0 0 19092014A2NEUAnnexure-Updated Form1 PDF

M/S.
ARCHEAN CHEMICAL
INDUSTRIES PVT. LTD.
Form I for Amendment in

Environmental Clearance of Chemical
Fertilizer Manufacturing Unit and Co-
generation Power Plant (10 MW) at
Greater Rann of Kachchh, Near Hajipir,
Taluka Bhuj, District Kachchh, Gujarat.
SEPTEMBER 2014
Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development

AMENDMENT IN EC FOR CHEMICAL FERTILIZER MANUFACTURING
ARCHEAN CHEMICAL UNIT AND CO-GENERATION POWER PLANT (10 MW) AT QUALITY CONTROL
INDUSTRIES PVT. LTD. GREATER RANN OF KACHCHH SHEET
M/S. ARCHEAN CHEMICAL INDUSTRIES PVT. LTD.
Form I for Amendment in Environmental Clearance

of Chemical Fertilizer Manufacturing Unit and Co-
generation Power Plant (10 MW) at Greater Rann of
Kachchh, Near Hajipir, Taluka Bhuj, District
Kachchh, Gujarat.
© Kadam Environmental Consultants (‘Kadam’), September, 2014
This report is released for the use of the M/s. Archean Chemical Industries Pvt. Ltd., Regulators and
relevant stakeholders solely as part of the subject project’s Amendment in 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.
QUALITY CONTROL
Form I for Amendment in Environmental Clearance of Chemical Fertilizer Manufacturing
Name of
Unit and Co-generation Power Plant (10 MW) at Greater Rann of Kachchh, Near Hajipir,
Publication
Taluka Bhuj, District Kachchh, Gujarat.
Project Report Releas September,
1419391606 1 Version 1
Number No. ed 2014
Prepared By Bhavin Jambucha
Released By Jagdishchandra Rathi, EIA Coordinator
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.
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

ARCHEAN CHEMICAL UNIT AND CO-GENERATION POWER PLANT (10 MW) AT
INDUSTRIES PVT. LTD. GREATER RANN OF KACHCHH, GUJARAT TABLE OF CONTENTS
CONTENTS
1 SCOPING ................................................................................................... 1
1.1 FORM – 1 ............................................................................................... 1
2 DECLARATION: ......................................................................................... 10
3 ANNEXURES ............................................................................................. 11
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

INDUSTRIES PVT. LTD. GREATER RANN OF KACHCHH, GUJARAT TABLE OF CONTENTS
LIST OF ANNEXURES
Annexure 1: Details of Products, Raw Material, Manufacturing Process............................................ 12
Annexure 2: Site Plan and Layout Plan ......................................................................................... 17
Annexure 3: Water Consumption and Waste Water Generation Details ............................................ 19
Annexure 4: Effluent Treatment Scheme ....................................................................................... 21
Annexure 5: Details of Air Emissions ............................................................................................. 23
Annexure 6: Details of Hazardous Waste Generation and Disposal .................................................. 24
Annexure 7: Storage and Transportation Details of Products (Mainly Bromine) ................................ 25
Annexure 8: Risk Assessment Report ............................................................................................ 27
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 II

INDUSTRIES PVT. LTD. GREATER RANN OF KACHCHH, GUJARAT FORM 1
1 SCOPING
1.1 FORM – 1
The scoping for the project has been done based on FORM 1, as per EIA Notification, dated
September 14, 2006 amended as on date. The scoping details are as follows:
I. Basic Information
S.
Item Details
No.
1 Name of the Project/s Archean Chemical Industries Pvt. Ltd.
2 S. No. in the Schedule Project / Activity: 5(a) – Chemical Fertilizers
Proposed capacity / area / length / Proposed production capacity will be 1,96,000
3 tonnage to be handled/ command area MT/Annum. Proposed Land area will be used: 253
/ lease area / no. of wells to be drilled hectares.
Amendment in Existing EC approval. (EC condition
4 New / Expansion / Modernization number 19 as per F. No. J-11011/149/2010-IA
II(I) dated 2nd September, 2011)
S.N. Product Quantity
1 Sulphate of Potash 1,00,000
5 Existing Capacity / Area etc. 2 Liquid Bromine 12,500
3 Green Bromine 2,500
4 Epsomite 81,000
6 Category of Project (A or B) “A”
No, Does not fall under Protected area under
Wildlife Protection Act, 1972. Does not fall under
Does it attract the general conditions?
7 Critically Polluted Areas. No eco-sensitive area as
If yes, please specify.
per EA, 1986. International boundary beyond 10
Km.
Does it attract specific condition? If yes,
8 N.A.
please specify
Location Rann of Kachchh.
Plot Survey / Khasra No. Un-Survey Land
Village Nr. Hajipir
9
Tehsil / Taluka / Mandal Bhuj
District Kachchh
State Gujarat
Nearest railway station / airport / along Bhuj railway station – 110 Km
10
with distance in km. Bhuj Airport – 110 Km
Nearest town, city, district Nearest village : Hajipir –16 Km
11 headquarters along with distances in Nearest city : Bhuj –110 Km
kms District Headquarters: Bhuj
Village Panchayat, Zilla Parishad, Hajipir Gram Panchayat
12
Municipal Corporation, Local Body C/o Luna Juth Panchayat
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 1

S.
Item Details
No.
(complete postal address with At & P.O. Hajipir
telephone nos. to be given) Taluka: Bhuj, Pin Code- 370605
Dist. Kutch, Gujarat
13 Name of the applicant Archean Chemical Industries Pvt. Ltd.
5 th Floor, Tower II, TVH Beliciaa Towers, 94,
14 Registered address
MRC Nagar, Chennai – 600028, TamilNadu –India
Address for correspondence
Name Mr.V.Manickam
Designation Executive Vice President
”Anandam”, D/4, Nu-10-B, Opp. Lions Club,
Address Shaktinagar, P.O. Gandhidham,
15 Dist. Kutch, Gujarat.
Pin Code 370 201
E-mail manickam@acipl.co
044-43033444 /
Telephone no.
02836-234259/234158/233841
Fax no. 02836-233400
Details of alternative sites examined, if
Rann of Kutch is the best location for extraction of
16 any. Location of these sites should be
marine chemicals.
shown on the Toposheet.
17 Interlinked Projects None.
Whether separate application of
18 No.
interlinked project has been submitted?
19 If yes, date of submission N.A.
20 If no, reason N.A.
Whether the proposal involves approval
/ clearance under: if yes, details of the
same and their status to be given:
21 N.A.
The Forest (Conservation) Act, 1980
The Wildlife (Protection) Act, 1972
The C.R.Z Notification, 1991
Whether there is any Government order
22 N.A.
/ policy, relevant / relating to the site
23 Forest land involved (ha.) No. It is the Greater Rann Of Kachchh.
Whether there is any litigation pending
against the project and / or land in
which the project is proposed to be set
24 up? Name of the Court, Case No. No. New Project.
Order / directions of the Court, if any
and its relevance with the proposed
project

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.)
Details thereof (with approximate

Information/Checklist Yes
S. No. quantities / rates, wherever possible)
Confirmation /No
with source of information data
Permanent or temporary change in

land use, land cover or topography
1.1 including increase in intensity of land No The land is in saline desert.
use (with respect to local land use
plan)
Clearance of existing land, vegetation The present land is not used for any agricultural
1.2 No
and buildings? activity.
1.3 Creation of new land uses? No Already existing saline land under use.
Pre-construction investigations e.g.
1.4 No Preconstruction activities already completed.
bore houses, soil testing?
New plant constructed along with all the
1.5 Construction works? No
associated utilities.
1.6 Demolition works? No No demolition activities envisaged.
Temporary sites used for construction
Containerized accommodation provided for
1.7 works or housing of construction Yes
workers.
workers?
Above ground buildings, structures or
Process, utility buildings, stores, administration
1.8 earthworks including linear structures, Yes
buildings already constructed.
cut and fill or excavations
Underground works including mining
1.9 No N.A.
or tunneling?
1.10 Reclamation works? No N.A.
1.11 Dredging? No N.A.
1.12 Offshore Structure? No N.A.
Production and manufacturing Manufacturing process are given in Annexure

1.13 Yes
processes? 1.
Facilities for storage of goods or Store house provided for the storage of
1.14 Yes
materials? products. Details given in Annexure 7.
Sewage will be treated in sewage treatment
plant and reused for irrigation.
Process Waste water generated from the unit
will be treated in the Effluent treatment plant.
Facilities for treatment or disposal of The treated effluent will be sent back to the
1.15 Yes
solid waste or liquid effluents? solar evaporation ponds.
The ETP solid waste will be used for
strengthening of bunds of the solar ponds.
Other solid waste will be sent to TSDF – Details
in Annexure 5.


Confirmation /No
Facilities for long term housing of Housing facilities provided in nearby towns and
1.16 Yes
operational workers? villages.
New road, rail or sea traffic during

1.17 Yes New approach road constructed in the desert.
construction or operation?
New road, rail, air waterborne or other

transport infrastructure including new
1.18 No N.A.
or altered routes and stations, ports,
airports etc?
Closure or diversion of existing
transport routes or infrastructure
1.19 No N.A.
leading to changes in traffic
movements?
New or diverted transmission lines or
1.20 No N.A.
pipelines?
Impoundment, damming, culverting,
1.21 realignment or other changes to the No N.A.
hydrology of watercourses or aquifers?
1.22 Stream crossings? No N.A.
N.A. Desalination plant installed for domestic
Abstraction or transfers of water from
1.23 No and process requirement. Sea water will be
ground or surface waters?
used for process requirement.
Changes in water bodies or the land
1.24 No N.A.
surface affecting drainage or run-off?
Transport of personnel or materials for Transport of Personnel from nearby town.
1.25 construction, operation or Yes Construction material will also be transported
decommissioning? from nearby villages or town.
Long-term dismantling or
1.26 No N.A.
decommissioning or restoration works?
Ongoing activity during
1.27 decommissioning which could have an No N.A.
impact on the environment?
Influx of people to an area either We have provided employment to locals during
1.28 Yes
temporarily or permanently? construction and operational phase.
1.29 Introduction of alien species? No N.A.
Loss of native species or genetic
1.30 No N.A.
diversity?
1.31 Any other actions? No N.A.

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):

confirmation /No
Land especially undeveloped or
2.1 No N.A.
agricultural land (ha)
Water (expected source & competing Sea water will be used for operating the plant
2.2 Yes
users) unit: KLD Details given in Annexure 3.
2.3 Minerals (MT) No N.A.
Construction material stone,
No construction activity, all civil works
2.4 aggregates, sand / soil (expected No
completed.
source, MT)
2.5 Forests and timber (source, MT) No N.A.
We have our own Captive Power Plant of
Energy including electricity and fuels
capacity – 12 MWA CPP.
2.6 (source, competing users) unit: fuel Yes
Coal and lignite is being used as fuel in the
(MT), energy (MW)
boiler. Details given in Annexure 5.
Any other natural resources (use
2.7 Yes Brine from Rann.
appropriate standard units)
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.

Information / Checklist Yes
confirmation /No
Use of substances or materials, which
Chlorine will be used as raw material. Bromine
are hazardous (as per MSIHC rules) to
3.1 Yes will be one of the products. Details of Storage &
human health or the environment
Transportation given in Annexure 7.
(flora, fauna, and water supplies)
Changes in occurrence of disease or
3.2 affect disease vectors (e.g. insect or No N.A.
water borne diseases)
Affect the welfare of people e.g. by

3.3 No N.A.
changing living conditions?
Vulnerable groups of people who

could be affected by the project e.g.
3.4 No N.A.
hospital patients, children, the elderly
etc.,
3.5 Any other causes No N.A.

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

(MT/month)

confirmation /No
4.1 Soil, overburden or mine wastes No N.A.
Municipal waste (domestic and or
4.2 No N.A.
commercial wastes)
Hazardous wastes (as per Hazardous
4.3 Yes Details given in Annexure 6.
Waste Management Rules)
4.4 Other industrial process wastes No N.A.
4.5 Surplus product No N.A.
Gypsum in the form of ETP sludge will be
Sewage sludge or other sludge from
4.6 Yes produced and will be used in strengthening of
effluent treatment
bund.
Construction waste will be utilized for building
4.7 Construction or demolition wastes Yes internal RCC road. Steel waste will be sold as
scrap.
4.8 Redundant machinery or equipment No N.A.
4.9 Contaminated soils or other materials No N.A.
4.10 Agricultural wastes No N.A.
4.11 Other solid wastes No N.A.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)

confirmation /No
Emissions from combustion of fossil
Emissions from boiler, by using coal and lignite
5.1 fuels from stationary or mobile Yes
as fuel.
sources
Bromine from the bromine bottling plant. A
5.2 Emissions from production processes Yes scrubber installed for the same. Details given in
Annexure 5.
Emissions from materials handling
5.3 No N.A.
including storage or transport
Water will be sprayed to suppress the dust
Emissions from construction activities
5.4 No emissions due to transport of construction
including plant and equipment
materials to the site.
Dust or odours from handling of Water will be sprayed to suppress the dust
5.5 materials including construction Yes emissions due to transport of construction
materials, sewage and waste materials to the site.
5.6 Emissions from incineration of waste No N.A.
Emissions from burning of waste in
N.A. no burning activity will be carried out in
5.7 open air (e.g. slash materials, No
open space.
construction debris)
5.8 Emissions from any other sources No N.A.

