ENVIRONMENTAL IMPACT
ASSESSMENT REPORT
FOR
TAMIL NADU PETROPRODUCTS LTD
(EPICHLOROHYDRIN [ECH] PLANT)
“PROPOSED CHANGE IN PRODUCT MIX FROM ECH TO
PROPYLENE OXIDE (PO)”
AT
VILLAGE: MANALI
DIST: THIRUVALLUR
STATE: TAMIL NADU
[PROJECT TERMED UNDER CATEGORY 5 (E) PETROCHEMICAL BASED PROCESSING]
REPORT PREPARED BY
HUBERT ENVIRO CARE SYSTEMS PVT LTD.,
CHENNAI
AUGUST 2014
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
ACKNOWLEDGEMENT
The following people are gracefully acknowledged for their fullest support in rendering needful
information regarding the project and kind cooperation in fulfilling the report
Tamilnadu Petroproducts Limited
Mr.M.PazhaniandyPillai - Whole Time Director (Operations)
Mr.B.PramodPillai- General Manager (Operations)
Mr.K.Pattabi- General Manager (Site)
Mr.A.Rajakumar – Deputy Manager (Safety)
Mr.N.SuriyaKumar – Sr. Engineer (Technical Services)
Hubert Enviro Care Systems Pvt. Ltd.
Dr.J.R.Moses
Dr.Rajkumar Samuel
Dr.V.Sundararaj
Mr.A.Manoharan
Dr.T.P.Natesan
Mr.V.Dhivakar
Ms.RamaaPrakash
Ms.A.Ragatharani
Mr.V.Venkateswaran
Mr.K.G.Gowthaman
Envision Enviro Engineers Pvt. Ltd.
Ms. Smitha Rajesh
Mr.Jignesh Patel
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
Table of Contents EXECUTIVE SUMMARY ......................................................................................................................... i
1 INTRODUCTION ............................................................................................................................... 1
1.1 COMPANY BACKGROUND ...................................................................................................... 1
1.2 PROMOTERS AND BACKGROUND ......................................................................................... 1
1.3 MANUFACTURING FACILITY&CURRENT STATUS ........................................................... 1
1.4 CHANGE OF PRODUCT MIX ..................................................................................................... 2
1.5 JUSTIFICATION FOR THE PROJECT ....................................................................................... 2
1.6 MARKET POTENTIAL ................................................................................................................ 2
1.6.1 Propylene Glycol........................................................................................................................ 2
1.6.2 Polyols ........................................................................................................................................ 3
1.7 PROJECT SETTING ..................................................................................................................... 4
1.8 PROJECT LOCATION ................................................................................................................. 6
1.9 EIA REQUIREMENT ................................................................................................................... 7
1.10 ENVIRONMENTAL AND RELATED ACTS AND RULES APPLICABLE ................................................... 7
1.11 METHODOLOGY ADOPTED FOR THE STUDY ................................................................... 12
1.11.1 Objectives of this EIA report ................................................................................................ 12
1.11.2 EIA Process .......................................................................................................................... 12
2 PROJECT DESCRIPTION ............................................................................................................. 14
2.1 ABOUT THE PROJECT ............................................................................................................. 14
2.2 PROJECT LOCATION ............................................................................................................... 14
2.3 LAND REQUIREMENTS .......................................................................................................... 19
2.4 MANPOWER .............................................................................................................................. 20
2.5 PLANT LAYOUT ....................................................................................................................... 20
2.6 RAW MATERIAL REQUIREMENTS ....................................................................................... 20
2.6.1 Source of raw materials ........................................................................................................... 20
2.7 MANUFACTURING PROCESS ................................................................................................ 22
2.7.1 Existing Epichlorohydrin Plant ............................................................................................... 22
2.7.2 Manufacturing Process of Propylene Oxide ............................................................................ 27
2.8 UTILITIES AND SERVICES ..................................................................................................... 30
2.8.1 Water System ............................................................................................................................ 30
2.8.2 Water Supply ............................................................................................................................ 34
2.8.3 Sewage Treatment Plant .......................................................................................................... 36
2.8.4 Effluent Treatment Plant .......................................................................................................... 38
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
a) Design of Outfall Pipeline ........................................................................................................... 42
2.9 STEAM SYSTEM ....................................................................................................................... 43
2.10 COMPRESSED AIR SYSTEM ................................................................................................... 43
2.11 INERT GAS SYSTEM ................................................................................................................ 44
2.12 STORAGE FACILITIES ............................................................................................................. 44
2.13 POWER SUPPLY ........................................................................................................................ 44
2.14 STACK DETAILS ....................................................................................................................... 44
3 BASELINE ENVIRONMENTAL STATUS .................................................................................. 46
3.1 INTRODUCTION ....................................................................................................................... 46
3.2 AIR AND METEOROLOGICAL ENVIRONMENT ................................................................................ 46
3.2.1 Reconnaissance ........................................................................................................................ 46
3.2.2 Micro metrology ....................................................................................................................... 48
3.2.3 Base line air quality status ....................................................................................................... 50
3.3 NOISE ENVIRONMENT ........................................................................................................... 53
3.3.1 Reconnaissance ........................................................................................................................ 53
3.3.2 Community noise levels ............................................................................................................ 54
3.3.3 Baseline Noise status ............................................................................................................... 54
3.4 WATER ENVIRONMENT ......................................................................................................... 55
3.4.1 Hydrogeology ........................................................................................................................... 55
3.4.2 Reconnaissance ........................................................................................................................ 57
3.4.3 Baseline Water quality Status .................................................................................................. 58
3.4.4 Surface water Quality .............................................................................................................. 61
3.4.5 Ground water quality ............................................................................................................... 63
3.5 SOIL ENVIRONMENT .............................................................................................................. 64
3.6 LAND USE .................................................................................................................................. 67
3.6.1 Geomorphology ........................................................................................................................ 69
3.7 TERRESTRIAL ECOLOGY ....................................................................................................... 70
3.7.1 Scrub Eco-system (Dry Evergreen Vegetation) ....................................................................... 70
3.7.2 Tidal Eco-system ...................................................................................................................... 70
3.7.3 Mangrove Eco-system .............................................................................................................. 70
3.7.4 Marsh Eco-system .................................................................................................................... 71
3.7.5 Agro Ecosystem ........................................................................................................................ 71
3.7.6 Flora......................................................................................................................................... 71
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
3.7.7 Fauna ....................................................................................................................................... 72
3.8 AQUATIC ECOLOGY ............................................................................................................... 73
3.8.1 Planktons .................................................................................................................................. 73
3.8.2 Fishes ....................................................................................................................................... 73
3.9 SOCIO ECONOMIC ENVIRONMENT ..................................................................................... 74
3.9.1 Social Indicators ...................................................................................................................... 75
3.9.2 Economy of the District............................................................................................................ 78
3.9.3 Land use and Resource availability ......................................................................................... 79
3.9.4 Industries .................................................................................................................................. 80
3.9.5 Discussion with local people.................................................................................................... 81
4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ................. 83
4.1 IMPACT IDENTIFICATION ..................................................................................................... 83
4.2 CONSTRUCTION AND COMMISSIONING PHASE .............................................................. 83
4.3 COMMISSIONING OF PLANT ................................................................................................. 83
4.4 OPERATION PHASE ................................................................................................................. 83
4.4.1 Air Environment ....................................................................................................................... 84
4.4.2 Water Environment .................................................................................................................. 91
4.4.3 Noise Environment ................................................................................................................... 91
4.4.4 Land Environment .................................................................................................................... 92
4.4.5 Flora And Fauna ...................................................................................................................... 94
4.5 IMPACT ASSESSMENT ............................................................................................................ 94
4.5.1 Matrix method .......................................................................................................................... 95
5 ANALYSIS OF ALTERNATIVES ............................................................................................... 100
5.1 INTRODUCTION ..................................................................................................................... 100
5.2 SITE SELECTION .................................................................................................................... 100
5.3 PROJECT ALTERNATIVES .................................................................................................... 102
5.3.1 Site alternatives ...................................................................................................................... 102
5.3.2 Fuel alternatives .................................................................................................................... 103
5.3.3 Water supply alternatives....................................................................................................... 103
5.3.4 Alternative Technologies........................................................................................................ 103
5.3.5 Justification for the Selected Technology .............................................................................. 104
6 ENVIRONMENTAL MONITORING PROGRAM.................................................................... 106
6.1 INTRODUCTION ..................................................................................................................... 106
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Hubert Enviro Care Systems Pvt. Ltd.
6.2 MONITORING METHODOLOGIES ...................................................................................... 108
6.3 REPORTING & DOCUMENTATION ..................................................................................... 108
7 ENVIRONMENTAL MANAGEMENT PLAN ........................................................................... 110
7.1 INTRODUCTION ..................................................................................................................... 110
7.2 OBJECTIVES OF EMP .................................................................................................................. 110
7.3 EMP STRUCTURE AND ORGANIZATION IN TPL .......................................................................... 111
7.4 EMP ROLES AND RESPONSIBILITIES ........................................................................................... 111
7.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE .................. 113
7.5.1 Air Quality.............................................................................................................................. 114
7.5.2 Noise Environment ................................................................................................................. 114
7.5.3 Water Quality and Water Resources ...................................................................................... 115
7.5.4 Solid Waste ............................................................................................................................. 115
7.5.5 Land Environment .................................................................................................................. 115
7.5.6 Ecology................................................................................................................................... 115
7.5.7 Socio Economic ...................................................................................................................... 115
7.6 ENVIRONMENTAL MANAGEMENT PLAN FOR OPERATION PHASE .......................... 116
7.6.1 Air Quality.............................................................................................................................. 116
7.6.2 Noise Environment ................................................................................................................. 119
7.6.3 Water Quality and Water Resources ...................................................................................... 119
7.6.4 Effluent Treatment Plant ........................................................................................................ 122
7.6.5 Solid & Hazardous Wastes .................................................................................................... 122
7.6.6 Land Environment .................................................................................................................. 123
7.6.7 Ecology................................................................................................................................... 124
7.6.8 Green Belt Development Plan................................................................................................ 124
7.6.9 Socio – Economic Environment ............................................................................................. 126
7.6.10 Occupational Health and Safety Program ......................................................................... 130
7.6.11 Environmental Policy of TPL ............................................................................................. 131
7.6.12 Fire & Explosion Controls ................................................................................................. 132
7.6.13 On line Leak detections ...................................................................................................... 135
7.6.14 Chemicals Management System ......................................................................................... 136
7.7 OCCUPATIONAL HEALTH / INDUSTRIAL HYGIENE PROGRAM.................................. 137
7.7.1 Occupational Health Monitoring ........................................................................................... 137
7.7.2 Emergency Management ........................................................................................................ 138
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
7.7.3 Materials Handling Storage and Transportation .................................................................. 138
7.7.4 H&S Audits & Inspections program ...................................................................................... 139
7.7.5 Industrial Hygiene Monitoring .............................................................................................. 140
7.8 ENVIRONMENTAL MANAGEMENT CELL ........................................................................ 142
7.8.1 Responsibilities of Environment Management Cell ............................................................... 143
7.8.2 Monitoring of Environment .................................................................................................... 144
7.8.3 Laboratory Facilities ............................................................................................................. 146
7.8.4 Corporate Responsibility for Environmental Protection (CREP) ......................................... 146
7.8.5 Budgetary Provisions for EMP .............................................................................................. 150
8 CONSENT- COMPLIANCE STATUS ......................................................................................... 151
8.1 APPLICABILITY OF ENVIRONMENTAL CLEARANCE ..................................................................... 151
8.2 CONSENT FOR EXISTING OPERATION ......................................................................................... 151
8.3 COMPLIANCE CONDITIONS ......................................................................................................... 151
9 PROJECT BENEFITS ................................................................................................................... 160
9.1.1 Polyols .................................................................................................................................... 160
9.1.2 Miscellaneous applications .................................................................................................... 161
10 SUMMARY & CONCLUSION ..................................................................................................... 162
11 DISCLOSURE OF CONSULTANTS ENGAGED ...................................................................... 164
LIST OF FIGURES
Figure 1-1 Location of the Project Site ........................................................................................................ 6
Figure 1-2 EIA Process Cycle .................................................................................................................... 13
Figure 2-1 Location of the Project Site ...................................................................................................... 15
Figure 2-2 10 Km Radius Google Map of the Site and Surroundings ....................................................... 17
Figure 2-3 Google Image of Project Site.................................................................................................... 18
Figure 2-4 Topo map showing 5 km around the site .................................................................................. 18
Figure 2-5 Process overview of Allyl Chloride Section............................................................................. 24
Figure 2-6 Process overview of Epichlorohydrin Section.......................................................................... 25
Figure 2-7 ECH Material balance - ALC unit ............................................................................................ 26
Figure 2-8 Mass Balance for Epichlorohydrin Production ........................................................................ 26
Figure 2-9Flow diagram of propylene Oxide plant .................................................................................... 28
Figure 2-10 Mass Balance for Propylene Oxide ........................................................................................ 30
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
Figure 2-11 Emergency Eye washer .......................................................................................................... 33
Figure 2-12 Safety Showers ....................................................................................................................... 33
Figure 2-13 Water balance for existing ECH plant .................................................................................... 35
Figure 2-14 Water Balance for Proposed PO Manufacturing .................................................................... 36
Figure 2-15 Sewage treatment Plant Process Flow .................................................................................... 37
Figure 2-16Effluent Treatment Plant in the site ......................................................................................... 40
Figure 2-17Proposed Effluent Treatment Plant.......................................................................................... 41
Figure 3-1Google earth Image Showing the Location of Air quality Sampling Stations ......................... 48
Figure 3-2 Wind rose Data for Manali ....................................................................................................... 50
Figure 3-3 Hydro geological map of Thiruvallur district ........................................................................... 57
Figure 3-4Google Earth Image Showing the Location of Sampling Stations ............................................ 60
Figure 3-5 Water sampling at different locations ....................................................................................... 60
Figure 3-6Google Earth Image showing Location of Soil sampling.......................................................... 65
Figure 3-7 Soil Sampling Location ............................................................................................................ 66
Figure 3-8 Land use / Land cover Map of the Study area .......................................................................... 68
Figure 3-9 Land Use classification chart .................................................................................................... 69
Figure 3-10 Geomorphologic map of the project site ................................................................................ 70
Figure 3-11 District Decadal Growth Rate ................................................................................................ 75
Figure 3-12 Statistics of Main workers ..................................................................................................... 76
Figure 3-13 Bar chart for Operational land holding ................................................................................... 77
Figure 3-14 School in Manali ..................................................................................................................... 77
Figure 3-15 Product at net and constant prices .......................................................................................... 78
Figure 3-16 Per Capita Income at Net and Constant Prices ....................................................................... 79
Figure 3-17 Discussion with the local fisherman ....................................................................................... 82
Figure 3-18 Discussion with a worker in the study area ............................................................................ 82
Figure 4-1 Ground Level Concentration (GLC) of SOX at 10 Km radius(without DG set) ..................... 87
Figure 4-2 Zoomed image - (GLC) of SOX at 10 Km radius (without DG set) ......................................... 87
Figure 4-3 Ground Level Concentration (GLC) of SOX at 10 Km radius (With DG set) ......................... 88
Figure 4-4 Zoomed Image of GLC of SOX at 10 Km radius (With DG set) ............................................. 88
Figure 4-5 Ground Level Concentration (GLC) of NOX at 10 Km radius ................................................. 89
Figure 4-6 Zoomed Image - (GLC) of NOX at 10 Km radius .................................................................... 89
Figure 4-7 Ground Level Concentration (GLC) of PM at 10 Km radius ................................................... 90
Figure 4-8 Zoomed Image - (GLC) of PM at 10 Km radius ...................................................................... 90
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
Figure 4-9 Noise level Contour- Isoline view ............................................................................................ 92
Figure 4-10 Land use in the year 2005 ....................................................................................................... 93
Figure 4-11 Land use in the year 2008 ....................................................................................................... 93
Figure 4-12 Land use in the year 2014 ....................................................................................................... 94
Figure 7-1 Chlorine Sensor in Chlorine scrubber stack ........................................................................... 117
Figure 7-2 Online Chlorine sensor connected to TNPCB ........................................................................ 117
Figure 7-3 Continuous Ambient Air Quality Station at the site ............................................................... 118
Figure 7-4 Rain water harvesting system – Roof top rain water collection system ................................. 122
Figure 7-5 Rain Water Percolation Pit ..................................................................................................... 122
Figure 7-6 Photos of existing Green belt.................................................................................................. 125
Figure 7-7 Fire Alarm point ..................................................................................................................... 133
Figure 7-8 Water Monitor ........................................................................................................................ 134
Figure 7-9 Sprinkler System in Storage Tanks ........................................................................................ 135
Figure 7-10 Propylene Detector ............................................................................................................... 136
Figure 7-11 Chlorine detector .................................................................................................................. 136
Figure 7-12 Organizational set up for Environmental Management plan ................................................ 143
LIST OF TABLES
Table 1-1Change in Products and Production Capacity 2
Table 1-2 List of Industries Within 10 Km radius of the Project Site 4
Table 1-3Applicable Acts and Rules for the Proposed Project 9
Table 2-1 Change in Products and Production Capacity 14
Table 2-2 Salient Features of Project and Surrounding features 16
Table 2-3 Land use breakup details 19
Table 2-4 Source and Transportation of Raw materials and products 21
Table 2-5 Raw materials used in existing and proposed facility 21
Table 2-6 Epichlorohydrin characteristics 27
Table 2-7 Water Consumption for Existing and Proposed plant 34
Table 2-8 Dimensions of Outfall pipeline 42
Table 2-9 Output Design Details 43
Table 2-10Existing Stack Details 44
Table 2-11Existing stack details utilized for proposed facility 45
Table 3-1Locations of the Ambient Air Quality Stations 47
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
Table 3-2 Meteorological observations 49
Table 3-3 Test Methods used for the Analysis of ambient air quality parameters 51
Table 3-4 Summary of findings of ambient air quality monitoring (Average) 52
Table 3-5Table Summary of findings of Noise monitoring in the study area (Average) 54
Table 3-6 Summary of test methods used for the analysis of water quality parameters 58
Table 3-7 Locations of the water quality stations 59
Table 3-8 Summary of analytical results on Surface water samples collected in the study area 61
Table 3-9 Results of Ground water samples collected in the study area 63
Table -3-10Summary of findings of soil sampling studies in the study area (Average) 65
Table 3-11 Summary of analytical results of soil samples collected at different sampling stations 66
Table 3-12Landuse Classification and Area 68
Table 3-13 List of Domestic Flora in the Study Area 71
Table 3-14 List of Wild Fauna in the Study Area 72
Table 3-15 Amphibian 72
Table 3-16 Rodents 73
Table 3-17 List of Zooplankton identified within the Study Area 73
Table 3-18 Land Use data - Thiruvallur 79
Table 4-1Stack details in the existing ECH facility 84
Table 4-2Source of Process Emissions after Proposed change in Product Mix 85
Table 4-3 Reduction in emission load due to proposed change in product mix 85
Table 4-4 Stack Emission Details 86
Table 4-5 Predicted GLC for Proposed Stack 91
Table 4-6 Overall Impact Classification 96
Table 4-7 No-Project Scenario 96
Table 4-8 Project Scenario without EMP 97
Table 4-9 Project with EMP 98
Table 5-1 Impacts of alternative site location compared with the selected location 101
Table 6-1Post Project Environmental Monitoring Plan 107
Table 7-1 Responsibilities for EMP Implementation 111
Table 7-2 Quantity of Non hazardous waste 123
Table 7-3 Quantity of hazardous waste expected to be generated in the proposed facility 123
Table 7-4 Fire Fighting Equipments Available in the Plant 133
Table 7-5 Fire Alarm points and its components inside the plant 133
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
Table 7-6 Fire Water Storage Capacity 134
Table 7-7Pumps Available with Capacity 134
Table 7-8 Sprinklers Installed in the Plant 135
Table 7-9 Environmental Monitoring Plan 144
Table 7-10 CREP Points and Compliance status 146
Table 7-11CEPI (Comprehensive Environment Pollution Index) Action Plan Status 149
Table 7-12Cost for Environmental Protection Measures in (Rs.) 150
Table 8-1 Consented quantity vide order No 17966 dated 21.04.1999 151
Table 8-2Consent order under water Act No. 17966 dated 21.04.1999 151
Table 8-3 Renewal consent order under Air Act No. 28635dated 21.04.1999 152
Table 8-4 Consent order under Air Act- no. 14090 dated 03.11.2010 154
Table 8-5 Consent order under Water act- No.17966 dated 03.11.2010 156
Table 11-1Details of the Consultant 164
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List of Annexure
Annexure-1Location of Industries within 10 Km radius of the site
Annexure-2 TOR from MoEF dated 31/3/2014 for Proposed Change of Product Mix
Annexure-3 Topo sheet showing the Project site
Annexure-4 Land Documents
Annexure-5 CMA land Use Map
Annexure-6 Existing ECH Layout
Annexure-7 Proposed PO Layout
Annexure-8 Transportation Route for proposed PO unit
Annexure-9 CMWSSB receipt for water supply
Annexure-10 Treated effluent Disposal Pipeline to sea
Annexure-11 Monitoring Reports
Annexure-12 Rain water Harvesting pits Layout at site
Annexure-13 Layout showing the existing and proposed green belt development area
Annexure-14 Fire hydrant Layout
Annexure-15 MSDS of Raw materials and finished products
Annexure-16 Licence for storage of Propylene and Chlorine
Annexure-17 Consent To Establish for ECH plant obtained in 1993
Annexure-18 Consent To Operate Renewal for ECH Plant obtained in 1999
Annexure-19 Consent To Operate Renewal for ECH Plant obtained in 2010
Annexure-20 Consent To Operate Renewal application for ECH Plant in 2014
Annexure-21 Hazardous Waste Authorization from TNPCB for ECH Plant
Annexure-22 Consolidated Reports of Treated Effluent
Annexure-23 Lime Sludge disposal for brick Manufacturers
Annexure- 24 Consolidated Reports of Stack Monitoring
Annexure-25 Consolidated Reports of Ambient Air Quality Monitoring
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Annexure-26 LDAR Report
Annexure-27 Report of Ground Water Quality Monitoring at site
Annexure-28 Industrial Waste Management Membership
Annexure-29 Agreement with Ramky for disposal of Hazardous waste
Annexure-30 Risk Assessment and Disaster Management Plan
Annexure-31 Letter Regarding Exemption for Public Hearing
Annexure-32 NABETCertificate
TPL- EIA for Change of Product Mix
Hubert Enviro Care Systems Pvt. Ltd.
ABBREVATIONS
TPL Tamilnadu Petroproducts Limited
TIDCO Tamil Nadu Industrial Development Corporation Limited
SPIC Southern Petrochemical Industries Corporation Ltd
CMWSSB Chennai Metropolitan Water Supply and Sewage Board
TOR Terms of Reference
ECH Epichlorohydrin
LAB Linear Alkyl Benzene
PO Propylene Oxide
NAAQ National Ambient Air Quality Standards
CPCB Central Pollution Control Board
SEIAA State Environment Impact Assessment Authority
MoEF Ministry of Environment and Forests
CPA Critically Polluted Area
EIA Environmental Impact Assessment
HCl Hydrochloric acid
ALC Allyl Chloride
WTP Water Treatment Plant
RWR Raw Water Reservoir
FWR Fire Water Reservoir
ACF Activated Carbon Filters
DM Demineralization Plant
ETP Effluent Treatment Plant
STP Sewage Treatment Plant
FWPH Fire Water Pump House
MCR Main Control Room
MLSS Mixed Liquor Suspended Solids
TNPCB Tamil Nadu Pollution Control Board
HDPE High-density polyethylene
AAQM Ambient Air Quality Monitoring
APHA American Public Health Association
VOC Volatile Organic Compounds
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Hubert Enviro Care Systems Pvt. Ltd.
USEPA United States Environmental Protection Agency
BDL Below Detection Level
MMDA Madras Metropolitan Development Authority
SIDCO Small Industries Development Corporation
EMC Environmental Monitoring Consultant
GLC Ground Level Concentration
OHSAS Occupational Health and Safety Administration Standard
EMP Environmental Management Plan
IEMC Independent Environmental Monitoring Consultant
MACT Maximum Achievable Control Technology
LDAR Leak Detection and Repair
NESHAP National Emissions Standards for Hazardous Air Pollutants
NSPS New Source Performance Standards
PPE Personal protective equipment
SPCB State Pollution Control Board
TNWML Tamil Nadu Waste Management Limited
CSR Corporate Social Responsibility
PHA Process Hazard Analysis
SCBA Self Contained Breathing Apparatus
MSDS Material Safety Data Sheets
SABA Supplied Air Breathing Apparatus
PFT Pulmonary Function Tests
LFT Liver Function Tests
CFL Compact Fluorescent Lamp
CREP Corporate Responsibility for Environmental Protection
BLEVE Boiling Liquid Expanding Vapor Explosion
ALARP As Low As Reasonably Practicable level
HAZOP Hazard and Operability
PrHA Preliminary Process Hazard Analysis
ALOHA Aerial Locations of Hazardous Atmospheres
EPA Environmental Protection Agency
IARC International Agency for Research on Cancer
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Hubert Enviro Care Systems Pvt. Ltd.
LEL Lower Explosive Limit
AEGL Acute Exposure Guideline Level
HCD Heavy Chemical Division
SMS Safety Management System
TAC Tariff Advisory Committee
TNEB Tamil Nadu Electricity Board
CEC Chief Emergency Coordinator
CPCL Chennai Petroleum Corporation Limited
PAPL Petro Araldite Private Limited
MPL Manali Petrochemicals Limited
MFL Madras Fertilizers Limited
NABL National Accreditation Board for Testing and Calibration Laboratories
FAMCP Fire Alarm Manual Call Point
NABET National Accreditation Board For Education & Training
TPL- EIA for Change of Product Mix Executive Summary
Hubert Enviro Care Systems Pvt. Ltd. i
EXECUTIVE SUMMARY
1. Introduction
Tamilnadu Petroproducts Limited (TPL) was established in 1984 at Manali, Thiruvallur district in
Tamil Nadu State as a joint venture between TIDCO and SPIC manufactures Industrial
Intermediary Chemicals.Tamilnadu Petroproducts Limited (TPL) has established facilities to
manufacture 10908 MTPA of Epichlorohydrin since 1995 which is a key raw material in the
manufacture of epoxy resins, pesticides and in pharmaceutical formulations. The manufacturing
product is proposed to change from Epichlorohydrin to Propylene Oxide which uses same raw
material like propylene, lime, chorine with minor modification in the existing facility.
1.1. Project Details
TPL proposes to change the product mix from Epichlorohydrin to Propylene Oxide using same
raw materials
S.No Particulars Details
1. Project Product mix change- Epichlorohydrin
to Propylene Oxide
2. Geographical Location Village: Manali
Taluk: Thiruvottiyur
District: Thiruvallur
State: Tamil Nadu
3. Project Cost 12.96 Crores
4. Power Requirement 1.6MW
Standby DG-3.2MW
5. Project land area 38.72 acres
6. No of Employees 95
Contract based 180
7. Land use Special and Hazardous Industrial Use
Zone
8. Nearest Railway Station Chennai Central - 10 Km
Thiruvottiyur -2.1Km East
9. Nearest Airport Chennai Meenambakkam Airport - 38
km in south west direction
10. Nearest habitation Manali-2.6Km
TPL- EIA for Change of Product Mix Executive Summary
Hubert Enviro Care Systems Pvt. Ltd. ii
11. Densely populated area Thiruvottiyur-2.1 Km East
12. Inland water bodies Buckingham canal – 0.5 Km (East)
Surplus canal – 0.02 Km (North)
Satthankadu Lake–2.17 Km (South)
Madhavaram Lake–3.35Km (South
West)
Kadapakkam Panchayat Lake- 3.65
Km (North West)
Retteri – 7.64 Km (South West)
13. Source of water supply CMWSSB
14. Population in Manali 58,174 as per the census data (2014)
15. Highway Manali SH 56 road- Adjacent to site
16. Sea port Chennai port – 5 Km South East
Ennore Port – 10.9 Km North East
17. Forest/Wildlife Sanctuary Nil within 10Km radius
18. Industries around TPL MPL, CPCL, Indian Additives
Limited
1.2. Type of Project
Petrochemical based processing units located inside the notified industrial Area/estate are listed at
S.N. 5(e) under category „B‟. However, due to the applicability of general condition due to project
location within 10Km from Critically Polluted Area is treated as category 'A‟ and appraised by
Expert Appraisal Committee. The report is in accordance to the Terms of Reference (TORs) given
for Environmental Clearance application for product change on 31st March 2014.
2. Project Description
2.1 Location
The project site is located in Industrial town, Manali Village, ThiruvottiyurTaluk, Thiruvallur
districtin thestate ofTamil Nadu. It is located in north ofChennaiCity. It is 25 kms away from
Chennai city. The proposed area falls in the co-ordinates of 13°10'50.94"N, 80°16'47.91"E
towards North, 13°10'35.51"N, 80°16'45.12"E towards West, 13°10'32.29"N, 80°17'8.98"E
towards East.
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2.2 Change of Product Mix
Considering the demand for propylene Oxide in the country, TPL is proposing to change the
product mix to produce Propylene Oxide instead of Epichlorohydrin using existing facility. The
change in products and production capacity details are given in Table ES-1
ES-1 Change in Products and Production Capacity
S. No. Description Existing (MTD) Proposed (MTD)
1 Epichlorohydrin 30.3 NIL
2 Hydrochloric Acid 17.3 NIL
3 Chlorinated Organics 13.3 6.75
4 Propylene Oxide NIL 45
2.3 Justification of The Project
To meet the existing shortfall of Propylene Oxide in Indian Market, the existing facility of
ECH will be used to manufacture Propylene Oxide with the same raw materials(like
propylene, lime and chlorine).
Propylene Oxide will be supplied to Manali Petrochemicals Limited and other users.
2.4 Land Requirements
ES-2Land Breakup details
S. No. Description Area (Sq.m)
1. Total Plot Area 156694.29 /38.72 Acres
2. Factory coverage area 17900
3. Administration building 848
4. Green belt Existing - 16187.43 (10.3%)
Proposed - 32374.85 (20.7%)
Total – 48562.28 (31%)
5. Roads and Pavement 25786
6. Storage Area 20372
7. Parking Area 1177
8. Utilities 25440
9. Vacant area 16609.41 (vacant area is considered after
development of additional green belt).
