m/s. nirma ltd.environmentclearance.nic.in/writereaddata/...nirma ltd. revised form 1 – proposed...

M/S. NIRMA LTD.

Revised Form 1 : Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat

MAY, 2018

Kadam Environmental Consultants w w w . k a d a m en v i r o . c o m

Env i ro nme nt for Deve lopme nt

NIRMA LTD.

REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA

PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT

KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL

SHEET

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 II

M/S. NIRMA LTD.

Revised Form 1 : Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar, Gujarat © Kadam Environmental Consultants (‘Kadam’), May, 2018

This report is released for the use of the M/s. Nirma Ltd., Regulators and relevant stakeholders solely

as part of the subject project’s Environmental Clearance process. Information provided (unless

attributed to referenced third parties) is otherwise copyrighted and shall not be used for any other

purpose without the written consent of Kadam.

PROJECT DETAILS

Name of

Publication Revised Form 1 requiring Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at Kalatalav, Near Bhavnagar, Gujarat.

Project

Number 1730141406 Report No. 1 Version 2 Released May, 2018

Prepared &

Managed By

K.K. Antani, Shweta Rajput,

Bhavin Jambucha, & Nirma Ltd.

Representatives

Released By Sangram Kadam

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-6131000

Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T:0124-4242430 to 436

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.

Kadam also believes that the facts presented in the report are accurate as on the date it was written. However, it

is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any

liability resulting from the use or application of the information contained in this report. The information is not

intended to serve as legal advice related to the individual situation.

NIRMA LTD.


PRODUCTION AND CAPTIVE POWER PLANT IN EXISTING FACILITY AT

KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 III

CONTENTS

1 SCOPING................................................................................................ 1

ANNEXURES

Annexure 1: General and Specific Location Map .............................................................................. 2

Annexure 2: Project Boundary Map ................................................................................................ 3

Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ....................... 4

Annexure 4: Details of Air Emissions ............................................................................................... 5

NIRMA LTD.


PRODUCTION AND COGENERATION POWER PLANT IN EXISTING FACILITY

AT KALATALAV, NEAR BHAVNAGAR FORM - 1

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 1

1 SCOPING

The scoping for the project has been done based on REVISED FORM 1, as per EIA Notification, dated

September 14, 2006 amended as on date. The scoping details are as follows:

I. Basic Information

S.

No. Item Details

1 Name of the Project

Expansion in Soda Ash (2800 TPD to 4300 TPD) and Caustic Soda (750

TPD to 1000 TPD) and cogeneration Plant (197.18 MW to 350 MW) at

Existing Facility of Nirma Ltd., Kalatalav, Near Bhavnagar, Gujarat.

2 S. No. in the Schedule

Sector

No. Project or activity Category

4 4(e ) Soda Ash Plant A

4(d) Caustic Soda A

1 1(d), Thermal Power Plants A

3

Proposed capacity / area / length / tonnage

to be handled/ command area / lease area /

no. of wells to be drilled

Sr.

No. Project or activity

Capacity (tpd)

Existing Proposed Total

1. Cogeneration Plant

(Area = 69,100m2)

197.18

MW

152.82

MW 350

Soda Ash Plant (Area = 2,61,548.33 m2; )

1. Light Soda Ash Plant 2800 1500 4300

2. Dense Soda Ash * 1800 600 2400

Dense Soda Ash is conversion of Light Soda Ash

Caustic Soda Plant (Area = 2,88,945.55 m2)

1. Caustic Soda (100%) 750 250 1000

2. Hydrochloric Acid

(100%) 280 220 500

Caustic Soda Plant – By Products

1. Chlorine Gas (100%) 665.2 220.8 886

2. Hydrogen (100%) 18.75 6.25 25

3. Sodium Hypo Chlorite

(100%) 12 3 15

4 New / Expansion / Modernization Expansion

5 Existing Capacity / Area etc. Mentioned in Table vide Sr. No. 3

6 Category of Project (A or B) A

7 Does it attract the general conditions? If

yes, please specify. No

8 Does it attract specific condition? If yes,

please specify No

9 Location General Location is provided in Annexure 1. Site Boundary is shown in

Annexure 2. Toposheet is shown in Annexure 3.

NIRMA LTD.





S.

No. Item Details

Plot Survey / Khasra No. Survey No. 478/p, 447 - 453, 455 - 457

Village Kalatalav

Tehsil / Taluka / Mandal Bhavnagar

District Bhavnagar

State Gujarat

10 Nearest railway station / airport / along with

distance in km.

Nearest Railway Station

Bhavnagar Railway Station : ~ 10 km

Nearest Airport

Bhavnagar : ~ 10 km

11 Nearest town, city, district headquarters

along with distances in kms

Nearest Town/City/District Headquarter

Bhavnagar (District Headquarter) : ~ 9.0 km

12

Village Panchayat, Zilla Parishad, Municipal

Corporation, Local Body (complete postal

address with telephone nos. to be given)

Panchayat: Sarpanch, Kalatalav

Zilla Parishad: District Development Office,

District Panchayat, Bhavnagar – 364001

Phone No. 0278-2426810

Municipal Corporation: District Collector Office, Opp. Galaxy Cinema,

Kalanala, Bhavnagar – 364001

Phone no.: 0278 - 2428822

13 Name of the applicant Nirma Ltd.,

14 Registered address

Nirma Ltd.

Nirma House, Ashram Road, Nr. Income Tax office, Ahmedabad -

380009

15

Address for correspondence Same as Above

Name Mr. Ashish Desai

Designation Vice President (Project)

Address Nirma Ltd.

Nirma House, Ashram Road, Nr. Income Tax office, Ahmedabad

Pin Code 380009

E-mail [email protected]

Telephone no.

Fax No.

Ph: +91-79-27549319+91-79-27546603 / 05

Mobile No. +91-9825320090

16

Details of alternative sites examined, if any.

Location of these sites should be shown on

the Toposheet.

Not analyzed, since this expansion is on an existing site, with all requisite

facilities and infrastructure available.

17 Interlinked Projects No

18 Whether separate application of interlinked

project has been submitted? No

19 If yes, date of submission No

20 If no, reason NA

21

Whether the proposal involves approval /

clearance under: if yes, details of the same

and their status to be given:

CRZ Notification: Yes, applicable for seawater intake; Effluent disposal

outfall along with return cooling water pipeline and bittern disposal

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S.

No. Item Details

The Forest (Conservation) Act, 1980

The Wildlife (Protection) Act, 1972

The C.R.Z Notification, 1991

22 Whether there is any Government order /

policy, relevant / relating to the site No

23 Forest land involved (ha.) No

24

Whether there is any litigation pending

against the project and / or land in which

the project is proposed to be set up?

Name of the Court Case No.

Order / directions of the Court, if any and

its relevance with the proposed project

No

25 Project Cost (in Lacs) Rs. 132000 lacs

II Activity

1. Construction, operation or decommissioning of the project involving actions,

which will cause physical changes in the locality (topography, land use, changes in

water bodies, etc.)

S. No. Information/Checklist

Confirmation

Yes/

No

Details thereof (with approximate quantities / rates, wherever possible) with

source of information data

1.1

Permanent or temporary change in

land use, land cover or topography

including increase in intensity of

land use (with respect to local land

use plan)

No No, there is no permanent or temporary change in land. The proposed expansion is within

the existing premises, which will remain same.

1.2 Clearance of existing land,

vegetation and buildings? No

Land is already in use and as this is expansion project. Hence, clearance of existing land,

vegetation and buildings is not required.

1.3 Creation of new land uses? No No additional creation of new land usage as existing plant is already under industrial

usage.

1.4 Pre-construction investigations e.g.

bore houses, soil testing? No Not required.

1.5 Construction works? Yes As part of the Industrial Project, there will be construction of plant machinery, utilities, etc

within the existing facility.

1.6 Demolition works? No Existing facilities for cogeneration thermal power plant; Soda Ash Plant & Caustic soda

plant will be expanded with proposed new facilities.

1.7

Temporary sites used for

construction works or housing of

construction workers?

No

Most of the construction workers will be hired locally as far as possible. Sufficient

accommodation is available at workers colony, hence requirement of additional housing is

not envisaged.

1.8

Above ground buildings, structures

or earthworks including linear

structures, cut and fill or

excavations

Yes

Sr.

No.

Hazardous

Waste Category

Quantity (MTPA) Mode of

Disposal Existing Proposed Total

A. Soda Ash Division

1. Waste Oil /

Lube Oil

5.1 10 kl 5 kl 15 kl Collection,

Storage,

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Confirmation

Yes/

No



Transportation

&

disposal by

selling to

Registered

Recyclers

2. Spent ion

Exchange

resins

34.2 1830

lt/year

980 lt/year 2810

lt/year

Collection,

Storage,

Transportation,

Disposal by

selling to

authorized

recyclers or sent

to NECL

Nandesari

for Incineration.

3. Discarded

Bags /

drums /

containers

etc…

33.3 3.5 2 5.5 Collection,

Storage,

Transportation,

Disposal by

selling to

authorized

recyclers

B. Caustic Soda Plant

1. Waste Oil /

Lube Oil

5.1 30 kl 10 kl 40 kl Collection,

Storage,

Transportation

&

disposal by

selling to

Registered

Recyclers

2. Spent ion

Exchange

resins

34.2 2.56 1 3.56 Collection,

Storage,

Transportation,

Disposal by

selling to

authorized

recyclers or sent

to NECL

Nandesari for

Incineration.

3. Discarded

Bags /

drums /

containers

etc…

33.3 4.5 1.5 6 Collection,

Storage,

Transportation,

Disposal by

selling to

authorized

recyclers

4. Residue/ 16.2 6526 2175 8701 Collection,

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Confirmation

Yes/

No



Earthworks will involve cut and fill, excavations. It is likely cut and fill quantities will be

similar. Consequently it is likely that procurement of soil from outside the premises will be

minimal if any.

Sludge &

Filter sludge

Storage,

Transportation,

Disposal at

TSDF

5. ETP sludge 34.3 150 50 200 Collection,

Storage,

Transportation,

Disposal at

TSDF

6. Spent

Sulphuric

Acid (80%)

D2/II 6520 2173 8693 Collection,

Storage,

Transportation,

reuse

as raw material

for Nirma Ltd.

Moraiya and

other end users.

1.9 Underground works including

mining or tunneling? No Not Applicable

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore Structures No Not Applicable

1.13 Production and manufacturing

processes? Yes

Manufacturing process along with PFD and mass balances are provided in Pre-Feasibility

Report, Refer Ch-3, Section 3.5.

