HAWA - Hazardous Waste Management Project Karnataka Indo-German Technical Cooperation ASEM Advisory Services in Environmental Management Karnataka

State Pollution Control Board

German Technical Cooperation Deutsche Gesellschaft fur Technische Zusammenarbeit (GTZ) GmbH

Detailed Project Report (DPR) Treatment Storage and Disposal Facility (TSDF) for Karnataka Dobbasapete, Bangalore Rural District June 2004

HAWA - Hazardous Waste Management Project Karnataka Indo-German Technical Cooperation

Karnataka State Pollution Control Board KSPCB Deutsche Gesellschaft fur Technische Zusammenarbeit (GTZ) GmbH (German Technical Cooperation)

PN 96.2229.1 001.00 P 1214 - 2

Submitted to: Department of Forest, Ecology & Environment (DFEE), Government of Karnataka Submitted by: HAWA Project GTZ-KSPCB, Karnataka Date: June, 2004

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List of Acronyms: AAS AFAS APCS APIIC APPCB BIS BOO BS BT CA CEO CERCLA CETP CFC CFE CII CL CPCB DEWATS DFEE DMP DSCR EDF EIA EIRA EMP EPH ERF ETP EU EWL FDI FI GIDC GM GoI GoK GSDP GSPCB GTZ HAWA HDPE HR HW HWM ICAR IHW IMD IRR
KSPCB / GTZ

Atomic Absorption Spectro Photo meter Automatic Fire Alarm System Air Pollution Control Systems Andhra Pradesh Industrial Infrastructural Corporation Andhra Pradesh Pollution Control Board Bureau of Indian Standards Build Own Operate British Standards Bio-Technology Contracting Authority Chief Executive Officer Comprehensive Environmental Response Compensation and Liability Act Common Effluent Treatment Plant Chloro Flouro Carbons Consent for Establishment Confederation of Indian Industries Clay Liner Central Pollution Control Board Decentralized Waste Water System Department of Forests, Ecology and Environment, Government of Karnataka Disaster Management Plan Debt Service Coverage Ratio Environment Development Fund Environmental Impact Assessment Environmental Impact and Risk Assessment Environmental Management Plan Environmental Public Hearing Environmental Relief Fund Effluent Treatment Plant European Union Equivalent Waste Location Foreign Direct Investment Financial Institution Gujarat Industrial Development Corporation General Manager Government of India Government of Karnataka Gross State Domestic Product Gujarat State Pollution Control Board German Technical Cooperation Hazardous Waste Management project High Density Poly Ethylene Human Resource Hazardous Waste Hazardous Waste Management Indian Council of Agricultural Research Incinerable Hazardous Waste Indian Meteorological Department Internal Rate of Return
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IT KHWMA KIADB KSPCB MIDC MoEF MoUs MPCB MSIHC MT NAAQS NE NEPA NFPA NNE NOC PAH PCB PCC PLCC PFA PO POHC PPG PVCA R. H RCC REIA R-EIRA RHW ROE ROI RO-RO RPM SLM SPCB SPV SSHW SSW SW TOC TOR TPA TREM TSDF UGD USBR USEPA VF WDV WM

Information Technology Karnataka Hazardous Waste Management Agency Karnataka Industrial Area Development Board Karnataka State Pollution Control Board Maharashtra Industrial Development Corporation Ministry of Environment and Forests, New Delhi Memoranda of Understanding Maharashtra Pollution Control Board Manufacture Storage and Import Hazardous Chemicals Metric Tons National Ambient Air Quality Standards North East National Environment Protection Agency National Fire Protection Agency North North East No Objection Certificate Polycyclic Aromatic Hydrocarbons Printed Circuit Board Pollution Control Committee Port Land Cement Concrete Pulvarised Flue Ash Private Operator Principal Organic Hazardous Constituents Peri Plane Gneiss Poly Vinyl Chloride Armoured Relative Humidity Reinforced Cement Concrete Rapid Environmental Impact Assessment Rapid Environmental Impact and Risk Assessment Reprocessable Hazardous Waste Return on Equity Return on Investment Roll on Roll off Respirable Particulate Matter Straight Line Method State Pollution Control Board Special Purpose Vehicle Scientific Storage Hazardous Waste South-South West South West Total Organic Carbon Terms of Reference Tonnes per Annum Transport Emergency Transport Storage Disposal Facility Under Ground Drainage System United States Bureau of Reclamation United States Environmental Protection Agency Valley Fills Written Down Value Waste Minimization

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List of Contents

0. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

EXECUTIVE SUMMARY Project Background Operator Model Site selection Site Description Site suitability Inventorisation of HW Characterization and Projection of HW Economic considerations Technology alternatives and selection Infrastructure for TSDF Operation of the TSDF Quality assurance during construction Transportation Determination of Location and Number of TSDF & Transfer Station Project Implementation Schedule Estimation of Liabilities Cost for HW-TSDF Karnataka Cost Estimates Financial Feasibility Environmental Aspects Legal considerations ANNEXES 161 129 134 12

i 1 2 8 9

13 27 62 66 81 89 102 105 115 124

140 155

171

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Details of Contents

0. 1. 2.

