NPL Industries KH Exe Summ Eng and Guj

NPL Industries Private Limited
Executi ve Summary of REIA Report

Proposed Project of Manufacturing of Textile Binders
& Auxiliaries
Location at: S.No. 748/P, 750/P,777/B/P, 780/P, Village : Bidaj,
Kheda, Gujarat
Prepared By:

Ramans Enviro Services Pvt. Ltd.
SF 23 & 24, Camps Corner, Near AUDA Garden, Prahaladnagar
Ahmedabad 380 015 Phone: 079-26937472. Fax: 079-40064440
E-mail:ramans_consultancy@rediffmail.com,
ramans.consultancy@gmail.com
AUGUST 2012

ExEcutivE summary : maNuFacturiNG PLaNt OF tExtiLE BiNDErs aND auxiLariEs
By NPL iNDustriEs Pvt. LtD. at viLLaGE : BiDaJ, Dist. : khEDa, GuJarat

E.1
1. For growing market demand of the textile binders and auxiliaries
Chiripal Group has intended to establish the manufacturing unit
named M/ s NPL Industries Private Limited.
EXECUTIVE SUMMARY

INTRODUCTION :
2. NPL Industries Pvt. Ltd. intends to serve the customers through
production of textile binders, textile auxiliaries, adhesive etc. through
innovative technology. NPL is looking for service driven business, to
work closely with customers to meet their specific needs and hence,
delivering satisfying and efficient solutions
3. The unit intends to engage itself in manufacturing of synthetic
adhesives and acrylic based emulsions for the paint and textile
industries in commitment to world class standards.
4. The proposed establishment falls under the Item 5 (f) of Schedule I of
Environmental Impact Assessment Notification dated 14/ 09/ 2006 under
the provisions of Environmental Protection Act, 1986. The location of the
proposed project is not within the any notified industrial estate; hence it
will be treated as Category A project.

PROJECT DESCRIPTION
5. The proposed project is coming up in the vicinity of Textile Park located
near village Bidaj, District Kheda, Gujarat State. National Highway 8 is
@ 500 m distance from the project site.
6. The cost for the proposed manufacturing plant will be @ Rs. 1737 lacs,
which includes cost of land, building and machineries. Out of this,
approximately Rs. 50- 55 Lacs will be toward implementation of Env.
Pollution control measures.
7. Land area acquired by M/ s. NPL Industries Pvt. Ltd. for the proposed
project is @ 9500 sq.m., out of which @1250 sq.m. will be for plant


E.2
facilities, whereas @ 2500 sq.m. will be developed in form of green
area.
8. The unit intends to engage itself in production activities of Textile
binders, Textile polysols, Adhesives, Paint binder, Leather binder,
Auxiliaries & Plasticizers @ 5000 MT/M.
9. The power requirement @ 200 KW will be satisfied Captive power plant
of Vraj Integrated Textile Park Ltd. There will be installation of D.G. set of
100KVA, which will be operated in case of emergency during power
failure.
10. The water requirement @ 163 KLD for the proposed project will be for
process, utility (Boiler & Cooling), washing and domestic purpose,
which will be satisfied through an integrated textile park - VITPL which is
being developed just adjacent to the site.
11. As the major quantity of process water goes as part of product, hence,
the quantity of process wastewater generated is less in compare to
process water consumption. The main source wastewater generation
from utilities such as RO plant, DM plant, Boiler and Cooling is RO reject,
DM regeneration, Boiler blow down and Cooling bleed off.
12. Wastewater from process and utilities will be resorted to primary
treatment followed by tertiary treatment of two stage Reverse osmosis
plant. Reject from the second stage of RO plant will be thermally
destructed through J acketed evaporator of @ 300 L/ hour.
13. The sources of gaseous emission identified are from the Boiler as well as
fugitive emissions from handling of raw materials. No process emissions
have been envisaged from the proposed manufacturing facility.
14. Gaseous emission from solid fuel based 3 TPH boiler will be controlled
by Multicyclone with stack height of 30 m.
15. The sources of hazardous waste generation are process waste, ETP
sludge, used oil, discarded containers which will be handled as per
HWM Rules, 2008 and its amendment.


E.3
16. The unit is committed towards the Health and Safety of workers. The
unit has provided adequate number of first aid boxes at strategic
locations and given training to designated person for the emergency
purpose. The unit has also appointed part-time medical officer for
medical assistance and for ensuring the better health of workers.
17. All the workers are provided with required personal protective
equipments as and when required as per the nature of job.