1.14 Facilities for storage of goods or

materials? No

Open storage for Harvested Salt, Limestone, Coke, Coal storage under Shed &

Product storage under Shed

1.15 Facilities for treatment or disposal

of solid waste or liquid effluents? Yes

Fly Ash shall be handled, stored and disposed of as per Fly Ash Notification, 2015 as

amended till date. The existing total effluent quantity is 5,86,445.2 m3/day. The effluent

quantity due to expansion activities would be 3,20,189.5 m3/day. Thus, after expansion,

the total effluent quantity would be 9,06,634.7 m3/day. Trade Effluent from expansion

activities will be treated in existing treatment facilities and discharged into Gulf of

Khambhat by outfall, diffuser system for detail please refer Ch-3, Section 3.7.3 of PFR.

NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water

and salt / sea water drawl based projects, such as Nirma Ltd., Kalatalav,

Bhavnagar Dist., cannot work without suitable sea discharge, considering the

huge volumes of sea water involved.

Hazardous Waste Generation details are as per table below:

Sr. No.

Solid Waste Quantity (MTPA)

Mode of Disposal Existing Proposed Total

1. Settling Pond Sludge

880 482 1362 Shall be used in road construction, salt works bund

preparation

2. Lime stone rejects /under size

700 375 1075 Shall be used in boilers for

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Confirmation

Yes/

No



desulphurization in boilers

3. Brine Sludge 19 10 29 Non-hazardous; Shall be dumped in

identified area

4. Fly ash / Bottom ash

2185 1693 3878 Brick manufacturing,

bund preparation, road making etc.

5. Incineration Ash 15 0 15 Brick manufacturing,

bund preparation, road making etc.

6. Saponification Solid Waste

3 0 3 Non-hazardous; Shall be dumped in

identified area

1.16 Facilities for long term housing of

operational workers? No

Sufficient accommodation available at workers colony, hence requirement of additional

housing is not envisaged.

1.17 New road, rail or sea traffic during

construction or operation? No

Due to proposed project, vehicular movement will be increased only during construction

phase.

1.18

New road, rail, air waterborne or

other transport infrastructure

including new or altered routes and

stations, ports, airports etc?

No No additional transport infrastructure is required due to the proposed expansion.

1.19

Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No It is not required to close or divert existing transport routes and infrastructure.

1.20 New or diverted transmission lines

or pipelines? No No any new or diverted transmission lines are proposed.

1.21

Impoundment, damming,

culverting, realignment or other

changes to the hydrology of

watercourses or aquifers?

No No change in hydrology of water courses/aquifers is envisaged.

1.22 Stream crossings? No Site does not involve any stream crossing.

1.23 Abstraction or transfers of water

from ground or surface waters? Yes

Ground Water

No abstraction of ground water is envisaged.

Surface Water/sea water

The existing total water quantity consumed is 14,06,574.1 m3/day. The water quantity

required due to expansion activities would be 3,60,000 m3/day. Thus, after expansion, the

total water quantity consumed would be 17,66,574.1 m3/day.

1.24

Changes in water bodies or the land

surface affecting drainage or run-

off?

No Not applicable.

1.25

Transport of personnel or materials

for construction, operation or

decommissioning?

Yes

During construction and implementation of the project period, transport of materials and

personnel will be through Coastal State Highway No. 6 (Bhavnagar-Ahmedabad) which is

at a distance of 14.0 km away from the project site in West direction.

1.26 Long-term dismantling or

decommissioning or restoration No

Proposed expansion does not involve any long term dismantling or decommissioning or

restoration works.

NIRMA LTD.






Confirmation

Yes/

No



works?

1.27

Ongoing activity during

decommissioning which could have

an impact on the environment?

No Not envisaged.

1.28 Influx of people to an area either

temporarily or permanently? Yes

During the construction phase around 150 workers and existing manpower is sufficient to

operate proposed expansion units. Local skilled and semi-skilled workers will be engaged

during construction phase.

1.29 Introduction of alien species? No Not applicable

1.30 Loss of native species or genetic

diversity? No No effect on species or generic diversity.

1.31 Any other actions? No Not visualized as required activities will not cause any physical changes in the locality.

2. Use of Natural resources for construction or operation of the Project (such as land,

water, materials or energy, especially any resources which are non-renewable or

in short supply):

S. No. Information/Checklist confirmation Yes /

No

Details thereof (with approximate quantities / rates, wherever

possible) with source of information data

2.1 Land especially undeveloped or agricultural

land (ha) No

The Plot area of the project duly developed, consists of 555 acre –Kalatalav

Complex. Expansion is proposed within area allotted for these plants within

Kalatalav Complex. The areas of the plants which would undergo proposed

expansion activities would be as under:

Cogeneration plant = 69,100 m2

Soda Ash plant = 2,61,548.33 m2

Caustic Soda plant = 2,88,945.55 m2

2.2 Water (expected source & competing users)

unit: KLD Yes

The source of existing water consumption for Nirma – Kalatalav Complex is Sea

water through RO / desalination plants. The existing water quantity consumed

is 14,06,574.1 m3/day. The water quantity required due to expansion activities

would be 3,60,000 m3/day. Thus, after expansion, the total water quantity

consumed would be 17,66,574.1 m3/day.

2.3 Minerals (MT) Yes During operation phase, coal, coke, pet coke & limestone shall be used based

on availability.

2.4 Construction material stone, aggregates,

sand / soil (expected source, MT) Yes

Construction materials like stones, aggregates, sand, bricks, steel, cement,

rubble, etc. will be procured from the local market.

2.5 Forests and timber (source, MT) No Not Applicable

2.6

Energy including electricity and fuels

(source, competing users) unit: fuel (MT),

energy (MW)

Yes

Electricity:

Power is supplied by captive cogeneration thermal power plant at the facility.

The existing power produced at the site is 197.18 MW. This is to be increased

by 152.82 MW. Thus, the total power consumption after expansion would be

350 MW.

Fuel for Cogeneration Power Plant:

The fuel requirement will be as per table below:

Sr. No. Fuel Type Quantity (tpd)


1. Coal 7440 5766 13206

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No



2. Lignite 7584 5878 13462

3. Pet Coke 1200 3912 5112

4. Limestone 1625 1259 2884

5. Light Diesel Oil

(kl/year) 210 163 373

6. HSD (kl/month) 955 740 1695

2.7 Any other natural resources (use

appropriate standard units) No Not Envisaged.

3. Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about

actual or perceived risks to human health.

S. No. Information / Checklist confirmation Yes /

No



3.1

Use of substances or materials, which are

hazardous (as per MSIHC rules) to human

health or the environment (flora, fauna, and

water supplies)

Yes Hazardous material like FO, HSD, LDO, Chlorine, Caustic will be used.

3.2

Changes in occurrence of disease or affect

disease vectors (e.g. insect or water borne

diseases)

No Not Applicable.

3.3 Affect the welfare of people e.g. by

changing living conditions? No Not Applicable.

3.4

Vulnerable groups of people who could be

affected by the project e.g. hospital

patients, children, the elderly etc.,

No No vulnerable groups live near project area.

3.5 Any other causes No Not envisaged.

4. Production of solid wastes during construction or operation or decommissioning

(MT/month)

S. No. Information/Checklist confirmation Yes/

No



4.1 Soil, overburden or mine wastes No Not envisaged.

4.2 Municipal waste (domestic and or

commercial wastes) Yes

Municipal Waste

Waste paper from administrative buildings, waste metals, kitchen waste

etc.

Disposal method

Waste paper and metal will be given to recyclers, and kitchen waste will be

converted into manure.

4.3 Hazardous wastes (as per Hazardous Waste

Management Rules) No Hazardous Waste Generation details are as per table in Sr. No. 1.15

4.4 Other industrial process wastes No Not Envisaged.

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No



4.5 Surplus product No Not Applicable.

4.6 Sewage sludge or other sludge from

effluent treatment Yes Details of the same shall be quantified in EIA report.

4.7 Construction or demolition wastes Yes Minimal quantity of debris, scraps, excavated soil, used cement bags, iron /

steel scrap and cardboards waste could be generated during construction

4.8 Redundant machinery or equipment No Not applicable.

4.9 Contaminated soils or other materials No Not applicable.

4.10 Agricultural wastes No Not envisaged.

4.11 Other solid wastes Yes Solid Waste Generation details are as per table in Sr. No. 1.15

5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)


No



5.1 Emissions from combustion of fossil fuels

from stationary or mobile sources Yes

Flue gas emissions like SPM, SO2 & NOx will be from stacks attached to

boilers. For more details refer Table 1-1.

5.2 Emissions from production processes Yes Process emissions from production process are given in Table 1-2

5.3 Emissions from materials handling including

storage or transport Yes

Dust generation is anticipated from coal storage and ash handling.

Arrangements for wetting and water spray / extraction of emission from

transfer points will be provided.

5.4 Emissions from construction activities

including plant and equipment Yes

Emission from diesel operated vehicles, concrete mixers and excavators

are anticipated. However these equipment will be maintained properly to

ensure minimum emissions and vehicles with PUC certificates will be used.

5.5

Dust or odours from handling of materials

including construction materials, sewage

and waste

No Not envisaged.

5.6 Emissions from incineration of waste No Not Applicable

5.7 Emissions from burning of waste in open air

(e.g. slash materials, construction debris) No Not envisaged.

5.8 Emissions from any other sources No None envisaged.

6. Generation of Noise and Vibration, and Emissions of Light and Heat:


No



6.1 From operation of equipment e.g. engines,

ventilation plant, crushers Yes

Noise will be generated from operation of coal crushers, boilers, turbines,

air blowers, plant machineries, etc. Adequate enclosures and necessary

PPE will be provided to exposed employee.

6.2 From industrial or similar processes Yes Noise shall be generated from boilers, compressors, etc. during operation

phase.

6.3 From construction or demolition Yes During construction phase, noise will be generated due to dumpers,

rollers, truck movement etc.

6.4 From blasting or piling No Not Applicable

6.5 From construction or operational traffic Yes During construction and operational phase noise will be generated due to

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No



trucks and other vehicles.

6.6 From lighting or cooling systems Yes Noise will be generation from Cooling tower fans.

6.7 From any other sources No No emissions of light and heat are envisaged.

7. Risks of contamination of land or water from releases of pollutants into the

ground or into sewers, surface waters, groundwater, coastal waters or the sea

S. No. Information/Checklist confirmation Yes

/ No



7.1 From handling, storage, use or spillage of

hazardous materials No

Proper care for handling of hazardous material will be taken as per the

MSIHC rules & HW management Rules. Moreover all of the hazardous

wastes are disposed as per guidance of State Pollution Control

Board. Same will be continued after proposed expansion.

7.2

From discharge of sewage or other effluents to

water or the land (expected mode and place of

discharge)

No

Final discharge will be reduced due to recycle and reuse concept. After

discharge from Kalatalav facility, the treated effluent is discharged into

the Gulf of Khambhat through an outfall comprising of diffuser system.

