Guidelines for Industries

Guidelines for Industries

The APPCB follows a set of guidelines in granting Consent for establishment to different industries. The guidelines that different industries have to follow are given below based on the Industry type. Please click on your relevant industry to access guidelines.

Guidelines for Cement Grinding Units :

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

The width of buffer zone to be maintained from the Road Land Boundary to the industry shed shall be as following:

CATEGORY	NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
Orange (Total investment upto Rs. 10 Crores)	25 m	20 m	10 m

The buffer zone shall be permitted to utilise for the following:

1. Vehicle parking.
2. Administrative building and security office.
3. Green belt.
4. Electrical Substation / transformers.
5. Fuel Station.
6. Water supply sumps and
7. Other non-industrial activities.

The distance between the boundary of the site and human habitation, educational institutions and religious places shall not be less than 300 m.

Minimum area of the site shall be Ac. 1.5.

Greenbelt shall be developed along the boundary of the land, with atleast two rows of tall growing plants such as Conocarpus (Dubai plants) etc., to act as a barrier to mitigate dust pollution.

Bag filter for grinding unit and cement silo shall be provided.

Stone Crushing Units

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

The distance between the boundary of the site and boundary of the

i) National Highway shall be -500 m

ii) State High way, MDR and other roads shall be -100 m

The distance between the boundary of the site and human habitation, educational institutions and religious places shall not be less than 500 m.

Preferably located near the quarries.

    Minimum area of land required – 3 acres.

 Green belt of width 5 m shall be developed along the boundary of the land, with atleast three rows of tall growing plants such as Conocarpus (Dubai plants) etc., to act as a barrier to mitigate dust pollution. A barricade with steel sheets shall be provided between the Crusher area and the green belt. The height of the barricade shall be 1.0 metre above the highest point of the stone crusher / conveyor belt.

Dairy Units (except Chilling units)

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

 The width of buffer zone to be maintained from the Road Land Boundary to the industry shed shall be as following:

S.NO	CATEGORY	NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
1	Red (integrated)	50 m	40 m	20 m
2	Orange (small scale)	25 m	20 m	10 m

 The buffer zone shall be permitted to utilise for the following:

1. Vehicle parking.
2. Administrative building and security office
3. Green belt.
4. Electrical Substation / transformers.
5. Fuel Station.
6. Water supply sumps and
7. Other non-industrial activities.

The distance between the boundary of the site and human habitation, educational institutions and religious places shall not be less than 300 m.

 Area of the green belt shall be @ one acre to dispose 10 KLD of treated waste water, in addition to the built-up area. (OR)

 The industry can discharge the treated effluents into surrounding fields, after submitting the NOC from the farmers to the Board.

• New Dairy units shall install bag filters as the control equipment for the boiler(s), if the distance between the boundary of the site and human habitation, educational institutions and religious places is less than 500 m.
• If, the distance between the boundary of the site of the new Dairy units and human habitation, educational institutions and religious places is equal to or more than 500 m, cyclone / multi-cyclones are sufficient as the control equipment for the boiler(s).
• If the fuel for the boiler is oil such as diesel, pollution control equipment is not required. Required stack height shall be provided.

LPG Bottling Unit (Upto 100 tonnes storage)

 The distance between the boundary of the site and boundary of any road shall be at least 100 m.

 The distance between the boundary of the site and human habitation (boundary of Town, Village etc.) shall be at least 1 km.

 Total area of land acquired – Ac. 5.0

 On site emergency plan to be prepared before the activity is commenced i.e. before the trial production.

Cashew Processing Unit

Drum Process

 To be located 1 km away from habitation

 No new units to be allowed in Palasa, Kasibugga & Mogilipadu.

 Distance between 2 units shall be 500 m.

 A distance of 500 m shall be maintained between the boundary of site and the edge of National & State Highway.

 A distance of 100 m shall be maintained from boundary of site and Edge of B.T. Roads in the Districts.

