1
FORM-1
for
PROPOSED EXPANSION OF SILICA SAND
PROCESSING PLANT (GLASS GRADE) & LPG STORAGE
CAPACITY FOR GLASS MANUFACTURING UNIT
of
M/s. GUJARAT GUARDIAN LTD. VILLAGE: KONDH, VALIA ROAD,
TAL: ANKLESHWAR - 393001, DIST: BHARUCH (GUJ.)
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
NABL Accredited Testing Laboratory
ISO 9001:2008 Certified Company
Aqua-Air Environmental Engineers P. Ltd.
403, Centre Point, Nr. Kadiwala School, Ring
Road, Surat - 395002
Prepared By:
2
APPENDIX I
(See paragraph - 6)
FORM 1
Sr.
No.
Item Details
1. Name of the project/s M/s. Gujarat Guardian Limited
2. S. No. in the schedule 2(b) & 6 (b)
3. Proposed capacity/ area/ length/
tonnage to be handled/ command area/
lease area/ number of wells to be drilled
Please refer Annexure – I
4. New/Expansion/Modernization Expansion
5. Existing Capacity/Area etc. Existing Capacity:
Glass Manufacturing Unit:
Float Glass, Mirror, Lacquered Glass & Coater Glass =
2,50,00,000 Sq. meter/Annum
Silica Sand (Glass Grade) and By-Products (Coarse, Fines
and Rejects) = 33,120 MT/Month
LPG Tanks: 4 Nos. (Capacity = 56.25 MT each) (Length =
16.2 m, Diameter = 3200 mm) i.e. Total Capacity = 225 MT
Total Proposed Capacity:
Glass Manufacturing Unit:
Float Glass, Mirror, Lacquered Glass & Coater Glass =
6,50,00,000 Sq. meter/Annum
(Existing = 2,50,00,000 Sq. meter/Annum + Additional
Proposed (Float Glass) = 4,00,00,000 Sq. meter/Annum)
Additional Silica Sand (Glass Grade) and By-Products
(Coarse, Fines and Rejects) = 53,380 MT/Month
Total Silica Sand (Glass Grade) and By-Products (Coarse,
Fines and Rejects) = 86,500 MT/Month
LPG Tanks: 6 Nos. (Capacity = 120 MT each) (Design
Pressure = 21 Kg/cm2, Length = 24000 mm, Tank ID = 4010
mm, Tank Shell = 28 mm thick, Dished End = 18 mm thick)
i.e. Total Capacity = 720 MT**
** The existing and proposed LPG storage Yard will be
merged and the total capacity (existing + proposed) will be
720 MT
6. Category of Project i.e. ‘A’ or ‘B’ 'A'
7. Does it attract the general condition? If
yes, please specify.
N/A
8. Does it attract the specific condition? If
yes, please specify.
No
Location 9.
Plot/Survey/Khasra No. As per the plot detail attached
3
Village Kondh, Valia Road
Tehsil Ankleshwar
District Bharuch
State Gujarat
10. Nearest railway station/airport along
with distance in kms.
Railway Station: Ankleshwar (15.5 km)
Airport: Surat (75 km)
11. Nearest Town, city, District Headquarters
along with distance in kms.
Kondh Village (1.5 km),
Bharuch (25 km)
12. Village Panchayats, Zilla Parishad,
Municipal Corporation, local body
(complete postal address with telephone
nos. to be given)
Kondh Village, Taluka: Ankleshwar – 393 001,
Dist: Bharuch (Gujarat)
13. Name of the applicant M/s. Gujarat Guardian Limited
14. Registered Address Village: Kondh, Valia Road,
Tal: Ankleshwar - 393001, Dist: Bharuch (Guj.)
Address for correspondence:
Name Mr. Shyam Raghuwanshi
Designation (Owner/Partner/CEO) Executive (EHS)
Address M/s. Gujarat Guardian Limited
Village: Kondh, Valia Road,
Tal: Ankleshwar - 393001, Dist: Bharuch (Guj.)
Pin Code 393 001
E-mail [email protected]
Telephone No. Phone: (02643) 275106 to 275115
Mob.: +91 7043058700
15.
Fax No. NA
16. Details of Alternative Sites examined, if
any.
Location of these sites should be shown
on a top of sheet.
NA
17. Interlinked Projects Proposed Float Glass Manufacturing Line 2, Refer Annexure
- I
18. Whether separate application of
interlinked project has been submitted?
No
19. If yes, date of submission NA
20. If no, reason As the Proposed Float Glass Manufacturing Line 2 does not
fall under Schedule of EIA Notification, 2006
21. Whether the proposal involves
approval/clearance under: if yes, details
of the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z. Notification, 1991?
No
22. Whether there is any Government
Order/Policy relevant/relating to the
site?
No
23. Forest land involved (hectares) NA
24. Whether there is any litigation pending
against the project and/or land in which
the project is propose to be set up?
(a) Name of the Court
(b) Case No.
NA
4
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
Capacity corresponding to sectoral activity (such as production capacity for manufacturing, mining
lease area and production capacity for mineral production, area for mineral exploration, length for
linear transport infrastructure, generation capacity for power generation etc.,)
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of with approximate quantities frates,
wherever possible) with source of information data
1.1 Permanent or temporary change in
land use, land cover or topography
including increase intensity of land
use (with respect to local land use
plan)
No Proposed Expansion Details:
Total Cost of the Project is Rs. 670 Crores
(Existing = 584 Crores + Additional = 86 Crores)
Total Plot Area = 6,55,990.4 m2
Green Belt :
Existing = 98,436 m2
Proposed = 1,18,040 m2
1.2 Clearance of existing land, vegetation
and Buildings?
Yes Already available
1.3 Creation of new land uses? Yes We are considering the procurement of less than 5
acres of additional land adjacent to the existing plant
boundary through lease or purchase. Such additional
land, if leased or purchased, will be utilized for truck
and contractor vehicle parking.
1.4 Pre-construction investigations e.g.
bore Houses, soil testing?
Yes Soil investigation will be done
1.5 Construction works? Yes Plant Layout attached as Annexure - II
1.6 Demolition works? Yes Demolition of existing sand plant
1.7 Temporary sites used for
construction works or housing of
construction workers?
No
1.8 Above ground buildings, structures or
earthworks including linear
structures, cut and fill or excavations
No Plant Layout attached as Annexure - II
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works? No
1.11 Dredging? No
1.12 Off shore structures? No
1.13 Production and manufacturing
processes?
Yes For detail Please refer Annexure –III
1.14 Facilities for storage of goods or
materials?
Yes Specified storage area shall be provided for storage
of goods, Raw materials & Finished products.
1.15 Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes For detail please refer Annexure – IV & V
1.16 Facilities for long term housing of
operational workers?
No
5
1.17 New road, rail or sea traffic during
Construction or operation?
Yes Internal Roads will be provided
1.18 New road, rail, air waterborne or
other transport infrastructure
including new or altered routes and
stations, ports, airports etc?
No
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in Traffic
movements?
No
1.20 New or diverted transmission lines or
Pipelines?
No
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or
aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water
form ground or surface waters?
No No ground water shall be used. The raw water shall
be supplied by Valia Water Supply System (Canal
Water).
1.24 Changes in water bodies or the land
surface Affecting drainage or run-off?
No
1.25 Transport of personnel or materials
for construction, operation or
decommissioning?
Yes Transportation of personnel, raw material and
products will be primarily by road only
1.26 Long-term dismantling or
decommissioning or restoration
works?
Yes We will be dismantling the existing Sand
beneficiation plant once the new float glass line
construction will start.
1.27 Ongoing activity during
decommissioning which could have
an impact on the environment?
Yes During decommissioning work, only dust
contamination will be there & water sprinklers shall
be utilized whenever necessary.
1.28 Influx of people to an area either
temporarily or permanently?
Yes M/s. Gujarat Guardian Limited will give direct
employment to local people based on qualification
and requirement. In addition to direct employment,
indirect employment shall generate ancillary business
to some extent for the local population.
1.29 Introduction of alien species? No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
6
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr. No. Information/checklist confirmation Yes/No Details there of (with approximate quantities
frates, wherever possible) with source of
information data
2.1 Land especially undeveloped or
agricultural land (ha)
No
2.2 Water (expected source & competing
users) unit: KLD
Yes The entire water requirement will be met through
Valia Water Supply System (Canal Water). For detail
please refer Annexure – VI
2.3 Minerals (MT) Yes Silica Sand
2.4 Construction material: stone,
aggregates, and / soil (expected
source – MT)
Yes Construction materials like crushed stones, sand,
rubble, cement, steel, etc. required for the project
shall be procured from the local market of the
region.
2.5 Forests and timber (source – MT) No
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel
(MT), energy (MW)
Yes For detail please refer Annexure – VI
2.7 Any other natural resources (use
appropriate standard units)
Yes 34 Wind Mills of 800 KW each are installed at
Dwarka Site.
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
3.1 Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna,
and water supplies)
Yes For detail please refer Annexure –VII.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
3.4 Vulnerable groups of people who could be
affected by the project e.g. hospital
patients, children, the elderly etc.
No
3.5 Any other causes No
(II) Production of solid wastes during construction or operation or decommissioning (MT/month)
7
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or
commercial wastes)
Yes Please refer Annexure – V
4.3 Hazardous wastes (as per Hazardous Waste
Management Rules)
Yes Please refer Annexure – V
4.4 Other industrial process wastes Yes Please refer Annexure – V
4.5 Surplus product No
4.6 Sewage sludge or other sludge from
effluent treatment
Yes
Please refer Annexure – V
4.7 Construction or demolition wastes
Yes
We will be dismantling the existing Sand
beneficiation plant once the new float glass line
construction will start and that will result into
generation of metal scrap and other waste.
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
Please refer Annexure – V
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr.)
Sr. No. Information/Checklist
confirmation
Yes/No Details there of (with approximate quantities/rates,
wherever possible) with source of information data
5.1 Emissions from combustion of
fossil fuels from stationary or
mobile sources
Yes For details Please refer Annexure – VIII
5.2 Emissions from production
processes
Yes For details Please refer Annexure – VIII
5.3 Emissions from materials
handling storage or transport
Yes All liquid raw materials, chemicals are procured
in tankers and are transferred through a closed pipe lines.
Solid raw materials (Batch) are feed into furnace through
close pipeline/chute/conveyors and the dust collection
hoppers are connected to a bag filter and ID fan.
Also, all hazardous chemicals (flammable) storage tanks
are provided with safety, Excess flow valve & remote
operating valve for safety wherever applicable.
5.4 Emissions from construction
activities including plant and
equipment
Yes During construction work, only dust contamination will be
there & water sprinklers shall be utilized whenever
necessary.
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste
Yes Dust will be taken care by using suitable engineering
controls & PPE’s
8
5.6 Emissions from incineration of
waste No
5.7 Emissions from burning of waste
in open air e.g. slash materials,
construction debris)
No
5.8 Emissions from any other
sources No
(III) Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data with source of information
data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes All machinery / equipment shall be well
maintained, shall have proper foundation with anti
vibrating pads wherever applicable. Expected Noise
level at different locations in the plant is enclosed
as Annexure – IX
6.2 From industrial or similar processes Yes Please refer Annexure – IX
6.3 From construction or demolition Yes Please refer Annexure – IX
6.4 From blasting or piling Yes Please refer Annexure – IX
6.5 From construction or operational traffic Yes Please refer Annexure – IX
6.6 From lighting or cooling systems Yes Please refer Annexure – IX
6.7 From any other sources No
7. Risks of contamination of land or water from releases of pollutants into the ground or into
sewers, surface waters, groundwater, coastal waters or the sea:
Sr. No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible) with source
of information data
7.1 From handling, storage, use or
spillage of hazardous materials
Yes Hazardous materials are stored in designated
storage area with bund walls for tanks. Other
materials are stored in bags/drums on pallets with
concrete flooring and no spillage is likely to occur.
All liquid raw materials are transported through
pumps and closed pipelines and no manual
handling is involved. Spill Containers are kept at
appropriate places to collect spillage. SOP for
collection, decontamination & disposal of spilled
materials are displaced at necessary locations. For
details please refer Annexure – VII
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
Yes The wastewater generated from Cooling & Washing
will be reused in Sand Plant for Sand processing
through recirculation. The Domestic wastewater
9
discharge) will be treated in Sewage Treatment Plant or stored
in septic tank or soak pit and will be reused for Land
Irrigation/Gardening. Hence, it will be a Zero Liquid
Discharge Plant.