The Co-Ordinates of the discharge point are:

1. Soda Ash Effluent Discharge - 21050’36.36”N, 72015’27.06”E

2. Bittern Discharge Point - 21049’39”N, 72011’44”E

7.3 By deposition of pollutants emitted to air into

the land or into water Yes

Shall be provided with EIA report after air dispersion modelling using site

specific meteorological data.

7.4 From any other sources No None identified.

7.5

Is there a risk of long term build-up of

pollutants in the environment from these

sources?

No

Adequate mitigation measures, monitoring and periodic maintenance of

equipment’s will ensure no risk of long term buildup of pollutants in the

environment.

8. Risk of accidents during construction or operation of the Project, which could

affect human health or the environment


No



8.1

From explosions, spillages, fires etc. from

storage, handling, use or production of

hazardous substances

Yes The associated hazard from the plant is fire in coal storage yard as well

as fuel storages.

8.2 From any other causes Yes

Common risks in factories such as Electric Shock, Hit by Objects, Fall /

Slips, Hot Work such as Welding and Cutting & during maintenance

activities.

8.3

Could the project be affected by natural

disasters causing environmental damage e.g.

floods, earthquakes, landslides, cloudburst

etc)?

Yes

Site falls under the seismic intensity Zone III, which is classified as

Moderate Damage Risk Zone. Thus, suitable seismic coefficients

accordingly shall be adopted while designing the structures to make it

earthquake resistant.

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9. Factors which should be considered (such as consequential development) which

could lead to environmental effects or the potential for cumulative impacts with

other existing or planned activities in the locality

S. No. Information/Checklist confirmation Yes / No Details thereof (with approximate quantities/ rates, wherever


9.1

Lead to development of supporting Facilities,

ancillary development or development

stimulated by the project which could have

impact on the environment e.g.: supporting

infrastructure (roads, power supply, waste

or waste water treatment, etc.) housing

development extractive industries supply

industries, (other)

Yes The proposed expansion project will encourage industrial growth,

employment and result in additional revenue for government.

9.2 Lead to after-use of the site, which could

have an impact on the environment No Not Applicable

9.3 Set a precedent for later developments No Not Applicable

9.4

Have cumulative effects due to proximity to

other existing or planned projects with

similar effects

No Very negligible cumulative effect, as adequate mitigation measures will

be provided.

III Environmental Sensitivity

S. No. Areas Name / Identity Aerial Distance (within 15 km) of the proposed project

location boundary

10.1

Areas protected under international

conventions, national or local legislation for

their ecological, landscape, cultural or other

related value

No No such areas exist within 15 Km radius of the proposed

project site.

10.2

Areas which are important or sensitive for

ecological reasons - Wetlands, watercourses

or other water bodies, coastal zone,

biospheres, mountains, forests

Coastal Zone

Reserved Forest

Project boundary is well beyond minimum distance of 500 m

from CRZ boundary.

Madhia Reserved Forest-8.2 km (West)

10.3

Areas used by protected, important or

sensitive species of flora or fauna for

breeding, nesting, foraging, resting, over

wintering, migration

No -

10.4 Inland, coastal, marine or underground

waters

Gundala Creek,

Malcolm Channel

& Bhavnagar

Creek (Gulf of

Khambhat)

Gundala Creek : About 6.5 km (North)

Malcolm Channel : 6.0 km (East),

Bhavnagar Creek: 3.0 km (South).

10.5 State, National boundaries No -

10.6

Routes or facilities used by the public for

access to recreation or other tourist, pilgrim

areas

Coastal State

Highway

Coastal State Highway No.6 (Bhavnagar-Ahmedabad) is

passing 14 km away from the project site in West direction.

10.7 Defense installations No None Identified

10.8 Densely populated or built-up area Yes Bhavnagar city is located approx. 10 km (aerial) away from the

NIRMA LTD.





S. No. Areas Name / Identity Aerial Distance (within 15 km) of the proposed project

location boundary

Kalatalav site of Nirma Ltd. in the South direction

10.9

Areas occupied by sensitive man-made land

uses (hospitals, schools, places of worship,

community facilities)

Yes Located within Bhavnagar city

10.10

Areas containing important, high quality or

scarce resources (ground water resources,

surface resources, forestry, agriculture,

fisheries, tourism, minerals)

No None Identified

10.11

Areas already subjected to pollution or

environmental damage. (Those where

existing legal environmental standards are

exceeded)

No None Identified

10.12

Areas susceptible to natural hazard which

could cause the project to present

environmental problems (earthquakes,

subsidence, landslides, erosion, flooding or

extreme or adverse climatic conditions)

No

Earthquake: The site falls in Seismic zone III (Moderate Risk)

as per Seismic Zone Map of India.

Cyclone: It is 6.0 km from Malcolm Channel (Gulf of Khambhat)

thus susceptible to natural hazards like cyclone/storm etc.

NIRMA LTD.



AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


ANNEXURES OF REVISED FORM 1

Annexure 1: General and Specific Location Map .............................................................................. 2

Annexure 2: Project Boundary Map ................................................................................................ 3

Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles ....................... 4

Annexure 4: Details of Air Emissions ............................................................................................... 5

NIRMA LTD.





Annexure 1: General and Specific Location Map

NIRMA LTD. REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION

POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 2: Project Boundary Map

NIRMA LTD. REVISED FORM 1 – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION

POWER PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 3: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles

NIRMA LTD.





Annexure 4: Details of Air Emissions

Air emissions from stationary sources are provided below:

Table 1-1 Details of Stacks APCM attached to Flue Gas Stacks

S. No. Stack Attached to Stack Height

(m)

Stack Top

Dia. (m) APCM

Expected

Pollutants*

Existing

Soda Ash Division

1 Boiler - A, B, C & D (100 TPH Each) 100 (Common

Stack) 5.04 ESP to Each Boiler PM, SO2 & NOx

2. DG Set (1000 KVA) 2 nos. 24 each 0.2 -- PM, SO2 & NOx

Caustic Soda & CPP Division

2 Boiler - E (200 TPH) 121 (Common

Stack) 4.5

ESP PM, SO2 & NOx

3 As per EC 2014 Boiler - F (200 TPH)

– Not Installed Yet ESP PM, SO2 & NOx

4

As per EC 2017 Boiler - G & H (350

TPH each ) – Installed One boiler

having capacity 410 TPH

121 (Common

Stack) 4.5 ESP PM, SO2 & NOx

5 DG Set (1000 kVA) 30 0.32 - PM, SO2 & NOx

6 DG Set (1500 kVA) 30

0.32

-

PM, SO2 & NOx

7 DG Set (1500 kVA)

Toilet Soap plant

8 Thermic Fluid Heater (3 nos.) 45 0.4 PM, SO2 & NOx

Proposed

Soda Ash Division

1. DG Set (2000 kVA) 30 0.32 -- PM, SO2 & NOx


1 Boiler - I & J (410 TPH + 130 TPH) * 121 (Common

Stack) 13.4# ESP PM, SO2 & NOx

2 DG Set (1850 kVA) 30 0.32 -- PM, SO2 & NOx

* Capacity of proposed boilers may vary however total proposed capacity of steam generation will

remain same as 540 TPH.

# Considering better dispersion, Engineering design has calculated the stack dia. as 13.4m

NIRMA LTD.





Table 1-2: Details of Process Emissions

Sr.

No. Vent Attached to Stack Height (m)

Stack

Dia. (m)

Air Pollution Control

System Pollutant

1

Soda Ash Plant – Existing & Proposed

Lime Kilns (A to H) – 8 nos. 68 (Common Stack) 0.8 4 scrubbers and 3 ESP in

Series PM, SO2, NOx

Ammonia Recovery System (A to E) - 5

nos. 56 (Common Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia

Lime Grinding System (A to E) - 5 nos. 60 (each) 0.65 Bag Filter PM

Calcinations Vessel (A to D) - 4 nos. 29 (each) 0.7 Water Scrubber PM

Densification 1 40 1.37 Water Scrubber PM



Lime Kilns (I to L) – 4 nos.

(Proposed) 68 (Common Stack) 0.8

Two scrubbers and two

ESP in Series PM, SO2, NOx

Ammonia Recovery System (F & G) 2

nos. (Proposed) 56 (Common Stack) 0.75 Brine Scrubbers (2 nos.) Ammonia

Lime Grinding System (F) - 1 no.

(Proposed) 60 0.65 Bag Filter PM

Calcinations Vessel (E & F) - 2 nos.

(Proposed) 29 (Common vent) 0.7 Water Scrubber PM

Densification 4 (Proposed) 51 1.37 Water Scrubber PM

2

Caustic Soda and CPP - Existing & Proposed

HCl Synthesis Unit – 1 30 0.1 Water Scrubbers HCl & Cl2

HCl Synthesis Unit - 2 30 0.1 Water Scrubbers HCl & Cl2



HCl Synthesis Unit – 5 (Proposed) 30 0.1 Water Scrubbers HCl & Cl2

Waste Gas Dechlorination

System - 1 30 0.3 18% NaOH Scrubber Cl2

Waste Gas Dechlorination System - 2 30 0.3 18% NaOH Scrubber Cl2

Waste Gas Dechlorination System – 3 30 0.3 18% NaOH Scrubber Cl2

Hydrogen unit with Flame arrestor and steam snuffing – 1

30 -- -- --

Hydrogen unit with Flame arrestor and

steam snuffing – 2 30 -- -- --

Hydrogen unit with Flame arrestor and

steam snuffing – 3 30 -- -- --

3. Bromine Plant

De-bromination System 30 0.3 Alkali Scrubber Bromine

4.

Chlorine & Hydrogen Derivatives

Solvent Recovery 30 0.3 Ceramic + Activated

Carbon Filter Aromatic Solvent

Hydrogenation Plant (purge gas) 30 0.3 Ceramic + Activated

Carbon Filter H2 + Aromatic Solvent

NIRMA LTD.





Sr.

No. Vent Attached to Stack Height (m)

Stack

Dia. (m)


System Pollutant

Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,

HCl, TOC

HCl Synthesis Unit 30 0.1 Water Scrubbers HCl

Chlorination Plant 30 0.3 Acidic/Water Scrubber (3

nos.) SO2, HCl, Cl2

Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2

Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2

Hydrogenation Plant (purge gas) 30 0.3 ---- H2

CONTACT DETAILS




Delhi / NCR

Spaze IT Park, Unit No. 1124, 11th Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T:0124-4242430 to 436

Kadam Environmental Consultants w w w . k a d a m e n v i r o . c om

Env i ro nme nt fo r Dev e lopment

M/S. NIRMA LIMITED

Revised Pre-Feasibility Report for Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat.