EXECUTIVE SUMMARY ....................................................................................................... 13 Project Background.................................................................... Error! Bookmark not defined. Operator Model .......................................................................... Error! Bookmark not defined. 2.1 Cooperation with Industries.................................................... Error! Bookmark not defined. 2.2 Operator Model....................................................................... Error! Bookmark not defined. 2.3 Stakeholders in operator model .............................................. Error! Bookmark not defined. 3. Site selection .............................................................................. Error! Bookmark not defined. 4. Site Description.......................................................................... Error! Bookmark not defined. 4.1 Physical features ......................................................................... Error! Bookmark not defined. 4.2 Geology ...................................................................................... Error! Bookmark not defined. 4.3 Soil.............................................................................................. Error! Bookmark not defined. 4.4 Hydro-geological aspects ........................................................... Error! Bookmark not defined. 4.4.1 Ground water ..................................................................... Error! Bookmark not defined. 4.4.2 Surface water ...................................................................... Error! Bookmark not defined. 5. Site suitability ............................................................................ Error! Bookmark not defined. 6. Inventorisation of HW ............................................................... Error! Bookmark not defined. 6.1 Overall quantity of HW .......................................................... Error! Bookmark not defined. 6.2 Scientific Storage HW or landfillable HW................................. Error! Bookmark not defined. 6.2.1 Priority industries ......................................................... Error! Bookmark not defined. 6.2.2 Priority categories ......................................................... Error! Bookmark not defined. 6.2.3 Priority industrial sectors............................................. Error! Bookmark not defined. 6.2.4 Priority districts ............................................................. Error! Bookmark not defined. 6.3 Inputs for TSDF...................................................................... Error! Bookmark not defined. 7. Characterization and Projection of HW ..................................... Error! Bookmark not defined. 7.1 Characterisation of HW .......................................................... Error! Bookmark not defined. 7.2 Projections of SSHW.............................................................. Error! Bookmark not defined. Assumptions ............................................................................... Error! Bookmark not defined. 7.2.3 Projections ...................................................................... Error! Bookmark not defined. 7.2.3 Capture Rates................................................................. Error! Bookmark not defined. 7.3 Inferences from Inventorisation, Characterisation and Projection of SSHW.................. Error! Bookmark not defined. 7.3.1 Pre-treatment facility .................................................... Error! Bookmark not defined. 7.3.2 Storage capacity of TSDF ............................................. Error! Bookmark not defined. 7.3.3 Location of TSDF ........................................................... Error! Bookmark not defined. 8. Economic considerations ........................................................... Error! Bookmark not defined. 8.1 Overall Economic Scenario in Karnataka............................... Error! Bookmark not defined. 8.2 Industrial Sector Growth in Karnataka ................................... Error! Bookmark not defined. 8.3 Review of policies relevant to TSDF ..................................... Error! Bookmark not defined. 8.4 Economic Incentives for TSDF .............................................. Error! Bookmark not defined. 9. Technology alternatives and selection ....................................... Error! Bookmark not defined. 9.1 Technology concept................................................................ Error! Bookmark not defined. 9.2 Pre-treatment technologies ..................................................... Error! Bookmark not defined. 9.2.1 Drying ................................................................................. Error! Bookmark not defined. 9.2.2 Stabilisation ........................................................................ Error! Bookmark not defined.
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9.2.3 Empty container management .................................... Error! Bookmark not defined. 9.3 Engineered Landfill ................................................................ Error! Bookmark not defined. 9.3.1 Type of landfill .............................................................. Error! Bookmark not defined. 9.3.2 Liner system ................................................................... Error! Bookmark not defined. 9.3.3 Leachate collection and management system ........... Error! Bookmark not defined. 9.3.4 Storm water management system .............................. Error! Bookmark not defined. 9.3.5 Sewage water treatment system ................................. Error! Bookmark not defined. 9.4 Control systems adopted......................................................... Error! Bookmark not defined. 9.4.1 Monitoring wells ........................................................... Error! Bookmark not defined. 9.4.2 Wheel/truck wash systems ......................................... Error! Bookmark not defined. 9.5 Other unique operating techniques adopted ........................... Error! Bookmark not defined. 9.5.1 Minimizing effluent generation .................................. Error! Bookmark not defined. 9.5.2 Rainwater harvesting.................................................... Error! Bookmark not defined. 9.5.3 Greenbelt ........................................................................ Error! Bookmark not defined. 9.6 Summary of selected technologies ......................................... Error! Bookmark not defined. 9.7 Comparative account of the three existing TSDFs in India.... Error! Bookmark not defined. 10. Infrastructure for TSDF ............................................................. Error! Bookmark not defined. 10.1 Facility description .............................................................. Error! Bookmark not defined. 10.1.1 Waiting Area, Entrance and Security Cabin .......... Error! Bookmark not defined. 10.1.2 Weigh Bridge and Control Building ....................... Error! Bookmark not defined. 10.1.3 Sampling Area ............................................................ Error! Bookmark not defined. 10.1.4 Administration/ Operation Building ..................... Error! Bookmark not defined. 10.1.5 Workshop and Garage .............................................. Error! Bookmark not defined. 10.1.6 Vehicle Washing Unit ............................................... Error! Bookmark not defined. 10.1.7 Delivery, Treatment and Storage Area ................... Error! Bookmark not defined. 10.1.8 Disposal Facility (Engineered Landfill) .................. Error! Bookmark not defined. 10.1.9 Solar Evaporation Pond for Leachate management ............ Error! Bookmark not defined. 10.1.10 Green Belt .................................................................... Error! Bookmark not defined. 10.2 Basic Infrastructure & Services........................................... Error! Bookmark not defined. 10.2.1 Road Connection........................................................ Error! Bookmark not defined. 10.2.2 Water Connection ...................................................... Error! Bookmark not defined. 10.2.3 Electricity Connection ............................................... Error! Bookmark not defined. 