7.3 By deposition of pollutants emitted
to air into the and or into water
No
7.4 From any other sources No
7.5 Is there a risk of long-term build up
of pollutants in the environment
from these sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
Sr.
No.
Information/Checklist
confirmation
Yes/No Details there of (with approximate quantities/rates,
wherever possible) with source of information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous
substances
Yes For detail please refer Annexure – VII
8.2 From any other causes No
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No
9. Factors which should be considered (such as consequential development) which could lead
to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr. No.
Information/Checklist confirmation
Yes/
No
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
9.1 Lead to development of supporting. utilities,
ancillary development or development
stimulated by the project which could have
impact on the environment e.g.
• Supporting infrastructure (roads, power
supply, waste or waste water treatment, etc.)
housing development
extractive industry
supply industry
other
Yes For detail please refer Annexure – X
9.2 Lead to after-use of the site, which could have
an impact on the environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to proximity to
other existing or planned projects with similar
effects
No
10
(IV) Environmental Sensitivity
Sr. No. Areas Name/
Identity
Aerial distance (within 5 km.) Proposed
project location boundary
1 Areas protected under international
conventions, national or local legislation for
their ecological, landscape, cultural or
other related value
No
2 Areas which important for are or sensitive
Ecol logical reasons – Wetlands,
watercourses or other water bodies,
coastal zone, biospheres, mountains,
forests
No
3 Area used by protected, important or
sensitive Species of flora or fauna for
breeding, nesting, foraging, resting, over
wintering, migration
No
4 Inland, coastal, marine or underground
waters
No No inland, costal or marine within 5 km
from the proposed expansion project
5 State, National boundaries No
6 Routes or facilities used by the public for
access to recreation or other tourist,
pilgrim areas
No
7 Defense installations No
8 Densely populated or built-up area Ankleshwar Ankleshwar is around 7 km from the
proposed expansion project site.
9 Area occupied by sensitive man-made land
uses Hospitals, schools, places of worship,
community facilities)
No
10 Areas containing important, high quality or
scarce resources (ground water resources,
surface resources, forestry, agriculture,
fisheries, tourism, minerals)
No
11 Areas already subjected to pollution
environmental damage. (those where
existing legal environmental standards are
exceeded) or
No
12 Areas susceptible to natural hazard which
could cause the project to present
environmental problems (earthquakes,
subsidence, landslides, flooding, erosion, or
extreme or adverse climatic conditions)
No
IV). Proposed Terms of Reference for EIA studies: For detail please refer Annexure–XI
11
12
LIST OF ANNEXURES
SR.
NO.
NAME OF ANNEXURE PAGE NOS.
I List of Products with their Production Capacity
List of Raw Materials
14
15-16
II Layout Map of the Plant 17-19
III Brief Manufacturing Process Description 20-33
IV Description of Effluent Treatment Plant with flow diagram 34-39
V Details of Hazardous Waste 40-41
VI Water, Fuel & Energy Requirements 42-44
VII Details of Hazardous Chemicals Storage & Handling 45
VIII Details of Stacks and Vents 46-48
IX Expected Noise level at Different source within the premises 49
X Socio-economic Impacts 50
XI Proposed Terms of Reference for EIA studies 51-52
XII Water Supply Letter 53-56
XIII TSDF & CHWIF Membership Letter 57-59
XIV Lease Deed Documents 60-83
XV CCA Copy of Year 1995 84-86
XVI Toposheet 87
13
ANNEXURE-I
LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY
Sr.
No.
Name of Unit Name of
Product
Existing
Capacity
Additional
Proposed
Capacity
Total Proposed
Capacity
Remarks
1 Glass
Manufacturing
Unit
Float Glass
Mirror,
Lacquered Glass,
Coater Glass
2,50,00,000
m2/Annum
4,00,00,000
m2/Annum
6,50,00,000
m2/Annum
-
2 Silica & Sand
Production
Unit
Silica Sand
(Glass Grade) &
By-Products
(Coarse, Fines &
Rejects)
33,120
MT/Month
53,380
MT/Month
86,500
MT/Month
-
3 LPG Storage - 225 MT
(4 x 56.25
MT of Length
= 16.2 m &
Diameter =
3200 mm)
495 MT 720 MT
(6 x 120 MT of
Design Pressure
= 21 Kg/cm2,
Overall Length =
24000 mm, Tank
ID = 4010 mm,
Tank Shell = 28
mm Thick,
Dished End= 18
mm Thick)
The Existing & Proposed
LPG Storage Yard will be
merged and the Total
Capacity (Existing +
Proposed) will be 720 MT
14
LIST OF RAW MATERIAL (EXISTING & PROPOSED)
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
Float Glass
1 Sand MT 14,000 21,315 35,315
2 Soda Ash MT 4,500 6,900 11,400
3 Dolomite MT 3,800 5,790 9,590
4 Limestone MT 1,400 2,160 3,560
5 Feldspar MT 850 1,300 2,150
6 Salt Cake MT 215 330 545
7 Carbon MT 21 32 53
8 Cullet MT 6,000 8,500 14,500
9 EP/Filter Dust MT 0 300 300
Wet Coater
1 Raw Glass Sq. Meter 5,83,000 - 5,83,000
2 Washing & Polishing Chemicals Kg 2,062 - 2,062
3 Tin Sensitizer Litre 119 - 119
4 Palladium Sensitizer Litre 45 - 45
5 Silver Solution
Silver Nitrate
Litre
Kg
2,600
1,088
- 2,600
1,088
6 Reducer/
Silver less solution
Litre
Litre
4,830
2,920
- 4,830
2,920
7 GMPA & GMPB Litre 1,190 - 1,190
8 Paint MT 68 - 68
9 Ortho-Xylene Litre 9,971 - 9,971
10 HCL-32% Litre 11,393 - 11,393
11 Caustic-32% Litre 13,508 - 13,508
12 Ferric Sulfate Kg 256 - 256
13 Copper Sulphate Pentahydrate Kg 1,440 - 1,440
14 Potassium Sodium Tartrate Kg 20 - 20
15 Iron Powder Kg 50 - 50
16 Sulphuric Acid Kg 230 - 230
Lacquered Glass
1 Raw Glass Sq. Meter 1,50,000 - 1,50,000
2 Washing and polishing chemical Kg 200 - 200
3 Adhesion Promoter Litre 50 - 50
4 Paint MT 10 - 10
A GLASSOLUX NG 9003 PURE WHITE Kg 2,500 - 2,500
B GLASSOLUX NG 2105 Sapphire Kg 2,500 - 2,500
C GLASSOLUX NG 3004 Burgundy Kg 2,500 - 2,500
D GLASSOLUX NG 6113 Fluo green Kg 2,500 - 2,500
E GLASSOLUX NG 9005 Black Kg 2,500 - 2,500
F Ivory Kg 2,500 - 2,500
G Red Kg 2,500 - 2,500
5 Ortho-Xylene Litre 1,000 - 1,000
15
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
Sand Beneficiation Plant
1 Raw Silica Sand MT 33,120 53,380 86,500
Coater Glass
1 Raw Glass Sq Meter 5,83,333 - 5,83,333
2 Washing and polishing chemical Kg 2,000 - 2,000
3 Zr Kg 20 - 20
4 Si – 8 wt % Al Kg 300 - 300
5 Nb – 10 wt % Zr Kg 140 - 140
6 Ni – 20 wt % Cr Kg 180 - 180
7 Ag Kg 100 - 100
8 TiOx Kg 5 - 5
9 Sn Kg 80 - 80
10 Zn – 2 wt % Al Kg 20 - 20
11 Ar m3 800 - 800
12 O2 m3 100 - 100
13 N2 m3 500 - 500
14 Vacuum Pump Oil Litre 400 - 400
15 Sand Blasting Material MT 5 - 5
Emission Control System
1 Aqueous Ammonia MT 350 350
2 Hydrated Lime MT 85 85
16
ANNEXURE-II
LAYOUT MAP OF THE PLANT
1) LAYOUT WITH NEW SAND PLANT FOR WHICH EC IS APPLIED
2) LAYOUT WITH NEW SAND PLANT AND FLOAT LINE 2
Float Line 2
New Sand Plant
17
LPG STORAGE LAYOUT (EXISTING)
18
LPG STORAGE LAYOUT (PROPOSED)
19
ANNEXURE-III
BRIEF PROCESS DESCRIPTION Existing and Proposed
Below is the manufacturing process for following products;
1. Sand Processing
2. Float Glass
3. Mirror Glass
4. Deco Crystal /Lacquered Glass
5. Sputter Coater
1. Existing Sand Beneficiation Process
The basic beneficiation process comprises of chemical and mechanical treatment of raw sand to remove
embedded heavy minerals, clay and over and under size grain. This involves washing sand with water and
then applying mechanical media to scrub the impurities and there after treating with chemicals to froth out
the heavy minerals and other impurities.
20
SAND PLANT (PROPOSED – CAPACITY ENHANCEMENT)
Process Description
Stage 1 (Feeding Circuit): Sand is received on two different Feed hoppers, which is fitted with belt feeder,
for effectively feeding sand ore to the circuit. Two different hoppers are used to treat two different feed
material having different characteristics. Hopper is also equipped with Grizzly of roughly 80mm bars to
eliminate extremely large oversized material that can damage the hopper. It is provided with a VSD and a
belt weighing system and thus feed to the system can be controlled and monitored continuously. The belt
feeder transfers the sand to the Feed Conveyor. This conveyor feeds the ProGrade screen.
Stage 2: The ProGrade™ screen is fitted with double decks to separate -50+10 mm, -10+2 mm, -2 mm
particles from the feed. The decks of the screen are fitted with high pressure water jet system with
individual controls which effectively wash the material and ensures proper screening. Both products are
collected on wing conveyors as Product # 1 and # 2.
Stage 3: Underflow of the ProGrade™ screen containing all <2mm particles, slurry report to a sump &
pump, this will feed the cyclone of EvoWash™ which is a fines treatment circuit. EvoWash™ system is a
combination of a sump, pump, dewatering screen and cyclones. The slurry containing all <2mm particles
are pumped to the cyclones from the sump. This removes a significant amount of ultrafine (~ <106
microns) out of the system. The underflow of these cyclones falls onto a dewatering screen integrated with
EvoWash™. This screen will dewater the fines. The clean and washed material as overflow from the screen
is feed attrition cell.
Stage 4: Pre-washed and dewatered Sand from the EvoWash™ is fed to an Attrition Cell for surface
cleaning. Provision for water addition is made to increase or decrease percentage solid inside Attrition cell
to either increase attrition time or decrease attrition time to control for intense scrubbing operation.
Stage 5: After attrition scrubbing, the sand slurry is taken into a sump to pump the slurry to a sizing screen
for separation of 600 micron. The oversize sand is stockpiled after moisture reduction (Further grinding
space will considered in the G.A drawing. The screen undersize (-600 micron) is sent to stage 6 for further
processing.
Stage 6: The screen undersize (-600 micron) sand slurry is then pumped to Hydro-cyclone for two stage
Gravity separation for removal of heavy minerals. Cyclone is used to control the proper feed slurry density
of spiral. Sand with heavy minerals is discharged as Concentrate and is rejected from the system and mixed
with secondary product. The combination of heavy and middling is also collected in another EvoWash™ for
stockpiling as another product through a transfer conveyor followed by a mobile conveyor.
Stage 7: The overflow of both the cyclones from the EvoWash™ in middling & heavy part &
EvoWash™ under the ProGrade™ is fed to NanoWash. This NanoWash is used for finer cut during de-
sliming and cyclone underflow is also collected on an Evoscreen for stockpiling as another product (-106+45
micron).
Stage 8: Final product after gravity separation is discharged as Tailings is pumped to Hydrocyclone and then
underflow of cyclone falls into a CFCU classifier for removal of rest of the ultrafine material. The principal of
operation of a CFCU is to use a constant upward stream to clarify heavy from lighter particles. In the case of
the heavier particles, weight has a greater effect than drag due to upward current, resulting in falling of the
heavier particles. Lighter particles are capable of remaining in suspension, so the addition of an upward
current is enough to drag them over a weir at the top surface of the clarifier. Slurry is fed as underflow of
the Hydrocyclone into the top of the clarifier while clean water is fed through evenly distributed spray
nozzles into the base of the tank. The heavier falling particles are removed near the base of the tank
21
through a pneumatically actuated and electronically controlled pinch valve. The pinch valve act as a rubber
sleeve inside a steel outer casing- the effect of pressurized air between the two is enough to completely
contract the circumference of the rubber sleeve. The time the pinch valve is open/closed is a key factor in
the type of material that is eventually produced.
