA (faint, onion-like odor)

Mock Drill Exercises Mock drills are conducted once in year. Exercises or drills have two basic

functions, namely training and testing of systems. While exercises do provide

an effective means of training in response procedures, their primary purpose is

to test the adequacy of the emergency management system and to ensure that

all response elements are fully capable of managing an emergency situation.

Mock drills are best means of accomplishing the following goals and objectives: 1. To reveal weaknesses in the plans and procedures before emergencies

occur.

2. To identify deficiencies in resources (both in manpower and equipment).

3. To improve the level of co-ordination among various response personnel,

departments and agencies.

4. To clarify each individual’s role and areas of responsibility.

Based on outcomes of emergency response plan will be updated accordingly.




7.9 DISASTER MANAGEMENT PLAN (DMP)

7.9.1 Objective of DMP

In order to be in a state of readiness to face any accident or disaster caused by

the project operation, a Disaster management plan is required to be prepared.

The plan should cover possible disaster, On and Off-site emergency

preparedness plans, establishment of emergency Control Centre (ECC).

Location of emergency services and duties of officers / staff during emergency.

Basic Contents of DMP

Basically, DMP contains following aspects

1. Description of site

2. Brief description of the plant

3. On – site Emergency plan

4. Off- site Emergency plan

Mode of Emergency

Process Emergency Natural Calamities Man-made &/or Extraneous

Heavy Toxic Leakage/ Spillage

Flood Riots/Civil Disorder/Mob Attack

Fire Earthquake Terrorism

Explosion Cyclone Sabotage

Failure of Critical Control system

Outbreak of Disease Bomb Threat

In-adequate maintenance Tsunami War/Hit by missiles

Abduction

Food Poisoning/Water Poisoning




On-Site Emergency

The On-site emergency plan: deals with, measures to prevent and control emergencies

within the factory and not affecting outside public or Environment.

Off-Site Emergency

The Off-site emergency plan: deals with, measures to prevent and control

emergencies affecting public and the environment outside the premises

7.9.2 On- Site Emergency Plan

Company has on-site emergency plan for existing site/activities. After proposed

expansion company will be update on-site emergency plan for proposed activity.

1. Scope of Site Emergency Plan

The existing site contain following nature of emergencies in the factory:

• Emission of chemical vapors into the shop floor ambience and any injurious effects of

physical contact with corrosive chemicals, inhalation of fumes, vapors and solvents.

The consequences is being off minor type and major emergency in this case is not

perceived.

• Fire preceded or followed by explosion. Explosion is in tanks, barrels, drums and

cylinders due to pressure build up. A safety arrangement is being made in pressure

vessels.

2. Preventive measures and plant safety

During construction

Safety precaution and preventive measures adopted in built in design, maintenance,

instrumentations, handling housekeeping, storage, loading, unloading, transportation

etc.

During operation

Colour code system: is/Will be adopted

Work permit system: is/Will be adopted

Safety Audit: Internally and externally planned

Breakdown/Periodic maintenance and preventive maintenance schedule: Schedule

is/will be prepared and regular breakdown maintenance is carried out after getting

written job order from department where the equipment is used.

Other precautions: All other precautions is/will be taken (need based) from time to

time.




1. Development of details inspection procedures for various equipment and system

2. Record keeping

All identified vital records of the factory is/will be kept in safeguard them in the event

of an emergency. Back up storage facility is/will be provided.

3. Safety Awareness among the workers

Details of training and periodic retraining programs for the personnel of safety and

fire department

Security guards who act as firemen during fire emergency are trained, retrained and

refreshed on regular basis. Safety professional is sent for external training and some

training program also conducted at works site by external experts of the field.

Details of Training and retraining programs for the workers

Training programs on safety aspects with special attention to firefighting are regular

feature of company. Plant organizes 3-4 sessions every month on safety aspects and

cover good number of workmen in these programs.

All these training programs would at least include the following:

• Lectures

• Seminars and workshop

• Practical Exercises

• Distribution and practice safety instructions

• Safety quiz contests/competitions for individual as also for groups

• Display of safety posters and safety slogans at convenient and conspicuous places.

• Explanation of instructions (in the language easily understood by workers) about the

possible hazards involved in handling of chemicals ad methods to deal with such

hazards failing which possible emergency situation are likely to arise.

• Developing safety instructions for every job and ensuring practice to these instructions/

booklets or manuals by workers.

• Educating workers about the

o Measures taken to ensure safety and control physical and health hazards.

o Physical and health hazards arising out from the exposure of handling substance

o Measures to be taken by workers to ensure safe handling, loading and unloading.

o Storage and transportation of hazardous substances




o Meaning of various labels and marking used on containers of hazardous substances and to whom to report

o Measures to be taken in case of any spillage or leakage.

4. Public Awareness

The provision of a liaison officer of factory to serve information with public, personnel

manager can play this role. Company can develop a formal public information

procedure during an incident. This may include pamphlets, newspaper stories, periodic

radio, TV announcements and instructive programs for school, inmates of hospitals,

as well as for the dependent aged persons. They provide accurate information to the

general public in order to prevent panic and protect themselves as well as others. As

certain information will need to be communicated quickly, one person would be

identified to serve as spokesperson. It is strongly recommended that the individual

identified has training and experience in public information spokesman can identify for

media, the appropriate individual who have specialized knowledge about the event

and its consequences. The claim of command would therefore include this

spokesperson other members of the response team would be instructed to direct all

communication, and public relation issues to this one person.

5. Medical facilities

Medical aid and services is/will be available and to be pressed into service at short

notice including action plan for medical management to deal with medical

emergencies.

Occupational Health Centre

• OHC is/will be provided with emergency care equipment, emergency medicines,

Documentation Facilities etc at the site.

• Strength and Status of medical staff at occupational Health Centre

• Qualified Doctor & other assistant shall be appointed.

• Medical Facilities is/will be provided inside the factory will be sufficient in case of First

Aid only. Company takes services from outside medical facilities.

6. Personal Protective Equipment

Company has arranged sufficient of PPEs in plant and provided to dust mask for

protection against dust, PVC Gloves for chemical handling, Splash Protection goggles




for splash protection, ear plug and ear muff from noise protection, leather palm for

general handling, helmet for head protection to their workers.

7. Details of firefighting arrangement

Fire is classified in following three classes. The appropriate fire extinguishers are used

to extinguish the different class of fire.

• Class A – General Fire – Cotton Waste, Paper, Rubbish and Scrap: water, ABC powder

type

• Class B – liquid Fire – All solvents, Resin, Paints, LDO, HSD: Mechanical foam, ABC

type

• Class C – Gaseous /Electrical fire – Gaseous fire & panels etc.: CO2, DCP/ABC

8. Disaster Control Measures

Disaster control measures including mutual aid scheme plan for coordination and

interaction with various external agencies including administrative agencies in the

event of a major risk occurrence and rescue and relief operation plan reflecting

possible projected target population that may be affected. Addresses and telephonic

directory of nearby hospital, Doctors and Nursing Homes will be made available in

disaster control centre.

Rescue and Relief operation plan

Rescue and relief operation plan would be formulated keeping in view all possible

incidents such as fire/explosion/release of toxic materials, spillage of hazardous

materials, release of radioactive materials etc. and to make following arrangement for

communication and appoint key persons to execute the plan.

Communication

Raising the alarm – Manager (Production)

Declaring the major emergency – Manager Manufacturing & plant Manager Works

Making the emergency known to:

• Those inside the works – HR Manager

• The outside emergency services – HR Manager

• Key personnel outside normal working hours – HR Manager

• To authorities of contact persons of neighboring factories.




Appointment of key personnel and essential workers

The following persons are appointed and their responsibilities and duties would be

specified and clearly spelt out

1. Site Main Controller (SMC)

2. Incident Controller (IC)

3. Other Key Personnel

4. Production heads

5. Manager Quality Control

6. Manager engineering

7. Safety Officer.

Action on site

1. Making emergency known to key personnel. Concerned person and agencies: Works

Incident controller

2. Evacuation: Shift Officer, Particular Area in charge

3. Controlling the situation: Production heads, Shift Officer, Works Incident Controller

4. Accounting for personnel: Works Incident Controller/Works Main Controller

5. Access the records: HR Manager/Works Main Controller

6. Termination of emergency: Works Main controller

7. Public Reaction: Works Main Controller/Personnel Manager

8. Rehabilitation: Works Main Controller/Personnel Manager

9. Re-Entry Procedure: Works Main Controller, works incident controller

Emergency Shutdown procedure

Shift Officer/Production head in consultation with Engineering. Manager has to shut

down, following the prescribed procedure.

Action off-Site

Informing the police, voluntary organization, local administration for rescue operation

and for controlling and regulation the traffic in order to save the mobile population

from effects of smoke due to fire etc. by works main controller/HR manager through

telephone. Making emergency known to community. By blowing three hooters of 30

seconds intermittent with interval of 10 seconds in between road traffic/rail

traffic/radio press/T.V. works main controller. HR Manager.




Emergency Organization chart

Emergency Control Centre (ECC):

The emergency control center (or room) is the place from which the operations to

handle the emergency are directed and coordinated. The site main controller, key

personnel and senior officers of the fire, police, factory inspectorate, district authorities

and emergency services will attend it. The center should be equipped to receive and

transmit information and directions from and to the incident controller and areas of

the works as well as outside. It should also have equipment for logging the




development of the incident to assist the controllers to determine any necessary

action.

In addition to the means of communication, the center should be equipped with

relevant data and equipment which will assist those manning the center to be

conversant with the developing situation and enable them to plan accordingly.

It should be sited in an area of minimum risk and close to a road to allow for ready

access by a radio-equipped vehicle for use if other systems fail or extra communication

facilities are needed.

For large sites or where Fire may occur might be anticipated, consideration should be

given to setting up two control centers to ensure, so far as is possible, that one will

be available for use, should the other be disabled. If necessary the police will assist to

set up an emergency control center remote from the works.

7.9.3 Off- Site Emergency Plan

Objective

In the effects of the accident or disaster inside the plant is felt outside its premises, it

calls for an off-site emergency plan (figure 7.17), which would be prepared and

documented in advance in consultation with the district authorities

The off-site emergency plan prepared herein is/will deal with those incidents identified

under Level – 3 in the on-site plan, which have the potential to harm persons or the

environment outside the boundary of the factory premises

Off-site emergency plan has been drawn up with a view to mobilize resources and

integrate with district contingency plan for an effective system of command and

control in combating the emergency.

Thus in brief the two main purpose of the off-site emergency plan are:

To provide the local / district authorities, police, fire brigade, doctors, surrounding

industries and the public, the basic information of risk and environment impact

assessment and to appraise them of the consequences and the protection prevention

measures and control plans and to seek their help to communicate with the public in

case of major emergency




To assist the district authorities for preparing the off-site emergency plan for the

district or particulate area and to organize rehearsal from time to time and initial

corrective action based on the lesson learnt

Figure 7.17: OFF-SITE EMEGENCY PLAN



Chapter 8

PROJECT BENEFITS 8.1 General

The existing UPL plant is engaged in manufacturing of different types of pesticides

& intermediates products and proposed to increase production capacities of

pesticides with addition of new products. The benefits of pesticides manufacturing

include increased food production, increased profits for farmers and the prevention

of crop diseases. Although pests consume or harm a large portion of agricultural

crops, without the use of pesticides it is likely that they would consume a higher

percentage and there will be loss of agricultural productivity. Due to the use of

pesticides, it is possible to combat pests and produce larger quantities of foods.

By producing more crops, farmers are also able to increase profits by having more

produce to sell. Pesticides also increase farm profits by helping the farmer save

money on labor costs. Using pesticides reduces the amount of time required to

manually remove weeds and pests from fields. Hence, expansion of UPL project

will help in increase in agricultural productivity indirectly by increasing production

of pesticides and its availability through reducing gaps in demand and supply of

pesticides in the area and region.

8.2 Employment Opportunities

The project will create extra opportunities of direct and indirect employment for

skilled and unskilled manpower. This will also increase the demand for essential

daily utilities in the local market. The project will have following benefits on

employment opportunities:

● The construction work, erection & commissioning and operation of the

proposed plant will require man-power;

● Considering the size of the project, additional manpower requirement during

operation phase after expansion will be 77 workers and 73 staffs;

● Local people will get employment opportunity after expansion;



● Thousands of people will get employment opportunities during transportation,

distribution, trading and sale of pesticides manufactured by UPL at Tarapur;

● Due to the proposed expansion of UPL project indirect employments/business

will be generated through every day purchase by additional staff and workers

from local traders of grocery, rental houses, garments purchases, vegetable

shop, local transportation, etc.

8.3 Other Tangible Benefits

The details of the tangible benefits through the proposed expansion of UPL plants

are given in below:

● The project will encourage industrial growth of pesticide sector specifically in

formulation units in the region;

● The company will have market growth of its own brands name in various

overseas countries;

● The company will carter pesticide products needs of the domestic market also;

● UPL will develop in-house manufacturing facilities with the state of art process,

quality control and R & D;

● As pesticide products will be used by farmers, agricultural growth and high crop

yield will be ascertained;

● The project will enhance tax benefits to the country and foreign exchange

savings;

● The UPL will undertakes various social activities.