MAY, 2018

Kadam Environmental Consultants w w w . k a d a m en v i r o . c o m

Envi ronment for Deve lopment

NIRMA LIMITED

REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA

PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR QUALITY CONTROL SHEET

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 II

M/S. NIRMA LIMITED

Revised Pre-Feasibility Report for Environmental & CRZ Clearance for Proposed Expansion in Nirma Chemical Complex at Village – Kalatalav, Taluka & District Bhavnagar Gujarat. © Kadam Environmental Consultants (‘Kadam’), May, 2018

This report is released for the use of the M/s. NIRMA LIMITED., Regulators and relevant stakeholders solely as part

of the subject project’s Environmental Clearance process. Information provided (unless attributed to referenced

third parties) is otherwise copyrighted and shall not be used for any other purpose without the written consent of

Kadam.

PROJECT DETAILS

Name of

Publication

Pre-Feasibility Report for Environmental Clearance for Proposed Expansion in Nirma Chemical Complex at

Village – Kalatalav, Taluka & District Bhavnagar, Gujarat

Project Number 1730141406 Report No. 1 Version 2 Released May, 2018

Prepared &

Managed By

Tanu Prasad & Bhavin Jambucha, K.K

Antani Released By Sangram Kadam

CONTACT DETAILS




Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road, Gurgaon, Haryana,

INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F:+91-124-4242433

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan. Kadam also

believes that the facts presented in the report are accurate as on the date it was written. However, it is impossible to dismiss

absolutely, the possibility of errors or omissions. Kadam therefore specifically disclaims any liability resulting from the use or

application of the information contained in this report. The information is not intended to serve as legal advice related to the

individual situation.

NIRMA LIMITED


PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 III

CONTENTS

1 EXECUTIVE SUMMARY ................................................................................................ 1

1.1 PLANT FEATURES AND PRODUCTION CAPACITY ......................................................................... 1

1.2 INFRASTRUCTURE ....................................................................................................... 1

1.3 UTILITY ................................................................................................................. 2

1.4 ENVIRONMENT ........................................................................................................... 2

1.5 SENSITIVITY ............................................................................................................. 2

1.6 CONCLUSION ............................................................................................................ 2

2 INTRODUCTION ......................................................................................................... 4

2.1 IDENTIFICATION OF PROJECT PROPONENT & PROJECT ................................................................. 4

2.1.1 Project Proponent ............................................................................................... 4

2.1.2 Proposed Project ................................................................................................ 4

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................... 4

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION .......................................... 5

2.4 DEMAND & SUPPLY GAP ................................................................................................. 5

2.5 EXPORT POSSIBILITY .................................................................................................... 5

2.5.1 Domestic / Export Market ..................................................................................... 5

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT .............................................. 5

3 PROJECT DESCRIPTION .............................................................................................. 6

3.1 TYPE OF PROJECT ....................................................................................................... 6

3.2 LOCATION OF THE PROJECT ............................................................................................. 6

3.3 DETAILS OF ALTERNATE SITES CONSIDERED ............................................................................ 8

3.4 SIZE OR MAGNITUDE OF OPERATION.................................................................................... 8

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ....................................................................... 9

3.5.1 Soda Ash (Existing + Expansion) ............................................................................. 9

3.5.2 Cogeneration Plant (Existing + Expansion) ................................................................ 14

3.6 UTILITIES .............................................................................................................. 15

3.6.1 Power Requirement ............................................................................................ 15

3.6.2 Fuel Requirement .............................................................................................. 15

3.6.3 Water Requirement ............................................................................................ 15

3.6.4 Storage Details ................................................................................................. 15

3.7 POLLUTION LOAD ON ENVIRONMENT DUE TO PROJECT................................................................. 15

3.7.1 Air Emissions & Control ....................................................................................... 15

3.7.2 Noise Generation ............................................................................................... 18

3.7.3 Waste Water Generation ...................................................................................... 18

3.7.4 Hazardous Waste & Other Solid Waste ..................................................................... 19

4 SITE ANALYSIS ........................................................................................................ 22

4.1 CONNECTIVITY ......................................................................................................... 22

4.1.1 By Road .......................................................................................................... 22

4.1.2 By Rail ........................................................................................................... 22

4.1.3 By Air ............................................................................................................ 22

4.2 LAND FORM, LAND USE & LAND OWNERSHIP .......................................................................... 22

NIRMA LIMITED


PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 IV

4.3 TOPOGRAPHY ........................................................................................................... 22

4.4 EXISTING INFRASTRUCTURE ............................................................................................ 22

4.5 SOIL CLASSIFICATION, GEOLOGY & DRAINAGE ........................................................................ 22

4.5.1 Soil Classification ............................................................................................... 22

4.5.2 Geology .......................................................................................................... 22

4.6 CLIMATIC DATA FROM SECONDARY SOURCES ........................................................................... 23

4.7 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 23

5 PLANNING BRIEF ..................................................................................................... 24

5.1 PLANNING CONCEPT .................................................................................................... 24

5.2 LANDUSE PLANNING .................................................................................................... 24

5.3 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL) ................................................... 24

5.4 AMENITIES/FACILITIES ................................................................................................. 24

6 PROPOSED INFRASTRUCTURE ................................................................................... 25

6.1 INDUSTRIAL AREA (PROCESSING AREA)................................................................................ 25

6.2 NON- PROCESSING AREA ............................................................................................... 25

6.3 GREENBELT ............................................................................................................. 25

6.4 SOCIAL INFRASTRUCTURE .............................................................................................. 25

6.5 CONNECTIVITY ......................................................................................................... 25

6.6 DRINKING WATER MANAGEMENT ...................................................................................... 25

6.7 SEWAGE SYSTEM ....................................................................................................... 25

6.8 INDUSTRIAL WASTE & SOLID WASTE MANAGEMENT .................................................................. 25

6.9 POWER REQUIREMENT & SUPPLY / SOURCE ........................................................................... 26

7 REHABILITATION AND RESETTLEMENT (R& R) PLAN .................................................... 27

8 PROJECT SCHEDULE AND COST ESTIMATE ................................................................... 28

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION......................................... 28

8.2 ESTIMATED PROJECT COST ............................................................................................ 28

8.2.1 Profitability ...................................................................................................... 28

9 ANALYSIS OF PROPOSAL .......................................................................................... 29

9.1 FINANCIAL AND SOCIAL BENEFITS...................................................................................... 29

NIRMA LIMITED


PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY AT

KALATALAV, NEAR BHAVNAGAR LIST OF ANNEXURES

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 V

ANNEXURES

Annexure 1: Preliminary Site Layout Map 31

Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles 32

Annexure 3: Long Term Meteorological Data for Bhavnagar City 33

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR LIST OF TABLES

KADAM ENVIRONMENTAL CONSULTANTS | MAY, 2018 VI

LIST OF TABLES

Table 1-1: Products Capacity (Existing & Proposed) ............................................................................................1

Table 2-1: Products Capacity (Existing & Proposed) ............................................................................................4

Table 3-1: Co-ordinates of Site Boundary ...........................................................................................................8

Table 3-2: Area Statement* ..............................................................................................................................8

Table 3-3: Details of Stack Emissions ............................................................................................................... 16

Table 3-4: Details of Process Emissions ............................................................................................................ 17

Table 3-5: Wastewater Generation Details ........................................................................................................ 18

Table 3-6: Solid Waste Generation & Disposal................................................................................................... 19

Table 3-7: Hazardous Waste Generation and Disposal ....................................................................................... 20

Table 6-1: Identification of Other Wastes ......................................................................................................... 26

Table 8-1: Tentative Project Time Schedule ...................................................................................................... 28

Table 8-2: Breakup of Project Cost .................................................................................................................. 28

LIST OF FIGURES

Figure 3-1: General Location of Proposed Project Site .........................................................................................6

Figure 3-2: Specific Map Showing Project Boundary ............................................................................................7

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR EXECUTIVE SUMMARY


1 EXECUTIVE SUMMARY

Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the

production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl

Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt and consumer salt to facilitate

quality production of their consumer products.

It is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District Bhavnagar, Gujarat.

Nirma Limited, Bhavnagar now proposes for modernization with expansion of their existing production plant

capacity.

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category

including Project / Activity: 1(d) Thermal Power Plant, 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant and

categorized under “A”.

1.1 Plant Features and Production Capacity

Existing cost of project is Rs. 3110 crores. The expected cost of the proposed expansion project will be around Rs.

1320 crores.

Details of existing and proposed products are listed in Table 1-1.

Table 1-1: Products Capacity (Existing & Proposed)

Sr.

No. Project or activity

Capacity (tpd)


1. Cogeneration Plant (Area = 69,100m2) 197.18 MW 152.82 MW 350

Soda Ash Plant (Area = 2,61,548.33 m2; )


2. Dense Soda Ash * 1800 600 2400

Dense Soda Ash is conversion of Light Soda Ash


1. Caustic Soda (100%) 750 250 1000

2. Hydrochloric Acid (100%) 280 220 500


1. Chlorine Gas (100%) 665.2 220.8 886

2. Hydrogen (100%) 18.75 6.25 25

3. Sodium Hypo Chlorite (100%) 12 3 15

1.2 Infrastructure

The proposed expansion would be implemented in Nirma Ltd.’s existing manufacturing facility at Kalatalav, near

Bhavnagar, Gujarat.

Main components of the existing project which includes Cogeneration Plant, Soda Ash Plant, Caustic Soda Plant,

Chlorine and Hydrogen derivatives plant, , Toilet soap plant and Bromine Plant and their associated utilities /

components like Boiler House of CFBC Boilers, Steam Turbine, Generator, Utility Area consisting of cooling tower,

ESP section Fly ash storage area. Water & wastewater infrastructure like Effluent Treatment Plant (ETP), Air

compressors & Hazardous storage facility area are being used.

NIRMA LIMITED





1.3 Utility

Power: The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH ,

total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.

* Capacity of proposed boilers may vary however total proposed capacity of steam generation will remain same as

540 TPH.

Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.

Fuel: Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr

for existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

Raw Water: Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater

intake – 14 x 105 m3/day. Additional seawater intake - 3.6 x 105 m3/day.

Manpower: Existing manpower at the operational site is 1630 nos. Manpower during Construction phase would be

150 nos. The manpower for operation phase of Expansion plants would be 100 nos. Thus, the total manpower

during full operation phase of Nirma-Kalatalav complex will be approximately 1730 nos.

1.4 Environment

Environmental issues associated with proposed units are:

Air Emissions: These would be due to presence of various Flue Gas stacks and process vents

Wastewater: The wastewater generated from the proposed activities would be treated in Effluent treatment

plant. The treated effluent would be discharged into the Gulf of Khambhat through existing outfall equipped

with diffuser system.

NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water and salt / sea water

drawl based projects, such as Nirma Ltd., Kalatalav, Bhavnagar Dist., cannot work without suitable

sea discharge, considering the huge volumes of sea water involved.

