PROPOSED EXPANSION OF SILICA SAND PRODUCTION...

1

FORM-1

for

PROPOSED EXPANSION OF SILICA SAND

PRODUCTION 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:











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:

Float Plant = 2,50,00,000 Sq. meter/Annum

Silica Sand (Glass Grade) = 33,120 MT/Month

LPG Tanks: 4 Nos. (Capacity = 56.25 MT each)

i.e. Total Capacity = 225 MT

Total Proposed Capacity:

Float Plant = 2,50,00,000 Sq. meter/Annum

Silica Sand (Glass Grade) = 86,500 MT/Month

LPG Tanks: 6 Nos. (Capacity = 120 MT each) i.e.

Total Capacity of 720 MT

6. Category of Project i.e. ‘A’ or ‘B’ 'A'

7. Does it attract the general condition?

If yes, please specify.

Yes. Located within 5 km of critically polluted

area (Ankleshwar).

8. Does it attract the specific condition?

If yes, please specify.

No

Location

Plot/Survey/Khasra No. As per the plot detail attached

Village Kondh, Valia Road

Tehsil Ankleshwar

District Bharuch

9.

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,

3

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 NA

18. Whether separate application of

interlinked project has been

submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

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.

(c) Orders/directions of the Court, if

any and its relevance with the

proposed project.

NA

• Capacity corresponding to sectoral activity (such as production capacity for

manufacturing, mining lease area and production capacity for mineral production,

4

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 will be carried out

within the existing premises.

Total Cost of the Project is Rs. 624 Crores

(Existing = 584 Crores + Additional = 40

Crores)

Total Plot Area = 6,55,990.4 m2

Green Belt = 80,936.51 m2

1.2 Clearance of existing land,

vegetation and Buildings?

Yes Already available

1.3 Creation of new land uses? No

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?

No

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 sand

beneficiation plant would be operational.

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No

1.28 Influx of people to an area

either temporarily or

permanently?

No 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 Land of 6,55,990.4 m2

2.2 Water (expected source &

competing users) unit: KLD

Yes The entire water requirement will be met

through Valia Water Supply System (Canal

Water). Water available from GIDC. For detail

please refer Annexure – VI

2.3 Minerals (MT) No

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)

No

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

7

(II) Production of solid wastes during construction or operation or decommissioning (MT/month)

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)

No

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules)

Yes Please refer Annexure – V

4.4 Other industrial process wastes No

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 sand

beneficiation plant would be operational

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.


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

8

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 All the waste shall be stored in designated place

and shall be transported to TSDF site in approved

closed vehicles owned by the TSDF authority.

Dust from drying will be collected in to dust

collector through cyclone separator & recovered

powder will be recycled back to process. Air

Handling Unit will be provided where ever

applicable.

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:



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

6.4 From blasting or piling No

6.5 From construction or operational

traffic

Yes

6.6 From lighting or cooling systems Yes Please refer Annexure – IX

6.7 From any other sources No

9

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:




7.1 From handling, storage, use or

spillage of hazardous materials

Yes Hazardous material shall be stored in

designated storage area with bund walls for

tanks. Other material will be stored in

bags/drums on pallets with concrete flooring

and no spillage is likely to occur. All liquid raw

materials shall be transported through pumps

and closed pipelines and no manual handling

shall be involved. Spill Container will be kept at

appropriate places to collect spillage. SOP for

collection, decontamination & disposal of

spilled material will be 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

discharge)

Yes The wastewater generated from Cooling,

Chilling & Washing will be reused in Sand Plant

for Sand Washing through recirculation. The

Domestic wastewater will be treated in Sewage

Treatment Plant 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.


confirmation

Yes/No Details there of (with approximate



8.1 From explosions, spillages, fires

etc from storage, handling, use

or production of hazardous

substances

Yes For detail please refer Annexure – VII

10

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

(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 Proposed expansion is within the existing

premises.

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

11

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 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 4 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,

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

13

LIST OF ANNEXURES

SR. NO. NAME OF ANNEXURE

I List of Products with their Production Capacity

II Layout Map of the Plant

III Brief Manufacturing Process Description

IV Description of Effluent Treatment Plant with flow diagram

V Details of Hazardous Waste

VI Water, Fuel & Energy Requirements

VII Details of Hazardous Chemicals Storage & Handling

VIII Details of Stacks and Vents

IX Expected Noise level at Different source within the premises

X Socio-economic Impacts

XI Proposed Terms of Reference for EIA studies

XII Water Supply Letter

XIII TSDF & CHWIF Membership Letter

XIV Lease Deed Documents

XV Toposheet

14

ANNEXURE-I

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

Float Plant Details:

Quantity in Square Meter/Annum S. No. Product

Permitted Additional Total

1 Float Glass

2 Mirror

3 Lacquered Glass

4 Coater Glass

2,50,00,000

- 2,50,00,000

Proposed Expansion Details:

SR.

NO.

PRODUCT NAME EXISTING CAPACITY

(MT/MONTH)

PROPOSED CAPACITY

(MT/MONTH)

1 Silica Sand (Glass Grade) 13,500 56,225

2 By-Products (Coarse, Fines and rejects) 19,620 30,275

3 Total 33,120 86,500

LPG Storage Tank Details

Existing Capacity:

LPG Tanks = 4 Nos. (Capacity = 56.25 MT each)

SR.