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2.5 Raw materials
ES-3 Raw materials used in existing and proposed facility
S. No. List of Raw Materials Existing
(MTPD)
Proposed
(MTPD)
1 Propylene (Grade - 95%) 20.8 40.5
2 Chlorine 64.6 67.5
3 Water (KLD) 2150 (Fresh water 1650,
Treated effluent- 500)
2150 (Fresh water 1650,
Treated effluent- 500 )
4 Furnace Oil 37.3
(Boiler -15.0,
DG – 20.5
Propylene Heater- 1.8)
35.5
(Boiler -15.0,
DG – 20.5)
5 Lime 31 65
3. Description of The Environment
3.1 Air and Meteorological Environment
Six ambient air quality stations were proposed within a radius of 5 km from the project site during
March to May 2014. Parameters such as VOC, heavy metals, gaseous pollutants and particulate
matter were analyzed. PM2.5 ranged between 21-32 μg/m3 across the monitoring locations, PM10
ranged between 51-60 μg/m3, SO2 varied between 11-15μg/m
3, NO2 varied between 14-25 μg/m
3,
NH3 ranged from 5-8.6 μg/m3, TVOC ranged from 1.5 – 3.1 μg/m
3and other NAAQ parameters
like O3, Pb, CO were below detectable limits. All the parameters of NAAQ standards were within
the prescribed limits.
3.2 Noise Environment
The prevailing ambient noise levels at study area were monitored at five locations within 10km
radius. The field observations during the study period indicate that the ambient noise levels during
day and night in the study area ranged between 50-72 dB(A) and 40-60 dB(A) respectively and
are well within the prescribed standards at all the different noise zones prescribed by CPCB.
3.3 Water Environment
To assess the quality of water around the project site seven sampling locations of surface water
and three locations for ground water were selected within 10km radius of the site for
Physiochemical parameters, heavy metals, and biological parameters. The pH of the surface water
ranged from 6.08 to 8.18 across the sampling stations. The Electrical conductivity of the sample
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ranged from 1602 to 30300µs/cm across the sampling stations. The E.C value was the highest at
Thiruvottiyur shore. The concentration of Total Dissolved solids (TDS) ranged between 1650 to
20260.0 mg/l across the sampling stations. The highest TDS is observed in Thiruvottiyur shore.
The total hardness varied from 120- 8500 mg/l. Total hardness is exceeding the limits at sampling
locations at Thiruvottiyur Shore and Opp. MFL bus stop. Total alkalinity exceeds the limits in
Opp. MFL bus stop. The concentration of chlorides varied from 183 to 19052.96 mg/l Chlorides
and total dissolved solids exceed limits in Thiruvottiyur Shore. Rest of the parameters in the
sampling stations were well within the prescribed limits. The concentration of other parameters
like Aluminum (mg/l), Chromium (mg/l), Lead (mg/l) and Chromium (mg/l) were below the
detection limits.
3.4 Soil Environment
Soil characteristics such as color, porosity, soil texture, chromium, copper, sodium, chlorides etc.,
were analyzed at four sampling locations within 10km radius of the site. Organic matter of the
soil ranged between 0.04 to 0.43%, organic carbon ranged between 0.04 to 0.38%.Sandy soil
ranged between 67.25 to 92.94%, silt varies between 1.08 to 4.68% and clay content ranged
between 5.83 to 28.07%.
3.5 Ecology
There are no Wild life sanctuaries/ / National /Parks/ Reserved forest within 10 Km radius of the
site and there is no rare/ endangered species within the project study area.
3.6 Socio-Economic Environment
The proposed site is located in Industrial Area. For the proposed change of product mix, there is
no additional requirement of land and the existing land is within Industrial area. Hence there is no
specific impact on Socio economics and no rehabilitation and resettlement is involved.
4. Anticipated Environmental Impacts & Mitigation Measures
The emission details for existing stack details are analyzed and modeled by AERMOD software
and assessment methods like matrix method.
Based on the AERMOD software the Maximum Ground level concentration is estimated and
based on the baseline monitoring data and Ground level concentration predicted. It is found that
concentration levels arising are within NAAQ limits.
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ES-4Predicted GLC for Proposed Stack
Parameters Baseline data
(µg/m3)
Estimated
Maximum
Incremental
Concentration
(µg/m3)
Predicted
Maximum
GLC (µg/m3)
Direction Downwind
distance
(km)
SOX 13 9.2 22.2 W 1
SOX* 13 22.3 35.3 W 1
NOX 25 4.14 29.14 W 1
PM 60 0.414 60.414 W 1
*Emission load predicted when DG is in continuous operation (Worst case scenario), however DG will
be used only as a backup in case of power failure.
ES-5 Reduction in emission load due to change of product mix
S.No Contents Existing (MTPD) Proposed (MTPD)
1. Particulate Matter 0.052 0.0507
2. SOx 2.984 2.84
3. NOx 0.505 0.5
4. HCl 0.00006 Nil
5. Chlorine 0.00001 0.00001
Total 3.5410 3.3907
Due to the proposed change in the product mix, there will be a decrease in air pollution.
5. Environmental Management Plan
The Environmental Management Plan during construction and operation phase is discussed to
ensure the environmental protection around the project area.
Additional20.7% green belt area is proposed along with the existing green belt area.
STP and ETP outlet should contain following requirements as per TNPCB/CPCB are Flow
meter, pH, BOD, COD, TSS for proposed product change.
Air quality mitigation measures available in the existing plant will be used in proposed
project are:
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Caustic scrubber with an Intallox saddle packing is used in the proposed PO plant to take
care of Chlorine emissions.
On line chlorine Monitoring system in the scrubber stack, will be used and connected to
Care Center TNPCB.
Dust scrubber is proposed for Milk of lime Plant.
Continuous Ambient Air Quality monitoring station is available to monitor the ambient air
quality.
LDAR program will be implemented to reduce fugitive emissions.
6. Occupational Health and safety
TPL medical surveillance program include following major elements:
Developing a OH-IH Medical Surveillance Program
Pre-Employment Examination and Periodic Medical Examinations
Determination of Fitness for Duty
Communications
Emergency Medical Treatment
Medical Records
7. Fire and Explosion Control
TPL has a structured and an extensive firefighting system that serves all the components of the
plant. The main features of the existing firefighting system in TPL is as follows:
The fire station inside the plant consists of the following components:
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A fully equipped fire station with trained firemen is available to serve the plan
whenever the emergency arise.
Two central multipurpose fire tenders are available that serves all the plants inside
TPL.
Fire alarm annunciation panel.
Communication facilities such as Wireless, Hotline (LAB, PO, CPCL), direct line
telephone and intercom facilities are accessible from all the locations of the plant.
Emergency PPEs are available (Leather gloves, dust mask, ear muff, goggles, PVC
coat, PVC pant, PVC hood, PVC gloves, helmet with face shield, asbestos lug guard,
asbestos apron, half mask, full mask, gum boot) and are provided to the employees
with sufficient training as to how and when to use them.
Fire fighting equipments like Fire suits, Chemical protection suit, Elkhart nozzle, triple
purpose nozzles, short branches are available to serve the employees in the time of
emergency.
Fire station is constructed with concrete wall and provided with fire protection doors.
8. Budgetary Provisions for EMP
The details of capital and recurring (per annum) budget earmarked for pollution control, operation
and maintenance of pollution control facilities, for greenbelt development and maintenance
ES-6 Budgetary Provisions for EMP
S.No Environmental
protection measures
Capital Cost
(Lakhs) Proposed
Recurring cost
per Annum
(Lakhs)
1. Air Pollution Control 50 25 5
2. Water Pollution
Control 300 35 50
3. Noise Pollution
Control 5 1 2
4. Occupational Health
and safety 50 - 10
5. Green belt
Development 2 5 2
6. Storm water
Management 20 7 3
7. Waste Management 20 5 3
8. Fire Fighting 120 15 10
Total 567 93 85
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9. Risk Assessment
Predicting and evaluating risk to take appropriate preventive measures during the operation phase.
The ALOHA software is used to identify the risks such as BLEVE, toxic vapour explosion for the
chemicals such as Propylene oxide, propylene and chlorine that are stored in the plant along with
the magnitude of its impacts. Also, additional safety measures are recommended for the same.
Emergency management plan, policies and principles for safety aspects of the employees is given
which are to be strictly followed by management and employees.
10. Applicability of Environmental Clearance for Existing Facility
Since the Epichlorohydrin plant commenced its operation in the year 1995, Environmental
Clearance was not applicable. Valid Consent to Establish has been obtained from TNPCB vide
Letter dated 22/9/1993 and Consent to Operate Renewal was obtained vide letter dated 21/4/1999.
The unit is not operational since 1st April, 2013 owing to unviable business opportunities for the
product.
11. Conclusion
The Environmental Impact Assessment report studied the proposed project and assessed its
predicted impacts on land, water, air, soil and biological environment of the region. After
studying the impacts and effects of the proposed project, some of the salient features and
observations with respect to the proposed project are as follows:
Due to elimination of propylene heater and HCl scrubbing unit, the emissions from
respective stack will be reduced in the proposed production unit, thereby reduction in the
overall air pollution load.
Project study area is not falling within 10 km radius of National Park, Wildlife Sanctuary,
etc.
As the proposed project falls within the existing site, there is no need for rehabilitation and
resettlement.
No extraction of ground water is proposed.
There will be no additional water requirement and no additional water discharge for the
proposed project. Hence there is no change in waste water discharge and water pollution
load with respect to quantity and quality.
Lime sludge will be disposed to brick manufacturers.
TPL has adequate safety measures and does not anticipate any adverse effect on health of
workers.
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For handling and storage of raw materials and finished products proper measures has been
considered.
On line chlorine Monitoring system in the existing scrubber stack, is available and
connected to Care Center TNPCB.
LDAR program is available and the same will be followed to reduce fugitive emissions.
Dust scrubber is proposed for Milk of lime Plant.
Additional 20.7% area of Green belt is proposed with existing Green belt area.
STP and ETP outlet will have online monitoring system for Flow meter, pH, BOD, COD,
TSS for proposed product change.
Other than the above, proposed project will be bringing in various economical, social and
environmental benefits to the Manali town, Tamil Nadu.
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1 INTRODUCTION
1.1 COMPANY BACKGROUND
Tamilnadu Petroproducts Limited (TPL) was established in 1984,at Manali, Thiruvallur district in
the State ofTamil Nadu.
TPL commenced commercial production in the year 1985 with manufacturing facilities for Linear
Alkyl Benzene (LAB), finding application in manufacture of detergents and cleaning agents.
TPL established a plant to manufacture 10908 MTPA of Epichlorohydrin (ECH) in the year 1995
which is a key raw material in the manufacture of epoxy resins, pesticides and certain
pharmaceutical formulations.
TPL also acquired the Heavy Chemicals Division from SPIC in the year 2000 which manufactures
Caustic Soda and Chlorine which are the most commonly used industrial chemicals in Textile, Pulp
& Paper, Soaps & Detergents and Aluminium industries in India.
1.2 PROMOTERS AND BACKGROUND
TPL is a joint venture between Tamil Nadu Industrial Development Corporation
Limited(TIDCO)wholly owned by the Government of Tamilnadu and Southern Petrochemical
Industries Corporation Ltd. (SPIC) with more than 80,000 shareholders.
TPL is a listed company on Bombay Stock Exchange and National Stock Exchange.
M/s. SPIC Limited, has diverse interest in fertilizers, other services.
TIDCO is a public financial institution engaged in promoting industries in the State of Tamil Nadu.
1.3 MANUFACTURING FACILITY&CURRENT STATUS
TPL has established the facility to manufacture Epichlorohydrin (ECH) of 10,908 MTPA in the
year 1995 realizing the vitality of ECH in epoxy resin polymers. The technology for manufacture of
ECH was obtained from M/s. Conser S.p.A Italy.
ECH is a key input used in Epoxy Resins for anti-corrosive surface coating in Chemical Plants,
Infrastructure, Telecommunication, Construction, Electronics etc., The existing ECH facility is
located at, Manali Industrial Area, Thiruvottiyur Taluk, Thiruvallur District. The unit is not
operational since 1stApril, 2013 owing to unviable business opportunities for the product.
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1.4 CHANGE OF PRODUCT MIX
Considering the demand for propylene Oxide in the country, TPL is proposing to change the
product from Epichlorohydrin to Propylene Oxide using the existing facility with the same raw
material. The change in products and production capacity details are given in Table 1-1.
Table 1-1Change in Products and Production Capacity
S. No. Description Existing (MTD) Proposed (MTD)
1 Epichlorohydrin 30.3 NIL
2 Hydrochloric Acid 17.3 NIL
3 Chlorinated Organics 13.3 6.75
4 Propylene Oxide NIL 45
1.5 JUSTIFICATION FOR THE PROJECT
To meet the existing shortfall of Propylene Oxide in Indian Market the existing facility of
ECH will be used to manufacture Propylene Oxide with the same raw materials (like
propylene, lime and chlorine).
Propylene Oxide will be supplied to Manali Petrochemicals Limited and other users.
1.6 MARKET POTENTIAL
Current imports of Propylene oxide is about 20000 MTA. Considering the domestic production, the
total demand for Propylene oxide is around 60000 MTA.
Current Propylene glycol imports is about 50000 MTA and polyol imports is more than 1 lakh tone
per annum.
The 15000 MTA Propylene oxide produced can be sold as such or used for making Polyols.
1.6.1 Propylene Glycol
Propylene glycol is used for various applications in industries viz
Pharmaceuticals
Food flavors and essences
Polyester resins
Perfumery compounds
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Cosmetics
Cigarettes
Tooth paste
Pesticides
Of this, Pharmaceuticals, food flavors and polyester resins manufacturing sectors account for
a major share in the present consumption of Propylene Glycol in the country.
1.6.2 Polyols
The polyols are broadly classified based on application as given below
Flexible Polyurethane foams
Rigid Polyurethane foams
Semi-rigid Polyurethane foams
Miscellaneous applications
a) Flexible Polyurethane foams–These are largely used for various household
applications such as furniture cushions, beds, mattresses etc. Also in automobiles, seat
cushions, arm rests coverings etc are made using flexible foams. In certain cases these
are used as packaging material for high value items. Some of the miscellaneous
applications include foam laminations, toys, and novelties.
b) Rigid Polyurethane foams -The specific thermal insulation characteristics of rigid PU
foams are far superior to that of all other polymeric foams. The obvious advantage of
polyurethane rigid foam is the lesser thickness required to achieve the same thermal
efficiency as other materials.
These are used as insulating materials in
Air conditioning and refrigeration industry (insulation of domestic refrigerators, Air
conditioner, refrigerated vans etc.,)
Process industry (insulation of process equipments, pipelines, storage tanks etc)
Transportation industry (insulation of rail coaches, bus coaches, air craft, ships etc)
c) Semi-rigid Polyurethane foams–They are used in the manufacture of steering wheels,
scooters/motorcycles/bicycles/car seats, arm rests, shoe soles etc.
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d) Miscellaneous applications -Polyols are also used in the manufacture of polyurethane
elastomer, coatings, paintings, adhesives/sealants, binders etc.
1.7 PROJECT SETTING
The site is located in Manali Industrial Area. Manali is a Northern Suburb of Chennai city. The
Industrial area caters to mostly Petrochemical based industries. Major industries located are given
below with its distance and direction from the site. The satellite imagery for the same around a
radius of 10 Km is attached as Annexure 1.
Table 1-2 List of Industries Within 10 Km radius of the Project Site
S.No Industry Product Distance &Direction
1. M/s.MRF Tyres Tyres 2.85 Km, E
2. M/s.Carborundum Universal Ltd Super Refractories 2.9 Km, E
3. M/s.CPCL Petroleum Refinery 1.1 Km, S
4. M/s.Indhumathi refineries Edible Oils 3.58Km, SE
5. M/s.Eveready industries Batteries 3.76Km, SE
6. M/s.IOCL Lube oil Plant 3.5Km, SE
7. M/s.Bharath Petroleum Lube oil Plant 5.2 Km, S
8. M/s.HPCL Terminal Oil Terminal 5.6 Km, S
9. M/s.Madras fertilizers Limited Fertilizers 1.4 Km, W
10. M/s.PetroAraldite Epoxy Resins 50 M, Adjacent
11. M/s.Manali Petrochemicals Limited Petrochemicals 65 M, SW
12. M/s.Indian Additives Limited Additives Adjacent opposite to the
site
13. M/s.TPL, Heavy Chemicals Division Chlor Alkali 20m, opposite to the site
14. M/s.TPL Linear Alkyl Benzene Division Petrochemicals Opposite to the site
15. M/s.IOC Bulk terminal & bottling
plant
1.65 Km, W
16. M/s.Toshiba JSW Turbine Turbines 1.86Km, NW
17. M/s.Sattva CFS Pvt. Ltd Warehouse 1.05 Km, NW
18. M/s.Tivary CFS Pvt. Ltd Ware house 4.3Km, N
19. M/s.NDR Ware housing Ware house 4.6Km, N
20. M/s.East coast organics Organic Chemicals 5.45 Km, N
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S.No Industry Product Distance &Direction
21. M/s.AshokLeyland Automobile 1 5.87Km, N
22. M/s.Vallur Thermal Power Plant Power Plant 6.81 Km, NE
23. M/s.India Cements Cement 6.9 Km, NE
24. M/s.North Chennai Thermal Power Station Power Plant 9.7 Km, NE
25. M/s.Coromandel Fertilizers Fertilizer 6.18 Km, NE
26. M/s.Hinduja Foundries Foundry 5.59 Km, NE
27. M/s.AshokLeyland Automobile 2 5.20Km, NE
28. M/s.Ennore Thermal Power Plant Power Plant 3.2Km, NE
29. M/s.NicholasPiramal Pharmaceutical 3.83Km, NE
30. M/s.Cetex Petrochemicals 0.6 Km, S
31. M/s.Kothari Petrochemicals 0.7 Km, S
32. M/s.SRF Polyesters 1 Km, SE
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1.8 PROJECT LOCATION
The project site is located at R.S.No.254/3 (part),259/2, 260/2, 261/2, 262/2, 263/2A, 265/1A1, 265/1A2,
266/1A.1A1B (part), 266/1A1B/2B1A2 (part),Manali Industrial Area, Manali Village, Thiruvottiyur
Taluk, Thiruvallur District in the state of Tamil Nadu. The proposed site falls in the co-ordinates of
13°10'50.94"N, 80°16'47.91"E towards North, 13°10'35.51"N, 80°16'45.12"E towards West,
13°10'32.29"N, 80°17'8.98"E towards East.The project site is situated on the State Highway 56 which is
called Manali High Road. The location of the project site is given in Figure 1-1.
Figure 1-1 Location of the Project Site
TPL Site
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1.9 EIA REQUIREMENT
The Government of India, Ministry of Environment and Forests (MoEF), New Delhi, vide
notification no. S. O. 1533 dated 14th
September, 2006, (subsequently amended by S. O. 3067(E)
dated 1st December 2009), has made it mandatory to obtain „Prior Environmental Clearance‟ for
change in the product mix of existing projects or activities entailing capacity addition with change
in process falling within the schedule to that notification from MoEF (for Category A projects) or
from SEIAA (for Category B projects).
The proposed project is about product change from Epichlorohydrin to propylene Oxide which falls
in Petrochemical based processing units located inside the notified industrial area/estate are listed in
schedule no. 5(e) under category „B‟. However, applicability of general condition due to project
location within 10Km from Critically Polluted Area (CPA) proposal is treated as category „A‟ and
will be appraised by expert Appraisal committee.
The application along with the project documents for the product mix change was submitted by
TPL on 5.09.2013 (Letter no: TPL/ENV/2013/5542).Based on the information furnished and
presentation done before the Expert Appraisal Committee (EAC) and after giving due consideration
to various aspects of the project, scoping of the project was done on the14th
Reconstituted Expert
Appraisal Committee (Industry) meeting held during 19th
and 20th
December, 2013 vide Agenda
No. 14.5.15 and Terms of Reference (TOR) were assigned for the EIA study by MoEF in the letter
F.No. J-11011/280/2013-IA-II (I) dated 31st March 2014. The TORs along with its point-wise
compliance are given at the end of the report and is attached as Annexure 2. Thus, TPL was
required to prepare an Environmental Impact Assessment (EIA) Study Report for the final appraisal
by EAC. With a view to evaluate likely impacts on various components of the environment because
of the proposed project, TPL took services of Hubert Enviro Care System Pvt. Ltd for preparation
of Environmental Impact Assessment Report.
1.10 Environmental and Related Acts and Rules Applicable
The following are some of the acts and rules related to environment which are applicable for the
proposed project:
1. EIA Notification 2006 and its amendments
2. Manufacture Storage and Import of Hazardous Chemicals Rules,1989and its amendments
3. Water(Prevention and Control of Pollution) Act,1974and its amendments
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4. Air(Prevention and Control of Pollution) Act,1981and its amendments
5. Hazardous Waste (Management, Handling and Transboundary movement)Rules,2008 and
its amendments
6. Public Liability InsuranceAct,1991 and its amendments
7. Environmental (Protection)Rules,1986 and its amendments
8. The Noise Pollution (Regulation and control) rules, 2000
9. Tamil Nadu Factories Rules 1950 and its amendments
10. Petroleum Act, 1934
11. Explosive Act,1884
12. Central Motor Vehicle Act, 1988
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The details of applicable Acts and Rules and the applicability to the project is given in Table 1-3.
Table 1-3Applicable Acts and Rules for the Proposed Project
S.No Act and rules applicable Purpose Objective Applicability
1. EIA Notification 2006 and its
amendments.
New projects, Expansion
modernization, change of
product mix of the
existing project
Protection and Improvement of
the Environment
Environmental clearance from Ministry of
Environment & Forest.
2. Manufacture, Storage and
Import of Hazardous
Chemicals Rules, 1989 and
its amendments
Handling of Hazardous
Chemicals
Regulate the manufacture,
storage and import of
Hazardous Chemicals
Preparation/ update of On-site Emergency
Preparedness Plan and submission to
Factory inspectorate.
Preparation/ update of Safety Report and
submit to Factory inspectorate.
Preparation of Material Safety Data Sheet.
3. Water (Prevention and
Control of Pollution) Act,
1974 and its amendments.
New projects, Expansion
modernization, change of
product mix of the
existing project,
Existing plants
Prevention, control and
abatement of water pollution
Consent to establish and Consent to
Operate from State Pollution Control
Board
4. Air (Prevention and Control
of Pollution) Act, 1981 and
its amendments.
New projects, Expansion
/modernization, change
of product mix of the
Prevention, control and
abatement of air pollution
Consent to Establish and Consent to
Operate from State Pollution Control
Board.
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existing project, Existing
industries
5. Hazardous waste
(Management, Handling and
Transboundary Movement
Rules) 2008 and its
amendments.
Management, Handling
and Transboundary
Movement of Hazardous
waste
Prevention, Control and
abatement of pollution
Hazardous waste Authorization from State
Pollution Control Board.
6. The Environmental
(Protection)Rules,1986 and
its Amendments
New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
Protection and Improvement of
the Environment
Environmental Standards as specified are
to be complied.
Submission of Environment Statement.
7. The Noise Pollution
(Regulation And Control)
Rules, 2000
New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
To protect the workers and
public from noise related
problems
Noise control measure.
Comply with Noise standards.
8. Public Liability Insurance
Act, 1991 and its
amendments
Transportation of
Hazardous Substance.
To provide immediate relief to
persons affected by accident
involving hazardous substances
and also for Establishing an
Environmental Relief fund
Provision of Liability Insurance Policy.
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9. Tamil Nadu Factories Rules
1950 and its amendments.
New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
Control of workplace
environment, and providing for
good health and safety of
workers
Factory License from Factory inspectorate.
10. Petroleum Act, 1934 New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
Production, Storage and import
of petroleum and provides the
regulations for the safety and
environmental measures
License acquired for storage and adequate
safety measures are in place.
11. Explosive Act, 1884 New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
Production, Storage and import
of explosive substance in and
around the project and provides
the regulations for the safety
and environmental measures
Safety measures are complied for the
storage of chemicals in the plant as per
PESO guidelines.
12. Central Motor Vehicle Act,
1988
New projects,
Expansion/modernization
change of product mix of
the existing project,
Existing industries
Check the pollution load of
vehicles inside the plant
Adequate environmental measures are put
in place to check the vehicular emissions.
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1.11 METHODOLOGY ADOPTED FOR THE STUDY
An Environmental Impact Assessment (EIA) is an assessment of the possible impact, whether
positive or negative, that a proposed project may have on the environment, together consisting of
the natural, social and economic aspects, i.e. aiming at “Sustainable Development” due to the
project activities.
1.11.1 Objectives of this EIA report
To ensure environmental considerations are explicitly addressed and incorporated into the
development decision-making process.
To anticipate and avoid, minimize or offset the adverse significant biophysical, social and
other relevant effects of the above project proposal.
To protect the productivity and capacity of natural systems and the ecological processes
which maintain their respective functions.
To promote development that is sustainable and optimizes resource use as well as
management opportunities.
To fully recognize the scope and requirements of the TOR and comply with the same.
1.11.2 EIA Process
The EIA process followed for this EIA report is composed of the following stages:
Study of project information
Screening & Scoping
Environmental pre-feasibility study & application for approval of TOR
Collection of detailed project management plan/report
Baseline data collection
Impact identification, Prediction & Evaluation
Mitigation measures & delineation of EMP
Risk assessment and safety & disaster management plan
Review & finalization of EIA Report
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Submission of EIA report for implementation of mitigation measures & EMP as well as
necessary clearances from relevant Authority.
The EIA Cycle based on the above stages has been presented as illustration in subsequent Figure.
1-2
Figure 1-2 EIA Process Cycle
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2 PROJECT DESCRIPTION
2.1 ABOUT THE PROJECT
Tamilnadu Petroproducts limited (TPL) has established facilities to make Epichlorohydrin (ECH)
since 1995 which is used in manufacture of epoxy resins, pesticides and in pharmaceutical
formulations, which is not operating since April 2013 as
cheaper imports of epoxy resins reduced the market process for ECH,
increase in raw material cost
The manufacturing product is proposed change from Epichlorohydrin to propylene oxide which
uses the same raw materials like propylene, lime, chorine with minor modification in the existing
facility. The change in products and production capacity are given below in Table 2-1
Table 2-1Change in Products and Production Capacity
S. No. Description Existing
(MTPD)
Proposed
(MTPD)
1. Epichlorohydrin 30.3 NIL
2. Hydrochloric Acid 17.3 NIL
3. Chlorinated Organics 13.3 6.75
4. Propylene Oxide NIL 45
2.2 PROJECT LOCATION
The project site is located in Industrial town and Municipality inThiruvallur districtin theIndianstate
ofTamil Nadu. It is located in north ofChennaiCity. It is 25 kms away from the Chennai city. The
Google image of 10 km radius is given in Figure 2-2.The topographic map of the site is attached as
Annexure 3
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Figure 2-1 Location of the Project Site
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Table 2-2 Salient Features of Project and Surrounding features
S.No Particulars Details
1. Project Product mix change- Epichlorohydrin to Propylene oxide
2. Geographical Location 13°10'50.94"N, 80°16'47.91"E Towards North
13°10'35.51"N, 80°16'45.12"E Towards West
13°10'32.29"N, 80°17'8.98"E Towards East
Village: Manali
Taluk: Thiruvottiyur
District: Thiruvallur
State: Tamil Nadu
3. Project Cost 12.96 crores
4. Power Requirement 1.6MW
Stand by DG-3.2MW
5. Project land area 38.72 Acres
6. Land Use asper CMDA Special and Hazardous Industrial Zone Vide Map no MP-
II/CMA (M) 3/2008
7. Topo sheet No. D4408 (66C8)
8. No. of employees 95
Contract based man power 180
9. Land use Special and Hazardous Industrial Use Zone Vide Map No.
MP-II/CMA(M) 3/2008
10. Nearest Railway Station Chennai Central-10 km
Thiruvottiyur-2.1 Km East
11. Nearest Airport Chennai Meenambakkam Airport - 38 km in south west
direction
12. Nearest habitation Manali - 2.6 Km
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Figure 2-2 10 Km Radius Google Map of the Site and Surroundings
13. Densely populated area Tiruvottiyur -2.1 Km
14. Inland water bodies Buckingham canal – 0.5 Km(East)
Surplus Canal – 0.02 Km (North)
Satthankadu Lake -2.17 Km (South)
Madhavaram Lake-3.35Km (South West)
Kadapakkam Panchayat Lake- 3.65 Km (North West)
Retteri – 7.64 Km (South West)
15. Source of water supply CMWSSB
16. Population in Manali 58,174 as per the census data (2014).
17. Highway Manali Road - SH 56 road- adjacent to the site
18. Sea port Chennai port – 5 Km South East
Ennore Port – 10.9 Km North East
19. Forest/Wildlife Sanctuary Nil with in 10 Km radius
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Figure 2-3 Google Image of Project Site
Figure 2-4 Topo map showing 5 km around the site
Project Site
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2.3 LAND REQUIREMENTS
The land use breakup of the existing plant is given below in Table 2-3.
Table 2-3 Land use breakup details
S. No. Description Area
1. Total Plot Area 156694.29 (Sq.m) /38.72 Acres
2. Factory coverage area 17900 (Sq.m).
3. Administration building 848 Sq.m
4. Green belt Existing - 16187.43 (10.3%)
Proposed - 32374.85 (20.7%)
Total – 48562.28 (31%)
5. Roads and Pavement 25786 Sq.m
6. Storage Area 20372 Sq.m
7. Parking Area 1177 Sq.m
8. Utilities 25440 Sq.m
9. Vacant area 16609.41 Sq.m(vacant area is considered
after development of additional green belt).
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The land documents are enclosed in Annexure-4.The land use of the site as per CMDA Land Use
map is enclosed in Annexure-5.
2.4 MANPOWER
The existing manpower at ECH facility can be used for operating the PO plant. The total manpower
for the proposed PO plant will be 95 employees and 180 contract manpower.
2.5 PLANT LAYOUT
The existing layout plan of ECH Plant is enclosed in Annexure-6 and the proposed layout plan of
Propylene Oxide is enclosed in Annexure-7.