Chapter 9

ENVIRONMENTAL COST BENEFITS ANALYSIS 9.1 General

The Environmental Cost Benefit Analysis was not recommended during scoping

stage and in ToR granted by Expert Appraisal Committee (EAC) of Ministry of

Environment, Forest & Climate Change (MoEF&CC). Hence, the Environmental

Cost Benefit Analysis was not carried out.

The total capital investment for proposed expansion is Rs 227.06 Crores including

expenses in Environmental Management Facilities @ Rs 10.58 Crores. The Unit

will be providing adequate equipment to take care of pollution generated. In the

yearly budget, sufficient amount will be provided to take care of operational

expenses and disposal costs.



Chapter 10

Environmental Management Plan 10.1 Introduction

The proposed expansion of existing UPL plant is associated with both positive and

negative impacts on the environment. The anticipated impacts from proposed

expansion of the existing plant should not affect environment but they should be

properly mitigated and managed. The proper Environmental Management Plan

(EMP) should be prepared for activities of the proposed expansion of existing UPL

plant to minimize negative impacts on the basis of prevailing environmental

conditions and likely impacts on various environmental parameters. Environmental

Management Plan will also facilitate monitoring of environmental parameters.

Environmental Management Plan is required for the formulation, implementation

and monitoring of environmental mitigation measures. EMP includes schemes for

proper and scientific treatment and disposal mechanism for polluted emissions,

effluents, sewage, solid and hazardous wastes. Apart from this, landscaping and

green belt development, safety aspect of the workers, noise control measures, etc.

are also included in the EMP. Adequate budgetary provisions are also made for

EMP implementation.

10.2 Purpose of Environmental Management Plan (EMP)

The various objectives of the Environmental Management Plan for the proposed

expansion of the UPL plant are as given below:

● to mitigate adverse environmental impacts and enhancement of positive

impact,

● treatment and disposal of liquid, gaseous and solid & hazardous wastes as per

statutory requirements,

● compliance with environmental standards and improvement in environmental

management,

● to maintain and enhancement green-belt development,



● to ensure safe working conditions for employees,

● to implement best practices for environmental management,

● to reduce fire hazards and toxic release,

● allocation of funds for environmental monitoring and management.

The proposed expansion of UPL plant will have some pollution potential to cause

both short term and long-term environmental degradation, if suitable mitigation

measures are not implemented. Therefore, suitable mitigation measures are

required for control of pollution and environmental management. Along with

control and regulatory measures, mitigation measures will yield fruitful results at

UPL plant after proposed expansion towards environment management. With the

availability of cost effective advanced technology and innovative environment

management practices, the EMP can act as an effective management tool to

provide management solutions to all environmental pollution concerns including

that of associated regulatory compliance.

10.3 Health, Safety and Environmental (HSE) Policy The UPL has Health, Safety and Environmental (HSE) Policy dated 16th July 2015.

Copy of UPL’s Health, Safety and Environmental (HSE) Policy is enclosed as

Annexure VI.

The management of UPL Limited is committed to safeguard the Health, Safety &

Environment for all by minimizing adverse effect due to its Industrial &

Agrochemical Products Manufacturing & Marketing operations, services and

project activities.

The company has implemented Responsible Care initiative and the Management

is committed to continual improvement in HSE by carrying out risk assessment of

its activities including proactive safety risk assessment with involvement of its

employees and take proactive actions for pollution prevention.

The Company will comply to all applicable statutory and other requirements

pertaining to Occupational Health, Safety and Environment. The Management will

make arrangement for information, education, training and retraining to our



employees, other interested parties and stakeholders about Occupational Health,

Safety & Environment as and when required.

The HSE Policy, objectives and targets, significant aspects, risk levels and

performances shall be reviewed periodically and communicated to our employees

and interested parties.

10.4 Environmental Management Cell UPL is fully conscious for environmental management, therefore, Environment

Management Cell has been formulated having officers from various disciplines to

co - ordinate the activities concerned with environmental management and

implementation of environment enhancement measures.

The cell is responsible for all environmental management activities such as ETP

operation, air pollution control equipment operation and maintenance, hazardous

waste management, green belt development, housekeeping, work floor

monitoring, occupation health and safety facilities, compliance of regulatory

compliance, etc. Environment management cell has following responsibilities:

● Records keeping of environmental data, documents and information in line with

the statutory requirements,

● Day to day basis implementation of environmental management and operation

of pollution control system, to achieve optimum efficiency of the air pollution

control equipment,

● Routine ambient air quality monitoring and stack monitoring at the plant,

● Sampling and analysis of untreated and treated effluents of ETP to ensure

desired efficiency,

● Ensure proper collection and disposal of hazardous wastes. Making efforts for

minimization, reuse and recycling of the hazardous wastes,

● Coordination with various departments of UPL plant to ensure environmental

management,

● Training for environment management for staff and workers at the plant,

● Ensure growth of Green Belt Development at the plant.



After the proposed expansion, the Environmental Management Cell and its

infrastructure will be augmented to take up additional responsibilities for

implementation of mitigation measures.

The Environmental Management Cell will also include the safety officer for

observing, inspecting and regulating the safety measures inside the plant premise.

The Environmental Management Cell will be responsible for maintaining records of

all the data, documents and information in line with the statutory requirements.

The major duties and responsibilities of Environmental Management Cell shall be

as given below:

● to implement the Environmental Management Plan,

● to assure regulatory compliance with all relevant rules and regulations,

● to ensure regular operation and maintenance of pollution control devices,

● to minimize environmental impacts of operations by strict adherence to the

EMP,

● to initiate environmental monitoring to ensure efficacy of environmental

management plan,

● review of monitoring results and corrective measures in case monitored

parameters exceeding specified limit,

● documentation of implementation of environmental practices and compliance

of applicable environmental laws/discharge standards,

● preparation of compliance report for consents and environmental clearance,

● coordination with regulatory agencies and monitoring laboratories.

Organizational structure of Environmental Management Cell of UPL is shown in the

form of block diagram in Figure 10.1.

10.5 Environmental Management Plan for Construction Phase

10.5.1EMP for Soil

During the construction phase, the following mitigation measures will be taken as

a part EMP for soil:



● Prior to excavation, top soil from fresh land with ground flora will be segregated

and stockpiled. Top soil will be used for greenbelt development and

landscaping at the plant site.

● Wastes and debris generated at the site will be collected time to time and

disposed suitably to avoid any contamination. The inert debris generated

during construction will be used for land filling at the site only.

● Fuel oil for construction equipment will be stored on the cemented floor.

● Excavation of foundations will be carried out during dry season to eliminate

possibility of erosion by runoff.

Vice President (Environment)

General Manager (Environment)

Manager (Environment)

Supervisor

(ETP) Gardeners

APC Operators

Monitoring Lab

Chemist

ETP

Operators

Figure 10.1: Organizational Structure of Environmental

Management Cell of project site



10.5.2EMP for Water Quality


a part EMP for water quality:

● Excavation work will be carried out during dry season and site will be restored

before rains,

● Silt chamber will be provided at discharge point of storm water from

construction area. Care will be taken during construction work and will not

create any obstruction/dips which can lead to accumulation of water within

premises leading to undesirable consequences like health and hygiene

problems, etc.,

● Compaction and leveling of construction area will be done after completion of

foundation and construction activities,

● Before unexpected rains, lose construction materials will be covered by

tarpaulin sheets.

10.5.3 EMP for Ambient Air Quality

The construction phase of the proposed expansion of the UPL plant will be for a

short period (about 12 months) and therefore, the anticipated impacts will also be

temporary for a short period. During construction activities, mainly emissions of

dust, vehicular emissions from movement of vehicles, excavation and civil

construction, erection & commissioning are expected. During the construction

phase, the following mitigation measures will be taken as a part of EMP for ambient

air quality:

● Sprinkling of water will be carried out on the loose soil area after excavation

to suppress dust,

● Sprinkling of water on unpaved construction areas at the site,

● Covering of loose construction materials,

● Maintenance of construction equipment and machineries to reduce exhaust

emissions,

● Ensure pollution under control certificate for vehicles transporting materials,

● Unloading of cement bags and close chamber,



● Construction workers will be provided appropriate dust masks,

● 3.5 m high curtain wall around the construction zone by garden net or tin

sheets.

10.5.4 EMP for Noise Levels The following mitigation measures will be implemented during construction period

to mitigate adverse impacts on noise levels:

● Provision of rubber padding/ noise isolators on construction machines

● Preventive maintenance of the machine/ equipment will be carried out;

● Provision of silencers to modulate the noise generated by machines;

● Provision of protective devices like ear muff/ plugs to the workers; and

● Monitoring of ambient noise levels will be carried out as per details given in

Chapter 6 or as stipulated by the CPCB/ MPCB.

10.5.5 EMP for Wastes Management

During construction phase of expansion of UPL plant, solid waste generation will

include debris, broken bricks and tiles, metal cuttings, packing cartons, wooden

scrap, etc. However, these materials will be inert in nature and will not result for

any contamination. These wastes will be properly sorted, segregated, disposed as

per stipulated regulations.


a part EMP for waste management:

● Waste generated from the construction site will be collected and disposed off

as per Construction and Demolition Waste Management Rule, 2016 after

segregation.

● Metal cuttings and packing materials will be sent for recycling.

10.5.6 EMP for Ecological Environment


a part EMP for ecological environment:



● Green belt at the plant site will be enhanced by planting tall saplings during

construction phase.

● Spraying of water on the leaves of green belt growing at the plant to remove

dust deposition.

10.5.7 Occupational Health & Safety

During the construction phase, the following mitigation measures is/will be taken

as a part EMP for Occupational Health & Safety:

● Water sprinkling to avoid dust emissions;

● Use of suitable PPEs like mask during arc welding operation;

● Electrical safety to be maintained as per regulations;

● Use of ear muff and plug in high noise areas;

● Use of safety belt while working at height;

● Induction training to worker to enhance safety of workers; and

● First aid facilities is/will be provided at the construction site.

10.5.8 EMP for Socio-Economic Environment


a part EMP for socio-economic environment:

● Local people from nearby villages will be given preference in employment for

construction work to the maximum extent possible;

● Proper sanitary and drinking water facilities will be provided to workers

engaged in construction activities;

10.6 Environmental Management Plan for Operation Phase

The operation phase of the proposed expansion of the UPL plant will be continuous

activity for production of pesticides & intermediates to meet the growing market

demand. Existing UPL has already implemented mitigation measure as per

application environmental regulations, conditions of CC&A and Environmental

Clearance. For operation phase of the plant after expansion, EMP/mitigation



measures have been developed for implementation to safe-guard environmental

concerns.

10.6.1 EMP for Water Environment

The mitigation measures for water environment for the operation phase of

proposed expansion of UPL plant are as given below:

● Trade effluents is/will be treated in ETP comprising primary, secondary and

tertiary treatment facilities. Treated waste water is/will be sent to Common

Effluent Treatment Plant (CETP) of Tarapur.

● Total effluent quantity after expansion will be 297 kld. UPL will provide ETP

having capacity of 300 kld after expansion.

10.6.2 EMP for Air Environment

During operation phase, at the existing plant and after proposed expansion,

boilers, DG sets, process vents, scrubber stacks will be sources of emissions. From

the boilers and DG Sets, SO2, NO2 and Particulate Matters (PM) are considered as

key pollutants. After expansion of existing plant, process emissions will be vented

out through separate stacks for manufacturing processes for Asulam, Tri Phenyl

Phosphate (TPPA), Ammonium Chloride, Triazinone, Acephate, Glyphosate,

Metribuzin (Common Plant Scrubber), Ammonium Sulphate, Phosphorus Acid Solid

& Solution, Di-Chlorvos (DDVP). Water and caustic/alkali scrubbers will be provided

to process vents as required to control emissions of HCl, Cl2, HBr, MeCl, H2S, NH3

and HC well within the stipulated emission standards.

During the operation phase, the following mitigation measures is/will be taken as

a part EMP for air quality:

● Proposed 10 tph coal fired boiler will be provided well designed and efficient

dust collectors/bag filters,

● Performance of dust collectors/bag filter provided at coal /husk fired boiler will

be ensured time to time,

● At proposed process stacks water, water + alkali scrubbers is/will be provided,

● Stack height for DG sets & boiler will be ensured as per CPCB guidelines,



● Regular monitoring of stacks/process vents is/will be carried out to ensure that

concentrations of pollutants are well within the permissible limit described in

CC&A,

● Predictive and preventive maintenance for valves, pumps, flanges, etc. will be

ensured to avoid possibility of leakage and fugitive emissions,

● Necessary measures is/will be taken to control fugitive emissions,

● Transport vehicles is/will be properly maintained to reduce vehicular emissions

and pollution under control certificate (PUC) will be obtained as per regulation,

● Regular maintenance of DG sets will be ensured in order to control emissions,

● Good housekeeping is/will be practiced in the plant.

10.6.3 EMP for Noise Environment

During the operational phase of the plant after expansion, boilers, coal crushers

and handling for boilers, DG sets, cooling tower, multi effect evaporators, etc.,

may generate high noise levels. Mitigation measures to control noise levels during

operation phase of UPL plant after expansion are as given below:

● DG sets room will be provided acoustic treatment to control the noise levels.

● Ear muff and plugs will be provided to workers working in relatively high noise

areas.

● Green belt will be enhanced for the attenuation of noise levels and to maintain

ambient noise quality within the statutory limit.

