Draft EIA Report - ppcb.gov.in of Public Hearings... · The state border of Punjab and Haryana ......

Draft EIA Report Expansion of Chemical Processing Unit of HPL Additives Ltd.,

Village: Bhagwanpur, Tehsil: Derabassi, Dist.: SAS Nagar, Punjab

Prepared by SBA ENVIRO SYSTEMS PRIVATE LIMITED

#201, DDA LOCAL SHOPPING CENTRE, E – BLOCK, VIKASPURI

NEW DELHI 110 0018

Environmental Impact Assessment Study

Expansion of Chemical Processing Unit of HPL Additives Ltd.,


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NO.1005/EIA/2018 REVISION: 0 DATE OF ISSUE: 03 May 2018.

SBA ENVIRO SYSTEMS PVT. LTD. 1

Chapter 1

Introduction




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Chapter 1

Introduction

1.0 PREAMBLE

HPL Additives Limited (formerly known a High Polymer Labs Limited) is an ISO 9001:2008,

ISO 14001:2004 and OHSAS 18001:2007 accredited organisation. It is one of the country’s

pioneers in manufacturing of Polymer Additives. The company has planned of expansion of

its existing chemical processing unit at Bhagwanpur, Derabassi, Punjab plant. The plant is

well connected with Derabassi-Barwala road and has close connection with Chandigarh

airport with a distance around 20km.

The existing unit of HPL Additives Limited at Bhagwanpur has only one product, i.e. Hydrazine

with a capacity 110 MT per month. Expansion of the plant is planned mainly to increase its

manufacturing strength with some additional products in relation to external market demand

as well as internal demand. The proposed additional products are as K-10, K-30, K-135L, K-

57L, K-18L, K-28, K-DA; HC-301, Hydrazo-dicarbonamide (HDC), Azo-dicarbonamide (ADC)

and other intermediate and by-products.

The plant is adjacent to Derabassi-Barwala road, which connects NH-152 (Ambala

Chandigarh Expressway). The nearest Airport is Chandigarh, which is connected with the

plant via NH-152 and Derabassi-Barwala road. Nearest railway station is Ghaggar, connected

with Derabassi-Barwala road with the distance of 8 km. The plant is also well connected with

nearest cities like Ambala, Panchkula etc.

The Identified land for expansion is owned by HPL Additives Ltd. The area is coming under

‘Free Enterprise Zone’ as per Notification no.: 3/4/87-3IB1/311 dated 09.01.90 by Govt. Of

Punjab, Dept. of Industries. So, there is no chance of productive soil loss, due to the area

within the Industrial land use. The proposed site is coming within the topographic sheet no.

H43K14 published by Geological Survey of India (with a scale of 1:50,000). The nearest water

bodies are Tangri River on the Eastern side of the plant and Ghaggar River on the western

side of the proposed unit, but well outside the notified industrial zone and the unit is situated

far from the Ghaggar River Basin High Flood Level zone. There isn’t any National park within

the Punjab state, also the state doesn’t have any ‘Coastal Regulation Zone’, the nearest




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Wildlife Sanctuary is Sukhna Wildlife Sanctuary, having around 30 km distance from project

location. Chandigarh was declared an ‘Air Pollution Control Area’ under the Air (Prevention &

Control of Pollution) Act, 1981 on 1st February, 1988 by the Ministry of Environment & Forests,

which has distance of around 20km from project site. The state border of Punjab and Haryana

has close proximity to the proposed unit with a distance of less than 1 km.

1.1 PURPOSE OF THE REPORT

The proposed expansion of chemical processing unit of existing unit, HPL Additives Ltd. at

Bhagwanpur, Derabassi, in Punjab attracts the EIA Notification, 2006 and amendments

thereafter, dated 14.09.2006 of Ministry of Environment Forests & Climate Change (MoEFCC)

and require Environmental Clearance under the category A of project activity 5(f) – “Synthetic

organic chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding

drug formulations; synthetic rubbers; basic organic chemicals, other synthetic organic

chemicals and chemical intermediates)”. As the proposed project situated within notified

industrial area, thus usually it attracts category ‘B’, but, the identified unit is situated closely to

the interstate border of Punjab & Haryana with a distance of 1 km, thus, the project attracts

General Condition and the project automatically shifts to the category ‘A’. With this respect the

project proponent had applied for the project to Expert Appraisal committee (EAC) of

MOEFCC.

A term of Reference (TOR) for EIA Study for the project had been applied on 08.09.2017. vide

application no. IA/PB/IND2/67956/2017. The TOR granted by ministry on 26.10.2017. vide file

no. IA-J-11011/460/2017-IA-II(I). A draft EIA & EMP report has been prepared for Public

consultation as accorded by the granted TOR from EAC, MOEFCC and will be submit to the

Punjab State Pollution Control Board.

The final EIA Report shall be prepared based on the notifications and guidelines published by

the MoEFCC from time to time and management plan shall be prescribed as according the

impact identified and issues would raise during public consultation.

1.2 WHAT IS THIS PROJECT

HPL Additives has planned for expansion of their existing production as well as newer

products as per market demand and they have plenty of open space to transform the plan

successfully in their Derabassi plant at Bhagwanpur village in Punjab. Having stabilized its




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enhanced manufacturing capacity in line with market dynamics, now HPL has drawn

aggressive plans to not only further supplement its manufacturing capabilities with expanded

production capacity of some antioxidants, core bulk blowing agent ADC but also to introduce

a few new products namely antioxidants for Oils and Lubricants and Clarifying agents for

Polymer industry to complement its product basket.

Expansion of the plant is mainly for increasing the manufacturing capacities with its

Antioxidants; K-10, K-30, K-135L, K-57L, K-18L, K-28, K-DA; HC-301, Hydrazine, Hydrazo-

dicarbonamide (HDC), Azo-dicarbonamide (ADC) and Adipic dihydrazide (ADH) other by-

products. Currently the unit is only producer of Hydrazine with a capacity of 110 MT/ month.

After proposed expansion the unit would produce 2253 MT/ month of products cumulatively.

The proposed expansion of antioxidant production as well as production of various newer

polymer additives will generate large number of job opportunity for skilled as well as semi or

un-skilled workers during construction phase for temporary purpose and regular purpose

during operation stage.

HPL Additives Ltd., Derabassi plant is well connected by roadways to nearby locations as well

as entire country. The plant is adjacent to Derabassi-Barwala road, which connects NH-152

(Ambala Chandigarh Expressway). The nearest Airport is Chandigarh, which is connected

with the plant via NH-152 and Derabassi-Barwala road. Nearest railway station is Ghaggar,

connected with Derabassi-Barwala road with the distance of 8 km. The plant is also well

connected with nearest cities like Ambala, Panchkula etc.




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Fig. 1.1: Site location with impact area in 1:200000 scale (source: Google Map-satellite image)

Figure 1.2: Proposed unit’s location (Source: Google Earth)

The proposed unit has a total owned area of 67414.57 sq. meter, out of which 5391.23 sq.

meter area is occupied by existing infrastructure. Thus, almost 90% area is open & green area,

which can utilise for proposed expansion, with environmental friendly manner. After proposed




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expansion, almost 33% land will be free for green belt and additionally the unit will initiate the

plantation concept outside the premises to increase green cover.

1.3 IDENTIFICATION OF PROJECT PROPONENT

HPL Additives Limited was incorporated in 1964. The company celebrated its Golden Jubilee

in April 2014 on completion of its 50 years of successful operations.

HPL Additives Limited (formerly known a High Polymer Labs Limited) is an ISO 9001:2008,

ISO 14001:2004 and OHSAS 18001:2007 accredited organisation. It is one of the country’s

pioneers in manufacturing of Polymer Additives. The product lines include Chemical Blowing

Agents for rubber and plastics, polymerization catalyst, Anti-oxidants, UV Stabilizers, Flame

retardants, Hydrazine Hydrates, Triazoles and Specialty chemicals.

The company has 80% share in the domestic market and export to more than 48 countries

across the world. Around 45% of its turn over comes from exports to Europe and America.

HPLA has four manufacturing sites in India: three in Faridabad (Haryana) and one in

Derabassi (Punjab). All plants are DCS/PLC controlled and equipped with state-of-the-art

instruments ensuring reliable and safe processes, while focusing majorly on ensuring safe

operating conditions and environment at all the plants.

All technologies are developed in house and with no technical know-how agreements, joint

ventures or collaborations for any product(s) manufactured by the company. The technology

development starts from the R&D centre and then progresses through the Technology

Development group, the Projects and Engineering Services group, the Manufacturing group,

the Environment group and the Health and Safety (EHS) group before it is finalized and

blueprinted. Inter-departmental interface and ratification ensures safety, reliability, efficiency

of processes, excellent product quality due to stringent design inputs and reduces

development and commercialization time.

Research & Development is the core of HPL Additives and recognized by the Department of

Scientific & Industrial Research, Ministry of Science, Government of India. It is furnished with

up-to-date and hi-tech equipment and instruments in order to cater to the evolving needs to

our customers and the market and boasts of highly qualified scientists and chemists from

leading academic institutions from across the country.




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In recognition of its work and efforts in R&D, HPLA has received many awards including the

DSIR National Award, ICC Acharya PC Ray Award for the Development of Indigenous

Technology (2005-06, 2009-10) and the PLASTCON (2009) for best research in Polymer

Science, Technology and Engineering. As a company we dedicate these accolades to our

brilliant and efficient team of scientists, engineers and management professionals.

Company’s progress has been made possible by the competent and dedicated workforce of

750 personnel comprising engineers, scientists, technicians and management experts

amongst the others. Working in a congenial environment, empowered HPL team pro-actively

and effectively responds to ever evolving market needs.

HPL firmly believes that its most valuable and productive assets are its Human force. It has

invested considerably in inducting and nurturing talents all through. Continuous on –the – job

and general management skills training supported by career path planning have created talent

pool ready to take on contemporary and future corporate challenges.

HPL Additives Limited supports principle of more effective chemicals regulatory system in

order to deliver sustainable health and environmental safety benefits and has formed special

group to ensure compliance with implementation of REACH.

Committed to its value drives of Adaptability, Dependability, Team- Work, caring, speed and

versatility, today HPL is in process of realizing its dream of being a transnational corporate in

next three years with green-field projects in China and Middle East Asia.

It is obvious that with projected economic growth, per capita consumption of plastics in India

shall grow substantially. Natural growth from larger number of consumers from normal

population growth shall be another add-on. With increase in consumption / production of

Plastics, demand of additives shall also increase proportionately. Significant to add that HPL

Additives’ product basket has an international foot-print as well and is not limited to domestic

market.

Vision of the Company

HPL Additives' vision is centred on its philosophy of success through innovation, continuous

improvement and excellence. Its vision is supported by its core values:

Adaptability, Dependability, Teamwork, Speed, Versatility and Caring.




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Directors of the company

Mr. Harcharan Singh (Chairman & Managing Director) is the key promoter of HPL. After

completing his post-graduation in Science from Punjab University in the year 1960, he worked

as a Scientific Officer in the field of Polymer and Polymer Additives in Shriram Institute of

Industrial Research for about 5 years. HPL Additives Limited was set up by Mr. Harcharan

Singh and his brothers in the year 1964 as a registered partnership firm which was later

converted into a company in the year 1976. He has an overall experience of 50 years in the

field of Polymers.

Mr. Singh was awarded the “Top CEO Award” by the Institute of Marketing and Management,

in January 1995. Recently he was honored by `Life Time Achievement Award’ in 2012 by

Faridabad Industries Association.

Mr. Umesh Anand (Managing Director) holds an honours degree in commerce from the

University of Delhi. He is an MBA from the College of William and Mary, Williamsburg, Virginia.

He has worked with Citicorp for three years as Project Manager/Unit Sales Manager. From

1991-1994 he was owning and managing a garment manufacturing and export company. In

the year 1995 he joined HPL Additives Limited where he currently is the Joint Managing

Director.

Mr. Anand’s prime responsibility includes strategizing for the organization and preparing it to

meet future challenges; with business development being another area of attention. He is also

exploring possibilities to market India’s research and a development capability internationally

in sync with country’s other prominent chemical manufacturers of country.

Mr. Satpal Singh (Director) has been involved with the company since its inception and

handles various activities related to factory administration, industrial relationships etc. He has

substantial work experience and is Occupier of all manufacturing sites of the company.

In addition, the company has 3 non-executive members in board of directors namely, Dr. Dilip

D. Ravetkar, and Dr. Veena Choudhary.




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1.4 SCOPE OF THE STUDY

In order to identify the environmental impacts due to construction and operation of proposed

expansion of Chemical processing unit, and its associated facilities and in order to draw a

suitable environmental management plan to mitigate impacts, an Environmental Impact

Assessment Study has been undertaken. The Terms of Reference (TOR) for EIA Study was

accorded by the EAC, MOEFCC. The compliance of the conditions stipulated in TOR

accorded by EAC, MOEFCC vide letter dated 26.10.2017 is presented in previous part of the

report.

HPL Additives Limited has appointed M/s SBA Enviro Systems Pvt. Ltd., New Delhi to carry

out the Environmental Impact Study and to prepare the Environmental Impact Assessment

(EIA) report, and present it to the EAC, MOEFCC to get clearance from the Ministry for the

proposed expansion of chemical processing unit at their Bhagwanpur, Derabassi unit in

Punjab.

SBA Enviro Systems Private Limited is a company registered under The Companies Act,

1956. It is now eighteen years old with an in-house strength of 42 employees and 25

Empanelled Experts. The organisation nurtured and developed by Mr. Sajjathe Sulthan,

eminent environmentalist, a post graduate in applied chemistry and management from India’s

premier institutions, he acquired expertise in environmental engineering, climate change

mitigation & adaptation, due diligence for statutory compliances and industrial health & safety.

With profound and vast experience, he now caters Indian Industry and CTCN-UNEP as

climate change expert, Accredited EIA coordinator and Functional Area Expert (FAE). The

organisation is also a member of Climate Change Centre and Network (CTCN) of UNEP and

part with UNGM.

SBA is an NABET accredited EIA Consultant Organization vide accreditation no.

NABET/EIA/1720/IA0027 dated June 13, 2017 and has several project sectors empowered

with experts of all functional areas.

The Functional Area Experts of SBA are specialized in Safety Audit, HAZOP Studies,

Emergency Preparedness, Energy Audit, Energy Efficiency Studies, Life Cycle Analysis,

Sustainability Studies, Hydrogeological Studies, Social Impact Assessment, GIS and Land

Use Mapping, Micro Meteorological Analysis, System Adequacy Analysis, Resource




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Conservation Studies, Water Quality Modelling, Air Quality Modelling for both Stationery and

Linear Development Projects, Noise Quality Modelling.

The baseline environmental data generation commenced on 1st November 2017 and

completed by 28th February 2018. The EIA Study covers baseline data generation, predictions

and evaluation of impact on various environmental components, preparation of EIA Report,

formulation of Environmental Management Plan and Disaster Management Plan.

The Scope of the EIA Study is briefly described in the following chapters,

Table 1.1: Chapter of EIA Report

Sl. No. EIA Structures Contents

1 Introduction • Purpose of the report

• Identification of project & project proponent

• Brief description of nature, size, location of the project

and its importance to the country, region

• Scope of the study – details of regulatory scoping

carried out (As per Terms of Reference)

2 Project Description Condensed description of those aspects of the project

(based on project feasibility study), likely to cause

environmental effects. Details should be provided to give

clear picture of the following:

• Type of project

• Need for the project

• Location (maps showing general location, specific

location, project boundary & project site layout)

• Size or magnitude of operation (incl. Associated

activities required by or for the project

• Proposed schedule for approval and implementation

• Technology and process description

• Project description. Including drawings showing project

layout, components of project etc. Schematic

representations of the feasibility drawings which give

information important for EIA purpose




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• Description of mitigation measures incorporated into

the project to meet environmental standards,

environmental operating conditions, or other EIA

requirements (as required by the scope)

• Assessment of New & untested technology for the risk

of technological failure.

3 Description of the

Environment

• Study area, period, components & methodology

• Establishment of baseline for valued environmental

components, as identified in the scope

• Base maps of all environmental components

4 Anticipated

Environmental Impacts &

Mitigation Measures

• Details of Investigated Environmental impacts due to

project location, possible accidents, project design,

project construction, regular operations, final

decommissioning or rehabilitation of a completed

project

• Measures for minimizing and / or offsetting adverse

impacts identified

• Irreversible and Irretrievable commitments of

environmental components

• Assessment of significance of impacts (Criteria for

determining significance, Assigning significance)

• Mitigation measures

5 Analysis of Alternatives

(Technology & Site)

In case, the scoping exercise results in need for

alternatives:

• Description of each alternative

• Summary of adverse impacts of each alternative

• Mitigation measures proposed for each alternative

• Selection of alternative

6 Environmental Monitoring

Program

• Technical aspects of monitoring the effectiveness of

mitigation measures (incl. Measurement

methodologies, frequency, location, data analysis,

reporting schedules, emergency procedures, detailed

budget & procurement schedules)

7 Additional Studies • Public Consultation




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• Risk assessment

• Social Impact Assessment. R&R Action Plans

8 Project Benefits • Improvements in the physical infrastructure

• Improvements in the social infrastructure

• Employment potential –skilled; semi-skilled and

unskilled

• Other tangible benefits

9 Environmental Cost Benefit

Analysis

If recommended at the Scoping stage

10 Environment Management

Plan

• Description of the administrative aspects of ensuring

that mitigative measures are implemented and their

effectiveness monitored, after approval of the EIA

11 Summary & Conclusion

(This will constitute the

summary of the EIA Report)

• Overall justification for implementation of the project

• Explanation of how, adverse effects have been

mitigated

12 Disclosure of

Consultants engaged

• The names of the Consultants engaged and their

brief resume and nature of Consultancy rendered




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Chapter 2

Project Description




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Chapter 2

Project Description

2.1 TYPE OF THE PROJECT

The proposed project of HPL Additives Limited at their Bhagwanpur, Derabassi unit in SAS

Nagar, Punjab is basically an expansion Plan. The company had planned for expansion of

their chemical processing unit with increment of production capacity of existing product as well

as addition of newer product. The existing unit is a global producer of organic polymer

additives such as hydrazine hydrate, which normally used as polymerisation initiators and

pharmaceutical intermediates. Thus, the project attracts EIA requirement for the expansion

and requires Environment Clearance prior to the project under activity 5(f) – “Synthetic organic

chemicals industry (dyes & dye intermediates; bulk drugs and intermediates excluding drug

formulations; synthetic rubbers; basic organic chemicals, other synthetic organic chemicals

and chemical intermediates)”. Additionally, the proposed project location is situated very close

to the inter-state boundary of Punjab & Haryana, thus, the project comes within the ‘A’

category.