BASELINE ENVIRONMENTAL SETTING
18. Study period for the baseline data generation work Winter season
(December 2011 to February 2012) and study area was considered as 6
Km radius considering site as center.
19. For Winter season (December 2011 to February 2012), primary data on
wind speed, wind directions, temperature and humidity were obtained
from the project site by installing Weather Monitoring Station.
20. The maximum temperature recorded during study period was in the
month of December 2011, i.e. 34
o
C, whereas the minimum
temperature recorded was in the month of J anuary 2012, i.e. 4
o
21. Total 6 ambient air quality stations were selected in the radius of 6 km
from the project site as centre considering the various factors.
C. The
relative humidity has varied from 15% to 90% during study period.
22. At all these sampling locations PM10, PM2.5, SO2, NOx

were monitored
to enable the comparison with ambient air quality standards
prescribed by the Central Pollution Control Board (CPCB).
PARAMETERS
MINIMUM VALUE
(g/m
3
MAXIMUM VALUE
(g/m )
3
)
PM 39.72 10 83.02


E.4
PM 28.00 2.5 50.50
Sulfur dioxide 9.42 21.64
Oxides of Nitrogen 14.16 35.40

23. As per additional TOR conveyed by EAC, Volatile organic compounds
were monitored at all AAQM sampling locations and the minimum and
maximum result has been presented at below table.
PARAMETERS
MINIMUM VALUE
(mg/m
3
MAXIMUM VALUE
(mg/m )
3
)
VOCs < 0.002 1.25

24. For characterization of water sources, Ground water samples (from 4
locations) and surface water samples (from 2 locations) were
collected and analyzed for drinking water quality parameters i.e.
physico-chemical parameters and heavy metals. All parameters were
found within permissible limit of IS 10500: 2000 (drinking water
standards). No heavy metals were found in any of the samples.
25. The noise levels were measured once during the study period at all
study locations for day time and night time. Noise levels were varied
between 56.17 to 71.66 during daytime and 41.09 to 64.33 at night time
during the study period.
26. Total 6 sampling locations within study area were identified for
characterization of soil. Physical characteristics of soil have been
delineated through specific parameters, viz. particle size distribution
(grain size analysis), porosity, water holding capacity and permeability
whereas data for chemical characterization of soil, selected
parameters viz. pH, electrical conductivity, cation exchange capacity,
and alkali matter and sodium absorption ratio have been analyzed.
27. Land use pattern of the study area have been obtained through LISS IV
satellite imaginary. Out of total 31428 Ha land, majority of the land area
i.e. @ 39% Crop land, followed by @ 12.93 % Water bodies including


E.5
river. Approximately 17 % land is covered with open as well as dense
scrub where as @ 8.8% land is covered with plantation.
28. A detailed on-site survey on flora and fauna existing in study area was
carried out. The study area does not have any identified
endangered species and also does not have any designated
forest, national park, sanctuaries.
29. The general observation of the site visit is that none of the plant and
animal species recorded is rare or endangered. The species of flora
and fauna found in the study area are common as anywhere and
everywhere.
30. Total population of study area is 96,683 with sex ratio of 911 and
average literacy rate of 61%.
31. At present, the study area has an average employment of 42.5%. Out
of which 35.5% are main workers and 7% are marginal workers. Out of
main and marginal workers, 50% workers depend on agriculture and
cultivation.
32. All villages have electric supply available for all purpose. All the villages
are having education facilities upto Primary education.
33. Medical facilities are found satisfactory. All villages have community
health workers. Some of the villages have Hospital facility also.
34. Tap and well, Tube well and Hand pump are prime sources of water in
all villages. For communication purpose, post office and phones are
available in most of the villages.
35. Villages are connected with paved roads. Bus is the main source of
transportation for all villages. Kanij, Sarsa and Geratpur villages have
availability of railway facility.

IMPACT ASSESSMENT
36. Impacts are identified due to proposed project in two phases:
Construction & Operation.


E.6
37. Impacts for construction phase will be short term temporary in nature
either positive or negative.
38. The negative impact will be on air quality and noise level due to
identified activities of proposed project during construction as well as
operation phases.
39. Green belt development will be the activity revealing beneficial
impacts on surrounding environment.
40. Employment generation will contribute positively to the local people
due to proposed project.
41. As the amount of ground water to be withdrawn for proposed project
is insignificant to the amount withdrawn by VITPL for its textile park,
there is no adverse impact anticipated on ground water quantity.
42. The anticipated quantity of effluent generated from the industrial plant
is @ 57.5 KLD, which will be treated in Treatment plant having primary
and tertiary treatment to achieve the quality of treated effluent so as
to recycle / reuse in the plant. As the treated effluent will be reused /
recycled in the plant, no direct impact on any environmental sink is
anticipated.
43. Stream containing high TDS (reject of second stage R.O.) will be
thermally destructed in evaporator.
44. The air quality will be affected moderately during construction phase
of proposed project. The unit has proposed to install lignite / agro
briquettes based boiler of 3 TPH capacity, Hence, for the control of flue
gas emissions, multi cyclone will be provided. No process emissions
have been envisaged from the proposed production facility.
45. There will be minor significant adverse impact on air quality during
operation phase of the project due to material handling, operation of
utilities. Development of Green belt of different species will absorb and
confine the pollutants within the premises.