● All the equipment will be designed/ operated in such a way that the noise level

shall not exceed 85 dB(A) as per the requirement of OSHA (Occupational Safety

and Health Administration).

● Proper maintenance of pumps, machinery, blowers, etc. will be ensured to

control noise levels.

10.6.4 EMP for Hazardous Wastes (Landfillable & Incinerable Waste) and Non- Hazardous

During the operation of the plant after expansion, hazardous wastes generated in

the form of incineration waste such as distillation residue, spent catalyst, aqueous

effluent from drum/tank/reactor washing, date expired & off specific pesticide and

used filter aids will be sent to Common Hazardous Waste Treatment Storage and



Disposal facility (CHWTSDF) for incineration. Used Oil generated from the

maintenance of DG sets will be handed over to CPCB authorized used oil recyclers.

Discarded containers (drums, carboys) contaminated with hazardous chemicals

will be sent for decontamination to CHWTSDF. Sludge generated from the ETP will

be sent to CHWTSDF for landfilling. Salt proposed to be generated from

evaporation of high TDS mother liquor will be sent to CHWTSDF for landfilling.

After expansion of the existing plant of UPL, approx. 120 tones ash (non-

hazardous) per month will be generated from coal or biomass/briquettes fired

boilers, which will be sold to bricks manufacturers or other end-users.

10.6.5 EMP for Occupational Health & Safety

During the operation phase of the plant after expansion, the following mitigation

measures is/will be implemented to improve occupational health & safety as given

below:

● Process is/will be carried out in closed system, following Standard operating

procedures (SOP).

● Dilution ventilation/local exhaust ventilation system is/will be provided.

● Hazardous materials is/will be handled by trained persons.

● MSDS of hazardous substances is/will be maintained and displayed.

● Suitable personal protective equipment (PPE) is/will be provided to all workers

in hazardous area.

● Do's and don'ts is/will be displayed at strategic locations in English and Marathi

languages.

● Relevant safety sign boards is/will be displayed at strategic locations.

● Firefighting facilities, fire hydrants, fire extinguishers, sprinkling system and

emergency exit is/will be ensured.

● Routine health check-up is/will be carried out for workers engaged in hazardous

operation.

● Regular training for workers working in hazardous area is/will be given time to

time.

● Regular mock drills of onsite emergency plan



● Company is/will update on site emergency plan for proposed expansion for

products activities and services.

● Daily safety talk to all employees

10.6.6 EMP for Socio-Economic Environment

During the operation phase of the plant after expansion, the following mitigation

measures will be implemented for socio-economic environment to strengthen

positive impacts:

● The operation of plant after expansion will create direct and indirect

employment opportunities during plant operation, transportation of raw

materials and transportation products as well as secondary services. The direct

man power requirement for existing UPL plant is 150 persons including 67 staff

and 83 workers. For plant operation after expansion, additional 73 staffs and

77 workers will be required. Total manpower requirement after proposed

expansion will be 140 staff and 160 workers. Preference will be given to locals

to provide employment as per their skills.

● The plant will undertake social welfare programs for the betterment of the

Quality of Life of villages around in collaboration with the local bodies under

the ESC programme,

● ESC programme have been prepared and will be implemented in nearby areas.

● Need base analysis will be carried out time to time to synchronize ESC activities

with the requirements of locals.

10.6.7 Health, Safety & Environment Management

UPL has adopted a practice of predictive and preventive maintenance. All the

equipment in the plant areas are inspected/ tested routinely. The various safety

equipment and critical instrumentations provided on various equipment are

inspected and tested frequently to ensure their operability all the time. All the first

aid and firefighting devices are also to be inspected, tested and maintained and

are kept in ready mode. Occupational health of all the employees in UPL plant after

expansion is/will be regularly monitored by external physician. If any abnormality

is found, necessary treatment is/will be given to staff and workers promptly.



Necessary health history cards and records is/will be maintained and same is/will

be updated regularly.

To ensure prevention of occupational hazards and to enhance safety at the UPL

plant, the following measures is/will be adopted:

● All pump and motors is/will be earthed and earth resistance is/will be

monitored.

● Floors, platforms, staircases, passages is/will be kept free of obstruction.

● Necessary safety measures is/will be explained to the workers through

induction and refresher trainings. Workers and staff is/will be periodically

trained and updated on the safety measures.

● Firefighting facilities is/will be augmented for expansion and tested regularly.

● All instrument and safety devices is/will be calibrated time to time at regular

interval. Records of calibration is/will be maintained.

● All the equipment of the plant is/shall be periodically tested as per standard.

● CPR is/will be displayed at DG sets room and training for giving CPR is/will be

given to workers and staff working at DG sets rooms.

● Adequate ventilation arrangement is/will be provided for safe and better

working condition in the plant as per the standards.

● Protection against lightning is/will be taken care in the plant.

● Medical check-up for workers is/will be carried at pre-employment and

regularly.

● Necessary Personal Protective equipment (PPE) is/will be provided to workers

and staff.

● Necessary safety, information and working signages is/will be displayed at the

plant at the strategic locations

● Mock drill is/will be carried regularly.

● Emergency response plan is/will be updated based on the findings of mock

drills.

10.6.8 Energy Conservation Measures At the UPL plant, the following energy conservation measures will be taken:



Boiler ● Establish an efficiency-maintenance program. Start with an energy audit and

follow-up, then make a boiler efficiency-maintenance program.

● Steam condensate is/will recycle back in to boiler.

● Company will provide economizer for stack for waste heat recovery.

Electrical Utilities Electricity Distribution System ● Schedule operations to maintain a high load factor,

● Shift loads to off-peak times,

● Minimize maximum demand by tripping loads through a demand controller,

● Stagger start-up times for equipment with large starting currents to minimize

load peaking,

● Use standby electric generation equipment for on-peak high load periods,

● Correct power factor to at least 0.90 under rated load conditions,

● Set transformer taps to optimum settings,

● Check utility electric meter with your own meter,

● Shut off unnecessary computers, lights, fans, printers, and copiers at night,

Motors ● Properly size to the load for optimum efficiency. (High efficiency motors offer

of 4 - 5% higher efficiency than standard motors),

● Use energy-efficient motors where economical,

● Use synchronous motors to improve power factor,

● Check alignment of motors,

● Provide proper ventilation (For every 10 oC increase in motor operating

temperature over recommended peak, the motor life is estimated to be

halved),

● Check for under-voltage and over-voltage conditions,

● Balance the three-phase power supply. (An imbalanced voltage can reduce 3 -

5% in motor input power),



● Demand efficiency restoration after motor rewinding. (If rewinding is not done

properly, the efficiency can be reduced by 5 - 8%).

Drives ● Use variable-speed drives for large variable loads,

● Use precision alignment,

● Check belt tension regularly,

● Eliminate variable-pitch pulleys,

● Use flat belts as alternatives to v-belts,

● Use synthetic lubricants for large gearboxes,

● Eliminate eddy current couplings,

● Shut them off when not needed.

ID Fans ● Use smooth, well-rounded air inlet cones for fan air intakes,

● Avoid poor flow distribution at the fan inlet,

● Minimize fan inlet and outlet obstructions,

● Clean screens, filters, and fan blades regularly,

● Use aerofoil-shaped fan blades,

● Minimize fan speed,

● Use low-slip or flat belts,


● Eliminate variable pitch pulleys,

● Use variable speed drives for large variable fan loads,

● Use energy-efficient motors for continuous or near-continuous operation,

● Turn fans off when not needed.

Blowers ● Use smooth, well-rounded air inlet ducts or cones for air intakes,

● Minimize blower inlet and outlet obstructions,

● Clean screens and filters regularly,

● Minimize blower speed,



● Use low-slip or no-slip belts,


● Eliminate variable pitch pulleys,

● Use variable speed drives for large variable blower loads,

● Use energy-efficient motors for continuous or near-continuous operation,

● Turn blowers off when they are not needed,

Pumps ● Operate pumping near best efficiency point,

● Modify pumping to minimize throttling,

● Adapt to wide load variation with variable speed drives or sequenced control

of smaller units,

● Repair seals and packing,

● Balance the system to minimize flows and reduce pump power requirements.

Cooling Towers ● Control cooling tower fans based on leaving water temperatures,

● Control to the optimum water temperature as determined from cooling tower

and chiller performance data,

● Use two-speed or variable-speed drives for cooling tower fan control,

● Turn off unnecessary cooling tower fans when loads are reduced,

● Balance flow to cooling tower hot water basin,

● Periodically clean plugged cooling tower water distribution nozzles,

● Install new nozzles to obtain a more-uniform water pattern,

● Optimize cooling tower fan blade angle on a seasonal and/or load basis,

● Correct excessive and/or uneven fan blade tip clearance and poor fan

balance,

● Divert clean air-conditioned building exhaust to the cooling tower during hot

weather,

● Re-line leaking cooling tower cold water basins,

● Check water overflow pipes for proper operating level.

● Optimize chemical use,

● Consider side stream water treatment,



● Restrict flows through large loads to design values,

● Shut off loads that are not in service,

● Take blow down water from the return water header,

● Optimize blow down flow rate,

● Automate blow down to minimize it,

● Install interlocks to prevent fan operation when there is no water flow,

● Establish a cooling tower efficiency-maintenance program. Start with an energy

audit and follow-up, then make a cooling tower efficiency-maintenance

program.

Lighting ● Reduce excessive illumination levels to standard levels using switching,

delamping, etc,

● Aggressively control lighting with clock timers, delay timers, photocells, and/or

occupancy sensors,

● Install efficient alternatives to incandescent lighting, mercury vapor lighting,

etc,

● Select lamps carefully with high power factor and long-term efficiency in mind,

● Upgrade obsolete fluorescent systems to Compact fluorescents,

● Consider day lighting, skylights, etc,

● Consider painting the walls a lighter color and using less lighting fixtures or

lower wattages,

● Use task lighting and reduce background illumination,

● Re-evaluate exterior lighting strategy, type, and control. Control it aggressively,

● Change exit signs from incandescent to LED.

DG Sets ● Optimize loading,

● Use waste heat to generate steam/hot water /power an absorption chiller or

preheat process or utility feeds,

● Use jacket and head cooling water for process needs,

● Clean air filters regularly.



Miscellaneous ● Meter any unmetered utilities. Know what is normal efficient use. Track down

causes of deviations,

● Shut down spare, idling, or unneeded equipment,

● Make sure that all of the utilities to redundant areas are turned off - including

utilities like compressed air and cooling water.

10.6.9 Natural Resource Conservation

At the UPL plant, natural resource conservation measures are/will be adopted in

the following ways:

● Energy conservation measures will be adopted to save the energy and avoid

wastage of energy under the policy of "energy saved is energy produced,"

● Heat from boiler stack flue gases is utilized for heating water through Heat

Recovery Units,

● Solvents are recovered above 95%.

● Use drip irrigation and sprinkling irrigation to improve irrigation efficiency and

reduce evaporation,

● Rain water harvesting system will be adopted to use rain water.

10.6.10 “Best Manufacturing practice” and “Safe Practice” for Handling Storage, Transportation and Unloading of Hazardous Chemicals The “best manufacturing practice” and “Safe Practice” for handling storage,

transportation and unloading of the hazardous chemicals, to be adopted at the

existing UPL plant after expansion are as given below:

10.6.10.1 Best Manufacturing Practices

The best manufacturing practice guidelines provide guidance for manufacturing,

testing, and quality assurance in order to ensure that desired quality of product

has been produced maintaining occupational health and safety. The best

manufacturing practices for existing UPL plant after expansion are as given below:



● The plant is/will maintain a clean and safety manufacturing area.

● Safe working conditions is/will be maintained in order to prevent minimize risk

and safety.

● Manufacturing processes is/will be clearly defined and controlled. All processes

is/will be validated to ensure consistency and compliance with specifications.

● Manufacturing processes is/will be controlled, and any changes to the process

is/will be evaluated.

● Instructions and procedures is/will be written in clear and unambiguous

language.

● Operators is/will be trained to carry out and document procedures.

● Records is/will be made, manually or by instruments, during manufacturing

that the demonstrated steps required by the defined procedures and

instructions are in fact taken and that the quantity and quality of the product

was as expected. Deviations is/will be investigated and documented.

● Records of manufacture that enable the complete history of a batch to be

traced are retained in a comprehensible and accessible form.

10.6.10.2 Safe Practices

At the UPL plant after expansion, safety practices is/will be followed to minimize

risk and same have been discussed in Chapter 7 in details and summarized below:

● A written process safety information document is/will be compiled for general

use. The document compilation is/will include an assessment of the hazards

presented toxicity/flammable information, Permissible exposure limits, physical

hazard data, thermal and chemical stability data, reactivity data, corrosively

data and information on process and mechanical design.

● The process design information in the process safety information compilation

is/will include P&IDs/PFDs; process chemistry; maximum intended inventory;

upper and lower limits, pressures, flows and compositions and process design

and energy balances.

● Personnel engaged in handling of hazardous chemicals is/will be trained to

respond in an unlikely event of emergencies.

● Safety measures in the form of DO’s and Don’ts is/will be displayed at strategic

locations especially in Marathi and English language.



● The plant is/will check and ensure that all instruments provided in the plant are

in good condition and documented.

● Safe work practices is/will be developed to provide for the control of hazards

during operation and maintenance.