2.6 RAW MATERIAL REQUIREMENTS
2.6.1 Source of raw materials
The raw materials used in the proposed site are acquired from different sources and different
modes of transport. The movement of the raw materials across the site is attached as
Annexure-8 . The details for the source and transportation of raw materials are as follows:
There is no change in the raw materials used for proposed modification. The details of raw
materials used for existing facility and proposed modification is given in Table 2-4
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Table 2-4 Source and Transportation of Raw materials and products
S.No Raw materials Storage
details
Quantity of
storage (MT)
Source Means of Transport
1. Propylene 2 Tanks
(2*346m3)
346 CPCL and
other
companies
3Tankers each of 16
KL per day
2. Chlorine NA (Pipe line) - HCD plant of
TPL
Pipelines
3. Lime Godown 300 Imported
through
Chennai Port
3Trucks of each of 22
Tonnes per day from
the Chennai port trust
to the plant
4. Furnace Oil (1X400 M3) 394.4 From LAB
Plant through
Pipeline/
tankers from
other sources
Pipeline inside the
site
5. Propylene Oxide 2 Bullets * 145 232 - 3Tankers each of 16
KL per day
6. Chlorinated
Organics
2 Tanks * 100 220 - 1 Tanker of 16 KL
once in two days
Table 2-5 Raw materials used in existing and proposed facility
S. No. List of Raw Materials Existing(MTPD) Proposed(MTPD)
1 Propylene
(Grade - 95 %) 20.8 40.5
2 Chlorine 64.6 67.5
3 Water (KLD) 2150 (Fresh water 1650
Treated effluent- 500)
2150 (Fresh water 1650,
Treated effluent- 500)
4 Furnace Oil 37.3 (Boiler -15.0, DG – 20.5,
Propylene Heater-1.8) 35.5 (Boiler -15.0, DG – 20.5)
5 Lime 31 65
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2.7 MANUFACTURING PROCESS
2.7.1 Existing Epichlorohydrin Plant
The manufacturing of Epichlorohydrin consists of two steps. 1) Manufacturing of allyl
chloride which is intermediate product and 2) Manufacture of Epichlorohydrin from allyl
chloride.
In allyl chloride reaction system, the dry gaseous propylene feed is first preheated to 80°C by
condensate in the super heater and then at 300°C in the furnace. This hot Propylene is fed to
the reactor where it mixes well with dry Chlorine gas exothermically. The reaction gases
leaving the chlorination reactor are quenched in the quench tower where in dichloropropane is
used as quenching medium which on vaporization cools the reaction gases and condenses the
heavy fractions at the bottom.
The over head vapours from the quench tower after partial condensation is then subjected to
chilling and partial condensation in three consecutive exchangers by means of depropanizer
over head vapors, cold vapour propylene and by vaporizing propylene respectively. The heavy
ends of the quench tower are striped in stripper and the residual bottom contents are disposed
to the chlorinated organic disposal system after cooling.
The condensed liquid or vapor mixture is fed to the depropanizer feed separator which
separates the vapor and liquid is than passed into depropanizer column at middle and lower
feed trays respectively. The depropanizer column separates the gaseous mixture of propylene
and hydrogen chloride at the top free of chlorinated organic and chlorinated organics at the
bottom. The over head gas steam from depropanizer column is then passed on to the hydrogen
chloride separation and recovery section and the bottom crude allyl chloride steam is sent to
purification system.
The crude allyl chloride is passed to the lights column where the light ends are removed
overhead. The bottom product stream of allyl chloride plus heavy ends is continuously
removed and is fed to the heavies column. In the heavies column, the overhead vapors
containing allyl chloride product is condensed and product cut is sent to storage vessel. The
bottom of the heavies column is partially used in quench tower and partially sent to
chlorinated by-products disposal system.
The hydrogen chloride and propylene gas is fed to the HCl absorber column where the acid
vapours are absorbed in DM water. The residual HCl vapors from the absorber is washed with
water and then preheated and fed to stripping column to remove the traces of light organics.
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Then, from the stripping column, the final HCl vapors are condensed and cooled subsequently
transferred to acid storage facility.
The gaseous propylene leaving the HCl recovery section is passed through caustic water
scrubber to remove traces of HCl. The scrubbed propylene vapours sent to compressor then
compressed in two stages, then condensed, cooled and liquefied. The liquid propylene is then
cooled by vaporizing propylene and the vaporized refrigerant propylene is sent to coalescer
which removes most of free water. The recycled liquid propylene stream and the fresh
propylene stream are together fed into drying system and after vaporization are fed to the
reactors.
The reaction for producing Epichlorohydrin is carried out by contacting allyl chloride and
chlorine previously diluted in aqueous solution. The liquid allyl chloride and gaseous chlorine
is metered into parallel mixers and fed to the reaction unit. The reaction is carried out at 40 to
50oC. The resultant chlorohydrins solution from the reactor is fed to the chlorohydrins
solution from the reactor is fed to the chlorohydration tank. The organic byproduct phase
trichloropropane is allowed to separate from the liquid in reaction circulation loop and the
dichlorohydrins is being fed to the Dehydrochlorination towers.
In the Dehydrochlorination system the premixing of dichlorohydrins stream and alkali takes
place followed by the conversion of dichlorohydrins into Epichlorohydrin takes place in the
steam stripped column by means of reaction with milk of lime. In further the overhead
stripper vapours are condensed and cooled and then phase separated.
In the dehydration still system, the removal of water contained in the raw Epichlorohydrin
takes place combined removing the low boiling organic impurities to produce a good purity
raw Epichlorohydrin.
The raw Epichlorohydrin is further effectively distilled in high efficiency structured packing
column to obtain 99% min. purity Epichlorohydrin which is free from high boiling impurities.
The heavy ends of the dehydration still column are fed to the extraction tower to recover
valuable Epichlorohydrin and dichlorohydrins. The residue of the extraction tower is sent to
disposal.
The overview of the process is given in Figure 2-5andFigure 2-6.
Mass balance for the existing ALC and ECH unit is given in Figure 2-7 and Figure 2.8
respectively.
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Figure 2-5 Process overview of Allyl Chloride Section
REACT
OR
SYSTE
M
PROPYL
ENE
SEPARA
TION
SYSTEM
PROPYLE
NE
COMPRES
SOR
SYSTEM
HCL
SEP.
SYSTE
M
HCL
STORAGE
SYSTEM
CRUDE
ALC
STORAG
E
SYSTEM
PURIFICA
TION
SYSTEM
CHLORIN
ATED
ORGANIC
S
STORAGE
SYSTEM
PROPYL
ENE
CHLORI
NE
PURE
ALC
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Figure 2-6Process overview of Epichlorohydrin Section
CHLORI
NE
PURE
ALC
REACTI
ON
SYSTEM
DEHYDRO
CHLORINAT
ION
SYSTEM
DEHYDRO
CHLORINAT
ION
SYSTEM
ECH
PURIFICAT
ION
SYSTEM
PRODUCT
ECH
STORAGE
SYSTEM
LIGHTS AND
HEAVIES
TO
CHLORINATED
ORGANICS
STORAGE
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Figure 2-7 ECH Material balance - ALC unit
Figure 2-8 Mass Balance for Epichlorohydrin Production
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Table 2-6 Epichlorohydrin characteristics
Sl. No. Characteristics Specification
1. Density gm/ml @ 200C 1.179-1.182
2. Color (Hazen Scale ) 15 Alpha Max
3. Refractive index (250C) 1.434 - 1.436
4. Purity WT% 99.5 Min
5. Moisture WT% 0.1 Max
6. Iron (ppm) 0.2 Max
2.7.2 Manufacturing Process of Propylene Oxide
The major raw material used in this process is propylene, which is received through tankers
and stored in two bullets. Propylene from the storage bullets is drawn to the propylene oxide
plant. Then it is vaporized and sent to the PO reactor. It reacts with chlorine and water to form
propylene chlorohydrin according to the following reaction.
Cl2 +H2O HCL +ClOH
ClOH + C3H6ClC3H6OH
The solution is then saponified with milk of lime to generate propylene oxide.
2ClC3H6OH+ Ca (OH)22C3H6O + CaCl2 + 2H2O
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Figure 2-9Flow diagram of propylene Oxide plant
The vapour of Propylene Oxide is stripper with steam and distilled to get final product. The
final product is sent to Propylene Oxide storage. The propylene oxide product is used for the
manufacture of propylene glycol and Polyether Polyols.
The basic process is based on reaction of vapour phase propylene with a mixture of chlorine
and water in liquid phase under controlled conditions followed by saponification of the
chlorohydrins formed with lime.
The different sections of the plant are
Propylene Vapourisation Section
Cholohydrination section
Saponification section
Purification section
2.7.2.1 Propylene Vapouriser
Propylene in the form of liquid obtained from the bullet would be vaporized on the shell
side of the vaporizer circulating the water on the tube side. The cold will be recovered in
the water and the chilled water will be used in different section of the plant. The Propylene
so vaporized would be piped through a control valve to the chlorohydrin reactor made of
Titanium.
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2.7.2.2 Chlorohydrination section
Propylene, Chlorine and water are continuously introduced into the bottom of the
Chlorohydrins reactor where Chlorohydrination takes place as the bubbles of propylene
and chlorine pass up in the reactor. The reactions that are taking place in the reactor are
exothermic in nature and temperature will settle down without external heating or cooling
due to enormous quantity of water that is under circulation in the reactor. The
Chlorohydrin solution thus obtained is overflowed from the reactor and sent to the
Saponification section.
2.7.2.3 Saponification section
A slightly excess calcium Hydroxide in an aqueous slurry form is used to saponify the
Propylene Chlorohydrin .The Chlorohydrin solution leaving the reactor is mixed with the
lime solution in a static mixer and is fed into the Saponifier where the Propylene
Chlorohydrin is saponified and converted into propylene oxide. The propylene oxide is
then stripped with live low pressure steam and is removed rapidly from the reaction zone
and taken to a distillation section for the further purification. The waste lime solution from
the bottom of the saponifier along with calcium chloride formed in the reaction is sent
through a hydrocyclone to remove the solid particles and clear solution is sent through
plate heat exchangers to recover the heat before discharging to the effluent treatment
section.
2.7.2.4 Purification section:
Distillate from the saponifier consists of propylene oxide and water with some chlorinated
byproducts. It is fed into the propylene oxide column where the crude propylene oxide is
further purified and the pure propylene oxide is condensed in the overhead condenser and
sent to storage tanks. The Propylene oxide column bottom consisting of chlorinated
Organics and water is fed to a decanter where water is separated and recycled back to the
reactor ,pure Chlorinated Organics is sent to storage and sold as a by-product.
2.7.2.5 Uses of Propylene Oxide:
About 60 and 70% of all Propylene Oxide is converted to polyether polyolsfor the
production of polyurethaneplastics.
About 20% of propylene oxide is hydrolyzed intopropylene glycol.
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Figure 2-10 Mass Balance for Propylene Oxide
2.8 UTILITIES AND SERVICES
The existing utilities and offsite of ECH will meet the requirements of the proposed PO facility.
2.8.1 Water System
Water received from CMWSSB is stored in reservoirs and treated at the Water Treatment
Plant (WTP).Depending on the applications, various treatments are done. We can divide the
Storage and WTP into various systems, viz.,
Raw water system
Service water system
Process water system
DM water system
Fire water system.
I. Raw Water System -Water is always received in fire water reservoir from
where it overflows to raw water reservoir. Inter compartment transfer and
transfer from fire water reservoir to raw water reservoir is possible. Water
can be received directly into any of these compartments. The storage
capacity of the raw water reservoir (RWR) is generally based on 3 to 4
days requirement. Storage capacity of the Firewater Reservoir (FWR) is
based on the Tariff Advisory Committee‟s Assessment of our plant. Raw
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water is pumped to Raw Water Treatment Plant using transfer pumps. The
RW Reservoir has a Chlorination system.
II. Service Water System -Raw water is pumped to a unit where suspended
particles are removed. Filtered water is drawn off from this unit outlet and
sent to the drinking water storage tank. A centrifugal pump with emergency
power supply discharges water from this tank to all the safety showers and
eye wash fountains in the plant as shown in the Figures 2-11, 2-12
respectively. Maintaining level is very critical in this tank.
III. Process Water System- A second stream from suspended solids removal
unit outlet flows through Activated Carbon Filters (ACF) operating in
parallel. ACF outlet water free of organics and residual chlorine is drawn
off as process water. One main stream flows to DM plant and another to
process water system from ACF outlet. Process water (PW) flows to
various parts of the plant in the following ascending order of distance.
Cooling tower make up
Main plant
In general, PW also flows to utility points. For the operation ease, all the
valves of PW system are kept in ground level and in one location. From
this location water is branched and sent to the various user points.
IV. DM Water System -After drawing Service water (SW) and Process Water
(PW), chlorine free water with charged ions flows to DM plant. DM water
is mainly used for the operation of boiler.The DM plant can be arranged in
different forms according to the requirement. One such form which consists
of a strong acid cation exchanger, followed by weak base anion exchanger,
degasser and strong base anion exchanger with regeneration facility and
acid / alkali proof tiled trench for effluent flow is described below.
A DM water storage tank, and transfer pumps are provided. DM plant is
operated manually. DM plant is designed to be in line continuously with
say, for example 16 hours of operation. Balance time is available for
regeneration. DM plant capacity is 60 m3/hr and regeneration is done after
say, 480 m3 of DMW production. This is called one service cycle. DM
Water pump discharges to Boiler, Main plant and also to DM plant for
SBA regeneration. Effluents flow to Effluent Treatment Plant (ETP) by
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gravity. Regeneration chemicals, 33% HCl and 20% NaOH are stored in
two separate tanks.
V. Fire Water System -The Tariff Advisory Committee of the State
Government gives the design requirements of Fire Fighting System. Fire
hydrants (pipelines) are provided underground with anti corrosive tape
wounded on it over molten bitumen throughout the plant. Water outlets
with valves are provided from these hydrants which have sluice valves at
various locations. These sluice valves enable us to attend underground leak
in hydrant after isolation. Water from the individual outlets can be used for
fighting fire. Outlets are provided in various forms – viz.,
Single hydrant.
Double hydrant.
Monitors.
Deluge valve cum automatic sprinkler system for storage tanks.
Main hydrant pumps motor driven as well as diesel engine driven take
suction from the firewater reservoir with spill back and connect to
underground fire water hydrant network. The network is continuously
charged with jockey pumps (motor driven). These pumps also take suction
from Fire Water Reservoir (FWR) and connect to the network. An
underground room called the Firewater Pump House (FWPH) houses the
pumps and enables flooded suction for the pumps. A Dewatering Pump is
provided for the pump house. Pumps running indication are provided in
DCS of Main Control Room (MCR), in repeater panel in MCR and in
SafetyBuilding panel.
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Figure 2-11 Emergency Eye washer
Figure 2-12 Safety Showers
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2.8.2 Water Supply
Water supply for both existing and proposed facility of TPL is obtained from CMWSSB. The
receipt form CMWSSB for watersupply is enclosed in Annexure- 9.Water requirement for
existing manufacturing facility - plant purpose, cooling, for process and steam makeup etc.,
is 2150m3/day. The proposed water consumption is 2150m
3/day as existing requirements.
There is no change in the water requirements.
Table 2-7Water Consumption for Existing and Proposed plant
S.No. Sources of water requirement Existing (m3/day) Proposed (m
3/day)
1. Cooling tower 230 220
2. Domestic 50 50
3. Process 1575 (1075 Fresh water +
500 Treated effluent)
1645 (1145 Fresh water + 500
Treated effluent)
4. DM plant regeneration 75 55
5. DM Water Make up to Boiler 220 180
Total 2150 2150
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Figure 2-13Water balance for existing ECH plant
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Figure 2-14Water Balance for Proposed PO Manufacturing
2.8.3 Sewage Treatment Plant
A combined Sewage treatment Plant for all TPL units is located at ECH plant for the Toilet
and canteen waste water.
Design
Capacity : 160 cu.m / day
BOD : 400 mg / l
Flow : Complete mix
MLSS mg/l : 3000 - 8000
Hydraulic Retention Time : 18 – 36 Hrs
BOD Removal : 90 – 98 %
2.8.3.1 Description
The sewage water generated from above source is pumped to Raw Effluent collection tank.
From Raw Effluent collection tank it is pumped to Aeration Tank through the Screen
Chamber. The solid particles retained in the Screen Chamber are periodically removed for
disposal. The screened effluent enters the Aeration tank. One number of 10 HP Aerator is
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provided to supply the necessary oxygen for biodegradation. Air diffusion is provided in
the aeration tank through air blower and diffuser arrangement.
The overflow from aeration tank is then sent to the Clarifier tank for settling. The bioflocs
formed in the aeration tank will be settled at the bottom of the Clarifier tank through
clarifier rake mechanism placed inside the clarifier tank. The settled sludge will be re-
circulated to the aeration tank in order to maintain MLSS concentration and the settled
sludge will be pumped to the sludge holding tank through the return sludge pump. A part of
the sludge is routed to the sludge draining bed (4 Nos). The clarified overflow will be
collected in the clarified water tank from where it is pumped to the Pressure sand filter
through filter feed pump in order to remove the suspended solids, organic matter & odour.
Sodium hypo chlorite dosing is given manually in the filtered water tank with the help of
dosing system for disinfection purpose.
The filtered water from Pressure sand filter will be collected in the filtered water tankand
used for gardening.
2.8.3.2 Disposal of Treated Sewage Effluent
Thetreated sewage collected is fully utilized for green belt development.
The same treatment system will be used for the proposed facility also.
Figure 2-15 Sewage treatment Plant Process Flow
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2.8.4 Effluent Treatment Plant
The wastewater is generated at ECH plant from the following sources:
Process waste stream from column bottom,
Cooling tower blow down,
Water treatment plant effluent,
Boiler blow down.
2.8.4.1 Treatment method for TPL
The treatment scheme envisages the following stages:
Primary Clarification -The effluent from ECH plant dehydrochlorination stream
column bottom enters the primary clarifier. A flocculent of Magnofloc is added to the
effluent. Sludge settles at the bottom and sent to rotary vacuum filter for separation. The
clear effluent from clarifier overflow is sent for further treatment.
Cooling -The clear effluent from Primary Clarifier enters at the top of the induced draft
cooling tower to reduce the temperature of the effluent. The cooled effluent collected at
the bottom and pumped to Equalization Tank.
Flow Equalization -Effluent from the cooling tower, other process effluents like
cooling tower blow down, water treatment plant effluents are collected in the
Equalization Tank. The treatment system incorporate flow equalization in order to have
a more consistent blend of organics to the downstream biological treatment process.
The Equalization Tank is provided with an agitator to keep the contents in suspension
and for thorough mixing of all effluents stream.The capacity of the Equalization Tank is
790 m3 which is about a hydraulic retention time of 7 hrs.
pH control system -The combined effluent from Equalization Tank enters pH
Correction Tank. Here pH of the combined effluent is neutralized if necessary, using
hydrochloric acid/Sodium hydroxide. pH Correction tank is provided with Agitator to
mix the contents.
The acid dosing system consists of 1 no. of Acid holding Tank, 2 nos Acid dosing
pumps. The Acid addition is controlled by the control of dosing pumps. Also provision
is given for 48 % sodium hydroxide dosing pumps. These pumps get supply
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fromSodium Hydroxide Tank. The effluent after pH Correction overflows from pH
Correction Tank to Bio-reactor.
Nutrients required for the Bio- reactors are also added in the pH Correction tank .
Biological treatment -The Bio-reactors, Ten in Nos are the heart of this treatment
process. The Bio-reactors are inoculated with specific culture developed to degrade the
pollutants present in the combined effluent. Bio-reactors are provided with Floating type
Surface Aerators to ensure an optimum Dissolved Oxygen (DO) level of 2 ppm and to
suit the BOD reduction profile in the Bioreactors. The required quantity of micro-
organism (MLSS) is to be maintained in the Bio-reactor by recycling sludge from the
secondary clarifier downstream of the Bio-reactor.
Nutrients required for the microbial growth (Urea and Di-Ammonium Phosphate DAP)
are added in required quantities in Bio – reactors.The overflows from Bio-reactors are
collected in Bio-reactors overflow Tank. The treated effluent from Bio-reactors
overflow tank is pumped by Flocculation Tank feed pump. Dissolved oxygen
measurement systems are installed in Bio-reactors, to control the running of Surface
Aerators so as to maintain an optimum DO level of 2 ppm.
Sludge Clarification -The effluents from Bio-reactors overflow tank containing around
4000 ppm MLSS enter the flocculation tank, by means of Flocculation feed pumps. In
the flocculation Tank, Flocculants are added in required quantities and are mixed well
by Agitator, where in poly-electrolyte is added in required quantity to enable the settling
of Secondary Sludge to be effected in secondary Clarifier.
After the flocculation Tank, the effluent enters secondary clarifier,which is provided
with a clarifying mechanism for settling the secondary solids. After settling the sludge
collected at the bottom of the secondary clarifier the solid concentration has reached to
9000 ppm from 4000 ppm, this is taken to the secondary thickener while the overflow
from the secondary clarifier flows by gravity to the treated effluent tanks.
The under flow from secondary clarifier with a concentration of about 9000 ppm MLSS
are fed into Bio-reactor as sludge recycling. Bleeding fed into secondary thickener to get
thickened sludge having a concentration of around 2.5%, while the overflow from
Secondary Thickener flows to the Bio-reactor. The under flow is taken to a filter press
for de-watering.
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Thickening- Filter press feed pumps takes the 2.5 % thickener sludge to a filter press
system. In the filter press the sludge is further de-watered from 2.5 % to solid cakes
containing around 70 % moisture. The filtrate is recycled back to bio-reactor, while the
solid cakes are disposed to a secured landfill facility (M/s. Tamilnadu Waste
Management Limited, Gummidipoondi)
Treated Effluent Tank - The over flow from the secondary clarifier flows to Treated
effluent tanks. This is further pumped to sea after meeting the requirements of TNPCB
norms for disposal by the existing treated effluent pumps.
Figure 2-16Effluent Treatment Plant in the site
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Figure 2-17Proposed Effluent Treatment Plant
2.8.4.2 Disposal of Treated Trade Effluent
The treated effluent collected in treated water tank is pumped to sea after meeting the
norms of TNPCB.
The effluent is pumped through HDPE pipeline in to the sea with diffuser arrangements at
the end. HDPE pipeline of 400 mm Outer Diameter, is provided for the out fall pipe line.
The length of the pipe line between the Land Fall Point and the diffuser in the sea is 700m.
Minimum clear velocity will be maintained continuously to avoid deposition and siltation
in the pipe line.
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a) Design of Outfall Pipeline
Input Design:
Table 2-8Dimensions of Outfall pipeline
Parameters Value
Outer dia in m 0.400
Deepwater wave height in m 0.75
Wave period in s 8.0
Wave crest angle with respect to the pipeline(deg) 10.0
Design depth in m 9.4
Current speed in m/s 0.2
Slop of sea bed in deg 2.3
Tk. Of conc.block in m 0.34
Outer dia.of conc. Blockin m 1.0
Dia of hole in m 0.41
Specific gravity of HDPE 0.955
Specific gravity of effluent 1.005
Specific gravity of sea water 1.025
Sea water temperature (⁰C) 25
M.O. C of pipe HDPE PE100, PN10
Soil type (1=clay,2=sand,3=gravel) 2
Buoyancy(50% air filled) 50
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Output Design
Table 2-9Output Design Details
Parameters Units Value
Buoyant force (100%) Kg 120
Buoyant Force (120%) Kg 144
Buoyant Force (200%) Kg 240
Volume of concrete m3 0.154
Weight of concrete in air kg 370
Weight f concrete in water kg 216
Spacing between blocks (for 120% buoyancy) m 1.8 c/c(selected- 1.5c/c)
Spacing between blocks (for 200% buoyancy) m 0.9 c/c (selected - 1.0 c/c)
The pipeline in intertidal zone of first 50m is buried 2m below the sea bed till the top of
pipeline. For next 100m, the pipeline is buried 1.0m below the seabed till the top of the
pipeline. The remaining portion of the pipeline will be laid on the seafloor which will be
left for natural burial.The Layout of effluent disposal line is enclosed in Annexure-10.
2.9 STEAM SYSTEM
The requirement of steam for the propylene oxide plant is about 5T/hr. steam of medium pressure
and low pressure is required.
The existing boiler produces 12.5T/hr steam at 17ksc(g).
2.10 COMPRESSED AIR SYSTEM
For the existing facility the compressed air is draw from TPL LAB plant through pipeline. For the
proposed facility also the same system will be followed. In case of necessity, the existing
instrument air compressor of 800 Nm3/hr capacity will supply the air to the proposed PO plant.
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2.11 INERT GAS SYSTEM
Inert gas is required for blanketing the tanks and vessels, flushing of instruments, process lines etc.
the total quantity of nitrogen required will be about 50-60 m3/hr. It is proposed to draw this nitrogen
from TPL LAB plant or by sourcing liquid nitrogen.
2.12 STORAGE FACILITIES
Storage for the following raw materials are available
Propylene – Bullets
Chlorine- Pipeline
Quick lime – 300MT (Godown)
It is proposed to modify the existing bullet to store propylene oxide.
2.13 POWER SUPPLY
Power supply for the existing ECH plant was 2.2 MW and the proposed Propylene Oxide will need
a power requirement of 1.6 MW. Apart from the main power supply, the proposed plant also has a
backup facilities in the form of a Generator run by Furnace oil with a capacity of 3.2 MW.
2.14 STACK DETAILS
Table 2-10Existing Stack Details
Source Stack Dia.
(m)
Stack
Height (m)
Stack
Temp.
(oC)
Stack
Velocity
(m/sec.)
Gas Discharge Qty.
(m3/hr)
Boiler 0.65 47.4 162 12.7 11450
Propylene heater 0.25 23.2 172 12.1 1050
DG 3.2 MW(Furnace oil) 1.0 31.5 241 13.5 30952
HCl Production unit stack 0.17 30 30 11.8 5000
Chlorine scrubber 0.17 30 32 11.7 800
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Table 2-11Existing stack details utilized for proposed facility
Source
Stack
Dia.
(m)
Stack
Height (m)
Stack
Temp.
(oC)
Stack
Velocity
(m/sec)
Gas Discharge Qty.
(m3/hr)
Boiler 0.65 47.4 162 12.7 11450
DG 3.2 MW
(Furnace oil) 1.0 31.5 241 13.5 30952
Chlorine scrubber 0.17 30 32 11.7 800
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3 BASELINE ENVIRONMENTAL STATUS
3.1 INTRODUCTION
Environment is a dynamic system which differs from place to place and changes over a period of
time. This change can be natural or anthropogenic. Natural changes occurring in the environment is
due to many factors and it is out of bounds to control by mankind. Anthropogenic changes or
impacts on the environment can be identified and suitable remedial measures can be implemented
to attenuate the impacts. To assess the impact of a project or activity it is necessary to generate
baseline environment information in the proposed project site. Base line environmental information
helps the decision makers to evaluate the present scenario and to predict the impact the project
might pose to the environment. Data on the prevailing environmental components such as air,
meteorology, water, noise, soil, ecology, and socio-economics are collected and analyzed. The
monitoring reports of the components are attached as Annexure-11.
3.2 Air and Meteorological Environment
The objective for collecting data on baseline ambient air quality is to predict the incremental
pollutant concentration that might occur during the construction and operation phase of the project.
If adverse impacts are anticipated suitable mitigation measures are proposed at the design stage of
the project itself. This survey gives information on type of air pollutant which will have significant
impact near the vicinity of the project location. To achieve this objective, 6 ambient air quality
stations are selected within a radius of 10 km from the project site. The air quality stations are
selected based on the predominant wind direction, wind speed and atmospheric stability category in
the region which governs the plume rise and dispersion of air pollutants. Selection of the stations
are also based on locations of existing sources of air pollution and sensitive receptors such as
hospitals, schools, thickly populated residential localities, elderly homes etc.
3.2.1 Reconnaissance
Reconnaissance survey was conducted upto 10 km radius from the project site which is
located in Northerncoast of Tamil Nadu in Thiruvallur District. The project site is situated in a
flat terrain with ground elevation varying from about 3-6 meters above mean sea level. The
surrounding impact zone of 5 km radial distance consisting of the rural, urban and industrial
areas is marked. In general the study area experiences predominant wind from SW-W-WWS
and SE. direction during the season March to May, The baseline status of air environment
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includes identification of specific air pollution parameters expected to have significant
impacts and assessing their existing levels in ambient air within the impact zone. The baseline
status of air environment with respect to the identified air pollutants can be assessed through
air quality monitoring programme using methodically designed air monitoring network.
To establish the baseline monitoring status of air environment in the study area during the
period of April, 2014, 6 AAQM locations within the radius of 5 kms (with one station outside
the radius) were selected using network design criteria and monitored as per CPCB guidelines
(Twice a week sampling and 24 hr continuous sampling each day). The selected sampling
locations reported in Table 3-1and Figure 3-1 below. The pollutants were analyzed during
ambient air quality monitoring as listed in latest MoEF notification.
The background ambient air quality has been monitored for all the 12 parameters as per 16th
September 2009, NAAQ standards
Table 3-1Locations of the Ambient Air Quality Stations
S.No Sampling station Geographical
coordinates
Aerial distance from
the site in (km)
Direction with
respect to site
1. AAQ1 - Site 13°10'37.64"N
80°16'58.00"E
SITE NA
2. AAQ2-Sekkadu
Village
13°10'23.73"N
80°15'0.28"E
3.2 West
3. AAQ3 -
Thiruvottiyur
13°10'1.49"N
80°17'40.42"E
1.7 South East
4. AAQ4 - Manali New
Town
13°12'22.12"N
80°16'30.71"E
3.2 North
5. AAQ5- Madhavaram 13° 9'15.58"N
80°14'52.71"E
4.5 South West
6. AAQ 6 - Korrukupet 13° 7'27.56"N
80°16'30.15"E
5.9 South
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Figure 3-1Google earth Image Showing the Location of Air quality Sampling Stations
3.2.2 Micro metrology
The study of micro-meteorological conditions of a particular region is of utmost importance to
understand the variations in ambient air quality status. The prevailing micrometeorology at
project site plays a crucial role in transport and dispersion of air pollutants released from the
plant. The persistence of the predominant wind direction and wind speed at the project site
will decide the direction and extent of the air pollution impact zone. The principal variables
which affect the air pollution dispersion and resultant air quality status micrometeorology are
horizontal transport and dispersion (average wind speed and directions), convective transport
and vertical mixing (atmospheric stability) and also topography of the area towards local
influences.