The project would not involve any additional land acquisition as the existing unit has 90% of

open area and planning & design has been made accordingly. The existing product of the unit

is Hydrazine Hydrate, having production capacity of 110 MT/ month, which will increase to 295

MT/month. There will be addition of 8 more products has been planned, which are namely,

Kinox-30, Kinox-10, HC-301, 3,4 DMB, Lube Antioxidants, HDC, ADC, ADH. Those products

mainly having phenolic derivatives and some raw materials having hazardous characters as

per the MSIHC amendment rules, 2016, thus the proposed project requires extensive study to

identify the impacts. Company shall deliver leadership towards identification of hazards &

implementation of impact mitigation concepts.

2.2 NEED OF THE PROJECT

HPL Additives has planned for expansion of their existing production as well as newer

products as per market demand in their Derabassi plant at Bhagwanpur village in Punjab.

Requirements of expansion and details of products are described below:

Justification of the Expansion

Spotting opportunities at global scale, in 2006 company had made a quantum leap forward

with a five-fold increase in its manufacturing capacities for Polymer Additives at its plant at




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village, Dudhola, Tehsil & District Palwal. The project was completed with in record time of 10

months and conceived and fully executed by HPL own team culminated in a state-of-art plant,

incorporating contemporary technology rather surpassing international benchmarks in many

critical domains.

The technology and support for successful absorption thereof for manufacturing these

products Anti-oxidants and UV Stabilizers was provided by company’s R&D centre.

Antioxidants and UV stabilizers play a vital role in the life cycle of polymer. The success of

anti-oxidants and UV Stabilizers depends on high purity, the presence of minimum impurities

and minimum residual catalyst. R&D team integrated technological tools like bench marking

for each product; impurity profile analysis and good manufacturing practices to achieve this.

As development and manufacturing of these products is complicated and involve high level of

automation as well as process control during manufacture of these Antioxidants, process

innovations were made to ensure right quality for its international market. HPL is the only

producer of these products in India through indigenously developed technology.

To optimize available resources and to take advantage of geographical site locations HPL has

now ear marked an ambitious expansion plant to triple capacities of some of the antioxidants

and to start producing an ADC intermediate at its raw material source at its Plant at Derabassi

in Punjab. HPL shall also change / readjust production portfolio of its Antioxidants currently

produced at its Dudhola plant so as to accommodate expansion of production facilities of some

other products, if so required.

HPL market its products across the world. As stated elsewhere around 50% of its turnover is

from exports, primarily to developed market like Europe and USA. Per Capita consumption of

plastics in India is quite low in comparison to world average consumption and way below per

capita consumption in developed countries. It is obvious that with projected economic growth,

per capita consumption of plastics in India shall grow substantially. Natural growth from larger

number of consumers from normal population growth shall be another add-on. With increase

in consumption/ production of Plastics, demand of additives shall also increase

proportionately.

Significant to add that HPL Additives product basket has an international foot-print as well and

is not limited to domestic market.




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2.3 LOCATION OF THE PROJECT

The proposed unit of the expansion project is located at Bhagwanpur village, within the block

Derabassi in Sahibzada Ajit Singh Nagar district, Punjab. HPL Additives Ltd., Derabassi plant

is well connected by roadways to nearby locations as well as entire country. The plant is

adjacent to Derabassi-Barwala road, which connects NH-152 (Ambala Chandigarh

Expressway). The nearest Airport is Chandigarh, which is connected with the plant via NH-

152 and Derabassi-Barwala road with a distance around 20 km. Nearest railway station is

Ghaggar, connected with Derabassi-Barwala road with the distance of 8 km. The plant is also

well connected with nearest cities like Ambala, Panchkula etc. The unit is also well connected

with National Capital Region with a roadways distance of 240 km via NH-152 & NH-44.

Fig. 2.1: Proposed Site location (red coloured bordered)

(Source: Google Earth)

The Identified land for expansion is owned by HPL Additives Ltd. The area is coming under

‘Free Enterprise Zone’ as per Notification no.: 3/4/87-3IB1/311 dated 9th January 990 by Govt.

Of Punjab, Dept. of Industries. So, there is no chance of productive soil loss, due to the area

within the Industrial land use. The nearest water bodies are Tangri River on the Eastern side

of the plant and Ghaggar River on the western side of the plant, but well outside the notified

industrial zone and also the site far away from Ghaggar River Basin High Flood Level zone.

There isn’t any National park within the Punjab state, also the state doesn’t have any ‘Coastal

Regulation Zone’, the nearest Wildlife Sanctuary is Sukhna Wildlife Sanctuary, having




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around 30 km distance from project location. Chandigarh was declared an ‘Air Pollution

Control Area’ under the Air (Prevention & Control of Pollution) Act, 1981 on 1st February, 1988

by the Ministry of Environment & Forests, which has distance of around 20km from project

site. The state border of Punjab and Haryana has close proximity to the site a distance below

1 km.

Table 2.1: Co-ordinates of the periphery of the proposed unit

Location mark

Latitude Longitude Elevation (AMSL)

Point 1 30⁰34'39.75" N 76⁰53'43.69" E 311 m

Point 2 30⁰34'43.45" N 76⁰53'35.19" E 311 m

Point 3 30⁰34'54.36" N 76⁰53'35.54" E 308 m

Point 4 30⁰34'54.27" N 76⁰53'40.65" E 308 m

Point 5 30⁰34'46.77" N 76⁰53'40.58" E 311 m

Point 6 30⁰34'46.61" N 76⁰53'43.95" E 311 m

2.4 ANALYSIS OF ALTERNATIVES

HPL Additives Limited has 4 production unit in India, one is in Bhagwanpur, Derabassi

(proposed expansion unit), one in Dudhola, Haryana and other 2 in Ballabhgarh, Haryana.

The proposed project requires 15,725 sq. meter area for infrastructure, 10,000 sq. meter area

for road and paved structure. The 3 units of HPL Additives Ltd. other than Bhagwanpur unit

don’t have that much of open space to install the same planned facility, whereas, the

Bhagwanpur unit has only 5,391.25 sq. meters of build-up area out of 67,414.57 sq. meters of

owned land. Thus, in respect of land availability the Bhagwanpur, Derabassi unit is ideal to

materialized the plan.

On the other hand, the other units have less roadways connectivity than the Bhagwanpur unit.

The proposed unit has very good roadways connectivity with local market as well as market

from raw materials would be brought. As, the area available in proposed unit is owned by the

proponent and the use of the land is industrial type, thus in case of expansion within the

existing premises might not requires any additional alternative land identification.




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In addition, after planned expansion of proposed chemical processing unit, there will have

16,000 sq. meters of Green belt area with around 50% of non-build-up open area with the

existing premises. The existing unit already have all the required infrastructure facilities and

resources. As the proponent will run the project with environmental friendly manner during

construction and operation phase, thus, the proposed unit would be the best alternative site

for planned expansion project.

2.5 EXISTING PROCESS PROFILE

Layout of the existing Unit

The proposed expansion project will be located at the existing unit of HPL Additives Ltd., at

Bhagwanpur, as the project is expansion of chemical processing unit.

The existing infrastructure has occupied the 5,391.25 sq. meters of area. Thus, almost

55,000.00 sq. meter area is open or green belt within the unit having almost 1800 of trees

which are planted by company in different time. The detailed break-up of existing plant layout

is provided below.

Fig. 2.2: Existing unit with green-belt (Green outlined area) &

Existing Infrastructure (yellow outlined area)





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Table 2.2: Break-up of existing infrastructure

Block

Nos. Description Dimension (m) Area (m²)

1 ADMIN BLOCK 32.82 x 15.00 492.3

2 ASSEMBLY POINT 42.30 x 10.00 423

3 GUARD ROOM 8.12 x 3.77 30.61

4 ENERGY METER ROOM 4.26 x 3.78 16.1

5 CAR PARKING 26.89 x 2.78 74.75

6 MOTOR CYCLE PARKING 16.70 x 7.00 116.9

7 D.G. ROOM & SUB STATION 32.40 x 10.53 341.17

8 GENERAL H/W & R/M STORES 17.18 x 10.53 180.91

9 FILLED DRUM STORAGE SHED 17.18 x 10.53 180.91

10 MAIN PLANT 24.75 x 24.46 605.39

11 DRUMMING ROOM 16.51 x 7.60 125.48

12 UTILITY BUILDING &

LABORATORIES 28.50 x 9.00 256.5

13 CHLORINE SHED 15.00 x 13.33 199.95

14 COOLING TOWER 15.33 x 9.72 149.01

15 DRYER THERMOPACK 14.65 x 9.60 140.64

16 TOILET 9.83 x 4.63 45.51

17 SEPTIC TANK 2.95 dia. x 2 Nos. 18.53

18 RAW WATER U/G TANKS 18.25 x 13.37 244

19 PUMP HOUSE 6.71 x 5.55 35.58

20 AMMONIA TANK SHED 8.41 x 5.55 62.07

21 WATER TANK 3.40 x 3.30 11.22

22 SOFT WATER TANK 4.40 x 2.40 10.56

23 WATER SOFTENING TANK 10.83 x 4.14 44.84

24 BOILER 29.31 x 13.94 408.58

25 BOILER HOUSE 7.36 x 5.73 42.17

26 CHIMNEY Día 2 mtr. 6.28




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27 WORK SHOP 31.51 x 9.97 314.15

28 WEIGHING BRIDGE 7.70 x 7.31 56.29

29 ETP 31.20 x 24.29 757.85

Total Area 5391.25

The differential land break-up of the existing unit are as follows:

Thick Green cover 14,300 sq. meter (Approx.)

Grass coverage 4,300 sq. meter (approx.)

Open area 40,000 sq. meter (Approx.)

Paved area 2,500 sq. meter (approx.)

Infrastructure 5,391.25 sq. meter

Utility

The existing unit equipped with 1 nos. 8 TPH Boiler, 100 TR Chilled Brine Plant, 100 TR

Chilled water system, 3 nos. 320 KVA DG set, 1600 TR Cooling tower, and 1 Thermopack

system with a capacity of 1 lakh KCAL, 1 water softening system etc.

Electricity

HPL Additives, Derabassi plant already has 1150 KW sanctioned power load from PSPCL for

existing production unit’s power requirement. Additionally, plant has 3x320 KVA DG sets for

stand by requirement.

Fuel

Existing requirement of HSD is 2 Kilo Litres per Month with a usage of 200 litre/ hour for 2-3

hours of running time. 280 Metric ton of Pet coke/ month is the usage capacity of the existing

system, which is used for Thermic fluid heater system as well as for Boiler, are being stored

in an open space near the boiler.

Raw material

There are 3 main raw materials are used to produce the only product Hydrazine Hydrate

namely, Caustic Lye (47.5%), Urea and chlorine with a monthly requirement of 1858, 317, 358

Metric tonnes respectively.

Water

Existing consumption of water is 221 KLD, the only source of required raw water is Ground

water Resource. The unit is operating with a bore well to extract the ground water, as there is

no such surface water stream or any water supply line within close proximity of the premises.

The application sought for essential regularisation of groundwater extraction. The daily




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extraction of groundwater is about 211 cubic meter, the existing borewell is fitted with 5 horse

powered submersible pump with an operational capacity of 40 cubic meters of discharge at

60 minutes operational duration. The raw water stored in storage tank and further treated by

Water softening system to utilize in Brine system of Boiler. The water requires for Cooling and

Chilling process transfers to the same from storage tank. Water for toilet usage also transfer

from storage tank, and drinking water used only after reverse osmosis treatment in each

drinking water facility area.

Table 2.3: Groundwater extraction facility details

Sl.

No. Particulars

Capacity of Existing

Bore Well

Quantity 1 nos.

1 Discharge (M3/Hr) 40

2 Operation(Hrs) 08-10

3 Operation (Days) 360

4 Horse power of pump 5

5 Fitted with meter or not? Yes

Fig. 2.3: Water balance of existing facility (Source: Unit’s usage data)




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Product

The existing unit at Bhagwanpur has only one principle product, which is Hydrazine Hydrate.

There is one more salt generates from the process as by-product.

Hydrazine Hydrate is an inorganic chemical having formula H2N4, H2O and IUPAC name of

Hydrazine. The chemical has molecular weight of 50.061 g/mol. It is a colourless flammable

liquid with an ammonia-like odour. Hydrazine is highly toxic and dangerously unstable unless

handled in solution. The existing unit produce hydrazine with variable concentration of 100%,

80% & 65% w/w. Hydrazine is Raw material for most chemical blowing agents, polymerisation

initiators and pharmaceutical intermediates. Oxygen scavenger thereby protecting steam and

hot water systems. Hydrazine derivatives are used in the manufacture of herbicides,

fungicides and plant growth regulators.

Fig. 2.4: Structure of Hydrazine Hydrate (Secondary Source)

Firstly, Caustic being chlorinated by Chlorine solution to form 12.5% Hypo solution (NaOCl).

Then transfers this hypo in storage tank, followed by feed tank for next reaction stage to react

the Urea solution and Hypo solution in pipe reactor through heat exchanger to make Hydrazine

of 3.60-3.67. Then condensate and reflux this hydrazine to make it further higher

concentration, as required.




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Fig. 2.5: Flow diagram of Hydrazine Hydrate (Source: Proponent)

Reactions to form Hydrazine

Cl2 + NaOH NaOCl + HCl

NaOCl + CO(NH2)2 + 2 NaOH N2H4, H2O + Na2CO3 + NaCl

Waste Generation

The existing unit has no such trade effluent except effluent generated from Floor and hand

washing at work floor. The quantity of such waste water generation is 10 KLD, the same is

treated in ETP system within the premises and treated water reuse in gardening purpose after

meeting the prescribed limit. The detail reuse is described in Water Balance diagram (fig. 2.3).




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The total generation of semi-solid sludge from ETP system is around 90 kg per month, it is

further dried in Sludge bed and stored in HDPE drum in Hazardous waste storage area and

periodically handover to authorise TSDF provider. The fly ash & bottom ash generated from

Thermopack and boiler is around 1.5 MT/ month, the same is reuses with Fuel (pet coke). The

principle hazardous waste is used oil from DG sets & other mechanical equipment, the

generation quantity is about 20 litre/ month, which is stored in HDPE drum at HW storage area

and transferred to authorised oil recycler, periodically. There is no other hazardous waste

generation from process, as the unit follows stringent safety rules and production process runs

as per the SOP’s, so, chances of spillage is negligible, and if happed, immediate response

and cleaning taken place. Additionally, the existing unit has generation of 200 HDPE bags

daily, which are sold out to the authorise dealer. The unit also have 10 biodegradable domestic

waste, generating from kitchen process, which used as manure in gardening.

Stack Details

Following are the detail of chimney of existing 8 TPH Boiler & 3 nos. DG sets of 320KVA.

Boiler Chimney (8TPH)

• Height: - 35 m

• Top Dia: 1400 MM

• Bottom Dia: 2200 MM

• Pollution control device: 2 stage Alkali scrubbers

DG set’s Chimney

• Height: - 10.77m

• Pollution control device: DOCC

Process Emission

Stack of Hypo Preparation area

• Height: 10 m

• Pollution control device: Alkali scrubber

Stack at Hydrazine production area

• Height: 16.3 m

• Pollution control device: Wet Scrubber




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Table 2.4: Point source Emission test report of Boiler stack

S. No. PARAMETERS

PRESCRIBED

LIMIT

RESULTS

1. Suspended particulate

matter

(mg /NM3)

500 432

2. Nitrogen dioxide

(mg /NM3)

120 27

3. Sulphur dioxide

(mg /NM3)

120 105

2.6 PROPOSED PROJECT PROFILE

Proposed Layout

The proposed premises have almost 55,000.00 sq. meters of open and green field area. The

organisation has planned the layout as per the area available and the proposed requirement.

The proposed expansion project will require 3 additional production blocks, expanded ware

house, SRP Area, UG Tank, Expanded Cooling tower system, expanded Boiler, Utility,

Expanded ETP etc. The detail break-up of proposed layout is given below.