● Personnel especially contractor workers at the plant is/will be made aware

about the hazardous substances stored at the plant and risk associated with

them.

● Predictive and preventive maintenance schedule is/will be prepared for new

equipment, piping, pumps, etc. and thickness survey is/will be done periodically

as per standard practices.

● Safety communication/motivation/promotion is/will be implemented.

● Safety education and training is/will be imparted to the workers available at

the plant area.

● Necessary first aid facilities is/will be provided at the plant at strategic locations.

● Occupational Health Centre is/will be established at the plant. Antidotes for all

hazardous chemicals is/will be available at occupational health center at the

plant.

● Workers engaged in handling of hazardous chemicals will be made aware of

properties of hazardous chemicals.

● In the plant, precaution and instructions is/will be displayed at strategic

locations in Marathi and English Languages.

● Adequate ventilation is/will be provided in the work floor environment.

● The work environment is/will be assessed and monitored regularly as local

ventilation is most effective method for controlling dust and gaseous emissions

at work floor.

● Safe operating procedures is/will be available for mostly all hazardous

materials, operations and equipment.

● The workers is/will be informed of consequences of failure to observe the safe

operating procedures.

● Work permit system is/will be followed at the plant.

● Records for near-miss, incidents and accidents is/will be maintained and

analyzed to take precautionary measures. There is no reportable accident in

past years at the plant.



● At the plant, safety audit is/will be carried out by the Audit team comprising of

safety professional, technical services, maintenance and process personnel.

● Necessary fire protection facilities is/will be provided at the plant after

expansion.

● Adequate numbers of fire extinguishers is/will be provided in production area.

● Easy availability of fire extinguishers and trained personnel is/will be insured to

operate extinguishers.

● All equipment and storage tanks/containers of flammable chemicals is/will be

bounded and earthed properly.

● The workers is/will be made aware about the hazards associated with manual

material handling.

● Communication system including public address system is/will be provided.

● The system is/will be initiated for checklist based routine safety inspection and

internal audit of the plant. Safety inspection team is/will be formed from various

disciplines and departments.

● Predictive and preventive maintenance schedule is/will be followed in religious

manner.

● Colour coding for piping and utility lines is/will be followed in accordance with

IS: 2379:1990.

● Before entering the tankers and trucks engaged in the transportation of

hazardous materials to the plant, Registration certificate for transportation of

hazardous materials, driving license to drive vehicles carrying hazardous

materials, fitness certificate, valid National permit, TREM Card, Insurance

papers, is/will be checked before allowing to enter the plant premises:

● Electrical Hazardous and safety is/will be properly managed at the proposed

plant.

● Electrical earth pits is/will be cleaned, covered and maintained in good

condition.

10.7 Green Belt Development

UPL Ltd. (Unit# 10) has already developed total approximately 1240 sq m of green

belt within the factory premises by planting about 300 trees. UPL has also planted

250 trees opposite to the site by adopting a crematorium (approximately land



area of 1000 sq. m). It is proposed to create additional green belt of 5865.96 sqm

area within 5 kms from the plant site.

Tree plantation for green belt is known for improving the aesthetic and

climatological environment of an area and properly designed green belt can help

in ameliorating air pollution to a very significant degree. Green belt works most

effective as a sink for particulate matter and gaseous emissions from ground level

sources, such as, fugitive emissions. Effectiveness of green belt for the elevated

sources is rather limited but its action as a green lung greatly helps in improving

the air quality of the area.

Green belt also helps in attenuating sound level as it acts as a barrier for sound

propagation. Plants native to an area are generally suggested to suit the prevailing

ecosystem and biogeochemical cycling. Native plants are more tolerant to disease

and result in better attenuation of pollutants. Green belts also provide habitat and

food for birds, small mammals and reptiles.

10.7.1 Design and Development of Green Belt

Green belt development planning for the proposed expansion of UPL plant has to

be done with the ecological perspective of the immediate surrounding

environment taking into consideration nature of pollutants, availability of space

and prominent wind directions. The green belt plantation details for the UPL plant

are as given below:

● Total green belt area is 5866 sq. m (0.58 ha)

● Considering 1500 trees per hectare, 870 plants will be planted in P x P distance

2.5m and R x R distance 3.0m.

● Plantation cost will be about Rs. 4.35 Lakh for 870 number of plants.

10.7.2 Guidelines & Technique for Green Belt Development

The structure & composition of vegetation in the study area as observed during

the baseline study, edaphic characteristics in the study area & CPCB guideline



(PROBES/75/1999-2000) for development of green belt are the basis for selection

of plant species for the UPL plant along with the following considerations:

● Local/native fast growing preferably non-fruiting trees & shrubs should be used

for plantation

● Plants should have preferably large leaf area



10.7.3 Species for Plantation of Green Belt Development

The details of the suggested plant species for green belt at the UPL plant are given

in Table 10.1. Green belt development plan for the UPL plant is shown in Figure

10.2.

Table 10.1: Suggested Species for Plantation within Plant Premises

Sr.

No.

Scientific Name Family Common

Name

Habitat

1. Terminalia bellirica Combretaceae Behda Tree

2. Terminalia chebula Combretaceae Hirda Tree

3. Syzygium cumini Myrtaceae Jambhul Tree

4. Garuga pinnata Burseraceae Kakad Tree

5. Ficus exasperate Moraceae Kharoti Shrub

6. Schleichera oleosa Sapindaceae Kusum Tree

7. Erythrina suberosa Fabaceae Pangara Tree

8. Carallia brachiate Rhizophoraceae Phanashi Tree

9. Albizia procera Fabaceae Pithungri Tree

10. Mangifera indica Anacardiaceae Amba Tree

11. Butea monosperma Fabaceae Palas Tree

12. Bauhinia racemosa Fabaceae Apta Tree

13. Azadirachta indica Meliaceae Neem Tree

14. Ficus racemose Moraceae Umbar Tree

15. Tamarindus indica Fabaceae Chinch Tree

16. Aegle marmelos Rutaceae Bel Tree

17. Polyalthia Longifolia Annonaceae False Asoka Tree

18. Grevillea robusta Proteaceae Silver oak Tree

19. Callistemon lanceolatus Myrtaceae Bottle brush Trees

10.8 Occupational Health & Safety after Expansion

10.8.1 Details of Occupational Health Program Various types of hazardous chemicals is/will be stored and handled at the UPL

plant after expansion for manufacturing of different types of pesticides. The



workers at the plant after expansion is/will be exposed directly or indirectly by

these chemicals. Necessary mitigation measures is/will be adopted to handle and

storage of hazardous chemicals within Threshold Limit Values (TLV)/ Permissible

Exposure Levels as per ACGIH (American Conference of Governmental Industrial

Hygienists) recommendations. The risk mitigation measures is/will be taken to

keep these chemicals within PEL/TLV.

The workers is/will be examined concerning their exposure to hazardous chemicals

during pre-placement and periodical medical monitoring annually. Liver Function

Tests (LFT) during pre-placement and periodical examination annually is/will be

carried.



Figure 10.2: Green Belt Development Plan



10.8.2 Occupational Health Surveillance Programme

Workers can be directly or indirectly exposed by hazardous chemicals during the

charging process or materials handling. UPL is/will take necessary measures to

keep hazardous chemicals exposures within the Permissible Exposure Limit (PEL)/

Threshold Limit Value (TLV). The following measures is/will be taken to maintain

Occupational Health & and safety at the plant after expansion:

● Process is/will be carried out in closed circuit system.

● Dilution ventilation/local exhaust ventilation system is/will be provided.

● Hazardous chemicals is/will be handled by trained person only following SOPs.

● MSDS of hazardous substances is/will be maintained and displayed as strategic

locations.

● Eyes and body wash system is/will be provided at required locations.

● Labeling and sign board is/will be provided accordingly.

● PPE is/will be provided and used during handling of hazardous chemicals.

● Evaluation of Exposure of Chemical is/will be carried out during pre-placement

and periodical medical monitoring

● Emergency /exposure examination and test is/will be carried out. Examination

is/will be based on irritation, sensitization of skin, respiratory system, eye,

shortness of breath.

● Test is/will be carried out as per handling of chemicals as per OSHA guideline.

Previous medical opinion of workers/employees as well as history is/will be checked.

The Occupational Health Surveillance Programme for the plant has been prepared,

which is/will be followed after expansion of the existing UPL plant. The objective

of Occupational Health Surveillance Programme is as given below:

● Workplace injuries, illness can be prevented and hazard should be identified.

● Evaluation of accident analysis due to unsafe acts and condition as well as

identified the health and safety problems in workplace.

● Effective Preventive measures strategies can be prepared.



● New technologies, educational activities, public awareness and regulatory and

policy changes can be achieved.

The overall mission of the Occupational Health Surveillance Program is to promote

the health, safety and quality of life of working people is/will be achieved. The

surveillance program can be improved by following action:

● Pre-placement examination and periodic examination is/will be carried out at

workplace.

● Emergency/exposure examination and test is/will be carried out. Examination

is based on irritation, sensitization of skin, respiratory system, eye, shortness

of breath.

● Maintain the work profile and medical history of employee/workers.

● Pulmonary function test is/will be carried out in case handling of formaldehyde.

● Written medical opinion to worker is/will be maintained.

● Health examination is/will be certified by qualified medical practitioners

10.8.2.1 Liver Function Tests (LFT) during Pre-placement and Periodical

Examination The liver function test (LFT) is blood test that gives an indication of whether the

liver is functioning properly. The test is also very useful to see if there is active

damage in the liver (hepatitis) or sluggish bile flow (Cholestasis). It is also

important to remember that diagnosis of liver disease depends on the combination

of patient history, occupational exposures, physical examination, laboratory

testing, biopsy and sometimes imaging studies such as ultrasound scans, and etc.

There are so many tests covered in LFT. They are as below with their normal values: AST (Aspartate Aminotransferase) : 5-40 iu/l

ALT (alaninie aminotransferase) : 5-35 iu/l

ALP (alkaline phosphatase) : 30-85 MILi/ml

GGT (gamma-glutamyl transpepdiase) : 5-27 u/l

Total Serum Protein : 6-8g/dl

Albumin : 3.2-4.5g/dl



Total Serum Bilirubin : 0.1-1.0mg/dl

Indirect Bilirubin : 0.2-0.8 mg/dl

Direct Bilirubin : 0.1-0.3 mg/dl

Urine Bilirubin : Negative

Interpretation and follow up of the test is varying with clinical context and results.

If there are minor abnormalities in the test, the repetition of the test may conduct

after 1 week of test result. If test values are within the range, the repetition of the

test may conduct after the one year of the test result. If there are chronic

abnormalities seen in the results, the repetition of the test may conduct twice in a

week and also consult with the doctors.

10.8.2.2 Pre-employment Medical Examination

For company employees as well as contract based workers following medical

examination is/will be carried out:

● Physical Examination.

● Hematology Profile - Complete Blood Count with Differential Count, E S R &

Blood Group & Rh factor.

● Liver Profile - S C G O T, S G P T & Serum Bilirubin.

● Kidney Profile - Blood, Urea, Uric Acid & Creatinine.

● Lipid Profile - Cholesterol, Trigycerides, HDL - Cholesterol – VLDL

Cholesterol, LDL Cholesterol, Cholesterol - HDL Cholesterol Ratio (Risk

Factor).

● Infectious Disease Profile - ELISA, HbsAG (Australia Antigen), V D R L.

● General Tests - Routine Urine & Stool Examination

● X - Ray Chest - P A View

● E C G Signed by Cardiologist

● Blood Sugar

● Sonography

Annual Medical Examination

● History & Physical Examination

● Complete Blood Count



● Vision Test – Far, Near & Colour

● Audiometric Test – Air Conduction

● Computerized Electrocardiography

● Computerized Lung Function Test

● Lipid Profile (Cholesterol, HDL Cholesterol, LDL Cholesterol, Triglycerides)

● Liver Function tests (SGPT)

● Kidney Function Test (BUN, Creatinine)

● Thyroid Stimulating Hormone (TSH)

● Digital Retinoscopy (Diabetes, Hypertension, Glaucoma, Age related

● Macular degeneration, Retinitis pigmentosa.)

● More Liver Function tests (Bilirubin, Alkaline phosphatase, Proteins, GGTP)

● S. Calcium (Bone test)

● S Uric acid (test for joints)

● Anaemia Profile (Total Iron, TIBC, % Transferrin saturation

● BCA Test

Annual health report for the Unit #10, UPL plant is given in Annexure VIII.

10.9 Rain Water Harvesting

The rainfall received in the area around the UPL Plant per annum is 1955 mm (as

per CGWB) and rainwater is calculated based on average rain fall on available roof

top area. Rain water harvesting details for roof top is given in Table 10.2.

Table 10.2: Rain Water Harvesting Details

Sr.

No. Details

Area

(Sq.m)

Rainfall

(mm)

Runoff

Coefficient

Average Rain

Water

Collection

(m3/year)

1. Rooftop

(ground coverage) 8138.52 1955 0.95 15115.27

Total 15115.27

@70% effective capture 10580.68



Calculations of Rainwater Pits

Considering a rainwater pit having size length 10m, breadth 10m, depth 10m.

Volume of the Pit = 10X10X10 = 1000 m3

Assume the Retention time for filling of one pit = 15 mins

Volume of the Rainwater available= 10580.68/4 m3 = 2645 m3

Number of Rainwater pits required= 2645/1000= 3 pits.