NO.

Storage Material No. of Tanks Capacity Total Capacity Tank Dimensions

1 LPG 4 56.25 MT (each) 225 MT Length = 16.2 m

Diameter = 3200 mm

Total Proposed Capacity:

LPG Tanks = 6 Nos. (Capacity = 120 MT each)

Proposed combine capacity: 720 MT

SR.

NO.

Storage

Material

No. of Tanks Capacity Total Capacity Tank Dimensions

1 LPG 6 120 MT

(each)

720 MT Design Pressure: 21 Kg/cm2

Overall Length = 24000 mm,

Tank ID 4010 mm,

Tank Shell = 28 mm thick

Dished End 18 mm Thick.

Note: M/s. Gujarat Guardian Limited is exploring the option to merge the existing and

proposed LPG storage yard for future so that the new LPG yard would be (existing + proposed)

capacity which is 720 MT. By proposing this we are also proposing that existing yard be

demolished and merged with new LPG storage yard in case above is the decision.

Existing LPG storage yard: 225 MT

Additional Proposed LPG storage: 495 MT

Total Storage of LPG onsite: 720 MT

15

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 0 14,000

2 Soda Ash MT 4,500 0 4,500

3 Dolomite MT 3,800 0 3,800

4 Limestone MT 1,400 0 1,400

5 Feldspar MT 850 0 850

6 Salt Cake MT 215 0 215

7 Carbon MT 21 0 21

8 Cullet MT 6,000 0 6,000

Wet Coater

1 Raw Glass Sq. Meter 5,83,000 0 5,83,000

2 Washing & Polishing Chemicals Kg 2,062 0 2,062

3 Tin Sensitizer Litre 119 0 119

4 Palladium Sensitizer Litre 45 0 45

5 Silver Solution

Silver Nitrate

Litre

Kg

2,600

1,088 0

2,600

1,088

6 Reducer/

Silver less solution

Litre

Litre

4,830

2,920 0

4,830

2,920

7 GMPA & GMPB Litre 1,190 0 1,190

8 Paint MT 68 0 68

9 Ortho-Xylene Litre 9,971 0 9,971

10 HCL-32% Litre 11,393 0 11,393

11 Caustic-32% Litre 13,508 0 13,508

12 Ferric Sulfate kg 256 0 256

Lacquered Glass

1 Raw Glass Sq. Meter 1,50,000 0 1,50,000

2 Washing and polishing chemical Kg 200 0 200

3 Adhesion Promoter Litre 50 0 50

4 Paint MT 10 0 10

A GLASSOLUX NG 9003 PURE WHITE Kg 2,500 0 2,500

B GLASSOLUX NG 2105 Sapphire Kg 2,500 0 2,500

C GLASSOLUX NG 3004 Burgundy Kg 2,500 0 2,500

D GLASSOLUX NG 6113 Fluo green Kg 2,500 0 2,500

E GLASSOLUX NG 9005 Black Kg 2,500 0 2,500

F Ivory Kg 2,500 0 2,500

G Red Kg 2,500 0 2,500

5 Ortho-Xylene Litre 1,000 0 1,000

Sand Beneficiation Plant

1 Raw Silica Sand MT 33,120 53,380 86,500

16

ANNEXURE-II

LAYOUT MAP OF THE PLANT

17

LPG STORAGE LAYOUT (EXISTING)

18

LPG STORAGE LAYOUT (PROPOSED)

19

ANNEXURE-III

BRIEF PROCESS DESCRIPTION

EXISTING

Below is the manufacturing process for following products;

1. Float Glass

2. Mirror Glass

3. Deco crystal Glass

1. 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

2. Glass Manufacturing

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

float glass industry worldwide has subsequently been essentially converted to the

float process. 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 would consist 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 materials would be 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 would be conveyed to the furnace

where the raw materials would be melted using either natural gas or fuel oil.

Molten glass from the furnace would flow by gravity and displaced into a tin bath

where a continuous ribbon would be formed by controlling glass temperature with

time. The ribbon would be pulled, or drawn, through the bath on a layer of molten

tin, the temperature of which would be controlled electrically. Upon existing the

bath, the ribbon of glass would enter the electrically heated annealing lehr where in

it would be cooled preparatory to cutting into sheets.

A computer controlled automatic cutting system would cut the ribbon into

predetermined sizes as dictated by customer orders. Pieces would than either be

placed racks, boxes, or on dollies for storage or direct shipment. Any waste or

damaged glass would be 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 and minor amounts of Rouges and Charcoal.

Silica sand would comprise about 60% of the total raw material input with Soda Ash,

Dolomite together making up about 35% of the total by weight. The remainder

would be distributed among Limestone, Salt cake, Charcoal and Rouge.

