environmental assessment and risk assessment...

Environmental Assessment and Risk Assessment StudyFor proposed expansion in existing unit of Gemasko Pharmachem Industries

at Plot no-6129/11/A, Phase-IV GIDC Estate, Vapi-396195STATE – GUJARAT, INDIA

EXECUTIVE SUMMARYEnvironmental Impact Assessment

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1 IntroductionM/. Gemasko Pharmachem Industries (GPI) proposes to start production of new products of the bulk drug category at theirexisting unit at Plot No. 6129/11/A in Vapi Industrial Estate of GIDC, Gujarat, India. The unit is an SSI engaged in distillation ofvarious industrial solvents and specialty diluents @ 150 MTM.Looking to the growing market of bulk drugs and having the required capital and plot area the partners now wish to startproduction of bulk drugs in addition to existing products enhancing the total production capacity to 170 MTM.The proposed project of expansion falls under category B, sr. no. 5(f) of the schedule of EIA notification dated 14th September2006. However since Vapi was declared critically polluted area by MoEF, required prior Environmental clearance is to beobtained from MoEF.

1.1 PURPOSE OF STUDYIn compliance to the requirement of the EIA notification, M/s. GPI have seeked environmental clearance from the Ministry.Application in prescribed Form-1 has been submitted. The proposal has been appraised by the Expert Appraisal Committee(Industry-2) on 11-05-2012 and the TORs have been finalized for preparation of Environmental Impact Assessment Report.Reference Documents :MoEF File No. : F. No. J-11011/26/2012- IA II (I)Appraisal by EAC (Industry-2) : on 11-05-2012Final TORs issued vide letter dated 25-07-2012

1.2 METHOD OF STUDYThe study is based on guidelines and manual issued by MoEF and SEAC, latest development in EIA methodologies and theAssessment Agency’s experience.and identifies the nature of activities involved and their impacts caused on variousenvironmental parameters. It subsequently suggests mitigation measures to be executed for safeguarding against anyenvironmental degradation. Finally, it suggests methods of implementing the environmental management plan.The REIA study involves;Step I : Identification of all the probable environmental impactsStep II : Prediction of the significance and magnitude of the impactsStep III : Evaluation of the overall impacts and mitigation of adverse

impacts to achieve sustainable development;Step IV : Preparation of REIA report and Environmental Impact Statement(EIS)2 The ProjectName of the Proponent : M/s. Gemasko Pharmachem IndustriesLocation of Unit : Plot no-6129/11/A, Phase-IV GIDC Estate,

Vapi-396195District Valsad, State – Gujarat, India

Total land acquired by the factory : Approx. 998 sq. mYear of Establishment : 2010Present Production Activity : 01)Distillation of various industrial solvents – 75 MTM

02) Specialty diluents – 75 MTMExisting and Proposed Products and their proposed capacity MT/Month

Sr.No

Product Consent AvailableFor Production

Mt/Month

EC Required ForAdditional Production

Of -Mt/Month

TotalProduction

Mt/Month

Remarks

01 Distillation of variousIndustrial Solvents

75 0.0 75.0 Existing product(No change)

02 Specialty diluents 75 0.0 75.0 Existing product(No change)

03 Amlodipine Besylate 0.0

2.0Either individual

OR total

2.0

New products(Bulk drugs)04 Tramadol HCl 0.0

05 Ramiprill 0.006 Artemether 0.007 Arteether 0.008 Olanzapine 0.009 Metformine HCl 0.0 18.0 18.0 New product

(Bulk drug)Total 150 20.0 170.0

The increase in production capacity is not much as compared to the existing capacity.




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Parameter Description

Cost of theProject

Rs. 200 lac (for expansion only)

Fuelrequirement

Sr.No.

Fuel used for Type of Fuel & consumption (estimated)

1(existing)

Thermic Fluid Heater1 lac kilocalorie / hr Natural Gas –

700 SM3/day (as and when available)ORLDO-36.5 KL/day

2(New)

Small Industrial Boiler –800 kg/h

3(new)

D.G set – 250 KVA LDO/HSD-20 lit/hr

Powerrequirement

The power requirements of the unit are fulfilled by M/s Daksin Gujarat Vij Co. Ltd.(D.G.V.C.L.) Proposed requirement of electricity will be 200 KW (50 KW (Existing) + 150KW (Proposed))

Manpowerrequirement Resource For Existing

ProductionFor Proposedproduction

Total(Existing +Proposed)

Man power 10 20 30

Fresh WaterRequirement

To increase from 10 m3/day to 19 m3/day to be supplied by GIDC

Wastewatergeneration

Industrial effluent to increase from 1m3/d to 5.5 m3/dDomestic effluent to increase from 1 m3/d to 1.5 m3/d

Utility requirement :Sr.No.

Type of Utility Existing Proposed additional

No. Capacity No. Capacity

1 Thermic fluid heater 1 1 lac Kcal/hr 1 ---

2 Small Industrial Boiler --- --- 1 800 kg/hr

3 DG set* --- --- 1 250 KVA

4 Cooling Tower 1 100 TR --- ---

5 Chilling plant 1 400 TR --- ---

6 Water Storage Tank 1 200 m3 --- ---

2.1 SALIENT FEATURES OF PROJECT SITEThe salient features, of the location of the industry, can be described through the natural and commercial resources and / orfacilities available in a particular area, which have been presented at Table below.

