PFD File

PFR & EMP
Environment Clearance for Lead Acid Battery Manufacturing Unit by M/s Luminous
Power Technologies Pvt. Ltd. at Plot-04, Sector-12, IIE, SIDCUL, Haridwar,
Uttarakhand
1. EXECUTIVE SUMMARY
Project Summary
1 Name of Company Luminous Power Technologies Private Limited, New
Delhi
2 Proposed Product Proposed setup of new production unit of product namely
Power Storage Lead Acid Batteries and thereafter addition
of new capacity in the third year.
3 Location SIDCUL, Haridwar (Uttarakhand)
4 Name of the project Environment Clearance for Lead Acid Battery
Manufacturing Unit by M/s Luminous Power
Technologies Pvt. Ltd. at Plot No. – 04, Sector – 12, IIE,
SIDCUL, Hardwar – 249403, Uttarakhand
5 Major raw material Lead
6 Production Units 1,00,000 Nos./Month
(Installed Capacity)
7 Water Requirement 241.98 KLD
8 Power Requirement 4750 KVA
9 Proposed manpower 1100 Nos.
10 Waste water quantity Domestic water – 39.6 KLD

Effluent from Industrial Process – 100.1 KLD
Disposal Pathway 100.1 KLD waste water will be generated from the
industrial process and 39.6 KLD domestic sewage will be
generated, which will be treated in proposed E.T.P.
(Capacity 120.0 KLD) & S.T.P. (Capacity 60.0 KLD)
respectively. After treatment treated water will be sent to
CETP, SIDCUL, Haridwar as per Inlet characteristic of
CETP.
11 Project cost estimate Project Capital cost of Rs. 418.39/- Crores
Details attached as Annexure XII.
2.0 INTRODUCTION OF THE PROJECT /BACKGROUND INFORMATION
2.1 Identification of the project and project proponent

Luminous Power Technologies Private Limited is 100 % subsidiary of Schneider
Luminous has been in business for 30 years now having 6 manufacturing units in
Himachal Pradesh and 1 battery plant at Hosur, Karnataka, network comprises of 28
sales offices, 1000 plus distributer network in India and presence abroad. The total sales
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turnover of Luminous is more than Electric (a French MNC headquartered in France – a
world leader in energy management). Luminous is a leading power solution and power
storage company having a vast portfolio of products comprising of Home UPS, Batteries,
Stabilizers, Solar Solutions, Home Electrical offerings like Fans, LED Lighting, Wires
and Switches.3400 crores.
2.2 Brief Description of Nature of Project.
The promoter company has proposed to setup a new unit at SIDCUL Industrial Estate,
Haridwar. The production capacity of Power Storage Batteries will be 100,000
Nos./month
Table-1.0
S. No. Products Capacity (Numbers per Month)
1. Lead Acid attery 1,00,000
2.3 Need for the Project & Importance to the Country
The increasing demand for power storage solutions due to shortage of electricity
especially in rural and semi-urban areas of India is never ending. Major population of the
country resides in rural area or semi-urban areas. Therefore, power being most common
source nowadays for human beings in day to day necessary activities like to provide
power for homes, for irrigation in fields, power for many kitchen equipment’s through
invertors etc.
2.4 Demand and Supply gap
The project is envisaged to meet the demand supply gap in both domestic market and
export market due to increasing dependence on new and shift from conventional sources
of power like coal, wood etc.
2.5 Imports Vs. Indigenous production

Production enhance the foreign exchange reserves in view of the proposed exports of few
types.
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2.6 Export Possibility:
There is an increase in demand globally for Power Storage Batteries due to operation
carried by Luminous in different countries and power being the necessity of everyone,
there are huge export possibilities.
2.7 Domestic/Export Markets

The products shall cater to both domestic and export markets.
2.8 Employment Generation (Direct & Indirect) due to the project