21

Batch House:

Raw material would be received at the plant site in trucks and/or rail cars. Materials

would be dumped into a hopper in a unloading area by a belt conveyer to a bucket

elevator where they would be discharged into the proper bins with the help of a

rotary spout. The concrete storage bins would be designed in such a way that

material segregation would be reduced to a minimum, an important quality

consideration in glass manufacturing. Each material would be weighed individually

on high accuracy industrial scales, and then checked on a totalizer scale prior to the

bin discharged into the mixer. The dry ingredients would be thoroughly mixed, and

then measured amount of water would be added to the mixer for wet mixing. After

mixing a precise amount of cullet would be layered on the mixed batch prior to

conveying to a melting furnace. The batch would be stored in large hopper over the

furnace feeder. In the event of mechanical or electrical failure of any batch, system

component, this hopper would provide mixed batch for about six hours of continues

feeding in to the furnace. Dust control equipment in the unloading area and batch

house would operate continuously to maintain a safe, healthy and working

environment for the employees, as well as to minimize dust and particulate

emissions.

Melting Furnace:

The melting furnace would be capable of melting clear glass at a desired rate. The

batch materials would be fed into the glass-melting furnace from the blanket. The

operation of the feeder would control by a precise glass level controller.

The melting furnace would be 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 would be pushed away from the furnace back wall by the blanket feeder.

Floating on top of the molten glass, the batch would pass under the fuel flames,

pouring out of the ports above the furnace side wall. Temperature exceeding 2900

degree F would melt the batch ingredients. Combustion products would be

discharged through a stack.

After the batch material melts into solution, the molten glass would be gradually

cooled in the refiner section of the furnace. By the time the glass would reach 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 would now be

delivered to the float bath in a constant pouring action through the channel.

Float Bath:

The float bath would consist of an electrically heated forming oven. The glass would

flow on to the surface of a pool of molten tin at approximately 2900 degree F. A

continuous ribbon would be drawn from this pool and transported and cooled along

the length of the float bath. The temperature of glass at the bath exist would be

approximately 1100 degree F, still a plastic material but solid enough to the removed

22

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 would be 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 would rapidly oxidize 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 degree 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 would 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 would emerge from the annealing lehr in continuous ribbon at a

temperature slightly above room temperature. The glass would pass under a

darkened booth where, under special lighting conditions, inspector would scan every

square foot for defects. An automated inspection system would detect defects in the

glass ribbon and help command the defect marking system to spray ink on the

defect. The glass sheets containing defect would be broken crushed and returned to

the batch house to be recycled with the raw materials.

The inspected ribbon would be cut to exact dimensions with precise, high-speed

cutters. The edge trim would be eliminated, crushed and returned to the batch

house. The glass sheets, free of defects, would now be boxed 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 would be shipped by truck.

23

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

24

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 paint 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.

25

Flowchart for Mirror:

26

1. Lacquered 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 smoothen 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

25

2. 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.

26

PROCESS FLOW DIAGRAM

27

SAND PLANT (PROPOSED – CAPACITY ENHANCEMENT)

Process Description

It is to be noted that the process description below is based upon preliminary information

and design only at this stage. Further test work particularly in regards to the settling velocity

of the slimes and efficiency of the dewatering/filter equipment will have ramifications on

the design of the final process.

FEED PREPARATION

Feed will be received in a dump hopper with a 150mm grizzly screen. Feed will be metered

into the circuit via belt feeder governed by a belt weigher on an inclined conveyor. The feed

will be conveyed into a drum scrubber where it will have water added. The drum scrubber is

intended to liberate the agglomerated material and free some of the clay material in the

feed. The discharged product will pass through a coarse screen attached to the drum to

remove any material >6mm.

DESLIMING AND SIZING STAGE

The scrubbed material will transfer via gravity to a desliming sump to be pumped to a

cyclone for removal of clay particles. The overflow of the cyclone containing the fine clay

particles will report to the thickener for processing. The underflow will report to a sizing

screen. All particles less than 600 micron will be pumped to the attritioner feed cyclone.

Oversize material will launder to the ball mill for comminution. Milled material will launder

back to the desliming sump for re-processing in the desliming cyclone.

ATTRITIONING STAGE

Material that passes through the sizing screen will be pumped to a cyclone above the

attritioner. The cyclone will dewater the feed to the attritioner to a high density prior to

laundering to the attritioner. The attritioner scrubs the high density slurry using a series of

rotating paddles to remove any contamination from the surface of the sand particles. The

overflow from the cyclone will launder via gravity to the thickener.

UP CURRENT CLASSIFICATION STAGE

After processing in the attritioner the slurry will be pumped to an up current classifier (UCC)

for classification by size using a current of rising water in a vessel. Larger, higher density

particles pass down through the current while smaller, lighter particles are lifted over a

weir. The flow rate of the up current water can be varied to adjust the cut size of the

particles reporting to the overflow. The UCC overflow consisting of particles

28

launder to a process sump feeding the product dewatering cyclone and screen. The product

will be dewatered and transferred to a conveyor system for stockpiling. The overflow

fraction of the cyclone will be laundered directly to the drum scrubber for re-use. The

middlings fraction will either be sent to the rejects process sump or returned to the spiral

feed sump in response to operational conditions and feed characteristics.

PROCESS WATER AND THICKENER

A process water tank will be the source of all water distribution through the circuit. Through

the use of dewatering equipment on all output streams MT has endeavored to minimize the

net water loss therefore reducing water make-up demand into the circuit. Clean water is

recirculated within the system, where possible, to reduce both thickener size and flocculent

consumption. Water removed from the circuit in high slimes stages will be treated in the

thickener using a flocculent such that clean water will flow over the weir. This water will

then report via a coarse static screen to the process water tank. Thickened slimes will flow

via the underflow to a process pump for transfer to the belt filter press. The filter press will

dewater the slimes as much as possible prior to stockpiling. A requirement for further

flocculent dosage prior to filtering will be determined in detailed test work.