Sr.No.

Particulars Details

1. Village Vapi2. Taluka Pardi3. District Valsad4. Latitude 20°21’22.49”N5. Longitude 72°56’25.32”E6. Nearest water bodies Daman ganga river- 3km towards SW

Kolak river-3.39 km towards NE7 Nearest Highway NH-8 –2.16 km towards NW




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Sr.No.

Particulars Details

State highway no. 5- 0.45 km towards S

State highway No. 185A – 1.04 km towards SW

8 Nearest Railway station Vapi- 3.50 km towards NW9 Nearest Airport/ Airbase Surat airport 86.07 km towards NW

2.2 ALTERNATIVE ANALYSIS & JUSTIFICATION OF THE PROJECTFor Project selection The Indian bulk drug industry is expected to expand at an annual growth rate of 21% to reach $16.91 billion by 2014,

according to a new report by market research firm Cygnus. The expansion looks to rope in new technologies hence increasing the efficiency of operation and also reduce the specific

utility consumption. The operational costs are expected to reduce hence increasing the profitability of the business and also reduce the energy

loads The existing infrastructure facilities and land availability shall be utilized to the fullest with more efficiency. The operational costs shall be reduced and the productivity shall increase The project has potential for exports and therefore add to foreign exchange. Also it shall reduce dependence on imports

hence reducing Forex risks. The present level of employment shall increase through requirement of skilled/unskilled labour, qualified professionals. Since the expansion is planned in the same factory premises, the existing workforce shall not be affected. There are also

chances of indirect employment generation to be rise.For Site selectionProposed expansion is planned in the same factory premises since - the existing plot area is sufficient Existing plot is located in notified area of Vapi GIDC estate and has the common features of a developed industrial

estate viz. water from GIDC supply, Natural gas as fuel from Gujarat gas company, power from DGVCL, road network,transportation facilitiesAvailability of Resources viz.

Water - from GIDC water supply.Fuel - Natural gas from M/s. GSPCPower - from Dakshin Gujarat Vij Co. Ltd. power supply line

Industrial AssociationsVapi Industrial Association (VIA)

Common Treatment and Disposal FacilitiesCETP - M/s. VAPI WASTE & EFFLUENT MANAGEMENT CO. LTD. (VWECL)

TSDF- M/s. VAPI WASTE & EFFLUENT MANAGEMENT CO. LTD. (VWECL)Common Incineration Plant - M/s.GEPIL SuratCommon Discharge of treated effluent into deep sea through u/g pipeline ofM/s. VAPI WASTE & EFFLUENT MANAGEMENT CO. LTD. (VWECL)

No reserved forests or sanctuaries or archeological sites are located in the vicinity of the area No rehabilitation or resettlement of local people

The plot at Vapi GIDC is also suitable project site is also justified as per the siting criteria delineated by MoEF

For technology / process selectionAs regards the proposed new products, batch processes selected are the only developed processes used by current producersover the world. The accuracy and operability of the processes are judged to be proven based on consistency of production andspecification of products manufactured by other national and international manufacturers.




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3 Baseline Environmental StatusFollowing the final TORs as issued by EAC, the impact or study area has been considered to be the area within radius of 5 kmfrom the project site.There are many SSI and MSI industries of different sectors and about 13 villages identified within the study area.Baseline data for the following environmental attributes are collected for this study: Meteorology Ambient Air Quality Surface and Ground Water Quality Ambient Noise Quality Soil Quality and Geological Data Land use pattern Ecological Information Socio-economic status Infrastructure facilities

3.1 METEOROLOGYOnsite monitoring was undertaken during 8th October 2012 to 31st January 2013.Looking at the recordings of temperature, it can be sited that the weather of the project site remains stable and dry for most partof the year so as to support plume rise.Relative Humidity is generally high during monsoon season.The maximum relative humidity recorded during the monitoring was 87% in the month of January.The wind speed in the project site are not too high with moderate drifts. The wind direction also has less variations.The predominant wind direction was observed to be from SW-NE.

3.2 EXISTING AMBIENT AIR QUALITYThe ambient air quality monitoring was carried out at 7 AAQM locations, with a frequency of twice a week continuously, toassess the existing air quality status. Parameters of Air pollutants specific to the study area were selected for monitoring viz.Particulate Matter (PM10), Sulphur dioxide (SO2), Oxides of nitrogen (NOx), Ammonia, Benzene and Benzo(a)pyrene, inaccordance to the TORs issued by EAC.The monitoring was carried out in accordance with the guidelines of Central Pollution Control Board (CPCB), scientific manual ofGPCB, and National Ambient Air Quality Standards (NAAQES) of CPCB.Location of Ambient Air Quality Monitoring Stations

Stn.Code

Location Approx. AerialDist. From thesite, km

Directionw.r.t projectsite

Type of Area Upwind or downwindw.r.t predominant wind

direction

1. Vapi Main town 4.1 NW Commercial Crosswind

2. Chirri 2.69 NNE Residential Downwind3. Chanod 2.31 SSW Residential Upwind4. Karambeli 4.1 SW Residential Upwind5. Dungra 2.71 SSE Residential Crosswind6. Pandor 4.17 NE Residential Downwind7. Project Site - - Industrial --