For determining the prevailing micro-meteorological conditions during the study period, an
automatic continuous digital weather station was installed at project site. The location is
chosen such that there is no obstruction to the flow of wind and sunlight. The hourly
meteorological data of wind speed, wind direction, temperature and solar radiation were
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recorded at the project site. These frequencies were computed on 8 hourly as well as 24 hourly
basis and the corresponding results are used to draw wind rose for 00-08hrs, 08-16 hrs, 16-24
hrs and 00-24hrs corresponding to study period as shown in subsequent sections. The terrain
is flat and elevation varied from 3-6 m above mean sea level when one travels from coast and
landward. The wind rose for the months of March, April and May2014 shows the
predominant winds from direction. The wind directions during the study period are SW-W-
WSW and SE. Accordingly, the impact zone will be spread in NE-E-ENE and NW directions.
The average wind speed observed during the study period is 3 m/sec with the considerable
frequency of a wind range of calm to about 22 km/hour. Due to its proximity with the Bay of
Bengal, the ambient temperature at project site ranged between 25-40°C while the relative
humidity range from 49-79% at project site. The meteorological data collected during
monitoring is used for interpretation of baseline status and to simulate the meteorological
conditions for prediction of impacts in modeling studies.
Table 3-2 Meteorological observations
S.No Parameter Observation
1 Wind Direction SW-SE-W-WSW
2 Wind Speed Range 2 to 8.8 m/sec
3 Annual Average Rainfall 1211 mm
4 Average Wind Speed 3 m/sec
5 Temperature Range Max. Temp: 40°C
Min. Temp: 25°C
6 Average Temperature 32°C
7 Humidity Range (24hr) 49 to 79 %
8 Cloud cover Partly cloudy
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Figure 3-2 Wind rose Data for Manali
3.2.3 Base line air quality status
The, mean value of Particulate Matter (PM2.5), Particulate Matter (PM10), Sulphur Dioxide
(SO2), Nitrogen Dioxide (NO2), CO μg/m3,Pb μg/m
3,O3,NH3, Benzene, Benzo (a) pyrene, As
and Ni at various monitoring locations during the AAQ monitoring period. The concentration
of SO2 ranged from 11-15 μg/m3
across the sampling stations. The highest concentration of
SO214.3 μg/m3was observed at AAQ3. The concentration of NO2 ranged from14-25μg/m
3
across the sampling stations. The highest concentration of NO2was 25 μg/m3was observed
atAAQ1 and AAQ3. The concentration of SO2and NO2 is well below the permissible level of
80 and 80 μg/m3.The concentration of PM2.5ranged between 21-32 μg/m
3 andPM10ranged
between 51-60 μg/m3. The concentrations of PM10 and PM2.5was found to be below the
permissible limit of100 and 60 μg/m3respectivelyat all the sampling stations. The
concentrations CO, Pb, Benzene, Benzo (a) pyrene,O3, As and Ni were BDL at all the
sampling stations.
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Table 3-3Test Methods used for the Analysis of ambient air quality parameters
S.No Parameters Analytical method NAAQ standards: 2009
1. Sulphur Dioxide (SO2),
μg/m3
IS: 5182 (Part - 2):2001
(Reaff:2006)
50 (Annual) 80 (24
Hours)
2. Nitrogen Dioxide (NO2),
μg/m3
IS: 5182 (Part - 6): 2006 40 (Annual) 80
(24 Hours)
3. Particulate Matter
(PM2.5), μg/m3
IS: 5182 (Part - 23): 2006 40 (Annual) 60
(24 hours)
4. Particulate Matter
(PM10), μg/m3
IS:5182 (Part– 23): 2006 60 (Annual) 100
(24 hours)
5. COμg/m3 IS: 5182 (Part – 10): 1999
(Reaff:2006)
2 (8 hours) 4 (1hour)
6. Pbμg/m3 IS: 5182 (Part – 22): 2004
(Reaff:2006)
0.5(Annual) 1 (24 hours)
7. O3, μg/m3 IS: 5182 (Part – 9): 1974 100(8hours) 180 (1hour)
8. NH3, μg/m3 APHA (air) 2nd edition
(Indophenol-blue method)
100(Annual) 400 (24
hours)
9. Benzene, μg/m3 IS: 5182 (Part – 11): 1999 (R
A:2009)
5 (Annual) 5 (Annual)
10. Benzo (a) pyrene, ng/m3 IS: 5182 (Part – 12): 2004 (R
A:2009)
1 (Annual) 1 (Annual)
11. Arsenic, ng/ m3 APHA (air) 2nd edition 6 (Annual) 6 (Annual)
12. Nickel, ng/ m3 APHA (air) 2nd edition 20 (Annual) 20 (Annual)
13. Total VOC μg/m3 USEPA TO17 - -
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Table 3-4 Summary of findings of ambient air quality monitoring (Average)
S.No Sampling stations Parameters
SO2
μg/m3
NO2
μg/m3
PM2.5
μg/m3
PM10
μg/m3
CO
μg/m3
Pb
μg/m3
O3 μg/m3 NH3
μg/m3
Benz-
ene
μg/m3
Benzo (a)
pyrene
ng/m3
As
ng/m3
Ni
ng/m3
TVOC
(μg/m3)
1. AAQ1 - Site 13 25 32 60 BDL
(DL 0.005)
BDL
(DL
0.05)
BDL
(DL10)
7.2 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
1.5
2. AAQ2-Sekkadu
Village
13.2 23 30 56 BDL
(DL0 .005)
BDL
(DL
0.05)
BDL
(DL10)
6.3 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
3.1
3. AAQ3 -
Thiruvottiyur
14.3 25 24 54 BDL
(DL0.005)
BDL
(DL
0.05)
BDL
(DL10)
7.1 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
2.3
4. AAQ4 - Manali
New Town
13.8 20 21 51 BDL
(DL 0.005)
BDL
(DL
0.05)
BDL(DL
10)
8.6 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
2.6
5. AAQ5-
Madhavaram
12.9 19 25 60 BDL
(DL0 .005)
BDL
(DL
0.05)
BDL(D1
0)
4.3 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
2.1
6. AAQ 6 -
Korrukupet
11.2 14 30 60 BDL
(DL0 .005)
BDL(DL
0.05)
BDL(DL
10)
5.2 BDL
(DL1)
BDL
(DL1)
BDL
(DL1)
BDL
(DL5)
2.6
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3.3 NOISE ENVIRONMENT
The study area consists of 10 km radiusfrom the site which consists of urban, rural and industrial
area. The noise generated due to operation of individual process units at an industrial site cause
significant impacts on the surrounding environment including nearby residential areas. Such
operations fall in the category of continuous primary sources. There are also some secondary noise
sources associated with almost all types of large scale industrial projects, which are mainly vehicles
used for transportation of materials as well as employees and material handling equipment at the
project site. However, such sources could be categorized as intermittent noise sources.
The prevailing ambient noise level at a particular location is nothing but the resultant (total) of all
kinds of noise sources existing at various distances around that location. The ambient noise level at
a location varies continuously depending on the type of surrounding activities. The ambient noise
level generally does not reflect any seasonal variation, however, the wind direction, rain, snow, fog
or any other barrier as well as direction of source play significant role in regulating the noise
propagation and ultimately the intensity of impact.
The current status of noise environment around the existing TPL industries is assessed through
identification of major noise sources, characterization of such noise sources, measurement of
prevailing ambient noise levels in the study area and measurement of noise levels due to vehicular
movements, according to existing land use pattern. The prevailing noise levels in the neighboring
industrial areas shall represent the baseline status for assessment of noise impacts from proposed
developments. The baseline study for noise environment has been carried out through
reconnaissance in the impact zone, identification of representative sampling locations and
monitoring of prevailing noise levels during study period.
3.3.1 Reconnaissance
Reconnaissance survey was conducted to locate the existing noise generating sources and
identify suitable locations to evaluate background noise levels. The project site is located in
northcoast of Tamil Nadu in Thiruvallur district. The surrounding impact zone of 10 km radial
distance consisting of the rural, urban and industrial areas is marked. State highways number
SH 56 passes by the site.
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Table 3-5Table Summary of findings of Noise monitoring in the study area (Average)
S.No Date Location Geographical coordinates Noise level in
dB(A) Leq
Day Night
1. 19.05.2014 Retteri 13°09'02.0"N and 080°12'56.7"E. 69 55
2. 19.05.2014 Tiruvottiyur
sea shore
13°11'02.5"N and 080°19'00.5"E 72 60
3. 19.05.2014 Jai-hind Nagar 13°11'04.2"N and 080°18'10.7"E. 59 49
4. 19.05.2014 Mathur 13°09'45.1"Nand 080°14'59.6"E. 50 40
5. 19.05.2014 ChinnaSekkadu 13°09'48.3"N and 080°15'30.5"E. 57 47
Since the project site is located in industrial zone there are many small scale and few large
scale industries which contribute to baseline noise levels. The heavy vehicular traffic on state
highway SH 56contributes significantly to the noise levels in study area. The commercial
activities in the individual villages also influence the background noise levels. The noise
levels in surrounding selected villages, industrial complexes and junction of the state
highways were monitored using a precision noise level meter.
3.3.2 Community noise levels
The community noise is determined by recording the day-night noise level (Ldn). Ldn is
defined as the 24 hours equivalent sound level derived with a penalty of 10 dB (A) is added to
the measured instantaneous noise level measured during night time. i.e. from 2200 hrs to 0600
hrs. This is because the same level of noise during night time is more annoying than day time.
Ldn for a given location is calculated from hourly equivalent sound levels (Leq) using the
following equation:
Ldn = 10 log [1/24{16(10(Ld/10)) + 8(10(Ln+10)/10))}]
Where, Ld – equivalent noise level during day time (0600 to 2200 hrs)
Ln – equivalent noise level during night time (2200 to 0600 hrs)
3.3.3 Baseline Noise status
The prevailing ambient noise levels along, the sites were monitored at 5 locations. During the
study period day time noise levels varied between50 to 72dB (A)across the sampling stations
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and night time noise levels varied from40 to 60 dB (A) across the sampling stations. The
details of the monitoring stations are presented in Table 3-5. The field observations during the
study period indicate that the ambient noise levels in the study area were well within the
prescribed standards at all the different noise zones prescribed by CPCB.
Limits set by CPCB
Industrial Area :Day Time -75 dB (A); Night Time - 70 dB (A)
Commercial :Day Time -65 dB (A); Night Time - 55 dB (A)
Residential Area :Day Time -55 dB (A); Night Time -45 dB (A)
Silence Zone :Day Time -50 dB (A); Night Time - 40 dB (A)
3.4 WATER ENVIRONMENT
The study area has medium sized water courses namely Periyathoppu Lake, Madhavaram Lake,
Korttalaiyar River etc. The project site is located 3.3 Km west of the Bay of Bengal. The project
site is located in Manali, where Petro Chemical industries are concentrated.
3.4.1 Hydrogeology
The project study area is underlain by both porous and fissured formations. The important
aquifer systems in the district are constituted by
i. unconsolidated & semi-consolidated formations
ii. weathered, fissured and fractured crystalline rocks.
The porous formations in the area include sandstones and clays of Jurassic age (Upper
Gondwana), marine sediments of Cretaceous age, Sandstones of Tertiary age and Recent
alluvial formations. As the Gondwana formations are well-compacted and poorly jointed, the
movement of ground water in these formations is mostly restricted to shallow levels. Ground
water occurs under phreatic to semi-confined conditions in the inter-granular pore spaces in
sands and sandstones and the bedding planes and thin fractures in shales. In the area
underlain by Cretaceous sediments, ground water development is rather poor due to the
rugged nature of the terrain and the poor quality of the formation water. Quaternary
formations comprising mainly sands, clays and gravels are confined to major drainage
courses in the district. The maximum thickness of alluvium is 30.0 m. whereas the average
thickness is about 15.0 m. Ground water occurs under phreatic to semi-confined conditions in
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these formations and is being developed by means of dug wells and filter points. Alluvium,
which forms a good aquifer system along the Araniyar and Korattalaiyar river bed which is
one of the major sources of water supply to urban areas of Chennai city and also to the
industrial units.
Ground water generally occurs under phreatic conditions in the weathered mantle and under
semi-confined conditions in the fissured and fractured zones at deeper levels. The thickness
of weathered zone in the district is in the range of 2 to 12 m. The depth of the wells ranged
from 8.00 to 15.00 m bgl.
The yield of large diameter wells tapping the weathered mantle of crystalline rocks ranges
from 100 to 500 lpm and are able to sustain pumping for 2 to 6 hours per day. The yield of
bore wells drilled down to a depth of 50 to 60 m ranges from 20 to 400 lpm. The yield of
successful bore wells drilled down to a depth of 150 m bgl during the ground water
exploration programme of Central Ground Water Board ranged from 1.2 to 7.6 lpm.
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Figure 3-3 Hydro geological map of Thiruvallur district
3.4.2 Reconnaissance
Reconnaissance survey was undertaken to ascertain the location of water bodies viz streams,
rivers, lakes etc. The sampling stations were chosen based on the existing pollution sources
near these water bodies and threat of pollution in the future. The flow in the rivers passing
through the study region are seasonal, high flows occur during monsoon season and low flow
occurs during summer season. The region receives rainfall predominantly during monsoon
season with an average annual rainfall of about 1211 mm per year. The South west monsoon
season is from July – Septemberand North east monsoon is from October to December.
Groundwater is the principal source for domestic and drinking purposes in almost all villages
near the study area. The water samples were collected and analyzed by standard test methods
which are given in table: The prevailing status of water quality has been assessed during
March - May.Three sampling stations forground water and sevensampling stations for surface
water were selected for the study the details are given in Table: 3-7and the findings of the
water quality monitoring study is summarized in Table 3-8
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Table 3-6 Summary of test methods used for the analysis of water quality parameters
S.No Parameter Measured Test Method
1. pH (at 25°C) IS:3025 (Part - 11): 1983 (Reaff: 2006)
2. Electrical Conductivity IS:3025 (Part - 14): 1983 (Reaff: 2006)
3. Color IS:3025 (Part- 4) 1983 (Reaff 2006)
4. Total Hardness as CaCO3 IS:3025 (Part - 21) 1983 (Reaff 2006)
5. Total Alkalinity as CaCO3 IS:3025,1 (Part - 23) 1986 (Reaff 2009)
6. Cadmium IS:3025 (Part 41) 1991
7. Chloride as Cl IS:3025 (Part - 32) 1988(Reaff 2009)
8. Total Dissolved Solids IS:3025:1(Part - 16) 1984 (Reaff 2006)
9. Aluminium asAl IS:3025 (Part - 55) 2003 (Reaff 2009)
10. Chromium asCr IS:3025 (Part - 52) 2003 (Reaff 2009)
11. LeadasPb IS:3025 (Part - 47) 1994 (Reaff 2009)
12. Zinc as Zn IS:3025 (Part - 49) 1994 (Reaff 2009)
13. Sodium as Na IS:3025,5(Part - 45) 1993 (Reaff 2006)
14. Temperature IS:3025 (Part - 9) 1983 (Reaff 2006)
15. Chemical oxygen demand
as O2 IS:3025 (Part-58)-2006
16. Dissolved Oxygen (mg/l) IS:3025 (Part - 38)1989 (Reaff 2009)
17. Salinity -
18. Copper as Cu IS:3025 (Part - 42)1992 (Reaff: 2009)
19. BOD,5 days @200C as O2 5210B APHA22
nd Edn 2012
20. Total coliform bacteria
(MPN/100ml) IS:1622 1981 (Reaff: 2009)
21. F-Coli IS:1622, 1981 (Reaff: 2009)
3.4.3 Baseline Water quality Status
Physico-chemical parameters along with biological indicators of pollution have been
identified for assessing the baseline status of water environment and identification of impacts
due to proposed developmental activities. In order to assess the water quality, standard
methods (IS Standards) were followed for sample collection, preservation and analysis in the
laboratory. The water quality was assessed by various Physiochemical parameters such as pH,
Electrical conductivity(µohms/cm), Color(Hazen Unit), Total Hardness
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(mg/l),Aluminium(mg/l), Zinc (mg/l), Total Alkalinity (mg/l), Chloride (mg/l),Cadmium
(mg/l), Total Dissolved Solids (mg/l), Sodium (mg/l), Lead(mg/l), Chromium (mg/l), copper
(mg/l) and chemical Oxygen Demand (mg/l).
Table 3-7Locations of the water quality stations
S.No Location Geographical coordinates Aerial distance from the site in
(km)
1. Nala Near Site 13°10'41.85"N
80°16'56.29"E
0.02
2. B.canal backside of
CPCL
13° 9'35.29"N
80°17'13.00"E
1.8
3. Thiruvottiyur Shore 13°11'02.5"N
080°19'00.5"E
4.7
4. Retteri 13°09'02.0"N
080°12'56.7"E
7.4
5. MadhavaramEri 13°09'45.1"N
080°14'59.6"E
3.7
6. Opp MFL bus stop 13° 10.632'N
80° 16.244'E
1.18
7. Near Deccan Bitumen 13°10'42.18"N
80°15'8.26"E
2.9
8. Chinnasekkadu 13°09'48.3"N
080°15'30.5"E
4.6
9. Near Thiruvottiyur
Railway station
13° 9'28.93"N
80°17'42.80"E
2.5
10. Jai-hind Nagar 13°11'04.2"N
080°18'10.7"E
2.7
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Figure 3-4Google Earth Image Showing the Location of Sampling Stations
Figure 3-5 Water sampling at different locations
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3.4.4 Surface water Quality
The water quality status in the study area revealed heavy pollution of surface water at all the
surface water quality monitoring stations. The pH of the surface water ranged from 6.10 to
8.18 across the sampling stations. The Electrical conductivity of the sample ranged from 2770
to 30300µohms/cm across the sampling stations. The E.C value was the highest at
Thiruvottiyurshore. The concentration of Total Dissolved solids (TDS) rangedbetween 1650
to 20260mg/l across the sampling stations. The highest TDS value of 20260 mg/l was
observed at Thiruvottiyurshore. The total hardness varied from 380- 8500 mg/l. The
concentration of chlorides varied from 504 to 19052.96 mg/l across the sampling stations.
High concentration of chlorides was observed at Thiruvottiyur shore.Other parameters like
aluminium, cadmium, Chromium Lead were well below the surface water quality standards.
Table 3-8Summary of analytical results on Surface water samples collected in the study area
S.N
o
Parameters Sampling stations Drinking water IS
10500 : 2012
Nala
Near
Site
B.Canal
at back
side of
CPCL
Thiruv
ottiyur
shore
Retteri Madha
varam
Eri
Opp.M
FL
Near
Decca
n
Bitum
in
Desira
ble
Permissibl
e
1. pH (at 25°C) 6.76 6.46 6.10 6.70 7.59 8.18 7.03 6.5-8.5 No
relaxation
2. Electrical
conductivity(
µohms/cm)
3240 3170 30300 2770 4130 8040 2930 -- --
3. Color
(Hazen Unit)
2.0 3.0 BDL
(DL 1)
3.0 3.0 1.0 3.0 5
(max)
15
4. Total
Hardness as
CaCO3
(mg/l)
560 540 8500 380 540 2000 380 200
(max)
600 (max)
5. Aluminium
(mg/l)
BDL
(DL 0.02)
BDL
(DL 0.02)
BDL
(DL 0.02)
BDL
(DL 0.02)
BDL
(DL
0.02)
BDL
(DL 0.02)
BDL
(DL
0.02)
0.03
(max)
0.2 (max)
6. Zinc (mg/l) 0.25 0.91 0.08 0.04 0.05 0.13 0.07 5
(max)
15 (max)
7. Total
Alkalinity as
640 600 140 320 560 1380 280 200
(max)
600 (max)
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S.N
o
Parameters Sampling stations Drinking water IS
10500 : 2012
Nala
Near
Site
B.Canal
at back
side of
CPCL
Thiruv
ottiyur
shore
Retteri Madha
varam
Eri
Opp.M
FL
Near
Decca
n
Bitum
in
Desira
ble
Permissibl
e
CaCO3
(mg/l)
8. Chloride
(mg/l)
633.45 593.86 19052.9 504.78 772 700 673 250
(max)
1000
(max)
9. Copper (mg/l) 0.03 0.03 0.14 0.03 0.04 0.19 0.04 0.05
(max)
1.5 (max)
10. Total
Dissolved
Solids (mg/l)
1880 1810 20260 1690 2480 1950 1650 500
(max)
2000
(max)
11. Cadmium
(mg/l)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL
0.01)
0.003
(max)
No
Relaxation
12. Sodium
(mg/l)
350 330 11410 290 456 280 380 - -
13. Total
Chromium
(mg/l)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL
0.01)
0.05
(max)
0.05 (max)
14. Lead (mg/l) BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL
0.01)
0.01
(max)
No
Relaxation
15. Chemical
oxygen
demand as O2
(mg/l)
60 88 256 40 52 280 40 - -
16. Temperature
(oC)
29.5 29.8 29.8 29.3 29.5 29.7 29.7 - -
17. Dissolved
Oxygen
(mg/l)
BDL
(DL 0.1)
BDL
(DL 0.1)
5.80 8.10 7.80 8.30 5.20 - -
18. Salinity (ppt) 1.15 1.07 34.40 0.91 1.39 69.7 1.21 - -
19. BOD, %days
@20oC as O2
(mg/l)
2.0 2.0 3.0 2.0 2.0 3.0 1.0 - -
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S.N
o
Parameters Sampling stations Drinking water IS
10500 : 2012
Nala
Near
Site
B.Canal
at back
side of
CPCL
Thiruv
ottiyur
shore
Retteri Madha
varam
Eri
Opp.M
FL
Near
Decca
n
Bitum
in
Desira
ble
Permissibl
e
20. Total
coliform
Bacteria
(MPN/100ml
)
---- ---- 140 130 500 <2 <2 6.5 8.5
21. Fecal
coliform
(MPN/100ml
)
----- ----- 70 50 300 Absent Absent - -
3.4.5 Ground water quality
The pH of the ground water was alkaline and ranged from 6.08 to 6.35 across the sampling
stations. The Electrical conductivity of the sample ranged from 1602 to 2610µohms/cmacross
the sampling stations. The E.C value was the highest atJai-hind Nagar. The concentration of
Total dissolved solids (TDS) ranged between 910.0 to 1620 mg/l across the sampling stations.
The highest TDS value of 1620 mg/l was observed at Jai-hind Nagar. The total hardness
varied from 120-760 mg/l. The concentration of chlorides varied from 183-475mg/l across the
sampling stations. High concentration of chlorides was observed at Jai-hind Nagar. The
concentration of other parameters like Aluminium (mg/l), Chromium (mg/l), Lead (mg/l) and
Chromium (mg/l) were below the detection limit.
Table 3-9Results of Ground water samples collected in the study area
S.No Parameters Sampling Stations Drinking water IS 10500 :
2012
Chinnasekkadu Near Thiruvottiyur
Railway station
Jai-hind
Nagar
Desirable Permissible
1. pH (at 25°C) 6.25 6.35 6.08 6.5-8.5 No relaxation
2. Electrical conductivity
(µohms/cm)
2580 1602 2610 -- --
3. Color (Hazen Unit) BDL
(DL 1)
2.0 5.0 5 (max) 15 (max)
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3.5 SOIL ENVIRONMENT
Assessment of soil characteristics is of paramount importance since the vegetation growth,
agricultural practices and production is directly related to the soil fertility and quality. The
predominant soil type is Brown soil followed by alluvial and sandy soils in the coastal areas. The
pH of the soil samples ranged from 7.22 to 8.26 across the sampling stations. The Electrical
conductivity of the soil samples ranged from155 to 211µohms/cm across the sampling stations. The
4. Total Hardness as
CaCO3 (mg/l)
760 290 120 200 (max) 600 (max)
5. Aluminium (mg/l) BDL
(DL 0.02)
BDL
(DL 0.02)
BDL
(DL 0.02)
0.03 (max) 0.2 (max)
6. Zinc (mg/l) 0.12 0.04 0.12 5 (max) 15 (max)
7. Total Alkalinity as
CaCO3 (mg/l)
320 230 400 200 (max) 600 (max)
8. Chloride (mg/l) 297 183 475 250 (max) 1000 (max)
9. Copper (mg/l) BDL
(DL 0.01)
0.02 0.02 0.05 (max) 1.5 (max)
10. Total Dissolved Solids
(mg/l)
1560 910 1620 500 (max) 2000 (max)
11. Cadmium (mg/l) BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
0.003
(max)
No
Relaxation
12. Sodium (mg/l) 160 96.0 270 - -
13. Total Chromium as Cr
(mg/l)
BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
0.05 (max) 0.05 (max)
14. Lead (mg/l) BDL
(DL 0.01)
BDL
(DL 0.01)
BDL
(DL 0.01)
0.01 (max) No
Relaxation
15. Chemical oxygen
demand as O2 (mg/l)
12 16.0 20 - -
16. Temperature (oC) 29.7 29.6 29.6 - -
17. Dissolved Oxygen
(mg/l)
6.20 5.70 6.30 - -
18. Salinity (ppt) 0.53 0.33 0.85 - -
19. BOD, %days @20oC as
O2 (mg/l)
1.0 1.0 1.0 - -
20. Total coliform Bacteria
(MPN/100ml)
17 <2 110 6.5 8.5
21. Fecal coliform
(MPN/100 ml)
8 Absent 80 - -
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E.C value was the highest at S3 sampling stations. The concentration of chlorides varied from
197.95mg/kg to 346.42mg/kg across the sampling stations. A high concentration of chlorides was
observed at S4 sampling station. The texture of sandy soil varied from 67.25 to 92.94%. Thehighest
percentage of sandy soil 92.94% was recorded at Mathur. The concentration of total phosphorus
ranged from 11.07-70.6 mg/kg and organic matter ranged from 10 to 30 % across the sampling
stations. Other parameters like cadmium (mg/l), Chromium (mg/l), were below the detection limit.
Table -3-10Summary of findings of soil sampling studies in the study area (Average)
S.No Aerial
distance
Location Geographical coordinates
1 3.80Km Mathur (S1) 13°9'822.0"N and 80°14.941"E
2 1.2Km Opp MFL bus stop (S2) 13°10.664"N and 80°16.226"E
3 2.69Km Chinnasekkadu (S3) 13°9.917"N and 80°15.601"E
4 2.80Km KCP limited (S4) 13°9.598"N and 80°18.005"E
Figure 3-6Google Earth Image showing Location of Soil sampling
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Figure 3-7 Soil Sampling Location
Table 3-11Summary of analytical results of soil samples collected at different sampling stations
S.No Parameters with units Sampling stations
S1 S2 S3 S4
1. pH at 25°C (1:10) 7.22 7.85 8.26 7.31
2. Electrical Conductivity (1:10) 155.0 184 211.0 202.0
3. Color Light grey Brown Grey Light brown
4. Chlorides (mg/kg) 270 198 297 346
5. Bulk density (gm/cc) 1.50 1.28 1.20 1.49
6. Sodium (mg/kg) 180.0 13.0 100.0 210.0
7. Potassium (mg/kg) 20.0 10.0 10.0 30.0
8. Organic matter (%) 0.43 0.24 0.10 0.04
9. Zinc (mg/kg) 18.15 37.29 26.27 8.20
10. Lead (mg/kg) 6.50 6.95 3.50 1.0
11. Cadmium (mg/kg) BDL (DL-0.1) 0.89 BDL BDL
12. Copper (mg/kg) 82.84 13.41 12.94 4.89
13. Porosity (%) 0.41 0.47 0.45 0.36
14. Total KjeldahlNitrogen (%) 0.053 0.046 0.05 0.049
15. Organic carbon (%) 0.38 0.21 0.08 0.04
16. Cation Exchange Capacity (meq/Kg) 8.2 4.7 1.3 1.4
17. Chromium (mg/kg) BDL
(DL 0.1)
BDL
(DL 0.1)
BDL
(DL 0.1)
BDL
(DL 0.1)
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S.No Parameters with units Sampling stations
S1 S2 S3 S4
18. Total phosphorus (mg/kg) 11.07 70.6 39.7 61.41
19. Soil texture (%) Sand 92.94 67.25 72.47 92.18
Silt 1.23 4.68 3.18 1.08
Clay 5.83 28.07 24.35 6.74
3.6 LAND USE
The land use/land cover in the study area of 10 km radius from the proposed change of product
mixfor Tamilnadu Petroproducts Limited is evaluated by using Recent land use/land cover
estimates from Resourcesat-1 LISS III (2009) image and data about spatial distribution of land
use/cover types obtained from database.
The study found that Towns/ cities (urban)was the most dominant class covering 40% followed by
(Agricultural land) crop land and Fallow land at 22.15 % and 14.08 % coastal wetland covers 5.66
%, (water bodies)reservoirs/ Lakes/ ponds and River/Stream/ canal covers 4.24 % and 3.08 %. The
Land use Map is given in Figure 3-6. There is no sensitive locations like Reserve Forests,
National Parks etc within the study area.
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Figure 3-8 Land use / Land cover Map of the Study area
Table 3-12Landuse Classification and Area
Land use Land cover Class Area (Sq. Km.)
Coastal Wetland 15.54
Cropland 60.83
Fallow land 38.67
Inland Wetland 0.22
Plantation 12.27
Reservoirs/ Lakes/ Ponds 11.63
River/ Stream/ Canals 8.47
Rural 7.89
Salt affected land 0.72
SandyArea 0.51
Scrub land 7.32
Urban 110.52
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Figure 3-9 Land Use classification chart
3.6.1 Geomorphology
The prominent geomorphic units identified in the district through interpretation of Satellite
imagery are Alluvial Plain, Old River Courses, Coastal plains, Shallow & deep buried
Pediments, Pediments and Structural Hills.
The elevation of the area ranges from 183 m above mean sea level (amsl) in the west to sea
level in the east. Four cycles of erosion has given rise to a complex assemblage of fluvial,
estuarine and marine deposits. The major part of the area is characterized by an undulating
topography with innumerable depressions which are used as irrigation tanks.
The coastal tract is marked by three beach terraces with broad inter-terrace depressions. The
coastal plains display a fairly lower level or gently rolling surface and only slightly elevated
above the local water surfaces or rivers. The straight trend of the coastal tract is resultant of
development of vast alluvial plains. There are a number of dunes in the coastal tract. The
below geomorphologic map is taken from the Multi-temporal satellite data from Resourcesat-
1 LISS III
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Figure 3-10 Geomorphologic map of the project site
3.7 TERRESTRIAL ECOLOGY
The study of terrestrial ecology within the study area of 10 km radius has been carried out through
field investigation and satellite imagery data as discussed earlier. The area can be classified into the
following ecological zone.