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

confirmation /No
From operation of equipment e.g.
6.1 No Manufacturing activity is in closed reactors.
engines, ventilation plant, crushers
6.2 From industrial or similar processes No N.A.
During construction, noise will be generated.
6.3 From construction or demolition Yes
This will be temporary in nature.
Piling activities will generate noise which will be
6.4 From blasting or piling No very localized. Ear muffs will be provided to the
workers.
Due to transport of construction materials by
From construction or operational trucks, noise will be generated. This will be
6.5 Yes
traffic temporary in nature. Moreover there is no
habitat in the 10 km radius zone.
6.6 From lighting or cooling systems No N.A.
6.7 From any other sources No N.A.
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

confirmation /No
From Chlorine and bromine handling.

From handling, storage, use or
7.1 Yes Risk Assessment Report is attached as
spillage of hazardous materials
Annexure 8.
Sewage is being treated in sewage treatment
From discharge of sewage or other
plant and is being utilized for development and
effluents to water or the land
7.2 No maintenance of greenbelt. Effluents after
(expected mode and place of
neutralization is be sent to solar evaporation
discharge)
ponds.
By deposition of pollutants emitted to Scrubbers is being installed for use chlorine and
7.3 Yes
air into the land or into water bromine.
7.4 From any other sources No N.A.
Is there a risk of long term build up of
7.5 pollutants in the environment from No N.A.
these sources?

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

affect human health or the environment

confirmation /No
From explosions, spillages, fires etc All safety measures is been taken as per
8.1 from storage, handling, use or Yes statutory norms. A detailed risk assessment is
production of hazardous substances given in Annexure 8.
8.2 From any other causes No N.A.
Could the project be affected by
natural disasters causing environmental
8.3 No N.A.
damage e.g. floods, earthquakes,
landslides, cloudburst etc)?
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. quantities/ rates, wherever possible) with
confirmation /No
source of information data
Lead to development of supporting

Facilities, ancillary development or
development stimulated by the project
By putting our industry in remote area there is
which could have impact on the
a rise of development of transport industry,
9.1 environment e.g.: supporting Yes
engineering units, housing development in the
infrastructure (roads, power supply,
area.
waste or waste water treatment, etc.)
housing development extractive
industries supply industries, (other)
Lead to after-use of the site, which
9.2 could have an impact on the No N.A.
environment.
9.3 Set a precedent for later developments No N.A.
Have cumulative effects due to
9.4 proximity to other existing or planned No N.A.
projects with similar effects
III. Environmental Sensitivity
S. Name / Aerial Distance (within 15 km) of the

Areas
No. Identity proposed project location boundary
Areas protected under international

1 conventions, national or local No N.A.
legislation for their ecological,

S. Name / Aerial Distance (within 15 km) of the

Areas
No. Identity proposed project location boundary
landscape, cultural or other related

value
Areas which are important or sensitive
for ecological reasons - Wetlands,
2 watercourses or other water bodies, No N.A.
coastal zone, biospheres, mountains,
forests
Areas used by protected, important or
sensitive species of flora or fauna for
3 No N.A.
breeding, nesting, foraging, resting,
over wintering, migration
Inland, coastal, marine or underground
4 No N.A.
waters
Our Plant site is located about 40 kms from
5 State, National boundaries Yes
the international border.
Routes or facilities used by the public
6 for access to recreation or other No N.A.
tourist, pilgrim areas
The area is controlled by Border Security
7 Defense installations Yes
Force.
8 Densely populated or built-up area No N.A.
Areas occupied by sensitive man-made
9 land uses (hospitals, schools, places of No N.A.
worship, community facilities)
Areas containing important, high
quality or scarce resources (ground
10 water resources, surface resources, No N.A.
forestry, agriculture, fisheries, tourism,
minerals)
Areas already subjected to pollution or
environmental damage. (Those where
11 No N.A.
existing legal environmental standards
are exceeded)
Areas susceptible to natural hazard
which could cause the project to
Earthquake Prone area. The construction
present environmental problems
12 Yes activity are strictly adhere to building norms
(earthquakes, subsidence, landslides,
laid down for earthquake zone.
erosion, flooding or extreme or adverse
climatic conditions)

INDUSTRIES PVT. LTD. GREATER RANN OF KACHCHH, GUJARAT ANNEXURES
3 ANNEXURES

Annexure 1: Details of Products, Raw Material, Manufacturing Process
List of Products are given in table below:
S. No. Products MT/Annum

2 Liquid Bromine 12,500
4 Epsomite 81,000
List of Raw Materials required:
S. No. Raw Material MT/Annum

1 Chlorine 8,395
2 98% Sulphuric Acid 5,853
3 Quick Lime 70 % CaO 4,875
4 Caustic Soda lye 50% 5,500
5 Caustic Soda flakes 504
6 Feed Bittern 42,40,800
7 Harvested Salt Mixture 7,65,000
8 Crude Magnesium Salts 2,95,000
9 Sea Water 36,36,506

Details of each Product:
1. Sulphate of Potash & Epsomite:

2 Epsomite 81,000
Raw material consumption per annum:

S. No. Material Quantity, MT
1 Harvested salt mixture 7,65,000
2 Crude magnesium salt 2,95,000
3 Sea water 11,62,000
Brief Process:
Harvested crude Magnesium salt will be leached in NaCl saturated circulating brine at an elevated
temperature making MgSO4 and minor amounts KCl (if any) get dissolved. After adjustment of the
solution in terms of MgSO4 concentration and post separation of non dissolved NaCl, the clear liquor
will be cooled to 10 - 15°C to produce a pure and NaCl free Epsomite. Some of this Epsomite will be
used in the process of SOP production, while the rest is saleable. The same circulation liquor will be
re-used and a small part will be bleed-off and sent to the solar pond system. The non dissolved NaCl
will be re-dissolved in Sea water and sent back to the solar ponds.
Secondly the Harvested Salt Mixture will be mixed with seawater in order to decompose Carnallite and
dissolve MgCl2. The remaining un-dissolved KCl, MgSO4 and NaCl mixture will be used for the SOP
process and the mother liquor called ‘Carnallite deomposed liquor’ which will be recycled to Solar
Pond.
The above two beneficiated raw salts 1) harvested epsomite salt and 2) harvested salt mixture will be
mixed together, in a KCl: MgSO4 concentration that corresponds to the same ratio as existing in
Kainite. This mixture called ‘Synthectic Kainite’ will be mixed with seawater and cooled SOP mother
liquor for dissolution, so that Primary Schoenite will be generated. The ‘Schoenite mother liquor’
separated from Primary Schoenite will be re-cycled to Solar Pond.
Primary Schoenite generated from the earlier stage and the recovered / secondary Schoenite will be
leached with Seawater at 48°C, by which K2SO4 begins to crystallize out while MgSO4 will remain in
solution. When the MgSO4 concentration will reach approx 225 g/1000g H2O, the resulting slurry will
be centrifuged, washed with small amount of fresh water and dewatered to produce SOP and a Hot
SOP mother liquor. The Hot SOP mother liquor will be cooled to 10 – 15°C in order to generate
recovered / secondary Schoenite and cooled SOP mother liquor, depending on the NaCl concentration
in Schoenite, purification of Schoenite will be accomplished by using a wash with fresh water and / or
a flotation to remove NaCl.

Chemical Reaction:
2KCl.MgSO4.3H20 + MgSO4 + 3H2O K2SO4.MgSO4.6H2O + MgCl2 + 3H20
(Solid) (Solid) (Liquid) (Solid) (Solution)
K2SO4.MgSO4.6H2O + 2H20 K2SO4 + MgSO4 + 8H20
(Solid) (Liquid) (Solid products) (Solution)
Flow Chart with Material Balance
2. Liquid Bromine & Green Bromine (New Product):

1 Liquid Bromine 12,500
Raw material consumption per annum:

S. No. Material Quantity, MT
1 Feed bittern 42,40,800
2 Sulphuric acid 98% 5,853
3 Chlorine 8,395
4 Caustic Soda (C/S)Lye 50% 5,500
5 Caustic Soda (C/S)Flakes 504
Brief Process:
Steaming out process (STO) for Liquid Bromine:
Feed bitterns from reservoir will be acidified to 3.5 pH by addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings. Steam and chlorine will be injected at the bottom
of the tower. Liberated bromine will be condensed and purified in a separate tower by heating with
indirect steam, Bromine will again get condensed and refluxed backed to top of tower and liquid
bromine will be drawn from the bottom of this purifying tower, cooled and bottled in glass bottles
and/or filled in ISO tanks for dispatch.
Air Blow out Process (ABO) for Liquid Bromine / Green Bromine:

Bittern from the reservoir will be acidified to pH 3.5 by the addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings; air and chlorine will be injected at the bottom of
the tower. Liberated Bromine laden by air will be made to react with soda ash or caustic soda solution
venting of unreacted air by circulating in a series of packed towers.
The reaction in the absorber reactor is as follows:
3Na2CO3 + 3Br2 = 5NaBr + NaBrO3 + 3CO2
or, 6NaOH + 3Br2 = 5NaBr + NaBrO3 + 3H2O
Part of this enriched alkaline solution (AB solution) will be the mixture of bromide, bromate
compounds from which again Bromine will be regenerated by the addition of acid. Regeneration of
Bromine will be done by a method similar to steaming out process but with smaller equipment as the
feed liquor will be highly concentrated.
5NaBr + NaBrO3 + 6HCl = 6NaCl + 3Br2 + 3H2O
Regenerated Bromine led out by steam given at the bottom of the tower will be condensed, separated
and processed further in distillation unit for the removal of impurities and packed in glass bottles
and / or in ISO tanks for dispatch.
Green Bromine:
Part of AB solution - the bromide bromate mixture from air blow out process will be taken for the
addition of chlorine to convert bromide to bromate and to maintain the ratio at 2:1. This converted
mixture will be again mixed with alkaline solution and proper concentration of bromate will be
maintained at a neutral pH by addition of caustic soda. This will be green Bromine in solution. It can
be evaporated to form solids by crystallizing in open pan or closed evaporator, cooled, packed in bags
and sold. It can also be sold as liquid in containers.
Flow Chart with Material Balance:


Annexure 2: Site Plan and Layout Plan
Site Plan

Site Layout Map

Annexure 3: Water Consumption and Waste Water Generation Details

Breakup of RO Water:
Proposed Water Proposed Waste Water

Sr.
Breakup Consumption Generation
No.
(KL/Day) (KL/Day)
a Process 387.5 74.1
b Boiler 390.3 390.3
c Washings 258.3 258.3
d Cooling 261.6 183.1
e Domestic 190 152
Total 1487.7 905.8


Annexure 4: Effluent Treatment Scheme
Sewage Treatment Plant
The sewage generated from the project will be taken to a sewage treatment plant and the treated
waste water will be used for green belt development and gardening. The total domestic waste water
generated will be about 152 m3/day.
Effluent Treatment Plant for Process Waste Water
The boiler blowdown, cooling tower blowdown, and washings effluent will be utilized for preparation of
lime slurry. The acidic effluent will be neutralized by this lime slurry in a stirred vessel. The settled
sludge which is gypsum will be utilized for strengthening of the bunds. The treated waste water is
recycled to solar ponds for solar evaporation
The waste water generated is acidic in nature. The acidity is mainly due to use of Sulphuric acid in the
reaction. The tentative characteristics of the untreated waste water are given as follows:
Sr. No. Parameter Range

1 pH 4.5-5.0
2 Suspended solids, mg/L 280 ~ 400 mg/L
3 Oil & Grease, mg/L 4 ~ 6 mg/L
4 BOD, mg/L 30 ~ 60 mg/L
5 COD, mg/L 100 ~ 150 mg/L

Flow Chart

Annexure 5: Details of Air Emissions
Air Pollution Control
Emissions from Boiler

A boiler with 50 % coal and 50% lignite as fuel will be used for the proposed project. A 60m height
stack with diameter at stack height of 1 m. is proposed. The fly ash generated will be sold to brick
manufacturers. To control the particulate matter an ESP is proposed.
The boiler will be equipped with air pollution control unit for control of particulate matter.
Sources of gaseous emissions from utility Boiler

Fuel used 50% Coal & 50% Lignite
Quantity of fuel 20000 TPA Coal + 30000 TPA Lignite
Type of emissions SO2, NOX & PM.
Stack height 60 meter
Stack diameter at the top 1 meter
Air pollution control system ESP is proposed to control the particulate matter
Details of Scrubber for Process Emissions

A scrubber will be attached to the bromine bottling section to capture the bromine gas liberated in the
process. It will be scrubbed using a packed tower primary scrubber (1 no.’s) followed by secondary
packed tower scrubber with caustic soda as scrubbing medium. The scrubber bleed will be recycled as
the process feed.
Stack attached to Bromine bottling section

Gas scrubbed Bromine
Stack height 20 meter
Type of primary scrubber Packed tower
Capacity of the primary scrubber 0.5 m3
No. of Scrubbers 1
Type of secondary scrubber Packed tower
Capacity of the secondary scrubber 1.5 m3
No. of Scrubbers 1
Scrubbing medium Caustic Soda
Disposal of scrubber bleed Recycled to Process feed