It is expected to generate employment for nearly 1,100 Persons.
3.0 PROJECT DESCRIPTION
3.1 Type of Project including interlinked and interdependent projects, if any:
The project is for Environmental Clearance Environment Clearance for Lead Acid
Battery Manufacturing Unit by M/s Luminous Power Technologies Pvt. Ltd. at Plot No.
– 04, Sector – 12, IIE, SIDCUL, Hardwar – 249403, Uttarakhand. Total land area for
Proposed Project is 32100.00 Sq. M. The project is to first setup of the battery
manufacturing plant will begin. The major plant facilities proposed for the project in the
total production capacity of power storage Lead Acid batteries of 100000 batteries/
month in the new unit situated at SIDCUL Industrial Area, District Haridwar
(Uttarakhand). Land area includes addition of production blocks, facility for utility
proposed.
3.2 Size or magnitude of operation:

The Manufacturing Capacity is presented in Table 2.
Table-2.0 Manufacturing Capacity

Products Capacity
Lead Acid Storage Batteries 1,00,000 Nos./Month
(Installed Capacity)
By products Nil Nil
Intermediate Products Nil Nil
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3.3 Process Description with process details (a schematic diagram/flow chart)
Grid Casting/ Spine Casting
Positive and negative grids are casted using lead alloys using grid casting machine.
These form the skeleton for holding the active material and current collection in the
batteries during charge and discharge.
Oxide manufacturing.
Pure lead is oxidized to form lead oxide. This in addition to additives forms the active
material. This gives the energy by undergoing electrochemical reactions with sulphuric
acid.
Paste mixing
This is process of mixing the lead oxide, sulphuric acid, DM water and required
additives and making the pastable mass of active material for pasting on the grids.
Pasting
This is the process of making the battery plates both positive and negative by pasting the
wet active material onto the grid structure.
Paste Filling
This process is used for making tubular positive plates. This process is also as paste
mixing process and after getting required density, Tubular plates are filled in this process.
Curing and drying
This is the process by which the wet pasted plates are subjected to curing under
controlled temperature and humidity so as to make the grid to paste adherence rigid and
the plates are now ready for assembling batteries. In case of tubular positive only drying
is required.
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Assembly
Both positive and negative plates are stacked alternately with a separator in between
them, quantity per individual models and are grouped. These groups are then inserted
into the container and checked for any short circuit and then the lid is fixed through
heat sealing operation. The sealed batteries will be then subjected to post burning
followed by colored epoxy filling for polarity identification and terminal bonding. It is
then checked for leak proof through air pressure testing and finally etched for coding.
Filling and charging.
The dry batteries assembled are then filled with sulphuric acid under controlled
volume / weight and put into charging. This is basically a cycle of charge and
discharge to covert the inactive material to active material after which the battery is
ready for service.
Figure-1: Battery Manufacturing Process
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Figure-2: Battery Manufacturing Flow Diagram
3.4 Raw material required likely source, marketing area of final product/s.
All the raw materials required for manufacturing mostly available in India or from
abroad. There are no banned chemicals or products which are proposed to be used. It is
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proposed to enter into long term arrangements with some of the raw material suppliers
both in India and overseas to avoid shortages at any time.
Table-03. Raw Material

S.No. Name of Raw material Unit Consumption
Total Consumption (Annual) as per
project report
1 Lead Antimony Alloy KG 22440000
2 Chemicals KG 51,00,000
3 PP Container Set Nos 10,20,000
4 PT Bag Nos 1,22,40,000
5 Packing Box Nos 10,20,000
3.5 Availability of water, its source, energy/power requirement and source:
Water is required for process, wet scrubbers, washing, cooling tower makeup and
domestic purposes. The required water shall be drawn from ground water sources and
rain water harvesting in addition to reuse of treated waste water.
Source of water supply: Ground water i.e. Bore wells
Total number of employees: 1100 Nos.
Water demand for human consumption is 49.5 KLD.
Table-04. Water Requirement
3.5.1 Water requirement, Waste Water Generation & mode of Disposal (KLD):
Sr. Particulars Total water Water requirement Total water
No. requirement (Proposed) requirement
(Existing)
1. Industrial Process - 87.0 87.0
2. Utilities i.e Boiler, - 79.0 79.0
Cooling tower, Wet
scrubber and other
2. Domestic Purpose - 49.5 49.5
3. Green Belt - 26.48 26.48
Total - 241.98 241.98
Total water requirement: 241.98 KLD