E.7
46. The dispersion modeling was done as per the general guidelines of
CPCB vide their publication Assessment of Impact to Air Environment:
Guidelines for conducting Air Quality Modeling, 1998 and using ISCST-3
model of USEPA. From the dispersion model, it is observed that the
predicted ambient air quality due to proposed plant operations is well
within limits specified by the CPCB.
47. Incremental increase within the study area due to proposed project will
be as follow :
a. Particulate matter : 0 1.97 g/ m3
b. SO2 : 0 1.77 g/ m3
c. NOx : 0 0.66 g/ m3
Thus it can be concluded that proposed plant operations will not
adversely impact the air quality. Further, it is emphasized that all the
emissions have to be strictly controlled as mentioned in the mitigation
measures and summarized in the Environmental Management Plan, to
maintain ambient air quality within norms in the future.
48. The proposed project land has been taken on lease from the VITPL, for
industrial purpose, hence, there will not be any conflict in change of
landuse pattern. So, there is no impact envisaged on existing land use
pattern of the project site.
49. Placement and fixation of heavy machineries and vessels will have
moderate impact on noise for particular time period only. There will be
continuous generation of noise during plant operations, operation of
boiler having minor significant impact on the environment.
50. As the proposed project is to be developed near the premises of
industrial park, no significant impact associated with displacement of
prevailing floral & faunal species is envisaged on surrounding biological
environment due to proposed project activity.
51. The proposed project is anticipated to have positive socio-economic
impact as it will generate employment during construction as well as


E.8
operation phase. The generation of employment will improve the
Quality of Life (QoL) of people of the region due to improvement in
income.

RISK ASSESSMENT STUDY
52. Risk assessment study has been carried out for the storage of identified
hazardous and toxic chemicals which will be used for manufacturing of
proposed products. The characteristic of the potential hazardous
material to be stored are identified for deciding preventive measures
required during storage, handling and transportation.
53. The chemicals to be hazardous or toxic in nature to be utilized are
identified and are acrylamide , ammonia, formaldyhyde , vinyl acetate
monomer , acrylonitrile , methanol, Epichlorohydrine, Acetic Acid,
styrene , formic acid.
54. Effect and consequence for the hazardous chemicals are carried out
specifically for thermal radiation, overpressure effect in case of
explosion and for toxic release scenario for IDLH concentration.
55. Most of the chemicals stored in container or drum and the
consequence analysis is carried out for rupture of 200 liter drum of
methanol , 1250 liter container of vinyl acetate monomer, 200 liter drum
of styrene and rupture of 200 liter drum of acrylonitrile and the pool fire
and thermal radiation distance are calculated based on the available
software of PHAST(Version 6.53.1) Software of DNV. The various
concentration foot prints are plotted and shown in detail in report.
56. For the worst case scenarios and Maximum credible accident scenario,
rupture of the drum/ container is considered and the distance for
thermal radiation concerning first degree burn, second degree burn
and third degree burn are evaluated. This will help in deciding the
appropriate control measures to be provided for minimizing the effect
in case of emergency.


E.9
57. The maximum damage distance for various chemicals is summarized as
follow.
Sr
no
Name of chemicals
and condition
Atmospheri
c condition
Maximum distance in m
37.5
kw/m2
12.5
kw/m2
4
kw/m2
1 Rupture of 200 liter
drum of Methanol
3 m/s D Not
reache
d
6.32 11.77
vinyl acetate
container
3 m/s D 12.41 32.34 51.24
3 Rupture of 200 l
styrene drum
3 m/s B 5.10 16.24 26.16
acrylonitirle drum
3 m/s D 5.59 15.19 23.67

58. However in event of release as a result of rupture in drum / container of
above chemical, explosive mass will not be formed in any stability class
and wind speed. Hence, no overpressure hazard due to both early and
late explosion is possible in any case.
59. Statutory guidelines have been followed for preparation of risk
mitigation measures on basis of risk analyzed. Fire fighting system as per
guideline will be installed and maintained.
60. The manual handling of chemical will be avoided as far as possible
and required safety measures will be provided for handling and
transportation of this chemical. Risk mitigation measures are specifically
provided for major and minor spills from drum and containers.
61. Occupational health surveillance program will be planned and
implemented during operational stage.