Solid & Hazardous Waste: Hazardous waste generated from the proposed project would be managed as per

the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016

1.5 Sensitivity

Project boundary is well beyond minimum distance of 500 m from CRZ boundary. About 6.5 km in North (Gundala

Creek), 6.0 km East side (Malcolm Channel), and 3.0 km in the South direction (Bhavnagar Creek). Project site falls

in Zone-III of Seismicity. Civil and Structures shall be designed according to applicable code. It is 6.0 km from

Malcolm Channel (Gulf of Khambhat) thus susceptible to natural hazards like cyclone/storm etc.

1.6 Conclusion

There is no adverse impact on the water environment due to the operation of the project. The air environment has

negligible effect due to the activities related to the operation of the project.

After implementation of pollution control measures there will be no emission from the plant beyond the norms

specified by Gujarat Pollution Control Board (GPCB). The project is not contributing to any adverse impact on the

surrounding soil, as the pollutants emitted are of the negligible amount.

Project intends to generate employment for local people and unskilled / semiskilled workers during construction

phase. If this project comes up, it will have social, financial benefits and will be environmentally sustainable.

NIRMA LIMITED





Pre-feasibility study confirms viability of the project.

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2 INTRODUCTION

2.1 Identification of Project Proponent & Project

2.1.1 Project Proponent

Nirma is one of the few names - which is instantly recognized as a true Indian brand, which took on mighty

multinationals and rewrote the marketing rules to win the heart of princess, i.e. the consumer.

Nirma, the proverbial ‘Rags to Riches’ saga of Dr. Karsanbhai Patel, is a classic example of the success of Indian

entrepreneurship in the face of stiff competition. Starting as a one-man operation in 1969, today, it has about

15,000+ employee-base and annual turnover is more than 10,000 Crores INR.

Nirma Ltd. is one of the leading soda ash producing company in India. The group has integrated backwards for the

production of detergents and toilet soaps by establishing industrial chemical manufacturing facilities of Linear Alkyl

Benzene, Alfa Olefin Sulfate, Soda Ash (light and dense), Caustic Soda, industrial salt, Cement and consumer salt to

facilitate quality production of their consumer products.

2.1.2 Proposed Project

Proposed project is for expansion in Existing Production Capacity.

2.2 Brief Description of nature of the Project

Details of existing and proposed products are listed in Table 2-1.

Table 2-1: Products Capacity (Existing & Proposed)

Sr. No. Project or activity Capacity (tpd)


Soda Ash Plant (Area = 2,61,548.33 m2)


2. Dense Soda Ash* 1800 600 2400

* Dense Soda Ash is conversion of Light Soda Ash


1. Caustic Soda (100%) 750 250 1000

2. Hydrochloric Acid (100%) 280 220 500


1. Chlorine Gas (100%) 665.2 220.8 886

2. Hydrogen (100%) 18.75 6.25 25

3. Sodium Hypo Chlorite

(100%) 12 3 15

1. Cogeneration Plant (Area =

69,100m2) 197.18 MW 152.82 MW 350

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR INTRODUCTION


2.3 Need for the Project and its Importance to the Country & Region

There is regular use of these products and has demand in local market as well as in export. This will meet the local

demand and generate employment.

2.4 Demand & Supply Gap

Limestone requirement is approximate 5050 TPD for existing Soda Ash Plant.

Additional approximate 3964 TPD (2705 TPD for SA + 1259 TPD for CPP) is required for proposed Soda Ash

Expansion and desulphurization in Cogeneration Plant. Limestone requirement will be met from the limestone mines

located in Junagadh & Porbandar districts as well as imports.

2.5 Export Possibility

2.5.1 Domestic / Export Market

There is regular use of these products and has demand in local market as well as in export. This will meet the local demand, generate employment and generate revenue for government.

2.6 Employment Generation (Direct & Indirect) due to the project

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION


3 PROJECT DESCRIPTION

3.1 Type of Project

As per the EIA notification dated 14th September, 2006, as amended till date, the proposed project falls in category

including Project / Activity: 1(d) Thermal Power Plant, 4(d) - Caustic Soda Plant, 4(e) - Soda Ash Plant and

categorized under “A”.

3.2 Location of the Project

Proposed project is located at Survey No. 478/p, 447 – 453, 455 - 457, Village – Kalatalav, Taluka & District

Bhavnagar, Gujarat.

Location map showing general location of proposed project is given in Figure 3-1. Specific Map showing project

boundary is given in Figure 3-2. The co-ordinates of the project site are given in Table 3-1.

Figure 3-1: General Location of Proposed Project Site

NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND CAPTIVE COGENERATION POWER

PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR PROJECT DESCRIPTION


Figure 3-2: Specific Map Showing Project Boundary

Red highlighted boundary shows boundary of Plant. No extra land is required.

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR SITE ANALYSIS


Table 3-1: Co-ordinates of Site Boundary

POINT LATITUDE LONGITUDE

A 21°51'56.83"N 72° 9'30.48"E

B 21°51'46.15"N 72°10'17.76"E

C 21°51'42.81"N 72° 9'23.53"E

D 21°51'39.12"N 72° 9'28.14"E

E 21°51'33.87"N 72° 9'27.12"E

F 21°51'32.87"N 72° 9'25.35"E

G 21°51'31.17"N 72° 9'25.11"E

H 21°51'30.23"N 72° 9'20.84"E

I 21°51'24.09"N 72° 9'20.45"E

J 21°51'23.82"N 72° 9'25.64"E

K 21°51'13.96"N 72° 9'26.98"E

L 21°51'12.59"N 72° 9'17.77"E

M 21°51'7.73"N 72° 9'13.03"E

N 21°50'51.17"N 72° 9'8.71"E

O 21°50'52.41"N 72°10'8.26"E

P 21°51'16.70"N 72°10'10.47"E

Q 21°51'23.75"N 72°10'15.83"E

3.3 Details of Alternate Sites Considered

The expansion and set-up of new project is within the existing chemical complex. Hence no alternative sites were

explored.

3.4 Size or Magnitude of Operation

Total plot area is 2249458 m2. The details of area calculations are given in Table 3-2. Site layout is provided as

Annexure 1.

Table 3-2: Area Statement*

S. No. Particular Area (Acre) Area (m2)

1 Plant facilities 84.0 339825

2 Storage (Raw Material & Finished Products) 23.0 92930

3 Storage (Fuel) 107.2 433940

4 Storage (Water) 7.5 30400

5 Storage (Others) 22.3 90286

6 Utilities 16.9 68250

7 Laboratory 0.9 3600

8 Approach Road(s) 3.2 13000

9 Green Belt 183.4 742321

10 ETP 3.1 12500

11 Office + Parking + Security 3.6 14500

12 Open area 100.8 407906

Total 555.8 2249458

* Area given are tentative and are subjected to changes, which will be clearly demarcated in the EIA study report.

NIRMA LIMITED





3.5 Project Description with Process Details

3.5.1 Soda Ash (Existing + Expansion)

The global theoretical equation for the production of soda ash, involving sodium chloride and calcium carbonate is

as follows;

2 NaCl + CaCO3 Na2CO3 + CaCl2

In practice the reaction is not possible and needs the participation of other substances and many different process

steps to get the final product. The first reaction involves absorption of ammonia in salt solution, followed by

reaction of ammoniated brine with carbon dioxide to obtain ammonium carbonate followed by ammonium

carbonate. The continuous introduction of carbon dioxide injection and cooling the solution, precipitation of sodium

bicarbonate is achieved and ammonium chloride is formed. The chemical reactions of the process are given below:

NaCl + H2O + NH3 NaCl + NH4OH

2 NH4OH + CO2 (NH4)2 CO3 + H2O

(NH4)2CO3 + CO2 + H2O 2 NH4HCO3

2 NH4HCO3 + 2 NaCl 2 NaHCO3 + 2 NH4Cl

Sodium Bicarbonate crystals are separated from the mother liquor by filtration, followed by thermal decomposition

to obtain sodium carbonate, water and carbon dioxide. Sodium carbonate, thus formed is called “light soda ash”

because its bulk density is approximately 0.5 t/m3.

2 NaHCO3 Na2CO3 + H2O + CO2

CO2 is recovered in the carbonation step. The mother liquor is treated to recover ammonia, by reacting with dry lime

followed by steam stripping to recover free gaseous ammonia, which is recycled to absorption step.

2 NH4Cl + H2O+CaO CaCl2 + 2 NH3 + 2 H2O

Carbon dioxide and Calcium oxide originate from limestone calcinations CaCO3 CaO + CO2. Calcium and

magnesium which are impurities in the brine are removed by reacting with alkali and carbon dioxide to produce

insoluble salts. Brine purification reactions are described in the following equations:

Ca2+ + CO32- CaCO3

Mg2+ + 2 OH- Mg (OH)2

The difference between Light and Dense Soda ash is bulk density & the size of particles. Dense Soda ash is produced

via the monohydrate process. The hot light soda ash discharge from Calciner is transported via chain conveyors and

bucket elevator to Hydrator. In hydrator Light Soda ash is mixed with water to form monohydrate according to the

exothermic reaction:

Na2CO3 + H2O Na2CO3.H2O

The next step is dehydration and drying of the monohydrate in Fluid Bed Dryer according to endothermic reaction:

Na2CO3.H2O Na2CO3 + H2O

The Dense Soda Ash is cooled and transported to storage to packing plant. The block diagram of the Soda Ash

Manufacturing unit is given in the Figure shown below:

NIRMA LIMITED





Coke 0.102 MT

Waste water 6.5 m3

Soda ash 1 MT

CaCl2 1.05 MT

CO2 gas

0.415 MT NH3 gas 0.32 MT

Reuse in next operation

Lime Stone 1.75 MT

Ammonia 0.003 MT

Water 6 m3

Sodium Sulphide

0.005 MT

Process

Salt- 2 MT

NIRMA LIMITED





Mass Balance

Caustic Soda (Existing + Expansion)

The Caustic soda manufacturing technology being used i.e. membrane technology is completely environment

friendly. The by products are hydrogen, chlorine & sodium hypo chlorite. Hydrochloric acid is manufactured using

H2 and Cl2 (produced from cell house).

Manufacturing process of Caustic Soda involves the following key steps:

Brine Saturation: Desirable circulating rate of brine in saturator is attained by dissolving salt from solar salt works

and depleted brine from the process. The water loss by membrane is compensated by supply of demineralized

water.

Chemical Preparation: In precipitation tanks saturated brine is treated to remove Ca, Mg & Sulphates by adding

Na2CO3, NaOH and Barium Chloride.

Clarification: Flocculants are added to enhance the settling. Impurities are removed in clarifier. Main impurities

are solids which are pumped to sludge filtration unit. Filtrate is recycled to clarifier.

Filtration: Anthracite filters are used to remove suspended solids.

Secondary Brine Purification: Polishing candle filters and ion exchange system is used for this process. The

objective of producing ultra-pure brine required for membrane cell operation is achieved. Polished brine after

heating through brine heater is passed through two ion exchange columns connected in series. The columns have

cation exchange resin, which provides active sites for adsorption of residual calcium and magnesium salts still

present in brine. Brine is passed through heat exchanger for achieving the temperature required at cell inlet.