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Map showing locations of AAQM stations

Ambient air quality was found to be within the prescribed regulatory limits. Within Study area the percentile values of parametersmonitored were found as below:

PM10 & PM2.5The main contribution to PM10 and PM2.5 at all the AAQM locations was primarily due to local activities such as industrial airemissions, vehicular movement, natural dust due to manual activities and prevailing wind.PM10 concentrations in the study area were ranging from 22-84 g/m3 with 98% percentile values in the range of 51-82 g/m3indicating the concentrations are within stipulated standards of NAAQS.PM2.5 concentrations in the study area were ranging from 11-42 g/m3 with 98% percentile values in the range of 22-38 g/m3indicating the concentrations are within stipulated standards of NAAQS.However, Vapi was declared as critically polluted area from 13-01-2010 to 26-10-2010 owing to CEPI score of 88.09. In year2010, the moratorium has been lifted and the current CEPI score of 70 has been achieved, however, Vapi GIDC is still undervigilance by the Central Pollution Control Board.

SO2SO2 concentrations (98th percentile) at all the locations were observed to be within stipulated standards of CPCB forresidential/rural region at all of the air quality monitoring locations during the study period. The range of SO2 was from 9-28g/m3 with 98th percentile values in the range of 12-19 g/m3.

NOxNOx concentrations (98th percentile) at all the locations were observed to be within stipulated standards of CPCB forresidential/rural region at all of the air quality monitoring locations during the study period.The range of NOx was from 09-25 g/m3 with 98th percentile values in the range of 15-25 g/m3.

AmmoniaAt all the AAQM locations (Industrial as well as residential) Ammonia values were below detectable limit.

BenzeneAt all the AAQM locations (Industrial as well as residential) Benzene values were below detectable limit.

Benzo(a)pyreneBenzo(a)pyrene at all the locations were observed to be within stipulated standards of CPCB during the study period.




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3.3 EXISTING NOISE LEVELSThe max. noise level measured in the industrial area under the impact zone was 64 dBA at project site in daytime and 56 dBA innight time also at project site, which were below the stipulated standards of CPCB.The noise levels of the residential area within the impact zone varied from 51-54 dBA in the daytime and 33-41 dBA in the nighttime, which are also below the specified limits.

3.4 GROUNDWATER AND HYDROLOGYBoth primary data as well as secondary data from EIC, delhi and Geological survey of India were gathered for groundwater tableand hydrology of the study area.

Total 6 wells were inventoried in and around the study area on 14-12-2012Table 3.10(c) Reduced water level measurement

The static water level is ranging between 4.02m to 9.00m from the existing ground surface. The contour map of reduced waterlevel was prepared. The general groundwater flow direction is found to be SW which is apparent from the map.

3.5 GROUNDWATER & SURFACEWATER QUALITYThe baseline water quality status in the region is established by analyzing surface water and ground water samples. Waterrequirement at GPI is to be met through GIDC supply.Ground water resources are predominantly exploited in most of nearby villages only for domestic and agricultural purposes.Table 3.10(a) Sampling Locations for Monitoring Surface and Ground Water QualitySr. No. Sampling

LocationsDirectionw.r.t. Project Site

Approximate Radial Distance FromProject Site (km)

SURFACE WATER1. Bil Khadi E 0.322. Damanganga river SW 3.203. Kolak river NEE 3.394. Karvad lake E 1.12

GROUND WATER1. Vapi Main town NW 4.12. Chirri NNE 2.693. Chanod SSW 2.314. Karambeli SW 4.15. Mohangam NE 3.726. Pandor NE 4.17

GW= Ground water, SW= Surface waterFrom the analysis, it shows that the quality of GIDC supplied water at the project site is satisfactory to serve for domesticpurposes as per Standards prescribed by Indian Standards Institution (ISI) for Drinking Water. The desirable limit as per the IS: 10500:1991 is 6.5 to 8.5. The pH value ranges from 7.10 to 8.37 in surface water

sample while 7.36 to 7.81 in groundwater samples. All the groundwater samples are within the permissible limit ofIndian drinking water standards 10500:1991 except Vapi.

In surface water samples, TDS values ranges between 130 mg/l (Damanganga River) and 2493 mg/l (Bil Khadi). All the groundwater samples are of very hard category of classification. As per the IS 10500:1991, 300 mg/l is

desirable limit and 600 mg/l is the permissible limit. Chlorides in all the groundwater samples are within the permissible limit of IS: 10500:1991. The chloride ion concentration in surface water bodies is ranging between 8 mg/l (Damanganga River) and 1126 mg/l

(Bil Khadi).




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The Total Hardness value ranges in surface water samples are between 86 mg/l at Damanganga River to 760 mg/l atBil Khadi.

Sulphate value founds to be within the permissible limit in all the groundwater samples of the study area except thegroundwater sample of Vapi

The minimum concentration of total alkalinity is found at the Chanod village, i.e., 215mg/l and maximum is 426 mg/l atKarambeli village groundwater sample. Total Alkalinity content in the study area is within the permissible limit of theIndian Standards.