Chemical Usage

The only chemical addition to the plant process will be a flocculant. Detailed test work will

determine the best type of flocculant for these slimes, what type of dosing system would be

most appropriate and at what rate flocculant will need to be added to the system to remove

the slimes and clarify the water. Assuming a dry granular type flocculant is to be used then

consumption has been assumed to be between approx. 0.5 to 1.5 metric tonne/month.

Product Mass Balance

Given the variability and range of feed sources the mass balance can vary markedly. Below is

an estimate based upon information provided by Gujarat Guardian.

Estimated Output Quantities as % per Month

Note: Values are based upon feed characteristics provided by GG.

Product Name

Minimum

Throughput

MT/month)

Maximum

Throughput

(MT/month)

Remarks

X Feed 100% Based upon nominal feed rate of 120 t/h at 80%

plant availability

A Finished Sand for Float

Glass 70% 90% Based upon range of values provided by GG

B Fines Rejection of (-) 150

micron 5% 25% 5% to 25% of head feed

C

Pebbles and Coarser

Particle (+) 6 mm to (-) 50

mm

0% 5% Allowance only

D Boulders (+) 50 mm 0% 0% Allowance only

E Rejected Clay 5% 25% This assumes 5-25% slimes however actual rejected

clay depends upon sale of clay product

F Any other (HMC) 2% 10%

This assumes 2-10% HMC within the head feed.

Actual reject depends upon saleability of HMC

product.

29

Proposed Sand Beneficiation Process Diagram

30

LPG SYSTEM START-UP TO FURNACE

This procedure will describe the entire startup process of the LPG system from the tanks to

the peak shaving station.

Under normal operating conditions the LPG system should have 80-90 Degree C water

running through the vaporizers.

1. Recirculation System:

a. Start circulating water:

i. Verify all valves are open to circulate water through the boiler and

vaporizer

ii. Ensure the water system has a pressure of 1-1.5 bar

iii. Start the recirculation pump for the desired vaporizer and hot water

generator (Note: valves have been provided to allow either hot water

generator to feed either vaporizer)

iv. Pump inlet pressure should be 1 – 1.5 bar and outlet should be 3.0 – 4.0 bar

depending on water temperature

31

i. Verify the vapor pressure before the second stage regulator is 2.5 bar.

ii. Open safety shut-off valve on second stage regulator by opening the

bypass valve while at the same time, pull down on the bottom handle.

iii. Verify the pressure after the second stage regulator is 300 mbar

iv. Check that the final regulated pressure is 50-60 mbar when burner is

working.

c. Hot Water Generator Startup

i. Verify control voltage to the boiler control panel from the 220V panel next to the

AES control panel is on.

ii. On the boiler control panel, Turn “Burner Control” switch to “on” and turn

“Circulation” switch to “on”.

iii. Check the Burner start-up sequence (ref. figure 3)

32

Note: If there is a burner fault (light F) reset by pressing button 2, if the fault reappears,

contact Engineering.

2. LPG Supply (ref. figure 4):

a. Verify that the tank valves are open. (They are normally all open)

b. Verify that the System pressure is above 4.8 bar at the liquid transfer pumps.

c. Verify that inlet and outlet valves of the pump(s) are open.

d. If system pressure is below 4.8 bar you will need to start one of the pumps.

e. The Liquid Return line going from the transfer pump to the tank(s) where LPG is

being consumed from should be open while the transfer pump is running

33

3. Vaporizers (ref. Figure 5.):

a. Confirm that the vaporizer that will be used is hot. The water inlet temperature

should be above 65oC. (Note: if water inlet temp is cold, the LPG liquid level will rise

in the vaporizer. If the LPG liquid level reaches the liquid carry over sensor or if the

vapor out temp is below 10oC, the solenoid valve allowing liquid LPG into the

vaporizer will close)

b. Power on the vaporizer from the vaporizer control panel.

c. The LPG liquid inlet valve should be closed

d. Open the vaporizer vapor discharge valve.

e. Open the LPG inlet pneumatic valve by pressing “inlet valve open/close” on the

Vaporizer control panel.

f. Open LPG liquid inlet ball valve slowly allowing LPG to the vaporizer.

34

4. Mixer/Blender (ref. figure 6.):

a. Ensure that the manual valves at the discharge of the mixer are closed

b. Open the inlet ball valves on the LP vapor and compressed air lines

c. Turn on the power at the control panel.

d. Open the inlet ball valves by pressing “Inlet valve open/close”.

e. Check the inlet pressure gauges. They should read around 6.2 bar on the

compressed air and 5.0 bar or greater on the LPG vapor.

f. If the pressure difference in less than 1.4 bar, then open the regulators by pressing

“POM start/stop”. [If not, check plant compressed air and/or start the liquid transfer

pumps (tank to vaporizer) if needed.]

g. Start the flare unit (this will allow the system to stabilize). The flare can be shut

down once LPG is flowing to the furnace.

h. Verify that the outlet pressure at the mixer is as follows:

i. When flowing LPG: 3.5 bar

ii. When outlet valves are closed: 4.0 bar

iii. Alarm pressure: 4.3 bar

Note: At this point, the PLC will energize the loading solenoid valve for a period of time,

overriding any alarm conditions. If all alarm conditions clear during this time, the mixer will

continue to operate. If any alarm conditions remain, the mixer will shut down. These alarm

conditions must be cleared before the mixer will start and remain in operation.