10.2.4 Sewage Waste Management..................................... Error! Bookmark not defined. 10.2.5 Storm water Management ........................................ Error! Bookmark not defined. 10.2.6 Emergency alert system (Automatic Fire Alarm System (AFAS) ................ Error! Bookmark not defined. 10.3 Other Equipment ................................................................. Error! Bookmark not defined. 10.3.1 Transformer ................................................................ Error! Bookmark not defined. 10.3.2 DG Set .......................................................................... Error! Bookmark not defined. 10.3.3 Pumps .......................................................................... Error! Bookmark not defined. 10.3.4 Mobile Equipment ..................................................... Error! Bookmark not defined. 11. Operation of the TSDF............................................................... Error! Bookmark not defined. 11.1 Staff for TSDF Operation.................................................... Error! Bookmark not defined. 11.2 Operational issues................................................................ Error! Bookmark not defined. 11.2.1 Operation of Transport to the TSDF ....................... Error! Bookmark not defined. 11.2.2 Waste Reception and Analysis................................ Error! Bookmark not defined. 11.2.3 Waste Treatment and Storage .................................. Error! Bookmark not defined. 11.2.4 Landfilling of Waste .................................................. Error! Bookmark not defined.
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11.2.5 Environmental and Operational Monitoring......... Error! Bookmark not defined. 11.2.6 Health and Safety....................................................... Error! Bookmark not defined. 11.2.7 Information and Customer/ Public Relation ........ Error! Bookmark not defined. 11.3 External Storage and Transportation................................... Error! Bookmark not defined. 11.3.1 Storage at the Generators Premises......................... Error! Bookmark not defined. 11.3.2 Pre Transport Precautions ........................................ Error! Bookmark not defined. 11.3.3 Loading and Transportation .................................... Error! Bookmark not defined. 11.4 Waste Reception and Types of Acceptable Waste.............. Error! Bookmark not defined. 11.4.1 Procedures for TSDF Entry/ Exit ............................ Error! Bookmark not defined. 11.4.2 Sampling and Conformity Control in Laboratory Error! Bookmark not defined. 11.4.3 Criteria for Waste Acceptable at Landfills for Hazardous Waste ............... Error! Bookmark not defined. 11.5 Waste Flow and Basic Operation of the TSDF ................... Error! Bookmark not defined. 11.5.1 Treatment Requirement ............................................ Error! Bookmark not defined. 11.5.2 Storage Requirements ............................................... Error! Bookmark not defined. 11.5.3 Traffic Restrictions and Vehicle Washing .............. Error! Bookmark not defined. 11.5.4 House keeping and Maintenance of Buildings and Equipment .................. Error! Bookmark not defined. 11.6 Landfilling of Waste............................................................ Error! Bookmark not defined. 11.6.1 Filling Plan .................................................................. Error! Bookmark not defined. 11.6.2 Initial Lift..................................................................... Error! Bookmark not defined. 11.6.3 Tipping of Waste ........................................................ Error! Bookmark not defined. 11.6.4 Spreading and Compaction of Waste ..................... Error! Bookmark not defined. 11.6.5 Surface Sealing ........................................................... Error! Bookmark not defined. 11.7 Leachate Management......................................................... Error! Bookmark not defined. 11.8 Monitoring........................................................................... Error! Bookmark not defined. 11.8.1 Meteorological Data .................................................. Error! Bookmark not defined. 11.8.2 Monitoring Emission Data From Landfill: Water and Leachate.................. Error! Bookmark not defined. 11.8.3 Monitoring of Groundwater .................................... Error! Bookmark not defined. 11.8.4 Topography of the site: data on the landfill body. Error! Bookmark not defined. 11.8.9 Monitoring of Leachate and Surface Water ........... Error! Bookmark not defined. 11.9 Reporting ............................................................................. Error! Bookmark not defined. 11.10 Environmental Management Systems ................................. Error! Bookmark not defined. 12. Quality assurance during construction....................................... Error! Bookmark not defined. 13. Transportation ............................................................................ Error! Bookmark not defined. 13.1 Waste Collection and Transportation logistics ............ Error! Bookmark not defined. 13.2 Scheduling of vehicles ..................................................... Error! Bookmark not defined. 13.3 Cost Estimation for transportation ................................ Error! Bookmark not defined. 13.3.1 District wise transportation costs ............................ Error! Bookmark not defined. 13.4 The Manifest System for Waste Transportation .......... Error! Bookmark not defined. 13.4.1 Compliance with the Manifest ................................. Error! Bookmark not defined. 13.5 Verification ..................................................................... Error! Bookmark not defined. 13.6 Record Keeping and Reporting ................................... Error! Bookmark not defined. 14. Determination of Location and Number of TSDF & Transfer Station ..... Error! Bookmark not defined. 14.1 Ideal TSDF Location .............................................................. Error! Bookmark not defined. 14.1.1 Effective distances from ideal TSDF location ........ Error! Bookmark not defined. 14.1.2 Cost of transportation from ideal TSDF location .. Error! Bookmark not defined.
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14. 3 Conceptual Design of Transfer Station North .............. Error! Bookmark not defined. 15. Project Implementation Schedule .............................................. Error! Bookmark not defined. 16. Estimation of Liabilities Cost for HW-TSDF Karnataka........... Error! Bookmark not defined. 16.1 Introduction and Background.............................................. Error! Bookmark not defined. 16.2 Super Fund .......................................................................... Error! Bookmark not defined. 16.3 Insurance ............................................................................. Error! Bookmark not defined. 16.4 Environmental Relief Fund (ERF) ...................................... Error! Bookmark not defined. 16.5 Calculation of funds ............................................................ Error! Bookmark not defined. 17. Cost Estimates............................................................................ Error! Bookmark not defined. 17.1 Phase wise investment cost ................................................. Error! Bookmark not defined. 17.1.1 Phase 1 cost ................................................................. Error! Bookmark not defined. 17.1.2 Phase 2 cost ................................................................. Error! Bookmark not defined. 17.1.3 Phase 3 cost ................................................................. Error! Bookmark not defined. 17.1.4 Phase 4 cost ................................................................. Error! Bookmark not defined. 17.1.5 Post Closure Phase cost............................................. Error! Bookmark not defined. 17.2 Summary of investment/fixed cost...................................... Error! Bookmark not defined. 17.3 Operation cost...................................................................... Error! Bookmark not defined. 17.3.1 Wages and salaries during operation ..................... Error! Bookmark not defined. 