Electrolysis: Brine flows into the anode chamber. Cl2 is liberated at the anode surface with depleted brine left

behind. Cl2 and depleted brine overflows from the anode chambers into the anolyte header. Weak caustic flows into

SALT

BRINE PREPARATION

RO / RAIN WATER LIME STONECOKE

LIME KILNS

ABSORPTION

CARBONATION

CALCINATION

DENSIFICATION

STORAGE

WASTE TREATMENT

DISTILLATION

COMPRESSION

GAS CONDENSATION

PACKING

FILTERATION

FINAL PRODUCTS

CLEAR LIQ. TO SALT WORKS

AIR

STEAM38-40% CO2

80-90% CO2

PURIFIED BRINECaCl2 Waste

CRUDE BICARBONATE

STEAM

LSA

DSA

LSA

LSA & DSA

MOTHER LIQUOR

NH4Cl

AMMONIA GAS

AMMONIA MAKE UP

LIME

CO2 + H2O

STEAM

ZERO

DISCHARGE

NIRMA LIMITED





the cathode chamber. H2 is generated at the cathode surface and OH ions combine with the Na+ ions diffusing

through the membrane. A two-phase mixture of 32% NaOH and hydrogen overflows into the catholyte header.

Anode Reaction: 2NaCl 2Na+ + Cl2 + 2 e –

Cathode Reaction: 2H2O + 2 e – 2OH– +H2

Overall Reaction: 2NaCl + 2H2O 2NaOH + Cl2 + H2

Catholyte System: In the catholyte header the two-phase mixture of NaOH and Hydrogen gets separated. This

catholyte stream is tapped as “Product” and fed to the caustic evaporation unit. Whole stream is not tapped and

some part is sent for internal consumption.

Anolyte Dechlorination: Depleted brine containing dissolved chlorine (called anolyte) is dechlorinated in two

stages: Vacuum dechlorination and chemical dechlorination. A part stream of chemically dechlorinated brine is be

purged out of the system to keep the sulphate within the desired levels.

Caustic Evaporation Unit: Here the incoming 32% Caustic is concentrated to 50%. The 50% caustic coming

from this unit can be stored in 50% storage tank.

Chlorine Treatment: The water vapor is removed, from the saturated chlorine, using series of coolers. The gas is

then passed through the moist chlorine filter to remove the entrained brine aerosol. In drying towers 98% H2SO4 is

used to dry moist chlorine.

The dried chlorine gas is compressed to the required pressure and then liquefied. Liquid chlorine from the liquefiers

is sent to liquid chlorine storage tanks. Sniff gas from the liquefier containing inlets and chlorine gas is sent to the

HCl synthesis unit. Excess sniff gas, is diverted to the waste air system.

Hydrogen Treatment: Hydrogen gas leaving the cells saturated with water vapor is cooled. The cooled gas is

passed through filters to remove the NaOH aerosols. Some amount of hydrogen is required for HCl synthesis and a

part of the gas is sent to caustic flaking unit to be used as fuel and a part is sent to hydrogen bottling through

hydrogen compressors as per requirement and the balance hydrogen is vented through with flame arrestor.

NIRMA LIMITED





HCl Synthesis Unit

Hydrogen is burnt in Chlorine atmosphere and the combustion gases are absorbed in water to yield a 32% HCl

solution. HCl produced is pumped to HCl head tank from HCl receiver for internal consumption within plant. The

Block diagram showing the Caustic Soda Manufacturing Process is shown in below figure:

Cl2 Gas

0.887 MT

H2 Gas

0.025 MT

Drift loss

0.12 MT

Evp. Loss

1.36 MT

Salt

1.564 MT Salt

Na2CO3 – 0.017 MT

2.81 MT- Na2CO3

H2SO4-98%

0.02 MT- H2SO4

α.cellulose

0.10 MT

Flocculent

0.01 MT

NaHSO3 – 1.268

MT

Process water

2560.66 MT

Sludge 0.012 MT

Water - 0.0035 MT

Liq. Effluent

1 MT

CT Blow Down

0.562 MT Purge Brine

1.32 MT

NaOH-1MT

Water - 284.0 MT

HCL-32% - 0.37MT

Water - 0.25 MT

Hypo – 0.016 MT

Water-MT – 0.014 MT

H2SO4-78% - 0.025 MT

NIRMA LIMITED





Schematic Diagram of Caustic Soda Manufacturing Process

3.5.2 Cogeneration Plant (Existing + Expansion)

In the case of lignite/coal-fired boilers, steam generation with any of following firing technology is technically

feasible:

Circulating fluidized bed combustion (CFBC)

Pressurized Fluidized Bed Combustion (PFBC)

Integrated Gasification Combined Cycle (IGCC)

Pulverized Fuel Firing (PF)

Circulating fluidized bed combustion (CFBC) technology is adopted for the proposed cogeneration plant. A 100 MW

cogeneration plant turbo-alternator and 350 TPH + 350 TPH (standby) lignite / coal / petcoke based CFBC Boilers,

along with cogeneration plant machineries will be installed in order to meet internal steam and power requirement

for the proposed expansion.

The steam generator units proposed for the plant will be compact, semi-outdoor, natural/assisted circulation,

balanced draft, single drum, water tube type provided with Circulating Fluidized Bed Combustion system using pan-

leg furnace configuration. In a typical Circulating Fluidized Bed furnace, the lignite fed on a bed of suitable inert

material with addition of a sorbent material (such as lime stone) is burnt in suspension through the action of

primary air distributed below the combustor floor. In addition, secondary air is introduced at suitable points in the

combustion zone to ensure controlled and complete combustion of the fuel. Suitable lignite feeding and limestone

feeding arrangements are provided in the typical Circulating Fluidized Bed Combustion systems and is commonly

used as bed material for initial start-up of the boiler. The steam generators will be designed for satisfactory

continuous operation with the range of lignite/coal expected for this plant without any need for auxiliary fuel oil for

fire stabilization etc. Lignite and Coal are used as fuel after mixing in appropriate ratio.

VENT

CAUSTIC TO STORAGE AND

FILLINGSALT SATURATION

BRINE PRECIPITATION

CHLORATE DESTRUCTION

CATHOLYTE SYSTEM

DM WATER/CONDENSATE

CHEMICALS Na2CO3,NaOH SALT

FLOCCULANT

NaHSO3, NaOH 32% SOLUTION

DM WATER

FLAKES STORAGEAND BAGGING

HYDROGEN BOTTLING

FLAKING UNIT

CAUSTIC EVAPORATION

CHLORINE LIQUEFICATION

HYDROGEN TREATMENT

LIQUID CHLORINE STORAGE

CHLORINE FILLING

48.5 / 50%NaOH SOLUTION

BRINE PURIFICATION

(ION EXCHANGE)

BRINE FILTRATION

SLUDGE FILTRATION

BRINE CLARIFICATION

ANOLYTE DECHLORINATION

SLUDGE

CHLORINE COOLING &

DRYING

98% H2SO4

CHLORINE COMPRESSION

ANODE CATHODE+ -

78% H2SO4

H2 TO STACK

HCL FILLING

HCL STORAGE

HCL SYNTHESIS UNIT

HYPO FILLING

HYPOCHLORITE STORAGE

WASTE GAS DECHLORINATION

VENT

SALT SATURATION

BRINE PRECIPITATION

CATHOLYTE SYSTEM

NIRMA LIMITED





Steam generating unit would be provided with electrostatic precipitator in the flue gas path. The overall efficiency

of ESP will be around 99.70% with one field remaining as operational standby. The ESP would have adequate

number of ash hoppers provided with electric heaters. The design of ESP will be such that the dust burden at the

outlet of chimney with one field out of service doesn’t exceed 50 mg/Nm3 at 100 % BMCR with worst fuel.

Common chimney for boiler G and H will be constructed. The NOx emission from the steam generator is least in

case of CFBC steam generator design in view of low combustion temperature maintained in the furnace. The steam

generator and auxiliaries will perform continuously within noise limits as per relevant standard specification but not

more than 85 dB (A) at 1.0 meter from any equipment or sub equipment. The steam from the boiler will go to back

pressure turbo generators. The extracted back pressure steam will be used in process.

3.6 Utilities

The estimated list of utilities required for the new project is as given below:

3.6.1 Power Requirement

The total additional power demand for the expansion has been estimated about 152.82 MW. The power

requirement will be met by installing additional coal / lignite / pet-coke based CFBC boiler (410 TPH & 130 TPH,

total 540 TPH*) along with Turbo-alternator and utilizing some surplus steam from existing boilers.


540 TPH.

Arrangement has also been made for sourcing power through sub-station of Gujarat State Electricity Board.

3.6.2 Fuel Requirement

Coal: 240.25 T/hr. &/or Lignite: 245 T/hr. &/or Pet coke: 163 T/hr. (93 T/hr for proposed boilers + 70 T/hr for

existing boilers). Light Diesel Oil (LDO) shall be required for start-up of CFBC boiler.

3.6.3 Water Requirement

Existing Seawater intake facility i.e. from Sonarai Creek, near village Gundala. Existing seawater intake – 14 x 105

m3/day. Additional seawater intake - 3.6 x 105 m3/day.

3.6.4 Storage Details

Unit will create additional storage facilities for products, raw materials as per the MSIHC rules.

3.7 Pollution Load on Environment due to project

Environmental issues include:

Air emissions;

Wastewater;

Solid Wastes.

3.7.1 Air Emissions & Control

Point Source

Likely air pollutants from proposed project shall be PM, SOx & NOx from flue gas stack, as point source.

NIRMA LIMITED





Volume Source

PM emission from coal storage yard is envisaged as volume source emissions.

Fugitive Emissions

Line Source Emissions

The ambient air quality & stack emissions will be maintained as per GPCB/CPCB norms.

Details of proposed stacks with fuel consumption and attached Air Pollution Control Equipment details are tabulated

in Table 3-3 & Table 3-4.