The minimum value of Total Alkalinity is found at Damanganga River water sample viz., 97 mg/l while maximum valueof 356 mg/l is found at Bil Khadi water sample.

Fluoride content in the study area is above the permissible limit of the Indian Standard. In surface water samples also,the fluoride ion concentration is high. Only Bil khadi water sample is within the permissible limit of Indian Standard10500:1991.

In the study area, the EC value in surface water samples is ranging between 197 µs/cm (DamangangaRiver) and 3745 µs/cm (Bil Khadi). The EC value in groundwater samples is ranging between 512 µs/cm (Chanod)and 3885 µs/cm (Vapi). EC < 250 is considered excellent, 250 – 750 is considered good, 750-2250 is consideredmedium and > 2250 is considered bad as per the CGWB classification.

3.6 SOIL QUALITYSoil samples were collected from 6 different locations during the study period in the study area and analyzed for physico-chemical characteristics.

Table No. 3.11(d) Chemical Characteristics of Soil

Sr.No. Parameter Unit

Sampling Station

Chirri Chanod Karambeli Mohangam Pandor Project site

1. pH -- 8.47 8.01 8.49 7.19 8.23 7.38

2. Electricalconductivity µ mhos/cm 238.6 167.3 234.5 65.89 108.3 2.621

3. SAR - 1.3 2.4 2.0 1.81 0.8 1.79

4. Water Holdingcapacity % 34 45 36 44 48 45

5. Cation exchangecapacity mg/gm 6.6 6.1 5.9 6.2 7.4 7.2

6. Ca gm/kg 0.34 0.28 0.16 0.20 0.18 5.537. Mg Gm/kg 0.03 0.05 0.14 0.08 0.02 0.318. Na gm/kg 0.3 0.52 0.46 0.38 0.14 1.69. K gm/kg 0.03 0.06 0.12 0.09 0.04 0.53

The soil found in the study area is of clayey type and porosity ranging between 32.7 to 50.8%. However, the permeability is lowas the clay does not have interconnecting pores.

3.7 LAND USE PATTERNThe baseline land use pattern, within 10 km radius of the project site, have been obtained from Environmental InformationCentre and state government publications related to land use data i.e. census and gazetteer books of Valsad district.The satellite imagery of Land use / Land cover of the area within 10 km aerial distance of the project site, is obtained fromEnvironmental Information Centre, Delhi.




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Table No. 3.13(a) Land use Pattern of the study area

About 25% of total land area under the region of interest is fallow land i.e. it is uncultivated while about 24% of the total landis occupied for agriculture purpose.

The habitant and settlement area comprising of villages is about 9.3%. The distribution of different land use patterns indicates that there is not any one particular type of land use with major

contribution which can be affected significantly by the impacts of the proposed expansion. Since the study area includes Vapi GIDC notified industrial area and industrial areas in DNH-UT ( ~ 4.5%), industrial activity

is of significance in the area.

3.8 ECOLOGICAL INFORMATIONTable No. 3.13(b) Nearest Important Geographical Features From Project SiteNatural Feature Name Distance

KmReligious and historic places 1. Fire temple at Udwada 16.3 km

Towards NW2. Lady Wilson museum (Dharampur) 31.08 km

Towards NEArchaeological monuments/sites None -Scenic areas 1. Silvassa 11.77 km

Towards SE

2. Daman 13.01 kmTowards NW

3. Khanvel Resort (S-DNH-UT) 28.18 kmTowards SE

Hill resorts/mountains/ hills 1. Silvassa 11.77 kmTowards SE

2. Saputara 88.10 kmTowards NE

3.Sahyadrimountains(Dharampur)

31.07 kmTowards NE

Beach resorts/ Health resorts Devka Beach (Daman) 13.7 kmTowards NW




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Natural Feature Name DistanceKm

Coastal areas rich in corals, mangroves, breedinggrounds of specific species Arabian Sea 12.49 km

Towards WEstuaries rich in mangroves, breeding ground ofspecific species Purna Estuary 63.49 km

Towards NW

Gulf areas Gulf of Khambhat 90.6 kmTowards NW

Biosphere reserves National park and wildlifesanctuaries 1. Vansda National Park 72.06 km

Towards NE

2. Purnawildlife Sanctuary 100 kmTowards NE

Natural lakes, swamps Seismic zones tribalSettlements 1. Karvad lake 1.13 km

Towards SE

2. Koparli lake 6 kmTowards NE

3. Valawad lake 5.69 kmTowards SW

Areas of scientific and geological interest None -Defense installations, specially those of securityimportance and sensitive to pollution None -

Border areas (international) None -Nearest international airport 1. Surat 86.07 km

Towards NW2.ChhatrapatiShivaji (Mumbai) 139.35 km

Towards S

Nearest domestic airport Daman airport(UT) 13 kmtowards NW

Tiger reserves/elephant reserve/turtle nestlinggrounds None -

Habitat for migratory birds None -Lakes, reservoirs, dams 1. DamanGanga Check dam 1.47 km