Annexure 6: Details of Hazardous Waste Generation and Disposal

From the proposed project, gypsum 10,725 TPA will be produced as a result of neutralization of ETP
sludge will be reused in making of bunds. Used oil (1 TPA) and discarded bags and containers (5 TPA)
will be sold to authorized recyclers. Fly ash (3600 TPA) will be sold to brick manufacturers.
Sr. Waste Waste Proposed

Mode of Disposal
No. Details Category Generation
ETP Sludge – Will be used for preparation and
1 34.3 10725 TPA
gypsum maintenance of bunds
Will be sold to authorized
2 Used oil 5.1 1 TPA
recyclers.
Will be sold to brick
3 Fly ash - 3600 TPA
manufacturers.
Discarded
Will be sold to authorized
4 bottles and 33.3 5 TPA
recyclers.
bags

Annexure 7: Storage and Transportation Details of Products (Mainly Bromine)

List of Proposed Products
Max.
Sr. Quantity Physical
Product Storage Stored in MOC
No. MT/Annum Form
at a time
HDPE
Sulphate Closed
1 1,00,000 30,000 Solid lined
of Potash Shed
bag
Containers MS
2 Bromine 12,500 300 Liquid / Glass Lead –
Bottles lined
HDPE
Green Closed
3 2,500 250 Solid lined
Bromine Shed
bag
HDPE
Heaps in
4 Epsomite 81,000 12,000 Solid lined
closed shed
bag
Bromine Packing Method and Transportation in Glass Bottles:
 Liquid Bromine will be filled in specially designed glass bottles of 1 liter capacity.
 Filled bottles will be duly sealed with bottle caps & inserts. These bottles will be packed in wooden
crates / plastic crates.
 Each wooden crate / plastic crate will have six partitions to accommodate six filled bottles.
 After keeping filled bottles in wooden crates cushion materials like vermiculate will be filled in
crate to avoid breakages if any enroute.
 After filling cushion materials in the wooden crates, crate will be packed with wooden lids duly
nailed & strapped with plastic strip.
 Each truck will carry approximately 4.032 MT bromine (224 wooden crates x 6 bottles each)
depending up on truck capacity.
 Loaded truck before leaving factory premises will be covered with Tarpalin.
 About INR. 18 per Kg will be spent as packing cost.
Safety Measures during Transportation:
 Each loaded truck will be provided with Sodium Thyosulphate (5 - 25 kg) for using enroute in case
of any leakages / spillages.
 Each truck driver carrying bromine will be imparted safety training on how to handle bromine in
case of spillages / leakages.
 Transport emergency card will be provided to each truck at the time of dispatch.
 Each truck driver will be having mobile set to establish contacts with factory on day to day till
truck reaches at destination point.

Checklist for Bromine Transport
 Good & sound condition of vehicles having road worthy certificate issued by RTO to be used for
bromine transport
 Trained drivers who are conversant with handling of hazardous chemicals are to be engaged for
bromine transport
 In house training to truck drivers every six months by safety officer to be imparted
 Safety PPE like, gum boots, hand gloves, face mask to be given to truck driver before leaving
loaded truck from factory gate
 Dispatch / safety department should ensure before leaving loaded truck from factory gate to
provide neutralization chemicals like Sodium Thyosulphate powder to truck driver and driver to be
guided how to use the chemicals in case of leakages /spillages
 Trem card to be handed over to truck driver which contains list of activities to be taken in case of
accidents.
 Truck driver should be instructed to carry loaded trucks only on good roads connected to state /
national highways & not to take any short routes.
 Truck driver should be instructed to carry mobile set & he should establish contact on day to day
with factory till truck reaches at destination point.
 Truck driver should be instructed to ply / drive the loaded truck only during day time & no driving
during night time.
 Truck drivers to be instructed to contact either our factory / Gandhidham office / Chennai office in
case of any accident happens like spillages/ leakages / toppeling of loaded truck
 On receipt of information from truck driver safety officer / production officer should depute rescue
team immediately with safety PPES to accident spot
 Head –safety should co-ordinate with rescue team till the matter get resolved.

Annexure 8: Risk Assessment Report

Archean Chemical Industries
Pvt. Ltd.
”Anandam” D/4, Nu-10-B, Opp. Lions Club,
Shaktinagar, P.O. Gandhidham-370 201
Dist. Kutch, Gujarat
RISK ASSESSMENT STUDY

( For Proposed Plant )
Nr. Hajipir, Ta: Bhuj,
Dist: Kuchchh.
PREPARED BY
VAIBHU SAFETY CONSULTANTS

FF-11, Akshat Complex,
Nr. Reliance Petrol Pump,
High Tension Road, Subhanpura,
Vadodara-390 023
Phone: 9825756467/9427838021 (M)
Prepared By Archean Chemical Industries Pvt. Ltd Page : 1

HSE Department Rev. : 00
CERTIFICATE
We are pleased to certify that this Risk Assessment study of Company has been
conducted by us.
This is the first Risk Assessment report of this company for new project and it has
been carried out during the month of June- 2010.
Risk Assessment is a legal requirement u/r 12-c & 68-O of the Gujarat Factories
Rules.
The recommendations are based on information supplied to us by the company and

our plant visits.
The Executive Summary is given in the beginning to highlight the important

summary of our report and methodology of the risk assessment carried out.
We are thankful to the Mr. Sethuram (Occupier) and Mr. R.R. Sorathia( Project
Incharge). In particular we acknowledge the continuous support given to us by Mr.
R.R.Sorathia for completion of this report.
FOR VAIBHU SAFETY CONSULTANT
Authorized Signatory

CONTENTS
SECTION CONTENTS NO. OF

NO. PAGES
1 Executive Summary 5
2 Objectives, Philosophy and methodology of 7
Risk assessment
3 Introduction of the unit 9
3.1 Company Introduction 9
3.2 Details of Unit 9
3.3 Project setting 12
3.4 Organisational setup 16
3.5 List Of Proposed product 16
3.6 List of Proposed Raw Material 16
3.7 Details of storage of Hazardous Materials in 17
Bulk and control measures provided
3.8 Brief Description of process plant 18
3.9 Hazardous Properties Of The Chemicals, 18
Compatibilities, Special Hazard & Antidotes
3.10 Facilities / System for process safety, 21
transportation, fire fighting system and
emergency capabilities to be adopted
4 Hazard identification 27
4.1 Introduction 27
4.2 DOW’s Fire and Explosion Index 28
4.3 Failure Frequencies 29
4.4 Identification of Hazardous area 31
5 Risk Assessment 33
5.1 Effects of Release of Hazardous Substances 33
5.2 Identification of High Risk Areas 34
5.3 Modes of Failure 34
5.4 Damage Criteria for heat radiation 36
6 Consequence Analysis 37
6.1 Consequence Analysis 37
6.2 Assessment of Consequences Modeling results 63
6.3 Comments 64
7 Risk Reduction Measures 65
7.1 Design 65
7.2 Process 65
7.3 Bromine Storage & Handling Safety 66

7.4 Operation and Maintenance 67
7.5 Recommendations 68
8 Disaster Management plan 70
8.1 On site emergency Plan (OSEP) 70
8.2 Scope of OSEP 71
8.3 Elements of OSEP 71
8.4 Methodology 71
8.5 Emergencies Identified 71
8.6 Others 72
8.7 Emergency Organisation 72
8.8 Emergency Facilities 72
8.9 Emergency Escapes 73
8.10 Assembly points 73
8.11 Wind sock 74
8.12 Emergency transportation 74
8.13 Emergency communication 74
8.14 Warning Alarm/ Communication of Emergency 74
8.15 Emergency responsibilities 74
8.16 Mutual Aids 74
8.17 Mock Drill 74

SECTION I
EXECUTIVE SUMMARY
1.0 Executive Summary

1.1 Archean Chemical Industries Pvt. Ltd. retained the services of Vaibhu Safety
Consultants for carrying out Risk Assessment Studies for their Hajipir, Bhuj proposed
plant.
1.2 Experts from Vaibhu Safety Consultants visited the site on 19-20/01/2010 for inspection
of facilities to be erected and commissioned at site as per site plan and the environs and for
collection of relevant information about the installation and the operations will be carried
out in the plant. They also held detailed discussions on various aspects will be incorporated
for Chlorine tonner handling facilities, Bromine manufacturing process, Bromine storage
and handling facilities, HSE management system, procedures(SOP) and it
implementation, Emergency management plan, Emergency handling facilities, Emergency
organization and action plan., with the officers of the company.
1.3 In this plant Chlorine, Caustic soda (NaOH), Sulfuric Acid will be majorly used as raw
materials and received through road tanker and stored in designated tank farm area.
1.4 Proposed unit is classified as Major Accident Hazards unit ( MAH Installation ) based on
the storage of Chlorine, Bromine and Sulfuric Acid listed hazardous chemicals more than
specified threshold quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-
1963 (2004).
1.5 The proposed unit is located at very remote place in Greater Rann Of Kutch, 16 kms north
of Hajipir, which is the nearest village.
1.6 Separate utility plant is provided for chilling cooling, Steam and Air utilities are common
for all plants.
1.7 Based on the data furnished and the study of the installation, certain hazards have been
identified and their consequences are modeled mathematically using HAMSGAP software.
1.8 The study indicates that possible hazards associated with the plant are confined to (a) HSD
storage tank area, road truck unloading area (b) Chlorine tonner storage area. (c) Bromine
Day tank of both process plant (d) ISO container filling area. Various hazard scenarios
have been identified for Risk Assessment and the consequences modeled. The results of
the analysis have been summarized in the table appended.
1.9 It will be observed from the summary that the consequences of hazards associated with any
possible spills / leaks except for catastrophic failure of Chlorine tonner and bromine day
tank release scenarios would be of a relatively small in nature and would be taken care of
with the proposed emergency facilities and the manpower deployed at the plant.
1.10 The possibility of occurrence of such hazards and their effects could be further reduced by
implementing the suggestions made in this report.

1.11 Catastrophic failure of Chlorine tonner and Bromine day tank and ISO container resulting
in major toxic releases is very unlikely events barring gross neglect of time tested safety
standards and procedures set up by the industry.
1.12 The possibility of occurrence of major toxic release and mishaps is considered very remote
and the field management’s total commitment to implementation of safety systems and
procedures.
1.13 However considering the potential for major hazards, however remote they may be,
associated with storage area, some suggestions are made in the subsequent chapters for
further improvement in the areas of safety, environmental impact, Emergency facilities and
emergency preparedness plan.
1.14 Conclusion Based on the
1) Risk Analysis study and information regarding the layout plan and safety systems.
2) Discussions with company officials,

CHAPTER II
OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT
2.1 Objective :
The main objectives of the Risk Assessment (RA) study is to determine damage due to
major hazards having damage potential to life & property and provide a scientific basis to
assess safety level of the facility.
The principle objective of this study was to identify major risks in the manufacture of
chemicals and storage of hazardous chemical at site and to evaluate on-site & off-site
consequences of identified hazard scenarios. Pointers are then given for effective
mitigation of hazards in terms of suggestions for effective disaster management,
suggesting minimum preventive and protective measures & change of practices to ensure
safety.
2.2 PHILOSOPHY :
This report is limited to the following:
Identification of major risk areas.

Hazard identification/Identification of failure cases
Consequential analysis of probable risks / failure cases
o Evaluation of heat radiation & pressure wave profiles for identified failure
cases
o Risk assessment on the basic of the above evaluation & risk acceptability
o Minimum preventive & protective measures to be taken to minimize risks to
maximum possible extent.
Giving pointers for effective disaster management
Suggesting other measures to further lower the probability of risk
2.3 Methodology
The procedure used for carrying out the Quantitative Risk Assessment Study is outlined
bellow:
Identify Credible Loss Scenarios for the facility under the study by discussion with
ACIPL. Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion
using software packages HAMSGAP.
Suggest mitigating measures to reduce the damage, considering all aspects of the facilities.
The flowchart of the methodology for the present study is shown in following page.