As mentioned above, the lightweight particles overflow the top weir of the tank. Both products will require
dewatering before they can be stockpiled. The level in the clarifier can be visually inspected through the
window in its side, however a pressure transducer near the base will give a much more accurate view of
the amount of material in the tank. This readout gives a percentage based on the current transducer
reading a target percentage that will regulate the pinch valves to attempt to achieve it.
After this sand is discharged to the dewatering screen, which ensures a low moisture content of the final
product. Through an inbuilt wing conveyor, the product is discharged to a mobile conveyor for creating
multiple stockpiles.
Stage 9: The combined slurry from the washing circuit (hydrocyclones overflow) will pass to our
AquaCycle® High-Rate Thickener to rapidly settle and control the tailings. Dense sludge of circa 450-
550g/litre will be issued from the integrated heavy-duty pump for discharge to a remote designated
settlement area. Part of clean recycled water (thickener overflow) is immediately released from the
Thickener and will be sent to the water tanks, ready for recycle to the washing system. The Thickener is
highly preferable to the majority of other mechanical settlement aids as there is virtually no agitation of
the sludge bed and polyelectrolyte usage is kept to a minimum; circa 5 to 7 times less than some other
well-known systems. Furthermore, the ability of the AquaCycle® to pump waste solids to a remote area for
final settlement means that valuable plant area is not taken up for sludge control.
Stage 10: The sludge is discharged to the sludge pond by an in-built slurry pump. A high pressure flexible
Feed Pipe is connected to existing slurry pipeline that is carrying the sludge to the pond. The polymer is
first properly mixed and stirred by the agitators within the Flocstation® tank (part of EasySettle system) and
a proper solution is prepared. The dosing system is equipped with rotameter to check necessary flow rate
and allowing required adjustments. PLC panel controls the entire process automatically. An assembly of In-
line mixer is installed on the slurry pipeline to facilitate proper mixing of polymers with the sludge during
dosing. The mixed solution of slurry and polymer is thereafter fed to the sludge pond consistently. As an
effect of polymer mixing with sludge allows the sludge to adhere to each other quickly by draining out
water content from its formed structure, clear water oozes out from it and the slurry is gradually solidified.
The clear water recovered from the sludge can be pumped out from the pond for reuse.
To reduce the amount of iron in high iron sand down to the required level, we would also be using either
magnetic separator or floatation process considering the uncertainty in availability of low iron sand in
future.
22
Proposed Sand Beneficiation Process Diagram
Raw Sand Processing Mass Balance Details:
Estimated Output Quantities as % per Month
S.No. Aspect Input % Quantity End use
1 Sand Feed 86500 100 Feed to the plant
2 Rejection Boulders 2 1730 Reuse in plant by crushing in rod mill
3 Feed to plant 84770 98 84770
4 Generation of pebbles 5 4238.5 Sale to Construction Industry
5 Feed to process 80531 80531.5
6 Clay generation 18 14495.67
Store in Lagoon and sale for
construction landfill vendor
7
Glass Grade generation 55 44292.325 Use for Glass production
8
Saleable Sand 27 21743.505
To be sold to resin coated sand
manufacturer
23
1. Glass Manufacturing
Existing (Float Line 1) and Proposed (Float line 2)
a) Float Glass
The basic float glass manufacturing process was invented in the mid- 1950’s due to inherent efficiency over
the then existing sheet and plate production methods. The most significant advantages of the float process
lie in its highly automated production process and the consistency of product quality. For example, the
float process compared to the sheet glass process requires less manual handling, it is more cost efficient to
produce and eliminates significant distortion in the glass. Over the last thirty years, there have been several
technological advances towards design and manufacture of refractories and equipment applicable to the
float glass manufacturing.
The float glass manufacturing process is consisting of receiving raw materials (Silica sand, Soda Ash,
Limestone, Dolomite, Salt Cake, and minor ingredient materials including Rouge and Charcoal) in bulk
quantities by rail and road from various locations. Raw material is unloaded and stored in batch house,
then weighed into batches, mixed and then layered with broken glass (“Cullet”) returned from the end of
the process line. The mixed batch is conveyed to the furnace where the raw materials is be melted using
either natural gas or combination of natural gas and LPG.
Molten glass from the furnace is flow by gravity and displaced into a tin bath where a continuous ribbon is
formed by controlling glass temperature with time. The ribbon is pulled, or drawn, through the bath on a
layer of molten tin, the temperature of which is be controlled electrically. Upon existing the bath, the
ribbon of glass enters the electrically heated annealing lehr where in it is be cooled preparatory to cutting
into sheets.
A computer controlled automatic cutting system is cut the ribbon into predetermined sizes as dictated by
customer orders. Pieces are than either is placed in racks, boxes, or on dollies for storage or direct
shipment. Any waste or damaged glass is being broken and recycled to the batch house as cullet. Additional
information about each stage of the manufacturing process is contained in the following sections.
Raw Materials:
Raw materials needed for the manufacture of float glass include Silica sand, Soda Ash, Limestone,
Dolomite, Salt Cake, feldspar and minor amounts of Rouges and Charcoal. Silica sand is comprised of about
60% of the total raw material input with Soda Ash, Dolomite together making up about 35% of the total by
weight. The remainder is distributed among Limestone, Salt cake, Charcoal and Rouge.
Batch House:
Raw material is being received at the plant site in trucks and/or rail cars. Materials is be dumped into a
hopper in a unloading area by a belt conveyer to a bucket elevator where they is be discharged into the
proper bins with the help of a rotary spout. The concrete storage bins are be designed in such a way that
material segregation is be reduced to a minimum, an important quality consideration in glass
manufacturing. Each material is weighed individually on high accuracy industrial scales, then checked on a
totalizer scale prior to the bin discharged into the mixer. The dry ingredients is thoroughly mixed, and then
measured amount of water is be added to the mixer for wet mixing. After mixing a precise amount of cullet
is be layered on the mixed batch prior to conveying to a melting furnace. The batch is being stored in large
hopper over the furnace feeder. In the event of mechanical or electrical failure of any batch, system
component, this hopper is providing mixed batch for about six hours of continues feeding in to the furnace.
Dust control equipment in the unloading area and batch house is operate continuously to maintain a safe,
healthy and working environment for the employees, as well as to minimize dust and particulate emissions.
24
Melting Furnace:
The melting furnace is being capable of melting clear glass at a desired rate. The batch materials are be fed
into the glass-melting furnace from the blanket. The operation of the feeder is control by a precise glass
level controller.
The melting furnace is being a large refractory structure enclosed in structure and binding steel. Many
different types of refractory materials are used in furnace construction. Each one is carefully selected to
use in certain areas where it will perform with a long life and not contribute to product defects. The
furnace refractory, if misapplied, can very often be a major source of glass defects. The batch material is
pushed away from the furnace back wall by the blanket feeder. Floating on top of the molten glass, the
batch is passing under the fuel flames, pouring out of the ports above the furnace side wall. Temperature
exceeding 2900 degrees F is melting the batch ingredients. Combustion products are being discharged
through a stack.
After the batch material melts into solution, the molten glass is being gradually cooled in the refiner
section of the furnace. By the time the glass is reaching the end of the melting furnace, it should be
completely free of un-melted batch particles and uniform in composition. This homogeneous blend of
molten glass is now being delivered to the float bath in a constant pouring action through the channel.
Float Bath:
The float bath is consisting of an electrically heated forming oven. The glass is flow on to the surface of a
pool of molten tin at approximately 2900 degrees F. A continuous ribbon is drawn from this pool and
transported and cooled along the length of the float bath. The temperature of glass at the bath exist is be
approximately 1100 degree F, still a plastic material but solid enough to the removed from the surface of
the tin with mechanical rolls. A flow of SO2 gas mixed with nitrogen is applied on these rolls to prevent any
damage to the bottom of glass ribbon by these or the subsequent rolls. The bath chamber is carefully
sealed and maintained under positive pressure by a nitrogen atmosphere made slightly reducing by the
addition of small amount of Hydrogen. This is necessary to maintain a clean pristine surface for the tin,
which is rapidly oxidized in air.
The molten glass, when flowing on the surface of the molten tin, forms a ribbon of perfectly flat parallel
surface 6 mm thick. Additional process manipulation of the glass can produce thickness ranging from 2 mm
to 12 mm and above. The ribbon emerges from the tin bath at different speeds to provide the desired
thickness.
Annealing Lehr:
The Annealing lehr must cool the glass ribbon from 1100 degrees F to approximately 200 degree F, in a
precise uniform manner to prevent residual stresses that make cutting difficult and also to prevent
temporary stresses that causes ribbon fractures. The lehr is use small amounts of electric heat to keep the
edge of the sheet from cooling faster than the center. There are special rollers and drive systems required
for the lehr as well as a sophisticated temperature control system to accomplish the controlled cooling.
Cutting Line:
The glass is emerging from the annealing lehr in continuous ribbon at a temperature slightly above room
temperature. The glass is passing under a darkened booth where, under special lighting conditions,
inspector is scanning every square foot for defects. An automated inspection system detects defects in the
glass ribbon and helps command the defect marking system to spray ink on the defect. The glass sheets
containing defect is be broken crushed and returned to the batch house to be recycled with the raw
materials.
The inspected ribbon is being cut to exact dimensions with precise, high-speed cutters. The edge trim is
eliminated, crushed and returned to the batch house. The glass sheets, free of defects, are now be boxed
25
or put on metal racks and warehoused for shipment. Special vacuum units are required to unload large
glass sheets. Due to the fragile nature of glass, most of the float glass leaving the plant is being shipped by
truck.
Process Block Diagram:
Product Sand
(Used as Raw Material for
Manufacturing of Float Glass)
Chemical
Dosing & Iron
Removal
Batching Melting Furnace
Forming
(Float Bath) Inspection Annealing Lehr
Cutting Line and Storage
Final Product Float Glass
(Used as Raw Material for Mirror Glass
Manufacturing)
Sand Mining
Screening Washing Sizing Sand Yard
26
b) Mirror from Float Glass
Silvered mirror is manufactured by deposition of silver by reduction process. Layer of silver deposited on
clear glass acts as reflective surface in which images can be seen clearly.
Raw floated glass is loaded flat on the atmospheric side on the loading table with the help of robotic arm.
This raw glass is rinsed with Ultra filtered water to get rid of separator powder, dirt, dust and any other
water-soluble contamination. After rinsing, Glass is cleaned and polished with the help of oscillating
cylindrical brushes and applying a polishing agent. This process smoothens the surface of glass and exposes
a fresh layer of glass.
On the cleaned glass surface, first layer of sensitizer, which is basically a tin chloride solution, is applied.
After first layer of sensitizer, second layer of super sensitizer i.e. Palladium chloride solution is sprayed.
After sensitization, glass surface is rinsed off with D.M water and silver nitrate solution along with the
reducer is sprayed. Silver nitrate is reduced to silver ion on the glass surface and deposited in multiple
layers, forming a reflective surface. This reflective surface of silver is protected by spraying tin solution, and
a reducer, which deposits a layer of tin over the layer of silver. This helps prolong the life of silver layer as it
is not exposed directly to corroding atmosphere.
After application of passivator, two coats of paint are applied with the help of curtain coater. First coat of
paint provides chemical and corrosion resistance protection to the reflective surface. Second layer of paint
provides mechanical resistance such as abrasion, dirt, dust etc. Both the paints are dried and cured in
ovens which use MW IR heaters as source of heat. After application of paints, glass passes through ovens at
a fixed speed for specified time duration and temperature. Mirror is then cooled, washed, branded and
packed.
27
Flowchart for Mirror:
28
c. Lacquered/Deco Crystal Glass from Float Glass
Lacquered glass is a back painted flat glass, used for decorative purposes.
Raw floated glass is loaded flat on the atmospheric side on the loading table with the help of robotic arm.
This raw glass is rinsed with Ultra filtered water to get rid of separator powder, dirt, dust and any other
water-soluble contamination. After rinsing, Glass is cleaned and polished with the help of oscillating
cylindrical brushes and applying a polishing agent. This process smoothens the surface of glass and exposes
a fresh layer of glass.