Towards SW2. Madhuban Dam on Damanganga river(DNH-UT)

21.83 kmTowards SE

3. Sarigam Reservoir 12.30 kmTowards SW

4. Kurze Dam reservoir (S-DNH-UT) 28.8 kmTowards S

Streams/rivers/estuary/seas 1. DamanGang River 3 kmTowards SW

2. Kolak River 3.39 kmTowards NE

3. Arabian Sea 12.5 kmTowards W

Railway lines Vapi railway line (Surat to Bombay) 3.50 kmTowards NW

Highways NH8 2.16 km to NWSH5 0.45 km to SSH185A 1.04 km to SWSH140 2.16 km to NW

Urban agglomeration Dadra(S-DNH-UT) 3.50 km to SEVapi main 3.92 km to NWBhilad 10.75 km to SWUmbergaon 27.35 km to SWDaman(UT) 13 km to NW




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3.9 ECOLOGY AND BIODIVERSITY IN THE STUDY AREASince the command area of the study covers only a 5 km radius the major part of the study area is the Vapi town and GIDCnotified industrial area of Vapi located in the northwest direction. In the northeast to east are located some of the villages andthe major part of the land is found to have agriculture along with few small water bodies. Towards west to southwest are fewmore villages and the major river that is encompassed in the current study is also situated in the west/southwest direction i.e.river Damanganga. Towards south and southeast are few densely populated villages and agriculture seems to be less in thispart of the study area.

As mentioned above the major part of the study area was Vapi town, the survey was conducted in and around the villages ofVapi town, namely, Chhiri, Vadiyavad, Rata, Pandor, Koprali, Dungra, Mohan gam, Chanod, Valvada, Karambeli and Karvadthat covered the 5 km radius. The type of soil was largely observed to be black cotton soil, with high fertility for agriculture.Mango orchards were mainly present in many of the villages that were surveyed, which suggested Mango to be the major cashcrop of this belt. Fallow land was rarely observed in the present study, since if the land had no cultivation then it was asettlement with houses of different structures. Protected Area of any category, i.e. National Park, Wildlife Sanctuary, ReservedForest or Conservation Reserve was not present within the 5 km radius of the study area. A checklist of naturally occurring f loraas well as cultivated and introduced species is tabulated in the report.

In present survey diversity of water birds was poor even though it was winter season, time for the migratory species to flock thetropical regions, but unfortunately there were no such wetlands in the entire study area that could support the migratorywaterfowl in large numbers. The only wetland observed was the Kharvad lake, wherein a small numbers of resident water birdswas recorded. However, the terrestrial bird diversity was rich and all the possible species that could be encountered in theagricultural fields or around human settlement and plantations did exist here. A checklist of the local avifauna is given in thereport.

Common domestic animals and birds are found in the villages, industrial area, agriculture fields and other vegetative land.As far as the mammals are concerned, again the mammalian diversity in the study area was poor due to the major area beingurban zone. Except for the domestic mammals that are a part of the human society, wild mammals in this region were very few.Not much livestock was observed in the villages, which raise a doubt whether locals are involved in animal husbandry or not. Oninquiring, we were informed that locals are involved in animal husbandry but the livestock population on per capita basis is nothigh as compared to the farmers in other parts of Gujarat. Apart from the livestock, feral animals such as dogs, cats and pigswere also observed near human settlements in villages as well as Vapi townBirds like crows, pigeons, Indian myna, black bulbul, koyal, and parrots were observed in good number. Hens and peacockswere seen in village areas.

It is evident from the results of the present study that no threatened species of flora or fauna was recorded from the prescribedstudy area, neither any protected area in form of national park, wildlife sanctuary, reserved forest or conservation reserve fallswithin the study area.The only strong recommendation is that the client should piously think over the green belt development in his premises, which initself is one of the major mitigating factors

5.7 Demography and Socio-EconomicsPrimary data collection was done through community survey based on personal interviews and questionnaire in total five (5)villages falling within a radial distance of 10 km from the project site.Significant observations with respect to availability of amenities in study area are as follows. Education facilities in study area are quite good because all villages have primary and secondary schools. There are

higher secondary school in Vapi, Chanod and Chhiri. Recently there are multidisciplinary colleges setup at Vapi andChhiri. For other college education, students have to travel to Surat at the nearest.

Health facilities are not satisfactory Karambeli and Pandor. There is no primary health centre or community healthcentre or dispensaries in these villages. Vapi is quite developed with over 10 public hospitals. Chanod and Chhirialso have dispensaries and hospitals.

In the study area drinking water facility is good as borewell and tap water is available almost in all the villages. postal and telegraph facilities are good in the entire study area. All villages are well connected through a network of Pucca road as well as Kaccha approach road. Bus is the main

mode of transportation and bus stands are provided at all villages. Private jeep service is also available. Railwaystation is also available to each village under survey.

Electricity for all purposes (agriculture as well as domestic and commercial) is available in all villages and town in thestudy area.

Agriculture productivity is average in this area owing to lack of skill, modern equipment. People migrate to nearbycities and town for miscellaneous jobs during summer season.