Fresh water requirement: 206.34 KLD
Recycle/reuse water: 35.64 KLD
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Table-4.1 Water Balance
S. Requirement Water Process Waste STP Available Treated
No. for Consumption Losses water /ETP water Recycled/
generation losses Reuse
A. Industrial 87.0 38.0 49.0 4.9 44.1
Process
B. Utilities i.e 79.0 20.0 59.0 3.0 56.0

Boiler,
Cooling tower,
Wet scrubber
and other
C. Domestic 49.5 9.9 39.6 4.0 35.6
Purpose (Reuse in green
belt & Flushing
purpose)
D. Green Belt 26.48 0 0 0.0 0.0
Total (KL/Day) 241.98 67.9 147.6 11.9 135.7
206.31 (Fresh)
+ 35.6
(Recycle)
Total water requirement = 241.98 KLD

Reuse water = 35.64 KLD
Net Water Requirement = 206.34 KLD (Fresh Water requirement)
Note:
▪ Waste water (49.0 KLD + 59.0 KLD = 108.0 KLD) will be generated from the
Industrial process + Utilities and will be treated in proposed ETP (Capacity –
120.0 KLD) to achieve the effluent character as per Inlet characteristics of CETP.
After treatment the treated effluent will be sent to CETP, SIDCUL.
▪ 39.6 KLD waste water will be generated from Domestic purpose which will be
treated in proposed STP (Capacity – 60.0 KLD), treated water will be reused in
Green belt and Flushing
3.5.2 Rainwater Harvesting & Groundwater Recharging
Rainwater harvesting in the present scenario holds vast potential in controlling runoff
and resulting water logging problems besides assuring an alternative source of water and
a supplement to existing natural resources in a wide variety of circumstances.
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A rainwater harvesting system comprises components of various stages namely-
Transporting rainwater through pipes or drains, Filtration, Storage in tanks for reuse or
recharge.
\
Fig: 03– Design of Typical Recharge Pit
The mode of harvesting are basically site specific and depends the amount of
precipitation, availability of total number of rainy days, nature of storage structures,
nature of aquifers etc.
In general CGWB norm suggest not to artificially recharging if water table is less than
5.0 m. Also recharging is not recommended for aquifers with TDS levels higher than
4000 mg/L or high levels of chemical composition like Nitrate, Fluoride, and Arsenic
etc.
In this project it has been planned to provide 04 Nos. rainwater harvesting recharge pit
(Trench) and 04 No. rain water harvesting tank. Rainwater collected from the rooftop
would be diverted by drain pipes to a settlement / filtration tank, from which it would
flow into the recharge pit. Water filters would be provided prior to the chamber to arrest
and separate any suspended matter present in the rain water. The recharge pits are
designed with three concentric circular chambers in which the outer chamber is filled
with sand, the middle one with coarse aggregate and the inner most layer with pebbles.
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Fig : 3.1 Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the unpaved
areas and allowed to get absorbed. Also there would be proper storm water drainage
network to collect the excess storm water runoff.
Rain Water Harvesting (RWH) System Calculation
Based on the area statement, the total roof/surface area receiving the rainfall is as
follows:
Total plot Area: 32100.00 m2

Ground coverage area of the unit receiving: 14400.0 m2
As per data available, the annual rainfall in Haridwar: 2136.7 mm
Total rainy days in a year: 80 days
Average rainfall per day: 2136.7/80 = 26.71 mm/day
The intensity of rainfall considered is 26.71 mm/hr, (Heavy rain fall) which generally
occurs in one hour (for the purpose of calculations, the higher value of rainfall intensity
is being considered in view of unpredictable nature of rainfall for arriving at total storage
volume)
Therefore, intensity of rainfall: 26.71 mm/hr
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RUN-OFF (Discharge)
Q = 10*C*I*A
Where:
Q: run off in cubic meters/hr
C: Co-efficient/Impermeability factor of the surface
I: Intensity of rainfall (26.71 mm/hr)
A: Total drainage area in hectare
Co-efficient of Run off/Impermeability Factor [C]
S. No. Description of Surface Value of run off