Boiling Process (modified guidelines)

In the 5th Board Meeting held on 20.04.2017 vide Resolution No. 97/2017, the Board approved the following revised guidelines for establishment of new Cashew Nut Processing Units:

 To be located 200 m away from habitation.

 No new units to be allowed in Palasa, Kasibugga and Mogilipadu clusters. However, new unit with boiling process will be allowed replacing sick unit in the said clusters where roasting process took place hitherto on submission of the proof of the existence of the old unit from any of the Government departments. Multiple new units in one premises, in place of one sick unit is not allowed.

 De-oiled cashew nut shell / bio-mass shall be used as fuel for the boiler and drier.

Guidelines for Pulverizing Units:

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

 The width of buffer zone to be maintained from the Road Land Boundary to the industry shed shall be as following:

CATEGORY	NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
Orange	25 m	20 m	10 m

 The buffer zone shall be permitted to utilise for the following:

1. Vehicle parking.
2. Administrative building and security office.
3. Green belt.
4. Electrical Substation / transformers.
5. Fuel Station.
6. Water supply sumps and
7. Other non-industrial activities.

 The minimum distance between the boundary of the site and human habitation shall be 300 m.

  Minimum area of the site shall be Ac. 1.5.

 Greenbelt  shall be developed  along the boundary  of the land, with atleast two rows of tall growing plants such as Conocarpus (Dubai plants) etc., to act as a barrier to mitigate dust pollution.

 Bag filter has to be provided for the pulverizer.

Para Boiling Rice Mills

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

 The width of buffer zone to be maintained from the Road Land Boundary to the industry shed shall be as following:

S.NO	CATEGORY	NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
1	Red (wastewater generation > 100 KLD or fuel consumption > 12 MTD or both )	50 m	40 m	20 m
2	Orange (wastewater generation <100 KLD or fuel consumption < 12 MTD or both )	25 m	20 m	10 m

 The buffer zone shall be permitted to utilise for the following:

1. Vehicle parking.
2. Administrative building and security office.
3. Green belt.
4. Electrical Substation / transformers.
5. Fuel Station.
6. Water supply sumps and
7. Other non-industrial activities.

 The distance between the boundary of the site and human habitation, educational institutions and religious places shall not be less 300 m.

 The new units shall not be located in the catchment area of drinking water source.

 Area of the green belt shall be @ one acre to dispose 10 KLD of treated waste water, in addition to the built-up area. (OR)

The industry can discharge the treated effluents into surrounding fields, after submitting the NOC from the farmers to the Board.

 Greenbelt  shall be developed  along the boundary  of the land, with atleast two rows of tall growing plants such as Conocarpus (Dubai plants) etc., to act as a barrier to mitigate dust pollution.

 Rice Husk / Boiler ash shall be stored in a separate closed sheds in one of the corners of the site, away from habitation, educational institutions and religious places and roads.

 Bag filter shall be provided to the Boiler. If the fuel for the boiler is oil such as diesel, pollution control equipment is not required. Required stack height shall be provided.

Pesticide Formulation Units

    No clusters of pesticide formulation units shall be permitted.

 The quality of product (after mixing) shall be ensured and certified by agricultural department before going into commercial production. The certificate shall be produced before the APPCB while applying for CFO or when the unit goes for expansion.

 The proponent has to substantiate the break-up the capital cost so that a proportionate amount is justified for pollution control measures for odour or dust causing products /processes.

 The solid, liquid and gaseous formulation units shall have extraction and scrubbing systems for mitigation of smell or to avoid any accidental leakages of poisonous gases.

 Bag filters shall be installed to trap particulate matter at all dust emission points in the process.

 Dry mopping vacuum cleaning of floor shall be adopted instead of wet floor washing and vessel cleaning as it prevents water contamination.

 Solid waste/drums shall be detoxified and they only disposed off by incineration or to the scrap dealers.

 The unit shall  be located at least a raidal distance of 1 km away from any human habitation excluding APIIC IEs/IDAs.

 All odour causing chemicals in the formulation units shall be stored in a separate place within the premises.