35

PROPANE GAS TO THE FURNACE (ref. figure 8):

1. After completing steps 1 – 5, communicate with the furnace to ensure the supply

pressure at the furnace is 3.5 bar and the incoming LPG valve is closed.

2. SLOWLY open the outlet valve to the furnace at the mixer.

3. Verify the peak shaving valve is closed and then open the isolation valve after the peak

shaving valve.

4. Using the peak shaving valve, slowly open the flow to the furnace and confirm that the

blended LPG vapor is flowing.

5. Once flow is confirmed, slowly close the natural gas valve feeding the furnace

36

NATURAL GAS TO THE FURNACE:

1. SLOWLY close the peak shaving valve on the LPG supply line as you slowly open the

natural gas supply valve.

2. You should now be able to hear the natural gas flowing to the furnace.

3. Leave the outlet valve at the mixer to the furnace open, and start the flare to bleed the

excess pressure from the supply line to the furnace.

LPG SYSTEM SHUTDOWN:

1. Vaporizers:

a. Shut off the liquid transfer pump (if running), this can either be done locally or from the

AES panel.

b. Close the vaporizer inlet valve, allowing the propane gas in the system to evacuate and

burn off using the flare

2. Mixer/Blender

a. Close mixer air and propane valves.

b. Close the solenoid supply to the regulators.

c. Close the flare valve at the outlet of the mixers.

3. LPG Storage Tanks:

a. Verify transfer pumps are off.

b. Close pump outlet valve only, leave the inlet valve open.

4. Flare stack:

a. Close the flare stack pilot valve and main line valve.

b. Swing the rain cap over the top of the flaring stack for weather protection.

37

EMERGENCY SHUT-DOWN SWITCHES (ESD) AND REMOTE OPERATED VALVES (ROV’s)

There are six (6) emergency shut-down pushbuttons located within the LPG area as follows:

a. Unloading shed #1

b. Unloading shed #2

c. Transfer pump shed

d. Hot Water Generator and Vaporizer shed (near overhead door)

e. Hot Water Generator and Vaporizer shed (west end)

f. Blender room

These buttons maintain a constant air supply to the ROV’s at the LPG supply tanks to keep

them open. During an emergency, any of these buttons can be pressed to stop ALL flow out

of the LPG tanks.

When any of these six buttons are pressed, it will trigger a relay in the main control panel.

The relay will release the compressed air out of the remote operated valves on the tanks.

There is also a manual 3 way valve on the compressed air supply in the hot water generator

and vaporizer shed that will stop the incoming supply of compressed air and dump the air

out of the line supplying the ROV’s. This will also cause the valves on the bottom of the

tanks to close.

Pull out the ESD pushbutton to reset the alarm and apply pressure back to the excess flow

valves.

38

ROV CONTROL PANEL (Figure 11)

Outside the South gate of the LPG yard there is a panel that allows you to control each ROV

Independently. This can be used if you want to utilize LPG from a specific tank. It also

receives signals from the high level sensors on the tanks (set at 85%). If one of the sensors is

tripped an alarm will be triggered at this station.

40

LPG UNLOADING PROCEDURE

This procedure will describe the unloading procedure using the new Alternate Energy

Systems (AES) equipment.

1. Pre-Unloading Checklist:

a. Prior to unloading the technician responsible should check the level of the tanks

by using the Roto-Gauge on the front (see figure 1)

b. Verify that there is enough room in the LPG tanks to unload the LPG (an LPG truck

in India will have around 18 tons of LPG). Note: Each tank has a 60 ton LPG capacity,

but they should not be filled up beyond the 85% mark (51 tons), if a tank is filled

beyond this point the high level alarms will trip.

c. For maximum unloading efficiency the LPG should be unloaded into two or more

tanks simultaneously (this is because the LPG liquid in lines at the top of the tanks is

2” and the liquid line feeding them from the unloading stations is 3”)

d. Once the tanks have been determined the liquid inlet and vapor inlet valves at the

top of these tanks should be opened (see figure 2).

e. Prior to connecting the liquid and vapor hoses to the tanker all valves in the

unloading shed should be closed.

41

2. Unloading LPG

a. It takes approximately 4 hours to fully unload an LPG tanker, ensure that the

proper personnel will be available to witness the entire unloading.

b. The first tanker should always pull up to the South unloading station, this will

allow the second tanker to pull in behind the first and unload at the North unloading

station (if required)

c. When the truck is in position the grounding lead on the unloading shed should be

connected to the frame of the truck

d. Connect the liquid and vapor unloading hoses to the truck.

e. Verify all the valves in the unloading shed are closed and SLOWLY open the valves

on the tanker. Check for leaks.

f. Once no leaks have been observed, slowly open the vent line on the liquid line to

purge the air from the line. Liquid will begin to flow through the check valve on the

unloading skid. When the liquid fills 50% of the check valve (this can be witnessed

through the sight glass) close the vent line.

g. Open the inlet and outlet valves on the liquid transfer pump (figure 3)

h. SLOWLY open the globe valve on the unloading skid. As it is opened LPG will begin

flowing from the truck to the tanks based on the pressure differential.