coefficient factor of the
surface (C)
1. Terraces, Hard paved surfaces 0.9-0.95
2. Paved Surfaces, roads 0.85-0.90
3. Gravel path, loosely paved walk, rocky surface 0.70-0.85
4. Brick paved, Compact ground 0.50-0.70
5. General Ground 0.50-0.60
6. Natural Ground, sloping ground 0.20-0.50
Run Off Calculation:
(i) Run off from ground coverage area of the proposed unit
Q1 = 10*0.8*26.71*14400.0/10000 (since 1 hectare = 10000 m2)
= 307.69 m3/hr
(ii) Run off from Landscape of the proposed unit
Q2 = 10*0.6*26.71*10593/10000
= 169.76 m3/hr
Total run off discharge (Q): Q1 + Q2 =307.69 + 169.76 = 477.45 m3/hr
Considering the first flush of rainwater after a dry period shall be allowed to run to waste
as it will be contaminated with dust, bird droppings etc.
Total run off = 0.9 * 477.45 = 429.70 m3/hr
Considering retention storage of rain water harvesting is 30 min
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Total capacity of RWH storage: 429.70 *30/60 = 214.85 m3
The total no. of RWH proposed: 04
Capacity of each RWH: 60.0 m3 (4 Nos)
3.5.3 Electricity:
Total Power Requirement 4750 KVA will be sourced from UPCL.
Alternate Power: In case of non-availability of UPCL power. Green insulated DG set

(1500 KVA x 02 Nos.) will be installed as standby arrangement. HSD (130.0 liters/ hr.)
will be used as fuel for the operation of DG set whenever is required during power
failure.
3.5.4 Fuel:
The HSD required for two DG set of 1500 KVA 130 lit./Hr. in case of power failure.
3.6 Quantity of wastes generated (liquid and solid) and Scheme for their
Management/disposal:
3.6.1 Process Details & Flow schematics of STP – Capacity 60 KL per day
Biological sewage treatment is a process where biological organisms are cultured and
allowed to consume the organic matter and multiply their population. This is by a
process where the organisms secrete enzymes through their cell walls; and these enzymes
solubilize the organic matter and the solution is drawn back into the organisms again
through their cell wall. This is the food. The organisms grow and multiply by a process
called binary fission whereby each organism splits into two complete new organisms.
This is called metabolism. The multiplied organisms are settled out and the clear treated
sewage is free from the organic matter. The metabolism can be by (a) aerobic
PRIMARY BIOLOGICAL TREATMENT
The physical activities used to implement the processes are called unit operations. For
example, the physical processes of screening, grit (sand) and suspended solids being
settled out are together referred to as primary treatment. The metabolic process is called
secondary treatment. Unit operation means the physical activity. For example, simple
settling of raw sewage is carried out in primary clarifiers. Pumping air into the sewage
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for supplying oxygen to the aerobic metabolism is called aeration. Settling of the
microorganisms after aeration is carried out in secondary clarifiers. The concentration of
settled out organics and microorganisms from primary settling or secondary settling or
both together is carried out in sludge thickeners. The anaerobic metabolism of thickened
sludge is carried out in sludge digesters.
SECONDARY BIOLOGICAL TREATMENT
Aerobic Treatment Process: The following treatment processes as also cited in the
advisory issued by the Ministry of Urban Development in March-2012 titled “Recent
Trends in Technologies in Sewage Treatment” fall under the classification of aerobic
treatment
Activated Sludge Process (ASP)

Sequencing Batch Reactor (SBR)
Moving Bed Bio Reactor (MBBR) / Fluidized Aerobic Bioreactor (FAB)
Membrane Bio Reactor (MBR)
Fig-4 Schematic Flow Diagram of the Proposed Sewage Treatment Plant (S.T.P.)
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3.6.2 Process Details & Flow schematics of Proposed Effluent Treatment Plant
Coagulation & Flocculation