Table 2.5: Break-up of layout for the proposed expansion project

Sl. no. Area details Space required

(m²)

1 Production Area 1 2400.00



4 Ware House (RM & FP) 1800.00

5 Utility Area 1200.00

6 Boiler 1250.00

7 ETP 1200.00

8 SRP area 625.00

9 UG Tank area 2000.00

10 Administration, EHS Dept. & QC

Lab 800.00

11 Paved area (approach road) 10000.00

12 Green Belt 16000.00

13 Open area 15000.00




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As per the layout plan, 13,525.00 sq. meter area required for build-up area, almost 10,000.00

sq. meter area will be constructed as paved structure. Additionally, almost 16,000.00 sq.

meters of area has been allotted for green belt. After expansion process, there will be

requirement of 33% green belt out of total area occupied, thus, unit will initiate regular

plantation plan to convert almost 22,000.00 sq. meters of land into green cover in contrast of

16,000.00 sq. meter area identified for green cover in proposed layout plan, as the unit also

would have 15,000.00 sq. meters of open or free spaces within the premises to fulfil the

sustainable goal. Additionally, the unit will also be fortunate to take part in social forest

plantation under the Corporate Environmental Responsibility Plan.




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Fig. 2.6: Layout plan for Proposed project (for detailed view refer ‘Annexure-Site Plan’)




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After Expansion different area would be classified as follows:

Build-up area 27%

Paved area 20%

Shed area 8-10%

Open & Green belt 43%

Utility

Power Requirement

The unit will require 7278 KW of power to fulfil the requirement of power for proposed

production capacity and for other accessory department. The Unit has applied for expansion

of grid supply to PSPCL and the authority has agreed to supply the maximum 5150 KW of

power to the unit through the state grid. For additional requirement the unit has planned to

replace 2 nos. 320 KVA generator by 2 new 2000 KVA green DG sets. There will not any

additional area required for, as the unit already planned for it and allotted the space for twin

DG within the DG room at Utility area. The new DG sets will equip with Acoustic cover to

control the Noise and Diesel Oxidation Catalytic Converter (DOCC) for Emission control.

Fig. 2.7: DG sets Location in DG Room (Proponent)




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There will be requirement of additional transformer with capacity of 2500 kVA. The unit also

planned for a 3000-kVA steam turbine system for captive use. The electrical distribution from

Panel to different electrical line towards different unit are as follows:

Fig. 2.8: Flow diagram of Electrical system (source: Proponent)




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Fig. 2.9: HT-LT Panel Distribution system (Source: proponent)

Boiler

The proposed expansion will require 30 TPH steam into the process in place of existing 8 TPH

steam. Thus, unit has been planned to install a new 30 TPH Boiler with 3,000 kVA turbine to

utilise the excess steam and generate power for captive use. The proposed boiler will have a

capacity of 66 kg pressure.

Stack

• Height: 50 m

• Bottom Dia: 2.7 m

• Top Dia: 1.5 m

• Material of Construction: Mild Steel

• Other details: Stack will be provided with lightening arrestor /Aviation lamp/ sampling

port /Earthing Strip / operating platform / cage ladder.

Cooling Tower

According to the updated utility plan, 2 cooling towers will be installed for requirement of

Production unit with the capacity of 1750 TR for AO and 2000 TR for Hydrazine Hydrate/

Hydrazodicarbonamide production, respectively. One more cooling tower with a capacity of

1500 TR will be installed for Utility area requirement and the 3 towers will be replaced the

existing one with the capacity of 1600 TR.




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Chilled Water Tank

2 additional chilled water system/ plant to be installed with a capacity of 500 TR and will be

replace the previous one of capacity 100 TR.

Chilled Brine Plant

There will be requirement of 785 TR brine water after the proposed expansion. The unit has

planned to install 20 numbers of Chilled Brine plant with a capacity of 60 TR.

Thermic Fluid Heater

The requirement of heat generation will be same as 100000 Kcal as existing. Thus, the existing

Thermopack system will be provide the same heat to the production requirement.

Additionally, 1 100 cubic meter capacity Demineralisation Plant (DM Plant) and 400 cubic

meter Water softening with pre-treatment plant will be operate to facilitate the process

requirement.

Fuel

The expanded diesel generator system will require 900 litres of LSD hourly for 2-3 hours of

running time. Thus, 50KL of Diesel storage will be required for captive power generation. The

proposed 30 TPH boiler and Thermic fluid heater will utilize pet coke/ LDO as fuel.

Approximately 1000 MT per month fuel would require for the same facility operation.

Water

The unit will require 1290 cubic meters of water after proposed expansion. As per research

data came out, it shows that 450 cubic meters of effluent will be generate and same will be

treated in Effluent treatment plant and treated water will be reused in process as well as in

green belt development purpose. Thus, the unit had been sought for ground water extraction

permission for 840 cubic meter/ day from Central Ground water Board, Application for GW

extraction document is attached.

The unit not have any access of surface water source or any other water supply line. Thus,

only source of raw water is ground water resource. The unit already has a bore well system

with an extraction capacity of 40 cubic meter/ hour. To fulfil the requirement of 840 cubic meter

ground water unit has planned for installation of 1 more bore well with a same capacity, i.e. 5

HP powered submersible pump will extract 40 cubic meters of water with a time of 60 minutes.

The pump will operate for 12 hours in a day. The extracted ground water will be stored in

underground storage tank. The unit already has 2 150 cubic meter capacity tank, to store the




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extracted quantity of water, the unit will require 2 more storage tank with a capacity of 300

cubic meter each.

After storage of raw water, water will pass through Pre-treatment to minimise the solids

present in the raw water. Pre-treated water will transfer to different requirement. 15 cubic

meters of water will be transfer to overhead storage tank for domestic use. Same will be used

for drinking purpose, sanitation purpose and kitchen purpose. Water for sanitation use would

not require further treatment, but water for cooking and drinking purpose will further treated by

Reverse Osmosis unit, which will install at the places of requirement.

On the other hand, water for AO process will further treat by Demineralisation concept to

remove all the minerals present in water and transferred to the requirement unit. For

Demineralisation process DM plant of 100 cubic meter capacity has been planned. The other

part, water will be transferred to Softening plant to remove Calcium & Magnesium and

minimise chances of vessel thickening by hard water. The soft water will be used in Hydrazine

Hydrate manufacturing process as well as in Boiler for steam generation. The condensate

from the Hydrazine Hydrate manufacturing unit shall be recirculated towards the boiler

requirement.

The unit will also require maximum quantities of water into the Cooling tower system to provide

controlled lower temperature by passing the temperature downed water within the vessel

towards production unit. The proposed facility will require 3 nos. separate Cooling tower, 1

2000 TR capacity for Hydrazine Hydrate production unit, one 1750 TR Cooling tower for AO

system and another 1500 TR one for Utility area. 202 cubic meters of water requires in cooling

tower designated for Hydrazine Hydrate and 188 cubic meters of water requires for AO system

one. On the other hand, cooling tower for utility will require 45 cubic meters of water daily.

Water will require for Chilling plant shall be provided by recycled water from ETP after desired

treatment for pre-requisite of Chilling plant make-up as well as requirement of prescribed limit

of effluent parameters by CPCB. Requirement of Boiler make-up water, Fire Hydrant tank

make-up water and gardening purpose also be fulfilled by recycled water from ETP. Thus,

facilitating the Zero Liquid Discharge concept, the unit will fulfil their desired water requirement.




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Fig. 2.10: Water Balance for Proposed Expansion (Source: Proponent data)

The detailed water requirement break-up is given below for the expansion facility.

Table 2.6: Water requirement break-up for after expansion facility

Description of different facility

Water requirement

(M³/ day) Type of Water

Domestic 15

Raw water

AO Process 100

Hydrazine Hydrate Process 125

Cooling Tower for AO system 188

Cooling Tower for HH/HDC 202

Cooling tower for Utility area 45

Boiler 165

Total 840

Boiler 125 Condensate from HH




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Chilling Plant 295

Recycled water Boiler 130

Gardening 20

Fire Hydrant Tank make-up 5

Total 450

Grand Total 1290

During, Construction phase, water will be used in controlled manner, and the unit is equipped

with monitoring of water extraction from bore well by metering system. The unit officials will

closely supervise the activity of contract persons during construction phase, to ensure the

misuse of water resource. On the other hand, quantitative calculation of water use during

construction phase is very difficult to deal, as the entire construction facility will run in different

cluster within the premises by multiple contractor.

Raw Material

As per demand and resource analysis done by the organisation, cumulatively 14 products

have been suggested for potential production after proposed expansion of the unit. For

production of 14 products (details given in product sub column), it is identified that 68 raw

materials will be required, the detail list of raw materials with their quantity of requirement is

given below in table 2.7.

Table 2.7: Raw materials required for production after proposed expansion

S. No. Raw Materials Consumption Per Month (MT)

Existing Products Expanded Products

1 Triethyl amine 3.19

2 Acetic acid 57.90

3 2,6 DTBP 371.5

4 Methyl Acrylate 82.20

5 Methanol 584.00

6 Xylene 245.00

7 Phosphorous Trichloride 9.58

8 Pentaerythritol 33.60

9 Caustic Soda Flakes 3.50

10 Potassium Hydroxide 1.50

11 Dibutyl amine 0.40




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12 Hydrazine Hydrate (100%) 324.00

13 Thioglycolate 12.60

14 Para-formaldehyde 131.60

15 Soda Ash 0.23

16 Diethyl amine 5.00

17 Methylene Di Chloride 383.20

18 Mesitylene 30.70

19 Toluene 64.00

20 Sulphuric Acid 205.0

35 HCl (30%) 1044.00

36 Ammonia soln. (20%) 45.29

37 D-Sorbitol 44.21

38 PTSA 19.89

39 Hexane 145.84

40 PEG 600 18.69

41 DMBC 150.40

42 Hexamine 296.00

43 Tec-07 0.36

44 K-68 0.19

45 Iso octyl alcohol 9.50

46 DBTA 0.01

47 Activated Carbon 0.33

48 Diphenyl amine 28.85

49 Anh. Aluminium chloride 5.20

50 Di-isobutylene 26.55

51 Cyclohexane 11.00

52 Bleaching Clay 10.55

53 Isotridecyl Alcohol 4.60

54 Thioglycolic acid (80%) 2.82

55 Formaldehyde soln. (37-38%) 3.27

56 2,4 DCP 21.56

57 TBAB 0.43

58 Diphenyl salicylate 3.00

59 3,4 ATRZ 0.52

60 Phenol 10.54

61 Caustic Lye (47.5%) 1858.00 4986.00

62 Urea(%w/w) 317.00 1718.00

63 Chlorine 358.00 960.00

64 Sodium Bicarbonate 0.48

65 Hydrobromic Acid (48%) 437.00

66 Hydrogen Peroxide (50%) 1478.00

67 Dimethyl Adipate 49.73




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68 EDTA 0.13

Fig. 2.11: Different storage locations for Raw materials (Source: Layout Plan)

After Proposed expansion there will be different storage area for solid and aqueous raw

materials. Isolated storage shed will be provided for Hazardous materials, especially for

Chlorine and Ammonia solution. All the storage locations are identified by red circular marks

in figure 2.11.




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Products and proposed process

There will 12 new product and 1 previous product, i.e. Hydrazine Hydrate with expanded

capacity be produce after proposed expansion.

The products are namely, Kinox 30, 10, 28, Hiclear 301, 3,4 Dimethyl benzaldehyde (3,4

DMB), Lube Antioxidants (Kinox 135L, 57L, 18L, Kinox DA), Hydrazodicarbonamide (HDC),

Azodicarbonamide (ADC), Adipic dihydrazide (ADH) and Hydrazine Hydrate (HH). The details

with chemical name, quantity and CAS number is provided below in table 2.8.

Table 2.8: Products after expansion with capacity

Sl.

No.

Product CAS No. Existing

Capacity/

Month

Proposed

capacity/

Month

1. 1,3,5-Trimethyl-2,4,6-tris (3,5-di-tert-butyl- 4-hydroxybenzyl) benzene

[Kinox-30]

1709-70-2 170MT

2. Pentaerythrityl tetrakis [3-(3,5-di-tert. butyl-4- hydroxyphenyl) propionate]

[Kinox-10)

6683-19-8 -- 220 MT

3. 1,3:2,4 Bis (3,4-dimethylbenzylidene) sorbitol [HC-301]

135861-56-2

-- 80 MT

4. 3,4 Dimethyl Benzaldehyde

[3,4 DMB]

5973-71-7 90 MT

5. Lube Antioxidants

5.1. Benzene propanoic acid, 3,5-

bis (1,1-dimethyl-ethyl)-4-

hydroxy-C7-C9 branched

alkyl esters

[Kinox-135L]

125643-61-0 15 MT

5.2 Butylated/ octylated diphenylamine [Kinox-57L]

68411-46-1 50 MT

5.3 Acetic acid, [[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl] methyl] thio]-C10-14 isoalkyl ester [Kinox-18L]

118832-72-7 10 MT

5.4 Bis (2,4-dicumylphenyl) pentaerythritol diphosphite

154862-43-8

25 MT




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[Kinox-28]

5.5 3-Salicyloylamino-1,2-4-triazole [Kinox-DA]

36411-52-6 5 MT

6. Hydrazine 7803-57-8 110 MT 295MT

7. Hydrazodicarbonamide [HDC]

110-21-4 645MT

8. Azodicarbonamide[ADC] 123-77-3 600MT

9. Adipic dihydrazide [ADH] 1071-93-8 48MT

• K30, K-10 & K-28

These are specialty grades of product category – Antioxidants, which are added to specific

synthetic polymers to retard oxidative degradation processes so that their physical properties

are retained and to ensure adequate life time.

Polyolefin account for roughly 60% of global demand for polymers. Polyolefin is a collective

name for hydrocarbon polymers including polyethylene. These are two of the widely used

polymers and account for more than half the total plastics world consumption, due to their low

cost and excellent versatile properties including strength, flexibility, lightness and easy

process ability. Antioxidants are used in polyolefin both for processing and long stability of

finished goods.

Global demand for polyolefin is very large. From a small base of 24 MMT (Million Metric Tons)

in 1983, it had reached 132 MMT in 2013 and currently expected to grow @ 6-7% per annum.

Faster growth albeit on a small demand base is taking place in India as well. India produced

7.3 MMT in 2013. Demand is growing @more than 10% per annum but very large

manufacturing capacity is coming alive in India in next one year or so i.e. OPAL at Dahej,

GAIL in Assam, MRPL in Mangalore and IOCL in Paradip.

HPL is the only Indian manufacturer of Antioxidants and is primed to take advantage of

domestic market growth.

• K-30- Stabilizers for Polypropylene film and tape application which require low water

carry over.

• K-10- is a long-term stabilizer for Polyolefin, Olefinic copolymer, Polyacetal, Polyamide

and synthetic adhesive.




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These two grades of Antioxidants are mainstay of given product category and well accepted

in market. With near optimum capacity utilization and increasing demand for our product, it is

but natural to expand manufacturing capacity to retail market base and remain relevant.

K-28-Is a specialized secondary antioxidant especially for water pipes. Due to low migration

of this antioxidant it is considered a better product than K-68 which we produce at Dudhola

plant.

Fig. 2.12: Process flow chart of Kinox-10




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Fig. 2.13: Process Flow chart for Kinox-10 Sludge Methanolysis

Table 2.9: Equipment list of Kinox-10

Kinox-30 will prepare in two steps.

2,6-DTBP to MMP: 2,6-DTBP (2,6-Di-tert-butyl phenol) will convert to MMP by reacting with

paraformaldehyde & methanol in presence of dual amine catalyst.

MMP to Kinox-30: MMP will react with mesitylene within MDC in presence of sulfuric acid

catalyst. MDC will distil out after reaction and product will isolate in methanol.




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Fig. 2.14: Process flow chart for Kinox-30




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Table 2.10: Equipment List of Kinox-30 (enclosed as Annexure)

K-28

Pentaerythritol will react with phosphorus trichloride in toluene in presence of TBAB catalyst

at 40-50oC to produce dichloro intermediate of Pentaerythritol. The produced intermediate will

react with 2,4-dicumyl phenol in toluene in presence of TBAB catalyst under reflux and

resulting mass will dilute by methanol to recover pure kinox-28.

Phosphorus trichloride will be being dropped in mix of Pentaerythritol, TBAB & toluene at 40-

50oC and will be allowed to react at 60-70oC for 4-8 hrs followed by solvent distillation to store

under inert atmosphere for next step.

The intermediate will be being dropped into the mix of 2,4-dicumyl phenol, TBAB & toluene

and will be allowed to react at reflux. After reaction completion monitoring on HPLC, excess




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solvent will be vacuum distilled and dilute with methanol to recover the precipitated product

and dry at 70-80oC to produce white crystalline free flow material with high purity (>99%) and

yield (>90%).

2.15: Process Flow chart of Kinox-28

Table 2.11: Equipment list of Kinox-28

S. No. Equipment MOC Capacity Quantity

1 Reactor 1 MSGL 5.0 Kl 1

2 Reactor 2 MSGL 12.0 Kl 1

3 Receiver MSGL 1.0 Kl 1

4 Condenser Graphite 1

5 Scrubber with tank and pumps Graphite Suitable size 1

6 Day tank for reaction 1 Mix MSGL 5.0 Kl 1

7 Receiver for Acidic Toluene MSGL 5.0 Kl 1

8 Receiver for Basic Toluene SS 3.0 Kl 1




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9 Condenser Graphite Large size 1

10 Receiver for MeOH SS 2.0 Kl 1

11 Steam jet Ejector Graphite 3 stage 1

12 Crystalliser SS 10 Kl 1

13 ANF SS 1

14 RVD SS 1

15 SR for Toluene with washing arrangement 1

16 SR for Methanol 1

17 UG tanks for toluene 10 Kl 2

18 UG tanks for MeOH filtrate and distillate 20 Kl 2

HC-301

It is a clarifying agent to remove all impurities from polyolefin material to impart clarity and

remove impurities. The product has been developed by company’s R&D division and tested

extensively to fine tune/optimize process. Clarifying agents are complementary to our existing

product basket, targeted at same customer base. Existing marketing and distribution channels

would be used to market this product.