3.7.1 Scrub Eco-system (Dry Evergreen Vegetation)
This type of ecosystem is dominated by Phoenix sylvestris species. Apart from typical scrub
jungle species, a few salt tolerant species were also recorded, probably because of the
proximity to the sea and the estuary.
3.7.2 Tidal Eco-system
The plant growing in this area are salt tolerant as they are covered by the saline water during
high tides. The species like Arthrocnemum indicum, Suaeda maritima are dominating species
in this ecosystem.
3.7.3 Mangrove Eco-system
This type of ecosystem existed in western bank of the river Korattailar. This is dominated by
Avicinnia marina. Sesuvium portulacastrum&Suaeda maritima. These plants are periodically
washed by the tides and as result in some areas quick sands are noticed.
Project Site
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3.7.4 Marsh Eco-system
The marshes are essentially fresh water supporting variety of plant. Acacia nilotica and
Azadirachata indica are the common species of the study area.
3.7.5 Agro Ecosystem
Rice and banana species of plant are the main species of this ecosystem.
3.7.6 Flora
The field investigation and satellite imagery data show, that the study area is a mixture of
agricultural, wasteland and get irrigated by the tanks and tube wells.
The dry tropical vegetation is observed within the study area. The experimental finding of the
pre monsoon season shows the dominance of grasses like Cyanodon dactylon followed by
Parthenium hysterophorus, Croton sparsiflorusand trees like Acacia nilotica, Azadirachta
indica, Annona squamosa, Delonix regia, Ficus benghalensis within the study area.
Table 3-13List of Domestic Flora in the Study Area
SI. No Botanical Name Family Name Vernacular Name
(Tamil)
1 Annona squamosa Annonaceae Atta
2 Alstonia scholaris Apocynaceae Elilappalai
3 Anthocephalus chinensis Rubiaceae Vellai
4 Acacia nilotica Fabaceae Karuvelamaram
5 Bambusa arundinacea Gramineae Mullumungil
6 Bauhinia variegata Fabaceae/Leguminosae Shemmandarai
7 Citrus aurantifolia Rutaceae Yelumicham
8 Delonix regia Caesalpiniaceae Mayaram
9 Ficus religiosa Moraceae Arasu
10 Ficus benghalensis Moraceae Mayarum
11 Mangifera indica Anacardiaceae Maangai
12 Psidium guajava Myrtaceae Koyya
13 Phoenix sylvestris Arecaceae Lcham
14 Tamarindus indica Fabaceae Amilampul
15 Ziziphus mauritiana Rhamnaceae Elentha
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3.7.7 Fauna
i. Domestic - The domestic animals are mainly mammals like cow, goat, cat, dog etc.
ii. Wild Animals -Since the natural forests constitute negligible of the forest area and since
they are in isolated pockets, the wild life does not offer a wide spectrum of species. Wild
animals are rarely seen due to absence of natural dense forest and land occupied by human
being. Other than these, some reptiles and amphibians can also be seen with a number of
bird species.
A list of birds, reptiles, amphibians and rodents based on information gathered from local
inquiries is presented.
Table 3-14List of Wild Fauna in the Study Area
SI.No Zoological Name Common Name
1 Ahaetulla nasuta Green whip snake
2 Athene brama Spotted owlet
3 Canis aureus Jackal
4 Eudynamys scolopacea Koel
5 Felis chaus Jungle cat
6 Funambulus pennantii and F palmarum Palm squirrels
7 Francolinus pondicerianus Patridge
8 Harpestes edwardsi Comman mongoose
9 Haliastur indus Brahminy kite
10 Lepus nigricollis Hare
11 Manis crassicaudata Pangolin
12 Milvus migrans govinda Pariyakite
13 Naja naja Cobra
14 Ptyas mucosa Comman rat snake
15 Suscus sp Shrew
Table 3-15Amphibian
1 Bufo melanostictus Toad
2 Rana cyanophlyctis Frog
3 Rana tigrina Frog
4 Rhacophorus bimaculatus Tree frog
5 Hyla arborea Tree frog
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Table 3-16 Rodents
1 Bandicota indica Badicoot
2 Mus musculus Mouse
3 Rattus rattus Rat
4 Ratufa indica Squirrel
3.8 AQUATIC ECOLOGY
The specific biological species (Fishes, Phytoplankton, Zooplankton etc.) for a particular
environmental conditions are the best indicators of environmental conditions are the best indicators
of environmental quality. Information on the environmental stress due to the impacts of any
industrial activities on the community structure serves as inexpensive and efficient early warning
and control system to check the effectiveness of the measures to prevent damage to a particular
ecosystem.
3.8.1 Planktons
Phytoplankton and Zooplankton are indicators of environmental stress. The quality and
quality of such biological species in a particular environmental largely depends on various
physicochemical characteristics of water such as pH, Conductivity, nutrients, BOD, alkalinity
etc.
3.8.2 Fishes
The fishes/ aquatic fauna of the study area is reported based on the field sampling and
confirmed by the local people and secondary data provided by Thiruvallur district office is
listed. The fishes like Chirocentrus dorab, Lesser Sardines, Anchoviella, Flying Fish,
Sciaenids, Caranx, Mackerel, Seer, Crabs found in good number in the study area.
Table 3-17List of Zooplankton identified within the Study Area
S.No Zooplankton
1. Favela species
2. Tintinnopsis species
3. Globigerina species
4. Acartia danae
5. Acartia erythraea
6. Acartia clausi
7. Calanns finmarchicns
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8. Paracalanus parvus
9. Microsetella norvegica
10. Microsetella rosea
11. Corycaeus danae
12. Oithona rigida
13. Oncaea venusta
14. Gastropod veliger
15. Brachionus urceolaris
16. Brachionu calyciflorus
17. Monostyla bulla
18. Paracalanus parvus
19. Labidocera acuta
20. Euterpina acutifrons
21. Macrosetella gracilis
22. Metis jousseaumei
23. Copilia vitrea
24. Oithona brevicornis
25. Bivalve veliger
26. Copepod nauplius
There is no National park/ Wild life Sanctuary/ Reserved forests within 10 Km radius of the
study area. There is no rare/endangered species within study area.
3.9 SOCIO ECONOMIC ENVIRONMENT
Manali is an Industrial town and Municipality in Thiruvallur district in the Indian state of Tamil
Nadu. It is located in north of Chennai City. As of 2011, the town had a population of 35,248.
Manali is a Northern Suburb of Chennai city. It borders Tiruvottiyur to the east, MathurMMDA to
the west, Kodungaiyur to the south, 100 ft road to the North. The main throughfares in the area is
KamarajarSalai,Chinna Mathur Road,Parthasarathy street. Main street in Manali isKamarajarSalai,
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school Street. Manali area is the home to petroleum refinery (Chennai Petrochemical Corporation
Limited or CPCL) and allied petrochemical industries.
3.9.1 Social Indicators
3.9.1.1 Demography:The population of the district is 3728104 as per 2011 Census. The male
population is 1876062 (50.32%) and the female population is 1852042(49.67%). The
Schedule Caste population is 22% of the total population. The area of the district is
342243Ha. The district‟s share of the state is 2.63%. Over 65% of population of district
lives in the urbanized part of the district. The Sex Ratio in the district is at 987 per 1000
male as per census 2011 compared to 971 during the 2001 census. It shows the awareness
of importance of girl child. The average national sex ratio is 940 as per Census 2011.
3.9.1.2 Population Density: The population density of the district is 1098 as per 2011 census, but
it was 776 as per 2001 census.
3.9.1.3 Decadal Growth: The decadal growth of the district is 35.25 during 2001-11 but it was
23.06 during 1991-01. It shows the dynamic migration and the vibrant economic activities
of the district. The State decadal growth for 2001-2011 is 15.60.
Figure 3-11 District Decadal Growth Rate
3.9.1.4 Occupation: The majority of working population is belonging to the main workers
category (81%) and marginal workers category is 19%. It shows the vibrancy of economy
of the area. In main workers category, “Others” consists of workers in services sectors,
industries Govt. dept. etc.
23.06
35.25
0
5
10
15
20
25
30
35
40
1991-01 2001-11
District Decadal Growth (%)
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Figure 3-12 Statistics of Main workers
3.9.1.1 Agriculture:Agriculture is one of the main occupations in the district .The net area sown is
31% of the total area. Paddy is the principal crop in the district. As per the dept. of
Economics and Statistics, GoT, there are 83912 acres are under paddy cultivation. The
ground nut cultivation is in 10348 Ha.
There are 1895 tanks in the district for irrigation purpose and there are 1929 dug wells and
9307 open wells in the district. There are 189 km canals serving irrigation in the district.
The majority of farmers are marginal landholders (below 1 Ha). Of the total farmers,
82.63% of them are marginal farmers. As the marginal farmers cannot depend on the
agricultural activities, they work as agriculture labors and non agriculture labors. Cattle
rearing is one of the income generating activities, mostly women-folks are involved in it.
As per Livestock Census 2004, there are 683535 live stocks in the district.
The majority of farmers are marginal landholders (below 1 Ha). Of the total farmers,
82.63% of them are marginal farmers. As the marginal farmers cannot depend on the
agricultural activities, they work as agriculture labors and non agriculture labors. Cattle
rearing is one of the income generating activities, for marginal farmers and mostly women-
folks are involved in it. As per Livestock Census 2004, there are 683535 live stocks in the
district.
4.84
13.88
3.34
77.94
0
10
20
30
40
50
60
70
80
90
Cultivators Agri.Labor Household Others
District -Main Workers (%)
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Source- Agriculture Census 2005
Figure 3-13Bar chart for Operational land holding
3.9.1.1 Education:Average literacy rate of Thiruvallur as per 2011 census is 84.03 compared to
76.94 of 2001. The male and female literacy were 89.69 and 78.32 respectively. The
literacy rate of male and female was at 85.26 and 68.39 according to 2001 census. There are
1417 primary schools in the district. The dropout rate is 1.36 which is higher when compare
to the State dropout rate (1.0).
Figure 3-14 School in Manali
195116
2454910426 3079 2955
0
50000
100000
150000
200000
250000
Operational Land Holding
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3.9.1.2 Health: There are 45 Primary health centers in the district. The medical facilities are
available in the district as Chennai City is nearby and also the district is more urbanized.
3.9.2 Economy of the District
The economy of the district depends on the agriculture and its allied activities besides
industrial growth. The district has an advantage of being near to Chennai city. So the
opportunities of evolving new industrial area are high.
The Gross Domestic Product (at Current Prices) of the district is increased exponentially from
657775 lakhs during 1999-00 to 1414211 lakhs during 2006-07.
Source: Department of Economics and Statistics, GoTN
Figure 3-15Product at net and constant prices
The per capita income of the district has increased from Rs.21167/- at 1999-00 to Rs.38388/- at 2006-07.
0
200000
400000
600000
800000
1000000
1200000
1400000
1600000
Rs.
La
kh
District Gross Domestic Product at Current and Constant
Prices (1999-2000 New series)
Ar Current Prices
At Constant prices
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Source: Department of Economics and statistics, GoTN
Figure 3-16 Per Capita Income at Net and Constant Prices
3.9.3 Land use and Resource availability
The types of soil predominantly found are red non-calcareous and coastal alluvial. The soil
found in the coastal region is of the erinaceous type (sandy), suitable for casuarina plants. The
predominant soil types are sand and sandy loam. Saline and alkaline soils also noticed in some
patches of Ambathur, Ponneri and Thiruvallur Division.
The Land use data of Thiruvallur district is given below in Table 3-17
Table 3-18Land Use data - Thiruvallur
Land
Use
Pattern
Geographical
area
Forest
area
Land under
non-
agricultural
use
Permanent
pastures
Cultivable
wasteland
Land
under
Misc
tree
crops
Barren Current
Fallows
Others
Ares
(„000
ha)
342.2 19.7 107.9 8.1 8.0 7.7 13.6 26.3 39.3
Source : ICAR 2011
3.9.3.1 Crops Cultivated (Thiruvallur)
i. Paddy: Paddy is the principal crop extensively cultivated during three season &
Sornavari (April to July), Samba (August to November) and Navarai (December to
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Ru
pe
es
Per Capita Income at Current and Constant Prices 1999-2000 New Series
At Current Prices
At Constant Prices
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March). Normal area under paddy is 82869 ha and Normal productivity of rice per ha.
is 3359 Kgs.
ii. Millets:The normal area under millets is 1578 ha. Among millets, cumbu is major
millet crop generally sown under rainfed condition in a normal area of 1220 ha. The
normal productivity under millet is 2049 Kgs / ha.
iii. Pulses: The normal area under pulses is 8611 ha under Kharif and Rabi seasons and
larger area of pulses is cultivated during Rabi season. The normal productivity of pulses
is 549 Kgs. / ha. The predominant pulses crop cultivated are Greengram, Blackgram
and Redgram.
iv. Oilseeds: Groundnut is the major oilseed crop cultivated in a normal area of 17401 ha
under Kharif and Rabi seasons. More area is cultivated during Rabi Season. The
Normal productivity is 4274 Kgs. / ha.
v. Sugarcane:Sugarcane is cultivated in a total area of 5848 ha. With normal cane
productivity of 117 MT / ha.
3.9.4 Industries
Thiruvallur district is one of the fastest developing districts in Tamil Nadu in terms of
Industrial Development. The district has many leading industries like Chennai Petroleum
Corporation Limited, Madras Fertilizers, Manali Petro Chemicals, MRF, Ashok Leyland, TI
Cycles, Britannia India Ltd, Parry India Ltd and Hindustan Motors. It also has the Ennore
Thermal Power Station and the Avadi Tank Factory. The District has 16 Industrial Estates, all
in operation: 11 developed by the Government and 5 by Private Organisation.
3.9.4.1 Government
Ambattur Industrial Estate, Ambattur.
Electrical Industrial Estate, Kakalur.
SIDCO Industrial Estate, Chennai - 98.
Industrial Estate, Madhavaram.
SIDCO Industrial Estate, Kakalur
Petrochemical Industrial Estate, Vichoor
SIDCO Industrial Estate, R.K. Pet
SIDCO Industrial Estate, Gummidipoondi
Industrial Estate, Mugappair
3.9.4.2 Private
G.K. Industrial Estate, Porur
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M.M.Industrial Estate, Alapakkam
Moccaram Industries, VelappanChavadi
Nagappa Industrial Estate, Puzhal
EkambaraNaicker Industrial Estate, Alapakkam
This district has 16940 Small Scale Industries, notable among them being food, wood, textile,
chemical, engineering, non-metallic and leather industries.
3.9.5 Discussion with local people
The discussion with local people centered on the ecology of the area and also people and
natural resources. Out of the discussions, the following points emerged
i. The water quality of the areas has really gone down
ii. Drinking water availability is a real problem.
iii. To some extent, agriculture is affected due to the impact of industrialization.
iv. The employment opportunities in the area are generally less
v. Workers for agriculture in the interior areas, are not available,
vi. The practice of agriculture is not yielding meaningful returns to satisfy the expectations
of the farmers.
vii. In general transport, education facilitates and support for health is not up to the mark.
viii. If the developmental programme is taken up involving the people with financial
assistance, youngsters remarked that they will be able to decide and lead a better way of
life based on training and entrepreneurship.
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Figure 3-17 Discussion with the local fisherman
Figure 3-18 Discussion with a worker in the study area
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4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION
MEASURES
4.1 IMPACT IDENTIFICATION
To identify and assess the impact of the proposed product mix change, the entire project has been
divided into two phases:
Pre - operational Phase (Expansion erection/Construction)
Operational Phase
4.2 CONSTRUCTION AND COMMISSIONING PHASE
As TPL has complete infrastructure suitable for manufacturing of proposed products, no major
construction activity will be carried-out. Only minor civil work like foundation of new vessels etc.
will be carried-out. The broad activities during this period will be as follows:
Foundation work only for new machinery.
Erection of only new mechanical equipments
Synchronization of various equipments / processes
4.3 COMMISSIONING OF PLANT
Construction cum commissioning phase of the projectwill be for a shorter duration as compared to
operational phase. Construction cum commissioning phase will mainly involve noise pollution
(erection of mechanical machineries etc.) and demand for water (for domestic requirement of
construction and commissioning work force). Though Aesthetics and Socio-economic factors are
also identified, the impacts related to the same will be marginal.Local man power will be used
during this phase. Similarly, there will be no displacement and rehabilitation of people due to the
proposed product mix change.
4.4 OPERATION PHASE
Because of its potential to create long-term impacts, this phase is very important from the
environmental impact point of view. The basic impacts like gaseous emissions, water consumption
and solid waste will have the potential to adversely affect air, water and land / soil in the vicinity of
the project site.
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This phase will broadly include the following direct and indirect activities / actions:
Storage and transportation of raw materials and finished products.
Gaseous emissions
Effluent Generation, treatment and disposal
Noise Generation
Solid waste generation
4.4.1 Air Environment
Base line data reveals that ambient air quality in the study area for the Parameters PM2.5,
PM10, SO2, NO2, are well within the permissible Limits as prescribed by the National
Ambient Air Quality Standards (NAAQ) for Industrial Area, Residential, Rural & Other area.
Emission of PM, SOx& NOx from stacks attached to Boiler, DGs and Chlorine from scrubber
are the only source of air pollution.
Table 4-1Stack details in the existing ECH facility
Source Stack Dia.
(m)
Stack
Height
(m)
Stack
Temp.
(oC)
Stack
Velocity
(m/sec.)
Gas Discharge Qty.
(m3/hr)
Boiler 0.65 47.4 162 12.7 11450
Propylene heater 0.25 23.2 172 12.1 1050
DG 3.2 MW (Furnace oil) 1.0 31.5 241 13.5 30952
HCl Production unit stack 0.17 30 30 11.8 5000
Chlorine scrubber 0.17 30 32 11.7 800
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Table 4-2Source of Process Emissions after Proposed change in Product Mix
S.No. Description and Source of
Generation
APC measures provided Point of Discharge height (m)
1 Emission from Boiler Common Stack 47.4
2 Emissions from DG Stack Common Stack 31.5
3 Chlorine from production unit Scrubber and Stack 30
Table 4-3Reduction in emission load due to proposed change in product mix
S.No Contents Existing (MTPD) Proposed (MTPD)
1. Particulate Matter 0.052 0.0507
2. SOx 2.984 2.84
3. NOx 0.505 0.5
4. HCl 0.00006 Nil
5. Chlorine 0.00001 0.00001
Total 3.5410 3.3907
As it is observed from the above table, the proposed project would result in a reduction in the
emission load as the existing stacks for propylene heater, HCl Production unit will not be used
in the proposed facility and the proposed facility will have a stack attached to the 12 TPH fuel
oil fired boiler, one to the DG, 3.2 MW and one stack attached to the chlorine scrubber. In
order to assess the air quality impact of the proposed change in product mix air quality
modelling was done using AERMOD software. Based on the Emission Details, Air
Dispersion Modelling was conducted and the estimated GLC‟s is shown in the Figure 4-1.
AERMOD Software Version 7.5.0 was used for dispersion modelling, site specific
meteorological data for three months (March, April and May 2014) were obtained from on
site metrological monitoring station. Data included in the data set were hourly wind speed,
wind direction, temperature, relative humidity, air pressure, precipitation etc
The emission from existing stackhas been taken as basis for modeling are shown below:
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Table 4-4 Stack Emission Details
S.No Source Fuel Height
(m)
Diameter
(m)
Exit
Velocity
(m/s)
Exit
Temperature
(0C)
SO2
Emission
Rate
(g/sec)
NO2
Emission
Rate
(g/sec)
Suspended
Particular
Matter
(g/sec)
1 Boiler FO 47.4 0.65 12.7 162 15 0.636 0.159
2 DG, 3.2
MW FO 31.5 1 13.5 241 20 5.15 0.42
3 Chlorine
scrubber - 30 0.17 11.7 32 0 0.002 0.001
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Figure 4-1 Ground Level Concentration (GLC) of SOX at 10 Km radius(without DG set)
Figure 4-2 Zoomed image - (GLC) of SOX at 10 Km radius (without DG set)
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Figure 4-3Ground Level Concentration (GLC) of SOX at 10 Km radius (With DG set)
Figure 4-4 Zoomed Image of GLC of SOX at 10 Km radius (With DG set)
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Figure 4-5Ground Level Concentration (GLC) of NOX at 10 Km radius
Figure 4-6 Zoomed Image - (GLC) of NOX at 10 Km radius
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Figure 4-7Ground Level Concentration (GLC) of PM at 10 Km radius
7
Figure 4-8Zoomed Image - (GLC) of PM at 10 Km radius
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Table 4-5 Predicted GLC for Proposed Stack
Parameters Baseline data
(µg/m3)
Estimated
MaximumIncremental
Concentration (µg/m3)
Predicted
MaximumGLC
(µg/m3)
Direction Downwind
distance
(km)
SOX 13 9.2 22.2 W 1
SOX* 13 22.3 35.3 W 1
NOX 25 4.14 29.14 W 1
PM 60 0.414 60.414 W 1
*Emission load predictedwhen DG is in continuous operation (Worst case scenario), however DG will be
used only as a backup in case of power failure.
Due to the proposed change in the product mix, existing Propylene heater & HCL production
unit will not be operated and therefore there will be a marginal decrease in air pollution load.
As seen from the above table the concentration levels arising from the proposed change in
product mix are within the NAAQ limits.
4.4.2 Water Environment
The proposed project facility will generate 4.76 KLD wastewater from domestic purposes and
1805 KLD wastewater from industrial processes. The sewage generated will be treated in STP
& the treated water will be used for gardening. The effluent generated from the process will
be treated in ETP & disposed to sea. The Existing ETP is capable of handling the flow of
2702 KLD in the primary & secondary treatment and there will be no additional effluent load.
The proposed change in product mix involves no additional water requirement and no
additional discharge from the site. Moreover, there will be no change in pollution load with
respect to quantity and quality.
4.4.3 Noise Environment
The impacts of the proposed product mix change on the noise levels of the surrounding areas
were modeled using CUSTIC software. All equipments in the plant is designed/operated to
have a noise level not exceeding 85 to 90 dB(A) as per the requirement of Occupational
Health and Safety Administration Standard (OHSAS). In addition, since most of the noise
generating equipment would be in closed structures, the noise transmitted outside would be
still lower. The isopleths of the noise modeling is given as the Figure 4-9. From the below
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model it can be inferred that the noise level at the surrounding vicinity of the site is
anticipated to be within the prescribed standards.
Scale-X-axis 2900m; Y-axis 1900m
Figure 4-9 Noise level Contour- Isoline view
4.4.4 Land Environment
One of the factor that is usually considered as a major impact from any project is the land use
change. But since the proposed project is product mix change under the same TPL site, no
land use change is foreseen, as the current land use is that of industries. A land use change of
the project site from 2003 to 2014 is shown in the figure.
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Figure 4-10Land use in the year 2005
Figure 4-11Land use in the year 2008
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Figure 4-12Land use in the year 2014
As seen from the above slides, the land use remains Industrial since 2005, but gradual increase
in Human settlements can be seen from 2008.
4.4.5 Flora And Fauna
4.4.5.1 Forest Area -No forest area exists within10 km radius from the project site and hence no
impact. is envisaged.
4.4.5.2 Wild Life -No wild life crossing is found along the project corridor.
4.4.5.3 Cattle Grazing -No cattle grazing grounds have been found along the corridor of Impact.
4.4.5.4 Aquatic life –Korttalaiyar River is located adjacent to the site boundary. Sewage &
Effluent generated from the industry will be treated in STP & ETP. The treated sewage
will be used for gardening. The effluent generated from the site is treated and disposed in
sea. The same method will be followed for product change also. The treated effluent will
meet the standards prescribed by the Pollution Control Board and there is no significant
impact on aquatic life.
4.5 IMPACT ASSESSMENT
A number of techniques are available for the assessment of impacts. Each of these techniques has
their own advantages and disadvantages. The selection of any of these techniques for any particular
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project depends largely upon the choice of judgment of the analysis. The technique chosen should
be comprehensive, easy to understand, systematic and flexible. Considering these criteria, for this
project, the matrix method was used, with an impact scale of -4 to +4.
4.5.1 Matrix method
Impact identification and assessment of the site can be assessed by the matrix method,
popularly known as Leopold matrix method, which is a universal tool for the EIA studies. The
matrix used for the EIA consists of project activities on the x-axis and the environmental
components likely to be affected by these activities on the y-axis. Each cell of the matrix
represents a subjective evaluation of the impact of the particular components, in terms of
magnitude importance. A blank cell indicates no impact of the activity on the component. The
magnitude (m) is represented by a number from 1-4 where,
1= minimal
2= appreciable
3= significant
4= severe
A positive sign indicates a beneficial impact and the negative sign indicates an adverse
impact. The importance (w) of the impact is given on a scale of 1-4 in each cell. This number
indicates the relative importance of the impact of the activity on the concerned component for
this project. The magnitude and importance are multiplied to give a score for each cell
(mijwij). The scores of individual cells in each row are added to determine the total impact of
all project activities on each component. Similarly, the scores in individual cells in each row
are added to determine the total impact of each activity on all the environmental components
likely to be affected. The grand total of all cells indicate the total project impact. This can be
represented by the following equation:
Total project impact= mijwij
Where mij = (positive or negative) magnitude of the jth activity on the ith environmental
component and wij = importance of the jth activity on the ith environmental component
Since both m and n vary from 1-4 the total score in each cell can theoretically vary between -
16 and +16, therefore the total project impact can vary between (-16*total number of cells in
the matrix) and (16*total number of cells in the matrix), to compare scores from the matrices
containing different number of cells, the total project score can be normalized to a scale of
100 as follows:
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Total project impact
Total project impact = -------------------------------------------- * 100
16 * Total number of cells in matrix
On the scale, the overall impact can be classified as follows:
Table 4-6Overall Impact Classification
Total project impact (Scale of 100) Magnitude
-100 to –75 Severely adverse
-75 to –50 Significantly adverse
-50 to -25 Appreciably adverse
-25 to -16 Minimally adverse
-15 to -6 Low Adverse Impact
-5 to 0 Extremely low adverse impact
0 to 25 Minimally beneficial
25 to 50 Appreciably beneficial
50to 75 Significantly beneficial
75 to 100 Highly beneficial
4.5.1.1 Alternative scenarios
Impact score for the project was calculated for three scenarios using the matrix method
described above. Matrices were prepared to represent each of these scenarios:
a) Scenario 1 - No Project
This scenario considers that there is no change in product mix. The existing activities
in the plant and the consequent secondary growth were also considered in evaluating
the impact in this “no project” scenario.
Table 4-7No-Project Scenario
Environmental Components
likely to be affected
Activities likely to affect Environmental Components
Construction
Activities
Process Solid/Hazardous
waste
Impacts on
components
Air Quality Magnitude 0 -1 -1 -6
Importance 3 3 3
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Noise and
Vibration
Magnitude 0 -1 -1 -5
Importance 3 3 2
Surface water
quality
Magnitude 0 0 0 0
Importance 4 4 4
Ground water
quality
Magnitude 0 0 0 0
Importance 4 4 4
Water Resources Magnitude 0 -2 0 -8
Importance 4 4 4
Soil Quality Magnitude 0 0 -1 -3
Importance 3 3 3
Flora and Fauna Magnitude 0 0 0 0
Importance 2 2 2
Land use Pattern Magnitude 0 0 0 0
Importance 4 4 4
Employment Magnitude 0 0 0 0
Importance 4 4 4
Total impact of activity -22
Total impact of activity on a scale of 100 -5
The total project impact for this scenario was found to be –5, which is extremely low adverse
impact
b) Scenario 2 - Project without EMP
Proposed change in product mix takes place without any Environmental Management
measures.
Table 4-8Project Scenario without EMP
Environmental Components
likely to be affected
Activities likely to affect Environmental Components
Construction
Activities
Process Solid/Hazardous
waste
Impacts on
Components
Air Quality Magnitude -2 -4 -3 -27
Importance 3 3 3
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Noise and
Vibration
Magnitude 1 2 1 12
Importance 3 3 3
Surface water
quality
Magnitude -1 -3 -1 -20
Importance 4 4 4
Ground water
quality
Magnitude -2 -3 -4 -36
Importance 4 4 4
Water Resources Magnitude 0 -2 0 -8
Importance 4 4 4
Soil Quality Magnitude -2 -2 -3 -21
Importance 3 3 3
Flora and Fauna Magnitude -1 0 0 -2
Importance 2 2 2
Land use Pattern Magnitude 0 0 0 0
Importance 4 4 4
Employment Magnitude 2 1 1 16
Importance 4 4 4
Total impact of activity -86
Total impact of activity on a scale of 100 -20.0
The total project impact for this scenario was found to be –20, which is minimally adverse
impact
c) Scenario 3 - Project with EMP
Proposed change in product mix takes place with proper Environmental Management
measures.
Table 4-9Project with EMP
Environmental Components
likely to be affected
Activities likely to affect Environmental Components
Construction
Activities
Process Solid/Hazardous
waste Management
Impacts on
components
Air Quality Magnitude -1 -2 -1 -12
Importance 3 3 3
Noise and Magnitude -1 -1 0 -6
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Vibration Importance 3 3 3
Surface water
quality
Magnitude 0 0 0 0
Importance 4 4 4
Ground water
quality
Magnitude 0 0 0 0
Importance 4 4 4
Water Resources Magnitude -1 -3 0 -16
Importance 4 4 4
Soil Quality Magnitude -1 0 -1 -6
Importance 3 3 3
Flora and Fauna Magnitude 0 0 0 0
Importance 2 2 2
Landscape Magnitude 0 0 0 0
Importance 4 4 4
Employment
&socio
economics
Magnitude 3 4 3 40
Importance 4 4 4
Total impact of activity 0
Total impact of activity on a scale of 100 0
There is minimally adverse impact on Air, water, soil & noise quality. However due to the
employment activities proposed by the proponent the cumulative impact for this scenario is
found to be 0, which is neither beneficial nor adverse to the Environment, The main objective
of the proposed project is to bring the economically viable production of Propylene Oxide and
use it beneficially.
For the proposed product mix, the emission load from stack is reduced. Hence the impact
should be positive.
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5 ANALYSIS OF ALTERNATIVES
5.1 INTRODUCTION
This chapter presents a comparative analysis of various alternatives considered to avoid or
minimize impacts that would be inevitable in technically advanced processes. Several alternatives
are analyzed for avoiding localized environmental impacts & arriving at the proposed processes.
Screening procedure for the alternatives considered are presented in the following sections. The
consideration of alternatives to a proposal is a requirement of the EIA report. Range of alternatives
selected for analysis includes - Site alternatives, Fuel alternatives, Water supply alternatives,
Technology alternatives. The relative impact of each alternative is compared against the baseline
environment to select a preferred alternative.