 The units shall have at least 50-80% open area other than the factory built up area.

Sponge Iron Units – Guidelines / Code of practice for Pollution prevention for Sponge Iron Plants (CPCB)

Air Pollution

Stack Emission from Kiln

i) Adequately designed ESP or any other adequate air pollution control system/combination of system should be installed to achieve the prescribed stack emission standards

As installation and operation of Pollution Control Equipment for plants with less than 100 TPD capacity is not economically viable, therefore, it is recommended that plants with less than 100 TPD shall not be permitted in future.

Program for phasing out old plants having capacity less than 100 TPD shall be worked out by the State Pollution Control Board.

ii) All Pollution control equipment should be provided with separate electricity meter and totaliser for continuous recording of power consumption. The amperage of the ID fan should also be recorded continuously. Non-functioning of Pollution control equipment should be recorded in the same logbook along with reasons for not running the Pollution Control Equipment.

iii)  The safety cap/emergency stack of rotary kiln type plant, which is generally installed above the After Burner Chamber (ABC) of feed end column should not be used for discharging untreated emission, bypassing the air pollution control device.

iv)  In order to prevent bypassing of emissions through safety cap and non-operation of ESP or any other pollution control device, software controlled interlocking facility should be provided on the basis of real time data from the plant control system, to ensure stoppage of feed conveyor, so that, feed to the kiln would stop automatically, if safety cap of the rotary kiln is opened or ESP is not in operation. The system should be able to take care of multiple operating parameters and their inter relations to prevent any possibility of defeating the basic objective of the interlock. The system should be foolproof to prevent any kind of tempering. The software based interlocking system, proposed to be installed by industry should be get approved by the concerned State Pollution Control Board, for its adequacy, before installation by the industry.

v)  Mechanical operated system for timely collection and removal of the flue dust generated in ESP or any other pollution control device shall be installed.

Stack Emission from de-dusting units

All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions.

Fugitive Emission

The measurement may be done, preferably on 8-hour basis with high volume sampler. However, depending upon the prevalent conditions at the site, the period of measurement can be reduced.

 Effluent Discharge

All efforts should be made to reuse and re-circulate the water and to maintain zero effluent discharge.
Storm water / garland drain should be provided in the plant.

 Noise Control

The industry should take measures to control the Noise Pollution so that the noise level standards already notified for Industrial area are complied.

 Solid Waste Management

CharChar should be mixed with coal or coal washery rejects and used as fuel in Fluidized Bed Combustion Boilers (FBC) for generation of power. The plants having capacity 200 TPD and above should install Fluidized Bed Combustion Boilers (FBC) for generation of power. Also the smaller capacity individual Sponge Iron Plants (Capacity upto 100 TPD) and operating in cluster can collectively install common Fluidized Bed Combustion Boilers (FBC) for power generation. The Sponge Iron Plant are free to explore other options / possibilities to use char for generation of power. Char can be sold to local entrepreneurs for making coal briquettes. It can also be mixed with coal fines, converted to briquettes and used in brick kilns.

Under no circumstances char should be disposed off in agricultural fields/other areas. Logbook for daily record, of Char production and usage must be maintained by the industry and the record shall be made available to officials of CPCB/SPCB/PCC during inspection.

Kiln AccretionsThe kiln accretions are heavy solid lumps and can be used as sub- base material for road construction or landfill, after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact.

Gas Cleaning Plant (GCP)/Scrubber SludgeThe sludge should be compacted and suitably disposed off after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact.

Flue Dust / Fly ashFlue dust is generated from air pollution control system i.e. ESP or any other air pollution control system installed with kiln. Secondary flue dust is also generated from Bag Filters or any other air pollution control equipment installed with Raw Material Handling, Coal Crusher, Cooler Discharge and Product house unit. The reuse/ recycling of the flue dust generated / collected may be explored and suitably implemented.

Fly ash brick manufacturing plant should be install for fly ash utilization. Fly ash can be utilized in cement making by Cement industry also.