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4 Prediction Of Impacts And Environment Management PlanThe Environmental Impacts of the project are assessed for three phases :

I. Construction PhaseII. Erection and Commissioning PhaseIII. Operational Phase

The various activities to be carried during each phase are also identified. The Environmental attributes considered for impactassessment are as under :Sr. No. Environmental Attributes Relative Importance (%)

1. Land 112. Water 143. Air 184. Living space4.1 Human (Social) 144.2 Human (Economic) 144.3 Other living entities (Ecological) 135. Natural resources for fuel (Natural Gas) 16Total 100

The impact identification is done using impact – activity matrices for all three phases of the project.The prediction and magnitude of the impacts is determined using various prediction tools.

4.1 CONSTRUCTION & ERECTION PHASE OF THE PROJECT4.2 CONSTRUCTION & ERECTION PHASE OF THE PROJECTEMP for Impacts on Air Environment

Slightly adverse impacts on ambient air quality such as dusting, PM and noise generation from machinery and transportvehicles, local disturbance, increased road traffic, labour camp mobilization are envisaged during construction of plant and otherutility facilities. These effects will however, be temporary and reversible and confined to the project area. The mitigation /management measures proposed are :• dusting will be reduced by sprinkling of water.• Maintenance of construction equipment to minimize exhaust emission and noise pollution• Placing of unwanted material as noise barriers along noise emitting area• Ear muffs and ear plugs to workers

EMP for Impacts on Water EnvironmentDuring construction, water shall be consumed from GIDC supply. Vigilent check shall be kept to avoid wastage.No wastewater shall be discharged during the construction period.Proper sanitation facilities will be provided for the workers and domestic waste generated would be collected and treatedappropriately using septic tanks and soak pits.

EMP for Impacts on Land EnvironmentThe area proposed for expansion is within factory premises and is fairly plain with no prominent vegetation and tree plantation.Hence no adverse impact is envisaged on site-specific topography due to preparation of site, civil construction and structuralconstruction. Minor impact may be observed due to generation of dust for which water sprinkling shall be done at regularintervals. PM deposition from vehicular emission shall be of minor nature looking to the small scale of construction.Sewage wastes shall not be directly discharged into the land but collected and treated in septic tanks and soak pits.Plastic sheets or tarpaulin shall be used for storage of construction materials

EMP for impacts on Human (social) Environment• During construction and erection, minor dusting and noise generation shall affect the aesthetics and can cause local

disturbance.• Dusting can be reduced by sprinkling of water. Maintenance of construction equipment to minimize exhaust emission

and noise pollution• Placing of unwanted material as noise barriers along noise emitting area• Ear muffs and ear plugs to workers

EMP for impacts on Human (economical) Environment• During construction and commissioning of proposed project, the facilities such as supply of construction material and

machinery, their transport would lead to employment of local people and would be beneficial to the local & industrial




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people. Since, the local labour will be sought for construction and installation of the machinery; it will also benefit theeconomy of the area. Commodity requirements and food requirements of labour camps shall also increase the retailmarket of the area.

EMP for impacts on Ecological EnvironmentNo uncommon flora or fauna are present in the study area. The project land is acquired by GIDC for industrial development andtherefore there is no displacement of local flora and fauna as well as no change in present land use pattern. The managementof air, water and land environment as proposed in the previous sections, shall ensure that there is no adverse impact on theterrestrial and aquatic ecology of the area.

EMP for use of fuel resources (Natural gas)Workers shall be provided with cleaner fuel for domestic use so that the local vegetation is not targeted for fuel requirement andthis shall be monitored during the construction phase. Cleaner fuel shall be used for construction activities.

4.3 OPERATIONAL PHASEEMP for Air EnvironmentThe flue gas emissions shall remain within permissible limits since natural gas is to be used as fuel.Process emission shall be controlled through proper scrubber system.The comparison of the anticipated air emissions with the source emission standards and calculated maximum ground levelconcentrations with ambient air quality standards indicates that the air pollutant concentrations, from source and in ambient air,are expected to be quite below the stipulated limits, for proposed project.

Action plan to control and monitor secondary fugitive emissions from all the sourcesIn addition to this, the industry has proposed adequate control measures for control of fugitive emissions as listed below : Natural gas shall be used as fuel so that the flue gas emission remains within permissible limits. Proper stack height

as prescribed by SPCB shall be provided with sampling provisions. All reactors shall be closed and provided with primary and secondary condensers for vapor recovery All the storage tanks shall be under negative pressure to avoid any leakages. Safety devices shall be provided on storage tanks and reactors. Breathers, N2 blanketing will be provided for all the storage tanks. Closed handling systems will be provided for chemicals and solvents During transfer of materials, spillages shall be avoided In case of a leakage, provision for immediate isolation of such equipment will be made. The company shall provide a well defined Leak Detection and Repair (LDAR) program for quantification and control of

fugitive emissions. The detectors sensitivity will be in ppm levels. Safety interlocking systems and automatic shutdown systems shall be provided on critical equipment Mechanical seals will be provided for pumps/agitators for reactors for reduction of fugitive emissions Environmental Monitoring Plan shall be developed for regular monitoring of flue gas emissions, work place

environment and ambient air quality. A green belt shall be developed and maintained in 33% of the plot area. Plantation in the green belt shall be in

accordance to the guidelines of CPCB. To maintain a proper record for the periodic maintenance of the equipments and operations. Work areas surrounding the plant shall be paved to avoid dust formation caused by movement of vehicles. A proper record for the fuel consumption, start-up time and duration of boiler operation, energy consumption is

advised to be maintained. Unloading of the raw materials shall be carried as per the Safe Operating procedures. Operators shall be provided training for handling of hazardous chemicals and ensured that they follow the SOPs. Separate storage areas for flammable and non-flammable chemicals Contained storage areas Flameproof electrical and fittings Entry restrictions at flammable and hazardous material handling and storage locations

