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217 views533 pages

NACL Draft EIA Report - Compressed

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HARMOHAN DAS

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NACL INDUSTRIES LIMITED

SY.NO.177, ARINAMA AKKIVALASA VILLAGE,

ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

DRAFT EIA REPORT

1. ENVIRONMENTAL IMPACT ASSESSMENT

2. ENVIRONMENT MANAGEMENT PLAN
3. COMPLIANCE OF TERMS OF REFERENCE
4. CERTIFIED COMPLIANCE REPORT
5. ANNEXURES

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

NACL Industries Limited TEAM Labs and Consultants
Plot No 12-A, C Block, Lakshmi Towers, B-115-117 & 509, Annapurna Block,
Nagarjuna Hills, Punjagutta Aditya Enclave, Ameerpet,
Hyderabad – 500 082 Hyderabad-500 038.
Phone: +91 9989433866 Phone: 040-23748 555/23748616,
E-mail ID: [email protected] Telefax: 040-23748666

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

1. ENVIRONMENTAL IMPACT ASSESSMENT REPORT

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
Contents

CONTENTS
Section Description Page
No.
1.0 Introduction of the Project 1-1
1.1 Product Profile 1-3
1.2 Technology 1-6
1.3 Plant Location & Layout 1-6
1.31 Purpose of the Report 1-7
1.4 Plant Layout 1-7
1.5 Scope of EIA Studies 1-12

2.0 Introduction 2-1

2.1 Need of the Project 2-5
2.1.1 Plant Layout 2-6
2.1.2 Process Description 2-9
2.2 Utilities 2-9
2.3 Water Requirement 2-10
2.4 Pollution Control Facilities 2-11
2.4.1 Water Pollution 2-11
2.4.1.1 Process Description and Technical Specification of ETP 2-13
2.4.2 Air Pollution 2-22
2.4.2.1 Emissions from Utilities 2-22
2.4.2.2 Emissions from Process 2-25
2.4.2.3 Diffuse Emissions 2-27
2.4.2.4 Fugitive Emissions 2-28
2.4.2.5 Odour Management 2-28
2.4.3 Solvent Use and Recycle 2-29
2.4.4 Solid Waste 2-33
2.4.5 Noise Pollution 2-37

3.0 Description of the Environment 3-1

3.1 Introduction 3-1
3.2 Land environment 3-1
3.2.1 Physiography 3-1
3.2.2 Geology 3-4
3.2.3 Hydrogeology 3-6
3.2.4 Soils 3-8
3.3 Water environment 3-13
3.3.1 Surface water resources 3-13
3.3.1.1 Surface water quality 3-13
3.3.1.2 Ground water resources 3-16
3.3.1.3 Quality of ground water 3-16
3.4 Air environment 3-19
3.4.1 Meteorology 3-19
Contents

4.0 Anticipated Environmental Impacts& Mitigation Measures 4-1

4.1 Identification of Impacts 4-1
4.1.1 Impact Networks 4-4
4.2 Prediction and Assessment of Impacts 4-14
4.2.1 Methodology of Rapid Impact Assessment Matrix 4-14
4.2.2 Air Environment 4-18
4.2.2.1 Air Quality Impact Predictions 4-22
4.2.2.2 Utility Emissions 4-24
4.2.2.3 Air Quality Modeling Results 4-25
4.2.2.4 Process Emissions 4-34
4.2.2.4.1 Prediction of Concentration of Solvents in the Indoor Environment Due 4-35
to Solvent Loss and Fugitive Emissions
4.2.3 Water Environment 4-37
4.2.3.1 Rainwater Harvesting 4-46
4.2.4 Noise Environment 4-47
4.2.4.1 Prediction of Impact on Noise Quality 4-50
4.2.5 Land Environment 4-52
4.2.6 Biological Environment 4-57
4.2.7 Socio-economic Environment 4-63
4.2.7.1 Corporate Environment Responsibility 4-68
4.2.8 Prediction of Impact on Vehicular Traffic 4-69
4.3 Limitation and Uncertainty 4-70

5.0 Analysis of Alternatives 5-1

5.1 Alternative Sites 5-1
5.2 Alternative in Process 5-1
5.2.1 Alternatives in Technology 5-2
5.2.2 Alternatives in treatment/mitigation options 5-2
Contents

6.0 Environmental Monitoring Program 6-1

6.1.1 Introduction 6-1
6.1.2 Objectives 6-2
6.1.3 Methodology 6-2
6.1.4 Ambient Air Quality (AAQ) Monitoring 6-3
6.1.5 Water Quality Monitoring 6-5
6.1.6 Noise Level Monitoring 6-8
6.1.7 Responsibility of Monitoring And Reporting System 6-9
6.1.7.1 Work Zone Monitoring for Hazardous Chemicals 6-10
6.2 Environmental Monitoring Budget 6-11

7.0 Additional Studies 7-1

7.0 Introduction 7-1
7.1 Objectives and Scope 7-1
7.2 Project Details 7-2
7.3 Process Description 7-5
7.4 Plant Facilities 7-5
7.4.1 Production Area 7-6
7.4.2 Utilities 7-6
7.4.3 Quality Control, R&D Lab 7-7
7.4.4 ETP and Solid waste storage 7-7
7.4.5 Ware Houses 7-7
7.4.6 Tank Farm Area 7-8
7.4.7 Administrative Office 7-8
7.4.8 Cylinders storage Area 7-8
7.4.9 House Keeping 7-8
7.4.10 Coal and Ash Storage 7-9
7.4.11 Facility layout and design 7-9
7.5 Hazard Analysis and Risk Assessment 7-13
7.5.1 Introduction 7-13
7.5.2 Hazard Identification 7-13
7.5.2.1 Hazards in Unit Operations 7-14
7.5.3 Fire & Explosion Index (F & EI) 7-20
7.5.3.1 Methodology 7-20
7.5.4 Hazard and Operability Study (HAZOP) 7-22
7.5.5 Hazard Factors 7-23
7.5.6 Common Causes of Accidents 7-24
7.6 Maximum Credible Accident and Consequence Analysis (MCACA) 7-25
7.6.1 Methodology 7-26
7.6.2 Identification of Vulnerable Areas 7-26
7.6.3 Representative Accident Scenarios 7-27
7.7 Consequence Analysis 7-28
7.7.1 Release Models and Source strength 7-29
7.7.2 Results of Consequence Analysis 7-31
Contents

7.7.2.1 Analysis of Hazardous Scenarios 7-31

7.7.2.1.1 Heat radiation effects 7-31
7.7.2.1.2 Toxic Dispersion Damage Distances 7-33
7.7.2.1.3 Overpressure effects 7-33
7.7.3 Observations 7-33
7.7.4 Recommendations 7-34
7.7.5 Toxic Management Plan 7-35
7.7.5.1 Tanker Loading and Unloading 7-36
7.7.6 Transportation 7-38
7.8 Disaster Management Plan 7-44
7.8.1 Introduction 7-44
7.8.2 Objectives of Emergency Management Plan (ON-SITE) 7-45
7.8.3 Scope of ONSEP 7-46
7.8.4 Methodology of Developing ONSEP 7-46
7.8.5 Elements of Onsite Emergency Plan 7-46
7.8.5.1 Emergencies Identified 7-47
7.8.5.2 Emergency Organization 7-47
7.8.5.3 Emergency Facilities 7-49
7.8.5.4 Emergency Procedures 7-52
7.8.5.5 Rescue and Rehabilitation 7-54
7.8.5.6 Emergency Responsibilities 7-55
7.8.6 Remedial Action 7-60
7.8.7 Basic Action in Emergencies 7-60
7.8.8 Fire Fighting Operations 7-61
7.8.9 Details of Transport Facilities in emergency 7-61
7.8.10 List of Personnel Trained In First Aid 7-62

8.0 Project Benefits 8-1

8.1 Introduction 8-1
8.2 Employment Potential 8-1
8.3 Corporate Environment Responsibility 8-1
8.3.1 Proposed Corporate Environmental Responsibility (CER) Activities 8-2
8.4 Tax Income 8-2

9.0 Environment Cost Benefit Analysis 9-1

10.0 Environment Management Plan 10-1

10.0 Introduction 10-1
10.1 Safety, Health, and Environment Division 10-1
10.2 Project Implementation Schedule 10-3
10.3 Environmental Policy 10-4
10.4 Mitigation Measures and Responsibility 10-5
10.4.1 Operation Phase 10-6
Contents

10.5 CREP Guideline and Compliance 10-10

10.6 Other Management Practices 10-10
10.7 Cost Estimate for Environment Management Plan 10-11

11.0 Summary& Conclusion 11-1

11.0 Introduction 11-1
11.1 Location of the Project 11-1
11.2 Product Profile 11-2
11.3 Manufacturing Process 11-4
11.4 Utilities 11-4
11.5 Water Requirement 11-5
11.6 Baseline Environmental Data 11-6
11.7 Identification and Quantification of Impacts 11-6
11.7.1 Impacts on Air quality 11-6
11.7.2 Impacts on Water 11-6
11.7.3 Impacts on Noise quality 11-7
11.7.4 Impacts on Soil 11-7
11.7.5 Impacts on Flora and Fauna 11-7
11.8 Environmental Monitoring Programme 11-7
11.9 Alternatives 11-7
11.10 Additional Studies - Risk Assessment 11-8
11.11 Project Benefits 11-8
11.12 Environment Management Plan 11-8
11.12.1 Liquid Effluents 11-8
11.12.2 Air Pollution 11-9
11.12.3 Solvent Use and Recycle 11-10
11.12.4 Solid Waste 11-10
11.12.5 Noise Pollution 11-10
11.12.6 Occupational Safety and Health 11-11
11.12.7 Prevention, maintenance and operation of Environment Control Systems 11-11
11.12.8 Transport systems 11-11
11.12.9 Reduce, Recycle and Reuse 11-12
11.12.10 Green Belt Development 11-12
11.13 Corporate Environment Responsibility 11-12
11.14 Environment Management Department 11-12

12.0 Disclosure of Consultants Engaged 12-1

Contents

List of Tables
Section Description Page No.

1.1 Manufacturing Capacity- Existing/Permitted 1-3

1.2 Manufacturing Capacity- After Expansion 1-4
1.3 List of By-products- After Expansion 1-6
1.4 Land Use Break-up of Site 1-7
1.5 Geo-coordinates of the project site area 1-8
1.6 Required Approvals and Applicable statutes 1-13

2.1 Manufacturing Capacity- Permitted 2-1

2.2 Manufacturing Capacity- After Expansion 2-3
2.3 List of By Products 2-5
2.4 List of Utilities 2-9
2.5 Total Water Balance – After Expansion 2-10
2.6 Total Effluent Generated and Mode of Treatment 2-12
2.7 Quantity and Quality of Process Effluents – Product Wise (API’s) 2-12
2.8 Details of Treatment Facilities 2-15
2.9 Technical Specifications of Effluent Treatment Plant 2-17
2.10 Emission Details of Pollutants from Stack 2-22
2.11 Effective Stack Height Calculation based on CPCB Formula 2-23
2.12 Technical Specifications of ESP – 50 TPH Boiler 2-23
2.13 Quantity and Mode of Treatment of Process Emissions 2-26
2.14 Technical Specifications of Two Stage Scrubber 2-26
2.15 Total Solvent Balance – Product Wise 2-30
2.16 Solid Waste Generated from Process – Product Wise after expansion 2-34
2.17 Total Solid Waste Generated and Mode of Disposal 2-36

3.1 Salient features of the project 3-1

3.2 The Succession of Geological Formations 3-4
3.3 Soil analysis data 3-11
3.4 Soil Test Results – Reference Tables 3-12
3.5 Water analysis data –surface water 3-13
3.6 Locations of Ground water Sampling 3-16
3.7 Water analysis data – Ground water 3-18
3.8 Meteorological data at IMD Station 3-20
3.9 Frequency Distribution of Wind Speeds and Wind Directions 3-23
3.10 Locations of ambient air quality monitoring stations 3-26
3.11 Summary ambient air quality status 3-28
3.12 Air Quality Index of AAQ Data 3-30
3.13 Effects on Human Beings at Different Noise Levels 3-32
3.14 Equivalent Noise levels in the study area 3-32
3.15 Population Distribution – Study Area 3-34
Contents

3.16 Literacy Study Area 3-35

3.17 Employment - Study Area 3-36
3.18 Main workers Study Area 3-37
3.19 Land Utilization Pattern 3-40
3.20 List of Floral Species 3-49
3.21 Threatened and Endangered Animal Species 3-64

4.1 Activity and Environmental Impact (Impact Identification Matrix) - 4-10

Construction Stage
4.2 Activity and Environmental Impact (Impact Identification Matrix) - Regular 4-11
Operation Stage
4.3 Activity and Environmental Impact (Impact Identification Matrix) - Incidents 4-12
and Accidents
4.4 Activity and Environmental Impact (Impact Identification Matrix) – 4-13
Decommissioning
4.5 Impacts on Air Environment 4-19
4.6 Impact Significance - Air Environment 4-21
4.7 Salient Features of the ISCST3 Model 4-23
4.8 Emission Details of Pollutants from Stack 4-25
4.9 Predicted GLC’s at Monitoring Locations 4-26
4.10 Cumulative Concentrations at Various Villages 4-26
4.11 Mitigation Measures for Utility Emissions - Construction and Operation 4-32
4.12 Technical Specifications of Electro Static Precipitators – Coal fired Boilers 4-32
4.13 Mitigation Measures for Process Emissions 4-34
4.14 Technical Specifications of Two Stage Scrubbing System 4-34
4.15 Solvent Loss and the Predicted Airborne Concentrations 4-36
4.16 Mitigation Measures for Diffuse and Fugitive Emissions 4-36
4.17 Impacts on Surface Water 4-39
4.18 Impacts on Ground Water 4-40
4.19 Impacts Significance - Surface Water 4-41
4.20 Impacts Significance - Ground Water 4-41
4.21 Mitigation Measures for Water Environment 4-42
4.22 Technical Specifications of Effluent Treatment System 4-42
4.23 Technical Specifications of Biological Treatment Plant 4-43
4.24 Impacts on Noise Level 4-48
4.25 Impact Significance – Noise Level 4-49
4.26 Sources of Noise Generation (Tentative) 4-51
4.27 Noise Levels Mitigation Measures - Construction and Operation stages 4-51
4.28 Impacts on Land Environment 4-54
4.29 Impact Significance – Land environment 4-56
4.30 Impacts and Mitigation Measures – Land Environment 4-57
4.31 Action Plan for Proposed Enhancement of Greenbelt 4-59
4.32 Impacts on Flora 4-60
Contents

4.33 Impacts on Fauna 4-61

4.34 Impact Significance – Flora 4-62
4.35 Impact Significance – Fauna 4-62
4.36 Impacts and Mitigation Measures - Biological Environment 4-63
4.37 Impacts on Socio Economic 4-65
4.39 Impact Significance – Socio Economic 4-67
4.39 Impacts and Mitigation Measures – Scio-Economic Environment 4-68
4.40 Activity Wise CER – Tentative Budget (2022-23 to 2026-27) 4-69
4.41 Modified level of services for connecting roads 4-70

6.1 National Ambient Air Quality Standards 6-3

6.2 Indian Standard Drinking Water Specifications – IS: 10500:1991 6-5
6.3 Noise level standards 6-8
6.4 Environmental Monitoring Plan 6-9
6.5 Environmental Monitoring Budget 6-11

7.1 Proposed Manufacturing Capacity-After Expansion 7-3

7.2 List of By-products- After Expansion 7-4
7.3 List of Raw Materials and Inventory 7-5
7.4 List of Utilities 7-7
7.5 Control Measures 7-11
7.6 Hazards associated with Unit Operations 7-14
7.7 Hazard Associated and Mitigative/ Control Measures with Manufacturing 7-16
Activity
7.8 Applicability of GOI Rules to Storage/Pipeline 7-18
7.9 Physical Properties of Raw Materials and Solvents 7-19
7.10 Degree of Hazard for F&EI 7-21
7.11 Fire & Explosion Index for Tank farm 7-21
7.12 Failure Rate Data 7-25
7.13 Ignition Sources of Major Fires 7-25
7.14 Details of Solvent Tank Form 7-27
7.15 General Failure Frequencies 7-28
7.16 Damage due to Incident Radiation Intensities 7-30
7.17 Radiation Exposure and Lethality 7-30
7.18 Damage Due to Peak over Pressure 7-31
7.19 Heat Radiation Damage Distance – Tank Farm (Pool Fire) 7-32
7.20 Heat Radiation Damage Distance – Hydrogen Cylinders 7-32
7.21 Toxic Dispersion Damage Distances 7-33
7.22 Frequency of Health Monitoring 7-38
7.23 Truck Incidents – Initiating and Contributing Causes 7-39
7.24 Transportation Specific Concerns 7-39
7.25 Action Plan and Responsibility 7-40
7.26 List of Fire Extinguishers 7-51

10.1 Implementation and Monitoring of Mitigation Measures –Construction Stage 10-6

Contents

10.2 Impacts and Mitigation – Operational Stage 10-7

10.3 Environmental Management Cost estimate 10-11
10.4 Item Wise Tentative Capital Cost Estimate for Environment Management 10-11

11.1 Manufacturing Capacity-After Expansion 11-2

11.2 List of By-products- After Expansion 11-4
11.3 List of Utilities 11-5
11.4 Water Balance 11-5
11.5 Total Effluent Generated and Mode of Treatment 11-9
Contents

List of Figures
Section Description Page No.

1.1 Location of NACL Industries Limited 1-9

1.2 Plant Layout of NACL Industries Limited 1-10

2.1 Plant Location of NACL Industries Ltd 2-7

2.2 Plant Layout of NACL Industries Ltd. 2-8
2.3 Water Balance Flow Diagram 2-11
2.4 Schematic Diagram of Effluent Treatment System 2-16

3.1 Site and Plant Photographs – NACL Industries Limited 3-2

3.2 Base map of the study area 3-3
3.3 Geomorphology map of the study area 3-5
3.4 Hydro geological Map of the study area 3-7
3.5 Land Use and Land Cover of the study area 3-9
3.6 Soil Sampling Locations 3-10
3.7 Drainage pattern of the study area 3-15
3.8 Water sampling locations (Ground water) 3-17
3.9 Wind rose diagram at site 3-24
3.10 Ambient air quality monitoring locations 3-27
3.11 Graphs showing the results of ambient air quality 3-29
3.12 Noise Sampling Locations 3-31
3.13 Peak Hour Traffic 3-33
3.14 Population distribution of the Study Area 3-35
3.15 Literacy of Study Area 3-36
3.16 Employment - Study Area 3-38

4.1 Conceptual Model of Agrochemicals 4-2

4.2 Conceptual Model of Impacts Effects due to Manufacturing Activity 4-3
4.3 Impacts on Air Environment 4-5
4.4 Impacts on Water Environment 4-6
4.5 Impacts on Solid waste and Soil Quality 4-7
4.6 Noise impact on Surrounding Environment 4-8
4.7 Impacts on Socio-Economic on Environment 4-9
4.8 Isopleths Showing 24 Hourly GLC’s of PM 4-27
4.9 Isopleths Showing 24 Hourly GLC’s of PM10 4-28
4.10 Isopleths Showing 24 Hourly GLC’s of PM2.5 4-29
4.11 Isopleths Showing 24 Hourly GLC’s of SO2 4-30
4.12 Isopleth showing 24 Hourly GLC’s of NOx 4-31
4.13 Photographs of Existing Greenbelt– NACL Industries Limited. 4-59

7.1 Plant Layout of NACL Industries Limited 7-10

7.2 Steps in Consequence Calculations 7-29
Contents

7.3 Emergency Organization (ON SITE) Chart 7-48

10.1 Organogram Safety, Health, and Environment Division 10-2

10.2 Reporting Mechanism for Non- Compliance 10-5
M/s. NACL Industries Ltd
Environmental Impact Assessment Report

1.0 INTRODUCTION

1.0 Introduction of the Project (Terms of Reference No. 2(ii))

NACL Industries Limited. (formerly known as Nagarjuna Agrichem Ltd) was
established in 1994 and has grown into a well-integrated agrochemicals company with
multiple manufacturing facilities. The product range comprises Insecticides (for
controlling attack of insects on crop), Herbicides (for controlling weed infestation in
crop husbandry) and Fungicides (to protect cropfrom disease-causing fungus) and
other minor chemicals like plant growth regulators, etc. The demand and supply of
agrochemicals in the current global context is marked by the increased demand for
agrochemicals and restricted supply of the same. As the population increases there is
increased need for, improved yields of the crop-by-crop protection measures to ensure
food security sustainably. Toxic and water-soluble agrochemicals are being replaced
with less toxic and water insoluble agrochemicals across the world to enhance yields
protecting crops from pests, fungal diseases and weeds with minimum impact on soil
and water environments. Demand for such agrochemicals is increasing across the
world as well as in our country. The increasing demand for food in the developing
countries also pushes the demand for agrochemicals.

M/s. NACL Industries Limited (formerly known as Nagarjuna Agrichem Ltd) obtained
environment clearance vide letter no. F.No. J-11011/75/2007-IA II (I) dated 30.07.2007
to manufacture agrochemicals. The unit had renewed consent for operation vide order
No. APPCB/VSP/VZN/53/CFO/HO/2021 dated 12.03.2021 valid till 28.02.2025. It is
proposed to increase the manufacturing capacity of agrochemicals from 30 TPD to 70.1
TPD and also include Captive Co-generation Power Plant of 6 MW in existing site area
of 100 acres. The capital cost for proposed expansion is Rs. 65 crores, towards
additional facilities utilities and enhancement of zero liquid discharge facility.

M/s. NACL Industries Limited. is conscious of its responsibility towards the society in
minimizing the pollution load due to the proposed expansion and accordingly decided
to carry out the Environmental Impact Assessment to identify the negative and positive
impacts due to the project, and to delineate effective measures to control and mitigate

1-1 Team Labs and consultants

M/s. NACL Industries Ltd
Environmental Impact Assessment Report

the environmental pollution. M/s. NACL Industries Limited. has appointed Team
Labs and Consultants for the preparation of Environmental Impact Assessment report.

This report adopted the definition of Impact assessment given by international

association of impact assessment as the “Process of identifying the future consequences
of a current or proposed action.” The “Impact” is the difference between what would
happen with action and what would happen without (Ref: IAIA 2009). Accordingly,
baseline data collection was initiated to establish the current environmental scenario, by
collecting primary and secondary data, immediately after the receipt of work order.
Reconnaissance survey of the region was carried out during September 2020, and
various sampling locations to monitor environmental parameters have been identified.
Subsequently, monitoring has commenced for collection of data on meteorology,
ambient air quality, surface and ground water quality, soil characteristics, noise levels,
flora and fauna at the specified locations during October to December 2020. The other
studies such as socio-economic profile, land use pattern etc. are based on secondary
data collected from various Government agencies and validated through primary
surveys. The ambient air monitoring locations have been selected based on the initial
air dispersion modeling carried out by using the meteorological data generated at India
Meteorological Department (IMD).

Field team of M/s. Team Labs and Consultants worked in the study area during
October to December 2020 and base line data for various environmental components
i.e., air, water, soil, noise and flora and fauna and socio economic status of people was
collected in a circular area of 10 km radius by taking the industry site as the center
point, to assess the existing environmental status as per the guidelines specified by
Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India.
This report presents the results of environmental impact assessment study along with
the environmental management plan, necessary to avoid or mitigate the observed
environmental impacts due to the proposed synthetic organic chemicals manufacturing
unit.

1-2 Team Labs and consultants

M/s. NACL Industries Ltd
Environmental Impact Assessment Report

1.1 Product Profile (Terms of Reference No. 3(ii)

The manufacturing capacity of permitted and proposed products after expansion is
presented in Table 1.1 and 1.2 and the list of by-products is presented in Table 1.3.
Table 1.1 Manufacturing Capacity – Existing / Permitted
S. Name of Product Capacity (TPD)
No Group Group Group Group Group Group Group Group
1 2 3 4 5 6 7 8
1 Profenofos 9.5 6 5.5 7.5 9 5 15.5 15
2 Propiconazole 2 3.5 3 1 1 0.5
Bromoketal
Intermediate)
3 Tricyclazole 1 2.5 2 1 1 0.5
4 Myclobutanil 0.3 0.3 0.3 0.3 0.3 0.1
5 Pretilachlor 4.3 4.7 6.5 4 6 5
6 Thifluzamide 0.5 0.1 0.5 0.4 0.5 0.6 0.5 0.65
7 Flucarbazone Sodium 0.55 0.2 0.185 0.7 0.4 0.6
8 Tebuconazole/ 0.25 0.2 0.1 0.2 0.75
Oxirane
(Intermediate)
9 Hexaconazole 0.1 0.2 0.1 0.1
10 Difenthiuron 0.1 0.2 0.1 0.1
11 Imidacloprid 0.1 0.1 0.1 0.1 0.1
12 Epoxiconazole 0.1 0.5 0.1 0.1 0.1
13 Cyproconazole 0.5 0.1 0.1 0.1 0.1
14 Omethoate 0.5 0.7 0.6 0.7 0.8 0.4
15 Metribuzin 0.3 0.5 0.5 0.5 0.1 0.2
16 Pendimethalin 0.1 0.1 1 0.1 0.1
17 Clodinafop 0.2 0.2
18 Difenoconazole 0.2 0.05 0.1 0.1 0.1
19 Quizalafop P Ethyl 0.1 0.1 0.3 0.5 1.25
20 Thiamethoxam 0.2 0.1 0.3 1.5 0.2
21 Bispyribac Sodium 0.1 0.095 0.2 0.1
22 Tefluthrin 0.45 0.1 0.2
23 Cloquintocet Mexyl 0.1 0.1
24 2,3 Dichloro Pyrydine 0.15 0.06 0.06 0.4 0.5 0.3
25 Cypermertharin 0.35 0.15 0.1 0.1
26 Carbendazim 0.08 0.35 0.1
27 Trifloxystrobil 0.15 0.15
28 Azoxystrobin 0.1 1 0.15 0.2 0.1
29 Bifenthrin 0.05 0.08 0.15 0.15 0.1
30 Thiophanate Methyl 0.05 0.05 0.05 0.05 1.75
31 Verbenone 0.05 0.15 0.15 0.15
32 (Z)-hezatec –11-en-1- 0.05 0.15 0.15 0.1 0.15
yl acetate
33 (Z)-hezatec – 9-enal 0.05 0.15 0.09 0.15 0.15
34 Trimedlure 0.05 0.15 0.09 0.1 0.1 0.1

1-3 Team Labs and consultants

M/s. NACL Industries Ltd
Environmental Impact Assessment Report

35 (8E,10E) –Dodoca-8, 0.05 0.15 0.1 0.1 0.15

10- dyen-1-ol
36 7Z,11Z hexadeca 0.05 0.15 0.09 0.1 0.1 0.15
dienyl acetate
37 7E, 9Z dodoca dienyl 0.05 0.1 0.09 0.1 0.1 0.15
acetate
38 8Z Dodecinyl acetate 0.05 0.1 0.15 0.1 0.1 0.1
39 (Z)-Octadeca –13 – 0.05 0.1 0.09 0.1 0.1 0.15
enyl acetate
40 R & D products 0.05 0.05 0.05 0.05 0.05 0.05 0.05
41 Triazinone / 10 7.84 7 8.9 6 9.4 7 9.5
Thricarbo hydrazide
/ Dichloro
Pinacolene /
Pinacolene
42 Lambda- cyhalothrin 1.5 0.55
43 Fipronil 0.5 0.5
44 Ethephon 1
45 Glufosinate- 1 1
ammonium
46 Clethodim 1
47 S-Metolachlor 1 1
48 Tribenuron methyl 1 1
Total 29.65 30 29.95 30 30 29.15 30 30
Note: Any one combination will be manufactured at given time

Table 1.2 Manufacturing Capacity – After Expansion

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19 Tricyclazole 41814-78-2 2.5

20 Fenbuconazole 114369-43-6 1.0
21 Myclobutanil 88671-89-0 1.0
22 Thifluzomide 130000-40-7 0.8
23 Hexaconazole 79983-71-4 1.0
24 Tebuconazole / Oxirane (Intermediate) 107534-96-3 1.0
25 Difenconazole 119446-68-3 0.5
26 Epoxiconazole 135319-73-2 0.5
27 Cyproconazole 94361-06-5 0.5
28 Thiophanate-methyl 23564-05-8 1.0
29 Azoxystrobin 131860-33-8 1.0
30 Trifloxystrobin 141517-21-7 1.0
31 Pendimethalin 40487-42-1 1.5
32 Pretilachlor 51218-49-6 4.0
33 Metribuzin 21087-64-9 1.6
34 Dimethomorph 110488-70-5 2.0
35 Clodinofop-Propargyl 105512-06-9 1.0
36 Bispyribec Sodium 125401-92-5 1.0
37 Bensulfuron Methyl 83055-99-6 1.0
38 Glufosinate Ammonium 77182-82-2 1.0
39 Quizalofop-p-ethyl 100646-51-3 1.0
40 Tribenuron Methyl 101200-48-0 0.5
41 Clethodim 99129-21-2 1.0
42 Pinoxsulam 219714-96-2 1.0
43 S-Metolachlor 87392-12-9 1.0
44 Verbinone 1196-01-6 0.2
45 (Z)-hezatec – 11-en-1-yl acetate 34010-21-4 0.2
46 (Z)-hezatec – 9-enal 56219-04-6 0.2
47 (8E,10E) – Dodoca-8, 10-dyen-1-ol 76600-88-9 0.2
48 7Z,11Z hexadeca dienyl acetate 53042-81-2 0.2
49 7E, 9Z dodoca dienyl acetate 54364-62-4 0.2
50 8Z Dodecinyl acetate 28079-04-1 0.2
51 (Z)-Octadeca – 13 – enyl acetate 60037-58-3 0.2
52 R&D Products 0.1
Total 70.1
II Bio Based Agro Chemicals
1 Pseudomonas Fluorosense+ Bacillus Subitilis 0.17
2 Trichoderma Harzianum+Verticillium 0.17
chlamydosporium
3 Ampelomyces quisqualis+BeauveriaBassiana 0.17
4 Beauveria bassiana+ Metarhizium anisopliae 0.17
5 Beauveria bassiana 0.17
6 Metarhizium anisopliae 0.17
7 Verticillium lecanii+Beauveria Bassiana 0.17
8 Hirsutella thompsonii+Beauveria Bassiana 0.17
9 Hirsutella thompsonii 0.17
Total 1.53
Captice Co-generation power plant 6 MW

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Agrochemicals Formulations
S.No Name of Product Unit Capacity
1 Granules MT/year 20000
2 Liquids Kl/Year 25000
3 Powders MT/year 5000
Total 50000 50000

Table 1.3 List of By-products – After Expansion

S.No Name of the Product By-Product Quantity
(Kg/day)
1 Triazinone Hydrochloric Acid (30%) 2470
NASH solution 1300
2 Myclobutanil Sodium Bromide 1070
3 Difenoconazole Potassium Chloride 183.5
Potassium Bicarbonate 246.4
4 Tribenuron-methyl Technical Ethanol 116.5
5 Dil. HCl (25%) from Scrubbers 5228.5
6 HBr (25%) from Scrubbers 1359.7

1.2 Technology
The technology for the product profile is indigenous based on organic chemistry. The
facility shall have required infrastructure to manufacture multiple products. The
product profile has been finalized based on the market demand and the technology
compatibility. The synthesis involves reaction of chemicals in a solvent medium,
followed by separation, purification and drying.

1.3 Plant Location and Layout

The plant site of 100 acres is located at Sy. No. 177, Arinama Akkivalasa village,
Etcherla mandal, Srikakulam district, Andhra Pradesh. The site is located at the
intersection of 180 16’31” (N) latitude and 830 47’33” (E) longitude. The plant site is
surrounded by open agricultural lands in east, west and south directions, chilakapalem
road connecting to Akkivalasa village in north direction. The main approach road is
NH-5 is at a distance of 0.53 km in south direction. The nearest habitation from the site
is Kesavadasupeta located at distance of 0.3 km in northwest direction. The nearest
town is Srikakulam at a distance of 10.6 km in NE direction. The nearest railway
station is Ponduru at a distance of 10.5 km in north direction and nearest airport is
Visakhapatnam located at a distance of 85 km in southwest direction. Pedda gedda a
seasonal stream is at a distance of 4.2 km in SW direction. Chitti gedda a seasonal

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stream is at a distance of 4.7 km in SW direction. There are no reserve forests, national

Parks, sanctuary, biosphere reserves, ecologically sensitive area, critically polluted area
and interstate boundary within the impact area of 10 km surrounding the site.

1.3.1 Purpose of the Report

Prior environmental clearance is mandated by Ministry of Environment, Forest and

Climate Change (MoEFCC), vide SO 1533, dated September 14, 2006, for establishment
or expansion of technical grade pesticides manufacturing units. The terms of reference
for the environmental impact assessment studies were obtained from MoEF&CC vide
letter no. F.No. J-11011/75/2007-IA II (I) dated 24.06.2020 as part of environmental
clearance process.

1.4 Plant Layout

The proposed expansion is within the existing site area of 100 acres. Location of unit is
presented in Fig 1.1 and layout is presented in Fig 2.2. The land use details of the plant
site based on the layout is presented in Table 1.4. The Geo coordinates of the project
site area are presented in Table 1.5.
Table 1.4 Land Use Break-up of Site
Description Area (Acres) %
Built-up area (Production, Utility Blocks) 25.66 25.66%
Green belt area 34 34%
Roads area 5.2 5.2%
Parking 1.6 1.6%
Open area 21.64 21.64%
Tank Farm Area 8.9 8.9%
ZLD Area 3 3%
Total 100 100%

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Table 1.5 Geo-coordinates of the project site area

S.No Latitude Longitude S.No Latitude Longitude
1 18°16'31.13"N 83°47'34.47"E 22 18°16'10.74"N 83°47'18.79"E
2 18°16'32.08"N 83°47'35.75"E 23 18°16'11.03"N 83°47'17.82"E
3 18°16'32.99"N 83°47'37.90"E 24 18°16'11.20"N 83°47'17.60"E
4 18°16'33.61"N 83°47'38.59"E 25 18°16'11.10"N 83°47'17.08"E
5 18°16'33.90"N 83°47'39.22"E 26 18°16'11.15"N 83°47'16.71"E
6 18°16'32.33"N 83°47'38.99"E 27 18°16'10.36"N 83°47'15.93"E
7 18°16'32.82"N 83°47'40.29"E 28 18°16'8.98"N 83°47'15.36"E
8 18°16'30.83"N 83°47'42.98"E 29 18°16'9.33"N 83°47'14.40"E
9 18°16'27.90"N 83°47'45.91"E 30 18°16'12.05"N 83°47'15.26"E
10 18°16'24.88"N 83°47'43.94"E 31 18°16'12.97"N 83°47'16.23"E
11 18°16'18.04"N 83°47'44.26"E 32 18°16'15.07"N 83°47'17.65"E
12 18°16'14.24"N 83°47'43.96"E 33 18°16'15.66"N 83°47'13.34"E
13 18°16'11.39"N 83°47'43.04"E 34 18°16'18.01"N 83°47'13.68"E
14 18°16'11.84"N 83°47'39.95"E 35 18°16'17.59"N 83°47'17.13"E
15 18°16'12.02"N 83°47'36.43"E 36 18°16'25.64"N 83°47'19.42"E
16 18°16'11.76"N 83°47'32.97"E 37 18°16'25.89"N 83°47'18.32"E
17 18°16'9.89"N 83°47'27.82"E 38 18°16'28.23"N 83°47'18.36"E
18 18°16'9.84"N 83°47'24.35"E 39 18°16'29.74"N 83°47'26.41"E
19 18°16'8.72"N 83°47'20.78"E 40 18°16'29.87"N 83°47'30.19"E
20 18°16'9.38"N 83°47'19.77"E 41 18°16'31.41"N 83°47'33.90"E
21 18°16'9.66"N 83°47'18.71"E 42 18°16'31.06"N 83°47'34.14"E

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Fig 1.1 Location of NACL Industries Limited (Terms of Reference No. 4(ii))

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Fig 1.2 Plant Layout of NACL Industries Limited (Terms of Reference No. 4(vi) & (viii)

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Site Photographs of NACL Industries Ltd.

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1.5 Scope of EIA Studies

EIA study involves three basic components, viz. identification, prediction and
evaluation of impacts. The brief scope of EIA study incorporating the Standard terms of
reference (TOR) obtained from MoEFCC is as follows:

• An intensive reconnaissance and preliminary collection of environmental

information to plan field study.

• Field studies to collect preliminary information, particularly on the quality of the

physical environment. Experienced scientists and engineers will collect the data.

• Base line data generation and characterization of air, water, soil, noise and
vegetation in the ten kilometer radius area (impact zone) over a period of Three
months.

• A thorough study of the process including provisions for pollution control, and
environmental management that includes prediction of impacts and relevant
mathematical modeling.

• Preparation of Environmental Management Plan suggesting suitable methods for

mitigating and controlling the pollution levels in EMP by adoptive management
considering uncertainty, a mitigating and ignorance in impact assessment
prediction. Environmental Monitoring Plan is suggested for monitoring the
pollution loads at various facilities in the premises and to ensure compliance
with the statutory requirements.

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Table 1.6 Required Approvals and Applicable statutes

Legal Instrument Responsible Ministries Applicability Remarks
(Type, Reference, or Bodies
Year)
Environment Central government Yes Prior environmental
(Protection) Act, 1986 nodal agency, MoEFCC clearance vide So 1533
and amendments can delegate to state dt. 14.9.2006 and its
departments of amendments till date
environment has to be obtained.
The project is
categorized as A
Water (Prevention Central Pollution Control Yes Consent to establish
and Control of Board (CPCB), and and to operate need to
Pollution) Act, 1974 Andhra Pradesh Pollution be obtained
and amendments Control Board (APPCB).
Air (Prevention and Yes Consent to establish
Control of Pollution) and to operate need to
Act, 1981 and be obtained
amendments
Noise Pollution Yes Prescribed noise
(Regulation & standards to be
Control) Rule 2000 adopted and followed
and amendments
Forest Government of Andhra No The project site does
(Conservation) Act, Pradesh (GoAP) and not consist of any
1980 and Government of India forest land area.
amendments (GoI)
Wildlife (Protection) National Board of No No sanctuary, or
Act, 1972 and Wildlife (NBWL). national park located
amendments within 10 km radius
Ancient Monuments Archaeological Survey of No No archaeological
and Archaeological India monument within 10
Sites & Remains Act, km of the project site
1958 and amendment area boundary.
Hazardous Wastes Central and State Yes Authorization for
(Management and Pollution Control Board hazardous waste
Handling) Rules, (CPCB/SPCB) storage, transport,
1989 and and disposal has to be
amendments obtained.
Right to Fair Central / State No No displacement of
Compensation and Government People and no
Transparency in acquisition of land.
Land Acquisition,
Rehabilitation and
Resettlement Act,
2013 and
amendments
Andhra Pradesh Govt of Andhra Pradesh No The project site does
Panchayat Extension not fall under notified

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Legal Instrument Responsible Ministries Applicability Remarks

(Type, Reference, or Bodies
Year)
to Scheduled Areas scheduled area.
Rules, 2011
Water, Land and Govt of Andhra Pradesh No The expansion is
Trees Act, 2002, within existing site
GoAP (WALTA, act area.
2002)
The Motor Vehicles State Transport Authority Yes Pollution under
Act, 1988 control certification
for all vehicles plying
in and out of the
project.
The Public Liability Insurance Company Yes To provide for public
Insurance Act 1991 liability insurance for
the purpose of
providing immediate
relief to he persons
affected by accident
occurring while
handling any
hazardus substance
and for matters
connected therewith
or incidental thereto.

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2.0 PROJECT DESCRIPTION

2.0 Introduction
M/s. NACL Industries Limited (formerly known as Nagarjuna Agrichem Ltd) obtained
environment clearance vide letter no. F.No. J-11011/75/2007-IA II (I) dated 30.07.2007
to manufacture agrochemicals. The unit had renewed consent for operation vide order
No. APPCB/VSP/VZN/53/CFO/HO/2021 dated 12.03.2021 valid till 28.02.2025. It is
proposed to increase the manufacturing capacity of agrochemicals from 30 TPD to 70.1
TPD and also include Captive Co-generation Power Plant of 6 MW in existing site area
of 100 acres. The capital cost for proposed expansion is Rs. 65 crores, towards
additional utilities and enhancement of zero liquid discharge facility. The
manufacturing capacity of permitted and proposed products and by products is
presented in Table 2.1, Table 2.2 & Table 2.3.
Table 2.1 Manufacturing Capacity – Permitted
S. Name of Capacity (TPD)
No Product Group Group Group Group Group Group Group Group
1 2 3 4 5 6 7 8
1 Profenofos 9.5 6 5.5 7.5 9 5 15.5 15
2 Propiconazole 2 3.5 3 1 1 0.5
Bromoketal
Intermediate)
3 Tricyclazole 1 2.5 2 1 1 0.5
4 Myclobutanil 0.3 0.3 0.3 0.3 0.3 0.1
5 Pretilachlor 4.3 4.7 6.5 4 6 5
6 Thifluzamide 0.5 0.1 0.5 0.4 0.5 0.6 0.5 0.65
7 Flucarbazone 0.55 0.2 0.185 0.7 0.4 0.6
Sodium
8 Tebuconazole/ 0.25 0.2 0.1 0.2 0.75
Oxirane
(Intermediate)
9 Hexaconazole 0.1 0.2 0.1 0.1
10 Difenthiuron 0.1 0.2 0.1 0.1
11 Imidacloprid 0.1 0.1 0.1 0.1 0.1
12 Epoxiconazole 0.1 0.5 0.1 0.1 0.1
13 Cyproconazole 0.5 0.1 0.1 0.1 0.1
14 Omethoate 0.5 0.7 0.6 0.7 0.8 0.4
15 Metribuzin 0.3 0.5 0.5 0.5 0.1 0.2

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16 Pendimethalin 0.1 0.1 1 0.1 0.1

17 Clodinafop 0.2 0.2
18 Difenoconazole 0.2 0.05 0.1 0.1 0.1
19 Quizalafop P 0.1 0.1 0.3 0.5 1.25
Ethyl
20 Thiamethoxam 0.2 0.1 0.3 1.5 0.2
21 Bispyribac 0.1 0.095 0.2 0.1
Sodium
22 Tefluthrin 0.45 0.1 0.2
23 Cloquintocet 0.1 0.1
Mexyl
24 2,3 Dichloro 0.15 0.06 0.06 0.4 0.5 0.3
Pyrydine
25 Cypermertharin 0.35 0.15 0.1 0.1
26 Carbendazim 0.08 0.35 0.1
27 Trifloxystrobil 0.15 0.15
28 Azoxystrobin 0.1 1 0.15 0.2 0.1
29 Bifenthrin 0.05 0.08 0.15 0.15 0.1
30 Thiophanate 0.05 0.05 0.05 0.05 1.75
Methyl
31 Verbenone 0.05 0.15 0.15 0.15
32 (Z)-hezatec –11- 0.05 0.15 0.15 0.1 0.15
en-1-yl acetate
33 (Z)-hezatec – 9- 0.05 0.15 0.09 0.15 0.15
enal
34 Trimedlure 0.05 0.15 0.09 0.1 0.1 0.1
35 (8E,10E) – 0.05 0.15 0.1 0.1 0.15
Dodoca-8, 10-
dyen-1-ol
36 7Z,11Z hexadeca 0.05 0.15 0.09 0.1 0.1 0.15
dienyl acetate
37 7E, 9Z dodoca 0.05 0.1 0.09 0.1 0.1 0.15
dienyl acetate
38 8Z Dodecinyl 0.05 0.1 0.15 0.1 0.1 0.1
acetate
39 (Z)-Octadeca –13 0.05 0.1 0.09 0.1 0.1 0.15
– enyl acetate
40 R & D products 0.05 0.05 0.05 0.05 0.05 0.05 0.05
41 Triazinone / 10 7.84 7 8.9 6 9.4 7 9.5
Thricarbo
hydrazide /
Dichloro
Pinacolene /
Pinacolene

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42 Lambda- 1.5 0.55

cyhalothrin
43 Fipronil 0.5 0.5
44 Ethephon 1
45 Glufosinate- 1 1
ammonium
46 Clethodim 1
47 S-Metolachlor 1 1
48 Tribenuron 1 1
methyl
Total 29.65 30 29.95 30 30 29.15 30 30
Note: Any one combination will be manufactured at given time.

Table 2.2 Manufacturing Capacity –After Expansion

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23 Hexaconazole 79983-71-4 1.0

24 Tebuconazole / Oxirane (Intermediate) 107534-96-3 1.0
25 Difenconazole 119446-68-3 0.5
26 Epoxiconazole 135319-73-2 0.5
27 Cyproconazole 94361-06-5 0.5
28 Thiophanate-methyl 23564-05-8 1.0
29 Azoxystrobin 131860-33-8 1.0
30 Trifloxystrobin 141517-21-7 1.0
31 Pendimethalin 40487-42-1 1.5
32 Pretilachlor 51218-49-6 4.0
33 Metribuzin 21087-64-9 1.6
34 Dimethomorph 110488-70-5 2.0
35 Clodinofop-Propargyl 105512-06-9 1.0
36 Bispyribec Sodium 125401-92-5 1.0
37 Bensulfuron Methyl 83055-99-6 1.0
38 Glufosinate Ammonium 77182-82-2 1.0
39 Quizalofop-p-ethyl 100646-51-3 1.0
40 Tribenuron Methyl 101200-48-0 0.5
41 Clethodim 99129-21-2 1.0
42 Pinoxsulam 219714-96-2 1.0
43 S-Metolachlor 87392-12-9 1.0
44 Verbinone 1196-01-6 0.2
45 (Z)-hezatec – 11-en-1-yl acetate 34010-21-4 0.2
46 (Z)-hezatec – 9-enal 56219-04-6 0.2
47 (8E,10E) – Dodoca-8, 10-dyen-1-ol 76600-88-9 0.2
48 7Z,11Z hexadeca dienyl acetate 53042-81-2 0.2
49 7E, 9Z dodoca dienyl acetate 54364-62-4 0.2
50 8Z Dodecinyl acetate 28079-04-1 0.2
51 (Z)-Octadeca – 13 – enyl acetate 60037-58-3 0.2
52 R&D Products 0.1
Total 70.1
II Bio Based Agro Chemicals
1 Pseudomonas Fluorosense+ Bacillus Subitilis 0.17
2 Trichoderma Harzianum+Verticillium 0.17
chlamydosporium
3 Ampelomyces quisqualis+BeauveriaBassiana 0.17
4 Beauveria bassiana+ Metarhizium anisopliae 0.17
5 Beauveria bassiana 0.17

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6 Metarhizium anisopliae 0.17

7 Verticillium lecanii+Beauveria Bassiana 0.17
8 Hirsutella thompsonii+Beauveria Bassiana 0.17
9 Hirsutella thompsonii 0.17
Total 1.53
Captice Co-generation power plant 6 MW
Agrochemicals Formulations
S.No Name of Product Unit Capacity
1 Granules MT/year 20000
2 Liquids Kl/Year 25000
3 Powders MT/year 5000
Total 50000 50000

Table 2.3 List of By – Products

2.1 Need of the Project

World population is increasing at an alarming rate and in the Indian sub continent,
population growth is more than that of the developed countries. Farming community in
our country are finding it very difficult because of insecurity due to poor yields of crops
and in ability to compete in the global market due to poor quality of crop output and
presence of pesticide residues. The yield of the crop depends on various environment
related aspects, usage of fertilizers to provide primary and secondary nutrients and
control of pests, weeds by using safe crop protection chemicals.

Vision of promoters starting this company is to make environmentally friendly crop

protection chemicals available to the formers in our country at affordable prices. Such

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chemicals are presently sold by few leading multinationals. Dosages per acre of these
chemicals are very low compared to conventional crop protection chemicals and are
relatively less toxic. Solubility of these chemicals in water is negligible because of which
water sources will not get contaminated after application in the field. However, these
chemicals are very expensive because of which our formers are still depending on
conventional agrochemicals which are highly toxic and are likely to cause
contamination of water sources. Manufacture of this class of crop protection chemicals
in our country at affordable prices in our country will encourage formers to switch over
to enviro friendly crop protection chemicals.

2.1.1 Plant Layout

The proposed expansion is within the existing site area of 100 acres. Location of unit is
presented in Fig 2.1 and layout is presented in Fig 2.2. The manufacturing facility
consists of following;
1. Production Blocks 6. Tank Farm
2. Utilities 7. Cylinder Storage Area
3. Quality Control, R&D Facility 8. Administrative Office
4. Effluent Treatment Plant 9. Coal and Ash Storage Area
5. Warehouse 10. HWA Storage Area

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Fig 2.1 Plant Location of NACL Industries Ltd.

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Fig 2.2 Plant Layout of NACL Industries Ltd.

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2.1.2 Proces Description

The manufacturing process for the above-mentioned products involves chemical
synthesis utilizing mainly organic chemicals as raw materials in batch process.
Agrochrmicals which have unitque physical and chemical properties are manufactured
in batch process. Typically, a series of chemical reactions are performed in multi-
purpose reactors and the products are isolated by extraction, crystallization and
filtration. The finished products are usually dried, and milled. The manufacturing
process of each product, reaction scheme, material balance and flow diagram are
presented in separate annexure.

2.2 Utilities
The proposed expansion requires additional steam for process, ZLD system and solvent
recovery system. It is proposed to establish coal fired boilers of capacity 1 x 50 TPH coal
fired boiler in addition to existing 1 x 16 TPH, 1 x 10 TPH coal fired and 1 x 6 TPH oil
fired boilers. It is proposed keep existing boiler as standby after establishment of
proposed 1 x 50 TPH boiler. It is proposed to establish 1 x 10 lakh k.cal/hr and 1 x 6
lakh k.cal/hr thermic fluid heaters as part of expansion. The total power requirement is
estimated to be 4.0 MW. The DG sets required for emergency power during load shut
down is estimated at 2 x 2000 kVA proposed in addition to existing 1 x 1000 kVA and 2
x 500 kVA. The list of utilities is presented in Table 2.4.
Table 2.4 List of Utilities
S.No Utility Existing Proposed After
expansion
1 Coal Fired Boilers (TPH) 1 x 16 1 x 50, 1 x 50,
1 x 10 1 x 16 *
1 x 10 *
2 Furnace oil boiler (TPH) 1x6 -- 1x6*
3 Thermic Fluid Heaters (K.cal/hr ) 1 x 10 Lakh 1 x 10 Lakh
1 x 6 Lakh 1 x 6 Lakh
4 DG Sets (kVA)# 1 x 1000, 2 x 2000 2 x 2000
2 x 500 1 x 1000
2 x 500
* Standby after expansion #DG sets will be used during load shut down by Transco.

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2.3 Water Requirement

Water is required for process, scrubbers, washing, R&D, cooling tower makeup, steam
generation and domestic purposes. Total water required shall increase from 590 KLD to
2285 KLD after expansion. The fresh water consumption is optimized by reusing treated
wastewater to an extent of 1160 KLD, thus reducing fresh water consumption to 1125
KLD during operation. Fresh water is sourced from ground water. Water balance flow
diagram is presented in Fig 2.3. The water balance for daily consumption after
expansion is presented in Table 2.5.
Table 2.5 Total Water Balance - after Expansion
Purpose INPUT KLD OUTPUT KLD
Fresh Water Recycled Water Loss Effluent
Process 170 170 55** 265*
Washings 25 50 5 70
Scrubber 10 140 55# 95
Boiler Feed 480 18 462##
Cooling Tower 200 800 700 300
Raw water pre-treatment rejects 120 120
Domestic 80 20 60
Water for gardening 40 40
Gross Total 1125 1160 893 1372
Total 2285 2265
* Process effluents contain soluble raw materials, byproducts, solvents etc.
** carried along with by-products # carried along with scrubbed HCl
## contaminated steam of 426 KLD

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Fig 2.3 Water Balance Flow Diagram after expansion

2.4 Pollution Control Facilities
Liquid Effluents, air emissions and solid wastes are the major pollutants from the
process operations of agrochemicals and intermediates manufacturing activity. The
pollution control measures proposed to treat/mitigate the emissions and effluents are
described as follows.

2.4.1 Water Pollution

The main sources of effluent generation from the plant are from process, floor washings,
blowing downs from boiler and cooling tower, and domestic effluents. The effluents
generated in the process, separation techniques and during purification contain organic
residues of raw materials, solvents, and products. Some of the raw materials used in
the process are also inorganic in nature. Hence the effluents contain both organics and
in-organics in various quantities leading to high COD and TDS levels respectively. The

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total effluent generated and mode of treatment is presented in Table 2.6. The compiled
characteristics of process effluents for each product are presented in Table 2.7.
Table 2.6 Total Effluent Generated and Mode of Treatment
Description Quantity (KLD) Mode of Treatment
Permitted After
Expansion
HTDS Effluents
Process 75 265 Sent to Stripper followed by MEE and
Scrubber Effluent 35 95 ATFD. Stripper Condensate sent to
Raw water pre- 120 Cement Plants for Co-Incineration. MEE
treatment rejects and ATFD Condensate sent to Biological
treatment plant followed by RO. RO
rejects sent to MEE and permeate is
reused in cooling towers make-up,
washings, scrubbers and process
Total I 110 480
LTDS Effluents
Washings 70 Sent to Biological Treatment System
Process – LTDS 40.5 followed by RO. RO permeate reused for
Boiler Blow downs 36 cooling tower makeup. RO rejects sent to
Contaminated steam 426 MEE and permeate is reused in cooling
from boiler 184 towers make-up, washings, scrubbers and
Cooling Tower Blow 300 process.
downs
Domestic 25 60
Total II 249.5 892
Grand Total (I+II) 359.5 1372

Table 2.7 Process Effluents Quantity and Quality – Product Wise after Expansion
S. Product Name Quantity (Kg/Day) Conc. (mg/l)
No Water TDS COD Total TDS COD
Input Effluent
1 Cloquintocet Mexyl 1500 1039.2 2592.8 400813
2 Triazinone / 3236 2100 1546.8 6625 316981 233479
Thiocarbohydrazide/ Dichloro
Pinacolone /Pinacolone
4 Profenofos 1500 739.1 159.1 2599.6 284301 61214
6 Fipronil 4840 799.6 10.1 5845.2 136789 1724
7 Imidachloprid 2500 701 3347.8 209378
9 Lambda Cyhalothirin 1400 2381 3961 601111
11 Cypermethrin 1235 140.4 1375.4 102066
12 Carbendazim 4595 860.2 5455.2 157691

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16 Emamactin Benzoate 744 620.6

18 Propiconazole / Bromoketal 2020 738.4 63.1 2930.7 251949 21540
(Intermediate)
19 Tricyclazole 3500 26.1 3712.2 7021
20 Fenbuconazole 7000 347.2 111 7493.2 46337 14813
21 Myclobutanil 4500 1083.4 129.2 5815.7 186288 22208
22 Thifluzomide 14000 157.2 221.7 14376.1 10938 15419
23 Hexaconazole 7000 428.5 310.4 7687.2 55745 40380
24 Tebuconazole / Oxirane 4000 310.8 401.5 4645.4 66902 86438
(Intermediate)
25 Difenconazole 1932 3215.9 1849.6 6733.6 477595 274679
26 Epoxiconazole 1833 125 2181.6 3776 33104 577754
27 Cyproconazole 2500 473.7 3035.4 156050
28 Thiophanate-methyl 356 341.4 64.9 751.4 454265 86378
29 Azoxystrobin 6000 480.5 48.0 6520.5 73690 7361
30 Trifloxystrobin 8020 138 449.7 8532.7 16173 52699
32 Pretilachlor 1300
33 Metribuzin 22000 2639.1 62.2 25359.5 104066 2453
34 Dimethomorph 3000 103 3149.4 32705
35 Clodinofop-Propargyl 1000 1093.2 36 2123.2 514890 16955
40 Tribenuron Methyl 5000 2324 43.5 8075.3 287788 5387
42 Pinoxsulam 1000 35.3 301.7 1286.7 27467 234436
43 S-Metolachlor 1100 224.9 49.6 1494.3 150488 33176
44 Verbinone 3333 130.1 1375.4 5081.8 25601 270653
45 (Z)-hezatec – 11-en-1-yl acetate 5000 1040 331 6315.8 164666 52402
46 (Z)-hezatec – 9-enal 2860 3390 2859.5 8632.9 392684 331231
47 (8E,10E) – Dodoca-8, 10-dyen-1- 4000 1402 615.1 5914.6 237041 104000
ol
48 7Z,11Z hexadeca dienyl acetate 5 1 0.1 6.5 156473 18169
49 7E, 9Z dodoca dienyl acetate 350 20 93.5 447.9 44651 208752
50 8Z Dodecinyl acetate 900 97.5 170.4 1147.9 84917 148486
51 (Z)-Octadeca – 13 – enyl acetate 9 1.5 0.5 11 131528 41767

2.4.1.1 Process Description and Technical Specification of Effluent Treatment System

The Effluent management system is developed to ensure `Zero Liquid Discharge’,
which begins with Segregation of effluents to ensure effective of both high and low
COD/TDS streams. The effluents are segregated into two streams; High COD/ TDS
and Low COD/ TDS streams. Effluents generated from Process, scrubbers, raw water
pre-treatment rejects are considered as High COD/TDS. Blow downs from boiler,

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cooling towers, contaminated steam from MEE, washings and domestic activity are
considered as Low COD/TDS stream.

High TDS/ COD Effluents

The treatment system for treating High TDS/ COD effluents consists of equalization,
neutralization, flocculation tank, stripper, multiple effect evaporator (MEE) followed by
agitated thin film dryer (ATFD). The organic distillate from the stripper is sent to
cement plants for co-incineration and aqueous bottom from stripper is sent to MEE
followed by ATFD for evaporation. The condensate from the MEE and ATFD are sent to
Effluent treatment plant based on biological treatment. Salts from ATFD are disposed to
TSDF.

Low TDS/ COD Effluents:

These effluents along with the condensate from MEE and ATFD are treated in primary
treatment consisting of equalization, neutralization, and primary sedimentation
followed by secondary biological treatment consisting of aeration tank and clarifier.

The treated effluents after biological treatment are subjected to tertiary treatment in a
reverse osmosis (double RO) system. Permeate from RO is reused for process,
washings, scrubber and cooling towers make-up while rejects are sent to MEE followed
by ATFD. Sludge from various units of Biological treatment is thickened in sludge
handling system and sent to TSDF. Schematic diagram of effluent treatment system is
presented in Fig 2.4. Details of treatment facilities are presented in Table 2.8. The
effluent treatment system shall be developed in modules for ease of operation.
Technical specifications of proposed effluent treatment system are presented in Table
2.9.

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Table 2.8 Details of Treatment Facilities

S. Facility Description Capacity (KLD) Operating
No Existing Proposed Total after Volume (KLD)
Expansion
1 Stripper -- 1 x 300 1 x 300 265
2 Multiple Effect Evaporator 1 x 420 1 x 420 2 x 420 648.6
(MEE)
3 Agitated Thin Film Dryer -- 2 x 60 2 x 60 97.7
(ATFD)
4 Biological Treatment Plant 1 x 600 2 x 600 3 x 600 1505
5 RO Plant – I 1 x 350 2 x 700 2 x 700
1505
1 x 350
6 RO Plant – II 1 x 150 2 x 250 2 x 250 602
1 x 150
Note: Proposed facility will be established in modules

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Fig 2.4. Schematic Diagram of Effluent Treatment plant

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Table 2.9 Technical Specifications of Effluent Treatment Plant

Data Module Module
1 1
Capacity : 600 600 m3/day
Flow : 502 502 m3/day
BOD : 4000 4000 mg/l
COD : 8000 8000 mg/l
Total Dissolved Solids : 8000 8000 mg/l
1. Bar Screen Chamber
Flow rate : 75 75 m3/hr
Peak factor : 3 3
Peak flow : 225 225 m3/hr
Velocity through screen : 0.8 0.8 m/hr
Clear area through rack opening : 281.3 281.3 m2
Gross area : 1.2 1.2 times net area
Gross area : 338 338 m
2. Oil & Grease Trap (O&G)
Flow Rate : 600 600 kg/day
Flow Rate in min : 0.417 0.417 m3/min
Resident Time : 10 10 min
Depth from inlet : 0.3 0.3 m
Volume of the tank : 4.17 4.17 m3
Area : 13.89 13.89 m2
length of the tank (l=b) : 3.73 3.73 m
Width of the tank : 3.73 3.73 m
3. Equalization tank
Average flow : 75 75 m3/hr
Peak flow : 263 263
Hydraulic retention time : 12 12 hrs.
Volume of the tank : 3150 3150 m3
Assuming depth : 2 2 m
Area : 1575 1575 m2
Assuming length to width ratio (1:1) ; l=b
length of the tank : 39.7 39.7 m (Say 3.8 m)
width of the tank : 39.7 39.7 m (Say 3.8 m)
Air required for agitation : 0.01 0.01 m3/ m2 min
Total air required : 1.05 1.05 m3/hr
Air blower required : 3 3 m3/hr
4. Neutralization Tank
Average flow : 75.0 75.0 m3/hr
Hydraulic retention time : 12 12 hrs.
Volume : 900 900 m3
Biological Treatment
Data
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Design Capacity : 600 600 m3/day

Flow : 502 502 m3/day
Peak flow : 1003 1003 m3/day
Inlet BOD : 4000 4000 mg/l
Inlet COD : 8000 8000 mg/l
Inlet Total Dissolved Solids : 8000 8000 mg/l
8. Neutralization Tank
Average flow : 50.0 50.0 m3/hr
Hydraulic retention time : 12 12 hrs.
Volume : 600 600 m3
9.Aeration Tank - 1
Inlet BOD : 4000 4000 mg/l
Inlet COD : 8000 8000 mg/l
Inlet TDS : 8000 8000 mg/l
Outlet BOD : 600 600 mg/l
Outlet COD : 1200 1200 mg/l
Outlet TDS : 7920 7920 mg/l
MLSS : 3200 3200 mg/l
F/M ratio : 0.18 0.18
Flow : 600 600 m3/day
Volume of the Aeration Tank - 1 : 4166.7 4166.7 m3
Check for Detention time : 166.7 166.7 12 – 24 hrs
Assuming depth : 3.5 3.5 m
Area of the tank : 1190.48 1190.48 m2
Width of the tank : 34.50 34.50 m
Length of the Tank : 17.25 17.25 m
Oxygen is required for every Kg BOD5 removed : 2.00 2.00 kgs
Oxygen requirement for aeration : 4013 4013 kg/day
O2 in Air % : 0.21 0.21 %
Density of Air : 1.2 1.2 Kg/m3
Oxygen Transfer Efficiency : 0.06 0.06 %
Oxygen requirement : 50 50 m3/kg
O2/day
Air Required : 132720 132720 m3/day
: 3261 3261 cfm
Total air required (consider 35 % excess) : 4402 4402 Kg O2/day
10.Clarifier - 1
Design quantity : 600 600 m3/m2-day
Surface loading rate of average flow : 8 8 m2
Surface area provided : 75 75 m
length of the tank (2l=b) : 8.66 8.66 m (Say 2.5 m)
Width of the tank : 4.33 4.33 m (Say 1.5 m)
Inlet BOD : 600 600 mg/l
Inlet COD : 1200 1200 mg/l
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Inlet TDS : 7920 7920 mg/l

Outlet BOD : 502 502 mg/l
Outlet COD : 1200 1200 mg/l
Outlet TDS : 5940 5940 mg/l
11.Aeration Tank - 2
Inlet BOD : 502 502 mg/l
Inlet COD : 1200 1200 mg/l
Inlet TDS : 5940 5940 mg/l
Outlet BOD : 90 90 mg/l
Outlet COD : 215 215 mg/l
Outlet TDS : 5881 5881 mg/l
MLSS : 3200 3200 mg/l
F/M ratio : 0.18 0.18
Flow : 600 600 m3/day
Volume of the Aeration Tank - 2 : 2612.9 2612.9 m3
Check for Detention time : 104.5 104.5 12 – 24 hrs
Assuming depth : 3.5 3.5 m
Area of the tank : 746.55 746.55 m2
Width of the tank : 27.32 27.32 m
Length of the Tank : 13.66 13.66 m
Oxygen is required for every Kg BOD5 removed : 2 2 kgs
Oxygen requirement for aeration : 602 602 kg/day
O2 in Air % : 0.21 0.21 %
Density of Air : 1.2 1.2 Kg/m3
Oxygen Transfer Efficiency : 0.06 0.06 %
Oxygen requirement : 50 50 m3/kg
O2/day
Air Required : 19908 19908 m3/day
: 489 489 cfm
Total air required (consider 35 % excess) : 660 660 Kg O2/day
12.Clarifier - 2
Design quantity : 600 600 m3/m2-day
Surface loading rate of average flow : 12 12 m2
Surface area provided : 50.0 50.0 m
length of the tank (2l=b) : 7.07 7.07 m (Say 2.5 m)
Width of the tank : 3.54 3.54 m (Say 1.5 m)
Inlet BOD : 90 90 mg/l
Inlet COD : 215 215 mg/l
Inlet TDS : 5881 5881 mg/l
Outlet BOD : 75 75 mg/l
Outlet COD : 215 215 mg/l
Outlet TDS : 4410 4410 mg/l
13. Holding tank
Average flow : 50.0 50.0 m3/hr
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Peak factor : 2 2 m3/hr

Peak flow : 100.0 100.0 m3/hr
Provide min 1.5 hours holding capacity.
Hence required volume of the tank : 150 150 m3
14. Pressure Sand Filter:
Design : 600 600 m3/day
Flow : 502 502 m3/day
Inlet TDS : 4410 4410 mg/l
Outlet TDS : 3087 3087 mg/l
Rate of filtration assumed as : 15 15 m3/m2/hr
Requirement of treated water for usage in 20 hrs : 25 25.1 m3/hr
Dia of filter of 1 nos. : 1459.5 1459.5 mm
15. Activated Carbon Filter:
Design : 600 600 m3/day
Flow : 502 502 m3/day
Inlet TDS : 3087 3087 mg/l
Outlet TDS : 2470 2470 mg/l
Rate of filtration assumed as : 15 15 m3/m2/hr
Requirement of treated water for usage in 20 hrs : 25.1 25.1 m3/hr
Dia of filter of 1 nos. : 1459.55 1459.55 mm
16. Reverse Osmosis -1:
Design Capacity : 700 700 KLD
Operating capacity : 502 502 KLD
Recovery : 60% 60%
17. Reverse Osmosis - 2:
Design Capacity : 250 250 KLD
Operating capacity : 231.5 231.5 KLD
Recovery : 70% 70%

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Exisitng ZLD System Photographs

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2.4.2 Air Pollution

The manufacturing process consists of reaction, separation and purification. The reaction
is conducted in closed reactors, while the separation is conducted in centrifuge, filtration
equipment etc. The purification would be conducted in reactors or filtration equipment.
The transfer of materials will be through closed pipelines. Various sources of emissions
are identified from process operations. The usage of boiler for steam generation and DG
sets for emergency power also release emissions.

2.4.2.1 Emissions from Utilities

The sources of air pollution are proposed 1 x 50 TPH coal fired boiler, existing 1 x 16
TPH, 1 x 10 TPH coal fired and 1 x 6 TPH oil fired boilers. It is proposed kept existing
boiler as standby after expansion. It is proposed to establish 1 x 10 lakh k.cal/hr and 1 x
6 lakh k.cal/hr thermic fluid heaters as part of expansion. Standby DG sets of 2 x 2000
kVA are proposed in addition to the existing 1 x 1000 and 1 x 500 kVA, will be used
during load shutdown. Electro static precipitator is used as air pollution control
equipment for proposed 1 x 50 TPH coal fired boiler. DG sets shall be provided with
stack heights based on the CPCB formula for effective stack height. The emission rates of
SO2, NOx and PM from each stack are presented in Table 2.10. Effective stack height
calculation for proposed boiler and thermic flud heater is presented in Table 2.11 and
technical specifications of ESP are presented in Table 2.12.
Table 2.10 Emission Details of Pollutants from Stack
S. Stack Connected to Stack Dia of Temp. Of Exit Pollutant Emission
No Ht stack exhaust Velocity Rate (g/sec)
(m) (m) gases (0C) (m/sec) PM SO2 NOx
Existing
1 1 x 16 TPH coal fired 30 0.65 140 5.57 0.4 0.52 0.18
boiler*
2 1 x 10 TPH coal fired 30 0.25 160 8.23 0.05 0.14 0.18
boiler*
3 1 x 6 TPH oil fired 30 0.8 160 6 0.01 0.62 0.33
boiler*

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4 1 x 1000 kVA DG 6.5 0.35 180 8.5 0.01 0.04 0.12

Set**
5 2 x 500 kVA DG Set** 7 0.1 180 6.8 0.002 0.01 0.02
Proposed
1 1 x 50 TPH Coal fired 60 2.2 165 10.2 1.8 3.2 3.6
boiler
2 1 x 10 Lakh Kcal 30 0.5 160 4.5 0.06 0.08 0.12
Thermic Fluid Heater
3 1 x 6 Lakh Kcal 20 0.3 180 6.2 0.03 0.03 0.09
Thermic Fluid Heater
4 2 x 2000 kVA DG sets 10 0.3 200 10.2 0.02 0.06 0.08
* Standby after expansion ** DG sets will be used during load shutdown.

Table 2.11 Effective Stack Height Calculation based on CPCB Formula

On SPM Basis - Coal Fired Boiler Unit Value
50 TPH
Boiler Capacity TPH 50
Coal Consumption TPD 170.44
Ash Generation @ 45% of coal consumtion TPH 0.71
Fly ash (5% of total Ash) TPH 0.036
SPM Emission rate gms/Sec 9.86
Stack Height Calculated (SPM) H= 74*(Q0.27) m 30.05
On SO2 Basis - Coal Fired Boiler Unit Value
Sulphur Content in Coal % (by wt. Max.) 0.45%
SO2 Emission Rate Kg/hr 63.91
SO2 Emission Rate gms/Sec 17.75
Stack Height Calculated (SO2) H= 14*(Q0.3) m 48.73

Table 2.12 Technical Specifications of ESP – 50 TPH Boiler

Boiler Capacity Units 50 TPH
Chamber design
No of gas passages Nos 10
Spacing between electrodes mm 400
Height of collecting plate Feet 30
No of fields Nos 4
Length of each field Feet 12
Hopper arrangement 1.4 P (3)
Hopper valley angle Deg 55 deg
Fuel Indian coal and Imported coal
Gas Flow Am3/hr 75200
Temperature Deg C 160
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Maximum Inlet Dust load gm/Nm3 Indian coal: 50

Imported Coal: 10
Outlet Emission mg/Nm3 <115
(All field working at Wet basis)
Plate Area m2 3700
Specific Collection area m2/m3/s 100
Velocity through ESP m/s 0.6
Treatment time Sec 25
Migration Velocity cm/s 7
No of Electrical fields Nos. 4
No of Mechanical fields Nos. 4
COLLECTING ELECTRODE SPECIFICATIONS:
Height of panel M 10
Material CRCA sheet (IS 513 grade - "D")
Thickness SWG 18
Panel width mm 45
EMITTING ELECTRODE SPECIFICATIONS:
Height of electrode m 12
Type e - Tube
Material ERW Tubes & Carbon Steel Studs
Clearance between two Collectors mm 400
Spacing between Emitter & Collector electrode mm 200
MATERIAL SPECIFICATIONS:
Thickness/Specification/Sizes
Casing 3 mm 5 mm
Hopper 4 mm 5 mm
Inlet/Outlet Nozzles 3 mm 5 mm
Cladding thickness 24 SWG 24 SWG
ELECTRICAL SPECIFICATIONS
TR Sets Qty 4 nos
TR Control type Microprocessor controlled
RAPPING SYSTEM SPECIFICATIONS
Collecting plate rappers 4 Sets
e- Tube rappers 34Sets
Gas distribution plate rappers 1 Set
Type TIGI
DESIGN PRESSURE
Maximum/ Minimum mm WG ±200 mm WC
Maximum pressure drop flange to flange mm WG 25
Casing Mechanical Design Temperature 0C 200

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Exisitng Bag Filter Connected to 16 TPH Coal Fired Boiler

2.4.2.2 Emissions from Process

The manufacturing process consists of reaction, separation and purification. The reaction
is conducted in closed reactors, while the separation is conducted in centrifuge, filtration
equipment etc. The purification would be conducted in reactors or filtration equipment.
The transfer of materials is through closed pipelines. The following sources of emissions
are identified.

Process Emissions: Process emissions contain ammonia, carbon dioxide, hydrogen,

hydrogen bromide, bromine, chlorine, sulfuric acid, sulfur dioxide and hydrogen
chloride. Ammonia, hydrogen chloride, hydrogen bromide is sent to scrubber in series.
Sodium chloride from HCl scrubbing, Sodium bromide from hydrogen bromide
scrubbing, ammonium chloride from ammonia, sodium sulphate from sulfuric acid,
Sodium sulphate from sulfur dioxide scrubbing is sent to ETP. The other gas expected in
the process is carbon dioxide is let out into atmosphere following a standard operating
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procedure, while hydrogen gas is let out into atmosphere through a water column. The
quantity of process emissions is presented in Table 2.13. Technical Specifications of two
stage scrubber is presented in Table 2.14.

Table 2.13 Quantity and Mode of Treatment of Process Emissions – after expansion
S.No Product Name Name of Gas Quantity Mode of Treatment
(Kg/day)
1 2, 3 Dichloro Pyridine Hydrogen Chloride 570.6 To Scrubber
2 Profenofos Hydrogen bromide 216.7 To Scrubber
3 Imidacloprid Hydrogen Chloride 285.5 To Scrubber
4 Bifenthrin Hydrogen Chloride 86.2 To Scrubber
5 Diafenthiuron Ammonia 44.2 To Scrubber
6 Propiconazole Hydrogen bromide 269 To Scrubber
7 Tricylazole Ammonia 89.9 To Scrubber
8 Thifluzamide Hydrogen Chloride 318.8 To Scrubber
Sulfur dioxide 121.2 To Scrubber
Chlorine 82.2 To Scrubber
9 Hexaconazole Hydrogen Chloride 116.2 To Scrubber
10 Difenoconazole Hydrogen Chloride 89.7 To Scrubber
11 Epoxiconazole Hydrogen Chloride 201.0 To Scrubber
12 Pendimethalin Sulphuric Acid 348.7 To Scrubber
13 Quizalofop-P-Ethyl Hydrogen Chloride 97.9 To Scrubber
14 Clethodim technical Hydrogen Chloride 101.4 To Scrubber
15 S-Metolachlor Carbon dioxide 155.0 Let into atmosphere
Technical safely
Hydrogen 0.3 Let into atmosphere
safely through water
column

Table 2.14 Technical Specifications of Two Stage Scrubber

Type Packed Tower Scrubber Two Stage
MOC PP/FRP 5 mm PP+8mm FRP
Air Flow Rate 2500CFM
Inlet Temp. 350C
Inlet Gas Pressure Atmospheric
Batch 24 Hrs
Scrubbing medium for IstStage Water 10% NaOH Solution
Scrubbing medium for IIndStage Caustic Solution (or) Acid
Blower
MOC PPFRP
Capacity 2500CFM
Suction Pressure − 250mmWC
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Discharge Pressure 60mmWC

HP/RPM 5HP/1900RPM
Circulation System
Flow Rate 15 M3/hr
Head 30 Meters
Motor Make FLP
MOC PP
Storage/ Recirculation Tank
Capacity 3 KL
Size 1700mm Dia X 2300mm Ht.
MOC PP/FRP

Exisitng Two Stage Scrubbing System

2.4.2.3 Diffuse Emissions

Emissions are also released from various operations of manufacturing like drying,
distillation, extraction etc. These emissions mainly contain volatile contents of the
material sent for processing. The emissions are normally passed through vent scrubber
before releasing into atmosphere to mitigate odor. The emissions from distillation are
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passed through condensers, which mitigate odor. Vent condensers in series to reactors,
distillation columns, driers and centrifuge etc. are provided to mitigate VOC emissions
release. Other vents are connected to common headers and scrubbers. The transfer
pumps shall be provided with double mechanical seals. The transfer of solvents will be
mainly by closed pipeline systems, while drum transfer is by using air operated
diaphragm pumps in closed hoods. The charging of solid raw materials shall be by
powder transfer system to avoid dust emissions, safety and hazard of static electricity.
Safety relief valves rupture disc, Breather provided to reactors, thermal insulation, vent
condenser and nitrogen blanketing provide for bulk storage tanks. Thermal insulation
and condensers will be provided for storage tanks of low boiling point solvents. The
reactor or solvent storage tank vents when not use shall be kept closed.

2.4.2.4 Fugitive Emissions

Fugitive emissions are anticipated from equipment leakage and transfer spills. The
periodic maintenance program shall ensure integrity of equipment mitigating the
equipment leakage. The spills however shall be managed by adopting the spill
management scheme as mentioned in the respective MSDS. The fugitive emissions shall
be reduced by closed transfer and handling of all hazardous solvents and chemicals.
The ventilation system provided will reduce the health impact on employees by way of
dilution of work room air and also dispersion of contaminated air.

2.4.2.5 Odour Management

Odour is caused mainly by diffuse and fugitive emissions of low boiling organic
chemicals/ compounds releasing volatile organic compounds. The above-mentioned
measures for mitigation and control of diffuse and fugitive emissions shall reduce release
of VOC’s into atmosphere and the resultant odour

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2.4.3 Solvent Use and Recycle

Solvents are used for extraction of products and as reaction medium. Solvents constitute
major consumable material of synthetic organic chemical manufacturing, mainly used as
reaction medium. The used solvents constitute major waste stream of synthetic organic
chemical manufacturing. Hence it is proposed to recycle the solvents by distillation for
reuse in process, thereby reducing the total solvent consumption in the plant and
reducing the waste quantity to be disposed. There is not mixed solvent usage in proposd
product process, hence extraction of used solvents will be done by simple distillation
after completion of operation is each stage. Simple distillation consists of a column
connected to reactor vapour line followed by double distillation process and vacuum
pump. The distilled solvents will be reused for process for product washings and
impurities removal. Distillation process generates residues which are mainly organic in
nature containing significant calorific value, and can be sent to cement plants for co-
incineration as fuel. The total solvent balance product wise and stage wise is presented
in Table 2.15.

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Table 2.15 Total Solvent Balance – Product Wise After Expansion

Product Name Name of Solvent Quantity (Kg/Day)
Solvent Recovered Fugitive To waste water Residue
Input loss
Cloquintocet mexyl Dimethylformamide 3400 3230 17 153.0
Triazinone Xylene 350 340 2 8.8
2, 3 Dichloro Pyridine Toluene 5165 4906.8 25.8 232.4
Thiamethoxam Dimethylformamide 10806 10265.7 54.0 486.3
Fipronil Ethylene dichloride 4200 4074 14.7 8.4 102.9
Imidacloprid Toluene 5000 4850 17.5 132.5
Acetamiprid Methanol 1900 1843 9.5 47.5
Lambda Cyhalothrin n-Hexane 2381 2262 12 107.1
Iso propyl alcohol 1000 950 5 10 35.0
Bifenthrin n-Hexane 600 570 3 27.0
Cypermethrin n-Hexane 2053 1950.35 10.265 92.4
Pymetrozine Toluene 2000 1940 7 53.0
Emomectin Benzoate Methanol 300 291 0.3 0.582 8.1
Diafenthiuron Solvent C9 1500 1425 7.5 67.5
Acetonitrile 1500 1425 8 67.5
Propiconazole Benzene 100 97 0.35 2.7
Hexane 9000 8730 31.5 238.5
Dimethyl sulfoxide 1000 970 3.5 2 24.5
Tricylazole Dichloroethane 2000 1940 7 53.0
Xylene 2000 1940 7 53.0
Fenbucanazole Xylene 8000 7760 40 200.0
Dimethyl sulfoxide 100 97 0.5 1 1.5
Myclobutanil Dimethyl formamide 4000 3880 14 40 66.0
Thifluzamide Toluene 8000 7760 28 212.0
Acetonitrile 3000 2910 10.5 30 49.5
Hexaconazole Dichloromethane 6000 5820 21 60 99.0
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Dimethyl formamide 3000 2910 10.5 30 49.5

Tebuconazole Dichloromethane 4000 3880 14 40 66.0
Cyclohexane 1000 970 3.5 26.5
N-Methyl-2-Pyrrolidone 1000 970 3.5 10 16.5
Difenoconazole EDC 1932 1835.4 9.66 19.3 67.6
Cyclohexane 923 876.85 4.615 41.5
Epoxiconazole Cyclohexane 84 79.8 0.42 3.8
Cyproconazole Toluene 4000 3800 20 180.0
Thiophanate Methyl Acetone 5409 5138.55 27.045 54.1 189.3
Azoxystrobin DMF 5000 4750 25 225.0
Toluene 5000 4750 25 225.0
Methanol 4000 3800 20 40 140.0
Trifloxystrobin Methylene Dichloride 7375 7006.25 36.88 331.9
n-Heptane 2212 2101.4 11.06 99.5
Methanol 2560 2432.00 12.8 25.6 89.6
DMF 3731 3544.5 18.7 167.9
Toluene 3109 2953.6 15.5 139.9
Methanol 2500 2375.0 12.5 25 87.5
Pretilachlor Toluene 1000 970.0 3.5 26.5
Dimethomorph Toluene 1500 1455.0 5.25 39.8
Clodinofop-propargyl Dimethyl formaide 3000 2910.0 10.5 30 49.5
Bis-Pyribac Sodium Toluene 9231 8769.5 46.2 415.4
Acetone 12308 11692.6 61.5 553.9
Bensulfuran Methyl Xylene 1600 1552.0 5.6 42.4
Methanol 2000 1940.0 7 53.0
Glufosinate-ammonium Methanol 3000 2850.0 15 135.0
Quizalofop-P-Ethyl Toluene 3933.8 3737.1 19.7 177.0
Cyclohexane 4470.6 4247.1 22.4 201.2
Tribenuron-methyl Technical Acetonitrile 3625 3516.3 18.1 36.3 54.4
Clethodim technical n-Hexane 2000 1940.0 7 53.0
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Penoxsulam Dimethyl sulfoxide 2020 1959.4 7.1 4.0 49.5

S-Metolachlor Technical Hexane 600 582.0 3 6 9.0
1,2-dichloroethane 2000 1940.0 10 20 30.0
Verbenone Acetonitrile 4366 4147.9 21.8 43.7 152.8
MTBE 4111 3905.2 20.6 185.0
(Z)-hezatec-11-en-1-yl acetate Methanol 7900 7505.0 39.5 7.9 347.6
Methyl tert-butyl ether 2220 2109.0 11.1 99.9
Acetic acid 790 750.5 4.0 7.9 27.7
Toluene 5200 4940.0 26 234.0
(Z)-hezatec – 9-enal Methanol 11290 10725.5 56.5 112.9 395.2
Methyl tert-butyl ether 3170 3011.5 15.9 142.7
MDC 10740 10203.0 53.7 483.3
Hexane 4690 4455.5 23 211.1
(8E,10E) – Dodoca-8, 10-dyen-1- Tetrahydrofuran 3560 3382.0 17.8 160.2
ol Methyl tert-butyl ether 2200 2090.0 11 99.0
Methanol 3160 3002.0 16 31.6 110.6
7E, 9Z Dodeca dienyl acetate Tetrahydrofuran 600 582.0 3 6 9.0
Hexane 850 824.5 4.25 8.5 12.8
Dimethylformamide 300 291.0 1.5 3 4.5
8Z Dodecenyl acetate Methanol 540 523.8 2.7 5.4 8.1
Toluene 822 797.3 4.11 20.6

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2.4.4 Solid Waste

Solid wastes are generated from process, solvent distillation, wastewater treatment and
utilities. Process residue contains mainly unreacted raw materials and byproducts.
These are collected from the reactors and other process equipment and stored in drums.
Solvent residue is generated from distillation units, the residues are tarry substances
with good calorific value, and are stored in drums. The other major waste is salts from
multiple effect evaporator and agitated thin film dryer section of effluent treatment
system. These salts are stored in HDPE lined bags. All solid waste storage
containers/drums/bags are labeled showing the source, nature of hazard and type of
wastes. All the hazardous wastes are stored in a closed shed with fire safety measures,
and the shed is provided with a leachate collection facility connected to effluent
conveyance lines. The stripper distillate, process residue and solvent residue are sent to
cement plants for co-incineration based on acceptability. If these wastes are not suitable
for co-incineration, the same is sent to TSDF facility. Mixed solvents shall be sent to
authorized recyclers /cement plant for co-incineration while spent solvents are
recovered within plant premises. The evaporation salts are sent to TSDF. Filter media,
activated carbon and catalysts are sent to TSDF. Waste oil and used batteries from the
DG sets are sent to authorized recyclers. The sludge from effluent treatment plant is
considered hazardous and the same is sent to TSDF. The other solid wastes expected
from the unit are containers, empty drums which are returned to the product seller or
sold to authorize buyers after detoxification. The process wastes are compiled for each
product wise is presented in Table 2.16. Thequantity of solid waste generated in the
plant and the disposal practice is presented in Table 2.17.

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Table 2.16 Solid Waste Generated from Process – Product WiseAfterExpansion

S. Product Name Quantity (Kg/Day)
No Organic Inorganic Solvent Spent Catalyst Hyflow Total
residue Residue residue Carbon
1 Cloquintocet Mexyl 315.4 153.0 468.4
2 Triazinone / 1200 8.8 1208.8
Thiocarbohydrazide/
Dichloro Pinacolone
/Pinacolone
3 2,3 Di chloro 2.9 19685 232.4 570.6 235.3
Pyridine
4 Profenofos 450.2 450.2
5 Thiamethoxam 193.1 598.7 486.3 679.3
6 Fipronil 136.8 102.9 239.7
7 Imidachloprid 507.9 132.5 640.4
8 Acetamiprid 206.6 47.5 254.1
9 Lambda Cyhalothirin 142.1 162 304.1
10 Bifenthirin 51.2 27 78.2
11 Cypermethrin 15.7 92.4 15 108.1
12 Carbendazim 141.4 141.4
13 Pymetrozine 139.9 53 192.9
16 Emamactin Benzoate 204 8.1 212.1
17 Diafenthiuron 6 135.0 141.0
18 Propiconazole / 55.2 265.7 320.9
Bromoketal
(Intermediate)
19 Tricyclazole 45.7 106.0 151.7
20 Fenbuconazole 132.9 201.5 334.4
21 Myclobutanil 25.5 66 8 91.5
22 Thifluzomide 689.1 261.5 950.6
23 Hexaconazole 1.7 148.5 150.2
24 Tebuconazole / 60.9 109 169.9
Oxirane
(Intermediate)
25 Difenconazole 118.5 109.2 227.7
26 Epoxiconazole 86.2 3.8 90.0
27 Cyproconazole 300.4 180 480.4
28 Thiophanate-methyl 40.2 189.3 229.5
29 Azoxystrobin 133.4 590 723.4
30 Trifloxystrobin 188.3 431.4 619.7
32 Pretilachlor 39.8 26.5 66.3
33 Metribuzin 164.5 164.5
34 Dimethomorph 55.1 39.8 94.8
35 Clodinofop- 207.6 49.5 257.1
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Propargyl
36 Bispyribec Sodium 683.7 969.3 1652.9
37 Bensulfuron Methyl 142.9 95.4 238.3
38 Glufosinate 155.8 1982.3 135 290.8
Ammonium
39 Quizalofop-p-ethyl 0.0
40 Tribenuron Methyl 621.8 54.4 676.1
41 Clethodim 337.9 53.0 390.9
42 Pinoxsulam 21.2 49.5 70.7
43 S-Metolachlor 43.1 39.0 40 82.1
44 Verbinone 111.1 337.8 448.9
45 (Z)-hezatec – 11-en-1- 1520 709.2 100 2329.2
yl
46 (Z)-hezatec – 9-enal 2170 1232.2 140 3542.2
47 (8E,10E) – Dodoca-8, 1100 369.8 1469.8
10-dyen-1-ol
48 7Z,11Z hexadeca 3.2 0.3 0.1 3.3
dienyl acetate
49 7E, 9Z dodoca dienyl 558.7 26.3 584.9
acetate
50 8Z Dodecinyl acetate 104.8 28.7 7.0 140.5
51 (Z)-Octadeca – 13 – 1.3 0.3 0.1 1.6
enyl acetate
Total 13491.6 22266.3 8498.3 162.0 633.6 247.1 22399.0

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Table 2.17 Total Solid Waste Generated and Mode of Disposal

S.No Source Unit Quantity Mode of Disposal
Permitted After
Expansion
1 Organic residue TPM 127.2 404.75 Incineration in their own
2 Distillation Bottom Residue TPM 7.8 255 premises /Authorised
3 Organic-Stripper Distillate KLM 342 cement plants for
4 Spent Carbon TPM 4.9 coprocessing / AFRF for
pre-processing and
onward disposal to
cement industries for co-
processing
5 Spent Solvents TPM 1348 6000 Shall be recovered in
solvent recovery plant
within the premises / to
Cement industries for co-
processing
6 Spent Mixed Solvents TPM 1498 Sent to authorized
recovery units or Cement
Plants for Co-incineration
7 Boiler Ash TPD 18 Sold to Brick
manufactures and cement
plants
8 a) Detoxified Container / No.s/ 3600 15000 Sold to authorized
Liners drums Annum 1400 7500 vendors
b) HDPE Carboys) Fiber
Drums
9 Waste Oil Kg/month 0.3 10 Incineration in their own
premises /Authorized
recyclers
10 Used batteries No’s/ 500 Buy back with supplier
Annum
11 Inorganic salts TPM 505 428.6 Sent to TSDF
12 Evaporation Salts TPM 924
13 Catalyst TPM 19
14 Hyflow TPM 7.4
15 Incineration ash TPM 0.07 15
16 ETP Sludge TPM 1 25

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2.4.5 Noise Pollution

The noise levels may increase due to motors, compressors, turbine, DG set and other
activities. The major source of noise generation is turbine which emit noise levels of
above 100 dB (A) at a reference distance of 1m from the source. The steam generator
and auxiliaries will perform continuously within noise limits as per relevant standard
specification but not more than 85 dB (A) at 1 meter from any equipment or sub-
equipment. The machines and equipment shall have noise arresting system / low noise
levels to limit noise level. Further, all noise generating equipment shall be housed
within acoustic enclosure (where ever possible), to ensure attenuation of noise. The
employees shall be trained in the mitigation measures and personal protection
measures to be taken to prevent noise related health impacts. Hearing conservation
program is adopted to ensure that employee's hearing is not affected during his
working life to an extent greater than that usually occurring with age and to preserve it
at a level sufficient for normal speed perception.