RISK ASSESSMENT STUDY METHODOLOGY FLOWCHART
START
FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION
LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS
IDENTIFICATION OF FAILURE SCENARIOS & QUANTIFICATION OF

PROBABLE HAZARDS ASSOCIATED WITH THEM
DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OF

HAZARDS
DEFINING RELEASE TYPE (CONTINUOUS OR INSTANTANIOUS ) &

DETERMINE RELEASE RATES
SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING
PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS
EVALUATION OF POTENTIAL RISK TO THE SURROUNDING

POPULATION
DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIAL

MEASURES
END

SECTION III
INTRODUCTION OF THE UNIT
3.1 COMPANY INTRODUCTION
M/s. Archean Chemicals Industries Pvt. Ltd., is going to establish its manufacturing
unit of Fertilizer products and Bromine and Green Bromine at & post Village Hajipir,
Taluka Bhuj, Dist. Kutch.-370605
Archean Group is a privately held and professionally managed business conglomerate with
diversified business interests in high growth sectors including mining & minerals,
industrial salt, shipping & shipbuilding, building materials, energy, oil & gas services, and
industrial chemicals & fertilizers.
Established in 1984 by Chairman, Mr. P B Anandam, Archean Group has strategic

investments and transnational operations across India, Europe, South America, Middle
East, Africa, Southeast and North Asia. Today, Archean has employees throughout the
world with 1,050 employees in India and over 3,500 employees globally.
Business verticals in which the group operates today include:
• Mining and Minerals (Core Minerals, PT Core Mineral Indonesia)

• Industrial Salt (Jakhau Salt Co. Pvt. Ltd., Bharat Salt Refineries Ltd.)
• Building Materials (Archean Granites Pvt. Ltd.)
• Shipping (Good earth Maritime Limited and its subsidiaries)
• Industrial Chemicals and Fertilizer (Industries Chimiques du Sénégal – ICS)
Archean Group has a track record of successfully implementing various projects and
expansions in the above fields. One of the group company, Archean Chemical Industries
Pvt. Ltd. is putting up this marine chemical complex in Greater Rann of Kutch.
Proposed unit is classified as Major Accident Hazards unit ( MAH Installation ) based on
the storage of the listed hazardous chemicals more than specified threshold
quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004).
3.2 DETAILS OF UNITS
Sr. No. Particulars

1. Full Name & Address of : M/s. Archean Chemicals Industries Pvt. Ltd.
Unit ”Anandam” D/4, Nu-10-B, Opp. Lions Club,
Shaktinagar, P.O. Gandhidham-370 201 Dist.
Kutch, Gujarat
2. Telephone No. : 044-43033444
02836-234259/234158/233841
Fax No. 02836-233400
Email sethuram@archeangroup.com /
rrs@archeangroup.com

3. Site Address : M/s. Archean Chemicals Industries Pvt. Ltd
Nr. Hajipir, Taluka Bhuj,
Dist. Kutch.-370605
4. Month & Year of : Upcoming unit
Establishment
5. Full name & Address of : Mr. Sethuram
the occupier 5th Floor, Tower – 2,
TVH Beliciaa Tower No. 94, MRC Nagar,
Chennai – 600 028
6. Full name & Address of : Mr. R.R.Sorathia
the Factory manager ”Anandam” D/4, Nu-10-B, Opp. Lions Club,
Shaktinagar, P.O. Gandhidham-370 201 Dist.
Kutch, Gujarat
7. Man Power : Upcoming unit
8. No. Of shift & Shift : I shift : 07.00 to 015.00 Hrs

timing II Shift : 15.00 to 23.00 Hrs
III shift :23.00 to 07.00 Hrs
General Shift : 09.00 to 18.00 Hrs
9. Environs
(Nearest Facilities)
1. Railway Station : Bhuj railway station – 110 Km
Bhuj Airport – 110 Km
2. Police Station : Police Station - Nakhatrana (65 km)
3. Fire Station : Bhuj Fire station – 110 Km
4. Hospitals : Hospital - Nakhatrana (65 km)

10. Meteorogical Data
Latitude 23º 49’ 53.16” N

Longitude 69º 14’ 12.19” E
Temperature
Maximum 45º C
Minimum 2ºC
Relative Humadity :
Maximum 56 %
Minimum 7%
Annual Rain Fall :
Average 162.7 mm

Seasonal wind directions :
Jan- Feb N / NNW / ENE

March – Sept SW / WSW
Oct to Dec N / NNE
Wind Velocity :
Avg. Wind Speed 6 m/s

11. Total Land at Plant Proposed Land area used will be: 262 hectares.
12. Power connection Demand : 10MW
13. DG Set 750 KVAX 3 Nos
14. List of emergency facilities (proposed)
A. DCP type 5 kg fire extinguishers 25 nos
B. CO2 type fire extinguishers 4.5 kgs 10 nos
C. Sand Buckets 10 nos
D. Safety helmets 200 nos
E. Water curtain nozzles 2 nos
F. Stretchers 01 nos
G. First aid box with anti snake serum 10 nos
H. Rubber hand gloves 200 nos
I. Resuscitator 05 no
J. Electric siren with 3 km range 01 no
K. Hand operated siren 2 nos
L. Pressure type self contained breathing apparatus with 06 nos
spare cylinder (30 minutes)
M. Safety Shower 10 nos
15. Fire Water Reservoir :- 2000 M3

16. Other Source of Water : Sea
17. Fire Pump Details (Proposed)
Pump Detail Number of Head Capacity KW/HP
Pump (Flow)
Jockey Pump 01 70 mtr 10.8 m3/h 10
Electrical Pump 01 70 mtr 173m3/h 70
Total 02 Nil Nil Nil

18. License & Approval:
A. Factory Inspectorate Licence No : To be Applied
B. GPCB To be applied after EC

C. Solid waste Disposal Member ship :
D. Explosive Particulars Licence no Validity

licence No : Chlorine To be applied
3.3 PROJECT SETTING:
The plant is located at 730 13’ 10” East longitude & 210 18’30” North latitude Nr. Hajipir
village, Ta: Bhuj, Dist : Kuchchh in Gujarat State. The area is classified as Greater Rann
of Kuchchh.
The site location is shown as figure 1.1. and plant layout is provided as figure 1.2.
M/s. Archean Chemical Industries Pvt. Ltd., intends to setup a unit in Greater Rann Of
Kutch, Near Hajipir, Ta.: Bhuj, District: Kutch, Gujarat. The company intends to
manufacture Sulphate of Potash, Liquid Bromine, Green Bromine and Epsomite. The total
area required by the plant will be about 62 hectares. The proposed site is about 16 kms
north of Hajipir, which is the nearest village.

Figure 1.1

Figure 1.2

Figure 1.2 A

3.4 ORGANISATIONAL SET UP
Factory Manager
Plant manager
Shift Incharge / Plant Technicians / Chemists /

Maintenance Engineers / Electricians & mechanics
Helper/ Worker
3.5 LIST OF PROPOSED PRODUCTS
Table-3.1
Sr. No. Product Quantity Max. Storage Physical Stored In MOC

MT/Annum At A Time form
MT
1 Sulphate of 1,00,000 30, 000 Solid Closed Shed HDPE
Potash lined bag
2 Bromine 12,500 300 Liquid Containers/ MS
Glass bottles Lead-
lined
3 Green Bromine 2,500 250 Solid Closed shed HDPE
lined bag
4 Epsomite 81,000 12000 Solid Heaps in closed HDPE

Shed lined bag
3.6 LIST OF PROPOSED RAW MATERIALS
Sr. Raw Material Quantity Max. Storage Physical Stored In MOC

No. MT/Annum At A Time form
MT
1 Chlorine 8,395 280 Liquid Tonners MS/CH
2 Quick Lime 70 % 4,875 115 Solid Bags in closed HDPE
CaO Shed
3 Caustic Soda lye 5,500 200 Liquid Tanks MS
50%
4 Caustic Soda flakes 504 20 Solid Bags in closed HDPE
Shed
5 98% Sulphuric 5,853 200 Liquid Tanks MS
Acid
6 Kainite 7,65,000 3,60,000 Solid Open Shed Loose
7 Sea Water 36,36,506 10,00,000 Liquid Pond Loose
8 Feed Bittern 42,40,800 25,00,000 Liquid Pond Loose
9 Epsomite 2,95,000 1,00,000 Solid Open shed Loose

3.7 Details of Storage of Hazardous Materials in Bulk
NAME OF MAX. STORAGE PLACE OPERATING TYPE OF CONTROL

HAZARDOUS CAP.[Qty.] OF IT’S PRESSURE HAZARD MEASURE PROVIDED
SUBSTANCE STORAGE AND TEMP.
Liquid 18MT X 10 Nos. ISO ATP Toxic & Separate store will be made in cool
Bromine, ISO MS lead container / corrosive and dry place.
lined containers Plant store Safe handling procedure for bromine
=180 MT and 3 Area will be prepared, displayed and
Kg x 40000 glass trained to employees.
bottles packed in Emergency handling procedure will
6667 wooden be prepared and train for the same.
boxes each PPEs will be procured and made it
Containing 6 compulsory for bromine handling.
bottles =120 MT Close process will be designed for
4 m3 x 2 nos. MS bromine handling.
glass lined Day Nitrogen pressure or pump transfer
tanks - maximum Air blow will be adopted for bromine handling.
storage at any out process Hazard identification and emergency
point of time will Area action plan will be prepared and train
be 18 all plant people for the same.
MT SOP will be prepared for safe
15 m3 x 2 nos. handling and storage of Bromine
MS glass lined NFPA lable will be prepared and
Day tanks - displayed on containers & storage
maximum storage Steaming tank.
at any point of out process
time will be 72 Plant
MT
Green 250 MT in HDPE Storage ATP Corrosive
Bromine lined bags Area
Caustic Soda 20 MT Godown ATP Corrosive Safety Showers provided
Flakes, Caution note provided
Dyke wall provided
Caustic Soda 200 MT Tank Corrosive Level gauge provided.
lye 50% Double drain valve provided to tank
Required PPEs provided to all
employees
Sulphuric 200 MT Storage ATP Corrosive Double drain valve will be provided
Acid Tanks MS tank to sulfuric Acid storage tank
Full body protection will be provided
to operator.
Caution note and emergency first aid
will be displayed and train for the
same to all employees.
Safety shower and eye wash will be
provided in storage tank area and
plant area.
Total close process will be adopted
for Sulfuric acid handling.
Dyke wall will be provided to storage
tank
Tanker unloading procedure will be
prepared.
SOP will be prepared for sulfuric
Acid handling.
Training programme will be
conducted for safe handling and
emergency handling of Sulfuric Acid.

Chlorine 900 Kg x 300 Tonners ATP Corrosive Following steps will be adopted.
Nos. Tonners • SOP will be prepared for safe handling
of Chlorine tonners.
• Chlorine Emergency Kit will be
procured and kept ready at chlorine
shed.
• Chlorine Hood with blower will be
provided with scrubbing arrangement.
• Safety Shower and eye wash will be
provided in Chlorine shed area.
• Tonner handling EOT crane will be
installed in Chlorine shed area for safe
tonner handling.
• Safety Valve will be provided on
chlorine header line and it will be
connected to caustic scrubber.
• SCBA sets will be kept ready at
chlorine handling area.
• Safety valve will be provided on
vaporizer header and outlet of safety
valve connected to scrubber.
• Flow and temperature controllers will
be provided on process line.
HSD for fuel 24KL X 1 No. Licence Atmospheric Fire

U/G tank premises Ambient
temp.
Transport:
1. Raw Material :
Chlorine will be transported in tonners.
Sulphuric acid will be transported in closed tanks.
2. Finished Product:
Bromine will be transported in closed ISO tanks or closed bottles.
3.8 BRIEF DESCRIPTION OF PROCESS
Process description, Flowchart and reactions are provided in EIA report.
3.9 MSIHC Report:
According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical

Rules, 1989), a report on the toxicity characteristics for the chemicals involved is as
presented below in the form of tables.

HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD AND ANTIDOTES
Table-3.3
HAZARDOUS PROPERTIES OF CHMICALS INVOLVED
LD50 LD50 Flammable FP Class (As per Chemical Class

Sr TLV LC 50 LEL UEL BP
Chemicals Oral Dermal Gas @20 Deg. petroleum (As per MSIHC
No ppm mg/l % % Deg. C
mg/Kgs mg/Kgs Deg. C (Y/N) C classification) Rules)
1 Chlorine N.A N.A N.A 293 N N.A N.A N.A -34 A Hazardous
ppm/1hr.
2 Liquid Bromine 0.1 2600 N.A 2700 N N.A N.A N.A 58 -- Hazardous
mg/m3
3 98% Sulphuric Acid N.A 2140 N.A 510 N N.A N.A N.A 290 -- Hazardous
mg/m3
F = FIRE T = TOXIC
E = Explosive R = REACTIVE
BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT
UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY
VD = VAPOUR DENSITY ER = EVAPORATION RATE
H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS
R = REACTIVE HAZARD BR = BURNING RATE
TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION
STEL = SHORT TERM EXPOSURE LIMIT NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-usa

TABLE 2.5 :Applicability Of MSIHC Rules, 1989:
APPLICABILITY OF MSIHC Rules, 1989 (As Ammended in 2000)

Storage of Chemical
Sr.No. Chemical Class Chemical Name Quantity at Storage Total Qty Thresold Quantity as per Schedule 3 (MT)
works (MT) (MT)
Column 3 Column 4
1 Extremely Flammable Liquid Nil Nil Nil 1000 5000
2 Very Highly Flammable Liquids Nil Nil Nil 1500 10000
Highly Flammable liquids which
3 Nil Nil Nil 25 200
remains liquid under pressure
4 Highly Flammable liquids Nil Nil Nil 2500 20000
5 Flammable liquids Nil Nil Nil 5000 50000
6 Flammable Gas Nil Nil Nil 15 200
7 Extremely Toxic Nil Nil Nil Not Specified Not Specified
8 Highly Toxic Nil Nil Nil Not Specified Not Specified
9 Toxic Nil Nil Nil Not Specified Not Specified
Sulfuric Acid 200
Not Specified Not Specified
Epsomite
10 Hazardous
Liquid Bromine 300 300 40 --
Chlorine 280 280 10 25

3.10 Facilities / System for process safety, transportation, fire fighting system and
emergency capabilities to be adopted
Following facilities and system will be installed / implemented.
3.10.1 Process safety
1. Process will be carried out in close loop and system.