The coagulation/flocculation process is for the removal of chemical oxygen demand
(COD), biological oxygen demand (BOD) and total suspended solids (TSS) in
wastewater. Coagulation is a process used to neutralize charges and form a gelatinous
mass to trap (or bridge) particles thus forming a mass large enough to settle or be trapped
in the filter. Flocculation is gentle stirring or agitation to encourage the particles thus
formed to agglomerate into masses large enough to settle or be filtered from solution.
Clarification/Sedimentation
• Primary settler is commonly used in rectangular clarifiers to increase the
settling capacity by reducing the vertical distance a suspended particle must
travel.
• High efficiency tube settlers use a stack of parallel tubes, rectangles or flat
pieces separated by a few inches (several centimeters) and sloping upwards in
the direction of flow. They provide a very large surface area onto which
particles may fall and become stabilized.
• Because flow is temporarily accelerated between the plates and then
immediately slows down, this helps to aggregate very fine particles that can
settle as the flow exits the plates.
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Fig -5. Schematic Flow diagram of the proposed Effluent Treatment Plant (E.T.P.)
4.0 SITE ANALYSIS
4.1 Plant Location
The Proposed manufacturing unit i.e. M/s Luminous Power Technologies Pvt. Ltd. is
located at Plot no.4, Sector 12 IIE, SIDCUL, Haridwar, Uttarakhand. The nearest
National Highway NH-58 (Delhi-Rishikesh) is 3.82 Km S away from the site. The
Nearest railway station Hardwar Railway station approx. 7.06 Km- E direction from
the site and the nearest Airport Jolly grant Airport approx. 29.39 Km in NE direction
from the site. Land details & documents are attached as Annexure – XIII.
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Project Site Coordinates:
The project site is located Latitude: 29°56'58.7"N, Longitude: 78°04'51.9"E. Corner

coordinates of the proposed site is as below:
S. No. Latitude Longitude

1. 29°57'2.72"N 78° 4'48.26"E
2. 78° 4'48.26"E 78° 4'51.98"E
3. 29°56'54.55"N 78° 4'53.49"E
4. 29°56'54.34"N 78° 4'51.52"E
5. 29°56'57.26"N 78° 4'50.68"E
6. 29°56'57.12"N 78° 4'48.80"E
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Figure-6: Project Location
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Figure-7: Plant Layout
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Figure: 8.1: 5 K.M RADIUE MAP
Figure-8.2: 10 K.M RADIUS MAP
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Figure-9. Satellite image Project site
5.0 Quantity of waste to be Generated (liquid and solid) and scheme for their
management/disposal.
Table-05 Details of Hazardous Wastes and Other Solid Wastes
S. No Name of Hazardous Schedule & Quantity/ Method of Disposal

Waste Category (as per Annum
HWM Rules,2016)
01 Lead Bearing Cat. - 9.1 1440000 Collection, Storage,
Residues Kg/Year Transportation & Disposal
to authorized
decontamination facility
02 Lead Ash or Cat. - 9.2 5000 Collection, Storage,

particulate from Flue kg/Year Transportation & Disposal
Gas at Incineration Unit.
03 Sludge and Filters Cat.- 3.1 2500 Collection, Storage,

contaminated with Kg/Year Transportation & Disposal
oil at Incineration Unit.
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04 Waste & Residue CAT -5.2 3250 Collection, Storage,

containing Oil Kg/Year Transportation & Disposal
at Incineration Unit.
05 Chemical sludge Cat.- 35.3 22000 Collection, Storage,

from waste water Kg/Year Transportation & Disposal
treatment (ETP to authorized Vendor
Sludge )
06 Empty Barrels Cat-33.1 5000 Collection, Storage,
/Containers/Liners/ Kg/Year Transportation & Disposal
Contaminated with to authorized Vendor
Hazardous
Chemicals/WASTE
07 Used Spent Oil Cat. 5.1 3000 Collection, Storage,
Ltr/YEAR Transportation & Disposal
to authorized Vendor
Used spent oil will be calculated based on DG set.

Table-06: Solid Waste Generation
Sl. Name of Other Quantity/ Annum Method of Disposal
No Solid Waste
01 Plastic Waste Can be assessed To authorized recycler
after continuous
Plant Operation
02 Waste packaging Can be assessed To Paper recyclers
material (paper, after continuous
gutta, etc) Plant Operation
03 STP sludge 500.00 Kg Used in horticulture as Organic
Manure
6.0 PLANNING BRIEF
The project is envisaging to be completed in Phase wise as it involves installation of

higher capacity processing equipment’s besides improving of yield and the production
shall be initiated thereon.
7.0 PROPOSED INFRASTRUCTURE
7.1 Power Requirement and Supply/Source

Total Power Requirement 4750 KVA will be sourced from UPCL.
Alternate Power: In case of non-availability of UPCL power. Green insulated DG set