On the cleaned glass surface, a layer of neutral silicone adhesive along with DI water is sprayed, allowed to
settle and then excess is rinsed. After application of adhesive, a coat of paint is applied with the help of
curtain coater. Paint is baked in electrically heated ovens for a fixed duration at certain temperature, which
is dependent on thickness of glass and color of paint.
Lacquered glass is cooled, washed, branded and packed.
Flowchart for Lacquered Glass:
Raw Glass
UF WaterWashing with UF
waterdrained
Cerium
Oxide
slurry
Cleaning with
Cerium Powderdrained
UF WaterFinal cleaning with
cylindrical brushesDrained
GMP A &
GMP B SolnAdhesive spray drained Packing
Dryer & Preheat Branding
Base Coat paint
CurtainFace wash
Base Coat Oven Top Coat Oven
29
d. Coater Glass from Float Glass
Float glass is used as the primary raw material for the coating operation. The glass is washed using ultra-
pure water. A de-ionization and/or reverse osmosis (DI/RO) water treatment system is used to obtain the
water purity necessary for washing the glass. A small amount of a detergent is added to the wash water. A
scrubbing media, typically Aluminum Oxide, may be also be used to clean the glass. After the glass has
been washed, it is air dried and then conveyed to the coater.
The coater is a high-tech process in which a molecular-level deposit of metals and other compounds are
bonded to the glass. This molecular-level thickness of coating compounds provides the glass with various
reflective and refractive properties. The coater consists of a series of vacuum chambers in which the
washed glass in conveyed into. Once the glass is in the vacuum chamber, short strong pulses of electricity
are sent through both the glass and a ‘target’. The target is a pre-manufactured source of the coating.
Examples of coating target materials include: Silver, Nickel, Chromium, Titanium, Aluminum, Tin, Zinc, and
Silicone. None of the target materials used is emitted/released to atmosphere, because of a vacuum
pressure within the coater.
The target material is atomized by bombarding it with positively charged Argon ions from plasma. These
are created by feeding gas into the plasma at the cathode (or target). A magnetic field determines the
density of the plasma. The metal atoms emitted from the cathode target will adhere to the glass substrate.
So that the gas discharge process can be initiated and maintained, the related electrostatic field intensity is
necessary. These are created by a sputter power/current supply.
After the glass receives the appropriate layers of coating, it is conveyed out of the coater, rinsed with
water, cut into specific sizes, packed to reduce breakage, stored, and ultimately shipped to customers.
30
PROCESS FLOW DIAGRAM
31
Proposed LPG Storage design and safety concept note:
1.0 INTRODUCTION
The mounded storage of LPG has proved to be safer compared to above ground storage vessels
since it provides intrinsically passive and safe environment and eliminates the possibility of Boiling
Liquid Expanding Vapour Explosion (BLEVE). The cover of the mound protects the vessel from fire
engulfment, radiation from a fire in close proximity and acts of sabotage or vandalism. The area of
land required to locate a mounded system is minimal compared to conventional storage.
2.0 SAFETY SAFETY INSTRUMENTATION
According to OISD-150, each mounded bullet shall have at least two Pressure Safety Relief Valves
(PSV/SRV).
The full flow capacity of each PSV / SRV on mounded bullets shall be minimum 30 % of the capacity
required for an equivalent size of above ground vessel.
In case of non-availability of flare system, the discharge from safety valve shall be vented vertically
upwards to atmosphere without any intermediate valve on downstream side at an elevation of 3-
meter (minimum) from the top of the mound or exposed nozzle whichever is higher for effective
dispersion of hydrocarbons.
A weep-hole with a nipple at low point shall be provided on the vent pipe in order to drain the
rainwater. Weep-hole nipples shall be so oriented that in case of safety valve lifting and
consequent fire, the flame resulting from LPG coming out from weep-hole does not impinge on the
vessel or structure. A loose-fitting rain cap with a chain (non-sparking) fitted to vent pipe shall be
provided on top of SRV.
Pressure safety relief valves shall be placed in well ventilated area.
2.1. FIRE SAFE DESIGN
All the automatic valves shall be of fire safe design and leakage class VI.
2.2. EARTHING AND BONDING
Copper jumpers shall be provided on flange connections for LPG/ Propylene pipelines to avoid
damage from static electricity as a bonding provision.
Earthing shall be provided for all the equipment.
All the electrical equipment and lighting fixtures shall be flame-proof as per the Hazardous area
classification. For hazardous area classification, refer hazardous area classification drawing.
2.3. FIRE PROOFING
Fire proofing of mounds shall be done.
2.4. PURGING
Before use of any equipment, it shall be purged with nitrogen to replace air.
2.5. LAYOUT CONSIDERATION
Each mound shall have accessibility from all sides. Each Mound shall have accessibility to Fire
tender from at least two sides.
2.6. SEPRATION DISTANCES
a) Between mounded LPG storage and boundary, property line, group of buildings not associated
with LPG plant shall be 15 meters.
Further between edge of the mound and boundary, property line, group of buildings not
associated with LPG plant shall be 5 meters.
b) Between mounded LPG storage and any other (other than LPG pump/compressor house)
facility associated with LPG plant (e.g. decantation shed) shall be 15 meters.
c) Between mounded LPG storage vessel and firewater pump house and / or Firewater tank shall
be 30 meters.
d) The minimum inter-distance between the edge of the vessel(s) in a mound shall be determined
by the site conditions and the need for safe installation, testing, maintenance and removal of
vessels. However, in any case this distance shall not be less than 1.5 m between the vessels
having diameter of 2 m and 2 m for all other cases.
32
e) Other distances and location considerations shall be as per OISD-150.
2.7. CATHODIC PROTECTION SYSTEM
Mounded bullet shall be protected against corrosion by providing cathodic protection system.
Suppressed current type of cathodic protection system shall be provided for pressurized mounded
bullets of LPG as per OISD-150.
2.8. FIRE DETECTION AND PROTECTION SYSTEM
Automatic fire detection and protection (Fixed) system based on heat detection through thermal
fuses/ quartz bulbs/ EP detectors shall be provided as per OISD-150. Sensors shall be installed at
all critical places as below:
A. Minimum One detector shall be provided on each exposed portion of the vessel. However, if
the nozzles are covered in a dome, each group shall have at least two detectors.
B. At least one detector shall be provided near ROV on all liquid line (s).
2.9. GAS DETECTION SYSTEM
Suitable gas detectors shall be placed at critical locations in the LPG storage area such as near
the ROVs, in inspection tunnel, inside the nozzle box enclosure (if provided) or dome
connection, near water draining/ sampling points as per OISD-150.
3.0 INSTRUMENTATION
3.1. INSTRUMENTATION FOR MOUNDED BULLETS FOR LPG
All the fittings / instruments shall be suitable for use at not less than the design pressure of the
vessel and for the temperatures appropriate to the worst operating conditions.
The fire safe Remote Operated Valve (s) (ROV) shall be provided on first flange on liquid line (s)
from the vessel either from bottom or top as per the design considerations. There shall not be any
other flanges, or any other tapping up-to the ROV, structures. ROV provided shall be of Leakage
class VI.
The flange joints of valves shall either have spiral wound metallic gaskets or ring joints. Plain
asbestos sheet / reinforced gaskets shall not be used.
Each storage vessel shall have minimum two different types of level indicators and one
independent high level switch. High level alarm shall be set at not more than 85% level of the
volumetric capacity of the vessel.
Each vessel shall also be provided with one pressure and temperature measuring instrument. The
pressure gauge shall be provided with two isolation valves and an excess flow check valve.
Differential pressure (DP) type gauge should not be used for level measurement.
All process connection shall be provided with excess flow check valve.
Temperature gauge provided on the vessel in thermos-well shall be welded to vessel.
All the process / Instrument Connections to bullet shall have Excess Flow Check valves.
4.0 CONCLUSION As per OISD guideline all above mentioned safety points has been followed in design of plot plan
and Mounded bullet layout. Both FL-01 & FL-02 is outside of fenced Hazardous area of Mounded
bullet. Hence both FL-01 & FL-02 are at safe location from LPG storage yard.
33
ANNEXURE-IV
EXISTING TREATMENT PROCESS
DETAILS OF STP
Process Description of Sewage Treatment Plant
The Domestic waste water (Sewage) from the service/amenity blocks of plant flows through gravity
towards a dedicated Sewage Treatment Plant provided within the GGL Ankleshwar Premise.
As per the original design, sewage/domestic waste water through gravity flows into the 1st Unit of STP
provided viz. the equalization tank through hand racked bar screens. The sewage in the Equalization tanks
is kept well mixed with the help of air supply through 2 blowers (1 working 1 standby) The Equalized
sewage is pumped to the Aeration Tank by means of 1 Nos. submersible pump.
The Aeration Tank is designed for Extended Aeration for considerable reduction of organic matter. To
maintain the MLSS in Aeration Tank and for continuous oxygen supply to maintain the DO levels, surface
Aerator provided in the Aeration Tank is kept in continuous operation also we have provided back up air
supply line from blowers which are used for supply air in equalisation tank. The overflow from the Aeration
tank is taken to the Clarifier. In the Clarifier, the particulate as well as colloids and suspended solids are
allowed to settle down by gravity. For better settlement, we have provided flocculent dosing in secondary
clarification process. The supernatant thus formed is taken to filter feed tank by gravity, where we have
provided filtration process by passing the water through Pressure sand filter and Activated charcoal filter
and finally collected into treated water tank cum chlorine contact tank.
To kill the pathogenic bacteria, we are using sodium Hypochloride chemical, doing is through the
automated dosing pump which doses the quantity based on the PPM level of water in treated water tank
to maintain the minimum 0.5 PPM all the time before pump it to reuse for gardening by means of a piping
network. The partial sludge from the Clarifier is recycled back to Aeration Tank, which accelerates the
aerobic digestion of sewage. As and when required, part of sludge is wasted to sludge drying beds. The
filtrate from the Sludge Drying Beds is returned back to the bar screen chamber by gravity and the solar
dried sludge is used as manure for gardening purpose.
Adequacy Statement of Existing STP Units is suitable to 90 KLD Hydraulic Load and Characterization &
Additional 15 KLD
Sr. No. Parameters GPCB Limit for Sewage Outlet water
1 BOD < 20
2 SS < 30
3 Residual Chlorine 0.5
DISPOSAL MODE OF SEWAGE
The domestic waste water after treatment in STP is used for irrigating the green belt area within the plant
Premise. Consolidated Consent and Authorization Order No. AWH-62530 of GPCB valid up to 27-01-2019,
stating the parameters for disposal of treated domestic waste water for gardening.
34
Details of Existing Sewage Treatment Plant
Description of Units and sizing of Existing Sewage Treatment Plant are enlisted in Table
Sr. No. Name of the Unit Size Capacity/Volume No. of Units
1 Screen Chamber 3.3 x 2.5 x 3.5 m SWD 28.9 m3 1
2 Equalization Tank 4.0 x 3.5 x 3.5 m SWD 49 m3 1
3 Aeration Tank 6.0 x 5.0 x 3.0 m SWD 90 m3 1
4 Secondary Clarifier 4.0 m Diameter x 1.5 m
SWD 19 m3 1
4 Chlorine Contact Tank 4.0 x 2.0 x 5.0 m SWD 40 m3 1
5 Sludge Drying Beds 3.0 x 2.0 m with 1.5 m
Sludge Application Depth
Area = 6 m2 x 6 Nos.
= 36 m2 6 Nos.
6 MCC Panel/Return
Sludge Pump House ---- ---- 1
7 Flocculation dosing tank Capacity 500 litres Capacity 500 litres 1
8 PSF 5 m3/Hr capacity 5 m3/Hr capacity 1
9 ACF 5 m3/Hr capacity 5 m3/Hr capacity 1
Description of Existing Sewage Treatment Plant
1. Inlet Collection Sump and Screen Chamber: (1 No.)
The prime purpose of providing the Inlet Collection sump cum Screen Chamber is that the sewage through
gravity from the entire plant Premise is conveyed to this unit. MSEP Fine Screens of 50 mm spacing are
provided to arrest any large floating matter, settle-able solids, rags, plastics etc. Fine bar screens shall be
manually cleaned periodically. Dimensions of Existing Inlet Collection Sump cum Screen Chamber are 3.3 x
2.5 x 3.5 m SWD (Side Water Depth) with a retention time of 12.8 hours at an existing flow of 54 KLD.