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CHAPTER 3.0 DESCRIPTION OF THE ENVIRONMENT

3.1 Introduction
Impact is defined as difference between what would happen with action and
without. Hence the baseline data is an integral aspect of Environmental Impact
Assessment Report to establish what is happening without the project, by conducting
a baseline data study. Baseline data reflects present status of environment before
initiation of any activity of the proposed expansion project. Baseline data facilitates
impact assessment as the effects of the proposed expansion are superimposed on
baseline data. The study was conducted in the impact area; 10 km radius area
surrounding the project site, during October – December, 2020. Studies were
undertaken to generate baseline data of Micrometeorology, Ambient air quality
(AAQ), water quality, noise levels, flora and fauna, land use, soil quality and socio-
economic status of the community were collected.

3.2 Land Environment

Land and soil constitute basic components of physical environment. The expansion
project may cause changes in land, soil and denudational processes in different
intensities contingent on scale and sptial proximity of the activity and receptors.
Land and soil may be altered within the vicinity of 5 km radius and to a lesser extent
upto 10 km radial distance due to development of the project.

3.2.1 Physiography
Sailent features of the Project are presented in Table 3.1.
Description Remarks
Name of the Project Expansion of Arochemicals manufacturing capacity
and inclusion of bio-based agrochemicals and
Captive Co-generation Power Plant
Location of the Project Sy No: 177. Arinama Akkivalasa Etcherla Mandal,
Srikakulam, Andhra Pradesh
Project / Activity 5 (b) – Agrochemicals Manufacturing Unit
Category (A/B1/B2) A
New / Expansion / Modernization Expansion
Product Agrochemicals Manufacturing Unit
Capital Cost, Rs.65 crores
Land Use Pattern (Forest, Grazing, Private Land – 100 acres
Agricultural, Barren etc.)
Latitudes (North) 18°16'14.29"N – 18°16'32.64"N

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Description Remarks
Longitudes (East) 83°47'17.64"E - 83°47'48.99"E
Survey of India sheet No 65 N/15
Elevation above Mean Sea Level 52-60 m
(AMSL), m
Seismic zone Seismic Zone: II as per IS: 1893 (part -1): 2002 and
can be classified as Least Active seismic Zone
Site surroundings North : Connect road
East : Open lands
West : Open lands
South : Open lands
Nearest Village Kesavadasupeta village – 0.3 km – NW direction
Accessibility to site Road connecting – North direction
Road access Chilakapalem to Lolugu road - 0.3 km - NE
direction, NH 5 road – 0.6 km – SE.
Nearest Town Srikakulam – 10.6 km – NE direction
District Head quarters Srikakulam – 10.6 km – NE direction
Nearest Railway station Ponduru – 10.5 km – N direction
Nearest airport Visakhapatnam Airport – 85 km – SW direction
Major Industries Nil within 10 km
Water Bodies Seasonal Pedda Gedda stream 4.2 KM - SW
Seasonal Chitti Gedda stream 4.7 km - SW
The Project / Activity attracts the Not Applicable
provisions of CRZ
Reserve Forest Nil within 10 km
Inter-state boundary and Nil within 10 km
international boundary
Protected Areas notified under the Nil within 10 km
Wild Life (Protection) Act, 1972
Eco-sensitive areas as notified under Nil within 10 km
section 3 of the E (P) Act, 1986
Critically polluted areas as identified Nil within 10 km
by the Central Pollution Control
Board from time to time
The site photographs are presented in Figures 3.1. The base map of the study area is
presented in Figure 3.2.

Figure 3.1 Site and Plant Photographs (Terms of Reference No. 4(vii))

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Figure 3.2 Base map of the study area

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3.2.2 Geology (Terms of Reference No. 4(x))

The Study area physiographically comprises of Eastern Ghat tectonic complex of
Archaean age. Plains with scattered hills in the central, southern and eastern parts of
impact area is observed. The rock types are represented by granulite group of rocks
like Khondalites and Charnockites. These are overlain by laterites of Sub-recent age.
The Khondalite suite of rocks is represented by quartz-feldspar-garnet stilliminate
gneisses, quartzites and calc granulites. These formations are medium to coarse
grained and gneissic in texture. The color of rocks is generally red. Quartzites occur
as bands and occur more towards the contact zones between leptynites and
Khondalites. The charnockite group of rocks include acidic-intermediate and basic
hypersthene granulites/gneisses. These are hard, massive and dark colored and are
generally pink, medium grained and granulitic in texture. These are represented by
feldspathic gneisses with bands of charnockite. They occupy mainly low-lying areas
and occupy the crestal parts of antiforms, quartz, orthoclase, plagioclase and garnet
are essential constituents.
The regional structure identified in the area consists of second generation antiform.
Quaternary deposits are represented by laterites/lateritic gravel and surficial
deposits. Colluvium is debris material along the foothills essentially derived from
Khondalite hill ranges by fluvial action near Vempadu and Payakaraopet hill range.
It is composed of sand, silt, clay and gravel in varying proportions. Colluvium is
followed by weathered rock. Red sediments are unique in the area associated with
hill flanks and in valleys. The recent sediments constitute coarse to fine sands,
gravels, silts and clays. The red sand and lateritic soils are mostly distributed in the
study area. The chronological succession of the geological formations of the area is
presented in Table 3.2. Geological map of the study area is presented in Figure 3.3.
Table 3.2 The Succession of Geological Formations
Geological Age Type of Formation
Sub recent to recent Sand, gravel, silt and clay
Upper Cretaceous
Pre-Cambrains (Bhimas) Sandstones, Limestones and Shales
Archean Gneissic complex rocks, diorite, coarse grained Granite
with doleritic dyke intrusions.

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Figure 3.3 Geomorphology map of the study area

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3.2.3 Hydrogeology (Terms of Reference No. 4(x))

The hydrogeological conditions prevailing generally depend on various factors like
climate, rainfall, topography, geological setting and structure of the area. In turn the
occurrence and movement of groundwater also depend on these factors. The rocks
occurring in the area can be broadly classified as two types viz; hard and soft rocks.
Crystalline formations like khondolites, charnockites, migmatites and gneisses etc. can
be grouped as hard rocks, while the unconsolidated formations like the alluvial
sediments can be classified as soft rocks. The semi consolidated formations like
sandstones are grouped under soft rocks, though limited in occurrence. The
occurrence and movement of groundwater in the different geological formations of
the area Ground water occurs under the water table conditions in the weathered
basalts in the joints and fractures. Thickness of weathering in traps ranges up to 26 m.
Bore wells depth range between 26 and 30 m. Generally, in well bores from the bottom
of the dug wells pierced through the entire thickness of weathered zone in order to
increase the yield of the wells. The bore well sustain pumping for 6 to 8 hours/day
with fast recovery of water levels in this area. The depth of open wells generally
ranges from 8.5 to 10.5 m. The depth of water level in the study area ranges between
pre monsoon season 7.6 to 9.8 m (May, 2020), post monsoon season 3.6 to 4.7 m (Nov,
2020). The applied area exists sub-dendritic to dendritic drainage pattern.
Hydrogeological Map of the study area is presented in Figure 3.4. The water
requirement of the proposed project is abstracted from borewells within the site.

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Figure 3.4 Hydrogeological Map of the study area

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3.2.4 Soils
Soil may be defined as a thin layer of earth’s crust that serves as a natural medium
for the growth of plants. It is the unconsolidated mineral matter that has been
subjected to and influenced by genetic and environmental factors such as parent
materials, climate, organisms and physico-chemical action of wind, water and
sunlight, all acting over a period of time. Soil differs from the parent materials in
the morphological, physical, chemical and biological properties. Also, soil differs
among them in some or all the genetic or environmental factors, therefore, some
soils are yellow, some are black, and some are coarse textured. Soil functions as a
reservoir of nutrients for plants and crop providing mechanical anchorage and
favorable tilth, facilitating food and biomass production. The other functions of
soil include controlling and regulating interaction of water flow and quality,
facilitating carbon sequestration, providing habitat, preserving cultural heritage,
providing platform for buildings and roads in addition to providing raw materials
by way of minerals, building stones, gravel etc.

Soil analysis for various indicators reflecting various soil functions is proposed as
part of baseline data collection. The Soil characteristics include both physical and
chemical parameters reflecting various soil functions ranging from biodiversity,
production, water and solute flow, nutrient cycling, filtering and buffering, and
structural support. M/s. Team Labs and Consultants field team carried out soil
survey to assess the soil characteristics of the study area. The land use and land
cover map of the study area is shown in Figure 3.5. It may be noted that the land
use land cover map reflects predominant agriculture nature of the impact area,
and also its dependence on tanks for irrigation. Representative soil sampling was
done at several important locations and these locations are shown in Figure 3.6.
Analytical data of soil samples is presented in Table 3.3.

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Figure 3.5 Land Use and Land Cover of the study area (Terms of Reference No. 4(ix))

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Figure 3.6 Soil Sampling Locations

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Table 3.3 Soil Analysis Data (Terms of Reference No. 6(viii))

Parameter Unit S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8
pH - 7.26 7.16 7.02 7.64 7.59 7.24 7.21 7.54
Electrical Conductivity (EC) dS/m 0.462 0.342 0.185 0.314 0.324 0.298 0.265 0.513
Bulk Density g/cc 1.18 1.18 1.18 1.25 1.25 1.25 1.11 1.18
Cation-Exchange Capacity (CEC) Col (+)/kg 2.87 3.47 2.38 3.60 4.51 3.93 2.93 3.59
Infiltration rate mm/hour 25 17 24 24 24 26 25 17
Porosity % 56 56 56 53 53 53 58 56
Water Holding Capacity % 5.92 6.75 7.59 8.14 7.71 6.18 6.30 6.04
Moisture % 6.29 7.24 8.21 8.86 8.36 6.59 6.73 5.12
Organic Matter % 1.26 1.89 1.18 1.25 1.41 1.23 1.52 1.65
Carbonates % Nil Nil Nil Nil Nil Nil Nil Nil
Sand % 53 50 59 61 56 54 54 46
Silt % 30 38 26 23 30 34 33 37
Clay % 17 12 15 16 14 12 13 17
Organic Carbon % 0.73 1.10 0.68 0.73 0.82 0.71 0.88 0.96
Nitrogen (as N) % 0.013 0.011 0.012 0.016 0.016 0.012 0.02 0.017
Carbon / Nitrogen Ration (C/N) - 56.2 99.7 57.0 45.3 51.1 59.5 55.1 56.3
Phosphorus (as P) % 0.264 0.437 0.631 0.589 0.461 0.765 0.778 0.617
Potassium (as K) mg/kg 134 98 65 167 113 546 113 214
Sodium (as Na) mg/kg 162 374 271 356 316 289 349 294
Calcium (as Ca) mg/kg 172 198 89 172 268 107 67 164
Magnesium (as Mg) mg/kg 116 72 71 92 182 86 95 113
Calcium/Magnesium ratio - 1.48 2.75 1.25 1.87 1.47 1.24 0.71 1.45
Sodium Absorption Ratio (SAR) - 2.34 5.79 5.20 5.45 3.65 5.05 6.43 4.33
Chlorides (as Cl) mg/kg 1964 2694 1746 1249 1679 1634 1349 1624
Sulphates (as SO4) mg/kg 82 96 45 31 37 46 36 67
Zinc (as Zn) mg/kg 31 26 29 13 46 25 31 30
Texture - Sandy Sandy Sandy Sandy Sandy Sandy
loam Loam loam loam loam loam loam Loam
S1-Site, S2-Keshavadasupeta, S3-Chilakapalem, S4-Pattusalipeta, S5-Allinagaram, S6-Narsapuram, S7-Echerla, S8-Neliveda

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The test results of soil samples collected in the impact area are interpreted
referring to the book; “Interpreting soil test results” by Pam Hazelton and Brian
Murphy. The reference tables are presented in Table 3.4. The pH of soil samples
ranges from Neutral to mildily alkaline. The cation exchange capacity of the soils
is very low in all smaple locations. The level of nitrogen is very low in all samples,
while the potassium levels are low in six samples, medium in one sample and
high in one sample. The calcium magnesium ratios of the samples reflect is Ca
deficient in two samples and low Ca in all samples. Bulk density of soil of impact
varies from 1.18 g/cc among loam and 1.11-1.25 g/cc among sandy loam. The
porosity values range from 53-58 % among Sandy loam (6 sample), Soil texture is
predominantly Sandy loam.
Table 3.4 Soil Test Results – Reference Tables
General interpretation of pH Measured Rating for Cation Exchange Capacity
pH Range Classification CEC (Cmol)+)/kg
<4.5 Extremely Acidic Very low <6 *
4.51 -5.0 Very Strong Acidic Low 6-12
5.1-5.5 Strong Acid Moderate 12-25
5.6- 6.0 Moderately Acid High 25-40
6.1-6.5 Slightly acid Very High >40
6.6-7.3 Neutral Source: Metson (1961)
7.4-7.8 Mildily Alkaline * Soils with CEC less than three are often
7.9 -8.4 Moderately Alkaline low in fertility and susceptible to soil
8.5-9.0 Strongly Alkaline acidification.
>9.0 Very Strongly Alkaline
Source: Bruce and Rayment (1982).
Ca/mg Ratio Base Saturation as a Criterion of
Leaching
Description Range (%BS) Rating
<1 Ca Deficient 70-100 Very Weakly Leached
1-4 Ca (Low) 50-70 Weakly Leached
4-6 Balanced 30-50 Moderately Leached
6-10 Mg (Low) 15-30 Strongly Leached
>10 Mg deficient 0-15 Very Strongly Leached
Source: Eckert (1987) Source: Metson (1961)
Rating of Total Nitrogen Extractable Potassium (K)
Rating (% by W) Description K
<0.05 Very low low <150 ppm* (< 0.4 meq/100 g soil)
0.05-0.15 Low medium 150–250 ppm (0.4–0.6 meq/100 g soil)
0.15-0.25 Medium high 250–800 ppm (0.6–2.0 meq/100 g soil)
0.25-0.50 High excessive >800 ppm (>2.0 meq/100 g soil)
>0.5 Very High Source: Abbott (1989)
Source: Bruce and Rayment (1982)

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3.3 Water Environment

Industrial development of any region is contingent on the availability of sufficient

water resources, as most of the process industries require water for process or
cooling purposes. The proposed project envisages to use a desalination plant for
its water requirement reducing the impact on ground water and or surface water
resources. The water resources in the impact area broadly fall into following
categories; surface water sources mainly consisting of tanks and ponds and
ground water sources of tube wells, dug wells and dug/bore wells which abstract
accumulated water in the acquifers in the deeper strate of ground.

3.3.1 Surface Water Resources

There are a few surface waters bodies like natural lakes and tanks in the study
area. The drainage pattern of the impact area is dendritic and the flow is mainly
into a Pedda gedda including the site area which drains in south west direction of
the site. The drainage pattern of the impact area is presented in Figure 3.7.

3.3.1.1 Surface Water Quality

The sampling locations of ground water are presented in Figure 3.8. The analytical
results of water samples drawn from various locations in the study area during
monitoring are presented in Table 3.5.

Table 3.5 Water Analysis Data –Surface Water (Terms of Reference No. 6(iv))
Parameters SW-1 SW-2 SW-3 Units Method of Analysis IS
2296:1982
Temperature 27 27 27 oC IS:3025 part 09:1984 (RA:2017) NS
Colour 5 5 5 Hazen IS:3025 part 04:1983 (RA:2017) 300
Turbidity 0.5 0.4 0.2 NTU IS:3025 part 10:1984 (RA:2017) NS
pH 7.04 6.93 6.69 - IS:3025 part 11:1983 (RA:2017) 6.5-8.5
Total Solids 494 397 383 mg/l IS:3025 part 15:1984 (RA:2019) NS
Total Dissolved Solids 482 387 371 mg/l IS:3025 part 16:1984 (RA:2017) 1500
Total Suspended 12 10 12 mg/l IS:3025 part 17:1984 (RA:2017) NS
Solids
Total Hardness (as 345 150 141 mg/l IS:3025 part 21:2009 (RA:2019) NS
CaCO3)
Calcium (as Ca) 70 34 30 mg/l IS:3025 part 40:1986 (RA:2019) NS
Magnesium (as Mg) 41 16 16 mg/l IS:3025 part 46:1994 (RA:2019) NS
Sodium (as Na) 29 67 65 mg/l IS:3025 part 45:1993 (RA:2019) NS
Potassium (as K) 6.0 2.9 1.9 mg/l IS:3025 part 45:1993 (RA:2019) NS
Total Alkalinity (as 75 110 125 mg/l IS:3025 part 23:1986 (RA:2019) NS

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CaCO3)
Chloride (as Cl) 169 103 89 mg/l IS:3025 part 32:1988 (RA:2019) 600
Sulphates (as SO4) 55 33 27 mg/l IS:3025 part 24:1986 (RA:2019) 400
Nitrite Nitrogen (as 18 12 16 mg/l IS:3025 Part 34:1988 (RA:2019) 50
NO3)
Silica (as SiO2) 1.1 5.4 2.9 mg/l IS:3025 part 35:1988 (RA:2019) NS
Fluoride (as F) 0.17 0.31 0.11 mg/l IS:3025 part 60:2008 (RA:2019) 1.5
Residual, Free <0.2 <0.2 <0.2 mg/l IS:3025 part 26:1986 (RA:2019) NS
Chlorine
Mineral Oil Nil Nil Nil mg/l IS:3025 part 39:1991 (RA:2019) NS
Aluminium (as Al) <0.5 <0.5 <0.5 mg/l APHA-3500 Al:2017 NS
Arsenic (as As) <0.001 <0.001 <0.001 mg/l IS:3025 part 37:1988 (RA 2019) 0.2
Boron (as B) <0.1 <0.1 <0.1 mg/l APHA- 4500 B:2017 NS
Cadmium (as Cd) <0.01 <0.01 <0.01 mg/l IS:3025 part 41:1992 (RA:2019) 0.01
Hexavalent <0.05 <0.05 <0.05 mg/l IS:3025 part 52:2003 (RA:2019) 0.05
Chromium (as Cr6+)
Copper (as Cu) <0.01 <0.01 <0.01 mg/l IS:3025 part 42:1992 (RA:2019) 1.5
Iron (as Fe) 0.52 0.46 0.45 mg/l IS:3025 part 53:2003 (RA:2019) 50
Lead (as Pb) <0.01 <0.01 <0.01 mg/l IS:3025 part 47:1994 (RA:2019) 0.1
Manganese (as Mn) <0.01 <0.01 <0.01 mg/l APHA-3500 Mn :2017 NS
Mercury (as Hg) <0.01 <0.01 <0.01 mg/l IS:3025 part 48:1994 (RA:2019) NS
Nickel (as Ni) <0.01 <0.01 <0.01 mg/l IS:3025 part 54:2003 (RA:2019) NS
Selenium (as Se) <0.001 <0.001 <0.001 mg/l IS:3025 part 56:2003 (RA:2019) 0.05
Zinc (as Zn) 0.29 0.31 0.11 mg/l IS:3025 part 49:1994 (RA:2019) 15
DO 4.2 4.5 4.1 mg/l Is:3025 Part 38:1989 (RA:2019) 4
BOD 2.6 2.1 3.5 mg/l IS:3025 Part 58:2006 (RA:2017) NS
COD 11 7.5 9.8 mg/l IS:3025 Part 44:1993 (RA:2019) 3
SW1- Narayana Sagaram, SW2- Chilakapalem, and SW3- Echcrla

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Figure 3.7 Drainage Pattern of the study area (Terms of Reference No. 4(xi))

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3.3.1.2 Ground Water Resources

Ground water is the accumulation of water below ground surface, caused by rainfall
and its subsequent percolation through pores and crevices. Percolated water
accumulates till it reaches impervious strata consisting of confined clay or confined
rocks. Occurrence of ground water is controlled by landform, structure and
lithology. Ground water abstraction is by means of dug wells, dug cum driven wells,
and bore wells and open alluvial. Ground water resources are ample in the study
area. The state authorities have also provided tube wells fitted with hand pump for
the drinking water requirement of villages in the study area. Presently the drinking
water needs are mostly met from ground water resources.

3.3.1.3 Quality of Ground Water (Terms of Reference No. 6(vi))

Representative samples are collected from various dug wells and bore wells in the
study area. The analytical results of water samples drawn from various locations in
the study area are presented in Table 3.6. The map showing locations of sample
collection (Figure 3.8) is also presented. Whereas Total dissolved solids are 603-1008
mg/l, which is contributed by sodium and chlorides reflecting on coastal nature of
the site area. Water hardness is caused primarily by the presence of cations such as
calcium and magnesium and anions such as carbonate, bicarbonate, chloride and
sulfate in water. Water hardness has no known adverse effects; however, some
evidence indicates its role in heart disease. Hard water is unsuitable for domestic use.
In this region, the total hardness varies between 330-490 ppm. According to Sawyer
and McCarty’s classification for hardness, 1 sample falls under hard class and 6
samples fall under very hard class, reflecting coastal nature of the impact area.
Table 3.6 Locations of Ground water Sampling
S. No Location Name Direction Form site Distance from Site (Km)
GW - 1 Site - -
GW – 2 Keshavadasupeta NW 0.3
GW – 3 Chilakapalem E 0.4
GW – 4 Pattusalipeta SW 1.5
GW – 5 Allinagaram SE 1.4
GW – 6 Narsapuram NW 1.9
GW – 7 Echerla NE 2.0
GW – 8 Neliveda NE 2.48

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Figure 3.8 Water Sampling Locations (Ground water)

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Table 3.7 Water Analysis Data – Ground Water

Parameters GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 GW-8 Units Method of IS
Analysis 10500:2012
Standard
Temperature 27 27 26 25 27 25 27 26 oC IS:3025 part 09:1984 (RA:2017) -
Colour 1 2 1 3 3 2 2 2 Hazen IS:3025 part 04:1983 (RA:2017) 5
Turbidity 0.6 0.2 0.9 0.2 0.7 0.3 0.2 0.6 NTU IS:3025 part 10:1984 (RA:2017) 1
pH 6.88 7.09 7.05 7.30 6.78 7.36 6.70 6.94 - IS:3025 part 11:1983 (RA:2017) 6.5-8.5
Total Solids 603 640 879 816 796 1008 995 755 mg/l IS:3025 part 15:1984 (RA:2019) NS
Total Dissolved Solids 598 634 872 809 790 998 987 749 mg/l IS:3025 part 16:1984 (RA:2017) 500
Total Suspended Solids 5 6 7 7 6 10 8 6.0 mg/l IS:3025 part 17:1984 (RA:2017) NS
Total Hardness (as CaCO3) 250 310 552 380 445 600 650 395 mg/l IS:3025 part 21:2009 (RA:2019) 200
Calcium (as Ca) 58 70 112 70 92 158 140 80 mg/l IS:3025 part 40:1986 (RA:2019) 75
Magnesium (as Mg) 26 33 66 50 52 50 73 47 mg/l IS:3025 part 46:1994 (RA:2019) 30
Sodium (as Na) 94 82 81 124 90 105 99.0 87.0 mg/l IS:3025 part 45:1993 (RA:2019) NS
Sodium Absorption -
Ratio (SAR) 2.59 2.03 1.50 2.77 1.86 1.87 1.69 1.91 IS:3025 part 45:1993 (RA:2019) -
Potassium (as K) 7.5 1.6 9.2 18 9.9 9.5 16 21 mg/l IS:3025 part 23:1986 (RA:2019) NS
Total Alkalinity (as CaCO3) 200 295 250 375 275 285 400 275 mg/l IS:3025 part 32:1988 (RA:2019) 200
Chloride (as Cl) 167 113 273 178 223 331 292 185 mg/l IS:3025 part 24:1986 (RA:2019) 250
Sulphate (as SO4 )- 9 7 17 3 9 10 7 9 mg/l IS:3025 Part 34:1988 (RA:2019) 200
Nitrate Nitrogen (as NO3) 19 37 35 22 32 31 37 39 mg/l IS:3025 part 35:1988 (RA:2019) 45
Silica (as SiO2) 15 25 23 22 11 18 18 17 mg/l IS:3025 part 60:2008 (RA:2019) NS
Fluoride (as F-) 0.34 0.26 0.62 0.24 0.64 0.13 0.17 0.64 mg/l IS:3025 part 26:1986 (RA:2019) 1.0
Manganese (as Mn) <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 mg/l IS:3025 part 48:1994 (RA:2019) 0.10
Zinc (as Zn) 0.13 0.27 0.25 0.16 0.12 0.26 0.13 0.17 mg/l IS:3025 part 43:2003 (RA:2019) 5.0
GW1-Site, GW2-Keshavadasupeta, GW3-Chilakapalem, GW4-Pattusalipeta, GW5-Allinagaram, GW6-Narsapuram, GW7-Echerla, GW8-Neliveda

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3.4 Air Environment

3.4.1 Meteorology
Micro meterological studies are simultaneously conducted with air quality
monitoring. Meteorology plays a vital role in facilitating dispersion of pollutants;
once discharged into the atmosphere, their transport, dispersion and diffusion into
the environment. Meteorological data is necessary for interpretation of baseline
data and for air quality impact predictions. Since meteorological data show wide
fluctuations with time, meaningful interpretation can only be drawn from long
term and reliable data. Such source of data is the India Meteorological Department
(IMD) that maintains a network of meteorological stations at several important
locations. The climatorlogical table for nearest IMD station at Kalingapatnam for
the period 1981-2010 is presented in Table 3.8. The data indicates that
predominant wind direction was from SW during summer season and the highest
temperature of 46.90C was observed in the month of May.

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Table 3.8 Meteorological data at IMD Station

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3.4.2 Meteorological Station at Plant Site (Terms of Reference No. 6(i))

The micro meteorological data at the industry site is collected simultaneously
with ambient air quality monitoring. The station was installed at a height of 10
meters above the ground level and the same is located in such a way that there
are no obstructions facilitating free flow of wind. Wind speed, wind direction,
humidity, temperature and rainfall are recorded on hourly basis. Salient features
of micro meteorological data collected are as follows:

1. Wind Direction and Speed:

The hourly wind speed and wind direction observations are computed for the
study period and the same are presented in Table 3.9 and the wind rose
diagrams are presented in Figure 3.9. The following observations can be made
from the collected data;

• Calm period is observed to be 5.43 % during the time of monitoring.

• The predominant wind direction is Southwest.

• Other than predominant wind directions wind was blowing in west-southwest

and south-southwest.

• Mostly the wind speeds are observed to be in the range of 10-15 kmph and 5-10
kmph.

2. Temperature: (a) Maximum: 42.90C (b) Minimum: 18.70C (c) Average: 28.90C

3. Humidity: The daily relative humidity values are observed to range between
29-64%.

4. Rain Fall: (a) Maximum: 6.4 mm (b) Minimum: 0 mm (c) Mean: 0.8mm

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Table 3.9 Frequency Distribution of Wind Speeds and Wind Directions

Wind Speed in kmph
Wind Direction
Calm 1-5 5-10 10-15 >15 Total
N 0.14 0.09 0.23
NNE 0.36 0.27 0.63
NE 1.45 0.95 1.45 0.18 4.03
ENE 0.45 0.59 0.82 0.32 2.17
E 0.86 0.54 0.09 0.05 1.54
ESE 0.82 0.14 0.95
SE 0.50 0.23 0.72
SSE 2.13 1.54 0.77 0.91 5.34
S 3.40 4.76 2.04 1.63 11.82
SSW 1.95 2.99 2.72 0.50 8.15
SW 2.54 5.30 7.84 12.73 28.40
WSW 3.94 7.74 4.76 3.44 19.88
W 4.62 2.36 0.14 7.11
WNW 0.82 0.23 0.23 0.05 1.31
NW 0.68 0.18 0.09 0.09 1.04
NNW 0.27 0.59 0.23 0.14 1.22
Calm 5.43 5.43
Total 5.43 24.91 28.40 21.24 20.02 100.00
(Monitoring Period: October – December, 2020)

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WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

NORTH

29%

23.2%

17.4%

11.6%

5.8%

WEST EAST

WIND SPEED
(m/s)
SOUTH >= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

End Date: 12/31/2020 - 23:00
MODELER:

M/s.Team Labs and

Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

Figure 3.9 Wind Rose Diagram at Site

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3.4.3 Ambient Air Quality (Terms of Reference No. 6(ii))

Air pollution means the presence in the outdoor atmosphere of one or more or
combinations thereof in such quantities and of such duration as are or may tend to
be injurious to human, plant or animal life or property. Air pollutants include
smoke, vapors, soot, fumes, gases, mist, odors, particulate matter, radioactive
material or noxious chemicals. With the proposed expansion of the API
manufacturing unit a range of criteria pollutants and non criteria pollutants from
process and operations are released into the atmosphere that are dispersed and
have a significant impact on neighborhood air environment. Thus, collection of
base line data of air environment occupies a predominant role in the impact
assessment. The ambient air quality status across the study area forms basis for
prediction of the impacts due to the proposed expansion project.

The data required to assess air quality impacts in and around neighborhood is
achieved by designing such a network, which encompasses micro meteorological
conditions, quantity and quality of emissions, locations, during, resources /
monitoring technology and operational criteria.

3.4.4 Scope of Field Study

The scope of baseline status of the ambient air quality can be assessed through a
well-designed ambient air quality stations network. Ambient air quality
monitoring of the study area consisting of 10 km radius with the plant site as the
center point was carried out during the study period. Ambient air quality was
monitored at eight locations spread over entire study area. Figure 3.10 presents
the locations of eight ambient air quality-monitoring stations. At each sampling
station monitoring was carried out for 24 hours in a day for 2 days a week and
for three months. The major air pollutants monitored on 24 hourly basis are;
PM10, PM2.5, Sulfur dioxide and Oxides of Nitrogen. Sampling and analysis of the
above variables is according to the guidelines of Central pollution control board.
National ambient air qualiy standards are presented in Annexure I.

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3.4.5 Description of Sampling Locations (Terms of Reference No. 6(ii))

The location of ambient air quality stations is contingent on the meteorological
status of the area. Hence the micro meteorological data was collected before
initiating the ambient air quality monitoring. Table 3.10 presents the ambient air
quality locations and their distances and directions from the plant site.

Table 3.10 Locations of Ambient Air Quality Monitoring Stations

S. No Location Direction w.r.t Plant Distance from plant site, km
1. Site - -
2. Keshavadasupeta NW 0.3
3. Chilakapalem E 0.4
4. Pattusalipeta SW 1.5
5. Allinagaram SE 1.4
6. Narsapuram NW 1.9
7. Echerla NE 2.0
8. Neliveda NE 2.8

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Figure3.10 Ambient Air Quality Monitoring Locations

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3.4.6 Ambient Air Quality Status (Terms of Reference No. 6(iii), B3)

The baseline data for ambient air quality is presented in Table 3.11. It may be
noted that the monitoring values for VOC and HCl are below detectable limits at
all monitoring including the plant area. The observed values are found to be
within the prescribed NAAQ standards. Graphical representation of ambient air
quality is presented in Figure 3.11.
Table 3.11 Summary Ambient Air Quality Status
Pollutant Maximum Minimum Mean 98 Percentile
1) Location: site
PM10 46 40 43.12 46
PM2.5 22 18 19.81 22
SO2 10 8 9.15 10
NOx 12 10 10.98 12
VOC (in PPM) 6.3 0.3 2.8 6.0
HCl 2.4 1.1 1.8 2.2
2) Location: Keshavadasupeta
PM10 45 39 41.62 45
PM2.5 20 18 19.08 20
SO2 10 9 9.54 10
NOx 12 10 11.31 12
VOC (in PPM) 2.2 0.3 2.1 2.1
HCl 1.1 0.7 1.2 1.0
3) Location: Chilakapalem
PM10 47 42 44.04 47
PM2.5 21 17 19.54 21
SO2 11 8 9.73 11
NOx 13 10 11.68 13
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL
4) Location: Pattusalipeta
PM10 43 36 39.12 43
PM2.5 23 19 20.77 23
SO2 11 9 10.04 11
NOx 13 11 11.96 13
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL
5) Location: Allinagaram
PM10 45 40 42.42 45
PM2.5 21 17 18.65 21
SO2 9 7 8.38 9
NOx 11 8 10.06 11
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL
6) Location: Narsapuram
PM10 42 37 39.50 42
PM2.5 18 15 16.00 18

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Pollutant Maximum Minimum Mean 98 Percentile

SO2 10 8 9.27 10
NOx 12 10 11.12 12
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL
7) Location: Echerla
PM10 50 44 47.12 50
PM2.5 23 20 21.77 23
SO2 12 10 11.46 12
NOx 14 12 13.75 14
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL
8) Location: Neliveda
PM10 49 43 45.92 49
PM2.5 24 20 22.42 24
SO2 13 11 12.19 13
NOx 16 13 14.63 16
VOC (in PPM) BDL BDL BDL BDL
HCl BDL BDL BDL BDL

Figure 3.11 Graphs Showing the Results of Ambient Air Quality

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Table 3.12 Air Quality Index of AAQ Data

S.No Location AQI AQI Category Associated Health Impacts
Index (Range)
AAQ-1 Site 49
AAQ-2 Keshavadasupeta 45
AAQ-3 Chilakapalem 47
AAQ-4 Pattusalipeta 43 Good
Minimal Impact
AAQ-5 Allinagaram 45 (0-50)
AAQ-6 Narsapuram 42
AAQ-7 Echerla 50
AAQ-8 Neliveda 49

3.4.7 Noise Environment

Noise is an unwanted sound without musical quality. Artificial noise and its impact
on environment, grown apace with advancing human civilization. Noise pollution is
equally hazardous to environment as air, water and other forms of pollution.
Various noise measurement units have been introduced to describe, in a single
number, the response of an average human to a complex sound made up of various
frequencies at different loudness levels. The most common scale is, weighted decibel
dB(A), and measured as the relative intensity level of one sound with respect to
another sound (reference sound).

Impact of noise levels depend on its characteristics (instantaneous, intermittent or

continuous in nature), time of day (day or night) and location of noise source. Table
3.13 shows the effects of different noise levels on human beings. The environmental
impact of noise can have several effects varying from noise induced hearing loss to
annoying, depending on noise levels.

The assessment of noise pollution on neighborhood environment due to the plant

area was carried out keeping in view, all the considerations mentioned above. The
existing status of noise levels is measured at ninelocations at various villages within
the study area. Figure 3.12 presents noise level monitoring locations. The
monitored noise levels are shown in Table 3.14. Noise levels are observed to be with
inthe prescribed limits of rural and residential areas.

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Figure 3.12 Noise Sampling Locations

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Table 3.13 Effects on Human Beings at Different Noise Levels

Source Noise Effects
LevelB(A)
Large Rocket Engine (near by) 180 Threshold of Pains
Hydraulic Press ( 1 m ) 130
Jet take off (60 m) 120 Maximum vocal effort possible
Automobile Horn (1m) 120
Construction Noise (3m) 110
Jet Take off (600 m) 110
Shout, Punch, Press, Circular Saw 100 Very annoying
Heavy Truck (15m), Farm Machinery 90 Prolonged exposure
Endangers Lathes, Sports Car, Noisy
Machines hearing loss
Automobile (15m) 80 Annoying
Freeway Traffic (15m) 70 Telephone is difficult, intrusive
Loud Conversations 60
Living Room in Home 50 Quiet
Power Station (15m) 50
Bed Room in Home 40
Soft Whisper (5m) 30 Very quiet
Tick of Wall clock (1m) 30
Low radio Reception 20
Whisper 20
Rattling of Leaves by Breeze 10 Barely audible
0 Threshold of hearing

Table 3.14 Equivalent Noise levels in the study area (Terms of Reference No. 6(vii))
Direction Distance Equivalent Noise Levels dB(A)
Location w.r.t plant from Plant
Leq day Leqnight
site site, km
Site - - 51 41
Keshavadasupeta NW 0.3 48 33
Chilakapalem E 0.4 49 34
Pattusalipeta SW 1.5 46 33
Allinagaram SE 1.4 47 32
Narsapuram NW 1.9 49 31
Echerla NE 2.0 48 34
Neliveda NE 2.8 47 32

3.4.8 Traffic Study (Terms of Reference No. 6(ix))

Traffic study was conducted during three alternative days including a holiday to
arrive at peal traffic hours. Peak traffic was observed during 8 – 9 AM consisting of
mainly passangers traffic is 618 PCU. Graphical representation of peak hour traffic is
presented in Figure 3.13.

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Figure 3.13 Peak Hour Traffic

3.5 Socio Economic Environment (Terms of Reference No. 6(xi))

Industrial development reflects in social development, i.e., growth in infrastructure

facilities, growth in employment rates, increased demands for housing, and other
amenities etc., which will have a bearing on the socio-economic status.

Socio-economic survey is conducted to ascertain the existing socio-economic status to

compare the same with the developments due to the project. Baseline data of
demographic characteristics- occupational status, literacy, health status and the
access to infrastructure facilities for social development in the project area has been
studied from the secondary data collected from census department by Team Labs
and Consultants.

Demographic characteristics of the study area falling within 10 km radius of the

project site have been compiled to assess the pre-project socio-economic status.
Secondary data has been collected from various government agencies i.e., chief
planning officer, Srikakulam district and other government departments of forestry,
irrigation etc., and Mandal Development Offices of the relevant government
departments. Census 2011 was complied and presented as follows;

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3.6 Demography
The study area falls under the following mandals of Srikakulam district; Etcherla,
Laveru and Ponduru in Andhra Pradesh. Study area comprises of 90 revenue villages
and 18 hamlets.

3.6.1 Population Distribution

The population distribution of the study area is presented in Table 3.15. The
population density in the study area is less reflecting the rural nature and lack of
irrigation facilities. The total population of the area is 191865 consisting of 97457
males and 94408 females. The population density in this area reflects the rural area.
The population of the scheduled castes is 20889 consisting of 10588 males and 10301
females, while the scheduled tribe population is 758 consisting of 403 males and 355
females, which is 10.89 and 0.4% of the total population respectively.
Table 3.15 Population Distribution – Study Area
Category kms Total
0-3 3-5 5-7 7-10
Total Population 11314 29414 25435 125702 191865
Total Population – Male 5718 15056 13116 63567 97457
Total Population – Female 5596 14358 12319 62135 94408
Population <6 years 1365 2958 2656 13799 20778
Male <6 years 699 1481 1363 7106 10649
Females < 6years 666 1477 1293 6693 10129
Scheduled Caste Population - Total 1546 2942 3229 13172 20889
Male – SC 787 1520 1584 6697 10588
Female – SC 759 1422 1645 6475 10301
Scheduled Tribe Population Total 24 99 147 488 758
Male – ST 13 56 78 256 403
Female – ST 11 43 69 232 355

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Figure 3.14 Population distribution of the Study Area

3.6.1.1 Literacy
Census operations consider a literate as a person who is above six years old and who
can write and read as per the census. Table 3.16 presents the literacy levels in the
study area. The population below six years old is 20778 consisting of 10649 males
and 10129 females, which is 10.83 % of the study area population. The percentage of
literacy level in the study area among males is 65.7 and 46.6 among females of total
polulation. It may be observed that the literacy level among females is comparatively
less than males.

Table 3.16 Literacy Study Area

Category kms Total
0-3 3-5 5-7 7-10
Total Population 11314 29414 25435 125702 191865
Total Population – Male 5718 15056 13116 63567 97457
Total Population – Female 5596 14358 12319 62135 94408
Population <6 years 1365 2958 2656 13799 20778
Male <6 years 699 1481 1363 7106 10649
Females < 6years 666 1477 1293 6693 10129
Total Literates 5597 15491 13608 61634 96330
Male –Literates 3209 9150 8200 36490 57049
Female – Literates 2388 6341 5408 25144 39281
Total Illiterates 5717 13923 11827 64068 95535
Male –Illiterate 2509 5906 4916 27077 40408
Female – Illiterate 3208 8017 6911 36991 55127

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Figure 3.15 Literacy of Study Area

Figure 3.15 Literacy Study Area

3.6.1.2 Employment/Occupation
Work is defined as participation in any economically productive activity -
Physical/mental. The work force is classified into three categories: a) main workers,
b) marginal workers and c) non-workers. Main workers are those who work for a
substantial part of the year for a living such as salaried employees, agricultural labor
etc. Marginal workers are those who worked the previous year but have not worked
for a substantial part of this year. Non-workers constitute students, house wives,
dependents, pensioners etc. Table 3.17 presents the population distribution for
employment.

It may be observed that a majority of the study area population falls in the non
worker category among 50.75 % of the total population and the marginal workers
from about 13.1% of the total population. The male female difference is also
significant in all the regions and in all the categories. There are few females among
the workers where as there are more non workers and marginal workers among
females.
Table 3.17 Employment - Study Area
Category kms Total
0-3 3-5 5-7 7-10
Total Population 11314 29414 25435 125702 191865
Total Population – Male 5718 15056 13116 63567 97457
Total Population – Female 5596 14358 12319 62135 94408

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Total Workers 5117 13484 12033 63867 94501

Total Workers – Male 3298 8305 7377 37095 56075
Total Workers – Female 1819 5179 4656 26772 38426
Total Main Workers 3442 10348 9769 45882 69441
Main workers – Male 2528 6879 6540 29746 45693
Main Workers – Female 914 3469 3229 16136 23748
Total Marginal Workers 1675 3136 2264 17985 25060
Marginal Workers – Male 770 1426 837 7349 10382
Marginal Workers – Female 905 1710 1427 10636 14678
Total Non-Workers 6197 15930 13402 61835 97364
Non-Workers – Male 2420 6751 5739 26472 41382
Non-Workers – Female 3777 9179 7663 35363 55982

The main workers are further classified into; Total cultivators: those who engage a
single worker or his family member to cultivate land for payment in money, kind or
share; Agricultural labor : those who work in other’s lands for wages; household
workers: workers involved in manufacturing and processing industries in the house
hold industries; and other services; Livestock, forestry, fishing and allied activities;
Workers involved in mining and quarrying; Workers involved in manufacturing and
processing industries in the house hold industries; non house hold industries;
construction workers; workers in trade and commerce; workers involved in
transport, storage and communication ; and other services: government employees,
teachers, priests, artists etc. Table 3.18 presents the main workers distribution
among the study area population. It may be observed that over 19% of the study area
population is involved in cultivation or agriculture labor, followed by other services
to the tune of 13.82%. It may also be observed that the people involved in non
household industry are significantly more reflecting on the industrial nature of the
area. Significant differences are observed among the male and female workers,
Female workers are found to be more in agricultural activity largely due to more
percentage of females being agricultural labor.
Table 3.18 Main workers Study Area
Category kms Total
0-3 3-5 5-7 7-10
Total Population 11314 29414 25435 125702 191865
Total Population – Male 5718 15056 13116 63567 97457
Total Population – Female 5596 14358 12319 62135 94408
Total Main Workers 3442 10348 9769 45882 69441
Main workers – Male 2528 6879 6540 29746 45693

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Main Workers – Female 914 3469 3229 16136 23748

Total Cultivators 217 1488 1351 7140 10196
Cultivators – Male 167 1076 961 5159 7363
Cultivators- Female 50 412 390 1981 2833
Total Agriculture Labor 1546 5352 5309 21422 33629
Agriculture Labor – Male 942 2898 3012 11500 18352
Agriculture Labor – Female 604 2454 2297 9922 15277
Total Household Workers 155 214 181 1754 2304
Household Workers – Male 112 149 98 1050 1409
Household Workers – Female 43 65 83 704 895
Total Others 1524 3294 2928 15566 23312
Others – Male 1307 2756 2469 12037 18569
Others – Female 217 538 459 3529 4743

Figure 3.16 Employment - Study Area

3.6.1.3 Living Standards and Infrastructure

Sustainable development of any area is dependent not only the population but also
on the availability of infrastructure which leads to better living standards. The
infrastructure facilities are essential in providing education, awareness, health,
communication, potable water, transport etc. The standards of living are the sum of
the availability of the infrastructure to the subject community, wide variations in
terms of income, economic conditions and patterns of spending.

The infrastructure facilities available in the impact zone are reflecting the rural
nature of the entire study area.

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I. Educational Facilities
The educational facilities available in the rural areas are meager, despite the
proximity to urban area of Vijayanagaram. There are 134 primary schools, 29
middle schools and 2 high schools in the study area. There is one junior college in
the area. Five of the villages in the study area do not have any educational facilities.
The higher educational need of the population is met by Ranastalam, Pusapatirega
and Sathivada. Vizianagaram and Srikakulam has a number of engineering colleges,
PG colleges, Junior colleges and degree colleges, apart from a Maharajah's Institute of
Medical Sciences, Vizianagaram and Andhra University Campus, Vizianagaram. The
ditrict capital Vizianagaram caters to the educational needs of surrounding areas as
far as 70 kms.

II. Health facilities

The medical and health facilities available in the impact zone are inadequate; there
are five PHC, twenty-seven PHS and no child welfare centers and 1 RP centre in the
entire area. The health needs of the population in this area are met by quacks and
other semi qualified persons.

III. Availability of Potable Water

The entire population in this area is dependent on ground water for drinking purposes.
There are no protected water supply schemes in all the villages except in 3 villages.
About 14 villages in the study area are dependent on tube wells, while the remaining
villages are dependent on wells and hand pumps.

IV. Transport and Communication

Transport is essentially provided by the Andhra Pradesh State Road Transport
Corporation (APSRTC). Most of the study area has excellent road network in all the
villages except in one village, which has kacha roads. APSRTC bus facility is
available for the all the villages. However, it is observed that a number of private
transport vehicles are observed in the area connecting them to Vizianagaram,
Ranastalam.

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V. Sources of Energy and Availability

The primary source of energy in the study area is electricity, and the entire study
area has electricity for agriculture and domestic purpose. The urban areas have LPG
facility for their cooking purpose. A significant number of people in the urban area
are also dependent on Kerosene for cooking purposes, which is contingent on the
vagaries of public distribution system. A majority of the rural area is mostly
dependent on Kerosene, dried cow dung cakes, wood from roadside trees for their
domestic energy needs.

VI. Post and Telegraph facilities

There are 5 post offices in the area and two post and Telegraph office in the study area.
Phone facilities however are extended to some of the villages.

VII. Housing
Census defines the house hold as a group of persons living together and sharing their
meals from a common kitchen. The number of households in the impact zone is
33945, while the number of the houses is 33864. The density of the households is
approximately five. The traditional houses made up of mud walls and covered by
dry common grass and leaves of bourses are commonly found in the rural area,
which are not considered pucca houses. The government has been augmenting the
housing standards by constructing housing colonies for various weaker sections of
the society.

3.6.2 Land Utilization

Land use patterns can be prepared on the basis of revenue records though it is not an
exact indicator of the actual use of the land at a given time. Land use is presented
under the heads of area under forest cover irrigated land, area under cultivation and
cultivable wasteland in Table 3.19
Table 3.19 Land Utilization Pattern
Category km Total
0-3 3-5 5-7 7-10 Area, Ha
Area under Non-Agricultural 248.67 338.72 411.33 1679.22 2677.94
Uses
Barren & Un-cultivable Land 281.42 304.65 1893.85 2479.92
Area
Permanent Pastures and 0.03 102 110 204.85 416.88

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Other Grazing Land Area

Land Under Miscellaneous 111.41 148.43 65.18 286.78 611.8
Tree Crops etc. Area
Culturable Waste Land Area 31.14 107.08 274.37 1304.12 1716.71
Fallows Land other than 7.85 203.24 280.92 492.01
Current Fallows Area
Current Fallows Area 86.07 269.45 183.88 815.2 1354.6
Net Area Sown 1477.68 3862.05 3837.35 17762.06 26939.14
Area Irrigated by Source 191.99 1109.74 1240.85 5850.77 8393.35
Total 2146.99 6226.74 6630.85 30077.77 45082.35

3.6.3 Project Economy

M/s. NACL Industries Limited, proposed to expansion of Arochemicals
manufacturing capacity and inclusion of bio-based agrochemicals and Captive Co-
generation Power Plant over an area of 100 acres at Sy. No. 177, Arinama Akkivalasa
village, Etcherla mandal, Srikakulam district, Andhra Pradesh. There is a potential
for direct/indirect employment of about 200 people during operation phase and
60during construction phase due to the proposed expansion. The project shall have
positive impact on socioeconomic environment due to provision of employment both
direct and indirect and proposed CER activities. The employers will contribute to the
provident fund, ESI and provide facilities as per the relevant labor act.

The proximity of Srikakulam will provide access to extensive medical facilities

available apart from the ESI medical facilities to the employees and their families.
An industrial Canteen is established by the company.

It may be concluded that satisfactory amenities are available for the population of the
impact zone, while the amenities are available either within the village or at a
minimum distance of 5 km. The chemical complex has been contributing to the
industrial growth of the area, which in turn; generates employment, and improve the
infrastructure facilities of the area by strengthening the same economically.

3.7 Flora and Fauna (Terms of Reference No. 6(x))

The study was carried out in project site and study area i.e., 10.0 km periphery from
the project site. The study was carried out scientifically using primary and secondary
data in order to bring out factual information on the ecological conditions of the
project site and its surroundings. Biological assessment of the site was done to

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identify the presence of any Rare or Endangered or Endemic or Threatened (REET)

species of flora or fauna in the project site as well its impact area to identify whether
there are any ecologically sensitive area within the area that is likely to be impacted.
The study also designed to suggest suitable mitigation measures if necessary, for
protection of wild life habitats conservation of REET species if any.

Objectives of the Study

The basic objectives of the study are to evaluate the status of the flora and fauna of the
project site and surrounding area with specific reference to the rare or endangered or
endemic or threatened (REET) species. The study is also designed to evaluate the
adverse impacts of the proposed project activity, if any and to suggest
remedial/mitigation measures in accordance with the objectives as desired by the IAIA
and the Ministry of Environment, Forests and Climate Change (MOEFCC),
Government of India (GOI). With these objectives in mind, the following work was
undertaken by a team of experienced professionals:

Methods of study
1. Baseline data of Terrestrial and Aquatic biological environment by studying
distribution pattern, community structure, population dynamics and species
composition of Flora and Fauna. Secondary data is collected from various sources.
2. Areas used by protected, important or sensitive species of Flora or Fauna for
breeding, nesting, foraging, resting, over wintering, migration shall be as
ascertained.
3. Photo documentation of the flora and fauna including local habitats showing the
ecological status of the project site.
4. Discussing the predicted impacts by the proposed activity with local villagers and
EIA functional area experts on air, water, noise and other pollutants.
5. Impacts quantification through vegetation analysis.
6. Preparation of the mitigation measures if applicable.

Survey Types used

1. Reconnaissance survey (Near Agricultural, water bodies, Human habitations and
Road side) to list out general flora and fauna.

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2. Quadrate and Line transact methods for quantification of flora.

3. Direct & indirect observations for fauna.
4. Point count method for birds near water bodies.

Methodology
A reconnaissance survey has been made randomly to observe the critical habitats to
study in detail. General interviews were made with local people on native animals and
medicinal plants used frequently. A thorough review was made at each sampling point
and spent about 20-30 minutes at each point. The present environmental condition is
observed at site area and adjoining areas.

A detailed survey of flora and fauna was carried out during the study period. Field
visits are personally carried by expert members. The project details were collected from
EIA coordinator and discussed the possible impacts of the project on flora and fauna.
Secondary data collected from the GIS division especially the maps related to Land use
and Land cover, forest type, forest cover, villages / settlements, road, rail network etc.
The total area was analyzed in detail and with GIS tools and marked around 12
sampling points by covering the various ecosystems of impact area in all the directions.
Only photographs were taken during the field survey and no damage is created to flora
and fauna during the sampling. Specimens were not collected and preserved.

Equipment / Instruments deployed

➢ Digital Camera (NIKON P510)
➢ Binoculars
➢ GPS (Garmin)
➢ Measuring tape
➢ Field observation book & data forms

Floral study
Quadrate method has been used for carryout the study of trees, shrubs, herbs and
grasses. 20 m X 20 m Quadrates for tree species, 5 m X 5 m quadrates for shrubs and 1
m X 1 m quadrates for herbs. Statistical analysis is made for 10 sampling points.
Species were compared with standard floras and identifying the plants need for
conservation. The status of the each species was represented by common, sporadic or

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rare. The data was compared with the list mentioned in red data book to check REET
species.

Ecological parameters viz., abundance, density, frequency, Relative abundance (RA),

Relative density (RD), Relative frequency (RF), Important value index (IVI), Shannon-
Wiener diversity index were derived from the quantitative primary data collected
during field survey.

Importance Value Index (IVI): RD + RF +RA

Species Diversity
Shannon Diversity Index (H’) has been used for estimating the diversity among the site
area and adjoining areas in order to know the species richness and dorminance.
H’= -  Pi. ln Pi
S= Number of individuals of one species
Where Pi = --------------------------------------------------------
N = Total number of all individuals in the sample
ln = logarithm to the base “e”
Communities with less number of species with high level of dominance or low level of
uniformity will have lower diversity. Thus it is a statistical function based on the
richness and evenness components. Evenness and dominance are inversely related. This
can be also calculated through Statistical Software “PAST”.

Faunal study
A detailed study has been carried out for faunal species by direct and indirect methods.
Direct sightings were made for aves, reptiles and insects and secondary data on
mammals was collected from local villagers. Bird surveys were carried out through
point count method at dawn and desk near water bodies. These techniques are accepted
in EIA studies as per the EIA Notification of 2006. The species sighted were
photographed and identified with standard pictorial guides. Scheduling of species was
done according to Wild life (Protection act) 1972 and IUCN is done for each species and
checked the REET species. No quantitative data was calculated as some species are
listed through secondary source. As the animals were migratory, habitats used by
protected, important or sensitive species for breeding, nesting, foraging, resting, over
wintering, migration were ascertained.

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Rationale for Survey Method

The present proposed project site is within the existing industry. The number of
quadrants finalized after taking Area species curve. The wastes and other pollution
related aspects are also studied to know the impacts. The landuse and land cover,
hydrogeology aspects and soil factors are also considered while studying the impacts.
The sampling points are taken in all the directions and ecosystems along with the wind
direction pattern.

Identification of Species
Species of flora and fauna are identified through local field guides. Unidentified plants
are taken pictures and later confirmed by BSI, ZSI and forest officials.

Secondary Data
List of flora and fauna from Forest Department, Previous studies for EIA and other
NGOs research in the study area and local villager’s information was taken into
consideration while preparing the list and other parts of the report.

The species specific literature is also gathered and checked with primary data.
Flora: Forest department working plan
Within the project site the area is totally covered with small herbs and grass varieties.
The proposed project falls in
❖ 6D – Deccan Peninsula Deccan Plateau as per the Biogeography Classification of
India.
❖ Hot Semi arid type as per the India's Köppen climate classification.
The vegetation of the study area falls under
✓ 5A:Southern tropical dry deciduous forests C3: Southern dry mixed deciduous
forest;
✓ 6A: Southern tropical thorn forests DS1: Southern thorn scrub, 2S1: Secondary dry

deciduous forest by revised classification of Indian forest types (Champion and Seth, 1968).
These types of forests are seen throughout the Eastern Ghats and few parts of Western Ghats of
the country.

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The proposed project site does not encounter with any kind of forest types like Reserve
Forest, Protected forest or un- classed Forest (declared Protected under “The Indian
Forest Act, 1927”) and “Forest (Conservation) Act, 1980 with Amendments Made in
1988”. (Source: Forest Department). Further no tree cutting is involved in the project as
there is no vegetation at all within this project site. Thus, no forest Clearance is required
for the proposed development. There are no Scheduled species recorded within the
proposed construction site.

Wetland
No wetland notified under “The Ramsar Convention – 1971” or listed under “the
National wetland Conservation Programme – 2009” is reported within 10 km from
project boundary.

Within the Site

The priliminary studies reveal that there are more natural as well as planted species of flora
inside the industry. The natural species includes Coconut, Palm trees, Borassus, Neem, Ficus
benghalensis, Ficus microcorpe and more number of climbers and grass species. The shrubs
include Calotropis and Datura stramonium. Ground flora is dominant with common grass varities.
Near the plantation zone, Cressa cretica, Ipomea prescarpe are predominant. These two speices
generally occur near sea shores. Cressa cretica is used as medicinal plant and cultivated. This
species is a perennial halophyte (Hemicryptophyte) that lives in salty oases or in seasonally wet
depressions in wet sandy areas, including such as temporary pools and marshes. The proposed
unit is within the plant and need not to clear any type of vegetation.

Among the trees found in the core area, Ficus religiosa, Ficus bengahalensis and Acacia
nilotica are represented by more than a couple of individuals in the entire core area
while others like Azadirachta indica, Butea monosperma, Ponagamia pinnata, Leucaena
leucocephala are represented by few plants only. It is represented by sparse thorny scrub
vegetation in between the fallow agriculture land. The major part of the study area is
devoid of large trees except Azadiracta indica, Borassus and Phoenix and mainly consists
of scattered and sparse shrubs i.e. Euphorbia caducifolia, Balanites aegyptiaca, Opuntia
dillenii, Prosopis juliflora, Casia auriculata and Zizyphus numularia the major grasses
include several species of Cyperus and herbs such as Euphorbia hirta, Tridax procumbance.
Within the core zone a huge number of Anacardium species with an average GBH of 132

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cm and up to 9 m tall. In the remaining patch Clerodndron inerme, Calotropis procera, Sida
acuta, Ziziphus nummularia, Lantana camera, Parthenium histerophorus are sporadically
scattered. There are no rare or endangered or endemic or threatened (REET) plants in
the core area. There are no forests or wild life sanctuaries or biosphere reserves or
nesting or breeding grounds for any of the rare species or other protected areas within
the core area. The project site is not situated within or adjacent to any cultural heritage
sites, protected areas, site area and adjoining area of protected areas, or special areas for
protecting biodiversity. As such the area identified for the existing Cement plant site is
not ecologically sensitive.

The proposed site is with manmade ecosystem with few selected trees, shrubs and
herbs. Entire area is with terrestrial vegetation is without any forest or agriculture land
and it was devoid of any ecologically sensitive biological resources. There are no REET
species present in the core zone. No migratory corridors or breeding grounds for faunal
species present here.

The common butterflies, Honey bees, dragonflies, birds were sighted here. Within the
site, certain trees such as Polyalthia longifolia, Peltophorum pterocarpum, Azadiracta indica,
Terminalia catappa and Palm trees near the entrance and other ornamental species and hedge
species raised in the site.

The faunal composition generally with arboreal and semi arboreal based animals. Some
very common small animals like Squirrels, rats, skinks and lizards are generally found
here. In aves, only spotted doves and blue rock pigeons are seen. Butterflies are fairly
attracted to the ornamental plants and water present on grasses.

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Dodonaea viscosa Carissa spinarum

Barleria prionitis
Carissa carandas

Cressa cretica Dactyloctenium aegyptium

The faunal composition was also estimated based on the direct and indirect evidences.
Eucalyptus globules, Casuarina equisetifolia, Thespecia populnea, Delonix regia, Dalbergia
sisso, Pongamia pinnata and Polyalthia longifolia, Phoenix aculis, Borassus flabellifera,
Azadirachta indica, Prosopis spicegera, Ficus sp, Acacia sp, Tribulus terrstris, Achyranthus
aspera, Euphorbia caudifolia, E. tirucelli, Opuntia are mainly restricted to waste and
culturable waste lands. Albizia procera, Albizia lebbeck, Delonix regia, Azadirchta indcia,

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Peltoforum sp., Terminalia catapa, Psidium guava, Dalbergia sisso and Tamarindus indica are
predominant near surrounding villages.

Endemic, Threatened and Endangered Plant Species

In the floristic checklist, the study area shows rich floristic diversity. Number of floral
species in the study area are 155. A good number of species are commercially cultivated
in orchards. Number of plant species have medicinal value and also important for other
non-timber produces. From the present survey it appears that none of the endangered
plant species exist in the study area.

Vegetation structure
Trees: The most common tree species occurring are Pongamia pinnata, Polyalthia
longifolia, Albizia lebbeck, Bauhinia purpurea, Casuarina equisetifolia, Eucalyptus globulus,
Bauhinia purpurea, Plumeria alba, Ficus benghalensis, Azadirachta indica, Phoenix sylvestris,
Alstonia scholaris, Acacia auriculiformis, Pithecellobium dulce, Caesalpinia pulcherrima, Ficus
microcape, Grewia hirsuta, Peltophorum pterocarpum, Anacardium occidentale and Bambusa
arundinacea.

Shrubs: The most common shrubs are Lantana camera, Hyptis suaveolens, Cassia
auriculata, Calotropis procera, Prosopis juliflora, Acacia leucocephala, Catunaregam spinosa,
Caesalpinia bonducella, Canthium parviflorum, Carissa carandas, Capparis sepiaria, Celastrus
paniculata.

Herbs: The most common herbs are Tridax procumbens, Cassia occidentalis, Crotan
bonplantianum, Datura metel, Eclipta alba, Boerhavia diffusa, Tephrocia purpuria, Achyranthes
aspera. Cassia tora, Abutilon indicum Ipomoea macrantha

Climbers: The commonly seen climbers are Capparis horrida Abrus precatorius,
Hemidesmus indicus, Clitoria ternatea, Cuscuta reflexa, Desmodium triflorum, Pergularia
daemia, Desrris scandans, Hemidesmus indicus, Ipomoea pes-caprae, Ipomoea nil, Ipomoea
macrantha, Mucuna pruriens, Evolvulous alsinoides, Gloriosa superba.

Grasses: The common grass species are Chloris barbata, Cyperus castaneus, and Cynodon
dactylon Dactyloctenium aegyptium, Digitaria ciliaris, Eragrostis tenella, Fimbristylis cymosa,
Ilaloipsis binata and Imperata cylindrica.

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Table 3.20 List of Floral Species (* primary data)

S.No Scientific Name Family Habit Status
1* Acacia auriculiformis Leguminosae Tree Common
2* Acacia chundra Mimosaceae Tree Common
3* Acacia leucophloea Leguminosae Tree Common
4 Acacia nilotica Leguminosae Tree Common
5* Acacia pennata Leguminosae Tree Common
6 Ailanthus excelsa Simaroubaceae Tree Rare
7* Ailanthus triphysa Simaroubaceae Tree Rare
8 Alangium salviifolium Cornaceae Tree Rare
9* Albizia amara Leguminosae Tree Common
10 Albizia lebbeck Leguminosae Tree Common
11* Alstonia scholaris Apocynaceae Tree Common
12* Anacardium occidentale Anacardiaceae Tree Common
13* Annona squamosa Annonaceae Tree Common
14 Antidesma diandrum Euphorbiaceae Tree Common
15* Artocarpus heterophyllus Moraceae Tree Common
16 Atlantia monophilla Rutaceae Tree Common
17* Azadirachta indica Meliaceae Tree Common
18 Bambusa arundinacea Poaceae Tree Common
19* Baringtonia acutangula Barringtoniaceae Tree Common
20 Bauhinia purpurea Leguminosae Tree Common
21* Bauhinia racemosa Leguminosae Tree Common
22* Bauhinia retusa Leguminosae Tree Sparse
23* Bauhinia variegata Leguminosae Tree Sparse
24* Borassus flabellifer Arecaceae Tree Common
25* Bridelia tomentosa Euphorbiaceae Tree Common
26 Butea monosperma Leguminosae Tree Sparse
27* Caesalpinia pulcherrima Fabaceae Tree Common
28 Canthium dicoccum Rubiaceae Tree Sparse
29* Cassia fistula Leguminosae Tree Common
30 Cassia siamea Leguminosae Tree Common
31 Casuarina equisetifolia Casuarinaceae Tree Common
32 Cedreala toona Meliaceae Tree Rare
33 Ceiba pentandra Malvaceae Tree Common
34 Chloroxylon swietenia Meliaceae Tree Sparse
35* Cipadessa fruiticosa Meliaceae Tree Rare
36* Cocos nucifera Arecaceae Tree Common
37* Cordia myxa Ehretiaceae Tree Rare
38* Cretaeva religiosa Capparidaceae Tree Rare
39 Dalbergia paniculata Leguminosae Tree Common
40* Dalbergia sissoo Leguminosae Tree Common
41 Dalbergia spinosa Leguminosae Tree Common
42 Delonix regia Leguminosae Tree Common
43* Dichrostachys cinerea Leguminosae Tree Sparse
44* Diospyrous clyloroxylon Ebenaceae Tree Sparse
45* Diospyrous crispa Ebenaceae Tree Sparse
46* Diospyrous ferrea Ebenaceae Tree Sparse
47 Diospyrous montana Ebenaceae Tree Sparse

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S.No Scientific Name Family Habit Status

48 Diospyrous sylvatica Ebenaceae Tree Sparse
49* Elaeodendron glaucum Celastraceae Tree Rare
50* Erythroxylon monogynum Linaceae Tree Sparse
51* Eucalyptus globulus Myrtaceae Tree Common
52* Ficus benghalensis Moraceae Tree Common
53* Ficus hispida Moraceae Tree Sparse
54 Ficus microcape Moraceae Tree Common
55 Ficus racemosa Moraceae Tree Common
56* Ficus religiosa Moraceae Tree Common
57 Ficus retusa Moraceae Tree Common
58* Ficus tomentosa Moraceae Tree Rare
59 Ficus tsiela Moraceae Tree Rare
60* Garcinia spicata Clusiaceae Tree Rare
61 Gmelina arborea Lamiaceae Tree Sparse
62 Gmelina asiatica Verbenaceae Tree Sparse
63* Grewia hirsuta Tiliaceae Tree Common
64 Grewia laevigata Tiliaceae Tree Common
65 Grewia pilosa Tiliaceae Tree Common
66* Grewia tiliaefolia Tiliaceae Tree Common
67* Gymnosporia spinosa Celastraceae Tree Sparse
68* Helectres isora Sterculiaceae Tree Sparse
69 Holarrhena antidysenterica Apocynaceae Tree Sparse
70 Hymenodycton excelsum Rubiaceae Tree Sparse
71 Lannea coromandalica Anacardiaceae Tree Common
72* Leucaena leucocephala Leguminosae Tree Common
73* Limonia acidissima Rutaceae Tree Sparse
74* Mangifera indica Anacardiaceae Tree Common
75* Manikera hexandra Sapotaceae Tree Common
76 Mimosops elangi Sapotaceae Tree Common
77 Morinda tinctoria Rubiaceae Tree Common
78* Moringa oleifera Moringaceae Tree Common
79 Murraya paniculata Rutaceae Tree Common
80* Nerium odoratum Apocynaceae Tree Common
81 Ochna jabotapita Ochnaceae Tree Sparse
82* Peltophorum pterocarpum Leguminosae Tree Common
83* Petrospermum suberifolium Sterculiaceae Tree Rare
84* Phoenix sylvestris Arecaceae Tree Common
85* Phyllanthus emblica Phyllanthaceae Tree Sparse
86 Pithecellobium dulce Leguminosae Tree Common
87* Plumeria alba Apocynaceae Tree Common
88* Plumeria rubra Apocynaceae Tree Sparse
89 Polyalthia cerasoides Annonaceae Tree Rare
90 Polyalthia longifolia Annonaceae Tree Common
91* Pongamia pinnata Leguminosae Tree Common
92* Prosopis chilensis Leguminosae Tree Common
93* Prosopis juliflora Leguminosae Tree Sparse
94* Pterocarpus marsupium Leguminosae Tree Sparse
95 Pterolobium indicum Caesalpinaceae Tree Sparse

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S.No Scientific Name Family Habit Status

96* Samanea saman Sapindaceae Tree Common
97 Sapindus emerginatus Sapindaceae Tree Common
98* Semecarpus anacardium Anacardiaceae Tree Sparse
99* Spondias mangifera Anacardiaceae Tree Sparse
100 Streblus asper Moraceae Tree Sparse
101 Syzygium cumini Myrtaceae Tree Common
102* Tamarindus indica Leguminosae Tree Common
103 Tecoma stans Bignoniaceae Tree Common
104* Tectona grandis Lamiaceae Tree Common
105 Terminalia arjuna Combretaceae Tree Common
106* Terminalia bellarica Combretaceae Tree Common
107* Terminalia catappa Combretaceae Tree Sparse
108* Terminalia chebula Combretaceae Tree Common
109 Thespesia populnea Malvaceae Tree Common
110* Vitex negundo Verbenaceae Tree Sparse
111* Wrightia tinctoria Apocynaceae Tree Sparse
112* Ziziphus mauritiana Rhamnaceae Tree Common
113 Ziziphus xylopyrus Rhamnaceae Tree Common
114* Acacia intsia Mimosodeae Shrub Rare
115* Acanthus ilicifolius Acanthaceae Shrub Sparse
116* Agave americana Asparagaceae Shrub Sparse
117* Caesalpinia bonducella Caesalpinaceae Shrub Common
118* Calotropis procera Apocynaceae Shrub Common
119* Canthium parviflorum Rubiaceae Shrub Sparse
120 Capparis sepiaria Capparidaceae Shrub Sparse
121* Carissa carandas Apocynaceae Shrub Common
122 Carissa spinarum Apocynaceae Shrub Common
123 Casearia tomentosa Flacourtiaceae Shrub Rare
124* Cassia auriculata Leguminosae Shrub Common
125 Celastrus paniculata Celastraceae Shrub Sparse
126* Clerodendrum infortunatum Verbenaceae Shrub Sparse
127* Dodonaea viscosa Sapindaceae Shrub Common
128* Euphorbia cactus Euphorbiaceae Shrub Common
129 Euphorbia lactea Euphorbiaceae Shrub Common
130 Euphorbia nivulia Euphorbiaceae Shrub Sparse
131 Euphorbia tirucalli Euphorbiaceae Shrub Common
132* Euphorbia trigona Euphorbiaceae Shrub Common
133 Flacourtia ramontchi Flacourtiaceae Shrub Common
134* Flacourtia sepiaria Fabaceae Shrub Common
135* Glycosmis pentaphylla Rutaceae Shrub Common
136 Hugonia mystax Linaceae Shrub Common
137* Ipomoea carnea Convolvulaceae Shrub Common
138* Ixora coccinea Rubiaceae Shrub Sparse
139* Jasminum cuspidatum Oleaceae Shrub Sparse
140 Jasminum roxburghianum Oleaceae Shrub Common
141* Jatropha glandulifera Euphorbiaceae Shrub Sparse
142* Lantana camara Verbenaceae Shrub Common
143* Memecylan edule Melastromaceae Shrub Rare

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S.No Scientific Name Family Habit Status

144* Mimosa pudica Mimosodeae Shrub Sparse
145* Opuntia dillenii Cactaceae Shrub Common
146 Opuntia elatior Cactaceae Shrub Common
147* Pandanus fascicularis Pandanaceae Shrub Rare
148 Parkinsonia aculeata Leguminosae Shrub Rare
149 Pavetta indica Rubiaceae Shrub Sparse
150* Randia dumetorum Rubiaceae Shrub Common
151 Randia malabarica Rubiaceae Shrub Common
152* Salvadora persica Salvadoraceae Shrub Sparse
153 Tarenna asiatica Rubiaceae Shrub Sparse
154* Vernonia divergens Asteraceae Shrub Sparse
155* Xanthium indicum Asteraceae Shrub Rare
156* Xanthium strumarium Asteraceae Shrub Rare
157 Ziziphus oenopolia Rhamnaceae Shrub Common
158 Ammannia baccifera Lythraceae Hydrophyte Common
159 Aponogeton natans Aponogetonaceae Hydrophyte Sparse
160* Azolla pinnata Salviniaceae Hydrophyte Common
161 Eichornia crassipes Pontederiaceae Hydrophyte Sparse
162 Hydrilla verticillata Hydrocharitaceae Hydrophyte Common
163* Ipomoea aquatica Convolvulaceae Hydrophyte Rare
164* Lemna minor Araceae Hydrophyte Common
165 Limnophila Plantaginaceae Hydrophyte Rare
166 Marsilea quadrifolia Marsileaceae Hydrophyte Common
167* Nelumbo nucifera Nelumbonaceae Hydrophyte Common
168 Neptunia oleracea Leguminosae Hydrophyte Sparse
169 Nymphaea pubescens Nymphaeaceae Hydrophyte Rare
170 Nymphoides hydrophylla Menyanthaceae Hydrophyte Rare
171* Operculina turpethum Convolvulaceae Hydrophyte Common
172* Pistia Araceae Hydrophyte Common
173* Typha angustata Typhaceae Hydrophyte Common
174 Vallisneria Hydrocharitaceae Hydrophyte Sparse
175* Abutilon indicum Malvaceae Herb Common
176* Acalypha indica Euphorbiaceae Herb Common
177* Achyranthes aspera Amaranthaceae Herb Common
178* Aerva lanata Amaranthaceae Herb Common
179 Ageratum conyzoides Asteraceae Herb Sparse
180* Alternanthera sessilis Amaranthaceae Herb Common
181 Alysicarpus heterophyllus Fabaceae Herb Rare
182 Amaranthus spinosus Amaranthaceae Herb Common
183 Amaranthus viridis Amaranthaceae Herb Common
184* Argemone mexicana Papaveraceae Herb Common
185 Barleria prionitis Acanthaceae Herb Sparse
186* Blepharis maderaspatensis Acanthaceae Herb Common
187 Blumea mollis Asteraceae Herb Common
188 Boerhavia diffusa Nyctaginaceae Herb Common
189 Boerhavia erecta Nyctaginaceae Herb Common
190 Caralluma umbellata Apocynaceae Herb Sparse
191* Cassia occidentalis Leguminosae Herb Common

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S.No Scientific Name Family Habit Status

192 Cassia tora Leguminosae Herb Common
193* Catharanthus roseus Apocynaceae Herb Sparse
194* Cleome viscosa Cleomaceae Herb Common
195* Colius aromaticus Lamiaceae Herb Sparse
196 Commelina benghalensis Commelinaceae Herb Common
197 Corchorus trilocularis Malvaceae Herb Sparse
198* Cressa cretica Convolvulaceae Herb Common
199 Crotalaria retusa Leguminosae Herb Sparse
200 Crotalaria verrucosa Leguminosae Herb Common
201* Croton bonplandianus Euphorbiaceae Herb Common
202* Datura metel Solanaceae Herb Rare
203* Datura stramonium Solanaceae Herb Common
204* Eclipta alba Asteraceae Herb Sparse
205* Euphorbia hirta Euphorbiaceae Herb Common
206* Euphorbia pulcherima Euphorbiaceae Herb Rare
207 Hyptis suaveolens Lamiaceae Herb Common
208* Indigofera linnaei Leguminosae Herb Sparse
209 Leucas aspera Lamiaceae Herb Common
210 Leucas cephalotes Lamiaceae Herb Rare
211 Ludwigia perennis Onagraceae Herb Common
212* Mimosa pudica Leguminosae Herb Sparse
213 Mollugo cerviana Molluginaceae Herb Rare
214 Mollugo nudicaulis Molluginaceae Herb Common
215* Ocimum sanctum Lamiaceae Herb Common
216* Oldenlandia umbellata Rubiaceae Herb Sparse
217 Oxalis corniculata Oxalidaceae Herb Sparse
218* Parthenium hysterophorus Asteraceae Herb Common
219* Pavonia zeylanica Malvaceae Herb Sparse
220 Pedalium murex Pedaliaceae Herb Common
221* Phyllanthus amarus Phyllanthaceae Herb Common
222 Phyllanthus virgatus Phyllanthaceae Herb Rare
223 Physalis minima Solanaceae Herb Sparse
224 Portulaca quadrifida Portulacaceae Herb Common
225 Rhynchosia beddomei Leguminosae Herb Sparse
226* Salicornia brachiata Chenopodiaceae Herb Common
227* Sesamum alatum Pedaliaceae Herb Common
228* Sida acuta Malvaceae Herb Common
229* Sida cordifolia Malvaceae Herb Common
230* Sida spinosa Malvaceae Herb Sparse
231* Solanum nigrum Solanaceae Herb Common
232* Solanum surattense Solanaceae Herb Common
233* Spermacoce stricta Rubiaceae Herb Sparse
234 Sphaeranthus indicus Asteraceae Herb Sparse
235 Striga angustifolia Orobanchaceae Herb Sparse
236* Trichodesma indicum Boraginaceae Herb Rare
237* Tridax procumbens Asteraceae Herb Common
238* Triumfetta pentandra Malvaceae Herb Sparse
239* Urena lobata Malvaceae Herb Common

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S.No Scientific Name Family Habit Status

240* Waltheria indica Malvaceae Herb Sparse
241* Zizyphus nummularia Rhamnaceae Herb Common
242 Andropogon contortus Poaceae Grass Common
243* Aristida setacea Poaceae Grass Common
244* Brachiaria eruciformis Poaceae Grass Common
245 Chloris barbata Poaceae Grass Common
246* Chrysopogan montanus Poaceae Grass Common
247 Cymbopogon citratus Poaceae Grass Sparse
248 Cymbopogon martini Poaceae Grass Sparse
249* Cyperus flavidus Cyperaceae Grass Common
250* Cyperus rotundus Cyperaceae Grass Common
251* Dactyloctenium aegyptium Poaceae Grass Rare
252* Digitaria ciliaris Poaceae Grass Common
253* Eragrostis tenella Poaceae Grass Rare
254 Fimbristylis cymosa Cyperaceae Grass Common
255* Ilaloipsis binata Poaceae Grass Common
256* Imperata cylindrica Poaceae Grass Common
257* Ischaemum pilosum Poaceae Grass Common
258* Phragmites karka Poaceae Grass Common
259 Saccharum spontaneum Poaceae Grass Common
260 Schima nervosum Poaceae Grass Common
261* Spinifex littoreus Poaceae Grass Common
262 Trachys muricata Poaceae Grass Sparse
263* Zizania latifolia Poaceae Grass Common
264 Abrus precatorius Leguminosae Climber Common
265 Aristolochia bracteata Aristolochiaceae Climber Rare
266* Asparagus racemosus Asparagaceae Climber Sparse
267 Capparis horrida Capparidaceae Climber Common
268* Cardiospermum halicacabum Sapindaceae Climber Rare
269* Cissus quadrangularis Vitaceae Climber Common
270* Cissus quadrangularis Vitaceae Climber Sparse
271* Clitoria ternatea Leguminosae Climber Common
272* Coccinia grandis Cucurbitaceae Climber Rare
273* Cuscuta reflexa Cuscutaceae Climber Common
274 Desmodium triflorum Leguminosae Climber Common
275 Desrris scandans Fabaceae Climber Common
276* Dioscorea hispida Dioscoreaceae Climber Rare
277 Evolvulous alsinoides Convolvulaceae Climber Common
278* Gloriosa suparba Liliaceae Climber Rare
279* Hemidesmus indicus Asclepiadaceae Climber Common
280 Ichnocarpus frutescens Liliaceae Climber Rare
281* Ipomoea hederifolia Convolvulaceae Climber Rare
282 Ipomoea macrantha Convolvulaceae Climber Common
283 Ipomoea nil Convolvulaceae Climber Common
284 Ipomoea obscura Convolvulaceae Climber Common
285 Ipomoea pes-caprae Convolvulaceae Climber Common
286* Leptadenia reticulata Asclepiadaceae Climber Sparse
287 Luffa cylindrica Cucurbitaceae Climber Rare

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S.No Scientific Name Family Habit Status

288 Merremia tridentata Convolvulaceae Climber Rare
289* Mimisa rubicailis Mimosaceae Climber Common
290* Mucuna pruriens Fabaceae Climber Sparse
291* Oxystelma esculentum Apocynaceae Climber Sparse
292 Pergularia daemia Apocynaceae Climber Common
293* Plumbago zeylanica Plumbaginaceae Climber Rare
294 Smilax zylanicum Smilcaceae Climber Rare
295* Tinospora cardifolia Minispermiaceae Climber Rare
296* Vanda tessellata Orchidaceae Climber Sparse

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Fauna within studya area

There common mongoose, Squirrels are sighted apart from few reptilian species. From
the secondary source (local people working in the plant) it is also revealed that presence
of jackals and snakes exists here.
Avifaunal diversity
Common bird species such as Herons, Paddy egrets, Green bee eaters, Indian rollers,
Parakeets, White headed babblers, Weaver birds, Mynas, Black drangos, Crows,
Sparrows are sighted here.
List of Mammals
S.No. Scientific Name Common Name WPA Status IUCN
1 Bendicota bengalensis Indian mole rat LC
2 Bendicota indica Bandicoot rat LC
3 Mus booduga Little Indian Field mouse LC
4 Mus musculus House Mouse LC
5 Rattus rattus House rat LC
6 Cynopterus sphinx Short-Nosed Fruit Bat Schedule V LC
7 Rousettus leschnaulti Fruit bat Schedule V
8 Funambulus palmarum Three striped palm squirrel LC
9 Herpestes edwardsii Indian grey Mongoose Part II of Schedule
II LC
10 Sus scrofa Wild pig
11 Felis chaus Jungle cat LC
12 Viverricula indica Civet Cat LC
13 Vulpes bengalensis Common Fox LC
14 Lepus nigricollis Black-naped Hare S-IV LC
15 Macaca mulatta Macaque Rhesus LC
16 Semnopithecus entellus Part II of Schedule
Deccan Hanuman Langur II LC

Aves
All the listed birds are Least Concern under IUCN and Schedule - IV under Wild life
(Protection Act) 1972
S. No Scientific Name Common Name I - WPA IUCN
1 Accipiter badius Crested Shikra (Indian Shikra) S-IV LC
2 Accipiter nisus Eurasian Sparrow Hawk S-IV LC
3 Accipiter virgatus Besra Sparrow Hawk S-IV LC
4 Acridotheres ginginianus Bank Myna S-IV LC
5 Acridotheres tristis Common Myna S-IV LC
6 Acrocephalus agricola Paddy Field Warbler S-IV LC
7 Acrocephalus stentoreus Reed Warbler S-IV LC
8 Actitis hypoleucos Common Sandpiper S-IV LC
9 Alcedo atthis Small blue Kingfisher S-IV LC
10 Allauda gulugula Eastern-Sky lark S-IV LC

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S. No Scientific Name Common Name I - WPA IUCN

11 Amaurornis phoenicurus White Breasted water hen S-IV LC
12 Ammemamea phoenicurus Rufous tailed Finch lark S-IV LC
13 Anas acuta Northern Pintail S-IV LC
14 Anastomus oscitans Asian Open bill Stork S-IV LC
15 Anhinga melanogaster Darter or Snake Bird S-IV LC
16 Anthus rufulus Paddy filed pipit S-IV LC
17 Apus affinis House Swift S-IV LC
18 Ardea alba Large Egrets S-IV LC
19 Ardea cinerea Grey Heron S-IV LC
20 Ardea intermedia Medium Egret S-IV LC
21 Ardea purpurea Purple Heron S-IV LC
22 Ardeola grayii Indian Pond Heron S-IV LC
23 Artamus fuscus Ashy Swallow Shrike S-IV LC
24 Athene brama Spotted Owlet S-IV LC
25 Aythya ferina Common Pochard S-IV LC
26 Bubulcus ibis Cattle Egret S-IV LC
27 Calandrella raytal Indian Short-toed lark S-IV LC
28 Calidris ferruginea Curlew sand piper S-IV LC
29 Calidris minuta Little Stint S-IV LC
30 Calidris temminckii Temminck's Stint S-IV LC
31 Casmerodius albus Large Egret S-IV LC
32 Centropus parroti Southern Coucal S-IV LC
33 Centropus sinensis Crow Pheasant S-IV LC
34 Ceryle rudis Lesser Pied Kingfisher S-IV LC
35 Cettia major Chestnut-crowned Bush Warbler S-IV LC
36 Charadrius alexandrinus Kentish Plovers S-IV LC
37 Charadrius hiaticula Common Ringed Plover S-IV LC
38 Charadrius leschenaultia Sand Plover S-IV LC
39 Chroicocephalus ridibundus Black Headed Gull S-IV LC
40 Cinnyris asiaticus Purple Sunbird S-IV LC
41 Circus aeruginosus Eurasian Marsh Harrier S-IV LC
42 Cisticola juncidis Streaked Fantail Warbler S-IV LC
43 Clamator jacobinus Pied Crested Cuckoo S-IV LC
44 Columba livia Blue Rock Pigeon S-IV LC
45 Copsychus saularis Oriental Magpie Robin S-IV LC
46 Coracana novachollandiae Large Cuckoo Shrike S-IV LC
47 Coracias benghalensis Indian Roller S-IV LC
48 Corvus Macrorhynchos Jungle Crow S-IV LC
49 Corvus splendens House Crow S-IV LC
50 Cuculus micropterus Indian Cuckoo S-IV LC
51 Cyornis tickelliae Tickell’s Blue-Flycatcher S-IV LC
52 Cypsiurus balasiensis Asian Palm Swift S-IV LC
53 Delichon urbicum Northern House Martin S-IV LC
54 Dendrocitta vagabunda Rufous Treepie S-IV LC
55 Dendrocygna javanica Lesser whistling- Duck S-IV LC
56 Dicrurus caerulescens White-Bellied Drango S-IV LC
57 Dicrurus macrocercus Black Drongo S-IV LC
58 Dinopium benghalense Lesser Golden backed S-IV LC

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S. No Scientific Name Common Name I - WPA IUCN

Woodpecker
59 Dumetia hyperythra Rufus-bellied Babbler S-IV LC
60 Egretta garzetta Little Egret S-IV LC
61 Egretta garzetta Western Reef Egret S-IV LC
62 Egretta intermedia Smaller Egret S-IV LC
63 Elanus caeruleus Black Winged Kite S-IV LC
64 Eremopterix grisea Ashy-crowned sparrow-lark S-IV LC
65 Eudynamys scolopacea Asian Koel S-IV LC
66 Euodice malabarica White Throated Munia S-IV LC
67 Falco tinnunculus Common kestrel S-IV LC
68 Francolinus pondicerianus Grey Patridge S-IV LC
69 Fulica atra Common Coot S-IV LC
70 Galerida cristata Common Crested Lark S-IV LC
71 Gallicrex cinerea Water Cock S-IV LC
72 Gallinago gallinago Common Snipe S-IV LC
73 Gallinula chloropus Common(Indian) Moorhen S-IV LC
74 Gelochelidon nilotica Gull-billed Tern S-IV LC
75 Gracupica contra Asian Pied starling S-IV LC
76 Halcyon smyrnensis White breasted kingfisher S-IV LC
77 Haliaeetus leucogaster White bellied sea eagle S-IV LC
78 Haliastur Indus Brahamimy Kite S-IV LC
79 Himantopus himantopus Black-winged Stilt S-IV LC
80 Hirundo daurica Red Rumped Swallows S-IV LC
81 Hirundo rustica Common Swallow S-IV LC
82 Hydrophasianus chirurgus Pheasant Tailed Jacana S-IV LC
83 Ixobrychus sinensis Yellow Bittern S-IV LC
84 Lanius cristatus Brown shrike S-IV LC
85 Lanius schach Long tailed shrike S-IV LC
86 Lanius schach Rufus Backed Shrike S-IV LC
87 Lanius vittatus Bay-backed Shrike S-IV LC
88 Larus brunnicephalus Brown Headed Gull S-IV LC
89 leptocoma zeylonica Purple Rumped Sunbird S-IV LC
90 Lonchura atricapilla Black Headed Munia S-IV LC
91 Lonchura punctulata Scaly-breasted munia S-IV LC
92 Lonchura punctulata Spotted Munia S-IV LC
93 Megalaima haemacephala Coppersmith Barbet S-IV LC
94 Merops orientalis Small Bee-eater S-IV LC
95 Metopidius indicus Bronze-winged Jacana S-IV LC
96 Milvus migrans Black kite(Pariah Kite) S-IV LC
97 Mirafra erythroptera Red-winged Bush-lark S-IV LC
98 Monticola solitaries Blue Rock Thrush S-IV LC
99 Motacilla alba White wagtail S-IV LC
100 Motacilla cinerea Grey Wagtail S-IV LC
101 Motacilla citreola Yellow Headed Wagtail S-IV LC
103 Motacilla flava Yellow wagtail S-IV LC
102 Motacilla flava Yellow Wagtail S-IV LC
Pied wagtail/ White browed
104 Motacilla maderaspatensis wagtail S-IV LC

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S. No Scientific Name Common Name I - WPA IUCN

105 Mycteria leucocephala Painted Stork S-IV LC
106 Nectarinia asiatica Purple Sunbird S-IV LC
107 Nectarinia zeylonica Purple-Rumped Sunbird S-IV LC
109 Nettapus coromandelianus Cotton Teal S-IV LC
108 Nettapus coromandelianus Cotton Pygmy-goose S-IV LC
110 Numenius arquata Eurasian curlew S-IV LC
111 Numenius phaeopus whimbrel S-IV LC
112 Nyctyornis athertoni Blue tailed Bee eaters S-IV LC
113 Ocyceros birostris Grey Hornbills S-IV LC
114 Oriolus oriolus Eurasian golden oriole S-IV LC
115 Orthotomus sutorius Common Tailor Bird S-IV LC
116 Passer domesticus House Sparrow S-IV LC
117 Pellorneum ruficeps Spotted Babbler S-IV LC
118 Phalacrocorax carbo Cormorant Great S-IV LC
119 Phalacrocorax niger Little Cormorant S-IV LC
120 Phylloscopus maculipennis Ashy Warblers S-IV LC
121 Podieceps cristatus Great crested Grebe S-IV LC
122 Polceus philippinus Baya Weaver S-IV LC
123 Porphyrio porphyrio Purple Moorhen S-IV LC
124 Prina socialis Ashy Prinia S-IV LC
125 Prinia hodgsonii Grey Breasted Prinia S-IV LC
126 Psittacula eupatria Alexandrian parakeet S-IV LC
127 Psittacula krameri Rose Ringed Parakeet S-IV LC
128 Pycnonotus cafer Red vented Bulbul S-IV LC
129 Saxicola caprata Pied Bush Chat S-IV LC
130 Saxicoloides fulicata Indian Robin S-IV LC
131 Sterna acuticauda Black billed Tern S-IV LC
132 Sterna albifrons Little Tern S-IV LC
133 Sterna aurantia Indian river tern S-IV LC
134 Sterna hirundo Common Terns S-IV LC
135 Streptopelia chinensis Spotted Dove S-IV LC
136 Streptopelia decaocto Eurasian Collared Dove S-IV LC
137 Streptopelia orientalis Spoted dove S-IV LC
138 Streptopelia senegalensis Laughing Dove S-IV LC
139 Streptopelia turtur Turtle Doves S-IV LC
140 Stur nus roseus Rosy Starling(Rosy Pastor) S-IV LC
141 Sturnia pagodarum Brahminy Starlings S-IV LC
142 Sturnus contra Asian Pied Starling(Pied Myna) S-IV LC
143 Sturnus Malabaricus Grey Headed Starling( Myna) S-IV LC
144 Sturnus vulgaris Common Starling S-IV LC
145 Surniculus lugubris Drongo Cuckoo S-IV LC
146 Tachybaptus ruficollis Little Grebe S-IV LC
147 Tadona ferruginea Brahaminy Shelduck (Duck) S-IV LC
148 Tephrodornis pondiceria Common Wood Shrike S-IV LC
149 Terpsiphone paradise Asian Paradise-Flycatcher S-IV LC
150 Tringa glareola Wood Sandpiper S-IV LC
151 Tringa ochropus Green sandpiper S-IV LC
152 Turdoides caudatus Common Babbler S-IV LC

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S. No Scientific Name Common Name I - WPA IUCN

153 Turdoides malcolmi Large Grey Babblers S-IV LC
154 Turdoides striata Jungle Babbler S-IV LC
155 Upupa epops Common Hoopoe S-IV LC
SIV- Schedule IV

Reptiles
S.No Scientific Name Common Name IWPA IUCN
1 Calotes versicolor Common Garden Lizard LC
2 Sitana ponticeriana Fan-throated lizard LC
3 Calotes rouxi Forest Calottes LC
4 Chameleo zylanicus Chameleon S-II LC
5 Dendrelaphis tristis Common Indian Bronze back LC
6 Lycodon aulicus Common Wolf Snake LC
7 Ptyas mucosa Indian Rat Snake S-II LC
8 Ahaetulla nasutus Common green tree Snake LC
9 Enhydris enhydris Common Smooth Water Snake LC
10 Macropisthodon plumbicolor Green keel back LC
11 Xenochrophis piscator Checkered Keel back S-II LC
12 Bungarus caeruleus Common Indian Krait LC
13 Hemidactylus brooki Brook’s Gecko LC
14 Hemidactylus flaviviridis Northern house Gecko LC
15 Mabuya carinata Common Skink LC
16 Varanus bengalensis Indian Monitoring Lizard S-II LC
17 Vipera ruselli Russell’s viper S-II LC
18 Naja naja Indian Cobra S-II LC
19 Ophiophagus hannah King cobra S-II LC
20 Echis carinatus Saw scaled viper LC

Amphians
S.No Scientific Name Common Name Family Status IWPA
1 Bufo melanostictus Common Indian Bufonidae LC S-IV
Toad
2 Euphlyctis cyanophlyctis Skittering Frog Ranidae LC S-IV
3 Euphlyctis hexadactylus Indian Pond Frog Ranidae LC S-IV
4 Hoplobatrachus tigerinus Indian Bull Frog Ranidae LC S-IV
5 Polypedates maculates Common Tree Frog Rhocophoridae LC S-IV

Fishes
Taxonomic composition of fish fauna from Secondary source
SNo. Scientific Name Common Name Population IUCN CAMP
Status Status Status
1 Notopterus notopterus Grey feather back C LC LRnt
2 Catla catla Catla A VU LRnt
3 Labeo ariza Reba carp C LC NE
4 Labeo rohita Rohu A LC LRnt

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SNo. Scientific Name Common Name Population IUCN CAMP

Status Status Status
5 Labeo calbasu Black rohu M LC LRnt
6 Cirrhinus mrigala Mrigal C LC LRnt
7 Cirrhinus reba Reba carp C LC VU
8 Ctenopharyngodon idella grass carp M LC NE
9 Cyprinus carpio Common carp M VU NE
10 Hypophthalmichthys molitrix Silver carp M NT DD
11 Osteobrama cotio cotio Cotio A LC LRnt
12 Puntius chola Swamp barb A LC VU
13 Puntius ticto Ticto barb C LC LRnt
14 Puntius sarana Olive barb C LC VU
15 Puntius sophore Spot-fin swamp A LC LRnt
barb
16 Puntius terio Onespot barb C LC LRnt
17 Puntius dorsalis Long snouted barb C LC EN
18 Puntius pethia gelius Golden barb C LC NE
19 Rasbora daniconius Slender rasbora M LC LRnt
20 Salmostoma bacaila Large razorbelly A LC LRlc
minnow
21 Salmostoma phulo Fine scale razor C NE NE
belly minnow
22 Amblypharyngodon microlepis Indian carplet A LC NE
23 Amblypharyngodon Mola carplet A LC LRlc
microlepismola
24 Danio devario Devario danio, C EN NE
25 Schistura corica Polka Dotted R LC NE
26 Aplocheilus panchax Blue panchax C LC DD
27 Mystus bleeker Day’s mystus A LC VU
28 Mystus cavasius Gangetic mystus A LC LRnt
29 Mystus gulio Long C LC NE
WhiskersCatfish
30 Mystus tengara Tengara mystus A LC NE
31 Mystus vittatus Striped A LC VU
dwarfcatfish
32 Ompok bimaculatus Butter Catfish M NT EN
33 Ompok pabda Pabdah catfish R NT EN
34 Wallago attu Boal M NT LRnt
35 Pangasius pangasius Pangas catfish R LC NE
36 Eutropiichthys vacha Air R LC VU
breathingcatfishes
37 Clarias batrachus Batchwa vacha C LC VU
38 Clarias gariepinus African catfish R NE NE
39 Heteropneustes fossilis Stinging catfish R LC VU
40 Anguilla bengalensis Indian Long fin eel M LC EN
41 Xenentodon cancila Freshwater garfish A LC LRnt
42 Channa orienalis Walking snakehead C NE VU
43 Channa panctatus Giant snakehead C LC LRnt
44 Channa striatus Bandedsnakehead C LC LR-Ic

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SNo. Scientific Name Common Name Population IUCN CAMP

Status Status Status
45 Mastacembelus aral R LC LRnt
46 Mastacembelus armatus Zig zag spiny eel M LC VU
47 Mastacembelus pancalus Barred spiny eel A LC LRnt
48 Glossogobius giuris Tank/Bar-eyed A LC LRnt
goby
49 Gobiopsis macrostoma Long Jawed goby R NE NE
50 Trichogaster faciatus Banded gaurami M LC LRnt
51 Oreochromis mossambicus Mozambique C NT NE
Tilapia
52 Anabas testudineus Climbing perch M DD VU
53 Etroplus maculatus Ornage chromid A LC NE
54 Chanda nama Elongate glass C LC NE
perchlet
55 Ambassis ranga Indian glassy C LC NE
A= Abundant (76-100%); C = Common (51-75%); M = Moderate (26-50%); R = Rare (1-25%)
EN- Endangered; VU- Vulnerable: LRnt- Lower risk near threatened; LRlc- Lower risk least
concern; LC- Least concern; DD- Data Deficient; NE- Not evaluated, NT: Near threaten.