Table 3-3: Details of Stack Emissions

S. No. Stack Attached to Stack Height

(m)

Stack Top

Dia. (m) APCM

Expected

Pollutants*

Existing

Soda Ash Division

1 Boiler - A, B, C & D (100 TPH

Each)

100 (Common

Stack) 5.04 ESP to Each Boiler PM, SO2 & NOx

2. DG Set (1000 KVA)

2 No. 24 each 0.2 -- PM, SO2 & NOx


2 Boiler - E (200 TPH) 121 (Common

Stack) 4.5

ESP PM, SO2 & NOx

3 As per EC 2014 Boiler - F (200

TPH) – Not Installed Yet ESP PM, SO2 & NOx

4

As per EC 2017 Boiler - G & H

(350 TPH each ) – Installed

One boiler having capacity 410

TPH

121 (Common

Stack) 4.5 ESP PM, SO2 & NOx

5 DG Set (1000 KVA) 30 0.32 - PM, SO2 & NOx

6 DG Set (1500 KVA) 30

0.32

-

PM, SO2 & NOx

7 DG Set (1500 KVA)

Toilet Soap plant

8 Thermic Fluid Heater (3 No.) 45 0.4 PM, SO2 & NOx

Proposed

Soda Ash Division

1. DG Set (2000 KVA) 30 0.32 -- PM, SO2 & NOx


1 Boiler - I & J (410 TPH + 130

TPH) *

121 (Common

Stack) 13.4# ESP PM, SO2 & NOx

2 DG Set (1850 KVA) 30 0.32 -- PM, SO2 & NOx


540 TPH.

# Considering better dispersion, Engineering design has calculated the stack dia. as 13.4m

NIRMA LIMITED





Table 3-4: Details of Process Emissions

Sr. No. Vent Attached to Stack Height

(m)

Stack Dia.

(m)


System Pollutant

1

Soda Ash Plant – Existing & Proposed

Lime Kilns (A to H) – 8 nos. 68 (Common

Stack) 0.8

4 scrubbers and 3 ESP in

Series PM, SO2, NOx

Ammonia Recovery System (A to

E) - 5 nos.

56 (Common

Stack) 0.75 Brine Scrubbers (5 nos.) Ammonia

Lime Grinding System (A to E) - 5

nos. 60 (each) 0.65 Bag Filter PM

Calcinations Vessel (A to D) - 4

nos. 29 (each) 0.7 Water Scrubber PM




Lime Kilns (I to L) – 4 nos.

(Proposed)

68 (Common

Stack) 0.8

Two scrubbers and two

ESP in Series PM, SO2, NOx

Ammonia Recovery System (F &

G) - 2 nos. (Proposed)

56 (Common

Stack) 0.75 Brine Scrubbers (2 nos.) Ammonia

Lime Grinding System (F- 1 no.)

(Proposed) 60 0.65 Bag Filter PM

Calcinations Vessel (E & F - 2

nos.) (Proposed)

29 (Common

vent) 0.7 Water Scrubber PM

Densification 4 (Proposed) 51 1.37 Water Scrubber PM

2

Caustic Soda and CPP - Existing & Proposed





HCl Synthesis Unit – 5

(Proposed) 30 0.1 Water Scrubbers HCl & Cl2






System – 3 30 0.3 18% NaOH Scrubber Cl2

Hydrogen unit with Flame

arrestor and steam snuffing – 1 30 -- -- --





3. Bromine Plant

De-bromination System 30 0.3 Alkali Scrubber Bromine

4.


Solvent Recovery 30 0.3 Ceramic + Activated

Carbon Filter Aromatic Solvent

Hydrogenation Plant (purge gas) 30 0.3 Ceramic + Activated H2 + Aromatic Solvent

NIRMA LIMITED





Sr. No. Vent Attached to Stack Height

(m)

Stack Dia.

(m)


System Pollutant

Carbon Filter

Incinerator & its scrubber 30 0.3 Water Scrubber PM, SO2, CO, NOx,

HCl, TOC

HCl Synthesis Unit 30 0.1 Water Scrubbers HCl

Chlorination Plant 30 0.3 Acidic/Water Scrubber (3

nos.) SO2, HCl, Cl2

Chlorination Plant 30 0.3 Alkali Scrubber (3 nos.) Cl2

Chlorination 30 0.3 Water Scrubber SO2, HCl, Cl2

Hydrogenation Plant (purge gas) 30 0.3 ---- H2

3.7.2 Noise Generation

From the proposed project, noise shall be generated from the various activities. Source of noise generation are:

The heavy machinery like crane, dumper, roller, bulldozers etc. will be used during daytime during construction

phase;

Operation of plant machinery and diesel generator set;

Vehicle movement for transportation of raw material.

3.7.3 Waste Water Generation

The main source of the industrial wastewater generation will be from domestic, process, utilities, washing and

others. The total quantity of effluent will be increased from 5,86,445.2 KLD to 9,06,634.7 KLD. Entire quantity of

wastewater will be treated in existing treatment facilities. In existing scenario Treated effluent is partly reused /

recirculated in salt works and around 12000 m3/day of Soda Ash effluent and 6000 m3/day of Bittern is being

disposed off in to the sea at a discharge point suggested by National Institute of Oceanography (NIO).

In proposed expansion, Additional soda ash effluent, additional bittern & cooling water will be disposed in sea along

with existing effluent and bittern at point suggested by NIO. Return cooling water of 3,00,000 m3/day will be

disposed into deep sea at a discharge Point suggested by NIO on permanent basis and during emergency purpose /

monsoon 8,60,000 m3/day will be disposed into sea.

NOTE: Zero Liquid cannot be implemented by us since the drawl is of sea water and salt / sea water drawl based

projects, such as Nirma Ltd., Kalatalav, Bhavnagar Dist., cannot work without suitable sea discharge, considering

the huge volumes of sea water involved.

Details of Waste water generation are given in Table 3-5.

Table 3-5: Wastewater Generation Details

Sr. No. Source Wastewater Generation (m3/day)


Soda Ash plant

1. Domestic 184 99 283

2. Process 32547 17436 49983

3. Boiler 216 0 216

4. Cooling 473571 286840 760411

5. Others 0 0 0

Total (I) 506518 304375 810893

Toilet Soap plant

1. Domestic 48 0 48

2. Process 0 0 0

3. Washing 25 0 25

NIRMA LIMITED





Sr. No. Source Wastewater Generation (m3/day)


4. Cooling 275 0 275

Total (II) 348 0 348

Caustic Soda Plant & CPP

1. Domestic 11 3.5 14.5

2. Process 750 250 1000

3. Boiler 1340 447 1787

4. Cooling 43842 14614 58456

Total (III) 45943 15314.5 61257.5

Salt works

1. Salt works 11000 500 11500

Total (IV) 11000 500 11500

Bromine plant

1. Cooling tower 1000 0 1000

2. Process 12500 0 12500

Total (V) 13500 0 13500


1. Domestic 6.6 0 6.6

2. Process + DM 1595 0 1595

3. Cooling + Chilling 2977 0 2977

4. Boiler 0 0 0

5. Washing/Others 41 0 41

Total (VI) 4619.6 0 4619.6

RBC Plant, Calcium Chloride plant & Phosphoric acid plant

1 Domestic 8.6 0 8.6

2 Process 4250 0 4250

3 Cooling 258 0 0

Total (VII) 4516.6 0 4516.6

Grand Total (I to VI) 586445.2 320189.5 906634.7

3.7.4 Hazardous Waste & Other Solid Waste

The main source of hazardous waste generation will increase after proposed expansion. ETP sludge will be dispose

to TSDF site. Used oil will be sold to authorized recycler and discarded containers & plastic liners will be sold to

registered recyclers.

The details of Solid & hazardous waste are given in Table 3-6 & Table 3-7.

Table 3-6: Solid Waste Generation & Disposal

Sr. No. Solid Waste

Quantity (TPD)

Mode of Disposal Existing Proposed

After

Expansion

1 Settling Pond Sludge 880 482 1362 Shall be used in road construction,

salt works bund preparation

2 Lime stone rejects /

under size 700 375 1075

Shall be used in boilers for

desulphurization in boilers

3 Brine Sludge 19 10 29 Non-hazardous; Shall be used

dumped in identified area

4 Fly ash/ Bottom ash 2185 1693 3878 Brick manufacturing, bund

preparation, road making etc…

5 Incineration Ash --- 15 15 Brick manufacturing, bund

preparation, road making etc…

NIRMA LIMITED





Sr. No. Solid Waste

Quantity (TPD)


After

Expansion

6 Saponification

Solid Waste 3 0 3

Non-hazardous; Shall be

dumped in identified area

Table 3-7: Hazardous Waste Generation and Disposal

Sr. No. Hazardous Waste Category

Quantity (MTPA)


Total After

Expansion

1

Soda Ash Plant

Waste Oil / Lub. Oil from 5.1 10 5 15

Collection, Storage,

Transportation & disposal

by selling to Registered

Recyclers

Spent ion exchange resins 34.2 1830 lt/year 980 lt/year 2810 lt/year


Transportation, Disposal

by selling to authorized

recyclers or sent to NECL

Nandesari for

Incineration.

Discarded

bags/drums/containers etc… 33.3 3.5 2 5.5




recyclers

2

Caustic Soda Plant

Waste Oil/ Lub. Oil from 5.1

30 kl 10 kl 40 kl Collection, Storage,



Recyclers

Spent ion exchange resins 34.2

2.56 1 3.56 Collection, Storage,



recyclers or sent to NECL

Nandesari for

Incineration.

Discarded

Bags / drums / containers

etc…

33.3 4.5 1.5 6




recyclers

Residue/ Sludge & Filter

sludge 16.2 6526 2175 8701



at TSDF

ETP sludge 34.3 150 50 200



at TSDF

Spent Sulphuric Acid (80%) D2 6520 2173 8693


Transportation, reuse as

raw material for Nirma

Ltd. Moraiya and other

end users.

3 Toilet Soap Plant

NIRMA LIMITED





Sr. No. Hazardous Waste Category

Quantity (MTPA)


Total After

Expansion

Waste Oil/ Lub. Oil from 5.1 0.45 0 0.45




Recyclers

ETP sludge 34.3 48 0 48



at TSDF

Glycerin foot D6-II 72 0 72



by selling to M/s.

Ultratech Cement for Co-

incineration in cement kiln

/ NECL for Incineration.

Spent Sulphuric Acid (80%) D2 24000 0 24000


Transportation, reuse as

raw material for Nirma

Ltd. Moraiya and other

end users.

4


Waste Oil/ Lub. Oil 5.1 10 0 10




Recyclers

Discarded containers/

Barrels/empty drums/empty

bags

33.3 10 0 10

Collection, Storage and

disposal by selling to

authorized recyclers.

ETP sludge 34.3 120 0 120



at TSDF

Glycerin foot D6-II 5356 0 5356

Collection, Storage &

incineration in plant

incinerator.

Catalyst from regeneration 35.2 1.2 0 1.2



at Common Haz. Waste

incineration facility

Spent Carbon from solvent

recovery 35.3 3 0 3




incineration facility

Spent Carbon from ETP 34.3 3 0 3



at TSDF

Distillation Residue 36.4 550 0 550




incineration facility.

NIRMA LIMITED





4 SITE ANALYSIS

4.1 Connectivity

4.1.1 By Road

The nearest highway (Bhavnagar-Ahmedabad SH-6 Coastal highway) is about 14.0 kms away from the plant in the

West direction.

4.1.2 By Rail

Major railway station for public transportation is Bhavnagar Railway Station located at an aerial distance of ~10 Km

from the project site in the South-South West Direction.