2. Equalization Tank: (1 No.)
The main objective of providing an Equalization Tank is to store and homogenize the sewage waste water
in this unit so as to have constant load onto the further treatment units. Dimensions of Equalization tank
are 4.0 x 3.5 x 3.5 m SWD (Side Water Depth) with a retention time of 21.7 hours at an existing flow of 54
KLD. After equalization, sewage will be pumped into the Aeration Tank through pumps manually. This is
important to prevent back flow of sewage into the Screen Chamber cum Inlet Collection sump.
3. Aeration tank: (1 No.)
Extended Aeration is adopted as the biological treatment wherein micro organisms are introduced in waste
water which has the capacity to stabilize the organic matter present in sewage and in turn results in
reduction of BOD load. Aeration is provided so that the waste water is brought in contact with oxygen
which serves as energy for the micro organisms for aerobic decomposition. Aeration tank is provided with
surface aerator for providing required amount of dissolved oxygen for microbial activity. MLSS (Mixed
Liquor Suspended Solids) shall be maintained in the Existing Aeration tank at retention time of 24 hours has
been provided. Treated sewage from aeration tank will be discharged under gravity into the Secondary
Clarifier. Dimensions of Existing Aeration tank are 6.0 x 5.0 x 3.0 m SWD (Side Water Depth) with a
retention time of 40 hours at an existing flow of 54 KLD.
35
4. Secondary Clarifier: (1 No.)
The biological sludge generated in Aeration tank will be allowed to settle in Secondary Clarifier. Secondary
Settling for circulation of clarified biomass is essential to maintain required MLSS concentrations in
Aeration Tank. The return sludge from the bottom of the Secondary Clarifier will be withdrawn and re-
circulated back to Aeration tank for maintaining required MLSS concentration by means of sludge
recirculation pumps and partly wasted to Sludge Drying Beds. Effluent from Aeration tank is received into
central well of secondary clarifier from where it is allowed to move down and subsequently moved up with
very slow velocity. In the process of downward and upward movement MLSS is settled down and clear
supernatant effluent is obtained at the outlet of the clarifier; the basic purpose of the secondary clarifier is
to separate solids from liquids by the process of gravity sedimentation. The clarifier is of conventional type
having central shaft for scrapping, from where the clarified effluent is transferred to Chlorine Contact Tank.
Dimensions of Existing Secondary Clarifier are 4.0 m Diameter x 1.5 m SWD (Side Water Depth) with a
retention time of 8.37 hours at an existing flow of 54 KLD.
5. Flocculent Chemical dosing tank: (1No)
The Flocculent Chemical dosing attached to secondary clarifier is used to help better settlement of solids
and to prevent any solids into the pressure sand filter and activated charcoal filter system for better
operation, less maintenance and better efficiency with better treated waste water quality parameters
complying with CCA conditions.
6. Sodium Hypochlorite mixing and treated water tank: (1 No.)
The clarified sewage from Secondary Clarifier shall be pumped to the Chlorine Contact Tank cum final
treated water storage tank. The clarified sewage will be dossed with sodium Hypochloride solution for
disinfection and killing of pathogenic bacteria and viruses. Chlorine dosing is controlled such that the
resulting treated waste water has residual chlorine of 0.5 mg / lit. The treated waste water is being further
pumped and re-used for irrigating the green-belt area with GGL Ankleshwar Plant Premise.
Dimensions of Existing Chlorine Contact Tank are 4.0 x 2.0 x 5.0 m SWD (Side Water Depth) with a retention
time of 17.7 hours at an existing flow of 54 KLD.
The treated waste water from the outlet of Chlorine contact tank is stored in a Final Collection sump within
the plant Premise.
7. Sludge Drying Beds: (6 Nos.)
The biological sludge formed in the Secondary Settling tank shall be discharged directly to sludge drying
beds. The resulting sludge shall be solar dried in the sludge drying beds. Six Nos. of sludge drying beds are
provided of dimensions 3.0 x 2.0 m and sludge application depth of 0.3 m. The sludge drying bed will be
divided into compartments to facilitate in easy sludge drying handling and disposal. The dried sludge is
being currently used as a fertilizer or manure within the existing green belt area at GGL Plant Premise.
36
Proposed New 40 KLD Sewage Treatment Plant Process Description:
The existing conventional STP plant will be replaced with new SBT technology as described below to
achieve better quality of treated waste water parameters with hassle free operation.
Description of Infrastructure used for proposed new Sewage Treatment Plant Units:
1. Inlet Collection Sump and Screen Chamber: (1 No.)
The prime purpose of providing the Inlet Collection sump cum Screen Chamber is that the sewage through
gravity from the entire plant Premise is conveyed to this unit. MSEP Fine Screens of 50 mm spacing are
provided to arrest any large floating matter, settle-able solids, rags, plastics etc. Fine bar screens shall be
manually cleaned periodically. Dimensions of Existing Inlet Collection Sump cum Screen Chamber are 3.3 x
2.5 x 3.5 m SWD (Side Water Depth) with a retention time of 12.8 hours at an existing flow of 54 KLD.
2. Equalization Tank: (1 No.)
The main objective of providing an Equalization Tank is to store and homogenize the sewage waste water
in this unit so as to have constant load onto the further treatment units. Dimensions of Equalization tank
are 4.0 x 3.5 x 3.5 m SWD (Side Water Depth) with a retention time of 21.7 hours at an existing flow of 54
KLD. After equalization, sewage will be pumped into the Aeration Tank through pumps manually. This is
important to prevent back flow of sewage into the Screen Chamber cum Inlet Collection sump.
3. Bio-Reactor : (2 No.)
The process is a batch processes in which wastewater is pumped and applied onto the top surface of the
Bioreactor as shown in Figure 1. Raw sewage is collected in Raw Water Tank (RWT) after initial screening
and settling. The raw sewage is pumped on top of a SBT Bio Reactor where it percolates through a
geological media. The treated water is from BR-1 collected and again treated for reuse quality and
collected at the bottom of the Bio-Reactor (BR-2) and stored in a Treated Water Tank (TWT). The design
has suitable provision for manual removal of suspended solids from the biofilter surface. Distribution of
wastewater over the media is achieved via pumping, piping and distribution arrangements. Separate
distribution lines are provided for raw wastewater as well as recycle water. The suspended solids are
filtered out which includes additives that combine with organic of waste to produce manure. Solids are
typically retained in the settling tank and then can be removed mechanically. Water first percolates
through the bioreactor media which in houses cultured media in 40-60 min and gets collected into the
collection tank. It can then be pumped on to the media again (recycling) in order to achieve maximum solid
liquid contact. The recirculation mode is provided for further polishing of the effluent. Dissolved organic
and inorganic are oxidized and the water is purified further.
Dimensions of bio reactor tank are 3.0 x 5.0 x 3.0 m.
37
4. Sodium Hypochlorite mixing and treated water tank: (1 No.)
The clarified sewage from Secondary Clarifier shall be pumped to the Chlorine Contact Tank cum final
treated water storage tank. The clarified sewage will be dossed with sodium Hypochlorite solution for
disinfection and killing of pathogenic bacteria and viruses. Chlorine dosing is controlled such that the
resulting treated waste water has residual chlorine of 0.5 PPM. The treated waste water is being further
pumped and re-used for irrigating the green-belt area.
Dimensions of Existing Chlorine Contact Tank are 4.0 x 2.0 x 5.0 m.
The treated waste water from the outlet of Chlorine contact tank is stored in a Final Collection sump within
the plant Premise.
5. Sludge Drying Beds: (6 Nos.)
The biological sludge formed in the Secondary Settling tank shall be discharged directly to sludge drying
beds. The resulting sludge shall be solar dried in the sludge drying beds. Six Nos. of sludge drying beds are
provided of dimensions 3.0 x 2.0 m and sludge application depth of 0.3 m. The sludge drying bed will be
divided into compartments to facilitate in easy sludge drying handling and disposal. The dried sludge is
being currently used as a fertilizer or manure within the existing green belt area at GGL Plant Premise.
38
EXPECTED CHARACTERISTIC OF EFFLUENT
LAST MONITORING ANLYSIS REPORT
39
ANNEXURE-V
HAZARDOUS WASTE GENERATION AND DISPOSAL
S.
No.
Items Category
as per HW
Rules
Quantity
As per
CCA 2018
Additional
Proposed
Total Treatment and Disposal
Method
1 Used Oil 5.1 25
KL/Year
25
KL/ Year
50
KL/ Year
Sending to Registered
Refiners for recycle / reuse /
Incineration
2 Waste residue containing
oil
5.2 20
MT/ Year
20
MT/ Year
40
MT/ Year
Send to GPCB registered
TSDF for land Filling or
Incineration
3 Process wastes, residues &
debris from production
and/or industrial use of
paints, pigments, lacquers,
varnishes, plastics and inks
21.1 20
MT/ Year
- 20
MT/ Year
Send to licensed disposal
company
Recycle as a fuel or
Incineration
4 Spent solvents from the
production and/or
industrial use of solvents
20.2 5 MT/
Year
- 5 MT/
Year
Send to licensed disposal
company
Recycle as a fuel or
Incineration
5 Discarded Containers &
barrels contaminated with
hazardous
wastes/chemicals
6 Discarded Bags / Liners
contaminated with
hazardous
wastes/chemicals
33.1
240
MT/ Year
- 240
MT/ Year
Collection, Storage,
transportation, Disposal by
selling to Registered
Vendors for recycle/ reuse
7 Furnace/reactor residue
and debris
1.1 60
MT/ Year
90
MT/ Year
150
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
8 Inorganic Tin compounds B 17 1
MT/ Year
1.5
MT/ Year
2.5
MT/ Year
Send to licensed disposal
company for Recycling /
landfill
9 Spent catalyst and
molecular sieves
1.6 4
MT/ Year
- 4
MT/ Year
Send to licensed disposal
company for Recycling /
landfill
10 Spent ion exchange resin
containing toxic metal
(upcoming 1200 KL Ro resin
to be added
35.2 15
MT/ Year
- 15
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF or
recycle
11 Chemical sludge from
waste water treatment
35.3 5
MT/ Year
695
MT/ Year
700
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
12 Coater Sand Blasting
Debris
Z32 75
MT/ Year
- 75
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
40
Solid (Non-Hazardous) Wastes:
S.
No
Waste Type Existing Proposed
Additions
Total Disposal Method
1. Mirror and Lacquered
Cullet
100
MT/Month
- 100 MT/Month Sell as non-hazardous waste
for recycling / reuse
2. Bad Batch 100
MT/Month
150 MT/Month 250 MT/Month Recycling/reuse /Landfill
3. G-Core 100
KG/Month
150 KG/Month 250 MT/Month Reuse in-house for water
neutralization / landfill /
recycling / reuse
4. Rejected Sand 2200
MT/Month
3500 MT/Month 5700
MT/Month
Recycling in house / selling
to water treatment plant and
construction industry /
Landfill
5. Lagoon reclaim waste 7000
MT/Month
8000 MT/Month 15000
MT/Month
Recycling in house by having
sales to various end users
like foundries, resin coated
sand manufacturers,
ceramics and tiles
manufacturers, filter bed
manufacturers, construction
industry etc / and /or at
construction Landfill
6. Cullet 2500 MT/
month
4000 MT/Month 6500
MT/Month
Recycling in house / Sell to
recyclers
7. Sludge Generation
from STP
1 MT/Month 1 MT/Month 2 MT/Month Using as manure in-house
8. Furnace refractory
waste, Wool, Mud,
Cement etc.
10 MT/Month 20 MT/Month 30 MT/Month Sent for Construction site
land filling/recycle/reuse
9. Cullet Dust 40 MT/Month 60 MT/Month 100 MT/Month Sent for Construction site
land filling/recycle/reuse
10. E-waste 250 KG /
Month
400 KG / Month 650 KG /
Month
Sold to GPCB approved
recycler
11. Trash and Packaging
material waste
20 MT/Month 30 MT/Month 50 MT/Month Sold to scrap vendor
12. Metal Scrap 10 MT/Month 25 MT/Month 35 MT/Month Sold to scrap vendor
13. Solid waste from flue
gas treatment (EP or
Filter Dust)
- 300 MT/Month 300 MT/Month Reused as a raw material
41
ANNEXURE-VI
WATER, FUEL & ENERGY REQUIREMENT
WATER CONSUMPTION
WASTEWATER GENERATION
* 450 KL/day of domestic wastewater is/will be treated in STP or stored in soak pit or septic tank and then
used for gardening
Proposed waste water recycling plant capacity
Float plant 1: 500 KLD
Flaot Plant 2: 200 KLD
Total ETP or waste water recycling capacity: 700 KLD & out of that 650 KLD will be recycled.