Invertebrates
S. No. Scientific Name Common Name Family
1 Acraea violae Tawny Coster Nymphalidae
2 Anax guttatus Dragon fly Aeshnidae
3 Anax immaculifrons Dragon fly Aeshnidae
4 Appias albina darada Common Albatross Pieridae
5 Badamia exclamationis Brown Awl Hesperiidae
6 Belenois aurota aurota Indian Pioneer Pieridae
7 Borbo bevani Bevan's Swift Hesperiidae
8 Borbo cinnara Rice Swift Hesperiidae
9 Brachythemis contaminata Dragon fly Libellulidae
10 Castalius rosimon rosimon Continental Common Pierrot Lycaenidae
11 Catochrysops strabo strabo Oriental Forget-me-not Lycaenidae
12 Catopsilia pyranthe pyranthe Mottled Emigrant Pieridae
13 Catopsilia crocale Lemon Emigrant Pieridae
14 Cepora nerissa nerissa Common Gull Pieridae
15 Chilades lajus lajus Indian Lime Blue Lycaenidae
Himalyan Dark Clouded
Colias fieldii fieldii Pieridae
16 Yellow
17 Colotis danae danae Crimson Tip Pieridae
18 Colotis etrida Small Orange Tip Pieridae
19 Colotis eucharis eucharis Plain Orange Tip Pieridae
20 Crocothemis servilia servilia Dragon fly Libellulidae
21 Curetis thetis Indian Sunbeam Lycaenidae
22 Danaus chrysippus chrysippus Plain Tiger Nymphalidae
23 Danaus genutia genutia Striped Tiger Nymphalidae
24 Delias eucharis Common Jezebel Pieridae
25 Diplacodes trivialis Dragon fly Libellulidae
26 Euchrysops cnejus cnejus Oriental Gram Blue Lycaenidae

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S. No. Scientific Name Common Name Family

27 Euploea core core Common Crow Nymphalidae
28 Eurema brigitta rubella Red-line Small Grass Yellow Pieridae
Oriental Common Grass
Eurema hecabe simulata Pieridae
29 Yellow
30 Euthalia aconthea meridionalis Baron Nymphalidae
31 Everes lacturnus syntala Dakhan Cupid Lycaenidae
32 Freyeria trochylus trochylus African Grass Jewel Lycaenidae
33 Graphium agamemnon menides Dakhan Tailed Jay Papilionidae
34 Graphium nomius nomius Indian Spot Sword Tail Papilionidae
35 Graphium sarpedon teredon Dakhan Blue Bottle Papilionidae
36 Hasora chromus chromus Oriental Banded Awl Hesperiidae
37 Hypolimnas bolina jacintha Oriental Great Eggfly Nymphalidae
38 Hypolimnas misippus Danaid Eggfly Nymphalidae
39 Ictinogomphus rapax Damsel fly Gomphidae
40 Ischnura senegalensis Damsel fly Coenagronidae
41 Ixias marianne White Orange Tip Pieridae
42 Ixias pyrene sesia Yellow Orange Tip Pieridae
43 Jamides celeno celeno Oriental Common Cerulean Lycaenidae
44 Junonia almana almana Oriental Peacock Pansy Nymphalidae
45 Junonia hierta hierta Oriental Yellow Pansy Nymphalidae
46 Junonia iphita iphita Oriental Chocolate Pansy Nymphalidae
47 Junonia lemonias lemonias Chinese Lemon Pansy Nymphalidae
48 Junonia orithya ocyale Dark Blue Pansy Nymphalidae
49 Leptotes plinius plinius Asian Zebra Blue Lycaenidae
Oriental Common Evening
Melanitis leda leda Nymphalidae
50 Brown
51 Melanitis phedima bela Dark Evening Brown Nymphalidae
Himalian Great Evening
Melanitis zitenius zitenius Nymphalidae
52 Brown
53 Moduza procris undifragus Commander Nymphalidae
54 Neptis hylas varmona Common Sailer Nymphalidae
55 Pachliopta hector Crimson Rose Papilionidae
56 Papilio demoleus Lime Butterfly Papilionidae
57 Papilio polytes polytes Common Mormon (polytes) Papilionidae
58 Papilio polytes romulus Common Mormon (romulus) Papilionidae
59 Papilio polytes stichius Common Mormon (stichius) Papilionidae
60 Pareronia valeria hippia Common Wanderer Pieridae
61 Phalanta phalantha phalantha Common Leopard Nymphalidae
62 Polyura athamas athamas Common Nawab Nymphalidae
63 Prosotas nora Common Line Blue Lycaenidae
64 Pseudozizeeria maha ossa Dakhan Pale Grass Blue Lycaenidae
65 Spialia galba galba Indian Grizzled Skipper Hesperiidae
66 Symphaedra nais Baronet Nymphalidae
67 Tarucus nara Rounded Pierrot Lycaenidae
68 Telicota ancilla bambusae Dark Palm Dart Hesperiidae
69 Tirumala limniace exoticus Blue Tiger Nymphalidae
70 Urothemis signata signata Dragon fly Libellulidae
71 Zizeeria karsandra Dark Grass Blue Lycaenidae

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S. No. Scientific Name Common Name Family

72 Zizina otis indica Lesser Grass Blue Lycaenidae

Identification of local Protected Species

As per Botanical Survey of India records and available published literature pertaining
to the study area and current detailed study of project site, no threatened, endangered
and rare plant species were observed from the study area. The topomap indicating the
absence of National park, Sanctuary, Elephant/Tiger Reserve, Migratory routes/ Wild
life corridor with in 10 km radius indicates that this region is not ecologically very
significant. As per the Wild life (Protection Act) 1972, those animals, which have been
enlisted in the schedules of the Act, have been presented below. The schedules are
based on the species namely, rare, endangered, threatened, vulnerable etc. According
to threat of extinction Schedule-I contains those species which need topmost priority,
while II, III, IV and V have lesser degree of threat. Most of the avi-fauna has been listed
in Schedule–IV. As per the list of avi-faunal species, these are mostly local migrant
species only.
Table 3.21 Threatened and Endangered Animal Species
Herpestes javanicus Common Indian Mongoose Part II of Schedule II LC
Semnopithecus entellus Deccan Hanuman Langur Part-II of Sch-II LC
Chameleo zylanicus Chameleon S-II LC
Ptyas mucosa Indian Rat Snake S-II LC
Xenochrophis piscator Checkered Keel back S-II LC
Varanus bengalensis Indian Monitoring Lizard S-II LC
Vipera ruselli Russell’s viper S-II LC
Naja naja Indian Cobra S-II LC
Ophiophagus hannah King cobra S-II LC

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CHAPTER 4.0 ANTICIPATED ENVIRONMENTAL IMPACTS &

MITIGATION MEASURES

4.1 Identification of Impacts

Identification of impacts is one of the basic analytical steps of EIA for subsequent
prediction and evaluation of impacts. Impact is a change in baseline due to interaction
of a development activity with environment, or interaction of environment with
development activity, or change in baseline due to a manmade emergency or a natural
disaster. The impacts were assessed for construction stage, operation stage, emergency
scenarios and decommissioning stage for the proposed expansion of NACL Industries
Limited. The conceptual site model of Agrochemicals manufacturing activity is presented
in Fig 4.1 and typical effects of technical grade pesticide manufacturing activity is
presented in Fig 4.2.

The interaction of project expansion activity on the environment was assessed by posing
questions related to each aspect of project activity envisaged as part of proposed
expansion of the plant, to identify valued eco components. After broad identification of
impacts, an interaction table enumerating the activity vs factors of various environmental
components was prepared for various stages of project implementation considering the
entire life cycle of construction, operation and decommissioning. The operational stage
was considered for both regular operation and for incidents and emergencies caused by
both human errors and extreme weather phenomena. The critical aspects of accident
release of chlorine and chloroform are also considered.

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TRANSPORATAION OF
RAW MATERIALS AND POWER
FINISHED GOODS CONSUMPTION

UTILITIES PARKING
(BOILER, DG PRE-
SETS, HVAC)
TREATMENT PROCESS BLOCKS

EFFLUENT SOLID WASTE

TREATMENT SOLID WASTE WAREHOUSE TANK FARM
STORAGE
TOP SOIL WATER TABLE

WATER WITHDRAWL

Fig 4.1 Conceptual Model of Agrochemicals

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Fig 4.2 Conceptual Model of Impacts Effects due to Manufacturing Activity

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4.1.1 Impact Networks

The purpose of identifying the impacts is that it aids in making appropriate decision to
mitigate the adverse consequences if any. The extent and scale of impacts and the
consequences based on value judgments are generalized while identifying impacts; as it
is imperative that the impact will normally lead to a chain of reactions. Network charts
brings out to certain extent the appropriate levels of risks that may occur due to the
interventions while interacting with biophysical and social systems due to the proposed
expansion of technical grade pesticide manufacturing unit during its life time of
construction, operation and decommission including emergency scenarios both natural
and manmade. Fig 4.3 to 4.7 present the identified impacts for various components of
environment viz. air, noise, water, land and socio-economic aspects. The impact
identification matrix indicating the environmental factors anticipated to have an impact
due to the expansion and impacts due to environment on the proposed expansion are
presented in Table 4.1 to 4.4.

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Fig 4.3 Impacts on Air Environment

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Fig 4.4 Impacts on Water Environment

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Fig 4.5 Impacts on Solid waste and Soil Quality

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Fig 4.6 Noise Impact on Surrounding Environment

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Changing Out-Migration
In-Migration Tradition
and Transport Facilities
Culture
Salaries
Ease of living
Industrial
Quality of life
Activity Gender
Employment Equity
Taxes

Development of
Social Infrastructure
RM and Resources Water Stress Stress on Health
Facilities
Stress on
Housing
Traffic Demand
Impact
Business Opportunity Urban Sprawl
Stress on Municipal/ Urban Heat Island
Local body
infrastructure

Fig 4.7 Impacts on Socio-Economic on Environment

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Table 4.1 Activity and Environmental Impact (Impact Identification Matrix) - Construction Stage
Environment Abiotic Biotic Socio Others
Component Climate Atmosphere Land Water Economic
Factors

Occupational health
Noise and vibration

Waste Management
Micrometeorology

Climate Change
Socio Economic
Ground Water
Surface Water
Air quality

Fire Safety
and safety
Geology

Fauna
Flora
Soil
Activity
Construction Stage √
Clearing and Grubbing √ √ √ √ √ √ √
Leveling by way of cut and √ √ √ √ √ √ √ √ √
fill
Foundation excavation √ √ √ √ √ √ √ √
Civil Construction √ √ √ √ √ √
Equipment and machinery √ √ √ √ √
erection
Electrical installation √ √ √ √ √
plumbing and piping √ √ √ √ √
painting works √ √ √ √ √
√ Indicates Impact

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Table 4.2 Activity and Environmental Impact (Impact Identification Matrix) - Regular Operation Stage
Environment Abiotic Socio
Biotic
Component Climate Atmosphere Land Water Economic Others

Micrometeoro

Surface Water

Occupational
Management
Air quality

Fire Safety
health and
Noise and

Economic
vibration

Geology

Ground

Climate
Change
Waste
Fauna

safety
Water

Socio
Flora
logy

Soil
Factors

Activity
Operation Stage
Regular Operation √
Raw material and finished product transport √ √ √ √ √
Raw material and finished product storage √ √ √
Transfer of raw materials and products √ √ √ √
Water use √ √
Effluent generation √ √ √ √
Domestic Wastewater generation √ √ √ √
Utility emissions √ √ √ √ √ √ √ √ √ √
Process emissions √ √ √ √ √ √ √ √ √
Diffuse emissions √ √ √ √ √ √ √ √ √
Wastewater storage √ √ √ √
Solid waste transfer and storage √ √ √ √ √ √
Solvent storage and use √ √ √ √
Waste transport √ √ √ √
Effluent transfer and Treatment √ √ √ √ √ √
Wastewater Transfer and Treatment √ √ √ √ √
Emissions control √ √ √ √ √ √ √ √
Machine and Equipment Operation √ √
Solvent Recycle √ √ √ √
√ Indicates Impact

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Table 4.3 Activity and Environmental Impact (Impact Identification Matrix) - Incidents and Accidents
Environment Abiotic Biotic Socio Others
Component Climate Atmosphere Land Water Economic
Factors

Occupational health
Noise and vibration

Waste Management
Micrometeorology

Climate Change
Socio Economic
Ground Water
Surface Water
Air quality

Fire Safety
and safety
Geology

Fauna
Flora
Soil
Activity
Operation Stage
Incidents and Accidents
Spillage √ √ √ √ √ √ √ √ √ √
Fugitive emissions √ √ √ √ √ √ √
Equipment Failures √ √
Batch failures √ √
Containment failure √ √ √ √ √ √ √ √ √
Fire accidents √ √ √ √ √ √
Accidents during transport of √ √ √ √ √ √ √ √ √ √
Raw materials and products
Accidents during transport of √ √ √ √ √ √ √ √ √ √
wastes
Arson and Vandalism √ √ √ √ √ √ √ √ √
Extreme Weather phenomenon √ √ √ √ √ √ √ √ √ √ √
√ Indicates Impact

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Table 4.4 Activity and Environmental Impact (Impact Identification Matrix) – Decommissioning
Environment Abiotic Biotic Socio Others
Component Climate Atmosphere Land Water Economic
Factors

Occupational health
Noise and vibration

Waste Management
Micrometeorology

Climate Change
Socio Economic
Ground Water
Surface Water
Air quality

Fire Safety
and safety
Geology

Fauna
Flora
Soil
Activity
Plant Decommissioning √
Inventory preparation √
Transfer and disposal of chemicals √ √ √ √ √ √ √ √ √ √
Transfer and disposal of wastes √ √ √ √ √ √ √ √ √ √
Decontamination of equipment and containers √ √ √ √ √ √ √ √ √
Disposal of Equipment √ √
Dismantling of facility √ √ √ √ √ √
Demolition Waste √ √ √ √ √
Site cleanup √ √ √ √ √ √ √ √
Capping drains and locking water sources √ √ √ √ √
√ Indicates Impact

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4.2 Prediction and Assessment of Impacts

The identified impacts are assessed by posing questions related each activity of proposed
expansion and their interaction with environment during the life cycle of the
manufacturing unit i.e., construction, operation and decommissioning stages including
incident and accidents scenario during operation stage. The statutory limits of ambient
air quality, noise, emissions and discharges as mandated by the MoEFCC was considered
to classify the quantifiable impacts as acceptable or not acceptable. However, there are
few impacts that cannot be quantified, which need to be qualitatively assessed. There are
a number of methods for quantitative assessment of impacts to calculate impact
significance. The qualitative assessment of impacts require characterization with respect
to its magnitude, geographic extent, duration, frequency, reversibility, probability of
occurrence, confidence rating and impact rating. The manual published by MOEF&CC
prescribes the following process for determining the significance of impact; first, an
impact is qualified as being either negative or positive. Second, the nature of impacts such
as direct, indirect, or cumulative is determined using the impact network. Third, a scale
is used to determine the severity of the effect; for example, an impact is of low, medium,
or high significance. Accordingly, it was proposed to quantify the impacts which are a
direct result of the activities contingent on availability of reliable prediction tools. In case
quantification was not feasible, a subjective assessment of impact significance using
Rapid Impact Assessment Matrix (RIAM) was used. Rapid Impact Assessment Matrix
(RIAM) is constructed from a set of well-defined assessment criteria and a collection of
specific environmental indicators or components. The environmental indicators are
carefully chosen for the purpose of evaluating the potential impacts of the alternatives
that are being considered (Pastakia and Jensen, 1998).

4.2.1 Methodology of Rapid Impact Assessment Matrix

The RIAM is suited to EIA where a multi-disciplinary team approach is used, as it

allows for data from different sectors to be analyzed against common important criteria
within a common matrix, thus providing a clear assessment of the major impacts. With
the assessment criteria typically arrayed as the columns of the matrix and the indicators
as the rows, the cells are comprised of numbers which provide a measure of the

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expected impacts of the indicators when measured against the assessment criteria.
Technically, the assessment process is comprised of four steps that must be completed
in sequence: Step I — create a set of indicators, Step II — provide numerical values for
the indicators, Step III — compute environmental scores and Step IV — evaluate the
alternatives. RIAM is based on the knowledge that certain specific criteria are common
to all impact assessments, and by scaling these criteria it becomes possible to record the
values of the assessments made. RIAM works with both negative and positive impacts.
Not all criteria can be given the same weight, and so the criteria are divided into two
groups: those which individually are important in their impact; and those that
collectively important. The important assessment criteria fall into two groups: (A)
Criteria that are of importance to the condition, and which can individually change the
score obtained. (B) Criteria that are of value to the situation, but individually should
not be capable of changing the score obtained. The value ascribed to each of these
groups of criteria is determined by the use of a series of simple formulae. These
formulae allow the scores for the individual components to be determined on a defined
basis.
The process can be expressed:
(a1) x (a2) = aT
(b1) + (b2) + (b3) = bT
(aT) x (bT) = ES

Group (A) criteria

Importance of condition (A1)
A measure of the importance of the condition, which is assessed against the spatial
boundaries or human interests it will affect. The scales are defined:
4 = important to national/international interests
3 = important to regional/national interests
2 = important to areas immediately outside the local condition
1 = important only to the local condition
0 = no importance.

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Magnitude of change/effect (A2)

Magnitude is defined as a measure of the scale of benefit/dis-benefit of an impact or a
condition:
+ 3 = major positive benefit
+ 2 = significant improvement in status quo
+ 1 = improvement in status quo
0 = no change/status quo
- 1 = negative change to status quo
- 2 = significant negative dis-benefit or change
- 3 = major dis-benefit or change.

Group (B) criteria

Permanence (B1)
This defines whether a condition is temporary or permanent, and should be seen only
as a measure of the temporal status of the condition
1 = no change/not applicable
2 = temporary
3 = permanent.

Reversibility (B2)
This defines whether the condition can be changed and is a measure of the control over
the effect of the condition.
1 = no change/not applicable
2 = reversible
3 = irreversible.

Cumulative (B3)
This is a measure of whether the effect will have a single direct impact or whether there
will be a cumulative effect over time, or a synergistic effect with other conditions.
1 = no change/not applicable
2 = non-cumulative/single
3 = cumulative/synergistic

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Environmental components
The RIAM requires specific assessment components to be defined through a process of
scoping; and these environmental components fall into one of four categories, which
are defined as follows:

Physical/chemical: Covering all physical and chemical aspects of the environment,

including finite (non-biological) natural resources, and degradation of the physical
environment by pollution.

Biological / ecological: Covering all biological aspects of the environment, including

renewable natural resources, conservation of biodiversity, species interactions, and
pollution of the biosphere.

Sociological / cultural: Covering all human aspects of the environment, including social
issues affecting individuals and communities; together with cultural aspects, including
conservation of heritage, and human development.

Economic / operational: To qualitatively identify the economic consequences of

environmental change, both temporary and permanent, as well as the complexities of
project management within the context of the project activities. The use of these four
categories can be, in itself, a competent tool for EIA, though each category can be further
sub-divided to identify specific environmental components that better demonstrate the
possible impacts. The degree of sensitivity and detail of the system can thus be
controlled by the selection and definition process for these environmental components.
Criteria for Significance of Impacts based on Environmental Scores
Environmental Score Range Description of Range Bands
Bands
+72 to +108 +E Major Positive Change/Impacts
+36 to + 71 +D Significant Positive Change/Impacts
+19 to + 35 +C Moderately positive change/impacts
+10 to + 18 +B Positive Change/Impacts
+1 to +9 +A Slightly Positive Change/impacts
0 N No Change/status quo/not applicable
-1 to -9 -A Slightly Negative Change/impacts
-10 to - 18 -B Negative Change/Impacts
-19 to - 35 -C Moderately negative change/impacts
-36 to -71 -D Significant negative change/impacts

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-72 to -108 -E Major negative change/impacts

4.2.2Air Environment
The sources of air pollution from proposed expansion are utility emissions, process
emission, emissions from pollution control facilities, and storages in addition to diffuse
emissions during equipment operation and fugitive emissions due to equipment failures,
containment failures and spillages. The direct impact of utility emissions from boilers
and DG sets consists of particulate matter, sulfur dioxide, and oxides of nitrogen resulting
in change in criteria air contaminants in ambient air quality. The process emissions and
other emissions are hazardous and may result in change in health of the receptors both
flora, and fauna including humans. The adoption of adequate mitigation measures shall
reduce the impact to low levels. Storage of solvents may also lead to diffuse emissions
unless adequate mitigation measures like breather valves, double lined storage and
condensers are adopted.

The quantifiable impacts on air environment are predicted using various air quality
impact prediction models for utility emissions and diffuse emissions due to handling and
operation of solvents. The impact prediction for accident scenarios is addressed in
consequence analysis of risk assessment chapter. All these emissions impact air quality
negatively, resulting in health impacts indirectly. The anticipated impacts on air
environment are presented in Table 4.5 and, Table 4.6 presents significance of each
impact based on RIAM.

The impact assessment indicates that the proposed expansion of agrochemicals

manufacturing activity will have significant negative change /impacts due to change in
greenhouse gases, whereas negative change/ impacts is anticipated due to change in
criteria air contaminants, health and odor related contaminants, and negative impacts on
soil and flora due to wet and dry deposition of pollutants, whereas there is no
impact/change in change in visibility and eutrophication of sensitive ecosystem.

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Table 4.5 Impacts on Air Environment

Impact Change in Change in Change in Change Effects on Effects on Eutrophication
Criteria air health and greenhouse in vegetation due soil due to of sensitive
contaminants odor related gases visibility to dry and wet dry and wet ecosystem due
contaminants deposition deposition N20 deposition
Activity
Construction Stage
Clearing and Grubbing √ √
Leveling by way of cut and fill √
Foundation excavation √
civil construction √
Equipment and machinery √
erection
painting works √
Operation Stage - Regular
Operation
Raw material and finished √
product transport
Raw material and finished √
product storage
Transfer of raw materials and √
products
Effluent generation √
Domestic Wastewater √
generation
Utility emissions √ √ √ √ √ √
Process emissions √ √ √ √
Diffuse emissions √
Wastewater storage √
Solid waste transfer and storage √
Solvent storage and use √

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Waste transport √
Effluent transfer and Treatment √
Wastewater Transfer and √
Treatment
Emissions control √ √
Solvent Recycle √
Operation Stage - Incidents
and Accidents
Spillage √ √ √
Fugitive emissions √ √ √ √
Containment failure √ √ √
Fire accidents √ √ √
Accidents during transport of √ √
Raw materials and products
Accidents during transport of √
wastes
Arson and Vandalism √ √ √
Extreme Weather phenomenon √ √ √
Plant Decommissioning
Transfer and disposal of √
chemicals
Transfer and disposal of wastes √
Decontamination of equipment √
and containers
Dismantling of facility √
Demolition Waste √
Site cleanup √ √
Capping drains and locking √
water sources
√ Indicates Impact

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Environmental Impact Assessment Report

Table 4.6 Impact Significance - Air Environment

Impact Importance Magnitude Permanence Reversibility Cumulative (a1) x (a2) (b1) + (b2) + (aT) x (bT) Significance
of condition of change/ (B1) (B2) (B3) = aT (b3) = bT = ES
(A1) effect (A2)
Change in Criteria 2 -1 3 3 3 -2 9 -18 -B
air contaminants
Change in health 2 -3 3 2 3 -6 8 -48 -D
and odor related
contaminants
Change in 1 -1 2 2 3 -1 7 -7 -A
greenhouse gases
change in visibility 1 0 1 1 1 0 3 0 N
Effects on 2 -2 1 1 3 -4 5 -20 -C
vegetation due to
dry and wet
deposition
Effects on soil due 2 -1 1 1 3 -4 5 -20 -C
to dry and wet
deposition
Eutrophication of 0 0 1 1 1 0 3 0 N
sensitive ecosystem
due N20 deposition

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M/s. NACL Industries Limited.
Environmental Impact Assessment Report

4.2.2.1 Air Quality Impact Predictions

A large number of different mathematical models for dispersion calculations are in
practice in many parts of the world. Most of the models for prediction of downwind
concentrations are based on Gaussian dispersion. The principle behind the Gaussian
dispersion models is Gaussian probability distribution of concentration in both vertical
and horizontal cross wind directions about the plume central line.

Predictions of ground level concentrations of the pollutants were carried out based on
site meteorological data collected during the study period. For calculation of predicted
ground level concentrations, ISCST3 model of Lakes Environmental based on USEPA,
ISCST3 algorithms, was used; as it’s based on more sophisticated algorithm incorporating
deposition, better algorithm for area sources, etc.

Overview of New Features in the ISC3 Models

The ISC3 models include several new features. A revised area source algorithm and
revised dry deposition algorithm have been incorporated in the models. The ISC3 models
also include an algorithm for modeling impacts of particulate emissions from open pit
sources, such as surface coal mines. The Short-Term model includes a new wet deposition
algorithm, and also incorporates the COMPLEX1 screening model algorithms for use
with complex and intermediate terrain. When both simple and complex terrain
algorithms are included in a Short-Term model run, the model will select the higher
impact from the two algorithms on an hour-by-hour, source-by-source, and receptor by-
receptor basis for receptors located on intermediate terrain, i.e., terrain located between
the release height and the plume height.

Some of the model input options have changed and newer input options have been added
as a result of the new features contained in the ISC3 models. The source deposition
parameters have changed somewhat with the new dry deposition algorithm, and there
are new source parameters needed for the wet deposition algorithm in the Short-Term
model. There are also new meteorology input requirements for use of the new deposition
algorithms. The option for specifying elevation units has been extended to source
elevations and terrain grid elevations, in addition to receptor elevations.

4-22 Team Labs and Consultants

M/s. NACL Industries Limited.
Environmental Impact Assessment Report

The utility programs, STOLDNEW, BINTOASC, and METLIST have not been updated.
While they may continue to be used as before, they are not applicable to the new
deposition algorithms in the ISC3 models. The salient features of the ISCST3 model are
presented below in Table 4.7.
Table 4.7 Salient Features of the ISCST3 Model
S.No Item Details
1 Model name ISCST3 (Based on USEPA algorithm)
2 Source Types Point, Area, Volume, Open Pits
3 Dispersion Equation Steady State Gaussian Plume Equation
4 Diffusion Parameters Pasquill Gifford Co-efficient
5 Plume Rise Briggs Equation
6 Time Average 1 hr to Annual/Period Has Short Term and Long-Term
modeling options
7 Deposition Both Dry and Wet Deposition
8 Application Input Data:
(i) Source Data Stack co-ordinates
(ii) Receptor Data Grid interval, number of receptors, receptor elevations
(iii) Meteorological Hourly meteorological data i.e. wind speed, direction,
Data ambient temperature, stability and mixing heights

Model Formulation
The model uses the following steady state Gaussian plume equation. The basic equation
for calculating the concentration of pollutants for any point in x, y, z co-ordinates is given
below:
C(x,y,z,H) = Q/2yz U exp[-1/2(y/y)2] x [exp{-1/2(z-h/z)2}
+ exp{-1/2 (z+H/z)2}]

Where;
C= Concentration of pollutants in mg/m3
Q= Strength of emissions in g/sec.
H= Effective Height (m), i.e., physical height + plume raise
y, z= diffusion coefficients in y and z directions in m.
U= average wind velocity in m/sec.
The following assumptions are made in Gaussian dispersion model.

This model assumes no diffusion in the down wind direction and thus applicable to a
plume and not a puff of pollutant. The dispersion parameter values used for horizontal
dispersion coefficient and vertical dispersion coefficients are those given in the “Work
book of atmospheric dispersion estimates”. These dispersion coefficients assume a

4-23 Team Labs and Consultants

M/s. NACL Industries Limited.
Environmental Impact Assessment Report

sampling time of about 10 min., the height values of interest to be in the lowest several
hundred meters of the atmosphere, a surface corresponding to the open country. The
stacks are tall enough to be free from building turbulence so that no aerodynamic down
wash occurs. The given stability exists from ground level to well above the top of the
plume.

The Gaussian dispersion model has been tested extensively for its validity and found to
be reasonably applicable for different atmospheric conditions. BIS has also adopted this
basic plume dispersion model. Hence the same model is adopted for predictions of
downwind concentrations of pollutants in this report.

Meteorological Data
Data recorded by the weather monitoring station at site on wind speed, direction, solar
isolation, temperature and cloud cover at one hourly interval for three months i.e. One
full season has been used for computations.

Mixing Height
The mixing heights for ambient air quality predictions are adopted from Atlas of Hourly
Mixing Height and Assimilative Capacity of Atmosphere in India by S.D Attri, Siddartha
Singh, B. Mukhopadhya and A.K Bhatnagar, Published by Indian Metrological
Department, New Delhi. 2008. The mixing heights range from 300 to 1450 m during
summer season. There is no record of inversion for this area (Reference: Atlas of Hourly
Mixing Height and Assimilative Capacity of Atmosphere in India by S.D Attri, Siddartha
Singh, B. Mukhopadhya and A.K Bhatnagar, Published By Indian Metrological
Department, New Delhi. 2008). There is no record of inversion in this area as observed
from the IMD data.

4.2.2.2 Utility Emissions

The sources of air pollution due to criteria air pollutants from proposed expansion of
NACL Industries Limited. are boilers and DG sets. The major pollutants generated from
the fuel combustion are SO2, NOx and Particulate Matter. Based on fuel analysis and
combustion details the emission rates of above pollutants are calculated. The speciation
of PM based on the particle size was done using AP -42 emission factors of USEPA. The

4-24 Team Labs and Consultants

M/s. NACL Industries Limited.
Environmental Impact Assessment Report

emission rates of SO2, NOx and Particulate Matter from each stack are presented in Table
4.8.
Table 4.8 Emission Details of Pollutants from Stack
S. Stack Connected Stack Dia of Temp. Exit Pollutant Emission
No to height, stack, m Of Velocity, Rate, g/sec
m exhaust m/sec PM SO2 NOx
gases, 0C
Existing
1 1 x 16 TPH coal 30 0.65 140 5.57 0.4 0.52 0.18
fired boiler*
2 1 x 10 TPH coal 30 0.25 160 8.23 0.05 0.14 0.18
fired boiler*
3 1 x 6 TPH oil fired 30 0.8 160 6 0.01 0.62 0.33
boiler*
4 1 x 1000 kVA DG 6.5 0.35 180 8.5 0.01 0.04 0.12
Set**
5 2 x 500 kVA DG 7 0.1 180 6.8 0.002 0.01 0.02
Set**
Proposed
1 1 x 50 TPH Coal 60 2.2 165 10.2 1.8 3.2 3.6
fired boiler
2 1 x 10 Lakh Kcal 30 0.5 160 4.5 0.06 0.08 0.12
Thermic Fluid
Heater
3 1 x 6 Lakh Kcal 20 0.3 180 6.2 0.03 0.03 0.09
Thermic Fluid
Heater
4 2 x 2000 kVA DG 10 0.3 200 10.2 0.02 0.06 0.08
sets
* Standby after expansion ** DG sets will be used during load shutdown.

4.2.2.3 Air Quality Modeling Results (Terms of Reference No. 7(i))

Predictions of ground level concentrations of the pollutants were carried out based on
site meteorological data collected during October to December 2020. A grid of 10 km X
10 km with a receptor interval of 400 meters is considered for calculation of ground level
concentrations.

The composition of particulate matter was obtained from USEPA AIRCHIEF AP-42 and
the same was considered in determining the source concentration of PM10 and PM2.5 for
prediction purpose. It may be noted that the predicted values of the SO 2 and NOx are
based on the assumption that the DG sets are used constantly, whereas the DG set usage
is only during load shut down from TRANSCO.

4-25 Team Labs and Consultants

M/s. NACL Industries Limited.
Environmental Impact Assessment Report

The predicted ground level concentrations at air quality monitoring locations is

presented in Table 4.9 and cumulative concentrations are tabulated in Table 4.10. It
may be observed from the table that the predicted results show that the incremental rise
over existing base line status of ambient air quality is within the limits prescribed by
National Ambient Air Quality standards (NAAQ), and hence the impact due to the
proposed project is low on ambient air quality. Hence the control measures and height
of stack is sufficient to disperse the pollutants into the atmosphere and keeping the
baseline levels within the prescribed limits. The predicted ground level concentrations
are graphically displayed for SPM, PM10, PM2.5, SO2, and NOx respectively in Figure 4.8
– 4.12.
Table 4.9 Predicted GLC’s at Monitoring Locations
S.No Monitoring Direction Distance Predicted GLC (g/m3)
Location (km) PM PM10 PM2.5 SO2 NOx
1 Keshavadasupeta NW 0.3 0.01 0.00 0.00 0.013 0.018
2 Chilakapalem E 0.4 0.10 0.04 0.02 0.153 0.213
3 Pattusalipeta SW 1.5 0.04 0.01 0.01 0.059 0.082
4 Allinagaram SE 1.4 0.01 0.00 0.00 0.018 0.025
5 Narsapuram NW 1.9 0.01 0.00 0.00 0.017 0.024
6 Echerla NE 2.0 0.35 0.14 0.06 0.547 0.763
7 Nandivada NE 2.8 0.31 0.12 0.06 0.482 0.672

Table 4.10 Cumulative Concentrations at Various Villages

Station Distance, Baseline Predicted GLC, g/m3 Cumulative
Km Concentration, g/m3 Concentration, g/m3
PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx
Keshavadasupeta NW 45 20 10 12 0.00 0.00 0.013 0.018 45.00 20.00 10.01 12.02
Chilakapalem E 47 21 11 13 0.04 0.02 0.153 0.213 47.04 21.02 11.15 13.41
Pattusalipeta SW 43 23 11 13 0.01 0.01 0.059 0.082 43.01 23.01 11.06 13.08
Allinagaram SE 45 21 9 11 0.00 0.00 0.018 0.025 45.00 21.00 9.02 10.83
Narsapuram NW 42 18 10 12 0.00 0.00 0.017 0.024 42.00 18.00 10.02 12.02
Echerla NE 50 23 12 14 0.14 0.06 0.547 0.763 50.14 23.06 12.55 15.16
Nandivada NE 49 24 13 16 0.12 0.06 0.482 0.672 49.12 24.06 13.48 16.27

4-26 Team Labs and Consultants

PROJECT TITLE: M/s. NACL Industries Limited.
Environmental Impact Assessment Report

8000

0.49
6000
4000

49
0.
2000

9
0.4

0.4
0

9 312 0.63
-2000
-4000
-6000
-8000

-8000 -6000 -4000 -2000 0 2000 4000 6000 8000

PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL ug/m^3

0.489 0.633 0.791 0.949 1.107 1.265 1.423

COMMENTS: SOURCES: COMPANY NAME:

3 M/s.NACL Industries Limited,

RECEPTORS: MODELER: WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

M/s.TeamLabs and NORTH

0 29%

Consultants,Hyderabad
23.2%

17.4%

11.6%

5.8%

WEST EAST

OUTPUT TYPE: SCALE: 1:125,466 SOUTH

WIND SPEED
(m/s)
>= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

CONC
End Date: 12/31/2020 - 23:00
MODELER:

0 5 km
M/s.Team Labs and
Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

MAX: PROJECT NO.:

1.42323 ug/m^3

ISC-AERMOD View - Lakes Environmental Software

Figure 4.8 Isopleths Showing 24 Hourly GLC’s of PM

4-27 Team Labs and Consultants

PROJECT TITLE:
M/s. NACL Industries Limited.
Environmental Impact Assessment Report

8000
6000
4000
2000
0

312 0.25
-2000
-4000
-6000
-8000

-8000 -6000 -4000 -2000 0 2000 4000 6000 8000

PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL ug/m^3

0.253 0.316 0.380 0.443 0.506 0.569

COMMENTS: SOURCES: COMPANY NAME:

3 M/s.NACL Industries Limited,

RECEPTORS: MODELER: WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

M/s.TeamLabs and NORTH

0 29%

Consultants,Hyderabad
23.2%

17.4%

11.6%

5.8%

WEST EAST

OUTPUT TYPE: SCALE: 1:125,466 SOUTH

WIND SPEED
(m/s)
>= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

CONC
End Date: 12/31/2020 - 23:00
MODELER:

0 5 km
M/s.Team Labs and
Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

MAX: PROJECT NO.:

0.56929 ug/m^3

ISC-AERMOD View - Lakes Environmental Software

Figure 4.9 Isopleths Showing 24 Hourly GLC’s of PM10

4-28 Team Labs and Consultants

PROJECT TITLE: M/s. NACL Industries Limited.
Environmental Impact Assessment Report

8000
6000
4000
2000
0

312 0.11
-2000
-4000
-6000
-8000

-8000 -6000 -4000 -2000 0 2000 4000 6000 8000

PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL ug/m^3

0.114 0.142 0.171 0.199 0.228 0.256

COMMENTS: SOURCES: COMPANY NAME:

3 M/s.NACL Industries Limited,

RECEPTORS: MODELER: WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

M/s.TeamLabs and NORTH

0 29%

Consultants,Hyderabad
23.2%

17.4%

11.6%

5.8%

WEST EAST

OUTPUT TYPE: SCALE: 1:125,466 SOUTH

WIND SPEED
(m/s)
>= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

CONC
End Date: 12/31/2020 - 23:00
MODELER:

0 5 km
M/s.Team Labs and
Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

MAX: PROJECT NO.:

0.25618 ug/m^3

ISC-AERMOD View - Lakes Environmental Software

Figure 4.10 Isopleths Showing 24 Hourly GLC’s of PM2.5

4-29 Team Labs and Consultants

PROJECT TITLE: M/s. NACL Industries Limited.
Environmental Impact Assessment Report

8000
6000
4000

0.99
2000

0
0

.9
312 9
-2000
-4000
-6000
-8000

-8000 -6000 -4000 -2000 0 2000 4000 6000 8000

PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL ug/m^3

0.991 1.239 1.486 1.734 1.982 2.229

COMMENTS: SOURCES: COMPANY NAME:

3 M/s.NACL Industries Limited,

RECEPTORS: MODELER: WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

M/s.TeamLabs and NORTH

0 29%

Consultants,Hyderabad
23.2%

17.4%

11.6%

5.8%

WEST EAST

OUTPUT TYPE: SCALE: 1:125,466 SOUTH

WIND SPEED
(m/s)
>= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

CONC
End Date: 12/31/2020 - 23:00
MODELER:

0 5 km
M/s.Team Labs and
Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

MAX: PROJECT NO.:

2.22929 ug/m^3

ISC-AERMOD View - Lakes Environmental Software

Figure 4.11 Isopleths Showing 24 Hourly GLC’s of SO2

4-30 Team Labs and Consultants

PROJECT TITLE: M/s. NACL Industries Limited.
Environmental Impact Assessment Report

8000

1.04
6000
4000

04
1.
2000

8
1.3
1.04 1.
04
0

312
-2000
-4000
-6000
-8000

-8000 -6000 -4000 -2000 0 2000 4000 6000 8000

PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL ug/m^3

1.038 1.384 1.730 2.076 2.421 2.767 3.113

COMMENTS: SOURCES: COMPANY NAME:

3 M/s.NACL Industries Limited,

RECEPTORS: MODELER: WIND ROSE PLOT: DISPLAY:

Wind Speed
Direction (blowing from)

M/s.TeamLabs and NORTH

0 29%

Consultants,Hyderabad
23.2%

17.4%

11.6%

5.8%

WEST EAST

OUTPUT TYPE: SCALE: 1:125,466 SOUTH

WIND SPEED
(m/s)
>= 4.20
2.80 - 4.20
1.40 - 2.80
0.28 - 1.40
Calms: 5.43%

COMMENTS: DATA PERIOD: COMPANY NAME:

Start Date: 10/1/2020 - 00:00 M/s.NACL Industries Limited, Srikakulam.

CONC
End Date: 12/31/2020 - 23:00
MODELER:

0 5 km
M/s.Team Labs and
Consultants, Hyderabad
CALM WINDS: TOTAL COUNT:

5.43% 2208 hrs.

AVG. WIND SPEED: PROJECT NO.:

2.59 m/s

WRPLOT View - Lakes Environmental Software

MAX: PROJECT NO.:

3.11307 ug/m^3

ISC-AERMOD View - Lakes Environmental Software

Figure 4.12 Isopleths Showing 24 Hourly GLC’s of NOX

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Mitigation measures for utility emissions during construction and operation phases are
presented in Table 4.11. Technical specifications of control equipment are presented in
Table 4.12.
Table 4.11 Mitigation Measures for Utility Emissions - Construction and Operation
Activity Impact Mitigation measure
Construction phase
Emission from ➢ Change in air quality ➢ PUC certification of transport
transportation of materials ➢ Change in visibility vehicles.
➢ Health Impact ➢ Water sprinkling system on
roads.
➢ Periodic maintenance.
Emissions from DG sets ➢ Change in air quality ➢ Effective stack height.
➢ Health Impact ➢ Periodic maintenance.
Material Transfer ➢ Increase noise levels ➢ Reduced drop height.
➢ Rubber padding at discharge
point and at the impact point,
avoidance of metal bunkers.
Operation Phase
Emissions from Boilers ➢ Change in air quality ➢ Electro Static Precipitators
➢ Health Impacts (ESP).
➢ Usage imported coal with <
0.5% sulfur content
➢ Effective stack height
Emissions from Thermic ➢ Change in air quality ➢ Bag Filters.
Fluid heater ➢ Health Impacts ➢ Usage imported coal with <
0.5% sulfur content
➢ Effective stack height
Standby DG sets ➢ Change in air quality ➢ Stack height based on CPCB
➢ Health Impacts formula

Table 4.12 Technical Specifications of ESP – 50 TPH Boiler

Boiler Capacity Units 50 TPH
Chamber design
No of gas passages Nos 10
Spacing between electrodes mm 400
Height of collecting plate Feet 30
No of fields Nos 4
Length of each field Feet 12
Hopper arrangement 1.4 P (3)
Hopper valley angle Deg 55 deg
Fuel Indian coal and Imported coal
Gas Flow Am3/hr 75200
Temperature Deg C 160
Maximum Inlet Dust load gm/Nm3 Indian coal: 50
Imported Coal: 10
Outlet Emission mg/Nm3 <115
(All field working at Wet basis)

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Environmental Impact Assessment Report

Plate Area m2 3700

Specific Collection area m2/m3/s 100
Velocity through ESP m/s 0.6
Treatment time Sec 25
Migration Velocity cm/s 7
No of Electrical fields Nos. 4
No of Mechanical fields Nos. 4
COLLECTING ELECTRODE SPECIFICATIONS:
Height of panel M 10
Material CRCA sheet (IS 513 grade - "D")
Thickness SWG 18
Panel width mm 45
EMITTING ELECTRODE SPECIFICATIONS:
Height of electrode m 12
Type e - Tube
Material ERW Tubes & Carbon Steel Studs
Clearance between two Collectors mm 400
Spacing between Emitter & Collector electrode mm 200
MATERIAL SPECIFICATIONS:
Thickness/Specification/Sizes
Casing 3 mm 5 mm
Hopper 4 mm 5 mm
Inlet/Outlet Nozzles 3 mm 5 mm
Cladding thickness 24 SWG 24 SWG
ELECTRICAL SPECIFICATIONS
TR Sets Qty 4 nos
TR Control type Microprocessor controlled
RAPPING SYSTEM SPECIFICATIONS
Collecting plate rappers 4 Sets
e- Tube rappers 34Sets
Gas distribution plate rappers 1 Set
Type TIGI
DESIGN PRESSURE
Maximum/ Minimum mm WG ±200 mm WC
Maximum pressure drop flange to flange mm WG 25
Casing Mechanical Design Temperature 0C 200

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4.2.2.4 Process Emissions

Mitigation measures for process emissions are presented in Table 4.13. Technical
specifications of control equipment are presented in Table 4.14
Table 4.13 Mitigation Measures for Process Emissions
Activity Impact Mitigation measure
Carbon dioxide ➢ Change in odor and health ➢ Let out into atmosphere by
related containments standard operating procedure
Hydrogen ➢ Change in odor and health ➢ Let out into atmosphere through
related containments water column
➢ Property Damage
Ammonia ➢ Change in odor and health ➢ Two stage scrubbing system
Sulphur dioxide related containments
Hydrogen Chloride ➢ Change in air quality
Hydrogen Bromide
Chlorine

Table 4.14 Technical Specifications of Two Stage Scrubbing System

1.0 Design Specification
1.1 Gas Flow rate (Basis of Design) Nitrogen with traces of VOCs, HCl, SO2 and air
Max flow rate: 5000 Cum/hr
1.2 Gas inlet Temperature 50°C (Max.)
1.3 Negative draft created by Venturi (-) 400 mmWC
2.0 First Stage Venturi Scrubber
2.1 Scrubbing Liquid Recirculated 10 % caustic
2.2 Liquid Flow rate 130 m3/hr
2.3 Pressure 3 kg/cm2 (g)
2.4 Suction / Discharge / Motive Size 200 / 200 / 100
(NB)
2.5 Jet Venturi Scrubber Body 3 mm PVDF - 5mmFRP (V)
2.6 Capacity of scrubber tank 20 KL
3.0 Second Stage Packed bed Tower
3.1 Scrubbing Liquid Recirculated 10 % caustic & 10 % Hypo solution
3.2 Scrubbing Liquid Flow rate to the 3 m3/hr
tower
3.3 Scrubbing Liquid Pressure 1.03kgf/cm2
3.4 Pressure Drop Across the Tower 60 mm WC (Approx.)
3.5 Packed Tower shell 4 mm PVDF - 8 mm FRP (V)
3.6 Tower Internal (Pall ring Packings, Glasses, Mesh pad Mist.
Eliminator, Spary cone nozzle, Support Plate etc)
3.7 Pall Ring/ Tellerette Ring 1”
4.0 Storage cum Circulation Tank for Scrubbing liquid
4.1 Diameter 2700 mm
4.2 Height 3500 mm
4.3 Volumetric Capacity 20 KL

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4.2.2.4.1 Diffuse and Fugitive Emissions

Prediction of Concentration of Solvents in the Indoor Environment Due to Solvent
Loss and Fugitive Emissions
EVAPMOD a simple Box model was used to calculate the solvent concentration in the
indoor environment. The methodology adopted was to calculate the concentration for
the product profile on campaign basis, which has the largest quantity of solvent losses.

General Box Model:

Indoor air pollution models developed and used by USEPA and others consider the
conservation of air contaminant mass in a volume or "box" of workroom air. Airborne
concentrations are derived by solving the following general equation (Jay jock, 1988):
C = (Ain - Aout) / Volume of Box ---------- (1)
Where
C = Concentration at time ti (assume C=0 @ t0 = 0)
Ain = Mass of contaminant that went into the box during time interval ti - t0
Aout = Mass of contaminant that left the box during time interval ti - t0
The diffusion coefficient and the generation rate of the contaminant were calculated to
arrive at the airborne concentration in the environment.

For the General Ventilation Model, the overall estimate of the airborne concentration of
a contaminant is obtained by use of following equation.
Cv = (1.7*105) Ta*G
M*Q*m
Where: C v = Contaminant concentration in workplace (ppm)
Ta = Ambient temperature of the air (K)
G = Vapor generation rate (gm/sec)
M = Molecular Weight (gm/gm-mole)
Q = Ventilation rate (ft3/min)
m = Mixing factor (dimensionless)
The solvent loss and the predicted airborne concentrations of the various solvents are
tabulated in the Table 4.15.

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M/s. NACL Industries Limited.
Environmental Impact Assessment Report

Table 4.15 Solvent Loss and the Predicted Airborne Concentrations

S.No Name of Solvent Fugitive Air borne Solvent TLV
Loss Conc. (ppm) (ppm)
1 Acetic Acid 4 2 10
2 Acetone 88.6 45.3 1000
3 Acetonitrile 46.4 33.5 40
4 Benzene 0.4 0.1 25
5 Cyclohexane 30.9 10.9 25
6 Dimethyl Formamide 15.1 6.1 10
7 Dimethyl sulfoxide 5.5 2.1 10
8 Ethylene Dichloride 41.4 12.4 200
9 n-Hexane 94.4 32.5 500
10 n-Heptane 11.1 3.3 500
11 Isopropyl Alcohol 5 2.5 400
12 Methanol 191.6 177.5 200
13 Methylene Dichloride 125.6 44 50
14 Methyl tert-butyl ether 58.5 20 40
15 N-Methyl-2-Pyrrolidone 3.5 1 100
16 Tetrahydrofuran 20.8 8.6 200
17 Toluene 243.6 78.5 200
18 Xylene 54.4 15.2 100

It may be observed that the predicted air borne concentration of solvents are within the
prescribed TLV standards within the work room area. The predicted air borne
concentrations range from 0.1 to 177.5 ppm. The predicted airborne concentration of
solvents is in the range of 0.5 to 88.8% of TLV value. It may be concluded that the
dispersion of these solvents into atmosphere shall have low impact as the releases from
the work room shall be a maximum of 88.8% of TLV values due to dilution followed by
dispersion in atmosphere. Mitigation measures for process emissions are presented in
Table 4.16.
Table 4.16 Mitigation Measures for Diffuse and Fugitive Emissions
Activity Impact Mitigation measure
Transfer of Raw ➢ Change in odor and ➢ Closed operation system
materials, health related ➢ Less bends in pipeline system
Solvents containments ➢ Minimal number of flanges
➢ Effect on soil due to dry ➢ AOD pumps for drum transfer
and wet deposition ➢ Powder transferring system
➢ Dip pipe provision to reactors
➢ PPE to employees
➢ House-keeping
Distillation of ➢ Change in odor and ➢ Dual condensing system
solvents, health related ➢ Vacuum Pumps
containments ➢ Agitated nutche filter and dryer
(ATFD) system

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Activity Impact Mitigation measure

Filtration and ➢ Vent condenser to dryer PPE to
Drying employees
operations ➢ House-keeping
Bulk Storage of ➢ Change in odor and ➢ Vent condensing system
solvents health related ➢ Nitrogen blanketing
containments ➢ Pressure relief valve
➢ Breather values
➢ Thermal insulation
➢ House-keeping

4.2.3 Water Environment

Water environment of the proposed expansion consists of usage of ground water and
generation of wastewater from process, utilities, domestic usage. The total fresh water
required of quantity after expansion is 2285 KLD. The abstraction of ground water for
industrial use shall have negative and direct impact with medium significance as the
plant shall be a competing user for farmers in the surrounding area. The effluent
generation in the plant may have a direct negative impact with high significance, on
both ground and surface water regimes, if mitigation measures are not adopted and the
effluents are disposed without treatment. The release of effluents on to the soil, may
change ground water quality, change in run off quality, change in ground water and
surface water interaction, change in channel morphology leading to deterioration of
production levels of both terrestrial and aquatic flora and fauna, resulting in higher
concentrations of chemicals in food chain. The treated effluent after proposed expansion
will be reused completely for utility makeup water. Hence the impact of wastewater
shall be for the duration of plant operation, with negative impact due to ground water
abstraction. The impacts due to various activities during the life time of the project
including emergency scenarios on water environment for both surface water and
ground water is presented in Tables 4.17 and 4.18 respectively. The impact significance
is calculated using RIAM and presented in Tables 4.19 and 4.20 respectively for both
surface and ground water environment respectively.

The impact assessment indicates that the proposed expansion of manufacturing activity
on surface water has moderately negative change/ impact due to change in surface
water quality and release of process related chemicals and spillage, negative change/

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impacts due to change in erosion and sedimentation, slightly negative change /impacts
due to change in runoff quality, runoff peak flow, surface water quality, surface and
ground water interaction, change in channel morphology and Dry and wet deposition
leading to acidity.

The impact assessment indicates that the proposed expansion of manufacturing activity
on ground water will have slightly negative change/ impact due to change in ground
water quality, flow regime and change in ground water and surface water interaction.
Mitigation measures for water environment are presented in Table 4.21. Technical
specifications of effluent treatment system are presented in Table 4.22.

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Table 4.17 Impacts on Surface Water

Impact Change Change Change Change Change in Change in Change in Dry and
in in in in surface and channel erosion and wet
runoff runoff surface Surface ground morphology sedimentation deposition
quantity peak drainage water water leading to
flow pattern Quality interaction acidity
Activity
Construction Stage
Leveling by way of cut and fill √ √ √ √ √ √
civil construction √ √ √ √ √
Operation Stage
Regular Operation
Raw material and finished product transport
Effluent generation
Domestic Wastewater generation
Utility emissions √
Process emissions √
Solid waste transfer and storage
Effluent transfer and Treatment
Wastewater Transfer and Treatment
Incidents and Accidents
Spillage √
Containment failure √
Accidents during transport of Raw materials √
and products
Accidents during transportation of wastes √
Arson and Vandalism √
Extreme Weather phenomenon √ √
Plant Decommissioning
Transfer and disposal of chemicals √
Transfer and disposal of wastes √

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Decontamination of equipment and √

containers
Dismantling of facility
Demolition Waste √
Site cleanup √
Capping drains and locking water sources √ √
√ Indicates Impact

Table 4.18 Impacts on Ground Water

Impact Change in Change to ground Change in Change in ground
ground water water quality ground water water and surface
quantity flow regime water interaction
Activity
Construction Stage
Foundation excavation √ √ √ √
Operation Stage
Regular Operation
Water use √ √ √ √
Operation Stage
Incidents and Accidents
Spillage √
Containment failure √
Accidents during transport of Raw materials and products √
Accidents during transport of wastes √
Extreme Weather phenomenon √ √
Plant Decommissioning
Capping drains and locking water sources √ √
√ Indicates Impact

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Table 4.19 Impacts Significance - Surface Water

Impact Importa Magnitude Permane Reversibil Cumulat (a1) x (b1) + (aT) x Significance
nce of of nce (B1) ity (B2) ive (B3) (a2) = (b2) + (bT) =
conditio change/effe aT (b3) = bT ES
n (A1) ct (A2)
Change in runoff quantity 1 -1 3 2 2 -1 7 -7 -A
Change in runoff peak flow 1 -1 3 2 2 -1 7 -7 -A
Change in surface drainage pattern 1 1 3 3 2 1 8 8 +A
Change in Surface water Quality 1 -1 2 2 2 -1 6 -6 -A
Change in surface and ground 1 -1 3 3 2 -1 8 -8 -A
water interaction
Change in channel morphology 1 1 3 2 2 1 7 7 +A
Change in erosion and 1 -1 3 2 2 -1 7 -7 -A
sedimentation
Release of process related 2 -2 3 2 2 -4 7 -28 -C
chemicals and spills
Dry and wet deposition leading to 2 -1 2 2 2 -2 6 -12 -B
acidity

Table 4.20 Impacts Significance - Ground Water

Impact/aspect Importance Magnitude Permanence Reversibility Cumulative (a1) x (b1) + (aT) x Significance
of of change/ (B1) (B2) (B3) (a2) = (b2) + (bT) =
condition effect (A2) aT (b3) = ES
(A1) bT
Change in ground water quantity 2 -2 3 2 3 -4 8 -32 -C
Change to ground water quality 2 -1 2 2 2 -2 6 -12 -B
Change in ground water flow 2 -1 2 2 2 -2 6 -12 -B
regime
Change in ground water and 2 -1 2 2 2 -2 6 -12 -B
surface water interaction

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Table 4.21 Mitigation Measures for Water Environment

Activity Impact Mitigation measure
Development of ➢ Change in ground water ➢ Provision of storm water drains
Infrastructure for quantity in the first stage of construction.
operation facility ➢ Change in ground water ➢ Rain water harvesting
regime
➢ Change in ground water
and surface water
interaction
OPERATION PHASE
Process effluent ➢ Change in ground water ➢ Segregation of effluents
quality ➢ Zero liquid discharged
➢ Soil contamination principle based Effluent
➢ Health Impacts treatment system followed by
complete reuse of treated
wastewater.

Table 4.22 Technical Specifications of Effluent Treatment System

S.No Description Unit Value Value
Stripper
1 Design Capacity KLD 1 x 300
2 Feed Rate Kl/hr 10.0-15.0
3 Specific Gravity of Feed ≈ 1.03
4 Initial Feed COD PPM 20000-90000
5 Feed Total Solid % 1.0-2.0
6 High Heating Temperature OC 95 – 100
7 High COD Condensate recovery LPH 150-200
8 Dry Saturated Steam at 12.0 Kg/cm2 (g) TPH 2.0-4.0
9 Cooling Water circulation rate for condenser m3/hr 10.0-15.0
10 Cooling Water Inlet Temperature OC 30 – 32
11 Cooling Water Outlet Temperature OC 38 – 40
Multiple Effect Evaporator (MEE)
1 Design Capacity KLD 1 x 420 1 x 420
2 Feed Rate Kl/hr 15.0-21.0 15.0-21.0
3 Feed Concentration mg/l 20000-90000
4 Feed Temperature OC 30-40.0 30-40.0
5 Initial Solids % 5.0-10.0 5.0-10.0
6 Solids in Concentrate % 35.0-40.0 35.0-40.0
7 Concentrate Output Kl/hr 1.5 – 2.0 1.5 – 2.0
8 Water Evaporation Rate Kl/hr 15.0- 20.0 15.0- 20.0
9 Designed Water Evaporation Rate Kl/hr 40 40
10 Dry Saturated Steam at 12.0Kg/cm (g)2 TPH 3.0 – 5.0 3.0 – 5.0
11 Cooling Water Circulation Rate at 30 – 32OC m3/hr 10.0-15.0 10.0-15.0
12 Cooling Water Inlet Temperature OC 30 – 32 30 – 32
13 Cooling Water Outlet Temperature OC 38 – 40 38 – 40
Agitated Thin Film Dryer (ATFD)
1 Designed Capacity KLD 1 x 60 1 x 60
2 Feed Rate Kl/hr 2.0-3.0 2.0-3.0

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3 Initial Feed Solid Content % 35.0-40.0 35.0-40.0

4 Final Moisture in Dry Bag-gable Product % 2.0-3.0 2.0-3.0
5 Water Evaporation Rate Kl/hr 2.0 – 2.5 2.0 – 2.5
6 Designed Water Evaporation Kl/hr 2.5 2.5
7 Solid Output in Bag-gable @ 5– 6% moisture Kl/hr 2.0-2.25 2.0-2.25
8 Dry Saturated Steam at 12.0Kg/cm2 (g) TPH 0.5-1.5 0.5-1.5
9 Cooling Water Circulation Rate at 30 – 32OC m3/hr 2.0 – 2.5 2.0 – 2.5
10 Cooling Water Inlet Temperature OC 30 – 32 30 – 32
11 Cooling Water Outlet Temperature OC 38 – 40 38 – 40

Table 4.23 Technical Specifications of Biological Treatment Plant – Proposed

Data Module Module
1 1
Capacity : 600 600 m3/day
Flow : 502 502 m3/day
BOD : 4000 4000 mg/l
COD : 8000 8000 mg/l
Total Dissolved Solids : 8000 8000 mg/l
1. Bar Screen Chamber
Flow rate : 75 75 m3/hr
Peak factor : 3 3
Peak flow : 225 225 m3/hr
Velocity through screen : 0.8 0.8 m/hr
Clear area through rack opening : 281.3 281.3 m2
Gross area : 1.2 1.2 times net
area
Gross area : 338 338 m
2. Oil & Grease Trap (O&G)
Flow Rate : 600 600 kg/day
Flow Rate in min : 0.417 0.417 m3/min
Resident Time : 10 10 min
Depth from inlet : 0.3 0.3 m
Volume of the tank : 4.17 4.17 m3
Area : 13.89 13.89 m2
length of the tank (l=b) : 3.73 3.73 m
Width of the tank : 3.73 3.73 m
3. Equalization tank
Average flow : 75 75 m3/hr
Peak flow : 263 263
Hydraulic retention time : 12 12 hrs.
Volume of the tank : 3150 3150 m3
Assuming depth : 2 2 m
Area : 1575 1575 m2
Assuming length to width ratio (1:1) ; l=b
length of the tank : 39.7 39.7 m (Say 3.8
m)

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width of the tank : 39.7 39.7 m (Say 3.8

m)
Air required for agitation : 0.01 0.01 m3/ m2 min
Total air required : 1.05 1.05 m3/hr
Air blower required : 3 3 m3/hr
4. Neutralization Tank
Average flow : 75.0 75.0 m3/hr
Hydraulic retention time : 12 12 hrs.
Volume : 900 900 m3
Biological Treatment
Data
Design Capacity : 600 600 m3/day
Flow : 502 502 m3/day
Peak flow : 1003 1003 m3/day
Inlet BOD : 4000 4000 mg/l
Inlet COD : 8000 8000 mg/l
Inlet Total Dissolved Solids : 8000 8000 mg/l
8. Neutralization Tank
Average flow : 50.0 50.0 m3/hr
Hydraulic retention time : 12 12 hrs.
Volume : 600 600 m3
9.Aeration Tank - 1
Inlet BOD : 4000 4000 mg/l
Inlet COD : 8000 8000 mg/l
Inlet TDS : 8000 8000 mg/l
Outlet BOD : 600 600 mg/l
Outlet COD : 1200 1200 mg/l
Outlet TDS : 7920 7920 mg/l
MLSS : 3200 3200 mg/l
F/M ratio : 0.18 0.18
Flow : 600 600 m3/day
Volume of the Aeration Tank - 1 : 4166.7 4166.7 m3
Check for Detention time : 166.7 166.7 12 – 24 hrs
Assuming depth : 3.5 3.5 m
Area of the tank : 1190.48 1190.48 m2
Width of the tank : 34.50 34.50 m
Length of the Tank : 17.25 17.25 m
Oxygen is required for every Kg BOD5 removed : 2.00 2.00 kgs
Oxygen requirement for aeration : 4013 4013 kg/day
O2 in Air % : 0.21 0.21 %
Density of Air : 1.2 1.2 Kg/m3
Oxygen Transfer Efficiency : 0.06 0.06 %
Oxygen requirement : 50 50 m3/kg
O2/day
Air Required : 132720 132720 m3/day
: 3261 3261 cfm
Total air required (consider 35 % excess) : 4402 4402 Kg O2/day
10.Clarifier - 1

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Design quantity : 600 600 m3/m2-day

Surface loading rate of average flow : 8 8 m2
Surface area provided : 75 75 m
length of the tank (2l=b) : 8.66 8.66 m (Say 2.5
m)
Width of the tank : 4.33 4.33 m (Say 1.5
m)
Inlet BOD : 600 600 mg/l
Inlet COD : 1200 1200 mg/l
Inlet TDS : 7920 7920 mg/l
Outlet BOD : 502 502 mg/l
Outlet COD : 1200 1200 mg/l
Outlet TDS : 5940 5940 mg/l
11.Aeration Tank - 2
Inlet BOD : 502 502 mg/l
Inlet COD : 1200 1200 mg/l
Inlet TDS : 5940 5940 mg/l
Outlet BOD : 90 90 mg/l
Outlet COD : 215 215 mg/l
Outlet TDS : 5881 5881 mg/l
MLSS : 3200 3200 mg/l
F/M ratio : 0.18 0.18
Flow : 600 600 m3/day
Volume of the Aeration Tank - 2 : 2612.9 2612.9 m3
Check for Detention time : 104.5 104.5 12 – 24 hrs
Assuming depth : 3.5 3.5 m
Area of the tank : 746.55 746.55 m2
Width of the tank : 27.32 27.32 m
Length of the Tank : 13.66 13.66 m
Oxygen is required for every Kg BOD5 removed : 2 2 kgs
Oxygen requirement for aeration : 602 602 kg/day
O2 in Air % : 0.21 0.21 %
Density of Air : 1.2 1.2 Kg/m3
Oxygen Transfer Efficiency : 0.06 0.06 %
Oxygen requirement : 50 50 m3/kg
O2/day
Air Required : 19908 19908 m3/day
: 489 489 cfm
Total air required (consider 35 % excess) : 660 660 Kg O2/day
12.Clarifier - 2
Design quantity : 600 600 m3/m2-day
Surface loading rate of average flow : 12 12 m2
Surface area provided : 50.0 50.0 m
length of the tank (2l=b) : 7.07 7.07 m (Say 2.5
m)
Width of the tank : 3.54 3.54 m (Say 1.5
m)
Inlet BOD : 90 90 mg/l

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Inlet COD : 215 215 mg/l

Inlet TDS : 5881 5881 mg/l
Outlet BOD : 75 75 mg/l
Outlet COD : 215 215 mg/l
Outlet TDS : 4410 4410 mg/l
13. Holding tank
Average flow : 50.0 50.0 m3/hr
Peak factor : 2 2 m3/hr
Peak flow : 100.0 100.0 m3/hr
Provide min 1.5 hours holding capacity.
Hence required volume of the tank : 150 150 m3
14. Pressure Sand Filter:
Design : 600 600 m3/day
Flow : 502 502 m3/day
Inlet TDS : 4410 4410 mg/l
Outlet TDS : 3087 3087 mg/l
Rate of filtration assumed as : 15 15 m3/m2/hr
Requirement of treated water for usage in 20 hrs : 25 25.1 m3/hr
Dia of filter of 1 nos. : 1459.5 1459.5 mm
15. Activated Carbon Filter:
Design : 600 600 m3/day
Flow : 502 502 m3/day
Inlet TDS : 3087 3087 mg/l
Outlet TDS : 2470 2470 mg/l
Rate of filtration assumed as : 15 15 m3/m2/hr
Requirement of treated water for usage in 20 hrs : 25.1 25.1 m3/hr
Dia of filter of 1 nos. : 1459.55 1459.55 mm
16. Reverse Osmosis -1:
Design Capacity : 700 700 KLD
Operating capacity : 502 502 KLD
Recovery : 60% 60%
17. Reverse Osmosis - 2:
Design Capacity : 250 250 KLD
Operating capacity : 231.5 231.5 KLD
Recovery : 70% 70%

4.2.3.1 Rainwater Harvesting

The storm water from open areas, and green belt area, and the plant area is collected
in a storm water storage tank in south part of the site and reused for plant and
process. The storage pond has a capacity of 5000 m3 facilitating ground water
recharge and reducing the dependence on ground water partially.

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Existing Storm Water Storage Pond

4.2.4 Noise Environment

The project activities that have an impact on noise environment are operation of
turbine, motors, pumps, compressors, DG sets resulting in direct impact of increasing
ambient noise levels both within the plant area and outside. Excessive noise will
trigger health risks such as headaches, depression, deafness and retardation of
sensory mechanisms in the impact area population. The incremental noise levels due
to these activities were predicted and the values reflect low impact outside the
premises. The increase in noise levels shall have low impact, restricted to within site
area due to its low magnitude and occasional frequency. The incremental noise levels
however shall have direct negative impact on the noise levels, with low significance
due to mitigation measures and also due to absence of sensitive receptors within 1.07
km of the sources. The impact significance is calculated using RIAM. The impacts
due to various activities during the life time of the project including the emergency
scenarios on noise levels is presented in Table 4.24. The impact significance on noise
levels is presented in Table 4.25.

The impact assessment indicates that the proposed expansion of manufacturing

activity will have negative change/impact due to change in ambient noise levels and
change in behavior due to noise, whereas slightly negative change/ impacts are
anticipated due to effects on sensitive receptors leading to gradual impairment.

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Table 4.24 Impacts on Noise Level

Impact Noise and Change in Change in Effects on sensitive
vibration ambient noise behavior receptors leading to
levels due to noise gradual impairment
Activity
Construction Stage
Clearing and Grubbing √ √
Leveling by way of cut and fill √ √
Foundation excavation √ √
civil construction √ √
Equipment and machinery erection √ √
Electrical installation √ √
plumbing and piping √ √
Operation Stage
Regular Operation
Raw material and finished product transport √
Transfer of raw materials and products √
Emissions control √ √
Machine (Turbine) and Equipment operation √ √ √ √
Incidents and Accidents
Equipment Failures √ √
Fire accidents √ √
Extreme Weather phenomenon √ √
Plant Decommissioning
Dismantling of facility √ √
Site Cleanup √
√ Indicates Impact

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Table 4.25 Impact Significance – Noise Level

Impact Importance of Magnitude Permanence Reversibility Cumulative (a1) x (a2) (b1) + (aT) x Significance
condition of change/ (B1) (B2) (B3) = aT (b2) + (bT) =
(A1) effect (A2) (b3) = bT ES
Change in ambient 2 -1 3 2 3 -2 8 -16 -B
noise levels
Change in behavior 2 -1 3 2 2 -2 7 -14 -B
due to noise
Effects on sensitive 2 -1 1 1 1 -2 3 -6 -A
receptors leading to
gradual impairment

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4.2.4.1 Prediction of Impact on Noise Quality

The sound pressure level generated by noise source decreases with increasing distance
from the source due to wave divergence. An additional decrease in sound pressure
levels also occurs with increasing distance from the source due to atmospheric effect
or interaction with the objects in the transmission path. This is due to excess
attenuation. The sound pressure level is also affected by medium of travel and
environmental conditions. The propagation model has been devised to take into
account these factors and predict the noise levels at various distances round a single
or a multiple source. The model uses the following formula as a basis for such
predictions.
(Lob) = (Lr) - (Ldiv) - (Latm)
Where (Lob) = Observed noise level at a distance R from source
(Lr) = Noise level of source measured at reference distance r
(Ldiv) = Loss due to divergence at distance R from source
= 20 log (R/r)
(Latm) = Attenuation due to atmosphere at distance R from the source.
= a x R/100, where a is atmospheric attenuation coefficient in
dB (A)/100m.
For hemispherical wave divergence in a homogenous loss free atmosphere
(Latm) = 0.
The total impact of all sources at particular place is then estimated by adding as the
contribution of noise from each of the following sources as follows;
i=n (Lob)i/10
(Leq) = 10 log  {10 }
i=1
Where n = total number of sources

The calculated noise levels are further super imposed (logarithmically) on the
background noise levels. The model assumes that the noise spectrum is mainly
centered on a spectrum of 1000 Hz and attenuation due to building materials is also at
the same frequency. DhwaniPro is a computer program developed to undertake
construction, industrial and traffic noise propagation modeling for which an
environmental noise assessment may be required. A variety of scenarios can be created
quickly in DhwaniPro, allowing the user to determine the impact of changing the
source, layout and adding/ removing the effects of shielding due to noise mitigation
devices such as barriers.

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The major sources of noise generation and noise levels ranging from 87 dB (A) - 104
dB (A), considered for modelling is presented in Table 4.26. The predicted cumulative
noise levels due to the source and the existing level as calculated from the logarithmic
model without noise attenuation ranged between 45 and 80 dB(A) at distances ranging
between 100-150 m which falls within the plant boundary. The impact of noise on the
population in the surrounding area will be negligible, as the nearest habitation is at
least 0.3 km away from the site. Noise levels mitigation measures during construction
and operation stage are presented in Table 4.27.
Table 4.26 Sources of Noise Generation (Tentative)
S. No Sources of Generation Noise Levels (dB(A)
Minimum Maximum
1 Coal Conveyor Belt 86 96
2 Compressor 87 100
3 Boiler Feed Pump 84 97
4 Turbine Floor 85 98
5 FD Fan 83 104
6 ID Fan 76 89
7 Cooling Towers 74 79

Table 4.27 Noise Levels Mitigation Measures - Construction and Operation stages
Activity Impact Mitigation measure
Construction phase
Transport vehicles ➢ Increase in Noise levels ➢ Avoidance of engine idling.
➢ Transport during day time.
➢ Periodic maintenance.
Construction equipment: ➢ Increase in noise levels, ➢ Periodic maintenance.
drills, Pneumatic and vibration ➢ Enclosed operator room.
equipment, excavators, ➢ Attenuating screens between
dumpers etc. operators and sources.
➢ Periodic maintenance.
➢ Barriers, guard covers,
isolation of equipment,
antivibration pads.
➢ Training to operators and
drivers.
➢ PPE to operators.
Material Transfer ➢ Increase noise levels ➢ Reduced drop height.
➢ Rubber padding at discharge
point and at the impact
point, avoidance of metal
bunkers.
Other construction works ➢ Impact on workers’ ➢ Training to workers.
health due to noise ➢ PPE.
levels

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Activity Impact Mitigation measure

Operation Phase
Transport vehicles ➢ Increased noise levels ➢ Periodic maintenance.
on site. ➢ Training to drivers.
➢ Avoidance of idling engines.
Turbine, ➢ Increased noise levels. ➢ Acoustic insulation of
➢ Impact on employee operational control rooms.
health. ➢ Vibration monitoring.
➢ Vibration. ➢ Periodic maintenance.
➢ PPE to employees.
➢ Hearing conservation
program
DG sets ➢ Increased noise levels. ➢ Acoustic enclosures
➢ Impact on employee ➢ PPE to employees
health.
➢ Vibration
Compressors, pumps ➢ Increased noise levels. ➢ PPE to employees
and Motors ➢ Impact on employee ➢ Proper lubrication
health. ➢ Modernization of equipment
➢ Vibration

4.2.5 Land Environment

There will not be any change in land use, the proposed expansion is within existing
land area. The proposed expansion involves construction of additional blocks, utilities,
enhancement of ZLD system and storages. There is no major alteration of terrain,
however it may lead to additional sealing of land due to foot print of the structures.
The proposed expansion shall also result in increased generation of solid waste, mainly
process residues and solid waste from treatment facilities and control measures which
will be sent to cement plants as auxiliary fuel for co-processing. The low concentration
and high-volume wastes of brine sludge is sent to TSDF. Handling of hazardous waste
has a potential to contaminate soil, ground water, land capability and permeability of
soil. The impact on land environment is mainly due to accidental spillages of
chemicals, effluents and wastes. The impact significance is calculated using RIAM.
The impacts due to various activities during the life time of the project including the
emergency scenarios on land environment is presented in Table 4.28. The impact
significance on land environment is presented in Table 4.29.

The impact assessment indicates that the proposed expansion of manufacturing

activity will have moderately negative change/ impacts due to change in soil bio

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diversity and ecological integrity: C/N ratio, negative change/ impacts due to
accidental release of chemicals leading to degradation of soil quality, soil compaction,
and change in acid buffering function due to wet and dry deposition: CEC and base
saturation, whereas slightly negative change/ impacts due to change in erosion, land
capability, ground sealing, permeability, loss of emission protection and loss of
nutrients due to land use operations. Mitigation measures during construction and
operation stage are presented in Table 4.30.

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Table 4.28 Impacts on Land Environment

Impact Soil Erosi Accidental Soil bio Alterati Land Soil Ground Change in Change in acid Loss of
profile on releases diversity on of capabili compa sealing: filter buffering emission
disturba leading to and terrain ty ction change function: function due to protectio
nce degradation ecological effects in water permeability wet and dry n
of soil integrity: balance deposition: CEC
quality C/N ratio and base
saturation
Activity
Factors
Construction Stage
Levelling by way of √ √ √ √ √ √ √ √
cut and fill
Foundation √ √ √ √ √
excavation
Civil Construction √
Utility emissions √
Process emissions √
Diffuse emissions √
Operation Stage
Incidents and
Accidents
Spillage √ √ √ √
Fugitive emissions √ √ √
Containment failure √ √ √
Accidents during √ √ √
transport of Raw
materials and
products
Accidents during √ √
transport of wastes

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Arson and √
Vandalism
Extreme Weather √
Phenomena
Plant
Decommissioning
Transfer and √ √
disposal of
chemicals
Transfer and √ √
disposal of wastes
Decontamination of √ √
equipment and
containers
Site cleanup √ √ √
Capping drains and √
locking water
sources
√ Indicates Impact

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Table 4.29 Impact Significance – Land environment

Impact Importance Magnitude of Perma Reversibi Cumu (a1) x (a2) (b1) + (b2) (aT) x (bT) = Significance
of condition change/effect nence lity (B2) lative = aT + (b3) = bT ES
(A1) (A2) (B1) (B3)
Soil profile disturbance 1 -2 3 2 2 -2 7 -14 -B
Erosion 1 -1 2 2 2 -1 6 -6 -A
Accidental releases 2 -1 2 2 2 -2 6 -12 -B
leading to degradation of
soil quality
Soil bio diversity and 2 -2 2 2 2 -4 6 -24 -C
ecological integrity: C/N
ratio
Alteration of terrain 1 -2 3 3 2 -2 8 -16 -B
Land capability effects 1 -1 2 2 2 -1 6 -6 -A
Soil compaction 1 -2 2 2 2 -2 6 -12 -B
Ground sealing: change 1 -1 3 3 2 -1 8 -8 -A
in water balance
Change in filter function: 1 -1 3 3 2 -1 8 -8 -A
permeability
Change in acid buffering 2 -1 2 2 2 -2 6 -12 -B
function due to wet and
dry deposition: CEC and
base saturation
Loss of emission 1 -1 2 2 2 -1 6 -6 -A
protection
Loss of nutrients due to 1 -1 2 2 2 -1 6 -6 -A
land use operations

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Table 4.30 Impacts and Mitigation Measures – Land Environment

Activity Impact Mitigation measure
Construction phase
Infrastructure ➢ Soil profile disturbance ➢ Will be confirmed within the site
development ➢ Accidental release of oils, premises.
paints etc. leading to ➢ Segregation at source and
degradation of soil quality disposal to Municipal Solid
➢ Erosion water facilities
➢ Ground water sealing; ➢ Provision of storm water drains
change in water balance in the first stage of construction.
Operation Phase
Storage of raw ➢ Spillages of solvents, RM ➢ Dedicated tank farm with
materials, solvents, during loading leading to concrete flooring, epoxy painting
coal storage soil contamination and floor for above ground level
ground water contamination storage tanks.
➢ Change in air quality ➢ Acid proof lining
➢ Health impact ➢ Dedicated entry road to tank
farm
➢ Covered shed for coal storage
Storage of Process ➢ Accidental release of oils, ➢ Designated covered storage
residue, solvent paints etc. leading to ➢ Labeled containers
residue, stripper degradation of soil quality ➢ Garland drain to storage facility
distillate, Spent ➢ Fire Accident ➢ Disposal to Cement plants for
carbon ➢ Change in odor and health co-incineration
related containments ➢ Personal Protective Equipment
(PPE)
ETP sludge, MEE ➢ Soil contamination ➢ Designated covered storage
salts ➢ Change in odor and health ➢ Labeled containers
related containments ➢ Garland drain to storage facility
➢ Disposal to Cement plants for
co-incineration
➢ Personal Protective Equipment
(PPE)
Coal Ash ➢ Change in air quality ➢ Storage silo with ash conditioning
➢ Health impact facility
➢ Disposal to brick/cement
manufacturers

4.2.6 Biological Environment

The ecological factors that are considered most significant as far as the impact on flora
and fauna concerned are:

1. Whether there shall be any reduction in species diversity?

2. Whether there shall be any habitat loss or fragmentation?
3. Whether there shall be any additional risk or threat to the rare or endangered or
endemic or threatened (REET) species?

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4. Whether there shall be any impairment of ecological functions such as

(i) disruption of food chains,
(ii) decline in species population and or
(iii) Alterations in predator-prey relationships?
5. Whether it is possible to attain the global objectives of ‘no net loss’ of biodiversity?