2. DCS operation plant. Built in safety technology will be adopted for
bromine manufacturing plant.
3. Instrument & Plant Air System will be provided for control all
parameters.
4. High level, low level, High pressure, low pressure, high temp, high
flow, low flow indication and cut off interlocking will be provided on
storage as well as process reactors.
5. Safety valve provided on reactor and pressure storage tanks.
6. Electric earthing (Double) will be provided.
7. Emergency handling equipments like SCBA sets, Fire extinguishers,
Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit,
Air line respirator, will be provided.
8. Industrial waste water after neutralization in ETP will be sent to solar
evaporation ponds.
9. Scrubbers provided on all process vents and online air monitoring
system will be provided on process venting system and parameters will
be maintained as per GPCB norms.
10. Chilling & cooling alternative arrangement with standby pumps will
be provided.
11. Chlorine will be charged in reactor by close loop. Flow, Temperature
and pressure will be maintained as per process requirement by DCS
control system and interlocking and cutoff control will be provided on
reactor.
3.10.2 Bromine Storage & Handling Safety
12. The amount of bromine in storage will be kept to a minimum.

13. Minimize the dispersal of bromine vapors by locating the storage area
on low ground. Low curbs or walls (called dikes), 200 mm high, will
be provided to protect the area from external flooding and to minimize
the dispersal of bromine vapors. The minimum diked volume will be
be equivalent to the largest storage tank plus 10%.
14. Adequate size sump will be provided for collecting bromine spills and
pump away collected rainwater and fire-fighting water.
15. Floors will be of impervious construction, preferably concrete.
16. Bromine iso tanks should be stored no closer than 10 meters from
human or animal consumable articles. Explosives and flammable
materials should not be stored close to bromine.

17. There should be a strengthened approach way for emergency vehicles
on two sides of the installation.
18. Hoses will be PTFE with stainless steel braid covering and carbon
steel flanges. Screwed fittings will not used.
19. Provide lightning protection.
20. There would be sufficient bromine storage tank capacity or an empty
iso tank to accommodate the transfer of bromine from a leaking
container
21. Area where bromine will be used or stored will be enclosed so that
unauthorized persons and animals are prevented from entering the
area. Adequate lighting will be provided to allow sufficient night
surveillance. Surveillance will be provided 24 hours a day.
22. Personnel escape routes will be clearly marked and it will be
maintained without any obstructions including adequately sized doors
and windows.
23. Facilities like offices, eating, showering and changing rooms, will be
located in up wind direction and remote from the area where bromine
is handled or stored. Provide an adequate supply of clean water for
washing and showers.
24. Emergency siren, telephone will be provided in storage area for the
reporting of accidents or emergency situations. The emergency
telephone numbers will be displayed at prominent locations and it
include the fire department, ambulance service, emergency response
team, hospital and police.
25. A wind sock will be provided which will clearly visible from all
points on the site and replaced as required. This is required for
indicating wind strength and direction.
26. Emergency respirator equipment cabinets( Cupboard) will be installed
not more than 30 meters or ten seconds walking distance from any
location in the storage area.
27. Showers and eyewash fountains will be provided, clearly marked, well
lit and with unobstructed access.
28. Signs will be posted prominently at the site entrance and throughout
the installation with area maps showing access ways, hydrant
locations, emergency showers, location of emergency equipment and
emergency telephone numbers.
29. All management and operating personnel involved in the use or
handling of bromine will undergo safety training, in addition to
specific task training.
30. Only experienced well-trained operators will be allowed to receive and
unload bromine receptacles.
31. The management will ensure that emergency response plans have been
made and coordinated with the emergency response local authorities.
32. Bromine glass bottle capacity 3.0 / 3.5 Kg and six bottles are stored in
one packing box.
33. Bromine will be stored in dry and cool place and well ventilated area.
34. Safety permit for hazardous material loading unloading will be
prepared and implemented.

35. Fire hydrant system and water sprinkler system installed at tank farm
area.
3.10.3 Loading Procedure for ISO container.
36. Open pressure release line blind flange and connect ISO container
pressure release line to plant scrubber header line and open valve. Use
a new rubber gasket (use limit - 24 hours) to ensure tight connection.
37. Make sure the absorber unit is working and capable of handling vented
bromine fumes from ISO container.
38. Remove the blind flange above the valve.
39. Connect charging line to the valve inlet. Use a new rubber gasket (use
limit - 24 hours) to ensure tight connection.
40. Open the valve and all the valves in your liquid loading line.
41. Start pump for charging bromine in ISO container.
42. Personal protective equipment will be used as per requirements and
details given bellow.
43. Liquid bromine will be charge through bromine storage tank, which
will be on weighing shell so transfer quantities can be measured.
Generally ISO container of 18MT will be used for shipping.
44. When the container filled, Off charging pump. Drain flexible hose
properly in ISO container and close charging line valve and ISO
container charging line valve.
45. Disconnect hose connection safely and blind ISO container charging
line as well as storage tank charging line.
46. Disconnect vent line and blind ISO container vent line.
47. Close cover dome and pin it securely.
3.10.4 Safe Transportation procedure to be adopted for Bromine ISO container and
bromine glass bottle crate.
The driver and assistant driver of any vehicle transporting bromine should
comply with the following requirements:
48. GPS will be installed in all the trucks and ISO container vehicle.
49. Driver and assistant will be trained in using GPS.
50. Open space separated from public highway and public dwellings,
where public does not normally pass. No passengers are allowed.
51. The crew shall know how to use fire-fighting appliances.
52. The driver or driver's assistant may not open a package containing
bromine.
53. Bromine receptacles are not to be checked with open flames.
54. No smoking is permitted around the transport unit or in the vicinity of
the vehicle during handling operations.
55. The engine is to be shut off during all handling operations unless
required to drive pumps, hoist, etc.
56. Parking brakes are to be applied whenever parked.

57. If the vehicle is parked on a road at night or with poor visibility,
warning signs are to be placed 10 meters ahead of and behind the
vehicle.
58. TREM CARD provided to all transporters and trained for
transportation Emergency of Hazardous chemicals.
59. All trucks having 1 kg Sodium Thiosulfate bag.
3.10.5 Personal Safety Precautions
Following personal Protective equipments are to be made compulsory when handling

Bromine.
60. American National Standards Institute (ANSI) approved chemical

safety goggles at all times when handling Br2.
61. Use a full face shield over eyewear.
62. Full body protection PVC suite
63. Eyewash fountains should be located in areas where bromine is
handled, used or stored.
64. When in danger of contact with liquid bromine, wear an approved
chemical resistant suit.
65. PVC boots should be worn over shoes for extra protection.
66. Have NIOSH approved respirators and self-contained breathing
apparatus available.
67. Gloves : 100% Nitrile rubber gloves or Neoprene gloves
3.10.6 Safety Practices in the Work Area
68. We will inform our all employees of the potential hazards of contact
with bromine and train them in appropriate first-aid procedures.
69. Bromine handling areas will be clearly marked and restricted to
qualified, trained personnel only.
3.10.7 Ventilation
70. We will maintain bromine vapor concentration in the work area to less
than 0.1 ppm with adequate exhaust hoods, ventilation systems and
scrubbers. Analyze air for proper control.
71. Transfer or repackage bromine only in a controlled, closed
environment.
72. Exhaust ventilating systems will be used in enclosed areas where
bromine is handled.
3.10.8 Containers And Storage
one packing box.

3.10.9 Neutralization in case of spillage leakage
75. Neutralization with Lime Powder.
3.10.10Emergency Procedures
In case of bromine emergencies, follow recommended first aid and emergency response
procedures adopted
3.10.11Transportation Emergencies
In emergency situations resulting from vehicle accidents:

76. Notify the local police, fire departments, emergency responders and
the carrier.
77. Isolate the area.
78. Any person not dressed in proper protective clothing and not using a
NIOSH approved self-contained breathing apparatus should be kept a
safe distance away.
79. Call to the supplier
80. Seek immediate medical assistance for those injured and follow
recommended first aid procedures.
3.10.12Leaking Containers
81. When handling a leaking bottle personal protective clothing, goggles

and NIOSH approved self contained breathing equipment must be
worn.
82. Clear contaminated area of non-essential personnel and send them to
assembly point.
83. Pour hypo solution*, lime and water slurry or soda ash solution over
the spill. Hypo-bromine reactions produce hydrobromic acid.
84. Dry sodium thiosulfate and liquid bromine produce a violent reaction;
do not mix them.
85. Using cold water, wash neutralized bromine into a sump for transfer to
an approved waste disposal facility where the waste can be processed.
86. Ventilate the area to remove the ammonium bromide and any bromine
fumes. Scrub the floors and equipment with soap and water.
3.10.13First Aid Procedure
87. Immediate medical assistance is required if bromine is swallowed,

inhaled or has contacted the eyes or skin.
88. If bromine has been ingested, do not give anything by mouth. Seek
medical attention immediately. Do not induce vomiting.
89. If bromine has been inhaled, move the exposed person to a well
ventilated area. Seek medical attention immediately. The victim
should be placed in a comfortable sitting or partly reclining position.
The exposed individual should avoid exertion. If vomiting occurs, turn

the patient on his side to avoid choking. Keep the patient warm. If the
patient is coughing and showing signs of respiratory distress, properly
trained personnel should administer oxygen.
90. For skin contact, the affected area must be flooded immediately with
large amounts of clean water from a safety shower or other appropriate
source of flowing water. Wash with 10 % sodium Thiosulfate solution
& again wash with water. Seek medical attention immediately. All
contaminated clothing, including shoes, should be removed as quickly
as possible while the victim is under the shower. Washing should be
continued for a minimum of 30 minutes. If possible, continue to wash
the affected area during transport to medical facilities. (Extended
wash times of two hours or more have proven beneficial.)
91. If bromine liquid or vapor contacts the eyes, they must be irrigated
immediately with large amounts of running water. Eye wash stations
are preferable for irrigation. If one is not available, a hose, water
source with a liberal, gentle flow may be utilized. The eyelids must be
held apart during irrigation to ensure contact of water with all
accessible tissues of the eyes and lids. Eyes should be washed
continuously for a minimum of 30 minutes. If possible, continue
flushing the eyes while transporting the employee to a physician. In
all cases of bromine injury, obtain immediate medical attention.
Provide emergency personnel with information about all materials
used by the person and provide appropriate information about bromine
and first aid procedures.

SECTION IV
HAZARD IDENTIFICATION
4.1 INTRODUCTION
Risk assessment process rests on identification of specific hazards, hazardous areas and
areas vulnerable to effects of hazardous situations in facilities involved in processing and
storage of chemicals.
In fact the very starting point of any such assessment is a detailed study of materials
handled & their physical / chemical / thermodynamic properties within the complex at
various stages of manufacturing activity. Such a detailed account of hazardous materials
provides valuable database for identifying most hazardous materials, their behaviour
under process conditions, their inventory in process as well as storage and hence helps in
identifying vulnerable areas within the complex.
Hazardous posed by particular installation or a particular activity can be broadly

classified as fire and explosive hazards and toxicity hazards. Whether a particular
activity is fire and explosive hazardous or toxicity hazardous primarily depends on the
materials handled and their properties.
It will be from the above discussion that study of various materials handled is a
prerequisite from any hazard identification process to be accurate. Based on this study
the hazard indices are calculated for subsequent categorization of units depending upon
the degree of hazard they pose.
The main hazard in this plant only bromine manufacturing, handling and storage,
concern has always been toxic release prevention and control as these are the main hazard
posed by this unit. This concern has grown through the lose of life, property and
materials experienced after experienced after major disasters, which have occurred over
the years.
Identification of hazards is the most important step to improve the safety of any plant.
The hazard study is designed to identify the hazards in terms of chemicals, inventories
and vulnerable practices /operations.
The hazard evaluation procedures use as a first step by chemical process industries and
petroleum refineries are checklists and safety reviews. Dow and Mond fire and explosion
indices, which make use of past experience to develop relative ranking of hazards, is also
extensively used. For predictive hazard analysis, Hazard and Operability studies
(HAZOP), Fault tree analysis, Event tree analysis, Maximum credible accident and
consequence analysis etc are employed.

4.2 Dow’s fire and Explosion Index (F & EI)
4.2.1 Steps in fire and explosion index calculation are given below :
Select Pertinent Process
Determine Material Factor
Calculate GHP(F1), Calculate SPH(F2), special

General Process Hazards process Hazards
Determine Hazard Factor

F1 X F2 =F3
F3XMaterial Factor
=F & E Index
Determine Exposure area
4.2.2 Results of fire explosion and toxicity indices.