17.3.2 Estimation of overhead expenses ............................ Error! Bookmark not defined. 17.3.3 Treatment expenses ................................................... Error! Bookmark not defined. 17.3.4 Disaster Management Fund ..................................... Error! Bookmark not defined. 18. Financial Feasibility................................................................... Error! Bookmark not defined. 18.1 Methodology for financial analysis..................................... Error! Bookmark not defined. 18.2 Assumptions used for the analysis ...................................... Error! Bookmark not defined. 18.3 Means of finance ................................................................. Error! Bookmark not defined. 18.4 Depreciation ........................................................................ Error! Bookmark not defined. 18.5 Insurance ............................................................................. Error! Bookmark not defined. 18.6 Loan Servicing Statement ................................................... Error! Bookmark not defined. 18.7 Costing of gate fee............................................................... Error! Bookmark not defined. 18.8 Profit and loss statement...................................................... Error! Bookmark not defined. 18.9 Conclusions and Recommendations.................................... Error! Bookmark not defined. 19. Environmental Aspects .............................................................. Error! Bookmark not defined. 19.1 Ground water....................................................................... Error! Bookmark not defined. 19.2 Surface Water Quality ......................................................... Error! Bookmark not defined. 19.3 Air Quality........................................................................... Error! Bookmark not defined. 19.4 Noise Quality....................................................................... Error! Bookmark not defined. 19.5 Traffic volume..................................................................... Error! Bookmark not defined. 19.6 Socio-economics ................................................................. Error! Bookmark not defined. 19.7 Natural Disasters ................................................................. Error! Bookmark not defined. 19.8 Landfill Stability.................................................................. Error! Bookmark not defined. 19.9 Other Risks Associated - Quantitative Risks........................... Error! Bookmark not defined. 20. Legal considerations .................................................................. Error! Bookmark not defined. 20.1 Applicable Legislative Framework........................................... Error! Bookmark not defined. 20.1.1 The Hazardous Wastes (Management & Handling) Rules (HWMH Rules), 1989 as amended in January 2000 and May 2003 ................................ Error! Bookmark not defined. 20.1.2 EIA Notification and Environmental Public Hearing Error! Bookmark not defined. 20.1.3 Water (Prevention & Control of Pollution) Act, 1974 and Water Cess Act, 1974 ....................................................................................................... Error! Bookmark not defined. 20.1.4 Air (Prevention and Control of Pollution) Act, 1981 .. Error! Bookmark not defined. 20.1.5 State Environmental Clearance ..................................... Error! Bookmark not defined.
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20.1.6 Manufacture Storage & Import of Hazardous Chemicals (MSIHC) Rules 1989 and amendment 2000 ......................................................................... Error! Bookmark not defined. 20.1.7 The Central Motor Vehicles Act, 1988 and Rules, 1989 ............ Error! Bookmark not defined. 20.1.8 The Public Liability Insurance (PLI) Act, 1991 ............ Error! Bookmark not defined. 20.1.9 The Factories Act, 1948 & Rules .................................... Error! Bookmark not defined. 20.1.10 The Explosives Act 1984 & Rules 1993 ....................... Error! Bookmark not defined. 20.1.11 The Petroleum Act 1934 and The Petroleum Rules 1976 ........ Error! Bookmark not defined. 20.1.12 Requirement of Environmental Statement ................ Error! Bookmark not defined. 20.1.13 Land Acquisition ........................................................... Error! Bookmark not defined. 20.2 Guidelines related to Hazardous Wastes Landfills................... Error! Bookmark not defined. 20.2.1 Guidelines For Transportation of Hazardous Waste . Error! Bookmark not defined. 20.2.2 Guidelines For Owner/Operator Of Hazardous Waste Storage Treatment And Disposal Facility.......................................................................... Error! Bookmark not defined. 20.2.3 Criteria for Hazardous Waste Landfills ....................... Error! Bookmark not defined. 20.2.4 Ready Recknor: Hazardous Wastes Management ..... Error! Bookmark not defined. 20.2.5 Guidelines for Setting up of Operating Facility: Hazardous Waste Management ....................................................................................................... Error! Bookmark not defined. 21. ANNEXES ................................................................................. Error! Bookmark not defined. 21.1 Government of Karnataka site clearance order for Dobbasapete....... Error! Bookmark not defined. 21.2 Land details of TSDF Dobbaspete site................................ Error! Bookmark not defined. 21.3 Site Location Map of Proposed Hazardous Waste TSDF Site near Dobbasapete, Bangalore Error! Bookmark not defined. 21.4 Projections of SSHW quantities for the 20 yrs of operation of TSDF (without waste minimization).................................................................................... Error! Bookmark not defined. 21.5 Projections of SSHW quantities (after waste minimization) for the 20 yrs of operation of TSDF Error! Bookmark not defined. 21.6 Drawings TSDF Dobbasapete ............................................. Error! Bookmark not defined.
List of figures Figure - 1 Operator Model or Management Structure with Fund flow for the TSDF .Error! Bookmark not defined. Figure - 2 Site Map with survey numbers and boundaries ..................... Error! Bookmark not defined. Figure - 3 Underground strata of Dobbasapete site ................................. Error! Bookmark not defined. Figure - 4 Proportion of three types of HW in Karnataka ....................... Error! Bookmark not defined. Figure - 5 Priority ranking of industries generating SSHW .................... Error! Bookmark not defined. Figure - 6 Industrial distribution of SSHW ................................................ Error! Bookmark not defined. Figure - 7 Ranking of SSHW based on HW categories............................. Error! Bookmark not defined. Figure - 8 Key categories of SSHW quantities ........................................... Error! Bookmark not defined. Figure - 9 Sector-wise distribution of SSHW ............................................. Error! Bookmark not defined. Figure - 10 Key sectors and the corresponding cumulative SSHW........ Error! Bookmark not defined. Figure - 11 Sector wise distribution of SSHW ........................................... Error! Bookmark not defined. Figure - 12 Key districts contributing to SSHW in Karnataka................. Error! Bookmark not defined. Figure - 13 SSHW quantity growths in the next 20 years ........................ Error! Bookmark not defined. Figure - 14 Projection of HW growth based on pre-treatment including sectoral growth ............. Error! Bookmark not defined. Figure - 15 Comparative Annual Industrial Sales growth for Karnataka & India Error! Bookmark not defined.