6. Whether it is possible to improve the biological diversity through the proposed

activity?

There is no direct threat to any rare or endangered or threatened biological species as

indicated by the baseline data, as the proposed expansion is within the existing site
area. The project is not going to cause any fragmentation of habitat or disruption of
food cycles or destruction of breeding grounds or blockade of migratory routes. The
major impacts of the project are mainly during construction and subsequently on
account of atmospheric pollution. The industry is required to limit its emissions as per
the NAAQ of 2009. It has to strictly adhere to the conditions stipulated by the
regulatory bodies. The project authorities are going to take all steps and measures in
order to strictly comply with National Ambient Air Quality Standards of 2009. The
project may not have impacts on terrestrial flora and fauna. Further, as there are no
rare or endangered or threatened (RET) species within the impact area, the expansion
does not pose any direct threat to the survival of any rare species. Hence, the proposed
expansion activity is unlikely to pose any additional threat to REET species in the
impact area. It may be concluded that the impacts are indirect, and positive due to
development of green belt, and of low significance. The impacts due to various
activities during the life time of the project including the emergency scenarios on flora
and fauna are presented in Tables 4.31 and 4.32 respectively. The impact significance
on Flora and Fauna are presented in Tables 4.33 and 4.34 respectively. Mitigation
measures during construction and operation stage are presented in Table 4.35.

The impact assessment indicates that the proposed expansion of manufacturing

activity on flora will have slightly negative change/impacts on removal of
traditionally used plants, reduction in species and community diversity and landscape
diversity, whereas negative change/ impacts due to terrestrial vegetation reduction,
potential acid input and N2 deposition and fragmentation of habitat. The impact

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assessment indicates that the proposed expansion on fauna will have negative
change/ impacts due to loss or alteration of habitat availability, fragmentation of
habitat, and reduced habitat connectivity, increased morality risk and reduce
abundance/ diversity. Photographs of existing greenbelt development layout is
presented in Fig 4.13. Action plan for proposed enhancement of greenbelt is presented
in Table 4.31.

Fig 4.13 Photographs of Existing Greenbelt– NACL Industries Limited.

Table 4.31 Action Plan for Proposed Enhancement of Greenbelt

S.No Year No. of saplings to be planted Budget (Rs)
1 2022-23 4000 1,75,000
2 2023-24 3500 1,70,000
3 2024-25 4500 2,25,000
4 2025-26 5000 2,50,000
5 2026-27 5000 2,50,000
Total 22,000 10,70,000

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Table 4.32 Impacts on Flora

Impact Terrestrial Removal of Reduction in Reduction Potential Fragmentation
vegetation traditionally species and in acid input of habitat
reduction used plants community landscape and N2
diversity diversity deposition
Activity
Clearing and Grubbing √ √ √ √ √
Operation Stage
Regular Operation
Utility emissions √
Process emissions √
Diffuse emissions √
Emissions control √
Operation Stage
Incidents and Accidents
Spillage √
Fugitive emissions √
Containment failure √
Accidents during transport of Raw materials and √
products
Accidents during transport of wastes √
Arson and Vandalism √
Extreme Weather phenomenon √ √ √
Plant Decommissioning
Transfer and disposal of chemicals √
Transfer and disposal of wastes √
Decontamination of equipment and containers √
√ Indicates Impact

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Table 4.33 Impacts on Fauna

Impact Habitat Habitat Reduced Increased Reduced
availability- loss fragmentation habitat mortality abundance/
or alteration connectivity risk diversity
Activity
Construction Stage
Clearing and Grubbing √ √ √ √ √
Levelling by way of cut and fill √ √ √ √ √
Operation Stage
Regular Operation
Utility emissions √
Process emissions √
Diffuse emissions √
Emissions control √
Operation Stage
Incidents and Accidents
Spillage √
Fugitive emissions √
Containment failure √
Accidents during transport of Raw materials and products √
Accidents during transport of wastes √
Arson and Vandalism √
Extreme Weather phenomenon √
Plant Decommissioning
Transfer and disposal of chemicals √
Transfer and disposal of wastes √
Decontamination of equipment and containers √
√ Indicates Impact

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Table 4.34 Impact Significance – Flora

Impact/aspect Importance Magnitude of Permanence Reversibility Cumulative (a1) x (b1) + (aT) x Significance
of condition change/effect (B1) (B2) (B3) (a2) = (b2) + (bT) =
(A1) (A2) aT (b3) = bT ES
Terrestrical vegetation 1 -2 2 3 2 -2 7 -14 -B
reduction
Removal of traditionally 1 -1 2 2 2 -1 6 -6 -A
used plants
Reduction in species and 1 -1 2 2 2 -1 6 -6 -A
community diversity
Reduction in landscape 1 -1 2 2 2 -1 6 -6 -A
diversity
Potential acid input and N2 2 -1 2 2 2 -2 6 -12 -B
deposition
Fragmentation of habitat 2 -1 3 3 3 -2 9 -18 -B

Table 4.35 Impact Significance – Fauna

Impact Importance of Magnitude Permanence Reversibility Cumulative (a1) x (b1) + (b2) (aT) x Significance
condition (A1) of (B1) (B2) (B3) (a2) = + (b3) = (bT) =
change/effect aT bT ES
(A2)
Habitat availability - loss 2 -1 2 2 2 -2 6 -12 -B
or alteration
Habitat fragmentation 2 -1 2 3 2 -2 7 -14 -B
Reduced habitat 2 -1 3 3 2 -2 8 -16 -B
connectivity
Increased mortality risk 2 -1 3 2 2 -2 7 -14 -B
Reduced 2 -1 2 2 2 -2 6 -12 -B
abundance/diversity

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Table 4.36 Impacts and Mitigation Measures - Biological Environment

Activity Impact Mitigation measure
Construction ➢ Habitat loss ➢ Optimizing foot print
Phase ➢ Habitat fragmentation ➢ Plantation before starting construction work.
➢ Development of greenbelt.
➢ Replantation of trees
Operation ➢ Reduction in species ➢ Plantation of native species, preferably
Phase and community similar species that are getting removed
diversity ➢ Avoidance of monoculture plantation.
➢ Storage of top layer of soil and reuse.

4.2.7 Socio-economic Environment

The proposed project envisages additional employment to 200 people, with monthly
salary outlay of Rs. 40 lakhs which will have a direct positive impact. The proximity
of the site to Srikakulam town is 10.6 km, which has adequate infrastructure with
respect to housing, education, transport, health and civic amenities, may have low
impact on infrastructure availability. The impact on health was assessed by air quality
impact predictions and was observed to be within prescribed NAAQ standards. There
will be medium significant, direct negative impact due to community expectations and
public safety concern as the unit handles, and produces hazardous chemicals. The
proposed corporate environment responsibility (CER) activities from the company
shall also enhance the public approval for the proposed expansion and ensure
improvement in infrastructure in the surrounding villages. The impacts due to
various activities during the life time of the project including the emergency scenarios
on Socio-economic environment is presented in Table 4.37. The impact significance
calculated using RIAM method on socio-economic environment is presented in Table
4.38. Mitigation measures are presented in Table 4.39.

The proposed expansion shall have moderately negative impact on traffic, health
concern, public safety concern, while negative impact on traditional use impact,
impact on health, common water resource both ground and surface water, slightly
negative change/ impacts on migration: in and out. Positive impacts are anticipated
due to change/ impacts on employment, housing, change in quality of life, business
opportunity for locals in associated activities, whereas moderately positive change/

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impacts on social infrastructure, community expectations, gender equity, positive

change/ impacts on municipal / local body infrastructure.

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Table 4.37 Impacts on Socio Economic

Impact Empl Migrati Housi Social Munici Traffic Traditi Impa Impact on Chan Commu Gender Busin Heal Public
oym on: in ng infrastr pal/ Impact onal ct on common ge in nity equity ess th safety
ent and out impact ucture Local use healt water quali expecta oppor conc concern
Body impact h resource both ty of tions tunity ern
Infrastr ground and life
ucture surface water
Activity
Construction Stage √ √ √
Clearing and √ √
Grubbing
Levelling by way of √
cut and fill
Foundation √
excavation
civil construction √
Equipment and √ √
machinery erection
Electrical installation √ √
plumbing and piping √ √
painting works √
Operation Stage
Regular Operation √ √ √ √ √ √ √ √
Raw material and √ √ √
finished product
transport
Water use √
Utility emissions √
Process emissions √
Diffuse emissions √
Waste transport √ √ √
Operation Stage √
Incidents and
Accidents

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Spillage √ √ √
Fugitive emissions √ √ √
Equipment Failures √ √
Batch failures
Containment failure √ √
Fire accidents √
Accidents during √ √
transport of Raw
materials and
products
Accidents during √ √
transport of wastes
Plant √ √ √ 1
Decommissioning
Inventory √
preparation
Transfer and disposal √
of chemicals
Transfer and disposal √
of wastes
Decontamination of √
equipment and
containers
Disposal of √
Equipment
Dismantling of √
facility
Demolition Waste √ √
Site cleanup √
Capping drains and √
locking water sources
√ Indicates Impact

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Table 4.38 Impact Significance – Socio Economic

Impact Importance Magnitude Permanence Reversibility Cumulative (a1) (b1) + (b2) (aT) Significance
of of change (B1) (B2) (B3) x + (b3) = x
condition /effect (A2) (a2) bT (bT)
(A1) = aT = ES
Employment 3 2 3 3 3 6 9 54 +D
Migration: in and out 1 -1 3 3 3 -1 9 -9 -A
Housing impact 2 2 3 3 3 4 9 36 +D
Social infrastructure 2 2 2 3 3 4 8 32 +C
Municipal/Local Body 2 1 2 3 3 2 8 16 +B
Infrastructure
Traffic Impact 2 -2 2 3 3 -4 8 -32 -C
Traditional use impact 1 -2 3 2 2 -2 7 -14 -B
Impact on health 2 -2 3 2 3 -4 8 -32 -C
Impact on common water 2 -1 3 2 3 -2 8 -16 -B
resource both ground
and surface water
Change in quality of life 2 2 3 3 3 4 9 36 +D
Community expectations 2 2 2 3 2 4 7 28 +C
Gender equity 2 2 2 3 2 4 7 28 +C
Business opportunity 2 2 3 3 3 4 9 36 +D
Health concern 2 -2 2 3 3 -4 8 -32 -C
Public safety concern 2 -2 2 3 3 -4 8 -32 -C

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Table 4.39 Impacts and Mitigation Measures – Scio-Economic Environment

Impact Mitigation measure
➢ Traffic ➢ Provision of dedicated parking facility
➢ TREM cards to vehicle drivers
➢ Regular training program for drivers
➢ Avoidance of truck movement during shift changes
➢ Avoidance of truck loading and movement during peak hours.
➢ Temporary sheds for driver
➢ Impact on health ➢ Implementation of pollution control measures
➢ Conducting regular health camps in surrounding villages
➢ Traditional ➢ Implementation of corporate environmental responsibility (CER)
impact activities

➢ Impact on ➢ CER activity providing drinking water

common water ➢ Dependence on sea water desalination
resources
➢ Infrastructure of ➢ Avenue plantation
village ➢ Development of greenery in surrounding villages as part of CSR
➢ Infrastructure renovation/development as part of CER based on
requirement mentioned during public hearing.

4.2.7.1 Corporate Environment Responsibility

The proposed expansion provides an opportunity for the local people to get
employment directly or indirectly and helps in the upliftment of the socioeconomic
status of the area. The project proponents propose to involve in social activities of the
stakeholders/surrounding community by planning the betterment of neighboring
social conditions through awareness and welfare programs will ensure an improved
relation, useful in the long run. Many of the beneficiaries of such programs shall
include own employees as well. The goodwill of the local populace can never be
ignored. Another important facet of social environment identified by the project
proponents is a green appearance, hence the management will develop a green belt
towards aesthetic beautification as the same is necessary to be considered as a
responsible, social neighbor. The budget allocated for funding corporate social
responsibility activity is as follows;

Corporate Environment Responsibility: The ministry of Environment, Forest and

Climate Change issued an office memorandum mandating corporate environment
responsibility expenditure contingent on the capital cost of the project, in addition to

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the expenditure on environmental management. The office memorandum

prescribed a CER expenditure of 1 % for brown field projects of less than Rs. 100
crores. The capital cost of the proposed expansion is Rs. 65 crores and hence must
spend Rs. 65 lakhs towards corporate environment responsibility.

Local Content: About 200 no. of employees are from the surrounding villages. Local
produce like rice, vegetables, milk etc. is procured from surrounding villagers by the
canteen.

Capacity building: Skill development, and provision of infrastructural facilities for

drinking water, education and health.

Payment of Taxes: The proposed industry will be paying above Rs. 50 crores per year
towards various central and state taxes.

The following activities are identified to be implemented by the project proponent in

consultation with local public representatives and revenue authorities. The list of
activities village wise is presented in Table 4.40.
Table 4.40 Activity Wise CER – Tentative Budget (2022-23 to 2026-27)
S. Name of Village Activity Total
No Health School Potable Plantation Rs.
Camps Infrastructure RO Plant Lakhs
Cost (in Rs. Lakhs)
1 Harinam Akkivalasa 3.5 3 4 1.5 12
2 Chilkapalem 4 2 5 1.5 12.5
3 Allinagaram 4 4 6 3 17
4 Keshavadasupeta 2.5 2.5 5 2.5 12.5
5 Bhagavandasupeat 3 2 4 2 11
Total 17 13.5 24 10.5 65

4.2.8 Prediction of Impact on Vehicular Traffic

As the plant is located adjacent to the NH-5 there will not be any unauthorized shop
or settlements along the road connecting the plant site. The traffic density of the
connecting road is low mainly consisting of local transport, commercial and passenger
vehicle traffic. There will be 5-10 additional truck trips per day to the factory due to
proposed expansion.

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The traffic study for the connecting road revealed that the peak traffic volume in PCU
is 618 during 8 to 9AM and the level of service of the connecting road remains A, after
proposed expansion also. Modified level of service for connecting roads considering
the additional truck trips for proposed expansion is presented in Table 4.41. It may
be noted that the peak traffic volume is during shift changeover only, while material
transport traffic volume is less.
Table 4.41 Modified level of services for connecting roads
Road Existing Existing Additional Modified Modified Modified Los
volume, volume/ volume/hr Volume volume/ & performance
PCU/hr Capacity (peak) Capacity
Service
road to 218 0.12 40 258 0.14 “A” (Excellent)
NH-5

4.3 Limitation and Uncertainty

The paradigm of post normal science assumes that science is neither value free nor
certain in contrast to normal science, and it is imperative to consider uncertainty due
to ambiguity and ignorance in the science of impact assessment. It may be noted that
cause and effect relation cannot be sufficiently established, as current understanding
of natural systems is insufficiently clear to account for all the potential variation.
Prediction and assessment are conducted on the basis of known assumed causal
relationships only, and the chance of unknown cumulative and or causal relationships
may change the impacts and their significance. Hence the uncertainty due to
ambiguity and ignorance of causal relations warrants adaptive management.

Therefore, it is suggested to incorporate resilience in impact assessment and the

consequent environment management. Accordingly, the proponent shall endeavor to
update the impact assessment in light of any additional knowledge or information
indicating potential adverse impacts and shall incorporate adaptive management.

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5.0 ANALYSIS OF ALTERNATIVES

The proposal is to expand the manufacturing capacity of agrochemicals from 30 TPD to

70.1 TPD, include Captive Co-generation Power Plant of 6 MW in existing site area of
100 acres located at Sy. No. 177, Arinama Akkivalasa village, Etcherla mandal,
Srikakulam district, Andhra Pradesh. Analysis of alternatives was undertaken to assess
process, technology and treatment options to identify the optimum options. The siting
alternatives were not assessed in this case as it was an expansion project. The objective
of this assessment is to identify best available technology not entailing excessive costs,
and to reduce pollution loads by optimizing both raw material and resource
consumption.

5.1 Alternative Sites

The proposal is for expanding the manufacturing capacity without any addition of land
area. The existing site area is sufficient for proposed expansion and hence there is no
requirement of alternative site or additional site area.

5.2 Alternatives in Process

The process mass intensity was mainly contributed by water and solvents. Solvents are
used as a medium of reaction for all the stages of process. The material balance of each
stage of the product was reviewed and it was observed that the solvent usage was
ranging from 2 to 12.3 KLD. Solvents like Methylene dichloride, Ethylene dichloride,
tetrahydrofuran etc. were observed to be used in the manufacturing process of various
products. The management has been a pioneer of conducting research and development
of agrochemicals and is in process of identifying potential solvents from the list of
preferred solvents based on green chemistry principles, i.e., water, methanol, ethanol,
propanol, ethyl acetate etc.

The usage of high-pressure water jet in place of fill and vacate method of washing is
chosen as the best alternative of equipment washing. The product washings will be
optimized by agitating the wash product thereby reducing number of washings. The
management proposed to assess process mass intensity of each stage of manufacturing

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and evaluate the best options of reducing the process mass intensity by reducing usage
of water and solvents in addition to improving the yields of reaction.

5.2.1 Alternatives in Technology

Technical grade agrochemical is mainly batch process, with usage of day tanks, reactors,
and centrifuge, filters and dryers, wherein each stage of process involves different type
of equipment which are potential sources of diffuse emissions. Hence the alternatives
were reviewed for various aspects ranging from charging raw materials into reactors to
drying of product. Manual charging of material shall be completely avoided to reduce
diffuse emissions and loss into atmosphere of raw materials.

The constant flux cooling jacket reactors are proposed for regulating the process
temperature without altering the jacket temperature for quick cooling of reaction mass
to avoid diffuse emissions and loss of media. Other technologies identified for adoption
are dip pipe provision for transfer of liquid materials from day tanks to reactors to avoid
static electricity, air operated diaphragm (AOD) pumps for transfer of materials from
drums, powder transfer systems for solids and transfer by pipeline. The identified
alternative for filter and dryers was agitated nutche filter and dryer (ANFD) which
serves the purpose of both filtration and drying thereby reducing transfer of material
from one equipment to the other resulting in reduced diffuse emissions. It is proposed
to enhance the capacity of solvent recovery system by installing fractional distillation
columns in place of simple distillation to increase purity of recovered solvents, which
can be reused in process, thereby reducing solvent usage and resulting diffuse emissions.
Seamless pipes will be used for piping, with a smaller number of bends and flanges to
avoid loss of material and fugitive emissions. Double mechanical sealed flanges for
solvent transfer pipelines, PTFE pumps for transfer of corrosive material transfer and
charging are the identified alternatives proposed for implementation.

5.2.2 Alternatives in treatment/mitigation options

The emission sources in the proposed expansion project are utilities, storages, process
and effluent treatment system. The alternatives assessed for air pollution control
equipment for the proposed boiler are cyclone, multicone cyclone, scrubbers, bag filter

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and electro static precipitator. Electro static precipitator is selected as the optimum
technology for boilers considering its large capacity and to ensure particulate emission
standards as prescribed by CPCB/SPCB. The alternatives assessed for mitigating
emissions from process are scrubber with single stage, and double stage, and condensers,
and to mitigate diffuse emissions, nitrogen blanketing with breather valves and thermal
insulation for storages; nitrogen blanketing for low boiling solvents was assessed.
Condensers are proposed to mitigate both diffuse and process emissions and the
alternatives of cooling medium assessed were RT water, cold water, chilled brine. Cold
water and chilled brine were identified as the best medium to mitigate release of VOC
emissions into atmosphere.

Zero liquid discharge based effluent treatment system is being used for treated effluent
disposal and the same is practised after expansion also. The concentration of effluents is
high for TDS and COD from multiple streams. Accordingly, a complex system involving
chemical precipitation, physical separation and filtration by RO and biological treatment
was identified considering the inadequacy of a single and simple technology to treat
complex wastes from agrochemical manufacturing, to ensure reuse of treated
wastewater. The adoption of zero liquid discharge-based treatment system however
observed to be a source of solid waste as the organic and inorganic components are
separated, as either stripper condensate and or salts from multiple effect evaporator
(MEE) and agitated thin film dryer (ATFD). The management identified this aspect and
proposed to identify alternative solid waste treatment/disposal methods, and
accordingly proposed to assess the feasibility of extracting saleable by-products,
disposing the stripper condensate for co-incineration in cement plants.

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6.0 ENVIRONMENTAL MONITORING PROGRAM

6.1.1 Introduction

Environmental monitoring is part of EIA follow up to assess the effectiveness of

control/mitigation management measures proposed and adopted by the project
authority during construction, operation, emergency situations, and closure or
decommission stages. The follow up monitoring facilitates to evaluate management, and
communication of the environmental performance of the project also. The follow up of
EIA after obtaining prior environmental clearance shall consist of monitoring,
evaluation, management, and communication for NACL expansion project. The
definition of these terms adopted by International Association for Impact Assessment
(IAIA) based on Arts et al (2001); Morrison-Saunders and Arts (2004) is as follows;
monitoring: the monitoring, analysis, and collection of data followed by comparison with
standards, predictions or expectations; evaluation: the appraisal of the conformity with
standards, predictions or expectations and the environmental performance of the
activity, akin to audit, wherein an objective comparison of monitoring results with
predefined criteria is made; management: making decisions and necessary action to
address the concerns arising out of monitoring and evaluation, wherein decisions may
be taken by the proponent (NACL) or by the regulator (MoEFCC or APPCB); and
communication: informing the stakeholders about the results of EIA follow-up (to
provide feedback on project/plan implementation and EIA processes).

These follow up programs may involve direct participation of stakeholders also, with
respect to monitoring, evaluation, and management. This follows up activity will
provide a feedback loop to project authority and regulators to ensure adaptive
management, ensuring continual assessment of impacts, and converting EIA/EMP into
a dynamic document. The objective of the follow up is threefold, a. monitoring and
evaluation of EIA activity to assure the adequacy of environment management at micro-
scale, b. evaluation of EIA systems at the macro scale addressing the efficiency and
effectiveness of the EIA system and c. evaluation of the utility of EIA at the meta scale
addressing the key question of whether EIA works?
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Accordingly, environmental monitoring is envisaged for various phases of the project

ranging from construction to decommissioning. The monitoring program elaborates
applicable standards, selection of environmental parameters for monitoring, type of
monitoring, frequency of monitoring, location of monitoring, data analysis, reporting
schedule, emergency procedure, responsibility, and the budget for monitoring.

6.1.2 Objectives

The objectives of the environmental monitoring programme are;

• Evaluation of the efficiency of mitigation and pollution control measures;

• Updating of the actions and impacts of baseline data;

• Adoption of additional mitigation measures if the present measures are insufficient;

• Generating data, which may be incorporated into the environmental management

plan in future projects.

6.1.3 Methodology

The proposed expansion involves construction of few facilities, electro mechanical works
related utilities, manufacturing facilities and enhancement of zero liquid discharge
facility. The Construction activity results in mainly air emissions consisting of dust and
particulates, increased noise levels, wastewater from domestic water use, construction
and demolition waste in addition to municipal solid waste and empty containers and
other hazardous wastes. The operational phase results in mainly air emissions, liquid
effluents, and solid wastes in significant quantity. Accidents and incidents may result in
air emissions consisting volatile organics, increased noise levels, effluents from
firefighting, and other solid wastes due to accidental spillages. The decommissioning
stage results in air emissions consisting of dust and particulates, increased noise levels,
effluents from cleaning and detoxification, etc., and solid wastes consisting of demolition
wastes and other hazardous and non-hazardous wastes. Hence the monitoring program
shall address the above aspects within the plant, outside the battery limit, and at the
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sensitive locations in the impact area. The monitoring program includes visual
observations, frequent sampling, and monitoring, continuous monitoring, and analysis
of selected parameters. Monitoring methodology for air quality, noise levels, water
quality, solid wastes and soil, ecology, and biodiversity cover the following key aspects:

• Components to be monitored
• Parameters for monitoring of the above components
• Monitoring frequency
• Monitoring standards
• Responsibilities for monitoring
• Direct responsibility
• Overall responsibility
• Monitoring costs.
Environmental monitoring of the parameters involved and the threshold limits specified
are discussed below for the proposed expansion of agrochemicals unit of M/s. NACL
Industries Limited.

6.1.4 Ambient Air Quality (AAQ) Monitoring

Ambient air quality parameters recommended are PM10, PM2.5, Oxides of Nitrogen
(NOX), Sulphur Dioxide (SO2), Volatile Organic Compounds (VOC), Chlorine, and HCl.
These are to be monitored at designated locations starting from the commencement of
construction activity for expansion. Data will be generated at all identified locations in
accordance to the National Ambient Air Quality Standards (Table 6.1) location, duration
and the pollution parameters to be monitored and the responsible institutional
arrangements are detailed out in the Environmental Monitoring Plan.
Table 6.1 National Ambient Air Quality Standards
S.No Pollutant Time Concentration in Ambient Air
Weighted
Industrial, Ecological Methods of
Average
Residential, Sensitive Area Measurement
Rural and (Notified by
Other Area Central
Government)

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1 Sulphur Dioxide Annual* 50 20 Improved west and

(SO2) GaekeUltraviolet
24 Hours** 80 80 fluorescence
2 NitrogenDioxid Annual* 40 30 Modified Jacob &
e (NO2) Hochheiser (Nn-Arsenite)
24 Hours** 80 80 Chemiluminescence
3 Particulate Annual* 60 60 Gravimetic
Matter (Size TOEM
Less than 10 24 Hours** 100 100 Beta Attenuation
µm) or PM10
4 Particulate Annual* 40 40 Gravimetic
Matter (Size TOEM
Less than 24 Hours** 60 60 Beta Attenuation
2.5µm) or PM2.5
5 Ozone (O3) 8 hours** 100 100 UV Photometric
Chemilminescence
1 hour** 180 180 Chemical Method
6 Lead (Pb) Annual* 0.50 0.50 AAS /ICP method after
sampling on EPM 2000 or
24 hours** 1.0 1.0 equivalent filter paper
ED-XRF using Teflon
filter.
7 Carbon 8 hours** 02 02 Non Dispersive Infra Red
Monoxide (CO) (NDIR)
1 hour** 04 04 Spectroscopy
8 Ammonia Annual* 100 100 Chemilminescence
(NH3) 24 hours** 400 400 Indophenol blue method
Gas Chromotography
based continuous
analyzer
9 Benzene (C6H6) Annual* 05 05
Absorption and
Desorption followed by
GC analysis
10 Benzo (o) Annual* 01 01 Solvent extraction
Pyrene(BaP) – followed by HPLC/GC
Particulate analysis
Phase only,
11 Arsenic (As), Annual* 06 06 AAS/ICP method after
sampling on EPM 2000 or
equivalent filter paper
12 Nickel (Ni), Annual* 20 20 AAS/ICP method after
sampling on EPM 2000 or
equivalent filter paper
*Average Arithmetic mean of minimum 104 measurement in a year taken for a week 24 hourly at uniform
interval.
**24 hourly/8 hourly values should meet 98 percent of the time in a year

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6.1.5 Water Quality Monitoring

The physical and chemical parameters recommended for analysis of water quality
relevant are pH, total solids, total dissolved solids, total suspended solids, oil and grease,
COD, BOD, chloride, sulfate, Oil and Grease. The location, duration and the pollution
parameters to be monitored and the responsible institutional arrangements are detailed
in the Environmental Monitoring Plan. The monitoring of the water quality is to be
carried out at all identified locations in accordance to the Indian Standard Drinking
Water Specification – IS 10500: 1991 (stated inTable6.2)
Table 6.2 Indian Standard Drinking Water Specifications – IS: 10500:1991
S. No Substance or Requirem Undesirable Effect Methods Remarks

Limit in the
Permissible

Absence of
Characteristics ent Outside the Desirable of Test

Alternate
Source
(Desirable Limit (Ref. To
Limit) IS)

ESSENTIAL CHARACTERISTICS
1 Colour, Hazen 5 Above 5, consumer 25 3025 Extended to 25 only if
units, Max. acceptance decreases (Part 4) toxic substances are not
1983 suspected, in absence of
alternate sources
2 Odour Unobjectio - - 3025 a) Test cold and when
nable (Parts5): heated
1984 b) Test at several
dilutions
3 Taste Agreeable - - 3025 Test to be conducted
(Part 7& 8) only after safety has been
1984 established
4 Turbidity NTU, 5 Above 5, consumer 10 3025 -
Max. acceptance decreases (Part 10)
1984
5 pH Value 6.5 to 8.5 Beyond this range, the No 3025 -
water will affect the relaxatio (Part 11)
mucous membrane n 1984
and/or water supply
system
6 Total hardness 300 Encrustation in water 600 3025 -
(as CaCO3) supply structure and (Part 21)
mg/l, Max adverse effects on 1983
domestic use
7 Iron (as Fe) 0.3 Beyond this limit 1 32 of 3025 : -
mg/l, Max taste/appearance are 1964
affected, has adverse
effect on domestic uses
and water supply struc-

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S. No Substance or Requirem Undesirable Effect Methods Remarks

Limit in the
Permissible

Absence of
Characteristics ent Outside the Desirable of Test

Alternate
Source
(Desirable Limit (Ref. To
Limit) IS)

tures, and promotes iron

bacteria
8 Chlorides (as 250 Beyond this limit, taste, 1000 3025 -
CI) mg/l, Max corrosion and palatibility (Part 32)
are affected 1988
9 Residual, free 0.2 - - 3025 To be applicable only
chlorine, mg/l, (Part 26) when water is
Min 1986 chlorinated. Tested at
consumer end. When
protection against viral
infection is required, it
should be Min 0.5 mg/l
DESIRABLE CHARACTERISTICS
1 Dissolved 500 Beyond this palatability 2000 3025 -
solids mg/l, decreases and may cause (Part 16)
Max gastro intestinal irritation 1984
2 Calcium (as Ca) 75 Encrustation in water 200 3025 -
mg/l, Max supply structure and (Part 40)
adverse effects on 1991
domestic use
3 Magnesium (as 30 Encrustation to water 100 16, 33, 34 of -
Mg), mg/l, Max supply structure and IS 3025: 1964
adverse effects on
domestic use
4 Copper (as Cu) 0.05 Astringent taste, 1.5 36 of 3025: -
mg/l, Max discoloration and cor- 1964
rosion of pipes, fitting and
utensils will be caused
beyond this
5 Manganese (as 0.1 Beyond this limit 0.3 35 of 3025: -
Mn) mg/l, Max taste/appearance are 1964
affected, has adverse
effects on domestic uses
and water supply
structures
6 Sulphate (as 200 Beyond this causes gastro 400 3025 May be extended up to
200 SO4) mg/l, intestinal irritation when (Part 24) 400 provided (as Mg)
Max magnesium or sodium are 1986 does not exceed 30
present
7 Nitrate (as 45 Beyond this, may cause 100 3025 (Part -
NO2) mg/l, methaemoglobinemia 34) 1988
Max
8 Fluoride (as F) 1 Fluoride may be kept as 1.5 23 of 3025: -
mg/l, Max low as possible. High 1964

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S. No Substance or Requirem Undesirable Effect Methods Remarks

Limit in the
Permissible

Absence of
Characteristics ent Outside the Desirable of Test

Alternate
Source
(Desirable Limit (Ref. To
Limit) IS)

fluoride may cause

fluorosis
9 Phenolic 0.001 Beyond this, it may cause 0.002 54 of 3025: -
compounds (As objectionable taste and 1964
C6H5OH) mg/l, odour
Max
10 Mercury (as 0.001 Beyond this, the water No (see Note) To be tested when
Hg) mg/l, Max becomes toxic relaxatio Mercury ion pollution is suspected
n analyzer
11 Cadmium (as 0.01 Beyond this, the water No (See note) To be tested when
Cd), mg/l, Max becomes toxic relaxatio pollution is suspected
n
12 Selenium (as 0.01 Beyond this, the water No 28 of 3025: To be tested when
Se), mg/l, Max becomes toxic relaxatio 1964 pollution is suspected
n
13 Arsenic (As As) 0.05 Beyond this, the water No 3025 To be tested when
mg/l, max becomes toxic relaxatio(Part 37) pollution is suspected
n 1988
14 Cyanide (As 0.05 Beyond this limit, the No 3025 To be tested when
CN), mg/l, Max water becomes toxic relaxatio (Part 27) pollution is suspected
n 1986
15 Lead (as Pb), 0.05 Beyond this limit, the No (see note) To be tested when
mg/l, Max water becomes toxic relaxatio pollution is suspected
n
16 Zinc (As Zn). 5 Beyond this limit it can 15 39 of 3025: To be tested when
Mg/l, Max cause astringent taste and 1964) pollution is suspected
an opalescence in water
17 Anionic 0.2 Beyond this limit it can 1 Methylene- To be tested when
detergents (As cause a light froth in blue pollution is suspected
MBAS) mg/l, water extraction
Max method
18 Chromium (As 0.05 May be carcinogenic No 38 of 3025: To be tested when
Cr6+) mg/l, above this limit relaxatio 1964 pollution is suspected
Max n
19 Poly nuclear - May be carcinogenic - - -
aromatic above this limit
hydrocarbons
(as PAH) g/1,
Max
20 Mineral oil 0.01 Beyond this limit un- 0.03 Gas -
mg/l, Max desirable taste and odour Chromatogr
after chlorination take aphic
place method
21 Pesticides Absent Toxic 0.001 - -
mg/l, Max
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S. No Substance or Requirem Undesirable Effect Methods Remarks

Limit in the
Permissible

Absence of
Characteristics ent Outside the Desirable of Test

Alternate
Source
(Desirable Limit (Ref. To
Limit) IS)

22 Radioactive materials: 58 of -
3025:01964
23 a) Alpha - - 0.1 - -
emitters Bq/l,
Max
24 Beta emitters - - 1 - -
pci/1, Max
25 Aluminium (as 200 Beyond this limit taste 600 13 of -
Al), mg/l, Max becomes unpleasant 3025:1964
26 Aluminium (as 0.03 Cumulative effect is 0.2 31 of 3025: -
Al), mg/l, Max reported to cause 1964
dementia
27 Boron, mg/l, 1 - 5 29 of 3025: -
Max 1964
Source: Indian Standard Drinking Water Specification-IS10500:1991

6.1.6 Noise Level Monitoring

The measurements for monitoring noise levels would be carried out at all designated
locations in accordance to the Ambient Noise Standards formulated by Central Pollution
Control Board (CPCB) in 1989 (refer Table 6.3) Sound pressure levels would be
monitored on twenty-four-hour basis. Noise level will be recorded at a “A” weighted
frequency using a “slow time response mode” of the measuring instrument. The location,
duration and the noise pollution parameters to be monitored and the responsible
institutional arrangements are detailed in the Environmental Monitoring Plan (Table 5.3)
Table 6.3 Noise level standards (CPCB)
Type Noise level for Day Noise level for
Industrial area Time Leq75 dB(A) Night Time
70 dB(A)
Commercial area 65 55
Residential area 55 45
Silence zone 50 40
Day time - 6.00 am - 9.00 pm (15 hours)
Night time - 9.00 pm - 6.00 am (9 hours)
The monitoring plan along with environmental parameters and the time frame is
presented in the Table 6.4.

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Table 6.4 Environmental Monitoring Plan (Terms of Reference No. 7 (xii))

S. Particulars Monitoring Standards Duration Important monitoring
No Frequency of parameters
Sampling
Ambient Air Quality Monitoring
1 Within Industry Continuous Air (Preven- Continuo PM10, PM2.5, SO2, NOx,
3 places tion and us Cl2, HCl and VOC
2 Two locations outside Monthly Control of 24 hrs PM10, PM2.5, SO2, NOx
industry site Pollution) and VOC
2 Work Place Monthly Rules, 8 hr SPM, VOC
Monitoring: CPCB, 1994
Production blocks 10
locations, Solvent
Tankfarm and ETP
area
Stack Emissions Monitoring
1 Utility Stacks :3 nos. Monthly Air (Preven- --- PM, SO2, NOx, VOC,
Coal fired boilers, 1no tion and HCl, recommended
furnace oil boiler, 2 Control of methods of CPCB.
nos. Thermic fluid Pollution)
heater and 5 no.s DG CPCB, 1994
sets.
Water Quality Monitoring
1 Process water Daily Water Grab pH, TDS, SS, BOD,
Quality COD and Oil & Grease
standards by Hardness, , chlorides,
CPCB using APHA or BIS
analytical methods.
2 Effluents Stream wise Quarterly Grab pH, TDS, SS, BOD,
COD using APHA or
BIS analytical
methods.
3 Treated effluent after Daily Grab pH, TDS, TSS, COD,
ZLD System BOD and Oil and
Grease using APHA or
BIS analytical
methods.
Noise Quality Monitoring
1 Noise Levels at 2 Quarterly Noise stan- 24hrs Equivalent Noise
Locations within dards by levels in dB(A)
plant site and 2 CPCB
locations outside the
plant site,
Kesavadasupeta and
Akkivalasa villages
Soil Quality Monitoring

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1 Soil - 3 locations Once a year pH, EC, CEC, Lead,

within the site; Near Moisture, Texture,
production blocks (10 Bulk Density etc.
no.s), Solvent tank
farm area and ETP
area.

6.1.7 Responsibility of Monitoring and Reporting System

The overall responsibility of monitoring the above parameters shall lie with the
management of NACL Industries Limited. The maintenance/environment wing shall be
responsible for day-to-day monitoring of effluent, raw water and treated water quality.
The Ambient air quality, Stack emissions, soil, noise and water quality shall be monitored
by either third party or by the Environment management division of the unit.

NACL Industries Ltd have established a laboratory and also obtain accreditation from
NABL as a testing laboratory for environmental monitoring. The laboratory has facility
to collect, monitor and analyses samples for ambient air quality, stack emissions, solid
waste, wastewater and noise levels. The equipment and instruments are purchased in
accordance with “guidelines for recognition of environmental laboratories under
Environment (protection) act, 1986” CPCB, 2009. Records shall be maintained for
analysis of raw effluents and treated effluents, ambient air quality data, stack emissions
monitoring results, micrometeorological data and noise levels. These records are not
only required for the perusal of the Pollution Control Board authorities but also to derive
at the efficiencies of the pollution control equipment as the objective of the project
proponent is not only compliance with statutory regulations, but also a serious
commitment towards clean environment.

The industry shall maintain the records as per the hazardous waste regulations and EPA
regulations and apply for the annual consents for air and water, and renewal of
authorization for the storage of hazardous waste as per Hazardous Waste (Handling
&Management) Rules, 1989. The records of hazardous waste manifest will be
maintained.

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Reporting system provides the necessary feedback for project management to ensure
compliance with stipulated standards and facilitate adaptive management. The rationale
for a reporting system is based on accountability to ensure that the measures proposed
as part of the environmental management plan get implemented in the project.

6.1.7.1 Work Zone Monitoring for Hazardous Chemicals

(Terms of Reference No. Sp. TOR (4))

Periodic Work zone monitoring is carried out to review indoor toxic chemicals
concentration. The periodicity of monitoring is dependent on the concentrations i.e.,
below or above TLV values, ranging from once a month in case of higher values to once
a year in case of lower values.

6.2 Environmental Monitoring Budget

The environmental monitoring budget for monitoring air, water, soil, and noise levels is
presented in Table 6.5. It may be noted that the annual expenditure for environmental
monitoring is Rs. 11.67 Lakhs. As per CPCB guideline, the calibration procedures for
analyzers shall conform to US EPA methodologies and shall include daily calibration
checks, biweekly precision checks and linearity checks every six weeks. All analyzers
shall undergo full calibration every six weeks. Data obtained from these calibration
checks and copies of associated Quality Assurance and calibration documentation, shall
be submitted to the PCB along with the Air Quality Data.
Table 6.5 Environmental Monitoring Budget
Particulars Monitoring Frequency Unit Cost Annual Cost
Rs. Rs.
Ambient Air Quality Monitoring Monthly 7500 320000
Work Place Monitoring Monthly 2000 240000
Stack Emissions Monitoring Monthly 2700 194400
DG Set Stack Emissions Monitoring Quarterly 2700 54000
Process water Daily 500 165000
Effluents - Stream wise Quarterly 600 4800
Treated effluent (ETP water) Daily 600 198000
Noise Level Monitoring Quarterly 1000 12000
Soil Quality Once a year 2000 24000
Total (Rs.) 1167200

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7.0 ADDITIONAL STUDIES

7.0 Introduction
This chapter presents the risk assessment study results for the plant operations, transport
and storage of raw materials, and identifies maximum credible accident scenarios to draw
the emergency management plan addressing various credible scenarios identified.

7.1. Objectives and Scope

The production of agrochemicals involves usage of many chemicals which are both
hazardous and toxic in nature. The risks associated with the chemical industry are
commensurate with their rapid growth and development. Apart from their utility,
chemicals have their own inherent properties and hazards. Some of them can be
flammable, explosive, toxic or corrosive etc. The whole lifecycle of a chemical should be
considered when assessing its dangers and benefits. In order to ensure the health and
safety of persons at or near the facilities, Govt. has approved some regulations. The
regulation requires Employers to consult with employees in relation to:
- Identification of major hazards and potential major accidents
- Risk assessment
- Adoption of control measures
- Establishment and implementation of a safety management system
- Development of the safety report

The involvement of the employees in identification of hazards and control measures

enhances their awareness of these issues and is critical to the achievement of safe
operation in practice. In order to comply with regulatory authorities, M/s NACL
Industries Limited have entrusted Team Labs and Consultants, Hyderabad to review and
prepare Hazard analysis and Risk assessment for their facility along with an approach to
on-site emergency preparedness plan as required under the acts and rules. (Manual on
emergency preparedness for chemical hazards, MOEF, New Delhi). In this endeavor, the
methodology adopted is based on;

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• visualizing various probable undesirable events which lead to major accidents

• detailed and systematic assessment of the risk associated with each of those
hazards, including the likelihood and consequences of each potential major accident
event; and
• identifying the technical and other control measures that are necessary to reduce
that risk to a level that is as low as reasonably practicable

The strategy to tackle such emergencies, in-depth planning and person(s) or positional
responsibilities of employees for implementation and coordination of timely and effective
response measures are described in onsite detail in Emergency Plan.

7.2 Project Details

The plant site of 100 acres is located at Sy. No. 177, Arinama Akkivalasa village, Etcherla
mandal, Srikakulam district, Andhra Pradesh. The site at the intersection of 180 16’31” (N)
latitude and 830 47’33” (E) longitude. The plant site is surrounded by open agricultural
lands in east, west and south directions, chilakapalem road connecting to Akkivalasa
village in north direction. The main approach road is NH-5 is at a distance of 0.53 km in
south direction. The nearest habitation from the site is Kesavadasupeta located at distance
of 0.3 km in northwest direction. The nearest town is Srikakulam at a distance of 10.6 km
in NE direction. The nearest railway station is Ponduru at a distance of 10.5 km in north
direction and nearest airport is Visakhapatnam located at a distance of 85 km in southwest
direction. Pedda gedda a seasonal stream is at a distance of 4.2 km in SW direction. Chitti
gedda a seasonal stream is at a distance of 4.7 km in SW direction. There are no reserve
forests, national Parks, sanctuary, biosphere reserves, ecologically sensitive area, critically
polluted area and interstate boundary within the impact area of 10 km surrounding the
site. The manufacturing capacity after expansion is presented in Table 7.1 and by products
in Table 7.2

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Table 7.1 Proposed Manufacturing Capacity – After Expansion

S.No Name of the Product CAS No. Capacity
(TPD)
1 Cloquintocet Mexyl 99607-70-2 0.5
2 Triazinone / Thiocarbohydrazide/Dichloro 2231-57-4 10
Pinacolone /Pinacolone
3 2,3 Di chloro Pyridine 2402-77-9 0.5
4 Profenofos 41198-08-7 15.0
5 Thiamethoxam 153719-23-4 1.0
6 Fipronil 120068-37-3 1.0
7 Imidachloprid 138261-41-3 0.5
8 Acetamiprid 135410-20-7 0.5
9 Lambda Cyhalothirin 91465-08-6 1.0
10 Bifenthirin 82657-04-3 1.0
11 Cypermethrin 52315-07-8 0.5
12 Carbendazim 10605-21-7 0.5
13 Pymetrozine 123312-89-0 0.5
14 Telfluthrin 79538-32-2 0.5
15 Pyriproxyfen 95737-68-1 1.0
16 Emamactin Benzoate 155569-91-8 1.0
17 Diafenthiuron 80060-09-9 1.0
18 Propiconazole / Bromoketal (Intermediate) 60207-90-1 3.0
19 Tricyclazole 41814-78-2 2.5
20 Fenbuconazole 114369-43-6 1.0
21 Myclobutanil 88671-89-0 1.0
22 Thifluzomide 130000-40-7 0.8
23 Hexaconazole 79983-71-4 1.0
24 Tebuconazole / Oxirane (Intermediate) 107534-96-3 1.0
25 Difenconazole 119446-68-3 0.5
26 Epoxiconazole 135319-73-2 0.5
27 Cyproconazole 94361-06-5 0.5
28 Thiophanate-methyl 23564-05-8 1.0
29 Azoxystrobin 131860-33-8 1.0
30 Trifloxystrobin 141517-21-7 1.0
31 Pendimethalin 40487-42-1 1.5
32 Pretilachlor 51218-49-6 4.0
33 Metribuzin 21087-64-9 1.6
34 Dimethomorph 110488-70-5 2.0
35 Clodinofop-Propargyl 105512-06-9 1.0
36 Bispyribec Sodium 125401-92-5 1.0
37 Bensulfuron Methyl 83055-99-6 1.0
38 Glufosinate Ammonium 77182-82-2 1.0
39 Quizalofop-p-ethyl 100646-51-3 1.0

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40 Tribenuron Methyl 101200-48-0 0.5

41 Clethodim 99129-21-2 1.0
42 Pinoxsulam 219714-96-2 1.0
43 S-Metolachlor 87392-12-9 1.0
44 Verbinone 1196-01-6 0.2
45 (Z)-hezatec – 11-en-1-yl acetate 34010-21-4 0.2
46 (Z)-hezatec – 9-enal 56219-04-6 0.2
47 (8E,10E) – Dodoca-8, 10-dyen-1-ol 76600-88-9 0.2
48 7Z,11Z hexadeca dienyl acetate 53042-81-2 0.2
49 7E, 9Z dodoca dienyl acetate 54364-62-4 0.2
50 8Z Dodecinyl acetate 28079-04-1 0.2
51 (Z)-Octadeca – 13 – enyl acetate 60037-58-3 0.2
52 R&D Products 0.1
Total 70.1
II Bio Based Agro Chemicals
1 Pseudomonas Fluorosense+ Bacillus Subitilis 0.17
2 Trichoderma Harzianum+Verticillium 0.17
chlamydosporium
3 Ampelomyces quisqualis+BeauveriaBassiana 0.17
4 Beauveria bassiana+ Metarhizium anisopliae 0.17
5 Beauveria bassiana 0.17
6 Metarhizium anisopliae 0.17
7 Verticillium lecanii+Beauveria Bassiana 0.17
8 Hirsutella thompsonii+Beauveria Bassiana 0.17
9 Hirsutella thompsonii 0.17
Total 1.53
Captive Co-generation power plant 6 MW

Agrochemicals Formulations
S.No Name of Product Unit Capacity
1 Granules MT/year 20000
2 Liquids Kl/Year 25000
3 Powders MT/year 5000
Total 50000 50000
Table 7.2 List of By-products – After Expansion
S.No Name of the Product By-Product Quantity
(Kg/day)
1 Triazinone Hydrochloric Acid (30%) 2470
NASH solution 1300
2 Myclobutanil Sodium Bromide 1070
3 Difenoconazole Potassium Chloride 183.5
Potassium Bicarbonate 246.4
4 Tribenuron-methyl Technical Ethanol 116.5

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5 Dil. HCl (25%) from Scrubbers 5228.5

6 HBr (25%) from Scrubbers 1359.7

Table 7.3 List of Raw Materials and Inventory (Terms of Reference No. 3(iv) & (3(v))
S. Name of Raw Inventory Mode of Storage Physical Nature of
No Material (MT) Form Chemical
1 Acetic Acid 1 x 10 SS Storage Tank Liquid Flammable,
Corrosive
2 Acetone 2 x 50 SS Storage Tanks Liquid Flammable
3 Acetonitrile 2 x 50 SS Storage Tanks Liquid Toxic
4 Bromine 2 x 10 SS Storage Tanks Liquid Toxic
5 Benzene 1x1 SS Storage Tank Liquid Toxic
6 Chlorine Tonners Tonners Liquid Toxic
7 Cyclohexane 1 x 30 SS Storage Tank Liquid Highly Flammable
8 Dimethyl Formamide 2 x 30 SS Storage Tanks Liquid Flammable
9 Dimethyl sulfoxide 1 x 30 SS Storage Tank Liquid Irritant and
flammable
10 Ethylene Dichloride 1 x 30 SS Storage Tank Liquid Carcinogenic
11 n-Hexane 1 x 30 SS Storage Tank Liquid Flammable
12 n-Heptane 1 x 30 SS Storage Tank Liquid Flammable
13 Isopropyl Alcohol 1 x 10 SS Storage Tank Liquid Flammable
14 Methanol 2 x 50 SS Storage Tanks Liquid Flammable
15 Methylene Dichloride 2 x 50 SS Storage Tanks Liquid Carcinogenic
16 Methyl tert-butyl ether 1 x 30 SS Storage Tank Liquid Flammable
17 N-Methyl-2- 1 x 10 SS Storage Tank Liquid Toxic
Pyrrolidone
18 Tetrahydrofuran 1 x 30 SS Storage Tank Liquid Flammable /
Carcinogenic
19 Toluene 2 x 50 SS Storage Tanks Liquid Flammable
20 Xylene 1 x 30 SS Storage Tanks Liquid Toxic

7.3 Process Description

The manufacturing process for all the products is presented as separate Annexure.

7.4 Plant Facilities

The manufacturing facility shall be provided with
1. Production Blocks 6. Tank Farm
2. Utilities 7. Cylinder Storage Area
3. Quality Control, R&D Facility 8. Administrative Office
4. Effluent Treatment Plant 9. Coal and Ash Storage Area
5. Warehouse 10. HWA Storage Area

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The production facilities shall be designed for proper handling of materials and machines.
Safety of operators, batch repeatability and process parameter monitoring shall be the
major points of focus in the design of facility. The current Good Manufacturing Practices
(GMP) guidelines shall be incorporated as applicable to synthetic organic chemicals
manufacturing facilities.

7.4.1 Production Area

The Production blocks will consist of SS and glass lined reactors, storage tanks, shell &
tube heat exchangers, evaporators, vacuum pumps, packed columns, Agitated Nutche
Filter and Dryers, crystallizers, layer separators etc. The area shall be provided with
proper concealed drainage facility and all process facilities shall be performed under
protective environment.

7.4.2 Utilities:
The proposed expansion requires additional steam for process, ZLD system and solvent
recovery system. It is proposed to establish coal fired boilers of capacity 1 x 50 TPH coal
fired boiler in addition to existing 1 x 16 TPH, 1 x 10 TPH coal fired and 1 x 6 TPH oil fired
boilers. It is proposed keep existing boiler as standby after establishment of proposed 1 x
50 TPH boiler. It is proposed to establish 1 x 10 lakh k.cal/hr and 1 x 6 lakh k.cal/hr
thermic fluid heaters as part of expansion. The total power requirement is estimated to be
4.0 MW. The DG sets required for emergency power during load shut down is estimated
at 2 x 2000 kVA proposed in addition to existing 1 x 1000 kVA and 2 x 500 kVA. The list of
utilities is presented in the following Table 7.4.

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Table 7.4 List of Utilities

S.No Utility Existing Proposed After
expansion
1 Coal Fired Boilers (TPH) 1 x 16 1 x 50, 1 x 50,
1 x 10 1 x 16 *
1 x 10 *
2 Furnace oil boiler (TPH) 1x6 -- 1x6*
3 Thermic Fluid Heaters (K.cal/hr) 1 x 10 Lakh 1 x 10 Lakh
1 x 6 Lakh 1 x 6 Lakh
4 DG Sets (kVA)# 1 x 1000, 2 x 2000 2 x 2000
2 x 500 1 x 1000
2 x 500
* Standby after expansion #DG sets will be used during load shut down by Transco.

7.4.3 Quality Control, R&D Lab

The QC department shall comprise of an in-process lab with instruments like HPLC, GC
etc. It will be maintained by highly qualified and trained people. Process development
laboratory is provided for in-house process development, initial evaluation of process
technology in case of technology transfer, back-up for production department to address
any issues arising during commercial production.

7.4.4 ETP and Solid waste storage

The total effluents segregated into four streams; high COD/ TDS, Low COD/TDS, high
COD and Low TDS and high TDS streams based on source of generation. These effluents
are treated in effluent treatment plant based on Zero Liquid Discharge principle and the
treated effluent is reused for process, washings, scrubbers and cooling tower make-up.

7.4.5 Ware Houses:

The plant shall have sufficient storage facility for safe handling of raw materials. All solid
raw materials shall be stored in marked areas with proper identification. Liquid raw
materials and solvents like which are available in drums will be stored according to
material compatibilities and flammability. Adequate firefighting facilities shall be
provided as per NFPA norms.

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7.4.6 Tank Farm Area:

A separate tank farm area shall be provided to avoid cross contamination and inveiw of
safety storage. All liquid raw materials, specially solvents with high inventory and also
for toxic, corrosive chemicals shall be provided with dykes to ensure safety in case of tank
failure. Acid proof lining for the dykes shall be provided for acid storage tanks.
Condensers for low volatile solvent storage tanks vents. Vent Condensers for
dichloromethane and chloroform storage tanks vents. Liquid Chlorine will be stored on
tonners in closed shed with vents connected to emergency scrubber. Chlorine sensors,
rupture discs are provided at storage area.

7.4.7 Administrative Office:

An Administrative office shall be provided at the entrance of the factory to ensure the
entry of authorized personnel only into the premises.

7.4.8 Cylinders storage Area:

Gas cylinders storage should conform to SMPV-Unfired rules-1981.Chlorine storage tanks
will be stored in a dedicated area with interlocks and continuous chlorine leak detection
system monitoring system. Hydrogen cylinders will be stored in approved Gas Storage
pad. Chained and capped when not in use. Operational cylinder should be firmly secured.
Pressure regulator, metal piping, non-return valve, and safe residue bleed off arrangement
should be incorporated in installation design. Strict hot work control and display of
danger signs should be ensured

7.4.9 House Keeping:

A regular housekeeping schedule with adequate preventive maintenance shall been
assured so that the plant is consistently maintained as per GMP standards.

7.4.10 Coal and Ash Storage:

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Coal will be stored under covered shed with water sprinkler system in emergency. Ash
silos will be provided for storage and handling of ash generated from combustion of coal.
Water sprinkling system shall be installed on stocks of coal in required scales to prevent
spontaneous combustion and consequent fire hazards. The stack geometry shall be adopted
to maintain minimum exposure of stock pile areas towards predominant wind direction.

7.4.11 Facility layout and design:

The layout of all the various areas required for the facility, as mentioned above is
considered. In laying out the above areas, isolation of the various process areas from the
utilities and non-process areas is considered in view of both containment and cGMP. A
tentative plant layout is shown in Fig 7.1.

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Fig 7.1 Plant Layout of NACL Industries Limited

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Table 7.5 Control Measures

Significant Risks Control Measures
Solvent Tank Farm and Chemical Tank Farm
Fire/ Explosion • Restrict inventory to licensed quantities in Solvent Tank Farm.
• Fenced Solvent Tank Farm.
• Fenced Solvent Tank Farm capable of being locked when not in use.
• Access Control and control of visitors
• Control of ignition sources.
• All electrical equipment and fittings to be flameproof as per area
classification.
• Provision of foam cover to cover the largest dyke area
• Water spray cooling arrangements for all tanks
• Fire hydrants and fire monitors
• Solvent Storage Tanks to have N2 blanketing
• Earthrite system for earthing of tankers carrying solvents.
• Spark arresters on vehicles
• Wetting of road and tyres before unloading
• NO dry grass inside the fenced area
• No parking inside/ near the tank farm.
• No obstruction on the road for free movement of fire tender.
• No solvent pumping in night shift – Daytime operations only.

Loss of Containment • Dykes for all tanks (Dyke capacity to be min. 110% of tank capacity
and Spillage and dyke distance from tank to be min half the tank height).
• Tanker unloading area (road) to be dyked.
• Availability of the Spill control kit.

Injury at the time of • Provision of PPE to stores personnel.

loading/ unloading • Operations by trained stores personnel only.

Bulk Materials Store (liquid chemicals) Drum Yard and Special Chemicals Store
Fire/ Explosion • Fenced area, Access Control and control of visitors
• Building capable of being locked when not in use.
• Control of ignition sources.
• Control of inventory to minimum possible
• Segregation of materials.
• Smoke/ Heat detection system (non-electricity based)
• No water based firefighting setup around the store.
• Adequate CAUTION displays
• Fire hydrants and fire monitors
• Provision of foam
• No electrical installation inside the Store
• Adequate natural light and ventilation.

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Significant Risks Control Measures

• Daily night inspection by Shift Manager.
• No dry grass inside the fenced area
• Emergency exit.

Loss of Containment • Arrangements of drums in rows of two (two levels max) and a gap
Spillage of at least 2 feet between rows and from the walls all around.
• Storage in open area on hard impervious floor surrounded by a
dyke/ sill. (For Bulk Materials Store and New Solvent Drum Shed)
• Availability of the Spill control kit

Ergonomics – Poor • Provision of PPE to stores personnel.

posture leading to • Loading/ unloading only by trained stores personnel.
illness/ injury.
Injury at the time of
loading/ unloading
Raw Materials Warehouse, Finished Goods Warehouse, Packing Materials Warehouse, and
Engineering Store
Fire • Access Control and control of visitors
• Fenced area
• Building capable of being locked when not in use.
• Control of ignition sources.
• Control of inventory to optimal levels
• Segregation of flammable materials.
• Segregation of materials.
• Battery charging not to be done inside the warehouse except for
penicillin warehouse, that too during daytime only.
• Installation of Smoke/ Heat detectors
• Adequate hydrant points outside/around the building
• NO dry grass in open areas.
• Daily night inspection by Shift Manager.
• Emergency exit.
• Availability of DCP, Foam and CO2 fire extinguishers, Spill Control
kit.
Spillage • Availability of the Spill control kit
Falling Objects • Mandatory head and foot protection when inside the warehouse.

Ergonomics – Poor • Provision of other PPE to stores personnel.

posture leading to • Loading/ unloading only by trained stores personnel.
illness/ injury.
Injury at the time of
loading/ unloading

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7.5 Hazard Analysis and Risk Assessment (Terms of Reference No. 3(ix))
7.5.1 Introduction.
Hazard analysis involves the identification and quantification of the various hazards
(unsafe conditions) that exist in the plant. On the other hand, risk analysis deals with the
identification and quantification of risks, the plant equipment and personnel are exposed
to, due to accidents resulting from the hazards present in the plant.

Hazard and risk analysis involve very extensive studies, and requires a very detailed
design and engineering information. The various hazard analysis techniques that may be
applied are hazard and operability studies, fault-tree analysis, event-tree analysis and
failure modes and effects analysis.

Risk analysis follows an extensive hazard analysis. It involves the identification and
assessment of risks; the neighboring populations are exposed to as a result of hazards
present. This requires a thorough knowledge of failure probability, credible accident
scenario, vulnerability of population's etc. Much of this information is difficult to get or
generate. Consequently, the risk analysis is often confined to maximum credible accident
studies.

In the sections below, the identification of various hazards, probable risks, maximum
credible accident analysis, consequence analysis are addressed which gives a broad
identification of risks involved in the plant.

7.5.2 Hazard Identification (Terms of Reference No. 3(ix))

The Hazard identification process must identify hazards that could cause a potential major
accident for the full range of operational modes, including normal operations, start-up,
and shutdown, and also potential upset, emergency or abnormal conditions. Employers
should also reassess their Hazard identification process whenever a significant change in
operations has occurred or a new substance has been introduced. They should also

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consider incidents, which have occurred elsewhere at similar facilities including within the
same industry and in other industries.

7.5.2.1 Hazards in Unit Operations

The various unit operations often involve hazardous material handling under hazardous
operating conditions, adopting hazardous reactions. The general safety considerations for
such unit operations have to be taken into consideration of phase changes, catalysts used,
reaction kinetics, and equilibrium and heat effects. Hazards associated with unit
operations is presented in Table 7.6. Hazards associated with agrochemicals
manufacturing activity are presented in Table 7.7.
Table 7.6 Hazards associated with Unit Operations
S. No. Unit Operation Hazards
1. Transfer of flammable solvents- Spills during transfer, Containment failure,
pumping, vacuum Transfer or Fires due to static charges & ingress of air,
pump transfer or manual transfer exposure to toxic & harmful vapors.
to reactors or containers
2. Extraction of layer with flammable Solvent evaporation, leaking of vapor and
solvents or Toxic solvents igniting
Air entry with flammable mixture may result
in explosions
Exposure to Toxic vapor during extraction &
layer separation
3. Heat Transfer during Reaction If the temperature increase beyond the set
limit, then the Hot reaction mass may bump
through the reactor openings or vents,
resulting in loss of material confinement
Runaway reaction due to exothermicity
4. Distillation Ingress of air while breaking vacuum, resulting
in fire & explosion
Impurity/ un reacted raw material/ by
product getting decomposed at higher
temperature than the set point resulting in
explosion
Static charges generation during collection and
transfer of distilled solvent, resulting into fire
Cooling failure may result into loss of solvent
and may cause fire
5. Filtration Choking of filter resulting in over
pressurization and loss of containment of

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filtrate
Vibration due to uneven cake settling in
centrifuge- may result into fire and accident
Fire due to static charges& flammable vapor-
air mixture over open Nutch filter
Fire due to static charges & ingress of air
6. Drying Overheating during drying may result into fire
and explosion
Air ingress and static charges during Fluid Bed
Drying may result in explosion
Fire & explosion due to static charges due to
low ignition energy & thermal decomposition
7. Milling, Pulverization & Sifting Potential explosion hazard if the powder has
very low minimum ignition energy & Kst
value and prone to generate static charges
8. Blending Fall hazard & caught in Hazard during
Blending operation

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Table 7.7 Hazard Associated and Mitigative/ Control Measures with Manufacturing Activity
Event Hazardous event Causes of Hazards System elements / events that Prevention and mitigation control
ID No. can lead to a major accident measures/ safety relevant components
1 Fires from spills Spills of flammable are more Spills are contained within Plant design specifications ex. Stainless
likely to be involved in fires. the bounded areas. Size of steel for piping and minimum flanges.
Spills can be the result of fire will depend on spill size Equipment inspection and maintenance
mechanical failures and time delay to ignition procedures. Operating procedures and
ex. Corrosion of pipes training. Control of ignition sources.
oversells operational errors Fire protection systems ex. Hydrants,
due to human factors or foam, monitors and fire extinguishers as
control problems (ex. Faulty currently available on the site.
high-level protection)
2 Over pressuring Failure of the pressure control Failure of pressure relief Interlock provided
the pressure valve
vessel
3 Pump Fires Pumps being dead headed or Localized fire at pump Preventive maintenance for pumps.
seal failures Fire protection system ex. Hydrants,
foam, monitors and fire extinguishers as
currently available on the
site
4 Leak during road Failure of flexible hose Leak of material from road High level of surveillance and use of leak
tanker transport connection, leaks from valves tanker, resulting in fire if detection during unloading.
or fittings flammable material gets Permit system for loading / unloading.
ignited. Impact to people, Dyke system for tanker unloading
property and the
environment due to
radiant heat
5 Toxic gas/liquid Failure of pumps and Leak from tank / or from High level surveillance and use of leak
leak corrosive joints unloading tanker, resulting detection, periodical maintenance should
dispersion of toxic gas to the be followed
atmosphere and
surrounding area

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After identifying hazards through a qualitative process, quantification of potential

consequences of identified hazards using simulation modelling is undertaken. Estimation
of probability of an unexpected event and its consequences form the basis of quantification
of risk in terms of damage to property, environment or personnel. Therefore, the type,
quantity, location and conditions of release of a toxic or flammable substance have to be
identified in order to estimate its damaging effects, the area involved, and the possible
precautionary measures required to be taken.

Considering operating modes of the facility, and based on available resources the following
hazard identification process chosen are:
a) Fire Explosion and Toxicity Index (FETI) Approach;
b) HAZOP studies;
c) Maximum Credible Accident and Consequence Analysis (MCACA);
d) Classification of Major Hazard Substances;
e) Manufacture Storage and Import of Hazardous Chemical Rules, 1989 (GOI Rules,
1989);
f) Identification of Major Hazardous Units.

The physical properties of solvents used in the process are presented in Table 6.2 which
forms the basis for identification of hazards during storage and interpretation of the
Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 (GOI Rules, 1989)

The interpretation of “The Manufacture Storage and Import of Hazardous chemicals”

issued by the Ministry of Environment and Forests, GOI, which guides the preparation of
various reports necessary for safe handling and storage of chemicals shows that the
present project requires preparation of safety reports before commencing operation and
risk assessment is not mandatory. The applicability of various rules is presented in Table
7.8.

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Table 7.8 Applicability of GOI Rules to Storage/Pipeline

S.No Name of Chemical Inventory Threshold Quantity (T) Applicable
KL For Application of Rules Rules
5,7-9, 13-15 10 - 12
1 Acetic Acid 1 x 10 1500 10000 4 (1) (a), (2), 5,15
2 Acetone 2 x 50 1500 10000 4 (1) (a), (2), 5,15
3 Acetonitrile 2 x 50 1500 10000 4 (1) (a), (2), 5,15
4 Bromine 2 x 10 1500 10000 4 (1) (a), (2), 5,15
5 Benzene 1x1 1500 10000 4 (1) (a), (2), 5,15
6 Chlorine Tonners 1500 10000 4 (1) (a), (2), 5,15
7 Cyclohexane 1 x 30 1500 10000 4 (1) (a), (2), 5,15
8 Dimethyl Formamide 2 x 30 1500 10000 4 (1) (a), (2), 5,15
9 Dimethyl sulfoxide 1 x 30 1500 10000 4 (1) (a), (2), 5,15
10 Ethylene Dichloride 1 x 30 1500 10000 4 (1) (a), (2), 5,15
11 n-Hexane 1 x 30 1500 10000 4 (1) (a), (2), 5,15
12 n-Heptane 1 x 30 1500 10000 4 (1) (a), (2), 5,15
13 Isopropyl Alcohol 1 x 10 1500 10000 4 (1) (a), (2), 5,15
14 Methanol 2 x 50 1500 10000 4 (1) (a), (2), 5,15
15 Methylene Dichloride 2 x 50 1500 10000 4 (1) (a), (2), 5,15
16 Methyl tert-butyl ether 1 x 30 1500 10000 4 (1) (a), (2), 5,15
17 N-Methyl-2-Pyrrolidone 1 x 10 1500 10000 4 (1) (a), (2), 5,15
18 Tetrahydrofuran 1 x 30 1500 10000 4 (1) (a), (2), 5,15
19 Toluene 2 x 50 1500 10000 4 (1) (a), (2), 5,15
20 Xylene 1 x 30 1500 10000 4 (1) (a), (2), 5,15
Acetic Acid 1 x 10 1500 10000 4 (1) (a), (2), 5,15

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Table 7.9 Physical Properties of Raw Materials and Solvents

Name of Raw material TLV Toxicity Level Flammable Limit Chemical Class
(ppm) LD50 LD50 LC 50 (As per MSIHC
Oral Dermal (mg/1) LEL UEL FP BP Class (As per Rules)
(mg/kg) (mg/kg) (%) (%) (OC) (OC) Petroleum
Classification
Acetone 1000 5800 20000 5540 2.6 13.0 <-20 56.2 B Highly Flammable
Cyclohexane 300 12705 2000 13900 1.2 8.2 -18 81 B Flammable
Dichloromethane 50 670 2800 2270 6.0 11.4 13 40.0 B Carcinogenic
Dimethyl Formamide 10 2800 1500 15 2.2 16.0 58 153 C Flammable
Hexane 50 28710 2000 >20 1.0 8.1 -22 69 B Flammable
Ethyl acetate 400 5620 18000 2500 2.1 11.5 -4 77 B Highly Flammable
Isopropyl alcohol 400 5045 12800 100000 2.0 12.7 12 82.4 B Highly Flammable
Methanol 200 5628 15800 64000 5.5 36.5 11 64.5 A Flammable
Toluene 200 636 12124 313 1.2 8.0 4 110.6 B Highly Flammable
Xylene 100 3567 12126 4595 1.0 7.6 30 144.4 B Flammable
Methyl Iso Butyl Ketone 100 2080 16000 8.2 1.2 8.0 14 117 B Flammable
Acetic Acid 10 3310 1060 88 4.0 19.9 39 118 B Flammable
Acetonitrile 40 3800 988 1000 3.0 17.0 2 81.6 B Highly Flammable
n-Heptane 400 15000 9750 4900 1.0 7.0 -4 98.4 A Highly Flammable
Dimethyl Sulfoxide 50 14500 5000 40250 1.8 63.0 95 189 B Flammable
Tetrahydrofuran 200 1650 2000 2160 1.5 12.4 -21.5 66 A Highly Flammable
N-Methyl-2-Pyrrolidine 540 3914 7000 8000 1.3 9.2 91 202 B Highly Flammable

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7.5.3 Fire & Explosion Index (F & EI):

7.5.3.1 Methodology
Dow Chemical Company issued a guideline for hazard determination and protection. By
this method a chemical process unit is rated numerically for hazards. The numerical
value used is the Fire and Explosion Index (F&EI) which is most widely used for hazard
evaluation in chemical process industries.

The guide applies to process unit only and not to auxiliary units such as power
generating stations, plant water systems, control rooms, fired heaters, structural
requirements, corrosive nature of material handled and personal safety equipment. These
are regarded as basic features that do not vary according to the magnitude of the fire and
explosion hazard involved. The guide also does not cover the processing and handling of
explosives such as dynamite, TNT etc.

Computation of F&EI

The F&EI is calculated as a product of Material factor, General process hazard factor, and
special process hazard factor The Material factor is a measure of the intrinsic rate of
potential energy release from fire or explosion of most hazardous material or mixture of
materials present in significant quantity, whether it is raw material, intermediate,
product, solvent etc. by combustion or chemical reaction. “In significant quantity” here
means such quantity that the hazard represented by the material actually exists. The
National Fire Protection Agency of USA (NFPA) have specified standard values for
material factor which should be used for F&EI calculations and are available in Dow’s
Hazard Classification Guide. In case itis not readily available, it can be calculated using
the heat of combustion, flammability indices etc.

The F&EI index is calculated as a product of Material factor, General process hazard factor,
and Special process hazard factor.

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Hazard Ranking
Table 7.10 Degree of Hazard for F&EI
F&EI Index Range Degree of Hazard
1 – 60 Light
61 – 96 Moderate
97 – 127 Intermediate
128 – 158 Heavy
159 & above Severe

The estimated values of F&EI and hazard ranking are given in the Table 7.11. The radius
of exposure is determined by 0.26meter x respective F&EI. The estimated values of F&EI
reflect light hazard in view of the low volume of chemicals.

The fire and explosion index evaluation can be very useful in developing plant layouts or
adding equipment and buildings to existing plants. Evaluation of the F&EI calculations
and layout considerations will result a safe, operable, maintainable and cost-effective
arrangement of equipment and buildings.
Table 7.11 Fire & Explosion Index for Tank farm
S. Name of Solvent Fire & Radius of Degree of
No. Explosion Index Exposure (m) Hazard
(F1*F2*MF) F&EIx0.26
1 Acetone 94.3 24.5 Moderate
2 Cyclohexane 137.7 35.8 Heavy
3 Di Methyl formamide 26.3 6.8 Light
4 Dichloromethane 105.3 27.4 Intermediate
5 Hexane 105.3 27.4 Intermediate
6 Isopropyl alcohol 105.3 27.4 Intermediate
7 Methanol 104.5 27.2 Intermediate
8 Methyl Iso Butyl Ketone 112.8 29.3 Intermediate
9 Toluene 112.8 29.3 Intermediate
10 Xylene 112 29.1 Intermediate
11 Ethylene Dichloride 115.3 27.8 Intermediate
12 Dimethyl Sulfoxide 26.3 6.8 Light

F& E index value calculated considering the maximum storage capacity of chemical and
values are found to be Intermediate for most of the chemicals stored in bulk quantity,

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moderate for acetone storage, light for dimethyl formamide and dimethyl sulfoxide, while
heavy for cyclohexane storage reflecting the threshold limits as prescribed in MSHC rules.

7.5.4 Hazard and Operability Study (HAZOP)

Hazard and Operability Study (HAZOP) is a highly structured and detailed technique,
developed primarily for application to chemical process systems. A HAZOP can generate
a comprehensive understanding of the possible ‘deviations from design intent’ that may
occur. However, HAZOP is less suitable for identification of hazards not related to
process operations, such as mechanical integrity failures, procedural errors, or external
events. HAZOP also tends to identify hazards specific to the section being assessed, while
hazards related to the interactions between different sections may not be identified.
However, this technique helps to identify hazards in a process plant and the operability
problems. It is performed once the engineering line diagrams of the plant are made
available. It is carried out during or immediately after the design stage. The purpose of
the study is to identify all possible deviations from the way the design/operation is
expected to work and all the hazards associated with these deviations. A multi-
disciplinary team was constituted with chemical, mechanical and instrumentation
engineers, R&D chemist and production manager. It is important to keep the team small
enough to be efficient, while retaining a sufficient spread of skills and disciplines for all
aspects of the study to be covered comprehensively. The group discussion is facilitated
by a Chairman and the results of the discussion are recorded by a Secretary. Every
investigation must be led by Chairman who is familiar with the HAZOP study technique,
which is primarily concerned with applying, controlling the discussions and stimulating
team thinking.

The preparative work for HAZOP studies consisted of four stages i.e., obtaining the data,
converting into usable form, planning the sequence of the study and arranging the
necessary meetings. The documents referred to for the study include process description,
process flow diagrams, P&I diagrams plant layout, operating manuals including startup

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& shutdown, safety instructions etc., The parameters such as temperature, pressure, flow,
level were investigated for deviation and hazard situations are identified.

Some basic definitions of terms frequently used in HAZOP studies are deviation, causes,
consequences and guide words etc., Deviations are departures from the design intent
which are discovered by systematically applying the guide words. Causes are the reasons
why deviations might occur. Consequences are the reasons why deviations should they
occur. Guide words are simple words used to understand a particular plant section in
operating condition in order to guide and simulate the creative thinking process and so
discover deviations. NO, less, more, as well as, part of, reverse, other than are guide
words used.

Potential problems as represented by the consequences of the deviation should be

evaluated as they arise and a decision reached on whether they merit further
consideration or action. Except for major risk areas where a fully quantitative assessment
is required this decision is made semi-quantitatively on the consequence (usually scaled
as trivial, important or very probable).

7.5.5 Hazard Factors

A study of past accident information provides an understanding of failure modes and
mechanisms of process and control equipment and human systems and their likely effects
on the overall plant reliability and safety. Some of the major contributing factors for
accidents in chemical industries are:
S. No Contributing Factor Percent Loss
1 Equipment design faults 41
2 Process design faults 10
3 Operator errors 31
4 Maintenance deficiencies 12
5 Material hazards 6

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7.5.6 Common Causes of Accidents

Engineering and Instrumental
Based on the analysis of past accident information, common causes of major chemical
plant accidents are identified as:
• Poor house keeping
• Improper use of tools, equipment, facilities
• Unsafe or defective equipment facilities
• Lack of proper procedures
• Improving unsafe procedures
• Failure to follow prescribed procedures
• Jobs not understood
• Lack of awareness of hazards involved
• Lack of proper tools, equipment, facilities
• Lack of guides and safety devices
• Lack of protective equipment and clothing

Failures of Human Systems

An assessment of past chemical accidents reveals human factor to be the cause for over
60% of the accidents while the rest are due to other plant component failures. This
percentage will increase if major accidents alone are considered for analysis. Major
causes of human failures reported are due to:

• Stress induced by poor equipment design, unfavorable environmental conditions,

fatigue, etc.
• Lack of training in safety and loss prevention.
• Indecision in critical situations.
• Inexperienced staff being employed in hazardous situations.

Often, human errors are not analyzed while accident reporting and accident reports only
provide information about equipment or component failures. Hence, a great deal of
uncertainty surrounds analysis of failure of human systems and consequent damages.
The number of persons/materials are potentially exposed to a specific hazard zone is a
function of the population density and distribution near the accident location. The failure

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rate data and ignition sources of major fires are presented in the following Tables 7.12
and 7.13.
Table 7.12 Failure Rate Data
S.No Item International Data
1. Process Controllers 2.4 x 10-5 hr-5
2. Process control valve 2.0 x 10-6 hr-1
3. Alarm 2.3 x 10-5 hr-1
4. Leakage at biggest storage tank 5.0 x 10-5 yr-1
5. Leakage of pipe line 1 x 10-7 m-1 yr-1
6. Human Failure 1 x 10-4 (demand)-1

Table 7.13 Ignition Sources of Major Fires

S.No Ignition Source Percent
1. Electrical (wiring of motors) 23%
2. Smoking 18%
3. Friction 10%
4. Overheated material 8%
5. Burner flames 7%
6. Combustion sparks 5%
7. Spontaneous ignition 4%
8. Cutting & welding 4%
9. Exposure (fires jumping into new areas) 3%
10. Mechanical sparks 2%
11. Molten substances 1%
12. Chemical actions 1%
13. Static sparks 1%
14. Lightening 1%
15. Miscellaneous 1%

7.6 Maximum Credible Accident and Consequence Analysis (MCACA)

The potential hazards due to flammable and toxic nature of the raw materials, process
streams and products can be quantified. However, it is necessary to carry out a hazard
analysis study to visualize the consequences of an unexpected release from chemical
plant, which consists of a number of process units and tank farm facilities. The present
study provides quantified picture of the potential hazards and their consequences.

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7.6.1 Methodology
MCACA aims at identifying the unwanted hazardous events, which can cause maximum
damage to plant and personnel. At the first instance, all probable accident scenarios are
developed. Scenarios are generated based on properties of chemicals, physical conditions
under which reactions occur or raw materials stored, as well as material strength of
vessels and conduits, in-built valves and safety arrangements, etc. Creating a scenario
does not mean that it will occur, only that there is a reasonable probability that it could. A
scenario is neither a specific situation nor a specific event, but a description of a typical
situation that covers a set of possible events or situations.

The following steps are involved in identifying the maximum credible accident scenarios.
a. A detailed study of the process and plant information including process flow diagrams
and piping & instrumentation diagrams.
b. Hazard classification of chemicals, operations and equipment.
c. Identification of representative failure cases of vessels and the resulting release
scenarios
d. Establishment of credibility of visualized scenarios based on past accident data.

7.6.2 Identification of Vulnerable Areas

The unit operations in the process and storage areas involve mass and energy transfer
operations to effect the necessary physical changes. Nature of chemicals and the
operating conditions create special hazardous situations. In the present case the chemicals
handled are flammable and toxic in nature. With these factors in mind a thorough
examination of the process information is carried out and a list of inventories of the
hazardous chemicals is prepared to identify the hazardous situations. Based on the raw
material consumptions determined from the pilot scale studies, experience in handling
commercial scale processes and logistics in procurement of raw materials, the inventories
to be maintained for each of the raw material and its mode of storage is determined. High
inventory liquid raw materials like solvents are usually stored in tank farms, while solids

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and other low inventory liquids are stored in ware house based on compatibility,
reactivity, toxicity etc. with appropriate safety and firefighting facilities to handle any
kind of emergencies. The solvent tank farm and the capacity of each tank is presented in
Table 7.14.
Table 7.14 Details of Solvent Tank Farm
S.No Name of Solvent Tank Capacity Dimensions (m) Tank Volume in
(KL) Height Diameter KL
1 Acetone 50 3.6 5.0 51
2 Acetic Acid 30 3.1 4.0 30
3 Acetonitrile 50 3.6 5.0 51
4 Cyclohexane 30 3.1 4.0 30
5 Dimethyl Formamide 30 3.1 4.0 30
6 Dimethyl Sulfoxide 30 3.1 4.0 30
7 Ethylene Dichloride 30 3.1 4.0 30
8 Hexane 30 3.1 4.0 30
9 Isopropyl alcohol 10 2.1 3.2 11
10 Methanol 50 3.6 5.0 51
11 Dichloromethane 50 3.6 5.0 51
12 Tetrahydrofuran 30 3.1 4.0 30
13 Toluene 50 3.6 5.0 51
14 Xylene 30 3.1 4.0 30

7.6.3 Representative Accident Scenarios

A study of past accidents, which took place in similar process units and the present plant,
provides reasons and course of accidents and there by focusing on most critical areas. A
thorough examination of engineering details indicated many possible scenarios like
gasket leak, pinholes in pipes and vessels apart from rupture of pipelines and vessels and
catastrophic failure of vessels resulting in a pool. Heat radiation damage distances for
Pool fire was considered.

Failure Frequency:
The release scenarios considered above can be broadly divided in to two categories
(i) Catastrophic failures which are of low frequency and
(ii) Ruptures and leaks which are of relatively high frequency

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Vapor or liquid release from failure of gasket, seal and rupture in pipe lines and vessels
fall in second category whereas catastrophic failure of vessels and full-bore rupture of
pipe lines etc., fall in to first category. Typical failure frequencies are given in Table 7.15.

Table 7.15 General Failure Frequencies

Item Mode of failure Failure frequencies
Pressure Vessel Serious leak 1.0*10-5/Year
Catastrophic 3.0*10-6/Year
Pipe lines
=50 mm dia Full bore rupture 8.8*10-7/m.year
Significant leak 8.8*10-6/m.year
>50 mm =150 mm dia Full bore rupture 2.6*10-7/m.year
Significant leak 5.3*10-6/m.year
>150 mm dia Full bore rupture 8.8*10-8/m.year
Significant leak 2.6*10-6/m.year
hose Rapture/Failure 4.0*10-5/hr
Unloading arm Rapture/Failure 3.0*10-8/hr
Check valve Failure on demand 1.0*10-4/on demand
motor operated valve Failure on demand 1.0*10-3/ on demand
Flange Leak 3.0*10-4/ Year
Pump seal Leak 5.0*10-3/ Year
Gasket failure Failure 5.0*10-5/ Year
Process safety valve(PSV) Lifts heavily 4.0*10-3/ Year
Blocked 1.0*10-3/ Year
Lifts lightly 6.0*10-2/ Year

7.7 Consequence Analysis

The accidental release of hazardous chemicals leads to subsequent events, which actually
cause the damage. The damages are of three types.
1) Damage due to heat radiation.
2) Damage due to Over pressure effects subsequent to explosion
3) Damage due to toxic effects
The type of damage and extent of damage depends on nature of chemical, the conditions
of release, atmospheric conditions and the subsequent events. The sequence of probable
events following the release of a hazardous chemical is schematically shown in Figure

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7.2. In the present study ALOHA software from USEPA is used. These models for various
steps are described in the following sub-sections.

7.7.1 Release Models and Source strength

This depends on the nature of failure of the unit and the content of the unit and operating
temperature and pressure of the unit. The release may be instantaneous due to total
failure of storage unit or continuous due to leakage or rupture of some component of the
storage facility. The material discharged may be gas or liquid or the discharge could be
manifested through two phase flow.

Fig 7.2 Steps in Consequence Calculations

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The following criteria tables present heat radiation intensities (Table 7.16), radiation
exposure and lethality (Table 7.17), and damage due to peak over pressure is presented
in Table 7.18
Table 7.16 Damage Due to Incident Radiation Intensities
S. No Incident Type of Damage Intensity
Radiation Damage to Equipment Damage to the People
(KW/m2)
1 37.5 Damage to process Equipment 100% lethality in 1 min.
1% lethality in 10 sec.
2 25.0 Minimum energy required 50 % lethality in 1min.
to ignite wood at indefinitely long
Significant injury in 10 sec.
exposurewithout a flame
3 19.0 Maximum thermal radiation ---
intensity allowed n thermally
unprotected adjoining equipment.
4 12.5 Minimum energy to ignite with 1% lethality in 1 min.
a flame, melts plastic tubing
5 4.0 -- Causes pain if duration is
longer than 20 sec, however
blistering is unlikely ( First degree
burns)
6 1.6 -- Causes no discomfort on
Longer exposure
Source: Techniques for Assessing Industrial Hazards by World Bank

Table 7.17 Radiation exposure and lethality

Radiation Intensity Exposure Time 1% Lethality Degree Burns
(KW/m2) (seconds)
1.6 -- 0 No Discomfort even after
longer exposure
4.5 20 0 1st
4.5 50 0 1 st
8.0 20 0 1 st
8.0 50 <1 3 rd
8.0 60 <1 3 rd
12.0 20 <1 2 nd
12.0 50 8 3 rd
12.5 -- 1 --
25.0 -- 50 --
37.5 -- 100 --

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Table 7.18 Damage Due to Peak Over Pressure

Human Injury Structural Damage
Peak Over Type of Damage Peak over Type of Damage
Pressure(bar) Pressure(bar)
5–8 100% lethality 0.3 Heavy (90%Damage)
3.5 – 5 50% lethality 0.1 Repairable (10%Damage)
2–3 Threshold lethality 0.03 Damage of Glass
1.33 – 2 Severe Lung damage 0.01 Crack of Windows
1 – 11/3 50% Eardrumrupture - -
Source: Marshall, V.C.(1977)’ How lethal are explosives and toxic escapes.

7.7.2 Results of Consequence Analysis

The damages due to the accidental release of chemicals are of three types.
a) Damage due to heat radiation
b) Damage due to Over pressure effects subsequent to explosion
c) Damage due to Toxic effects

7.7.2.1 Analysis of Hazardous Scenarios

The hazardous chemicals involved are stored within the threshold limits of storage and
hence few representative chemicals mainly solvents were studied.

7.7.2.1.1 Heat radiation effects (Terms of Reference No. Sp. TOR (13))
When a non-boiling liquid spills, it spreads into a pool. The size of the pool depends on
the availability of the bund and obstacles. The heat load on objects outside a burning pool
of liquid is calculated with the heat radiation model. The average heat radiation intensity,
the diameter-to-height ratio dependent on the burning liquid, geometric view, distance
from the fire, relative humidity of air, horizontal or vertical orientation of the object
radiated with respect to fire are factored. All storage tanks in tank-farm area are provided
with dykes. For each of the hazardous chemicals involved various scenarios such as pipe
line leaks of 5mm or pipeline ruptures or catastrophic vessel ruptures of the inventories
as outlined have been considered and damage distances for Lower Flammability Limits
(LFL) and heat radiation effects for the three levels of intensity are calculated and
presented in Table 7.19. Heat radiation damage distances for most of the scenarios are

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not occurring in the case of release from 50 mm holes at a height of 0.1 m from the bottom
of the tank for one hour, in the storage tanks. In case of pipeline leaks, 5 mm leaks are
considered for 15 mm and 50 mm pipe sizes. The release rates from 5 mm leaks are
observed to be low, and these leaks have low incident hazard. The concentration of the
flammable material in the vapor cloud was found to be below the lower flammability
limits.
Table 7.19 Heat Radiation Damage Distances – Tank Farm (Pool Fire)
S.No Name of Raw material Tank Dia Height Hole Release Heat radiation
(KL) (m) (m) Dia Rate damage
(mm) (Kg/min) distances in m
(Kg/sec) for KW/m2
37.5 12.5 4.0
1 Acetone 50 3.6 5.0 50 90.4 <10 13 19
2 Acetic Acid 30 3.1 4.0 25 104.0 <10 10 13
3 Acetonitrile 50 3.6 5.0 25 95.5 11 14 19
4 Cyclohexane 30 3.1 4.0 50 89.7 <10 15 20
5 Dimethyl Formamide 30 3.1 4.0 50 99.2 <10 13 18
6 Dimethyl Sulfoxide 30 3.1 4.0 50 107.0 <10 12 16
7 Ethylene Dichloride 30 3.1 4.0 50 107.0 12 14 27
8 Hexane 30 3.1 4.0 50 82.6 11 14 19
9 Isopropyl alcohol 10 2.1 3.2 50 90.2 <10 12 18
10 Methanol 50 3.6 5.0 50 90.6 <10 11 15
11 Dichloromethane 50 3.6 5.0 50 48.7 12 14 24
12 Tetrahydrofuran 30 3.1 4.0 25 95.7 <10 13 19
13 Toluene 50 3.6 5.0 50 94.2 11 15 26
14 Xylene 30 3.1 4.0 25 95.7 <10 15 22

Table 7.20 Heat Radiation Damage Distance – Hydrogen Cylinders

S. Scenario Release Storage Tank Details Heat radiation damage
No. Description Rate distances in m for KW/m2
Kg/sec Height Diameter Storage 37.5 12.5 4.0
(m) (m) Pressure
1 Hydrogen Gas 5.42 0.87 0.27 350 Bar <10 12 20
Cylinder
(50Kg)

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7.7.2.1.2 Toxic Dispersion Damage Distances

The storage of toxic chemicals was evaluated with respect to failure of containment
resulting in toxic dispersion and the toxic damage distances were calculated using
ALOHA software. The results of the same are presented in Table 7.21.
Table 7.21 Toxic Dispersion Damage Distances
S. Scenario IDLH Release Distance Storage Tank Details
No. Description (ppm) Rate (m) Height Dia Total Storage
Kg/sec (m) (m) Volume Pressure
(m3)
1 Chlorine Tonner 10 0.30 640 2.1 0.8 1 7atm
2 Ammonia (20%) 300 0.48 187 3.2 2.0 10 9.68atm
3 Bromine 3 5.13 3500 5.0 3.6 50 Atmospheric
4 30% 50 0.01 42 5.0 3.6 50 Atmospheric
Hydrochloric
Acid (Puddle)

7.7.2.1.3 Overpressure effects:

When an unignited gas cloud mixes with air and reaches the flammable range and if the
cloud ignites wither a flash fire or flash fire explosion can occur. Since the burning time is
shorter, instead of heat radiation from a flash fire, peak overpressure as a function of
distance from the centre of the cloud is derived. In case of pipeline leaks, damage
distances due to overpressure effects are not observed. The values are found to be similar
as there are no pressurized storage tanks in the tank farm, and the over pressure
distances are contingent on the tank capacity.