Water Consumption (KL/day) Sr. No. Usage
(As per Earlier TORs) As per new
CCA 2018
Proposed
Float line 2
Final (Considering New
Expansion)
1. Domestic 350 350 120 470
2. Process 25 25 25 50
3. Boiler NA NA NA NA
4. Cooling & Chilling 400 200 300 500
5. Washing 775 1245 -250 995
6. Gardening 100 100 50 150
7. For dust
quenching
0 0 533 533
Total 1650 1920 778 2698 – 650(WWTP) = 2048
Wastewater Generation (KL/day) Sr. No. Section
As per
Earlier TORs
As per new
CCA 2018
Proposed
changes in
existing
wastewater
generation
Proposed
Float line 2
Final
(Considering New
Expansion)
1. Domestic 205* 205* 205 205 410*
2. Process 0 0 0 0 0
3. Boiler NA NA NA NA NA
4. Cooling & Chilling
(Existing)
150 150 125 200 325
5. Washing 566 816 650 0 650
6. Gardening 0 0 0 0 0
Total 921 1171 980 405 1385
42
WATER BALANCE DIAGRAM (TOTAL PROPOSED)
TOTAL POWER REQUIREMENT & SOURCE OF POWER
Power requirement will be 12.7 MW (Existing = 8.7 MW + Additional Proposed = 5 MW) which will be taken
from GEB. 4 Nos. of (155 KVA each) & 2 Nos. of (2.5 MW each), 2 Nos. of (500 KVA) & 3 Nos. of (2.1 MW
each) DG Sets will be kept for emergency power back up.
FUEL REQUIREMENT
Quantity S.No Fuel
Existing Additional Total Proposed
1 Natural Gas 6000 m3/hr 10000 m3/hr 16000 m
3/hr
2 LPG 4 MT/hr 6.4 MT/hr 10.4 MT/hr
3 Diesel 1515 Ltrs /Hr 2025 Ltrs/Hr 3540 Ltrs /Hr
43
ANNEXURE-VII
STORAGE DETAILS OF HAZARDOUS CHEMICALS
Existing and Proposed:
Sr.
No.
Name
of the
Materia
l
Type
of
Hazard
Kind
of
Storag
e
Max.
quantity
to be
stored
(MT)
Storage
condition
i.e. temp.
Pressure
Tank
Dimensi
ons
Dyke
Dimension
s
Existin
g
Propose
d
Additio
ns
Total
1 Ammon
ia
Corrosi
ve,
Toxic
Bullets 20 4 to 7.5
Kg/cm2
Length:
6.546 m
Dia: 2 m
32’ x 32’ x
1’
Yes No We will
not have
ammonia
storage
for
cracking
purpose
for float
line 1 and
2
2 Hydrog
en
Inflam
mable
Bullets Under
finalizatio
n stage
Under
finalizatio
n stage
Under
finalizati
on stage
NA No Yes We will
have
Hydrogen
storage
for float
line 1 and
2
2 LPG
Storage
Flamm
able
Bullets 56.25 x 4
= 225
5 to 8.5
Kg/Cm2
Dia:
3200
mm
Length:
16.126
m
MOC:
SA-
515/SA
35 x 11.2
m
Yes No
2 LPG Flamm Bullets 120 x 6 = 21 Dia: 35 x 11.2 No Yes
We will
demolish
the
existing
LPG Set
up and
club with
the
proposed
higher
44
Storage able 720 Kg/Cm2 4010
mm
Length:
24 m
m capacity
LPG
storage
facility for
Float 1
and 2
3 H2SO4
Storage
Corrosi
ve
Tank 4 KL Atmosph
eric
Pressure
Dia: 1.15
m
Length:
2.85 m
7 x 4.5 x
0.2 m
Yes No For Float
line 1
3 H2SO4
Storage
Corrosi
ve
Tank 4 KL Atmosph
eric
Pressure
Dia: 1.15
m
Length:
2.85 m
7 x 4.5 x
0.2 m
No Yes For Float
line 2
4 Diesel
Storage
Flamm
able
Tanks 145 KL 0.344
Kg/cm2
@ 200C
Ht: 4.2
m
Dia: 5.6
m
16.7 x 10.1
x 1 m
Yes No For Float
line 1
4 Diesel
Storage
Flamm
able
Tanks 145 KL 0.344
Kg/cm2
@ 200C
Ht: 4.2
m
Dia: 5.6
m
16.7 x 10.1
x 1 m
No Yes For Float
line 2
5 MTO &
Xylene
Flamm
able
Barrels 30 KL Atmosph
eric
Pressure
Room
Size:
7.7 x 9 x
7 m
7.7 x 9 x
0.5 m
Yes No The
existing
capacity
would be
sufficient
for Float 1
and 2
45
ANNEXURE-VIII
DETAILS OF STACKS & VENTS
Flue Gas Stacks
S. No. Sources of
Emission
Type of
Fuel
As Per
CTE
As per
CCA
(2018)
Additional Total Proposed
Stack
height
APCM
Natural
Gas
5990
m3/Hr.
5990
m3/Hr.
-- 5990
m3/Hr.
1. Melting
Furnace
(Existing) LPG
3.89
MT/Hr.
3.89
MT/Hr.
-- 3.89
MT/Hr.
91 m Low NOx Burner.
Low sulfur fuel.
Natural
Gas
- -- 9985
m3/Hr.
9985
m3/Hr.
2 Melting
Furnace
(Proposed) LPG
- -- 6.21
MT/Hr
6.21
MT/Hr
54 m Low NOx burner
and low sulfur
fuel. In addition,
an Emission
Control System
(ECS) may be
installed if
needed to meet
SO2 and NOX
emission limits
or, alternatively,
for other reasons
even if not
required to meet
limits. If
installed, the ECS
would consist of
a scrubber,
electrostatic
precipitator (EP),
and selective
catalytic
reduction system
or, alternatively,
a catalyst
impregnated
ceramic filter.
3. DG Set (2 Nos
of 2.5 MW)
Diesel 1200
Lit/Hr
1200
Lit/Hr.
- 1200
Lit/Hr.
30 m NA
4. DG Set (3 Nos
of 2.1 MW)
Diesel - - 1800
Lit/Hr.
1800
Lit/Hr.
30 m NA
5. DG Set (1 No.
of 500 KVA)
Diesel 135
Lit./Hr.
135
Lit./Hr.
- 135
Lit./Hr.
14 m NA
6. DG Set (1 No.
of 500 KVA)
Diesel - - 135
Lit./Hr.
135
Lit./Hr.
14 m NA
7. LPG Hot water
generator (2
Nos)
LPG 0.11
MT/Hr.
0.11
MT/Hr.
- 0.11
MT/Hr.
12 m NA
8. LPG Hot water
generator (2
Nos)
LPG - - 0.19
MT/Hr.
0.19
MT/Hr.
12 m NA
46
9. Diesel Engines
(1 and 2 of 155
KVA each)
Diesel 90
Lit./Hr.
(Total
for
both)
90 Lit./Hr.
(Total for
both)
- 90 Lit./Hr.
(Total for
both)
12 m
(Existing)
NA
10. Diesel Engines
(3 and 4 of 155
KVA each)
Diesel 90
Lit./Hr.
(Total
for
both)
90 Lit./Hr.
(Total for
both)
- 90 Lit./Hr.
(Total for
both)
11 m
(Existing)
NA
11. Diesel Engine,
(4 nos. for)
(open loop (1),
emergency
water system
(1) fire system
(2))
Diesel 180
Lit./Hr.
180
Lit./Hr.
- 180
Lit./Hr.
12 m
(Proposed
)
NA
12. Open loop and
Emergency
engines (FL2)
Diesel - - 90 Lit./Hr. 90 Lit./Hr. 12 m NA
13. Glass Edge
Burner
(Existing)
10
m3/Hr.
10 m3/Hr. -- 10 m
3/Hr. 16 m NA
14 Glass Edge
Burner
(Proposed)
Natural
Gas
- - 15 m3/Hr. 15 m
3/Hr. 16 m NA
Flue gas Emission parameters and Limits as per Approved CCA Existing operations (Float Line 1).
S.
No.
Stack attached to Parameter Applicable standards
Particulate matter 0.8 Kg/MT of Product drawn 1 Melting Furnace (Float 1)
TF 5.0 mg/NM3
Particulate Matter 75 mg/NM3
NOx (as NO2) (at 15%
O2), dry basis, in ppmv
1100
NMHC (as C) (at 15%
O2), mg/NM3
150
2 Diesel Engine 2.5 M (2 Nos) – Float 1
CO (at 15% O2),
mg/NM3
150
Particulate Matter < 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
3 Diesel Engine 500 KVA
(Float 1)
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
4 LPG Hot Water Generator Exhaust
(Existing 2 nos for Float 1)
NOx 50 PPM
Particulate Matter 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
5 Diesel Engine, (1,2.3,4) Float 1
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
6 Glass Edge Burner
(Float 1)
NOx 50 PPM
47
Flue gas Emission parameters and Limits as per “The Environment Protection Act & Rules 1986”: For Proposed (Float Line 2).
S.
No.
Stack attached to Parameter Applicable standards
Particulate matter 0.8 Kg/MT of Product drawn
SO2
500 mg/NM3
NOx
1000 mg/NM3
1 Melting Furnace (Float 2)
TF 5.0 mg/NM3
Particulate Matter 75 mg/NM3
NOx (as NO2) (at 15%
O2), dry basis, in ppmv
1100
NMHC (as C) (at 15%
O2), mg/NM3
150
2 Diesel Engine 2.1 M (3 Nos) – Float 2
CO (at 15% O2),
mg/NM3
150
Particulate Matter < 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
3 Diesel Engine 500 KVA
(Float 2)
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
4 LPG Hot Water Generator Exhaust
(Proposed 2 nos for Float 2)
NOx 50 PPM
Particulate Matter 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
5 Diesel Engine, (5 & 6 ) Float 2
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
6 Glass Edge Burner
(Float 2)
NOx 50 PPM
Process Vents
S.
No.
Stack attached to As
Per
CTE
As
per
CCA
2018
Proposed
number
of stacks
Total
Stacks
Stack
height in
Meters
for
proposed
stack
Pollutant
Emitted
APCM
1. Ammonia Cracking
Plant
1 1 - 1 21 PM,
Ammonia
Stack, Nitrogen
Purging
2. Hydrogen Generation
Plant
- - 1 1 16 PM, SO2,
NOx
Stack
3. Mirror Line Plant 7 7 - 7 12 Ammonia Stack
4. SO2 Vent (Float 1) 1 1 - 1 17 SO2 Stack
5. SO2 Vent (Float 2) - - 1 1 17 SO2 Stack
6. Batch House Raw
Materials DCF Vents
(Float 1)
9 9 - 9 36 PM Dust Collector
7. Batch House Raw
Materials DCF Vents
(Float 2)
- - 9 9 16 PM Dust Collector
8. Batch House Raw
Materials DCF Vents at
2 2 - 2 9 PM Dust Collector
48
Basement (Float 1)
9. Batch House Raw
Materials DCF Vents at
Basement (Float 2)
- - 2 2 16 PM Dust Collector
10. Batch House Unloading
DCF Vent (Float 1)
1 1 - 1 9 PM Dust Collector
11. Batch House Unloading
DCF Vent (Float 2)
- - 1 1 16 PM Dust Collector
12. Cullet Return System
DCF Vent (Float 1)
1 1 - 1 9 PM Dust Collector
13. Cullet Return System
DCF Vent (Float 2)
- - 2 2 16 PM Dust Collector
14. Hot Air Exhaust (Float
1)
5 5 - 5 16 PM Not Required
15. Hot Air Exhaust (Float
2)
- - 5 5 16 PM Not Required
16. Dust collector of cullet
sorting
1 1 - 1 16 PM Dust Collector
17. Dust Collectors for
Cullet Transport
- - 2 2 16 PM Dust Collector
18. Dust collector of
tunnels
3 - - 3 16 PM Dust Collector
19. Coater tempering
furnace stack
1 1 - 0 - - -
20. Dust collector of Coater
sand blasting
1 1 - 1 15 PM Dust collector
21. Dust collector of
hydrated lime storage
(Float 2)
1 1 18 PM Dust collector
22. Dust collector of
EP/Filter dust storage
(Float 2)
1 1 16 PM Dust collector
49
ANNEXURE-IX
_______________________________________________________________________
EXPECTED NOISE LEVEL AT DIFFERENT SOURCE WITHIN PREMISES
Various sources of noise in industry have been identified as under,
Pumps
Blowers
Rod Mill
The typical noise levels of equipments, as indicated by the equipments manufacturers are given below:
Sr. No. Name of Machinery / Units Noise level, dB(A)
1 Pumps 60 – 65
2 Blowers 80 – 85
3 Rod Mill 85 – 95
EXPECTED NOISE LEVELS:
SR. NO. SOURCE OF NOISE PERMISSIBLE LIMIT
(DAY/NIGHT)
dB (A)
EXPECTED NOISE
LEVEL dB (A)
1. Near Security Gate 75/70 60
2. Near Administration Building 75/70 60
3. Near Cooling tower & Utility Block 75/70 65
4. Near DM Plant 75/70 65
5. Near Process Plant 75/70 65
6. Near Canteen 75/70 50
• Ear muffs & ear plugs are provided to operators where ever noise level is higher than 85 dB(A)
inside the plant.