This is a single step condensation reaction between D-Sorbitol and 3,4-Dimethyl-

benzaldehyde at 35-40°C in presence of PTSA catalyst and Methanol and Hexane binary

mixture solvents for reaction.

Mix of D-sorbitol, PTSA and Methanol will react at 40oC for 8-12 hrs. After reaction completion,

product will neutralize with sodium hydroxide and filter on CNF to produce crude HC-301.

Product will purify in water to produce white crystalline product with high purity and yield.

Table 2.12: Equipment List of HC-301




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Fig. 2.16: Process flow chart of Hiclear-301

3,4-Dimethyl benzaldehyde

This is a two-step process for the preparation of 3,4-DMB. O-Xylene in excess will react with

30% HCl in presence of acetic acid and catalyst PTSA. After workup and neutralization of

organic product it will subjecting to next step reaction with hexamine in presence of acetic acid

and water. After reaction completion, organic product will be separated, washed and pH

neutralled with ammonia to recover crude product. Crude product is subjecting to fraction high

distillation to recover pure product.




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Fig. 2.17: Process flow chart of 3,4-DMB

Kinox range of lube antioxidants: K-135L/K057L/K018L

These products find their use as lube antioxidants for preventing thermal decay of oils and

lubricants over extended use. These are new products of HPLA and are a step towards

diversification. HPLA believes once it sets its foothold into this market newer opportunities

shall unfold for HPLA for future expansion.




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Kinox-135L

The manufacture of kinox-135 involves reaction of KIN-HPI – prepared in-house – with excess

alcohol (predominantly isooctylalcohol) in presence of dibutyltin oxide catalyst at high

temperature. After reaction, excess alcohol is recovered under reduced pressure.

Kin-HPI is reacts with isooctylalcohol in presence of DBTO at 160-180oC. After reaction

completion, excess alcohol is vacuum distilled and organic mass is collect and filter through

hyflo to get pure product with good yield and quality.

Fig. 2.18: Process flow chart of Kinox-135L




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Table 2.13: Equipment list of Kinox-135L

Kinox-57L

The manufacture of kinox-57L is a one-step reaction i.e. Alkylation of Diphenyl amine (DPA)

with Di-isobutylene (DIB) in presence of Aluminium trichloride (Anhydrous.) catalyst to give

Kinox-57L product.

DPA will react with DIB in presence of aluminium chloride at high temp 160-180oC. After

reaction completion, organic mass will be diluted with hexanes and neutralized with ammonia

and filtered to remove the salt. Solvent will be removed from the filtrate and organic mass will

be treated with clay inorganic material to remove the colour of the product. Clay will remove

by filtration and solvent will remove by distillation and pure product will be obtained as light

yellow viscous liquid by passing the material from micron filter.




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S. No.

TAG No. PROCESS DESCRIPTION CAPACITY MOC QTY.

A.) REACTORS

1 R-1 Glass Lined Reactor with PTFE or Glass lined Hopper for Reaction

2.5 KL GLR 1

2 R-2 Glass Lined Reactor for Work Up 4.0KL GLR 1

3 R-3 Stainless Steel for Reactor 2.0KL SS-316 1

B.) SURFACE CONDENSORS

4 PSC-1 Primary Condenser for R-1 5mtr² Graphite 1

5 SSC-1 Secondary Condenser for R-2 1 mtr² Graphite 1

C.) VESSELS/DAY TANK OR RECIEVER /TANK

6 V-1 Agitated Jacketed Vessel for Diphenylamine Melting

0.75KL SS-316 1

7 T-1 Cyclohexane Solvent Storage Tank (F) 5.0KL SS-316 1

8 T-2 Cyclohexane Solvent Storage Tank (R) 5.0KL SS 316 1




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9 V-1 DI-Isobutylene Charging Vessel 1.0KL SS 316 1

10 V-2 25% AQ. Liquid Ammonia Solution 0.2KL SS 316 1

11 MHT-1 Final ML Holding Tank 4.0KL SS 316 1

12 REC-1 Distillation Pre-Cut Receiver 0.2KL SS 316 1

13 REC-2 Recovered Cyclohexane Receiver 3.0KL SS 316 1

D.) FILTERS

14 F-1 Nutsche Filter 1.25KL SS 316 1

15 F-2 Leaf Filter 50mtr² SS 316 1

E.) FILTERS

PACKED COLUMN FOR CYCLOHEXANE DISTILLATION

16 PDC-1 Distillation Column with Complete Internals

Ht x Dia with Melapack Packing

SS-316 1

F.) DEDICATED COMPLETE SCRUBBER SYSTEM @ RXN STAGE

17 SCS-1 FRP Scrubber System, Lye Circulation Pump, Blower, Random Packing, Pipeline

Ѳ 850mm &6Mtr Packed

Ht FRP 1

Kinox-18L

The manufacture of kinox-18 comprises of two steps. In the first Esterification step,

isotridecylalcohol will react with thioglycolic acid in presence of sulfuric acid catalyst to give

thioglycolate.

The intermediate thioglycolate in the second step reacts with mannich base in-situ condition

reaction of 2,6-ditertbutylphenol and formaldehyde, to give Kinox-18.




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S. No.

TAG No.

PROCESS DESCRIPTION CAPACITY MOC QTY.

A.) REACTORS

1 R-1 Glass Lined Reactor for "THIOGLYCOLATE" Preparation with

3.0KL GLR 1

2 R-2 Glass Lined Reactor for REACTION 3.0KL SS-316 1

3 R-3 Stainless Steel Reactor for A/L & O/L Layer Separation & Recovery

4.0KL SS-316 1

B.) SURFACE CONDENSORS

4 PSC-1 Primary Condenser for R-1 2mtr² Graphite 1.2

5 SSC-1 Secondary Condenser for R-1 1.5 mtr² Graphite 0.95

6 PSC-3 Primary Condenser for R-3 2mtr² SSR 1

7 SSC-3 Secondary Condenser for R-3 1.5 mtr² SSR 1

C.) VESSELS/DAY TANK/ RECIEVER /TANK or Via Pipeline




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8 RV-1 Water Recovery Vessel @ "THIOGLYCOLATE" formation stage

100Ltrs or 0.1KL

SS-316 1

9 DT-1 Toluene (F) Day TANK for "THIOGLYCOLATE" formation & Reaction

4.0KL SS-316 1

10 GLP-1 Glass Lined Pot for Sulfuric Acid 5Lts GLR 1

11 CR-1 Charging Receiver for Isotridecylalchol 1.0KL SS 316 1

12 X Thioglycolic Acid Addition 0 0 0

13 CV-1 Charging Vessel of 32% HCHO 500Ltrs SS-316 1

14 DT-2 32% HCHO Day TANK 2.0KL SS-316 1

15 DT-3 RAW WATER Day Tank 2.0KL SS-316 1

16 CV-2 Charging Vessel of DEA (Dimethylamine) 100Ltrs SS-316 1

17 CV-3 Charging Vessel of TEA (Triethylamine) 50Ltrs SS-316 1

18 RR-1 Toluene Recovery Receiver 1KL SS-316 1

19 ALT-1 Aqueous Layer Tank 1.5KL SS-316 1

20 PL-1 2,6 DTDP 0 0 0

D.) FILTERS

21 F-1 Nutsche Filter 1.25KL SS 316 1

KINOX-DA

Charged Phenyl salicylate (RM/162) will be used in dry reactor and heat to 45-50 0C to make

clear solution. Then charge 3-ATRZ (RM/164) with help of vacuum (250 mmHg) charge

Phenol (RM/163). Heat the reaction mass to 100-110 0C. Again, apply vacuum (250 mmHg)

and increase temp.135-1400C to recover low boiler. Break the vacuum and raise the reaction

mass temperature to 180-1850C and maintained for 6 h. Then cool the reaction mass to 95-

100 0C and charge methanol (RM/108) in reactor. Now transfer the whole mass to crystallizer

and cool to 28-30 0C followed by filtration in centrifuge. Wash the slurry with methanol

(RM/108) again and collect the filtrate in storage tank. Test the solid sample in QC (%T 95.0

min.) and then dry the wet cake in dryer at temp. 60-65 0C for 1-1.5 h till %LOD < 0.10.

Pulverized the material as per particle size desired.




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Fig. 2.21: Process flow chart of Kinox-DA

Table 2.16: Equipment list of Kinox-DA

S. No.

EQUIPMENT DETAIL MOC CAPACITY QTY.

1 Reactor with Suitable Condenser (Main + Guard)

Suitable with Phenol

6 KL 1

2 Day Tank for Methanol SS316 2 KL 1

3 Hopper for Solid RMs Charging SS316 1

4 Hot Oil Cooler 1

5 Crystallizer with Suitable Condenser (Main + Guard)

Suitable with Phenol

6 Vacuum Pump SS316 650 mm Hg 1

7 ANF 9 M2 1

8 Centrifuge




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9 Filtrate Tank 2 KL 1

10 RVD SS316 9 M3 1

11 Receiver with Condenser SS316 1 KL 1

12 2 stage steam ejectors SS316 10 torr 1

13 Hot water Tank with Pump 10 KL 1

14 Pulveriser SS316 1

15 Storage Tank for Methanol with Pump

SS316

UG Tanks as Defined in

Solvent Storage Area

Drawing

1

16 Storage Tank for Filtrate with Pump 1

17 Solvent Recovery for Methanol (Having Phenol)

1

18 Storage Tank for Distilled Methanol with Pump

1

19 Storage Tank for Residue Collection (For Distillation of Phenol)

10 KL 1

20 Phenol Recovery System with Suitable Column and Condenser

21 Storage Tank (Jacketed) for Distilled Phenol with Pump

Hydrazine Hydrate by continuous process

Current production process of Hydrazine Hydrate (HH) is based on batch production, wherein

4% Hydrazine is produced by reaction of Sodium hypochlorite with technical Urea followed by

treatment with caustic flakes. This process requires physical addition of solid caustic soda

flakes in a tank which is laboursome and prone to manual handling hazard due to labour

intervention.

HPL Additives Limited has now developed a new continuous process for the production of

intermediate HDC directly through in-situ manufacturing of dilute Hydrazine solution, wherein

caustic soda lye will be used and there will be no requirement of solid caustic flakes and the

process will involve mechanical handling, thus, it will safer to handling.




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This continuous process for the production of HDC offers the potential to increased efficiencies

and consistent product quality, on the other hand the process will also reduce the

manufacturing costs and run in more environmentally viable manner. With continuous

operation and ongoing inline analysis, process parameters are more closely will be monitored

and maintained at optimal values, leading to more consistent processes and product quality,

which in turn will reduce waste generation, product losses and downtime.

Hydrazodicarbonamide (HDC) – ADC Intermediate

Preparation of reaction solution: Hydrazine hydrate will neutralize with Sulphuric acid to

make Hydrazine sulphate. Urea will be hydrated in water to prepare aqueous urea solution in

70 degrees Celsius. After completion of solid urea addition, the temperature will be raised to

80 degrees Celsius to make the solution more homogeneous by dissolving urea properly.

Process: The first process will be neutralization of Hydrazine hydrate in presence of urea with

the boiling reactor. By raising the temperature with the help of controlled steam flow, ammonia

will be liberated during reaction process and the same will recover by Ammonia recovery

system having columns, condensers, PHE and Ammonia circulation system.

HDC Washing: There will be requirement of washing of produced HDC, and it will take place

by transfer of HDC slurry from boiling reactor to washing reactor. The detail washing process

is given in flow diagram.




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Fig. 2.22: HDC Process flow chart

Fig 2.23: HDC washing process flow chart




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Table 2.17: Equipment list of HDC process

Azodicarbonamide (ADC)

ADC is a chemical blowing agent which is produced at one of the plants of HPL Additives and

is made from Hydrazine Hydrate and Technical Urea through HDC production which is an

intermediate. ADC capacities are limited to the extent of HDC availability/capacities which in

turn is dependent on Hydrazine availability. HPL Additives currently producing Hydrazine

Hydrate at its Derabassi plant, but capacities are much lower than requirements. Keeping in

mind the increasing demand of ADC in international as well as in domestic market, HPL plans

to expand ADC capacities. To meet Hydrazine/HDC requirements HPL is taking up HDC and

ADC manufacturing (in-situ production of HDC) plans at Derabassi site which shall enable it

to meet additional ADC requirements.




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Fig. 2.24: ADC Process flow chart

Adipic Dihydrazide (ADH)

It is Curing agent for epoxy heat curable resins, suitable for encapsulating electronic

components Chain extender and cross-linking agent. It is also used as Stabiliser for fibre grade

synthetic resin. ADH is a symmetrical molecule with a C4 backbone and the reactive group is

C=ONHNH2. Dihydrazide are made by the reaction of an organic acid with hydrazine.

Fig. 2.25: Characteristic detail of ADH




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2.26: Process flow chart of ADH

Table 2.18: Equipment list of ADH Process

Equipment MOC Capacity Quantity (Nos.)

Remarks

Process

Reactor SS-304 8KL 1 New

Primary condenser

SS-316 1 New

Secondary condenser

SS-316 1 New

Vent condenser SS-316 1 New

Crystallizer SS-304 8KL 1 New

ANF SS-304 1

CFM (Top discharge)

48” 1 No.

RVD SS-304 9 KL 1 No. New

Day Tank SS-304 1.5KL 2 Nos. [1No.- DMA 1No.- HH]

New

Hot water jacketed tank

3KL 1 No. (for DMA)

New

Filtrated tank (non-jacketed)

5 KL 1 No New




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(for filtrate recycling)

Pump with flame-proof motor) (for filtrate recycling)

8 Nos. New

Drum Pump 1 No. New

Table 2.18a: Equipment list for solvent recovery system of ADH

Equipment MOC Capacity Quantity (Nos.)

Remarks

Solvent Recovery Plant

Neutsch Filter SS-304 1 New

Packed Column SS-316 1 New

Reboiler for distillation

1 New

Primary Condenser

SS-316 1 New

Secondary Condenser

SS-316 1 New

Product Receiver SS-304 10 KL 2 New

Reflux Drum SS-304 1 New

Process Pump SS-316 4 New

2.7 WASTE GENERATION

Aqueous waste

The unit will generate approximately 450 cubic meters of waste water after proposed

expansion of chemical processing unit. The production process of various product will

generate almost 310 cubic meters of aqueous waste and domestic facility shall generate 10

cubic meters of grey water and other domestic waste water.

There will be 6 major waste water generation facility from various production unit, viz. Kinox-

30, Kinox-18, HDC, ADC, Solvent recovery, Vacuum System. The other facility namely Kinox-

10, Hiclear-301, 3,4-DMB, Kinox-135L, Hydrazine will not generate any waste water from

production process. Floor washing waste will also being transferred to ETP facility.

Table 2.19: Trade effluent quantity from Expansion products

S.NO. Product Name Production (Mt)

Aqueous waste

Generation (Kg/MT)

Total Aqueous waste

Generation (Kl)/day

1 Kinox-30 170 1390.6 7.9




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2 Kinox-18 10 2253 0.8

3 HDC 645 1000 21.5

4 ADC 600 5000 100.0

5 Solvent Recovery 250 6500 54.2

6 Effluent Generated Through Vacuum System 125

Total Trade effluent to ETP /day 309.3

The unit will have accompanied with 2 large toilet facilities near the production area, with

latrine and washroom facility for separate male & female usage and there will be one more

toilet & washroom facility at administrative building, which is already is in place. There will be

generation of waste from RO reject in drinking water facility and from kitchen wash basin. All

the waste water from these facilities shall be transferred to Septic tank through sewage

pipeline and overflow of the same will be transferred to Biological treatment tank of the ETP

to provide nutrient for microorganisms of the ETP and the same waste water will also be

treated with effluent to recycle the waste within the premises. The detailed waste water

treatment scheme is provided in EMP (chapter 8).

There will be almost 120 cubic meters of waste generation from various utility facility. The 30

TPH boiler will generate 45 kilo litters of waste water due to blow down. The softening system

and other filtration facility in pre-treatment of raw water will generate 60 kilo litters of backwash

water, Demineralisation system and cooling facility will generate 15 kilo litters of waste water

in a day. The total generated waste water will be transferred to ETP system and treated

according the requirement.

Table: 2.20: Waste water generation form Utility

Sl. No.

Facility name Quantity of Liquid waste generation

(m3/day)

1 Boiler (blow down water) 45.00

2 Backwash water from DM Plant & pre-treatment facility

60.00

3 Demineralisation system & Cooling System 15.00




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The quality of influent are as follows:

Table: 2.21: Influent quality

Sl. No. Source of Influent Quality of influent in (ppm)

COD BOD pH TDS

1 Kinox-30 11000-12000

3000-3500 8-8.5

2 Kinox-18 25000-30000

6000-7000 9

3 HDC 7000-8000 1400-1500 6-7

4 ADC 10000-12000

2500-3000 2

5 Solvent Recovery 500-600 180-200 7-8

6 Effluent Generated

Through Vacuum System 37000-38000

12000-13000

7-8

7 Influent from Utility 4000-4500 1000-1200 6-7 4000-5000

8 Domestic Waste

(RO Reject) 0 0 7-8 1200

9 Domestic Waste

(Sewage) 200 450-600 7-8 1000

The total influent shall be treated in Effluent Treatment plant. As per plan, there would be 2

ETP facility to achieve the reuse requirement, the total area allotted for the ETP is about 1200

square meter. The waste from domestic use shall be transferred to Septic tank through

sewage line, and overflow shall be forwarded to the ETP facility. The treated effluent shall be

recycled in various use, 295 cubic meters of recycled water shall be used in chilling system

and 130 cubic meters of water in boiler make-up respectively. The effluent shall be treated as

per the norm prescribed by CPCB and as requirement of unit itself. The make-up water for

Chilling system and Boiler shall be treat further with softening and filtration facility to achieve

soft water with very less solid contains, pre-requisite for the same facility. The balance

recycled water shall be used for gardening purpose and make-up for Fire Hydrant tank.