7.7.3 Observations:

From the previous incident records published in literature and hydrocarbon release data
bases, it has been observed that pinhole leaks contribute highest percentage whereas the
second cause is small sized leaks of 50 mm diameter in tank farm. Accordingly, the
consequence analysis was carried out for 50 mm sized leaks in the tank farm.

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7.7.4 Recommendations:

The following are the recommendations to minimize the hazards and improve the safety
of the proposed plants. Plants of this nature, which handle a variety of chemicals, face
problems of fire and vapor cloud explosions. It has been observed that the damage
distances are more or less confined to the plant area only. Taking precautionary safety
measures as outlined below can further minimize these effects.
1. As the new products would be introduced along with exiting products, adequacy of
emergency facilities (like fire protection, scrubber capacity etc.) are to be re-evaluated.

2. Water reactive Chemicals should be segregated from the RM Stores and must be
stored in a dedicated isolated shed having Auto Operated DCP Skid to extinguish
fire.

3. Hydrocarbon Vapor Leak detection system for early detection of undesirable

conditions should be provided near Bulk solvent Flammable Solvent Tanks area.

4. PPE Matrix Chart is to be prepared & displayed at various places

5. Chemical Incompatibility Charts should be prepared and displayed in Warehouses,

Raw Materials storage areas, production blocks etc.

6. The redundancy of Temperature gauge for critical reaction w.r.t. temperature rise/ or
of exothermic nature must be provided.

7. The Onsite Emergency Plan needs to be reviewed in view of identified new

emergencies due to HARA Study or HAZOPS.

8. Special arrangement to prevent entry of escaping chemicals and its compatibility with
existing arrangements are also to be evaluated. Especially this is relevant for vacuum
system, AHUs etc.

9. It is recommended that transfer of flammable solvent and other chemicals are to be

done by pumping and preferably not by vacuum wherever applicable.

10. Skid Mounted Auto Modular DCP type fire protection is to be installed over reactor
areas or other unit operations wherever Hydrogenation is done, over Leaf filter, Over
Nutch filter area etc.

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11. Nitrogen Inertization is to be ensured during charging of flammable solvents to

reactors

12. The scrubber vent terminal, vented contents are to be monitored to ensure that
neutralization is adequate.

13. All flammable solvents would be transferred to charge tanks by pumping and manual
transfer would be avoided wherever being done presently.

14. Suggested to provide suitable fire suppression system over Hydrogenator &
Hydrogen Battery Manifold area.

15. It is recommended to develop Specific Emergency Instruction and Emergency

Shutdown Procedures for the Production Operation like Chlorination reaction,
Hydrogenation, Nitration reaction, Friedel Crafts Reaction, Grignard Reactions etc and
need to be familiarized to employees.

16. During batch distillation and recovery or recycling of flammable solvents, it is

recommended to ensure that ingress of air is avoided to prevent formation of
flammable or explosive mixtures. Such ingress could occur during intentional
vacuum breaking or during power failure and inert gas system is to be always in
position.

17. As the over- exposure to intermediates, chemicals and finished products can be
injurious to health, awareness of such conditions, avoidance of such conditions, use
of suitable personal protection, early detection of undesirable health conditions and
medical management measures are to be developed and included as procedures.

7.7.5 Toxic Management Plan (Terms of Reference No. Sp. TOR (14))
Handling: Storage & handling in compliance with MSDS. The transfer of solvents shall be
mainly by closed pipeline systems, while solvents are transferred from drums by using
air operated diaphragm pumps in closed hoods. Solid raw materials are charged by
using hoppers to avoid dust emissions and hazard of static electricity. SOP’s are used for
better operational control.

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Engineering Control Measures: Filtration and drying is conducted in closed conditions.

Forced dry ventilation system will be given to hoods. Vent condensers in series to
reactors, distillation columns, driers and centrifuge to mitigate atmospheric emissions of
toxics. Solvents with low boiling point will be stored in insulated storage tanks.

Vents of secondary condensers connected to vacuum pumps followed by tertiary

condenser. Common headers connecting all the process vents and the same are connected
to scrubbers. Low boiling solvents tanks are connected with reflux condensers to
minimise the loss. The transfer pumps shall be provided with mechanical seals.

7.7.5.1 Tanker Loading and Unloading: Solvents and liquid raw materials are stored in
bulk storage tanks. Imported liquid raw materials in ISO tankers and indigenous raw
materials in tankers are transferred to bulk storage tanks as indicated below;
1. Material of construction of tanks is SS, MS, Glass Lined depending on the
compatibility with the liquid raw materials stored. All tanks are above ground
with impermeable concrete floors. Dykes are provided to contain leaks if any from
storage tanks. Volume of the Dyke is 20 % more than that of Storage tanks.

2. All liquids are transferred from tankers to Storage tanks using centrifugal pumps
with mechanical seals. SS , PEFE pipe lines and SS Flexible hoses with high
pressure rating are provided to transfer liquids under completely closed
conditions.

3. Dip pipes are provided inside bulk storage tank to avoid accumulation of static
electricity. Earthing provided to all storage tanks . Earthing is also provided with
earthing clips for tankers before unloading. Experienced persons trained in the
area handling of Hazardous chemicals are available round the clock to personally
supervise compliance with all safety issues such as earthing , proper connection of
metallic hoses to tanker , operation of the pump , Nitrogen Blanketing etc.

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4. Markings are made on all Bulk Storage tanks indicating the name of the raw
material stored.

5. Nitrogen blanketing is provided to all bulk storage tanks containing flammable

materials.

6. Breather valves with flame arrestors are provided for bulk storage tanks
containing volatile organic chemicals. Breather valves are set at high pressure to
minimize breathing losses.
7. Raw materials from Bulk Storage tanks are transferred to day tanks in the process
plant using pumps with mechanical seals through Pipe lines. All pipe lines pass
through the pipe bridge above ground.

8. Dip pipes and earthing provided for day tanks as well.

9. Level transmitters with high level switch and automatic tripping of pumps at high
level provided for all day tanks to prevent overflow.

10. Products in liquid form are filled in ISO Tankers or drums. The product is stored
in a bulk tank under nitrogen blanketing and with earthing arrangements. ISO
container is flushed with Nitrogen and the finished product is transferred to the
tank with a pump. High precision level transmitters, flow meters are provided to
storage tanks with isolation valves on the transfer line to fill precise quantity in
ISO tanker. After filling the set quantity, isolation valves on transfer line
automatically closes and transfer pump also trips.

Personnel Protective Equipment: Personal protective equipment shall be provided to all

employees including contract employees. All the employees shall be provided with
gumshoe, helmet, masks, goggles. The other equipment like ear muffs, gloves, respirators,

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aprons etc., will be provided to employees depending on the work area allocated to them.
The PPE selection shall strictly follow the prescribed guidelines of MSDS.

Health Monitoring of Employees: The pre-employment screening and periodic medical

examination shall follow the guidelines of factories act. The pre-employment screening
shall obtain medical history, occupational history followed by physical examination and
baseline monitoring for specific exposures.
Table 7.22 Frequency of Health Monitoring
Occupation Type of evaluation Frequency
Process Physical Height Once a year
area Observation Weight for regular
Eyes Color vision employees.
Detailed Test Hearing Ability; Physical Status, Lung Half yearly
function test, General Condition; Previous for contract
Accidents, Skin Infections; Any Physical employees
Handicap
Clinical Heart; Hydrocele; Central Nervous System;
Observation Liver functioning; Diabetes; Any operations
undergone; Symptoms of communicable and
other contagious disease and Medical fitness
Noise Audiometry Annually
prone areas

7.7.6 Transportation (Terms of Reference No. 7(iii)

All the raw materials and finished products are transported by road. Dedicated parking
facility will be provided in an area of 1.6 acres for transport vehicles. As the plant is
located adjacent to the national highway there will not be any unauthorized shop or
settlements along the road connecting the plant site. There will be 10-15 additional truck
trips per day to the factory due to expansion. Safety signages placed at various locations
in the battery limit. The drivers of the vehicles will be provided with TREM cards and
will be explained the measure to be adopted during various emergencies.

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Transportation of raw materials may result in accidents due to high speed collision, low
speed collision, overturning and non-accident-initiated release. The initiating and
contributing causes are presented in Table 7.23
Table 7.23 Truck Incidents – Initiating and Contributing Causes
Human Errors Equipment Failures System or Procedural External Events
Failures
Driver Non-dedicated trailer Driver incentives Vandalism/
Impairment Sabotage
Speeding RR crossing guard Driver training Rain
Driver Overtired Failure Carrier selection Fog
Contamination Leaking Valve Container Specification Wing
Overfilling Leaking Fitting Route selection Flood/washout
Other Vehicle's Brake Failure Emergency response Fire at rest
Driver training areas/parking
areas
Taking Tight Insulation/Thermal Speed Enforcement Earthquake
Protection Failure
Unsecured Load Relief device failure Driver rest periods Existing accident
Tire failure Maintenance Inspection
Soft shoulder
Overpressure Time of day Restrictions
Material defect
Steering failure
Sloshing
High center of gravity
Corrosion; Bad Weld;
Excessive Grade
Poor Intersection design
Suspension system

The scenarios presented for storages are calculated for transport related
incidents/accidents and presented in Table 7.24.
Table 7.24 Transportation Specific Concerns
Concern Road
Spill on Water Over or near a body of water
Unconfined Pools In an undisturbed flat area
BELVE-Induced catastrophic vessel Possible if sufficient quantity in car with small leak to
failure feed fire or if double tank trailer or burning fuel leak
Toxic products of combustion or Dependent on material and whether ignition occurs
reaction

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Table 7.25 Action Plan and Responsibility

Emergency Action Plan Person Responsible
PRODUCTION BLOCKS
Toxic Chemical Implementation of safe shutdown procedures and stop the flows. Operators
release Inform to Shift in –charge Operators
Instruct the personnel on production floor to wear PPE and ensure its Shift in –charge
use.
Communication to security by emergency phone 555 and Head- Shift in –charge
production.
Deployment of operators & helpers of the particular section for Block in charge or Head- Production.
combating operators.
Calling maintenance personnel for initiating, necessary action for Shift in- charge, Block in charge and
controlling emergency. Head- Production
If the local emergency turns into On-site, follow the line of command Shift in- charge, Block in charge and
as per emergency plan. Head- Production
Fire In case of fire shout loudly FIRE, FIRE, and FIRE and break the nearest Operator / Incident identifier. Shift
fire manual call point. in- charge
Instruct the operator / helper to pick up the appropriate fire Shift in- charge
extinguishers
If fire spreads to On-site nature, inform to Head Production Block in charge or Head- Production.
consequently implement On- site emergency plan.
Chemical Spills Implementation of safe shut down procedure and stops the materials Operator
flows, inform to shift in- charge.
Ensure proper usage of PPE by concerned Operator or workmen. Shift in-charge
Assess the quantity of material spill and inform to Head Production. Shift in-charge
Initiate salvage & cleanup operations Block in charge or Head- Production.
Give all clear for restarting operations.
Electrical Fires In case of fire shout loudly FIRE, FIRE, and FIRE and break the nearest Operator / Incident Identifier
fire manual call point.
Instruct the operator / helper to pick up the portable fire extinguishers Shift in-charge or Block in charge
DCP or CO2.

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Inform to electrical maintenance personnel to stop power supply to the Shift in-charge or Block in charge
effected sections
Shut down the operations in the affected area
Extinguish the fire with DCP or CO2. Extinguishers Electrical Staff (technician /engineer)
Inform to Block superintend or Head- Production about the status Shift in-charge
Replace the damaged electrical equipment or cable due to fire Electrical Staff
Restart the operations after thorough inspection of electrical MCC and Block in charge or Head- Production
earthing
TANK FARM
Pool Fire/ Tank fire / Shout “Fire, Fire, Fire and break the nearest fire manual call point. Operator/Incident Identifier (Who
Bund fire Inform to security, Head Production and Block In charge notices fire)
Shift in-charge
Ensure the usage of PPE’S by the concerned operators, workers Block Shift in-charge
Mobilize firefighting equipment like Fire extinguishers, Movable Block Shift in-charge
trolley mounted Fog nozzle to the spot and instruct firefighting team
and security to start fire water hydrant pumps
Instruct Mechanical and Electrical maintenance personnel to look after Block in charge or Head- Production
un interrupted water supply to cool adjacent tanks
Inform Head Production
If the fire turns into On-site, switch on, on site emergency procedures
WARE HOUSE
Material Spills Implementation of safe shutdown procedure and stop the material Operator / Incident Identifier
flows, inform to Stores in charge
Ensure proper usage of PPE by concerned operator/fitter/ workmen Stores in charge
Assess the quantity of material spill and inform to Head Production/ Stores in charge
Head Materials
Initiate salvage & cleanup operation Head Production / Materials
Give All Clear for restarting operations
Electrical fires Shout “Fire! Fire! Fire!” break the nearest fire manual call point and Operator / Incident Identifier Stores
inform to Stores in charge, security, Head Materials/production in charge
Instruct operator/ workman to pick up DCP/CO2 fire extinguisher Stores in charge

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and ensure it proper operation

Inform to Electrical maintenance personnel to stop the power supply
to the effected sections
Shut down the operation in the affected area Stores in charge/Electrical
maintenance
Inform to Head Materials/ production about the status Stores in charge
Replace the damaged electrical equipment due to fire
Restart the operations after thorough inspection of electrical MCC and Stores in charge/Electrical
earthing maintenance
CHLORINE STORAGE
Leakage from Break the nearest manual call point and Inform to Shift in charge and Operator / Incident Identifier
Cylinder valve security
Inform to Maintenance department and Head production Shift in charge/operator
Wear on line air mask/ SCBA Operator
Rectify the leakage using chlorine emergency kit Operator/ Maintenance personnel
Leakage from pipe Inform to Shift in charge if there is a sudden drop in pressure in vapor Operator/Incident Identifier
line line because of failure of the pipe line
Wear on line Air mask/SCBA Operator/Incident Identifier
Close remote valve on chlorine liquid line near the suction of chlorine Shift in charge /operator
evaporator
Inform to Maintenance in charge/Head production Shift in-charge
Evacuate near the area where chlorine is leaking Shift in-charge/ Head production
Shut down the operations in the plant safely Shift in-charge
Failure of Inform to Shift in-charge Operator/Incident Identifier
evaporation system Wear on line air mask / SCBA Operator
Close remote valve on chlorine liquid line near the suction of chlorine Shift in-charge/operator
evaporator
Inform to Maintenance in charge/Head production Shift in-charge
Evacuate the areas which are likely to be affected because of chlorine
Shut down the operations in the plant safely
Replace damaged portion, hydro test at 30kg /cm2 and then restart Head production & Head

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the operation maintenance

BROMINE STORAGE
Leakage from Storage Inform to Shift in-charge Operator/Incident Identifier
tank valve Start the scrubber to suck the vapors from the storage tank Operator/Incident Identifier
Wear on line air mask/ SCBA Operator
Close the valve near the bulk storage tanks Operator/Fitter

Leakage from pipe Inform to Shift in-charge Operator/Incident Identifier

line Wear on line air mask/SCBA Operator
Close the nitrogen gas valve to the tanker Close remote valve on Operator
bromine liquid line near the suction valve
Inform to Maintenance in charge/Head production Shift in-charge
Evacuate near the area where bromine is leaking Shift in-charge/ Head production
Shut down the operations in the plant safely Shift in-charge
Failure of Inform to Shift in-charge Operator/Incident Identifier
evaporation system Wear on line air mask / SCBA Operator
Bromine drain in tile ling underground tank to store it and put the Operator
water in to the tank
to control the bromine vapors
Inform to Maintenance in charge/Head production Shift in-charge
Evacuate the areas which are likely to be affected because of chlorine Shift in-charge/ Head production
Shut down the operations in the plant safely Shift in-charge

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7.8 Disaster Management Plan (Terms of Reference No. 7(xiii)

7.8.1 Introduction
A disaster is a catastrophic situation in which suddenly, people are plunged into
helplessness and suffering and, as a result, need protection, clothing, shelter, medical and
social care and other necessities of life.

Disasters can be divided into two main groups. In the first, are disasters resulting from
natural phenomena like earthquakes, volcanic eruptions, storm surges, cyclones, tropical
storms, floods, avalanches, landslides, and forest fires. The second group includes
disastrous events occasioned by man, or by man's impact upon the environment. Examples
are armed conflict, industrial accidents, radiation accidents, factory fires, explosions and
escape of toxic gases or chemical substances, river pollution, mining or other structural
collapses, air, sea, rail and road transport accidents and can reach catastrophic dimensions
in terms of human loss.

There can be no set criteria for assessing the gravity of a disaster in the abstract since this
depends to a large extent on the physical, economic and social environment in which it
occurs. However, all disasters bring in their wake similar consequences that call for
immediate action, whether at the local, national or international level, for the rescue and
relief of the victims. This includes the search for the dead and injured, medical and social
care, removal of the debris, the provision of temporary shelter for the homeless, food,
clothing and medical supplies, and the rapid re- establishment of essential services.

An emergency may be said to begin when operator at the plant or in charge of storage of
hazardous chemicals cannot cope up with a potentially hazardous incident, which may turn
into an emergency. The emergencies could be a major fire or explosion or release of toxic
gas or a combination of them.

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The proposed expansion will store fuels, which are flammable in nature, and the storage
will be as per the Controller of Explosives and OISD norms. The hierarchy of the employees
is yet to be determined and the project is still in the initial stages of designing. Hence a
tentative disaster management plan is prepared to be suitably modified before
commissioning of the plant.

7.8.2 Objectives of Emergency Management Plan (ON-SITE)

(Terms of Reference No. 7(xiii)
A quick and effective response during emergency can have tremendous significance on
whether the situation is controlled with little loss or it turns into a major emergency
Therefore, the objectives of this Onsite Emergency Plan (ONSEP);

During Emergency: Is to provide basic guidance to the personnel for effectively combating
such situations to minimize loss of life, damage to property and loss of property.

• To localize the emergency and if possible eliminate it;

• To minimize the consequences of an emergency;
• To prevent spreading of the damage in other areas;
• To give necessary warning to plant personnel and neighborhood;
• To maximize resource utilization and combined efforts towards the emergency
operations;
• To mobilize internal resources and utilize them in the most effective way;
• To arrange rescue of persons, transport and treatment of causalities;
• To seek necessary help from industries in neighborhood or local authorities;
• To provide information to government agencies and to provide information to
public.

During Normal Time:

• To keep the required emergency equipment in stock at right places and ensure
their working condition;
• To keep the concerned personnel fully trained in the use of emergency equipment;
• Preserving records, evidence of situation for subsequent emergency etc.

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7.8.3 Scope of ONSEP

This ONSEP is prepared for industrial emergencies like fires, explosions, toxic releases,
asphyxia and does not cover natural calamities and societal disturbances related
emergencies (like strikes, bomb threats, civil Commissions etc). Also, the scope of this
ONSEP is limited to onsite emergencies and does not include measures for off site
Emergency Management. Necessary information with regards to Off Site Emergency
Management will be furnished to district authorities.

7.8.4 Methodology of Developing ONSEP

The consideration in preparing this Emergency Plan includes the following steps:
• Identification and assessment of hazards and risks;
• Identifying, appointment of personnel & Assignment of Responsibilities;
• Identification and equipping Emergency Control Center;
• Identification of Assembly, Rescue points, Medical Facilities;
• Formulation of plan and of emergency sources;
• Training, Rehearsal & Evaluation;
• Action on Site.

Earlier, a detailed Hazard Analysis and Risk Assessment were carried out for the plant
facilities and the hazards are quantified. The likely locations of hazards and consequences
are evaluated, duly following the standard procedure.

7.8.5 Elements of Onsite Emergency Plan

Important elements considered in this plan are:
• Identification of emergencies
• Emergency organization
• Emergency facilities
• Emergency procedures
• Communications during emergency
• Rescue, Transport and Rehabilitation
• Roles and responsibilities of key personnel and essential employees
• Mutual aid.

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7.8.5.1 Emergencies Identified

Spillage, pool fire, are the possible emergencies in the pipelines, fire near storage, DG
set, and Transformers are the other possible emergencies.

The other emergencies are asphyxiation of persons, apart from risks due to cyclonic
conditions, earth quake, lightning, floods (natural calamities), sabotage, bombing (social
and other reasons) etc. which are not under the management control.

Priority of protection in the event of an emergency is; Life and safety of personnel,
preservation of property, restoration of normalcy.

7.8.5.2 Emergency Organization

1. Emergency Organization is for effective management of situation in an Emergency.
This is based on General shift Organization & Shift Organization.
a. General Organization
Vice President-Manufacturing / Site Head is the over all in charge of the site
b. Shift Organization consists of
i.
One Shift In-charge looks after each block.
ii.
Operators
iii.
Contract workers
iv.Senior Chemist/chemist works in the Laboratories.
v.Sr. Fitter / Technician look after Electrical / Mechanical, Utilities including
Boiler.
c. In Occupational Health Center, Male nurse in each shift & FMO are available in day
time.
d. In Security wing (working under P&A dept.), Security Persons are posted in each shift,
covering areas like Main Gate, Administration block, Warehouse and ETP. Except at
Main Gate, other Security Persons are on rounds in their respective areas.

e. Warehouse operates only in General Shifts.

f. Ambulance is available round the clock at main gate.
g. Factory Medical Officer is available on call, in addition to visit to the Factory, Every
day as per schedule.

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2. Site head is the Emergency Head.

3. Head-Technical Dept. is designated as Site Main Controller. He will report to

Emergency Head and take instructions. He is available in General Shift only. In his
absence, DGM – Manufacturing will hold the responsibility.

4. All Head of the Departments (HODs) are identified as Emergency Response Team
members.

5. Shift In-charge is always, the Incident Controller till DGM – Manufacturing reaches the
site, then the charge can be delegate to DGM - Mfg. He would directly report to Site main
controller for the purposes of Onsite Emergency Mitigation Measures. He is assisted by
the entire Block in charges in the Shift.

6. In the event of an Emergency Situation, Emergency Response Team Members &

Security Personnel reports to Site Main Controller and take instructions from him.

7. Safety team acts as Emergency Team.

Fig 7.3 Emergency Organization (ON SITE) Chart

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7.8.5.3 Emergency Facilities

Emergency Control Center (Vice president Manual Call Points (MCP)
Cabin & Near Gate-1

Firefighting System
Fire detection system (Heat Detectors) Water & foam monitors
Automatic foam & water sprinkler system Down comer pumps
Fire Hydrant system Two sets of fire hydrant pump system
Hose reel Portable Fire extinguishers
Sand buckets Wind Sock
Occupational Health Center (OHC)
Personnel Protective Equipment Fire Proximity Suits
Self-contained breathing apparatus Fall arrestors
Safety ladders Carbon dioxide cylinders
Eye wash / Body wash showers Multi gas analyzers
Oxygen Analyzers
Communication & Transport
Mega Phone DG sets
Walkie – Talkie’s Ambulance /Emergency Transport Vehicle
Public Address System

a) Emergency Control Center (ECC)

It is a location where all key personnel like Chief Coordinator, Emergency controller,
maintenance coordinator can assemble and monitor aspects related to emergency and
take decisions related to emergency. The office room is designated as ECC. In case if this
area is affected, zone security room is designated as alternative ECC.
The following information and facilities would be maintained at the ECC in Plant Control
room:
Latest copy of Onsite Emergency Plan and Offsite Emergency Plan (as provided by
District Emergency Authority)
• Intercom Telephone;
• P& T Telephone;
• Telephone directories (internal and P&T);
• Factory Layout, site plan;

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• P&I diagrams, electrical connections plans indicating locations of hazardous

inventories, sources of safety equipment, hydrant layout, location of pump house,
road plan, assembly points, vulnerable zones, escape routes;
• Hazard chart;
• Emergency shutdown procedures for generators and fuel supply system;
• Nominal roll of employees;
• List and addresses of key personnel;
• List and addresses of emergency coordinators;
• List and addresses of first aid providers;
• List and addresses of employees trained in fire fighting;
• List and addresses of qualified trained persons;
• Material safety data sheets of raw materials;
• Duties of key personnel;
• Important addresses and telephone numbers including those of fuel supplying
company, government agencies, neighboring industries and other sources of help,
outs side experts;

The following emergency equipment is made available at alternate ECC (Security point):
• Automatic Fire Detection system (Heat detectors)
• Automatic Fire Protection systems (water & foam sprinklers)
• Manual call points (MCP)
• Fire Hydrant system
• Eye /body wash showers are located in all Departments and tank Farm
• Self-contained breathing apparatus.
• Hose reels
• Portable fire extinguishers
• Sand buckets
• Water & foam monitors

b) Assembly points
➢ Assembly point is that location where the persons who are not connected with
emergency operations can await either for further instructions or for rescue,
transport and rehabilitation.

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➢ Outside of the Admin Building & near Security Gate-II are considered as safe
assembly Points

c) Firefighting Facilities
The firefighting facilities which shall be provided are presented in Table 7.26.
Table 7.26 List of Fire Extinguishers
S.No Description of Item Quantity
1. DCP 10 kg 10 Nos.
2. Foam 50 ltrs 5 Nos.
3. CO2 22.5 kg 10 Nos.
4. CO2 6.8 kg 10 Nos.
5. ABC Soda Acid 5 kg 10 Nos.
6. ABC Soda Acid 1 kg 10 Nos.
7. Fire Buckets with stand 20 Nos.

d) Location of First aid Boxes

The first aid boxes will be located at the following places: preparation areas,
administrative office, time office, and will be under the charge of security coordinator.

e) Emergency siren
Emergency siren will be provided with 0.5 km range of audibility and the location will be
time office. The siren will operate on regular supply and also on emergency electrical
supply. Shift electrical engineer of plant on receipt of information from shift incharge, is
authorized to operate the siren.

f) Emergency escapes
Emergency escapes in the plant area and floor wise emergency escapes will be
conspicuously marked.

g) Wind sock
Wind socks to observe the wind directions will be installed on the top of Turbine Plant
house.

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7.8.5.4 Emergency Procedures

a) Procedure for Raising Emergency alarm
Whenever and whoever notices an emergency or a situation with a potential emergency
should forthwith raise alarm by calling on the available communication network or
shouting or approaching the shift incharge, furnishing details. Anybody noticing fire
should inform the plant control room immediately. The shift electrical engineer at control
room informs the site controller.

b) Control Room staff

If an emergency is reported then plant control room staff must, request for the location,
nature and severity of emergency and obtain the caller's name, telephone number, and
inform the shift incharge or site controller who ever are available in the shift.

c) Emergency communication
a. Any person(s) in the common area or person(s) in the Production block or Utility can
identify emergency Situation. Whosoever sees such a situation; he has to immediately
communicate to the concerned Shift in-charge / Block in-charge Security by intercom or
walkie -talkie hand set. Shift in-charge / Block In-charge inform to incident controller.

b. Emergency Communication is done with the Site Main Controller / Emergency

through walkie –talkie handsets or land line phone to all emergency response members.
Emergency head after receiving the information of emergency he rush Emergency
Control Center and instruct the Site Main Controller and In-Controller to assume the
scenario and its impact, type of emergency. The Security receiving the emergency
communication, will announce for declaring Emergency the plant by public address (PA)
system as per the instruction of the Site Controller/ Emergency Head.

c. Emergency notification is also done by electrically operated Siren (Emergency Siren

operates on emergency power supply.

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d. Operating the Siren in nodes of waxing and waning as per emergency siren practice is
an indication of significant emergency situation in the Factory. SOperator (Security) is
given training of how to operate the same.

e. Emergency Siren is operated under the authority of Site Main Controller/ Emerghead.

f. Plant personnel are made familiarized of the Emergency Siren code

g. It is the responsibility of Safety In-charge to ensure good condition of Emergency Siren

/ Public address system and is available on Emergency Power Supply.

3. Security person receiving the information from Intercom / Observer passes on the
same to Safety Head, Ambulance Driver & OHC Assistant.

4. Emergency communication would be precise; covering name of the person identified

the emergency, time, type of emergency, exact location, nature of emergency etc.

5. Important Telephones Numbers are posted in bold letters. It is the responsibility of

Safety Department to ensure correctness of Telephone Numbers, by incorporating
changes when takes place.

6. Emergency Fire Services would be informed on the authority of Emergency Head /

Site Main Controller or his authority.

7. It is the responsibility of every Key Person to intimate his whereabouts to the

Emergency Head while he is away from his office

8. Emergency communication to District Emergency Authority, Police, Factory

Inspectorate, Pollution Control Board and other statutory authorities are done only by
Emergency Head or his Authority.

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9. Emergency Head / Site Main Controller in consultation with Incident Controller would
order for all clear siren indicating that emergency is overcome. Continuous operation of
siren for two minutes is an indication of All Clear.

d) Warning/Alarm Communication of emergency

Emergency siren would be operated to alert all other employees on the orders of manager
(electrical). The emergency is communicated by the Emergency siren mode of wailing for
3 minutes. When the emergency has been brought under control, the Emergency
controller will direct plant control staff giving an 'all clear signal', by way of normal siren
(continuously for 3 minutes).

7.8.5.5 Rescue and Rehabilitation

Emergency vehicle will be made available round the clock under the charge of manager
(electrical) who is emergency coordinator. Security personnel are trained in rescue
operations. Persons rescued would be taken to First aid centre for further medical
attention or Safe Assembly Points as per the condition of the rescued person.

a) Transport Vehicles and Material Trucks

The transport vehicles and vehicles with materials would immediately withdraw to
outside the factory. Security guard of the shift is responsible for this. Transport vehicles
would wait at the security at the main entrance to provide emergency transport. This is
ensured by security coordinator.

b) Mock drill
Occasional mock drill is essential to evaluate that the ONSEP is meeting the objectives.
Adequate training is given to all staff members before conducting the mock drill. Mock
drills will be initiated with table top exercise, followed by pre-informed mock drills, and
few uninformed mock drills in the first phase. Functional exercises (communication,

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Emergency shut down, fire fighting at different locations, rescue etc.) are carried out in
the second phase.

Mock drills will familiarize the employees with the concept and procedures and help in
evaluating their performance. These scheduled and unscheduled mock drills are
conducted during shift change, public holidays, in night shift once in 6 months.
Response time, strict adherence to discharge of responsibilities, difficulties and
inconsistencies experienced are recorded and evaluated. Fire officer will assists
Emergency coordinator in designing and extending such mock drills and in evaluating
the response.

c) Review
The Emergency plan is reviewed periodically to evaluate the effectiveness, and during
change in organizational structure, isolation of equipment for longer duration, and
during increase in inventory of fuel and other chemicals. Manger Electrical and
Emergency coordinator initiates and authorizes such review as and when required, and
the changes if any will be duly informed to all the employees concerned.

7.8.5.6 Emergency Responsibilities

I. Chief Coordinator
The chief coordinator shall be General manger and Alternate is Manager Electrical.
• He is overall incharge of emergency operations.
• He reaches emergency control center as soon as he receives emergency
information.
• He coordinates with emergency controller, maintenance coordinator.
• He provides necessary resources required at the emergency site.
• He will inform the inspector of factories, and other statutory authorities.
• Prepares accident report/investigation.
• Arranges for keeping records of chronological events and orders an
investigation report and preserves evidence.
• Gives a public statement if necessary.

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II. Emergency controller - Shift in charge

On receiving the message about emergency;
• He will assume charge as chief coordinator till general manger arrives at
scene and takes charge as a chief coordinator.
• Takes actions to minimize the consequences and directs emergency
management and fire control/other causes with available personnel to put
off or to reduce the consequences.
• On the arrival of chief coordinator, he will hand over the charge of Chief
coordinator and assists him.
• He will identify the need of evacuating any personnel in the vicinity of the
affected zone.
• Exercises operational control of the installation and outside the affected area
and directs emergency operations.
• Declares emergency and orders plant control room for operation of
emergency siren.
• Continuously reviews and assesses possible development to determine
most probable courses of events.
• Initiates suspension of all work permits during the period of major
emergency for safe guarding the plant and other personnel.

III. Incident Controller

The Supervisor assumes the role of incident controller in the following instances of
emergencies.
• Protects himself and proceeds to site quickly.
• Assess the magnitude of the incident.
• Initiates the emergency procedure to secure the safety of the workers and
minimise damage to installation and property.
• He will undertake all possible steps for safe isolation of plant systems, first
aid and fire fighting.
• He keeps in touch with plant control room till emergency controller arrives
at the scene of emergency,
• Organizes essential employees present in the shift.

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•Ensures that adequate personal protective equipment is available foe

essential employees.
• Arranges for search of causalities.
• Arranges evacuation of non-essential workers to assemble at designated
assembly points.
• During the fire fighting operations seeks help from electrical/mechanical
maintenance personnel for isolation of machine/section involved in fire as
the need arises.
• Once the situation is under control, guides different persons for salvage and
cleanup operations.
• Assists in assessing the loss, preparation of accident report with the
assistance of security officer and senior officials of respective departments
present during the accident, investigates the fire with a view to find out
causative factors ad action needed to prevent recurrence.
IV. Communicator – production supervisor
• The Control Room Shift Electrical Engineer assumes the role of
Communicator and passes the information related to emergency to Incident
Controller and Chief Coordinator.
• Other vulnerable installation in the plant is alerted about the emergency.
• On the Instructions from chief coordinator, neighboring installations are
alerted about the emergency.
• On the instructions from Chief Coordinator, mutual assistance is called
from neighboring industries.
• On the instructions from Chief Coordinator, seeks help form fire brigade.
• Provides emergency Telephone rosters are provided in Plant control room
and Fire Station.
V. Maintenance Coordinator
Dy. Manager Mechanical shall assume the role of maintenance coordinator. His
responsibilities include;
• Protecting him self.
• Reaching the emergency spot.
• Arranging all resources for assisting Emergency controller to mitigate the
Emergency scene, with respect to maintenance requirements.

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• Assisting Emergency controller in arranging the needed containment

measures.
• Undertaking post emergency maintenance work upon termination of
emergency.
• Ensuring availability of adequate quantities of protective equipment and
other emergency materials, spare parts etc at Emergency control center.
• Ensuring upkeep of fire systems, emergency lighting in order.

VI. Resource Coordinator

Shift in charge shall assume the responsibility of resource coordinator.
• Arranges first aid, rescue acts, ambulance, attendance roster checking and
security.
• Interacts with chief coordinator for all emergency operations.
• Assists chief coordinator with necessary data and coordinates the
emergency activities.
• Maintains liaison with civil administration and mutual aid agencies -
neighboring industrial management.
• Ensures availability of humanitarian needs and maintenance of
rehabilitation center.
• Ensures emergency transport facility.
• Mobilizes extra medical help from outside if necessary.
• Maintains first aid and medical emergency requirements.
• Keeps list of qualified first aid providers and seeks their assistance.
• Ensures availability of necessary cash for rescue/rehabilitation and
emergency expenditure.
• Coordinates mutual aid.
• Participates in reviewing Emergency plan and arranges revision if required.
VII. Security Coordinator.
The production supervisor will assume the responsibilities of security coordinator, and
his responsibilities are;
• On receipt of fire call from plant control he prepares for fire fighting and
collects necessary equipment.
• Organizes rescue of persons trapped in work areas.

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• Assists administration coordinator in organizing Mock drills, evaluation

and debriefing.
• During normal situations keeps the fire fighting capabilities in fully ready
condition by maintaining equipment.
• Organizes fire drills on periodic basis and evaluates the same.
• Arranges to clear off unconnected persons and trucks from the vicinity and
off the main gate.
• Instructs security guards posted on duty in the nearby industries to cordon
off the affected section and to control the crowd at the scene of fire.
• Arranges to control law and order till local authorities for Law and order till
police arrive at site.
• Post security guard at the scene of fire to check for possible re-ignition, after
the emergency is over.
• Assists Resource coordinator in organizing Mock Drills, evaluation and
debriefing.
VIII. Person Noticing Fire
Any employee on noticing fire will take the following steps;
• Takes protection
• Raises alarm – shouts fire! Fire!! Fire!!! Or other emergency.
• Informs Shift Incharge, or at the control room over telephone giving clear
message about the exact location of fire and names of
equipment/machinery involved in fire.
• If Telephone is not working, quickly goes to either Plant Control Room and
informs.
IX. Trained Fire Fighting Person
The employees trained in fire fighting will take the following steps in the event of fire
apart from following the instructions of security coordinator apart from;
• Protects self
• Raises alarm
• Attempts to put out the fire using fire extinguishers.
• If necessary, operates fixed fire fighting equipment.
• Stands by in safety for further instructions.

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7.8.6 Remedial Action

The cause of emergency is identified and action is taken from operation point of view
such as isolating or shutdown etc.

I. Failure of pipelines: feeding into the pipeline is stopped. Isolate the leaking
pipeline by closing the relevant valves. Transfer the material present to other
pipelines. Shutdown the pump. Close the suction and discharge valves of the
pump

II. Personal Protection: The people, who are assigned to the rescue operations,
must wear suitable personnel protective equipment such as self-contained
breathing apparatus and fire suit. They should remain in the incident area as
long as he can safely stay there. In spite of the wearing safety protective
equipment if he is unable to stay in the contaminated area, he should leave
immediately.

7.8.7 BASIC ACTION IN EMERGENCIES

Immediate action is the most important factor in emergency control because the first few
seconds count, as fires develop and spread very quickly unless prompt and efficient
action is taken.
• Take immediate steps to stop leakage/fire and raise alarm simultaneously.
• Initiate action as per fire organization plan or disaster management plan, based on
gravity of the emergency.
• Stop all operations and ensure closure and isolation valves.
• All effort must be made to contain leakage/fire.
• Saving of human life shall get priority in comparison to stocks/assets.
• Plant personnel with specific duties should assemble at the nominated place.
• All vehicles except those required for emergency use should be moved away from
the operating area, in an orderly manner by the predetermined route.
• Electrical system except for control supplies, utilities, lighting and fire fighting
system should be isolated.
• If the feed to the fire cannot be cut off, the fire must be controlled and not
extinguished.

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• Start water spray system at areas involved or exposed to fire risks to avoid domino
effects.
• In case of leakage of chemicals without fire and inability to stop the flow, take all
precautions to avoid source of ignition.
• Block all roads in the adjacent area and enlist police support for the purpose if
warranted.

7.8.8 FIRE FIGHTING OPERATIONS

Enlist support of local fire brigade and neighboring industries.
• Firefighting personnel working in or close to unignited vapor clouds or close to
fire must wear protective clothing and equipment including safety harness and
manned lifeline. They must be protected continuously by water sprays. Water
protection for fire fighters should never be shut off even though the flames appear
to have been extinguished until all personnel are safely out of the danger area.

• Exercise care to ensure that static charge is not generated in vapor cloud. For this
purpose solid jet of water must be avoided, instead fog nozzles must be used.

• Fire fighters should advance towards a fire in down wind direction.

• If the only valve that can be used to stop the leakage is surrounded by fire, it may
be possible to close it manually. The attempt should be directed by trained
persons only. The person attempting closure should be continuously protected by
means of water spraying (thorough fog nozzles), fire entry suit, water jet blanket
or any other approved equipment. The person must be equipped with a safety
harness and manned lifeline.

• Any rapid increase in pressure or noise level of should be treated as a warning of

over pressurization. In such case all personnel should be evacuated immediately.

• In case of any emergency situation, it is of paramount importance to avoid

endangering human life in the event of fire, involving or seriously exposing plant
equipment.

7.8.9 Details of Transport Facilities in emergency

• Hire transport 50 seated bus
• Hire transport 40 seated bus

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• Company owned 40 seated bus

• Company owned 5 seated cars
• Maruthi seated jeep
• TATA Winger vehicle 12 Seated
• Company owned Innova vehicles 5 seats
• Ambulance Van

7.8.10 LIST OF PERSONNEL TRAINED IN FIRST AID

S.No Name of the Employee E.No Designation Department
1 A.Dharma Rao 90668 Asst. Executive E.T.P
2 G.S.N.Raju 90181 Executive E.T.P
3 P.Srinivasa Rao 90590 Operator B-5
4 G.Srinivasa Rao 90924 Operator B-5
5 D.Satyanarayana Rao 90731 Chemist PD Lab
6 B.Ramana 90067 Sr.Executive Q.C
7 B.V.Appala Naidu 90689 Operator B-1
8 M.K.M.Naidu 90687 Operator B-2
9 V.N.Markandeswara 90647 Operator B-3
Rao
10 K.Balaraju 90763 Operator B-3
11 N.Madhava Rao 90070 Sr.Operator Utility
12 S.Rajesh 90692 Operator B-6
13 G.Appala Naidu 90962 Asst. Executive Q.C(E.T.P)
14 B.Srinivasarao Security Guard S/G
15 P.Papa Rao Security Guard S/G
16 G.Ramesh Kumar 91167 Operator B-4
17 V.S.Satyanarayana 91152 Jr.Executive B-4
18 S.Thirupathirao 90773 Asst EHS
19 D.A.N.Raju 91059 Asst EHS
20 R.Raja Rao 90048 Asst Material
21 V.Venkata rao 90083 Driver P&A
22 G.Rambabu 91065 Asst Material
23 K.Raja Rao 90335 Asst Material
24 J.Vinay Kumar 91218 Welfare officer HPD
25 S.Raju 90833 Engineer Systems
26 A.Satyanarayana 91212 Fitter Maintinence
27 B Appala Raju 91163 Trainee Electrical
28 J Srikanth 91250 GET Electrical
29 M Sanyasi Raju 96133 Asst ETP
30 D.Bangara Raju 90182 Executive ETP
31 Ch Chalapathi Rao 91251 Operator RO Plant

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Environmental Impact Assessment Report

32 S Srinivasa Raju 90031 Executive Eng.Store

33 S.Simhachalam 90588 Shift.Operater B-5
34 P Maheswara Rao 90910 Shift.Operater B-5
35 G.Durga Rao 91032 Shift.Operater B-5
36 K Rami Naidu 91040 Trainee B-5
37 Shiek Mannan 91049 Shift.Operater B-5
38 P Sankara Rao 91050 Shift.Operater B1
39 V.Koteswara Rao 90062 Sr Operater B2
40 PVLN Raju 90093 Asst.Prod B3
41 B.Sridhar 90506 Shift.Operater B3
42 K Srinivasa Raju 90782 Shift.Operater B4
43 D Venkata Rao 91115 Jr Executive B4
44 M Asiri Naidu 90274 Executive B4
45 T Govinda Rao 90858 Shift.Operater SRP
46 Ch Chandra Sekhar First Aid Asst Dispensary
47 A Rama Rao 90960 Foreman Boiler
48 K Suri Babu 90705 Welder Mech
49 B Srinivasa Rao 90928 Asst Safety
50 E.Murali 90650 Asst Safety
51 G Ramaiah 90981 Junior Executive Production
52 S Kanthi Swaroop 91036 Junior Executive Production
53 K Venkata Ramana 91195 Junior Executive Production
54 T Vasudeva Rao 91198 Junior Executive Production
55 I Satyanarayana 91197 Junior Executive Production
56 B.Vijaya Krishna 91321 Junior Executive Production
57 S.Jagadeesh 91170 Engineer Mechanical
58 K.Mallesh 91337 Trainee Mechanical
59 G V V Prasad 90553 Executive Electrical
60 P.Sai Mohan 91331 Get Instrumentation
61 A.Rama Rao 90960 Foreman Boiler
62 S.Dharma Rao 90700 Sr.Operator Safety
63 P Sridhar 91101 Junior Executive Env - Lab
64 V.Naga Babu 90496 Junior Executive QC
65 Ch.Bala Krishna 90967 Junior Executive Production
66 T.Trinadha Naidu 90940 Junior Executive Production
67 G.Jagan 91322 Junior Executive Production
68 J.Srikanth 91250 Get Electrical
69 Ch.Ramana 90882 Asst. HPD
70 D.Krishna 91278 Fitter Mechanical

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Environmental Impact Assessment Report

List o f Company Panel Doctors

Name of the Doctor Phone Number Distance
Dr.K.Ammannaidu
M.S Gen.Surgen 08942-221010 13KM
Santhi Nursing Home
Srikakulam

Dr.P.L.N.Raju M.B.B,S, 08942-221010 13KM

DO K.C Eye Hospital
Srikakulam
Dr.T.V.Ramana Rao M.D
R.R.Skin Hospital, Vinus plaza, Day & 08942-221285 13KM
Night 94404 12989
Jn. Srikakulam

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Environmental Impact Assessment Report

Fire Hydrant Layout – NACL Industries Limited

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Environmental Impact Assessment Report

8.0 PROJECT BENEFITS

8.1Introduction (Terms of Reference No. 2(iii))

M/s. NACL Industries Limited (formerly known as Nagarjuna Agrichem Ltd) proposed
to increase the manufacturing capacity of agrochemicals from 30 TPD to 70.1 TPD and
also include Captive Co-generation Power Plant of 6 MW in existing site area of 100 acres.
The capital cost for proposed expansion is Rs. 65 crores, towards additional facilities,
utilities and enhancement of zero liquid discharge facility.

8.2 Employment Potential

The proposed expansion will provide additional employment to 200 people. It will be
spending approximately Rs. 24.5 lakhs of rupees every month on salaries providing
bread and succour to 200 families additionally. The proposed expansion will also
generate indirect employment to the locals during construction phase in the order of 100
people for a period of 18-24 months. The employers will contribute to the provident
fund, ESI and provide facilities as per the relevant labour act.

8.3 Corporate Environment Responsibility

The ministry of Environment, Forest and Climate Change issued an office memorandum
mandating corporate environment responsibility expenditure contingent on the capital
cost of the project, in addition to the expenditure on environmental management. The
office memorandum prescribed a CER expenditure of 1 % for brown field projects of less
than Rs. 100 crores. The capital cost of the proposed project is Rs. 65 crores and hence
must spend Rs. 65 lakhs towards corporate environment responsibility. The programs
identified by the ministry are drinking water supply, sanitation, health, education, skill
development, roads, cross drains, electrification including solar power, solid waste
management facilities, scientific support and awareness to local farmers to increase yield
of crop and fodder, rain water harvesting, soil moisture conservation works, avenue
plantation, plantation in community areas etc.

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Environmental Impact Assessment Report

8.3.1 Proposed Corporate Environmental Responsibility (CER) Activities

CER is a process with the aim to embrace responsibility for the industrial activity and
encourage a positive impact through its activities on the environment, employees,
communities and stakeholders. The objective is to obtain a social license from the stake
holders who are likely to be affected due to the proposed manufacturing activities. The
tentative list of identified CER activities is presented in chapter 10, and finalized after
public hearing.

8.4 Tax Income

The proposed capital expenditure of Rs. 65 crores include GST on various equipment and
services to the tune of Rs. 50 crores from proposed expansion. The provision of
employment also directly contributes to additional income tax and also indirectly
contributes to additional GST due to various transactions. The operation of the project
also results in additional GST from revenue, additional income tax on profits and from
employee salaries. The project may also save on valuable foreign exchange by replacing
some of the imports and also earn foreign exchange by exporting few technical grade
pesticides.

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Environmental Impact Assessment Report

9.0 ENVIRONMENT COST BENEFIT ANALYSIS

The TOR letter F.No. F.No. J-11011/75/2007-IA II (I) dated 24.06.2020, does not mention
Environment Cost Benefit Analysis and hence the same was not conducted.

9-1 Team Labs and Consultants

NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

2. ENVIRONMENT MANAGEMENT PLAN

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
M/s. NACL Industries Ltd.
Environment Management Plan

10.0 ENVIRONMENT MANAGEMENT PLAN

10.0 Introduction
Environment management plan can be effectively implemented to mitigate the
pollution levels by observing the following; avoidance, source reduction, on site
recycling, by product extraction, and offsite recycling as first choice followed by
treatment, release and disposal. The mitigation/control measures proposed to be
adopted for expansion in addition to the existing ones which include modification to
engineering design, inclusion of new technology, change in work practices during
operations and required personal protection equipment to minimize the residual
impacts that are predicted, are presented in the previous chapters. The management
plan is drawn in consultation with the R&D team, project team and environmental
consultants. During the review R&D team informed that increasing the product yields
by improving on reaction conditions or by using catalysts to ensure optimized usage of
raw materials resulting in low pollution load and better-quality product is a major
objective of their development wing.

The environment management plan as prescribed by the EIA notification seeks a

description of the administrative aspects of responsibility for implementing,
monitoring, and establishing feedback loops for adaptive management. The
environment management shall be entrusted to the environment management
department of Safety, Health and Environment (SHE) division of NACL Industries Ltd.
during operation phase and by a small team of safety, health and environment group
during construction phase.

10.1 Safety, Health, and Environment Division

The proposed expansion related construction and erection works will be supervised
by the existing SHE division of the unit.

The operation phase shall require a larger department for safety health and
environment headed by a General Manager who would report to the director
operations/Managing Director. The GM (SHE) will be a senior person with post-

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Environment Management Plan

graduation in engineering with at least 20 years of experience in safety, health, and

environment divisions of similar industries or large-scale industries. The qualifications
and experience of senior managers, engineers, and supervisors are as mentioned in the
previous paragraph. Chemists should have a B.SC., with chemistry as a subject or
post-graduation in chemistry (preferably analytical chemistry). The organogram of
Safety, Health, and Environment department is presented in Figure 10.1

Fig 10.1 Organogram Safety, Health, and Environment Division

The responsibility of environment department includes;

• Supervision and Monitoring of all environment management measures,

• Preparation of monitoring reports,

• Conducting environmental audit reports,

• Identification of innovative management measures for reducing wastes, recycling

wastes, and or avoiding the wastes.

• Obtaining statutory approvals and submission of periodic compliance reports

• Monitoring of compliance of consents, Environmental clearance, and other

authorizations.

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Environment Management Plan

• Co-ordinate in obtaining ISO 14001, 9001 and ISO 45001 certification

• Implementation of ISO 14001 and ISO 45001

• Conducting training programs of environment management to various divisions.

• Co-ordination with other divisions in ISO 9001 implementation

• Liaisoning with statutory organizations like APPCB, MoEFCC, CPCB etc.

• Co-ordinating with Director (operations) and Managing Director during plant

upsets due to failure of pollution control measures.

• Co-ordinate with third party environmental consultants for expansion activities.

10.2 Project Implementation Schedule

The proposed expansion project will be commissioned by end of year 2023.
Accordingly, the project is scheduled to achieve completion and trial runs within 24
months from commencement of construction.

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Environment Management Plan

10.3 Environmental Policy

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Environment Management Plan

10.4 Mitigation Measures and Responsibility

The mitigation measures are explained in detail in Chapter 4. Salient features of
mitigation measures at place/proposed are presented in Table 10.1 for both
construction and operation phases. The environment management department shall
be responsible for monitoring the compliance and provide feedback to top
management and also to the respective division. The responsibility of implementing
the mitigation measures lies with respective division during operation phase, and
project management division and contractors during construction phase.

Safety, Health and Environment (SHE) Division will be responsible for the compliance
of the environmental conditions laid down in Environment Clearance and adhere to
the Environmental Laws and Regulations. Six monthly compliance report with respect
to the conditions stipulated by MoEFCC will be submitted regularly to the Regional
Office of MoEFCC. Work instruction for reporting and addressing non-compliance
related to EC/CTE/CTO conditions is laid down in Standard Operating Procedure
(SOP). In case of any violation of any statutory conditions, the same will be reported
to the Managing Director and subsequently to Board of Directors and other
Stakeholders. The Board of Directors will review the non-compliance and its
corrective actions. Incident reporting mechanism is shown in Fig 10.2

Fig 10.2 Reporting Mechanism for Non- Compliance

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Environment Management Plan

Table 10.1 Implementation and Monitoring of Mitigation Measures –Construction

Impacts Mitigation Measures Implementation Responsibility
Urban Heat ➢ Vegetation: Avenue plantation, Project management and
Island Effect green area Horticulturists
➢ Pathways and parking areas:
Paver blocks
Emission from ➢ PUC certification of transport Respective contractors
transportation of vehicles
materials
Sediment load on ➢ Schedule excavation during Project management and
drainage non-monsoon season, Respective contractors
➢ Cover disturbed soils as quickly
as possible.
➢ Stabilized entry and exit point
Contour Maintain the levels as far as possible Project management
Disturbance
Loss of Reuse for Horticulture Project management and
Productive soil Horticulturists
from excavation
Noise from Proactive maintenance and Project management and
Construction avoidance of high noise generating Respective contractors
Equipment construction activity during night
time
Noise from DG Acoustic enclosure and effective Maintenance Department and
sets Stack height Project management
Energy Solar panels on roof tops wherever Project management
possible.
Occupational Personal protective equipment, First SHE Head
safety Aid Room
Construction ➢ Recyclables like paper, Steel, SHE Head and Respective
Wastes Plastics to recyclers contractors
➢ Concrete wastes for road
construction
➢ Containers to authorized
buyers.
➢ Lubricants and batteries to
authorized recyclers

10.4.1 Operation Phase

During operation stage the major pollution from proposed expansion is from liquid
effluents from process, utilities and domestic facilities, and air pollution from utilities
and or combustion of fuels/wastes. The effluent treatment system will convert most
of the liquid effluents to solids by way of evaporation salts and ETP sludge. The
management, mitigation and enhancement measures identified for significant impact
sources are presented as follows;

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Environment Management Plan

Table 10.2 Impacts and Mitigation – Operational Stage

Source Mitigation Measures Budget Responsibility
Allocated
(Rs. Lakhs)
AIR
Emissions from fuel combustion Electro Static Precipitators (ESP) – 1 x 50 TPH 93 Maintenance Manager
Bag-filters – 1 x 16 TPH and 1 x 10 TPH followed by Boiler In-charge
Effective stack height - 1 x 10 Lac k.cal and 1 x 6 lac k.cal Thermic and operators
fluid heaters
Effective stack height – Standby DG sets
Low ash and sulfur content fuel usage
Process emissions Double stage scrubbing system 45 SHE engineer followed by
Water Columns process operators
Chlorine, HCl and Hydrogen sensors
Diffuse emissions Closed transfer of raw materials/solvents 65.6 SHE engineer followed by
Dual condensing system process engineer and
Vacuum Pumps operators
Vent Scrubber
Vent Condenser for low vapor pressure solvents
Nitrogen blanketing to storage tanks
Automatic Powder Transferring system
Personal Protective Equipment (PPE)
Fugitive Emissions Spill control 20 EHS engineer
Periodic proactive maintenance
Ventilation
Personal Protective Equipment (PPE)
Odor Nuisance Closed transfer 26 EHS engineer followed by
Good House-keeping Housekeeping staff.
Spill control
Sensors
WATER

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Environment Management Plan

Abstraction of ground water Rain water harvesting and roof run off storage EHS engineer
Process effluents Segregation of effluents, 1328 ETP Manager, operators and
Washings Treatment in effluent treatment plant and treated wastewater chemists
Scrubber effluents sent to marine disposal after achieving marine discharge
Utility blow downs standard prescribed.
R & D wastewater
Domestic washings wastewater
NOISE AND VIBRATION
Process area (Turbine) Attenuating screens 35 EHS Engineer followed by
Personal Protective Equipment (PPE) DG sets operators and Co-
Compressors and DG sets Acoustic enclosure generation power plant
Equipment, motors, pumps Casings and guard manager
Transport Limited vehicle movement in plant boundary
SOLID WASTE
I. Hazardous Waste
Process residue, solvent residue, Designated covered storage 12 Environment Engineer
stripper distillate, Spent carbon Labeled containers followed maintenance staff
Garland drain to storage facility
Disposal to Cement plants for co-incineration
Personal Protective Equipment (PPE)
ETP sludge, MEE salts Designated covered storage 6
Labeled containers
Garland drain to storage facility
Disposal to TSDF
Personal Protective Equipment (PPE)
II. Non-Hazardous Waste
Coal Ash Storage silo with ash conditioning facility 4 Environment Engineer
Disposal to brick/cement manufacturers followed maintenance staff
OTHERS

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Environment Management Plan

Storage of raw materials and Tank farm with vent condenser facility for low vapor pressure 30 EHS Engineer and
solvents solvents Production manager
Designated covered storage followed by operators
Closed transfer system for all liquids
Dedicated day tanks at production blocks
Employee exposure to chemicals Occupational Health Centre 20 EHS engineer, production
Self-contained breathing apparatus managers and operators
Standard operating procedure
Health checkup on recruitment
Periodic health checkup during employment
Engineering controls like closed transfer, hoods etc.
Employee rotation
Personal protective equipment
Education, training and periodic mock drill
Transport of raw materials and TREM cards 5 Logistics manager
finished products Driver training and briefing

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10.5 CREP Guideline and Compliance

CREP Guideline Compliance
Segregation of waste streams Segregation of waste streams at source
Detoxification and treatment of high High COD waste streams are neutralized and
COD waste streams detoxified as present practice
Improvement in Solvent recovery Single solvents are recovered and reused in process.
Mixed solvents are distilled to remove moisture and
sold to authorized recovery units/ cement plants for
co-incineration.
Hazardous Air Pollution Control Three stage condensers are provided for all vents of
reactors and low volatile organics storage tanks.
Nitrogen Blanketing is provided for low boiling
solvent storage tanks. Two stage scrubbers will be
provided for process emissions.
Control of Fugitive Emissions Scrubbers proposed to all vents and for process
/VOC’s emissions. Electrostatic Precipitators/Bag filters for
boilers. Double stage condensers are provided for all
vents of reactors and low volatile organic storage
tanks.
Up-gradation of Incinerator Hazardous waste sent to cement plants for co-
incineration
Minimum scale of production to Production capacities optimized.
afford cost of pollution control
Non-Complying Units (as indentified Not Applicable
by SPCB) should meet the notified
standards by December 2003-Bank
guarantee to be submitted to SPCB by
non-complying units by June 2003.

10.6 Other Management Practices

The industry will maintain records as per the hazardous waste regulations and EPA
regulations and apply for the annual consents for air and water, and renewal of
authorization for the storage of hazardous waste as per Hazardous Waste (Handling &
Management) Rules, 1989 and subsequent amendments. The records of hazardous
waste manifest will be maintained.

The industry shall obtain the consent for operation (CFO) as required under section
25/26 of the Water Act, 1974 and under section 21/22 of Air Act, 1981 before trial
production and commissioning from the State Pollution Control Board. The CFO will be
renewed each year by the industry. The industry will obtain the necessary permissions
under Hazardous Waste (Management and Handling) Rules 1989, and Manufacture,

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Environment Management Plan

Storage and Import of Hazardous Chemicals Rules, 1989, issued by the Ministry of
Environment and Forests, New Delhi. The industry will submit environmental
statement every year before September 30, and monthly water cess returns. The
management ensures that it will comply with all the directions and regulations issued
by the Ministry of Environment and Forests, New Delhi, State and Central Pollution
Control Boards. The Consent for Establishment, Consent for Operation will be displayed
in a conspicuous location for the information of the inspecting authorities of different
departments.

10.7 Cost Estimate for Environment Management Plan

It is estimated that the total capital cost for implementing the Environment Management
plan is Rs. 22.52 crores, while the recurring costs for the same is Rs. 21.84 crores/year.
The cost estimate is presented in Table 10.3. The item wise tentative capital cost estimate
for environment management measures is presented in Table 10.4.
Table 10.3 Environment Management Cost estimate
S.No Description Capital Recurring Cost
1 Air pollution Control 492 73.8
2 Water pollution Control 1537 1550
3 Noise pollution Control 27.2 6.8
4 Environment Monitoring and Management 11 1.7
5 Occupational Health 90.8 36.3
6 Green Belt 11 3.3
7 Others (S. Waste) 18 512.4
8 Tentative cost for proposed CER 65
Total (Lakhs) 2252 2184.3
Note: Value in Rs. Lakhs

Table 10.4 Item Wise Tentative Capital Cost Estimate for Environment Management
S.No Description Cost
(Rs. Lakhs)
I Air pollution
Electro Static Precipitator 85
Scrubbers 72
Condensers 315
Vacuum pumps 12
Ash handling system 8
Total - I 492
II Safety
Breather Valves 1.6

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Environment Management Plan

Rupture disks 2
Safety relief valves 5
Total - II 8.6
III Occupational safety
Self-contained breathing apparatus 75
Personal protective equipment 7.2
Total - III 82.2
IV Water
Effluent treatment system 1500
Effluent storage tanks 20
Rain water harvesting structures 5
Effluent and sewage transfer lines 12
Total - IV 1537
V Noise
Acoustic enclosures 9.7
Guards, casing, attenuating screens 13
Vibration control pads 4.5
Total - V 27.2
VI Solid waste
Storage area for hazardous waste 12
Detoxification area 6
Total - VI 18
VII Green Belt 11
Total - VIII 11
VIII Environmental monitoring
Laboratory 6
Monitoring equipment 5
Total - VIII 11
Total (I+II+III+IV+V+VI+VII+VIII) 2187

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Environmental Impact Assessment Report

CHAPTER 11.0 SUMMARY AND CONCLUSION

11.0 Introduction
M/s. NACL Industries Limited (formerly known as Nagarjuna Agrichem Ltd) obtained
environment clearance vide letter no. F.No. J-11011/75/2007-IA II (I) dated 30.07.2007 to
manufacture agrochemicals and environment clearance, which was transferred to NACL
Industries Limited vide letter no. J-11011/75/2007-IA II (I) dated 18.12.2020. The unit had
renewed consent for operation vide order No. APPCB/VSP/VZN/53/CFO/HO/2019
dated 04.10.2018 valid till 28.02.2021.

It is proposed to increase the manufacturing capacity of agrochemicals from 30 TPD to 70.1

TPD, inclusion of Captive Co-generation Power Plant of 6 MW in existing site area of 100
acres located at Sy. No. 177, Arinama Akkivalasa village, Etcherla mandal, Srikakulam
district, Andhra Pradesh. The capital cost for proposed expansion is Rs. 65 crores, towards
additional production blocks, utilities and enhancement of zero liquid discharge facility.
The cost estimate for environment management is Rs. 22.52 crores with annual recurring
expenditure of Rs. 21.84 crores. Prior environmental clearance is mandated by Ministry
of Environment, Forest and Climate Change (MoEFCC), vide SO 1533, dated September
14, 2006, for establishment or expansion of technical grade pesticides manufacturing units.
The terms of reference for the environmental impact assessment studies were obtained
from MoEF&CC vide letter no. F.No. J-11011/75/2007-IA II (I) dated 24.06.2020 as part of
environmental clearance process. The certified compliance letter from the regional office
of MoEFCC, Vijayawada, Andhra Pradesh is obtained vide letter no. F. No.
IRO/VIJ/EPE/03-01/2021 dated 12.03.2021.

11.1 Location of the Project:

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Environmental Impact Assessment Report

direction. The nearest habitation from the site is Kesavadasupeta located at distance of 0.3
km in northwest direction.

The nearest town is Srikakulam at a distance of 10.6 km in NE direction. The nearest railway
station is Ponduru at a distance of 10.5 km in north direction and nearest airport is
Visakhapatnam located at a distance of 85 km in southwest direction. Pedda gedda a
seasonal stream is at a distance of 4.2 km in SW direction. Chitti gedda a seasonal stream is
at a distance of 4.7 km in SW direction. There are no reserve forests, national Parks,
sanctuary, biosphere reserves, ecologically sensitive area, critically polluted area and
interstate boundary within the impact area of 10 km surrounding the site.

11.2 Product Profile

The manufacturing capacity after expansion is presented in Table No. 11.1 and the list of
by-products after expansion is presented in Table 11.2.
Table 11.1 Manufacturing Capacity - After Expansion
S.No Name of the Product CAS No. Capacity
(TPD)
1 Cloquintocet Mexyl 99607-70-2 0.5
2 Triazinone / Thiocarbohydrazide/Dichloro 2231-57-4 10
Pinacolone /Pinacolone
3 2,3 Di chloro Pyridine 2402-77-9 0.5
4 Profenofos 41198-08-7 15.0
5 Thiamethoxam 153719-23-4 1.0
6 Fipronil 120068-37-3 1.0
7 Imidachloprid 138261-41-3 0.5
8 Acetamiprid 135410-20-7 0.5
9 Lambda Cyhalothirin 91465-08-6 1.0
10 Bifenthirin 82657-04-3 1.0
11 Cypermethrin 52315-07-8 0.5
12 Carbendazim 10605-21-7 0.5
13 Pymetrozine 123312-89-0 0.5
14 Telfluthrin 79538-32-2 0.5
15 Pyriproxyfen 95737-68-1 1.0
16 Emamactin Benzoate 155569-91-8 1.0
17 Diafenthiuron 80060-09-9 1.0
18 Propiconazole / Bromoketal (Intermediate) 60207-90-1 3.0
19 Tricyclazole 41814-78-2 2.5
20 Fenbuconazole 114369-43-6 1.0
21 Myclobutanil 88671-89-0 1.0
22 Thifluzomide 130000-40-7 0.8
23 Hexaconazole 79983-71-4 1.0

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24 Tebuconazole / Oxirane (Intermediate) 107534-96-3 1.0

25 Difenconazole 119446-68-3 0.5
26 Epoxiconazole 135319-73-2 0.5
27 Cyproconazole 94361-06-5 0.5
28 Thiophanate-methyl 23564-05-8 1.0
29 Azoxystrobin 131860-33-8 1.0
30 Trifloxystrobin 141517-21-7 1.0
31 Pendimethalin 40487-42-1 1.5
32 Pretilachlor 51218-49-6 4.0
33 Metribuzin 21087-64-9 1.6
34 Dimethomorph 110488-70-5 2.0
35 Clodinofop-Propargyl 105512-06-9 1.0
36 Bispyribec Sodium 125401-92-5 1.0
37 Bensulfuron Methyl 83055-99-6 1.0
38 Glufosinate Ammonium 77182-82-2 1.0
39 Quizalofop-p-ethyl 100646-51-3 1.0
40 Tribenuron Methyl 101200-48-0 0.5
41 Clethodim 99129-21-2 1.0
42 Pinoxsulam 219714-96-2 1.0
43 S-Metolachlor 87392-12-9 1.0
44 Verbinone 1196-01-6 0.2
45 (Z)-hezatec – 11-en-1-yl acetate 34010-21-4 0.2
46 (Z)-hezatec – 9-enal 56219-04-6 0.2
47 (8E,10E) – Dodoca-8, 10-dyen-1-ol 76600-88-9 0.2
48 7Z,11Z hexadeca dienyl acetate 53042-81-2 0.2
49 7E, 9Z dodoca dienyl acetate 54364-62-4 0.2
50 8Z Dodecinyl acetate 28079-04-1 0.2
51 (Z)-Octadeca – 13 – enyl acetate 60037-58-3 0.2
52 R&D Products 0.1
Total 70.1
II Bio Based Agro Chemicals
1 Pseudomonas Fluorosense+ Bacillus Subitilis 0.17
2 Trichoderma Harzianum+Verticillium 0.17
chlamydosporium
3 Ampelomyces quisqualis+BeauveriaBassiana 0.17
4 Beauveria bassiana+ Metarhizium anisopliae 0.17
5 Beauveria bassiana 0.17
6 Metarhizium anisopliae 0.17
7 Verticillium lecanii+Beauveria Bassiana 0.17
8 Hirsutella thompsonii+Beauveria Bassiana 0.17
9 Hirsutella thompsonii 0.17
Total 1.53
Captice Co-generation power plant 6 MW

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Environmental Impact Assessment Report

Agrochemicals Formulations
S.No Name of Product Unit Capacity
1 Granules MT/year 20000
2 Liquids Kl/Year 25000
3 Powders MT/year 5000
Total 50000 50000

Table 11.2 List of By-products – After Expansion

11.3 Manufacturing Process

Chemical synthesis produces majority of agro chemicals in the market. Chemical synthesis
consists of four process steps - reaction, separation, purification, and drying. Large volumes
of solvents are used during chemical syntheses as medium, extractions, and solvent
interchanges. The manufacturing process of the above-mentioned molecules involve
various types of reactions like acetylyzation, protection, deprotection, hydrolysis etc. The
manufacturing process of all the compounds, reactions involved, material balance are
presented in chapter 2 of EIA report.

11.4 Utilities
The proposed expansion requires additional steam for process, ZLD system and solvent
recovery system. It is proposed to establish coal fired boilers of capacity 1 x 50 TPH coal
fired boiler in addition to existing 1 x 16 TPH, 1 x 10 TPH coal fired and 1 x 6 TPH oil fired
boilers. It is proposed to keep existing boiler as standby after establishment of proposed 1
x 50 TPH boiler. It is proposed to establish 1 x 10 lakh k.cal/hr and 1 x 6 lakh k.cal/hr
thermic fluid heaters as part of expansion. The total power requirement is estimated to be
4.0 MW. The DG sets required for emergency power during load shut down is estimated at

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2 x 2000 kVA proposed in addition to existing 1 x 1000 kVA and 2 x 500 kVA. The list of
utilities is presented in Table 11.3.
Table 11.3 List of Utilities
S.No Utility Existing Proposed
After
expansion
1 Coal Fired Boilers (TPH) 1 x 16 1 x 50 1 x 50,
1 x 10 1 x 16 *
1 x 10 *
2 Furnace oil boiler (TPH) 1x6 1x6*
3 Thermic Fluid Heaters (K.cal/hr ) 1 x 10 Lakh 1 x 10 Lakh
1 x 6 Lakh 1 x 6 Lakh
4 DG Sets (kVA)# 1 x 1000, 2 x 2000 2 x 2000
2 x 500 1 x 1000
2 x 500
* Standby after expansion #DG sets will be used during load shut down by Transco

11.5 Water Requirement

Water is required for process, scrubbers, washing, R&D, cooling tower makeup, steam
generation and domestic purposes. Total water required shall increase from 590 KLD to
2285 KLD after expansion. The fresh water consumption is optimized by reusing treated
wastewater to an extent of 1160 KLD, thus reducing fresh water consumption to 1125 KLD
during operation. Fresh water is sourced from ground water. The water balance for daily
consumption is presented in Table 11.4.
Table 11.4 Water Balance
Purpose INPUT KLD OUTPUT KLD
Fresh Water Recycled Water Loss Effluent
Process 170 170 55** 265*
Washings 25 50 5 70
Scrubber 10 140 55# 95
Boiler Feed 480 18 462##
Cooling Tower 200 800 700 300
Raw water pre-treatment rejects 120 120
Domestic 80 20 60
Water for gardening 40 40
Gross Total 1125 1160 893 1372
Total 2285 2265
* Process effluents contain soluble raw materials, byproducts, solvents etc.
** carried along with by-products # carried along with scrubbed HCl
## contaminated steam of 426 KLD.

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11.6 Baseline Environmental Data

The baseline data was collected in the study area during October - December 2020. The
baseline data includes collection of Samples of ground water, surface water and soil,
monitoring of ambient air quality, noise levels, ecological status and meteorological
parameters. The analytical results show that the values are within the prescribed limits for
air quality. The ground water quality is observed to be above the limits for potable purpose
when compared to the prescribed standards of IS: 10500 – 2012 at few locations.

11.7 Identification and Quantification of Impacts

The impact assessment report has identified various sources of pollution and quantified the
pollution loads due to proposed expansion. The sources of pollution are air emissions from
utilities and process; liquid effluents from process, utilities and domestic usage; solid wastes
from process, treatment systems and utilities; and noise pollution from utilities, and process
equipment. A detailed impact assessment was made using rapid impact assessment matrix
method. The salient features are presented as follows.

11.7.1 Impacts on Air quality: The impacts on air quality is due to the emissions from, coal
fired boilers, and standby DG sets. The incremental concentrations are quantified using ISC-
AERMOD model based on ISCST3 Algorithm for proposed utilities of NACL Industries
Limited. The results indicate marginal increase in ambient air quality concentration. The
predicted values for PM, PM10, PM2.5, SO2 and NOx are 1.42, 0.57, 0.26, 2.23 and 3.11 g/m3
respectively and the maximum values are observed at a distance of 0.5 km in northeast
direction, and the cumulative values of baseline air quality combined with predicted values
are found to be within the prescribed limits of National Ambient Air Quality Standards.
The mitigative and control measures of air pollution shall ensure that the impact on air
quality is local – within the site area and its surroundings. The fugitive and diffuse
emissions were quantified and a box model was used to predict air borne concentrations,
and the results indicate work room concentrations, less than threshold limit values (TLV)
for various solvents.

11.7.2 Impacts on Water: Water is essentially used for process and utilities and domestic
purposes. The required water quantity after expansion will be met from ground water. No
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impact on water quality is expected due to discharge of effluents as zero liquid discharge is
envisaged, which ensures reuse of treated wastewater for process, washings, scrubbers and
cooling towers makeup. There is no usage of treated wastewater for on land irrigation..

11.7.3 Impacts on Noise quality: The noise levels may increase due to turbine, compressors,
motors, DG set and other activities which emit noise levels ranging from 87 dB (A) - 104 dB
(A). The predicted cumulative noise levels (as calculated by the logarithmic model without
noise attenuation) ranged between 100-150 m. The impact due to increased noise levels
shall be restricted to the site area.

11.7.4 Impacts on Soil: The solid wastes generated from process, utilities and effluent
treatment plant may have significant negative impacts if disposed indiscriminately. The
total solid waste will be stored separately in Hazardous waste storage area. Solid waste will
be sent to cements plants for co-incineration based on calorific value or sent to TSDF. The
operational phase impacts observed to be negative, shall be neutral after mitigation due to
effective implementation of management measures in handling, storing and transferring of
solid waste, effluents and chemicals, and development of green belt.

11.7.5 Impacts on Flora and Fauna: There are no endangered species of flora and fauna in
the impact area. The impact on biotic environment is neutral with the effect confined mainly
to the site area.

11.8 Environmental Monitoring Programme

It is proposed to monitor Ambient Air Quality (AAQ) for PM 10, PM2.5, SO2, NOX, VOC, Cl2
and HCl, while work room monitoring includes monitoring of VOC, Cl2 and HCl. Point
source emissions of stacks of boiler and DG sets are monitored quarterly. Noise levels are
monitored quarterly. Raw water and treated wastewater are monitored on daily basis,
while Soil analysis is done once in a year.

11.9 Alternatives
The proposal is for expanding the existing unit, which obtained environmental clearance.
Hence there is no requirement of alternative site or additional site area.

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11.10 Additional Studies - Risk Assessment

Risk assessment was conducted and the heat radiation damage distances of pool fire in the
tank farm was limited to 26 m for a heat radiation of 4 KW/m2 in the case of
dichloromethane solvent, and the same was within the plant premises.

11.11 Project Benefits

The proposed expansion will provide additional employment to 200 people. The proposed
project will also generate indirect employment to the locals during construction phase in
the order of 60 people for a period of 18-24 months. The proposed expansion shall have
positive impact on socioeconomic environment due to provision of employment both direct
and indirect and proposed CER activities.

11.12 Environment Management Plan

The management plan is drawn in consultation with project proponents and technical
consultants after evaluating various mitigation and control measures to address the impacts
identified, predicted and monitored. The impacts during construction stage are temporary
and less significant, the management plan for impacts identified during operation stage is
described as follows;

11.12.1 Liquid Effluents

The effluent generated from the proposed expansion is mainly from process, washings,
scrubbing, utility blow downs, RO/DM rejects and domestic wastewater. The effluents
from process, scrubbers and raw water treatment are considered as HTDS stream, while
wastewater from utility blow downs, washings, contaminated steam and domestic
wastewater are considered LTDS stream. HTDS effluents will treat in stripper followed by
MEE and ATFD, and MEE and ATFD in the case of effluents from RO/DM rejects and
scrubber. All LTDS effluent along with condensate from MEE and ATFD shall be treated
in biological treatment followed by RO system. RO Rejects are sent to MEE and permeate is
used for process, washings, scrubbers and cooling towers make up. Salts from ATFD are
disposed to TSDF. Sludge from various units of Biological treatment are thickened in sludge
handling system and sent to TSDF. Total Effluent generated and mode of treatment is
presented in Table 11.5.
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Table 11.5 Total Effluent Generated and Mode of Treatment

Description Quantity (KLD) Mode of Treatment
Permitted After
Expansion
HTDS Effluents
Process 75 265 Sent to Stripper followed by MEE and
Scrubber Effluent 35 95 ATFD. Stripper Condensate sent to
Raw water pre- 120 Cement Plants for Co-Incineration. MEE
treatment rejects and ATFD Condensate sent to Biological
treatment plant followed by RO. RO rejects
sent to MEE and permeate is reused in
cooling towers make-up, washings,
scrubbers and process
Total I 110 480
LTDS Effluents
Washings 70 Sent to Biological Treatment System
Process – LTDS 40.5 followed by RO. RO permeate reused for
Boiler Blow downs 36 cooling tower makeup. RO rejects sent to
Contaminated steam 426 MEE and permeate is reused in cooling
from boiler 184 towers make-up, washings, scrubbers and
Cooling Tower Blow 300 process.
downs
Domestic 25 60
Total II 249.5 892
Grand Total (I+II) 359.5 1372

11.12.2 Air Pollution

The sources of air pollution are proposed 1 x 50 TPH coal fired boiler, existing 1 x 16 TPH,
1 x 10 TPH coal fired and 1 x 6 TPH oil fired boilers. It is proposed to keep existing boiler
as standby after expansion. It is proposed to establish 1 x 10 lakh k.cal/hr and 1 x 6 lakh
k.cal/hr thermic fluid heaters as part of expansion. Standby DG sets of 2 x 2000 kVA are
proposed in addition to the existing 1 x 1000 and 1 x 500 kVA, will be used during load
shutdown. Electro static precipitator is used as air pollution control equipment for
proposed 1 x 50 TPH coal fired boiler. DG sets shall be provided with stack heights based
on the CPCB formula for effective stack height.

Process emissions contain ammonia, carbon dioxide, hydrogen, hydrogen bromide,

bromine, chlorine, sulfuric acid, sulfur dioxide and hydrogen chloride. Ammonia,
hydrogen chloride, hydrogen bromide is sent to scrubber in series. Sodium chloride from
HCl scrubbing, Sodium bromide from hydrogen bromide scrubbing, ammonium chloride
from ammonia, sodium sulphate from sulfuric acid, Sodium sulphate from sulfur dioxide
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scrubbing is sent to ETP. The other gas expected in the process is carbon dioxide is let out
into atmosphere following a standard operating procedure, while hydrogen gas is let out
into atmosphere through a water column.

Emissions are also released from various operations of manufacturing like centrifuge,
drying, distillation, extraction etc. These emissions mainly contain volatile contents of the
material used for processing. It is proposed to provide vent condensers in series to reactors,
distillation columns, driers and centrifuge etc. to mitigate VOC emissions release. Other
vents are connected to common headers and scrubbers.

11.12.3 Solvent Use and Recycle

Solvents are used for extraction of products and as reaction medium. Used solvents are
recovered by distillation for reuse. Residues from distillation columns and mixed solvents
shall be sent to TSDF for incineration or cement plants for co-incineration. If any of the
distilled spent solvents are not reused due to statutory reasons the same shall be sold to end
users.

11.12.4 Solid Waste

Solid wastes are generated from process, solvent distillation, effluent treatment system, DG
sets and boilers. Stripper distillate, process residue and solvent residue are sent to cement
plants for co-incineration based on acceptability as the same contain significant calorific
value and are predominantly organic in nature. If these wastes are not suitable for co-
incineration, the same are sent to TSDF facility. The evaporation salts from ATFD, and
sludge from ETP are sent to TSDF for landfill. Waste oil and used batteries from the DG sets
are sent to authorized recyclers. Other solid wastes expected from the unit are containers,
empty drums which are returned to the product seller or sold to authorized buyers after
detoxification. Coal ash from boilers and thermic fluid heater is sold to brick manufacturers.

11.12.5 Noise Pollution

Noise is anticipated from turbines, compressors, motors, and DG sets. DG sets shall be
provided with acoustic enclosure. Noise absorbing walls are proposed for turbine room and
the control room shall be acoustically enclosed. Engineering controls like acoustic

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enclosures, barriers, shields, and anti-vibrating pads are provided to ensure reduction of
noise levels and vibration. Employees working in noise generating areas shall be provided
with appropriate personnel protective equipment.

11.12.6 Occupational Safety and Health

Direct exposure to chemicals or its raw materials may affect health of employees. Direct
exposure to hazardous materials is eliminated by providing closed handling facilities.
Personal Protective Equipment (PPE)i.e., hand gloves, safety goggles, safety shoes, safety
helmets, respiratory masks etc. are provided to all the employees working in the plant.
Online chlorine, VOC monitors shall be installed to monitor the ambient air quality of the
same, while chlorine sensors are also used for identifying potential hazard areas. Company
will adopt a policy of providing PPEs to all personnel including contract workers. Periodic
medical checkup in addition to checkup during recruitment is adopted to monitor health
status of employees.

11.12.7 Prevention, maintenance and operation of Environment Control Systems

The pollution control equipment, and the effluent treatment system is monitored
periodically to estimate their efficiency and performance potential as part of adoptive
management. Proactive maintenance and monitoring program for all equipment and
machinery is adopted to identify the problems/under performance of the equipment.
Necessary measures will be adopted to rectify the identified problems/defects. The
management agrees that the results of monitoring will be reviewed periodically to adopt
new measures if necessary, for efficient pollution control.

11.12.8 Transport systems

All the raw materials and finished products are transported by road. Dedicated parking
facility is provided for transport vehicles. There will be 5-10 additional truck trips per day
to the factory for transporting raw materials and products due to proposed expansion.
Traffic signs are placed in the battery limit. The drivers of vehicles will be provided with
TREM cards of chemicals and materials to be transported, and will be explained the
measure to be adopted during various emergencies.

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11.12.9 Reduce, Reuse and Recycle

A number of measures are proposed to achieve high yields and reduce generation of wastes.
It shall be endeavor of the R&D team to improve yields through constant research and
development activities. The solvents shall be recycled for reuse in the process after
distillation. Mother liquors from the first crop shall be reused for process. It is proposed to
use third and fourth washing water for first and second washing of the reactor and
centrifuges. The steam condensate shall be reused for boiler feed. It is also proposed to
explore recovery of various salts from MEE salts, and from process effluents to reduce
effluent loads, and quantity of solid waste.

11.12.10 Green Belt Development

Green belt is recommended as one of the major components of EMP to enhance
environmental quality through mitigation of fugitive emissions, attenuation of noise levels,
balancing eco-environment, prevention of soil erosion, and creation of aesthetic
environment. It is proposed to enhance green belt area to 34 acres, covering the boundary
of the site as part of environment management plan. Native species are identified for
plantation based on CPCB guidelines for development of green belt.

11.13 Corporate Environment Responsibility

11.14 Environment Management Department

The Environment Management Cell of the project headed by the executive director, chief
chemical engineer, assistant chemical engineer, environment engineer, safety officer
followed by Jr. engineers, Junior executives, Chemists and fitters.

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CONCLUSION
The study was conducted during the post monsoon season of 2020. It is observed that
negative impacts are anticipated on air quality, soil and water due to the emissions, effluents
and other discharges both intended and unintended. It is observed that positive impacts are
anticipated on socio-economic status due to employment generation. The hierarchy of
avoidance, reduction, reuse, recycle, treat, release, dispose was followed in preparing the
management plan, with a provision for adaptive management, considering, changing
statutory provisions, post project monitoring and post normal science paradigm of
uncertainty, ambiguity and ignorance.

The proponent assures to implement all the measures with an objective of ensuring least
difference between pre and post project environmental scenarios. It may be concluded that
the management measures proposed shall ensure mitigation of negative impacts and the
resultant residual impacts.

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CHAPTER 12.0 DISCLOSURE OF CONSULTANTS ENGAGED

Declaration by Experts Contributing to the EIA

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

EIA coordinator:

Name: G.V. Reddy

Signature and Date: 03.04.2021

Period of involvement: January 2020

Contact information: Team Labs and Consultants, B115 - 117, 509, Aditya Enclave,
Ameerpet, Hyderabad 500038.