Finalization of various options such as fuel type and construction materials, keeping in view of the
obligatory points and environmental safety aspects etc. The Project alternatives without mitigation
measures and with mitigation measures are analyzed before choosing the proposed alternatives. The
objective of this chapter is to highlight some of the salient issues considered for exercising the
alternative options.
5.2 SITE SELECTION
The proposed existing project with product mix change, Propylene Oxide manufacturing, is
proposed inside the existing TamilnaduPetroproducts Limited situated in Manali, Thiruvallur
district.
The criterion for site selection included the below mentioned points:
The proposed project site is suitable from operation point of view since it is situated in the
already existing manufacturing unit.
The project site shall not require displacement of habitation and away from the habitation
area. As it is located inside the existing plant, there is no habitation present inside the
project area.
The plot allotted for the plant is flat and stable to increase its resistance against any natural
disturbances like earthquake.
The project site is above the flood level and thus will avoid any accident in case of flooding
from the nearby canal.
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The project site is free from any environmental restrictions like forest, natural parks; wild
life sanctuaries.
The project does not involve any displacement of local residents as it is located inside the
existing premises.
In addition to the above mentioned issues various environmental issues are also considered
while choosing the current location which is given in Table 5-1
Table 5-1Impacts of alternative site location compared with the selected location
Environmental
Issues
Options
Comments If located outside the
existing plant
Centrally located
within the existing
plant
Water flows
andquality
Larger project
footprintcreates
potential forincreased
disturbance andpollution
Project footprint
minimized,reducing
potential forimpacts on
water to aminimum
Ability to minimize
projectfootprint is a
major factor in
mitigating
environmental impacts Air quality Extended
footprintincreases
potential fordust
emissions;potential for
greaterexposure of
adjacentcommunities
toprogrammed
emissions,depending on
location
Project footprint
minimized,reducing
potential for
dustgeneration to a
minimum;buffer
mitigates
againstexposure of
adjacentcommunities to
emission ofgases and
fumes
Noise andvibration Increased potential for
greater exposure of
noise levels to
adjacentcommunities
Decreased potential for
exposure of noise levels
to adjacent communities
Soil Larger footprint
increasesland and
directimpact on soils
Optimized
footprintminimizes land
take anddirect impact on
soils
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Biodiversity Larger footprint
increasesland
acquisition and
directimpact on flora
and fauna
Optimized footprint
Nil land acquisition and
nodirect impact on flora
and fauna
Landscape Larger footprint
increases
land acquisition and
visual
impact
Optimized footprint
No land acquisition
andvisual impact
Socio-
economicissues
No significant discrimination in regard to socio-
economicfactors
Potential impacts of
proximity of industries
with nearby
settlements is
decreased
Transportationissues No significant discrimination in regard to
transportationissues, unless a processing site was
selected remotefrom the existing facilities, in which
case, there would be potential for major impacts
related to transportation
Ability to minimize
Projectfootprint is a
major factor
inmitigating
againstenvironmental
impacts
5.3 PROJECT ALTERNATIVES
This project can lead to economic prosperity as there is good market potential for Propylene Oxide
and its derivatives Propylene Glycol and Polyether Glycol. The purpose of PO manufacturing unit
is to meet the growing demand of Propylene Glycol and Polyol.
5.3.1 Site alternatives
Since this is a product mix change project, there is only a minor change in the existing
Epichlorohydrin plant, the area earmarked for future development inside the already existing
site will best fit in terms of ease in operation. Therefore this project is located inside the
existing TPL plant. The process equipment, supporting infrastructure and pollution control
equipment will be installed inside the existing premises.
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5.3.2 Fuel alternatives
Fuels like Coal, Bio Briquette and Natural Gas werethe alternatives considered as fuel source.
The safety aspects and pollution aspects of each fuels during transport, storage, usage,
availability and end products of combustion is considered and discussed. The existing premise
doesnot have the required space for storage of coal, and combustion of coal generates large
amounts of SPM and gaseous emissions like SO2 and NOX. The generation of fly ash during
the coal combustion will add to the burden of EMP team in disposing them to cement
industries or brick kilns. The storage of Natural gas in the existing premises will be unsafe due
to space constraints and close proximity of many industries nearby. After analyzing the safety
and economic alternatives, it was decided to have fuel oil as the source of fuel inside the plant.
5.3.3 Water supply alternatives
The selection procedure and evolution of the preferred option for process water has
involvedmany water supply studies and consideration of options, including those addressed
duringearlier feasibility and other scoping studies. Fundamental options for water supply in
the initial screening included:
Groundwater
Existing surface storage facilities
Use of municipal water supply.
Since the site is located within the Industrial Estate and CMWSSB is already providing water
supply, the same will be utilized for process modification.
5.3.4 Alternative Technologies
Propylene Oxide (PO) can be manufactured by different process technologies, that varies
according to the raw material requirements, process conditions, economic feasibility and so
on. Some of the process technology alternatives for the production of PO are given below and
compared with the existing process for the proposed site.
5.3.4.1 POSM Technology -POSM (Propylene Oxide/Styrene Monomer) technology is used for
about a third of the world's production of propylene oxide and involves the reaction of
propylene and ethylbenzene to produce propylene oxide and styrene.
5.3.4.2 POMTBE Technology–TBA a coproduct of propylene oxide (PO), is produced by PO
manufacturers.Although it can be used directly as an oxygenate, it can also be used as a
rawmaterial in the production of MTBE.An alternative epoxidation route uses isobutane
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which makes a tertiary-butyl alcohol (TBA) co-product that can be converted to methyl
tertiary butyl ether (MTBE).
5.3.4.3 Direct oxidation-The direct gas-phase oxidation of propylene by molecular oxygen has
long been the most desirable as well as challenging goal of production of PO. However,
despite considerable effort, no economically viable catalyst has yet been found.
5.3.4.4 Hydrogen Peroxide -Hydrogen Peroxide method is also called as Organic Peroxide
Method. In this method, there is a method using Ethyl benzene and a method using
isobutane, and in each of them PO is synthesized by indirect epoxidation of propylene using
ethyl benzenehydro peroxide or tert-butyl hydroperoxide as the organic peroxide. A styrene
monomer (SM) or tert-butanol (TBA) is produced as the co-product.
5.3.4.5 Chlorohydrin Technology- In the chlorohydrin process, propylene reacts with the mixture
of Chlorine and water forming propylene chlorohydrin (PC), followed by the reaction of PC
with lime (Ca(OH)2) to form PO and CaCl2 as a co-product. Nearly 50% of world PO
production is currently based on this method.
5.3.5 Justification for the Selected Technology
Some of the reasons for TPL to implement the Chlorohydrin technology for the production of
PO in the proposed facility are as follows:
Same raw materials as that of ECH
Catalyst is not required
No storage constraints as Chlorine is readily transported via pipelines from the unit‟s HCD
Plant.
Most of the equipments used in the production of ECH can be used readily in this
technology.
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6 ENVIRONMENTAL MONITORING PROGRAM
6.1 INTRODUCTION
The Environmental Monitoring Program is laid out based on the following definition of
environmental monitoring:
“Environmental effects monitoring is the repetitive and systematic measurement of the
characteristics of environmental components to test specific hypotheses of the effects of human
activity on the environment. Environmental monitoring is undertaken primarily to determine the
environmental effects of human activities, and secondarily to increase understanding of cause-effect
relationships between human activity and environmental change.”
Environmental monitoring programs provide the necessary information to:
i. Verify the accuracy of EIA predictions;
ii. Determine the effectiveness of measures to mitigate adverse effects of projects on the
environment.
Feedback from environmental monitoring programs will be used to:
i. Determine whether more or less stringent mitigation measures are needed; and
ii. To improve the predictive capabilities of EIA‟s.
Environmental monitoring program is a vital process of any management plan of the development
project. This helps in signalling the potential problems resulting from the proposed project and will
allow for prompt implementation of effective corrective measures. The environmental monitoring
will be required for the constructionand operational phases.
The main objectives of environmental monitoring are:
To assess the changes in environmental conditions,
To monitor the effective implementation of mitigation measures,
Warn significant deteriorations in environmental quality for further prevention action,
In order to meet the above objectives the following parameters need to be monitored,
Rehabilitation and Resettlement Program,
Afforestation,
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Water Quality and Public Health,
Air and Noise quality
Soil Conservation, and
Sanitation and Waste Disposal
Post Project Environment Monitoring Program
The summarized form of post monitoring details is presented in the following Table 6.1.
Table 6-1Post Project Environmental Monitoring Plan
S.
No
Area of
Monitoring
Frequency of Sampling Parameters to be Analyzed
1 Ambient Air
Quality
Monthly once 24 hourly All the 12 parameters given in NAAQS
VOC – online
2. Noise
(Workplace)
Every six months by in
house staff and yearly by
external agencies
Ambient Equivalent continuous Sound
Pressure Levels (Leq) near compressors,
motors, reactors, DG sets at day and night-
time.
3. Stack Emission
monitoring
Continuous -online PM, CO, SOx and NOx
4. Effluent (inlet
and outlet)
Monthly pH, Temp, TSS, TDS, Chloride, sulphide,
sulphate, fluoride, Ammoniacal Nitrogen,
Sodium, Copper, Zinc, Phenolic compounds,
oil and grease, Boron, BOD,COD, Total
residual Chlorine, Arsenic, Cadmium, Total
chromium, Hexavalent Chromium, Lead,
Selenium, Mercury, Pesticides, Alpha
emitters, Free Ammonia, Dissolved
phosphates, Total Kjeldahl nitrogen, Cyanide,
Nickel, Residual Sodium Carbonate. .
5. Sewage (inlet
ad outlet)
Monthly pH, Temperature, Oil and grease, TDS, TSS,
BOD.
6 Process Water
Quality
Quarterly pH, Temp, TSS, TDS, Conductivity, Hardness,
Chlorides, Sulphates, Silica, Total Residual
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S.
No
Area of
Monitoring
Frequency of Sampling Parameters to be Analyzed
Chlorine, Iron.
6. Drinking Water
Quality
Quarterly Color, Odour, pH, Turbidity, Taste, TDS,
Total Hardness, Calcium, Magnesium,
Chlorides, Iron, Sulfate, Manganese, Copper,
Nitrate, Fluorides, Lead, Zinc, Total
Chromium, Residual Chlorine, Total
Alkalinity, Aluminium, Mercury, Cadmium,
Arsenic
7. Soil Monthly once Physicochemical properties, Nutrients, Heavy
metals
8. Noise
monitoring
(Ambient)
Once in a month Noise level in dB (A)
9. Workplace
monitoring
Quarterly VOC & Lux Level
6.2 MONITORING METHODOLOGIES
Monitoring of environmental samples shall be done as per the guidelines provide by
MoEF/CPCB/TNPCB. The methods conducted or applied shall be approved or sanctioned by the
any recognized body or authority i.e. MoEF/CPCB/TNPCB.
6.3 REPORTING & DOCUMENTATION
All the necessary reports and documents shall be prepared complying to the statutory rules &
regulations. Proper and due care shall be taken to adhere to the laid down rules and regulation by
the government. Regular and periodic record shall be kept in order to ensure easier, comparable and
review and projection of past, present and future performances. Also, the management shall ensure
to prepare separate records for water, wastewater, solid waste, air, emissions and soil regularly and
periodically in order to provide better and smooth vigilance.
The management shall look into the fact that as soon as the preparation of reports gets over it shall
be forwarded to the concerned authority with due care for the purpose of reviewing. Adhering to the
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rules and regulations the management shall ensure that the outcome of the reports and the
conclusions been drawn shall be prepared as per the laid down regulations and procedures. No
breach of any convention shall be availed.
These reports/documents shall be regularly and periodically reviewed and any
changes/discrepancies found in mitigation measures/operation/management/technology shall be
brought into notice instantaneously and all possible corrective actions shall be taken to match the
discrepancies.
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7 ENVIRONMENTAL MANAGEMENT PLAN
7.1 INTRODUCTION
This Environmental Management Plan (EMP) for the Tamilnadu Petroproducts Ltd (TPL) identifies
the principles, procedures and methods that will be used to control and minimize the environmental
impacts of the proposed minor construction and operational activities associated with the product
mix change project. It is intended to ensure that commitments made by the TPL to minimize project
related environmental and social impacts are upheld throughout all project phases.
As part of our ongoing commitment to excellence in environmental and social performance we will
ensure the following:
Fulfill all environmental conditions associated with project approvals
Develop, promote and foster a shared sense of responsibility for environmental and
performance of the project.
Promote environmental awareness and understanding among employees, contractors through
training,
Identification of roles and responsibilities towards environmental management and linking
project performance to overall environmental performance
Monitor environmental performance throughout the project and implement an
Adaptive management approach to continuous improvement and to meet the future
regulations.
7.2 Objectives of EMP
Propose practical measures to avoid, reduce, restore, and compensate for identified adverse
impacts.
Conserve highly significant aspects of the biophysical, cultural and social environments.
Protect human health and safety.
Inform an environmentally sound and sustainable engineering design process.
Propose a plan to monitor and manage project implementation, such that the project is
environmentally sustainable and it optimizes the resource use.
Preparation of Afforestation or Greenbelt Development scheme.
Preparation of rain water harvesting scheme and energy conservation actions
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To prepare a capital cost estimate and annual recurring cost for Environmental Management
Plan.
7.3 EMP Structure and Organization in TPL
This EMP is designed as an overriding document in a hierarchy of control plans, and sets out the
overarching framework of environmental management principles that will be applied to the project
during preconstruction, construction and operation phase of the project.
The EMP contains guiding environmental principles and procedures for communication, reporting,
training, monitoring and plan review to which all TPL staff, contractors and subcontractors are
required to comply with throughout the preconstruction, construction and operation phases of the
proposed product change mix of Propylene Oxide manufacturing facility.
The EMP should also be considered as an overall framework document that establishes the terms of
reference for all project environmental and social sub-plans that will completed including the
following:
Environmental Supervision Plan (construction);
Environmental Monitoring Plan (Operation); and
Social and Health Management Plan (Operation).
7.4 EMP Roles and Responsibilities
This section describes the organizational structure and responsibilities for implementation of the
EMP as shown in Table 7-1
Table 7-1Responsibilities for EMP Implementation
S.No Organization Responsibility
1. M/S TPL Overall responsibility for environmental performance of TPL.
Decision-maker on applicable policies to the TPL.
Overall supervisory role during the construction phase
Overall responsibility for EMP implementation during the operating phase
Review reports of the Environmental Monitoring Consultant
(EMC)
Responsible for changes to the EMP as part of an adaptive approach to
environmental and social management of the TPL.
2. M/S TPL Develop an environmental unit, headed by the Project Environmental Officer
to implement EMP responsibilities.
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S.No Organization Responsibility
Oversight, implementation, monitoring and compliance of the EMP and any
approval conditions, including construction supervision and performance of
all TPL staff, contractors and all subcontractors.
Review of EMP performance and implementation of correction action, or
stop work procedures, in the event of breaches of EMP conditions, that may
lead to serious impacts on local communities, or affect the reputation of the
project.
Ensuring effective communication and dissemination of the content and
requirements of the EMP to contractors and subcontractors.
Assisting the contractor with implementation of EMP sub-plans.
Ensuring compliance to all project social commitments, including
Implementation of corporate social responsibility.
Report environmental performance of the project directly to MoEF.
Report on environmental performance also to other government regulators as
required.
3. Supervising
Engineer
Implementation of the Environmental Monitoring Plan during construction
and operation.
Supervision of contractor performance of implementation of the
Construction.
Reporting any incidents or non-compliance with the EMP to the TNPCB.
Ensuring adequate training and education of all staff involved in
environmental supervision.
Making recommendations to the MoEF regarding EMP performance as part
of an overall commitment to continuous improvement.
4. Construction
Contractor
Preparation and implementation of the Construction Management Plan
Prepare and maintain records and all required reporting data as stipulated by
the EMP, for submission to the Supervising Engineer.
Ensure that all construction personnel and subcontractors are informed of the
intent of the EMP and are made aware of the required measures for
environmental and social compliance and performance
During construction, maintain traffic safety along access roads, with special
emphasis on high trafficked areas
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S.No Organization Responsibility
5. Independent
Environmental
Monitoring
Consultant
(IEMC)
Report to MOEF on project compliance with environmental and social
commitments in the EMP, EIA and other applicable standards.
7.5 ENVIRONMENTAL MANAGEMENT PLAN FOR CONSTRUCTION PHASE
Environmental monitoring will be done during construction and operation. The focus of monitoring
during the construction phase will be to implement systematic observations to periodically measure
the success of proposed mitigation measures and continue baseline data collection. The majority of
construction monitoring shall be done visually and verified by the Construction Supervisor. An
Independent Environmental Monitoring Consultant (IEMC) will be responsible for carrying out
environmental sampling and monitoring on all environmentally related issues regarding the
Construction Contractor‟s activities. Specific aspects to be addressed during construction include:
1. Air quality
2. Noise
3. Water quality and water resources
4. Solid waste
5. Land environment
6. Ecology
7. Socio Economic
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7.5.1 Air Quality
Since Tamilnadu Petroproducts Ltd has complete infrastructure, no major construction
activity will be carried-out. Only minor civil work like foundation for new vessels, boiler
house and supporting infrastructure for the new machineries will be carried out. During
construction activities, dust resuspension and emissions from the movement of vehicles and
construction activity is expected. However, following measures will be taken to reduce /
contain such emissions.
Water will be sprinkled on inner roads to prevent re-suspension of dust into ambient
air due to movement of heavy vehicles etc.
Roads shall be kept free from mud, debris and other obstacles.
Separate civil construction material storage yard will be created within the site and it
will be enclosed.
Cement bags will be separately stored under cover in bales. Sand will be stacked under
tarpaulin cover.
Transport vehicles and construction equipments / machineries will be properly
maintained to reduce air emissions.
Idle running of vehicles will be minimized during material loading / unloading
operations.
All construction workers will be provided appropriate PPEs like dust mask, ear plug,
helmet, safety belt etc. and it will be mandatory for them to wear while entering the
site itself.
Increase signage and speed limit postings.
7.5.2 Noise Environment
Following measures are proposed during construction period to mitigate adverse impacts of
noise
Construction activities should be confined to daylight hours.
All machineries to be used for construction purpose will be of highest standard of
reputed make and compliance of noise pollution control norms by these equipments
will be emphasized by TPL.
All construction workers working in high noise areas will be provided appropriate
PPEs like ear muffs and made to wear them during working hours.
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7.5.3 Water Quality and Water Resources
Maximum water requirement for construction purpose including domestic water
requirement of construction workers is estimated to be approximately 3 KLD.
Since the construction workers are hired from nearby villages there will be no housing
facility at the site for construction workers and hence lesser water requirement
Proper and sufficient sanitary facility already exists at the site in the form of Toilets &
STP.
7.5.4 Solid Waste
Main solid waste generation during construction phase will be construction debris like
rubble, brick bats, debris, steel scrap, wooden scrap, sand, gravel etc. However, these
materials are inert in nature and will not result into leaching of any substance or its
constituent.
These materials will be carefully sorted and will be used within premises for filling of
low lying areas.
Wooden scrap, steel scrap will be given to authorized scrap dealers.
On completion of civil work, all debris etc. will be completely removed from site to
avoid any incompatibility with future use.
All the wastes will be stored at a designated site within the premises to prevent
scattered discharge on land.
7.5.5 Land Environment
Top soil layers shall be stored for reclamation and re-vegetation and reforestation at
approved locations.
Re-contour slopes
Ensure proper drainage is maintained
Re-vegetate, wherever feasible to contain runoff.
7.5.6 Ecology
Project site is an existing unit with a number of shrubs and trees. There is no cutting of trees
for the product mix change project and no major impact on ecology is anticipated.
7.5.7 Socio Economic
As there will be no temporary housing colony for construction workers, no socio economic
impact due to the same is envisaged. Overall socioeconomic effect of construction phase will
be positive due to direct and indirect employment opportunity for the local population.
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7.6 ENVIRONMENTAL MANAGEMENT PLAN FOR OPERATION PHASE
Monitoring during the operation phase shall reflect those environmental and socio-economic issues
that may persist upon completion of construction activities. Monitoring shall focus on evaluating
the effectiveness of project mitigation measures and continue baseline monitoring and sampling.
The mitigation measures to prevent adverse impact during the operation phase of the project shall
focus on the following:
Air quality
Noise environment
Water quality and water resources
Solid and hazardous waste
Land environment
Ecology
Socio Economic
7.6.1 Air Quality
Following measures are proposed to mitigate negative impact during the operation phase of
the project on the surrounding air environment.
Existing caustic scrubber with an Intallox saddle packing is used in the proposed PO plant
to take care of Chlorine emissions. Height of scrubber (5.5 m) and the packing bed height
(3.5 m) are as per statutory requirements.
On line chlorine Monitoring system in the existing scrubber stack is available and
connected to Care Air Centre of TNPCB.
Adequate spares of critical components of scrubber system are kept to ensure trouble-free
operations and continuous compliance to emission norms.
Transport vehicles will be properly maintained to reduce air emissions.
Vehicles will be periodically checked for pollutant emissions against stipulated norms.
Idle running of vehicles will be minimized during material loading / unloading operations.
Dust scrubber is proposed for Milk of lime Plant
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Figure 7-1 Chlorine Sensor in Chlorine scrubber stack
Figure 7-2 Online Chlorine sensor connected to TNPCB
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Figure 7-3 Continuous Ambient Air Quality Station at the site
7.6.1.1 Air Emissions
The major source of emission is from Boiler stack, DG stack, scrubber stack connected to
reactors. The details of proposed source of air pollution & corresponding Air Pollution
control equipment are already given in Chapter 4 Environmental Impacts and mitigation
measures.
7.6.1.2 Fugitive Emission Control
a) Leak Detection and Repair -Leak Detection and Repair (LDAR) is a program
implemented to comply with environmental regulations for reducing the fugitive
emissions of targeted chemicals into the environment. Several standards such as
Maximum Achievable Control Technology (MACT) standards, New Source
Performance Standards (NSPS), National Emissions Standards for Hazardous Air
Pollutants (NESHAP) and Central Pollution Control Board (CPCB) require the
monitoring and reporting of these fugitive emissions from process equipment.
The environmental regulation prescribes LDAR programs as a means of reducing
emissions with specified standards and applies to monitoring and repairing process
components.
As a part of industrial hygiene as well as environmental monitoring, TPL carried
out the leak detection and repair study as per CPCB guideline through an MoEF
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approved lab. Leak Detection and Repair (LDAR) is a program implemented to
comply with environmental regulations for reducing the fugitive emissions of
targeted chemicals into the environment.
7.6.2 Noise Environment
Following measures are proposed to mitigate negative impact of operation phase of the project
on the surrounding noise environment
All the noise generating equipments will be designed / operated to ensure that noise level
does not exceed 75 dB (A) during day and 70 dB (A) during night at plant boundary as per
the requirement of Central / State Pollution Control Board.
Noise generating sources will be maintained properly to minimize noise generated by
them.
Wherever feasible, acoustic enclosures will be provided for compressors.
Walls and ceilings of buildings will be lined with sound absorbing materials, wherever
required.
Compliance with noise control norms will be given due importance at the time of purchase
of various equipments and it will be mentioned while placing the purchase orders and
guarantee for noise standards will be sought from suppliers.
Moreover, all the personnel working in other high noise generating areas too will be
provided with sufficient ear protecting devices.
Green belt will act as a noise barrier.
Training will be imparted to personnel to generate awareness about effects of noise and
importance of using PPEs.
7.6.3 Water Quality and Water Resources
Following measures are proposed to mitigate negative impact of operation phase of the project
on the water quality and water resources.
Total water requirement for operation phase of the proposed project is estimated at 2150KLD
and is proposed to be met through municipal water supply(CMWSSB).The proposed project
will generate45KLD wastewater from domestic purposes and1805 KLD wastewater from
industrial processes. There will be no additional water discharge in the proposed project and
no change in pollution load with respect to quantity and quality. The sewage arising from
domestic purposes will be treated separately and reused for irrigating greenbelt.
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7.6.3.1 Domestic waste water
The Sewage Generated from Canteen, toilet & wash area are treated separately in STP. The
treated water from STP will be used for Green Belt maintenance. The process flow and
details are given in Chapter 2, Project Description. STP outlet will have the following
requirements as per TNPCB//CPCB - continuous monitoring for Flow pH, BOD,
COD,TSS.
7.6.3.2 Rain water harvesting system
Rain water harvesting system is installed and all rain water will be collected, filtered and
stored for reuse within our plant process. This system is been implemented for conservation
of water. The roof top water is collected through pipe system which is treated and used.
The rainwater harvesting pits will be provided near major built up areas, so that the roof
water can be directly sent to nearest Rainwater harvesting pit. The excess water if any from
the rainwater harvesting pits is diverted to storm water drains.
7.6.3.3 Rain Water Harvesting Details and Calculations
1. The rain water harvesting is proposed to augment the ground water table and also to
meet some of the water requirement of the project during rainy season.
2. Rooftop water from the terrace is proposed to be collected in rain water harvesting
sump which will be used for domestic purposes after appropriate treatment.
3. Storm water run-off road / paved / landscaped areas will be directed to shallow
recharge pits constructed along storm water drains for recharging the ground water.
4. The location of Rain water harvesting pits inside the proposed plant layout is
attached as Annexure-12
Design Parameters
Intensity of Rain fall Considered = 50 mm/hr or 0.050 m/hr
Coefficient for run off considered
Roof Top & Terrace - 0.90
Paved area - 0.70
Other building area - 0.60
Landscaped area - 0.20
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Area Details
Total road Area & Paved area - 26963 Sq.m
Total Roof Area - 1100 Sq.m
Other building area - 17648 Sq.m
Total Landscape Area - 65171.29 Sq.m (Green belt + Vacant area)
Hence, the Total Quantity of Rainfall Will Be: Q= A x P x R
Q= Quantity of rainwater run - off in cu.m / hr.
A= Area of catchments drained in sq.m
P = Permeability factor
R = Rainfall intensity in mm / hr.
Road Area : 26963 Sq.m x 0.70 x 0.050 m =943Cu.m/hr. (A)
Landscape Area : 65171.29 Sq.m x 0.20 x 0.050 m =651.71Cu.m/hr. (B)
Roof Area : 1100 Sq.m x 0.90 x 0.050 m =50 Cu.m/hr. (C)
Other building area : 17648 Sq.m x0.60 x0.050m = 530 Cu.m /hr (D)
Hence, total volume of rainwater run - off will be:
(A) + (B) + (C) + (D) = 2174.71 Cu.m/hr.
Rainwater Management Measures
Run-off from Terraces:
The run-off from the Terraces shall be separately piped to fire water tank, after duly filtering
the same. This water is proposed to be used for fire fighting.
Run-off from Roads, Paved area & Landscape areas:
The calculated run-off from roads/pavements, landscaped area and other building area are
2174.71 m³ /hr in total
This run-off is proposed to be channelized through storm drains to individual recharge pits
and the rain water will be re-charged into underground aquifers. Excess run off will be
discharged into to external storm water drain.
Total Run-off: Podium Area/Hardscape & Driveway & Landscape
Data assumed:
Considering 15 min of rainfall
Volume of rainwater available for recharging =527m³
Size of Rainwater Percolation Pit – 2 m Dia X 3 m, Depth
Volume of pit = (3.14x r2 X Depth)= 3.14 X (1.41)2 X 3=18.7Cu.m/pit
Total No of storage pit required =527/18.7= 29
Infiltration rate = 10cms/hr =0.1m/hr
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Total number of Percolation pits required = 29 Nos
No. of Pits provided= 15 Nos.
Figure 7-4 Rain water harvesting system – Roof top rain water collection system
Figure 7-5 Rain Water Percolation Pit
7.6.4 Effluent Treatment Plant
The Effluent generated from the plant is treated in the Effluent Treatment Plant and disposed
in Sea. The specification and process details are given in Chapter -2 Project Description.
ETP Outlet will have the following requirements as per TNPCB//CPCB - continuous
monitoring for Flow pH, BOD, COD,TSS.
7.6.5 Solid & Hazardous Wastes
The following measures are proposed to mitigate negative impact of solid waste generation
during the operation phase of the project. The Solid waste generation can be broadly
categorized in to Non- Hazardous & Hazardous. Non-hazardous wastes in the form of MOL
rejects amounts to 2200 MT/annum and Rotary Vaccum Drum Filter(Lime) sludge amounts to
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950 MT/annum. The details of waste generation in existing & proposed project are listed
below. Non Hazardous wastes like Packing material will be disposed through authorized
vendors, Food waste from canteen, Garden waste will be composted and used as a manure for
the green belt.
The quantity of hazardous waste expected to be generated in the proposed facility is given in
Table 7-3
Table 7-2 Quantity of Non hazardous waste
S.No Type of waste Quantity Storage
1. Packaging material 1 MTPA Sold to recyclers
2. Garden waste 5 MTPA Composting and used as manure
3. STP sludge 5 MTPA
4. Lime Sludge 3150 MTPA Sold to brick manufactures
(Annexure-23)
Table 7-3Quantity of hazardous waste expected to be generated in the proposed facility
S.No Type of Hazardous
waste
Quantity Storage
1. Used oil 2.0 MT/year Stored in barrels and sold to
SPCB authorized vendor
2. Waste oil 140 MT/year Stored in barrels and disposed to
authorized vendors
3. ETP Sludge 300 MT/year Stored and disposed to M/s.
TNWML, Gummidipoondi
TPL has obtained Hazardous waste Authorization for the existing ECH facility and the same
is enclosed in Annexure-21. The quantity of Hazardous waste generated for proposed
modification will be same as that of existing facility.
7.6.6 Land Environment
Following measures are proposed to mitigate negative impact of operation phase of the project
on the land environment.
Air emissions are effectively controlled by use of scrubbers and therefore deposition of
air pollutants in and around the premises and surrounding area is not envisaged.
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Disposal of solid waste is carried out through authorized vendor.
As the treated effluents are disposed off the sea, impact on the land environment is not
envisaged.
All the hazardous wastes to be generated from the project will be properly stored and
disposed as per the hazardous waste authorization issued by SPCB.
Hazardous materials are prohibited to be drained or dumped in the premises. Accidental
spills shall be cleaned, reported and monitored.
Thus, no impact on land is envisaged due to discharge of gaseous emission, solid waste
or liquid effluent from the proposed product mix change.