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Figure - 16 Mechanical stabilizers ............................................................... Error! Bookmark not defined. Figure - 17 Master plan of the proposed TSDF at Dobbasapete ............. Error! Bookmark not defined. Figure - 18 Flow Diagram of HW Movement within the TSDF.............. Error! Bookmark not defined. Figure - 19 Basic operation flow chart for a TSDF .................................... Error! Bookmark not defined. Figure - 20 Multi-container Vehicles for Waste Collection ...................... Error! Bookmark not defined. Figure - 21 Manifest System ......................................................................... Error! Bookmark not defined. Figure - 22 Effective distances for transport of SSHW from ideal TSDF location (Shimoga) ......... Error! Bookmark not defined. Figure - 23 Implementation Schedule (Tender and Construction Phase)............... Error! Bookmark not defined. Figure - 24 Constructions and Operation Schedule Phase 1 ................ Error! Bookmark not defined. Figure - 25 Constructions and Operation Schedule Phase 2 ................ Error! Bookmark not defined. Figure - 26 Constructions and Operation Schedule Phase 3 ................ Error! Bookmark not defined. Figure - 27 Constructions and Operation Schedule Phase -4 ............... Error! Bookmark not defined. List of Tables Table - 1 Database summary used for quantification............................... Error! Bookmark not defined. Table - 2 Overall summaries of results of quantification of HW in Karnataka ..... Error! Bookmark not defined. Table - 3 Distribution of SSHW ................................................................... Error! Bookmark not defined. Table - 4 Characterisation of HW in Karnataka ........................................ Error! Bookmark not defined. Table - 5 Sector wise projections of SSHW quantities in TPA for the first 5 years Error! Bookmark not defined. Table - 6 Projected SSHW quantities in TPA after waste minimization for the first 5 years .......... Error! Bookmark not defined. Table - 7 Projection of HW growth for twenty years in TPA for selected categories .. Error! Bookmark not defined. Table - 8 Projection of SSHW based on sectoral growth rates and type of pre-treatment .............. Error! Bookmark not defined. Table - 9 Capture Rates for HW of different origin for the next 20 years............... Error! Bookmark not defined. Table - 10 Projected volume of pre-treatment of different HW at TSDF for 20 yrs of operation ... Error! Bookmark not defined. Table - 11 Estimation of area required for drying of SSHW based on type of stabilisation ........... Error! Bookmark not defined. Table - 12 Storage area requirements for additives .................................. Error! Bookmark not defined. Table - 13 Sectorwise Industrial Growth - 1999 to 2003 ........................... Error! Bookmark not defined. Table - 14 Quantities of HW after treatment.............................................. Error! Bookmark not defined. Table - 15 Summary of selected technologies ............................................ Error! Bookmark not defined. Table - 16 Comparative account of general information of the existing three TSDFs in India ...... Error! Bookmark not defined. Table - 17 Comparative account of technology ......................................... Error! Bookmark not defined. Table - 18 Mobile Equipment for TSDF operation .................................... Error! Bookmark not defined. Table - 19 TSDF Operation Staff .................................................................. Error! Bookmark not defined. Table - 20 Standards prescribed for leachate quality................................ Error! Bookmark not defined. Table - 21 Collection protocol of Meteorological data.............................. Error! Bookmark not defined. Table - 22 Sampling frequency for leachate ............................................... Error! Bookmark not defined. Table - 23 Groundwater monitoring ........................................................... Error! Bookmark not defined. Table - 24 Monitoring aspects for topography .......................................... Error! Bookmark not defined. Table - 25 Collection factors for loading efficiencies ................................ Error! Bookmark not defined. Table - 26 Determination of number of trips for various vehicle capacities .......... Error! Bookmark not defined.
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Table - 27 Requirement of number of vehicles for different logistic groups.......... Error! Bookmark not defined. Table - 28 Cost of Transportation 18 t vehicle ........................................ Error! Bookmark not defined. Table - 29 Cost of Transportation 7 t vehicle ........................................... Error! Bookmark not defined. Table - 30 The costs for transportation based on the logistics grouping Error! Bookmark not defined. Table - 31 District wise transportation costs .............................................. Error! Bookmark not defined. Table - 32 Effective distances for transport of SSHW from ideal TSDF location (Shimoga)........... Error! Bookmark not defined. Table - 33 District wise effective and total cost of transportation from each district to ideal TSDF location at Shimoga ................................................................................ Error! Bookmark not defined. Table - 34 Cost of transportation from specific districts North of Bangalore, directly to TSDF Dobbasapete............................................................................................ Error! Bookmark not defined. Table - 35 Economics of transporting fractional loads through a transfer station Error! Bookmark not defined. Table - 36 Summary of the phase -1 cost .................................................... Error! Bookmark not defined. Table - 37 Summary of the phase -2 cost .................................................... Error! Bookmark not defined. Table - 38 Summary of the phase -3 cost .................................................... Error! Bookmark not defined. Table - 39 Summary of the phase -4 cost .................................................... Error! Bookmark not defined. Table - 40 Summary of the Post closure phase cost .................................. Error! Bookmark not defined. Table - 41 Fixed cost summary .................................................................... Error! Bookmark not defined. Table - 42 Wages and salaries during landfill period............................... Error! Bookmark not defined. Table - 43 Wages and salaries during Post closure stage......................... Error! Bookmark not defined. Table - 44 Estimates of Overhead Expenses............................................... Error! Bookmark not defined. Table - 45 Cost of use of equipment for treatment.................................... Error! Bookmark not defined. Table - 46 Cost of use of additives............................................................... Error! Bookmark not defined. Table - 47 Yearly Treatment Costs of HW received at TSDF (per ton basis).......... Error! Bookmark not defined. Table - 48 Disaster Management fund for twenty years .......................... Error! Bookmark not defined. Table - 49 Depreciation computed as per Companys Act ...................... Error! Bookmark not defined. Table - 50 Depreciation computed as per Income Tax Act ...................... Error! Bookmark not defined. Table - 51 Preconstruction insurance cost .................................................. Error! Bookmark not defined. Table - 52 Loan Servicing Statement ........................................................... Error! Bookmark not defined. Table - 53 Quantities to be processed in TPA ............................................ Error! Bookmark not defined. Table - 54 Unit costs of Treatment Rs./ Ton .............................................. Error! Bookmark not defined. Table - 55 Variable costs- cost of Operations Rs. in Lakhs....................... Error! Bookmark not defined. Table - 56 Total Direct Costs for the TSDF during 20 yrs ........................ Error! Bookmark not defined. Table - 57 Year wise Average Gate Fee...................................................... Error! Bookmark not defined. Table - 58 Income statement......................................................................... Error! Bookmark not defined. Table - 59 Net profit & loss as per CA & as per IT.................................... Error! Bookmark not defined. Table - 60 List of Applicable Key Legislation for Setting up and Operation of proposed Hazardous Wastes TSDF in Karnataka.................................................................... Error! Bookmark not defined.