Functional area experts:

S. Functional Name of the Involvement Signature and
No. areas expert/s (period and task**) date
Period of involvement: January 2020 till
date
1 AP T. Ravi Kiran Site visit, Design of AAQ network,
supervision of AAQ monitoring,
Compilation of emissions and
characteristics, assessment of impacts due
to the proposed expansion, identification
of mitigation measures, preparation of
EMP for AP, Preparation of monitoring
plan for AP.
2 WP G.V. Reddy Site visit, identification of monitoring
stations, supervision of sampling,
Characterization of effluent streams,
segregation of effluent streams, ZLD for
effluent treatment, assessment of impacts
due to the proposed expansion,
identification of mitigation measures,
preparation of EMP for WP, Preparation
of monitoring plan for WP.
3 HW G.V. Reddy Site visit, Characterization of solid
wastes, storage, and disposal plan for

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various solid wastes, assessment of

impacts due to the proposed expansion,
identification of mitigation measures,
preparation of EMP for SHW.
4 SE G.V. Reddy Site visit, primary and secondary data
collection of the impact area, assessment
of impacts due to the proposed expansion
on socio economic status and project
economy, preparation of CSR plan,
Preparation of SE part of EIA report.
5 EB I. Sivarama Site visit, primary and secondary data
Krishna collection related to ecology and
biodiversity, assessment of impacts based
on IAIA guidelines, preparation of
mitigation measures, preparation of
green belt plan and cost estimate,
preparation of EB part of EIA report.
6 GEO & G.V.A. Identification of water sheds of the area
HG Ramakrishna by preparing the drainage map,
assessment of ground water potential of
the site and impact area, preparation of
rain water harvesting plan, assessment of
impacts due to ground water abstraction
and mitigation measures.
7 Noise Brijesh Kumar Identification of monitoring stations.
Identification of noise generating sources
existing and due to the proposed
expansion, identification of mitigation
measures, preparation of EMP.
Preparation of monitoring plan for Noise
levels.
8 AQ M. Srinivasa Assisting AP FAE in identifying the AAQ
Reddy monitoring stations by providing normal
climatological and other historical data,
Identification of Micrometeorological
data monitoring station, supervision of
met data collection using Automatic
weather station, Preparation of emission
details, Air quality impact prediction
modeling, Calculation of work room
concentrations of solvents using box
model, Assessment of results and
preparation of isopleths, assisting the AP

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FAE and EIA coordinator in preparation

of EMP.
9 LU G.V.A. Preparation of land use land cover map
Ramakrishna using satellite imagery, ground truth
study, assessing the impacts due to
project. Preparation of FAE report.
10 RH D. Sadasivudu Site visit, assessment of hazop reports,
identification of sources of hazards,
S. Chandrasekhar assessment of storages proposed
Babu expansion in comparison with statutory
regulations and calculation of FETI to
assess the scope of risk assessment,
preparation of isopleths for various
scenarios as part of consequence analysis,
identification of mitigation measures
preparation of disaster management plan.
AP- Air Pollution Prevention, Monitoring and Control, WP- Water Pollution Prevention, Control
and Prediction of Impacts, SHW- Solid Waste and Hazardous Waste Management, SE- Socio-
Economics, EB- Ecology and Biodiversity, HG- Hydrology, Ground Water and Water
Conservation, GEO- Geology, SC- Soil Conservation, AQ, Meteorology, Air Quality Modeling
and prediction, LU- Land Use, RH- Risk Assessment & hazard Management
List of software programmes Models for Environmental Studies
1. AEROMOD for Air Quality prediction
2. PHAST Model / ALOHA model for Risk Assessment
3. dhwaniPRO v4 – Noise propagation

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Declaration by the Head of the accredited consultant organization/ authorized person

I, G.V. Reddy, hereby, confirm that the above-mentioned experts prepared the EIA of
NACL Industries Limited and EIA Coordinator (EC) is fully aware of the content. The
consultant organization shall be fully accountable for any mis-leading information. No
unethical practices have been carried out and external data / text has not been used
without proper acknowledgement, while preparing this EIA report.
Certificate of Plagiarism check
Title of EIA Report: Expansion of Agrochemicals and inclusion of
and captive co-generation power plant.
Name of Accredited Organisation: Team Labs and Consultants
Unique Identification Number: 0321-17-01
Name of EIA Co-ordinator: G.V. Reddy
Date and Sign of EIA Co-ordinator:
Name: G.V. Reddy
Designation: Proprietor Signature:

Date and Sign of Head of ACO / authorised person:

Name: G.V. Reddy Designation: Proprietor

Name of the EIA consultant organization: Team Labs and Consultants

NABET Certificate No. & Issue Date: NABET/EIA/1821/SA 0114, dt.04.09.2020

12-4 Team Labs and consultants

NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

3. COMPLIANCE OF TERMS OF REFERENCE

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
No.J-11011/75/2007-IA II (I)
Goverment of India
Minister of Enviroment,Forest and Climate Change
Impact Assessment Division
***

Indira Paryavaran Bhavan,

Vayu Wing,3rd Floor,Aliganj,
Jor Bagh Road,New Delhi-110003
24 Jun 2020

To,

M/s NACL INDUSTRIES LIMITED

Sy.No. 177, Arinama Akkivalasa, Etcherla Mandal, Srikakulam,
Srikakulam-532403
Andhra Pradesh

Tel.No.040-33185100; Email:[email protected]

Sir/Madam,

This has reference to the proposal submitted in the Ministry of Environment, Forest
and Climate Change to prescribe the Terms of Reference (TOR) for undertaking detailed EIA
study for the purpose of obtaining Environmental Clearance in accordance with the provisions of
the EIA Notification, 2006. For this purpose, the proponent had submitted online information in the
prescribed format (Form-1 ) along with a Pre-feasibility Report. The details of the proposal are
given below:

1. Proposal No.: IA/AP/IND2/153326/2020

Expansion of Agrochemicals Manufacturing Unit

(From 30 TPD to 70.1 TPD) and inclusion of
Bio-based agrochemicals and Captive Co-
2. Name of the Proposal: generation Power Plant 6 MW at Sy. No. 177,
Arinama Akkivalasa village, Etcherla mandal,
Srikakulam district, Andhra Pradesh. by M/s.
NACL Industries Limited

3. Category of the Proposal: Industrial Projects - 2

4. Project/Activity applied for: 5(b) Pesticides industry and pesticide specific

intermediates (excluding formulations)

5. Date of submission for TOR: 15 May 2020

In this regard, under the provisions of the EIA Notification 2006 as amended, the Standard TOR
for the purpose of preparing environment impact assessment report and environment
management plan for obtaining prior environment clearance is prescribed with public consultation
as follows:
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/
ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

5(b): STANDARD TERMS OF REFERENCE FOR CONDUCTING

ENVIRONMENT IMPACT ASSESSMENT STUDY FOR PESTICIDES
INDUSTRY AND PESTICIDE SPECIFIC INTERMEDIATES
(EXCLUDING FORMULATIONS)AND INFORMATION TO BE
INCLUDED IN EIA/EMP REPORT
A. STANDARD TERMS OF REFERENCE
1) Executive Summary
2) Introduction
i. Details of the EIA Consultant including NABET accreditation
ii. Information about the project proponent
iii. Importance and benefits of the project
3) Project Description
i. Cost of project and time of completion.
ii. Products with capacities for the proposed project.
iii. If expansion project, details of existing products with capacities and whether adequate land
is available for expansion, reference of earlier EC if any.
iv. List of raw materials required and their source along with mode of transportation.
v. Other chemicals and materials required with quantities and storage capacities
vi. Details of Emission, effluents, hazardous waste generation and their management.
vii. Requirement of water, power, with source of supply, status of approval, water balance diagram,
man-power requirement (regular and contract)
viii. Process description along with major equipments and machineries, process flow sheet
(quantative) from raw material to products to be provided
ix. Hazard identification and details of proposed safety systems.
x. Expansion/modernization proposals:
a. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for
the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the
latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests
as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated
in all the existing environmental clearances including Amendments shall be provided. In
addition, status of compliance of Consent to Operate for the ongoing Iexisting operation
of the project from SPCB shall be attached with the EIA-EMP report.
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR
PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

b. In case the existing project has not obtained environmental clearance, reasons for not
taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification
2006 shall be provided. Copies of Consent to Establish/No Objection Certificate and
Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and
CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance
report to the conditions of consents from the SPCB shall be submitted.
4) Site Details
i. Location of the project site covering village, Taluka/Tehsil, District and State, Justification
for selecting the site, whether other sites were considered.
ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale
on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)
iii. Details w.r.t. option analysis for selection of site
iv. Co-ordinates (lat-long) of all four corners of the site.
v. Google map-Earth downloaded of the project site.
vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant
area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout
of Industrial Area indicating location of unit within the Industrial area/Estate.
vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show
photographs of plantation/greenbelt, in particular.
viii. Landuse break-up of total land of the project site (identified and acquired), government/
private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not
required for industrial area)
ix. A list of major industries with name and type within study area (10km radius) shall be
incorporated. Land use details of the study area
x. Geological features and Geo-hydrological status of the study area shall be included.
xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km
radius of any major river, peak and lean season river discharge as well as flood occurrence
frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the
project site and maximum Flood Level of the river shall also be provided. (mega green field
projects)
xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process
and expected time of complete possession of the land.
xiii. R&R details in respect of land in line with state Government policy
5) Forest and wildlife related issues (if applicable):
i. Permission and approval for the use of forest land (forestry clearance), if any, and
recommendations of the State Forest Department. (if applicable)
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/
ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineating
the forestland (in case of projects involving forest land more than 40 ha)
iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest
status shall be submitted.
iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves,
Migratory Corridors of Wild Animals, the project proponent shall submit the map duly
authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location
and the recommendations or comments of the Chief Wildlife Warden-thereon
v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State
Government for conservation of Schedule I fauna, if any exists in the study area
vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the
Standing Committee of the National Board for Wildlife.
6) Environmental Status
i. Determination of atmospheric inversion level at the project site and site-specific micro-
meteorological data using temperature, relative humidity, hourly wind speed and direction
and rainfall.
ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other
parameters relevant to the project shall be collected. The monitoring stations shall be based
CPCB guidelines and take into account the pre-dominant wind direction, population zone
and sensitive receptors including reserved forests.
iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the
NAQQM Notification of Nov. 2009 along with - min., max., average and 98% values for
each of the AAQ parameters from data of all AAQ stations should be provided as an annexure
to the EIA Report.
iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)
and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.
v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if
yes give details.
vi. Ground water monitoring at minimum at 8 locations shall be included.
vii. Noise levels monitoring at 8 locations within the study area.
viii. Soil Characteristic as per CPCB guidelines.
ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials,
additional traffic due to proposed project, parking arrangement etc.
x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area
shall be given with special reference to rare, endemic and endangered species. If Schedule-
I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and
furnished.
xi. Socio-economic status of the study area.
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR
PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

7) Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based on
site-specific meteorological features. In case the project is located on a hilly terrain, the
AQIP Modelling shall be done using inputs of the specific terrain characteristics for
determining the potential impacts of the project on the AAQ. Cumulative impact of all sources
of emissions (including transportation) on the AAQ of the area shall be assessed. Details of
the model used and the input data used for modelling shall also be provided. The air quality
contours shall be plotted on a location map showing the location of project site, habitation
nearby, sensitive receptors, if any.
ii. Water Quality modelling - in case of discharge in water body
iii. Impact of the transport of the raw materials and end products on the surrounding environment
shall be assessed and provided. In this regard, options for transport of raw materials and
finished products and wastes (large quantities) by rail or rail-cum road transport or conveyor-
cum-rail transport shall be examined.
iv. A note on treatment of wastewater from different plant operations, extent recycled and reused
for different purposes shall be included. Complete scheme of effluent treatment. Characteristics
of untreated and treated effluent to meet the prescribed standards of discharge under E(P)
Rules.
v. Details of stack emission and action plan for control of emissions to meet standards.
vi. Measures for fugitive emission control
vii. Details of hazardous waste generation and their storage, utilization and management. Copies
of MOU regarding utilization of solid and hazardous waste in cement plant shall also be
included. EMP shall include the concept of waste-minimization, recycle/reuse/recover
techniques, Energy conservation, and natural resource conservation.
viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed
plan of action shall be provided.
ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than
1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall
be included. The green belt shall be around the project boundary and a scheme for greening
of the roads used for the project shall also be incorporated.
x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest
rainwater from the roof tops and storm water drains to recharge the ground water and also to
use for the various activities at the project site to conserve fresh water and reduce the water
requirement from other sources.
xi. Total capital cost and recurring cost/annum for environmental pollution control measures
shall be included.
xii. Action plan for post-project environmental monitoring shall be submitted.
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/
ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency Management
Plan including Risk Assessment and damage control. Disaster management plan should be
linked with District Disaster Management Plan.
8) Occupational health
i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual
workers
ii. Details of exposure specific health status evaluation of worker. If the workers' health is being
evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far
& Near vision, colour vision and any other ocular defect) ECG, during pre placement and
periodical examinations give the details of the same. Details regarding last month analyzed
data of above mentioned parameters as per age, sex, duration of exposure and department
wise.
iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards
and whether they are within Permissible Exposure level (PEL). If these are not within PEL,
what measures the company has adopted to keep them within PEL so that health of the workers
can be preserved,
iv. Annual report of heath status of workers with special reference to Occupational Health and
Safety.
9) Corporate Environment Policy
i. Does the company have a well laid down Environment Policy approved by its Board of
Directors? If so, it may be detailed in the EIA report.
ii. Does the Environment Policy prescribe for standard operating process / procedures to bring
into focus any infringement / deviation / violation of the environmental or forest norms /
conditions? If so, it may be detailed in the EIA.
iii. What is the hierarchical system or Administrative order of the company to deal with the
environmental issues and for ensuring compliance with the environmental clearance
conditions? Details of this system may be given.
iv. Does the company have system of reporting of non compliances / violations of environmental
norms to the Board of Directors of the company and / or shareholders or stakeholders at
large? This reporting mechanism shall be detailed in the EIA report
10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the
labour force during construction as well as to the casual workers including truck drivers during
operation phase.
11) Enterprise Social Commitment (ESC)
i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise
Social Commitment based on Public Hearing issues and item-wise details along with time
STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR
PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

bound action plan shall be included. Socio-economic development activities need to be

elaborated upon.
12) Any litigation pending against the project and/or any direction/order passed by any Court of Law
against the project, if so, details thereof shall also be included. Has the unit received any notice
under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water
Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.
13) 'A tabular chart with index for point wise compliance of above TOR.

B. SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FOR PESTICIDES

INDUSTRY AND PESTICIDE SPECIFIC INTERMEDIATES (EXCLUDING
FORMULATIONS)
1. Commitment that no banned pesticides will be manufactured.
2. Detailsonsolvents to be used,measuresfor solventrecovery and for emissions control.
3. Details of process emissions from the proposed unit and its arrangement to control.
4. Ambient air quality data should include VOC, other process- specific pollutants* like NH3*,
chlorine*, HCl*, HBr*, H2S*, HF*, CS2 etc., (*-as applicable)
5. Work zone monitoring arrangements for hazardous chemicals.
6. Detailed effluent treatment scheme including ssegregation for units adopting 'Zero' liquid discharge.
7. Action plan for odour control to be submitted.
8. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly
that they co-process organic solid/hazardous waste generated.
9. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste in
TSDF, if any.
10. Material Safety Data Sheet for all the Chemicals are being used/will be used.
11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.
12. Details of incinerator if to be installed.
13. Risk assessment for storage and handling of hazardous chemicals/solvents. Action plan for handling
& safety system to be incorporated.
14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

***
TOR Compliances

Compliance of Terms of Reference

Compliance of Standard TOR for “Pesticides Industry and Pesticide Specific Intermediates” Issued
by MoEF&CC for EIA/EMP report for Projects/Activates requiring Environmental Clearance Under
EIA Notification, 2006

S. No Compliance of Terms or Reference Response

A. STANDARD TERMS OF REFERENCE
1 Executive Summary Included in EIA report.
2 Introduction
i. Details of the EIA Consultant including EIA Consultants:
NABET accreditation Team Labs and Consultants
List of QCI/NABET Consultants:
NABET/EIA/1821/SA 0114,
dt.04.09.2020
ii. Information about the project proponent Presented in Chapter 1 of EIA report
at Page No. 1-1
iii. Importance and benefits of the project Presented in Chapter 8 of EIA report
at Page No. 8-1,8-2
3 Project Description
i. Cost of project and time of completion. Cost of Project for Proposed
Expansion is 65 crores.
ii. Products with capacities for the proposed Presented in Chapter 1 of EIA report
project. at Page No. 1-3,1-4,1-5.
iii. If expansion project, details of existing Presented in Chapter 1 of EIA report
products with capacities and whether at Page No. 1-3,1-4, 1-5.
adequate land is available for expansion, The proposed expansion is within
reference of earlier EC if any. existing plant site
Total land area (existing): 100 acres.
iv. List of raw materials required and their Presented in Chapter 7 of EIA report
source along with mode of transportation. at Page No. 7-5
v. Other chemicals and materials required with Presented in Chapter 7 of EIA report
quantities and storage capacities at Page No. 7-5
vi. Details of Emission, effluents, hazardous Presented in Chapter 10 of EIA report.
waste generation and their management.
vii. Requirement of water, power, with source of
Total water required: 2285 KLD
supply, status of approval, water balance Fresh water: 1125 KLD
diagram, man-power requirement (regular Detailed water balance is presented in
and contract) Chapter 2 of EIA Report at Page No.
2-10 to 2-11
viii. Process description along with major Presented as separate Annexure
equipment’s and machineries, process flow
sheet (quantative) from raw material to
products to be provided
ix. Hazard identification and details of Presented in Chapter 7 of EIA report
proposed safety systems.
x. Expansion/modernization proposals:
a. Copy of all the Environmental Copy of Environmental Clearance and
Clearance(s) including Amendments status of compliance of conditions
thereto obtained for the project from stipulated in EC presented in
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TOR Compliances

MOEF/SEIAA shall be attached as an Annexure - I. Point wise compliance

Annexure. A certified copy of the latest of Consent for Operate (CFO)
Monitoring Report of the Regional Office Presented at Annexure – II. The
of the Ministry of Environment and certified compliance letter from the
Forests as per circular dated 30th May, regional office of MoEFCC,
2012 on the status of compliance of Vijayawada, Andhra Pradesh is
conditions stipulated in all the existing obtained vide letter no. F. No.
environmental clearances including IRO/VIJ/EPE/03-01/2021 dated
Amendments shall be provided. In 12.03.2021.
addition, status of compliance of Consent
to Operate for the ongoing existing
operation of the project from SPCB shall
be attached with the EIA-EMP report.
b. In case the existing project has not Not Applicable
obtained environmental clearance,
reasons for not
taking EC under the provisions of the
EIA Notification 1994 and/or EIA
Notification
2006 shall be provided. Copies of
Consent to Establish/No Objection
Certificate and
Consent to Operate (in case of units
operating prior to EIA Notification 2006,
CTE and CTO of FY 2005-2006) obtained
from the SPCB shall be submitted.
Further, compliance report to the
conditions of consents from the SPCB
shall be submitted.
4 Site Details
i. Location of the project site covering village, M/s. NACL Industries Limited
Taluka/Tehsil, District and State, (formerly known as Nagarjuna
Justification Agrichem Ltd)., at Sy. No. 177,
for selecting the site, whether other sites Arinama Akkivalasa village, Etcherla
were considered. mandal, Srikakulam district, Andhra
Pradesh.
The proposed expansion is within
existing plant site
Total land area (existing): 100 acres
ii. A topo sheet of the study area of radius of Presented in Chapter 1 of EIA report
10km and site location on 1:50,000/1:25,000 at Page No. 1-9.
scale on an A3/A2 sheet. (including all eco-
sensitive areas and environmentally sensitive
places)
iii. Details w.r.t. option analysis for selection of Proposal is for expansion of
site manufacturing capacity within
existing plant site.
iv. Co-ordinates (lat-long) of all four corners of The site is located at the intersection
the site. of 180 16’31” (N) latitude and 830

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TOR Compliances

47’33” (E) longitude.

v. Google map-Earth downloaded of the project Enclosed at Annexure - I
site.
vi. Layout maps indicating existing unit as well Plant layout is presented in Chapter 1
as proposed unit indicating storage area, of EIA report at Page No. 1-10
plant
area, greenbelt area, utilities etc. If located
within an Industrial area/Estate/Complex,
layout of Industrial Area indicating location
of unit within the Industrial area/Estate.
vii. Photographs of the proposed and existing (if Photographs of Plant site is presented
applicable) plant site. If existing, show in Chapter 3 of EIA report at Page No.
Photographs of plantation/greenbelt, in 3-2
particular.
viii. Land use break-up of total land of the project Plant layout is presented in Chapter 1
site (identified and acquired), government/ of EIA report at Page No. 1-10
private - agricultural, forest, wasteland,
water bodies, settlements, etc shall be
included. (not
required for industrial area)
ix. A list of major industries with name and Land use and Land Cover map of the
type within study area (10km radius) shall be study area is presented in Chapter 3
Incorporated. Land use details of the study of EIA report at Page No. 3-40
area
x. Geological features and Geo-hydrological Presented in Chapter 3 of EIA report
status of the study area shall be included. at Page No. 3-4 to 3-7
xi. Details of Drainage of the project up to 5km Drainage pattern of the impact area is
radius of study area. If the site is within 1 km presented in Chapter 3 of EIA report
radius of any major river, peak and lean at Page No. 3-15
season river discharge as well as flood
occurrence Frequency based on peak rainfall
data of the past 30 years. Details of Flood
Level of the Project site and maximum Flood
Level of the river shall also be provided.
(mega green field
projects)
xii. Status of acquisition of land. If acquisition is The proposed expansion is within
not complete, stage of the acquisition process existing plant.
and expected time of complete possession of Total land area (existing): 100 acres
the land.
xiii. R&R details in respect of land in line with Not Applicable. Expansion within
state Government policy. existing site area.
5 Forest and wildlife related issues (if applicable):
i. Permission and approval for the use of forest Not Applicable
land (forestry clearance), if any, and
recommendations of the State Forest
Department. (if applicable)
ii. Land use map based on High resolution The present proposal is for expansion
satellite imagery (GPS) of the proposed site within existing plant site; however,
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TOR Compliances

delineating the forestland (in case of projects land use map is presented in Chapter
involving forest land more than 40 ha) 3 of EIA report at Page No. 3-9
iii. Status of Application submitted for obtaining Not Applicable
the stage I forestry clearance along with
latest
status shall be submitted.
iv. The projects to be located within 10 km of the There are no reserve forests, national
National Parks, Sanctuaries, Biosphere Parks, sanctuary, biosphere reserves,
Reserves, Migratory Corridors of Wild ecologically sensitive area, critically
Animals, the project proponent shall submit polluted area and interstate boundary
the map duly authenticated by Chief Wildlife within the impact area of 10 km
Warden showing these features vis-à-vis the surrounding the site.
project location and the recommendations or
comments of the Chief Wildlife Warden-
thereon.
v. Wildlife Conservation Plan duly Not Applicable
authenticated by the Chief Wildlife Warden
of the State Government for conservation of
Schedule I fauna, if any exists in the study
area.
vi. Copy of application submitted for clearance Not Applicable
under the Wildlife (Protection) Act, 1972, to
the
Standing Committee of the National Board
for Wildlife.
6 Environmental Status
i. Determination of atmospheric inversion level Site-specific micrometeorological data
at the project site and site-specific presented in Chapter 3 of EIA report
micrometeorological data using temperature, at Page No. 3-20 to 3-22
relative humidity, hourly wind speed and
direction and rainfall.
ii. AAQ data (except monsoon) at 8 locations for AAQ data presented in Chapter 3 of
PM10, PM2.5, SO2, NOX, CO and other EIA report at Page No. 3-25 to 3-30
parameters relevant to the project shall be
collected. The monitoring stations shall be
based CPCB guidelines and take into account
the pre-dominant wind direction, population
zone and sensitive receptors including
reserved forests.
iii. Raw data of all AAQ measurement for 12 AAQ data is presented in Chapter 3 of
weeks of all stations as per frequency given EIA report at Page No. 3-25 to 3-30
in the NAQQM Notification of Nov. 2009
along with - min., max., average and 98%
values for
each of the AAQ parameters from data of all
AAQ stations should be provided as an
annexure to the EIA Report.
iv. Surface water quality of nearby River (100m Surface water Monitoring locations
upstream and downstream of discharge presented in Chapter 3 of EIA report

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TOR Compliances

point) at Page No. 3-13 to 3-14.

and other surface drains at eight locations as
per CPCB/MoEF&CC guidelines.
v. Whether the site falls near to polluted stretch Sy. No. 177, Arinama Akkivalasa
of river identified by the CPCB/MoEF&CC, if village, Etcherla mandal, Srikakulam
yes give details. district, Andhra Pradesh.
vi. Ground water monitoring at minimum at 8 Ground Monitoring locations
locations shall be included. presented in Chapter 3 of EIA report
at Page No. 3-16 to 3-18.
vii. Noise levels monitoring at 8 locations within Noise levels monitoring is presented
the study area. in Chapter 3 of EIA report at Page No.
3-30 to 3-32
viii. Soil Characteristic as per CPCB guidelines. Soil Characteristics is presented in
Chapter 3 of EIA report at Page No. 3-
8 to 3-12
ix. Traffic study of the area, type of vehicles, Traffic study of the area is presented
frequency of vehicles for transportation of in Chapter 3 of EIA report at Page No.
materials, additional traffic due to proposed 3-32,3-33
project, parking arrangement etc.
x. Detailed description of flora and fauna Flora and Fauna of the Impact area is
(terrestrial and aquatic) existing in the study presented in Chapter 3 of EIA report
area shall be given with special reference to at Page No. 3-41 to 3-65
rare, endemic and endangered species. If
Schedule-I fauna are found within the study
area, a Wildlife Conservation Plan shall be
prepared and furnished.
xi. Socio-economic status of the study area. Socio-Economic status of the impact
area is presented in Chapter 3 of EIA
report at Page No. 3-33 to 3-39
7 Impact and Environment Management Plan
i. Assessment of ground level concentration of Predictions of ground level
pollutants from the stack emission based on concentrations using ISC-AERMOD
site-specific meteorological features. In case using ISCST3 model is of the
the project is located on a hilly terrain, the pollutants presented in Chapter 4 of
AQIP Modelling shall be done using inputs EIA report at Page No. 4-26 to 4-31.
of the specific terrain characteristics for
determining the potential impacts of the There will be 5-10 additional truck
project on the AAQ. Cumulative impact of trips due to proposed expansion.
all sources of emissions (including Emissions considered from transport
transportation) on the AAQ of the area shall of vehicles as line source.
be assessed. Details of the model used and
the input data used for modelling shall also
be provided. The air quality contours shall
be plotted on a location map showing the
location of project site, habitation nearby,
sensitive receptors, if any.
ii. Water Quality modelling - in case of Not applicable
discharge in water body
iii. Impact of the transport of the raw materials There will be 5-10 additional truck

Page 5
TOR Compliances

and end products on the surrounding trips due to proposed expansion.

environment shall be assessed and provided. Truck transport Incidents and
In this regard, options for transport of raw concerns are presented in Chapter 10
materials and finished products and wastes of EIA report at Page No. 10-8.
(large quantities) by rail or rail-cum road
transport or conveyor cum- rail transport
shall be examined.
iv. A note on treatment of wastewater from Quantity, quality of effluent
different plant operations, extent recycled generated from different operation is
and reused for different purposes shall be presented in Chapter 2 of EIA report
included. Complete scheme of effluent at Page No. 2-12
treatment. Characteristics of untreated and
treated effluent to meet the prescribed Effluent Treatment System is
standards of discharge under E (P) Rules. presented in Chapter 2of EIA report at
Page No. 2-13
v. Details of stack emission and action plan for Presented in Chapter 10 of EIA report
control of emissions to meet standards. at Page No. 10-7.
vi. Measures for fugitive emission control Presented in Chapter 10 of EIA report
at Page No. 10-7.
vii. Details of hazardous waste generation and Presented in Chapter 2 of EIA report
their storage, utilization and management. at Page No. 2-36.
Copies of MOU regarding utilization of solid
and hazardous waste in cement plant shall
also be included. EMP shall include the
concept of waste-minimization,
recycle/reuse/recover Techniques, Energy
conservation, and natural resource
conservation.
viii. Proper utilization of fly ash shall be ensured Ash generated from existing boilers
as per Fly Ash Notification, 2009. A detailed are sent to brick manufactures and
plan of action shall be provided. cement plants
ix. Action plan for the green belt development Green belt is developed in an area
plan in 33 % area i.e. land with not less than of 34 Acres. Layout showing green
1,500 trees per ha. Giving details of species, belt development is presented in
width of plantation, planning schedule etc. Chapter 4 at Page No. 4-59.
shall be included. The green belt shall be
around the project boundary and a scheme
for greening of the roads used for the project
shall also be incorporated.
x. Action plan for rainwater harvesting Storm water pond of capacity 5000 m3
measures at plant site shall be submitted to KLD is developed. Details are
harvest rainwater from the roof tops and presented in Chapter 4 of EIA report
storm water drains to recharge the ground at Page No. 4-46.
water and also to use for the various
activities at the project site to conserve fresh
water and reduce the water requirement
from other sources.
xi. Total capital cost and recurring cost/annum Total Capital Cost: Rs. 65 crores
for environmental pollution control EMP Cost estimate: Rs. 2252 Lakhs

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measures Recurring Cost on EMP: Rs. 2184.3

shall be included. Laksh/annum.
Details are presented in Chapter 10 at
Page no. 10-11,10-12
xii. Action plan for post-project environmental Presented in Chapter 6 of EIA report
monitoring shall be submitted. at Page No. 6-9.
xiii. Onsite and Offsite Disaster (natural and Disaster Management Plan is
Man-made) Preparedness and Emergency presented in Chapter 7 of EIA report
Management Plan including Risk at Page No.7-44.
Assessment and damage control. Disaster
management plan should be linked with Onsite and Offsite Disaster is
District Disaster Management Plan. presented in Chapter 7 of EIA report
at Page No.7-45, 7-48.
8 Occupational Health
i. Plan and fund allocation to ensure the Total: 90.8 Lakhs/annum
occupational health & safety of all contract
and casual workers
ii. Details of exposure specific health status Medical health check-up is presented
evaluation of worker. If the workers' health in Chapter 10 of EIA report at Page
is being evaluated by pre designed format, No. 10-9.
chest x rays, Audiometry, Spirometry, Vision
testing (Far & Near vision, colour vision and
any other ocular defect) ECG, during pre
placement and
Periodical examinations give the details of
the same. Details regarding last month
analysed data of above-mentioned
parameters as per age, sex, duration of
exposure and department
wise.
iii. Details of existing Occupational & Safety Presented in Chapter 10 of EIA report
Hazards. What are the exposure levels of at Page No. 10-9
hazards and whether they are within
Permissible Exposure level (PEL). If these are Suitable PPE is prescribed to the
not within PEL, what measures the company employees working in area where the
has adopted to keep them within PEL so that conc. Exceeds PEL values.
health of the workers can be preserved, Simultaneously the project and R&D
team are consulted to suggest
mitigative measures and or
engineering control measures.

The focus shall always be in ensuring

concentration within PEL by adopting
engineering controls as when
requires.
iv. Annual report of heath status of workers Annual report of Health Status of
with special reference to Occupational workers is enclosed at Annexure – III
Health and
Safety.
9 Corporate Environment Policy
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i. Does the company have a well laid down Corporate Environment Policy is
Environment Policy approved by its Board of presented in Chapter 10 of EIA report
Directors? If so, it may be detailed in the EIA at Page No. 10-4.
report.
ii. Does the Environment Policy prescribe for Environment manager is responsible
standard operating process / procedures to to bring to focus to higher
bring into focus any infringement / management in case of deviation/
deviation / violation of the environmental or violation of the environmental or
forest norms / conditions? If so, it may be forest norms / conditions.
detailed in the EIA.
iii. What is the hierarchical system or Environment Management Cell is
Administrative order of the company to deal presented in Chapter 10 of EIA report
with the environmental issues and for at Page No. 10-2.
ensuring compliance with the environmental
clearance
Conditions? Details of this system may be
given.
iv. Does the company have system of reporting Yes. Details of Environment
of non compliances / violations of Management Cell is presented in
environmental norms to the Board of Chapter 10 of EIA report at Page No.
Directors of the company and / or 10-2.
shareholders or stakeholders at large? This
reporting mechanism shall be detailed in the
EIA report
10 Details regarding infrastructure facilities such as Presented in Chapter 1 of EIA report
sanitation, fuel, restroom etc. to be provided to at Page No. 1-7.
the labour force during construction as well as to
the casual workers including truck drivers during
operation phase.
11 Enterprise Social Commitment (ESC)
i. Adequate funds (at least 2.5 % of the project Corporate Social Responsibilities –
cost) shall be earmarked towards the Budget is presented in Chapter 4 of
Enterprise Social Commitment based on EIA report at Page No. 10-68 ,10-69.
Public Hearing issues and item-wise details
along with time bound action plan shall be
included. Socio-economic development
activities need to be elaborated upon.
12 Any litigation pending against the project and/or No Individual Court case against the
any direction/order passed by any Court of Law Project.
against the project, if so, details thereof shall also be
included. Has the unit received any notice under
the Section 5 of Environment (Protection) Act, 1986
or relevant Sections of Air and Water Acts? If so,
details thereof and compliance/ATR to the
notice(s) and present status of the case.
13 A tabular chart with index for points wise Enclosed at Compliance of Terms of
compliance of above TOR. Reference along with EIA & EMP.
B. SPECIFIC TERMS OF REFERENCE FOR EIA STUDIES FOR PESTICIDES INDUSTRY AND
PESTICIDE SPECIFIC INTERMEDIATES (EXCLUDING FORMULATIONS)
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TOR Compliances

1 Commitment that no banned pesticides will be M/s. NACL Industries Limited

manufactured. undertake that they will not
manufacture any agrochemicals
banned by Government of India
2 Details on solvents to be used, measures for solvent Details of solvents is given in EIA
recovery and for emissions control. report at Page No. 2-30 to 2-32.
3 Details of process emissions from the proposed Detail of process emission and mode
unit and its arrangement to control. of treatment is presented in
Environment Management Plan of
EIA report at Page No. 2-26.
4 Ambient air quality data should include VOC, AAQ data is presented in Chapter 3 of
other process-specific pollutants* like NH3*, EIA report at Page No. 3-25 to 3-30
chlorine*, HCl*, HBr*, H2S*, HF*,etc., (*-as
applicable)
5 Work zone monitoring arrangements for Presented in Chapter 6 of EIA report
hazardous chemicals. at Page No. 6-11.
6 Detailed effluent treatment scheme including Details of Effluent Treatment System
segregation of effluent streams for units adopting presented in Environment
'Zero' liquid discharge. Management Plan of EIA report at
Page No. 2-15 to 2-21.
7 Action plan for odour control to be submitted. Presented in Environment
Management Plan of EIA report at
Page No. 10-7.
8 A copy of the Memorandum of Understanding Agreement enclosed
signed with cement manufacturers indicating
clearly that they co-process organic
solid/hazardous waste generated.
9 Authorization/Membership for the disposal of Agreement with cement plants is
liquid effluent in CETP and solid/hazardous waste enclosed
in TSDF, if any.
10 Material Safety Data Sheet for all the Chemicals are Enclosed at Annexure – II
being used/will be used.
11 Authorization/Membership for the disposal of Sent to lined land fill within the
solid/hazardous waste in TSDF. premises. Organic residues sent to
cement industries for co-processing.
12 Details of incinerator if to be installed. Presented in Environment
Management Plan of EIA report at
Page No. 10-9 to 10-10.
13 Risk assessment for storage and handling of Presented in Chapter 7 of EIA report
hazardous chemicals/solvents. Action plan for
handling & safety system to be incorporated.
14 Arrangements for ensuring health and safety of Presented in Environment
workers engaged in handling of toxic materials. Management Plan of EIA report at
Page No. 10-9.

Page 9
APPENDIX I
(See Paragraph-6)
FORM 1

Note : If space provided against any parameter is inadequate,Kindly upload supporting document under 'Additional
Attachments if any' at the last part of the Form1. Please note that all such Annexures must be part of single pdf document.

(I) Basic Information

S.No. Item Details

Whether it is a violation case and application is being

submitted under Notification No. S.O.804(E) dated No
14.03.2017 ?

Expansion of Agrochemicals Manufacturing Unit (From 30 TPD to 70.1 TPD)

and inclusion of Bio-based agrochemicals and Captive Co-generation Power
Name of the Project/s
Plant 6 MW at Sy. No. 177, Arinama Akkivalasa village, Etcherla mandal,
1. Srikakulam district, Andhra Pradesh. by M/s. NACL Industries Limited
Brief summary of project Annexure-Brief summary of project
Proposal Number IA/AP/IND2/153326/2020
Project Cost (in lacs) 6500

2. 5(b) Pesticides industry and pesticide specific intermediates (excluding

S. No. in the schedule
formulations)
Project Sector Industrial Projects - 2

Proposed capacity/area/length/tonnage to be
3. handled/command area/lease area/number or wells to Expansion of Agrochemicals from 30 TPD to 70.1 TPD ha.
be drilled

4. New/Expansion/Modernization Expansion
Proposal Number IA/AP/IND2/153325/1900
MoEF file number(Previous EC) J-11011/75/2007-IA II (I)
Uploaded EC letter Annexure-Uploaded EC letter

5. Existing Capacity/Area etc. 30 ha.

6. Category of project i.e. 'A' or 'B' A

Does it attract the general condition? If yes, please

7. No
specify

8. Does it attract the specific condition? If yes, please

No
specify

9. Sy. No. 177, Arinama Akkivalasa village, Etcherla mandal, Srikakulam

Location of the project
district, Andhra Pradesh
Shape of the project land Block (Polygon)
Uploaded GPS file Annexure-GPS file
Uploaded copy of survey of India Toposheet Annexure-Survey of india toposheet
Plot/Survey/Khasra No. Sy. No. 177
Town / Village Arinama Akkivalasa
State of the project Andhra Pradesh

Details of State of the project

S.no State Name District Name Tehsil Name

(1.) Andhra Pradesh Srikakulam Etcherla

Nearest railway station along with distance in kms Chilakapalem Railway Station, 1.3 km
10.
Nearest airport along with distance in kms Vishakaptnam Airport, 85.7 km

Nearest Town/City/District Headquarters along with

11. Srikakulam , 12 km
distance in kms

Village Panchayats, Zila Parishad, Muncipal

12. Corporation, Local body (Complete postal address with Arinama Akkivalasa
telephone nos. to be given)

13. Name of the Applicant Chantati

Plot No a2 A, C Block, Lakshmi Towers, Nagarjuna Hills, Punjagutta,

14. Registered Address
Hyderabad

15. Address for correspondance:

Name of the Company NACL INDUSTRIES LIMITED
Name of the Applicant Chantati
Designation (Owner/ Partner/ CEO) Sr Vice President Mfg
Pin code 532403
E-mail [email protected]
Telephone No. 040-33185100
Fax No. 040-
Copy of documents in support of the
competence/authority of the person making this
NIL
application to make application on behalf of the User
Agency .

16. Details of Alternative Sites examined, if any. Location

No
of these sites should be shown on a toposheet

17. Whether part of Interlinked projects? No

Whether separate application of Interlinked project has

18. N/A
been submitted?

19. If Yes, MoEF file number N/A

Date of submission N/A

20. If No, Reason N/A

21. Whether the proposal involves Approval/ Clearance under: if yes, details of the same and their status to be given
(i) Whether the proposal involves approval/clearance
No
under the Forest (Conservation) Act,1980?
(ii) Whether the proposal involves approval/clearance
No
under the wildlife (Protection) Act,1972?
(iii) Whether the proposal involves approval/clearance
No
under the C.R.Z notification, 2011?

22. Whether there is any Government Order/Policy

No
relevent/relating to the site?

23. Whether any Forest Land Involved? No

Area of Forest land Involved (hectares) N/A

24. Whether there is any litigation pending against the

project and/or land in which the project is proposed to No
be set up?
(a) Name of the Court N/A
(b) Name of the Sub court N/A
(c) Case No. N/A
(d) Orders/directions of the court, if any and relevance
N/A
with the proposed project

(II) Activity

Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the
1
locality (topography, land use, changes in water bodies, etc.)

S.No Details there of (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

Permanent or temporary change in land use, land cover

No additional land is proposed for expansion. The expansion is within
1.1 or topography including increase in intensity of land No
existing site area of 100 acres.
use (with respect to local land use plan)

1.2 Clearance of existing land, vegetation and buildings? No The proposal is for expansion of agrochemicals manufacturing unit.

1.3 Creation of new land uses? No Existing – industrial

Pre-construction investigations e.g. bore houses, soil

1.4 Yes Soil test done
testing?

Construction activity involves creation of additional blocks, utilities

1.5 Construction works? Yes like Boilers, Chilling Plant etc. and enhancement of Zero Liquid
Discharge (ZLD) system.

1.6 Demolition works? No No structures for demolition

Temporary sites used for construction works or housing

1.7 No Construction labor from local villages shall be employed.
of construction workers?

Above ground buildings, structures or earthworks

Storage facilities shall be constructed. No major cut and fill or
1.8 including linear structures,cut and fill or excavations Yes
excavation is anticipated.
and fill or excavations
1.9 Underground works including mining or tunneling? No No underground works like mining and tunneling.

1.10 Reclamation works? No

1.11 Dredging? No

1.12 Offshore structures? No

1.13 Production and manufacturing processes? Yes Enclosed in Annexure – I

1.14 Facilities for storage of goods or materials? No Raw materials and solvents shall be stored with safety precautions.

Solid waste shall be disposed to end users/recyclers or sent to

Facilities for treatment or disposal of solid waste or
1.15 Yes incineration. Effluent generated from the plant are treated and
liquid effluents?
reused. Details presented in Annexure II

1.16 Facilities for long term housing of operational workers? No Local people shall be employed.

New road, rail or sea traffic during construction or

1.17 No
operation?

New road, rail, air water borne or other transport

1.18 infrastructure including new or altered routes and No
stations, ports, airports etc?

Closure or diversion of existing transport routes or

1.19 No
infrastructure leading to changes in traffic movements?

1.20 New or diverted transmission lines or pipelines? No

Impoundment, damming, culverting, realignment or

1.21 other changes to the hydrology of watercourses or No
aquifers?

1.22 Stream crossings? No

Total water requirement after expansion would be 2285 KLD out of

Abstraction or transfers of water from ground or
1.23 Yes which 1125 KLD shall be met from ground water and the balance
surface waters?
shall be recycled water.

Changes in water bodies or the land surface affecting

1.24 No
drainage or run-off?

The construction material shall be drawn from local sources within 10

Transport of personnel or materials for construction,
1.25 Yes – 15 km. There is no transport of personnel, as the construction
operation or decommissioning?
workers shall be drawn from local villages.

Long-term dismantling or decommissioning or

1.26 No
restoration works?

Ongoing activity during decommissioning which could

1.27 No
have an impact on the environment?

Influx of people to an area in either temporarily or The proposed project shall increase the employment potential and
1.28 Yes
permanently? hence may lead to migration to surrounding villages.

1.29 Introduction of alien species? No

1.30 Loss of native species or genetic diversity? No No, as the proposed expansion is within existing unit.

1.31 Any other actions? No

Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially
2
any resources which are non-renewable or in short supply):

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha) No Existing Unit

Total water requirement after expansion would be 2285 KLD out of

2.2 Water (expected source & competing users) unit: KLD Yes which 1125 KLD shall be met from ground water and the balance
shall be recycled water (Water Balance Enclosed in Annexure III)

2.3 Minerals (MT) No

Construction material – stone, aggregates, sand / soil

2.4 Yes Will be sourced from the local villages.
(expected source – MT)

2.5 Forests and timber (source – MT) No

2.6 Energy including electricity and fuels (source, Yes The required energy shall be drawn from proposed co-generation
competing users) Unit: fuel (MT),energy (MW) power plant of 6MW capacity. Backup DG sets of 2 x 2000 kVA are
proposed in addition to existing 1 x 1000 kVA and 2 x 500 kVA to
cater to energy requirement during load shut downs. The other
energy source is proposed coal fired boiler of 1 x 50 TPH to meet the
steam requirement both for process and ZLD system, while existing 1
x 16 TPH, 1 x 10 TPH coal fired and 1 x 6 TPH oil fired boilers will be
kept as standby after expansio
Any other natural resources (use appropriate standard
2.7 No
units)

Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or
3
the environment or raise concerns about actual or perceived risks to human health

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

Hazardous chemicals shall be used for manufacturing of pesticide

Use of substances or materials, which are hazardous
manufacturing. MSIHC rules shall be followed during storage,
3.1 (as per MSIHC rules) to human health or the Yes
transportation and handling of raw materials. Hazardous chemicals
environment (flora, fauna, and water supplies
and solvent shall be stored and handled in closed systems

Changes in occurrence of disease or affect disease

3.2 No
vectors (e.g. insect or water borne diseases)

Affect the welfare of people e.g. by changing living Shall increase the employment potential for locals and affect the
3.3 Yes
conditions? living conditions for betterment.

Vulnerable groups of people who could be affected by No sensitive receptors are present in the immediate vicinity of the
3.4 the project e.g. hospital patients, children, the elderly No site. The project shall not have any significant impact on vulnerable
etc. groups of people.

3.5 Any other causes No

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

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

4.1 Spoil, overburden or mine wastes No

Wastes from canteen, other commercial wastes like paper, empty

4.2 Municipal waste (domestic and or commercial wastes) No
containers etc.

The hazardous wastes generated during construction contain waste

oils and batteries from DG sets. The quantity of hazardous waste
Hazardous wastes (as per Hazardous Waste
4.3 Yes generated during operation contain salts from evaporators, stripper
Management Rules)
distillate, process residue, and solvent residues, ETP sludge and
filtration media etc. enclosed in Annexure – IV

4.4 Other industrial process wastes Yes Enclosed at Annexure IV

4.5 Surplus product No

Sludge from Effluent treatment plant and evaporation salts shall be

4.6 Sewage sludge or other sludge from effluent treatment Yes
sent to TSDF.

Construction activity involves creation of additional utilities like

4.7 Construction or demolition wastes No
boilers, Chilling Plant etc. and enhancement of ZLD system

4.8 Redundant machinery or equipment No

Structures of all waste treatment facilities are made of concrete and

4.9 Contaminated soils or other materials Yes also above ground to eliminate the possibility of any contamination
due to seepage and for ease of maintenance.

4.10 Agricultural wastes No

4.11 Other solid wastes Yes Enclosed at Annexure IV

5 Release of pollutants or any hazardous, toxic or noxious substances to air(Kg/hr)

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

Emissions from combustion of fossil fuels from Coal Shall be used as fuel. Quantity of fuel and emissions details are
5.1 Yes
stationary or mobile sources enclosed in Annexure V

HCl, SO2, NH3 will be sent to scrubbers and CO2, H2 and nitrogen
5.2 Emissions from production processes Yes
will be let out into atmosphere safely

Emissions from materials handling including storage or Material transfer takes place in closed pipeline systems using pumps
5.3 No
transport with mechanical seals.

5.4 Emissions from construction activities including plant Yes Dust may rise during transport of material and construction activity.
and equipment The dust emissions shall be mitigated by water spraying on the roads
within the premises.

Dust or odours from handling of materials including

5.5 No Sewage will be treated in the treatment plant.
construction materials, sewage and waste

5.6 Emissions from incineration of waste No

Emissions from burning of waste in open air (e.g. slash

5.7 No
materials, construction debris)

5.8 Emissions from any other sources No

6 Generation of Noise and Vibration, and Emissions of Light and Heat:

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

Material transport and construction equipment shall be source of

From operation of equipment e.g. engines, ventilation
6.1 Yes noise, while transfer pumps, vacuum systems, DG sets are the
plant, crushers
sources of noise during operation.

DG sets controlled by providing Acoustic Enclosures. DG sets will be

6.2 From industrial or similar processes Yes
used in case of power failure from APTRANSCO.

Noise during construction shall be due to construction equipment and

6.3 From construction or demolition Yes
emergency DG sets.

6.4 From blasting or piling No

6.5 From construction or operational traffic No The increased traffic shall not have any significant impact.

6.6 From lighting or cooling systems No

6.7 From any other sources No

Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters,
7
groundwater, coastal waters or the sea:

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

All the hazardous materials will be stored in MS drums, in a covered

From handling, storage, use or spillage of hazardous
7.1 No shed with concrete flooring so that there is no contamination of soil
materials
during spillage.

From discharge of sewage or other effluents to water or All effluents generated in plant will be treated in the Zero Liquid
7.2 No
the land (expected mode and place of discharge) Discharge (ZLD) system. No contamination is expected.

All the emissions from process are controlled by providing control

By deposition of pollutants emitted to air into the land equipment like scrubbers, Dust Collectors and emissions from
7.3 No
or into water proposed boiler shall be controlled by providing electro static
precipitators.

7.4 From any other sources No

Is there a risk of long term build up of pollutants in the

7.5 No
environment from these sources?

8 Risk of accidents during construction or operation of the Project, which could affect human health or the environment

S.No Details thereof (with approximate quantities/rates,

Information/Checklist confirmation Yes/No
wherever possible) with source of information data

From explosions, spillages, fires etc from storage, All Inbuilt Safety precautions will be adopted and there will not be
8.1 Yes
handling, use or production of hazardous substances any damage to environment or human health

8.2 From any other causes No

Could the project be affected by natural disasters

8.3 causing environmental damage (e.g. floods, No
earthquakes, landslides, cloudburst etc)?

Factors which should be considered (such as consequential development) which could lead to environmental effects or
9
the potential for cumulative impacts with other existing or planned activities in the locality

Details thereof (with approximate quantities/rates,

S.No Information/Checklist confirmation Yes/No
wherever possible) with source of information data
9.1 Lead to development of supporting utilities, ancillary Yes The project shall enhance the socio-economic status of the area by
development or development stimulated by the increasing the demand for housing, improving the employment. There
project which could have impact on the environment are no major support industries required for this plant.
e.g.:

Supporting infrastructure (roads, power

supply,waste or waste water treatment, etc.)
housing development
extractive industries
supply industries
Other

Lead to after-use of the site, which could have an

9.2 No
impact on the environment

9.3 Set a precedent for later developments No

Have cumulative effects due to proximity to other

9.4 No No similar units are present in the surrounding area.
existing or planned projects with similar effects

(III) Environmental Sensitivity

Aerial distance (within 15km.) Proposed project

S.No Areas Name/Identity
location boundary

Areas protected under international conventions,

1 national or local legislation for their ecological, No
landscape, cultural or other related value

Areas which are important or sensitive for ecological

2 reasons - Wetlands, watercourses or other water No
bodies, coastal zone, biospheres, mountains, forests

Areas used by protected, important or sensitive species

3 of flora or fauna for breeding, nesting, foraging, No
resting, over wintering, migration

4 Inland, coastal, marine or underground waters No

5 State, National boundaries No

Routes or facilities used by the public for access to

6 No
recreation or other tourist, pilgrim areas

7 Defence installations No

8 Densely populated or built-up area Yes Srikakulam town with population of about 2 lakhs.

Areas occupied by sensitive man-made land uses

9 (hospitals, schools, places of worship, community No 0.3 Km from the site
facilities)

Areas containing important, high quality or scarce

10 resources.(ground water resources,surface No
resources,forestry,agriculture,fisheries,tourism,minerals)

Areas already subjected to pollution or environmental

11 damage.(those where existing legal environmental No
standards are exceeded)

Areas susceptible to natural hazard which could cause

the project to present environmental problems
12 (earthquakes, subsidence, landslides, erosion, flooding No
or extreme or adverse climatic conditions) similar
effects

(IV) Proposed Terms of Reference for EIA studies

1 Uploaded Proposed TOR File Annexure-TOR file

2 Uploaded scanned copy of covering letter Annexure-scanned copy of covering letter

3 Uploaded Pre-Feasibility report(PFR) Annexure-PFR

Uploaded additional attachments(only single pdf

4 Annexure-Additional attachments
file)

Additional Attachments, if any

Attached File
EC 2007
Valid CFO

(V) Undertaking

I hereby give undertaking that the data and information given in the application and enclosures are true to be best of my
knowledge and belief and I am aware that if any part of the data and information found to be false or misleading at any
stage, the project will be rejected and clearance given, if any to the project will be revoked at our risk and cost.

V.(i) Name of Applicant Chantati

Designation Sr Vice President Mfg
Name of Company (Applicant Name should not be
NACL INDUSTRIES LIMITED
given here)
Plot No a2 A, C Block, Lakshmi Towers, Nagarjuna Hills, Punjagutta,
Address
Hyderabad
NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

4. STATUS OF COMPLIANCE OF THE CONDITIONS

STIPULATED IN THE ENVIRONMENTAL CLEARANCE

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
Speed Post

File No. IRO/VIJ/EPE/03-01/2021 Date: 12.03.2021

To
Shri Ashok Kumar Pateshwary
Director, Member Secretary (Industry-II),
Ministry of Environment, Forest and Climate Change,
Indira Paryavaran Bhawan, Jorbagh Road, Aliganj,
New Delhi – 110 003.
E-mail: [email protected]

Sub: Issue of Certified Compliance Report in respect of Expansion of

Pesticide Unit (12.5 TPD to 30 TPD), Change in Product Mix and
Captive Power Plant (4 MW) at Plot No. 177, Arinama Akkivalasa,
Allinagaram, Etcherla, Srikakulam, A.P. by M/s Nagarjuna Agrichem
Ltd.-reg.

Ref: Ministry’s Environmental Clearance Letter No. J-11011/75/2007-IA II

(I) dated 30.07.2007

Sir,
I am directed to draw your kind attention to the subject and
reference letter cited above and to state that the above project has been
monitored undersigned on 20.02.2021 for issue of Certified Compliance
Report. Based on the observations made while monitoring of project, the
detailed Certified Compliance Report has been prepared and enclosed for
kind information and further needful action.

Yours faithfully,
Encl: as above

(डॉ। सुरेश बाबु पसुपुलेटी)

(Dr. Suresh Babu Pasupuleti)
वै4ािनक-सी / उप िनदे शक (एस)
Scientist-C/Deputy Director (S)

Copy to: The Unit Head, M/s Nagarjuna Agrichem Ltd., Arinam
Akkivalasa, Allinagaram, Etcherla, Srikakulam, Andhra Pradesh-
532410.E-mail: mailto:[email protected] for kind information and further
necessary action.

वै4ािनक-सी / उप िनदे शक (एस)

Scientist-C/Deputy Director (S)
"मा%णत अनप
ु ालन -रपोट1 / Certified Compliance Report

SN Item Details
प-रयोजना का "कार Industry-II (Pesticides)
1.
Type of Project
2. प-रयोजना का नाम Expansion of Pesticide Unit (12.5 TPD to
Name of Project 30 TPD), Change in Product Mix and
Captive Power Plant (4 MW) at Plot No.
177, Arinama Akkivalasa, Allinagaram,
Etcherla, Srikakulam, A.P. by M/s
Nagarjuna Agrichem Ltd.
3. प-रयोजना "ा5धकरण का पता The Unit Head, M/s Nagarjuna Agrichem
Address of project authorities Ltd., Arinam Akkivalasa, Allinagaram,
Etcherla, Srikakulam, Andhra Pradesh-
532410.
4. पया1वरणीय 9वीकृ;त प< सं0 एवं ;तथी J-11011/75/2007-IA II (I) dated
Env. Clearance Letter No. & Date 30.07.2007
5. Aे<ीय काया1लयप< सं0 IRO/VIJ/EPE/03-01/2021
Regional Office File No.
6. 9थल दौरा;तथी 20.02.2021
Date of Site Visit
7. प-रयोजना कE ि9थ;त Operational
Status of Project

8. प-रयोजना कE वत1मान ि9थ;त / Present status of the Project:

The project was monitored by undersigned on 20.02.2021. During monitoring,
Shri C. V. Rajulu, Sr. V. P. (Operation), Shri K. Seshagiri Rao, GM (Manufacturing),
Shri Omnamassiviah, DGM (Production), Shri Chinnadurai, AGM (Env), Shri R.
Srinivas, Manager (ETP), Shri Venkata Raju, Sr. Manager (Safety) and other Officials
were present. As per the discussions held during monitoring and information
provided by Project Authorities (PAs), the total land of the project is 100 acres and
the present installed project area covered under 24 acres. There are six nos. of
processing blocks were present in the project premises. PAs have obtained CFO and
Hazardous waste authorization vide letter no. APPCB/VSP/VZN/53/CFO/HO/2019
dated 04.10.2019 for production of 48 products. It has been observed that the
Project Authorities (PAs) have complied or are in process of complying the conditions
stipulated in EC. The detailed observations are as follows:

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 1 of 20

9. Stipulated Conditions:
A. Specific Conditions
i. The gaseous emissions (SO2, NOx, HCl, and Cl2 & Br2) and particulate
matter from various process units shall confirm to the standards
prescribed by the concerned authorities from the time to time. Bromine
(Br2) shall be monitored on-line. At no time the emission levels shall go
beyond the stipulated standards. In the event of failure of pollution
control system(s) adopted by the unit, the respective unit shall not be
restarted until the control measures are rectified to achieve the desired
efficiency.

Status: Partially complied

As per the discussions held during monitoring and information provided by

PAs, it has been observed that the PAs have installed online stack monitoring
devices for stacks connected to incinerator and boiler and monitoring PM, SO2,
NOx and CH4. PAs are also monitoring the stack emissions by third party
monitoring agency of M/s SV Enviro Labs & Consultants, Vishakhapatnam
which is approved by Ministry and accredited by NABL. As per the monitoring
conducted in the month of November, 2020, the stack emissions are as
follows:

Incinerator Stack Emissions:

Sl.No. Parameter Unit Result

01 Particulate Matter (PM) mg/Nm3 31.0
02 Sulphur Dioxide (SO2) mg/Nm3 50.2
03 Oxides of Nitrogen (NOx) mg/Nm3 40.9
04 Carbon Monoxide (CO) mg/Nm3 32.6
05 Methane (CH4) ppm <0.5
06 HCl mg/Nm3 18.4
07 Total Organic Carbon (TOC) mg/Nm3 5.0
08 HF mg/Nm3 1.5
09 Cd + TH (and its compounds) mg/Nm3 <0.02
10 Hg (and its compounds) mg/Nm3 <0.02
11 Sb + As + Pb + Cr + Co + Cu + mg/Nm3 <0.1
Mn + Ni + V (and its compounds)

16 Ton Boiler stack:

Sl.No. Parameter Unit Result

01 Particulate Matter (PM) mg/Nm3 33.2

Generator Stacks:

Sl.No. Parameter Unit 500 KVA-1 500 KVA-2 1000KVA

01 PM mg/Nm3 46.9 44.9 49.9

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 2 of 20

02 SO2 mg/Nm3 43.3 46.0 40.2
03 NOx mg/Nm3 52.0 48.5 61.7

Hot Oil Boiler stack:

Sl.No. Parameter Unit Result

01 Particulate Matter (PM) mg/Nm3 49.9
02 Sulphur Dioxide (SO2) mg/Nm3 57.1
03 Oxides of Nitrogen (NOx) mg/Nm3 38.0

Process Scrubber Stacks:

Sl.No. Parameter Process Scrubber

I III IV V VI VII
01 HCL Mist (mg/Nm3) 17.8 13. 16.5 13.6 17.0 13.9
5
02 Ammonia (mg/Nm3) 25.0 22. 22.0 19.0 26.8 23.9
0
03 Phosphate as P2O5 Nil Nil Nil Nil Nil Nil
(mg/Nm3)
04 Chlorine as Cl2 <1.0 <1. <1.0 <1.0 <1.0 <1.0
(mg/Nm3) 0
05 Hydrogen Sulfide as 0.94 0.8 1.8 0.8 1.9 0.9
H2S (mg/Nm3)
06 PM (mg/Nm3) 1.89 1.3 3.0 2.0 3.0 2.1
07 Chloromethane as 5.02 4.1 7.2 4.3 5.2 4.6
CH3Cl (mg/Nm3)
08 HBr (mg/Nm3) 0.8 0.5 1.9 0.7 0.9 1.3

In addition, PAs have also installed three (03) continuous ambient air quality
monitoring stations (CAAQMS) located at ETP, Main Gate and Pond station for
monitoring of PM2.5, PM10, SO2, NOx and VOC. During the day of monitoring,
the AAQ levels are as follows:

Parameter At ETP Main Gate Pond

PM2.5 (µg/m3) 4.22 6.90 7.48
PM10 (µg/m3) 7.40 24.40 12.90
SO2 (µg/m3) 23.31 23.90 11.26
NOx (µg/m3) 6.58 8.93 5.70
VOC (ppm) 0.30 0.00 0.15

PAs are also monitoring ambient air quality (AAQ) at four (04) locations viz.,
Near Safety Office, Near Canteen Area, Near ETP Area and Near Pond Area by
third party monitoring agency of M/s SV Enviro Labs & Consultants,
Vishakhapatnam which is approved by Ministry and accredited by NABL. As
per the monitoring conducted in the month of November, 2020, the AAQ levels
are as follows:

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 3 of 20

Parameter Near Safety Near Near ETP Near Pond
Office Canteen Area Area Area
PM2.5 (µg/m3) 24.5 19.3 27.1 20.5
PM10 (µg/m3) 60.4 50.2 68.3 54.8
SO2 (µg/m3) 12.6 11.4 14.2 10.3
NOx (µg/m3) 11.2 10.6 13.4 9.6
NH3 (ppm) 30.0 28.1 34.6 28.3

It has been stated that, in the event of failure of pollution control system(s)
adopted by the unit, the respective unit is not being restarted until the control
measures are rectified to achieve the desired efficiency.

It has been observed that the HCL, Cl2 and Br2 in gaseous emissions. Online
Br2 monitoring system is not available.

It is required to monitor HCL, Cl2 and Br2 in gaseous emissions and also
required to install online Br2 monitoring system.

ii. New pesticides standards issued by the Ministry shall be followed.

Status: Being complied

It has been observed that the PAs are in process of following new pesticides
standards issued by the Ministry.

iii. Action shall be taken to reduce the air emissions in the work zone
environment as far as possible. All the materials shall be handled in
completely closed system to avoid fugitive emissions during handling and
transportation and regularly monitored. Water scrubber fallowed by the
caustic scrubbers shall be provided to control gaseous emissions. Action
shall be taken to reduce the emissions as far as possible. Vents of all the
storage tanks, batch tanks or reactors shall be connected to the
scrubbers to scrub acid mist and solvent vapors. Hoods shall be installed
in the drumming operations of HBr and HCl and connected to the
scrubber and scrubbed vapors shall be sent to ETP for further treatment.

Status: Being complied

It has been observed that the PAs are in process of reducing the air emissions
in the work zone environment as far as possible. As per the discussions held
during monitoring, the following air pollution control equipment’s are installed
in the plant operations.

S.No Description
1 Spray Dryer, Cyclone Separator, Ventury Scrubber and Packed
Scrubber For R/Kiln Incinerator -- All Process vents
2 Caustic Wet Scrubber for Block I & II
3 Caustic Wet Scrubber for Block - III

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 4 of 20

4 Caustic Wet Scrubber for Block - IV
5 Sulphuric Acid Scrubber for TMA recovery in Profenophos Plant -
Vent Connected to Incinerator
6 Wet Scrubber for vent gases from Block - V
7 Vent from Wet Scrubber of Profenophos plant Connected to Rotary
Kiln/ Incinerator
8 Vent from Wet Scrubber of Tricyclazole plant Connected to Rotary
Kiln/ Incinerator
9 Vent from Wet Scrubber of B-I & II Connected to Rotary Kiln/
Incinerator
10 Vent from Multiple Effect Evaporator - I, II, III & IV connected to
Rotary Kiln/ Incinerator
11 Vent from Wet Scrubber of Profenophos plant Connected to Rotary
Kiln/ Incinerator
12 Scrubber for recovery of Hydro Bromic Acid in Profenophos plant
13 Scrubber for recovery of Hydro Bromic Acid in Propiconazole plant
14 Wet Scrubber for Fluid Bed Dryer vent at Block – II : Dust
15 Dust Collection system for coal handling unit and coal crusher
unit at coal fired boiler
16 Bag Filters for collection of dust from Flue gases of Coal fired
Boiler
17 Ammonia Stripper for LTDS treatment
18 Replaced centrifuges with ANFs
19 Provided exhaust hood with scrubber
20 pH meters provided for all Potassium Hydroxide scrubber to check
pH and maintain between 12 to 8.5 pH
21 At critical areas VOC meters provided with alarm at pipe lines.
22 Critical pipelines are monitored through preventive maintenance
team
23 Portable VOC meter procured for monitoring inside & outside
monitoring at specific points

It has been stated that all reactor vents, storage tank vents and scrubber
vents wherever necessary are connected to incinerator through dump tanks
and analyzers installed to monitor the conditions. TREM card system
implemented during transportation of hazardous material. All raw material
movement inside the plant is through pipeline & closed drums to ensure zero
emissions. ANF's provided in place of centrifuges, where ever possible and
hoods provided for centrifuges and connected to scrubber.

iv. Solvent recovery shall not be less than 98%. All ventury equipment shall
have vapor recovery system. The solvent shall be condensed in
condensers using cooling tower, chilled and chilled brine to control odor.
All the solvents in used shall be monitored in the treated effluent.

Status: Being complied

As per the discussions held during monitoring, it has been observed that the

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 5 of 20

PAs are in process of recovering solvent more than 98%. The recovered
solvents are being reused in the process. The solvents are being condensed in
condensers using cooling tower, chilled and chilled brine to control odor. All
the solvents in used are being monitored in the treated effluent.

v. Bromine shall be recovered from NaBr, HBr and KBr solutions and
recycled. HCl and Para-Chloro Phenol shall be sold to authorized parties.

Status: Being complied

It has been observed that the PAs are recovering Br from NaBr, HBr and KBr
solutions and recycled. HCl and Para-Chloro Phenol are being sold to
authorized parties.

vi. ESP or bag filter shall provide to control gaseous emissions from the
captive power plant. Dust extraction system shall be provided to coal
crusher conveyors and coal charging point of the bin. The flue gas
emissions shall conform to the standards prescribed by the APPCB.

Status: Being complied

It has been observed that the PAs have provided bag filters were provided to
the boilers and dust extraction systems were provided. It has been stated that
the bags are being changed periodically. It has also been stated that the
extraction system and dust containing measures followed for one conveyor
system, other being stopped. As per the monitoring reports submitted, it has
been observed that the flue gas emissions are within limit.

vii. Total water requirement from Nagavali river shall not exceed 1380
m3/day. The waste water shall be segregated into different streams for
effective treatment and recycling purpose. All the High TDS and High
COD effluents shall be treated in multiple effect evaporators (MEE) and
discharged into sea through marine outfall. Treated water (condensate)
shall be recycled to cooling tower. MEE concentrate and ETP sludge shall
be treated in rotary kiln. Finally treated effluent shall be discharged to
the sea through pipe line at 1.25 km. A diffuser shall be provided at the
end of pipeline. TF-4 test shall be done before discharging treated
effluent into the sea. The quality of the treated effluent shall conform to
the standards prescribed by APPCB/EPA Rules.

Status: Being complied

It has been observed that, at present, PAs are using only ground water for
plant operations. PAs have also implemented Zero Liquid Discharge system
and the water consumption is being maintained below specified water. No
treated water is being discharged to the sea.

It has been observed that the PAs have installed multi effect evaporators in the
process and the effluent is being segregated as high TDS and low TDS and are

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 6 of 20

being treated through respective ETP channels and the treated water are being
recycled and reused in the process.

viii. Coal ash from coal-fired captive power plant shall be stored in ash and
sold to cement and brick manufacturers. ETP sludge, Evaporation salts,
Incineration ash, Rotary kiln salts shall be stored in secured landfill and
sent to TSDF. Spent solvents shall be recovered in the solvent recovery
plant and then sold to authorized agencies. Spent oil shall be given to
recyclers and used lead acid batteries shall be given back to dealers.

Status: Being complied

As per the discussions held during monitoring, it has been observed that the
coal ash from coal-fired captive power plant are being sold to cement and brick
manufactures. ETP sludge, evaporation salts, incineration ash, rotary kiln
salts are being sent to TSDF. Spent solvents are being recovered in the solvent
recovery plant and then sold to authorized agencies. Spent oil are being given
to recyclers and used lead acid batteries are being given back to dealers.

ix. All the organic waste shall be incinerated in the incinerator. Incinerator
shall be upgraded and meet the Central Pollution Control Board (CPCB)
guidelines. The incinerator shall have destructive efficiency of 99.9% and
destructive efficiency of the incinerator shall be assessed by an agency
like CPCB and report submit.

Status: Partially complied

It has been observed that, all the organic waste is being incinerated in the
incinerator. It has been stated that the incinerator has been upgraded as per
the Central Pollution Control Board (CPCB) guidelines and the destructive
efficiency is 99.9%.

It is required to assess the destructive efficiency of the incinerator by

CPCB and the report to be submitted.

x. As proposed in EIA/EMP, green belt adequate width and density shall be

developed in at least 66 ha (66%) out of 100 ha. Area to mitigate the
effect of fugitive emissions all round the plant. The development of green
belt along the boundary wall, open space and avenue roads shall be
provided in consultation with the local DFO as per the CPCB guidelines.

Status: Being complied

It has been observed that the PAs are in process of developing green belt in
and around the project premises and till date a decent amount of green belt
has been developed. As per the information provided, the plantation details for
the year 2019-2020 is as follows:

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 7 of 20

Plantation Status for the year 2019-2020
1 Green Belt Area 3000 Gulmohera, Pongamia Trees,
Spothodia, Neem Trees,
Pletophorum
2 Green Belt Down 2000 Accossia, Bauhonia white
Area flowers, Spothodia
3 Temple Area 200 Carpet Grass
Mounts Sq.mtrs
500 Durantha gold
600 Meri Gold
300 Chamanti
4 Miyawaki 1200 Gulmohera, Pletophorum,
Bottle Brush Trees
5 Miyawaki 1500 Accossia, Berry (Nerudu),
Neem Trees
6 Time Office 20 Foxtail palm trees
Sorroundi
20 flowers
7 Main Gate Area 90 Sapota, Neem Trees
Visitor
8 Vehicles Parking 50 Alabanda yellow keeper
Area

xi. The company shall adopt waste minimization/cleaner production

techniques to reduce the pollution load and action plan in this regard
shall be submitted to the Ministry within three months.

Status: Being complied

As per the discussions held during monitoring, it has been observed that the
PAs are in process of adopting waste minimization/cleaner production
techniques to reduce the pollution load.

xii. The company shall under take rain water harvesting measures to
recharge the ground water as well as reduce the consumption of fresh
water.

Status: Being complied

It has been observed that the PAs have implemented the rain water harvesting
measures to recharge the ground water as well as reduce the consumption of
fresh water. It has been stated that the PAs are also in process of expanding
the capacity of rain water harvesting system.

xiii. The project proponent shall comply with the environmental protection
measures and safe guards recommended in EIA/EMP Risk analysis
reports as well as the recommendations of the public hearing panel.

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 8 of 20

Status: Being complied

As per the discussions held during monitoring, it has been observed that the
PAs are complying the environmental protection measures and safe guards
recommended in EIA/EMP, Risk analysis reports as well as the
recommendations of the public hearing panel.

xiv. The company shall under take eco-development measures including

community welfare measures in the project area for the overall
improvement of the environment. The eco-development plan should be
submitted to the APPCB within three months of receipt of this letter for
approval.

Status: Being complied

It has been observed that the PAs are in process of implementing eco-
development measures in and around the project area. It has been stated that
the plantation in villages of A. A. Valasa, Kesawadas puram, in surrounding
areas and R.O Drinking water supply to 4 villages, etc., are being implemented
under CSR. The details of CSR activities undertaken for the year 2019-20 are
as follows:

Sl.No Activity Village

Water Tankers to villages Barikpeta,Avanampeta,Parvathamakall
1 for domestic purpose alu,Pattusali peta, Pedakotha palli,
Seshu peta, Chilakapalem junction -3
points
AA Valasa - DRO Plant Drinking water supply by Autos –
Transportation charges & Operator
2 Charges + power bills
Chilakapalem - DRO Plant Drinking water supply by Autos –
Transportation charges & Labour
charges + power bills
Kesavadaasupuram--DRO Drinking water supply- Maintenance
Plant Charges
Bhagavandasupeta -- DRO Drinking water supply- Maintenance
Plant Charges
3 One praja police in chilakapalem Jn
Vidya Volunteer to A A Valasa-02, Chilakapalem-06,
4 surrounding, Village Munipeta-01, NP Agraharam-01,
Schools - 21 nos for 11 Bhagavandaspet-01, Allinagaram-08,
Months Kasavadaspuram-01, PP peta-1
5 Bhagavandasupeta Power bills for bore wells
6 Sheshupeta Power bills for bore wells
7 Civil Works Grama KD Puram
devatha chaduru
8 Scholarships Scholarships provided to nearby UP
school's children

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 9 of 20

Fire Victims assistance Dharmavaram
9 relief provided at
Dharmavaram for 18
persons (Rice packets,
Sarees & towels)
10 Gara peta temple Garapeta
development
expenditure
11 Contribution provided forKD Puram & Seshupeta etc
village Festiv
12 Contribution provided forAllinagaram
village Festiv
13 Provided sports kits AA valasa
(Volleyball and
cricket kits provided
14 Chalivendram Chialakapalem
15 Provided sports kits Seshupta & KD Puram,
(Volleyball and Bhagavandasupeta,
cricket kits provided
16 Furniture Provided KD Puram
17 Water tanker provided to Tandamvalasa, Ponduru Mandal
all villages Villages
18 Water Supply and other 28 Nos of Government school - required
related works in works completed
surrounding schools

xv. As mentioned in EIA/EMP, Rs.18.50 Cores an Rs.6.00 Cores earmarked

towards capital cost and recurring expenditure/ annum shall be used
exclusively to implement the conditions stipulated by the Ministry of
Environment & Forest as well as the state government and shall submit
an implementation schedule for all conditions stipulated herein. The
funds shall not be diverted for any other purposes.

Status: Being complied

It has been observed that the PAs have spent around Rs. 70.377 Cores
towards capital cost to implement the conditions stipulated by Ministry and
APPCB, since 2005 onwards and around Rs.18.0 Cores per annum is being
spent towards environment control measures.

xvi. Environmental clearance under the CRZ Notification shall be obtained

and recommendations of the National Institute of Oceanography shall be
followed.

Status: Not applicable at present

It has been observed that the PAs have implemented Zero Liquid Discharge
(ZLD) system for the project. The treated effluent is being reused in the

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 10 of 20

process and no effluent is being discharged outside of the project.

B. General Conditions
i. The project authorities must strictly adhere to the stipulations made by
the Andhra Pradesh Pollution Control Board (APPCB) and the State
Government.

Status: Being complied

It has been observed that the PAs are in process of strictly adhere to the
stipulations made by the Andhra Pradesh Pollution Control Board (APPCB)
and the State Government.

ii. No further expansion or modifications in the plant shall be carried out

without prior approval of the Ministry of Environment and Forests. In
case of deviations or alterations in the project proposal from those
submitted to this Ministry for clearance, a fresh reference shall be made
to the Ministry to assess adequacy of the conditions imposed and to add
additional environmental protection measures required, if any.

Status: Partially complied

It has been observed that the EC dated 30.07.2007 has been granted by
Ministry for production of following products:

Sl.No. Products Qty (MTPD)

01 Acephate 3.5
02 DDVP 2.0
03 Propiconazole 3.0
04 Tricyclozole 2.0
05 Profenofos 7.0
06 Pretilacholr 6.5
07 Isoxaben 1.0
08 DAAM 0.75
09 4-HBAGE 0.5
10 Myclobutonil 1.5
11 Thifluzomide 1.0
12 Fenbuconazole 0.75
13 DMBCP 0.5
Total 30.0

However, it has been observed that the PAs have obtained Consent for
operation (CFO) vide letter no. APPCB/VSP/VZN/53/CFO/HO/2019 dated
04.10.2019 for production of following 48 products:

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 11 of 20

Quantity
S. No Name Of The (TPD)
Product Group Group Group Group- Group
-1 -2 -3 4 -5
1. Acephate 0.0 3.5 0.0 0.0 0.0
2. Profenofos 7.0 0.0 6.0 7.0 8.0
3. Propiconazole
/Bromoketal 4.0 2.0 5.75 6.0 3.0
(Intermediate)
4. Tricyclazole 2.0 3.0 3.0 2.50 2.50
5. Myclobutanil 1.0 1.5 0.0 0.0 0.5
6. Pretilachlor 6.5 5.0 4.0 5.0 3.0
7. Thifluzamide 0.7 0.7 0.5 0.5 0.5
8. Flucarbazone 0.55 0.5 0.5 0.5 0.5
Sodium
9. Tebuconazole/
Oxirane 0.0 0.5 1.0 1.0 0.0
(Intermediate)
10. Hexaconazole 0.0 0.0 0.0 1.0 1.0
11. Difenthiuron 0.0 0.5 0.5 0.5 0.5
12. Imidacloprid 0.0 0.72 0.0 0.0 1.0
13. Epoxiconazole 0.0 0.28 1.0 0.08 0.18
14. Cyproconazole 0.0 0.0 0.0 1.0 1.0
15. Amicarbazone 0.0 0.5 0.0 0.0 0.0
16. Omethoate 0.7 0.0 1.0 0.5 0.0
17. DAAM 0.60 0.75 0.0 0.75 0.75
18. MMT 0.0 0.0 0.25 0.0 0.5
19. DBTFMA 0.0 0.5 0.5 0.0 0.5
20. 1,2- PDL 1.5 0.0 1.5 1.5 0.0
21. Metribuzin 1.2 0.0 0.0 0.0 0.0
22. Pendimethalin 1.2 0.0 0.0 0.0 0.0
23. Clodinafop 0.3 0.5 0.0 0.0 0.0
24. Glyphosate 0.0 0.0 0.0 1.5 0.0
25. Difenoconazole 0.0 0.3 0.3 0.0 0.3
26. Quizalafop P Ethyl 0.0 0.6 0.6 0.67 0.6
27. Thiamethoxam 0.0 0.5 0.0 0.3 0.0
28. Bispyribac sodium 0.0 0.0 0.5 0.0 0.0
29. Rimsulfuron 0.0 0.3 0.3 0.0 0.0
30. Tefluthrin 0.0 0.35 0.35 0.0 0.0
31. Cloquintocet Mexyl 0.4 0.1 0.0 0.0 0.0
32. Acetamiprid 0.65 0.75 0.0 0.0 0.0
33. Bensulfuron 0.0 0.1 0.1 0.0 0.1
Methyl
34. Quizalafop P 0.0 0.8 0.0 0.0 0.7
Tefurly
35. 2,3 Dichloro 0.5 0.5 0.0 0.0 0.6

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 12 of 20

Pyrydine
36. 2,3,6 Tri Chloro 1.2 1.2 0.0 0.0 1.32
Pyridine
37. 2,5 Dichloro 0.0 0.5 0.5 0.0 0.0
Phenyl
38. Cypermertharin 0.0 0.6 0.7 0.0 0.0
39. Carbendazim 0.0 0.7 0.7 0.0 0.0
40. Trifloxystrobin 0.0 0.3 0.0 0.0 0.5
41. Azoxystrobin 0.0 0.5 0.0 0.0 0.5
42. Bifenthrin 0.0 0.0 0.05 0.0 0.1
43. Fipronil 0.0 0.3 0.0 0.0 0.3
44. Emamectin, 0.0 0.0 0.4 0.0 0.4
Benzoate
45. Thiophene 0.0 1.0 0.0 0.0 1.0
46. Thiophanate 0.0 0.15 0.0 0.0 0.15
Methyl
Total (MT/Day) 30.0 30.0 30.0 30.0 30.0
No. of Products 17 34 24 16 28

In addition to the above, PAs have also obtained Consent for establishment
(CFE) vide letter no. APPCB/VSP/VZN/53/CFE/HO/2010 dated 06.02.2019
and APPCB/VSP/VZN/53/CFE/HO/2010 for 01.04.2019 for change in the
product mix. As per CFE dated 01.04.2019, the change in the production mix
is as follows:

Quantity
S. Name of the (TPD)
No Product Group - Group Group Grou Grou Grou Grou Gro
1 -2 -3 p- 4 p -5 p-6 p–7 up
-8
1. Profenofos 9.5 6.0 5.5 7.5 9.0 5.0 15.5 15.0
Propiconazole
2. Bromoketal 2.0 3.5 3.0 1.0 1.0 0.5 0.0 0.0
(Intermediate)
3. Tricyclazole 1.0 2.5 2.0 1.0 1.0 0.5 0.0 0.0
4. Myclobutanil 0.3 0.3 0.3 0.3 0.3 0.1 0.0 0.0
5. Pretilachlor 4.3 4.7 6.5 4.0 6.0 5.0 0.0 0.0
6. Thifluzamide 0.5 0.1 0.5 0.4 0.5 0.6 0.5 0.65
7. Flucarbazon 0.5 0.2 0.185 0.7 0.4 0.6 0.0 0.0
e Sodium 5
Tebuconazole/
8. Oxirane 0.0 0.25 0.2 0.1 0.0 0.2 0.0 0.75
(Intermediate
)
9. Hexaconazole 0.0 0.1 0.2 0.1 0.0 0.1 0.0 0.0
10. Difenthiuron 0.0 0.1 0.2 0.1 0.0 0.1 0.0 0.0
11. Imidacloprid 0.0 0.1 0.1 0.1 0.1 0.1 0.0 0.0
12. Epoxiconazole 0.0 0.1 0.5 0.1 0.1 0.1 0.0 0.0
13. Cyproconazole 0.0 0.5 0.1 0.1 0.1 0.1 0.0 0.0
14. Omethoate 0.5 0.7 0.6 0.7 0.8 0.4 0.0 0.0

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 13 of 20

15. Metribuzin 0.3 0.5 0.5 0.5 0.1 0.2 0.0 0.0
16. Pendimethalin 0.0 0.1 0.1 1.0 0.1 0.1 0.0 0.0
17. Clodinafop 0.0 0.0 0.2 0.0 0.0 0.2 0.0 0.0
18. Difenoconazole 0.0 0.2 0.05 0.1 0.1 0.1 0.0 0.0
19. Quizalafop 0.0 0.1 0.1 0.3 0.5 1.25 0.0 0.0
P Ethyl
20. Thiamethoxam 0.0 0.2 0.1 0.3 1.5 0.2 0.0 0.0
21. Bispyriba 0.0 0.1 0.095 0.2 0.0 0.1 0.0 0.0
c sodium
22. Tefluthrin 0.0 0.0 0.0 0.45 0.1 0.2 0.0 0.0
23. Cloquintoce 0.0 0.0 0.0 0.0 0.1 0.1 0.0 0.0
t Mexyl
24. 2,3 Dichloro 0.1 0.06 0.06 0.4 0.5 0.3 0.0 0.0
Pyrydine 5
25. Cypermertharin 0.0 0.35 0.0 0.15 0.1 0.1 0.0 0.0
26. Carbendazim 0.0 0.0 0.08 0.35 0.0 0.1 0.0 0.0
27. Trifloxystrobil 0.0 0.0 0.0 0.0 0.15 0.15 0.0 0.0
28. Azoxystrobin 0.0 0.1 1.0 0.15 0.2 0.1 0.0 0.0
29. Bifenthrin 0.0 0.0 0.08 0.15 0.15 0.1 0.0 0.0
5
30. Thiophanat 0.0 0.05 0.05 0.05 0.05 1.75 0.0 0.0
e Methyl
31. Verbenone 0.0 0.15 0.0 0.0 0.15 0.15 0.0 0.0
5
(Z)-hezatec –
32. 11-en-1-yl 0.0 0.15 0.0 0.15 0.1 0.15 0.0 0.0
acetate 5
33. (Z)-hezatec – 9- 0.0 0.15 0.09 0.0 0.15 0.15 0.0 0.0
enal 5
34. Trimedlure 0.0 0.15 0.09 0.1 0.1 0.1 0.0 0.0
5

35. (8E,10E) – 0.0 0.15 0.0 0.1 0.1 0.15 0.0 0.0
Dodoca-8, 5
10- dyen-1-ol

36. 7Z,11Z 0.05 0.15 0.09 0.1 0.1 0.15 0.0 0.0
hexadeca
dienyl
acetate
37. 7E, 9Z dodoca 0.05 0.1 0.09 0.1 0.1 0.15 0.0 0.0
dienyl acetate
38. 8Z Dodecinyl 0.05 0.1 0.15 0.1 0.1 0.1 0.0 0.0
acetate
(Z)-Octadeca –
39. 0.05 0.1 0.09 0.1 0.1 0.15 0.0 0.0
13 – enyl
acetate
40. R&D 0.05 0.05 0.05 0.05 0.05 0.05 0.0 0.05
products
Triazinone /
Thricarbohydra
41. zi de / Dichloro 10.0 7.84 7.0 8.9 6.0 9.4 7.0 9.5
Pinacolene /
Pinacolene

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 14 of 20

42. Lambda- 0.0 0.0 0.0 0.0 0.0 0.0 1.5 0.55
cyhalothrin
43. Fipronil 0.0 0.0 0.0 0.0 0.0 0.0 0.5 0.5
44. Ethephon 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0
45. Glufosinate- 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
ammonium
46. Clethodim 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0
47. S-Metolachlor 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
48. Tribenuron 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
methyl
Total (TPD) 29.65 30.0 29.95 30.0 30.0 29.15 30.0 30.0
No. of 22 35 35 36 35 41 10 10
Products

Subsequently, PAs have obtained CFO and Hazardous waste authorization

vide letter no. APPCB/VSP/VZN/53/CFO/HO/2019 dated 04.10.2019 for
production of above 48 products.

As per the discussions held during monitoring, it has been observed that
the PAs have increased number of products from 13 (as per EC dated
30.07.2007) to 46 (as per CFO 23.08.2018) and also obtained CFE (dated
01.04.2019) and CFO (dated 04.10.2019) for production of 48 products
without obtaining prior approval from Ministry. It is required to provide
detailed explanation in this regard.

iii. Adequate number of influent and effluent quality monitoring stations

shall be set up in consultation with the APPCB. Regular monitoring shall
be carried out for relevant parameters.

Status: Partially complied

It has been observed that the PAs are monitoring effluent flow through
monitoring station. The influent and effluent parameters are being monitored
by third party monitoring agency of M/s SV Enviro Labs& Consultants,
Vishakhapatnam which is approved by Ministry and accredited by NABL. As
per the monitoring conducted in the month of November, 2020, the influent
and effluent parameters are as follows:

S.No. Parameter Influent Effluent

01 pH 8.69 7.92
02 Total Dissolved Solids (mg/L) 2560 2086
03 Suspended Solids (mg/L) 92 30
04 COD (mg/L) 1815 196
05 BOD (3 days, 27 oC) 708 72
06 Oil & grease (mg/L) 5.2 <1.0

It is required install adequate number of influent and effluent quality

monitoring stations in consultation with the APPCB.

It is also recommended to monitor relevant water quality parameters for

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 15 of 20

influent and effluent of ETP once in every two months and the
monitoring reports to be submitted along with six monthly compliance
reports.

iv. The project authorities must strictly comply with the rules and
regulations under the Manufacture, Storage and Import of Hazardous
Chemicals Rules, 2000. Prior approvals of Chief Inspector of Factories,
Chief Inspector of Explosives, Fires Safety Inspectorate etc, must be
obtained.

Status: Being complied

It has been observed that the PAs are in process of complying the rules and
regulations under the Manufacture, Storage and Import of Hazardous
Chemicals Rules, 2000. As per the information provided, the following
approvals have obtained by PAs:

1. Certification for use of Boiler: vide no. 10799 dated 02.01.2021 from
Andhra Pradesh Boiler Inspection Department.
2. Director of Factories: Letter No. LAE05-14023/25/2019-D SEC – DOF
dated 29.03.2019 from Factories Department, Govt. of Andhra Pradesh.
3. Fire Certificate: Letter No. 9694/IISB/EWRFO/SRIV20I2 dated
24.09.2020 from A.P. State Disaster Response and Fire Services
Department, Govt. of Andhra Pradesh.
4. Public Liability (Act) Insurance Policy: Policy No.
181632027120000004
5. PESO Licence: Vide No. P/HQ/AP/15/1396(P4846) dated 02.12.2020.
In addition to above, PAs have obtained CFO and Hazardous waste
authorization vide letter no. APPCB/VSP/VZN/53/CFO/HO/2019 dated
04.10.2019.

v. The project authorities must strictly comply with the rules and
regulations with regard to handling and disposal of hazardous wastes in
accordance with the Hazardous Wastes (Management and Handling)
Rules, 2000. Authorization from the APPCB muse be obtained for
collection, storage, treatment and disposal of hazardous wastes.

Status: Being complied

As stated above, it has been observed that the PAs are in process of complying
the rules and regulations under the Manufacture, Storage and Import of
Hazardous Chemicals Rules, 2000. PAs have obtained CFO and Hazardous
waste authorization vide letter no. APPCB/VSP/VZN/53/CFO/HO/2019 dated
04.10.2019.

vi. The overall noise levels in and around the plant area shall be kept well
within the standards (85 dBA) by providing noise control measures

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 16 of 20

including acoustic hoods, silencers, enclosures etc. on all sources of
noise generation. The ambient noise levels shall conform to the
standards prescribed under the Environment (P) Rules, 1989 viz., 75 dBA
(day time) and 70 dBA (night time).

Status: Partially complied

As per the discussion held during monitoring, it has been observed that the
PAs are in process of taking control measures including acoustic hoods,
silencers, enclosures etc. on all sources of noise generation to keep the overall
noise levels in and around the plant area within the standards (85 dBA). The
noise levels are being monitored by third party monitoring agency of M/s SV
Enviro Labs& Consultants, Vishakhapatnam which is approved by Ministry
and accredited by NABL. As per the monitoring conducted in the month of
November, 2020, the noise levels were monitored at 14 locations and the levels
are within the prescribed limits.

It is recommended to monitor noise levels once in every two months and

the monitoring reports to be submitted along with six monthly
compliance reports.

vii. Occupational health surveillance programme shall be undertaken as

regular exercise for all the employees, specifically for those engaged in
handling hazardous substances. First aid facilities in the Occupational
Health Care Center shall be strengthened and medical records of each
employee should be maintained separately.

Status: Being complied

It has been observed that the PAs are regularly conducting occupational
health surveillance of the employees, specifically for those engaged in handling
hazardous substances. First aid facilities in the Occupational Health Care
Center have been strengthened and medical records of each employee are
being maintained separately.

viii. A separate Environment Management Cell equipped with full fledged

laboratory facilities shall be set up to carry out the Environmental
Management and monitoring functions.

Status: Being complied

It has been observed that the PAs have a separate Environment Management
Cell equipped with laboratory facilities to carry out the Environmental
Management and monitoring functions.

ix. The project proponent shall also comply with all the environmental
protection measures and safeguards recommended in the EIA/EMP
report.

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 17 of 20

Status: Being complied

It has been observed that the PAs are in process complying all the
environmental protection measures and safeguards recommended in the
EIA/EMP report.

x. The implementation of the project vis-à-vis environmental action plans

shall be monitored by Ministry’s Regional office at Bangalore / APPCB /
CPCB. A six monthly compliance status report should be submitted to
monitoring agencies.

Status: Being complied

The condition is being complied with. Integrated Regional Office (IRO),

Vijayawada is being monitored the conditions stipulated in EC and
environmental action plans.

xi. The Project Proponent should advertise in at least two local newspapers
widely circulated in the region around the project, one of which shall be
in the vernacular language of the locally concerned informing that the
project has been accorded environmental clearance by the Ministry and
copies of the clearance letter are available with the APPCB / Committee
and may also be seen at Website of the Ministry and Forests at
http://envifor.nic.in. The advertisement shall be made within 7 days
from the date of issue of the clearance letter and a copy of the same shall
be forwarded to the Ministry’s Regional Office at Bangalore.

Status: Partially complied

As per the discussions held during the monitoring, it has been observed that
the PAs are not submitting the compliance of general conditions. It has been
stated that the condition has been complied.

It is required to submit the copies of newspaper advertisements to IRO,

Vijayawada for records.

xii. The Project Authorities shall inform the Regional Office as well as the
Ministry the date of financial closure and final approval of the project by
the concerned authorities and the date of start of land development
work, if any.

Status: Partially complied

As per the discussions held during the monitoring, it has been observed that
the PAs are not submitting the compliance of general conditions.