Typically the tanks will be around 6 bar and the truck will be around 7 bar when

unloading begins.

42

i. When the pressure in the truck lowers and gets closer to the pressure in the tanks

the flow will slow down. At this point the liquid transfer pump can be turned on.

j. Eventually the pump will begin to vibrate because the pressure in the truck is not

high enough. At this time the transfer pump should be shut off, and the compressor

should be turned utilized.

k. BEFORE TURNING ON THE COMPRESSOR slowly open the ALL the valves on the

vapor line in the unloading shed and the skid (including the compressor bypass

valve). The pressure between the tanker and the tanks having LPG unloaded to them

will equalize. The 4-way valve should be pointing to the LEFT in order to pressurize

the tanker by pulling vapor from the LPG tanks.

l. Verify all the valves are open, if a valve is closed on the discharge side of the

compressor the pressure will quickly rise, causing a very unsafe condition.

m. Turn on the compressor, the pressure gauges for the suction and return lines on

the compressor should be equal because the bypass valve is open. Very SLOWLY

close the bypass valve while monitoring the discharge pressure. The pressure should

rise slightly and LPG liquid will once again begin flowing to the tanks. Note: the

discharge pipe going from the compressor to the tanker will heat up due to the

compressed gases; this is normal and can be used as a verification the flow is in the

correct direction.

n. Monitor the pressure on the tanker, it should not go above 8 bar, if it does shut off

the compressor until it drops below 7.5 bar and start again. If time is a concern the

transfer pump can also be turned on again to maximize the flow to the tanks (if the

transfer pump begins to vibrate again turn off the pump and continue unloading

with the compressor)

43

o. If there is too much flow coming from the truck tanker, the excess flow valve on

the truck will trip and flow will be reduced or cut off completely. If this happens, shut

the valve on the truck (you will hear the excess flow valve reset when flow is

stopped) and slowly open it again.

p. Throughout the process the LPG level on the truck and the tanks being unloaded

to should be checked and recorded.

q. When the Roto-Gauge on the truck shows less than 3% only the unloading

compressor should be used (while making sure the truck tanker does not exceed 8

bar pressure.

r. As the last amounts of liquid leave the truck the check valve will begin to shut and

LPG will cease to flow. When this happens the compressor should be turned off and

all the valves on the liquid line should be shut and the remaining LPG in the

unloading hose should be SLOWLY vented until all pressure is gone. At this point the

hose can be removed from the truck.

3. Depressurizing the truck

a. SLOWLY open the vapor bypass line around the compressor. This will cause the

pressure in the truck to equalize with the LPG tanks in the yard.

b. When the pressure difference drops to the point where vapor is no longer flowing

on its own the 4-way valve on the compressor should be rotated so that the handle

is pointed UP. In this configuration the compressor will pull vapor from the truck and

load it back into the tanks.

44

c. BEFORE TURNING ON THE COMPRESSOR verify ALL the valves on the vapor line in

the unloading shed and the skid are open (including the compressor bypass valve).

d. Turn on the compressor and verify the pressure on the suction and discharge are

correct.

e. Continue to run the compressor until the pressure on the tanker is around 2.5 bar.

f. Turn the compressor OFF

g. Close all the valves on the vapor line and the outlet of the truck.

h. Depressurize the hose using the vent on the skid by SLOWLY opening the valves.

i. The vapor hose can now be removed from the truck.

j. Close the valves on top of the LPG tanks

k. Close the gates to the LPG yard

l. Unloading Complete

45

ANNEXURE-IV

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 an 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 dose 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

Sr. No. Parameters GPCB Limit for Sewage Outlet water

1 BOD < 20

2 SS < 30

3 Residual Chlorine � 0.5

46

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.

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 Units with Suggestive Modifications

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.

47

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.

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.

48

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.

Contingency plan for incidents possibly encountered in sewage treatment plant

� CONTENTS

1) Introduction

2) Objective

3) Activation of contingency plan

4) Emergency action

5) Deactivation of contingency plan.

� Introduction

The contingency plan is to provide guidelines for all employee of plant in dealing with

different incidents, which have potential of environmental nuisance

� Objectives

The contingency plan has following objectives.

1) To avoid and, if not possible, to minimize environmental impact to the surroundings.

2) To seek assistance from relevant work agents for emergency handling.

3) To minimize damages to affected plant.

4) To ensure emergency procedure required is organized & implemented in an orderly

manner.

� Activation Of contingency plan

Types of incidents, which is considered to vulnerable to giving rise to possible

environmental nuisance, are given below.

a) Power failure

Mains failure leading to total blackout in a part or whole of STP plant area; interruption

of power supply due to failure of switchgear & operator malpractice.

b) Fire breakout

Setting furniture & equipment on fire through negligence, overheating of equipment &

improper handling of inflammable materials.

c) Abnormal effluent

Abnormal swage to plant, which directly affect normal operation of process.

d) Swage overflow

49

Excessive flow particularly in rainy season burst of pipes, treatment failure due to

inadequate standby equipment

e) Non-compliance with discharge standard.