Bottom AshBottom ash may have objectionable metallic compounds, therefore should be stored in properly designed landfills as per CPCB guidelines to prevent leaching to the sub-soil and underground aquifer.

GeneralSolid waste management program should be prepared with thrust on reuse and recycling. Solid waste disposal site should be earmarked within the plant premises. The storage site of solid waste should be scientifically designed keeping in view that the storage of solid waste should not have any adverse impact on the air quality or water regime, in any way.

The various types of solid wastes generated should be stored separately as per CPCB guidelines so that it should not adversely affect the air quality, becoming air borne by wind or water regime during rainy season by flowing along with the storm water.

 Raw Material handling and Preparation

i)  Unloading of coal by trucks or wagons should be carried out with proper care avoiding dropping of the materials from height. It is advisable to moist the material by sprinkling water while unloading.

ii)  Crushing and screening operation should be carried out in enclosed area. Centralized de- dusting facility (collection hood and suction arrangements followed by de-dusting unit like bag filter or ESP or equally effective method or wet scrubber and finally discharge of emission through a stack) should be provided to control Fugitive Particulate Matter Emissions. The stack should confirm to the emission standards notified for de-dusting units. Water sprinkling arrangement should be provided at raw material heaps and on land around the crushing and screening units.

iii)  Work area including the roads surrounding the plant shall be asphalted or concreted.

iv)  Enclosure should be provided for belt conveyors and transfer points of belt conveyors.
The above enclosures shall be rigid and permanent (and not of flexible/ cloth type enclosures) and fitted with self- closing doors and close fitting entrances and exits, where conveyors pass through the enclosures. Flexible covers shall be installed at entry and exit of the conveyor to the enclosures, minimizing the gaps around the conveyors.In the wet system, water sprays/ sprinklers shall be provided at the following strategic locations for dust suppression during raw material transfer:

– Belt conveyor discharge/ transfer point
– Crusher/screen discharge locations

 Waste Heat Recovery Boiler (WHRB)

Sponge Iron Plants of capacity more than 100 TPD kilns shall use Waste Heat Recovery Boiler (WHRB) for generation of power.

 Cooler Discharge and Product Separation Unit

Permanent and rigid enclosures shall be provided for belt conveyors and transfer points of belt conveyors. Dust extraction cum control system preferably bag filters or ESP to arrest product loss in cooler discharge and product separation area shall be installed.

 Char based Power Plant

For plant having capacity of 200 TPD of cumulative kiln capacity, the power production through FBC boiler using char as a part of fuel, is a viable option. Power generation through FBC boiler using char as a part of fuel be implemented in a phased manner within 4 years of commissioning and targeting for 100% utilization of char.

Individual Sponge Iron Plants of capacity upto 100 TPD and located in cluster can install a common char based power plant collectively.

 New Sponge Iron Plants

i)  No New Sponge Iron Plant will be commissioned without installation of Pollution control systems as stipulated in the Standards. The concerned State Pollution Control Board will accord consent to operate only after Physical verification of the adequacy of the Installed pollution control systems for meeting the standards and stipulated conditions in the consent to establish.

ii)  All new kilns shall have the independent stack with the kiln or multi-flue stacks in case two or more kilns are joining the same stack for better dispersion of pollutants.

iii)  Any entrepreneur having more than 2×100 TPD kiln may install WHRB for power generation, as it’s a techno-economic viable option. For plants having capacity of 200 TPD or more, power generation using char in FBC Boiler as part of fuel is techno-economic viable option, therefore, new plants must install FBC boiler for power generation at the time of installation of the industry.

iv)  Any new sponge iron plant being installed along with the other downstream facilities of converting the sponge iron into steel with/without further processing the steel should meet the target of 100% utilization of sensible heat of DR (Direct Reduction) Gas and Char for power generation. Wet scrubbing system for kiln off-gas treatment for such plants should not be opted.