It is required to submit the details regarding the date of financial closure

and final approval of the project by the concerned authorities and the
date of start of land development work.

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 18 of 20

10. Observations:
The PAs have complied or are in process of complying the conditions stipulated by
the Ministry. In this context, information/action plans have been sought on following
points.
1. It has been observed that the PAs have increased number of products from 13
(as per EC dated 30.07.2007) to 46 (as per CFO 23.08.2018) and also obtained
CFE (dated 01.04.2019) and CFO (dated 04.10.2019) for production of 48
products without obtaining prior approval from Ministry. It is required to
provide detailed explanation in this regard.
2. It is required to monitor HCL, Cl2 and Br2 in gaseous emissions and also
required to install online Br2 monitoring system.
3. It is required to assess the destructive efficiency of the incinerator by CPCB
and the report to be submitted.
4. It is recommended to monitor the environmental parameters viz., Stack
Emissions, Ambient Air Quality (AAQ), Work Zone Emissions, Noise levels,
Water Quality, etc by MoEFCC/NABL accredited laboratory and the monitoring
reports to be submitted along with six monthly compliance reports.
5. It is required install adequate number of influent and effluent quality
monitoring stations in consultation with the APPCB.
6. It has been observed that the PAs are not submitting the compliance of general
conditions. It is required to submit the same along with six monthly
compliance reports.
7. As per MOEFCC circular no. J-11013/41/IA.II.(I) dated 30.06.2009 & OM No.
J-11013/5/2011-IA.I dated 05.08.2011, it is required to upload compliance
report in company/project website. In addition, it is required to provide the ID
of the website where the compliance report is being uploaded.
8. It is required to submit the copies of newspaper advertisements to IRO,
Vijayawada for records.
9. It is required to submit the details regarding the date of financial closure and
final approval of the project by the concerned authorities and the date of start
of land development work.
11. Recommendations:
This project can be put up in the following tick-marked category of compliance
status.

• Compliance status could not be judged as the project was shut down / not in
operational during the site visit.
• No non-compliances detected. No any further action is required.
Ö Minor non-compliances detected (not of immediate danger to health &
safety of the people). Letter issued to project authorities for taking
corrective measures.

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 19 of 20

• Serious non-compliances detected. Recommended to issue a Show-Cause Notice
to Project Authorities.

(डॉ। सरु े श बाबु पसप

ु ल
ु ेट/)
(Dr. Suresh Babu Pasupuleti)
वै2ा3नक-सी / उप 3नदे शक (एस)
Scientist-C/Deputy Director (S)

J-11011/75/2007-IA II (I) dated 30.07.2007 Page 20 of 20

NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

5. ANNEXURES

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

ANDHRA PRADESH POLLUTION CONTROL BOARD

D.No.33-26-14D/2, Near Sunrise Hospital, Pushpa Hotel Centre,
Chalamalavari Street, Kasturibaipet, Vijayawada – 520 010
Phone. No.0866-2463200, Website : http://pcb.ap.gov.in/

RED CATEGORY
RENEWAL OF CONSENT & HAZARDOUS AUTHORISATION

Consent Order No : APPCB/VSP/VZN/53/CFO/HO/2021- 12/03/2021

CONSENT is hereby granted for Operation under section 25/26 of the Water (Prevention &
Control of Pollution) Act, 1974 and under section 21 of Air (Prevention & Control of
Pollution) Act 1981 and amendments thereof and Authorisation under Rule 6 of the
Hazardous & Other Wastes (Management and Transboundary, Movement) Rules, 2016 and
the rules and orders made there under (hereinafter referred to as 'the Acts’, `the Rules’)
to:

M/s. NACL Industries Limited,

Plot No. 177, Arinama Akkivalasa (V),
Allinagaram Post, Etcherla (M),
Srikakulam District
E-mail: [email protected]

(Hereinafter referred to as 'the Applicant') authorizing to operate the industrial plant to

discharge the effluents from the outlets and the quantity of emissions per hour from the
chimneys as detailed below:

i) Out lets for discharge of effluents:

Outlet Quantity
Outlet Description Point of Disposal
No. (KLD)
1 Process Effluents – HTDS 75 • To Steam stripper followed by
evaporation in Multiple Effect
Evaporators
• MEE condensate shall be sent to
Incinerator / Rotary Kiln / biological ETP.
2 35 • MEE concentrate shall be sent to
All Wet Scrubbers Bleed Off
ATFD.
• Salts shall be disposed to the
TSDF.
3 Process Effluents – LTDS 40.5 • After biological treatment,
treated effluents shall be sent to
Boiler Blow Down & Cooling RO plants.
4 184
Tower Blow Down – LTDS • RO Rejects to MEE followed by
ATFD / Spray Drier.
Domestic Effluent After
5 25 • RO Permeate to reuse for
pretreatment
process / cooling tower makeup.

ii) Emissions from chimneys:

File No.APPCB-11022/114/2018-TEC-CFO-APPCB

Chimney Description of Chimney Quantity of Emissions at

No. peak flow
1. Attached to 16 TPH New Boiler (coal fired) 11,736 m3/hr
Attached to 10 TPH Coal Fired Boiler
2. Attached to 6 TPH oil fired Boiler (standby) 18,530 m3/hr
3. Attached to Hot Oil Heater
4. Attached to rotary kiln-II of 90 TPD
5. Attached to rotary kiln-I of 30 TPD (Standby)
6. Process Vents attached to --
Ortho Chloro Phenol formation stage in Profenofos --
production block
Profenofos production block --
Dichlorovos production block --
Propiconazole production block --
Tricyclazole production block --
Isoxaben production block --
Bromine Recovery Plant --
Pretilachlo production block --
Thifluzamide production block --
Fenbucanzole production block --
DMBCP production block --
7. Attached to 1 x 1000 KVA and 2 x 500 KVA D.G. Sets --

iii) HAZARDOUS WASTE AUTHORISATION (FORM – II) [See Rule 6 (2)]:

M/s. NACL Industries Limited (Formerly M/s.Nagarjuna Agrichem Limited), Arinama

Akkivalasa (V), Etcherla (M), Srikakulam District, is hereby granted an authorization to
operate a facility for collection, reception, storage, treatment, transport and disposal of
Hazardous Wastes namely:

• HAZARDOUS WASTES WITH RECYCLING OPTION:

S. Name of the Stream Quantity Method of disposal
No hazardous waste
1 Process Liquid 29.1 of 127.2 TPM Incineration in their own premises / shall
residues (Organic) Schedule - be routed through M/s. APEMC so as to
I send to preprocessors / cement industries
2 Distillation bottom 20.3 of 7.8 TPM for co processing. (as utilizable waste)
residues Schedule -
I
3 Used Oil / Spent 5.1 of 0.3 TPM Shall be routed through M/s. APEMC so as
Lubricating Oil Schedule - to send to APPCB authorized agencies for
I preprocessors / recycling. (as recyclable
waste)
4 Containers and 33.1 of Shall be routed through M/s. APEMC so as
container Liners of Schedule - to send to outside agencies, after
Hazardous chemicals I complete detoxification for re-use /
• HDPE Drums 3600 recycle. (as recyclable waste)
• HDPE Bags Nos/Annu
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

m.
1400
Nos/Annu
m
5 Spent Solvents 29.4 of 1347.9 Shall be recovered in solvent recovery
Schedule - TPM plant within the premises / shall be routed
I through M/s. APEMC so as to send to
cement industries for co processing. (as
utilizable waste)

• HAZARDOUS WASTES WITH DISPOSAL OPTION:

S. Name of the Stream Quantity Disposal option
No. hazardous waste
1 ETP Sludge 35.3 of
1.0 TPM
Schedule - I
Shall be routed through M/s. APEMC so as to
2 Inorganic Salts
35.3 of send to TSDF, Parawada, Visakhapatnam
from Rotary kiln / 505 TPM
Schedule - I District for Secured land filling. (as
ATFD
Landfillable waste).
3 Incineration Ash 37.2 of
0.07 TPM
Schedule - I

This consent order is valid for manufacture of the following products along with
quantities indicated below only:

Quantity
(TPD)

S Gro
. Grou Grou u Gro
N Name of the p- p Grou Grou Grou Grou p – up -
o Product 1 -2 p -3 p- 4 p -5 p - 6 7 8
1
. Profenofos 9.5 6.0 5.5 7.5 9.0 5.0 15.5 15.0
Propiconazole
2
. Bromoketal 2.0 3.5 3.0 1.0 1.0 0.5 0.0 0.0
(Intermediate )
3
. Tricyclazole 1.0 2.5 2.0 1.0 1.0 0.5 0.0 0.0
4
. Myclobutanil 0.3 0.3 0.3 0.3 0.3 0.1 0.0 0.0
5
. Pretilachlor 4.3 4.7 6.5 4.0 6.0 5.0 0.0 0.0
6
. Thifluzamide 0.5 0.1 0.5 0.4 0.5 0.6 0.5 0.65
7 Flucarbazone Sodium
. 0.55 0.2 0.185 0.7 0.4 0.6 0.0 0.0

Tebuconazole/
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

8
. Oxirane 0.0 0.25 0.2 0.1 0.0 0.2 0.0 0.75
(Intermediate )
9
. Hexaconazole 0.0 0.1 0.2 0.1 0.0 0.1 0.0 0.0
1
0
. Difenthiuron 0.0 0.1 0.2 0.1 0.0 0.1 0.0 0.0
1
1
. Imidacloprid 0.0 0.1 0.1 0.1 0.1 0.1 0.0 0.0
1
2
. Epoxiconazole 0.0 0.1 0.5 0.1 0.1 0.1 0.0 0.0
1
3
. Cyproconazole 0.0 0.5 0.1 0.1 0.1 0.1 0.0 0.0
1
4
. Omethoate 0.5 0.7 0.6 0.7 0.8 0.4 0.0 0.0
1
5
. Metribuzin 0.3 0.5 0.5 0.5 0.1 0.2 0.0 0.0
1
6
. Pendimethalin 0.0 0.1 0.1 1.0 0.1 0.1 0.0 0.0
1
7
. Clodinafop 0.0 0.0 0.2 0.0 0.0 0.2 0.0 0.0
1
8
. Difenoconazole 0.0 0.2 0.05 0.1 0.1 0.1 0.0 0.0
1 Quizalafop P
9
. 0.0 0.1 0.1 0.3 0.5 1.25 0.0 0.0
Ethyl
2
0
. Thiamethoxam 0.0 0.2 0.1 0.3 1.5 0.2 0.0 0.0
2 Bispyribac Sodium
1
. 0.0 0.1 0.095 0.2 0.0 0.1 0.0 0.0

2
2
. Tefluthrin 0.0 0.0 0.0 0.45 0.1 0.2 0.0 0.0
2 Cloquintocet Mexyl
3
. 0.0 0.0 0.0 0.0 0.1 0.1 0.0 0.0

2 2,3 Dichloro Pyrydine 0.15 0.06 0.06 0.4 0.5 0.3 0.0 0.0
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

4
.

2
5
. Cypermertharin 0.0 0.35 0.0 0.15 0.1 0.1 0.0 0.0
2
6
. Carbendazim 0.0 0.0 0.08 0.35 0.0 0.1 0.0 0.0
2
7
. Trifloxystrobil 0.0 0.0 0.0 0.0 0.15 0.15 0.0 0.0
2
8
. Azoxystrobin 0.0 0.1 1.0 0.15 0.2 0.1 0.0 0.0
2
9
. Bifenthrin 0.05 0.0 0.08 0.15 0.15 0.1 0.0 0.0
3 Thiophanate Methyl
0
. 0.0 0.05 0.05 0.05 0.05 1.75 0.0 0.0

3
1
. Verbenone 0.05 0.15 0.0 0.0 0.15 0.15 0.0 0.0
(Z)-hezatec –
3
2
. 11-en-1-yl 0.05 0.15 0.0 0.15 0.1 0.15 0.0 0.0
acetate
3 (Z)-hezatec – 9-
3
. 0.05 0.15 0.09 0.0 0.15 0.15 0.0 0.0
enal
3
4
. Trimedlure 0.05 0.15 0.09 0.1 0.1 0.1 0.0 0.0
3
5
. (8E,10E) –Dodoca-8, 10- dyen-1-ol 0.05 0.15 0.0 0.1 0.1 0.15 0.0 0.0
3
6
. 7Z,11Z hexadeca dienyl acetate 0.05 0.15 0.09 0.1 0.1 0.15 0.0 0.0
3
7
. 7E, 9Z dodoca dienyl acetate 0.05 0.1 0.09 0.1 0.1 0.15 0.0 0.0
3
8
. 8Z Dodecinyl acetate 0.05 0.1 0.15 0.1 0.1 0.1 0.0 0.0
3 (Z)-Octadeca –13 – enyl acetate 0.05 0.1 0.09 0.1 0.1 0.15 0.0 0.0
9
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

.
4
0
. R & D products 0.05 0.05 0.05 0.05 0.05 0.05 0.0 0.05
Triazinone / Thricarbohydrazi
4 de / Dichloro Pinacolene /
1 Pinacolene 10.0 7.84 7.0 8.9 6.0 9.4 7.0 9.5
4
2
. Lambda- cyhalothrin 0.0 0.0 0.0 0.0 0.0 0.0 1.5 0.55
4
3
. Fipronil 0.0 0.0 0.0 0.0 0.0 0.0 0.5 0.5
4
4
. Ethephon 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0
4
5
. Glufosinate- ammonium 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
4
6
. Clethodim 0.0 0.0 0.0 0.0 0.0 0.0 1.0 0.0
4
7
. S-Metolachlor 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
4
8
. Tribenuron methyl 0.0 0.0 0.0 0.0 0.0 0.0 1.0 1.0
Total (TPD) 29.65 30.0 29.95 30.0 30.0 29.15 30.0 30.0

No. of Products 22 35 35 36 35 41 10 10

The industry shall manufacture only one group at any point of time.

By-products:
Grou Grou Grou Grou Grou Grou Grou
S. Product Bi- p Group p p p p p p
No
. Products 1 2 3 4 5 6 7 8

25% HBr
1 Profenophos 9.04 5.71 5.23 7.14 8.56 4.76 14.75 14.27
Solution
25%
NaBr 18.48 11.67 10.70 14.59 17.50 9.72 30.14 29.17
Solution
25% HBr 0.0 0.0
2 Propiconazole 2.36 4.13 3.54 1.18 1.18 0.59
Solution
3 Tricyclazole 25% HCl 0.81 2.02 1.61 0.81 0.81 0.40 0.0 0.0
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

25% 0.0 0.0

4 Myclobutanil 1.05 1.05 1.05 1.05 1.05 0.35
NaBr
5 Pretilachlor 25% HCl 4.01 4.38 6.06 3.73 5.60 4.66 0.0 0.0

6 Hexaconazole 30% HCl 0.00 0.04 0.08 0.04 0.00 0.04 0.0 0.0

KCl, 0.0 0.0

7 Difenoconazole 0.00 0.03 0.01 0.02 0.02 0.02

Quizalafop P KHCO3 0.0 0.0

8 0.00 0.05 0.05 0.15 0.26 0.64
Ethyl
Quizalafop-P 0.0 0.0
9 HCL 0.00 0.30 0.30 0.91 1.52 3.79
Tefuryl
10 Bifenthrin HCL 0.00 0.00 0.01 0.01 0.01 0.01 0.0 0.0

Tribenuron
11 Ethanol 0.00 0.00 0.00 0.00 0.00 0.00 0.13 0.13
Mythyl

This order is subject to the provisions of `the Acts’ and the Rules’ and orders made there
under and further subject to the terms and conditions incorporated in the schedule A, B &
C enclosed to this order.

This combined order of consent & Hazardous Waste Authorisation shall be valid for a period
ending with the 28th day of February, 2025.

DR. B.MADHUSUDHANA RAO, JCEE(MSRB), O/o JOINT

CHIEF ENVIRONMENTAL ENGINEER4-APPCB
To
M/s. NACL Industries Limited,
Plot No. 177, Arinama Akkivalasa (V),
Allinagaram Post, Etcherla (M),
Srikakulam District

Copy to:
1. The Joint Chief Environmental Engineer, Zonal Office, Visakhapatnam for
information and necessary action.
2. The Environmental Engineer, Regional Office, Srikakulam for information and
necessary action.

SCHEDULE – A
1. Any up-set condition in any industrial plant / activity of the industry, which result
in, increased effluent / emission discharge and/ or violation of standards stipulated
in this order shall be informed to this Board, under intimation to the Collector and
District Magistrate and take immediate action to bring down the discharge /
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

emission below the limits.

2. The industry should carryout analysis of waste water discharges or emissions
through chimneys for the parameters mentioned in this order on quarterly basis and
submit to the Board.
3. All the rules & regulations notified by Ministry of Law and Justice, Government of
India regarding Public Liability Insurance Act, 1991 should be followed as
applicable.
4. The industry should put up two sign boards (6x4 ft. each) at publicly visible places
at the main gate indicating the products, effluent discharge standards, air emission
standards, hazardous waste quantities and validity of CFO and exhibit the CFO
order at a prominent place in the factory premises.
5. Notwithstanding anything contained in this consent order, the Board hereby
reserves the right and powers to review / revoke any and/or all the conditions
imposed herein above and to make such variations as deemed fit for the purpose of
the Acts by the Board.
6. The industry shall ensure that there shall not be any change in the process
technology, source & composition of raw materials and scope of working without
prior approval from the Board.
7. The applicant shall submit Environment statement in Form V before 30th September
every year as per Rule No.14 of E(P) Rules, 1986 & amendments thereof.
8. The applicant should make applications through Online for renewal of Consent
(under Water and Air Acts) and Authorization under HWM Rules at least 120 days
before the date of expiry of this order, along with prescribed fee under Water and
Air Acts and detailed compliance of CFO conditions for obtaining Consent & HW
Authorization of the Board.
9. The industry should immediately submit the revised application for consent to this
Board in the event of any change in the raw material used, processes employed,
quantity of trade effluents & quantity of emissions. Any change in the management
shall be informed to the Board. The person authorized should not let out the
premises / lend / sell / transfer their industrial premises without obtaining prior
permission of the State Pollution Control Board.
10.Any person aggrieved by an order made by the State Board under Section 25,
Section 26, Section 27 of Water Act, 1974 or Section 21 of Air Act, 1981 may within
thirty days from the date on which the order is communicated to him, prefer an
appeal as per Andhra Pradesh Water Rules, 1976 and Air Rules 1982, to Appellate
authority constituted under Section 28 of the Water(Prevention and Control of
Pollution) Act, 1974 and Section 31 of the Air(Prevention and Control of Pollution)
Act, 1981.
11.The industry shall be liable to pay Environmental Compensation / Other
Environmental Taxes, if any environmental damage caused to the surroundings, as
fixed by the Collector & District Magistrate or any other competent authority as per
the Rules in vogue.
12.The industry may explore the possibility of tapping the solar energy for their
energy requirements.
13.The industry should educate the workers and nearby public of possible accidents
and remedial measures.

SCHEDULE - B
1. The industry shall comply with the following conditions within stipulated time,
failing which the bank guarantee of Rs. 2 lakhs submitted by the industry will be
forfeited without any notice:
i. The ash collection silo provided for the boiler is not functional and the ash is
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

dumped on the floor, which is generating fugitive dust emissions in the

surrounding area. Fugitive dust emissions were also generated while handling
coal. The industry shall make the ash collection silo provided for the boiler
functional by 31.05.2021 and no ash shall be dumped on the floor,
generating fugitive dust emission in the surrounding area. Also, the industry
shall take measures to control dust emissions while handling coal
2. The industry provided hood on the top of the equalization tank only, but has not
provided scrubber to the vent of hood on the top of the equalization tank. The
industry shall provide scrubber to the equalization tank by 31.03.2021.
3. Not provided closed shed to accommodate the drums containing chemicals &
wastes. The industry shall provide a shed to accommodate drums containing
chemicals & wastes on elevated platform under shed by 31.03.2021 with a provision
to collect leachate / spillages in the collection pit. There shall not be any spillages
of chemicals / effluents on ground. In no case the drums shall be stored on the
naked open ground.
4. Not provided mechanical seals to the MEE, Rotary Kilns and Spray Dryers to avoid
leaking of the effluent. During inspection, still leakages were observed. The
industry shall provide mechanical seals to the MEE, Rotary Kilns and Spray Dryers to
avoid leaking of the effluent by 31.03.2021.
5. Not complied with the condition "The built up in TDS in waste water or floor
washings of the incinerator shall not exceed 1000 mg/lt over and above the TDS of
raw water" and the samples collected from Storm water drain near Rotary Kiln have
the values of TDS-1336, COD- 648, BOD-226 mg/l. The industry shall built up in TDS
in waste water or floor washings of the incinerator shall not exceed 1000 mg/lt over
and above the TDS of raw water without fail.
6. Not provided data loggers to the VOC analysers. The industry shall provide VOC
meters with real time data transmission facility through internet of things (IoT)
shall be installed near the production blocks and near the chemical storage tanks
and link to the servers of APPCB and CPCB by 31.03.2021.
7. VOCs were observed from production block – III & V, at boiler area and at
equalization tank -10.6 ppm. The Industry shall carry out the LDAR (Leak Detection
and Rectification ) programme for all production blocks, Boiler and ETP area
including pipelines, at least once in a quarter and ensure that the VOCs, fugitive
emissions are eliminated.
8. TMA (Tri Methyl Amine) smell was observed in the surroundings. The industry shall
take up the recovery of TMA (Tri Methyl Amine) completely before sending to the
incinerator without fail.
9. Not installed CAAQMS with display board at Dr. B.R. Ambedkar University. The CFO
committee exempted the installation of CAAQM station at Dr. B.R. Ambedkar
University.
10.Incinerator is not in working condition and the rotary kiln was out of order. The
industry shall keep the incinerator (standby) in working condition and shall replace
the rotary kiln by 30.06.2021 and shall maintain the temperature sensors attached
to Rotary kiln to APPCB website.
11.Though the industry installed online stack monitoring system for incinerator stack,
the data is not transmitted to APPCB server. The industry shall transmit the data of
online stack monitoring system attached to incinerator (standby) stack to APPCB
server by 30.06.2021.
12.Not provided display board outside the premises with all the consented standards,
as per NGT direction. The industry shall provide display board outside the premises
with all the consented standards, as per NGT direction by 31.03.2021

WATER POLLUTION:
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

2. The source of water is Ground Water (Bore wells)*. The industry shall take steps to
reduce water consumption to the extent possible and consumption shall NOT
exceed the quantities mentioned below:
Quantity
S. No. Purpose
(KLD)
a) Process 83.0
b) Boiler Feed 158.0
c) Cooling (Makeup) for process and utilities 279.0
d) Domestic 30.0
e) Gardening 40.0
Total : 590.0
* The industry shall obtain necessary amendment in the Environmental Clearance from
the MoEF&CC, New Delhi regarding the source of raw water.

3. The industry shall provide separate electromagnetic flow meters for assessing the
water consumption used and waste water generation for process, reactor & floor
washings, scrubber, boiler blow down, cooling tower blow down, RO/DM Plant and
Domestic purposes and maintain records for the same.
4. The industry shall segregate the effluents into i) High TDS & High COD, ii) Low TDS
& Low COD, iii) utility blow down streams and shall be treated as stipulated streams
at source & adopt requisite treatment to maintain zero liquid discharge (ZLD).
5. The industry shall collect the above mentioned effluent streams in above ground
level collection tanks separately.
6. The industry shall maintain magnetic digital flow meters with totalisers at following
points: a. Inlet of Stripper. b. Inlet of MEE. c. Outlet of MEE. d. Inlet and outlet of
ETP, e. Inlet and outlet of RO Plants.
7. The industry shall ensure that effluents shall not be discharged onland or any water
bodies or aquifers or outside under any circumstances. Floor washings shall be
admitted into effluent collection system only and shall not be allowed to find their
way into storm water drains or open areas.
8. Container & Container liners shall be detoxified at the specified covered platform
with dyke walls and the wash wastewater shall be routed to collection tank after
characterization.
9. The wash water/rain water from the MEE, incinerator & RO plant areas shall be
routed to the ETP for treatment and shall not be allowed to mix with storm water.
10.The industry shall construct rainwater runoff tank for collection and storage of first
flush storm water. The industry shall maintain dry condition outside drains in non-
rainy season. Storm water shall be channelized through separate drains passing
through a HDPE lined pit having capacity of 10 minutes (hourly average) of rainfall.
11.The industry shall maintain 3 Nos. of piezo wells in the industrial premises to check
the ground water quality at regular intervals and submit the report to RO,
Srikakulam.
12.The industry shall carry out the monitoring for all Pesticides which are being
produced or proposed to be produced in the ground water at regular intervals in the
upstream and down streams of the industry. The consolidated monitoring results
shall be submitted to the concerned Regional Office, APPCB.
13.The industry shall maintain flow meter and web camera at the outlet of RO
permeate as per CPCB directions dated 05.02.2014 / 02.03.2015 and guidelines
issued regarding online monitoring systems issued from time to time and same
connected to CPCB and APPCB

AIR POLLUTION:
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

14.The emissions shall not contain constituents in excess of the prescribed limits
mentioned below.
Chimney Parameter Emission Standards
No.
1 to 3 Particulate Matter 115 mg/Nm3
Particulate Matter 50 mg/Nm3
Hcl 50 mg/Nm3
SO2 200 mg/Nm3
CO 100 mg/Nm3
Total Organic Carbon 20 mg/Nm3
HF 4 mg/Nm3
4 & 5* NOX 400 mg/Nm3
Hydrocarbons 10 PPM
Dioxins/Furans 0.1 ng TEQ/Nm3
Metals
Cd + Th (and its compounds) 0.05 mg/Nm3
Hg (and its compounds) 0.05 mg/Nm3
Sb + As +Pb + Cr + Co + Cu + Mn + Ni + V (and its 1.5 mg/Nm3
compounds)
* All monitored values shall be corrected to 11 % Oxygen on dry basis. The CO2
concentration in tail gas shall not be less than 7 %

HCl 20 mg/Nm3
Cl2 5 mg/Nm3
H2S 5 mg/Nm3
P2O5 (as H3PO4) 10 mg/Nm3
6
NH3 30 mg/Nm3
Particulate matter with pesticides compounds 20 mg/Nm3
CH3Cl 20 mg/Nm3
HBr 5 mg/Nm3

15.The industry shall comply the standards for emission and discharges for all other
parameters as per the standards notified by MoEF, Vide GSR No. 446 (E),
Dt.13.06.2011. and amendments thereof, for Pesticides manufacturing &
Formulation industry.
16.The industry shall comply with emission limits for DG sets upto 800 KW as per the
Notification G.S.R.520 (E), dated 01.07.2003 under the Environment (Protection)
Amendment Rules, 2003 and G.S.R.448(E), dated 12.07.2004 under the Environment
(Protection) Second Amendment Rules, 2004. In case of DG sets more than 800 KW
shall comply with emission limits as per the Notification G.S.R.489 (E), dated
09.07.2002 at serial no.96, under the Environment (Protection) Act, 1986.
17.The industry shall comply with ambient air quality standards of PM10 (Particulate
Matter size less than 10 micro grams) - 100 micro gram/ m3; PM2.5 (Particulate
Matter size less than 2.5 micro grams) - 60 micro gram/ m3; SO2 - 80 micro gram/
m3; NOx - 80 micro gram/ m3, Ammonia – 400 micro gram/ m3; Benzene- 5 micro
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

gram/ m3; at the periphery of the industry. Standards for other parameters as
mentioned in the National Ambient Air Quality Standards CPCB Notification No.B-
29016/20/90/PCI-I, dated 18.11.2009 Noise Levels: Day time - (6 AM to 10 PM) - 75
dB (A) Night time - (10 PM to 6 AM) - 70 dB (A).
18.The industry shall maintain dedicated multi stage scrubbers to the process vents to
control the process emissions, NH3, SO2, HCl, Bromine and other gaseous emissions.
The industry shall maintain online pH monitoring system to the scrubbers provided
to treat the process emissions. Scrubbed liquid shall be recycled as far as possible
and finally shall be sent to stripper, MEE followed by ATFD for terminal treatment.
The details of chemicals consumption used in the scrubber should be recorded and
kept accessible for the inspection officials of the Board.
19.The industry shall ensure that the emissions containing Bromine gases shall be
routed through water scrubber, caustic scrubber provided in series. The vent of the
caustic scrubber shall be dipped into dilute caustic soda lye for effective removal of
Bromine in the emissions. The industry shall evaporate the scrubber liquid from
Bromine recovery plant in the MEE system.
20.The industry shall maintain spent bromine recovery unit within the premises and
the recovery efficiency of Bromine recovery unit shall not be less than 99%.
21.The industry shall not use or generate odour causing substances or Mercaptans and
cause odour nuisance in the surroundings.
22.The industry shall maintain odour control measures such as scrubbers for TMA,
H2SO4 emissions, Dry vacuum pumps, Nitrogen blanketing for storage tanks,
Common ducting system with extraction system to production blocks for control of
odour.
23.The evaporation losses in solvents shall be controlled by taking the following
measures:
a. Chilled brine circulation shall be carried out to effectively reduce the
solvent losses into the atmosphere.
b. Transfer of solvents shall be done by using pumps instead of manual
handling.
c. Closed centrifuges shall be used to reduce solvent losses.
d. All the solvent storage tanks shall be connected with vent condensers to
prevent solvent vapours.
e. The reactor vents shall be connected with primary & secondary condensers
to prevent escaping of solvent vapour emissions into atmosphere.
24.The industry shall provide & maintain online continuous emission monitoring
system to the Boilers & incinerator stacks and shall connect the data to the APPCB.
Rotary kiln shall be maintained with online connection to APPCB website indicating
parameters like VOC, SOX, NOX, SPM values in the stack, temperature primary &
secondary combustion chambers.
25.The industry shall provide and maintain VOC analyser in the CAAQM stations. The
industry shall calibrate the online emission monitors, CAAQM stations, VOC monitors
and other sensors at regular intervals. The industry shall inform the RO, Srikakulam
about the calibration schedule and calibration shall be done in presence of the
Board officials.

GENERAL

26.The industry shall not manufacture new products and not exceeding the production
quantity without CFE / CFO of the Board.
27.The industry shall ensure that there shall not be any change in the process
technology, source of raw material and scope of working without prior approval
from the Board.
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

28.The industry shall provide separate energy meters for Effluent Treatment Plant
(ETP), and Air pollution Control equipments to record energy consumed.
29.Under no circumstances, the Hazardous Waste shall be burnt in the boiler.
30.Primary combustion chamber of the incinerator shall be maintained more than 850
±500C and Secondary Combustion temperature shall be maintained more than
1050±500C.
31.The industry shall store all raw materials in closed area and feed liquid raw
materials through closed pumping to reactors and tanks to reduce the odour
nuisance.
32.The industry shall maintain the following records and the same shall be made
available to the inspecting officers of the Board:
a. Daily production details (ER-1 Central Excise Returns).
b. Quantity of Effluents generated, treated, recycled/reused.
c. Log Books for pollution control systems.
d. Characteristics of effluents and emissions.
e. Hazardous/non hazardous solid waste generated and disposed.
f. Inspection book.
g. Manifest copies of effluents / hazardous waste.
33.The industry shall provide multi gas sensors with alarm in production blocks and
SRU.
34.The industry shall evaluate the performance of solvent recovery system for each
stream-wise and shall furnish plan of action to maintain the solvent recovery
efficiency more than 95% for every stream.
35.The industry shall comply with the following as per Standard Operating Procedures
of CPCB prescribed for SRP(Captive utilization):
a. The vent of the condenser shall be passed through VOC absorption media like
activated carbon.
b. Installation of online analyser for TOC at the vent out let in time bound manner
c. Online emission monitoring system for VOC emission should be installed in stack
attached to vent of the condenser and online emission data be connected to APPCB
Server.
36.The industry shall submit quarterly compliance report for the Standard Operating
Procedures of CPCB prescribed for SRP(Captive utilization) along with monitoring
reports carried out by NABL accredited or EPA approved Laboratories.
37.The industry shall contain the smell problem and shall avoid the accumulation of
hazardous wastes in their premises beyond the permitted limits. In case the
industry fails to comply, the Board will take action against the industry which may
include the reduction of production capacities drastically.
38.The industry shall isolate the storage of highly flammable chemicals, solvents &
other raw materials from the rest of facilities in the plant premises. Proper earthing
shall be provided in all the electrical equipment wherever solvent handling is done.
39.The industry shall develop green belt in all the vacant places within three months.
In future, excess green belt over and above 33 % of total area can be utilized for
industrial activity as per requirement of industry.
40.The industry shall renew the PLI policy which includes Environmental Relief Fund
(ERF) and submit copy to RO, Srikakulam on yearly base.
41.The industry shall conduct Health studies and Cholinesterase test for the
employees exposed by the National Institute of Occupational Health, (Ahmedabad,
Bangalore, and Kolkotta) and the results of the studies shall be submitted to Board
every six months.
42.Industry shall take action on recommendations on health studies carried out on the
employees of M/s. NACL Industries Ltd.,
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

43.The industry should submit mock drill report carried out at least once in six
months, as required under the Manufacture, Storage and Import of Hazardous
Chemicals Rules, 1989.
44.The industry shall submit the information regarding usage of Ozone Depleting
Substance once in six months to the Board.
45.The industry shall comply with the Regulation of Persistent Organic Pollutants
Rules,2018 notified by the MoEF&CC Notification vide G.S.R. 207 (E) dated
30.05.2018. As per the notification, the following 7 chemicals are prohibited to
manufacturer, trade, use, import and export:
a. Chlordecone,
b. Hexabromobiphenyl,
c. Hexabromodiphenyl ether and heptabromodiphenyl ether (commercial octa-
BDE),
d. Tetrabromodiphenyl ether and pentabromodiphenyl ether (commercial
penta-BDE),
e. Pentachlorobenzene,
f. Hexabromocyclododecane and
g. Hexachlorobutadine.
46.The industry shall update the information in OCEMS - Industry Information Data
Entry Software for Compliance Reporting Protocol in PART-II (Sections F & G) Every
Quarter on 1st January, 1st April, 1st July and 1st October through this software
system.
47.The industry shall submit half-yearly compliance report for the schedule A,B& C
conditions stipulated in CFO & HWA order audited through NABL / MoEF accredited
laboratories.
48.Any other directions / circulars / notices issued by CPCB, MoEF&CC and APPCB
shall be followed from time to time.

Special conditions:
49.The industry shall submit a copy of the NOC issued by the Andhra Pradesh State
Disaster Response and Fire Service Dept., (APSDRFSD) at concerned Regional Office,
APPCB.
50.The industry shall prepare a safety report and carry out an independent safety
audit report of the respective industrial activities including chemical storages /
isolated storages by an expert not associated with such industrial activity as
required under Rule 10 of MSIHC Rules, 1989 and get it approved by the Factories
Dept., and submit the compliance along with copy of the safety report, safety audit
report and safety certificate at concerned Regional Office, APPCB.
51.The industry shall identify major accident hazard chemicals & list out the
hazardous chemicals endangered to human health & environment, and the details
shall be furnished to the Factories Department and the Regional Office, APPCB time
to time duly certifying the same by the industry. Further, the industry shall extend
training to the working personnel while handling hazardous chemicals for the
prevention of accidents and necessary antidotes to ensure safety, as per the MSIHC
Rules, 1989.
52.The industry shall carryout calibration of safety equipment and leak detection
systems at regular intervals and shall certify the same with the Factories
Department. That certified copy shall be submitted to the APPCB, Regional Office.
53.The industry shall install fluorescent Wind Vane at the highest point in the industry
premises.
54.The industry shall inventory the hazardous wastes and its quantities stored within
the industry premises as per the Hazardous and Other Wastes (Management and
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

Transboundary Movement) Rules, 2016 (HOWM Rules, 2016) and shall furnish the
details to Regional Office, APPCB on a monthly basis duly certifying the same by the
industry.
55.The industry shall submit Risk analysis and risk assessment covering worst scenario
clearly describing impact within the industry premises and outside the industry
premises and emergency response system.
56.The industry shall inventorize the storage quantities of hazardous chemicals (raw
materials), products, as per the hazard nature of reactivity / toxicity / flammability
/ explosive stored/handling in the premises as defined in the Management of
Storage, Import of Hazardous Chemicals (MSIHC) Rules, 1989 and the details shall be
furnished to the Factories Department and to the Regional Office, APPCB on
monthly basis duly certifying the same.
57.The industry shall submit the copy of the safety audit report and On-Site / Off Site
Emergency Plans as applicable after being certified by the Factories Department to
the APPCB, Regional Office from time to time, if the storage quantity of hazardous
chemicals is equal to or, in excess of the threshold quantities specified in schedule
2 & 3 of MSIHC Rules, 1989.
58.The industries and isolated storages that are storing hazardous chemicals less than
the threshold quantities mentioned under MSIHC Rules, 1989 shall submit safety
certificate to the concerned Regional Office, APPCB

SCHEDULE – C
[see rule 6(2)
[CONDITIONS OF AUTHORISATION FOR OCCUPIER OR OPERATOR HANDLING HAZARDOUS
WASTES ]
1. The authorised person shall comply with the provisions of the Environment
(Protection) Act, 1986, and the rules made there under.
2. The authorisation shall be produced for inspection at the request of an officer
authorised by the State Pollution Control Board.
3. The person authorised shall not rent, lend, sell, transfer or otherwise transport the
hazardous and other wastes except what is permitted through this authorisation.
4. Any unauthorised change in personnel, equipment or working conditions as
mentioned in the application by the person authorised shall constitute a breach of
his authorisation.
5. The person authorised shall implement Emergency Response Procedure (ERP) for
which this authorisation is being granted considering all site specific possible
scenarios such as spillages, leakages, fire etc. and their possible impacts and also
carry out mock drill in this regard at regular interval of time;
6. The person authorised shall comply with the provisions outlined in the Central
Pollution Control Board guidelines on “Implementing Liabilities for Environmental
Damages due to Handling and Disposal of Hazardous Waste and Penalty”.
7. It is the duty of the authorised person to take prior permission of the State
Pollution Control Board to close down the facility.
8. An application for the renewal of an authorisation shall be made as laid down under
these Rules.
9. Any other conditions for compliance as per the Guidelines issued by the Ministry of
Environment, Forest and Climate Change or Central Pollution Control Board from
time to time.

Specific Conditions:
10.The industry shall not store hazardous waste for more than 90 days as per the
Hazardous and Other Wastes (Management & Transboundary Movement) Rules,
File No.APPCB-11022/114/2018-TEC-CFO-APPCB

2016.
11.The industry shall enter an agreement with the Cement industries for disposal of
incinerable waste or shall dispose to Alternative Fuel Raw material facility (AFRF)
OR to TSDF for co-incineration.
12.The industry shall transport the hazardous waste to cement industries through GPS
vehicle.
13.The industry shall store Used / Waste Oil and Used Lead Acid Batteries in a secured
way in their premises till its disposal to the manufacturers / dealers on buyback
basis.
14.The industry shall maintain 7 copy manifest system for transportation of waste
generated and a copy shall be submitted to concerned Regional Office of APPCB.
The driver who transports Hazardous Waste should be well acquainted about the
procedure to be followed in case of an emergency during transit. The transporter
should carry a Transport Emergency (TREM) Card.
15.The industry shall maintain proper records for Hazardous and Other Wastes stated
in Authorisation in Form-3 i.e., quantity of Incinerable waste, land disposal waste,
recyclable waste etc., and file annual returns in Form-4 as per Rule 20 (2) of the
Hazardous and Other Wastes (Management & Transboundary Movement) Rules,
2016.
16.The industry shall comply with the provisions of HWM Rules, 2016 in terms of
interstate transport of Hazardous Waste and manifest document prescribed Under
Rule 18 and 19 of the HWM Rules, 2016.
17.Hazardous Waste annual return shall be filed by June 30th for the period ensuring
31st March of the year.

The industry shall submit Half yearly compliance reports to all the stipulated conditions
in Environmental Clearance (EC), Consent for Establishment (CFE) and Consent for
Operation (CFO) through website i.e., https://pcb.ap.gov.in by 1st of January and 1st
July of every year. The first half yearly compliance reports shall be furnished by the
industry and second half yearly compliance reports shall be the audited through
MoEF&CC recognized and National Accreditation Board for Laboratory Testing
(NABL) accredited third party.

DR. B.MADHUSUDHANA RAO, JCEE(MSRB), O/o JOINT

CHIEF ENVIRONMENTAL ENGINEER4-APPCB
To
M/s. NACL Industries Limited,
(Formerly M/s. Nagarjuna Agrichem Limited),
Plot No. 177, Arinama Akkivalasa (V),
Allinagaram Post, Etcherla (M),
Srikakulam District
NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

MANUFACTURING PROCESS, REACTION SCHEMES,

PROCESS FLOW DIAGRAM AND MATERIAL BALANCE

Project No. 0321-17-01

March 2021

STUDIES AND DOCUMENTATION BY

SUBMITTED TO
ANDHRA PRADESH POLLUTION CONTROL BOARD,
REGIONAL OFFICE, SRIKAKULAM
NACL Industries Limited Process Description

2.0 PROCESS DESCRIPTION

2.1 Proces Description

The manufacturing process for the above-mentioned products involves chemical
synthesis utilizing mainly organic chemicals as raw materials in batch process.
Agrochemicals which have unitque physical and pharmacological properties are
manufactured in batch process. Typically, a series of chemical reactions are performed in
multi-purpose reactors and the products are isolated by extraction, crystallization and
filtration. The finished products are usually dried, and milled. The manufacturing
process of each product, reaction scheme, material balance and flow diagram are
presented in the following pages.

2.1.1 Process Description of Cloquintocet Mexyl

Reaction Schemes
Stage I:

Stage II:

O O H O O

O O
N N
+
H 2 O
+

O H M o l. W t.: 1 8
C l C l
C 1 1 H 7 C lK N O 3 C 7H 16O C 18H 22C lN O 3
M o l. W t.: 2 3 7 .6 M o l. W t.: 1 1 6 .2 0 M o l. W t.: 3 3 5 .8 2

1-1 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description
Stage I: 5-chloro 8-hydroxy quinoline and dimethyl formamide are taken in round
bottom flask at room temperature. Reaction mixture temperature is raised to 30 to 35 °C
and potassium carbonate is added to the above mixture for 15- 20 minutes. Mono
chloroacetic acid is added for two hours at room temperature. The reaction mixture is
stirred at 45-50°C for 10 hours. The reaction mixture is monitored by GC. Checked the
un-reacted 5-Chloro 8-hydroxy quinoline, if un-reacted is < 0.5% reaction mixture is
taken for the next step

Stage II: Reaction mixture temperature is cooled to 30-35 °C. 2-Heptanol is added to the
reaction mixture over a period of 3 hours at 30--35 °C and maintained for half an hour.
Temperature is raised to 90-95 °C and maintained for 15 hours at 90- 95 °C. Checked the
unreacted stage-I by GC, if un-reacted Stage –I is < 0.5%., the reaction mass is filtered,
filter cake is washed with dimethylformamide. Dimethylformamide is removed
completely under vacuum at 60 °C for 2- 3 hours. Water is added slowly, reaction
mixture cooled to room temperature, then cooled to 0-5°C and maintained for 2-3 hours.
Reaction mixture is filtered and washed with water, to obtain Cloqintocet mexyl
Technical. Schematic diagram of Cloquintocet Mexyl shown in Fig 2.1 and material
balance for Cloquintocet Mexyl is presented in Table 2.1

1-2 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.1 Process Flow Diagram of Cloquintocet Mexyl

1-3 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.2 Process Description of Triazinone / Thiocarbohydrazide/Dichloro Pinacolone

/Pinacolone
Reaction Schemes
Stage I:
H3C OH O CH3 O
H3C H3C
H3C CH3 CH3 Cl
CH3 OH
Isoamylene Dichloropinacolone
Pinacolone Cl

CH3 O CH3 O
H3C
H3C
NH S
H3C OH O
N NH
N SH TCH HO Trimethylpyruvic aci
H2N NH NH2
Triazinone

S
S
+ H2N NH2

Process Description
Stage I: Isoamylene is converted to Pinacolone in presence acid catalyst and
formaldehyde, which is chlorinated to yield Dichloropinacolone. This dichloroderivative
is then oxidized to keto acid which is coupled with Thicarbanohydrazide (TCH) to give
Triazinone. Schematic diagram of Triazinone / Thiocarbohydrazide/Dichloro Pinacolone
/Pinacolone is shown in Fig 2.2 and material balance for Triazinone /
Thiocarbohydrazide/Dichloro Pinacolone /Pinacolone is presented in Table2.2

1-4 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.2 Process Flow Diagram of Triazinone / Thiocarbohydrazide/Dichloro

Pinacolone /Pinacolone

1-5 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.3 Process Description of Profenofos

Reaction Schemes
Stage I:

Stage II:

Stage III:

Stage IV:

1-6 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description:
Stage I: After charging chlorobenzene initially, ortho-chloro phenol is taken into a glass-
lined Reactor and bromine is added at a controlled rate from a batch tank. A temperature
range of 25-43oC is maintained. During addition, bromine reacts with ortho-chloro
phenol and forms hydrogen bromide and 4-bromo-2-chloro-phenol in the solvent media
of chlorobenzene.

Stage II: 4-Bromo-2-Chlorophenol (BCP) is condensed with diethyl thiophosphoroyl

chloride (DETC) in the presence of trimethylaminesulphate and other catalysts. During
the reaction, BCP reacts with DETC and forms 4-Bromo-2-Chlorophenyl diethyl
phosphorotheiate (EPT) and hydrochloric acid, which reacts instantaneously with caustic
and forms sodium chloride. After completion of the reaction, settle the mass for 1hour at
15oC and then, a fore-cut of aqueous trimethylamine is distilled and is recycled. The
organic and aqueous layers are separated.

Stage III: The EPT formed is reacted with 30% TMA under controlled conditions to
obtain Ammonium salt of EPT. The temperature is maintained at 70oC for 6 hours. The
excess TMA is distilled off and the water and organic layers are separated. The aqueous
layer is sent to ETP and the organic layer, which consists of the Ammonium salt of EPT,
is transferred to another reactor for Profenofos reaction.

Stage IV: The n-propyl bromide is added into the reactor where it reacts with the
concentrated ammonium salt of EPT and forms Profenofos and n-propyl-ethyl
ammonium bromide. After completion of the reaction, the reaction mass is maintained at
60oC for 4 hours. Process flowdiagram of get Profenofos is shown in Fig 2.3 and material
balance for get Profenofos is presented in Table 2.3.

1-7 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.3 Process Flow Diagram of Profenofos

1-8 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.4 Process Description of Thiamethoxam

Reaction Schemes
Stage I:
NO2
NO2 N
N
Cl
S
DMF N N
N NH + Cl KHCO3 + KCl
N S K2CO3
N +
+ O
O
Cl
C4H8N4O3 C4H3Cl2NS C8H10ClN5O3S
Mol. Wt.: 160.13 Mol. Wt.: 168.04 Mol. Wt.: 138.2 Mol. Wt.: 291.72 Mol. Wt.: 100.11 Mol. Wt.: 74.55

Process Description:

Stage I: N,N-Dimethyl formamide, K2CO3, 3,6-Dihydro-3-methyl-N-nitro-2H-1,3,5-

oxadiazin-4-amine, 2-chloro 5-chloromethyl thiazole are charged at room temperature.
Reaction mixture is heated to 90-95°C and maintained for 10-12 hours. After starting
material is consumed, reaction mixture is filtered, and the resulting organic layer is
evaporated under vacuum to give Thiamethoxam. Process flowdiagram of
Thiamethoxam is shown in Fig 2.4 and material balance for Thiamethoxam is presented
in Table 2.4.

1-9 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.4 Process Flow Diagram of Thiamethoxam

2.1.5 Process Description of Fipronil

Reaction Schemes

Stage I:
F3C S CN
O
N F3C S CN
H2N N
Cl Cl H2N N
Ethylene dichloride N
H2O2 + H2SO4 Cl Cl + H2O + H2SO4
+

CF3
Fipronil Sulfide CF3
C12H4Cl2F6N4S H2O2 H2O4S Fipronil
Mol. Wt.: 421.15 Mol. Wt.: 34.01 Mol. Wt.: 98.08 C12H4Cl2F6N4OS H2O H2O4S
Mol. Wt.: 437.15 Mol. Wt.: 18.02 Mol. Wt.: 98.08
CAS No: 120067-83-6 CAS No:120068-37-3

1-10 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description:
Stage I:2,3-Dimethyl-4-Nitro-pyridine-1-oxide reacts with Trifluoro Ethanol in presence
of Potassium Carbonate, then acylation with Acetic Anhydride in presence of Acetic
acid, then followed by hydrolysis with Sodium Hydroxide and finally salt formation
with Isopropyl Alcohol Hydrochloride in presence of Methyl Isobutyl Ketone and
Toluene as solvent media and gets purified with Carbon and Hyflo to give 2- (Hydroxy
5-amino-3-cyano-1-(2,6-dichloro-4-trifloromethylphenyl)-4-trifluoromethyl thio pyrazole
and ethylene dichloride are charged in the reactor at RT. Reaction mixture is heated to
12-15ºC. 50% H2O2 and 90% H2SO4 are added simultaneously over a period of 3-4
hours. The reaction temperature is raised to 28-30°C and maintained for 2.0 hrs. Reaction
is monitored by chromatographic method. After completion of reaction, reaction mass is
send to work up. Reaction mass is slowly added to chilled water at 10-12°C for 2 hrs.
Eethylene dichloride (extra) is added to the above mixture. This mixture is heated to 60°C
and separated the organic and aqueous layers. The obtained organic layer is washed with
water and 5% NaHCO3 solution followed by water. Solvent is removed up to 50% from
organic layer under reduced pressure and remaining organic layer is cooled to 5-10ºC.
Crystals are formed in the organic layer and which are send to filtration. The solid
material is Fipronil technical. Process flowdiagram of Fipronil is shown inFig 2.5 and
material balance for Fipronil is presented in Table 2.5.

1-11 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.5 Process Flow Diagram of Fipronil

1-12 Team Labs and Consultants

2-chloro-5-chloromethyl-
6-methoxy- pyridine
3-pyridinecarboxaldehyde
dimethyl acetal

NACL Industries Limited O

Process Description
+
K S Cl CH3 H3C CH3
addition methylation S
HO CH3
2.1.6
N + OHSDescription
Process
C Schlorination
of Imidachloprid
C ClO N
CH3 C
O
CH3
potassium hydroxide dimethylsulphate
sodium methylate
phosphorus
carbon disulfide S Cl
methanol N O S
pentachloride solvent: toluene methyl alcohol O
ReactionO Schemes 3-(−trichloro)picoline
CH3
S,S-dimethyl-6-methoxy-
nicotinic acid
Stage I: 3-pyridinecarboxaldehyde
dithiocarbonate
dimethyl acetal
O
H3C chlorination
O Clformation
imine ammonia
N
C CH3
phosphorus Cl
N
O trichloride
CH3
condensation CH3 CH3
2-chloro-5-chloromethyl-
NH 6-methoxy-
cyclisation S S pyridine
nitration
3-pyridinecarboxaldehyde acid
N dimethyl
NHacetal O2N CH3 CH3
H 2 concentrated HN S
N NO2 N S sulfuric acid
NH2
Stage II: CH3
+
dimethyl N-nitroimido-
K S CH3 acetic
2-(nitroimino)- addition dimethylimido- S
methylation
imidazolidine+
HO CH3 S C S dithiocarbonate O dithiocarbonate
ethylenediamine potassium hydroxide dimethylsulphate CH3
methanol carbon disulfide solvent: toluene S O S

S,S-dimethyl-
Cl N N dithiocarbonate
NH condensation
N Cl + N Cl N
imine formation H
N
ammonia
H
N NO2
NO2
2-chloro-5-chloromethyl-
2-(nitroimino)- imidacloprid CH3
pyridine condensation CH3
NH cyclisationimidazolidine S nitration
S
acid
N NH2 O2N CH3 CH3
H concentrated HN S
N NO2 N S sulfuric acid
NH2
Process Description:
2-(nitroimino)-
dimethyl N-nitroimido- acetic
dimethylimido-
dithiocarbonate dithiocarbonate
imidazolidine ethylenediamine
Stage I: 6-methoxy-3-pyridine carboxaldehyde dimethyl acetal is chlorinated using
chlorine
Cl
gas to get 2-chloro -5 chloromethyl
NH
Pyridine, generated
condensation
N hydrochloric
N acid gas is
scrubbed
N Cl +
in water & dilutedHNsodium hydroxide solution, Cl Organic layer
N
N
His taken to the
N NO2
NO2
stage 2.
2-chloro-5-chloromethyl-
2-(nitroimino)- imidacloprid
pyridine
imidazolidine

Stage II: Stage-1, product, 2-chloro -5 chloromethyl Pyridine, is condensed with 2-

nitroimino) imidazolidine to get imidacloprid, product is filter washed and dried to get
Imidacloprid technical. Process flowdiagram of Imidachloprid is shown in Fig 2.6 and
material balance for Imidachloprid is presented in Table 2.6.

1-13 Team Labs and Consultants

NACL Industries Limited Process Description

Methyl chloro format

Cyanamide CYCLODEHYDRATION
Potassium hydroxide

Water
Toluene WORK UP

Aqueous

Ortho phenylene di amine

Stage-1 CONDENSATION &
CYCLISATION

Water WORK UP

Aqueous
Toluene

FILTRATIONN

ML's for recovery of toluene

IMIDACLOPRIDE WET

DRYING

IMIDACLOPRIDE
TECHNICAL

Fig 2.6 Process Flow Diagram of Imidachloprid

1-14 Team Labs and Consultants

Acetamiprid
Process Description:

NACL Industries
N-Cyano methyl Acetamidate Limited
(NCMA) Process
is reacted with 2-Chloro 5-(methyl amino Description
methyl)
Pyridine (CMAMP) in Methanol as solvent media at a sub-atmospheric temperature (10 –
15°C). After the reaction is completed the product is filtered and dried to obtain technical
2.1.7
gradeProcess
product.Description
The mother of Acetamiprid
liquor is distilled to recover Methanol solvent which is then
recycled.
Reaction Schemes
Process Reaction:
CH3

N C N CN
H3CO CH2NHCH3 CH2
C=NCN + CH3
N
Cl N
H3C Cl
NCMA CMAMP ACETAMIPRID
N-cyanomethyl [2-Chloro-5-(methyl amino methyl) MW. = 222.5
Acetamidate Pyridine
MW.= 98 MW.= 156.5 +
CH3OH
METHANOL
MW.= 32

Process Description:
N-Cyano methyl Acetamidate (NMCA) is reacted with 2-Chloro 5-(methyl amino methyl)
pyridine (CMAMP) in methanol as solvent media at a sub-atmospheric temperature (10-
15, Degree C). After the reaction is completed the product is filtered and dried to obtain
technical grade product. The mother liquor is distilled to recover solvent which is then
recycle. Process flow diagram of Acetamiprid is shown in Fig 2.7 and material balance
Acetamiprid is presented in Table 2.7.

Process Flow Diagram:

ACETAMIPRID TECHNICAL - MATERIAL BALANCE (ALL QUANTITIES ARE IN KG/TONN)

NCMA 520
CMAMP 700 METHANOL 143
METHANOL 1800 CONDENSATION

2877

METHANOL FOR WASHING 150 METHANOL RECOVERY 1900

FILTRATION, DRYING &
SOLVENT RECOVERY
METHANOL LOSS 50
RESIDUE 77

ACETAMIPRID
1000

Material Balance:
Fig 2.7 Process Flow Diagram of Acetamiprid
Material Balance for Acetamiprid
Input/MT of Product
S.No. Raw Materials
(KG)
1 NCMA 520
2 1-15
CMAMP Team Labs and Consultants
700
3 Methanol 1950
Total 3170
Output/MT of Product (KG)
Air
S. No. Liquid Solid Remarks
NACL Industries Limited Process Description

2.1.8 Process Description of Lambda Cyhalothirin

Reaction Schemes
Stage I:

Process Description:
Meta Phenoxy Benzaldehyde is reacted with Sodium Cyanide to form Meta Phenoxy
Benzaldehyde Cyanhydrin as an intermediate. This o reaction with FluoroPropenyl Acid
Chloride (TFP Acid Chloride) form the Product Cyhalothrin. In this process n – Hexane
is used as solvent along with phase transfer catalyst.

1-16 Team Labs and Consultants

NACL Industries Limited Process Description

The reaction mass of Cyhalothrin is washed by Soda Ash solution as well as water.
Solvent n-Hexane is stripped off to get pure Cyhalothrin oil. Finally Cyhalothrin oil is
epimerized to give Lambda Cyhalothrin of 85%. As aqueous layer which contains traces
of Sodium Cyanide is detoxifiedby the treatment of Sodium Hypochlorite solution (8-
10%) up to < 0.2 ppm level. Then it is mixed up with main ETP stream for further
treatment. Process flowdiagram Lambda Cyhalothirin is shown in Fig 2.8 and material
balance for Lambda Cyhalothirin is presented in Table 2.8.

Fig 2.8 Process Flow Diagram of Lambda Cyhalothirin

1-17 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.9 Process Description of Bifenthirin

Reaction Schemes
Stage I:
O
OH Cl O
Cl F
F
+ F F + HCl
O F
F

2-methyl-3-biphenyl methyl alcohol Cyhalothric acid chloride Bifenthrin Cl

C23H22ClF3O2 ClH
C14H14O C9H9Cl2F3O
Mol. Wt.: 422.87 Mol. Wt.: 36.46
Mol. Wt.: 198.26 Mol. Wt.: 261.07

Process Description:
It is manufactured in a single step reaction of 2-methyl-3-biphenyl methanol with 3-((E)-2-
chloro-3,3,3-trifluroprop-1-enyl)-2,2-dimethylcyclopropanecarboxylicacid chloride
(Cyhalothric acid chloride). Process flowdiagram of Bifenthirin is shown in Fig 2.9 and
material balance for Bifenthirin is presented in Table 2.9.

Fig 2.9 Process Flow Diagram of Bifenthirin

1-18 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.10 Process Description of Cypermethrin

Reaction Schemes
Cl
Cl O + NaCN
Cl +
O
O Sodium cyanide
meta phenoxy benzaldehyde
Cypermethric acid chloride
CNNa
C8H9Cl3O C13H10O2 Mol. Wt.: 49.01
Mol. Wt.: 198.22
Mol. Wt.: 227.51

Cl
O + NaCl
O Cl
CN O
Cypermethrin Sodium chloride
C22H19Cl2NO3
Mol. Wt.: 416.30 Mol. Wt.: 58.44

Process Description:
A solution of sodium cyanide is prepared in SS reactor and further n-hexane is charged
along with Catalyst and soda ash. In another reactor a mixture of cypermethric acid
chloride, m-phenoxy benzaldehyde and n-hexane is prepared and kept at 10-15ºC. This
mixture is added to the first reactor at room temperature and maintained the same
temperature for 1 hour. The organic layer is then washed successively with plain water,
hypochlorite solution, aqueous acetic acid and again with plain water. It is then passed
through sparkler filter and hexane is distilled out first at normal pressure and then under
vacuum to remove the traces to get cypermethrin technical. Process flowdiagram of
Cypermethrin is shown in Fig 2.10 and material balance for Cypermethrin is presented in
Table 2.10.

1-19 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.10 Process Flow Diagram of Cypermethrin

2.1.11 Process Description of Carbendazim

Reaction Schemes
Stage I:
O
NH2 O N O
+ CaNCN NH
+ + CaCl2 + NH4Cl
NH2 Cl O Dil HCl N
M. Wt: 36 H
2x36= 72 Ammonium Chloride
O-phenylenediamine Calcium Cyanamide Methyl chloroformate Carbendazim-Tech Calcium Chloride
Mol. Wt.: 108.14 Mol. Wt.: 80.10 Mol. Wt.: 94.50 Mol. Wt.: 191.19 Mol. Wt.: 110.98 Mol. Wt.: 53.49

1-20 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description:
Stage I: Calcium cyanamide and water are charged in the reactor at RT. The resulting slurry
is heated to 40-450C and maintained at this temperature for 1.0 h. Methyl chloroformate is
added slowly over a time of 1.0 h at 40-450C. The reaction mixture is further maintained at
40-450C for 1.0 h. The reaction mixture subjected to filtration. The mother liquor obtained by
filtration is taken in another reactor at RT and O-Phenylenediamine is charged at RT. The
reaction mixture is heated to 90-950C. 6N HCl was added drop wise so that, pH of the RM is
in the range of 3-4. RM is filtered, obtained cake. Cake is our desire Carbendazim-Technical.
Process flowdiagram of Carbendazim is shown in Fig 2.11 and material balance for
Carbendazim is presented in Table 2.11.

Water
Charged at RT
Calcium Cyanamide

Heat to 40-450C, & Maintain for 1.0 h

Methyl Chloroformate Addition at 40-450C, & Maintain for 1.0 h

Filteration Inorganic salts

Filter Mls

O-Phenylenediamine Charged at RT

6 N HCl
Note: Addn such that pH 3.0- Heat to 90-950C, & Maintain for 4-5 h
4.0

Proceed for workup when O-O-

Phenylenediamine <3%
HPLC-TA

Filtration Filter mls

Carbendazim-Technical

Fig 2.11 Process Flow Diagram of Carbendazim

1-21 Team Labs and Consultants

Pymetrozine
Process Description
Process Description:NACL Industries Limited
Charge 3-Pyridine carboxaldehyde, 1,2,4-Triazine-3(4H)-1,4-Amino-5,6-dihydro-6-methyl and
2.1.12
toluene Process
in a reactorDescription of Pymetrozine
under stirring. Raise the temperature to 65°C and maintain for 6 hrs.

Reaction Schemes
Once the reaction completes, distil half of the toluene and cool to crystallize the mass.
Centrifuge and dry the crude mass to get technical grade Pymetrozine. Recover the toluene
from the ML by distillation.
Stage I:
Process Reaction:
O
H3C NH2
N
H
+
N
N N O
3 Pyridinecarboxaldehyde H
M.W.- 107 1,2,4- Triazin - 3(4H) 1,4- Amino
-5,6- Dihydro-6-Methyl
M.W.- 128

H3C N
HO
CH N
+ 2
N
N
H

PYMETROZINE
MW.= 217

Process Description:
Charge 3- Pyridine carboxaldehyde, 1,2,4-Triazine-3(4H)-1,4 Amino-5,6-dihydro-6-methyl
and Toluene in a reactor under stirring. Raise the temperature to 65°C and maintain for 6
Hrs. Once the reaction completes, distil half of the toluene and cool to crystalize the mass.
Centrifuge and dry the crude mass to get technical grade Pymetrozine. Recover the
toluene from the ML by distillation. Process flowdiagram of Pymetrozine is shown in Fig
2.12 and material balance for Pymetrozine is presented in Table 2.12.

1-22 Team Labs and Consultants

NACL Industries Limited Process Description

Process Flow Diagram:

PYMETROZINE TECHNICAL - MATERIAL BALANCE (ALL QUANTITIES ARE IN KG/TONN)

3 PYRIDINE
519
CARBOXALDEHYDE
1,2,4 TRIAZINE-3 (4H) 1,4 -
AMINO-5,6 -(DIHYDRO-6- 639
METHYL) REACTOR
TOLUENE 2000

3158

TOLUENE RECOVERY 975

DISTILLATION LOSS 15

AQUEOUS LAYER 158

2010

FILTRATION & SOLVENT TOLUENE RECOVERY 975

RECOVERY
LOSS 15
1020

DRYING LOSS 20
DRYING

PYMETROZINE
1000

Fig 2.12 Process Flow Diagram of Pymetrozine

1-23 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.13 Process Description of Emamactin Benzoate

Reaction Schemes

Process Description:
It is a composite mixture of 90% emamectin B1a and 10% emamectin B1b as their benzoate
salts. It is isolated from fermentation of streptomycessavermitis with an anthelminic and
acaricidal. Then methylamine is added in the mixture. Finally, benzoate salt is prepared by
reaction with methyl benzoate. Process flowdiagram of Emamactin Benzoate is shown in Fig
2.13 and material balance for Emamactin Benzoate is presented in Table 2.13.

1-24 Team Labs and Consultants

NACL Industries Limited Process Description

Mass Balance
Mass balance of Emamectin benzoate

IN PUT Kg OUT PUT Kg

Streptomycess avermemitis 50
Anthelminic 45
Formentation
Acaricidal 50
Water 654

Methyl amine 20 Addition & Aqueous effluent 620

Isolation

Methyl benzoate 25
Benzylation
Water 90

Methanol 300 Emamectin benzoate 110

Purification &
Recovered Methanol 290
Crystalization
Residue 214

Total 1234 1234

Fig 2.13 Process Flow Diagram of Emamactin Benzoate

2.1.14 Process Description of Diafenthiuron
Reaction Schemes
Stage I:

S H
N S C N-
Solvent C-9
H2N
165oC
O O

2,6-diisopropyl 4-phenoxy phenyl thiourea N-(2,6-diisopropyl-4-phenoxy phenyl)-isothiocyanate

C19H24N2OS C19H21NOS-
Mol. Wt.: 328.48 Mol. Wt.: 311.44

Stage II:

S H
S C N- N
acetonitrile
NH
t-butylamine
O
C4H11N
O
Mol. Wt.: 73.14

N-(2,6-diisopropyl-4-phenoxy phenyl)-isothiocyanate 3-(2,6-diisopropyl-4-phenoxyphenyl)-1-tert-butylthiourea

C19H21NOS- C23H32N2OS
Mol. Wt.: 311.44 Mol. Wt.: 384.58

1-25 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description:
Stage I: The dried DIPPT is maintained at 165oC in solvent C-9 for 16 hours with
liberation of ammonia gas. After completion of the reaction conversion, the reaction
mass is cooled to 90oC and water is charged. The mass is cooled to 60oC and the organic
layer is separated. The organic phase is washed with water at 60oC. The washed organic
is distilled out under reduced pressure to recover solvent C-9, leaving the intermediate
ITC.

Stage II: Preparation of N-(2,6-diisopropyl-4-phenoxy phenyl)-isothiocyanate

The intermediate ITC is reacted with tert-butylamine in solvent acetonitrile at 60oC for 8
hours. After completion of the reaction, the reaction mass is cooled to 0oC and the slurry
mass is filtered. The cake is washed with chilled acetonitrile and the washed wet cake is
dried to get Diafenthiuron-technical. Process flowdiagram of Diafenthiuron is shown in
Fig 2.14 and material balance for Diafenthiuron is presented in Table 2.14.

Fig 2.14 Process Flow Diagram of Diafenthiuron

1-26 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.15 Process Description of Propiconazole / Bromoketal (Intermediate)

Reaction Schemes
Stag I:

Stage II:

Process Description:
Stag I:
2,4- Dichloroacetophenone (DiCAP) is reacted with pentane 1,2 diol (1,2PDL) to form
acetal compound in the presence of 1,2 - dichloroethane. Para toluene Sulphonic Acid
(PTSA) is used as a catalyst. Water, which is formed during the reaction, is removed and
PTSA remains in the aqueous layer.
Stage II:
The acetal compound is reacted with bromine to form Bromoketal. A batch tank is used
to add bromine slowly to the acetal compound in 1,2-dichloroethane. The required

1-27 Team Labs and Consultants

NACL Industries Limited Process Description

quantity of bromine is pumped from the bulk storage tank to the batch tank. Hydrogen
bromide gas evolves during the reaction and it is scrubbed with water to obtain 30% HBr
solution, which is sent to bromine recovery unit. The bromoketal mass is neutralized
with aqueous NaOH and the unreacted bromine reacts with NaOH to form NaBr. Then,
the layers are separated. The aqueous layer is sent to ETP for treatment. 1,2
dichloroethane is distilled off from the organic layer. Process flowdiagram of
Propiconazole / Bromoketal (Intermediate)is shown in Fig 2.15 and material balance for
Propiconazole / Bromoketal (Intermediate) is presented in Table 2.15

1-28 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.15 Process Flow Diagram of Propiconazole / Bromoketal (Interm

ediate)

1-29 Team Labs and Consultants

NACL Industries Limited Process Description

2.1.16 Process Description of Tricyclazole

Reaction Schemes
Stag I:

Process Description:
Stage I: Orthotoluidine is dissolved in chlorobenzene and is reacted with ammonium
thiocyanate under reflux to form ortho toulyl urea. The liberated ammonia reacts with
sulfuric acid and ammonium sulfate is formed. The reaction mass is reacted with chlorine
to form 2-amino-4-methyl benzo thiazole. The off gas, HCl, is scrubbed with water and is
sold out as dilute hydrochloric acid. The product is filtered and the solid product is taken
for Tricyclazole reaction. The chlorobenzene in the filtrate is separated and recovered by
distillation and aqueous salts are disposed as fertilizer. Process flowdiagram of
Tricyclazole is shown in Fig 2.16 and material balance for Tricyclazole is presented in
Table 2.16.

1-30 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.16 Process Flow Diagram of Tricyclazole

2.1.17 Process Description of Fenbuconazole
Reaction Schemes
Stage I:

Stage II:

1-31 Team Labs and Consultants

NACL Industries Limited Process Description

Stage III:

Process Description:
Stage I:
The reaction is complete in a matter of minutes at 70-90oC. The DMSO is striped off.
The excess BC is removed by steam distillation and the residue Intermediate I product is
dissolved in dichloromethane (DCM). The organic phase is then washed with water.
The 53% solution of intermediate I in DCM is transferred to the next step.
Stage II:
The second step is the alkylation of intermediate I with DCM to make intermediate II
using phase transfer catalysis. The DCM solution of intermediate I from the first step is
slowly added to a mixture of DCM, and a phase transfer catalyst. The DMSO is stripped
off, the crude product is dissolved in xylene at 80oC.
Stage III: The final purification step is crystallization form the xylene by cooling below
5oC. The product is recovered by filtering washing first with xylene then isopropanol.
The normal purity of technical fenbuconazole is 97% coming out. Process flowdiagram of
Fenbuconazole is shown in Fig 2.17 and material balance for Fenbuconazole is presented
in Table 2.17.

1-32 Team Labs and Consultants

NACL Industries Limited Process Description

Fig 2.17 Process Flow Diagram of Fenbuconazole

2.1.18 Process Description of Myclobutanil
Reaction Schemes
Stage I:

1-33 Team Labs and Consultants

NACL Industries Limited Process Description

Stage II:

Stage III:

Process Description:
Stage I: Para Chloro phenyl acetonitrile (PCAN) is reacted with N Butyl Bromide (NBB)
in presence of sodium hydroxide 48 % solution in water media to produce 2-Butyl-2-(4-
chlorophenyl) acetonitrile - (BCPA) After reaction, extra water is added, stirred and
organic is separated out. The crude BCPA is taken for next step. Aqueous sodium
bromide solution is sold out for bromine recovery.
Stage II: BCPA is then reacted with Dibromo methane (DBM) in presence of sodium
hydroxide 48% solution in water as solvent media; to produce 2-Butyl -2-chloromethyl-2-
(4-chlorophenyl) acetonitrile (BCAN) BCAN is worked up by addition of water and
layers separated. The aqueous layer is sold to outside parties for Bromine/Bromide
recovery. The organic layer containing BCAN is isolated and taken for final Myclobutanil
reaction.
Stage III: BCAN is reacted with sodium 1,2,4 Triazole in solvent media dimethyl
formamide (DMF) to produce final product Myclobutanil. Process flowdiagram of

1-34 Team Labs and Consultants

NACL Industries Limited Process Description

Myclobutanil is shown in Fig 2.18 and material balance for Myclobutanil is presented in
Table 2.18.

Fig 2.18 Process Flow Diagram of Myclobutanil

2.1.19 Process Description of Thifluzomide

Reaction Schemes
Stage I:

1-35 Team Labs and Consultants

NACL Industries Limited Process Description

Stage II:

Stage III:

Stage IV:

Stage V:

1-36 Team Labs and Consultants

NACL Industries Limited Process Description

Process Description:
Stage I: The first step in the synthesis of Thifluzamide is chlorination of freshly distilled
ETFAA. The ETFAA needs to be distilled slowly before use because the molecule tends
to form a dimer upon standing.
Stage II: The ETFAA is reacted with chlorine gas in the absence of any solvent. After
warming to ambient temperature and purging dissolved HCl with nitrogen, the CI-
ETFAA is isolated without further purification as a colorless oil
Stage III: The CI-ETFAA is then reacted with thioacetamide in acetonitrile using
triethylamine as an acid scavenger to form the thiazole ester which is converted, without
isolation, to the thiazole acid by reaction with NaOH followed by acidification
Stage IV: The thiazole acid is recovered as a beige solid by filtration, washing and
drying. The thiazole acid is then converted to the thiazole acid chloride by reaction with
thionyl chloride in toluene.
Stage V: The final step of the synthesis is the reaction of the thiazole acid chloride with
DBTFMA in acetonitrile. The thifluzamide final product is precipitated form the solvent
by addition of water. Product recovery is filtration. Process flowdiagram of
Thifluzomide is shown in Fig 2.19 and material balance for Thifluzomide is presented in
Table 2.19.

Fig 2.19 Process Flow Diagram of Thifluzomide

1-37 Team Labs and Consultants

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2.1.20 Process Description of Hexaconazole

Reaction Schemes
Stage I:
O
Cl-

O Al+++ Cl-
-
Cl
+
Cl
Cl Cl Cl Cl

1,3-dichlorobenzene n-valeryl chloride 2,4-dichloro valerophenone

C6H4Cl2 C5H9ClO C11H12Cl2O
Mol. Wt.: 147.00 Mol. Wt.: 120.58 Mol. Wt.: 231.12

Stage II:
O
O

S dimethyl sulfate
+ KOH
Cl Cl Cl Cl

2,4-dichloro valerophenone dimethyl sulphide oxirane

C11H12Cl2O C2H6S C12H13Cl2O
Mol. Wt.: 231.12 Mol. Wt.: 62.13 Mol. Wt.: 245.15

Stage III:

N N

O HO N

NH
K2CO3
+ N N DMF
Cl Cl Cl Cl

oxirane 1,2,4-triazole HEXACONAZOLE

C12H13Cl2O C2H3N3 C14H17Cl2N3O
Mol. Wt.: 245.15 Mol. Wt.: 69.1 Mol. Wt.:314.21

Process Description:
Stage I: n-valeroyl chloride is added to 1,3-dichlorobenzene and anhydrous aluminium
chloride at 60oC for 2 hours. The addition of Lewis acid is an exothermic and the
temperature goes to 90oC. The reaction mass is maintained at 90oC for 3 hours and is
drowned into chilled water, maintaining the temperature below 10oC. The mass is

1-38 Team Labs and Consultants

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stirred, settled and separated. The organic phase is washed with water twice. The
washed organic layer is distilled out under reduced pressure to recover 1,3-
dichlorobenzene and finally the product, 2,4-dichloro valerophenone.
Stage II: Dimethyl sulfate is added to a solution of water, dimethyl sulfide and phenone
at 40oC for 1 hour. The reaction mass is maintained for 6 hours at 40-42oC and cooled to
30oC. Potassium hydroxide is added slowly at 38-42oC and the reaction mass is
maintained for 10 hours at 42oC. After completion of the reaction, the temperature is
raised to recover dimethyl sulfide till 80oC. The mass is cooled to 40oC and water is
added. The reaction mass is extracted with dichloromethane for 4 times at room
temperature. All the dichloromethane extracts are combined and distilled out under
reduced pressure till temperature 85oC to recover dichloromethane and leaving oxirane.
Stage III: Oxirane is added to a mixture of N,N-dimethylformamide, potassium
carbonate and 1,2,4-triazole at 135oC. The reaction mass is maintained at 145oC for 12
hours. After completion of the reaction, the mass is cooled to 40oC and filtered to
remove excess reactants. The filtered mass is distilled out to recover N,N-
dimethylformamide at 80oC under reduced pressure. After completion of the recovery
of DMF, the molten mass is added to water at temperature below 20oC. The slurry mass
is filtered at 10oC to obtain wet product, which is dried at 50oC to get Hexaconazole-
technical. Process flowdiagram of Hexaconazole is shown in Fig 2.20 and material
balance for Hexaconazole is presented in Table 2.20

1-39 Team Labs and Consultants

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Fig 2.20 Process Flow Diagram of Hexaconazole

2.1.21 Process Description of Tebuconazole / Oxirane (Intermediate)

Reaction Schemes
Stage I:

O water
S
+
O
Cl KOH
Cl

1-(4-chlorophenyl)-4,4-dimethyl-3-pentanone dimethyl sulphide 2-(4-chlorophenethyl)-2-tert-butyloxirane

C13H17ClO C2H6S C14H19ClO
Mol. Wt.: 224.73 Mol. Wt.: 62.13 Mol. Wt.: 238.75

1-40 Team Labs and Consultants

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Stage II:
N

N
N
HO
NH
NaOH
+ N N
O NMP
Cl
Cl

1-(4-chlorophenyl)-4,4-dimethyl-3-(1H-1,2,4-
2-(4-chlorophenethyl)-2-tert-butyloxirane 1,2,4-triazole triazol-1-ylmethyl)pentan-3-ol
C14H19ClO C2H3N3 C16H22ClN3O
Mol. Wt.: 238.75 Mol. Wt.: 69.1 Mol. Wt.: 307.82

Process Description:
Stage I: Dimethyl sulfate is added to a solution of water, dimethyl sulfide and
pentanone at 40oC for 1 hour. The reaction mass is maintained for 6 hours at 40-42oC
and cooled to 30oC. Potassium hydroxide is added slowly at 30-35oC and the reaction
mass is maintained for 18 hours at 42oC. After completion of the reaction, the
temperature is raised to recover dimethyl sulfide till 80oC. The mass is cooled to 40oC
and water is added. The reaction mass is extracted with dichloromethane for 3-4 times at
room temperature. All the dichloromethane extracts are combined and distilled out
under reduced pressure till temperature 85oC to recover dichloromethane and leaving
oxirane.
Stage II: Oxirane and N-methyl pyrrolidinone are charged and the temperature of the
mass is raised to 120oC. Sodium hydroxide flakes , 1,2,4-triazole and water are added
to the reaction mass at 120oC. The reaction mass is maintained at 120oC for 4 hours.
After completion of the reaction, the solvent is removed at 80oC under reduced pressure.
Water is added to the molten mass at 70-80oC and the mass is slowly cooled to 20oC.
The slurry mass is filtered at 20oC to obtain wet product. The wet product is charged
into cyclohexane and the mass is maintained at 70oC for 1 hour. The mass is cooled to
20oC, filtered and dried at 50oC to get Tebuconazole-technical. Process flowdiagram of

1-41 Team Labs and Consultants

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Tebuconazole / Oxirane (Intermediate) is shown in Fig 2.21 and material balance for
Tebuconazole / Oxirane (Intermediate) is presented in Table 2.21.

Fig 2.21 Process Flow Diagram of Tebuconazole / Oxirane (Intermediate)

2.1.22 Process Description of Difenconazole

Reaction Schemes
Stage I:
Cl
O Cl
O AlCl3 + HCl
+ Cl O
O Cl Cl

C12H8Cl2O C2H2Cl2O C14H9Cl3O2 ClH

Mol. Wt.: 239.10 Mol. Wt.: 112.94 Mol. Wt.: 315.58 Mol. Wt.: 36.46

Stage II:
Cl
Cl

O
O O HO O
PTSA O
Cl +
Cl
HO H2O
+
Cl
Cl
C14H9Cl3O2 C3H8O2
C17H15Cl3O3
Mol. Wt.: 315.58 Mol. Wt.: 18.02
Mol. Wt.: 76.09
Mol. Wt.: 373.66

1-42 Team Labs and Consultants

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Stage III:
Cl
Cl

Cl
H

N O
Cl
O + N + K2CO3
N O

+ KCl + KHCO3
O

Cl N
N
C14H9Cl3O2 C2H3N3 N

Mol. Wt.: 315.58 Mol. Wt.: 69.07 M. Wt:138 C17H15Cl3O3 ClK CHKO3

Mol. Wt.: 373.66 Mol. Wt.: 74.55 Mol. Wt.: 100.12

Process Description:
Stage I: AlCl3 is charged to Dichloroethane, followed by choroacetyl chloride at 20 ~ 25 °
and maintained for 30 minutes. Reaction mixture cooled to 0 ~ 5 ° C. To it, cold solution
of 3,4 '- Dichloro Diphenyl ether is added slowly. The reaction is exothermic. It is
maintained for 2 hours and then slowly heated to 25 ° C ~ 30 ° C and kept for for 2 hours.
The reaction solution is poured next into ice water, organic layer is separated and
washed with water.
Stage II: The residue of stage-1 is charged in cyclohexane and chlorobenzene, PTSA, 1,2 -
propylene glycol are added at room temperature. Reaction mixture is heated to reflux
and water is collected by azeotropic distillation (dehydration). Reaction mixture is cooled
to room temperature. Reaction mixture washed with aq NaHCO 3 and then the organic
layer is washed with water once again. The solvent is removed under reduced pressure.
Stage III: The residue of stage 2 is charged in dichloroethylene and sulfolane and stirred
at room temperature. Potassium triazole was added to the reaction mixture and stirred
rapidly. Heated to 210 ° for 2 hours. Reaction mixture cooled to 60 ° C ~ 70 ° C and
filtered to remove KCl. The filter cake is washed with sulfolane. The combined filtrate
and washings were evaporated under reduced pressure to get Difenoconazole Technical.

1-43 Team Labs and Consultants

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Process flowdiagram of Difenconazole is shown in Fig 2.22 and material balance for
Difenconazole is presented in Table 2.22.

3 ,4 ' - D i c h l o r o D i p h e n y l e t h e r
A lC l3 F r i e d e l c r a f t s a c y l a t io n
D ic h lo ro eth a n e
C h l o r o a ce t y lc h l o r id e

w a te r w ork up
s o d i u m b ic ar b o n a t e s o l n

A q u e o u s was te

D i s t i l la t i o n

D ic h lo ro eth a n e
c rud e

C y c lo h ex a n e
PTSA D i o x o l a n e fo rm a t i o n
1 , 2 P r o p y l e n e g ly c o l

S o d iu m b i c arb o n a te
c y c lo h e x a n e w ork u p

D i s t i l la t i o n

S ulfola ne
P o t a s si u m t ri a z o l e C rude
e t h y le n e

sulfola ne
s a l t f il t r a ti o n

KCl

1-44 Team Labs and Consultants

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Filtrate

D i s t i l la t i o n

S u lf o l a n e

D i f e n oc o n a z o l e c a k e

D ry in g

D i f e n oc o n a z o l e T e c h n i c a l

Fig 2.22 Process Flow Diagram of Difenconazole

2.1.23 Process Description of Epoxiconazole

Reaction Schemes
Stage I:
F F

NH
Cl NMP
+
N N
NaOH
N N
O O

Cl N Cl

C15H11Cl2FO C2H3N3 C17H13ClFN3O

Mol. Wt.: 297.15 Mol. Wt.: 69.07 Mol. Wt.: 329.76
2-chloromethyl-2-(4-fluorophenyl)- 1H-1,2,4-triazole 3-(2-chlorophenyl)-2-(4-fluorophenyl)oxiranylmethyl-
3-(2-chlorophenyl)-oxirane 1H-1,2,4-triazole
EPOXICONAZOLE

1-45 Team Labs and Consultants

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Process Description:
Oxirane is added to solvent N-methyl pyrrolidinone. The temperature of the reaction
mass is raised to 120oC and sodium hydroxide flakes , 1,2,4-triazole and water are
added at 120oC. The reaction mass is maintained at 120oC for 4-6 hours. After
completion of the reaction, the mass is distilled out to recover NMP at below 80oC under
reduced pressure. After completion of the recovery of NMP, water is added to the
molten mass at 70-80oC. The mass is cooled to 20oC and the slurry mass is filtered to
obtain wet product. The wet product is purified in cyclohexane at 70oC for 1 hour and
the mass is cooled to 20oC. The slurry mass is filtered, washed with cyclohexane and the
washed wet product is dried at 50oC to get Epoxiconazole-technical. Process
flowdiagram of Epoxiconazole is shown in Fig 2.23 and material balance for
Epoxiconazole is presented in Table 2.23

Fig 2.23 Process Flow Diagram of Epoxiconazole

1-46 Team Labs and Consultants

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2.1.24 Process Description of Cyproconazole

Reaction Schemes
Stage I:

Stage II:

Process Description:
Stage I: 1-(4-chlorophenyl)-2-cyclopropyl-propan-1-one (CPDP propanone)
is epoxidized to oxirane using dimethyl sulfide and potassium hydroxide. The converted
oxirane extracted into toluene and washed with water. The oxirane/toluene organic
layer is taken to the stage 2. The below is the chemical reaction with material balance.
Stage II: The oxirane/toluene is condensed with 1,2,4-triazole using catalyst potassium
carbonate. After completion of the reaction, the mass is washed with water and distilled
out to recover toluene partly and cooled. The cooled mass is filtered and dried to obtain
Cyproconazole-technical. The mother liquor is distilled out to recover toluene, which is
recycled in the next batch. Process flowdiagram of Cyproconazole is shown in Fig 2.24
and material balance for Cyproconazole is presented in Table 2.24

1-47 Team Labs and Consultants

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Pentanone
Dimethyl sulfide EPOXIDATION
Potassium hydroxide

Water
Toluene WORK UP

Aqueous

1,2,4-triazole
Potassium carbonate CONDENSATION

Water WORK UP

Aqueous
Toluene

DISTILLATION

FILTRATION

ML's for recovery of toluene

CYPROCONAZOLE WET

DRYING

CYPROCONAZOLE
TECHNICAL

Fig 2.24 Process Flow Diagram of Cyproconazole

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2.1.25 Process Description of Thiophanate-methyl

Reaction Schemes
Stage I:
O
O
NH2 NH HN
O
O NH HN
+ 2 NaSCN + O
2 Cl
S S 2 NaCl
NH2 O +

C6H8N2 CNNaS C2H3ClO2

Mol. Wt.: 81.07 C12H14N4O4S2 ClNa
Mol. Wt.: 108.14 Mol. Wt.: 94.50
Mol. Wt.: 342.40 Mol. Wt.: 58.44
O-Phenylene diamine Sodium thiocyanate Methyl Chloroformate
Thiophanate Methyl-Technical Sodium Chloride
2x81.07 2x94.05
2 x 58.44

Process Description:
Stage I: Sodium thiocyanate and acetone are charged in the reactor at RT. The resulting
slurry is heated to 30-350C. Methyl chloroformate is added over a time of 0.5 h at 30-
350C. The Reaction mixture was cooled to at 0-50C. O-Phenylenediamine is added
portion wise into the reactor at 0-50C. The reaction mixture was allowed to RT and
stirred for 1.0h. The reaction mass is subjected to filtration and the obtained cake is
washed with water. The obtained cake is our desire Thiophanate methyl-Technical.
Process flowdiagram of Thiophanate-methyl is shown in Fig 2.25 and material balance
for Thiophanate-methyl is presented in Table 2.25

1-49 Team Labs and Consultants

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Fig 2.25 Process Flow Diagram of Thiophanate-methyl

2.1.26 Process Description of Azoxystrobin

Reaction Schemes
Stage I:
O O

O O OH O O CN
O Cl CN 18-crown-6 ether O O
+ K2CO3 + KCl + KHCO3
N N + DMF N N
Mol. Wt.: Mol. Wt.:
Methyl-3-methoxy-2-(2-(6-chloro C7H5NO Mol. wt.: 138 74.55 100.12
pyrimidine-4-yloxy)phenyl) acrylate C22H17N3O5
Mol. Wt.: 119.12 Mol. Wt.: 403.39
C15H13ClN2O4
2-Cyanophenol
Mol. Wt.: 320.73 Azoxystrobin
CAS: 611-20-1
CAS: 131860-97-4

Process Description: Methyl-3-methoxy-2-(2-(6-chloropyrimidine-4-

yloxy)phenyl)acrylate, 2-Cyanophenol, catalytic amount of 18-crown-6 ether and DMF
are charged at room temperature. K2CO3 is charged at 25-35˚C. The resulting reaction
mass is heated to 75-80˚C for 2-3 hrs. When reaction completes, distil out solvent from

1-50 Team Labs and Consultants

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reaction mass. Water is charged at RT, separate the organic layer and distilled out to get
the crude product. The resulted crude product is crystallized in Methanol to get the
crystalline solid. Process flowdiagram of Azoxystrobin is shown in Fig 2.26 and material
balance for Azoxystrobin is presented in Table 2.26

Fig 2.26 Process Flow Diagram of Azoxystrobin

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2.1.27 Process Description of Trifloxystrobin

Reaction Schemes
Stage I:
O
O
N
N O O
O O MDC
Br O N O
+
+ O N O H
AIBN
Br (E)-methyl-2-(2-bromomethyl
(E)-methyl-2-(2-methylphenyl)-2- phenyl)-2-methoxyiminoacetate Succinimide
methoxyiminoacetate NBS

C11H13NO3 C4H4BrNO2 C4H5NO2

C11H12BrNO3
Mol. Wt.: 207.23 Mol. Wt.: 177.98 Mol. Wt.: 99.09
Mol. Wt.: 286.12

Stage II:

OH
O N
Methanol
NH2OH. HCl NaOH + 2 H2O + NaCl
+ +
F F F F
F F
Hydroxyl amine Sodium Hydroxide 3-(Trifluromethyl)acetophenone
3-(Trifluromethyl)acetophenone Hydrochloride oxime
C9H7F3O HNaO C9H8F3NO Mol. Wt.: Mol. Wt.:
ClH4NO
Mol. Wt.: 188.15 Mol. Wt.: 40.00 Mol. Wt.: 203.16 18.02 58.44
Mol. Wt.: 69.49
2X18= 36

Stage III:
O O
N OH N
O O N O O
DMF
N
Br + + K2CO3 O
+ KBr + KHCO3
F F
F F
(E)-methyl-2-(2-bromomethyl 3-(Trifluromethyl)acetophenone Potassium Carbonate
phenyl)-2-methoxyiminoacetate oxime Trifloxystrobin F
F
C11H12BrNO3 C9H8F3NO
Mol. Wt.: 286.12 Mol. Wt.: 203.16 Mol. Wt.: 138.21 C20H19F3N2O4 Mol. Wt.: Mol. Wt.:
Mol. Wt.: 408.37 119.00 100.12

Process Description:
Stage I: To a solution of (E)-methyl-2-(2-methylphenyl)-2-methoxyimino acetate in MDC,
N-Bromosuccinimide (NBS), catalytic amount of AIBN are charged and the resulting
reaction mass is heated to reflux for 4-5 hrs. After completion of starting material, water
is charged at RT and separate the organic layer. Organic layer is distill out to get the
crude product. The resulted crude product is crystallized in 5% Ethyl acetate and n-
Heptane to get the crystalline solid.
Stage II: To a solution of 3’-(Trifluoromethyl)acetophenone, Hydroxyl amine
Hydrochloride in Methanol, aqueous Sodium Hydroxide solution is added slowly at RT.
The resulting reaction mass is stirred for 8-10 hrs. After completion of starting material,

1-52 Team Labs and Consultants

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distill out the aqueous Methanol completely. Water is charged into crude, stirred for 30
minutes and filtered the precipitated product. The resulted wet cake is dried in vacuum
oven at RT for 10 hrs.
Stage III: To a solution of 3-(Trifluoromethyl)acetophenone oxime in DMF, K2CO3 is
charged and stir for 30 mins at RT. To this solution (E)-methyl-2-(2-bromomethylphenyl)-
2-methoxyiminoacetate is charged and stirred for 24 hrs at 15- 20˚C . After completion of
starting materials, RM is filtered and distill-out the DMF completely to get crude. The
resulted crude is diluted with Toluene and wash with water. Separate the organic layer
and distilled out completely. The resulted crude crystallized in Methanol to get the
Trifloxystrobin as a white solid. Process flowdiagram of Trifloxystrobin is shown in Fig
2.27 and material balance for Trifloxystrobin is presented in Table 2.27
Stage I:

1-53 Team Labs and Consultants

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Stage II:

Stage III:

Fig 2.27 Process Flow Diagram of Trifloxystrobin

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2.1.28 Process Description of Pendimethalin

Reaction Schemes
Stage I:

Process Description:
Stage I: NEPDA is charged to 1,2-dichloroethane at room temperature. Conc H2SO4 is
added to the reaction mixture at 20-25°C. 70% strength HNO3 is added slowly to the
reaction mixture at 20-25°C. Maintained for 1.0 h at 20-25°C and separated the layers.
Conc HCl is added to organic layer and stirred at room temperature for 2.0 h. The
organic layer is evaporated to give desired PENDIMETHALIN-TECHNICAL. Process
flowdiagram of Pendimethalin is shown in Fig 2.28 and material balance for
Pendimethalin is presented in Table 2.28

Fig 2.28 Process Flow Diagram of Pendimethalin

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2.1.29 Process Description of Pretilachlor

Reaction Schemes
Stage I:

Stage II:

Process Description:
Stage I: 2,6 Diethylaniline (DEA) is reacted with Chloro Propoxy Ethane (CPE) to give
intermediate N Propoxy Ethyl 2,6 Diethyl Aniline hydrochloride (PEDA.HCl) at 130 deg
C. After the reaction, reaction mass is neutralised with caustic at room temperature upto
pH 7.0. Aq.layer containing NaCl is separated out and organic layer PEDA is washed
with water and taken to the Pretilachlor reaction.