Plant overloaded in terms of quantity or quality. Illegal discharge of toxic waste.

� Emergency action

Action to be taken, where appropriate, are shown below

o To detect sign of abnormality

o To investigate & assess environmental impact

o Wherever required arrange emergency equipment

o To consider various actions to implement measures to mitigate

environmental impact & restore plant to normal operation.

o To plan corrective action & preventive action to improve plant reliability

� Deactivation of contingency plan

Contingency plan will be deactivated when the concerned plant is brought back to

normal working condition & potential of generating environmental nuisance is

eliminated.

50

FLOW DIAGRAM

51

EXPECTED CHARACTERISTIC OF EFFLUENT

52

ANNEXURE-V

HAZARDOUS WASTE GENERATION AND DISPOSAL

S. No. Items Category Existing Additional Total Treatment and Disposal

Method

1 Used Oil 5.1 25

KL/Year

- 25

KL/Year

Collection, Storage,

Transportation & Sending to

Registered Refiners for recycle

/ reuse

2 Chemical Sludge

from Wastewater

Treatment

35.3 5

MT/Year

- 5

MT/Year


Transportation & Disposal by

landfill at authorized TSDF

3 Waste residue

containing oil

5.2 20

MT/Year

- 20

MT/Year


Transportation & Sent to GPCB

registered TSDF for land Filling

or Incineration

4 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


Transportation & Sent to

licensed disposal company

Recycle as a fuel or

Incineration

5 Spent solvents from

the production

and/or industrial use

of solvents

20.2 5

MT/Year

- 5

MT/Year



licensed disposal company

Recycle as a fuel or

Incineration

7 Discarded Containers

& barrels

contaminated with

hazardous

wastes/chemicals

33.3

240

MT/Year

- 240

MT/Year



selling to Registered Vendors

8 Furnace/reactor

residue and debris

from pyrolytic

operations

D1 60

MT/Year

- 60

MT/Year




9 Inorganic Tin

compounds

B 7 1

MT/Year

- 1

MT/Year



licensed disposal company for

Recycling

10 Spent catalyst and

molecular sieves

1.7 4

MT/Year

- 4

MT/Year



licensed disposal company for

Recycling

11 Spent ion exchange

resin containing toxic

metal

34.2 15

MT/Year

- 15

MT/Year




53

Solid (Non-Hazardous) Wastes:

S.No Waste Type Permitted Additional Total Disposal Method

1. Mirror Cullet 100

MT/Month

0 100

MT/Month


Transportation & Sold as non-

hazardous waste for recycling

/ reuse

2. Bad Batch, Gcore, other NH

organic chemicals

100

MT/Month

0 100

MT/Month


Transportation &

Recycling/Reuse/Landfill

3. G-Core 100

Kg/Month

0 100

Kg/Month


Transportation & Reuse in-

house for water

neutralization

4. Waste sand 9200

MT/Month

5800

MT/Month 15000

MT/Month


Transportation & Recycling in

house / Landfill & Recycled in

house

5. Cullet 2500

MT/Month

0 2500

MT/Month


Transportation & Recycling

in house / Landfill

6. Sludge Generation from STP 1

MT/Month

0 1

MT/Month

Collection, Storage, Transportation &

Using as manure in-house

7. Furnace refractory waste,

Kwool, Mud, Cement etc.

10 MT/

Year

0 10 MT/

Year


Sent for Construction earth-

filling

8. Cullet Dust 40

MT/Month

0 40

MT/Month


Sold To GPCB approved

recycler

9. E-waste 250

Kg / Month

0 250

Kg /

Month


Sold to scrap vendor

10. Trash and Packaging

material waste

20

MT/Month

0 20

MT/Month


Sold to scrap vendor

11. Metal Scrap 10

MT/Month

15

MT/Month 25

MT/Month


Sold as non-hazardous waste

for recycling / reuse (increase

in scrape would be because

of demolish of existing sand

beneficiation plant)

54

ANNEXURE-VI

_______________________________________________________________________

WATER, FUEL & ENERGY REQUIREMENT

WATER CONSUMPTION AND WASTEWATER GENERATION: NO CHANGE

Water Consumption Waste Water Generation Sr.

No.

Section

(KL/day)

Existing Proposed Existing Proposed

1. Domestic 350 350 205* 205*

2. Process 25 25 0 0

3. Boiler NA NA NA NA

4. Cooling & Chilling 400 400 150** 150**

5. Washing 775 775 566** 566**

6. Gardening 100 100 0 0

Total 1650 1650 921 921

* 205 m3/day of domestic wastewater is treated in STP and then reused for land

irrigation/gardening.

** 716 (i.e. 150 + 566) m3/day is recycled back to Sand Plant for Sand Washing.

55

WATER BALANCE DIAGRAM (TOTAL PROPOSED)

Domestic

350

Washing

775

Water Consumption

1650

Domestic

205

Cooling &

Chilling

400

Wastewater

716

Washing

566

Cooling

150

716

Reused back in Sand Plant for

Sand Washing and irrigation –

Process

25

Gardening

100

All Figures in KL/Day

STP and Septic Tank

205

Reused for Land

Irrigation/Gardening

56

TOTAL POWER REQUIREMENT & SOURCE OF POWER

Power requirement is 6.5 MW which is taken from GEB in addition 4 Nos. of (155 KVA each)

& 3 Nos. of (2.5 MW, 2.5 MW & 500 KVA) DG Sets will be kept for emergency power back

up. We also have 34 wind mills installed at Dwarka (Gujarat).