Therefore, 22 Number of pits will be required to cater the maximum rainwater

available and its further treatment & usage.

The maximum water that can be received on the plant surface during rainfall will

not more than 70% i.e. 10580.68 m3/year from total 15115.27 m3/year.

10.10 Odour Control Action Plan

At the plant, some of the hazardous chemicals / solvents are odorous and may

create odour. Therefore, well-planned odour control system to reduce the odour

is already available at the plant. Odour control action plan comprise the following

measures:

● All odorous / toxic chemicals are handled in bulk through close piping. Handling

of such chemicals in carboys is not allowed.

● Vent condensers have been provided on the solvent and odorous chemical

storages tanks.

● Pumps with mechanical seal for odorous chemicals or usage of seal-less pumps

for solvents have been implemented.

● Certain chemicals like Ethyl Mercaptan, are maintained at low temperature, to

reduce emissions

● Usage of scrubbers or carbon adsorption system to take of emissions from

storage tanks

● Usage of closed sampling system to avoid odour problem



The source of odour at the plant and its control measure is given below in Table

10.3.

Table 10.3: Main Odorous compounds, Properties, Exposure, Type of

Odour and Its Health Impact

Compound Properties Exposure &

Odour

Health impact

Ammonia (NH3) Colorless, stable

at Room temp

TWA-50ppm,

Ammonia can

strong, high

corrosive in

presence of Cu

and its alloys

Exposure can

cause Coughing,

chest pains

Difficulty in

breathing

Chlorine (Cl2) Greenish Yellow

gas, Extremely

reactive

TLV-0.5 ppm,

pungent

suffocating bleach

like odour

Can cause itching

and burning of the

Eyes, nose, throat

Hydrogen

Sulphide (H2S)

Colorless gas,

stable, highly

Inflammable

TWA-10 ppm,

smell, of Rotten

eggs

High toxic may be

fatal if inhaled.

Skin Contact may

cause burns

Ethyl Mercaptan Colorless gas,

stable under

normal storage

condition

Odour threshold is

0.001 ppm

Highly toxic,

affects central

nervous System

Sulphur Dioxide

(SO2)

Colorless gas,

stable,

incompatible

with strong

reducing or

oxidizing

agents,

TWA 2ppm,

irritating pungent

odor

Can cause fatal



Compound Properties Exposure &

Odour

Health impact

Tri Methyl

Phosphite (TMP)

Colourless Liquid

with a

Characteristic

Pungent Order

TLV-TWA: 10 mg/m3 (2ppm), Odour

Threshold: 0.0001 ppm (ACGIH)

Skin Eyes and

Mucous Membrane

irritants

Di Methyl

Sulphate (DMS)

Colorless oily

liquid, odorless

to a faint onion-

like odor

Odour Threshold not established as per

USEPA, IDLH: 7ppm (NIOSH),

Extremely toxic

vapors and liquid -

- a few whiffs or

contact on skin

could be fatal.

Source: Materials Safety Data Sheets (MSDS) and “A Comprehensive Guide to the

Hazardous Properties of Chemical Substances by Pradyot Patnaik (A John Wiley &

Sons, Inc Publication, 2007)

Odor control action plan implemented at the existing plant are given in Table

10.4.

Table 10.4: Odor Control Action Plan Implemented at Existing Plant

Sr.

No.

Source Action Plan

1) Provided process scrubber as per

process emission requirement.

Closed handling system for

various chemicals and products.

2) Use of ISO tankers for Hazardous

Chemicals and Closed transfer

system.

Usage of seal less pumps for

transferring of toxic/hazardous

chemicals

3) Mechanical seals for certain reactors

to prevent leakage of hazardous

chemicals

Regular inspection and

Preventive maintenance of

pumps, valves, pipes etc., as per

maintenance software (SAP).

4) Online sensors for Hazardous

Chemicals like Cl2, Bromine, Methyl

Bromide etc.

Vent of certain plants connected

to common condenser &

scrubber



Odour generating operations and proposed control measures for proposed

expansion of UPL’s existing plant are given Table 10.5.

Table 10.5: Odour Generating Operations and Activities

after Proposed Expansion of Existing Plant

Sr.

No. Probable sources Proposed Control measures

1) Pumps handling odorous

chemicals and pressurized

gases, especially H2S

● Use of mechanical seals in pumps

or seal less pumps and

compressors, and seal less pump

if feasible

● Proper maintenance of pipelines

and pipe-fittings

● Online sensors for Hazardous

Chemicals like Cl2, Bromine,

Methyl Bromide, H2S etc.

2) At reactors during charging of

liquid chemicals and solid

chemicals as well as during

process reactions and process

operations

● Provide dedicated measuring tank

for each reactor

● Closed loop pumping of Liquid

raw materials

● Process scrubber as per process

emission requirement.

3) Pressure Relief Valve

Emissions from pipelines

● To be connected to APCD in case

of toxic gases

4) Release from Sampling Lines ● Using a closed loop sampling

system.

5) Emissions from Bulk Storage

Tanks during storage, loading

and unloading

● ISO tankers for Hazardous

Chemicals and Closed transfer

system.

● Provided breather valves, PSVs,

rupture discs & Install vapor

recovery systems.



Sr.

No. Probable sources Proposed Control measures

6) Leaks from Valves, Flanges,

plugs and instrument

connections

● Use Welded

pipes

wherever

feasible

● Suitable

gasket

material to be

used

● Suitable gland

packing to be

used in valves

● Regular

inspection and

Preventive

maintenance

7) Chemical vapor from wet cake

in filtration and drying area

● Adopt covered transfer systems

and fume extraction systems

wherever required

● Provide PPE to workers

8) storing drums and bags in

warehouse

● Local exhausts and roof top

ventilators

● Prevent spillage by providing drip

pans, proper handling equipment,

min. manual operations

9) Open effluent collection drains

and conc. effluent storage

open tanks

● Effluent drains shall be covered

with minimum inspection covers

● Concentrated effluent shall be

stored in closed tanks wherever

possible

10.11 Enterprise Social Commitment (ESC) Programme

At UPL, Enterprise Social Commitment (ESC) programmes have been in practice

since decades. The goal of ESC is to be responsible for social activities and

encourage a positive impact through these activities on the environment,

consumers, employees, communities, stakeholders and all other related spheres.

M/s. UPL Ltd is committed towards Social Responsibilities, and it’s a pleasure to

involve in such efforts and budget will be planned for 2.5% of the total profit of



the project. (Proposed capital investment @227.06 Crores, Budget for ESC/CSR

@ 5.76 Crores)

UPL Ltd. is continuously involved in various Socio-economic welfare programmes

since 1969 with the inception of its manufacturing operations at Vapi, Gujarat

which indicates an active Enterprise Social Commitment (ESC) over the last five

decades. The group has central ESC team for planning and execution of ESC

activities.

Five Year ESC Planning

Proposed expansion capital investment will be Rs 227.06 Crores. UPL will spent

2.5 % of total capital investment (@5.76 Crores) for Enterprise Social

Commitment. All ESC projects at Tarapur will be undertaken in six key focus areas

and will be implemented according to company’s ESC policy. Further, a deep need

analysis study will be conducted to clinically understand the need of society, to

estimate their causes and to make action plan for addressing those needs. The

summary of five years Annual budget for ESC is given in Table 10.6.

Six Key focus areas of UPL’s ESC:

1) Agriculture Development

2) Health & Sanitation

3) Environment & Nature Conservation

4) Education & Empowerment

5) Employability & Entrepreneurship

6) National & Local Area needs

Table 10.6: Summary Five-Year Annual Budget

Sr. No.

Key Focus Areas ESC Project Budget (Rs)

1 Agriculture Development UPL KhedutPragati @ Tarapur 67,42,381.00

2 Health & Sanitation UPL School Sanitation 1,75,97,615.00

3 Environment & Nature Conservation

UPL Social Forestry 1,70,58,224.00

4 Education & Empowerment 67,42,381.00



5 National & Local Area needs As per need assessment 94,39,334.00

Total 5,75,79,935.00 Source: UPL Limited

Details of five years budget for Enterprise Social Commitment (ESC) programme

of UPL Tarapur is given in Table 10.7.

1. Agriculture Development (UPL KhedutPragati) UPL KhedutPragati Program is an Agriculture Development initiative implemented

by the ESC department of UPL limited. This programme is mainly focused on

agriculture development because agriculture is the backbone of rural India. More

than 70% of the total population is dependent directly or indirectly on agriculture

for its subsistence. Considering the situation surrounding Tarapur villages, multiple

agriculture projects will be carried out under the umbrella of “UPL KhedutPragati”

Goal “To enhance food security and

improve the socio-economic

conditions of small holders and

marginal farmers by providing

sustainable agricultural

solutions in a period of 5 years”

Objectives: ✓ To increase the knowledge of farmers by training and awareness campaign

✓ To improve the agriculture productivity by introducing best package of

practices in agriculture

✓ To enhance the water use efficiency by providing innovative irrigation practices

(Drip/Sprinkler/lift irrigation etc)

Strategy:

Regular Capacity

Building

Providing Improved agriculture Practices

Agriculture

Mechanisation Farmers

Organisation

Market Linkage



UPL Khedut Pragati will be based on making the agriculture more sustainable and

profitable venture for the farmers through increasing the yield of agriculture

produce, reducing the cost of cultivation and better management of natural

resources. The strategy which was adopted to execute is detailed below:

2. Health and Sanitation

UPL will work on its School Sanitation Programme by making toilet blocks in

surrounding schools. When we work on sanitation programme the Building toilets

is only the beginning and possibly the easiest part. To make it sustainable

sanitation programme we will also work on 5 major issues:

a) A toilet has no meaning without availability of water – Even though it would

add first to the overall initial investment. We will ensure water facility is

connected to school toilet complex.

b) The second important issue is changing hygiene habits of kids going to school.

Merely providing a toilet in school might not work when the kid is used to

answering nature's call in the open fields. Even teachers have that habit. We

will work on behavioral aspect.

c) The third issue is maintaining the toilets, keeping the soak pits clean for

instance so that it doesn’t becomes breeding ground for germs and diseases.

This can be done by having a token fee of Rs 1 per month, which goes in

funding the maintenance. This is important because after the initial thrust

School toilet has to be self-sustaining and not supported only through external

financial aid.

d) The fourth issue with school toilets is about ownership. How to make the

students responsible for the process? The idea is to make teacher and student

owner of school toilet. We will have something like a cabinet, with say one of

the students appointed as health minister who would be responsible with his

school mates to run the show.

e) The fifth and final is designing the toilets of the future. For instance, having a

biogas unit (technologies to convert sludge-to-energy, having horticulture to

use water, working in new toilet technologies like new pit latrines, septic tank

emptying technologies etc.



3. Vasudha Programme (Environment & Nature Conservation) The strategy envisaged for Nature Conservation is called as UPL Vasudha

Programme. Vasudha in Sanskrit means the Mother Earth, the giver of wealth. The

UPL Vasudha Programme is aiming for integrated nature conservation project

involving all stakeholders.

UPL Social Forestry - To enhance the biodiversity

by increasing the forest cover which will give

sustainable livelihood opportunity to local

community”.

Eco Club Project - This is an initiative to make the

young generation aware about the importance of

protecting nature and maintaining ecological balance.

These clubs are formed in schools and students

participate in environment related activities through these clubs.

4. Education & Empowerment UPL will go for School Development Programme and will have provision for

infrastructure support to government school to enhance the access and to provide

enabling condition for quality education.

Up-gradation of School ✓ Providing class rooms with furniture, library, Integrated Laboratory, Computer

room, Head Art and Craft room, Toilet Blocks, Drinking water etc.

✓ Strengthening of existing schools through construction of additional

classrooms, Laboratories, Library, computer room, separate toilets for girls

and boys, resource room for Science, etc,

✓ Vocational Education related workshops

✓ Major repair for school building



This will be a need based initiative and as per availability of funds 5. Local Area Need Being a responsible corporate citizen, UPL always respond to address the local

area need by undertaking development initiative to help our community grow. We

do all need based activity for community around our factory sites.

UPL focus areas will include: ✓ Response to Natural Disaster

✓ Suraksha Abhiyan (Road safety, Girl Safety and Industrial Safety)

✓ Support of Non-Financial Aid

✓ Any other Development Activity

The proposed expansion project of existing UPL plant will provide direct

employment to the people of the area and thousands will get business opportunity

to feed the demand of project and the people working for the project. Small market

will be developed to feed daily demand of the people working for the proposed

project. There is a provision of separate allocation of fund under ESC and 2.5 %

of the total profit gain due to proposed project and same will be invested for the

infrastructure development of the local people of the area. People will get medical,

education and business opportunities. UPL will make need based survey in the

area under supervision of local panchayat and district administration. The needy

person will be supported as per requirement. This will improve infrastructure and

economic status of the people living in the area. Other project proponent will take

advantage of developed infrastructure of the area to set up industry which will

further improve infrastructure and economy of the area.



Table 10.7: Five Year Budget for Enterprise Social Commitment (ESC)

Sr.

No.