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Stage II: The crude PEDA is washed with water and caustic & NaCl solution is
separated. The organic layer (PEDA) is taken into solvent toluene and chloro acetyl
chloride is gradually added to form Pretilachlor at 60 deg C. After reaction, the mass is
filtered and the product is concentrated. Process flowdiagram of Pretilachlor is shown in
Fig 2.29 and material balance for Pretilachlor is presented in Table 2.29

Fig 2.29 Process Flow Diagram of Pretilachlor

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2.1.30 Process Description of Metribuzin

Reaction Schemes
Stage I:
O
O
NH2
N
NaOH NH2
x + (CH3O)2SO2 N
2
N H2SO4 2 x
N SH N
Mol. Wt.: 126
H2O N S

C7H12N4OS C8H14N4OS
Mol. Wt.: 200.26 Mol. Wt.: 214.29

+
SO42-
96

Process Description:
Stage I: 88% H2SO4 is charged into the reactor and heated to 50-55°C. Butylthione is
added to the reaction mixture lot wise at 50-55°C. Dimethyl sulphate is added to the
reaction mass slowly for 1.0 hr at 50-55°C. The reaction is monitored by GC. When the
starting material is below 2%, reaction mass pH is adjusted to 8 to 8.5 by using 20%
NaOH solution. The mixture is maintained at RT for 3.0 hours. Reaction mass is filtered,
washed with water. Cake is purified with water and dried to get pure Metribuzin
technical. Process flowdiagram of Metribuzin is shown in Fig 2.30 and material balance
for Metribuzin is presented in Table 2.30.
BUTYTHION
SULPHURIC ACID S-METHYLATION
DMS

SODIUM HYDROXIDE
WORK UP
WATER

AQUEOUS

FILTRATION

METRIBUZIN WET

DRYING

METRIBUZIN TECHNICAL

Fig 2.30 Process Flow Diagram of Metribuzin

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2.1.31 Process Description of Dimethomorph

Reaction Schemes
Stage I:

Process Description:
Stage I: To the stirred solution of benzophenone in toluene was added sodium hydroxide
and N-acetyl morpholine reaction was then heated at 105 °C for 8h. After completion of
reaction water was added and layer was separated. Half of the toluene was recovered
and product was crystallized in toluene then filtered and dried to get dimethomorph.
Process flowdiagram of Dimethomorph is shown in Fig 2.31 and material balance for
Dimethomorph is presented in Table 2.31

Fig 2.31 Process Flow Diagram of Dimethomorph

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2.1.32 Process Description of Clodinofop-Propargyl

Reaction Schemes
Stage I:
F

Cl F O
O KO O

+ DMF
+ 2 K2CO3 + 2 + KF
KHCO3
N
N F O OH OH Cl O
C5H2ClF2N FK
C9H10O4 CK2O3 C14H11ClFNO4
Mol. Wt.: 149.53 Mol. Wt.: 182.17 Mol. Wt.: 311.69 Mol. Wt.: 100.15
Mol. Wt.: 138.21 Mol. Wt.: 58.10

Stage II:

F
F
O O O
O KO O + KCl

+ Cl
N
N Cl O
Cl O

CLODINOFOP-PROPARGYL

C14H10ClFKNO4 C3H3Cl
C17H13ClFNO4
Mol. Wt.: 349.78 Mol. Wt.: 74.51 Mol. Wt.: 349.74
ClK
Mol. Wt.: 74.55

Process Description:
Stage I: (R) –(+) -2-(4-Hydroxy phenoxy) propionic acid ( DHPPA ) and
dimethylformamide are taken in reactor at room temperature. Reaction mixture
temperature is raised to 30 to 35 °C and Potassium carbonate is added to the above
mixture over a period of 15- 20 minutes. During the addition slight exothermic nature of
reaction mass is observed. The reaction mixture is stirred at 100 to 105 °C for half an
hour. Reaction mixture is cooled to RT.

2,3 Difluoro 5-chloro pyridine is added to the reaction mixture at 30-35 °C for 2 hours
and maintained for 4 hours at 100-105 °C . If unreacted DHPPA is < 0.5% by HPLC area
then reaction should be terminated and used in the next step.

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to the reaction mixture for 2 hours at 30--35 °C and maintained for half an hour.
Reaction temperature is raised to 40-45 °C and maintained for 10 hours at same
temperature. Monitored the reaction mass for un-reacted stage-I by HPLC and
propargyl chloride content by G.C. If un-reacted Stage –I is < 0.5%, reaction should be
terminated. The reaction mass is filtered and cake is washed with dimethylformamide.
Solvent is removed completely under reduced pressure at 60 °C for 2-to 3 hours. Water
is added to the crude mass, it is cooled to room temperature slowly. It is further cooled
to 0-5°C maintained for 2-3 hours. Reaction mass is filtered and washed with water to
obtain Clodinofop-propargyl Technical, which is dried. Process flowdiagram of
Clodinofop-Propargyl is shown in Fig 2.32 and material balance for Clodinofop-
Propargyl is presented in Table 2.32.

Fig 2.32 Process Flow Diagram of Clodinofop-Propargyl

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2.1.33 Process Description of Bispyribec Sodium

Reaction Schemes

O
N

COOH O
COONa
O S O N
HO OH O
+ 2 CH3SOONa
N N + O
+ 2 3 NaOH
N
O O
N
O

C7H6O4 C7H10N2O4S HNaO CH3NaO2S

Mol. Wt.: 218.23 Mol. Wt.: 40.00 C19H17N4NaO8
Mol. Wt.: 154.12 Mol. Wt.: 102.09
Mol. Wt.: 452.35

3 H2O
+
H2O
Mol. Wt.: 18.02

Process Description:
Dihydroxybenzoic acid, toluene, TBAB and NaOH are charged at 25-30°C. Reaction
mixture is heated to 100°C and water collected by azeotropic distillation for 3-4hrs.
Sodium salt is formed in the reaction which is cooled to 70°C. 4,6dimethoxy-2-
methylsolphonyl pyridine(DMSP) and toluene are added to the reaction mixture, heated
to 80°C and maintained for 8-10 hours. Reaction mixture is cooled to 25-30°C and the
reaction mixture is filtered. The solid is washed with toluene. Product is further purified
in acetone. Process flowdiagram of Bispyribec Sodium is shown in Fig 2.33 and material
balance for Bispyribec Sodium is presented in Table 2.33.

1-62 Team Labs and Consultants

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DIHYDROXY BENZOIC ACID

TOLUENE
TBAB CONDENSATION & SALT
NaOH FORMATION
DMSP

TOLUENE WORK UP

AQUEOUS

ACETONE BIS-PYRIBAC CRUDE

SODIUM BICARBONATE

WORKUP

FILTRATION

AQUEOUS

DRYING

BIS-PYRIBAC TECHNICAL

Fig 2.33 Process Flow Diagram of Bispyribec Sodium

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2.1.34 Process Description of Bensulfuron Methyl

Reaction Schemes
Stage I:

Process Description:
Stage I: Charge xylene and 4,6- Dimethoxy pyrimidine -2-amines and Heat the reaction
mass to 60 oC then Add solution of Methyl-2- {[Isocyanate sulfamoyl] Methyl} Benzoate
in xylene gradually over a period 2-3 hrs. at 60-65 oC then Maintain reaction mass at 60-
70 oC for 10 hrs. and check the unreacted 4-6 Dimethoxy pyrimidine -2-amine.
After completion of reaction, distill out xylene under vacuum 20 mm/Hg at 80 oC.and
To the residue, add methanol and heat reaction mass to 60 oC for one hrs. And cool it to
room temperature for 2 hrs and filter the solid and wash with methanol.Dry the solid at
70 oC for 3 hrs Rxn. of Methyl-2- {[Isocyanate Sulfamoyl] Methyl} Benzoate with 4, 6-
Dimethoxy pyrimidine -2- Amine to form Bensulfuran Methyl Tech. Process
flowdiagram of Bensulfuron Methyl is shown in Fig 2.34 and material balance for
Bensulfuron Methyl is presented in Table 2.34.

1-64 Team Labs and Consultants

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Fig 2.34 Process Flow Diagram of Bensulfuron Methyl

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2.1.35 Process Description of Glufosinate Ammonium

Reaction Schemes
CN
O

P NH2 + HPO3Na2 + 2 H2O +

+ H2PO3Na 4HCl
OH
H2NaO3P HNa2O3P H2O ClH
C5H11N2O2P Mol. Wt.: 36.46
Mol. Wt.: 103.98 Mol. Wt.: 125.96 Mol. Wt.: 18.02
Mol. Wt.: 162.13
2x18.02=36.04 4x36.46=145.
84

O O

P OH
+ 2 H3PO3 + 3NaCl + NH4Cl
OH

NH2 H3O3P ClNa ClH4N

Mol. Wt.: 82.00 Mol. Wt.: 58.44 Mol. Wt.:
C5H12NO4P 53.49
Mol. Wt.: 181.13 2x82=164 3x58.44=175.32
Process Description:
20% Aqueous sodium phosphate solution is charged in to reactor at room temperature.
10% Aqueous disodium phosphate solution is charged at room temperature. (3-amino-3-
cyano-propyl)-methyl-phosphinic acid is added at 25°C for 2 hours. The reaction mixture
is heated to 65-70°C and stirred for 10 hour. The reaction mass is cooled to room
temperature. 30% Aqueous hydrochloric acid is added to adjust pH 3-4. The reaction
mixture is filtered and material is used in the next step without further purification.
Process flowdiagram of Glufosinate Ammonium is shown in Fig 2.35 and material
balance for Glufosinate Ammonium is presented in Table 2.35.

1-66 Team Labs and Consultants

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Fig 2.35 Process Flow Diagram of Glufosinate Ammonium

2.1.36 Process Description of Quizalofop-p-ethyl
Reaction Schemes
Stage I:

O S O
O
OH TEA O S O

O + O HCl
+

O O

ClH
M.Wt:118.3 M.Wt:190.65
M.Wt:272.3 Mol. Wt.: 36.46

Stage II:
Cl

Cl N
N
N OH

N
+ + 2 KOH
O + KCl + 2 H2O

Cl OH

HKO H2O
OK ClK
M.Wt:110 Mol. Wt.: 56.11 C14H8ClKN2O2 Mol. Wt.: 18.02
M.Wt:199 Mol. Wt.: 74.55 1
Mol. Wt.: 310.78

1-67 Team Labs and Consultants

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Stage III:
O
OK
O
O O
O
O
O S O O OK
N
+ O O
O S
N +
N
Cl N

STAGE:I STAGE II QUIZALOFOP-P-ETHYL C7H7KO3S

M.Wt:272.3 M.Wt:294.69 M.Wt:372.5 Mol. Wt.: 210.29

Process Description:
Stage I: (-) L- Ethyl lactate, triethyl amine (TEA) are charged to the reactor at 25-30 °C.
Reaction mixture is cooled to 0-5°C. TBAB, DMF and p-Toluenesulfonyl chloride are
added to the reaction mixture at 0-5°C and stirred for 8-10 hours at the same
temperature. If reaction completed then added Toluene at 0-5° C and stirred for 15-30
minutes. H2O is charged at 0-5° C and raised temperature to 25-30° C. Layers are
separated, the organic layer is washed NaHCO3, water and followed by brine. Organic
layer is distilled completely under vacuum at 45° C, obtained the residue. The residue is
taken for the next step. The below is chemical reaction with material balance.
Stage II: 2, 6 Dichloroquinoxaline, Hydroquinone are charged in to the reactor at room
temperature. KOH solution (KOH dissolved in H2O) is added to the reaction mixture at
room temperature. The reaction mixture is heated to 88-90° C and stirred for 8-10 hours.
Reaction mixture is cooled to 45-50° C, H2O is charged to the reactor at 45-50°C and
Stirred for 1-2 hours at same temperature. Reaction mixture was filtered and washed
with H2O to obtain the solid. Solid was dried under reduced pressure at 50-55°C. The
solid is taken for the next step.

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Stage III: Solid of stage-II material, K2CO3 are charged in cyclohexane at 25-30°C.
Reaction mixture is heated to 100°C and water collected by Azeotropic distillation at
100°C for 2-3 hours. The residue of stage-I is charged to the reaction mixture at 110°C
and stirred for 12-14 hours at 110°C. Reaction mixture is cooled to 80°C and filtered the
salts at 80°C. The solids are washed with hot cyclohexane. The filtrate is cooled to 10-
15°C and stirred for 6-8 hours at 10-15°C. Filtered the solid and washed with chilled
cyclohexane, obtained the solid. The solid is dried under reduced pressure to give
Quizalofop-P-ethyl Technical. The below is chemical reaction. Process flowdiagram of
Quizalofop-p-ethyl is shown in Fig 2.36 and material balance for Quizalofop-p-ethyl is
presented in Table 2.36.

1-69 Team Labs and Consultants

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Fig 2.36 Process Flow Diagram of Quizalofop-p-ethyl

1-70 Team Labs and Consultants

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2.1.37 Process Description of Tribenuron Methyl

Reaction Schemes
Stage I:
O O

O N N O O O
O + O O
N + OH
S O N N O S N
NH2 NH
O O N
N
C8H9NO4S C2H6O
C9H14N4O3 C15H17N5O6S
Mol. Wt.: 215.23 Mol. Wt.: 46.07
Mol. Wt.: 226.23 Mol. Wt.: 395.39

Process Description:
Stage I: Methyl 2-(aminosulfonyl)benzoate, acetonitrile are charged in the reactor at 25-
30° C and cooled to 0-5° C. 1,8-Diazabicyclo[5.4.0]undec-7-ene (DBU) is charged to the
reactor and stirred for 15 minutes. 2-Methoxy-4-methyl-6-(methylamino ethyl
carbamate)-1,3,5-triazine is dissolved in acetonitrile and charged to reaction mixture at
0-5° C, maintained for 4-5 hrs. Water and 1.0 N HCl are added at 0-5°C and stirred for 1
hour. Reaction mixture is filtered; Filter is washed with water. The solid is dried under
vacuum at 45-50° C for 5-6 hours to get Tribenuron-methyl Technical. The below is the
chemical reaction with material balance. Process flowdiagram of Tribenuron Methyl is
shown in Fig 2.37 and material balance for Tribenuron Methyl is presented in Table
2.37.

1-71 Team Labs and Consultants

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Methyl 2-(aminosulfonyl)benzoate

2-Methoxy-4-methyl-6-
(methylamino ethyl carbamate)-1,3,5-triazine COUPLING
Acetonitrile
DBU

Water
Workup
Hydrochloric acid

Filtration Aqueous

Drying

TRIBENURON-METHYL

Fig 2.37 Process Flow Diagram of Tribenuron Methyl

2.1.38 Process Description of Clethodim
Reaction Schemes
Stage I:
O O
O N
O OH Cl
O
+ ClH.H N Cl + H2O + HCl
2 S OH

S
C14H22O3S C3H7Cl2NO C17H26ClNO3S H2O ClH
Mol. Wt.: 270.39 Mol. Wt.: 144.00 Mol. Wt.: 359.91 Mol. Wt.: 18.02 Mol. Wt.: 36.46

Process Description:
5-[2-(Ethylthio) propyl]-3-hydroxy-2-propionyl-2-cyclohexen-1-one, hexane are charged
to the reactor at room temperature. O-(3-Chloro allyl) hydroxylamine hydrochloride is
added to the reactor at RT. Resulting mixture is heated to 30ºC and maintained for 8

1-72 Team Labs and Consultants

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hours. Reaction is monitored by chromatographic technique and after completion of

reaction, reaction mass is subjected for work up to get the desired Clethodim technical.
Process flowdiagram of Clethodim is shown in Fig 2.38 and material balance for
Clethodim is presented in Table 2.38.

Fig 2.38 Process Flow Diagram of Clethodim

2.1.39 Process Description of Pinoxsulam
Reaction Schemes
Reaction Scheme:

Process Description:
To the mixture of trizolopyrimidine amine, DMSO and pyridine was added substituted
benzene sulphonyl chloride and reaction mixture was stirred for 8h. After completion of

1-73 Team Labs and Consultants

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reaction DMSO is distilled out completely. To the crude mixture water was added,
stirred and filtered. Filtrate was dried completely to afford desired product as
penoxsulam. Process flowdiagram of Pinoxsulam is shown in Fig 2.39 and material
balance for Pinoxsulam is presented in Table 2.39.

DMSO
Reaction
Trizole pyrimidine amine
Benzene sulphonyl Chloride

DMSO
Distillation
Water

Crystallization

MLR
Filtration

Drying

Product

Fig 2.39 Process Flow Diagram of Pinoxsulam

2.1.40 Process Description of S-Metolachlor

Reaction Schemes
Stage I:

NH2
N
O
O + H2SO4 H2O H2SO4
+ + +

C9H13N C4H8O2 H2O4S C13H19NO H2O H2O4S

Mol. Wt.: 135.21 Mol. Wt.: 88.11 Mol. Wt.: 98.08 Mol. Wt.: 205.30 Mol. Wt.: 18.02 Mol. Wt.: 98.08

1-74 Team Labs and Consultants

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Stage II:

O
O
H
N
NH
Pd/C
+ H2 +

H2
C13H19NO Mol. Wt.: 2.02
Mol. Wt.: 205.30
C13H21NO
Mol. Wt.: 207.31

Note: Palladium/ Carbon is catalyst. Pd/ C is recovered aftercompletion of reaction.

Stage III:

O O
O
H H
Cl
NH N
Cl O
+ + NaHCO3 NaCl + H2O
+ CO2 +
Cl
C13H21NO C2H2Cl2O C15H22ClNO2 CO2 ClNa H2O
CHNaO3
M. Wt.: 207.31 M Wt.: 112.94 M. Wt.: 84.01 M. Wt.: 283.79 M. Wt.: 44.01 M Wt.: 58.44 M. Wt.: 18.02

Process Description:
Stage I: Methoxyacetone, 2-methyl-6-ethyl aniline and hexane are charged in the
reactor at RT. H2SO4 is added catalytic amount to the mixture at RT. The resulting
mixture is heated to 80-85ºC and maintained at same temperature for 6.0 h. After
reaction completion, solvent is removed under reduced pressure at 80-85ºC to give
yellow oil. The yellow oil is used in the next reaction without further purification.
Stage II: Stage-I product (yellow oil product), ethylene chloride are charged in the
hydrogenation reactor at RT. Palladium on carbon is charged into reactor at RT. Reactor
is purged with nitrogen 3 times. Reactor is filled with H2 and evacuated and again H2
is filled freshly. The resulting mixture is heated to 40-45ºC and 3.0MPa pressure
maintained for 5.0 h. After reaction completion, the material is filtered to recover

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palladium/carbon. Water is added to the filterate, solvent is removed at atmospheric

pressure. Solid is formed when material is cooled to room temperature and solid is
filtered to get S-configuration compound. This compound is used in the next reaction
without further purification.
Stage III: Step-II(S-configuration product), dichloroethane are charged in the reactor at
RT. NaHCO3 is added to reactor at Room temperature. The resulting solution is cooled
to -5ºC with chilled brine water. Chloroacetyl chloride is added to the reactor at -5ºC
(during addition temperature should not exceed more than -5ºC). Reaction is
maintained for 5h at same temperature. Water is added to the reactor and separated
layers. Solvent is removed from organic layer under reduced pressure to get S-
Metolachlor technical. Process flowdiagram of S-Metolachlor is shown in Fig 2.40 and
material balance for S-Metolachlor is presented in Table 2.40.

1-76 Team Labs and Consultants

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1. 2-methyl-6-ethylaniline
2. Methoxy acetone Charge at RT
3. Hexane

H2SO4 Addition at RT

Heat to 80-85°C and

maintained for 6h

Solvent
Distillation
recovery

Yellow oily compound

(stage-I)
Without purification next
reaction
1. EDC Charge to stage-I at
2.Pd/C RT

Gas filling at RT
H2 gas

Heated to 40-45°C and

maintained for 5h

Recovered
Filtered Pd/C

Recovered
Charged at RT Pd/C
Water

Recovered
Distillation
EDC

Colled to 0°C &

Filteration
Aqueous
waste

Solid (Stage-II)

1-77 Team Labs and Consultants

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1. Stage-II
2. Dichloroethane Charge at RT
3. NaHCO3

Cooled to -5°C

Chloroacetyl chloride Charge at -5°C and

maintainened for 5h

Water Charged at 5°C

Layers separation
Aqueous waste

Organic Layer

Distillation Solvent recovery

S-Metolachlor
Technical

Fig 2.40 Process Flow Diagram of S-Metolachlor

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2.1.41 Process Description of Verbinone

Reaction Schemes
Stage I:

Process Description:
Stage I: Alpha Pinene reacts with TBHP (70%) in presence of Copper Iodide and
Oxygen using acetonitrile as solvent at ambient temperature. The reaction mass is then
diluted with water and extracted using MTBE solvent, distilled to yield the title
compound. Process flowdiagram of Verbinone is shown in Fig 2.41 and material
balance for Verbinone is presented in Table 2.41.

Fig 2.41 Process Flow Diagram of Verbinone

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2.1.42 Process Description of (Z)-hezatec – 11-en-1-yl acetate

Reaction Schemes
Stage I:

Process Description:
Stage I: Hexadecynol is reduced in presence of Nickel and Sodium borohydride
catalyst using Hydrogen and Methanol as solvent. The crude is then distilled to recover
solvent, diluted with MTBE and extracted suing MTBE and purified to yield the stage 1
compound. The stage 1 is then esterified using Acetic acid/Toluene mixture in presence
of acid catalyst, worked up to yield the title compound. Process flowdiagram of (Z)-
hezatec – 11-en-1-yl acetate is shown in Fig 2.42 and material balance for (Z)-hezatec –
11-en-1-yl acetate is presented in Table 2.42.

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Fig 2.42 Process Flow Diagram of (Z)-hezatec – 11-en-1-yl acetate

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2.1.43 Process Description of (Z)-hezatec – 9-enal

Reaction Schemes
Stage I:

Process Description:
Stage I: Hexadecynol is reduced in presence of Nickel and Sodium borohydride
catalyst using Hydrogen and Methanol as solvent. The crude is then distilled to recover
solvent, diluted with MTBE and extracted suing MTBE and purified to yield the stage 1
compound. The Stage 1 compound is then oxidized in MDC as solvent using PCC,
distilled to yield the title compound. Process flowdiagram of (Z)-hezatec – 9-enal is
shown in Fig 2.43 and material balance for (Z)-hezatec – 9-enal is presented in Table
2.43.

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Fig 2.43 Process Flow Diagram of (Z)-hezatec – 9-enal

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2.1.44 Process Description of (8E,10E) – Dodoca-8, 10-dyen-1-ol

Reaction Schemes
Stage I:

Process Description:
Stage I: The chloro compound reacts with Magnesium in THF in presence of
copper/Lithium catalyst which then further reacted with acetate compound to yield
stage 1. It is then desalinated using acid catalyst in Methanol to yield the title
compound. Process flowdiagram of (8E,10E) – Dodoca-8, 10-dyen-1-ol is shown in Fig
2.44 and material balance for (8E,10E) – Dodoca-8, 10-dyen-1-ol is presented in Table
2.44.

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Fig 2.44 Process Flow Diagram of (8E,10E) – Dodoca-8, 10-dyen-1-ol

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2.1.45 Process Description of 7Z,11Z hexadeca dienyl acetate

Reaction Schemes
Stage I:

Process Description:
Stage I: The Chloro olefinic compound reacts with Magnesium in presence of
Iodine/Dibromo ethane to yield the magnesium the magnesium complex which is then
further reacted with bromo compound to yield the Stage 1 Ester. It is then reduced
using Nickel and sodium borohydride catalyst using Hydrogen in Methanol which
after isolation yield the title compound. Process flowdiagram of 7Z,11Z hexadeca dienyl
acetate is shown in Fig 2.45 and material balance for 7Z,11Z hexadeca dienyl acetate is
presented in Table 2.45.

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Fig 2.45 Process Flow Diagram of 7Z,11Z hexadeca dienyl acetate

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2.1.46 Process Description of 7E, 9Z dodoca dienyl acetate

Reaction Schemes
Stage I:

Process Description:
Stage I: The chloro aldehyde reacts with phosphonium bromide salt in presence of base
in THF to yield the Stage 1. This is isolated and then reaction with potassium acetate in
DMF to yield the title compound. Process flowdiagram of 7E, 9Z dodoca dienyl acetate
is shown in Fig 2.46 and material balance for 7E, 9Z dodoca dienyl acetate is presented
in Table 2.46.

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Fig 2.46 Process Flow Diagram of 7E, 9Z dodoca dienyl acetate

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2.1.47 Process Description of 8Z Dodecinyl acetate

Reaction Schemes
Stage I:

Process Description:
Stage I: The Dodecynol is reduced using Hydrogen in Methanol using Nickel and
sodium borohydride /EDA to yield the Stage 1 alcohol. It is then esterified using Acetic
acid /Toluene using Acid catalyst, isolated to yield the title compound. Process
flowdiagram of 8Z Dodecinyl acetate is shown in Fig 2.47 and material balance for 8Z
Dodecinyl acetate is presented in Table 2.47.

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Fig 2.47 Process Flow Diagram of 8Z Dodecinyl acetate

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2.1.48 Process Description of (Z)-Octadeca – 13 – enyl acetate

Reaction Schemes
Stage I:

Process Description:
Stage I: 13Octadecynol reacts with Sodium borohydride and Nickel acetate in presence
of Hydrogen gas using Methanol as solvent to yield Stage 1. It is then esterified using
Acetic acid and Toluene using a acid catalyst to yield Title compound. Process
flowdiagram of (Z)-Octadeca – 13 – enyl acetate is shown in Fig 2.48 and material
balance for (Z)-Octadeca – 13 – enyl acetate is presented in Table 2.48.

Fig 2.48 Process Flow Diagram of (Z)-Octadeca – 13 – enyl acetate

1-92 Team Labs and Consultants

Table 2.1 Material Balance of Cloquintocet mexyl

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
5-Chloro 8-hydroxy quinoline 850.3 Cloquintocet mexyl 1000 Final Product
Dimethylformamide (DMF) 3400 Potassium Chloride 443.7 To Waste Water
Potassium carbonate 823.1 Potassium bicarbonate 595.6 To Waste Water
Mono chloro acetic acid 281.4 Water 53.6 To Waste Water
2-Heptanol 346 Solvent
Water 1500 DMF
Hydrochloric Acid 107.5 DMF Recovered 3230 Recovered and reuse
DMF Loss 17 Fugitive loss
DMF Residue 153 Solvent residue
Organic
5-Chloro 8-hydroxy quinoline 315.4 Organic Residue
Water 1500 To Waste Water
Total Input 7308.3 Total Output 7308.3
Table 2.2 Material Balance of Triazinone
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Isoamylene 302 Triazinone 1000 Final product
30% HCL 1211 30% HCL 2470 By-product
Formaldehyde 563 NASH solution 1300 By-product
Cl2 gas 870 Solvents
HH 750 Xylene
Cat 1 1 Xylene Recovered 340 Recovery & reuse
Cat 2 18 Xylene Loss 2 Fugitive loss
CS2 537 Xylene Residue 9 Solvent in residue
NaOCl 4500 Organics Residue 1200 Organic Residue
HTDS 1289 To Waste Water
H2SO4 758 LTDS 2100 To Waste Water
Water 3236 Moisture loss 150 To Waste Water
Xylene 350.0 Water 3236 To Waste Water
Total Input 13095.0 Total Output 13095.0
Table 2.3 Material Balance of Profenofos
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Ortho Chloro Phenol 390.0 Profenofos 1000.0 Final Product
Bromine 428.0 Hydrogen bromide 216.7 To Scrubber By Product
Diethyl Thiophosphoryl chloride 504.8 Proplethyl ammonium bromide 450.2 Organic residue
Sodium hydroxide 506.0 Sodium Chloride 739.1 To wastewater
n-propyl bromide 329.4 Unreacted Organics
Trimethyl Amine Sulfate 25.0 Ortho Chloro Phenol 45.9 To wastewater
Trimethyl Amine 220.0 Trimethyl Amine Sulfate 25.0 To wastewater
Water 1500.0 Trimethyl Amine 61.7 To wastewater
Hydrogen Chloride 363.5 Unreacted Inorganics
Sodium hydroxide 398.9 To Neutralization
Water 1727.9 To wastewater
Total Input 4266.7 Total Output 4266.4
Table 2.4 Material Balance of Thiamethoxam

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
3-Methyl-4-nitroimino- 742 Thiamethoxam 1000 Final Product
tetrahydro-1,3,5-
oxadiazine
2-chloro 5-chloromethyl 576 Potassium Bicarbonate 343.2 Inorganic Residue
thiazole
Potassium Carbonate 473.7 Potassium Chloride 255.6 Inorganic Residue
Dimethylformamide 10806 Solvent
(DMF)
DMF
DMF Recovered 10265.7 Recovery & reuse
DMF Loss 54 Fugitive loss
DMF Residue 486.3 Solvent in residue
Organic
3-Methyl-4-nitroimino- 193.1 Organic Residue
tetrahydro-1,3,5-
oxadiazine
Total Input 12597.8 Total Output 12597.8
Table 2.5 Material Balance of Fipronil
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
5-amino-3-cyano-1-(2,6-dichloro-4- 1100 Fipronil 1000 Final Product
trifluoromethylphenyl)-4-
trifluoromethylthio pyrazole
Hydrogen peroxide 162 Water 41.2 To waste water
Sulphuric acid 425 Solvent
Sodium bicarbonate 100 Ethylene dichloride (EDC)
Ethylene dichloride (EDC) 4200 EDC Recovered 4074.0 Recovered and reuse
Water 4840 EDC loss 14.7 Fugitive loss
Sodium hydroxide 346.7 EDC in water 8.4 To waste water
EDC in residue 102.9 Solvent residue
Unreacted Organics
5-amino-3-cyano-1-(2,6-dichloro-4- 136.8 organic residue
trifluoromethylphenyl)-4-
trifluoromethylthio pyrazole
Unreacted Inorganics
Hydrogen peroxide 84.2 To waste water
Sodium bicarbonate 100 To waste water
Sodium sulphate 615.4 To waste water
Water 4996 To waste water
Total Input 11173.6 Total Output 11173.6
Table 2.6 Material Balance of Imidacloprid
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
6-methoxy-3-pyridine 750.0 Imidacloprid 1000.0 Final Product
carboxaldehyde dimethyl acetal
Chlorine 277.7 Hydrogen chloride 285.5 To scrubber
2-nitroimino) imidazolidine 765.7 Solvent
Phosphorus trichloride 225.0 Toluene
Sodium hydroxide 326.0 Toluene Recovered 4850.0 Recovered and reuse
Toluene 5000.0 Toluene loss 17.5 Fugitive loss
water 2500.0 Toluene in residue 132.5 Solvent residue
Hydrogen Chloride 297.475 Unreacted Organics
6-methoxy-3-pyridine 251.3 organic residue
carboxaldehyde dimethyl acetal
2-nitroimino) imidazolidine 256.6 organic residue
Unreacted Inorganics
Phosphorus trichloride 225.0 To waste water
Sodium Chloride 476.0 To waste water
Water 2646.9 To waste water
Total Input 10141.9 Total Output 10141.3
Table 2.7 Material Balance of Acetamiprid
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
N-Cyano methyl Acetamide (NCMA) 520 Acetamiprid 1000.0 Final product

2-chloro 5 - (methyl amino methyl) 830 Methanol 143.8 Recovery & reuse
pyridine (CMAMP)
Methanol 1900 Solvents
Methanol
Methanol reovered 1843 Recovery & reuse
Methanol loss 9.5 Fugitive loss
Methanol residue 47.5 Solvent in residue
Organics
N-Cyano methyl Acetamide 79.6 Organic residue
(NCMA)
2-chloro 5 - (methyl amino 127.1 Organic residue
methyl) pyridine (CMAMP)
Total Input 3250.4 Total Output 3250.4
Table 2.8 Material Balance of Lambda Cyhalothrin
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Meta Phenoxy Benzaldehyde 448 Lambda Cyhalothrin 1000 Final product
TP Acid Chloride 610 Solvent
Sodium Cyanide 122 n-Hexane
n-Hexane 2381 n-Hexane Recovered 2262 Recovery & reuse
catalyst 10 n-Hexane Loss 12 Fugitive loss
Soda ash 952 n-Hexane Residue 107 Solvent in residue
Iso propyl alcohol (IPA) 1000 IPA
Catalyst 2 152 IPA Recovered 950 Recovery & reuse
8-10% Sodium hypochlorite 1429 IPA Loss 5 Fugitive loss
Water 1400 IPA to Waste Water 10 To wastewater
IPA Residue 35 Solvent in residue
Organic Residue
Meta Phenoxy Benzaldehyde 180 To wastewater
TP Acid Chloride To wastewater
Sodium Cyanide To wastewater
catalyst 162 To Solid Waste
Inorganic Residue
Soda ash 952.0 To wastewater
8-10% Sodium hypochlorite 1429.0 To wastewater
Water 1400.0 To wastewater
Total Input 8504.0 Total Output 8504.0
Table 2.9 Material Balance of Bifenthrin

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
2-Methyl-3-biphenyl methyl alcohol 520.0 Bifenthrin 1000.0 Final Product
Cyhalothric acid chloride 617.4 Hydrochloric Acid 86.2 To Scrubber by product
n-Hexane 600.0 Solvent
n-Hexane
n-Hexane Recovered 570.0 Recovery & reuse
n-Hexane Loss 3.0 Fugitive loss
n-Hexane Residue 27.0 Solvent in residue
Organic
2-Methyl-3-biphenyl methyl alcohol
51.2 Organic Residue
Total Input 1737.4 Total Output 1737.4
Table 2.10 Material Balance of Cypermethrin

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
Cypermethric acid chloride 562.2 Cypermethrin 1000.0 Final Product
M-Phenoxy benzaldehyde 476.1 Sodium Chloride 140.4 To Waste Water
n-Hexane 2053 Solvent
Water 1235 n-Hexane
Sodium Cyanide 117.7 n-Hexane Recovered 1950.4 Recovery & reuse
Catalyst 15 n-Hexane Loss 10.3 Fugitive loss
n-Hexane Residue 92.4 Solvent in residue
Organic
Cypermethric acid chloride 15.7 Organic Residue
Catalyst 15 To Solid Waste
Water 1235 To Waste Water
Total Input 4459.1 Total Output 4459.1
Table 2.11 Material Balance of Carbendazim

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
O-Phenylenediamine (98%) 707 Carbendazim 1000 Final Product
Calcium Cyanamide (60%) 419 Calsium Chloride 580.5 To Waste Water
Methyl Chloroformate (98%) 494.3 Ammonium Chloride 279.8 To Waste Water
Water 4595 Organic
18% Aq HCl (for Reaction) 381.3 O-Phenylenediamine 141.4 Organic Residue
(98%)
Water 4595 To Waste Water
Total Input 6596.5 Total Output 6596.6
Table 2.12 Material Balance of Pymetrozine
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
3-Pyridine carboxaldehyde 519 Pymetrozine 1000 Final Product
1,2,4 triazine-3 (4H) 1,4-Aamino- 620.9 water 82.9 carried along with
5,6-(dihydro-6-methyl) organic residue
Toluene 2000 Solvent
Toluene
Toluene Recovered 1940 Recovered and reuse
Toluene loss 7 Fugitive loss
Toluene in residue 53 Solvent residue
Unreacted Organics
3-Pyridine carboxaldehyde 26 organic residue
1,2,4 triazine-3 (4H) 1,4-Aamino-5,6- 31 organic residue
(dihydro-6-methyl)
Total Input 3139.9 Total Output 3139.9
Table 2.13 Material Balance of Emomectin Benzoate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Streptomycess averm emitis 50 Emomectin Benzoate 110 Final product
Anthelminic 45 Solvents
Acaricidal 50 Methanol
Methyl amine 20 Methanol recovered 291 Recovery & reuse
Methybenzoate 25 Methanol loss 0.3 Fugitive loss
Methanol 300 Methanol to wastewater 0.6 To wastewater
Water 744 Methanol residue 8.1 Solvent in residue
Organics
Residue 204 Organic Residue
Effluent 620 To wastewater
Total Input 1234.0 Total Output 1234.0
Table 2.14 Material Balance of Diafenthiuron

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
2, 6 - diisopropyl-4-phenoxy 860.1 Diafenthiuron 1000 Final Product
phenyl thiourea
Solvent C9 1500 Ammonia 44.2 To scrubber
Tert-Butyl Amine 190.2 Solvent
Acetonitrile 1500 Solvent C9
Solvent C9 Recovered 1425 Recovered and reuse
Solvent C9 Loss 7.5 Fugitive loss
Solvent C9 Residue 67.5 Solvent residue
Acetonitrile
Acetonitrile Recovered 1425 Recovered and reuse
Acetonitrile Loss 8 Fugitive loss
Acetonitrile Residue 67.5 Solvent residue
Organic
2, 6 - diisopropyl-4-phenoxy 6.0 organic residue
phenyl thiourea
Total Input 4050.3 Total Output 4050.2
Table 2.15 Material Balance of Propiconazole
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
2,4- Dichloroacetophenone 684.2 Propiconazole 1137 Final Product
pentane 1,2 diol 376 Hydrogen bromide 269 To scrubber byproduct
Bromine 532 Potassium bromide 398.9 To wastewater
1,2,4-triazole 251 water 119.7 To wastewater
Potassium hydroxide 204 Solvent
Sodium hydroxide flakes 323 Benzene
Benzene 100 Benzene Recovered 97 Recovered & reuse
Hexane 9000 Benzene loss 0.4 Fugitive loss
Dimethyl sulfoxide (DMSO) 1000 Benzene in residue 2.7 Solvent residue

water 2020 Hexane

Hexane Recovered 8730 Recovered & reuse
Hexane loss 31.5 Fugitive loss
Hexane in residue 238.5 Solvent residue
Dimethyl sulfoxide
(DMSO)
DMSO Recovered 970 Recovered & reuse
DMSO loss 3.5 Fugitive loss
DMSO in water 2 To waste water
DMSO in residue 24.5 Solvent residue
Unreacted organics
2,4- Dichloroacetophenone 55.2 Organic residue
pentane 1,2 diol 30.4 To waste water
1,2,4-triazole 20.2 To waste water
Unreacted Inorganics
Potassium hydroxide 16.4 To waste water
Sodium hydroxide flakes 323 To waste water
water 2020 To waste water
Total Input 14489.8 Total Output 14489.8
Table 2.16 Material Balance of Tricylazole
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
2-amino-4-methyl benzo thiazole 913 Tricylazole 1000 Final Product

Hydrazine 178 Ammonia 90 To scrubber

Formic acid 256 Water 190 To waste water
Dichloroethane (DCE) 2000 Solvent
Xylene 2000 Xylene
Water 3500 Xylene Recovered 1940 Recovered & reuse
Xylene loss 7 Fugitive loss
Xylene in residue 53 Solvent residue
Dichloroethane (DCE)
DCE Recovered 1940 Recovered & reuse
DCE loss 7 Fugitive loss
DCE in residue 53 Solvent residue
Unreacted organics
2-amino-4-methyl benzo 46 Organic residue
thiazole
Hydrazine 9 To waste water
Formic acid 13 To waste water
Unreacted Inorganics
Water 3500 To waste water
Total Input 8848 Total Output 8848
Table 2.17 Material Balance of Fenbucanazole
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Benzyl cyanide 408.7 Fenbucanazole 1000 Final product
Chloro styrene 483.5 Hydrochloric acid 108.4 To neutralization
Methyl chloride 297 Sodium chloride 347.2 To wastewater
Na.1,2,4Triazole 317 Solvents
Xylene 8000 Xylene
Dimethyl sulfoxide (DMSO) 100 Xylene recovered 7760 Recovery & reuse
Water 7000 Xylene loss 40 Fugitive loss
Sodium hydroxide 119 Xylene residue 200 Solvent in residue
Dimethyl sulfoxide (DMSO)
DMSO Recovered 97 Recovery & reuse
DMSO Loss 0.5 Fugitive loss
DMSO to Wastewater 1 To wastewater
DMSO to Residue 1.5 Solvent in residue
Organics
Benzyl cyanide 60.9 Organic residue
Chloro styrene 72 Organic residue
Methyl chloride 44.2 To wastewater
Na.1,2,4Triazole 47.3 To wastewater
Inorganics
Water 7054 To wastewater
Total Input 16725.1 Total Output 16725.2
Table 2.18 Material Balance of Myclobutanil
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
p-Chloro Phenyl Aceto 550.1 Myclobutanil 1000 Final Product
Nitrile (PCAN)
n-Butyl Bromide (NBB) 497.4 Sodium Bromide 1069.9 By Product
Sodium hydroxide 290.5 Water 124.7 To waste water
Dibromo methane (DBM) 632.1 Solvent
1,2,4 Triazole 331.1 Dimethyl formamide (DMF)
Dimethyl formamide (DMF) 4000 DMF Recovered 3880 Recovered & reuse
Catalyst 8 DMF loss 14 Fugitive loss
Water 4500 DMF in water 40 To waste water
DMF in residue 66 Solvent residue
Unreacted Organics
p-Chloro Phenyl Aceto Nitrile Organic residue
(PCAN) 25.5
n-Butyl Bromide (NBB) 23 To waste water
Dibromo methane (DBM) 29.3 To waste water
1,2,4 Triazole 15.3 To waste water
Unreacted Inorganis
Sodium hydroxide (48%) 13.4 To waste water
Catalyst 8 Solid waste
Water 4500 To waste water
Total Input 10809 Total Output 10809
Table 2.19 Material Balance of Thifluzamide
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Ethyl trifluoro actoacetate (ETFAA) 562.2 Thifluzamide 1000 Final Product

Chlorine 216.5 Hydrogen chloride 318.8 To scrubber

Thiacetamide 229.4 Water 34.1 To waste water
Sodium hydroxide 122.2 Ethyl alcohol 87.1 To waste water
Hydrogen chloride 111.5 Sodium chloride 110.9 To waste water
Thionyl Chloride 225.3 Sulfur dioxide 121.2 To scrubber
DiBromo Methyl Tri Fluoro Amide 1022.8 Solvent
(DBTFMA)
Triethyl amine 67.6 Toluene
Toluene 8000 Toluene Recovered 7760 Recovered and reuse
Acetonitrile 3000 Toluene loss 28 Fugitive loss
Water 14000 Toluene in residue 212 Solvent residue
Acetonitrile
Acetonitrile Recovered 2910 Recovered and reuse
Acetonitrile loss 10.5 Fugitive loss
Acetonitrile in water 30.0 To waste water
Acetonitrile in residue 49.5 Solvent residue
Unreacted Organics
Ethyl trifluoro actoacetate organic residue
(ETFAA) 213.5
Thiacetamide 87.1 organic residue
DiBromo Methyl Tri Fluoro 388.4 organic residue
Amide (DBTFMA)
Triethyl amine 67.6 To waste water
Unreacted Inorganis
Chlorine 82.2 To scrubber
Sodium hydroxide 46.4 To waste water
Water 14000 To waste water
Total Input 27557.5 Total Output 27557.5
Table 2.20 Material Balance of Hexaconazole
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
1,3-dichlorobenzene 470.1 Hexaconazole 1000 Final Product
384.6 Hydrogen chloride 116.2 To scrubber By
n-valeroyl chloride Product
Dimethyl sulphide 199 Methylene 47.8 To waste water
1,2,4-triazole 221.3 Hydrogen sulphide 108.5 To waste water
Ammonium chloride 20 Solvent
Dimethyl sulphate 120 Dimethyl formamide (DMF)
Potassium hydroxide 180 DMF Recovered 2910 Recovered and reuse
Dichloromethane (DCM) 6000 DMF loss 10.5 Fugitive loss
Dimethyl formamide (DMF) 3000 DMF in water 30 To waste water
Potassium carbonate 120 DMF in residue 49.5 Solvent residue
water 7000 Dichloromethane (DCM)
DCM Recovered 5820 Recovered and reuse
DCM loss 21 Fugitive loss
DCM in water 60 To waste water
DCM in residue 99 Solvent residue
Unreacted Organics
1,3-dichlorobenzene 0.9 organic residue
n-valeroyl chloride 0.8 organic residue
Dimethyl sulphide 0.4 To waste water
1,2,4-triazole 0.4 To waste water
Dimethyl sulphate 120 To waste water
Unreacted Inorganics
Ammonium chloride 20 To waste water
Potassium hydroxide 180 To waste water
Potassium carbonate 120 To waste water
water 7000 To waste water
Total Input 17715 Total Output 17715
Table 2.21 Material Balance of Tebuconazole
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
1-(4-chlorophenyl)-4,4-dimethyl-1- 768.5 Tebuconazole 1000 Final Product
3-pentanone
Dimethyl sulphide 212.5 Methylene 45.6 To waste water
1,2,4-triazole 236.3 Hydrogen sulphide 110.8 To waste water
Dimethyl sulfate 239 Solvent
Potassium hydroxide 160 N-Methyl-2-Pyrrolidone (NMP)
Dichloromethane (DCM) 4000 NMP Recovered 970 Recovered and reuse
Sodium hydroxide flakes 40 NMP loss 3.5 Fugitive loss
Cyclohexane 1000 NMP in water 10 To waste water
N-Methyl-2-Pyrrolidone (NMP) 1000 NMP in residue 16.5 Solvent residue
water 4000 Dichloromethane (DCM)
DCM Recovered 3880 Recovered and reuse
DCM loss 14 Fugitive loss
DCM in water 40 To waste water
DCM in residue 66 Solvent residue
Cyclohexane
Cyclohexane Recovered 970 Recovered and reuse
Cyclohexane loss 3.5 Fugitive loss
Cyclohexane in residue 26.5 Solvent residue
Unreacted Organics
1-(4-chlorophenyl)-4,4-dimethyl-1-3- 38.4 organic residue
pentanone
Dimethyl sulphide 10.6 organic residue
1,2,4-triazole 11.8 organic residue
Dimethyl sulfate 239 To waste water
Unreacted Inorganis
Potassium hydroxide 160 To waste water
Sodium hydroxide flakes 40 To waste water
water 4000 To waste water
Total Input 11656.3 Total Output 11656.3
Table 2.22 Material Balance of Difenoconazole

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
3,4- Dichloro Diphenyl ether 707 Difenoconazole 1000 Final Product
Chloro acetyl chloride 278 Hydrochloric Acid 89.7 To Scrubber
1,2- Propylene glycol 187.3 Water 44.4 To waste water
170.5 Potassium Chloride 183.5 To waste water by product
1, 2, 4 Triazole
Potassium Carbonate 339.7 Potassium Bicarbonate 246.4 To waste water by product
Ethylene 7 Solvent
EDC 1932 Cyclohexane
Aluminium Chloride 517 Cyclohexane Recovered 876.9 Recovered and reuse
Sodium Bicarbonate 1932 Cyclohexane Loss 4.6 Fugitive loss
Cyclohexane 923 Cyclohexane Residue 41.5 Solvent residue
PTSA 15 EDC
Sulfolane 1500 EDC Recovered 1835.4 Recovered and reuse
Potassium Triazole 337 EDC Loss 9.7 Fugitive loss
Water 1932 EDC to Waste Water 19.3 To waste water
EDC in Residue 67.6 Solvent residue
Organic
3,4- Dichloro Diphenyl ether 118.5 Organic Residue
PTSA 15 To waste water
Sulfolane 1500 To waste water
Ethylene 7 To waste water
Inorganic
Aluminium Chloride 517 To waste water
Sodium Bicarbonate 1932 To waste water
Potassium Triazole 337 To waste water
Water 1932 To waste water
Total Input 10777.5 Total Output 10777.5
Table 2.23 Material Balance of Epoxiconazole

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
2-chloromethyl-2-(4- 1724.4 Epoxiconazole 1818.0 Final Product
fluorophenyl)-Oxirane
1H-1, 2, 4 - triazole 380.8 Hydrochloric Acid 201.0 To Scrubber
NMP 1818.0 Solvent
Sodium Hydroxide 125.0 Cyclohexane
Cyclohexane 84.0 Cyclohexane Recovered 79.8 Recovered and reuse
Water 1833.0 Cyclohexane Loss 0.4 Fugitive loss
Cyclohexane in Residue 3.8 Solvent residue
Organic
2-chloromethyl-2-(4- 86.2 Organic Residue
fluorophenyl)-Oxirane
NMP 1818.0 To Waste Water
Inorganic
Sodium Hydroxide 125.0 To Waste Water
Water 1833 To Waste Water
Total Input 5965.2 Total Output 5965.2
Table 2.24 Material Balance of Cyproconazole

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
CPCP propanone 720.2 Cyproconazole 1000.0 Final Product
Dimethyl sulfide 212.9 (CH3)SK 295.4 Organic Residue
Potassium hydroxide 192.3 Water 61.8 To Waste Water
1,2,4-triazole 236.7 Potassium carbonate 473.7 To Waste Water
Potassium carbonate 473.7 Toluene
Toluene 4000.0 Toluene Recovered 3800.0 Recovery & reuse
Water 2500.0 Toluene Loss 20.0 Fugitive loss
Toluene Residue 180.0 Solvent in residue
Organic
CPCP propanone 5.0 Organic Residue
Inorganic
Water 2500 To Waste Water
Total Input 8335.9 Total Output 8335.9
Table 2.25 Material Balance of Thiophanate Methyl

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
O-Phenylenediamine (98%) 356.0 Thiophanate Methyl 1000.0 Final Product
Sodium thiocyanate 473.5 Sodium Chloride 341.4 To Waste Water
Methyl Chloroformate (98%) 552.0 Solvent
Acetone 5409.0 Acetone
Water 356.0 Acetone Recovered 5138.6 Recovery & reuse
Acetone Loss 27.0 Fugitive loss
Acetone Waste Water 54.1 To Waste Water
Acetone Residue 189.3 Solvent in residue
Organic
O-Phenylenediamine (98%) 40.2 Organic Residue
Water 356.0 To Waste Water
Total Input 7146.5 Total Output 7146.5
Table 2.26 Material Balance of Azoxystrobin

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
(E)-methyl-3-methoxy-2-(2- 999.9 Azoxystrobin 1110.0 Final Product
(6-chloropyrimidine-4-
yloxy)phenyl)acrylate
2-Cyanophenol 327.8 Potassium Chloride 205 To WasteWater
18-crown-6 ether 16 Potassium Bicarbonate 275.5 To WasteWater
Potassium Carbonate 379.7 Solvent
DMF 5000 DMF
Water 6000 DMF Recovered 4750 Recovered and Reuse
Toluene 5000 DMF Loss 25 Figitive Loss
Methanol 4000 DMF Residue 225 Solvent Residue
Toluene
Toluene Recovered 4750 Recovered and Reuse
Toluene Loss 25 Figitive Loss
Toluene Residue 225 Solvent Residue
Methanol
Methanol Recovered 3800 Recovered and Reuse
Methanol Loss 20 Figitive Loss
Methanol to Waste 40 To Waste Water
Water
Methanol Residue 140 Solvent Residue
Organic
(E)-methyl-3-methoxy-2- 117.4 Organic Residue
(2-(6-chloropyrimidine-
4-yloxy)phenyl)acrylate

18-crown-6 ether 16 Organic Residue

Water 6000 To Waste Water
Total Input 21723.5 Total Output 21723.9
Table 2.27 Material Balance of Trifloxystrobin

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
(E)-methyl-2-(2-methylphenyl)- 921.0 Stage I Product 1082.0 To Stage III Product
2-methoxyiminoacetate

N-Bromosuccinimide (NBS) 673.1 Succinimide 374.7 To Waste Water

Azoxybisisobutyronitrile 51.0 Solvent
(AIBN)
Methylene Dichloride (MDC) 7375.0 MDC

Sodium bisulfite 138.0 MDC Recovered 7006.3 Recovered and Reuse

n-Heptane 2212.0 MDC Loss 36.88 Figitive Loss
Water 8020.0 MDC Residue 331.9 Solvent Residue
n-Heptane
n-Heptane Recovered 2101.4 Recovered and Reuse
n-Heptane Loss 11.1 Figitive Loss
n-Heptane Residue 99.5 Solvent Residue
Organic
(E)-methyl-2-(2-methylphenyl)- 137.3 Organic Residue
2-methoxyiminoacetate

Azoxybisisobutyronitrile 51.0 Organic Residue

(AIBN)
Sodium bisulfite 138.0 To Waste Water
Water 8020.0 To Waste Water
Total Input 19390.0 Total Output 19390.0

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
3’-(Trifluoromethyl) 640.0 Stage II Product 621.0 To Stage III Product
acetophenone
Hydroxylamine. HCl 212.4 Water 110.2 To Waste Water
Sodium Hydroxide 122.3 Sodium Chloride 178.6 To Waste Water
Water 2560.0 Solvent
Methanol 2560.0 Methanol
Methanol Recovered 2432.00 Recovered and Reuse
Methanol Loss 12.8 Figitive Loss
Methanol to Waste Water 25.6 To Waste Water
Methanol Residue 89.6 Solvent Residue
Organic
3’-(Trifluoromethyl) 64.9 Organic Residue
acetophenone
Water 2560.0 To Waste Water
Total Input 6094.7 Total Output 6094.7

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
Stage I Product 1082.1 Trifloxystrobin 1000.0 Final Product
Stage II Product 621.1 Potassium Bromide 291.4 To Waste Water
Potassium Carbonate 338.4 Potassium bicarbonate 245.2 To Waste Water
DMF 3731.0 Solvent
Toluene 3109.0 DMF
Water 3732.0 DMF Recovered 3544.45 Recovered and Reuse
Methanol 2500.0 DMF Loss 18.7 Figitive Loss
DMF Residue 167.9 Solvent Residue
Toluene
Toluene Recovered 2953.6 Recovered and Reuse
Toluene Loss 15.5 Figitive Loss
Toluene Residue 139.9 Solvent Residue
Methanol
Methanol Recovered 2375.0 Recovered and Reuse
Methanol Loss 12.5 Figitive Loss
Methanol to Waste Water 25.0 To Waste Water
Methanol Residue 87.5 Solvent Residue
Organic
Stage I Product 381.4 Organic Residue
Stage II Product 123.6 Organic Residue
Water 3732.0 To Waste Water
Total Input 15113.6 Total Output 15113.6
Table 2.28 Material Balance of Pendimethalin

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
NEPDA 1027 Pendimethalin 1000 Final Product
70% HNO3 1038 Sulphuric Acid 348.7 To Scrubber
H2SO4 1117 Water 128.1 To Waste Water
1,2-dichloroethane 2018 Organic
Con HCl 774 NEPDA 346.9 Organic Residue
1,2-dichloroethane 2018 Organic Residue
70% HNO3 590 To Waste Water
H2SO4 768.3 To Waste Water
Con HCl 774 To Waste Water
Total Input 5974 Total Output 5974
Table 2.29 Material Balance of Pretilachlor
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
2,6 Diethylaniline (DEA) 503.5 Pretilachlor 1000 Final Product

Chloro Propoxy Ethane (CPE) 414 Sodium chloride 128.7 To waste water
Sodium hydroxide 128.4 water 116.9 To waste water
chloro acetyl chloride (CAC) 381.9 Triethylamine hydrochloride 441.4 To waste water
Triethyl Amine (TEA) 341.3 Solvent
Toluene 1000 Toluene
Water 1300 Toluene Recovered 970 Recovered and reuse
Toluene loss 3.5 Fugitive loss
Toluene in residue 26.5 Solvent residue
Unreacted Organics
2,6 Diethylaniline (DEA) 25.2 To waste water
Chloro Propoxy Ethane (CPE) 20.7 organic residue
chloro acetyl chloride (CAC) 19.1 organic residue
Triethyl amine 17.1 To waste water
Unreacted Inorganis
Water 1300 To waste water
Total Input 4069 Total Output 4069
Table 2.30 Material Balance of Metribuzin
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Butylthion 1099.1 Metribuzin 1000.0 Final Product
Dimethyl sulphate 346.3 Unreacted Organics
Sulphuric acid 1593.0 Butylthion 164.5 organic residue
Sodium hydroxide 1485.7 Dimethyl sulphate 51.8 To waste water
water 22000.0 Unreacted Inorganics
Sodium sulphate 2639.1 To waste water
water 22668.6 To waste water
Total Input 26524.1 Total Output 26524.0
Table 2.31 Material Balance of Dimethomorph
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(4-chlorophenyl)(3,4- 751.0 Dimethomorph 1000.0 Final Product
dimethoxyphenyl)methanone
N-acetylmorpholine 350.5 water 46.4 To waste water
Sodium hydroxide 103.0 Solvent
Toluene 1500.0 Toluene
water 3000.0 Toluene Recovered 1455.0 Recovered & reuse
Toluene loss 5.3 Fugitive loss
Toluene in residue 39.8 Solvent residue
Unreacted Organics
(4-chlorophenyl)(3,4- 37.5 organic residue
dimethoxyphenyl)methanone
N-acetylmorpholine 17.5 organic residue
Unreacted Inorganics
Sodium hydroxide 103.0 To waste water
Water 3000.0 To waste water
Total Input 5704.5 Total Output 5704.5
Table 2.32 Material Balance of Clodinofop-propargyl
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(R) –(+) -2-(4-Hydroxy phenoxy) 614.0 Clodinofop-propargyl 1000 Final Product
propionic acid (DHPPA)
Potassium carbonate 931.6 Potassium bicarbonate 572.8 To waste water
Dimethyl formaide (DMF) 3000 Potassium fluoride 166.1 To waste water
2,3 Difluoro 5-chloro pyridine 504 Potassium chloride 213.2 To waste water
Proargyl chloride 251.2 Solvent
water 1000 Dimethyl formaide (DMF)
DMF Recovered 2910 Recovered and reuse
DMF loss 10.5 Fugitive loss
DMF in water 30 To waste water
DMF in residue 49.5 Solvent residue
Unreacted Organics
(R) –(+) -2-(4-Hydroxy phenoxy) 93.1 organic residue
propionic acid (DHPPA)
2,3 Difluoro 5-chloro pyridine 76.4 organic residue
Proargyl chloride 38.1 organic residue
Unreacted Inorganics
Potassium carbonate 141.2 To waste water
water 1000 To waste water
Total Input 6300.8 Total Output 6300.8
Table 2.33 Material Balance of Bis-Pyribac Sodium
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Dihydrobenzoic acid 474.0 Bis-Pyribac Sodium 1000.0 Final Product
Dimethylsulfonylpyrimidine 964.9 Sodium methanesulfinate 451.4 Organic Residue
Sodium hydroxide 265.3 Water 119.5 To Waste Water
Tetra-n-butylammonium 99.0 Organic
bromide (TBAB)
Toluene 9231.0 Toluene
Acetone 12308.0 Toluene Recovered 8769.5 Recovered & reuse
Toluene Loss 46.2 Fugitive loss
Toluene Residue 415.4 Solvent residue
Acetone
Acetone Recovered 11692.6 Recovered & reuse
Acetone Loss 61.5 Fugitive loss
Acetone Residue 553.9 Solvent residue
Organic
Dihydrobenzoic acid 133.3 Organic Residue
Tetra-n-butylammonium bromide 99.0 Organic Residue
(TBAB)
Total Input 23342.2 Total Output 23342.2
Table 2.34 Material Balance of Bensulfuran Methyl
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
4,6- Dimethoxy pyrimidine -2- 418 Bensulfuran Methyl 1000 Final Product
amines
Methyl-2- {[Isocyanate 617.7 water 43.9 carried along with
sulfamoyl] Methyl} Benzoate organic residue
carbon dioxide 118.5 Solvent
Xylene 1600 Xylene
Methanol 2000 Xylene Recovered 1552 Recovered and reuse
Xylene loss 5.6 Fugitive loss
Xylene in residue 42.4 Solvent residue
Methanol
Methanol Recovered 1940 Recovered and reuse
Methanol loss 7 Fugitive loss
Methanol in residue 53 Solvent residue
Unreacted Organics
4,6- Dimethoxy pyrimidine -2- 40 organic residue
amines
Methyl-2- {[Isocyanate sulfamoyl] 59 organic residue
Methyl} Benzoate
carbon dioxide 11.3 Let into the
atmosphere
Total Input 4754.2 Total Output 4754.2
Table 2.35 Material Balance of Glufosinate-ammonium
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(3-amino-3-cyano-propyl)-methyl- 974 Glufosinate-ammonium 1000 Final product
phosphinic acid
Sodium Dihydrogen Phosphate 525 Phosphonic acid 828 Inorganic Residue
Sodium Hydrogen Phosphite 636 Sodium chloride 885 Inorganic Residue
Hydrogen Chloride 736 Ammonium chloride 270 Inorganic Residue
Water 182 Solvents
Ammonia 86 Methanol
Methanol 3000 Methanol Recovered 2850 Recovery & reuse
Methanol Loss 15 Fugitive loss
Methanol Residue 135.0 Solvent in residue
Organics
(3-amino-3-cyano-propyl)- 156 Organic Residue
methyl-phosphinic acid
Total Input 6138.2 Total Output 6138.1
Table 2.36 Material Balance of Quizalofop-P-Ethyl
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
p-Toluenesulfonyl chloride 983.5 Quizalofop-P-Ethyl 1000.0 Final Product
(-) L- Ethyl lactate 317.6 Hydrogen Chloride 97.9 To Scrubber by
product
TEA 295.3 Potassium Chloride 200.1 Inorganic Residue
TBAB 83.0 Water 97.2 Carried along with
organic residue
DMF 75.4 Potassium Toluenesulphonate 564.5 Organic residue
Toluene 3933.8 Solvent
Sodium bicarbonate 196.7 Toluene
2,6-dichloroquinaoxzaline 534.2 Toluene Recovered 3737.1 Recovery & reuse
Hydroquinone 444.9 Toluene Loss 19.7 Fugitive loss
KOH 300.7 Toluene Residue 177.0 Solvent in residue
K2CO3 1105.9 Cyclohexane
Cyclohexane 4470.6 Cyclohexane Recovered 4247.1 Recovery & reuse
Cyclohexane Loss 22.4 Fugitive loss
Cyclohexane Residue 201.2 Solvent in residue
Organic
p-Toluenesulfonyl chloride 471.7 Organic residue
TBAB 83.0 Organic residue
DMF 75.4 Organic residue
Hydroquinone 444.9 Organic residue
Inorganic
Sodium bicarbonate 196.7 Inorganic Residue
K2CO3 1105.9 Inorganic Residue
Total Input 12741.6 Total Output 12741.7
Table 2.37 Material Balance of Tribenuron-methyl Technical
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
2-Methoxy-4-methyl-6-(methylamino 665 Tribenuron-methyl Technical 1000 Final product
ethyl carbamate)-1,3,5-triazine

Methyl 2-(aminosulfonyl)benzoate 633 Ethanol 116.5 By-product

Acetonitrile 3625 Solvents
1,8-Diazabicyclo[5.4.0]undec-7-ene 440 Acetonitrile
(DBU)
water 5000 Acetonitrile recovered 3516 Recovery & reuse
Hydrochloric acid 1450 Acetonitrile loss 18.1 Fugitive loss
Sodium hydroxide 1589 Acetonitrile to wastewater 36.3 To wastewater
Acetonitrile residue 54.4 Solvent in residue
Organics
2-Methoxy-4-methyl-6- 93.1 Organic residue
(methylamino ethyl carbamate)-
1,3,5-triazine
Methyl 2- 88.6 Organic residue
(aminosulfonyl)benzoate
1,8-Diazabicyclo[5.4.0]undec-7- 440 Organic residue
ene (DBU)
Inorganics
Sodium chloride 2324 To wastewater
Water 5715.1 To wastewater
Total Input 13402.3 Total Output 13402.3
Table 2.38 Material Balance of Clethodim technical
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
5-[2-(Ethylthio) propyl]-3- 939 Clethodim technical 1000 Final Product
hydroxy-2-propionyl-2-
cyclohexen-1-one
O-(3-Chloro allyl) hydroxylamine 500.1 water 50 Carriend along with
hydrochloride organic residue
n-Hexane 2000 Hydrogen chloride 101.4 To scrubber
Solvent
Hexane
Hexane Recovered 1940 Recovered and reuse
Hexane loss 7 Fugitive loss
Hexane in residue 53 Solvent residue
Unreacted Organics
5-[2-(Ethylthio) propyl]-3-hydroxy-2- 187.8 organic residue
propionyl-2-cyclohexen-1-one
O-(3-Chloro allyl) hydroxylamine 100 organic residue
hydrochloride
Total Input 3439.1 Total Output 3439.3
Table 2.39 Material Balance of Penoxsulam
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
Trizolopyrimidine amine 424.8 Penoxsulam 1000.0 Final Product
sulphonyl chloride 706.8 Pyridine Hydrochloride 238.7 To waste water
pyridine 172.2 Solvent
Dimethyl sulfoxide (DMSO) 2020.0 Dimethyl sulfoxide (DMSO)
Water 1000.0 DMSO Recovered 1959.4 Recovered & reuse
DMSO loss 7.1 Fugitive loss
DMSO in water 4.0 To waste water
DMSO in residue 49.5 Solvent residue
Unreacted Organics
Trizolopyrimidine amine 21.2 organic residue
pyridine 8.6 To waste water
Unreacted Inorganics
sulphonyl chloride 35.3 To waste water
Water 1000.0 To waste water
Total Input 4323.9 Total Output 4323.9
Table 2.40 Material Balance of S-Metolachlor Technical
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
2-methyl-6-ethylaniline 500 S-Metolachlor Technical 1000 Final product
Methoxy acetone 326 Carbon dioxide 155 Let into atmosphere safely
Hydrogen 7 Sodium chloride 206 To wastewater
Chloroacetylchloride 418 Water 127.0 To wastewater
Sodiumbicarbonate 310.6 Solvents
Hexane 600 Hexane
Sulphuric acid 3 Hexane recovered 582 Recovery & reuse
10% Pd/C 40 Hexane loss 3.0 Fugitive loss
1,2-dichloroethane 2000 Hexane to wastewater 6.0 To wastewater
Water 1100.0 Hexane residue 9.0 Solvent in residue
Sodium hydroxide 2.4 1,2-dichloroethane
1,2-dichloroethane recovered 1940 Recovery & reuse
1,2-dichloroethane loss 10 Fugitive loss
1,2-dichloroethane to wastewater 20 To wastewater
1,2-dichloroethane residue 30 Solvent in residue
Organics
2-methyl-6-ethylaniline 23.5 Organic residue
Methoxy acetone 15.3 To wastewater
Chloroacetylchloride 19.6 Organic residue
Pd/C 40 To solid waste
Inorganics
Sodiumbicarbonate 14.6 To wastewater
Water 1101.1 To wastewater
Sodium sulfate 4.3 To wastewater
Hydrogen 0.3 Let into atmosphere safely
through water column
Total Input 5306.8 Total Output 5306.8
Table 2.41 Material Balance of Verbenone

Input Quantity Output Quantity Remarks

(Kg/day) (Kg/day)
(1S,5S)-2,6,6-Trimethyl 1111 Verbenone 1000 Final Product
bicyclo[3.1.1]hept-2-ene ((−)-α-
Pinene)
Copper iodide 19 Solvent
TBHP (70%) 1575 Acetonitrile
Acetonitrile 4366 Acetonitrile Recovered 4148 Recovery & reuse
MTBE 4111 Acetonitrile Loss 21.83 Fugitive loss
Water 3333 Acetonitrile to Waste Water 43.7 To wastewater
Sodium Sulphate 111 Acetonitrile Residue 152.8 Solvent in residue
MTBE
MTBE Recovered 3905 Recovery & reuse
MTBE Loss 20.6 Fugitive loss
MTBE Residue 185.0 Solvent in residue
Organic
(1S,5S)-2,6,6-Trimethyl 111 Organic Residue
bicyclo[3.1.1]hept-2-ene ((−)-α-
Pinene)
TBHP (70%) 1102.5 To wastewater
Inorganic
Copper iodide 19.0 To wastewater
Sodium Sulphate 111 To wastewater
Water 3805.5 To wastewater
Total Input 14626.0 Total Output 14626.0
Table 2.42 Material Balance of (Z)-hezatec-11-en-1-yl acetate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
hexadec-11-yn-1-ol 1000 (Z)-hezatec-11-en-1-yl acetate 1000 Final Product
Nickel Acetate 520 Solvents
Sodium Borohydride 90 Methanol
Ethylene Diamine 250 Methanol Recovered 7505 Recovery & reuse
Methanol 7900 Methanol Loss 39.5 Fugitive loss
HCl 440 Methanol WasteWater 7.9 To wastewater
Methyl tert-butyl ether 2220 Methanol Residue 347.6 Solvent in residue
Water 5000 Methyl tert-butyl ether
Sodium Chloride 300 Methyl tert-butyl ether Recovered 2109 Recovery & reuse
Sodium Sulphate 210 Methyl tert-butyl ether Loss 11.1 Fugitive loss
Hyflow 100 Methyl tert-butyl ether Residue 99.9 Solvent in residue
Stage-I 1000 Acetic acid
Acetic acid 790 Acetic acid Recovered 751 Recovery & reuse
PTSA 10 Acetic acid Loss 4.0 Fugitive loss
Toluene 5200 Acetic acid to Waste Water 7.90 To wastewater
Acetic acid Residue 27.7 Solvent in residue
Toluene
Toluene Recovered 4940.0 Recovery & reuse
Toluene Loss 26.0 Fugitive loss
Toluene Residue 234.0 Solvent in residue
Organic Residue
Stage-I 1000 Organic Residue
Hyflow 100 To Solid Waste
Ethylene Diamine 250 To wastewater
Nickel Acetate 520 Organic Residue
PTSA 10 To wastewater
Inorganic Residue
Sodium Borohydride 90 To wastewater
HCl 440 To wastewater
Water 5000 To wastewater
Sodium Chloride 300 To wastewater
Sodium Sulphate 210 To wastewater
Total Input 25030.0 Total Output 25030.0
Table 2.43 Material Balance of (Z)-hezatec – 9-enal

Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
hexadec-9-yn-1-ol 1430 (Z)-hezatec – 9-enal 1430 Final Product
Nickel Acetate 740 Solvent
Sodium Borohydride 130 Methanol
Ethylene Diamine 360 Methanol Recovered 10726 Recovery & reuse
Methanol 11290 Methanol Loss 56.45 Fugitive loss
Methyl tert-butyl ether 3170 Methanol to Waste Water 112.9 To wastewater
Water 2860 Methanol Residue 395.2 Solvent in residue
HCl (35%) 630 Methyl tert-butyl ether
Sodium Chloride 430 Methyl tert-butyl ether Recovered 3012 Recovery & reuse
Sodium Sulphate 290 Methyl tert-butyl ether Loss 15.9 Fugitive loss
Hyflow 140 Methyl tert-butyl ether Residue 142.7 Solvent in residue
Stage-I 1430 MDC
Pyridimium chloro chromate 1910 MDC Recovered 10203 Recovery & reuse
MDC 10740 MDC Loss 53.7 Fugitive loss
Hexane 4690 MDC Residue 483.30 Solvent in residue
Celite 1910 Hexane
Hexane Recovered 4456 Recovery & reuse
Hexane Loss 23 Fugitive loss
Hexane Residue 211 Solvent in residue
Organic Residue
Nickel Acetate 740 Organic Residue
Ethylene Diamine 360 To wastewater
Stage-I 1430 Organic Residue
Pyridimium chloro chromate 1910 To wastewater
Celite 1910.0 To wastewater
Hyflow 140 To solid waste
Inorganic Residue
HCl (35%) 630 To wastewater
Sodium Borohydride 130 To wastewater
Sodium Chloride 430 To wastewater
Sodium Sulphate 290 To wastewater
Water 2860.0 To wastewater
Total Input 42150.0 Total Output 42150.0
Table 2.44 Material Balance of (8E,10E) – Dodoca-8, 10-dyen-1-ol
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(6-chlorohexyloxy) trimethylsilane 1000 (8E,10E) – Dodoca-8, 10-dyen-1-ol 900 Final Product
Magnesium 140 Solvent
Iodine 10 Tetrahydrofuran
Dibromoethene 1 Tetrahydrofuran Recovered 3382 Recovery & reuse
(2E, 4E)-hexa-2,4-dienyl acetate 470 Tetrahydrofuran Loss 17.80 Fugitive loss
Lithium chloride 20 Tetrahydrofuran Residue 160.2 Solvent in residue
Copper(II) chloride 30 MTBE
Tetrahydrofuran 3560 MTBE Recovered 2090 Recovery & reuse
Ammonium chloride 200 MTBE Loss 11 Fugitive loss
MTBE 2200 MTBE Residue 99.0 Solvent in residue
Sodium Chloride 200 Methanol
Sodium Sulfate 200 Methanol Recovered 3002.0 Recovery & reuse
Water 4000 Methanol Loss 16 Fugitive loss
Stage-1 1000 Methanol to Waste Water 31.6 To wastewater
HCl (35%) 82 Methanol Residue 110.60 Solvent in residue
Methanol 3160 Organic Residue
Sodium bicarbonate 130 (6-chlorohexyloxy) trimethylsilane 100 Organic Residue
Sodium Chloride 400 Iodine 10.0 To wastewater
Dibromoethene 1.0 To wastewater
(2E, 4E)-hexa-2,4-dienyl acetate 470.0 To wastewater
Stage-1 1000.0 Organic Residue
Inorganic Residue
Lithium chloride 20.0 To wastewater
Magnesium 140.0 To wastewater
Sodium Chloride 600.0 To wastewater
Sodium Sulfate 200.0 To wastewater
Copper(II) chloride 30.0 To wastewater
Ammonium chloride 200.0 To wastewater
HCl (35%) 82.0 To wastewater
Sodium bicarbonate 130.0 To wastewater
Water 4000.0 To wastewater
Total Input 16803.0 Total Output 16803.0
Table 2.45 Material Balance of 7Z, 11Z Hexa deca dienyl acetate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(Z)-1-chlorooct-3-ene 1.5 7Z, 11Z Hexa deca dienyl acetate 1 Final product
Magnesium Turnings 0.3 Solvents
Tetrahydrofuran (THF) 6.8 Tetrahydrofuran (THF)
Iodine 0.01 THF recovered 7 Recovery & reuse
1,2 Dibromo ethane 0.01 THF loss 0.03 Fugitive loss
8-bromooct-7-ynyl acetate 2.8 THF wastewater 0.1 To wastewater
Curpous Iodide 0.1 THF residue 0.1 Solvent in residue
Ammonium Chloride 0.3 Methyl tert-butyl ether (MTBE)
Methyl tert-butyl ether (MTBE) 2.0 MTBE recovered 2 Recovery & reuse
Sodium chloride 0.4 MTBE loss 0.0 Fugitive loss
Sodium sulphate 0.3 MTBE to wastewater 0.0 To wastewater
Water 5.4 MTBE residue 0.0 Solvent in residue
Organics
Organic 0.4 Organic residue
1,2 Dibromo ethane 0.01 To wastewater
8-bromooct-7-ynyl acetate 2.8 Organic residue
Inorganics
Magnesium Turnings 0.3 Inorganic residue
Iodine 0.01 To wastewater
Curpous Iodide 0.1 To wastewater
Ammonium Chloride 0.3 To wastewater
Sodium chloride 0.4 To wastewater
Sodium sulphate 0.3 To wastewater
Water 5.4 To wastewater
Total Input 19.8 Total Output 19.8
Table 2.46 Material Balance of 7E, 9Z Dodeca dienyl acetate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
(E)-9-choronon-2-enal 119 7E, 9Z Dodeca dienyl acetate 99 Final product
Propyl triphenyl phosphonium 345 Tri phenyl phosphine oxide 272 Organic residue
bromide
Potassium tert.butoxide 94.6 Solvents
Tetrahydrofuran (THF) 600 Tetrahydrofuran (THF)
Hexane 850 THF recovered 582 Recovery & reuse
Water 350 THF loss 3 Fugitive loss
Sodium sulphate 10 THF wastewater 6 To wastewater
Stage-1 98.8 THF residue 9 Solvent in residue
Potasium acetate 60.4 Hexane
Dimethylformamide (DMF) 300 Hexane recovered 825 Recovery & reuse
Sodium sulphate 10 Hexane loss 4.3 Fugitive loss
Hexane to wastewater 8.5 To wastewater
Hexane residue 12.8 Solvent in residue
Dimethylformamide (DMF)
DMF recovered 291 Recovery & reuse
DMF loss 1.5 Fugitive loss
DMF to wastewater 3 To wastewater
DMF residue 4.5 Solvent in residue
Organics
Organic 93.2 Organic residue
Stage-1 98.8 Organic residue
Potasium acetate 60 To wastewater
Potassium tert.butoxide 95 Organic residue
Inorganics
Sodium sulphate 10 To wastewater
Sodium sulphate 10 To wastewater
Water 350 To wastewater
Total Input 2837.9 Total Output 2837.9
Table 2.47 Material Balance of 8Z Dodecenyl acetate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
8-dodecynol 100 8Z Dodecenyl acetate 95 Final product
Nickel acetate 55 Solvents
Sodium Borohydride 10 Methanol
Ethylene diamine 33 Methanol reovered 524 Recovery & reuse
Methanol 540 Methanol loss 2.7 Fugitive loss
Hyflow 7 Methanol to wastewater 5.4 To wastewater
Toluene 822 Methanol residue 8.1 Solvent in residue
Sodium sulphate 10 Toluene
Sodiumchloride 40 Toluene recovered 797 Recovery & reuse
Hydrochloric acid 17 Toluene loss 4.11 Fugitive loss
Stage-I 100 Toluene residue 20.6 Solvent in residue
Acetic acid 39 Organics
p-Toluenesulfonic acid (PTSA) 10 Organic 4.8 Organic residue
Water 900 Nickel acetate 55 To wastewater
Sodium Sulphate 10 Ethylene diamine 33.0 To wastewater
Sodium hydroxide 19 p-Toluenesulfonic acid (PTSA) 10.0 To wastewater
Stage-I 100.0 Organic residue
Acetic acid 39.2 To wastewater
Inorganics
Sodium Borohydride 10.2 To wastewater
Hyflow 7.0 To hyflow
Sodium sulphate 10.0 To wastewater
Sodiumchloride 67.2 To wastewater
Sodium Sulphate 10.0 To wastewater
Water 908.4 To wastewater
Total Input 2711.5 Total Output 2711.5
Table 2.48 Material Balance of (Z)-Octadeca-13-enyl acetate
Stage I
Input Quantity Output Quantity Remarks
(Kg/day) (Kg/day)
13-Octadecynol 1 (Z)-Octadeca-13-enyl acetate 1 Final product
Nickel acetate 0.4 Solvents
Sodium Borohydride 0.1 Methanol
Ethylene diamine 0.2 Methanol reovered 5.2 Recovery & reuse
Methanol 5.4 Methanol loss 0.03 Fugitive loss
Hyflow 0.1 Methanol to wastewater 0.1 To wastewater
Toluene 8.2 Methanol residue 0.1 Solvent in residue
Sodium sulphate 0.1 Toluene
Sodiumchloride 0.2 Toluene recovered 8.0 Recovery & reuse
Hydrochloric acid 0.4 Toluene loss 0.04 Fugitive loss
Stage 1 1.0 Toluene residue 0.2 Solvent in residue
Acetic acid 0.3 Organics
p-Toluenesulfonic acid (PTSA) 0.1 Ethylene diamine 0.2 To wastewater
Water 9.0 Stage 1 1.0 Organic residue
Sodium sulfate 0.1 p-Toluenesulfonic acid (PTSA) 0.1 To wastewater
Sodium hydroxide 0.4 13-Octadecynol 0.3 Organic residue
Inorganics
Nickel acetate 0.4 To wastewater
Sodium Borohydride 0.1 To wastewater
Hyflow 0.1 To hyflow
Sodium sulphate 0.1 To wastewater
Sodiumchloride 0.8 To wastewater
Sodium sulfate 0.1 To wastewater
Water 9.2 To wastewater
Total Input 26.94 Total Output 26.94
NACL INDUSTRIES LIMITED
SY.NO.177, ARINAMA AKKIVALASA VILLAGE,
ETCHERLA MANDAL, SRIKAKULAM DISTRICT,
ANDHRA PRADESH

STUDIES AND DOCUMENTATION BY

TEAM Labs and Consultants
QCI: MoEF&CC OM, List A-1
(An ISO 45001:2018, SIO 14001: 2015 &
ISO 9001: 2015 Certified Organization)
B-115, Annapurna Block, Aditya Enclave
Ameerpet, Hyderabad-500 038.
Phone: 040-23748 555/616,
Telefax: 040-23748666
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NACL Draft EIA Report - Compressed

Uploaded by

NACL Draft EIA Report - Compressed

Uploaded by

NACL INDUSTRIES LIMITED

SY.NO.177, ARINAMA AKKIVALASA VILLAGE,

DRAFT EIA REPORT

1. ENVIRONMENTAL IMPACT ASSESSMENT

Project No. 0321-17-01

STUDIES AND DOCUMENTATION BY

1. ENVIRONMENTAL IMPACT ASSESSMENT REPORT

Project No. 0321-17-01

STUDIES AND DOCUMENTATION BY

2.0 Introduction 2-1

3.0 Description of the Environment 3-1

3.4.2 Meteorological Station at Plant Site 3-22

4.0 Anticipated Environmental Impacts& Mitigation Measures 4-1

5.0 Analysis of Alternatives 5-1

6.0 Environmental Monitoring Program 6-1

7.0 Additional Studies 7-1

7.7.2.1 Analysis of Hazardous Scenarios 7-31

8.0 Project Benefits 8-1

9.0 Environment Cost Benefit Analysis 9-1

10.0 Environment Management Plan 10-1

10.5 CREP Guideline and Compliance 10-10

11.0 Summary& Conclusion 11-1

12.0 Disclosure of Consultants Engaged 12-1

1.1 Manufacturing Capacity- Existing/Permitted 1-3

2.1 Manufacturing Capacity- Permitted 2-1

3.1 Salient features of the project 3-1

3.16 Literacy Study Area 3-35

4.1 Activity and Environmental Impact (Impact Identification Matrix) - 4-10

4.33 Impacts on Fauna 4-61

6.1 National Ambient Air Quality Standards 6-3

7.1 Proposed Manufacturing Capacity-After Expansion 7-3

10.1 Implementation and Monitoring of Mitigation Measures –Construction Stage 10-6

10.2 Impacts and Mitigation – Operational Stage 10-7

11.1 Manufacturing Capacity-After Expansion 11-2

1.1 Location of NACL Industries Limited 1-9

2.1 Plant Location of NACL Industries Ltd 2-7

3.1 Site and Plant Photographs – NACL Industries Limited 3-2

4.1 Conceptual Model of Agrochemicals 4-2

7.1 Plant Layout of NACL Industries Limited 7-10

7.3 Emergency Organization (ON SITE) Chart 7-48

10.1 Organogram Safety, Health, and Environment Division 10-2

1.0 Introduction of the Project (Terms of Reference No. 2(ii))

1-1 Team Labs and consultants

This report adopted the definition of Impact assessment given by international

1-2 Team Labs and consultants

1.1 Product Profile (Terms of Reference No. 3(ii)

1-3 Team Labs and consultants

35 (8E,10E) –Dodoca-8, 0.05 0.15 0.1 0.1 0.15

Table 1.2 Manufacturing Capacity – After Expansion

1-4 Team Labs and consultants

19 Tricyclazole 41814-78-2 2.5

1-5 Team Labs and consultants

Table 1.3 List of By-products – After Expansion

1.3 Plant Location and Layout

1-6 Team Labs and consultants

stream is at a distance of 4.7 km in SW direction. There are no reserve forests, national

1.3.1 Purpose of the Report

Prior environmental clearance is mandated by Ministry of Environment, Forest and

1.4 Plant Layout

1-7 Team Labs and consultants

Table 1.5 Geo-coordinates of the project site area

1-8 Team Labs and consultants

1-9 Team Labs and consultants

1-10 Team Labs and consultants

Site Photographs of NACL Industries Ltd.

1-11 Team Labs and consultants

1.5 Scope of EIA Studies

• An intensive reconnaissance and preliminary collection of environmental

• Field studies to collect preliminary information, particularly on the quality of the

• Preparation of Environmental Management Plan suggesting suitable methods for

1-12 Team Labs and consultants

Table 1.6 Required Approvals and Applicable statutes

1-13 Team Labs and consultants

Legal Instrument Responsible Ministries Applicability Remarks

1-14 Team Labs and consultants

2.0 PROJECT DESCRIPTION