Hence, no significant adverse effect on the air environment has been envisaged.The noise impact due to operation is not major in the present study. The existing noise levels are found within permissible limits.Following measures are taken for noise abatement and control :- Ear muffs and ear plugs to operators- Maintenance of pumps and machinery and all rotating equipment- To avoid use of internal village roads for transport vehicles- Proper loading and unloading procedures- Maintaining the greenbelt since it also helps in reducing noise




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EMP for Water EnvironmentFor the proposed project, water requirement @ 19 m3/d shall be obtained from GIDC supply and therefore no impact on thequantum of ground water resources is envisaged.The wastewater quantity shall increase after proposed expansion owing to new products to be added. The quality of effluentshall also change since the new products are of different category and shall generate about 5.5 m3/d effluent. Unit hasproposed to install new ETP @ 12 m3/d capacity with primary, secondary and tertiary treatment, which shall be adequate andefficient to treat the effluent within inlet norms of CETP of M/s. VWEMCL, Vapi. Treated effluent is to be sent to CETP for finaltreatment and disposal into deep sea. Hence, there shall be no negative impact on surface and ground waters.Adequate provisions have been proposed for preventing contamination of storm water by implementing proper house-keepingpractices and SOPs to prevent spillages and contaminated surface runoff going to storm water drains.

EMP for Land EnvironmentThe ground level concentrations as predicted from air dispersion modeling, are low enough so as not to alter the quality ofambient air as well as not to affect the surrounding soil due to deposition of air pollutants.Also all wastes shall be stored in separate areas with proper arrangements for disposal. Proper housekeeping practices shallbe followed to minimize spillages. Preventive maintenance of equipment and piping shall be carried out to prevent leakages.LDAR system shall also be implemented.

Action plan for safe handling of hazardous chemicals during storage and transportation is also drafted and shall be implementedby the proponent.

Impacts on Human (Social) Environment Groundwater and surface water sources of local populace shall not be affected. There shall be no discharge of treated wastewater onto land outside factory premises and therefore the groundwater

and surface water quality shall not be affected due to the project. Storm water discharge shall be arrested by providing garland drains and contamination shall be prevented by

controlling spillages. The solid wastes shall be stored, handled and disposed in compliance with the amended H/W management rules. Adequate safety measures shall be provided to prevent and control the hazards associated with storage and handling

of hazardous chemicals. The tank farms and other storage areas shall be designed and constructed as per the applicable rules and regulations

w.r.t safe distances, layout and storage quantities. The plant operations shall be carried out with safe operating procedures and using appropriate instrumentation and

control systems. Fire-extinguishers shall be provided at all required locations. Plant operators shall be provided required PPE and training for SOPs. Adequate first-aid and medical facilities shall be provided to workers. On-site emergency plan shall be prepared and upgraded periodically.

Impacts on Human (Economic) EnvironmentThe project will lead to skilled and unskilled, long term and short term, technical and managerial employment for operation of theplant. In addition to providing direct employment, the project will also give chances of indirect employment in marketing andother sectors. Local populace shall be given preference for employment.

Impacts on Ecological EnvironmentIt is noteworthy, that the proposed project is in the Industrial estate and no ecologically sensitive zone is located in the vicinity ofthe area.The industry has proposed to enhance the green belt to about 30% of the total plot area, which will support the local species offlora and fauna.

Impacts on Natural Resources of FuelThe industry shall use natural gas as fuel, which is expected to be available in adequate and consistent supply in the region.

5 Occupational Safety and Hazard ManagementOccupational Health centre (OHC)An Occupational Health Centre (OHC) in compliance with statutory requirement shall be developed by the factory managementequipped with First-Aid facilities for accommodation of two persons at a time.The facilities and equipment to be made available at the OHC are :




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1 Bed Oxygen Cylinder Artificial Respirator Sphygmomanometer for BP Weighing Machine First Aid accessories

The center shall be attended by trained first-aid assistants in three shifts and a part-time doctor.

Onsite Medical treatmentA panel of visiting doctors is appointed by the unit to cater to medical needs of the employees, for various categories i.e general,orthopedics, ENT, etc.

Medical examination practicePre-employment medical check-up is done by qualified medical practitioner and records are maintained.Full medical check up of all employees is taken once in a year and records are maintained.Health Register in Form No. 32 (prescribed under Rule 68 T and 102) is maintained.Certificate of fitness is issued to workers by factory medical officer in Form No. 33.