4.1.3 By Air

Bhavnagar has its own airport, Bhavnagar Airport, which is at ~10 Km from project site.

4.2 Land Form, Land use & Land Ownership

There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma

Limited. Land Cover will be as per the Site Layout Map as shown in Annexure 1.

4.3 Topography

Project site is shown on Toposheet in Annexure 2.

4.4 Existing Infrastructure

Existing infrastructure like roads, power supply, water supply line, etc. are readily available at the site.

4.5 Soil Classification, Geology & Drainage

4.5.1 Soil Classification

Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. The soil type is a mixture

of sand & gravel with intermediate golden colour laterites with clay as binder. The subsoil strata of the study area

consist of a mixture of sandy gravel with clay as binder in the top 10 m. Thereafter the strata of about 50 m is a

thick layer of Grayish-blue clay having very hard to stiff consistency tending to rock like formation. The topsoil

around Kalatalav is made up of coarse saline soil poor in nutrients.

Most of the 10 km radial zone around Kalatalav has alluvial deposits and consists of sandy soil, tidal mudflats,

raised beaches and freshwater alluvium. Clay (size < 0.002mm) amount in the soil samples ranges from 17% to

22%; Silt (size 0.002 to 0.075 mm) in the soil samples is 14% to 18% Sand (size 0.075 to 0.475mm) in the soil

samples is 50% to 58% and gravel (size > 4.75 mm) in soil samples is 10% to 14%.

4.5.2 Geology

The Bhavnagar district is located in the south-eastern part of Saurashtra peninsula of Gujarat. It falls in the seismic

zone-III as per IS 1893 (part -1) 2003. Peninsula is bounded by sea on all sides except northeast side where it is

flanked by alluvium plains of main land.

NIRMA LIMITED





Bhavnagar district shows diverse features like uneven, rocky (basaltic) land surface traversed by mountain

ranges/ridges and trappean dykes. Most of the district is composed of Weathered to Hard & massive Deccan Trap

formation, which is impervious with low yield. Rocks with cracks, fractures and fissures provide some discharge and

potable water quality.

4.6 Climatic data from secondary sources

Information presented in subsequent paragraphs is from the Indian Meteorological Department (IMD), Long Term

Climatological Tables, 1981-2010, Bhavnagar (A). These tables give useful information about a region’s weather,

since they are collected over a 29-year period. Copy of the same is attached as Annexure 3.

Mean daily maximum temperature is recorded in the month of May at 40.0°C. From October to December, both day

and night temperatures begin to decrease rapidly. January is generally the coldest month, having minimum

morning temperature at 13.9°C. During the post-monsoon months of October, November, December day

temperatures remain between 17.8ºC - 26.7ºC. In winters, i.e. December, January and February, average day

temperatures remain between 16.2 – 18.8ºC.

The total rainfall in year is observed to be 655.9 mm. Distribution of rainfall by season is 2.4 mm in winter

(December, January, February), 5.2 mm in summer (March, April, May), 612.4 mm in monsoons (June, July,

August, September) and 35.9 mm in post-monsoons (October, November, December). Annual total heaviest rainfall

recorded in 24 hrs is observed to be 434.4 mm on 20th July, 1996.

An online weather logger was set up at Plant site. The co-ordinates for the same are 21051’14.1”N; 72010’32.8”E.

4.7 Social Infrastructure Available

Educational Facilities

As per 2001 census in all 5 villages, there are 4 primary schools & other educational facilities are in 10 km radius of

the study area.

Medical Facilities

Out of 4 villages in the study area, one has Primary Health Sub-Centers & other medical facilities are within 10 km

of the study area. Almost all medical facilities are available there.

Drinking Water Supply

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility.

Communication & Transport

The main mode of public transport available in the study area is by bus service. All villages are near Bhavnagar, so

almost all villages have approach to railway station as western railway meter gauge line is passing through nearby.

Post & Telegraph

There are 5 villages in study area, 2 villages have post office facility at doorstep & almost all have phone facility.

Power Supply

All the villages are getting power supply for domestic purposes.

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR PLANNING BRIEF


5 PLANNING BRIEF

5.1 Planning Concept

Site falls under the seismic Zone III, which is classified as Low Risk zone (Area liable to shaking Intensity VI (and

lower). Thus, suitable seismic coefficients accordingly shall be adopted while designing the structures to make it

earthquake resistant.

Basic facilities of infrastructure like admin building, processing area, storage area, internal roads etc. are already

developed in the project site.

5.2 Landuse Planning

There will be no change in landuse as the necessary expansion will be within the integrated complex of Nirma Ltd.

5.3 Assessment of Infrastructure Demand (Physical & Social)

No additional infrastructure demand is required.

5.4 Amenities/Facilities

Within the study area (i.e. 10 kms) basic amenities/ facilities like there are 4 primary schools & other educational

facilities, is available in all the nearby villages. Out of 4 villages in the study area, one has Primary Health Sub-

Centres & other medical facilities are within 10 km of the study area. Bhavnagar is nearest city to the study area,

which is around 10 km away from project site. Almost all medical facilities are available there.

All the villages in the study area have two or more sources of drinking water. All villages in study area have tap

water supply (almost all) with tank water supply. One village has well water facility. The main mode of public

transport available in the study area is by bus service. All villages are near Bhavnagar, so almost all villages have

approach to railway station as western railway meter gauge line is passing through nearby. Majority of villages in

the study area is connected with pucca road. Out of 5 villages in study area, 2 villages have post office facility at

doorstep & almost all have phone facility. All the villages are getting power supply for domestic purposes.

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing unit comprises of following sections:

Boiler House consisting of CFBC Boilers – 2 Nos., Steam Turbine, Alternator / Generator;

Fuel storage area;

Utility Area consisting of cooling tower, compressors, ESP section, ETP area;

Fly Ash & Hazardous waste storage area.

Adequate storage space for fuel storage, hazardous and other solid waste is already available. Additional storage

space will be provided as per the requirement.

6.2 Non- Processing Area

Existing non processing area includes Weighbridge, Administrative Building, Laboratory, Security cabins, Workers

restroom, Vehicle Shed, Water reservoirs for raw water and fire hydrant system, Temporary storage sites, Works

block etc.

6.3 Greenbelt

Nirma has done extensive plantation in around 110 acres and spared total 183.4 acres for greenbelt development. Unit is also taking interest to develop greenbelt peripheral outside of the factory premises

6.4 Social Infrastructure

Refer Chapter 4, Section 4.7.

6.5 Connectivity

Refer Chapter 4, Section 4.1.

6.6 Drinking Water Management

Drinking water source for the existing Nirma plant at Kalatalav is from RO plant.

6.7 Sewage System

Sewage would be generated from the various units within the manufacturing facility. The existing sewage quantity

generated is 258.2 m3/day. The sewage expected to be generated for proposed expansion would be 102.5 m3/day.

Thus, the total sewage generation would be 360.7 m3/day. The sewage would be disposed off in soak pits of

individual plants and the same is being used in greenbelt development.

6.8 Industrial Waste & Solid Waste Management

Solid and hazardous waste as mentioned in Chapter 3, Section 3.7.4 shall be collected, stored, disposed to

authorized vendors and sold to local suppliers as per it’s characterization and based on the prescribed Fly Ash

NIRMA LIMITED



KALATALAV, NEAR BHAVNAGAR PROPOSED INFRASTRUCTURE


Notification, 2015 & Hazardous Waste Rules, 2016 amended till date. Other wastes to be generated from the

project are tabulated in Table 6-1. Details will be provided in EIA report.

Table 6-1: Identification of Other Wastes

S. No. Type of Waste Constituents

1 Municipal Solid Waste Kitchen waste, cardboard, paper and garden wastes

2 Inorganic Waste Scraps, paper bags, cardboards and glassware’s etc.

3 Plastic Waste Plastic bags, plastic scraps etc.

4 E-waste CD’s, LAN Cables, Fuses, Data cables, circuit boards, etc.

5 Biomedical Waste Syringe, Bandages, used cotton, medicine etc.

6 Construction & Demolition waste Debris

6.9 Power Requirement & Supply / Source

Refer Chapter 3, Section 3.6.1.

NIRMA LIMITED


PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY

AT KALATALAV, NEAR BHAVNAGAR REHABILITATION AND

RESETTLEMENTS


7 REHABILITATION AND RESETTLEMENT (R& R) PLAN

Since no additional land is acquired for the proposed expansion project, and all the proposed units will be inside the

existing plant premises, R & R issues are not envisaged.

NIRMA LIMITED


PRODUCTION AND CAPTIVE COGENERATION POWER PLANT IN EXISTING FACILITY

AT KALATALAV, NEAR BHAVNAGAR PROJECT SCHEDULE & COST

ESTIMATE


8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Likely date of start of construction and likely date of completion

The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized

committee. Tentative schedule for the project to be completed is given in Table 8-1.

Table 8-1: Tentative Project Time Schedule

S. No. Activities Start Finish

1 EC Approval August, 2018 December, 2018

2 Detailed Engineering April, 2019 July, 2019

3 Procurement and Delivery August, 2019 Delivery start from

December, 2019

4 Construction at Site (Buildings, Mech., Piping, Elec., Inst etc.) August 2019 December, 2020

5 Pre Commissioning January, 2021 June, 2021

6 CTO Approval July, 2021 January, 2022

7 Process Startup and Stabilization September, 2021 March, 2022

8.2 Estimated Project Cost

The project cost is estimated to be INR 1320 crores. The breakup of project cost is given in Table 8-2.

Table 8-2: Breakup of Project Cost

S. No. Particulars Amount (INR in Crores)

1 Soda Ash Plant 570

2 Caustic Soda and CPP 750

Total Project Cost 1320

8.2.1 Profitability

The project has been conceived upgrading old inefficient sets with new efficient sets, hence increasing profitability.

Further capacity enhancement leads to a reasonable ROI, based on consuming plant expansion.

NIRMA LIMITED


PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANALYSIS OF PROPOSAL


9 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

During the construction phase around 150 workers and existing manpower is sufficient to operate proposed

expansion units. Local skilled and semi-skilled workers will be engaged during construction phase.

NIRMA LIMITED


PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


ANNEXURES

NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 1: Preliminary Site Layout Map

NIRMA LIMITED REVISED PFR – PROPOSED EXPANSION IN SODA ASH, CAUSTIC SODA PRODUCTION AND COGENERATION PLANT IN

EXISTING FACILITY AT KALATALAV, NEAR BHAVNAGAR ANNEXURES


Annexure 2: Project Site Located on Toposheet showing 3, 5, 7 & 10 km Radii Circles




Annexure 3: Long Term Meteorological Data for Bhavnagar City

m/s. nirma ltd.environmentclearance.nic.in/writereaddata/...nirma ltd. revised form 1 – proposed...

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