7.6.7 Ecology
Since the proposed project is equipped with the treatment system, and the treated effluent will
be disposed to sea. Solid wastes generated during the operation phase are disposed off through
authorized vendor and hence no impact is anticipated due to solid waste in and around the site.
The air pollution control devices expected to be installed at the proposed modification facility
will control release of air pollutants to a greater extent, however a two tiered thick green belt
consisting of shrubs and trees around the periphery of the site has been planned to intercept
and arrest air pollutants released at various heights and to attenuate the increased quantity of
air pollutants released into the environment. It is expected that the ecology of the region is
preserved by these mitigation measures.
7.6.8 Green Belt Development Plan
TPL has already developed a greenbelt of 4 acres of the total plot area in consultation with
horticulture experts as per Ministry of Environment and Forests/Central Pollution Control
Board guidelines. Adequate numbers of saplings are planted all along the periphery of the
plant, roadways and available open spaces. The major aim of greenbelt development plan is to
attenuate air pollutants released into the environment but it can also help in overall
improvement in the environmental conditions of the project site. The plan will address the
following issues such as attenuation of air pollution, noise reduction, improving the
biodiversity of the region, adding aesthetics and combating soil erosion and prevention of land
degradation.
A well designed green-belt helps in intercepting particulate matter and gaseous pollutants and
helps in purifying the air. Trees acts as effective barrier and absorber of noise. The green belt
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around an industry acts as a buffer in the event of emission control equipment failure and acts
as an indicator in the event of toxic release by visible morphological changes in the leaves,
stem etc. To accrue the benefits of greenbelt and to maximize its potential in environmental
management around an industry, choice of the green belt tree and shrub species plays a vital
role.
In the proposed project, additional 8 acres of green area is proposed. Hence the total green
area will be 12 Acres (33 % of plot area).The layout showing existing and proposed green belt
development in the project site is attached as Annexure-13.This green belt development will
be done in phased manner in 3-5 years.
7.6.8.1 Plantation Along Road Sides
As part of the initiative to improve the green cover near the roadways of the site. Trees and
shrubs will be planted along the roadsides. Since automobiles are the source of pollution of
gaseous and particulate pollutants the choice of plants for road side includes shrubs of
height 1 to 1.5 meter, medium sized trees of 3-5 meter height and tall trees of 10-20 m
height. Medium sized trees, alternating with shrubs are ideal for sorption of particulates and
gases.
Figure 7-6 Photos of existing Green belt
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7.6.8.2 Selection of Trees
For development of greenbelt it is advisable to select tree species high are tolerant to air
pollutants, since certain species of trees has the ability to uptake large quantities of SO2 than
other species and grow at a faster rate by utilizing the available nutrients in the soil etc.
In general, following factors have to be considered for the selection of tree species.
Native tree species should be preferred over non native trees.
The trees must be tolerant to all the pollutants present in the area.
The trees which are evergreen and forms large round canopy with broad leaves.
The morphological feature of leaves like rough surfaced and large number of stomatal
aperture.
The trees should be able to grow faster and should help in stabilization of the soil.
The trees should maintain ecological, land and hydrological balance of the region.
7.6.9 Socio – Economic Environment
TPL is committed to the socio – economic up-lift of the people in region and has actively
involved in formulating and implementing proactive measures as part of the corporate social
responsibility.
The following activities are carried on by TPL as a part of Corporate Social Responsibility
(CSR).
7.6.9.1 Toilets for Panchayat Middle school - Sadayankuppam Village, Manali
Tamilnadu Petroproducts Limited Manali has constructed toilets in one of the school unit
in Sadayankuppam, Manali town, Chennai. This is a village inhabited by the economically
weaker sections. They still perform open defecation in school. This causes a lot of
difficulties and health problems to children in school.
TPL has involved many people in several discussions concerning this project and it is with
their consent and based on their felt-need, this project is being implemented. TPL has
constructed total 4 toilets in school.
Cost-1.5 Lakhs
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7.6.9.2 Stationery items and Notebooks to Students at Panchayat Middle School
Sadayankuppam, Manali, Chennai
The children‟s studying in the Panchayat middle school are extremely poor and hence they
do not have the opportunity to have admission in a proper school. They usually study in
Govt. run schools where the standard of education is very low. The Govt. run schools are
always free and so the poor children can afford to go the same. However the lack of
stationary facilities can prove to be an obstacle for their progress in education.
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TPL has provided stationery items and notebooks to the students who are studying in
school that will be useful in their education.
Cost –Rs.25000/-
7.6.9.3 Painting of interior & exterior walls, benches, provision of Tables, Chairs and
Blackboards to Panchayat Middle School, Sadayankuppam, Manali, Chennai.
Basic needs are to be given to the students in school where they can study with no
difficulties.
The basic requirements like chairs tables and blackboards are sponsored to the school by
TPL and also exterior and interior school buildings are painted.
Cost – Rs.1.25 Lakhs
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7.6.9.4 Tree plantation at Panchayat Middle School, Sadayankuppam, Manali, Chennai
TPL with a responsibility towards the society and environment has planted the trees in a
school in Sadayankuppam, which reduces the environmental pollution and provides shade
to the children. The environmental awareness has been given to the students to save
environment for a clean and green surrounding.
Cost-Rs.10000/-
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7.6.10 Occupational Health and Safety Program
TPL is committed to protecting the safety, health and well-being of its employees, the
community in which they operate a wider environment.
TPL review and improve its processes, services and products to reduce industrial risk and
impacts. TPL educate, train and motivate employees to conduct their activities in a safe,
healthy and environmentally responsible manner.
The Health and Safety management system provides the framework towards organized efforts
and procedures for identifying workplace hazards and reducing exposure to harmful situations
and substances and thereby reducing accidents. It also includes training of personnel in
accident prevention, accident response, emergency preparedness and use of protective
clothing and equipment. Systems are put in place to ensure the safe handling, movement,
storage, recycling, reuse, or management of waste, air emissions and wastewater discharges.
The organization implements a series of checks and balances in administrative procedures and
authorizations such that all process safety related matters receive proper review and approval
prior to initiating changes or modifications.
The Factories Act specifies the permissible exposure levels (PEL) and Threshold Limit
Values (TLV),which has to be strictly adhered for a better occupational health and safety in
the site. Several measures are taken by TPL to keep the values below TLV.
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7.6.10.1 Process Safety
Process safety is treated as a priority and Process safety reviews are conducted on a periodic
basis and findings addressed prior to the start-up of new or modified processes.
Process Hazard Analysis (PHA) necessitates the site for identifying, evaluating, controlling,
and documenting hazards at various times and stages in the life cycle of a processes and
operations.
PHA is conducted for the following:
New processes, products, materials and facilities prior to startup
Cyclical/Periodic PHAs of existing facilities
Dismantling of a process facility
Management of change (e.g. process design basis, hazards of materials, equipment
design basis, personnel, etc)
PHAs include the activities of identification of significant hazards, consequence analysis,
human factors evaluation and facility siting evaluation, inherently safer process evaluation,
risk analysis, and development of recommendations.
7.6.10.2 Operational control measures
Vapor / Fumes control:
The process involved corrosive chemicals operation equipments are connected to wet
scrubber with suitable scrubbing media.
Storage tank operational control measures to be provided
Secondary cooling system is enabled.
7.6.11 Environmental Policy of TPL
TPL has a structured environmental policy, that is committed to environmental protection
through:
Conservation of natural resources and
Waste minimization
Some of the salient features of the environmental policy of TPL are:
Improve the environmental performance through innovative techniques, best work
practices and technology upgradation.
Carry out all the activities complying with applicable environmental laws and
regulations and strive to go beyond.
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Conserve water, fuel oil, electrical energy and hydrocarbon feed stocks through
promotion of recovery, recycle and waste minimization techniques.
Ensure safe storage and transportation of raw materials and finished products.
Continually improve the Environmental Management System.
Enhanceenvironmental awareness amongst employees and contractors through
education and training.
7.6.12 Fire & Explosion Controls
Fire fighting system is one of the important areas that is vital for the safety in a chemical
plant. TPL has a structured and an extensive fire fighting system that serves all the
components of the plant. The main features of the fire fighting system in TPL is as follows:
The fire station inside the plant consists of the following components:
A fully equipped fire station with trained firemen is available to serve the plan
whenever the emergency arise.
Two centralmultipurpose fire tenders are available that serves all the plants inside
TPL.
Fire alarm annunciation panel
Communication facilities such as Wireless, Hotline (LAB, PO, CPCL), direct line
telephone and intercom facilities are accessible from all the locations of the plant.
Emergency PPEs are available (Leather gloves, dust mask, ear muff, goggles, PVC
coat, PVC pant, PVC hood, PVC gloves, helmet with face shield, asbestos lug guard,
asbestos apron, half mask, full mask, gum boot) and are provided to the employees
with sufficient training as to how and when to use them.
Fire fighting equipments like Fire suits, Chemical protection suit, Elkhart nozzle, triple
purpose nozzles, short branches are available to serve the employees in the time of
emergency.
Fire station is constructed with concrete wall and provided with fire protection doors.
Fire hydrant system inside the existing ECH plant will be used for the proposed PO plant and
the same is attached as Annexure-14. The list of fire fighting equipments used in the plant are
as follows:
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Table 7-4Fire Fighting Equipments Available in the Plant
S.No Equipments Nos.
1 Single Hydrant 1
2 Double Hydrant 59
3 Fire Escape hydrant 19
4 Water Monitors 11
5 DCP Extinguisher – 70 Kg 10
6 DCP Extinguisher – 10 Kg 69
8 CO2 Extinguisher – 4.5 kg 31
9 CO2 Extinguisher – 22.5 kg 5
10 Fire Buckets 24
11 SCBA 7
12 Online air breathing apparatus 5
The list of Fire Alarm points and its components inside the plantis given below
Table 7-5Fire Alarm points and its components inside the plant
S.No Equipments Nos.
1 Fire Alarm Call Point 33 + 1 in Culvert
2 Smoke detector 95 + 1 in culvert
3 Siren 5 + 1 Hand operated manual siren at the north entrance of Main
Control Room
4 Windsock 5
Figure 7-7Fire Alarm point
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The capacity of Fire water storage is given below:
Table 7-6Fire Water Storage Capacity
S.No Storage type Capacity
1 Fire water Storage capacity 2 x 1193 = 2386 m3
2 Fresh water Reservoir 5605 + 5332 = 10937 m3
3 Total water storage capacity 12130m3
The capacity and types of pumps present in the Fire pump room are as follows
Table 7-7Pumps Availablewith Capacity
Plant Pump Name Capacity
PO
Jockey Pump – 2 Nos 40 m
3/hr
40 m3/hr
Electrical Driven pump – 1 Nos 610 m3/hr
Diesel Driven Pump – 2 Nos 410 m
3/hr
410 m3/hr
Figure 7-8 Water Monitor
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The number of sprinklers installed in the plant are as follows
Table 7-8Sprinklers Installed in the Plant
Plant Total No. of
Sprinkler
Sprinkler mode Remarks
Auto Manual
ECH Plant 11 --- 11 Sprinklers are tested
periodically.
Culvert at Manali Express
highway
Water curtains have been provided at both the ends
Figure 7-9 Sprinkler System in Storage Tanks
7.6.13 On line Leak detections
TPL has provided on-line leak detectors for the control of emissions as well as any leaks
during emergencies. The detectors previously installed in the ECH plant is used for the
proposed plant. Some of the important detectors installed in the plant are given below.
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Figure 7-10 Propylene Detector
Figure 7-11 Chlorine detector
7.6.14 Chemicals Management System
TPL‟s policy of protecting employee health and safety and the environment requires safe
management of chemicals throughout the life cycle. Since the nature of TPL‟s activities are
such that highly hazardous and carcinogenic chemicals are employed and the inventories of
chemicals are large, a well conceived system of chemicals management is put in place to
enable the facility to conform to the EHS policy as well as meet the requirements of the
regulations applicable to the operations.
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The Chemicals Management system provides with a framework for managing the various
aspects associated with handling chemicals in a safe and environmentally sound manner with
the below salient features.
Detailed guideline
New Chemical Approval
MSDS/Chemical Hazard Review
Hazardous chemical classification and hazardous substances based on MSIHC rules,
1989.
Bulk Chemical storage safety inspections
Chemical transport safety checklists
7.7 OCCUPATIONAL HEALTH / INDUSTRIAL HYGIENE PROGRAM
Industrial Hygiene is one of the fast emerging fields and is a critical requirement for the well being
of employees, for which TPL has developed a comprehensive Occupational health program.
The occupational Health Management system / the industrial hygiene and medical system protects
and enhances health, productivity, and wellness by anticipating, recognizing, evaluating,
controlling, and managing workplace health hazards (e.g. chemical, physical, biological,
ergonomic, psychological, etc). These systems also mitigate illnesses and injuries by promptly
recognizing, treating, investigating, and taking corrective actions.
TPL‟s Occupational Health & Wellness Program covers the policies, work practices and procedures
to provide a safe and healthy environment and protect the shop floor employees, laboratory
employees and researchers from health hazards associated with the use of hazardous chemicals.
7.7.1 Occupational Health Monitoring
7.7.1.1 Medical Surveillance Program:Medical surveillance program is essential to assess and
monitor employees' health and fitness both prior to employment and during the course of
work; to determine fitness for duty and to provide emergency and other treatment as needed.
Effectiveness of a medical program depends on active involvement of employees.TPL
medical surveillance program include following major elements:
Developing a OH-IH Medical Surveillance Program
Pre-Employment Examination and Periodic Medical Examinations
Determination of Fitness for Duty
Communications
Emergency Medical Treatment
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Medical Records
7.7.1.2 Pre-Employment Screening / Examinations- All employees shall be subject to pre-
placement medical examinations to determine their fitness for the nature of jobs on site.
Potential exposures to the work environment shall be considered before placing an
employee on the job.
7.7.1.3 Periodic Medical Examinations- Periodic medical examination is the same as the pre-
employment screening and may be modified according to current conditions, such as
changes in the employee's symptoms, site hazards, or exposures.
Comparison of sequential medical reports with baseline data is essential to determine
biologic trends that may mark early signs of adverse health effects, and thereby facilitate
appropriate protective measures. The frequency and content of examinations are normally
one year.Apart from this for workers working in Hazardous area, medical examination is
conducted by Doctor authorised by Factory Inspectorate.
7.7.2 Emergency Management
TPL is committed to constructively report and investigate all EHS incidents (e.g. near misses,
illnesses, injuries, process safety, environmental, fire, distribution accidents, etc) to establish
the facts and hence take prompt steps to prevent a recurrence.
A detailed Incident Investigation and Reporting (IIR) guideline is in place to assure an
effective and efficient incident reporting and investigation process, and implementing
appropriate corrective or preventive measures to prevent recurrence of such incidents.
The essential aspects of Emergency Management system is given below:
Identification of potential emergency scenarios and schedule
Revision of Emergency response plan based on Consequence Analysis
Emergency Response Team Training
Periodic evacuation mock drills and observations of gaps - Table top exercises
Onsite Emergency Preparedness and Response Plan
7.7.3 Materials Handling Storage and Transportation
Considered the properties of the materials involved in order to establish efficient
material handling procedure.
Operators are physically qualified and trained in the operation of the equipment and
the safe practice followed.
General consideration concerning the storage of the materials is piled, cradled, cross
tied, packed and blocked so that they will not fall or slide.
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Safe rules for the manual handling of the materials and operation of the vehicles is
practiced.
7.7.4 H&S Audits & Inspections program
TPL has established and implemented a comprehensive Audit and Inspection program to be
carried out and managed by competent resources.
External Safety Audit
Internal Safety Audit
Special Fire safety audits /Fire Risk Assessments
Self and Inter/ Cross unit audits
Critical equipment safety inspection
Emergency and life saving equipment inspection
IMS (Integrated Management System) Internal and External audits
Daily Safety Inspection
Monthly Environmental inspection
Daily Workplace exposure monitoring using VOC meters - PID
Vessels and storages are tested for their integrity at regular frequency.
Preventive / opportunity maintenance carried out.
Condition monitoring techniques are followed.
Sensors and alarms are provided to alert on fugitive emissions.
Area monitoring by personal sampler is carried out.
Measurement of noise level and illumination is carried out.
Personal protection equipments and measures
Chemical Handling Area: Non-respiratory protection such as Helmet, Safety goggles,
Nitrile /Neoprene/PVC gloves, Safety shoes and respiratory protection such as
Full/half face respirator with organic /inorganic cartridge. Material loading/unloading
operations, Supplied Air Breathing Apparatus (SABA) are being used.
Welding operation: Welding face shield, leather apron, leather gloves and safety shoes
are being used by welders. Helper use UV resistant goggles, leather apron, leather-
gloves and safety shoes.
Gas Cutting operation: IR resistant goggles, leather gloves, safety shoes are being used
by both cutter and helper.
Boiler operation: Cotton type retardant suit, IR resistant goggles, helmet, safety shoes
and cotton gloves.
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Concentrated Acid and Base handling (i.e. Sulphuric acid/HCL/Caustic Lye): Full
body PVC suit, Gum boot and PVC gloves.
Electrical Work area (MCC and PCC): 410 V to 22KV electrical resistance gloves,
Electrical safety shoes (without metal toe guard) and helmet and electrical gloves
Tested date and due date are marked legibly.
Working at Height: Personal fall protection (i.e. Full body harness), helmet and
Safety-shoes.
Other safety features available during emergency situation in the site
Breathing air stations are provided through out the plant area with full face mask and
air is supplied from a dedicated compressor and the air is fed to the system after
purification.
Emergency shower and eye washers are located in all plant areas and water supply is
assured from a dedicated sources.
Self contained breathing sets are available and people have been trained of it‟s use.
Proximity suits are available for use in fire emergency.
Chemical protective suits to deal with most offensive chemicals are available.
7.7.5 Industrial Hygiene Monitoring
TPL has carried out Health hazards monitoring for the existing plant through the following
activities and the same will be implemented for the proposed product mix change project.
Exposure to airborne chemical substances in the workplace were monitored by through area
and personnel monitoring depending of the nature of the processes, sources of chemical
exposure and toxicity of the chemicals by the following sampling methods.
7.7.5.1 Area Monitoring- sampling pumps or passive monitoring badges are placed at static/fixed
locations to collect airborne chemicals in the areas. Time weighted average (TWA)
concentration of the chemicals present in the air was calculated.
7.7.5.2 Personnel Monitoring- This is a method using personal passive monitoring badges or
sampling pumps attached to the individuals, subject to chemical exposure. TWA then
computed from the analytical results and determined the exposure level to the individuals.
7.7.5.3 Noise Monitoring - Measurement of individual noise sources (e.g. compressors, motors,
reactors, DG etc.) were monitored by in-house program in every six month as periodical
base in addition to the yearly monitoring by external agencies.
7.7.5.4 Industrial health monitoring - Some of the existing measures in the ECH plant and the
proposed measures that has to be implemented to improve industrial health and safety for
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the proposed product mix change project are listed below and the same will be followed as a
part of the Industrial health and safety program for PO plant:
Regular inspection and maintenance of pollution control systems.
All measures related to safety such as safety appliances, training, safety awards,
posters, slogans are undertaken.
The workers exposed to noisy sources are provided with ear muffs/plugs.
Adequate facilities for drinking water and toilets are provided to the employees.
The fire and safety equipments are properly utilized and maintained regularly.
The health of the workers will be regularly checked by a well qualified
Doctor and proper records will be kept for each worker.
Isolated storage for all hazardous chemicals with adequate safety measures, sign
board outside storage etc.,
Fire – proof electric fittings are used.
Good air circulation will be ensured within the plant area.
Training has been given to deal with emergency situation, to operate fire
extinguishers, to provide first – aid to affected persons by arranging safety work-
shop once in six months.
Showers and hand – wash are provided in vicinity of work area with ample
quantity of water available.
Fire and Smoke detectors are installed at suitable place in the premises to get alert
warning and avoid major accident.
Automatic water sprinklers areinstalled throughoutthe building to retard spread of
fire.
On site emergency plan is prepared and implemented to safe guard human life and
property.
Occupational health tests such as Liver Function Tests (LFT) and Pulmonary
Function Tests (PFT) are conducted frequently to monitor the health of the
workers and are well documented.
Moreover, based on past occupational health record of its existing unit, TPL has
already put in place adequate safety measures and does not anticipate any adverse
effect on health of workers.
7.7.5.5 General considerations
For good housekeeping of the project, following measures will be planned:
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Maintaining cleanliness of roads to prevent accumulation of dust and waste
material.
Inculcating positive attitude among employees for good house – keeping.
Maintaining hygienic conditions near drinking water source and toilets.
Waste - minimization, Recycle / Reuse / Recover Techniques &Energy
conservation
Unit will take following steps in this regard:
High efficiency pumps with auto level cut off is installed.
Liquid chemicals dosing is through metering pumps.
CFLs with high frequency ballast shall be used.
Energy efficient fluorescent tube lights/CFL are used for office areas.
Self starters and variable drives are installed for motors.
All tanks are installed with level controllers and cut off for pumps.
Process improvement by R & D to reduce waste water generation.
7.8 ENVIRONMENTAL MANAGEMENT CELL
In addition to preparing an EMP, it is also necessary to have a permanent organizational set up to
for the effective implementation of environmental management plan. Environmental Management
Cell increase the strength of the environmental management team to deal with EMP effectively and
efficiently. Hence will create a team consisting of officers from various departments to co-ordinate
the activities concerned with management and implementation of the environmental control
measures. This team will undertake the activity of monitoring the stack emissions, ambient air
quality, noise level, and water quality etc. either departmentally or by appointing external agencies
wherever necessary. Regular monitoring of environmental parameters will be carried - out to find
out any deterioration in environmental quality and also to take corrective steps, if required, through
respective internal departments. The Environmental Management Cell will also collect data about
health of workers, green belt development etc. Organogram of the Environmental Management Cell
is presented in Figurebelow:
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Figure 7-12Organizational set up for Environmental Management plan
7.8.1 Responsibilities of Environment Management Cell
The cell will also be responsible for monitoring of the plant safety and safety related systems
which include :
Checking of safety related operating conditions.
Visual inspection of safety equipment‟s.
Preparation of a maintenance plan and documentation of maintenance work specifying
different maintenance intervals and the type of work to be performed.
Other responsibilities of the cell will include :
Submit annual Environmental statement (in Form – V). This Form –V will be
submitted every year before 30th September.
Timely renewal ofConsents & Authorization will also be taken care of.
Submitting environmental monitoring report toTNCPB. Data monitored by the cell
will be submitted to the Board regularly. The cell will also take mitigation or
corrective measures as required or suggested by the Board.
Keeping the management updated on regular basis about the conclusions / results of
monitoring activities and propose measures to improve environment preservation and
protection.
Conducting regular safety drills and training programs to educate employees on safety
practices.
Whole Time Director
(Operations)
Deputy Manager (safety)
Deputy manager (ENV)
Firemen Field Staff (ENV)
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A qualified and experienced safety officer will be responsible for the identification of
the hazardous conditions and unsafe acts of workers and advise on corrective actions,
organise training programs and provide professional expert advice on various issues
related to occupational safety and health.
Conducting safety and health audits to ensure that recommended safety and health
measures are followed.
7.8.2 Monitoring of Environment
A regular monitoring of environmental parameters like air, water, industrial effluent, noise
and soil as well as performance of pollution control facilities and safety measures in the plant
are important for proper environmental management of any project.
Therefore, the environment and safety cell will handle monitoring of air and water pollutants
as well as the solid wastes generation as per the requirements of Tamil Nadu Pollution Control
Board and Central Pollution Control Board.
Monitoring of various parameters will be carried out regularly to assess the pollution level
inside the plant and in nearby area. Useful to compile pollution related data for remedial
measures and find out efficiency level of pollution control measures adopted.
Table 7-9Environmental Monitoring Plan
S.
No
Particulars Frequency of
monitoring
Parameters for Monitoring
1. Air pollution monitoring
Scrubber monitoring Once in a month Chlorine
Boiler and DG Stack
emissions
Once in a month PM, SOX, CO and NOx
Ambient air quality within
the premises of the
proposed unit
Once in a month All 12 parameters as given in NAAQS
At 1 location in Prevalent
Down
Wind Direction
Once in a month
At 1 location in Up Wind
Direction
Once in a month
2. Noise monitoring
At various locations within Once in amonth Noise Levels in dB(A)
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the
premises
3. Water quality monitoring (Surface and Process)
One location Once in amonth pH, Color, Turbidity,
TSS, TDS, COD,BOD,
Chlorides, Sulphates,
Total Alk. Ca & Mg, Hardness, Fluoride etc.
4 Soil Quality monitoring
One location near
Hazardous waste storage
area at site and one
location outside site
Once a month Physicochemical properties, Nutrients, Heavy
metals
5 Ground water quality monitoring
One location near
Hazardous waste storage
area at site and one
location outside site
Once a month Physicochemical properties, Heavy metals
6 Effluent Quality monitoring
Inlet and outlet of ETP Once a month pH, Temp, TDS, TSS, Chloride, Sulphide,
Sulphate, fluoride, ammoniacal Nitrogen,
Sodium, Copper, Zinc, Phenolic compounds,
Oil and Grease, Boron, BOD, COD, Total
Residual Chlorine, Arsenic, Cadmium, Total
Chromium, Hexavalent Chromium, Lead,
Selenium, Mercury, Pesticides, Alpha
emitters, Free Ammonia, Disssolved
Phosphates, Total Kjeldhal nitrogen,Cyanide,
Nickel, Residual Sodium Carbonate.
7 Sewage Quality Monitoring
STP inlet and outlet Once a month pH, temperature, TDS,TSS, BOD
8 Work place Monitoring Quarterly Noise, VOC, Lux levels
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7.8.3 Laboratory Facilities
Full fledged laboratory is available at TPL to analyze and monitor the quality of air, water and
noise in the plant surroundings.
7.8.4 Corporate Responsibility for Environmental Protection (CREP)
Table 7-10 CREP Points and Compliance status
S.No Action points Compliance Status
1 Adoption of state-art technology State of art technology is adopted for process technology
and engineering to control the emission at the design
stage itself.
2 Management of storm water
Storm water generated from process area and tank farm
area during initial hours of rain is pumped to effluent
treatment plant for treatment.
3 Effective detoxification and waste
water scheme
Full fledged activated sludge process based effluent
treatment plant is available.
Adequate numbers of suspended aerators and diffuser are
provided for better aeration and reduction of COD.
Neutralization pit is available for uniform mixing of
effluents to avoid the shock load of high COD (Max of
1200- 1500 ppm) to the treatment system.
4 Control of emission from
combustion
As a pollution abatement and fuel conservation measure,
DG set is provided with waste heat recovery boiler to
produce steam from the flue gas waste heat &this had
reduced the fuel consumption in boilers.
Also DG is fitted with low NOx components.
5 Proper functioning of point
source emission control systems
All scrubbers (chlorine vent gas scrubber, HCI absorber)
in our unit are in continuous operation.
Control equipment has got 100% standby and starts
automatically if one fails. Backup power supply is also
available through emergency DG sets, which starts
automatically.
Continuous online sensor is available in the stacks for
monitoring of chlorine & HCI vapour and monitoring
data has been connected to CAC TNPCB server.
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S.No Action points Compliance Status
Stack emission is being monitored by our laboratory and
TNPCB laboratory.
6 LDAR programme
Continuous Online detectors, for Propylene, Chlorine and
Allyl chloride are available at critical locations.
Also, Leak Detection and Repair programme is being
followed at scheduled frequency and recorded and
reviewed.
Continuous online VOC sensor is provided for
monitoring in ambient air and monitoring data has been
connected to CAC, TNPCB server.
7 Handling of halogenated organics
Chlorinated organics (halogenated Organic) is a by-
product in the process and stored in storage tanks.
Since the CO is in liquid form and having high boiling
point (>1000C), there is no possibility for CO vapour to
escape to flare.
It is sold as a product and also burnt to produce
Hydrochloric Acid.
Scrubber is provided to take care of Chlorine vapour
emissions if any.
Continuous online sensor is available in the stack for
monitoring of chlorine & HCL vapour and monitoring
data has been connected to CAC, TNPCB server.
8 Control of fugitive emissions of
carcinogenic components
Online detectors are provided to check the fugitive
emissions and health checks of the workers are being
carried out once in three months and monitored and
recorded.
9 Management of solid waste Facility is available for proper storage of hazardous waste
at the site.
ETP waste will be disposed to a secured landfill facility.
Used oil is sold to CPCB/SPCB authorized vendor.
Waste oil is used as fuel in heaters.
Manifest system is being followed during transportation
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S.No Action points Compliance Status
of hazardous wastes.
10 Proper operation of incinerator Not applicable
11 Optimizing the inventory of
hazardous chemicals
In a highly competitive market, inventory management
already calls for minimum storage only. TPL follows the
same.
Continuous efforts are taken to optimize the inventory of
all chemicals. The maximum storage of most of the
hazardous chemicals at any time is not more than 10 days
requirement and is based on the transportation time from
the source of suppliers.
12 Self-regulation by industry
through regular monitoring and
environmental auditing
Air emission and liquid effluents are being monitored in
the laboratory at the TPL at regular intervals.
Also it is being monitored by TNPCB.
Environmental issues are reviewed on a daily basis in the
plant meetings and in the environment management
meeting.
13 Organizational restructuring and
accreditation of environmental
manager of industry
This is taken care during recent organizational
restructuring.
Also, in line with this, head of the business unit, who has
wide and in depth knowledge of the plant., is made as the
chairman of the Environment Management Committee.
Other members of the committee are mostly chemical
engineers, with adequate knowledge and experience in
process industries to assist the chairman.
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Table 7-11CEPI (Comprehensive Environment Pollution Index) Action Plan Status
S.No Condition Status
1 Online sensor for monitoring chlorine
will be provided and monitoring data will
be uploaded to TNPCB server by July
2010.
Completed.
Chlorine online sensor is provided in
Ambient Air and in stack and monitoring
data has been uploaded to Care Air centre,
TNPCB server on 15.07.2010
2 To conduct AAQ survey as per the
NAAQS, 2009
Ambient Air quality Survey is being was
conducted regularly through external
laboratory as per the new standards.
3 Environmental monitoring will be carried
out through accredited laboratory also.
Environmental monitoring is being carried
out through external accredited laboratory
from October 2010.
4 The marine impact study will be
conducted either jointly with M/s. MPL
or stand-alone.
Marine impact study for the treated
effluent discharge into the sea was
conducted through accredited EIA
consultant and the report is sent to the
pollution control board dated
5 Replacing of Ferric chloride with
environment friendly coagulant in ETP to
improve colour.