Solid Waste

After the proposed expansion of production facility, the same would generate Denatured

carbonate, chloride-based salt as by-product from continuous hydrazine hydrate production

process. There shall be generation of 3098 Metric Tonnes/ month of salt after expansion

process, the entire volume of salt shall be sell out to the detergent industry.




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The process will also generate sludge from Methanolysis, Kinox-30, HPI process. Total 110

Metric Tonnes/ month of hazardous natured solid waste shall be stored in Hazardous waste

storage area and transferred to M/s. Nimbua Greenfield Punjab Limited periodically, as the

organisation is tied up recycling contract with the same authorised TSDF agency.

The estimated sludge generation from Effluent Treatment shall be 10 metric tonnes/ month.

The same will be stored in HDPE bags/ drums and transferred to M/s. Nimbua Greenfield

Punjab Limited periodically. The Fly ash and bottom ash shall be generated with the tune of 5

metric tonnes/ month, as the pet coke contains 0.5% of ash. The generated ash shall be mixed

with fresh pet coke and reused as fuel for boiler & thermic fluid heater. Total quantity of

Domestic (biodegradable) waste would be 1.5 MT, the same will be prepare for compost and

used as manure in gardening within the unit premises. The unit will also generate 150 kg/

month paper waste from office use, same will be sell out to scraper.

Drums and bags will also be generated after using raw materials within the process. The

drums and bags also be reused for storage of waste & Hazardous waste, the excess materials

will be sell out to authorised dealer of HDPE/ MS materials. The quantity of generation of this

type of scrap is as follows:

MS Drum 96 nos./ day

HDPE Drum 18 nos./ day

Jar /Can 20 nos./ day

HDPE bags 200nos./ day

Paper bags 45 nos./ day

Hazardous Waste

After proposed expansion of chemical processing unit, the generation of hazardous waste

would comprise of multiple types, viz. Spent oil, oil residue, ash, process sludge, ETP sludge,

Discarded chemicals from QC etc.

The various production process would involve generation of process chemical/ solvent waste.

Oil recovery/ distillation process would recover the solvent/ chemicals with maximum extent

and same will be recycled to the process. After distillation/ solvent recovery process, residue

would generate with a tune of 9 metric tonnes per month, same will be stored in HDPE Drum

at Hazardous waste storage room and transferred to M/s. Nimbua Greenfield Punjab Limited

periodically. Additionally, the process shall generate 110 MT/ month of process sludge, which




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will further treat in Incinerator and residue will be stored and transferred to authorised TSDF

agency. The ETP process will also generate the hazardous sludge, the dried 10 metric tonnes/

month of sludge shall be stored within HDPE drum/ bags at Haz. Storage room. The fly ash

and bottom ash shall be mixed and recycled with fuel of Boiler/ Thermic fluid heater. There

also be generation of spent/ used oil from DG sets, motors and gear boxes, the estimated 500

Ltr/ month of used oil shall be stored in HDPE drum and transferred to authorised oil recycler

in regular interval. The discarded/ expired chemicals of Quality Control lab shall be disposed

off at Hazardous waste storage room in HDPE Drum, the discarded chemical drums shall be

labelled properly for identification and stored away from any flammable items. The unit will run

according the MSIHC rules, 2000 and amendment thereafter, also, the unit is accredited with

BS OHSAS 18001: 2007, so unit will manage their entire facility as per their Health & safety

Management policy.

2.8 TRANSPORTATION

The raw materials shall be exported from Delhi, Gujrat, Mumbai and mode of transportation

shall only be heavy vehicular by roadways. The finish products shall be transported through

truck facility to Gujarat, Allahabad, Mirzapur, Mumbai, Hyderabad as well as exported outside

the country by ship transport. The nearest port from the unit is in Gujarat.

2.9 HUMAN RESOURCE

The proposed expansion will require huge numbers of unskilled and semi-skilled labour during

construction time. The Construction activity shall be run by contract organisation with

supervision of unit officials. The contracted labours shall be resourced from local habitation

only, thus, it will be potential job generating project. During Production process, activity shall

demand highly skilled professional, which will be resourced by competency basis and semi-

skilled, trained industrial human resource shall be sourced from locality as well as from other

area also. According to the estimation, there will be requirement of 329 numbers of Semi-

skilled as well as highly skilled human resource. The detailed estimated human resource

requirement during production phase is given below:




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Table 2.22: Human Resource Requirement

Kinox-10 Kinox-30 HC-301 /DMB

Other Streams

Proposed Proposed Proposed

Production (Mt)/month 220 170 170

Reaction floor

Supervisor 3 4 3

Operator 10 12 6

Casual worker 6 12 6

Crystallisation and Filtration Floor

Supervisor 4

Operator 3 7 4

Drying Floor

Supervisor 0

Operator 4

Casual worker 15

Common Facility

Supervisor 1

Casual worker 6

Post Dryer operation

Supervisor 3

Operator and workers 30

Total 22 98 19 190

2.10 PROJECT COST & COMPLITION

The proposed project will cost tentatively around 231 crores. The value is based on tentative

estimation, thus ±10% variation in actual expense might be possible. The valuation was

certified by Chartered Accountant only. The proposed project would require one and half years

to construct the desired facility with equipment installation after getting the Environment

Clearance and other consent from concerned government departments. The detail break-up

of project cost is given below:




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Table 2.23: Project Cost




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Chapter 3

Description of the

Environment




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Chapter 3

Description of the Environment

3.1 INTRODUCTION

A description about the existing environment resources, including physical and ecological

resources, economic development of the region and social and cultural resources are

presented in this section. Broad aspects on various environmental parameters (geology, soil,

topography, climate, land use, water resources, water quality, air quality, noise quality, tourism

and cultural resources) which are likely to be affected (direct or indirect) by the proposed

Expansion of Chemical processing unit project of HPL Additives Limited at Bhagwanpur,

Derabassi are covered within this chapter and next chapter of Impact Assessment. The

environmental parameters as per TOR issued by the EAC, MOEFCC dated 26th October, 2017

was collected and analysed as a part of environmental impact assessment report. The

monitoring also follows the guidelines of “Technical EIA Guidance Manual for Synthetic

Organic Chemical Industry” by the Ministry of Environment, Forests and Climate Change,

Govt. of India. The extent of study was 10 Km with circular impact area in respect to proposed

project in centre locus.

The Environmental Monitoring was carried out by the Environment Team of M/s ITL Labs

Private Limited of Mangolpuri Industrial Area, Phase I, New Delhi, a MOEFCC accredited

laboratory for conducting Baseline Monitoring of the project for the purpose of EIA, for the

proposed project of “Expansion of Chemical processing unit project of HPL Additives Limited

at Bhagwanpur, Derabassi”. The Laboratory is also accredited by NABL, and IMS, ISO

9001:2008 for Hazardous Chemical Usage and Quality assurance.

Sahibzada Ajit Singh Nagar

Sahibzada Ajit Singh Nagar District has been carved out of areas falling in Ropar and Patiala

district as 18th District of Punjab on 14th April 2006. Because of its contiguous with the union

territory of Chandigarh. The district includes Mohali, Kharar and Derabassi Tehsils. It is located

in the north east part of Punjab. and is part of Patiala division. The District includes 383 villages

including 9 villages are un inhabited. The important township in the district are Kharar, Kurali,

Mohali, Zirakpur & Derabassi. The district is spread over geographical area of 1092.64 sq.

kms. The rural area constitutes 1021.77 sq.kms. as compared to urban area of 70.87 sq.kms.




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Derabassi block consists of 102 villages out of which there are 3 un-inhabited villages. As per

2011 census, the total population of the block is 130246 out of which 69869 are males and

60377 are females. This block is having total area of 26596 hectare with a good number of

small scale units. Chemical paints, Steel tubes, plywood, handlooms are some of the

industries which have coffered good employment to a number of persons. The proposed

project lies within the Derabassi block.

Fig. 3.1: Proposed Project site in SAS Nagar District map (source: Punjab Police.gov.in)

Proposed

Project Site




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3.2 CLIMATE & RAINFALL

Derabassi has humid subtropical climate (Köppen: Cwa) characterised by a seasonal rhythm:

very hot summers, mild winters, unreliable rainfall and great variation in temperature (−1 °C

to 46 °C OR 30.2 °F to 114 °F). The average annual rainfall is 1110.7 mm. The city also

receives occasional winter rains from the Western Disturbance originating over

the Mediterranean Sea.

The western disturbances usually bring rain predominantly from mid-December till end of April

which can be heavier sometimes with strong winds and hails if the weather turns colder (during

March–April months) which usually proves disastrous to the crops. Cold winds usually tend to

come from the north near Shimla, capital of Himachal Pradesh and from the state of Jammu

and Kashmir, both of which receive their share of snowfall during wintertime.

The area experiences the following seasons and the respective average temperatures:

• Spring: The climate remains the most enjoyable part of the year during the spring

season (from February-end to early-April). Temperatures vary between (max) 13 °C to

20 °C and (min) 5 °C to 12 °C.

• Autumn: In autumn (from September-end to mid-November.), the temperature may rise

to a maximum of 30 °C. Temperatures usually remain between 10° to 22° in autumn.

The minimum temperature is around 6 °C.

• Summer: The temperature in summer (from Mid-April to June-end) may rise to 44 °C.

The temperatures might sometime rise to 44 °C in mid-June. Temperatures generally

vary between 40 and 42 °C.

• Monsoon: During monsoon (from early-July to mid-September), Derabassi receives

moderate to heavy rainfall and sometimes heavy to very heavy rainfall (generally during

the month of August or September). Usually, the rain bearing monsoon winds blow from

south-west/south-east. Mostly, the city receives heavy rain from south (which is mainly

a persistent rain) but it generally receives most of its rain during monsoon either from

North-west or North-east. Maximum amount of rain received by the city of Chandigarh

during monsoon season is 195.5 mm in a single day.




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• Winter: Winters (November-end to February-end) are mild but it can sometimes get

quite chilly in Derabassi. Average temperatures in the winter remain at (max) 5 °C to

14 °C and (min) -1 °C to 5 °C. Rain usually comes from the west during winters and it is

usually a persistent rain for 2–3 days with sometimes hailstorms. The area witnessed

bone-numbing chill as the maximum temperature on Monday, 7 January 2013 plunged

to a 30-year low to settle at 6.1 degrees Celsius.

Fig. 3.2: Historical Climate data of the area (Source: IMD Database)

The Baseline environmental monitoring data of the proposed project has been carried out for

1 season, i.e. during Winter season, from November 2017 to January 2018. The Climate

station had been installed at proposed project premises to find out post monsoon

climatological data for carrying out detailed study of impact at proposed impact area related

to climatological factor (rainfall, windspeed, humidity etc.). The data had been collected on

hourly basis and detail data of baseline monitoring is provided with the report – “Annexure-

Environmental Monitoring Report”.

Temperature

During November to January, the area experiences pleasant to very low temperatures. During

night times in multiple occurrences the temperature goes down below zero degree.

Table 3.1: Baseline Climate data of climate station at proposed unit premises

Monthly Summary for November 2017

Actual Normal Departure Remarks

High (⁰ C) 34.2 28 + 6.2 Occurs on 29.11.2017.

Low (⁰ C) 9.5 10.5 - 1.0 Occurs on 09.11.2017.

Average high (⁰ C) 27.3

Average low (⁰ C) 10.5




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Precipitation (mm) 0 9.4 - 9.4

Monthly Summary for December 2017

Actual Normal Departure

High (⁰ C) 33.2 23° + 10.2 Occurs on 01.12.2017.

Low (⁰ C) 5.3 6.7 - 1.4 Occurs on 09.12.2017.



Precipitation (mm) 5.7 21.9 - 16.2 only rainfall day was

11.12.2017.

Monthly Summary for January 2018

Actual Normal Departure

High (⁰ C) 20.7 21° - 0.3 Occurs on 03.01.2018.

Low (⁰ C) - 0.5 6.1 - 6.6 Occurs on 09.01.2018.



Precipitation (mm) 0 33.1 - 33.1

According to the baseline data of climate station at proposed unit premises, the November

month experiences as much as 34.2 degree Celsius on 29th of November, and as low as 9.5

degree Celsius on 9th November. December month also experiences some hot days with

highest maximum temperature rise up to 33.2 degree Celsius on 01.12.2017. During these

months, the lowest temperature was minus 0.5 degree Celsius on 9th of January during mid

night, the only day, when temperature goes down below the zero degree.

Rainfall

According to historical data, these monsoon month also experiences rainfall due to the

western disturbance with average of 4.8 rainfall days cumulatively in the season. But, during

our climatological monitoring, the monitoring station only experiences a single rainfall day on

11th of December, 2017 with only 5.7 mm of precipitation. Whereas, the historical data claims

that during these 3 months, the area got about 64.4 mm of rainfall. Thus, the present season

has drift of about 58.7 mm of rainfall. Thus, it is could be said that the area got very less rainfall

during monitoring phase with compare to average historical rainfall. The below compare chart

describes historical rainfall average by ‘Orange line’, and actual rainfall by ‘Blue bar’.




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Fig 3.3: Rainfall drift chart

Humidity

The area experiences very fluctuating humidity feature of climate. The humidity sometimes

reaches 100% concentration and on the other hand setting down to minimum of 4% humidity.

The moisture trend in air shows that the early morning air contains maximum of moisture, as

humidity reaches 70-100% during 4 o’clock to 10 o’clock and humidity peaks almost 98-100%

during 4.30 am to 8.30 am. The air contains minimum saturation of moisture during evening

and early phase of night time, as during this time humidity goes down below 50% and minimum

humidity of below 10% occurs during 4.30 pm to 6.30 pm. All the humidity data has been

collected automatically from the weather station installed at proposed project premises at

Derabassi during November’17 to January’18.

Table 3.2: Monthly maximum and minimum humidity trend of the impact area

Month Maximum Humidity

(%) Minimum Humidity

(%)

November, 17 98 8

December, 17 100 6

January, 18 98 4

Cloudiness

The area experience mostly sunny days during November to January. According to historical

data, the area has 26.5, 24.7, 20.6 sunny days in an average during November, December,

Actual

Historical rainfall

Precipitation(mm) in

November, 17

Precipitation(mm) in

December, 17

Precipitation(mm) in January,

18

05.7

0

9.4

21.9

33.1

RAINFALL ANALYSIS

Actual Historical rainfall




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January month respectively. In contrast, Cloudiness persist on an average 4.5, 5.3, 10.4 days

during November, December, January respectively.

Fig. 3.4: Cloudiness Comparison data (Source: Meteoblue.com)

Wind

The area experience moderate wind velocity. The average wind speed varies between 5-12

km/h. During baseline monitoring from November, 2017 to January, 2018, the maximum

windspeed detected was 25.2 km per hour. The climate station data shows that there was 11

hours, when wind speed was more than 19 km per hour. The wind speed comparison data

and wind rose diagram is given below for better understanding of wind character of the area.

The wind speed and humidity are the direct influencing factor over point source emission

dispersion and ambient pollutant’s concentration in localised area.

Table 3.3: Wind speed comparison data

Month Maximum Wind speed

(km/h) Minimum Wind speed

(km/h)

November, 17 23.3 0.02

December, 17 25.2 2.1

January, 18 25.2 2.5




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Fig. 3.5: Wind rose diagram of the area (Source: Meteoblue.com)

3.3 AMBIENT AIR QUALITY

Actual monitoring of baseline environmental component was carried out strictly according to

the parameters prescribed in the Granted TOR. The ambient parameters as per TOR issued

by the EAC, MOEFCC was collected and analysed as a part of Environmental Impact

Assessment report. The monitoring also follows the guidelines on “Technical EIA Guidance

Manual for Synthetic Organic Chemical Industry” by the Ministry of Environment, Forests and

Climate Change, Govt. of India. The extent of study was 10 Km with circular impact area in

respect to proposed project in centre locus.




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The Environmental Monitoring was carried out by the Environment Team of M/s ITL Labs

Pvt. Ltd., New Delhi for the project of “Expansion of Chemical processing unit of HPL

Additives at Bhagwanpur village. The monitoring was carried out from 1st of November, 2017

to 31st January, 2018 (one season, 12 weeks). The monitoring and analysis was carried out

as per CPCB/ MOEF&CC guidelines.

Fine Particulate Samplers (FPS) has been used for PM2.5 Sampling. Respirable Dust

Samplers (RDS) with gaseous attachment have been used for PM10 Sampling. RDS with

Gaseous attachment assembly is used for the collection of gaseous pollutants such as SO2 &

NOx. The details of the instrument used for sampling, testing methods are given below.

Table 3.4a: Sampling Instrument Details

Instrument Make Model No. Range and Sensitivity

1) Respirable

Dust Sampler

(RDS) for PM10

M/s. Envirotech

Instruments Pvt.

Ltd. – New Delhi

APM – 460 BL &

411

0.02 – 01.8

m3/min

±0.02 m3/min

0.2 – 3 LPM

± 0.2 LPM

2) Fine Particle

Sampler(FPSS)

for PM2.5

Make: Spectro SLE-FPS 105 &

SLE GA133

1 m3/hour 0.2 – 1.0

LPM

Noise monitoring Make Lutron Model: SL 4013 30 – 130 dB 0.1 dB

Table 3.4b: Filter paper details

APPRATUS MAKE SIZE SIZE PRODUCT

CATEGORY NO.

Filter Paper

(PM10)

M/S Whatman

International Ltd.