(1500 KVA x 02 Nos.) will be installed as standby arrangement. HSD (130.0 liters/ hr.)
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will be used as fuel for the operation of DG set whenever is required during power
failure.
7.2 Equipment’s
There will be Grid casting machines, Oxide mills, Paste mixtures, Curing ovens and
Assembly equipment along with MHE Utilities Equipment and EHS Equipment.
7.3 Air Pollution Control System
The sources of air pollution from the plant will be from proposed utilities. The stack
heights will be provided as per the guidelines of CPCB for effective stack heights.
In the battery plant, the main sources for air pollution are the emissions from stacks
attached to various parts of the processing sections and standby DG sets. Bag filters
blower are connected to Lead dust generating points like oxide mill, Grid Casting, Plate
cutting & Assembly. Wet Scrubbers, blower and chimney are connected to acid fume
generating operation charging. DG sets are connected with stacks of adequate height.
Stack height of 30 mt is ensured in all Lead dust emitting stacks. Periodic stack emission
test is carried out by Sate Pollution Control Board & NABL accredited Lab.
Table-07: Air Pollution Control System for Process Vents

S.No. Process Nature of Controlling Discharge
Emission Equipment Method
1. Plate Casting Lead Fume & Wet Scrubber Through 30
(Grid & Spine) Smoke System Mtr. Stack
2. Oxide Generation Lead Fume & Wet Scrubber Through 30
Smoke System Mtr. Stack
3. Paste Mixing & Plate Lead Dust , Acid Wet Scrubber Through 30
Pasting Fume System Mtr. Stack
4. Plate Filling Slurry/Lead Dust PRS & WRS/ N/A Through
(Wet/ Dry) Bag Filter 30 Mtr. Stack
System
5. Plate Curing & Drying Moist Air Demisters N/A
Filter
6. Plate Parting & Lead Dust Bag Filter Through 30
Brushing System Mtr. Stack
7. Plate Enveloping & Lead Dust Bag Filter Through 30
Stacking System Mtr. Stack
8. Battery Assembly Lead Fume & Bag Filter & Through 30
Smoke Wet Scrubber Mtr. Stack
System
9. Charging & Packing Acid Fume Wet Scrubber Through 30
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System Mtr. Stack
10. Acid Dilution Acid Fume, Wet Scrubber Through 30
Effluent System Mtr. Stack
11. Bag Slitting System Lead Dust Bag Filter Through 30
System Mtr. Stack
12. Electrical Backup Smoke N/A As Per DG Set
(DG Set) Stack Norm
13. Steam Boiler Smoke N/A As Per DG Set
Stack Norm
7.4 Hazardous Waste
Hazardous wastes i.e. ETP sludge, Spent Oil, Lead Ash, Discarded Containers/ Barrels
generated during operation Phase dealt as per Hazardous and Other Wastes
(Management and Trans- boundary movement) Rules, 2016. Details of Hazardous waste
is attached as Annexure – IX.
7.5 Solid waste Management

The Domestic Waste is being segregated at source and collected in bins & disposed as
per CPCB norms. Details of Solid waste is attached as Annexure – VI.
8.0 Green Belt
Local native species suitable for this region will be planted with a view to attenuate air
pollutants, to resist noise propagation from DG Set and uptake of treated effluent to
some extent, the green belt of project site and in vacant areas (33% of the total acquired
land) will be developed. Tree plantation will be undertaken in a large scale on land
vacated after cessation of construction activities. Open spaces, where tree plantation is
not possible will be planted with flowering herbs and grass which act as soil binders and
also helpful in preventing erosion of topsoil. Proposed green belt will be maintained up
to maximum onsite and remaining will be developed in nearby area.
9.0 SAFETY MEASURES:
Company will be provided full proof fire hydrant system & kinds of fire extinguishers to
ensure the safe working environment. Face mask, Hand gloves and other PPE’s will be
provided to workers. The organization will always implement & maintain documented
Occupational health & Safety objectives.
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9.1. ON-SITE EMERGENCY MANAGEMENT PLAN
(A) Emergency can be because of following:
(a) Fire due to short circuit in the building/ equipment.
(b) Accident during material handling, production process or equipment operations,