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0. EXECUTIVE SUMMARY
0.1 Background Industrial activities do generate considerable amount of waste. Some of the waste generated by certain industries is hazardous in nature. Because of their characteristic quality of being corrosive or flammable, or reactive, toxic or persistent in nature, such wastes are termed as Hazardous Wastes. In spite of new technologies, improved production, waste treatment and management strategies like reduce, reuse and recycle; there is still a certain quantity of waste that needs to be disposed in a scientific way. Karnataka State Pollution Control Board (KSPCB) with technical assistance of German Technical Cooperation and consultancy by ERM GmbH, is in the process of evolving an effective Hazardous Waste Management (HWM) strategy for Karnataka. Establishment of a technically sound, operationally sustainable Treatment, Storage and Disposal Facility (TSDF) is one such activity of the cooperation. A separate project called HAWA project has been conceived to carryout this activity. 0.2 Operator Model

The TSDF is proposed to be of Design, Build, Own, Operate & (Transfer) DBOO(T) and to be given to a Private Operator (PO) who would be selected through a National Competitive Bidding procedure. The basic design would be provided by the HAWA project with the overall responsibility for design to be vested with the PO. The source of revenue for the PO would be the gate fee collected for the HW on per ton basis, which includes the treatment and disposal cost. Transportation of the HW from the industries could be by the industries, or by the PO or a third party. Land for the TSDF is to be leased by the Department of Forest, Ecology & Environment (DFEE), Government of Karnataka (GoK) at lease rate of Rs.100/acre/yr for 1 year of construction, approximately 20 yrs of operation and 30 years of post-closure period. The Land along with the facility is to be transferred to GoK after satisfactory completion of post closure phase. As the proposed TSDF is the first of its kind in Karnataka and would be a monopoly for the initial few years, it was decided to have a monitoring control by a Government Agency. Hence, the formation of a Contracting Authority (CA) was contemplated. For the construction and commissioning phase, the Karnataka Industrial Area Development Board (KIADB) would be the CA and a separate registered society, under the Special Purpose Vehicle SPV would take over this function. The KSPCB would undertake the environmental monitoring as per the Hazardous Waste (Management & Handling) Rules, 1989, amended 2003. 0.3 Site selection