203 x 254mm Glass Microfibre S-10

Batch No-G015DO7

Filter Paper

(PM2.5)

M/S Whatman

International Ltd.

47 mm Teflon




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NO2 present in the ambient air was estimated by taking 25 ml of absorbing solution (0.01 M

NaOH) in an impinger and passing air at the rate of 0.5 lpm. The absorbing solution was

brought to laboratory and analysed for NO2 by colour development using sulphanilamide and

NEDA. The colour intensity was measured using spectrophotometer at 540 nm and compared

with standards for estimating the concentration level in sample.

SO2 present in the ambient air was estimated by taking 25 ml of absorbing solution (0.1 M

Tetra-chloro Mercurate) in an impinger and passing air at the rate of 0.5 lpm. The absorbing

solution was brought to laboratory and analysed for SO2 by colour development using

formaldehyde, sulphamic acid and para-rosanilene. The colour intensity was measured using

spectrophotometer at 560 nm and compared with standards for estimating the concentration

level in sample.

Table 3.5a: Ambient Air Quality monitoring standard methods by NAAQS (2009)




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Table 3.5b: Analysis method adopted by Laboratory

A) AMBIENT AIR

Sl.

No

PARAMETERS METHOD

1 Particulate matter (PM10) IS 5182: 2006 (Page 23)

2 Particulate Matter (PM2.5) WI/ENV/04

3 Sulphur Dioxide (SO2) IS 5182:2001 (Page 2)

4 Nitrogen Dioxide (NO2) IS 5182:2006 (Page 6)

5 Carbon monoxide (CO) IS 5182:2006 (Page 10)

6 Volatile Organic carbon

(VOC) Method of Air Sampling & analysis 3rd Edition

7 Hydrogen Fluoride (HF)

M No. 809, Method of Air Sampling & analysis 3rd Edition

8 Ammonia (NH3)

M No. 401 Method of Air Sampling and Analysis, 3rd Edition

9 Hydrogen Sulphide(H2S)

M No.812 Method of Air Sampling and Analysis 3rd Edition

10 Hydrogen Chloride(HCl)


11 Chlorine


8 sensitive locations were selected within the 10 km impact area of the proposed project as

per the granted TOR terms and locations are identified by reminding the wind directional

character and different sensitive locations situated around the project site. Sensitive locations

were identified with preference given to the receptors like, Institution, Hospital, Children’s

playground, Heavy movement roads, congested Market place etc. There is no ecological

sensitive place within the impact area had been identified, thus, the same did not considered

during sampling station identification. The monitoring was carried out for 12 weeks, and 2

sampling in each week, i.e. total 24 sampling took place in each location. The details of

sampling stations are described below.

Table 3.6: Ambient Air Quality Monitoring details

Location Code

Location Name Sampling dates

AAQ-1 Project Site 4.11.2017. 8.11.2017.

11.11.2017. 15.11.2017.

AAQ-2 Barwala, on Derabassi-Barwala road




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AAQ-3 Derabassi, near dense population

zone

18.11.2017. 22.11.2017.

25.11.2017. 28.11.2017.

03.12.2017. 07.12.2017.

09.12.2017. 14.12.2017.

16.12.2017. 20.12.2017.

26.12.2017. 30.12.2017.

06.01.2018. 09.01.2018.

13.01.2018. 16.01.2018.

20.01.2018. 22.01.2018.

27.01.2018. 30.01.2018.

AAQ-4 Fatehpur Viran village

AAQ-5 Ramgarh village

AAQ-6 Dabkauri Village

AAQ-7 Swami Parmananda college –

Sensitive zone

AAQ-8 Mauli village play ground - Sensitive

zone

Fig. 3.6: Sampling Station for Ambient Air Quality Monitoring

Table 3.7a: Ambient Air Quality Monitoring report

Monitoring Station Code

AAQ1 AAQ2 AAQ3 AAQ4

Permissible Limit (NAAQS)

24 hours/ Annual

PM10 (µg/m3)

Minimum 76.5 87.0 92.0 71.1 100

Maximum 92.7 98.7 104.4 80.6

PM2.5 (µg/m3)

Minimum 48.2 49.9 52.8 40.8 60

Maximum 56.0 62.3 65.9 50.9




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SO2 (µg/m3)

Minimum 7.2 13.4 15.3 9.6 80

Maximum 9.8 18.0 16.9 12.9

NOX (µg/m3)

Minimum 15.6 19.7 21.5 14.7 80

Maximum 23.1 25.1 23.6 18.7

CO mg/m3 Minimum 0.75 0.8 0.8 0.6

2 Maximum 1.1 0.9 1.0 1.1

Volatile Organic Carbon (VOC)

(µg/m3)

Minimum 0.6 0.7 0.7 0.3

Maximum 1.6 2.0 2.1 0.8

Hydrogen Fluoride (HF)

(µg/m3) BDL 100

Ammonia (NH₃) (µg/m3)

Minimum 15.8

400 Maximum 23.1

Hydrogen

Sulphide (H2S) (µg/m3)

BDL 150

Hydrogen Chloride (HCl)

ppm BDL 100

Chlorine ppm BDL

Table 3.7b: Ambient Air Quality Monitoring report

Monitoring Station Code

AAQ5 AAQ6 AAQ7 AAQ8

Permissible Limit (NAAQS)

24 hours/ Annual

PM10 (µg/m3)

Minimum 79.8 72.3 77.9 72.2 100

Maximum 90.7 82.2 88.6 82.2

PM2.5 (µg/m3)

Minimum 43.1 39.1 42.1 39 60

Maximum 54.7 49.6 53.4 49.5

SO2 (µg/m3)

Minimum 10.3 9.3 10.1 9.4 80

Maximum 14.6 13.2 14.3 13.3

NOX (µg/m3)

Minimum 15.9 14.4 16.3 14.3 80

Maximum 21 19 21.5 18.9

CO mg/m3 Minimum 0.66 0.6 0.73 0.68

2 Maximum 0.77 0.7 0.85 0.79

Volatile Organic Carbon (VOC)

(µg/m3)

Minimum 0.4 0.4 0.4 0.3

Maximum 0.9 0.8 0.9 0.6




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The impact area experience maximum wind flow on Northern-North-eastern (NNE) and North-

eastern (NE) and moderate wind flow towards western direction. Thus, sampling stations like

Dabkauri village and Derabassi town would be the most affected areas due to the proposed

project. But, significantly result shows that Dabkauri village was not affected that much due to

the existing unit and all the pollutant parameters are well within the prescribed limit in this

place, due to long distance between the project site and village. Interestingly, the sampling

stations near Derabassi-Barwala road and near the Derabassi town showing high

concentration of Particulate matter in the air, thus, it can be concluded that, due to heavy

vehicle movement and high population inference also contributed on the concentration of

Particulate matter. The project site sampling station also showing the high concentration of

dust particle, but below the prescribed limit. During, Construction phase and expanded

production phase, the dust particle concentration would be very high if the proper management

action not taken. The other gaseous pollutant’s concentration was well below the prescribed

limit at all sampling station. It is recommended that, during construction phase, monitoring at

Derabassi and on Derabassi-Barwala road should be continued with regular interval to identify

further mitigation approaches. Additionally, stringent air pollution control mechanism is

suggested to minimise air pollution at source.

3.4 AMBIENT NOISE

Noise attribute to proposed project site and surroundings will depends on factors such as

construction activity, the type and condition of the vehicles active on the road, equipment and

machines in operation etc. Also, some secondary attribution of noise generating factors could

trigger high level of noise, e.g. close proximity of other high noise generating industry, market

area, Military Basecamp, Other construction activity, frequent movement of Earth mover etc.

Excessive high noise levels are major concern for sensitive receptors such as Silence Zone

i.e. eco-sensitive area, Hospital, Educational institute, religious place etc. The proposed

project unit neither have those high noise generating secondary factors nor the Silence zones

within the close proximity.

Ambient noise quality at the project impact area has been assessed by undertaking noise level

monitoring at 8 sampling station comprising at the proposed premises as well as at different

sensitive zone like industrial zone, commercial zone, silence zone etc. The detail sampling

station is given below.




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Table 3.8: Ambient Noise Quality Monitoring Stations

Location Code Sampling Station Location

ANQ-1 Project site (Main Gate) – Industrial Zone

ANQ-2 Project site (Back side) – Industrial Zone

ANQ-3 Govt Primary Health centre, Barwala – Silence Zone

ANQ-4 Derabassi Main Market – Commercial Zone

ANQ-5 Scholar public school, Mauli – Silence Zone

ANQ-6 Ramgarh Village -Residential Zone

ANQ-7 Swami Parmananda college, Derabassi -Silence Zone

ANQ-8 Batwal village – Residential Zone

8 locations identified for Noise quality monitoring at project impact area by emphasising the

requirement of 4 different noise level receptor zone.

Industrial Zone: Within the Proposed project site, Back side of the proposed project

premises.

Commercial Zone: At Derabassi Main Market

Residential Zone: At Ramgarh village and at Batwal village

Silence Zone: Near Govt Primary Health centre, Barwala; near Scholar public school,

Mauli; near Swami Parmananda college, Derabassi.

Fig. 3.7: Ambient Noise Quality Monitoring Stations map




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Table 3.9a: Ambient Noise Quality Monitoring Report

Parameter Result dB(A) Limits in dB(A)

ANQ-1 ANQ-2 ANQ-3 ANQ-4 Area Code

Category of area/zone

Day time

Night time

Lday 54.7 61 54.2 57.1 A Industrial

Area 75 70

Lnight 39.5 51.1 39.3 47.9 B Commercial

Area 65 55

Lmax 64.5 65.5 64.3 61.4 C Residential

Area 55 45

Lmin 34.8 37.9 33.3 34 D Silence Zone 50 40

Table 3.9b: Ambient Noise Quality Monitoring Report

Parameter Result dB(A) Limits in dB(A)

ANQ-5 ANQ-6 ANQ-7 ANQ-8 Area Code

Category of area/zone

Day time

Night time

Lday 51.7 53.1 53.2 49 A Industrial

Area 75 70

Lnight 37.9 38.6 42.6 41.1 B Commercial

Area 65 55

Lmax 61.3 63.4 57.8 52.6 C Residential

Area 55 45

Lmin 32 32.9 32.6 30.5 D Silence Zone 50 40

The result shows in the ambient noise quality monitoring during November, 2017 to January,

2018, some of the results crosses the prescribed limit of the specified zone. But, none of the

result at within the proposed unit premises and near the proposed project premises above the

prescribed limit. That means, it could be say that areas having high noise level might be

affected by temporary or time-specific secondary noise issues, like heavy rush and population

influx or movement of vehicles near the silence zone receptor. Thus, it could be concluded

that the proposed project would not interfere massively to the near habitation and location by

high noise generation. Additionally, the proposed project would generate moderately higher

level of noise during construction phase, but those activity shall be restricted in day-time only.

During, operational phase, noise pollution control measures shall be adopted by unit authority

as per the Environmental Management Plan to mitigate the high noise generation at source

itself.

3.5 TOPOGRAPHY

The Topography of the district is even. It is mostly a plain of alluvial type. It also has loam to

heavy loam and sand to sandy loam soils in certain parts of the district. Soil is rich in nutrients

and suitable for crops like wheat, Paddy, Maize, potato and Vegetables etc. The proposed




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area of the expansion project has plain terrain with an elevation range from 317 (1040 ft) meter

to 308 meter (1010 ft). The topographic map of the proposed project is attached with the

report.

Fig. 3.9: Elevation map of Proposed project area (red circled area)

(Source: Topographic-map.com)

3.6 GEOMORPHOLOGY & SOIL

Geomorphology of the area mainly identified as alluvial plains which is an outcome of the

alluvial deposit of Indo-Gangetic river systems ranging in age from Pleistocene to recent

Period, comprises of thick sand and silty sand layers interbedded with silt and clay beds. The

soils are mainly developed on alluvium under the dominant influence of climate followed by

topography and time. The deposition of newer alluvium commenced after the final upheaval

of Himalayas (Siwaliks) and continued all through the Pleistocene up to the present.




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The district soil can be broadly grouped into two depending upon its geomorphic features as

alluvial fan and alluvial plains. Alluvial fans are deposited by hill torrents with a wavy plain

rather than a steep slope. Adjacent to the alluvial fan are the alluvial plains which forms a part

of large Indo- Gangetic Quaternary basin comprises of thick sand and silty sand layers

interbedded with silt and clay beds. The alluvial plains are of vital economic value as it supports

the dense population of the district. The soils are mainly developed on alluvium under the

dominant influence of climate followed by topography and time. The major soil type of the

district is weakly solonized tropical arid brown soils.

The soil of the proposed project area is sandy slit type containing almost 50% of sand, 42%

of slit and very less clay molecules. The colour of the soil is brown with porosity of 23.4%.

Soil Quality Monitoring

Soil quality has been tested by identifying 8 locations within the proposed project impact zone.

The detail of sampling points for soil quality analysis is given below. The soil samples are

analysed by the Method prescribed in “Manual soil testing in India, Department of Agriculture

& corporation, Ministry of Agriculture Government of India, New Delhi, January’2011 “.

Table 3. 10: Soil Quality analysis locations

Location Code Location Name

SQ-1 Project Site

SQ -2 Barwala

SQ -3 Derabassi

SQ-4 Fatehpur Viran

SQ-5 Ramgarh

SQ-6 Dabkauri village

SQ-7 Mauli village

SQ-8 Batwal




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Table 3.11a: Soil Quality Analysis Report

Sl.

No SAMPLE LOCATION SQ1 SQ2 SQ3 SQ4

PARAMETER

1 pH 7.4 7.15 7.21 7.24

2 Appearance Brown Brown Brown Brown

3 Texture Sandy Silt Sandy Silt Sandy Silt Sandy Silt

a) Gravel (%) 2.5 2.6 2.2 2.7

b) Sand content (%) 49.3 51.8 51.5 48.4

c) Silt content (%) 42.8 40.2 42.4 42.6

d) Clay content (%) 5.4 5.4 3.9 6.3

4 Water holding capacity

(%)

21.2 21.2 21.4 22.5

5 Conductivity (µS/cm) 394 409 434 402

6 Iron as Fe (mg/kg) 2.11 2.15 2.41 2.74

7 Zinc as Zn (mg/kg) 0.52 0.47 0.61 0.35

8 Copper as Cu (mg/kg) 0.81 0.66 0.49 0.77

9 Cadmium as Cd(mg/kg) BDL (0.001) BDL (0.001) BDL (0.001) BDL (0.001)

10 Bulk Density (gm/cm3) 1.37 1.28 1.39 1.21

11 Nitrogen as N (%) 0.38 0.32 0.36 0.33

12 Phosphorous as P (%) 0.23 0.41 0.24 0.25

13 Potassium as K (%) 0.84 0.62 0.72 0.61

14 Sodium as Na (%) 0.45 0.23 0.18 0.32

15 Chloride as Cl(mg/kg) 20.8 18.8 19.5 22.7

16 Total alkalinity(mg/kg) 385 409 407 433

17 Moisture content (%) 8.44 8.15 8.8 2.5

18 Lithium(mg/kg) BDL (0.01) BDL (0.01) BDL (0.01) BDL (0.01)

19 Boron(mg/kg) BDL (0.01) BDL (0.01) BDL (0.01) BDL (0.01)

20 Porosity (%) 23.4 24.9 24.3 23.6

Table 3.11b: Soil Quality Analysis Report

Sl.

No SAMPLE LOCATION S-5 S-6 S-7 S-8

PARAMETER

1 pH 7.35 7.08 7.15 7.33

2 Appearance Brown Brown Brown Brown

3 Texture Sandy Silt Sandy Silt Sandy Silt Sandy Silt

a) Gravel (%) 4.2 2.3 3.5 3.8

b) Sand content (%) 48.5 50.8 47.2 50.2

c) Silt content (%) 42.6 42.6 45.8 41.6

d) Clay content (%) 4.7 4.3 3.5 4.4

4 Water holding capacity

(%)

21.7 20.8 22.3 22.19

5 Conductivity (µS/cm) 419 354 388 395

6 Iron as Fe (mg/kg) 2.98 2.08 2.01 2.15

7 Zinc as Zn (mg/kg) 0.51 0.54 0.50 0.41




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8 Copper as Cu (mg/kg) 0.76 0.39 0.65 0.77

9 Cadmium as Cd(mg/kg) BDL (0.001) BDL (0.001) BDL (0.001) BDL (0.001)

10 Bulk Density (gm/cm3) 1.44 1.48 1.42 1.47

11 Nitrogen as N (%) 0.46 0.38 0.34 0.41

12 Phosphorous as P (%) 0.32 0.44 0.36 0.42

13 Potassium as K (%) 0.81 0.71 0.61 0.62

14 Sodium as Na (%) 0.38 0.35 0.45 0.44

15 Chloride as Cl(mg/kg) 33.2 30.8 29.6 29.8

16 Total alkalinity(mg/kg) 344 371 320 34

17 Moisture content (%) 2.63 2.85 2.6 2.2

18 Lithium(mg/kg) BDL (0.01) BDL (0.01) BDL (0.01) BDL (0.01)

19 Boron(mg/kg) BDL (0.01) BDL (0.01) BDL (0.01) BDL (0.01)

20 Porosity (%) 25.5 24.8 24.6 24.2

The soil monitoring of the sampling locations shows that the soil of the area has moderate

water holding capacity with very less contains of soil moisture. There are no trace elements

are found in analysis report which indicates any soil pollution due the existing project. The

proposed project would monitor with proper soil management measures to minimise any kind

of soil pollution.