FUEL REQUIREMENT

Quantity S.No Fuel

Existing Additional Total Proposed

1 Natural Gas 6600 m3/hr - 6600 m

3/hr

2 LPG 4 MT/hr* - 4 MT/hr*

3 Diesel 1515 Ltrs /Hr 60 Ltrs/Hr 1575 Ltrs /Hr

57

ANNEXURE-VII

STORAGE DETAILS OF HAZARDOUS CHEMICALS

Existing:

Sr.

No.

Name of the

Material

Type of

Hazard

Kind of

Storage

Max.

quantity to

be stored

(MT)

Storage

condition

i.e. temp.

pressure

Tank Dimensions Dyke

Dimensions

1 Ammonia Corrosive,

Toxic

Bullets 20 4 to 7.5 Kg/cm2 Length: 6.546 m

Dia: 2 m

32' x 32' x 1'

2 LPG Storage Flammable 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

3 H2SO4

Storage

Corrosive Tank 4 KL Atmospheric

Pressure

Dia: 1.15 m

Length: 2.85 m

7 x 4.5 x 0.2 m

4 Diesel

Storage

Flammable Tanks 145 KL 0.344 Kg/cm2 @

200C

Ht: 4.2 m

Dia: 5.6 m

16.7 x 10.1 x 1 m

5 MTO &

Xylene

Flammable Barrels 30 KL Atmospheric

Pressure

Room Size:

7.7 x 9 x 7 m

7.7 x 9 x 0.5 m

Proposed:

Sr.

No.

Name of the

Material

Type of

Hazard

Kind of

Storage

Max.

quantity to

be stored

(MT)

Storage

condition

i.e. temp.

pressure

Tank Dimensions Dyke

Dimensions

1 Ammonia Corrosive,

Toxic

Bullets 20 4 to 7.5 Kg/cm2 Length: 6.546 m

Dia: 2 m

32' x 32' x 1'

2 LPG Storage Flammable Bullets 120 x 6 =

720

21 Kg/Cm2 Dia: 4010 mm

Length: 24 m

35 x 11.2 m

3 H2SO4

Storage

Corrosive Tank 4 KL Atmospheric

Pressure

Dia: 1.15 m

Length: 2.85 m

7 x 4.5 x 0.2 m

4 Diesel

Storage

Flammable Tanks 145 KL 0.344 Kg/cm2 @

200C

Ht: 4.2 m

Dia: 5.6 m

16.7 x 10.1 x 1 m

5 MTO &

Xylene

Flammable Barrels 30 KL Atmospheric

Pressure

Room Size:

7.7 x 9 x 7 m

7.7 x 9 x 0.5 m

58

ANNEXURE-VIII

_______________________________________________________________________

DETAILS OF STACKS & VENTS

There is no addition or changes in the Flue Gas Stacks & Process Vents

Flue Gas Stacks

Sr.

No.

Stack Attached

To

No. of

Stacks

Height From

Ground (m)

Fuel Used Air Pollution

Control System

Expected

Pollutants

1. Melting Furnace 1 91 Natural Gas,

LPG

Low NOx Burner,

Stack height

PM,TF

2. DG Set

(2.5 MW)

1 30 Diesel - PM, NOx,

NMHC, CO

3. DG Set

(2.5 MW)


NMHC, CO

4. DG Set

(500 KVA)


NMHC, CO

5. LPG Hot water

generator

exhaust

1 12 LPG - PM, SO2, NOx

6. Diesel Engine 1

(155 KVA)

1 12 Diesel - PM, NOx, CO

7. Diesel engine 2

(155 KVA)


8. Diesel engine 3

(155 KVA)


9. Diesel engine 4

(155 KVA)


10. Glass Edge

Burner

1 16 Natural Gas,

LPG

- PM, SO2, NOx

59

Process Vents

S.

No.

Stack attached to No. of

Stacks

Stack

height (m)

Pollutant

Emitted

Air Pollution Control

Measures Attached

1. Main Melting Furnace 1 91 PM, TF Stack

2. Ammonia Cracking Plant 1 21 PM,

Ammonia

Stack, Nitrogen

Purging

3. Mirror Line Plant 7 12 VOC,

Ammonia

Stack

4. SO2 Vent 2 17 SO2 Stack

5. Batch House Raw

Materials DCF Vents

9 36.5 PM Dust Collector

6. Batch House Raw

Materials DCF Vents at

Basement

2 5.5 PM Dust Collector

7. Batch House Unloading

DCF Vent

1 6 PM Dust Collector

8. Cullet Return System DCF

Vent

1 3 PM Dust Collector

9. Hot Air Exhaust 5 16 PM Not Required

60

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.

61

ANNEXURE-X

_______________________________________________________________________

SOCIO - ECONOMIC IMPACTS

1) EMPLOYMENT OPPORTUNITIES

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

tempo

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