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The site selected for setting up the TSDF is Dobbasapete site after examining 21 candidate sites in Karnataka. An Environment Impact Assessment study was carried out for this site. A Public Hearing was also completed successfully for the site. Subsequently site clearance was accorded by the GoK vide its order GO - No. FEE 293 ECO 2002, Bangalore dated 21.04.2004. GoK is in the process of acquiring this Land and is expected to be completed by December 2004.

0.4

Site Description Dobbasapete Site

Dobbasapete site is about 48 km Northwest of Bangalore city. It is located in Bangalore Rural District, Nelamangala Taluk, Sompura Hobli, Thimmanayakanahalli & Pemmanahalli villages, adjacent to Dobbasapete KIADB industrial estate. The extent of land required for the TSDF is 105.18 acres. The site is bounded by National Highway NH 207 in the North, a dry nallah in the east, TDPS factory and service road leading to National Highway NH-4 in the south and agricultural land in the west. 0.5 Site suitability

The ground water table in the site is below 60 m as against the minimum 2m requirement of Central Pollution Control Board (CPCB). The field permeability value of soil in the area is 2.5 x 10-7 m/s to 2.5 x 10-8 m/s which is highly suitable in setting up a landfill as the rate of percolation of contaminants in case of an accident will be very low. The site has a natural gradient of 2.2%, which has been effectively used in the design of leachate collection system as no pumping of leachate is envisaged and flow is by gravity. A Natural clay barrier extending from a depth of 20m and extending upto 30 m exists in the site making it suitable for landfill construction. The presence of two National Highways, especially the one which connects the entrance of TSDF which has a 4 lane highway will help in smooth traffic flow, reducing accidents. 0.6 HW Inventory

The total Scientific Storage Hazardous Waste (SSHW) or landfillable Hazardous Waste is about 38,736 TPA excluding 13.1 category of HW, which is process dust from iron and steel industries (this category can be classified as HW only after chemical analysis). In Karnataka just 15 industries contribute to 70% of the SSHW and just 10 categories contribute to 80% of SSHW. Category 32.3 sludge containing adsorbable organic halides from pulp & paper is the highest category and chemical sector (24%) is highest industrial sector contributing to SSHW. Shimoga (23%) district is the highest contributor of SSHW followed by Bangalore Urban (19%). 0.7 HW Characterization

The SSHW is characterized into 57 sub-categories as per schedule 1 & 2 of HW Rules, 2003. Category 32.3 from schedule-1, which is sludge containing adsorbable organic

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halides from Pulp and paper industries, is the highest category of waste generated in Karnataka besides 13.1. The second highest category is 34.1, which are flue gas cleaning residue from air and water purifiers. The HW thus characterized reveals that the type of treatment required could be grouped into four types, viz., are drying, stabilization (lime, flyash, cement, flyash & cement), shredding and direct landfilling. About 40% HW requires drying, about 83% requires stabilization, 2% shredding and the rest direct landfilling. 0.8 HW Projections

HW inventorisation for the base year (2003) was required to be projected for the next 20 years. As the TSDF will not start receiving HW until 2006, it is required to project the waste quantity from 2006 to 2025. An additional quantity of about one lakh tons of HW from illegal dumpsites will also be available by 2006. However, this waste will be accepted by the TSDF only if fresh HW generated from industries is not available. About 1,98,851 t of accumulated SSHW from industries will also be available by 2006 for the TSDF. The HW projections were undertaken based on industrial sectoral growth and waste minimization factors. Reduction of waste due to pre-treatment and increase due to additives were also considered for the projections. A capture rate was also applied to the waste for each year. Thus the projected landfill material for 20 years was estimated to be 7.86 lakh tons. Hence the design capacity of the landfill was considered to be eight lakh tons. 0.9 Technology alternatives

Various technologies are available for treating and disposing the HW. Nevertheless, appropriate technologies based on the types of HW, environmental considerations and cost effectiveness has to be considered while selecting the technologies. As about 40% of HW in Karnataka requires drying the technology chosen was solar drying as against belt filter press which generates effluent which also needs additional treatment. Four types of stabilisation are required for which the manual stabilisation method is recommended using wheel loaders. Empty containers (metal) which have residues of HW is recommended to be pressed using a drum press and then landfilled and the plastic drums are recommended to be shredded. The type of landfill recommended is of Above & Below ground and the liner system to be used is modified single composite liner, which has an extra thick clay liner (CL). The leachate collection system to be used is leachate pipes 0.10 Infrastructure

The facilities that are proposed in the TSDF are as follows:

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A Waiting Area for the trucks with HW. A Security Cabin, Weigh Bridge and Control Building to undertake the initial inventory/manifest control and Sampling Area to take waste samples which have to be analyzed in the laboratory are proposed. The facility will have an administration/Operation Building which consists of an Analytical Laboratory, Sample Storage area, Public Relations Office / Information Centre, Room for KSPCB/CA representative, Meeting room , Administrative staff office, Canteen and Kitchen and Cloak Rooms and Toilets. The waste received in the TSDF needs to be treated. This is undertaken in the block of buildings with the following facilities. A Receiving or Delivery area where each type of waste is received in different compartments is also present. The waste thus received is treated in different cubical in the treatment building. Prior to the treatment, the waste is stored in Storage rooms. Separate monsoon storage is also provided in the facility. Besides, a Vehicle washing area for trucks if it gets contaminated with HW is provided. A workshop to repair the vehicles and other equipment and an empty container storage shed is also present. The Disposal Facility is an Engineered Landfill and the associated environment treatment facilities like Solar evaporation pond with a minimum effluent treatment facility and Rain water harvesting pond is provided. 0.11 Operation of TSDF