E.10
62. DMP will be prepared for the proposed manufacturing plant and
implemented.

ENVIRONMENTAL MANAGEMENT PLAN
63. Optimum use of water will be done for construction phase as well as for
labours with adequate water supply to labours for drinking water and
sanitation facilities.
64. Dust will be the main pollutant affecting the ambient air quality during
construction phase alongwith gaseous emissions during transportation
of required materials. For suppression of dust during construction
activities, water will be sprinkled.
65. The performance of ETP will be monitored continuously. Any deviation
in performance will be subjected to corrective measures through root-
cause analysis.
66. The regular environment monitoring shall be done through established
laboratory.
67. For proposed project, all transferring and feeding areas will be well
covered to avoid any fugitive emissions. For the process area of the
plant, proper ventilation will be provided on the shop floor for
proper air circulation to maintain the work area air quality.
68. The segregation and storage of all hazardous solid waste generated
will be done for the proposed project.
69. Proper storage, handling and disposal of all type of hazardous solid
wastes as per the guidelines prescribed will be ensured.
70. Regular maintenance of equipments / machineries will be done by
application of proper lubricating agent. Enclosures and barriers will be
provided to pumps and machineries producing high noise levels for
proposed project.


E.11
71. There will be practice of pre medical checkup and regular medical
checkup of employees and periodical training will be imparted for
better occupational health of workers.
72. Trained workers will be employed for all the hazardous process
operations within the plant and will be supervised by experienced
supervisors.
73. Antidotes as well as MSDS for all the chemicals will be made available
within the factory premises.


E.12
1.
NPL Industries Pvt. Ltd.
.

:
2. NPL Industries Pvt. Ltd. ,
.
NPL
3. Paint Textile Synthetic Adhesive
Acrylic Based Emulsion .
4. ,
1986 14/09/2006 1 5 (f)
;
A .

5. ,
, - 8 @ 500
.
6. @ 1737
. . 50 - 55
.
7. NPL Industries Pvt. Ltd
1250 2500
.


E.13
8. textiles binders,
textiles polysols, adhesives, paint binder, lather binders, Auxiliaries
plasticizers
9. Vraj Integrated Textile Park Ltd 200 KW
100KVA, DG Set

10. 163 KLD ,
Process, Utility ( ),
VITPL
11. ,
R.O. Reject, DM Regeneration, Boiler Blow down
Cooling Bleed off
12.
R.O. Plant
R.O. Plant R.O. Reject 3
Jacketed Evaporator
13.
fugitive emission

14. 3 TPH 30
Multicyclone .
15. ETP sludge HWM ,
2008


E.14
16. .

.

17.

18. (
) 6
. .
19.
( ), ,
.
20. ) 34
o
c
4
o
21. 6 . .

c
15% 90%
22. PM
10
, PM
2.5
, SO
X
, NO
X

(CPCB)

( / )

( / )
PM
10

PM
2.5


E.15
SO
2

NO
x

23. EAC TOR , AAQM VOC

.

( )

( )
VOCs 0,002 < 1.25

24. ( (4 )
(2 )

IS (Drinking water
standards) .
25.
.
.
26.

grain size
analysis), porosity, permeability
.
cation exchange capacity,
.


E.16
27. LISS IV

% %
%
28. .
, .
29.
.
.
30.
% .
31. % . %
% . , 50%
.
32. .
.
33. .
. .
34. ,
. ,
.
35. .
. .
-
36.

37.


E.17
38.

39. .
40.
41. VITPL

42.
R.O. Plant

43. R.O. Plant R.O. Reject
Jacketed Evaporator
44.
3 TPH

45.

46. CPCB
"
" 1998 USEPA ISCST-3 .
CPCB
.
47.

/


E.18
/
/

48. VITPL ,
.
49.
.

50.

51.
.

52.

53. , ,
, , , ,
, , .
54.
IDLH
55.
DNV PHAST


E.19
56.
,
.
.
57. .

37.5
kw/m2
12.5
kw/m2
4
kw/m2
1
200

3 m/s D
--
2
1250

3 m/s D

3
200

3 m/s B

4
200

3 m/s D

58.

59.

60.
.
.
61.
.
62. DMP .


E.20

63.

64.

65.

66.
67. ,
,

68.
69.
70.
.
71.

72.

73. MSDS antidotes

NPL Industries KH Exe Summ Eng and Guj

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Executi ve Summary of REIA Report

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