TABLE- 4.1
Sr. Material Storage Nh Nf Nr M GPH SPH FEI Degree of Radius Th Ts TI Degree of
No Stored Qty. F hazard of expo. Hazard
(ft.)
1. Chlorine 900 Kg. X 3 0 0 1 2.05 2.82 5.8 Light 4.9 250 125 22.0 Severe
280 Nos.
2. Bromine 18 MT ISO 3 0 0 1 2.05 2.82 5.8 Light 4.9 325 125 26.4 Severe
Cont. / 3 kg
Bottle
3. Sulfuric acid 200MTX1 1 3 0 1 2.05 1.5 5.3 Light 4.5 250 125 20.1 Severe
Tanks
4. HSD 24 0 0 0 10 2.55 1.93 49.21 Light 41 0 50 2.4 Light
FEI= MF x GPH x SPH
TI = Th + Ts x ( 1+ GPH tot + SPH tot )

-------------
100
Nh = NFPA Health rating GPH = General Process Hazard
Nf = NFPA Fire rating SPH = Special Process Hazard
Nr = NFPA Reactive rating FEI = Fire Explosion Index
MF = Material Factor Th = Penalty Factor
Ts = Penalty for Toxicity TI = Toxicity Index

4.3 Failure Frequencies
4.3.1 Hazardous material release scenarios can be broadly divided into 2 categories
I) catastrophic failures which are of low frequency and

II) ruptures and leaks which are of relatively high frequency.
Releases from failure of gaskets, seal, rupture in pipelines and vessels fall in the second
category whereas catastrophic failure of vessels and full bore rupture of pipelines etc fall
into the first category.
4.3.2 Typical failure frequencies are given below:-
TABLE-4.2
Item Mode of failure Failure frequencies

Atmospheric Catastrophic failure 10-9 /yr
storage Significant leak 10-5 /yr
Process Pipelines
< = 50 mm dia Full bore rupture 8.8 x 10-7 /m.yr
Significant leak 8.8 x 10-6 /m.yr
> 50 mm <=150mm dia Full bore rupture 2.6 x 10-7 /m.yr
< 150 mm dia Full bore rupture 8.8 x 10-8 /m.yr
Hoses Rupture 3.5 x 10-2 /m.yr

TABLE-4.3
TABLE-4.4

4.4 Identification of Hazardous Areas:
A study of process for manufacturing as given in chapter 2 of the report indicates the
following:
Various raw materials used in the manufacturing processes are listed in Table-3.2 in
Section-3 along with mode / type of storage & storage conditions. It can be readily seen
that raw materials even though hazardous in nature, are used in continuous process &
inventory is low at process plant. However some chemicals such as Chlorine, sulphuric
Acid are used / common in more than one process & therefore their inventory requirement
is higher. Bromine, Sulphuric Acid and Chlorine are stored separately . List of chemicals
stored in larger quantities is provided in Table-4.5
Following areas considered as a Hazardous area of the plant.
(a) CCOE approved Chlorine tonner Shed

(b) Bromine Day tank area.
(c) Bromine ISO container filling station.
(d) Sulfuric Acid storage area.
4.4.1 Evaluation Of Hazards :
4.4.1.1 Major inventory of Hazardous chemicals within the factory premises are-
The materials were studied with respect to their flammability, reactivity and toxicity based
on the criteria given by the NFPA (NFPA ratings). Material factor values were determined
using these ratings. General process hazards and Special process hazards for all the
materials stored were determined as per the guidelines given by DOW Chemicals
Company in DOW Index. FEI values for all these materials were calculated form the
above data.
Value of material factor, General Process Hazard & Special Process Hazard as also FEI /
TI values & degree of hazard are given in Table 4.1 It can be seen storage in tank farms is
mostly in the Severe category due to pressure storage and highly flammable and toxic
nature of chemicals. The radius of exposure for various tanks considering FEI Values is
also calculated and presented in the Table.
4.4.1.2 Evaluation of Process Areas :
Proposed Bromine process plant would be a state of the art Technology process fully
automatic DCS operation and continuous process plant. Thus the inventory of
hazardous chemicals is in the plant is very small.
Proposed plants will be controlled by Distributed Control System (DCS) to provide an
integrated plant control built in safety devices. Process parameters control and
interlocking will be provided and foolproof safety interlocking and logics applied at
design level and maintained.

Thus Produce units will do not warrant any detailed calculations as consequences due
to any worst case scenario due to small quantity of material & damage is such a case is
expected to be limited to within the factory premises.
Considering this, the risk analysis and consequences studies are concentrated on
storage in bulk.

SECTION V
RISK ASSESSMENT
5.1 Effects Of Releases Of Hazardous Substances
Hazardous substances may be released as a result of failures / catastrophes,

causing possible damage to the surrounding area. In the followin g
discussion, an account is taken of various effects of release of hazardous
substances and the parameters to be determined for quantification of such
damages.
In case of release of hazardous substances the damages will depend largely

on source strength. The strength of the source means the volume of the
substance released. The release may be instantaneous or semi-continuous.
In the case of instantaneous release, the strength of the source is given in
kg and in semi-continuous release the strength of the source depends on the
outflow time (kg/s.).
In order to fire the source strength, it is first necessary to determine the

state of a substance in a vessel. The physical properties, viz. Pressure and
temperature of the substance determine the phase of release. This may be
gas, gas condensed to liquid, liquid in equilibrium with its vapour or
solids.
Instantaneous release will occur, for example, if a storage tank fails.

Depending on the storage conditions the following situations may occur.
The source strength is equal to the contents of the capacity of the storage
system.
In the event of the instantaneous release of a liquid a pool of liquid will

form. The evaporation can be calculated on the basis of this pool.
Pool Fire
In the event of the instantaneous release of a liquid a pool of liquid will
form. The evaporation can be calculated on the basis of this pool.
The heat load on object outside a burning pool of liquid can be calculated
with the heat radiation model. This model uses average radiation intensity,
which is dependent on the liquid. Account is also taken of the diameter-to-
height ratio of the fire, which depends on the burning liquid. In addition,
the heat load is also influenced by the following factors :

Distance from the fire
The relative humidity of the air (water vapour has a relatively high
heat-absorbing capacity)
the orientation i.e. horizontal/vertical of the objective irradiated with
respect to the fire.
DISPERSION CASES :
PLUMES :
Plumes are continuous release of hazardous gases and vapours. Smoke from
a chimney is an example. Plumes can cause FIRES AND EXPLOSIONS as
secondary scenarios.
PUFFS :
Puffs are instantaneous release of hazardous gases and vapours. Puffs can
give rise to FIRE BALLS and vapour cloud explosions(VCE). A special
case of vapour cloud explosion is the Boiling Liquid Evaporating Vapour
Explosion (BLEVE).
SPILLS POOL:
Spills are liquid pools created by leaking liquid chemicals. Spills cause
evaporation and dispersal of toxic gases and if the spilled liquid is
flammable, then it can catch fire creating a pool fire also the vapours can
cause explosion.
5.2 Identification of High Risk Areas :
Following areas considered as a High Risk area of the plant.
(a) CCOE approved Chlorine tonner Shed

(b) Bromine Day tank area.
(c) Bromine ISO container filling station.
(d) Sulfuric Acid storage area.
5.3 Modes of Failure:
5.3.1 Following failure are considered for detailed analysis and safe distances computed:
Liquid release due to catastrophic failure of storage vessel or road tanker.

Liquid release through a hole/crack developed at welded joints/flanges / nozzles /
valves etc.
Vapour release due to exposure of liquid to atmosphere in the above scenarios.
Considering the quantity of storages & nature of Toxic nature storage, following scenarios
were taken up for detailed analysis & safe distances computed :

Dispersion of vapour up to LC-50 ( Fatal ), Immediate Danger to Life and Health
(IDLH ) and TLV ( Threshold Limit Value ) concentration Dispersion of vapour to
toxic end points
Failure cases considered for consequence analysis are representative of worst-case

scenarios. Probability of occurrence of such cases is negligible (less than 1 x 10-6 per
year) because of strict adherence to preventive maintenance procedures within the
complex. General probabilities for various failure is provided in Table-4.2, 4.3 and
4.4, but consequences of such cases can be grave & far reaching in case such systems
fail during life history of the company. Hence such scenarios are considered for
detailed analysis. It is to be noted however that such situations are not foreseeable or
credible as long as sufficient measures are taken. Also, consequence analysis studies
help us evaluate emergency planning measures of the Company.
Table-5.2
Scenario Failure Type Failure Mode Consequence
No.
1. Puff Isopleth Simulation Catastrophic Puff dispersion up to LC 50
For Chlorine Tonner failure Human, IDLH and TLV
Catastrophic Failure level.
2. Point source plume release Random failure Point source dispersion up
for Chlorine liquid/ gas to LC 50 Human, IDLH and
phase valve failure. TLV level.
3. Spill Pool Evaporation 200 Catastrophic Spill pool Evaporation
MT Sulfuric Acid storage failure dispersion up to LC 50,
Tank catastrophic failure IDLH and TLV level.
4. Puff release for Bromine Catastrophic Puff release up to LC 50,
12 MT Day tank failure IDLH and TLV level.
catastrophic failure
5. Spill pool Evaporation for Catastrophic Spill pool Evaporation
Bromine 12 MT Day tank failure dispersion up to LC 50,
catastrophic failure IDLH and TLV level.
45 MT Day tank failure IDLH and TLV level.
Bromine 45 MT Day tank failure dispersion up to LC 50,
catastrophic failure IDLH and TLV level.
18 MT ISO container failure IDLH and TLV level.
Bromine 18 MT ISO failure dispersion up to LC 50,
container catastrophic IDLH and TLV level.
failure.
10. HSD road tanker unloading Random failure Unconfined Pool file.
hose 100 release

5.4 Damage Criteria For Heat Radiation:
Damage effects vary with different scenarios. Calculations for various

scenarios are made for the above failure cases to quantify the resulting
damages.
The results are translated in term of injuries and damages to exposed

personnel, equipment, building etc.
Tank on fire /Pool fire due to direct ignition source on tank or road tanker
or catastrophic failure or leakage or damage from pipeline of storage
facilities or road tanker unloading arm, can result in heat radiation causing
burns to people depending on thermal load and period of exposure.
All such damages have to be specified criteria for each such resultant
effect, to relate the quantifier damages in this manner, damage criteria are
used for Heat Radiation.
TABLE 5.3
DAMAGE CRITERIA – HEAT RADIATION
Heat Radiation
Incident Flux KW/m2 Damage
38 100% lethality, heavy damage to tanks
37.5 100% lethality, heavy damage to equipment.
25 50% lethality, nonpiloted ignition
14 Damage to normal buildings
12.5 1% lethality, piloted ignition
12 Damage to vegetation
6 Burns (escape routes)
4.5 Not lethal, 1st degree burns
3 1st degree burns possible
(personnel only in emergency allowed)
2 Feeling of discomfort
1.5 No discomfort even after long exposure

CHAPTER VI
CONSEQUENCE ANALYSIS
6.1 Consequence analysis.
In the risk analysis study, probable damages due to worst case scenarios
were quantified and consequences were analyzed with object of emergency
planning. Various measures taken by the company and findings of the study
were considered for deciding acceptability of risks.
6.1.1 Weather Data :
Average wind speed : 5 m / sec.

Average Ambient Temperature : 35 deg. c.
Average Humidity : 30 %
Atmospheric Stability : CD
6.1.2 Assumption :
6.1.2.1 For Chlorine supply system as follows.
♦ Chlorine tonner catastrophic failure i.e. 900 kg gas puff dispersion

♦ For Chlorine liquid/ gas phase valve failure release scenario, we
have considered release rate 1000 grms/sec. Maximum contents of
the tonners will be release within 900 seconds or 15 minutes.
♦ We have calculated following hazardous distance for the above
mentioned scenarios.
♦ Fatality (LC-50 for Human)
♦ Immediate danger to life and health (IDLH) concentration area
♦ TWA/TLV concentration distance( Meters)
6.1.2.2 For Sulfuric Acid storage tanks/ road tanker as follows.
♦ Storage tank catastrophic failure i.e. So3 fumes puff dispersion

♦ For Sulfuric Acid outlet line valve failure release scenario, we have
considered fumes release rate 1000 grms/sec. 900 kgs release within
15 minutes.
♦ Fatality Human ( LC-50 )

6.1.2.3 For Bromine Day tank/ ISO container as Follows..
♦ Bromine Day tank catastrophic failure puff dispersion

♦ Bromine Spill pool Evaporation.
♦ Fatality ( LC-50 )
6.1.2.4 For HSD Road tanker catastrophic failure( Unloading arm 100 % failure)
Catastrophic failure is considered for 20 MT HSD road tanker while

unloading and due to unconfined spread of liquid on ground and ignition
source availability, unconfined pool fire will occur.

Scenario-1 Puff Isopleth Simulation For Chlorine Tonner Catastrophic Failure
TABLE –A FOR CHLORINE

Scenario : PUFF DISPERSION
Input Data Results of Computations
Stored quantity 1 MT Tonner Max. ground level conc. 456393 ppm
Instantaneous Puff 900 kgs Dist. of maxi. ground level 17 meter
Release quantity conc.
Molecular weight 70.9
Wind speed 3.0 m/s
Density ( Air) 2.49kg/m3
Hazard Level Concentration End point

(PPM) (Meter)
LC50 Human 1017 210.30
IDLH 10 856.39
TWA/ TLV 1 1619.16
• LC50 HUMAN (1017 ppm) area up to 210 meter, IDLH (Immediate danger to life and health)
concentration area up to 856 meter and TWA (1 PPM ) area up to 1619 meter. Therefore 856
meter area in wind direction is considered as evacuation area.