Ferric chloride is replaced with
environment friendly coagulant in the
flocculation tank of ETP.
Results are encouraging in color and
quality improvement in the treated effluent.
6 Replacing of Ferric Chloride with
environment friendly coagulant in ETP to
reduce ETP sludge (hazardous waste)
generation.
Ferric chloride is replaced with an
environment friendly coagulant (Flocool –
120 and Flocool-1020) in the flocculation
tank of ETP.
Results are encouraging in color and
quality reduction of sludge generation.
ETP sludge generation:
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S.No Condition Status
Period – Apr 09 - March10 – 150MT
Period –Apr 10 - March 2011- 124MT
Period – Apr 11 – March 2012 – 115MT
7 Green belt development 150 nos of trees were planted during Dec
2012.
7.8.5 Budgetary Provisions for EMP
Adequate budgetary provisions have been made by TPL for execution of environmental
management plan. The details of capital and recurring (per annum) budget earmarked for
pollution control, operation and maintenance of pollution control facilities, for greenbelt
development and maintenance will be as given in Table 7-12.
Table 7-12Cost for Environmental Protection Measures in (Rs.)
S.No Environmental protection
measures
Capital Cost
(Lakhs) Proposed
Recurring cost
per Annum
(Lakhs)
1. Air Pollution Control 50 25 5
2. Water Pollution Control 300 35 50
3. Noise Pollution Control 5 1 2
4. Occupational Health and
safety 50 - 10
5. Green belt Development 2 5 2
6. Storm water Management 20 7 3
7. Waste Management 20 5 3
8. Fire Fighting 120 15 10
Total 567 93 85
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8 CONSENT- COMPLIANCE STATUS
8.1 Applicability of Environmental Clearance
Since the Epichlorohydrin plant commenced its operation in the year 1995, Environmental
Clearance was not applicablevide Section III (b) of EIA notification dated 27/1/1994
8.2 Consent For Existing Operation
TPL has established facilities to make Epichlorohydrin (ECH) in the year 1995, the company is in
possession of valid consent order form TNPCB Vide order No 14090 dated 03.11.2010. The unit is
not operational since 1stApril, 2013 owing to unviable business opportunities for the product.
The Consent to Establish vide Letter dated 22/9/1993 is enclosed in Annexure-17. The Renewal for
Consent to Operate vide letter dated 21/4/1999, 3/11/2010 and application for renewal dated
28/3/2014 are enclosed in Annesure-18, Annexure-19 and Annexure-20respectively. Hazardous
waste Authorization for existing facility is enclosed in Annexure-21.
Table 8-1 Consented quantity vide order No 17966 dated 21.04.1999
S.No Products Quantity
1 Epichlorohydrin 909 T/month
2 Hydrochloric Acid 518 T/day
3 Chlorinated Organics 400 T/day
8.3 Compliance Conditions
Table 8-2Consent order under water Act No. 17966 dated 21.04.1999
S.No. Condition Status
1 The unit shall operate and maintain the
effluent treatment plant to treat the trade
effluent so as to achieve the standards
prescribed by the Board
Effluent Treatment Plant has been operated and
being maintained efficiently and effectively to
treat the trade effluent.
During the time of operation treated effluent
was periodically analyzed through TNPCB
Laboratory, in-house and NABL/ MoEF
approved external Laboratory.
The consolidated Report of Treated Effluent is
enclosed in Annexure-22.
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S.No. Condition Status
2 The unit shall maintain proper temperature
and atmosphere to obtain the correct product
during fractional distillation
Proper temperature is being maintained to
obtain the correct product during fractional
distillation.
3 The unit shall not discharge any trade effluent
into the nearby nulla, which carries the
surplus from Red Hills
Treated effluent is discharged only to sea
through M/s. Manali Petrochemicals Limited‟s
treated effluent disposal pipeline, after
satisfying the standards prescribed by the
Board
4 The unit shall discharge the effluent through
M/s. Manali Petrochemicals Limited‟s
pipeline into the Bay of Bengal after
satisfying the standards prescribed by the
Board
Treated effluent is discharged only to sea
through M/s. Manali Petrochemicals Limited‟s
treated effluent disposal pipeline.
5 The unit shall provide the Fire extinguishers
to avoid any explosion of fire
Fire fighting facilities are provided to prevent
any explosions. The photographs of fire
fighting systems are given in Section 7.6.11 of
this Report (Chapter -7)
6 The unit shall dispose the solid waste as
reported
The agreement executed for disposal of
Hazardous waste with quantity is enclosed in
Annexure-29
Lime sludge generated is sent to Brick
manufacturers. The receipt of the same is
enclosed in Annexure-23
7 The unit shall store the Epichlorohydrin in a
cool dry place to avoid fire hazard
Epichlorohydrin is stored in tanks with
adequate fire fighting facilities.
Table 8-3Renewal consent order under Air Act No. 28635dated 21.04.1999
S.No. Condition Status
1 The unit shall operate and maintain the Air
Pollution control measures so as to achieve
the ambient air standards prescribed by the
Air Pollution control measures are operated and
maintained efficiently to achieve the ambient
air quality standards. The APC measures
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S.No. Condition Status
Board provided are enclosed in Section
Ambient Air quality is monitored through
TNPCB laboratory, In-house laboratory and
NABL/ MoEF approved external laboratory.
The reports of Stack Monitoring is enclosed in
Annexure-24 and Ambient Air Quality
Monitoring is enclosed in Annexure-25
2 The unit shall provide a proper diversion for
the flare towards a wind direction
Complied
3 The chlorine gas shall be vented into
atmosphere after allowing it to pass through a
scrubber.
Counter current scrubber with dilute caustic lye
solution is provided to absorb chlorine
emission from process Reactor area.
Chlorine online continuous sensor is provided
in the stack and connected to TNPCB (Care
Air Centre) for real time monitoring from
15.07.2010.
4 The toxic liquids are to be incinerated and the
resulting process emission to be tested
periodically. To avoid any discharge of toxic
gas and to avoid suffocation.
i. There is no toxic liquid generated from
the ECH plant. However byproduct -
Dichloro Propane (chlorinated Organics)
is sold in the market.
ii. Upon requirement, Dichloro propane is
burnt to produce HCL and emission
from HCL production unit is Counter
current scrubbed with water to remove
chlorine and HCL vapours.
iii. Continuous online sensor is available in
the stack to monitor HCL emission and
monitoring data has been connected to
TNPCB Care Air Centre) for real time
monitoring from 15.07.2010.
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S.No. Condition Status
iv. Stack monitoring and Ambient Air
quality survey were carried out by an
MoEF approved laboratory on and the
report of analysis is enclosed as
Annexure- 24.
5 The unit shall continue to develop green belt
around the premises of the unit.
Green belt has been developed inside and
outside the factory premises covering about
4.0acres and the photographs enclosed
Tree saplings are regular planted during world
Environment Day celebrations.
We have proposed to develop additional green
belt around the premises.
6 The unit shall maintain emission standards of
150 g/m3
for the particulate matter.
Stack monitoring was conducted by TNPCB on
1.12.2011 and the report of analysis is enclosed
as Annexure -24
Table 8-4Consent order under Air Act- no. 14090 dated 03.11.2010
S.No. Condition Status
1 The unit has to comply the directions as
issued in proceeding dated 31.12.09 in
respect of installation of online air quality
monitoring and data uploading
Online continuous monitors are provided
for monitoring chlorine and VOC in
ambient air and connected to TNPCB (Care
Air Centre) for real time monitoring from
15.07.2010.
Online continuous monitors are provided
for monitoring chlorine in scrubber stack
and HCL vapour in Hydrochloric acid
production unit stack. Monitoring data has
been uploaded to CAC, TNPCB from
15.07.2010
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S.No. Condition Status
2 The unit shall operate and maintain the air
pollution control measures continuously and
efficiently to satisfy the ambient air quality
standards prescribed in ministry of
Environment and Forests notification dated
16.11.2009 and the emission standards
prescribed by the board.
Ambient air quality was conducted through
an NABL/MoEF approved laboratory and
the results attached as Annexure-25
3 For protection, improving the quality of
environment, the unit shall have self
monitoring system for stack emission,
fugitive emission ambient air quality,
untreated/ treated trade effluent/ sewage
effluent / ground water/ soil quality and
surface water monitoring, hazardous/ non
hazardous solid waste generation, reduction
recycling and scientific disposal options so as
to ascertain the compliance status of
standards prescribed by Tamil Nadu pollution
control board, ministry of environment and
forests, EP Acts 1986
Fully fledged laboratory facilities are
available for monitoring of air, water waste
water, and ground water samples.
Continuous online sensors are provided for
monitoring chlorine, Hydrochloric acid
vapour and VOC and the monitoring data
has been connected to CAC for continuous
monitoring at TNPCB.
Online detectors for monitoring chlorine
and propylene are installed at appropriate
location for continuous fugitive emission
monitoring.
Treated trade effluent and sewage effluents
are analyzed regularly by TPL laboratory,
external accredited laboratory and by
TNPCB laboratory. The reports are
enclosed in Annexure- 22
4 The unit shall carry out detailed environment
Audit study on water, air, land environment
and prepare detailed action plan for reduction
of pollution at source so as to minimize the
generation of pollution load before July 2010.
Environment Audit study on water, air, land
environment was conducted through
external consultants M/s.
HubertEnviroCare system(P) Ltd. and
submitted to TNPCB vide letter dated
TPL/ENV/24/2012 dated 21.03.2012
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S.No. Condition Status
5 The unit shall ensure that the units activities
shall not create any environmental impact to
the nature eco system and shall have remedial
action plan by ascertaining the existing
status.
Effluent treatment plant has been operated
efficiently and effectively to ensure to
protect environment by maintaining the
TNPCB standards.
Hazardous wastes generated at ECH plant
are handled as per the authorization
obtained from TNPCB.
Ambient air quality is being continuously
monitored and monitoring data has been
connected to CAC, TNPCB ascertain that
our adherence towards environmental
standards prescribed by TNPCB/ MoEF.
Treated sewage is utilized for gardening
and green belt development.
6 The unit shall furnish the proposal with action
plan for compliance of proposed revised
standards for petrochemical plants.
Action plan will be submitted during start-
up of the proposed change of product mix.
7 The unit shall have a leak detection program
and shall furnish the quarterly report.
Leak detection program is available. The
analysis report is enclosed in Annexure -26
Table 8-5Consent order under Water act- No.17966 dated 03.11.2010
S.No. Condition Status
1 The unit shall furnish the compliance status of
conditions stipulated in the authorization issued under
hazardous waste (M,H, and TM) Rules 2008.
Furnished Regularly to the Board
2 For protection, improving the quality of environment,
the unit shall have self monitoring system for stack
emission, fugitive emission ambient air quality,
untreated/ treated trade effluent/ sewage effluent/
Full-fledgedin house laboratory
facilities are available for
monitoring of air, water, waste
water, ground water samples.
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S.No. Condition Status
ground water/ soil quality and surface water
monitoring, hazardous/ non hazardous solid waste
generation, reduction recycling and scientific disposal
options so as to ascertain the compliance status of
standards prescribed by Tamil Nadu Pollution control
board, ministry of environment and forests, EP Acts
1986.
Continuous online sensors are
provided for monitoring chlorine,
Hydrochloric acid vapour and
VOC and the monitoring data has
been connected to CAC for
continuous monitoring at TNPCB.
Online detectors for monitoring
chlorine and propylene are
installed at appropriate location
for continuous fugitive emission
monitoring.
Effluent treatment plant has been
operated efficiently and effectively
to ensure to protect environment
by maintaining the TNPCB
standards.
3 The unit shall carry out detailed environment audit
study on water, air, land environment and prepare
detailed action plan for reduction of pollution at source
so as to minimize the generation of pollution load
before July 2010.
Environment Audit study on
water, air, land environment was
conducted through external
consultants M/s.
HubertEnviroCare system(P) Ltd.
and submitted to TNPCB vide
letter dated TPL/ENV/24/2012
dated 21.03.2012.
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S.No. Condition Status
4 The unit shall ensure that the unit‟s activity shall not
create any environment impact to the nature eco
system and shall have remedial action plan by
ascertaining the existing status.
Effluent treatment plant has been
operated efficiently and effectively
to ensure to protect environment
by maintaining the TNPCB
standards.
Hazardous wastes generated at
ECH plant are handled as per the
authorization obtained from
TNPCB.
Ambient air quality is being
continuously monitored and
monitoring data has been
connected to CAC, TNPCB
ascertain that our adherence
towards environmental; standards
prescribed by TNPCB/MoEF.
5 The unit shall not discharge any waste water into
nearby water courses directly/indirectly.
Treated effluent is discharges to
sea thro M/S Manali
petrochemicals Limited‟s pipeline
after satisfying the standards
prescribed by the board.
Treated sewage is used for
gardening.
6 The unit shall furnish the proposal with action plan for
compliance of proposed revised standards for
petrochemical plants.
Action plan will be submitted
during start-up of the proposed
change of product mix.
7 The unit shall monitor the ground water in and around
the sludge area by providing piezometers.
Ground water (test bore well
water) is analyzed regularly by
external laboratory and by TNPCB
laboratory. The reports are
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S.No. Condition Status
attached in Annexure -27
8 The unit has to dispose the accumulated hazardous
wastes obtaining authorization from the board.
Hazardous wastes generated at
ECH plant are handled/ disposed
as per the authorization obtained
from TNPCB. Authorization No.
3563 dated 17.12.2009. The
Industrial Waste Management
Membership is enclosed in
Annexure-28 and agreement with
Ramky for Disposal of Hazardous
Waste is enclosed in Annexure-29
9 The unit shall conduct the marine impact study where
the treated effluents discharge into the sea.
TPL has conducted Marine impact
study for the treated effluent
discharge into sea through
accredited EIA consultant M/s.
HubertEnviroCare system,
Chennai .and submitted to
TNPCB.
10 The unit has to monitor the effluent quantity and
quality at the outlet at sea.
Monitoring is being done by
TNPCB.
11 The unit has to revamp the effluent treatment plant by
using alternative coagulation/ flocculants.
Ferric chloride is replaced with an
environment friendly coagulant
(Flocool-120 and flocool- 1020) in
the flocculation tank of ETP.
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9 PROJECT BENEFITS
9.1 MARKET POTENTIAL
MPL is the only domestic manufacturer of Propylene Oxide. The Propylene Oxide is mostly
consumed in-house to manufacture Propylene glycol and Polyol. There is good market potential for
Propylene oxide and its derivatives Propylene glycol and Polyol.
Current imports of Propylene oxide is about 20000 MTPA. Considering the domestic production,
the total demand for Propylene oxide is around 60000 MTPA.
Current Propylene glycol imports is about 50000 MTPA and polyol imports is more than 1 lakh
tone per annum.
The 15000 MTPA Propylene oxide produced can be sold as such or used for making Propylene
Glycol and Polyols.
Propylene glycol is used for various applications in industries viz
Pharmaceuticals
Food flavors and essences
Polyester resins
Perfumery compounds
Cosmetics
Cigarettes
Tooth Paste
Pesticides
Of this, Pharmaceuticals, food flavors and polyester resins manufacturing sectors account for a
major share in the present consumption of Propylene Glycol in the country.
9.1.1 Polyols
The polyols are broadly classified based on application as given below
Flexible Polyurethane foams
Rigid Polyurethane foams
Semi-rigid Polyurethane foams
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9.1.1.1 Flexible Polyurethane Foams
Flexible foams are largely used for various household applications such as furniture
cushions, beds, mattresses etc. Also in automobiles, seat cushions, arm rests coverings etc are
made using flexible foams. In certain cases these are used as packaging material for high
value items. Some of the miscellaneous applications include foam laminations, toys, and
novelties
9.1.1.2 Rigid Polyurethane foams
The specific thermal insulation characteristics of rigid PU foams are far superior to that of all
other polymeric foams. The obvious advantage of polyurethane rigid foam is the lesser
thickness required to achieve the same thermal efficiency as other materials.
These are used as insulating materials in
Air conditioning and refrigeration industry (insulation of domestic refrigerators, Air
conditioner, refrigerated vans etc.,)
Process industry (insulation of process equipments, pipelines, storage tanks etc)
Transportation industry ( insulation of rail coaches, bus coaches, air craft, ships etc)
9.1.1.3 Semi-rigid Polyurethane foams
Semi-rigid PU foams are used in the manufacture of steering wheels,
scooters/motorcycles/bicycles/car seats, arm rests, shoe soles etc.
9.1.2 Miscellaneous applications
Polyols are also used in the manufacture of polyurethane elastomer, coatings, paintings,
adhesives/sealants, binders etc.
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10 SUMMARY & CONCLUSION
10.1 SUMMARY
The Environmental Impact Assessment report studied the proposed project and assessed its
predicted impacts on land, water, air, soil and biological environment of the region. The proposed
project was found to be complying with all the environmental, health and safety standards, and is
planning to use efficient equipments and advanced technologies to reduce its air emission, water
and waste generation. It is also taking proper care in its hazardous chemicals and waste handling. It
has also laid down solid plans to monitor and combat any disaster or emergency situation in the
project.
Other than the above, proposed project will be bringing in various economical, social and
environmental benefits to the Manali town, Tamil Nadu and to the county. The Social, Economical
and Environmental benefits of the project includes the ones mentioned in the earlier chapter.
10.2 CONCLUSION
After studying the impacts and effects of the proposed project, some of the salient features and
observations with respect to the proposed project are as follows:
Due to elimination of propylene heater and HCl scrubbing unit, the emissions from
respective stack will be reduced in the proposed production unit, thereby reduction in the
overall air pollution load.
Project study area is not falling within 10km radius of National Park, Wildlife Sanctuary,
etc.,
As the proposed project falls within the existing site, there is no need for rehabilitation and
resettlement.
No extraction of ground water is proposed.
There will be no additional water requirement and no additionalwater discharge for the
proposed project.
No change in waste water discharge and water pollution load with respect to quantity and
quality.
Lime wastes are disposed to brick manufacturers.
Hazardous wastes are disposed as per hazardous waste rules.
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TPL has adequate safety measures and does not anticipate any adverse effect on health of
workers.
For handling and storage of raw materials and finished products proper measures has been
considered.
.On line chlorine Monitoring system available in the existing scrubber stack, will be used
and connected to Care Center TNPCB.
LDAR program is available and same will be followed to reduce fugitive emissions
Dust scrubber and it is proposed for Milk of lime Plant.
STP and ETP outlet will have flow measurement, pH, BOD, COD, TSS for online
monitoring.
Additional 20.7% area of Green belt is proposed apart from the existing Green belt area.
10.3 RECOMMENDATIONS
With the above benefits, environmental, societal commitment and readiness of the project, the
environmental impact assessment report strongly affirms and recommends the proposed project of
product change mix. Some of the recommendations given by the consultant with respect to the
project are as follows:
Suggestions of qualitative risk analysis study will be followed to minimize accidents and for
safe operations.
Environmental Management Plan will be strictly adhered to minimize the environmental
impacts of proposed project.
Green belt development will be well maintained to improve the aesthetics and biodiversity
of the area.
TPL-EIA for Change of Product Mix Disclosure of Consultants
Hubert Enviro Care Systems Pvt. Ltd. Page 164
11 DISCLOSURE OF CONSULTANTS ENGAGED
Details of the consultancy and consultant engaged are as follows:
Table 11-1Details of the Consultant
Consultant Hubert Enviro Care Systems Pvt Ltd, Chennai
NABET Certificate No NABET/ EIA/ 1013/ 041
EIA Coordinator Dr.JRMoses
1. National Accreditation Board for Testing and Calibration Laboratories (NABL) accreditation for
Laboratory services for ISO17025
2. MoEF Recognized Laboratory
3. ISO 9001:2008 qualified and certification by URS
4. Environmental Management System complying AS/NZS ISO 14001:2004
5. Occupational Health & Safety Management System OHSAS 18001:2007
6. Approved byKarnataka PCB and Kerala PCB.
7. Achilles joint qualification system. Achilles Id.15148
8. Kiwa Quality Management System
TPL-EIA for Change of Product Mix
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TERMS OF REFERENCE
S. No TOR Points Compliance Status
provided in the report
1. A separate chapter on status of compliance of Environmental
Conditions granted by State/Centre to be provided. As per
circular dated 30th May, 2012 issued by MoEF, a certified
report by RO, MoEF on status of compliance of conditions on
existing unit to be provided in EIA/EMP report.
Chapter 8, Pg 149
2. Executive summary of the project Pg i
3. Justification of the project. Chapter 1, Pg 2
4. Promoters and their background. Chapter 1, Pg 1
5. Regulatory frame work. Chapter 1, Pg 7
6. Environment clearance for the existing unit issued by the
Ministry (reasons, if not obtained), Consent to Operate and
Authorization accorded by the SPCB.
Annexure-17,18,19,20
and 21
7. Data for the stack emissions, fugitive emissions; water
requirement and water balance chart; waste water generation,
treated effluent quality, re-utilization and disposal of
solid/hazardous waste for the existing unit.
Chapter 2,
Stack emission – Pg 43
Water balance- pg.14
ETP – Pg 37
Solid and hazardous
waste – Pg 121
8. Project location and plant layout. Chapter 2, Pg 14
Annexure – 6 & 7
9. Infrastructure facilities including power sources. Chapter 2,Pg 29
10. Total cost of the project along with total capital cost and
recurring cost / annum for environmental pollution control
measures.
Project cost - Table 2.2 Pg
-16
Cost for Pollution Control
TPL-EIA for Change of Product Mix
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-Table7.12 pg 148
11. Project site location along with site map of 10 km area and site
details providing various industries, surface water bodies,
forests etc.
Chapter 2, Fig 2.2 Pg 17
Annexure-1
12. Present land use based on satellite imagery for the study area
of10 km radius. Details of land availability for the project along
with supporting document.
Land for the project
Chapter 2.
Table 2.-3, Pg 19
Annexure-4
Land use of study area
Chapter -3
Fig. 3-8, pg- 67
13. Location of National Park / Wildlife sanctuary / Reserve forest
with in10 km radius of the project.
Not applicable
14. Permission from the State Forest Department regarding the
impact of the proposed plant on the surrounding reserve forests.
Not applicable
15. Details of the total land and break-up of the land use for green
belt and other uses.
Chapter 2, Table 2-3 Pg18
16. List of products along with the production capacities. Chapter 2, Table-2.1, Pg
14
17. Detailed list of raw material required and source, mode of
storage.
Chapter 2, Table 2.4, 2-5
Pg 21
18. Manufacturing process details along with the chemical reactions
and process flowchart.
Chapter 2, Pg 22 -28
19. Action plan for the transportation and storage of raw materials
and products.
Chapter -2
Table 2-4 pg 21,
Annexure-8
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20. Sources and quantity of fuel (coal etc.) for the boiler. Measures
to take care of SO2emission. A copy of Memorandum of
Understanding (MoU) signed with the coal suppliers should be
submitted, incase coal is used.
Not applicable as coal is
not used. Furnace oil
requirements Chapter 2,
Table 2-4, Pg 21
21. Site-specific micro-meteorological data using temperature,
relative humidity, hourly wind speed and direction and rainfall
is necessary.
Chapter 3, Table 3.2, Pg
48
Annexure-11
22. Ambient air quality monitoring at 6 locations within the study
area of 5km, aerial coverage from project site as per NAAQES
notified on 16th
September, 2009. Location of one AAQMS in
downwind direction.
Chapter 3, Table 3.1, Pg
46
23. One season site – specific micro-meteorological data using
temperature, relative humidity, hourly wind speed and direction
and rain fall and AAQ data (except monsoon) for PM2.5, PM10,
SO2, NOx, CO, HC including VOCs shall be collected. The
monitoring stations shall take into account the pre-dominant
wind direction, population zone and sensitive receptors
including reserved forests. Data for water and noise monitoring
shall also be included.
Chapter 3, Table 3.4, Pg
51
Table 3-5, pg 53
Table 3-8, pg 60
Annexure-11
24. Air pollution control measures proposed for the effective control
of gaseous/ process emissions with in permissible limits.
Emphasis should be on effective control of VOC and odour.
Chapter 7, Pg 108
25. Name of all the solvents to be used in the process and details of
solvent recovery system.
Not applicable
26. Design details of ETP, incinerator, if any along with boiler,
scrubbers/bag filters etc.
Chapter 2, 2.8.4, Pg 29
27. Details of water and air pollution and its mitigation plan. Chapter 7 Pg 108
28. Action plan to control ambient air quality as per NAAQS
Standards notified by the Ministry on16th September, 2009.
Chapter 7, Pg 114
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29. An action plan prepared by SPCB to control and monitor
secondary fugitive emissions from all the sources.
Chapter7,7.6.1, Pg 114
30. Determination of atmospheric inversion level at the project site
and assessment of ground level concentration of pollutants from
the stack emission based on site-specific meteorological
features. Air quality modeling for proposed plant.
Chapter 4, Pg 82
31. Permission from competent Authority for the drawal of water.
Water balance chart for existing and product mix change project
including quantity of effluent generated recycled and reused and
effluent discharge.
Chapter 2, Pg 34, 35 Fig-
2-13,2-14
Annexure- 9 CMWSSB
Receipt
32. Complete scheme of effluent treatment. Characteristics of
untreated and treated effluent to meet the standard. Treated
waste water to meet the norms of CETP/ marine discharge.
Chapter 2,
2.8.4 Pg 37 -41
33. Zero discharge effluent concepts to be adopted. Not applicable
34. Ground water quality monitoring minimum at 6 locations shall
be carried out. Geological features and Geo-hydrological status
of the study area and ecological status (Terrestrial and Aquatic).
Chapter 3, , Table-3-9
Pg 62
35. The details of solid and hazardous wastes generation, storage,
utilization and disposal particularly related to the hazardous
waste calorific value of hazardous waste and detailed
characteristic of the hazardous waste.
Chapter 7, Pg 121
36. Material Safety Data Sheet for all the Chemicals are being used/
will be used.CAS No./ RTECS No./DOT/UNetc to be
mentioned against each chemicals.
Annexure-15
37. Details of chlorine handling and storage facilities. Measures to
be taken in case of leakage along with alarm system.
Annexure-30
Risk Assessment
38. Authorization/ Membership for the disposal of solid /hazardous
waste in TSDF.
Annexure-21, 28, 29
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39. Risk assessment for storage for chemicals/ solvents. Action plan
for handling &safety system.
Annexure 30-Risk
Assessment
40. Action plan for development of green belt over 33% of the total
project area within plant premises with atleast 10 meter wide
green belt on all sides along the periphery of the project area, in
downward direction, and along roadsides etc.
Chapter 7, Pg122
Annexure- 13
41. Action plan for rain water harvesting measures at plant site shall
be included to harvest rain water from the roof tops and storm
water drain store charge the ground water.
Chapter 7, Pg 117
Annexure-12
42. Details of occupational health programme. Chapter 7, , Pg 135- 139
i. To which chemicals, workers are exposed directly or indirectly. -do-
ii. Whether these chemicals are within Threshold Limit Values
(TLV)/ Permissible Exposure Levels as per ACGIH
recommendation.
-do-
iii. What measures company have taken to keep these chemicals
within PEL/TLV? How the workers are evaluated concerning
their exposure to chemicals during pre-placement and periodical
medical monitoring.
-do-
iv. What are onsite and offsite emergency plan during chemical
disaster.
Annexure-30 Emergency
Preparedness Plan
v. Liver function tests(LFT) during pre-placement and periodical
examination.
Chapter 7, Pg-138
43. Details of occupational health surveillance programme. Chapter 7, Pg 138
44. Socio-economic development activities shall be in place. Chapter 3, 7 Pg-73
45. Note on compliance to the recommendations mentioned in the
CREP guidelines.
Chapter 7, 7.8.4, Pg 144
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46. Detailed Environment management Plan (EMP) with specific
reference to details of air pollution control system, water &
waste water management, monitoring frequency, responsibility
and time bound implementation plan for mitigation measure
shall be provided.
Chapter 7, Pg 108
47. EMP shall include the concept to waste-minimization, recycle /
reuse / recover techniques, Energy conservation, and natural
resource conservation.
Chapter 7, Pg-114
48. Total capital cost and recurring cost / annum for environmental
pollution control measures
Chapter7,Table7-12
Pg-148
49. Corporate Environmental Responsibility Chapter 7, Pg140
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.
Chapter 7, Pg 141
ii. Does the Environmental Policy prescribe for standard operating
process / procedures to bring into focus any in fringement /
deviation / violation of the environmental or forest norms /
conditions? If so, it may be detailed in the EIA report.
-do-
iii. What is the hierarchical system or Administrative order of the
company to deal with the environmental issues and for ensuring
compliance with the EC conditions? Details of this system may
be given.
Chapter 7, Pg 141
iv. Does the company have a system of reporting of noncompliance
/ violations of environmental norms to the Board of Directors of
the company and / or shareholders or stake holders at large?
This reporting mechanism should be detailed in the EIA report.
Not applicable
50. Any litigation pending against the project and / or any direction /
order passed by any Court of Law against the project, if so,
details thereof.
Not applicable
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51. A tabular chart with index for point wise compliance of above
TORs.
Pg-163-168
The following general points shall be noted:
i. All documents shall be properly indexed, page numbered. ii.
Period / date of data collection shall be clearly indicated.
Provided
ii. Authenticated English translation of all material provided in
Regional languages.
-
iii. The letter /application for EC shall quote the MOEF file No. and
also attach a copy of the letter.
Annexure-2
iv. The copy of the letter received from the Ministry shall be also
attached as an annexure to the final EIA-EMP Report.
Annexure-2
v. The final EIA-EMP report submitted to the Ministry must
incorporate the issues in this letter. The index of the final EIA-
EMP report must indicate the specific chapter and page no. of
the EIA-EMP Report.
-
vi. Certificate of Accreditation issued by the QCI to the
environmental consultant shall be included.
Annexure -32
vii. It was decided that TOR s prescribed by the Expert Appraisal
Committee (Industry) shall be considered for preparation of
detailed report for the above mentioned project in addition to all
the relevant information as per the Generic Structure of EIA
given in Appendix III and III Ain the EIA Notification, 2006.
After detailed deliberations, the Committee exempted the public
hearing as per Section7(i), III Stage(3), Para(i)(b)of EIA
Notification 2006, subject to submission of authentic document
from the State Govt. indicating that the project is located in the
notified industrial area. The final EIA/EMP report shall be
submitted to the Ministry for obtaining environmental clearance.
-