• Regular preventive maintenance of equipments is carried out.
50
ANNEXURE-X
_______________________________________________________________________
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
During construction phase, skilled and unskilled manpower will be needed. This will temporarily increase
the employment opportunity. Secondary jobs are also bound to be generated to provide day-to-day needs
and services to the work force. This will also temporarily increase the demand for essential daily utilities in
the local market. The manpower requirement for the proposed diversification is expected to generate
some permanent jobs and secondary jobs for the operation and maintenance of plant. This will increase
direct / indirect employment opportunities and ancillary business development to some extent for the local
population. This phase is expected to create a beneficial impact on the local socio-economic environment.
2) INDUSTRIES
During construction of the project, the required raw materials and skilled and unskilled laborers will be
utilized maximum from the local area. The increasing industrial activity will boost the commercial and
economic status of the locality, to some extent.
3) PUBLIC HEALTH
During construction period, workers will be provided with basic amenities like safe water supply, low cost
sanitation facilities, first aid, required personal protective equipment, etc. The company regularly
examines, inspects and tests its emission from sources to make sure that the emission is below the
permissible limit and Hence, there will not be any significant change in the status of sanitation and the
community health of the area, as sufficient measures will be taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
Since the new expansion in existing factory (sand beneficiation plant) will have proper linkage for the
transport and communication, the development of this project will not cause any additional impact. In
brief, as a result of the project there will be no adverse impact on communication, as sufficient measures
will be proposed to be taken under the EMP. The proposed project is not expected to make any significant
change in the existing status of the socio - economic environment of this region.
51
ANNEXURE-XI
_______________________________________________________________________
PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
1. Project Description
Justification of project.
Promoters and their back ground
Project site location along with site map of 5 km area and site details providing various industries,
surface water bodies, forests etc.
Project cost
Regulatory framework
Project location and Plant layout.
Existing infrastructure facilities
Water source and utilization including proposed water balance.
Product spectrum (proposed products along with production capacity) and process
List of hazardous chemicals with their toxicity levels.
Mass balance of each product along with the batch size
Storage and Transportation of raw materials and products.
Existing environmental scenario
2. Description of the Environment and Baseline Data Collection
Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5 km area.
Study of Data from secondary sources.
Other industries in the impact area
Prevailing environment quality standards
Existing environmental status vis a vis air, water, noise, soil in 5 km area from the project site. For SPM,
RSPM, SO2, NOx.
Ground water quality at 5 locations within 5 km.
Complete water balance
3. Socio Economic Data
Existing socio-economic status, land use pattern and infrastructure facilities available in the study area
were surveyed.
4. Impacts Identification and Mitigatory Measures.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
6. Risk Assessment
• Objectives, Philosophy and methodology of risk assessment
• Details on storage facilities
• Identification of hazards
• Consequence analysis through occurrence & evaluation of incidents
52
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
• Safety precautions for the storage of Chemicals and vapour condensation.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Occupational Health and Safety Program for the Project.
10. Information on Rain Water Harvesting
11. Green Belt Development Plan
53
ANNEXURE-XII
_______________________________________________________________________
LETTER FOR WATER SUPPLY
54
55
56
57
ANNEXURE-XIII
TSDF & CHWIF MEMBERSHIP LETTER
58
59
60
ANNEXURE-XIV
_______________________________________________________________________
LEASE DEED DOCUMENTS
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
ANNEXURE-XV
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CCA COPY OF YEAR 1995
85
86
87
ANNEXURE-XV
_______________________________________________________________________
TOPOSHEET
Format for Brief Write-Up (Amendment proposals/Extension of validity of EC/ToR)
1. Kindly provide details of earlier project along with details of EC/ToR granted for the project with
letter no and date of issue.
TOR Letter No. J-11011/382/2017-IA-II(I) dated August 21, 2017
2. Status of Implementation of the earlier EC facilities and schedule of completion of balance
facilities in case of Extension of validity of EC.
Not Applicable as the Project is at TOR Amendment Stage
3. Impact prediction and management plan along with fund provision for the proposed amendment
(in case of amendment)
There is no change in impact and respective management plan because of TOR amendment. More
details will be covered in EIA report for the EC applicable project.
Addition of 46 crore in the project cost (New sand plant + LPG storage) as we have now included the
cost of utilities, roads, amenities and surrounding area development, etc. in the project cost. The
above cost does not include the project cost of non-EC interlinked float line 2.
4. Amendment required. (In case of amendment)
We are requesting for Amendment in TORs because of following reasons:
1. To indicate the End Use of Sand Processing Plant Product by addition of non-EC Float Glass
Manufacturing Line with capacity 4,00,00,000 m2/Annum i.e. Total Capacity becomes 6,50,00,000
m2/Annum
LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY
Sr.
No.
Name of Unit Name of Product Existing Capacity Additional
Proposed
Capacity
Total Proposed Capacity Remarks
1 Glass
Manufacturing
Unit
Float Glass
Mirror,
Lacquered Glass,
Coater Glass
2,50,00,000
m2/Annum
4,00,00,000
m2/Annum
6,50,00,000
m2/Annum
-
2 Silica & Sand
Production Unit
Silica Sand (Glass
Grade) & By-
Products (Coarse,
Fines & Rejects)
33,120 MT/Month 53,380
MT/Month
86,500 MT/Month -
3 LPG Storage - 225 MT
(4 x 56.25 MT of
Length = 16.2 m &
Diameter = 3200
mm)
495 MT 720 MT
(6 x 120 MT of Design
Pressure = 21 Kg/cm2,
Overall Length = 24000 mm,
Tank ID = 4010 mm, Tank
Shell = 28 mm Thick, Dished
End= 18 mm Thick)
The Existing &
Proposed LPG
Storage Yard will be
merged and the Total
Capacity (Existing +
Proposed) will be 720
MT
LIST OF RAW MATERIAL (EXISTING & PROPOSED)
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
Float Glass
1 Sand MT 14,000 21,315 35,315
2 Soda Ash MT 4,500 6,900 11,400
3 Dolomite MT 3,800 5,790 9,590
4 Limestone MT 1,400 2,160 3,560
5 Feldspar MT 850 1,300 2,150
6 Salt Cake MT 215 330 545
7 Carbon MT 21 32 53
8 Cullet MT 6,000 8,500 14,500
9 EP/Filter Dust MT - 300 300
Wet Coater
1 Raw Glass Sq. Meter 5,83,000 - 5,83,000
2 Washing & Polishing Chemicals Kg 2,062 - 2,062
3 Tin Sensitizer Litre 119 - 119
4 Palladium Sensitizer Litre 45 - 45
5 Silver Solution
Silver Nitrate
Litre
Kg
2,600
1,088
- 2,600
1,088
6 Reducer/
Silver less solution
Litre
Litre
4,830
2,920
- 4,830
2,920
7 GMPA & GMPB Litre 1,190 - 1,190
8 Paint MT 68 - 68
9 Ortho-Xylene Litre 9,971 - 9,971
10 HCL-32% Litre 11,393 - 11,393
11 Caustic-32% Litre 13,508 - 13,508
12 Ferric Sulfate Kg 256 - 256
13 Copper Sulphate Pentahydrate Kg 1,440 - 1,440
Consumption Quantity Per Month Sr.
No. Raw Material
UOM Permitted Proposed
Additions Total
14 Potassium Sodium Tartrate Kg 20 - 20
15 Iron Powder Kg 50 - 50
16 Sulphuric Acid Kg 230 - 230
Lacquered Glass
1 Raw Glass Sq. Meter 1,50,000 - 1,50,000
2 Washing and polishing chemical Kg 200 - 200
3 Adhesion Promoter Litre 50 - 50
4 Paint MT 10 - 10
A GLASSOLUX NG 9003 PURE WHITE Kg 2,500 - 2,500
B GLASSOLUX NG 2105 Sapphire Kg 2,500 - 2,500
C GLASSOLUX NG 3004 Burgundy Kg 2,500 - 2,500
D GLASSOLUX NG 6113 Fluo green Kg 2,500 - 2,500
E GLASSOLUX NG 9005 Black Kg 2,500 - 2,500
F Ivory Kg 2,500 - 2,500
G Red Kg 2,500 - 2,500
5 Ortho-Xylene Litre 1,000 - 1,000
Sand Beneficiation Plant
1 Raw Silica Sand MT 33,120 53,380 86,500
Coater Glass
1 Raw Glass Sq Meter 5,83,333 - 5,83,333
2 Washing and polishing chemical Kg 2,000 - 2,000
3 Zr Kg 20 - 20
4 Si – 8 wt % Al Kg 300 - 300
5 Nb – 10 wt % Zr Kg 140 - 140
6 Ni – 20 wt % Cr Kg 180 - 180
7 Ag Kg 100 - 100
8 TiOx Kg 5 - 5
9 Sn Kg 80 - 80
10 Zn – 2 wt % Al Kg 20 - 20
11 Ar m3 800 - 800
12 O2 m3 100 - 100
13 N2 m3 500 - 500
14 Vacuum Pump Oil Litre 400 - 400
15 Sand Blasting Material MT 5 - 5
Emission Control System
1 Aqueous Ammonia MT 350 350
2 Hydrated Lime MT 85 85
2. To include the Non-EC Interlinked Project (addition of Float Glass Manufacturing Line) in the FORM
1
3. To update the Line Item 7 of Form 1 with respect to attracting General Condition.
4. To submit Revised Water Balance based on New Sand Plant GPCB CTE Application.
WATER, FUEL & ENERGY REQUIREMENT
WATER CONSUMPTION
WASTEWATER GENERATION
* 450 KL/day of domestic wastewater is/will be treated in STP or stored in soak pit or septic tank and then used
for gardening
Proposed waste water recycling plant capacity
Float plant 1: 500 KLD
Flaot Plant 2: 200 KLD
Total ETP or waste water recycling capacity: 700 KLD & out of that 650 KLD will be recycled.
Water Consumption (KL/day) Sr. No. Usage
(As per Earlier TORs) As per new
CCA 2018
Proposed
Float line 2
Final (Considering New
Expansion)
1. Domestic 350 350 120 470
2. Process 25 25 25 50
3. Boiler NA NA NA NA
4. Cooling & Chilling 400 200 300 500
5. Washing 775 1245 -250 995
6. Gardening 100 100 50 150
7. For dust
quenching
0 0 533 533
Total 1650 1920 778 2698 – 650(WWTP) = 2048
Wastewater Generation (KL/day) Sr. No. Section
As per
Earlier TORs
As per new
CCA 2018
Proposed
changes in
existing
wastewater
generation
Proposed
Float line 2
Final
(Considering New
Expansion)
1. Domestic 205* 205* 205 205 410*
2. Process 0 0 0 0 0
3. Boiler NA NA NA NA NA
4. Cooling & Chilling
(Existing)
150 150 125 200 325
5. Washing 566 816 650 0 650
6. Gardening 0 0 0 0 0
Total 921 1171 980 405 1385
WATER BALANCE DIAGRAM (TOTAL PROPOSED)
TOTAL POWER REQUIREMENT & SOURCE OF POWER
Power requirement will be 12.7 MW (Existing = 8.7 MW + Additional Proposed = 5 MW) which will be taken
from GEB. 4 Nos. of (155 KVA each) & 2 Nos. of (2.5 MW each), 2 Nos. of (500 KVA) & 3 Nos. of (2.1 MW each)
DG Sets will be kept for emergency power back up.