3.7 LAND USE PATTERN

The land use pattern of the 10 km impact area of the proposed project site has been analysed

in Google Earth imagery. The area is dominated by habitation zones and industrial clusters

formations. The rivers flow within the impact area are Ghaggar Towards Northern part to

South-western part & Tangri river towards North-eastern to south-eastern part. There is

multiple surface water flow like agricultural canals are flowing within the area, but there is no

ecological sensitive zone with the impact area identified except Chattbir zoological park at

Chatt towards Extreme South-west in the 10 km impact zone. The dense green covers also

comprising 2.5% of area. The detail habitations and industries around the proposed expansion

project is given below descriptively.

Within the 5 km impact zone of the proposed project, the habitation areas are namely,

Bhagwanpur, Kura Wala, Haripur Hindan, Bahadurgarh, Rampur Sainian, Sundarpur, Kami,

Bir babupur, Sultanpur, Raipur-alias-sunderpur, Bir ferozari, Nimbuan, Sundran, Saidpur,

Pandwala, Haibatpur, Bhagat Singh Nagar, Saidpura, Gulabgarh, Mahiwala, Bir-dandrala,

Dandrala, Bir-kheri, Kheri gujjar, Jitpur, Sangrana, Behra.




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Fig. 3.10: Land use map of 10 km Impact zone of the proposed project (Scale: 1:35000)


Within the 10 km impact zone of the proposed project, the habitation areas are namely,

Rehawar, Barwala, Palasra, Haripur, Dhandaurru, Batwal, Khatauli, Nagal, Alipur,

Sukhdarshanpur, Toka, Shamtu, Khangesra, Bhanoo, Mattewali, Kot, Lana, Behar,

Jaswantgarh, Dabkauri, Billa, Kaiwali, Nagalmoginand, Jhiwiwala, Manka, Moor thikri,

Ramgarh, Panchkula extension, Per Machula, Daffarpur, Kishanpura, Bir pir Machhalia,

Sanauli, Nagla, Gazipur, Singpura, Derabassi, Ramgarh bhudda, Mirpur, Shatabgarh,

Bakarpur, Bhankarpur, Rauni, Ibrahimpura, Paragpur, Issapur Rouni, Jagadhri, Dhanauni,

Mehmadpura, Sheikhpur kalan, Karkaur, Haripur kurha, Devi nagar, Janetpur, Jawaharpur,

Issapur Jangi, Gholu majra, Mussepur, Toganpur, Bhagwasi, Mianpur, Bijanpur,

Bhagwanpura, Tohffapur, Kheri jattan, Jeoli, Jandli, Jhawansa, Seoli, Fatehpur viran, Navan

gaon, Bhareli, Mauli.

Table 3.12: Land use break-up of the impact zone

Sl. No. Land use type Percentage of

the area

1 Surface water body 2.20%

2 Other water flow/ canal 0.30%

3 Dense Green cover 2.50%




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4 Habitation & Industrial Use 56.40%

5 Open land, Green area, Agricultural use 38.60%

Table 3.13: Industries list at Project Impact area

Sl. No.

Industry name Location/ Address

1 A P Paper Mills Limited Bhagwanpur

2 A-One Tiles Bhagwanpur

3 ADH Polymers Pvt. Ltd. Issapur Janghi

4 Aar Par Glasses Pvt. Ltd. Behra

5 Aay Kay Pipes Pvt. Ltd. Saidpura

6 Aay Pee Industries Bhagwanpur

7 Acme Industries Derabassi

8 Alaska Fabtech Pvt. Ltd. Kurawala

9 Allegers Medical Systems Ltd. Bhankarpur

10 Amba Poly Plast Ltd. Bhagwanpur

11 Ammonia Supply Company Derabassi

12 Aspee Springs Limited Derabassi

13 Avdesh Tracks Jawaharpur

14 Avon Meters Pvt. Ltd. Derabassi

15 A V Forgings Pvt. Ltd. Mahiwala

16 B & H Electrodes Pvt. Ltd. Saidpura

17 Bassi Steels Limited Gholu majra

18 Bassi Tubes Pvt. Ltd. Saidpura

19 Chandigarh Spinning Mills Ltd. Bhagwanpur

20 Contour Automotive products Ltd. Bhankarpur

21 Core Metal Crafts Limited Saidpura

22 D D Agro Foods Pvt. Ltd. Kurawala

23 D R T Pipes Pvt. Ltd. Saidpura

24 Dwarka Minerals & Chemicals Pvt. Ltd. Bhagwanpur

25 Emmbros Forgings Pvt. Ltd. Rampur Sainian

26 Empire Multipack Pvt. Ltd. Kurawala

27 Empire Packages Pvt. Ltd. Mahiwala

28 ETE Electrogears Pvt. Ltd. Derabassi

29 Euro Containers Saidpura

30 Evershine Electricals Works (1) Haripur Hinduan

31 Excess Sanitations Derabassi

32 Expo Forgings Pvt. Ltd. Rampur Sainian

33 Federal Agro Industries Behra

34 Fertichem Cotspin Limited Saidpura




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35 Flourish Paper & Chemicals Ltd. Bhagwanpur

36 G G Chemicals & Phermacuticals Pvt.

Ltd. Bhagwanpur

37 Hansa Tubes Pvt. Ltd. Haibatpur

38 Hella India Lighting Ltd. Derabassi

39 Hindustan Eletrodes Janetpur

40 Indian Yarns Limited Himayunpur

41 Ind-swift Labofratories Ltd. Bhagwanpur

42 Ind-Swift Limited Jawaharpur

43 Instant Remedies Pvt. Ltd. Gholu Majra

44 Jai Castings Derabassi

45 Jai Multi Engineering Co. Bhagwanpur

46 Jai Parvati Forge Limited Bhagwanpur

47 JTL Infra Ltd. Gholu majra

48 Juneja Overseases Behra

49 Kalgidhar Fabricators Saidpura

50 Kansal Engineering Saidpura

51 Laxmi Fasteners Limited Kurawala

52 Mirage Toughened Glasses Pvt. Ltd. Kurawala

53 Mukul Shree Udyog Bhagwanpur

54 Nachiketa Papers Limited Ramgarh

55 Nactar Life Sciences Limited Saidpura

56 Nidhi Pipes Limited Derabassi

57 Paras Steels Bhagwanpur

58 Pioneer Bricks Pvt. Ltd. Bahadurgarh

59 Pioneer Polish Industries Bhagwanpur

60 Saboo Coatings Limited Haibatpur

61 Samrat Laminators Pvt. Ltd. Bhagwanpur

62 Sourav Chemicals Limited Saidpura

63 S G Enterprise Bhagwanpur

64 Solution Engineers Bhagwanpur

65 Shree Balaji Feeds Bhagwanpur

66 Surya International Gulabgarh

67 Saraswati Agro Chemicals (India) Pvt.

Ltd. Nimbua

68 Syan Fabricators & Engineers Bhagwanpur

69 Usha Yarns Limited Rampur Sainian

70 Vardhman Chemtech Limited Nimbua

71 Vatika Spinning Mills Ltd. Saidpura




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3.8 DRAINAGE

There are 2 main rivers flow within the proposed impact zone of expansion project, viz.

Ghaggar River towards western part, and Tangri River towards Eastern part. Ghaggar river

enters within the state from Haryana near Duffarpur village by merging two stream and flows

South-westerly before getting one flow of Sukhna Choe before Bhankarpur and flows further

westerly and then Southerly to exit the state near sadhanpur, which is almost 21 km away

from the proposed project site. The proposed project unit is situated at left/ east bank of the

Ghaggar river, and safely away from flood basin of Ghaggar. The maximum gauge reading for

Ghaggar river high flood occurrence in past 30 years is 30.4 ft or 9.3 meter, the normal flow

level of Ghaggar river is 280 AMSL, in contrast the proposed unit premises has average 311

meters of elevation from mean sea level, and have minimum distance of 6.5 kilometres

towards North-West, thus, the unit is safe from any flood risk of Ghaggar river basin.

The Tangri river is a tributary of Ghaggar river, flows south-easterly in respect to the proposed

project unit. The river originates from Shivalik range and flows towards south with Punjab-

Haryana border and meets Ghaggar river near Kharkan, extreme south of the state. The left

stream of the river has minimum of 5.45 km distance from the proposed site and the river flows

on 310 m elevation level, which is almost same as the proposed unit elevation. But, the unit

has further elevation for civil structures which would avoid any flood risk.

3.9 SURFACE WATER SOURCE

The proposed unit has not any surface water source availability with close proximity to utilize

the resource within the plant’s activity. There are multiple surface water bodies, but no one

has huge surface area, thus, all are could be considered as small pond. The nearest pond at

kami village also has a distance of 2.4 km from the project unit, thus, it is not feasible that the

water of the pond could be utilize in the unit’s activity. Thus, it is clear that there is no surface

water availability for production usage of HPL Additives Ltd. at Bhagwanpur. The other ponds

identified at the impact zone are situated at Barwala, Palasra, Mauli, Seikhpur kalan,

Bhagwanpur, Dhanauni respectively.

Surface Water Quality

Surface water quality had been assessed by selecting 8 sampling stations in impact zone, 2

samples out of which were river water stream of Ghaggar at upstream and downstream. The

other samples were collected as grab sampling from different ponds within the impact zone.

The details of sampling locations and analysis reports are given below.




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Table 3.14: Sampling stations of Surface water quality analysis


SW-1 Barwala pond

SW-2 Palasara pond

SW-3 Bhagawanpura

SW-4 Bhareli road

SW-5 Dhanauni

SW-6 Mauli village

SW-7 Ghaggar River down stream

SW-8 Ghaggar River up stream

Fig. 3. 11: Sampling Stations pointer in map for Surface water Monitoring

Table 3.15a: Surface water Quality Analysis report

Sl. No. PARAMETERS SW 1 SW 2 SW 3 SW 4

1 pH 7.5 7.6 8.1 7.5

2 Colour Colourless Colourless Colourless Colourless

3 Odour Odourless Odourless Odourless Odourless




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4 Temperature ⁰C 18.6 15.6 17.8 18.6

5 Turbidity, NTU <1.0 <1.0 <1.0 <1.0

6 Electrical Conductivity 715 658 802 727

7 TDS, mg/l 452 395 575 409

8 Total Suspended

Solids, mg/l 26 31.0 24 21

9 Dissolved Oxygen

(DO), mg/l 6.1 6.0 5.8 6.2

10 BOD at 27ºC for 3

days, mg/l 7.0 10.0 14.0 6.0

11 Oil & Grease, mg/l Nil Nil Nil Nil

12 Phenolic Compounds

as C6H5OH, mg/l BDL BDL BDL BDL

13 Boron as B, mg/l BDL BDL BDL BDL

14 Lead, mg/l BDL BDL BDL BDL

15 Mercury, mg/l BDL BDL BDL BDL

16 Copper, mg/l BDL BDL BDL BDL

17 Total Chromium, mg/l BDL BDL BDL BDL

18 Aluminium as Al, mg/l BDL BDL BDL BDL

19 Iron, mg/l 0.21 0.18 0.15 0.14

20 Cadmium, mg/l BDL BDL BDL BDL

21 Zinc, mg/l 0.08 0.12 0.25 0.12

22 Manganese, mg/l BDL BDL BDL BDL

23 Arsenic, mg/l BDL BDL BDL BDL

24 Cyanide as CN, mg/l BDL BDL BDL BDL

25 Nickel as Ni, mg/l BDL BDL BDL BDL




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26 Total Hardness (as

CaCO3), mg/l 245 224 345 249

27 Calcium (as Ca), mg/l 70.5 63.8 85.4 70.2

28 Magnesium (as Mg),

mg/l 21.0 18.4 25.1 20.4

29 Sodium (as Na), mg/l 18.4 15.2 23.1 19.7

30 Potassium (as K), mg/l 2.5 2.8 3.4 2.4

31 Fluoride (as F), mg/l 0.2 0.26 0.44 0.18

32 Chloride (as Cl), mg/l 36.0 31.8 32.6 33.5

33 Sulphate (as SO4),

mg/l 60.2 50.4 72.5 62.8

34 Nitrate (as NO3) mg/l 14.5 15.6 16.4 17.1

35 Total Nitrogen (as N),

mg/l 18.6 17.6 23.8 18.5

36 Total Phosphorous (as

P), mg/l 4.5 4.2 3.4 4.2

37 Total Coliform Count,

cfu /100ml 354 385 204 367

38 Faecal Coliform, cfu

/100ml 242 278 165 238

Table 3.15b: Surface water Quality Analysis report

Sl. No. PARAMETERS SW 5 SW 6 SW 7 SW 8

1 pH 7.35 7.54 8.21 7.27

2 Colour Colourless Colourless Colourless Colourless

3 Odour Odourless Odourless Odourless Odourless

4 Temperature ⁰C 18.2 15.8 19.2 18.2

5 Turbidity, NTU <1.0 <1.0 <1.0 <1.0




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6 Electrical Conductivity 554 608 778 675

7 TDS, mg/l 357 3740 539 486

8 Total Suspended

Solids, mg/l 24 31.0 27 25

9 Dissolved Oxygen

(DO), mg/l 6.0 6.2 6.1 6.4

10 BOD at 27ºC for 3

days, mg/l 8.0 6.0 7.0 4.0

11 Oil & Grease, mg/l Nil Nil Nil Nil

12 Phenolic Compounds

as C6H5OH, mg/l BDL BDL BDL BDL

13 Boron as B, mg/l BDL BDL BDL BDL

14 Lead, mg/l BDL BDL BDL BDL

15 Mercury, mg/l BDL BDL BDL BDL

16 Copper, mg/l BDL BDL BDL BDL

17 Total Chromium, mg/l BDL BDL BDL BDL

18 Aluminium as Al, mg/l BDL BDL BDL BDL

19 Iron, mg/l 0.36 0.21 0.32 0.23

20 Cadmium, mg/l BDL BDL BDL BDL

21 Zinc, mg/l 0.12 0.15 0.18 0.16

22 Manganese, mg/l BDL BDL BDL BDL

23 Arsenic, mg/l BDL BDL BDL BDL

24 Cyanide as CN, mg/l BDL BDL BDL BDL

25 Nickel as Ni, mg/l BDL BDL BDL BDL

26 Total Hardness (as

CaCO3), mg/l 202 198 296 234




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27 Calcium (as Ca), mg/l 56.5 48.8 72.4 55.2

28 Magnesium (as Mg),

mg/l 23.0 28.4 35.1 23.4

29 Sodium (as Na), mg/l 21.6 15.2 23.1 19.7

30 Potassium (as K), mg/l 2.8 2.8 3.4 2.4

31 Fluoride (as F), mg/l 0.6 0.26 0.44 0.18

32 Chloride (as Cl), mg/l 31.0 41 38 29

33 Sulphate (as SO4),

mg/l 56.2 44.8 63.2 44.1

34 Nitrate (as NO3) mg/l 7.2 5.6 6.2 8.8

35 Total Nitrogen (as N),

mg/l 12.6 17.5 23.1 18.4

36 Total Phosphorous (as

P), mg/l 4.2 4.6 3.8 4.8

37 Total Coliform Count,

cfu /100ml 361 309 207 354

38 Faecal Coliform, cfu

/100ml 236 265 168 261

All the water analysis reports showing that the samples are considerably well below to the

prescribed limit in respect to biological constituents and metallic constituents, but sample of

Mauli village showing high salinity with Total Dissolved Solid concentration of 3740 ppm. All

the samples except the Mauli village one are hard in nature. None the water samples are

turbid in nature. The unit will operate with Zero Liquid Discharge concept and utilize the treated

water within the activity, thus, the unit would not affect the area’s surface water resource.

3.10 HYDROGEOLOGY

The Derabassi block is occupied by Quaternary Alluvial deposits belonging to the vast Indo-

Gangetic alluvial plains, which forms the main aquifer system. Groundwater occurs under

phreatic conditions in the shallow aquifers while leaky confined to confine conditions occur

along the deeper aquifers of Quaternary alluvial deposits. The proposed site situated in




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eastern part of the district - SAS Nagar, water level of the area ranges between 10 to 20

meters below ground level (bgl). Seasonal fluctuation 0.0 m to 2.0 m shows that, in general,

there is an overall decline in the water level.

Groundwater resource potential of the area has been assessed as per Groundwater Resource

Estimation Methodology (GEC-97) as on 31.03.09 by considering administrative block as the

assessment unit. The Net Annual Ground Water Availability of the block is 11,907 hams,

existing ground water draft for all uses is 15,612 hams. Provision for domestic and industrial

requirement supply to 2025 years is 2225 ham. Net ground water availability for future

irrigation development is - 4185 ham (i.e. deficit against demand). The stage of groundwater

development in Derabassi block is 133 % and falls under Over Exploited category.

Ground water Quality

Ground water quality had been assessed by selecting 8 sampling stations in impact zone. The

details of sampling locations and analysis reports are given below.

Table 3.16: Ground water Quality Monitoring Stations


GW-1 Project Site

GW-2 Barwala

GW-3 Derabassi

GW-4 Fatehpur Viran

GW-5 Ramgarh

GW-6 Dabkauri village

GW-7 Mauli village

GW-8 Batwal

Table 3.17a: Groundwater quality analysis report

Sl.

No.