Towards management of occupational health and safety in the unit, some requirements for maintaining an efficient system aredescribed hereunder: In-house Training programs as well as programs with help of outside agencies on Health hazards and safety for the

workers and staff should be carried out, as staff is company’s liability. Trainings should cover topics on fire fighting,awareness training for hazards, first aid etc.

The proponent should ensure proper handling of all spillages by introducing spill control procedures for variouschemicals.

Work permit system shall be established for specific task Aspects of industrial hygiene to be adhered to at the time of site layout planning and construction Required PPE should be provided wherever applicable and the workers should be acquainted with all required

personnel protective equipment. The management should ensure proper use of PPE by workers and explore methods for reducing the fugitive

emissions. The management should ensure that the transporters of hazardous chemicals are provided with PPE. The hazardous chemicals must be stored in their respective specified area. Material safety data sheet for all the concerned materials shall be available at the site. Regular health checkups shall be carried out by qualified medical practitioners and proper records should be

maintained for this. Adequate fire fighting equipments shall be provided at relevant areas. Emergency telephone numbers should be displayed at required places. In addition to the above, to check the preparedness, the company shall carry out regular audits of the safety systems.

Company should plan a yearly schedule for inspections of safety devices and maintain record for it. Regular internalas well as external audits should be carried out.

On-site emergency plan to be prepared and upgraded periodically. Separate ways / gates for entry and exit in project premises. Sufficient parking area with unidirectional vehicular movement with separate entry and exit. Two or more staircases on each floor in all high rise buildings (more than four floors). Approach distance to any

staircase shall not be more than 30 mt on each floor. Sufficient lighting, ventilation, drinking water facility, sanitary blocks, fire fighting and first aid arrangements. Safe and ergonomic design and layout of plant, machinery, tools and control equipments keeping in view the safety

and pollution prevention in mind. Effective pollution control measures for land, water and air. To observe the NBC norms for parking, margins, etc. for building construction projects (See part B-3 for detail) Pressure Vessels, etc. should be designed properly for safe and efficient working and Standard Operating Practice

(SOPs) should be prepared for the same.The above measures shall ensure that occupational health of the workers is maintained and they are not subjected toharmful concentrations of dust, noise, heat and chemical vapors through inhalation, injestion or through skin absorption aswell as are prevented from musculo-skeletal disorders like backache, pain in joints, fatigue etc. which are caused byimproper plant layout and elevations.




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6 Green belt developmentFor the given project, GPI has already developed 10% of total plot area i.e 100 sq.m land as green belt which shall beaugmented to 30% of the plot area in phases after the project obtains Environmental Clearance.Five year Green belt development plan has been formulated for additional 200 sq. m plantation to increase the green belt toabout 30% of total plot area as per the guidelines of MoEF and SPCB.Major type of tree / plantation : eucalyptus, neem, casurina, peltofarm, seasom, seven, kher

7 Rain Water Harvesting SystemIt is advised by EIA agency to explore possibilities of rain water harvesting from building roof tops in GPI. The collected watercan be utilized for domestic sanitation purpose or washing purpose.The potential of roof top rainwater harvesting for roof are of 400 sq. m for an average annual rainfall of 1100 mm, works out tobe 720 litres per day.

8 Socio-economic Development activitiesAlthough the project is of small scale and the investment is only Rs. 200 lac, the project proponent has committed to contributetowards the social and economic development of the villages around Vapi GIDC.The proponent has intended to support the following welfare activities of the GIDC and gram panchayat by way of donation andparticipation : arranging medical camps Augmenting local public health centre particularly in rainy season so as to avoid spread of diseases like dysentery & other diseases linked with mosquito

growth Vaccination programmes providing scholarships to willing students for suitable vocational training Sponsor modern amenities, tools for education like computers & AV facilities Plantation in surrounding bare lands Celebrations of festivals and other social occasions

The management shall provide separate budget for socio-economic welfare activities in their yearly plan.

9 Cost Provision For Environmental Mitigation MeasuresApprox. Rs. 25 lac as capital expenditure and Rs. 9 lac per annum as recurring expenses have been allotted for EnvironmentalManagement by the proponent.

10 Post project MonitoringA detailed monitoring schedule has been prepared to ensure effectiveness of the environmental management plan. The plancovers monitoring of ambient environment, ground water, noise, soil, drinking water and stack monitoring as well as work placemonitoring.

11 ConclusionM/s. Gemasko Pharmachem Industries strongly believes in the concept of eco-friendly industrialization. The company hasadequate technical and managerial capability for successful implementation and safe operation of chemical Plant.The project shall involve implementation of cleaner production techniques and resource optimization together with use ofadvanced technology to increase the efficiency and productivity of the unit.Apart from eco-friendly operations, various socio-economic developmental activities will be undertaken by the company to bringabout overall socio-economic development in the study area.

As evaluated and shown at Chapter 4, the cumulative value of significance of the project, in terms of the impacts on theenvironment, works out to be (-)0.61, which indicates that the project will have negligible impacts and therefore, with theproposed mitigation measures and proper implementation of the suggested Environmental Management Plan, the project isconsidered to be viable.

The proponent of the project has agreed to proceed in line with the EIA agency’s comments and advices to mitigate the adverseimpacts to the most techno-economically viable extent.