Scenario-2 Point source plume release for Chlorine tonner liquid/ gas phase valve failure
TABLE –B FOR CHLORINE

Scenario : POINT SOURCE PLUME RELEASE
Stored quantity 1 MT Max. ground level conc. 501046ppm
Rate of release 1000 g/s Dist. of maxi. ground level 5 meter
Molecular weight 70.9 conc.
Wind speed 6.0 m/s
Density ( Air) 2.49kg/m3
Hazard Level Concentration End point

(PPM) (Meter)
LC50 HUMAN 1017 51.91
IDLH 10 445.25
TWA/ TLV 1 1035.91
concentration area up to 445 meter and TWA (1 PPM ) area up to 1038 meter. Therefore 445
meter area in wind direction is considered as evacuation area.

Scenario – 3 Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic
failure
TABLE – C
Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic failure
Scenario : SPILL POOL

Stored quantity 200 MT End point
Release Rate 1000 Gms/ Sec. ( As SO3) (meter)
LC50 Human 460 ppm (1460 mg/m3) 59.85
IDLH value 3.0ppm (15mg/m3) 587.63
TLV value 0.2 ppm (1mg/m3) 1349.6
Results
concentration( 3 ppm) area up to 587.63 meter and TWA (0.2 PPM ) area up to 1349.6 meter.
Therefore 587.63 meter area in wind direction is considered as evacuation area.

Scenario – 4 Puff Release for Bromine 12 MT day tank catastrophic failure
TABLE – D
Puff Release for Bromine 12 MT dat tank catastrophic failure
Scenario : Puff release

Release quantity 12 MT (meter)
LC50 Human 1075 ppm 902
IDLH value 3.0 ppm 8369
TLV value 0.1 ppm 30273
Results
concentration( 3.0 ppm) area up to 8369 meter and TWA (0.1 PPM ) area up to 30273 meter.
Therefore 8369 meter area in wind direction is considered as evacuation area.

Scenario – 5 Spill Pool Evaporation for Bromine 12 MT day tank catastrophic failure
TABLE – E
Spill Pool Evaporation for Bromine 12 MT day tank catastrophic failure

Evaporation rate 1500 g/s (meter)
Results

Scenario – 6 Puff Release for Bromine 45 MT day tank catastrophic failure
TABLE – F
Puff Release for Bromine 45 MT dat tank catastrophic failure

Results
• LC50 HUMAN (1075 ppm) area up to 1487 meter, IDLH (Immediate danger to life and
health) concentration( 3.0 ppm) area up to 13794 meter and TWA (0.1 PPM ) area up to 49808
meter. Therefore 13794 meter area in wind direction is considered as evacuation area.

Scenario – 7 Spill Pool Evaporation for Bromine 45 MT day tank catastrophic failure
TABLE – G
Spill Pool Evaporation for Bromine 45 MT day tank catastrophic failure

LC50 Human 1075 ppm 68.55
Results

Scenario – 8 Puff Release for Bromine 18 MT ISO container catastrophic failure
TABLE – H
Puff Release for Bromine 18 MT ISO container catastrophic failure

Results
• LC50 HUMAN (1075 ppm) area up to 1051 meter, IDLH (Immediate danger to life and
health) concentration( 3.0 ppm) area up to 9757 meter and TWA (0.1 PPM ) area up to 49808
meter. Therefore 35274 meter area in wind direction is considered as evacuation area.

Scenario – 9 Spill Pool Evaporation for Bromine 18 MT ISO container catastrophic failure
TABLE – I
Spill Pool Evaporation for Bromine 18 MT ISO container catastrophic failure

LC50 Human 1075 ppm 61.97
Results

Scenario –10 Unconfined Pool Fire for HSD road tanker catastrophic failure
TABLE –J
Unconfined Pool Fire for Solvent road tanker catastrophic failure
Scenario : UNCONFINED POOL FIRE

Stored quantity 20 KL Max. IHR at flame centre height 115 Kw/m2
Pool diameter 17(m) Flame centre height 20 meter
Pool liquid depth 0.1 (m) Maximum Flame width 19.09 meter
Wind speed 6 m/s Mass burning rate liquid 2.1 kg/ m2/min.
Liquid Density 820 kg/m3 Flame burnout time 71.11 Mims.
Incident Intensity of IHR- Effect if IHR at Height of Simulation

Heat Radiation Isopleth
(IHR) at ground Distance
level KW /m 2 ( Meters )
37.5 18.5 Damage to process equipment. 100 % Fatal in 1 Min. 1 %
fatal in 10 sec.
25.0 22.7 Min. to ignite wood ( without flame contact ). 100 % fatal
in 1 Min. Significant injury in 10 sec.
12.5 32.1 Min. to ignite wood (with flame contact). 1 % fatal in 1
min. 1 st deg. burn in 10 sec.
4.0 56.7 Pain after 20 secs. Blistering unlikely.
1.6 89.6 No discomfort even on long exposure.
Results
♦ In the 18.5 meter radius area is considered as 100% fatality in 1 min.

♦ In the 22.7 meter radius first degree burn in 10 sec.
♦ In the 56 meter radius area will give pain after 20 seconds. Blistering unlikely.
♦ In the 89.6 meter radius area is considered as safe area and no discomfort even on long
exposure.

6.2 Assessment Of Consequence Modeling Results :
Results of consequence analysis for the release of toxic chemicals are depicted in Table
6.3.
TABLE - 6.3
Type of failure considered Spill quantity Evaporati LC50 IDLH TLV

consideration on Rate Distance Distance Distance
Max. in meter in meter in meter
Credible loss Grm/ Sec.
scenario in
MT.
Scenario-1 Puff Isopleth 900 kgs - 210 856 1619
Simulation For Chlorine
Tonner Catastrophic
Failure
Scenario-2 Point source 900 kgs 1000 51 445 1035
plume release for
Chlorine tonner liquid/
gas phase valve failure
Scenario-3 Spill Pool 200 MT 1000 59 587 1349
Evaporation 200 MT
Sulfuric Acid storage
Tank catastrophic failure
Scenario-4 Puff release 12 MT - 902 8369 30273
for Bromine 12 MT Day
tank catastrophic failure
Scenario-5 Spill pool 12 MT 1500 50 1418 10017
Scenario-2 Evaporation
Evaporation for Bromine
45 MT Day tank
for Bromine 18 MT ISO
container catastrophic
failure
Evaporation for Bromine
18 MT ISO container
catastrophic failure.

6.3 Comments
The appended table 6.3 summarizes the consequences of the various hazards analyzed
under this study.
As can be seen from the results of the summary of the Risk Analysis study, the Fatality
zone due to bromine up to 1485 meters in worst case scenario. Immediate Danger to life
and health up to 13795 meter. In case of Bromine release, evacuation zone maximum up to
13795 meter and company has to plan for evacuation accordingly. It is observed on the
Google map there is no any village or residential or any industrial activity in 15 kms.
vicinity area. In such case only company employees may be affected.
On site Off site emergency preparedness plan
On site Off site emergency plan to be prepared.
Emergency handling facilities and training:
All employees should be well aware about possible emergencies and its consequences,
emergency control equipments and practices to control such hazardous condition within
premises.

SECTION VII
RISK REDUCTION MEASURES
Some of the safeties and risk reduction measures adopted and recommended for the safety of the
plant are as follows:-
7.1 Design
7.1.1 During the design stage itself adequate care has been taken for design, selection,
fabrication, erection and commissioning of Flammable and toxic liquid handling facilities
and other equipment, piping, pipe fittings, electrical equipment etc. relevant and prevalent
international and Indian standards has been followed for design, fabrication, inspection of
the storage tanks and other equipment.
7.1.2 Civil foundations will be suitably designed to take care of earthquakes, cyclones,
landslides, flooding, collapse of structures etc.
7.1.3 Plant operator and staffs will be selected well experience and qualified for chemical plant
operation.
7.1.4 All key personals will be trained for emergency handling procedures and regular Mock-
Drills has been conducted on various scenarios.
7.2 Process
1. Process will be carried out in close loop and system.

2. DCS operation plant. Built in safety technology will be adopted for
bromine manufacturing plant.
3. Instrument & Plant Air System will be provided for control all
parameters.
4. High level, low level, High pressure, low pressure, high temp, high
flow, low flow indication and cut off interlocking will be provided on
storage as well as process reactors.
5. Safety valve, provided on reactor and pressure storage tanks.
6. Electric earthing (Double) will be provided.
7. Emergency handling equipments like SCBA sets, Fire extinguishers,
Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit,
Air line respirator, will be provided.
8. Industrial waste water after neutralization in ETP will be sent to solar
evaporation ponds.
9. Scrubbers provided on all process vents and online air monitoring
system will be provided on process venting system and parameters will
be maintained as per GPCB norms.
10. Chilling & cooling alternative arrangement with standby pumps will
be provided.
11. Chlorine will be charged in reactor by close loop. Flow, Temperature
and pressure will be maintained as per process requirement by DCS

control system and interlocking and cutoff control will be provided on
reactor.
7.3 Bromine Storage & Handling Safety
1. The amount of bromine in storage will be kept to a minimum.

2. Minimize the dispersal of bromine vapors by locating the storage area
on low ground. Low curbs or walls (called dikes), 200 mm high, will
be provided to protect the area from external flooding and to minimize
the dispersal of bromine vapors. The minimum diked volume will be
be equivalent to the largest storage tank plus 10%.
3. Adequate size sump will be provided for collecting bromine spills and
pump away collected rainwater and fire-fighting water.
4. Floors will be of impervious construction, preferably concrete.
5. Bromine iso tanks should be stored no closer than 10 meters from
human or animal consumable articles. Explosives and flammable
materials should not be stored close to bromine.
6. There should be a strengthened approach way for emergency vehicles
on two sides of the installation.
7. Hoses will be PTFE with stainless steel braid covering and carbon
steel flanges. Screwed fittings will not used.
8. Provide lightning protection.
9. There would be sufficient bromine storage tank capacity or an empty
iso tank to accommodate the transfer of bromine from a leaking
container
10. Area where bromine will be used or stored will be enclosed so that
unauthorized persons and animals are prevented from entering the
area. Adequate lighting will be provided to allow sufficient night
surveillance. Surveillance will be provided 24 hours a day.
11. Personnel escape routes will be clearly marked and it will be
maintained without any obstructions including adequately sized doors
and windows.
12. Facilities like offices, eating, showering and changing rooms, will be
located in down wind direction and remote from the area where
bromine is handled or stored. Provide an adequate supply of clean
water for washing and showers.
13. Emergency siren, telephone will be provided in storage area for the
reporting of accidents or emergency situations. The emergency
telephone numbers will be displayed at prominent locations and it
include the fire department, ambulance service, emergency response
team, hospital and police.
14. A wind sock will be provided which will clearly visible from all
points on the site and replaced as required. This is required for
indicating wind strength and direction.
15. Emergency respirator equipment cabinets( Cupboard) will be installed
not more than 30 meters or ten seconds walking distance from any
location in the storage area.

16. Showers and eyewash fountains will be provided, clearly marked, well
lit and with unobstructed access.
17. Signs will be posted prominently at the site entrance and throughout
the installation with area maps showing access ways, hydrant
locations, emergency showers, location of emergency equipment and
emergency telephone numbers.
18. All management and operating personnel involved in the use or
handling of bromine will undergo safety training, in addition to
specific task training.
19. Only experienced well-trained operators will be allowed to receive and
unload bromine receptacles.
20. The management will ensure that emergency response plans have been
made and coordinated with the emergency response local authorities.
one carat.
23. Safety permit for hazardous material loading unloading will be
prepared and implemented.
24. Fire hydrant system and water sprinkler system installed at tank farm
area.
25. Sodium Thiosultate 10 % solution & lime powder to be kept available
near bottling area.
7.3.1 Pumps
a) Required out let valve and NRV provided on pump outlet.

b) Modular fire extinguishers provided near of most of the pumps.
c) FLP type and mechanical seal type pump installed for flammable chemicals.
7.3.2 Pipelines
a) Proper supports and clamping are provided

b) Double earthing provided to all electrical motors.
c) Colour code as Per IS maintained.
7.4 Operation and Maintenance
Operations and maintenance of the plant is being in accordance with the well-established
safe practices. Some of the guidelines are as follows:-
a) Periodic testing of hoses for leakages and continuity.

b) Earthing of all plant equipment and earthing of vehicles under unloading operations.
c) Annual testing of all safety relief valves.
d) Planned preventive maintenance of different equipment for their safety and reliable
operations.
e) Inspection of the storage tanks as per prefixed inspection schedule for thickness
measurement, joint and weld efficiency etc.
f) Comprehensive color code scheme to identify different medium pipes.

g) Strict compliance of safety work permit system.
h) Proper maintenance of earth pits.
i) Strict compliance of security procedures like issue of identify badges for outsides, gate
pass system for vehicles, checking of spark arrestors fitted to the tank lorries etc.
j) Strict enforcement of no smoking regime.
k) Periodic training and refresher courses to train the staff in safety, fire fighting and first
aid.
7.5 Recommendations
7.5.1 From the Risk Analysis studies conducted, it would be observed that by and large, the risks
are confined within the factory boundary walls in case of fire & explosion, except in the
event of a catastrophic failure of storage tanks of Bromine it will create OFF site
emergency situations and required more attention and emergency preparedness for combat
such situations. To minimize the consequential effects of the risk scenarios, following
steps are recommended.
Plant should meet provisions of the Manufacture, storage & Import of Hazardous
Chemicals Rules, 1986 & the factories Act, 1948.
Air line respirator provision to be made in Chlorine and bromine handling & storage
tank farm area.
Chlorine hood with blower and neutralizing pit arrangement needs to be made at
Chlorine tonners storage area.
React with water and generate toxic fumes while contact with water caution note to be
displayed in Bromine and Sulfuric Acid tank farm area.
Fire hydrant system to be installed as per TAC/NFPA Norms in each plant and
buildings.
Dyke wall and collection pit with drain valve needs to be provided in storage area and
one underground dumping vessel to be provided for bromine emergency spillage.
Tanker unloading and Bromine loading procedure needs to be displayed at tanker
loading/unloading area.
Periodic On Site Emergency Mock Drills and occasional Off Site Emergency Mock
Drills to be conducted, so those staffs are trained and are in a state of preparedness to
tackle any emergency.
Emergency handling facilities and fire protection system as per provided in report to
be procure and maintained in tip top condition at all time.
Safe operating procedure to be prepared for hazardous process and material handling
process.
Safety devices and control instruments to be calibrated once in a year.
Proper colour work as per IS 2379 to plant pipeline and tank, equipments to be done
once in a six month to protect from corrosion.
Permit to work system to be implemented 100 % for hazardous work in the plant.
Safety manual as per Rule-68 K & P and Public awareness manual as per 41 B & C be
prepared and distributed to all employees and nearby public.
The details of emergency equipments are given in this report along with its quantity to
be procured and maintained at site.
Manual call points for emergency identification to be installed in plant premises.