Parameters GW1 GW2 GW3 GW4 Test Method

I Colour (Hazen

Unit)

<1 <1 <1 <1 IS:3025 (Pt-4)-1983




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Ii Odour Unobjection

able

Unobjection

able

Unobjection

able

Unobjection

able

IS:3025 (Pt-5)-1983

Iii Taste Agreeable Agreeable Agreeable Agreeable IS:3025 (Pt-7&8)-

1984

Iv Turbidity, NTU 4 3 3 2 IS:3025 (Pt-10)-1984

V pH Value 6.75 7.82 7.35 7.61 IS:3025 (Pt-11)-1983

Vi Total Hardness

(as CaCO3),

mg/l

502 181 176 296 IS:3025 (Pt-21)-1983

Vii Iron (as Fe),

mg/l

0.115 0.018 0.018 0.021 IS:3025 (Pt-53)-2003

Viii Chloride (as Cl),

mg/l

168 19.2 19.6 21.8 IS:3025 (Pt-32)-1988

Ix Fluoride (as F),

mg/l

<1.0 <1.0 <1.0 <1.0 IS:3025 (Pt-60)-2008

X Dissolved

solids, mg/l

1054 402 418 502 IS:3025 (Pt-16)-1984

Xi Calcium (as

Ca), mg/l

121 41.4 41 51 IS:3025 (Pt-40)-1991

Xii Magnesium (as

Mg), mg/l

57 15.6 19 17 IS:3025 (Pt-46)-1994

Xiii Copper (as Cu),

mg/l

BDL (0.01) BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-42)-1992

Xiv Manganese (as

Mn), mg/l


Xv Sulphate (as

SO4), mg/l

155 2.1 1.5 3.2 IS:3025 (Pt-24)-1986

Xvi Nitrate (as NO3),

mg/l

4.2 1.8 1.1 1.1 IS:3025 (Pt-34)-1988

Xvii Phenolic

compounds

(as C6H5OH),

mg/l


Xvii

i

Mercury (as

Hg), mg/l

BDL

(0.0002)

BDL

(0.0002)

BDL

(0.0002)

BDL

(0.0002)

IS:3025 (Pt-2)-2004

Xix Cadmium (as

Cd), mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL (0.002) IS:3025 (Pt-2)-2004

Xx Selenium (as

Se), mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL (0.002) IS:3025 (Pt-56)-2003




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Xxi Arsenic (as As),

mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL (0.002) IS:3025 (Pt-37)-1988

Xxii Cyanide (as

CN), mg/l


Xxii

i

Lead (as Pb),

mg/l


Xxi

v

Zinc (as Zn),

mg/l


Xxv Anionic

detergents

(as MBAS), mg/l

BDL (0.1) BDL (0.1) BDL (0.1) BDL (0.1) Methylene-blue

extraction method

Xxv

i

Chromium (as

Cr 6+), mg/l

BDL

(0.003)

BDL

(0.003)

BDL

(0.003)

BDL (0.003) IS:3025 (Pt-52)-2003

Xxv

ii

Mineral oil, mg/l BDL

(0.001)

BDL

(0.001)

BDL

(0.001)

BDL (0.001) IS:3025 (Pt-39)-1991

Xxv

iii

Alkalinity, mg/l 365 198 201 178 IS:3025 (Pt-23)-1986

Xxi

x

Aluminium (as

Al), mg/l


Xxx Boron, mg/l BDL (0.1) BDL (0.1) BDL (0.1) BDL (0.1) IS:3025 (Pt-57)-2005

Xxx

i

Coliform/100ml,

MPN

Less than 1 Less than 1 Less than 1 Less than 1 IS: 1622:1981

Xxx

ii

Escherichia

coli/100ml

Absent Absent Absent Absent IS: 1622:1981

Table 3.17b: Groundwater quality analysis report

Sl.

No.

Parameters GW-5 GW-6 GW-7 GW8 Test Method

I Colour (Hazen

Unit)

<1 <1 <1 <1 IS:3025 (Pt-4)-1983

Ii Odour Unobjecti

onable

Unobjection

able

Unobjection

able

Unobjection

able

IS:3025 (Pt-5)-1983

Iii Taste Agreeable Agreeable Agreeable Agreeable IS:3025 (Pt-7&8)-

1984

Iv Turbidity, NTU 3 3 3 2 IS:3025 (Pt-10)-1984

V pH Value 6.68 7.52 7.08 7.4 IS:3025 (Pt-11)-1983

Vi Total Hardness 257 358 214 281 IS:3025 (Pt-21)-1983




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(as CaCO3),

mg/l

Vii Iron (as Fe),

mg/l

0.085 0.071 0.083 0.06 IS:3025 (Pt-53)-2003

Viii Chloride (as Cl),

mg/l

21 105 58.2 90.5 IS:3025 (Pt-32)-1988

Ix Fluoride (as F),

mg/l

<1.0 <1.0 <1.0 <1.0 IS:3025 (Pt-60)-2008

X Dissolved

solids, mg/l

461 406 405 447 IS:3025 (Pt-16)-1984

Xi Calcium (as

Ca), mg/l

41.4 38 52 45 IS:3025 (Pt-40)-1991

Xii Magnesium (as

Mg), mg/l

22.4 17.2 21.9 18.2 IS:3025 (Pt-46)-1994

Xiii Copper (as Cu),

mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-42)-1992

Xiv Manganese (as

Mn), mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-59)-2006

Xv Sulphate (as

SO4), mg/l

30.8 15.2 2.6 12.4 IS:3025 (Pt-24)-1986

Xvi Nitrate (as NO3),

mg/l

3.6 1.8 1.5 1.2 IS:3025 (Pt-34)-1988

Xvii Phenolic

compounds

(as C6H5OH),

mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-43)-1992

Xviii Mercury (as

Hg), mg/l

BDL

(0.0002)

BDL

(0.0002)

BDL

(0.0002)

BDL

(0.0002)

IS:3025 (Pt-2)-2004

Xix Cadmium (as

Cd), mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

IS:3025 (Pt-2)-2004

Xx Selenium (as

Se), mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

IS:3025 (Pt-56)-2003

Xxi Arsenic (as As),

mg/l

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

BDL

(0.002)

IS:3025 (Pt-37)-1988

Xxii Cyanide (as

CN), mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-27)-1986

Xxiii Lead (as Pb),

mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-2)-2004




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Xxiv Zinc (as Zn),

mg/l

BDL

(0.02)

BDL (0.02) BDL (0.02) BDL (0.02) IS:3025 (Pt-49)-1994

Xxv Anionic

detergents

(as MBAS), mg/l

BDL (0.1) BDL (0.1) BDL (0.1) BDL (0.1) Methylene-blue

extraction method

Xxvi Chromium (as

Cr 6+), mg/l

BDL

(0.003)

BDL

(0.003)

BDL

(0.003)

BDL

(0.003)

IS:3025 (Pt-52)-2003

Xxvii Mineral oil, mg/l BDL

(0.001)

BDL

(0.001)

BDL

(0.001)

BDL

(0.001)

IS:3025 (Pt-39)-1991

Xxviii Alkalinity, mg/l 185 152 147 156 IS:3025 (Pt-23)-1986

Xxix Aluminium (as

Al), mg/l

BDL

(0.01)

BDL (0.01) BDL (0.01) BDL (0.01) IS:3025 (Pt-55)-2003

Xxx Boron, mg/l BDL (0.1) BDL (0.1) BDL (0.1) BDL (0.1) IS:3025 (Pt-57)-2005

Xxxi Coliform/100ml,

MPN

Less than

1

Less than 1 Less than 1 Less than 1 IS: 1622:1981

Xxxii Escherichia

coli/100ml

Absent Absent Absent Absent IS: 1622:1981

The ground water test report shows that the borewell within the proposed unit premises has

affected by Turbidity, the Total hardness, Total Dissolved Solids, Alkalinity in the water sample

exceeded the desirable limit of drinking water. The water reveals that the ground water at the

proposed project area is Hard, turbid and alkaline with containing higher amount of dissolved

solids. Thus, it is not suitable for drinking and industrial purpose without prior treatment. The

unit will require soft water and demineralised water for process needs, with accordingly the

unit will develop pre-treatment facility to minimise the turbidity, alkalinity and dissolved solids

up to 250-300 ppm, for requirement of minimisation of hardness, the facility will install the

softening plant before Boiler use and Process use. For requirement of drinking purpose, the

unit will install the RO system at the point of drinking water usage area to settle down further

the dissolved solids concentration up to 100 ppm.

The groundwater test report of the sampling location – Derabassi reveals that the ground water

of the area is slightly alkaline and not good for drinking use. It is clear that, the alkalinity

increment trend in the area’s ground water is a result of secondary contamination of the water

resource and due to the over-exploitation of the ground water, Thus, it is the responsibility to

the enterprise owners to restrict any contamination due to the industrial activity, as the area is

mainly dependent on ground water resource and the right of it firstly goes to the drinking use.




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The ground water quality of Fatehpur Viran village shows that, it is affected by total hardness

issue, as the result of TH exceeded the desirable limit of it, also, the water is not good for

drinking use without any treatment. All the other sampling stations report showing that the

ground water quality of those area is not acceptable for drinking use, thus minimum filtration

facility is required after tube or bore well facility to provide the villagers drinkable water, as

most the villages within the impact zone are depends only on ground water resource. The

development of high productive agricultural practices, industries and changing life style of

people have taken place which has affected the quality of surface and ground water and

making the resource more prone to deterioration. The ground water in the project impact area

is alkaline in nature with medium to high salinity. Thus, it is also suggested that the unit should

adopt a plan for water resource optimisation and provide training to the villager within close

proximity for better understanding of water resource.

3.11 BIODIVERSITY

The proposed unit has almost 1800 large trees having different age with almost 55,000.00

square meters of open and green field area. During expansion process, some of the plant

would be cutting down for purpose of clearance of land within the premises. But, in contrast,

after expansion, there will be almost 31,000. 00 square meters of area available for plantation,

and 16,000.00 sq. meters of land area has already been identified as green coverage

according the proposed layout plan. Additionally, the unit management will adopt the regular

social plantation plan to achieve the CO2-O2 balance. The existing trees are common wood

and fruit bearing trees, no one are endemic or endangered in nature. The detail list of trees is

given below.

Table 3.18: Plant species available within the plant premises

Sl. No. Plant common name Scientific name Number

1 Jamun Syzygium cumini (L.) Skeels 17

2 Amrood Psidium guajava L. 8

3 Safeda Eucalyptus obliqua L. Her 1504

4 Pipal Ficus religiosa L. 4

5 Kikar Vachellia karroo 27

6 Shisham Dalbergia sissoo Roxb. 54

7 Shahtut Morus sp. 5




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8 Sagwan Tectona grandis L.f. 5

9 Falidar 20

10 Babool Vachellia nilotica L. 5

11 Silver Cyathea sp. L. 30

12 Papri Terminalia catappa L. 7

13 Mango Mangifera indica L. 7

14 Neem Azadirachta indica A.Juss. 46

15 Amla Phyllanthus emblica L. 15

16 Arjun Terminalia arjuna (Roxb.) Wight & Am. 18

17 Harad Terminalia chebula Retz. 9

18 Bahera Terminalia bellirica (Gaertn.) Roxb. 16

19 Haati fal 9

Species occurring very rarely in the Punjab Shivalik’s include 3 species of Algae, 2 species of

Fungi, 5 species of Pteridophytes, and 44 species of Angiosperms (PSoER, 2005). Species

like Terminalia bellirica and T.chebula seem to be the victims of overexploitation for medicinal

purpose. Likewise, Grewia optiva (leaves used as fodder), Pueraria tuberosa (edible tubers e)

and Bauhinia vahlii (leaves used for making food plates) have suffered extensive damage

because of the utilization of different parts for various purposes. The native and dominant flora

of the semi-arid Punjab like Prosopis cineraria and Tecomella undulata find a prominent place

under the 'threatened' category because of levelling of sand-dunes for agricultural purposes

(Sharma, 2002). Amongst fauna the globally threatened species are 2 types of reptiles,

namely, brown river turtle, Indian rock python; 6 species of birds – White-rumped vulture (Gyps

bengalensis), Long-billed vulture or griffon (Gyps indicus), Oriental Darter (Anhinga

melanogaster), Ferruginous Pochard (Aythya nyroca ), Pallid Harrier (Circus macrourus) and

Painted Stork (Mycteria leucocephala) ; and 2 species of mammals, Smooth coated Otter

(Lutrogale perspicillata) and Indian Pangolin (Manis crassicaudata ) (Source: ZSI).

As per the ZSI report, the unit has 2 plant species at their premises, which are categorised as

local victim due to over-exploitation for medicinal use, the unit would not have any such use,

but due to site clearance activity, plant species would be cut down, the special care is

suggested to deviate the specific species cutting to maximum extent. On the other hand, there

are no bird corridor within the impact area, no other endangered fauna’s breeding centre also

located within the impact area. The impact area only crossing the very little part of the Chattbir

Zoological park, but the distance the location is almost 9.8 km from the proposed project site




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and the eco-sensitive zone is a well-protected amusement cum zoological park. Thus, it would

have predicted that no effect will disturb the wildlife of the zoo.

3.12 HAZARD PROFILE

In upper to mid reaches of the Indus Basin, rivers like Jhelum and Chennab are the cause of

flooding. Major flooding is generally associated with the monsoon low depression that

develops in the Bay of Bengal and move across India in west/north-westerly direction to enter

Pakistan. Apart from river floods that particularly affect districts of Sialkot, Narowal, Mandi

Bahuddin, Sargodha, Khushab, Shikhupura, Layyah, Rajanpur, D.G. Khan, Jhang,

Muzaffargarh and Jehlum, flash floods also hit hilly and mountain areas of Punjab, which may

cause landslides and road erosion. The confluence of river basins, the canal irrigation network

and interrupted drainage system are some of the major reasons for flooding in Punjab. Thus,

the proposed location would not have any Flood risk at all.

Drought is a slow on set phenomenon that affects various sectors in the vulnerable areas.

They affect large geographic areas than floods or other hazards. Drought has many definitions

but the common one is the meteorological drought that is characterised by a reduction in

rainfall over a region for a specified period (day/month/season/year) below a specified amount,

usually defined as some proportion (percentage) of the long-term average for the specified

time period. The main arid rangelands in the province include Cholistan, D. G. Khan and Thal

areas. Rainfall variation during different seasons is also considerably high. Climate in lower

southern part of the province is arid and hyper-arid. Low rainfall and precipitation resulted in

the lowest water levels recorded in Pakistan. In the year 2000 the rainfall was 14 percent lower

than that in 1999, following on from declines of 13.2 percent and 26.2 percent in 1999 and

1998 respectively. 21% of Punjab province's economy was affected by the drought of 1998-

2002. According to the Meteorological Department, the districts of Rawalpindi, Chakwal,

Jhelum, Bahawalpur, R.Y. Khan, D.G. Khan, Khushab, Multan, Attock, Mianwali,

Bahawalnagar, Bhakkar, Layyah, Rajanpur, Narowal and Muzafargarh are prone to drought

hazard. Thus, the proposed project area does not have any high drought risk.

The term landslide is used in its broad sense to include downward and outward movement of

slope forming materials (natural rock and soil). It is caused by heavy rain, soil erosion and

earth tremors and also happens in areas under heavy snow. The proposed project area is out

of any landslide risk, as the terrain is more or less plain, and does not have any river flow

within close proximity.




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As the unit has very close proximity to the highway and Derabassi-Barwala road, the road has

frequented heavy vehicle movement, and the unit also have regular heavy vehicle movement,

thus, the industry requires freight movement management scheme to minimise the risk of road

accident.

The unit is prone to industrial accident risk as the industry deals with multiple hazardous

chemicals. The unit is accredited with BS OHSAS 18001:2008 management system, and

additional Disaster management plan has already been designed and prepared with reflection

to the additional chemicals after proposed expansion. The unit will manage and run as per the

guidelines prescribed by the MOEFCC and OSHA.

The proposed Project area is lies within the seismic zone IV, thus the area would have risk of

earth quake with moderately high effect. The expansion construction shall be incorporated as

per the approved building plan.

3.13 SOCIAL STRUCTURE

In 2011, the district had population of 994,628 of which male and female were 529,253 and

465,375 respectively. The density of the state increased to 909 persons per square kilometres

from 629 persons in 2001, thus, the area experiences huge population growth due to massive

development from agricultural dominance to industrial growth. It is resulting the job potential

conflict also, the unit will require almost 330 nos. of human resource after expansion, thus, it

will be beneficial to area’s demographic and social growth. The district has sex ratio of 879

with literacy rate of 83.80 percent. The area is well developed with industrial infrastructure.

The proposed unit has close connectivity with social commodities like Hospital, School, Bank,

Post offices etc.

3.14 ARCHEOLOGICAL AND CULTURAL PLACES

Fateh Burj

Chappar Chiri, has 35 kilometres of distance from proposed project unit, has a special place

in Sikh history. It was here that Banda Singh Bahadur, one of the most respected Sikh warriors,

won a decisive battle against Wazir Khan, commander of the Mughal army.




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A grand memorial, Fateh Burj, set amidst a vast landscaped complex to mark that victory, is

a befitting tribute, albeit a few centuries late. It stands at the centre of the field where the battle

was fought in 1710. I have some reasonably decent visuals from a recent visit.

Fig. 3.12: Fateh Burj

Mohali Cricket Stadium

The proposed unit has close proximity to the Mohali cricket stadium. The stadium has 25 km

of distance from the proposed unit. The stadium has been hosted multiple prestigious national

and international cricket matches.

Chhatbir Zoological Park

Chhatbir Zoo (formally Mahendra Chaudhary Zoological Park), is a zoological park situated

close to Zirakpur, India. The zoo was constructed in the 1970s and is home to a large variety of

birds, mammals and reptiles. The zoo was inaugurated on 13 April 1977 by the then governor of

Punjab Mahendra Mohan Choudhry, and it was christened as Mahendra Chaudhury Zoological

Park. Initially the zoo was populated by a small number of animals brought from Guwahati

Zoo, Assam. The zoo has an almost 17 km roadways distance from the proposed project site.

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