Focus Area Project Particulars Year 1 Year 2 Year 3 Year 4 Year 5 Total

1 Agriculture

Development

UPL

KhedutPragati

@ Tarapur

Training &

Capacity

Building

1,000,000 1,150,000 1,322,500 1,520,875 1,749,006 6,742,381

Technological

support

(Irrigation,

Farm

Mechanization)

Input Support

(Seed,

Fertilizers etc)

2 Health and

Sanitation

UPL School

Sanitation

Building Toilet

blocks

2,500,000 2,875,000 3,306,250 3,802,188 4,372,516 16,855,953

Awareness

Programme

110,000 126,500 145,475 167,296 192,391 741,662

3 Environment

& Nature

Conservation

UPL Social

Forestry

Tree

Plantation

2,500,000 2,875,000 3,306,250 3,802,188 4,372,516 16,855,953



UPL Eco Club School garden

& Environment

awareness

30,000 34,500 39,675 45,626 52,470 202,271

4 Education &

Empowerment

Infrastructure

& quality

education

support in

surrounding

schools

1,000,000 1,150,000 1,322,500 1,520,875 1,749,006 6,742,381

5 National &

Local Area

Needs

As per Need

Assessment

1,400,000 1,610,000 1,851,500 2,129,225 2,448,609 9,439,334

Total 8,540,000 9,821,000 11,294,150 12,988,273 14,936,513 57,579,936

Source: UPL Limited



10.12 Compliance to Corporate Responsibility for Environmental Protection (CREP) Guidelines Details of compliance to Corporate Responsibility for Environmental Protection

(CREP) Guidelines by UPL are discussed below:

10.12.1 Segregation of Waste Streams and Treatment

● UPL has implemented segregation of plant/process specific waste streams at

the existing plant and same will be applied to after expansion for additional

wastes streams also.

● UPL has segregation system for inorganic effluent, organic biodegradables

effluent, high TDS effluent, toxic effluent, etc.

● After the expansion of the existing plant high TDS effluents from manufacturing

of Metribuzin, Ammonium Chloride, Triazinone, Glyphosate, Clomazone,

Sulfosulfuron and Devrinol will be sent in multiple-effect evaporator (MEE), and

salt generated will be disposed off to CHWTSDF for landfilling.

● Low COD streams generated from Boiler, Cooling Tower, Metribuzin Plant,

Sewage effluent etc. are treated in ETP and then sent to CETP of Tarapur.

● Effluent generated at the plant are treated in ETP comprising primary,

secondary and tertiary treatment

● High TDS & low COD effluent are evaporated in Multi Effect Evaporator (MEE)

● Toxic & organic COD wastes are sent to Common Incinerator at CHWTSDF.

10.12.2 Treatment of High COD and Toxic Wastes Streams

Generated high COD and Toxic streams (Aqueous/Organic) is/will be sent to

CHWTSDF at Taloja for Incineration.

10.12.3 Improvement in Solvent Recovery

Solvents are recovered at every possible level and recovery above 95% is achieved

through efficient recovery systems at the plant.



10.12.4 Air Emission Pollutant Control

Air emission pollutants like HCl, H2S, NH3, HC, HBr, Cl2 and MeCl from process

emissions from manufacturing of Asulam, Tri Phenyl Phosphate (TPPA),

Ammonium Chloride, Triazinone, Acephate, Glyphosate, Metribuzin (Common Plant

Scrubber), Ammonium Sulphate, Phosphorus Acid Solid & Solution and Di-Chlorvos

(DDVP) will be removed using efficient scrubber systems and the performance of

these scrubbers will be monitored regularly internally and through external party.

10.12.5 Control of Fugitive Emissions / VOCs From the existing UPL plant and after expansion, fugitive emissions may be

generated from handling of solvents and other hazardous chemicals. Fugitive

emissions may also be generated from leak of hazardous materials during transfer

through piping from tanker to storage tanks. Some fugitive emissions may be

generated during charging of raw materials in the reactors and minor leakage from

pumps, flanges, etc.

The following measures as implemented at existing plant, will be adopted for

control of fugitive emissions after expansion also:

● For fugitive emission control, seal less pumps are used for transfer of toxic

chemicals

● In critical reactors, mechanical seals are also provided.

● Closed sampling system is also implemented.

● Suitable chilling system is provided to secondary condenser for VOC emission

control.

● Regular inspection is carried out with reference to pumps, valves, pipes etc.,

as per the maintenance software – SAP – preventive maintenance of the plant.

● Dust masks are provided to working personnel,

● All production activities are carried out in closed conditions to minimize

possibility of fugitive emission,

● Use of closed circuit system for all the process operations,



● The plant set-up is a MS structure with shed, which can provide sufficient

ventilation to reduce work exposure,

● Regular predictive and preventive maintenance are carried for piping and

pumps to eliminate risk of leak and subsequently fugitive emissions,

● The fugitive emissions from hazardous chemicals are controlled by proper

storage and handling method preferably equipped with leak proof pipes,

● Supervision is done at time of transfer of hazardous materials from tankers and

any kind of spill, leak is prevented by immediate actions,

● Work place monitoring at storage area as well as production area is conducted

and necessary actions for keeping risk free workplace environment are taken

on regular basis,

● Necessary PPEs like face mask as well as emergency facility are provided at

storage area of hazardous chemicals.

10.12.6 Bio Assay Test and Toxicity Factor

UPL is conducting Bio Assay & Toxicity Factor (Tf) test and will continue after

expansion.

10.12.7 Incineration of Hazardous Wastes

Incinerable wastes generated at the UPL plant is sent to common incinerator of

Mumbai Waste Management Limited (MWML) at Taloja. Same practice will

continue after proposed expansion of the existing plant.

10.12.8 Long Term Strategies for Reduction in Wastes The following waste minimization measures are already undertaken in existing

plant of UPL. Same will be applied after expansion also.

● Use of automated filling to minimize spillage,

● Metering and control of quantities of active ingredients to minimize waste,

● Use of close feed system to the reactors,

● Use of automated filling to minimize spillage,

● Adoption of efficient solvent recovery system,



● Venting equipment through vapor recovery systems,

● Use of high pressure hoses for equipment cleaning to reduce water

consumption and wastewater generation.

● Waste converted in to valuable by-products.

● High calorific value waste will be sent for co-processing at cement industry.

● Heat recovery system in boiler by proving economizer.

● Recovery of by-products and sold to actual end-users.

● Raw material consumption reduction by improving product yield.

● Steam condensate recycling in to boiler.

● MEE condensate recycling in to process.

● Boiler ash (non-hazardous) will be sent to brick manufacturer or other end-

users.

10.13 Budgetary Provisions for EMP Implementation

For implementation of mitigation measures and environmental management plan,

capital cost and recurring expenditure will be involved. The budgetary estimates

for capital cost and recurring expenditure are given in Table 10.8.

Table 10.8: Budget for EMP Implementation

Sr.

No.

Component Particulars Capital

Investment

(Lakhs)

Recurring

Expenditure

per Annum

(Lakhs)

1. Air Dust Collectors/ bag

filters, Process

Vent/Stacks Scrubbers.

70 30.0

2. Water Low and high COD/TDS

stream to MEE. ETP

comprising of pre-

primary, primary,

secondary & tertiary

treatment, STP, etc.

790.45 70.0



Sr.

No.

Component Particulars Capital

Investment

(Lakhs)

Recurring

Expenditure

per Annum

(Lakhs)

3. Rain Water

Harvesting

Installation of RWH

System & Annual Cleaning

of RWH tank

20.0 3.00

4. Hazardous

Waste Area

and its

Management

Purchase of Additional

Containers for Storage of

Hazardous Waste

107.67 400

5. Occupational

Health &

Safety

Health medical checkup of

workers, PPEs for

Workers. Emergency

Preparedness, Fire

hydrant systems, fire

extinguishers, emergency

control room, OHC and

HAZOP study

1134.85 20

6. Environment

Monitoring &

Management

Environment Monitoring

as per monitoring plan

0.00 4.38

7. Enhancement

of Green Belt

Development and

maintenance of green belt

90 6.0

Total (Rs. in lakhs) 2212.97 533.38



Chapter 11

SUMMARY AND CONCLUSIONS

11.1 Introduction

UPL Limited, Unit#10 located at Plot No. E51/1, E51/2, and E-52, MIDC Notified

Industrial Estate, Tarapur, Boisar, District Palghar in Maharashtra state, is

engaged in manufacturing of various Technical Grade Pesticides, intermediates

chemicals and pesticide formulation products. The existing unit was established

and operated by M/s Punjab Chemicals & Crop Protection Limited and obtained

environmental clearance for expansion from Ministry of Environment, Forest

and Climate Change vide letter no F. No. J-11011/712/2007-IA II (I) dated 15

April 2008. The existing unit was taken over by UPL Limited on 14 March 2014.

UPL has planned to expand manufacturing capacities of existing Pesticides

Technical, intermediates, pesticide formulation products and manufacturing of

additional pesticide technical, pesticide intermediates and formulation products

namely, Acephate (Technical), Di Chlorvos (DDVP) (Technical), Glyphosate

(Technical), Clomazone (Technical), Sulfosulfuron (SF-10) (Technical),

Pyrazosulfuron Ethyl (Technical), Bensulfuron Ethyl (Technical), Metsulfuron

Methyl (Technical), Asulam (Technical), Azoxystrobin (Technical), Devrinol

(Technical) and Asulox (formulation). The Unit is presently manufacturing one

Pesticide Technical @ 1620 TPA, 06 (six) Pesticide Intermediate @1968 TPA,

02 (Two) inorganic chemicals @ 5100 TPA and 02 (two) Pesticide Formulation

products @2700 TPA. It is proposed to expand Pesticide Technical capacity

from 1620 TPA to 27120 TPA (11 new products and expansion of existing 1

product, total expansion @ 25500 TPA); Pesticide Specific Intermediate

capacity from 1968 TPA to 18900 TPA ( 2 new products and expansion of

existing 6 product, total expansion @ 16932 TPA); Inorganic chemical capacity

from 5100 TPA to 18000 TPA (1 new product and expansion of existing 1

product, total expansion @ 12900 TPA inclusive of 1 discontinued product i.e.

Potassium Chloride. EC is not applicable for inorganic chemicals), Pesticide

Formulation capacity from 2700 TPA to 15000 TPA (1 new product and

expansion of existing 1 product, total expansion @ 12300 TPA inclusive of 1

discontinued product i.e. Glyphosate 41 % SL Formulation. EC is not applicable

for Formulation products. Proposed expansion will be carried out within existing



premises of UPL Ltd. having 23,454 m2 (2.3454 hector) area and investing Rs.

227.06 Crores as capital cost for expansion project.

11.1.1 Terms of Reference for EIA Study

The proposal for the proposed project was considered by EAC Industry -2 in

18th meeting held on 23 January 2017. Subsequently, MoEF&CC issued ToR

vide letter no. J-11011/7/2017-IA.II (I) dated 29/04/2017. ToR amendment

proposal was considered in the 24th EAC meeting held on 16th June 2017, and

amended ToR with exemption of public hearing and waiving point of installation

of ZLD condition was issued by MoEF&CC on 23/10/2017.

11.2 Project description 11.2.1Existing and Proposed Production Capacity

The production capacities of existing and proposed products are given below:

Sr. No

Product Name

Existing Capacity (TPA)


(TPA)

Total Capacity

After Expansion (TPA)

CAS Numbe

r LC50 LD50

Category

As per EC Notificatio

n 2006



1


1620 4980 6600 21087-

64-9

Fish-96 hr

80 ppm

2000 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 6000 6000 30560-

19-1 2050 mg/l

1447 mg/kg

A-5(b) Pesticide

(Insecticide)

3


0 1200 1200 62-73-7

Fish (96 hr) 200 mg/l

Oral- 50 mg/kg

A-5(b)

Pesticide

(Insecticide)


0 1200 1200 1071-83-6

rat (4 h)

>4.98 mg/l

Rat-oral 5600 mg/kg

A-5(b)

Pesticide

(Herbicide)



Sr. No

Product Name



(TPA)

Total Capacity


CAS Numbe

r LC50 LD50

Category


n 2006


0 2400 2400 8177-89-1

96 h- fish- 34

mg/l

2077 mg/kg

A-5(b)

Pesticide

(Herbicide)

6


0 120 120 141776-

32-1

Fish (96 h) > 96

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

7


0 600 600 93697-74-6.