Fire & Safety organization to be setup and qualified safety officer with supporting
staff to be employed for implementation of HSE management system.
On line gas detection system needs to be provided in Chlorine shed area and Bromine
storage tank farm area and work place exposure to be maintained in plant bellow TLV
concentration at all time..
All vents to be connected with scrubber system.
A HAZOP study to be carried out for Bromine manufacturing plant and storage
facilities.
Induction safety course to be prepared and trained all new employees before starting
duties in plant.
Bromine transportation to be facilitated with GPS system for better emergency
handling purpose.
All employees who will be handle Bromine shall be well experience and well trained
for bromine handling before starting the job and records to be maintained as per
requirements of F.A. Sec.-41 B.
All drivers and his assistant shall be well trained and to be certified for Safe bromine
transportation and emergency.
Emergency preparedness plan to be designed as per activities hazard and hazardous
scenarios considered in risk assessment.

SECTION VIII
DESASTER MANAGEMENT PLAN
An onsite emergency in the industries involving hazardous processes or in hazardous installations

is one situation that has potential to cause serious injury or loss of life. It may cause extensive
damage to property and serious disruption in the work area and usually, the effects are confined to
factory or in several departments of factory, premise. An emergency begins when operator at the
plant or in charge of storage cannot cope up with a potentially hazardous incident, which may tum
into an emergency.
8.1 ONSITE EMERGENCY PLAN
8.1.1 OBJECTIVES OF ONSITE EMERGENCY PLAN
A quick and effective response at during an emergency can have tremendous significance
on whether the situation is controlled with little loss or it turns into a major emergency.
Therefore, purpose an emergency plan is to provide basic guidance to the personnel for
effectively combating such situations to minimize loss of life, damage to property and loss
of property.
An objective of Emergency Planning is to maximize the resource utilisation and combined

efforts towards emergency operations are as follows. :
8.1.2 DURING AN EMERGENCY.
To increase thinking accuracy and to reduce thinking time.

To localize the emergency and if possible eliminates it.
To minimize the effects of accident on people and property.
To take correct remedial measures in the quickest time possible to contain the incident
and control it with minimum damage.
To prevent spreading of the damage in the other sections.
To mobilize the internal resources and utilize them in the most effective way
To arrange rescue and treatment of causalities.
8.1.3 DURING NORMAL TIME.
• To keep the required emergency equipment in stock at right places and ensure the
working condition.
• To keep the concerned personnel fully trained in the use of emergency equipment.
• To give immediate warning tooth surrounding localities in case of an emergency
situation arising.
• To mobilize transport and medical treatment of the injured.
• To get help from the local community and government officials to supplement
manpower and resources.

• To provide information to media & Government agencies, Preserving records,
evidence of situation for subsequent emergency etc.
8.2 SCOPE OF OSEP
This OSEP is prepared for industrial emergencies like fires, explosions, toxic releases, and
asphyxia and does not cover natural calamities and societal disturbances related
emergencies (like strikes, bomb threats, civil commission’s etc.)
8.3 ELEMENTS OF ONSITE EMERGENCY PLAN
The important elements to be considered in plan are
Emergency organization
Emergency Facilities.
Roles and Responsibilities of Key Personnel and Essential Employee.
Communications during Emergency
Emergency Shutdown of Plant & Control of situation.
Rescue Transport & Rehabilitation.
Developing Important Information.
8.4 METHODOLOGY.
The consideration in preparing Emergency Plan will be included the following steps:
• Identification and assessment of hazards and risks.

• Identifying, appointment of personnel & Assignment of Responsibilities.
• Identification and equipping Emergency Control Centre.
• Identifying Assembly, Rescue points Medical Facilities.
• Formulation of plan and of emergency sources.
• Training, Rehearsal & Evaluation.
• Action on Site.
Earlier, a detailed Hazard Analysis and Risk Assessment was carried out on hazards and
their likely locations and consequences are estimated following the standard procedure.
However the causing factors for above discussed end results may be different and causing
factors are not discussed in this plan.
8.5 EMERGENCIES IDENTIFIED
Emergencies that may be likely at bulk fuel storage area, process plant, cylinder storage
area, and drum storage shed, and autoclave reactor area. There are chances of fire and
explosive only.

8.6 OTHERS
Other risks are earthquake, lightning, sabotage, bombing etc., which are usually, not in the
purview of management control.
8.7 EMERGENCY ORGANISATION.
Plant organization is enclosed. Based on the plant organization, which includes shift
organization, an Emergency Organization is constituted towards achieving objectives of
this emergency plan.
Plant Manager is designated as Overall in Charge and is the Site Controller.
The following are designated as Incident Controllers for respective areas under their
control. Shift in charge Engineer (Plant Operations) is designated at Incident Controller for
all areas of plant.
8.8 EMERGENCY FACILITIES
8.8.1 EMERGENCY CONTROL CENTRE (ECC)
It is a location, where all key personnel like Site Controller, Incident Controller etc. can
assemble in the event of onset of emergency and carry on various duties assigned to them.
Plant Manager’s Office is designated as Emergency Control Centre. It has P&T telephone
as well as internal telephones, ECC is accessible from plant located considerably away
from process plant, Storage’s and on evaluation of other locations, Plant Manager’s Room
find merit from the distance point of view, communication etc.
8.8.2 FACILITIES PROPOSED TO BE MAINTAINED AT EMERGENCY CONTROL

CENTRE (ECC)
The following facilities and information would be made available at the ECC
• Latest copy of Onsite Emergency Plan and off sites Emergency Plan (as provided by
District Emergency Authority).
• Intercom Telephone.
• P&T Telephone.
• Telephone directories (Internal, P&T)
• Factory Layout, Site Plan
• Plans indicating locations of hazardous inventories, sources of safety equipment,
hydrant layout, location of pump house, road plan, assembly points, vulnerable zones,
escape routes.
• Hazard chart.
• Emergency shut-down procedures.
• Nominal roll of employees.
• List and address of key personnel

• List and address of Emergency coordinators.
• List and address of first aides,
• List and address of first aid fire fighting employees,
• List and address of qualified Trained persons.
8.8.3 FIRE FIGHTING FACILITIES.
• Internal hydrant system

• Portable extinguishers
8.8.4 FIRE PROTECTION SYSTEMS
These systems are proposed to protect the plant by means of different fire protection
facilities and consist of
• Hydrant system for exterior as well as internal protection of various buildings/areas of

the plant.
• Portable extinguishers and hand appliances for extinguishing small fires in different
areas of the plant.
• Water cum foam monitor to be provided in bulk fuel storage area.
• Fire water pumps.
• Two (2) independent motor driven pumps each of sufficient capacity and head are
proposed for the hydrant systems which is capable to extinguish Fire or cooling
purpose.
8.8.5 HYDRANT SYSTEM.
Adequate number of fire hydrants and monitors will be provided at various locations in
and around the buildings and other plant areas. The hydrants will be provided on a
network of hydrant mains drawing water from the hydrant pump, which starts
automatically due to drop of pressure in the event of operating the hydrant valves. We are
suggesting you to go for TAC approved hydrant system for foolproof safety and benefit
from fire policy premium.
8.9 EMERGENCY ESCAPES
The objective of the emergency escape is to escape from the hazardous locations, to the
nearest assembly point or the other safe zone, for rescue and evacuation.
8.10 ASSEMBLY POINT.
Assembly point is location, where, persons unconnected with emergency operations would
proceed and await for rescue operation.

8.11 WIND SOCK.
Wind socks for knowing wind direction indication would be provided at a suitable location
to visible from many locations. It is proposed to install windsocks at E.O storage area and
Administration Building so as to be visible from different locations in the plant.
8.12 EMERGENCY TRANSPORT.
Emergency Ambulance would be stationed at the Administration Office and round the
clock-driver would be made available for emergency transportation of injured etc.
However, the other vehicles of the company also would be available for emergency
services.
8.13 EMERGENCY COMMUNICATION.
There are two kinds of communication system provided.
(a) Regular P&T phones with intercom facility.

(b) Mobile phone
8.14 WARNING/ALARM/COMMUNICATION OF EMERGENCY
The emergency would be communicated by operating electrical siren for continuously for
five minutes with high and low pitch mode.
8.15 EMERGENCY RESPONSIBILITIES:
Priority of Emergency Protection.
• Life safety
• Preservation of property
Restoration of the normalcy
8.16 MUTUAL AID
While necessary facilities are available and are updated from time to time, sometimes, it
may be necessary to seek external assistance; it may be from the neighboring factories or
from the State Government as the case may be.
8.17 MOCK DRILL
Inspite of detailed training, it may be necessary to try out whether, the On site – Off site
Emergency Plan works out and will there be any difficulties in execution of such plan. In
order to evaluate the plan and see whether the plan meets the objectives of the On site –
Off site Emergency Plan, occasional mock drills are contemplated. Before undertaking the
drill, it would be very much necessary to give adequate training to all staff members and
also information about possible mock drill. After few pre-informed mock drills, few UN-

informed mock drills would be taken. All this is to familiarize the employees with the
concept and procedures and to see their response. These scheduled and unscheduled mock
drills would be conducted during shift change, public holidays, in night shift etc. To
improve preparedness once in 6 months and performance is evaluated and Site Controller
maintains the record. Incident Controller (IC) coordinates this activity.

Kadam
Environmental Consultants
www.kadamenviro.com
Environment for Development
CONTACT DETAILS
Vadodara (Head Office)
871/B/3, GIDC Makarpura, Vadodara, India – 390 010.
E: kadamenviro@kadamenviro.com; T:+91-265-3001000; F: +91-265-3001069
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: delhi@kadamenviro.com; T: +91-124-4242430 to 436; F: +91-124-4242433

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M/S.

Form I for Amendment in

Environment for Development

M/S. ARCHEAN CHEMICAL INDUSTRIES PVT. LTD.

Form I for Amendment in Environmental Clearance

Prepared By Bhavin Jambucha

Released By Jagdishchandra Rathi, EIA Coordinator

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

1.1 FORM – 1 ............................................................................................... 1

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

Annexure 2: Site Plan and Layout Plan ......................................................................................... 17

Annexure 3: Water Consumption and Waste Water Generation Details ............................................ 19

Annexure 4: Effluent Treatment Scheme ....................................................................................... 21

Annexure 5: Details of Air Emissions ............................................................................................. 23

Annexure 6: Details of Hazardous Waste Generation and Disposal .................................................. 24

Annexure 7: Storage and Transportation Details of Products (Mainly Bromine) ................................ 25

Annexure 8: Risk Assessment Report ............................................................................................ 27

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 II

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 1

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 2

Details thereof (with approximate

Permanent or temporary change in

1.11 Dredging? No N.A.

1.12 Offshore Structure? No N.A.

Production and manufacturing Manufacturing process are given in Annexure

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 3

Details thereof (with approximate

New road, rail or sea traffic during

New road, rail, air waterborne or other

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 4

Details thereof (with approximate

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

Details thereof (with approximate

Affect the welfare of people e.g. by

Vulnerable groups of people who

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 5

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

Details thereof (with approximate

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

Details thereof (with approximate

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 6

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

Details thereof (with approximate

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

Details thereof (with approximate

From Chlorine and bromine handling.

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 7

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

Details thereof (with approximate

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

Details thereof (with approximate

Lead to development of supporting

III. Environmental Sensitivity

S. Name / Aerial Distance (within 15 km) of the

Areas protected under international

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 8

S. Name / Aerial Distance (within 15 km) of the

landscape, cultural or other related

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 9

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 11

Annexure 1: Details of Products, Raw Material, Manufacturing Process

List of Products are given in table below:

S. No. Products MT/Annum