resulting in injury to personnel or damage od asset.
(c) Natural calamity- such as earthquake/ flood/lighting.
(B) Proposed plan for Emergency Management on-site: The company has formed a
group of members for an Emergency i.e Site Main Controller, Deputy Site Main
Controller, Incident Main controller, Deputy Incident Main Controller, Emergency
Response Team, EHS coordinator, and Engineering Coordinator etc.
It is documented plan to deal with an emergency occurred in premises. In which the role
of every person has defined & every person will act as accordingly. We will evaluate our
plan by performing mock drill regularly.
10.0 REHABILITATION AND RESETTLEMENT (R&R PLAN)
Not Applicable to this project.
11.0 PROJECT COST ESTIMATES
The cost of the project and means of finance is proposed to be as follows:
Table-08: Project Cost Estimation
SL Particulars Amount (Rs

No in Lakh)
1 Land 2,200
2 Buildings 1400
3 MHE & Utilities Equipment 3500
4 Plant & Machinery 12520
5 Other Utilities & EHS 2890
6 Working Capital (3 Months) 19,315.39
TOTAL 41825.39
Detailed report of Project Cost is attached as Annexure XII.
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PFR & EMP

10 Waste water quantity Domestic water – 39.6 KLD

2.0 INTRODUCTION OF THE PROJECT /BACKGROUND INFORMATION

2.1 Identification of the project and project proponent

2.2 Brief Description of Nature of Project.

2.3 Need for the Project & Importance to the Country

2.4 Demand and Supply gap

2.5 Imports Vs. Indigenous production

2.6 Export Possibility:

2.7 Domestic/Export Markets

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

3.0 PROJECT DESCRIPTION

3.1 Type of Project including interlinked and interdependent projects, if any:

3.2 Size or magnitude of operation:

Table-2.0 Manufacturing Capacity

3.3 Process Description with process details (a schematic diagram/flow chart)

Grid Casting/ Spine Casting

Curing and drying

Filling and charging.

Figure-1: Battery Manufacturing Process

Figure-2: Battery Manufacturing Flow Diagram

Table-03. Raw Material

3.5 Availability of water, its source, energy/power requirement and source:

Table-04. Water Requirement

Total water requirement: 241.98 KLD

B. Utilities i.e 79.0 20.0 59.0 3.0 56.0

Total water requirement = 241.98 KLD

3.5.2 Rainwater Harvesting & Groundwater Recharging

Fig : 3.1 Cross section of Recharge Trench

Rain Water Harvesting (RWH) System Calculation

Total plot Area: 32100.00 m2

Therefore, intensity of rainfall: 26.71 mm/hr

S. No. Description of Surface Value of run off

Run Off Calculation:

Total run off = 0.9 * 477.45 = 429.70 m3/hr

Considering retention storage of rain water harvesting is 30 min

Total Power Requirement 4750 KVA will be sourced from UPCL.

Alternate Power: In case of non-availability of UPCL power. Green insulated DG set

PRIMARY BIOLOGICAL TREATMENT

SECONDARY BIOLOGICAL TREATMENT

Activated Sludge Process (ASP)

Coagulation & Flocculation

4.0 SITE ANALYSIS

4.1 Plant Location

The project site is located Latitude: 29°56'58.7"N, Longitude: 78°04'51.9"E. Corner

S. No. Latitude Longitude

2. 78° 4'48.26"E 78° 4'51.98"E

3. 29°56'54.55"N 78° 4'53.49"E

4. 29°56'54.34"N 78° 4'51.52"E

5. 29°56'57.26"N 78° 4'50.68"E

6. 29°56'57.12"N 78° 4'48.80"E

Figure-6: Project Location

Figure-7: Plant Layout

Figure: 8.1: 5 K.M RADIUE MAP

Figure-8.2: 10 K.M RADIUS MAP

Figure-9. Satellite image Project site

Table-05 Details of Hazardous Wastes and Other Solid Wastes

S. No Name of Hazardous Schedule & Quantity/ Method of Disposal

02 Lead Ash or Cat. - 9.2 5000 Collection, Storage,

03 Sludge and Filters Cat.- 3.1 2500 Collection, Storage,

04 Waste & Residue CAT -5.2 3250 Collection, Storage,

05 Chemical sludge Cat.- 35.3 22000 Collection, Storage,

Used spent oil will be calculated based on DG set.