Fish (96 h) >180 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)

8

Bensulfuron Methyl

0 600 600

A-5(b)


83055-99-6

Fish (96 h) >150 mg/l

5000 mg/kg

Pesticide

(Herbicide)

9


0 600 600 74223-

64-6

Rat (4 h) 5 mg/l

5,000 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 4800 4800 3337-71-1

Fish (96 h) >5000 mg/l

>1200 mg/kg

A-5(b)

Pesticide

(Herbicide)


0 1800 1800 131860-

33-8

Rat- 0.96

mg/kg

5,000 mg/kg

A-5(b)

Pesticide

(Fungicide)

12 Devrinol (Technical) (proposed)

0 1200 1200 15299-

99-7

Rat (4 h) > 5 mg/l


A-5(b)

Pesticide

(Herbicide)

Total – A 1620 25500 27120


13


240 1560 1800 101-02-

0 Not

listed Rat- 1600

mg/kg A-5(b)



Sr. No

Product Name



(TPA)

Total Capacity


CAS Numbe

r LC50 LD50

Category


n 2006


0 7200 7200 21087-

64-0 Not

listed


A-5(b)

15


0 1800 1800 115-86-

6 Not

listed


A-5(b)

16


900 4200 5100 02-12-7719

50 ppm

18 mg/kg A-5(b)

17


600 600 1200 10025-

87-3 32pp

m 380 mg/kg A-5(b)

18

Phosphorous Acid Crystals (existing and proposed)

120 780 900 10294-

56-1 Not

listed Not listed A-5(b)

19


48 252 300 7664-38-2

Not listed

Rat – 2,550 mg/kg

A-5(b)

20


60 540 600 04-11-7758


Total- B 1968 16932 18900

Total (A+B) 3588 42432 46020



Sr. No

Product Name



(TPA)

Total Capacity


CAS Numbe

r LC50 LD50

Category


n 2006


1


3600 11400 15000 7783-20-2

NA 2840mg/k

g


0 3000 3000 12125-

02-9 NA

1650mg/kg

3


1500 -1500 0 7447-40-7

NA 2600mg/k

g

Total – C 5100 12900 18000


4


900 -900 0 -- -- --

5


1800 1200 3000 -- -- --


0 12000 12000 -- -- --

Total – D 2700 12300 15000

Total– C+D 7800 25200 33000


11388 67632 79020

* No Product is banned (as per CIB) from above table.



11.2.2 By Product List (Existing and After Expansion)

The details of by-products quantity from existing manufacturing processes and

after expansion of UPL plant are presented below:

Details of By-product quantity from Existing Manufacturing Process and After Expansion

Sr No By Product Name Existing quantity

(TPA)

Additional quantity

(TPA)

Total quantity

(TPA)


1 30% HCl 1200 21312 22512


2 30% NaSH 0 9360 9360



5 Methanol 0 1180.8 1180.8

6 Phenol 0 155.4 155.4


8 Ammonium Sulphate Solution (15%) 0 5683.2 5683.2

9 Acetic Acid (30%) 0 8496 8496

10 Acetic Acid (45%) 0 5664 5664

11 Acetic Acid (99%) 0 2574 2574

12 Sodium Acetate (27%) 0 12900 12900


14 NaBr 0 33000 33000

Total 1200 114964.2 116164.2

Source: UPL Limited

Applicable by-products will be considered in hazardous wastes and disposed as per Hazardous & Other Waste (Management & Trans-Boundary Movement) Rules 2016.

11.2.3 Utilities and Water Requirements

Existing power requirement is 1508 KW and additional after expansion will be

2824 KW. After expansion, total power requirement will be 4332 KW which will

be supplied by MSEB (Maharashtra State Electricity Board). There are existing



2 nos. of DG sets (capacity: 500 KVA and 250 KVA) are installed at present and

additional two DG Sets of 750 KVA capacity each will be installed to meet the

power requirement in the event of grid power failure. Existing Boiler @ 10 TPH

(coal @ 985 kg / hr, biomass / briquettes / rice husk @ 2460 kg / hr capacity

and one standby Boiler @ 4 TPH (FO @ 125 LPH) are installed. Additionally,

one boiler @ 10 TPH (Coal @ 2 TPH) is proposed. Imported Coal is/will be

sourced from Indonesia and FO, LDO and HSD is being and will be sourced

from local Supplier.

Total existing water requirement for industrial & domestic purpose is 166.56 KLD

& additional demand for proposed expansion is 538.5 KLD. Total water

requirement after expansion will be 705.06 KLD which will be supplied by MIDC

Notified Industrial Area of Tarapur.

11.3 Description of the Environment

As per ToR, studies were conducted during pre-monsoon season from 01.03.2017 to 31.05.2017.

11.3.1 Ambient Air Quality

Ambient Air quality monitoring was carried out twice a week at 8 locations for

one season from 1st March 2017 to 31st May 2017.

The maximum and minimum concentrations for PM10 were recorded as 95.94

µg/m3 and 65.94 µg/m3, respectively. The maximum concentration of PM10 was

recorded at the Project site and minimum concentration was observed at village

Kumbhavali. The mean concentrations range between 74.69 and 89.03 µg/m3.

98th percentile values for PM10 during study period range between 79.74 to

95.64 µg/m3.

The maximum and minimum concentrations for PM2.5 were recorded as 55.87

µg/m3 and 20.81 µg/m3, respectively. The maximum concentration was

recorded at Project site and the minimum concentration was recorded at village

Pam. The mean concentrations range between 26.72 and 48.66 µg/m3. 98th

percentile values for PM2.5 during study period range between 30.42 to 55.77

µg/m3.

The maximum and minimum SO2 concentrations were recorded as 25.84 µg/m3




and the minimum concentration was recorded at village Kumbhavali. The mean

values were observed from 13.96 µg/m3 to 22.43 µg/m3. 98th percentile values

for SO2 during study period range between 15.63 to 25.77 µg/m3.

The maximum and minimum NO2 concentrations were recorded as 45.84 µg/m3


and the minimum concentration was recorded at Kumbhavali. The mean values

for NO2 were observed in the range between 21.39 and 37.64 µg/m3. 98th

percentile values for NO2 during study period range between 28.19 to 44.6

µg/m3.

The 8-hourly CO concentrations during study period vary in the range of 154

to 435 µg/m3. The maximum CO concentration was found as 435 µg/m3 at plant

site and minimum CO concentration was 154 µg/m3 at Pam. The mean CO

concentrations vary from 226 to 352 µg/m3. 98th percentile values for CO during

study period range between 257 to 412 µg/m3.

The NH3 concentrations were found BDL to 12.23 g/m3 during the study

period. The concentrations of Ozone, Benzene, Benzo (a) Pyrene (BaP), Lead,

Arsenic, Nickel in ambient air quality were found below detection limit during

the study period.

All parameters monitored in AAQM locations are well within limits of NAAQS

11.3.2 Stack Emission Monitoring

During the study period stack emission monitoring was carried out for all the

stacks at the existing plant. Stack monitoring parameters are within the

permissible emission standards as stipulated in CC&A by MPCB for the existing

UPL Plant.

11.3.3 Waste Water Generation

Total existing waste water generation is 38.1 KLD and additional will be 258.9 KLD.

After proposed expansion, generated effluent of 297 KLD will be treated in proposed

Effluent Treatment Plant (ETP) @ capacity of 300 KLD. Treated waste water from ETP

is/will be sent to CETP of Tarapur for further treatment and disposal. After expansion,

generated sewage will be treated in ETP along with industrial effluent.



11.3.4 Hazardous Waste Generation and Disposal

After expansion total Landfilling waste generation will be 2584 MTM (Existing:

0.3 MTM + Proposed: 2583.7 MTM). Generated landfilling wastes will be sent

to Mumbai Waste Management Limited (MWML, Taloja) for landfilling. After

expansion total Incineration waste generation will be 1663.82 MTM (Existing:

9.75 MTM + Proposed: 1654.07 MTM). Generated incineration waste will be

sent to Mumbai Waste Management Limited (MWML, Taloja) for incineration

and also for co-processing at cement industry on their suitability. High COD and

toxic concentrated effluent is being/will be treated in the common incinerator

of MWML, Taloja. High TDS effluent streams will be treated in Multiple Effect

Evaporation (MEE) System.

Discarded containers / drums / carboys 9636 numbers per month will be sold

to MPCB authorized party. Plastic bags 51562 number per month will be sent

to scrap dealers / CHWTSDF at Taloja for landfilling, after decontamination.

Used Oil 500 liters per month will be sold to CPCB registered re-recyclers. Used

batteries 5 numbers per month will be sold to MPCB authorized parties. Spent

solvent 10 MT per month will be sold to end-users or recyclers or will be used

for co-processing. Spent Acid 2 MT per year will be sold to end-users or

recyclers. Fly Ash (non-hazardous waste) 120 MT per month will be sold to

brick manufacturers or other end-users.

11.3.5 Soil Quality

As per soil analysis data (pH: 7.63-8.05, Conductivity: 0.141-1.58 mS/cm,

Organic Carbon: 0.6-2.27 %, Organic Matter: 1.04-3.92 %, Available N: 182-

285 kg/ha, Available Phosphorous: 47.3-66.2 kg/ha, Arsenic: BDL-2.1 mg/kg,

Nickel: BDL-3.11 mg/kg, Zinc: 1.23-16.2 mg/kg (µg/g), Copper: 9.32-24.4

mg/kg (µg/g), Iron: 12.47-32.72 mg/kg (µg/g), Manganese: 3.45-8.88 mg/kg

(µg/g), Total Boron: 0.42-0.62 mg/kg, Exchangeable Calcium: 6.73-12.9

meq/100g, Exchangeable Magnesium: 1.52-2.26 meq/100g, Exchangeable

Sodium: 1.58-2.76 meq/100g, Exchangeable potassium: 0.16-0.48 meq/100g

; while other parameters such as cadmium, Chromium and Lead are Below

Detection Limit-BDL) it is concluded that surface soils are neutral to alkaline in

reaction, but normal from salinity view point.



11.3.6 Noise Monitoring Details

As per Noise monitoring data, result of day time noise monitoring (06:00 AM to

10:00 PM) are 49.66-64.8 dB (A) and for night time monitoring (10:00 PM to

06:00 AM) are 39.81-55.93 dB (A) and all values are well within permissible

limit.

11.3.7 Details of Flue Gas and Process Stacks

After expansion, total 7 nos of flue gas stacks (Existing: 4 nos+ Additional: 3

nos) and 12 nos of process stacks (Existing: 2 nos+ Additional: 10 nos) will be

installed. Adequate size and No. of Air Pollution Control Measures (APCM)

are/will be provided to achieve the statutory norms.

11.3.8 Surface Water Monitoring Details

Surface water parameters such as conductivity, Total Dissolved Solids, Chloride,

Sulphate, Nitrate, Sodium at Navapur location were found slightly higher than

the desired value as the site is near to sea.

11.3.9 Ground Water Quality

Ground water monitoring (pH: 7.62-7.9, TDS: 447.2-1238 mg/l, Total

Hardness: 246-466 mg/l, Total Alkalinity: 236- 400 mg/l etc) for all locations

meet the standard IS 10500 – 2012.

11.3.10 Socio Economic Aspects

For existing plant operation around 150 persons (67 UPL employees + 83

contractual employees) and additional manpower requirement for proposed

expansion 150 persons (73 UPL employees + 77 contractual employees). Total

300 persons (140 UPL employees + 160 contractual employees) will be required

after expansion.



11.4 Anticipated environmental impacts and mitigation measures 11.4.1 Air quality Modelling and Impact

Incremental Highest 24 hourly GLCs value 3.71 µg/m3 for Particulate Matter

(PM 10 or PM 2.5), 5.54 µg/m3 for Sulphur Dioxide (SO2), 2.11 µg/m3 for

Nitrogen Dioxide, 0.17 µg/m3 for HCl, 0.018 µg/m3 for Cl2, 0.16 µg/m3 for NH3,

0.011 µg/m3 for H2S, 0.014 µg/m3 for MeCl, 0.004 µg/m3 for HBr, 0.015 µg/m3

for PCl3, 0.0096 µg/m3 for HC is obtained at (+) 000 m, (-) 500 m at distance

of 0.500 km and 180o angle from North (clockwise).

The resultant ground level concentrations at all locations are found to be well

within the NAAQS.

Since the 24-hourly predicted incremental GLC values from UPL Plant after

expansion when added together with 24-hourly baseline values of Particulate

Matter, SO2 and NO2 remain below the 24-hourly ambient air quality standards

of 80 µg/m3 for SO2 & NO2 and 100 µg/m3 for PM10 in industrial, residential,

rural and other area. 24 Hourly GLC values for HCl, Cl2, NH3, H2S, MeCl, HBr,

PCl3, and HC are also extremely low and negligible. It is important to mention

that impact of existing plant operation in terms of GLCs values has already

included in baseline air quality values monitored in the area. Therefore,

operation of the plant after expansion will not cause any appreciable adverse

impact on ambient air quality of the study area.

11.4.2 Mitigation Measures during Construction Phase

All measures will be taken to minimize impact on environment by proper

planning.

11.4.3 Mitigation Measuring during Operation Phase

For issues related to water pollution, air pollution and hazardous waste management, following mitigation measures is / will be implemented



Water Pollution

The Unit has ETP @ 50 KLD capacity and will be augmented up to 300 KLD. Treated effluent is being sent to CETP at Tarapur, meeting their inlet norms for further treatment

Air Pollution

• Unit is/will install process scrubbers to mitigate the air pollutants generated from the process plant

• Ambient air quality is/will be monitored

Hazardous waste management

• From manufacturing activities, various hazardous wastes is/will be

generated. Hazardous wastes generated will be sent to CHWTSDF at Taloja for landfilling or incineration as applicable.

11.5 Analysis of alternatives (technology and site)

No alternative site has been proposed for expansion in pesticides, pesticide

intermediates and pesticide formulation plants as expansion is carried out in

existing plant premises. Project site is situated in notified industrial area of

MIDC, Tarapur

11.6 Environmental Monitoring Plan

Post project environmental monitoring is/will be done as per MoEF&CC / CPCB

/MPCB guidelines by following recommended/standard method approved by

MoEF&CC / CPCB. Regular record review is will be done for change in financial

requirement, parameter for environmental monitoring. Project proponent will

maintain the pollution load under permissible limit after expansion and will take

necessary precautions to maintain the same. The cost of monitoring plan for

construction phase (12 months) of the proposed expansion is estimated as Rs.