FUEL REQUIREMENT
Quantity S.No Fuel
Existing Additional Total Proposed
1 Natural Gas 6000 m3/hr 10000 m3/hr 16000 m
3/hr
2 LPG 4 MT/hr 6.4 MT/hr 10.4 MT/hr
3 Diesel 1515 Ltrs /Hr 2025 Ltrs/Hr 3540 Ltrs /Hr
DETAILS OF STACKS & VENTS: Flue Gas Stacks
S. No. Sources of
Emission
Type of
Fuel
As Per
CTE
As per CCA
(2018)
Additional Total Proposed
Stack height
APCM
1. Melting Furnace
(Existing)
Natural
Gas
5990
m3/Hr.
5990
m3/Hr.
-- 5990 m3/Hr. 91 m Low NOx Burner. Low
sulfur fuel.
LPG
3.89
MT/Hr.
3.89 MT/Hr. -- 3.89 MT/Hr.
2 Melting Furnace
(Proposed)
Natural
Gas
- -- 9985 m3/Hr. 9985 m3/Hr. 54 m Low NOx burner and
low sulfur fuel. In
addition, an Emission
Control System (ECS)
may be installed if
needed to meet SO2
and NOX emission
limits or, alternatively,
for other reasons even
if not required to meet
limits. If installed, the
ECS would consist of a
scrubber, electrostatic
precipitator (EP), and
selective catalytic
reduction system or,
alternatively, a catalyst
impregnated ceramic
filter.
LPG
- -- 6.21 MT/Hr 6.21 MT/Hr
3. DG Set (2 Nos of
2.5 MW)
Diesel 1200
Lit/Hr
1200 Lit/Hr. - 1200 Lit/Hr. 30 m NA
4. DG Set (3 Nos of
2.1 MW)
Diesel - - 1800 Lit/Hr. 1800 Lit/Hr. 30 m NA
5. DG Set (1 No. of
500 KVA)
Diesel 135
Lit./Hr.
135 Lit./Hr. - 135 Lit./Hr. 14 m NA
6. DG Set (1 No. of
500 KVA)
Diesel - - 135 Lit./Hr. 135 Lit./Hr. 14 m NA
7. LPG Hot water
generator (2 Nos)
LPG 0.11
MT/Hr.
0.11 MT/Hr. - 0.11 MT/Hr. 12 m NA
8. LPG Hot water
generator (2 Nos)
LPG - - 0.19 MT/Hr. 0.19 MT/Hr. 12 m NA
9. Diesel Engines (1
and 2 of 155 KVA
each)
Diesel 90 Lit./Hr.
(Total for
both)
90 Lit./Hr.
(Total for
both)
- 90 Lit./Hr.
(Total for
both)
12 m
(Existing)
NA
10. Diesel Engines (3
and 4 of 155 KVA
each)
Diesel 90 Lit./Hr.
(Total for
both)
90 Lit./Hr.
(Total for
both)
- 90 Lit./Hr.
(Total for
both)
11 m
(Existing)
NA
11. Diesel Engine, (4
nos. for) (open loop
(1), emergency
water system (1)
fire system (2))
Diesel 180
Lit./Hr.
180 Lit./Hr. - 180 Lit./Hr. 12 m
(Proposed)
NA
12. Open loop and
Emergency engines
(FL2)
Diesel - - 90 Lit./Hr. 90 Lit./Hr. 12 m NA
13. Glass Edge Burner
(Existing)
Natural
Gas
10 m3/Hr. 10 m3/Hr. -- 10 m3/Hr. 16 m NA
14 Glass Edge Burner
(Proposed)
- - 15 m3/Hr. 15 m3/Hr. 16 m NA
Flue gas Emission parameters and Limits as per Approved CCA: Existing operations (Float Line 1).
S.
No.
Stack attached to Parameter Applicable standards
1 Melting Furnace (Float 1) Particulate matter 0.8 Kg/MT of Product drawn
TF 5.0 mg/NM3
Particulate Matter 75 mg/NM3
NOx (as NO2) (at 15%
O2), dry basis, in ppmv
1100
NMHC (as C) (at 15% O2),
mg/NM3
150
2 Diesel Engine 2.5 M (2 Nos) – Float 1
CO (at 15% O2), mg/NM3 150
Particulate Matter < 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
3 Diesel Engine 500 KVA
(Float 1)
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
4 LPG Hot Water Generator Exhaust
(Existing 2 nos for Float 1)
NOx 50 PPM
Particulate Matter 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
5 Diesel Engine, (1,2.3,4) Float 1
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
6 Glass Edge Burner
(Float 1)
NOx 50 PPM
Flue gas Emission parameters and Limits as per “The Environment Protection Act & Rules 1986”: For Proposed (Float Line 2).
S.
No.
Stack attached to Parameter Applicable standards
Particulate matter 0.8 Kg/MT of Product drawn
SO2
500 mg/NM3
NOx
1000 mg/NM3
1 Melting Furnace (Float 2)
TF 5.0 mg/NM3
Particulate Matter 75 mg/NM3
NOx (as NO2) (at 15%
O2), dry basis, in ppmv
1100
NMHC (as C) (at 15% O2),
mg/NM3
150
2 Diesel Engine 2.1 M (3 Nos) – Float 2
CO (at 15% O2), mg/NM3 150
Particulate Matter < 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
3 Diesel Engine 500 KVA
(Float 2)
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
4 LPG Hot Water Generator Exhaust
(Proposed 2 nos for Float 2)
NOx 50 PPM
Particulate Matter 0.2 g/KW-hr
NOx + HC < 4.0 g/KW-hr
5 Diesel Engine, (5 & 6 ) Float 2
CO < 3.5 g/KW-hr
Particulate Matter 150 mg/NM3
SO2 100 PPM
6 Glass Edge Burner
(Float 2)
NOx 50 PPM
Process Vents S.
No.
Stack attached to As
Per
CTE
As
per
CCA
2018
Proposed
number of
stacks
Total
Stacks
Stack
height in
Meters for
proposed
stack
Pollutant
Emitted
APCM
1. Ammonia Cracking Plant 1 1 - 1 21 PM, Ammonia Stack, Nitrogen Purging
2. Hydrogen Generation Plant - - 1 1 16 PM, SO2, NOx Stack
3. Mirror Line Plant 7 7 - 7 12 Ammonia Stack
4. SO2 Vent (Float 1) 1 1 - 1 17 SO2 Stack
5. SO2 Vent (Float 2) - - 1 1 17 SO2 Stack
6. Batch House Raw Materials
DCF Vents (Float 1)
9 9 - 9 36 PM Dust Collector
7. Batch House Raw Materials
DCF Vents (Float 2)
- - 9 9 16 PM Dust Collector
8. Batch House Raw Materials
DCF Vents at Basement
(Float 1)
2 2 - 2 9 PM Dust Collector
9. Batch House Raw Materials
DCF Vents at Basement
(Float 2)
- - 2 2 16 PM Dust Collector
10. Batch House Unloading
DCF Vent (Float 1)
1 1 - 1 9 PM Dust Collector
11. Batch House Unloading
DCF Vent (Float 2)
- - 1 1 16 PM Dust Collector
12. Cullet Return System DCF
Vent (Float 1)
1 1 - 1 9 PM Dust Collector
13. Cullet Return System DCF
Vent (Float 2)
- - 2 2 16 PM Dust Collector
14. Hot Air Exhaust (Float 1) 5 5 - 5 16 PM Not Required
15. Hot Air Exhaust (Float 2) - - 5 5 16 PM Not Required
16. Dust collector of cullet
sorting
1 1 - 1 16 PM Dust Collector
17. Dust Collectors for Cullet
Transport
- - 2 2 16 PM Dust Collector
18. Dust collector of tunnels 3 - - 3 16 PM Dust Collector
19. Coater tempering furnace
stack
1 1 - 0 - - -
20. Dust collector of Coater
sand blasting
1 1 - 1 15 PM Dust collector
21. Dust collector of hydrated
lime storage (Float 2)
1 1 18 PM Dust collector
22. Dust collector of EP/Filter
dust storage (Float 2)
1 1 16 PM Dust collector
HAZARDOUS WASTE GENERATION AND DISPOSAL
S.
No.
Items Category
as per HW
Rules
Quantity
As per CCA
2018
Additional
Proposed
Total Treatment and Disposal
Method
1 Used Oil 5.1 25 KL/Year 25
KL/ Year
50
KL/ Year
Sending to Registered
Refiners for recycle / reuse /
Incineration
2 Waste residue containing oil 5.2 20
MT/ Year
20
MT/ Year
40
MT/ Year
Send to GPCB registered TSDF
for land Filling or Incineration
3 Process wastes, residues &
debris from production
and/or industrial use of
paints, pigments, lacquers,
varnishes, plastics and inks
21.1 20
MT/ Year
- 20
MT/ Year
Send to licensed disposal
company
Recycle as a fuel or
Incineration
4 Spent solvents from the
production and/or industrial
use of solvents
20.2 5 MT/ Year - 5 MT/ Year Send to licensed disposal
company
Recycle as a fuel or
Incineration
5 Discarded Containers &
barrels contaminated with
hazardous wastes/chemicals
6 Discarded Bags / Liners
contaminated with
hazardous wastes/chemicals
33.1
240
MT/ Year
- 240
MT/ Year
Collection, Storage,
transportation, Disposal by
selling to Registered Vendors
for recycle/ reuse
7 Furnace/reactor residue and
debris
1.1 60
MT/ Year
90
MT/ Year
150
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
8 Inorganic Tin compounds B 17 1
MT/ Year
1.5
MT/ Year
2.5
MT/ Year
Send to licensed disposal
company for Recycling /
landfill
9 Spent catalyst and molecular
sieves
1.6 4
MT/ Year
- 4
MT/ Year
Send to licensed disposal
company for Recycling /
landfill
10 Spent ion exchange resin
containing toxic metal
(upcoming 1200 KL Ro resin
to be added
35.2 15
MT/ Year
- 15
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF or
recycle
11 Chemical sludge from waste
water treatment
35.3 5
MT/ Year
695
MT/ Year
700
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
12 Coater Sand Blasting Debris Z32 75
MT/ Year
- 75
MT/ Year
Collection, Storage,
transportation, Disposal by
landfill at authorized TSDF
Solid (Non-Hazardous) Wastes:
S.
No
Waste Type Existing Proposed
Additions
Total Disposal Method
1. Mirror and Lacquered
Cullet
100
MT/Month
- 100 MT/Month Sell as non-hazardous waste
for recycling / reuse
2. Bad Batch 100
MT/Month
150 MT/Month 250 MT/Month Recycling/reuse /Landfill
3. G-Core 100 KG/Month 150 KG/Month 250 MT/Month Reuse in-house for water
neutralization / landfill /
recycling / reuse
4. Rejected Sand 2200
MT/Month
3500 MT/Month 5700 MT/Month Recycling in house / selling to
water treatment plant and
construction industry / Landfill
5. Lagoon reclaim waste 7000
MT/Month
8000 MT/Month 15000
MT/Month
Recycling in house by having
sales to various end users like
foundries, resin coated sand
manufacturers, ceramics and
tiles manufacturers, filter bed
manufacturers, construction
industry etc / and /or at
construction Landfill
6. Cullet 2500 MT/
month
4000 MT/Month 6500 MT/Month Recycling in house / Sell to
recyclers
7. Sludge Generation
from STP
1 MT/Month 1 MT/Month 2 MT/Month Using as manure in-house
8. Furnace refractory
waste, Wool, Mud,
Cement etc.
10 MT/Month 20 MT/Month 30 MT/Month Sent for Construction site land
filling/recycle/reuse
9. Cullet Dust 40 MT/Month 60 MT/Month 100 MT/Month Sent for Construction site land
filling/recycle/reuse
10. E-waste 250 KG /
Month
400 KG / Month 650 KG / Month Sold to GPCB approved
recycler
11. Trash and Packaging
material waste
20 MT/Month 30 MT/Month 50 MT/Month Sold to scrap vendor
12. Metal Scrap 10 MT/Month 25 MT/Month 35 MT/Month Sold to scrap vendor
13. Solid waste from flue
gas treatment (EP or
Filter Dust)
- 300 MT/Month 300 MT/Month Reused as a raw material