 General Guidelines

i)  Extensive plantation/Green belt shall be developed along the roads and boundary line of the industry. A minimum 15 m width Green Belt along the boundary shall be maintained. However, the green belt may be designed scientifically depending upon the requirement and local and mix species of plants may be selected for the green belt.

ii)  Monitoring of stack emissions, fugitive emissions, trade effluent and noise level shall be done as per CPCB regulations.

iii)  Pollution control systems shall be operated as an integral part of production to ensure minimum emissions. Pollution Control System shall start before conveyor operation/operation of plant. Similarly pollution control system shall be stopped only after completion of conveyor operation/operation of plant so that possibility of dust settlement in ducts can be eliminated. Continuous evacuation of dust (from Dust catchers, ESPs, Bag filter hopper etc.) shall be organized.

 Siting Guideline for Sponge Iron PlantsSiting of new sponge iron plants shall be as per respective State Pollution Control Board guidelines. However the following aspects shall also be considered:

i)  Residential habitation (residential localities/ village) and ecologically and/or otherwise sensitive areas: A minimum distance of at least 1000 m (1.0 km) to be maintained.

ii)  The location of Sponge Iron Plant should be at least 500 m away from National Highway and State Highway .

iii)  Radial distance between two Sponge Iron Plants should be 5 km for plants having capacity 1000 TPD or more.

Sitting Guidelines for Transportation / Communication System

 In the 5th Board Meeting held on 20.04.2017 vide resolution no. 98/2017; the Board approved the following revised guidelines with respect to distance between the industries and the roads:

S.NO.	CATEGORY	WIDTH OF BUFFER ZONE TO BE MAINTAINED FROM THE ROAD LAND BOUNDARY TO THE INDUSTRY SHED:
		NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
1	Red	50 m	40 m	20 m
2	Orange	25 m	20 m	10 m
3	Green	Exempted from the distance criteria.

 The buffer zone shall be permitted to utilise for the following:

• Vehicle parking.
• Administrative building and security office.
• Green belt.
• Electrical Substation / transformers.
• Fuel Station.
• Water supply sumps and
• Other non-industrial activities.

  These guidelines shall be applicable to industries other than those categories of industries for which specific guidelines are formulated by the Board.

 These guidelines are not applicable to the industries to be located within industrial estates.

Tyre Pyrolysis units:

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

  The width of buffer zone to be maintained from the Road Land Boundary to the industry shed shall be as following:

CATEGORY	NATIONAL HIGHWAYS	STATE HIGHWAYS	MDR / VILLAGE ROADS
Red	50 m	40 m	20 m

The buffer zone shall be permitted to utilise for the following:

1. Vehicle parking.
2. Administrative building and security office.
3. Green belt.
4. Electrical Substation / transformers.
5. Fuel Station.
6. Water supply sumps and
7. Other non-industrial activities.

 Shall be located atleast 500 m away from habitations.

 Burners shall be installed to flare up excess non condensable gases with safety arrangements.

 Air pollution control equipment shall be provided to control the flue gas emissions generated during the heating of the Pyrolysis reactor.

 No further distillation of oil shall be carried out.

 The by-products, carbon black shall be collected properly and stored in closed shed without causing any spillages before selling to outside parties.

Solvent Recovery units:

These siting guidelines are applicable to the units with total investments upto Rs. 10.0 Crores.

These siting guidelines are not applicable for the units proposed in the IEs/IDAs/Industrial Parks/ SEZ etc., and for expansion of the existing units.

 The solvent recovery units shall be installed in Industrial Estates / industrial parks / IDAs / SEZs.

 The solvent recovery units shall dispose the inorganic hazardous waste to TSDF for land filling and organic residue to TSDF for incineration / cement plants for co-processing.

 The solvent drums shall be kept on concrete platform only with covered roof. The platform shall be provided with sufficient dyke wall with leachate collection system.

 All the solvent storage tanks shall be provided with vent condensers to prevent solvent vapour.

 Transfer of solvents shall be done by using pumps only instead of manual handling.

 Proper earthing shall be provided in all the electrical equipment wherever solvent handling is done.