64,000/- while for operation phase cost of monitoring plan is estimated as Rs.

9,68,000/-. During operation phase environmental monitoring will be carried

every year. Fresh budget will be allocated every year for environmental

monitoring.



11.7 Additional Studies – Risk Assessment

Additional studies have been carried out as per ToR. As per OM J-

11011/36/2014-IA. I dated 10.12.2014, Public Consultation is not applicable for

this expansion project at MIDC notified industrial estate, Tarapur. Identification

of hazards in proposed project activity is of primary significance. Qualitative

and quantitative both risk has been analysed. Storage and handling of

Methanol, Toluene, Xylene, CS2, Di Ethyl Amine, 1-4 Dioxane, 2-Ethyl Hexanol,

Acetonitrile, Di Ethyl Carbonate, Di Ethyl Formamide, Ethyl Mercaptan, Ethyl

Acetate, Formaldehyde, Hexane, Isopropyl Alcohol, Mono Isopropyl Amine, N

N Di Methyl Aniline, Phenol, Tri Methyl Phosphite, Ethyl Hexanol have been

considered for consequence analysis, storage and handling of solid chemicals,

corrosive chemicals, toxic chemicals have been considered for qualitative risk

assessment. Specific mitigation measures for safety at storage area for

hazardous chemicals and safety systems / safeguards / control measures to

reduce risk of fire, explosion and toxic release, disaster preparedness and

emergency management plan has also been incorporated in Chapter 7. To

minimize the risk and to enhance the safety at the plant after expansion, risk

mitigation measures suggested in study will be implemented after expansion.

HAZOP Studies will be carried out before start-up of the plant.

11.8 Project Benefits

The benefits of pesticides manufacturing include increased food production,

increased profits for farmers and the prevention of crop diseases. Pesticides

also increase farm profits by helping the farmer save money on labor costs.

Using pesticides reduces the amount of time required to manually remove

weeds and pests from fields. Hence, expansion of UPL project will help in

increase in agricultural productivity indirectly by increasing production of

pesticides and its availability through reducing gaps in demand and supply of

pesticides in the area and region. Expansion project will give major physical

and social benefit due to development of infrastructure as well as generation of

employment (approx. 150 nos. of employee). Expansion project would help in

increasing living standard of the nearly populations/ habitants through CSR

program.



11.8.1 ESC Activities The Unit is already carrying out various ESC activities which will be continued 2.5 %

of project cost will be earmarked for ESC activities in the local area. Proposed

expansion capital investment will be Rs 227.06 Crores. UPL will spent 2.5 % of total

capital investment (@5.76 Crores) for Enterprise Social Commitment. All ESC projects

at Tarapur will be undertaken in six key focus areas (Agriculture Development, Health

& Sanitation, Environment & Nature Conservation, Education & Empowerment,

Employability & Entrepreneurship, National & Local Area needs) and will be

implemented in five years according to company’s ESC policy.

11.9 Environmental Cost Benefit Analysis

Expansion project will be carried out at existing unit in Tarapur MIDC Notified Industrial Estate, during scoping / ToR stage, no recommendation of environmental cost benefit analysis was suggested by Appraisal Committee hence conducting details Cost Benefit Analysis is deemed not necessary for this particular project

11.10 Environmental Management Plan

The main purpose of EMP is to minimize the identified potential environmental

impacts to be generated from the proposed project and to mitigate the

consequences. During construction phase materials will be transported through

covered trucks. Construction activities will be carried out during day time only.

Regular water sprinkling will be done to reduce PM concentration in the

atmosphere. PPEs will be provided to workers and first aid facilities shall be

kept at designated locations during construction phase.

During operation phase the industry will maintain comprehensive environment

management plan in place for the proposed unit which will covers all the

environment protection measures to mitigate adverse environmental impact.

High Toxic effluent steams is/will be treated in incinerator, High TDS effluent

stream is/will be treated in MEE. While normal effluent i.e. boiler blow down,

cooling tower blow down, floor washing, Condensate from MEE/boiler etc. will

be treated in ETP. Treated effluent is/will be discharged in CETP, Tarapur.

Coal/HSD/LDO will be used as fuel in proposed utility hence negligible flue gas

emission. Additionally, proper scrubbing systems and dust collector/bag will be

provided to control process emission after expansion. Hazardous Waste

(Landfillable & Incinerable) Management is/will be done as per Hazardous and



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

Noise level within the plant premises is/will be measured regularly and will try

to maintain within permissible limit.

From EIA Studies and baseline data, the following environment management plans are finalized: ▪ The Unit will augment their ETP to take care of pollution load ▪ The treated effluent will be continued to be sent to CETP at Tarapur meeting

their inlet norms ▪ The effluent quality is/will be continuously monitored using continuous

monitoring system consisting of online COD meter, TOC / TN meter, pH meter, magnetic flow meter and TSS meter. The data is/will be continued to be transferred to CPCB web site

▪ For flue gas emission control, company is/will be provided dust collector/ bag filter and continuous monitoring systems.

▪ Along with new plants or expansion, appropriate air pollution control system like process scrubbers, is/will be installed and operated

▪ Routine AAQ monitoring and stack monitoring is/will be done ▪ Unit has identified hazardous waste generation and efforts is/will be made

for minimization, reuse and recycling of hazardous waste ▪ The Unit will continue to send their landfillable and incinerable waste to

CHWTSDF of MWML at Taloja ▪ The Unit will implement EMS ISO 14001, OHSAS 18001 and QMS ISO 9001 ▪ The Unit has considered capital investment for implementation of EMP @

Rs 2212.97 Lakhs and considered recurring expenditure of Rs 533.38 Lakhs per annum

11.10.1 Green Belt Development UPL (Unit# 10) has already developed total approx. 1240 sq m of green belt

within the factory premises. UPL has also planted 250 trees opposite to the site

by adopting a crematorium (approx. land area of 1000 sq. m). It is proposed

to create additional green belt of 5865.96 sqm area within 5 km from the plant

site.

11.11 Conclusion

The proposed project is located in MIDC Notified Industrial area, Tarapur and

would not have any considerable impact on environment with efficient mitigation

measures implemented. The waste generation in form of gas (flue and

process), effluent and solid waste may have impacts on environmental

parameters but the proponent has installed and planned most efficient



technologies for prevention of emissions and treatment of effluent and sewage.

Further, the solid/hazardous waste will be disposed of through common TSDF

site. Hence, there would not be any considerable impacts on environment. With

the implementation of the mitigation measures and EMP, the proposed project

activities will have positive beneficial effect on the local population, economic

output and other related facilities viz. employment generation, development of

business, transportation etc. Risk assessment including emergency response

plan and DMP has been prepared to handle any sort of emergencies.

Hence, looking to the overall project justification, process, pollution potential

and pollution prevention measures /technologies installed by proponent,

environmental management activities of proponent; it has been concluded that

the project would not have any considerable impacts on environment as well as

socio-economic and ecological conditions of the project area after expansion.

Therefore, proposed project is considered to be environmentally safe.



Chapter 12

DISCLOSURE OF CONSULTANTS

12.1 The Consultant

M/s Shivalik Solid Waste Management Limited (SSWML) has been appointed by

M/s UPL Ltd (Unit # 10) as consultant to carry out Environmental Impact

Assessment study of the proposed expansion of the existing pesticides plant at

Tarapur.

12.2 Profile of Shivalik Solid Waste Management Ltd.

Brief profile of SSWML is as given below:

Name of the Consultancy

Company M/s. Shivalik Solid Waste Management Ltd.

Address

Registered Office:

Village-Majra, P.O. Dabhota, Tehsil Nalagarh, Distt.

Solan, Himachal Pradesh – 174101 Phone/Telefax:

01795-260427, 260227

Zirakpur Office:

SCO 20-21, 2ndFloor, Near Hotel Dolphin, Baltana,

Zirakpur Punjab- 140604 Phone/Telefax: 01762–

509496

E-mail Address [email protected]

[email protected]

Website www.sswml.net

Nature of Services

Treatment, Storage & Disposal Facility, EIA

Consultancy, Environmental, Health & Safety

Auditing, EMS, Environmental Monitoring &

Laboratory Analytical Services, Waste water

Management, Energy Audit, Greens Concept

Development, etc.

mailto:[email protected]

mailto:[email protected]

http://www.sswml.net/



Shivalik Solid Waste Management Limited (SSWML), Nalagarh is offering high

quality technical services in the field of EIA, Environment, Health & Safety (EHS),

and Environmental Monitoring & Laboratory Analytical Services etc. SSWML is

supported by distinguished professionals, engineers, scientists etc. SSWML

Professionals have excellent experience in executing EIA and other environmental

projects.

For Environmental Monitoring related work SSWML has in-house laboratory

approved by NABL. The following experts are associated with SSWML for EIA and

Environmental projects. The following experts are associated with SSWML for EIA

and Environmental projects.

12.3 EIA Coordinator and Functional Area Experts

Details of EIA Coordinator and Functional Area Experts involved in the EIA report

of UPL Limited (Unit #10) are given in Table 12.1. Team Members (TM) and FAA

(Functional Area Associate) Associated with the study are given in Table 12.2.

Table 12.1: EIA Coordinator and Functional Area Experts (FAEs) for the Project

S.

No.

Functional Areas Name of the

Expert/s

Involvement

(Period &Task**)

I. EIA Coordinator Mr. Ashok Kumar

Sharma

Feb 2017 –till date

EIA Co-Coordinator Mr. Vinod Kumar

Gautam

Oct 2017 to till

II. Functional Area Expert

1. AP* (Air Pollution

Monitoring, Prevention

& Control)

Ms. Daksha Gupta Quantification of Air pollution and Assessment of Impacts. Period of Involvement: Mar

2017 –till date



S.

No.


Expert/s

Involvement

(Period &Task**)


Mr. Ashok Kumar

Sharma & Mr. Vinod

Kumar Gautam

Assisted approved FAE during study period Coordinating safety studies, finalization of DMP, contribution to RA/DMP Documentation and contribution to EIA documentation.

3. WP* (Water Pollution Monitoring, Prevention & Control)

Dr P N Parameswaran

& Mr Snehal R.

Lokhandwala

Quantification of water pollution and Assessment of Impacts. Period of Involvement: Mar

2017 –till date.


Ms. Daksha Gupta &

Mr. Vinod Kumar

Gautam & Dr. P N

Parameswaran

Quantification of Solid & Hazardous Waste and Assessment of Impacts. Period of Involvement: Mar

2017 –till date

5. SE* (Socio-economics)

Sayantani Chatterjee Collection and Compilation of Socio-economic data. scenario and CSR Plan. Period of Involvement: May 2017 –till date

6. EB* (Ecology & Biodiversity)

Dr. I. S. Dua, Mr

Silbhadra Brahma &

Shivani Dutt.

Conducted primary survey work at site, collected information about flora and fauna from Forest department and checked. Period of Involvement: May

2017 –till date.

7. HG* (Hydrology, Ground Water & Water Conservation)

Yamesh Sharma Provided guidance on

Hydrology aspects of the

EIA Report.



S.

No.


Expert/s

Involvement

(Period &Task**)

8. GEO* (Geology) Subhash Chander

Sharma

Geology and

geomorphologic analysis

based on secondary data.


BS Lole. Interpretation of baseline

data of soil analysis and its

interpretation. Preparation

of draft report considering

impact and mitigation on

Soil as per guidelines.

Table 12.2: Team Members (TM) and FAA (Functional Area Associate) Associated with the Study

S. No.

Functional Areas Name of the TM/FAA


1. AP* (Air Pollution Monitoring, Prevention & Control)

Vishal Kalhapure Assisted approved FAE Period of Involvement: during study period. Assisted FAE in Site visit, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM).

2. WP* (Water Pollution Monitoring, Prevention & Control)

Kashyap Bhatt Assisted approved FAE during study period. Assisted approved FAE, in selection of sampling locations for surface and ground water sampling, evaluation of water pollution control management, identification of impacts, suggestion of mitigation measures, contribution to EIA documentation.


Vishal Kalhapure Assisted approved FAE in Identification of solid and Hazardous Wastes generated, designs for temporary storage facilities



S. No.

Functional Areas Name of the TM/FAA


for hazardous wastes, mitigation measures for management of hazardous waste, contribution to the EIA documentation.


S. Brahma (TM) & Sanjay Sharma (TM)

Assisted approved FAE and site visited and collection of base line data of soil analysis and along with field observation, Preparation of draft report.

5. NV* (Noise & Vibration)

Niraj Kumari Parihar Assisted approved during study period, analysis of data, identification of impacts and mitigation measures, and contribution to EIA documentation.


Baseem Zafar Assisted approved FAE during study period Coordinating safety studies, finalization of DMP, contribution to RA/DMP Documentation and contribution to EIA documentation.

7. AQ* (Meteorology, Air Quality Modeling & Prediction)

Baseem Zafar Assisted approved in checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM), and contribution to EIA documentation& compilation of report.

8. SE* (Socio-economics) Sunita Dhirta Assisted approved FAE in Collection and Compilation of Socio-economic data.

environmental impact assessment (eia)environmentclearance.nic.in/writereaddata/eia/3010201815... ·...

Documents