A total number of 36 staff has been proposed in order to ensure a one shift operation of the TSDF (8 hours/day, five days/week). In case that waste quantities increase an extension up to a 1.5 shift operation (12 hours/ day, six days/ week) might be considered what would require a limited increase of operational staff. The vehicle which collects HW from the industries is not allowed into the landfilling area. They are allowed only till the receiving station. This is undertaken to avoid mandatory wheel wash and subsequently effluent generation. Hence, a separate truck is provided to carry the HW from the receiving area to the landfill. The HW received will first be subjected to a chemical examination (finger print analysis) to match with the declared waste. If the HW is found conforming to the norms, it will be sent for treatment. After appropriate treatment like drying, stabilization (cement, flyash and or lime), shredding, it will be landfilled. The treated HW is placed in different cells in five phases in the landfill. The approximate period of operation is 20 years. 0.12 Transportation - Heuristics

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The inventory data of each industry has been analyzed to segregate industries based on the tonnage of SSHW generated in a period of 90 days. SSHW quantities in multiples of 17 t will be transported by an 18 t vehicle. The SSHW quantities which are greater than 6 t in a quarter but lower than 17 t will be transported by a 7t vehicle. The balance quantities will be transported by a 7 t vehicle by conveniently combining with similar compatible wastes from other industries in the vicinity. If the third option is not feasible, then the fractional quantity is collected by a 7 t vehicle and transported to the TSDF in order to conform to the 90 day rule. The number of trips required for Full load of 18 T vehicle is 519, Full load of 7 ton vehicle is 77, partial load of 7 ton vehicle is 139 and fractional load of 7 ton vehicle is 23 trips. Thus 14 numbers of 18 t vehicle and 6 numbers of 7t vehicles are required to transport SSHW in Karnataka to the TSDF. The transport network could be grouped into three groups based on the distances to be traveled. Group A to & fro trip in 1 day (150 km), Group B to & fro in 2 days (150 350 km) and Group C to & fro in 3 days (> 350 km). This was used to calculate the transportation logistics cost. Total cost of transportation/qtr is Rs.68.85 lakhs, which implies an effective cost of Rs. 690 per ton of waste. The weighted average cost per ton km over an effective distance of 218 km is Rs.3.17. The overall weighted average cost per tonne km for 18 t vehicle is Rs. 1.67/- and for 7 t vehicle is Rs. 3.15/-. 0.13 Number & Location of TSDF With the present quantities of HW in Karnataka only one TSDF is economical. Moments study results showed that the ideal location for TSDF is at Honnali (near Harihar), Shimoga as it has the lowest effective distance of 155 km, whereas for Dobbasapete is 218 km. Effective cost of transportation to Shimoga from all the districts is Rs. 596/ t of waste. However due to site characteristics, the next best location of Dobbasapete was selected. Corresponding cost for Dobbasapete is 16% more Rs.690/t. 0.14 Requirement of transfer station Since Dobbasapete has higher transport costs, feasibility of setting up an intermediate transfer station was examined. This transfer station location was identified near Harihar. Effective cost if a transfer station is set up will reduce the transportation cost by 1.64%. However, this does not include cost of Transfer station infrastructure. Hence, with the present quantity of HW, a transfer station in the first phase is not justified. 0.15 Project Implementation Schedule Timeframe for tendering 90 days starting September 2004 Evaluation and finalizing of tendering 60 days after tender submission February 2005. Selection of Private Operator, March 2005. Mobilisation of resources for PO by April 2005 Start of construction April 2005 Establishment of SPV by Dec 2005
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Construction time 1 yr (end: March 2006) Commissioning of TSDF April 2006

0.16 Liability Cost Liability cost is computed for: Post closure monitoring of 30 yrs yearly deposit of Rs.15.87 lakhs + interest on it (maintained as Escrow account by CA) Disasters/accidents during operations & post closure upfront corpus of Rs.169 lakhs + interest on it (maintained by CA/GoK) Compensation for affected people Rs.4.5 lakhs Premium/yr. (insurance company to be given by discretion of DC. Called ERF) The liability cost would amount to Rs.170/t of HW. 0.17 Project Cost Estimation Total project cost is Rs. 37.02 Crores (Rupees Thirty Seven Crores), which is inclusive of 10% contingency. The phase 1 cost is Rs.13.49 crores including 10% contingency. The cost of buildings is estimated to be Rs.4.46 Crores and the landfill cost is Rs.24.42 Crores. The equipment cost is Rs.4 Crores. 0.18 Financial Analysis The Debt - Equity ratio considered is 70:30. For a project cost of Rs.37 Crores, the average Gate Fee would be Rs.989/t excluding transportation cost and Rs.1869/- including transportation cost. The Debt Service Coverage Ratio (DSCR) value with the above gate fee would be 1.53 and an ROE of 17%. There are about nine different tariff based on type of treatment required and the range will be between Rs.600 to Rs.1500/- excluding the transportation cost. 0.19 Economic instruments recommended Government of India (GoI) grant of Rs.2 crore to PO will reduce the gate fee by Rs.100/t Providing interest subsidy to 6% will reduce the gate fee to Rs.1850/t with out GoI grant and to Rs. 1800/t with GoI grant

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